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Page 1 of 47
Annexure 1
WATER EXPULSION TEST FACILITY
Quantity: 2 nos.
1.1) Scope
The scope includes supply, installation and commissioning of water
expulsion test facility as per the details given below.
Water expulsion test set up will be used for evaluating the performance of
valves. Schematic of water expulsion system set up is given in Fig.1.1. Water
tank will be pressurised by Nitrogen/Helium through test valve and water will
be expelled from tank. The expelled water will be collected in a collection
trough placed on a weighing machine. The set up shall have the following
systems.
a) Pneumatic circuit, High pressure water tank, Collection tank, weighing
machine etc. as per Figure 1.1.
b) A common Stainless Steel structure to which the entire system shall be
compactly integrated and necessary console (Stainless Steel) for
operation.
Remote operation/control of valves, data acquisition, display and recording
is not under the scope of supplier.
1.2) Test sequence
a) Test article (valve) will be connected to line 1 (ref. Fig1.1) at point A.
b) The water tank will be remotely filled with required amount of water
through the DM water line by opening SV3. The Water level and quantity
filled will be recorded by flow meter as well as level transmitter.
c) Pressure regulator PR1 will be set at 17 bar and then the solenoid valve
(SV1) will be opened to pressurise the tank to 17 bar. And then SV1 will be
closed.
d) The tank will be further pressurised using test article (not scope of
supplier) connected to line 1.
e) After the test duration, valves in the test article will be commanded to
close and pressure inside the tank will be vented using SV2 after closing
MGV3.
Page 2 of 47
Figure 1.1: Water Expulsion test set up schematic
Outlet port suitable for 1 ½”line
Point A
Page 3 of 47
1.3) Specification of items/ components (Quantity mentioned is for one unit)
HIGH PRESSURE WATER TANK (T1 IN FIGURE 1.1)
Quantity : 1 no.
Tag number : T1
Maximum Allowable Working
Pressure
: 25 bar
Volume : 150 litres
Diameter : 500 mm (appx.)
Design code : ASME Section VIII, Div. 1
Material of construction : SS304L/ 316L
Following features shall be provided
2. Safety provisions – Burst disk (BD1) &Safety relief valve (SRV1 in Fig. 1.1).
3. The tank inside shall be cleaned and degreased to Oxygen service standard.
Inside of the tank and outside shall be electro-polished to make free of any
contamination.
4. Material certificate from Govt. Approved lab for all pressure bearing parts shall
be submitted.
5. Ultrasonic test certificate for the plates used for fabrication of tank shall be
submitted.
6. Hydrostatic pressure testing of the tank at 1.5 times the MAWP and pneumatic
testing of the tank at 1.1 times the MAWP as per design code shall be
carried out in presence of LPSC Engineers.
7. 100% Radiography examination shall be carried out for all Butt joints on the
vessels as per ASME Sec. IX with X-ray to 2% equivalent sensitivity. All the
radiographic films shall be submitted to the Department for review
and clearance.
8. Necessary outlets of suitable sizes shall be provided for fixing instruments and
components.
9. Drawing clearance from LPSC shall be obtained before proceeding with
fabrication of the tank.
COLLECTION TROUGH
Water collection capacity : 50 litres (minimum)
Material of Construction : Stainless steel.
Following features shall be provided
1) The size of the collection tank based on the weighing machine platform size.
2) Manual Ball Valve shall be provided at the bottom of tank for emptying the
tank.
3) Top lid with provision for rigidly fixing the outlet plumbing from Tank 1.
4) Provision for lifting the lid also shall be provided.
Page 4 of 47
WEIGHING MACHINE
Capacity : 100 Kg
Platter size : 500 mm X 500 mm (minimum)
Accuracy : less than 10g.
Power supply : 230 V AC, 50 Hz
Data acquisition : In built RS 232/0-10 V DC
Make : Essae or Equivalent
Calibration : Calibration certificate shall be provided
Solenoid Valves
Valve Body material : SS 304 or 304L / 316L
Voltage : 24V DC
Working medium : Helium (for SV1 and SV2)
DM water (for SV3)
Nominal working pressure : 25 bar
Type
Size :
: Direct acting, normally closed
To match with inlet and outlet lines.
Allowable leak rate : Bubble tight shut off
Make : GSR Ventiltechnik, Germany / Jefferson
valves / U V Intl., Chennai
Quantity : 3, (SV1, SV2, SV3 in Figure 1.1)
Certification : Certificate of conformance shall be provided
Analog Pressure gauge
Wetted parts Material : SS 316/ SS 304
Range : 0 – 30 bar
Type : Without oil filling
Dial size : 4 inch
Accuracy : ± 0.5% of Full Scale
Make : Ashcroft/Wika, Germany/Budenberg, UK
Quantity : 2 Nos. (APG1& APG2 in Figure 1.1)
: Party may select a pressure range based on
the nominal working range
Digital Pressure transmitter :
Type of measurement : Absolute
Accuracy : ± 0.075% of span
Pressure unit : bar
Nominal working range : 0 - 30 bar
Diaphragm material : Stainless steel
Material of body of transmitter : Aluminium
Working voltage range : 18 – 32 V
Page 5 of 47
Output signal : 4 to 20 mA.
Local display : Local LCD display
Manifold for communicating pressure line/ vent port with manual valves also shall
be supplied
Communication capability : Through HART communication protocol
Calibration of transmitter : Minimum 5 steps ascending and descending
Make : Smar/ Rosemount/ Rochester
Quantity : 1 No. (PTG1 in Figure 1.1)
Safety Relief Valve
Type : Spring actuated conventional type
Material of Construction, body : SS 304 or 304L / 316
Allowable leak : Bubble tight shut off
Nominal set pressure : 22 bar
Note : Safety valve orifice shall be designed to
relieve the Pressure in case of regulator
failure
Make : Audco India Ltd., Maraimalainagar/Crosby
Valve &Engg Co. Ltd., England/Tyco Sanmar
Ltd., Chennai/IMI Bailey Birkitt Ltd.,
England./Butec
Quantity : 1 No. (SRV1 in Figure 1.1)
Needle Valve
Type : Panel mounted
Allowable leak : Bubble tight shut off
Working medium : Helium (for NV1, NV2 and NV4)DM Water
(for NV3)
Size : To match with inlet and outlet line sizes
Handle type : Bar handle with length of nearly 70 mm
Material : SS 304 or 304L / 316
Working pressure : 25bar (for NV1, NV3 and NV4), Quantity – 3
nos.
: 150 bar (for NV2), Quantity – 1 no
Make : Swagelok/ Parker/Butec
Pressure regulator with filter
Material Body : Brass/ SS
Regulator type : Self venting
Ratio of variation of set pressure
to Variation in inlet
pressure(Decay ratio)
: less than 2%
Leakage across seat in closed
condition
: Bubble tight
Nominal Inlet Pressure : 150- 50 bar
Page 6 of 47
Nominal control range : 1 – 25 bar
Minimum Delta P : 25 bar
Flow Coefficient (Cv) : 0.3 (Minimum)
Filter
Material for body and mesh : SS 304L/SS 316L/321
Body type : Y type/T type.
Filter Element : Pleated mesh
Filter rating : 14 micron (absolute)
Quantity : 1 set. (PR1& F1 in Fig. 1.1)
Make : Tescom /Dutch/Hale-Hamilton/Drastar.
End connection: Swivel union: Threaded swivel union with O-ring face seal. The
companion fitting shall be provided with butt welding ends, which shall be suitable
to mate with the interfacing tubes.
Level Transmitter
Type : Guided wave Radar/Ultrasonic
Probe material : Stainless Steel
Accuracy : ±1 % of FS
Unit : mm/cm
Nominal working pressure : 25 bar
Material of body of transmitter : Aluminium
Working voltage range : 18 – 32 V
Output signal : 4 to 20 mA during normal operation
Local display : Local LCD display
Calibration of transmitter : Minimum 5 steps ascending and descending
Make : Smar/ Rosemount/ Rochester
Quantity : 1 No. (LTG 1 in Figure 1.1)
Flow meter (FM1)
Type : Turbine flow meter with transmitter
Fluid Medium : Water
Size : 1/2 inch
Flow range : 0.2 – 0.8 lit/sec
Operating pressure : 25 bar(g)
Material Body : SS 316
Flange : SS 316
Rotor : 430SS/ ANC21/17-4 PH
Bearing : Tungsten carbide, Sleeve bearing
End connection : Flanged as per ANSI B16.5
Turn down : 10:1
Linearity : ± 0.25% of reading over linear operating
range at water
Transmitter output : 4-20 mA
Page 7 of 47
Calibration : 10 point water calibration by Manufacturer
factory / any approved laboratory traceable
t national standard. Certificate to be
provided.
Make : Hoffer Flow Controls. INC,/ ITT Controls
B.V.,/ Barton Instrument Systems Ltd, Kuppers Electromechanik GMBH/
Cameron Measurement Systems/ Equivalent.
Quantity : 1 No. (FM1 in Figure1.1)
Filter (F2)
Flow rate : 0.4 litre/ second of water (appx.)
Permissible pressure drop : 0.5 bar (appx.)
Material for body and mesh : SS 304L/SS 316L/321
End connection : Flanged
Filter Element : Pleated mesh
Body type : Y type/T type
Filler rating : 100 micron (absolute)
Quantity : 1 no.(F2)
Make : Ultrafilters, Bangalore/Puronics Systems , Bangalore/Classic filters
Certification : Certificate of conformance shall be provided
Manual globe valve (MGV1, MGV2 & MGV3)
Application : Isolation
Material : SS 304/316
Permissible leak across seat : Bubble tight
Working pressure : 5 bar (MGV1) 25 bar (MGV2 and MGV3)
Fluid Medium : Water (MGV1, MGV3), Helium (MGV2)
End connection : Flanged (ANSI B 16.5).
Size : To match with inlet and outlet pipeline sizes. Body with full port.
Make : AMPO Spain, Flow Serve USA, Weka AG
Switzerland, IRI Ireland SA, France, L&T
valves, Chennai, Niton, Poyam valves
Certification : Certificate of conformance shall be provided
Tubes
Material : SS 304 or 304L / 316
Size : As per Figure 1.1. Thickness shall be
selected based on operating pressures.
Make : Sandvick, Swagelok, Tubacex
Page 8 of 47
1.4) TERMS AND CONDITIONS FOR ANNEXURE 1
1) An engineering layout drawing as per given schematic drawing shall be
prepared by the party and submitted for necessary approval before staring
the work.
2) Certificate of conformity for major items shall be provided along with the
unit.
3) Circuit diagram of the unit shall be neatly marked on a panel.
4) The total system shall be integrated as a unit. Sufficient space shall be
provided between operating knobs/ handles during design for easy operation.
5) Pneumatic leak check: After completion of the integration, the unit shall be
subjected to pneumatic leak test with Nitrogen gas up to maximum operating
pressure of the unit and necessary certificate shall be issued by the
manufacturer. Snoop solution shall be used to detect the leak.
6) Party shall have previous experience in supply of flow systems. The details
shall be submitted along with quotation.
7) Pre-Delivery inspection: Pre- Delivery inspection shall be carried out by LPSC
engineer after completion of the integration work.
8) Spares: The following indicative flow components shall be supplied as spares.
Apart from this party may quote additional spares if required as optional.
9) Party shall provide compliance matrix for all the points mentioned above.
Wherever parameter is specified with numerals, the reply shall be in
numerals and other statements like “Yes complied or agreed” alone are not
acceptable and such offers shall not be considered.
Sl.
No.
Item Quantity
1 Pressure regulators (PR1 & F1 ) 1 set.
2 Needle valves (NV2 ) 2 nos.
3 Filter (F2) 1 No.
4 Safety relief valve (SRV 1) 1 No.
5 Solenoid valve (SV1) 1 No.
Page 9 of 47
Annexure 2
FILTRATION UNITS & FLUSHING CHAMBERS
Quantity – 4 nos.
2.1) Filtration Units (Quantity 4 Nos.)
Scope of work
The scope includes design, supply, installation and commissioning of Iso-
propyl Alcohol (IPA)/ Water based filtration units and flushing tanks. This
facility will be used for the IPA/Water filtration. Various systems required for
this facility is given below. Detailed process diagram is given in Fig 2.2. All
the systems/components used in filtration systems shall be of high purity
class and these should not generate any contamination. The facility will be
configured as three units namely pressurisation console, Filtration unit and
Control and Instrumentation unit.
a) GN2 pressurisation system (Refer Figure 2.2)
Pressurisation system provides regulated GN2 pressure for IPA/
Water tanks. Inlet pressure of 150 bar will be initially regulated to
intermediate pressure of 40 bar. This is further regulated to around 5 bar to
pressurise IPA/Water tanks. Pressurisation unit shall be configured as stand-
alone unit with SS frames and sheets (electro-polished). The schematic of
the system is given in Figure 2.2.
b) IPA/Water Filtration system (Refer Figure 2.2).
• IPA/Water in IPA/Water drum is pumped to the overhead tank (T1) using
air operated diaphragm pump (P1).
• The overhead collection tank shall have 60litre IPA/Water storage capacity
and shall equip with safety features such as Safety relief valve & Burst
disc.
• A primary filtration system with four staged T-type/Y type cartridge filters
shall filter the IPA/water in T1 and store in T2 which has a capacity of 40
litre.
• Tank 2 shall also have safety features such as Safety relief valve & Burst
disc.
• Primary filtration system (FS2) shall have provision for monitoring
pressure drop across each filter to identify clogging.
• The pressurised IPA/Water in tank 2, shall pass through one more level of
filtration (FS3 inline membrane filters) before being supplied to various
applications and for flushing unit tank.
• All the electro-pneumatic valves in IPA/Water lines will be operated
remotely from control room.
• The circuit shall be designed as per Figure 2.2 and the items/components
shall be sourced from parties given in Table 2 in Section 2.3 only.
List of items required for GN2 pressurisation system, IPA/Water Filtration
system are listed in Table 2 in Section 2.3. The items shall be sourced from
parties given the table only.
Page 10 of 47
c) Control and Instrumentation Unit
Control and Instrumentation unit shall perform the following functions
a) Control of all Electro pneumatic/ Solenoid valves from PC.
b) Acquisition and display of pressure data from transmitters, Fluid level in
tanks from Level indicators etc.
c) Mimic diagrams of the circuit displaying functional status of EP and solenoid
valves.
d) Emergency tank pressure venting options through EP valve.
e) Real time monitoring and control of every component from PC.
The control and instrumentation unit shall be composed of a PLC and PC with
visualisation and control. Automatic operation and control of the system shall be
done through PC. Party must supply a standard PC along with supply. Necessary
cabling between the control and instrumentation unit and the filtration and
flushing system is under the scope of the supplier (Appx. Distance – 7 metre).
Detailed documentation for the electrical wiring and interconnections shall be
provided.
2.2) Test article/tubes flushing chamber (Quantity 4 Nos.)
This unit is for flushing the test article mainly tubes. The item to be flushed/
cleaned shall be placed on a platform which will be closed after placing the test
article and connecting the inlet line. The system shall have an inlet fluid line with
four number of outlets to connect test article/tubes. The tube connections shall
be designed to withstand 40 bar pressure. The flushed out IPA/ water will be
drained through the grated steel platform on which the item is placed. The
flushed out IPA will be drained out from the system through an outlet drain
valve. The overall size and other specifications of the Flushing/ Cleaning
chamber is given in Table1. An overall layout of the item is as per Figure 2.1.
Table 1: Specification of test article flushing chamber
Sl.
No.
Parameter Requirement
1 Overall size 1.5m X 0.8m X 0.8m (Depth)
(Approx.)
2 Tube cleaning chamber size As per Figure 2.1
3 Maximum tube pressure 40 bar
4 Material of construction of body and
grating
Stainless steel (SS 304/316)
SS sheet thickness : 2 mm (min.)
5 The top lid of the chamber shall be hinged and shall be made of
Polycarbonate on Aluminium frame.
6 Provision for collecting the flushed fluid shall be provided as per Fig.2.1.
7 Outlet with ball valve for shall be provided for drain.
8 There shall be provision for locking the door mechanically
9 Castor wheels: Castor wheels with locking mechanism shall be provided.
10 An overall schematic of the item is provided in Figure 2.1.
Page 11 of 47
Figure 2.1: Test article flushing chamber
Page 12 of 47
2.3) Specification of Items/ Components for IPA/ Water Filtration units
Table 2: List of Items for GN2 pressurisation system, IPA/Water Filtration system
Sl.
No.
Item (Quantity mentioned is for one unit only.) (Refer Figure 2.2)
1 Needle valves
Type : Panel mounted Allowable leak : Bubble tight shut off
Handle type : Bar type handle with 70 mm minimum length. Material : SS 304 or 304L / 316 Make : Swagelok/ Parker/ Thompson
Nominal working
pressure
Quantity
150 bar 1 Nos. (NV1)
40 bar 4Nos. (NV2,3,4,10)
10 bar 2 Nos. (NV11,12)
5 bar 7Nos. (NV5,6,7,8,9,13,14)
2 Solenoid Valve
Valve Body material : SS 304 or 304L / 316 Voltage : 24V DC Type : Direct acting, Normally closed
Allowable leak rate : Bubble tight shut off Nominal Working pressure : 5 bar
Quantity : 2 Nos. (SV1 and SV2) Make : GSR Ventiltechnik/ Jefferson / U V Intl.
3 Check Valves Working medium : Isopropyl Alcohol/ Water Body Material : SS 304 or 304L / 316
Nominal working pressure : 5 bar Quantity : 2 Nos. (CV1 and CV2)
Make : Swagelok/ Novaswiss/ Haskel
4 Safety relief valve
Material of Construction, : SS 304 or 304L / 316 body Allowable leak : Bubble tight shut off
Note : Safety valve orifice shall be designed to relieve the pressure in case of regulator failure
Make : Thomson/Swagelok/Butec
Nominal Set Pressure Quantity
44 bar 1 Nos. (SRV1)
11 bar 1 Nos. (SRV3)
5.5 bar 3 Nos. (SRV2,4,5)
Page 13 of 47
5 Electro Pneumatic Valve (EP Valve) Working medium : IPA/ Water
Application : ON/ OFF Pattern : Globe valve
Actuation : Electro-pneumatically operated Inlet & outlet size : ½ inch Nominal working pressure : 5 bar
End connection : Flanged. Normal position : closed
Command pressure : less than 10 bar Material of Construction : Body and Bonnet : ASTM A 182 Gr. F 304L/ 316 L / 321
Design code : BS 15762/ BS 1873/ API 6-D/ ASME B16.34 Test Code : BS12266 Part 1/ API 598/ ASME B16.34
Certificate of conformance shall be provided.. Limit switch for the remote ON/OFF status indication shall be provided.
Actuator
Type : Linear actuator, diaphragm/piston type, spring
return, fails safe for globe valves. Normal position : Closed Command gas : GN2 at 6 to 7 bar.
Solenoid
3 way, Normally closed, SS316 body, 7 bar acting pressure, 24V DC, single coil, continuous energisation.
Status Switch Type : Cylindrical Inductive Type Proximity Sensor
(switch).Explosion proof type. Electrical Configuration : DC, 2 wire Nominal Voltage : 8 V
Operating Voltage : 5 – 25 V
Quantity : 7 (EPV1to 7 in Figure 2.2) Make : AMPO Spain, Flow Serve USA, Weka AG
Switzerland, IRI Ireland SA, France, L&T valves,
Chennai. Butec.
6 Digital Pressure transmitter
Type of measurement : Gauge, Explosion proof type. Accuracy : ± 0.075% span
Pressure unit : bar Nominal working range : 0 - 40 bar Diaphragm material : Stainless steel
Material of body of transmitter: Aluminium Working voltage range : 18 – 32 V
Output signal : 4 to 20 mA during normal operation Local display : Local LCD display Manifold for communicating pressure line/ vent port with manual valves
Page 14 of 47
Communication capability : Through HART communication protocol Calibration of transmitter : Minimum 5 steps ascending and descending
Make : Smar / Rosemount/ Rochester. Quantity : 2 Nos. (DPT1 & DPT 2 in Figure 2.2)
7 Manual Globe Valve
Nominal Working pressure : 5 bar( MGV1 to 3) Fluid Medium : IPA/ Water Actuation : Hand – operated (Manual)
Application : Isolation Permissible leak across seat: Bubble tight as per API 598 or Rate A of BS 12266
Part 1. End connection : Flanged. Inlet & outlet size : ½ inch.
Material of Construction :
Body and Bonnet : ASTM A 182 Gr. F 304L/ 316 L / 321 Design code : BS 15762/ BS 1873/ API 6-D/ ASME B16.34 Test Code : BS12266 Part 1/ API 598/ ASME B16.34
Tests
Certificate of conformance shall be provided. Quantity : 3 Nos. (MGV1, MGV2, MGV3)
Make : AMPO Spain, Flow Serve USA, Weka AG Switzerland, IRI Ireland SA, France, L&T valves, Chennai
8 Analog Pressure gauge Wetted parts Material : SS 316/ SS 304
Type :Without oil filling Dial size : 4 inch
Accuracy : +- 0.5% of Full Scale Note: Party may select a pressure range based on the nominal working range Make: Ashcroft/Wika/Heiss/Bouden Berg
Nominal Working Range
Quantity
0 – 150 bar
1 Nos. (APG1)
0 – 10 bar
3 Nos. (APG3, APG4, APG5 and APG6)
0-50 bar APG 2
Page 15 of 47
9 Pressure regulator. Material : Body – Brass/ SS
Regulator type : Self venting. Regulator handle diameter : 80 to 90 mm
Cv – 0.2 (nominal) Ratio of variation of set
pressure to variation in inlet pressure (decay ratio) : less than 2%
Leakage across seat in closed condition : bubble tight
Make : Tescom /Swagelok/Hale Hamilton/ Drastar
Nominal Inlet
pressure
Nominal outlet
pressure
Quantity
150 bar 0 – 40 bar 1 No. (PR1)
40 bar 0 – 10 bar 1No. (PR3)
40 bar 0 – 5 bar 1No. (PR2)
10 Filter Fluid : Nitrogen
Type : Welded inline Filters Filter element : Pleated mesh SS element
Maximum working pressure : F1 (40 bar), F2 & F3 (5 bar), F4 (10 bar), F5 (150 bar)
Make : Festo/Legris/parker/ Swagelok
Nominal
Pore size (micron)
Quantity
7 4 Nos.
(F1,F2,F3 and F4)
15 1 Nos. (F5)
11 IPA/ Water filters
Type : T-type/Y-type Working medium : IPA/Water
Filter element : Wire mesh type, supported on perforated cartridge. Filter &Cartridge material : SS 304/316 Clogging Indicators: clogging indicators shall be provided for the filter.
Nominal
Pore size (micron)
Working
pressure
Quantity
20 5 bar 1 Nos. (F6 in Figure 2.2)
Page 16 of 47
12 IPA/ Water primary filtration system Type : T-type/Y-type
Number of filters : 4 Working medium : IPA/Water
Filter element : Wire mesh type, supported on perforated cartridge. Grade of filtration : 20 µm, 5um, 1.2 um, 0.4 um Nominal working pressure : 5 bar
Cartridge material : SS 304/316 Clogging Indicators : Separate clogging indicators shall be provided for
each filter. Quantity : 1 Nos. (FS2 in Figure 2.2) Make : Ultrafilters, Bangalore/Puronics Systems,
Bangalore./Classic filters
13 IPA/Water secondary Filtration system Type : Inline Millipore make membrane filters with SS
holder. Number of filters : 4
Working fluid : IPA/ Water Filter Holder : Stainless Steel filter 90 mm holders Grade of filtration : 20 µm. 5um, 1.2um, 0.4 microns
Filter material : Hydrophilic PTFE Nominal working pressure : 5 bar
Quantity : 1 Nos. (FS3 in Figure 2.2)
14 Air operated diaphragm pump
Minimum flow rate : 3 lit/min ( min.) Working fluid : Iso-propyl Alcohol/ Water Quantity : 2 Nos. (P1 and P2 in Fig. 2.2)
The pump shall be rated for handling clean fluids and it should not generate any contamination to the fluid.
15 IPA/ Water tanks Maximum Allowable
Volume& working pressure : 60 litre, 5 bar ( For T1), 40 litre , 5 bar ( for T2) Diameter : 350 mm (appx.) Design code : ASME Section VIII, Div. 1
Material of construction : SS304L/ 316L
Following features shall be provided, - Safety provisions – Burst disk & Safety relief valve (SRV5 for T1, SRV4 for
T2 in Fig. 2.2).
- The tank inside shall be cleaned and degreased to Oxygen service standard. - Material certificate from Govt. Approved lab for all pressure bearing parts
shall be submitted. - Ultrasonic test certificate for the plates used for fabrication of tank shall be
submitted. - Hydrostatic pressure testing of the tank at 1.5 times the MAWP and
pneumatic testing of the tank at 1.1 times the MAWP as per design code
shall be carried out in presence of LPSC Engineers. - 100% Radiography examination shall be carried out for all Butt joints on the
vessels as per ASME Sec. IX with X-ray to 2% equivalent sensitivity. All the radiographic films shall be submitted to the Department for
Page 17 of 47
review and clearance. - Necessary outlets of suitable sizes shall be provided for fixing instruments
and components. - Drawings shall be submitted to LPSC for approval before proceeding with
fabrication of tanks.
16 IPA/Water storage tank (T3 in Figure 2.2) Tank volume : 60 L Material of construction : Poly -propylene ( 15 mm sheet)
Size : 750 mm (L) X 750 mm ( W) X 700 mm (H) Level indicators shall be attached to the tank.
17 Command bottle:
Water capacity : 5 litre Material : SS 316/304 Working pressure : 10 bar
Stamping : ASME U stamped standard bottle. Make : Tobul, Haskel, Maximator.
18 Level Transmitter Type : Guided wave Radar/Ultrasonic
Explosion proof type (Suitable for IPA) Probe material : Stainless Steel Accuracy : ±1 % of FSD.
Unit : mm/cm Nominal working pressure : 25 bar( DLT 1,2 & 3)
Material of body of transmitter: Aluminium Working voltage range : 18 – 32 V Output signal : 4 to 20 mA during normal operation
Local display : Local LCD display Communication capability : Through HART communication protocol
Calibration of transmitter : Minimum 5 steps ascending and descending Make : Smar/ Rosemount/ Rochester. Quantity : 3 Nos. (DLT 1,2,3 in Figure 2.2)
19 Seamless Tubes and Fittings
Material : SS 304 or 304L / 316 Size : ½”tube, thickness shall be for selected considering
operating pressure. Length required per unit : 20m (Approx.) Make : Sandwick, Swagelok, Tubacex
Page 18 of 47
Figure 2.2: Schematic of IPA/Water Filtration and Flushing facility
Page 19 of 47
2.4) TERMS AND CONDITIONS
1) An engineering layout drawing as per given drawing shall be prepared by the
party and submitted for necessary approval before staring the work. The
supplier shall source the items as mentioned in the specification.
2) Certificate of conformity for each element also shall be provided along with
the item.
3) All items shall be cleared by LPSC Engineers before starting the integration.
4) Pneumatic leak check: After completion of the integration, the unit shall be
subjected to pneumatic leak test with Nitrogen gas up to maximum operating
pressure of the unit and necessary certificate shall be supplied.
5) Party shall have previous experience in manufacture and supply of flow
systems. The Purchase order details shall be submitted.
6) Pre-Delivery inspection: Pre- Delivery inspection shall be carried out by LPSC
engineer after completion of the integration work. The system shall be
demonstrated using water as the working medium in the factory. Items shall
be despatched to LPSC only after PDI.
7) Spares: The following indicative flow components shall be supplied as spares.
Apart from this party may quote additional spares if required as optional.
8) Party shall provide compliance matrix for all the points mentioned above.
Wherever parameter is specified with numerals, the reply shall be in
numerals and other statements like “Yes complied or agreed” alone are not
acceptable and such offers shall not be considered.
------------------------------------
Sl.
No.
Item Quantity
1 Pressure regulators (PR1, PR2) 1 each
2 Needle valves (NV1 ) 2 nos.
3 Membrane filter for FS3 Pack of 50 each for each filter
grade.
4 Spare filter elements for FS2 1 No. for each filter grade.
5 Safety Relief Valve (SRV4) 1 Nos.
Page 20 of 47
Annexure 3
PNEUMATIC TEST UNIT WITH GAS BOOSTER
Quantity – 5 Nos.
3.1) General Configuration & Description
1. The Pneumatic Test unit shall be able to provide pressures up to 800 bar.
Inlet pressure of 100 - 150 bar must be boosted to 800 bar. The schematic of the pneumatic unit is given in figure 3.1.
2. The supplier shall integrate gas booster system capable of delivering an outlet pressure of 800 bar. Detailed specification as per table1 in Section 3.2.
3. The unit shall work with Nitrogen/ Helium as media.
4. The gas booster system with components shall be compactly integrated together on a single unit with stainless steel frame & panel and shall have
good workmanship & appearance.
5. Panel drawing approval shall be obtained from LPSC before integration of the
system.
6. The different elements of the system shall be sourced only from the brands specified in Table 1 in Section 3.2.
7. NPT threaded connections shall be avoided wherever possible.
8. Layout of the booster unit and tube laying details are provided in Figure 3.1.
3.2) Specification of items/ Components
Table 1: Specification of items/component for pneumatic test unit with booster
Sl.
No Item (Quantity specified is for one unit) (Refer Figure 3.1)
1
Needle valves
Allowable leak : Bubble tight shut off
Handle type : Bar type with length minimum 70mm
Material : SS 304 or 304L / 316
Make : Swagelok/ Parker / Butec
Nominal working pressure
Quantity
10 bar 2Nos.(Marked as NV4 and NV5)
150 bar 3 Nos. (Marked as NV1, NV2, NV3)
800 bar
9 Nos. (Marked as NV6, NV7, NV8, NV9, NV10, NV11, NV12, NV13,
NV14)
Page 21 of 47
2
Check Valves
Type : Soft seal Poppet type
Poppet material : SS 316
Body Material : SS 304 or 304L / 316
Make : Swagelok/ Novaswiss/ Butec / Parker
Nominal working pressure
Quantity
150 bar 1 Nos. (CV1)
800 bar 1 Nos. (CV2)
3
Filter
Type : T type cartridge filters meeting the flow
requirement of booster with minimum
pressure drop.
Material of construction : Stainless Steel SS 304/316
Make : Festo/Legris/parker/ Swagelock
Nominal working pressure
Nominal Pore size (micron)
Quantity
10 bar 40 1 Nos. (F1)
150 bar 15 1 Nos. (F2)
800 bar 7 1 Nos. (F3)
4
Filter
Type : Inline Filters
Filter element : SS element
Nominal working pressure : 800 bar
Nominal pore size : 7 micron
Quantity : 3 Nos. (F4, F5 and F6)
Make : Haskel/ Legris/ Festo/ Swagelok/Parker
Page 22 of 47
5
Pressure transmitter
Type of measurement : Absolute.
Accuracy : ± 0.075% span.
Pressure range : bar
Diaphragm material : Stainless steel
Material of body of transmitter: Aluminium
Working voltage range : 18 – 32 V
Output signal : 4 to 20 mA.
Local display : Local LCD display
Manifold for communicating pressure line/ vent port with manual valves
shall be supplied.
Communication capability : Through HART communication protocol
Calibration of transmitter : Minimum 5 steps ascending and descending
Make : Smar/Rosemount/Rochester
Nominal working Range
Quantity
0 – 10 bar
1 Nos. (DPT 1)
0 – 150 bar 1Nos.(DPT 2)
0 – 800 bar 2 Nos. (DPT 3 and DPT4)
6
Analog Pressure gauge
Wetted parts Material : SS 316/ SS 304
Type : Without oil filling
Dial size : 4 inch
Accuracy : ±0.5% of Full Scale
Note : Party may select a pressure range based on
the nominal working range
Make : Ashcroft/Wika/Heiss/Budenberg
Nominal Working
Range Quantity
0 – 10 bar 1 Nos. (APG 1)
0 – 150 bar 1 Nos. (APG 2)
0 – 800 bar 2 Nos. (APG3 and APG4)
7
Proportional relief valve
Material of Construction,
body : SS 304 or 304L / 316
Allowable leak : Bubble tight shut off
Make : Haskel/ /Swagelok/ Parker
Nominal Set Pressure& Flow rate Quantity
11 bar.
Flow rate: Based on compressor Flow rate
1 Nos. (SRV 1)
880 bar Flow rate: Based on booster flow rate
1 Nos. (SRV 2)
Page 23 of 47
8
Solenoid Valve
Valve Body material : SS 304 or 304L / 316
Voltage : 24V DC
Type : Direct acting, Normally closed
Allowable leak rate : Bubble tight shut off
Make : GSR Ventiltechnik/ Jefferson / U V Intl.
Nominal working pressure
Quantity
10 bar 1 Nos. (SV3)
150 bar 2 Nos. (SV1 and SV2 )
800 bar 7 Nos. (SV4 to SV10)
9
Pneumatic Gas Booster
Type : Two stage booster
Gas Inlet : 100 - 150 bar
Gas Outlet : 800 bar(min.)
Drive air pressure : Max 10 bar
Piston displacement : 35 ml/ cycle (min.)
Nominal cycling speed : 60 Cycles per minute
Nominal gas flow rate : 0.2 standard cubic meters per minute
minimum at 100 bar inlet, 800 bar outlet, 6
bar drive pressures.
Make : Haskel/ Hydraulics International
Air Pilot Switch shall be provided at inlet (or equivalent system) to stop the
booster when supply pressure falls to the adjusted set point. Also, air Pilot Switch shall be provided at outlet to stop the booster when outlet pressure reaches adjusted set point
10
Gas receiver for Individual units
Water capacity : 3 Liter (min.)
Material : SS 316
Working pressure : 1000 bar (min.)
Stamping : ASME U stamped
Make : Tobul/ Haskel/ Hydraulic International
11
Pressure regulator
Material : Body – Brass/ SS
Regulator type : Capture venting type
Regulator handle diameter : 80 to 90 mm
Ratio of variation of set
pressure to variation in
inlet pressure (decay ratio): less than 2%
Cv of regulator : 0.2 (minimum)
Leakage across seat in
closed condition : bubble tight
Nominal Inlet Pressure : 150 bar (for PR1) and 800 bar (for PR2)
Page 24 of 47
Control range : 1- 10 bar (for PR1), 150 – 800 bar(for PR2)
Quantity : 2 Nos. (PR1 and PR2 in Fig.3.1)
Make : Swagelok/Hale Hamilton/Thomson
12
Seamless Tubes and fittings
Material : SS 304 or 304L / 316
Size : as per Figure 3.1
Thickness : Shall be suitable for line pressures.
Make : Ratnamani, Sandwik, Swagelok, Tubacex,
DK Lok
Page 25 of 47
Figure 3.1: Schematic of pneumatic test unit with booster
POINT ‘A’
Page 26 of 47
QUANTITY AND LINE LENGTH REQUIREMENT
1) Five units are required. All the five units will have the same arrangement for
items shown in box in Figure 3.1. However, the line length after point A will be
different for each of the five units.
2) The cumulative line length of all the five units after point A is approximately
150m.
3.3) TERMS AND CONDITIONS
1) An engineering layout drawing as per given drawing shall be prepared by the
party and submitted for necessary approval before staring the work. The
supplier shall source the items as mentioned in the specification only.
2) Certificate of conformity for each element also shall be provided along with the
item.
3) Calibration certificate for pressure gauges & transmitters shall be furnished
along with the unit.
4) All items shall be cleared by LPSC Engineers before starting the integration of
unit.
5) All pipings and fittings shall be cleaned thoroughly with IPA and purge with air/
nitrogen before the starting the final integration.
6) The inlet/ Outlet and Drive air interfaces on the booster shall be engraved with
appropriate warnings.
7) Circuit diagram of the booster shall be neatly marked on the unit.
8) Sufficient space shall be provided between operating knobs/ handles during
panel design for easy operation.
9) Pneumatic leak check: After completion of assembly, the unit shall be subjected
to pneumatic leak test with Nitrogen gas up to maximum operating pressure
and necessary certificate shall be provided.
10) Party shall have previous experience in manufacture of systems of similar
specification.
11) Pre-Delivery inspection: Pre- Delivery inspection shall be carried out by LPSC
engineer after completion of the integration work. Units shall be dispatched to
LPSC, Valiamala only after PDI.
12) Spares: The following indicative flow components shall be supplied as spares.
Apart from this party may quote additional spares if required as optional.
Page 27 of 47
13) Party shall provide compliance matrix for all the points mentioned above.
Wherever parameter is specified with numerals, the reply shall be in numerals
and other statements like “Yes complied or agreed” alone are not acceptable
and such offers shall not be considered.
Sl.
No.
Item Quantity
1 Pressure regulators (PR2 ) 1 Nos.
2 Needle valves (NV6 ) 2 nos.
3 Filter (F4) 2 No.
4 Safety relief valve (SRV 2) 1 No.
5 Solenoid valve (SV4) 2 No.
Page 28 of 47
Annexure 4
PNEUMATIC DISTRIBUTION SYSTEM
4.1) SCOPE OF WORK
The scope of work include design, fabrication, procurement, supply, installation,
testing, commissioning and demonstration of centralized pneumatic supply
system for supply of Helium and Nitrogen gas including user point consoles and
stainless steel plumbings (tubing) for two Control components Assembly
(Control system & Components) Facilities (ECAT- Earth Storable Component
Assembly & Test Facilities& IFAT- Integrated Fluid Component
Assembly & Test Facilities) at LPSC, Valiamala.
1. There are two centralized pneumatic distribution systems, one for ECAT
and another for IFAT. The centralized pneumatic distribution system shall
supply gaseous Helium and Nitrogen from cylinders to the user points in each
facility. Centralized system for ECAT shall have one helium main console and
one nitrogen main console and for IFAT shall have three helium main consoles
and three nitrogen main consoles connected to respective cylinders. Pneumatic
lines shall be routed from cylinders to main consoles and from these consoles to
the user point consoles.
2. The user points in the clean rooms and other facilities shall be provided with
user point consoles with necessary fluid components as per requirement given
in subsequent sections.
3. The construction of all plumbing shall be with high quality orbital TIG welding
with 100% fusion except for component interfaces and console to plumbing
interfaces. Clearance of the welded joints shall be subjected to radiography
test. The component interfaces and console to plumbing line interfaces shall be
with standard double compression ferrule fittings. All the stainless steel tubes
shall be subjected for pickling and passivation before final assembly as per
Table 7 in Section 4.2.
4. Clearance from LPSC shall be obtained for the detailed design and layout
configuration prior to commencement of fabrication/assembly of the entire
system.
5. Installation, commissioning, integration, testing and demonstration of the entire
system shall be carried out “On Site” basis in LPSC, Valiamala. Main consoles
and user point consoles shall be brought to LPSC as fully integrated.
6. The gas supply line for gaseous helium and nitrogen from the cylinder bank to
the user points shall be of SS tubes (approximate length of 2250 meters) with
½” outside diameter for both ECAT and IFAT. Refer figure 4.1 for ECAT
layout and figure 4.2, 4.3 and 4.4 for the IFAT layout.
7. The gas supply line from gas cylinders to the user point contains approximately
128 nos. of elbow joints and 92 nos. of tee joints.
8. Entire tubing shall be routed (laid) externally on walls both inside and outside
the facility above the window level for easy maintenance purpose. Where ever
required for crossing the wall, suitable holes shall be drilled on the wall. The
Page 29 of 47
holes shall be closed after laying the line using appropriate closing
mechanisms/materials. The entire tubing shall be securely anchored with
suitable anchoring mechanism.
9. Pneumatic supply system shall be provided with appropriate color coding as per
the relevant ISO standard for clear identification by means of stickers. The
tubing shall be anchored/fixed with suitable arrangement for elegant look.
There are three types of consoles
a) Main consoles for GN2 &GHe.
b) User point console for GN2 &GHe.
c) User point console for low pressure GN2.
The details of these consoles are given below.
4.1.1) Main consoles for nitrogen and helium
Quantity of main consoles required in ECAT and IFAT is given below,
Table 1: Quantity of main consoles
Drg. No. Application Qty. (Nos)
Remarks ECAT IFAT
Figure 4.5
Helium gas 1 3 As per Bill of materials in Table 2
in Section 4.1.3
Nitrogen gas 1 3
Total 2 6
4.1.2) Configuration details for gaseous Helium and Nitrogen main consoles
a. The inlet pressure for the main console is 250 bar for Helium, and Nitrogen.
b. The supporting structure for panels at control stations and user point consoles
shall be made up of stainless steel. The stainless steel supporting structure
shall be grouted/ fixed in the wall by the vendor with appropriate anchoring
mechanisms.
c. Vendor shall optimally design the panel sizes and respective final drawings
shall be approved by LPSC, before fabrication and assembly.
d. Complete construction, fittings, tubing in the console shall be made of
stainless steel (SS 316) material and shall be designed with a factor of safety
of minimum four times of operating pressure.
e. Consoles locations shall be provided with schematic diagram of the fluid
circuits with clear identification of valves, etc and its operating positions like
open/close by means of good quality sticker.
f. The following table gives the list of components, brief specifications,
recommended make and materials of construction and the quantity for main
consoles.
Page 30 of 47
4.1.3) List of components for Main console (Refer Figure 4.5)
Note: Nominal size of each panel shall be, 1.0 X 0.7 X 0.4 meters (Approx.)
Table 2: List of components for main console (Quantity mentioned for one console)
Sl. No
Description/Specification of the components
Qty. (Nos.) (GN2/ GHe)
Recommended make
1.
Check Valve (CV1 & CV2) (To avoid flow in reverse direction)
Operating pressure : 250 bar Body material: SS316
Interface size : ½” interface
02
Swagelok/ Parker/ Hamlet/ GCE/ DK-LOK
2.
Gas filter (F1) Operating pressure : 250 bar
Range: 10µ abs Body material: SS316
Type: Metallic, pleated mesh type Interface size : ½” interface
01
Swagelok/ DK-LOK/
Parker/ Norman/ M/s. Puronics Systems,
Bangalore
3.
Gas filter (F2) Operating pressure : 120 bar Range: 5µ abs
Body material: SS316 Type: Metallic, pleated mesh type
Interface size : ½” interface
01
Swagelok/ DK-LOK/ Parker/ Norman/ M/s.
Puronics Systems, Bangalore
4.
Pressure gauge (PG1)
Bourdon tube material: SS316 Pressure range: 0-500 bar
Dial size: 6”, Accuracy: 1% FSO
01
Mass/ Wika/ GCE
5.
Pressure gauge (PG2) Bourdon tube material: SS316
Pressure range: 0-300 bar Dial size: 6”, Accuracy: 1% FSO
01
Mass/ Wika/ GCE
6.
Needle Valve (NV1,2,3,4 and 5) Operating pressure : 250 bar
Material: SS316 Type: Full port Interface size : ½” interface
05
Swagelok/ Parker/ DK-LOK/ Hamlet/ GCE
7.
Pressure regulator (PR) Inlet pressure: 250 bar
Outlet pressure: 0 to 120barmax. CV : 0.3
Body Material: SS316 Diaphragm: SS316 Interface size : ½” interface
01
Tescom/ IMF/ Dutch/ GCE
8.
Safety Relief Valve (SRV1& SRV2) Body Material: SS316
Set pressure :132 bar Interface size : ½” interface
02
Swagelok/ Parker/
Hamlet/GCE/ DK-LOK
9. Tubes and Fittings a. Seamless tube:
Tube size: 1/2” OD, thickness
Page 31 of 47
suitable for the requirement.
(ASTM 269/ equivalent) Material: SS 316 L Operating pressure:250 bar
b. Fittings: Union, Union elbows,
Union tee, reducing unions, cross plugs, bulk heads, caps etc.
Material: SS 316 Operating pressure: 250 bar
Size: As deemed necessary in order to suit the components interface
Sandvik/ Swagelok/ Parker/ Tubacex
Sandvik/ Swagelok/ Parker/ DK-LOK
4.1.4) User point console details
Table 3: User point console details
Drg. No. Gas Line details Qty (Nos.)
Remarks ECAT IFAT Total
Figure 4.6
Helium gas (GHe) 19 18 37 Bill of materials as per Table 4 in Section 4.1.6
Nitrogen gas (GN2) 21 22 43
Total 80
Figure 4.7 Nitrogen gas low pressure (GN2LP)
10 15 25
Bill of materials as
per Table 5 in Section 4.1.7
4.1.5) Configuration for user points consoles
a. The user point consoles in clean room and other facilities shall have regulated
inlet pressure of 120 bar.
b. The user point consoles, for GHe and GN2 shall be comprised of one inlet filter,
one pressure gauge and one needle valve as per section 4.1.6 (Refer Figure
4.6).
c. The user point consoles for GN2 low pressure (GN2LP) shall be comprised of
inlet filter, needle valves, inlet pressure gauge, pressure regulator, safety
relief valve, outlet pressure gauge and outlet filter as per the section 4.1.7.
(Refer Figure 4.7)
d. The user point consoles shall be configured with ½” OD SS tubings.
e. The supporting/ mounting frame/panel shall be made up of stainless steel and
each control panel shall be designed and respective final drawings shall be
approved by LPSC before implementation.
f. The control panels shall be of wall mounting type consisting of specified items
as per section-4.1.6 and 4.1.7.
Page 32 of 47
g. The Safety Relief valves shall be pre-set to 1.1 times of operating pressure
and shall be provided with locking by wire lock after demonstration.
h. The interconnection shall be made up of welded construction with orbital TIG
welding. The weld joints shall be subjected to radiography test and cleared as
per applicable standards.
i. The component interfaces shall be provided with double compression ferrule
joints.
j. The user point consoles are of wall mountable type. Vendor shall provide the
necessary anchoring/fixing mechanism for wall mounting. Vendor shall provide
the proposed overall size of the user point panels with material,
anchoring/mounting provisions, weight etc. at the time quotation.
k. All the user point consoles locations shall be provided with schematic diagram
of the fluid circuits with clear identification of valves etc and its operating
positions like open/close.
l. All the user point consoles shall be identified with proper colour as per ISO
standard by appropriate good quality sticker.
m. Each user point console shall be provided with schematic diagram indicating
the fluid circuits with valves open/close positions of the valves etc.
n. The following(Sections 4.1.6 and 4.1.7) gives the list of components, brief
specifications, recommended make, material of construction and the quantity
for the user point consoles inside the clean room and other facilities.
4.1.6) List of components for GN2/ GHe user point consoles (Refer Fig. 4.6)
Table 4: List of components for GN2/ GHe user point consoles
(Quantity is mentioned for one Console)
Sl. No
Description/Specification of the components
Quantity
(Nos) (GN2/GHe)
Recommended Make
1.
Gas filter (F) Operating pressure : 120 bar
Range: 10µ abs Body material: SS316
Type: Metallic, pleated mesh type Interface size : ½” interface
01
Swagelok/ DK-LOK/
Parker/ Norman/ M/s.Puronics Systems,
Bangalore
2.
Needle Valve (NV) Operating pressure : 120 bar Material: SS316
Type: Full Port Interface size : ½” interface
01
Swagelok/ DK-LOK/ Parker/ Hamlet/ GCE
3.
Pressure gauge (PG) Bourdon tube material: SS316
Operating Pressure: 0-150 bar Dial size: 6”, Accuracy: 1% FSO
01
Mass/ Wika/ GCE
4. Tubes and Fittings � Seamless tube:
Page 33 of 47
Tube size: 1/2” OD, thickness
suitable for the requirement. (ASTM 269/ equivalent) Material: SS 316 L
Operating pressure: 120 bar
� Fittings: Union, Union elbows, Union tee, reducing unions, cross plugs, bulk heads, caps
etc. Material: SS 316
Operating pressure: 120 bar Size: As deemed necessary in order to suit the components
interface
Sandvik/ Swagelok/ Parker/ Tubacex
Sandvik/ Swagelok/ Parker/ DK-LOK
4.1.7) List of components for User point console for Low pressure GN2 (Refer
Figure 4.7)
Note: Nominal size of each panel shall be 0.5x0.5x0.4 meters (Approx.)
Table 5: List of components for User point consoles for low pressure GN2
(Quantity mentioned is for one Console)
Sl.
No
Description/Specification of the
components
Quantity
(Nos)
Recommended
Make
1. Gas filter (F1) Operating pressure : 120 bar Range: 10µ abs
Body material: SS316 Type: Metallic, pleated mesh type
Interface size : ½” interface
01 Swagelok/ DK-LOK/ Parker/ Norman/ M/s.Puronics Systems, Bangalore
2. Needle Valves (NV1,2 and 3)
Operating pressure : 120 bar Type: Full Port Material: SS316
Interface size : ½” interface
03 Swagelok/ DK-LOK/ Parker/
Hamlet/ GCE
3. Pressure gauge (PG1)
Bourdon tube material: SS316 Operating Pressure: 0-150 bar
Dial size: 6”, Accuracy: 1% FSO
01 Mass/ Wika/ GCE
4. Pressure regulator(PR)
Inlet pressure: 120 bar Outlet pressure: 0 to 10 bar max. CV : 0.3
Body Material: SS316 Diaphragm: SS316
Interface size : ½” interface
01 Tescom/ IMF/ Dutch/ GCE
Page 34 of 47
5. Safety Relief Valve (SRV)
Body Material: SS316 Set pressure: 11 bar Spring kit for Relief Valve set
Interface size: ½” interface
01 Swagelok/ DK-LOK/ Parker/
Hamlet/GCE
6. Pressure gauge(PG2) Bourdon tube material: SS316
Pressure range: 0-20 bar Dial size: 6”, Accuracy: 1% FSO
01 Mass/ Wika/ GCE
7. Gas filter (F2) Operating pressure : 10 bar Range: 5µ abs
Material: SS316 Type: Metallic, pleated mesh type
Interface size : ½” interface
01 Swagelok/ Parker/ Norman/ M/s.PuronicsSystems,
Bangalore
8. Tubes and Fittings
� Seamless tube: Tube size: 1/2” OD, thickness suitable for the requirement.
(ASTM 269/ equivalent)
Material: SS 316 L Operating pressure: 120 bar
� Fittings: Union, Union elbows, Union tee, reducing unions,
cross plugs, bulk heads, caps etc. Material: SS 316
Operating pressure: 120 bar Size: As deemed necessary in
order to suit the components interface
Sandvik/ Swagelok/ Parker/ Tubacex
DK-LOK/Sandvik/ Swagelok/ Parker
4.1.8) Tests to be carried out
a. The main consoles for Nitrogen and Helium gas shall be proof pressure tested
for 375bar (1.5 times of 250bar) by isolating the components which are out of
range for this pressure.
b. The user point consoles shall be proof pressure tested for 180bar (1.5 times of
120 bar) by isolating the components which are out of this pressure.
c. Plumbings of GN2 and GHe line originate from gas cylinder and end at main
console shall be subjected to proof test of 500 bar (2 time of 250 bar).
d. Plumbings of GN2 and GHe line start from main console and end at user point
console shall be subjected to proof test of 240 bar (2 time of 120 bar).
e. Leak testing using Helium gas at operating pressure shall meet the specification
of ≤1x10-6Std cc/sec for all the lines including interconnecting lines between gas
Page 35 of 47
bank room and clean room and other facilities. Necessary Helium gas and MSLD
measurement support will be provided by LPSC.
f. The functional capabilities of all the components shall be demonstrated.
g. All the consoles shall be tested and certified for maximum rated operating
pressure independently
4.1.9) List of items to be supplied as spare separately
Table 6: List of Spares
Sl. No
Description/Specification of the components
Recommended make Qty. (Nos.)
1. Check Valve
Operating pressure : 250 bar Body material: SS316 Interface size : ½” interface
Swagelok/ DK-LOK/
Parker/ Norman/ GCE
2
2. Gas filter Operating pressure : 250 bar
Range: 10µ abs Body material: SS316
Type: Metallic, pleated mesh type Interface size : ½” interface
Swagelok/ DK-LOK/ Parker/ Norman/ Hamlet/
GCE
2
3. Pressure gauge Bourdon tube material: SS316 Pressure range: 0-500 bar
Dial size: 6”, Accuracy: 1% FSO
Mass/ Wika/ GCE 2
4. Needle Valve
Material: SS316 Operating pressure : 250 bar
Type: Full Port Interface size : ½” interface
Swagelok/ DK-LOK/
Parker/ Hamlet/ GCE
4
5. Pressure regulator Inlet pressure: 250 bar Outlet pressure: 0 to 150 bar max.
CV : 0.3 Body Material: SS316
Diaphragm: SS316 Interface size : ½” interface
Tescom/ IMF/ Dutch/ GCE 2
6. Safety Relief Valve Body Material: SS316 Set pressure :132 bar
Interface size : ½” interface Spring kit for Relief Valve set
Swagelok/ DK-LOK/ Parker/ Hamlet/GCE
2
7. Gas filter Operating pressure : 120 bar
Range: 10µ abs Material: SS316 Interface size : ½” interface
Type: Metallic, pleated mesh type
Swagelok/ DK-LOK/ Parker/ Norman/
M/s.Puronics Systems, Bangalore
10
8. Needle Valve Material: SS316
Swagelok/ Parker/ DK-LOK Hamlet/ GCE
15
Page 36 of 47
Operating pressure : 120 bar
Type: Full Port Interface size : ½” interface
9. Pressure regulator Inlet pressure :120 bar Outlet pressure: 0 to 10 bar max.
CV : 0.3 Body Material: SS316
Diaphragm: SS316 Interface size : ½” interface
Tescom/ IMF/ Dutch/ GCE 2
10. Safety Relief Valve Body Material: SS316 Set pressure:11 bar
Interface size : ½” interface Spring kit for Relief Valve set
Swagelok/ DK-LOK/ Parker/ Hamlet/GCE
2
11. Pressure gauge Bourdon tube material: SS316
Pressure range: 0-150 bar Dial size: 6”, Accuracy: 1% FSO
Mass/ Wika/ GCE 10
12. Gas filter Operating pressure : 10 bar Range: 5µ abs
Material: SS316 Interface size : ½” interface
Type: Metallic, pleated mesh type
Swagelok/ DK-LOK/ Parker/ Norman/ M/s.Puronics Systems,
Bangalore
2
13. Pressure gauge Bourdon tube material: SS316 Pressure range: 0-20 bar
Dial size: 6”, Accuracy: 1% FSO
Mass/ Wika/ GCE 2
4.1.10) ACCEPTANCE CRITERIA AND WARRANTY
Acceptance Criteria: Final acceptance will be after completion of installation,
successful testing, and demonstration of functionality.
Warranty: All the components used in the modules and total module shall have
warranty for a period of one-year minimum from the date of acceptance.
4.2) GENERAL CONDITIONS
1. LPSC will supply the gas cylinders for Nitrogen and Helium. Hence the supplies
of these items are not part of the scope of work.
2. All the components to be purchased from the standard make as mentioned
above in the section of 4.1.3, 4.1.6, 4.1.7, and 4.1.9 with respective warranty
certificates and valid calibration certificates. The items indicated in the section
4.1.9 as spare shall be supplied to LPSC along with delivery.
3. During execution of work, changes/improvements suggested by the party or
LPSC can be implemented with mutual agreement.
4. Vendor shall arrange necessary support equipment, machines, tools,
accessories, etc. LPSC will not provide anything.
Page 37 of 47
5. All necessary safety precautions to be taken by the vendor during execution of
work and also vendor is responsible for personnel safety of the work force
engaged by him for this work.
6. Detailed technical specification including make, model no. and part number shall
be provided by the party for all the components with certificate of conformance.
7. No inter mixing of components of multi brand for same type of items shall be
allowed to have the warranty and reliability of individual make/brand (For
example in case of supply of valves, all the valves shall be of same
brand/make)
Table 7: Procedure for pickling and passivation of SS tubes
Sl.No. Step Procedure Time
1. Degreasing Using Isopropyl
Alcohol/Tricholoroethylene
10 mins
2. Drying Components are dried at RT 10 mins
3. Alkali cleaning NaOH : 50-100 gm Water : 1000 CC
Temperature : RT
30mins
4. Water rinse Cleaning with water jet till pH
is neutral (6.5-7.5)
05mins
5. Acid pickling Nitrc acid (70%) : 80-100cc
Hydrofluoric acid : 20-30 cc DM/Distilled Water : Remaining
Temperature : RT
15mins
6. Water rinse Cleaning with water jet till pH
is neutral (6.5-7.5)
05mins
7. Passivation Nitric acid (70%) : 200 cc
DM/Distilled Water : 800 cc Temperature : RT
30mins
8. Neutralisation Neutralisation is done in alkaline cleaning solution mentioned in 03
10 mins
9. Water rinse Cleaning with water jet till pH is neutral /7
5mins
10. DM water rinse Cleaning with DM water 5mins
11. IPA rinse Components are rinsed with
IPA for fast drying
5mins
12. Oven drying Components are dried in oven
at 70-800C
60mins
13. Packing and storage Packed in sealed polythene
cover
Notes:
1. The acids, alkalies, solvents always should be of A.R/G.R grade.
2. Fresh solution to be prepared for each batch to carry out pickling & passivation.
Page 38 of 47
Figure 4.1: Layout of ECAT
P R E
C L E A N RO O M 1 6
G H e
G H e
G N 2
G N 2
G H e
G H e
G N 2
G N 2
G N 2
G H eG H e
G H e
G N 2
G N 2
G N 2
G N 2
G N 2
G N 2
G H e G H e
G H e
G H e
G H e
G N 2
G H e
4 0 5 5 ,4
G N 2 L P
G N 2 L P
G N 2 L P
G N 2
G H e
G N 2
G N 2
C L E A N R O O M
C L E A N R O O M - 2
L A Y O U T O F E C A T G N 2
G H e
G N 2
G H e
G H e
G N 2
G N 2
G N 2 L P G H e
G N 2
G N 2 L P
G N 2 L PG N 2 L P
G H e
G H e
G N 2
G N 2
P H
G N 2 L PG N 2 L P
G N 2 L P
N 2
N 2
H e
H IG H P R E S S U R E
C O M P R E S S O R
R O O M
IN S T R U M E N T A T IO N
R O O M
HIG
H P
RE
SS
UR
E T
ES
T
2 1 0 m ²4 2 .4 m ²
5 5 m ²
C H E M IC A L
S U R F A C E
T R E A T M E N T
F A C IL IT Y
E N V IR O N M E N T A L
L A B
P R O O F
T E S T L A BW IR IN G &
W IN D IN G L A B
C L E A N R O O M - 1
T H E R M A L L A B
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Figure 4.2: Layout of IFAT Ground Floor
LAYOUT OF IFAT
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Figure 4.3: Layout of IFAT First Floor
LAYOUT OF IFAT
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Figure 4.4: Layout of IFAT Second Floor
LAYOUT OF IFAT
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Annexure 5
GENERAL TERMS AND CONDITIONS
1. A pre-bid meeting is scheduled to be held on 3rd January 2020 at LPSC Valiamala at 11 AM by inviting the parties who are interested to participate in the two-part tender for giving them an overall idea about the configuration and
installation of Pneumatic test set ups. This is to enable the parties to understand the technical requirements and criticalities involved. Bidders interested to
participate in the pre-bid meeting may register their name before 5 PM, 2nd January 2020 by sending an email to pso_1@lpsc.gov.in or spso_purchase@lpsc.gov.in.
2. This is a two-part tender. Part 1 is Techno commercial bid and Part 2 is price bid.
PART 1 - TECHNO- COMMERCIAL BID
Techno-Commercial Bid shall include the following documents. a. Technical bid addressing each and every specification and these should be
given in compliance statement for all specifications as given in Annexure 6. b. Schedule of deviations, if any from the tender specification shall be
explicitly spelt out. c. A complete technical description, along with catalogues of the various items
shall be provided along with quotation.
d. Company profile of the vendor highlighting the following shall be given along with quotation:
• Infrastructural facilities such as factory area, machineries, equipment, material handling devices, instruments, tools, tackles, etc owned by the vendor.
• Previous experience: Party shall provide details of similar projects undertaken by them in the past for aerospace or similar applications.
Party shall attach relevant contract/ purchase order copies of the customer and other details to substantiate their claims. Party should have executed at least one similar type of project to reputed firms like
PSU’s, Aerospace/Defence/Reputed private industries. • Clientele specifying the clients to whom the vendor has undertaken
similar projects indicating their address, telephone, fax, email, contact person etc.
• Quality management system: If the vendor is certified for ISO
9000:2000 quality management system, a copy of the certificate by the accredited agency shall be produced.
e. Commercial part of the techno-commercial bid shall address the commercial aspects including filling of compliance statement for commercial terms attached as Annexure along with tender.
f. An un-priced price bid format shall also form part of the Part 1 offer.
NOTE: ANY PART OF PRICE BEING PRESENT IN THE PART 1 WILL LEAD TO AUTOMATIC REJECTION OF OFFER.
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PART 2 - PRICE BID
The price bid shall include the following. a. Total cost of design, Fabrication of all test set ups including installation and
commissioning. b. Cost of spares (cost break up showing cost of each spare part) as per our
requirement & any other spares party recommends for trouble free
operation of the facilities. Cost of each spare is mandatory. c. Cost of Non Comprehensive AMC for two years after the warranty period on
yearly basis shall be quoted separately.
3. Department, based on final evaluation may or may not decide to split the order
among parties. Hence, it is mandatory to quote the cost of each type of facilities with their spare and AMC separately in price bid.
4. PAYMENT TERMS: The Purchaser shall make payment of the price as per the
following milestones:
a. The Purchaser shall pay to the Supplier 30 % of the total price, on receipt of purchase order acceptance against bank guarantee. The payment shall be
released after receipt of invoice (commercially certified) by the Purchaser from the Supplier. The following documents shall accompany the invoice
while claiming this milestone payment: a. Order acceptance from the supplier. b. Bank guarantee for the sum of payment valid till the installation and
commissioning of the items at LPSC, Valiamala. b. The Purchaser shall pay to the Supplier 60 % of the total price, on receipt of
all the items at LPSC, Valiamala. The payment shall be released on receipt of all the items and invoice (commercially certified) from the Supplier. The following documents shall accompany the invoice while claiming this
milestone payment: a. Joint declaration by the Purchaser and the Supplier of having successfully
completed the Pre-Delivery Inspection and subsequent clearance certificate.
c. The Purchaser shall pay to the Supplier 10 % of the total price, upon erection
& commissioning of the all the items at Purchaser’s premises. The payment shall be released after commissioning and receipt by the Purchaser of invoice
(commercially certified) from the Supplier. The following documents shall accompany the invoice while claiming this milestone payment: a. Purchaser’s certification of having successfully completed erection and
commissioning of all the units. b. Warranty certificate
c. Performance bank guarantee for 10% of the total price valid over the warranty period
d. Operation and Maintenance Manuals.
5. Delivery: The overall completion period reckoned from the date of release of
purchase order to the date of completion of erection & successful commissioning of the items at LPSC, Valiamala shall be 8 months.
6. The Supplier shall warrant all the items against any faulty material or
workmanship for a period of 12 months from the date of commissioning at the Purchaser’s site.
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7. Spares and service support for 10 years from the date of supply/ installation of the system to be ensured by the party.
8. PERFORMANCE BANK GUARANTEE
The Supplier shall guarantee the successful and satisfactory performance/
operation of all the items under the conditions and for the services specified. As
a performance security, the Supplier shall furnish a performance bank guarantee
for 10 % of the Purchase Order price to guarantee the faithful performance of all
the items with all the specifications and terms specified herein valid for the
warranty period as specified above. On due performance, the performance bank
guarantee shall be automatically cancelled and returned to the Supplier within
30 days after expiry of the warranty period.
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