technical amendment no. -02 - bharat petroleum · technical amendment no. -02 ... - - drain...

TECHNICAL AMENDMENT No. -02 FOR FIRED HEATER PACKAGE FOR GTU PROJECT

BPCL-MUMBAI

DOCUMENT No.

A918/T-7601/TA-02 Rev. 0

of 3

Sr.

No. Document No.

Page No.

Clause No.

Subject Modifications / Additions / Deletions

1 A918-160-80-45-1201 Rev. B

- - Radiant Tube Wall Thickness Of Heater No. 160-F-002B

Modification Radiant Tube wall thickness type shall be “AW”. Tube wall thickness type “MW” mentioned on the drawing to be ignored.

2 A918-160-80-45-SP-0002 Rev 0

8 3.0 Equipment Summary

Modification Following portion of clause 3.0 to be modified as below: “…and two Balanced Natural Draft Vertical…” modified to “…and two Balanced Draft Vertical…”

3 A918-160-80-45-1202

Rev. B

- View “Y/201”

Return Bend Schedule

Modification Crossover Return Bend thickness schedule shall be “Sch 40” instead of “Sch 80”.

4. 6-42-0003 Rev-3 - - Std. Spec. for ID/FD Fans

Addition Standard specification for ID/FD fan document no. 6-42-0003 Rev-3 as referred in Fan specifications was missing in the Tender document. Same is added in the Tender Index and is attached herewith.

5. A918-160-80-45-OD-0002 - - Technical Compliance

Technical Compliance for Fired Heaters Document No. A918-160-80-45-OD-0002 was missing in the Tender document. Same is attached.

6. A918-160-80-45-1202

Rev. B

- View “X/201”

Return Bend Material

Modification Convection Return Bend Material shall be “A403 WP347H” instead of “A403 WP347”.

7. A918-160-80-45-0105

Rev. B

A918-160-80-45-0208

Rev. B

- - ID Fan Inlet Configuration

For both APH Systems, Single Entry ID Fans as per GA drawing are acceptable.

TECHNICAL AMENDMENT No. -02 FOR FIRED HEATER PACKAGE FOR GTU PROJECT

BPCL-MUMBAI

DOCUMENT No.

A918/T-7601/TA-02 Rev. 0

of 3

Sr.

No. Document No.

Page No.

Clause No.

Subject Modifications / Additions / Deletions

8. Technical Part of Tender

(Damper Datasheet no. A918-160-02-44-DS-84

and A918-160-02-44-DS-78 )

- Entire Document

Modification in FD Fan discharge damper and

addition of a new damper at ID fan

Inlet

Modifications: For both APH systems, existing FD Fan discharge dampers are changed from self-closing type to HIC operated type dampers (being operated manually from control room). Change has been reflected in revised Rev.1 datasheet attached with this amendment. Additions: For both APH systems, ID Fan inlet shall have an HIC (control room) operated damper. New Damper added in Rev.1 damper datasheet.

9. Technical Part of Tender

Heater Air Preheat System P&ID

A918-160-02-44-1171 and A918-160-02-44-1172

Revisions marked

Changes marked in Rev.0 heater

P&ID

Modifications: Changes as hand marked in Rev.0 heater APH system P&IDs shall be applicable. The Rev-1 P&IDs after incorporation of hand marked comments shall be provided Post Order.

11. Heater Air Preheat System P&ID

A918-160-02-44-1171 and A918-160-02-44-1172

- - Drain Connection in CFG Duct from

APH to ID Fan

Material for 3”NB Drain nozzle in the CFG duct from APH to ID Fan shall be SS:304.

12. A918-160-80-45-0105

Rev. B

A918-160-80-45-0208

Rev. B

- - Hand Hole in CFG Duct from APH to ID Fan

Additions: For both APH Systems, Handhole of size 8”NB with 150# Flange and MOC SS:304 shall be provided in the CFG duct from APH to ID Fan.

13. Tender Index

A918-160-80-45-MC-T-7601

- - - Revised Tender Index Rev-2 is attached.

Note for Bidders: Bidder to submit duly signed and stamped copy of this Amendment along with enclosures (if any).

(SIGNATURE AND STAMP OF BIDDER)

2 21.09.2017 REVISED AND ISSUED WITH TENDER PG MK MK

1 01.09.2017 ISSUED FOR TENDER KK PG MK

0 30.06.2017 ISSUED FOR TENDER RS PG MK

Rev. No

Date Purpose Prepared

by Checked

by Approved

by

Format No. EIL 1641-1924 Rev. 1

TECHNICAL PORTION OF TENDER FOR FIRED HEATER PACKAGE

DOCUMENT No.

A918-160-80-45-MC-T-7601 Rev. 2

Page 1 of 1

Copyright EIL – All rights reserved

TECHNICAL PORTION OF TENDER

FOR

FIRED HEATER PACKAGE

UNIT : GASOLINE HYDROTREATMENT UNIT (160)

PROJECT : GTU

CLIENT : BPCL, MUMBAI

JOB NO. : A918


TECHNICAL PORTION OF TENDER

FOR FIRED HEATER PACKAGE

DOCUMENT No. A918-160-80-45-MC-T-7601

Rev. 2Page 2 of 10


INDEX OF CONTENTS

SL. No.

DOCUMENT TITLE DOCUMENT NO. REVISION

No. I TECHNICAL CHECKLIST FOR BID SUBMISSION & BQC

1. Checklist (Technical) for Bidder reference for ‘ZERO DEVIATION’ bid A918-160-80-45-OD-0001

0

2. Technical Compliance for Fired Heater Package

A918-160-80-45-OD-0002 0

3. Bidder Qualification Criteria (Technical) for Furnace Package

(REFER NIT)

0

II FIRED EQUIPMENT MECHANICAL

A JOB SPECIFICATIONS

4. Scope of Work A918-160-80-45-SW-0001 0

5. Job Specification for Fired Heater Package

A918-160-80-45-SP-0002 0

6. Specification for procurement of pressure parts

A918-160-80-45-SP-0003

0

7. Specification for procurement of tube support castings

A918-160-80-45-SP-0004

0

8. Specification for Procurement of Steam Air Pre Heater

A918-160-80-45-SP-0005

0

9. Specificationforprocurement ofcast & glass tube air preheater

A918-160-80-45-SP-0006 0

10. Specification for procurement of Dampers and shut off blinds

A918-160-80-45-SP-0007

0

11. Specification for external Insulation of duct for fired Heaters

A918-160-80-45-SP-0008 0

12. Specification for Procurement of Expansion Joints

A918-160-80-45-SP-0009 0

13. Basis of Structure Design A918-160-80-45-SP-0010 0 14. Site Specific Seismic Spectra A918-000-16-54-DB-0001 0

15. Specification for Modularization of Fired Heater Package

A918-160-80-45-SP-0011 0

16. 3D Modeling requirement for fired heater package

A918-160-16-43-SOW-7601 A

17. Vendor Data Requirement A918-160-80-45-VDR-7601 A

B DRAWINGS:

B1. Splitter Re-boiler Heater

18. Foundation Loading Plan for Splitter heater (160-F-0001) & 1st and 2nd Stage HDS Heaters (160-F-0002A/B)

A918-160-80-45-0100 1

19. General arrangement cross section, long. Sec

A918-160-80-45-1101 B

1



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20. General arrangement plans-1 A918-160-80-45-1102 B


22. General arrangement stack and plans A918-160-80-45-1104 B

23. APH system ducting layout plan A918-160-80-45-0105 B

24. APH system ducting layout elevation A918-160-80-45-0106 B

B2. 1st and 2nd Stage HDS Heater

25. Foundation loading plan A918-160-80-45-1200 A

26. General arrangement cross section A918-160-80-45-1201 B

27. General arrangement long Sec & plan A918-160-80-45-1202 B




31. General arrangement stack A918-160-80-45-1206 B

32. APH system ducting layout plan A918-160-80-45-0208 B

33. APH system ducting layout elevation A918-160-80-45-0209 B

B3. COMMON

34. Tube supports castings A918-160-80-45-1207 B

35. General notes for GA drawings A918-160-80-45-4110 A

36. Equipment Layout A918-160-16-43-00001 1

C. EIL STANDARDS

37. Convection Section Intermediate Tubesheet Support Bracket with 102x102 Bearing Surface (Light Pattern)

7-17-0102 5

38. Wall Tube Hanger (Medium Duty) for 168.3 O/D Vertical Radiant Tubes

7-17-0104 1

39. Wall tube hanger (heavy duty) for 168.3 O/D vertical radiant tubes

7-17-0121 5

40. Tube support lug for crossovers & jumpovers of vertical radiant tubes

7-17-0139 5

41. Tube support lug for vertical radiant tubes 7-17-0140 5

42. Chain link reinforcement for insulation concrete lining

7-17-0202 5

43. Anchor Spacing and Types for Castable Lining

7-17-0205 5

44. Anchor for vertical insulating concrete walls with backup insulation

7-17-0208 5

45. Insulating concrete anchors for walls and overhead surfaces (50≤ lining thickness ≤ 75mm)

7-17-0212 5

46. Insulation details at pressure relief doors for cabin or circular heaters

7-17-0305 4

47. Detail of Insulation at Tube Supports for Concrete Walls

7-17-0306 5

48. Insulation details at floor mounted burners 7-17-0307 5

49. Insulation details of floor peep holes 7-17-0309 5

50. Insulation at ends of extended surface 7-17-0313 4

1

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tubes

51. Insulation Details at Floor Access Door in Vertical Tube Heaters

7-17-0314 6

52. Insulation details at access door 7-17-0318 5

53. Insulation details at observation doors in convection walls

7-17-0319 5

54. Insulation details at sight door 7-17-0320 5

55. Tube sealing detail 7-17-0322 5

56. Header Box with removable panels for convection section

7-17-0404 5

57. Bolts and shear plate for intermediate tube sheet support bracket (light)

7-17-0407 4

58. Hinged access door for steel stack 7-17-0410 5

59. Details of Tube Pulling doors for flat arch 7-17-0411 4

60. Floor access doors for vertical tubes heaters

7-17-0412 5

61. Fabricated pressure relief door for cabin and circular heater

7-17-0414 3

62. (510x610) observation door for convection wall

7-17-0415 4

63. Details of fabricated 4" dia self-closing floor peephole

7-17-0417 5

64. 510X 610 Fabricated Door for use in Top of Breeching

7-17-0418 5

65. Details of 610 wide x 610 or 850 high bolted access door for vertical walls

7-17-0419 4

66. Details of lifting lugs and tie rods for convection section (packaged units)

7-17-0420 4

67. Floor sleeves for spigot guides on top supported vertical tubes.

7-17-0421 4

68. Temporary shipping handling bracing for convection section (packaged units)

7-17-0422 4

69. Arrangement of painters trolley for circular stack

7-17-0423 4

70. Mounting plate for nameplate for heaters. 7-17-0427 4

71. Steel stack field splice details 7-17-0428 4

72. Shipping spiders for prefabricated stacks (for stack diameters upto 3050)

7-17-0439 4

73. Fixing Details of Wall Tube Hanger for 6 inch NB Tube and Under

7-17-0440 4

74. Fixing details for wall tube hanger 8” N.B. tube

7-17-0441 4

75. Shear plate and bolts for cast tube hangers vertical cylindrical heaters

7-17-0443 4

76. Detail of stack strakes 7-17-0444 4

77. Fabricated end tube sheets and support plates (convection)

7-17-0446 4

78. Carbon Steel Guide Angles for Intermediate Tube sheets

7-17-0451 4

79. Ladder and cage details (side step type) 7-17-0454 4



DOCUMENT No.

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Page 5 of 5


SL. No.


No.

80. Ladder and cage details (step through type)

7-17-0455 4

81. Stair details (for use with chequered plate or grating platforms)

7-17-0456 4

82. Details of circular platforms with open type flooring

7-17-0459 4

83. Details of rectangular platforms with open type flooring

7-17-0460 4

84. Hand rail details 7-17-0461 4

85. 230 x 130 Sight Door Mounting for Curved Surfaces

7-17-0463 4

86. Steel stack top ring & painters trolley rail 7-17-0465 4

87. Tube Pulling Bracket 7-17-0472 4

88. Fabricated sight door assembly with glass (120x220 opening)

7-17-0473 0

89. Auxiliary connection detail for heater system

7-17-0475 0

90. Instrument / auxiliary coil connection detail 7-17-0476 0

91. Misc. steel connection details 7-17-0477 0

92. Damper control cable 7-17-0512 4

93. Coil Guide Spigot for Top Supported Vertical Tubes

7-17-0606 5

94. Vertical Radiant Tubes 7-17-0611 5

95. Coil guide spigot (with coupling ) for top supported vertical tubes

7-17-0613 5

96. Name Plate 7-17-0701 4

97. List of abbreviations. 7-17-0705 4

98. Draughting symbols 7-17-0707 4

99. Detail of welded column splice (unequal parallel flange section)

7-68-0206 0

100. Welded column splice (unequal joist section)

7-68-0207 4

101. Splicing detail for rolled sections 7-68-0208 5

102. Beam to beam and beam to column connection details.

7-68-0211 5

103. Welding Symbols 7-68-0251 5

104. Typical detail of weld length for angle members

7-68-0653 3

105. Detail of moment connection for MC [ ] column to [ ] beam

7-68-0654 3

106. Typ. detail of moment connection with MB column to MB beam

7-68-0660 2

107. Welded shear connection details for parallel flange beam with parallel flange beam

7-68-0686 0

108. Details of moment connection for parallel flange beams with parallel flange columns

7-68-0687 0

109. Welded shear connection details for parallel flange beam with parallel flange column

7-68-0688 0

110. Shear connections welded type - beam to 7-68-0689 3



DOCUMENT No.

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Page 6 of 6


SL. No.


No.

beam

D. BPCL STANDARDS

111. Detail of galvanized grating (Type-A, heavy duty)

FS-536 -

112. Technical specification of Paint coating AE-S-5430 1

E. EIL SPECIFICATIONS

113. Standard Specification for execution of fired Heaters and Air Preheating System

6-17-0001 5

114. Standard Specification for Steelwork of Fired Heaters and Air Preheating System.

6-17-0002 5

115. Standard Specification of Coil work for fired heaters

6-17-0003 4

116. Standard specification for studded tubes for fired heater

6-17-0004 5

117. Standard specification of finned tubes for fired heaters.

6-17-0005 5

118. Standard Specification of Tube Support Castings for Fired Heaters

6-17-0007 5

119. Standard Specification for Design and Supply of Cast Tube Air Preheater

6-17-0010 1

120. Standard specification for design and supply of dampers / shut off blinds

6-17-0013 0

121. Standard specification for Design and supply of Glass air preheater

6-17-0014 0

122. Standard specification for fabric type expansion joints

6-17-0016 0

123. Standard specification for quality checks for fabrication erection and execution of fired heaters

6-17-0017 0

124. Standard specification for heater system leakage testing through smoke generation

6-17-0018 0

125. Standard specification for miscellaneous refractory and auxiliary material used in fired heaters

6-17-0020 1

126. Standard specification for workmanship and quality plan for refractory work in fired heater

6-17-0021 1

127. Standard specification for hot insulation of vessels, piping and equipment

6-44-0002 5

128. Technical notes for pipes 6-44-0051 6

129. Technical Notes for valves 6-44-0052 6

130. Technical notes for flanges, spectacle blinds and drip rings

6-44-0053 6

131. Technical notes for butt welded, socket welded and screwed fittings

6-44-0054 6

132. Technical notes for gaskets (for pressure parts)

6-44-0056 4

133. Technical notes for bolts and nuts (for pressure parts)

6-44-0057 4

134. Specification for Documentation Requirements from Contractors

6-78-0002 1

135. Format for completeness of final 3-78-0004 1



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documentation

136. Standard Specification for Refractory Material Sampling, Inspection and Criteria for Acceptance.

6-79-0001 1

137. Standard Specification for Fire Bricks 6-79-0003 1

138. Standard Specification for C.F. Blankets 6-79-0005 2

139. Standard Specification for Castable applications

6-79-0007 2

140. Standard Specification for Insulating Castable

6-79-0008 2

III PROCESS – THERMAL

A. 1st Stage HDS Heater

141. Burner datasheet A918-160-02-44-DS-72 A

142. Skin thermocouples datasheet (common) A918-160-02-44-DS-70 0

143. Flow instrument datasheet (common) A918-160-02-44-DS-74 0

144. Air preheater datasheet (common) A918-160-02-44-DS-75 A

145. SAPH datasheet A918-160-02-44-DS-80 A

B. 2nd Stage HDS Heater


147. Damper datasheet (common) A918-160-02-44-DS-84 1

148. Sob datasheet (common) A918-160-02-44-DS-85 0

149. FD fan datasheet (common) A918-160-02-44-DS-87 0

150. ID fan datasheet (common) A918-160-02-44-DS-88 0

151. Piping & Instrumentation Diagram A918-160-2-44-P&ID-1171 0

C. Splitter Heater


153. Skin thermocouples datasheet A918-160-02-44-DS-92 0

154. Flow instrument datasheet A918-160-02-44-DS-93 0

155. Air preheater datasheet A918-160-02-44-DS-96 A

156. SAPH datasheet A918-160-02-44-DS-97 A

157. FD fan datasheet A918-160-02-44-DS-98 0

158. ID fan datasheet A918-160-02-44-DS-99 0

159. Damper datasheet A918-160-02-44-DS-78 1

160. Sob datasheet A918-160-02-44-DS-83 0

161. Piping & Instrumentation Diagram-Splitter A918-160-2-44-P&ID-1172 0

D Burner Specification

162. Job Specification for burners A918-160-02-44-SP-01 A

163. Job Specifications for CFD A918-160-2-44-SP-02 A

164. Recommended Vendor List A918-160-02-44-OD-01 A

165. List of Sub-Vendor for Ignition System A918-160-02-44-OD-02 A

166. Checklist for the bidders A918-160-02-44-OD-03 A

167. Instructions to Bidders A918-160-02-44-OD-04 A

168. Standard Specification for Forced Draft Burners for Fired Heaters

6-17-0008 4

169. Specification for Quality management system requirements from Contractors

6-78-0001 0

170. Specification for documentation 6-78-0003 0

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requirements from Suppliers

171. Inspection & Test Plan for Burners of Fired Heaters

6-81-0114 1

172. Vendor Data Requirement- Burners A918-160-2-44-VDR-0001 A

IV ROTATING EQUIPMENT(S&ME-2)

173. Scope of Supply / Works A918-160-80-43-SOW-7601 A

174. Special Instructions to bidders A918-160-80-43-SI-7601 A

175. Operation and Maintenance Spares Philosophy

AES-3711 A

176. Mandatory Spares for ID/FD fans A918-160-80-43-SL-7601 A

177. Datasheet for Forced Draft Fan of Splitter Heater

A918-160-80-43-DS-0001 A

178. Datasheet for Forced Draft Fan of 1st and 2nd stage Reactor Heater

A918-160-80-43-DS-0002 A

179. Datasheet for Induced Draft Fan of Splitter Heater

A918-160-80-43-DS-0003 A

180. Datasheet for Induced Draft Fan of 1st and 2nd stage Reactor Heater

A918-160-80-43-DS-0004 A

181. Vendor data requirement for ID/FD Fans A918-160-80-43-VDR-7601 A

182. Experience record proforma – (ID/FD fans)

A918-160-80-43-ER-7601 A

183. ITP for pump reciprocating (plunger/piston)

6-81-0053 3

184. Standards Specification for ID/FD Fans 6-42-0003 3

V ELECTRICAL

185. Scope of work & job specification (Electrical) for ID-FD fans

A918-160-16-50-SOW-7601 0

186. Data sheet for Medium Voltage S.C. Induction Motor

A918-160-16-50-DS-7601

0

187. Datasheet for Variable Frequency Drive A918-160-16-50-DS-7602 0

188. Electric load data A918-160-16-50-DS-7603 0

189. Vendor Data Requirement

(For ID & FD Fans Motors) A918-160-16-50-VR-7601 0

190. Specification for Flameproof Control Stations

6-51-0006 5

191. Specification for MV variable frequency drive system

6-51-0038 2

192. Speciation for Numerical Relays 6-51-0055 2

193. Specification for energy efficient medium voltage induction motors

6-51-0064 1

194. Specification for electrical equipment installation

6-51-0081 4

195. Specification for field inspection, testing and commissioning of electrical installations

6-51-0087 3

196. Specification for electrics of package 6-51-0093 4

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equipment.

197. Inspection & test plan for flameproof control stations

6-81-1006 3

198. Inspection & test plan for MV variable frequency drive system

6-81-1038 2

199. Inspection & test plan for MV motors 6-81-1032 5

200. Inspection & test plan for Numerical Relay 6-81-1055 2

VI INSTRUMENTATION

201. Job specifications-FD fan A918-160-16-51-SP-1009 A

202. FIDU -drawing A918-160-16-51-1001 A

203. Skin thermocouple heater A918-160-16-51-DS-4001 A

204. Venturi tubes Data sheet A918-160-YF-DS-0001 A

205. Thermocouple assembly head drawing-sheet2

A918-160-16-51-4002/2 A

206. Job specifications-APH A918-160-16-51-SP-1010 A

207. Thermocouple assembly head drawing-sheet1

A918-160-16-51-4002/1 A

208. Job specifications- burner A918-160-16-51-SP-1011 A

209. Skin thermocouples A918-160-16-51-DS-4002 A

210. Job specifications-heater A918-160-16-51-SP-1012 A

211. Heater tube skin thermocouple drawing A918-160-16-51-3001 A

212. Vendor data requirements-heater A918-160-16-51-VDR-7601 A

213. Standard specification for local control panel and accessories(electronic/pneumatic)

6-52-0072 3

214. Standard specification for heater tube skin thermocouples.

6-52-0043 4

215. Instrument connections on (fired heaters) 7-52-0010 4

216. ITP for heater tube skin thermocouples 6-81-2043 4

217. Standard specification for signal cables. 6-52-0046 7

218. ITP for signal cables 6-81-2046 3

219. ITP for local control panel & accessories 6-81-2072 3

VII CONSTRUCTION

220. Construction Supervision And

Management A918-00-160-19-41-0001 0

221. Inspection & test plan (ITP) heater

package 6-82-5000 0

222. Standard specification for PMI at

construction sites 6-82-0002 3

223. Standard specification for color coding of

piping material 6-82-0003 2

224. Standard specification for piping and 6-82-0004 1

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heater (fired) coil material traceability at

construction sites

225.

Inspection & Test Plan (ITP) for incoming

material checking for contractor’s supplied

materials

6-82-1010 1

226. Standard specification for erection of

equipment & machinery 6-76-0001 3

227.

Standard specification for application of

torque and hydraulic bolt tension for

flange joints

6-76-0002

2

228. Standard specification for HSE

management at construction site

6-82-0001

(Refer commercial part)

7

229.

Calibration requirements of monitoring

and measuring devices at construction

sites

7-82-0002


0

230.

Qualification and experience requirements

of key personnel and penalty for their non-

mobilization

7-82-0003


0

VIII INSPECTION

231. Inspection methodology for package items A918-9-1842-1001 0

232. Standard specification for positive material identification (PMI) at vendor's work

6-81-0001 3

233. Inspection & test plan for seamless pipes 6-81-0003 5

234. Inspection & test plan for valves 6-81-0004 5

235. Inspection & test plan for forged, seamless and welded fittings

6-81-0005 6

236. Inspection & test plan for flanges, spectacle blinds & drip rings

6-81-0006 4

237. Inspection & test plan for bolting material 6-81-0007 4

238. Inspection & test plan for gaskets 6-81-0008 3

239. ITP for ID/FD Fans 6-81-0054 3

IX MISCELLANEOUS

240. Vendor List A918-160-85-41-VL-07 0

http://edmslite.eil.co.in/edms/viewDocument/09000200836d566c


TECHNICAL COMPLIANCE FOR

FIRED HEATER PACKAGE

DOCUMENT No.

A918-160-80-45-OD-0002 Rev.0

Page 1 of 1


TECHNICAL COMPLIANCE FOR FIRED HEATER PACKAGE

PROJECT : GTU

UNIT: GASOLINE HYDROTREATMENT UNIT (160)

OWNER : BPCL, MUMBAI

EIL JOB NO. : A918

TENDER NO. : A918-160-80-45-MC-T-7601

BIDDER CONFIRMS THAT HIS OFFER AGAINST THIS TENDER (INCLUDING ALL TECHNICAL AMENDMENTS) IS IN TECHNICAL COMPLIANCE AND THERE ARE ‘NO TECHNICAL DEVIATIONS’.

BIDDER’s NAME:

BIDDER’s STAMP:

DATE:

NOTE: 1) Offer shall not be evaluated if this sheet is not signed / stamped

and enclosed along with the Offer.

2) Offer shall be considered as technically not acceptable if anything else (like bidder’s understanding, basis of quoting, clarification, deviation, scope etc.) is mentioned on this sheet.

A101

Line

A101

Typewritten Text

0

Document No.DAMPER A918-160-02-44-DS-78DATASHEET Rev. No. 1

Page 1 of 6

UNIT : GTU HEATER NO : 160-F-0001

CLIENT : BPCL MUMBAI LOCATION : MUMBAI

NO DAMPER NO 160-GHV-7201 160-GHV-7202/7203

1 SERVICE MAIN STACK DAMPER COLD AIR FROM FD FANS

2 TYPE (MULTIPLE / SINGLE LEAF) MULTIPLE MULTIPLE

3 LOCATION STACK FD FAN DISCHARGE DUCT

4 FUNCTION (ISOLATION/ CONTROL) ISOLATION & CONTROL ISOLATION

NORMAL POSITION FOR ISOLATION DAMPER - OPEN

5 DUCT POSITION (VERTICAL / HORIZONTAL) TO SUIT DUCT ARRANGEMENT TO SUIT DUCT ARRANGEMENT

6 LINING DETAILS MATERIAL AS PER MECHANICAL GAD NONE

THICKNESS AS PER MECHANICAL GAD -

CLOSED FUNCTION

UPSTREAM MEDIUM FLUE GAS AIR

UPSTREAM CONDITION MIN NOR MAX MIN NOR MAX

TEMPERATURE (ºC) 338 ATM

7 PRESSURE (MMWC) (-) 7.0 ATM

DOWNSTREAM MEDIUM FLUE GAS AIR

DOWNSTREAM CONDITION MIN NOR MAX MIN NOR MAX

TEMPERATURE (ºC) 146 40

PRESSURE (MMWC) ATM (+) 352

8 MINIMUM TIGHTNESS AGAINST 99.5 99.5

LEAKAGE (BASED ON FLOW) (%) (ON MAXIMUM FLOW) (ON MAXIMUM FLOW)

OPEN CONDITION

MEDIUM FLUE GAS AIR

MIN NOR MAX MIN NOR MAX

FLOW RATE (KG/HR) 12425 24845 29815 9410 21270

9 TEMPERATURE (ºC ) 318 338 338 12 40

UPSTREAM PRESSURE (MMWC) (-) 6.0 (-) 6.0 (-) 7.0 (+) 33 (+) 352

PRESSURE DROP (MMWC) * * 3.0 * 5

DENSITY (KG/M³) 0.57 0.55 0.55 1.23 1.12

1 20/09/17 REVISED AS MARKED AJ SS SS

0 27/06/17 ISSUED FOR ENGINEERING AJ SS SS

NO DATE DESCRIPTION BY CHK APPD

Format No. 3-0545-2008 Rev. 0 Copyrights EIL – All rights reserved

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DAMPER NO. GHV-7201 GHV- 7202/7203

10 DESIGN TEMPERATURE ( ºC ) 500 65

DESIGN PRESSURE (MMWC) (-) 50 TO (+) 25 (+) 600

11 FLOW AREA, M² (MIN) REFER GAD REFER GAD

12 FLANGE TO FLANGE DIMENSION (MM) 300 300

13 MAXIMUM TIME TO OPEN / CLOSE (SEC) 10 10

14 SUGGESTED MINIMUM MATERIAL BLADE SS 304 SS 304

OF CONSTRUCTION SHAFT SS 304 SS 304

ACTUATOR (FOR CONTROL) PNEUMATIC POWER CYLINDER PNEUMATIC POWER CYLINDER

15 TYPE AUTOMATIC / MANUAL (NOTE-3) MANUAL THROUGH HIC(NOTE-3)

INSTRUMENT AIR SUPPLY PRESSURE 5.0/ 6.0/ 6.5 5.0/ 6.0/ 6.5

(MIN / NOR. / MAX) (KG/CM²G) (NOTE-6) (NOTE-6)

POSITIONER (YES / NO) YES YES

16 SIGNAL PRESSURE (KG/CM²G) 0.2 TO 1.0 0.2 TO 1.0

DAMPER POSITION AT 0.2 KG/CM²G OPEN OPEN

DAMPER POSITION AT 1.0 KG/CM²G CLOSE CLOSE

LIMIT SWITCHES (YES / NO) YES YES

17 TYPE OPEN & CLOSE INDICATION PROXIMITY TYPE OPEN & CLOSE INDICATION PROXIMITY TYPE

QUANTITY TWO TWO

ELECTRICAL SUPPLY SPECIFICATION 24V DC(IS) FOR SOV ; 24V DC(IS) FOR LIMIT SWITCHES 24V DC(IS) FOR SOV ; 24V DC(IS) FOR LIMIT SWITCHES

18 SOLENOID VALVE (YES / NO) YES YES

19 ELECTRICAL AREA CLASSIFICATION AS SPECIFIED ELSEWHERE AS SPECIFIED ELSEWHERE

20 FAIL SAFE POSITION LOCK AT LAST POSITION LOCK

(TENDENCY TO OPEN) (NOTE-10)

21 INTERLOCK ACTUATION POSITION OPEN OPEN / CLOSE

22 NOTES :-

1. Control dampers GHV-7201,7204 & 7205 shall be sized to utilize maximum allowable pressure drop, as specified,

for proper controllability of the damper. It is required that normal load leads to 50-70 % opening of damper.

2. All dampers shall be provided with external position indicator which shall be visible while operating winch & cable arrangement.

3. Arrangment shall be provided to delink the the pneumatic actuator / power cylinder and operate the damper manualyy with winch & cable arrangement

from grade / nearest operating platform for dampers GHV-7202,7203,7204,7205,7206,7207 and from grade for damper GHV-7201.

4. Damper shall have auto manual control via limit switches.Damper GHV-7201 shall be controlled via 1.Manual control from DCS 2.Manual control through local panel

5. Dampers GHV-7201,7202,7203, 7204,7205,7206 shall attain fail safe position, as specified in event of instrument air failure/electrical supply.

6. Instrument air pressure given is at battery limit. Adequate pressure loss across FR, tubing, solenoid valve, pilot valve, lock valve, speed regulation etc.

where ever applicable, to be considered for designing power cylinder. During Startup instrument air pressure at B/L shall be 5.0 / 6.0 / 6.5 KG/CM2G (MIN./NOR./MAX.)

7. Cylinder body is to be designed for a mechanical design pressure of 11.5 Kg/cm2g @ 65 deg C.

'*' indicates vendor to furnish / confirm.

'8. Vendor to ensure smooth operation of dampers and furnish control scheme for dampers GHV-7201/ 7204,7205,7206.

Vendor control scheme must ensure the safe position and interlock actuation position of the damper.

9 All damper operating components shall be replaceable without removing the damper from the duct.

10 Counter weights to be provided to enable gradual opening of dampers in case of signal / instrument air failure or interlock actuation.

For GHV-7201, vendor shall furnish damper caharecterstics curve showing flow rate Vs pressure drops for different % openings (i.e. 0 to 100 %).


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CLIENT : BPCL LOCATION : MUMBAI, INDIA

NO DAMPER NO GHV-7204 GHV-7205

1 SERVICE AIR INLET TO GLASS APH APH BYPASS DAMPER


3 LOCATION ENTRY DUCT TO GLASS APH AIR SIDE BYPASS DUCT

4 FUNCTION (ISOLATION/ CONTROL) ISOLATION & CONTROL ISOLATION & CONTROL

NORMAL POSITION FOR ISOLATION DAMPER - -


6 LINING DETAILS MATERIAL AS PER MECHANICAL GAD AS PER MECHANICAL GAD

THICKNESS AS PER MECHANICAL GAD AS PER MECHANICAL GAD

CLOSED FUNCTION

UPSTREAM MEDIUM AIR AIR



7 PRESSURE (MMWC) (+) 140 (+) 322

DOWNSTREAM MEDIUM AIR AIR


TEMPERATURE (ºC) ATM 308




OPEN CONDITION

MEDIUM AIR AIR


FLOW RATE (KG/HR) 24460 4180 24460

9 TEMPERATURE (ºC ) 55 55 55

UPSTREAM PRESSURE (MMWC) (+) 322 (+) 168

PRESSURE DROP (MMWC) 5 * 25

DENSITY (KG/M³) 1.07 1.07 1.07



Page 4 of 6

DAMPER NO. GHV-7204 GHV-7205


DESIGN PRESSURE (MMWC) (+) 600 (+) 600




14 SUGGESTED MINIMUM MATERIAL BLADE CS SS 304



15 TYPE MANUAL- HIC OPERATED MANUAL- HIC OPERATED







LIMIT SWITCHES (YES / NO) NO NO

17 TYPE

QUANTITY


18 SOLENOID VALVE (YES / NO)


20 FAIL SAFE POSITION LOCK AT LAST POSITION LOCK AT LAST POSITION

(TENDENCY TO OPEN) (NOTE-10) (TENDENCY TO OPEN) (NOTE-10)

21 INTERLOCK ACTUATION POSITION

22 NOTES :-



Page 5 of 6




1 SERVICE HOT AIR OUTLET OF CAST APH ID FAN SUCTION DAMPER

2 TYPE (MULTIPLE / SINGLE LEAF) * MULTIPLE

3 LOCATION HOT AIR DUCT FROM CAST APH ID FAN INLET

4 FUNCTION (ISOLATION/ CONTROL) ISOLATION ISOLATION

NORMAL POSITION FOR ISOLATION DAMPER OPEN OPEN




CLOSED FUNCTION

UPSTREAM MEDIUM AIR FLUE GAS


TEMPERATURE (ºC) ATM ATM

7 PRESSURE (MMWC) ATM ATM

DOWNSTREAM MEDIUM AIR FLUE GAS



PRESSURE (MMWC) (+) 143 ATM



OPEN CONDITION

MEDIUM AIR FLUE GAS


FLOW RATE (KG/HR) 24460 27940

9 TEMPERATURE (ºC ) 308 146

UPSTREAM PRESSURE (MMWC) (+) 225 (-) 210

PRESSURE DROP (MMWC) 2 3 (MAX)

DENSITY (KG/M³) 0.6 0.84


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DESIGN PRESSURE (MMWC) (+) 600 (-) 300 TO (+) 25


12 FLANGE TO FLANGE DIMENSION (MM) 300 REFER GAD

13 MAXIMUM TIME TO OPEN / CLOSE (SEC) - 10



ACTUATOR (FOR CONTROL) MANUAL PNEUMATIC POWER CYLINDER

15 TYPE - AUTOMATIC / MANUAL

INSTRUMENT AIR SUPPLY PRESSURE - 5.0/ 6.0/ 6.5

(MIN / NOR. / MAX) (KG/CM²G) - (NOTE-6)

POSITIONER (YES / NO) NO YES

16 SIGNAL PRESSURE (KG/CM²G) - 0.2 TO 1.0

DAMPER POSITION AT 0.2 KG/CM²G - OPEN

DAMPER POSITION AT 1.0 KG/CM²G - CLOSE


17 TYPE

QUANTITY

ELECTRICAL SUPPLY SPECIFICATION 24V DC(IS) FOR SOV ; 24V DC(IS) FOR LIMIT SWITCHES

18 SOLENOID VALVE (YES / NO) NO

19 ELECTRICAL AREA CLASSIFICATION AS SPECIFIED ELSEWHERE

20 FAIL SAFE POSITION LOCK

21 INTERLOCK ACTUATION POSITION CLOSE

22 NOTES :-


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UNIT : GTU HEATER NO : 160-F-0002 A/B



1 SERVICE MAIN STACK DAMPER HOT FLUE GAS DAMPER (0002A)


3 LOCATION STACK TOP OF CONV. OF HTR. 0002A






CLOSED FUNCTION

UPSTREAM MEDIUM FLUE GAS FLUE GAS



7 PRESSURE (MMWC) (-) 10.0 ATM

DOWNSTREAM MEDIUM FLUE GAS FLUE GAS



PRESSURE (MMWC) ATM (-) 8.0



OPEN CONDITION

MEDIUM FLUE GAS FLUE GAS


FLOW RATE (KG/HR) 5300 22500 27000 540 4500 5400

9 TEMPERATURE (ºC ) ~350 ~360 368 ~350 ~360 380

UPSTREAM PRESSURE (MMWC) (-) 8.0 (-) 9.0 (-) 10.0 (-) 8.0 (-) 8.0 (-) 7.0

PRESSURE DROP (MMWC) * * 3.0 * * 3.0

DENSITY (KG/M³) 0.54 0.55 0.55 0.54 0.55 0.54

1 20.09.2017 REVISED AS MARKED RM SS SS

0 23.06.2017 ISSUED FOR ENGINEERING RM SS SS

NO DATE DESCRIPTION BY CHK APPD



Page 2 of 10



DESIGN PRESSURE (MMWC) (-) 50 TO (+) 25 (-) 50 TO (+) 25







15 TYPE AUTOMATIC / MANUAL (NOTE-3) AUTOMATIC / MANUAL (NOTE-3)









QUANTITY TWO TWO






21 INTERLOCK ACTUATION POSITION OPEN OPEN

22 NOTES :-

1. Control dampers GHV-7101/7102 /7103 & 7107 shall be sized to utilize maximum allowable pressure drop, as specified,

in point 9, for proper controllability of the damper. It is required that normal load leads to 50-70 % opening of damper.

2. All dampers shall be provided with external position indicator which shall be visible while operating winch & cable arrangement.

3. Arrangment shall be provided to delink the the pneumatic actuator / power cylinder and operate the damper manualyy with winch & cable arrangement

from grade / nearest operating platform for dampers GHV-7106/ 7107/ 7108/ 7109/ 7110/ 7111/ 7104/ 7105 and from grade for dampers GHV-7101/ 7102/ 7103.

4. Damper shall have auto manual control via limit switches.Damper GHV-7101/ 7102/ 7103 shall be controlled via 1.Manual control from DCS 2.Manual control through local panel

5. Dampers GHV-7101/ 7102/ 7103/ 7104/ 7105/ 7106/ 7107/ 7109/ 7110/ 7111 shall attain fail safe position, as specified in event of instrument air failure/electrical supply.

6. Instrument air pressure given is at battery limit. Adequate pressure loss across FR, tubing, solenoid valve, pilot valve, lock valve, speed regulation etc.

where ever applicable, to be considered for designing power cylinder. During Startup instrument air pressure at B/L shall be 5.0 / 6.0 / 6.5 KG/CM2G (MIN./NOR./MAX.)

7. Cylinder body is to be designed for a mechanical design pressure of 11.5 Kg/cm2g @ 65 deg C.

'*' indicates vendor to furnish / confirm.

'8. Vendor to ensure smooth operation of dampers and furnish control scheme for dampers GHV-7101/ 7102/ 7103/ 7104/ 7105/ 7106/ 7107/ 7109/7110/ 7111.

Vendor control scheme must ensure the safe position and interlock actuation position of the damper.

9 All damper operating components shall be replaceable without removing the damper from the duct.

10 Counter weights to be provided to enable gradual opening of dampers in case of signal / instrument air failure or interlock actuation.

For GHV-7101/ 7102/ 7103, vendor shall furnish damper caharecterstics curve showing flow rate Vs pressure drops for different % openings (i.e. 0 to 100 %).


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NO DAMPER NO GHV-7103 GHV-7104/ 7105

1 SERVICE HOT FLUE GAS DAMPER (0002B) COLD AIR FROM FD FANS


3 LOCATION TOP OF CONV. OF HTR. 0002B FD FAN DISCHARGE DUCT

4 FUNCTION (ISOLATION/ CONTROL) ISOLATION & CONTROL ISOLATION



6 LINING DETAILS MATERIAL AS PER MECHANICAL GAD NONE

THICKNESS AS PER MECHANICAL GAD -

CLOSED FUNCTION

UPSTREAM MEDIUM FLUE GAS AIR



7 PRESSURE (MMWC) ATM ATM

DOWNSTREAM MEDIUM FLUE GAS AIR



PRESSURE (MMWC) (-) 8.0 (+) 430



OPEN CONDITION

MEDIUM FLUE GAS AIR


FLOW RATE (KG/HR) 5400 18000 21600 3700 18700

9 TEMPERATURE (ºC ) ~350 ~360 365 12 40

UPSTREAM PRESSURE (MMWC) (-) 7.0 (-) 7.0 (-) 7.0 (+) 13 (+) 430

PRESSURE DROP (MMWC) * * 3.0 * 5

DENSITY (KG/M³) 0.54 0.55 0.55 1.23 1.12


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DAMPER NO. GHV-7103 GHV- 7014/ 7105


DESIGN PRESSURE (MMWC) (-) 50 TO (+) 25 (+) 600




14 SUGGESTED MINIMUM MATERIAL BLADE SS 304 CS



15 TYPE AUTOMATIC / MANUAL (NOTE-3) MANUAL THROUGH HIC









QUANTITY TWO TWO






21 INTERLOCK ACTUATION POSITION OPEN OPEN/ CLOSE

22 NOTES :-


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1 SERVICE AIR INLET TO GLASS APH APH BYPASS DAMPER


3 LOCATION ENTRY DUCT TO GLASS APH AIR SIDE BYPASS DUCT






CLOSED FUNCTION




7 PRESSURE (MMWC) (+) 165 (+) 380



TEMPERATURE (ºC) ATM 344.2




OPEN CONDITION

MEDIUM AIR AIR


FLOW RATE (KG/HR) 21400 4180 21360

9 TEMPERATURE (ºC ) 55 55 55



DENSITY (KG/M³) 1.07 1.07 1.07



Page 6 of 10







14 SUGGESTED MINIMUM MATERIAL BLADE CS SS 304



15 TYPE MANUAL- HIC OPERATED MANUAL- HIC OPERATED








17 TYPE

QUANTITY







22 NOTES :-



Page 7 of 10




1 SERVICE HOT AIR OUTLET OF CAST APH HOT AIR TO INDIVIDUAL HEATER

2 TYPE (MULTIPLE / SINGLE LEAF) * MULTIPLE

3 LOCATION HOT AIR DUCT FROM CAST APH HOT AIR TO F-0002A

4 FUNCTION (ISOLATION/ CONTROL) ISOLATION CONTROL

NORMAL POSITION FOR ISOLATION DAMPER OPEN -




CLOSED FUNCTION



TEMPERATURE (ºC) ATM 55

7 PRESSURE (MMWC) ATM (+) 100




PRESSURE (MMWC) (+) 140 ATM

8 MINIMUM TIGHTNESS AGAINST 99.5 BEST ACHIEVABLE

LEAKAGE (BASED ON FLOW) (%) (ON MAXIMUM FLOW)

OPEN CONDITION

MEDIUM AIR AIR


FLOW RATE (KG/HR) 21400 430 4280

9 TEMPERATURE (ºC ) 344.2 55 344.2



DENSITY (KG/M³) 0.57 1.07 0.57



Page 8 of 10






13 MAXIMUM TIME TO OPEN / CLOSE (SEC) - 10



ACTUATOR (FOR CONTROL) MANUAL PNEUMATIC POWER CYLINDER

15 TYPE - AUTOMATIC/ MANUAL

INSTRUMENT AIR SUPPLY PRESSURE - 5.0/ 6.0/ 6.5

(MIN / NOR. / MAX) (KG/CM²G) - (NOTE-6)

POSITIONER (YES / NO) NO YES

16 SIGNAL PRESSURE (KG/CM²G) - 0.2 TO 1.0

DAMPER POSITION AT 0.2 KG/CM²G - OPEN

DAMPER POSITION AT 1.0 KG/CM²G - CLOSE


17 TYPE

QUANTITY

ELECTRICAL SUPPLY SPECIFICATION 24V DC(IS) FOR SOV ; 24V DC(IS) FOR LIMIT SWITCHES

18 SOLENOID VALVE (YES / NO) NO

19 ELECTRICAL AREA CLASSIFICATION AS SPECIFIED ELSEWHERE

20 FAIL SAFE POSITION LOCK AT LAST POSITION



22 NOTES :-



Page 9 of 10




1 SERVICE HOT AIR TO INDIVIDUAL HEATER ID FAN INLET DAMPER


3 LOCATION HOT AIR TO F-0002B INLET OF ID FAN

4 FUNCTION (ISOLATION/ CONTROL) CONTROL ISOLATION





CLOSED FUNCTION

UPSTREAM MEDIUM AIR FLUE GAS

UPSTREAM CONDITION MIN NOR MAX MAX


7 PRESSURE (MMWC) (+) 100 ATM


DOWNSTREAM CONDITION MIN NOR MAX MAX


PRESSURE (MMWC) ATM ATM

8 MINIMUM TIGHTNESS AGAINST BEST ACHIEVABLE 99.5

LEAKAGE (BASED ON FLOW) (%) (ON MAXIMUM FLOW)

OPEN CONDITION

MEDIUM AIR FLUE GAS

MIN NOR MAX MAX

FLOW RATE (KG/HR) 4460 17125 24450

9 TEMPERATURE (ºC ) 55 344.2 146

UPSTREAM PRESSURE (MMWC) (+) 165 (-) 190

PRESSURE DROP (MMWC) * 5 3 (MAX)

DENSITY (KG/M³) 1.07 0.57 0.84


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DESIGN PRESSURE (MMWC) (+) 600 (-)300 TO (+)25


12 FLANGE TO FLANGE DIMENSION (MM) 300 REFER GAD





15 TYPE AUTOMATIC/ MANUAL MANUAL-HIC OPERATED








17 TYPE

QUANTITY






21 INTERLOCK ACTUATION POSITION CLOSE

22 NOTES :-


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■31 ENGINEERS QUI taffl-eg w INDIA LIMITED

IA Govl of Intha Undertakm9) 1.17,1

STANDARD SPECIFICATION FOR INDUCED DRAFT/ FORCED DRAFT FANS

STANDARD SPECIFICATION No.

6-42-0003 Rev. 3 Page 1 of 23

rsv-s (91 1.

STANDARD SPECIFICATION FOR INDUCED DRAFT/FORCED DRAFT

FANS

3 28.11.13 Revised & Issued as Standard Specification MG "' NK DB SC

2 13.05.08 Reaffirmed & Issued as Standard Specification JSD NK VKM VC

1 01.09.03 Revised & Issued as Standard Specification NK KDS RK SKG

0 17.03.98 Issued as Standard Specification PS KDS SKG AS

Standards Standards

Rev. No

Date Purpose Prepared

by Checked

by

Committee Convenor

Bureau Chairman

Approved by

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

■.12'n

ENGINEERS INDIA LIMITED

In Go. of Ind. Underlakingf



6-42-0003 Rev. 3 Page 2 of 23

Abbreviations: AMCA Air Movement & Control Association

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASTM American Society for Testing and Materials

BIS Bureau of Indian Standards

BS British Standards

DCI Document Control Index

DCS Distributed Control System

EQC Equipment Qualification Criteria

FD Forced Draft ID Induced Draft ISA Instruments Society of America

ISO International Organization for Standardization

LCP Local Control Panel LGB Local Gauge Board

MCR Maximum Continuous Rating

NACE National Association of Corrosion Engineers

P&ID Piping and Instrumentation Diagram

PTC Power Test Codes

PTR Proven Track Record

VDOCS Vendor Data Requirements

VFD Variable Frequency Drive

EDMS Electronic Document Management System

Rotating Equipment Standards Committee Convenor: Mr Dinesh Bhatia

Members: Mr Nalin Kumar Mr Tarun Kumar Mr Anukul Mandal Mr Rakesh Misra Mr JS Duggal Mr KVK Naidu (Projects)


ENGINEERS fs~rr farZ5 INDIA LIMITED

IA Govt of Intlla UndertaMing)



6-42-0003 Rev. 3 Page 3 of 23

1~1 F22,12,1,1,1,1.«)

Contents

General Page No.

4 1.1 Scope 4 1.2 Alternative designs 5 1.3 Conflicting requirements 5 1.4 Referenced publications 5 1.5 Equipment qualification criteria .5

Amendments to ANNEX E of API standard 560 E. 1 Definition of terms 7 E.2 General 7 E.2.2 Fan housing 9 E. 2.3 Fan housing connection 9 E.2.5 Rotating elements 9 E.2.6 Shaft sealing of fans 10 E.2.7 Critical speeds/resonance 10 E.2.8 Vibration and balancing 10 E.2.9 Bearings and bearing housings 10 E.2.1 0 Lubrication 10 E.2.11 Materials 10 E.3.2 Accessories 11 E.3.2 Drivers I 1 E.3.3 Couplings and guards 11 E.3.4 Controls and instrumentation 12 E.3.4.3 Dampers or variable inlet vanes 12 E.3.5 Piping and appurtenances 12 E.3.6 Coatings, insulation and jacketting 12 E.4 Inspection and testing 13 E.4.3 Preparation for shipment 14 E.5 Vendor data 14

Appendix A - Fluid coupling 21

Format No. 8-00-0001-F1 Rev. 0

Copyright EIL All rights reserved


2,2,7 151,05717 fF Govt of india Undertaking)



6-42-0003 Rev. 3 Page 4 of 23

General

1.1 Scope

This specification together with the attendant data sheets and other specifications / attachments to the inquiry document defines the minimum requirements for the design, manufacture, inspection, testing and supply of Induced Draft (ID) and Forced Draft (FD) Fans and their auxiliaries, for use in refinery based furnace/heater installations and other process applications.

1.1.2 Vendor shall make all possible efforts to comply strictly to the requirements of this specification and other specifications/attachments to inquiry/order. 1n case deviations are considered essential by the vendor (after exhausting all possible efforts) these shall be separately listed in the vendor's proposal under separate section titled as "List of deviations/exceptions to the inquiry document". Deviation shall be listed separately for each document with cross-reference to Page No./Section/Clause No./Para etc. of the respective document supported with proper reasons for the deviation for purchaser's consideration. Any deviation not listed under the above section, even if reflected in any other portion of the proposal shall not be considered applicable. No deviation or exception shall be pennitted without the written approval of the purchaser.

1.1.3 Compliance with this specification shall not relieve the vendor of the responsibility of furnishing equipment and accessories/auxiliaries of proper design, materials and workmanship to meet the specified start up and operating conditions. In case the vendor considers requirement of additional instrumentation, controls, safety devices and any other accessories/auxiliaries essential for safe and satisfactory operation of the equipment, he shall recommend the same along with reasons in a separate section along with his proposal and include the same in his scope of supply.

1.1.4 Except as modified herein, the ID/FD Fans and their auxiliaries shall be designed, manufactured, tested and supplied strictly in accordance with the Annex E of API Standard 560, Fourth Edition, Aug 2007 "Fired Heaters for General Refinery Service."

1.1.5 Except for new paragraphs, the number and title of the paragraphs in the following Modifications to Annex E of API Standard 560correspond to the respective clauses and sub-clauses of the above standard. Clauses not addressed in this specification shall be strictly in accordance to Annex E of API Standard 560, Fourth Edition, Aug 2007 requirements.

The word in parenthesis following the number or title of a clause indicates the following: (Addition) • An addition to a clause or sub-clause referred to. (Modification) • An amplification or rewording has been made to a part of the

corresponding clause / sub-clause but not a substitution replacing the entire clause/ sub-clause.

(substitution) • A substitution has been made for the corresponding clause / sub-clause.

(New) • A new clause / sub-clause having no corresponding clause / sub-clause in the Standard.

(Delete) This clause / sub-clause is deleted.

1.2 Alternative designs The vendor shall not offer any alternative designs for proposal requirements.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved

ENGINEER.S

5giLIC INDIA LIMITED ■•ww-r, t-f,aadadvd,a)

IA Govt of India Undertaking)



6-42-0003 Rev. 3 Page 5 of 23

1.3 Conflicting requirements In case of conflict between this specification and the attendant data sheets, job specifications (if any) and other attached specifications the following order of precedence shall govern: 1. Equipment Data Sheets. 2. Job Specifications (if any) 3. P&ID's (if any) 4. This specification 5. Other specifications 6. Other referred codes and standards

1.4 Referenced publications Unless otherwise specified, the editions of the following standards, codes and specifications that are in effect at the time of issue of this specification shall, to the extent specified herein form a part of this specification.

AMCA Air Movement and Control Association Std. 210 - Laboratory Methods of Testing Fans for Rating Purposes Std. 801 - Industrial Process / Power Generation Fans — Specification

Guidelines Std. 802 - Industrial Process / Power Generation Fans — Establishing

Performance using Laboratory Models Std. 803 Industrial Process / Power Generation Fans — Site Performance Test

Standard

API American Petroleum Institute Std. 677 - General Purpose Gear Units for Petroleum, Chemical, and Gas

Industry Services

ASME The American Society of Mechanical Engineering PTC-11

-

Large Industrial fans.

BSI British Standards Institution BS:848

-

Fans for general purpose Part-1 Methods for testing performance

BIS Bureau of Indian Standards IS:4894

-

Specification for Centrifugal Fans

ISO International Organisation for Standardisation ISO:1940 - Balancing qualities of Rotating rigid bodies.

NACE National Association of Corrosion Engineers Std. MR0103 Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum

Refining Environments

1.5 EQUIPMENT QUALIFICATION CRITERIA

1.5.1 Unless otherwise specified elsewhere, the Equipment Qualification Criteria (EQC) specified vide para 1.5.2 to 1.5.3 of this specification shall be applied for acceptance of the offered Fan model and its manufacturer.

1.5.2 (a) The vendor shall be an established ID/FD Fan manufacturer having adequate design, engineering, manufacturing and testing facilities for fans and shall be the single point responsibility vendor for the complete fan package.


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(b) The vendor shall have designed, engineered, packaged, tested and supplied, in the last TEN (10) years, from the proposed manufacturing plant, at least ONE (1) ID/FD fan package which is from the same model series with similar type of drive arrangement* & type of driver having similar driver power. As a minimum, this package shall have completed ONE Year of satisfactory operation at site, as on the bid due date. (*.. dual drive, variable Irequeney drive, variable speed through fluid coupling etc.)

1.5.3 The ID/FD Fan model offered shall be from the existing regular manufacturing range of the vendor. The offered ID/FD Fan model shall meet the following minimum service and manufacturing experience requirements: ID/FD Fan proposed shall be identical in terms of model and similar in terms of power rating, flow rates, differential pressure, operating pressure & temperature, gas handled, speed range, type of drive, impeller diameter, type of impeller blades, mechanical design, materials, etc. as compared to at least ONE UNIT designed, manufactured, tested and supplied from the proposed manufacturing plant in the last TEN years and as a minimum this unit shall have completed ONE year of satisfactory operation at site, as on bid due date.

More than one past supply reference can be cited to meet the qualification requirement.

1.5.4 In case, the vendor is a licensee and does not meet on his own the above criteria as per 1.5.3, he can substitute the references of his Collaborator (licensor) provided the following conditions are met.

1.5.4.1 The vendor shall be regular & established manufacturer of ID/FD fans and shall have supplied smaller & larger sizes of ID/FD fans from the proposed manufacturing plant and proves to the satisfaction of the purchaser that he does possess the manufacturing & testing facilities for the offered ID/FD fan(s).

1.5.4.2 His Collaborator (licensor) meets the criteria as per 1.5.3.

1.5.4.3 His license agreement is valid and continues to remain valid till, at-least TWO years after the delivery of the ID/FD fans.

1.5.4.4 His Collaborator (licensor) furnishes a written back up guarantee regarding design, mechanical integrity and performance of the equipment equivalent to as if the equipment were manufactured & supplied by the Collaborator (licensor).

1.5.5 Proven Track Record

Vendor shall complete the Experience Record Proforma's enclosed with the inquiry document to amply prove that the offered ID/FD Fans meet the EQC for technical acceptance. Vendor may furnish additional information to justify that the EQC is being met. In addition, manufacturer's catalogue and general reference list for ID/FD Fans shall also be furnished along with the proposal.


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Amendments to Annex E of API standard 560

E.1 Definition of terms

E.1.4 (New) Unless otherwise specified, fan vendor shall certify & guarantee the performance of the fan at the rated point.

E.1.3 (Modification) Note-1 of this clause stands deleted.

E.1.15 (New) Witness Inspection and testing means that a hold shall be applied to the production schedule and the test carried out with the purchaser/purchaser's representative in attendance.

E.1.16 (New) Observed Inspection and testing means that the purchaser requires notification of the test timing. However, the test is performed as scheduled, and if the purchaser/purchaser's representative is not present the vendor can conduct the test without waiting for the purchaser/purchaser's representative.

E.2.1 General

E.2.1.1 (Addition) The vendor shall develop arrangement of the fan & driver equipment including ducting and auxiliaries in accordance with the purchaser's requirement particularly with regard to the orientation of inlet & outlet connections of the fan. The arrangement shall provide adequate clearance areas and safe access for operation, maintenance, and removal. The vendor shall also indicate recommended location of operating/maintenance platforms, around the fan-driver unit, if required.

E.2.1.4 (Substitution) Motors & instruments shall be as per the electrical & instrumentation specifications enclosed with inquiry / order.

E.2.1.5 (Modification) The last sentence of the paragraph shall be modified to read as under: If recommended by the vendor, the requirement of field dowelling (if required after final alignment) shall be indicated on the General Arrangement Drawing.

E.2.1.7 (Modification) The words "unless otherwise specified" stands deleted.

Fan design considerations

E.2.1.9 (Substitution) The rated speed of the Forced Draft/Induced Draft fan shall not exceed 1000 rpm unless otherwise approved by purchaser.

For fan selection, it should also be considered that -

Reduced speed is desirable for erosive service and for units subject to fouling deposit on the rotor;

E.2.1 .1 0 (Substitution) Unless otherwise specified in the data sheets, ID Fans arrangement and bearing support shall be as per AMCA 801:2001, Arrangement 3, i.e. Double Inlet Double Width(DIDW)



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with fan impeller located between bearings.

Unless otherwise specified in the data sheets, FD Fans arrangement and bearing support shall be as per AMCA 801:2001, Arrangement 7 design i.e. Single Inlet Single Width (SISW) with fan impeller located between bearings.

For the above required arrangements, the indicated alternate arrangement as per AMCA 801:2001 i.e. separate sole plate mounted motor and bearings can only be accepted after specific purchaser's approval.

The bearings shall be mounted independently of the fan housing on rigid pedestals and sole plates, and the bearings shall be protected from air or gas streams.

E.2.1 .1 0(b) (Modification) The words '1800 rpm' shall be replaced with the words '1000 rpm'.

E.2.1.11 (Modification) The word Turchaser' shall be replaced with the words 'Fan vendor' in the second sentence of the paragraph.

E.2.1 .12 (Substitution) The head-capacity characteristic of the Fan shall rise continuously from the maximum capacity to surge. The Fan shall, without the use of a bypass, be suitable for stable operation at all capacities higher than the surge capacity shown in the proposal. Unless other wise specified, fans shall have a continuously rising pressure characteristic (pressure versus flow rate plot) from the rated capacity to 60% or less of rated flow. Performance curves, corrected for the specified gas at the specified conditions, shall be based on performance tests in accordance with AMCA 210, including, where applicable, evase and inlet box(es). Application that include a variable-frequency drive (VFD) and/or a non-parabolic system resistance curve shall be reviewed in details to ensure stable operation of the fan over the intended operating range.

E.2.1 .1 5(b) (Modification) The height of inlet stack for the FD fan shall be as a minimum 6 meter above grade. In case a flow element (i.e. annubar, venturi etc.) is required, the inlet stack height shall be increased to accommodate the straight length required upstream & downstream of the proposed flow element to maintain the flow accuracies.

E.2.1.1 5(c) (Substitution) The FD fan-inlet equipment shall include intake cap or rain-hood, trash-screen(s), inlet filters (when specified), inlet stack / duct along with supports, inlet damper or guide vanes, inlet boxes, silencer, flexible connection(s) etc. as required.

The vendor shall also provide necessary brackets welded to the inlet stack, for mounting a platform(s) & access ladder(s) (both by purchaser) around the stack for maintenance of flow element.

The 1D fan-inlet equipment shall include inlet duct along with supports (when specified), inlet damper or guide vanes, inlet boxes, flexible connection(s), companion tlange(s) etc. as required.

All components that are shipped separately shall be flanged for assembly. The inlet equipment assembly shall be designed for the load(s) (i.e. wind, seismic, shear, over-turning moments etc.) indicated in the inquiry.


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E.2.1.16 (New) The fan outlet equipment shall include flexible connection(s), companion flange(s), outlet damper etc., as required. The type of outlet damper (i.e. slide gate type, multi-louver type, slide plate type etc.) shall be as specified in the inquiry.

E.2.1 .17 (New) When the gas handled contains matter that lends itself to accumulation on the internal parts of Fan or may cause wear, a provision shall be made for injecting one or more atomised sprays into the fan to prevent such effects. Unless otherwise specified, the cleaning system shall be designed for cleaning in stand-still condition. The medium for cleaning for FD fans shall be Water and for ID fans it shall be LP Steam. Elements of blade cleaning system inside the fan housing shall be made of corrosion resistant material and shall be adequately supported to resist damage due to vibration. The vendor shall include in his proposal the complete details of such arrangements, when offered.

E.2.1 .18 (New) Unless otherwise specified, the maximum permissible sound pressure Level of the train shall not exceed 88 dBA measured at 1 meter from equipment surface for the recommended range of operation.

E.2.2 Fan housing

E.2.2.1 (Addition) Unless otherwise specified, Corrosion Allowance (CA) shall be as under: (a) FD Fan: 3 mm (b) ID Fan: 3 mm

E.2.2.2 (Addition) If the fan housing/inlet box(es) size and construction does not permit such a size of access door, the casing shall be equipped with removable panels to allow for inspection and cleaning of impeller and casing internale.

E.2.3 Fan housing connection

E.2.3.1 (Substitution) Inlet and outlet nozzles shall terminate in duct-type flanges suitable for interconnection with the purchaser's system. The nozzle orientation shall be in accordance with the information on the data sheets / arrangement drawings. Facings of all connections shall be adequate to prevent leakage with proper gaskets and bolting.

E.2.3.2 (Substitution) Accessible drain connection of minimum 50 mm (2 inch) size with block valve and blind flange shall be provided at the lowest point of the casing and inlet box(es).

E.2.5 Rotating elements

E.2.5.1 (a) (Modification) Hollow airfoil construction shall be used only for FD fans.

E.2.5.1 (b) (Delete)

E.2.5.1 (c) (Modification) Single thickness having a non-airfoil shape, shall be us used only for ID Fans.

E.2.5.2 (Modification) The words `Blade design shall be specified by the Purchaser' stand deleted.



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E.2.5.5 (Modification) Un-keyed fits are not acceptable however flanged mounted impellers can be offered. Cast iron or Ductile iron hubs are not acceptable.

E.2.5.8 (Modification) The words `If specified by the purchaser. stand deleted.

E.2.5.9 (New) Fan manufacturer shall examine the need of providing a barring over mechanism. Where required, the same shall be included in vendor's scope of supply.

E.2.6 Shaft sealing of fans

E.2.6.3 (New) Unless otherwise specified, shaft seals shall be of asbestos free gland packing or labyrinth type.

E.2.6.4 (New) Shaft sleeve shall be of SS 316 in case of ID Fans.

E.2.7 Critical speeds/resonance

E.2.7.4 (Modification) The words "If specified" stand deleted from the first line.

E.2.7.7 (New) In case of fan trains incorporating gearbox and/or dual drive, vendor shall perform and fumish torsional vibration analysis for the complete train. No torsional natural frequency shall be within ±10 percent of any of the operating speed, including trip speed.

E.2.8 Vibration and balancing

E.2.8.3 (Modification) The words specified by Purchaser" stand deleted.

E.2.9 Bearings and Bearing housings

E.2.9.6 (Addition) Unless otherwise specified, bearing housings for ID fans shall be provided with water cooling as a standard feature.

E.2.9.8 (New) Bearing housings shall be provided with labyrinth type shaft seals to prevent oil leakage or contamination.

E.2.10 Lubrication

E.2.1 0.5 (New) The bearing housing shall be equipped with a reservoir of ample capacity, fitted with a sight glass and a constant oil level device.

E.2.11 Materials

E.2.1 1.1.2 (Substitution) The materials employed shall be selected with due regard to the gas handled, operating and design conditions and the site conditions. Materials exposed to 1-12S service shall comply with NACE MR 0175/NACE MR 0103 (as applicable).


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E.2.11.1.6 (New) Damper or variable guide vane operating mechanisms, linkages, and other external parts subject to rotary or sliding motions shall be corrosion resistant materials suitable for the site environment. Internal operating parts subject to rotary or sliding motions shall be stainless steel or other equally corrosion resistant material. Minor parts associated with such mechanisms (bolts, nuts, springs, washers, gaskets and keys) shall have equal corrosion resistance.

E.3.2 Accessories

E.3.2 Drivers

E.3.2.3 (Substitution) For FD fans, the motor rating shall also be adequate for operation of FD fans at the specified minimum ambient conditions at the rated speed in un-throttled conditions or the start-up conditions specified on data sheets.

E.3.2.4 (Substitution) For ID fans, the motor rating shall also be adequate for operation of ID fans at the specified minimum flue gas temperature at the rated speed in un-throttled conditions or the start-up conditions specified on data sheets.

E.3.2.7 (Substitution) Electric motor drivers shall have a maximum continuous rating (MCR) (i.e. service factor equal to 1) not lower than the following:

Fan Rated Power in KW Motor MCR (% of Fan Rated BKW) (Including gear & coupling losses) < 18.5 125% > 18.5 to<55 115% > 55 110%

Steam turbine driver rating shall be at-least 110% of the rated power required (including gear & coupling losses) for any of the specified operating conditions. As a minimum, steam turbine rating shall be equal to the selected motor rating.

E.3.2.10 (Delete)

E.3.2.1 1 Gear Box (New) Speed Increasers and Reducers shall be in accordance with API Std. 677 (up to 1500 kW). Beyond 1500 kW, Gear box shall be as per API 613.

E.3.2.12 Belt Drives (New) Belt drives shall not be used for ID Fans & FD Fans.

E.3.2.13 Variable Frequency Drives (New) Variable frequency drives (VFD) system shall be as per electrical specifications enclosed with the inquiry/order.

E.3.2.14 Hydraulic/Fluid Coupling (New) Refer Annexure A for complete details.

E.3.2.15 Tools (New) When tools and fixtures not commercially available are required to disassemble, assemble, or maintain the units, they shall be included in vendor's scope of supply and furnished as part of the initial supply of the fans.



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E.3.3 Couplings and guards

E.3.3.1 (Addition) Vendor shall provide alI metallic, dry, flexible type couplings with spacer. The coupling shall have a minimum service factor of 1.5 over driver rating.

E.3.3.4 (New) Couplings and shaft ends shall be straight bored and not tapered fit up to a driver rating of 1500 KW. Above 1500 KW, Coupling & shaft ends can be tapered fit in accordance with API Std. 671.

E.3.3.5 (New) All exposed rotating parts shall be enclosed in removable, weather proof, metallic guards of robust construction. The guards shall be made from non-sparking materials. Coupling guard shall be supported from the baseplate. The Coupling Guard shall be sufficiently rigid to withstand deflections as a result of bodily contact of nominally 100 kg.

E.3.4 Controls and instrumentation

E.3.4.1.3 General (New) Instrumentation and their installation shall conform to the purchaser's instrumentation specification referred in the inquiry document.

E.3.4.2.1 (Addition) The fan flow shall be controlled through variable IGV's, Inlet Dampers, speed variation through variable speed fluid coupling or variable speed driver as specified. In case variable speed coupling is specified as a means to vary operating speed of the fan, the vendor shall provide a fluid coupling and associated instrumentation and controls, which shall conform to the requirements as specified in the Appendix-A of this specification and shall be included in fan vendor's scope of supply.

E.3.4.3 Dampers

E.3.4.3.1 (Modification) Unless otherwise specified in damper specification enclosed with inquiry document. The damper shall have opposed blade construction in case of control dampers.

E.3.4.3.2 (Modification) The words specified" stand deleted.

E.3.4.3.6 (New) Outlet dampers and Flow control dampers, when provided, shall be capable of manual operation with a force not exceeding 10 kgf. When specified on the data sheets, dampers shall be equipped with actuators for remote operation. Damper panels shall be free from flutter and shall be mounted in a manner that they can under no circumstances enter the body of fan in the event of breakage.

E.3.4.3.7 (New) If the ID fan is equipped with an inlet box damper, it shall be ensured by the fan vendor that the inlet duct does not foul with each other and with either of the inlet box dampers & their actuators. The inlet box dampers shall be easily approachable by ensuring that their actuators are on the outer side of Y type transition piece.

E.3.5 Piping and appurtenances (New)

E.3.5.3 (New) The supporting structure for the suction stack and rain-hood of the FD Fan shall be


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engineered by the fan vendor and supplied by purchaser / heater contractor (as applicable).

E.3.5.4 Base Plate (New)

E.3.5.4.1 Vendor shall furnish a common baseplate for the motor, gear reducers, variable speed fluid coupling if any and the inboard bearing pedestals. Outboard Bearings shall be supported on rigid independent pedestal and soleplate, outside the fan housing. Also the fan and supporting structure for ducts shall be foundation mounted so as to be unaffected by vibration or by other forces from the fan.

E.3.5.4.2 Baseplates shall be of fabricated construction and provided with grouting holes. Anchor bolts shall be furnished along with the baseplate and outboard bearing pedestal. Baseplates shall be provided with levelling pads, levelling and alignment screws and lifting lugs.

E.3.5.5 Blanking Plates (New) In case, blanking plates at discharge of FD fans are required to be provided by the fan vendor, then fan vendor to note that installation/removability of the same shall be carried without disturbing the fan components. In addition the storage location on the fan body for blanking plates shall be shown in the FD fan general arrangement drawing.

E.3.5.6 Vibration Isolators (New) In case the ID/FD fans are mounted on furnace top as in case of cracker furnaces, vibration isolators along with any positive holding arrangement like bolts shall be provided for the mounting of the same.

E.3.6 Coatings, insulation and jacketting

E.3.6.2.1 (Modification) Substitute "70°C" in place of "83°C".

(Addition) The clips or studs shall be placed on 300 mm centers and drilled for holding wires for installation of insulation having a thickness of minimum 50 mm.

E3.6.2.2 (Modification) Substitute "70°C" in place of "83°C" and "Maximum ambient temperature" in place of "27 °C".

E.4 Inspection & testing

E.4.1.6 Mechanical Inspection

(a) (Modification) The words "If specified by the purchaser" stand deleted.

(c) (Modification) The words "If specified by the purchaser" stands deleted in case the process gas contains H2S.

E.4.2.1 (Modification) Delete the words "Many fan such a requirement" from the paragraph.

(Modification) The words 'five working days' shall be replaced by `thirty days (4 weeks)'.

E.4.2.2 (a) (Modification) The words `two hours' shall be replaced with `four hours'.



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E.4.2.4

E.4.2.4.1

E.4.2.4.2

E.4.2.5

E.4.2.5.1

(d) (Addition) Refer E.2.8.3 for allowable vibration limits. The rise in bearing oil temperature with continuous running of the fan shall be within the allowable limits, but shall not exceed 39°C above ambient.

Performance Test (New)

The vendor shall carry out performance test in his shop either as per AMCA Standard 210 or ASME PTC-11 or BS:848:Part-1 or IS:4894.

The measured performance of the fan shall fall within permissible tolerances of the quoted performance for guaranteed case. Permissible tolerances are: i) Capacity: No negative tolerance ii) Static Differential Pressure: No negative tolerance iii) Power absorbed: +0%

General (New)

The purchaser's inspector shall have access to the manufacturer's shop at all times during which work on the equipment is in progress. The vendor shall have the responsibility of providing the purchaser's inspector with all requisite facilities/equipment for carrying out satisfactory inspection.

E.4.2.5.2 The purchaser shall receive a written notice at least 30 days before the date of the equipment becoming ready for inspection and testing.

E.4.2.5.3 Witness Testing by purchaser's/purchaser's representative's participation in the testing shall be as specified on the data sheet.

E.4.2.5.4 The purchaser/purchaser's representative shall have access to the vendor's Quality Control Program for review.

E.4.2.5.5 Vendor shall furnish the following data for examination by the purchaser/purchaser's representative during Shop Inspection and Testing. i) All necessary material test certificates. ii) Running Test Data to verify that the requirements of the specification are being met. iii) Quality Assurance Records.

E.4.2.5.6 All coating/painting of surfaces shall be deferred until the specified inspection of that part is completed.

E.4.2.5.7 All dimensions shall fall within the tolerances shown on the approved drawings. In the absence of approved tolerances, the manufacturer's standard shall apply.

E.4.2.5.8 Acceptance of shop test does not constitute a waiver of requirements to supply equipment as per order and to meet field performance ander specified operating conditions nor does purchaser's shop inspection relieve the vendor from his responsibilities.

E.4.2.5.9 Steam turbine driven fans can be tested using the manufacturer's shop driver. Relevant data of the shop driver, including efficiency and power factor for various loads, shall be made available.

E.4.3 Preparation for shipment

E.4.3.1 (Modification) Unless otherwise specified, the equipment shall be protected for a storage period of 12 months at site. If any extra precaution is to be taken by the Purchaser for storage beyond


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12 months the same shall be explicitly indicated in the operation and maintenance manuals.

E.4.3.3 (New) The vendor shall, upon completion of inspection and tests, apply at least one coat of a primer on all un-machined surfaces. Exposed machined surfaces and the interior of the fan shall be sprayed with a suitable rust inhibitor.

E.4.3.4 (New) All untapped openings shall be provided with 4 mm thick metal closures with full rubber gaskets and bolted with not less than 4 bolts. Tapped openings, not otherwise closed, shall be plugged.

E.4.3.5 (New) The equipment shall be suitably packed, fastened to avoid damage during transit and crated for shipment. Lifting, unpacking and handling instructions shall be securely attached to the exterior of the largest packing in a well marked weather proof container. The upright position, lifting points, gross weight and dimensions shall be clearly marked on each package. Each package shall properly identify the equipment contained therein.

E.5 Vendor's data (Substitution) The entire clause is substituted by the following text.

E.5.1 Proposals The vendor's proposals shall as a minimum include the following: a) All data sheets, drawings and documents listed under "PRINTS WITH QUOTE" in

the enclosed Vendor Data Requirement Form. b) List of recommended commissioning spares included in the offer. c) List of mandatory spares (where specified by the purchaser) included in the offer. d) List of Vendor's Standard Spare Parts For Two Years Normal Operation

This list shall be made separately for each items including auxiliaries and drivers in the form of a table & shall show : i) Part name, description and number. ii) Quantity installed in one unit. iii) Quantity recommended per unit for 2 years normal operation. iv) Quantity recommended for number of units of an item as specified in the

inquiry. v) Quantity recommended as insurance for the number of units of an item

specified in the inquiry. e) An itemised list of special tools included in the offer. f) Any start-up, shutdown or operating restrictions required to protect the integrity of the

equipment. g) Any limitations of vendor's test-facility to carryout the specified tests. h) A specific compliance statement that the scope of supply, the offered

equipment/systems and all its components are in strict accordance with the data sheets, job specifications, this specifications and all other attachments, except for specific deviations as listed in the proposal.

E.5.2 Contract Data

E.5.2.1 General

E.5.2.1.1 Drawings and data as required after purchase order has been specified in Vendor Data Requirement. Vendor to note that the drawing/document descriptions/titles as given in the Vendor Data Requirement are generic in nature. It is possible that against one drawing/document specified there are several drawings to be furnished by the vendor or



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E.5.2.1.2

vice versa. Vendor shall complete & forward a document "Vendor Data Index & Schedule", Document Control Index (DCI) to the purchaser (Destination & contact person as per order). This document shall list out in consolidated form all drawings and documents required by purchaser (As specified in Data Sheets, Specifications and Vendor Data Requirement forms enclosed with the order). Against each drawing/document vendor shall indicate the vendor's drawing numbers, titles, Rev. No., category (whether for information or approval) and schedule of submission.

This shall be the first document to be submitted by vendor within two weeks of order. No drawing shall be taken up for review till DCI for the inquiry/order is finalized by vendor.

A11 transmittal letters (covers), drawings and data shall have a title block (in addition to vendor's standard title block) which shall as a minimum contain the following contract information:

i) Purchaser's and Consultant's Corporate Name ii) Project Name. iii) Equipment Name and Item No. iv) Purchase Order No. v) Purchase Requisition No.

Title Block on drawings shall be placed on the lower right hand corner.

E.5.2.1.3 A1l vendor data/drawings/documents shall be in English Language and in Metric Systems.

E.5.2.1.4 Data specified in the VDR is the minimum requirements of Purchaser. Any additional document/data required or requested by Purchaser for engineering or construction shall also be made available by the vendor.

E.5.2.1.5 Whether or not specified the vendor shall furnish the following, before shipment: - As built running clearances and when applicable; thrust bearing, radial bearing and

seal running clearances. - A supplementary list of spare parts other than those included in his original

proposal. The supplementary list shall include recommended spare parts, cross-sectional or assembly type drawings, parts numbers, materials, prices and delivery period. The vendor shall forward this supplementary list to the purchaser promptly after receipt of the reviewed drawings and in time to permit order and delivery of parts before field start-up.

- A parts list for all equipment supplied. The list shall include pattem, stock, or production drawing numbers and materials of construction. The list shall completely identify each part so that the purchaser may determine the interchangability of the parts with other equipment furnished by the same manufacturer. Standard purchased items shall be identified by the original manufacturer's name and part number.

- At least 8 weeks before shipment, the vendor shall submit his preservation, packaging and shipping procedures to the purchaser's for his review.

E.5.2.3 Co-ordination Meeting When specified, a co-ordination meeting shall be field at Purchaser's office, preferably within 4 weeks of order. An agenda shall be prepared for this meeting and would include the following points related to technical aspects.

a. Any clarifications required by the vendor on purchaser's order. b. Vendor Data Index & Schedule. c. Vendor Data Review/approval modalities. d. Sub-vendor lists proposed by vendor. e. Utility requirements.


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f. Preliminary General Arrangement & layout drawings & purchaser's interface drawings.

E.5.2.4 Drawings

E.5.2.4.1

E.5.2.4.2

E.5.2.4.3

E.5.2.4.4

The number of prints and/or reproducible required and the times within which these are to be submitted by vendor are specified in Purchaser's inquiry/order. Drawing review shall be through EDMSNDOCS in soft, as per the details provided elsewhere in inquiry document.

The purchaser's review of the vendor's drawings shall not constitute permission to deviate from any requirements in the purchase order/specifications unless specifically agreed upon in writing. After the drawings have been reviewed, the vendor shall furnish certified copies in the quantity specified. All drawings shall preferably be in A4 or A3 size. All drawings must be clearly legible and shall be folded to 216 mm x 279 mm size.

General Arrangement Drawing A general arrangement drawing shall contain as a minimum the following information:

i) Outline dimensions (minimum three views) (All principal dimensions). ii) Allowable forces and moments on suction and discharge nozzles. iii) Location (in all three planes), size, type, rating and identification of all

purchaser's interface connections including those of vents, drains lubricating oil, sealing fluid, cooling water, steam & Electrical/Instrumentation.

iv) Direction of rotation viewing from the driving end. v) Weight of each assembly/component. vi) Weight & location of centre of gravity of the heaviest assembly/components

that must be handled for erection. vii) Identification and weight, dimensions of the heaviest assembly / subassembly /

component required to be handled for maintenance. viii) Maintenance clearances and dismantling clearances including clearances

required for removal/installation of rotor. ix) Speeds of Driven Equipment and driver and driver rating. Location of driver

terminal box (in case of Electric Driver) x) Layout of auxiliary equipment and operating platform. xi) Make, Type and Size of couplings and the location of guards and their

coverage. xii) A list of reference drawings if any. xiii) A list of any special weather-protection and climatic features.

Foundation Drawings A foundation drawing shall indicate complete information required for foundation design by purchaser including the following: i) Foundation bolt sizes & pipe sleeve details and pocket sizes & locations. ii) Grouting thickness and other necessary technical details. iii) Static weight of each independently grouted item (such as fan, fluid coupling,

gear-box, driver, change-over clutches, control panel etc.) and location of centre of gravity of each of such items in all three planes.

iv) Weight distribution for each bolt/subsole-plate location and total static weight. v) Dynamic loads, if any, caused due to various items grouted independently. (The

cause of generation of such loads shall also be indicated). vi) The direction and magnitude of unbalance forces and moments (with their phase

angles) generated by the out of balance of the rotating / moving parts of the machine at the relevant operating conditions. [These loads and their locations are to be given in all three planes. These shall be utilised for computing the amplitudes of vibration of the foundation].

vii) GD2 value of each item resolved to driver speed.



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viii) Maximum permissible amplitude of vibration on the foundation at the base level. (The location of the points on the foundation base where such amplitudes are not to be exceeded shall be given in all three planes). The reference of relevant code, if any, shall also be indicated.

ix) Total mass of rotating parts. x) Suggested dynamic factor and ratio of weight of foundation to weight of

machine. xi) Short circuit loads caused in motor drivers. xii) Operating speed of the machine and the driver. xiii) Scope of Supply of the Foundation Bolts (unless otherwise specified, by

vendor). xiv) Maximum permissible magnitude of the unbalance forces and moments

generated by the out of balance of the rotating / moving parts of the machine as allowed by the relevant codes, if any. (The reference of such code, if any, shall also be indicated).

xv) Recommended separation margin (if any), between the machine operating speeds and the natural frequencies of the machine foundation system along with the basis of such recommended separation margins.

[Note: Unless otherwise indicated by vendor, the dynamic forces as given in v) & xi) above are considered as additional static loads for designing the foundations statically. Such dynamic forces are not unbalance forces and therefore, these shall not be utilised for computing the amplitudes of vibration.]

E.5.2.4.5

E.5.2.4.6

E,.5.2.4.7

Layout Drawing (For multi-skid packages) This drawing shall contain as a minimum the following information: i) Layout of all skid/equipment and their auxiliaries, vessels, control panels,

exchangers etc. Vendor shall furnish an optimised layout (considering the space allocated, site wind conditions, area classification, the type of equipment located in the vicinity etc.) indicating elevation and dimension of skids/equipment.

ii) Minimum spacing required between the various skids/equipment and between the skids and the walls/columns/roof for an easy accessibility and maintenance.

iii) Layout for water piping, trenches for water piping, cable tray/trenches layout. iv) Piping arrangement and piping support arrangement/location for piping in

vendor's scope. v) Layout for auxiliary equipment and operating platform details. vi) Specification for crane/mono rail (including suggested mono rail layout)

recommended for maintenance and height of the lifting hook from the centreline of equipment.

Field Alignment Diagram The diagram shall indicate the relative displacement to be kept between the centrelines of various equipments at the time of installation, so that ander normal running conditions the equipments get fully aligned. This relative displacement should be decided on the basis of centreline temperature rise data of driver, gear box/transmission system, driven equipment.

P&I Diagrams (with Bill of Materials) Vendor shall supply P&I Diagrams along with Bill of Materials of each system in the vendor's scope of supply or specified in the order. P&I Diagram shall indicate the system details, location of various auxiliaries, instruments, controls and safety devices as required. Line sizes, piping class, valve sizes and class shall be clearly marked on the P&ID. Vendor's scope and purchaser's scope shall be clearly demarcated. Each item shall be identified by an item No./item tag no., which shall correspond to the item no. shown on the bill of materials. The bill of materials shall include items number, normal value, set value, range, quantity per unit, make and other specifications as applicable. Legends adopted shall be indicated either at the bottom of

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved

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drawing or on a separate drawing. The legends shall be as per ISA.

E.5.2.4.8

E.5.2.4.9

Cross-sectional Drawing(with Bill of Materials) The vendor shall supply cross-sectional or assembly type drawings for all equipment furnished showing all parts, design assembly and running clearances, and balancing data required for erection and maintenance. Each part shall be numbered which shall correspond to the part number on the bill of materials. The bill of materials shall include the part no., name of component, materials quantity installed per unit & sizes where applicable (say for bolts, nuts, rings, gaskets etc.). A11 bought-out items shall also be indicated with make and brief specifications. A separate cross-sectional drawing showing installation and setting dimensions for the seals shall be furnished.

Installation Manual The vendor shall provide sufficient written instructions, including a cross-reference list of all drawings, to enable the purchaser to correctly install the equipment and prepare the equipment for start-up. It shall include any special information required for proper installation that is not on the drawings, special alignment or grouting procedures, utility specifications (including quantity) and all installation data. It shall also contain the following information: (a) Instructions for erecting, piping, aligning (including the expected thermally

induced shaft centreline shift between normal site ambient temperature position and that at normal equipment operating temperature).

(b) A description of rigging procedures, including the lifting of the assembled equipment, and methods of disassembly, repair, adjustment, inspection and reassembly of the equipment and auxiliaries.

(c) Pre-commissioning/commissioning/functional test procedures and acceptance criterion.

E.5.2.4.10 Operation and Maintenance Manual

This manual shall provide sufficient written instructions and data to enable purchaser to correctly operate and maintain the equipment ordered. It shall include a section to cover special instructions for operation at extreme environmental and/or extreme operating conditions. The following shall be included in this manual: (a) Instructions covering start-up, normal shutdown, emergency shutdown,

operating limits and routine operational procedures. (b) A description of equipment construction features and the functioning of

component parts or systems (such as control, lubrication, sealing systems etc.). (c) Outline and sectional drawings, schematics and illustrative sketches in

sufficient details to identify all parts and clearly show the operation of all equipment and components and the methods of inspection and repair. Standardised sectional drawings are acceptable only if they represent the actual construction of the equipment.

(d) The following maintenance information: i.

Maximum and minimum bearing, labyrinth and seal clearances including any other clearance between moving and stationary parts of the equipment affecting proper running and maintenance of the equipment.

ü.

Instructions for measuring and adjusting cold clearances, shaft run-out, concentricity etc. Rotor float allowance.

iv. Interference fits on parts that are required to be removed or replaced for maintenance of normally consumable spares.

v. Balancing tolerances. vi. Lubricating schedules indicating recommended grades of oil, their

properties, replacement period etc. vii. Normal maintenance procedure.



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viii. Preventive maintenance schedules and criterion for replacement of parts.

ix. Trouble - shooting procedures. (e) The following reassembly information:

i. Bolting sequence and torque values for all bolts affecting equipment performance/integrity/safety.

ii. Reassembly sequences together with required inspection checks. iii. Adjustment procedures to achieve required positions, clearances, float

and so forth. iv. Detailed procedures for pre-operational checks, including settings and

adjustments. v. Seals and coupling installation procedures. vi. Parts list indicating cross-sectional drawings of various assemblies and

sub-assemblies, part numbers, materials of construction etc. to facilitate identification of parts and for procurement of spares.

E.5.2.4.11 Performance Characteristic Curves

E.5.2.4.11.1 The vendor shall provide complete performance curves to encompass the map of operations, with any limitations indicated thereon.

E.5.2.4.1 1.2 All curves submitted prior to final performance testing shall be marked "PREDICTED". Any set of curves resulting from a test shall be marked "TESTED".

E.5.2.4.1 1.3 Certified test curves and data shall be submitted within 15 days after testing and shall include STATIC PRESSURE, power recalculated to the proper operating speed and efficiency plotted against capacity.

E.5.2.4.12 Data Sheet

E.5.2.4.12.1 The Vendor shall provide completely filled in data sheets, first for "AS PURCHASED" and then for "AS BUILT". This shall be done by the vendor correcting and filling out the data sheets and submitting copies to the purchaser.

E.5.2.4.1 3 Technical Data Manual/Mechanical Catalogue

E.5.2.4.13.1 Technical Data Manual/Mechanical catalogue is a compilation of "AS BU1LT" drawings and data, manufacturing and test records, installation, operating and maintenance instructions.

E.5.2.4.1 3.2 Not tater than two weeks after successful completion of all specified tests, the vendor shall furnish the required number of technical data manual/mechanical catalogues for the equipment, any auxiliaries and instruments that the vendor is providing. The technical data manual/mechanical catalogue shall include the following documents as a minimum: i) All drawings and data as listed in the vendor data index & schedule. (For

drawings, where purchaser's approval is required, the final certified drawings shall be attached.) Sections shall be organised in a manner that data & drawings related to one subject is grouped together such as Mechanical, Electrical, Instrumentation etc.

ii) All manufacturing, inspection and test data and records. iii) Following information shall also be included in the Technical Data

Manual/Mechanical Catalogue: 1. Storage instructions for storing and preserving the equipment (including

driver and all the auxiliary units) at the plant site before installation of the same.

2. Instructions for preserving the equipment after it has been installed. This is Format No. 8-00-0001-F1 Rev. 0


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particularly required in cases where a long time gap is expected between equipment installation and commissioning.

3. Field performance test procedures and acceptance criterion.

E.5.2.4.13.3

Technical Data Manual/Mechanical Catalogue shall be in Hard board folder(s) of size 265 mm x 315 mm and shall not be more than 90 mm thickness; it may be of several volumes and each volume shall have a volume number, index of volumes & index of contents of that particular volume.

E.5.2.4.13.4 Title sheet (Top sheet) of each volume of Technical Data Manual/Mechanical catalogue shall contain the contract information as defined under E.5.2.4.13.2 besides the volume number.

E.5.2.4.13.5 In case order contains more than one item, separate dedicated Technical Data Manual/Mechanical catalogues shall be submitted for each item.

E.2.2.4.14 Two (2) Sets of Final/As-Built drawings, documents shall also be submitted as electronic files on secondary storage media (CD-ROM/DVD-ROM disks)



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APPENDIX A - Fluid Coupling

A.1 General

A.1.1 Scope This appendix describes the minimum requirements for the design, manufacture, inspection, testing and supply of Fluid couplings and its auxiliaries, used for Fans.

A.1.2 Equipment Qualification Criteria

A.1.2.1 The fluid-coupling model offered shall be from the existing regular manufacturing range of the fluid-coupling manufacturer. The offered fluid-coupling model shall meet the following minimum service and manufacturing experience requirements. Fluid coupling proposed shall be identical in terms of model series and similar in terms of power rating, speed, mechanical design, materials etc. as compared to at least ONE UNIT designed, manufactured, tested and supplied from the proposed manufacturing plant in the last TEN years and as a minimum, this unit shall have completed ONE year of satisfactory operation at site, as on bid due date.

A.2 Basic design

A.2.1 Fluid coupling shall be self-supporting on either side by bearing housing and shall be of box type construction.

A.2.2 All metallic, dry, flexible type couplings with spacer shall be provided between the fluid coupling and the driver/fan.

A.2.3 The fluid coupling and the driver shall be mounted on a common base plate.

A.2.4 The oil cooler shall have at least 20% on over design margin on heat duty.

A.3 Controls & instrumentation

A.3.1 Capacity of fan shall be regulated with a stepless variable speed-scoop tube controlled fluid coupling.

A.3.2 For the control of scoop tube, the same shall be provided with pneumatic actuators, positioners, all connecting linkages, air kit, dust cover, manual operator, air lock relay, position transmitter for indicating the position of scoop tube etc. Provision shall also be made available for manual operation. Speed indication of the coupling shall be provided. In the event of instrument air, plant air or electric power failure, pneumatic actuator of the scoop tube shall decouple the fluid coupling (i.e. zero speed).

A.3.3 The instrumentation & controls shall be suitable for the specified area classification.

A.3.4 Unless otherwise specified, as a minimum, for each fluid coupling, following indicating instrument and instruments for alarm annunciation and shutdown annunciation/actuation shall be provided by the vendor:

A.3.4.1 Temperature Indications: • Circulation Oil to Fluid Coupling - Locally mounted Temperature Gauge • Cooling Water Return from Oil Cooler - Locally mounted Temperature Gauge

A.3.4.2 Speed Indications : • Fan Speed Indication on LGB/LCP. • Potential free Repeat Contact for Fan Speed Indication on Remote panel/DCS.


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A.3.4.3 Push Button Stations: • Main Equipment Start on LGB/LCP • Main Equipment Stop on LGB/LCP • Potential free Repeat Contact for Main Equipment Stop from Remote

panel/DCS.

A.3.4.4 Alarm and Shutdown Annunciation: • Low Cooling Water Flow from Oil Cooler - Alarm Annunciation on Remote

Panel/DCS. • High Oil Temperature supply and/or return from Fluid Coupling - Alarm

Annunciation on Remote Panel/DCS. • High-High Oil Temperature supply and/or return from Fluid Coupling -

Shutdown Annunciation on Remote Panel/DCS and Interlock to trip the fan.

A.3.4.5 Fan vendor shall wire and provide indicating lamps on the LGB/LCP for visual indication of common alarms and common shutdown alarms. Potential Free Contacts for the same shall be provided by the purchaser at the LGB/LCP. The LGB/LCP shall be suitable for the specified area classification.

A 3.4.6 Other instrumentation & controls, as deemed necessary by the vendor, for safe operation of the fluid coupling, shall be also provided by the vendor.

A.3.5 Fan vendor shall provide sight flow glasses on all oil lines and breather valve on oil reservoir of fluid coupling.

A.4 Inspection & testing

A.4.1 The following Tests shall be conducted at the Fluid Coupling Manufacturer's shop. These tests shall be witnessed by Purchaser/Purchaser's representative.

1. Heat Test / Temperature Rise Test. 2. Free Running Test. 3. Performance Test for all the operating conditions i.e. at different speeds of the

Fan. 4. Vibration Test. 5. Overspeed Test.

A.4.2 Vendor shall submit a detailed test procedure under all the above-mentioned headings, for purchaser's review & approval during detailed engineering stage.


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