tender. no. tata consulting engineers limited section

TENDER. NO. TCE.6758A-B-300-001

TATA CONSULTING ENGINEERS LIMITED SECTION: Title

Master Index SHEET i OF iii

ISSUE

R0

MASTER INDEX

TO

BIDDING DOCUMENT FOR BLENDING UNIT

BHARAT PETROLEUM CORPORATION LIMITED, URAN, MUMBAI

(BIDDING DOCUMENT NO: TCE-6758A-B-300-001)

NIT NO. - 6758A_TCE/BPCL_RFQ_001 of 121



Master Index SHEET ii OF iii

ISSUE

R0

PART – I: GENERAL & COMMERCIAL

SL. NO.

SPECIFICATION NO. REV NO. DESCRIPTION NO. OF SHEETS

1. Acknowledgement & Intention To Bid (to be sent immediately after down loading of the tender)

2

2. TCE.6758A-B-300-001 R0 Instructions To Bidders 25

3. TCE.6758A-B-300-001 R0 Bidder‟s Qualification Criteria 1

4. TCE.6758A-B-300-001 R0 Concurrent Assignments and Experience list

2

5. TCE.6758A-B-300-001 R0 Deviation List 2

6. TCE.6758A-B-300-001 Integrity Pact 4

7. TCE.6758A-B-300-001 R0

ANNEXURE-I TO SPC Scope of Work

2

8. TCE.6758A-B-300-001 R0

ANNEXURE-II TO SPC Scope of Supply

3

9. TCE.6758A-B-300-001 R0

ANNEXURE-III TO SPC Terms of Payment

3

10. TCE.6758A-B-300-001 R0 Quality Management System 6

11. TCE.6758A-B-300-001 R0 General Purchase Conditions 36

12. TCE.6758A-B-300-001 R0 Special Purchase Conditions 11

13. TCE.6758A-B-300-001 R0 List of Approved Makes / Vendors 29

14. TCE.6758A-B-300-001 R0 Commercial Questionnaire 10

15. TCE.M4-903 R5 Drawings, Engineering Documents and Instruction Manuals

6

16. TCE.M4-907 R7 Spares and Maintenance Tools and Tackles

2

17. TCE.6758A-B-300-001 R0 Mandatory Spare Part List 4

18. TCE.M4-908 R6 Training of Purchaser‟s Personnel 1

19. TCE.M4-914 R7 Progress Schedule and Reports 3

20. TCE.6758A-954 R0 Schedule of Distribution of Drawings and Documents

2

21. TCE.6758A-B-300-001 R0 Performance Guarantee Parameters 3

22. TCE.6758A-B-300-001 R0 Schedule Of Price 7




Master Index SHEET iii OF iii

ISSUE

R0

PART II - TECHNICAL SL. NO. SPECIFICATION NO. REV NO. DESCRIPTION NO. OF

SHEETS

1. TCE.6758A-B-300-001 R0 Technical Specification - Process 7

2. TCE.6758A-300-PI-8601 R0 Schematic Diagram of Blending unit 1

3. TCE.6758A-CH-X-PDS-10U007 R0 Data sheet for Static Mixture 1 1

4. TCE.6758A-CH-X-PDS-10U008 R0 Data sheet for Static Mixture 2 1

5. TCE.6758A-A-580-600 R0 Instrumentation Specification for Blending unit 41

6. TCE.6758A-A-580-601 R0 General Specification for DCS 20

7. TCE.6758A-300-PP-1551 R0 Piping Material Specification 3

8. TCE.6758A-B-300-001 R0 Painting Specification 3

9. TCE.6758A-104-02 R0 Thermal Insulation for Cold Surfaces Insulation data sheet

7 2

10. TCE.6758A-134-01 R0 Welding Specification for Piping Systems 24

11. TCE.M4-904 R9 Shop Inspection and Tests 7


SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION:

TCE.6758A-B-300-001 SHEET OF 4

ISSUE R0

PART II


TCE.6758A-300-B-001

TATA CONSULTING ENGINEERS LIMITED SECTION: WRITE UP

TECHNICAL SPECIFICATION SHEET 1 OF 7

Contents

1. GENERAL INFORMATION…………………………………………………………………………2

2. METEROLOGICAL DATA……………………………………………………………...…………..2

3. UTILITIES…………………………………………………………………………………………….2

4. SCOPE OF SUPPLY AND SERVICES………………………………………………...…………3

5. PROCESS DESCRIPTION, OPERATING & CONTROL PHILOSOPHY…………….……….7


TCE.6758A-300-B-001



1. GENERAL INFORMATION

1.1. Item No. : LPG Blending Package Unit

1.2. Number required : One

1.3. Project : Propane & Butane Blending

1.4. Owner / Purchaser : Bharat Petroleum Corp. Ltd.

1.5. PMC : TATA Consulting Engineers Ltd.

1.6. Location : Uran, Maharashtra (JNPT, Mumbai)

1.7. Installation : Outdoor

1.8. Hazardous Area Classification : Zone 2, Gas group II A/ II B

1.9. Design Code : Manufacturing standard

1.10. Manufacturer for all components : Refer Vendor List

1.11. Model No. for all components : By Vendor

1.12. Quotation No. & Date : By Vendor

2. METEROLOGICAL DATA 2.1. Site Altitude : 7.5 m above Mean Sea Level

2.2. Seismic Zone Factor : ZONE IV

2.3. Seismic Coefficient : 0.05

2.4. Ambient Temperature (Dry bulb) : 10ºC (min), 40ºC (max)

2.5. Barometric Pressure : 1.033 kg/cm²a

2.6. Design Wet Bulb Temperature : 29ºC

2.7. Relative Humidity : 60% (min). 95% (max)

2.8. Rainfall : 408 mm in 24 hours (Daily Maximum) Design Hourly Rainfall Avg. 2000 mm (3 months – mid June to mid Sept)

2.9. Wind : 50 m/s (Design Wind Load)

3. UTILITIES 3.1. Instrument Air

Pressure : Minimum – 4.0 kg/cm²g


TCE.6758A-300-B-001



Maximum – 7.0 kg/cm²g

Design – 9.0 kg/cm²g

Dew Point : -40°C at atmospheric pressure

Instrument air will be made available at one point near the blending skid. Further distribution to the individual consumers within the package shall be in vendor’s scope. Instruments shall be capable of functioning at minimum air pressure also.

3.2. Power Supply

Motors : 415 V ± 10%, 50 Hz ± 5%, 3 Phase : 6.6 KV ± 10%, 50 Hz ± 5%, 3 Phase

Solenoid valves : 240 V

4. SCOPE OF SUPPLY AND SERVICES The supplier’s scope of supply/ work for this unit shall be, but not limited to Design, Manufacturing, Procurement, Inspection, Testing, Supply and provide all necessary documents for obtaining all statutory approvals.

It is not the intent to specify completely herein, all aspects of design and construction of equipment. Nevertheless, the equipment shall conform, in all aspects, to high standard of engineering, design, workmanship and shall be capable of performing in continuous commercial operation in a manner acceptable to Purchaser. Purchaser shall have the right to reject or accept any work or material which in their assessment is not complete to meet the requirements of this specification and/ or applicable Local/ International Standards.

Any additional equipment, material & services which are not specifically mentioned herein, but are required to make the blending package unit complete in every respect in accordance with the technical specification and for safe operation and guaranteed performance, shall be deemed to be covered under the scope of this specification and included in scope of supply/ work.

4.1. Supply

Main Equipment: 1 Nos. of LPG Blending Package Unit. Blending package Unit will contain following components: Sr. No. Item Designation Quantity

1 Pipe Static Mixer for Propane and Butane Blending 1

2 Pipe Static Mixer for Propane from Storage Tank and Condensate (mainly Propane) from MSV. 1


TCE.6758A-300-B-001



Sr. No. Item Designation Quantity

3 Flow Control Valve for Propane line into Pipe static mixer -1. 1

4 Flow Control Valve for Butane line into Pipe static mixer -1. 1

5 Mass Flow Meter for Propane line into Pipe static mixer -1. 1

6 Mass Flow Meter for Butane into Pipe static mixer -1. 1

7 Mass Flow Meter for blended product (LPG) line from Pipe static mixer -1. 1

8 Pressure Transmitter for Propane line into Pipe static mixer -1. 1

9 Pressure Transmitter for Butane line into Pipe static mixer -1. 1

10 Pressure Transmitter for blended product (LPG) line from Pipe static mixer -1. 1

11 Temperature Transmitter for Propane line into Pipe static mixer -1. 1

12 Temperature Transmitter for Butane line into Pipe static mixer -1. 1

13 Temperature Transmitter for blended product (LPG) line from Pipe static mixer -1. 1

14 Online Three cylinder Gas Chromatogram for Propane, Butane and Blended Product (LPG). 1

15 Online Reid Vapour Pressure Analyzer on Blended Product line (LPG). 1

16 Strainer cum Vapour Eliminator for Propane line into Pipe static mixer -1. 1

17 Strainer cum Vapour Eliminator for Butane line into Pipe static mixer -1. 1

18 Thermal Relief Valve for Propane line into Pipe static mixer -1. 1

19 Thermal Relief Valve for Butane line into Pipe static mixer -1. 1

20 Actuated Valve on Propane line to Pipe static mixer -2. 1

21 Actuated Valve on Butane line to Pipe static mixer -1. 1

22 Actuated Valve on Condensate line (mainly Propane) to Pipe static mixer -2. 1

23 Pressure Transmitter for Condensate (mainly Propane) line from MSV to Pipe static mixer -2. 1


TCE.6758A-300-B-001



Sr. No. Item Designation Quantity

24 Pressure Control Valve for Condensate (mainly Propane) line from MSV to Pipe static mixer -2. 1

25

Control System including software, flow computer & Control Cabinet incl. DCS with communication interface to central DCS for blender based on Online Reid Vapour Analyzer. (MODE-1 – mentioned in pt. 5), Operator (manually on the control system) set target vapour pressure. (MODE-2 – mentioned in pt. 5), Ratio Control. (MODE-3 – mentioned in pt. 5) as per specification no. TCE.6758A-A-580-600, TCE.6758A-A-580-601. Bidders to note that Yokogawa DCS Model CS3000 which is OPC compliant, is available at site with spare I/Os. Required I/Os for the blending skid will be made available by BPCL. Bidders can use the same for blending operation and coordinate with Yokogawa for blending programming and be cost competitive

26 Interconnecting piping and associated valves 1 set

27

Instrument air manifold with valve at battery limit on the skid and tubing for instrument air from manifold to the instruments. Instrument air line to the air manifold valve will be by others.

1 set

28 Explosion proof junction boxes with cabling between field instruments to junction boxes. Cabling between junction box to DCS in control room is be Others

1 set

28 Structural steel for skid manufacturing 1 set

29 Assembly of all the above items into Blending skid at Bidder’s shop and supply the assembled skid to site

30 Set of special tools (if required) 1 set

31 Mandatory and commissioning spares 1 set

Bidder to additionally quote for supply of operational spares for Five years trouble operation. This will not be considered for bid evaluation. Client may order the same in future

4.2. SERVICES

Design & Engineering Mechanical design, Detail Engineering Preparation of detailed P & I D indicating all equipments, line numbers, control

scheme, equipment / instrument tags, process interlocks etc. for Battery limit tie in points.

Civil information drawing including civil loads and foundation load data with all dynamic loads, wind and seismic loads and all foundation bolts.


TCE.6758A-300-B-001



Equipment arrangement drawings, MOC, empty weight, operating, hydrostatic

weight, equipment layout drawing considering the operation and maintenance requirements. Vendor to specify any special layout and arrangement required.

Datasheets/ drawing of all Instrumentation equipment/ Item. Utility consumption as applicable. Service and maintenance instruction/ Operating Manual. Special storage instruction for packing and shelf life of the packing. Inspection & test plan Certificate of conformity. Documentation.

Site Activities Supervision of erection and commissioning Adequate training for the BPCL operating personnel

Service AMC for 5 years after warranty period.

5. PROCESS DESCRIPTION, OPERATING & CONTROL PHILOSOPHY 1. Propane and Butane streams from existing in tank (cryogenic) pump discharge

(after being air heated) shall be blended in static pipe mixer -1. Additionally, prior to the mixing of propane and butane, provision shall be kept for Condensate (mainly Propane) from Mounded Storage Vessels to be blended with Propane stream (from cryogenic tank) in pipe static mixer -2.

2. The combined stream from pipe static mixer -2 will be further mixed with Butane stream in pipe static mixer -1 to produce LPG for TLF gantry or cylinder filling. The individual streams of propane and butane shall pass through vapour eliminator, strainer, check valves, temperature and pressure transmitters, followed by respective control valves and Coriolis type Mass Flow meter. Downstream of mass flow meters, individual streams will be combined in the pipeline and passed through the pipe static mixer -1.

3. The blended stream from blender 1 will be sent to TLF gantry and for cylinder

filling.

4. MODE 1: RVP Control – The operator shall set the desired Vapour pressure for blended product in the DCS. Blending will start with the control valves on both the streams in fully open condition. Reid vapour pressure of both the streams will be calculated in DCS based on the composition of various components measured by GC and the vapour pressure of the different components fed in the DCS. Based on the RVP calculated for the streams, the mass flow measurement and the desired vapour pressure set in DCS the individual flow of the streams will be controlled by operating the control valve. From the feed back received from the RVP analyser


TCE.6758A-300-B-001



installed at the LPG line the signal to the control valves will be fine tuned to achieve the desired Vapour pressure and Constant flow rate at the outlet of Blender. Time taken for RVP to analyse shall be around 6 minutes. Within 15 minutes of start up the circuit should get stabilised. For these 15 minutes the product will be sent to back to Mounded storage bullet.

5. MODE 2: In case of failure of RVP Analyzer, a target vapour pressure of blended product shall be set by the operator from DCS. Blending will start with the control valves on both the streams in fully open condition. Reid vapour pressure of both the input streams will be calculated in DCS based on the composition of various components measured by GC and the vapour pressure of the different components fed in the DCS. Based on the RVP calculated for the streams, the mass flow measurement and the desired vapour pressure set in DCS the individual flow of the streams will be controlled by operating the control valve. In this case there is no feed back since the RVP analyser at the outlet is not working.

6. MODE 3: For ratio control (between Propane and Butane) by Density measurement, a cascade Loop to be implemented in the DCS between LPG flow controller & Propane flow controller. LPG flow controller will measure the LPG flow rate with set-point (adjustable).Output of LPG flow controller (scaled to suitable range) will become Set-point for Propane flow controller. Input to the Ratio controller will be density corrected flow rates of component streams with a set-point (adjustable). Output of the ratio controller will drive set-point of Butane flow controller. Thus Butane flow is actually the manipulated variable to achieve required grade of LPG. Following parameters are considered to be recipe parameters & can be adjusted at an point of time.

7. The maximum vapour pressure will be automatically controlled at 10.5 bar (g) at 40°C through a controller which will control flow of individual streams. The controller shall not accept values of vapour pressure input by the operator beyond the specified range – minimum of 5.2 bar (g) and a maximum of 10.5 bar (g).

8. A Pressure Control Value shall be provided on the Condensate line from Mounded Storage Vessels for reducing the pressure to a specified valve for mixing.

9. The vapour pressure values (derived from component concentration/ composition)

– given by online gas chromatogram analyzer on the blended product stream shall be logged into the system for record.


ISSUE

FOR R0 ISSUE ONLY

FILE

NAME: F042R4.DWG

I&C

MECH

CIVIL

CHEM

ELEC

DEPT

SIGNATURE

CLEARED

DATE

DO NOT SCALE

REVISIONS

DATE

CLEARED

ELEC

CHEM

DRN

CIVIL

MECH

I&C

APPD

FILE NAME

:

OFFICE-DISC:

CHD:

DRN:

SCALE:

DATE

(R0 ISSUE)

TCE FORM NO. 042 R4

NO

DWG

APPROVED

DATE

ISSUE

SIZE-A2

P & I DIAGRAM FOR

LPG BLENDING UNIT, URAN

TCE.6758A-300-PI-8601

LPG BLENDING TERMINAL,

URAN, MAHARASHTRA

BPCL INDIA

P & I DIAGRAM FOR

LPG BLENDING UNIT

P1

NTS

SSS

CH

AE

TE

TRV

FC

NO

XV

LEGEND & SYMBOLS:

NOTES:

PSV

FT

PSV

TRV

MASS BALANCE

STREAM N0.

DESCRIPTIO

N

OP. TEMPERATURE (°C

)

PROPANE FROM

STORAGE TANK

15

17.44

CONDENSATE

FROM MSV

45

25.02

15

18.06

FLOW RATE

(kg/hr.)

0.0

23244.0

69732.0

OP.PRESSURE(kg

/cm

²g)

PY

PCV

FC

15 - 45

16.50 - 17.0

BUTANE FROM

STORAGE TANK

(EX. MIN)

(MIN)

(MAX)

0.0

45770.0

91539.8

-46488.0

120140.0

-45770.0

114783.80

TT TI

15 - 45

16.0 - 17.0

-116220.0

211679.8

45

17.40

LOW PRESSURE

CONDENSATE

0.0

45770.0

91539.8

PROPANE MIX

FROM 10U008

NO

NO

FT

FC

NO

TE

FT

TT TI

AT

NO

NO

TE TT TI

PT PI

PIT

TT

FT

AEAT

AEAT

PT PI

PT PI

TRV

NO

NO

AE AT

AE AT

AE AT

NOTE-1

NOTE-2

NOTE-3

12

34

56

NOTE-1

NOTE-2

NOTE-2

NOTE-2

NOTE-2


10U007 TCE CONSULTING ENGINEERS LIMITED

TATA CONSULTING ENGINEER

SECTION

PROCESS DATA SHEET FOR STATIC MIXER SHEET 1 OF 1

RE

V.

NO. GENERAL REV.

NO. CONSTRUCTION DATA

1. 1 ITEM TAG NO.

10U007 INSIDE PIPE DIAMETER * mm

mm 2. 2 QUANTITY

1 / One SCHEDULE / THICKNESS * mm

3. 3 SERVICE LPG Blending LENGTH FLANGE TO FLANGE * mm

4. DESIGN CODE ASME SEC.VIII DIV. 1, ANSI B16.5

MIXING ELEMENTS FIXED / REMOVABLE

5. 5 BIDDER / VENDOR

* NO.OF ELEMENTS *

6. MODEL NO. * POSITION HORIZONTAL / VERTICAL

7. 7 LOCATION OUTDOOR / INDOOR JACKET YES / NO

8. 8 DUTY INTERMIT. / CONT. 16hr/day DESIGN TEMP.: PIPE / JACKET -45 / 55 0C NA 0C

9. 9 DESIGN PRESS.: PIPE / JACKET 35 kg/cm2(g) NA kg/cm2(g)

10. PHYSICAL PROPERTIES

HYDROTEST PRESS. : PIPE /

JACKET

52.5

kg/cm2(g) NA kg/cm2(g)

11. 1

1 FLUID NAME PROPAN

E BUTANE COMP. 3

CORROSION ALLOWANCE :

PIPE / JACKET 1.5 mm NA mm

12.

PHASE :

GAS/LIQ./SOLID LIQUID LIQUID NA

SURFACE TREATMENT &

PAINTING REFER NOTE 5

13. DENSITY kg/m3

P

P

457.7 -

518.2 587.7 NA MATERIAL OF CONSTRUCTION

14. 1

4 VISCOSITY cP

0.08 -

0.117 0.188 NA HOUSING LTCS

15. SOLIDS : SIZE & % - - NA INTERNALS LTCS

16. 1

6 PERFORMANCE DATA CLADDING / LINING NA

17. FLUID NAME PROPANE BUTANE COMP. 3 FLANGES LTCS

18. FLOWRATE,kg/hr 45769.9 –

114783.8

46488 –

120140 NA BOLTS & NUTS LTCS

19. PRESSURE, kg/cm2g 16.5 – 17 18.06 NA GASKETS SS 304 spwd

20. TEMPERATURE, 0C 15 – 45 15 NA SUPPORTS CS

21. ACTUAL PRESSURE DROP * kg/cm2 NOZZLES LTCS

22. ALLOWABLE PRESSURE DROP Refer 5.3 of TCE.6758A-

300-B-001 JACKET NA

23. DEGREE OF HOMOGENEITY * % NOZZLE SCHEDULE (REFER NOTE 4)

24.

MEASURED PARAMETER FOR

DEGREE OF HOMOGENEITY

COMPOSITION /

TEMPERATURE /

DENSITY

SIZE

NB

RATING

# FACING FINISH

25. PURPOSE OF MIXING BLENDING /

SUSPENDING SOLIDS/ INLET * * * *

26.

DISSOLVING/HEAT

TRANSFER/GAS DISP. OUTLET * * * *

27. ACCESSORIES BY VENDOR SIDE NOZZLE * * * *

28. LIFTING LUGS YES / NO JACKET INLET * * * *

29. COMPANION FLANGES,

NUTS,BOLTS & GASKETS

AS PER PIPING SPEC. /

NA JACKET OUTLET * * * *

30. EARTHING BOSS YES / NO VENT * * * *

31. INSULATION YES / NO DRAIN * * * *

32. WEIGHT OF STATIC MIXER : INSPECTION & TESTS (REF.NOTE 3, 6)

33. 1) EMPTY * kgs. HYDROTEST YES / NO

34. 2) OPERATING * kgs. HOMOGENEITY TEST YES / NO

35. 3) FULL OF WATER * kgs. PRESSURE DROP TEST YES / NO

36. MATERIAL TEST CERTIFICATE YES / NO

37. 4

0 SPARK TEST ( NOTE 8 ) YES / NO

38. OVERALL SPACE REQUIREMENTS : * mm x mm x mm

39. NOTES: 1) * - INDICATES BIDDER TO SPECIFY. 2) NA - INDICATES NOT APPLICABLE.

40. 3) - ALL TEST INSTRUMENTS SHALL BE TRACEABLE TO NATIONAL STANDARDS.

41. 4) REFER ATTACHED PIPING MATERIAL SPECIFICATIONS

42. 5) REFER ATTACHED SPECS. FOR SURFACE TREATMENT & PAINTING

43. 6) REFER ATTACHED SPECS FOR SHOP INSPECTION REQUIREMENTS

44. 7) DIRECTION OF FLUID FLOW TO BE MARKED ON DRAWINGS & EQUIPMENT BY BIDDER.

45. 8) SPARK TEST TO BE PERFORMED FOR LINED ITEMS.

REV. NO PPD.

BY: DG TCE JOB NO. CLIENT : BPCL, INDIA

PPD. BY

/ DATE

/ / CKD.

BY: SS TCE-6758A

PROJECT : LPG BLENDING UNIT AT URAN

MAHARASHTRA

CKD. BY

/ DATE

/ / DATE: 13-04-

2012

PDS NO. : TCE-6758-CH-X-PDS- BL-001

R0

R0

R0 2

002

-09

-30

T

CE

.M4

-CH

-X-P

DS

-440

F

ILE

NA

ME

: P

DS

440.D

OC


10U008 TCE CONSULTING ENGINEERS LIMITED

TATA CONSULTING ENGINEER

SECTION

PROCESS DATA SHEET FOR STATIC MIXER SHEET 1 OF 1

RE

V.

NO. GENERAL REV.

NO. CONSTRUCTION DATA

1. 1 ITEM TAG NO.

10U008 INSIDE PIPE DIAMETER * mm

mm 2. 2 QUANTITY

1 / One SCHEDULE / THICKNESS * mm

3. 3 SERVICE Propane & Condensate Blending LENGTH FLANGE TO FLANGE * mm

4. DESIGN CODE ASME SEC.VIII DIV. 1, ANSI B16.5

MIXING ELEMENTS FIXED / REMOVABLE

5. 5 BIDDER / VENDOR

* NO.OF ELEMENTS *

6. MODEL NO. * POSITION HORIZONTAL / VERTICAL

7. 7 LOCATION OUTDOOR / INDOOR JACKET YES / NO

8. 8 DUTY INTERMIT. / CONT. 16hr/day DESIGN TEMP.: PIPE / JACKET -45 / 55 0C NA 0C

9. 9 DESIGN PRESS.: PIPE / JACKET 35 kg/cm2(g) NA kg/cm2(g)

10. PHYSICAL PROPERTIES

HYDROTEST PRESS. : PIPE /

JACKET

52.5

kg/cm2(g) NA kg/cm2(g)

11. 1

1 FLUID NAME CONDEN

SATE PROPANE COMP. 3

CORROSION ALLOWANCE :

PIPE / JACKET 1.5 mm NA mm

12.

PHASE :

GAS/LIQ./SOLID LIQUID LIQUID NA

SURFACE TREATMENT &

PAINTING REFER NOTE 5

13. DENSITY kg/m3

P

P

457.70 518.2 NA MATERIAL OF CONSTRUCTION

14. 1

4 VISCOSITY cP 0.0803 0.117 NA HOUSING LTCS

15. SOLIDS : SIZE & % - - NA INTERNALS LTCS

16. 1

6 PERFORMANCE DATA CLADDING / LINING NA

17. FLUID NAME CONDEN

SATE PROPANE COMP. 3 FLANGES LTCS

18. FLOWRATE,kg/hr 45769.9 –

91539.8

23244 –

69732 NA BOLTS & NUTS LTCS

19. PRESSURE, kg/cm2g 17.4 17.4 NA GASKETS SS 304 spwd

20. TEMPERATURE, 0C 45 15 NA SUPPORTS CS

21. ACTUAL PRESSURE DROP * kg/cm2 NOZZLES LTCS

22. ALLOWABLE PRESSURE DROP Refer 5.3 of TCE.6758A-

300-B-001 JACKET *

23. DEGREE OF HOMOGENEITY * % NOZZLE SCHEDULE (REFER NOTE 4)

24.

MEASURED PARAMETER FOR

DEGREE OF HOMOGENEITY

COMPOSITION /

TEMPERATURE /

DENSITY

SIZE

NB

RATING

# FACING FINISH

25. PURPOSE OF MIXING BLENDING /

SUSPENDING SOLIDS/ INLET * * * *

26.

DISSOLVING/HEAT

TRANSFER/GAS DISP. OUTLET * * * *

27. ACCESSORIES BY VENDOR SIDE NOZZLE * * * *

28. LIFTING LUGS YES / NO JACKET INLET * * * *

29. COMPANION FLANGES,

NUTS,BOLTS & GASKETS

AS PER PIPING SPEC. /

NA JACKET OUTLET * * * *

30. EARTHING BOSS YES / NO VENT * * * *

31. INSULATION YES / NO DRAIN * * * *

32. WEIGHT OF STATIC MIXER : INSPECTION & TESTS (REF.NOTE 3, 6)

33. 1) EMPTY * kgs. HYDROTEST YES / NO

34. 2) OPERATING * kgs. HOMOGENEITY TEST YES / NO

35. 3) FULL OF WATER * kgs. PRESSURE DROP TEST YES / NO

36. MATERIAL TEST CERTIFICATE YES / NO

37. 4

0 SPARK TEST ( NOTE 8 ) YES / NO

38. OVERALL SPACE REQUIREMENTS : * mm x mm x mm

39. NOTES: 1) * - INDICATES BIDDER TO SPECIFY. 2) NA - INDICATES NOT APPLICABLE.

40. 3) - ALL TEST INSTRUMENTS SHALL BE TRACEABLE TO NATIONAL STANDARDS.

41. 4) REFER ATTACHED PIPING MATERIAL SPECIFICATIONS

42. 5) REFER ATTACHED SPECS. FOR SURFACE TREATMENT & PAINTING

43. 6) REFER ATTACHED SPECS FOR SHOP INSPECTION REQUIREMENTS

44. 7) DIRECTION OF FLUID FLOW TO BE MARKED ON DRAWINGS & EQUIPMENT BY BIDDER.

45. 8) SPARK TEST TO BE PERFORMED FOR LINED ITEMS.

REV. NO PPD.

BY: DG TCE JOB NO. CLIENT : BPCL, INDIA

PPD. BY

/ DATE

/ / CKD.

BY: SS TCE-6758A

PROJECT : LPG BLENDING UNIT AT URAN

MAHARASHTRA

CKD. BY

/ DATE

/ / DATE: 13-04-

2012

PDS NO. : TCE-6758-CH-X-PDS- BL-002

R0

P0

R0 2

002

-09

-30

T

CE

.M4

-CH

-X-P

DS

-440

F

ILE

NA

ME

: P

DS

440.D

OC


SPEC. NO. TCE.6758A-A-580-600

TATA CONSULTING ENGINEERS LIMITED SECTION:

INSTRUMENTATION SPECIFICATION FOR LPG BLENDING PACKAGE

SHEET 1 OF 41

TCE FORM NO. 329 R5 FILE NAME: F329R5.DOC

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Table of Contents 1. GENERAL INFORMATION……………………………………………………………..........2

2. CODES & STANDARDS.........................................................................................3

3. BASIC DESIGN CRITERIA....................................................................................5

4. OPERATION PHILOSOPHY OF BLENDING UNIT …………………………………….....7

5. FUNCTIONAL REQUIREMENTS OF BLENDING SOFTWARE …………………………7

6. CONTROL SYSTEM SPECIFICATIONS …………………………………………………...8

7. BLENDING SOFTWARE REQUIREMENTS……………………………………………….14

8. SALIENT FEATURES OF DIGITAL CONTROL VALVES………………………………...15

9. CORIOLIS MASS FLOW METER SPECIFICATIONS…………………………………….16 10. PRESSURE CONTROL VALVE…………………………………………………………… 18

11. ON-OFF VALVE.............................................................................................................20

12. PRESSURE TRANSMITTER........................................................................................22

13. SPECIFICATIONS FOR MULTI STREAM (MINIMUM 3 STREAMS …………………...23

ON LINE GAS CHROMATOGRAPH)

14. SPECIFICATION FOR REID VAPOR PRESSURE ANALYSER …………………….30 15. PRESSURE GAUGE………………………………………………………………………….34

16. TEMPERATURE GAUGE …………………………………………………………………… 35

17. TEMPERATURE ELEMENT………………………………………………………………… 37

18. TEMPERATURE TRANSMITTER………………………………………………………… 39

19. GAS DETECTOR ……………………………………………………………………………40


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1. GENERAL

This specification covers the general requirements of instrumentation to be provided for Propane Butane Blending Unit for OWNER’S Uran. This specification shall be read in conjunction with the following specifications / design guidelines attached. Vendor to prepare offer on LSTK basis.

1.1 CONTRACTOR'S RESPONSIBILITIES Contractor's responsibilities for instrumentation engineering shall include, but are not limited to, the following:

(a) Instrumentation engineering including engineering of field instruments, analysers and sampling system, control system, development, supply and installation of software packages, preparation of material take-off like cables, impulse and air piping ,cable trays, junction boxes, structural steel etc. Preparing interlock and logic schemes, instrument installation sketches, hook-ups, Loop drawings etc.

(b) Procurement and supply of all instruments (Field & Control Room) such as control valves, analysers, DCS based control system including all the hardware & software required for blending skid, power Distribution board(PDB’s).

(c) Transportation and unloading of blending skid and DCS system at site.

(d) Supervision of erection & Installation of Instruments at site.

(e) Integration with existing DCS.

(f) Supervision of Loop checking and commissioning of the I&C system upto DCS along with OWNER’s's/consultant's staff, carry out guarantee test runs, running the facilities till final handing over to the OWNER’s.

(g) Documentation including as-built documentation.

(h) Supply and termination of various interconnecting cables between marshalling racks and system hardware cabinets will be in Bidder’s Scope.

(i) All the network cables to operating station and Engineering Station will be in Bidders scope.

(j) The Laying cables from field to marshalling cabinet and termination of the same shall be by others.

(k) Supply of mandatory spares, common spares & 5years recommended spares.

(l) Design, Supply & Erection of all Ex-Proof junction boxes (JB) and Air Manifolds along with required erection hardware. All the accessories required such as mounting supports, cable glands, etc for Junction boxes shall also be in the scope of contractor.

(m) Any other items required for completing I&C system for the Blending Skid.

(n) Factory Acceptance tests (FAT) to meet the design specifications & functional requirements (for the items supplied by Contractor).

(o) Integration, Site Acceptance Tests (SAT) including loop checking & commissioning, trial runs of all the above systems to meet the design


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specifications & functional requirements.

(p) UPS power supply feeders of 110V AC upto PDB located in DCS control room.

(q) Training of Purchaser’s personnel.

2. CODES & STANDARDS

The design, manufacture, inspection of all equipment and systems covered herein shall conform to the latest editions of codes and standards mentioned below. Where a conflict between the codes might exist, the most stringent requirements shall govern.

ASME PTC 19.3 ASME Performance test codes - supplement on instruments and apparatus, Part 3 temperature measurement

API (American Petroleum Institute) API RP-520 Design & Installation of Pressure Relieving Systems in

Refineries

API RP 521 Guide for Pressure Relieve and Depressurising Systems

API RP 526 Flanged Steel Safety Relief Valves

API RP 527 Commercial Seat Tightness of safety Relief Valves with Metal to Metal Seats

RP551- Part -1 Process Measurement Instrumentation

RP552 Transmission Systems

RP553 Refinery Control Valves

RP554 Process Instrumentation and Control

RP555 Process Analyzers

API 607 Specification for Fire Test for Valves

API 6FA Fire test for Soft seated Quater turn Valves

IS (Indian Standards) IS - 2148 Enclosure for instruments in hazardous area

IS - 2848 Industrial Platinum resistance thermometer

IS - 3624 Pressure & Vacuum Gauges

IS-13947 Protection Class for Enclosure, Cabinets, Control Panels and Desks

IEC (International Electro-Technical Commission) IEC 60751 Industrial Platinum Resistance Thermometer Sensors.

I EC 60079-0 Electrical apparatus for Explosive Gas atmosphere

IEC 60079-1 Construction & Verification Test of Flameproof Enclosure for Electrical Apparatus.


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IEC 60079-2 Electrical Apparatus for Explosive gas Atmosphere - Electrical Apparatus Type of Protection "P"

IEC 60079-7 Electrical Apparatus for Explosive gas Atmosphere, Part 7: Increased Safety EEx'e'

IEC 60079-8 Classification of Maximum Surface Temperature

IEC 60079-11 Electrical Apparatus for Explosive gas Atmosphere, Part 11: Construction & Test of Intrinsically Safe and Associated Apparatus.

IEC 60079-16 Electrical Apparatus for Explosive gas Atmosphere - Artificial Ventilation for Protection of Analyzer houses

IEC60801 Electromagnetic compatibility for Industrial Process Measurement and Control equipment.

IEC 61131-3 (1993-03)

Programmable controllers – Part 3, Programming Languages

IEC 61131 Programmable controllers

BS (British Standards) BS EN ISO 5167-1

Measurement of fluid flow by means of pressure differential devices

ISA (Instrument Society of America) ISA S12.4 Instrument purging for reduction of hazardous area

classification

ISA S 5.1 Instrumentation symbols and identification

ISA S-5.2 Graphic symbols for Distributed Control/Shared Display Instrumentation Logic and Computer system

ISA S7.3 Quality standard for instrument air

ISA S18-1 Alarm Sequence

S-75.01 Flow equations for sizing control valves.

S-75.04 Face to Face Dimension for Flangeless Control Valve Body

EN

EN 10204- 2.2 – Material Test Report for Instrument Wetted Parts

EN 10204- 3.1B – Material Test Report for Flanges & Spacer Rings

All codes and standards referred shall be the latest version on the date of offer made by the Bidder unless otherwise indicated.


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3. BASIC DESIGN CRITERIA 3.1 All field instruments being offered/ supplied should have been operating

satisfactorily in a hydrocarbon industry like Refinery, Petrochemical and Gas Processing Plant under similar process conditions for at least 4000 hrs. Proven Track Record (PTR) for all field instruments shall be considered for minimum of 4000 hours and for system oriented items such as Analysers, PLC, controllers etc., the same shall be minimum 1 year.

3.2 The instrumentation selected for the unit shall be rugged in design. Prototype design or equipment of experimental nature or design undergoing testing etc., shall not be selected and supplied.

3.3 All I&C equipment shall be fully tropicalised. All instruments shall be suitable for use in hot, humid, tropical & dusty climate in which corrosive gases may be present. The instruments shall be suitable for outdoor installations, considering temperature, humidity etc., as per the data given elsewhere in the tender document. All instruments, their supports including all mounting hardware, manifolds, and fittings shall be suitable for the application.

3.4 The design of electronic instruments shall be in compliance with the electromagnetic compatibility requirements as per IEC 801 “Electromagnetic compatibility for Industrial Process Measurement & Control Equipment”.

3.5 All Field mounted instruments shall be weatherproof to IP-65. All instruments of submersible type shall be protected to IP-68. The instruments shall be suitable for the area classification.

3.6 The standard signals for measurements & control signals shall be 4-20 mA. 3.7 All transmitters shall be SMART type with HART protocol unless otherwise

indicated. All transmitters shall have local digital indication (LCD). 3.8 Valve positioners shall be conventional type unless otherwise indicated,

operating on input signal of 4-20 mA. 3.9 In addition, vendor shall provide the 'Manufacturer's certificate of Conformity' to

purchaser's specifications as per clause 2.2 of EN 10204.

3.10 Instrumentation for Hazardous Areas 3.10.1 Certified intrinsically safe equipment shall be used, in general, in hazardous

area. In case intrinsically safe equipment is not available, flameproof/ex-proof enclosures shall be provided.

3.10.2 Intrinsically safe, flameproof instruments/ enclosures shall be certified to the specified hazardous area by a statutory body like FM, UL, CENELEC, CMRI etc. In addition for instruments installed in hazardous area, CCOE (Chief Controller of Explosives) certification shall be complied with. CCOE Certificates for all instruments installed in hazardous area shall be provided by the vendor. This Vendor shall ensure that CCOE certification for instruments is available before mechanical completion of the plant.


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3.10.3 Intrinsically Safe System Requirements

(a) Safety barriers with galvanic isolation (active barriers) shall be used to achieve intrinsically safe signals. The intrinsic safe barrier shall be certified for intrinsic safety by any statutory authority. Intrinsic safe barrier shall be provided also for potential free contacts wired from switches in hazardous areas.

(b) Barriers must be selected based on entity concept. Cable parameters shall also be considered while matching entity parameters.

(c) Each input & output in a loop shall have separate barrier. No barrier shall be shared between two loops or inputs/outputs.

(d) Any intrinsically safe loop requiring any device to be connected in the hazardous side permanently or temporarily shall also be intrinsically safe.

(e) Following concepts shall be applied for protection if intrinsically safe or flameproof concept cannot be applied.

i. Increased safety method. ii. Pressurization method.

3.11 For junction boxes mounted outdoors, IP 65 protection class shall be provided. For junction boxes mounted indoors, IP 52 protection class shall be provided. Junction boxes and cable glands for ex-proof instruments (if any) shall be ex-proof.

3.12 All valve manifolds for instruments shall be fabricated at site. 3.13 All transmitters (flow, level, pressure, temperature) shall be of SS-316 MOC

minimum for body, flanges and all wetted parts. For Superior material shall be provided if process condition demands, subject to TCE/OWNER’S’S’s approval.

3.14 Enclosures of field transmitters and switches shall be die cast aluminium with epoxy painting as a minimum.

3.15 Material of construction for solenoid valves shall be SS 316 i.e. body & wetted parts.

3.16 All pneumatic tubing shall be of SS 316, unless otherwise specified. 3.17 The rating of flanges for instruments shall be 300# as per ANSI. Higher rating

shall be provided as per the piping material specification for the application. 3.18 Cable entry for instruments shall generally be ½” NPT (F). 3.19 All instruments mounted outdoors shall be provided with FRP canopy for

protection from top & sides. 3.20 All instruments shall be provided with SS tag plate.

Power Supply 3.21 Primary source of power shall be 110 V AC + 10%, 50 Hz, UPS power.


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3.22 The voltage levels shall be as specified in the respective package specifications.

3.23 24 VDC power supply required shall be derived by the bidder using 24 V DC power supply units in redundant configuration with diode Or-ing. The maximum loading of the power supply units at full load shall not exceed 75%.

3.24 Instrument power circuits shall be individually protected with the help of MCBs. 3.25 Electric actuators for valves & dampers shall operate on 415 V AC, 3 Ph, 50

Hz. Air Supply

3.26 Instrument air shall be made available at the battery limits of the package. Instrument air quality shall be as per ISA-S7.3

4. OPERATION PHILOSOPHY OF BLENDING UNIT

The blending control system shall be located in the existing LPG control room. Refer Process Engineering Specification Doc No.( TCE.6758A-300-B-001)for details of operations philosophy.

5. FUNCTIONAL REQUIREMENTS OF BLENDING SOFTWARE 5.1 FIELD EQUIPMENTS (refer P&ID for LPG blending unit, document

no. TCE-6758A-300-PI-8601)

Ratio control blenders are suitable for any liquid hydrocarbon blending application provided the quality of the feedstock & final product is consistent and known. To achieve the same following major field instruments shall be provided. (a) Coriolis Mass Flow Meters for Propane, Butane & LPG.

(b) 3-Stream online Gas chromatograph to monitor Mole fraction of Propane, Butane & blended LPG. Coriolis. Mass Flow Meters will also monitor real-time density & specific gravity of all three streams.

(c) Online Reid Vapor Pressure Analyser for measurement of vapour pressure of the blended product.

(d) Digital Control Valves.

(e) Pneumatically Actuated On-Off Valve

(f) Pressure Control valve.

(g) Temperature Element (RTD).

(h) Temperature Transmitter.

(i) Pressure Transmitter.

(j) Gas Sensors shall b e installed near the blender assembly with alarms as an additional safety feature.

(k) Any other instrumentation as required by process.

5.2 CONTROL PHILOSOPHY

Refer to specification no. TCE.6758A-300-B-002


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6. CONTROL SYSTEM SPECIFICATIONS

The control system shall provide following functions. (a) Process control & interlocks.

(b) Monitoring

(c) Alarm management

(d) Event logging & Historising / trending

(e) Report generation

(f) Communication with existing DCS systems (Modbus or OPC)

(g) Diagnostics

System is to be designed to ensure consistent quality throughout the batch even during tank changes, feedstock starvation, loss of power or the unlikely failure of a system component.

6.1 FUNCTIONAL REQUIREMENTS

6.1.1 BASIC PROCESS CONTROL FUNCTIONS

Basic process control functions shall be executed at the DCS using predefined algorithms with configurable parameters. As a minimum, predefined basic process control functions shall include the following:

(a) PID control

(b) Ratio control

(c) Gap control

(d) Split range control

(e) Lead / lag control

(f) Mathematical functions such as addition, subtraction, etc.

(g) Logic algorithms such as "AND", "OR", Time Delay, Override selection, flip/flop

(h) Logic, Set/Reset, etc.

(i) Flow compensation (pressure and temperature).

As a minimum, the System shall have the capability for back initialise, set point tracking, and PV tracking.

Since PID control & Ratio control functions will be extensively required for the blending application, they are elaborated below.

6.1.2 PID CONTROL The PID function in DCS shall combine the necessary logic to perform analog input processing, proportional-integral-derivative (PID) control with the option for nonlinear control (including error-squared and notched gain), and analog output processing. It shall support mode control, signal scaling and limiting, feedforward control, feedback control, override tracking, alarm limit detection, and signal status propagation.

The function should support minimum of two modes viz. Auto & Manual.


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There should be facility to apply Low & High limits to both Setpoint & Outputs with a facility to override the same when in Manual mode. Also it should be possible to limit rate of change of Setpoint & Outputs individually in up & down directions.

The PID function shall support following equations/structures

(a) PID Action on Error

(b) PI Action on Error, D Action on PV

(c) I Action on Error, PD Action on PV

(d) PD Action on Error

(e) P Action on Error, D Action on PV, ID Action on Error

(f) I Action on Error, D Action on PV.

Status propagation of I/O as well as upstream/downstream blocks (e.g. cascade loop) & mode switching should be efficiently handled by PID function. The control system shall have integral package for "Auto-Tuning" of PID loops with both "On-demand tuning approach" & "Adaptive-tuning approach"

6.1.3 RATIO CONTROL The Ratio (RTO) function is usually employed to drive the flow rate of a secondary flow stream to a set point that is a specified ratio of a primary flow stream. The block has two inputs: Input 1 which is the flow rate of the primary stream and Input 2 the flow rate of the secondary flow stream. The Ratio block's set point is the ratio (secondary flow rate) / (primary flow rate). This output is normally fed out to a PID flow controller for the secondary stream.The Ratio function shall support signal filtering, mode control, output tracking, and alarm detection. This function block is normally used in a cascade configuration and hence supports normal block-to-block communication. It shall have configurable gain & the output equation should be OUTPUT = (SETPOINT) * (GAIN) *(Input1) Similar to PID block, it shall also support High & Low limits for Set points & Outputs. There should be facility to limit rate of change of Setpoint & Output individually in up/down directions. It shall also support Auto, Manual & Cascade with bumpless transfer on mode transitions.

6.1.4 PRODUCT BLENDING

The features of the Product Blending shall include:

(a) Store characteristics and/or composition for component & product streams.

(b) Select product specification for blending, its throughput.


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(c) Optimization algorithms for blending

(d) React to process disturbances and equipment failure with minimum operator intervention.

(e) Start and stop, resume, cancel blends

(f) Store blend audit trails.

6.2 GENERAL SYSTEM REQUIREMENTS

6.2.1 REAL TIME DATA STORAGE The system shall have a real time and historical data collection facility to support trends, logs, and reports as required. It shall also be possible to transfer data to removable media for long term storage and/or archiving.

6.2.2 DIAGNOSTIC AND MAINTENANCE REPORTING System shall be capable of executing comprehensive diagnostics. As minimum, the System shall provide summary of:

(a) Field circuit failures,

(b) I/O card failures,

(c) Processor CPU / Memory Overload,

(d) Signal transmission faults (communication link),

(e) Network performance reports,

(f) Power supply failures,

(g) Processor failures,

(h) Short circuit/open loop,

(i) Software forcing. 6.2.3 Environment

Control System equipment shall be installed in a pressurised, air-conditioned, non-hazardous environment within control room. Field devices shall be suitable for operation in a refinery & shall be suitable for installation in the hazardous areas.

6.2.4 System Availability & Redundancy The system shall be, cost effectively, designed to achieve an availability of 99.99% with an assumed Mean Time To Repair (MTTR) of 8.0 hours or less and a Mean Time Between Failure (MTBF) of 40,000 hours or more. In order to meet the required system availability, redundancy and/or fault tolerant technology shall be incorporated. As a minimum, the following equipment shall be redundant:


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(a) Communication Networks ,the redundancy shall be in cable ,common module & switches.

(b) DCS Processors

(c) Power Modules

(d) Power Supply convertors (eg 110 VAC to 24 DC convertor) with diode OR-ring.

The redundant system shall be designed so that, on failure, automatic changeover to alternative equipment/communication path shall take place seamlessly. In addition, the equipment shall be supplied with the facility for manual changeover. It shall be possible to replace and test any equipment/communication path without disrupting the execution of the processor (hot swappable).

6.2.5 Power Supply & Grounding The control system shall be powered by two separate 110V AC UPS feeds. The UPS shall provide 30 minutes minimum back-up time. Instrument earth shall be provided separate from power earth. In case, I.S instruments are used, its control system vendor responsibility to provided I.S. IO cards or suitable barriers. They shall be grounded to separate I.S. earth.

6.2.6 DCS PROCESSOR UNIT

The DCS Processor Unit shall be redundant and hot swappable. Upgrading firmware, system configuration (i.e. adding/deleting/changing IO configuration) shall be possible without halting loop execution. Normally, the DCS shall execute control loops at 0.5 second. However, the DCS shall be capable of executing control loops at 250ms (or faster) if needed.

6.2.7 DCS I/O MODULES I/O shall be allocated such that independent process units/trained equipment can be maintained, or, a failure of I/O module shall not affect independent (or mutually exclusive) process areas.

(a) All outputs shall be individually fused.

(b) All inputs and outputs shall be short circuit proof.

6.2.8 ACCESS CONTROL & PROTECTION

Access control shall be applied to operating areas and then to associated process units. It shall support at least four different access profiles via removable key and/or by a pre-configured password protected access profiles:

(a) Operator,

(b) Maintenance / Engineer,

(c) Supervisor,

(d) Systems Administrator.


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The network shall only be used for communication by predetermined System network devices. The network shall not permit unauthorised network devices to be connected with the system network. External connections with System network shall be prohibited.

6.2.9 PC / SERVER PROTECTION A virus scanner shall be installed on all PCs and servers. The type of virus scanner software and security policy shall be approved by Customer.

6.2.10 REMOTE ACCESS Remote access shall be permitted to the DCS network for remote diagnostics by system Vendor. This connection shall not be a permanent installation.

6.2.11 PRINTER

The DCS shall be provided with printers capable of printing in A3 and A4 paper sizes on demand.

6.2.12 SYSTEM & MARSHALLING CABINETS The field multi-core cables shall be terminated on terminal strips inside a marshalling cabinet. The signals in the multi-core cables shall be "patch wired" to the DCS termination assemblies also located in the marshalling cabinets. The signals are transferred to the system I/O modules via robust system cables. A typical marshalling cabinet may house:

(a) Terminal strips

(b) DCS termination assemblies

(c) Power supply and distribution circuits for instrument power

(d) Signal conditioners (i.e. pulse / current converter, isolators).

(e) IS barriers

A typical system cabinet may house:

(a) Control system chassis, processors, IO modules

(b) System Servers

(c) System power distribution circuits

(d) Network Infrastructure (Hubs, Switches). For application with limited I/O quantity, the vendor may suggest to club marshalling & System components in the same cabinet.

6.2.13 OPERATOR INTERFACE DCS Vendor supplied operator console shall be provided complete with integrated keyboard, monitors, and pointer device. A console may comprise of the following equipment:


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DCS graphics shall show a graphical representation of the process plant. The operator interface shall consist of standard graphics, faceplates, trends, and symbols to provide a complete and integrated interface for monitoring and control of the plant. Graphic displays can be divided into "standard" and "custom" types. The custom graphic display details a schematic presentation of the plant at different levels, from overview level right through to equipment detail level. These graphic shall be accessible by function keys on the operator keyboard. The real time data within these displays shall be automatically updated with a configurable refresh rate of four seconds or less. Under fast update mode, the refresh rate shall be no more than 2 seconds. The appearance and operation of all displays shall follow a standard and consistent approach for the entire plant, including display layout, data, and alarm representation, audio alerts, colour choices, and navigation procedures. This shall apply equally to licensor/package units as for main process units, off-sites and utilities. A display hierarchy shall be provided and shall show on "site map" type graphic(s). For example, the plant overview display shall give access to unit or area menu overview displays, and further down to associated process unit graphics and sub unit graphics and package/machinery graphics.

6.2.14 ALARM SYSTEM Dedicated display/screen on the operator console shall display all process alarms chronologically. Clicking on the alarm tag shall automatically change to related graphic screen. It shall be possible to filter the alarm based on process unit. Any component failure shall be annunciated. Alarms shall be categorised in to minimum 4 priorities (journal, low, medium, high). For each category, the audio and visual representation shall be different on both DCS graphics and alarm display. Time stamp of the alarm or event shall be at the controller level. Alarm suppression facility shall be available to manually/automatically suppress alarms. DCS graphic shall show list of masked alarm by equipment, process unit etc.

6.2.15 NETWORK ARCHITECTURE

DCS networks and their infrastructure (i.e. switches, firewalls) communication links shall be fault tolerant. The redundant/secondary communication path shall either be used continuously or checked at least once per minute to ensure correct operation. Status changes shall be alarmed at the operator consoles. Manual changeover facilities shall also be provided.

6.2.16 GENERAL

The offered system shall have the provision to synchornize with the existing Plant DCS system (Yokogawa Centum 3000)


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7. BLENDING SOFTWARE REQUIREMENTS The main objective of this module is to automate the blending system startup, operation and shutdown. This module performs sequencing and ramping the component valves until the proper flows are established and the Flow Ratio Control can take over. At the end of the blend, as indicated by the total blended amount reaching its target, the module will automatically shut down the blending system in an orderly manner. The module will automatically trigger the blend totalizers to zero out when a new blend is started. Operators use the main startup screen for initiating or terminating a blend. Component and finished product tanks are defined along with target ratios, blend mode, batch size, target blend rate and other control parameters. Initial blend orders and recipe targets may be entered manually by the operator or stored as recipes in recipe modules. Recipes shall have a completely flexible structure that allows any type of data (ratio targets, quality specifications, additives, etc.) to be part of a recipe record. The main Blend sequence function chart (SFC) executes the start up sequences, by opening valves, starting pumps, and ramping component flows to the desired ratio targets. If there is a detected equipment malfunction during the blend, the Fail Monitor application brings the blend to a Hold state until the malfunction can be corrected. Once corrected, the blend can then resume from the point of interruption. The blend ratio controller performs the calculation of component flow controller targets to meet a total blend flow rate set point and the associated ratio targets. This controller observes all variable limits, including both flow rate and valve positions, to control ratios even if the total flow target cannot be reached. This control module must interact with the start/stop operations to smoothly take control on startup and pass control on shutdown. Component ratios can either be set manually by the operator or remotely by a higher level application. The blend ratio controller also performs the "pacing" function that decreases the master blend flow target whenever a maximum valve constraint on one of the components is approached. The ratio controller observes maximum and minimum limits on the flows, header pressure limits and valve position limits for: The Blend Regulatory Control module needs to be operated in two different modes:

(a) Ratio Control - Component flow set points are calculated from the target ratio times the Master Blend rate that is set by the operator.

(b) Volume Control - Component flows are adjusted to control the flow totalizers to the target ratio. This allows the system to compensate for ramping or pacing conditions that have caused the aggregate ratios to deviate from their desired target.

The blender needs to be operated in Continuous or Batch mode. In Batch mode operation, the blender stopping sequence is initiated when the desired batch quantity has been reached.


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8. SALIENT FEATURES OF DIGITAL CONTROL VALVES For the proposed blending facility, Power Cylinder type Pneumatically Operated and Electrically Actuated Multi Stage Digital Control Valve has been considered which is a Piston Type Digital Control Valve fitted in each propane & butane line with fail-safe design & ANSI leakage class VI positive Bubble Tight Shut-off. It is so designed that precise flow rate control and delivery of fluid products with an electronic DCS controller against the settings provided at a preset value is achieved. It is automatically controlled by DCS Controller Cards for low flow start up, high flow rate control, low flow shutdown and the start shut off. This valve also provides maximum flow meter accuracy by maintaining a constant flow rate with varying line pressures. It features an external pilot control loop that consists of a normally open solenoid pilot, a normally closed solenoid pilot, strainer and opening/closing controls. General Specifications: Flowrate

Propane Stream 4 (Min / Max) :- 45770 Kg/hr /114783 Kg/hr

Butane Stream 5 (Min / Max) :- 46488 Kg/hr /120140 Kg/hr

LPG Stream 6 (Min / Max) :- 116220 Kg/hr / 211680 Kg/hr Pressure Propane Stream 4 (Min / Max) :- 16.50Kg/cm2 / 17.0Kg/cm2

Butane Stream 5 (Operating) :-18.06Kg/cm2

LPG Stream 6 (Min / Max) :- 16.0Kg/cm2 / 17.0Kg/cm2 Temperature Propane Stream 4 (Min / Max) :- 15 °C / 45 °C

Butane Stream 5 (Operating) :- 15 °C

LPG Stream 6 (Min / Max) :- 15 °C / 45 °C

Material of Construction: Main valve Body Steel –ASTM-A352-GR-LCC Main Valve Cyclinder SS Heat treaded 17-4 Valve Piston SS 304 Seat Ring SS 304 O-Ring Standard-Viton Other internal Parts SS Pilot Valve.Strainer/Needle Valve Trim

SS


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Tubing & Fitting Standard SS

Type : Globe / Piston

Fire safe : Required (As per API 6FA / API 607)

Quick closing required :Required (20 Sec Max)

Leakage Class : class V

Actuation media : Air

Failure Position : Fail to Close

Radiography Test : Required

Some of the important features and benefits of Digital control valves desirable in offered system are indicated below:-

(a) Fail safe on loss of power / medium

(b) Precise flow rate & batch control

(c) Modular Construction - All internal parts including seat and seat ring may be removed as a cartridge assembly without the need to remove the valve body from the system piping.

(d) No diaphragms and stuffing boxes.

(e) 45° body design assures high capacity and low pressure drop.

(f) Positive (bubble tight to class VI) shut-off.

(g) Linear control characteristics with uniform response speed. DRAWINGS & DOCUMENTS: (a) Vendor to submit all the test certificates for consultant/purchaser's review &

records. (b) Vendor to submit data sheets, actuator sizing, spring spring action (valve

Open/Close), dimensional drawings showing mounting details, weld end details, actuators, stem removal spacings, hand wheel orientation, weight and parts list: for purchaser's approval.

9. CORIOLIS MASS FLOW METER SPECIFICATIONS

Flowrate



LPG Stream 6 (Min / Max) :- 116220 Kg/hr / 211680 Kg/hr


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Pressure Propane Stream 4 (Min / Max) :- 16.50Kg/cm2 / 17.0Kg/cm2

Butane Stream 5 (Operating) :-18.06Kg/cm2

LPG Stream 6 (Min / Max) :- 16.0Kg/cm2 / 17.0Kg/cm2 Temperature Propane Stream 4 (Min / Max) :- 15 °C / 45 °C

Butane Stream 5 (Operating) :- 15 °C

LPG Stream 6 (Min / Max) :- 15 °C / 45 °C

Mass Flow Accuracy : +/-0.10 % (10:1 Turndown) or better Mass Flow Repeatability : +/-0.05% (10:1 Turndown) Density Accuracy : +/-0.005 gm/cc Density Repeatability : +/-0.0002 gm/cc Turndown :10 : 1 Wetted Part Material : SS 316 Temp Class : T3 Flange :SS316 Type : Coriolis Type

Desirable Coriolis Mass flow Meter Features : (a) The Coriolis flow meter shall be dual tube type and should generate electrical

pulse signals corresponding to the flow rate. Coriolis meter shall be suitable for the service conditions specified herein.

(b) Metering range ability, within the specified total accuracy limits of +/-0.10% of rate (repeatability of +/-0.05% net), shall be for a minimum ratio of 10:1 for mass flow rate and Density accuracy of +/-0.0005 gm/cc (repeatability of +/- 0.0002 gm/cc) for density measurement for the entire range

(c) Pressure compensation should be provided for the offered Coriolis meters for better performance, with the pressure transmitter mounted downstream of the Coriolis meter. Vendor to provide mass and volume accuracy chart of the meter considering both pressure and temperature compensation effect. Pressure and temperature compensation to be done in Flow computer.


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(d) Separate temperature transmitter is to be provided for flow compensation.

The specification for the Flowmeters will remain same for Flowmeters in both the

blending skid.

10. PRESSURE CONTROL VALVE

GENERAL Service : Propane

Pressure (Operating) : 25.02 Kg/cm2

Temperature (Operating) : 45°C

Flowrate Propane Stream 2 (Min / Max) :- 45770 Kg/hr / 91539 Kg/hr PIPING DATA Material : SS 316

Inlet/outlet size : Bidder to State VALVE DATA

Body style : Globe

Port : Single

Trim : Un-balanced

Application : Modulating

Failsafe action : Bidder to state

VALVE BODY Rating : ANSI B 16.5 300#

End connection : As Per PMS

Material : As Per PMS

Flow direction : To be indicated on Body

BONNET DETAILS Type : Standard

Material : SS

Gasket : Neoprene/Viton

Packing material : PTFE

TRIM Flow characteristics : Equal percentage

Guiding : Top

Seat : Metal

Stem mterial : SS316


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Plug material : SS316

Seat material : SS316

Guide/Cage Material : SS316

VALVE ACTION Push down to : Close

Flow direction : Flow to Open

ACTUATOR Type : Diaphragm

Diaphragm material : Nitrile rubber

Size/effective area : *

Spring to : Open

Increase in signal stem moves : up

Hand wheel : Not Required

Adjustable stop : Required

Travel indicator : Yes

Mounting : Horizontal

ACCESSORIES: Air filter regulator : Required – 2 Nos

a) Body : SS

b) Filter : Sintered Bronze

c) Filter Size : 5 micron

d) Input / Output Gauges : Required

I/P Converter a) Input Signal / Output Signal : 4-20 mA / 0.2 - 1 kg/cm² (g)

b) Intrinsically Safe : Required

c) Linearity / Electrical conn. : +/-0.5% of span / 1/2" NPT (F)

d) Input / Output Gauges : Required

e) Pneumatic Connection : 1/4" NPT (F) Name plate : SS

Airlock device : NA

Booster : NA

Volume tank : NA

PAINTING Protection for rust prevention : Required

Codes and standard : As per IS-6005, 1970


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Raw finish and paint finish : To be confirmed by bidder

DESIGN DATA Pressure : Refer Follow up sheet

Temperature : Refer Follow up sheet

Shutoff diff pressure : Refer Follow up sheet

Shut of class (leakage) : Class IV

Codes and standards : ASME/ANSI, ISA 75.01

TEST: Hydrostatic test, seat leakage test : As per ANSI B16-104

CV test : As per ISA procedure

Radiography Test : Required

Calibration and hysteresis test : Required

Actuator leakage test : Required

DRAWINGS/DOCUMENTS: Vendor to submit all the test certificates for consultant/purchaser's review & records.

Vendor to submit data sheets, Calculations for valve sizing, I/P Convertor, outlet velocity, flashing, noise and actuator sizing, dimensional dwgs showing mounting details, weld end details, actuators, stem removal spacings, hand wheel orientation, weight and parts list: for purchaser's approval.

Note: (a) I/P Convertor , actuators and accessories requiring tubing shall be mounted,

valved & tubed.

(b) Valves with anti-flashing, low noise, anti-cavitation trim shall be selected if noise level exceeds 85dBA @ 1mt distance.

(c) Valve should be Fire Safe, following API 6FA / API 607

11. ON-OFF VALVE

Pressure

Stream 1 (Operating) :- 17.44 Kg/cm2

Stream 2 (Operating) :- 25.02 Kg/cm2

Temperature

Stream 1 (Operating) :- 15°C

Stream 2 (Operating) :- 45°C Flowrate


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Stream 1 (Min / Max) :- 23244Kg/hr /69732 Kg/hr

Stream 2 (Min / Max) :- 45770Kg/hr / 91539 Kg/hr

VALVE DATA

Body style : Ball

Size

Stream 1 : Bidder to State

Stream 2 : Bidder to State

Port : Single

Trim : Un-balanced

Application : Modulating

VALVE BODY Rating : ANSI B 16.5 150#

End connection : Flanged

Material : SS 316

Flow direction : To be indicated on Body ACTUATOR Type : Pneumatic

Hand wheel : Required

Travel indicator : Yes (For Valve Open/Close status)

Mounting : As per required

ACCESSORIES AIR FILTER REGULATOR : Required – 1Nos.each valve

Body : SS

Filter : Sintered Bronze

Filter Size : 5 micron

Input / Output Gauges : Required

LIMIT SWITCH:

Type : SPDT , Proximity

Quality : 2 Nos. for each valve

Contact / rating : 2A, 24V DC

Switching position : Open &Close position

PAINTING


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Protection for rust prevention : Required

Codes and standard : As per IS-6005, 1970

Raw finish and paint finish : To be confirmed by bidder

TESTS: Hydrostatic test, seat leakage test : As per ANSI B16-104

Actuator leakage test : Required

Material traceability : Required

Performance test of Actuator : Required

DRAWINGS & DOCUMENTS: Vendor to submit all the test certificates for consultant/purchaser's review & records.

Vendor to submit data sheets, actuator sizing, spring spring action (valve Open/Close), dimensional drawings showing mounting details, weld end details, actuators, stem removal spacings, hand wheel orientation, weight and parts list: for purchaser's approval.

12. PRESSURE TRANSMITTER

Pressure element : Capacitance type

Pressure(Operating) : 25 Kg/cm2

Temperature (Operating) : 45°C

Accuracy : ± 0.075% of Calibrated Span

Long term reproducibility : ± 0.25% of Upper range limit over

Six months

Repeatability : 0.050% of Span

Rangeability : 50 : 1

External zero span Adj : Required

Zero suppression / elevation : Required

Case : Die –Cast low copper Aluminum

Cable Entry : 1/2" NPT (F), second entry shall be plugged.

Cable Gland : Double Compression type (Nickel plated

Brass)

Enclosure class : IP 65

Gasket : Buna-N

Vent & drain : Required

Static pressure effect : ± 0.2% Of URL per 50 Kg/cm²


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Name plate : SS

DRAWINGS AND DOCUMENTS The Bidder shall submit the following drawings/documents after award of contract for review & approval by Purchaser/ Consultant. (a) Duly filled data sheets PressureTransmitter and accessories (b) Catalogues for PressureTransmitteand accessories. (c) QAPs (d) Drawings showing mounting details, weld end details, weights, termination details

etc. (e) All certificates including calibration reports, type test & routine test certificates. (f) Mandatory spare part list Recommended spare list for 5 years continuous

operation Vendor shall indicate the sheath OD and the same shall suit the

13. SPECIFICATIONS FOR MULTI STREAM (MINIMUM 3 STREAMS ON LINE GAS

CHROMATOGRAPH) 13.1 GENERAL SPECIFICATION

Stream Compositions

Stream Phase (Vapour/ Liquid)

Stream Temperature Min/Max

Stream Pressure Min/Max

Stream 4 Propane Liquid 15°C/45°C 16.50 Kg/cm2/17.01 Kg/cm2

Stream 5 Butane Liquid 15°C 18.06 Kg/cm2

Stream 6 LPG Liquid 15°C/45°C 16.0 Kg/cm2/17.01 Kg/cm2

Flowrate



LPG Stream 6 (Min / Max) :- 116220 Kg/hr / 211680 Kg/hr Carrier Gas: Typically zero-grade helium or nitrogen ,Hydrogen not acceptable

13.2 Vender's scope of supply shall include supply of following major components as per specification as a minimum:


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(a) Auto retractable Sample probe & sample tubing

(b) Sample Conditioning system

(c) Field Mounted GC Analyzer unit

(d) GC operating software suitable for diagnostics and maintenance activity

(e) All Cables, Glands, Terminals, Tubing, structural items, cable trays, supports, panel accessories, enclosures, mounting accessories required for installation of the system.

(f) Communication port in GC for interfacing with the DCS supplied by the bidder.

(g) Laptop computer suitable for configuration of GC, data archiving, diagnostics etc along with software. Licensed operating system (Windows XP), suitable software for GC communication, diagnostics etc shall be supplied.

(h) All necessary software for operation & maintenance of the system licensed in OWNER'S name.

(i) Cable & connectors for interconnection with DCS, interfacing software (GC side) & integration.

(j) The GC shall be with ex-proof enclosure or shall be housed in Purged Panel.

(k) Necessary locking arrangement for restricting the access to the GC panels where applicable.

(l) Special & standard tools and tackles required for operation & maintenance of GC. (m) Hard & soft copies of hardware & software manuals, GA drawing, wiring diagram,

calculations, and all other relevant documentation. (n) Spares & all consumables for commissioning. (o) Calibration gas & carrier gas Cylinders which will be skid mounted in field and

suitable for installation in hazardous area and specified weather condition.

13.3 The vendor's scope of work shall also include the following as a minimum:

(a) Validation of analyzer during commissioning by using certified calibration sample gas.

(b) Painting of complete system for protection against saline & tropical atmosphere. Any work not specifically mentioned but otherwise required, as per statutory rules / codes and standards / specifications and/or for the completion and operation of equipment have to be done by the vendor without any commercial implications..

13.4 Purchaser's data sheets indicate type, minimum sampling system requirements and material of construction for Gas Chromatograph and its sampling system. However, this does not absolve the vendor of the responsibility for proper selection with respect to the following:

(a) Proper design of the sampling system and gas chromatograph to measure the

component of interest to the stated accuracy.


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(b) Selection of materials for all the parts of the gas chromatograph system so as to be compatible with the process stream and surrounding atmosphere as per purchaser's data sheets.

13.5 Vendor shall note that the offered instruments shall be suitable for the following

ambient conditions :

Refer to Process Engineering Specification Doc No.( TCE.6758A-300-B-002) Point No.2

13.6 Vendor shall be responsible for selection of the correct model no. of instruments to meet the specifications contained in this spec. In case of model no. required to be changed at later date, the same shall be done by the vendor without any price or delivery implications.

13.7 Separate Enclosure, if required, necessary Sample Handling System, Tubing

from main pipeline to Analyser Cabin, helium & calibration gas cylinders, Skid for mounting are under Vendor's scope.

13.8 Special Tools and Tackles for Operation & Maintenance of GC. List must be furnished along with the offer.

13.9 DRAWINGS & DATA

Vendor shall submit all the data/drawings/documents as indicated below:

14.6.1 Along with the offer Vendor's Offer shall include a detailed specification sheet for Gas Chromatograph system which shall contain the following information:

(a) All the details regarding type, construction, materials, accessories etc. of the On-line Gas Chromatograph along with technical catalogue.

(b) Detailed sketch showing various components of sampling and sample conditioning system.

(c) Sample flow rates required for achieving response time, the recommended length and size of the sampling tube between process tap and sampling system.

(d) Any special cabling requirements including shielding and grounding requirements and maximum permissible distances of separation between the field and the control room mounted units etc.

(e) Consumption figures of electrical power and other utilities for each gas chromatograph system.

(f) Overall dimensions of major units dimension of the skid to be mounted in field.

14.6.2 AFTER PLACEMENT OF ORDER


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Vendor shall submit certified drawings and specification sheets for Gas Chromatograph which shall include the following (* marked shall be submitted for approval) (a) * Bill of Material of the complete G.C system. (b) * G.A. drawing with overall Dimension of both Sampling unit & 19" Rack (wherever

applicable). (c) Sampling interconnection details identifying each component with make and

model number. (d) Detailed interconnection diagram for process, piping and tubing. (Hook up

Diagram) (e) Installation drawings. (f) Cabling details including shielding / grounding requirements. (g) Utility consumptions. (h) Technical Literatures, Installation & Commissioning Manuals for all supplied items. (i) Quality Assurance Plan. (j) Software required for the systems. (k) Cable Parameters (Capacitance, inductance, L/R ratio) for interconnection

cable between field and the control room mounted units for intrinsically safe system.

(l) The details of the heat load, humidity particulate / chemical filtration etc. of the system.

(m) Foundation details 13.10 DESIGN AND CONSTRUCTION

(a) Essential Criteria: The offered ONLINE GAS CHROMATOGRAPHS shall comply with the following essential criteria failing which the offered bids shall be liable for rejection.

(b) The GC offered against this tender, shall be from his existing range of production & bidder shall certify to this effect.

(c) Bidder should submit a certificate from any end user to whom the offered model GC has been supplied earlier, stating that the supplied GC has been working satisfactorily for atleast One years.

(d) The ONLINE GAS CHROMATOGRAPH shall consist of sampling system with calibration & carrier gas cylinders in the field and programmable control unit in the control room having online communication with field unit.

(e) Offered Gas Chromatograph Controller shall be Control Room mounted Full Function Controller and shall provide Nos. 4 -20 ma equal to no of Channels DC Analog Outputs totally independent from RS -485 / RS -232 / Ethernet Serial Link Outputs. GC Controller shall be able to perform AGA -8 Calculations as per Gross -1 or Gross -2 Method in the event of serial Communication Link Failure from Gas Chromatograph Controller.

(f) The method of calculation i.e. ISO 6976 or ASTMD 3588 or GPA 2172 shall be user selectable. The methods shall be the latest versions at the time of commissioning.

(g) Bidder shall offer GC certified with 24 Hour Environmental Test Chamber test meeting the complete ambient operating temperature range from -18 to + 55 Deg C & meeting the specified repeatability limits. Bidder to submit sample environmental test chamber test certificate along with the Bid

(h) For Ease of Maintenance & operation Offered GC shall be able to operate without any need of instrument air in the field.


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13.11 In general Gas Chromatograph and sampling systems shall be designed and

constructed in accordance with API - MPMS (Relevant portions).

13.12 Process Stream sampling shall be continuous.

13.13 The Gas Chromatograph performance shall be within specifications when the supply

voltage varies by + 10% of specified value and supply frequency varies by + 3 HZ of specified value.

13.14 Unless otherwise specified material of all components wetted by sample shall be ANSI -316 SS.

13.15 In addition to the certificate from statutory body, for instruments supplied for projects in India, approval from CCOE (Chief Controller of Explosives) shall also be furnished by vendor irrespective of their place of manufacture and the same is mandatory. In case CCOE certificate is not available now, vendor to confirm to supply the same for each item before shipment.

13.16 All interconnecting wiring shall be colour coded / numbered and terminal blocks

clearly identified.

13.17 The sampling system, Gas Chromatograph Analyser, Bottles etc. shall be supplied pre - mounted on cabinet of self-standing skid, in general. The foundation of skid shall have holes to anchor it to the ground with anchor bolts. The enclosure to skid shall be weatherproof to IP 55, as a minimum.

13.18 The Gas Chromatograph shall provide isolated analog current outputs.

13.19 Process sample return point and utilities as required will be made available near the Gas Chromatograph at pressure and temperature conditions specified in the data sheet for each Gas Chromatograph as single point supply and return. In general, all the offered items are to comply with maximum pressure and temperature data specified in data sheets. In exceptional cases, standard cell or such part of instrument with a rating lower than maximum pressure and temperature can be offered provided suitable conditioning means and hardware are provided and adequate safety devices with proper hook up enabling discharge to a flare header is provided. Multi - point distribution of utilities and process sample, is to be arranged by vendor following good engineering practices.


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13.20 SAMPLING SYSTEM

13.20.1 The sampling system shall be furnished with all the necessary equipment and accessories to condition and regulate the sample to acceptable levels.

13.20.2 The sampling system shall be engineered, designed, fabricated and furnished completely assembled as an integral part of the Gas Chromatograph Analyzer or as a separate Unit.

The sampling system shall be designed on the basis of the utilities available as indicated in the job specifications.

13.20.3 Each sampling system component shall be capable of being removed without disassembling the entire system.

13.20.4 Sampling system shall be designed for easy integration with the Gas Chromatograph Analyser in the field.

13.20.5 Sampling system design shall be such that the sample drawn for analysis is truly representative of the process stream. Extra care shall be exercised in the selection of the various components forming the sampling system.

13.20.6 The sampling system shall be designed to move the sample from the process to the Gas Chromatograph in the shortest possible time. Due consideration shall be given to the size of the sample tubing to avoid possible plugging. Any requirement of steam tracing of sample tubing shall be indicated in the bid.

13.20.7 Vendor shall clearly indicate the details of sample disposal to be provided by purchaser. When details of sample return points are indicated in purchaser's data sheet, sampling system shall be designed to meet the requirement.

13.20.8 Sampling system shall consist of one or more of the following components as

required by the service conditions shown on the instrument data sheets : filters (coarse and fine), pressure regulators, relief valves, flow indicators, flow controllers, temperature indicators, scrubbers, heaters, coolers, dryers, moisture filters, sample pumps, aspirators etc. Vender in the bid with proper reasoning shall include any additional requirement.

13.20.9 Filters shall be always dual and it shall be possible to remove and replace one of the filters without upsetting the operation of the Gas Chromatograph.

13.21 NAMEPLATE

11.8.1 The Gas Chromatograph and its accessories shall have a SS nameplate firmly attached to it at a visible place, furnishing the following information as applicable:

(a) Tag number as per purchaser's data sheets.

(b) Manufacturer's Serial No. and Model No.

(c) Manufacturer's name / trade mark.

(d) Range

(e) Area classification in which the equipment can be used.


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13.22 INSPECTION AND TESTING

13.22.1 Vendor shall submit the following test certificates and test reports for purchaser's review:

(a) Material test certificate for all wetted parts (MIL certificates).

(b) Twenty Four hour environmental test chamber repeatability test report for establishing the repeatability of the offered GC for the complete operating temperature range.

(c) Calibration report for all Gas Chromatographs.

(d) Effect of interfering components present in the process sample.

(e) Certificates from statutory bodies for use in area classification indicated in data sheet.

13.23 Witness Inspection

13.23.1 The Gas Chromatographs shall be subjected to pre - dispatch inspection by the purchaser.

Following tests shall be carried out, as a minimum: - (a) Physical dimensional verification and workmanship.

(b) Leak checking of complete system using nitrogen or instrument air.

(c) The Gas Chromatographs shall be calibrated using a test sample 50% of scale reading for the component of interest. Deviation of actual calibration from the calibration curve supplied by vendor shall be within + 1% of span.

(d) Repeatability shall be demonstrated for a period of at least 8 hours continuously using a standard sample.

(e) Effect of variation in the power supply, voltage and frequency, to be verified. The Gas Chromatograph must function satisfactorily.

(f) Review of all test certificates and test reports indicated in para 5.0 of this specification.

13.24 SHIPPING

13.24.1 All threaded and flanged openings shall be suitably covered to prevent entry of foreign material

13.24.2 Each major part shall be sealed in thick plastic bags. Suitable moisture absorbent shall be provided for electronic components.

13.25 REJECTION

Vender shall make his offer in detail, with respect to every item of the purchaser's specifications. Any offer not confirming to this shall be summarily rejected.

13.26 All documents and literatures are to be supplied in English Language. The Unit of measurement for all the parameters will be as per Data sheet


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13.27 All the Field mounted equipments, Control room mounted instruments and necessary tubing, cables, enclosures; mounting accessories are in vendor's scope. The system should be supplied in a ready to install condition at site. All the operation, performance and maintenance guideline to be demonstrated during Inspection

14. SPECIFICATION FOR REID VAPOR PRESSURE ANALYSER

GENERAL SPECIFICATION

UNIT 1

Stream Compositions

Stream Phase (Vapour/ Liquid)

Stream Temperature

(Min/Max)

Stream Pressure (min/Max)

Stream 6 LPG Liquid 15°C/45°C 16.0 Kg/cm2/17.01 Kg/cm2

Flowrate

Stream 6 (Min / Max) :- 116220 Kg/hr / 211680 Kg/hr Repeatability : +/- 1.8 psig Reproducibility : +/-2.8 psig

Accuracy : Should meet ASTM D-1267

Power : 100-240 VAC, 50-60 Hz Enclosure : Weather proof housing: IP 54

Instrument Air : Supply connection – ¼ inch tube minimum Supply Pressure 60 psig minimum Fast Loop Supply : Required Purge Gas Supply : Purge gas supply if required by the system should be Nitrogen or other inert gas except hydrogen


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14.1 Vendor shall note that the offered instruments shall be suitable for the following ambient conditions:

Refer to Process Engineering Specification Doc No.( TCE.6758A-300-B-002) Point No.2

14.2 Vender's scope of supply shall include supply of following major components as per

specification as a minimum:

(a) Field Mounted RVP Analyzer unit

(b) RVP operating software suitable for diagnostics and maintenance activity

(c) All Cables, Glands, Terminals, Tubing, structural items, cable trays, supports, panel accessories, enclosures, mounting accessories required for installation of the system.

(d) Laptop computer suitable for configuration of RVP, data archiving, diagnostics etc along with software. Licensed operating system (Windows XP), suitable software for RVP communication, diagnostics etc shall be supplied.

(e) All necessary software for operation & maintenance of the system licensed in OWNER’S name.

(f) Cable & connectors for interconnection with flow computer / DCS, interfacing software (RVPside) & integration of flow computer / DCS

(g) The GC shall be with ex-proof enclosure or shall be housed in Purged Panel.

(h) Necessary locking arrangement for restricting the access to the RVP panels where applicable.

(i) Concrete / steel platform for mounting the skid (to be supplied by vendor)

(j) Special & standard tools and tackles required for operation & maintenance of RVP.

(k) Hard & soft copies of hardware & software manuals, GA drawing, wiring diagram, calculations, and all other relevant documentation.

(l) Spares & all consumables for commissioning. 14.3 NAMEPLATE

14.3.1 The Reid Vapor Pressure Analyser and its accessories shall have a SS nameplate firmly attached to it at a visible place, furnishing the following information as applicable:

(a) Tag number as per purchaser's data sheets.

(b) Manufacturer's Serial No. and Model No.

(c) Manufacturer's name / trade mark.

(d) Range

(e) Area classification in which the equipment can be used.

14.4 INSPECTION AND TESTING


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14.4.1 Vendor shall submit the following test certificates and test reports for purchaser's review:

(a) Material test certificate for all wetted parts (MIL certificates).

(b) Calibration report for RVP.

(c) Certificates from statutory bodies for use in area classification indicated in data sheet.

14.5 WITNESS INSPECTION

14.5.1 The Reid Vapor Pressure analyser shall be subjected to pre - dispatch inspection by the purchaser.

Following tests shall be carried out, as a minimum: - (g) Physical dimensional verification and workmanship.

(h) Leak checking of complete system using nitrogen or instrument air.

(i) Reid Vapor Pressure analyser shall be calibrated using a test sample 50% of scale reading for the component of interest. Deviation of actual calibration from the calibration curve supplied by vendor shall be within + 1% of span.

(j) Repeatability shall be demonstrated for a period of at least 8 hours continuously using a standard sample.

(k) Effect of variation in the power supply, voltage and frequency, to be verified. The Reid Vapor Pressure analyser must function satisfactorily.

(l) Review of all test certificates and test reports.

14.6 DRAWINGS & DATA

Vendor shall submit all the data/drawings/documents as indicated below: Vendor shall submit all the data/drawings/documents as indicated below:

14.6.1 Along with the offer Vendor's Offer shall include a detailed specification sheet for Gas Chromatograph system which shall contain the following information:

(a) All the details regarding type, construction, materials, accessories etc. of the On-line Reid Vapor Pressure along with technical catalogue.

(b) Any special cabling requirements including shielding and grounding requirements and maximum permissible distances of separation between the field and the control room mounted units etc.

(c) Consumption figures of electrical power and other utilities for each Vapor Pressure system.

(d) Overall dimensions of major units dimension of the skid to be mounted in field.


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14.6.2 AFTER PLACEMENT OF ORDER Vendor shall submit certified drawings and specification sheets for Reid Vapor Pressure which shall include the following (* marked shall be submitted for approval) (a) * Bill of Material of the complete G.C system. (b) * G.A. drawing with overall Dimension of both Sampling unit & 19" Rack (wherever

applicable). (c) Sampling interconnection details identifying each component with make and

model number. (d) Detailed interconnection diagram for process, piping and tubing. (Hook up

Diagram) (e) Installation drawings. (f) Cabling details including shielding / grounding requirements. (g) Utility consumptions. (h) Technical Literatures, Installation & Commissioning Manuals for all supplied items. (i) Quality Assurance Plan. (j) Software required for the systems. (k) Cable Parameters (Capacitance, inductance, L/R ratio) for interconnection

cable between field and the control room mounted units for intrinsically safe system.

(l) The details of the heat load, humidity particulate / chemical filtration etc. of the system.

(m) Foundation details 14.7 SHIPPING

14.7.1 All threaded and flanged openings shall be suitably covered to prevent entry of foreign material

14.7.2 Each major part shall be sealed in thick plastic bags. Suitable moisture absorbent shall be provided for electronic components.

14.8 REJECTION

Vender shall make his offer in detail, with respect to every item of the purchaser's specifications. Any offer not confirming to this shall be summarily rejected.

14.9 All documents and literatures are to be supplied in English Language. The Unit of measurement for all the parameters will be as per Data sheet

14.10 All the Field mounted equipments, Control room mounted instruments and necessary tubing, cables, enclosures; mounting accessories are in vendor's scope. The system should be supplied in a ready to install condition at site. All the operation, performance and maintenance guideline to be demonstrated during Inspection .


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15. PRESSURE GAUGE

Pressure Propane Stream 4 (Min / Max) : 16.50Kg/cm2 / 17.0Kg/cm2

Butane Stream 5 (Operating) :18.06Kg/cm2

LPG Stream 6 (Min / Max) :16.0Kg/cm2 / 17.0Kg/cm2

Temperature

Propane Stream 4 (Min / Max) : 15 °C / 45 °C

Butane Stream 5 (Operating) : 15 °C

LPG Stream 6 (Min / Max) : 15 °C / 45 °C

Pressure element : Bourdon

Accuracy : ± 1 % of FSD

Over range Protection : 130% of FSD

Range : Bidder to State

Dial Size : 150mm

Dial Colour : White, Black Numeral

Mounting : Bidder To State

Case Material : SS 304

Ring Type : Standard

Blow-Out Protection : Required (at the back)

Glass Material : Toughened Borosilicate

Pressure Element Material : SS 3316

Socket Material : Socket Material

Connection Size : Bidder to State

Connection Location : Bottom

Pointer Material : SS 304

Micrometer Adjustable : Required

Movement : SS 316

IP Protection : IP 65

Name plate : SS


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DRAWINGS AND DOCUMENTS The Bidder shall submit the following drawings/documents after award of contract for review & approval by Purchaser/ Consultant. (a) Catalogues for Pressure Gauge and accessories. (b) QAPs (c) Drawings showing mounting details, weld end details, weights, termination details

etc. (d) All certificates including calibration reports, type test & routine test certificates. (e) Mandatory spare part list Recommended spare list for 5 years continuous operation

16. TEMPERATURE GAUGE



LPG Stream 6 (Min / Max) :16.0Kg/cm2 / 17.0Kg/cm2 Temperature



LPG Stream 6 (Min / Max) : 15 °C / 45 °C Temperature Element type : Bimettalic Function : Direct Reading Steam Length : Biddder to state Steam Dia : Biddder to state

Accuracy : ± 1 % of FSD

Over range Protection : 130% of FSD

Range : Bidder to State

Dial Size : 150mm

Dial Colour : White, Black Numeral

Mounting : Bidder To State

Case Material : SS 304


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Ring Type : Standard

Glass Material : Toughened Borosilicate

Temperature Element Material : SS 3316

Socket Material : Socket Material

Connection Size : Bidder to State

Gasket : PTFE

Pointer Material : SS 304

Micrometer Adjustable : Required

Movement : SS 316

IP Protection : IP 65

WELL Instrument Connection : Bidder to State

Process Connection : Bidder to State

Well Material : SS 316

Bore Concentricity : ± 5% of wall thickness

Plug with chain for thermowell : Required, SS316

Name plate : SS

Note (a) The stem bulb diameter must match with the bore diameter of the thermowell. (b) Bar Stock Thermowell if length is less than 600mm and Fabricated Thermowell if

length is above 600mm. (c) Vendor shall check for the possibility of wake frequency induced damage, based on

ASME PTC 19.3 wake frequency calculations.

DRAWINGS AND DOCUMENTS The Bidder shall submit the following drawings/documents after award of contract for review & approval by Purchaser/ Consultant. (a) Duly filled data sheets for Temperature Gauge and accessories (b) Catalogues for Temperature Gauge and accessories. (c) QAPs (d) Drawings showing mounting details, weld end details, weights, termination details

etc. (e) All certificates including calibration reports, type test & routine test certificates. (f) Wake Frequency Calculations (g) Mandatory spare part list Recommended spare list for 5 years continuous


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17. TEMPERATURE ELEMENT

Propane Stream 4 (Min / Max) : 16.50Kg/cm2 / 17.0Kg/cm2


LPG Stream 6 (Min / Max) :16.0Kg/cm2 / 17.0Kg/cm2 Temperature



LPG Stream 6 (Min / Max) : 15 °C / 45 °C Type : RTD Material : Platinum Resistance : 100 Ω at 0˚C Single/Double or Other : Single Diameter : Bidder to state Sheath Material : SS 316 Insulation : Compact MgO Accuracy : As per IEC-751, Class A Spring Loaded : Required Response Time : < 10 Sec (without thermowell) for 63% step change in temperature Nipple-Union-Nipple Fitting : 1/2" NPTF HEAD Material : Die Cast Aluminium Terminal Block : Spring Loaded with terminals suitable for 1.5 sq.mm. cable Cable Entry : 1/2" NPTF IP Rating : IP-65


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Ex-proof Enclosure : Required, Ex-proof to Zone 1, Gr. IIC, T4 Chain Material : SS-304 No of entry : 2 Nos. (1 used, 1 plugged) WELL Instrument Connection : Bidder to state Process Connection : Bidder to state Construction Type : Tapered with Barstock Construction Well Material : SS-316 Flange Material : Bidder to state Bore Concentricity : ± 5% of wall thickness

Plug with chain for thermowell : Required, SS316

Name plate : SS

Note (a) Calibration shall be in accordance with IEC-751Class A.. (b) Vendor shall indicate the sheath OD and the same shall suit the thermowell ID. (c) Vendor shall check for the possibility of wake frequency induced damage, based on

ASME PTC 19.3 wake frequency calculations.

DRAWINGS AND DOCUMENTS The Bidder shall submit the following drawings/documents after award of contract for review & approval by Purchaser/ Consultant. (h) Duly filled data sheets for RTD & thermowell and accessories (i) Catalogues for RTD & thermowell and accessories. (j) QAPs (k) Drawings showing mounting details, weld end details, weights, termination details

etc. (l) All certificates including calibration reports, type test & routine test certificates. (m) Wake Frequency Calculations (n) Mandatory spare part list Recommended spare list for 5 years continuous


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18. TEMPERATURE TRANSMITTER



LPG Stream 6 (Min / Max) : 16.0Kg/cm2 / 17.0Kg/cm2 Temperature Propane Stream 4 (Min / Max) : 15 °C / 45 °C


LPG Stream 6 (Min / Max) : 15 °C / 45 °C

Type : 2- Wire Loop Powered Transmitter

Cold Junction Compensation (T/C) : Not Required

Burn Out Protection (Upscale) : Not Required

Enclosure / IP Rating : Die Cast Aluminium/ IP-65

Painting : Grey (Epoxy Painting)

Power Supply / Load Resistance : 24 V DC Loop Powered / 600 Ω

RTD cable connection : Required, Suitable for Dual sensors

Accuracy : ± ±0.1 % of Calibrated Span

Input/ Output Isolation : Required

Integral display : LCD

Electrical Connection : 1/2" NPT(F)

Communication Type : Bidder to State

Mounting Brackets : Required

Name plate : SS

Note (a) Calibration standard shall be same as RTD. For RTD, the calibration standard is

specified as IEC 751, Class A. (b) The temperature transmitter shall have dual compartment housing. (c) Transmitter shall support RTD PT 100, PT 1000 & all types of thermocopules which

shall be configurable.

DRAWINGS AND DOCUMENTS The Bidder shall submit the following drawings/documents after award of contract for review & approval by Purchaser/ Consultant.


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(g) Duly filled data sheets Temperature Transmitter and accessories (h) Catalogues for Temperature Transmitter and accessories. (i) QAPs (j) Drawings showing mounting details, weld end details, weights, termination details

etc. (k) All certificates including calibration reports, type test & routine test certificates. (l) Mandatory spare part list Recommended spare list for 5 years continuous

operation Vendor shall indicate the sheath OD and the same shall suit the

19. GAS DETECTOR

Type : Infrared based ,point type gas detector

Gases to be Analysed : Hydrcarbon vapour, Methane gas,Propane

Butane

Material of Construction : SS 316

range : 0~100% lel

Area Classifications : zone 2 ,IIa/IIb ,Temperature T3

Immunity to catalytic poisoning : Required

Temperature compensation : Required Type of wiring : 4 Wire Accuracy : ±2% lel

Sensor life : 3 years minimum

Response time : By Vendor

Fail safe feature : Required

Power Supply : 24v dc Protection : flame proof and weather proof to ip 66. necessary protection against dust and splash shall be provided. Output signal : compatible for comunicating to FGS controller and inbuilt hart protocol

Self diagnostic features : Required for both detector fault and dirty

Optics.

Mounting accessories : Required for surface mounting/pole

mounted. vendor to provide necessary

support as pole, brackets, nuts,bolts.

Cable entry : ¾” NPT(F). proper cable entry with internal

terminal block shall be provided.


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High concentration alarm : Required

Dual adjustable setpoint for gas alarms : Required

Immunity to RF/FM interference : Required

Linearized Output : Required

DRAWINGS/ DOCUMENTS (a) Vendor shall submit catalogue & data sheet for review & comments by Purchaser/

Consultant. (b) Vendor shall submit Instruction Manual for Records.


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GENERAL SPECIFICATIONS DISTRIBUTED CONTROL SYSTEM FOR

LPG BLENDING PACKAGE UNIT SHEET 1 OF 20


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1. GENERAL 1.1 This specification covers the general requirements of Distributed Control

System to be supplied for Propane-Butane Blending Unit at BPCL-Uran. This specification shall be read in conjunction with Instrumentation Specification for Blending Unit (Doc. No.TCE.6758A-A-580-600).

1.2 The Contractor is required to arrive at the exact hardware and software requirements based on this specification, the frozen P&IDs, and the Instrumentation Specification for Blending Unit (Doc. No.TCE.6758A-A-580-600) requirements.

1.3 Bidders to note that Yokogawa DCS Model CS3000 which is OPC compliant, is available at site with spare I/Os. Required I/Os for the blending skid will be made available by BPCL. Bidders can use the same for blending operation and coordinate with Yokogawa for blending programming and be cost competitive

2. CONTRACTOR’S RESPONSIBILITIES 2.1 Contractor‟s responsibilities shall include, but are not limited to, the following:

a) System engineering. b) Supply of system hardware and software. c) System programming and configuration. d) Implementing control strategies. e) Configuration of various displays. f) Generation of history database and reports. g) Generation of logging reports and other management information

reports. h) Factory acceptance testing. i) Packing and forwarding. j) Transport to site. k) Installation at site. l) Supply and termination of various interconnecting cables between

marshalling racks and between marshalling racks and system hardware cabinets.

m) Loop checking and commissioning. n) Providing documentation in required number of sets during engineering

and also as-built documents after commissioning including Loop Diagrams.

o) Providing training for owners‟ operation & maintenance personnel in DCS vendor‟s works and also at site.

p) Preparation of specifications, procurement, inspection, erection, integration and commissioning of all bought out items included in contractor‟s scope of supply.

3. IMPORTANT DESIGN CONSIDERATIONS


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3.1 Hardware Requirements: 3.1.1 All sub-systems of the DCS shall be able to operate satisfactorily for ambient

temperature 8 °C to 38 °C and maximum humidity of 98%. 3.1.2 The system shall provide the same make and model 24 VDC bulk power

supplies for all system components. These bulk supplies are to be installed in system cabinets and/or in stand-alone power supply cabinets

3.1.3 All system controllers and controller power supplies shall be completely redundant. Secondary controllers shall be capable of waiting in a stand-by mode, mirroring the operation of the primary controller. When an error or fault is detected the standby-by controller shall bumplessly assume control, the faulted controller shall remain off-line. Returning the faulted controller to an on-line condition shall require manual intervention.

3.1.4 Controller power supplies shall receive 24 VDC power from the bulk power supplies for each system.

3.1.5 Power conditioning and isolation shall be performed at the power supply for each controller. Power distribution shall be performed in a manner such that any single power supply failure will not cause loss of operation of any module.

3.1.6 Controllers shall be capable of plug and play detection of any new I/O sub-system device or module (i.e., HART, Ff, wireless, etc.).

3.1.7 Controller resident configurations shall be stored in flash memory providing an infinite storage time. The use of batteries for controller memory is not permitted.

3.1.8 Bulk power supplies shall be capable of being powered from two incoming 110/230 VAC sources. The primary 110/230 VAC source shall be from a UPS and the second 110/230 VAC source shall be from an emergency power source. The system shall be designed such that loss of either source shall not affect the system operation

3.1.9 Each bulk power supply shall be designed to facilitate “live-system” power supply replacement. The clients preferred design is for each power supply to be fitted with a disconnect switch or circuit breaker in the 110/230 VAC feed to the bulk power supply

3.1.10 The power supplies shall be capable of withstanding incoming voltage or frequency variations of 110/230VAC 10% - 50/60 Hz 5%.

3.1.11 The system shall be designed “fault tolerant”, by selecting high grade components of proven quality and proper design of system electronics. Redundancy of Servers/ Workstations is not required.

3.1.12 The system shall have a high MTBF value, high availability of 99.99% and shall have a well- proven record of operating satisfactorily in continuous processing plant for a minimum of one year. No prototype hardware or hardware of an experimental nature shall be supplied.

3.1.13 Galvanic / optical isolation shall be provided for all field signals. Isolation shall also be provided between the channel so that fault in one I/O channel does not affect the working of other channel.


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3.1.14 The system shall be capable of interacting with other plant systems and computers over a well established communication network like Ethernet conforming to IEEE802.3.

3.1.15 All electronic components / cards except those in OES, supervisory computer, off-line blend simulator and printers shall have conformal coating so as to have a very high corrosion resistance conforming to class G-3 as per ANSI / ISA S71.04.

3.1.16 On-line replacement of any module shall be possible (i.e. removal and addition of a module) without de-energizing the system. Further, there should not be any interruption in the system functioning while replacing a faulty module. The controller and IO cards should be Auto sensing and Auto addressing itself.

3.1.17 Transient, Static and EMI/RFI protection The system shall be internally protected against system errors and hardware damage resulting from a) Electrical transients on power/signal wiring. b) Connecting and disconnecting devices or removing or inserting printed

circuit boards. 3.1.18 The DCS system shall be capable of withstanding noise errors due to

electromagnetic interference (EMI) or radio frequency interference (RFI) including nearby radio stations, handheld 2-way walkie-talkie sets, mobile phones, electrical storms, solenoids, relays or contractors carrying heavy currents. RFI/EMI noise immunity shall be as per SAMA standard PMC 33.1. The surge withstands capability for input/output modules shall be as per IEEE 472.

3.2 Software Requirements: 3.2.1 The operator stations and engineering station shall be WINDOWS XP based

minimum, of latest version. A firewall protection shall be provided to guard the operating system and real time database against external virus attacks.

3.2.2 The system shall have capability to exchange information with other software packages, devices and platforms and shall be OPC compliant for all tags. All hardware and software necessary for this shall be considered by the contractor.

3.2.3 It shall be possible to auto-tune any control loop on selective basis automatically. Tuning parameters computed by the system shall either be loaded automatically or manually by operator.

3.2.4 The software package for loop tuning may reside/run on any system hardware including controller sub-system, supervisory computer, etc. The tuning software must ensure that the process is not disturbed whenever a loop is being tuned.

3.2.5 The system shall have an extensive set of self-diagnostic routines, which shall locate and identify the system failure at least upto module level through detailed diagnostic displays.


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3.2.6 The system shall have the capability of detecting open sensors and bad PV value with an alarm.

3.2.7 The method of data access by any user on the system network shall be by I/O tag name and not by any physical or logical address.

4. SYSTEM OVERVIEW

4.1 The DCS shall have the following main components. a) Operator / Engineering Station consisting of:

Video display units (VDUs). Operator‟s/engineer‟s keyboards. Printers

b) Multi-loop controllers & data acquisition system. c) Communication network and associated hardware. d) Supervisory computer e) Marshalling cabinets f) System hardware cabinets g) Power distribution cabinets. h) Interconnection cables i) Other auxiliary devices not specified but used for plant operation. j) Any other device needed to implement the requirements of this

specification.

5. FUNCTIONAL SPECIFICATIONS 5.1 Operator / Engineering Station (OES)

Two operator / engineering stations (OES) shall be provided. Following minimum specifications shall govern.

5.1.1 Each OES shall be standalone type. It shall be a PC with WINDOWS XP operating system minimum, keyboard, mouse, 320 GB HDD min., CD/DVD read / write drive, dual redundant communication interface with system data highway and its own power supply. The CPU shall be Core I7 3.2 GHz. min. The display shall be 20” LCD type. Touch screen facility is not required.

5.1.2 Each OES shall have access to the complete database for control and monitoring. Normally both shall be used by the operators for plant operation. In the event of any fault in any one of the stations, the plant can be operated through one. In addition, at any given time, any one of the OES can also be used as an engineering station. Concept of software lock shall be used for the purpose. This shall be done by authorized persons using their log-in password.

5.1.3 In the engineering mode the OES shall be used to perform the following functions a) To build graphics using the graphic builder program. b) The configure control loops/monitoring loops/logic/sequences. c) To assign I/Os to various I/O modules during generation of application

software.


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d) To write/edit user written programmes in higher level languages. e) To download the generated application software to various system

nodes. f) To generate “self documentation” i.e. It should be possible to store the

generated information on a storage media as well as to enable user to take a printout of the same.

5.1.4 Dynamic data shall be updated in all the stations simultaneously. Similarly any configuration changes made in the system shall be downloaded in all the stations simultaneously transparent to the operator.

5.1.5 Each OES shall have its own power supply isolation through an MCB. 5.1.6 OES / Supervisory Computer shall be console /Rack mounted. Table top

version is not acceptable. Two operator chairs are included in scope of supply.

5.2 Standard Displays 5.2.1 Display call up time for various displays shall be a maximum of 2 seconds.

Display update time shall be a maximum of 2 seconds.

5.2.2 The system shall have the following types of displays as a standard. Requirements of each type are stated only briefly. a) Group Display

This shall enable an operator to view a group of tags in the form of faceplates just like on a conventional control panel. Operator can operate the plant through this display.

b) Detailed Loop Status Display This shall be used by engineers to analyze the behaviour of a loop. All loop constants can be changed only through this display. Tuning of a loop shall be done through this display.

c) Displays For Alarm Handling These shall normally list chronologically all alarms in a plant. It shall be possible to sort/filter alarms according to priority, plant unit, just as in any other database management software. Operator can acknowledge and reset alarms through this display. Minimum two levels of alarm priorities shall be available. Emergency high & low. Each type shall be annunciated by different audible and visual means.

d) Trend Displays These shall display one/more process variables in a graph as in a recorder. It shall have following facilities minimum at operator level.

Select/delete a process tag for trending Trend any variable, analog/digital; any value, instantaneous,

average, etc. Assign different sampling frequency and time interval for viewing

to each variable. Zooming of Y and X axis.


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The memory capacity shall be sized assuming all analog inputs to be trended at a sampling rate of 1 sec. with storage of 30 days. Vendor to submit calculations to show how the same is achieved.

e) Graphic Displays These shall be used most frequently for control and monitoring of the plant by the operators. The graphics shall have minimum following features

Graphics shall be fully dynamic and interactive. Animation facility shall be available.

Facility to build user symbols and store them in a graphic library. Commonly used features like windowing, zoom in/out, etc. Easy to use builder package. This shall include commonly used

tools like cut & paste; object embedding and drawing tools (like find end point/mid-point of a line, centre of a circle, tangent, etc.) found in CAD packages.

f) System Diagnostic Displays

These shall be generated automatically by the system as soon as system configuration is loaded into the system. These displays shall be hierarchical type to trace faults up to module level with suitable alarm and annunciation.

g) System Configuration Displays These shall be used by engineers to build a loop, build logic, configure a sequence, etc. Once a configuration is loaded into the system, the display shall show the various process parameters dynamically.

5.2.3 It shall be possible to open a window of any operator‟s display in any other display.

5.3 Special Displays 5.3.1 These shall be used by the operator to view / enter data for blending. These

should be user configurable and are mainly of two types: a) Status Displays

These shall display information such as the ratio of the different streams being blended, their flow rates; final blend flow rate, pacing conditions influencing the blend; and alarms of all measurements associated with blending. This should also display information such as average and instantaneous property calculations for each batch being blended etc

b) User Interface Displays

These displays shall be used for entering data / operation commands. These shall be used to enter data such as strapping tables for tanks, net volume available, tank level, temperature etc.; setting of alarms for process parameters. Through these displays operator shall define


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blend ratios, set ramp-up and ramp-down rates for a batch, set alarms, give blend batch numbers, modify blend rules, set optimization objectives, define pacing conditions, constraints etc.

5.3.2 The special displays shall be user configurable and arranged in a hierarchical fashion to enable the operator to look at the entire blending operation as an overview or to any specific detail.

5.4 Keyboards 5.4.1 Operator & Engineer‟s keyboards shall be standard QWERTY type. Special

keyboards with dedicated assignable keys are not required. 5.5 Printers 5.5.1 Three printers shall be supplied as per following requirements:

A LAN printer accessible from any OES, colour ink-jet type, size A4/A3 to print DCS screens, system self-documentation, daily / shift logs, blend reports, etc. A 136 column dot matrix printer accessible from all OES to print alarms, operator actions. A black & white laser type, size A4, dedicated to off-line blend simulator.

5.5.2 Printers shall be supplied with self-standing enclosure. The enclosure shall be provided with an additional shelf to stack papers, ribbons, ink cartridges, etc.

5.6 Additional Software Following additional software shall be loaded in each OES: a) Software for dynamic display of control drawings. b) Software for dynamic display of logic drawings c) Self documentation package d) Logging and report generation package e) Long term archival /Historian package f) Licensed MS Office package (one license to be loaded in one of the

OES) 5.7 Multi-loop Controllers/Data Acquisition System

5.7.1 This shall be used to for closed loop control / data acquisition. This shall also have capabilities to execute process sequences and interlock logic.

5.7.2 The system shall have the capabilities to execute the standard control algorithms and calculations for process control applications.

5.7.2.1 Following algorithms shall be available as a standard. PID, PID with external bias, PID on/off, PID gap, PID with cascade and

ratio, PID with adaptive gain & reset. Lead lag/compensation Dead time compensation High/low/middle/average signal selector Temperature, pressure compensation for flow Pulse input scaling Integration and totalizing (resettable and non-resettable counters of 6

digits)


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Elapsed time computing Velocity limiter Self tuning Ramp generation Alarm generation on PV, SV, MV other values, rate of charge, etc. (min.

4 alarms/PV shall be available) Blend Ratio & Property Control Algorithm shall be available in controller/DCS

5.7.2.2 The system shall have following mathematical and logic functions as a minimum. Addition, subtraction, multiplication, division Square root/square Moving average Piecewise linearization Cold junction compensation for thermocouple inputs Exponential, logarithmic functions Absolute value Comparator And, OR, Invertor, Ex-OR, Flip-flop (JK, SR) timers (up-to 24 hours)

Vendor shall indicate additional function available if any.

5.7.2.3 The configuration software shall be IEC 61131 compliant.

5.7.3 The system shall accept the following types of inputs as standard and generate following outputs as standard:

a) Analog Inputs

i. Voltage : 1~5 VDC, 0~10 VDC. Min. input impedance 10M .

ii. Current : 4~20 mA DC both active and passive. Max. Input impedance 250

iii. Resistance : RTD, Pt100 (IEC 751)

iv. Thermocouples : All types (IEC 584-2)

b) Status Inputs

i. Potential free contacts/ Transistor Open Collector

: Momentary type / latched type

ii. Inductive proximity type

: (NAMUR; Sensors)

c) Pulse inputs (Both powered &

: 0-10 kHz min.


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non powered)

a) Analog Outputs

i. Current : 4~20 mA DC (permissible load resistance of 750 min

ii. Voltage : 1~5 VDC (into load resistance of 1M min.)

b) Status Outputs

i. Potential free contacts

: 240V AC 5A, 24V DC 2A

5.7.4 Two wire transmitters shall be powered through active barriers or (in case of non-hazardous area) through the analog input card.

5.7.5 Independent channel shall be provided for each transmitter with necessary current limiting circuit to guard against short circuit/accidental earthing of field wires.

5.7.6 It shall be possible to have latched as well as pulse outputs from the system. In case of pulse output it shall be possible to have positive as well as negative pulse. Pulse width shall be adjustable individually from 0~60s.

5.7.7 Interrogation voltage for all digital inputs shall be 230V AC.

5.7.8 For all types of alarms dead band shall be configurable individually between 1%~5% of span.

5.7.9 A/D converter shall have a minimum resolution of 16 bits. 5.7.10 D/A converter shall have a minimum resolution of 12 bits. 5.7.11 The number of inputs / outputs per I/O module shall be restricted to the

following maximum.

Analog In, 4-20mA, HART (16 Channel)

Analog Out, 4-20mA, HART (8 Channel)

RTD In (8 Channel)

Thermocouple In (8 Channel)

Discrete In, +12vDC, NAMUR (16 Channel)

Discrete In, +24vDC, Dry Contact (16 Channel)

Discret In, +24 VDC Isolated (16 Channel)

Discrete Out, +24vDC, Dry Contact (16 Channel)

Discrete Out, Isolated DC (16 Channel)

Discrete In 120 VAC Isolated (8/16 Channel)

Discrete In 230 VAC Isolated (8/16 Channel)

Discrete Out VAC Isolated (supports 20 to 250 VAC signals) (16 Channel)


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5.7.12 Scan Time 5.7.12.1 It shall be possible to assign variable scan rates loop wise for all the loops. By

definition scan time means the time taken to read the field input, A/D conversion & linearization of the same, performing control algorithms specified as per requirement and outputting the result including D/A conversion.

5.7.12.2 The detailed requirements of scan time for various control requirements are

as follows Closed control loops 250ms Monitoring loops 1s Interlock Logic 500ms

In case open loop inputs are used as an auxiliary inputs in closed loops (e.g. temperature compensation in a flow control loop) these shall be executed at the same rate as the closed loop (250ms) Special execution time requirements for BPC and BRC are mentioned in the “Instrumentation Specification for Blending Unit” Doc. No. TCE.6758A-A-580-600 attached elsewhere.

5.7.12.3 Hardware/software redundancy requirements are as given below: Power supply for controller CPU 1:1 redundant Controller CPU and memory 1:1 redundant CPU communication interface with I/O 1:1 redundant CPU communication interface with system data highway 1:1 redundant Power supply to I/O racks 1:1 redundant I/O communication interface with CPU 1:1 redundant Analog input modules for closed control loops 1:1 redundant Analog output modules for closed control loops 1:1 redundant Analog input modules for monitoring loops no redundancy

reqd. Digital input modules for interlocking 1:1redundant Digital output modules for interlocking 1:1redundant Other DI/DO modules no redundancy

reqd.

5.7.12.4 The controller sub-system memory, tag capacity, etc. shall be sized considering i) as built I/O requirements of Blending Unit, ii) additional I/O


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requirements as per clause 14.0 of this specification and considering 20% (of i + ii) installed I/Os. In addition the system shall have 20% usable spare space to mount I/Os in future. The CPU loading including the future I/O requirements shall not exceed 70%. The CPU loading considering the present I/O requirements (including 20% installed spares) shall not exceed 60%. Number of multi-loop controllers shall be decided based on these guidelines. CPU loading shall be demonstrated during FAT.

5.8 Communication Networks

5.8.1 The control network communications system shall employ a fully redundant Ethernet network to interface between all BPCS controllers, operating consoles, engineering consoles, application stations and wired and wireless gateways. No single point of failure should result in communication loss between any and all network resident devices. The Ethernet network system shall employ TCP/IP communications to all network resident devices with a minimum bandwidth of 100Mbit/sec

5.8.2 This shall include all the hardware and software needed for communication between various system nodes as well as devices within a node. In general it can be classified broadly into following categories.

a) Main data highway on which various nodes of the system shall communicate

b) Internal communication bus on which various intelligent devices within a node shall communicate

c) Serial communication interface between a controller and analyzers.

5.8.3 Main Data Highway 5.8.2.1 This is the most important communication network and shall facilitate peer to

peer communication with all the nodes in the system viz., operator / engineer station, control & data acquisition system, supervisory computer, printers, and other devices if any.

5.8.2.2 This shall be a 100% redundant highway system for operational security. The system diagnostic display shall indicate the status of active & standby highway at any given time.

5.8.2.3 In case of a fault with active highway the redundant one shall take over communication functions automatically, instantaneously and smoothly, without any loss of information.

5.8.2.4 The health of both highways shall be checked continuously and faults annunciated through a system alarm.

5.8.2.5 The system architecture and software shall be such that it shall be possible to physically add or remove a node, on/from, highway without interrupting ongoing communication with other nodes.

5.8.2.6 Similarly in case of a failure of one or more nodes, the same shall be automatically bypassed. The communication with other nodes carries on uninterrupted.


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5.8.2.7 The communication transmission shall be fast enough so that even during plant upsets, shutdowns or startups, the highway is not jammed.

5.8.2.8 At any point of time, The highway loading shall not exceed a maximum of 50% of its capacity i.e. there shall be 50% spare capacity available in the basic network for future. This shall be demonstrated during FAT.

5.8.2.9 Each of the segments of Main Data Highway shall be routed differently (in separate conduits and via different path) to prevent damage to both in case of an accident.

5.8.4 Internal I/O Communication Bus

5.8.3.1 This shall connect various I/O modules within a node to the CPU executing control, data acquisition, logic execution and other tasks.

5.8.3.2 This shall be a 100% redundant bus system.

5.8.3.3 Health of the active and standby bus shall be available on system status display.

5.8.3.4 In case of a fault with active bus the redundant shall take over communication functions automatically, instantaneously and smoothly without any loss of information.

5.8.3.5 It shall be possible to add, remove or change I/O modules on-line, without interrupting ongoing communication with other modules.

5.8.3.6 In case of a failure of one or more modules, the same shall be automatically bypassed. Communication with other modules carries on uninterrupted.

5.8.3.7 In case the I/O modules can be located remotely from the CPU (RIO), the data transfer rate shall be fast enough to ensure that there is no compromise on scan time.

5.8.3.8 At any point of time, the bus loading shall not exceed a maximum of 60% of its capacity i.e. there shall be 40% spare capacity available in the basic network for future use.

5.8.5 Communication With Peripherals

5.9 This shall be serial communication type RS232C, RS422/RS485, etc. Alternatively it can be Ethernet TCP IP. For communication with analyzers and IMS this shall be fully redundant.

5.10 Marshalling Cabinets

5.9.1 These shall be used to terminate all field cables as well as for grouping of various signals from the field devices.

5.9.2 These shall also be used to mount other hardware like trip amplifiers, termination assemblies, safety barriers, relays, etc.

5.9.3 Marshalling cabinets shall be self standing type with front & rear doors. All the cabinets shall be provided with magnetic latches and door locks and it should be possible to open all the locks with a single key. Door handles shall be flush type. Lifting hooks shall be provided. 100 mm channel base shall be provided at the bottom for mounting. Removable gland plates for all cables shall be provided at the bottom. For prefabricated system cables between marshalling cabinets and system hardware cabinets a separate gland plate with split


SPEC. NO. TCE.6758A-A-580-601





ISSUE P0

holes & rubber grommets shall be provided. Bunching of these cables and routing them through a single big cutout is not acceptable. If unarmoured cables are used these shall be routed through GI conduits.

Dimensions & colour of all marshalling cabinets shall be identical from point of view of good aesthetics. Painting shall be oven baked (2 primer coats and 2 final coats) epoxy/powder coating, with matt finish.

5.9.4 Cabinets shall be sufficiently illuminated with fluorescent lamps. Ventilation fans shall be provided. Ventilation louvers shall provided with wire netting to prevent entry of insects. 240V AC, 5A, utility socket with switch shall be provided in every panel.

5.9.5 Cabinets shall be provided with bus-bars for safety earth / instrument earth. All bus-bars shall be Cu- Ni/Cr plated. Bus-bars for instrument earth shall be mounted on insulated supports.

5.9.6 The design of marshalling cabinets shall be such that whenever a group of cabinets is bolted together it shall be easily possible to do interwiring within them. Use of external cabling to do interconnection between cabinets shall be restricted only to those cases where cabinets/group of cabinets are geographically separate from one another.

5.9.7 Internal layout of marshalling cabinets shall ensure that there is no overcrowding of components and maintenance accesses are properly obtained. Terminal strips shall be easily accessible and ferrules readable. All components shall be mounted on front and rear surfaces of the mounting plate. No component shall be mounted on the sides/doors/gland plates or in the bolting space provided between two adjacent cabinets.

It is preferred to mount barriers, field termination assemblies, signal conditioning cards, in marshalling cabinets and wire them up to the incoming terminal strips; so that at site only pre-fabricated system cables need to be terminated from marshalling cabinets to the I/O modules thus saving valuable erection time. In general, cross panel wiring between marshalling cabinets shall be limited to barest minimum. Ferruling philosophy shall be “Cross” plus “Self”.

5.9.8 All terminals shall be single tier type only. Multi-tier terminals are not acceptable. Type of terminals to be used shall be as follows:

Analog inputs / outputs Link type Digital inputs from plant Link type Digital inputs from electrical switchgear Fused type Digital outputs to plant / electrical switchgear Fused type

Fuses/links shall be put in both the legs. All digital input / outputs shall be through interposing relays with LEDs for indication. Powered outputs to field solenoid valves shall be individually tapped from a bus bar and then wired to the fused terminal. Looping of terminals is not acceptable. In case Printed Circuit Board (PCB) mounted relays are used for driving solenoid valves, only fused type PCBs shall be used with individual fuses for each output. Power to very small loads (trip amplifiers, isolators, active


SPEC. NO. TCE.6758A-A-580-601





ISSUE P0

barriers, etc.) within a cabinet, shall be tapped from a bus bar and distributed through fused terminals.

5.9.9 All field cables shall be terminated on terminal strips only and not directly on any other hardware (e.g. barriers). All spare cores of multi cables shall be terminated on terminal strips on a 1:1 basis as in junction box. No core shall be left open or unterminated.

5.9.10 All lables shall be rear engraved plastic / printed.

5.9.11 Marshalling cabinets shall be Rittal make.

5.11 System Hardware Cabinets

5.10.1 These shall be used to mount the system hardware, like controllers, I/O racks etc.

5.10.2 The colour depth and height of these cabinets shall be identical to that of marshalling cabinets. All other specifications of these shall remain identical to those of marshalling cabinets already given earlier.

5.12 Power Distribution Cabinets

5.11.1 These shall be used to mount the hardware required to distribute power at various voltage levels to different consumers.

Separate cabinets shall be considered for different voltage levels. In case the extent of power distribution is very limited for a particular voltage, it can be combined with other voltage level in one cabinet. However this shall be done only by providing adequate protective shielding / physical separation between the two distributions.

5.11.2 Power distribution cabinets shall be provided with a voltmeter / ammeter and a „power on‟ indication lamp, for each voltage level. For three phase power, a single voltmeter / ammeter with a selector switch shall be provided. Incoming isolation shall be through MCCBs for current rating above 50A. For rating below this, double/triple pole MCBs shall be provided as required.

Distribution of power to various downstream loads shall be done using bus-bars only and double / triple pole MCBs. No looping of power supplies shall be acceptable.

Size of terminals for outgoing cables shall be chosen as per the size and type cable chosen for each load.

5.11.3 Dimensions colour and other specifications shall be identical to those of marshalling cabinets.

5.13 Interconnection Cables

5.12.1 To be provided by DCS vendor. Cables should be standard specifications only.

5.14 Miscellaneous Requirements

5.13.1 Earthing

Each panel, cabinet, console and other equipment in control room shall be provided with an earthing lug. All these lugs shall be properly secured to the AC mains earthing bus.


SPEC. NO. TCE.6758A-A-580-601





ISSUE P0

All circuit grounds of electronic instruments, shields and drain wires of signal cables shall be connected to instrument ground which is electrically isolated from the AC mains earthing bus. The instrument ground bus is connected to independent instrument system ground through insulated cables.

Each panel shall be connected to earth pits through two parallel runs of cables.

5.15 Interface With Other Systems

5.14.1 DCS shall be interfaced to the following through dual redundant interface

Process Plant DCS System (Yokogawa Centum 3000)

RS -485 Modbus / TCP –IP ETHERNET protocol shall be used for serial communication as a minimum with the Existing DCS system. All necessary Hardware / Software required for Interface with the Existing Yokogawa DCS at new DCS end shall be in the scope of Bidder, however Coordination with Yokogawa DCS vendor for satisfactory completion of the job shall be considered by the bidder.

6. TRAINING

6.1 Contractor shall train owners‟ maintenance engineers as well as operations staff in DCS vendor‟s works. The training imparted shall be by qualified and experienced staff available. It shall be exhaustive and aimed at making owners‟ maintenance & operations staff self reliant for most of the day to day applications. For training, contractor shall make available as close a model of the system with all the representative nodes, as the actual system to be installed. It is envisaged that following be covered in the training:

6.2 Maintenance Staff Training

a) System architecture b) Functions of each node c) Hardware in each node d) Complete application software. (This shall cover everything from basics

like generation of various system nodes to advance language programming, configuration and debugging etc.).

e) Commonly occurring hardware problems and the maintenance procedures to be followed.

f) Various diagnostic programmes available for their use and interpretation. g) Routine preventive maintenance procedures. h) Maintenance of various peripheral devices like printers, copiers etc.

6.3 Operations Staff Training

This shall be restricted to the operation of the system. This shall broadly cover the following:

a) System architecture b) Functions of each node c) Functions of various keys in the keyboard d) Generation of displays like graphics, group, trend groups, etc


SPEC. NO. TCE.6758A-A-580-601





ISSUE P0

e) Display hierarchy, access methods for various displays, switching between different types of displays, etc

f) Control of plant from various displays g) Alarm handling. h) Development of blending model and their debugging (Restricted to

supervisory staff only). i) Logging software

6.4 For purposes of training, detailed literature, instruction & maintenance manuals in English shall be arranged by the contractor.

Duration of training and the number of participants are as given below:

Hardware and Software Maintenance Training

No of persons & duration: Five persons in each batch, total two batches of 10 days each.

Location : DCS supplier‟s works

Operation Staff Training

No. of persons & duration: Five persons in each batch, total two batches of 5 days each.

Location : DCS supplier‟s works / Site

7. FACTORY TESTING AND ACCEPTANCE

7.1 Contractor shall test and demonstrate the functional integrity of the system hardware and software. No material or equipment shall be transported until all required tests are successfully completed and certified “Ready for Shipment” by the Owner / TCE.

7.2 Within seven days of award of DCS order, the contractor shall furnish to owner/TCE the following:

HDM, SDM, FAT, SAT procedure. Power Supply / Heat Load Calculations. Sample colour scheme for process lines and sample graphic. Sample copy of logs, reports. One copy of system operation manual. Other available features like font sizes, colours, line thickness,

historisation capabilities, etc. 7.3 The owner reserves the right to be involved and satisfy himself at each and

every stage of inspection. The owner shall be free to request any specific test on any equipment considered necessary by him although not listed in this specification, as a part of approval of factory testing procedure. The cost of performing all tests shall be borne by the contractor.

7.4 Contractor to note that acceptance of any equipment or the exemption of inspection or testing shall in no way absolve the contractor of the responsibility for delivering the equipment meeting all the requirements as stipulated in the specifications.


SPEC. NO. TCE.6758A-A-580-601





ISSUE P0

7.5 It shall be contractor‟s responsibility to modify and/or replace any hardware and modify the software if the specified functions are not completely achieved satisfactorily during testing and factory acceptance.

7.6 For final integrated inspection of the system, the vendor shall give a minimum notice of 3 weeks to Owners.

7.7 The inspection and factory acceptance shall be carried out as follows:

7.7.1 Hardware Inspection

a. Checks on general workmanship like fabrication quality, paint quality, whether paint shade identical to all cabinets etc.

b. Dimensional inspection for base frame, height, depth, gland plates etc.

c. Power supply, wiring checks for fans, tubelights etc.

d. Supply/signal wiring checks including colour code checking, checking of ferrules, correctness of wiring, size of wires, proper segregation of wires etc.

e. Provision of terminals of correct size and type.

f. Operation of various lamps, push buttons, MCBs, annunciators, relays, ammeters and other instruments mounted on the consoles or within the cabinets.

g. Megger test for power distribution cabinets.

h. Provision of earthing busbars for safety earth/system earth etc.

i. If a group of panels/consoles is to be mounted and bolted together in the final layout frozen the same shall be offered for inspection exactly in the same fashion to check inter panel wiring, mechanical alignment etc.

j. All system modules shall be checked for their correct mountings in respective slots as per configuration frozen.

k. Redundancy wherever specified shall be checked for:

Power supply I/O cards CPU / CPUs Communication (between nodes as well as within a node).

l. Scan times as specified shall be checked for random inputs/outputs.

m. Individual modules wherever possible shall be checked for their performance.

n. All volatile memory shall be checked for battery backup by tripping power for the duration given in the Contractor‟s specifications.

o. Checking of correct functioning of key-board operation.

p. Checking of CPU loading.

q. System diagnostics shall be thoroughly checked for all sub-systems on local level as well as on operator / engineering console. These shall include failure of a sub-system, module, power supply, interface unit,


SPEC. NO. TCE.6758A-A-580-601





ISSUE P0

failure of transfer to redundant module on main module failure etc. and other detailed diagnostic displays. Diagnostic alarms for any ventilation fan failure shall also be checked.

r. Testing of proper functioning of all printers.

s. Testing of system features like synchronization of system clocks, selective tuning from engineering console, key-lock functions etc.

7.7.2 Software Checks

These shall include, but not limited to, the following:

100% check on the generated data base. This includes checks on:

a. Correctness of tag number and description.

b. Measuring range.

c. Input type, input conditioning.

d. Algorithms to be executed.

e. Output type and conditioning if any.

f. Other details if required.

All graphics shall be checked 100% for static and dynamic details. These include:

a. Checking all graphics for correctness w.r.t. P&ID.

b. Checks on line thickness, colour, equipments, tags, units of measurement.

c. Checking of modifier conditions wherever specified.

d. Switching between various operating pages as per philosophy frozen.

e. Operation of all keys on the keyboard shall be checked. Various printing

operations like, operator changes, alarms, guide messages etc. shall be

simulated and checked at random.

f. Group displays shall be checked for correctness of grouping.

g. Alarm priorities shall be checked for randomly chosen alarms.

h. All complicated loops shall be checked 100% from input stage to output for

correctness of configuration.

i. All logic & sequence operations shall be checked 100% from input to output

by forcing/ enabling various I/Os through software.

j. Any higher language programmes like BPC & BRC shall be checked 100% either by simulation or by feeding requisite inputs and checking the outputs.

k. Logging operation shall be checked.

l. Communication between different 3rd party devices and DCS along with its redundancy shall be checked. The contractor shall arrange the required hardware from these parties to the DCS vendor‟s shop for this purpose. Alternatively contractor shall demonstrate the same through a sample MODBUS / OPC software loaded on a PC.


SPEC. NO. TCE.6758A-A-580-601





ISSUE P0

8. INSTALLATION, PRE-COMMISSIONING AND COMMISSIONING

8.1 Contractor shall ensure that a team of experienced engineers, technicians and other staff from the vendor is deputed for the purpose of installation, pre-commissioning and commissioning of the system at site.

Following activities are included in the Contractor‟s scope:

a. Transportation of system from site stores to control room.

b. Unpacking the system and inspection of the same for any damages.

c. Erection of the system in the existing control room/cabinet room. Refer “Special Requirements” Clause 14 of this document for expected work to be carried out by the contractor.

d. Inter cabinet wiring/cabling for all signal, power supply and system cables.

e. Powering up the system, loading the system configuration and carry out internal loop checks for correctness of wiring. This shall be carried out from marshalling cabinets/dummy consoles etc. upto OES.

f. Co-ordinate with Owners/TCE during complete loop/interlock checking of the Blending Unit. This shall be done at least at 4 points in instrument range and with printer online.

g. Consolidate all loop checking reports with Owners/TCE.

h. Correction of all drawings to make them “as built”.

i. Commissioning of the blending unit with assistance from Owners. This includes tuning of all loops, implementing configuration changes, interlock changes; commissioning of BPC/BRC including implementation of blend recipe changes; etc.

j. During commissioning, the contractor shall provide required qualified and experienced manpower to carry out the activity above. Contractor shall include all costs that will be incurred for this in his quotation.

9. FINAL ACCEPTANCE Owner shall take over the system along with analyzers from contractor after final acceptance test (SAT).

The integrated system shall run uninterruptedly for four weeks from date of commissioning of the whole plant. Any loss of time due to reasons like power failures, forced shutdowns etc. which are due to no fault of the contractor shall also be counted as run time. However, if any major software / hardware failure of the system occurs due to which the system or a part thereof has to be shutdown the test shall be conducted afresh on the whole system.

10. SPARES PHILOSOPHY

20% wired spares to be provided. Also 20 % of spare slots to be provided in Rack to install additional cards for future use.

11. PROVEN TRACK RECORD (PTR)


SPEC. NO. TCE.6758A-A-580-601





ISSUE P0

The offered system shall be shall have a PTR of 4000 hours of continuous successful, uninterrupted, operation for at least two refineries in India or worldwide.

13. VENDOR LIST FOR BOUGHT OUT ITEMS

Vendors for commonly required bought out items are as given below:

Terminals : Phoenix, Wago Barriers : MTL, P&F Trip amplifiers / isolators : MTL, P&F, Yokogawa Lamps / selector switches : Siemens / L&T / Technic Relays : Omron / OEN Contactors : Siemens / Schneider Electric Voltmeter / ammeter : Automatic Electric


SPEC. NO. TATA CONSULTING ENGINEERS LIMITED SECTION: Write-up

TCE.6758A-300-PP-1551 PIPING MATERIAL SPECIFICATION GRADE : BE57C SHEET : 1 OF 3

SERVICE :- PROPANE, BUTANE AND LPG

P-T

R

ATI

NG

TEMP. ºC -45 -29 CA (mm) :- 1.5

PR. kg/cm2 g 35.32 35.32 FLANGE FACING:- RF, 125 RA

NOM. PIPE SIZE NB 15 20 25 40 50 80 100 150 200 250 300 350

OUTSIDE DIA. mm 21.3 26.7 33.4 48.3 60.3 88.9 114.3 168.3 219.0 273.0 323.9 355.6

THICKNESS MM 3.73 3.91 4.55 5.08 3.91 5.49 6.02 7.11 6.35 6.35 6.35 7.92

NOM. PIPE SIZE NB 400

OUTSIDE DIA. mm 406.4

THICKNESS mm 7.92

LINE JOINT 40 NB & BELOW :- SW COUPLING

50 NB & ABOVE:- BUTT WELDED

ITEM

NOMINAL PIPE

SIZE RANGE NB

MATERIAL SPECIFICATION

DIMENSIONAL

STANDARD REMARKS

PIPES

15 – 40 ASTM A 333 GR. 6 ASME B-36.10 PE, SEAMLESS, SCH 80

50 – 150 ASTM A 333 GR. 6 ASME B-36.10 BE, SEAMLESS, SCH 40

200 – 400 ASTM A 333 GR. 6 ASME B-36.10 BE, SEAMLESS, SCH 20

NIPPLES 15 – 40 ASTM A 333 GR. 6 ASME B-36.10 PBE, SEAMLESS

BW

FI

TTIN

GS ELBOWS (90°/ 45°-

1.5D), CAPS, REDUCERS (ECC. / CONC.), TEES (EQUAL / RED.)

50 – 350 ASTM A 420 GR. WPL 6 ASME B-16.9 BW (THK. TO MATCH PIPE THK.)

SW

FI

TTIN

GS

ELBOWS (90°/ 45°), TEES (EQUAL / RED.), COUPLING (FULL / HALF/RED.)

15 – 40 ASTM A 350 GR LF2 CLASS 1

ASME B-16.11 SW

SWAGE (CONC. / ECC.) 15 – 80 ASTM A 350 GR LF2

CLASS 1 BS-3799 PBE (THK. TO MATCH PIPE THK.)

UNIONS 15 – 40 ASTM A 350 GR LF2 CLASS 1 BS-3799 SW

BRANCH CONNECTION 15 – 350 --- --- REFER BRANCH CONNECTION CHART

FLANGES

15 – 40 ASTM A 350 GR LF2 CLASS 1 ASME B-16.5 SW, 300, RF / 125 AARH

50 – 150 ASTM A 350 GR LF2 CLASS 1 ASME B-16.5 WN, 300, RF / 125 AARH, SCH 40

200 – 400 ASTM A 350 GR LF2 CLASS 1 ASMB B-16.5 WN, 300, RF / 125 AARH, SCH 20

BLIND FLANGES 15 – 400 ASTM A 350 GR LF2 CLASS 1 ASME B-16.5 300, RF / 125 AARH

STUD BOLTS 15 – 400 ASTM A 320 GR.L7 ASME B-18.2

REV. NO. R0 PPD. BY: SS JOB NO. CLIENT: BPCL, Uran ISSUE DATE 30-03-12 CHD. BY: KR TCE. PROJECT: PMC SERVICES FOR R0 REV. BY SS DATE: 30-03-12 6758A BLENDING UNIT AT URAN

TCE FORM NO. 087 R5 FILE NAME: 6758APP1551R0.DOC


SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION: Write-up

TCE.6758A-300-PP-1551 PIPING MATERIAL SPECIFICATION GRADE : BE57C SHEET : 2 OF 3

ITEM NOMINAL PIPE SIZE RANGE

NB

MATERIAL SPECIFICATION

DIMENSIONAL STANDARD

REMARKS

HEAVY HEX. NUTS 15 – 400 ASTM A 194 GR. 4 ASME B 18.2

GASKETS 15 – 400 SP. WND SS304 + GRAFIL

ASME B 16.20 – ASME B 16.5 4.5MM THK, SPIRAL, 300

THREADED FITTINGS :- CAPS

15 – 40 ASTM A 333 GR. 6 ASME B-16.11 SCREWED

TYPE OF VALVE

SIZE RANGE MATERIAL PR.

RATING TYPE OF ENDS

SPECIFICATION OR

TAG NUMBER REMARKS

NB BODY TRIM ANSI

GLOBE VALVE 15 – 40 A350 GR

LF2 CLASS 1

SS 304 800 SW, 800, B-16.11 G63 DMN. STD :- API-602

Note 1

GLOBE VALVE 50 – 250 ASTM A352 GR. LCB SS 304 300

FLGD, 300, B-16.5, RF /125

AARH T33 DMN. STD :- BS-1873

GLOBE VALVE 300 – 400 ASTM A352 GR. LCB SS 304 300

FLGD, 300, B-16.5, RF /125

AARH T33 DMN. STD :- B-16.34,

Note 2

CHECK VALVE 15 – 40 A350 GR

LF2 CLASS 1

SS 304 800 SW, 800, B-16.11 C63 DMN. STD :- API-602

CHECK VALVE 50 – 400 ASTM A352 GR. LCB SS 304 300

FLGD, 300, B-16.5, RF /125

AARH C33 DMN. STD :- BS-1868

BALL VALVE 15 – 40 A350 GR

LF2 CLASS 1

SS 304 800 SW, 800, B 16.11 B33 DMN. STD :- ISO-

17292, Note 1

TYPE OF SPECIALITY

SIZE RANGE

NB

MATERIAL PR. RATING

ANSI

TYPE OF ENDS

SPECIFICATION OR

TAG NUMBER REMARKS

BODY TRIM & INT

STRAINER - 15 – 40 A350 GR

LF2 CLASS 1

INT: SS304 800 SW SP1–XXX Y-TYPE

STRAINER – 50 – 150 A 350 GR LCB INT: SS304 300 WN, RF SP2–XXX Y – TYPE

STRAINER – 200 – 400 A 350 GR LF2 CL 1 INT: SS304 300 WN, RF SP2–XXX Y – TYPE

NOTES:- 1. With 100 mm pipe piece on each side. 2. With Gear Operator 3.


TCE FORM NO. 087 R5 FILE NAME: 6165APP1551R0.DOC


SPEC. NO. TATA CONSULTING ENGINEERS LIMITED SECTION: Write-up

TCE.6758A-300-PP-1551 PIPING MATERIAL SPECIFICATION GRADE :

BE57C SHEET: 3 OF 3

BRANCH CONNECTION CHART

SIZE

BRANCH inch/mm

RUN 15 20 25 40 50 80 100 150 200 250 300 350 400

15 T

20 RT T

25 RT RT T

40 RT RT RT T

50 SL RT RT RT T

80 SL SL SL SL RT T

100 SL SL SL SL RT RT T

150 SL SL SL SL WL RT RT T

200 SL SL SL SL WL WL RT RT T

250 SL SL SL SL WL WL RT RT RT T

300 SL SL SL SL WL WL WL RT RT RT T

350 SL SL SL SL WL WL WL RT RT RT RT T

400 SL SL SL SL WL WL WL RT RT RT RT RT T

LEGEND : T - STRAIGHT TEE RT - REDUCING TEE C - HALF COUPLING TL -THREADOLET SL - SOCKOLET WL - WELDOLET P - PIPE TO PIPE N - NIPOLET

R - REINFORCED


FILE NAME: 6758APP1551R0.DOC TCE FORM NO. 088 R3


SPEC. NO. TATA CONSULTING ENGINEERS LIMITED

TCE.6758A-B-300-001

SECTION : D

PAINTING SPECIFICATION SHEET 1 OF 3

ISSUE R0

1.0 SCOPE

1.1 This specification establishes the minimum requirements for surface preparation, application and inspection of painting for carbon steel pipes, equipment and supports. Painting shall be applied for corrosion protection, service / temperature indication and warning for specific hazards.

1.2 Stainless steel surfaces, both insulated and non-insulated and galvanized steel items shall not be painted. Machined parts of operating equipment and gasket contact surfaces shall also not be painted.

1.3 The CONTRACTOR shall submit a detailed plan for surface preparation and painting for review in specific cases where painting shall be as per “Manufacturer’s Standard”.

2.0 CODES & STANDARDS

IS8629 : Code of practice for protection of iron and steel structures from atmospheric corrosion.

ISO 8501.1/1S: Preparation of steel substrates before application of paints and related products

SSPC : Steel Structure Painting Council – Surface preparation specification

3.0 SURFACE PREPARATION

3.1 Surface preparation of new steel surfaces includes removal of mill scale together with all rust and surface contaminants, such as grease, dirt and all pollutants.

3.2 All weld spatters, rough welds and sharp edges shall be removed or ground smooth prior to blast cleaning.

3.3 All insulated pipes - The surfaces shall be mechanically cleaned to St3 degree. Very thorough cleaning with wire brush shall be done

3.4 All structures

3.4.1 The surfaces shall be blast cleaned to SA 2½ - “Near white blast cleaning” as in ISO 8501.1/1S.

3.4.2 Blast cleaned surfaces shall provide good adhesion for the primers but shall not show excessive roughness. Anchor pattern shall be RZ: 40-70 for zinc silicate primer and RZ: 35-50 for all other primers.



TCE.6758A-B-300-001

SECTION : D


ISSUE R0

3.4.3 Blast cleaning shall not be executed when the surface temperature is less than 30C above dew point of surrounding air or the relative humidity is above 90%. Compressed air used for blast cleaning shall be free from water, oil or other contaminants.

3.5 Blast cleaning shall be executed using abrasives like steel / malleable iron shots, steel / crushed chilled iron grit or chopped steel wire.

4.0 PAINTING

4.1 All insulated pipes shall be applied with one coat of inert Pigment / Epoxy resin based aromatic / polyurethane as binder-Resin of 50 m DFT.

4.2 All structures shall be applied with primer coat of modified aluminium epoxy mastic of 100 m DFT / Intermediate coat of MIO/Epoxy resin of 75 m DFT followed by final two coats of inert Pigment / Epoxy resin based aliphatic / polyurethane as binder-Resin of 40 m DFT each.

4.3 Care shall be taken to ensure that the quality of prepared surface shall not deteriorate before application of paint.

4.4 Sufficient time, as recommended by the paint manufacturer shall be provided for curing of paint before application of next coat of paint. All painted surfaces shall be cured at ambient temperatures.

4.5 Primer, intermediate and finish coats shall be fully compatible and appropriate paint materials shall be obtained from the same paint manufacturer.

4.6 Any type of paint, crayon or tape shall not be used for colour coding of stainless steel surfaces. Solvents used for cleaning the stainless steel surfaces shall be free of chlorides.

4.7 Piping and equipment shall be painted as per colour code provided by the ENGINEER / OWNER.

4.8 In cases where shop coating has been damaged while handling, damaged and blistered coating shall be removed by blast cleaning wherever possible or by hand or power tool cleaning. Edges of breaks shall be feathered and specified number of primer and finish coats shall be applied.

5.0 INSPECTION AND TESTS

5.1 Visual examination of surface preparation shall be carried out in accordance with ISO 8501.1/1S. Profile checks for prepared surface shall be using “Profilometer” or comparator films.



TCE.6758A-B-300-001

SECTION : D


ISSUE R0

5.2 DFT check for intermediate and final coating layers shall be carried out and offered for ENGINEER / OWNER’s examination also. Acceptance criteria shall be as per SSPC-PA 2.

5.3 Painted portions shall be checked for porosity and adhesion visually. If the number of pores per square metre exceeds three, entire area shall be blast cleaned and painted again.


TCE.6758A-E-590-001

TATA CONSULTING ENGINEERS LIMITED SECTION: D SUBSECT D8

INSULATION SPECIFICATION FOR COLD INSULATION

SHEET 1 OF 7

ISSUE

R2

1.0 SCOPE

1.1 This specification covers the technical requirements and essential particulars for

the supply, application and finishing of the complete thermal insulation for cold

equipment, piping systems, air-conditioning ducts etc. for temperatures between

ambient and (-) 80oC and also for dual temperatures (both hot and cold) service

with hot temperature above ambient and up to 230oC. Unless specified otherwise

in section C and/or data sheet A, the scope of supply of the CONTRACTOR shall

include, but not be limited to, the following items :

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

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

specified and required

(c) Auxiliary materials such as binding and lacing wires, wire netting, bands,

screws, pop rivets etc., as specified and required

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

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

2.0 CODES AND STANDARDS

2.1 The supply and application of thermal insulation and finishing covered under this

specification shall comply with all currently applicable statutes, regulations and

safety codes in the locality where it is to be applied. The materials and application

shall also conform to the latest editions of the codes and standards listed. Nothing

in this specification shall be construed to relieve the CONTRACTOR of this

responsibility.

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

IS 737 Wrought Aluminium and Aluminium Alloy Sheet and Strip for

General Engineering Purposes

IS 3144 Mineral Wool Thermal Insulation Materials - Method of Test

IS 14164 Industrial Application and Finishing of Thermal Insulation

Materials at Temperatures above (-) 800C and up to (+) 750

0C

BS 5608 Preformed Rigid Polyurethane (PUR) and Polyisocyanurate

(PIR) Foams for Thermal Insulation of Pipework and Equipment

BS 5970 Thermal Insulation of Pipework and Equipment (in the

Temperature Range (-) 1000C to (+) 870

0C )

3.0 MATERIALS

3.1 GENERAL


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3.1.1 All materials shall be new and fresh, incombustible, fire retardant, rot-proof, non-

hygroscopic, vermin proof, fungus proof, non-injurious to health, chemically

inert, non-corrosive to steel and aluminium (even if soaked in water for extended

periods) and shall be guaranteed to withstand continuously and without

deterioration the minimum and maximum temperatures to which these shall be

subjected to under the specified applications.

3.1.2 The insulation materials and any component of the finished insulation job shall

not react chemically, singly or in combination, with water or moisture to form

substances that are more actively corrosive to applied surface than water or

moisture alone.

3.1.3 In order to protect the workers from the hazards of insulation materials, suitable

protective gadgets shall be provided. Required safety precautions shall be taken

during handling and application of insulation.

3.1.4 The insulation material shall be kept dry at all times during transport, storage and

installation. Decking and covering tarpaulins alone are not adequate for any

length of time and shall not be allowed except in extreme emergencies and only

for short period. Stacking of insulation materials directly on ground shall not be

done. No wet insulation shall be installed. If wet insulation is present, it shall be

removed and replaced with new dry insulation. The insulation may be protected

with plastic film but shall be vented to prevent sweating.

3.2 INSULATION MATERIALS

The insulation material shall be one or more of the following types as specified in

data sheet A.

SL.

NO.

INSULATION MATERIAL STANDARD DENSITY,

Kg/M3

TEMP. RANGE, 0C

MATERIAL

CODE

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

3.3 INSULATION ADHESIVES

The insulation adhesive shall be one or more of the following types as specified

in data sheet A.

Material Description Material Code

3.3.1 Hot bitumen of grade 85/25 or 85/40 conforming to IS 702 shall

be uniformly applied at 1.5 Kg/M2 on the surface to be insulated.

A similar layer shall also be applied on the inside surface of the

insulation. This material shall not be used for stainless steel

surfaces.

BIT

3.3.2 MAS 83 with 0.5 mm wet film thickness shall be uniformly

applied at 0.5 lit/M2 by trowelling. MAS 83 shall not be used

with polystyrene as insulation material. MAS 83 can be used

MAS 83


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only between (-) 46 and (+) 149oC.

3.4 VAPOUR BARRIERS

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

sheet A.


3.4.1 MAS 130 with 1.02 mm wet film thickness primer coat at 1.0

lit/M2 and 2.25 mm wet film thickness finish coat at 2.5 lit/M

2

shall be uniformly applied over the insulation by spatula or

trowelling. MAS 130 shall not be used with polystyrene as

insulation material. MAS 130 can be used only between (-) 40

and (+) 60oC.

MAS 130

3.5 FINISHING MATERIALS

The finishing material shall be one or more of the following types as specified in

data sheet A.


3.5.1 Aluminium sheet as per IS 737, designation 31000, condition

H3.

AL1

(a) Insulation outside diameter 150 to 450 mm - sheet

thickness 20 SWG

(b) Insulation outside diameter below 150 mm - sheet

thickness 22 SWG

(c) Equipment - sheet thickness 18 SWG

3.6 AUXILIARY MATERIALS

3.6.1 Binding and Lacing Wires

Binding and lacing wire shall be annealed GS 24 SWG.

3.6.2 Wire Netting

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

3.6.3 Bands

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

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


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sheets aluminium or

SS 304, 20 mm wide

3.6.4 Screws

Screws shall be of self-tapping type and shall be of aluminium or stainless steel

for aluminium sheets and GS for GS sheets.

3.6.5 Pop Rivets

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

for GS sheets.

4.0 APPLICATION

4.1 GENERAL

4.1.1 The application of insulation shall be made in a professional manner. The

insulation shall be applied to all surfaces when these are at ambient temperature.

Ample provision shall be made for the maximum possible thermal movement and

the insulation shall be applied in a manner which shall avoid breaking or

telescoping due to alternate periods of contraction and expansion. A single layer

of insulation shall not be more than 75 mm thick.

4.1.2 Insulation shall be applied after all leak tests on equipment and piping are over

and the section of the plant has been specifically released by the PURCHASER

for such work. If insulation has to be applied before the leak test, all welded and

flanged joints shall be left exposed and insulated after satisfactory completion of

the leak test.

4.1.3 All surfaces to be insulated shall be clean and dry before the insulation is applied.

The surfaces shall be cleaned of all foreign material such as scale, dirt, rust and

paint, by the use of steel wire brushes and steel scrapers, where necessary. Where

a surface is not free of paint the CONTRACTOR shall notify the PURCHASER

of the condition for remedial action. The insulation shall be applied after remedial

action, suggested by the PURCHASER, has been taken by the CONTRACTOR.

One coat of primer paint shall be applied and allowed to dry before application of

insulation.

4.1.4 After cleaning and application of one coat of primer paint on the surface to be

insulated, the insulation adhesive shall be applied for fluid operating temperatures

between 200C and (-) 20

0C. Insulation material of required thickness shall be

stuck to the surface with joints staggered. The adjoining sections shall be tightly

pressed together. All the joints shall be sealed with adhesive material. Voids, if

any, shall be packed with suitably cut pieces of insulation material. Vapour

barrier and insulation finish shall be applied as per paras 3.4 and 3.5 or 4.5

respectively.


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4.1.5 Where multilayer insulation is provided, insulation adhesive shall be used

between two layers, based on temperature criterion given in para 4.1.4.

4.1.6 If aluminium or GS sheet is specified as finishing material, all joints shall be

sealed with bitumastic paint and made effectively weather and water-proof. For

temperatures between (-) 40 and (+) 120oC, MAS 94 may also be used as sealant.

MAS 94 shall, however, not be used with polystyrene as insulation material. All

flat surfaces shall be adequately sloped to prevent pools of water collecting. The

sheet shall be protected internally with 2 coats of bitumastic paint.

4.1.7 All actions shall be taken to complete the application of finishing on exposed

surfaces covered with insulation before closing the day's work. If this is not

practicable, adequate precautions shall be taken to protect the insulation from

weather, for example by wrapping it with polythene sheet, roofing felt or other

approved material.

4.2 PIPES, PIPE FITTINGS, VALVES AND SPECIALITIES

4.2.1 All vertical pipes shall be provided with suitable insulation supports to prevent

the insulation from collapsing due to its own weight. Any welding required,

shall be carried out by the CONTRCATOR with the prior permission of the

PURCHASER and only under his direct supervision. Where welding is not

permitted, suitable clamped supports shall be used. The insulation shall be

applied starting from bottom up. Mattress type insulation materials shall be

clamped from top.

4.2.2 All pipe fittings, valves and specialities shall be covered with the same type and

thickness of insulation as specified for the adjoining pipe. On pipe fittings,

insulation outside diameter shall be same as the outside diameter of adjacent pipe

insulation. Unless specified otherwise in section C, valves and specialities of 100

mm NB and larger sizes shall be provided with removable box type insulation.

Box shall be fabricated from sheet material specified for adjoining pipes. Pipe

insulation on adjoining flanges shall be stopped at one bolt length plus 25 mm

before flange to permit removal of the bolts and nuts. The insulation shall be

applied after the finish has been applied over insulation on the adjacent piping.

Flanged joints shall also be insulated with removable type of boxes. Arrangement

shall be similar to that for valves.

4.2.3 The sheets shall be installed with the longitudinal lap joints at 450 below the

horizontal for horizontal pipes and the joints sealed with bitumastic paint.

4.2.4 On vertical pipes the sheets shall be applied working from bottom up. Each

section of sheets shall have a minimum overlap of 50 mm longitudinally and

circumferentially. Each circumferential joint shall be made weather-proof by

securing with a band of sheet material and sealing with bitumastic paint.

Longitudinal lap joints shall be fixed with screws or pop rivets at approximately

150 mm centres.


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

4.3.1 Weather hoods shall be provided for insulated piping passing through roof and

external walls.

4.3.2 EQUIPMENT

4.3.3 Where the insulation material is in the mattress form, cleats in the form of wire

nails or nuts or angles and flats for supporting the insulation material, shall be

welded to the equipment by others. If wire nails are to be used as insulation

cleats, these shall be bent and secured with the metal fabric of the mattress, after

the insulation has been applied. Where insulation cleats are in the form of M6

and M10 nuts, the CONTRACTOR shall supply and install bolts of suitable

length for fixing the insulation. The insulation applied to equipment shall be

reinforced with wire netting. One course of wire netting shall be applied to the

surface of the equipment and each layer of insulation shall be backed up with

wire netting. All irregularities of the surface shall be filled and levelled over with

insulating cement. All mattress joints shall be butted tightly and the mattresses

shall be secured with 20 mm wide 24 SWG GS bands at 450 mm centres. After

banding, all mattress edges shall be laced tightly.

4.3.4 All equipment, unless specified otherwise, shall have a smooth aluminium or GS

sheet finish as specified in data sheet A, applied in a manner similar to that

specified for piping. For fixing of aluminium or GS sheets, wooden spacer rings

at 1000 mm centres shall be fixed to the equipment by the CONTRACTOR. All

vertical and horizontal sheets shall be overlapped a minimum of 75 mm. The

lapped joints of adjoining sections of sheets shall be secured with screws or pop

rivets. On all equipment above 2500 mm diameter and flat surfaces, the sheet

shall be further secured by circumferential bands at approximately 1000 mm

centres. Each sheet joint shall be sealed with bitumastic paint. The roof sections

shall overlap the side walls to prevent water seepage between insulation and the

equipment wall. Side wall sheets shall be securely banded at intersections of the

side wall and roof sections.

4.3.3 All equipment manholes, hatches, bolted or screwed cover plates, flanged ends

etc. shall have removable box type insulation, with same thickness of insulation

as for adjacent surfaces. Insulation adjoining such equipment openings shall be

tapered towards these openings to permit removal of bolts, screws, heads, covers

or plates with no damage to adjacent surface insulation or cover.

4.3.4 Nozzles and other connections on tanks and other equipment shall be insulated in

the same manner as the pipes.

4.3.5 Pump casing shall be completely insulated with removable type of boxes

fabricated from the specified sheet material. Proper care shall be taken to

maintain continuity of vapour barrier between static and removable portion of

insulation.


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4.3.6 Name plates on equipment shall not be insulated. Proper care shall be taken to

eliminate seepage of moisture from such un-insulated portions into the insulating

material.

4.4 CONTRACTION JOINTS IN INSULATION

Depending on the type of insulation material used and the operating temperature,

contraction joints shall be provided for equipment or pipes to prevent rupturing or

buckling when the cold surface contracts.

5.0 MEASUREMENT

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

6.0 MISCELLANEOUS

Approval of the PURCHASER shall be obtained of samples of all materials and

necessary test certificates of approved national laboratories, before despatching

these to site. Insulation shall not be applied until specific release is given by the

PURCHASER.


TATA CONSULTING ENGINEERS LIMITED SECTION : D8

. DATA SHEET A

TCE.6758A-E-590-001

THERMAL INSULATION FOR COLD SURFACES SHEET : 1 OF 2

(CARBON STEEL EQUIPMENT & PIPING)

1. AMBIENT TEMPERATURE : 45 OC 13.

2. 14.

3. 15.

4. 16.

5. 17.

6. INSULATION MATERIALS 18.

6.1 EQUIPMENT: EP/PUR/PIR/PF/LRG/U150 19.

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

PSG/U150 21.

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

PIR/PF/LRG/U150 23.

6.4 24.

6.5 25.

7. INSULATION ADHESIVES : BIT/CPRX/ 26.

MAS 83 27.

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

9. FINISHING MATERIALS 29.

9.1 EQUIPMENT : FC/AL1/GS1/MAS 134

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

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

GS1/MAS 134 31.

9.4 32.

9.5 33.

10. INSULATING CEMENT MATERIAL: 34.

SAME AS THE BASIC INSULATION 35.

MATERIAL 36.

11. 37.

12. 38.

NOTES

1.

REV. NO. PPD. BY : BSR JOB NO. CLIENT: BPCL, URAN

DATE CHD. BY : KR TCE. PROJECT: BLENDING PROJECT IN

URAN LPG BOTTLING PLANT REV. BY DATE : 30-03-12 6758A

GE

NE

RA

L

CO

MP

AN

ION

SP

EC

IFIC

AT

ION

S (

NO

TE

-1)

ISS

UE

NO

. R

4

MA

TE

RIA

LS

TE

ST

S A

ND

IN

SP

EC

TIO

N


TATA CONSULTING ENGINEERS LIMITED SECTION : D8

DATA SHEET A1

TCE.6758A-E-590-001

THERMAL INSULATION FOR COLD SURFACES SHEET : 2 OF 2

(CARBON STEEL EQUIPMENT & PIPING)

INSULATION THICKNESSES IN mm FOR INSULATION MATERIALS

PUR,PIR AND PF

OPERATING

TEMP. oC AMB.

TO 19 TO

9 TO -1 TO

-11 TO

-21 TO

-31 TO

-41 TO

-51 TO

-61 TO

-71 TO

PIPE SIZE

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

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

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

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

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

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

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

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

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

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

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

200 AND ABOVE AND

FLAT SURFACES

40 50 75 100 125 150 150 150 175 200 225

NOTES

1. INSULATION THICKNESSES SPECIFIED DO NOT INCLUDE THICKNESS OF FINISHING

MATERIALS SUCH AS CEMENT SAND PLASTER, ALUMINIUM OR GS SHEET, BINDING AND

LACING WIRES, WIRE NETTING AND BANDS ETC.

2. FOR INSULATION THICKNESS FOR TAIL END AIR-CONDITIONING DUCT AND EVAPORATIVE

COOLING SYSTEM ETC. REFER SECTION C OF THE ENQUIRY DOCUMENT.

REV. NO. PPD. BY : BSR JOB NO. CLIENT: BPCL, URAN

DATE CHD. BY : KR TCE. PROJECT: BLENDING PROJECT IN

URAN LPG BOTTLING PLANT REV. BY DATE : 30-03-12 6758A

ISS

UE

NO

. R

4


SPEC. NO.

TATA CONSULTING ENGINEERS LIMITED SECTION: D TCE.6758A-B-300-001

WELDING SPECIFICATION FOR EQUIPMENT AND PIPING SYSTEM

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TCE FORM NO.329 R3 FILE NAME: 6165APP1568R0.DOC

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

carbon steel, low alloy steel and stainless steel for LPG Marketing Terminal Project. Site fabrication also covers any fabrication in a shop set-up at site.

1.2 The welded joints include the following:

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

(b) Socket welding and fillet joints

(c) All types of branch welds

(d) Any other joints not specifically covered above

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

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

2.0 CODES AND STANDARDS 2.1 The welding of all piping systems including equipment, welding

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

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

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

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

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

Welding and Brazing Qualifications (f) Standards of the Pipe Fabrication Institute


SPEC. NO.



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(g) BS 2633-Specification for Class I Arc Welding of Ferritic Steel Pipe

work for Carrying Fluids (h) Any other codes and standards specified in Section C of enquiry

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

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

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

of the applicable code shall govern. 3.0 WELDING PROCESSES 3.1 The following welding processes shall be used for shop-fabricated and

field- fabricated piping systems :

(a) Gas Tungsten Arc Welding (GTAW)

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

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

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

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

(b) On butt welds in low alloy steel for the filler passes in all sizes (c) On butt welds in stainless steel for the filler passes in all sizes 3.4 For carbon steel piping, in sizes 40 mm and smaller, where butt welding is

required, the entire butt welding including root pass may be carried out by SMAW process in 150 class piping systems except for steam tracers.


SPEC. NO.



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

3.6 Other welding processes such as submerged arc welding are also

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

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

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

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

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

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

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

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

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

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

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

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

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

contaminations such as rust, oil, grease and such foreign matter. 4.7 Low hydrogen electrodes shall be used for weld joints in carbon steel if

the wall thickness exceeds 19 mm, except that non-low hydrogen electrodes shall be permitted for the root pass.


SPEC. NO.



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

welds in carbon steel. 4.9 Refer Table 1 for welding specifications and electrodes. 5.0 WELDING QUALIFICATIONS 5.1 Qualification of the welding procedures to be used and the performance of

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

5.2 No production welds shall be undertaken until the qualification

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

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

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

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

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

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

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

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

QW-482, form QW-483 and form QW-484. Other forms are also acceptable subject to approval by the PURCHASER.


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

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

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

5.10 Welding supervisors shall have qualifications such as engineering degree

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

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

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

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

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

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

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

6.0 PREPARATION FOR WELDING 6.1 Surfaces to be welded shall be smooth, uniform and free from fins, tears

and other defects, which would adversely affect the quality of the weld.


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

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

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

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

6.4 Internal misalignment shall be reduced by trimming but such trimming

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

6.5 Fillet welds, socket welds and welded - on branch connections shall be as

per ASME B31.3 or in accordance with IBR for IBR systems. 6.6 Reinforcing pads and saddles shall have a good fit with the parts to which

they are attached. A vent hole shall be provided on the side of any pad or saddle to reveal leakage in the weld and to allow venting during welding and heat treatment. Pad or saddle shall be added after the branch weld has undergone examination and necessary repairs.

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

Where flame cutting is used, the effect on the mechanical and metallurgical properties of the base metal shall be taken into consideration. Flame cutting of alloy steel pipes is not allowed. However, flame cutting of carbon steel pipes is permitted. Wherever practicable, flame cutting shall be carried out by machine. Machine flame-cut edges shall be substantially as smooth and regular as those produced by edge planing and shall be cleaned free of slag. Manual flame cutting shall be permitted only where machine flame cutting is not practicable and with the approval of the PURCHASER, and such surfaces shall be ground or dressed to a smooth finish as required by the specification and to the satisfaction of the PURCHASER. Slag, scale or oxides shall be removed by grinding to bright metal at least two (2) mm beyond the burnt area.

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

conditions of preheating and postweld heat treatment as for the welding of each class of material. However, post-weld heat treatment is not required when :

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

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


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all remaining slag, scale or oxides shall be removed by grinding to bright metal at least two (2) mm beyond the burnt area, or

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

sequence leading to a weld end preparation where welding immediately follows.

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

methods may be used for edge preparation. Cut surfaces shall be machined or ground smooth after plasma cutting.

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

preparation shall be checked by the PURCHASER. If the specified tolerances are exceeded, this shall be corrected (with prior approval) by grinding, machining or any other method acceptable to the PURCHASER.

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

pass. 7.0 TECHNIQUE AND WORKMANSHIP 7.1 Components to be welded shall be aligned and spaced as per the

requirements of the code and WPS. Special care is required when GTAW process is employed.

7.2 Alignment and spacing shall be achieved using suitable wires to maintain

the gap. These shall be removed after tack welding. The ends to be welded shall be held using suitable clamps, yokes or other devices which will not damage the surfaces in any manner. It shall be ensured that welding operations do not result in distortions.

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

only by qualified welders or welding operators and with filler metal equivalent to that used in the root pass. Tack welds shall be fused with the root pass weld, except that those which have cracked shall be removed. Peening is prohibited on the root and final passes of a weld. The required preheat shall be maintained prior to tack welding.

7.4 No welding shall be carried out if there is any impingement in the weld

area of rain, snow, excessive wind or if the weld area is wet. 7.5 Irrespective of the class of steel, root runs shall be made without

interruption other than for changing the electrodes or to allow the welder to reposition himself. Root runs made in the shop may afterwards be allowed to cool by taking suitable precautions to ensure slow cooling e.g. by wrapping in a dry asbestos blanket. Welds made at site shall not be


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allowed to cool until the thickness of weld metal deposited exceeds one third of the final weld thickness or 10 mm, whichever is greater.

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

welding be avoided. Where such interruption is unavoidable, either the pre-heat shall be maintained during the interruption or the joint shall be wrapped in dry asbestos blankets to ensure slow cooling. Before recommencing welding, preheat shall be applied again.

7.7 Welded-on bridge pieces and temporary attachments shall preferably be

avoided. Where approved by the PURCHASER, these may be used. Material of these shall be compatible with material with which they are temporarily welded. All such pieces shall be removed after welding of pipe joints and the weld area ground flush. These areas shall be subject to liquid penetrant or magnetic particle examination for high yield strength materials (YS > 3200 kg/cm2) or when the component thickness exceeds 20 mm or for P3 and P4 group materials. These pieces shall be welded by qualified welders and with electrodes compatible with the parent pipe material. The preheating requirements of pipe material shall be applied and maintained during the welding of attachments. These temporary attachments shall be removed by grinding, chipping, sawing or by arc or flame gouging. When arc or flame gouging is used, at least three (3) mm of metal shall be left around the pipe surface which shall be removed by grinding.

7.8 The arc shall be struck only on those parts of parent metal where weld

metal is to be deposited. When inadvertent arc-strikes are made on the base metal surfaces outside the joint groove, the arc-strikes shall be removed by grinding and shall be examined by liquid penetration or magnetic particle examination procedures.

7.9 Oxides shall not be permitted to form during welding or heat treatment or

both, on the internal surfaces of pipes which will not be subsequently cleaned. Inert gas purging is an acceptable method to prevent such oxidation. All joints in materials which contain more than 1¼% chromium shall be purged to assure that less than 1% of oxygen is present on the joint underside before initiation of the welding. The purging operation shall be maintained for a minimum of two (2) passes.

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

least 99.95% pure. Purging shall be carried out at a flow rate depending on diameter of pipe until at least five (5) times the volume between dams is displaced. In no case shall the initial purging period be less than 10 minutes. After initial purging, the flow of the backing gas shall be reduced to a point where only a slight positive pressure prevails. Any dams used in purging shall be fully identified and removed after welding and accounted


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for in order to avoid leaving them in the system. The rate of flow for shielding purposes shall be established in the procedure qualification.

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

temperature. 7.12 All equipment necessary to carry out the welding, for supporting of the

work, for preheating and post weld heating including thermal insulation for retaining the heat and for the protection of the welder shall be provided by the CONTRACTOR at no extra cost. All necessary precautions shall be taken during cutting and welding operations. It shall be ensured that proper ventilation is available in the welding area and adequate protective gear such as goggles, masks, gloves, protection for the ears and body are used at all times. For guidelines refer ANSI standard Z49.1, “Safety in Welding and Cutting”.

7.13 After deposition, each layer of weld metal shall be cleaned with a wire brush to remove all slag, scale and defects, to prepare for the proper deposition of the next layer. The material of wire brush shall be compatible with pipe material. Stainless steel materials shall be cleaned with grinding wheels or stainless steel brushes which have not been used on other materials. Either aluminium oxide or silicon carbide grinding wheels shall be used. Special care shall be taken to secure complete and thorough penetration of the fusion zone into the bottom of the weld. It is recommended that the root run be checked by liquid penetrant or magnetic particle procedures for critical process piping.

7.14 Upon completion of welding, the joints shall be wrapped in dry asbestos

blankets to ensure slow cooling, unless post-weld heat treatment is applied immediately.

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

treated until inspected and approved by the PURCHASER. Welds shall be prepared and ground in such a way that the weld surfaces merge smoothly into the base metal surface.

7.16 Except where necessary to grind flush for non-destructive examination,

reinforcement for butt welds may be provided. The height of such reinforcement shall meet the requirements of the code. The reinforcement shall be crowned at the centre and tapered on each side of the joined members. The exposed surface of the weld shall be ground where required to present a workmanlike appearance and shall be free from depressions below the surface of the joined members. The exposed surface of the butt welds shall be free from undercuts greater than 0.5 mm in depth, overlaps or abrupt ridges or valleys and shall merge smoothly into the pipe surface at the weld toe. However, undercuts shall not encroach on the minimum section thickness.


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7.17 Repair of weld metal defects shall meet the requirements of the code. 7.18 Any weld repair shall be subject to the approval of the PURCHASER. 7.19 In the event of several unsuccessful repair attempts or if the

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

7.20 IDENTIFICATION OF WELDS Wherever code symbol stamps are required on carbon steel and ferritic

alloy steel piping they shall be applied directly to the pipe with low stress dotted design metal die stamps or to a small stainless steel plate especially provided for such marks. These plates shall be lightly tack welded to the pipe using electrodes, of diameter three (3) mm or less, of the type specified for the material. Before making the required tack weld, the pipe material in the immediate surrounding area shall be preheated, as required, by electric means or propane or natural gas burners. Cooling shall take place under asbestos insulation in a draft-free area. Stress relieving of these welds is not required. Steel stamping directly on the surface of alloy steel piping with other than low stress die stamps shall not be used.

7.21 SEAL WELDS 7.21.1 Seal welding shall be carried out by qualified welders and in accordance

with approved drawings. 7.21.2 Threaded joints that are to be seal welded shall be made without the use

of thread lubricating compound. Seal weld shall cover all exposed threads.

7.22 WELD ENCROACHMENT AND MINIMUM DISTANCE BETWEEN

WELDS 7.22.1 Welded joints, more specifically longitudinal welds, shall be placed not

closer than 50 mm to opening or branch welds, reinforcements, attachment devices or from supports, etc. In case of deviation, the PURCHASER may specify additional non-destructive examination.

7.22.2 The longitudinal welds of two adjacent pipes or components shall be

staggered by at least 30o. The minimum distance between welds shall be 50 mm or three (3) times the wall thickness, whichever is greater. Longitudinal welds shall not be situated at the bottom of the pipe. Intersection of welds shall be avoided as far as possible. If such welds are present, they shall be subject to suitable Non-Destructive Testing (NDT) at the discretion of the PURCHASER.


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8.0 PREHEATING 8.1 Preheating prior to tack welding, welding and thermal cutting shall be used

as a means of crack prevention and improving weld reliability. The general requirements of post-weld heat treatment also apply to preheating.

8.2 Preheating shall be used as per the recommendations of ASME B31.3,

Table 330.1.1. For IBR systems, the requirements of IBR shall govern. Preheating of austenitic stainless steels is not required, except at low ambient temperatures, in which case a minimum preheat temperature of 10oC is recommended. Table 2 gives the requirements of preheating for commonly used materials.

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

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

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

the weld preparation. 8.5 Where preheating is specified, welding shall continue without interruption.

In case interruption cannot be avoided, preheating shall be continued for at least thirty (30) minutes after interruption. Also refer para 8.9.

8.6 Oxy-acetylene preheating shall not be applied. 8.7 For preheating, fuel gas/air torches, burner systems (high velocity gas or

oil burners) or electrical heating may be used either locally or in a furnace. For preheating above 250oC, electric heating (resistance or inductive heating) is preferred.

8.8 Approved temperature - indicating crayons, thermocouples or digital

contact pyrometers shall be used to measure preheat and interpass temperatures. A calibration report of the pyrometers and thermocouples shall be available.

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

maintained at or above the preheat temperature until the weld is completed.

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

wall thickness of 19 mm or greater may only be interrupted, provided at least 10 mm of weld metal is deposited, or 25% of the welding groove is filled, whichever is greater. If the welding is interrupted prior to the above, the weld area shall be adequately covered with insulating material to ensure slow cooling. After cooling and before welding is resumed, visual


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examination of the weld shall be performed to assure that no cracks are formed. Required preheat shall be applied before welding is resumed.

9.0 POSTWELD HEAT TREATMENT Post-weld heat treatment shall meet the requirements of para 331 of

ASME B31.3. For IBR systems, post-weld heat treatment shall be as per IBR. Table 3 summarises the post-weld heat treatment requirements for commonly used materials.

9.1 GENERAL REQUIREMENTS 9.1.1 A complete automatic temperature recording shall be made of preheating

and stress relieving operations. Where propane gas burners or electrical resistance coils are employed, a complete temperature record of the preheating and stress relieving operation shall be made by means of a box type potentiometer. Other means of recording temperatures are permissible subject to the PURCHASER’S approval.

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

performed with electric induction or electric resistance coils. Suitable gas burning equipment using natural gas or propane may be employed.

9.1.3 At no time during a stress relieving/preheating cycle shall any water or liquid cooling medium be employed.

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

the heavier section shall govern the selection of width of the heated band and the duration of the holding period.

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

thermocouples tack-welded to the surface and potentiometers shall be used on the pipe under at least four (4) layers of asbestos paper. The hot junctions of the thermocouples shall be located on either side of the joint at least 12 mm from the edge of the joint but no further away than 100 mm. When employing induction heating, at least six (6) turns of induction cable shall be used on each side of the weld. Induction coils shall be wrapped on top of the asbestos paper protecting the thermocouples with the first turn approximately 150 mm from the centre of the weld.

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

However, the procedure shall be limited to pipes below 100 mm NPS and shall be approved by the PURCHASER.

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

proportioned on the basis of one (1) hour per 25 mm of wall thickness of the thickest section at the joint, but in no case less than one (1) hour.


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9.1.8 For tubing joints and socket welded joints, pads, bosses, branch welds and couplings, one (1) thermocouple shall be positioned at a minimum distance of two (2) pipe wall thicknesses from the weld.

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

the preheating, welding and stress relieving operations to prevent distortion. When a butt welded joint is to be post-weld heat treated and the piping is cold-sprung, the forces required to position the pipes shall be maintained by external means until the completion of the heat treatment procedure.

9.1.10 All heating and cooling must be performed in still air. 9.1.11 The governing thickness for the post-weld heat treatment shall be the

thicker of the two components joined by welding. For deviations from this requirement for branch welds, fillet welds etc., reference shall be made to the applicable paragraph of ASME B 31.3.

9.1.12 The CONTRACTOR shall submit a detailed written procedure for the post-

weld heat treatment for the approval of the PURCHASER. 9.2 CARBON STEEL 9.2.1 Welded joints in carbon steel piping systems shall be stress relieved,

upon completion of the welding operation, in accordance with Table 3. 9.2.2 When local stress relief is employed, the welded joint shall be heated to a

temperature of not less than 625°C the temperature level shall be maintained between 625°C and 675°C, one (1) hour per 25 mm of wall thickness but in no case less than one (1) hour. The weld area shall then be allowed to cool undisturbed in still air to a temperature not exceeding 315°C. All welded joints in pipe sizes 100 mm and larger, shall be heated by means of electric induction coils or resistance heating. Welded joints in pipes smaller than 100 mm shall be stress relieved by means of electrical resistance coils or suitable propane or natural gas torches only.

9.2.3 Heating and Cooling Carbon steels, after having reached their specific stress relief

temperatures, may be cooled in the furnace or under wraps, i.e., leaving the induction coils or resistance heaters and insulation in place. This means that, at the stress relief temperatures, the power to the furnace or heating coils may be shut off and cooling takes place in the furnace or with all insulation and coils remaining on the pipe. For furnace stress relief, the doors of the furnace may be opened after the power is shut off, at or below 315°C. Thermocouples controlling the temperatures shall remain during the cooling cycle so that excessive cooling, if it occurs, can


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be observed and immediately corrected. The stress relieving coils and insulation shall only be removed after the piping has cooled to below 315°C or if stress relieved in a furnace the pipe may be removed from the furnace and permitted to cool in still air at a temperature not below 10°C.

9.3 ALLOY STEEL 9.3.1 All welds in alloy steel piping shall be stress relieved after the welding

operation in accordance with Table 3. Immediately after welding, the material shall be wrapped in asbestos and allowed to cool.

9.3.2 Local Stress Relief All welded joints in pipes 100 mm size and larger shall be locally stress

relieved by means of electric induction coils or resistance heating. Welded joints in smaller pipe sizes shall be stress relieved by means of electric resistance coils or suitable propane or natural gas torches only.

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

section shall be heated uniformly to the temperature specified. The temperature shall be maintained for a period of time proportioned on the basis of one (1) hour per 25 mm of wall thickness of the piece having the greatest wall thickness in the furnace charge, but, in no case, less than one (1) hour.

9.4 AUSTENITIC STAINLESS STEEL Welded joints in austenitic stainless steel piping need not be stress

relieved after welding. 9.5 The rate of heating and cooling during stress relieving operations shall not

exceed 315°C per hour up to a thickness of 50 mm at the weld. 10.0 ELECTRODES 10.1 The specification and size of the electrodes, voltages and amperages,

thickness of beads and number of passes shall be as specified in the approved welding procedure or otherwise agreed in writing. Only basic coated electrodes shall be used, which will deposit weld metal having the same or higher physical properties and similar chemical composition to the members being joined. For each batch of approved brand, certificate showing compliance with the specification shall be submitted to the PURCHASER for review before being released for use. All electrodes shall be purchased in sealed containers and stored properly to prevent deterioration. All low hydrogen electrodes, after baking as per the manufacturer’s recommendations, shall be stored in ovens kept at 80 to 100°C before being used. Recommendations of the electrode


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manufacturer shall be strictly followed. Until the electrodes are taken out for welding, they shall be stored in portable ovens. The electrodes shall not be exposed to open atmosphere.

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

thoriated tungsten electrode conforming to SFA-5.12-86 EWTh-2 (AWS-A5.12-80, EWTh-2) classification shall be used.

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

Code Section II Part C or any other equivalent code. 10.4 As welding electrodes deteriorate under adverse conditions of storage

leading to dampness in the electrode coating, they shall normally be stored in dehumidified air-conditioned rooms or in hot boxes or ovens in their original sealed containers whose temperatures shall be maintained within specified limits. The condition of electrodes shall be frequently inspected. Electrodes with damage to coating shall not be used. Electrodes shall remain identified until consumed. It is preferable to procure low hydrogen electrodes in hermetically sealed containers and preserve them without damage to the containers.

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

manufacturer for the use in the position in which the welds are to be made. Electrodes which have the areas of flux covering broken away or damaged shall not be used.

10.6 Table 1 gives recommendations on electrodes to be used for carbon, low

alloy and austenitic stainless steels. 11.0 INSPECTION AND TESTING 11.1 The PURCHASER shall have free access to inspect welding or any other

related operations at any time and at any stage of fabrication. 11.2 The PURCHASER may require non-destructive testing of any weld for

reasons other than those given in the specification. The responsibility for the cost of such testing shall be mutually decided between the PURCHASER and the CONTRACTOR.

11.3 The CONTRACTOR shall inform the PURCHASER when the weld

preparation and setting up for welding of various members selected by the PURCHASER is in progress so that the PURCHASER can inspect the assembly before welding starts.

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

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11.5 Any examination by non-destructive methods on low alloy steels shall be performed after post-weld heat treatment.

11.6 For a welded branch connection, the examination of and any necessary

repairs shall be completed before any reinforcing pad is added. 12.0 EXAMINATION OF WELDS 12.1 Examination refers to the quality control functions performed by the

CONTRACTOR during fabrication, erection and testing. 12.2 As a minimum, the following shall be examined by visual examination :

(a) Materials and components to ensure that these are as per the specification and are free from defects. If defects are noticed on “free-issue” items, these shall be brought to the notice of the PURCHASER without delay.

(b) Joint preparation and cleanliness (c) Preheating as applicable (d) Fit-up, joint clearance, and internal alignment prior to joining

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

material, position and electrode (f) Condition of the root pass after cleaning - external and where

accessible, internal (g) Slag removal and weld condition between passes (h) Appearance of the finished joint

12.3 Acceptance for the visual examination shall be as per ASME B 31.3 or IBR as applicable.

12.4 Other types of examination shall be as defined in Tables 4 and 5, unless

otherwise mentioned in section C of enquiry specification. For the purpose of examination, fluids are categorised, in accordance with ASME B 31.3, as Category D, Normal Service and Category M and supplemented by other requirements.

13.0 QUALIFICATION AND CERTIFICATION OF NON-DESTRUCTIVE

EXAMINATION PERSONNEL


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13.1 The CONTRACTOR’s examining personnel shall have training and experience commensurate with the needs of the specified examinations. NDT supervisors/ examiners shall be qualified at level II or above.

13.2 The CONTRACTOR shall make available to the PURCHASER copies of

certificates of qualification of the examiners he proposes to use for the PURCHASER’s approval.

14.0 METHODS OF EXAMINATION The methods of examination used, radiographic (RT), liquid penetrant

(PT) or magnetic particle (MT), shall be in accordance BPV Code, Section V.

15.0 ACCEPTANCE STANDARDS 15.1 Levels of acceptance of defects in welds shall be in accordance with

ASME B 31.3. 15.2 For IBR piping, the levels of acceptable defects shall be as per IBR. 16.0 REPAIR WELDING 16.1 All defects in welds requiring repair shall be removed by flame or arc

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

(a) Cutting through the weld (b) Cutting out a length of pipe containing the weld, or (c) Removing the weld metal down to the root depending upon the

magnitude of the defects.

16.2 After removing the defect, the welds shall be examined by the same non-destructive testing methods as specified for the original weld and the same acceptance criteria shall hold good.

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

welding procedures as those used in making the original welds including preheating and stress relieving if originally required.


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TABLE 1

WELDING SPECIFICATION CHART

SL. NO.

BASE MATERIAL P. NO.

WELDING PROCESS FILLER MATERIAL GAS NOTES

ROOT FILLER ROOT FILLER PURGING

SHIELDING

1.0 CARBON STEELS

1.1

SIZES 40 mm AND/OR 3 mm THK

1 GTAW GTAW ER 70S2 OR

ER 70S3

ER 70S2 OR

ER 70S3

- - 1

1.2

SIZES 50 mm THK 19 mm

1 SMAW SMAW E 6010 E 6013 - -

1.3

SIZES 50 mm THK 19 mm

1 GTAW SMAW ER 70S2 OR

ER 70S3

ER 7018 OR

ER 7016

- - 2

2.0 LOW ALLOY STEELS

2.1

1¼% Cr ½% Mo

4 GTAW SMAW ER 80S B2

E8016/E 8018-B2

- -

2.2

2¼% Cr 1% Mo

5 GTAW SMAW ER90S B3

E9015/ E 9016/ E 9018-B3

ARGON ARGON 3 to 8

3.0 AUSTENITIC STAINLESS STEELS

3.1

TYPE 304 (304L)

8 GTAW GTAW for THK 4.5 mm

ER 308 (ER 308L)

ER 308 (ER 308L)

ARGON ARGON 3 to 8

SMAW for THK > 4.5mm

E 308 (E 308L)

3.2

TYPE 316 (316L)

8 GTAW GTAW for THK 4.5 mm

ER 316 (ER316L)

ER 316 (ER 316L)

ARGON ARGON 3 to 8


E 316 (E 316L)

3.3 TYPE 321 8 GTAW GTAW for

THK 4.5mm

ER 321/ ER 347

ER321/ ER 347

ARGON ARGON 3 to 8


E321/E347


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TABLE 1 (CONTD.)

SL. NO.

BASE MATERIAL

P. NO.

WELDING PROCESS

FILLER MATERIAL GAS NOTES

ROOT FILLER ROOT FILLER PURGING SHIELDING 4.0 STAINLESS

STEEL TO CARBON STEEL

4.1 SS 304/321 8 to 1

GTAW/ SMAW

SMAW ER309

ER309

- -

4.2 SS 316 8 to 1

ER310Mo E310Mo - -

NOTES 1. For 300 and higher class systems. For 150 class systems, refer para 3.4. For

fillet welds SMAW process with E6013 can be used. 2. Low hydrogen electrodes shall also be used for critical systems such as

chlorine, hydrogen, caustic and similar toxic inflammable fluids and also whenever the wall thickness exceed 19 mm.

3. The argon shielding gas flow rate shall not be less than 0.34 m3/hr. 4. Nitrogen can be used as an alternative to argon for purging purpose only. 5. For fillet welds, electrode can be used instead of filler wire. 6. For GTAW process, electrode shall be 2% thoriated tungsten. 7. Initial purging prior to welding process shall be a minimum of five (5) times the

volume between dams or ten minutes minimum whichever is higher. When welding commences, the purge gas flow shall ensure that the gas pressure is only marginally higher than atmospheric pressure to ensure no roof concavity.

8. Back purging using argon/nitrogen shall be maintained for a minimum of two

passes. 9. Electrodes / filler wires manufactured by reputed firms duly approved by the

PURCHSER shall only be used. 10. Electrodes shall have at least the same or higher physical properties and

similar chemical composition to the members being joined. 11. Read the table in conjunction with para 3.0


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TABLE - 2

PREHEAT REQUIREMENTS

SL. NO.

BASE MATERIAL P. NO. NOMINAL WALL

THICKNESS , mm

SPECIFIED MINIMUM TENSILE

STRENGTH, MPa

RECOMMENDED MINIMUM PREHEAT

TEMPERATURE, ° C

1. CARBON STEEL 1 25 490 10

2. LOW ALLOY STEEL - 1¼% Cr ½% Mo

4 ALL ALL 149

3. LOW ALLOY STEEL - 2¼%Cr 1% Mo

5 ALL ALL 177


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TABLE 3

POSTWELD HEAT TREATMENT REQUIREMENTS

SL. NO

.

BASE MATERIAL P. NO.

NOMINAL WALL

THICKNESS,

mm

SPECIFIED MINIMUM TENSILE

STRENGTH, MPA

METAL TEMPERATURE

RANGE ° C

BRINELL

HARDNESS

MAX.

1. CARBON STEEL 1 19 ALL NONE -

2. CARBON STEEL 1 > 19 ALL 625-675 -

3. LOW ALLOY STEEL 1¼% Cr ½% Mo

4 13 490 NONE -


4 > 13 ALL 704 to 746 225


5 13 490 NONE -


5 > 13 ALL 704 to 760 241

7. AUSTENITIC STAINLESS STEELS

8, 9 ALL ALL NONE -

NOTES 1. In IBR systems, in carbon steels, postweld heat treatment is also required,

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

2. All low alloy steel welds in IBR systems shall be postweld heat treated at the

temperature range of 620 to 660° C for 1 1/4% Cr 1/2% Mo steels and at a range of 660 to 750°C for 2 1/4% Cr 1% Mo steels.


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TABLE 4 WELD EXAMINATION (OTHER THAN ‘IBR’)

SL. NO.

FLUID SERVICE CATEGORY AS PER

ASME B 31.3

TYPE OF EXAMINATION

EXTENT OF EXAMINATION

GIRTH BUTT WELD

SOCKET AND FILLET WELDS

BRANCH WELDS (FABRI-CATED)

FABRICATED MITRES /

REDUCERS

ATTACH MENT

WELDS

1.0 CATEGORY D VISUAL 100% 100% 100% 100% 100%

LT/MT - - 5% - -

RT (ABOVE GROUND)

10% - - 10% -

RT (UNDER GROUND)

100% - - - -

2.0 NORMAL VISUAL 100% 100% 100% 100% 100%

RT 10% - - 10% -

LT/MT - 10% 10% - 10%

3.1 CATEGORY M & PIPING GRADE – BE57C (Propane / Butane / LPG SERVICE)

VISUAL

RT

LT/MT

100%

100%

100% (FOR ROOT RUN)

100%

-

100%

100%

-

100%

100%

100%

100% (FOR ROOT RUN)

100%

-

100%

3.2 HIGH PRESSURE (ASME 600 CLASS AND HIGHER)

3.3 CRITICAL SERVICES SUCH AS CHLORINE, CAUSTIC, HYDROGEN AND OTHERS AS DEFINED IN SECTION-C

3.4 LOW TEMPERATURE [<(-)80°C]

3.5 SEVERELY CYCLIC AS PER ASME B 31.3

NOTES Fluid services are categorised as follows (as per ASME B 31.3) 1. Category D : Fluid is non-flammable, non-toxic, and not damaging to human

tissues, and design pressure is 1.035 M Pag(150 psig) and design temperature is 186°C and not below (-) 20°C.

2. Category Normal : Not Category D, not category M, not “high pressure” as per ASME B31.3 and not subject to severe cycling as defined in ASME B 31.3.


SPEC. NO.



SHEET OF 24 OF 4

23

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TITLE


3. Category M : Toxic Services which can damage human tissue after a single exposure even if prompt remedial measures are taken.


SPEC. NO.



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TABLE 5

WELD EXAMINATION (IBR PIPING)

SL. NO.

ANSI PRESSURE CLASS

NOM PIPE SIZE, mm

TYPE OF EXAMINATION

EXTENT OF EXAMINATION

GIRTH BUTT WELD

SOCKET AND

FILLET WELDS

BRANCH WELDS

FABRICATED

ATTACHMENT WELDS

1. ALL ALL VISUAL 100% 100% 100% 100%

2. 150 AND 300

100 RT 10% - - -

50 to 80 RT 2% - 2% -

40 LT/MT - 2% - -

3. 600 AND HIGHER

50 RT 100% - - -

40 LT/MT NOTE 2

100% 100% 10%

NOTES

1. The extent of examination shown above is minimum and any additional requirement as required by ‘IBR’ shall also be considered.

2. For root runs of butt welds in sizes 50 mm (100%)


SPEC. NO. TCE.M4-904

TATA CONSULTING ENGINEERS LIMITED SECTION: E

SHOP INSPECTION AND TESTS SHEET 1 OF 7

ISSUE R9

TCE FORM NO. 329 R5 FILE NAME: M4904R9.DOC

1.0 SCOPE This specification covers the requirements for Shop Inspection and Tests to be

carried out by the PURCHASER/CONSULTANT/INSPECTION AGENCY. 2.0 GENERAL 2.1 The plant and equipment covered by the PURCHASE ORDER/CONTRACT

shall be subjected to inspection and testing. The VENDOR/CONTRACTOR shall provide all services to establish and maintain quality of workmanship in his works and that of his SUB-VENDOR’s/SUB-CONTRACTOR’s works to ensure the mechanical accuracy of components, compliance with approved drawings, identification and acceptability of all materials, parts and equipment.

2.2 For supply of systems, the VENDOR/CONTRACTOR shall, at the start of the

PURCHASE ORDER/CONTRACT, furnish a total list of items in his scope of work. This list, giving a brief description of the item, quantity, names of probable SUB-VENDORS/SUB-CONTRACTORS, and a blank column for agency for final approval of drawings and documents, shall be submitted for approval by PURCHASER/CONSULTANT. The blank column shall be filled by PURCHASER/CONSULTANT. The list shall be submitted within two weeks from the date of Letter of Intent.

2.3 For systems and major items such as pressure and load bearing items,

machineries etc., the VENDOR/CONTRACTOR shall furnish quality plan giving details of checks and tests to be conducted by them on material, process, sub-assembly and assembly. These shall include requirements as prescribed in the applicable specifications, codes and statutory requirements. The quality plan shall be reviewed by the PURCHASER/CONSULTANT and the stages to be witnessed and verified shall be indicated by the PURCHASER/CONSULTANT in the approved quality plan.

2.4 The VENDOR/CONTRACTOR shall give the PURCHASER/CONSULTANT

written notice of any material being ready for testing as per format enclosed. The clear notice period shall be seven (7) days for local inspection and fifteen (15) days for outstation inspection. Such tests shall be to the VENDOR’s/CONTRACTOR's account except for the expenses of the PURCHASER/CONSULTANT. The PURCHASER/CONSULTANT, unless the inspection of the tests is virtually waived, shall fix a date for inspection with the VENDOR/CONTRACTOR and attend such tests within fifteen (15) days of the date on which the equipment is notified as being ready for test and inspection failing which, the VENDOR/CONTRACTOR may proceed with the tests and shall forthwith forward to the PURCHASER/CONSULTANT duly certified copies of tests in triplicate. If the VENDOR/CONTRACTOR fails to offer the equipment for inspection as per the agreed date, he is liable to pay for the time and expenses for the infructuous visit of the PURCHASER/CONSULTANT.

2.5 In all cases where inspection and tests are required whether at the premises or

works of the VENDOR/CONTRACTOR or of any SUB-VENDOR/SUB-CONTRACTOR or at laboratory, the VENDOR/CONTRACTOR, except where otherwise specified, shall provide free of charge all facilities such as labour,





ISSUE R9


materials, electricity, fuel, water, stores, test bed, apparatus and instruments, laboratory tests etc. as may be required by the PURCHASER/CONSULTANT to carry out effectively such tests of the equipment in accordance with the PURCHASE ORDER/CONTRACT and shall give facilities to the PURCHASER/ CONSULTANT to accomplish testing.

2.6 The PURCHASER/CONSULTANT shall at all working hours have access to all

parts of the VENDOR’s/CONTRACTOR's and his SUB-VENDOR’s/SUB-CONTRACTOR's factory where the items of the plant are being prepared, for carrying out inspection activities as deemed necessary. A set of the relevant latest approved drawings with approval marking of the PURCHASER/ CONSULTANT and drawings for proprietary items shall be made available by the VENDOR/CONTRACTOR to the PURCHASER/CONSULTANT, for reference during inspection.

2.7 In the case of stage inspection hold points, the VENDOR/CONTRACTOR shall

proceed from one stage to another only after the component is inspected by the PURCHASER/CONSULTANT and written permission given to proceed further. The same procedure shall be adopted for any rectifications and repairs suggested by the PURCHASER/CONSULTANT.

2.8 The PURCHASER/CONSULTANT shall have the right to inspect any

machinery, material, structures, equipment or workmanship furnished or used by the VENDOR/CONTRACTOR and may reject any which is defective or unsuitable for the use and purpose intended, or which is not in accordance with the intent of the PURCHASE ORDER/CONTRACT. The VENDOR/ CONTRACTOR, upon demand by the PURCHASER/CONSULTANT, shall remedy or replace at the VENDOR’s/CONTRACTOR's expense such defective or unsuitable items of the plant, or the PURCHASER/CONSULTANT may, at the expense of the VENDOR/CONTRACTOR, remedy or replace such defective or unsuitable items of the Plant.

2.9 All principal mill test reports, the VENDOR/CONTRACTOR inspection and tests

reports, test certificates and test curves shall be supplied for all inspection and tests carried out including other records such as stress relieving charts, radiographic charts and other non-destructive testing records in accordance with the provisions of the PURCHASE ORDER/CONTRACT, duly certified by the main VENDOR/CONTRACTOR. The PURCHASER/CONSULTANT shall reserve the right to call for certificates of origin and test certificates for all raw material and equipment at any stage of manufacture.

2.10 The PURCHASER/CONSULTANT shall within fifteen (15) days from the date of

inspection as defined herein give notice in writing to the VENDOR/ CONTRACTOR of any non-conformance pertaining to all or any equipment and workmanship which in his opinion is not in accordance with the PURCHASE ORDER/CONTRACT. The VENDOR/CONTRACTOR shall give due consideration to such objections and shall either make the modifications that may be necessary to meet the said objections or shall confirm in writing to the PURCHASER/CONSULTANT giving reasons therein that no modifications are necessary to comply with the PURCHASE ORDER/CONTRACT.





ISSUE R9


2.11 When the factory tests and documentation have been satisfactorily completed at the VENDOR’s/CONTRACTOR's or SUB-VENDOR's/CONTRACTOR's works, the PURCHASER/CONSULTANT shall issue acceptance note or shipping release note or a certificate to this effect within fifteen (15) days after completion, but if the tests are not witnessed by the PURCHASER/ CONSULTANT, the certificate or comments thereof shall be issued within fifteen (15) days of the receipt of the VENDOR’s/CONTRACTOR's test certificate by the PURCHASER/CONSULTANT. Failure of the PURCHASER/ CONSULTANT to take such an action shall not prevent the VENDOR/ CONTRACTOR from proceeding with the work. The completion of these tests or the issue of the certificates shall not bind the PURCHASER/ CONSULTANT to accept the equipment, should it, on further tests after erection, be found not to comply with the PURCHASE ORDER/CONTRACT.

2.12 None of the plant and the equipment to be furnished or used in connection with

the PURCHASE ORDER/CONTRACT shall be despatched until shop inspection, satisfactory to the PURCHASER/CONSULTANT has been made. However, such shop inspection and/or certification shall not relieve the VENDOR/CONTRACTOR of his responsibility for furnishing the plant and the equipment conforming to the requirements of the PURCHASE ORDER/ CONTRACT nor prejudice any claim, right or privilege which the PURCHASER/ CONSULTANT may have because of the use of defective or unsatisfactory items. Should the PURCHASER/CONSULTANT waive the right to inspect any item, such waiver shall not relieve the VENDOR/CONTRACTOR in any way from his obligation under the PURCHASE ORDER/CONTRACT. In the event of the PURCHASER’s/CONSULTANT's inspection revealing poor quality of goods, the PURCHASER/CONSULTANT shall be at liberty to specify additional inspection procedures, if required, to ascertain the VENDOR/CONTRACTOR's compliance with the equipment specifications.

3.0 SUB-ORDERS AND SUB-CONTRACTS 3.1 In order to facilitate the inspection of bought-out materials and plant, the

VENDOR/CONTRACTOR shall submit for approval, three (3) copies of all sub-orders and sub-contracts placed by him as soon as these are issued. Copies of any drawings referred to in the sub-order or sub-contracts shall also be submitted, unless agreed otherwise by the PURCHASER/CONSULTANT.

3.2 The sub-orders, sub-contracts and drawings referred to above shall include all

components which are subjected to electrical and mechanical pressure or stress when the plant is in operation, and also auxiliaries and spares which are to be directly despatched to site from the SUB-VENDOR’s/SUB-CONTRACTOR's works.

3.3 All sub-orders and sub-contracts of the main VENDOR/CONTRACTOR shall

clearly be marked with the main VENDOR’s/CONTRACTOR's name and the PURCHASER’s/CONSULTANT’s name and the PURCHASE ORDER/ CONTRACT reference. These shall include the following statement:

The plant or the equipment which is the subject of this PURCHASE ORDER/

CONTRACT shall comply in every respect with the requirements of the





ISSUE R9


PURCHASER’s/CONSULTANT's technical specifications and shall be subject to inspection and tests to the satisfaction of the PURCHASER/CONSULTANT.

3.4 For the purpose of this para, it is obligatory on the VENDOR/CONTRACTOR

that he advises his SUB-VENDOR/SUB-CONTRACTOR of the pertinent clauses in this specification when ordering bought-out plant, equipment or materials. In particular, the VENDOR/CONTRACTOR shall advise every SUB-VENDOR/SUB-CONTRACTOR that he is required to supply design calculations, drawings, inspection reports and test certificates strictly in accordance with this specification and technical information for inclusion in the Instruction Manual as specified in Section E of the Enquiry Document. The SUB-VENDORS/SUB-CONTRACTORS should also be reminded that they shall include with their offer all tools and appliances necessary for proper maintenance and all spare parts in accordance with Section E of the Enquiry Document. Itemised prices of the recommended spare parts shall be submitted together with the appropriate part numbers and drawings.

3.5 Sub-ordering and sub-contracting for major items such as pressure and load

bearing items, machinery etc. can be done only with the approval of the PURCHASER/CONSULTANT.

4.0 MATERIAL TESTS 4.1 In the event of the PURCHASER/CONSULTANT being supplied with the

certified particulars of tests which have been carried out for the VENDOR/ CONTRACTOR by the supplier of material, the PURCHASER/CONSULTANT may, at his own discretion, accept the same as proper evidence of compliance with the requirements of appropriate specifications for the materials.

4.2 The VENDOR/CONTRACTOR is to provide test pieces as required by the

PURCHASER/CONSULTANT to enable him to determine the quality of material supplied under the PURCHASE ORDER/CONTRACT. If any test piece fails to comply with the requirements, the PURCHASER/CONSULTANT may reject the entire lot of material represented by the test piece.

4.3 Critical materials used in manufacture of the equipment and construction of the

plant covered by the PURCHASE ORDER/CONTRACT may also be subjected to one or more of the Non-Destructive Tests (NDT) as called for in the enquiry document or as mutually agreed. Salvaging of material due to unacceptable defect is to be attempted by the VENDOR/CONTRACTOR only after getting specific concurrence from the PURCHASER/CONSULTANT and according to the approved procedures.

5.0 WELDING 5.1 All welding involved in construction and fabrication of the plant and items

covered under the PURCHASE ORDER/CONTRACT shall be carried out in accordance with specifications and applicable codes.

5.2 Welding procedures and welders' qualifications shall be approved by the

PURCHASER/CONSULTANT. Where applicable, welders shall be tested as





ISSUE R9


detailed in codes specified for pipe welding, vessel welding and structural welding and appropriate to the corresponding weld position using test pieces of appropriate parent metal to be used on the job. The PURCHASER/ CONSULTANT shall have the right to have any welder re-tested at any time during the PURCHASE ORDER/CONTRACT.

5.3 Recommendations of applicable codes shall be followed for non-destructive

tests, wherever applicable. 5.4 Copies of all welding procedures, procedure qualification records, welders'

performance qualification certificates, post-heating and stress relieving records, NDT records and other test results shall be made available upon request of the PURCHASER/CONSULTANT.

6.0 FABRICATION AND INSPECTION Fabrication and inspection procedures for vessels, heat exchangers, pipes,

tubes and valves etc. shall be in accordance with procurement specifications, quality plan, applicable codes or any other approved equal.

7.0 TESTS AT MANUFACTURER'S WORKS 7.1 GENERAL The tests at works shall include electrical, mechanical and hydraulic tests in

accordance with the appropriate clauses of Statutory Regulation, relevant codes and standards and approved drawings and specifications and in addition any test called for by the PURCHASER/CONSULTANT to ensure that the plant being supplied fulfils the requirements of the specifications. The VENDOR/ CONTRACTOR shall carry out all the shop tests and inspections specified under individual items of the equipment in Section-D of the enquiry document, in addition to those normally required as per codes and standards. For items not covered by any code or specifically mentioned in the specifications, the tests are to be agreed with by the PURCHASER/CONSULTANT. If considered necessary by the PURCHASER/CONSULTANT, multi-part assemblies shall be fully erected and tested in the works prior to packing and despatch to the site.

7.2 TEST CERTIFICATES Test certificates including test records, performance curves and balancing

certificates shall be supplied according to the Distribution Schedule. All the tests shall be carried out in accordance with the provisions of the PURCHASE ORDER/CONTRACT.

All test certificates must be endorsed with sufficient information to identify the

material or the equipment to which the certificates refer, and must carry at the top right hand corner the identification of the PURCHASER/CONSULTANT and the PURCHASE ORDER/CONTRACT.





ISSUE R9


7.3 CALIBRATION All instruments used for critical measurement such as pressure gauges for leak

tests, instruments for measuring performance parameters; instruments for precision dimension measurements shall have valid calibration certificates traceable to national standards. This means that the calibrating agency engaged by the VENDOR/CONTRACTOR shall use instruments which are in turn calibrated by Government approved agencies and such information shall be recorded in the calibration certificate issued by the calibrating agency by giving the certificate number, date and date of validity of the certificate given by the Government approved agency.

FORMAT FOR INSPECTION REQUEST FROM THE

VENDOR/CONTRACTOR To, TATA CONSULTING ENGINEERS LIMITED,

Attn: Mr/Ms

PROJECT MANAGER Dear Sir/Madam, Items detailed below are ready for inspection. Please arrange inspection and

confirm the date. 1. PURCHASER 2. PROJECT 3. PURCHASE ORDER/CONTRACT

REFERENCE NUMBER

4. CONSULTANT (TCE) REFERENCE

NUMBER

5. SUB-VENDOR/SUB-CONTRACTOR 6. SUB-VENDOR’s/SUB-CONTRACTOR’s

ADDRESS

7. PLACE OF INSPECTION AND ADDRESS 8. CONTACT PERSON, PHONE, FAX AND

E-MAIL ID

9. DESCRIPTION OF ITEM AND QUANTITY 10. NATURE OF INSPECTION REQUIRED





ISSUE R9


11. PROPOSED DATES 12. WEEKLY HOLIDAY We confirm that the items have been fully inspected and tested by us. All stages

of inspection as per approved quality plan have been carried out by us and all material test certificates, quality control records and test reports and valid calibration reports of measuring and testing instruments with traceability to national level are ready with us.

Thanking you and awaiting your confirmation, Yours faithfully, Note 1 Following clear notice periods (Date of Receipt at TCE to Date of

Inspection) are required: (a) Local Inspection - 7 days (b) Outstation Inspection - 15 days Note 2 Weekly Holidays for TCE - Saturday and Sunday cc: Purchaser cc: Sub-Vendor/Sub-Contractor
