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THERMAX LIMITED BOILER & HEATER GROUP
Document No.: QH0581-7830-210 Rev: 0 Date: 12/06/2019 Pages :09
DOCUMENT TITLE: Execution philosophy
EIL JOB NO. : A545 PACKAGE /UNIT NO.: 681-LZ-102-A/B/C/D/E/F/G & H PR CODE : A545-680-LM-PR-7830 DORC Reference No.: THERMAX JOB NO. : QH0581/582/583/584/585/586/587/588 SUPPLY: HEAT RECOVERY STEAM GENERATOR PACKAGE
OWNER :- DANGOTE OIL REFINING COMPANY
Project Name:
0 Rev.
12.06.2019 Date
05-JUL-2019 KUMAR PRAMOD(B891)
First Issue Purpose
VD Prepared By
VD Checked By
VD Approved By
Page 2 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Boiler Brief Specifications:
Site Location
Lekki FTZ, Lagos, Nigeria
Type/Model
Natural Circulation, Single drum, Supplementary Fired HRSG
No. of units
Steam Generation – 110 TPH Steam Pressure – 107 Kg/cm2(g) Steam Temperature – 520 Deg C Fuel - Natural Gas/Flue Gas/LCO/IFO 8
EDC
6th April’17--- Project no : QH581-8
Parameters & Fuel
FOB Mundra Port - Material below 30T FAS Mundra Port - Material above 30T 14 Months 15 Months 16 Months 17 Months
CDC
from EDC for Unit 1 & 2 from EDC for Unit 3 & 4 from EDC for Unit 5 & 6 from EDC for Unit 7 & 8
List of Annexures For Signed off Scope List, Refer Annexure 1 For AVL Refer Annexure 2 Latest GA of HRSG Refer Annexure 3 Read Annexure 4, WBS specific philosophy (table) in conjunction with this document. Shop allocation is part of this annexure 4. For Process Improvements – Valve Release refer annexure 5 A] GENERAL 1. Dangote’s PO received on Thermax ,Mundra (SEZ) and therefore all project material will be shipped from Mundra port only. All our PRPs will be Ti PRPs except for Third country shipment. As of now no Third country shipment is envisaged in this job. 2. Boiler design code is as per ASME SEC-1-UN STAMPED. 3. All 8 HRSGs will be assembled in water front inside Mundra Port. 4. Please take a note of all the new WBS added for mandatory spares of individual bought out items & for mundra assembly WBS. Engg, Materials to take necessary accesses to PLM etc in advance to prevent hurdles during execution. 5. Mandatory spares & Commissioning spares are per unit. Page
05-JUL-2019 1 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 3 of 19
Thermax Limited Boiler & Heater Group
6.
7.
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Since Budget & time frame are very tight, proactive care need to be taken during execution stage by respective departments to have sufficient savings/floats while negotiating with vendors. Regarding structural material section deviation, additional vendor approval discussions is being carried out with EIL.
B] GENERAL POINTS FOR ENGINEERING 1. When there is additional requirements w.r.t the either Contract (eg in form of customer comments in TL or vendor documents) or Qty/weight overrun w.r.t budget, Details of these Qty/Weight additions/overruns should be e mailed by Lead Engg to PPM, & PPM concurrence to be taken before Baan Entries. Detailed back up documents will be attached during Weight Overrun/Cost Overrun clearance.
2. Whichever engineering department is releasing a document through DDR they will be the Owner of this document & they will directly get the interface inputs, other inputs if any from other internal engg departments as per project requirement. In case of any issue they need to escalate to engineering planner, PM, concerned HODs as applicable. This applies to specification release & corresponding vendor document approval also. 3. Any clarity with respect to tender should be highlighted by engineering upfront so that we can get the clarity from EIL/Dangote during KOM. During execution phase vendor documents should be approved after TL review process. EIL document approval should not be linked to TL’s vendor document approval. Any additional 4. Any vendor deviations, if genuinely required needs to be taken up with EIL & settled before issuing PO to vendor. Due to time constraints, if we need to go ahead with ordering, PM will give the final decision regarding the same.
C] GENERAL POINTS FOR PROCUREMENT 1. Approved vendor list (AVL) is applicable & Refer annexure 1 for the same. This vendor list also applicable for our vendor, sub vendors etc. 2. For Items not available in AVL, TL will submit vendor PTRs to EIL for approval. 3. Chinese/ East European vendors are acceptable provided they are in AVL or comply with the EIL specification and meet PTR requirement. 4. All shelf life material manufacturing to be done only after taking written confirmation from PM. 5. The purpose of creating new WBS for individual item spares is having a single owner for a WBS, special focus and also to ensure separate PO & packing for these spares which will be opened only in Dangote Site. 6. The Purpose of creating new WBS for Mundra Assembly items is to identify & ensure special focus for Module items & ensure separate packing for the same. Page
05-JUL-2019 2 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 4 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
7. Attached excel file of the WBS wise execution philosophy may indicate the sourcing plan/country of origin as per our budget basis & final decision of best vendor needs to be taken during execution. 8. First advance for this job is awaited hence sub vendor PO will only be placed on clearance from SBU/BU Head till the time we receive First Advance. 9. Fabrication Vendor loading & blasting/painting loading needs to be planned meticulously to avoid any helpless situations after loading.
D] SPECIFIC POINTS Sr . Details N o. A Mech Engg
Plan of Action
By Whom
1. AMR revalidation for Superheater tubes, pipes and attemperator pipes 2. Budget, schedule basis of B & H, TECC of all the structures within the module is bolted & the same will be followed for execution. EIL has given clearance for IS 2062 E 250 BR structural steel in place of S275 JR 3. IS2062 shall also be used for plate fabricated items like Casing, Ducting, Base Frame, shipping frame etc. 4. Module to Module connections which are to be done at site will be bolted. 5. Design of Structures as per AISC Codes may be acceptable. 6. Thermally spray aluminum paint not applicable for this package.
By When
Mech Eng
22/04/17
Mech Eng
Info
Mech Eng
Info
Mech Engg
Info
Mech Engg
Info
Mech Engg
Info
7. All Fuel Line piping, Page
05-JUL-2019 3 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 5 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details
B Process Engg
Page
05-JUL-2019 4 of 8
KUMAR PRAMOD(B891)
Plan of Action
By Whom
By When
Valves shall be of SS material after Filter upto Burner Inlet. 8. Fire proofing is not applicable. 9. NACE is not applicable for HRSG package.
Projects/ Engg
Info
Engg
Info
1. There will be Total 3 fuel skids-1 for Natural gas & FG, 1 for IFO/ LCO & 1 for propane 2. Steam drum holdup time 2min between NWL to LLT 3. The Piping B/L isolation valve sizes shall be as per EIL P&ID 4. Corrosion allowance shall be 1mm AS tubes, 1.5mm CS tubes, 3mm for drum, casing & duct:3mm 5. Burner shall be capable of COMBINATION FIRING for any ONE liquid and any ONE gaseous fuel at the same time. 6. Minimum liner material is SS409. However for bottom it is min SS 304 with 2 mm thk
Process
Info
Process
Info
Process
Info
Process
Info
Process
Info
Process
Info
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 6 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details
C E&I
Page
05-JUL-2019 5 of 8
KUMAR PRAMOD(B891)
Plan of Action
By Whom
1. All Fuel Line piping, Valves shall E & I be of SS material after Filter up to Burner Inlet including LPG lines. 2. BMS PLC shall be SIL-3 TMR/QMR 1 per HRSG. 3. BOP PLC shall be SIL-3 TMR/QMR 1 per HRSG 4. SB PLC shall be Non SIL DMR 1 per HRSG. 5. Steam Tracing shall be provided for all Fuel Lines. 6. All Instrumentation shall be suitable for Zone IIA/IIB , T3 area classification. 7. SWAS & CEMS shall be located in Shelter with HVAC. We have considered common Shelter SWAS and CEMS. 8. DCS is excluded from our scope of supply. 9. Foundation field bus Instruments shall be considered for Closed Loop and Open Loop other than those used in interlocks for BMS and BOP. 10. Intrinsically Safe Instruments to be used for Hazardous area protection. 11. Prefabricated Hook Ups are not required for this Project. 12. Vortex flowmeter to be used for Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
By When
Info
Approved by NDN
Page 7 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details
Plan of Action
By Whom
By When
all applications for Line sizes 6 inch and below. E&I
Info
13. SS Junction Box shall be provided for all FF signals. 14. 2 nos Handheld configurator is specified for each HRSG. We can optimize this during execution by reducing the quantity suitably. 15. Ultrasonic Flow meter shall be provided only for Flare. 16. Flowmeter for Instrument Air & Plant Air shall be vortex type. 17. Flowmeter for Cooling water shall be electromagnetic type. 18. Temperature Transmitter shall be provided for all Temperature elements. 19. Field Mounted PC based HMI with Annunciator shall be provided for each HRSG. The details requirement for the same shall be discussed during detail Engg for optimization. 20. For all fuel lines On/OFF Valve shall be Ball Type only. 21. GWR to be used for Level measurements below 2400mm tapping distance. However for Steam drum there are additional special requirements (2 GWR + 1 EDLI for BMS, DPT for control). 22. AMC is applicable for PLC and Analyzer. We have provided separate quotation for AMC. 23. Instrument Cabling scope is upto Field Junction Box. However FO Cabling for CEMS, SWAS shall be supplied upto Control Room. 24. Supply of cabling between BMS, BOP, DCS, MCC is in our scope. 25. Distance between equipments are mentioned in Tender Page
05-JUL-2019 6 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 8 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details
Plan of Action
By Whom
specification. 26. LT MCC per Boiler for Motor rating below 55KW is only our scope. E&I 27. LTMCC, EMCC shall be located in Substation 11. 28. All LT, HT Cabling from Field to SS-11 for equipments supplied by us is in our scope. 29. Complete Lighting (LED) within HRSG package is in our scope. 30. PDB for MOV and Sootblower shall be supplied by us. 31. Sootblower PDB shall be flameproof type. 32. Microprocessor based Electrical Control System & RTU panel shall be supplied by us. The exact configuration shall be discussed with EIL during Detail Engg stage. 33. Overground Earthing is in our scope. 34. Hazardous area classification for Electrical items shall be as per IS5572. 35. Fireproofing is not applicable. 36. During the pre-kick off meeting EIL insisted for Schneider make PLCs since for entire Dangote complex they are going to procure Schneider make PLCs. Thermax to revert on this issue.
Page
05-JUL-2019 7 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
By When
Info
Approved by NDN
Page 9 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details Procurement
D
E QC – Material Inspection
QC – Packing Inspection
Page
05-JUL-2019 8 of 8
KUMAR PRAMOD(B891)
Plan of Action
By Whom
Refer WBS wise Excel format for procurement & dispatch condition portion
By When
Mat
Info
QC needs to take special care QC during inspections to ensure material with respect to TL drawings, specifications. Any errors is supply may lead to huge back charges since erection is not in TL scope
Info
For Items which are getting packed in Wooden boxes - Only After physical packing in boxes, Packing slip to be prepared. After this inspection, boxes needs to be closed by vendors which needs to be witnessed QC. Packing slip needs to be signed off between vendor & QC prior to dispatch. It should contain Name & contact no of QC personnel who ever have cleared the consignment. Pressure will not be put on QC for urgency during packing inspection. Even after this, if any shortage is observed within the individual boxes with respect to packing slip it will be processed by QC & they will be the single point contact for arranging the material from vendor through functional departments as per site requirement. This philosophy will apply to all the items & not restricted to Hardware.
Info
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
QC
Prepared by ARV
Approved by NDN
Page 10 of 19
Refer comment sheet attached
05-JUL-2019 KUMAR PRAMOD(B891)
Page 11 of 19
THERMAX LIMITED BOILER & HEATER GROUP - This document is retained for information. It is vendor's
responsibility to comply with all the MR/PR requirement. If Document No.: QH0581-7830-210 anything found missing at later stage then vendor to comply the
same without any cost and time implication.
Rev: 0 Date: 12/06/2019 Pages :09
DOCUMENT TITLE: Execution philosophy
Code: R (With Comments) Checked by: PK Date: 05/07/2019
EIL JOB NO. : A545 PACKAGE /UNIT NO.: 681-LZ-102-A/B/C/D/E/F/G & H PR CODE : A545-680-LM-PR-7830 DORC Reference No.: THERMAX JOB NO. : QH0581/582/583/584/585/586/587/588 SUPPLY: HEAT RECOVERY STEAM GENERATOR PACKAGE
OWNER :- DANGOTE OIL REFINING COMPANY
Project Name:
0 Rev.
12.06.2019 Date
05-JUL-2019 KUMAR PRAMOD(B891)
First Issue Purpose
VD Prepared By
VD Checked By
VD Approved By
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Boiler Brief Specifications:
Site Location
Lekki FTZ, Lagos, Nigeria
Type/Model
Natural Circulation, Single drum, Supplementary Fired HRSG
Parameters & Fuel
No. of units
Steam Generation – 110 TPH Steam Pressure – 107 Kg/cm2(g) Steam Temperature – 520 Deg C Fuel - Natural Gas/Flue Gas/LCO/IFO 8
Fuel gas th
EDC
6 April’17--- Project no : QH581-8 FOB Mundra Port - Material below 30T FAS Mundra Port - Material above 30T
Vendor to check and attach these annexures
Page 12 of 19
14 Months 15 Months 16 Months 17 Months
CDC
from EDC for Unit 1 & 2 from EDC for Unit 3 & 4 from EDC for Unit 5 & 6 from EDC for Unit 7 & 8
List of Annexures For Signed off Scope List, Refer Annexure 1 For AVL Refer Annexure 2 Latest GA of HRSG Refer Annexure 3 Read Annexure 4, WBS specific philosophy (table) in conjunction with this document. Shop allocation is part of this annexure 4. For Process Improvements – Valve Release refer annexure 5 A] GENERAL 1. Dangote’s PO received on Thermax ,Mundra (SEZ) and therefore all project material will be shipped from Mundra port only. All our PRPs will be Ti PRPs except for Third country shipment. As of now no Third country shipment is envisaged in this job. 2. Boiler design code is as per ASME SEC-1-UN STAMPED. 3. All 8 HRSGs will be assembled in water front inside Mundra Port. 4. Please take a note of all the new WBS added for mandatory spares of individual bought out items & for mundra assembly WBS. Engg, Materials to take necessary accesses to PLM etc in advance to prevent hurdles during execution. 5. Mandatory spares & Commissioning spares are per unit. Page
05-JUL-2019 1 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 13 of 19
Thermax Limited Boiler & Heater Group
6.
7.
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Since Budget & time frame are very tight, proactive care need to be taken during execution stage by respective departments to have sufficient savings/floats while negotiating with vendors. Regarding structural material section deviation, additional vendor approval discussions is being carried out with EIL.
B] GENERAL POINTS FOR ENGINEERING 1. When there is additional requirements w.r.t the either Contract (eg in form of customer comments in TL or vendor documents) or Qty/weight overrun w.r.t budget, Details of these Qty/Weight additions/overruns should be e mailed by Lead Engg to PPM, & PPM concurrence to be taken before Baan Entries. Detailed back up documents will be attached during Weight Overrun/Cost Overrun clearance.
2. Whichever engineering department is releasing a document through DDR they will be the Owner of this document & they will directly get the interface inputs, other inputs if any from other internal engg departments as per project requirement. In case of any issue they need to escalate to engineering planner, PM, concerned HODs as applicable. This applies to specification release & corresponding vendor document approval also. 3. Any clarity with respect to tender should be highlighted by engineering upfront so that we can get the clarity from EIL/Dangote during KOM. During execution phase vendor documents should be approved after TL review process. EIL document approval should not be linked to TL’s vendor document approval. Any additional 4. Any vendor deviations, if genuinely required needs to be taken up with EIL & settled before issuing PO to vendor. Due to time constraints, if we need to go ahead with ordering, PM will give the final decision regarding the same.
C] GENERAL POINTS FOR PROCUREMENT 1. Approved vendor list (AVL) is applicable & Refer annexure 1 for the same. This vendor list also applicable for our vendor, sub vendors etc. 2. For Items not available in AVL, TL will submit vendor PTRs to EIL for approval. 3. Chinese/ East European vendors are acceptable provided they are in AVL or comply with the EIL specification and meet PTR requirement. 4. All shelf life material manufacturing to be done only after taking written confirmation from PM. 5. The purpose of creating new WBS for individual item spares is having a single owner for a WBS, special focus and also to ensure separate PO & packing for these spares which will be opened only in Dangote Site. 6. The Purpose of creating new WBS for Mundra Assembly items is to identify & ensure special focus for Module items & ensure separate packing for the same. Page
05-JUL-2019 2 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 14 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
7. Attached excel file of the WBS wise execution philosophy may indicate the sourcing plan/country of origin as per our budget basis & final decision of best vendor needs to be taken during execution. 8. First advance for this job is awaited hence sub vendor PO will only be placed on clearance from SBU/BU Head till the time we receive First Advance. 9. Fabrication Vendor loading & blasting/painting loading needs to be planned meticulously to avoid any helpless situations after loading.
D] SPECIFIC POINTS Sr . Details N o. A Mech Engg
Plan of Action
By Whom
1. AMR revalidation for Superheater tubes, pipes and attemperator pipes 2. Budget, schedule basis of B & H, TECC of all the structures within the module is bolted & the same will be followed for execution. EIL has given clearance for IS 2062 E 250 BR structural steel in place of S275 JR 3. IS2062 shall also be used for plate fabricated items like Casing, Ducting, Base Frame, shipping frame etc. 4. Module to Module connections which are to be done at site will be bolted. 5. Design of Structures as per AISC Codes may be acceptable. 6. Thermally spray aluminum paint not applicable for this package.
By When
Mech Eng
22/04/17
Mech Eng
Info
Mech Eng
Info
Mech Engg
Info
Mech Engg
Info
Mech Engg
Info
7. All Fuel Line piping, Page
05-JUL-2019 3 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 15 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details
B Process Engg
Corrosion allowance for drum internals shall be 1.5 mm shall also be mentioned
Page
05-JUL-2019 4 of 8
KUMAR PRAMOD(B891)
Plan of Action
By Whom
By When
Valves shall be of SS material after Filter upto Burner Inlet. 8. Fire proofing is not applicable. 9. NACE is not applicable for HRSG package.
Projects/ Engg
Info
Engg
Info
1. There will be Total 3 fuel skids-1 for Natural gas & FG, 1 for IFO/ LCO & 1 for propane 2. Steam drum holdup time 2min between NWL to LLT 3. The Piping B/L isolation valve sizes shall be as per EIL P&ID 4. Corrosion allowance shall be 1mm AS tubes, 1.5mm CS tubes, 3mm for drum, casing & duct:3mm 5. Burner shall be capable of COMBINATION FIRING for any ONE liquid and any ONE gaseous fuel at the same time. 6. Minimum liner material is SS409. However for bottom it is min SS 304 with 2 mm thk
Process
Info
Process
Info
Process
Info
Process
Info
Process
Info
Process
Info
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 16 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details
C E&I
Page
05-JUL-2019 5 of 8
KUMAR PRAMOD(B891)
Plan of Action
By Whom
1. All Fuel Line piping, Valves shall E & I be of SS material after Filter up to Burner Inlet including LPG lines. 2. BMS PLC shall be SIL-3 TMR/QMR 1 per HRSG. 3. BOP PLC shall be SIL-3 TMR/QMR 1 per HRSG 4. SB PLC shall be Non SIL DMR 1 per HRSG. 5. Steam Tracing shall be provided for all Fuel Lines. 6. All Instrumentation shall be suitable for Zone IIA/IIB , T3 area classification. 7. SWAS & CEMS shall be located in Shelter with HVAC. We have considered common Shelter SWAS and CEMS. 8. DCS is excluded from our scope of supply. 9. Foundation field bus Instruments shall be considered for Closed Loop and Open Loop other than those used in interlocks for BMS and BOP. 10. Intrinsically Safe Instruments to be used for Hazardous area protection. 11. Prefabricated Hook Ups are not required for this Project. 12. Vortex flowmeter to be used for Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
By When
Info
Approved by NDN
Page 17 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details
Plan of Action
By Whom
By When
all applications for Line sizes 6 inch and below. E&I
Info
13. SS Junction Box shall be provided for all FF signals. 14. 2 nos Handheld configurator is specified for each HRSG. We can optimize this during execution by reducing the quantity suitably. 15. Ultrasonic Flow meter shall be provided only for Flare. 16. Flowmeter for Instrument Air & Plant Air shall be vortex type. 17. Flowmeter for Cooling water shall be electromagnetic type. 18. Temperature Transmitter shall be provided for all Temperature elements. 19. Field Mounted PC based HMI with Annunciator shall be provided for each HRSG. The details requirement for the same shall be discussed during detail Engg for optimization. 20. For all fuel lines On/OFF Valve shall be Ball Type only. 21. GWR to be used for Level measurements below 2400mm tapping distance. However for Steam drum there are additional special requirements (2 GWR + 1 EDLI for BMS, DPT for control). 22. AMC is applicable for PLC and Analyzer. We have provided separate quotation for AMC. 23. Instrument Cabling scope is upto Field Junction Box. However FO Cabling for CEMS, SWAS shall be supplied upto Control Room. 24. Supply of cabling between BMS, BOP, DCS, MCC is in our scope. 25. Distance between equipments are mentioned in Tender Page
05-JUL-2019 6 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 18 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details
Plan of Action
By Whom
specification. 26. LT MCC per Boiler for Motor rating below 55KW is only our scope. E&I 27. LTMCC, EMCC shall be located in Substation 11. 28. All LT, HT Cabling from Field to SS-11 for equipments supplied by us is in our scope. 29. Complete Lighting (LED) within HRSG package is in our scope. 30. PDB for MOV and Sootblower shall be supplied by us. 31. Sootblower PDB shall be flameproof type. 32. Microprocessor based Electrical Control System & RTU panel shall be supplied by us. The exact configuration shall be discussed with EIL during Detail Engg stage. 33. Overground Earthing is in our scope. 34. Hazardous area classification for Electrical items shall be as per IS5572. 35. Fireproofing is not applicable. 36. During the pre-kick off meeting EIL insisted for Schneider make PLCs since for entire Dangote complex they are going to procure Schneider make PLCs. Thermax to revert on this issue.
Page
05-JUL-2019 7 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
By When
Info
Approved by NDN
Page 19 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details Procurement
D
E QC – Material Inspection
QC – Packing Inspection
Page
05-JUL-2019 8 of 8
KUMAR PRAMOD(B891)
Plan of Action
By Whom
Refer WBS wise Excel format for procurement & dispatch condition portion
By When
Mat
Info
QC needs to take special care QC during inspections to ensure material with respect to TL drawings, specifications. Any errors is supply may lead to huge back charges since erection is not in TL scope
Info
For Items which are getting packed in Wooden boxes - Only After physical packing in boxes, Packing slip to be prepared. After this inspection, boxes needs to be closed by vendors which needs to be witnessed QC. Packing slip needs to be signed off between vendor & QC prior to dispatch. It should contain Name & contact no of QC personnel who ever have cleared the consignment. Pressure will not be put on QC for urgency during packing inspection. Even after this, if any shortage is observed within the individual boxes with respect to packing slip it will be processed by QC & they will be the single point contact for arranging the material from vendor through functional departments as per site requirement. This philosophy will apply to all the items & not restricted to Hardware.
Info
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
QC
Prepared by ARV
Approved by NDN
THERMAX LIMITED BOILER & HEATER GROUP
Document No.: QH0581-7830-210 Rev: 0 Date: 12/06/2019 Pages :09
DOCUMENT TITLE: Execution philosophy
EIL JOB NO. : A545 PACKAGE /UNIT NO.: 681-LZ-102-A/B/C/D/E/F/G & H PR CODE : A545-680-LM-PR-7830 DORC Reference No.: THERMAX JOB NO. : QH0581/582/583/584/585/586/587/588 SUPPLY: HEAT RECOVERY STEAM GENERATOR PACKAGE
OWNER :- DANGOTE OIL REFINING COMPANY
Project Name:
0 Rev.
12.06.2019 Date
05-JUL-2019 KUMAR PRAMOD(B891)
First Issue Purpose
VD Prepared By
VD Checked By
VD Approved By
Page 2 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Boiler Brief Specifications:
Site Location
Lekki FTZ, Lagos, Nigeria
Type/Model
Natural Circulation, Single drum, Supplementary Fired HRSG
No. of units
Steam Generation – 110 TPH Steam Pressure – 107 Kg/cm2(g) Steam Temperature – 520 Deg C Fuel - Natural Gas/Flue Gas/LCO/IFO 8
EDC
6th April’17--- Project no : QH581-8
Parameters & Fuel
FOB Mundra Port - Material below 30T FAS Mundra Port - Material above 30T 14 Months 15 Months 16 Months 17 Months
CDC
from EDC for Unit 1 & 2 from EDC for Unit 3 & 4 from EDC for Unit 5 & 6 from EDC for Unit 7 & 8
List of Annexures For Signed off Scope List, Refer Annexure 1 For AVL Refer Annexure 2 Latest GA of HRSG Refer Annexure 3 Read Annexure 4, WBS specific philosophy (table) in conjunction with this document. Shop allocation is part of this annexure 4. For Process Improvements – Valve Release refer annexure 5 A] GENERAL 1. Dangote’s PO received on Thermax ,Mundra (SEZ) and therefore all project material will be shipped from Mundra port only. All our PRPs will be Ti PRPs except for Third country shipment. As of now no Third country shipment is envisaged in this job. 2. Boiler design code is as per ASME SEC-1-UN STAMPED. 3. All 8 HRSGs will be assembled in water front inside Mundra Port. 4. Please take a note of all the new WBS added for mandatory spares of individual bought out items & for mundra assembly WBS. Engg, Materials to take necessary accesses to PLM etc in advance to prevent hurdles during execution. 5. Mandatory spares & Commissioning spares are per unit. Page
05-JUL-2019 1 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 3 of 19
Thermax Limited Boiler & Heater Group
6.
7.
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Since Budget & time frame are very tight, proactive care need to be taken during execution stage by respective departments to have sufficient savings/floats while negotiating with vendors. Regarding structural material section deviation, additional vendor approval discussions is being carried out with EIL.
B] GENERAL POINTS FOR ENGINEERING 1. When there is additional requirements w.r.t the either Contract (eg in form of customer comments in TL or vendor documents) or Qty/weight overrun w.r.t budget, Details of these Qty/Weight additions/overruns should be e mailed by Lead Engg to PPM, & PPM concurrence to be taken before Baan Entries. Detailed back up documents will be attached during Weight Overrun/Cost Overrun clearance.
2. Whichever engineering department is releasing a document through DDR they will be the Owner of this document & they will directly get the interface inputs, other inputs if any from other internal engg departments as per project requirement. In case of any issue they need to escalate to engineering planner, PM, concerned HODs as applicable. This applies to specification release & corresponding vendor document approval also. 3. Any clarity with respect to tender should be highlighted by engineering upfront so that we can get the clarity from EIL/Dangote during KOM. During execution phase vendor documents should be approved after TL review process. EIL document approval should not be linked to TL’s vendor document approval. Any additional 4. Any vendor deviations, if genuinely required needs to be taken up with EIL & settled before issuing PO to vendor. Due to time constraints, if we need to go ahead with ordering, PM will give the final decision regarding the same.
C] GENERAL POINTS FOR PROCUREMENT 1. Approved vendor list (AVL) is applicable & Refer annexure 1 for the same. This vendor list also applicable for our vendor, sub vendors etc. 2. For Items not available in AVL, TL will submit vendor PTRs to EIL for approval. 3. Chinese/ East European vendors are acceptable provided they are in AVL or comply with the EIL specification and meet PTR requirement. 4. All shelf life material manufacturing to be done only after taking written confirmation from PM. 5. The purpose of creating new WBS for individual item spares is having a single owner for a WBS, special focus and also to ensure separate PO & packing for these spares which will be opened only in Dangote Site. 6. The Purpose of creating new WBS for Mundra Assembly items is to identify & ensure special focus for Module items & ensure separate packing for the same. Page
05-JUL-2019 2 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 4 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
7. Attached excel file of the WBS wise execution philosophy may indicate the sourcing plan/country of origin as per our budget basis & final decision of best vendor needs to be taken during execution. 8. First advance for this job is awaited hence sub vendor PO will only be placed on clearance from SBU/BU Head till the time we receive First Advance. 9. Fabrication Vendor loading & blasting/painting loading needs to be planned meticulously to avoid any helpless situations after loading.
D] SPECIFIC POINTS Sr . Details N o. A Mech Engg
Plan of Action
By Whom
1. AMR revalidation for Superheater tubes, pipes and attemperator pipes 2. Budget, schedule basis of B & H, TECC of all the structures within the module is bolted & the same will be followed for execution. EIL has given clearance for IS 2062 E 250 BR structural steel in place of S275 JR 3. IS2062 shall also be used for plate fabricated items like Casing, Ducting, Base Frame, shipping frame etc. 4. Module to Module connections which are to be done at site will be bolted. 5. Design of Structures as per AISC Codes may be acceptable. 6. Thermally spray aluminum paint not applicable for this package.
By When
Mech Eng
22/04/17
Mech Eng
Info
Mech Eng
Info
Mech Engg
Info
Mech Engg
Info
Mech Engg
Info
7. All Fuel Line piping, Page
05-JUL-2019 3 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 5 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details
B Process Engg
Page
05-JUL-2019 4 of 8
KUMAR PRAMOD(B891)
Plan of Action
By Whom
By When
Valves shall be of SS material after Filter upto Burner Inlet. 8. Fire proofing is not applicable. 9. NACE is not applicable for HRSG package.
Projects/ Engg
Info
Engg
Info
1. There will be Total 3 fuel skids-1 for Natural gas & FG, 1 for IFO/ LCO & 1 for propane 2. Steam drum holdup time 2min between NWL to LLT 3. The Piping B/L isolation valve sizes shall be as per EIL P&ID 4. Corrosion allowance shall be 1mm AS tubes, 1.5mm CS tubes, 3mm for drum, casing & duct:3mm 5. Burner shall be capable of COMBINATION FIRING for any ONE liquid and any ONE gaseous fuel at the same time. 6. Minimum liner material is SS409. However for bottom it is min SS 304 with 2 mm thk
Process
Info
Process
Info
Process
Info
Process
Info
Process
Info
Process
Info
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 6 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details
C E&I
Page
05-JUL-2019 5 of 8
KUMAR PRAMOD(B891)
Plan of Action
By Whom
1. All Fuel Line piping, Valves shall E & I be of SS material after Filter up to Burner Inlet including LPG lines. 2. BMS PLC shall be SIL-3 TMR/QMR 1 per HRSG. 3. BOP PLC shall be SIL-3 TMR/QMR 1 per HRSG 4. SB PLC shall be Non SIL DMR 1 per HRSG. 5. Steam Tracing shall be provided for all Fuel Lines. 6. All Instrumentation shall be suitable for Zone IIA/IIB , T3 area classification. 7. SWAS & CEMS shall be located in Shelter with HVAC. We have considered common Shelter SWAS and CEMS. 8. DCS is excluded from our scope of supply. 9. Foundation field bus Instruments shall be considered for Closed Loop and Open Loop other than those used in interlocks for BMS and BOP. 10. Intrinsically Safe Instruments to be used for Hazardous area protection. 11. Prefabricated Hook Ups are not required for this Project. 12. Vortex flowmeter to be used for Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
By When
Info
Approved by NDN
Page 7 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details
Plan of Action
By Whom
By When
all applications for Line sizes 6 inch and below. E&I
Info
13. SS Junction Box shall be provided for all FF signals. 14. 2 nos Handheld configurator is specified for each HRSG. We can optimize this during execution by reducing the quantity suitably. 15. Ultrasonic Flow meter shall be provided only for Flare. 16. Flowmeter for Instrument Air & Plant Air shall be vortex type. 17. Flowmeter for Cooling water shall be electromagnetic type. 18. Temperature Transmitter shall be provided for all Temperature elements. 19. Field Mounted PC based HMI with Annunciator shall be provided for each HRSG. The details requirement for the same shall be discussed during detail Engg for optimization. 20. For all fuel lines On/OFF Valve shall be Ball Type only. 21. GWR to be used for Level measurements below 2400mm tapping distance. However for Steam drum there are additional special requirements (2 GWR + 1 EDLI for BMS, DPT for control). 22. AMC is applicable for PLC and Analyzer. We have provided separate quotation for AMC. 23. Instrument Cabling scope is upto Field Junction Box. However FO Cabling for CEMS, SWAS shall be supplied upto Control Room. 24. Supply of cabling between BMS, BOP, DCS, MCC is in our scope. 25. Distance between equipments are mentioned in Tender Page
05-JUL-2019 6 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 8 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details
Plan of Action
By Whom
specification. 26. LT MCC per Boiler for Motor rating below 55KW is only our scope. E&I 27. LTMCC, EMCC shall be located in Substation 11. 28. All LT, HT Cabling from Field to SS-11 for equipments supplied by us is in our scope. 29. Complete Lighting (LED) within HRSG package is in our scope. 30. PDB for MOV and Sootblower shall be supplied by us. 31. Sootblower PDB shall be flameproof type. 32. Microprocessor based Electrical Control System & RTU panel shall be supplied by us. The exact configuration shall be discussed with EIL during Detail Engg stage. 33. Overground Earthing is in our scope. 34. Hazardous area classification for Electrical items shall be as per IS5572. 35. Fireproofing is not applicable. 36. During the pre-kick off meeting EIL insisted for Schneider make PLCs since for entire Dangote complex they are going to procure Schneider make PLCs. Thermax to revert on this issue.
Page
05-JUL-2019 7 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
By When
Info
Approved by NDN
Page 9 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details Procurement
D
E QC – Material Inspection
QC – Packing Inspection
Page
05-JUL-2019 8 of 8
KUMAR PRAMOD(B891)
Plan of Action
By Whom
Refer WBS wise Excel format for procurement & dispatch condition portion
By When
Mat
Info
QC needs to take special care QC during inspections to ensure material with respect to TL drawings, specifications. Any errors is supply may lead to huge back charges since erection is not in TL scope
Info
For Items which are getting packed in Wooden boxes - Only After physical packing in boxes, Packing slip to be prepared. After this inspection, boxes needs to be closed by vendors which needs to be witnessed QC. Packing slip needs to be signed off between vendor & QC prior to dispatch. It should contain Name & contact no of QC personnel who ever have cleared the consignment. Pressure will not be put on QC for urgency during packing inspection. Even after this, if any shortage is observed within the individual boxes with respect to packing slip it will be processed by QC & they will be the single point contact for arranging the material from vendor through functional departments as per site requirement. This philosophy will apply to all the items & not restricted to Hardware.
Info
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
QC
Prepared by ARV
Approved by NDN
Page 10 of 19
Refer comment sheet attached
05-JUL-2019 KUMAR PRAMOD(B891)
Page 11 of 19
THERMAX LIMITED BOILER & HEATER GROUP - This document is retained for information. It is vendor's
responsibility to comply with all the MR/PR requirement. If Document No.: QH0581-7830-210 anything found missing at later stage then vendor to comply the
same without any cost and time implication.
Rev: 0 Date: 12/06/2019 Pages :09
DOCUMENT TITLE: Execution philosophy
Code: R (With Comments) Checked by: PK Date: 05/07/2019
EIL JOB NO. : A545 PACKAGE /UNIT NO.: 681-LZ-102-A/B/C/D/E/F/G & H PR CODE : A545-680-LM-PR-7830 DORC Reference No.: THERMAX JOB NO. : QH0581/582/583/584/585/586/587/588 SUPPLY: HEAT RECOVERY STEAM GENERATOR PACKAGE
OWNER :- DANGOTE OIL REFINING COMPANY
Project Name:
0 Rev.
12.06.2019 Date
05-JUL-2019 KUMAR PRAMOD(B891)
First Issue Purpose
VD Prepared By
VD Checked By
VD Approved By
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Boiler Brief Specifications:
Site Location
Lekki FTZ, Lagos, Nigeria
Type/Model
Natural Circulation, Single drum, Supplementary Fired HRSG
Parameters & Fuel
No. of units
Steam Generation – 110 TPH Steam Pressure – 107 Kg/cm2(g) Steam Temperature – 520 Deg C Fuel - Natural Gas/Flue Gas/LCO/IFO 8
Fuel gas th
EDC
6 April’17--- Project no : QH581-8 FOB Mundra Port - Material below 30T FAS Mundra Port - Material above 30T
Vendor to check and attach these annexures
Page 12 of 19
14 Months 15 Months 16 Months 17 Months
CDC
from EDC for Unit 1 & 2 from EDC for Unit 3 & 4 from EDC for Unit 5 & 6 from EDC for Unit 7 & 8
List of Annexures For Signed off Scope List, Refer Annexure 1 For AVL Refer Annexure 2 Latest GA of HRSG Refer Annexure 3 Read Annexure 4, WBS specific philosophy (table) in conjunction with this document. Shop allocation is part of this annexure 4. For Process Improvements – Valve Release refer annexure 5 A] GENERAL 1. Dangote’s PO received on Thermax ,Mundra (SEZ) and therefore all project material will be shipped from Mundra port only. All our PRPs will be Ti PRPs except for Third country shipment. As of now no Third country shipment is envisaged in this job. 2. Boiler design code is as per ASME SEC-1-UN STAMPED. 3. All 8 HRSGs will be assembled in water front inside Mundra Port. 4. Please take a note of all the new WBS added for mandatory spares of individual bought out items & for mundra assembly WBS. Engg, Materials to take necessary accesses to PLM etc in advance to prevent hurdles during execution. 5. Mandatory spares & Commissioning spares are per unit. Page
05-JUL-2019 1 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 13 of 19
Thermax Limited Boiler & Heater Group
6.
7.
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Since Budget & time frame are very tight, proactive care need to be taken during execution stage by respective departments to have sufficient savings/floats while negotiating with vendors. Regarding structural material section deviation, additional vendor approval discussions is being carried out with EIL.
B] GENERAL POINTS FOR ENGINEERING 1. When there is additional requirements w.r.t the either Contract (eg in form of customer comments in TL or vendor documents) or Qty/weight overrun w.r.t budget, Details of these Qty/Weight additions/overruns should be e mailed by Lead Engg to PPM, & PPM concurrence to be taken before Baan Entries. Detailed back up documents will be attached during Weight Overrun/Cost Overrun clearance.
2. Whichever engineering department is releasing a document through DDR they will be the Owner of this document & they will directly get the interface inputs, other inputs if any from other internal engg departments as per project requirement. In case of any issue they need to escalate to engineering planner, PM, concerned HODs as applicable. This applies to specification release & corresponding vendor document approval also. 3. Any clarity with respect to tender should be highlighted by engineering upfront so that we can get the clarity from EIL/Dangote during KOM. During execution phase vendor documents should be approved after TL review process. EIL document approval should not be linked to TL’s vendor document approval. Any additional 4. Any vendor deviations, if genuinely required needs to be taken up with EIL & settled before issuing PO to vendor. Due to time constraints, if we need to go ahead with ordering, PM will give the final decision regarding the same.
C] GENERAL POINTS FOR PROCUREMENT 1. Approved vendor list (AVL) is applicable & Refer annexure 1 for the same. This vendor list also applicable for our vendor, sub vendors etc. 2. For Items not available in AVL, TL will submit vendor PTRs to EIL for approval. 3. Chinese/ East European vendors are acceptable provided they are in AVL or comply with the EIL specification and meet PTR requirement. 4. All shelf life material manufacturing to be done only after taking written confirmation from PM. 5. The purpose of creating new WBS for individual item spares is having a single owner for a WBS, special focus and also to ensure separate PO & packing for these spares which will be opened only in Dangote Site. 6. The Purpose of creating new WBS for Mundra Assembly items is to identify & ensure special focus for Module items & ensure separate packing for the same. Page
05-JUL-2019 2 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 14 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
7. Attached excel file of the WBS wise execution philosophy may indicate the sourcing plan/country of origin as per our budget basis & final decision of best vendor needs to be taken during execution. 8. First advance for this job is awaited hence sub vendor PO will only be placed on clearance from SBU/BU Head till the time we receive First Advance. 9. Fabrication Vendor loading & blasting/painting loading needs to be planned meticulously to avoid any helpless situations after loading.
D] SPECIFIC POINTS Sr . Details N o. A Mech Engg
Plan of Action
By Whom
1. AMR revalidation for Superheater tubes, pipes and attemperator pipes 2. Budget, schedule basis of B & H, TECC of all the structures within the module is bolted & the same will be followed for execution. EIL has given clearance for IS 2062 E 250 BR structural steel in place of S275 JR 3. IS2062 shall also be used for plate fabricated items like Casing, Ducting, Base Frame, shipping frame etc. 4. Module to Module connections which are to be done at site will be bolted. 5. Design of Structures as per AISC Codes may be acceptable. 6. Thermally spray aluminum paint not applicable for this package.
By When
Mech Eng
22/04/17
Mech Eng
Info
Mech Eng
Info
Mech Engg
Info
Mech Engg
Info
Mech Engg
Info
7. All Fuel Line piping, Page
05-JUL-2019 3 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 15 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details
B Process Engg
Corrosion allowance for drum internals shall be 1.5 mm shall also be mentioned
Page
05-JUL-2019 4 of 8
KUMAR PRAMOD(B891)
Plan of Action
By Whom
By When
Valves shall be of SS material after Filter upto Burner Inlet. 8. Fire proofing is not applicable. 9. NACE is not applicable for HRSG package.
Projects/ Engg
Info
Engg
Info
1. There will be Total 3 fuel skids-1 for Natural gas & FG, 1 for IFO/ LCO & 1 for propane 2. Steam drum holdup time 2min between NWL to LLT 3. The Piping B/L isolation valve sizes shall be as per EIL P&ID 4. Corrosion allowance shall be 1mm AS tubes, 1.5mm CS tubes, 3mm for drum, casing & duct:3mm 5. Burner shall be capable of COMBINATION FIRING for any ONE liquid and any ONE gaseous fuel at the same time. 6. Minimum liner material is SS409. However for bottom it is min SS 304 with 2 mm thk
Process
Info
Process
Info
Process
Info
Process
Info
Process
Info
Process
Info
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 16 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details
C E&I
Page
05-JUL-2019 5 of 8
KUMAR PRAMOD(B891)
Plan of Action
By Whom
1. All Fuel Line piping, Valves shall E & I be of SS material after Filter up to Burner Inlet including LPG lines. 2. BMS PLC shall be SIL-3 TMR/QMR 1 per HRSG. 3. BOP PLC shall be SIL-3 TMR/QMR 1 per HRSG 4. SB PLC shall be Non SIL DMR 1 per HRSG. 5. Steam Tracing shall be provided for all Fuel Lines. 6. All Instrumentation shall be suitable for Zone IIA/IIB , T3 area classification. 7. SWAS & CEMS shall be located in Shelter with HVAC. We have considered common Shelter SWAS and CEMS. 8. DCS is excluded from our scope of supply. 9. Foundation field bus Instruments shall be considered for Closed Loop and Open Loop other than those used in interlocks for BMS and BOP. 10. Intrinsically Safe Instruments to be used for Hazardous area protection. 11. Prefabricated Hook Ups are not required for this Project. 12. Vortex flowmeter to be used for Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
By When
Info
Approved by NDN
Page 17 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details
Plan of Action
By Whom
By When
all applications for Line sizes 6 inch and below. E&I
Info
13. SS Junction Box shall be provided for all FF signals. 14. 2 nos Handheld configurator is specified for each HRSG. We can optimize this during execution by reducing the quantity suitably. 15. Ultrasonic Flow meter shall be provided only for Flare. 16. Flowmeter for Instrument Air & Plant Air shall be vortex type. 17. Flowmeter for Cooling water shall be electromagnetic type. 18. Temperature Transmitter shall be provided for all Temperature elements. 19. Field Mounted PC based HMI with Annunciator shall be provided for each HRSG. The details requirement for the same shall be discussed during detail Engg for optimization. 20. For all fuel lines On/OFF Valve shall be Ball Type only. 21. GWR to be used for Level measurements below 2400mm tapping distance. However for Steam drum there are additional special requirements (2 GWR + 1 EDLI for BMS, DPT for control). 22. AMC is applicable for PLC and Analyzer. We have provided separate quotation for AMC. 23. Instrument Cabling scope is upto Field Junction Box. However FO Cabling for CEMS, SWAS shall be supplied upto Control Room. 24. Supply of cabling between BMS, BOP, DCS, MCC is in our scope. 25. Distance between equipments are mentioned in Tender Page
05-JUL-2019 6 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
Approved by NDN
Page 18 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details
Plan of Action
By Whom
specification. 26. LT MCC per Boiler for Motor rating below 55KW is only our scope. E&I 27. LTMCC, EMCC shall be located in Substation 11. 28. All LT, HT Cabling from Field to SS-11 for equipments supplied by us is in our scope. 29. Complete Lighting (LED) within HRSG package is in our scope. 30. PDB for MOV and Sootblower shall be supplied by us. 31. Sootblower PDB shall be flameproof type. 32. Microprocessor based Electrical Control System & RTU panel shall be supplied by us. The exact configuration shall be discussed with EIL during Detail Engg stage. 33. Overground Earthing is in our scope. 34. Hazardous area classification for Electrical items shall be as per IS5572. 35. Fireproofing is not applicable. 36. During the pre-kick off meeting EIL insisted for Schneider make PLCs since for entire Dangote complex they are going to procure Schneider make PLCs. Thermax to revert on this issue.
Page
05-JUL-2019 7 of 8
KUMAR PRAMOD(B891)
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
Prepared by ARV
By When
Info
Approved by NDN
Page 19 of 19
PROJECT EXECUTION PHILOSOPHY FOR HRSG CUSTOMER – DANGOTE OIL REFINING COMPANY
Thermax Limited Boiler & Heater Group
Sr . N o.
Details Procurement
D
E QC – Material Inspection
QC – Packing Inspection
Page
05-JUL-2019 8 of 8
KUMAR PRAMOD(B891)
Plan of Action
By Whom
Refer WBS wise Excel format for procurement & dispatch condition portion
By When
Mat
Info
QC needs to take special care QC during inspections to ensure material with respect to TL drawings, specifications. Any errors is supply may lead to huge back charges since erection is not in TL scope
Info
For Items which are getting packed in Wooden boxes - Only After physical packing in boxes, Packing slip to be prepared. After this inspection, boxes needs to be closed by vendors which needs to be witnessed QC. Packing slip needs to be signed off between vendor & QC prior to dispatch. It should contain Name & contact no of QC personnel who ever have cleared the consignment. Pressure will not be put on QC for urgency during packing inspection. Even after this, if any shortage is observed within the individual boxes with respect to packing slip it will be processed by QC & they will be the single point contact for arranging the material from vendor through functional departments as per site requirement. This philosophy will apply to all the items & not restricted to Hardware.
Info
Document No.
Rev. No.
Date
QH581/2017/001
1
21/4/2017
QC
Prepared by ARV
Approved by NDN
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