technical specification for effluent treatment plant...

VISAKH MARKETING INSTALLATION RESITEMENT

PROJECT – LPG TERMINAL

Doc No: 256324-500-RQ-MEC-013 Rev: B of 26

P:\Andheri\IndiaProject\256324 HPCL- LPG\10 Procurement\TENDER\17 ETP\Final\Editable\Technical Attachments\2.1-

Tech Specs for ETP.doc

TECHNICAL SPECIFICATION

FOR

EFFLUENT TREATMENT PLANT

(ETP)

Hindustan Petroleum Corporation Ltd

Viskaha Dispatch Station

VR-ATP Area, Naval Base Post

Visakhapatnam - 530 014

Andhra Pradesh

Mott MacDonald Consultants (India) Pvt. Ltd.

Kothari House, CTS No. 185

Off Andheri - Kurla Road

Andheri (East)

Mumbai 400 059






TECHNICAL SPECIFICATION

FOR

EFFLUENT TREATMENT PLANT

(ETP)

Client HINDUSTAN PETROLEUM CORPORATION LTD.

MMCI Project No. 256324

Issue and Revision Record:

Rev Date Originator Checked Approved Description

A 30.07.09 SPW SVJ PJC Issued for Comments

B 15.02.10 ASA SM PJC Issued for Tender

C

Group Disclaimer

"This document has been prepared for the titled project or named part thereof and should not be relied upon or

used for any other project without an independent check being carried out as to its suitability and prior written

authority of Mott MacDonald being obtained. Mott MacDonald accepts no responsibility or liability for the

consequences of this document being used for a purpose other than the purposes for which it was commissioned.

Any person using or relying on the document for such other purpose agrees, and will by such use or reliance be

taken to confirm his agreement, to indemnify Mott MacDonald for all loss or damage resulting there from. Mott

MacDonald accepts no responsibility or liability for this document to any party other than the person by whom it

was commissioned.”






List of Content Page No

1 Introduction 5

2 Location and Environmental Conditions 6

3 Scope of Supply 6

3.1 Process Description 6

3.2 Equipment and Materials 7

3.3 Engineering Services 9

3.4 Exclusions 10

4 Applicable Codes, Specifications and Standards 10

4.1 General 10

4.2 Codes and Standards 10

4.3 Other Specifications and Standards 11

4.4 Conflicting Requirements 11

5 Design Requirements 11

5.1 Mechanical Requirements 11

5.2 Civil Requirements 11

5.3 Instrumentation Requirements 11

5.4 Electrical Requirements 17

6 Quality Assurance 18

7 Inspection and Testing 18

7.1 Factory Inspection & Testing 18

7.2 Vendor Requirements 19

7.3 Performance Guarantee 19

7.4 Works Inspection and Notification 20

8 Vendor Documentation 20

8.1 Documents/ Information to be supplied with offer 20

8.2 Document/ Information to be supplied After Award of Contract 20

9 Manufacturing Schedule 21

10 Spares and Special Tools 21

10.1 Spares 21

10.2 Special Tools 21






11 Packing and Shipping 21

12 Installation and Commissioning 21

Appendix A: Attachments 22

Appendix B: Water Quality 23

Appendix C: Requisition of Engineering Documents (Red Form) 24

Appendix D: Table of Compliance 25






1 Introduction

1.1 This specification covers the minimum requirements for the design, engineering, material

procurement, civil construction, fabrication, painting, assembly, Inspection, supply, shipment,

erection and commissioning of Effluent Treatment Package (ETP) for “Re-sitement of

Integrated Marketing Facility at Vishakhapatnam – LPG Terminal.”

Definitions:

Company/End User/ Owner : Hindustan Petroleum Corporation Ltd (HPCL)

Purchaser : Hindustan Petroleum Corporation Ltd (HPCL)

Engineer / Consultant : Mott MacDonald Consultants (India) Pvt. Ltd.

Vendor : Supplier of Effluent Treatment Package (ETP).

Shall : This is to be understood as a mandatory in relation to the

requirements of this document.

Should : This is to be understood as a strong recommendation to

comply with the requirements of this document

The ETP is as follows:

Sr.

No. Tag No. Quantity Description

1 500ETP-001 ONE Effluent Treatment Plant – 10 m3/d (8 hours)

1.2 The Vendor shall be responsible for the design, engineering, construction, fabrication,

assembly, inspection, co-ordination, testing, delivery and proper performance of the ETP.

1.3 The Vendor shall ensure that the design complies with the requirements of this requisition and

its referenced specifications and standards. The data sheets, which form part of this

specification, shall be completed by the Vendor. The Vendor shall highlight any non-

compliance at the offer stage in the Table of Compliance, Appendix D. The Table of

Compliance and filled in data sheets shall form a part of the offer. Not providing completed

compliance table and data sheets can cause rejection of the offer. Failure to clearly identify

specific deviations shall be assumed by the Purchaser to be total compliance with the

requisition.

Only those deviations that are specifically agreed to, by the Purchaser prior to award of the

order will be incorporated into the purchase order. Deviations to the specification will not be

allowed after award of order. Unless referred to in the Table of Compliance (Appendix D), it

will be assumed that all specifications are adhered to and that they do not have implications

with respect to cost, delivery and integrity of the equipment.

1.4 The Vendor shall procure third party material from vendors listed in the approved Vendor List

only, unless the particular type of material is not covered by the list, and a special dispensation

to deviate from the list has been granted in writing by the Purchaser. Company will reject any

materials found at any stage to be out of the approved VENDOR or sub Vendor list.

1.5 Note that “lead times” will not be considered by the COMPANY as a justifiable reason for

using alternate VENDOR.






1.6 This requisition shall in no way relieve the Vendor from final guarantee as to materials,

apparatus, workmanship and performance of the equipment and services supplied.

1.7 All correspondence and documentation shall be in English. All measurements and units shall

be in SI units.

Where necessary for a specific application, alternative units may be indicated in brackets

behind the SI units.

1.8 The VENDOR shall guarantee the equipment and all component parts against defective

workmanship and improper materials for the agreed period following the date of delivery of

the equipment or from commencement of operation as agreed. The VENDOR shall replace or

repair (the carrying out of all work including uncovering, removal, procurement and

reinstallation and construction as may be necessary) the components that are defective at their

own cost during the guarantee period at a suitable time to the COMPANY. Guarantee period

shall be as per the Contract and to be covered in commercial documentation.

2 Location and Environmental Conditions

For local conditions refer Document no. 256324-500-SP-GEN-001.

3 Scope of Supply

3.1 Process Description

The waste water effluent shall be subjected to physio-chemical treatment so that the treated

effluent shall meet the stipulations laid down by the Central Pollution Control Board.

The following steps shall form the process of treatment:

a) The untreated effluent from various locations like Cylinder washing, Water test bath,

Hydrotesting, soap water trays, etc of the LPG terminal shall reach the ETP through surface

drains by HDPE pipes, after passing through vapour seals. The effluent generated by these

streams shall be approx. 6 m3/day.

b) The caustic soda stream from the paint booth in the cylinder testing shed is neutralized with

10% Sulphuric acid in the Neutralization tank. The Transfer pumps shall also be used for

mixing acid in the caustic by recirculation. Once the pH in the range of 7.5 to 8.5 is sensed by

the pH meter, the recirculation will be stopped and effluent is pumped to main ETP through

Pressure Sand Filter (PSF).The quantity of effluent generated by this stream is 2000 litres/day.

Provision for backwash with service water shall be provided to the pressure sand filter.

c) The water requirement for the cylinder degassing is 50m3/day (1000 cylinders degassed per

day). At a time not more than 6 cylinders are degassed at a time i.e. the water requirement per

batch is approximately 300 liters. This water is pumped from the underground tank (5 m3

capacity) to the empty cylinder degassing via filter. After degassing the water is recycled back

to the underground tank and reused. The underground water is replenished by a continuous

supply of service water at the rate of 250 litres/ hour. The overflow from the underground tank

is taken to main ETP by surface drain, which is approximately 2 m3/day.

d) The main ETP shall be designed to treat 10 m3 of effluent generated in 8 hours shift from all

sources listed from (a) to (c) above.

(i) After passing through the bar screen, all free floating matters in the effluent stream

including the oil and grease shall be collected in the oil and grease trap. This collected

oil and grease is removed manually by hand-rack from time to time.






(ii) The effluent, after passing through the Oil and grease trap, is collected in the

underground equalization tank after passing through the coarse and fine screens to arrest

the larger and smaller particles respectively.

(iii) The effluent is made homogeneous in the equalization tank. Homogeneous effluent

from the equalization tank is pumped to the reaction tank.

(iv) In the reaction tank, agitator shall be provided for mixing the dosing chemicals with the

effluent. The chemical dosing results in the precipitation, which entraps the colloidal

things thus results in the removal of dissolved matter. The conversion of micro flocs

into macro flocs is facilitated by the addition of poly-electrolyte dosing in the reaction

tank.

(v) From reaction tank, the effluent overflows to the settling tank. Here the macro flocs

settle down as the chemical sludge. The Backwash water of the Pressure Sand Filter

(Cylinder wash Area) and Dual Media Filter is also collected in the settling tank for

further treatment.

(vi) The effluent from the settling tank overflows to the buffer tank.

(vii) From the buffer tank, the effluent is pumped and discharged through a dual media filter.

The treated water shall be sent for horticulture purpose to the nearby green belt.

(viii) The sludge collected at the bottom of the settling tank is taken to the sludge drying beds

for drying. After drying, the dried sludge cake is removed manually from the sludge

drying beds. These filled bags are to be stored in the covered hazardous waste pit.

e) Effluent from cylinder washing and cylinder degassing shall be collected in main ETP located

as shown in attached part drawing (256324-500-PIP-A0-3000-1/2) and schematics (256324-

500-SKT-MEC-002).

f) The sequence of the above treatment process is indicated in the Treatment Scheme (256324-

500-SKT-MEC-002 (2 sheets)) is attached with this requisition. The equipments shall be

designed such that the entire effluent generated per day shall be treated in 8 hours shift.

g) Vendor can propose an alternate scheme to minimise total hardware required, if possible, as

an option to the basic scheme. The Vendor shall make every effort to optimise the scheme.

h) Vendor shall carry out the Hazardous Area Classification for the proposed ETP and shall

ensure the instruments and electrical components suitable for the Area Classification, as per

IS: 5572 (1994).

i) Vendor to note that the control panel shall be located in a safe area near the ETP. All the

signals required to monitor the operation of the plant shall be repeated and made available to

be connected by others, though a serial link (soft signals) to the central control panel.

Necessary interface to connect the above cables shall be provided by the control panel vendor.

3.2 Equipment and Materials

Scope of supply of Effluent Treatment Plant shall include but not necessarily be limited to

following. Any additional equipment required to achieve treated water quality shall be

included by the Vendor in their scope of supply and shall mention the details of the same in the

bid document.

A. Equipments and Materials for ETP section of Cylinder washing area.

• Dilution tank suitable for diluting H2SO4 to 10% from 98%. Preferable Material of

construction is CS tank with lead lining or PTFE lining. Diaphragm dosing Pumps

(1W+1S) with FLP motors, pulsation dampner, Piping and Valves for dosing 10% H2SO4






in the neutralizing tank. The tank and Dosing Pumps shall be skid mounted with to

facilitate quick erection & interconnection at site.

• Neutralizing tank of 3 m3 capacity for collection of effluent with caustic soda.

• Pressure Sand filter complete with frontal Piping, Valves, Media, Interconnecting Piping

and Internals. Filter design shall be as per ASME Section VIII Div. I, latest edition.

• Filter feed/ Transfer Pumps with FLP Motors (1W+1S) mounted on common base plate

complete with flexible spacer type couplings, non-sparking coupling guards, suction and

discharge piping and valves. The head of this pump shall be sufficient to transfer

neutralised and filtered water to Main ETP.

• All Civil work (excluding Piling), Interconnecting Piping & Pipe supports, Ladders,

Crossovers, Power cabling, Control Cabling, Instrumentation, Earthing, etc. within this

ETP area and interconnection with main ETP.

B. Equipments and Materials for ETP Section of Degassing shed.

• Underground storage sump for water storage of 5 m3 capacity. With suitable overflow

arrangement for transfer of water to main ETP.

• Water transfer pumps of capacity 10 m3/hr with FLP Motors (1W+1S) mounted on

common base plate complete with flexible spacer type couplings, non-sparking coupling

guards, suction and discharge piping and valves. The head of this pump shall be sufficient

to transfer water from pit up to empty cylinder filling via filter.

• Filter (Basket type or Cartridge) to remove suspended particles from the water being filled

in empty cylinders for degassing.

• All Civil work (excluding Piling), Interconnecting Piping & Pipe supports, Ladders,

Crossovers, Power cabling, Control Cabling, Instrumentation, Earthing, etc. within this

ETP area and interconnection with main ETP.

• A Rotameter that will ensure continuous flow of 0.25 m3/hr to the underground storage

sump.

C. Equipments and Materials for Main ETP.

• Bar Screen at the inlet Oil and Grease trap.

• Design and Construction of Oil & Grease Trap, Equalisation tank, Reaction tank, Dosing

Tanks, Settling tank, Buffer tank, Treated water tank, Sludge drying beds and Hazardous

waste pit.

• Effluent transfer pumps with FLP motors (1W+1S) mounted on common base plate


discharge piping with valves. These pumps are for transfer of equalised effluent from

equalisation tank to reaction tank. The Effluent flows by gravity from reaction tank to

Settling tank to Buffer tank.

• Filter Feed Pumps with FLP Motors (1W+1S) mounted on common base plate complete

with flexible spacer type couplings, non-sparking coupling guards, suction and discharge

piping and valves. Suction of these pumps shall be taken from Buffer tank.

• Dual Media filter complete with frontal Piping, Valves, Media, Interconnecting Piping and

Internals. Filter design shall be as per ASME Section VIII Div. I, latest edition.






• Filter Backwash Pumps with FLP Motors (1W+1S) mounted on common base plate


discharge piping and valves. Suction of backwash pump shall be taken from Treated water

tank.

• Treated Water Pumps for Gardening with FLP Motors (1W+1S) mounted on common base

plate complete with flexible spacer type couplings, non-sparking coupling guards, suction

and discharge piping and valves. The discharge pressure of the pump shall be 5 kg/cm2g.

• Complete Civil design and Construction of Sumps, Pits, Equipment foundations and

Control room. Piling for Pits & foundations, as required, by others.

• All necessary interconnecting piping/tubing and valves within the battery limit of the

package.

• Purchaser will provide one point Instrument air supply within battery limit. Vendor to

provide the estimated Instrument Air Supply requirement.

• Instrumentation as required complete with control panel for control and monitoring the

quality of treated water.

• Motor Control Centre (MCC), Local Control Panel, Supply of cables within the battery

limit and termination in the control panel/ MCC located in safe area near the ETP

Purchaser shall provide one point power supply in the MCC Incomer.

• Interfacing with the ETP of cylinder washing area & ETP of degassing shed including

required piping, cables, civil works etc.

D. Equipments and Materials Common for all ETP areas and Main ETP.

• Lifting & Earthing lugs for packaged unit, Vessels and Pump sets.

• Anchor bolts, fixing bolts, jack screw bolts, shims, etc.

• First fill of lubricants to be supplied separately along with the pump sets.

• Commissioning & Start-up Spares.

• Spares for two years trouble free operation. Vendor to furnish the list for the same.

• Inspection and testing as specified.

• Submission of documents as specified in this document.

• Painting, preservation, preparation for shipment and delivery at site.

• Special tools if required (Bidder to provide list in the bid).

• Construction, Installation & Commissioning.

3.3 Engineering Services

The Vendor shall provide engineering services, which shall include, but not necessarily be

limited to, the following:

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

of supply.

• Preparing Civil foundation design and drawings for construction at site.

• Resolving engineering queries related to the equipment and components within the scope

of supply.



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• Performing and coordinating all aspects of design.

• Providing progress reports etc.

• Providing expediting services for all sub-vendors.

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

equivalent.

• Erection & Commissioning to be quoted separately.

• Attendance of kick-off meetings, coordination meetings, Design reviews meetings in the

Consultant’s/Purchaser’s office.

• Resolve/incorporate all action points from Design reviews, HAZOP, etc.

• Any technical document if required by Purchaser for statutory approval shall be furnished

by vendor.

3.4 Exclusions

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

• Piping/ trenches up to collection tank and beyond the outlet nozzle of last equipment in the

treatment scheme.

• Service water will be provided for Backwash of Pressure Sand Filters in the Cylinder

Washing Area at one point.

• Interconnecting power cabling and cable trays to vendor supplied MCC of ETP and

Purchaser’s PMCC.

• Instrument air connection piping up to battery limit.

• Cable between Vendor’s Control panel and Purchaser’s Control room.

• Piling required for Pits & Equipment foundations.

4 Applicable Codes, Specifications and Standards

4.1 General

The design, fabrication, assembly, inspection, testing, painting, packing and shipment of

equipment shall be in accordance with the latest edition of the codes, specifications and

standards (including standards / specifications mentioned therein) listed in this requisition.

The Vendor shall provide an itemized list of any comments or exceptions to the specification

and its attachments. Only those comments / exceptions that are accepted by Purchaser will be

incorporated into the requisition at the time of the order.

4.2 Codes and Standards

ASME Section VIII Div. I Rules for Construction of Unfired Pressure vessels

ASME B 16.5 (2003) Pipe Flanges and Flanged Fittings.

ISO 9000 (2005) Quality Management and Quality Assurance Standards.

ISO 10474 (1991) Inspection Documents

ISO 5199: 2002 Technical Specification for Centrifugal Pumps Class II



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4.3 Other Specifications and Standards

Refer Appendix-A for other specifications & standards.

4.4 Conflicting Requirements

In case of conflict between documents relating to the enquiry or purchase order, the following

priority of documents shall apply:

First priority : Purchase order and variations thereto

Second priority : Data sheets and drawings

Third priority : This requisition

Fourth priority : Other Specifications

Fifth Priority : Referred Codes & Standards

Note: Should any conflict arise either before or after order placement of order, the

Vendor shall immediately inform the Purchaser for technical resolution of the conflict.

5 Design Requirements

5.1 Mechanical Requirements

5.1.1 Pumps shall be supplied as per the requirements of Specification for Non-API Centrifugal

Pumps (Doc. No. 256324-500-SP-MEC-004) Pump set (Pump and Motor) shall be mounted on

common base plate.

5.1.2 The internals of the Oil & Grease Trap, Reaction tank and settling tank unit shall be FRP for

corrosion protection.

5.1.3 Skid mounted Filter Vessels with internals, media, piping and valves. Material of construction

for vessels shall be suitable for the effluent characteristics specified.

5.1.4 Skid mounted Duel Filter Vessels with internals, piping and valves. Material of construction

for vessels shall be Carbon steel with suitable coating on the inside to avoid corrosion.

External surfaces shall be painted as per the specification for painting.

5.1.5 Auto valves, if required shall be pneumatically operated type only.

5.2 Civil Requirements

5.2.1 All RCC shall be of Grade M30.

5.2.2 The reinforcement shall be of Grade 500.

5.2.3 All foundations & Underground tanks shall rest on Pile foundation.

5.2.4 Slag cement shall be used for construction.

5.3 Instrumentation Requirements

5.3.1 The Instruments shall be supplied as mentioned in the scope of supply for effective control and

monitoring of the system.



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5.3.2 All the Instruments shall be suitable for Zone 1, Gas Group IIA/IIB.

5.3.3 Instrument air supply if required, is available. The pressure range is 4.5 to 7.0 kg/cm2.

Purchaser will provide one point Instrument air supply within the battery limit of the bidder.

5.3.4 Controls shall be PLC based and all soft signals covering for dynamic graphic information of

ETP shall be made available for connection (By Others) to Owner’s control room.

5.3.5 Control Panel, if Electrical panel not combined with Automation with suitable partition, shall

be supplied by vendor. The Control Panel shall be fabricated from cold rolled MS sheets of

minimum 2mm thickness for load bearing members, 1.6mm for non load bearing members an

3mm for gland plates. Panel shall be rated for IP-55, weather protection.

5.3.6 All Instruments, Junction boxes, cables, control panels etc. shall be supplied and hooked up in

the skid. All on-skid cabling shall be terminated in skid mounted Local panels by the vendor.

5.3.7 All Instruments/PLC supplied in the package shall be from approved vendor list. Bidder shall

take the approval from MMCI for instruments not found in the approved list. Local panel shall

be provided with sunshade.

5.3.8 ETP shall be provided with its own PLC (if necessary) to control, monitor and safeguard the

system. The PLC’s shall be mounted in a local control panel (LCP) provided with necessary

indications.

5.3.9 Controls, sequencing logic and safe guarding of the complete ETP shall be bidder’s

responsibility. Vendor shall furnish the control and safeguarding logic of the package for

review and approval.

5.3.10 Clean & dirty earthing shall be made available inside LCP and separated accordingly

5.3.11 Vendor shall inform the total consumption of Instrument air.

5.3.12 All instruments to be visible from grade level otherwise platform shall be provided.

5.3.13 Vendor shall include in their offer, spares for Critical solenoids.

5.3.14 Instrument data sheets shall be completed by the vendor for all instruments supplied in the

format provided to the bidder.

5.3.15 The identifying tag number shall be neatly & clearly marked on each instrument.

5.3.16 Dial size of Pressure shall be 150 mm & Temperature Gauge shall be 100mm. Dial size of

Receiver Gauge shall be 50mm. The scale plates shall be aluminium or laminated plastic with

white face & black figures.

5.3.17 Pressure gauge & Temperature gauge range shall be within middle third of the instrument

range in normal operating condition. Pressure Gauge exposed to vacuum shall be capable of

withstanding full vacuum.

5.3.18 Instruments shall meet the minimum requirements of IP 65 for ingress protection in

accordance with IEC 60529.

5.3.19 All instruments shall be individually valved by block and bleed valve at the tap off to allow

depressurization, in-place testing and maintenance of the instrument without shutting down the

equipment/package unit.

5.3.20 Cable entry to all instruments shall be ½ inch NPT. Spare cable entries shall be suitably

plugged with stopping plugs.

5.3.21 Materials of construction for instrument equipment shall be compatible to the corrosion

resistance, pressure and temperature conditions of the process fluids handled. Generally, all

instrument wetted parts, in contact with the process fluid shall be SS316 (minimum), or of a

material equal to or better than that of the related vessel or line.



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5.3.22 List of approved vendors

1. PROGRAMMABLE LOGIC CONTROLLER

SR.NO. NAME OF VENDOR

1. ALLEN BRADLEY (Rockwell Automation India Pvt Ltd)

2. GE FANUC SYSTEMS PVT LTD

3. SCHNEIDER MODICON

4. SIEMENS

5. HONEYWELL

2. ELECTRONIC TRANSMITTERS (PT, DPT, LT, TT)


1. EMERSON PROCESS MANAGMENT

2. ENDRESS & HAUSER

3. YOKAGAWA

4. HONEYWELL

3. pH INSTRUMENT


1. ZWELLEGER

2. FORBES POLYMETRON PVT LTD

3. ABB

4. EMERSON

4. ROTAMETER


1. CHEMTROLS

2. EMERSON

3. KROHNE

5. PNEUMATIC VALVE ACTUATORS


1. ADAMS

2. BETIS



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3. VIRGO

4. VELAN

5. ORTON

6. TYCO –BIFI

7. ELOMATIC

6. CONTROL VALVE


1. FISHER XOMOX

2. MASONEILAN

3. TYCO

4. FLOWSERVE INDIA

5. SAMSON CONTROLS

6. INSTRUMENTATION LTD.

7. METSO AUTOMATION

7. PRESSURE SAFETY/RELIEF, THERMAL SAFETY/RELIEF VALVE


1. ANDERSON & GREENWOOD

2. L&T

3. TYCO

4. INSTRUMENTATION LTD.

5. FAINGER LASER

8. PRESSURE, TEMPERATURE GAUGE, D.P. GAUGE


1. WIKA INSTRUMENTS

2. ASHCROFT

3. GENERAL INSTRUMENTS CONSORTIUM

9. LEVEL GAUGE


1. JERGUSON

2. K-TEK



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3. MAGNETROL

10. RTD


1. GENERAL INSTRUMENTS CONSORTIUM

2. WAAREE INSTRUMENTS LTD.

3. ALTOP INDUSTRIES

4. PYRO ELECTRIC & ALLIED INSTRUMENTS PVT. LTD.

11. RELAY & RELAY BOARDS


1. OMRON AUTOMATION PVT LTD

2. TELEMECHANIQUE

3. P&F

4. PHEONIX

5. HONEYWELL

6. SIEMENS

12. SOLENOID VALVE


1. ASCO

2. HERION

3. NORGREN

13. PUSHBUTTONS


1. TEKNIC

2. L&T

3. SIEMENS

4. MERLIN GERIN-TELEMECHANIQUE SCHNEIDER ELECTRIC

5. CONTROL & SWITCHGEAR-CANDS



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14. MCB


1. MDS

2. MERLIN GERIN-SCHNEIDER ELECTRIC

3. SIEMENS

4. L&T

15. CABLES


1. ASSOCIATED CABLES PVT. LTD.

2. UNIVERSAL CABLES

3. ICON CABLES (KERPEN)

4. LAPP

5. CORDS CABLES

6. KEI INDUSTRIES LIMITED

16. RTD CABLES


1. LAPP

2. DELTON

3. UNIVERSAL CABLES

4. UNIFLEX CABLES Ltd


17. POWER CABLES


1. CCI


3. UNIVERSAL CABLES

4. FINOLEX

5. LAPP



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18. TUBE AND TUBE FITTINGS


1. SWAGELOK

2. PARKAR HANNIFEN INDIA PVT LTD

03. ASTEC INSTRUMENTS PVT. LTD

5.4 Electrical Requirements

5.4.1 Motors shall be supplied as per attached Motor specification no. 256324-500-SP-ELE-010.

5.4.2 Vendor shall submit the Motor Datasheet with all the data filled by the Motor Manufacturer.

5.4.3 Purchaser shall provide one point power supply within the battery limit of the package vendor.

Further distribution & control shall be in the scope of packaged vendor.

5.4.4 Local control panel shall have all necessary standard features viz.

• Motor ON/OFF push buttons

• Process interlocking provisions

• Auto / Manual selection position

• Motor ON/OFF indication

5.4.5 Local control panel shall be suitable for Safe location near ETP.

5.4.6 Normal 240 volts single phase (non UPS) power supply shall be derived from ETP MCC to

Local control panel.

5.4.7 Electrical Panel

Purchaser shall provide 415V, 3phase, 50Hz, power supply to ETP MCC and it shall be

located near ETP in safe area. Vendor shall decide exact location of ETP MCC panel suitably

in safe area. The auxiliary power requirements at various voltage levels (AC and/or DC) and

to the control panel shall be derived within the panel by providing necessary transformers,

rectifiers, fuses, etc. by the Vendor.

The Electrical Panel shall be fabricated from cold rolled MS sheets of minimum 2mm

thickness for load bearing members, 1.6mm for non load bearing members an 3mm for gland

plates. Panel shall be suitable for outdoor installation with IP-55 ingress protection.

The Electrical panel shall also house the starter and breaker units for the drive motors and

these feeders shall be fixed type. Motor starter feeder shall be chosen to provide Type-2 co-

ordination. Motors rated upto 15KW shall be started direct on line (DOL starter) and 15KW

and above shall have Star-Delta starter. Supply for Motor space heater shall be derived from

this panel. Suitable power feeders shall be provided for control panel.

Electrical Panel shall have Start, Stop Push buttons and Indication provision for all drives.

5.4.8 Local Control Station for each drive shall be provided near the drive.

5.4.9 LV Cables

All Power and Control cables shall be 1.1kv grade, XLPE insulated, multi standard conductor,

single/multi core, steel armoured, extruded PVC inner shealthed and extruded FRLS PVC



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outer shealthed. Cable of size 6 sq.mm and below shall be of copper conductor. Cable of Size

10 sq.mm and above shall be aluminium conductor confirming to IS 7098 (Part-1).

6 Quality Assurance

The Vendor shall maintain and use a Quality System which is based on ISO 9000 to control

the work. If the Vendor elects to sub-contract part of the work he shall ensure that only those

sub-contractors or suppliers are used who can demonstrate that they operate Quality Systems

based on ISO 9001 or ISO 9002 as applicable.

The Vendor shall give his sub-contractors or suppliers assistance in attaining the required

standard, if necessary. This shall not relieve the Vendor of his responsibility for the quality of

the finished work. The Company / Consultant reserve the right to audit the Vendor’s Quality

System.

The Vendor shall assign sufficient full time personnel to the project to ensure the Quality

Assurance / Quality Control System, documented in a Quality Assurance / Control Manual, is

maintained and kept up-to-date throughout the duration of any purchase order. The Vendor’s

Quality Assurance / Control System shall become an integral part of any purchase order.

Vendor shall organize a prefabrication / inspection meeting with the Company / Consultant.

Vendor shall submit QA plan/Inspection test plan for Purchaser’s/Consultant’s review and

approval within 2 weeks from the date of Purchase Order/LOI/FOI.

7 Inspection and Testing

7.1 Factory Inspection & Testing

The responsibility for inspection, certification, etc. of all materials, parts lies with the Vendor.

The Vendor shall specify all of the inspection and testing requirements in the Quality

Assurance plan (QAP)/ Inspection Test plan (ITP) which shall identify the activities requiring

the Company / Consultant's approval, review, witnessing etc.

Inspection and testing requirements shall be in accordance with the applicable standards as

listed in this requisition and the data sheets and Vendor’s Quality Assurance Plan/ Inspection

test plan approved by Purchaser/ Consultant.

All equipment shall be inspected for compliance with:

• Requirements of the Company/Consultant’s specifications, data sheets and correspondence

thereafter.

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

standards therein.

• QAP/ ITPs produced by the Vendor duly approved by Purchaser/ Consultant.

Purchaser’s/ Consultant’s Inspectors have the right to request additional inspections or tests to

ensure that the equipment complies with this specification and all relevant codes and

standards.

All equipment shall be presented for inspection in an unpainted state except for the final

inspection. All instruments and other equipment necessary for testing shall be supplied by the

Vendor and the same shall be checked and certified by the Company / Consultant’s inspector.



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Any defects found by the Company / Consultant’s appointed Inspector shall be rectified in his

presence. Where this is not possible or practical, check lists shall be prepared and signed by

the Inspector stating all “pending items”. Copies of these lists shall be sent to the

Company/Purchaser to enable their subsequent checking.

Mill and shop inspection shall not relieve the Vendor from his contractual responsibility for

replacing any defective material and for repairing any defective workmanship that may be

discovered in the field.

The Vendor shall be responsible for co-coordinating the inspection and testing of sub-vendor

supplied equipment, and for ensuring that the Company / Consultant’s representatives are

given the necessary access for inspection, and adequate warning of inspection and tests.

The Vendor (and all sub-Vendors) shall give the Company and its’ representatives, without

charge, all reasonable facilities and access for the purpose of inspecting the equipment to

ensure that it is manufactured in accordance with the Specification.

All spare parts shall be subjected to the same inspection standards and full material

certification as the main order.

The equipment shall not leave the Vendor’s factory before all discovered defects have been

rectified and without the written permission of the Company/Consultant.

Materials for all pressure retaining components & wetted components shall be certified in

accordance with ISO 10474 - 3.1B and that for non-pressure retaining components like

structural components, platforms, ladders, shall be certified in accordance with ISO 10474 -

2.2.

Final hydro test pressure shall be held for a minimum period of 30 minutes. Chloride contents

of water used for hydro test shall not exceed 20 ppm for stainless steel and chloride content

may be permitted up to 250 ppm for carbon steel.

7.2 Vendor Requirements

Any acceptance or release of equipment following an inspection or test activity shall in no way

relieve the Vendor of his responsibility to provide guarantees as to the suitability of the

materials, workmanship and performance of the equipment in accordance with this

Requisition.

7.3 Performance Guarantee

Unless otherwise agreed, all equipment shall be guaranteed as follows:

All equipment shall perform satisfactorily under the operating conditions and provide treated

water quality as per Appendix B of this requisition and shall be fit for the purpose intended.

The Vendor shall guarantee following as a minimum at site conditions:

• Sustained operation at the conditions outlined in this specification and relevant documents.

• Consumption of utilities like Water, Chemicals and Electrical power.



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• The mechanical and structural integrity, workmanship and the materials of construction

used.

7.4 Works Inspection and Notification

The supplier shall send inspection notification at least 2 weeks in advance and shall send a

minimum of fifteen (15) working days notice prior to carrying out the Factory Acceptance Test

(FAT). The notification shall contain as a minimum the following information:

• Project Title, MMCI Project number.

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

• Purchase Order reference

• Date of inspection

• Details of equipment to be tested / inspected and the status of the equipment (whether it is

complete).

8 Vendor Documentation

8.1 Documents/ Information to be supplied with offer

The Vendor shall provide the Consultant with the following information as a minimum along

with the offer. These documents shall include, but not be limited to the following:

a. The completed Table of Compliance (Appendix D).

b. Equipment Data sheets for Vessels and Pumps under scope of supply.

c. Piping and Instrumentation Diagram with description of Interlocks.

d. A detailed scope of supply that fully describes the equipments offered & treatment

scheme.

e. Pump performance curves.

f. General arrangement drawings with complete layout, dimensions, Termination details and

Load data for foundation design.

g. Commissioning Spare parts list.

h. 2-Years operation spare part list.

i. Complete list of special tools required, if any.

j. All utility consumptions such as power requirement, utility water requirement and

Chemical consumption.

k. Instrument Datasheets giving details of Manufacturer, Model number, Type of Instrument,

etc.

8.2 Document/ Information to be supplied After Award of Contract

Vendor shall provide Purchaser/Consultant with documents and drawings as described in the

'General Conditions of Contract'. However, document requirements as specified in the

'Requisition for Engineering Documents (RED)' attached with Appendix C shall be followed

as a minimum requirement.



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9 Manufacturing Schedule

Within 2 weeks of the receipt of the Purchase Order/ LOI the manufacturer shall submit detail

bar chart schedule showing the dates for the following milestone activities, as minimum:

i) Issue of vendor drawings.

a. Issue for comments/approval

b. Issue of final drawings

c. Issue of O&M Manuals

ii) Equipment available for Testing.

iii) Completion of packing and readiness for dispatch.

10 Spares and Special Tools

10.1 Spares

As a minimum spares following shall be included:

• The supply of spares for start-up and commissioning

• Vendor to recommend two years operation spares and furnish separate price in the offer.

The Vendor shall also provide all consumables during erection up to commissioning and

reliability testing. In case of any additional spares if required during commissioning stage, the

same shall be supplied by Vendor free of cost.

The Vendor shall complete and submit SPIR forms 8 weeks after Vendor’s acceptance of the

Purchase Order. Spare parts for the normal operation shall be selected by the End User from

the electronic version of Spare Parts Lists and Interchange ability Record (SPIR).

10.2 Special Tools

The Vendor shall supply a set of any special tools, which are required for the installation,

commissioning, operation and maintenance of the equipment being supplied. A list of special

tools shall be supplied along with the offer.

11 Packing and Shipping

For Packaging, Shipping and delivery of equipment at site and unloading requirements,

'Agreed Conditions of Contract' shall be referred.

12 Installation and Commissioning

Vendor shall provide qualified personnel for the civil construction, installation, testing, pre-

commissioning and commissioning of the Effluent treatment plant.



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Appendix A: Attachments

Document No. Rev. Description

256324-500-SP-ELE- 010 A Specification for Electric Motors (Electric

Motor Datasheet)

256324-500-SP-MEC-004 B Specification for Non-API Centrifugal pumps

for general services.

256324-500-SKT-MEC-002 B ETP Treatment Schematics

256324-500-PIP-A0-3000 (Sheet 1/2) 0 Part Drawing of Overall Plot Plan

256324-500-SP-GEN-001 B Local Conditions

Blank Instrument Datasheets

• Data sheet for Differential Pressure

Transmitter

• Data Sheet for Level Switch - High High /

Low Low(Displacer Type)

• Data Sheet For Pressure Safety Valve

(PSV)

• Data Sheet For Temperature Gauge

• Data Sheet For Pressure Gauge



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Appendix B: Water Quality

Effluent Inlet Characteristics:

Temperature : 20- 40 oC

Colour : Muddy

pH : 5 to 8

Oil & Grease : 2 to 5 mg/l

TSS : 150-200 mg/l

TDS : 1000 – 1200 mg/l

BOD : 50-100 mg/l (3 days @ 27 oC)

COD : 150-250 mg/l

Detergent : 0.01 mg/l

Note: Oil shall be free oil, no emulsified oil to be considered.

Treated Effluent Characteristics:

The treated effluent characteristics shall be as per Ministry of Environment and Forest notification dated

18th March, 2008.

pH : 6.0 to 8.5

Oil & Grease : <5 mg/litre

BOD (3 days, 27° C) : <15 mg/litre

COD : <125 mg/litre

Suspended Solids : <20 mg/litre



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Appendix C: Requisition of Engineering Documents (Red Form)

Owner/Purchaser’s Office Consultant’s Office

HINDUSTAN PETROLEUM CORPORATION LTD.

Krishna Shree, 2nd Floor, Gandhi Nagar, 1st Main Road-Adyar,

Chennai – 600 020

Mott MacDonald Consultants (India) Pvt. Ltd

Kothari House, CTS No. 185 Off Andheri – Kurla Road, Andheri (East)

Mumbai 400 059, India ; Tel 09122 3083 5000

DRAWINGS Required number for TIMING FOR SUBMITTAL

Approval Final issue - for approval 2 weeks after order date

Approval drawings / Final drawings to be submitted

under cover of an ADS form / FDS form respectively

Transpa

rencies

Prints Disk Prints - final issue 2 weeks after approval date

Documents shall be submitted to:

Vendor Doc. Schedule 4 1 3

General arrangement 4 1 3

Piping & Instrumentation Diagram 4 1 3

Piping Layout with Termination details 4 1 3

Civil design, Civil drawings, Foundation loading and

bolt location plan

4 1 3

Cross section drawing with BOM and MOC 4 1 3

Completed Pump, Motor data sheets 4 1 3

Performance curves for Pumps and motors 4 1 3

Motor Datasheet,GA drawing & Terminal Box

Drawing

4 1 3

GA and Control Schematic drawings for Local Control Panel, Instrument hook-up diagram, loop diagram,

layout, Termination details, MTO, etc. MCC in

vendor’s scope.

4 1 3

Production Schedule 4

Progress Report 4 Monthly Once.

Performance Test Procedure including FAT, NDT

Procedures

4 1 3

Quality plan satisfying ISO 9000 requirements 4 1 3

Manufacturing, Inspection & testing sequence plan/

QAP

4

SPARE PARTS DOCUMENTS 1 3

ESPIR forms including 1 transparency 1 3

Lubrication schedules 1 3

TEST AND INSPECTION DOCUMENTS Prints Documents to be submitted under transmittal Documents shall be submitted to:

Manufacturing report 1 3

Material certificates to: ISO 10474 - 3.1B 1 3

Electrical certificates to Cenelec / Baseefa/ATEX Compliance/CMRI 1 3

Static / dynamic balancing certificates 1 3 Purchasing Office via courier service within 4 weeks

Performance test Report & Performance Curves 1 3 of relevant test / inspection.

Heat treatment graphs

Calibration certificates of Instruments 1 3

OPERATING DOCUMENTS Purchasing Office via courier service not later than

time of dispatch of equipment.

Installation instructions 1 3

Operating instructions 1 3 Combine into one manual

Maintenance instructions 1 3

ADDITIONAL REQUIREMENTS:

1. Referenced standards / codes shall be the latest issue unless otherwise stated.

Invoice must certify that the drawings and engineering documents specified

above have been dispatched to all parties concerned. Any deviation from the timing for submittal of documents shall be notified to

the Approval / Distribution Offices by fax or E mail.

Shop fabrication shall not be started before the required approval drawings

have been released for construction by the party concerned, unless otherwise

stated on the "Approval Drawing Specification".

Each document shall bear the item / tag and order reference number and be

dispatched by air mail, unless other instructions are stated on the RED.

Units / dimensions to be used on Engineering documents shall be SI.

The documents shall be in English. Description on drawings and similar documents may be in other languages provided English translations are

also given.

Drawings and documents shall be suitable for microfilming and comply

with accepted national or international standards for the preparation of

technical drawings. Only the following standard sizes should be used: A4,

A3, A2, A1.



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Appendix D: Table of Compliance

The Vendor shall confirm below their acceptance of all the clauses contained in the specification or

otherwise make clarifications or exceptions that shall be noted below:-

CLIENT: HINDUSTAN PETROLEUM

CORPORATION LTD.

VENDOR REF. NO.

REF. NO.: 256324-500-RQ-MEC-013 Rev. B

CLAUSE

NO.

CONFORMS

Y/N

ALTERNATIVE

Y/N

CLARIFICATION

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

2.0

3.0

3.1

3.2

3.3

3.4

4.0

4.1

4.2

4.3

4.4

5.0

5.1

5.2

5.3

5.4

6.0

7.0

7.1

7.2

7.3

7.4

8.0



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CLIENT: HINDUSTAN PETROLEUM

CORPORATION LTD.

VENDOR REF. NO.

REF. NO.: 256324-500-RQ-MEC-013 Rev. B

CLAUSE

NO.

CONFORMS

Y/N

ALTERNATIVE

Y/N

CLARIFICATION

8.1

8.2

9.0

10.0

10.1

10.2

11.0

12.0

Appendix A

Appendix B

Appendix C

Appendix D