Air Separation Unit

Owner: EPs Contractor:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

COVER SHEET

ThinkXperT

MC:

REQUISITION FOR :

ALWAYS REFER TO PIDEC REQ. NO. PIDEC No.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT INQUIRY

Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

PURCHASE ORDER

1

OF

REV.

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57

This Requisition is issued to obtain quotation for supply and delivery of:

AIR SEPARATION UNIT

as per this Requisition and its attachments.

REQUISITION CONTENTS 1. Scope of Work This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

2. Scope of Supply 3. Requisition Notes 4. List of Attachments

DE

EXT

INQ

R

Eng. Phase

Purpose of Distribution (POD)

Purpose of Issue (POI)

Owner's Action

03

28.05.2014

Issued for Inquiry

B.Hamidi

M.Hashemi

M.Hashemi

M.Jalali

02

05.05.2014

Issued for Inquiry

B.Hamidi

M.Hashemi

M.Hashemi

M.Jalali

01

26.01.2014

Issued for Inquiry

B.Hamidi

M.Hashemi

M.Hashemi

M.Jalali

00

07.10.2013

Issued for Inquiry

D.Zeidani

M.Hashemi

M.Hashemi

M.Jalali

Rev.

Date

Description

Prepared by

Checked by

Approved by

Project

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

1.

REV.

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

2

OF

03

57

SCOPE OF WORK Vendor’s scope of work includes but not limited to the following items with requirements stated in the requisition and all its attachments.

1.1

GENERAL

Main Quotation

Options

          

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

      03

1.1.2

Fabrication /Manufacturing

1.1.3

Assembly

1.1.4

Shop test and inspection as per attachment No.6

1.1.5

Painting ( Primer and Intermediate coating )

1.1.6

Packing (Including N2 filling)

1.1.7

Marking

1.1.8

Site supervision and start up services

1.1.9

Training

1.1.11 Performance guarantee 1.1.12 Erection 1.1.13 Commissioning

OTHERS

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03

Design & Engineering

1.1.10 Mechanical guarantee

  1.2

1.1.1

 

1.2.1 Documentation 1.2.2 Instrumentation and Control 1.2.3 Wiring and tubing for instrument within skid 1.2.4 Internals such as internal piping, baffles, inlet distributors and their support, vortex breakers and wire screen around VB or in the inlet of nozzle (if any), impingement plates, internal rungs, support for packing/ hold down & grid support, internal flanges and etc. 1.2.5 All external welded attachments, including reinforcement pad around nozzles, lifting and tailing trunnion / lugs, clips (for piping, ladder, platform, insulation, earthing), pipe davit and etc. 1.2.6 Ladders and platforms complete with bolting. 1.2.7 Review of PIDEC’s related drawings such as (foundation drawings etc.) 1.2.8 Skid ( Steel structure for the equipment such as compressors, driver, auxiliary equipment and systems ) 1.2.9 HAZOP and SIL study (The HAZOP and SIL study meeting shall be held in presence of Owner, Contractor, and third party.). 1.2.10 Engineering for Fire Fighting and F&G system related to ASU Plant 1.2.11 Architectural design for control room and substation building

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

2.

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

3

OF

REV.

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57

SCOPE OF SUPPLY Vendor’s scope of supply shall include but not limited to the followings with all accessories and as required according to this requisition, its attachments and references:

2.1

03

GENERAL

 

2.1.1 Items and quantities as stated in the material summary list. (point 2.3)



2.1.3 Spare parts for erection, pre-commissioning, commissioning and startup



This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

03

2.1.4 Spare parts for two years operation

      

2.1.5 Capital spare parts ( if any )



2.1.12 Documents as per the attached RFD ( requirements for documents) form



2.1.13 Final Vendor data book

2.2

2.1.6 Consumables for site erection 2.1.7 Chemical and lubricants 2.1.8 Special erection and maintenance tools ( if any ) 2.1.9 Special calibration tools ( if any ) 2.1.10 Test equipment ( during shop test ) 2.1.11 Name Plate (s)

OTHERS

 

2.2.1 Local Instruments



2.2.3 Cabling bulk materials including cable glands, conduit pipes, etc. 2.2.4 Instrument air supply line piping material including valves, fitting, flanges, bolts & nuts, gasket, etc. 2.2.5 Air line tubing materials including fittings

      03

2.1.2 Installation / Mounting accessories

 

2.2.2 Junction boxes

2.2.6 Installation and support material for above 2.2.7 All steel structures including supporting structures , shelters , T-supports and their accessories & attachments 2.2.8 Platform, stairway, ladder and hand rail on equipment. 2.2.9 Piping material including valves, flanges, bolts, nuts, pipe supports, pipe hangers and etc. 2.2.10 Ducting material, if any. 2.2.11 Companion flange with bolts/nuts and gasket at B.L.

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

03

   

03



This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

NOTE :

OF

57

2.2.13 Painting material for touch-up, Concrete coating & painting (where needed) 2.2.14 One layer of final coating material at site. 2.2.15 Initial charge of column packing (filter elements, etc.). 2.2.16 Equipment, apparatus and consumable for analysis and test required for normal operation and guarantee test run 2.2.17 Welding electrode 2.2.18 Transportation saddle 2.2.19 Gasket, bolt & nut for reducing and blind flanges and internal nozzles. 2.2.20 Sliding plates, templates, liners, insert plate & shims.

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SHEET

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03

Owner No.: BU-30-P-000-PRO-REQ-0008

2.2.12 Deleted

 

REV.

PIDEC NO.: 1210-00-PR-REQ-104

2.2.21 Insulation material 2.2.22 Lubricant for initial fill and two years operation. 2.2.23 Resin/Catalyst/absorbent for initial fill and two years operation. 2.2.24 All required facilities for Fire fighting and F&G system related to ASU Plant.

03

1. The package (all equipment, devices & etc.) shall be seaworthy packed and shall be protected from any corrosion during manufacturing, transportation, site store before erection and start up. 2. Vendor shall supply all relevant equipment, instruments, etc. to make the package complete in all respect even-though it is not listed in the specifications and requisition or in the Vendor’s offer.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

2.3 2.3.1

REV.

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

5

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MATERIAL SUMMARY LIST EQUIPMENT

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

The following list of equipment is as minimum requirement and Vendor shall provide all the necessary equipment, piping and valves to meet the requirements.

SR.

ITEM NO.

1

30-PU-6101 (Note 5,6)

ITEM DESCRIPTION

AIR SEPARATION UNIT that includes two cold boxes equipped with three air compression trains mainly composed of :

QTY

UNIT (m/kg/set/...)

1

Set

1.1

Main air compressors

2(W)+1(St.by)

Set

1.2

Booster air compressors

2(W)+1(St.by)

Set

1.3

Air pre-cooling systems

1.4

Molecular sieves absorbent vessels

1.5

Each condensing steam turbines (for each main air compressor and booster air compressor train) including condensation unit

1.6

Cold Box

1.7

1.8

2 (one stand by pump to be considered for each set of pumps)

1(W)+1(St.by) (for each train of compressor)

Set

Set

2(W)+1(St.by)

Set

2

Set

Expansion turbine

1(W)+1(St.by) (for each train of cold box)

Set

Exchangers Cold Box

One complete set (for each train)

Set

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

1.9

03

Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

Rectification Cold Box

6

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57

One complete set (for each train)

Set

1

Set

2

Liquid nitrogen storage tanks and vaporizer

3

Liquid oxygen storage tank and vaporizer

1

4

Independent instrument air and plant air package

1

Set

5

Control and ESD system

1

Set

6

Spare parts for erection commissioning and start-up (for SR. 1,2,3,4,5)

1

Set

1

Set

1

Set

7

REV.

PIDEC NO.: 1210-00-PR-REQ-104

Set

Spare parts for two years operation (for SR. 1,2,3,4,5) 8

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Capital spares (for SR. 1,2,3,4,5)

NOTE : 1. TAG No. of equipment and Instruments will be specified according to project numbering procedure.(Attachment 10) 2. Any other equipment/system not included in the above list, but necessary for right and satisfactory operation of the unit shall be considered in the scope of this requisition designed and supplied by Vendor without any price impact. 3. Number of required equipment besides their detailed specifications to be specified by Vendor. 4. W: Working , St.by: Stand by 5. Vendor of ASU shall consider the future expansion provisions for the third train of ASU and related main air compressor(s) in the design of package. Moreover the hydraulic design of all common facilities and interconnections including utility, feed and products piping and etc shall be performed and supplied for three similar trains of ASU and its air compressor(s). 6. The optimum number of air compressor trains to be proposed by Vendor considering the quantity of available steam in the site.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

2.3.2

REV.

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

7

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57

INSTRUMENT AND ELECTRICAL

Vendor shall provide all necessary instrumentation, internals and electrical to meet the requirement. 2.4

EXCLUSION

2.4.1 Foundation works (Anchor bolts calculation is by Vendor & supply by others) 03

2.4.2 Structural/ detail design of buildings (including G.A and Foundation, HVAC design, Plumbing Design, F&G, etc). 2.4.3 Site erection 2.4.4 MV line feeder cables 2.4.5 Underground conduits for power and instrument cables

03

2.4.6 Fire detection and alarm system related to buildings are excluded, although all signal related to F&G of the buildings shall be implemented in ASU Plant F&G Panel by Vendor.

03

2.4.7 Supply of hydrant/monitor/hose reels connected to fire water network. (Fire water system to be designed by Vendor). 2.4.8 Installation of insulation materials for equipment and piping off skid 2.4.9 Loading of adsorbents and catalyst 2.4.10 Filling of perlite for thermal insulation chambers

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

2.4.11 Utilities from Out Side Battery Limits (OSBL) 03

2.4.12 Underground piping , trench and open ditch

03

2.4.13 HVAC

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Rev.

03

Description

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

8

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57

3.

REQUISITION NOTES

3.1

GENERAL

3.1.1

Design and construction of the Air Separation Unit (ASU) shall be in accordance with this specification. In addition, Vendor shall comply with all applicable codes, laws and regulations of the jurisdiction in which the equipment is to be operated.

3.1.2

Vendor shall design and fabricate the package to meet the requirements mentioned in air separation unit process specification in item 3.2.

3.1.3

If any discrepancy is found during procuring, design and fabrication stages, Vendor shall immediately inform PIDEC and shall obtain necessary clarification / approval before proceeding with the job any further.

3.1.4

Vendor shall complete/sign the attached letter of conformity and list his probably deviations from this requisition clearly in his quotation

3.1.5

Equipment covered by this requisition shall be supplied in accordance with the requirement set forth herein and attached reference documents that are to be considered as an integral part of this requisition.

3.1.6

Compliance with the provisions of this requisition does not relieve the Vendor of the responsibility of furnishing the equipment of proper design, mechanically suited to meet performance guarantees at the specified operating condition.

3.1.7

Package shall be designed to be operable down to 60% of normal flow rate for each train.

3.1.8

Vendor shall fill out all equipment data sheets and submit for PIDEC and Owner review and approval.

3.1.9

Deleted

3.1.10

Material and corrosion allowances shall be considered for a minimum of 25 years safe operation.

3.1.11

Material selection shall be made based on the referenced specifications as per American codes and standards.

3.1.12

Drawings, calculations and documents shall be submitted as indicated on the attached RFD sheets (attach. No.3).

3.1.13

All drain lines from drums / filters, etc. inside the package shall be grouped together as far as possible and shall be routed to drain into a common drain funnel.

3.1.14

Vendor shall furnish details of anchor bolts (i.e. size, number, material and setting plans ) according to 1210-00-ST-ESS-746 (attached to this requisition).

REV.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

03

03

Description

REV.

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

9

OF

03

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3.1.15

Air Separation Unit including all accessories shall be shop painted as per project painting specification 1210-00-PI-ESS-406 (attached to this requisition). Surface preparation as per SA 2 ½ and one coat proper primer and one coat proper intermediate and one finish coat as 1210-00-PI-ESS-406 (attached to this requisition).

3.1.16

This package shall be suitable for operation under out-door conditions as per attached ambient and site condition and utility data 1210-00PR-ESS-101 (attached to this requisition).

3.1.17

Vendor shall tabulate foundation loads including shear and axial moment loads in erection, operation and test conditions for seismic loads and wind load as per UBC97.

3.1.18

Default nozzle loads should be as per: 1210-00-PV-ESS-242 (attached to this requisition). Vendor shall submit supporting calculations showing that the above loading data are exact, neither short nor conservative, any time when the PIDEC requests.

3.1.19

Material for pressure vessels, and piping shall procured as per project requested codes & Standards.

3.1.20

Vendor should submit the HAZOP and SIL study for ASU package at his own cost based on PFD, P&ID, Plot Plan and Equipment data sheets and safety-related equipment checklist. Vendor should provide information about the reported accidents in similar Plants in the world during HAZOP meetings.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

The HAZOP and SIL study meeting should be held in presence of Owner, PIDEC and third party. Vendor should introduce at least three qualified and internationally well known companies as third party of HAZOP and SIL study and the selected third party for HAZOP study is subject to Owner/PIDEC approval. Vendor is responsible for implementation of any required modification and changes based on HAZOP and SIL study recommendations at his own cost. 3.1.21

Sub Vendors/suppliers shall be approved by Owner /PIDEC prior to placement of sub-orders. List of sub-Vendors shall be submitted at proposal stage.

3.1.22

Before start of fabrication Vendor shall submit QC plan and ITP to BUPC and PIDEC for approval.

3.1.23

Vendor shall submit the design calculations (based on attachment No.3) for PIDEC approval prior to fabrications. Fabrication shall not commence prior to PIDEC’s approval of documents.

3.1.24

For shipping of the equipment and materials, please refer to the document No. BU-00-GE-000-MEC-PRC-002-00, “Packing, Marking and Shipping Instruction” (attached to this requisition).

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC NO.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT Rev.

Owner No.: BU-30-P-000-PRO-REQ-0008

Description

SHEET

10

OF

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57

3.1.25

Design Requirements:

3.1.25.1

Codes, Rules and Standards The supply shall be in compliance with this specification, Codes, Rules, and Industrial Standards listed here below or elsewhere in the requisition or its attachments: • Rotating Equipment: - Air compressors: 2002

REV.

API Std 672 / API Std 617, 7th edition, July

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

and specification 1210-00-MC-MSS-301 (attachment no.12.18) - Steam turbines: API Std 612, 6th edition, November 2005, and specification 1210-00-MC-MSS-305 (attachment no. 12.19) - Expanders: API Std 617 7th. edition, July 2002 - Process pumps: API 610, 11th edition and specification 1210-00-MC-MSS-307 attached to this requisition. I specification 1210-00-MCMSS-308 for general service (attachment no. 12.21) for cooling water pumps - Cryogenic pumps: API 610, 11th edition and specification 1210-00-MC-MSS-307 (attachment no. 12.20). -Vibration Monitoring Systems: API Std 670 • Air coolers:

API Std 661

• S&T heat exchangers:

TEMA I API Std 660 I ASME VIII Div. 1 or 2

• Auxiliary S&T heat exchangers For rotating equipment:

Mfr Std

• Plate exchangers:

API Std 662 I Mfr Std

• Welded type heat exchangers:

Mfr Std

• Pressure vessels and pressurized tanks:

ASME VIII Div. 1 or 2

• Materials:

ASTM Std. Code

• Material quality certificate:

EN 10204-3.1

03

• Piping:

ASME B.31.3

03

• Flanges:

ASME B.16.5

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

03

03

Description

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

11

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03

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• Threaded connections:

ASME B1.1 and 8.20.1

• Safety relief valves:

API RP 520- 527 / ASME VIII

• Electrical equipment:

IEC / NEC / NEMA / ISO / ANSI / EN / CENELEC / BS

• Instruments:

ISO / ISA / IEC

• Design of structural steel:

AISC / ACI / U8C / BS

• UBC 97:

For Wind & Seismic Design Load

The latest edition for all above Specifications, Codes, Rules and Standards shall be in effect at date of purchase order. 3.1.25.2 In case of doubts of interpretation or conflicts among the specifications, the following decreasing order of priority shall be applied: 1. Duty specifications and data sheets 2. Client's specifications and documents mentioned or attached to this specification 3. This Specification (3.1.25.1) 4. National and International applicable standards and codes as listed in this Specification 5. Local Laws and Rules

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

REV.

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

SHEET

12

OF

03

57

Following specifications should be considered for ASU plant. Design Service Life Time Year Continuous Operation between Year Deriming(Defrosting) Time Required for Clean up hr Liquid/Warming/Deriming Start-up Time (Start of Turbo-Expander to O2 hr Purity) Start-up Time (Start of Turbo-Expander, With hr Liquid to O2 Purity) Start-up Time (After Temporary Stop to O2 hr Purity) Regeneration time for hr Molecular Sieves ASU Technology

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Owner No.: BU-30-P-000-PRO-REQ-0008

Description

3.1.26

REV.

PIDEC NO.: 1210-00-PR-REQ-104

25 >2

24 Vendor To Advise Vendor To Advise Vendor To Advise 4 Internal Compression

3.1.27

The Vendor shall specify the delivery time of ASU package.

3.1.28

The Vendor shall deliver equipment at BUPC site.

03

3.1.29

Vendor shall supply a list of proposed Sub-Vendors for each component such as motors, instruments, bearings, etc. indicating Sub-Vendor's model number, type, etc. along with their catalogues, drawings, etc, with first revision of offer for Owner/ PIDEC approval. Vendor shall not be free to substitute any other manufacturer or model unless so accepted by the PIODEC/ Owner.

03

3.1.30

For all purchased items, the overall responsibility as to their suitability and performance shall be of Vendor scope. Vendor shall ensure that all requirements of inspection, testing, drawings and documentation are complied by Sub-Vendors.

03

3.1.31

Vendor's service charges for erection and commissioning supervision and training for each section of the package will be separate and on daily basis.

03

3.1.32

Vendor shall fill out the Lubrication Schedule form, for lubrication details covering initial fill and two years normal operation (if applicable).

03

3.1.33

Bidder shall complete/sign the attached letter of conformity and list his probably deviations from this requisition clearly in his quotation.

03

3.1.34

UBC 97 to be followed for importance factor selection, in this regard based on table 16-K, equipment of ASU package could be categorized as “3. Special

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

13

OF

57

occupancy structures” except for Oxygen system/storage which shall be categorized as “2.hazardous facilities”. Related importance factor to be selected by Vendor. 3.2

PROCESS SPECIFICATION

3.2.1

The present process specification has the purpose of providing the required performances of the Air Separation Unit for the 5’000 MTD Methanol Plant and 1515.2 MTD MEG Plant in Assaluyeh (IRAN). The ASU plants will provide:  pure gaseous oxygen  pure gaseous nitrogen  liquid nitrogen buffer reservoir as well as evaporator for evaporation liquid nitrogen  liquid oxygen buffer reservoir as well as evaporator for evaporation liquid oxygen  independent instrument air and plant air package which will be located inside of ASU

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

The total required design capacity will be delivered by two units (cold boxes) equipped with three air compression trains (each train including one Main Air Compressor, Booster Air compressor , electric motor and steam turbine drivers). During normal operation, two air compression trains will be on stream, working in parallel, while one will be in stand-by. Each of air compressor trains on stream will have 55% normal capacity. The package will be provided with two parallel lines (2 cold boxes) each line shall be designed for 60500 Nm3/h gaseous oxygen. The provision for the third train of ASU and its related air compressor train(s) shall be considered in the design and supply of common facilities such as piping of feed air and products. As the steam with specification mentioned in this document is available for the driving of steam turbine, so the Vendor shall consider in its design the maximum consumption of steam in the steam turbine as driver of the air compressors. Then shortage of power for the air compressors can be supplied by electric motor. 03

The steam turbine driver is a medium pressure steam condensation type. Liquid Nitrogen production shall be considered for the first filling of LIN storage tank and compensation of evaporation loss of the LIN storage tank (the capacity of LIN production to be recommended by Vendor).

REV.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

3.2.2

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

14

OF

57

Expected performances and Technical Requirements The unit shall be designed to deliver 2 x 60500 Nm3/h of gaseous oxygen ( with a minimum purity of 99.8%) at B.L of ASU plant; capacity related to oxygen liquefaction to be added to total capacity of the ASU plant in order to keep constant flow of gases oxygen at B.L of the package. The Oxygen shall be available at B.L in two pressure level as per item 3.2.3.1of this requisition. The unit shall deliver 14000 Nm3/h of gaseous nitrogen normal flow rate and 25000 Nm3/h as maximum flow rate, with purity higher than 99.95%. The turndown capacity of each ASU unit shall be 60% of its normal flow rate. The three air compressors trains (two in operation and one stand by) for supplying feed air to two ASU trains shall be driven each by a condensation type steam turbine running on medium pressure steam.

03

Two trains will work in parallel during the normal operation.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

A liquid nitrogen buffer tank (350 m3 capacity) shall be foreseen within unit battery limits and connected to the gaseous nitrogen network after evaporation in the vaporiser dedicated for this function. The nitrogen evaporator will be designed for 14000 Nm3/h. The type of evaporator is recommended to be water bath. A liquid oxygen buffer tank (700 m3 capacity) (to be confirmed later) shall be foreseen within unit battery limits and connected to the gaseous oxygen network after evaporation in the vaporiser dedicated for this function. The oxygen evaporator will be designed for 60500 Nm3/h. The oxygen evaporator type is preferred to be water bath. Medium pressure steam available at unit battery limits shall be used also for the molecular sieves regeneration and liquid Nitrogen Vaporizer (if the steam has to be de-pressurized and de-superheated all facilities should be considered by Vendor inside the package). The Vendor should consider necessary facilities for uninterruptible nitrogen supply in case of ASU shutdown and for cooling down of the liquid nitrogen and oxygen transfer pumps. The Vendor shall provide detailed Process Flow Diagram plus the Heat & Material Balance table with expected figures for all streams.

REV.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC NO.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT Rev.

Owner No.: BU-30-P-000-PRO-REQ-0008

Description

SHEET

15

OF

REV.

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57

Sparing philosophy for ASU package is as following: Main Air Compressor Booster Air Compressor Expander turbine Cryogenic pumps

: : : :

Cooling pumps : Chilling pumps : Molecular sieves absorbent vessels:

2W+1St.by 2W+1St.by 1W+1St.by (for each train) 1W+1St.by (for each train and for each stream of liquid oxygen and liquid nitrogen) 1W+1St.by (for each train) 1W+1St.by (for each train) 1W+1St.by (for each train)

Future expansion space and design for the third train of ASU and related air compressors to be considered. An independent separate package for IA (Instrument Air) and PA (Plant Air) should be considered inside the ASU package and supplied by the Vendor. Electrical driver compressors should be considered for the IA/PA package. Sparing philosophy for IA/PA package: Main compressor: 2+1 (3 x 55%)

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

ASU Vendor shall design the plant in order to provide instantaneously back up N2 and O2 from relevant storage tanks in case of unit shut down. ASU will have a dedicated control system that shall be designed and supplied by ASU Vendor.

03

03

Vendor shall suggest cooling system by two options and shall report these options in his offer: A : cooling system by usage air media for cooling. B : cooling system by usage cooling water media for cooling. Consumption figures and requirements for both alternatives should be proposed by Vendor for Owner / PIDEC verification and finalizing. Cryogenic spill protection shall be considered by Vendor.

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC NO.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT Rev.

Owner No.: BU-30-P-000-PRO-REQ-0008

Description

SHEET

3.2.3

Products characteristics

3.2.3.1

Oxygen Demand and characteristics: Design Flowrate (as 100% O2) for Methanol and MEG Plants Normal Flowrate (as 100% O2) for Methanol and MEG Plants Temperature MP GOX Operating / Design LP GOX Operating /Design Mechanical Design Temperature Composition O2 N2 + Ar total

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Nm3/ h Nm3/ h °C bar g bar g °C

2 x 60500 Nm3/h

15 (1) 50/57 29/31.5 85

% % %

99.80 (min) 0.20(split by Vendor) 100.00

2 x 55000 Nm3/h (2)

(1) Minimum Temperature to be confirmed by Vendor. (2) Maximum normal flow rate for MeOH Plant : 75530 Nm3/h Maximum normal flow rate for MEG Plant : 36733 Nm3/h 3.2.3.2

Gaseous Nitrogen Demand:

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Service Total for design purpose of BUPC 3.2.3.3

Normal 14000

Nm3/h

Peak 25000

Gaseous Nitrogen characteristics: Temperature Pressure at ASU B.L. Mechanical Design Temperature Mechanical Design Pressure Dew point at atm. Composition N2 O2 CO CO2 Oil S H2O H2 (1) To be confirmed by Vendor.

°C bar g °C

Ambient (1) 7.5 min/ 8.5 normal/ 9 max 85

bar g

10.5

°C

-70

% ppm (vol) ppm (vol) ppm (vol) ppm (vol) ppm (wt) ppm (wt) ppm (wt)

99.9 2 max 10 max 1 max 0.5 max 0.2 max 1 max 1 max

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC NO.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT Rev.

03

Owner No.: BU-30-P-000-PRO-REQ-0008

Description

3.2.3.4

SHEET

17

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57

Liquid Nitrogen: Buffer Tank capacity

m3

350 (2)

Liquid nitrogen continuous production to be minimized and should be adequate to compensate storage losses for self-cooling. (1) Buffer tank filling max capacity flow rate: 5 m3/h (min), 10 m3/h max, Vendor to optimize. (2) Buffer tank shall be completed with Nitrogen Evaporator which shall be able to produce 14000 Nm3/h (minimum) of gaseous nitrogen as per para 3.2.3.2. (3) Nitrogen temperature shall be not more than 20°C below site temperature.(Min. operating temperature related to vaporized nitrogen shall not be less than 5 °C) . 3.2.3.5

Service Methanol Plant (ISBL) Storage Tanks Polishing Unit Flare Unit Bushehr Petrochemical Complex (excluding above units) Total for design purpose of BUPC

03

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Instrument Air Demand from Independent Instrument air and Plant air package:

3.2.3.6

Nm3/h Nm3/h Nm3/h Nm3/h Nm3/h

Nm3/h

Normal 800

Peak 900

65

215

5135

6885

6000

8000

Instrument Air characteristics: Temperature Pressure at ASU B.L. Mechanical Design Temperature Mechanical Design Pressure Dew Point Max particle size

°C bar g °C bar g °C µm

Ambient (1) 6.5 min / 8.5 normal / 9 max 85 10.5 - 40 / Oil Free 5

(1) To be confirmed by Vendor. (2) Any required facility for purification and drying of air including internals, molecular sieves, interconnection piping, manual/ automatic valves, instrumentation, regeneration system and etc. should be provided by Vendor of the package. (3) Instrument Air/ Plant Air receiver to be considered in the independent instrument air and plant air package. Buffer volume, which will supply instrument air to the instrument air main header, shall be designed for, at

REV.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

REV.

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

Description

SHEET

18

OF

57

least, 30 minutes of normal consumption of whole Bushehr Petrochemical complex. (4) Instrument Air back-up in case of ASU shut-down and buffer volume consumption to be provided by OSBL. This is necessary for the safe shut-down of Bushehr Petrochemical Complex in case no instrument air will be available from ASU. 3.2.3.7

Plant Air demand from Independent Instrument air and Plant air package: Service Methanol Plant (ISBL) Storage Tanks Polishing Unit Flare Unit Bushehr Petrochemical Complex (excluding above units) Total for design purpose of BUPC

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

3.2.3.8

Nm3/h Nm3/h Nm3/h Nm3/h Nm3/h

Nm3/h

Normal 200

Peak 500

NNF

420

2000

3600

2500

5000

Plant Air characteristics: Temperature Pressure at ASU B.L. Mechanical Design Temperature Mechanical Design Pressure Max particle size

°C bar g °C bar g µm

Ambient (1) 6.5 min / 8.5 normal / 9 max 85 10.5 5

(1) To be confirmed by Vendor. 3.2.4

Vendor shall indicate the expected consumption for all utilities.

3.2.4.1

Medium pressure steam The available Medium Pressure Steam (MPS) to be used, during normal operation, as motive fluid for compressors steam turbines will have the characteristic summarized in the following table. The available MPS flow rate from Methanol Plant will be 250 t/h. The Vendor shall consider in his design the maximum consumption of MPS for the steam turbine drivers of air compressors. Then the rest of drivers shall be considered as electric motor.

Pressure (bar g) Temperature (°C)

Minimum

Normal

Maximum

47 370

49 396

50.5 410

Mechanical Design 57&FV 425

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC NO.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT Rev.

Owner No.: BU-30-P-000-PRO-REQ-0008

Description

SHEET

19

OF

57

Vendor to state the possibility to start-up the unit and run it in case of Methanol Plant upset having MPS (the relevant flow rate to be given by the Vendor and to be confirmed by the purchaser) at the following conditions: Minimum Pressure (bar g) Temperature (°C)

3.2.4.2

38 400

Normal

Maximum Mechanical Design

40 410

42 430

47&FV 470

Cooling water Open loop cooling water will be available at process plant B.L. Thermal design

Mechanical Design

4.5 35

8.5 85

Supply Pressure (bar g) Supply Temperature (°C)

Max. allowed  T within process plant BL: 10°C (return temperature 45°C) Max. allowed  P within ASU plant BL: 1 bar (return pressure 3.5 bar g) Chloride content (as Cl-): 150 ppm wt (max)

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

3.2.4.3

No.

1

2 3 4 5 6 7 8

Electricity Electric power supply at ASU BL is 20000 V, 3ph, 3 wires, 50 Hz. The standard voltage rating for various utilization loads are as follows:

Item 2500 kW and above 150 kW and above 0.2 kW to 150 kW below 0.2 kW Construction and Maintenance Lighting Fixtures Emergency Lighting Instruments Controls for H.T. Boards+ H.V. Motors Controls for L.T. Board Expected short circuit level

AC/DC AC AC AC AC

Rated Voltage (V) 11000 6000 400 230

Phase/Wire 3/3 3/3 3/3 1/2

AC AC AC AC

230 - 400 230 230 110

1/2 - 3/4 1/2 1/2 1/2

DC AC AC

110 --230 --1400 MVA @ 20kV supply

REV.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC NO.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT Rev.

Owner No.: BU-30-P-000-PRO-REQ-0008

Description

3.2.5

Site Information

3.2.5.1

Plant Location

SHEET

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The Plant is located at Bandar Assaluyeh, Iran. 3.2.5.2

Site Climatic Condition

3.2.5.2.1 Air Temperatures - Max. recorded temperature - Min. recorded temperature - Max wet bulb temperature - Dry bulb design temperature - Max temperature for mechanical, civil and structural design - Max. temperature for equipment exposed to sunlight (design value) - Minimum Design Metal Temperature

03

3.2.5.2.2

52°C 5°C 33°C 50°C 55°C 85°C 5°C

Air Humidity

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

- Max. relative humidity in summer 76% - Min. relative humidity in winter 74% - Design relative humidity and temperature 76% at 48°C - Design relative humidity for Electrical equipment 80% 3.2.5.2.3

Barometric Pressure and Altitude The barometric pressure at site is ranging from 990 to 1'100 mbar.

3.2.5.2.4

Wind a) Max wind velocity

b) Prevailing wind direction

- 125 km/h at 10 m above ground for structural design - 16 m/s at 10 m above ground for flare thermal radiation North-West

For mechanical and civil structures design purpose, wind shall be considered from all directions.

REV.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC NO.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT Rev.

Owner No.: BU-30-P-000-PRO-REQ-0008

Description

3.2.5.2.5

SHEET

21

03

57

Rainfall and Snow Precipitation a) Design Rainfall precipitation values in 3 minutes: in 10 minutes: in 1 hour: in 1 day:

3.2.5.2.6

OF

REV.

17 mm 24 mm 40 mm 70 mm

b) Rainfall value for sewer design

40 mm/hr

c) Design snow load

25 kg/m2

Other Climatic Phenomena to Consider a) Sand storm – to be considered b) Thunder and lightning – to be considered c) Sea breeze – to be considered

3.2.5.2.7

Earthquake (Seismic Factor) Earthquake shall be considered for ZONE 4 as per UBC.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

3.2.5.2.8

3.2.5.2.9

Other Data Transportation capacity  Max. weight  Max load per axle  Max height  Max width  Max length

: Provisional and national roads

Transportation by sea:

No limitation by size or weight.

: up to 96 ton : 12 ton : 5.2 m :5m : 50 m

Available Unit Area

03 The available plant area for Air Separation Unit corresponds to 140 m(fixed) x 80 m (Vendor to confirm) Two trains and INA/PA packages shall be located in available area. The third train should be arranged in additional area (if required). 3.3

EQUIPMENT Each train of the Air Separation Unit shall be complete with all the accessories and auxiliaries necessary for safety and satisfactory operation and shall include, but shall not be limited to, the main equipment listed below:

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

03

Description

3.3.1

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

22

OF

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Process Main Air Compressor (MAC)

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Each MAC will include the following main components: • Inlet filter, self cleaning type, suitable for the site environment conditions • Centrifugal multistage integrally geared compressor oil free • Shaft sealing system • Automatic flow regulation system by Inlet Guide Vane (IGV) • Automatic anti-surge control and protection system • Blow off valve and blow off silencer • Safety relief valve (inter stage and final stage) • Speed gear • Flexible coupling/s • Vibration and axial position probes I transducers for compressor bearings • Compressor Inter-cooler • Compressor After-cooler • Steam turbine driver (common for MAC and BAC(Booster Air Compressor)) The steam turbine shall mainly include: - Steam chest - Trip & throttle valve - Electronic governor - Speed sensors - Emergency trip device - Over speed trip device - Exhaust shutoff valve - Shaft seals including gland vacuum system with condenser and ejectors - Vibration and axial position probes I transducers for turbine bearings - Turning device • Steam turbine exhaust condensing unit - Each train with air or water cooled condenser • Common Lube Oil system for turbine, gears and centrifugal compressors bearings • Electric Motor drivers for remaining MAC and BAC (in case that MPS to be insufficient for all the MAC and BAC) • Skid assembly including compressors, driver, auxiliary equipment and systems, instrumentation, junction boxes and local control station 3.3.2

Air pre-purifying and drying unit dual vessel type, including internals, molecular sieves, interconnection piping, manual I automatic valves, instrumentation and regeneration system.

3.3.3

Booster Air Compressor (BAC) centrifugal multistage integrally geared. The BAC will be part of a common train with the MAC. MAC and BAC will be driven by a common steam turbine(for steam turbine driven air compressors only). For the motor driven compressors, each MAC and BAC shall have its own electric motor driver.. Each BAC will include the following main components:

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

• • • • • • • • • • •

03

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

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Centrifugal multistage integrally geared compressor Shaft sealing system Automatic flow regulation system Automatic anti-surge control system Blow off valve and blow off silencer Safety relief valve (inter stage and final stage) Speed gear Flexible coupling/s Vibration and axial position probes I transducers for compressor bearings Compressor Intercooler (see point 3.3.17) Compressor Aftercooler (see point 3.3.17)

3.3.4

Expansion turbine and auxiliary booster compressor integral unit, including automatic speed control device (two units shall be provided, one in operation + one in standby) for each train.

3.3.5

Heat exchangers cold box including: • Process heat exchangers • Internal interconnecting piping and supports • Manual and automatic valves • Instrumentation • Drain facilities • External shell and self-supported steel structure • Insulation materials (perlite, rockwool panels and cover sheets) • External and internal stairs and maintenance platforms

3.3.6

Rectification cold box including: • Medium and low pressure columns complete of internals • Condenser I reboiler • Sub-cooler • Internal interconnecting piping and supports • Manual and automatic valves • Instrumentation • drain facilities • External shell and self-supported steel structure • Insulation materials (perlite rockwool panels and cover sheets) • External and internal stairs and maintenance platforms

3.3.7

LIN (Liquid Nitrogen) and LOX (Liquid Oxygen) cryogenic pumps. Two pumps for each service (one in operation+ spare) shall be provided. LIN back up system shall be quick response type, so that no interruption taken place in the gaseous nitrogen supply to header (specially during the time for cooling down of the LIN pumps).

3.3.8

LIN 350 m3 volume buffer tank with pressure built up vaporizer and LIN vaporizer for GAN network feed.

3.3.9

LOX 700 m3 (to be confirmed later) volume buffer tank and LOX vaporized for GOX network feed shall be supplied by the Vendor.

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Rev.

03

Description

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

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REV.

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3.3.10

Main and booster air compressors shall comply with API 672 or API 617.”

3.3.11

Expanders shall comply with API 617, 7th. edition, July 2002.

3.3.12

The permissible speed range of the centrifugal compressors for continuous operation shall be clearly stated by the manufacturer.

3.3.13

The performance of the compressor units and the mechanical requirements shall be specified by the ASU Vendor.

3.3.14

The performance test of the compressor units shall be carried out by Vendor according to ASME PTC-10 or ISO 5389, latest edition)

3.3.15

The compressors shall be considered as a packaged units including at least: - Air intake - Inlet filter - Main Driver - Lubrication unit (common for compressor and driver) - Oil cooling system - Machinery monitoring system for compressors and drivers, including vibration probes, temperature probes and vibration monitors in suitable control panel. - Safety and control instrumentation - Anti surge device - Local panel

3.3.16

The compressors packages shall be designed and fabricated in accordance with all the rules of good engineering practice and taking into account any unusual condition peculiar. As a minimum, the following features shall be provided: • Suitable protection of the equipment to ensure the safety of personnel during operation and maintenance • Maximum reliability • Ease of maintenance

3.3.17

Below philosophy for the process air compressors intercoolers and aftercoolers to be considered as separate option: • MAC intercooler: - Cool down by air or water cooled heat exchangers • MAC aftercooler: - Cool down by air or water cooled heat exchangers • BAC intercoolers and aftercooler: - Cool down by air or water cooled heat exchangers

3.3.18

For expansion turbine and auxiliary booster compressor magnetic bearings are required.

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

3.3.19

REV.

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

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Steam turbines shall be horizontal design, multistage, condensing type. Medium pressure steam for steam turbine is available with the following characteristics: - Pressure (Minimum I Normal I Max): 47 I 49 I 50,5 barg - Temperature (Minimum I Normal I Max): 370 I 396 I 410 °C Exhaust steam condensation shall be as follows: - Steam turbines trains : operating pressure related to surface condenser to be modified / confirmed by Vendor

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

03

3.3.20

Steam Turbine selected for Compressors as a driver shall comply with API 612, 6th edition, November 2005, and specification 1210-00-MC-MSS-305 (attached to this requisition).

3.3.21

Special provisions for emergency lube oil supply to bearings and gears shall be made in case of turbine shut-down. This shall require overhead reserve oil tank to supply lube oil at adequate pressure when there is breakdown of power. Necessary control circuit shall also be provided for this system.

3.3.22

The turbine and auxiliary equipment shall be designed for outdoor operation.

3.3.23

Local control panel shall be adjacent to turbine for easy operation.

3.3.24

Vendor shall supply if any expansion joints or adaptor required between steam turbine and air or water cooled condenser.

3.3.25

The Lube oil system for Compressor package shall be designed and manufactured according to API 614, 5th edition, April 2008, and relevant specification (attached to this requisition).

3.3.26

Lube oil pumps shall comply with API 676, 2nd edition, December 1994.

3.3.27

Cryogenic Centrifugal pumps shall comply with API 610, 11th edition and specification 1210-00-MC-MSS-307 (attached to this requisition).

3.3.28

Centrifugal pumps for cooling water shall comply with specification for centrifugal pumps for general service 1210-00-MC-MSS-308 (attached to this requisition).

3.3.29

Vendor shall furnish complete information about pump characteristics: head, efficiency, power, NPSH vs. capacity for the fluid pumped and head vs. capacity for Max. and Min. Sizes of impeller.

3.3.30

Complementary Equipment /Materials Required for the complete ASU: • Interconnecting piping for process lines according to project piping classes inside the ASU BL, including supports and accessories • Interconnecting piping for utilities lines according to project piping classes inside the ASU BL, including supports and accessories

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

REV.

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• Set of control valves, on-off valves, solenoid valves, isolation valves, manual valves, etc for process and utilities lines. • PSV's including piping connection to relief points in safe location.

03

• Warm and cold insulation for piping and equipment as necessary. For equipment installed on skid the insulation must be, as far as possible, installed in supplier workshop; otherwise, as for the equipment supplied loose and the interconnecting piping, insulation materials in bulk shall be provided.(Vendor to provide specification for cold insulation as per operating condition of system .MTO for insulation should be provided by Vendor.) • Acoustic insulation and additional measures (acoustic hoods, silencers, baffles etc),as necessary to meet the noise limitation requirements. • The noise level to be respected is 85 dBA maximum at 1 meter from the edge of each skidded equipment or single equipment installed alone. • In case of exceeding the specified noise level, Vendor has to solve the noise exceeding problems providing all additional measures and materials at own cost. • During engineering design, Vendor shall indicate the overall sound power level of the whole package unit in operation. This information shall be considered for evaluation of the total noise impact of whole plant at the fence limit.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

• Vendor shall submit the expected noise data sheet. • Prefabricated structural steel for main structures and pipe racks, including erection materials • Platforms, stairs, ladders, handrail and grating, where necessary for accessing to the equipment, according to Mfr Std. • Surface preparation and painting according to the Project Technical Specification for Painting attached to this requisition. • Cable glands for instruments and junction boxes • First charge of adsorbents and I or catalysts, including provision for losses (quantities at least for two years operation). • First charge of lubricants (quantities at least for two years operation). • Flushing fluids - if any • Special tools for erection and maintenance

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

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• HAZOP and SIL study (The HAZOP and SIL study meeting shall be held in presence of Owner, Contractor, and third party). 3.4

03

PROCESS CONTROL

3.4.1

It is Vendor responsibility to design its package as required to permit safe and orderly start-up, shutdown and operation.

3.4.2

Vendor’s recommended start-up, shutdown and operating procedure, will be reviewed by PIDEC.

3.4.3

The above procedure shall be included in the package “operating and maintenance manual”.

3.5

INSTRUMENTATION ‘General’

3.5.1

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

3.5.2

The control and monitoring of ASU unit will be considered in a dedicated control room/building. Additionally, provisions shall be taken into account to perform data communication with offsite ITR. It should be noted that offsite DCS operator stations and cabinets (if any) will be installed in ASU control room. Control room design (including CCR, auxiliary room, Eng. room, ...) and relevant documents such as Control room layout, Cabinets & Operator/Engineering stations arrangement, cable ladder arrangements and etc. shall be provided by Vendor.

3.5.3

Vendor shall calculate and supply required power supply (110 V AC, 50 Hz, UPS) for control systems and field instruments (redundant feeders shall be considered for control systems of all packages).

3.5.4

Vendor shall design and supply “Safety & Instrument Grounding” requirements.

3.5.5

Vendor shall design and supply all the instrumentation necessary for the safe and efficient operation of the Air Separation Unit (ASU) to fulfill the process requirements specified in this requisition. This includes, but not limited to all the instruments and control required for safe and satisfactory start up, control and shut down of the package units.

3.5.6

All instruments in hazardous area shall be of intrinsically safe (IS) type. Using of explosion proof devices are only acceptable if IS type is not commercially available. Signals from/to MCC’s shall be considered as non-IS. All panels, enclosures and junction boxes shall be explosion protected according to their area classification. All field mounted instruments, enclosures and junction boxes shall be protected to IP-65.

3.5.7

SIL STUDY shall be performed for packages based on IEC- 61508 and ESD loops shall be classified accordingly. Necessary provisions to meet the results of SIL

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

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study shall be considered for PLC and instruments. 3.5.8

The process override or maintenance override switches shall be shown on relating diagram (if required) and the required facilities shall be foreseen as per Vendor’s common practice.

3.5.9

Air supply to pneumatic instruments and instrument air distribution inside ASU is in Vendor scope of supply and work.

3.5.10 All instruments and control systems shall be calibrated/ configured, programmed and debugged completely before delivery to minimize field works. PLC system and related equipments, barriers, power distributions etc. as well as cabinets, local panels shall be shop fabricated and wired up to the terminals, ready for installation and interconnection at site. 3.5.11 Vendor shall recommend spare parts for commissioning and 2-year operation. 3.5.12 All instruments and devices shall be supplied with nameplates indicating tag no., type, model no., serial no., range, type of protection, certifying authority, etc. 3.5.13 For FCS and respective cabinets, please refer to document No. 1210-00-IN-MSS601, “Material Standard Specification for Fieldbus Control System” (attached to requisition).

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

3.5.14 For instruments selection and control / safety systems design, please refer to document No. 1210-00-IN-ESS-603, “Engineering Standard Specification for Package Instrumentation” (attached to requisition). 3.5.15 For PLC-based control / shutdown system and respective cabinets, please refer to documents No.1210-00-IN-MSS-673, "material standard specification for programmable logic controllers" (attached to requisition) and 1210-00-IN-MSS-672, "material standard specification for cabinets" (attached to requisition). 3.5.16 For MMS, please refer to document No. 1210-00-IN-MSS-676, “Material Standard Specification for Machine Monitoring System” (attached to requisition). 3.5.17 For electrical interface with MCC’s, please refer to document No. 1210-00-IN-SKT005, “Instrument/Electrical Connection Details” (attached to requisition). 3.5.18 For Vendor documentation, please refer to document No. 1210-61-PR-RFD-104, “Requirement for Documents” (attachment No. 3). ‘Control System’ 3.5.19 The PLC’s used for shutdown of ASU shall be fully redundant (CPU, bus, communication modules, power supply, I/O cards, etc). 3.5.20 Galvanic isolator barriers (with HART feature for analog signals) shall be used.

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

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3.5.21 The PLC’s shall have the capabilities to integrate and work with the main instrumentation and control and shall have the communication capabilities to exchange data from and to other external PLC based control equipments and FCS. 3.5.22 Each PLC system shall communicate with Plant FCS (if any) by redundant bidirectional Modbus RTU through RS 485 physical layer. FCS will act as the master. Coordination with FCS Vendor has to be carried out by Vendor. 3.5.23 The PLC’s shall be provided with all required system software including application/utility programs, engineering/configuration tools, self-checking and selfdiagnostic fault detection capabilities. 3.5.24 The required shut-down, start-up and inter-lock diagrams, based on IEC 61131, shall be provided and implemented in ASU’s control system by Vendor. 3.5.25 The system logic shall be ‘fail safe’. All instruments shall be considered for fail to safe action upon loss of instrument air or electrical power. The input contacts to alarm, interlock and emergency shutdown system shall be close (make contact) during normal operation and open on alarm or trip. The solenoids shall be energized during normal operation and de-energized to trip. The status of all switches in normal operating conditions shall be logic high “1”. 3.5.26 Comprehensive system status information shall be available on standard displays. The PLC shall be capable of on-line replacement of any faulty module without requiring system shutdown.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

3.5.27 Sensors for shutdown shall be separated from sensors provided for measurement, control or pre-alarms. 3.5.28 PLC control system shall receive synchronization signal from Plant FCS, at predefined periods and make synchronized with Plant FCS. 3.5.29 Provision shall be made to facilitate Machine Monitoring interface to Machine Condition Monitoring (where applicable). 3.5.30 All the system hardware (including monitoring, control, protection, communications, communication with FCS, etc.) complete with all software (including application software) installed and loaded on the corresponding hardware, are subject to Factory Acceptance Test (FAT). FAT procedure shall be prepared by Vendor, approved by Owner and used as the guideline for performing FAT. Owner reserves the right to modify Vendor’s standard procedure. ‘Field Instruments’ 3.5.31 The instrumentation shall be rated to withstand the tropical, dust, humid environmental conditions. 3.5.32 Design and supply of all instruments, including process / air tubing and cabling are within Vendor’s scope of supply.

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

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3.5.33 All instruments shall be cabled up to auxiliary room through relevant junction boxes / local panels. 3.5.34 All instruments installation materials including fittings, isolation and drain valves, manifolds, junction boxes, cable ladders/trays, glands, instrument support, etc. are in Vendor’s scope of supply. 3.5.35 Vendor shall provide 4-20 mA, HART transmitters with integral indicator and potential free contacts switches. Solenoid valves shall be IS with 24 VDC voltage rating. All limit switches for automatic valves shall be proximity (NUMOR) type and intrinsically safe. 3.5.36 All instrument/automatic valves wetted parts and process/air tubing materials shall be S.S. 316 as minimum, other materials as per process conditions. 3.5.37 All cable entries shall be M20X1.5 with explosion-proof cable glands. 3.5.38 Isolating valves shall be provided for all instruments. Multi port gauge valves for pressure switches and gauges and 5-valve manifold for DP transmitters shall be considered.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

03

3.5.39 Guidelines for selection of Spare parts for commissioning/ start up and two years operation are listed below: Erection, pre-commissioning, commissioning and start-up spare parts For Control Panel Siganl Lamp 50% Fuse Elements 50% Field Transmitters: Gasket 30% Field Instruments: Air Pressure Regulators 10% Temperature Indicators 20% each type (min one ) Pressure Gauges 20% each type (min one ) Solenoid Valves 15% each type (min. one Set) Valve Positioners 15% each type (min. one Set) Cable – Single Pair 20% Cable – Multi Pair 20% Cable Glands 20% Junction Boxes – Large 1 min. Pipe and Tube 10% Fittings, all Type 15% each size Valves 20% min. one valve Manifold Valves 10% each type Cable Tray 20% DCS: Signal Lamps 50%

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

Fuse Elements Printer Paper Printer Ribbon Gas Chromatograph: Filter Elements Calibration Gas Cylinders Standard Gas Cylinders Other Gas Cylinders Other Analysers: Filter Elements Calibration Gas Cylinders Standard Gas Cylinders Other Gas Cylinders

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50% 4 Boxes Each Type 10 sets each type 20% 1 Cylinder (100 litres) each type 1 Cylinder (100 litres) each type 1 Cylinder (100 litres) each type 20% 1 Cylinder (100 litres) each type 1 Cylinder (100 litres) each type 1 Cylinder (100 litres) each type

Guidelines for selection of two years operation spare parts Flow Instruments Level Instruments Temperature Instruments Pressure Instruments Analyzers Control Valves:

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Valve Bodies

To be determined in conjunction with the equipment Vendor (based on Vendor’s experience on similar type of plant)

None unless service is corrosive or erosive. For corrosive or erosive service, shall be determined in conjunction with the Vendor.

Valve Plugs

1 of each size/min. 15% or 1

Seat Rings

2 of each size/min. 25% or 2

Actuator

10% (min. one per type/size)

Valve Stems

1 of each diameterThese vary in length depending on valve size. Purchase the longest of each dia. These can be cut to the correct size.

Steam packing

3 boxes of each size used/min.30%

Grease

3 boxes of each type used/min.20%

Diaphragms

2 of each size used min. 20%

Pressure Gauges

15% each type (min two)

Solenoid and Trip Valves

15% each type (min two)

REV.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC NO.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT Rev.

Owner No.: BU-30-P-000-PRO-REQ-0008

Description

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Valve Positioners

15% each type

Thermocouples

15% each type (min two)

57

Blank Orifice Plates Manual Loading Stations Instrument Air Filters (Regulation sets) Pressure Switches Plug-in Assemblies for Elect. Instr. Plug-in Assemblies for Pneum. Instr.

10%

Seal, Condensate and Vent Pots

(for all)

Solenoid and Trip Valves Thermowells Signal Lights

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

I/P Converters FCS/DCS/ESD/PLC (for each system) the Following Items: 20%, min. one for each type I/O Cards Main Cards Power Supply (AC, if any) Power Supply (DC, if any) Barrier Cards

1 set 1 set 1 set 20% for each type (min. 1 for each type)

On-Line Gas Chromatographs: Main Mother Cards Column Barrier Cards

One set One per type 20% for each type (min. 1 for each type)

REV.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

03

Description

3.6

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ELECTRICAL Furthermore to the items listed in table of scope of work/ supply below list to be considered as well:

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

S/N

Description

Scope of design (layout, calculation, MTO...)

Scope of supply of equipment

1

CCTV SYSTEM

V

V

2

TELEPHONE SYETEM

P

V

3

CALCULATION FOR SHORT CIRCUIT STUDIES

V

N/A

4

CALCULATION FOR LOAD FLOW STUDIES

V

N/A

5

CALCULATION FOR LARGE DRIVE STARTING STUDIES

V

N/A

6

CALCULATION FOR RELAY SETTING SCHEDULE & COORDINATION STUDIES

V

N/A

7

CALCULATION FOR ELECTRICAL LOAD BALANCE SUMMARY

V

N/A

8

SWITCHGEARS

V

V V

9

PDCS

V

10

TRANSFORMER

V

V

11

NGR

V

V

12

CABLE

V

V

13

D/G

V

V

14

EQUIPMENT ARRANGEMENT LAYOUT IN BUILDINGS

V

V

15

SUBSTATION CABLE ROUTING LAYOUT IN BUILDINGS

V

V

16

LIGHTNING PROTECTION LAYOUT

P

V

17

EARTHING IN BUILDINGS

P

V

18

EARTHING IN AREA

V

V

19

LIGHTING AND SMALL POWER IN BUILDINGS

P

V

20

LIGHTING AND SMALL POWER IN AREA

V

V

21

PAGING IN BUILDINGS

P

V

22

PAGING IN AREA

V

V

23

RADIO SYETEM

V

V

24

HEAT TRACING

V

V

25

FIRE ALARM IN BUILDINGS

P

V

26

FIRE ALARM IN AREA

V

V

27

CATHODIC PROTECTION

V

V

28

UPS

V

V

29

DC CHARGER

V

V

30

HAZARDOUS AREA CLASSIFICATION DRAWING

V

N/A

31

UNDERGROUND CABLE ROUTING

P

N/A

32

CABLE TRAY/LADDER/GLAND/ACCESSORIES

V

V

33

LIGHTING & DISTRIBUTION PANEL IN BUILDINGS

P

V

34

LIGHTING & DISTRIBUTION PANEL IN AREA

V

V

35

VARIABLE SPEED DRIVES

V

V

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description 36

LOCAL CONTROL STATION

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V

V

V: By Vendor P: By PIDEC N/A: Not Applicable

3.6.1

Selection, sizing and supply of electrical equipments should be as per the below project specifications: a. b. c. d. e. f. g. h. i. j.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

k. l. m. n. o. p. q. r.

3.6.2

1210-00-EL-MSS-502: Material standard specification for MV switchgears. 1210-00-EL-MSS-503: Material standard specification for LV switchgears. 1210-00-EL-MSS-504: Material standard specification for power and distribution transformers. 1210-00-EL-MSS-505: Material standard specification for PDCS. 1210-00-EL-MSS-506: Material standard specification for AC UPS. 1210-00-EL-MSS-507: Material standard specification for DC battery charger. 1210-00-EL-MSS-508: Material standard specification for electrical panel boards. 1210-00-EL-MSS-509: Material standard specification for electrical cables and wires. 1210-00-EL-MSS-510: Material standard specification for cathodic protection. 1210-00-EL-MSS-515: Material standard specification for electrical heat tracing. 1210-00-EL-MSS-517: Material standard specification for LV variable speed drives. 1210-00-EL-MSS-519A: Material standard specification for MV capacitor banks. 1210-00-EL-MSS-519B: Material standard specification for LV capacitor banks. 1210-00-EL-MSS-520: Material standard specification for aircraft warning lights. 1210-00-EL-MSS-521: Material standard specification for LV induction motors. 1210-00-EL-MSS-522: Material standard specification for MV and HV Motors. 1210-00-EL-MSS-528: Material standard specification for local control stations. 1210-00-EL-MSS-534: Material standard specification for MV variable speed drives.

Electrical installation/electrical design should be as per the below project specifications: a. b.

1210-00-EL-ESS-501: electrical system design. 1210-00-EL-ESS-502:

Engineering standard specification for Engineering standard specification for

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

REV.

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lighting system design. c. d. e. f.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

03

1210-00-EL-ESS-503: Engineering standard specification for earthing and lightning system design. 1210-00-EL-CSS-501: Construction standard specification for electrical installation in area. 1210-00-EL-CSS-502: Construction standard specification for electrical installation in building. 1210-00-EL-MSS-524: Material standard specification for Electrical Equipment as Part of Package.

3.6.3

Purchaser will provide only two 20KVAC, 50 HZ, 3Ph feeders from different sections of the source switchboards of main substation. Design and supply of a local substation based on above mentioned standard specifications included but not limited to transformers, bus ducts, switchgears, cables, wires, lighting/distribution panels, PDCS, trays, ladders, DC battery charger, UPS, lighting equipments, installation and fixing materials required for proper installation of the electrical equipment, etc. is in Vendor scope of work/supply. Electrical system distribution and philosophy should be as per “Engineering standard specification for electrical system design” no. 1210-00-EL-ESS-502.

3.6.4

Preparation of the following drawings / document in addition to the drawings and documents specified in attachment no. 3 of this requisition is in Vendor scope of work/supply (But not limited to follow): 1. CALCULATIONS: a. Power system calculations & studies. b. Short circuit study. c. Load flow studies. d. Large drive starting studies. e. Relay setting schedule & coordination studies. f. Electrical load balance summary. g. Cable sizing calculations (Sample calculation), reference lists. h. Lighting calculations & illumination levels (Sample calculation). i. Electrical heat tracing calculation list. (If any) 2. SINGLE LINE DIAGRAMS: a. Overall electrical one line diagram. b. Single line diagram for MV Switchgears. c. Single line diagram for LV Switchgears. d. Single line diagram for AC UPS. e. Single line diagram for DC Charger. f. Auxiliary supply distribution, lighting & receptacle panels single line diagram. g. Substation lighting & receptacle panel single line diagram. 3. ELECTRICAL CIRCUIT DIAGRAMS: a. Typical standard drawings for MV motor starter control circuit diagrams.

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

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b. Typical standard drawings for LV Motor starter and feeder control circuit diagrams. c. Typical standard drawings for control station circuit diagrams. 4. ELECTRICAL INTERCONNECTION DIAGRAMS: a. Electrical/Instrument interconnection diagram. b. MV & LV switchgears wiring interconnection diagrams. c. AC UPS & DC chargers wiring interconnection diagram. d. Variable speed drives / Power converters wiring interconnection diagram. (If any)

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

5. GENERAL LISTS & SCHEDULES: a. Electrical load schedule. b. Electrical cable schedule. c. Communication Cable Schedule. d. MV & LV switchgear schedules. e. Electrical cables drum index/schedule. f. Communication cables drum index/schedule. g. Motor control philosophy schedule. h. Local control station schedule. i. PDCS I/O list. j. Logic diagram for offered systems, if applicable. k. General arrangement drawing of electrical equipment showing connection points of earthing, electrical and control cables. l. Catalogued information for all electrical system, equipment and materials. 6. DATA SHEETS: a. Data sheet for MV & LV switchgears. b. Data sheet for power transformers. c. Data sheet for AC UPS. d. Data sheet for DC battery charger. e. Data sheet for electrical cables. f. Data sheet for LV variable speed drive. (If any) g. Data sheet for LV & MV electric motors. 7. LAYOUTS & DRAWINGS: a. Underground cable routing. b. Cable tray/ladder routing. c. ASU cable laying layout. d. ASU earthing layout. e. Heat tracing layout. (If any) f. Substation equipment arrangement Layout. g. Substation cable laying layout. h. Substation cable routing arrangement of views / sections. i. Substation earthing layout. j. Substation lightning protection layout. k. Fixing and installation details for all electrical works, such as cabling.

REV.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

8. MTO: a. b. c. d. e. f. g. h.

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MTO for cable tray/ladder. MTO for electrical cable glands. MTO for electrical junction box. MTO for lighting system. MTO for cable installation accessories such as termination kits. MTO for earthing and lightning materials. MTO for installation materials. MTO for Substation.

3.6.5

Communication between PDCS of main substation and PDCS of ASU local substation will be via serial link. PDCS of main substation is master in this case. All serial links should be MODBUS RTU via RS485. Baud rate and other protocol parameters will be specified in detail engineering stage.

03

3.6.6

Short circuit capacity at incoming of 20KV transformers is 40KA.

03

3.6.7

Deleted

3.6.8

Total electrical power consumption should be given with quotation.

3.6.9

All electrical consumers of the package should be summarized in a consumer list, showing consumer tag number, description, normal/emergency, rated power, absorbed power and voltage. (A preliminary consumer list should be given with quotation)

03 This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

REV.

PIDEC NO.: 1210-00-PR-REQ-104

3.6.10

3.6.11

Deleted

Motors installed outdoor which are directly exposed to sun radiation should be protected by sun canopy.

03

3.6.12

Deleted

03

3.6.13

Deleted

03

3.6.14

Deleted

03

3.6.15

Deleted

3.6.16

Vendor should complete and submit the purchaser electrical motor data sheets attached to the requisition for each motor separately. Note that “purchaser requirement” part of data sheet should be filled out completely by compressor manufacturer.

3.6.17

Supply of cable glands for purchaser cables will be by purchaser. Size of cables and cable gland threads will be specified during detail engineering stage.

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

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3.6.18

The electrical equipments are subject to test by Owner or third party inspector as specified in scope of inspection forms attached.

3.6.19

Deleted

3.6.20

It will be supposed that the compressors and all related electrical consumers will start and stop from local control panel and/or compressor UCP after required logic is established, so there will not be a direct control connection between package motors, oil pump motors, oil heaters and purchaser MCC. In the other word the start/stop commands of compressor, oil pumps, and oil heaters should be generated by UCP or plant FCS and sent to MCC. Note that start/stop push buttons should be installed on the compressor local control panel or separate push button stations should be provided by Vendor.

03

3.6.21

Deleted

03

3.6.22

Deleted

3.6.23

Spare parts for commissioning/start up and two years operation should be supplied as per listed below. Spare parts necessary for commissioning & startup and two years normal operation for other equipments such as transformers, switchgears, bus ducts, cables, panels lightings equipments and etc. should be recommended by Vendor:

03

Electrical Motors:

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

REV.

Commissioning & Startup Grease Nipples where applicable 10% Sleeve bearing complete set (One for each type) Temperature sensor for bearings 5% Bearing oil level sight glass 5% Plastic cooling fan 5% Power terminal block 2% Special items (Encoder, Cooling fan) Vendor recommendations

Two years spare parts No. of machines 1 Spare item Qty Set of bearings 1 Fan, terminal blocks, space heater (MV) per 5% type

2 Qty 1

3 Qty 1

4 Qty 2

5 Qty 2

More Qty 40%

5%

5%

5%

5%

5%

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC NO.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT Rev.

Description

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TWO YEARS OPERATION SPARE PARTS

Local Control Panels Fuse Elements Bulb for Signal Lamps Signal Lamp Selector Switch Push Button

50% 50% 50% 5% 5%

Vendor recommended Vendor recommended Vendor recommended Vendor recommended Vendor recommended

Local Control Station

5%

5%

Ammeter For Control Station and Switchgear

5%

Vendor recommended

Push button Selector switch

5% 5%

Vendor recommended Vendor recommended

Vendor recommended

Vendor recommended

Other equipments

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

SHEET

ERECTION, PRECOMMISSIONING, COMMISSIONING AND START-UP

ITEM

03

Owner No.: BU-30-P-000-PRO-REQ-0008

REV.

3.7

PIPING

3.7.1

All piping shall be terminated in package B.L. with ASME B16.5 flanges up to 24” and with ANSI B16.47 B for above 24” and at the coordination approved by PIDEC. (And shall be anchorage). Package B.L. shall be defined and coordinated with PIDEC in detail engineering.

3.7.2

The MPS is produced outside ASU Battery Limits. A single tie-in point will be considered. Location of tie-in point at B.L. must be agreed with the Vendor.

3.7.3

A single tie-in point will be considered for condensate return. Location of tie-in point at B.L. must be agreed with the Vendor.

3.7.4

Instrument air and plant air requirement for the whole Bushehr Petrochemical Complex, including ASU,will be produced inside ASU supplier Battery Limits. Instrument air and plant air required for first startup of ASU will be produced by external source. Instrument air and plant air requirements for users outside ASU Battery Limits are shown on ASU process specification in item 3.2.3.5 and 3.2.3.7. Location of tie-in point at B.L. must be agreed with the Vendor.

3.7.5

Vendor with the offer will submit a layout drawing, on which will be shown the proposed terminals location for incoming and outgoing process streams and service fluids at ASU B.L.:

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

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Incoming services: - MP steam - LP steam - Instrument air (for first start up only) - Plant air (for first start up only) - Cooling water supply Outgoing process streams and services: - HP GOX - MP GAN - Instrument air - Plant air - Cooling water return

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

- Condensate 3.7.6

Prefabricated piping for process and utilities interconnections between equipment and units inside B.L. shall be by the Vendor.

3.7.7

Supply and design of all piping inside package B.L. are by Vendor.

3.7.8

All supports for piping inside package B.L. shall be supplied and designed by Vendor.

3.7.9

Stress analyses of all piping inside package B.L. are by Vendor.

3.7.10

Design and supply of all spring supports and expansion joints for piping inside package are by Vendor.

3.7.11

Design and supply of all utility stations piping inside package B.L. are by Vendor.

3.7.12

Vendor shall provide piping plan and isometrics with support marking for all piping inside package B.L.

3.7.13

Supply of insulation and paint of all piping inside B.L. are by Vendor. MTO for the insulation and paint will be provided by Vendor.

3.8

VESSEL, FILTER & EXCHANGER

3.8.1

The vessels, filter and exchangers shall be designed, built, inspected, tested in accordance with the requirements of the TEMA, ASME Boiler and Pressure Vessel code, sec. VIII, Division 1, latest edition and addenda.

3.8.2

Minimum used thickness for shell and heads for drum shall be 6 mm (excluding C.A.)

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Rev.

03

Description

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3.8.3

For spherical or ellipsoidal heads, the thickness shall not be less than the adjacent shell thickness.

3.8.4

Heads shall preferably be in single piece. Heads having more than one seam should consist of the minimum possible number of pieces. All seams shall be fully radio graphed, irrespective of radiography requirement of the drum itself.

3.8.5

Loads (Shear & Moment) at base for drums at erection, operating and test condition should submit by Vendor.

3.8.6

All the documents which submit to PIDEC for review/comment shall be included in "Final Data Book".

3.8.7

Vendor design shall completely comply with codes and specifications in this requisition as a minimum requirement.

3.8.8

All requirements of ASME code for low temperature service (such as part ULT of ASME code should be considered in design of equipment.

3.8.9

Heads shall be specified hemispherical or ellipsoidal having a ratio of 2:1 as specified in datasheet except where specifically indicated approved by the purchaser. Torispherical dished and flanged heads may be accepted if suitably formed, and when the knuckle radius is not less than 10% of vessel inside diameter and the crown radius does not exceed the vessel inside diameter. Other head types shall be approved by the purchaser.

3.8.10

The maximum allowable working pressure shall be limited by shell or head; not by minor parts such as nozzle necks, reinforcing pads, cone-to-cylinder rings, etc.

3.8.11

Wind load shall be determined in accordance with UBC 97 and seismic load shall be determined in accordance with UBC 1997 (zone 4), using the site condition as per spec. No. 1210-00-PR-ESS-101 (attached to this requisition).

3.8.12

It is the Vendor's responsibility to properly determine all thicknesses of all parts of the pressure vessels and satisfy all the requirements of the respective codes and specifications. He must also assure the stability of the equipment under all loads including seismic, wind loads and dynamic loads. Also the thickness of shell/ head to be verified by WRC-107/297 and/or FEA at nozzle to shell and pad to shell junction and at any other attachments which induced local load on shell or head.

3.8.13

Vendor shall control the local stresses in pressure vessels due to reaction of support in various conditions (erection, hydro-test, startup, operating including seismic/wind/vibration loads) and shall provide appropriate provisions for this requirement, if deemed to be necessary through calculations.

3.8.14

For design of lifting, handling and transportation attachments (lifting and tailing lug), an impact (snatch) factor of 4 shall be considered

REV.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

42

OF

57

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

(For Trunnion impact (snatch) factor of 2 should be considered). 3.8.15

Local loads on nozzles to shell and head juncture as well as for reinforcing pad edge shall be verified according to WRC bulletin No 107 and complementary bulletin No 279.

3.8.16

All openings shall be self reinforced and application of pad reinforcement for openings is not permitted. For reinforcing of openings, Vendor is restricted to use only profiles in figure XIII-2124. (e) -1 of ASME III div 1, Mandatory appendix XIII. It is essential that the hub, the curved part and the nozzle wall of the self-reinforced shall be manufactured as an integrated part. Vessel's wall to nozzle connection style must be similar to sketches in attachments E3 & E4 (smooth transition from nozzle neck to the vessel's wall) for ease of inspection and higher reliability.

3.8.17

Actual hub thickness of self-reinforcement nozzles shall not be greater than 2xactual vessel thickness.

3.8.18

All manholes shall be fitted with forged flanges and covers with davits / hinges as shown on relevant standard drawing. Also all blind nozzles shall be furnished by blind, gasket and relevant fastening.

3.8.19

Vendor shall use test coupons in the vessels to predict vessel's endlife.

3.8.20

As a minimum, for achieving after forming thickness (base-plate thickness exclusive of the thickness of the cladding material, if any), Vendor shall add an increase of 1mm or 3% to required thickness (which is larger) and then round it up to the next even number. (Please notify that required thickness shall obtain from combination of loads, not pressure load solely. Moreover thickness of cladding / weld-overlay -if any- doesn't withstand any load).

3.8.21

Rigidity of all flanges shall be checked in accordance with ASME VIII, division 1, appendix 2. Rigidity factor for integral or optional flange types (KI) shall not be greater than 0.1. Vendor shall supply flanges satisfying this criterion.

3.8.22

Assembly / erection procedure as well as required calculations shall be prepared by Vendor.

3.8.23

Nozzles as well as pads and weld lines shall not be located on the knuckle of 2:1 elliptical heads in any way. Vendor is responsible to take care of this.

3.8.24

Critical discontinuities shall be verified by FEA based on purchaser's demand.

3.8.25

Fabrication shall not commence until the Vendor has received written authorization from PIDEC and getting mentioned authorization shall be traced by Vendor. However Vendor is responsible for any delay according to project schedule. Moreover, the Vendor shall not subcontract any work without written acceptance by PIDEC. This acceptance may require an audit at the subcontractor premises by

REV.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

43

OF

57

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

the PIDEC. 3.8.26

The anchorage configuration to be also indicated on general drawings.

3.8.27

Thermal and mechanical design to be submitted by Vendor for our review/comment.

3.8.28

Vendor of heat exchangers and parts shall be responsible for the correct execution of all work and observance of all applicable technical regulations and specifications. Vendor shall also be responsible for his subcontractors.

3.8.29

In addition following notes shall also be considered by Vendor for heat exchanger(s) / pressure vessels: 

All parts of all items covered by this requisition shall be in compliance with applicable requirements of TEMA standard as well as the Engineering Standard Specifications No. 121000-HM-ESS-286, 1210-00-HM-ESS-290 and Standard Drawing 1210-00-HM-SDG-285 (attached to this requisition).



For tube sheet design Vendor to consider ASME Code Sec.VIII Div.1 Part UHX and to be of extended type to ignore test ring.



Forming of U-tubes is in Vendor’s scope of supply and P.W.H.T. shall be done, after forming.



All parts of all items covered by this requisition shall be in compliance with applicable requirements of ASME code as well as the Engineering Standard Specifications No. 1210-00PV-ESS-241, 1210-00-PV-ESS-243, 1210-00-PV-ESS-248 (if any) and Standard Drawing 1210-00-PV-SDG-240 (attached to this requisition).

3.8.30

Vendor shall consider all requirements of the order and will supply required documents that proof perfect performance in all stages from beginning to end.

3.8.31

Material

3.8.31.1

Material shall be new and have proven design. Material and corrosion allowance shall be consistent to expected life specified herein before. Materials shall be as per ASME/ ANSI. Flanges shall be as per ASME B16.5 and ASME B16.47 series ‘B’ for rating of 150# and series ‘A’ for rating of 300# and more. Also flanges shall not be slip-on type.

3.8.31.2

The gaskets used for hydro test shall be of the same type as those used for operation. Supply of blind, bolts and gaskets for test are in Vendor’s responsibility.

3.8.31.3

Gasket material shall be asbestos-free with inner and outer S.S rings suitable for service, unless otherwise it is not suitable for service. Those gaskets or stud bolts used for tests (e.g. hydro-tests) to be replaced with new one for operation. Type of S.S. rings and S.S.

REV.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

44

OF

57

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

material used in the gaskets shall be identical to pressure vessels S.S. internals. 3.8.31.4

As a minimum, gaskets for internal flanges shall be asbestos free and suitable for the service and conditions referenced in the relevant data sheets.

3.8.31.5

Material mill test certificate shall be according to EN 10204 type 3.1.

3.8.31.6

The additional supplementary requirement for temperature embrittlement factor and impact properties after step cooling shall be met according to S62 and S63 of SA-387 Specification of ASME Sec II Part A.

3.8.32

Fabrication

3.8.32.1

For all welds in nozzles where back gouging is not possible, root pass shall be made with TIG welding procedure. The Vendor shall supply materials strictly in accordance with the specification attached.

3.8.32.2

All low alloy heads shall be shaped by hot forming at temperatures defined by Code (i.e. low alloy heads shall be hot formed only).

3.8.32.3

For any internal support attachments, continuous groove weld with full penetration shall be used. All welds attached to pressure retaining components as well as sharp edges should be ground to a smooth contour.

3.8.32.4

All weld toes shall be dressed.

3.8.32.5

The grinding of weld reinforcements shall carried out by use of automatic grinding machine, not manual, to reduce the forming of notch and remove the notches formed in the corner of weld lines.

3.8.32.6

Welding profile shall be suitably prepared for resisting against crack and brittle fracture.

3.8.32.7

All required repair work shall be reported to the purchaser, and repair work will only proceed after approval by the purchaser. The repaired weld shall be subjected, as a minimum requirement to the same testing and inspection requirements as the original weld. If during final inspection additional defects are discovered, the total weld seam or area shall be examined. If second repair is necessary, purchaser’s permission must be obtained prior to proceeding with the repairs.

3.8.32.8

The cost of all repairs and subsequent inspection/ heat treatment shall be responsibility of the Vendor.

3.8.32.9

Contour of forge parts before machining shall be in conformance with final desired shape of forge part after machining (as indicated in ASME code). It means that minimum machining shall be the main objective.

3.8.32.10

None of the clips pads shall cross or cover the weld lines / seams. All of the weld lines / seams shall be bare and uncovered (inside and outside).

REV.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Rev.

Description

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3.8.32.11

Cutting and beveling for S.S. items as well as cladded items -if anyshall be performed using plasma cutting method and/or Mechanical cutting/machining. Grinding and cutting wheels shall be free of carbon steel constituents and they shall be suitable for stainless steel materials.

3.8.33

Quality Control

3.8.33.1

All pressure vessels shall be 100% radiographed.

3.8.33.2

Roll bending direction of plates shall be lengthwise and should be marked by an arrow on the plates.

3.8.33.3

The edge preparation of all items shall be based on relevant WPS as well as assembling procedure developed by Vendor and approved by purchaser.

3.8.33.4

For nozzle to shell joint following to be met: 

For abutting nozzles in normal services Dye Penetrant Test (D.P.) shall be done on radially disposed surface of the opening and nozzle to shell welds. (Full D.P. for second side of welds after back gouging and final passes.) .



On nozzle neck to shell/head welds Radiography/Ultrasonic Test (before and after welding) shall be carried out. In addition, the internal surface of the shell /head for abutting nozzles as well as the radially disposed surface of the opening for inserted nozzles shall also be ultrasonically tested (before and after welding). This is to reveal the lamellar tearing cracks.

3.8.33.5

For double-welded butt joints (joints welded on both sides) the welding procedure shall specify fabricator's standard inspection procedure used to assure metal soundness after gouging and cleaning the backside of weld.

3.8.33.6

Any non-radiographable welds of non-austenitic steel shall be inspected by magnetic particle and/or ultrasonic methods.

3.8.33.7

Radiographic/ultrasonic examination and/or other non-destructive tests before/after P.W.H.T. (if required) and during welding/ edge preparation shall be strictly conducted by Vendor in accordance with Standard Specification attached to requisition and relevant ASME code. Also MP examination and hardness measurements to be conducted after final P.W.H.T.

3.8.33.8

Result of impact tests shall contain: 

Measurement of lateral expansion (In case of Production Test Plate is required)



Determination of percent shear fracture (In case of Production Test Plate is required)

REV.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC



PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

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Absorbed energy J (N.m)

3.8.33.9

Positive Material Identification test and ferrite check shall be done for Stainless and low Alloy steel.

3.8.33.10

Inspection/repair procedure for after commissioning shall be submitted to the purchaser.

3.8.33.11

Test procedure/condition/drawings shall be submitted to PIDEC for comment/approval before proceeding with any test.

3.8.34

Guarantee

3.8.34.1

For all bought-out items, the OVERALL RESPONSIBILITY as to their suitability and performance shall be that of the Vendor’s scope. Vendor shall ensure that all requirements of inspection, testing, drawing and documentation are complied with sub-Vendor (if any).

3.8.34.2

Any approvals given by purchaser do not relieve the Vendor of any responsibility regarding guarantees, workmanship and compliance with the specification and code.

3.8.34.3

Vendor shall guarantee all the services provided by him (his subVendors and himself) for correctness, completeness, reliability, integrity, mechanical design and detail engineering and fabrication activities leading to procurement of specified items, also Vendor shall guarantee the performance of the manufactured equipment during operations, start up, shut down, steam out and testes during the equipment service life due to his responsibility.

3.8.35

Cleaning and Painting

3.8.35.1 Pickling and passivation of stainless steel parts of equipment, S.S piping, all the S.S parts of internals and externals shall be performed in accordance with Vendor's specification and in complete compliance with ASTM A380 standard. Before commencement the work, Vendor's specification shall be submitted to purchaser for approval. 3.8.36

Packing and Shipping

3.8.36.1

To avoid any deformation of shell/ vessel (pieces) during transportation, necessary provisions shall be made by Vendor.

3.8.36.2

Inside and outside surfaces of pressure vessels shall be thoroughly cleaned and shall be free from grease, weld spatter, scatter, scale, slag, rust and any other foreign matter before testing and shall be thoroughly dried and cleaned after testing.

3.8.36.3

Vendor shall supply and determine location of lifting and tailing trunnions/lugs for transportation & erection with regarding to loading/unloading and taxi arrangement also site limitation.

3.8.36.4

All nozzles shall be suitably protected during transportation using blind caps/covers. Preparation for shipping includes the necessary

REV.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

REV.

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

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blinds for flanges and caps for butt weld nozzles; shall be supplied by Vendor. 3.8.36.5

Vendor shall make sure that the package/ internal components have enough stability during erection by means of calculations and stiffen them, if necessary.

3.8.36.6

All loss commodities packages to be temporary skidded providing stable and damage free transportation. All requirements for preparation a safe and acceptable shipment shall be conducted by Vendor (i.e. transportation support saddles, spiders, nitrogen filling, foam coating for S.S surfaces, seaworthy crates, Etc.) . Vessels subject to N2 neutralization shall be N2 filled and equipped with all required N2 filling and monitoring accessories prior to shipment.

3.8.37

Vendor shall furnish spare part list for static equipment commissioning & two years as per following detail. Gasket for Blind Flanges, Girth Flanges, MH & HH: Erection, Pre-commissioning ,Commissioning & Start Up: Two Years:

100% 200%

Stud Bolts and Nuts:

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Erection, Pre-commissioning ,Commissioning & Start Up: 5% (min 2sets) Two Years: 10% for each size/type and min. 1 off Spare Part List for Heat Exchangers: Sr. No.

Spare items

1 2

Gaskets Bolts and nuts

3

Erection, pre-commissioning, commissioning and start-up spare parts 100% 5% (Minimum two sets)

Tubes (including U-type heat exchangers) *: To be recommended by Vendor.

Two years spare parts

Capital spares

200% * 10% (Minimum * two sets) per size and type for special, alloy and C.S. material) 10% (from * longest tube of each size and material)

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

REV.

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3.8.38 Vendor shall furnish spare part list for air cooled heat exchangers as per attachment No. 9. 3.9 3.9.1

03

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

3.9.2

03

Civil / steel structure: The interface between the purchaser and the Vendor shall be the following: • Steel structures and supports: foundation base plates • Loose equipment: foundation base plates • Equipment assembled on skid: skid frame All the foundation works are considered out of Vendor scope of supply Vendor is responsible to provide Architectural drawing (Plan and Section) for control room and Substation building with incorporation of interconnection piping, instrument cabling , electrical cabling and etc. All required information for performing of detail engineering of buildings should be provided by Vendor (detail design of buildings including G.A and Foundation, HVAC design, Plumbing Design, F&G related to buildings should be performed by Others.

The following items shall be in the Vendor’s scope of work and supply: • Steel structures including gratings & accessories • Shelters including cranes, sandwich panels & accessories • Concrete coating & covering where needed • All steel structures including platforms, ladders, handrails & stairs • Bolts for equipment supports on structures

3.9.3

All civil works shall be in scope of Vendor excluding foundation & supply of anchor bolts. Scope of Vendor shall include supply of steel structure (ready for installation) , shelters & its covering , primers & coating for inside concrete structures , layout plan for the buildings , paintings ,etc.

3.10

SPARE PARTS Spare parts necessary for erection, pre-commissioning/ commissioning & start- up and two years normal operation shall be recommended by Vendor in the separate quotation attached blank forms with considering attachments No.4 and 5 as a minimum.

3.10.1

Spare parts for centrifugal pumps (attachment No. 7) and for centrifugal compressors and steam turbines (attachment No. 8) shall be considered by Vendor as a minimum requirement.

3.11

ANCHOR BOLTS

3.11.1

Anchor bolts shall be designed in accordance to the “project standards specification” 1210-00-ST-ESS-746 (attached to this requisition).

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

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3.11.2

No increase in allowable stress shall be taken, when wind or earthquake are considered according to U.B.C-1612.3.1.

3.11.3

Minimum distance between anchor bolts on the bolt circle shall be as follows:

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

- For bolts diameter of 64 mm and smaller: 450 mm - For bolts diameter of 75 mm and larger: 500 mm 3.12

INSPECTIONS, TESTING AND CERTIFICATION

3.12.1

Inspections and testing shall be carried out for all the equipment with reference to the minimum requirements of the Scope of Inspection and the inspection procedure, attached to this material requisition.

3.12.2

On the basis of both the scope of inspection and the inspection procedure the Vendor shall submit the own Quality Control Plan (QCP) including: • Inspections and tests specified by the referenced Codes, Rules and Standards, • Hold points • Supplied certifications • Acceptance criteria

3.12.3

The Vendor shall advise in writing three weeks in advance date and place where materials and/or equipment will be available for inspection and test.

3.12.4

The type and extent of tests shall be in strict compliance with the contractual codes, standards, data sheets and/or specifications attached to the material requisition.

3.12.5

All welding activities shall be performed in accordance with an approved welding procedure also if no any specifications or International codes apply. Therefore relevant welding map, welding procedure specification (WPS) and procedure qualification record (PQR) shall be submitted for approval before start of relevant activity.

3.12.6

All NDT procedure, such as RTE procedure, MPE procedure, PMI procedure, PWHT procedure, etc. shall be submitted for approval before start of relevant activity.

3.12.7

Vendor shall prepare and submit for review and approval the following procedures: Code B1 002

Fabrication Quality Control Plan (Inspection & Test Plan)

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Code B1301 Code B 1103 Code B1201 Code B1202

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

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Welding key form including WPS, PQR Testing procedure Post weld heat treatment procedure (if any) Non-Destructive Examination procedures

3.12.8

All the pressure-containing components of equipment shall be complete with material certifications as required by the applicable code.

3.12.9

All certification activities shall be carried out by the Vendor at his total own care and expenses. All certificates shall be collected in the Inspection Book.

3.12.10

Inspection Book will be prepared during the fabrication; after each test or inspection, the relevant certificate signed by Client Inspector shall be inserted.

3.12.11

The goods shall not be released if the Inspection Book is not complete with all the requested documents, signed by Authority/Client Inspector.

3.13

DOCUMENTATION

3.13.1

The Vendor shall attach a transmittal letter to every document submission.

3.13.2

The Vendor’s documents shall be revised according to PIDEC/Owner comments (if any) and submitted to a new approval within two weeks from comments reception.

3.13.3

The final drawings shall be complete with the stamped sentence "final certified drawings", signed by the Vendor and shall be sent.

3.13.4

PIDEC/Owner approval or comments will concern the general aspect of the design and will not relieve the Vendor from his responsibilities regarding the respect of the requirement contained in the material requisition.

3.13.5

The Instruction manuals shall include all the documents and bulletins necessary for clear descriptions and instructions for installation, pre-commissioning, commissioning, start up, operation, maintenance purpose, tailored for the present project. Instruction manual shall be issued in English language.

3.13.6

The final mechanical catalogue (Vendor Data Book) will be issued.

3.13.7

All documents and drawings issued after order shall be issued complete with at least the following information: • Client' s name • Plant name and location • Purchase order number • Equipment item number • Client document number

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

REV.

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

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• Vendor document number • Revision and description

PDMS 3D Model of ASU shall be prepared and delivered by Vendor

03

3.13.8

03

3.14

GUARANTEES

3.14.1

The Vendor shall guarantee: • that all materials are new and free from vices and defects; • that all materials are properly stored, fabricated and handled; • that noise emission level will comply with requirements of this material requisition. • that sub-supplier are well proven and referenced for the required application.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

• that uninterrupted operation period shall be not less than 2 years. 3.14.2

The unit shall be guaranteed to operate satisfactorily considering the site conditions, giving the process performances as required on the Air Separation Unit process specification in item 3.2. Performance guarantee will be tested after construction on site during a test run. The test procedure and the applicable tolerances will be mutually agreed with the Vendor before purchaser order.

3.14.3

Performance test shall be determined by averaging the results of 3 consecutive operating days (72 hours) at the specified full load condition. The test result will be averaged over the test run period.

3.14.4

The vendor shall guarantee the Design and Engineering work of the ASU Plant as a whole for the systems comprising the package.

3.14.5

The Vendor shall guarantee that design capacities, outputs, efficiencies, utility, emission and raw materials consumption and turndown requirements for the ASU Plant as a whole are met under conditions of safe and steady operation and under automatic control.

3.14.6

Any approval of documents and technical solutions shall in no way relieve Vendor responsibility and obligation.

3.14.7

The basic procedure for performance guarantee shall be furnished by Vendor for PIDEC/Owner approval.

3.14.8

Tests of plant capacity to meet design requirement will be made during a continuous plant test run of 72 hours duration. Such tests will normally be undertaken to include the whole ASU Plant at the same time. However, individual independent systems within the ASU Plant should be tested separately where the Owner expressly so agrees.

3.14.9

If a test run is interrupted and such interruption is not due to any failure or adverse performance of equipment the following shall apply: • The plant test shall be curtailed at a time to be noted and resumed as soon as practicable when normal plant operation is restored. The test shall then be

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

REV.

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

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03

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This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

continued for the remainder of the unexpired test run time to complete the stipulated test run duration. Where such interruptions to test prevent adequate test data from being obtained the Vendor and Owner shall agree on reasonable steps to be taken to obtain the data in future if this is important to establish that guarantees are met. 3.14.10

If a test is interrupted and such interruption is due to design defects in equipment, and / or systems which are detailed by the Vendor, the following shall apply: • The tests shall be abandoned, design aspects are verified, all endeavor made to identify the fault. And the defects are rectified, by the Vendor free of charge. • A new test shall then be made to cover the stipulated period of test as if no earlier test had been attempted.

3.14.11

Operation at turn-down rates either for the complete ASU Plant, or for an independent system within the ASU Plant, or for an equipment item forming part of the ASU Plant shall be performed over a continuous period of 72 hours which shall be separate from the performance tests described in above.

3.14.12

If the result of second Performance Test does not meet the Performance Guarantees of the Package, required modifications, alterations, additions, substitutions or replacements in Equipment and/or design etc. should be performed by Vendor at his own expense

3.14.13

If the PERFORMANCE GUARANTEES of the Package does not met during the first PERFORMANCE TEST and failure of PERFORMANCE GUARANTEES are not due to causes imputable to OWNER, all costs and expenses of Vendor's personnel related to subsequent PERFORMANCE TESTS or to corrective actions under Item 3.14.12 herein above for the period during which subsequent PERFORMANCE TESTS are being awaited or conducted, shall be borne by Vendor.

3.15

PRESERVATION

3.15.1 All unpainted surface shall be protected from corrosion during shipment and subsequent outdoor I indoor storage, by coating with a rust preventive. Spare parts shall be preserved from environmental corrosion, and preservation methods shall be suitable for long-term storage. All internal parts shall be coated with rust preventive prior to shipment. 3.16

SUBMISSION REQUIRED WITH VENDOR QUOTATION

3.16.1 Vendor may submit a list of deviations and clarifications (if any) referred to the applicable codes, standards, and the project specifications attached to this material requisition. 3.16.2 Vendor may propose also alternative solutions for different configuration of the ASU unit. In this case, the same will specify the advantages assured in comparison to that described in the specifications.

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

PIDEC NO.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

53

OF

57

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

3.16.3 The bid shall include at least the following technical information's and documents: 

Process description



PFD



P&ID



Equipment list



Data sheets for all rotating equipment



Description of main static equipment



Instrument list



Control philosophy



Description of unit operation modalities



Description of control panel operation



One line diagram



Utilities consumption list



Preliminary general dimensional drawing and layout



Prefabrication degree provided for shipping



Preliminary weight of main equipment



Preliminary weight of steel structures



Proposed painting cycle



Proposed Vendor list



Design and fabrication schedule



Detailed Reference list



Control System Architecture



General Arrangement of Control Panels

REV.

03

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

4.

Description

1

Bid Technical Check List

2

Letter of Conformity (Technical)

3

Requirement for Documents (RFD)

4

List of Spare Parts (Proposed by Vendor) Spare Parts List and Interchangeability Record (SPIR) – 1/2, 2/2

SHEET

54

OF

Document No.

Rev.

No. Of Sheets

Attachment No.1

01

1

Attachment No.2 1210-00-PR-RFD-104 (Attachment No.3) Attachment No.4

01

1

02

18

01

4

01

2

Attachment No.5

00

9

01

1

Attachment No.8

01

3

Attachment No.9

01

3

Numbering Procedure

1210-00-PM-PCJ-002

01

24

Will be prepared later

12

Vendor Document Management Procedure Inspection Procedure

1210-00-QC-PCJ-001

00

17

13

Ambient ,Site Condition & Utility Data

1210-00-PR-ESS-101

02

18

14

Units of Measurement

1210-00-PR-ESS-102

00

4

1210-00-PI-ESS-406

05

28

1210-00-PV-ESS-242

01

4

1210-00-EL-CSS-501

01

14

1210-00-EL-CSS-502

01

12

1210-00-EL-ESS-501

01

22

1210-00-EL-ESS-502

01

13

1210-00-EL-ESS-503

01

10

1210-00-EL-MSS-502

01

26

1210-00-EL-MSS-503

01

24

1210-00-EL-MSS-504

01

19

1210-00-EL-MSS-505

02

12

1210-00-EL-MSS-506

01

22

1210-00-EL-MSS-507

01

18

1210-00-EL-MSS-508

01

18

1210-00-EL-MSS-509

01

14

Scope Of Inspection (SOI)

7

9

Spare Parts for Centrifugal Pumps Spare Parts for Centrifugal Compressors and Steam Turbines Spare Parts for Air Cooled Heat Exchangers

10 11

15

03

57

1210-00-QC-SOI-104 (Attachment No.6) Attachment No.7

6

8

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Owner No.: BU-30-P-000-PRO-REQ-0008

REV.

LIST OF ATTACHMENTS

SR.

5

PIDEC NO.: 1210-00-PR-REQ-104

Specifications Engineering standard Specification for 15.1 Painting Engineering standard Specification for 15.2 Nozzle Loads on Static Equipment Construction standard specification for 15.3 electrical installation in area. Construction standard specification for 15.4 electrical installation in building. Engineering standard specification for 15.5 electrical system design. Engineering standard specification for 15.6 lighting system design. Engineering standard specification for 15.7 earthing and lightning system design. Material standard specification for MV 15.8 switchgears Material standard specification for LV 15.9 switchgears Material standard specification for power and 15.10 distribution transformers. 15.11 Material standard specification for PDCS 15.12 15.13 15.14 15.15

Material standard specification for AC UPS Material standard specification for DC battery charger Material standard specification for electrical panel boards. Material standard specification for electrical cables and wires.

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

4.

Description 15.16 15.17 15.18 15.19 15.20 15.21 15.22 15.23 15.24 15.25 15.26 15.27 15.28 15.29

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Owner No.: BU-30-P-000-PRO-REQ-0008

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LIST OF ATTACHMENTS

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PIDEC NO.: 1210-00-PR-REQ-104

15.30 15.31 15.32 15.33 15.34 15.35 15.36

03

15.37

03

15.38

03

15.39

03

15.40

03

15.41 15.42

Material standard specification for cathodic protection. Material Standard Specification for Electrical Heat Tracing Material standard specification for LV variable speed drives. Material standard specification for MV capacitor banks. Material standard specification for LV capacitor banks. Material standard specification for aircraft warning lights. Material Standard Specification for Low Voltage Induction Electric Motors Material Standard Specification for Medium Voltage Induction Electric Motors Material Standard Specification for Electrical Equipment as Part of Package Material standard specification for local control stations. Material standard specification for MV variable speed drives. Engineering Standard Specification for Anchor Bolt Engineering Standard Specification for Fire Proofing Engineering Standard Specification for Thermal Insulation Material Standard Specification for Piping Engineering Standard Specification for Shell & Tube Heat Exchangers Engineering Standard Specification for Air cooled Heat Exchangers Engineering Standard Specification for Pressure Vessels Engineering Standard Specification for Towers Engineering Standard Specification for Cladding and Lining Engineering Standard Specification for Package Instrumentation Engineering Standard Specification for Effluent Gathering System Engineering Standard Specification for fire protection system Engineering Standard Specification for fire and gas system Engineering Standard Specification for safety signs Material Standard Specification for Fieldbus Control System Material Standard Specification for Cabinets

Document No.

Rev.

No. Of Sheets

1210-00-EL-MSS-510

01

13

1210-00-EL-MSS-515

01

11

1210-00-EL-MSS-517

02

17

1210-00-EL-MSS-519A

01

11

1210-00-EL-MSS-519B

01

10

1210-00-EL-MSS-520

01

7

1210-00-EL-MSS-521

02

15

1210-00-EL-MSS-522

01

22

1210-00-EL-MSS-524

01

18

1210-00-EL-MSS-528

01

10

1210-00-EL-MSS-534

01

26

1210-00-ST-ESS-746

01

21

1210-00-ST-ESS-744

01

8

1210-00-PI-ESS-407

01

38

1210-00-PI-ESS-401

02

135

1210-00-HM-ESS-286

01

37

1210-00-HM-ESS-290

01

22

1210-00-PV-ESS-241

01

42

1210-00-PV-ESS-243

01

33

1210-00-PV-ESS-248

01

20

1210-00-IN-ESS-603

02

47

1210-00-PI-ESS-408

01

22

1210-00-SA-ESS-151

03

16

1210-00-SA-ESS-152

03

34

1210-00-SA-ESS-154

03

19

1210-00-IN-MSS-601

03

48

1210-00-IN-MSS-672

03

11

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

4.

Description 15.43 15.44 15.45 15.46 15.47 15.48 15.49

16

Material Standard Specification For Programmable Logic Controllers Material Standard Specification for Machine Monitoring System Material Standard Specification for Centrifugal Compressor Material Standard Specification for Special Purpose Steam Turbine Material Standard Specification for Centrifugal Pumps for Heavy Duty Services Material Standard Specification for Centrifugal Pumps for General Services Material Standard Specification for Lubrication, Shaft Sealing and Control Oil Systems and Auxiliaries

15.50

Packing, Marking and Shipping Instruction

15.51

Spare Part Procedure

SHEET

56

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Document No.

Rev.

No. Of Sheets

1210-00-IN-MSS-673

02

34

1210-00-IN-MSS-676

01

8

1210-00-MC-MSS-301

02

26

1210-00-MC-MSS-305

01

20

1210-00-MC-MSS-307

01

29

1210-00-MC-MSS-308

02

17

1210-00-MC-MSS-317

01

29

BU-00-GE-000-MECPRC-002-00

00

59

1210-00-PI-PPL-003

02

2

1210-00-ST-ESS-742

01

26

1210-00-ST-ESS-743

01

25

1210-00-ST-ESS-744

01

8

1210-00-ST-ESS-745

01

11

1210-00-ST-ESS-746

01

21

1210-00-ST-ESS-747

01

16

1210-00-ST-ESS-748

01

11

1210-00-ST-SDG-701

01

11

1210-00-ST-SDG-754

01

10

1210-00-ST-SDG-755

01

11

Drawings

16.12

Process Unit Plot Plan Engineering standard specification for concrete design and material Engineering standard specification for design of steel structure Engineering standard specification for fire proofing Engineering standard specification for blast resistant structures Engineering standard specification for anchor bolts Engineering standard specification for storage tank foundation Engineering standard specification for grouting Standard Drawings For General Notes And Abbreviations Standard Drawing for Handrail Standard Drawing for Grating and Chequered Plate Standard Drawing for Steel Stairs

1210-00-ST-SDG-756

01

11

16.13

Standard Drawing for Ladders

1210-00-ST-SDG-757

01

13

16.14

Standard Drawing for Fire Proofing

1210-00-ST-SDG-758

01

12

16.15

Standard drawings for buildings

1210-00-ST-SDG-760

01

117

16.16

Standard drawings for doors and windows Standard Drawing for Platform and Platform Support Standard Drawing for Shell & Tube Heat Exchangers Standard Drawing for Pressure Vessels

1210-00-ST-SDG-761

02

81

1210-00-PV-SDG-245

01

14

1210-00-HM-SDG-285

01

53

1210-00-PV-SDG-240

01

82

16.1

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Owner No.: BU-30-P-000-PRO-REQ-0008

REV.

LIST OF ATTACHMENTS

SR.

03

PIDEC NO.: 1210-00-PR-REQ-104

03

16.2

03

16.3

03

16.4

03

16.5

03

16.6

03

16.7

03

16.8

03

16.9 16.10 16.11

16.17 16.18 16.19

Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

AIR SEPARATION UNIT Rev.

Description

4.

Description 16.20

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Owner No.: BU-30-P-000-PRO-REQ-0008

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LIST OF ATTACHMENTS

SR.

17

PIDEC NO.: 1210-00-PR-REQ-104

Instrument/Electrical Connection Details

Data Sheets Typical Data Sheet for Low Voltage Electric 17.1 Motors (Ex) Typical Data Sheet for Low Voltage Electric 17.2 Motors (Non-Ex) Typical Data Sheet for Medium Voltage 17.3 Electric Motors (Ex) Typical Data Sheet for Medium Voltage 17.4 Electric Motors (Non-Ex)

Document No.

Rev.

No. Of Sheets

1210-00-IN-SKT-005

00

17

1210-00-EL-DSH-521 A

00

2

1210-00-EL-DSH-521 B

00

2

1210-00-EL-DSH-522 A

00

2

1210-00-EL-DSH-522 B

00

2

Attachment No. : 01 EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

Bid Technical Check List

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

REV.

PIDEC No.: 1210-00-PR-REQ-104

SHEET

Attention:

1

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

1

OF

1

THIS SHEET HAS TO BE RETURNED WITH THE QUOTATION.

YES

NO

NOT APPLICABLE

       

       

       

               

               

               

HAVE YOU INCLUDED IN YOUR QUOTATION :

1.1

LETTER OF CONFORMITY (TECHNICAL)

1.2

LIST OF INCONSISTENCIES

1.3

SPARE PART LIST

1.4

SPECIAL TOOLS

1.5

MANUFACTURING AND DELIVERY SCHEDULE

1.6

SUB-VENDOR LIST

1.7

QUALITY ASSURANCE MANUAL (OR CERTIFICATE)

1.8

REFERENCE LIST

2

03

Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

HAVE YOU STUDIED ,TAKEN INTO ACCOUNT AND WILL YOU FOLLOW INSTRUCTIONS STATED IN THE REQUISITION NOTES REGARDING:

2.1

ENGLISH LANGUAGE

2.2

UNITS OF MEASUREMENT

2.3

NAME PLATE

2.4

AMBIENT AND SITE CONDITION

2.5

PROGERRSS REPORTING

2.6

INSPECTION REQUIREMENTS

2.7

PARTIAL DELIVERY CONDITIONS

2.8

DOCUMENT REQUIREMENTS

2.9

PURCHASER’S DOCUMENT NUMBERING PROCEDURE

2.10

QUALITY DOSSIER

2.11

FINAL VENDOR DATA BOOK PREPARATION

2.12

FINAL DOCUMENT DELIVERY

2.13

FILLING THE SPIR FORM

2.14

MASTER AND DETAILED PACKING LIST

2.15

OVERALL RESPONSIBILITY

2.16

FABRICATION START

Vendor Name ,Date, Signature (VENDOR)

Attachment No. : 02 EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT Letter of Conformity

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

1

OF

1

TO : PETROCHEMICAL INDUSTRIES DESIGN & ENGINEERING COMPANY (PIDEC)

FROM : ....................................... (VENDOR )

Herewith we confirm that our quotation ...........................................in response to (QUOTATION )

your inquiry……….....1210-00-PR-REQ-104....... dated .....07.10.2013..is fully in (PURCHASER INQUIRY )

( DATE )

accordance with the conditions as stated therein and we confirm that all Technical requirements as stipulated in the above mentioned inquiry documents , have been adhered to, except deviations stated as per following notes.

This its rights rights is is the the property property ofof BUPC BUPCand andmust mustbebeheld heldin inconfidence. confidence.NoNodisclosure, disclosure, This document document with with all all its reproduction reproduction or or other other use use of of the the document document in in whole whole or or parts parts is is to to be be made made without without the the prior prior consent consent of of BUPC BUPC

No Deviation Deviation (Refer to Letter No. …………………)

Date, Signature (VENDOR)

NOTES: 1)

Deviations shall be listed separately with brief explanations.

2)

If no deviation exists, vendor shall specify by writing “No Deviation”.

REV.

03

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT

Owner No.: BU-30-P-000-PRO-REQ-0008

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

SHEET

1

REQUIREMENT FOR DOCUMENTS (RFD) OF

AIR SEPARATION UNIT

OF

18

REV.

03

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

Code

Purpose of Issue ( R=Review, I=Information, A=Approve )

Document Title

With Bid Copy

CD

2

OF

After Order Award Copy

CD

No.of Week

REV.

03

18 Upon order Completed prior to shipment Copy

Note

CD

SCHEDULING DOCUMENTS PN01

Manufacturing and production schedule

R

4

PN02

Drawing/ Document schedule

R

4

PN03

Sub-order schedule

R

4

PN04

Periodical status report

R

4

1

2

2

2

1,2

2

2

2

3

Notes: 1- The scope and extend of vendor reporting and scheduling document shall be set forth and agreed with planning engineer and procurement coordinator of the respective Project for each and every individual purchase order depending on complexity time sensitively and critically of the order. 2- Updated schedule shall be attached to periodical reports 3- Periodical reports shall be furnished as out lined in project specific procedure for vendor reporting and expediting.

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

QUALITY DOCUMENTS QC01

Letter of conformity

R

3

QC02

Bid technical checklist

R

3

QC03

Quality management system manual

I

3

QC04

Inspection & test plan

A

4

1

4

8

2

QC05

Inspection and shop test procedure

A

4

1

4

8

2

QC06

Vendor quality control records

A

8

2

2,4

QC07

Certificate of materials

A

8

2

2,4

QC08

Welding procedures (WPS,PQR if applicable)

A

8

2

QC09

Welder qualification records (if applicable)

A

8

2

2,4

QC10

Final certificate of inspection and release

A

8

2

2,4

QC11

NDT records (if any)

A

8

2

2,4

QC12

PWHT records / procedure (if any)

A

8

2

2,4

QC13

Alloy verification / PMI records (if any)

A

8

2

2,4

8

2

2

4

4

1

1

4

4

Notes: 1-Above mentioned documents also to be included in sub-supplier or sub contractor if applicable. 2-To be issued in process and before shipment. 3-Need not to be approved by PIDEC. 4-These Documents shall be endorsed by inspector in shop.

EXPORT DOCUMENTS PQ01

List of Sub-supplier

A

3

PQ02

Certificate Of Origin (4 Original + 4 Copies)

A

4+4

2

PQ03

Master Packing List (4 Original + 4 Copies)

A

4+4

2

PQ04

Detailed Packing List (4 Original + 4 Copies)

A

4+4

2

PQ05

Drawing for Oversize/Overweight Packages (If applicable)

R

3

8

8

2

PQ06

Material Handling Procedure (If applicable)

R

3

8

8

2

PQ07

Material Storage Procedure (If applicable)

R

3

8

8

2

PQ08

Bill of Lading (4 Original + 4 Copies)

R

4+4

2

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

Code

Purpose of Issue ( R=Review, I=Information, A=Approve )

Document Title

With Bid Copy

CD

3

OF

After Order Award Copy

PQ09

Commercial Invoice (4 Original + 4 Copies)

A

PQ10

Transportation Drawing(If applicable)

I

3

PQ11

Handling & Transport Protective Measures at Site (If applicable)

I

3

CD

No.of Week

REV.

03

18 Upon order Completed prior to shipment Copy

Note

CD

4+4

2

8

8

2

8

8

2,3

Notes: 1-To be issued periodically. 2-To be issued before shipment. 3-Need not to be approved by PIDEC.

02

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

SAFETY DOCUMENTS SA01

Material Safety Data Sheet (MSDS)

R

4

Email

8

8

2

1

SA02

HSE Instructions

A

4

Email

8

8

2

2

SA03

HSE Plans

I

SA04

Fire water network layout for ASU plant

A

4

Email

8

8

2

1

SA05

Fire fighting equipment layout for ASU plant

A

4

Email

8

8

2

1

SA06

Fire and gas alarm system sensor location for ASU plant

A

4

Email

8

8

2

1

SA07

Safety sign layout for ASU plant

A

4

Email

8

8

2

1

SA08

Escape route layout for ASU plant

A

4

Email

8

8

2

1

SA09

Block diagram for F&G system

R

4

Email

8

8

2

1

SA10

Cause and effect for F&G system

R

4

Email

8

8

2

1

SA11

Spray system drawing

A

4

Email

8

8

2

1

SA12

F&G panel detail drawing

R

4

Email

8

8

2

1

SA13

Installation details drawing for fire fighting system

R

4

Email

8

8

2

1

SA14

Installation details drawing for F&G system

R

4

Email

8

8

2

1

SA15

Safety equipment index

R

4

Email

8

8

2

1

SA16

Safety Manual

A

4

Email

8

8

2

1

SA17

data sheet for F&G facilities

A

4

Email

8

8

2

1

SA18

data sheet for fire fighting equipment

A

4

Email

8

8

2

1

SA19

data sheet for fire safety equipment

A

4

Email

8

8

2

1

SA20

data sheet for safety sign

A

4

Email

8

8

2

1

SA21

HAZOP procedure

A

4

Email

8

8

2

1

SA22

HAZOP study report

R

4

Email

8

8

2

1

SA23

HAZOP action close out

R

4

Email

8

8

2

1

SA24

SIL procedure

A

4

Email

8

8

2

1

SA25

SIL study report

R

4

Email

8

8

2

1

SA26

SIL verification report

R

4

Email

8

8

2

1

3

1

3

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

Code

Purpose of Issue ( R=Review, I=Information, A=Approve )

Document Title

With Bid Copy

CD

4

OF

After Order Award Copy

CD

No.of Week

REV.

03

18 Upon order Completed prior to shipment Copy

Note

CD

Notes: 1- MSDS shall be provided for all potentially dangerous materials such as: Chemicals, Catalysts, Lubrication Oil, Foam, Portable extinguishers (all types),Gases (CO2, Clean Agent, …), Paint, Solvent, Insulation material (PU, mineral wool, …), Perlite, Electrode, Resin, Coating material, Lining material (rubber, epoxy, …), Ionization heat detectors (including radioactive source), Nuclear Level elements (including radioactive source), All radioactive sources, All Laser sources. 2- HSE instructions shall be provided for all items of equipment of instrument that may be harmful to human health or safety in case of malfunction, including; electrical items, Rotating items, Instrument Items. 3- HSE Plan shall be provided for those manufacturers that our personnel may perform audit or inspection in their workshops, to ensure safety of our colleagues in such plants.

TECHNICAL DOCUMENTS TE01

Catalogue and Brochure

I

TE02

Dimensional and weight drawings

A

3

1 3

1

8

8

2

1,3

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

Notes: 1- To be issued before shipment. 2- Need not to be approved by PIDEC. 3- Drawings should be approved by PIDEC.

PROCESS

02

T1

PFD & Material balance

A

2

1

4

Email

8

2

T2

P&ID

A

6

1

7

Email

8

2

T3

Process description

A

2

1

4

Email

8

2

T4

Equipment list

A

2

1

4

Email

8

2

T5

Equipment datasheet

A

-

-

4

Email

8

2

T6

Instrument datasheet

A

-

-

4

Email

8

2

T7

Process control philosophy

A

-

-

4

Email

8

2

T8

Process control requirement

A

-

-

4

Email

8

2

T9

Cause & effect diagram

A

-

-

4

Email

8

2

T10

Interlock description

A

-

-

4

Email

8

2

T11

Operating / erection instruction

A

-

-

4

Email

8

2

T12

Operating / maintenance manual

A

-

-

4

Email

8

2

T13

Safety Manual

A

-

-

4

Email

8

2

T14

Specification for oxygen service

A

-

-

4

Email

8

2

T15

HAZOP study report and close out sheets

A

-

-

4

Email

8

2

T16

SIL study report and SIL verification

A

-

-

4

Email

8

2

T13

Utility consumption list

A

-

-

4

Email

8

2

T14

Chemical, adsorbent, catalyst, resin specifications & consumption list

A

-

-

4

Email

8

2

T15

Line list

A

-

-

4

Email

8

2

2

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

Code

Document Title

Purpose of Issue ( R=Review, I=Information, A=Approve )

With Bid

5

After Order Award

Copy

CD

Copy

CD

No.of Week

OF

03

18 Upon order Completed prior to shipment Copy

CD

Note

T16

Insulation property / requirement

A

-

-

4

Email

8

2

T17

Special piping items

A

-

-

4

Email

8

2

T18

Effluent Summary

A

-

-

4

Email

8

2

T19

Material Selection Diagram

A

2

1

4

Email

8

2

-

T20

Block Flow Diagram

A

2

1

4

Email

8

2

-

T21

Engineering Design Basis

A

2

1

4

Email

8

2

-

T22

Depressurizing Philosophy

A

-

-

4

Email

8

2

-

T23

Isolation Philosophy

A

-

-

4

Email

8

2

-

INSTRUMENT

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

REV.

T19

General Index

R

-

-

4

Email

8

2

T20

Filled out data sheets

R

-

-

4

Email

8

2

T21

Catalogue and brochure

R

-

-

4

Email

8

2

CALCULATIONS: T22

Calculation data (where applicable) for noise& control valves

R

-

-

4

Email

8

2

T23

Flow elements calculations

R

-

-

4

Email

8

2

T24

Safety valves calculations

R

-

-

4

Email

8

2

T25

Stress analysis Thermo well

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

GENERAL DRAWINGS: T26 T27

Drawings showing overall drilling and mounting dimensions Electrical wiring connection and junction box with terminal arrangement diagrams

T28

Process and Air Hook ups

R

-

-

4

Email

8

2

T29

Fabrication / erection drawings

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

T30

T31

T32 T33

Field layout indicating instruments and junction boxes locations and cable routing Local control panels (dimensions, specifications, front and internal general arrangements, wiring diagrams, terminations, etc.) Instruments materials and calibration certificates Local gauge board( dimensions, general arrangements, list of materials) LIST:

T34 T35 T36

Instrument list indicating type, make , characteristics and specification Cable list indicating cable type, length, source and destinations Instrument air and power requirements

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

Code

Document Title

Purpose of Issue ( R=Review, I=Information, A=Approve )

With Bid

6

After Order Award

Copy

CD

Copy

CD

No.of Week

OF

Copy

CD

Alarm and trip set point list

R

-

-

4

Email

8

2

T38

I/O list

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

CONTROL CABINET:

T39 T40

Sub-Vendor’s and main Supplier’s listings

A

-

-

4

Email

8

2

T41

Bill of Material (Hardware and software)

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

I

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

T42

T43 This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

Certifications and approvals for PLC’s and other peripheral hardware List of consumables for erection, commissioning and start-up

T44

T45 T46 T47 T48

T49 T50 T51 T52

T53

T54 T55 T56

Technical data sheets with component part no. for each component of the control system Proposed layout for the cabinets and other equipment in auxiliary/ control room, indicating dimensions, access spaces, weights, etc. Control philosophy (narratives) and proposed control system block diagram showing all system main hardware/equipment and their interconnections Electrical power consumption ,heat dissipation (both 110 VAC and 24 VDC) Electrical power supply distribution diagram which indicates cables size and fusing capacity for each feeder Detailed grounding and shielding requirements for all equipment Cabinet’s dimensions/ general arrangement and cabinets internal arrangements drawings. A reference list of projects where the offered system is at least two(2) year in operation Functional design specification for hardware and software Interconnecting cable schedule with cable list System internal cabling and terminations, including system internal cable list PLC loop wiring diagrams for each tag No. indicating tag No. , terminals , barriers/relays , I/O channels , installed spares , etc. Logic diagram and functional charts of the interlocks and sequences controls System configuration indicating system key codes and software distribution Hardware assignments including assignments of terminals, isolators, boards, I/O modules and channels, etc.

03

18 Upon order Completed prior to shipment

T37

T38

REV.

Note

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

Code

Document Title

Purpose of Issue ( R=Review, I=Information, A=Approve )

With Bid

7

After Order Award

Copy

CD

Copy

CD

No.of Week

OF

Copy

CD

T57

Factory / Site acceptance test procedure

A

-

-

4

Email

8

2

T58

Painting Specification

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

T60

T61

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

T62

Modbus list (including exchange signals with FCS system, address ,….) Calculation of overall system availability/reliability including the failure mode and effect analysis A fault finding/trouble shooting narrative for the complete system(Recommended format is an “if-then” connection diagram A list of special tools/ instruments needed for the owner to operate the system.

T63

Catalogue and Brochure

R

-

-

4

Email

8

2

T64

Test records (vendor’s quality control)

R

-

-

4

Email

8

2

T65

Test records (factory acceptable test)

A

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

T66 T67

Proposed Graphic display pages based on purchaser initial information (if any). Proposed logging and report formats (if any)

T68

Installation Manual

R

-

-

4

Email

8

2

T69

Operation Manual

R

-

-

4

Email

8

2

T70

Maintenance Manual

R

-

-

4

Email

8

2

T71

Engineering and user’s manual

R

-

-

4

Email

8

2

GOVERNOR SYSTEM: T72

System configuration and I/O listing

R

-

-

4

Email

8

2

T73

Programming manuals

R

-

-

4

Email

8

2

T74

Termination panels

R

-

-

4

Email

8

2

T75

Outline drawing

R

-

-

4

Email

8

2

T76

Filed connection diagram

R

-

-

4

Email

8

2

T77

Governor

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

VIBRATION MONITORING SYSTEM: T78 T79 T80

Manual for configuration software Expert and predictive condition monitoring software Vibration and condition Monitoring documents including, warning and shut down limits AS BUILT DRAWINGS:

T81

as built (within 2 weeks after vendor’s receipt of marked up drawings)

03

18 Upon order Completed prior to shipment

(system data base).

T59

REV.

Note

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

Code

Document Title

Purpose of Issue ( R=Review, I=Information, A=Approve )

With Bid

8

OF

After Order Award

Copy

CD

Copy

CD

No.of Week

REV.

03

18 Upon order Completed prior to shipment Copy

CD

Note

MECHANICAL T40

General Index

A

2

1

4

Email

8

2

T41

Complete/Filled-in data sheets (if required)

A

2

1

4

Email

8

2

T42

Mechanical Catalogue and brochure

R

-

-

4

Email

8

2

T43

Un-priced copy of suborders

A

-

-

4

Email

8

2

T44

Vendor Specifications (if any)

A

-

-

4

Email

8

2

-

-

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

CALCULATIONS T45

Weight estimation (item wised)

A

2

1

-

-

T46

Mechanical design calculations/ FEA analysis

A

-

-

4

Email

8

2

T47

Thermal design calculation( if required)

A

-

-

4

Email

8

2

T48

Nozzle load calculation

A

-

-

4

Email

8

2

T49

External load calculation

A

-

-

4

Email

8

2

T50

Foundation load diagram and calculation

A

-

-

4

Email

8

2

A

-

-

4

Email

8

2

A

-

-

4

Email

8

2

T51 T52

Anchor bolt sizing (Material, size and calculation) Total volume of fabrication and erection welding at site in kilograms

-

T53

Transportation calculation

A

-

-

4

Email

8

2

T54

Erection calculation

A

-

-

4

Email

8

2

DRAWINGS T55

General arrangement drawings

A

2

1

4

Email

8

2

T56

detail drawing with list of components

A

-

-

4

Email

8

2

T57

Support/ load Drawings

A

-

-

4

Email

8

2

T58

Part list

A

-

-

4

Email

8

2

T59

Name plate drawings

A

-

-

4

Email

8

2

T60

Gasket drawings

A

-

-

4

Email

8

2

T61

Piping support drawing

A

-

-

4

Email

8

2

T62

Platform & ladder detail drawings

A

-

-

4

Email

8

2

T63

Transportation drawing

A

-

-

4

Email

8

2

PROCEDURES T64

Shop test procedure / condition

A

-

-

4

Email

8

2

T65

Pressure test procedure

A

-

-

4

Email

8

2

T66

Heat treatment procedure ( if applicable )

A

-

-

4

Email

8

2

1

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD)

Project No. : 1210

Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

Code

Document Title

Purpose of Issue ( R=Review, I=Information, A=Approve )

With Bid

9

OF

After Order Award

Copy

CD

Copy

CD

No.of Week

Copy

CD

Painting procedure

A

-

-

4

Email

8

2

T68

Pickling & Passivating procedure for S.S. surfaces

A

-

-

4

Email

8

2

T69

Repair procedure ( if applicable )

A

-

-

4

Email

8

2

T70

Weld overlay procedure( if applicable )

A

-

-

4

Email

8

2

T71

Rubber lining procedure( if applicable )

A

-

-

4

Email

8

2

T72

Refractory/ Lining curing procedure( if applicable )

A

-

-

4

Email

8

2

T73

Transportation procedures and sketches

A

-

-

4

Email

8

2

T74

Erection procedure with sketch

A

-

-

4

Email

8

2

T75

Field test procedure

A

-

-

4

Email

8

2

T76

Inspection procedure/manual for after commissioning

A

-

-

4

Email

8

2

R

-

-

4

Email

8

2

R

-

-

4

Email

8

2

4

Email

T77 T78 T79

02

Anchor Bolt arrangement /calculation Foundation loading dead, operating ,wind & Earth Quake Architectural Drawings / Plan & Section With Required Openings

A

2

PIPING T79

Piping General arrangement

A

2

1

4

Email

8

2

T80

Required maintenance / access space

R

-

-

4

Email

8

2

T81

Piping Material Specification

R

-

-

4

Email

8

2

T82

Piping isometric

R

-

-

4

Email

8

2

T83

MTO for consumable material

A

-

-

4

Email

8

2

T84

MTO for loose piping items

A

-

-

4

Email

8

2

T85

Plot Plan

A

-

-

4

Email

8

2

T86

Painting Specification

A

-

-

4

Email

8

2

R

3

Email

8

2

A

3

Email

8

2

4

Email

8

2

4

Email

8

2

4

Email

8

2

ELECTRICAL T87 T88 T89

Technical Data & Specifications List of Deviations to Purchase Specifications Bearing type/ lubrication/ oil pressure/ flow rate / lubrication intervals

R

T90

Reference list

R

T91

Data Sheet Completed by Vendor with Actual Equipment Data

R

3

4

03

18 Upon order Completed prior to shipment

T67

STRUCTURE

REV.

Note

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

Code

T92 T93 T94 T95

General arrangement drawing showing dimensions and weight Main terminal box drawing showing main connections, size and No. of entries, etc. Outline drawing Showing Dimensions, Weights, Shipping Sections, Aisle Spaces, Foundation Details, Installation Details, etc. Torque/speed curves with internals & accelerating times at 80 & 100% voltage

With Bid

10

After Order Award No.of Week

OF

Copy

CD

Email

8

2

4

Email

8

2

4

Email

8

2

R

4

Email

8

2

Copy

CD

R

4

R R

Copy

3

CD

Thermal capability curve for MV motors

R

4

Email

8

2

T97

Current/speed curves

R

4

Email

8

2

R

4

Email

8

2

R

4

Email

8

2

4

Email

8

2

T99

Rotor drawing and data for torsional analysis Connection diagrams for RTD's heaters & other auxiliaries

3

03

18

Upon order Completed prior to shipment

T96

T98

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

Document Title

Purpose of Issue ( R=Review, I=Information, A=Approve )

REV.

T100

Electrical consumer list of package

A

T101

Electrical wiring/termination diagram

A

4

Email

8

2

T102

Eearthing/Lightning drawings

A

4

Email

8

2

T103

Cable laying drawings

A

4

Email

8

2

Note

02

Note: In addition to the above documents, all documents requested in section 3.6.4 of the requisition shall be provided by vendor MACHINERY MANUAL: T104

Installation Manual (Including alignment data/ drawings)

R

4

Email

8

2

3

T105

Operation Manual

R

4

Email

8

2

3

T106

Maintenance Manual

R

4

Email

8

2

3

T107

Technical data Manual

R

4

Email

8

2

3

PUMPS: T108

T109 T110

T111

Performance curve for operating conditions for each stage and for the whole pump as per API-610 Filled-out API format data sheets (pump, coupling, gear, lube system, Seal systems, etc.) Data sheet and drawings for all equipment and instrumentation inside the package General arrangement drawings for EACH EQUIPMENT and AUXILLIARY SYSTEM showing following items as min. : - Dimensioned location, size, rating and facing of nozzles and all other connections for hookup by others,

R

3

4

Email

6

8

2

R

4

5

Email

6

8

2

4

Email

6

8

2

5

Email

6

8

2

R

R

4

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

Code

Document Title

-

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

-

Purpose of Issue ( R=Review, I=Information, A=Approve )

With Bid Copy

CD

11

After Order Award Copy

CD

No.of Week

OF

Copy

CD

R

4

Email

8

2

T113

Equipment general drawings included all auxiliaries with bill of materials

R

4

Email

8

2

T114

Name plate drawings

R

4

Email

8

2

T115

Coupling drawing ,data sheet and catalogue

R

4

Email

8

2

T116

Fabrication / erection drawings

R

4

Email

8

2

T117

Auxiliary piping & Equipment drawing with loads and estimated moments for foundations and supply limits

R

4

Email

6

8

2

T118

Cross sectional drawing and bill of material

R

4

Email

6

8

2

T119

Detailed Drawing for sealing system

R

4

Email

6

8

2

R

4

Email

8

2

R

4

Email

8

2

R

4

Email

8

2

R

4

Email

8

2

R

4

Email

8

2

R

4

Email

8

2

T122 T123 T124 T125

Note

properly indicated and listed (composite for pumps, turbine, etc.) including list of connections. Min. height and max. weight for maintenance Maintenance platform for better access Location of terminal boxes and control panels Grounding detail Direction of rotation Center of gravity and listing points Dimensional and weight for all equipment in package

Drawing for ARC valves

T121

03

18

Upon order Completed prior to shipment

T112

T120

REV.

Thrust and radial bearing assembly drawing with parts list and loading data Rotor assembly drawing with bill of materials and part number Alignment and leveling diagram and data including allowable tolerances Equipment drawing and/or specification for each individual equipment, material, etc. Data sheet and drawings for all equipment and instrumentation inside the package Surface preparation and painting specifications and procedure

4

6

T126

As built clearance

R

4

Email

8

2

T127

Auxiliary piping & Equipment plant drawing with loads and estimated moments for foundations and supply limits

R

4

Email

8

2

T128

Part List for all package component

R

4

Email

8

2

PROCEDURES T129

Shop and site acceptance test procedure

R

4

Email

8

2

4

T130

Performance test procedures

R

4

Email

8

2

4

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

Code

Document Title

Purpose of Issue ( R=Review, I=Information, A=Approve )

With Bid Copy

CD

12

After Order Award Copy

CD

No.of Week

OF

REV.

03

18

Upon order Completed prior to shipment Copy

CD

T131

Run test procedures

R

4

Email

8

2

T132

Heat treatment procedure

R

4

Email

8

2

T133

Erection and preservation procedure

R

4

Email

8

2

T134

Hydro testing procedure

R

4

Email

8

2

T135

Fabrication / erection drawings

R

4

Email

8

2

T136

Certified rotor balance data for multistage pumps

R

4

Email

8

2

T137

Hydro-testing procedure

R

4

Email

8

2

T138

Equipment drawing and/or specification for each individual equipment, material, etc.

R

4

Email

8

2

Note

4

COMPRESSOR:

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

T139 T140 T141

T142

T143 T144 T145 T146 T147 T148 T149

General Index P & I diagram with supply limit and connections Filled-in data sheets (proposal/as-built) for Compressor, Gear, Noise, Coupling, control valves, anti-surge valve, etc. Performance curve for operating conditions for each stage as per API-617/ 672 (proposal/as-built) Start-stop sequences including data on operating restrictions to protect equipment during start-up operation and shutdown Utility consumption list Lubricant list including type and consumption Estimated/ exact weight (machine/ rotor), dimension and max. maintenance weight (proposal/as-built) Part list and bill of material for package List of exceptions to API-617/ API 672, and other purchase specifications Vendors standard surface preparation and painting specifications

R

6

7

Email

2

8

2

A

6

7

Email

6

8

2

A

4

5

Email

8

8

2

A

2

3

Email

8

8

2

R

3

4

Email

12

8

2

R

4

5

Email

6

8

2

R

2

3

Email

14

8

2

R

4

5

Email

12

8

2

R

2

3

Email

12

8

2

A

2

R

3

T150

Catalogue and Brochure

R

2

T151

Technical data and reference list

R

3

R

3

T152 T153 T154 T155

Statement of manufacturer’s testing capabilities Un-priced copies of sub-order(s) (main parts) Shipping weights and dimensions (estimated/as-built) Weather protection and winterization required at job site

R

2

4

Email

8

2

8

2

8

2

4

Email

5

Email

4

8

2

R

4

5

Email

22

8

2

R

3

4

Email

10

8

2

3

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

Code

Document Title

Purpose of Issue ( R=Review, I=Information, A=Approve )

With Bid Copy

CD

13

After Order Award

OF

Copy

CD

No.of Week

Copy

CD

T156

Mechanical design calculations/ analysis

R

4

Email

22

8

2

T157

Lateral analysis report

A

4

Email

10

8

2

T158

Torsional Vibration report

A

4

Email

10

8

2

T159

Vibration analysis report

A

4

Email

10

8

2

T160

Thermal design calculation

R

4

Email

22

8

2

T161

Anchor bolt detail (Material/size/calculation)

R

4

Email

8

8

2

T162

Foundation load diagram and calculation

R

4

Email

8

8

2

T163

External load calculation

R

4

Email

6

8

2

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

T164 T165

T166

R

4

5

Email

6

8

2

R

3

4

Email

6

8

2

R

4

5

Email

6

8

2

T167

Seal leakage rates

R

2

3

Email

6

8

2

T168

Balance piston leakage rates

R

2

3

Email

6

8

2

R

3

4

Email

6

8

2

R

2

3

Email

6

8

2

A

6

7

Email

6

8

2

R

7

Email

20

8

2

7

Email

20

8

2

7

Email

8

8

2

T169 T170

Minimum length of straight pipe required at machine inlet or side inlets Maximum and minimum allowable seal pressure for each compressor DRAWINGS

T171

T172

General arrangement drawing showing following items as min. : -Dimensioned location, weights, size, rating, and facing of nozzles and all other connections for hookup by others, properly indicated and listed (composite for compressor, turbine, etc.) including list of connections. - Min. height and max. weight for maintenance - Maintenance platform for better access - Location of terminal boxes and control panels - Name plate format - Grounding detail - Direction of rotation - Center of gravity and listing points Equipment drawings included all auxiliaries with bill of quantities

T173

Equipment part list with bill of materials

R

T174

Dimensional and weight Drawings for all equipment in package

R

6

03

18

Upon order Completed prior to shipment

CALCULATIONS

Allowable forces and moments for piping connections Foundation block diagram with weights, forces and moments Calculation for conditions of maximum thrust during start up and various operating cases.

REV.

Note

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

Code

T175

T176

T177

T178

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

T179

Document Title

Auxiliary piping & Equipment plant drawing with loads and estimated moments for foundations and supply limits Foundation drawing with distribution of load and moments, location and anchor bolts detail of compressor and auxiliaries with direction & magnitude of all rotating forces and location of C.G. ,limits of amplitudes and partial deflections Vibration and condition Monitoring documents including, warning and shut down limits, wiring diagram and bill of materials Anti -surge control diagram Cross-sectional drawing of compressor , seal, coupling, gear, pumps and etc. including all tolerances and necessary information Seal System drawings including: Seal system schematic and bill of material - Seal system arrangement drawing and list of connections - Seal system component drawings and data - Seal assembly drawing and part numbers - Buffer gas system schematic and bill of material - Buffer gas system arrangement drawing and list of connections Buffer gas system component drawing and data Assembly drawing of compressor, turbine, seal, coupling, gear, pumps and etc. including all tolerances and necessary information Thrust and radial bearing assembly drawing with parts list and loading data Rotor assembly drawing with bill of materials and part number Alignment and leveling diagram and data including allowable tolerances

Purpose of Issue ( R=Review, I=Information, A=Approve )

With Bid

14

After Order Award

OF

CD

No.of Week

Copy

CD

7

Email

6

8

2

5

Email

6

8

2

R

5

Email

10

8

2

R

4

Email

10

8

2

4

Email

14

8

2

R

5

Email

8

8

2

R

6

Email

22

8

2

R

6

Email

14

8

2

R

6

Email

22

8

2

R

6

Email

24

8

2

R

R

R

4

3

CD

03

18

Upon order Completed prior to shipment

Copy

Copy

REV.

Note

-

T180

T181

T182 T183 T184

PROCEDURES/ REPORTS T185

Site acceptance test procedure

R

5

Email

24

8

2

T186

Shop performance test procedures

R

5

Email

24

8

2

4

T187

Run test procedures

R

5

Email

24

8

2

4

T188

Hydro/helium testing procedure

R

5

Email

24

8

2

4

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

Code

Document Title

Purpose of Issue ( R=Review, I=Information, A=Approve )

With Bid Copy

CD

15

After Order Award

OF

REV.

03

18

Upon order Completed prior to shipment

Copy

CD

No.of Week

Copy

CD

Note

T189

Painting Procedure

A

5

Email

4

8

2

T190

Impeller over-speed test report

A

4

Email

24

8

2

5

T191

Mechanical running test report

A

4

Email

24

8

2

5

T192

Performance test data and curves

A

4

Email

24

8

2

5

T193

Rigging and lifting instructions.

R

5

Email

24

8

2

3

T194

Preservation Procedure

I

5

Email

24

8

2

3

T195

Preparation for storage at job site before installation

I

5

Email

24

8

2

3

STEAM TURBINE: T196

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

T197 T198 T199 T200 T201 T202 T203 T204 T205 T206

General Index P & I diagram with supply limit and connections Filled-in data sheets (proposal/as-built) for Turbine, noise, control valves, etc. Curves showing steam flow versus horsepower (estimated/certified) Curves showing extraction/induction performance (estimated/ certified) Curve showing steam flow versus valve lift Curve showing steam flow versus firststage pressure (certified) Curves showing steam flow versus speed and efficiency (estimated/certified) Steam correction factors (certified) Control- and governor-system description and schematic Over speed shutdown system description and schematic

R

6

7

Email

2

8

2

A

6

7

Email

6

8

2

A

4

5

Email

8

8

2

A

2

3

Email

10

8

2

A

2

3

Email

10

8

2

R

4

Email

10

8

2

A

4

Email

10

8

2

4

Email

10

8

2

R

3

Email

10

8

2

R

4

Email

12

8

2

R

4

Email

12

8

2

7

Email

4

8

2

A

3

T207

Part List for all package component

R

6

T208

Catalogues and Brochures

R

2

8

2

T209

Technical data and reference list

R

3

8

2

R

2

R

3

4

Email

4

8

2

T210 T211

List of exceptions to API 612 and other purchase specifications Vendors standard surface preparation and painting specifications

2

T212

Start - Stop sequences

R

3

4

Email

14

8

2

T213

Utility & lubrications consumption list

R

4

5

Email

14

8

2

5

Email

4

8

2

5

Email

22

8

2

4

Email

22

8

2

T214 T215

Unpriced copies of sub-order(s)(main parts) Shipping weights and dimensions (estimated/as-built)

R R

4

CALCULATIONS T216

Mechanical design calculations/analysis

R

3

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

Code

Document Title

Purpose of Issue ( R=Review, I=Information, A=Approve )

With Bid Copy

CD

16

After Order Award

OF

Copy

CD

No.of Week

Copy

CD

Thermal design calculation

R

4

Email

22

8

2

T218

Anchor bolt detail (Material size and calculation according to 1210-00-ST-ESS746 )

R

4

Email

8

8

2

T219

Foundation load diagram and calculation

R

4

Email

8

8

2

T220

External load calculation

R

4

Email

8

8

2

T221

Allowable forces and moments for piping connections

R

5

Email

8

8

2

T222

Vibration analysis data

A

4

Email

10

8

2

T223

Blading vibration analysis.

A

4

Email

10

8

2

T224

Lateral critical speed analysis

A

4

Email

10

8

2

T225

Torsional critical speed analysis

A

4

Email

10

8

2

T226

Transient torsional analysis.

A

4

Email

10

8

2

T227

Foundation block diagram with weights, forces and moments

R

3

4

Email

8

8

2

A

6

7

Email

6

8

2

R

7

Email

6

8

2

R

5

Email

14

8

2

R

5

Email

6

8

2

R

5

Email

6

8

2

R

5

Email

6

8

2

R

5

Email

6

8

2

R

7

Email

8

8

2

5

Email

8

8

2

R

5

Email

8

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2

R

5

Email

14

8

2

DRAWINGS

T228

T229 T230 T231 T232 T233 T234 T235

T236

T237 T238

General arrangement drawing showing, weights, dimensioned location, size, rating, and facing of nozzles and all other connections for hookup by others properly indicated and listed (composite for compressor, turbine, etc.) including list of connections. Equipment drawings included all auxiliaries with bill of quantities Turbine cross section drawing with list of components Seal assembly drawing and bill of material Gland sealing and leak-off schematic and bill of material Gland sealing and leak-off arrangement drawing and list of connections Gland sealing and leak-off component drawings and data Auxiliary piping & Equipment plant drawing with loads and estimated moments for foundations and supply limits Foundation drawing with distribution of load and moments, location and anchor bolts compressor and auxiliaries with direction & magnitude of all rotating forces and location of C.G., limits of amplitudes and partial deflections. Coupling assembly drawing & bill of material Thrust and radial bearing assembly drawing with parts list and loading data

R

4

03

18

Upon order Completed prior to shipment

T217

4

REV.

Note

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

Code

With Bid Copy

CD

17

After Order Award

OF

Copy

CD

No.of Week

Copy

CD

Rotor assembly drawing with bill of material and Part number

R

5

Email

14

8

2

T240

Vibration-probe sensing area/shaft drawing

R

4

Email

14

8

2

T241

Alignment diagram and data

R

4

Email

24

8

2

R

4

Email

14

8

2

Anticipated thermal movements for major connections PROCEDURES/ REPORTS

03

18

Upon order Completed prior to shipment

T239

T242

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

Document Title

Purpose of Issue ( R=Review, I=Information, A=Approve )

REV.

Note

T243

Site acceptance test procedure

R

5

Email

24

8

2

T244

Mechanical running test procedure

R

4

Email

24

8

2

4

T245

Repair procedure ( if applicable )

R

4

Email

24

8

2

4

T246

Hydro-testing procedure

R

5

Email

24

8

2

4

T247

Painting procedure

R

5

Email

4

8

2

T248

Rotor combined mechanical and electrical run-out

R

4

Email

16

8

2

T249

Hydro test logs (certified).

A

5

Email

24

8

2

5

T250

Rotor balance logs

R

5

Email

24

8

2

5

T251

Mechanical running test logs

A

4

Email

24

8

2

5

T252

Rigging and lifting instructions.

R

5

Email

24

8

2

3

T253

Preservation Procedure

I

5

Email

24

8

2

3

T254

Preparation for storage at job site before installation

I

5

Email

24

8

2

3

LUBE OIL SYSTEM: T255 T256 T257 T258

General Index P & I diagram with supply limit and connections Filled-in component data sheets including utility consumption list Catalogue and Brochure

R

6

7

Email

4

8

2

A

6

7

Email

6

8

2

A

4

5

Email

8

8

2

R

2

8

2

A

6

DRAWINGS

T259

T260 T261

General arrangement drawing showing, weights, dimensioned location, size, rating, and facing of all connections for hookup by others, properly indicated and listed including list of connections. Component out line drawings and bill of material system schematics

R R

4

7

Email

8

8

2

7

Email

8

8

2

5

Email

8

8

2

PROCEDURES T262

Site acceptance test procedure

R

5

Email

24

8

2

T263

Testing procedure

A

5

Email

24

8

2

4

Attachment No. : 03

BUSHEHR METHANOL PLANT

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Requirement for Documents (RFD) Doc. NO.1210-00-PR-RFD-104

Rev.:02

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

REV.

PIDEC No.: 1210-00-PR-REQ-104

SHEET

Code

T264

Document Title

Painting procedure and rust prevention

03

Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT Purpose of Issue ( R=Review, I=Information, A=Approve )

With Bid Copy

CD

R

18

After Order Award

OF

18

Upon order Completed prior to shipment

Copy

CD

No.of Week

Copy

CD

5

Email

10

8

2

Note

SPARE PART LISTS T265

Spare part list for erection, precommissioning, commissioning and start up

A

6

7

Email

4

8

2

T266

Spare parts list for 2 years of operation

A

6

7

Email

4

8

2

T267

Capital spare parts

A

6

7

Email

4

8

2

T268

List of special tools and devices

A

6

7

Email

4

8

2

Mechanical Catalogue & Quality Record Book

R

-

1

Email

8

2

-

This This document document with with all all its its rights rights isis the the property property of of BUPC BUPC and and must must be be held held in in confidence. confidence. No No disclosure, disclosure, reproduction or other use of the document in reproduction or isother of the document in whole or parts is to be made without the prior consent of BUPC whole or parts to beuse made without the prior consent of BUPC

Notes: (1) Mechanical Catalogue & quality record book shall be submitted to PIDEC/Purchaser, 2 months before shipment. (2) Equipment list shall contain all proper equipment information. (3) To be issued 4 weeks before shipment. (4) To be issued at least two months before performing the shop test. (5) To be issued after performing the test.

1

Attachment No. : 04 EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT List of Spare Parts

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT

Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

ThisThis document withwith all all its its rights is is thethe property of ofBUPC document rights property BUPCand andmust mustbebeheld heldininconfidence. confidence.No Nodisclosure, disclosure, reproduction or other useuse of the document in whole or parts is toisbe without the the priorprior consent of BUPC reproduction or other of the document in whole or parts to made be made without consent of BUPC

LIST OF SPARE PARTS

1

OF

4

REV.

03

Attachment No. : 04 Owner:

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

List of Spare Parts

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET EQUIPMENT

ThisThis document withwith all all its its rights is is thethe property of ofBUPC document rights property BUPCand andmust mustbebeheld heldininconfidence. confidence.No Nodisclosure, disclosure, reproduction or other useuse of the document in whole or parts is toisbe without the the priorprior consent of BUPC reproduction or other of the document in whole or parts to made be made without consent of BUPC

OF

03

4

SPARE PART SPECIFICATIONS

SR. No. TAG NO.

2

REV.

PART NUMBER

PART DESCRIPTION

UNIT PRICE (EURO)

TOTAL PRICE (EURO)

Attachment No. : 04 Owner:

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

List of Spare Parts

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

3

OF

REV.

03

4

SPARE PART SPECIFICATIONS

ThisThis document withwith all all its its rights is is thethe property of ofBUPC document rights property BUPCand andmust mustbebeheld heldininconfidence. confidence.No Nodisclosure, disclosure, reproduction or other useuse of the document in whole or parts is toisbe without the the priorprior consent of BUPC reproduction or other of the document in whole or parts to made be made without consent of BUPC

SR. No.

EQUIPMENT TAG NO.

PART NUMBER

PART DESCRIPTION

UNIT PRICE (EURO)

TOTAL PRICE (EURO)

Attachment No. : 04 Owner:

EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

List of Spare Parts

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

4

OF

REV.

03

4

SPARE PART SPECIFICATIONS SR. No.

EQUIPMENT TAG NO.

ThisThis document withwith all all its its rights is is thethe property of ofBUPC document rights property BUPCand andmust mustbebeheld heldininconfidence. confidence.No Nodisclosure, disclosure, reproduction or other useuse of the document in whole or parts is toisbe without the the priorprior consent of BUPC reproduction or other of the document in whole or parts to made be made without consent of BUPC

PART NUMBER

PART DESCRIPTION

UNIT PRICE (EURO)

TOTAL PRICE (EURO)

THE COMPLETION OF THE SPIR FORM (S) BY MANUFACTURER (S) / SUPPLIER (S)

The SPIR consists of main sheet and continuation sheets. The completed forms shall be distributed on A3 formats as specified in the purchase order. The manufacturer/supplier is requested to complete columns 1 to 11 and 20 of the form as described below. All information should be given in the English language. Column 1 :

EQUIPMENT REG. or TAG NO. Enter the same equipment registration- or tag number for each place of equipment as stated in the requisition -or purchase order.

Column 2 :

MANUFACTURER’S MODEL or TYPE State model, Type or other positive identification reference of the equipment / instrument ordered.

Column 3 :

Manufacturer’s serial No.

Column 4 :

NO. OF UNITS Enter the total number of pieces of identical equipment /instruments as quoted in columns 1, 2 and 3.

Column 5 :

NUMBER OF PARTS PER UNIT

State serial number or other indication reference of the equipment / instrument ordered (each)

For each unit (including identical units ) enter in the appropriate space the number of parts listed in each unit of equipment / instrument. Column 6 :

REQUISITION/ ORDER REF. NO.

Column 6a :

UNIT Enter the weight to kg of such items such as adhesives and grease .If items are supplied as sets state “ST”, if in pairs “PR “ and if it is single item (piece) state “PC “.

Column 7 :

TOTAL NUMBER OF IDENTICAL PARTS INSTALLED

State company’s requisition number or order reference number.

Enter the total number of identical parts covered by the equipment specified. In the case of identical units multiply the quantity of columns 5 by the number of units given in column 4. Column 8 :

DESCRIPTION OF PARTS List all parts which should be carried in stock for each of the three categories of spares. Including slow wearing parts. If an item is interchangeable between two or more units it should be listed only once ( refer to columns 10 and 20 )

Column 9 :

DRAWING NUMBER For each part in column 8 enter the manufacturer’s parts list and / or drawing number.

Column 10 :

MANUFACTURER’S PART NUMBER Enter the manufacturer’s unique reference number or other information which specifically identifies each part in the manufacture’s organization. NOTES FOR 10 & 20 In view of the wide variety of systems in use for identification of parts, It is not possible to lay down firm rules for completion of those columns.

Documents referred to must always be attached to the SPIR form by the manufacturer or supplier.

Manufacturers/ suppliers should give whatever identification system they use to positively identify parts and to show interchangeability with other existing equipment. Manufacturer’s/ supplier’s final cross sectional drawings. Workshop drawings and real part numbers may not always be available in the early stage of manufacture. This should not delay the completion of the SPIR form and subsequent ordering (see column 1) In such cases it is recommended that reference is to manufacturer’s documentation which is readily available such as brochures, exploded views, typical drawings of similar equipment in which the parts can be identified. As soon as final drawings etc. become available the SPIR from should be revised immediately. Column 11 :

MATERIAL SPECIFICATION Enter material specification in terms of full international standards and accepted conversions not manufacturer’s or sub-manufacturer’s reference.

Column 12 : thru 14

OPERATIONAL SPEAR PARTS RECOMMENDED BY MANUFACTURER Enter manufacture’s /supplier’s recommended quantities of operational spare parts which are required for : a) Erection and pre- commissioning .col. 12 b) Two years operation -col. 13 c) Commissioning and start -up .col. 14

Column 18 :

APROXIMATE UNIT PRICE State the ex works price per piece of each part in the currency shown at the top of the column, only for those parts not included in the requisition / order for the original equipment.

Column 20 :

REMARKS- SUPPLIERS PART NUMBER Enter the supplier’s unique identification number or items from third party manufacturers (bought- out items) such as ball bearings oil, seals mechanical seals, Gaskets, couplings, Instruments electrical parts, fuses relays etc, identifying sizes etc.

Owner :

EPs Contractor : Petrochemical Industries Design and Engineering  Company (PIDEC) Project No. : 1210

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Spare Parts List and Interchangeability Record

ALWAYS REFER TO PIDEC REQ. NO. PIDEC REQ No.: OWNER REQ No.:

AIR SEPARATION UNIT

4

No. of Units

1 2

1) All equipment having interchangeable items to be stated on same form. 2) Quote in column 10 part numbers showing interchangeability within equipment manufacturer's organization. 3) Quote in column 20 the original identification numbers for items of third party manufacture.("bought-out items") such as ball bearings, mechanical seals, couplings, fuses, auxiliaries. 4) Quote in column 11 name and type of material, e.g. bronze, cast iron, Stainless steel 304, Rubber, Buna Viton , etc.

3 4

6a

7

8

11

12

13

14

Address :

15

16

17

NUMBER OF PARTS PER UNIT

5

6

Equipment Purchase Order No.

PROJECT / PLANT : CONSIGNEE

Rev. :

:

ENGINEERED BY :

Approximate total value

Date: Sign

PIDEC

Delivery time

18

Remarks (See note 3 above)

19

20

Item No.

Approximate Total price in

MESC NO.

Approximate Unit price in

10

Manufacturer :

Classification of parts

9

Material (See note 4 above)

Drawing / Ref. No.

Manufacturer's Real Part No. (See note 2

Recommended by manufacturer

Manufacturer's Data

Recommended by contractor

DRAWINGS AS LISTED IN COLUMN 9 AND 10

Subject :

Date :

Quantity to be supplied

Total No. of identical parts

REMINDER : ATTACH TO THIS FORM ALL PART LISTS AND

Approved for purchase by:

Commissioning Spares

Operational Spare Parts

Required on site date:

to include all parts recommended to be kept for normal operation and slow wearing parts.

03

SPARE PARTS ORDER NO.

NOTES:

DESCRIPTION OF PARTS:

REV.

1210-00-PR-REQ-104 BU-30-P-000-PRO-REQ-0008 SHEET 1 OF 1

SPARE PARTS LIST AND INTERCHANGEABILITY RECORD

UNIT (Kg, No., Pair, Set)

Equipment reg. No. or Tag No.

2

Reference / Serial No.

1

3

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Equipment Class

Manufacturer's Model

21

ThinkXperT

MC:

REQUISITION FOR :

22

Attachment No. : 06 EPs Contractor:

BUSHEHR METHANOL PLANT

Petrochemical Industries Design and Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Scope of Inspection

Project No. : 1210

PIDEC Doc. NO.:1210-00-QC-SOI-104

Owner Doc. No.: BU-30-P-000-PRO-REQ-0008

Rev.:00

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION TITLE:

PIDEC No.: 1210-00-QC-SOI-104

03

Owner No.:

AIR SEPARATION UNIT (30-PU-6101)

SHEET

1

OF

REV.

9

SCOPE OF INSPECTION FOR

AIR SEPARATION UNIT(30-PU-6101)

TOTAL PAGES : 9

DE

EXT

INQ

A

Eng. Phase

Purpose of Distribution (POD)

Purpose of Issue (POI)

Owner's Action

00

09.10.2013

Issued for Inquiry

A.R.Farahbakhsh

H.R.Rezaei

H.R.Rezaei

M.Jalali

Rev.

Date

Description

Prepared by

Checked by

Approved by

Project

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Attachment No. : 06 EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

BUSHEHR METHANOL PLANT

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Scope of Inspection

Project No. : 1210

PIDEC Doc. NO.:1210-00-QC-SOI-104

Owner:

Owner Doc. No.: BU-30-P-000-PRO-REQ-0008

REQUISITION TITLE:

Rev.:00

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO. PIDEC No.: 1210-00-QC-SOI-104

AIR SEPARATION UNIT (30-PU-6101)

Owner No.:

SHEET

1.

2

OF

REV.

03

9

PROCEDURE: Please refer to project general shop inspection procedure (1210-00-QC-PCJ-001) which is attached to the requisition in order to find more information about inspection policy.

2.

DEFINITIONS: - INSPECTOR Inspector Means Project inspector and/or OWNER /his THIRD PARTY inspectors as will be introduced after order placement. - HOLD POINT (HP) The designated feature is to be witnessed by INSPECTOR. Vendor/manufacturer is to notify Project quality coordinator two weeks prior to performing the designated feature. Activities may not proceed until the continuation of work is permitted by Project Quality coordinator or waived in writing by him (“inspection waiver”). - WITNESS POINT (WP) The designated feature is to be witnessed by INSPECTOR. Vendor/manufacturer is to notify Project quality coordinator two weeks, prior to performing the designated feature. If the INSPECTOR fails to be present, activities may proceed without witnessing or waiving of the inspection as will be decided by Project quality coordinator. - RANDOM INSPECTION (RI) The inspection of the designated feature will take place during inspection visits as a standard performance. Vendor/manufacturer does not have to notify Project quality coordinator prior to performing the designated feature. Activities may proceed without witnessing or waiving by Project quality coordinator - REVIEW DOCUMENTATION (RD) Documentation will be reviewed/approved by Project Engineering team or INSPECTOR depend the nature of documents (refer to RFD form in order to find that documents which shall be reviewed & approved by Project engineering team and/or inspector). - WAIVED INSPECTION For the designated feature, shop inspection is not carried out, as will be decided by Project quality coordinator.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Attachment No. : 06 EPs Contractor:

BUSHEHR METHANOL PLANT

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Scope of Inspection

Project No. : 1210

PIDEC Doc. NO.:1210-00-QC-SOI-104

Owner:

Owner Doc. No.: BU-30-P-000-PRO-REQ-0008

Rev.:00

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION TITLE:

PIDEC No.: 1210-00-QC-SOI-104

AIR SEPARATION UNIT (30-PU-6101)

03

Owner No.:

SHEET

3

OF

REV.

9

ITEM: STATIC EQUIPMENT Inspection Extent:

PRE - INSPECTION MEETING

REV.

IN - PROCESS INSPECTION

DESCRIPTION OF INSPECTION POINTS

1-

Materials (Dimensions, Marking And Test Certificates)

FINAL INSPECTION HP

WP

RI

RD





2-

Storage Of Materials And Welding Consumables



3-

Welders qualifications (incl. Identification marks on welds)

 

4-

Adherence To Approved Procedures (Welding, Heat Treatment, Etc.)

5-

Adherence To Agreed Inspection Plan



6-

Workmanship, Cleanliness



7-

Weld Preparation And Fit-Up



8-

Second Side Of Welds After Back Gouging



9-

Installation Of First Set Of Internals

10- Execution Of (Major) Repairs

  

11- Visual And Dimensional Inspection Prior To Heat Treatment 12- Heat Treatment Execution



13- Nondestructive Testing Personnel Qualifications



14- Nondestructive Testing (Review Of All Radiographs)



15

Destructive Testing Results (Production Test plates)



16

Hardness Measurements In Final Condition



17- Alloy Verification Or Chemical Analysis (PMI Test If Required)



18- Reinforcing Pad Air-Soap Test

 

19- Visual Check Shell Internal 

20- Visual And Dimensional Inspection Prior To Hydrostatic testing 21- Hydrostatic testing



22- Installation Of Internals

 

23- Surface Preparation Prior To Painting, Coating, Lining 

24- Painting, Coating, Lining, Preservation, Pickling & Passivating 25- Final Visual And Dimensional Inspection

 

26- Ancillary Items (Spare Parts, Gaskets, Bolts And Nuts Etc.) 

27- Nameplate, Tagging, Marking, Color Coding 28- Preparation For Shipment 29- Documentation Review Prior To Release

 

Remarks: Where random inspection is specified, Approx 10% of the material will be inspected. This percentage will be increased in case deficiencies are found, or doubts about quality arise.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Attachment No. : 06 EPs Contractor:

BUSHEHR METHANOL PLANT

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Scope of Inspection

Project No. : 1210

PIDEC Doc. NO.:1210-00-QC-SOI-104

Owner:

Owner Doc. No.: BU-30-P-000-PRO-REQ-0008

Rev.:00

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION TITLE:

PIDEC No.: 1210-00-QC-SOI-104

AIR SEPARATION UNIT (30-PU-6101)

03

Owner No.:

SHEET

4

OF

REV.

9

ITEM: COMPRESSOR Inspection Extent:

PRE - INSPECTION MEETING

REV.

IN - PROCESS INSPECTION

DESCRIPTION OF INSPECTION POINTS

FINAL INSPECTION HP

WP

RI

RD



1-

Materials (Dimensions, Marking And Test Certificate)



2-

Storage Of Materials And Welding Consumables

 

3-

Welders Qualifications (Incl. Identification Marks On Welds)

4-

Adherence To Approved Procedure. (Welding, Heat Treatment, Etc.)



5-

Adherence To Agreed Inspection Plan



6-

Workmanship, Cleanliness



7-

Nondestructive Testing Personnel Qualifications



8-

Nondestructive Testing (Review Of All Radiographs)



9-

Destructive Testing (If Any)

 

10- Weld Preparation And Fit-Up 11- Execution Of (Major) Repairs



12- Heat Treatment Execution (If Any)



13- Reinforcing Pad Air-Soap Testing



14- Hydro Testing For Casing



15

Post Test Inspection



16

Balancing Of Rotor ,Impeller, Fan(Include Over speed Test If Required)





17- Gear Unit Run Test



18- Hardness Measurements (In Final Condition)



19- Alloy Verification Or Chemical Analysis

 

20- Lube Oil System: Hydro Testing 

21- Lube Oil System: Dimensional And Visual (Cleanliness)



22- Lube Oil System: Functional, Performance Test 23- Mechanical Running Test



24- Mechanical Running Test With Spare Rotor

 

25- Safety And Alarm Devices 26- Performance Test





27- Noise Level Measurement



28- Vibrations Measurement



29- Dismantling (Check Bearings, Clearances, Wear, Etc.)

 

30- Run Out Measurement(Deflection Check) 31- Capacity Control Test



32- Gearing, Pinion Forging And Main Wheel Forging Or Casting

 

33- Painting, Coating, Lining, Preservation, Pickling & Passivating



34- Ancillary Items (Glands, Cables, Thermometers, Etc.) 

35- Check Of Spare Parts 36- Final Visual And Dimensional Inspection

 

37- Nameplate, Tagging, Marking, Color Coding 38- Preparation For Shipment 39- Documentation Review Prior To Release

 

Remarks: Where random inspection is specified, Approx 10% of the material will be inspected. This percentage will be increased in case deficiencies are found, or doubts about quality arise.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Attachment No. : 06 EPs Contractor:

BUSHEHR METHANOL PLANT

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Scope of Inspection

Project No. : 1210

PIDEC Doc. NO.:1210-00-QC-SOI-104

Owner:

Owner Doc. No.: BU-30-P-000-PRO-REQ-0008

Rev.:00

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION TITLE:

PIDEC No.: 1210-00-QC-SOI-104

AIR SEPARATION UNIT (30-PU-6101)

03

Owner No.:

SHEET

5

OF

REV.

9

ITEM: STEAM TURBINE Inspection Extent:

PRE - INSPECTION MEETING

REV.

IN - PROCESS INSPECTION

DESCRIPTION OF INSPECTION POINTS

FINAL INSPECTION HP

WP

RI

RD

1- Materials (Dimensions, Marking And Test Certificate)





2- Storage Of Materials And Welding Consumables

 

3- Welders qualifications (incl. Identification marks on welds) 4- Adherence To Approved Procedures (Welding, Heat Treatment, Etc.)



5- Adherence To Agreed Inspection Plan



6- Workmanship, Cleanliness



7- nondestructive testing personnel qualifications



8- Nondestructive Testing (Review Of All Radiographs)

 

9- Destructive Testing Results (Production Test Plates) 

10- Alloy Verification Or Chemical Analysis 11- Execution Of (Major) Repairs

 

12- Heat Treatment Execution(If Any)



13- Run Out Test Of Shaft 14- Balancing Of Rotor (Included Over speed Test If Required)



15- Visual And Dimensional Inspection Prior To Hydro Testing

 

16- Hydro Testing 17- Mechanical Running Test



18- Noise Level Measurement



19- Vibrations Measurement

 

20- Heat Stability Test 21- Check Of Spare Parts



22- Safety And Alarm Devices



23- Dismantling (Check Bearings , Clearances , Etc)





24- Painting, Coating, Lining, Preservation, Pickling & Passivating





25- Ancillary Items (Spare Parts, Gaskets, Bolts And Nuts Etc.)





26- Final Visual And Dimensional Inspection

 

27- Nameplate, Tagging, Marking, Color Coding 28 Preparation For Shipment 29 Documentation Review Prior To Release

 

Remarks: Where random inspection is specified, approx. 10% of the material will be inspected. This percentage will be increased in case deficiencies are found, or doubts about quality arise.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Attachment No. : 06 EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

BUSHEHR METHANOL PLANT

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Scope of Inspection

Project No. : 1210

PIDEC Doc. NO.:1210-00-QC-SOI-104

Owner:

Owner Doc. No.: BU-30-P-000-PRO-REQ-0008

Rev.:00

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION TITLE:

PIDEC No.: 1210-00-QC-SOI-104

AIR SEPARATION UNIT (30-PU-6101)

03

Owner No.:

SHEET

6

OF

REV.

9

ITEM: MV ELECTRIC MOTORS Inspection Extent:

PRE - INSPECTION MEETING

REV.

IN - PROCESS INSPECTION

DESCRIPTION OF INSPECTION POINTS

FINAL INSPECTION HP

WP

1- Materials (Dimensions, Marking And Test Certificates)

RI

RD





2- Storage Of Materials And Welding Consumables



3- Adherence To Agreed Inspection Plan



4- Workmanship, Cleanliness



5- Installation of wiring and conduit (ex. Proof execution if req'd)



6- Dynamic balancing of rotor (incl. Over speed test if req'd)



7- Clearances And Run-Outs



8- Type Test



9- No-Load Test



10- Short-Circuit Test



11- Insulation Resistance Test



12- Dielectric Test



13- Winding Resistance Measurement



14- Bearing Insulation Check



15- Load Test At 50, 75 And 100% Load



16- Noise Level Measurement



17- Vibrations Measurement



18- Functional Test Of Auxiliary System

 

19- Ancillary Test (Gland, Cables, Thermometers, Etc.) 20- Final Visual And Dimensional Inspection

 

21- Nameplate, Tagging, Marking, Color Coding 22- Preparation For Shipment 23- Documentation Review Prior To Release

 

Remarks: Where random inspection is specified, approx. 10% of the material will be inspected. This percentage will be increased in case deficiencies are found, or doubts about quality arise.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Attachment No. : 06 EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

BUSHEHR METHANOL PLANT

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Scope of Inspection

Project No. : 1210

PIDEC Doc. NO.:1210-00-QC-SOI-104

Owner:

Owner Doc. No.: BU-30-P-000-PRO-REQ-0008

Rev.:00

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION TITLE:

PIDEC No.: 1210-00-QC-SOI-104

AIR SEPARATION UNIT (30-PU-6101)

03

Owner No.:

SHEET

7

OF

REV.

9

ITEM: LV ELECTRIC MOTOR Inspection Extent:

PRE - INSPECTION MEETING

REV.

IN - PROCESS INSPECTION

DESCRIPTION OF INSPECTION POINTS

FINAL INSPECTION HP

WP

RI

1- Materials (Dimensions, Marking And Test Certificates)



2- Storage Of Materials And Welding Consumables



3- Adherence To Agreed Inspection Plan



4- Workmanship, Cleanliness



RD

5- Installation of wiring and conduit (ex. Proof execution if req'd



6- Type Test 7- No-Load Test

 

8- Short-Circuit Test



9- Insulation Resistance Test



10- Dielectric Test



11- Winding Resistance Measurement



12- Bearing Insulation Check



13- Bearing Inspection After Heat Run



14- Load Test At 50, 75 And 100% Load 15- Noise Level Measurement

 

16- Vibrations Measurement

 

17- Ancillary Test (Gland, Cables, Thermometers, Etc.) 18- Final Visual And Dimensional Inspection



19- Nameplate, Tagging, Marking, Color Coding



20- Preparation For Shipment 21- Documentation Review Prior To Release

 

Remarks: Where random inspection is specified, Approx 10% of the material will be inspected. This percentage will be increased in case deficiencies are found, or doubts about quality arise.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Attachment No. : 06 EPs Contractor:

BUSHEHR METHANOL PLANT

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Scope of Inspection

Project No. : 1210

PIDEC Doc. NO.:1210-00-QC-SOI-104

Owner:

Owner Doc. No.: BU-30-P-000-PRO-REQ-0008

Rev.:00

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION TITLE:

PIDEC No.: 1210-00-QC-SOI-104

AIR SEPARATION UNIT (30-PU-6101)

03

Owner No.:

SHEET

8

OF

REV.

9

ITEM: INSTRUMENTATION Inspection Extent:

PRE - INSPECTION MEETING

REV.

IN - PROCESS INSPECTION

DESCRIPTION OF INSPECTION POINTS

FINAL INSPECTION HP

WP

RI

1-

Materials (Marking And Test Certificates)



2-

Workmanship, Cleanliness



3-

Leak Testing (Control Valve)



4-

Wiring and conduit installation (ex. Proof execution if req'd)



5-

Checking Of Characteristics On Each Instrument

6-

Functional Test



7-

Popping Test (Safety Valves)



8-

Hysteretic/ Torque Switches/Position Indicators (Valve Actuators)



9-

Setting, Calibration Of Instruments And Controls







10- Accessibility of controls, instruments, sight glasses, etc. 11- Final Visual And Dimensional Inspection

 

12- Nameplate, Tagging, Marking, Color Coding 13- Preparation For Shipment 14- Documentation Review Prior To Release

RD

 

Remarks: Where random inspection is specified, Approx 10% of the material will be inspected. This percentage will be increased in case deficiencies are found, or doubts about quality arise.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Attachment No. : 06 EPs Contractor:

BUSHEHR METHANOL PLANT

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

Scope of Inspection

Project No. : 1210

PIDEC Doc. NO.:1210-00-QC-SOI-104

Owner:

Owner Doc. No.: BU-30-P-000-PRO-REQ-0008

Rev.:00

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION TITLE:

REV.

PIDEC No.: 1210-00-QC-SOI-104

AIR SEPARATION UNIT (30-PU-6101)

03

Owner No.:

SHEET

9

OF

9

ITEM: PUMP Inspection Extent:

PRE - INSPECTION MEETING

REV.

IN - PROCESS INSPECTION

FINAL INSPECTION

DESCRIPTION OF INSPECTION POINTS

HP

WP

RI

RD



1-

Materials (Dimensions, Marking And Test Certificate)



2-

Storage Of Materials And Welding Consumables

 

3-

Welders Qualifications (Incl. Identification Marks On Welds)

4-

Adherence To Approved Procedure. (Welding, Heat Treatment, Etc.)

5-

Adherence To Agreed Inspection Plan



6-

Workmanship, Cleanliness





7-

Nondestructive Testing Personnel Qualifications



8-

Nondestructive Testing Reports



9-

Visual And Dimensional Check Of Castings Prior To Fabrication

 

10- Weld Preparation And Fit-Up 11- Execution Of (Major) Repairs



12- Hydro testing Casing, Barrel, Bowls, Dish, Head



13- Balancing of impeller / rotor (Multi Stage Pump)



14- Mechanical Running Test

 

15

Performance Test

16

Noise Level Measurement



17- Vibrations Measurement



18- NPSH Test (Note 2)

 

19- Painting, Coating



20- Ancillary Items (Glands, Cables, Thermometers, Etc.) 21- Final Visual And Dimensional Inspection

 

22- Nameplate, Tagging, Marking 23- Preparation For Shipment



24- Documentation Review Prior To Release



Remarks: 1)10% of the materials will be inspected randomly for each pump. This percentage will be increased in case deficiencies are found, or doubts about quality arise. 2) NPSHR test shall be provided if any of the following conditions are specified: - The flow rate is smaller than 1500cubic meter per hour and NPSH value is below 1 m. - The flow rate is greater than 1500cubic meter per hour and NPSH value is below 2 m.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Attachment No. : 07 EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

Spare Parts List Form

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

REV.

PIDEC No.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT

Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET SR. NO.

1.

CENTRIFUGAL PUMPS (Number of Machine)

1.1

Shaft, Impeller, Throat Bushing

1.2 1.3

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

PART DESCRIPTION

Mechanical Seal, Metallic Faces

1.5

Mechanical Seal Assembly

1.6

Sealing system: O-Rings & Gasket

1.7

Carbon Rings of Mechanical Seal Assembly

1.8

Gland packing

1.9

Mechanical seals

1.10

Carbon Teflon rings

1.11

Gasket sets and O-ring Sealing system O-Rings

OF

1

TWO YEARS SPARES

CAPITAL SPARES

1/2/3/4/5/6/More (Note 1)

(Note2)

1/1/1/1/2/2/30% of NO. of PUMPS 1/1/2/2/3/3/50% of NO Of PUMPS 1/2/3/4/5/6/100% of NO OF PUMPS 1/2/3/4/5/6/100% of NO OF PUMPS 1/1/1/1/2/2/25% of No. OF PUMPS 2/2/2/3/3/4/50% NO

Shaft Sleeve, Bearing Set, Impeller and Case Wearing Ring Gasket Set, Packing, Mechanical Seal, Non Metallic Faces, O-Ring, Gasket, Spring

1.4

1.12

ERECTION, PRECOM., COMMISSIONING & START UP SPARES

1

OF PUMPS

2/2/3/4/5/6/100% NO OF PUMPS

200% per mat’s / size. 100% per model / type. 500% per model / type. 100% 200%

1.13

REMARK: (1) (A) The parts listed above are the principal parts only. Other parts, such as impeller special bolts etc. shall be considered for recommendation in quantities consistent with the above table. (B) Spare impellers shall be ordered in the maximum diameters. (C) Quantities listed above are based on one part per pump. If the pump has more than one, the number of parts shall be modified accordingly.

(D) For rotary pumps, provide a matching set of rotors with shaft. (2) (A) One complete set of mechanical seal for each type.

03

Attachment No. : 08 EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT Spare Parts List Form

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT

Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET SR. NO.

1.

PART DESCRIPTION CENTRIFUGAL COMPRESSOR Complete spare rotor assembly (Remark 1) Coupling assembly Dry Gas Seal Sealing insert for impeller disc gas-side & shaft Gasket for compressor casing Gaskets & O-ring for internal piping Packings Labyrinths of each type Journal bearing assembly Journal bearing pads

ERECTION, PRECOM., COMMISSIONING & START UP SPARES

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Bolt, Nut, screw & washers

2.

3.

Pins Adjust liner Plug Cartridges for control oil filters Cartridges for seal gas filter Cartridges for buffer gas filters Gaskets for filters Gaskets for coolers Oil filter inserts Blind flanges for pressure testing Bypass and screening for oil flushing Flushing Nozzles (sets) GEAR BOX: Spare rotor for gear and pinion Bearing Set Seals STEAM TURBINE: Complete spare rotor assembly (Remark 1) Coupling Springs Labyrinths Steam strainer Gland packing Element for oil strainer Gasket & O-ring Bolt, nuts & washer

OF

TWO YEARS SPARES

03

3 CAPITAL SPARES

1 set 1 set

1 set 1 set

1 set (complete with thermo elements)

Thrust bearing assembly Thrust bearing pads

1

REV.

1 set 1 set 2 sets 2 sets 2 sets 2 sets 1 set 1 set 1 set

1 set (complete with thermo elements) 10% for Special bolts & nuts

1 set 1 set 1 set 2 sets 1 set

3 sets 10 x 10 x 2 sets 2 sets

1 set 2 sets

1 set 1 set 1 set 1 set 1 set 1 set

1 set 1 set

1 set

1 set 10% for Special bolts

2 sets 2 sets 2 sets 2 sets 2 sets 2 sets 1 set

Attachment No. : 08 EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT Spare Parts List Form

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT

Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

2

OF

& nuts

Seal ring Bush Valve seat, plug, bolts & nuts, spring, bushing (for control valves and emergency stop valve) Seat of seal ring & gasket for HP hydraulic cylinder Complete shoe for bearing Journal bearing assembly Journal bearing pads

2 sets 2 sets 1 set 2 sets 2 sets 1 set 1 set (complete with thermo elements)

Thrust bearing assembly

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Thrust bearing pads Oil retainer ring for bearing Set of seals Nozzles Eccentric guide Steam carrier ring Stator blades sets Oil filter element Accumulator bladder Governor side gland Cartridges for control oil filters Vapor hood Governor glands Governor valve gland packing Ext. valve gland packing Governor assembly Governor electronic and gauging parts: - Main board - Power supply - Gages Governor main part: - Speed adjust motors - Gear - Spring - Pilot valves - Bushing (bearing) Governor hydraulic system: - Relief valve Bypass and screening for oil flushing Blind flanges for pressure testing

1 set 1 set

1 set (complete with thermo elements)

1 set

1 set 2 sets 2 sets 1 set 1 set 1 set 1 set 5 set 1 set 2 sets 1 set 2 sets 2 sets 2 sets 2 sets 1 pc. 1 set 1 set 1 set 1 set 1 set 1 set 1 set 2 set 1 x per type

1 set 1 set

3

REV.

03

Attachment No. : 08 EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Owner:

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT Spare Parts List Form

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT

Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

3

OF

3

REMARK: 1. The spare rotors for Compressor and Turbine shall be with vertical storage arrangement with metal container having provision for N2 purge. Spare rotors shall be with fit -up check record.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

2. Quantities specified in percentage shall be round up to higher exact number e.g. 40 % of 3 QTY equal to 1.2 shall be considered 2 as a minimum.

REV.

03

Attachment No. : 09 Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT List of Spare Parts for Air Cooled Heat Exchanger

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104

AIR SEPARATION UNIT

Owner No.: BU-30-P-000-PRO-REQ-0008

SHEET

1

LIST OF SPARE PARTS FOR

ThisThis document withwith all all its its rights is is thethe property of ofBUPC document rights property BUPCand andmust mustbebeheld heldininconfidence. confidence.No Nodisclosure, disclosure, reproduction or other useuse of the document in whole or parts is toisbe without the the priorprior consent of BUPC reproduction or other of the document in whole or parts to made be made without consent of BUPC

AIR COOLED HEAT EXCHANGER

OF

3

REV.

03

Attachment No. : 09 Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT

Project No. : 1210

List of Spare Parts for Air Cooled Heat Exchanger

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET SR. NO.

01

02

Gaskets Sets and O-Rings Stud Bolts, Nuts, Washer Vibration Switch

100% -

Blades of Fans

-

5 % (min 2 sets) 5% (sets) One blade for each bay

PART DESCRIPTION Fan for Air Coolers

Air Cooled Exchangers

Tube support boxes

-

5% (min. one number)

-

10% (min. one number) See table 1 in sheet 2 of this attachment

Electric motors:

Grease nipples (where applicable)

ThisThis document withwith all all its its rights is is thethe property of ofBUPC document rights property BUPCand andmust mustbebeheld heldininconfidence. confidence.No Nodisclosure, disclosure, reproduction or other useuse of the document in whole or parts is toisbe without the the priorprior consent of BUPC reproduction or other of the document in whole or parts to made be made without consent of BUPC

-

Steel 5%: Nonferrous 2% (min. one number)

Number of Air-fin coolers using parts:

See table 2 in sheet 2 of this attachment

10%

-

03

3

TWO YEARS SPARES

Plug gaskets

04

OF

ERECTION, PRE, COMMISSIONING & START UP SPARES

Plugs

03

2

REV.

CAPITAL SPARES

Attachment No. : 09 Owner: EPs Contractor:

Petrochemical Industries Design and Engineering Company (PIDEC) Project No. : 1210

Bushehr Petrochemical Company (BUPC) Project No. :ME16

BUSHEHR METHANOL PLANT List of Spare Parts for Air Cooled Heat Exchanger

ThinkXperT

MC:

ALWAYS REFER TO PIDEC REQ. NO.

REQUISITION FOR :

PIDEC No.: 1210-00-PR-REQ-104 Owner No.: BU-30-P-000-PRO-REQ-0008

AIR SEPARATION UNIT

SHEET

3

OF

REV.

03

3

Table 1 Number of Air-fin Coolers Using Part Spare Item (a) I. V-belts Sheaves Set of Belts II. Fan Shaft Bearing (Upper & Lower) III. Coupling-Complete Couplings, Flanges, Gaskets, Seals IV. Fan Assemblies Automatic Pitch Control Hub Assembly Parts-Guide Bushing, Pitch Blocks, O-Rings, Calm Gaskets V. Bolt Assemblies, Fork Pins VI. Flexible Hose, Rotary Union VII. Automatic or Manual Adjustments Blade Retention Clamps, Pitch, Change Forks, Puch Rod, Stub (with pilot tubes) , Bearing Retainer Rings VIII. Spring Housing Gasket, Diaphragm, Blade Retainer Ring, Thrust Cover Gasket IX. Hub Assembly with Blade

1 Qty 0 1 1 1

2 Qty 0 2 1 1

3 Qty 0 3 1 1

4 Qty 0 4 2 1

5 Qty 0 5 2 1

6 Qty 0 6 3 1

7 or more Qty 1 100 % 50 % of No. of Air Fins 1

1

2

3

4

5

6

100 % of No. of Air Fins

1 1 1

2 1 1

3 1 1

4 1 2

5 1 2

6 1 2

100 % of No. of Air Fins 2 30 % of No. of Air Fins

1

1

1

1

2

2

20 % of No. of Air Fins

0

0

0

0

0

0

1 (b)

2 Qty 1 5%

3 Qty 1 5%

4 Qty 2 5%

5 Qty 2 5%

more Qty 40 % 5%

Table 2

ThisThis document withwith all all its its rights is is thethe property of ofBUPC document rights property BUPCand andmust mustbebeheld heldininconfidence. confidence.No Nodisclosure, disclosure, reproduction or other useuse of the document in whole or parts is toisbe without the the priorprior consent of BUPC reproduction or other of the document in whole or parts to made be made without consent of BUPC

Motors Number of Machines Spare Item Set of Bearings Fan, Terminal Blocks, Space Heater (MV) per Type

1 Qty 1 5%

 NOTES (a) Quantities shown are for each size and type of part (b) Twenty units or more. The parts listed are the principal parts only. (c) The parts listed are the principal parts only. Other parts shall be considered for recommendation in quantities consistent with the above table.

SPARE PARTS PROCEDURE

CONTENTS

1.

PURPOSE

3

2.

DEFINITIONS

3

3.

SCOPE AND OBJECTIVES

3

4.

PRINCIPLES

4

5.

PROCEDURE

5

6.

REFERENCES

8

7.

REPORTING

8

8.

2 YEARS SPARE PARTS COST CONTROL

8

9.

ATTACHMENTS

9

1.

PURPOSE This Spare Part Procedure governs and specifies the terms of performance of the supply of Spare Parts for the ...... Plant in IRAN, of BUSHEHR PETROCHEMICAL COMPANY.

2.

DEFINITIONS 

“CONTRACTOR”

NARGAN/PIDEC/EIED (means engineering contractor)



“OWNER”

means BUSHEHR PETROCHEMICAL COMPANY



“MC”



PURCHASER

means OWNER or his authorised representative



“VENDOR”

means any firm, company or organisation with whom a Purchase Order is placed by the PURCHASER and which is engaged by PURCHASER for the supply of EQUIPMENT or a part thereof.



“MR”

means Material Requisition.



“PO”

or Purchase Order means Purchase Order for base materiel



“PO-S”

or Purchase Order for Spares means Purchase Order for 2 years spare parts.



CONTRACT

means Contract between OWNER and CONTRACTOR

means Project Managing Contractor (ThinkExpert)

EQUIPMENT Class:

3.



(V) for VITAL EQUIPMENT, a breakdown of which would mean an immediate and serious interruption of vital operations in field or plant and with which no risk in the ordering and stocking of spare parts can be jusified



(E) for ESSENTIAL EQUIPMENT, engaged in primary operations, but with which a calculated risk can be taken in ordering and stocking of spare parts.



for AUXILIARY, general purpose and stand-by equipment, for secondary operations, the temporary lack of spare parts would not have a serious effect. Under this heading also comes the equipment of which there is a large number of units in used, thus ensuring a sufficient degree of protection in case of failure of one or more units.

SCOPE AND OBJECTIVES This procedure covers the procurement of spare parts for the Cracking Plant in IRAN, BUSHEHR OLEFIN PLANT: The objectives of this procedure are to: 

Give instructions for M-equipment and Major equipment spare parts monitoring



Give instructions for other equipment and materials spare parts monitoring



4.

Define actions related to the 3 categories of spare parts : 

Erection, precommissioning, commissioning and start-up spare parts



Capital spare parts



2 years spare parts

PRINCIPLES The types of spare parts are: Capital Spare Parts The capital spare parts to be supplied to OWNER by VENDOR are listed in the Attachment 2 of this procedure. These spares will be included in the same Purchase Order and shall be shipped together with the main equipment/material, separately packed and adequately marked for easy recognition and warehousing. Erection, Precommissioning and Commissioning and Start up Spare Parts They include parts of the equipment and materials (such as gaskets, O-rings, etc.) which are to be or may be replaced during each phase of field activities. PURCHASER will be asked on the Material Requisition the recommended requirements of precommissioning, commissioning and start-up operations spare parts. Vendor recommendation received with the offer will also be taken into account and checked by PURCHASER as per his experience and knowledge. These spares are included in the same Purchase Order, separately packed and adequately marked for easy recognition and warehousing and shall be shipped together with the main equipment/material. Those spares to be supplied to OWNER by VENDOR are listed in the Attachment 1 of this procedure. Two Years Operation Spare Parts The two years Spare Parts include all those parts that are normally required to maintain the Plant in a satisfactory working condition over a period of two years of continuous operation after start-up. The recommendation of these spares shall be recommended by VENDORS for OWNER’s selection and approval on the basis of the following agreed upon criteria: 

Type and quantities of spare parts as per Vendor recommendation,



Guidelines shown in paragraph 6 of this procedure.



Cost Control

With regards to the equipment for which no guidelines are given for minimum spare parts quantities in paragraph 6.0 of this procedure, the matter will be agreed later between

OWNER/CONTRACTOR/VENDOR with due recommended spare parts for such equipment.

consideration given

to

the

VENDOR’s

PURCHASER will obtain from VENDORS the quotation of the two years operation spare parts together with the quotation of the main equipment (the remain spare parts will be proposed as soon as possible in due course accordingly). To this purpose the applicable general guidelines for the selection of spare parts under following paragraph 6.0 will be attached to the Material Requisitions. PROCEDURE PURCHASER’s inquiry for the main materials shall ask bidders to submit a quotation for the 3 (three) types of spare parts, when applicable. For each classification of equipment classifivcations can be distinguished: – Vital equipment – Essential Equipment – Auxiliary and general purpose equipment Spare parts are divided into three classifications: – C for parts wearing out or deterioration during normal operation – Q for parts not normal stocked, but ordered on request only. – I for Insurance items. For each classification of equipment a spare part philosophy can be distingushed as follows:

SPARE PARTS

EQUIPMENT CLASSIFICATION Vital (V)

Essential (E)

Insurance

X

Replacement

X

X

Consumables

X

X

General (A)

X

When interpreted correctly this should help to avoid over-ordering of spare parts and replacement parts in particular. Purchase Orders of the Main Equipment and/or materials will normally include: 

The Capital Spares, if any,



Erection, Pre-commissioning, Commissioning and Start up Spares, if any



Priced lists of Spare parts for two years valid for 24 months, as optional item. The spare parts list may be preliminary and not complete in minor parts, since vendor has not yet developed the engineering, without detailed identification of single pieces (for instance wording “set of bearings” will be used). Prices however will be binding.

Alternatively to the above, the 2 years quoted spares will be ordered at time of PO for base material, but with separate PO-S, as per OWNER decision

4.1

SPARE PARTS FOR M-EQUIPMENT AND MAJOR EQUIPMENT As said before, such quotation will be requested with the main materials and shall contain: 

Priced quotation for capital spares (if required)



Price quotation for erection pre-commissioning, commissioning & start-up spares



Bidder’s priced recommendation of spares parts for two years, possibly using the SPIR form (see Attach.5)



Short description of each part,



Proposed quantity per spare parts item,



Unit prices and total prices per spares parts item,



Delivery time.

The priced quotation will be submitted to PURCHASER. PURCHASER may decide at time of PO for main material if to instruct PURCHASER to purchase also the selected spare parts with a dedicated PO-S. Alternatively, the quotation will be kept as reference, waiting the final priced list. The Spare Part list at first step will be preliminary and not complete in minor parts, in the second step, the VENDOR shall provide detailed identification of each “SET” etc of each Spare Part. It is noted that for items that are not peculiar to the specific supply (bearing, mechanical seals, etc) and that can be same for other supplies, PURCHASER will recommend not to purchase them, waiting for the interchangeability study. PURCHASER shall then expedite the receipt of final spare parts quotations. Upon receipt, PURCHASER shall verify the quotation, especially with respect to the following items:  Completely and properly filled out,  Check price against Vendor’s provisional spare parts quotation as per above requirements,  Completeness of required supporting documents, such as drawings, specifications. Upon verification, PURCHASER shall submit the final spare parts quotation with all pertaining documents to OWNER. Following the VENDOR recommendation and PURCHASER decisions, based on these final spare parts lists, PURCHASER shall in agreement with OWNER, purchase the selected parts revising the first PO-S, if previously done, or PURCHASER shall issue the PO-S. In order to reduce the stock of spare parts, PURCHASER shall, as far as possible, minimise the number of Vendors when the type of equipment is similar and provide a list of interchangeable parts, when feasible (e.g; bearings, mechanical seals). The final completed SPIR forms shall be supported by the following documents: a. Complete manufacturer’s parts list.

b. Relevant drawings, catalogue pamphlets and bulletins of the main or primary equipment. c.

Relevant parts lists, drawings, sketches and pamphlets of sub-suppliers of auxiliary equipment.

All spare parts shall be furnished with adequate packing. All packing shall bear lasting and visible identification with a description of the equipment to which it belongs, and the number of parts and of the diagram to which it relates. Such requirements for packing & marking are included in Packing and Marking Instructions no ................. VENDORS shall supply 1 (one) complete set of the special tools required for the installation of spare parts, supplying information for the future replacement of such tools. The spare parts supplied shall normally be identical to the parts already in the equipment. 4.2

SPARE PARTS FOR OTHER EQUIPMENT AND MATERIALS  Quotation for erection, pre-commissioning, commissioning & start-up spares will be requested with the main materials.  Bidder’s priced recommendation of spares parts for two years, using the SPIR form (see Attach.5), will be received during the development of the supply. Timing will be set during the negotiations for the PO definition. A budget price will be requested to the Vendor during such negotiations. The bid will include 

Identification of each part (identification shall include, part and position no, type and size, number, mat., dimension, class, dwg of parts if any, like bearing, oil seal, O-ring, mechanical seal, gasket and etc…)



Proposed quantity per spare parts item,



Unit prices and total prices per spares parts item,



Delivery time.

Upon receipt, PURCHASER shall verify the quotation, especially with respect to the following items:  Completely and properly filled out,  Completeness of required supporting documents, such as drawings, specifications.  Check price against budgetary price The priced quotation will be submitted to OWNER, with VENDOR recommendation. Based on PURCHASER decisions, PURCHASER shall award the PO-S. In order to reduce the stock of spare parts, PURCHASER shall, as far as possible, minimise the number of Vendors when the type of equipment is similar and provide a list of interchangeable parts, when feasible (e.g; bearings, mechanical seals). The final completed spare parts Interchangeability Record (SPIR) forms shall be supported by the following documents:

d. Complete manufacturer’s parts list. e. Relevant drawings, catalogue pamphlets and bulletins of the main or primary equipments. f. Relevant parts lists, drawings, sketches and pamphlets of sub-suppliers of auxiliary equipment.

All spare parts shall be furnished with adequate packing. All packing shall bear lasting and visible identification with a description of the equipment to which it belongs, and the number of parts and of the diagram to which it relates. Such requirements for packing & marking are included in Packing and Marking Instructions n° N270-10- PP-P365-606. The spare parts supplied shall normally be identical to the parts already in the equipment. VENDORS shall be responsible in supplying the Spare Parts even after stopping manufacturing up to TEN (10) years. 5.

REFERENCES As guideline for selection of two years operation spare parts, has been prepared on the basis of Attachment 4.

6.

REPORTING NOT APPLICABLE.

7.

2 YEARS SPARE PARTS COST CONTROL NOT APPLICABLE.

8.

ATTACHMENTS 

Attachment 1 :

Guideline for selection of Erection, Pre-commissioning, commissioning and start-up spares.



Attachment 2 :

Capital Spare-parts Requirement



Attachment 3:

Instructions to complete Spare Parts Interchangeability Record Forms (SPIR)



Attachment 4:

Guidelines for selection of two years operation spare parts



Attachment 5:

SPARE PARTS INTERCHANGEABILITY RECORD FORM (SPIR)



Attachment 6:

Example of Cost Breakdown (for two years operation spare parts)

ATTACHMENT 1

GUIDELINES FOR SELECTION OF ERECTION, PRECOMMISSIONING, COMMISSIONING AND START-UP SPARE PARTS

SPARE PARTS FOR ERECTION, PRECOMMISSIONING, COMMISSIONING AND START-UP

1. Spare Parts for Erection, Precommissioning, Commissioning and Start-up as per attached list shall be included in the scope of supply. PURCHASER shall check the Equipment’ spare parts list with Equipment Vendors. 2. In addition to the following tables regarding the subject of spare parts, PURCHASER shall check, as per his experience and knowledge and shall prepare similar format and quantity wise for other equipment and materials, which are not mentioned here below.

SPARE PARTS FOR ERECTION, PRECOMMISSIONING, COMMISSIONING AND START-UP PARTS NAME 1.

2.

Q.TY

FURNACES Gaskets for coil

50%

Burner Tiles

10%

Burner Tips Fire eyes

5% 10%

Gas valves seat

20%

Solenoid valves

20%

EXCHANGERS, REACTORS & DRUMS/TANKS Gaskets for Girth Flange, M/H & H/H

100%

Stud Bolts and Nuts for the above

5% (min. 2 sets)

Field-Installed Trays: Bolts and Nuts

15% (min. 2 sets)

Washers (metal and asb.)

20% (min. 2 sets)

Tray Clamps

10% (min. 2 sets)

Asb. Rope and Tape

25% (min. 2 sets)

Field-Installed Internals, Piping and Other Bolted Internals: Stud Bolts (Alloy and C.S.)

10% (min. 2 sets)

Washers and Nuts

10% (min. 2 sets)

Packing: Inert Balls

15%

Raschig Rings /Slotted Rings

15%

Fan for Air Cooler: Gaskets Sets and O-Rings 3.

STEAM GENERATOR Gaskets for Girth, M/H & H/H Stud Bolts and Nuts for the above Rotating Equipment

4.

STEEL STRUCTURE Bridge Crane:

100%

100% 5% (min. 2 sets) see item 5

5.

Bolts & Washers Gaskets

15% 10%

Contactors

5%

Tension Springs

10%

Fuse Elements

10%

Gaskets

25%

Oil Seals

25%

Relays

5%

Collectors

1 set each size

Contact shoes

1 set each size

Limit Switches

1 set each size

ROTATING EQUIPMENT Pump/Agitator: Gland Packing

200% per mat’s/size

Mechanical Seals

100% per model/type

Carbon Teflon Rings

500% per model/type

Gasket Sets and O-rings Sealing System O-Rings

100% 200%

Compressor: Gasket sets and O-ring

100%

Gasket Sets and O-ring

100%

Gland Packing

100%

Fan:

Steam Turbine: Carbon Rings

100%

Gaskets and Packing

100%

Gas Turbine: Gaskets and Packing Filter Element for Oil/Fuel

100% 1 set each size/material

Diesel Engine: Gaskets and Packing Filter Element for Oil/Fuel Electrical Equipment:

100% 1 set each size/material See Item 9

Instrumentation: Control Panel

See Item 10

Board Instruments Field Transmitters

See Item 10 See Item 10

Field Instruments

See Item 10

Others

6.

H.V.A.C. Bolts/Nuts/…. Rotating Equipment Heat Exchangers Filter Element Electrical Instrumentation:

See Item 5 0% 1 set each size/material See Item 9 See Item 10

Board Instruments

See Item 10

Field Transmitters Field Instruments

see Item 10 See Item 10

Piping /Duct

5% Quantity to be recommended by Vendor

SPECIAL EQUIPMENT Heat Exchanger

See Item 2

Rotating Equipment

See Item 5

Filter Element Piping

8.

5%

Control Panel

Others

7.

0%

1 set each size/mat’l 0%

Electrical

See Item 9

Instrumentation: Control Panel

see Item 10

Board Instruments

See Item 10

Field Transmitters

see Item 10

Field Instruments Others

See Item 10 0%

PIPING Gaskets, all sizes

20%

Stud Bolts less than 1”

15%

1” to 1 7/8 2” and over

10% 5%

Coating and Wrapping

Pipe

Note:

9. -

2” and below 3” to 6” 8” and over (*) Valves 2” and below Screwed & welded (*) Flanged (*) Valves 3” to 10” (*) Valves over 10” (*) Flanges up to 12” (*) 14” and over (*) Fittings welded up to 2” (*) 2 1/2” to 10” (*) 12” and over (*) Fittings Screwed up to 2” (*) 3” and over (*) Flanged all sizes (*) Hub and Spigot 3” to 12” (*)14” and over

10%

Carbon Steel 10% 5% 2% 10%

Alloy/SS 4% 2% 1% 5%

Cast Iron 0% 5% 5% 0%

2% 2% 0% 5% 2%

2% 2% 0% 3% 2%

0% 0% 0% 0% 0%

10% 5% 3%

6% 3% 2%

0% 0% 0%

5% 5%

3% 3%

0% 0%

0% 0%

0% 0%

5% 3%

As indicated with (*), where the percent gives the quantity consisting of a whole number plus a decimal less than 0.5, the decimal portion will be dropped; where the decimal portion is 0.5 and more, the next higher whole number quantity will be selected.

ELECTRICAL EQUIPMENT Switchgear, Motor Control Centers MV/LV Fuse Elements

50%

Bulb for Signal Lamps

50%

Signal Lamp

50%

Plastic door lock Plastic door handle

5% 5%

Feeder moving mechanism

2%

Control terminal blocks

5%

Micro switches

5%

Metering and transducers

5%

Trip coil of C.B.

5%

Close coil of C.B.

5%

Under voltage coil of C.B.

2%

Spring charger motor of C.B.

2%

Electronic cards of C.B. or contactors (if any)

2%

Protection relays Interposing relay panel

2%

Capacitors bank PDCS shall be added Vendor recommendations Local Control Panels & Control Stations Fuse Elements

50%

Bulb for Signal Lamps

50%

Signal Lamp

50%

Selector Switch

5%

Push Button

5%

Electrical Motors Grease Nipples where applicable Sleeve bearing complete set Temperature sensor for bearings

10% (One for each type) 5%

Bearing oil level sight glass Plastic cooling fan

5% 5%

Power terminal block

2%

Special items (Encoder, Cooling fan) Vendor recommendations Lighting Fixtures

1%

Flag Relay

2%

Time Relay

2%

Terminal Block Auxiliary Relays and Aux Contact Block

5% 1%

Moving Contacts For PURCHASER ≥ 55kW

15%

Fixed Contacts For PURCHASER ≥ 55kW

10%

Coils for Contactors

10%

Breathing Device and Silicagel

one of each type & size

Thermometer

10%

Local Control Station

5%

Ammeter For Control Station and Switchgear

5%

Push button

5%

Selector switch

5%

UPS: Fuse

20%

MCB (miniature circuit breaker)

10%

SCR DIODE

20% 10%

Transistor

20%

Control cards Signaling lamps Batteries

one per each type 10% 5%

Cooling fan on door

5%

Cooling fan for semiconductors 5%

5%

Special items (voltage relay) Electrolyte for batteries 2%

2%

Vendor recommendations Batteries chargers Fuse MCB (miniature circuit breaker)

10% 10%

SCR

10%

DIODE

10%

Transistor

10%

Control cards

one per each type

Signalling lamps

10%

Batteries

5%

FIRE ALARM system

*

Telephon system Paging system

* *

RADIO system

*

Emergency diesel generator

*

PDCS

*

Cathodic protection system

*

Variable speed drive (VSD)

*

Motorized valve (MOV)

* * These are the spare parts that Vendors shall recommend based on their experience.

Transformer Oil

2%

Cooling fan

2%

Winding thermo meter

2%

Oil thermo meter

2%

Oil level indicator Air bag

2% 2%

Gaskets

2%

Tank buchholz relay Conservator buchholz relay

2% 2%

Tap changer part Multi function protection device for sealed type transformers Vendor recommendations

1set for each type 2%

Sockets

(400V, 230V, 110V, 24V)

5%

Plugs

(400V. 230V, 110V, 24V)

20%

All special tool’s, equipment and spare parts required for commissioning and start-up shall be provided.

10.

INSTRUMENTATION For Control Panel: Bulbs for Signal Lamps

50%

Fuse Elements

50%

Board Instruments: Fuse Elements Chart Paper for Recorders Ink for or Recorders Pens for Recorders Field Transmitters: Gasket

50% 3 Boxes each type 7 Sets each type 50% 30%

Field Instruments: Air Pressure Regulators

10%

Temperature Indicators

20% each type (min one )

Pressure Gauges

20% each type (min one )

Solenoid Valves

15% each type (min. one Set)

Valve positioners Cable – Single Pair

15% each type (min. one Set) 20%

Cable – Multi Pair

15%

Cable Glands Junction Boxes – Large Pipe and Tube Fittings, all Type Valves

20% 1 min. 10% 15% each size 20% min. one valve

Manifold Valves Cable Tray

10% each type 20%

DCS: Bulbs for Signal Lamps Fuse Elements Printer Paper, Chart Paper Printer Ribbon

50% 50% 4 Boxes Each Type 10 sets each type

Blank Floppy Disks/Magnetic Tape Cartridge Gas Chromatograph: Filter Elements

10 pieces 20%

Calibration Gas Cylinders

1 Cylinder (100 litres) each type

Standard Gas Cylinders

1 Cylinder (100 litres) each type

Other Gas Cylinders

1 Cylinder (100 litres) each type

Other Analysers: Filter Elements

11.

12.

20%

Calibration Gas Cylinders

1 Cylinder (100 litres) each type

Standard Gas Cylinders

1 Cylinder (100 litres) each type

Other Gas Cylinders

1 Cylinder (100 litres) each type

PAINT & INSULATION Paint

10%

Insulation Material

10%

Insulation Band & Seal

10%

Insulating Cement

10%

Insulating Sheet Metal Insulation Wire

15% 10%

UTILITY EQUIPMENT Heat Exchanger, Vessel, Tank and Tower

See Item 2

Rotating Equipment

See Item 5

Filter Elements Piping

1 set each size/mat’l 0%

Electrical

See Item 9

Instrumentation: Control Panel

See Item 10

Board Instruments

See Item 10

Field Instruments

See Item 10

Others

0%

ATTACHMENT 2

CAPITAL SPARE PARTS REQUIREMENTS

LIST OF CAPITAL SPARE PARTS FOR CRACKING PLANT

 Cracked Gas Compressor: 

One set of compressor rotor



One set of turbine rotor



One set of dry gas seals

 Turbo-expander: 

One set of expander rotor

 Propylene Refrigerant Compressor: 

One set of compressor rotors



One set of turbine rotor



One set of dry gas seals

 Ethylene Refrigerant Compressor: 

One set of compressor rotors



One set of turbine rotors



One Set of dry gas seals

 Ethylene Boil off Compressor: 

One piston with Teflon piston ring for each size/each stage.



One cylinder liner for each size/each stage.

 For Cracking Furnaces:



for gas furnaces : 12 SMK coils (in loose compoments)



for liquid furnaces : 3 GK5 coils (in loose compoments) 3 tubes 1 (ID 48 x 6) (in loose compoments) 2 tubes 2 (ID 68 x 7) (in loose compoments) 1 Y-piece 48 x 68 1 Y-piece 68 x 96



8 single linear direct couple primary TLE in 4 sets of 2 double pipe TLE’s and including the refractory lined inlet piece.



1 secondary TLE.



1 flue gas ID fan for liquid furnace complete with electrical motor.

 

5 floor burners + 5 sidewall burners. For high pressure steam coils : 15,938 meter tube 60.3 x 8.74 of P1. 15,473 meter tube 60.3 x 8.74 of 347H. 15,938 meter tube 60.3 x 8.74 of 347H. 15,473 meter tube 60.3 x 8.74 of 347H. 8 return bends 180 degrees , 2” , of P1 8 return bends 180 degrees , 2” , of 347H

 For Pumps: 

For rotary pumps, one set of rotors with shaft for each type



One set of turbine rotors (for steam turbine drivers) for each type



One complete set of mechanical seal for each type

ATTACHMENT 3

INSTRUCTIONS TO COMPLETE SPARE PARTS INTERCHANGEABILITY RECORD FORMS

GUIDELINES FOR THE COMPLETION OF THE SPARE PARTS INTERCHANGEABILITY RECORD (SPIR) It is recommended that the lines and columns be completed by the equipment manufacture in the following sequence: Column 1

:

Enter the same equipment registration number or tag number for each piece of equipment as stated in the Material Requisition and/or Purchase Orders.

Column 2

:

Manufacturer’s model, type or other identification or other positive identification reference of the equipment/instruments ordered.

Column 3

:

Manufacturer’s serial number or other control reference of the equipment instruments as supplied.

Column 4

:

Total number of pieces of identical equipment/instruments as quoted in columns 1, 2, 3 and 6

Column 6

:

Purchasing COMPANY’s Material Requisition/Order reference number.

Column 8

:

Describe all parts in the English language. List all parts that should be carried in stock for manual operation and also list slow-wearing parts. If an item is interchangeable between two or more units, it should be listed once.

Column 9

:

For each part entered in column 8, enter the drawing number or reference number. Note: These drawings should be attached to the SPIR by the manufacturer.

Columns 10 A/B

:

Enter the reference number/letters or other information that identifies each part. Interchangeability with identical parts within manufacturer’s range should be indicated. Owing to the wide variety of systems in use for identification of parts, it is impossible to lay down firm rules for completing these columns. Manufacturers should give whatever identification system they use to positively identify parts and to show interchangeability with existing equipment. Manufacturer’s final cross-sectional drawings, workshop drawings, and real part numbers may not always be available in the early stage of manufacture. This may cause delays in timely preparation of manufacturer’s recommendation for initial spare

parts in column 13 and in the subsequent ordering of the same. To avoid such delays, it is recommended that reference be made to manufacturer’s documentation that is readily available, such as pamphlets, brochures, exploded views, and typical drawings of similar equipment. Column 11

:

Enter material specification in term of full international standards and accepted conventions, not manufacturer’s or submanufacturer’s references.

Column 5

:

For each unit or group of identical units, enter in the appropriate space the number of parts fitted in each unit of equipment or instrumentation.

Column 7

:

Enter the total number of identical parts in all equipment specified. In the case of identical units, multiply quantity in column 5 by the number of units given in column 4.

Column 12

:

Third party supplier

Column 18

:

Quantity to be ordered

Column 13

:

Enter manufacturer’s recommended ordered quantities of initial spare parts (pre-commissioning, commissioning and start-up). Enter PURCHASER’s recommended ordered quantities of initial spare parts (pre-commissioning, commissioning and start-up).

Column 14 Column 15

:

Enter manufacturer’s recommended ordered quantities for operation spare parts (two years operating).

Column 16

:

Enter PURCHASER’s recommended ordered quantities for operation spare parts (two years operating).

Column 19

:

Enter the price per piece of each part.

OWNER’S PROJECT TEAM SHOULD COMPLETE THE FOLLOWING PART OF THE SPIR FORM Column 21

:

For the classification of spare parts, i.e. :

C - for

:

Parts wearing out or deteriorating during normal operations, thus shown a fairly regular consumption. (Consumable parts)

Q - for

:

Parts not normal stocked, but ordered on request only.

I – for

:

Insurance items.

O - for

:

Temporary code number.

Column 22

:

In case this form is used as a requisition or identing document relevant column, signature, reference indicator and date should be entered to authorize purchase.

Column 23

:

Enter ROS date if using this form as requisition

IMPORTANT NOTE

The necessary provisions shall be made to fix the prices of spare parts for all EQUIPMENT AND MATERIALS for future purchasing of the spare parts by OWNER more than that which shall be purchased by PURCHASER for two years operations of the PLANT.

ATTACHMENT 4

GUIDELINES FOR SELECTION OF TWO YEARS OPERATION SPARE PARTS

TWO YEARS OPERATIONS SPARE PARTS Guidelines for Selection of 2 Years Operation Spare Parts. Spare Parts for equipment are shown in the following tables: Table 1

– Spare parts for centrifugal pumps

Table 2

– Spare parts for steam turbines and expanders

Table 3

– Spare parts for compressors

Table 4 Table 5

– Spare parts for reciprocating compressors – Spare parts for gear units

Table 6

– Spare parts for jet ejectors

Table 7

– Spare parts for electrical equipment

Table 8 Table 9

– Spare parts for instruments – Spare parts for pressure vessels and heat exchangers

Table 10 – Spare parts for furnaces/fans Table 11 – Spare parts for piping Note:

For all equipment not specifically mentioned in tables here above, the Vendor recommendation will be taken as basis for selection for Owner’s Approval.

TABLE 1 SPARE PARTS FOR CENTRIFUGAL PUMPS

Number of Pumps Using Part: Shaft, impeller, Throat Bushing

1 2 3 4 5 6 more 1 1 1 1 2 2 30% of No. of Pumps

Shaft Sleeve, Bearing Set, Impellers and case Wearing Rings

1 1 2 2 3 3 50% of No. of Pumps

Gasket Sets, Packing Mechanical Seal Non-metallic faces, O-rings, Gaskets, Springs Mechanical Seal, Metallic faces

1 2 3 4 5 6 100% of No. of Pumps

Mechanical Seal Assembly Sealing System: O-rings & Gasket

1 1 1 1 2 2 25% of No. of Pumps 2 2 2 3 3 4 50% of No. of Pumps

O-rings & Springs of MechanicalSeal Assembly

2 2 2 3 3 4 50% of No. of Pumps

Carbon rings of Mechanical Seal Assembly

2 2 3 4 5 6 100% of No. of Pumps

1 2 3 4 5 6 100% of No. of Pumps

NOTES: (a)

The parts listed above are the principal parts only. Other parts, such as impeller special bolts etc. shall be considered for recommendation in quantities consistent with the above table.

(b)

Spare impellers shall be ordered in the maximum diameters.

(c)

Quantities listed above are based on one part per pump. If the pump has more than one, the number of parts shall be modified accordingly.

(d)

For rotary pumps, provide a matching set of rotors with shaft.

TABLE 2 SPARE PARTS SPECIAL PURPOSE STEAM TURBINES AND EXPANDERS (ROTARY) Steam Turbines Number of Machines

1

Expanders (rotary) 2

Spare Items

1

2

Quantities

Diaphragms

1 set

1 set

1 set

1 set

Nozzles

1 set

1 set

-

-

2 sets

3 sets

Packing and Labyrinths Radial Bearings

200% 2 sets

3 sets

Thrust Bearings

100%

Thrust Bearings Pads

100%

Governor

1

1

1

1

6 sets

12 sets

6 sets

12 sets

1

1

1

1

Instrument Parts

1 set

2 sets

1 set

1 set

Gaskets

2 sets

4 sets

2 sets

4 sets

Trip and Throttle Valve Parts

1 set

1 set

1 set

1 set

Accumulator Bladder

1

2

1

2

Ejector Nozzles

1

2

-

-

Oil Cooler Bundle

1

1

1

1

Oil Pump

1

1

1

1

Oil Mist Elements

1

1

Transition Piece

1

1

Oil Filter Elements Couplings

Casing Bolt

Two per size, for each turbine

Insulating Washer

One Set per each Turbine if any

NOTES: a)

Quantities for washable oil filter elements can be reduced to 5.

b)

The parts listed are the principal parts only. Other parts shall be considered for recommendation in quantities consistent with the above table.

c) Decision on type of spare stems are to be agreed after final selection of steam turbine / expanders.

TABLE 3 SPARE PARTS COMPRESSORS – AXIAL/ROTARY/CENTRIFUGAL

No. of Machines

Centrifugal 1 2

Spare Items

Axial 1

Rotary 2

1

2

Quantities

Seals Radial Bearings

100% 100%

100% 100%

100% 100%

Thrust Bearings

100%

100%

100%

Thrust Bearing Pads (sets) Coupling Oil Filter Elements Instruments Parts (sets)

1 1

2 1

1 1

2 1

1 1

2 1

6 sets

12 sets

6 sets

12 sets

6 sets

12 sets

1

2

1

2

2

2

Accumulator Bladder Labyrinths

100%

100%

100%

Gaskets + O-rings (sets)

2

4

2

4

2

4

Oil Pumps Stators Blades

1 -

1 -

1 -

1 -

1 -

1 -

Casing

-

-

-

-

-

-

Timing Gears (sets)

-

-

-

-

1

1

Flushing Nozzles (sets) Oil Cooler

1

1

-

-

-

-

NOTES: a)

Quantities for washable oil filter elements can be reduced to 5.

b)

The Parts listed are the principal parts only. Other Parts shall be considered for recommendation in quantities consistent with the above table.

TABLE 4 SPARE PARTS FOR RECIPROCATING COMPRESSORS No. of Machine

1

Spare Item

3

Quantities

Pistons Cylinder Liners Valves Valves Parts (plates, springs, etc.) Piston Rods Packing Connecting Rods (each type) Cross Heads Cross Head Shoes Bearings Piston Rings Cylinders Unloaded Device Parts Lube pumps Lubricators Cross Head Pins Relief Valve Parts Spec. Bolts and Nuts Flushing Nozzles Crankshafts Couplings Instrument Parts Oil Filter Refills O-Rings/Gaskets Unloaded Assembles Cooler Bundle for Mounted Inter-coolers NOTE:

2

Integral

Frame

1 set 1 set 100% 3 sets 1 set 100% 1 100% 100% 100% 2 sets 1 set each type

1 set 1 set 100% 6 sets 1 set 100% 1 100% 100% 100% 4 sets 2 sets each type

1 set 1 set 100% 9 sets 1 set 200% 1 100% 100% 100% 6 sets 3 sets each type

1 1/2 set 100% 100% 1 each type 1 1 2 2 sets 1 1

1 1 set 100% 100% 1 each type 1 2 4 4 sets 1 1

1 1 set 100% 100% 1 each type 1 2 6 6 sets 1 1

The parts listed are the principal parts only.

Other parts shall be considered for recommendation in quantities consistent with the above table.

TABLE 5 SPARE PARTS FOR SPECIAL PURPOSE GEAR UNITS

No. of Machines Spare Item Radial Bearings Couplings Quill Shafts Labyrinths Gaskets Instrument Parts Thrust Bearings Thrust Bearing Pads

NOTE:

1

2 Quantities 100%

1 1

1 1 100%

2 sets 1 set

4 sets 2 sets 100%

1 set

2 sets

The parts listed above are the principal parts only. Other parts shall be considered for recommendation in quantities consistent with the above table.

TABLE 6 SPARE PARTS FOR JET JECTORS

Items

Quantities

Nozzles (As far as applicable)

1 each size

Diffusers (As far as applicable)

1 each size

TABLE 6A MINIMUM SPARE PARTS FOR AGITATOR (MIXER)

Stems Shaft sleeve bearing set, Gasket set, Packing seal spring seal, Nonmetallic faces, Gaskets and Spring

Quantities 100% per Nos. of each type/size of agitator

Mechanical seal assembly

50% of Nos.

Mechanical seal, metallic faces

100% of Nos.

Mechanical seal, non-metallic parts like C.R, wedge etc. if any,

100% of Nos.

TABLE 7 SPARE PARTS FOR ELECTRICAL EQUIPMENT Quantities * 1) Switchgears:

2) Power Motor Control Center:

MV Fuses

15%

Protection and Flag Relay

2%

Time Relay

2%

Lamps

30%

Space Heaters

10%

L.V. Fuses

30%

Terminal Blocks

2%

Auxiliary Relays

1%

Metering Device

10%

Moving Contacts For PURCHASER ≥ 55 kW

20%

Fixed Contacts For PURCHASER ≥ 55 kW

20%

Circuit Breakers

10%

Contactors

10%

Metering

15%

CT

20%

PT

20%

L.V. Fuses

15%

Time Delayed Relays

8%

Lamps

10%

Space Heaters

10%

Terminal Blocks

7%

Auxiliary relays

To be determined later in conjunction with the equipment vendor “

Contactors and Contact Block Thermal overload Relays

“

Motor Circuit Breakers complete Unit for each Type & Size Moving Contact For PURCHASER ≥ 55 kW

10%

Fixed Contacts For PURCHASER ≥ 55 kW

20%

Metering Device

15%

CT each Type

20%

PT

20%

Main Circuit Breaker 3) Transformers:

4) Power Material:

5) Lighting Materials

Buchholz Relays

20%

One per each type One each type & size

Thermometer

10%

Bushing (MV, LV)

50%

Air Bag (For each Type)

1 Set

Measuring and Control Devices

20%

CT of Neutrol Resistor

10%

a)

Local Control Stations

5%

b)

Sockets 400V AC

10%

c)

Plugs 400V AC

15%

a)

Switches

10%

b)

Fuses

30%

c)

Sockets (230V, 110V, 24V)

10%

d)

Plugs (230V, 110V, 24V)

20%

e)

Lighting Fixtures

10%

f)

Ballast Lamps

5%

g)

Lamps

20%

h)

Portable 110V AC, 50HZ with transformer (Ex Type) Socket Plug

10%

i)

Hand Lamp 24V, AC, 50HZ (Ex Type)

30 Nos.

6) MOTORS Number of motors

1 2 3 4 5

more more

Local Control Station

1 1 1 2 2

40%

No of machines

1 2 3 4 5

more

Set of bearing

1 1 1 2 2

40%

Fan, Terminal, Blocks, Space, Heater (MV) per Type

5%

7) UPS: Fuse

30%

MCB (miniator circuit breaker)

15%

SCR (one complete module)

30%

Signaling Lamp and Protective Device

15%

Diod

10%

Transistor (one complete module)

30%

Control Cards Batteries Isolator switch (make before breake) (by pass)

One per each type 10% One per each type

8) Battery Charger: Fuse

30%

MCB

15%

SCR (one complete module)

30%

Diod

10%

Signaling Lamps

15%

Control Cards Batteries 9) Telephone System: 10) Paging System: 11) Radio System: 12) Fire Alarm System: 13) Neutral Grounding System: 14) Bus Duct:

One per each type 10%

These are the spare parts required for two years operation. Vendor shall recommend the spares based on their experience. *

The quantities indicated are only preliminary estimation, so the firm quantities will be specified later in conjunction with recommendations of equipment vendors.

TABLE 8 SPARE PARTS FOR INSTRUMENTS

Items

Quantities

Flow Instruments Level Instruments Temperature Instruments Pressure Instruments

To be determined in conjunction with the equipment Vendor (based on Vendor’s experience on similar type of plant)

Analysers Control Valves: Valve Bodies

None unless service is corrosive or erosive. For corrosive or erosive service, shall be determined in conjunction with the equipment Vendor.

Valve Plugs

1 of each size/min. 15% or 1

Seat Rings

2 of each size/min. 25% or 2

Actuator

10% (min. one per type/size)

Valve Stems

1 of each diameterThese vary in length depending on valve size. Purchase the longest of each dia. These can be cut to the correct size.

Steam packing

3 boxes of each size used/min. 30%

Grease

3 boxes of each type used/min. 20%

Diaphragms

2 of each size used min. 20%

Pressure Gauges

15% each type (min two)

Solenoid and Trip Valves

15% each type (min two)

Valve Positioners

15% each type

Thermocouples

15% each type (min two)

Dial Thermometers Blank Orifice Plates Manual Loading Stations Instrument Air Filters (Regulation sets) Pressure Switches Plug-in Assemblies for Elect. Instr. Plug-in Assemblies for Pneum. Instr. Seal, Condensate and Vent Pots

10% (for all)

Solenoid and Trip Valves Thermowells Signal Lights I/P Converters FCS/DCS/ESD/PLC (for each system) the Following Items: I/O Cards

5%, min. one for each type

Main Cards

1 set

Power Supply (AC, if any)

1 set

Power Supply (DC, if any)

1 set

On-Line Gas Chromatographs: Main Mother Cards

One set

Column

One per type

Barrier Cards

5% for each type (min. 1 for each type) TABLE 9

SPARE PARTS FOR PRESSURE VESSELS & HEAT EXCHANGERS

Item 1)

2)

Heat Exchangers-Shell and Tube: (U type included) -

Tubes

10% from longest tube of each size and material.

-

Bolts

-

Gaskets

Special, Alloy, and C.S. material: 10% per Size and Type 200%

Pressure Vessels -

3)

Quantities

Gaskets Bolts

200% 10% (Special, Alloy or size 2” diam. or greater), minimum one number.

Air Cooled Exchangers -

Plugs Plug gaskets Cover plate gaskets Tube support boxes

Steel 5%; Non-ferrous 2% (min. one number) 5% (min one number) 100% 10% (min one number)

Spare Items 4)

Quantities (a)

Number of Air-fin Coolers Using Part.

1 2 3 4 5 6 7 or more

i.

V-belts.Sheaves (Driven & Driver) - Set of Belts

0000001

ii.

Fan Shaft Bearing (Upper & Lower)

111223

50% of No. of Air Fins

iii.

Speed Reducers (Gear Box) – Shaft & pinion - Bearing Set O-Rings, Seals, Lockwashers, Locknuts

111222

30% of No. of Air Fins

111223

50% of No. of Air Fins

Couplings – Complete Coupling,

1111111

iv.

1 2 3 4 5 6 100%

Flanges, Gaskets, Seals

5)

v.

Fan Assemblies Automatic Pitch Control Hub Assembly arts Guide Bushing, Pitch Blocks, O-Rings, Clam Gaskets

123456

100% of No. of Air Fans

vi.

Bolt Assemblies, Fork Pins

123456

100% of No. of Air Fans

vii.

Flexible Hose, Rotary Union

1111112

viii.

Automatic or Manual Adjustments: Blade Retention Clamps, Pitch, Change Forks, Puch Rod, Stub (with pilot tubes) Bearing Retainer Rings

111222

30% of No. of Air Fans

20% of No. of Air Fans

ix.

Spring Housing Gasket, Diaphragm, Blade Retainer Ring, Thrust cover Gasket

111122

x.

Hub Assembly with Blades

0000001

* (a) (b) (c)

NOTES Quantities shown are for each size and type of part Twenty units or moreThe parts listed are the principal parts only. The parts listed are the principal parts only. Other parts shall be considered for recommendation in quantities consistent with the above table.

(b)

Plate type Exchanger: Plate gasket

100%

Flow Plate

10%

Nozzle Gasket

200%

Glue (1 Kg Pot)

1

TABLE 10 SPARE PARTS FOR FURNACES / FANS

ITEM

QUANTITIES

(To be proposed by Vendor / PURCHASER and to be concluded by Owner prior to Placement of Purchase Order)

TABLE 11 SPARE PARTS FOR PIPING

Item 

Valves up to 1 1/2” complete units

Quantities 5% for each size, type and material

 Valves from 2” to 6”

2% (minimum 2 pieces) for each size type and material

 Valves from 6” to 12”

1 piece for each size, type and material

complete units  Valves above 12”

1 only if installed valves quantity is greater than 20 For special case and critical valves less Shall be cleared and quoted by PURCHASER than 20”  Valves up to 10”

Gland packing and bonnet gasket

10% (Gland Packing for class 1500 and more, minimum 20%)

 Valves from 2” to 10”

Set of changeable inner parts

2 for each type, size and material

 Valves above 10”

Set interchangeable inner parts: - Bonnet gasket and stem packing  Piping gaskets and bolts set for each

1 for each type, size and material

10%

size and type  Steam Trap (Thermostatic)

2% for each size and type

 Steam Trap (another type)

1 piece for each size and type

ATTACHMENT 5

SPARE PARTS INTERCHANGEABILITY RECORD FORM (S.P.I.R.)

ATTACHMENT 6

EXAMPLE OF COST BREAKDOWN (for two years operation spare parts)

EXAMPLE OF COST BREAKDOWN (for two years operation spare parts)

Equipment/Material Centrifugal compressor package Centrifugal pumps … … Piping CR instruments and cabinets Field instruments Motors Field electrical material SS boards PURCHASER PROCUREMENT SERVICES TOTAL

Budget

Forecast

Actual PO-S value

ATTACHMENT NO.:17.1 BUSHEHR METHANOL PLANT

EPs CONTRACTOR:

Bushehr Petrochemical Company (BUPC)

Petrochemical Industries Design & Engineering Company (PIDEC)

Genaral Design Data

Project No. : 1210

OWNER:

DATA SHEET FOR LOW VOLTAGE ELECTRIC MOTORS (Ex) Project No. : ME16 Doc No. :

Rev. : 00

Tag Nos :

Manufacturer

:

Service :

Plant Location

:

Client

Purchase Order No. :

:

Assaluyeh, Iran

Enviromental Condition

Applicable Standards and Reference Documents Project Specification

:

1210-00-EL-MSS-521

Location

Paint Specification

:

1210-00-PI-ESS-406

Ambient Air Temperature

Outdoor, Tropicalized

Applicable Standard

:

IEC 60034

Humidity

:

80% Max.

Altitude

:

22.2 m

:

Min. 5°C

:

Area Classification(IEC 60079-10) :

Zone 2, IIC, T2

400V ± 5%

System Earthing

Solidly Earthed

50Hz - 5%, +2%

Short circuit capacity at input :

Power System System Voltage &Variations

:

System Frequency &Variations : Particulars of Equipment

Unit

Purchaser's Requirements VTA

Basic Data

Frame Size Rated Voltage

V

400

Rated Frequency

Hz

50

Required Shaft Brake Power

KW

*

Rated Power

KW

* 3 phases

No. of Phases

S1

Duty

*

No. of Poles / Synchronous Speed

Star

Stator Connection

Class F

Insulation Class

48°C

Design Temperature

Class B

Temperature Rise

IP54

Ingress Protection Classification (IEC 60529)

TEFC, IC411 , IC511 , IC611 (As per sec. 4.4 of 1210-00-EL-MSS-521)

Cooling Type (IEC 60034-6) A

VTA

PU

VTA

PU

VTA

Full Load Turque

Nm

VTA

Break Down Torque

PU

VTA

Performance Characteristics

Full Load Current Efficiency Power Factor

(FL ( FL

/ /

3/4 FL 3/4 FL /

/

1/2FL) 1/2FL)

Pull Up Torque

PU

VTA

Full Load Speed

rpm

VTA

%

VTA

Slip at Full Load / 75% Load

VTA

Over Speed Capability No Load Losses

VTA

watt

Direct on Line/Variable Speed

Starting Method

VTA

Hazardous Area Certification

Starting Characteristics

Starting Performance (IEC60034-12) Maximum Allowable Stall Time

( Hot / Cold)

3 from cold state / 2 from hot state

Maximum No. of Successive Starts in Hour Starting Current Locked Rotor Power Factor Locked Rotor Torque

( Un / 0.8xUn) ( Un / 0.8xUn) ( Un / 0.8xUn)

VTA

Sec.

PU (A)

VTA (shall not exceed 700% of FLC)

PU

VTA

PU

VTA

Run-Up Time (Full Load)

( Un / 0.8xUn)

Sec.

VTA

Run-Up Time (No Load)

( Un / 0.8xUn)

Sec.

VTA

Allowable Run-Up Time from Cold State (Un / 0.8xUn)

Sec.

VTA

Allowable Run-Up Time from Hot State (Un / 0.8xUn)

Sec.

VTA

--

EEx nA II T2 or EEx e II T2 or EEx d IIC T2 (As per sec. 4.3.7 of 1210-00-EL-MSS-521)

Motor Explosion Protection Type / Gas Group / Temp. Class Terminal Boxes Explosion Protection Type / Gas Group / Temp Class Ex "e" Motor te Time

--

EEx nA II T2 or EEx e II T2 or EEx d IIC T2

Sec.

VTA

--

VTA

VTA

Recommended Thermal O/L Relay Certifying Authority

Note 1: VTA: Vendor to Advise Note 2: (*) in "Purchaser Requirement" column should be filled out by driven equipment vendor. Note 3: Motors which are controlled by "Vareiable Speed Drive" should be Ex “de” type. Sheet 1 of 2

:

Vendor's Data

Max. 48°C

ATTACHMENT NO.:17.1 BUSHEHR METHANOL PLANT

EPs CONTRACTOR:

Petrochemical Industries Design & Engineering Company (PIDEC) Project No. : 1210

Bushehr Petrochemical Company (BUPC)

DATA SHEET FOR LOW VOLTAGE ELECTRIC MOTORS (Ex) Doc No. :

Particulars of Equipment

Unit

Purchaser's Requirements *

Stator Material

Ferromagnetic Material

Enclousure Material

Sheet Steel/ Cast Iron

Rotor Cage Material

Copper/ Die Cast Aluminium

Cooling Fan Material

Metallic (Brass, Bronze or Aluminum)

Rotation Facing Drive End (CW/CCW)

*

Finish Color

RAL 5010

Motor Weight

Kg

VTA

Rotor (Uncoupled) Inertia

Kg.m2

VTA

Driven Load Inertia (at Motor Speed)

Kg.m2

Coupling Type

Mechanical Detail

dB(A)

85

dB

VTA

Noise Silencer

Yes/No

VTA

Integral Breather / Drain (IEC60034-5)

Yes/No

VTA

Drive End Bearing Type/ Make & Size

VTA

No. of Drive End Bearings

VTA

None Drive End Bearing Type / Make & Size

VTA

No. of None Drive End Bearings

VTA

Method of Bearing Lubrication

VTA

Bearing Ingress Protection (IEC 60529)

IP55

Minimum Bearing Lifetime, Motor Only

hr

Maximum Relubrication Interval

hr

Shaft

VTA VTA Extended / Solid / Hollow

Max. Shaft Voltage

mV rms

VTA

Insulated Bearings

Yes/No

VTA

Bearing Insulation Rating

KV

VTA

mm

VTA (If applicable)

mm/S

14 acc. to grade d A) VTA (IEC 60034 60034-14

rpm

VTA

Lifting Lug

Yes/No

Yes

Anti Condensation Heater

+/-

Vib i at N d S d P k Vibration No L Load, Selflf M Mounted, Peakk to P Peak Critical Speed (First/Second)

Accessories

* Direct/ Gear Box/ Pulley

Maximum Sound Pressure Level at one Meter (Full Load) Sound Power level

Rotor Axial Float

Yes/No

No

Anti Condensation Heater Power

W

-

Anti Condensation Heater Voltage

VAC

-

Winding Temperature Detector

Yes/No

No

Bearing Temperature Detector

Yes/No

No

Temperature Sensor for VFD Controled Motors or Motors with critical operating conditions

PT-100 type/Thermistor type (if applicable)

Frame Earth / Terminal Box Earth

Yes/No

Yes (External Stud /Internal Terminal)

Accelerometer Shock Pulse Measurement Device

Yes/No

VTA

Anti Rotational Device

Yes/No

VTA

Vibration Switch

Yes/No

VTA

Sun Canopy

Yes/No

VTA

Differential Protection CT's in Neutral Terminal Box

Yes/No

NO

Ingress Protection of Terminal Box

IP55

Power Terminal Box Type Power Terminal Box Location (IEC 60034-7)

Project No. : ME16 Rev. : 00

Mounting (IEC 60034-7)

Terminal Box & Cable Connection

OWNER:

Phase Insulated Top or Right (looking from drive end) Rotatable by 90° and 180°

Power Cable Type

Cu/XLPE/PVC

Power Cable No. & Size

**

Power Cable Gland & Entries

**

Power Cable Entry Direction

**

Heater Cable Type

-

Heater Cable No. & Size

-

Heater Cable Gland & Entry

-

Instrument Cable Type

**

Instrument Cable No. & Size

**

Instrument Cable Gland & Entry

**

Note 1: VTA: Vendor to Advise Note 2: (*) in "Purchaser Requirement" column should be filled out by driven equipment vendor. Note 3: (**) Will be informed to motor vendor after receiving preliminary motor data. Sheet 2 of 2

Vendor's Data

ATTACHMENT NO.:17.2 BUSHEHR METHANOL PLANT

EPs CONTRACTOR:

Bushehr Petrochemical Company (BUPC)

Petrochemical Industries Design & Engineering Company (PIDEC)

DATA SHEET FOR LOW VOLTAGE ELECTRIC MOTORS (Non-Ex) Project No. : ME16

Project No. : 1210

Genaral Design Data

OWNER:

Doc No. :

Rev. : 00

Tag Nos :

Manufacturer

:

Service :

Plant Location

:

Client

Purchase Order No. :

:

Assaluyeh, Iran

Applicable Standards and Reference Documents

Enviromental Condition

Project Specification

:

1210-00-EL-MSS-521

Location

Paint Specification

:

1210-00-PI-ESS-406

Ambient Air Temperature

Applicable Standard

:

IEC 60034

Humidity Altitude

Outdoor, Tropicalized

: :

Min. 5°C

80% Max.

:

22.2 m

:

Area Classification(IEC 60079-10) :

Safe Area

System Earthing

Solidly Earthed

Power System System Voltage &Variations

:

400V ± 5%

System Frequency &Variations :

50Hz - 5%, +2%

Particulars of Equipment

Unit

Basic Data

Rated Voltage

V

400

Rated Frequency

Hz

50

Required Shaft Brake Power

KW

*

Rated Power

KW

No. of Phases

S1

Duty

*

No. of Poles / Synchronous Speed

Star

Insulation Class

Class F

Design Temperature

48°C

Temperature Rise

Class B IP54

Ingress Protection Classification (IEC 60529)

TEFC, IC411 , IC511 , IC611 (A per sec. 4 (As 4.4 4 off 1210 1210-00-EL-MSS-521) 00 EL MSS 521)

Cooling Type (IEC 60034-6) 60034 6)

Performance Characteristics

Full Load Current Efficiency Power Factor

(FL ( FL

/ /

3/4 FL 3/4 FL /

/

1/2FL) 1/2FL)

A

VTA

PU

VTA

PU

VTA

Full Load Turque

Nm

VTA

Break Down Torque

PU

VTA

Pull Up Torque

PU

VTA

Full Load Speed

rpm

VTA

Slip at Full Load / 75% Load

%

Over Speed Capability watt

Starting Method

VTA ( Hot / Cold)

Sec.

Maximum No. of Successive Starts in Hour Starting Current Locked Rotor Power Factor Locked Rotor Torque

VTA Direct on Line/Variable Speed

Starting Performance (IEC60034-12) Maximum Allowable Stall Time

VTA VTA

No Load Losses

Starting Characteristics

* 3 phases

Stator Connection

Hazardous Area Certification

Short circuit capacity at input : Purchaser's Requirements VTA

Frame Size

( Un / 0.8xUn) ( Un / 0.8xUn) ( Un / 0.8xUn)

VTA 3 from cold state / 2 from hot state

PU (A)

VTA (shall not exceed 700% of FLC)

PU

VTA

PU

VTA

Run-Up Time (Full Load)

( Un / 0.8xUn)

Sec.

VTA

Run-Up Time (No Load)

( Un / 0.8xUn)

Sec.

VTA

Allowable Run-Up Time from Cold State (Un / 0.8xUn)

Sec.

VTA

Allowable Run-Up Time from Hot State (Un / 0.8xUn)

Sec.

VTA

-

-

-

-

Sec.

-

Motor Explosion Protection Type / Gas Group / Temp. Class Terminal Boxes Explosion Protection Type / Gas Group / Temp. Class Ex "e" Motor te Time Recommended Thermal O/L Relay Certifying Authority

-

:

-

Note 1: VTA: Vendor to Advise Note 2: (*) in "Purchaser Requirement" column should be filled out by driven equipment vendor.

Sheet 1 of 2

Vendor's Data

Max. 48°C

ATTACHMENT NO.:17.2 BUSHEHR METHANOL PLANT

EPs CONTRACTOR:

Project No. : 1210

DATA SHEET FOR LOW VOLTAGE ELECTRIC MOTORS (Non-Ex) Project No. : ME16 Doc No. :

Particulars of Equipment

Rev. : 00

Unit

Purchaser's Requirements *

Mounting (IEC 60034-7)

Ferromagnetic Material

Stator Material Enclousure Material

Sheet Steel/ Cast Iron

Rotor Cage Material

Copper/ Die Cast Aluminium

Cooling Fan Material

Metalic (Brass, Bronze or Aluminum) *

Rotation Facing Drive End (CW/CCW)

RAL 5010

Finish Color Kg

VTA

Rotor (Uncoupled) Inertia

Kg.m2

VTA

Driven Load Inertia (at Motor Speed)

Kg.m2

Motor Weight

Mechanical Detail

Maximum Sound Pressure Level at one Meter (Full Load) Sound Power level

dB(A)

85

dB

VTA

Noise Silencer

Yes/No

VTA

Integral Breather / Drain (IEC60034-5)

Yes/No

VTA

Drive End Bearing Type/ Make & Size

VTA

No. of Drive End Bearings

VTA

None Drive End Bearing Type / Make & Size

VTA

No. of None Drive End Bearings

VTA

Method of Bearing Lubrication

VTA

Bearing Ingress Protection (IEC 60529)

IP55

Minimum Bearing Lifetime, Motor Only

hr

Maximum Relubrication Interval

hr

40000 VTA Extended / Solid / Hollow

Shaft Max. Shaft Voltage

mV rms

VTA

Insulated Bearings

Yes/No

VTA

KV

VTA

mm

VTA (If applicable)

mm/S

VTA (IEC 60034-14 acc. to grade A)

rpm

VTA

Lifting Lug

Yes/No

Yes

Anti Condensation Heater

Bearing Insulation Rating Rotor Axial Float

+/-

Vibration at No Load, Self Mounted, Peak to Peak Critical Speed (First/Second)

Accessories

* Direct/ Gear Box/ Pulley

Coupling Type

Yes/No

No

Anti Condensation Heater Power

W

-

Anti Condensation Heater Voltage

VAC

-

Winding Temperature Detector

Yes/No

No

Bearing Temperature Detector

Yes/No

Temperature Sensor for VFD Controled Motors or Motors with critical operating conditions

No PT-100 type/Thermistor type (if applicable)

Frame Earth / Terminal Box Earth

Yes/No

Yes (External Stud /Internal Terminal)

Accelerometer Shock Pulse Measurement Device

Yes/No

VTA

Anti Rotational Device

Yes/No

VTA

Vibration Switch

Yes/No

VTA

Sun Canopy

Yes/No

VTA

Differential Protection CT's in Neutral Terminal Box

Yes/No

NO

IP55

Ingress Protection of Terminal Box

Phase Insulated

Power Terminal Box Type

Terminal Box & Cable Connection

OWNER: Bushehr Petrochemical Company (BUPC)

Petrochemical Industries Design & Engineering Company (PIDEC)

Power Terminal Box Location (IEC 60034-7)

Top or Right (looking from drive end) Rotatable by 90° and 180°

Power Cable Type

Cu/XLPE/PVC

Power Cable No. & Size

**

Power Cable Gland & Entries

**

Power Cable Entry Direction

**

Heater Cable Type

-

Heater Cable No. & Size

-

Heater Cable Gland & Entry

-

Instrument Cable Type

**

Instrument Cable No. & Size

**

Instrument Cable Gland & Entry

**

Note 1: VTA: Vendor to Advise Note 2: (*) in "Purchaser Requirement" column should be filled out by driven equipment vendor. Note 3: (**) Will be informed to motor vendor after receiving preliminary motor data.

Sheet 2 of 2

Vendor's Data

ATTACHMENT NO.:17.3 BUSHEHR METHANOL PLANT

EPs CONTRACTOR:

Petrochemical Industries Design & Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC)

DATA SHEET FOR MEDIUM VOLTAGE ELECTRIC MOTORS (Ex)

Project No. : 1210

Genaral Design Data

OWNER:

Doc No. :

Project No. : ME16

Rev. : 00

Tag Nos :

Manufacturer

:

Service :

Plant Location

:

Client

Purchase Order No. :

:

Assaluyeh, Iran

Applicable Standards and Reference Documents

Enviromental Condition

Project Specification

:

1210-00-EL-MSS-522

Location

Paint Specification

:

1210-00-PI-ESS-406

Ambient Air Temperature

Outdoor, Tropicalized

Applicable Standard

:

IEC 60034

Humidity

:

Altitude

:

: :

Min. 5°C

Max. 48°C

80% Max. 22.2 m

Area Classification(IEC 60079-10) :

Zone 2, IIC, T2

Power System System Voltage &Variations

:

System Frequency &Variations : Particulars of Equipment

6KV/11KV ± 5%

System Earthing

50Hz, ±2%

Short circuit capacity at input :

Unit

Basic Data

Rated Voltage

V

6000 / 11000

Rated Frequency

Hz

50

Required Shaft Brake Power

KW

*

Rated Power

KW

S1

Duty No. of Poles / Synchronous Speed

* Star

Insulation Class

Class F 48°C

Design Temperature

Class B

Temperature Rise Ingress Protection Classification (IEC 60529)

IP54 TEFC, IC411 , IC511 , IC611 , IC616 , IC7A1W7 (As per sec. 4.4 of 1210-00-EL-MSS-522)

Cooling Type (IEC 60034-6) A

VTA

1/2FL)

PU

VTA

1/2FL)

PU

VTA

F ll L Full Load dT Turque

N Nm

VTA

Break Down Torque

PU

VTA

Pull Up Torque

PU

VTA

Full Load Speed

rpm

VTA

%

VTA

Full Load Current Efficiency

Performance Characteristics

Power Factor

( FL (FL

/ /

3/4 FL

/

3/4 FL /

Slip at Full Load / 75% of Load

Starting Characteristics

Over Speed Capability

VTA

No Load Losses

watt

VTA

First Critical Speed

RPM

VTA

Second Critical Speed

RPM

Starting Method

VTA Direct on Line/Variable Speed

Starting Performance (IEC60034-12)

VTA

Starting Current

( Un / 0.8xUn)

Locked Rotor Power Factor

( Un / 0.8xUn)

Locked Rotor Torque

( Un / 0.8xUn)

Run-Up Time (coupled)

( Un / 0.8xUn)

PU (A)

VTA (shall not exceed 550%) VTA

PU

VTA

Sec.

VTA VTA

Run-Up Time (Un coupled)

( Un / 0.8xUn)

Sec.

Maximum Allowable Stall Time (*)

Hot / Cold

Sec.

VTA

Heating / Cooling

Min.

VTA

Heating / Cooling

Min.

Thermal Time Constant

Thermal Modeling

* 3 phases

No. of Phases

Stator Connection

K factor (Note 3) Start up Time Constant

VTA VTA 3 from cold state / 2 from hot state in operetaing temp.

Maximum No. of Successive Starts in Hour Allowable Run-Up Time from Cold State (Un / 0.8xUn)

Sec.

Allowable Run-Up Time from Hot State (Un / 0.8xUn)

Sec.

VTA

Rotor Short/Long Term Time Constant

Sec./Min

VTA (for motors above 1000KW)

Stator Short/Long Term Time Constant

Sec./Min

VTA (for motors above 1000KW)

ºC

VTA (for motors above 1000KW)

Motor Explosion Protection Type / Gas Group / Temp. Cllass

--

EEx nA II T2 or EEx e II T2 or EEx d IIC T2 (As per sec. 4.3.7 of 1210-00-EL-MSS-522)

Terminal Boxes Explosion Protection Type / Gas Group / Temp. Class

--

EEx nA II T2 or EEx e II T2 or EEx d IIC T2

Ex "e" Motor te Time

Sec.

VTA

Certifying Authority

--

VTA

Max. Temperature Allowed for Rotor

Hazardous Area Certification

Purchaser's Requirements *

Frame Size

VTA

Note 1: VTA: Vendor to Advise

Sheet 1 of 2

:

Resistance Earthed

Vendor's Data

ATTACHMENT NO.:17.3 BUSHEHR METHANOL PLANT

EPs CONTRACTOR:

Project No. : 1210

DATA SHEET FOR MEDIUM VOLTAGE ELECTRIC MOTORS (Ex) Project No. : ME16 Doc No. :

Particulars of Equipment

Rev. : 00

Purchaser's Requirements

Unit

Mounting (IEC 60034-7)

*

Stator Material

Ferromagnetic Material

Enclousure Material

Sheet Steel/ Cast Iron

Rotor Cage Material

Copper

Cooling Fan Material

Metallic (Brass, Bronze or Aluminum)

Rotation Facing Drive End (CW/CCW)

*

Finish Color

RAL 5010

Motor Weight

Kg

VTA

Rotor (Uncoupled) Inertia

Kg.m2

VTA

Driven Load Inertia (at Motor Speed)

Kg.m2

*

Coupling Type

Direct/ Gear Box/ Pulley

Maximum Sound pressure Level at one Meter (Full Load)

dB(A)

85

dB

VTA

Noise Silencer

Yes/No

VTA

Integral Breather / Drain (IEC60034-5)

Yes/No

VTA

Mechanical Detail

Sound Power Level

Drive End Bearing Type/ Make

VTA

No. of Drive End Bearings

VTA

None Drive End Bearing Type / Make

VTA

No. of None Drive End Bearings

VTA

Method of Bearing Lubrication (Grease/Oil Ring)

VTA

Bearing Ingress Protection (IEC 60529)

IP55

Minimum Bearing Lifetime, Motor Only

hr

Maximum Relubrication Interval

hr

40,000 VTA

Shaft

Extended / Solid / Hollow

Max. Shaft Voltage

mV rms

VTA

Insulated Bearings

Yes/No

Yes/No (As per sec. 10.8 of 1210-00-EL-MSS-522)

Bearing Insulation Rating

KV

VTA

mm

VTA (as per IEC 60072)

mm/S

VTA (IEC 60034-14 acc. to grade A)

rpm

VTA

Lifting Lug

Yes/No

Yes

Anti Condensation Heater

Yes/No

Yes

W

VTA

Rotor Axial Float

+/-

Vibration at No load, Self Mounted, Peak to Peak Critical Speed (First/Second)

Anti Condensation Heater Power Anti Condensation Heater Voltage Winding Temperature Detector Number & Type Winding Temperature Alarm/Trip

Accessories

Bearing Temperature Detector Number & Type

VAC

230

Yes/No

6 ( acc. to IEC 60751 & sec. 9.1 of 1210-00-EL-MSS-522)

°C

Yes

Yes/No

VTA ( Note 4 & sec 10.1 of 1210-00-EL-MSS-522)

Bearing Temperature Alarm/Trip

°C

VTA

Frame Earth / Terminal Box Earth

Yes/No

Yes (External Stud /Internal Terminal)

Accelerometer Shock Pulse Measurement Device

Yes/No

VTA

Anti Rotational Device

Yes/No

VTA

Vibration Switch

Yes/No

VTA

Sun Canopy

Yes/No

VTA

Differential Protection

Yes/No

Note 5 Summation method: 3No.s Current transformers to be installed in the neutral point terminal box of the motor

Differential Protection Scheme CT's to Be Supplied By

Motor Manufacturer

Diff.Protection CT's Ratio/Burden/Accuracy class

**

Diff.Protection CT's Resistance/Knee Point Voltage/Current

Terminal Box & Cable Connection

Speed Switch with Control Unit

** Yes/No

**

Ingress Protection of Terminal Box

--

IP55

Power Terminal Box Type

--

Phase Insulated/ Phase Segregated

Power Terminal Box Location (IEC 60034-7)

--

Right (looking from drive end) Rotatable by 90° and 180° degree increments

Neutral Terminal Box

OWNER: Bushehr Petrochemical Company (BUPC)

Petrochemical Industries Design & Engineering Company (PIDEC)

Yes/No

Yes

Power Cable Type

--

Cu/XLPE/SE/SCR/PVC

Power Cable No. & Size

--

**

Power Cable Gland & Entries

--

**

Power Cable Entry Direction

--

**

Heater Cable Type

--

Cu/XLPE/PVC

Heater Cable No. & Size

--

**

Heater Cable Gland & Entry

--

**

Instrument Cable Type

--

**

Instrument Cable No. & Size

--

**

Instrument Cable Gland & Entry

--

**

Note 1: VTA: Vendor to Advise Note 2: (*) in "Purchaser Requirement" column should be filled out by driven equipment vendor. Note 3: (**) Will be informed to motor vendor after receiving preliminary motor data. Note 4: Bearing RTD(PT100) should be considered for motors with sleeve bearings. Note 5: Diffrential protection CTs should be considered for motors over 1000KW.

Sheet 1 of 2

Vendor's Data

ATTACHMENT NO.:17.4 BUSHEHR METHANOL PLANT

EPs CONTRACTOR:

Petrochemical Industries Design & Engineering Company (PIDEC)

Bushehr Petrochemical Company (BUPC)

DATA SHEET FOR MEDIUM VOLTAGE ELECTRIC MOTORS (Non-Ex)

Project No. : 1210

Genaral Design Data

OWNER:

Doc No. :

Project No. : ME16

Rev. : 00

Tag Nos :

Manufacturer

:

Service :

Plant Location

:

Client

Purchase Order No. :

:

Assaluyeh, Iran

Applicable Standards and Reference Documents

Enviromental Condition

Outdoor, Tropicalized

Project Specification

:

1210-00-EL-MSS-522

Location

Paint Specification

:

1210-00-PI-ESS-406

Ambient Air Temperature

Applicable Standard

:

IEC 60034

Humidity

:

80% Max.

Altitude

:

22.2 m

: :

Max. 48°C

Min. 5°C

Area Classification(IEC 60079-10) :

Safe Area

Power System System Voltage &Variations

:

System Frequency &Variations : Particulars of Equipment

6KV/11KV ± 5%

System Earthing

50Hz, ±2%

Short circuit capacity at input :

Unit

Basic Data

Frame Size Rated Voltage

V

6000 / 11000

Rated Frequency

Hz

50

Required Shaft Brake Power

KW

*

Rated Power

KW

No. of Phases

* Star

Insulation Class

Class F 48°C

Design Temperature Temperature Rise

Class B

Ingress Protection Classification (IEC 60529)

IP54 TEFC, IC411 , IC511 , IC611 , IC616 , IC7A1W7 (As per sec. 4.4 of 1210-00-EL-MSS-522)

Cooling Type (IEC 60034-6) A

VTA

1/2FL)

PU

VTA

1/2FL)

PU

VTA

Full Load Turque

Nm

VTA

Break Down Torque

PU

VTA

Pull Up Torque

PU

VTA

Full Load Speed

rpm

VTA

%

VTA

Full Load Current

Performance Characteristics

( FL (FL

/ /

3/4 FL

/

3/4 FL /

Slip at Full Load / 75% of Load

Starting Characteristics

Over Speed Capability

VTA

No Load Losses

watt

VTA

First Critical Speed

RPM

VTA

Second Critical Speed

RPM

Starting Method

VTA Direct on Line/Variable Speed

Starting Performance (IEC60034-12)

VTA

Starting Current

( Un / 0.8xUn)

Locked Rotor Power Factor

( Un / 0.8xUn)

Locked Rotor Torque

( Un / 0.8xUn)

Run-Up Time (coupled)

( Un / 0.8xUn)

PU (A)

VTA (shall not exceed 550%) VTA

PU

VTA

Sec.

VTA

Run-Up Time (Un coupled)

( Un / 0.8xUn)

Sec.

VTA

Maximum Allowable Stall Time (*)

Hot / Cold

Sec.

VTA

Heating / Cooling

Min.

VTA

Heating / Cooling

Min.

Thermal Time Constant K factor (Note 3)

Thermal Modeling

*

S1

No. of Poles / Synchronous Speed

Power Factor

Vendor's Data

3 phases

Duty

Efficiency

Resistance Earthed

*

Stator Connection

Start up Time Constant

VTA VTA 3 from cold state / 2 from hot state in operetaing temp.

Maximum No. of Successive Starts in Hour Allowable Run-Up Time from Cold State (Un / 0.8xUn)

Sec.

Allowable Run-Up Time from Hot State (Un / 0.8xUn)

Sec.

VTA

Rotor Short/Long Term Time Constant

Sec./Min

VTA (for motors above 1000KW)

Stator Short/Long Term Time Constant

Sec./Min

VTA (for motors above 1000KW)

ºC

VTA (for motors above 1000KW)

-

-

Max. Temperature Allowed for Rotor

Hazardous Area Certification

Purchaser's Requirements

:

Motor Explosion Protection Type / Gas Group / Temp. Cllass Terminal Boxes Explosion Protection Type / Gas Group / Temp. Class

VTA

-

-

Ex "e" Motor te Time

Sec.

-

Certifying Authority

-

-

Note 1: VTA: Vendor to Advise Note 2: (*) in "Purchaser Requirement" column should be filled out by driven equipment vendor. Note 3: permissible thermal energy produced by negative sequence current in a three phase induction motor. This parameter will be used for negative sequence relay setting (ANSI 46)

Sheet 1 of 2

ATTACHMENT NO.:17.4 BUSHEHR METHANOL PLANT

EPs CONTRACTOR:

Petrochemical Industries Design & Engineering Company (PIDEC) Project No. : 1210

Bushehr Petrochemical Company (BUPC)

DATA SHEET FOR MEDIUM VOLTAGE ELECTRIC MOTORS (Non-Ex) Doc No. :

Particulars of Equipment

Purchaser's Requirements

Unit

*

Stator Material

Ferromagnetic Material

Enclousure Material

Sheet Steel/ Cast Iron

Rotor Cage Material

Copper

Cooling Fan Material

Metalic (Brass, Bronze or Aluminum)

Rotation Facing Drive End (CW/CCW)

*

Finish Color

RAL 5010

Motor Weight

Kg

VTA

Rotor (Uncoupled) Inertia

Kg.m2

VTA

Driven Load Inertia (at Motor Speed)

Kg.m2

*

Coupling Type

Direct/ Gear Box/ Pulley

Maximum Sound pressure Level at one Meter (Full Load)

dB(A)

85

dB

VTA

Noise Silencer

Yes/No

VTA

Integral Breather / Drain (IEC60034-5)

Yes/No

VTA

Mechanical Detail

Sound Power Level

Drive End Bearing Type/ Make

VTA

No. of Drive End Bearings

VTA

None Drive End Bearing Type / Make

VTA

No. of None Drive End Bearings

VTA

Method of Bearing Lubrication (Grease/Oil Ring)

VTA

Bearing Ingress Protection (IEC 60529)

IP55

Minimum Bearing Lifetime, Motor Only

hr

Maximum Relubrication Interval

hr

40,000 hr. VTA

Shaft

Extended / Solid / Hollow

Max. Shaft Voltage

mV rms

VTA

Insulated Bearings

Yes/No

Yes/No (As per sec. 10.8 of 1210-00-EL-MSS-522)

Bearing Insulation Rating

KV

VTA

mm

VTA (as per IEC 60072)

mm/S

VTA (IEC 60034-14 acc. to grade A)

rpm

VTA

Lifting Lug

Yes/No

Yes

Anti Condensation Heater

Yes/No

Yes

W

VTA

Rotor Axial Float

+/-

Vibration at No load, Self Mounted, Peak to Peak Critical Speed (First/Second)

Anti Condensation Heater Power Anti Condensation Heater Voltage Wi di T Winding Temperature t Detector D t t Number N b &T Type Winding Temperature Alarm/Trip

Accessories

Bearing Temperature Detector Number & Type

VAC

230

Yes/No

6 ( acc. tto IEC 60751 & sec. 9 9.1 1 off 1210 1210-00-EL-MSS-522) 00 EL MSS 522)

ºC

Yes

Yes/No

VTA ( Note 4 & sec 10.1 of 1210-00-EL-MSS-522)

Bearing Temperature Alarm/Trip

ºC

VTA

Frame Earth / Terminal Box Earth

Yes/No

Yes (External Stud /Internal Terminal)

Accelerometer Shock Pulse Measurement Device

Yes/No

VTA

Anti Rotational Device

Yes/No

VTA

Vibration Switch

Yes/No

VTA

Sun Canopy

Yes/No

VTA

Differential Protection

Yes/No

Note 5 Summation method: 3No.s Current transformers to be installed in the neutral point terminal box of the motor

Differential Protection Scheme CT's to Be Supplied By

Motor Manufacturer

Diff.Protection CT's Ratio/Burden/Accuracy class

**

Diff.Protection CT's Resistance/Knee Point Voltage/Current

Terminal Box & Cable Connection

Speed Switch with Control Unit

Project No. : ME16 Rev. : 00

Mounting (IEC 60034-7)

** **

Yes/No

Ingress Protection of Terminal Box

--

IP55

Power Terminal Box Type

--

Phase Insulated/ Phase Segregated

Power Terminal Box Location (IEC 60034-7)

--

Right (looking from drive end) Rotatable by 90° and 180° degree increments

Neutral Terminal Box

OWNER:

Yes/No

Yes

Power Cable Type

--

Cu/XLPE/SE/SCR/PVC

Power Cable No. & Size

--

**

Power Cable Gland & Entries

--

**

Power Cable Entry Direction

--

**

Heater Cable Type

--

Cu/XLPE/PVC

Heater Cable No. & Size

--

**

Heater Cable Gland & Entry

--

**

Instrument Cable Type

--

**

Instrument Cable No. & Size

--

**

Instrument Cable Gland & Entry

--

**

Note 1: VTA: Vendor to Advise Note 2: (*) in "Purchaser Requirement" column should be filled out by driven equipment vendor. Note 3: (**) Will be informed to motor vendor after receiving preliminary motor data. Note 4: Bearing RTD (PT100) should be considered for motors with sleeve bearings. Note 5: Diffrential protection CTs should be considered for motors over 1000KW.

Sheet 2 of 2

Vendor's Data