Tech. Spec.for Propylene Compressor.pdf

VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006

Rev: B

Page 1 of 26

MATERIAL REQUISITION FOR PROPYLENE COMPRESSOR

Hindustan Petroleum Corporation Ltd

Mott MacDonald Consultants (India) Pvt. Ltd.

Visakha Dispatch Station

Kothari House, CTS No. 185

VR-ATP Area, Naval Base Post

Off Andheri - Kurla Road

Visakhapatnam - 530 014

Andheri (East)

Andhra Pradesh

Mumbai 400 059

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006

Rev: B

Page 2 of 26

MATERIAL REQUISITION FOR PROPYLENE COMPRESSOR

Client

HINDUSTAN PETROLEUM CORPORATION LTD.

MMCI Project No.

256324

Issue and Revision Record: Rev

Date

Originator

Checked

Approved

Description

A

02/06/09

SVJ

SPW

PJC

Issued for Comments

B

06/08/09

SVJ

SPW

PJC

Issued for Comments – LPG Compressor replaced with LPG Cylinder Evacuation Compressor.

Group Disclaimer "This document has been prepared for the titled project or named part thereof and should not be relied upon or used for any other project without an independent check being carried out as to its suitability and prior written authority of Mott MacDonald being obtained. Mott MacDonald accepts no responsibility or liability for the consequences of this document being used for a purpose other than the purposes for which it was commissioned. Any person using or relying on the document for such other purpose agrees, and will by such use or reliance be taken to confirm his agreement, to indemnify Mott MacDonald for all loss or damage resulting there from. Mott MacDonald accepts no responsibility or liability for this document to any party other than the person by whom it was commissioned.”

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006

Rev: B

Page 3 of 26

List of Content

Page No

1

Introduction

5

2

Location and Environmental Conditions

6

3

Scope of Supply

6

3.1

Equipment and Materials

6

3.2

Extra for Non Lubricated Construction

7

3.3

Bottles, Accessories, Piping

7

3.4

Instrumentation

7

3.5

Local Control Panel

8

3.6

Motor

8

3.7

Engineering Services

8

3.8

Exclusions

9

4

5

Applicable Codes, Specifications and Standards

9

4.1

General

9

4.2

Codes and Standards

9

4.3

Other Specifications and Standards

10

Design Requirements

10

5.1

Mechanical Requirements

10

5.2

Instrumentation Requirements

10

5.3

Electrical Requirements

11

5.4

Piping Requirements

11

6

Quality Assurance

11

7

Inspection and Testing

11

7.1

Factory Inspection & Testing

11

7.2

Scope of Inspection & Certificates

13

7.3

Vendor Requirements

13

7.4

Performance Testing and Guarantee:

13

7.5

Works Inspection and Notification

14

8

9

Vendor Documentation

14

8.1

Documents/Information to be supplied with offer

14

8.2

Documents/Information to be supplied After Award of Contract

15

Manufacturing Schedule

15

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006

10

Rev: B

Page 4 of 26

Spares and Special Tools

15

10.1

Spares

15

10.2

Special Tools

15

11

Packing and Shipping

15

12

Installation and Commissioning

16

Appendix A: Attachments

17

Appendix B: Requisition of Engineering Documents (Red Form)

18

Appendix C: Table of Compliance

20

Appendix D: Instrumentation Design Requirements

21

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006

Rev: B

Page 5 of 26

1

Introduction

1.1

This specification covers the minimum requirements for the design, engineering, material procurement, fabrication, painting, assembly, Inspection, supply and shipment of Propylene Compressor for “Resitement of Integrated Marketing Facility at Vishakhapatnam - LPG Terminal.

The List of Compressors is as follows: Sr. Tag No. No. 1 500C-002

Quantity 01 no.

Description Propylene Compressor

1.2

The Vendor shall be responsible for the design, engineering, fabrication, assembly, inspection, co-ordination, testing, delivery and proper functioning of the Compressors.

1.3

The Vendor shall ensure that the design complies with the requirements of this requisition and its referenced specifications and standards. The data sheets, which form part of this specification, shall be completed by the Vendor. The Vendor shall highlight any noncompliance at the offer stage in the Table of Compliance, Appendix C. The Table of Compliance and filled in data sheets shall form a part of the offer. Not providing completed compliance table and data sheets can cause rejection of the offer. Failure to clearly identify specific deviations shall be assumed by the Purchaser to be total compliance with the requisition. Only those deviations that are specifically agreed to, by the Purchaser prior to award of the order will be incorporated into the purchase order. Deviations to the specification will not be allowed after award of order. Unless referred to in the Table of Compliance (Appendix C), it will be assumed that all specifications are adhered to and that they do not have implications with respect to cost, delivery and integrity of the equipment.

1.4

The Vendor shall procure third party material from vendors listed in the approved Vendor List only, unless the particular type of material is not covered by the list, and a special dispensation to deviate from the list has been granted in writing by the Purchaser. Company will reject any materials found at any stage to be out of the approved VENDOR or sub Vendor list.

1.5

Note that “lead times” will not be considered by the COMPANY as a justifiable reason for using alternate VENDOR.

1.6

This requisition shall in no way relieve the Vendor from final guarantee as to materials, apparatus, workmanship and performance of the equipment and services supplied.

1.7

All correspondence and documentation shall be in English. All measurements and units shall be in SI units. Where necessary for a specific application, alternative units may be indicated in brackets behind the SI units.

1.8

The VENDOR shall guarantee the equipment and all component parts against defective workmanship and improper materials for the agreed period following the date of delivery of the equipment or from commencement of operation as agreed. The VENDOR shall replace or repair (the carrying out of all work including uncovering, removal, procurement and reinstallation and construction as may be necessary) the components that are defective at their

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006

Rev: B

Page 6 of 26

own cost during the guarantee period at a suitable time to the COMPANY. Guarantee period shall be as per the Contract and to be covered in commercial documentation.

2

Location and Environmental Conditions For local conditions refer Document no. 256324-500-SP-GEN-001.

3

Scope of Supply 3.1

Equipment and Materials Scope of supply of each Compressor shall include but not necessarily be limited to following and mechanical datasheets. The unit shall be supplied complete in itself including all auxiliaries and accessories required for normal and safe operation of unit. Major items of supply are listed below. Vendor shall, however, include any other item that may not be specifically listed but is considered necessary for the operation of the unit and furnish particulars of the same in bid. Scope of supply shall include but not be limited to the following:

A) Propylene Compressor (Tag No.500C-002) Single stage, Air-cooled, Non-Lubricated, Cross-head type, Reciprocating Propylene Compressor complete with standard equipment including the following (Model No. D291 AM3FDENSNN of CORKEN or Equivalent is preferred). • • • • • • • • • • • • • • • • • • • • • • •

Gas ends engineered for LPG Service, Heat resistant paint on cylinder heads and in gas passages to prevent rust. Gas cushioned A-type channel valves. Self venting packing case Two compartment distance piece: Type ‘D’ as per API -618,5th Edition, 2007. Suction Filter with silencer Knock Out drum with drain valves Full floating Aluminium Alloy bearings. Full floating, self adjusting, double acting, carbon filled Teflon cylinder & partition packing rings. Instruments and skid mounted automation panel. V belt drive, motor pulley, anti-static V belts. Completely enclosed non-sparking V belt guard Foundation bolts fixing bolts, jack screw bolts, shims for compressor and motor Slide rails for motor. Electric motors, Local Control Panel. Cabling and Cable termination within skid. Base plate with Lifting & Earthing lugs Commissioning & Start-up Spares. (for more details refer section 11.1) List of Spares for two years trouble free operation (for more details refer section 11.1) Inspection and testing as specified in clause 8 of this specification. Submission of documents as specified in this document (Appendix B). Painting, preservation, preparation for shipment and delivery at site. Special tools if required (Bidder to provide list in the bid). Supervision of Installation & Commissioning (Separate visit for Installation & commissioning shall be considered).

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006

3.2

Teflon non-lubricating wearing and piston rings. Teflon full floating piston rod packing. Specially honed cylinders. Special wiper rings in partition plate stuffing box. Heat resistant paint of cylinder heads and in gas passages to prevent rust. Oil baffle collar on piston rod.

Bottles, Accessories, Piping







3.4

Page 7 of 26

Extra for Non Lubricated Construction







3.3

Rev: B

Suction Liquid Separator cum Pulsation Dampner with SS demister as per ASME Section- VIII Div. 1 with manual drain valve. Discharge Pulsation Dampner as per ASME Section VIII Div. 1 with manual drain valve. 1 No. Swing check type Non-return valve on the gas discharge side. 1 No. Safety relief valve full flow type on gas discharge. Gas piping (MOC - Carbon steel for LPG and LTCS for Propylene) between suction separator discharge flange and cylinder suction flange. 140 micron inline strainer with spool piece on gas inlet.

Instrumentation All instruments shall be Flameproof, suitable for Zone 2 gas Group IIA / IIB.
















Dial pressure gauges SS Bourdon type with 1/2” NPT connection. Isolation valves shall be double block and bleed type and flanged, one each to be located at • Gas suction • Gas discharge • Lube oil header Bimetallic Temperature gauges with 2” flanged thermowell in SS 304 bar stock. Thermo wells, one each to be located at gas suction and discharge. Low oil pressure shutdown transmitter with flanged isolation valve (double block & bleed type). Low suction pressure shutdown transmitter with flanged isolation valve (double block & bleed type). High discharge pressure shutdown transmitter with flanged isolation valve (double block & bleed type). Temperature transmitter on the compressor body. Pressure transmitter for Low cooling water pressure for Propylene Compressor. Liquid level indicator on suction separator. Flameproof (IIA/IIB) Solenoid valves for 0-50-100% for capacity control (Flanged Type). 4 way two position pneumatic valve with Solenoid valves, Position Switch, tubing, etc. Level Transmitter, Pressure Indicator and Level indicator on KO Drum. Cabling (to be supplied in free lengths) for field mounted Instruments 30m maximum per instrument. Flameproof Junction Box, as required.

Notes: 1) All instruments / piping / cabling to be supplied loose, in free lengths from vendor’s works.

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006

Rev: B

Page 8 of 26

2) One Digital Input shall be given by Purchaser per each unit for Emergency Trip interlock of Compressor. Vendor to provide space for termination and cable entry into the local panel supplied along the package. 3.5

Local Control Panel



Relay based, Flameproof with solid state alarm annunciation Panel along with Local Control Panel suitable for use in Zone 2 Gas Group IIA/IIB Area as per IS 2148. The panel shall have all necessary standard features viz. • Motor on/off push buttons • Test/acknowledge/reset push buttons • Timer to bypass low lube oil pressure switch during start up • Manual Selector switch for 0-50-100% Capacity control • Starting interlock for Auto unloaded starting.

Fault Annunciation Table for Local Control Panel: Sr. No.

Fault Description

Simultaneous Alarm & Trip

1.

Low lube oil pressure

X

2.

Low gas suction pressure

X

3.

High gas discharge pressure

X

4.

High liquid level in suction Separator

X

5.

Spare

X

6.

High & Low Level alarms from Evacuation Vessels 500BOP-052 A/B

X

Note: Vendor shall provide one number common fault alarm, compressor run status and position of 2 nos., 4 way valves (unloading position & depressurizing position) in soft signal form or as potential free contact, to be wired by others to Client control panel. This is required only for Propylene Compressor. 3.6

Motor


3.7

Squirrel Cage Induction Motor of suitable rating, 4-pole, flameproof ( suitable for Zone 2 Gas Group IIA / IIB )

Engineering Services The Vendor shall provide engineering services, which shall include, but not necessarily be limited to, the following: •

Providing/Coordinating detailed design of all equipment and components within the scope of supply.

•

Providing Static & Dynamic loads and anchoring plan for the design of Civil foundation by others.

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006

3.8

Rev: B

Page 9 of 26

•

Resolving engineering queries related to the equipment and components within the scope of supply.

•

Performing and coordinating all aspects of design.

•

Providing progress reports etc.

•

Providing expediting services for all sub-vendors.

•

Providing quality assurance including all sub-vendors with respect to ISO 9000 or equivalent.

•

Supervision of Erection & Commissioning to be quoted separately.

•

Any technical document required for statutory approval shall be furnished by vendor.

Exclusions The following are excluded from the Vendor's scope and will be provided by others: •

Equipment foundations, however design shall be based on Vendor supplied foundation load data.

•

Process piping up to Compressor suction and discharge connections.

•

Interconnecting power cabling and cable trays between motor terminal boxes, and Purchaser’s MCC.

•

Interconnection of earthing bosses and underground earth conductor.

•

Interconnecting cables for Trip Signal from and to Control room Panel and Local Control Panel.

4 Applicable Codes, Specifications and Standards 4.1

General The design, fabrication, assembly, inspection, testing, painting, packing and shipment of equipment shall be in accordance with the latest edition of the codes, specifications and standards (including standards / specifications mentioned therein) listed in this requisition. The Vendor shall provide an itemized list of any comments or exceptions to the specification and its attachments. Only those comments / exceptions that are accepted by Purchaser will be incorporated into the requisition at the time of the order.

4.2

Codes and Standards API 618, 5th Edition,Dec2007

Reciprocating Compressors for Petroleum, Petrochemical and Natural Gas Industries.

API 520, Part 1, 8th Edition, 2008

Sizing and Selection

API 520, Part 1, 5th Edition, 2003

Installation

API 521, 4th Edition, 1997

Guide for Pressure-relieving and depressurising systems.

th

API 620, 11 Edition, 2008

Design & Construction of Large welded, low pressure storage tanks.

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006

4.3

Rev: B

Page 10 of 26

ASME Sec. VIII Div. I, 2007

Rules for Construction of Pressure Vessels.

ASME Sec. II Part A, 2007

Ferrous Materials Specification.

ASME B 16.5 (2003)

Pipe Flanges and Flanged Fittings.

ISO 9000 (2005)

Quality Management and Quality Assurance Standards.

ISO 10474 (1991)

Inspection Documents

Other Specifications and Standards Appendix - D

Specification for Instrumentation in Packaged items.

256324-500-SP-ELE-010 Rev. A

Specification for Electric Motors

256324-500-SP-GEN-001 Rev.A

Local Conditions

5 Design Requirements 5.1 Mechanical Requirements 5.1.1

Compressors shall be supplied as a complete package per the requirements of this Specification, P & ID nos. 256324-500-PID-A0-1061 (1/1) and 256324-500-PID-A0-1062 (1/1), API618 5th Edition, Dec 2007 and Mechanical Datasheet (Doc. No. 256324-500-DSMEC-018).

5.1.2

The compressor shall conform to API 618, as far as possible. The compressor shall be motor driven, water-cooled type reciprocating compressor. Alternatively Vendor can offer Aircooled type compressor.

5.1.3

The frame shall be completely enclosed and provided with gas tight distance piece between the cylinder frame and the crankcase. The distance pieces shall have ample opening and shall be provided with gas tight covers for easy access to packing. Metallic and Teflon oil wiper rings shall be provided to percent oil leakage.

5.1.4

The piston and packings shall be of full floating design. The piston rings and packing material shall be suitable for Propylene service and shall preferably be of PTFE or equivalent material.

5.1.5 The cylinder shall be either provided with a liner or designed to provide upto 3 mm maximum of re-boring without affecting the design pressure of the frame. 5.1.6

5.2

The drive unit such as V belt drive shall be of antistatic and non Sparking materials. All moving parts such as V belts, couplings etc. wherever provided shall be protected by suitable guards. The valves shall have ample effective areas permitting low gas velocities across valve opening. The valve shall be renewable and made of hardened steel resistant to abrasion and corrosion.

Instrumentation Requirements All the Instruments shall be as per specification mentioned in Appendix D. Vendor shall submit the Complete Instrument datasheets with relevant data filled along with bids.

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006

Rev: B

Page 11 of 26

Vendor to note that Instrument air (Min. 4.5 kg/cm2 and Max. 7.5 kg/cm2) is available at the battery limit at one point. 5.3 Electrical Requirements 5.3.1 Motors shall be supplied as per attached Motor specification no. 256324-500-SP-ELE-010. 5.3.2 Vendor shall submit the Motor Datasheet with all the data filled by the Motor Manufacturer. 5.4 Piping Requirements 5.4.1 5.4.2

Vendor shall provide General arrangement drawing with co-ordinates for all Tie-ins. Vendors shall clearly define the space requirement. Flanged termination/ tie-in points shall be provided with companion flanges.

6 Quality Assurance The Vendor shall maintain and use a Quality System which is based on ISO 9000 to control the work. If the Vendor elects to sub-contract part of the work he shall ensure that only those sub-contractors or suppliers are used who can demonstrate that they operate Quality Systems based on ISO 9001 or ISO 9002 as applicable. The Vendor shall give his sub-contractors or suppliers assistance in attaining the required standard, if necessary. This shall not relieve the Vendor of his responsibility for the quality of the finished work. The Company / Consultant reserve the right to audit the Vendor’s Quality System. The Vendor shall assign sufficient full time personnel to the project to ensure the Quality Assurance / Quality Control System, documented in a Quality Assurance / Control Manual, is maintained and kept up-to-date throughout the duration of any purchase order. The Vendor’s Quality Assurance / Control System shall become an integral part of any purchase order. Vendor shall organize a prefabrication / inspection meeting with the Company / Consultant. Vendor shall submit QA plan for Purchaser’s and Consultants review and approval within 15 days weeks from the date of Purchase Order/LOI.

7 Inspection and Testing 7.1

Factory Inspection & Testing Scope of Inspection: • • • • • • • •

Approval of Quality assurance plan and Inspection test plan. Stage wise inspection as per approved quality assurance plan/ Inspection test plan. Review of material test certificates, Lab. Test reports, etc. Performance of the equipment. Review of CCOE / PESO and CMRI approval certificates for the FLP items. Review of manufacturer’s test certificates for the bought out items. Any other specific items as decided by the Consultant/ TPIA to meet the tender requirements. Any other requirements as specified in the individual specifications.

The responsibility for inspection, certification, etc. of all materials, parts lies with the Vendor. The Vendor shall specify all of the inspection and testing requirements in the quality assurance plan/ Inspection test plan which shall identify the activities requiring the Company / Consultant's / TPIA approval, review, witnessing etc. P:\Andheri\IndiaProject\256324 HPCL- LPG\10 Procurement\TENDER\16 Piping Works Tender\Final\Annexures- Piping Tender\Annexure3\MDS,Specs-Mech\Editable\Tech. Spec.for Propylene Compressor.doc

VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006

Rev: B

Page 12 of 26

Inspection and testing requirements shall be in accordance with API-618 5th edition, 2007 this specification and the data sheets. All equipment shall be inspected for compliance with: •

Requirements of the specifications, data sheets and correspondence thereafter.

•

Applicable Codes, standards and specifications, which shall also include sub-referenced standards therein.

•

Quality assurance plan/ Inspection and test plans and Procedures produced by the Vendor, duly approved by the Owner/ Consultant.

Purchaser’s/ Consultant’s Inspectors have the right to request additional inspections or tests to ensure that the equipment complies with this specification and all relevant codes and standards. All equipment shall be presented for inspection in an unpainted state except for the final inspection. All instruments and other equipment necessary for testing shall be supplied by the Vendor and the same shall be checked and certified by the Company / Consultant’s inspector. Any defects found by the Company / Consultant’s appointed Inspector shall be rectified in his presence. Where this is not possible or practical, check lists shall be prepared and signed by the Inspector stating all “pending items”. Copies of these lists shall be sent to the Company/Purchaser to enable their subsequent checking. Mill and shop inspection shall not relieve the Vendor from his contractual responsibility for replacing any defective material and for repairing any defective workmanship that may be discovered in the field. The Vendor shall be responsible for co-ordinating the inspection and testing of sub-vendor supplied equipment, and for ensuring that the Company / Consultant’s representatives are given the necessary access for inspection, and adequate warning of inspection and tests. The Vendor (and all sub-Vendors) shall give the Company/ Consultant’s representatives, without charge, all reasonable facilities and access for the purpose of inspecting the equipment to ensure that it is manufactured in accordance with the Specification. All spare parts shall be subjected to the same inspection standards and full material certification as the main order. The equipment shall not leave the Vendor’s factory before all discovered defects have been rectified and without the written permission of the Company/Consultant. Materials for all pressure retaining components & wetted components shall be certified in accordance with ISO 10474 - 3.1B and that for non-pressure retaining components like structural components, platforms, ladders, shall be certified in accordance with ISO 10474 2.2. Final hydro test pressure shall be held for a minimum period of 30 minutes. Chloride contents of water used for hydro test shall not exceed 20 ppm for stainless steel and chloride content may be permitted up to 250 ppm for carbon steel.

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006 7.2

Rev: B

Page 13 of 26

Scope of Inspection & Certificates DESCRIPTION

CERTIFICATE

WITNESS

Material test certificate for Piston rod, connection rod, Crankshaft and cylinder

Yes

-

b.

Hydro test for Cylinder

Yes

Yes

c.

Ultrasonic / Dye Penetrant test certificate for piston rod

Yes

-

No Load Mechanical Run Test of compressor

Yes

Yes

Yes

-

Yes

Yes

Yes

-

Yes

-

Compressor: a.

d.

Accessories: a.

FLP Motor - Routine test certificate as per IS 2148 ; PESO/CCOE /CMRS certificates

b.

Volume Bottles: - Hydro test at Vendor’s place - Material Compliance Certificate - Radiography and Mill Test Certificate

c.

7.3

FLP Instruments: CMRS Certificate

Yes

Vendor Requirements Any acceptance or release of equipment following an inspection or test activity shall in no way relieve the Vendor of his responsibility to provide guarantees as to the suitability of the materials, workmanship and performance of the equipment in accordance with this Requisition.

7.4

Performance Testing and Guarantee: •

Compressors shall demonstrate sustained operation at conditions mentioned in the datasheets.

•

All equipment and component parts shall be guaranteed by vendor against defective material, design and workmanship for a period of one year after being put in service.

•

The vendor shall carry out the performance test run of the Equipments/ Machine at site after satisfactory installation. Training of operators shall be given at site during commissioning period without any extra cost to owner.

•

The vendor shall be solely responsible for smooth and trouble free performance of the equipment during the guarantee period .Vendor shall have to carry out any rectifications/ replacement at his own cost.

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006 7.5

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Works Inspection and Notification The supplier shall send inspection notification at least 2 weeks in advance and shall send a minimum of fifteen (15) working days notice prior to carrying out the Factory Acceptance Test (FAT). The notification shall contain as a minimum the following information: •

Project Title, MMCI project number.

•

Manufacturer’s full address, contact name, telex / telefax / telephone numbers.

•

Purchase Order reference

•

Date of inspection

•

Details of equipment to be tested / inspected and the status of the equipment (whether it is complete).

8 Vendor Documentation 8.1

Documents/Information to be supplied with offer The Vendor shall provide the Consultant with the following information as a minimum along with the offer. These documents shall include, but not be limited to the following: a. The completed Table of Compliance (Appendix C). b. Completed data sheets (Compressor & Motor), which are attached with this requisition, with supplier data added. c. Filled Instrument datasheets with calculations as applicable. d. A detailed scope of supply that fully describes the equipments offered. e. Performance curves. These curves shall include the specified duties and design conditions as required on the enquiry data sheets. f.

Control Panel GA and details.

g. General arrangement drawings with dimensions and Load data for foundation design. • For all equipment whether base plate mounted or not, the outline drawings shall include approximate weights, overall dimensions, size, rating and approximate locations of main nozzles, centerline height and shaft extension details, approximate dismantling clearances and approximate handling weights. They shall also include the tentaive location of main electrical connections. h. P & IDs for complete system being offered with Tie-ins identified. i.

Cause and effect diagram for the package.

j.

Cross-sectional drawings including main construction features, details of seals, bearings and other mechanical details

k. Schematics or Flow Diagrams including reasonably accurate gas or fluid flows, lube, seal oil and control oil, all instrumentation, valves, safety devices and control schemes. l.

Commissioning Spare parts list.

m. 2-Years operation spare part list. n. Complete list of special tools required, if any. o. All utility consumptions such as power requirement, utility requirement like Water, Air, N2, etc. for each Compressor. p. Experience list as per clause 5 of this requisition. P:\Andheri\IndiaProject\256324 HPCL- LPG\10 Procurement\TENDER\16 Piping Works Tender\Final\Annexures- Piping Tender\Annexure3\MDS,Specs-Mech\Editable\Tech. Spec.for Propylene Compressor.doc

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Rev: B

Page 15 of 26

Documents/Information to be supplied After Award of Contract Vendor shall provide Purchaser/Consultant with documents and drawings as described in the 'General Conditions of Contract'. However, document requirements as specified in the 'Requisition for Engineering Documents (RED)' attached with Appendix B shall be followed as a minimum requirement.

9

Manufacturing Schedule Within 2 weeks of the receipt of the Purchase Order/ LOI/ FOI the manufacturer shall submit detail bar chart schedule showing the dates for the following milestone activities, as minimum: i)

Issue of vendor drawings. a. Issue for comments/approval b. Issue of final drawings c. Issue of O&M Manuals

10 10.1

ii)

Equipment available for Testing.

iii)

Completion of packing and readiness for dispatch.

Spares and Special Tools Spares Bidder to quote separately for spares of Compressor in the following format: •

The supply of spares for start-up and commissioning

•

Vendor to recommend two years operation spares and furnish separate price in the offer. (This list, as a minimum, should include all Gaskets, Complete set of Bearings, Valve internals, Piston Ring and Packing Ring sets including Instruments as per the quantity built in one compressor unit.)

The Vendor shall also provide all consumables during erection up to commissioning and reliability testing. In case of any additional spares if required during commissioning stage, the same shall be supplied by Vendor free of cost. The Vendor shall complete and submit SPIR forms 8 weeks after Vendor’s acceptance of the Purchase Order. Spare parts for the normal operation shall be selected by the End User from the electronic version of Spare Parts Lists and Interchange ability Record (SPIR). 10.2

Special Tools The Vendor shall supply a set of any special tools, which are required for the installation, commissioning, operation and maintenance of the equipment being supplied. A list of special tools shall be supplied along with the offer.

11

Packing and Shipping For Packaging, Shipping and delivery of equipment at site and unloading requirements, 'Agreed Conditions of Contract' shall be referred.

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12

Rev: B

Page 16 of 26

Installation and Commissioning Vendor shall provide qualified personnel to supervise the installation, testing, precommissioning and commissioning. Prices for these services shall be given separately.

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Appendix A:

Rev: B

Page 17 of 26

Attachments

Equipment Data Sheets Document No. 256324-500-DS-MEC-018

Rev. A

Description Mechanical Datasheet for Propylene Compressor

Rev.

Description P & I Diagrams for LPG/Propylene Sick Tank / Wagon Unloading Compressor P & I Diagrams for LPG Sick Cylinder Evacuation Facility and Purging Unit. Plot Plan Electric Motor Datasheet (Part of Specification for Electric Motors – 256324500-SP-ELE-010) Differential Pressure Transmitter (Level) (Blank Datasheet Format) Pressure Gauge (Blank Datasheet Format) Pressure Transmitter (Blank Datasheet Format) Temperature Transmitter (Blank Datasheet Format) Pressure Safety Valve (Blank Datasheet Format)

Other Documents Document No. 256324-500-PID-A0-1061(1/1)

B

256324-500-PID-A0-1062(1/1)

B

256324-500-PIP-A0-3000

D

-

-

-

-

-

-

-

-

-

-

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Appendix B:

Rev: B

Page 18 of 26

Requisition of Engineering Documents (Red Form)

Owner/Purchaser’s Office

Consultant’s Office

HINDUSTAN PETROLEUM CORPORATION LTD. Krishna Shree, 2nd Floor, Gandhi Nagar, 1st Main Road-Adyar, Chennai – 600 020

Mott MacDonald Consultants (India) Pvt. Ltd Kothari House, CTS No. 185 Off Andheri – Kurla Road, Andheri (East) Mumbai 400 059, India ; Tel 09122 3083 5000

DRAWINGS

Required number for Approval

Approval drawings / Final drawings to be submitted under cover of an ADS form / FDS form respectively

Prints

TIMING FOR SUBMITTAL Final issue

- for approval 2 weeks after order date

Disk

- final issue 2 weeks after approval date Documents shall be submitted to:

Prints

Transpa rencies

Vendor Doc. Schedule General arrangement Foundation loading and bolt location plan Cross section drawing with BOM and MOC Completed data sheets of all Main & Auxiliary equipments Performance curves for Compressor and motors Motor Speed/Torque curves Coupling GA drawings Motor GA drawing & Terminal Box Drawing P&ID for the Package with the battery limit Cause & Effect diagarm Equipment list Utility Consumption list Functional Description of Control System Lay out & Construction details of Local Instrument Panels Electrical Cable Schedule Wiring & Termination diagram Instrument & Junction Box Location Plan Instrument Cable Termination details – Junction Boxes Control Narrative Lifting beam/frame details along with calculations List & Drawings of special tools Instruments Datasheets Production Schedule Progress Report Performance Test Procedure including FAT, NDT Procedures, WPS, PQR, WPQ Quality plan satisfying ISO 9000 requirements Manufacturing, inspection & testing sequence plan SPARE PARTS DOCUMENTS SPIR forms including 1 transparency Lubrication schedules TEST AND INSPECTION DOCUMENTS Documents to be submitted under transmittal Manufacturing reports

4 4 4 4 4

1 1 1 1 1

3 3 3 3 3

4 4 4 4 4 4 4 4 4 4

1 1 1 1 1 1

1 1

3 3 3 3 3 3 3 3 3 3

1 1 1 1 1 1 1

3 3 3 3 3 3 3 3

1

3

1

3

4 4 4 4 4 4 4 4 4 4 4 4 4

Monthly Once.

1 1 1

3 3 3 Prints Documents shall be submitted to:

1

3

Material certificates to: ISO 10474 - 3.1B

1

3

Electrical certificates to Cenelec / Baseefa/ATEX Compliance/CMRI

1

3

Static / dynamic balancing certificates

1

3

Purchasing Office via courier service within 4 weeks

Performance test Report & Performance Curves

1

3

of relevant test / inspection.

Heat treatment graphs, if applicable

1

3

Calibration certificates of Instruments

1

3

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Rev: B

Page 19 of 26 Purchasing Office via courier service not later than time of dispatch of equipment.

Installation instructions 1 3 Operating instructions 1 3 Combine into one manual Maintenance instructions 1 3 ADDITIONAL REQUIREMENTS: 1. Referenced standards / codes shall be the latest issue unless otherwise stated. Invoice must certify that the drawings and engineering documents specified Units / dimensions to be used on Engineering documents shall be SI. above have been dispatched to all parties concerned. The documents shall be in English. Description on drawings and similar Any deviation from the timing for submittal of documents shall be notified to documents may be in other languages provided English translations are the Approval / Distribution Offices by fax or E mail. also given. Shop fabrication shall not be started before the required approval drawings Drawings and documents shall be suitable for microfilming and comply have been released for construction by the party concerned, unless otherwise with accepted national or international standards for the preparation of stated on the "Approval Drawing Specification". technical drawings. Only the following standard sizes should be used: A4, Each document shall bear the item / tag and order reference number and be A3, A2, A1. dispatched by air mail, unless other instructions are stated on the RED.

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006

Appendix C:

Rev: B

Page 20 of 26

Table of Compliance

The Vendor shall confirm below their acceptance of all the clauses contained in the specification or otherwise make clarifications or exceptions that shall be noted below:CLIENT: HINDUSTAN PETROLEUM CORPORATION LTD. REF. NO.: 256324-500-RQ-MEC-006 Rev. B CLAUSE CONFORMS ALTERNATIVE NO. Y/N Y/N 1.0

VENDOR REF. NO.

CLARIFICATION

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 2.0 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4.0 4.1 4.2 4.3 5.0 5.1 5.2 5.3 5.4 6.0 7.0 7.1 7.2 P:\Andheri\IndiaProject\256324 HPCL- LPG\10 Procurement\TENDER\16 Piping Works Tender\Final\Annexures- Piping Tender\Annexure3\MDS,Specs-Mech\Editable\Tech. Spec.for Propylene Compressor.doc

VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006

Rev: B

CLIENT: HINDUSTAN PETROLEUM CORPORATION LTD. REF. NO.: 256324-500-RQ-MEC-006 Rev. B CLAUSE CONFORMS ALTERNATIVE NO. Y/N Y/N 7.3

Page 21 of 26

VENDOR REF. NO.

CLARIFICATION

7.4 7.5 8.0 8.1 8.2 9.0 10.0 10.1 10.2 11.0 12.0 Appendix A Appendix B Appendix C Appendix D

Appendix D: 1.0

Instrumentation Design Requirements

Hazardous Area Classification & Protection

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• •

•

Rev: B

Page 22 of 26

Instruments located in hazardous area shall be certified to meet or exceed the electrical hazardous area defined by Area classification. All instruments shall comply as per hazardous area classification as mentioned in the mechanical datasheets. Instruments certified for use in the specified hazardous area classification shall be recognized by authority like FM, CENELEC, PTB, BASSEFA, ATEX etc. All solenoid valves and where IS circuits are not available due to higher voltage level shall be explosion proof and certified for use in specified hazardous area. Each electrical equipment to be used in Hazardous shall be marked with type of protection, gas group and temperature class as well. 2.0

Ingress protection / Weather Proof

The Following minimum degree of Protection as per IEC 60529 shall apply to all the Instrumentation equipment. • Indoor Equipment/Panel IP 42 • Outdoor Equipment/Panel IP 65 In addition to the above, field Instruments located outdoors, exposed to direct sunlight and not meeting the plant environmental conditions shall be protected with sunshades. 3.0 • • • • • •

•

•

•

•

•

General Requirement for Instrument and Control System

Bidder shall provide all transmitter of SMART, two wire type, 4-20 mA output with HART protocol, 24 VDC loop powered, with local digital indicator. Transmitter shall have +/- 0.25% of full scale accuracy as minimum & Gauge shall have +/-1% of full scale accuracy as minimum. The identifying tag number shall be neatly & clearly marked on each instrument. Dial size of Pressure gauge shall be 150 mm and Temperature gauge shall be 100mm. The scale plates shall be aluminium or laminated plastic with white face & black figures. Pressure gauge and Temperature gauge range shall be within 75% of full scale range. Pressure Gauge exposed to vacuum shall be capable of withstanding full vacuum. Instruments shall meet the minimum requirements of IP 65 for ingress protection in accordance with IEC 60529. In general, no process switches shall be used, instead transmitters with local indication shall be used. All instruments shall be individually valved by block and bleed valve at the tap off to allow depressurization, in-place testing and maintenance of the instrument without shutting down the equipment/package unit. Cable entry to all instruments shall be ½ inch NPT. EExd certified adaptors are acceptable where ½” NPT cable entries are not provided. . Spare cable entries shall be suitably plugged as per the hazardous area classification with stopping plugs. Materials of construction for instrument equipment shall be compatible to the corrosion resistance, pressure and temperature conditions of the process fluids handled. Generally, all instrument wetted parts, in contact with the process fluid shall be SS316 (minimum), or of a material equal to or better than that of the related vessel or line. Solenoid valve coil shall be rated for continuous with class F insulation. In general, Solenoid valves shall be certified EEx”d” for Zone 1 applications. Solenoid coils shall be of 24V DC, low power consumption, 12 W maximum. It shall be provided with suppression diode mounted in solenoid assembly. Proper access shall be provided from grade or Platform for field devices (Transmitters, Valves, Temperature sensors etc) for operation & maintenance. If necessary, additional maintenance platforms specifically for instruments shall be provided.

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Normal mode of operation for the unit shall be start/stop from local panel. For all differential pressure (level and pressure) instruments, single block and bleed type valves shall be provided for pipe / vessel class up to 600# Vendor shall provide configuration HART extractor files (DTM) for all HART transmitters. For the Instrument process connection details refer to the Doc: - 254624-500-SP-INT-002 4.0

The Supplement Requirements for Supply / Services of Instrument and Control Packaged equipment.

Instrument data sheets shall be prepared by the vendor for all package unit instrumentation as per MMCI format (Draft format attached) and submitted to the Owner/Consultant for approval. Instruments on the package unit shall be supplied as per specifications and from Approved vendor list. Vendor shall submit brief description regarding various controls in the package along with the offer. The Vendor shall clearly highlight any exceptions to our specifications in their offer. Vendor shall include in his scope of supply documentation and calibration certificates for all the instruments supplied in the package unit. 4.1 •

• •

•

• • • • • • •

All pressure gauges shall have 1/2" NPT (M) connections. Process connections at take off point for pressure transmitters shall be minimum 1/2” for clean Gas/Water/N2 service. The use of reducing bushings to connect pressure instruments to process lines is not permitted. Local pressure gauges shall normally have a weather proof stainless steel case with a solid front and rubber blow-out disc of 25 mm (1") diameter. The lens shall be shatter proof glass. Pressure gauge pointers shall be balanced and provided with a micrometer adjustment so that zero shift may be corrected. All gauges shall be provided with Kg/cm2 indication in black letters on white background. Pressure gauges for pulsating or vibrating service, and on the discharge of all pumps, shall be liquid (Glycerine) filled with internal zero adjustment. The full face shall be covered by the liquid and the filling plug shall act as a blow out seal with internal pressure of 10 psig or greater. Pressure gauges shall be ranged such that normal operating is between 30 – 70% of scale; except on pulsating service where it shall be restricted to 60 % of scale. All pressure gauges shall have SS 316 bourdon tube and movement as a minimum. The pressure and differential pressure measuring instruments shall be located below the taps for liquids and condensable. Pressure Transmitter shall be 24V DC loop powered, 2 wire, with 4 to 20 mA, HART protocol output signal. Over range protection shall be provided for at least 130% the maximum operating pressure. Also a vacuum protection shall be provided for complete vacuum. As far as possible all Pressure switches application shall utilize pressure transmitters. All Pressure and differential pressure measurements in SS 316 construction with block and bleed facility (e.g. using standard 2-valve, 3-valve or 5-valve instrument manifold as applicable).

4.2 •

Pressure

Temperature

Locally mounted indicators/gauges of process temperatures shall be bimetallic thermometers with 100 mm dial, every-angle heads and stainless steel cases.

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006 • •

•

•

•

• •

•

•

• • •

•

Level

Displacer type instrument gauge with transmitter can be used for level measurements including liquid to liquid interface. Level Transmitter shall be 24V DC loop powered, 2 wire, with 4 to 20 mA, HART protocol output signal. Top mounted Level Transmitters shall be used based on Owner/Consultant approval. Other special type of level instruments like ultrasonic type, capacitance type, RF admittance, nucleonic type shall be used as necessitated by application requirements with prior approval from Owner/Consultant. 4.4

•

Page 24 of 26

Temperature sensing elements shall be always mounted in thermo well and all Temperature sensing elements used shall be duplex type. Material for thermowells shall be minimum ANSI type 316 stainless steel, machined from single bar stock in a tapered configuration. Better materials and ratings shall be specified as required by the Piping Material Specification. 3 wire RTD, Pt. 100, shall be used for temperature sensing in Motor bearing / winding applications. The KW rating of the motor shall be the criteria for determining application of temperature sensing in motor. For Equipments having high vibrations RTD's with remote mounted heads shall be provided. Whenever RTDs are provided for motors, they shall supplied completely with rail mounted (inside Junction box) temperature transmitters, 2 wire, loop powered, 24 VDC, 4-20mA, which will be hardwired to OWNER ESD system. Standard thermo well lengths for piping shall be 230mm ( for pipe size ≤ 4” ) or 255 mm ( for pipe size ≥ 6 ). The minimum flange size shall be 2" with pressure rating as per piping class / design pressure. Standard thermowell lengths for pressure vessels shall be 455 mm. Lagging shall be standard length, except where insulation thickness is greater, then lagging shall be 1” longer than thickness of insulation. Refer Annexure-B (Drawing no. 256324-500-INT-5975) for typical Thermowell drawing. Field indicating type transmitters within the sensor termination assembly shall be used to the maximum extent possible. Temperature Transmitter shall be 24 VDC loop powered, 2 wire, with 4 to 20 mA, HART Protocol output signal. The temperature measuring circuit for transmitters for RTD inputs shall be the resistance bridge circuit type. Consideration shall be given to ambient temperature and/or temperature radiation wherever the “in head” transmitter is used. If an “in head” mounting of the transmitter is to be avoided due to this consideration, the transmitter is to be mounted local to the sensor. Calculation shall be provided by vendor for thermowell Vortex shedding resonance (WAKE) frequency to ensure no stress cracking will occur. Wake frequency shall not exceed 80% of the natural frequency of thermowell at maximum fluid velocity. 4.3

•

Rev: B

Safety valves

The overpressure protection devices shall be installed to meet the requirements and sizing of safety devices for vessels, piping and equipment in accordance with the ASME Pressure Vessel Code, Section I and VIII, ANSI B31.3, API-RP520 and API-RP521. Safety and relief valves shall be direct spring loaded type. For liquid service and non-coded duties i.e. thermal relief they can be semi-nozzle with screw connections. Plain closed bonnets shall be specified, with a tapped and plugged vent for easy conversion to balanced type valves. Exposed spring bonnets shall be specified for steam service above 200°C as required by ASME Boiler and Pressure Vessel Code, Section I.

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - LPG TERMINAL Doc No: 256324-500-RQ-MEC-006 •

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• • • • • • •

Page 25 of 26

As a minimum all relief valves shall have carbon steel bodies with stainless steel trim, but in all cases the material shall conform to the piping specification. When the set pressure is within 10% of the normal working pressure, balanced bellow valve shall be used. Screwed connections shall be supplied on valves with inlets 3/4" and smaller. Threaded connections on valves shall be ANSI B1.20.1 pipe threaded ends. Flanged connections shall be provided on valves, 1" inlet size or larger. Minimum inlet rating shall be ANSI Class 150. Valve flanges shall match the rating and facing of mating flanges on vessels or piping. Body flanges shall be in accordance with ANSI B16.5 except for the thickness. Pressure and vacuum relief valves for storage tanks shall normally be of the weight loaded or pilot operated type, and sized in accordance with API 620 and API 2000. 4.5

• •

Rev: B

Installation for Instruments

All instruments installation shall follow API 551. Process tubing between primary pressure connections and instruments or instrument manifolds shall be ½ inch OD, SS 316 tubes, wall thickness 0.035 inch as a minimum. Double Ferrule Swagelok/Parker type fittings in ASTM 316 stainless steel must be strictly enforced as a minimum. Other materials may be used based on process requirement. Where ¼ inch OD connections are required by the instrument or instrument manifold, reducing fitting shall be used at the instrument. Instrument process tubing shall conform to ASTM A269, type 316 stainless steel, seamless, annealed and pickled. Tubing fittings shall be SS316 Swagelok compression type fittings, or Owner/Consultant approved. All compression fittings shall be of double ferrule design. Where SS316 stainless steel is deemed unsuitable, the vendor may propose an alternative, with justification, for approval by Owner/Consultant. Instruments located outside of control panels shall be installed as close as practicable to the process connection and may be surface, yoke, universal 2 inch pipe, or bracket mounted. Instruments shall not be supported by process piping, handrails or equipment subject to vibration. Instrument supports shall be welded where possible not bolted, to the platform. Instrument supports shall not be welded on to the equipment, piping, railings and ladders. Instrument supports shall be located at an elevation where the centre line of the instrument is 1500mm above grade, walkways or platform and within reasonable reach for servicing. 4.6

Special Tools

Vendor shall identify / supply any special tools required for the package unit equipment as part of the package wherever required. Programming/configuration tools shall be provided (if required) & all licensed software / functional / application software shall be included in the supply. Any special cables for data communication shall be supplied along with the configuration tools. 4.7 Spares The Vendor shall include with the quotation following spares along with relevant cross sectional drawings and parts list Mandatory spares recommended by manufacturer Spare parts for start-up / commissioning.

5.0

Approved Vendors List for Instruments

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Page 26 of 26

ELECTRONIC SMART TRANSMITTERS (PT, DPT, LT, TT) SR.NO. 1. 2. 3. 4.

NAME OF VENDOR EMERSON PROCESS MANAGEMENT ENDRESS & HAUSER YOKOGAWA HONEYWELL

PRESSURE GAUGE, LEVEL GAUGE & ACCESSORIES SR.NO. 1 2 3 4 5 6

NAME OF VENDOR WIKA INSTRUMENTS INDIA LTD. PRECISION INDUSTRIES (ASHCROFT ) DRESSER PRODUCTS JERGUSON CLARKE-RELIANCE ENDRESS & HAUSER

JUNCTION BOXES & CABLE GLANDS (FLAME PROOF) SR.NO NAME OF VENDOR 1. 2. 3 4 5 6 7

BALIGA LIGHTING EQUIPMENTS LIMITED FLAMEPROOF EQUIPMENTS PVT. LTD. SUDHIR SWITCHGEARS CEAG STHAL FLEXPRO ELECTRICALS FCG POWER INDUSTRIES PVT. LTD

SOLENOID VALVES SR.NO NAME OF VENDOR 1. 2. 3. 4.

ASCO HERION NORGREN ROTEX

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