technical specification tankage
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TANKAGE TECHNICAL SPECIFICATION
Signature & Seal of Bidder Page 1
TECHNICAL SPECIFICATION
CONTENTSChapter No. Title Page No.
I Special Instructions to Tenderers 2
II Technical Specification 5
01.00 Scope of work 5
02.00 Scope of Supply of Materials 7
03.00 Material Specification 10
04.00 Design and Drawings 11
05.00 Fabrication and Erection 11
06.00 Fabrication and installation of underground tanks 22
07.00 Cathodic protection 24
08.00 Inspection 30
09.00 Testing of Tanks 31
10.00 Calibration of Tanks 33
11.00 Miscellaneous 33
12.00 Welding Requirements 34
13.00 Gauge Pole sleeve 35
14.00 Data to be furnished by successful bidder 35
15.00Technical specification for Civil works 36
Annexure I Specification for Nozzles and Pipes 50
Annexure II List of Standards 51
Annexure III Quality Assurance Plan 53
Annexure IV Painting details 58
Annexure V Drawing Index 65
Annexure VI Tank Data Sheet 66
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I. SPECIAL INSTRUCTIONS TO TENDERERS
01.00 GENERAL
01.01 Hindustan Petroleum Corporation Limited (HPCL) is setting up additional storagetanks at Ajmer, Jaipur and Rewari Terminals These Terminals are currently under
operation. The tender is being floated for construction of additional tanks for HSD & MS
and also Water storage tank.
01.02 The scope of this tender consists of the construction of mild steel tanks required for
storing MS ,HSD & Water as under
Details of tanks to be constructed are shown in the Table below:
FR Floating Roof, CR- Cone Roof, OR-Open Roof
Floating roof shall be of single-deck pontoon type for tanks of dia. more than 12m andup to 60m. Sand pad foundations shall be provided for supporting the vertical storage
tanks.
01.03 The materials, design and workmanship shall satisfy the relevant Standards, the job
specifications contained herein and codes referred to. Where the job specifications
LOCATION Details of tanks to be constructed Design Code
Ajmer 24 M Dia x 14 M Ht- 2 Nos. (FR)-MS
18 M Dia x 12 M Ht- 2 Nos. (FR)- HSD API 650
Jaipur 28 M Dia x 14 M Ht - 1 Nos (FR)- HSD
18 M Dia x 13 M Ht - 2 Nos (FR)-MS API 650
Rewari 17 M Dia x 12 M Ht - 1 No. (FR)-MS
20 M Dia x 14 M Ht - 2 Nos (CR)-HSD
13 M Dia x 14 M Ht 1 No. (OR)-Water
API 650
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stipulate requirements in addition to those contained in the standard codes and
specifications, these additional requirements shall also be satisfied. In the absence of any
standard / specification / codes of practice for detailed specifications covering any part
of the work covered in this tender document, the instruction / directions of Engineer-in-charge will be binding on the contractor.
01.04 Wherever it is stated in this Tender document that a particular supply is to be effected or
that a particular work is to be carried out, it shall be understood that the same shall be
effected/ carried out by the contractor at his cost, unless a different intention is
specifically and expressly stated herein or otherwise explicit from the context.
01.05 The tenderer shall visit the site before quoting to get himself acquainted with site
conditions, availability of water, power, approach etc, No delay whatsoever shall be
entertained on this account.
01.06 The specification of the products stored will be as per the latest BIS specifications.
02.00 CONSTRUCTION PROGRAMME
02.01 A detailed bar chart showing various activities shall be prepared by the bidders. The work
shall be executed strictly as per the agreed time schedule. The period of completion shall
include, the time required for mobilization and testing as well as rectification, if any,
testing and completion in all respects to the entire satisfaction of the Engineer-in-charge.
02.02 A joint program of execution of work will be prepared by the contractor in consultation
with Engineer-in-charge.
02.03 Monthly / weekly construction program shall be made by the contractor jointly with
Engineer-in-charge based on availability of work fronts and the joint construction
program.
02.04 The contractor shall scrupulously adhere to these Targets / Program by deploying
adequate personnel and construction tools and tackles. He shall also supply all materials
in his scope of supply in time to achieve the targets set out in the weekly and the monthly
program.
02.05 The contractor shall monitor and report about labour and equipment deployed along withthe progress of work done on previous day on daily basis.
03.00 CONSTRUCTION WATER AND POWER
Construction water and power (including the requirement for testing and calibration of
tanks) will not be made available by the owner and the contractor at his own cost shall
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arrange the same without any liabilities on the part of owner. The rates quoted shall be
inclusive of the same.
03.01 The Contractor shall drill the required number of bore wells/ arrange water thru tankers at
his cost.03.02 The Contractor shall arrange his own source of power from their DG set or from SEB
directly without any cost to the owner.
04.00 TESTS AND INSPECTION
04.01 The contractor shall carry out the various tests as enumerated in the technical
specifications of this tender document and the technical documents that will be furnished
to him during the performance of the work. No separate payment shall be made.
04.02 The contractor shall carry out at his cost, all the tests either on the field or through external
laboratories, concerning the execution of the work and supply of materials by the
contractor.
04.03 The work is subject to inspection at all times by the Engineer-in-charge. The contractor
shall carry out all instructions given during inspection and shall ensure that the work is
being carried out according to the technical documents and the relevant codes of practice
during the performance of the work.
04.04 Any work not conforming to the execution drawings, specifications or codes shall be
rejected forthwith and the contractor shall carry out the rectification at his own cost.
04.05 Results of all inspection and tests shall be recorded in the inspection reports, test reports
etc., which will be approved by the Engineer-in-charge. These reports shall form part of
the completion documents.
04.06 Inspection and Acceptance of works shall not relieve the contractor from any of his
responsibilities under this contract.
05.00 SITE CLEANING
05.01 The contractor shall take care to clean the working site from time to time for easy access to
work site and for safety. Working site should be always kept cleared to the entire
satisfaction of the Engineer-in-charge.
05.02 Before handing over any work to the owner, the contractor in addition to other formalities
to be observed as detailed in the document shall clear the site to the entire satisfaction of
Engineer-in-charge.
06.00 COORDINATION WITH OTHER AGENCIESWork shall be carried out in such a manner that the work of other agencies operating at
the site is not hampered due to any action of the contractor. Proper co-ordination with
other agencies will be the responsibility of the contractor. In case of any dispute, the
decision of Engineer-in-charge shall be final and binding on the contractor.
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07.0 SAFETY PRECAUTIONS AND HOT WORK
07.01 Contractor shall have to take all safety precautions for carrying out hot work in the
premises after obtaining hot work permit from location in charge at his own cost as
directed by the Engineer-in-charge. Necessary safety equipment such as safety belts,helmet, etc., and other safety instruments are to be positioned by the contractor and the
same shall be used by the work force as per work requirement. The contractor has to
enforce the same. In addition to the above Contractor shall maintain their own set of
Portable fire extinguishers, hose reel & nozzle for necessary hook up with the nearest
hydrant point in case of emergency.
07.02 Safety distance as per CCE rules and Oil Industry Safety Directorate shall be maintained
strictly.
07.03 All exhaust of vehicle & engines shall be fitted with spark arrestor and all temporary
electrical supplies and cabling should have proper Main Isolator, Distribution board,
ELCB and temporary shade. All cable joints made at site should be properly covered with
insulated.
08.00 Third Party Inspection
08.01 Third Party Inspection will be required for
a. Swivel Joints for Articulated Roof Drain
b. Primary & Secondary Seal
The approved parties for carrying out TPI for a & b are EIL, DNV, BVQI & IRS.
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II. TECHNICAL SPECIFICATION
01.00 SCOPE OF WORK
01.01 The scope of work of the bidder shall include complete design, selection of materials,
preparation of drawings, detailed engineering, supply (except free issue steel plates),obtaining approvals of Engineer in charge/owner, transportation, storage at site,
fabrication, installation, erection, testing, calibration, commissioning and establishing the
required parameters to the satisfaction of HPCL, of the storage tanks inclusive of all
fittings, appurtenances and other attachments there to and sub-assemblies wherever
required. The scope also includes construction of sand pad foundation as well as
installation of cathodic protection system as enumerated elsewhere in the specification.
The complete work shall be done in strict compliance with engineering drawings/ data
sheets, specifications from the below mentioned standards/codes.
API-650, tenth edition, 2000 for above ground tanks.
A list of standards and codes recommended for general guidance is enclosed as
Annexure II.
01.02 The scope of work of the bidder is defined in general and shall include the following
but not limited to the same. The bidder shall also carry out the jobs that are not listed
here but required for completion of the job in all respects as per the specifications,
standards, drawings, codes and instructions of Engineer-in-charge whether
specifically mentioned in the drawing or not.
01.02.01 Loading, handling and transportation of all free issue materials from supply point /
store of work site / Contractors store and return the unused / scrap materials to work
site storage point after completion of the work including supply of all tools, tacklesand accessories etc.
01.02.02 Procurement and supply of materials and consumables as indicated in contractors
scope of supply.
01.02.03 Erection of the tank shell for vertical tanks shall be by hydraulic jacking arrangement.
Fabrication of tank bottom, shell, roof, wind girders, etc. including cutting of plates
and structural sections to required size, edge preparation, rolling, fitting, welding etc.
01.02.04 Design, Supply and fixing of all nozzles, flanges, elbow, bends etc. as per specification
drawings and data sheets. Only standard forged pipe fittings shall be used. Fabrication
and erection of supports for pipes, instruments etc. on tanks.
01.02.05 Design, Supply, fabrication and erection of spiral stairways, catwalk, handrails,platforms, top landing and maintenance platforms, walkway, self leveling type rolling
ladder and track, curb angles etc.
01.02.06 Design, TPI for design,Supply and installation of distributed anode based impressed
current cathodic protection system for tank bottom plates of product tanks at Ajmer &
Jaipur.
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01.02.07 Design, Supply and installation of water risers and ring mains (fixed spray system) and
spray nozzle arrangement around tank in two/three rows i.e., above and below wind
girders.
01.02.08 Radar level gauges for continuous level measurement and RTDs for averagetemperature measurement are envisaged for all the petroleum storage tanks. Suitable
installation provision and mounting arrangements shall be provided for the same as
required by the instrument supplier.
01.02.09 Design, Supply and installation of fixed foam fire fighting system as per OISD
requirement. Piping , Supply & fixing of foam maker, pourer, deflection board, etc.
01.02.10 Radiography, DP test, MP test and all other tests on tanks as per code, drawings and
testing procedures by approved testing agencies apart from routine, visual and
dimensional check. The Contractor shall arrange necessary tools and tackles for
carrying out the tests.
01.02.11 Carrying out hydrostatic, pneumatic, vacuum and other test as specified in
codes/standards using tenderers own equipment.
01.02.12 Calibration of tanks and getting approval from statutory authorities as per IS 2007 -
1974 and IS 2008 - 1961. Calculations and preparation of calibration charts and
submitting to HPCL.
01.02.13 Carrying out roof floatation test for floating roof as per codes/standards.
01.02.14 Design and Supply of appurtenances like nozzles, manholes, vents, hatches, primary
roof drains, earth connections, gauge connection with covers etc. and installation of
these items on the tanks.
01.02.15 Design, supply and installation of Primary & Secondary Roof seal and its accessories as
per specification.
01.02.16 Clearing job sites of all surplus material, debris, scrap, construction equipment etc. asper directions of Engineer-in-charge.
01.02.17 Internal & External painting of Tanks. Accomplishment of any other item of work
required for making the storage tank ready for commissioning.
01.02.18 Quantity of steel given is approximate. Payment shall be made for quantities of plates
laid / erected duly certified by the Engineer at site. Payment of steel plates will be
made basis theoretical weight taken as 7.85g/cc.
01.02.19 Scope of work of the contractor includes construction of tank foundations for all the
tanks. The foundation shall be of stone columns overlaid with Sand filling,
anticorrosive layer & seal coat.
01.02.20 Design & Preparation of all detailed and working drawings for various components ofstorage tanks (Cone ,Open Top & FR) and getting the same reviewed / approved by
HPCL. Supplying of all drawings and documents as specified.
01.02.21 Supply of spares, wearing parts, consumables for two year trouble free operation
where various sizes are involved such as in gaskets, bolts, nuts, studs etc., quantity of
spares shall be 10% but not less than 2 number for each size.
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01.02.22 Supply of gauge Pole sleeve for Floating roof tanks.
01.02.23 Excavation, sand filling ,anticorrosive layer, seal coat, PCC/RCC & other misc civil
works. Supply & erection of fire screen and temporary wall on Fire wall anddismantling/disposal after completion of work.
01.03 The design, fabrication and installation shall be in conformity with regulations of CCOE,
OISD and other statutory bodies.
01.04 Design calculations for complete roof for buoyancy, stability, roof drains, tilting, leg
supports, bleeder vents etc. and getting the same approved by TPI and submission of
the same for HPCLs review.
01.05 Design, Supply, erection & testing of Articulated Roof Drain for Floating roof tank as per
specification. TPI for swivel joints.
02.00 SCOPE OF SUPPLY OF MATERIAL
The scope of supply of contractor/ owner is given below and contractors shall quote rates
based on this.
02.01 OWNERS SCOPE OF SUPPLY : Only Steel Plates as under:
Steel plates of all thickness for bottom, shell, wind girders and floating roof of all tanks.
Steel plates for fabrication of reinforcement pad plates for shell and roof nozzles and
appurtenances. Steel plates for foam dam and shell extension for deflection for foam
pourer. Datum plates under the gauge well pipes, bearing plates for pipe supports.
Incase of Rewari, pipes and valves required for piping work will also be supplied by
HPCL.
However the fabrication of the above plates in the required shape and size is in the
scope of the contractor. It may be necessary to change the thickness and size of steel
plates before commencement of work or during the progress of work, depending on the
availability of steel plates. The contractor shall have no extra claim because of such
changes and shall accept final measurement of the finished job without any allowance
whatsoever.
MS plates in sizes available as indicated below from SAIL/ ESSAR/ LLOYDS/ TISCO/
JINDAL/Others will be supplied to site and the contractor shall prepare fabricationdrawings accordingly for approval, prior to commencement of fabrication work.
Sl. No. Plate Size (LXW) in mm Plate thickness in mm
1 6300 X 2000 8, 10, 10, 12, 14, 16,18
2 6300 X 1500 5, 6, 8
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3 8000 x 2000 5,6,8,10,12,14,16,18
Basis for procurement of steel plates:
1. API 650 has been adopted for the design of storage tanks.
2. Corrosion allowance of 1.5 mm has been considered.3. Minimum thickness of Bottom plates shall be 8 mm and annular plate as 10mm.
The arrangement of steel plates considered for procurement by the owner for different
locations of the storage tanks and the thickness of the same are indicated in the enclosed
drawings. The contractor shall confirm the adequacy of the same.
02.02 CONTRACTORS SCOPE OF SUPPLY: All other materials other than steel plates for
tanks as under:
Materials, consumable/ non-consumable not mentioned under Owners Scope of supply,
but required for satisfactory completion of the job shall be supplied by the contractorinclusive of the following but not limited to the same:
All the welding rods, erection materials, scaffolding, bending and cutting machine,
oxygen, acetylene, grease, oils, labour etc.
The procurement and supply in sequence and at the appropriate time of all materials
and consumables including structural steel (Plates & sections) required for completion of
works as per drawings, specifications and standards except the materials specifically
listed in Cl.no 2.01 above shall entirely be the contractors responsibility. The items to be
supplied by the contractor are in general but not limited to following:
A) All steel plates required for the components other than those listed in Cl.2.1.2.
B) All consumables such as electrodes, filler wires, acetylene, grease, oil, gases,
electricity etc.
C) All structural steel sections wherever required for Cone roof structure,curb angles,
Top wind girders Supports/stiffeners/ extensions for stairways, Top wind girder
bracings, Secondary wind girders, supports for Fire water Cooling Spray Headers/
risers, supports for Foam system risers, spiral stairways, landings , platforms, handrails,
bracing for foam dam, Inlet and Outlet Nozzle Troughs, Gratings(which may be
fabricated by the Contractor at a workshop/ factory outside HPCL premises), stiffeners
for Shell extension and supports for top platform, etc.
D) All pontoon stiffeners for single deck floating roof.
E) Rolling Ladder, internal ladders, hand rail for stairways, ladders, platforms,etc.
F) All seamless pipes for nozzle necks 200mm NB and below, internal pipes, Nozzle
necks for openings more than 200mm,Materials for Inlet/ Outlet Nozzle troughs, floating
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roof supports, bleeder vents, emergency drain, bottom drain extension, extension piping
for roof drain, etc.
G) All pipe fittings, valves, flanges, matching flanges and blind covers wherever
specified for all nozzles, stainless steel wire mesh for emergency drain, brass items and
brazing for Auto bleeder vents.
H) Primary roof drain after (Third Party Inspection for swivels) with associated rigid
piping sections, if any adequately supported on Bottom/ from deck underside, necessary
shoes/ guards, etc as per Manufacturers instructions including swivels, brass non return
valve, extension piping etc.
I) Bolts, nuts and SS spiral wound gaskets for roof & shell manholes, nozzles with blind
cover/ matching flange, bolts & nuts for roof structure and other structural works.
J) Seals (Primary & Secondary) of approved make, guide rollers, roof stoppers, earthingcable, shunts etc. Primary & Secondary seals for MS & ULMS F/R Tanks. Seals shall be
supplied after Third Party Inspection.
K) Rim Vent along with relief valves..
L) Gauge well & Gauge Hatch with cover.
M) Pipes, fittings, flanges and bolts and nuts and spray Nozzles and orifice plates and
structural supports for Piping for Fixed water Cooling spray system.
N) Pipes, fittings, flanges, orifice plates, Foam makers/ Pourers and deflectors on point
of spray on shell and structural supports for Piping for Foam system
O) Support arrangement required for cooling system.
P) Internal Bolts & Gaskets.
Q) Water including CI for hydrotesting & calibration.Strapping tapes & accessories for
calibration.
R) Radiographic Films & Consumables for NDT.
S) Earth connections, support cleats for pipes, structurals & cables.
T) Any Blind flanges, valves, nipples, plugs, bolts, nuts, gaskets, etc required for
conducting hydrostatic testing and any other test required by HPCL.
U) All primer materials and painting materials, scaffolding, blasting medium and
related equipment for Painting.
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V) Brass Plate for sealing still well annular space, Gasket, Gauge Pole sleeve for still well
(W) Providing tools, tackles, hoist/crane, jacks, instruments, supervision etc. required for
completion of the work as per drawing, specification and codes. The contractor shall
hand over test certificates for all items supplied by him to the owner for verification and
approval.
(X) All type of appurtenance for floating roof & shell. All types of paints and paintings
system for A/G Tanks.
(Y) All materials, labor, tools, machinery and accessories required for Civil works related
to Tanks.
(Z) All materials, labor, equipment & accessories related to CP system for tanks
Note:
While every effort has been made to list all the supply items, it shall be the sole
responsibility of the Contractor to review the list and seek clarifications, if any at thetime of Unpriced Bid itself. HPCL undertakes to provide only Free Issue Steel plates
for Fabrication, pipes & valves incase of Rewari, and all the other items shall be
supplied by the Contractor only. No claims/ disputes by the Bidder/ Contractor shall
be entertained by HPCL at a later date. The above items are to be supplied by the
party for Floating Roof, Cone roof & OTVT Tank as applicable. The items have been
covered in SOR & specification, except 10% spares like studs/nuts/gaskets etc which
shall be supplied by the party at the time of handover on the basis of final Bill of
quantities, at no extra cost.
02.03 RECOVERY AND INVENTORY OF STEEL PLATES
02.03.01 Steel plates required for the fabrication and erection of tanks as per the owners scope
of supply will be issued to the contractor by engineer-in-charge with full
measurements. Contractor shall sign and hand over the material receipt to engineer-in-
charge after thorough checking of the same.
02.03.02 All steel plates thus issued shall be strictly accounted by the contractor.
02.03.03 All off cuts and unused plates shall be property of owner and shall be returned by the
contractor to owners store, after weighing all off cuts plates at his cost.
02.03.04 Non-recoverable plates excluding off cuts shall not be more than 0.5% of the erectedplate weight.
02.03.05 Off cuts, unused steel plates non-returned and any excess non recoverable plates
beyond 0.5% of the weight of erected plates shall be recovered at twice the landed cost
of plates from contractors bills.
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02.03.06 Contractor shall be fully responsible for correctness of sizes of plates indicated in the
fabrication drawings to be prepared by him. In case any plate gets damaged/ spoiled
by the contractor due to his fault, cost of the same will be recovered at twice the
landed cost of plates from contractors bills.
02.04 Civil Works
02.04.01 The civil works required for the tanks included under this tender are included in the
scope of the tenderer. Refer to the specification of the civil works part.
03.00 MATERIAL SPECIFICATIONS:
Steel plates for tanks shall conform to IS-2062 Gr. A/B, 1999. Man hole neck rings, bolting
flanges and cover plates shall be fabricated from MS plates conforming to IS 2062 Gr. A/B
1999. Nozzles of all sizes shall be fabricated from seamless pipelines conforming to
specification given in Annexure-I.
All slip on and blind flanges shall be fabricated from SA 105 material. Further they shallconform to ASA class 150 with holes drilled as per ANSI B.16.5.
All structural steel sections for columns, column bases, beams, girders, rafters, curb
angles, hand rails, roof top railings, inter connecting bridges, flat gratings, rolling ladder
with track, rollers, axles, rods and bars shall conform to IS-808 latest edition.
Gauge well pipes shall be seamless pipes for floating roof tank. Gauge hatches shall be ofspark proof aluminium with quick opening cover and locking arrangement. All landing
platform floors, spiral staircase steps, self-levelling steps of the rolling ladder, roof top
platform floors shall be provided with MS flat gratings in honeycomb pattern.
.
Metallic Spiral Wound Gaskets for manholes, nozzles, fitted with blind flanges shall
conform to specification IS 7719 75. Thickness of gaskets shall be 1.5mm up to 300mm
NB nozzle and 3mm above 300mm NB nozzles. However before conducting hydro test
the flange joint shall be provided CAF gaskets. There shall be two numbers of spares for
each size location wise.
Bolts and nuts for all nozzles fitted with blind flanges shall conform to IS 1367 and bolts
and nuts for all structurals shall conform to IS 1363 92.
Gate valves and non-return valves on pressure relief line shall be of forged steel
construction of class 800 conforming to API 602 and BS 5352 respectively.
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Pressure testing shall be done as per API 598/ BS 6755. Pipe fittings shall be of 3000 lbs
rating.
Welding electrodes for all plates of thickness 14mm and above, annular ring to bottomplates and shell to bottom plate welding shall be of low hydrogen (basic coated) as per
AWS classification SFA 5.1. For all other welding high cellulose / rutile type as per AWS
specification SFA 5.1 are acceptable. Advani Orlecon / ESAB/ Phillips / D and H Sechron /
Hanavar / Mailam / GEE make electrodes only shall be used.
Materials listed above shall be considered as minimum qualities for materials. An
equivalent or superior quality may be substituted. No substitution shall be made without
the written consent of Engineer-in-Charge. All materials shall be new, first class quality
and of the type and grade specified.
04.00 DESIGN AND DRAWINGS
Floating /Open roof tanks shall be designed in accordance with API 650, 10th Edition,
2000 and applicable Appendix with latest edition and supplement and the horizontal
cylindrical tanks shall be as per IS: 10987-92.
All basic drawings with design data and material specifications are attached with this
tender document for tendering quotation as listed in Annexure-II. Final drawings with
revisions if any shall be prepared and submitted for review / approval after award of
contract or Purchase order by the contractor.
Floating & Cone roof tanks shall be designed by the contractor considering design data
given in each drawing and calculations shall be submitted for review / approval / records
with regard to following in line with API-650 guidelines.
a) Design calculations / data sheets for plate thickness, stability calculations, wind girders
etc.
b) Buoyancy calculations for roof, calculations for roof drains, bleeder vents etc.
c) Structural calculations for roof leg supports, roof rim plates & Structural supports of
cone roof tank. Venting size calculation for Roof vent of Cone roof and Auto bleeder vent,
rim vent for floating roof tanks.
Design calculations of the tank shall be approved by a competent design agency and shallbe submitted to HPCL.
05.00 FABRICATION AND ERECTION
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Before commencing the job all plates shall be squared, diagonally checked, stenciled and
stacked in order of execution of work. Plates shall be checked for splitting if any
particularly. Split plates or laminated plates shall be rejected. Plates thus prepared shall
be offered for inspection to the Engineer-in-Charge. Contractor shall arrange allequipment and labour necessary for inspecting and measuring all the plates. After the
plates are approved they shall be stencilled and stacked properly. Plates shall be
thoroughly checked for all dimensions and diagonality. Fabrication and erection of the
tanks shall be carried out as per drawings reviewed / approved by HPCL.
05.01 BOTTOM
The underside of bottom plates shall be blast cleaned to SA 21/2 and painted with two
coats of tank mastic paint of approved make before laying. The underside of tank shall be
protected for corrosion by cathodic protection technique.
Bottom plate shall have a uniform slope of 1:50/100. Plates shall be lap welded and the
over lap shall not be less than 5 times the plate thickness unless otherwise specified. For
sketch plates/ annular plates, the overlap shall be given as per the code.
For all tanks diameter more than 13m annular plates shall be provided and these annular
plates shall be butt welded with backing strips. Joints between annular plates and sketch
plates shall be lap welded.
Datum plate for calibration/ gauging of product level in the tanks shall be welded on to
the bottom horizontally to perfect level and directly below the gauge well. Weldingsequence to be adopted shall be indicated in the drawings submitted by contractor and
this shall be followed so as to cause minimum shrinkage and distortion.
Bearing plates of the pipe supports shall be centred under each support for the floating
roof and welded to the tank bottom by continuous fillet weld of size equivalent to plate
thickness. These bearing plates shall be of sizes 600 x 600 x 10mm. Overlaps in joints of
bottom and roof plates will not be measured and paid separately.
05.02 SHELL
All the tanks included in this tender shall be constructed by Hydraulic Jacking uparrangement. All vertical and horizontal shell joints shall be full penetration and full
fusion welds. The shell joints shall be double welded butt joints using any one of the
edge preparation permitted by API 650. Details of the weld and edge cutting shall be
shown in the drawings and shall be approved by HPCL.
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Shell plate arrangement and thickness as planned are as indicated in the enclosed
drawings.
Top curb angle shall be lap welded to the top course of shell with the flange turnedoutwards unless otherwise specified.
Tank heights that are indicated in the tender are nominal and the actual heights might
undergo minor changes to suit the construction.
The stiffening ring or wind girder where necessary shall be welded to the tank at the
location shown in the drawing duly stiffened with gussets and struts welded to shell.
Welding shall be of same quality as used for shell. Primary wind girder shall be provided
as a walkway with all around hand railings. Horizontal portion of stiffening rings shall
be provided with drain holes of 25mm dia. These holes shall have suitable arrangement
so as to avoid rain water from moving to tank shell.
Curb angle and stiffening ring joints shall not come in line with the vertical weld joints of
the shell plate. These joints shall offset each other by at least 1.0M. First shell course
plates shall be so arranged that vertical joints clear the annular ring welds or sketch plate
welds by at least 360mm. Vertical joints of shell course shall also clear the nozzle
attachment welds or reinforcement pad welds as per API 650. Holes shall not be made on
shell plates for erection purpose. Shell plate alignment shall be within the limits specified
in API 650.
D/P test and Oil chalk test shall be carried out for shell to bottom joint. For shell tobottom joint, low hydrogen electrodes shall be used. Internal weld seams of floating roof
tanks shall be smooth and even to allow proper movement of roof without damage to the
seals.
During fabrication contractor shall provide guy ropes and other means to secure semi
finished storage tanks against damage due to wind. Wind girders shall be welded to
tanks at the earliest. The lifting of shells should not be commenced without fixing of wind
girders.
05.03 FLOATING ROOF
Floating roof shall be of pontoon type for diameter more than 12m with multiple
compartments and shall be liquid proof to meet the minimum requirements of API 650.
Each compartment of floating roof shall be provided with specified manhole with cover.
Central deck and pontoons shall be suitably stiffened and calculations for structural
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integrity of floating roof shall be submitted to HPCL for review. Centre deck of the
floating roof shall be fabricated out of 5/6mm thick plates. Pontoon bottom shall be of
6mm plates. Pontoon Roof and compartment plates shall be of 5mm thick plate where the
same shall be 6 mm. Inner and outer rim plates shall be designed by the contractor andcalculations forwarded to HPCL. 16mm and 8mm plates have been considered for the
plate procurement for the inner/ outer rim plates respectively.
Deck shall have permanent slope to the centre to avoid stagnation of rainwater. When
floating roof is in highest position, tank shall be capable of holding its designed capacity.
Foam dam shall be provided with 5mm thick plates, for all the tanks as per standard to
contain the foam to seal area. Floating roof shall be of low deck (minimum vapour space)
type. Central deck of the floating roof shall be provided with two through deck manholes
with ladders. Suitable stainless steel leaf springs shall be provided at the bottom rim of
the deck @ 2.5 m c/c around the periphery for holding the deck centrally. Necessary
stainless steel bolt, nuts, washers, etc, also shall be provided.
05.05 STAIRWAYS, LANDING PLATFORMS AND RAILINGS
05.05.01 Stairways and Platforms
Each tank shall be provided with stairway with hand railing and landing platforms for
access to the roof. Each step shall be supported by a vertical square rod as specified. The
steps shall be fabricated out of MS flats bent in honeycomb pattern. The steps on one
side shall be welded to tank shell. Raised platforms as per size indicated in the standard
drawing shall be provided at the top of the stairway and shall be extended suitably to
permit easy access to the two gauge well pipes for each of the tanks.
A self-levelling rolling stairway shall be provided for access from platform to the
floating roof. Roller track fixed to the roof shall permit movement of the stairway. Brass
rollers for the rolling stairway shall be provided to avoid sparking. The steps for the self-
levelling ladder also shall be of MS flat grating in honeycomb pattern.
05.06 TANK APPURTENANCES
05.06.01 Manholes and nozzles
All manholes shall be according to API 650. The cut edges of the manhole shall be
ground smoothly. The axis connecting both the manholes shall be generally in the
direction of the wind prevailing locally. Shell and deck manholes shall be 600mmnominal diameter. Pontoon manholes shall be of 500 mm nominal diameter. The
dimensions of the nozzle shall be in accordance with API 650 unless otherwise
mentioned in the approved drawings. The out side end of the inlet and outlet nozzles
shall be provided with slip-on flanges to facilitate fixing of the gate valve and the inside
end shall be provided with a semi-circular MS trough as per drawing. Position of the
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nozzles shall be such as to facilitate easy connection to the main running pipeline in the
depot/ installation. Product inlet /outlet nozzle flanges shall be of class 150. Flange holes
shall be drilled as per ANSI-B-16.5. Manhole and nozzle reinforcing pad plates shall be
provided with 6mm threaded tell tale holes for testing purpose. Nozzles shall be weldedto the tank with the same quality electrodes as used for shell welding. Manholes and
nozzles shall be provided with gaskets, nut and bolts as specified.
05.06.02 Floating roof supports
The number of supports shall be sufficient to ensure non-deformity of the roof and tank
bottom when the roof is resting on the legs. The pipe supports shall be provided with
cotter pins as specified in the drawing and suitable for two level operations. For this,
holes shall be provided on the top portion of the legs to adjust the cotter pin. Leg
supports shall be of 80 mm NB seamless SCH 80 pipes and sleeves shall be of 100mm
NB seamless SCH 80 pipes. There shall be two operating levels of 2m and 1.2 m from the
tank bottom plates.
Pipe supports shall rest on the bearing plate after hydro test of tank. These bearing
plates shall be stitch welded 50 to 60 mm c/c. Corrosion allowance shall be provided for
roof supporting pipes and sleeves also.
05.06.03 Roof drain
1.1 The intent of this specification is to cover the scope of design, supply, erection, testing
and commissioning of Swivel Jointed Articulated Roof Drain required for draining rainwater from the roofs of Floating Roof Vertical Tanks for the petroleum products viz
HSD, ULHSD, MS, ULMS and SKO.
1.2 Compliance of this specification will not relieve the tenderer of his responsibility
for supplying the equipment / items of proper design, material and workmanship to
meet the specified operating requirements and also proper workmanship and
performance of the facilities under the contract.
1.3 Any additional material, which are not specifically mentioned in the technical
specifications but are required to make the system complete in all respects for safe
operation and guaranteed performance, shall be included in the scope of work of thetenderer.
1.1 All materials supplied shall be new, of best quality and tested in accordance with the
latest version of the relevant Indian Standards or relevant International Standard and
codes acceptable to HPCL The tenderer shall indicate make and grade of all bought out
items for approval from HPCL.
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1.2 Specification of the products are as given below :
Product HSD ULHSD MS ULMS SKO/ATF
Density at 15 C 0.87 0.86 0.77 0.775 0.84
Viscosity, cst 20 C 8 8 0.7 0.7 1.53
Vapour Pressure,
kg./cm at 38 C
0.1 0.1 0.7 0.7 0.3
Operation
Temperature
50 C
1.3 All drawings and instructions shall be in English language. Dimensions in drawings;
technical data, weights and quantities shall be in metric units.
2.0 SCOPE OF WORK FOR ARTICULATED SWIVEL JOINTED ROOF DRAIN SYSTEM
A. Design, manufacture / fabrication, testing, supply of roof drain system to work site
B. Assembling, transportation at work spot, erection, testing and commissioning of the roof
drain for the storage tanks as per the details given in Bill of Quantities.
The following shall also form scope of work.
i) The tenderer shall supply at his cost all equipment / piping, all necessary skilled
and unskilled personnel, hoists, tools and tackles, instruments, safety
implements and other accessories required for assembly, erection, testing and
commissioning of the Roof Drain system for the tanks.
ii) The tenderer shall give complete calculations for design of drain system,
complete technical specification of the equipment offered and general
arrangement drawings for the approval of HPCL, sufficiently in advance of the
commencement of manufacture. Such approval, when accorded, shall however,
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not relieve the tenderer of his responsibilities towards satisfactory and trouble
free performance of the roof drain system.
iii) All the equipment shall be shop tested according to the relevant standards. The
particulars of the proposed tests shall be submitted to HPCL for approval before
conducting the tests. HPCL shall be given full access to all the tests. The
supplier shall inform HPCL sufficiently in advance so that if HPCL desires, his
representative can witness the tests. All the certificates shall be submitted for
the approval of HPCL before clearance for dispatch of the equipment can be
given.
iv) Tenderer shall furnish certificates for swivel joints, pipes, valves etc forming
part of roof drain system.v) The tenderer shall also additionally supply all necessary spares required during
erection and commissioning, free of cost, for roof drain system.
vi) The tenderer shall furnish to HPCL the complete drawings, documents, test
certificates, etc. as indicated in this technical specification for approval /
information and record.
vii) The tenderer shall guarantee the material, workmanship, and satisfactory
performance of the complete roof drain systems for a period of 5 years from
the date of completion of work. The completion date as mentioned in the
Work Completion Certificate shall be considered as starting date. The partyshall give Performance Bank Guarantee equivalent to the cost of Roof drain
with a validity of 5 years as above from any Schedule Bank.
3.0 TECHNICAL SPECIFICATION
3.1 The tenderer shall design and size the roof drain system for each tank for a rainfall of
100 mm / hr. The system shall be suitable for draining the water collected at the roof
sump through the shell nozzle near tank bottom. For design of roof drain, when the
roof is at low leg the height difference between sump drain outlet of roof and at thedischarge end at outlet may be considered as 1.5 m. The offered roof drain system shall
include / incorporate items / equipment that are well proven, tried and tested for
operation in petroleum storage tanks especially in Indian conditions.
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The satisfactory operation of the roof drain without any damage / leakage shall be
ensured, considering the vertical and sideways movements of the roof while in
operation. The materials of constructions of Gaskets and seals shall be compatible for
operation with the product in the tank. All studs and nuts for roof drain shall be of SS.
3.2 ARTICULATED SWIVEL JOINT ROOF DRAIN :
The roof drain system shall be of swivel jointed type with articulated steel pipes. The
system shall include Swivel Joints (ASTM A105 body with viton seals) Split type Design
having anti corrosive sealing surface & Hardened Ball races to Min 55HRC, Seamless
pipe (ASTM A106 Gr. B Schedule 40), Elbows (ASTM A234 WPB Schedule 40), Flanges
including with matching flanges for the roof drain system (ASTM A105 SORF Class 150),
SS 304 spiral wound gasket, Flanged Non-return valves at roof sumps (BS 1868, Class
150, Cast steel body, brass lining on flap), Supporting structures / legs, fasteners, chains
etc complete in all respects for safe operation of the system. The welding of pipe joints
shall be carried out by ASME section IX qualified welders.
Makes of Pipes shall be SAIL, Maharashtra seamless ltd, Jindal pipes ltd, TISCO, MAN,Welspun, PSL or any other reputed make with the approval of HPCL.
Makes of NRV valves shall be Econo valves Pvt. Ltd., BDK Engineering Industries Ltd.,
Fouress Engineering (I) Ltd., Steel Strong Valves Pvt. Ltd., NSSL Ltd, Shalimar Valves Pvt.
Ltd., Flow Chem Industries, AV Valves Ltd., Audco India Ltd, KSB pumps Ltd or Any
other reputed make with the approval of HPCL. Make of Swivel Joint will be Technika,Associate Engineers, PentaTech or any other reputed make with prior approval of HPCL.
Assembly of Two Swivel Joints & pipes till flanged ends will be purchased from the Swivel
Joint Mfgrs for better concentricity & alignments of the Swivel Joints. Only pipes having
flanges at both ends & structures will be made at site.
Roof Drain will have sufficient joints to take care of Vertical movement of the roof and other
movements such as Rolling, pitching, Rocking about vertical axis or Lateral movements of
the roof. This will be achieved by fixing additional Swivel joints
Note: The location of drain sump on the deck shall be considered at the centre of the
deck. The party should refer the scheme attached with the tender. 8 Nos 6 swivel and 2
Nos 8 swivel has to be provided for the Roof drain per tank.
4.0 INSPECTION & TESTING : Swivel joints along with accessories shall have to be
inspected by Third Party agency at bidders cost prior to delivery at site.
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4.1 The items under the scope of supply of Roof Drain System shall be inspected by HPCL
at the manufacturers or his sub contractors works. The tenderer shall furnish, Quality
Assurance Plan (QAP) he proposes to follow at the factory and the tests to be conducted.
This shall clearly define and identify the stages of inspection, scope of test, list ofdocuments to be furnished.
The tests shall include, but not limited to the following :-
Life cycle test for 20000 cycle of rotation at air / hydraulic pressure of 5 Kg/cm. No
indentation mark on ball races shall be there after dismantling the swivel joint (Type
test).
Swivel joint shall be externally pressure tested at 4 Kg/ cm pneumatically.
Bending moment test for base swivel at 1000 cycle of rotation and hydro test for swivel
joint with bending moment at 15 Kg/ cm pressure for 10 min. No indentation marks
shall be there on ball races after dismantling the swivel joint (Type test).
The tenderer shall arrange all facilities required during inspection and testing at his cost.
HPCL shall have the right to inspect / witness the tests at various stages of fabrication /
manufacture / installation. The inspection shall be carried out at suppliers works / his
subcontractors works / site. Inspection of the item shall be done only with a view to
ensure that the same is manufactured, tested and supplied as per prescribed
specifications. The inspection shall in no way relieve the supplier of his responsibility as
per the contract and shall in no way be binding on HPCL
Manufacturers test certificate shall be furnished for all bought out materials. Wherever
such certificates are not available, the tenderer shall get the items tested at his expense at
government recognized laboratories, mutually agreed upon with HPCL.
Any defects noticed during the inspection / testing at site shall be rectified by the
tenderer at his cost as advised by the site engineer and inspection / testing carried out
for fool proof working.
The roof drain system shall be pressure tested to 50 PSI after installation in the tank. The
contractor shall perform the test in the presence of the engineer-in-charge. Any defects /
leakage observed during the testing shall be repaired by the contractor at free of cost toHPCL.
5.0 DRAWINGS / INFORMATION TO BE SUBMITTED
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The following drawings and documents in two copies shall be submitted along with the
offer. Data sheets / catalogues / literature / drawings of the items offered indicating :
a. Materials of construction and standards for different components of the
roof drain system.
b. General arrangement drawings indicating the lay patterns, cross sectional
drawings and showing the highest and lowest operating level details.
c. Make of Swivel joints, Pipes and NRV.
d. Pipe size considered for roof drain system with sizing calculations.
List of deviations, if any.
05.06.04 Roof vents
Two types of roof vents shall be provided in case of floating roof tank. One is auto
bleeder vent and the other is rim vent. For Cone roof tank, single/multiple Roof vent(s)
of adequate size shall be provided
Automatic bleeder vent of specified size shall be so designed as to open before the roof
touches lowest position and to close when the roof rises above this point.
Pressure vacuum relief valve ((PVRV) type Rim vents shall be provided for venting the
void space between the stored liquid and seal. The connecting pipe shall be fabricated
out of MS ERW pipe as specified, with a slip on flange at the top. PVRV shall be of
Aluminium construction.
05.06.05 Gauge well
Gauge wells with perforations shall be provided from rooftop down to the bottom and
have dimensions as indicated in the detailed drawing. The top of the gauge shall be
provided with an aluminium gauge hatch with cover and fireproof gasket and a flange
for 50mm pipe. Cover shall be spark proof type. The other gauge well diametrically
opposite shall be provided with a SORF flange at top. The gauge well shall be fixed in
perfect verticality by means of angle sections as shown in the drawing.
The well pipe shall extend to the top of stair way platform. 2 Nos. of gauge wells located
diametrically opposite shall be provided for each of the tanks. Gauge well shall be of
200mm seamless SCH 40 pipe. The sleeve provided in the pontoon for the gauge well
pipe should be of 350 mm diameter. 20 mm thick brass flange shall be provided in thesleeve for the gauge well pipes to pass through. 50 mm SCH 40 pipe with flange shall be
provided inside one of the gauge-well pipes for average temperature sensing of
products inside the tanks.
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05.06.06 Roof seal
Primary Seal
Mechanical Shoe Seals comprise a metallic sealing ring, which is held in permanent
contact with the tank shell and extends into the product by a system of independenthanger and pusher mechanisms, and with a continuous sealing apron curtain closing
the gap between the rim and the top of the Shoe. The product vapors are contained
between the shoe , apron curtain and the floating roof.
The design of the Mechanical Shoe Seal should be Channel Hanger Type with
independent hanger and pusher devices. The design of the Mechanical Shoe Seal
should be such that in service installation is enabled with no hot work allowed i.e. no
welding or flame cutting. The Mechanical Shoe Seal should conform tightly to shell
plate contours adaptable to existing rim and shell configuration, including wide
variations in rim gap.
The seal is characterized by a shoe-to-shoe slip joint connection, which allows for any
variation in the rim space irregularities between the rim and tank shell, while
containing the product vapors. It should be custom designed to suit the tank.
The Channel hanger type assembly should successfully maintain a constant seal
elevation even with a wide rim space. Galvanized shoes shall conform to ASTM A 924
and a G90 coating or equivalent and shall have a minimum nominal thickness of 1.5
mm (16 gauge). Stainless steel shoes shall have a minimum nominal thickness of 1.2
mm (18 gauge). Stainless steel shall conform to the requirements of ASTM A 240/A
240M (austenitic type only).
Pusher mechanism should be SS conforming to the requirement of Stainless Steel as
given above.Static Shunt to be SS conforming to the requirement of Stainless Steel as
given above.All fasteners to be galvanized for seals of galvanized construction & SS for
SS construction. Hanger Channels assembly should be minimum 14 gauge.Seal
Curtain/ Dip.Curtain should be compatible with stored product, recommended 0.5mm
thk PTFE. A protective mechanism should be provided to protect the vapor curtain.
VENDOR / MANUFACTURER ELIGIBILTY
Vendor shall have proven experience in supplying & installing the mechanical Shoe
Seal with necessary documentary proof for having executed such jobs. The seal shouldmeet CPCB requirements
INSPECTION CRITERIA :
Maximum seal gap area will be 200 cm2/m of tank diameter.
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Scope of Third Party Inspection:
Seal Curtain: Testing of properties to be witnessed and verified.
Mass of Zinc Coating on Mechanical Seal Components to be witnessed & Verified.Othertests to be carried out at a reputed laboratory and the results shall be furnished for
review / approval.
Secondary Seal
Secondary seal shall be of compression plate rim mounted horizontal or vertical
(preferably horizontal), made from series of metallic sheet joined together to form a
ring with a non-metallic tip that slide on the inside surface of the tank shell. The joints
to be bolted or sliding and to incorporate gasket at the point of overlap of the
compression plate.
Compression plate of the secondary sealing system should be sized to match the
existing annular space between the tank shell & the floating roof. The compression
plate should be clamped on the Rim flat/angle with channels duly galvanized. The
compression plate to have the compression channel gasketing. It should provide Leak
tight joint between the plates. Each seal plate should be sealed with the adjacent plate
in a fashion to eliminate vapor loss.
Galvanized compression plates shall conform to ASTM A 924 and a G90 coating or
equivalent and shall have a minimum nominal thickness of 1.5 mm (16 gauge).
Stainless steel compression plates shall have a minimum nominal thickness of 1.2 mm
(18 gauge). Stainless steel shall conform to the requirements of ASTM A 240/A 240M(austenitic type only).
Static Shunt to be SS conforming to the requirement of Stainless Steel as given above.All
fasteners to be galvanized for seals of galvanized construction & SS for SS
construction.A protective mechanism should be provided to facilitate smooth re-entry
of the secondary Seal onto the Tank Shell in the event of Tank overfilling. Secondary
seal system shall be tight fitted, rim mounted, with a wiper Tip made of a polymer
compatible to the stored product.The Sealing Gasket to be made of a polymer
compatible to the stored product.
Seal shall have very low coefficient of friction, shall not damage or score the tank shell.
Metallic seal components shall have adequate corrosion protection for long life. All
material used in the seal manufacturing shall be tested and certified for extended use in
hydrocarbon products.
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It should be custom designed to suit the tank. Additionally, the secondary seal should
have the following design features,
A. Safely ground lightening strike.
B. Minimize seal gap and shed water to the extent possible.
C. Capable in operating effectively over irregular rim gaps.
D. To install from above the deck without any hot works.
E. Seal material must be compatible with product stored.
F. Non-metallic parts must resist cracking and tearing.
G. Metallic components must resist corrosion.
H. To be able to dismantle the secondary seal, without affecting evaporative loss control
characteristics of primary seal.
I. Secondary seal shall extend from the roof to the tank shell and shall not be attached
to the primary seal.
VENDOR / MANUFACTURER ELIGIBILTY
Vendor shall have proven experience in supplying & installing the mechanical Shoe
Seal with necessary documentary proof for having executed such jobs. The seal should
meet CPCB requirements.
INSPECTION CRITERIA :
Maximum seal gap area will be 20 cm2/m of tank diameter
Scope of Third Party Inspection.
Wiper Tip Material : Testing of properties to be witnessed and verified.
Mass of Zinc Coating on Secondary Seal Components: To be witnessed & Verified.
Tests of other components to be carried out at a reputed laboratory and the
results shall be furnished for review / approval.05.06.09 Settling marker
ISA 50 x 50 x 6 and 100mm long settling markers shall be provided on the tank shell 0.5
m above the bottom plate for taking readings of tank settlement during hydrostatictesting.
05.06.10 Tolerance in fabrication
Shell plate: Plate cutting: +/- 1.5 mm on length +/- 1.5 mm on width
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Shell: For the purpose of tanks to have acceptable appearance and to permit proper
functioning of floating roof, the tank shall have tolerance strictly as specified in API
650-2000.
Floating roof tolerance: Tolerance allowed and annular clearance between shell andfloating roof shall be compatible with requirements specified as per API 650-2000.
05.06.11 Electrical & Automation System:
The tender envisages supply and installation and commissioning of electrical and
automation system of the additional product tankages and integrate with the existing
electrical and automation system of the location. All the tanks in the above Terminals
are provided with Radar Gauge with tank side indicator ,temperature element with
water bottom sensor of Saab make supplied by Automation vendor for the particular
location. The all the tank valves are provided with one MOV and one HOV. The
contractor shall integrate new MOVs with the help of actuator supplier or thru
automation vendor to the existing MOV panels of the system. The existing
automation system at Ajmer and Jaipur has been installed and commissioned by M/s
L & T ( contact person Mr Wagle09821604718) and in Rewari by M/s Honeywell
(contact person Mr Snehal 09860869200) .
The contractor is required to supply the same make or equivalent instruments which
are already installed in the location for easy maintenance and trouble free operation.
06.00 Underground Tank: Not Applicable
07.00 Cathodic protection for tank bottom of above ground product storage tanks07.01 Design of the system
All materials shall conform to relevant BIS and other standards specified. System shall
be complete in all respects to achieve the protection standards specified. These
specifications provide only the basic requirements. It shall be responsibility of the
Contractor to collect and take into consideration all the parameters to develop
acceptable engineering practice for the Impressed Current Cathodic protection system.
The Contractors scope of work shall include but not be limited to:
1. Soil/ Sand resistivity survey and soil/sand chemical analysis in Tank Farm area.
2. Submission and acceptance of soil / sand resistivity report.
3. Submission of design calculations and layout plan for the CP system.4. Certification / approval by a competent authority / agency for the design calculation
and installation procedure.
5. Preparation and acceptance of Detailed Engineering Package.
6.Supply and installation of all equipments/materials.
7. Preparation and acceptance of Testing and Commissioning Procedures.
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8. Testing and commissioning of Impressed Current Cathodic protection system.
9. As Built documentation.
The major equipment covered under the specification shall include polymeric anodes,
reference electrodes, junction boxes (AJB and CJB), test stations / boxes, transformerrectifier units (TRU), power cables, anode header cables, tail cables, cathode header
cables, reference cables etc. The installation work shall include necessary insulating
joints, backfill, epoxy encapsulations, thermit welding / soldering, cable markers etc. The
work of placing the Anodes, connecting the cable etc. shall be carried out along with the
other civil works at the right time and with proper co-ordination with the other
contractors.
07.02 Design Guidelines
The cathodic protection system for the tank bottom shall be specifically engineered to
protect tank bottom structure continuously for a minimum period of 30 years. The CP
system shall be designed for 100% bare steel. The cathodic protection system shall be
ngineered to meet the following protection criteria:
1. The structure to soil potential shall be 0.85V (minimum) to - 1.2 V (maximum) (OFF
condition) with reference to Copper/Copper Sulphate Reference Electrode.
2. Minimum polarization shift of 100 mV measured between the tank bottom metallic
surface and permanent reference electrode in contact with soil.
3. The minimum requirement of cathodic protection current shall be 10 mA / sq. m for
the tank bottom plate.
07.03 Codes and Standards
The cathodic protection system shall be engineered, supplied, installed, tested and
commissioned in accordance with latest applicable standards / recommended practices
of NACE, API, ANSI, BS and IS. In particular, the system shall conform to:API RP 651 1997: Cathodic protection of above ground storage Tanks.
NACE RP0193-2001: External cathodic protection of on-Grade Metallic
Storage Tank Bottoms.
NACE RP0285 : Control of External Corrosion on metallic Buried, Partially buried or
Submerged Liquid storage Systems.
BS CP-1021 : Code of practice of cathodic protection.In addition the work shall conform
to requirements of following regulations. (latestrevision)Indian electricity acts and rules.
CCOE regulations, (Nagpur) Chief electrical inspectorate of the respective state. Indian
petroleum act. Fire insurance regulation.
Equipment and materials shall be engineered, manufactured and selected for use under
the following site conditions:
Ambient Temperature : 50C to 500C : 00C to 500C
Relative humidity : 95% maximum : 95% maximum
Climate description : Tropical / Marine normal corrosive or saline soil
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: Tropical normal corrosive soil
The cathodic protection system shall be engineered for continuous operation under the
above site conditions and fully tropicalized.
07.05 Materials and Construction07.05.01 General
Requirements of major equipments are indicated in these specifications. However
contractor shall submit detail specifications of each equipment. All equipments shall be
new and procured from approved and reputed manufacturers. Contractor shall offer
only equipments which have proven service track record and a reference list of similar
make / type shall be provided. As far as possible, all equipments shall be located in safe
areas. Any equipment required to be installed in hazardous area shall satisfy all
requirements dictated by the hazard classification of area in which the equipment and /
or materials are to be installed. It will be ensured that manufacturer of installed electrical
equipments, incorporates all statutory safety provisions. Electrical equipment and
materials for use in hazardous areas shall be certified by an approved certifying
authority such as CCOE/CMRS.
07.05.02 Anode
The distributed anode design shall be based on soil resistivity survey data, external
bituminous padding / sand padding and other specification of tank foundation. The
number and configuration of distributed anodes will be determined by total current
requirement of structure to be protected and optimum current density of the anode
material selected. It shall be so engineered that a uniform and ample current distribution
will be obtained. Anode material shall be carbon based conductive polymer cable
(factory packed carbonaceous material) or equivalent of reputed make with provensupply records of use in Storage Tank Bottom plate cathodic protection. It is preferred to
avoid splicing of anodes in the sand pad foundation.
07.05.03 Transformer Rectifier Unit
Cathodic protection system of each tank shall be in general powered by a separate
transformer rectifier unit. In some cases 2 tanks can be combined for a single power
source. However, voltage drop shall be checked to be within the tolerance. Transformer
will be double wound, air cooled type with electrostatic shield between the windings.
The transformer insulation will be F class. It shall be floor mounted, suitable for indoor
installation and shall be dust / vermin proof. Transformer rectifier unit shall be sized tocater to the protective current demand required for installation with 100% spare
capacity. The DC output voltage of rectifier unit shall not exceed 50V. The rectifier shall
have continuous reading flush mounted DC voltmeter and ammeter for measuring
output voltage and current. Meters shall be accurate and shall be linear from zero to full
scale. Rectifier will be silicon type with adequate cooling arrangement and with
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moisture and humidity resistant finish. It will be mounted on suitable supports.
Adequate filtering arrangement will be provided to limit the ripple content to less than
5% at rated output. The Input/ output of rectifier units will be protected by fast acting
fuses of suitable ratings. Transient surge suppressors will also be provided across. DCoutput terminals and AC input terminals to protect the rectifier against surges. Each
diode and SCR will be provided with suitable surge suppressors. The TRU shall be
equipped with a circuit breaker for the incoming power supply. Power supply to TR
units will be drawn from the feeders of PMCC provided in the Terminal / Depot at 415V,
50 Hz. All the CP TR unit panels shall be located in a room earmarked for the panels.
A) Auto Mode
The unit will be generally working in this mode. The operation of the unit in this mode
will be controlled by upto three reference signals, which will be fed simultaneously. The
unit will have fully solid state Automatic Reference Selector logic to select the least
protected reference out of the three reference signals. The output DC voltage of the unit
in this mode will vary right from 0 V to 50V and from 0A to 50 A (or 75 A as the case
may be) to maintain all the reference signals within the protected range under all
operating conditions. The response of the unit will be instantaneous in order to suppress
extremely fast acting external stray currents. The typical reference regulation in this
mode will be within + 10 mV under all conditions. In case of failure of any reference
signal, the unit will ignore that signal and provided an alarm to indicate failure of that
particular reference input. However, the operation of the unit will not be affected in any
manner due to failure of any of the reference inputs. The unit will continue maintaining
the remaining healthy signals at the protective level. In event of failure of all reference
signals, the unit will provide alarm All Reference Fail and output of the unit will be
adjusted to preset value which will be operator adjustable from 0 V to rated value.Facility will also be provided for manual selection of any one of the three reference
inputs for control. Suitable metering arrangement will also be provided to monitor all
the three external reference signals as well as the internal reference signal
independently. Independent fast acting electronic current limit circuit will be provided
to limit the output current of the unit in Auto Mode to any value from 0 A to rated value
as desired by the operator.
B) Automatic Voltage Current Control mode (AVCC) mode
This will be the second mode of operation. The working of this mode will be
independent of the Manual mode and failure of the unit in Auto mode will not affect
operation in this mode. The output voltage of the unit will be adjustable to any valuefrom OV to rated voltage by means of step less voltage setter. The set voltage will be
maintained within 1% of the set value for change in line voltage from 180V to 270 V
and change in load from zero to full load. The output current of the unit will be
adjustable to any value from 0A to rated value by means of a step less current setter. The
current will be regulated within + 1% of the set value for change in line voltage from 180
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V to 270V and change in load within the specified limits. The response of both current
controller and voltage controller will be ultra fast, instantaneous type there will be no
change in output voltage and current even for a step change in load and input.
C) Manual modeThe control of output in this mode will be without any electronic component. A separate
Auto Transformer with tappings will be provided for voltage control in this mode. The
output will be adjustable from OV to rated value in steps.
Annunciation system
Complete annunciation system will be provided to indicate the followings
1. Under protection.
2. Over protection.
3. Over current (Automatically adjustable over complete range).
4. Ref. 1 fail.
5. Ref. 2 fail.
6. Ref. 3 fail.
7. All Ref. Fail.
8. Reference 1 lowest.
9. Reference 2 lowest.
10. Reference 3 lowest.
11. Subsequent reference electrodes
The transformer rectifier unit shall be provided with current interrupter to facilitate
recording of ON/OFF structure-to-soil potential.
07.05.04 Test station / box
The test boxes shall be used for potential measurement. It shall be installed near each
tank at four different locations. Test box shall be flameproof, weatherproof, with push-button and DC voltmeter suitable for outdoor installation in hazardous area. Test box
shall be made of aluminum alloy (LM-6) or stainless steel. Test box shall be suitable for
mounting on MS support. A minimum of 30% spare terminals shall be provided in each
test box. DC voltmeter with scale 0-3V shall be incorporated in the-test box for taking
potential measurement. The accuracy of voltmeter shall be not less than + 1%. The
nameplate of test box shall carry following information:
Test box number. Test box connection scheme.
07.05.05 Permanent reference cells
High purity Copper / Copper Sulphate Reference electrodes with proven high reliabilityshall be provided for stable structure to soil potential measurement. The permanent
reference electrode shall have negligible drift in its lifetime and should have a stability of
0.1%. The life of half cell permanent reference electrode shall be comparable with the
design of CP system. Permanent Copper/Copper sulphate reference electrode shall be
Stelth 2 of M/s Borin / Harco of USA. A minimum of six permanent reference
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electrodes for tank dia > 30 m and three for tank dia < 30 m shall be located underneath
the tank bottom plate at the following locations:
- At the center of bottom plate
- Near the rim of the bottom plate- In between center and the rim of the bottom plate.
07.05.06 Anode Junction Box
Anode Junction Box shall be made of stainless steel or cast aluminum alloy having
degree of protection lP55. It shall have arrangement for terminating main positive and
negative cables. The anode junction box shall have current divide facility and measuring
shunt for current measurement. The anode junction box shall beflameproof/explosion
proof, if installed in classified area.
07.05.07 Backfill (If required)
The backfill material of anode cable trench shall consist of charcoal/coke powder having
minimum carbon content of 80 to 90%. This additional charcoal / coke shall be provided
in the trench so that anode cable sets embedded with charcoal / coke. Above it normal
soil available in the foundation shall be provided.
07.05.08 Cables
All cables used for cathode and anode header circuits (including test leads) shall be 1100
V grade, single core, copper conductor, and PVC insulated GI wire armored cable. The
reference electrode cable and anode lead wire cable shall be 1100V grade single core
standard copper conductor with a double insulation system. The primary insulation
shall be PVC sheathing jacket over the primary insulation. The minimum cross section
shall be as follows:
Copper conductor:Test Lead cable 6 mm2
Anode and Cathode header cable (for tanks 48 m dia and below)35 mm2Anode and Cathode header cable (for tanks 64 m dia and below)50 mm2
Anode lead cables 16 mm2
Cathode lead cable 16 mm2
Reference electrode cable 6 mm2
Multi core reference cable 1.5 mm2
07.06. Soil Resistivity survey
The contractor shall carry out soil resistivity survey of the tank farm area and shall study
the details of all backfill materials used for the entire tank foundation and accordingly
judiciously select the design soil resistivity data. To carry out soil resistivity
measurement, Wenners 4-pin method shall be used. Contractor shall also carryout teststo check the presence of chlorides and Sulphate Reducing Bacteria.
07.07 Laying and installation
07.07.01 Installation of Anode (Cable)
The anode cable is to be installed beneath the tank bottom with normal cable laying
technique. A proper coke fill around the anodes has to be ensured. Anode cable shall be
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laid in trench approximately within 1 m depth from the tank bottom. A perforated PE
pipe shall be used as a conduit through gravel and concrete foundation ring in order to
provide mechanical protection to the cable. The anode cable shall be in individual loops/
single cable with each loop / cable extending outside tank wall. This will help to powereach anode cable / loop individually and to access as required. The CP Contractor will
provide a detailed methodology of laying the anodes in foundation for owners
approval.
07.07.02 Laying of PVC pipe for monitoring of Tank to Soil potential using portable
reference electrode
A perforated PVC or FRP pipe will be provided for getting a continuous profile of tank
to soil potential from the perimeter to the center. The pipe will be laid from the
perimeter of the tank to the center of the tank during the period of installation of
permanent half cell itself. The pipe will be installed at shallow angle so as to reduce IR
drop and perforated in a manner that it allows to be temporarily flooded. The intent of
this arrangement is that a submersible Copper / Copper Sulphate electrode can be
inserted into the pipe using stiff wire or small diameter pipe to obtain a profile of tank to
soil potential across the tank bottom. The open end of the pipe shall have arrangement
of plugging through threaded socket.
07.07.03 Installation of Permanent Half Cell
Minimum of three nos. of permanent half cells per tank shall be installed at a suitable
depth preferably at a depth of 300 mm from the tank bottom plate so as to provide a
close measurement of structure (tank bottom) to soil potential. The lead wires from the
reference electrodes will be corrosion resistant type and will pass through PE /PVC pipe
laid from the tank outer foundation ring to tank center place. These wires will then
properly be laid upto the Test box for termination.07.07.04 Cable to structure connection
All cable connections to the tank bottom plate / structure shall be made by an exothermic
process, CADWELD, THERMOWELD or equivalent method.
07.07.05 Installation schedule
The installation of cathodic protection system shall be broadly grouped in following
manner:
Laying of main anode cable beneath the tank bottom. This work shall be scheduled to
undertake during the tank foundation construction. The jobs may be planned in the
following manner:
a) During the construction of tank foundation, the construction of foundation is haltedwhen it is at desired height from the level of tank bottom plate for laying the anode
cable.
b) Laying of anode cable as per engineered configuration will start with normal cable
laying technique using manual excavation.
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c) The cable shall be laid extending the tank concrete foundation ring with cable passing
through a perforated PE duct put on the gravel portion and upto the concrete
foundation ring of the foundation.
d) The cable ends appearing outside the foundation ring shall be properly sealed so as toimpede any water or soil ingressing the cable. The protruded cable ends so protected
shall be kept temporarily embedded in with proper marking so as to locate afterwards.
Similarly laying of permanent half cells, intent to monitoring CP system shall be
completed at this stage only. The permanent half cell wires shall be taken though a hard
PE pipe similar to the arrangement detailed above.
e) Once completed the foundation work of this tank will restart, the cable laying activity,
shall resume in other tank in the similar manner as described in the foregoing.
f) The other activities like Anode junction box installation, all cable laying work, cathode
cable, test lead cable jointing tank body, test lead boxes etc shall be undertaken after
completion of tank painting jobs. This measure is considered to avoid any potential
damage to cable and other equipment of the CP system intended to install in the Tank
Farm Area.
g) While details in foregoing para are kept pending, the installation of TR unit in the
Tank Farm MCC room/ CP Panel room including all its related civil work and electrical
interconnection with MCC shall be taken up consequent to the completion of anode
cable laying work.
07.08 Civil Works
All civil works associated with complete Impressed Current Cathodic Protection system
are included in the scope of contractor. This shall include making cable trenches and
foundation of all equipments, Anode junction box, test boxes and minor civil works. etc.
07.09 CommissioningThe installed CP system shall be commissioned as per approved testing / commissioning
procedures and by following model:
Before the energisation of CP unit, natural structure to soil potential value shall be
recorded at test station of each tank. After taking natural soil to tank potential, the CP
output for the relevant tank shall be switched ON. Output current of the TR Unit shall
be adjusted to achieve the maximum potential value of - 1.5V with respect to copper /
Copper Sulphate Electrode for at least 48 hours.Output current of anodes shall be
adjusted. CP station output of the respective tank shall be set at the designed values.
Observation of structure-to-soil potential shall be recorded at each of the installed test
station. CP station operating parameters shall be recorded. Utmost care shall beexercised to allow the structure to polarize before structure to soil potential values are
recorded across the span for the tank bottoms Structure to soil potential measurement
with both ON / OFF potential method shall be repeated after 15 days of polarization
using current interruption technique. The maximum OFF potential shall be 1.2 V. As a
result of these tests / commissioning if any deficiencies are found in the system, the same
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shall be rectified by the contractor at no extra cost or time effect, to the complete
satisfaction of the Owner/ Owners representative.
07.10 Credentials of CP Contractor and Preferred makes
The Contractor for carrying out the Cathodic protection system shall have a proventrack record of minimum 5 years of designing, installing, testing and commissioning of
similar jobs for above ground storage tanks. Relevant documentary proof shall be
furnished for verification of the experience. In the absence of these credentials this
portion of the tender will not be evaluated.
Preferred makes: Polymer anodes : Raychem / Matcor USA
TRU : Canara electric controls.
Reference electrodes : Borin USA / Harco USA.
Polarisation Cells : Kirk.
Cables : CCI / Fort Gloster / RPG / Special Cables /Nicco
Universal Surge Arresters : Dehn + Sohne Germany.
Junction Boxes : FEPL / Sudhir electrical / FCG GEAG / Baliga
The tenderer can indicate alternate makes, with process performance for the above
items,
which will be subject to evaluation / approval by client / consultant.
08.00 INSPECTION
08.01 ACCESS FOR INSPECTION
Inspection shall be co-ordinated with the Engineer-in-Charge at all times. All tanks shall
be offered for inspection to Engineer-in-Charge in stages as desired by him. In-Charge
shall have free access to all works at all times. The contractor shall provide all tools,
equipment and labour to the Engineer-in-Charge for proper inspection. All inspections
will be carried in accordance with the requirements of this specification. Approval ofEngineer-in-Charge shall in no way relieve the contractor of his responsibilities for
proper execution of works.
08.02 lnspection and Testing of Cathodic Protection Equipment at Manufacturers Works
All components / equipments of Cathodic protection system shall be subjected to
minimum testing and inspection requirements, manufacturers works, as per relevant
codes and standards in presence of Contractor. Owner reserves right to depute his
representative for inspection/testing. The manufacturer/contractor shall furnish all
facilities to Owner for entry to respective works and for testing / inspection at his own
care and expense. Minimum 15 days notice shall be given for inspection.08.03 Field Testing of Cathodic Protection syste
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