Dm Plant Specifications

HAZIRA PIPE MILL LIMITED COATING PLANT

TECHNICAL SPECIFICATION FOR DM PLANT

ESSAR ENGINEERING SERVICES LIMITED HAZIRA

TSP NO: 1010460000TSP45H003-R00

APRIL, 2010  

                                                                                                              FORMATNO: EESL(H).PRA.DM.025.F01 

0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

CONTENTS Chapter no.

Description

Page no.

1.0

GENERAL INFORMATION

2

2.0

SCOPE OF WORK

2

3.0

TECHNICAL SPECIFICATION

5

4.0

STANDARDS & CODES

21

5.0

PAINTING

25

6.0

DELIVERY

27

7.0

WORKMANSHIP AND PERFORMANCE GUARANTEE

27

8.0

HSE REQUIREMENTS

28

9.0

DOCUMENTS TO BE SUPPLIED

29

Confidential

ANNEXURES I

SITE CONDITIONS

32

II

FORMAT FOR DEVIATION FROM TENDER DOCUMENT

33

III

TENDER QUALIFICATION CRITERIA

34

IV

OVERALL SUPPLY & IMPLEMENTATION SCHEDULE

34

V

TECHNICAL DATA SHEETS TO BE FILLED BY VENDORS

35

VI

FEED WATER QUALITY

40

VII

DM WATER QUALITY

40

VIII

SCHEME OF DM PLANT

TSP No.:- 1010460000TSP45H003-R00

1 No

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

1.0

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

GENERAL INFORMATION Hazira Pipe Mill Limited (HPML), a group company of ESSAR is setting up a pipe plant of 0.6 MTPA capacities near to the existing M/s. Essar Steel Ltd plant at Hazira. The plant will consist of H-SAW Mill, L-SAW Mill & Anti corrosion coating facilities. To meet the DM water requirement of plant, DM plant has one stream [1 x 100%] and OBR of 140 m3 operating on 20 hrs. basis is planned. This specification is intended to cover the design, manufacture, testing at manufacturer's works and delivery at site properly packed for transport, erection, commissioning and site testing, transit insurance, storage, commissioning, supervision of erection for the DM water package and accessories . It is not the intent to specify completely herein all the details of design, construction of the equipment, erection supervision, commissioning and testing requirements. However, the equipment shall conform in all respects to high standards of engineering, design and workmanship and be capable of performing in continuous commercial operation up to the Seller’s guarantee ensuring high degree of reliability, ease of operation and maintenance of the equipment in a manner acceptable to the Buyer who will interpret the meaning of drawings and specifications and shall be entitled to reject any work or material which in his judgment is not in full accordance therewith. In the event of conflict between requirements of any two clauses of the specification documents or requirements of different codes / standards, specified, the more stringent requirement as per the interpretation of the Buyer shall apply.

Confidential

All necessary co-ordination with regard to sub-contracted equipment shall be carried out by the Seller. The Buyer will communicate only with the Seller for all matters pertaining to this contract.

2.0

SCOPE OF WORK

2.1

The scope of Seller shall comprise design, engineering, procurement, manufacture, inspection and testing at Seller or his sub-Seller’ works, packing, loading, forwarding, transport and delivery to site, supervision of erection & commissioning, painting, testing, carrying out performance and guarantee tests at site of the systems / equipment inclusive of all Mechanical, Electrical, Instrumentation & Control systems, equipment structural works, furnishing input data to the Buyer / Project Manager, necessary to put into commercial operation a highly reliable safe, efficient and environmentally compliant, D M Water Plant for HPML. The systems and equipment shall conform to the technical requirements as specified in separate sections.

2.2

The Seller shall perform all the works specified in accordance with this specification. Further, the Sellers performance of the works under the Contract shall be in accordance with good engineering and construction practices, notwithstanding the fact that every item involved may not be specifically mentioned, or the item mentioned may be inadequate for its intended purpose. Details and items which are not specifically mentioned herein shall also be adequately and properly performed by

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

Confidential

the Seller at no extra cost if such details and / or items are reasonably necessary to complete the package. 2.3

All equipment shall be new, and of reputed and approved make. The make of all bought out equipment, as well as major sub-Seller shall be as of approved makes.

2.4

The intent of this specification is to relieve the Buyer of the necessity of engaging or supplying any labor, service, equipment or material required to complete the Plant Water Systems package.

2.5

The Seller shall render complete engineering services for the project including complete basic and detailed engineering, design submission and documentation as specified as required for a good design and installation ensuring efficiency, operability, availability, maintainability and reliability of the plant. Prior to commencement of the engineering work all aspects of design, viz., criteria for selection and sizing of all equipment and systems, design margins, analysis and design calculations, etc. shall be stated by Seller in design basis reports. As part of design submissions, the design basis reports shall be submitted by Seller for approval by Buyer. The approved design basis reports shall form the basis for the detailed engineering work.

2.6

The Seller shall prepare and submit detailed equipment general arrangement drawings, equipment loadings, embedment, pockets, etc necessary for preparation of civil construction drawings. The scope of design services to be provided also includes preparation of design basis reports. All design calculation and detailed drg. for civil works are included in scope of work.

2.7

At any stage during the performance of the works, the Buyer may require upgradation / improvements in the Contracted plant and consequent modification in the equipment / system designs in view of additional information available at a later date(s) or feedback(s) received during execution / operation of similar units. If so desired by Seller, Buyer shall make the necessary design modifications and carry out the up-gradation / improvements in the plant.

2.8

During the course of review of detailed engineering, it may be essential in Buyers opinion to obtain data and information on similar equipment and plants engineered by Seller. In case, Buyer so desires the Seller shall submit such analogous data and information to the Buyer.

2.9

The Seller shall co-operate with the Buyers other Sellers and Engineer and freely exchange with them such technical information as are necessary to obtain the most efficient and economical design and to avoid unnecessary duplication of efforts. The Engineer shall be provided with copies of all correspondences addressed by the Seller to other Sellers and Engineer in respect of such exchange of technical information.

2.10

The Seller shall submit to Buyer all major items that he deems necessary to be sub-contracted. The Seller shall not change Sub- Sellers without prior approval of the Buyer.

2.11

The scope of work shall include all the piping work including various types of Valve including large size butterfly valves, rubber expansion joints, pipe fittings,

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

hangers & supports for smooth and trouble free operation. •

Rubber Expansion joints of suitable design with required integral piping at pumps discharge. The rubber expansion joints shall be supplied with control units and consisting of stretcher bolt plates, bolts, nuts, washers, lock nuts, retaining ring and two (2) nos. companion flanges for each expansion joints along with bolts and nuts.

•

DM water discharge piping upto DM water storage tank .

•

Piping between various equipment/tanks relevant to each of the systems covered under various sections of the specification. All pipes in this D.M plant shall be of MSRL.

•

Air release valves wherever required.

•

All drains and vents with valves for the pipelines as mentioned above mentioned to suit lay out requirement.

•

Any other piping & valves, which are not specifically mentioned but essentially, required for the system to be complete in all respects.

•

The Seller shall refer attached PFD No. 1010860000BEN45H0011 for clarity on scope of supply.

2.12

The Seller shall also submit to the Buyer monthly progress reports and any other reports as required by Buyer / Statutory authorities.

2.13

Supervision of erection of the complete plant & equipment as supplied under this Specification.

2.14

Deployment of all manpower required for supervision of erection, commissioning and other services to be rendered under this specification

2.15

Tools and tackles including all special tools and tackle, as required, for the entire Plant.

Confidential

2.15.1 Furnishing all documents, engineering & construction drawings, design basis reports, optimization study reports, design calculations, equipment data sheets from manufacturers, quality assurance plans, testing procedures, operation and maintenance manuals, commissioning procedures, ‘As built” drawings, etc. 2.16

Training of Buyers personnel (engineers and technicians) covers, training in all aspects including system design, installation, testing, commissioning, operation and maintenance.

2.17

The scope matrix related with Mechanical is as per Table-1 & for Instrumentation & Automation is as per Table-2 & Table-3 at Sr.No. 3.14 of this document

2.18

The above list of work is not exhaustive. Any additional works, whether or not

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

specifically described in this document and incidental to complete in all respects shall be deemed to be included in the scope of work. 2.19

Seller shall provide process calculation for the resin quantity selected for SAC (Strong Acid Cat ion), SBA (Strong Base Anion) & MB (Mixing Bed).

2.20

Seller shall submit list of recommended spares required for smooth operation and maintenance of DM plant for two years period.

2.21

Control panel for the DM plant is in vendor scope.

2.22

MOC of all pipes for DM plant shall be of MSRL. EXCLUSIONS a) Construction of tanks.

3.0 TECHNICAL SPECIFICATION 3.1

The DM plant shall be sized for a total output (OBR) of 140 m3 with 1X100% stream to meet the DM requirements of the plant. For deciding DM Plant design capacity, Seller shall consider less than 4 hrs as time for regeneration of water. The Feed water quality will be as per Annexure VI. The DM plant shall essentially include but not be limited to the following:a) 1x100% Activated carbon filter. 2x100% air blowers b) 1x100% capacity Strong Acid Cation units c) 1x100% capacity Degasser towers, 2x100% air blowers for each degasser, 1x100% degassed storage tanks and 2x100% degassed water pumps. d) 1x100% Strong Base Anion unit. e) 1X100% capacity Weak Base Anion units f)

1x100% capacity MB units

g) 2x100% capacity MB air blowers. h) 2 x 100 % capacity DM regeneration pumps. i)

One (1) No, neutralizing pit of effective capacity based on 120% of maximum daily regeneration wastes from one stream.

j)

2 x 100% neutralizing pumps. The pumps shall be of horizontal centrifugal type.

Confidential

k) 1x100% DM water storage tank with 2 X 100% DM Water transfer pumps.

TSP No.:- 1010460000TSP45H003-R00

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

l)

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

One (1) No. neutralizing chemical tank (with a provision to lead acid / alkali depending on the nature of DM regeneration effluents.

One safety shower and eye wash fountain. Acid/Alkali Dosing System Acid Regeneration System for Cation, MB & Neutralization Pit

3.2

One (1) No. Acid measuring cum dilution tank, each for Cation units, MB unit & neutralization pit. Metering pumps or Ejectors with associated accessories Alkali Regeneration System for SBA, MB, WBA & Neutralization Pit.

3.3

One (1) No. Alkali measuring cum dilution tank, each for SBA, WBA units, MB units & Neutralization Pit. Metering pumps or Ejectors with associated accessories 3.4

Activated Carbon Filters

¾ Total Numbers

One (1) x 100% capacity

¾ Type

Vertical

¾ Air Blowers

2 x 100% capacity

¾ Material of Construction of vessel: MSRL ¾ No of Streams ¾

Operating hrs per day

¾ Back wash cycle ¾

3.5

Capacity of each stream

¾ No of Streams

Confidential

: 20 hrs. : After 20 hrs operation. : 7 m3/hr

SAC (STRONG ACID CATION):

¾ Capacity of each stream ¾

:1

Operating hour per day

: 7 m3/hr :1 : 20 hrs

¾ OBR

:140 m3

¾ MOC of the vessel

: MSRL

TSP No.:- 1010460000TSP45H003-R00

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

a) AMT (ACID MEASURING TANK) FOR SAC (STRONG ACID CATION) ¾ Capacity of tank

: Suitable for one regeneration.

¾ No of tanks

:1

¾ MOC of tower & tank

: MSRL

¾ Metering pumps with ejector assembly:2 Nos 3.6

DEGASSER SYSTEM ¾ Type

:Forced draught

¾ No. required

:One (1) x 100%

¾ Capacity of stream

: 7 m3/hr

¾ Degassed Water Tank o Quantity

:One (1)

o Material of Construction

::MSRL

¾ Degassed Blowers o Quantity

:2 x 100%

¾ Regeneration pumps: 2 Nos 3.7

WBA (WEAK BASE ANION)

¾ Capacity of each stream ¾ No of streams

: 7 m3/hr :1

¾ Operating hour per day

: 20 hrs

¾ OBR

: 140 m3

¾ MOC of vessel

: MSRL

a)

CMT (CAUSTIC MEASURING TANK) FOR WBA (WEAK BASE ANION) ¾ Capacity of tank

: Suitable for one regeneration.

¾ No of tanks

:1

¾ MOC of tower & tank

: MSRL

Confidential

¾ Metering pumps with ejector assembly : 2 Nos

TSP No.:- 1010460000TSP45H003-R00

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

3.8

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

SBA (STRONG BASE ANION)

¾ Capacity of each stream

: 7 m3/hr

¾ No of streams

:1

¾ Operating hour per day

: 20 hrs

¾ OBR

: 140 m3

¾ MOC of vessel

: MSRL

a) CMT (CAUSTIC MEASURING TANK) ¾ Capacity of tank

: Suitable for one regeneration.

¾ No of tanks

:1

¾ MOC of tower & tank

: MSRL

¾ Metering pumps with ejector assembly: 2 Nos

3.9

MB (MIXED BED)

¾ Capacity of tank

: 7 m3/hr

¾ No of stream

:1

¾ Operating hrs per day

: 20 hrs

¾ OBR

: 420 m3

¾ MOC of the vessel

: FRP

¾ Blower

: 2 Nos

a) AMT (ACID MEASURING TANK) FOR MIXING BED ¾ Capacity of tank

: Suitable for the one regeneration

¾ No of tank

:1

¾ MOC of the vessel

: FRP

¾ Metering pumps with ejector assembly: 2 Nos

b) CMT (CAUSTIC MEASURING TANK) FOR MIXING BED ¾ Capacity of tank

: Suitable for the one regeneration

¾ No of tank

:1

¾ MOC of the vessel

: FRP

Confidential

¾ Metering pumps with ejector assembly: 2 Nos

TSP No.:- 1010460000TSP45H003-R00

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

3.10 NEUTRALISATION PIT: Pumps: 2 Nos a)

AMT (ACID MEASURING TANK) FOR NEUTRALISATION PIT ¾ Capacity of tank

: Suitable for the one regeneration

¾ No of tank

:1

¾ MOC of the vessel

: FRP

¾ Metering pumps with ejector assembly: 2 Nos

b)

CMT (CAUSTIC MEASURING TANK) FOR NEUTRALISATION PIT ¾ Capacity of tank

: Suitable for the one regeneration

¾ No of tank

:1

¾ MOC of the vessel

: FRP

¾ Metering pumps with ejector assembly: 2 Nos

3.11

DM WATER STORAGE TANK: Capacity of Storage tank:

50 m3

MOC of the tank:

MSRL

Civil drawing of the storage tank is in vendor scope. Silica Gel & PP Ball are in vendor scope. DM Water transfer pumps: Quantity: 2 Nos. Flow rate: 7 m3/hr. Head: 30 mwc. 3.12

Pumps for pumping water from degasser to WBA: 2 Nos

3.13

Regeneration of water from DM storage tank: 2 Nos

3.14

The guaranteed quality shall be as follows: Activated Carbon Filter (ACF): The quality of treated water from each ACF at design flow rate shall be guaranteed under correction as below: Residual Chlorine, colour, and Organics: Nil. DM Plant

Confidential

The quality of DM water at the outlet of mixed bed units at design flow rate shall be TSP No.:- 1010460000TSP45H003-R00

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

guaranteed under correction as follows: a) Conductivity at the outlet b) pH c) Hardness d)Total Alkalinity e) Chloride f) Sulphate

not greater than 1 μmho/cm @ 25 Deg c 6.8 – 7.2 Nil <1 mg/l <1 mg/l < mg/l

3.15 INSTRUMENTATION & CONTROL SYSTEM

Measurement Requirement • • • • • • • ¾ ¾ ¾ ¾ ¾

Inlet and outlet pressure indicators for vessels and discharge pressure indicators for various pumps. Conductivity transmitter at outlet of each ion exchange unit. Conductivity comparators shall be provided for SAC / SBA /MB. Flow transmitters at outlet of each ion exchange unit Flow Integrator at SAC, SBA & MB. pH analyzer at SBA, MB, SAC & Neutralization pit outlets. Differential pressure switches Pressure switches Flow switches at filter outlet. Density indicators for regenerant chemical solutions. Tanks including degassed water storage tanks and DM regeneration tank level indicators and level switches with protection interlocks for associated pumps. Instrumentation & control cables and erection hardware.

The Instrumentation & Control System shall facilitate the safe, reliable, efficient and easy operation of the DM plant. The scope of the Seller shall include the complete design, engineering, documents generation and submittal, manufacturing, shop testing, supply, unloading, storage & handling, erection, field calibration, testing and commissioning at site of the Instrumentation & control (I&C) system for the DM plant. The scope shall include submission of O&M manuals, obtaining statutory approvals and training of Buyers personnel. For other equipments supplied by others (as detailed later in this section of the specification as per Annexure-2), the scope shall include supply and engineering of field instrumentation, cabling and operation & control of the referred equipments from the DM plant.

Confidential

Systems/Equipments to be provided by the Seller: a)

Instrumentation Cables along with all the accessories including cable trays, lugs, ferrules, conduits etc. between field instrument, JB and also Electrical Switchgears.

b)

Local Control Panels as applicable.

c)

Complete Field Instrumentation including all Field sensors, Field instruments with mounting accessories & erection hardware, final control elements i.e. control valves with position feedback transmitter, On-Off valves with accessories etc.

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

d)

Sellers scope includes the field instruments, cabling up to the panel, all engineering (logics, graphic screens, etc.) for implementing the operation, monitoring, interlocks and protection of the above systems in the system. It shall be responsibility of DM plant vendor to successfully & timely commissioning of the DM plant. Please refer Table -2 for the scope matrix.

e)

Any other I & C equipment not specified but necessary to meet the specified functional requirements of the system shall be provided by Seller.

f)

Sellers scope also includes the field instruments, cabling from field instruments to DM plant panel for storage tank instruments as per Table – 3

g)

Control room GA finalization as per panel data available.

h)

Instrumentation earthing scheme/requirements.

i)

Cable engineering.

Table - 1 SCOPE OF SUPPLY Sr. No.

Design & engineering

Material supply

Material Erection

Erection Supervision

Commissioning & Supervision

1

Activated carbon filters

SELLER

SELLER

ESSAR

SELLER

SELLER

2

Strong acid cation (SAC) with acid measuring tanks (AMT)

SELLER

SELLER

ESSAR

SELLER

SELLER

SELLER

SELLER

ESSAR

SELLER

SELLER

SELLER

SELLER

ESSAR

SELLER

SELLER

SELLER

SELLER

ESSAR

SELLER

SELLER

SELLER

SELLER

ESSAR

SELLER

SELLER

3

SELLER

SELLER

ESSAR

SELLER

SELLER

8

Degasser system Weak base anion with caustic measuring tank (CMT) Strong base anion with caustic measuring tank (CMT) Mixing bed (MB) with acid & caustic measuring tank Neutralisation Pit with 2 pumps & acid & caustic measuring tank 2 Pumps for degasser

SELLER

SELLER

ESSAR

SELLER

SELLER

9

Regeneration pumps ( 2 Nos)

SELLER

SELLER

ESSAR

SELLER

SELLER

10

Two years recommended spares

SELLER

SELLER

NA

NA

NA

11

Piping

SELLER

SELLER

ESSAR

SELLER

SELLER

12

Flow meter

SELLER

SELLER

ESSAR

NA

NA

13

Ph meter

SELLER

SELLER

ESSAR

NA

NA

14

Conductivity meter

SELLER

SELLER

ESSAR

NA

NA

15

Tools & tackles

-

-

-

4 5 6 7

Confidential

Description

TSP No.:- 1010460000TSP45H003-R00

-

SELLER

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

Table - 2 INSTRUMENTATION & CONTROL SCOPE OF SUPPLY Sr. No. 1 2 3 4 5 6 7 8

Design & engineering

Material supply

Material Erection

Erection Supervision

Commissioning & Supervision

SELLER

SELLER

ESSAR

SELLER

SELLER

SELLER

SELLER

ESSAR

SELLER

SELLER

SELLER

SELLER

ESSAR

SELLER

SELLER

Cable glands & lugs Cable & cable tray with erection hardware between DM Plant MCC and control panel

SELLER

SELLER

ESSAR

SELLER

SELLER

SELLER

SELLER

ESSAR

SELLER

SELLER

Control Panel Field junction Box (JB) with all necessary mounting accessories & erection hardware

SELLER

SELLER

ESSAR

SELLER

SELLER

SELLER

SELLER

ESSAR

SELLER

SELLER

Two years recommended spares

SELLER

SELLER

NA

NA

NA

Description Field Instruments including erection hard wares & Mounting accessories Cables & cable trays from field instruments to Junction Box (JB) with erection hardware Cables & cable tray from Junction Box (JB) to Control Panel with erection hardware

Confidential

DOCUMENTATION 1

Hook up & installation drawings for instruments containing all necessary details

SELLER

NA

NA

NA

NA

2

Instrument location drawing containing all necessary details

SELLER

NA

NA

NA

NA

3

Operation & control Philosophy with description/ write up

SELLER

NA

NA

NA

NA

4

Logic block diagram & interlock with functional description

SELLER

NA

NA

NA

NA

5

List of soft signals to be interfaced with Main plant DCS

SELLER

NA

NA

NA

NA

6

Technical specification & data sheet for all instruments

SELLER

NA

NA

NA

NA

7

Technical specification & data sheet for cables & JB

SELLER

NA

NA

NA

NA

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

Table- 3 INSTRUMENTS RELATED TO STORAGE TANKS SR. NO.

1

2

TANK DESCRIPTION

INSTRUMENTS

DM water storage tank

Level switch-External Cage Float operated (HH,H,L,LL) Level indicator (Float & board type) Level transmitter

1 1

Level indicator (Float & board type )

1

Neutralisaton Pit

QTY.(Nos) 4

Level switch-External Cage Float operated (HH,H,L,LL) Level transmitter

4 1

Level indicator (Float & board type ) 3

4

5

For each chemical dilution tanks in the DM plant

1

Level switch-External Cage Float operated (HH,H,L,LL) Level transmitter

4 1

Cable engineering & supply from all tank related instruments to DM plant control system

100Mtr each per instruments (Vendor to provide unit rate for the same)

Engineering & supply of JBs for all tank related instruments

1 no. each for DI & AI per tank (Vendor to provide unit rate for the same)

The Essential Spares shall be supplied as detailed below. •

For all field Instruments, a min of one (1) or 20% of the quantity of each type or range, whichever is higher is to be provided. Information to be furnished with the offer

• •

Proposed operation and control philosophy of the plant. P & ID with BOQ

Confidential

Information to be furnished after the award of contract a) Write-up on the Operation philosophy. b) Description and write-up of control and interlocking system. c) Complete GA diagrams and layout diagrams with foundations details of all panels, desks and consoles, wherever applicable; control room layout drawing. d) Detail wiring diagrams of all panels, system cabinets, etc. wherever TSP No.:- 1010460000TSP45H003-R00

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

e) f) g) h) i) j) k) l) m) n) o)

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

applicable. List of final I/O of Complete DM plant Flow chart for sequential operation, logic diagrams and control schemes. Quality assurance/quality control plan. Complete Instrument Schedule. Data sheets & technical literature for instruments/ equipments. Instrument installation diagram showing all erection hardware. Power supply arrangement for field mounted instruments/panels/sub systems. Shop and site Test Records. Cable Schedule and interconnection diagram. 'As built' drawings. Operation & maintenance manual

General Instrumentation Requirement: Field instruments, analyzers and local gauges shall be provided to meet the protection, interlock and monitoring functions of the plant. General guidelines for selection of field instrumentation are listed below. Seller shall submit data sheets for all instruments for approval by the Buyer during detailed engineering stage. 1. All transmitters should be electronic smart type. 2. Transmitters & Junction-Box protection class should confirm to IP 65 as per IEC. 3. All transmitters should have integral local display meter 4. Operating transmitter voltage should be 12-36 VDC 5. Accuracy of transmitter should be with in ± 0.5% 6. Standard output signal range for electronic transmitter should be 4-20 mA. (2-wire type) 7. Measuring element & all wetted parts for Transmitter & Gauges shall be SS-316, unless process media necessitates use of other materials. 8. Sensing Element of all field devices shall be able to withstand the specified over-pressure range of 125% (for at least 30 mins.) without affecting their elastic characteristic & performance. 9. All measurements are in metric unit. 10. RTD element should be Pt-100 3 wire Duplex system and confirm to DIN standard 11. All field instruments shall be provided with SS tag indicating followings: • Instrument Tag • Model No. • Instrument Range/Set-point

Confidential

• Input/Output signal

TSP No.:- 1010460000TSP45H003-R00

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

12. Fail safe positions, limit switches should be weather proof. Limit switches contacts shall be 2NO+2NC & Rating shall be 230VAC, 5Amp. 13. Junction-Box & Remote Control Panel colour should confirm to shade of Siemens Gray(RAL7035). 14. Erection material such as SS tube & Fittings, Junction Box, cable trays, cables, and cable glands shall be vendor’s scope. 15. For local Temperature measuring bimetal thermometers Dial size shall be 150 mm. Sensing elements, Capillary & Thermo well MOC shall be SS-316. 16. All the Gauges shall be of +/- 1.0% accuracy type. 17. For pressure gauge dial size shall be 150 mm. Sensing elements MOC shall be SS- Burdon type. 18. All the Gauges shall have external zero adjustment facility & minimum IP65 housing. Gauges shall have linear scale & dial colour shall be white. 19. All the Gauges shall be supplied with shatter proof glass type. ¾pH Measurement Solid state/micro processor based system with system accuracy of 0.02 pH, auto temperature compensation, auto zero check, manual zero and span calibration, integral indicator, automatic ultrasonic cleaner, iso potential adjustment having flow type cells. Housing for electrode and analyser shall be IP65. Output shall be isolated 4-20 mA DC linear signal. Accessories shall include preamplifier, screened junction box for electrode. ¾ Conductivity Measurement Solid state/micro-processor based system with an accuracy of +/-1 %FSD, auto temperature compensation, auto calibration, zero check and integral indicator having gate valve insertion type (with drawable) cell for hotwell conductivity measurements and flow line (screwed) type cell for other services. Housing for cell and analyser shall be weather and water proof. Output shall be isolated 4-20 mA DC linear signal.

Cables: Individual pair shielded & overall shield twisted pair copper cables shall be used for analog signals & overall shielded cables shall be used for digital signals. All these cables shall be armoured. All the insulation including overall sheath shall be FRLS quality. The wire size shall be 1.5sq.mm. Ferruling indicating terminal numbers on termination side shall be followed. Colour coding shall be as per IEC189-2. Only sleeve type ferruling with printed terminal numbers shall be used. Cross ferruling shall be adopted.

Confidential

Instrumentation Cables: Instrumentation cables shall be 1100VAC grade, stranded high conductivity annealed, tinned copper, twisted pair (with min. 20 twists for meter) extruded PVC insulated with overall and / or individual screening, extruded PVC inner sheathed, galvanized steel wire armoured, extruded outer sheathed with FRLS PVC compound. The conductor size shall be minimum1.5 sq.mm. Triplex cables similar to TSP No.:- 1010460000TSP45H003-R00

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TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

instrumentation cables may be used for RTDs. Instrumentation cables carrying digital signals shall have overall screening along with drain wire and analogue signal carrying cables shall have each pair screening and overall screening along with each pair drain wire and overall drain wire. Shield shall have 25% overlap and 100% coverage. Shield thickness shall be 0.06 mm (min.) and tinned copper drain wire of 0.8mm dia. Nominal. Control Cables: Control cables shall be 1100V AC grade, multicore, minimum 1.5 sq.mm cross section, stranded copper conductor having 7 strands, PVC insulated, inner FRLS PVC sheathed of type ST-1, galvanized steel wire armoured and outer sheath made of FRLS PVC compound of type ST-1. In situations where accuracy of measurement or voltage drop in control circuit, warrant, higher cross sections as required shall be used. For all the CT & PT cables, minimum 2.5 sq.mm cables shall be used. Solenoid valve Power supply cables shall be minimum 2.5 sq.mm. LIST OF SUB-VENDORS FOR INSTRUMENTATION AND CONTROL SYSTEM 1. ULTRASONIC TYPE LEVEL SWITCHES/TRANSMITTERS a) Nivo Controls Pvt Ltd. b) SB Electro Mechanics Ltd. c) E & H. d) Emerson Process Management e) Kisler & Morse 2. INSTRUMENT CABLES a) TCL b) Delton c) Fort Globster Industries d) Universal Cables Ltd e) Reliance Cables f) Gems Cab g) Cords Cable Industries h) Polycab 3. CONTROL CABLES a) Delton b) TCL c) Universal Cables ltd d) Reliance Cables e) Gems Cab. f) Cords Cable Industries g) Polycab

Confidential

4. DISPLACEMENT TYPE LEVEL TRANSMITTERS a) Dresser Masoneilan b) Emerson Process Management c) Magnetrol d) Yamatake e) Endress & Hauser

TSP No.:- 1010460000TSP45H003-R00

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TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

5. ILLUMINATED PUSH BUTTONS a) EAO b) H & B c) L & T d) Ronan e) Tata Honeywell f) Siemens 6. LEVEL GAUGES a) Chemtrols Engg. b) Levcon c) Sigma Instruments co. d) Technomatic (India) pvt. ltd. e) Teleflo Instruments co. ltd. 7. LEVEL SWITCHES a) Bells Control Ltd. b) Levcon c) Magnetrol d) Placka 8. POSITION TRANSMITTER a) Endress & Hauser b) Yamatake c) Siemens d) Gulde 9. PRESSURE INDICATORS a) Bells Controls ltd. b) General Instruments c) A.N. Instruments d) Gauges Bourdon e) Industrial Eqpt. co. f) Waaree Instruments Ltd. g) Odion 10. PRESSURE SWITCHES a) Indfoss (India) Ltd. b) Switzer Instruments ltd. c) Varma Trafag d) A.N. Instruments e) Waaree Instruments Ltd 11. PUSH BUTTONS a) Honeywell b) Larsen & Toubro ltd. c) Siemens ltd. d) Tele Mechanic

Confidential

12. RELAYS a) Jyothi b) ABB TSP No.:- 1010460000TSP45H003-R00

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TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

c) Paramount d) Omron e) SIEMENS 13. TEMPERATURE INDICATORS a) G.I.Consortium b) Bells Controls c) Waaree instruments ltd d) Dresser-USA 14. TERMINAL BLOCKS a) Phoenix b) Weidmueller c) Wago 15. MINIATURE CIRCUIT BREAKERS a) Siemens b) ABB c) L & T NOTES: Wherever the make is not specified for any item, the Seller shall indicate 2 or 3 reputed makes, out of which Buyer shall select any one which is acceptable, suggest an acceptable make. This shall have no price implication. 3.15

ELECTRICAL DESIGN REQUIREMENTS The scope of work includes Supply, Detailed design, Manufacture, Testing at Works, Transportation to site including freight and insurance charges, Storage at site, Super vision of Erection, Testing and Commissioning of all the Electrical equipment like motors, junction boxes and other electrical items power and control cables associated with the DM plant package as per the specification given below: Detailed Engineering including but not limited to preparation of equipment-wise detailed technical specification conforming to relevant IS standards, estimation of bill of quantity, Quality Plan, Manufacturing and delivery schedule, Inspection and testing requirements, packing and transportation requirements, storage and handling requirements, documentation requirements, General Arrangement drawings, SLDs, Schematics, Electrical load list containing Rating, Duty, Full load and Starting current for motors etc., for procurement and installation of DM Plant package related electrical equipment are included as part of DM Plant package.

Confidential

All equipments supplied / designed as part of DM plant package shall fully conform to the latest version of IS standards at the time of placement of order and shall also conform to relevant Indian statutory regulations / standards.

TSP No.:- 1010460000TSP45H003-R00

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TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

•

All Motors associated with DM Plant package (included in the scope of supply of the selected DM Plant vendor).

•

Cable carrier system including but not limited to cable trays, bends, cable tray supports, conduits, fire stops/breaks for Power, control & instrumentation cables in DM Plant area.

•

Fire stops are basically fire proof sealing of cable entry into a building or through a barrier wall to prevent spread of the fire from one area/room to the adjacent area/room. Fire breaks are fire proofing compound coating provided along the run of the cable length at regular intervals (say 10 to 15 meters) to prevent spread of the fire along the cable route within a given area.

•

Marshalling boxes, Junction boxes and power distribution boards as required for DM Plant Package.

•

Secondary Earthing of all equipment supplied under DM Plant package.

•

All equipments designed / supplied as part of DM Plant package shall meet the requirements of relevant IS standards and local statutory requirements as applicable.

•

DC load requirement for DM Plant package equipment to be furnished by Vendor during detailed engineering. TERMINAL POINTS The DM Plant Control panel/ Junction box/ Marshalling box will be the terminal point for the DM Plant package. EXCLUSIONS • Cables and cable carrier system for other than DM Plant package (i.e. from purchaser's equipment to bidder equipment). • Primary earthing (Earth pits) DRIVE MOTORS • All motors shall be suitable for 380V, ±10%, 3ph, 50 Hz ±5% AC supply.

Confidential

• The motors being supplied under this contract shall comply with the specification M4203-01 & the following specific requirements: •

Motors shall be capable of starting and accelerating the load with the applicable method of starting without exceeding acceptable winding temperatures, when the supply voltage is in the range of 80-110% of the rated voltage.

•

Motors above 200KW shall be provided with vibration pads on which purchaser will mount his vibration monitoring device.

•

All motors covered under the scope of this specification shall be designed to withstand at least 5% harmonics in supply voltage.

TSP No.:- 1010460000TSP45H003-R00

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TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

•

The maximum double amplitude vibration for the motors shall be limited to the following:

•

a) For 380V motors with speed upto 1500 rpm

- 40 microns

•

b) Above 1500 rpm and upto 3000 rpm

- 15 microns

•

Winding of motors rated above 30 kW shall be provided with space heaters suitable for 230V, 1Ph, 50Hz AC supply.

•

All motors above 2.2 kW shall be delta connected & those motors below 2.2kW should be star connected. All the six terminal leads shall be brought out in the main terminal box with shorting strips provided.

•

All motors shall be suitable for bi-directional rotation.

•

Separate terminal box shall be provided for space heaters, RTD’s & thermistors. The main terminal box shall be rotatable in four positions at 90deg.

•

All motors above 15HP shall be provided with on line greasing facility.

•

All motors shall be suitable for restarting against a residual voltage of 40% in opposition to the supply voltage & minimum starts of 3 equally spaced starts per hour or 2 cold starts & 1 hot restart /hour.

•

Maximum noise level measured at a distance of 1.0M from the outer surface of any motor shall not exceed 85 db(A).

•

In addition to the data listed under enclosed data sheet for motors, the vendor shall furnish the following information after the award of contract:

•

Negative phase sequence current (unbalance current (I2) withstand capability curve for large motors.)

•

Thermal time constant (Heating time constant) for all motors. Earthing System

•

Secondary Earthing of All equipment covered under DM Plant package specification shall be in vendor's scope. Only primary earthing (i.e. earth pits / providing risers from the main earth grid) will be provided by the purchaser. SPARES

• •

BIDDER shall propose a list of recommended spares with recommended quantity and unit prices for two years trouble free operation for all the electrical equipment included in their scope. BIDDER shall include the price for the following start up and essential spares In their quoted price for DM Plant.

Confidential

For Motors (i)

Bearing – two sets of each type

TSP No.:- 1010460000TSP45H003-R00

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(ii)

Cooling fan- one no. of each type.

4.0

Standards & Codes:

4.1

All equipment, system and services covered under this specification shall comply with all currently applicable statutes, regulations and safety codes. Nothing in this specification shall be construed to relieve the Seller of his responsibility.

4.2

The standards not indicated in the specification are also acceptable, if they are established to be equal or superior to the standards indicated in the specification.

4.3

If the Seller offers equipment and systems conforming to other International Standards than those specified in the specification, the English translation of such standards shall be furnished by the Seller. In such a case, if such standards are acceptable to the buyer the stipulations of the English version of the Standards shall alone be binding and not the stipulations in the original language.

4.4

In the event of any conflict between the codes and the standards referred to elsewhere in the specification and the requirements of this specification, more stringent of the two shall govern.

4.5

The indicative list of Codes and standards is furnished below for reference of the Seller

Sr. No. 1 2 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 Confidential

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

TITLE OF STANDARD American National Standard Institute (ANSI) American Society for Testing Materials (ASTM) American Society of Mechanical Engineers (ASME) ASME Section I – Code of practice for Power Boiler ASME section II (Part A, B and C) - Materials (Ferrous, Non Ferrous and filler materials respectively.) ASME Section V – code of practice for Non Destructive Testing ASME Section VIII – Code of practice for Pressure vessels. ASME Section IX – code of practice for Welders’ Performance Qualifications MSS –SP-58859-Hangers and Supports. ANSI B 16. 104 – Valve leakages acceptance. ASME B16.1 Cast iron pipe flanges and flanged fittings, class 25,125,250, 800 ASME B16.10 Face-to-face and end-to-end dimensions of valves ASME B16.11 Forged steel fittings, socket-welding and threaded ASME B16.25 Butt welding ends ASME B16.28 Wrought steel butt welding short radius elbows and returns ASME B16.34 Valves – flanged, threaded and welding end ASME B16.5 Pipe flanges and flanged fittings

TSP No.:- 1010460000TSP45H003-R00

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3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23

3.24

3.25

3.26

3.27

3.28

3.29

3.30

3.31 4 5.1 5.2

Confidential

6

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

ASME B16.9 Factory-made wrought steel butt welding fittings ASME B31.1 Power piping ASME B36.10M Welded and seamless wrought steel pipe ASME B36.19M Stainless steel pipe ASME PTC8.2 Centrifugal pumps ASME PV CODE 8 DIV.1 Pressure vessels – division 1 ASME PV CODE 9 Welding & brazing qualifications ASTM A 105 / A105M Specification for carbon steel forging for piping applications ASTM A 106 Specification for seamless carbon steel pipe for high temperature Service ASTM A 182 / 182M Specification for forged or rolled alloy steel pipe flanges, forged fittings and valves and parts for high temperature service ASTM A 193 /A 193M Specification for alloy steel and stainless steel bolting materials for high temperature service ASTM A 194/A 194M Specification for carbon and alloy steel nuts for bolts for high pressure or high temperature service or both ASTM A 216 / A216M Specification for steel castings, carbon suitable for fusion welding or high temperature service ASTM A 234 / A234M Specification for piping fittings of wrought carbon steel and alloy steel for moderate and high temperature service ASTM A 312 / A 312M Specification for seamless and welded austenitic stainless steel Pipe ASTM A 333 / A 333M Specification for seamless and welded steel pipe for low temperature service ASTM A 403 / A403M Standard specification for wrought austenitic stainless steel piping fittings EJMA Standards of the expansion joint manufacturers association EN 287 PT1 Approval testing of welders – fusion welding – steels EN 288 PT3 Specification and approval of welding procedures for metallic materials – welding procedure tests for the arc welding of steels American Welding Society ( AWS)

TSP No.:- 1010460000TSP45H003-R00

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7 8 9 10 11 12 13 13.1 13.2 13.3 13.4 13.5 13.6 14 14.1

14.2 15. 16. 17. 18. 19. 19.1 19.2 19.3 19.4 19.5 19.6 19.7 19.8 19.9 19.10 19.11 19.12 19.13 19.14 19.15 19.16 Confidential

19.17

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

Indian Boiler Regulations (IBR) BS 848 – Fans for general purpose National Fire Protection Association (NFPA) Hydraulic Institute Standards (HIS) Heat Exchange Institute (HEI) Tubular Exchange Manufacturer’s Association (TEMA) ASME Power Test Codes (PTC) Performance Test codes for fired steam generators (PTC 4) Performance Test Codes for Steam Turbines (PTC 6) ASME Performance Test Code for Centrifugal Pumps (PTC 8.2) ASME Performance Test Code for Feed water heaters (PTC 12.1) ASME Performance Test Code for Condensers (PTC 12.2) ASME Performance Test Code for deaerator (PTC 12.3) International Organisation for Standardisation (ISO) ISO – 7919 – Part –2: Land based steam turbines and generators in excess of 50 MW with normal operating speeds of 1500 r/min, 1800 r/min, 3000 r/min, 3000 r/min, 3600 r/min ISO – 10816 – Part 2: Land based steam turbines and generators in excess of 50 MW with normal operating speeds of 1500 r/min, 1800 r/min, 3000 r/min, 3000 r/min, 3600 r/min. Deutsche Industrie Normen (DIN) VDI Tariff Advisory Committee (TAC) of India Loss Prevention Association (LPA) of India Indian Standards (IS) IS 5: Colours for ready mixed paints and enamels IS:104: Ready mixed paint, brushing, Zinc Chrome, priming IS:158: Ready mixed paint, brushing, bituminous, black, leadfree, acid, alkali, water and heat resisting IS 277: Galvanised Steel sheets IS 702: Industrial Bitumen IS 803: Code of practice for design, fabrication, erection of vertical mild steel cylindrical welded oil storage tanks. IS 807: Code of practice for design, manufacture, erection, testing (structural portion) of cranes and hoists IS 1239: Mild steel tubes, Tubulars and other wrought steel Fittings, specification – Part 1 IS 1303: Glossary of terms relating to paints IS:1477: Code of practice for painting of ferrous metals in buildings (Parts I & II) IS 2062: Steel for general structural purposes IS:2074: Ready mixed paint, air drying, red Oxide Zinc Chrome, Priming IS 2266: Steel wire ropes for general engineering purposes IS:2338:Code of practice for finishing of wood and wood based materials (Parts I & II) IS 2379: Colour code for identification of pipelines IS:2524: Code of practice for painting of non-ferrous metals in buildings (Parts I & II) IS:2395: Code of practice for painting of concrete, masonry

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19.18 19.19 19.20 19.21 19.22 19.23 19.24 19.25 19.26 19.27 19.28 19.29 19.30 19.31 19.32 19.33 19.34 19.35 19.36 19.37 20 21 22 22.1 22.2 23

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

and plaster surfaces (Parts I & II) IS: 2932: Enamel,synthetic, exterior (a) undercoating (b) finishing IS 3041: Silica Gel IS:3140: Code of practice for painting asbestos cement building Products IS 3588: Electric axial fans IS 3589: Seamless or electrically welded steel pipes for water gas and sewage (168.3 mm to 2032 mm outside diameter) IS 3938: Electric wire rope hoists IS 4671: Expanded polystyrene for thermal insulation purposes IS 4894: Centrifugal fans IS 5120: Technical requirements for roto dynamic special purpose pumps IS 5290: Specification for landing valves IS 5312: Specification for Swing check type Reflux (Non return) valves for water works purposes – Part –1: Single door Pattern. IS 7413: Code of practice for application and finishing of thermal industrial application and finishing of thermal insulation IS 7938: Code for Air receivers IS 8154: Pre formed calcium silicate insulation (for temperatures upto 650 Deg C) IS 8183: Bonded mineral wool IS 9137: Code of acceptance test for centrifugal, mixed flow and axial pumps – Class C IS 11989: Code for Air driers IS 13834: Cranes classification. IS 14164: Industrial application and finishing of thermal insulation material at temperature above –80 Deg C and upto 700 Deg C – Code of practice IS 14846: Sluice valve for water works purposes (50 mm to 1200 mm size) – Specification Underwriter Laboratories (UL) 555 – Fire dampers Oil Industry Safety Directorate (OISD) American Petroleum Institute API 617: Centrifugal Compressors for Petroleum, Chemical and Gas Service Industry Services API 672: Packaged Integrally Geared Centrifugal Air compressors for Petroleum, Chemical and Gas Industry Services. American Water Works Association (AWWA).

Confidential

NOTE: The above list of codes and standards is indicative and for the guidance of the package. Codes and standards indicated in the respective sections and data sheets shall also be referred for completeness. Seller to indicate any additional list of codes and standards, which he deems necessary for the design of his equipment/system.

TSP No.:- 1010460000TSP45H003-R00

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5.0

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

PAINTING PREPARATION OF SURFACES: All surfaces to be painted shall be thoroughly cleaned of all grease, oil, loose mill scale, dust, rust and any other foreign matter. Mechanical cleaning by power tool and scrapping with steel wire brushes shall be adopted to clear the surfaces. However, in certain locations where power tool cleaning cannot be carried out, sand scrapping may be permitted with steel wire brushes and/or abrasive paper. Cleaning with solvents shall be resorted to only in such areas where other methods specified above have not achieved the desired results. Cleaning with solvents shall be adopted only after written approval of the Engineer PRIMER PAINT: After the surface is prepared, one coat of Zinc Phosphate primer conforming to IS: 2074 shall be applied. After this first coat is dried up completely, second coat of red oxide primer shall be applied. Primer shall be applied by brushing to ensure a continuous film without ‘holidays’. The dry film thickness of each coat shall be minimum 25 microns.

Confidential

FINISH PAINT: Synthetic enamel paint conforming to IS: 2932 shall be used for finish coats. The colour/shade shall be as approved by the ENGINEER. After cleaning the dust on the dried up primer, first coat of synthetic enamel shall be applied. After this first coat dries up hard, the surface is wet scrubbed cutting down to a smooth finish and ensuring that at no place the first coat is completely removed. After applying second coat, allowing the water to get evaporated completely, third finish coat of synthetic enamel paint shall be applied.

TSP No.:- 1010460000TSP45H003-R00

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TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

SUGGESTED COLOUR CODES FOR PAINTING: SL.NO.

ITEM/SERVICE

1.0

Structures, platforms, galleries, ladders and handrails

2.0

Fans, pumps, motors, compressors

3.0

Tanks (without insulation and cladding)

a. b.

4.0

e.

632

Aluminium

-

-

-

Indoor Vessels & all other proprietary equipment (without insulation & cladding)

Light grey

631

-

-

Light grey

631

Light grey (Powder coated) Light grey (Powder coated) Signal red

631/707 8 of IS 1650 537

Sea green

217

Light orange

557

Sea green

217

French blue

166

Sea green

217

French blue

166

Sea green

217

French blue

166

Sea green

217

White

-

Control & relay panels

d.

IS-5

Outdoor

6.0

c.

COLOUR (BAND)

631

Switchgear

b.

Dark Admiralty Grey

IS-5

Light Grey

5.0

7.0 8.0 a.

COLOUR

Machinery guards Water D M Water Bearing cooling water Potable & filtered water Service & clarified water Raw water

Notes: 1.0

This colour code basically refers to IS: 2379 for piping with necessary modifications

Confidential

2.0 For any item left out, colour coding will be decided after Buyer’s approval.

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TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

6.0 DELIVERY The delivery of all the materials covered under this specification shall be for HPML and as per the address mentioned in the LOI/ Purchase Order. The delivery period is 4 months from the date of placement of order/Issue of LOI. Unless requested by Buyer, Seller shall dispatch material with all its attachments, documents etc as a single lot with logical identification of packing. All material shall be packed suitable for prevention of damage during transit and deterioration during storage.

7.0 WORKMANSHIP AND PERFORMANCE GUARANTEE PERFORMANCE TESTS 7.1

Upon the completion of ‘Reliability (Trial) Operation’ and issuance of ‘Provisional Taking Over Certificate’ by the Buyer, or at such time as may be otherwise mutually agreed to by the parties concerned, the Seller shall notify in writing to the BUYER/PROJECT MANAGER / CONSULTANT that the DM Plant Package is ready for performance tests but only after liquidating all the major and minor defects.

7.2

The performance tests shall be conducted at site for the Package including all major equipment and systems supplied by the Seller. The Sellers commissioning Engineers shall make the Package ready for such tests and assist the Buyer in operation during the tests. The test will be commenced after the ‘stable operation has been attained at the end of ‘Reliability operation’. The date of commencement of the performance tests shall be as soon as practicable on completion of the ‘reliability operations’ or as may be mutually agreed upon between the Seller and Buyer.

7.3

The performance test instruments shall be of precision type with instrument accuracy limits as required and defined in the applicable performance test codes such that measurement uncertainty does not exceed the values agreed to by the Seller in the Schedule of Performance Guarantees. The performance tests shall be carried out as per test codes agreed in schedule of performance guarantees.

7.4

All test instrumentation for the performance tests as required shall be supplied by the Seller on loan basis. All costs associated with the supply, calibration, installation and return of the test instrumentation / data loggers / computers etc. are deemed to have been included in the contract price. The test shall be in accordance with those specified or as per agreed performance test codes. Batch calibration will not be accepted.

7.5

Any special equipment, tools and tackles required for successful completion of the performance tests shall be provided by the Seller.

7.6

Reporting Of Test Results

Confidential

The report (s) shall include as a minimum, the following: i. Description of the test procedures ii. Standards that were used TSP No.:- 1010460000TSP45H003-R00

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iii. iv. v. vi. vii. viii. ix.

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

Instrumentation details and calibration Full schematic diagrams with indication of instrument test location and identification tag of same. Test logs and summary of test readings used for performance calculations Full set of correction curves Computation of test results. Computations to prove measurement uncertainty is within acceptable limits. Conclusions of performance tests : test passed or not

8.0 HSE REQUIREMENTS Pollution The Seller shall offer a plant so as to meet the pollution control requirements of statutory authorities. Emissions and discharges of solid, liquid, gaseous and other effluents from the area of the Sellers scope of work shall fully comply with all requirements and limits specified in Environmental (Protection) Act, 1986, Minimum National Standards (MINAS), along with all latest amendments to all of the above requirements, stipulations of the Gujarat Pollution Control Board (GPCB) and Ministry of Environment and Forests (MoEF) and any other central or local statutory requirements regarding environmental pollution and its abatement. The hazardous waste material handling and disposal plan shall be submitted by the Seller as per the pollution control board norms. Noise Control The criterion for environmental noise is that the design of the station and its components shall not exceed, in any continuous mode of operation, the level stipulated by MoEF and/or Pollution Control Board at any point on the site boundary. Presently the norm is such that the noise level shall not exceed 85 dBA at 1.5 m from the equipment surface and 50 dBA at the plant boundary. DM Regeneration Wastes Regeneration waste be collected and treated in neutralizing pit and shall be discharged to ETP

Confidential

All monitoring equipment shall be handed over to the Buyer after Commissioning.

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TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

9.0 DOCUMENT TO BE SUPPLIED The Seller shall furnish a comprehensive and detailed schedule of drawings and design documents, which shall be submitted by him after award of Contract indicating submission dates against each document. The list shall be subject to the approval of the Buyer. The documents shall be divided into two categories: For approval For information / reference only SL. NO. I

GENERAL

1.0

Project network schedule

A

2.0

Monthly progress report

I

3.0

Equipment list

I

4.0 II

Detailed painting specification including colour code scheme. This shall contain surface treatment, coating, thickness, colour, type and brand of paint for all equipment required at shop and at the site. MECHANICAL EQUIPMENT/PIPING SYSTEMS

A

1.0

Detailed piping layout drawings (plan and section)

A

2.0

A

5.0

Piping bill of materials (system wise) Loading plan drawings indicating pipe load intensities and concentrated loads (magnitudes and locations) Catalogues for valves & specialties, hangers and supports and shock absorbers Line sizing calculations including pressure drop Calculations

A

6.0

Valve & specialties list

A

7.0

Piping schedule

A

8.0 III 1.0 2.0 3.0

Detailed data sheets for valves & specialties. WATER SYSTEMS Water balance diagram General arrangement (GA) Flow diagrams / PIDs

A

4.0

Technical specification for all major equipment

A

5.0

Performance / Characteristic curves for all pumps, fans, butterfly valves, etc

I

QUALITY , INSPECTION , SHOP AND SITE TESTING Quality assurance plan for all the systems/ equipments/ components including materials Preliminary and final shop test schedule for all the systems/ equipment/

A

3.0 4.0

IV 1.0 Confidential

APPROVAL(A)/ INFORMATION(I)

DESCRIPTION

2.0

TSP No.:- 1010460000TSP45H003-R00

A I

A A

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

3.0 4.0 5.0 V 1.0 VI

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

components. Material test certificates and performance test certificates for all equipment tested at works. Procedure for tests before taking-over which shall include performance guarantee tests, unit characteristic test , reliability test etc. Inspection test reports including test certificates as called for in quality assurance plan for all the systems/equipment/ components. OPERATION AND MAINTENANCE MANUALS Operation and Maintenance manuals for all the systems/ equipment/ components of the plant. AS BUILT DRAWINGS / DOCUMENTATION Documents submitted during bid stage, shall be revalidated or revised as required and submitted as certified document for approval / information of the Buyer. System schematic drawings, pipeline and instrumentation diagrams Design basis reports Specification for major bought-out items Equipment data sheets and general arrangement drawings Materials for construction Layout drawings Operation logic diagrams Typical control circuits Protection schemes Quality assurance Plans The Seller shall submit to the Buyer instruction manuals for all equipment covered under the contract at least thirty (30) days before the first shipment of the equipment. In addition, the Seller shall provide at least six (6) months before the time of commissioning and before taking over of the plant and equipment, a consolidated manual for the complete plant detailing out instructions for operation and maintenance.The operating manuals and maintenance instructions manual shall be submitted in the form of one (1) original and adequate copy (hard bound) as well as two (2) copies in compact disks (CDs). The instruction manuals shall be subject to approval of the Buyer. If after the commissioning and the initial operation of the plant, the instruction manuals require modifications / additions, the same shall be incorporated by the Seller and the updated final version of the manuals shall be submitted. The Seller shall submit to the Buyer, a preliminary plant handbook which shall contain all approved design basis and design calculations, the design and performance data of various plant, equipment and systems covering the complete project including single line flow diagrams,

Confidential

“As-built” Documentation The Seller shall provide and keep up to date “As built drawings of all structures constructed and all equipment and accessories and miscellaneous metal works erected or installed. These drawings shall show all changes and revisions from the original drawings and specifications, including the exact “As-built” locations, sizes TSP No.:- 1010460000TSP45H003-R00

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I A I

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

and kind of equipment and accessories, miscellaneous metal works, embedded piping and electrical systems and other concealed items of work. These drawings shall be kept in Seller’s field office but shall be made available at all times for review of the BUYER. At the end of every work, all entries, changes or revisions made in the drawings by the Seller shall be checked and approved by the Engineer. Reproducible prints with requisite copies of all “As-Built” drawings shall be progressively handed over to the Buyer after taking over of the plant by the Buyer. In addition, all the asbuilt drawings / documents shall be submitted to the Buyer in the form of CDs. Seller shall note that document as per Annexure III are required for considering the evaluation of offer.

Confidential

The technical data sheet (Annexure V) is mandatory for considering the evaluation of the offer

TSP No.:- 1010460000TSP45H003-R00

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA Annexure I

SITE CONDITIONS Following site conditions shall be borne in mind during designing / fabrication of equipment / units as well as erection and commissioning and testing. The meteorological details of the site shall be indicated below.

Temperature Mean yearly Temperature

:

26.6 ºC

Maximum Absolute Temperature

:

45.6 ºC

Mean Yearly maximum daily Temperature

:

42.3 ºC

Mean Yearly minimum temperature

:

10.9 ºC

Maximum rainfall in 24 hours

:

459mm

Avg. annual rainfall

:

1,203.5mm

Rainfall

Seismic Zone

:

Zone-III, IS 1893 part 1&4

Wind Predominant wind Direction

Confidential

Avg. speed

TSP No.:- 1010460000TSP45H003-R00

:

South to West :

12.2 Km/h

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

Annexure II FORMAT FOR DEVIATION FROM TENDER DOCUMENT Sl. No.

Clause No.

Tenderer’s Deviations

Reason for Deviation

We hereby certify that the above mentioned are the only deviations from the tender documents.

Signature

:

Name

:

Designation

:

Confidential

Company seal

TSP No.:- 1010460000TSP45H003-R00

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA Annexure III

TENDER QUALIFICATION CRITERION Attached Separately

Annexure IV OVERALL SUPPLY & IMPLEMENTATION SCHEDULE

SI. No.

WORK DESCRIPTION

1.0

Design & Engineering

2.0

Equipment Manufacture

A

Structural (for items fabricated at works)

B

Mechanical

C

Bought out items

Start

WEEKS FROM Fish

i) Ordering on sub vendors ii) Manufacturing schedule & progress status iii) Delivery

Confidential

3.0

Equipment delivery at site

A

Structural (for items fabricated at works)

B

Mechanical

TSP No.:- 1010460000TSP45H003-R00

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA Annexure V

Confidential

TECHNICAL DATA SHEETS TO BE FILLED UP BY SELLER 1.0

Activated Carbon filter

a)

Size of each unit (dia. x HOS)

mxm

b)

Design flow rate (gross)

m3/hr

c)

Pressure drop across the unit inclusive of frontal piping, fittings, valves & instruments i)

Clear condition

kg/cm2

ii)

Design flow rate (gross)

kg/cm2

d)

Backwash flow rate

m3/hr

e)

Air blower’s capacity and discharge pressure

m3/min/kg/cm2

f)

Design Pressure

kg/cm2

2.0

Strong Acid Cation Units

a)

Size of each unit (dia x HOS)

mxm

b)

Design flow rate (gross)

m3/hr

c)

Gross output between regenerations

m3

d)

Productive output between regenerations i)

Base offer

m3

ii)

Alt offer

m3

e)

Resin make & models

f)

Resin quantity per unit

g)

Type of regeneration

h)

Regeneration level

i)

Derated exchange capacity

j)

Quantity of 30% HCl/unit/regeneration

TSP No.:- 1010460000TSP45H003-R00

lit

kg/ m3 kg/ m3 m3

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

3.0

Degasser Unit

a)

Size of each unit (dia c HOS)

b)

Design flow rate (gross) m3/hr

c)

Size of degassed water tank (diaxHOS)

d)

Degassed water pumps

e)

Confidential

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

mxm

mxm

i)

Capacity / pump

m3/hr

ii)

Head

mlc

Degasser air blowers i)

Capacity / blower

m3/min

ii)

Discharge pressure

kg/cm2

4.0

Strong Base Anion Units

a)

Size of each unit (dia x HOS)

mxm

b)

Design flow rate (gross)

m3/hr

c)

Gross output between regenerations

m3

d)

Productive output between regenerations i)

Base offer

m3

ii)

Alt offer

m3

e)

Resin make & models

f)

Resin quantity per unit

g)

Type of regeneration

h)

Regeneration level

i)

Derated exchange capacity

kg/ m3

j)

Quantity of 48% NaOH/unit/regeneration

m3

TSP No.:- 1010460000TSP45H003-R00

lit

kg/ m3

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

5.0

Weak Base Anion Units

a)

Size of each unit (dia x HOS)

mxm

b)

Design flow rate (gross)

m3/hr

c)

Gross output between regenerations

m3

d)

Productive output between regenerations

e)

ESSAR ENGINERING SERVICES LTD. HAZIRA

m3

i)

Base offer

m3

ii)

Alt offer

m3

Resin make & models f)

Resin quantity per unit

lit

g)

Type of regeneration

h)

Regeneration level

i)

Derated exchange capacity

kg/ m3

j)

Quantity of 48% NaOH/unit/regeneration

m3

kg/ m3

k) Bidder to indicate details of layered bed vessel if in case the option is offered 6.0

Mixed Bed Units a)

Size of each unit (dia x HOS)

mxm

b)

Design flow rate (gross)

m3/hr

c)

Gross output between regenerations

m3

d)

Productive output between regenerations

e)

i)

Base offer

m3

ii)

Alt offer

m3

Resin make & models i)

Confidential

f)

m3

Cation resin

lit

ii) Anion resin Resin Quantity per unit

lit

i)

lit

Cation resin

TSP No.:- 1010460000TSP45H003-R00

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

ii) g)

h)

i)

j)

7.0

Confidential

8.0

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00 Anion resin

ESSAR ENGINERING SERVICES LTD. HAZIRA

lit

Regeneration levels i)

Cation resin

kg/ m3

ii)

Anion resin

kg/ m3

Derated exchange capacity i)

Cation resin

kg/ m3

ii)

Anion resin

kg/ m3

Regenerant consumption i)

Quantity of 30% HCl/unit/reg.

ii)

Quantity of 98% NaOH/unit/reg.

m3 m3

Mixed Bed Air Blowers i)

Capacity per bower

m3/hr

ii)

Discharge pressure

kg/ m3

Neutralization System a)

Capacity per pump

m3/hr

b)

Head

kg/cm2

Control Panel a)

Make

b)

Dimensions

9.0

Electrical load list

10.0

Brief details of chemical dosing

11.0

Scheme & Layout

TSP No.:- 1010460000TSP45H003-R00

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

DATA SHEETS FOR PUMPS SL.NO.

ITEMS

1.

Designation

2.

Number offered

3.

Design capacity

m3/hr.

4.

Differential head

mlc

5.

Shut-off head

mlc

6.

Hydrostatic test pressure

kg/cm2 (g)

7.

Number of stages

8.

Pump efficiency at duty point

%

9.

Pump speed

rpm

10.

Pump BKW

(KW)

11.

Power input to driver at duty point

kW

12.

NPSH required

mlc

13.

Driver efficiency

%

14.

Suction nozzle

15.

Size

16.

Discharge nozzle

17.

Size

18.

Type of coupling

19.

Minimum capacity for continuous

operation 20.

Confidential

UNIT

BIDDER

mm mm

m3/hr.

External water requirement for sealing

& cooling

Required.

21.

Weight of bare pump

kg

22.

Weight of driver

kg

23.

Weight of common base plate

kg

24.

Moment of inertia of pump rotor

kg-m2

TSP No.:- 1010460000TSP45H003-R00

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0.6 MTPA,PIPE PLANT HAZIRA PIPE MILL LIMITED

TECHNICAL SPECIFICATION FOR D M PLANT TSP NO: 1010460000TSP45H003-R00

ESSAR ENGINERING SERVICES LTD. HAZIRA

Annexure – VI FEED WATER QUALITY

CLARIFIED WATER S.NO

PARAMETERS

UOM FEED TO DM

1

TEMP

2

PH

Deg Cent

25-30 7.6 – 8.3

3 CONDUCTIVITY at 25 Deg.Cel Micro mho / cm 550 4 TURBIDITY NTU 40 5 TOTAL SUSPENDED SOLIDS PPM 40 6 TOTAL HARDNESS AS CaCO3 Mg/l 150 7 Ca HARDNESS AS CaCO3 Mg/l 75 8 Mg HARDNESS AS CaCO3 Mg/l 75 9 CHLORIDES AS Cl Mg/l 55 10 TA AS CaCO3 Mg/l 100 11 FREE CHLORINE AS CI Mg/l 0.3 Note-- Plus 10% design margin shall be added on above Ionic load(Feed water) for Design

Annexure VII DM Water Quality

Confidential

Feed Water Quality to DM  pH

6.8-7.2

Conductivity@25DegC Hardness Total alkalinity Chloride Sulphate

< 1 μS/cm Nil <1 mg/l <1 mg/l <1 mg/l

TSP No.:- 1010460000TSP45H003-R00

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