spec no tata consulting engineers limited · 2013. 12. 9. · tce.6079a-104-02 thermal insulation...

SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION: D TCE.6079A-104-02

THERMAL INSULATION FOR HOT & COLD SURFACES

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FILE NAME: 6079A10402R0.DOC TCE FORM NO. 329 R3

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GENERAL ENGINEERING SPECIFICATION FOR


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CONTENTS

1.0 THERMAL INSULATION OF HOT SURFACES

2.0 THERMAL INSULATION OF COLD SURFACES

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1.0 SCOPE

This specification covers the technical requirements and essential particulars for the supply, application and finishing of the complete thermal insulation for hot equipment, piping systems, flues, ducts, steam generator casing, fixture casing, steam turbine etc. up to an operating temperature of 5650C. This specification is not applicable where the insulation is to be used for dual temperature (both hot and cold) service. Unless specified otherwise in section C and/or data sheet A, the scope of supply of the CONTRACTOR shall include, but not be limited to, the following items :

(a) Insulation materials of all types as specified and required

(b) Finishing materials of all types as specified and required

(c) Auxiliary materials such as binding and lacing wires, wire netting, bands, screws etc., as specified and required

(d) Angles, clamps, lugs etc. for supporting insulation

(e) Weather hoods

(f) Any other material as may be required for making the insulation complete

2.0 CODES AND STANDARDS

2.1 The supply and application of thermal insulation and finishing covered under this specification shall comply with all currently applicable statutes, regulations and safety codes in the locality where it is to be applied. The materials and application shall also conform to the latest editions of the codes and standards listed. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility.

2.2 The following are some of the codes and standards relevant to this specification :

IS 277 Galvanised Steel Sheets (Plain and Corrugated)

IS 737 Wrought Aluminium and Aluminium Alloy Sheet and Strip for General Engineering Purposes

IS 3144 Mineral Wool Thermal Insulation Materials - Method of Test

IS 3677 Unbonded Rock and Slag Wool for Thermal Insulation

IS 3690 Unbonded Glass Wool for Thermal Insulation

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IS 8154 Preformed Calcium Silicate Insulation for Temperatures up to 650°C.

IS 8183 Bonded Mineral Wool

IS 9842 Preformed Fibrous Pipe Insulation

IS 14164 Industrial Application and Finishing of Thermal Insulation Materials at Temperatures above (-) 800C and up to (+) 7500C

BS 5970 Thermal Insulation of Pipework and Equipment (in the Temperature Range (-) 1000C to (+) 8700C)

3.0 GENERAL DESIGN REQUIREMENTS

3.1 All exposed portions of the plant which operate at temperatures of 650C and above during normal operation shall be thermally insulated so that the temperature on the outer surface of the finish does not exceed 600C based on an ambient temperature of 300C in still air conditions, unless specified otherwise in data sheet A.

3.2 Insulation thickness for rock wool and glass wool materials have been indicated in data sheet A. These insulation thickness do not include thickness of finishing materials such as cement sand plaster, aluminium or Galvanised Steel (GS) sheet, binding and lacing wires, wire netting and bands etc.

3.3 Insulation thickness indicated in data sheet A shall be regarded as the minimum requirement. BIDDER may provide higher thickness in order to meet the design criteria indicated at para 3.1.

3.4 Equipment and piping which are not insulated from heat conservation considerations but have a surface temperature exceeding 650C shall be insulated for personnel protection when :

(a) The bottom of the equipment or pipe is less than 2 metres from the ground or working floor or platform or walkway, or

(b) The equipment or pipe, or parts thereof, are within 600 mm from a working floor or platform or walkway

Equipment and piping to be insulated for personnel protection, shall be insulated to the extent that the temperature on the outer surface of the finish does not exceed 600C.

3.5 Equipment in horizontal position, which are to be insulated for personnel protection, shall be fully insulated when the equipment outside diameter is less than 1250 mm and to a height of 2 metres from the working floor or platform for larger sizes.

4.0 MATERIALS

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4.1 GENERAL

4.1.1 All materials shall be new and fresh, incombustible, fire retardant, rot-proof, non-hygroscopic, vermin proof, fungus proof, non-injurious to health, chemically inert, non-corrosive to steel and aluminium (even if soaked in water for extended periods) and shall be guaranteed to withstand continuously and without deterioration the maximum temperature to which these shall be subjected to under the specified applications.

4.1.2 The insulation materials and any component of the finished insulation job shall not react chemically, singly or in combination, with water or moisture to form substances that are more actively corrosive to applied surface than water or moisture alone.

4.1.3 In order to protect the workers from the hazards of insulation materials, suitable protective gadgets shall be provided. Required safety precautions shall be taken during handling and application of insulation.

4.1.4 The insulation material shall be kept dry at all times during transport, storage and installation. Decking and covering tarpaulins alone are not adequate for any length of time and shall not be allowed except in extreme emergencies and only for short period. Stacking of insulation materials directly on ground shall not be done. No wet insulation shall be installed. If wet insulation is present, it shall be removed and replaced with new dry insulation. The insulation may be protected with plastic film but shall be vented to prevent sweating.

4.2 INSULATION MATERIALS

The insulation material shall be one or more of the following types as specified in data sheet A.

Material Description Material Code

4.2.1 Unbonded rock wool mattress as per IS 3677 Type 2 at an application density of 150 Kg/M3 for temperatures 65 to 3990C

U150


4.2.2 Unbonded rock wool mattress as per IS 3677 Type 2 at an application density of 200 Kg/M3 for temperatures 400 to 5650C

U200

4.2.3 Unbonded glass wool mattress as per IS 3690 Type 2 at an application density of 80 Kg/M3 for temperatures 65 to 5500C

U80

4.2.4 Lightly resin-bonded rock wool mattress as per IS 8183 at an application density of 100 Kg/M3 for temperatures 65 to

L100

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3990C

4.2.5 Lightly resin-bonded rock wool mattress as per IS 8183 at an application density of 150 Kg/M3 for temperatures 400 to 5650C

L150

4.2.6 Bonded rock wool pipe sections as per IS 9842 at an application density of 144 Kg/M3 for temperatures 65 to 5650C

PS1

4.2.7 Calcium silicate preformed blocks, slabs and pipe sections as per IS 8154 at an application density of 200 Kg/M3 for temperatures 65 to 5650C

CS1

4.3 FINISHING MATERIALS

The finishing material shall be one or more of the following types as specified in data sheet A.


4.3.1 Portland cement and inorganic fibre with water proofing compound at an application density of 1050 to 1100 Kg/M3

FC

4.3.2 Aluminium sheet as per IS 737, designation 31000, condition H3 for insulation material codes U150, U 200 and U 80

AL1

(a) Insulation outside diameter above 450 mm - sheet thickness 18 SWG

(b) Insulation outside diameter 150 to 450 mm - sheet thickness 20 SWG


(c) Insulation outside diameter below 150 mm - sheet thickness 22 SWG

(d) Flues and ducts - sheet thickness 1.0 mm

(e) Steam generator casing and rear wall enclosure - sheet thickness 1.6 mm

4.3.3 Aluminium sheet as per IS 737, designation 31000, condition H3 for insulation material codes L100, L150, PS1 and CS1

AL2


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4.3.4 GS sheet as per IS 277, designation GP, for insulation material codes U150, U200 and U80

GS1

(a) Insulation outside diameter above 450 mm -sheet thickness 20 SWG






4.3.5 GS sheet as per IS 277, designation GP, for insulation material codes L100, L150, PS1 and CS1

GS2





(e) Steam generator casing and rear wall enclosure-sheet thickness 1.2 mm

4.4 AUXILIARY MATERIALS

4.4.1 Binding and Lacing Wires

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(a) For temperatures up to 3990C : Annealed GS 20 SWG

(b) For temperatures from 400 to 5650C : Annealed SS 304 20 SWG

4.4.2 Wire Netting

(a) For temperatures up to 3990C : 20 SWG GS wire with 20 mm hexagonal opening

(b) For temperatures from 400 to 5650C : 20 SWG SS 304 wire with 20 mm hexagonal opening

4.4.3 Bands

(a) For securing insulation material : 20 SWG GS, 20 mm wide

(b) For securing aluminium and GS sheets

: 24 SWG anodised aluminium or SS 304, 20 mm wide

(c) For securing aluminium foil on SS surface

: 24 SWG aluminium, 20 mm wide

4.4.4 Screws

Screws shall be of self-tapping type and shall be of aluminium or stainless steel for aluminium sheets and GS for GS sheets.

5.0 INSULATION OF EQUIPMENT AND PIPING (EXCEPT STEAM TURBINE)

5.1 GENERAL

5.1.1 The application of insulation shall be made in a professional manner. The insulation shall be applied to all surfaces when these are at ambient temperature. Ample provision shall be made for the maximum possible thermal movement and the insulation shall be applied in a manner which shall avoid breaking or telescoping due to alternate periods of expansion and contraction. A single layer of insulation shall not be more than 75 mm thick.

5.1.2 Insulation shall be applied after all leak tests on equipment and piping are over and the section of the plant has been specifically released by the PURCHASER for such work. If insulation has to be applied before the leak test, all welded and flanged joints shall be left exposed and insulated after satisfactory completion of the leak test.

5.1.3 All surfaces to be insulated shall be clean and dry before the insulation is applied. The surfaces shall be cleaned of all foreign material such as scale,

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dirt, rust and paint, by the use of steel wire brushes and steel scrapers, where necessary. Where a surface is not free of paint the CONTRACTOR shall notify the PURCHASER of the condition for remedial action. The insulation shall be applied after remedial action, suggested by the PURCHASER, has been taken by the CONTRACTOR.

5.1.4 Carbon steel and low alloy steel surfaces to be insulated shall be thoroughly cleaned by wire brushing. For operating temperatures below 125°C, the surface shall be given one coat of heat-resistant aluminium paint of coating thickness not less than 20 microns.

5.1.5 All stainless steel surfaces to be insulated shall be protected against chloride attack as follows :

(a) For operating temperatures up to 500°C, the stainless steel surfaces shall be mechanically separated from insulation surface by wrapping with 0.1 mm (42 SWG) thick aluminium foil. Application and other details shall be same as those described for steam traced piping in para 5.2.6.

(b) Above 500°C, the metal surface shall be given one coat of heat-resistant aluminium paint of coating thickness not less than 20 microns.

5.1.6 All sheet metal joints shall be sealed with bitumastic paint and made effectively weather and water-proof. All flat surfaces shall be adequately sloped to prevent pools of water collecting. The sheet shall be protected internally with 2 coats of bitumastic paint.

5.1.7 All actions shall be taken to complete the application of finishing on exposed surfaces covered with insulation before closing the day’s work. If this is not practicable, adequate precautions shall be taken to protect the insulation from weather, for example by wrapping it with polythene sheet, roofing felt or other approved material.

5.2 INSULATION ON PIPING

5.2.1 All vertical pipes shall be provided with suitable insulation supports to prevent the insulation from collapsing due to its own weight. Suggested method is indicated in TCE.M4-104-54. Any welding required, shall be carried out by the CONTRACTOR with the prior permission of the PURCHASER and only under his direct supervision. Where welding is not permitted, suitable clamped supports shall be used. The insulation shall be applied starting from bottom up. Mattress type insulation materials shall be clamped from top.

5.2.2 If rock wool preformed pipe section insulation material is used, the sections shall be fitted closely to the pipe. Where there is more than one layer of insulation material, all joints shall be staggered. Each section shall be held in place by circumferential bands or wires at spacing not greater than 450 mm. If mattress is used, the insulation shall be formed to fit the pipe and applied with edges pulled together tightly at the longitudinal joint and secured by lacing wire. The insulation shall be turned to bring this joint to the lower side. Adjacent

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length shall be butted closely and laced together with lacing wire. Mattress insulation shall be backed-up by wire-netting on one side. For insulation thickness of more than 75 mm, where application shall be in two or more layers, each layer of mattress shall be backed up with wire netting.

5.2.3 When calcium silicate is the insulation material, all pipes up to and including 300 mm nominal diameter shall be covered with preformed rigid sections to form a robust pipe covering. Larger sizes shall be covered with segmental blocks moulded to a diameter to fit the curved surfaces. All sectional and segmental insulation shall be carefully fitted to the pipes with side and end joints butted tightly and securely wired in place at spacing not greater than 400 mm.

5.2.4 The ends of all wire loops shall be firmly twisted together with pliers, bent over and carefully pressed into the surface of the insulation. All calcium silicate insulation joints shall be fully staggered and any cavities between joints and cracks if any in both inner and outer layers shall be filled with insulating cement.

5.2.5 When preformed insulation material is used, the number of segments shall be minimum and all joints shall be filled with the same basic insulation material in loose form.

5.2.6 The thickness of insulation for steam traced lines shall be the higher value as determined by the size and temperature of the steam tracer and the service line. The tracer shall be tightly wired to the main pipe at intervals of 500 mm. Aluminium foil not less than 0.1 mm thick (42 SWG) shall then be wrapped around both the pipe and tracer with an overlap of at least 25 mm and wired or banded in place. This is to prevent insulation from separating the pipe and tracer and to provide a hot air enclosure and also to provide a barrier to radiant energy leaving the pipe. The insulation proper shall then be fitted and finished in the normal way. Cross-section of preformed insulation shall be suitable for accommodating tracers.

5.2.7 All insulation shall be protected by a finishing material as specified in data sheet A. The sheets shall be installed with the longitudinal lap joints at 45° below the horizontal for horizontal pipes and the joints sealed with bitumastic paint. On vertical pipes the sheets shall be applied working from bottom up. Each section of sheets shall have a minimum overlap of 50 mm longitudinally and circumferentially. Each circumferential joint shall be made weather-proof by securing with a band of sheet material and sealing with bitumastic paint. Longitudinal lap joints shall be fixed with screws at approximately 150 mm centres.

5.2.8 Weather hoods shall be provided for insulated piping passing through roof, and external walls as per TCE.M4-104-50.

5.3 INSULATION ON PIPE FITTINGS, VALVES AND SPECIALITIES

5.3.1 All pipe fittings, valves and specialities shall be covered with the same type and thickness of insulation as specified for the adjoining pipe, with the special

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provisions and/or exceptions as listed below. On pipe fittings, insulation outside diameter shall be same as the outside diameter of adjacent pipe insulation.

5.3.2 Unless specified otherwise in section C or data sheet A, all valves and specialities, shall also be insulated to the same extent as the adjacent piping.

5.3.3 Unless specified otherwise in section C, valves and specialities of sizes 100 mm NB and larger shall be provided with removable box type insulation. Box shall be fabricated from sheet material specified for adjoining pipes. Pipe insulation on adjoining flanges shall be stopped at one bolt length plus 25 mm before flange to permit removal of the bolts and nuts. The insulation shall be applied after the finish has been applied over insulation on the adjacent piping. A typical arrangement is shown in TCE.M4-104-51.

5.3.4 Flanged joints shall be insulated. Arrangement shall be similar to that for valves shown in TCE.M4-104-51. Unions shall not be insulated.

5.3.5 Non-metallic expansion joints shall not be insulated. Metallic expansion joints identified in bill of materials shall be insulated.

5.3.6 Traps shall not be insulated. However, trap discharge lines and safety valve discharge lines shall be insulated for personnel protection only.

5.3.7 Pipe hanger clamps shall be covered with insulation along with the pipe. Upper bolts of three-bolt hanger clamps shall not be insulated. A typical arrangement is shown in TCE.M4-104-53. On piping outdoors, a weather hood packed with waterproof sealing material shall be supplied and installed.

5.4 INSULATION ON EQUIPMENT

5.4.1 Where the insulation material is in the mattress form, cleats in the form of wire nails or nuts or angles and flats for supporting the insulation material, shall be welded to the equipment by others. If wire nails are to be used as insulation cleats, these shall be bent and secured with the metal fabric of the mattress, after the insulation has been applied. Where insulation cleats are in the form of M6 and M10 nuts, the CONTRACTOR shall supply and install bolts of suitable length for fixing the insulation. The insulation applied to equipment shall be reinforced with wire netting. One course of wire netting shall be applied to the surface of the equipment and each layer of insulation shall be backed up with wire netting. All irregularities of the surface shall be filled and levelled over with insulating cement. All mattress joints shall be butted tightly and the mattresses shall be secured with 20 mm wide 24 SWG GS bands at 450 mm centres. After banding, all mattress edges shall be laced tightly.

5.4.2 When calcium silicate is the insulation material, segmental blocks moulded to fit the curved surfaces shall be used for cylindrical portions of the equipment. Flat blocks shall be used for equipment of diameter greater than 2500 mm and for flat surfaces.

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5.4.3 For equipment up to 2500 mm in diameter and temperatures up to 200°C, the blocks shall be cut and fitted so that the inner diameter of insulation is 13 mm greater than the equipment outside diameter to take care of equipment circumferential expansion. The blocks shall be applied tightly butted and sealed with insulating cement. The insulation shall be secured by circumferential bands in such a way that tension of the bands produces compression on the butt edges rather than on the surface towards the equipment.

5.4.4 For equipment either above 2500 mm in diameter or at temperatures above 200°C, a 25 mm thick rock wool fibre mattress insulation shall be applied around the equipment prior to the application of calcium silicate. Calcium silicate blocks must be cut and fitted to the outside radius of the equipment plus the thickness of the rock wool spacer insulation. The insulation, when installed, shall not compress the fibrous mattress.

5.4.5 All equipment, unless specified otherwise, shall have a smooth aluminium or GS sheet finish as specified in data sheet A, applied in a manner similar to that specified for piping. For fixing of aluminium or GS sheets, spacer rings at 1000 mm centres shall be welded to the equipment by the CONTRACTOR. If welding is not permitted, spacer rings shall be suitably clamped. Spacer ring material shall be the same as that of the surface to be insulated. All vertical and horizontal sheets shall be overlapped a minimum of 75 mm. The lapped joints of adjoining sections of sheets shall be secured with screws. On all equipment above 2500 mm diameter and flat surfaces the sheet shall be further secured by circumferential bands at approximately 1000 mm centres. Each sheet joint shall be sealed with bitumastic paint. The roof sections shall overlap the side walls to prevent water seepage between insulation and the equipment wall. Side wall sheets shall be securely banded at intersections of the side wall and roof sections.

5.4.6 All equipment manholes, hatches, bolted or screwed cover plates, flanged ends etc. shall have removable box type insulation, with same thickness of insulation as for adjacent surfaces. Insulation adjoining such equipment openings shall be tapered towards these openings to permit removal of bolts, screws, heads, covers or plates with no damage to adjacent surface insulation or cover. A typical detail of manhole insulation is shown in TCE. M4-104-56.

5.4.7 Nozzles and other connections on tanks, heaters and other equipment shall be insulated in the same manner as the pipes.

5.4.8 Pump casing shall be completely insulated with removable type of boxes fabricated from the specified sheet material.

5.4.9 Name plates on equipment shall not be insulated.

5.5 CEMENT SAND PLASTER FINISH

5.5.1 On piping and equipment, where cement sand plaster finishing is specified in data sheet A, a barrier of polythene bonded hessian with the hessian layer outwards or bituminised Kraft paper shall be provided over the insulation. A

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total of 15 mm thick cement sand (1:4) plaster shall be applied in two layers after a GS wire netting is stretched over the entire surface of the barrier and securely fastened down. The plaster shall be hand-trowelled over the wire netting to a smooth finish. Curing shall be carried out by wrapping damp hessian cloth around the plaster. The application of finishing plaster shall be terminated, at the end of day's work, at an expansion joint.

5.5.2 The cement sand plaster finish shall have the following properties :

(a) A light shower of rain, falling immediately after application shall not wash off the plaster.

(b) At any time, one week or more after application, it shall not shatter if struck a sharp blow with a 0.7 Kg hammer. Such a blow may damage the finishing locally but shall not cause large pieces to break away.

(c) When set, it shall withstand prolonged exposure to the weather without additional protection.

5.5.3 Outdoors, the finishing plaster shall be applied immediately after application of insulation. If this is not practicable, the CONTRACTOR shall take adequate precautions to protect the insulation from weather, e.g. by wrapping it with polythene sheet, roofing felt or other approved material.

6.0 INSULATION EXPANSION JOINTS

Necessary insulation expansion joints shall be provided to prevent cracking of rigid insulation and hardsetting finishing cement layer. Insulation expansion joints shall be provided at intervals as shown in TCE.M4-104-54. These shall also be fitted on both sides and within 1000 mm of each bend and branch connections. At the insulation expansion joint, there shall be complete cut through the insulation and the sheet metal covering shall be provided with sliding joints.

7.0 STEAM TURBINE INSULATION

7.1 Steam turbine and its integral piping shall be lagged with calcium silicate plastic composition in multiple layers.

7.2 Before applying the insulation, the surface to be insulated shall be thoroughly cleaned with wire brush to remove all dirt, rust and scale. After cleaning, the insulation shall be applied in successive layers to the required thickness. Each individual layer shall be properly dried before the next layer is applied.

7.3 The heating of the steam turbine cylinder before the application and drying of the individual layers shall be by infra-red lamps. The CONTRACTOR shall provide all equipment and make all necessary arrangements.

7.4 The insulation shall be reinforced with GS wire netting and lacing. Where layer interface temperature is 4000C and above, SS 304 wire netting and lacing

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shall be used. Reinforcing wire netting shall be provided over each successive layer of insulation.

7.5 The insulation shall be secured to the steam turbine cylinder and steam chests. For securing the insulation properly, nuts shall be provided on the outer steam turbine casing and steam chest. Studs of suitable length shall be screwed on to the nuts and the insulation shall be held rigidly by the studs.

7.6 The studs shall be wrapped with asbestos mill board paper or rope to avoid direct contact of the wire-mesh with the studs. The studs shall be of stainless steel material.

7.7 The insulation shall be finished with a layer of hard setting insulating cement, trowelled to a smooth finish, to prevent damage.

7.8 The steam turbine shall then be covered with 1.2 mm thick aluminium appearance cladding.

8.0 MEASUREMENT

Measurement of insulation over equipment and piping shall be as per IS 14164.

9.0 GUARANTEES

9.1 The CONTRACTOR shall demonstrate to the PURCHASER that the temperature of the outer surface of the finish has not exceeded 60°C. Temperature shall be measured at the middle of a segment of piping run to be mutually agreed. Two measurements, one at the top and other at the bottom, shall be taken at the measuring points. These temperatures shall be taken as the representative temperature for that length of piping.

9.2 The CONTRACTOR shall guarantee that, if the temperature on the outer surface of the finish exceeds 60°C, the CONTRACTOR shall either replace the insulation with a superior material or provide additional insulation thickness at the PURCHASER'S discretion at no extra cost to the PURCHASER.

10.0 MISCELLANEOUS

Approval of the PURCHASER shall be obtained of samples of all materials and necessary test certificates of approved national laboratories, before despatching these to site. Insulation shall not be applied until specific release is given by the PURCHASER.

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TCE.6079A-104-02

TATA CONSULTING ENGINEERS LIMITED SECTION : D

DATA SHEET A THERMAL INSULATION FOR HOT SURFACES SHEET : 1 OF 2

1. AMBIENT TEMPERATURE : REFER BASIS OF DESIGN OC

8.6

2. 8.7

3. 9. INSULATING CEMENT MATERIAL :

4. SAME AS THE BASIC INSULATION

5. MATERIAL

6. 10.

7. INSULATION MATERIALS 11.

7.1 EQUIPMENT : U150/U200/U80/L100/ 12.

L150/CS1 13. TCE.6079A-104-50

7.2 PIPING SYSTEMS : U150/U200/U80/ 14. TCE.6079A-104-51

L100�/L150�/PS1�/CS1 15. TCE.6079A-104-52

7.3 FLUES AND DUCT: U150/U200/U80/ 16. TCE.6079A-104-53

L100/L150/PS1/CS1 17. TCE.6079A-104-54

7.4 STEAM GENERATOR CASING : U150/ 18. TCE.6079A-104-56

U200/U80/L100/L150/CS1 19. TCE.6079A-104-57

7.5 STEAM TURBINE : NOTE � 20.

7.6 21.

7.7 22.

8. FINISHING MATERIALS 23.

8.1 EQUIPMENT : FC AND/OR AL1/AL2/ 24.

GS1/GS2 25. AS PER TCE.M4-904 AND/OR TCE.M4-

8.2 PIPING SYSTEMS : FC AND/OR AL1/ 185-01 AND TCE.M4-185-71

AL2/GS1/GS2 26. TEST CERTIFICATES FOR ALL

8.3 FLUES AND DUCT: AL1/AL2/GS1/GS2 MATERIALS REQUIRED : YES/NO

8.4 STEAM GENERATOR CASING : FC 27.

AND/OR AL1/AL2/GS1/GS2 28.

8.5 STEAM TURBINE : NOTE � 29.

NOTES

� FOR SIZES 400 mmNB AND ABOVE. � FOR SIZES UPTO 350 mmNB. � REFER PARA 7.0 ON SHEET 12 OF 14 OF WRITE-UP OF TCE.M4-104-02.

REV.NO. PPD. BY : SCD JOB NO. CLIENT: BPCL, MUMBAI

DATE CHD. BY : AV TCE.

REV. BY DATE : 06/07/10 6079A PROJECT: CCR REFORMER

TCE FORM NO. 330 R1FILE NAME: DA10402R9.DOC

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DATA SHEET A THERMAL INSULATION FOR HOT SURFACES SHEET : 2 OF 2

INSULATION THICKNESSES IN mm FOR ROCK WOOL AND GLASS WOOL

INSULATION MATERIALS U80, U150, U200, L100, L150 AND PS1

OPERATING 65 101 151 201 251 301 351 401 451 501 551 TEMP. OC TO TO TO TO TO TO TO TO TO TO TO PIPE SIZE 100 150 200 250 300 350 400 450 500 550 565 mm NB

15 25 25 40 40 50 65 80 90 100 115 125 20 25 25 40 50 50 65 80 90 100 125 135 25 25 40 40 50 65 80 90 100 115 125 135 40 25 40 40 50 65 80 90 100 125 140 150 50 25 40 40 50 65 80 100 115 125 150 160 65 25 40 50 50 65 90 100 115 140 150 160 80 25 40 50 50 80 90 100 125 140 165 175 100 40 50 50 65 80 90 115 125 150 165 175 125 40 50 50 65 80 90 115 125 150 175 185 150 40 50 50 65 80 100 115 140 165 180 190 200 40 50 50 65 80 100 125 140 165 190 200 250 40 50 50 65 90 100 125 150 175 200 210 300 40 50 65 75 90 115 125 150 175 200 210 350 50 65 75 75 90 115 140 150 175 215 225 400 50 65 75 75 90 115 140 165 190 215 225 450 50 65 75 75 90 115 140 165 190 225 235 500 50 65 75 100 115 115 140 165 190 225 235 600 50 65 75 100 115 115 140 165 200 225 235 650 50 65 75 100 115 115 140 175 200 240 250 700 50 65 75 100 115 115 150 175 200 240 250 800 50 65 75 100 115 125 150 175 200 240 250 900, 950 50 65 75 100 115 125 150 175 215 240 250 1000 AND ABOVE

AND FLAT SURFACES

50 65 75 100 115 130 170 200 250 300 310

NOTES 1. INSULATION THICKNESSES SPECIFIED DO NOT INCLUDE THICKNESS OF FINISHING

MATERIALS SUCH AS CEMENT SAND PLASTER, ALUMINIUM OR GS SHEET, BINDING AND LACING WIRES, WIRE NETTING AND BANDS ETC.

2. INSULATION THICKNESSES ARE BASED ON ALUMINIUM SHEET FINISH, AN AMBIENT TEMPERATURE OF 30OC, FINISH OUTER SURFACE TEMPERATURE OF 60OC AND STILL AIR CONDITIONS.

REV.NO. PPD. BY : SCD JOB NO. CLIENT: BPCL, MUMBAI


REV. BY DATE : 06/07/10 6079A PROJECT: CCR REFORMER


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TATA CONSULTING ENGINEERS LTIMITED SECTION : D

DATA SHEET B

THERMAL INSULATION FOR HOT SURFACES SHEET : 1 OF 2

ENQUIRY/ SPECIFICATION NO. TCE.

SL. NO.

BIDDER ITEM

1.0 MAXIMUM GUARANTEED TEMPERATURE ON

THE OUTER SURFACE OF FINISH OC


2.1 EQUIPMENT U150/U200/U80/L100/L150/

CS1

2.2 PIPING SYSTEMS U150/U200/U80/L100�/ L150�/PS1�/CS1

2.3 FLUES AND DUCTS U150/U200/U80/L100/L150/

PS1/CS1

2.4 STEAM GENERATOR CASING U150/U200/U80/L100/L150/

CS1

2.5 STEAM TURBINE


3.1 EQUIPMENT FC AND/OR AL1/AL2/GS1/

GS2

3.2 PIPING SYSTEMS FC AND/OR AL1/AL2/GS1/

GS2

3.3 FLUES AND DUCTS AL1/AL2/GS1/GS2

3.4 STEAM GENERATOR CASING FC AND/OR AL1/AL2/GS1/

GS2

3.5 STEAM TURBINE

4.0 DENSITY OF EACH OF THE INSULATING Kg/M3

MATERIALS

5.0 IS ANY INSULATION MATERIAL CORROSIVE

TO CARBON STEEL OR ALLOY STEEL YES / NO

SURFACE IN CONTACT ?

NOTES TO BIDDER

1. DATA SPECIFIED IN DATA SHEET-A HAS NOT BEEN REPRODUCED IN DATA SHEET-B. IN CASE OF DEPARTURE FROM DATA SHEET-A, BIDDER SHALL BRING OUT THE SAME IN SCHEDULE OF DEVIATIONS, FAILING WHICH IT SHALL BE CONSTRUED THAT BIDDER COMPLIES WITH THE REQUIREMENTS STIPULATED IN DATA SHEET-A.

2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER

DATE

TCE FORM NO. 294 R1FILE NAME: DB10402R8.DOC

ISSU

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PART IIB of 221

TCE.6079A-104-02

TATA CONSULTING ENGINEERS LTIMITED SECTION : D

DATA SHEET B

THERMAL INSULATION FOR HOT SURFACES SHEET : 2 OF 2


SL. NO.

BIDDER ITEM

6.0 INSULATION THICKNESSES FOR ALL

INSULATION MATERIALS SELECTED, IN THE WHETHER ENCLOSED

FORMAT SIMILAR TO THAT IN DATA SHEET A, YES / NO

TO BE ENCLOSED

NOTES

� FOR SIZES 400 mmNB AND ABOVE � FOR SIZES UPTO 350 mmNB

NOTES TO BIDDER



SIGNATURE OF BIDDER

DATE


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PART IIB of 221



1


ISSUE R0

TITLE

DATA SHEET C

DATA TO BE FURNISHED BY THE CONTRACTOR AFTER THE AWARD OF CONTRACT

1. List of drawings and documents to be submitted for review, approval and information with scheduled submission dates

2. Quality Assurance Plan (QAP)

3. List of insulation materials with specifications and properties like density, thermal conductivity etc.

4. Values for thermal conductivity at various mean temperatures for all insulation materials

5. List of finishing materials with specifications

6. List of auxiliary materials with specifications

7. Test certificates for insulation and other materials

8. Detailed insulation application and finishing procedure

PART IIB of 221


THERMAL INSULATION FOR COLD SURFACES

SHEET 1 OF 10

ISSUER0

TITLE

TCE FORM NO. 329 R3 FILE NAME : M410403R0.DOC

1.0 SCOPE

1.1 This specification covers the technical requirements and essential particulars for the supply, application and finishing of the complete thermal insulation for cold equipment, piping systems, air-conditioning ducts etc. for temperatures between ambient and (-) 80oC and also for dual temperatures (both hot and cold) service with hot temperature above ambient and up to 230oC. Unless specified otherwise in section C and/or data sheet A, the scope of supply of the CONTRACTOR shall include, but not be limited to, the following items :

(a) Insulation materials of all types as specified and required

(b) Insulation adhesives, vapour barriers and finishing materials of all types as specified and required

(c) Auxiliary materials such as binding and lacing wires, wire netting, bands, screws, pop rivets etc., as specified and required

(d) Angles, clamps, lugs etc. for supporting insulation

(e) Weather hoods

(f) Any other material as may be required for making the insulation complete


2.1 The supply and application of thermal insulation and finishing covered under this specification shall comply with all currently applicable statutes, regulations and safety codes in the locality where it is to be applied. The materials and application shall also conform to the latest editions of the codes and standards listed. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility.

2.2 The following are some of the codes and standards relevant to this specification :

IS 277 Galvanised Steel Sheets (Plain and Corrugated)

IS 737 Wrought Aluminium and Aluminium Alloy Sheet and Strip for General Engineering Purposes

IS 3144 Mineral Wool Thermal Insulation Materials - Method of Test

IS 3677 Unbonded Rock and Slag Wool for Thermal Insulation

IS 4671 Expanded Polystyrene for Thermal Insulation Purposes

PART IIB of 221



SHEET 2 OF 10

ISSUER0

TITLE


IS 8183 Bonded Mineral Wool

IS 9842 Preformed Fibrous Pipe Insulation

IS 14164 Industrial Application and Finishing of Thermal Insulation Materials at Temperatures above (-) 800C and up to (+) 7500C

BS 3927 Rigid Phenolic Foam (PF) for Thermal Insulation in the Form of Slabs and Profiled Sections

BS 5608 Preformed Rigid Polyurethane (PUR) and Polyisocyanurate (PIR) Foams for Thermal Insulation of Pipework and Equipment

BS 5970 Thermal Insulation of Pipework and Equipment (in the Temperature Range (-) 1000C to (+) 8700C )

3.0 MATERIALS

3.1 GENERAL

3.1.1 All materials shall be new and fresh, incombustible, fire retardant, rot-proof, non-hygroscopic, vermin proof, fungus proof, non-injurious to health, chemically inert, non-corrosive to steel and aluminium (even if soaked in water for extended periods) and shall be guaranteed to withstand continuously and without deterioration the minimum and maximum temperatures to which these shall be subjected to under the specified applications.

3.1.2 The insulation materials and any component of the finished insulation job shall not react chemically, singly or in combination, with water or moisture to form substances that are more actively corrosive to applied surface than water or moisture alone.

3.1.3 In order to protect the workers from the hazards of insulation materials, suitable protective gadgets shall be provided. Required safety precautions shall be taken during handling and application of insulation.

3.1.4 The insulation material shall be kept dry at all times during transport, storage and installation. Decking and covering tarpaulins alone are not adequate for any length of time and shall not be allowed except in extreme emergencies and only for short period. Stacking of insulation materials directly on ground shall not be done. No wet insulation shall be installed. If wet insulation is present, it shall be removed and replaced with new dry insulation. The insulation may be protected with plastic film but shall be vented to prevent sweating.

PART IIB of 221



SHEET 3 OF 10

ISSUER0

TITLE



The insulation material shall be one or more of the following types as specified in data sheet A.

SL. NO.

INSULATION MATERIAL STANDARD DENSITY, Kg/M3

TEMP. RANGE, 0C

MATERIAL CODE

1. Fire-retardant quality expanded polystyrene IS 4671 20 (-)80 to 80 EP

2. Rigid polyurethane / Polyisocyanurate foam BS 5608 32 (-)80 to 110 PUR/ PIR

3. Phenolic foam BS 3927 32 (-)80 to 130 PF

4. Lightly resin-bonded glass wool mattresses IS 8183 32 (-)40 to 230 LRG

5. Resin-bonded glass wool pipe sections IS 9842 85 (-)40 to 230 PSG

6. Unbonded rock and slag wool IS 3677 150 (-) 80 to 230 U150

3.3 INSULATION ADHESIVES

The insulation adhesive shall be one or more of the following types as specified in data sheet A.


3.3.1 Hot bitumen of grade 85/25 or 85/40 conforming to IS 702 shall be uniformly applied at 1.5 Kg/M2 on the surface to be insulated. A similar layer shall also be applied on the inside surface of the insulation. This material shall not be used for stainless steel surfaces.

BIT

3.3.2 CPRX compound shall be uniformly applied at 1.5 Kg/M2 on the surface to be insulated. A similar layer shall also be applied on the inside surface of the insulation. This material shall not be used for stainless steel surfaces.

CPRX

3.3.3 MAS 83 with 0.5 mm wet film thickness shall be uniformly applied at 0.5 lit/M2 by trowelling. MAS 83 shall not be used with polystyrene as insulation material. MAS 83 can be used only between (-) 46 and (+) 149oC.

MAS 83

PART IIB of 221



SHEET 4 OF 10

ISSUER0

TITLE


3.4 VAPOUR BARRIERS

The vapour barrier shall be one or more of the following types as specified in data sheet A.


3.4.1 Hot bitumen of grade 85/25 or 85/40 conforming to IS 702 shall be uniformly applied at 2.5 Kg/M2 on the outer surface of insulation and allowed to dry. Reinforced Plastic (RP) tissue paper shall be applied on the dried bitumen. This material shall not be used for stainless steel surfaces.

VB1

3.4.2 0.1 mm thick factory-laminated aluminium foil with craft paper shall be provided. All joints shall be provided with 50 mm overlap and all joints shall be sealed with aluminium tape. For temperature between (-) 43 and (+) 149oC MAS 35 may also be used as sealant.

ALF

3.4.3 MAS 130 with 1.02 mm wet film thickness primer coat at 1.0 lit/M2 and 2.25 mm wet film thickness finish coat at 2.5 lit/M2 shall be uniformly applied over the insulation by spatula or trowelling. MAS 130 shall not be used with polystyrene as insulation material. MAS 130 can be used only between (-) 40 and (+) 60oC.

MAS 130


The finishing material shall be one or more of the following types as specified in data sheet A.


3.5.1 Portland cement and inorganic fibre with water proofing compound at an application density of 1050 to 1100 Kg/M3.

FC

3.5.2 Aluminium sheet as per IS 737, designation 31000, condition H3.

AL1




PART IIB of 221



SHEET 5 OF 10

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TITLE



(d) Air-conditioning ducts - sheet thickness 24 SWG

(e) Equipment - sheet thickness 18 SWG

3.5.3 Galvanised Steel (GS) sheet as per IS 277, designation GP GS1




(d) Air-conditioning ducts - sheet thickness 26 SWG

(e) Equipment- sheet thickness 20 SWG

3.5.4 MAS 134 with 1.0 mm wet film thickness at 1.0 lit/M2 shall be uniformly applied when using over porous insulation materials. Wet film thickness shall be 0.5 mm at 0.5 lit/M2 for impervious insulation surfaces including polystyrene. MAS 134 can be used only between (-)18 and (+) 82oC.

MAS 134

3.6 AUXILIARY MATERIALS

3.6.1 Binding and Lacing Wires

Binding and lacing wire shall be annealed GS 24 SWG.

3.6.2 Wire Netting

Wire netting shall be with GS 24 SWG wire and 20 mm hexagonal opening.

3.6.3 Bands

(a) For securing insulation material : 24 SWG GS, 20 mm wide

(b) For securing aluminium and GS : 24 SWG anodised sheets aluminium or

PART IIB of 221



SHEET 6 OF 10

ISSUER0

TITLE


SS 304, 20 mm wide

3.6.4 Screws

Screws shall be of self-tapping type and shall be of aluminium or stainless steel for aluminium sheets and GS for GS sheets.

3.6.5 Pop Rivets

Pop rivets shall be of aluminium or stainless steel for aluminium sheets and GS for GS sheets.

4.0 APPLICATION

4.1 GENERAL

4.1.1 The application of insulation shall be made in a professional manner. The insulation shall be applied to all surfaces when these are at ambient temperature. Ample provision shall be made for the maximum possible thermal movement and the insulation shall be applied in a manner which shall avoid breaking or telescoping due to alternate periods of contraction and expansion. A single layer of insulation shall not be more than 75 mm thick.

4.1.2 Insulation shall be applied after all leak tests on equipment and piping are over and the section of the plant has been specifically released by the PURCHASER for such work. If insulation has to be applied before the leak test, all welded and flanged joints shall be left exposed and insulated after satisfactory completion of the leak test.

4.1.3 All surfaces to be insulated shall be clean and dry before the insulation is applied. The surfaces shall be cleaned of all foreign material such as scale, dirt, rust and paint, by the use of steel wire brushes and steel scrapers, where necessary. Where a surface is not free of paint the CONTRACTOR shall notify the PURCHASER of the condition for remedial action. The insulation shall be applied after remedial action, suggested by the PURCHASER, has been taken by the CONTRACTOR. One coat of primer paint shall be applied and allowed to dry before application of insulation.

4.1.4 After cleaning and application of one coat of primer paint on the surface to be insulated, the insulation adhesive shall be applied for fluid operating temperatures between 200C and (-) 200C. Insulation material of required thickness shall be stuck to the surface with joints staggered. The adjoining sections shall be tightly pressed together. All the joints shall be sealed with adhesive material. Voids, if any, shall be packed with suitably cut pieces of insulation material. Vapour barrier and insulation finish shall be applied as per paras 3.4 and 3.5 or 4.5 respectively.

PART IIB of 221



SHEET 7 OF 10

ISSUER0

TITLE


4.1.5 For fluid operating temperatures below (-) 200C, the insulation shall be applied directly over the surface to be insulated without applying the insulation adhesive. Vapour barrier shall be applied over the insulation material. Vapour barrier and insulation finish shall be applied as per paras 3.4 and 3.5 or 4.5 respectively.

4.1.6 Where multilayer insulation is provided, insulation adhesive shall be used between two layers, based on temperature criterion given in para 4.1.4.

4.1.7 If aluminium or GS sheet is specified as finishing material, all joints shall be sealed with bitumastic paint and made effectively weather and water-proof. For temperatures between (-) 40 and (+) 120oC, MAS 94 may also be used as sealant. MAS 94 shall, however, not be used with polystyrene as insulation material. All flat surfaces shall be adequately sloped to prevent pools of water collecting. The sheet shall be protected internally with 2 coats of bitumastic paint.

4.1.8 All actions shall be taken to complete the application of finishing on exposed surfaces covered with insulation before closing the day's work. If this is not practicable, adequate precautions shall be taken to protect the insulation from weather, for example by wrapping it with polythene sheet, roofing felt or other approved material.

4.2 PIPES, PIPE FITTINGS, VALVES AND SPECIALITIES

4.2.1 All vertical pipes shall be provided with suitable insulation supports to prevent the insulation from collapsing due to its own weight. Suggested method is indicated in TCE.M4-104-58. Any welding required, shall be carried out by the CONTRCATOR with the prior permission of the PURCHASER and only under his direct supervision. Where welding is not permitted, suitable clamped supports shall be used. The insulation shall be applied starting from bottom up. Mattress type insulation materials shall be clamped from top.

4.2.2 All pipe fittings, valves and specialities shall be covered with the same type and thickness of insulation as specified for the adjoining pipe. On pipe fittings, insulation outside diameter shall be same as the outside diameter of adjacent pipe insulation. Unless specified otherwise in section C, valves and specialities of sizes 100 mm NB and larger shall be provided with removable box type insulation. Box shall be fabricated from sheet material specified for adjoining pipes. Pipe insulation on adjoining flanges shall be stopped at one bolt length plus 25 mm before flange to permit removal of the bolts and nuts. The insulation shall be applied after the finish has been applied over insulation on the adjacent piping. A typical arrangement is shown in TCE.M4-104-51. Flanged joints shall also be insulated with removable type of boxes. Arrangement shall be similar to that for valves.

PART IIB of 221



SHEET 8 OF 10

ISSUER0

TITLE


4.2.3 The sheets shall be installed with the longitudinal lap joints at 450 below the horizontal for horizontal pipes and the joints sealed with bitumastic paint.

4.2.4 On vertical pipes the sheets shall be applied working from bottom up. Each section of sheets shall have a minimum overlap of 50 mm longitudinally and circumferentially. Each circumferential joint shall be made weather-proof by securing with a band of sheet material and sealing with bitumastic paint. Longitudinal lap joints shall be fixed with screws or pop rivets at approximately 150 mm centres.

4.2.5 Valves shall be insulated up to and including their bonnet flange.

4.2.6 Insulation of pipe hanger clamps shall be as per TCE.M4-104-59.

4.3.1 Weather hoods shall be provided for insulated piping passing through roof and external walls as per TCE.M4-104-50.

4.3.2 EQUIPMENT

4.3.3 Where the insulation material is in the mattress form, cleats in the form of wire nails or nuts or angles and flats for supporting the insulation material, shall be welded to the equipment by others. If wire nails are to be used as insulation cleats, these shall be bent and secured with the metal fabric of the mattress, after the insulation has been applied. Where insulation cleats are in the form of M6 and M10 nuts, the CONTRACTOR shall supply and install bolts of suitable length for fixing the insulation. The insulation applied to equipment shall be reinforced with wire netting. One course of wire netting shall be applied to the surface of the equipment and each layer of insulation shall be backed up with wire netting. All irregularities of the surface shall be filled and levelled over with insulating cement. All mattress joints shall be butted tightly and the mattresses shall be secured with 20 mm wide 24 SWG GS bands at 450 mm centres. After banding, all mattress edges shall be laced tightly.

4.3.4 All equipment, unless specified otherwise, shall have a smooth aluminium or GS sheet finish as specified in data sheet A, applied in a manner similar to that specified for piping. For fixing of aluminium or GS sheets, wooden spacer rings at 1000 mm centres shall be fixed to the equipment by the CONTRACTOR. All vertical and horizontal sheets shall be overlapped a minimum of 75 mm. The lapped joints of adjoining sections of sheets shall be secured with screws or pop rivets. On all equipment above 2500 mm diameter and flat surfaces, the sheet shall be further secured by circumferential bands at approximately 1000 mm centres. Each sheet joint shall be sealed with bitumastic paint. The roof sections shall overlap the side walls to prevent water seepage between insulation and the equipment wall. Side wall sheets shall be securely banded at intersections of the side wall and roof sections.

PART IIB of 221



SHEET 9 OF 10

ISSUER0

TITLE


4.3.3 All equipment manholes, hatches, bolted or screwed cover plates, flanged ends etc. shall have removable box type insulation, with same thickness of insulation as for adjacent surfaces. Insulation adjoining such equipment openings shall be tapered towards these openings to permit removal of bolts, screws, heads, covers or plates with no damage to adjacent surface insulation or cover. A typical detail of manhole insulation is shown in TCE.M4-104-56.

4.3.4 Nozzles and other connections on tanks and other equipment shall be insulated in the same manner as the pipes.

4.3.5 Pump casing shall be completely insulated with removable type of boxes fabricated from the specified sheet material. Proper care shall be taken to maintain continuity of vapour barrier between static and removable portion of insulation.

4.3.6 Name plates on equipment shall not be insulated. Proper care shall be taken to eliminate seepage of moisture from such un-insulated portions into the insulating material.

4.4 CONTRACTION JOINTS IN INSULATION

Depending on the type of insulation material used and the operating temperature, contraction joints shall be provided for equipment or pipes to prevent rupturing or buckling when the cold surface contracts. A typical detail of contraction joint is shown in TCE.M4-104-60.

4.5 CEMENT SAND PLASTER FINISH

Where cement sand plaster finish is specified following procedure shall be followed :

4.5.1 Indoor Application

After the application of hot bitumen or CPRX compound vapour barrier, the surface shall be wrapped with GS wire netting, butting all the joints and lacing down with lacing wire. The ends of all wire loops shall be firmly twisted together with pliers, bent over and carefully pressed into the surface of insulation.

A total of 15 mm thick finishing cement sand(1:4) plaster shall be applied in two layers after a GS wire netting is stretched over the entire surface of insulation material and securely fastened down. The plaster shall be hand- trowelled over the wire netting to a smooth finish. The application of finishing plaster shall be terminated, at the end of day’s work, at a contraction joint.

4.5.2 Outdoor Application

PART IIB of 221



SHEET 10 OF 10

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TITLE


After the application of the plaster as per procedure for indoor application, an additional 6 mm thick water-proofing compound Shalikote 30 or equivalent shall be applied in two layers. Outdoors, the finishing plaster shall be applied immediately after application of insulation. If this is not practicable, the CONTRACTOR shall take adequate precautions to protect the insulation from weather, e.g. by wrapping it with polythene sheet, roofing felt or other approved material.

4.5.3 The cement sand plaster finish shall have the following properties :

(a) A light shower of rain, falling immediately after application shall not wash off the plaster.

(b) At any time, one week or more after application, it shall not shatter if struck a sharp blow with a 0.7 Kg hammer. Such a blow may damage the finishing locally but shall not cause large pieces to break away.

(c) When set, it shall withstand prolonged exposure to the weather without additional protection.

5.0 DUAL TEMPERATURE INSULATION

For dual temperature application, resin-bonded glass wool or unbonded rock or slag wool thermal insulation shall be provided, depending on the lower temperature limit given in para 3.2. Insulation thicknesses shall be as indicated in Insulation Schedule (Equipment) and Insulation Schedule (Piping). The insulation application procedure shall be same as that for cold surfaces.

6.0 MEASUREMENT

6.1 Measurement of insulation over equipment and piping shall be as per IS 14164.

6.2 Measurement for air-conditioning ducts shall be taken over finished insulation surface and 5% additional area shall be considered to account for reinforcement and flanged angle joints.

7.0 MISCELLANEOUS

Approval of the PURCHASER shall be obtained of samples of all materials and necessary test certificates of approved national laboratories, before despatching these to site. Insulation shall not be applied until specific release is given by the PURCHASER.

PART IIB of 221



SHEET 1 OF 1


ISSUE R0

TITLE

DATA SHEET C





4. Values of thermal conductivity at various mean temperatures for all insulation materials

5. List of insulation adhesives, vapour barriers and finishing materials with specifications




PART IIB of 221

PART IIB of 221

TCE.6079A-104-03


DATA SHEET A THERMAL INSULATION FOR COLD SURFACES SHEET : 1 OF 3

1. AMBIENT TEMPERATURE : REFER BASIS OF DESIGN OC

13. TCE.M4-104-50

2. 14. TCE.M4-104-51

3. 15. TCE.M4-104-52

4. 16. TCE.M4-104-56

5. 17. TCE.M4-104-57

6. INSULATION MATERIALS 18. TCE.M4-104-59

6.1 EQUIPMENT: EP/PUR/PIR/PF/LRG/U150 19. TCE.M4-104-60

6.2 PIPING SYSTEMS : EP/PUR/PIR/PF/LRG/ 20.

PSG/U150 21.

6.3 AIR-CONDITIONING DUCT : EP/PUR/ 22.

PIR/PF/LRG/U150 23.

6.4 24.

6.5 25.

7. INSULATION ADHESIVES : BIT/CPRX/ 26.

MAS 83 27.

8. VAPOUR BARRIERS : VB1/ALF/MAS 130 28.

9. FINISHING MATERIALS 29. AS PER TCE.M4-904 AND/OR TCE.M4-

9.1 EQUIPMENT : FC/AL1/GS1/MAS 134 185-01 AND TCE.M4-185-71

9.2 PIPING SYSTEMS:FC/AL1/GS1/MAS 134 30. TEST CERTIFICATES FOR ALL

9.3 AIR-CONDITIONING DUCT : FC/AL1/ MATERIALS REQUIRED : YES/NO

GS1/MAS 134 31.

9.4 32.

9.5 33.

10. INSULATING CEMENT MATERIAL: 34.

SAME AS THE BASIC INSULATION 35.

MATERIAL 36.

11. 37.

12. 38.

NOTES

1. FOR STAINLESS STEEL EQUIPMENT, PIPING AND DUCT SURFACES INSULATION ADHESIVE

SHALL BE MAS 83 AND VAPOUR BARRIER SHALL BE ALF OR MAS 130.

REV.NO. PPD. BY: SCD JOB NO. CLIENT: BPCL, MUMBAI


REV. BY DATE: 06/07/10 6079A PROJECT: CCR REFORMER


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PART IIB of 221

TCE.6079A-104-03



INSULATION THICKNESSES IN mm FOR INSULATION MATERIALS EP, LRG AND PSG

OPERATING TEMP. oC

AMB. TO

19 TO

9 TO

-1 TO

-11 TO

-21 TO

-31 TO

-41 TO

-51 TO

-61 TO

-71 TO

PIPE SIZE mmNB

20 10 0 -10 -20 -30 -40 -50 -60 -70 -80

15 25 25 40 50 50 65 75 100 100 125 150

20 25 25 40 50 50 75 75 100 100 125 150

25 25 25 40 50 65 75 100 100 125 125 150

40 25 40 50 65 75 100 100 100 125 125 150

50 25 40 50 65 75 100 100 100 125 150 175

65 40 40 50 75 75 100 100 125 125 150 175

80 40 40 50 75 75 100 100 125 125 150 175

100 40 50 50 75 100 100 125 125 150 150 175

125 50 50 50 75 100 100 125 150 150 175 200

150 50 50 75 75 100 125 125 150 150 175 200

200 AND ABOVE AND FLAT SURFACES

50 65 100 125 150 175 200 200 225 250 275

NOTES

1. INSULATION THICKNESSES SPECIFIED DO NOT INCLUDE THICKNESS OF FINISHING MATERIALS SUCH AS CEMENT SAND PLASTER, ALUMINIUM OR GS SHEET, BINDING AND LACING WIRES, WIRE NETTING AND BANDS ETC.

2. FOR INSULATION THICKNESS FOR TAIL END AIR-CONDITIONING DUCT AND EVAPORATIVE COOLING SYSTEM ETC. REFER SECTION C OF THE ENQUIRY DOCUMENT.





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TCE.6079A-104-03



INSULATION THICKNESSES IN mm FOR INSULATION MATERIALS PUR,PIR AND PF

OPERATING TEMP. oC AMB.

TO 19 TO

9 TO -1 TO

-11 TO

-21 TO

-31 TO

-41 TO

-51 TO

-61 TO

-71 TO

PIPE SIZE mmNB

20 10 0 -10 -20 -30 -40 -50 -60 -70 -80

15 20 20 30 40 40 50 65 75 75 100 125

20 20 20 30 40 40 65 65 75 75 100 125

25 20 20 30 40 50 65 75 75 100 100 125

40 20 30 40 50 65 75 75 75 100 100 125

50 20 30 40 50 65 75 75 75 100 125 150

65 30 30 40 65 65 75 75 100 100 125 150

80 30 30 40 65 65 75 75 100 100 125 150

100 30 40 40 65 75 75 100 100 125 125 150

125 40 40 40 65 75 75 100 125 125 150 175

150 40 40 65 65 75 100 100 125 125 150 175

200 AND ABOVE AND FLAT SURFACES

40 50 75 100 125 150 150 150 175 200 225

NOTES

1. INSULATION THICKNESSES SPECIFIED DO NOT INCLUDE THICKNESS OF FINISHING MATERIALS SUCH AS CEMENT SAND PLASTER, ALUMINIUM OR GS SHEET, BINDING AND LACING WIRES, WIRE NETTING AND BANDS ETC.

2. FOR INSULATION THICKNESS FOR TAIL END AIR-CONDITIONING DUCT AND EVAPORATIVE COOLING SYSTEM ETC. REFER SECTION C OF THE ENQUIRY DOCUMENT.




FILE NAME: DA10403R0.DOC TCE FORM NO. 330 R1

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PART IIB of 221

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A-104-03 DATA SHEET B

THERMAL INSULATION FOR COLD SURFACES SHEET : 1 OF 1


SL. NO.

BIDDER ITEM

1. INSULATION MATERIALS

1.1 EQUIPMENT EP/PUR/PIR/PF/LRG/U150

1.2 PIPING SYSTEMS EP/PUR/PIR/PF/LRG/PSG/U150

1.3 AIR-CONDITIONING DUCT EP/PUR/PIR/PF/LRG/U150

2 INSULATION ADHESIVES BIT/CPRX/MAS 83

3. VAPOUR BARRIERS VB1/ALF/MAS 130

4. FINISHING MATERIALS

4.1 EQUIPMENT FC/FAL1/GS1/MAS 134

4.2 PIPING SYSTEMS FC/FAL1/GS1/MAS 134

4.3 AIR-CONDITIONING DUCT FC/FAL1/GS1/MAS 134

5.0 DENSITY OF EACH OF THE INSULATING MATERIALS Kg/M3

6.0 IS ANY INSULATION MATERIAL CORROSIVE TO CARBON STEEL OR ALLOY STEEL SURFACE IN CONTACT

YES / NO

7.0 INSULATION THICKNESSES FOR ALL INSULATION MATERIALS SELECTED, IN THE FORMAT SIMILAR TO THAT IN DATA SHEET A, TO BE ENCLOSED.

WHETHER ENCLOSED YES / NO

NOTES TO BIDDER



SIGNATURE OF BIDDER

DATE


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SHEET 1 OF 1


ISSUE R0

TITLE

DATA SHEET C





4. Values of thermal conductivity at various mean temperatures for all insulation materials

5. List of insulation adhesives, vapour barriers and finishing materials with specifications




PART IIB of 221

SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION: D

TCE.6079A-187-01 WELDING SPECIFICATION FOR

SHOP AND SITE FABRICATED EQUIPMENT

SHEET 1 OF 21 OF 4

ISSUE

R0

1.0 SCOPE

This specification shall apply to shop and site fabrication of all welded joints in

carbon steel, low alloy steel and stainless steel equipment like pressure vessels,

tanks, columns and heat exchangers etc. The specification shall apply to all the

joints indicated below:

(a) Butt joints produced by double sided welding which produce the same

quality of deposited weld metal on both inside and outside weld surfaces

(b) Butt joints produced by single sided welding having backing strip which

remains in place and full penetration butt weld without backing strip

(c) Corner or those joints connecting two (2) members approximately at right

angles to each other in the form of L or T

(d) Partial penetration welds of the groove type which are used for

connections not subjected to external loading

(e) Fillet welded joints of approximately triangular cross-section joining two

(2) surfaces at approximately right angles to each other and having a throat

dimension at least 70% of the thinner of the parts being joined but not less

than 6 mm

(f) Welds attaching nozzles and other connections

(g) Welds which are used to join non-pressure parts like supports, lugs,

brackets, stiffeners and other attachments to the vessel wall

(h) Any other similar joint which is not specified above but may be

encountered during fabrication


2.1 The welding equipment, welding consumables, preheating, Postweld Heat

Treatment (PWHT), other auxiliary functions and welding personnel shall comply

with all currently applicable statutes, regulations and safety codes in the locality

where the equipment are to be fabricated and installed. Nothing in this

specification shall be construed to relieve the VENDOR/CONTRACTOR of this

responsibility. Specifically, the latest editions of the codes and standards listed

below shall apply:

(a) ASME Boiler and Pressure Vessel Code (BPV Code), Section II Part C -

Material Specifications for Welding Rods, Electrodes, and Filler Metals

(b) ASME BPV Code, Section V - Non-destructive Examination (NDE)

(c) ASME BPV Code, Section VIII Division 1- Rules for Construction of

Pressure Vessels

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(d) ASME BPV Code, Section IX - Welding and Brazing Qualifications

(e) American Society of Non-destructive Testing (ASNT) SNT-TC-IA-

Recommended Practice

(f) Indian Boiler Regulations (IBR)

(g) Any other codes and standards specified in Section C or data sheet A of

Section D of enquiry specification

2.2 The codes and standards listed in para 2.1 form an integral part of this

specification. In the event of conflict between this specification and the codes and

standards, the more stringent shall govern.

2.3 If no specific requirements are given in this specification, the requirements of the

applicable code shall govern.

3.0 WELDING PROCESSES

The following welding processes shall be used:

3.1 GAS TUNGSTEN ARC WELDING (GTAW)

3.1.1 The root pass of single-sided groove welds without backing

3.1.2 Full penetration nozzle connection where other side is inaccessible

3.1.3 Any butt and fillet weld on equipment with thickness 5 mm or less

3.1.4 For all passes of butt and fillet welding of nozzles on equipment and integral

piping of size 50 mm NB or smaller

3.2 Shielded Metal-Arc Welding (SMAW)

3.3 SUBMERGED ARC WELDING (SAW)

Maximum weld deposit per pass shall be 12.7 mm for carbon steel (P-1) and 9.5

mm for other materials.

3.4 Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding (FCAW)

processes

3.5 Other processes such as plasma-arc and electro-slag welding may be used only

with the approval of the PURCHASER and depending upon the process and

application proposed. These processes may require testing in addition to that

specified by the governing procedure qualification code.

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3.6 Table 1 gives recommendations for welding processes to be used for carbon, low

alloy and austenitic stainless steels.

4.0 WELDING CONSUMABLES

4.1 The VENDOR/CONTRACTOR shall provide, at no additional cost, all the

welding consumables such as electrodes, filler wires, flux, oxygen, acetylene and

argon etc., in order to complete the welding in all respects. The consumables shall

be from reputed and approved manufacturers. All the consumables shall be

approved by the PURCHASER.

4.2 The electrodes and filler wires shall be of the class specified in Table 1 Welding

Specification Chart.

4.3 Electrode qualification test records shall be submitted for the PURCHASER's

approval. The VENDOR/CONTRACTOR shall also submit batch test certificates

from the electrode manufacturer for physical and chemical tests.

4.4 Electrodes shall be in sealed containers and adequate care shall be taken for

storage, strictly in accordance with the manufacturer’s recommendations.

4.5 Electrodes, which have been removed from the original containers, shall be kept

in baking ovens as per the manufacturer’s recommendations and, once these are

taken out, shall be consumed within the time limits stipulated by the

manufacturer. Care shall be taken in handling the electrodes to prevent any

damage to the flux covering. Portable ovens shall be used for carrying the

electrodes from the main oven to the field. Electrodes of different specifications

shall be stored in different compartments of a baking oven to avoid mix up.

4.6 The electrodes, filler wires and flux used shall be free from contamination such as

rust, oil, grease and such foreign matter.

4.7 Low hydrogen electrodes shall be used for weld joints in carbon steel if the wall

thickness exceeds 19 mm and low alloy steel of all thicknesses except that non-

low hydrogen electrodes shall be permitted for the root pass of carbon steel only.

4.8 If ultimate tensile strength of base material permits, E 6010 electrodes may be

used, for root pass of butt welds and for fillet welds, in carbon steel.

5.0 WELDING QUALIFICATIONS

5.1 Qualification of the welding procedures to be used and the performance of

welders and welding operators shall conform to the requirements of the BPV

Codes and Section IX. For equipment under the purview of IBR, these shall also

meet the requirements of IBR.

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5.2 No production welds shall be undertaken until the qualification requirements are

completed to the satisfaction of the PURCHASER.

5.3 When impact testing is required by the code or by the specification, these

requirements shall be met in qualifying welding procedures.

5.4 The VENDOR/CONTRACTOR shall be responsible for qualifying any welding

procedure, welders and welding operators intended to be deployed. The

VENDOR/CONTRACTOR shall submit the Welding Procedure Specification

(WPS) for acceptance by the PURCHASER. After approval by the

PURCHASER, the procedure qualification test shall be carried out by the

VENDOR/CONTRACTOR, at his own expense, duly witnessed by the

PURCHASER. A complete set of test results, in specified format, shall be

submitted to the PURCHASER for approval immediately after successful

completion of procedure qualification test. All tests as required by the BPV code

Section IX or IBR shall be carried out. The WPS shall require re-qualification, if

any of the essential variables or supplementary variables is altered.

5.5 Welders and welding operators shall be qualified in accordance with BPV Code

and Section IX or IBR, as applicable. The qualification shall be carried out in the

presence of the PURCHASER. Only those welders and welding operators who

are qualified by the PURCHASER shall be deployed on the job. For equipment

under the purview of IBR, approval of the local IBR inspector shall be obtained by

the VENDOR/CONTRACTOR.

5.6 Welders and welding operators shall always keep their identification cards with

them and shall produce them on demand. The VENDOR/CONTRACTOR shall

issue the identity cards after the same are duly certified by the PURCHASER.

Welder or welding operator, who is not in possession of the identity card, shall not

be allowed to work.

5.7 The VENDOR/CONTRACTOR shall use forms as per BPV code, section IX,

form QW-482, form QW-483 and form QW-484. Other forms are also acceptable

subject to approval by the PURCHASER.

5.8 Unless agreed otherwise, the VENDOR/CONTRACTOR shall advise the

PURCHASER, in writing, at least three (3) weeks before any welder or welding

operator is deployed on the work, the names and qualifications of the proposed

welders, welding operators and welding supervisors. It shall be the

VENDOR/CONTRACTOR’s responsibility to ensure that all welders and welding

operators employed by him or his SUB-VENDORS/SUB-CONTRACTORS, on

any part of the work either in the VENDOR/CONTRACTOR’s or his SUB-

VENDOR/SUB-CONTRACTOR’s works or at site are fully qualified as required

by the code. Each welder and welding operator shall qualify for all types of

welds, positions and materials or material combinations he may be called upon to

weld.

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5.9 Should the PURCHASER require to qualify or requalify any welder or welding

operator, the VENDOR/ CONTRACTOR shall make available, at no extra cost to

the PURCHASER the men, equipment and materials for the tests. The cost of

testing the welds shall be borne by the VENDOR/CONTRACTOR.

5.10 Welding supervisors shall have qualifications such as engineering degree or

engineering diploma in welding technology with adequate knowledge of welding

consumables, welding machines, NDE and a minimum of five (5) years of

experience in supervising welding of joints.

5.11 All welding, including the tacking up of all welds shall be carried out by qualified

welders and welding operators as per approved WPS. Any weld made by other

than a qualified welder or welding operator or not carried out as per approved

WPS shall be cut out and re-welded.

5.12 For purposes of identification and to enable tracing full history of each joint, each

welder and welding operator employed on the work shall be given a designation.

The welder and welding operator’s designation and the date on which the joint

was made, shall be stamped near the relevant joint and on the relevant drawings

also. Copies of the drawings so marked shall be furnished to the PURCHASER

for record purposes. For austenitic stainless steels, welder and welding operator’s

designation shall be applied with water-proof paint or by etching or stenciling

machine that is not detrimental to the metal. Alternatively, record cards may be

used.

5.13 For each welder and welding operator, a record card shall be maintained showing

the procedures for which he is qualified. These cards shall note the production

welds, the date of the welding done, the type of defects produced and their

frequency. The record shall be reviewed once in a week by the PURCHASER and

those welders and welding operators whose work required a disproportionate

amount of repair shall be disqualified from welding. Re-qualification of welders

and welding operators disqualified more than three (3) times shall be entirely at

the discretion of the PURCHASER. As far as possible, the qualification shall be

carried out at the location (site or shop) where the actual fabrication and welding

work is to be carried out.

6.0 PREPARATION FOR WELDING

6.1 Surfaces to be welded shall be smooth, uniform and free from fins, tears and other

defects, which would adversely affect the quality of the weld. All welding faces

and adjoining surfaces, for a distance of at least 50 mm from the edge of the

welding groove or 12 mm from the toe of the fillet in the case of socket welded or

fillet welded joints, shall be thoroughly cleaned of rust, scale, paint, oil or grease,

both inside and outside.

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6.2 Joints for welding shall be as per the project specifications and approved

fabrication drawings.

6.3 Butt joints shall be prepared as per ASME BPV Code Section VIII Division 1,

unless specified otherwise. For equipment under the purview of IBR, these shall

be as per IBR. Any other end preparation which meets the WPS is acceptable.

6.4 Internal misalignment shall be reduced by trimming but such trimming shall not

reduce the finished wall thickness below the required minimum wall thickness.

Trimming shall not be abrupt. It shall be tapered with a minimum slope of 1:3.

Root opening of the joint shall be within the tolerance limits of the WPS.

6.5 Welds shall be as per ASME BPV Code Section VIII Division 1 or in accordance

with IBR for equipment under the purview of IBR.

6.6 Reinforcing pads and saddles shall have a good fit with the parts to which they are

attached. A tell-tale hole shall be provided on the side of any pad or saddle to

reveal leakage in the weld and to allow venting during welding and heat

treatment. Pad or saddle shall be added, after the branch weld has undergone

satisfactory visual and NDE.

6.7 The ends shall be prepared by machining, grinding, flame cutting or plasma

cutting. Where flame cutting is used, the effect on the mechanical and

metallurgical properties of the base metal shall be taken into consideration. Flame

cutting of alloy steel is not advisable. If alloy steel is cut using flame, the heat

affected zone shall be removed completely by grinding and/or machining.

Magnetic Particle (MT) or Liquid Penetrant (PT) testing shall be carried out to

ensure soundness of edges. However, flame cutting of carbon steel is permitted.

Wherever practicable, flame cutting shall be carried out by machine. Machine

flame-cut edges shall be substantially as smooth and regular as those produced by

edge planing and shall be cleaned free of slag. Manual flame cutting shall be

permitted only where machine flame cutting is not practicable and with the

approval of the PURCHASER, and such surfaces shall be ground or dressed to a

smooth finish as required by the specification and to the satisfaction of the

PURCHASER. Slag, scale or oxides shall be removed by grinding to bright metal

at least two (2) mm beyond the burnt area.

6.8 Thermal cutting of carbon steel shall be performed under the same conditions of

preheating and PWHT as for the welding of each class of material. However,

PWHT is not required when:

(a) The heat affected zone produced by thermal cutting is removed by

mechanical means immediately after cutting. However, in any case, all

remaining slag, scale or oxides shall be removed by grinding to bright

metal at least two (2) mm beyond the burnt area, or

(b) Thermal cutting is part of fabrication, manufacturing or erection sequence

leading to a weld end preparation where welding immediately follows.

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6.9 On austenitic stainless steels, plasma cutting, machining or grinding methods shall

be used for edge preparation. Flame cutting is not permissible. Cut surfaces shall

be machined or ground smooth after plasma cutting. Stainless steel materials shall

be ground with Al2O3 grinding wheels and cleaned with stainless steel wire

brushes.

6.10 Before fitting up the weld joint, the profile and dimensions of the weld end

preparation shall be checked by the PURCHASER. If the specified tolerances are

exceeded, this shall be corrected (with prior approval) by grinding, machining or

any other method acceptable to the PURCHASER.

6.11 Fit-ups shall be examined by the PURCHASER prior to welding the root pass.

7.0 TECHNIQUE AND WORKMANSHIP

7.1 Stainless steel welding shall be carried out at a location away from carbon steel

welding.

7.2 Components to be welded shall be aligned and spaced as per the requirements of

the code and WPS.

7.3 Alignment and spacing shall be achieved using suitable wires to maintain the gap.

These shall be removed after tack welding. The ends to be welded shall be held

using suitable clamps, yokes or other devices which will not damage the surfaces

in any manner. It shall be ensured that welding operations do not result in

distortions.

7.4 Earthing shall be provided on the job using earthing clamps of similar material as

the job. Earthing shall not be given through welding rotators.

7.5 Tack welds at the root joint, for maintaining joint alignment, shall be made only

by qualified welders or welding operators and with filler metal equivalent to that

used in the root pass. Tack welds shall be fused with the root pass weld, except

that those which have cracked shall be removed. Peening is prohibited on the root

and final passes of a weld. The required preheat shall be maintained prior to tack

welding. Means shall be made available to measure preheat temperature.

7.6 No welding shall be carried out if there is any impingement in the weld area of

rain, snow, excessive wind or if the weld area is wet.

7.7 Irrespective of the class of steel, root runs shall be made without interruption other

than for changing the electrodes or to allow the welder or welding operator to

reposition himself. Root runs made in the shop may afterwards be allowed to cool

by taking suitable precautions to ensure slow cooling e.g. by wrapping in a dry

asbestos blanket. Welds made at site shall not be allowed to cool until the

thickness of weld metal deposited exceeds one third of the final weld thickness or

10 mm, whichever is greater.

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7.8 When welding alloy steels, it is strongly recommended that interruption of

welding be avoided. Where such interruption is unavoidable, either the preheat

shall be maintained during the interruption or the joint shall be post heated or

wrapped in dry asbestos blankets to ensure slow cooling. Before recommencing

welding, preheat shall be applied again.

7.9 Welded-on bridge pieces and temporary attachments shall preferably be avoided.

Where approved by the PURCHASER, these may be used. Material of these shall

be compatible with material with which they are temporarily welded. All such

pieces shall be removed after welding of joints and the weld area ground flush.

These areas shall be subjected to MT and PT examination. These pieces shall be

welded by qualified welders and welding operators and with electrodes

compatible with the parent material. The preheating requirements of material shall

be applied and maintained during the welding of attachments. These temporary

attachments shall be removed by grinding, chipping, sawing or by arc or flame

gouging. When arc or flame gouging is used, at least three (3) mm of metal shall

be left around the surface which shall be removed by grinding. This metal shall

not be removed by hammering or by use of force.

7.10 The arc shall be struck only on those parts of parent metal where weld metal is to

be deposited. When inadvertent arc-strikes are made on the base metal surfaces

outside the joint groove, the arc-strikes shall be removed by grinding and shall be

examined by MT and PT procedures.

7.11 Oxides shall not be permitted to form during welding or heat treatment or both, on

the internal surfaces which will not be subsequently cleaned. Inert gas purging is

an acceptable method to prevent such oxidation. All joints in materials which

contain more than 1¼ % chromium shall be purged to assure that less than 1% of

oxygen is present on the joint underside before initiation of the welding. The

purging operation shall be maintained for a minimum of two (2) passes.

7.12 Argon gas used in GTAW process for shielding and purging shall be at least

99.95% pure. Purging shall be carried out at a flow rate depending on diameter

until at least five (5) times the volume between dams is displaced. In no case

shall the initial purging period be less than 10 minutes. After initial purging, the

flow of the backing gas shall be reduced to a point where only a slight positive

pressure prevails. Any dams used in purging shall be fully identified and removed

after welding and accounted for in order to avoid leaving them in the system. The

rate of flow for shielding purposes shall be established in the procedure

qualification.

7.13 Thorough check shall be exercised to maintain the required inter-pass

temperature.

7.14 All equipment necessary to carry out the welding, for supporting of the work, for

preheating and PWHT including thermal insulation for retaining the heat and for

the protection of the welder and welding operator shall be provided by the

VENDOR/CONTRACTOR at no extra cost. All necessary precautions shall be

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taken during cutting and welding operations. It shall be ensured that proper

ventilation is available in the welding area and adequate protective gear such as

goggles, masks, gloves, protection for the ears and body are used at all times. For

guidelines refer ASME standard Z49.1, “Safety in Welding and Cutting”.

7.15 After deposition, each layer of weld metal shall be cleaned with a wire brush to

remove all slag, scale and defects, to prepare for the proper deposition of the next

layer. The material of wire brush shall be compatible with parent material.

Stainless steel materials shall be cleaned with grinding wheels or stainless steel

brushes which have not been used on other materials. Either aluminium oxide or

silicon carbide grinding wheels shall be used. Special care shall be taken to

secure complete and thorough penetration of the fusion zone into the bottom of

the weld. It is recommended that the root run be checked by MT or PT procedures

for critical equipment.

7.16 If specified, upon completion of welding, the joints shall be wrapped in dry

asbestos blankets to ensure slow cooling, unless PWHT is applied immediately.

7.17 No welding or welded parts shall be painted, plated, galvanised or heat treated

until inspected and approved by the PURCHASER. Welds shall be prepared and

ground in such a way that the weld surfaces merge smoothly into the base metal

surface, particularly for welds which are to undergo NDE.

7.18 Except where necessary to grind flush for NDE, reinforcement for butt welds may

be provided. The height of such reinforcement shall meet the requirements of the

code. The reinforcement shall be crowned at the centre and tapered on each side

of the joined members. The exposed surface of the weld shall be ground where

required to present a workmanlike appearance and shall be free from depressions

below the surface of the joined members. The exposed surface of the butt welds

shall be free from undercuts, overlaps or abrupt ridges or valleys and shall merge

smoothly into the surface at the weld toe.

7.19 Repair of weld metal defects shall meet the requirements of the code.

7.20 Any weld repair shall be subject to the approval of the PURCHASER.

7.21 In the event of several unsuccessful repair attempts or if the PURCHASER feels

that a satisfactory repair is not feasible, the joint shall be completely remade.

7.22 It is preferable to use welding rectifier or DC generator for welding of ausenitic

steels and while using low hydrogen electrodes.

7.23 IDENTIFICATION OF WELDS

Wherever code symbol stamps are required on carbon steel and ferritic alloy steel

they shall be applied directly on to the member with low stress dotted design

metal die stamps or to a small stainless steel plate especially provided for such

marks. These plates shall be lightly tack welded using electrodes, of diameter

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three (3) mm or less, of the type specified for the material. Before making the

required tack weld, the material in the immediate surrounding area shall be

preheated, as required, by electric means or propane or natural gas burners.

Cooling shall take place under asbestos insulation in a draft-free area. Stress

relieving of these welds is not required. Steel stamping directly on the surface of

alloy steel with other than low stress die stamps shall not be used.

7.24 SEAL WELDS

7.24.1 Seal welding shall be carried out by qualified welders and welding operators and

in accordance with approved drawings.

7.24.2 Threaded joints that are to be seal welded shall be made without the use of thread

lubricating compound. Seal weld shall cover all exposed threads.

7.25 WELD ENCROACHMENT AND MINIMUM DISTANCE BETWEEN WELDS

7.25.1 Welded joints, more specifically longitudinal welds, shall be placed not closer

than 50 mm to opening or branch welds, reinforcements, attachment devices or

from supports etc. In case of deviation, the PURCHASER may specify additional

NDE.

7.25.2 The longitudinal welds of two adjacent components shall be staggered by at least

30o. The minimum distance between welds shall be 50 mm or three (3) times the

wall thickness, whichever is greater. Intersection of welds shall be avoided as far

as possible. If such welds are present, they shall be subject to suitable NDE at the

discretion of the PURCHASER.

8.0 PREHEATING

8.1 Preheating prior to tack welding, welding and thermal cutting shall be used as a

means of crack prevention and improving weld reliability. The general

requirements of PWHT also apply to preheating.

8.2 Preheating shall be used as per the recommendations of ASME BPV Code Section

VIII Division 1. For equipment under the purview of IBR, the requirements of

IBR shall govern. Preheating of austenitic stainless steels is not required, except at

low ambient temperatures, in which case a minimum preheat temperature of 10oC

is recommended. Table 2 gives the requirements of preheating for commonly used

materials.

8.3 The preheating zone shall extend 75 mm or a distance equal to four (4) times the

material thickness, whichever is greater, beyond the edge of the weld.

8.4 The preheat temperature shall be measured at least 75 mm away from the weld

preparation.

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8.5 Where preheating is specified, welding shall continue without interruption. In case

interruption cannot be avoided, preheating shall be carried out before re-

commencement of welding.

8.6 Oxy-acetylene preheating shall not be applied.

8.7 For preheating, fuel gas/air torches, burner systems (high velocity gas or oil

burners) or electrical heating may be used either locally or in a furnace. For

preheating above 250oC, electric heating (resistance or inductive heating) is

recommended.

8.8 Approved temperature - indicating crayons, thermocouples or digital contact or

laser pyrometers shall be used to measure preheat and inter-pass temperatures. A

calibration report of the pyrometers and thermocouples shall be available.

8.9 When the preheat temperature is 150oC or higher, the metal shall be maintained at

or above the preheat temperature until the weld is completed.

8.10 The welding of groove welds in low alloy steels of P-3 to P-5 groups with wall

thickness of 19 mm or greater may only be interrupted, provided at least 10 mm of

weld metal is deposited, or 25% of the welding groove is filled, whichever is

greater. If the welding is interrupted prior to the above, the weld area shall be

adequately covered with insulating material to ensure slow cooling. After cooling

and before welding is resumed, visual examination of the weld shall be performed

to assure that no cracks are formed. Required preheat shall be applied before

welding is resumed.

9.0 POSTWELD HEAT TREATMENT

PWHT shall meet the requirements of ASME BPV Code Section VIII Division 1.

Table 3 summarises the PWHT requirements for commonly used materials. For

equipment under the purview of IBR, PWHT shall be as per IBR.

9.1 GENERAL REQUIREMENTS

9.1.1 A complete automatic temperature recording shall be made of preheating and

stress relieving operations. Where propane gas burners or electrical resistance

coils are employed, a complete temperature record of the preheating and stress

relieving operation shall be made by means of a box type potentiometer. Other

means of recording temperatures are permissible subject to the PURCHASER's

approval.

9.1.2 Stress relief may be local or full furnace. Local stress relief shall be performed

with electric induction or electric resistance coils. Suitable gas burning equipment

using natural gas or propane may be employed.

9.1.3 At no time during a stress relieving/preheating cycle shall any water or liquid

cooling medium be employed.

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9.1.4 Where members being joined are unequal in thickness, the dimension of the

heavier section shall govern the selection of width of the heated band and the

duration of the holding period shall be based on maximum weld thickness.

9.1.5 For local stress relief, using electrical methods, a minimum of two (2)

thermocouples tack-welded to the surface and potentiometers shall be used on the

part under at least four (4) layers of asbestos paper. The hot junctions of the

thermocouples shall be located on either side of the joint at least 12 mm from the

edge of the joint but no further away than 100 mm. When employing induction

heating, at least six (6) turns of induction cable shall be used on each side of the

weld. Induction coils shall be wrapped on top of the asbestos paper protecting the

thermocouples with the first turn approximately 150 mm from the centre of the

weld.

9.1.6 Local stress relief using gas torches or ring burners may be employed. However,

the procedure shall be limited to small items and shall be approved by the

PURCHASER.

9.1.7 The stress relieving temperature shall be maintained for a period of time

proportioned on the basis of one (1) hour per 25 mm of weld thickness at the joint,

but in no case less than one (1) hour.

9.1.8 For piping joints and socket welded joints, pads, bosses, branch welds and

couplings, one (1) thermocouple shall be positioned at a minimum distance of two

(2) pipe wall thicknesses from the weld.

9.1.9 Equipment on both sides of any joint shall be adequately supported throughout the

preheating, welding and stress relieving operations to prevent distortion.

9.1.10 All heating and cooling rates shall be maintained as per ASME BPV Code and

time-temperature charts from the recorder shall be made available for review and

acceptance.

9.1.11 The VENDOR/CONTRACTOR shall submit a detailed written procedure for the

PWHT for the approval of the PURCHASER.

9.2 CARBON STEEL

9.2.1 Welded joints in carbon steel shall be stress relieved, upon completion of the

welding operation, in accordance with Table 3.

9.2.2 When local stress relief is employed, the welded joint shall be heated to a

temperature of not less than 600°C. The temperature level shall be maintained

between 600 and 650°C, one (1) hour per 25 mm of weld thickness but in no case

less than one (1) hour. The weld area shall then be allowed to cool undisturbed in

still air to a temperature not exceeding 315°C.

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9.2.3 Heating and Cooling

Carbon steels, after having reached their specific stress relief temperatures, may

be cooled in the furnace or under wraps, i.e., leaving the induction coils or

resistance heaters and insulation in place. This means that, at the stress relief

temperatures, the power to the furnace or heating coils may be shut off and

cooling takes place in the furnace or with all insulation and coils remaining on the

part. For furnace stress relief, the doors of the furnace may be opened after the

power is shut off, at or below 315°C. Thermocouples controlling the temperatures

shall remain during the cooling cycle so that excessive cooling, if it occurs, can be

observed and immediately corrected. The stress relieving coils and insulation shall

only be removed after the part has cooled to below 315°C or if stress relieved in a

furnace the part may be removed from the furnace and permitted to cool in still air

at a temperature not below 10°C.

9.3 ALLOY STEEL

9.3.1 Welds in alloy steel shall be stress relieved after the welding operation in

accordance with Table 3. After welding, the material shall be wrapped in asbestos

and allowed to cool slowly if PWHT is not carried out immediately.

9.3.2 For full furnace stress relief of a welded assembly, the entire fabricated section

shall be heated uniformly to the temperature specified. The temperature shall be

maintained for a period of time proportioned on the basis of one (1) hour per 25

mm of weld thickness of the piece having the greatest weld thickness in the

furnace charge, but in no case, less than one (1) hour.

9.4 AUSTENITIC STAINLESS STEEL

Welded joints in austenitic stainless steel need not be stress relieved after welding.

Solution annealing shall be carried out, if specified.

10.0 ELECTRODES

10.1 The specification and size of the electrodes, voltages and amperages, thickness of

beads and number of passes shall be as specified in the approved welding

procedure or otherwise agreed in writing. Only basic coated electrodes shall be

used, which will deposit weld metal having the same or higher physical properties

and similar chemical composition to the members being joined. For each batch of

approved brand, certificate showing compliance with the specification shall be

submitted to the PURCHASER for review before being released for use. All

electrodes shall be purchased in sealed containers and stored properly to prevent

deterioration. As welding electrodes deteriorate under adverse conditions of

storage leading to dampness in the electrode coating, they shall normally be stored

in dehumidified air-conditioned rooms or in hot boxes or ovens in their original

sealed containers whose temperatures shall be maintained within specified limits.

The condition of electrodes shall be frequently inspected. Electrodes with damage

to coating shall not be used. Electrodes shall remain identified until consumed. It

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is preferable to procure low hydrogen electrodes in hermetically sealed containers

and preserve them without damage to the containers.

10.2 All low hydrogen electrodes, after baking as per the manufacturer’s

recommendations, shall be stored in ovens kept at 80 to 100°C before being used.

Recommendations of the electrode manufacturer shall be strictly followed. Until

the electrodes are taken out for welding, they shall be stored in portable ovens.

The electrodes shall not be exposed to open atmosphere.

10.3 For welding of all grades of steel and alloys by the GTAW process, a 2% thoriated

tungsten electrode conforming to SFA-5.12-86 EWTh-2 (AWS-A5.12-80, EWTh-

2) classification shall be used.

10.4 All electrodes to be used on alloy and carbon steel shall conform to ASME BPV

Code Section II Part C or any other equivalent code.

10.5 The type of electrodes used shall be only those recommended by the manufacturer

for the use in the position in which the welds are to be made.

10.6 Current and polarity shall be maintained as recommended by the electrode

manufacturer.

11.0 INSPECTION AND TESTING

11.1 The PURCHASER shall have free access to inspect welding or any other related

operations at any time and at any stage of fabrication.

11.2 The PURCHASER may require NDE of any weld for reasons other than those

given in the specification. The responsibility for the cost of such testing shall be

mutually decided between the PURCHASER and the VENDOR/CONTRACTOR.

11.3 The VENDOR/CONTRACTOR shall inform the PURCHASER when the weld

preparation and set-up for welding of various members selected by the

PURCHASER are in progress so that the PURCHASER can inspect the assembly

before welding starts.

11.4 The responsibilities of the PURCHASER's representative shall in no way reduce

the VENDOR/CONTRACTOR’s responsibilities to ensure that the work is

carried out in accordance with the specification.

11.5 Any examination by NDE methods shall be performed before or after PWHT

based on the applicable code requirements.

11.6 For a welded branch connection and for any weld, necessary repairs and NDE

shall be completed before any reinforcing pad is added.

12.0 EXAMINATION OF WELDS

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12.1 Examination refers to the quality control functions performed by the VENDOR /

CONTRACTOR during fabrication, erection and testing.

12.2 As a minimum, the following shall be examined by visual examination:

(a) Materials and components to ensure that these are as per the specification

and are free from defects. If defects are noticed on “free-issue” items,

these shall be brought to the notice of the PURCHASER without delay.

(b) Joint preparation and cleanliness

(c) Fit-up, joint clearance, and internal alignment prior to joining

(d) Preheating as applicable

(e) Variables specified by the welding procedure, including filler material,

position and electrode

(f) Condition of the root pass after cleaning - external and where accessible,

internal

(g) Slag removal and weld condition between passes

(h) Appearance of the finished joint and weld dimensions

12.3 Acceptance for the visual examination shall be as per ASME BPV Code Section

VIII Division 1 or IBR as applicable.

13.0 QUALIFICATION AND CERTIFICATION OF NDE PERSONNEL

13.1 Approved and documented NDE procedure prepared by level III personnel shall

be made available.

13.2 The VENDOR’s/CONTRACTOR’s examining personnel shall have training and

experience commensurate with the needs of the specified examinations. NDE

supervisors/ examiners shall be qualified at level II or above of ASME BPV Code

Section V.

13.3 The VENDOR/CONTRACTOR shall make available to the PURCHASER copies

of certificates of qualification of the examiners he proposes to use for the

PURCHASER’s approval.

14.0 METHODS OF EXAMINATION

The methods of examination used, Ultrasonic (UT), Radiographic (RT), MT and

PT shall be in accordance with ASME BPV Code, Section V.

15.0 ACCEPTANCE STANDARDS

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15.1 Levels of acceptance of defects in welds shall be in accordance with ASME BPV

Code Section VIII Division 1.

15.2 For equipment under the purview of IBR, the levels of acceptable defects shall be

as per IBR.

16.0 REPAIR WELDING

16.1 All defects in welds requiring repair shall be removed by flame or arc gouging,

grinding, chipping or machining. The major repairs may involve:

(a) Cutting through the weld

(b) Cutting out a portion of material containing the weld, or

(c) Removing the weld metal down to the root depending upon the magnitude

of the defects.

16.2 After removing the defect, the repaired portion and adjacent area shall be

examined by the same NDE methods as specified for the original weld and the

same acceptance criteria shall hold good.

16.3 All the repair welds shall be made using the same or other specified welding

procedures as those used in making the original welds including preheating and

stress relieving if originally required.

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TABLE 1

WELDING SPECIFICATION CHART

FOR COMMONLY USED MATERIALS

SL.

NO. BASE MATERIAL

P.

NO.

WELDING

PROCESS

FILLER

MATERIAL NOTES

ROOT FILLER ROOT FILLER

1.0 CARBON STEELS

1.1 5 mm THICK 1 GTAW GTAW

ER 70S2

OR

ER 70S3

ER 70S2

OR

ER 70S3

1.2 5 mm AND 19 mm THICK 1

GTAW

OR

SMAW

SMAW

OR

SAW

ER 70S2

OR

ER 70S3

OR

E 6010

E 6013

F6--EL8

OR

E 7018

F7--EL12

1.3 19 mm THK 1

GTAW

OR

SMAW

SMAW

OR

SAW

ER 70S2

OR

ER 70S3

OR

E 6010

E 7018

F7--EL12 1

2.0 LOW ALLOY STEELS

2.1 1¼% Cr ½% Mo 5 mm THICK 4 GTAW GTAW ER 80S

B2 ER 80S B2

2.2 1¼% Cr ½% Mo 5 mm THICK 4 GTAW SMAW ER 80S

B2

E 8016

OR

E8018-B2

2.3 2¼% Cr 1% Mo 5 mm THICK 5 GTAW GTAW ER 90S

B3 ER 90S B3 2 TO 7

2.4 2¼% Cr 1% Mo 5 mm THICK 5 GTAW SMAW ER90S

B3

E 9015

OR

E 9016

OR

E 9018-B3

2 TO 7

3.0 AUSTENITIC STAINLESS STEELS

3.1 TYPE 304

(304L) 8 GTAW

GTAW

for

5 mm

THICK ER 308

(ER 308L)

ER 308

(ER 308L)

2 TO 7 SMAW

for

> 5 mm

THICK

E 308

(E 308L)

3.2 TYPE 316

(316L) 8 GTAW

GTAW

for

5 mm

THICK ER 316

(ER316L)

ER 316

(ER 316L)

2 TO 7 SMAW

for

> 5 mm

THICK

E 316

(E 316L)

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TABLE 1 (CONTD.)



SL.

NO. BASE MATERIAL

P.

NO.

WELDING

PROCESS

FILLER

MATERIAL NOTES

ROOT FILLER ROOT FILLER

3.3 TYPE 321 8 GTAW

GTAW

for

5 mm

THICK ER 321

OR

ER 347

ER 321

OR

ER 347

2 TO 7 SMAW

for

> 5 mm

THICK

E 321

OR

E 347

4.0 STAINLESS STEEL TO CARBON

STEEL

4.1 SS 304/321 8 to 1

GTAW

OR

SMAW

SMAW

ER 309

OR

E 309

E 309

4.2 SS 316 8 to 1

GTAW

OR

SMAW

SMAW

ER 309

Mo

OR

E 309

Mo

E 309 Mo

4.3 SS 304L 8 to 1

GTAW

OR

SMAW

SMAW

ER 309L

OR

E 309L

E 309L

4.4 SS 316L 8 to 1

GTAW

OR

SMAW

SMAW

ER 309

MoL

OR

E 309

MoL

E 309 MoL

NOTES

1. Low hydrogen electrodes shall be used for critical systems such as chlorine, hydrogen,

caustic and similar toxic inflammable fluids and also whenever the wall thickness

exceeds 19 mm

2. The argon shielding gas flow rate shall not be less than 0.34 M3/Hr.

3. For purging and shielding argon gas shall be used. However, nitrogen may be used as an

alternative to argon for purging purpose only. In case of stainless steel, nitrogen may be

used where corrosion resistance is not critical.

4. For fillet welds, SMAW may be used instead of GTAW for thicknesses above 5 mm.

5. For GTAW, electrode shall be 2% thoriated tungsten.

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TABLE 1 (CONTD.)



6. Initial purging prior to welding process shall be a minimum of five (5) times the volume

between dams or ten minutes minimum whichever is higher. When welding commences,

the purge gas flow shall ensure that the gas pressure is only marginally higher than

atmospheric pressure to ensure no root concavity.

7. Back purging using argon/nitrogen shall be maintained for the root run and a minimum of

one (1) additional pass.

8. Electrodes and filler wires manufactured by reputed firms duly approved by the

PURCHASER shall only be used.

9. Electrodes shall have at least the same or higher physical properties and similar chemical

composition to the members being joined.

10. Read the table in conjunction with para 3.0

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TABLE-2

PREHEAT REQUIREMENTS

SL.

NO.

BASE MATERIAL P. NO. NOMINAL

WALL

THICKNESS ,

mm

SPECIFIED

MINIMUM

TENSILE

STRENGTH,

mPa

RECOMMENDED

MINIMUM

PREHEAT

TEMPERATURE,

° C

1. CARBON STEEL 1 25 490 10

2. CARBON STEEL 1 25 490 100

3. LOW ALLOY STEEL -

1¼% Cr ½% Mo

4 ALL ALL 149

4. LOW ALLOY STEEL -

2¼%Cr 1% Mo

5 ALL ALL 210

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TABLE 3

POSTWELD HEAT TREATMENT REQUIREMENTS

(FOR COMMONLY USED STEEL MATERIALS)

SL.

NO.

BASE MATERIAL P. NO. NOMINAL

WALL

THICKNESS

mm

METAL

TEMPERATURE

RANGE

° C

1. CARBON STEEL 1 32 NONE

2. CARBON STEEL 1 > 32 600 TO 650

3. LOW ALLOY STEEL

1¼% Cr ½% Mo

4

GR 1

AND 2

ALL 600 TO 650

4. LOW ALLOY STEEL

2¼% Cr 1% Mo

5A

GR 1

ALL 680 TO 700

5. AUSTENITIC STAINLESS

STEELS

8, 9 ALL NOTE 3

NOTES

1. In IBR systems, in carbon steels, PWHT is also required, when the carbon

percentage exceeds 0.25%, at the temperature range of 600 +/- 20 C.

2. For all low alloy steel welds under the purview of IBR, the PWHT shall be carried

out at the temperature range of 620 to 660° C for 1 1/4% Cr 1/2% Mo steels and

at a range of 660 to 750°C for 2 1/4% Cr 1% Mo steels.

3. Solution annealing shall be carried out after welding of austenitic stainless steel as

per the applicable services.

4. For equipment in carbon steels or alloy steels and meant for lethal service, PWHT

of all welds shall be carried out.

PART IIB of 221

SPEC. NO. TATA CONSULTING ENGINEERS LIMITED FRONT PAGE TCE.6079A-134-01

GENERAL ENGINEERING SPECIFICATION – WELDING SPECIFICATION FOR PIPING SYSTEMS

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TCE FORM NO.329 R3FILE NAME : 6079A13401R0.DOC

GENERAL ENGINEERING SPECIFICATION -

WELDING SPECIFICATION FOR PIPING SYSTEMS

PART IIB of 221

SPEC. NO. TATA CONSULTING ENGINEERS LIMITED CONTENTS TCE.6079A-134-01

GENERAL ENGINEERING SPECIFICATION - WELDING SPECIFICATION FOR PIPING SYSTEMS

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CONTENTS

1.0 SCOPE ................................................................................................................ 1

2.0 CODES AND STANDARDS ................................................................................. 1

3.0 WELDING PROCESSES ..................................................................................... 2

4.0 WELDING CONSUMABLES ............................................................................... 3

5.0 WELDING QUALIFICATIONS ............................................................................. 4

6.0 PREPARATION FOR WELDING ......................................................................... 6

7.0 TECHNIQUE AND WORKMANSHIP ................................................................... 7

8.0 PREHEATING ................................................................................................... 11

9.0 POSTWELD HEAT TREATMENT...................................................................... 12

10.0 ELECTRODES .................................................................................................. 14

11.0 INSPECTION AND TESTING ............................................................................ 15

12.0 EXAMINATION OF WELDS .............................................................................. 16

13.0 QUALIFICATION AND CERTIFICATION OF NON-DESTRUCTIVE EXAMINATION PERSONNEL ........................................................................... 17

14.0 METHODS OF EXAMINATION ......................................................................... 17

15.0 ACCEPTANCE STANDARDS ........................................................................... 17

16.0 REPAIR WELDING............................................................................................ 17

TABLES

1.0 WELDING SPECIFICATION CHART 18

2.0 PREHEAT REQUIREMENTS 20

3.0 POSTWELD HEAT TREATMENT REQUIREMENTS 21

4.0 WELD EXAMINATION (IBR PIPING) 24

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1.0 SCOPE

1.1 This specification shall apply to site fabrication of all welded joints in

carbon steel, low alloy steel and stainless steel for chemical and industrial plant piping systems. Site fabrication also covers any fabrication in a shop set-up at site.

1.2 The welded joints include the following:

(a) All butt welding joints of the longitudinal and circumferential type for attachments in piping, castings and forgings of all components

(b) Socket welding and fillet joints

(c) All types of branch welds

(d) Any other joints not specifically covered above

1.3 For welding of materials not covered by this specification, reference shall

be made to specific project requirements covered in section C of enquiry specification.


2.1 The welding of all piping systems including equipment, welding

consumables, preheating, postweld heat treatment, other auxiliary functions and welding personnel shall comply with all currently applicable statutes, regulations and safety codes in the locality where the systems are to be installed. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility. Specifically, the latest editions of the codes and standards listed in following paragraphs shall apply :

(a) ASME B31.3 - Pressure Piping Code for Process Piping (b) Indian Boiler Regulations (IBR) (c) ASME Boiler and Pressure Vessel Code (BPV Code), Section II

Part C - Material Specifications for Welding Rods, Electrodes and Filler Materials

(d) ASME Boiler and Pressure Vessel Code (BPV Code), Section V -

Non-Destructive Examination (e) ASME Boiler and Pressure Vessel Code (BPV Code), Section IX -

Welding and Brazing Qualifications

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(f) Standards of the Pipe Fabrication Institute

(g) BS 2633-Specification for Class I Arc Welding of Ferritic Steel Pipework for Carrying Fluids

(h) Any other codes and standards specified in Section C of enquiry

specification. 2.2 The codes and standards listed in para 2.1 form an integral part of this

specification. In the event of conflict between this specification and the codes and standards, the more stringent shall govern.

2.3 If no specific requirements are given in this specification, the requirements

of the applicable code shall govern. 3.0 WELDING PROCESSES

3.1 The following welding processes shall be used for shop-fabricated and

field- fabricated piping systems :

(a) Gas Tungsten Arc Welding (GTAW)

(b) Shielded Metal Arc Welding (SMAW) Welding by oxyacetylene process shall not be used. 3.2 GTAW process shall be used for the following :

(a) On butt welds in carbon steels, in sizes 40 mm and smaller in all passes for 300 class and higher systems (in case butt welds are required) and for steam tracers. Also refer Table 1.

(b) On butt welds in alloy steels for the root pass in all sizes (c) On butt welds in stainless steels for the root pass in all sizes 3.3 SMAW process shall be used for the following:

(a) On butt welds in carbon steel, in sizes 50 mm and larger, for the filler passes

(b) On butt welds in low alloy steel for the filler passes in all sizes (c) On butt welds in stainless steel for the filler passes in all sizes

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3.4 For carbon steel piping, in sizes 40 mm and smaller, where butt welding is required, the entire butt welding including root pass may be carried out by SMAW process in 150 class piping systems except for steam tracers.

3.5 For IBR systems, all processes used shall be as approved by the IBR inspector.

3.6 Other welding processes such as submerged arc welding are also

acceptable provided the process is properly qualified and approval obtained from the PURCHASER.

3.7 All butt welds shall be considered as full penetration welds. 3.8 Table 1 gives recommendations for welding procedures to be used for

carbon, low alloy and austenitic stainless steels. Welding from inside of the pipe after back gouging and chipping is not envisaged. However, if the CONTRACTOR proposes to use such a method, a detailed written procedure shall be submitted for the PURCHASER’s approval.

4.0 WELDING CONSUMABLES

4.1 The CONTRACTOR shall provide, at no additional cost, all the welding

consumables such as electrodes, filler wires, oxygen, acetylene, argon etc., in order to complete the welding in all respects. The consumables shall be from reputed and approved manufacturers. All the consumables shall be approved by the PURCHASER.

4.2 The electrodes and filler wires shall be of the class specified in the

welding electrode chart. 4.3 Electrode qualification test records shall be submitted for PURCHASER’s

approval. The CONTRACTOR shall also submit batch test certificates from the electrode manufacturer for physical and chemical tests.

4.4 Electrodes shall be in sealed containers and adequate care shall be taken

for storage, strictly in accordance with the manufacturer’s recommendations.

4.5 Electrodes, which have been removed from the original containers, shall

be kept in ovens as per the manufacturer’s recommendations and, once these are taken out, shall be consumed within the time limits stipulated by the manufacturer. Care shall be taken in handling the electrodes to prevent any damage to the flux covering. Portable ovens shall be used for carrying the electrodes from the main oven to the field.

4.6 The electrodes, filler wires and flux used shall be free from

contaminations such as rust, oil, grease and such foreign matter.

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4.7 Low hydrogen electrodes shall be used for weld joints in carbon steel if the wall thickness exceeds 19 mm, except that non-low hydrogen electrodes shall be permitted for the root pass.

4.8 E 6010 electrodes may be used for root pass of butt welds and for fillet

welds in carbon steel. 4.9 Refer Table 1 for welding specifications and electrodes. 5.0 WELDING QUALIFICATIONS

5.1 Qualification of the welding procedures to be used and the performance of

welders and welding operators shall conform to the requirements of the BPV Code, Section IX. For IBR systems, these shall also meet the requirements of IBR.

5.2 No production welds shall be undertaken until the qualification

requirements are completed to the satisfaction of the PURCHASER. 5.3 When impact testing is required by the code or by the specification, these

requirements shall be met in qualifying welding procedures. 5.4 The CONTRACTOR shall be responsible for qualifying any welding

procedure and welders intended to be used. The CONTRACTOR shall submit the Welding Procedure Specification (WPS) for acceptance by the PURCHASER. After approval by the PURCHASER, the procedure qualification test shall be carried out by the CONTRACTOR, at his own expense, duly witnessed by the PURCHASER. A complete set of test results shall be submitted to the PURCHASER for approval immediately after successful completion of procedure qualification test. All tests as required by the BPV code Section IX or IBR shall be carried out. The WPS shall require re-qualification if any of the essential variables or supplementary variables is altered.

5.5 Welders shall be qualified in accordance with BPV Code, Section IX or

IBR, as applicable. The qualification shall be carried out in the presence of the PURCHASER. Only those welders who are qualified and approved by the PURCHASER shall be used on the job. For IBR systems, approval of the local IBR inspector shall be obtained by the CONTRACTOR.

5.6 Welders shall always keep their identification cards with them and shall

produce them on demand. The CONTRACTOR shall issue the identity cards after the same are duly certified by the PURCHASER. Welder, who is not in possession of the identity card, shall not be allowed to work.

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5.7 The CONTRACTOR shall use forms as per BPV code, section IX, form QW-482, form QW-483 and form QW-484. Other forms are also acceptable subject to approval by the PURCHASER.

5.8 Unless agreed otherwise, the CONTRACTOR shall advise the

PURCHASER, in writing, at least three (3) weeks before any welder is employed on the work, the names and qualifications of the proposed welders and welding supervisors. It shall be the CONTRACTOR’s responsibility to ensure that all welders employed by him or his SUB-CONTRACTORS, on any part of the CONTRACT either in the CONTRACTOR’s/his SUB-CONTRACTOR’s works or at site are fully qualified as required by the code. Each welder shall qualify for all types of welds, positions and materials or material combinations he may be called upon to weld.

5.9 Should the PURCHASER require to test or retest any welder, the

CONTRACTOR shall make available, at no extra cost to the PURCHASER, the men, equipment and materials for the tests. The cost of testing the welds shall be borne by the CONTRACTOR.

5.10 Welding supervisors shall have qualifications such as engineering degree

or engineering diploma in welding technology with adequate knowledge of non-destructive testing and a minimum of five (5) years of experience in supervising welding of pipe joints.

5.11 All welding, including the tacking up of all welds shall be carried out by

approved welders. Any weld made by other than an approved welder shall be cut out and re-welded.

5.12 For purposes of identification and to enable tracing full history of each

joint, each welder employed on the work shall be given a designation. The welder’s designation and the date on which the joint was made, shall be stamped on the relevant piping and marked on the relevant drawings also. Copies of the drawings so marked shall be furnished to the PURCHASER for record purposes. For austenitic stainless steels, welder’s designation shall be applied with water-proof paint that is not detrimental to the pipe. Alternatively, record charts may be used.

5.13 For each welder, a record card shall be maintained showing the

procedures for which he is qualified. These cards shall note the production welds, the date of the welding done, the type of defects produced and their frequency. The record shall be reviewed once in a week by the PURCHASER and those welders whose work required a disproportionate amount of repair shall be disqualified from welding. Requalification of welders disqualified more than three (3) times shall be entirely at the discretion of the PURCHASER.

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6.0 PREPARATION FOR WELDING

6.1 Surfaces to be welded shall be smooth, uniform and free from fins, tears

and other defects, which would adversely affect the quality of the weld. All welding faces and adjoining surfaces, for a distance of at least 150 mm from the edge of the welding groove or 12 mm from the toe of the fillet in the case of socket welded or fillet welded joints shall be thoroughly cleaned of rust, scale, paint, oil or grease, both inside and outside.

6.2 Joints for welding, whether socket welding or butt welding shall be as per

the project piping material specifications. 6.3 Butt joints shall be prepared as per ANSI B16.25 unless specified

otherwise. For piping under the purview of IBR, these shall be as per IBR. Any other end preparation which meets the WPS is acceptable.

6.4 Internal misalignment shall be reduced by trimming but such trimming

shall not reduce the finished wall thickness below the required minimum wall thickness. Root opening of the joint shall be within the tolerance limits of the WPS.

6.5 Fillet welds, socket welds and welded - on branch connections shall be as

per ASME B31.3 or in accordance with IBR for IBR systems. 6.6 Reinforcing pads and saddles shall have a good fit with the parts to which

they are attached. A vent hole shall be provided on the side of any pad or saddle to reveal leakage in the weld and to allow venting during welding and heat treatment. Pad or saddle shall be added after the branch weld has undergone examination and necessary repairs.

6.7 The ends shall be prepared by machining, grinding or flame cutting.

Where flame cutting is used, the effect on the mechanical and metallurgical properties of the base metal shall be taken into consideration. Flame cutting of alloy steel pipes is not allowed. However, flame cutting of carbon steel pipes is permitted. Wherever practicable, flame cutting shall be carried out by machine. Machine flame-cut edges shall be substantially as smooth and regular as those produced by edge planing and shall be cleaned free of slag. Manual flame cutting shall be permitted only where machine flame cutting is not practicable and with the approval of the PURCHASER, and such surfaces shall be ground or dressed to a smooth finish as required by the specification and to the satisfaction of the PURCHASER. Slag, scale or oxides shall be removed by grinding to bright metal at least two (2) mm beyond the burnt area.

6.8 Thermal cutting of carbon steel piping shall be performed under the same

conditions of preheating and postweld heat treatment as for the welding of each class of material. However, postweld heat treatment is not required when :

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(a) The heat affected zone produced by thermal cutting is removed by

mechanical means immediately after cutting. However, in any case, all remaining slag, scale or oxides shall be removed by grinding to bright metal at least two (2) mm beyond the burnt area, or

(b) Thermal cutting is part of fabrication, manufacturing or erection

sequence leading to a weld end preparation where welding immediately follows.

6.9 On austenitic stainless steels, plasma cutting, machining or grinding

methods may be used for edge preparation. Cut surfaces shall be machined or ground smooth after plasma cutting.

6.10 Before fitting up the weld joint, the profile and dimensions of the weld end

preparation shall be checked by the PURCHASER. If the specified tolerances are exceeded, this shall be corrected (with prior approval) by grinding, machining or any other method acceptable to the PURCHASER.

6.11 Fit-ups shall be examined by the PURCHASER prior to welding the root

pass. 7.0 TECHNIQUE AND WORKMANSHIP

7.1 Components to be welded shall be aligned and spaced as per the

requirements of the code and WPS. Special care is required when GTAW process is employed.

7.2 Alignment and spacing shall be achieved using suitable wires to maintain

the gap. These shall be removed after tack welding. The ends to be welded shall be held using suitable clamps, yokes or other devices which will not damage the surfaces in any manner. It shall be ensured that welding operations do not result in distortions.

7.3 Tack welds at the root joint, for maintaining joint alignment, shall be made

only by qualified welders or welding operators and with filler metal equivalent to that used in the root pass. Tack welds shall be fused with the root pass weld, except that those which have cracked shall be removed. Peening is prohibited on the root and final passes of a weld. The required preheat shall be maintained prior to tack welding.

7.4 No welding shall be carried out if there is any impingement in the weld

area of rain, snow, excessive wind or if the weld area is wet. 7.5 Irrespective of the class of steel, root runs shall be made without

interruption other than for changing the electrodes or to allow the welder to reposition himself. Root runs made in the shop may afterwards be

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allowed to cool by taking suitable precautions to ensure slow cooling e.g. by wrapping in a dry asbestos blanket. Welds made at site shall not be allowed to cool until the thickness of weld metal deposited exceeds one third of the final weld thickness or 10 mm, whichever is greater.

7.6 When welding alloy steels, it is strongly recommended that interruption of welding be avoided. Where such interruption is unavoidable, either the preheat shall be maintained during the interruption or the joint shall be wrapped in dry asbestos blankets to ensure slow cooling. Before recommencing welding, preheat shall be applied again.

7.7 Welded-on bridge pieces and temporary attachments shall preferably be

avoided. Where approved by the PURCHASER, these may be used. Material of these shall be compatible with material with which they are temporarily welded. All such pieces shall be removed after welding of pipe joints and the weld area ground flush. These areas shall be subject to liquid penetrant or magnetic particle examination for high yield strength materials (YS > 3200 kg/cm2) or when the component thickness exceeds 20 mm or for P3 and P4 group materials. These pieces shall be welded by qualified welders and with electrodes compatible with the parent pipe material. The preheating requirements of pipe material shall be applied and maintained during the welding of attachments. These temporary attachments shall be removed by grinding, chipping, sawing or by arc or flame gouging. When arc or flame gouging is used, at least three (3) mm of metal shall be left around the pipe surface which shall be removed by grinding.

7.8 The arc shall be struck only on those parts of parent metal where weld

metal is to be deposited. When inadvertent arc-strikes are made on the base metal surfaces outside the joint groove, the arc-strikes shall be removed by grinding and shall be examined by liquid penetration or magnetic particle examination procedures.

7.9 Oxides shall not be permitted to form during welding or heat treatment or

both, on the internal surfaces of pipes which will not be subsequently cleaned. Inert gas purging is an acceptable method to prevent such oxidation. All joints in materials which contain more than 1¼% chromium shall be purged to assure that less than 1% of oxygen is present on the joint underside before initiation of the welding. The purging operation shall be maintained for a minimum of two (2) passes.

7.10 Argon gas used in GTAW process for shielding and purging shall be at

least 99.95% pure. Purging shall be carried out at a flow rate depending on diameter of pipe until at least five (5) times the volume between dams is displaced. In no case shall the initial purging period be less than 10 minutes. After initial purging, the flow of the backing gas shall be reduced to a point where only a slight positive pressure prevails. Any dams used in purging shall be fully identified and removed after welding and accounted

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for in order to avoid leaving them in the system. The rate of flow for shielding purposes shall be established in the procedure qualification.

7.11 Thorough check shall be exercised to maintain the required interpass

temperature. 7.12 All equipment necessary to carry out the welding, for supporting of the

work, for preheating and postweld heating including thermal insulation for retaining the heat and for the protection of the welder shall be provided by the CONTRACTOR at no extra cost. All necessary precautions shall be taken during cutting and welding operations. It shall be ensured that proper ventilation is available in the welding area and adequate protective gear such as goggles, masks, gloves, protection for the ears and body are used at all times. For guidelines refer ANSI standard Z49.1, “Safety in Welding and Cutting”.

7.13 After deposition, each layer of weld metal shall be cleaned with a wire brush to remove all slag, scale and defects, to prepare for the proper deposition of the next layer. The material of wire brush shall be compatible with pipe material. Stainless steel materials shall be cleaned with grinding wheels or stainless steel brushes which have not been used on other materials. Either aluminium oxide or silicon carbide grinding wheels shall be used. Special care shall be taken to secure complete and thorough penetration of the fusion zone into the bottom of the weld. It is recommended that the root run be checked by liquid penetrant or magnetic particle procedures for critical process piping.

7.14 Upon completion of welding, the joints shall be wrapped in dry asbestos

blankets to ensure slow cooling, unless postweld heat treatment is applied immediately.

7.15 No welding or welded parts shall be painted, plated, galvanised or heat

treated until inspected and approved by the PURCHASER. Welds shall be prepared and ground in such a way that the weld surfaces merge smoothly into the base metal surface.

7.16 Except where necessary to grind flush for non-destructive examination,

reinforcement for butt welds may be provided. The height of such reinforcement shall meet the requirements of the code. The reinforcement shall be crowned at the centre and tapered on each side of the joined members. The exposed surface of the weld shall be ground where required to present a workmanlike appearance and shall be free from depressions below the surface of the joined members. The exposed surface of the butt welds shall be free from undercuts greater than 0.5 mm in depth, overlaps or abrupt ridges or valleys and shall merge smoothly into the pipe surface at the weld toe. However, undercuts shall not encroach on the minimum section thickness.

7.17 Repair of weld metal defects shall meet the requirements of the code.

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7.18 Any weld repair shall be subject to the approval of the PURCHASER. 7.19 In the event of several unsuccessful repair attempts or if the

PURCHASER feels that a satisfactory repair is not feasible, the joint shall be completely remade.

7.20 IDENTIFICATION OF WELDS Wherever code symbol stamps are required on carbon steel and ferritic

alloy steel piping they shall be applied directly to the pipe with low stress dotted design metal die stamps or to a small stainless steel plate especially provided for such marks. These plates shall be lightly tack welded to the pipe using electrodes, of diameter three (3) mm or less, of the type specified for the material. Before making the required tack weld, the pipe material in the immediate surrounding area shall be preheated, as required, by electric means or propane or natural gas burners. Cooling shall take place under asbestos insulation in a draft-free area. Stress relieving of these welds is not required. Steel stamping directly on the surface of alloy steel piping with other than low stress die stamps shall not be used.

7.21 SEAL WELDS 7.21.1 Seal welding shall be carried out by qualified welders and in accordance

with approved drawings. 7.21.2 Threaded joints that are to be seal welded shall be made without the use

of thread lubricating compound. Seal weld shall cover all exposed threads.

7.22 WELD ENCROACHMENT AND MINIMUM DISTANCE BETWEEN

WELDS 7.22.1 Welded joints, more specifically longitudinal welds, shall be placed not

closer than 50 mm to opening or branch welds, reinforcements, attachment devices or from supports, etc. In case of deviation, the PURCHASER may specify additional non-destructive examination.

7.22.2 The longitudinal welds of two adjacent pipes or components shall be

staggered by at least 30o. The minimum distance between welds shall be 50 mm or three (3) times the wall thickness, whichever is greater. Longitudinal welds shall not be situated at the bottom of the pipe. Intersection of welds shall be avoided as far as possible. If such welds are present, they shall be subject to suitable Non-Destructive Testing (NDT) at the discretion of the PURCHASER.

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8.0 PREHEATING

8.1 Preheating prior to tack welding, welding and thermal cutting shall be used

as a means of crack prevention and improving weld reliability. The general requirements of postweld heat treatment also apply to preheating.

8.2 Preheating shall be used as per the recommendations of ASME B31.3,

Table 330.1.1. For IBR systems, the requirements of IBR shall govern. Preheating of austenitic stainless steels is not required, except at low ambient temperatures, in which case a minimum preheat temperature of 10oC is recommended. Table 2 gives the requirements of preheating for commonly used materials.

8.3 The preheating zone shall extend 75 mm or a distance equal to four (4)

times the material thickness, whichever is greater, beyond the edge of the weld.

8.4 The preheat temperature shall be measured at least 75 mm away from

the weld preparation. 8.5 Where preheating is specified, welding shall continue without interruption.

In case interruption cannot be avoided, preheating shall be continued for at least thirty (30) minutes after interruption. Also refer para 8.9.

8.6 Oxy-acetylene preheating shall not be applied. 8.7 For preheating, fuel gas/air torches, burner systems (high velocity gas or

oil burners) or electrical heating may be used either locally or in a furnace. For preheating above 250oC, electric heating (resistance or inductive heating) is preferred.

8.8 Approved temperature - indicating crayons, thermocouples or digital

contact pyrometers shall be used to measure preheat and interpass temperatures. A calibration report of the pyrometers and thermocouples shall be available.

8.9 When the preheat temperature is 150oC or higher, the metal shall be

maintained at or above the preheat temperature until the weld is completed.

8.10 The welding of groove welds in low alloy steels of P-3 to P-5 groups with

wall thickness of 19 mm or greater may only be interrupted, provided at least 10 mm of weld metal is deposited, or 25% of the welding groove is filled, whichever is greater. If the welding is interrupted prior to the above, the weld area shall be adequately covered with insulating material to ensure slow cooling. After cooling and before welding is resumed, visual examination of the weld shall be performed to assure that no cracks are formed. Required preheat shall be applied before welding is resumed.

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9.0 POSTWELD HEAT TREATMENT

Postweld heat treatment shall meet the requirements of para 331 of

ASME B31.3. For IBR systems, postweld heat treatment shall be as per IBR. Table 3 summarises the postweld heat treatment requirements for commonly used materials.

9.1 GENERAL REQUIREMENTS 9.1.1 A complete automatic temperature recording shall be made of preheating

and stress relieving operations. Where propane gas burners or electrical resistance coils are employed, a complete temperature record of the preheating and stress relieving operation shall be made by means of a box type potentiometer. Other means of recording temperatures are permissible subject to the PURCHASER’S approval.

9.1.2 Stress relief may be local or full furnace. Local stress relief shall be

performed with electric induction or electric resistance coils. Suitable gas burning equipment using natural gas or propane may be employed.

9.1.3 At no time during a stress relieving/preheating cycle shall any water or liquid cooling medium be employed.

9.1.4 Where members being joined are unequal in thickness, the dimension of

the heavier section shall govern the selection of width of the heated band and the duration of the holding period.

9.1.5 For local stress relief, using electrical methods, a minimum of two (2)

thermocouples tack-welded to the surface and potentiometers shall be used on the pipe under at least four (4) layers of asbestos paper. The hot junctions of the thermocouples shall be located on either side of the joint at least 12 mm from the edge of the joint but no further away than 100 mm. When employing induction heating, at least six (6) turns of induction cable shall be used on each side of the weld. Induction coils shall be wrapped on top of the asbestos paper protecting the thermocouples with the first turn approximately 150 mm from the centre of the weld.

9.1.6 Local stress relief using gas torches or ring burners may be employed.

However, the procedure shall be limited to pipes below 100 mm NPS and shall be approved by the PURCHASER.

9.1.7 The stress relieving temperature shall be maintained for a period of time

proportioned on the basis of one (1) hour per 25 mm of wall thickness of the thickest section at the joint, but in no case less than one (1) hour.

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9.1.8 For tubing joints and socket welded joints, pads, bosses, branch welds and couplings, one (1) thermocouple shall be positioned at a minimum distance of two (2) pipe wall thicknesses from the weld.

9.1.9 Piping on both sides of any joint shall be adequately supported throughout

the preheating, welding and stress relieving operations to prevent distortion. When a butt welded joint is to be postweld heat treated and the piping is cold-sprung, the forces required to position the pipes shall be maintained by external means until the completion of the heat treatment procedure.

9.1.10 All heating and cooling must be performed in still air. 9.1.11 The governing thickness for the postweld heat treatment shall be the

thicker of the two components joined by welding. For deviations from this requirement for branch welds, fillet welds etc., reference shall be made to the applicable paragraph of ASME B 31.3.

9.1.12 The CONTRACTOR shall submit a detailed written procedure for the

postweld heat treatment for the approval of the PURCHASER. 9.2 CARBON STEEL 9.2.1 Welded joints in carbon steel piping systems shall be stress relieved,

upon completion of the welding operation, in accordance with Table 3. 9.2.2 When local stress relief is employed, the welded joint shall be heated to a

temperature of not less than 625°C the temperature level shall be maintained between 625°C and 675°C, one (1) hour per 25 mm of wall thickness but in no case less than one (1) hour. The weld area shall then be allowed to cool undisturbed in still air to a temperature not exceeding 315°C. All welded joints in pipe sizes 100 mm and larger, shall be heated by means of electric induction coils or resistance heating. Welded joints in pipes smaller than 100 mm shall be stress relieved by means of electrical resistance coils or suitable propane or natural gas torches only.

9.2.3 Heating and Cooling Carbon steels, after having reached their specific stress relief

temperatures, may be cooled in the furnace or under wraps, i.e., leaving the induction coils or resistance heaters and insulation in place. This means that, at the stress relief temperatures, the power to the furnace or heating coils may be shut off and cooling takes place in the furnace or with all insulation and coils remaining on the pipe. For furnace stress relief, the doors of the furnace may be opened after the power is shut off, at or below 315°C. Thermocouples controlling the temperatures shall remain during the cooling cycle so that excessive cooling, if it occurs, can be observed and immediately corrected. The stress relieving coils and

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insulation shall only be removed after the piping has cooled to below 315°C or if stress relieved in a furnace the pipe may be removed from the furnace and permitted to cool in still air at a temperature not below 10°C.

9.3 ALLOY STEEL 9.3.1 All welds in alloy steel piping shall be stress relieved after the welding

operation in accordance with Table 3. Immediately after welding, the material shall be wrapped in asbestos and allowed to cool.

9.3.2 Local Stress Relief All welded joints in pipes 100 mm size and larger shall be locally stress

relieved by means of electric induction coils or resistance heating. Welded joints in smaller pipe sizes shall be stress relieved by means of electric resistance coils or suitable propane or natural gas torches only.

9.3.3 For full furnace stress relief of a welded assembly, the entire fabricated

section shall be heated uniformly to the temperature specified. The temperature shall be maintained for a period of time proportioned on the basis of one (1) hour per 25 mm of wall thickness of the piece having the greatest wall thickness in the furnace charge, but, in no case, less than one (1) hour.

9.4 AUSTENITIC STAINLESS STEEL Welded joints in austenitic stainless steel piping need not be stress

relieved after welding. 9.5 The rate of heating and cooling during stress relieving operations shall not

exceed 315°C per hour upto a thickness of 50 mm at the weld. 10.0 ELECTRODES

10.1 The specification and size of the electrodes, voltages and amperages,

thickness of beads and number of passes shall be as specified in the approved welding procedure or otherwise agreed in writing. Only basic coated electrodes shall be used, which will deposit weld metal having the same or higher physical properties and similar chemical composition to the members being joined. For each batch of approved brand, certificate showing compliance with the specification shall be submitted to the PURCHASER for review before being released for use. All electrodes shall be purchased in sealed containers and stored properly to prevent deterioration. All low hydrogen electrodes, after baking as per the manufacturer’s recommendations, shall be stored in ovens kept at 80 to 100°C before being used. Recommendations of the electrode manufacturer shall be strictly followed. Until the electrodes are taken out

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for welding, they shall be stored in portable ovens. The electrodes shall not be exposed to open atmosphere.

10.2 For welding of all grades of steel and alloys by the GTAW process, a 2%

thoriated tungsten electrode conforming to SFA-5.12-86 EWTh-2 (AWS-A5.12-80, EWTh-2) classification shall be used.

10.3 All electrodes to be used on alloy and carbon steel shall conform to BPV

Code Section II Part C or any other equivalent code. 10.4 As welding electrodes deteriorate under adverse conditions of storage

leading to dampness in the electrode coating, they shall normally be stored in dehumidified air-conditioned rooms or in hot boxes or ovens in their original sealed containers whose temperatures shall be maintained within specified limits. The condition of electrodes shall be frequently inspected. Electrodes with damage to coating shall not be used. Electrodes shall remain identified until consumed. It is preferable to procure low hydrogen electrodes in hermetically sealed containers and preserve them without damage to the containers.

10.5 The type of electrodes used shall be only those recommended by the

manufacturer for the use in the position in which the welds are to be made. Electrodes which have the areas of flux covering broken away or damaged shall not be used.

10.6 Table 1 gives recommendations on electrodes to be used for carbon, low

alloy and austenitic stainless steels. 11.0 INSPECTION AND TESTING

11.1 The PURCHASER shall have free access to inspect welding or any other

related operations at any time and at any stage of fabrication. 11.2 The PURCHASER may require non-destructive testing of any weld for

reasons other than those given in the specification. The responsibility for the cost of such testing shall be mutually decided between the PURCHASER and the CONTRACTOR.

11.3 The CONTRACTOR shall inform the PURCHASER when the weld

preparation and setting up for welding of various members selected by the PURCHASER is in progress so that the PURCHASER can inspect the assembly before welding starts.

11.4 The responsibilities of the PURCHASER’s representative shall in no way

reduce the CONTRACTOR’s responsibilities to ensure that the work is carried out in accordance with the specification.

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11.5 Any examination by non-destructive methods on low alloy steels shall be performed after postweld heat treatment.

11.6 For a welded branch connection, the examination of and any necessary

repairs shall be completed before any reinforcing pad is added. 12.0 EXAMINATION OF WELDS

12.1 Examination refers to the quality control functions performed by the

CONTRACTOR during fabrication, erection and testing. 12.2 As a minimum, the following shall be examined by visual examination :

(a) Materials and components to ensure that these are as per the specification and are free from defects. If defects are noticed on “free-issue” items, these shall be brought to the notice of the PURCHASER without delay.

(b) Joint preparation and cleanliness (c) Preheating as applicable (d) Fit-up, joint clearance, and internal alignment prior to joining

(e) Variables specified by the welding procedure, including filler

material, position and electrode (f) Condition of the root pass after cleaning - external and where

accessible, internal (g) Slag removal and weld condition between passes (h) Appearance of the finished joint

12.3 Acceptance for the visual examination shall be as per ASME B 31.3 or IBR as applicable.

12.4 Other types of examination shall be as defined in Tables 4 and 5, unless

otherwise mentioned in section C of enquiry specification. For the purpose of examination, fluids are categorised, in accordance with ASME B 31.3, as Category D, Normal Service and Category M and supplemented by other requirements.

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13.0 QUALIFICATION AND CERTIFICATION OF NON-DESTRUCTIVE EXAMINATION PERSONNEL

13.1 The CONTRACTOR’s examining personnel shall have training and

experience commensurate with the needs of the specified examinations. NDT supervisors/ examiners shall be qualified at level II or above.

13.2 The CONTRACTOR shall make available to the PURCHASER copies of

certificates of qualification of the examiners he proposes to use for the PURCHASER’s approval.

14.0 METHODS OF EXAMINATION

The methods of examination used, radiographic (RT), liquid penetrant

(PT) or magnetic particle (MT), shall be in accordance BPV Code, Section V.

15.0 ACCEPTANCE STANDARDS

15.1 Levels of acceptance of defects in welds shall be in accordance with

ASME B 31.3. 15.2 For IBR piping, the levels of acceptable defects shall be as per IBR. 16.0 REPAIR WELDING

16.1 All defects in welds requiring repair shall be removed by flame or arc

gouging, grinding, chipping or machining. The major repairs may involve :

(a) Cutting through the weld (b) Cutting out a length of pipe containing the weld, or (c) Removing the weld metal down to the root depending upon the

magnitude of the defects.

16.2 After removing the defect, the welds shall be examined by the same non-destructive testing methods as specified for the original weld and the same acceptance criteria shall hold good.

16.3 All the repair welds shall be made using the same or other specified

welding procedures as those used in making the original welds including preheating and stress relieving if originally required.

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TABLE 1


SL. NO.

BASE MATERIAL

P. NO.

WELDING PROCESS

FILLER MATERIAL GAS NOTES

ROOT FILLER ROOT FILLER PURGING

SHIELDING

1.0

CARBON STEELS

1.1

SIZES ≤40 mm AND/OR 3 mm THK

1 GTAW

GTAW ER 70S2 OR ER

70S3

ER 70S2 OR ER

70S3

- - 1

1.2

SIZES ≥50 mm THK ≤19 mm

1 SMAW

SMAW E 6010 E 6013 - -

1.3

SIZES ≥50 mm THK ≥ 19 mm

1 GTAW

SMAW ER 70S2 OR ER

70S3

ER 7018OR

ER 7016

- - 2

2.0

LOW ALLOY STEELS

2.1

1¼% Cr ½% Mo

4 GTAW

SMAW ER 80S B2

E8016/E 8018-B2

- -

2.2

2¼% Cr 1% Mo

5 GTAW

SMAW ER90S B3

E9015/ E 9016/ E 9018-

B3

ARGON

ARGON 3 to 8

3.0

AUSTENITIC STAINLESS STEELS

3.1

TYPE 304 (304L)

8 GTAW

GTAW for THK ≤ 4.5 mm

ER 308 (ER 308L)

ER 308 (ER

308L)

ARGON

ARGON 3 to 8

SMAW for THK > 4.5mm

E 308 (E 308L)

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SL. NO.

BASE MATERIAL

P. NO.

WELDING PROCESS

FILLER MATERIAL GAS NOTES

ROOT FILLER ROOT FILLER PURGING

SHIELDING

3.2

TYPE 316 (316L)

8 GTAW

GTAW for THK ≤ 4.5 mm

ER 316 (ER316L)

ER 316 (ER

316L)

ARGON

ARGON 3 to 8


E 316 (E 316L)

3.3

TYPE 321 8 GTAW

GTAW for THK ≤ 4.5mm

ER 321/

ER 347

ER321/ ER 347

ARGON

ARGON 3 to 8


E321/E347

4.0

STAINLESS STEEL TO CARBON STEEL

4.1

SS 304/321 8 to 1

GTAW/ SMAW

SMAW ER309

ER309

- -

4.2

SS 316 8 to 1

ER310Mo

E310Mo - -

NOTES 1. For 300 and higher class systems. For 150 class systems, refer para 3.4. For

fillet welds SMAW process with E6013 can be used. 2. Low hydrogen electrodes shall also be used for critical systems such as

chlorine, hydrogen, caustic and similar toxic inflammable fluids and also whenever the wall thickness exceed 19 mm.

3. The argon shielding gas flow rate shall not be less than 0.34 m3/hr. 4. Nitrogen can be used as an alternative to argon for purging purpose only. 5. For fillet welds, electrode can be used instead of filler wire. 6. For GTAW process, electrode shall be 2% thoriated tungsten.

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7. Initial purging prior to welding process shall be a minimum of five (5) times the

volume between dams or ten minutes minimum whichever is higher. When welding commences, the purge gas flow shall ensure that the gas pressure is only marginally higher than atmospheric pressure to ensure no roof concavity.

8. Back purging using argon/nitrogen shall be maintained for a minimum of two

passes. 9. Electrodes / filler wires manufactured by reputed firms duly approved by the

PURCHSER shall only be used. 10. Electrodes shall have at least the same or higher physical properties and

similar chemical composition to the members being joined. 11. Read the table in conjunction with para 3.0

TABLE - 2

PREHEAT REQUIREMENTS

SL. NO.

BASE MATERIAL P. NO.

NOMINAL WALL

THICKNESS , mm

SPECIFIED

MINIMUM TENSILE

STRENGTH, MPa

RECOMMENDED MINIMUM

PREHEAT TEMPERATUR

E, ° C

1. CARBON STEEL 1 ≤ 25 490 10

2. LOW ALLOY STEEL - 1¼% Cr ½% Mo

4 ALL ALL 149

3. LOW ALLOY STEEL - 2¼%Cr 1% Mo

5 ALL ALL 177

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TABLE 3

POSTWELD HEAT TREATMENT REQUIREMENTS

SL. NO.

BASE MATERIAL

P. NO.

NOMINAL WALL

THICKNESS,

mm

SPECIFIED

MINIMUM TENSILE STRENGTH, MPA

METAL TEMPERATURE RANGE °

C

BRINELL HARDNE

SS MAX.

1. CARBON STEEL

1 ≤ 19 ALL NONE -

2. CARBON STEEL

1 > 19 ALL 625-675 -

3. LOW ALLOY STEEL 1¼% Cr ½% Mo

4 ≤ 13 ≤ 490 NONE -


4 > 13 ALL 704 to 746 225


5 ≤ 13 ≤ 490 NONE -


5 > 13 ALL 704 to 760 241

7. AUSTENITIC STAINLESS STEELS

8, 9 ALL ALL NONE -

NOTES 1. In IBR systems, in carbon steels, postweld heat treatment is also required,

when the carbon percentage exceeds 0.25%, at the temperature range of 600 +/- 20°C.

2. All low alloy steel welds in IBR systems shall be postweld heat treated at the

temperature range of 620 to 660° C for 1 1/4% Cr 1/2% Mo steels and at a range of 660 to 750°C for 2 1/4% Cr 1% Mo steels.

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TABLE 4 WELD EXAMINATION (OTHER THAN ‘IBR’)

SL. NO

.

FLUID SERVICE CATEGORY AS

PER ASME B 31.3

TYPE OF EXAMINATIO

N

EXTENT OF EXAMINATION

GIRTH

BUTT WEL

D

SOCKET

AND FILLE

T WELD

S

BRANCH

WELDS (FABRI-CATED)

FABRICATED MITRES

/ REDUCER

S

ATTACH

MENT WELD

S

1.0 CATEGORY D VISUAL 100% 100% 100% 100% 100%

LT/MT - - 5% - -

2.0 NORMAL VISUAL 100% 100% 100% 100% 100%

RT 10% - - 10% -

LT/MT - 10% 10% - 10%

3.1 CATEGORY M VISUAL RT

LT/MT

100% 100% 100% (FOR ROO

T RUN)

100% -

100%

100% -

100%

100% - -

100% -

10% 3.2 HIGH PRESSURE

(ASME 600 CLASS AND HIGHER)

3.3 CRITICAL SERVICES SUCH AS CHLORINE, CAUSTIC, HYDROGEN AND OTHERS AS DEFINED IN SECTION-C

3.4 LOW TEMPERATURE [<(-)80°C]

3.5 SEVERELY CYCLIC AS PER ASME B 31.3

NOTES Fluid services are categorised as follows (as per ASME B 31.3)

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1. Category D : Fluid is non-flammable, non-toxic, and not damaging to human tissues, and design pressure is ≤ 1.035 M Pag(150 psig) and design temperature is ≤ 186°C and not below (-) 20°C.

2. Category Normal : Not Category D, not category M, not “high pressure” as per

ASME B31.3 and not subject to severe cycling as defined in ASME B 31.3. 3. Category M : Toxic Services which can damage human tissue after a single

exposure even if prompt remedial measures are taken.

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TABLE 5

WELD EXAMINATION (IBR PIPING)

SL. NO

.

ANSI PRESSU

RE CLASS

NOM PIPE SIZE, mm

TYPE OF EXAMINATI

ON

EXTENT OF EXAMINATION

GIRTH BUTT WELD

SOCKET AND FILLET WELD

S

BRANCH WELDS

FABRICATED

ATTACHMENT WELDS

1. ALL ALL VISUAL 100% 100% 100% 100%

2. 150 AND 300

≥ 100 RT 10% - - -

50 to 80 RT 2% - 2% -

≤ 40 LT/MT - 2% - -

3. 600 AND HIGHER

≥ 50 RT 100% - - -

≤ 40 LT/MT NOTE 2

100% 100% 10%

NOTES

1. The extent of examination shown above is minimum and any additional requirement as required by ‘IBR’ shall also be considered.

2. For root runs of butt welds in sizes ≥ 50 mm (100%)

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SPEC. NO. TCE.M4-904

TATA CONSULTING ENGINEERS LIMITED SECTION: E

SHOP INSPECTION AND TESTS SHEET 1 OF 7

ISSUE R9

TCE FORM NO. 329 R5 FILE NAME: M4904R9.DOC

1.0 SCOPE This specification covers the requirements for Shop Inspection and Tests to be

carried out by the PURCHASER/CONSULTANT/INSPECTION AGENCY. 2.0 GENERAL 2.1 The plant and equipment covered by the PURCHASE ORDER/CONTRACT

shall be subjected to inspection and testing. The VENDOR/CONTRACTOR shall provide all services to establish and maintain quality of workmanship in his works and that of his SUB-VENDOR’s/SUB-CONTRACTOR’s works to ensure the mechanical accuracy of components, compliance with approved drawings, identification and acceptability of all materials, parts and equipment.

2.2 For supply of systems, the VENDOR/CONTRACTOR shall, at the start of the

PURCHASE ORDER/CONTRACT, furnish a total list of items in his scope of work. This list, giving a brief description of the item, quantity, names of probable SUB-VENDORS/SUB-CONTRACTORS, and a blank column for agency for final approval of drawings and documents, shall be submitted for approval by PURCHASER/CONSULTANT. The blank column shall be filled by PURCHASER/CONSULTANT. The list shall be submitted within two weeks from the date of Letter of Intent.

2.3 For systems and major items such as pressure and load bearing items,

machineries etc., the VENDOR/CONTRACTOR shall furnish quality plan giving details of checks and tests to be conducted by them on material, process, sub-assembly and assembly. These shall include requirements as prescribed in the applicable specifications, codes and statutory requirements. The quality plan shall be reviewed by the PURCHASER/CONSULTANT and the stages to be witnessed and verified shall be indicated by the PURCHASER/CONSULTANT in the approved quality plan.

2.4 The VENDOR/CONTRACTOR shall give the PURCHASER/CONSULTANT

written notice of any material being ready for testing as per format enclosed. The clear notice period shall be seven (7) days for local inspection and fifteen (15) days for outstation inspection. Such tests shall be to the VENDOR’s/CONTRACTOR's account except for the expenses of the PURCHASER/CONSULTANT. The PURCHASER/CONSULTANT, unless the inspection of the tests is virtually waived, shall fix a date for inspection with the VENDOR/CONTRACTOR and attend such tests within fifteen (15) days of the date on which the equipment is notified as being ready for test and inspection failing which, the VENDOR/CONTRACTOR may proceed with the tests and shall forthwith forward to the PURCHASER/CONSULTANT duly certified copies of tests in triplicate. If the VENDOR/CONTRACTOR fails to offer the equipment for inspection as per the agreed date, he is liable to pay for the time and expenses for the infructuous visit of the PURCHASER/CONSULTANT.

2.5 In all cases where inspection and tests are required whether at the premises or

works of the VENDOR/CONTRACTOR or of any SUB-VENDOR/SUB-CONTRACTOR or at laboratory, the VENDOR/CONTRACTOR, except where otherwise specified, shall provide free of charge all facilities such as labour,

PART IIB of 221




ISSUE R9


materials, electricity, fuel, water, stores, test bed, apparatus and instruments, laboratory tests etc. as may be required by the PURCHASER/CONSULTANT to carry out effectively such tests of the equipment in accordance with the PURCHASE ORDER/CONTRACT and shall give facilities to the PURCHASER/ CONSULTANT to accomplish testing.

2.6 The PURCHASER/CONSULTANT shall at all working hours have access to all

parts of the VENDOR’s/CONTRACTOR's and his SUB-VENDOR’s/SUB-CONTRACTOR's factory where the items of the plant are being prepared, for carrying out inspection activities as deemed necessary. A set of the relevant latest approved drawings with approval marking of the PURCHASER/ CONSULTANT and drawings for proprietary items shall be made available by the VENDOR/CONTRACTOR to the PURCHASER/CONSULTANT, for reference during inspection.

2.7 In the case of stage inspection hold points, the VENDOR/CONTRACTOR shall

proceed from one stage to another only after the component is inspected by the PURCHASER/CONSULTANT and written permission given to proceed further. The same procedure shall be adopted for any rectifications and repairs suggested by the PURCHASER/CONSULTANT.

2.8 The PURCHASER/CONSULTANT shall have the right to inspect any

machinery, material, structures, equipment or workmanship furnished or used by the VENDOR/CONTRACTOR and may reject any which is defective or unsuitable for the use and purpose intended, or which is not in accordance with the intent of the PURCHASE ORDER/CONTRACT. The VENDOR/ CONTRACTOR, upon demand by the PURCHASER/CONSULTANT, shall remedy or replace at the VENDOR’s/CONTRACTOR's expense such defective or unsuitable items of the plant, or the PURCHASER/CONSULTANT may, at the expense of the VENDOR/CONTRACTOR, remedy or replace such defective or unsuitable items of the Plant.

2.9 All principal mill test reports, the VENDOR/CONTRACTOR inspection and tests

reports, test certificates and test curves shall be supplied for all inspection and tests carried out including other records such as stress relieving charts, radiographic charts and other non-destructive testing records in accordance with the provisions of the PURCHASE ORDER/CONTRACT, duly certified by the main VENDOR/CONTRACTOR. The PURCHASER/CONSULTANT shall reserve the right to call for certificates of origin and test certificates for all raw material and equipment at any stage of manufacture.

2.10 The PURCHASER/CONSULTANT shall within fifteen (15) days from the date of

inspection as defined herein give notice in writing to the VENDOR/ CONTRACTOR of any non-conformance pertaining to all or any equipment and workmanship which in his opinion is not in accordance with the PURCHASE ORDER/CONTRACT. The VENDOR/CONTRACTOR shall give due consideration to such objections and shall either make the modifications that may be necessary to meet the said objections or shall confirm in writing to the PURCHASER/CONSULTANT giving reasons therein that no modifications are necessary to comply with the PURCHASE ORDER/CONTRACT.

PART IIB of 221




ISSUE R9


2.11 When the factory tests and documentation have been satisfactorily completed at the VENDOR’s/CONTRACTOR's or SUB-VENDOR's/CONTRACTOR's works, the PURCHASER/CONSULTANT shall issue acceptance note or shipping release note or a certificate to this effect within fifteen (15) days after completion, but if the tests are not witnessed by the PURCHASER/ CONSULTANT, the certificate or comments thereof shall be issued within fifteen (15) days of the receipt of the VENDOR’s/CONTRACTOR's test certificate by the PURCHASER/CONSULTANT. Failure of the PURCHASER/ CONSULTANT to take such an action shall not prevent the VENDOR/ CONTRACTOR from proceeding with the work. The completion of these tests or the issue of the certificates shall not bind the PURCHASER/ CONSULTANT to accept the equipment, should it, on further tests after erection, be found not to comply with the PURCHASE ORDER/CONTRACT.

2.12 None of the plant and the equipment to be furnished or used in connection with

the PURCHASE ORDER/CONTRACT shall be despatched until shop inspection, satisfactory to the PURCHASER/CONSULTANT has been made. However, such shop inspection and/or certification shall not relieve the VENDOR/CONTRACTOR of his responsibility for furnishing the plant and the equipment conforming to the requirements of the PURCHASE ORDER/ CONTRACT nor prejudice any claim, right or privilege which the PURCHASER/ CONSULTANT may have because of the use of defective or unsatisfactory items. Should the PURCHASER/CONSULTANT waive the right to inspect any item, such waiver shall not relieve the VENDOR/CONTRACTOR in any way from his obligation under the PURCHASE ORDER/CONTRACT. In the event of the PURCHASER’s/CONSULTANT's inspection revealing poor quality of goods, the PURCHASER/CONSULTANT shall be at liberty to specify additional inspection procedures, if required, to ascertain the VENDOR/CONTRACTOR's compliance with the equipment specifications.

3.0 SUB-ORDERS AND SUB-CONTRACTS 3.1 In order to facilitate the inspection of bought-out materials and plant, the

VENDOR/CONTRACTOR shall submit for approval, three (3) copies of all sub-orders and sub-contracts placed by him as soon as these are issued. Copies of any drawings referred to in the sub-order or sub-contracts shall also be submitted, unless agreed otherwise by the PURCHASER/CONSULTANT.

3.2 The sub-orders, sub-contracts and drawings referred to above shall include all

components which are subjected to electrical and mechanical pressure or stress when the plant is in operation, and also auxiliaries and spares which are to be directly despatched to site from the SUB-VENDOR’s/SUB-CONTRACTOR's works.

3.3 All sub-orders and sub-contracts of the main VENDOR/CONTRACTOR shall

clearly be marked with the main VENDOR’s/CONTRACTOR's name and the PURCHASER’s/CONSULTANT’s name and the PURCHASE ORDER/ CONTRACT reference. These shall include the following statement:

The plant or the equipment which is the subject of this PURCHASE ORDER/

CONTRACT shall comply in every respect with the requirements of the

PART IIB of 221




ISSUE R9


PURCHASER’s/CONSULTANT's technical specifications and shall be subject to inspection and tests to the satisfaction of the PURCHASER/CONSULTANT.

3.4 For the purpose of this para, it is obligatory on the VENDOR/CONTRACTOR

that he advises his SUB-VENDOR/SUB-CONTRACTOR of the pertinent clauses in this specification when ordering bought-out plant, equipment or materials. In particular, the VENDOR/CONTRACTOR shall advise every SUB-VENDOR/SUB-CONTRACTOR that he is required to supply design calculations, drawings, inspection reports and test certificates strictly in accordance with this specification and technical information for inclusion in the Instruction Manual as specified in Section E of the Enquiry Document. The SUB-VENDORS/SUB-CONTRACTORS should also be reminded that they shall include with their offer all tools and appliances necessary for proper maintenance and all spare parts in accordance with Section E of the Enquiry Document. Itemised prices of the recommended spare parts shall be submitted together with the appropriate part numbers and drawings.

3.5 Sub-ordering and sub-contracting for major items such as pressure and load

bearing items, machinery etc. can be done only with the approval of the PURCHASER/CONSULTANT.

4.0 MATERIAL TESTS 4.1 In the event of the PURCHASER/CONSULTANT being supplied with the

certified particulars of tests which have been carried out for the VENDOR/ CONTRACTOR by the supplier of material, the PURCHASER/CONSULTANT may, at his own discretion, accept the same as proper evidence of compliance with the requirements of appropriate specifications for the materials.

4.2 The VENDOR/CONTRACTOR is to provide test pieces as required by the

PURCHASER/CONSULTANT to enable him to determine the quality of material supplied under the PURCHASE ORDER/CONTRACT. If any test piece fails to comply with the requirements, the PURCHASER/CONSULTANT may reject the entire lot of material represented by the test piece.

4.3 Critical materials used in manufacture of the equipment and construction of the

plant covered by the PURCHASE ORDER/CONTRACT may also be subjected to one or more of the Non-Destructive Tests (NDT) as called for in the enquiry document or as mutually agreed. Salvaging of material due to unacceptable defect is to be attempted by the VENDOR/CONTRACTOR only after getting specific concurrence from the PURCHASER/CONSULTANT and according to the approved procedures.

5.0 WELDING 5.1 All welding involved in construction and fabrication of the plant and items

covered under the PURCHASE ORDER/CONTRACT shall be carried out in accordance with specifications and applicable codes.

5.2 Welding procedures and welders' qualifications shall be approved by the

PURCHASER/CONSULTANT. Where applicable, welders shall be tested as

PART IIB of 221




ISSUE R9


detailed in codes specified for pipe welding, vessel welding and structural welding and appropriate to the corresponding weld position using test pieces of appropriate parent metal to be used on the job. The PURCHASER/ CONSULTANT shall have the right to have any welder re-tested at any time during the PURCHASE ORDER/CONTRACT.

5.3 Recommendations of applicable codes shall be followed for non-destructive

tests, wherever applicable. 5.4 Copies of all welding procedures, procedure qualification records, welders'

performance qualification certificates, post-heating and stress relieving records, NDT records and other test results shall be made available upon request of the PURCHASER/CONSULTANT.

6.0 FABRICATION AND INSPECTION Fabrication and inspection procedures for vessels, heat exchangers, pipes,

tubes and valves etc. shall be in accordance with procurement specifications, quality plan, applicable codes or any other approved equal.

7.0 TESTS AT MANUFACTURER'S WORKS 7.1 GENERAL The tests at works shall include electrical, mechanical and hydraulic tests in

accordance with the appropriate clauses of Statutory Regulation, relevant codes and standards and approved drawings and specifications and in addition any test called for by the PURCHASER/CONSULTANT to ensure that the plant being supplied fulfils the requirements of the specifications. The VENDOR/ CONTRACTOR shall carry out all the shop tests and inspections specified under individual items of the equipment in Section-D of the enquiry document, in addition to those normally required as per codes and standards. For items not covered by any code or specifically mentioned in the specifications, the tests are to be agreed with by the PURCHASER/CONSULTANT. If considered necessary by the PURCHASER/CONSULTANT, multi-part assemblies shall be fully erected and tested in the works prior to packing and despatch to the site.

7.2 TEST CERTIFICATES Test certificates including test records, performance curves and balancing

certificates shall be supplied according to the Distribution Schedule. All the tests shall be carried out in accordance with the provisions of the PURCHASE ORDER/CONTRACT.

All test certificates must be endorsed with sufficient information to identify the

material or the equipment to which the certificates refer, and must carry at the top right hand corner the identification of the PURCHASER/CONSULTANT and the PURCHASE ORDER/CONTRACT.

PART IIB of 221




ISSUE R9


7.3 CALIBRATION All instruments used for critical measurement such as pressure gauges for leak

tests, instruments for measuring performance parameters; instruments for precision dimension measurements shall have valid calibration certificates traceable to national standards. This means that the calibrating agency engaged by the VENDOR/CONTRACTOR shall use instruments which are in turn calibrated by Government approved agencies and such information shall be recorded in the calibration certificate issued by the calibrating agency by giving the certificate number, date and date of validity of the certificate given by the Government approved agency.

FORMAT FOR INSPECTION REQUEST FROM THE

VENDOR/CONTRACTOR To, TATA CONSULTING ENGINEERS LIMITED,

Attn: Mr/Ms

PROJECT MANAGER Dear Sir/Madam, Items detailed below are ready for inspection. Please arrange inspection and

confirm the date. 1. PURCHASER 2. PROJECT 3. PURCHASE ORDER/CONTRACT

REFERENCE NUMBER

4. CONSULTANT (TCE) REFERENCE

NUMBER

5. SUB-VENDOR/SUB-CONTRACTOR 6. SUB-VENDOR’s/SUB-CONTRACTOR’s

ADDRESS

7. PLACE OF INSPECTION AND ADDRESS 8. CONTACT PERSON, PHONE, FAX AND

E-MAIL ID

9. DESCRIPTION OF ITEM AND QUANTITY 10. NATURE OF INSPECTION REQUIRED

PART IIB of 221




ISSUE R9


11. PROPOSED DATES 12. WEEKLY HOLIDAY We confirm that the items have been fully inspected and tested by us. All stages

of inspection as per approved quality plan have been carried out by us and all material test certificates, quality control records and test reports and valid calibration reports of measuring and testing instruments with traceability to national level are ready with us.

Thanking you and awaiting your confirmation, Yours faithfully, Note 1 Following clear notice periods (Date of Receipt at TCE to Date of

Inspection) are required: (a) Local Inspection - 7 days (b) Outstation Inspection - 15 days Note 2 Weekly Holidays for TCE - Saturday and Sunday cc: Purchaser cc: Sub-Vendor/Sub-Contractor

PART IIB of 221

SPEC NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D TCE-6079A-186-21 MINIMUM INSPECTION REQUIREMENTS FOR STEAM

TURBINE ROTORS & TURBINE ASSEMBLY

SHEET OF 3 OF 4

1

ISSUE

R0

TCE FORM 329 R3

INSPN

CATEGORY

1. ROTOR :

Mechanical properties

Chemical Composition

Heat Treatment Charts Review

Residual stress measurement

Heat stability test

(For HP & IP rotors)

UT after machining before

groove cutting

Microstructure

MT after proof machining

Visual, Dimensional and Runout

checks after finish machining

Boroscopic and borosonic

examinations (if applicable)

Copper sulphate test on Lock

Screws and Lacing Wire

Runout check (on bladed rotor)

Balancing and overspeed tests

Vibration analysis

Final runout checks

Review of test

certificates

100%

100%

C

C

C

B

C

C

C

C

C

B

C

A

A

A

A

PART IIB of 221



SHEET OF 3 OF 4

2

ISSUE

R0

TCE FORM 329 R3

INSPN

CATEGORY

2. STATOR AND :

ROTOR BLADES

Mechanical Properties



Hardness check

UT on forgings/barstock/Raw matls.

Crack detection on finished blades

Spectroscopic test on finished blades

Vibration/Frequency check on LP blades

Review of test

certificates

100%

MT 100%

10%

10%

C

C

C

C

C

C

C

A

3. STEAM INLET :

VALVES

Dimension of spindle

Valve Lift

A

A

4. TURBINE :

ASSEMBLY

Check for clearance between shaft seal

casing and shaft sealing rings

Check for clearances on antirotation device

in shaft seal casing joint

Check for radial and axial alignment of

inner and outer casings

Axial and radial blade clearances

Casing bolts identification and tightening

procedure verification

Minimum radial and axial clearances of

assembled turbine

A

A

A

A

A

A

PART IIB of 221



SHEET OF 3 OF 4

3

ISSUE

R0

TCE FORM 329 R3

INSPN

CATEGORY

5. DISC AND COUPLING :

FORGING (If applicable)


Microstructure


Heat treatment chart review

UT & MT

100 %

C

A

C

C

A

6.

PERFORMANCE TEST :

No load performance tests (if applicable)

A

NOTES:

(I) INSPN CATEGORY :

A - WITNESSED BY TCE/PURCHASER

B - WITNESSED BY TCE/PURCHASER’S DISCRETION

C - CERTIFICATES REVIEW BY TCE/PURCHASER

(II) ACCEPTANCE NORMS:

(1) MATERIALS : As per applicable material specifications

(2) WELDING : As per ASME Section-IX

(3) NON DESTRUCTIVE : As per ASME Section-V/Section-VIII Div 1

TESTING requirements

(4) DYNAMIC BALANCING : As per ISO 1940/VDI 2060

(5) NOISE LEVEL : Max 85 dB at 1.0m distance

(6) VIBRATION LEVEL : VDI 2056 – ‘Good’ Zone

(7) NO LOAD PERFORMANCE TEST : As per PTC

(III) PT - LIQUID PENETRANT TESTING

MT - MAGNETIC PARTICLE TESTING

UT - ULTRASONIC TESTING

RT - RADIOGRAPHIC TESTING

PART IIB of 221

SPEC NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D TCE-6079A-186-22 MINIMUM INSPECTION REQUIREMENTS FOR

STEAM TURBINE CASINGS

SHEET OF 3 OF 4

1

ISSUE

R0

TCE FORM 329 R3

INSPN

CATEGORY

1. HP Casing :

(Outer & Inner)

Mechanical properties,


Microstructure

Visual, Dimensional checks

(Before machining)


RT, UT and MT on all

accessible areas before

machining

RT/UT and MT on all fillet

weld connections of

nozzles/attachments on the

casing

Dimensional inspection after

final machining

Hydraulic tests

UT of HP casing (Inner) before

groove cutting

100%

100%

C

A

C

C

A

A

A

A

A

2. LP Casing :

(Outer & Inner)

Mechanical Properties,


UT of plates

Welding Procedure &

Welder’s Performance &

Qualifications


Visual, Dimensional checks

Review of test certificates

100%

C

C

C

C

A

PART IIB of 221



SHEET OF 3 OF 4

2

ISSUE

R0

TCE FORM 329 R3

INSPN

CATEGORY

3.

IP Casing :

(Outer & Inner)

(If applicable)

RT of butt joints

MT/PT on all fillet welds, connections

of nozzles/attachments on the casing



UT of plates/castings

Visual & Dimensional checks


RT of weld ends (after finish

machining)

MT on all accessible areas

RT of butt joints

RT/UT and MT on all fillet weld

connections of nozzles/attachments on

the casing

Hydraulic tests

100%

100%

Review of test

certificates

100 %

100%

100%

100%

A

A

C

C

A

C

A

A

A

A

A

NOTES:

(I) INSPN CATEGORY :

A - WITNESSED BY TCE/PURCHASER

B - WITNESSED BY TCE/PURCHASER’S DISCRETION

C - CERTIFICATES REVIEW BY TCE/PURCHASER

PART IIB of 221



SHEET OF 3 OF 4

3

ISSUE

R0

TCE FORM 329 R3

(II) ACCEPTANCE NORMS:

(1) MATERIALS

(2) WELDING

(3) NON DESTRUCTIVE TESTING

: As per applicable material specifications

: As per ASME Section-IX

: As per ASME Section -V/ Section-VIII Div. 1

requirements

(III) PT - LIQUID PENETRANT TESTING

MT - MAGNETIC PARTICLE TESTING

UT - ULTRASONIC TESTING

RT - RADIOGRAPHIC TESTING

PART IIB of 221

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3 ROTOR ASSEMBLY D

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5 COMPLETED ITEM A A D D A A D B

6 LININGS, IF ANY A A

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LEGEND

A - WITNESSED BY TCE.

B - WITNESSED BY TCE IF REQUIREMENT IS SPECIFIED.

C - RECORDS VERIFIED BY TCE WHEREVER APPLICABLE.

D - A OR C, AT TCE'S DISCRETION WHEREVER APPLICABLE.

NOTES

1 - ALL STAGES SHALL BE CHECKED 100 % BY VENDOR AND RECORDS THEREOF SHOWN TO TCE.

2 - WITNESSING BY TCE MAY BE 100 % OR ON RANDOM SAMPLES.

3 - THIS DOCUMENT SHALL BE READ IN CONJUNCTION WITH INSPECTION REQUIREMENTS MENTIONED IN TCE.

M4 - 904 AND RELEVANT TECHNICAL SPECIFICATIONS.

4 - THE PRESSURE GAUGES AND INSTRUMENTS FOR MEASURING CRITICAL PARAMETERS SHALL HAVE VALID

CALIBRATION CERTIFICATE TRACEABLE TO NATIONAL LABORATORY.

5. AS PER API 610TH EDITION.

SH

EE

T

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F 1

SE

CT

ION

D

ISS

UE

R0

PART IIB of 221

PART IIB of 221

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3 SHAFT MATERIAL, GEAR BLANKS D D C D B B C C

4 MACHINED SHAFT, GEARS D D B B D D D D

5 BEARINGS, FASTENERS, OIL SEALS C D C

6 ASSEMBLED GEAR BOX A A A A A A A C

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LEGEND

A - WITNESSED BY TCE

B - WITNESSED BY TCE IF REQUIREMENT IS SPECIFIED.

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D - A OR C, AT TCE'S DISCRETION WHEREVER APPLICABLE.

NOTES

1 - ALL STAGES SHALL BE CHECKED 100 % BY VENDOR AND RECORDS THEREOF SHOWN TO TCE.

2 - WITNESSING BY TCE MAY BE 100 % OR ON RANDOM SAMPLES.

3 - THIS DOCUMENT SHALL BE READ IN CONJUNCTION WITH INSPECTION REQUIREMENTS MENTIONED IN TCE.

M4 - 904 AND RELEVANT TECHNICAL SPECIFICATIONS.

4 - THE PRESSURE GAUGES AND INSTRUMENTS FOR MEASURING CRITICAL PARAMETERS SHALL HAVE VALID

CALIBRATION CERTIFICATE TRACEABLE TO NATIONAL LABORATORY.

SH

EE

T

1 O

F 1

SE

CT

ION

D

ISS

UE

R0

PART IIB of 221

TATA CONSULTING ENGINEERS LIMITED SECTION: FACING PAGE

TCE.6079A-CH-300-DC-01 PROJECT DESIGN BASIS SHEET OF iii

P0 01/07/2010

JRT

JRT

SCD

CRK

AVD

CSP

SN

AV

REV NO . DATE

PREPARED BY

PChE PME PCE PEE PICE CLEARED BY

APPROVED BY

CHECKED BY

i

TCE FORM 032 R2

PROJECT DESIGN BASIS

CLIENT : BHARAT PETROLEUM CORPORATION LIMITED

PROJECT : PMC SERVICES FOR UTILITIES & OFFSITES OF NHT/CCR

LOCATION : MAHUL BPCL REFINERY , MUMBAI

CONSULTANT : TATA CONSULTING ENGINEERS LIMITED

TCE JOB NO : TCE – 6079A

FILE NAME : 6079ACH300DC01 Floppy :

PART IIB of 221

TATA CONSULTING ENGINEERS LIMITED SECTION:CONTENTS

TCE.6079A-CH-300-DC-01 PROJECT DESIGN BASIS

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FORM NO. 120 R3

CONTENTS

1.0 INTRODUCTION ........................................................................................................... 1

2.0 DEFINITION OF PROJECT ........................................................................................... 1

3.0 PLANT LOCATION ........................................................................................................ 4

4.0 METEOROLOGICAL DESIGN DATA............................................................................. 6

5.0 ECONOMIC CRITERIA .................................................................................................. 8

6.0 UTILITY SPECIFICATIONS ........................................................................................... 8

7.0 GENERAL DESIGN PHILOSOPHY ............................................................................. 27

8.0 EQUIPMENT DESIGN PHILOSOPHY ......................................................................... 27

9.0 INSTRUMENTATION ................................................................................................... 44

10.0 PIPING & INSULATION ............................................................................................... 45

11.0 SAFETY AND ENVIRONMENTAL REQUIREMENTS .................................................. 46

12.0 PROCESS FLOW DIAGRAMS AND PIPING & INSTRUMENTATION DIAGRAMS ..... 48

13.0 EQUIPMENT DESIGNATION AND NUMBERING SYSTEM ........................................ 49

14.0 STANDARDS & CODES .............................................................................................. 50

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TATA CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP


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FORM NO. 120 R3

REVISION STATUS SHEET

REV. NO. DATE DESCRIPTION P0 01/07/2010 Issued for Client’s comments

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1.0 INTRODUCTION This Engineering Design Basis is for PMC services for the utilities & offsites of NHT/CCR services Project contains technical information) to be followed for the offsite packages. This Engineering Design Basis defines overall design requirements, and common design philosophy, with the intent of ensuring uniformity in design practices.

2.0 DEFINITION OF PROJECT 2.1 Definition of Utilities and Off Sites

(a) Definition of Utilities and Off Sites Facilities

Utilities & Offsites

Sr. No. Facility Unit

No. New/

Existing Capacity

1 Nitrogen Plant 412 New As Required

2 HC Flare 415 New As Required

3 Acid gas Flare 416 New As Required

4 DM Water Plant 417 New As Required

5 Condensate Polishing Unit 409 New As Required

6 Air Compressor 410 New As Required

7 Air Dryer 411 New As Required

8 Air Compressor for Nitrogen 413 New As Required

9 Cooling Water Pumps 143 New As Required

10 Fuel Gas- Distribution System 143 New As required

11 Naphtha Distribution 143 New As required

12 Cooling Water - Distribution 143 New As required

13 DM Water - Distribution 143 New As required

14 Boiler Feed Water - Distribution 143 New As required

15 Condensate, distribution 143 New As required

16 Service Water - Distribution 143 New As required

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Utilities & Offsites

Sr. No. Facility Unit

No. New/

Existing Capacity

17 Medium Pressure Steam - distribution 143 New As required

18 Low Pressure Steam- distribution 143 New As required

19 Power - Distribution 143 New As required

20 Instrument Air - Distribution 143 New As required

21 Plant Air - Distribution 143 New As required

22 Nitrogen - Distribution 143 New As required

23 Hydrogen - Distribution 143 New As required

24 Closed Blow Down- 143 New As required

25 Oily Water Sewer - 143 New As required

26 Fire Water Distribution System 143 New As required

27 Contaminated Rain Water System - 143 New As required

28 Sour Water Collection and transfer 143 New As required

29 Drinking Water 143 New As required

30 Acid flare line 143 New As required

31 Hydro Carbon Flare Line 143 New As Required

2.2 Units Of Measurement

2.2.1 MKS system of measurement shall be followed, with the exception of piping / tubing & equipment nozzles sizes which shall be reported in inches. Defaults measurement units are given below:

Parameter MKS Units

Temperature °C

Pressure (gauge) kg/cm2g

Pressure (absolute) kg/cm2a

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Parameter MKS Units

Mass / Weight kg

Pipe Length / Equipment size m / mm

Pipe Diameter / vessel nozzle size in

Liquid relative density Sp. Gr T°C/15°C

Liq density kg/m3

Vap density kg/m3

Furnace draught mm of WC

Storage tank pressure mm of WC

Vacuum mm of Hg

Flowing mass Kg/hr

Flowing vapor kg/h or m3/hr

Flowing liquid M3/hr or MT/D & litres/hr for metering Pump

Flowing Gas m3/hr

Fouling Resistance m2. °C. h / kcal

Gas / Vapour flow at Normal Conditions Nm3/hr at 0°C & 760 mmHga

Gas / Vapour flow at Standard Conditions

Sm3/hr at 15.5°C & 760 mmHga

Thermal conductivity kcal/hr-m-°C

Heat Transfer coefficient kcal/hr-m2-°C

Enthalpy kcal/kg

Heat Duty MMkcal/hr

Viscosity cP

Kinematic Viscosity cst

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Parameter MKS Units

Composition Vol %

Power kW

Area m2

Volume m3

The normalized conditions for gas measurement are:

Standard: 760 mmHg, 15.5 Degree C (60 Degree F) (Sm3/h)

Normal: 760 mmHg, 0 Degree C (Nm3/h)

2.2.2 Material Balance in PFD shall be reported in following units

(a) GASES: Nm3/hr or Sm3/h kg/hr MT/D

(b) LIQUIDS: m3/hr or MT/D kg/hr m3/hr MT/D

2.2.3 For datasheet preparation, flow rates will be specified as per equipment/ instrument datasheet standards.

3.0 PLANT LOCATION 3.1 Site Location

(a) Plant Location : Mahul, Mumbai

(b) State : Maharashtra

(c) Nearest Important Town : Mumbai

(d) Nearest Railway : Mumbai

(e) Nearest Port : Mumbai

(f) Nearest Airport : Chatrapati Shivaji Airport, Mumbai

3.2 Source of water

(a) Fresh Water : Mumbai Municipal Corporation

(b) Cooling Water : Circulating Raw Water

(c) Fire water : Sea Water (with raw water for flushing of lines)

(d) Fire Water : Specific critical equipments as per OISD standards

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(e) Fire Water for SS equipment

: Fire Water (with Raw Water for flushing of lines / equipment)

Transformers fire fighting will be sea water with raw water connection for testing of the system and flushing out the lines.

3.3 Rainy season : June -September 3.3.1 Annual Rainfall (Max/Min/A vg) : Max.: 125mm/hr

3.4 Wind & Seismic Design: 3.4.1 Wind load

According to IS 875

Basic wind speed: 44 m/sec.

Design wind pressure: Refer Table below

Height (m) Class 'A' Class 'B ' Class 'C '

in KN/Sq.m. in KN/Sq.m. in KN/Sq.m.

10 1.16 1.28 1.15

15 1.28 1.38 1.25

20 1.33 1.47 1.33

25 1.46 1.61 1.44

30 1.52 1.68 1.52

35 1.59 1.76 1.61

40 1.63 1.80 1.65

45 1.67 1.85 1.69

50 1.71 1.89 1.73

60 1.75 1.93 1.78

70 1.79 1.98 1.82

80 1.81 2.00 1.85

90 1.83 2.02 1.87

100 1.86 2.04 1.90

110 1.16 1.28 1.15

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Height (m) Class 'A' Class 'B ' Class 'C '

in KN/Sq.m. in KN/Sq.m. in KN/Sq.m.

120 1.28 1.38 1.25

130 1.33 1.47 1.33

Note: Linear interpolation / extrapolation may be done.

4.0 METEOROLOGICAL DESIGN DATA 4.1 This section presents relevant data towards process engineering.

Sr No Parameter Minimum /

winterizing Normal / Average

Maximum / Design

(A) METEOROLOGICAL DATA

1. Elevation above mean sea level, m 6.71

2. Ambient temperature, °C 12/9 40/42

3. Relative humidity, % 100% @ 320 C

4. Rainfall data: for 1-hour period 102mm For

CRWS loading

5. Wind data (a) wind velocity

(b) Predominant wind direction

9m/s

W to E

SW to NE

(B) DATA FOR EQUIPMENT DESIGN

6. Design dry bulb temperature, °C 40

7. Design wet bulb temperature, °C 30

8. Low ambient temperature for MDMT, °C 12

9. Design Air Temperature for Air cooled exchangers °C where followed by water cooling

Design Dry Bulb Temperature + 2°C

10. Design Air Temperature for Air cooled exchangers °C where not followed by water cooling

Design Dry Bulb Temperature + 5°C

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Sr No Parameter Minimum /

winterizing Normal / Average

Maximum / Design

11. Coincident temperature and relative humidity for Air Blower / Air Compressor design

32°C & 100% RH

12. Design temperature for electrical MCC / PCC 45°C

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5.0 ECONOMIC CRITERIA 5.1 Unit Rates for Utilities

Sr. No Utility Unit Rs/Unit

1 Power kWH 5.00

2 Medium Pressure Steam

Metric Ton 2046.14

3 Low Pressure Steam Metric Ton 1841.53

4 Recirculationg Cooling Water

1000 m3 2567.43

5 Boiler Feed Water Metric Ton 365.45

6 Demineralised Water Metric Ton 67.91

7 Fuel Naphtha Metric Ton 28710.29

8 Nitrogen Nm3 4.93

9 Instrument Air 1000 Nm3 814.26

10 Raw Water m3 40.88

11 Plant Air 1000 Nm3 604.86

12 Fuel Gas Metric Ton 20402.72

13 R LNG Metric Ton 17463.70

14 HCl (30%) Kg 2.55

15 Caustic Lye ( 100% ) Kg 30.68

5.2 Loading Criteria for Package Units and Rotary Units

Additional cost to be loaded will be calculated as follows:

Utility cost per hour x 8000 hrs x 5 .

6.0 UTILITY SPECIFICATIONS 6.1 Utility Conditions at Unit Battery Limits

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The following ar the pressures required at the battery limit of CCR/NHT at grade.

Table-6.1: Utility conditions at unit battery limits

[All battery limit pressures are as measured at grade]

Sr. No. Parameter Minimum Normal Maximum Mech. Design

1. MEDIUM PRESSURE (MP) STEAM (Consumer) KCS(IBR) C.A. 1.5 mm

Pressure, kg/cm2g 13 15 20 23

Temperature 0, C 280 290 340 400

2. LOW PRESSURE (LP) STEAM (Consumer) KCS(IBR) C.A. 1.5 mm

Pressure, kg/cm2g 2 2.5 3.5 6.5

Temperature 0, C Saturated. Saturated. 150 180

3. CONDENSATE RETURN (SUSPECT/PURE) @ CPU Battery Limit KCS C.A. 1.5 mm

Pressure, kg/cm2g (Suspect /Pure) Later 10.8/9.7 Later 15

Temperature, C Later Later Later 180

4. RAW COOLING WATER KCS, C.A. 1.5 mm

Supply Pressure, kg/cm2g 3.5 4.5 5 7

Return Pressure, kg/cm g 2.0 2.5 3.0 7

Supply Temperature, °C 34 70

Return Temperature, C 45 70

5. RAW WATER

Pressure, kg/cm2g 3.5 4 4.5 7

Temperature 0, C 80

6. PROCESS WATER SS304L, C.A. 1.5 mm

Pressure, kg/cm2g 3.0 4.0 6.0 11.0

Temperature, °C 40 40 40 40

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7. FIRE FIGHTING WATER MS CEMENT LINE

Pressure, kg/cm2g 7 10 16.17

Temperature, C Ambient *

8. SERVICE WATER KCS, C.A. 1.5 mm

Pressure, kg/cm2g 4.0 4.5 5.0 9.0

Temperature, C Amb. Amb. Amb. 65

9. DEMINERALISED WATER SS304L, C.A. 1.5 mm

Pressure, kg/cm g 3 4 6 11

Temperature, C 40 40 40 65

10. BOILER FEED WATER (MP) KCS(IBR) C.A. 1.5 mm

Pressure, kg/cm2g 21 35

Temperature, 0C 105 REV04 150

11. PLANT AIR KCS C.A. 1.5 mm

Pressure, kg/cm2g 5 6 7 10.5

Temperature, 0C 45 65

12. INSTRUMENT AIR KCS C.A. 1.5 mm (Up to VA" Galvanized CS CA 1.5mm- CA HOLD)


Temperature, C 45 65

13. FUEL GAS Two pipe classes(l) KCS, (2) KCS + 3% Ni (for -52°C) C.A. 1.5 mm for both

Pressure, kg/cm2g 2.5 3 4.5 8

Temperature, 0C 45 65

14 NAPHTHA

Supply Pressure, kg/cm2g * * * *By BPCL

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Temperature, 0C * * *

15 NITROGEN KCS C.A. 1.5mm


Temperature, °C AMB 65

16 FLARE Two pipe classes(l) KCS, (2) KCS + 3% Ni (for -52°C)

C.A. 1.5 mm for both. Both classes to be suitable for H2 service

Pressure, kg/cm2g 0.1 1.7 3.5

Temperature, °C 200

17 ACID FLARE KCS, C.A. 3.0 mm and to be suitable for H2 service

Pressure, kg/cm2g 0.1 0.7 3.5

Temperature, 0C 150

18 CBD And OWS UG MOC KCS C.A. 3 mm + Cathodic Protection, Wrapping

Pressure, kg/cm2g 3.5

Temperature, 0C 130

Refrigeration if required will be generated within battery limits.

6.2 STEAM & CONDENSATE SYSTEMS 6.2.1 Default philosophy towards design of equipment generating or consuming steam:

(a) All steam consuming equipment including heat exchangers shall be mechanically rated based on maximum pressure and temperature of steam at battery limit and thermally designed for minimum battery limit pressure and temperature.

(b) NORMAL steam conditions shall be used for operating utility estimates, heat and material balances and battery limits connectivity.

(c) Steam system shall be designed as per relevant IBR guidelines.

(d) IBR safety valves will not have inlet isolation valves.

(e) For IBR documents Design Pressure shall be considered same as MAWP.

(f) Steam system relief valves shall be designed for design steam header pressure plus overpressure allowed by IBR.

6.2.2 Condensate recovery.

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(a) Condensate recovery from line steam traps: Yes No

(b) Condensate recovery from steam tracer traps: Yes No

(c) Alternate drain facility on grade to be provided for all steam traps.

6.2.3 Condensate recovery from steam consumers shall be done in one of the following ways:

Flash HP and MP condensate for recovery of LP steam. Return LP condensate under own pressure to utility system. Condensate return shall be two-phase.

Flash HP and MP condensate for recovery of LP steam.

Route MP and LP condensate for flashing into separate condensate flash drum.

All steam trap outlet to be connected in a group and condensate recovery system to be provided. Suitable arrangement shall be made to reduce the loss of steam from copper tubing. Steam trap local drains shall have soak pits. .

6.3 WATER SYSTEMS 6.3.1 For cooling water consumers connected to a recirculating cooling water system the

connection as in figure - 6.1 shall be provided. Back-flush to be from Supply header in case of exchangers at 18m and above while it shall be from the return header in case of exchangers at lower elevation. Back flush arrangement shall be provided for:

All cooling water consumers

Only overhead condensers

Cooling water consumers with water line sizes greater than ' NB

Figure - 6.1 Typical cooling water piping and instrumentation at heat exchangers

All CW returns will have butterfly valve

Upstream Drain for TSV

CW RETURN

CW SUPPLY

This connection 2 sizes less than line size to be provided with Butterfly valves

CW supply valves: 8 inch and below gate valves and above 8 inch butterfly valves

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6.3.2 All pump cooling water lines (for bearing cooling, gland cooling and seal cooling) shall be minimum 1 "NB. Tapping for cooling water to be taken from top of the cooling water supply header. The return line routing, will be:

Cooling water will be put in atmospheric vessel and pumped back to the cooling water header.

Return lines to be connected to separate header routed back to cooling tower sump.

Cross over shall be provided between cooling water supply and return headers in each unit for flushing.

A drain minimum 2" will be provided on the supply and return header dead ends of each unit.

Cross overs shall be provided between supply and return for all sub-headers with butterfly valves

Table6.2: Water Quality

Parameter DM Water BFW Raw

Water Process Water

Circ. Raw Water

MINAS water

PH 7.0-8.5 6.5-8 7.5-8.5 6.5-8.5

Turbidity, NTU (5 min settled) Nil - Nil Nil 20-30

(50max)

Total suspended solids, ppmw - 50-75

Total dissolved solids, ppmw Nil 5-7.5 75-160 Nil 375-650

Conductivity® 20 °C, micromho/cm <0.2 10-15 80-200 <0.2 800-

1500

M. Alkalinity (as CaCO3), ppmw - 50-60 100-120

Ca Hardness as CaCO3, ppmw Nil 18-30 Nil 90-150 20-100

Mg Hardness as CaCO3, ppmw 10-60

Total Hardness as CaCO3, ppmw Nil 50-75 250-375 30-160

Total cation / anion as -

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Water Process Water

Circ. Raw Water

MINAS water

CaCO3, mg/1

Total Silica as SiO2, ppmw <0.02 0.05 20-40 <0.02 100-200 10-25

Colloidal Silica as SiO2, mg/1 Nil Nil -

Sodium as Na, mg/1 -

Potassium as K, mg/1 -

Phosphates, ppm 1-3

Dissolved Ammonium salts, ppm 10-50

Chlorides as Cl, ppmw <0.1 15-40 <0.1 100-225 100-800

Free chlorine, ppmw - 2.0

Sulphates as SO4, mg/1 - 10-12 170-225

Organophosphates as PO4, mg/1 -

Organic matter, ppmw - 0.2-0.5

Nitrates as NO3, mg/1 - 80-300 $

Dissolved oxygen, mg/1 -

Total Iron + Copper, mg/1 -

Lead as Pb, microgram/1 -

Total Sulphur as S, ppmw <0.02 <0.02

Manganese as Mn, mg/1 -

Iron as Fe, ppmw <0.02 0.03 0.4 <0.02 l.O(max) <0.1

Chromium as Cr, mg/1 -

Total copper as Cu, ppmw <0.003 0.005 <0.003

Oil & Grease, ppmw Nil Nil 10(max)

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Water Process Water

Circ. Raw Water

MINAS water

KmnO4 consumption, ppmw <3 10 5-8 <3 30-40

(50max)

Polymeric dispersant, mg/1 20-30

Zinc Sulphate as Zn, mg/1 -

HEDP as PO4, mg/1 8-10

BOD, ppmw -

COD, ppmw <10 - 50-100$

Total Bacterial Counts (TBC) Counts /ml 60000-

100000#

Sulfate Reducing Bacteria Counts / 100 ml 40-60 #

Nitrifying bacteria Counts /100 ml 0-10$

Oxidation reduction potential mV 500-800

#: Before Addition of ClO2. $: Before Addition Sea water shall be used for fire fighting. Specification tabulated below:

Table-6.3: Fire Water Quality (Sea Water)

Parameters Units Value

pH 8 to 8.5

Total dissolved solids ppmw Max 64500

M alkalinity (as CaCO3) ppmw 195

Ca hardness as CaCO3 ppmw 1500

Total hardness as CaCO3 ppmw 8925

Total silica as SiO2 mg/1 22.5

Chloride as Cl ppmw 29850

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Free chlorine ppmw 0.2-0.3

Sulphates as SO4 mg/1 5825

Iron as Fe ppmw 1 max

Oil and grease ppmw lmax

KMNO4 consumption ppmw 30-40 , 50 max

olymerix dispersant mg/1 20-30

6.4 COMPRESSED AIR & NITROGEN SYSTEMS 6.4.1 The specifications of plant air and instrument air are indicated in

Table-6.4 Plant Air & Instrument Air quality

Sr. No. Parameter Plant Air Instrument Air

1 Dew Point at atmospheric pressure water-free (-) 40 °C

2 Oil Content, ppm Nil Nil

Duration in which system is to be pressurized for leak test: 12 hours.

Table-6.5 : Inert Gas quality (Nitrogen)

Sr. No Contents Quantity

1 Nitrogen % volume 99.9

2 Oxygen ppm volume < 10

3 Carbon Monoxide ppm volume 10

4 Carbon Dioxide ppm volume 3

5 Noble gases ppm volume 50

6 Dew Point at atmospheric pressure -100°C

6.5 FUEL SYSTEMS 6.5.1 Liquid fuel system for the project shall be one of the following.

No liquid fuel system applies to the project.

Existing liquid fuel system shall cater to the project.

Two new liquid fuel systems for the total project:

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Low sulphur fuel oil for:

Normal sulphur fuel oil for rest of units.

Other:

6.5.2 Fuel gas system for the project shall be as highlighted in the following list.

No fuel gas system applies to the project.

Existing fuel gas system shall make up short fall to the project.

New fuel gas system for the total project:

Integrated to existing facility: Hook-up from existing FG system can be provided to new system for FG consumption.

Independent of existing facility

Natural Gas backup for refinery fuel gas with

Preferential Natural Gas consumers identified

Fuel Gas consumers identified

Individual units provided with independent Natural Gas backup

Table 6.6: Fuel Gas Composition

Sr. No. Parameter Fuel Gas – 1 Fuel Gas-2 Fuel Gas-3

1 Composition wt% mol% wt%

Hydrogen 10.6 0 6.03

Ammonia

Carbon Dioxide 0.15

Carbon Monoxide

Oxygen

Nitrogen 0.24

Hydrogen Sulphide 0.01 0.01 0.01

Water

Methane 11.1 97.173 8.85

Ethane 15.2 1.65 10.59

Ethylene 4.4 1.92

Propane 25 0.53 19.32

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Sr. No. Parameter Fuel Gas – 1 Fuel Gas-2 Fuel Gas-3

Propene 6.4 2.79

Propylene 6.43

i-Butane 10.69 0.09 13.79

n-Butane 9.2 0.14 17.31

i-Butene 0.2 8.58

i-Pentane 3.1 0.007 1.98

n-Pentane 1 0.003 0.54

n-Hexane 0.01

C5(+) 0.9 0.52

C6(+) 2.2 0.007 1.33

Total Sulfur ppmv 100 100 100

2 Particulates micron 20 20 20

3 LHV, Kcal/kg

Note:

1. Max CO+CO2 content of 5 wt% and n-pentane of 11 wt% is expected.

6.6 FLARE SYSTEMS 6.6.1 Flare systems for the project shall be:

New facility to be installed for HC & Acid gas

New facility integrated with the existing system

Single flare for all released streams

Normal flare for hydrocarbons and Acid gas flare for released acid gases

Separate high pressure flare header for flared hot, hydrogen rich gases

Separate flare header for HC and Acid gases to be considered.

Flare type: Demountable & smokeless, steam assisted

6.6.2 Philosophy of relieving flammable vapours shall be:

Vapour releases of all molecular weights to be connected to flare system

Vapour releases below molecular weight of_____vented to atmosphere

6.6.3 There will be a common unit KOD in ISBL, apart from the main knock-out drum at the flare stack.. The main KOD, sized to separate out liquid droplets down to a size of 300µm. The

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liquids from Unit KOD will be routed to the slop system.

6.6.4 Maximum flare backpressure shall be considered for sizing of pressure relief devices:

6.6.5 Overpressure (as percentage of set pressure) for sizing relief valves shall be

Sr.No Contingency Low pressures < 70 kg/cm2g

High pressures > 70 kg/cm2g

1 Steam generating / consuming equipment 5% 5%

2 Fire case 21% as per designer

3 Thermal relief 25% as per designer

4 Operational failures 10% as per designer

6.6.6 Design Constraints for flare network sizing other than maximum backpressure at PSV outlet:

(a) Velocity in PSV tail pipes at rated flow <0.5 Mach

(b) Velocity in Unit Flare header & sub-headers at required capacity for governing scenario <0.2 Mach.

6.6.7 Fuel gas shall be used as a purge gas for flare header.

6.6.8 Applicable OISD standards to be followed.

6.7 LIQUID PUMPOUT & DRAIN SYSTEMS 6.7.1 Caustic drains:

Drains will be provided in DM plant area. Drains will be gravity based.

6.7.2 Acidic drains:

Drains will be provided in DM plant area. Drains will be gravity based.

6.7.3 OWS, CBD, Drains of all Instruments / Equipment at elevated platforms can be combined after the last isolation valve into respective header for each service and then brought to grade level.

6.7.4 Drain for Control Valves

All control valves shall be provided with a minimum of 3/4" drain connection with valves, as indicated below:

- Upstream & downstream of all control valves.

- Control valve drains shall not be connected to CBD.

- Flare Drain valve shall be blind flanged.

6.7.5 Vent and Drains for Level Instruments

All stand pipes shall have drain and vent connections connected to OWS. The isolation valves should be provided for isolation of stand pipe from the vessel and isolation of each

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instrument connected to the stand pipe. In H2S service, stand pipe shall be vented to flare.

6.7.6 Vents and Drains in Piping

All Piping vent and drain shall be blind flanged.

Sr. No.

Pipe size in inches

Vent Size in inches

Drain size in inches Disposal

Utilities

1 4 & below ¾ ¾ Locally Drained

2 6 to 10 ¾ 1 Locally Drained

3 12 & above 1 1 Locally Drained

6.7.7 Vents and Drains in Heat Exchangers

(a) If high point vent and low point drain are not available, 2"NB x 300# (min.) flanged vents and drains shall be provided at high and low points respectively on all heat exchangers. All drains shall be having double block valves with spectacle blinds that are connected to CBD / OWS.

All vents shall have valves and blinds.

(b) Exchangers in total condensing service shall be provided with 2" vent connection at the opposite end of the inlet.

6.7.8 Vents and Drains in Pump Casing

For non-volatile services, casing vents and pump drains shall be routed to appropriate sewer or closed drain system. - For volatile services, casing vents and drains shall be routed to the relief header and OWS.

6.7.9 General Guidelines

(a) Two block valves are required for all class 900 and higher vents and drains that can be open to the atmosphere (for example, blanking locations and drains). Valves that are blinded or plugged and will not be opened to line pressure during operations do not require two block valves. The primary block valve for drains shall be a gate valve.

(b) Where the possibility of auto refrigeration exists when venting or draining, all drains shall be provided with two valves in a series. The primary valve shall be a non-throttling valve (gate or ball) and second valve shall be a throttling valve (globe), located at a minimum distance of 0.6m downstream of the first valve.

(c) The main flare headers shall be provided with double block valves, spectacles blind and drain (3/4") within unit battery limit. The valve shall be locked open and shall be installed in a horizontal plane with stem pointing downwards.

6.8 ELECTRICAL SYSTEMS 6.8.1 Power Supply

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Sr.No. Voltage Level

Fault Level Voltage, Frequency, Application

1.0 HV 40kA for 1 sec (i.e.1500 MVA at 6.6 kV)

6.6kV(+/-10%), 3 PH, 3 W, 50 Hz(+/-3%), AC, Resistance grounded (Earth fault current restricted to 400A) for HV Motors and Distribution Transformer

2.0 LV1 50kA for 1 sec (i.e.36MVA at 0.415kV) for LV load other than Lighting

0.415kV(+/-10%),3 PH, 4 W, 50 Hz (+/-3%), AC, Solidly grounded for LV Motors upto 132kW and other LV load

3.0 LV2 9kA for 1 sec, 240V for Lighting, 1-ph receptacle

0.240kV(+/-10%), 1 PH, 2 W, 50 Hz(+/-3%), AC, Solidly grounded for Lighting and other loads like receptacles, space heater

4.0 Standby Emergency Supply

50kA for 1 sec (i.e.36MVA at 0.415kV)

0.415kV(+/-10%), 3 PH, 4 W, 50 Hz(+/-3%), AC, Solidly grounded for LV Motors upto 132kW and other LV load from Emergency Power Distribution board

5.0 Combined Volt. & Freq. Variation

10%

6.8.2 Control Supply

Sr.No. Application Control Supply

1.0 For 6.6 kV Panels

240V(+/-10%), 1 PH, 50 Hz (+/-3%), AC for Spring charging motor, Space Heater, Lamp Circuit 110 V (+10%,-15%), DC for Tripping coil, Closing Coil, Indication lamps, annunciation Circuit (ungrounded)

2.0 For LT Breaker control and protection

240V, 1 PH, 50 Hz, AC for Spring charging motor, Space Heater, Lamp Circuit tapped from phase and Neutral before incomer 110 V, +10%,-15%, DC for Tripping coil, Closing Coil, Indication lamps, annunciation Circuit (ungrounded)

3.0 For instrumentation and control (DCS/PLC control)

110V(+/-1%), 1 PH, 50 Hz(+/-1%), AC UPS supply with floating neutral

4.0 For Motor Starter control

240V(+/-10%), 1 PH, 50 Hz (+/-3%), AC Tapped from phase and Neutral from the bus

6.8.3 Design Ambient Temp. for Electrical Equipment - 45°C

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TCE.6079A-CH-300-DC-01 PROJECT DESIGN BASIS SHEET 22 OF 53

FORM NO. 120 R3

ISSUE P0

(f) LCS for HT motors shall be provided with 1no. breaker control switch, 1No. ammeter with selector switch.

(g) All push buttons shall be fitted with two (2) NO and two (2) NC contacts, rated for 10 A at 240V AC.

(h) LCS shall be suitable for bottom cable entry with stopping plugs.

(i) Internal wiring shall be done with copper conductor HFFR wires shall be neatly done.

(j) All spare contacts shall be wired upto terminal block.

(k) Distance between cable gland plate and terminal block shall be minimum 150 mm for ease of termination.

(l) Two (2) Nos. earthing terminals shall be provided for external earthing. Earthing continuity bonds shall be provided.

6.8.9 CABLING SYSTEM

(a) Cables

? HV Power Cable shall be 6.6 kV Unearthed Grade, stranded Aluminium conductor, multi core, XLPE insulated, screened, extruded PVC inner sheathed, GI strip armoured, and extruded FRLS PVC outer sheathed cable, as per IS:7098 (Part- 2).

? LV Power Cable shall be 1.1 kV grade stranded copper conductor (up to 16 sq. mm) and stranded aluminum conductor (above 6 sq. mm) multi core, XLPE insulated, extruded PVC inner sheathed, GI wire / strip armoured, and extruded FRLS PVC outer sheathed cable, as per IS:7098 (Part- 1).

? Control Cable shall be 1.1 kV grade stranded copper conductor (of minimum 2.5 sq. mm), XLPE insulated, extruded PVC inner sheathed, GI wire / strip armoured, extruded FRLS PVC outer sheathed as per IS:7098 (Part-1).

? In control cables, 10% spare core (with minimum 1 core) shall be provided.

? 1.1 kV Grade, ERP Insulated and CSP / SR sheathed armoured Power and Control Cables (conforming to IS:6380 (Part- 1).shall be used for High temperature applicable.

? For other Details, Refer Specification TCE.6079A-Z-204.

(b) Cable Trays

? Ladder type cable trays shall be 2.5 mm thick with 100 mm high flange having standard width of e.g.300/450/600/750/900 mm.

? Perforated type cable trays shall be 2 mm thick with 65mm high flange having standard width of 50/ 100/ 150 mm.

? Hardware accessories for trays shall be of Galvanised Iron.

? Cable trays shall be supported at every 2.5 m maximum.

? Bending radius for elbows / tees / cross etc . shall be as per bending radius required recommended by cable manufacturer. Minimum bending radius shall be 300mm.

? Power and control / instrumentation cables shall be laid in separate trays.

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FORM NO. 120 R3

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(f) LCS for HT motors shall be provided with 1no. breaker control switch, 1No. ammeter with selector switch.

(g) All push buttons shall be fitted with two (2) NO and two (2) NC contacts, rated for 10 A at 240V AC.

(h) LCS shall be suitable for bottom cable entry with stopping plugs.

(i) Internal wiring shall be done with copper conductor HFFR wires shall be neatly done.

(j) All spare contacts shall be wired upto terminal block.

(k) Distance between cable gland plate and terminal block shall be minimum 150 mm for ease of termination.

(l) Two (2) Nos. earthing terminals shall be provided for external earthing. Earthing continuity bonds shall be provided.

6.8.9 CABLING SYSTEM

(a) Cables

? HV Power Cable shall be 6.6 kV Unearthed Grade, stranded Aluminium conductor, multi core, XLPE insulated, screened, extruded PVC inner sheathed, GI strip armoured, and extruded FRLS PVC outer sheathed cable, as per IS:7098 (Part- 2).

? LV Power Cable shall be 1.1 kV grade stranded copper conductor (up to 16 sq. mm) and stranded aluminum conductor (above 6 sq. mm) multi core, XLPE insulated, extruded PVC inner sheathed, GI wire / strip armoured, and extruded FRLS PVC outer sheathed cable, as per IS:7098 (Part- 1).

? Control Cable shall be 1.1 kV grade stranded copper conductor (of minimum 2.5 sq. mm), XLPE insulated, extruded PVC inner sheathed, GI wire / strip armoured, extruded FRLS PVC outer sheathed as per IS:7098 (Part-1).

? In control cables, 10% spare core (with minimum 1 core) shall be provided.

? 1.1 kV Grade, ERP Insulated and CSP / SR sheathed armoured Power and Control Cables (conforming to IS:6380 (Part- 1).shall be used for High temperature applicable.

? For other Details, Refer Specification TCE.6079A-Z-204.

(b) Cable Trays

? Ladder type cable trays shall be 2.5 mm thick with 100 mm high flange having standard width of e.g.300/450/600/750/900 mm.

? Perforated type cable trays shall be 2 mm thick with 65mm high flange having standard width of 50/ 100/ 150 mm.

? Hardware accessories for trays shall be of Galvanised Iron.

? Cable trays shall be supported at every 2.5 m maximum.

? Bending radius for elbows / tees / cross etc . shall be as per bending radius required recommended by cable manufacturer. Minimum bending radius shall be 300mm.

? Power and control / instrumentation cables shall be laid in separate trays.

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• 300 mm distance shall be provided between HV and LV power cable trays and between LV power to LV control / LV Signal cable trays.

• Cable tray width shall be decided considering 20% space for future cables. • Input for providing Plate inserts in slab ceiling or side walls for cable tray

installation shall be given by bidder to civil contractor. • For other Details, Refer Specification TCE.6079A-Z-205.

(c) Cable Laying • In Hazardous area, Cables shall be laid in built up trenches with sand filling

or overhead cable trays, whereas Cables in Non Hazardous area, shall be laid in Cable trays on rack or in built up trenches.

• HV cables shall be laid in single layer. • LV cable above Cables above 120 sq.mm. shall be laid in single layer. • LV cables below 120sq.mm. shall be laid in two layers considering 100mm

flange height. • LV control shall be laid in 3 layers considering 100mm flange height. • For other Details, Refer Specification TCE.6079A-Z-206.

(d) Cable Sizing

The cable sizes shall be selected based on the following considerations: • Rated current and associated derating factors due to ambient

temperature/group laying. • Short circuit withstand

o For 6.6kV motors – 40kA for 0.16secs. o For Motor feeder with Fuse Switch Unit – Let through energy of

fuses. o For Motor feeder with ACB – 50kA for 0.1sec.

• Voltage drop o 3 % between PMCC/MCC to motor terminals while running o 15% dip at motor terminals while starting o 5% between Lighting Panel to last light fitting.

(e) Cable Termination • Cable glands shall be double compression type and shall made up of Nickel

plated brass. • In Hazardous area, cable gland shall be flameproof type. • For other Details, Refer Specification TCE.6079A-Z-205.

6.8.10 LIGHTING SYSTEM (a) Lighting Panel

• Lighting panel shall be Sheet metal enclosed, fixed type, wall/ structure mounted, non compartmentalised.

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• Incomer shall be TPN MCB (9kA) with 3 Nos. ELCBs(30mA sensitivity) (1 No. for each phase).

• Outgoings shall be 10A SPN MCB (9kA). • Degree of protection shall be IP-52. • Min.10% spare outgoing shall be provided.

(b) Lighting Fixture

• In hazardous area, Flameproof fixtures shall be provided. • Indoor area such as substation control room, fluorescent fixture shall be

provided. • In open Plant, HPMV / MH well glass fitting shall be provided. • Aviation Warning Light (flashing type) shall be provided for Flare.

(c) Illumination Levels

Following Illumination Levels shall be maintained in different areas. • Open plant – 50 lux • Compressor house – 150 lux • Substation / switchgear room – 250 lux • Control room – 300 lux • Platforms – 100 lux

(d) Lighting wiring / Cabling

• All Outdoor fixtures shall be wired with the help of 3x2.5sq.mm. XLPE insulated copper armoured cable.

• All Indoor fixtures shall be wired with the help of 3x2.5sq.mm. XLPE insulated copper unarmoured cable or 2.5sq.mm. PVC insulated wires in GI conduits.

• Third core shall be used for earthing. • Maximum load on each circuit shall be 1 kW. • For other Details, Refer Specification TCE.6079A-Z-207 & 208.

6.8.11 EARTHING AND LIGHTNING PROTECTION SYSTEM (a) Main earth grid will of copper cable (green colour). (b) 2 Nos. earthing terminals/ pads shall be provided for each equipment. The sizes will

be provided to successful bidder based on equipment rating. (c) Static non-current carrying equipment shall also be provided with 2Nos. earthing

terminals. (d) Earthing System shall be as per IS-3043, whereas Lightning Protection system shall

be as per IS-2309.

6.9 CAUSTIC STORAGE, PREPARATION, DISTRIBUTION

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6.9.1 Fresh caustic receipt

Commercial caustic required in this project be sourced from the existing caustic handling facility at DM plant area/ Chemical handling area in Bitumen Blowing Unit.

6.9.2 Spent caustic shall be routed to effluent treatment plant.

6.9.3 Battery limit conditions for caustic distribution shall be as per Table-6.8.

Table-6.8: Caustic streams

Sr. No. Caustic stream Operating

condition Mechanical Design

P, kg/cm2g T,°C P, kg/cm2g T,°C

1 Fresh Caustic (20 wt%) 4 40 4.5 80

2 Spent Caustic By BPCL 45 4.5 80

Spent caustic shall be disposed off in ETP tank.

6.9.4 Fresh Caustic:

(a) Fresh caustic preparation

Caustic of highest concentration required in the project be also prepared in the same area as 6.9.1

(b) Fresh caustic distribution to NHT/CCR Plant

Pumped from central storage area directly to consuming units, whether needed continuously or needed in batches.

Pumped from central storage area directly after batches of relevant concentration are made to intermittent batch consumers such as during catalyst regenerations or other daily requirements. The batches of relevant concentration shall be pumped to relevant buffer tanks provided in the respective units for consumption.

(c) Fresh caustic distribution to DM Plant

Pumped from central storage area directly to consuming units, whether needed continuously or needed in batches.

Tap off to be done from existing DM plant services.

6.9.5 Caustic handling equipment shall be of Carbon Steel construction and stress relieved whenever required for the operating temperatures selected

6.9.6 Routing of Spent Caustic from NHT/CCR

Spent caustic storage in unit area for reuse by other consumers, provided substantial spent caustic reuse is possible in that area. Otherwise degassed spent caustic should be routed totally to ETP.

Spent caustic totally routed to effluent treatment plant

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7.0 GENERAL DESIGN PHILOSOPHY 7.1 Type of Buildings

Control Room

RCC Blast Proof Structural

Chemical filters to be considered for control room

Yes No

Compressor House / Nitrogen Plant:

RCC Structural

Electrical Rooms

HT substation pressurised Non-pressurised

Exhaust fan

MCC pressurised Non-pressurised

Exhaust fan

DG Set pressurised Non-pressurised

Exhaust fan

Rectifier, VFD, Charger, Excitation panel

HVAC

Pipe rack

RCC up to first tier Structural

8.0 EQUIPMENT DESIGN PHILOSOPHY Mechanical design conditions shall be as per Datasheet provided by UIPL. In cases where confirmation of design conditions during detail engineering is required, new equipments are added as a result of basic engineering for offsites/utilities or in case of missing information in UIPL documents, the following shall apply:

8.1 Selection of Mechanical Design Conditions

Equipment and piping systems shall be designed for the most stringent coincident temperature and pressure conditions, accommodating the maximum expected working pressure and temperature without causing a relieving condition. The design shall be such that instrument safeguarding systems or availability of emergency power or steam are not relied upon for overpressure protection. Abnormal conditions shall be evaluated considering a single contingency. A double or multiple contingency shall not be considered, but, if one failure is a result of another failure, both failures are to be considered as one

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contingency. Guide for "Pressure relief and depressurising systems", API RP 521 (latest edition) shall be followed for evaluating failures.

8.1.1 Mechanical design pressure for pressure systems

Mechanical design criteria laid down in this section shall be followed as standard. Deviations to these criteria are not permissible for any facility, except for high pressure equipment working above 70 kg/cm2 g or for identified critical equipment for which designer of a particular unit has to necessarily follow the designer's company standards that ensure plant safety and operating personnel protection.

(a) A pressure system protected by a pressure relief device connected to the flare system, shall have a mechanical design pressure, calculated at the location of the relieving device, as the higher of the following:

• Maximum operating pressure (kg/cm2g) x 1.1

• Maximum operating pressure + 2.0 kg/cm2

• 3.5 kg/cm2g

• Flare design pressure if the vessel is connected to flare.

• For maximum operating pressures less than 15 kg/cm2 g, use the maximum operating gauge pressure +1.5 kg/cm2.

Equipment normally operated under vacuum or subject to start-up or shut down evacuation is designed for full vacuum and for the highest pressure the equipment can experience in case of vacuum system failure.

Full vacuum will be specified for isolable equipment containing fluid having a vapour pressure lower than atmospheric pressure at ambient temperature.

Full vacuum is not specified for transient operations as steam purging where opening of vent is always considered. For equipment equipped with steam out the following sentence will be specified on the data sheet: "Subject to steam out conditions" with the pressure and temperature of the steam

(b) The design pressure at the bottom of the vessel and of associated pieces of equipment shall be determined by adding applicable maximum operating liquid heads and pressure gradients.

(c) Vessels operating under vacuum shall be, in general, designed for an external pressure of 1.033 kg/cm2a and full internal vacuum, and highest pressure it can experience in case of vacuum system failure unless otherwise specified.

(d) Emergency vacuum pressure can be considered based on the process requirements and assessment of transient operations.

(e) For a full liquid system at the discharge of a centrifugal pump, the mechanical design pressure shall be as under

Pdes = Pmax suction + ∆ Pmax

Where

Pmax suction = Maximum pressure at suction vessel bottom during suction system relieving conditions.

∆ Pmax = Pump differential pressure at pump shutoff head with maximum operating density. If not known:

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■ ∆Pmax = 1.3 x ∆H x pmax: constant speed pump

■ ∆Pmax = 1.1 x 1.2 x ∆H x pmax: variable speed pump

■ ∆Pmax = 1.3 x AH x pmax:high head multistage pump

■ ∆Pmax = 1.3 x 1.1 x AH x pmax: variable speed high head multistage pump

(f) For a full liquid system at the discharge of a positive displacement pump, the mechanical design pressure shall be the higher of

■ Pdes = Prated discharge = 2kg/cm2

■ Pdes = 1.1 x Prated discharge

Equipment in the discharge of a pump:

Equipment which could have to bear the shut off pressure of a pump in case of a valve closing (either control valve or block valve) is designed for the following pressure:

Design pressure =Design Pressure of suction vessel + Liquid height at vessel NHLL at pump suction + 120% of pump differential pressure

(g) For shell-and-tube heat exchangers, TCE shall specify the low pressure (LP) side shall be preferably specified with a design pressure at least equal to Ten/Thirteenth of high pressure (HP) side design pressure, in order to avoid having to install a pressure relief device on the LP side. The Ten/ Thirteen criteria shall necessarily be adhered to when:

1. LP fluid is on the tube side.

2. Relief discharge cannot be connected to flare header owing to nature of fluid.

3. Relief discharge is two-phase and cannot be connected conveniently to a low pressure destination with free-draining piping.

4. Liquid relief cannot be connected to a closed blow down system.

5. When the Ten/ Thirteen criteria calls for an increase by less than a factor of 1.3 of the mechanical design pressure of the LP side as would be calculated from normal estimation procedures.

However, based on process considerations and designer's own practice, heat exchanger can be designed without upgrading design pressure by providing tube rupture pressure relief valve after getting consent on case to case basis from owner.

When the design pressure of LP side is higher than 10/13 of the design pressure of HP side (according to code ASME Section VIII div I or 10/12.5 according to code ASME VIII div 2 and European Directive on Pressure Vessels) it is not necessary to provide relief facilities on the lower pressure side in the event of a tube rupture.

When the design pressure of LP side is lower than 10/13 of the design pressure of HP side (or 10/12.5) the design pressure of LP side will be increased up to 10/13 of the design pressure of the HP side (or 10/12.5) only

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for the heat exchanger, but not for the associated low pressure side piping. No specific safety device will be provided for tube rupture. However the low pressure side piping is to evaluated for over pressure by the detailed engineering contractor. The piping design pressure is to be up-rated if required or appropriate protection provided.

(h) Mechanical design temperature

(i) For systems operating at or above 0°C, the mechanical design temperature shall be the higher of the following:

■ Tdes = 65°C

■ Tdes = Tmax+15°C with minimum of 80 0C

■ Tdes = Trelief (excluding fire relief temperatures)

where,

Tmax = Maximum operating temperature expected considering different possible operations for the equipment or system, including air drying or gas drying conditions.

Trelief = Temperature corresponding to pressure relief conditions for an operational failure case (specifically excluding fire relief case).

(i) For systems operating below 0°C, the mechanical design temperature shall be equal to the lowest anticipated operating temperature

For operating temperatures below 0 degree C, minimum operating temperature minus 5 degree C or minimum ambient temperature.

• The effect of auto refrigeration due to depressurization to atmospheric pressure will be taken into consideration (Liquid Nitrogen systems for example).

• For feed/effluent exchangers of reaction sections + 25 degree C to be added to max. operating temperature to take into account the temperature profile modification at low capacity.

• In the case of coolant failure, the maximum operating temperature upstream of the cooler shall be considered as the downstream design temperature (i.e. exothermic reactor).

(j) For pressure vessels storing refrigerants or liquefied hydrocarbons at ambient temperature, the design temperature (based on depressurization) shall correspond to the coincident design pressure when this lowest temperature is reached. The coincident design pressure can be different from the maximum design pressure specified for the vessel depending upon the system under consideration. However, if this calls for a change in metallurgy, then other strategies to avoid this situation shall be evaluated.

(k) Steam-out conditions

Vessels provided with steam out conditions shall be designed for the following steam out conditions when LP Steam is considered adequate:

(a) Pressure = FV (Full Vacuum)

(b) Temperature = Maximum LP Steam temperature = 150°C

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If specific equipment requires steam out with MP steam, steam out temperature shall be specified accordingly.

Cyclic operating conditions For equipment subject to pressure and temperature swings, the magnitude and frequency of these swings will be given on the specification sheet.

(l) The maximum possible operating temperature is used as design temperature.

(m) Minimum Design Metal Temperature (MDMT)

Designer / Licensor shall specify MDMT. Ambient temperature data are as per Section 4

(n) Steam rings will be provided around large diameter hydrocarbon flanges handling hydrocarbons above the auto-ignition temperature of hydrogen.

8.2 Heat Exchangers Process data sheet provided by UIPL shall be followed for specification of heat exchangers. In cases where, new heat exchangers are added as a result of basic engineering for offsites/utilities or in case of missing information, the following shall apply:

8.2.1 Selection of shell and tube heat exchanger type

(a) Shell and tube heat exchanger BEM or AES single pass shall be used where 'Pure Counter-current' type is required. Double-pipe heat exchangers shall be in the event of infeasible shell-and-tube heat exchanger design.

(b) All shell and tube heat exchangers including compressor lube oil coolers shall follow TEMA-R. Preferred exchanger type for refinery services shall be horizontal, single pass shell, floating head tube bundle (TEMA type' S') arranged with two or more tube passes per shell. Tube pitch shall be square or rotated square for fouling services and triangular pitch for clean services (i.e. fouling resistance of <0.0002Hr-m2-oC/Kcal).

(c) U tubes are generally not preferred.

(d) No overdesign will be considered for the heat exchangersSelection of air-cooled heat exchange

8.2.2 Preferred sizes for shell and tube exchangers & with removable tube bundles

Tube length: 6 meters

Maximum tube bundle diameter:

1200mm for 9 m tube length

1400mm for 6 m tube length Layout / thermal design shall govern tube length at 6m or 9m

Maximum tube bundle weight:

15 ton

Preferred tube dimensions

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Tube metallurgy CS/Low AlloyHigh Alloy /

Stainless /Non ferrous

Titanium or other exotic materials

Tube diameter OD (mm) 25/20 25/20 25/20

Tube thickness(min) 2.5/2 2 Based on availability

Tube thickness for IBR Service (min) 2.5/2.3 2.3/2.3

8.2.3 Fouling factors

Fouling factors for utility streams:

Following default fouling factors are recommended for utility streams. If owner has other preferences, these may be indicated.

Service Fouling Factor in hr-m2-°C/kcal

Cooling Water 0.0004

Steam 0.0002

Air 0.0001

8.2.4 Constraints on tube-side velocities:

Service Minimum (m/see) Maximum (m/see)

Cooling Water 1.5 m/sec @ normal flow

1.0 m/s if tube wall temperature < 60°C

8.2.5 Condensate control for steam consumers

For normal steam flows < 1000 Kg/hr to a steam-heated exchanger, steam traps shall be considered for condensate removal. For larger consumers, in addition to the steam flow control valve, condensate shall be collected in a pot provided with a level control valve for condensate withdrawal.

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Figure-8.1 Typical condensate pot control scheme

8.3 VESSELS Process data sheet provided by UIPL shall be followed for vessels. In cases where confirmation of design conditions during detail engineering is required, new equipments are added as a result of basic engineering for offsites/utilities or in case of missing information in UIPL documents, the following shall apply:

8.3.1 Hold-up criteria:

It is recommended that the following minimum requirement towards hold-ups for vessels. Designers can adopt criteria that call for higher hold-up volumes, if warranted from a design point of view. The working hold up volumes are expressed as minutes of liquid residence time between Low Operating Level (LOL) and High Operating Level (HOL) while additional hold ups shall apply between the operating levels and corresponding tripping levels (LLL / HHL), when a shutdown is stipulated Working holdups:

Refer Hold Up Definitions as attached in Annexure 1.

8.3.2 Vessel dimensions:

Vessels will be sized according to inside diameter and 2:1 elliptical heads or hemispherical heads.

8.3.3 Nozzle requirements for vessels and towers:

(a) Designer recommends minimum sizes of vessel nozzles as:

Requirement Nozzle size

Minimum Process or Instrument Nozzle size in internally lined vessel

3 “ NB

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Requirement Nozzle size

Minimum Process or Instrument Nozzle in unclad vessel 2 “ NB

(b) For nozzles where no piping is connected, schedule shall be specified with at least 300# even if process consideration calls for lower pressure ratings of vessel nozzles, indicate below:

■ All nozzles upto: does not apply 2" NB

■ Pressure relief valve connection: yes no

■ Level instrument standpipes: yes no

■ All instrumentation connections: yes no

(c) Thermowell nozzles on vessels shall be flanged and will be 2" minimum ID. However, for lined vessels, nozzle size shall be 3" minimum. Nominal diameter shall be specified to ensure this minimum ID or ID of lining.

(d) Steamout connections shall be provided on vessels which are stipulated to be steamed out during normal startups or shutdowns. Steamout nozzles, 2"NB, shall be located, at minimum elevation, on the head of horizontal vessels and above the bottom tangent line for vertical vessels/ columns. Steamout nozzles shall be hard piped for all Columns handling hydrocarbons.

(e) For vessels and columns less than 900 mm diameter, body flange is to be provided. . Manways will be of minimum 24" OD . Larger sized manways shall be specified, as required, to facilitate the passage of internals. All manways shall have davit arrangement.

In vertical vessels, of 900mm diameter and above, provided with demisters, at least one manway shall be provided in the top head and one manway in the bottom section, to facilitate access from both sides of the demister, if feasible, based on tangent length to tangent length. For vertical vessels, less than 900mm diameter, the top head shall be flanged in case removable internals are present.

In horizontal vessels, the manway shall be preferably located on the vessel head, away from the end that has internals such as internal displacers or baffles. Large horizontal vessels above 3000 mm tangent length will additionally be provided with a blanked-off ventilation nozzle at the top of the vessel, near the end opposite the manway. The vessel vent nozzle can be welded to the ventilation nozzle blind flange.

In tray columns, manways shall be provided above top tray, below the bottom tray, at the feed tray, at any other tray at which removable internals are located, and at intermediate points so that the maximum spacing of manways in the tray section does not exceed 10 meters.

(f) Steamout, vent and drain nozzles and ventilation nozzles shall be as follows:

For vessels with steam out connections permanent steam piping shall be provided

(g) Steamout, vent and drain nozzles and ventilation nozzles shall be as follows:

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For vessels with steam out connections permanent steam piping shall be provided:

Vessel volume

Length (Horizontal

vessel)

Vent nozzle

Drain nozzle

Ventilation nozzle

less than 6.0 m3 - 2"NB 2"NB -

6.0 -15.0 m3 - 2"NB 2"NB -

more than 15 m3 - 2"NB 3"NB -

- 3000 mm-4500 mm - 4"NB

- 4500 mm - 7500 mm - 6"NB

- >7500 mm - 8"NB

(h) Level instrument nozzles

Refer General Engineering Specification – Instrumentation for details.

Process data sheet provided by UIPL shall be followed for columns and column internals. The following shall apply for completion of missing information (if any):

8.3.4 Tray & packing selection

Valve trays, in general, shall be preferred except for liquid-liquid mass transfer applications and for services where some extent of fouling is anticipated. Single-pass, Two-pass and Four-pass trays can be envisaged as appropriate. Three-pass trays are generally not preferred.

Random or structured packings shall be specified as considered necessary in services such as vacuum distillation or when found necessary to augment performance of an existing tower.

8.3.5 Tray / packing turndown

All trays and packings shall be designed for the same turndown as defined in respective specifications. In some services, the reflux and reboiler rates may be turned down to a ratio different from the unit turndown, while still meeting the overall turndown.

8.3.6 For columns of diameter < 900mm, flanged column sections shall be used. For such trayed columns, each set of 15 to 20 (maximum) trays should be approachable from column manholes one above and one below the set of trays. For such packed columns, each packed bed will have a manhole each above and below the bed. 300# handholes shall be provided just above the packing support plates, for removal of packings. These shall be two in number and opposite each other. In case the column diameter permits, one of the handholes shall be replaced by manhole.

8.3.7 Following requirements to be specify in datasheet for towers

(a) Column oversizing will be to 20% of normal flolwrates.

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(b) Trays shall be numbered from Top.

(c) Cartridge trays shall be considered for diameters less than 800 mm.

(d) Proper size tray manways shall be provided on each tray where tray drawings are deliverables.

(e) Operating range for the trays will be at least 50 to 120 per cent of normal loads.

8.3.8 Nozzle requirements for towers: Refer item 8.3.3 under "vessels".

8.4 Pumps Process data sheet and sparing provided by UIPL shall be followed for pumps. In cases where confirmation of specifications during detail engineering is required, new pumps are added as a result of basic engineering for offsites/utilities or in case of missing information, the following shall apply

8.4.1 Selection of type of pumps

■ All process pumps within process battery limits shall be specified to conform to API Standard 610 (10th Edition) and seals for these pumps shall be as per API682 3rd edition.

■ Pump specifications shall assume unsheltered outdoor location. The pipe rack above the pump bay may accommodate air-cooled heat exchangers, in which case, the unit has to be provided with a safety system to minimize accidental pump hydrocarbon leakages from being fanned out as an explosive vapour cloud.

■ In special applications, low flow, high head, high speed vertical sundyne type pumps can be specified, if found necessary.

■ For fire water system pumps, specifications to conform to TAC requirements.

■ If rated power is more than 160kw, couplings as per API 671 4th edition shall be used.

■ For metering pumps / reciprocating pumps double diaphragm type controlled volume pumps shall be used.

■ Vertical pit pumps shall be avoided as far as possible. Instead self priming horizontal pumps shall be preferred

8.4.2 Sparing of pumps

(a) Process pump services in continuous service will, in general, be provided with installed spare. Intermittent pump services such as chemical unloading, batch make-up, etc., shall not be provided with installed spare. These shall be decided on a case-to-case basis and possibility of common spares shall be examined

(b) Where more than one operating pump is found necessary for a service, or when defined by owner, pump capacity and spare shall be as follows

# Operating pumps Rated capacity per pump Spare pumps

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2 50% of total normal flow 1



8.4.3 Specification of pump seals

(a) Where seal less and dual mechanical seal are acceptable as per PDS, dual mechanical seal shall be preferred. Single mechanical seals shall normally be specified for centrifugal pumps unless other considerations prevail. Seal flushing where necessary, shall preferably be with the process fluid itself through an appropriate API seal plan for all clean liquids.

(b) External seal flushing oil shall be made a requirement only when a self-flushing plan is infeasible. For refinery services Light seal flushing oil (FLO) and a heavy flushing oil (HFLO) will be available. If otherwise, pumps shall be specified such that seal fluid shall be mutually decided by Owner and PMC.

(c) Dual mechanical seals (pressurized or unpressurized according to process considerations) or seal less pumps shall be considered in the following cases:

■ LPG and lighter

■ Hydrocarbon above their auto ignition temperature or at a naphtha temperature higher than 150°C

■ Toxic or carcinogenic fluid

■ Pump operating at high pressure higher than or equal 50 barg (To be confirmed by Rotary)

■ Sour water > 100 ppm H2S (emission seals)

■ Fouling service or environmentally hazardous service

■ For Hydrocarbon liquids with vapor pressure > 10 psi at pumping temperature

(d) Instrumentation for pump seals shall be determined during detailed engineering. For vacuum services, stationary metal bellow seal shall be specified.

8.4.4 Please refer 11.6.2 for minimum flow bypass for pumps

8.4.5 Pump cooling:

Cooling water used for pump seal / bearing cooling (indirect) shall be returned back to cooling water return header.

8.4.6 Motor specification for auto-start pumps:

For auto start pumps, electric motor shall be specified for end of the curve condition with discharge valve fully open conditions. For other pumps motors shall be sized as per API.

8.4.7 Other Specifications:

(a) Ten per cent over sizing will normally be specified. 20 per cent over sizing will be specified on reflux and reboiler flow rates.

(b) Electrical motor drivers will be specified for non critical services..

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Critical service is stated for equipment which must be maintained in operation in order to protect personnel, equipment, catalyst and environment.

Critical service equipment will be either driven by steam turbines or by electrical motors connected to the electrical emergency system

(c) In case of steam turbine driver selection for pump with critical service, the steam turbine will be specified for the normal operation, the electric motor for the spare pump.

(d) Continuous service process pumps will be specified with full spares.

(e) Common spares can be specified whenever appropriate for metering pumps

(f) Pumps shall be provided with permanent strainers.

(g) 10% minimum over sizing for system pressure loss.

(h) +10% for electric driver rated power and +20% for steam turbine driver rated power

(i) For centrifugal pumps - details as follows

• Seal less pumps shall not be considered.

• Flushing plan 53B is not acceptable. Plan 54 or Plan 52 shall be considered.

• First preference shall be given to pumps whose rated point is selected in between 90 % to 110 % of best efficiency point. Second preference shall be given to pumps whose rated point is selected in between 80 % to 110 % of best efficiency point.

• Vertical pit pumps shall be avoided as far as possible. Instead self priming horizontal pumps shall be preferred.

(j) Metering pumps & reciprocating pumps shall be double diaphragm type controlled volume pumps with discharge pulsation dampener.

8.5 Compressors Process data sheet provided by UIPL shall be followed for compressors. In cases where confirmation of specifications during detail engineering is required, new compressors are added as a result of basic engineering for offsites/utilities or residual basic of licensed units or in case of missing information , the following shall apply:

8.5.1 Selection of type of compressors

(a) Specification of a compressor shall assume installation under a compressor shed i.e. covered.

(b) Centrifugal air compressors, conforming to API Standard 672 (4th edition), will be specified where suitable. Axial compressors are not preferred below capacities of 150,000 Nm3/hr.

(c) Lube oil cooler for lube oil/seal oil & consoles of compressor shall be SS tubes.

(d) Anti-surge facility shall be specified for centrifugal compressors.

8.5.2 Following other details shall be considered:

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(a) Electrical motor drivers will be specified for non-critical services.

Critical service is stated for equipment which must be maintained in operation in order to protect personnel, equipment, catalyst and environment.

Critical service equipment will be either driven by steam turbines or by electrical motors connected to the electrical emergency system. The type of electrical emergency system for motors shall be defined by EPC/Owner.

8.6 Steam Turbine drives

Process data sheet provided by UIPL shall be followed for steam turbine. In cases where confirmation of specifications during detail engineering is required, new steam turbine are added as a result of basic engineering for offsites/utilities or in case of missing information in UIPL documents, the following shall apply:

8.6.1 Steam turbine drives shall be specified in extremely critical services where even short-term failure of a drive can result in a shutdown from where an operational recovery is difficult, time- consuming or has a large economic penalty, such as irreversible catalyst poisoning.

Steam turbine drives shall also be specified for the following drives that, among other considerations, shall ensure that a power failure does not automatically lead to a steam failure:

(a) Cooling water recirculation pumps yes no

8.6.2 Back pressure steam turbine shall be evaluated only when there is a matching large consumer of the let down within the same or immediately neighbouring unit. Condensing steam turbine drives shall otherwise be considered.

When there is a large use of LP steam a back pressure turbine a pump/compressor shall be evaluated in the unit to minimize let down through pressure reducing station from MP steam to LP steam level.

8.6.3 Condensing turbine exhaust

Steam condensing pressure at turbine exhaust shall be considered as 0.19kg/cm2 (a) for the purpose of basic engineering specifications. Only water cooling shall be considered for exhaust condensation. Cleanliness factor of 0.6 shall be considered for surface condensers.

8.6.4 Drive turbine shall confirm to fourth edition of API 611 5th Edition

8.7 IBR Requirements 8.7.1 Scope of IBR

Steam generators / steam users shall meet IBR regulations. Major IBR requirements are summarised below:

(a) Vessels: Any closed vessel exceeding 22.75 litres (5 gallons) in capcity which is used exclusively for generating steam under pressure and include any mounting or other fittings attached to such vessels, which is wholly or partly under pressure when steam is shut off.

(b) Piping: Any pipe through which steam passes and if :

(i) Steam system mechanical design pressure exceeds 3.5 kg/cm2 g or

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(ii) Pipe size exceeds 254 mm internal diameter

(c) All steam users ( heat exchangers, vessels, condensate pots etc.) where condensate is flashed to atmospheric pressure i.e downstream is not connected to IBR system are not under IBR and IBR specification break is done at last isolation valve upstream of the equipment

(d) All steam users where downstream piping is connected to IBR i.e. condensate is flashed to generate IBR steam, are covered under IBR.

(e) Steam tracer lines shall be excluded from IBR.

8.7.2 Material Certificate: (This section is only for information on IBR requirement)

(a) All item part of steam piping i.e. pipes, valves,fittings,traps,safety valves must have material certificates, countersigned by the local boiler inspectors.

(b) For imported items – Certificates issued by an authority empowered by Central Boilers Board ( As listed in the Appendix C of IBR) or under the law in force in a foreign country in respect of boilers manufactured in that country may be accepted.

(c) All drawings coming under the preview of IBR shall be certified by Local Boiler inspector.

8.7.3 All datasheets of equipment which come under IBR scope shall have the annotation: “IBR is applicable”.

8.8 Service Life

Service Life details for Equipments will be as follows:

Typical values, given here after in the following tables, shall be considered . These values will be taken as default values for the project if there is no mention of Client request values.

8.8.1 Equipment Design Life

The following design life may be applied to the design of the unit:

Type of Equipment Client request

- Reactors / Heavy wall vessels or exchangers (including non

removable internals and support beams if any ):

30 years

- Reactor removable internals: 20 years

- Columns, other vessels: 30 years

- Other heat exchangers: 30 years

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Type of Equipment Client request

- Stainless steel, high alloy and non ferrous material heat exchanger tube bundles:

10 years

- Carbon steel / low alloyed steel heat exchanger tube bundles:. 10 years

-Piping: 10 years

8.8.2 Corrosion allowance

The following values are resulting from experience based on process licensor know how in term of design criteria and on operating units feed-back as well. The given values might be reviewed in accordance with detailed engineering or client specific requirements. However, one must note that such a decision would be under the detailed engineering or client responsibility and should then be taken by considering the procedures of inspection used by the owner.

(a) Pressure Retaining Equipment Corrosion allowance shall be based on the designed number of years in service.

For Carbon steel

Normal operation Under Wet H2S Service

Standard recommendation

Client request

s Standard recommendation

Client request

Minimum corrosion allowance (CA)

3 mm (1/8") 6 mm (1/4")

For other materials:

Minimum corrosion allowance (CA) Standard recommendation

Low Alloyed Steel (up to 2 lA % Cr included) 3 mm (1/8")

Low Alloyed Steel (above 2 % % Cr and up to 9 % Cr

included) 3 mm

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Stainless Steel (11 %Cr and above) 0.75 mm (1/32")

High Alloy and Non Ferrous material 0mm

Note:

• For tubular heat exchangers, CA defined for tubes and shell sides, applies to pressure retaining elements. Tubesheet is concerned by CA on each side. Tubes are not concerned by CA, whichever the side.

• If equipment is cladded, thickness of clad is considered as CA with a minimum at 3 mm whatever the material. This minimum thickness is usually much higher than the CA estimated from corrosion rate.

• If equipment is overlaid, undiluted thickness of weld overlay is considered as CA.

• For auxiliary equipments, in atmospheric service, no CA is considered, if products are not corrosive.

(b) Internals Definitions: "Non removable internals" means: internal parts welded to the vessels.

"Removable internals" means: internals parts which are not welded to the vessels (dip tubes, mesh, mist eliminator, baffle manhole, fractionation trays, distributor trays, mixing trays, support trays, support beams, inlet diffusers, outlet collectors, quench pipes, thermocouples supports, etc.)

For Carbon Steel and Low Alloyed Steel (up to 9 % Cr included)


Removable internals On each exposed surface: 1/2 of total CA estimated from corrosion rate

Fixed internals and structural support beams

On each exposed surface: full CA estimated from corrosion rate applied to the vessel shell

For Stainless Steel (11 % Cr and above), High Alloy and Non Ferrous material:


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Removable internals

0 mm (if expected rate greater than or equal to 0.2 mpy 1/2 of total CA estimated from

corrosion rate shall be considered on each exposed surface)

Fixed internals and structural support beams (*)

On each exposed surface: full CA applied to vessel shell

Note:

• - No corrosion is considered for internal parts made from V-profile wire screen, wire mesh or knitted mesh.

(c) Process piping For uniform corrosion, corrosion allowance for piping can be distributed as follows:

Expected rate Corrosion Allowance

Standard recommendation

lower than or equal to 5mpy 1.5 mm (1/16")

greater than 5mpy and lower than or equal to 12mpy

3 mm (1/8")

greater than 12mpy and lower than or equal to 18mpy 4.5 mm (3/16")

greater than 18mpy and lower than or equal to 25mpy 6 mm (1/4")

greater than 25mpy Upgrade the Material Specification

mpy: thousandths of inch per year

As a standard general practice, corrosion allowance for carbon steel piping can usually be split into four different levels of specifications as mentioned here below.

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For Carbon Steel:

Environment Standard

recommendation

Client request

Non-corrosive environment Compressed Air, Nitrogen, Dry Hydrocarbon, etc.

0 mm 1.5 mm

Mildly-corrosive environment Cooling water, Humid Hydrocarbons, Steam, etc.

1.5 mm (1/16")

Moderately -corrosive environment Sour Water, Wet Sour Gas, Amines, Caustics, etc.

3 mm (1/8")

Severely -corrosive environment Aerated water, Hot Sulfur or Sulfide (greater than 260°C), Wet Salts, Wet CO2 (ambient temperature), Hot Steam (greater than 540°C), etc.

6 mm (1/4")

For other materials: Minimum corrosion allowance (CA)

Minimum corrosion allowance (CA)

Type of Material Standard

recommendation

Client request

Low Alloyed Steel (up to 9 % Cr included) 0.75 mm (1/32") 3 mm

Stainless Steel (11 %Cr and above) 0.75 mm (1/32") 1.5 mm

High Alloy and Non Ferrous material 0 mm

9.0 INSTRUMENTATION 9.1 Control Philosophy:

Process Control shall be facilitated through:

■ Flare area instruments shall be suitable of Zone-1, Gas group IIC, T4.

■ Nitrogen Plant, Air compressor shed and DM plant is considered as safe and the instruments will be suitable for safe area.

■ Programmable logic controllers (PLC) are to be used for Nitrogen package, Air compressor for nitrogen, Instrument air compressor. All the sequencing controls required for Flame monitoring in Flare will be a part of FFG control system.

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■ Monitoring of Signals from various package units will be as follows:

- Nitrogen Plant & Air compressor for Nitrogen signals in Aromatic Plant Control room.

- Instrument Air Compressor signals in Boiler House DCS.

- Flare Signals in Pump-House No. 5 DCS.

- Signals and commands of pure Condensate system shall be wired to Boiler House DCS.

- Signals and commands of im pure Condensate polishing system shall be wired to existing DM plant DCS..

■ Foundation Field bus ( FF) based DCS of the existing DM plant will be used for control & monitoring of the new DM plant.

9.2 General requirements:

Please refer “General Engineering Specifications – Instrumentation” Doc. No. TCE-6079A-580-IN-001.

10.0 PIPING & INSULATION 10.1 Piping specifications shall be mutually agreed between Owner and PMC.

10.2 All piping shall be above ground except for oily water sewer and closed blow down systems. Cooling water supply and return headers and firewater header can be provided underground, if found suited or necessary.

10.3 All condensing vapour and flare lines shall be without pockets and free draining requirement.

10.4 Future space on pipe racks: 15%.

10.5 Recommended insulation materials are

A) Hot insulation: Rock wool (mineral wool), Calcium silicate inner layer + rock wool outer layer for temperatures greater than 550 Deg C

B) Hot insulation electrically traced: Rock wool inner layer + Poly isocyanurate or polyurethane foam outer layer

C) Safety (Personnel Protection) Insulation: Rock wool (mineral wool), Calcium silicate-inner layer+ rock wool-outer layer) for temperatures beyond 550 Deg C.

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11.0 SAFETY AND ENVIRONMENTAL REQUIREMENTS

This section presents a short list of additional safety aspects that will be reflected, as appropriate, in the basic engineering design or in the detailed engineering stages. This list is not intended to be a complete enumeration of safety features for a project.

11.1 Push buttons for stopping critical motors, if identified, shall be provided at a safe location, away from the fire-zone of the respective motors. This is in addition to usual start/ stop push buttons provided for such motors (with locking arrangement)

11.2 Gas detectors shall be provided in the critical process and offsites areas. The requirement of steam / air curtain shall be based on designers / vendor requirement and as finalized to be consistent with rotating equipment seal selection and leakage potential.

11.3 Suction / discharge valves of suction filter should be close to the pump in order to avoid hydrocarbon wastage during filter cleaning and pump maintenance.

11.4 Flare line isolation valve at unit battery limits should be installed only in the horizontal line with stem in upside down (pointing downwards) position to avoid free fall of gate and blockage of flare system

11.5 Other requirements

1. Safety Showers 2. CCTV cameras shall be provided to monitor the flare

Safety valves which may be required for protecting equipment for fire case in accordance with API and IBR code requirements based on the final equipment size/location shall be provided.

11.6 Following Safety and Environmental requirements to be followed by TCE:

11.6.1 Shutdown of pumps by low low level in upstream vessel

Automatic shutdown of the process pumps shall be by Low Low Level set point (LSLL) via a Level Transmitter (LT)

11.6.2 Minimum flow bypass on centrifugal pumps with flow control

A minimum flow bypass with flow control for centrifugal pumps for the following cases shall be provided:

- for process reason (turndown), flow rate lower than or equal 30 per cent of max flow rate

- for any vessel which has a Low Low Level set point for tripping pump ;

Minimum flow by-pass provisions and controls Sr. No. Conditions Type of Control

1 Pump with discharge flow under level / temperature control Motor rating < =

15KW

Put line with globe valve, restriction orifice, local and DCS FI and gate valve

assembly back to suction line (after sufficient length for heat dissipation) /

vessel (below LLL) Size the line and RO for pump "min safe

flow"

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Revised rated flow = Process rated flow

+ "min safe flow" Revised normal flow = Process normal

flow + "min safe flow" Revised min flow = Process min flow +

"min safe flow"

2 Pump with discharge flow under level /

temperature control Motor rating >=15KW

Put a control valve assembly back to suction line (after sufficient length for

heat dissipation) / vessel (below LLL). A FIC at total discharge flow line shall

operate the control valve Size the control valve and line for "min

safe flow"

3

Pump with discharge flow is under flow control i.e. FC

When the process normal or rated flow is less than pump "min safe flow" and

motor rating <=15KW

Put line with globe valve, restriction orifice, local FI and gate valve assembly

back to suction line (after sufficient length for heat dissipation) / vessel

(below LLL) Size the line and RO for pump "min safe

flow" Revised rated flow = Process rated flow

+ "min safe flow" Revised normal flow = Process normal

flow + "min safe flow" Revised min flow = Process min flow +

"min safe flow"

4

Pump with discharge flow is under flow control i.e. FC When the process normal or rated flow is less than pump "min safe

flow" and motor rating >=15KW

Put a control valve assembly back to suction line (after sufficient length for

heat dissipation) / vessel (below LLL). A FIC at total discharge flow line shall

operate the control valve Size the control valve and line for the

difference of "min safe flow" and process min flow

5 Pump with discharge flow is under flow control i.e. FC When the process min flow is less than pump "min safe flow"

Put line with globe valve, restriction orifice, local FI and gate valve assembly

back to suction line (after sufficient length for heat dissipation) / vessel

(below LLL) Size the line and RO for the difference in

pump "min safe flow" and process

min flow. Do not revise pump rated and normal capacity.

6 When the process min flow is more than pump "min safe flow" No action required

Minimum circulation line final sizing will be carried out by Package Vendor /TCE.

The pump data sheet will specify the process flow without provision for the minimum flow which will be specified by the pump's vendor.

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Pump vendor shall indicate temperature rise if any, at minimum flow.

11.6.3 Automatic isolation valves (air operated valve) between process vessel and pumps

Automatic isolation valves shall be considered for:

- An inventory of the process vessel over 8 m3 and with a product above its auto ignition temperature or at a Naphtha temperature above 150 degree C ;

- An inventory of the process vessel above 16 m3 and a flammable product.

The closure of these valves shall result in the automatic shutdown of the corresponding pumps.

11.6.4 Prevention of back flow overpressure

Following devices will be considered at the pump discharge:

- P lower than or equal 40 barg: one check valve

- P higher than 40 barg and smaller than 80 barg: two check valves of different type .

- All check valves to be non slamming type

11.6.5 Seals on pumps

Dual mechanical seals (pressurized or unpressurized according to process considerations) or seal less pumps shall be considered in the following cases:

- Hydrocarbons above their auto ignition temperature or at a Naphtha temperature higher than 150 degree C

- Toxic or carcinogenic fluid

- Pump operating at high pressure higher than or equal 50 barg to be discussed.(rotary)

- Sour water > 100 ppm H2S (emission seals)

- Fouling service or environmentally hazardous service

- For Hydrocarbon liquids with vapor pressure > 10 psi at pumping temperature

11.7 OTHER ENVIRONMENTAL CONTROL

11.7.1 Emission norms as stipulated by CPCB, MPCB and other mandatory regulations shall be satisfied for the project. Liquid effluent shall conform to MINAS standards.

11.7.2 Noise level:

85 dB(A) at 1 meter from source without acoustic enclosure.

12.0 PROCESS FLOW DIAGRAMS AND PIPING & INSTRUMENTATION DIAGRAMS 12.1 The standard legend of BPCL shall be adhered to across all process facilities. In addition

valve short codes shall be indicated on PIDs.

12.2 Instrument requirements for P&IDs:

All designers are required to adhere to the following requirements in Piping & Instrumentation Diagrams:

■ Control valve / Shut-down valve failure position shall be indicated

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■ Control valve / Shut-down valve sizes shall be indicated, in final Rev of P&ID

■ Pressure relief valve set points shall be indicated

■ Pressure relief valve sizes with orifice designations shall be indicated

■ Interlocks shall be shown with sequence numbers matched to description

■ Minimum Flow stops, hand wheels for control valves, as required shall be shown.

■ Solenoid valves and limit switches shall be shown where applicable.

■ Coupons and corrosion probes wherever required shall be shown

■ Interface type level instruments shall be clearly identified in the P&ID.

■ Pressure and temperature elements shall be shown for flow measurement (except mass flow meters) with pressure and temperature compensation, where applicable.

■ Block & Bypass valves shall be provided for Mass Flow meters, Integral Orifices.

■ Rotating equipment status indication shall not be shown on PID.

12.3 Preferred drawing size and media:

All P&IDs and PFDs shall preferably be drawn in drawing size ISO Al. The CAD software used shall be AUTOCAD 2010.

All P&IDs and PFDs shall also be submitted on drawing size ISO Al. Hard and Soft copies of all P&IDs and PFDs and operating manual for package systems shall be furnished by package vendor.

13.0 EQUIPMENT DESIGNATION AND NUMBERING SYSTEM 13.1 Equipment numbering system:

Table-13.1: Equipment designation

Eqpt. Code Description Eqpt. Code Description AU RCC Tanks X Stack C Columns / Towers WHB Waste heat boiler (Exchanger)

CT Trays, general X Undefined package equipmentCW Demister for columns TG Turbo generator CP Packed internals for columns P Pumps EA Air cooled heat exchangers MP Pump drive, Electric motor

MEF Electrical drive for Air cooled heat exchangers TP Pump drive, Steam turbine

E Shell & tube heat exch (S&T Hx) PZ Power recovery turbine R Reactor

EP Plate heat exchanger RA Reactor mechanical mixer

F Fired furnace MRA Electrical drive for

reactor mechanical mixer

B Burners RT Reactor trays AP Air preheater RP Reactor packed internals FI Incinerator TB Storage bins G Filters TH Storage hoppers

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Eqpt. Code Description Eqpt. Code Description JA Ejectors, Vacuum system TI Storage silos

JE Evaporator TA Storage tank mechanical mixers

JS Static Mixer MTA Electrical drives for tank mechanical

mixers EB Expansion joint, general S Storage spheres JM Air mixer T Storage tanks K Compressor / Blowers V Vessels, drums, separators

MK Compressor /blower Drive, Electric motor VA Mechanical mixer for vessels

TK Compressor/blower Drive, Steam turbine M Miscellaneous Electrical

drives for mechanical mixer FD Forced draught fan VW Demister for vessels ID Induced draught fan VP Packing for vessels

MFD Electrical drive for FD fans ST Piping item, steam traps MID Electrical drives for ID fan AT Piping item, air traps AC Air conditioning plant S Piping item, in-line strainers XC Refrigeration plant MZ Electrical, miscellaneous CT Cooling Tower FA Flame arrestor

MCT Electrical drive for cooling tower DR Dryers X Package JU Silencer Y PSA unit PSV Pressure Safety Valve M Miscellaneous

14.0 STANDARDS & CODES 14.1 Applicable Codes & Standards

S.No Area Standards

1.1 Engineering standard TCE Standard Customer's Standard

1.2 National standard DIN IS

1.3 Material specification DIN ASTM / ASME (Edition 2008) IS

1.4 Petroleum industry code API

1.5 Pressure vessels and boiler code AD ASME 2007 Addenda 2008

1.6 Heat exchanger

DIN TEMA 9th EDITION 2007 Class R C B API 660 (8th Edition 2007)

1.7 Centrifugal Pumps DIN/ISO API 610 10th Edition,2004 Manufacturer Standards

1.8 Metering Pumps DIN/ISO

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S.No Area StandardsAPI675 2ndEdition,1994 Manufacturer Standards

1.9 Mechanical Seals for centrifugal pumps

API 682 3rd Edition,2004 & API 682 ERTA 2006

1.10 Special purpose Couplings API 671 4th Edition,2007 1.11 Centrifugal Fans / Blower API 673 II Edition,2002 1.12 Centrifugal Air Compressor API672 4thEdition,2004 1.13 Screw Compressor API 619 4th Edition,2004 1.14 Reciprocating Compressors API 618 5th Edition,2007

1.15 Lube oil, shaft sealing, control oil for centrifugal compressor API 614 5th Edition,2008

1.16 Steam Turbine of Cooling Water Pump API 611 5th Edition, 2008

1.18 Machines Manufacturer Standards

1.19 Piping DIN ANSI

1.20 Electrical code IS IEC

1.21 Instrumentation CENELEC TCE Norms

1.22 Civil code

IS:456 2000, IS 875 1987 , IS 1893 Part I 2002, Part IV 2005, IS 800 2007(for New Structures) IS:456 1964, IS 875 1987 , IS 1893 1984, IS 800 1984( for existing structures)

1.23 Hazardous area classification

IS 5572, 3rd Edition 2009 NEC IEC, API OISD 113

1.24 Tanks API 11th Edition, 2008

1.27 Pressure relieving devices

DIN /AD API 520 8TH edition2008 API 521 5TH Edition2007 API 526 6TH Edition2009 OISD 106

1.29 Blowdown & Sewer System OISD 109 1.20 Fire Fighting System OISD 115 1.21 Layouts For Oil & Gas Installations OISD 118

All relevant OISD, CCOE and CPCB codes shall be followed and deviations if any with mitigatory measures to be provided to BPCL

14.2 LAWS & REGULATIONS

1.0 Laws & Regulations The following local laws and regulations shall be observed 1.1 Pressure Vessels SMPV rule 1994 edn. & IBR as applicable.

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1.2 Boilers / Steam users Indian Boiler Regulation Act 1.3 Buildings and Structures Indian Factory Act / Tariff Advisory

Committee Civil Aviation Rules 1.4 Electrical I.E. Rules / I.E. Act / Electricity (Supply Act) /

Regulations for electrical equipment for buildings / ASEB Regulations / Indian Electricity Rules

1.5 Fire Fighting Fire Protection Manual of Tariff Advisory Committee

1.6 Water Pollution Water (Prevention and Control of Pollution) Act, 1974 Water (Prevention and Control of Pollution) Cess Act, 1977.

1.7 Air Pollution Air (Prevention and Control of Pollution) Act, 1977

1.8 Safety Indian Factory Act/Andhra Pradesh Factories Act/ Indian Explosives Act / Requirement of Chief Controller of Explosives Indian Petroleum Rules Oil Industry Safety Directorate

1.9 Aircraft Warning Indian Aviation Act 1.10 Noise Factory Act 1.11 Solid Waste Hazardous Waste Management Rules. 1.12 Environment Environment ( Protection ) Act, 1986 <Rev 04>

amended in 2008 <Rev04> Liquid effluent discharge, as per Minimal National Standards for liquid effluents and air emissions conforming to Pollution Control Board Standards

1.13 Level Instruments Atomic Energy Rules

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Annexure - I Level Definition for Vessels

LSHH

Level Switch High High

TL

LSHH

NHLL

LAH NLL

LAL

NLLL LSLL

TL

L

Very high level trip which triggers an ESD action and associated with a very high level alarm (LAHH) High Level trip will be implemented by a set point configured in ESD by using a level transmitter.

NHLL

Normal High Liquid Level High liquid level in normal operation Reference level used for hold-up calculation. There is no safety action and control / command associated with this level

LAH

Level Alarm High DCS pre-alarm high level. This alarm point is configured in the level controller (LIC) in the DCS. It indicates to the operator to proceed eventually t o a process action to avoid

• Automatic Shut down by LSHH if installed

• Vessel overfilling if LSHH not installed.

NLL

Normal Liquid Level. Not indicated on vessedl sketches and considered as 50% of the volume between NHLL and NLLL.

LAL Level Alarm Low DCS pre-alarm low level and same philosophy

as LAH but for low level. NLLL Normal Low liquid level

Low liquid level in normal operation. Reference level used for the hold-up calculations. There is no safety action and control / command action associated with this level.

LSLL Level Switch Low Low Very low level trip which triggers an ESD action and associated with a very low level alarm (LALL). It is in similar philosophy of LSHH but for vey low level.

TL Tangent Line Geometrical junction line between shell and top

/ bottom head. This is not the seam line. Hold up Volume

Hold up volume indicated in minutes in specifications / datasheets is the residence time defined between NHLL & NLLL based on filling / withdrawal rates.

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SPECIFICATION.NO.

TATA CONSULTING ENGINEERS LIMITED SECTION: F

TCE.6079A-B-610-024 CENTRIFUGAL PUMPS

EXPERIENCE RECORD PROFORMA

SHEET 1 OF 15

ISSUE R0

EXPERIENCE RECORD – CENTRIFUGAL PUMP ( HORIZONTAL )

ITEM : COOLING WATER PUMPS ITEM NUMBER : VENDOR : INSTRUCTIONS TO BIDDERS:

1. This proforma duly filled in shall be submitted for each item separately, along with the bid. 2. Since the information requested in this proforma will be utilized to assess provenness of offered model, it is in the

interest of the equipment manufacturer to pick up those cases out of total list of references which most closely match with the offered model. The equipment manufacturer shall also ensure that each & every information asked for is furnished and the same is correct and complete in all respects. Incorrect information furnished in this proforma shall render the bid liable for rejection.

3. While furnishing the materials, where asked for, the equipment manufacturer shall furnish ASTM equivalents also. 4. For the referred installation, the equipment manufacturer shall indicate the name of the person ( along with his address,

telephone no., fax no. /email – id etc.) who may be contacted by the Purchaser / his representative, if felt necessary. 5. The equipment manufacturer shall also furnish along with the bid his standard reference list for the offered equipment

model manufactured and supplied by him. 6. The equipment manufacturer shall clarify the meaning of each letter / digit used in the model designation below :

PART IIB of 221

SPECIFICATION.NO.




SHEET 2 OF 15

ISSUE R0

Description of Model designation system:

Sl. No.

PARAMETER

INFORMATION ON PROPOSED MODEL

INFORMATION ON REFERRED EXISTING

INSTALLATIONS

REMARKS

Ref. - 1 Ref.-2 Ref.-3

1 2 3 4 5 6 7

1 GENERAL

1.1 Cross reference to manufacturer’s standard Reference list

1.2 Make

1.3 Model Number

1.4 Number of units supplied

1.5 Type of driver ( Electric Motor/Steam Turbine/ Gas Turbine/IC Engine )

1.6 Driver rated KW / Speed ( rpm )

1.7 Drive ( Fixed speed / Variable Speed / Variable frequency

1.8 Name and edition of standard to which the pump conforms

1.9 Shop where pump is designed, manufactured, packaged, tested & supplied with address

2 OPERATING CONDITIONS

2.1 Fluid handled

2.2 Fluid temperature ( Min / Max )oC

2.3 Capacity (m3/hr)

2.4 Maximum Suction pressure (kg/cm2, a)

2.5 Differential Head, Rated ( m )

2.6 Differential Pressure, Rated ( kg/cm2)

2.7 NPSHR (m)

2.8 Efficiency

2.9 BKW, Rated

PART IIB of 221

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SHEET 3 OF 15

ISSUE R0

Sl. No.

PARAMETER



INSTALLATIONS

REMARKS


2.10 Minimum Continuous Stable Flow, (m3/hr)

2.11 Rated Speed

2.12 Speed range for variable speed drive

2.13 MAWP casing ( kg/cm2G) @150C @pumping temperature

3 CONSTRUCTION

3.1 No. of stages ( single / two )

3.2 Casing split ( Axial / Radial )

3.3 Impeller diameter – Rated / Maximum/ Minimum ( mm )

3.4 Whether the proposed model and reference models have identical hydraulic design (for impeller/ diffuser / volute )

3.5 Sealing Element ( packing / mechanical seal )

3.6 Type of mechanical seal ( Single / Double )

3.7 API Sealing Plan No.

3.8 API Cooling Plan

4 MATERIAL OF CONSTRUCTION

4.1 Material Code

4.2 Casing

4.3 Impellers

4.4 Shaft

5 OTHER INFORMATION ON INSTALLATIONS

5.1 Date of supply of entire unit

5.2 Date of commissioning of entire unit

5.3 No. of operating hours completed as on the date of issue of material requisition

5.4 Major Problems encountered

PART IIB of 221

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SHEET 4 OF 15

ISSUE R0

Sl. No.

PARAMETER



INSTALLATIONS

REMARKS


5.5 Name of plant

5.6 Purchaser’s Name and Address

Name ( Company / Organization )

Name of Contact Person

Address

Telephone No.

Fax No.

Email - id

PART IIB of 221

SPECIFICATION.NO.




SHEET 5 OF 15

ISSUE R0

EXPERIENCE RECORD – GEAR BOX ITEM : GEAR BOX FOR STEAM TURBINE DRIVER FOR CW PUMPS ITEM NUMBER : VENDOR : INSTRUCTIONS TO BIDDERS :

1. This proforma duly filled in shall be submitted for each item separately, alongwith the bid. 2. Since the information requested in this proforma will be utilized to assess provenness of offered model, it is in the

interest of the equipment manufacturer to pick up those cases out of total list of references which most closely match with the offered model. The equipment manufacturer shall also ensure that each & every information asked for is furnished and the same is correct and complete in all respects. Incorrect information furnished in this proforma shall render the bid liable for rejection.

3. While furnishing the materials, where asked for, the equipment manufacturer shall furnish ASTM equivalents also. 4. For the referred installation, the equipment manufacturer shall indicate the name of the person ( alongwith his address,

telephone no., fax no. /email - id etc. ) who may be contacted by the Purchaser / his representative, if felt necessary. 5. The equipment manufacturer shall also furnish along with the bid his standard reference list for the offered equipment


PART IIB of 221

SPECIFICATION.NO.




SHEET 6 OF 15

ISSUE R0


Sl. No.

PARAMETER INFORMATION ON PROPOSED MODEL


INSTALLATIONS

REMARKS


1 2 3 4 5 6 7

1 GENERAL

1.1 Cross reference to manufacturer’s Standard Reference list

1.2 Make

1.3 Model

1.4 No. of Units supplied

1.5 Type of driver

1.6 Driver Rating (kWx rpm )

1.7 Driven Machine

1.8 Shop where Gear Box is designed, manufactured and tested with location and address

2 GEAR BOX DETAILS

2.1 Codes / Standards followed ( API - 613/API-617/ Others )

2.2 Gear Box Ratings (kW)

2.3 Speed ( input / Output ) (rpm)

2.4 Maximum continuous speed ( input / output ) (rpm)

2.5 AGMA/ API S.F

2.6 Pitch Circle Diameter ( Pinion / Gear ) ( mm)

2.7 Pitch line velocity (m/sec.)

2.8 Gear Ratio

2.9 No. of stages

2.10 Center to Center distance between high speed & low sped shafts ( mm )

PART IIB of 221

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SHEET 7 OF 15

ISSUE R0

Sl. No.



INSTALLATIONS

REMARKS


2.11 Tooth Profile

2.12 Type of Gears : Single helical/Double helical/Herringbone

2.13 Type & No. of Bearings ( Radial )

2.14 Gear Shaft

2.15 Pinion Shaft

2.16 Type & No. of Bearings ( Thrust )

2.17 Gear shaft

2.18 Pinion Shaft

2.19 MATERIAL OF CONSTRUCTION

2.20 Casing

2.21 Pinion

2.22 Gear

2.23 Shaft ( high speed / low speed )

2.24 Bearings






3.5 Name of plant




Address

Telephone No.

Fax No.

Email - id

PART IIB of 221

SPECIFICATION.NO.




SHEET 8 OF 15

ISSUE R0

EXPERIENCE RECORD - STEAM TURBINE ( GENERAL PURPOSE )

ITEM : STEAM TURBINE DRIVER FOR COOLING WATER PUMPS

ITEM NUMBER : VENDOR : INSTRUCTIONS TO BIDDERS:

1. This proforma duly filled in shall be submitted for each item separately, along with the bid. 2. Since the information requested in this proforma will be utilized to assess provenness of offered model, it is in the interest

of the equipment manufacturer to pick up those cases out of total list of references which most closely match with the offered model. The equipment manufacturer shall also ensure that each & every information asked for is furnished and the same is correct and complete in all respects. Incorrect information furnished in this proforma shall render the bid liable for rejection.

3. While furnishing the materials, where asked for, the equipment manufacturer shall furnish ASTM equivalents also. 4. For the referred installation, the equipment manufacturer shall indicate the name of the person (along with his address,

telephone no., fax no. /email – id etc. ) who may be contacted by the Purchaser / his representative, if felt necessary. 5. The equipment manufacturer shall also furnish along with the bid his standard reference list for the offered equipment


PART IIB of 221

SPECIFICATION.NO.




SHEET 9 OF 15

ISSUE R0


Sl. No.



INSTALLATIONS

REMARKS


1 2 3 4 5 6 7

1 GENERAL

1.1 Cross reference to manufacturer’s Standard Reference list

1.2 Make

1.3 Model Number

1.4 No. of Units designed, manufactured, tested and Supplied as per API 611

1.5 Type of drive arrangement ( Direct / through Gear Box )

1.6 Type of Driven Equipment

1.7 Type of Lubrication System

1.8 Shop where Turbine is designed, manufactured and tested with complete address

1.9 Single valve / Multi Valve

1.10 Type : Condensing / Extraction Condensing/Back Pressure

1.11 No. of controlled extractions

1.12 No. of Uncontrolled extractions

1.13 No. of Inductions

2.0 OPERATING CONDITONS

2.1 Rated Power ( kW )

2.2 Power at zero extraction (kW )

2.3 Rated Speed ( rpm )

PART IIB of 221

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ISSUE R0

2.4 Speed Range ( rpm )

2.5 Inlet Steam Flow, Nor / Rated ( kg/hr )

2.6 Inlet Steam Pressure ( kg/cm2a)

2.7 Inlet Steam Temperature ( oC)

2.8 Exhaust Steam Pressure ( kg/cm2A)

2.9 Exhaust Steam Temperature ( oC)

2.10 Condenser C.W. inlet temperature ( oC)

2.11 Condenser C.W. outlet temperature ( oC)

2.12 1st Extraction / Induction

2.13 Type ( Controlled / Uncontrolled )

2.14 No. of Steam Inlet Valves

2.15 Steam Pressure ( Kg/cm2,a )

2.16 Steam Temperature ( oC)

2.17 Steam Quantity (Kg/hr.) (Min./Nor./Max.)

2.18 2nd Extraction / Induction





2.23 Steam Quantity (Kg/hr.) ( Min./Nor./Max.)

2.24 3rd Extraction / Induction





2.29 Steam Quantity ( Kg/hr.) ( Min./Nor./Max.)

PART IIB of 221

SPECIFICATION.NO.




SHEET 11 OF 15

ISSUE R0

3 CONSTRUCTIONAL FEATURES

3.1 First Section ( From Main Inlet to 1st Extraction / Induction or Main Inlet to Exhaust ( where no Extraction or induction is involved )

3.2 Curtice Stage

3.3 No. of Stages

3.4 1st Stag Curtice Wheel ( Yes / No )

3.5 Material of Curtice Wheel

3.6 Material of Curtice Blades

3.7 Material of Nozzles

3.8 Impulse Stages

3.9 No. of subsequent Impulse Stages

3.10 Material of Impulse Wheels

3.11 Material of Impulse Blades


3.13 Reaction Stages

3.14 No. of subsequent Reaction Stages

3.15 Material of Reaction Wheels

3.16 Material of Reaction Moving Blades

3.17 Material of Reaction Stationary Blades

3.18 Second Section ( 1st Extraction / Induction to 2nd Extraction/ Induction to exhaust for turbines with one Extraction/Induction )

3.19 Curtice Stage

3.20 No. of Stages





PART IIB of 221

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ISSUE R0

3.25 Impulse Stages










3.35 Third Section ( 2ndExtraction/Inductionto 3rd Extraction or 2nd Extraction /Induction to exhaust for turbines with two Extraction /Induction)

3.36 Curtice Stage

3.37 No. of Stages





3.42 Impulse Stages










PART IIB of 221

SPECIFICATION.NO.




SHEET 13 OF 15

ISSUE R0

3.52 Fourth Section ( 3rd Extraction / Induction to exhaust )

3.53 Curtice Stage

3.54 No. of Stages





3.59 Impulse Stages










3.69 Inlet Casing

3.70 Material of Casing

3.71 Design Temperature (oC)

3.72 MAWP @ design temperature (kg/cm2G)

3.73 MAWP @ 150C

3.74 Intermediate Casing




3.78 MAWP @ 150C

PART IIB of 221

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SHEET 14 OF 15

ISSUE R0

3.79 Exhaust Casing




3.83 MAWP @ 150C

3.84 Miscellaneous

3.85 Type of Steam seal (Gland/Carbon Ring/Dry)

3.86 Material of Shaft

3.87 Diameter of Shaft under Bearings (mm)

3.88 Diameter of Shaft under Coupling (mm)

3.89 Radial Bearings

3.90 - Type

3.91 - Make

3.92 Thrust Bearings

3.93 - Type

3.94 - Make

3.95 Span Between Bearings

3.96 Governor

3.97 Type

3.98 Make

3.99 Model

3.100 Class of governing ( as per NEMA )

3.101 Governor Actuation ( Electric, Hydraulic )






PART IIB of 221

SPECIFICATION.NO.




SHEET 15 OF 15

ISSUE R0

4.5 Name of plant




Address

Telephone No.

Fax No.

Email - id

PART IIB of 221

TCE FORM NO. 329R5

SPEC. NO. TCE.6079A-B-640-024

TATA CONSULTING ENGINEERS LIMITED SECTION: D

ELECTRICAL REQUIREMENTS FOR COOLING WATER

CIRCULATION PUMPS SHEET 1 OF 1

ISSUE R0

1. Supply of following motors along with Pumps:

1.1 HV (6.6kV) Flameproof Motors for Cooling water Circulating Pumps (Refer Specification No. TCE.6097A-B-Z-203).

2. Power Supply system

2.1 6.6kV, 3 phase, 50 Hz, AC Power Supply to Cooling water Circulation pump motors will be obtained from 6.6kV Switchboard in CCR Switch house.

2. Cabling System

2.1 Supply and installation of Cabling system will be by other contractor.

3. Earthing System

3.1 Supply and installation of Earthing system will be by other contractor.

4. Documents / Drawings to be submitted by Bidder

4.1 Along with the Bid

4.1.1 Motor Ratings

4.1.2 Data/ Document/ drawings listed in Data Sheet-B of Specifications.

4.2 After Award of Contract

4.2.1 Final Motor Ratings

4.2.2 Quality Assurance Plan for motors

4.2.3 Type Test and Routine Test Certificates for the motors after inspection of the equipment.

4.2.4 Data/ Document/ drawings listed in Data Sheet-C of Specifications.

PART IIB of 221

SPEC. NO. TCE.6079A-B-Z-203

TATA CONSULTING ENGINEERS LIMITED SECTION:

HIGH VOLTAGE INDUCTION MOTORS SHEET 1 OF 21

ISSUE R0

TCE FORM NO. 329 R5

1.0 SCOPE

1.1 The specification covers the design, material, constructional features, manufacture, inspection and testing at the VENDOR'S/his SUB-VENDOR'S works, delivery to site and performance testing of High Voltage induction motors rated above 1000V.


2.1 The design, material, construction, manufacture, inspection, testing and performance of induction motors shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. The equipment shall also conform to the applicable standards specified in data sheet A1 latest revision as on the date of offer Nothing in this specification shall be construed to relieve the VENDOR of this responsibility. In case of conflict between the standards and this specification, this specification shall govern.

3.0 DRIVEN EQUIPMENT

3.1 When this specification forms part of the driven equipment specification, information not given in the Data Sheet-A will be governed by the driven equipment specification.

3.2 Motors shall be capable of satisfactory operation for the application and duty as specified in the motor Data Sheet-A and as specified for the driven equipment.

4.0 PERFORMANCE AND CHARACTERISTICS

4.1 Motors shall be capable of giving rated output without reduction in the expected life span when operated continuously under either of the following supply conditions as specified in Data Sheet-A1.

Supply Condition

I II

a) variation of supply voltage from rated voltage +/- 6% +/-10%

b) Variation in supply frequency from rated frequency

+/- 3% +/- 5%

c) Combined voltage and frequency variation +/- 6% +/-10%

4.2 Motors shall be suitable for the method of starting specified in the Data Sheet-A.

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

4.4 Motors shall be capable of satisfactory operation at full load at a supply voltage of 80% of the rated voltage for 5 minutes, commencing from hot condition.

4.5 Motors shall withstand the voltage and torque stresses developed due to the vector difference between the motor residual voltage and the incoming supply

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TCE FORM NO. 329 R5

voltage equal to 150% of the rated voltage, during fast change over of buses. The duration of this condition is envisaged for a period of one second.

4.6 The locked rotor current of the motors shall not exceed the following values which are inclusive of 20% tolerance.

4.6.1 600% of full load current for motors upto and including 1500 kW.

4.6.2 450% of full load current for motors above 1500 kW.

4.7 Motors shall be capable of developing the rated full load torque even if the supply voltage drops to 70% of the rated voltage. The pull out torque of the motor shall be atleast 205% of full load torque.

4.8 Motors when started with the driven equipment coupled shall be capable of withstanding at least two successive starts from cold conditions & one start from hot condition without injurious heating of windings. The motors shall also be suitable for three equally spread starts per hour under the above referred supply conditions.

4.9 The locked rotor withstand time under hot conditions at 110% rated voltage shall be more than the starting time at minimum permissible voltage by atleast three seconds or 15% of the accelerating time whichever is greater. Provision of speed switch shall be avoided to the extent possible. In case the speed switch is required, it shall be indicated out by the bidder in his offer.

4.10 When a speed switch is mounted on the motor shaft , the same shall remain closed for speeds lower than 20% and open for speeds above 20% of the rated speed. The speed switch shall be capable of withstanding 120% over speed in either direction of rotation. If the speed switch requires any auxiliary voltage, it shall be suitable for the auxiliary voltage specified in Section-B - Project Information of the specification.

4.11 Motors shall be designed to keep torsional and rotational natural frequencies of vibration of the motor and driven equipment atleast twenty five (25) percent above or below, preferably above the motor operating speed (to avoid resonance in vibration over the operating speed) range.

4.12 The motors shall also be capable of running up again after voltage collapse to about 40% for approximate duration of 0.5 sec. Subsequent rise in voltage to 70% and further to 80% and 100%, the total duration not exceeding 20 sec.

5.0 INSULATION

5.1 Motors shall be given power house treatment. Additional treatments to withstand heavily salt polluted or similar atmospheric conditions shall be given based on the location indicated in Data Sheet-A.

5.2 The insulation shall be given tropical and fungicidal treatment for successful operation of the motor in hot, humid and tropical climate. The tropicalising treatment shall be as per the applicable standard.

5.3 The insulation system shall withstand steep front impulse voltage of value given as per Table-1 of IEC-60034-15 having front time of 0.2 microsecond.

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6.0 TEMPERATURE RISE

6.1 The temperature rises shall not exceed the values given in IS 12802. Under extremes of supply condition (clause 4.1 above), the temperature rise shall not exceed the value indicated in IS by 10

oC.

6.2 For motors specified for outdoor installation heating due to direct exposure to solar radiation shall be considered.

6.3 Atleast six resistance type temperature detectors for the stator winding each having D.C. resistance of 100 ohms at 0

oC, embedded in the stator winding at

locations where highest temperatures may be expected, shall be provided. The material of the ETD's shall be platinum. ETD shall be provided for each of the motor bearing & shall be wired upto the terminal box. The temperature detectors shall be of 3 wire, duplex type.

6.4 The highest temperature attained under practical conditions of operations within the rating of the motor by any part or any surface shall not exceed the values given in Table below in IS:13346.

TABLE

Class Maximum Surface Temperature

oC

T1 450

T2 300

T3 200

T4 135

T5 100

T6 85

6.5 For motors specified for outdoor installation account shall be taken of heating due to direct exposure to solar radiation.

7.0 CONSTRUCTIONAL FEATURES

7.1 All insulated windings shall be of Copper.

7.2 All Motors shall be provided with eyebolts, lugs or other means to facilitate safe lifting.

7.3 Vibration pads shall be provided when called for in the specification.

7.3.1 The constructional feature shall meet the requirements specified in respective IS & BS which are mentioned in Data Sheet A1 and A2 of this Section.

7.3.2 The motor construction shall be suitable for easy disassembly and reassembly. The enclosure shall be sturdy and shall permit easy removal of any part of the motor for inspection and repairs.

7.3.3 The motor bars shall not be insulated in the slot portion between the iron core laminations and the bars.

7.3.4 Unless otherwise approved, motors shall be designed to permit convenient access for drilling vertically through motor feet or mounting flange for

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installation of Purchaser’s dowel pins after motors are mounted with the driven equipment.

7.3.5 When the motor is supplied with driven equipment including a common base (bed place, channels etc.). The VENDOR shall ensure that such bed plate is adequately braced to keep vibrations and misalignment within satisfactory limits.

7.3.6 The motor name plate shall clearly indicate the type of enclosure, protection and gas group classification as per IS:13346.

8.0 BEARINGS

8.1 Unless otherwise specified in data sheet-A, motor bearings shall not be subjected to any external thrust load.

8.2 Unless otherwise specified, motor bearings shall have an estimated life of atleast 40,000 hrs.

8.3 The bearings shall permit running of the motor in either direction of rotation.

8.4 Greased ball bearings or greased roller bearings shall be of reputed make subject to the PURCHASER’s approval. The life expectancy of the bearing shall be stated.

8.5 The bearings shall be so constructed that the loss of lubricating fluid is kept to a minimum and greasing shall be possible without any dismantling operation.

8.6 When forced oil lubrication or water cooling is required, prior approval from the purchaser shall be obtained.

8.7 If the bearings are oil lubricated, a drain plug shall be provided for draining residual oil & an oil level sight gauge shall be provided to show the precise oil level required for stand still and running conditions.

8.8 Lubricants shall be selected for prolonged storage and normal use of the motors in tropical climate and shall contain corrosion and oxidation inhibitors. Grease shall have suitable bleeding characteristics to minimise setting.

8.9 Sleeve bearing for use with motors having flexible couplings with limited end play, shall have adequate axial end play to permit assembly so as to prevent transmitting of thrust from driven equipment to motor bearings.

8.10 On Line re-greasing arrangement shall be provided.

8.11 Each bearing shall be provided with a dial type thermometer. Each thermometer shall consist of 2 potential free contacts. They shall be designed to close independently at two different temperatures - one for 'Alarm' and another for 'Trip'.

8.12 The contact rating of the potential free contacts shall be 1A at 240V AC & 0.1A at 220V DC. Any auxiliary supply, if required shall be indicated by the bidder.

8.13 The thermometers shall be located at a convenient height for easy reading and handling.

8.14 One bearing shall be insulated to prevent shaft currents.

9.0 TERMINAL BOX

9.1 Separate terminal boxes shall be provided for each of the following :

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9.1.1 Stator Leads

9.1.2 Rotor leads (for wound motors)

9.1.3 Space Heaters

9.1.4 Temperature Detectors

9.2 The three phases shall be segregated by barriers of metal or fibre glass.

9.3 The cable box design shall be suitable for any type of cable termination kits available.

9.4 Terminal boxes shall have a degree of protection of atleast IP 55 for out door applicable.

9.5 Motor shall be provided with two (2) terminal boxes for stator terminals. One (1) terminal box shall be for phase terminals while other one for forming star connection. These should be interchangeable to facilitate cable routing.

9.6 Neutral terminal box for HT motors rated 1000 KW and above shall be suitable for mounting of three (3) Nos. wound/bar primary/ring type cast resin insulated current transformers for differential protection. These transformers shall be supplied and mounted in the motor terminal box. In addition to above, 3 Nos. of identical current transformers shall be supplied loose for mounting in the switchgear. Stator phase terminal box may either be phase segregated of standard terminal box suitable for both top and bottom entry of cables. (i.e. they should be capable of being turned through 180 Degrees). The terminal box shall be designed for termination of XLPE cables using heat shrinkable or push on type terminating Kit for motors rated below 1500KW and for motors rated 1500KW above Elasto Mould type termination kits shall be used. Terminal leading shall be stud type or leading wire type.

9.7 Terminals shall be of stud type & the terminal box shall be complete with necessary lugs, nuts, washers.

9.8 When single core cables are to be used the gland plates shall be of non magnetic material.

9.9 Sizes of terminal boxes and lugs shall suit the cable sizes mentioned in Data Sheet- A.

10.0 PAINT AND FINISH

10.1 All motor parts exposed directly to atmosphere shall be finished and painted to produce a neat and durable surface which would prevent rusting and corrosion. The equipment shall be thoroughly degreased, all rust, sharp edges and scale removed and treated with one coat of primer and finished with two coats of grey enamel paint.

11.0 HEATING DURING IDLE PERIODS

11.1 Motors rated shall have space heaters suitable for 240V, single phase, 50 Hz, AC supply. Space heaters shall have adequate capacity to maintain motor internal temperature above dew point to prevent moisture condensation during idle period. The space heaters shall be placed in easily accessible positions in the lowest part of the motor frame.

12.0 ACCESSORIES

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12.1 Two independent earthing points shall be provided on opposite sides of the motor, for bolted connection of the PURCHASER'S earthing conductors as specified in data sheet-A. The earthing pads shall be of non-corrodible metal welded or brazed. These earthing points shall be in addition to earthing stud provided in the terminal box.

12.2 Except when otherwise specified, the motors shall be provided with a bare shaft extension having a key slot and a key at the driving end.

12.3 The following details, in addition to those specified in applicable standards shall be included on the rating plate.

12.4 Temperature rise of windings in degree centigrade at rated load, rated voltage, frequency and ambient conditions and the method of measuring temperature rise. (Thermometer/ Winding resistance).

12.5 Type of bearings, recommended lubricant, lubricating interval & re-lubricating quantity.

13.0 ADDITIONAL REQUIREMENTS FOR MOTOR OF TYPE OF PROTECTION

Ex’d’

The most relevant items of IEC 60079-1 [17] are briefly listed below:

13.1 Construction Feature

13.1.1 A flameproof gland shall be provided wherever a shaft passes through the wall of a flameproof enclosure.

13.1.2 The length of flame path in a flameproof shaft entry associated with a sleeve bearing shall not be less than the diameter of the shaft, provided that the length of the flame path does not exceed 25 mm.

13.1.3 Shafts fitted with ball or roller bearings, the radial clearance in the flameproof shaft entry shall not exceed the maximum diametric clearance allowed for shaft entries used with sleeve bearings.

13.1.4 Terminal boxes fitted to the motor shall be of type protection Ex‘d’.

13.2 Fans

13.2.1 The free space between the external fan and any stationary part of the motor shall be at least 1/100 of the fan diameter with a minimum of 1 mm and a maximum of 5 mm.

13.2.2 If both opposing parts are machined, the clearance distance shall not be less than 1mm.

13.2.3 Fan materials shall be anti-static. Non-metallic air guides shall be suitably treated to avoid the build-up of static electricity. Fans manufactured in light alloy shall contain not more than 6% of magnesium by mass.

13.3 Auxiliary devices

13.3.1 Auxiliary devices mounted on the motor for protective, alarm or other purposes shall comply with the requirements of the appropriate standard for the type of protection for electrical equipment used in hazardous atmospheres.

13.4 Rating plate

13.4.1 In addition to the data as per IS, the following information shall be provided:

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TCE FORM NO. 329 R5

- The type of protection of the motor in accordance with IEC 60079 [17].

- The type of protection of the terminal box in accordance with IEC 60079 [17].

- The type of protection of auxiliary devices in accordance with IEC 60079 [17].

- Temperature group and gas group in accordance with IEC 60079 [17]

- Number of test certificate or registered mark of testing authority.

- Any information that is essential to ensuring the flameproof character of the enclosure.

- Area classification zone number

- The te time.(for Ex‘e’ motors)

- The minimum and if applicable maximum pressure during operation, or the minimum rate of flow or protective gas.(for Ex`p’ motors)

- The internal free volume, and the minimum volume of protective gas necessary for purging the enclosure.(for Ex`p’ motors)

14.0 TESTS

14.1 All Motors shall be subjected to all the routine tests as per applicable standard in the presence of the PURCHASER’s representative.

14.2 Following Type tests shall be performed in the presence of the PURCHASER’s representative for one of each rating:

14.2.1 Temperature rise test

14.2.2 Full load test to determine efficiency, power factor and slip

14.2.3 Momentary overload test

14.2.4 Test for vibration severity of motor

14.2.5 Test for Noise level of motor

14.2.6 Overspeed test

14.2.7 Polarisation index test. The minimum value of the polarisation index shall be 2 when determined as per IS-7816.

14.2.8 Pull out torque measurement (Direct/ Calculations)

14.2.9 Starting torque measurement (Direct/ Calculations)

14.3 For other type tests, certificates shall be provided for similar rating of the motors.

14.4 Type and routine tests certificates, as specified in the distribution schedule, shall be furnished for the PURCHASER’s approval.

14.5 All the meters, instruments, devices used for the testing purpose shall be properly calibrated by standard authorised agencies which shall be traceable to National standards. For each such instrument proper validity of calibration shall be documented by Vendor.

14.6 The shall be carried out on all motors rated at 3.3 kV and above. The minimum value of the polarisation index shall be 2 when determined as per IS-7816.

PART IIB of 221




ISSUE R0

TCE FORM NO. 329 R5

14.7 Coils of HV motors shall be tested as per IEC-60034-15. Dielectric tests to establish the insulation withstand level of Motors as indicated in clause 5.2 above shall be performed on a sample coil (identical to that to be used in the motor quoted for) for each type of HT Motor.

14.8 The test certificates shall be furnished from testing authorities like CMRS-Dhanbad, DGMS, DGFASLI-Mumbai or equivalent (ATEX /IEC –Ex certified).

PART IIB of 221

SPECIFICATION NO. TCE. 6079A-B-Z-203


HIGH VOLTAGE INDUCTION MOTORS

DATA SHEET A1 SHEET 9 OF 21

SL. NO. ITEM UNIT

REV. NO. 0 JOB NO.

TCE.

6079A

CLIENT: BHARAT PETROLEUM CORPORATION LIMITED, MUMBAI

PPD. BY RSN

CHD. BY AVD PROJECT: OFFSITES AND UTILITIES FOR CCR

DATE 22.01.11

TCE FORM NO. 330 R3

ISSUE R0

1.0 GENERAL

1.1 APPLICATION: PUMPS

1.2 NUMBERS REQUIRED 2

1.3 MAKES BHEL, CGL, ANSALDO-ITALY,ABB-UK, ALSTOM- SWITZERLAND / FRANCE, SIEMENS - GERMANY, MITSUBISHI - JAPAN, LOHER-GERMANY, FUJI-JAPAN, ALSTOM – UK, CEMP- ITALY

1.4 TYPE OF MOTOR SQUIRREL CAGE, Flameproof , TYPE

Ex-'d' suitable for Gas group –IIC

and Temperature class-T3

1.5 SUPPLY SYSTEM FAULT LEVEL MVA 457MVA,40KA

1.6 SUPPLY NEUTRAL – TYPE OF EARTHING

RESISTANCE EARTHED SYSTEM (EARTH FAULT CURRENT – 400A)

2.0 RATING

2.1 RATED OUTPUT kW (*)

2.2 RATED VOLTAGE 6.6 kV

2.3 NUMBER OF PHASES & FREQUENCY 3 PHASE, 50 Hz

2.4 VOLTAGE AND FREQUENCY VARIATION

Voltage variation - +/-10%, Frequency Variation - +/-3%, Combined - 10%

2.5 SYNCHRONOUS SPEED RPM (*)

3.0 DUTY

3.1 TYPE OF DUTY(CLAUSE 9.2 OF IS 325 and IS 12824)

Continuous

3.2 POWER REQUIRED BY LOAD (*)

4.0 METHOD OF STARTING D.O.L.

5.0 NO. OF SUCCESSIVE STARTS

5.1 COLD CONDITION 3

5.2 HOT CONDITION 2

6.0 INSULATION

6.1 CLASS OF INSULATION: F WITH TEMP. RISE CLASS-B

6.2 REF AMBIENT TEMPERATURE

45 0C

PART IIB of 221





SL. NO. ITEM UNIT

REV. NO. 0 JOB NO.

TCE.

6079A


PPD. BY RSN


DATE 22.01.11

TCE FORM NO. 330 R3

ISSUE R0

6.3 TEMPERATURE RISE BY WDG RESISTANCE METHOD

750C (CLASS B)

7.0 MAXIMUM SURFACE TEMPERATURE CLASSIFICATION (IS:8239)

AS PER TEMPERATURE CLASS-T3

8.0 LOCATION OUTDOOR

9.0 A) HAZARDOUS AREA DIVISION

(IS5572 OR EQUIVALENT:)

ZONE 2

10.0 B) GROUP CLASSIFACTION AS PER IS:2148 (FOR FLAME-PROOF ENCLOSURES HAVING HAZARDOUS GAS)

GAS GROUP-IIC,

11.0 C) WHETHER SUITABILITY FOR

HAZARDOUS DUST REQUIRED

NO

12.0 IF YES, TYPE OF DUST

13.0 ATMOSPHERE Chemical (Corrosive)

14.0 ENCLOSURE

14.1 TYPE OF COOLING (IS 6362) TEFC/CACA

14.2 DESIGNATION OF DEGREE OF PROTECTION (IS 4691)

IP 55

15.0 MAIN TERMINAL BOX

15.1 LOCATION AS SEEN FROM NON- DRIVE END

RIGHT/LEFT/TOP (*)

15.2 RATING

1, SHORT TIME

CURRENT:

DURATION:

2. DYNAMIC

(*)

40kA (RMS)

0.25 SECS

kA (PEAK)

15.3 EXTERNAL CABLE DETAILS

15.3.1 TYPE 6.6kV (UE), XLPE ARMOURRED

15.3.2 SIZE AND NUMBER OF CORES 3Cx185 ALUMINUM

15.4 EARTHING CONDUCTORS

15.4.1 MATERIAL Copper Insulated cable / Strip

15.4.2 SIZE 120sq.mm. / 50x6mm

PART IIB of 221





SL. NO. ITEM UNIT

REV. NO. 0 JOB NO.

TCE.

6079A


PPD. BY RSN


DATE 22.01.11

TCE FORM NO. 330 R3

ISSUE R0

16.0 MISCELLANEOUS REQUIREMENT

16.1 SHAFT ORIENTATION: HORIZONTAL

16.2 MOUNTING SYMBOL

(IS :2253 OR EQUIVALENT)

B3

16.3 ROTATION AS SEEN FROM NON-DRIVEN END

CLOCKWISE/ANTICLOCKWISE(*)

16.4 TYPE OF BEARING DRIVE END/NON DRIVE END(*)

16.5 WHETHER BED PLATE REQUIRED YES/NO (#)

16.6 MOTOR SHALL MATCH THE FOLLOWING TORQUE REQUIREMENTS OF THE DRIVEN EQUIPMENT:

(*)

a) STARTING TORUE b) FULL LOAD (RATED) TORQUE c) PULL OUT TORQUE

d) PULL UP TORQUE

(*)

16.7 COUPLING BY MOTOR SUPPLIER NO

16.8 IF YES, TYPE OF COUPLING

16.9 GD2 of LOAD

17.0 COLOUR SHADES OF PAINT Light Gray – Shade 631 of IS-5 Special varnishing and painting treatment to be given as the atmosphere is highly corrosive.

18.0 WHETHER CTs FOR DIFFERENTIAL PROTECTION REQUIRED FOR MOTORS >1000 kW

19.0 CTS FOR DIFFERENTIAL PROTECTION REQUIRED

YES

19.1 CT PARTICULARS

A) 3 CTS, ONE IN THE NEUTRAL LEAD OF EACH PHASE B) RATIO C) CLASS P. S. D) KNEE POINT VOLTAGE E) MAX. R. C. T. SECONDARY WINDING, F) MAX. EXCITING CURRENT AT 1/2 KPV

(#)

PART IIB of 221





SL. NO. ITEM UNIT

REV. NO. 0 JOB NO.

TCE.

6079A


PPD. BY RSN


DATE 22.01.11

TCE FORM NO. 330 R3

ISSUE R0

G) CLASS OF INSULATION

19.2 VIBRATION PADS REQUIRED (#)

20.0 TEMPERATURE DETECTORS / INDICATORS

20.1.1 EMBEDDED TEMPERATURE DETECTORS FOR WINDING REQUIRED

YES- Minimum 2 Nos. per phase Duplex type PT100 RTDs

20.1.2 EMBEDDED TEMPERATURE DETECTORS FOR BEARINGS REQUIRED

YES – Two Nos. at NDE and DE bearing- Duplex type PT100 RTDs

20.1.3 BEARING THERMOMETERS FOR DRIVING END & NON DRIVING ENDS REQUIRED

YES

21.0 SPACE HEATERS FOR MOTORS REQUIRED

YES

NOTES: 1. DETAILS MARKED THUS (*) WILL BE DECIDED AND INTIMATED BY THE BIDDER BASED

ON DRIVEN EQUIPMENT CHARACTERISTICS. 2. DATA MARKED THUS (#) WILL BE INTIMATED TO VENDOR AFTER PLACEMENT OF

ORDER.

PART IIB of 221





SL. NO. ITEM

REV. NO. 0 JOB NO.

TCE.

6079A


PPD. BY RSN


DATE 22.01.11

TCE FORM NO. 330 R3

ISSUE R0

1. INDUCTION MOTORS – THREE PHASE IS-325 BS EN- 60034-1

IEC-60034

2. ROTATING ELECTRICAL MACHINES IS-4722 BS EN- 60034-1

IEC-60034-1

3. SPECIFICATION FOR THREE PHASE INDUCTION MOTORS WITH TYPE OF PROTECTION ‘N’ (NON SPARKING FAN TYPE)

IS-9628 BS EN-60079-15

IEC-60079-15

4. ELECTRICAL APPARATUS FOR EXPLOSIVE GAS ATMOSPHERE - INCREASED SAFETY ‘e’

IS-6381 BS EN- 60079-7

IEC-60079-7

5. ELECTRICAL APPARATUS FOR EXPLOSIVE GAS ATMOSPHERE – FLAMEPROOF ENCLOSURE ‘d’

IS-2148 BS EN- 60079-1

IEC-60079-1

6. SINGLE PHASE INDUCTION MOTOR IS-996

7. CODE OF PRACTICE FOR CLIMATE PROOFING BS EN- 60034-5

IEC-60034-5

8. DESIGNATIONS FOR TYPES OF CONSTRUCTION AND MOUNTING ARRANGEMENTS OF ROTATING ELECTRICAL MACHINES

IS-2253 BS EN-60034-7

IEC-60034-7

9. TERMINAL MARKING FOR ROTATING ELECTRICAL MACHINERY

IS-4728 BS EN-60034-8

IEC-60034-8

10. DESIGNATION OF METHODS OF COOLING FOR ROTATING ELECTRICAL MACHINES

IS-6362 BS EN- 60034-6

IEC-60034-6

11. DEGREE OF PROTECTION PROVIDED BY ENCLOSURE FOR ROTATING ELECTRICAL MACHINERY

IS-4691 BS-EN 60034-3

IEC-60034-3

12. GUIDE FOR TESTING THREE PHASE INDUCTION MOTORS

IS-4029 BS EN 60034-2

IEC-60034-2

13. MEASUREMENT AND EVALUATION OF VIBRATION OF ROTATING ELECTRICAL MACHINES

IS-12075 BS EN 60034-14

IEC-60034-14

14. CLASSIFICATION OF HAZARDOUS AREAS FOR ELECTRICAL INSTALLATION

IS-5572 IEC-60079

15. DESIGNATION OF SLIDE RAILS FOR ELECTRIC MOTOR

IS-2968

16. PERMISSIBLE LIMITS FOR NOISE LEVEL FOR ROTATING ELECTRICAL MACHINES

IS-12065 BS EN- 60034-9

IEC-60034-9

17. GUIDE FOR TESTING INSULATION RESISTANCE OF ROTATING MACHINE

IS-7816

PART IIB of 221





SL. NO. ITEM

REV. NO. 0 JOB NO.

TCE.

6079A


PPD. BY RSN


DATE 22.01.11

TCE FORM NO. 330 R3

ISSUE R0

18. INDUCTION MOTORS - ENERGY EFFICIENT IS-12615 IEC-60034-3

19. GENERAL REQUIREMENT FOR ELECTRICAL APPARATUS FOR EXPLOSIVE GAS ATMOSPHERES

IS-13346

20. FLAMEPROOF AC MOTORS FOR USE IN MINES IS- 3682

21. STARTING PERFORMANCE OF SINGL SPEED THREE PHASE CAGE INDUCTION MOTORS FOR VOLTAGE UPTO 600V

IS-8789 BS EN-60034-12

IEC-60034-12

22. CAGE INDUCTION MOTORS WHEN FED FROM CONVERTERS – APPLICATION GUIDE

IEC-60034-17

23. ADJUSTABLE SPEED ELECTRICAL POWER DRIVE SYSTEM- EMC REQUIREMENTS AND SPECIFIC TEST METHODS

BS EN-61800

IEC-61800

24. DIMENSIONS AND OUTPUT SERIES FOR ROTATING ELECTRICAL MACHINES

IS-1231 BS EN-60072-1

IEC-60072-1

25. ELECTRICAL APPRATUS FOR EXPLOSIVE GAS ATMOSPHERE- CLASSIFICATION OF HAZARDOUS AREA

IS-5571 BS EN-60079-10

IEC-60079-10

26. TEST PROCEDURE FOR MEASUREMENT AND REQUIREMENTS OF LOSS TANGENT ANGLE OF COILS AND BARS FOR MACHINE WINDING - GUIDE

IS-13508

27. IMPULSE VOLTAGE WITHSTAND TEST IEC-60034-15

28. TEMPERATURE RISE MEASUREMENT OF ROTATING ELECTRICAL MACHINES

IS-12802

29. TYPE OF DUTY AND CLASSES OF RATING ASSIGNED TO ROTATING ELECTRICAL MACHINES

IS 12824

NOTE :

1. EQUIPMENT, ASSOCIATED ACCESSORIES, COMPONENTS/PARTS, RAW MATERIAL AND TESTS SHALL IN GENERAL CONFORM TO IS /IEC.

PART IIB of 221




DATA SHEET B SHEET 15 OF 21

ENQUIRY/SPECIFICATION NO.: BIDDER:

SL. NO.

ITEM UNIT

NOTES TO BIDDER SIGNATURE OF BIDDER & DATE

1. ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN SCHEDULE OF DEVIATIONS.


ISSUE R0

TCE FORM NO. 294 R3

1. 0 Application/Designation

2. 0 Manufacturer

3. Applicable standards

4. 3 Rated

a) Output KW

b) Speed RPM

c) Type

c) Frame size

5. Type of Duty (CI.9.2 of IS 325 OR Equivalent)

6. Supply conditions

a) 1) Rated voltage V

2) No. of phases

3) Frequency Hz

b) Allowable Variations in

1) Voltage %

2) Frequency %

3) Combined %

c) Permissible Unbalance in Supply Voltage

%

7. Current

a) Full Load Amps

b) Starting % FL

8. Method of Starting

9. Full Load Efficiency %

10. Full Load Power Factor

11. Class of Insulation

PART IIB of 221






SL. NO.

ITEM UNIT




ISSUE R0

TCE FORM NO. 294 R3

12. a) Reference ambient Temperature

b) Temp. rise by res. Method

Stator 0 C

Rotor 0 C

c) Temp. rise of bearing 0 C

13. Degree of Protection(IS 4691 or equivalent)

14. Type of Enclosure Ex'd'/Ex'e'/Ex'n'

15. Suitable for Outdoor Operation Yes/No

16. Normal winding connection Star/ Delta

17. Space Heater rating Watt

18. Temperature Class T1/T2/T3/ T4/T5/ T6

19. Time tE for Increased safety motors Secs

20. Suitability for hazardous dust Yes/No

21. (i) Type & No. of Terminals brought Out

(ii) Fault withstand capacity at rated voltage & duration

iii) Maximum size of Aluminium armoured cable that can be Terminated

cores X Sq mm

22. Dimensional Dwg. Enclosed

23. a) Permissible No. of equally spread starts per hour under normal service conditions

No.

b) Permissible No. of starts in quick succession with cold machine at room temp.

No.

PART IIB of 221






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ITEM UNIT




ISSUE R0

TCE FORM NO. 294 R3

c) Permissible No. of hot restarts No.

d) Starts per 8 hour period 24 hour period No.

24. CTs for differential protection (when specified in Data Sheet-A)

a) Type & Make

b) Ratio, accuracy class & burden

c) Class of insulation F/H

d) Rated voltage and frequency kV, Hz

e) Applicable standard

f) Dimensions of CTs

g) Separate terminal box for CTs provided Yes/No

h) If provided, dimensions of terminal box

25. Motor bearings

a) Permissible temperature rise for bearings

deg.C

b) Design ambient temp. assumed for above

deg.C

c) Bearing Make/No.

26. Type of bearing Lubricating Grease / Oil

27. Facility for On line Greasing of bearing

28. Maximum vibration mm/ sec

29. Max. value of induced shaft voltage. mv

30. Maximum Noise level dB

PART IIB of 221

SPEC. NO. TCE. 6079A-B-Z-203



DATA SHEET-C SHEET 18 OF 21

ISSUE R0

TCE FORM NO. 329 R5

INFORMATION TO BE SUBMITTED BY THE VENDOR

AFTER AWARD OF CONTRACT

1.0 Technical particulars as per data sheet B of tender specification. (Based on motor manufacturer)

2.0 Type and frame size :

3.0 Starting time (Secs)

3.1 With 100% voltage at terminals

3.2 With minimum voltage at terminals (at ____ % Rated voltage)

3.3 With 110% voltage at terminals

4.0 Safe stall time at 100/110% rated voltage under hot/cold condition.

5.0 Type and size of cable for which gland is provided in the terminal box :

6.0 Type of bearings and expected life.

7.0 Total weight of motor (kg)

7.1 Weight of Stator (kg)

7.2 Weight of Rotor (kg)

8.0 Motor GD2 :

9.0 Efficiency (%)

9.1 Full Load Efficiency

9.2 75% Load Efficiency



10.0 Power Factor

10.1 Full Load Power Factor

10.2 75% Load Power Factor



11.0 Torque (% FLT)

11.1 Starting

11.2 Maximum (Pullout torque)

11.3 Pull up torque

12.0 Type of Enclosure

13.0 Cooling designation

14.0 Space heaters

14.1 Rated voltage/number

PART IIB of 221





ISSUE R0

TCE FORM NO. 329 R5

14.2 Rating total

14.3 Separate terminal box provided

15.0 Motor reactances (Pu)

15.1 Subtransient reactance

15.2 Transient reactance

15.3 Steady state reactance

16.0 Guaranteed losses (kW)

16.1 Iron loss

16.2 Copper loss

16.3 Friction, Windage & Stray losses.

17.0 Motor outline dimension drawing (Number of copies as per distribution schedule)

18.0 Type test certificates (Number of copies as per distribution schedule)

19.0 Speed torque curve at rated & minimum starting voltage.

20.0 Current - speed curve.

21.0 Current - time curve.

22.0 Efficiency, power factor, slip, current against output curve.

23.0 Thermal withstand characteristic for motors of 100 kW & above - Hot & Cold.

24.0 Negative sequence current Vs time curve for motor of 100 kW & above.

25.0 Rotor voltage/Rotor current (for wound motors).

26.0 Bearing temperature indicator

26.1 Type and make

26.2 Quantity of BTDs

26.3 Number of contacts in each indicator

26.4 Contact rating at 220V DC at 240V AC

27.0 A separate dimensioned outline and general arrangement drawing of motor shall be furnished indicating the following: Name of Manufacturer, Wight of motor (kg.) – Static and dynamic Centre line of motor Foundation details, Openings ,embedment details in foundation for entry of all cables such as power, space heater, etc. Connection details of motor i.e, start/delta terminal markings, clearance between phases, Cable disconnecting facilities and direction of cable entry and cable glands (if provided).

28.0 Dimensions of terminal boxes for main power leads, space heater leads and ETD leads.

29.0 Size, type and overall diameter of cable for which terminal boxes are suitable.

30.0 Openings and embedments in foundationfor cable entry for power leads, space

PART IIB of 221





ISSUE R0

TCE FORM NO. 329 R5

heater leads, ETD leads and earthing conductor, etc. with relative locating dimensions and sizes in all views of motor.

31.0 Location of bearing thermometers and pockets for the same.

32.0 No. & type (NO/NC) of contacts provided on bearing thermometers.

33.0 Location and size of earthing terminals/holes in earthing pads.

34.0 Coupling type, diameter of shaft extension, dimensions of key slot and details of half coupling (if specified).

35.0 The following additional data/details should be shown on the motor drawing, when applicable.

36.0 Cooling water requirement for water cooled bearing (Lts/min).

37.0 Cooling water requirement for water cooled windings (Lts/min).

38.0 Required pressure of cooling water (kg/cm2).

39.0 Required maximum temperature of cooling water (oC).

40.0 Weight of cooler if removable (kg).

41.0 Oil level sight gauges for oil lubricated bearings

42.0 CMRS/ DGMS/ DGFASLI-Mumbai certification or fulfilling ATEX Directive/ IECex certification

DOCUMENTS TO BE SUBMITTED FOR INFORMATION.

1.0 Insulation

1.1 Material and treatment of insulation

2.0 Winding

2.1 Stator winding

(a) Connection

(b) Resistance/phase

2.2 Rotor winding

(a) Connection

(b) Resistance/phase

3.0 Bearing

3.1 DE Bearing

3.1.1 Type, No. & make

3.1.2 Lubricant

3.1.3 Initial quantity

3.1.4 Relubricating interval

3.1.5 Relubricating quantity

3.1.6 Anticipated life

PART IIB of 221





ISSUE R0

TCE FORM NO. 329 R5

3.2 NDE Bearing

3.2.1 Type, No. & make

3.2.2 Lubricant

3.2.3 Initial quantity

3.2.4 Relubricating interval

3.2.5 Relubricating quantity

3.2.6 Anticipated life

4.0 Motor bearing lubrication system -

Self lubrication/Forced oil lubrication

4.1 Forced oil lubrication system (if provided)

a) Whether this is compatible with forced oil lubrication system of driven equipment.

If NO, furnish the following details for motor bearing

i)Type, make and specification of oil

ii) Flow rate (Ltrs/Sec)

iii) Pressure (Kg/cm2)

iv) Quantity of lube oil pump sets provided for each motor

v) Local control panel provided for forced oil lubrication system of each motor

vi) Make, type and name plate particulars of lube oil pumps & 415V, 3 phase, 50Hz motors.

vii) Filters - Make & type

5.0 Air temperature detector (Internal)

(CACA/CACW motor)

5.1 Type & make

5.2 Number

5.3 Number of contacts in each indicator

5.4 Contact rating at - 220V DC- 240V AC

6.0 Terminal box

6.1 Location of main terminal box viewed from non drive end (Right/Left)

7.0 No load current of motor at rated voltage & frequency (for each type of motor)

8.0 Limiting rotor temperature for determining safe stall time

9.0 Instruction Manual (Number of copies as per distribution schedule)

PART IIB of 221

SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION: C TCE-6079A-B-610-024

INSTRUMENTATION SYSTEM SHEET OF 18 OF 4

1

ISSUE

R0

1.0 INSTRUMENTATION & CONTROL (I&C) SYSTEM COVERED UNDER

SCOPE:

1.1 This specification details the minimum technical requirements for the

instrumentation forming part of the Cooling Water Pumps Package for BPCL Petroleum Corporation Ltd. (BPCL) Mahul Refinery Project, India.

1.2 Contractor shall be responsible to provide all instrumentation, controls and protective functions required for the safe operation of the Cooling Water Pumps and to comply with statutory regulations, applicable codes & standards.

1.3 The System Contractor shall be fully responsible for design, sizing and selection of proper instruments, manufacture, supply, inspection & expediting, delivery at site including Quality Assurance of all the instrumentation and control pertaining to the Cooling Water Pumps.

1.4 Bidder shall, categorically, list out clause wise deviation to this specification and enclosed standards, if any, along with the offer. In the absence of which, it will be assumed that the Bidder is an total compliance to this specification.

1.5 In order to standardise with the plant instrumentation, the Contractor should supply the make of instruments according to the preferred vendor list attached with tender. For instruments not listed in the vendor list, makes for the same shall be subject to approval by BPCL.

1.6 Tests shall be done using calibrated instruments traceable to National or International standards.

1.7 Instrument installation shall be suitable for the environmental conditions, which apply for the intended location of the unit.

1.8 The scope of the Bidder shall be as follows:

Legends: D & S – Design and Supply E & C – Erection, Testing & Commissioning CS – Supervision of Erection, Testing and Commissioning X – Not applicable

ITEM DESCRIPTION

SCOPE

VENDOR OTHERS

D & S E & C CS D & S E & C CS

1. All field instruments alongwith erection hardware for the lube oil system, turbine including vibration and bearing temperature sensors. All safety & protection devices required for safe operation of turbine shall be provided

x x x

PART IIB of 221



2

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ITEM DESCRIPTION

SCOPE

VENDOR OTHERS

D & S E & C CS D & S E & C CS

by the Bidder.

2. Junction boxes (JB) along with required erection hardware and all accessories required such as mounting supports, cable glands, & terminals. All signals to be wired to Purchaser’s Panel shall be kept wired by the Bidder to the junction boxes. Further cabling from the junction boxes to Purchaser’s Panel shall be done by Others.

x x x

3. Completely tubed/piped local gauge boards with all gauges mounted

x x x

4. Interfacing of the local gauge board to the field including all tubing, fittings and accessories.

x x x

5. All cables including cable glands (at both ends) including termination and accessories between field instruments and junction boxes. All signals to be wired to Purchaser’s Panel shall be kept wired by Bidder upto Junction Boxes.

x x x

6. Factory Acceptance tests (FAT) to meet the design specifications & I&C functional requirements

Participation by

Purchaser

7. Integration, Site Acceptance Tests (SAT) including loop checking & commissioning, trial runs of all the above systems to meet the design specifications & functional requirements.

Only Supervision By Other contractor and Participation by

Purchaser

8. Supply and laying of earthing cables for body earthing from the field instruments/junction boxes to the nearest earth strip

x By Electrical contractor

PART IIB of 221



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2.0 FIELD INSTRUMENTS

2.1 The instruments for the pumps & turbine shall be designed & provided to ensure safe & reliable start-up, normal operation & shutdown. Instrumentation for the turbine shall generally be in accordance with API 611, Fifth Edition. General specifications of the instruments shall be as given below.

2.2 For any instruments supplied by the Contractor but not covered in this specifications, details for the same shall be submitted by the Contractor for review & approval by Purchaser/Consultant.

2.3 The design of electronic instruments shall be in compliance with the electromagnetic compatibility requirements as per IEC 801 “Electromagnetic compatibility for Industrial Process Measurement & Control Equipment”.

2.4 Field mounted electrical and electronic instruments shall be weatherproof to IP-65. All instruments of submersible type shall be protected to IP-68. The instruments shall be suitable for the area classification.

2.5 All instruments shall be suitable for the hazardous area specified in Section C for Centrifugal Pumps.

2.6 For hazardous areas, instrument input/output signals to Purchaser’s Panel shall be as follows:

Transmitters (2 wire ) Intrinsically safe

Transmitters (4 wire) Flameproof/Ex-proof with signal output intrinsically safe

Field switches Flameproof/Ex-proof (Switch contacts to be wired through safety barrier in Purchaser’s Panel to have IS signal)

RTD & Thermocouple Flameproof-Ex-proof

Solenoid valves Flameproof/Ex-proof

Vibration Probes Intrinsically safe

Limit Switches Flameproof-Ex-proof/ Intrinsically safe

Proximity Switches NAMUR type

2.7 Intrinsically safe, flameproof instruments/ enclosures shall be certified to the specified hazardous area by a statutory body like FM, UL, CENELEC, CMRI etc. In addition for instruments installed in hazardous area, CCOE (Chief Controller of Explosives) certification shall be complied with. CCOE Certificates for all instruments installed in hazardous area shall be provided by the vendor. The vendor shall ensure that CCOE certification for instruments is available before mechanical completion of the plant.

PART IIB of 221



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2.8 All line or equipment mounted instruments like control valves, pressure relief valves, thermowells, pressure gauges etc., installed on pipes and vessels under IBR shall be certified by IBR or their authorised representative. They shall comply to the special Piping Material Specification requirements specified elsewhere in the Tender document. Further installation items on the IBR lines like syphon, condensate chambers, pipe and pipe fittings, steam tracing fittings shall have IBR certification.

2.9 Wetted parts for instruments & valves shall be SS 316 as a minimum.

2.10 All pneumatic tubing shall be of SS 316, unless otherwise specified.

2.11 Cable entry for instruments shall generally be ½” NPT (F).

2.12 All instruments/devices shall be immune to interference due to normal walkie-talkies with output of 1 Watt UHF.

2.13 All instruments mounted outdoors shall be provided with FRP canopy for protection from top & sides.

2.14 All instruments shall be provided with SS tag plate.

2.15 The specification below provides only the qualitative specifications of instruments. Instruments not covered in this specification shall be submitted by the Vendor for approval. Vendor shall be fully responsible for design, material selection, sizing, selection of the proper instruments for their system.

2.15.1 Pressure Gauges

(a) Measuring range selected shall be such that normal indication is between 60% to 80% of range. However, maximum operating value shall not be more than 90% of range.

Type : Direct Reading

Sensing Element : Bourdon/ Diaphragm/ Capsule

Casing : SS 316

Movement : SS 304

Glass : Shatterproof

Dial size : 150 mm

Range : Vendor to State

Overrange Protection : 1.3 times the max. scale reading

Wetted Parts (including accessories like syphon, snubber, valve manifolds)

: Minimum – SS 316. Superior material to be considered if process condition demands, subject to TCE/BPCL’s

PART IIB of 221



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approval.

Accuracy : + 1.0 % of full scale

Upto + 2.0% of full scale for D.P.gauges

Accessories : (a) Blow-out Discs for pressure gauges

(b) Syphons for services above 75oC

(c) Snubbers where pulsation occur in the process.

(d) 2-valve manifold

(b) Solid front gauges shall be provided for ranges above 100 kg/ cm2.

2.15.2 Pressure Switches

(a) For pressure switches, the set points shall fall within 30% to 70% of the scale range selected.

(b) Material and sensor selection shall be on the same guidelines mentioned under pressure gauges.

(c) The switch differential shall be selected as per operating conditions.

Type : Non-indicating type

Casing : Die cast aluminum casing with epoxy painting

Repeatability : + 1 % of full scale reading

Micro switch contacts : 2 Nos. SPDT contacts rated 5A at 240V AC.

Overrange protection : 25% above maximum pressure for switches with range up to 150 kg/cm

2 and 15% above

maximum pressure for switches with range above 150 kg/cm

2 as per IS 3624

Accessories : Syphons for services above 75oC, snubber for

high pulsation applications, 2-valve manifold, and SS name plate

2.15.3 Level Switch

Type : Magnetic type top mounted float actuated level switch.

Material of float & float stem including all other wetted parts

: SS316. Superior material to be considered if process condition demands, subject to TCE/BPCL’s approval.

Mounting : Top Mounted

Operating Differential : Adjustable

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Housing : Die cast aluminum with epoxy painting

Switches : Microswitch, 2 Nos. SPDT

2.15.4 Thermometers

(a) Thermometers shall be provided for local temperature indication. Scale shall have black printing on white background. Scale ranges shall be selected such that normal temperature shall be indicated within 30 to 70% of the range.

Type : Indicating, Bi-metalic, all-angle

Dial : 150 mm

Glass : Shatterproof

Casing : SS 316

Micrometer pointer with external adjustment

: Required

Accuracy : + 1 % of span

Overrange protection : 150% of span

(b) Bi-metallic type dial thermometers shall be avoided where excessive vibrations are encountered. Only gas filled type with capillary extension shall be used in such cases. Mercury filled type shall not be used. Capillary tubing shall be minimum of SS 304 with SS flexible armouring.

2.15.5 Resistance Temperature Detectors

(a) Resistance Temperature Detectors (RTDs) shall be used for temperature measurements in the range -200 to 500

oC.

(b) RTD shall be used as primary element where greater accuracy & better reproducibility are required than that offered by thermocouple.

(c) Head cover shall be screwed type, with SS retaining chain fixed to body.

(d) Head cover shall be weather proof and ex-proof suitable to specified hazardous area classification.

Type : 3-wire, Pt 100, Single

Accuracy : As per IEC-751, Class A

Spring loaded : Required

Nipple-union-Nipple : Required of SS 316

Insulation : Mineral Insulated (MgO)

Sheath : SS 316

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Sheath diameter : 6 mm standard unless otherwise specified

Connection/ Termination Head : Die Cast Aluminum with epoxy painting

2.15.6 Thermocouple

(a) The type of thermocouple shall be selected based on the temperature in the application. The following guideline shall be followed:

i. Type K (Chromel - Alumel), (-) 200 to 1150°C.

ii. Type T (Copper - Constantan), (-)185 to 300°C.

iii. Type E (Chromel - Constantan), 0 to 800°C.

iv. Type R (Platinum, Platinum - 13% Rhodium), 0 to 1600°C.

v. Type B (Platinum - 30% Rhodium, Platinum - 6% Rhodium), 100 to 1600°C.

Wire Size : 16 AWG for Single & 20 AWG for Duplex type

Accuracy : As per IEC-584-2

Spring loaded : Required

Insulation : Mineral Insulated (MgO)

Sheath : SS 316

Sheath diameter : 6 mm standard unless otherwise specified

Connection/ Termination Head

: Die Cast Aluminum with epoxy painting

(b) Thermocouple extension wires and calibration shall conform to ANSI MC 96.1.

(c) In general thermocouples shall be ungrounded type.

(d) The thermocouple head shall be connected with thermowell with 3-piece union.

(e) Head cover shall be screwed type, with SS retaining chain fixed to body. Head cover shall be weather proof and ex-proof suitable to specified hazardous area classification.

(f) For duplex thermocouples, cable entry shall be 2 nos. 1/2" NPT (F) with one entry plugged with SS 304 plug.

(g) Terminals shall have separate screws for connecting element and extension cable.

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2.15.7 Thermowells

(a) All temperature elements shall be protected by thermowells, except surface (skin) temperature measurements and motor winding temperature measurements. Thermowell material shall be SS 316 unless material of special quality is called for according to process condition.

(b) They shall be fabricated out of barstock up to a length of 500 mm. Beyond 500 mm, fabricated construction shall be used considering the thickness of pipe.

(c) Flange mounted thermowells are preferred. Rating shall be provided as per the piping material specification for the application.

(d) In general, insertion length of thermowells shall be as follows:

Line Size Insertion Length

From 4” to 6” 280

150-200 (6"-8") 300

250-350 (10"-14") 350

400-450 (16"-18") 400

500 (20") & above 500

Vessels Nozzle standout + 200 mm

(e) Insertion length shall be measured from the outer surface of the pipe flange to the tip of the thermowell.

(f) For thermowell installation in pipelines, minimum pipe diameter has to be 4". Smaller pipelines have to be enlarged to 4" for thermowell installation.

(g) Only thermowell (test well) when specified, it shall be provided the element entry plugged with SS plug and SS chain.

(h) The design of the wells shall be verified by means of stress analysis, resulting from stream velocity condition. The wake frequency shall not exceed 66% of the thermowell natural frequency.

2.15.8 Rotameters

(a) These type instruments shall be used very selectively (shall be restricted to local measurements, utilities and purging only). Variable area flowmeters may be used where measurement with low accuracy is accepted.

(b) Accuracy of measurement shall be within +2% full scale. Rotameters

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shall be mounted in-line for pipe sizes upto 2 inches & for higher line sizes bypass rotameters shall be used. Rotameter rangeability shall be 10:1.

(c) Flow straightener shall be provided for pulsating flow. Cooling fins shall be provided for high temperature service (150 deg C & above) & extension well shall be provided for low temperature service (0 deg C and below). Jacket shall be provided for crystallizing fluid at ambient temperature.

(d) Glass tube rotameters shall be used for low pressure utility services for local indication. Metal tube rotameter shall be used for process fluids.

2.15.9 Flow Glass

(a) Use of sight glass/ flow glass shall be restricted/ avoided as possible. When the application/ process media is hazardous (i.e. flammable/ toxic etc), use of sight glasses shall be strictly avoided.

(b) Sight glasses shall be used for local indication of flow (i.e. presence or absence of flow of the liquid/gas media without measurement). Single window/ double window type shall be selected as per the available visibility & accessibility. These types of sight glasses are suitable for color/ visible media. For transparent liquids or gases; the rotary/ paddle/ ball type of sight glasses shall be used.

Type : Shall be selected as per the application media

Material : Toughened borosilicate shatterproof glass. The body material shall be Carbon steel with SS316 wetted parts (Body shall be coated with epoxy or polyurethane paint)

Line size : Same as pipe size

Accessories : SS Nameplate

End connections : As per piping material specification(PMS)

Applications : As required for local monitoring of flow in the process.

2.15.10 Solenoid Valves

(a) Solenoid valves (Direct acting type) shall be used as the pilot valve for operation of On/Off valves.

(b) Solenoid valves, wherever used for on-off valves, shall be universal type three-way and be operated on 24 V DC, unless otherwise specified. In-line solenoid valves shall be two-way.

(c) The solenoid valves shall be continuous rated type with class H coil insulation as per IEC 85/IS 1271.

(d) Solenoid valves shall be in energized condition during normal

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operation. It shall have integral junction box with 1/2" NPT(F) cable entry. Flying leads are not acceptable. However, in case of a unit whose control shall be from existing control room, the existing control philosophy shall prevail and the solenoid valve operating voltage may be as required.

(e) Free wheeling diode shall be provided across the solenoid.

(f) Solenoid valve body & trim shall be of SS316, as a minimum. Positioners with inbuilt SOV are NOT acceptable.

(g) The solenoid valves used in hazardous area shall be explosion proof {Ex (d) type}.

2.15.11 Pressure Relief Valves

(a) All pressure relieving devices shall be designed in accordance with ASME code for 'Boilers and Pressure Vessels', API-521 and Indian Boiler Regulations.

(b) Pressure relief valves shall be full nozzle, full lift type except for thermal relief valves.

(c) Lifting lever shall be specified for steam and air service. Open bonnet shall be used for steam service. Where it is not acceptable for the media to escape, a packed lever shall be used.

(d) 3/4" x 1" threaded (NPT) modified nozzle type valves with typically 0.38 cm

2 orifice size shall be specified for thermal relief.

(e) The body material shall, as a minimum, be as per piping specifications. Nozzle and disc material shall be SS316 as a minimum with machined stainless steel guide and spindle.

(f) The spring material of pressure relief valves shall be as follows unless otherwise necessary because of process conditions:

- 29°C to 250°C : Cadmium/nickel plated carbon steel.

above 250°C : Tungsten alloy steel.

below - 29°C : Stainless steel 316

(g) Flanged connection shall be for standard sizes 1" or larger.

(h) Where permissible, screwed connections shall be used on sizes 3/4" and below.

(i) All PSVs shall have 100% installed spares.

2.15.12 Junction Boxes

(a) Separate Junction boxes shall be provided for the following types of signals:

i. Analogue Input/ Analogue Output

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ii. Digital Input

iii. Digital Output. Separate junction boxes shall be provided for AC & DC interrogation voltages.

iv. Power Supply

v. Thermocouples

vi. Vibration Signals.

(b) Separate junction boxes shall be used for IS & non-IS signals.

(c) For junction boxes IP 65 protection class shall be provided. Junction boxes and cable glands provided shall be ex-proof to the hazardous area specified.

(d) Material of construction shall be as below:

i. Safe area – Cast Aluminium LM-6 body

ii. Hazardous area

Cast Aluminium LM-6 body, ex-proof with Ex(d) certification. These junction boxes shall be CCOE approved for the specified hazardous area class.

Junction boxes to which intrinsically safe signals are wired shall be same as those for the safe area, except that they shall be blue in colour.

(e) The junction boxes shall have terminals suitable for minimum of 2.5 mm

2 cable. 20% spare terminals shall be provided in each junction

box.

(f) Each junction box shall have a minimum of 20% or 2 Nos. minimum spare entries. All spare entries shall be provided with SS plugs. Branch cable entries shall be from the sides and cable entries for multipair/ multicore cables shall be from the bottom.

(g) Junction box colours shall be as below:

i. For Intrinsically safe signals– Blue

ii. Thermocouple signals – Yellow

iii. Others – Black

(h) A screwed, laminated plastic nameplate with the junction box number shall be provided on the cover plate.

(i) Separate shield bus shall be provided.

(j) All wiring for junction boxes shall be carried out with 1100V grade, stranded tinned copper conductors. All wiring shall be done with straight & cross ferruling. Ferrules shall be printed type. Ferrule

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material shall be silicone type. Ferruling for core/wire identification shall be done & shall be fitted at both ends of each wire.

(k) Terminal blocks shall be 660V grade, 20 amps rated, one-piece moulded, complete with screw type terminals, mounted on C channel and clip on type. All terminal strips shall be mounted on suitable anodized metallic or plastic stand off. Terminal strips shall be arranged group wise for incoming and outgoing cables separately.

(l) All terminals shall be of mechanical screw clamp type. Terminals shall be suitable to accept 2.5mm² size conductor for control and signal cable, as a minimum. Terminal blocks for different voltages or circuit type shall be segregated into groups and distinctively labelled.

(m) Termination shall be done using crimp type lugs. One terminal shall be used for terminating one wire only. Terminals shall be Phoenix or Wago type. Shorting shall be achieved through standard shorting links available.

(n) Markings on the terminal strips shall correspond to wire numbers on the wiring diagrams. Every terminal shall be uniquely identified within the terminal cabinet by means of a terminal number.

2.15.13 Type, Material & Construction For Local Gauge Boards

(a) Local Gauge Board specifications shall be in accordance with API 611, Fifth Edition. Fabrication shall be in best workmanship manner with cold rolled steel sheets. The gauge board shall be rigid self supporting structure and fabricated preferably from min 3 mm thick cold rolled sheet. The board shall be provided with lifting eye bolts of removable type.

(b) Fasteners used in fabrication shall be of Stainless steel. All hinges, screws other non painting parts shall be of stainless steel material.

(c) Mounting channel frame shall be made from ISMC 100 channel (100 x 50 x 6 mm).

(d) The entire surface of the board and accessories, comprising front, rear and sides shall be treated and painted as per following standards:

IS 1477 (Part-I) - Code of practice for painting of ferrous metals in

building (Pretreatment)

IS 1477 (Part-II) - Code of practice for painting of ferrous metals in

building (Painting)

IS 6005 - Code of practice for phosphate coatings of iron and steel

(e) After fabrication the board shall be painted using the 7 tank process. A final coat of finish paint of high grade lacquer enamel

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shall be given after assembly and filling of front board butt joints with suitable filler, to present a continuous panel surface. The finish of the final coat shall be of semi-gloss texture to minimise light reflection.

2.15.14 Labels

All front mounted equipment, as well as equipment mounted inside the junction boxes, local gauge boards shall be provided with individual labels with equipment designation engraved. These shall be laminated Perspex (1.6 mm thick) with black background and white lettering and shall be fixed to the panel by stainless steel screws (counter sunk). Only panel nameplate shall be metallic plate and it shall have the details of panel name. The lettering on the labels shall be subject to PURCHASER'S approval. Labels of internally mounted equipment shall be clearly visible.

3.0 CABLES

3.1 The minimum specifications of I&C cables shall be as below.

Conductor Electrolytic grade, annealed tinned stranded copper conductor for signal, triad & control cables

Primary insulation 85°C PVC as per IS-5831 Type C

Insulation grade 1100 V (IS 1554)

Twisted conductors

(a) Twisted into pair for Signal cables & thermocouple cables

(b) Three conductors twisted into triad for RTD cables

(c) Not applicable for control cables

Cable identification Running length of the cable shall be printed at least at every 5 metre interval

Pair identification With numbers at interval of not more than 250 mm as per vendors standard.

Individual + overall shielding

As per BS 5308. Individual & overall shielding required for signal, thermocouple & triad cables. Only overall shielding required for control cables & 24 V DC power cables.

Drain wire size 0.5mm2

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Drain wire material Multistranded annealed tinned copper in continuous contact with aluminium foil side of the shield

Drain wire resistance including shield

Shall not exceed 30 ohms/km

Tape thickness As per BS 5308

% coverage / overlap 100 % / 25%

Inner sheath Extruded PVC compound, Type ST-1 as per IS 5831

Armouring Galvanized steel wire armouring as per IS-

1554

Outer sheath Extruded flame retardant PVC type ST-2 as per IS-5831

PVC oxygen index Over 30%

PVC temperature index Over 2500C

Fire retardant As per IEC 332 Part III, Cat A

Electrical properties @ 200C

(A) Conductor resistance Maximum DC resistance as per IS 8130.

(B) Insulation resistance, Spark Test & Voltage Test

As per BS-5308

(C) Mutual capacitance at 1khz

As per BS 5308

(D) Capacitance between core & screen

As per BS 5308

(E) L/R ratio As per BS 5308

3.2 Thermocouple Extension Cables

All thermocouple extension cables shall be matched and calibrated in accordance with IEC-584-2. Inductance for thermocouple cables shall not exceed 4mH/km. For J-type thermocouples, inductance may be 8mH/km.

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3.3 Size of conductors shall be below:

Type of Cable Conductor Size

Signal Cables (Single Pair/ Multipair)

1.5 mm2

Control Cables 1.5 mm2. For solenoid valves, based on the

cabling distance & voltage drop, the conductor size shall be selected.

RTD Cables (Single Triad/Multitriad)

1.5 mm2

Thermocouple Extension Cables

16 AWG for single pair and 20 AWG for multipairs

3.4 Colour of Sheath

For thermocouple extension cables the inner and outer jacket colour shall be as per IS-8784. For signal and control cables, inner jacket colour shall be black. Outer jacket colour shall be light blue for intrinsically safe application and black for others.

4.0 CABLE GLANDS

All cable glands shall be double compression type cable glands. Cable glands for explosion proof enclosures shall be explosion proof type, suitable for the area classification. Cable glands shall be provided with check nut. All unused cable entries shall be plugged. All cable glands shall be of SS 304 and they shall be double compression type suitable for armoured cables. PVC shrouds shall be provided wherever required. All cable glands required for glanding of supplied cables at instrument as well as junction box end shall be provided.

5.0 IDENTIFICATION & MARKING

Each device shall be identified with the following information:

(a) Manufacturer’s name or identity

(b) Manufacturer’s model no./ serial no.

(c) Input range

(d) Tag No.

(e) Area Class & IP Class

(f) IS/Non-IS

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6.0 SPARES PHILOSOPHY

6.1 Mandatory Spares

Mandatory Spares for I&C System shall be as listed in Annexure-1. For other instruments which are not listed in Annexure-1, following philosophy shall be followed:

(a) Local gauges, instruments, switches, etc. – 5% of each type/model or 1 No. minimum whichever is higher

(b) All electronic items/ transmitters – 10% of each type/model or 1 No. minimum whichever is higher

(c) Control valves manufactured in India by Indian vendor – Nil

6.2 Commissioning Spares

All spares required for commissioning of the system & until handing over to Client shall be in the scope of supply of the vendor.

6.3 Recommended Operational Spares

Vendor shall supply a list of spare parts for each instrument and system required for 2 years of continuous operation. These spares shall be quoted separately.

6.4 Contractor shall provide a document indicating all spares being supplied against total quantity of each items supplied for Purchaser/ Consultant’s review/ approval during engineering stage after order placement. Even if this document is approved, if any spare is found to be not supplied as per specifications at the time of unit take over by BPCL, Contractor shall supply the same free of cost.

7.0 FACTORY ACCEPTANCE TESTS (FAT)

7.1 Contractor shall submit Quality Assurance Plans (QAPs) for instruments, gauge boards, cables and all other items supplied to Purchaser/ Consultant for review & approval. The QAPs shall cover all type tests, routine tests and performance tests. The FAT for the items shall be performed in accordance with the approved QAPs.

7.2 TCE/BPCL reserves the right to inspect critical instruments at vendor / sub vendors works along with vendor. List of these items shall be finalised after order. Instead of TCE/BPCL, inspection may be carried out by 3rd party for special imported items. There shall not be any additional price for 3rd party inspection.

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8.0 DOCUMENTS TO BE SUBMITTED BY CONTRACTOR:

8.1 The BIDDER shall ensure the following documents are prepared and submitted along with bid:

(a) Acceptance to the vendor list (signed and stamped copy).

(b) All sheets of Section C signed and stamped.

(c) List of I&C deviations (if any)

8.2 The CONTRACTOR shall submit the following drawings / documents after award of contract:

Sl. No.

Details

1. Instrument list indicating tag numbers, Make, Model No, Service, type of Instrument.

2. Data sheets for all the instruments, cables, junction boxes, alongwith the original catalogues.

3. Sizing calculation sheets for control valves, flow elements, if any.

4. Installation sketches (hook-ups) along with detailed Bill of Material.

5. The following drawings/ documents shall be submitted for the Local Gauge Board:-

(i) Front facia /rear arrangement layout showing all instruments with cut-outs, bezel dimensions, construction details, foundation details, interior G.A. drawings.

(ii) Bill of Material (B.O.M) indicating tag No, quantity, service & model no. of each instrument/item.

6. Junction box schedule alongwith termination details.

7. Construction details, mounting details, interior G.A. drawings, wiring drawings and Bill of Material for Turbine trip relay panel.

8. QAPs for all items like instruments, junction boxes, local gauge boards & cables.

9. Test procedure for FAT & SAT

10. Power supply load calculations

11. All certificates including calibration reports, type test & routine test certificates, CCOE certificates etc.

12. Spare parts:

(a) Mandatory spare part list (for all equipment items, instruments)

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Sl. No.

Details

(b) Recommended spare list for 2 years continuous operation

(c) Spares being supplied alongwith model nos., part nos. & quantity

13. Instruction manual for installation, operation, start-up and maintenance (per instrument type).

14. System operation and maintenance manual

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SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION: Annexure-1 TCE-6079A-B-610-024

MANDATORY SPARES

FOR INSTRUMENTATION

SHEET OF 2 OF 4

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PART DESCRIPTION QUANTITY REQUIRED QUOTED

YES/NO

Mandatory spares shall be quoted and included in base price as follows. Contractor shall quote mandatory spares for the instruments/ items offered in the Contractor’s package system.

1.0 FIELD INSTRUMENTS

1.1 Pressure Gauges 5% (Subject to min. of 1 No.) of each model, range, material of construction and rating, whichever is higher.

1.2 Draft Gauges 5% (Subject to min. of 1 No.) of each model, range, material of construction and rating, whichever is higher.

1.3 Temperature Gauges 5% (Subject to min. of 1 No.) of each model, range, material of construction and rating, whichever is higher.

1.4 Temperature Elements -RTD

5% (subject to minimum of 1 No) of each length of RTD with Thermo well, whichever is higher.

1.5 1

.

9

Thermocouple 10% (subject to minimum of 1 no) of each length & type of Thermocouple with thermo well, whichever is higher.

2.0 IN-LINE INSTRUMENTS

2.1 Control Valves & On-Off Valves (Manufactured outside India)

(a) 10% (subject to minimum of 1) of Positioners (pneumatic) with links of each type and make, whichever is higher.

(b) 5% (subject to minimum of 1) of limit switch box, SOV of each type.

(c) 5% (subject to minimum of1) of Air filter regulators along with gauges of each type, whichever is higher.

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SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION: Annexure-1 TCE-6079A-B-610-024

MANDATORY SPARES

FOR INSTRUMENTATION

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NO.

PART DESCRIPTION QUANTITY REQUIRED QUOTED

YES/NO

(d) 5% (subject to minimum of 1) of Bonnet Gaskets/gland packings, piston O-rings, bearing & liner (for all types of valves).

(e) 5% (subject to minimum of 1) of any special accessories provided along with the control valve like boosters , position transmitters (wherever applicable), proximity switches, I/P converters, quick exhaust valves, temp dependant fuses etc whichever is higher.

2.2 Pressure control Valve

(Self actuating valve) (Manufactured outside India)

Minimum 1 no of each type/size, rating etc. of Trim set consisting of seat, seat ring / seal ring, plug with stem, cage (wherever applicable), packing material for each valve to be provided as spare.

3.0 OTHER ITEMS

3.1 Snubber, Syphon, Gauge Saver, etc.

5% (subject to minimum of 1) of each item used, whichever is higher

3.2 Solenoid Valves 10% or minimum 2 nos. of solenoid valves of each type used.

3.3 Instrument Valves / Tube Fittings

10% for each type

3.4 Panel mounted instruments

5% or minimum one no. whichever is higher

4.0 MACHINE CONDITION MONITORING SYSTEM

10 % or minimum 2 nos. of vibration sensors and temperature sensors for bearing

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