supply of density meter skid 2 nos. ( liquid ) · quotation). a. technical bid b. priced bid 2.1...

Supply of Density Meter Skid ( Liquid ) for Manglya , Indore, MMBPL

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SUPPLY

OF

DENSITY METER SKID 2 Nos. ( LIQUID )

FOR

MANGLYA RECEIPT CUM DESPATCH TERMINAL,

INDORE

MUMBAI- MANMAD-BIJWASAN PIPELINE (MMBPL)

BHARAT PETROLEUM CORPORATION LIMITED.


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CONTENTS

SECTION - 1: INTRODUCTION………………………………………………………………………………….. 3 SECTION-2 : QUALIFICATION, PROVENNESS REQUIREMENTS & TECHNICAL FORMS………….. 5 SECTION-3 :

DATA SHEETS FOR DENSITY METER SKID………………………………………………. 14 SECTION -4 :

JOB SPECIFICATION FOR DENSITY METER SKID………….........................................37 SECTION-5 :

DELIVERY SCHEDULE, COMPLETION AND PAYMENT TERMS………………………...51 SECTION - 6 :

GENERAL REQUIREMENTS………………………………………………………………..… 54


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SECTION - 1: INTRODUCTION 1.0 GENERAL

1.1 INTRODUCTION

The Mumbai Manmad Bijwasan pipeline (MMBPL) of M/s Bharat Petroleum Corporation

Limited (BPCL) is having underground multi product pipe line for transfer of MS (Euro-IV),

SKO & HSD (Euro-IV) products for a distance of 1380KM from Mumbai Refinery to

Bijwasan (Delhi). Along the pipeline, the locations called Manglya Receipt cum Dispatch

Terminal in Madhya Pradesh State (610 KM from Mumbai) is provided with pumping

facilities for transportation of the product.

Under MMPL extension project (Manmad-Manglya pipeline) in 2003, density meters of

were provided for density measurement at Manglya receipt site. These density meters are

very important, since they are used for identification of product interface in pipeline and

also for the interface automation of product interface based on the density value interface.

During its operation in last few years and as the flow rate was increased on account of

capacity augmentation, frequent filter choking and slow response of the meters were

observed. Also as the sample tubing and sensor unit size of these density meters are very

small i.e., ¾ Inch size, the response time is very slow and frequent filter cleaning was

required . Also the Density meters are showing frequent variation in reading than actual &

affecting reliability of the equipment and product interface cutting operation at Manglya.

1.2 PURPOSE

Procurement of new Density Meter Skid 2 Nos. for Manglya Receipt Cum Pumping Station,

MMBPL.

Sr.

No.

Tag Number Location Distance from

Control Room

1. 70-DI-1701 Density Meter

with Skid &

Sample Pump

Station Block Valve 250 Meters

2. 70-DI-1702 Density Meter

with Skid &

orifice plate

Pigging Station

/Sampling manifold

150 Meters


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1.3 BRIEF DESCRIPTION OF THE PROJECT

Vendor has to supply Density Meter with Skid , sampling Pump 1 No. for Station Block

Valve area & Density Meter with Skid, restricted orifice plate 1 Nos. for Sampling area at

the Manglya Receipt Cum Dispatch Terminal, Indore Madhya Pradesh of Mumbai-

Manmad-Bijwasan Pipeline, BPCL.

Vendor’s scope shall include Design, Engineering, Procurement of material and bought out

items, Assembly at shop, Calibration Testing & Inspection at Manufacturers works,

Packing, Delivery, Documentation of Density Meter Skid complete with Density Transducer,

Transmitter, Sample Pumps Rotameter/ Flow Meter, Pressure Transmitter, Valves and

accessories, along with Density Converter, Interface Electronics and Interconnecting Signal

Cables between Density Meter Skid and Density Converter etc. including Commissioning

Spares.

The Density meter for Liquid shall be based on vibrating sensor with tuning fork and drive

electronics installed in a bypass (flow through sample chambers). A tuning fork is

maintained in resonance electronically by an electromagnetic circuit. The frequency of

resonance depends on the density of the fluid within vibrating tube and bandwidth is a

function of viscosity. The principle of operation used shall be simple in design and shall

avoid analytical complexity associated with development of information, which is

extraneous to the application.


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SECTION-2

QUALIFICATION, PROVENNESS REQUIREMENTS & TECHNICAL FORMS

2.0 BID STRUCTURE The vendor has to bid in two parts as per the instructions of the RFQ (Request for the

quotation).

a. Technical Bid b. Priced Bid

2.1 TECHNICAL BID QUALIFICATION CRITERIA 2.1.1 Vendor has to provide technical write-up on the technology, hardware and software

proposed for the Project. 2.1.2 Vendor has to submit the technical bid as per the Bid outline requirements in clause 2.2 of

this specification. 2.1.3 BPCL reserves the right to verify the correctness of documentary evidence furnished in the

offer. 2.1.4 BPCL reserves the right to assess the capability and capacity of Bidder. BPCL reserves the

right to verify the successful operation and performance of reference projects. Bidder shall arrange permissions for visiting these installations, if required. The permissions mentioned in the previous statement indicate the permissions for entry into the premises of the party where the vendor has installed similar Density Meter Skid system.

2.1.5 Bidder shall submit the Company profile indicating organization structure of bidding entity

along with Technical bid.

Note: Pre-bid meeting shall be called to clarify any doubts regarding the technical &

commercial terms & conditions of the tender. All vendors are requested to

clarify any doubts before submitting the bids.


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2.2 BID OUTLINE REQUIREMENTS 2.2.1 Bidder is required to mandatory make a proposal in a format as outlined below in order to

achieve the objective of maintaining uniform proposal structure. TECHNICAL BID : COVERING LETTER & SYNOPSIS OF THE PROPOSAL

CHAPTER I: QUALIFICATION SUMMARY

In this section Bidder is required to agree to all the points & submit all the supporting documents as per section 2.1

CHAPTER II: COMPOSITION OF THE BID

This chapter is to describe the various parties who have been involved to bid for this project clearly defining the Bidder. In addition, the project organization structure putting together various parties together with inter-relationship shall also be submitted.

CHAPTER III: FORMS

Bidder is required to complete Deviation Form [attached in Section -2].

CHAPTER IV: SCOPE OF WORK

(Complying with the requirements of Section 3, 4 of the SPECIFICATIONS)

CHAPTER V: SYSTEM TECHNICAL REQUIREMENTS

(Complying with the requirements of Section -3 of the SPECIFICATIONS) CHAPTER VI: INSTALLATION AND COMMISSIONING Complying with (the

Requirements of section 4 of the SPECIFICATIONS) CHAPTER VII: FACTORY ACCEPTANCE TEST, SITE ACCEPTANCE TEST,

TRIAL RUN (Complying with the requirements of Section 4 of the

SPECIFICATIONS)

CHAPTER VIII: PROJECT EXECUTION AND BAR CHART ACTIVITY

SCHEDULE (Complying with the requirements of Section-6 of the

SPECIFICATIONS)

CHAPTER IX: TECHNICAL BROCHURES.

2.2.2 Bidder is required to mandatory make a proposal in a format as outlined in cl. 2.2.1 above

and further it is in the interest of Bidder to submit complete and comprehensible proposal

leaving no scope for the COMPANY to raise any further questionnaires as the proposal


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may only be evaluated on the basis of what has been submitted by the bidder at the first

instance in order to adhere with very strict project schedule requirements.

2.2.3 Please note that the data indicated in this document needs to be maintained till the end of

the project. Any changes in the proposal during the actual execution have to be brought

into the notice of BPCL and permission has to be obtained from BPCL by giving proper

justification.

2.2.4 All quoted prices & rates shall be firm & valid for a minimum period of 180 days from the

date of submission of the Bids.

2.2.5 Bidder shall submit the Company profile indicating organization structure of bidding entity

along with bid qualification.

2.2.6 Bidder should ensure submission of complete information/ documentation in the first

instance itself. Qualification may be completed based on the details so furnished without

seeking any subsequent additional information.

2.2.7 Bidder shall submit all relevant documents of their proven track records and satisfactory

performance by giving detailed reference (e-mail address/ contact details) of end user(s).

Owner shall have the right to obtain feedback directly from any or all end user(s) about

bidder’s performance at their location.

2.2.8 The Vendor must follow the following guidelines while submitting their offer. Offer not

complying with these guidelines shall be rejected summarily without any intimation to the

Vendor.

a) The tender specifications (i.e. Data sheet, Technical specifications and other

attachments of this tender) shall be fully complied with, No deviations of any type are

acceptable in general.

b) Vendor shall submit the price details against each item number & Tag No./Item code

specified in the tender. No information/ description, technical or non – technical, other than

what is required as per price format shall be filled or submitted. The prices indicated in the

pricing schedule shall include prices of all accessories, inspection, testing and applicable

statutory certification requirements.

c) The submission of prices by the Vendor shall be construed to the mean that they have

confirmed compliance with all technical specifications of the corresponding item(s).

d) In case of any contradiction between this bidding instrument and any other document

attached with the tender, this bidding instruction shall govern.


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2.2.9 Vendor’s quotation shall include a detailed specification sheet for each Density Meter which

shall provide the following information:

a) Compliance to specification

b) Detailed specification sheet for each item, which shall provide information,

described as under. The material specification and units of measurement for various

parts in vendor's specification sheets shall be to the same standards as those

indicated in purchaser's data sheets.

1. All the details regarding type, construction materials etc. for various parts of the

density meter, its accessories & other on skid items.

2. Adjustable operating range

3. All design characteristics and performance characteristics.

4. Cable specification required and the maximum permissible cable length between

the meter and its associated receiver instrument (Density Meter).

c) Density meter sample pump, piping sizing (sizing of restriction orifice plate when

specified in data sheets).

d) Proven references for each offered model inline with clause-3 of this specification.

e) A copy of approval for flameproof enclosure/intrinsically safety, from local statutory

authority which is Chief Controller of Explosives (CCOE), Nagpur in India along with:

• Test certificate from recognized house CMRI/ERTL etc. for flame proof enclosure as per

relevant Indian Standard for all Indian manufactured equipments.

• Certificate of conformity from agencies like LCIE, ATEX, PTB, CSA, UL etc. for

compliance to ATEX etc. for all equipments manufactured outside India.

f) Deviations on technical requirements shall not be entertained. In case Vendor has any

valid technical reason, they must include a list of deviations tag number wise, summing up

all the deviations from the Purchaser's data sheets and other technical specifications along

with the technical reason for each of the deviation.

g) Overall estimated dimensions in millimeters of the Density meter skid.

Catalogues giving detailed technical specifications, model decoding details, drawings,

operating and maintenance manuals and other information for Density Meter and its

accessories covered in the bid.

2.2.10 The Vendor is responsible for the selection of the Density Transmitter, Sample Pump/

Restriction Orifice, Valves, Pressure Indicator, Sample Inlet/ Outlet piping, Density


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Converter etc including accessories and its material suitability to meet this specification in

totality. If at any stage, till the completion of the order, the offered instruments &

accessories are found unsuitable for the specified operating and design conditions, the

Vendor shall replace the same with a suitable item meeting the specification without any

schedule/cost implication.

2.2.11 Offered models for all items of the Density Meter Skid (Liquid) and all its accessories shall

be accompanied by detailed technical catalogues in English language. An offer without

catalogues shall be considered incomplete and is liable for rejection.

2.2.12 a) Offered models of Density Meter, Density Converter and accessories shall be field

Proven at least 4000 hrs in similar application as those indicated in the MR.

b) Vendors shall furnish specific Proven Track Record (PTR) for the offered models of

Density Meters and Density Converter for the successful continuous operations of 4000

hours in the process conditions similar to those as specified in the Datasheet of this tender.

Vendor shall furnish proven track record indicating the date of supply, date of

commissioning, plant/ project name and telephone/fax no. of the concern person with

satisfactorily working certificate from end user and the same is mandatory. Items with proto

type design or items not meeting criteria as specified above shall not be offered.

2.2.13 All material specifications for the various parts in the Vendors specification sheets shall be

to the same standard as those in Purchaser's data sheets.

2.2.14 Density Meter skid shall be supplied as per technical Specifications which must be

complete with density transducer, transmitter, Rotameter, pressure indicator, valves,

strainer, sample pumps etc. along with density converter, interface electronics, etc.

2.2.15 Vendor shall furnish General Arrangement drawings of the skid indicating density

transmitter and other accessories. Installation details of the skid shall also be furnished

along with the offer.

2.2.16 Vendor shall indicate in the offer the Recommended Frequency of Calibration, Procedure

for Calibration and Recommended Agencies for calibration.

2.2.17 Vendor shall furnish with the offer the required cabling schematic for each density meter

skid. The schematic shall clearly indicate the cables (along with the no. of cores & core

diameters etc) between the density meter and the density converter (for density &


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temperature signal, power etc). Also the power cable for the sample pump motor (as

applicable) shall also be indicated in the schematic.

2.2.18 Vendor shall supply all signal interconnecting cable (for density signal & internal

temperature RTD) as required for density meters / transmitters (at field) to density

converters (at control room in safe location) along with whether / flame proof junction box if

any.

2.2.19 The interconnecting signal cables shall be stranded, annealed, electrolytic copper

conductor with suitable conductor diameter. The cables shall be individual and overall

shielded. Cable pairs shall be with twisted cores. Cables shall be PVC or PE insulated and

flame retardant as per IEC-60332 and provided with amour and suitable for direct burial.

Cable parameter shall be selected by vendor suitable for the associated signal over the

required distance and considering the entity parameters of the associated IS devices.

2.2.20 All density meters shall be suitable for Water service also in addition to the fluids specified

in the data sheets.

2.2.21 The density meter transmitter shall be protected from surge due to lightening and

necessary surge protecting device shall be provided integrally with transmitter.

2.2.22 Vendor shall provide strainer in density meter skid at the pump inlet. Vendor shall select

mesh size of strainer suitable for the pump & density meter considering the presence of

nominal suspended particles in the pipeline fluid.

2.2.23 All piping materials including valves, flanged, fittings & gaskets shall be as per the piping

material specification (PMS) attached in this MR. The gasket material of Sp.wnd

SS316+graphite filled shall be used.

2.2.24 All types of barriers with 20% spares or min. one no. and related accessories required shall

be supplied in loose.

2.2.25 All the cables required shall be supplied along with the skid. The length of cable shall be

approx. 200 meters however final length will be indicated during detailed engineering.

2.2.26 Vendor shall also quote for any special tools needed for maintenance work on the meter

and its accessories. If any item has not been mentioned or quoted and needs to be

replaced in two years of operation shall be provided without any cost implication

2.2.27 Vendor to furnish per diem rates for supervision of installation & commissioning assistance

at site for Density Meter Skid and Density Converter. Vendor shall indicate estimated

number of days for each station.


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2.2.28 TECHNICAL DETAILS

a. The Density meter shall be supplied with single magnetic filter.

b. The magnet mounted in filter shall be of permanent type.

c. The magnet shall be of 1000 gauss and the filter shall be of 80 mesh.

d. The end connection of skid shall be of 2” Flanged end.

e. All valves and connections shall be flanged type and shall be dealt during

detailed engineering.

f. Ex-proof suitable for installation in Group IEC, ZONE 1,GR IIA,IIB,T3 LCS

for operating sample pump to be provided.

g. Inputs to Density Converter:

Frequency and temperature (4-wire RTD) from density transmitter.

External pressure/ temperature (from a separate PT/RTD) for correction in

the form of 4-20 mA.

h. Required Outputs from Density Converter:

Corrected (taking pressure and temperature compensation at 15 deg

centigrade) and uncorrected density in the form of 4-20 mA to flow

computer.

2.3 FORMS: FORM A: DEVIATION FORM (Technical)


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ITEM: DENSITY METER SKID-LIQUID SYSTEM

Name of Vendor: - Schedule of deviation: - 1. Vendor shall furnish here a consolidated list of deviations taken in his offer to the Tender

with necessary remarks for such deviations. 2. Deviations mentioned elsewhere in the offer but not listed in this form shall not be binding

on the owner. Any such deviations indicated elsewhere (other than this form) shall render the offer non-responsive and shall be liable to be rejected.

3. All the other clauses of the Tender, not listed herein shall be deemed to be fully complied

by the vendor. 4. All other clauses of the Tender shall be deemed to be fully complied by the vendor. 5. Only the deviations listed herein, in conjunction with the Tender shall constitute the

contract requirements for the award of job to the vendor.

Sr. No

Spec No

Clause No

Requirements as per Tender

Deviations by Vendor

Clarifications Remarks

Signature of authorized Signatory of vendor ………………… Name of authorized signatory ………………… Stamp & Date ……………………… Note: Additional sheets may be used as required. 2.4 Technical Questionnaire


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This questionnaire shall be duly filled in and submitted along with unpriced sets of offers to avoid further queries and to ensure proper evaluation of your offer in time. if this is not complied with your offer is liable to be rejected. ANSWER ‘YES’ ‘NO’ OR ‘NOT APPLICABLE

S.N DESCRIPTION BIDDER’S RESPONSE

1.

I)

ii)

iii)

iv)

Have you any deviations to the following:

General specifications (Clause wise)

Special Requirements. (Clause wise)

Instrument specifications indicated in the Data sheets.

The scope of supply as indicated in the material requisition.

If ‘yes’ have you included the list of Deviations?

(If No deviations are furnished, It will be assumed that all the

specifications and requirements of the subject requisition are

complied with and no deviations whatever will be accepted after the

placement of order.)

2. Have you quoted for the spare parts including consumable items

required for the startup and two years normal operation / maintenance

of the instruments?

3. Have you quoted for the mounting accessories, special calibration kits

and equipments (Complete with technical details) required if any, for

the erection, commissioning and maintenance of the instruments?

4.A)

B)

C)

Have you enclosed the relevant technical catalogue / literature in

ENGLISH language including model decoding details, drawing etc.

necessary for the evaluation of your offer?

Have you confirmed that the documents required as per the vendor data requirement will be supplied after placement of order? If so, have you indicated the extra price applicable if any?


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5. Have you furnished, the ‘shop inspection charges, if any, for inspection at your works by Third party? (The details of the tests to be carried out on the instruments during shop inspection are to be furnished.)

6. a) Have you furnished the certificates from statutory bodies viz. BASEEFA, FM, CSA etc. for the explosion proof construction / intrinsically safe design of the instruments wherever specified?

b) Have you furnished CCE/PESO certificates?

7. Have you confirmed that IBR certification in form III (C) or equivalent certification from statutory bodies viz Lloyds, Bureau veritas, TUV etc. will be furnished wherever specified?

8. Have you indicated separately the supervision charges for installation and commissioning , in case the same are included in your scope of work?

9. Have you furnished the estimated power / utility consumption and special cable requirements, if any for the instruments quoted?

10. Have you furnished the customer reference list in India /Abroad.

Note: If the answer is in negative, then furnish response thereof.


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SECTION-3

DATA SHEETS FOR DENSITY METER SKID

3.1 SCHEDULE OF QUANTITIES(SOQ) FOR DENSITY METER SKID AT MANGLYA :

Line Item

Description Unit Qty

1 Density Meter(Liquid) Skid, 600# , 70-DI-1701 at Station Block Valve, Manglya, Indore : Design, Engineering,Procurement of material and bought out items, Assembly at shop, Calibration Testing & Inspection at Manufacturers works, Packing, Delivery, Documentation of Density Meter Skid complete with Density Transducer, Transmitter, Sample Pumps, Rota-

meter / Flow Meter, Pressure Transmitter, Valves and accessories, along with Density Converter, Interface Electronics and Interconnecting Signal Cables between Density Meter Skid with Density Converter etc. including Commissioning Spares as per the enclosed Special Instruction.

SET 1

2 Density Meter (Liquid) Skid, 600# , 70-DI-1702 at Pigging Station, Manglya, Indore :

Design, Engineering, Procurement of material and bought out items, Assembly at shop, Calibration Testing & Inspection at Manufacturers works, Packing, Delivery, Documentation of Density Meter Skid complete with Density Transducer, Transmitter, orifice plate, Rota-meter / Flow Meter, Pressure Transmitter, Valves and accessories, along with Density Converter, Interface Electronics and Interconnecting Signal Cables between Density Meter Skid with Density Converter etc. including Commissioning Spares as per the enclosed Special Instruction.

SET 1

3 Supervision Charges for Erection /Installation, Hydrotest, Commissioning, participation in SAT, Integrated SAT etc which includes deputation of qualified personnels / experts to site during the Pre-commissioning, commissioning and warranty period.

Per Diem

10


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3.2 DATA SHEET FOR DENSITY METER SKID

3.2.1 Density Meter (Liquid)

UNITS: Flow> Liquid m*3/hr Pressure> Kg/cm*2 G Temperature > Deg C

General

1. Tag No. 070-DI-1701 070-DI-1702

2. Line No. 14”-P-70-1701

3. Line size 14”

4. Service Density measurement and Product Interface Detection In Multi-product Pipeline

5. Location Manglya Receipt cum Despatch Terminal, Indore, Madhya Pradesh, India.

Meter

6. Type Vibrating Tube

7. Process Piping & Sensor Minimum 1 inch tubing

8. End Connection: Size & Rating Facing & Finish

2 Inch ANSI 600# RF 125 AARH

9. Density Range 600 – 900 Kg/m3

10. Meter installation In Pipeline By-pass

11. Sample By-pass Using Sample Pump Using Restricted Orifice plate

12. Sample Return To Main Pipe line

13.

Material – Body & Flanges Stainless Steel

14. Other Wetted Parts Stainless Steel

15. Vibrating Element Ni-span-C

16. Density Accuracy +/- 0.1 kg/m3

17. Repeatability +/- 0.02 kg/m3

18. Response Time including Sample transport

Less than 30 seconds (Note 5)

Pre- amplifier cum Transmitter

19. Type – 2 wire/ 3 wire 2 –wire/3 Wire for density signal

20. Power Supply & Cable Entry 24 VDC (Note – 4), 3/4” NPTF

21.

Output Frequency Output for density & PT 100 for temperature

22. Enclosure Weather Proof to IP65, NEMA 4X

23. Intrinsically Safe Yes

24. Mounting Meter mounted ETER MOUNTED

Density Meter Skid and Options

25.

Density meter assembly Skid Mounted

26.

Skid Inlet & Outlet size & rating

Flanged 2” ANSI 600# 125 AARH

27.

Sample Pump with Strainer Required in Bypass


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28.

Rotameter, Pressure gauges Required, (Note – 1)

29.

Built –in Temperature sensor Required, 4wire PT 100

30.

Drain & vent Required

31 Interconnecting signal Cable Required Between density meter and density converter

32.

Density Converter Required (Remote mounted Note – 2)

33.

External Pressure & temperature signal

4- 20 mA signals will be provided by vendor to density converter for compensation.

Density Converter

34. Interface Detection Required with rate of change of density of 0.2 kg/m3 per minute in both increasing & decreasing rate.

35.

Outputs 4- 20 mA isolated for density signals.

36.

Power supply to density converter

230 V AC , 50 Hz

37. Fluid & State MS/ SKO/HSD/ATF

38.

Mainline Flow – Min/Nor/ Max.

250/550/ 700 m3/hr

Main Pipe line Service Conditions

39. Main line Pressure – Operating/ Design.

5 - 44 / 88 kg/cm2 (g)

1 - 3 / 20 kg/cm2 (g)

40.

Line Temp –Oper/ Max 5-45 / 65 Deg. C.

5-45 / 65 Deg. C.

41.

Oper. S.G./ Oper. Visc (cP) - / 0.45-23

42 Area Classification IEC ZONE 2 GR IIA, IIB T3

3.2.2 RESTRICTION ORIFICE PLATES


General Specs

1. Tag No. 070-RO-1701

2. Line No. 14”-P-70-1701

3. Line size & Schedule 14” & 19.1

4. Service For density meter of MS, SKO, ATF & HDS products.


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5. Maximum Pressure drop 0.3Kg/m3

6. Material SS 316

7. Thickness Minimum 3.18mm

8. Sizing As per ISO -5167 (Measurement of fluid flow by means of pressure differential devices inserted in circular cross-section conduits running full)

9. Mainline OD 14 Inch

10. Flanges To be provided by Vendor/buyer

11.

Flanges facing and finish RF 125 AARH

1) Notes: 1. Refer attached sketch - Typical Installation scheme.

2. Density Converter shall be suitable for panel mounting to be mounted on Purchaser’s control Panel in Control room in safe area.

3. Density meters, Pump, skid items & piping accessories shall be rated for the maximum design pressure as indicated above.

4. Density Transducer cum Transmitter to be powered from Density converter.

5. Vendor to consider sample inlet line size of 2”, 600# & length 2 meters (from tapping point to Skid inlet). Pump flow rate & meter flow rate to be selected/designed accordingly to minimize the travel time of sample

6. Density meter should be able to detect the interface for 5 different products with rate of change of density.

7. The density of different products at 15 deg. C. are as under:

8. Product MS (EURO-III/IV) HSD (EURO-III/IV) SKO/ATF

Density (kg/m3) 720-775 820-845 770-820

3.2.3 SAMPLING PUMP MINIMUM SPECIFICATION


1 Fluid Petrol , SKO, ATF & Diesel

2 Nominal Flow m3/Hr. 3

3 Nominal Head m 25

4 Impeller Type - *

5 Impeller Construction Closed

6 Speed To be designed by vendor

7 Design pressure at ambient 149 Kg/Cm2 G


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8 Discharge Pressure 1.96 Kg/Cm2 G

9 No. of stages 1

10 Suction port pressure rating 600 lb RF

11 Suction Port standard ANSI

12 Discharge port pressure rating 600 lb RF

13 Discharge port standard ANSI

14 Casing drain No Casing drain

15 Pump Material

i Casing 316 Stainless Steel

ii Impeller 316 Stainless Steel

iii Casing wear ring 316 Stainless Steel

Iv Shaft 316 Stainless Steel

V Bush Holder 316 Stainless Steel

vi Containment shell Alloy 625

vii IMR Assy 316 Stainless Steel

viii Internal Bearings Silicon Carbide

Ix Gasket 316L/Graphite

x O ring Viton

16 Self Suctioning YES

3.2.4 SAMPLING MOTOR MINIMUM SPECIFICATION DATA SHEET MEDIUM VOLTAGE ENERGY EFFICIENT INDUCTION MOTORS I. PURCHASER'S DATA :

A. Site conditions

1 Ambient temperature : Minimum: 5 °C, Maximum: 50 °C , Design: 40 °C

2 Relative humidity: 95 % 3 Atmospheric condition: Highly corrosive and dusty

4 applicable for Pipelines

5 Altitude: < 1000 m

6 Location: Outdoor

B. Technical particulars

1 Motor tag no.: By vendor during detailed engg.

2 Driven equipment name: Auxiliary motors for pump of density meter


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3 Voltage: 415V +/- 10 %

4 Phase: Three

5 Frequency: 50 Hz +/- 5 %

6 Fault level: 40 KA

7 Fault duration 1 Sec

8 System earthing: Solid earth

9 Duty: Continuous

10 Method of starting: Direct- On- Load (DOL)

11 Cable size: Later mm2

12 Cable type: Al Cond, PVC / XLPE cable

13 Temperature rise: 75 °C

14 Cooling: TEFC

15 Insulation class: Class B.

17 Hazardous area classification:

Zone 2

18 Gas group: IIA/IIB

19 Type of explosion protection:

Ex “d”

20 Type of ingress protection :

IP 55

21 Reacceleration: Required / Not required

22 Diff. protection CTs: Required / Not required

23 CT specs.: NA

24 Color shade: 632 as per IS 5

25 Space heater Required

26 RTD: Required / Not required

27 BTD: Required / Not required

28 RTD/BTD monitoring device:

Required / Not required

29

Applicable specification: Relevant IS /IEC and MMBPL-STD-ELECT -002

30 Operating speed range 10 - 110 %

31 Operation efficiency As per IS-12615


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II. VENDOR TO FURNISH :

DRIVEN EQUIPMENT MANUFACTURER'S DATA

1 Suggested motor rating: kW

2 Manufacturer:

3 Type of driver mounting:

4 Driven equipment: kW

5 Shaft kW:

6 kW at maximum load: kW

7 Speed: RPM

8 Rotation of eqpt. from coupling end:

9 Coupling type:

10 Torque required, starting: mkg

11 maximum: mkg

12 GD2 of eqpt., including flywheel: kgm2

excluding flywheel: kgm2

13 Maximum thrust: kg

14 Pulsation rate:

15 Starting condition:

MOTOR MANUFACTURER'S DATA

1 Rating: kW

2 Manufacturer:

3 Frame designation:

4 No. of poles:


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5 Full load speed: RPM

6 Mounting:

7 Full load torque (FLT):

8 Starting torque: % of FLT

9 Break down or pull out torque: % of FLT

10 Full load current (FLC): A

11 Starting current at 100% voltage: % of FLC

12 Rotation viewed from coupling end:

13 Starting time at 80% / 100% voltage: sec.

14 Locked rotor withstand time (cold/hot) at,

80% voltage: sec.

100% voltage sec.

15 Efficiency at 75% / 100% voltage

%

16 Power factor at 75% / 100% load

17 Space heater – voltage & power

18 Moment of inertia, GD2: kgm2

19 DE/NDE bearing type & no.:

20 Type of lubrication:

21 Type of main terminal box:

22 Type of neutral terminal box:

23 Weight of motor: kg

24 Thermisters, quantity: no.

make: type:

25 RTD, quantity: no.

make: type:

26 BTD, quantity: no.

make: type:


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27 Shaft voltage: V

28 Critical speed, 1st/2nd stage: RPM

29 Pressurization panel: C

Make: Type

30 Canopy:

Recommended list of maintenance spares for two years operation shall include the

following as minimum: Bearing DE/NDE one set b) Terminal box cover with screws c) Fan d) Terminal block

Starting time calculations shall be based on operating conditions specified in Material Requisition e.g. open valve condition/closed valve condition, at no load/under load, as applicable.

Vendor shall furnish the duly filled in data sheet separately for each motor clearly indicating the tag no. for each motor


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3.3 LIST OF ATTACHMENTS

S.N. Document Title Document No.

1 Specification for flame proof lighting and power panels. Annexure - 1 (7 Pages)

2 Specification for Medium and High Voltage Cables and Accessories

Annexure - 2 ( 10 Pages)

3 Specification for Hazardous area light fixtures and Junction Boxes

Annexure - 3 (7 Pages)

4 Specification for Electric Surface heating system Annexure – 4 ( 13 Pages )

5 Inspection and Test plan for Flame proof lighting and power panels

Annexure - 5 ( 5 Pages )

6 Inspection and Test Plan for Medium and High Voltage Cables & Accessories


7 Inspection and Test Plan for Hazardous Area lighting Fixtures and Junctions Boxes


8 Equipment Earthing Schedule Annexure - 8 (1 Pages)

9 Details for Hot dip Gal vanished ladder type cable trays Annexure - 9 (3 Pages)

10 Instrument Connection on Vessel, Standpipes and Tanks Annexure - 10 ( 3 Pages)

11 Instrument Connections on Pipes Annexure - 11 ( 3 Pages)

12 Manglya P&ID with proposed densitometer location. Annexure - 12 (1 Pages)

13 Specification of field instruments.

Annexure – 13 (15 Pages)

14 Specification for installation of field instruments. Annexure – 14 (19 Pages)

15 Specification for Medium Voltage Energy Efficient Induction Motors

Annexure – 15 (19 Pages)


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3.4 PROPOSED SKID P&ID:


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3.5 VENDOR DATA REQUIREMENT

S.N. Description Prints with Quotes

Certified Information required after Purchase Order

Soft Copy

Printed Matter

Date Needed

Date Promised

01 Dimensional Outline with Mounting details and model number

2 - 3+3 4 W

02 Connection by Purchaser (Piping, Electrical)

2

- 3 4 W

03 *Wiring Diagrams - - 3 4 W

04 Parts List - - 3 W/S

05 Recommended Two years operational spares parts with prices

2 - - -

06 Installation, Operations and Maintenance Instructions.

- 3 3 W/S

07

* Nomo graph & Sizing Calculations. Sizing calculations for : a. Total response time of the meter including sample transportation time and meter response time. b. Sizing calculation for orifice plates

2 3+3 4 W

08 *Loop Diagrams - - 3 4 W

09 Test Certificates as per cl. no. 4.5.0

- - 3 4 W

10 Certificate from Statutory Body 2 3 W/S

11 CCE approval certificate for electrical items & enclosures

- 3 W/S

12 Calibration report & test certificates for Densitometers

3 W/S

13 * Assembly Details 2 3 W/S

14 Technical Literature & Model decoding for each Item

2 - 3 W/S

15 Inspection and testing procedures - - 3 4W

16 Power consumption details 2 3 4W

17 Piping general arrangement drawing

- - 3 4W+W/S

18 Special test equipment/tool requirement for maintenance

- - 3 W/S

19 Specifications of Densitometer and Instruments

- - 3 W/S

20 Skid structural drawing - - 3 4 W+W/S

21 Documents as per Piping scope of work attached in Tender.

NOTES:

1. FOLD ALL DRAWINGS TO 216mm x 279mm AND ROLL TRANSPARENCIES. 2. VENDOR TO PROVIDE ALL TRANSPERANCIES AND PRINTED MATTER TO BPCL

LEGEND: CATEGORIES PRECEEDED WITH ‘*’ WILL BE APPROVED FOR FABRICATION BY BPCL. THE REMAINING DRAWINGS ARE NEEDED FOR INFORMATION ONLY. A/C = AS COMPLETED, A/R= AS REQUIRED, W/S= WITH SHIPMENT, W=

WEEKS


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SECTION -4

JOB SPECIFICATION FOR DENSITY METERS 4.0 GENERAL

4.1.1 Scope

4.1.1.1 This specification, together with the data sheets attached herewith covers the

requirements for the design, materials, nameplate marking, inspection, testing and

shipping of Skid mounted Density Metering systems and their accessories.

4.1.1.2 The related standards referred to herein and mentioned below shall be of the latest

editions prior to the date of the purchaser's enquiry:-

ANSI/ASME American National Standards Institute/ American Society of Mechanical

Engineers

B 1.20.1 Pipe Threads

B 16.5 Steel Pipe Flanges and Flanged Fittings

B 16.20 Ring-joint Gaskets and Grooves for Steel Pipe Flanges

ASME Sec VIII Boiler & Pressure vessel code rules for construction of Pressure vessels.

ASTM D1250 Standard Guide for use of Petroleum measurement tables

EN 50014 Electrical apparatus for potentially explosive atmospheres – General

Requirements

EN 50020 Electrical apparatus for potentially explosive atmospheres – Intrinsic Safety

Requirements

EN-10204 Inspection documents for metallic products

IEC 60079 Electrical Apparatus for Explosive Gas Atmospheres.

IEC 60529 Degree of Protection provided by Enclosures.

IS 13947 Degree of Protection provided by Enclosures for low Voltage Switchgear and Control gear.

IS 2148 Flameproof enclosures for electrical apparatus

IEC 60801 Electronic compatibility for Industrial Process Measurement and Control

Equipment.

4.1.1.3 In the event of any conflict between this specification, data sheets, related standards,

codes etc., the following order of priority shall govern:


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a) Statutory Regulations

b) Data sheets

c) Standard specifications

d) Codes and standards

4.1.1.4 In addition to compliance to purchasers specifications Vendor’s extent of responsibility

includes the following:

a) Purchaser's data sheets indicate the materials for body, trim and accessories of the

density meter. Alternative material of construction shall also be acceptable provided

these are compatible with the process fluid and its operating and design conditions

specified in the data sheets. It shall be vendor’s responsibility to guarantee the

selection of the offered material for the specified operating condition.

b) Sizing of the density meter and its accessories such as by Sample pump,

Restriction orifice, sample inlet/outlet piping.

c) Coordination and approvals from statutory authorities like CCOE etc, wherever

required.

4.1.2 Bids

4.1.2.1 Vendor’s quotation shall be strictly as per the special Instruction to Vendor and Vendor

Data Requirements attached with this MR.

4.1.2.2 Vendor's quotation shall include submission of statutory approval certificates & type test

certificates and a detailed specification sheet for each Density meter.

4.1.2.3 A Detailed technical offer is required, Vendor’s quotation shall include the following:

a) Compliance to Specification.

b) A detailed specification sheet for each item shall provide informations described

as under. The material specification and units of measurement for various parts in

vendor’s specification sheet shall be to the same standard as those indicated in

purchaser’s data sheets.

i) All details regarding type, construction materials etc for various parts

of density meter, its accessories and other on skid items.

ii) Adjustable range.

iii) Cable specifications required, maximum permissible cable length

between meter and its associated receiver instruments (Density

Meter).

iv) All design characteristics and performance characteristics.

c) Proven reference for each offered model in line with clause 1.2.4.


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d) Density meter, piping, sizing (sizing of restriction orifice plate), calculation total

response time (Density meter’s response time + sample transportation time).

e) Catalogues in English giving detailed technical specifications, model decoding

details and other information for each type of density meter and its accessories

covered in the bid.

f) A copy of approval for flameproof enclosure/intrinsically safety, from local statutory

authority which is Chief Controller of Explosives (CCE), Nagpur in India along with

Test certificate from recognised house CMRI/ERTL etc. for flame proof

enclosure as per relevant Indian Standard for all Indian manufactured

equipments.

Certificate of conformity from agencies like LCIE, ATEX, PTB, CSA, UL

etc. for compliance to ATEX etc. for all equipments manufactured outside

India.

g) Deviations on technical requirements shall not be entertained. In case vendor has any

valid technical reason, they may include a list of deviations tag number wise, summing

up all the deviations from the purchaser's data sheets and other technical

specifications along with the technical reason for each of the deviation.

h) Overall estimated dimensions in millimetres of the density meter skid.

4.1.2.4 All items, as offered, shall be field proven and should have been operating satisfactorily

individually for a period of minimum 4000 hours in the process conditions similar to those

as specified in the purchaser’s data sheets. Items with prototype design or items not

meeting proveness criteria specified above shall not be offered.

4.1.2.5 All documents submitted by the vendor including their quotation, catalogues, drawings,

operating and maintenance manuals etc. shall be in English language only.

4.1.2.6 Vendor shall also quote for the following:

a) Two years operational spares for each density meter and its accessories

covered in the bid.

b) Vendor shall also quote for any special tools needed for maintenance work on

the meter and its accessories. Vendor must confirm in their offer if no special

tools are needed for maintenance of the offered density meters.

4.1.3 Drawings and Data

4.1.3.1 Detailed drawings, data, catalogues and manuals required from the vendor are indicated

by the Purchaser in vendor data requirement sheets. The required number of


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reproducible and prints should be despatched to the address mentioned, adhering to the

time limits indicated.

4.1.3.2 The ‘Design, Installation and Maintenance Manual’ submitted by the vendor after

placement of purchase order shall include the following, as a minimum: vendor shall

submit certified drawings and specifications sheets for each density meter and its

accessories which are as following:

a) Specification sheet for each density meter, Rotameter, density converter and

its accessories.

b) Certified drawings for each assembled density meter skid, density Converter

etc., which shall provide dimensional details, internal construction details,

material of construction etc.

c) Copy of type test certificates.

d) Installation procedure for each density meter, accessories, transmitters,

density converter etc.

e) Calibration, maintenance procedure including replacement of its internal parts

wherever applicable

f) Graphs of correction factors such as pressure, temperature, and viscosity.

g) Weight in kilograms of each assembled density meter skid.

4.1.3.3 Vendor shall provide test certificates for all tests indicated in clause 4.0 of this specification.

In addition, vendor shall also provide the certificate of compliance to purchaser’s

specification as per applicable clause of EN 10204.

4.2.0 DESIGN AND CONSTRUCTION

4.2.1 Density meter

4.2.1.1 The Density meter for Liquid shall be based on vibrating sensor with tuning fork and drive

electronics installed in a bypass (flow through sample chambers) A tuning fork is

maintained in resonance electronically by an electromagnetic circuit. The frequency of

resonance depends on the density of the fluid within vibrating tube and bandwidth is a

function of viscosity.

4.2.1.2 The principle of operation used shall be simple in design and shall avoid analytical

complexity associated with development of information, which is extraneous to the

application.


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4.2.1.3 The design used shall provide maximum reliability, maximum on-line performance and

minimum maintenance. Instrument shall be field proven. No prototype instrument shall be

supplied. Technique of measurement used shall be interference free. It shall be immune

to other impurities in the fluid stream.

4.2.1.4 The density meter shall be rugged insensitive to vibration and shock. The density meter

shall have non-obstructed flow path through the instrument. The design shall be

insensitive to viscosity.

4.2.1.5 The accuracy of the density meter shall be ±0.1 kg/m3 and repeatability shall be ± 0.02

kg/m3 over the specified measurement range.

4.2.1.6 Density meters and the meter piping/valves, Rotameter, etc. shall be rated for the

maximum design pressure as indicated in the data sheets.

4.2.1.7 The Density meter shall be provided with online temperature measurement with built in

temperature sensor PT-100 for temperature compensation and specific gravity

measurement.

4.2.1.8 The flow direction shall be clearly stamped or cast on the body.

4.2.1.9 End connections

4. 2.1.9.1 Density meters shall have flanged end connections. Weld joints if any shall be of

radiographic quality.

4. 2.1.9.2 Unless otherwise mentioned, end connection details shall be as below:

a) Threaded end connections shall be to NPT as per ANSI B 1.20.1

b) Flanged end connections shall be as per ANSI B 16.5

c) Grooves of ring type joint flanges shall be octagonal as per ANSI B 16.20.

d) Flange face finish shall be serrated concentric to paragraphs 6.3.4.1, 6.3.4.2, and

6.3.4.3 of ANSI B 16.5.

4.2.1.10 Material of construction

4. 2.1.10.1 The material of construction of density meter Body & flanges and all wetted parts

(except vibrating element) shall be from corrosion resistance stainless steel and body

shall be as specified in the respective data sheets.

4. 2.1.10.2 The Density meter skid piping /valves & fittings shall be made of carbon steel as

per Piping Material Specification of respective piping class attached elsewhere. All

flanges shall be weld neck, raised face and shall meet ANSI B 16.5.


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4.2.1.11 Meter Sizing

4. 2.1.11.1 All the calculations and units of measurement shall be in metric standard only.

4. 2.1.11.2 Vendor shall furnish sizing calculations indicating flow through the meter,

Restriction orifice sizing. Vendor to consider the sample inlet/outlet line size & length,

pipe line operating pressures, density of the fluid and other parameters and justify the

selection of appropriate meter size, RO bore sizes. Very fast dynamic response is

required for the density meter; hence vendor shall design the RO, meter size &

accessories adequately and ensure that the fresh sample from pipeline is available in

meter within 60 seconds including transportation of sample, meter response, etc. Vendor

to furnish the calculation for sampling time.

4. 2.1.11.3 Vendor shall indicate the range of viscosities over which the measurement

accuracy remains within limits.

4.2.2 Density Meter Electronics

4.2.2.1 Meter electronics shall consist of primary head transducers/sensors, associated

preamplifier/ transmitters and density converter etc.

4.2.2.2 The Density transducer/preamplifier/transmitters unit, including junction boxes & cable

glands shall be suitable for installation in the field under the ambient condition specified.

Enclosures for all electrical items in field shall be Weather proof to IP 65 / NEMA 4X and

flameproof certified suitable to install in area classification. All field mounted items shall

have enclosures suitable for the area classification indicated in purchaser's data sheets.

4.2.2.3 Density Meter output signals from the meter electronics shall be without flying leads.

Separate cable entries shall be provided for output signal (frequency representing density,

temperature PT-100). Cable entry sizes shall be as per NPT standards. Power to the

density transducer/transmitter shall be from density converter.

4.2.2.4 The cable entry sizes between the transmitter and transducers shall be decided by vendor

and the weatherproof and flameproof cable glands to be supplied accordingly.

4.2.2.5 Meter electronics shall be capable of following output signals as minimum:

a) Frequency signal representing density.

b) Temperature signal (PT 100).

4.2.2.6 The design of electronic instruments shall be in compliance with the electromagnetic

compatibility requirements as per IEC 60801.


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4.2.2.7 The meter transducers shall be intrinsically safe certified suitable for the specified area

classification and weather proof to IP65/NEMA-4 and vendor shall supply necessary

isolating barriers between the transducers and preamplifier/transmitter. However the

transducer/sensor housing can be flameproof (EEx d) certified suitable for the specified

area classification instead of intrinsically safe.

4.2.2.8 The transmitter's enclosure housing the electrical parts shall be suitable for the area

classification indicated in the purchaser's data sheets. Unless otherwise specified, the

enclosure shall conform to the following standards:

Weatherproof housing - to IP 65 as per IEC 60529/ IS 13947

Flame proof housing - EX (d) as per IEC 60079/ IS 2148

Flameproof housing shall also be made weatherproof.

4.2.2.8 Density Converter

4.2.2.8.1 Meter electronics shall operate on 230 V AC 10%, 50 Hz 3% UPS or 24 VDC and

shall be protected from overload and from transients. Low power consumption is desired.

Supply voltage fluctuation of ± 10 percent from the specified value and supply frequency

fluctuation of ± 3 Hz from the specified value shall not affect the meter performance.

4.2.2.8.2 Each density converter shall be microprocessor-based unit designed to calculate density

or specific gravity, Viscosity, density at reference condition.

4.2.2.8.3 The Density converter shall be suitable for flush panel mounting and will be supplied

loose for mounting in purchaser’s control panel in control room.

4.2.2.8.4 The signal converter shall be field programmable and shall have extensive diagnostic

capability. Meter parameters and factors set into the converter shall be retained in non-

volatile memory and shall be secured with password such that unauthorized changes are

prohibited. Configuration software and firmware shall be provided.

4.2.2.8.5 Each density converter shall be provided with following facilities as a minimum:

a. Alphanumeric displays providing interface to operator.

b. Alarm/indications for status information.

c. Keyboard for data entry commands etc.

4.2.2.8.6 Each density converter shall, as a minimum, perform the following functions and where

necessary display relevant data:

a. Receive Frequency Density inputs signal from associated density meter.

b. Receiver input signals from associated external pressure and temperature (4-20mA

analog signals) transmitter.


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c. Receive 3 or 4 wire PT-100 temperature input from built in temperature sensor of

density meter.

d. Calculate the operating density, utilising frequency signal from density transducer.

e. Compensate density for effect of pressure and temperature, to obtain corrected

density at standard conditions at 15 deg C and 1.01325 bar absolute.

f. Computation of density at standard, normal or user defined base conditions.

g. Density convertor shall have calculation for temperature compensation as per ASTM

D-1250-80, pressure compensation as per API 1101.

h. Density convertor shall have interface detection software for advance warning of

approaching liquid interface.

i. Output interface alarm message (potential free contact) to purchaser’s central station

control system for logging & control.

j. Density analogue Outputs (4 – 20 mA isolated) signals for corrected and uncorrected

density signal to the station PLC control system for logging and control.

k. Display all measured and calculated variables.

l. Permanently display Corrected density with sufficient digits.

m. Watchdog timer to monitor internal circuits and to signal to central control system via

hardwiring, when a fault is detected.

n. Store in memory the applicable tables detailed in ASTM D1250 & ATSM D341 (or the

appropriate formula and procedures).

4.2.3 Density Meter Skid

4.2.3.1 The Density meter shall be skid mounted completely assembled & tested with density

meter, Rotameter, pressure gauge, strainer, isolation valves, skid piping, valves & fittings

etc. for quick installation and commissioning of equipment with minimum work at site. The

skid design shall be free standing suitable for hazardous area installation.

4.2.3.2 All piping shall be rigidly supported. Adequate pipe supports shall be provided for the

complete Density meter assembly. These shall be bolted to the skid structure and shall be

designed and located with due regards to weight distribution and operational pipe stress.

4.2.3.3 The skid shall be prefabricated and mounted on a steel frame. It shall have inlet and

outlet flanges suitable for inlet and outlet sides. It shall have separate drain and vent

connections.

4.2.3.4 Each skid shall be complete in all respect ready for alignment and grouting at site.


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4.2.3.5 All items shall be properly supported to avoid vibration. The vendor shall provide special

support as required.

4.2.3.6 Optimize access to instruments and fittings. All equipments shall be orientated to permit

servicing without undue dismantling and to have good access and maximum safety.

4.2.3.7 Lifting lugs and their supporting structure shall be designed for a load equal to two times

the weight to be lifted (Shipping weight).

4.2.3.8 All piping materials including valves and flanges shall be supplied as per the piping

material specification (PMS) attached along with this MR.

4.2.3.9 All interconnecting cables in skid and cables to control room shall be shielded and

armored.

4.2.3.10 All junction boxes, cable glands, and accessories shall be certified weather proof to

minimum IP55 and flame proof suitable for hazardous area classification IEC Zone 2, Gr.

IIA, IIB T3.

4.2.3.11 Pump shall be with certified flame proof enclosure.

4.2.3.12 Vendor shall provide overall dimensions of each skid with proposed modules of each skid

considered along with estimated dimensions, weight of each skid, foundation details

(suggestive) of each skid, along with the offer.

4.3.0 NAMEPLATE

4.3.1 Each Density meter and its accessory shall have a SS nameplate attached firmly to it at a

visible place, furnishing the following information:

a) Tag number as per purchaser's data sheet.

b) Manufacturers serial no. and model no.

c) Manufacturer's name/trade mark.

d) Nominal end connection size and rating in psi.

e) Body and trim material.

f) Calibrated range & units of measurement.

g) Area classification in which the equipment can be used.

h) Standards for body/trim material (e.g. ASTM).

4.4.0 RESTRICTION ORIFICE PLATE

4.4.1 General Scope

4.4.1.0 This specification, together with the data sheets covers the requirements for the

design, material, nameplate marking, inspection, testing and shipping of restriction orifice

plate.


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4.4.1.1 The related standards referred to herein and mentioned below shall be of the latest

editions prior to the date of the purchaser’s enquiry:

ANSI/ASME: American National Standards Institute / American Society of

mechanical Engineers.

B 36.10: Welded and Seamless Wrought Steel Pipe.

DIN-50049: Document on Material Testing.

4.4.1.2 In the event of any conflict between this specification, data sheets, relates standards,

codes etc. Vendor should refer the matter to the purchaser for clarifications and only after

obtaining the same should proceed with the manufacture of the items in question.

4.4.1.3 At the time of placement of order, purchaser’s detailed data sheets for each restriction

orifice plate will be sent to the vendor.

4.4.1.4 Purchaser’s data sheet indicates the materials for the restriction orifice plate.

However, this does not absolve the vendor of the responsibility for proper selection with

respect to the following:

a) Material for the restriction orifice plate suitable for the indicated fluid and its operating

conditions.

b) Proper sizing of the restriction orifice plate.

4.4.2 BIDS:

4.4.2.0 Vendors quotation shall include a detailed specification sheet for each restriction

orifice plate which shall provide all the details regarding type, construction, materials used,

thickness etc.

4.4.2.1 All the units of measurement for various items in the vendors specification sheets

shall be to the same standard as those in purchasers data sheets.

4.4.2.2 All the material specifications for the various parts in the vendors specification sheets

shall be to the same standards as those in purchasers data sheets.

4.4.2.3 Vendors shall attach a list of restriction orifice plates tag number wise, summing up all

the deviations, if any, from the purchasers data sheets. Also vendor should provide reasons

for these deviations, wherever possible.

4.4.2.4 Vendors quotation, drawing, specification sheets etc. Shall be in English.


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4.4.3 DRAWING AND DATA:

4.4.3.0 Detailed drawing and data required from the vendor are indicated by the purchaser in

vendor data requirement sheets. The required number of reproducible and prints should be

despatched to the address mentioned, adhering to the time limits indicated.

4.4.3.1 After placement of order, vendor shall submit a detailed calculation sheet for each

restriction orifice plate (whenever bore diameter calculation falls under vendors scope)

showing the formulas used.

4.4.3.2 Vendor shall provide test certificates for all the tests indicated in specifications. In

addition, vendor shall provide the Manufacturers certificate of conformity to purchasers

specifications.

4.4.4 DESIGN AND CONSTRUCTION:

4.4.4.0 Restriction orifice plate shall be concentric, square edged type.

4.4.4.1 For very high pressure drop across the plate, vendor shall consider multistage

restriction orifice design, either of the concentric or eccentric type.

4.4.4.2 Where weld in type restriction orifice plates have been specified, the welding and

preparation shall be as per ANSI/ASME B 36.10, unless otherwise specified.

4.4.4.3 Where the restriction orifice plate is to be mounted between ring type joint flanges,

vendor shall supply the plate with a plate carrying holder.

4.4.4.4 Each restriction orifice plate shall have an integral handle which shall, upon assembly

with flanges, extend to a distance of 50mm.

4.4.4.5 The internal and external diameter of pipe, the orifice bore diameter (whenever bore

diameter calculation falls under vendors scope) etc. Shall be supplied to the vendor at the

time of placement of the purchase order.

4.4.5 NAMEPLATE

4.4.5.0 Each orifice plate shall have the following nameplate information punched on its handle:

a) Tag no. As per purchasers data sheet.

b) Nominal pipe size in inches and rating in pounds.

c) Material of plate.

4.4.6 INSPECTION AND TESTING

4.4.6.0 Unless otherwise specified, purchaser reserves the right to test and inspect all items at

vendor’s works.


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4.4.6.1 Inspection and testing shall be carried out as per relevant standards unless otherwise

indicated in this document.

4.4.6.2 Vendor shall submit the following test certificates and test reports for purchasers review:

a) Material test certificate with detailed chemical analysis from the foundry (MIL certificate) for

the restriction orifice plates.

b) Dimensional test certificate.

4.4.7 WITNESS INSPECTION

4.4.7.0 Vendor shall offer all restriction orifice plates for pre-despatch inspection at his works.

Following tests/checks shall be carried out as a minimum:

a) Physical dimensional verification

b) Orifice smoothness verification.

c) Review of all certificates and test reports.

In the event of not witnessed by purchaser, the test shall anyway be completed by the

vendor and documents for same submitted for scrutiny.

4.4.8 SHIPPING

Each restriction orifice plate shall be packed inside thick polythene bag with suitable protective

packing outside. Each plate shall be packed separately.

4.4.9 REJECTION

Vendor shall make his offer in detail, with respect to every item of purchaser’s specifications. Any

offer not conforming to this shall be summarily rejected.

4.5.0 INSPECTION AND TESTING

4.5.1 Unless otherwise specified, purchaser reserves the right to test and inspect all items at

vendor’s works.

4.5.2 Vendor shall submit following test certificates and test reports for purchaser’s review:

a) Material test certificates as per EN 10204 clause 3.1B for Density meter, skid

pipes, pumps, valves and its accessories.

b) Certificates of radiography/X-ray for welded joints. Dye penetration test certificate

shall be provided where radiography/X-ray is not possible.

a) Hydrostatic test report as per para 4.4.3 of this specification.

b) Certificate from statutory body for intrinsically safe, flameproof enclosure for meter

electronics.


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c) Type test reports for weatherproof meter electronics and transmitter housing.

d) Calibration report for each density meter over entire range.

e) Dimensional test reports for each density meter, meter skid and its accessories.

4.5.3 Hydrostatic Test

4.5.3.1 Each density meter and skid piping accessories shall be subjected to hydrostatic

test. The hydrostatic test pressure shall be 1.5 times the maximum allowable working

pressure.

4.5.4 Inspection

4.5.4.1 All density meters and their accessories shall be offered for pre- despatch

inspection for the following as a minimum;

a) Physical/ dimensional checks and workmanship.

b) Calibration, including establishing accuracy and repeatability over the entire

range, on representative samples.

c) Review of all certificates and test reports as indicated at para 4.2 of this

specification.

In the event of not witnessed by purchaser, the tests shall anyway be completed

by the vendor and documents for same shall be submitted for scrutiny.

4.5.5 SHIPPING

4.6.1 All threaded and flanged openings shall be suitably protected to prevent entry of

foreign material.

4.6.2 The density converter and accessories shall be packed separately.

4.5.6 REJECTION

4.7.1 Vendor shall make his offer in detail, with respect to every item of the purchaser's

specifications. Any offer not conforming to this shall be summarily rejected.


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SECTION-5

DELIVERY SCHEDULE, COMPLETION AND PAYMENT TERMS 5.1.1 DELIVERY SCHEDULE: All the goods delivery against Purchase Order / LOA shall be delivered at site at the earliest but in

any case not later than 30 WEEK from the date of Purchase Order/ LOA.

In the event of delay on the part of the Vendor in effecting deliveries as agreed contractually,

Owner will levy a reduction in price for delayed completion @1/2%( one half of one percent) of

delayed order value per week of delay or part thereof subject to a maximum of 5% of total order

value separately for supply.

5.1.2 DELIVERY ADDRESS:

5.1.2.1 DELIVERY INSTRUCTIONS :

Materials shall be delivered by bidder at following site

Chief Manager In-Charge, Mumbai Manmad Bijwasan Pipeline, Bharat Petroleum Corporation Ltd., Manglya Receipt Terminal, Manglya –Sanwer Road, Manglya, Indore Madhya Pradesh- Postal Code: 453771 India.

Contact Number: +91-9425065623 Please note that BPCL shall accept material from 09:00Hrs to 18:00Hrs on all working days. Material shall be delivered strictly within the stipulated timings. In the event of award of contract, documents specified below shall form part of your supplies. Delivery challan with a copy of Purchase Order. Delivery challan shall contain the following along with other relevant details.

- Purchase order No. with date - Item description as per PO with Quantities supplied. - Complete Delivery Address as mentioned above. - Contact Details of Purchase Officer and Delivery location. - Duplicate copy of Transporter’s Excise invoice, if applicable. - Packing list of the consignment.

Supply of part quantities will be acceptable only at the discretion of BPCL. In all other cases bidder shall supply the entire quantity at a time.


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5.1.3 COMPLETION OF INSTALLATION AND COMMISSIONING:

The installation, integration, testing and commissioning at above site shall be completed

within 8 weeks from the receipt of the materials at site or issuing clearance for

commissioning by BPCL.

5.1.4 CONTACT PERSON

Chief Manager (Maint.), Pipelines, Bharat Petroleum Corporation Limited, 2nd floor, Admin Annexure, Mumbai Refinery, Mahul, Chembur, Mumbai 400074 E-mail: [email protected]

5.1.5 CONVEYNACE/LODGING/BOARDING:

The cost of conveyance, lodging/boarding etc. of contractor/ vendor’s personnel for the site

installation, commissioning and while imparting training to BPCL staff at site will be borne

by the contractor/ vendor.

5.1.6 PAYMENT TERMS

SUPPLY OF MATERIALS

100% payment will be made after Material receipt at site against submission of PBG each of 10 % of Supply PO value as per BPCL format. PBG of 10% Supply PO value shall be released after completion of two years warranty period

SUPERVISION FOR COMMISSIOING AT SITE:

The payment against the supervision charges will be released on actual quantity utilization within 30days from date of submission of invoices along with site commissioning report duly certified by BPCL Engineer In-charges.

5.1.7 WARRANTY PERIOD

5.1.7.1 Vendor shall be responsible for the manufacture in respect of proper design, quality,

mailto:[email protected]


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workmanship & maintenance of all equipment, accessories etc. supplied by the vendor including all services, spares and consumables for a period of 24 months after taking over the system at site, for meeting the functionality and performance requirements of

this contract. To fulfill the same, it shall be obligatory on the part of vendor to modify/ upgrade, rectify any hardware problems in the system or replace any hardware from the supplied equipments and modify/ upgrade, rectify the operating system software, Converter software, other software, supply the required spares and consumables and attend to the troubleshooting & maintenance of the complete system, free of cost, during startup and on-line operation & maintenance of the Density Meter , within the Warranty period. Any modifications/ upgradation or replacement of any hardware & software during warranty shall not affect the performance & functionality of the system. In addition to this vendor will also have to carry out the updation/change in setting based upon the input received from BPCL or thru their own analysis tools.

5.1.7.2 The replacement/ maintenance requirements of the total system shall be attended on call basis within 3 days from the first service call by COMPANY. The repair work should not however exceed 15 days otherwise warranty period shall be suitably extended.


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SECTION – 6 GENERAL REQUIREMENTS 6.0 GENERAL REQUIREMENTS

6.1 PROJECT PROGRAM AND DELIVERY REQUIREMENTS

6.1.1 Vendor shall submit a bar chart showing overall schedule of vendor's program for delivery,

installation & commissioning meeting the following requirements along with his offer along with the critical path. The detailed schedule will be submitted after placement of the order.

6.1.2 The time for completion of all the works under this project including supply & delivery of

equipments and systems at all specified stations, installation & commissioning of SRV Skid system and handing over to the company shall be within the time schedule specified in the bar chart decided jointly by COMPANY and the Vendor after the Purchase order is placed.

6.1.3 The vendor shall, within 10 days after receipt of notification of an award of Contract, provide the COMPANY with the detailed Project Execution Report (PER) diagram for approval by the COMPANY. After the work is started an updated PER diagram shall be supplied every week showing changes in scheduling which reflects the project status at the end of the previous week. The diagram shall cover but is not limited to: -

1. PROJECT EXECUTION ACTIVITIES 2. FUNCTIONAL DESIGN SPEC. (FDS) DOCUMENTS 3. BALANCE ENGINEERING 4. ORDERING OF EQUIPMENT 5. DRAWING/DOCUMENT REVIEW (COVERING ALL DOCUMENTS AND PLANNING 2 WEEKS REVIEW TIME STARTING FROM DOCUMENT RECEIVED IN BPCL OFFICE FOR EACH DOCUMENT) 6. PRE FAT FOR SYSTEM 7. FAT FOR SYSTEM 8. PACKAGING 9. TRANSPORTATION 10. INSTALLATION OF EQUIPMENTS

6.1.4 The vendor shall also submit every fortnight [or earlier] a "Hold up & Slippage Report" wherever necessary. He shall provide additional efforts whenever the PER diagram indicates a delay in completion date. All extra costs incurred by the vendor for such additional efforts in order to prevent a possible delay in the completion date shall be to his account.

6.2 SHIPMENT, HANDLING, PACKAGING AND TRANSPORTATION

6.2.1 The vendor shall be responsible for the handling and transportation, installation and

commissioning of the supplied equipment at the sites as specified. 6.2.2 Packing and Marking of the goods to be supplied shall be the responsibility of the vendor

and shall be such as to protect the equipment from damages due to transportation. 6.2.3 All equipments shall be individually packed in suitable containers/crates along with

cushioning packing designed to avoid damage to the equipments during transit and storage in accordance with best commercial practices and requirements of application specifications.


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6.2.4 The materials for packaging, packing, wrapping, sealers, moisture resistant barriers and corrosion preventives shall be of recognized brands and shall conform to best standards in the areas in which the articles are packed.

6.2.5 The packing shall protect the equipments from impact, vibration, static charge, rough handling, rain dust, damp, insects, rodents etc.

6.2.6 Each container shall be clearly marked with following information at various prominent places:

Company: ‘Name of the Company’ Project: ‘Name of the Project’ ‘ ’ Description of the equipment: ‘Equipment title’ Serial no.: ‘Serial no. of the equipment’ Address: ‘Destination address as per Purchase order’

6.3 PROJECT EXECUTION ORGANIZATION

6.3.1 Vendor shall furnish as a part of the proposal the project execution organization chart

showing the no., level and category of engineering managers envisaged to carry out the project execution & management functions including QA/QC support as per the contract requirements to the satisfaction of the COMPANY.

6.3.2 The project execution shall be carried out by appointing a Project coordinator who will be responsible for coordinating various activities within the respective disciplines.

6.3.3 Overall project management functions shall be carried out by Project Manager from the vendor, who shall control the execution of the project. The Project Manager should have at least 10 years experience and should have successfully executed at least two projects for system.

6.4 PROJECT SITE ORGANIZATION

6.4.1 Vendor shall furnish, as a part of the proposal, the project site organization chart showing

the no., level and type of engineers & specialists envisaged to carry out the complete works as per the contract requirements to the satisfaction of the COMPANY.

6.4.2 Vendor shall ensure that as a minimum suitable nos. of following type and level of

experienced engineers/ specialists shall be available at site, well conversant in their respective areas of specialization and experienced on system hardware, during installation, online testing, commissioning of the project.


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6.5 INDICATIVE INSPECTION AND TEST PLAN (IITP)

SL.NO.

STAGE CHARACTERISTICS QUANTUM OF CHECK

RECORD

SCOPE OF INSPECTION

SUB VENDOR

VENDOR

BPCL

1

Incoming material for sampling system including sample pump/orifice plate, sample filters, Rotameter/Flowmeter, pressure gauges, isolation valve etc. and piping & tubing.

Make, Model no , calibration & functional check, Material construction

100%

Manufacturers Test Certificate / Material Test Certificate

W R R

2 Final Inspection of assembled analysers

Visual check of all items including model no. & name plate verification of Density Meter with Skid, Sample Pump/ Orifice Plate.

Bill of Material check.

Check for retractable probe mechanism. (if specified)

Calibration check with sampling system including accuracy, linearity, repeatability, response time etc.

Check for span & zero calibration feature.

Check for various system functions & diagnostics.

Check for proper operation of system at specified voltage supply variations.

100%

Vendor Test Record / Inspection Witness Record

-

W W


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Check for analog, digital, serial outputs as per data sheets.

Test certificates for calibration

100%

Manufacturers Test Certificates

W R R

Electromagnetic & Radio Frequency compatibility requirements for the analysers.

Samples Type test Reports

- W/R R

Certificates from testing agency like BASSEFA, FM, PTB, CMRI etc. for analysers, electric heat traced tubes & other components for use in specified hazardous area.

BIS approval for analysers and other components manufactured indigenously for use in specified hazardous area.

100%

Statutory Approval Certificates / Type Test Reports

- R R

Statutory approval certificates for analysers, electrical heat traced tubes & other components from CCOE for use in specified hazardous area.

Degree of protection certificate as required.

100% Statutory Approval Certificates / Type Test Reports

- R R

3 Packing

Visual check & Proper packing to prevent entry of foreign material.

100% Packing List

- W -


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NOTES:

1. W – Witness, R – Review 2. Vendor to submit internal test reports, type test reports and statutory approval certificates before

offering items for inspection to BPCL.

Note: This is an Indicative Inspection & Test Plan identifying scope of inspection & review of documents by BPCL Agency as a minimum requirement. Detailed Quality Assurance/Control Plan indicating all specified requirements after issue of PO/PR/MR / PS shall be generated by Manufacturer/ Bidder/ Vendor & same duly approved by BPCL / TPI agency to be submitted to BPCL for information.