annexure 1 water expulsion test facility...page 1 of 47 annexure 1 water expulsion test facility...

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Annexure 1

WATER EXPULSION TEST FACILITY

Quantity: 2 nos.

1.1) Scope

The scope includes supply, installation and commissioning of water

expulsion test facility as per the details given below.

Water expulsion test set up will be used for evaluating the performance of

valves. Schematic of water expulsion system set up is given in Fig.1.1. Water

tank will be pressurised by Nitrogen/Helium through test valve and water will

be expelled from tank. The expelled water will be collected in a collection

trough placed on a weighing machine. The set up shall have the following

systems.

a) Pneumatic circuit, High pressure water tank, Collection tank, weighing

machine etc. as per Figure 1.1.

b) A common Stainless Steel structure to which the entire system shall be

compactly integrated and necessary console (Stainless Steel) for

operation.

Remote operation/control of valves, data acquisition, display and recording

is not under the scope of supplier.

1.2) Test sequence

a) Test article (valve) will be connected to line 1 (ref. Fig1.1) at point A.

b) The water tank will be remotely filled with required amount of water

through the DM water line by opening SV3. The Water level and quantity

filled will be recorded by flow meter as well as level transmitter.

c) Pressure regulator PR1 will be set at 17 bar and then the solenoid valve

(SV1) will be opened to pressurise the tank to 17 bar. And then SV1 will be

closed.

d) The tank will be further pressurised using test article (not scope of

supplier) connected to line 1.

e) After the test duration, valves in the test article will be commanded to

close and pressure inside the tank will be vented using SV2 after closing

MGV3.

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Figure 1.1: Water Expulsion test set up schematic

Outlet port suitable for 1 ½”line

Point A

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1.3) Specification of items/ components (Quantity mentioned is for one unit)

HIGH PRESSURE WATER TANK (T1 IN FIGURE 1.1)

Quantity : 1 no.

Tag number : T1

Maximum Allowable Working

Pressure

: 25 bar

Volume : 150 litres

Diameter : 500 mm (appx.)

Design code : ASME Section VIII, Div. 1

Material of construction : SS304L/ 316L

Following features shall be provided

2. Safety provisions – Burst disk (BD1) &Safety relief valve (SRV1 in Fig. 1.1).

3. The tank inside shall be cleaned and degreased to Oxygen service standard.

Inside of the tank and outside shall be electro-polished to make free of any

contamination.

4. Material certificate from Govt. Approved lab for all pressure bearing parts shall

be submitted.

5. Ultrasonic test certificate for the plates used for fabrication of tank shall be

submitted.

6. Hydrostatic pressure testing of the tank at 1.5 times the MAWP and pneumatic

testing of the tank at 1.1 times the MAWP as per design code shall be

carried out in presence of LPSC Engineers.

7. 100% Radiography examination shall be carried out for all Butt joints on the

vessels as per ASME Sec. IX with X-ray to 2% equivalent sensitivity. All the

radiographic films shall be submitted to the Department for review

and clearance.

8. Necessary outlets of suitable sizes shall be provided for fixing instruments and

components.

9. Drawing clearance from LPSC shall be obtained before proceeding with

fabrication of the tank.

COLLECTION TROUGH

Water collection capacity : 50 litres (minimum)

Material of Construction : Stainless steel.

Following features shall be provided

1) The size of the collection tank based on the weighing machine platform size.

2) Manual Ball Valve shall be provided at the bottom of tank for emptying the

tank.

3) Top lid with provision for rigidly fixing the outlet plumbing from Tank 1.

4) Provision for lifting the lid also shall be provided.

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WEIGHING MACHINE

Capacity : 100 Kg

Platter size : 500 mm X 500 mm (minimum)

Accuracy : less than 10g.

Power supply : 230 V AC, 50 Hz

Data acquisition : In built RS 232/0-10 V DC

Make : Essae or Equivalent

Calibration : Calibration certificate shall be provided

Solenoid Valves

Valve Body material : SS 304 or 304L / 316L

Voltage : 24V DC

Working medium : Helium (for SV1 and SV2)

DM water (for SV3)

Nominal working pressure : 25 bar

Type

Size :

: Direct acting, normally closed

To match with inlet and outlet lines.

Allowable leak rate : Bubble tight shut off

Make : GSR Ventiltechnik, Germany / Jefferson

valves / U V Intl., Chennai

Quantity : 3, (SV1, SV2, SV3 in Figure 1.1)

Certification : Certificate of conformance shall be provided

Analog Pressure gauge

Wetted parts Material : SS 316/ SS 304

Range : 0 – 30 bar

Type : Without oil filling

Dial size : 4 inch

Accuracy : ± 0.5% of Full Scale

Make : Ashcroft/Wika, Germany/Budenberg, UK

Quantity : 2 Nos. (APG1& APG2 in Figure 1.1)

: Party may select a pressure range based on

the nominal working range

Digital Pressure transmitter :

Type of measurement : Absolute

Accuracy : ± 0.075% of span

Pressure unit : bar

Nominal working range : 0 - 30 bar

Diaphragm material : Stainless steel

Material of body of transmitter : Aluminium

Working voltage range : 18 – 32 V

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Output signal : 4 to 20 mA.

Local display : Local LCD display

Manifold for communicating pressure line/ vent port with manual valves also shall

be supplied

Communication capability : Through HART communication protocol

Calibration of transmitter : Minimum 5 steps ascending and descending

Make : Smar/ Rosemount/ Rochester

Quantity : 1 No. (PTG1 in Figure 1.1)

Safety Relief Valve

Type : Spring actuated conventional type

Material of Construction, body : SS 304 or 304L / 316

Allowable leak : Bubble tight shut off

Nominal set pressure : 22 bar

Note : Safety valve orifice shall be designed to

relieve the Pressure in case of regulator

failure

Make : Audco India Ltd., Maraimalainagar/Crosby

Valve &Engg Co. Ltd., England/Tyco Sanmar

Ltd., Chennai/IMI Bailey Birkitt Ltd.,

England./Butec

Quantity : 1 No. (SRV1 in Figure 1.1)

Needle Valve

Type : Panel mounted


Working medium : Helium (for NV1, NV2 and NV4)DM Water

(for NV3)

Size : To match with inlet and outlet line sizes

Handle type : Bar handle with length of nearly 70 mm

Material : SS 304 or 304L / 316

Working pressure : 25bar (for NV1, NV3 and NV4), Quantity – 3

nos.

: 150 bar (for NV2), Quantity – 1 no

Make : Swagelok/ Parker/Butec

Pressure regulator with filter

Material Body : Brass/ SS

Regulator type : Self venting

Ratio of variation of set pressure

to Variation in inlet

pressure(Decay ratio)

: less than 2%

Leakage across seat in closed

condition

: Bubble tight

Nominal Inlet Pressure : 150- 50 bar

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Nominal control range : 1 – 25 bar

Minimum Delta P : 25 bar

Flow Coefficient (Cv) : 0.3 (Minimum)

Filter

Material for body and mesh : SS 304L/SS 316L/321

Body type : Y type/T type.

Filter Element : Pleated mesh

Filter rating : 14 micron (absolute)

Quantity : 1 set. (PR1& F1 in Fig. 1.1)

Make : Tescom /Dutch/Hale-Hamilton/Drastar.

End connection: Swivel union: Threaded swivel union with O-ring face seal. The

companion fitting shall be provided with butt welding ends, which shall be suitable

to mate with the interfacing tubes.

Level Transmitter

Type : Guided wave Radar/Ultrasonic

Probe material : Stainless Steel

Accuracy : ±1 % of FS

Unit : mm/cm


Material of body of transmitter : Aluminium


Output signal : 4 to 20 mA during normal operation



Make : Smar/ Rosemount/ Rochester

Quantity : 1 No. (LTG 1 in Figure 1.1)

Flow meter (FM1)

Type : Turbine flow meter with transmitter

Fluid Medium : Water

Size : 1/2 inch

Flow range : 0.2 – 0.8 lit/sec

Operating pressure : 25 bar(g)

Material Body : SS 316

Flange : SS 316

Rotor : 430SS/ ANC21/17-4 PH

Bearing : Tungsten carbide, Sleeve bearing

End connection : Flanged as per ANSI B16.5

Turn down : 10:1

Linearity : ± 0.25% of reading over linear operating

range at water

Transmitter output : 4-20 mA

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Calibration : 10 point water calibration by Manufacturer

factory / any approved laboratory traceable

t national standard. Certificate to be

provided.

Make : Hoffer Flow Controls. INC,/ ITT Controls

B.V.,/ Barton Instrument Systems Ltd, Kuppers Electromechanik GMBH/

Cameron Measurement Systems/ Equivalent.

Quantity : 1 No. (FM1 in Figure1.1)

Filter (F2)

Flow rate : 0.4 litre/ second of water (appx.)

Permissible pressure drop : 0.5 bar (appx.)

Material for body and mesh : SS 304L/SS 316L/321

End connection : Flanged

Filter Element : Pleated mesh

Body type : Y type/T type

Filler rating : 100 micron (absolute)

Quantity : 1 no.(F2)

Make : Ultrafilters, Bangalore/Puronics Systems , Bangalore/Classic filters


Manual globe valve (MGV1, MGV2 & MGV3)

Application : Isolation

Material : SS 304/316

Permissible leak across seat : Bubble tight

Working pressure : 5 bar (MGV1) 25 bar (MGV2 and MGV3)

Fluid Medium : Water (MGV1, MGV3), Helium (MGV2)

End connection : Flanged (ANSI B 16.5).

Size : To match with inlet and outlet pipeline sizes. Body with full port.

Make : AMPO Spain, Flow Serve USA, Weka AG

Switzerland, IRI Ireland SA, France, L&T

valves, Chennai, Niton, Poyam valves


Tubes


Size : As per Figure 1.1. Thickness shall be

selected based on operating pressures.

Make : Sandvick, Swagelok, Tubacex

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1.4) TERMS AND CONDITIONS FOR ANNEXURE 1

1) An engineering layout drawing as per given schematic drawing shall be

prepared by the party and submitted for necessary approval before staring

the work.

2) Certificate of conformity for major items shall be provided along with the

unit.

3) Circuit diagram of the unit shall be neatly marked on a panel.

4) The total system shall be integrated as a unit. Sufficient space shall be

provided between operating knobs/ handles during design for easy operation.

5) Pneumatic leak check: After completion of the integration, the unit shall be

subjected to pneumatic leak test with Nitrogen gas up to maximum operating

pressure of the unit and necessary certificate shall be issued by the

manufacturer. Snoop solution shall be used to detect the leak.

6) Party shall have previous experience in supply of flow systems. The details

shall be submitted along with quotation.

7) Pre-Delivery inspection: Pre- Delivery inspection shall be carried out by LPSC

engineer after completion of the integration work.

8) Spares: The following indicative flow components shall be supplied as spares.

Apart from this party may quote additional spares if required as optional.

9) Party shall provide compliance matrix for all the points mentioned above.

Wherever parameter is specified with numerals, the reply shall be in

numerals and other statements like “Yes complied or agreed” alone are not

acceptable and such offers shall not be considered.

Sl.

No.

Item Quantity

1 Pressure regulators (PR1 & F1 ) 1 set.

2 Needle valves (NV2 ) 2 nos.

3 Filter (F2) 1 No.

4 Safety relief valve (SRV 1) 1 No.

5 Solenoid valve (SV1) 1 No.

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Annexure 2

FILTRATION UNITS & FLUSHING CHAMBERS

Quantity – 4 nos.

2.1) Filtration Units (Quantity 4 Nos.)

Scope of work

The scope includes design, supply, installation and commissioning of Iso-

propyl Alcohol (IPA)/ Water based filtration units and flushing tanks. This

facility will be used for the IPA/Water filtration. Various systems required for

this facility is given below. Detailed process diagram is given in Fig 2.2. All

the systems/components used in filtration systems shall be of high purity

class and these should not generate any contamination. The facility will be

configured as three units namely pressurisation console, Filtration unit and

Control and Instrumentation unit.

a) GN2 pressurisation system (Refer Figure 2.2)

Pressurisation system provides regulated GN2 pressure for IPA/

Water tanks. Inlet pressure of 150 bar will be initially regulated to

intermediate pressure of 40 bar. This is further regulated to around 5 bar to

pressurise IPA/Water tanks. Pressurisation unit shall be configured as stand-

alone unit with SS frames and sheets (electro-polished). The schematic of

the system is given in Figure 2.2.

b) IPA/Water Filtration system (Refer Figure 2.2).

• IPA/Water in IPA/Water drum is pumped to the overhead tank (T1) using

air operated diaphragm pump (P1).

• The overhead collection tank shall have 60litre IPA/Water storage capacity

and shall equip with safety features such as Safety relief valve & Burst

disc.

• A primary filtration system with four staged T-type/Y type cartridge filters

shall filter the IPA/water in T1 and store in T2 which has a capacity of 40

litre.

• Tank 2 shall also have safety features such as Safety relief valve & Burst

disc.

• Primary filtration system (FS2) shall have provision for monitoring

pressure drop across each filter to identify clogging.

• The pressurised IPA/Water in tank 2, shall pass through one more level of

filtration (FS3 inline membrane filters) before being supplied to various

applications and for flushing unit tank.

• All the electro-pneumatic valves in IPA/Water lines will be operated

remotely from control room.

• The circuit shall be designed as per Figure 2.2 and the items/components

shall be sourced from parties given in Table 2 in Section 2.3 only.

List of items required for GN2 pressurisation system, IPA/Water Filtration

system are listed in Table 2 in Section 2.3. The items shall be sourced from

parties given the table only.

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c) Control and Instrumentation Unit

Control and Instrumentation unit shall perform the following functions

a) Control of all Electro pneumatic/ Solenoid valves from PC.

b) Acquisition and display of pressure data from transmitters, Fluid level in

tanks from Level indicators etc.

c) Mimic diagrams of the circuit displaying functional status of EP and solenoid

valves.

d) Emergency tank pressure venting options through EP valve.

e) Real time monitoring and control of every component from PC.

The control and instrumentation unit shall be composed of a PLC and PC with

visualisation and control. Automatic operation and control of the system shall be

done through PC. Party must supply a standard PC along with supply. Necessary

cabling between the control and instrumentation unit and the filtration and

flushing system is under the scope of the supplier (Appx. Distance – 7 metre).

Detailed documentation for the electrical wiring and interconnections shall be

provided.

2.2) Test article/tubes flushing chamber (Quantity 4 Nos.)

This unit is for flushing the test article mainly tubes. The item to be flushed/

cleaned shall be placed on a platform which will be closed after placing the test

article and connecting the inlet line. The system shall have an inlet fluid line with

four number of outlets to connect test article/tubes. The tube connections shall

be designed to withstand 40 bar pressure. The flushed out IPA/ water will be

drained through the grated steel platform on which the item is placed. The

flushed out IPA will be drained out from the system through an outlet drain

valve. The overall size and other specifications of the Flushing/ Cleaning

chamber is given in Table1. An overall layout of the item is as per Figure 2.1.

Table 1: Specification of test article flushing chamber

Sl.

No.

Parameter Requirement

1 Overall size 1.5m X 0.8m X 0.8m (Depth)

(Approx.)

2 Tube cleaning chamber size As per Figure 2.1

3 Maximum tube pressure 40 bar

4 Material of construction of body and

grating

Stainless steel (SS 304/316)

SS sheet thickness : 2 mm (min.)

5 The top lid of the chamber shall be hinged and shall be made of

Polycarbonate on Aluminium frame.

6 Provision for collecting the flushed fluid shall be provided as per Fig.2.1.

7 Outlet with ball valve for shall be provided for drain.

8 There shall be provision for locking the door mechanically

9 Castor wheels: Castor wheels with locking mechanism shall be provided.

10 An overall schematic of the item is provided in Figure 2.1.

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Figure 2.1: Test article flushing chamber

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2.3) Specification of Items/ Components for IPA/ Water Filtration units

Table 2: List of Items for GN2 pressurisation system, IPA/Water Filtration system

Sl.

No.

Item (Quantity mentioned is for one unit only.) (Refer Figure 2.2)

1 Needle valves

Type : Panel mounted Allowable leak : Bubble tight shut off

Handle type : Bar type handle with 70 mm minimum length. Material : SS 304 or 304L / 316 Make : Swagelok/ Parker/ Thompson

Nominal working

pressure

Quantity

150 bar 1 Nos. (NV1)

40 bar 4Nos. (NV2,3,4,10)

10 bar 2 Nos. (NV11,12)

5 bar 7Nos. (NV5,6,7,8,9,13,14)

2 Solenoid Valve

Valve Body material : SS 304 or 304L / 316 Voltage : 24V DC Type : Direct acting, Normally closed

Allowable leak rate : Bubble tight shut off Nominal Working pressure : 5 bar

Quantity : 2 Nos. (SV1 and SV2) Make : GSR Ventiltechnik/ Jefferson / U V Intl.

3 Check Valves Working medium : Isopropyl Alcohol/ Water Body Material : SS 304 or 304L / 316

Nominal working pressure : 5 bar Quantity : 2 Nos. (CV1 and CV2)

Make : Swagelok/ Novaswiss/ Haskel

4 Safety relief valve

Material of Construction, : SS 304 or 304L / 316 body Allowable leak : Bubble tight shut off

Note : Safety valve orifice shall be designed to relieve the pressure in case of regulator failure

Make : Thomson/Swagelok/Butec

Nominal Set Pressure Quantity

44 bar 1 Nos. (SRV1)

11 bar 1 Nos. (SRV3)

5.5 bar 3 Nos. (SRV2,4,5)

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5 Electro Pneumatic Valve (EP Valve) Working medium : IPA/ Water

Application : ON/ OFF Pattern : Globe valve

Actuation : Electro-pneumatically operated Inlet & outlet size : ½ inch Nominal working pressure : 5 bar

End connection : Flanged. Normal position : closed

Command pressure : less than 10 bar Material of Construction : Body and Bonnet : ASTM A 182 Gr. F 304L/ 316 L / 321

Design code : BS 15762/ BS 1873/ API 6-D/ ASME B16.34 Test Code : BS12266 Part 1/ API 598/ ASME B16.34

Certificate of conformance shall be provided.. Limit switch for the remote ON/OFF status indication shall be provided.

Actuator

Type : Linear actuator, diaphragm/piston type, spring

return, fails safe for globe valves. Normal position : Closed Command gas : GN2 at 6 to 7 bar.

Solenoid

3 way, Normally closed, SS316 body, 7 bar acting pressure, 24V DC, single coil, continuous energisation.

Status Switch Type : Cylindrical Inductive Type Proximity Sensor

(switch).Explosion proof type. Electrical Configuration : DC, 2 wire Nominal Voltage : 8 V

Operating Voltage : 5 – 25 V

Quantity : 7 (EPV1to 7 in Figure 2.2) Make : AMPO Spain, Flow Serve USA, Weka AG

Switzerland, IRI Ireland SA, France, L&T valves,

Chennai. Butec.

6 Digital Pressure transmitter

Type of measurement : Gauge, Explosion proof type. Accuracy : ± 0.075% span

Pressure unit : bar Nominal working range : 0 - 40 bar Diaphragm material : Stainless steel

Material of body of transmitter: Aluminium Working voltage range : 18 – 32 V

Output signal : 4 to 20 mA during normal operation Local display : Local LCD display Manifold for communicating pressure line/ vent port with manual valves

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Communication capability : Through HART communication protocol Calibration of transmitter : Minimum 5 steps ascending and descending

Make : Smar / Rosemount/ Rochester. Quantity : 2 Nos. (DPT1 & DPT 2 in Figure 2.2)

7 Manual Globe Valve

Nominal Working pressure : 5 bar( MGV1 to 3) Fluid Medium : IPA/ Water Actuation : Hand – operated (Manual)

Application : Isolation Permissible leak across seat: Bubble tight as per API 598 or Rate A of BS 12266

Part 1. End connection : Flanged. Inlet & outlet size : ½ inch.

Material of Construction :

Body and Bonnet : ASTM A 182 Gr. F 304L/ 316 L / 321 Design code : BS 15762/ BS 1873/ API 6-D/ ASME B16.34 Test Code : BS12266 Part 1/ API 598/ ASME B16.34

Tests

Certificate of conformance shall be provided. Quantity : 3 Nos. (MGV1, MGV2, MGV3)

Make : AMPO Spain, Flow Serve USA, Weka AG Switzerland, IRI Ireland SA, France, L&T valves, Chennai

8 Analog Pressure gauge Wetted parts Material : SS 316/ SS 304

Type :Without oil filling Dial size : 4 inch

Accuracy : +- 0.5% of Full Scale Note: Party may select a pressure range based on the nominal working range Make: Ashcroft/Wika/Heiss/Bouden Berg

Nominal Working Range

Quantity

0 – 150 bar

1 Nos. (APG1)

0 – 10 bar

3 Nos. (APG3, APG4, APG5 and APG6)

0-50 bar APG 2

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9 Pressure regulator. Material : Body – Brass/ SS

Regulator type : Self venting. Regulator handle diameter : 80 to 90 mm

Cv – 0.2 (nominal) Ratio of variation of set

pressure to variation in inlet pressure (decay ratio) : less than 2%

Leakage across seat in closed condition : bubble tight

Make : Tescom /Swagelok/Hale Hamilton/ Drastar

Nominal Inlet

pressure

Nominal outlet

pressure

Quantity

150 bar 0 – 40 bar 1 No. (PR1)

40 bar 0 – 10 bar 1No. (PR3)

40 bar 0 – 5 bar 1No. (PR2)

10 Filter Fluid : Nitrogen

Type : Welded inline Filters Filter element : Pleated mesh SS element

Maximum working pressure : F1 (40 bar), F2 & F3 (5 bar), F4 (10 bar), F5 (150 bar)

Make : Festo/Legris/parker/ Swagelok

Nominal

Pore size (micron)

Quantity

7 4 Nos.

(F1,F2,F3 and F4)

15 1 Nos. (F5)

11 IPA/ Water filters

Type : T-type/Y-type Working medium : IPA/Water

Filter element : Wire mesh type, supported on perforated cartridge. Filter &Cartridge material : SS 304/316 Clogging Indicators: clogging indicators shall be provided for the filter.

Nominal

Pore size (micron)

Working

pressure

Quantity

20 5 bar 1 Nos. (F6 in Figure 2.2)

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12 IPA/ Water primary filtration system Type : T-type/Y-type

Number of filters : 4 Working medium : IPA/Water

Filter element : Wire mesh type, supported on perforated cartridge. Grade of filtration : 20 µm, 5um, 1.2 um, 0.4 um Nominal working pressure : 5 bar

Cartridge material : SS 304/316 Clogging Indicators : Separate clogging indicators shall be provided for

each filter. Quantity : 1 Nos. (FS2 in Figure 2.2) Make : Ultrafilters, Bangalore/Puronics Systems,

Bangalore./Classic filters

13 IPA/Water secondary Filtration system Type : Inline Millipore make membrane filters with SS

holder. Number of filters : 4

Working fluid : IPA/ Water Filter Holder : Stainless Steel filter 90 mm holders Grade of filtration : 20 µm. 5um, 1.2um, 0.4 microns

Filter material : Hydrophilic PTFE Nominal working pressure : 5 bar

Quantity : 1 Nos. (FS3 in Figure 2.2)

14 Air operated diaphragm pump

Minimum flow rate : 3 lit/min ( min.) Working fluid : Iso-propyl Alcohol/ Water Quantity : 2 Nos. (P1 and P2 in Fig. 2.2)

The pump shall be rated for handling clean fluids and it should not generate any contamination to the fluid.

15 IPA/ Water tanks Maximum Allowable

Volume& working pressure : 60 litre, 5 bar ( For T1), 40 litre , 5 bar ( for T2) Diameter : 350 mm (appx.) Design code : ASME Section VIII, Div. 1

Material of construction : SS304L/ 316L

Following features shall be provided, - Safety provisions – Burst disk & Safety relief valve (SRV5 for T1, SRV4 for

T2 in Fig. 2.2).

- The tank inside shall be cleaned and degreased to Oxygen service standard. - Material certificate from Govt. Approved lab for all pressure bearing parts

shall be submitted. - Ultrasonic test certificate for the plates used for fabrication of tank shall be

submitted. - Hydrostatic pressure testing of the tank at 1.5 times the MAWP and

pneumatic testing of the tank at 1.1 times the MAWP as per design code

shall be carried out in presence of LPSC Engineers. - 100% Radiography examination shall be carried out for all Butt joints on the

vessels as per ASME Sec. IX with X-ray to 2% equivalent sensitivity. All the radiographic films shall be submitted to the Department for

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review and clearance. - Necessary outlets of suitable sizes shall be provided for fixing instruments

and components. - Drawings shall be submitted to LPSC for approval before proceeding with

fabrication of tanks.

16 IPA/Water storage tank (T3 in Figure 2.2) Tank volume : 60 L Material of construction : Poly -propylene ( 15 mm sheet)

Size : 750 mm (L) X 750 mm ( W) X 700 mm (H) Level indicators shall be attached to the tank.

17 Command bottle:

Water capacity : 5 litre Material : SS 316/304 Working pressure : 10 bar

Stamping : ASME U stamped standard bottle. Make : Tobul, Haskel, Maximator.

18 Level Transmitter Type : Guided wave Radar/Ultrasonic

Explosion proof type (Suitable for IPA) Probe material : Stainless Steel Accuracy : ±1 % of FSD.

Unit : mm/cm Nominal working pressure : 25 bar( DLT 1,2 & 3)

Material of body of transmitter: Aluminium Working voltage range : 18 – 32 V Output signal : 4 to 20 mA during normal operation

Local display : Local LCD display Communication capability : Through HART communication protocol

Calibration of transmitter : Minimum 5 steps ascending and descending Make : Smar/ Rosemount/ Rochester. Quantity : 3 Nos. (DLT 1,2,3 in Figure 2.2)

19 Seamless Tubes and Fittings

Material : SS 304 or 304L / 316 Size : ½”tube, thickness shall be for selected considering

operating pressure. Length required per unit : 20m (Approx.) Make : Sandwick, Swagelok, Tubacex

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Figure 2.2: Schematic of IPA/Water Filtration and Flushing facility

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2.4) TERMS AND CONDITIONS

1) An engineering layout drawing as per given drawing shall be prepared by the

party and submitted for necessary approval before staring the work. The

supplier shall source the items as mentioned in the specification.

2) Certificate of conformity for each element also shall be provided along with

the item.

3) All items shall be cleared by LPSC Engineers before starting the integration.

4) Pneumatic leak check: After completion of the integration, the unit shall be

subjected to pneumatic leak test with Nitrogen gas up to maximum operating

pressure of the unit and necessary certificate shall be supplied.

5) Party shall have previous experience in manufacture and supply of flow

systems. The Purchase order details shall be submitted.


engineer after completion of the integration work. The system shall be

demonstrated using water as the working medium in the factory. Items shall

be despatched to LPSC only after PDI.




Wherever parameter is specified with numerals, the reply shall be in

numerals and other statements like “Yes complied or agreed” alone are not

acceptable and such offers shall not be considered.

------------------------------------

Sl.

No.

Item Quantity

1 Pressure regulators (PR1, PR2) 1 each


3 Membrane filter for FS3 Pack of 50 each for each filter

grade.

4 Spare filter elements for FS2 1 No. for each filter grade.

5 Safety Relief Valve (SRV4) 1 Nos.

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Annexure 3

PNEUMATIC TEST UNIT WITH GAS BOOSTER

Quantity – 5 Nos.

3.1) General Configuration & Description

1. The Pneumatic Test unit shall be able to provide pressures up to 800 bar.

Inlet pressure of 100 - 150 bar must be boosted to 800 bar. The schematic of the pneumatic unit is given in figure 3.1.

2. The supplier shall integrate gas booster system capable of delivering an outlet pressure of 800 bar. Detailed specification as per table1 in Section 3.2.

3. The unit shall work with Nitrogen/ Helium as media.

4. The gas booster system with components shall be compactly integrated together on a single unit with stainless steel frame & panel and shall have

good workmanship & appearance.

5. Panel drawing approval shall be obtained from LPSC before integration of the

system.

6. The different elements of the system shall be sourced only from the brands specified in Table 1 in Section 3.2.

7. NPT threaded connections shall be avoided wherever possible.

8. Layout of the booster unit and tube laying details are provided in Figure 3.1.

3.2) Specification of items/ Components

Table 1: Specification of items/component for pneumatic test unit with booster

Sl.

No Item (Quantity specified is for one unit) (Refer Figure 3.1)

1

Needle valves


Handle type : Bar type with length minimum 70mm


Make : Swagelok/ Parker / Butec

Nominal working pressure

Quantity

10 bar 2Nos.(Marked as NV4 and NV5)

150 bar 3 Nos. (Marked as NV1, NV2, NV3)

800 bar

9 Nos. (Marked as NV6, NV7, NV8, NV9, NV10, NV11, NV12, NV13,

NV14)

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2

Check Valves

Type : Soft seal Poppet type

Poppet material : SS 316

Body Material : SS 304 or 304L / 316

Make : Swagelok/ Novaswiss/ Butec / Parker


Quantity

150 bar 1 Nos. (CV1)

800 bar 1 Nos. (CV2)

3

Filter

Type : T type cartridge filters meeting the flow

requirement of booster with minimum

pressure drop.

Material of construction : Stainless Steel SS 304/316

Make : Festo/Legris/parker/ Swagelock


Nominal Pore size (micron)

Quantity

10 bar 40 1 Nos. (F1)

150 bar 15 1 Nos. (F2)

800 bar 7 1 Nos. (F3)

4

Filter

Type : Inline Filters

Filter element : SS element


Nominal pore size : 7 micron

Quantity : 3 Nos. (F4, F5 and F6)

Make : Haskel/ Legris/ Festo/ Swagelok/Parker

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5

Pressure transmitter

Type of measurement : Absolute.

Accuracy : ± 0.075% span.

Pressure range : bar

Diaphragm material : Stainless steel

Material of body of transmitter: Aluminium


Output signal : 4 to 20 mA.


Manifold for communicating pressure line/ vent port with manual valves

shall be supplied.

Communication capability : Through HART communication protocol


Make : Smar/Rosemount/Rochester

Nominal working Range

Quantity

0 – 10 bar

1 Nos. (DPT 1)

0 – 150 bar 1Nos.(DPT 2)

0 – 800 bar 2 Nos. (DPT 3 and DPT4)

6

Analog Pressure gauge

Wetted parts Material : SS 316/ SS 304

Type : Without oil filling

Dial size : 4 inch

Accuracy : ±0.5% of Full Scale

Note : Party may select a pressure range based on

the nominal working range

Make : Ashcroft/Wika/Heiss/Budenberg

Nominal Working

Range Quantity

0 – 10 bar 1 Nos. (APG 1)

0 – 150 bar 1 Nos. (APG 2)

0 – 800 bar 2 Nos. (APG3 and APG4)

7

Proportional relief valve

Material of Construction,

body : SS 304 or 304L / 316


Make : Haskel/ /Swagelok/ Parker

Nominal Set Pressure& Flow rate Quantity

11 bar.

Flow rate: Based on compressor Flow rate

1 Nos. (SRV 1)

880 bar Flow rate: Based on booster flow rate

1 Nos. (SRV 2)

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8

Solenoid Valve

Valve Body material : SS 304 or 304L / 316

Voltage : 24V DC

Type : Direct acting, Normally closed

Allowable leak rate : Bubble tight shut off

Make : GSR Ventiltechnik/ Jefferson / U V Intl.


Quantity

10 bar 1 Nos. (SV3)

150 bar 2 Nos. (SV1 and SV2 )

800 bar 7 Nos. (SV4 to SV10)

9

Pneumatic Gas Booster

Type : Two stage booster

Gas Inlet : 100 - 150 bar

Gas Outlet : 800 bar(min.)

Drive air pressure : Max 10 bar

Piston displacement : 35 ml/ cycle (min.)

Nominal cycling speed : 60 Cycles per minute

Nominal gas flow rate : 0.2 standard cubic meters per minute

minimum at 100 bar inlet, 800 bar outlet, 6

bar drive pressures.

Make : Haskel/ Hydraulics International

Air Pilot Switch shall be provided at inlet (or equivalent system) to stop the

booster when supply pressure falls to the adjusted set point. Also, air Pilot Switch shall be provided at outlet to stop the booster when outlet pressure reaches adjusted set point

10

Gas receiver for Individual units

Water capacity : 3 Liter (min.)

Material : SS 316

Working pressure : 1000 bar (min.)

Stamping : ASME U stamped

Make : Tobul/ Haskel/ Hydraulic International

11

Pressure regulator

Material : Body – Brass/ SS

Regulator type : Capture venting type

Regulator handle diameter : 80 to 90 mm

Ratio of variation of set

pressure to variation in

inlet pressure (decay ratio): less than 2%

Cv of regulator : 0.2 (minimum)

Leakage across seat in

closed condition : bubble tight

Nominal Inlet Pressure : 150 bar (for PR1) and 800 bar (for PR2)

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Control range : 1- 10 bar (for PR1), 150 – 800 bar(for PR2)

Quantity : 2 Nos. (PR1 and PR2 in Fig.3.1)

Make : Swagelok/Hale Hamilton/Thomson

12

Seamless Tubes and fittings


Size : as per Figure 3.1

Thickness : Shall be suitable for line pressures.

Make : Ratnamani, Sandwik, Swagelok, Tubacex,

DK Lok

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Figure 3.1: Schematic of pneumatic test unit with booster

POINT ‘A’

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QUANTITY AND LINE LENGTH REQUIREMENT

1) Five units are required. All the five units will have the same arrangement for

items shown in box in Figure 3.1. However, the line length after point A will be

different for each of the five units.

2) The cumulative line length of all the five units after point A is approximately

150m.

3.3) TERMS AND CONDITIONS

1) An engineering layout drawing as per given drawing shall be prepared by the

party and submitted for necessary approval before staring the work. The

supplier shall source the items as mentioned in the specification only.

2) Certificate of conformity for each element also shall be provided along with the

item.

3) Calibration certificate for pressure gauges & transmitters shall be furnished

along with the unit.

4) All items shall be cleared by LPSC Engineers before starting the integration of

unit.

5) All pipings and fittings shall be cleaned thoroughly with IPA and purge with air/

nitrogen before the starting the final integration.

6) The inlet/ Outlet and Drive air interfaces on the booster shall be engraved with

appropriate warnings.

7) Circuit diagram of the booster shall be neatly marked on the unit.

8) Sufficient space shall be provided between operating knobs/ handles during

panel design for easy operation.

9) Pneumatic leak check: After completion of assembly, the unit shall be subjected

to pneumatic leak test with Nitrogen gas up to maximum operating pressure

and necessary certificate shall be provided.

10) Party shall have previous experience in manufacture of systems of similar

specification.


engineer after completion of the integration work. Units shall be dispatched to

LPSC, Valiamala only after PDI.



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Wherever parameter is specified with numerals, the reply shall be in numerals

and other statements like “Yes complied or agreed” alone are not acceptable

and such offers shall not be considered.

Sl.

No.

Item Quantity

1 Pressure regulators (PR2 ) 1 Nos.


3 Filter (F4) 2 No.

4 Safety relief valve (SRV 2) 1 No.

5 Solenoid valve (SV4) 2 No.

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Annexure 4

PNEUMATIC DISTRIBUTION SYSTEM

4.1) SCOPE OF WORK

The scope of work include design, fabrication, procurement, supply, installation,

testing, commissioning and demonstration of centralized pneumatic supply

system for supply of Helium and Nitrogen gas including user point consoles and

stainless steel plumbings (tubing) for two Control components Assembly

(Control system & Components) Facilities (ECAT- Earth Storable Component

Assembly & Test Facilities& IFAT- Integrated Fluid Component

Assembly & Test Facilities) at LPSC, Valiamala.

1. There are two centralized pneumatic distribution systems, one for ECAT

and another for IFAT. The centralized pneumatic distribution system shall

supply gaseous Helium and Nitrogen from cylinders to the user points in each

facility. Centralized system for ECAT shall have one helium main console and

one nitrogen main console and for IFAT shall have three helium main consoles

and three nitrogen main consoles connected to respective cylinders. Pneumatic

lines shall be routed from cylinders to main consoles and from these consoles to

the user point consoles.

2. The user points in the clean rooms and other facilities shall be provided with

user point consoles with necessary fluid components as per requirement given

in subsequent sections.

3. The construction of all plumbing shall be with high quality orbital TIG welding

with 100% fusion except for component interfaces and console to plumbing

interfaces. Clearance of the welded joints shall be subjected to radiography

test. The component interfaces and console to plumbing line interfaces shall be

with standard double compression ferrule fittings. All the stainless steel tubes

shall be subjected for pickling and passivation before final assembly as per

Table 7 in Section 4.2.

4. Clearance from LPSC shall be obtained for the detailed design and layout

configuration prior to commencement of fabrication/assembly of the entire

system.

5. Installation, commissioning, integration, testing and demonstration of the entire

system shall be carried out “On Site” basis in LPSC, Valiamala. Main consoles

and user point consoles shall be brought to LPSC as fully integrated.

6. The gas supply line for gaseous helium and nitrogen from the cylinder bank to

the user points shall be of SS tubes (approximate length of 2250 meters) with

½” outside diameter for both ECAT and IFAT. Refer figure 4.1 for ECAT

layout and figure 4.2, 4.3 and 4.4 for the IFAT layout.

7. The gas supply line from gas cylinders to the user point contains approximately

128 nos. of elbow joints and 92 nos. of tee joints.

8. Entire tubing shall be routed (laid) externally on walls both inside and outside

the facility above the window level for easy maintenance purpose. Where ever

required for crossing the wall, suitable holes shall be drilled on the wall. The

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holes shall be closed after laying the line using appropriate closing

mechanisms/materials. The entire tubing shall be securely anchored with

suitable anchoring mechanism.

9. Pneumatic supply system shall be provided with appropriate color coding as per

the relevant ISO standard for clear identification by means of stickers. The

tubing shall be anchored/fixed with suitable arrangement for elegant look.

There are three types of consoles

a) Main consoles for GN2 &GHe.

b) User point console for GN2 &GHe.

c) User point console for low pressure GN2.

The details of these consoles are given below.

4.1.1) Main consoles for nitrogen and helium

Quantity of main consoles required in ECAT and IFAT is given below,

Table 1: Quantity of main consoles

Drg. No. Application Qty. (Nos)

Remarks ECAT IFAT

Figure 4.5

Helium gas 1 3 As per Bill of materials in Table 2

in Section 4.1.3

Nitrogen gas 1 3

Total 2 6

4.1.2) Configuration details for gaseous Helium and Nitrogen main consoles

a. The inlet pressure for the main console is 250 bar for Helium, and Nitrogen.

b. The supporting structure for panels at control stations and user point consoles

shall be made up of stainless steel. The stainless steel supporting structure

shall be grouted/ fixed in the wall by the vendor with appropriate anchoring

mechanisms.

c. Vendor shall optimally design the panel sizes and respective final drawings

shall be approved by LPSC, before fabrication and assembly.

d. Complete construction, fittings, tubing in the console shall be made of

stainless steel (SS 316) material and shall be designed with a factor of safety

of minimum four times of operating pressure.

e. Consoles locations shall be provided with schematic diagram of the fluid

circuits with clear identification of valves, etc and its operating positions like

open/close by means of good quality sticker.

f. The following table gives the list of components, brief specifications,

recommended make and materials of construction and the quantity for main

consoles.

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4.1.3) List of components for Main console (Refer Figure 4.5)

Note: Nominal size of each panel shall be, 1.0 X 0.7 X 0.4 meters (Approx.)

Table 2: List of components for main console (Quantity mentioned for one console)

Sl. No

Description/Specification of the components

Qty. (Nos.) (GN2/ GHe)

Recommended make

1.

Check Valve (CV1 & CV2) (To avoid flow in reverse direction)

Operating pressure : 250 bar Body material: SS316

Interface size : ½” interface

02

Swagelok/ Parker/ Hamlet/ GCE/ DK-LOK

2.

Gas filter (F1) Operating pressure : 250 bar

Range: 10µ abs Body material: SS316

Type: Metallic, pleated mesh type Interface size : ½” interface

01

Swagelok/ DK-LOK/

Parker/ Norman/ M/s. Puronics Systems,

Bangalore

3.

Gas filter (F2) Operating pressure : 120 bar Range: 5µ abs

Body material: SS316 Type: Metallic, pleated mesh type


01

Swagelok/ DK-LOK/ Parker/ Norman/ M/s.

Puronics Systems, Bangalore

4.

Pressure gauge (PG1)

Bourdon tube material: SS316 Pressure range: 0-500 bar

Dial size: 6”, Accuracy: 1% FSO

01

Mass/ Wika/ GCE

5.

Pressure gauge (PG2) Bourdon tube material: SS316

Pressure range: 0-300 bar Dial size: 6”, Accuracy: 1% FSO

01

Mass/ Wika/ GCE

6.

Needle Valve (NV1,2,3,4 and 5) Operating pressure : 250 bar

Material: SS316 Type: Full port Interface size : ½” interface

05

Swagelok/ Parker/ DK-LOK/ Hamlet/ GCE

7.

Pressure regulator (PR) Inlet pressure: 250 bar

Outlet pressure: 0 to 120barmax. CV : 0.3

Body Material: SS316 Diaphragm: SS316 Interface size : ½” interface

01

Tescom/ IMF/ Dutch/ GCE

8.

Safety Relief Valve (SRV1& SRV2) Body Material: SS316

Set pressure :132 bar Interface size : ½” interface

02

Swagelok/ Parker/

Hamlet/GCE/ DK-LOK

9. Tubes and Fittings a. Seamless tube:

Tube size: 1/2” OD, thickness

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suitable for the requirement.

(ASTM 269/ equivalent) Material: SS 316 L Operating pressure:250 bar

b. Fittings: Union, Union elbows,

Union tee, reducing unions, cross plugs, bulk heads, caps etc.

Material: SS 316 Operating pressure: 250 bar

Size: As deemed necessary in order to suit the components interface

Sandvik/ Swagelok/ Parker/ Tubacex

Sandvik/ Swagelok/ Parker/ DK-LOK

4.1.4) User point console details

Table 3: User point console details

Drg. No. Gas Line details Qty (Nos.)

Remarks ECAT IFAT Total

Figure 4.6

Helium gas (GHe) 19 18 37 Bill of materials as per Table 4 in Section 4.1.6

Nitrogen gas (GN2) 21 22 43

Total 80

Figure 4.7 Nitrogen gas low pressure (GN2LP)

10 15 25

Bill of materials as

per Table 5 in Section 4.1.7

4.1.5) Configuration for user points consoles

a. The user point consoles in clean room and other facilities shall have regulated

inlet pressure of 120 bar.

b. The user point consoles, for GHe and GN2 shall be comprised of one inlet filter,

one pressure gauge and one needle valve as per section 4.1.6 (Refer Figure

4.6).

c. The user point consoles for GN2 low pressure (GN2LP) shall be comprised of

inlet filter, needle valves, inlet pressure gauge, pressure regulator, safety

relief valve, outlet pressure gauge and outlet filter as per the section 4.1.7.

(Refer Figure 4.7)

d. The user point consoles shall be configured with ½” OD SS tubings.

e. The supporting/ mounting frame/panel shall be made up of stainless steel and

each control panel shall be designed and respective final drawings shall be

approved by LPSC before implementation.

f. The control panels shall be of wall mounting type consisting of specified items

as per section-4.1.6 and 4.1.7.

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g. The Safety Relief valves shall be pre-set to 1.1 times of operating pressure

and shall be provided with locking by wire lock after demonstration.

h. The interconnection shall be made up of welded construction with orbital TIG

welding. The weld joints shall be subjected to radiography test and cleared as

per applicable standards.

i. The component interfaces shall be provided with double compression ferrule

joints.

j. The user point consoles are of wall mountable type. Vendor shall provide the

necessary anchoring/fixing mechanism for wall mounting. Vendor shall provide

the proposed overall size of the user point panels with material,

anchoring/mounting provisions, weight etc. at the time quotation.

k. All the user point consoles locations shall be provided with schematic diagram

of the fluid circuits with clear identification of valves etc and its operating

positions like open/close.

l. All the user point consoles shall be identified with proper colour as per ISO

standard by appropriate good quality sticker.

m. Each user point console shall be provided with schematic diagram indicating

the fluid circuits with valves open/close positions of the valves etc.

n. The following(Sections 4.1.6 and 4.1.7) gives the list of components, brief

specifications, recommended make, material of construction and the quantity

for the user point consoles inside the clean room and other facilities.

4.1.6) List of components for GN2/ GHe user point consoles (Refer Fig. 4.6)

Table 4: List of components for GN2/ GHe user point consoles

(Quantity is mentioned for one Console)

Sl. No


Quantity

(Nos) (GN2/GHe)

Recommended Make

1.

Gas filter (F) Operating pressure : 120 bar



01

Swagelok/ DK-LOK/

Parker/ Norman/ M/s.Puronics Systems,

Bangalore

2.

Needle Valve (NV) Operating pressure : 120 bar Material: SS316

Type: Full Port Interface size : ½” interface

01

Swagelok/ DK-LOK/ Parker/ Hamlet/ GCE

3.

Pressure gauge (PG) Bourdon tube material: SS316

Operating Pressure: 0-150 bar Dial size: 6”, Accuracy: 1% FSO

01

Mass/ Wika/ GCE

4. Tubes and Fittings � Seamless tube:

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Tube size: 1/2” OD, thickness

suitable for the requirement. (ASTM 269/ equivalent) Material: SS 316 L

Operating pressure: 120 bar

� Fittings: Union, Union elbows, Union tee, reducing unions, cross plugs, bulk heads, caps

etc. Material: SS 316

Operating pressure: 120 bar Size: As deemed necessary in order to suit the components

interface


Sandvik/ Swagelok/ Parker/ DK-LOK

4.1.7) List of components for User point console for Low pressure GN2 (Refer

Figure 4.7)

Note: Nominal size of each panel shall be 0.5x0.5x0.4 meters (Approx.)

Table 5: List of components for User point consoles for low pressure GN2

(Quantity mentioned is for one Console)

Sl.

No

Description/Specification of the

components

Quantity

(Nos)

Recommended

Make

1. Gas filter (F1) Operating pressure : 120 bar Range: 10µ abs

Body material: SS316 Type: Metallic, pleated mesh type


01 Swagelok/ DK-LOK/ Parker/ Norman/ M/s.Puronics Systems, Bangalore

2. Needle Valves (NV1,2 and 3)

Operating pressure : 120 bar Type: Full Port Material: SS316


03 Swagelok/ DK-LOK/ Parker/

Hamlet/ GCE

3. Pressure gauge (PG1)

Bourdon tube material: SS316 Operating Pressure: 0-150 bar


01 Mass/ Wika/ GCE

4. Pressure regulator(PR)

Inlet pressure: 120 bar Outlet pressure: 0 to 10 bar max. CV : 0.3

Body Material: SS316 Diaphragm: SS316


01 Tescom/ IMF/ Dutch/ GCE

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5. Safety Relief Valve (SRV)

Body Material: SS316 Set pressure: 11 bar Spring kit for Relief Valve set

Interface size: ½” interface

01 Swagelok/ DK-LOK/ Parker/

Hamlet/GCE

6. Pressure gauge(PG2) Bourdon tube material: SS316


01 Mass/ Wika/ GCE

7. Gas filter (F2) Operating pressure : 10 bar Range: 5µ abs

Material: SS316 Type: Metallic, pleated mesh type


01 Swagelok/ Parker/ Norman/ M/s.PuronicsSystems,

Bangalore

8. Tubes and Fittings

� Seamless tube: Tube size: 1/2” OD, thickness suitable for the requirement.

(ASTM 269/ equivalent)

Material: SS 316 L Operating pressure: 120 bar

� Fittings: Union, Union elbows, Union tee, reducing unions,

cross plugs, bulk heads, caps etc. Material: SS 316

Operating pressure: 120 bar Size: As deemed necessary in

order to suit the components interface


DK-LOK/Sandvik/ Swagelok/ Parker

4.1.8) Tests to be carried out

a. The main consoles for Nitrogen and Helium gas shall be proof pressure tested

for 375bar (1.5 times of 250bar) by isolating the components which are out of

range for this pressure.

b. The user point consoles shall be proof pressure tested for 180bar (1.5 times of

120 bar) by isolating the components which are out of this pressure.

c. Plumbings of GN2 and GHe line originate from gas cylinder and end at main

console shall be subjected to proof test of 500 bar (2 time of 250 bar).

d. Plumbings of GN2 and GHe line start from main console and end at user point

console shall be subjected to proof test of 240 bar (2 time of 120 bar).

e. Leak testing using Helium gas at operating pressure shall meet the specification

of ≤1x10-6Std cc/sec for all the lines including interconnecting lines between gas

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bank room and clean room and other facilities. Necessary Helium gas and MSLD

measurement support will be provided by LPSC.

f. The functional capabilities of all the components shall be demonstrated.

g. All the consoles shall be tested and certified for maximum rated operating

pressure independently

4.1.9) List of items to be supplied as spare separately

Table 6: List of Spares

Sl. No


Recommended make Qty. (Nos.)

1. Check Valve

Operating pressure : 250 bar Body material: SS316 Interface size : ½” interface

Swagelok/ DK-LOK/

Parker/ Norman/ GCE

2

2. Gas filter Operating pressure : 250 bar



Swagelok/ DK-LOK/ Parker/ Norman/ Hamlet/

GCE

2

3. Pressure gauge Bourdon tube material: SS316 Pressure range: 0-500 bar


Mass/ Wika/ GCE 2

4. Needle Valve

Material: SS316 Operating pressure : 250 bar


Swagelok/ DK-LOK/

Parker/ Hamlet/ GCE

4

5. Pressure regulator Inlet pressure: 250 bar Outlet pressure: 0 to 150 bar max.

CV : 0.3 Body Material: SS316

Diaphragm: SS316 Interface size : ½” interface

Tescom/ IMF/ Dutch/ GCE 2

6. Safety Relief Valve Body Material: SS316 Set pressure :132 bar

Interface size : ½” interface Spring kit for Relief Valve set

Swagelok/ DK-LOK/ Parker/ Hamlet/GCE

2

7. Gas filter Operating pressure : 120 bar

Range: 10µ abs Material: SS316 Interface size : ½” interface

Type: Metallic, pleated mesh type

Swagelok/ DK-LOK/ Parker/ Norman/

M/s.Puronics Systems, Bangalore

10

8. Needle Valve Material: SS316

Swagelok/ Parker/ DK-LOK Hamlet/ GCE

15

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Operating pressure : 120 bar


9. Pressure regulator Inlet pressure :120 bar Outlet pressure: 0 to 10 bar max.

CV : 0.3 Body Material: SS316

Diaphragm: SS316 Interface size : ½” interface

Tescom/ IMF/ Dutch/ GCE 2

10. Safety Relief Valve Body Material: SS316 Set pressure:11 bar

Interface size : ½” interface Spring kit for Relief Valve set

Swagelok/ DK-LOK/ Parker/ Hamlet/GCE

2

11. Pressure gauge Bourdon tube material: SS316


Mass/ Wika/ GCE 10

12. Gas filter Operating pressure : 10 bar Range: 5µ abs

Material: SS316 Interface size : ½” interface

Type: Metallic, pleated mesh type

Swagelok/ DK-LOK/ Parker/ Norman/ M/s.Puronics Systems,

Bangalore

2

13. Pressure gauge Bourdon tube material: SS316 Pressure range: 0-20 bar


Mass/ Wika/ GCE 2

4.1.10) ACCEPTANCE CRITERIA AND WARRANTY

Acceptance Criteria: Final acceptance will be after completion of installation,

successful testing, and demonstration of functionality.

Warranty: All the components used in the modules and total module shall have

warranty for a period of one-year minimum from the date of acceptance.

4.2) GENERAL CONDITIONS

1. LPSC will supply the gas cylinders for Nitrogen and Helium. Hence the supplies

of these items are not part of the scope of work.

2. All the components to be purchased from the standard make as mentioned

above in the section of 4.1.3, 4.1.6, 4.1.7, and 4.1.9 with respective warranty

certificates and valid calibration certificates. The items indicated in the section

4.1.9 as spare shall be supplied to LPSC along with delivery.

3. During execution of work, changes/improvements suggested by the party or

LPSC can be implemented with mutual agreement.

4. Vendor shall arrange necessary support equipment, machines, tools,

accessories, etc. LPSC will not provide anything.

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5. All necessary safety precautions to be taken by the vendor during execution of

work and also vendor is responsible for personnel safety of the work force

engaged by him for this work.

6. Detailed technical specification including make, model no. and part number shall

be provided by the party for all the components with certificate of conformance.

7. No inter mixing of components of multi brand for same type of items shall be

allowed to have the warranty and reliability of individual make/brand (For

example in case of supply of valves, all the valves shall be of same

brand/make)

Table 7: Procedure for pickling and passivation of SS tubes

Sl.No. Step Procedure Time

1. Degreasing Using Isopropyl

Alcohol/Tricholoroethylene

10 mins

2. Drying Components are dried at RT 10 mins

3. Alkali cleaning NaOH : 50-100 gm Water : 1000 CC

Temperature : RT

30mins

4. Water rinse Cleaning with water jet till pH

is neutral (6.5-7.5)

05mins

5. Acid pickling Nitrc acid (70%) : 80-100cc

Hydrofluoric acid : 20-30 cc DM/Distilled Water : Remaining

Temperature : RT

15mins

6. Water rinse Cleaning with water jet till pH

is neutral (6.5-7.5)

05mins

7. Passivation Nitric acid (70%) : 200 cc

DM/Distilled Water : 800 cc Temperature : RT

30mins

8. Neutralisation Neutralisation is done in alkaline cleaning solution mentioned in 03

10 mins

9. Water rinse Cleaning with water jet till pH is neutral /7

5mins

10. DM water rinse Cleaning with DM water 5mins

11. IPA rinse Components are rinsed with

IPA for fast drying

5mins

12. Oven drying Components are dried in oven

at 70-800C

60mins

13. Packing and storage Packed in sealed polythene

cover

Notes:

1. The acids, alkalies, solvents always should be of A.R/G.R grade.

2. Fresh solution to be prepared for each batch to carry out pickling & passivation.

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Figure 4.1: Layout of ECAT

P R E

C L E A N RO O M 1 6

G H e

G H e

G N 2

G N 2

G H e

G H e

G N 2

G N 2

G N 2

G H eG H e

G H e

G N 2

G N 2

G N 2

G N 2

G N 2

G N 2

G H e G H e

G H e

G H e

G H e

G N 2

G H e

4 0 5 5 ,4

G N 2 L P

G N 2 L P

G N 2 L P

G N 2

G H e

G N 2

G N 2

C L E A N R O O M

C L E A N R O O M - 2

L A Y O U T O F E C A T G N 2

G H e

G N 2

G H e

G H e

G N 2

G N 2

G N 2 L P G H e

G N 2

G N 2 L P

G N 2 L PG N 2 L P

G H e

G H e

G N 2

G N 2

P H

G N 2 L PG N 2 L P

G N 2 L P

N 2

N 2

H e

H IG H P R E S S U R E

C O M P R E S S O R

R O O M

IN S T R U M E N T A T IO N

R O O M

HIG

H P

RE

SS

UR

E T

ES

T

2 1 0 m ²4 2 .4 m ²

5 5 m ²

C H E M IC A L

S U R F A C E

T R E A T M E N T

F A C IL IT Y

E N V IR O N M E N T A L

L A B

P R O O F

T E S T L A BW IR IN G &

W IN D IN G L A B

C L E A N R O O M - 1

T H E R M A L L A B

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Figure 4.2: Layout of IFAT Ground Floor

LAYOUT OF IFAT

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Figure 4.3: Layout of IFAT First Floor

LAYOUT OF IFAT

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Figure 4.4: Layout of IFAT Second Floor

LAYOUT OF IFAT

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Annexure 5

GENERAL TERMS AND CONDITIONS

1. A pre-bid meeting is scheduled to be held on 3rd January 2020 at LPSC Valiamala at 11 AM by inviting the parties who are interested to participate in the two-part tender for giving them an overall idea about the configuration and

installation of Pneumatic test set ups. This is to enable the parties to understand the technical requirements and criticalities involved. Bidders interested to

participate in the pre-bid meeting may register their name before 5 PM, 2nd January 2020 by sending an email to [email protected] or [email protected].

2. This is a two-part tender. Part 1 is Techno commercial bid and Part 2 is price bid.

PART 1 - TECHNO- COMMERCIAL BID

Techno-Commercial Bid shall include the following documents. a. Technical bid addressing each and every specification and these should be

given in compliance statement for all specifications as given in Annexure 6. b. Schedule of deviations, if any from the tender specification shall be

explicitly spelt out. c. A complete technical description, along with catalogues of the various items

shall be provided along with quotation.

d. Company profile of the vendor highlighting the following shall be given along with quotation:

• Infrastructural facilities such as factory area, machineries, equipment, material handling devices, instruments, tools, tackles, etc owned by the vendor.

• Previous experience: Party shall provide details of similar projects undertaken by them in the past for aerospace or similar applications.

Party shall attach relevant contract/ purchase order copies of the customer and other details to substantiate their claims. Party should have executed at least one similar type of project to reputed firms like

PSU’s, Aerospace/Defence/Reputed private industries. • Clientele specifying the clients to whom the vendor has undertaken

similar projects indicating their address, telephone, fax, email, contact person etc.

• Quality management system: If the vendor is certified for ISO

9000:2000 quality management system, a copy of the certificate by the accredited agency shall be produced.

e. Commercial part of the techno-commercial bid shall address the commercial aspects including filling of compliance statement for commercial terms attached as Annexure along with tender.

f. An un-priced price bid format shall also form part of the Part 1 offer.

NOTE: ANY PART OF PRICE BEING PRESENT IN THE PART 1 WILL LEAD TO AUTOMATIC REJECTION OF OFFER.

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PART 2 - PRICE BID

The price bid shall include the following. a. Total cost of design, Fabrication of all test set ups including installation and

commissioning. b. Cost of spares (cost break up showing cost of each spare part) as per our

requirement & any other spares party recommends for trouble free

operation of the facilities. Cost of each spare is mandatory. c. Cost of Non Comprehensive AMC for two years after the warranty period on

yearly basis shall be quoted separately.

3. Department, based on final evaluation may or may not decide to split the order

among parties. Hence, it is mandatory to quote the cost of each type of facilities with their spare and AMC separately in price bid.

4. PAYMENT TERMS: The Purchaser shall make payment of the price as per the

following milestones:

a. The Purchaser shall pay to the Supplier 30 % of the total price, on receipt of purchase order acceptance against bank guarantee. The payment shall be

released after receipt of invoice (commercially certified) by the Purchaser from the Supplier. The following documents shall accompany the invoice

while claiming this milestone payment: a. Order acceptance from the supplier. b. Bank guarantee for the sum of payment valid till the installation and

commissioning of the items at LPSC, Valiamala. b. The Purchaser shall pay to the Supplier 60 % of the total price, on receipt of

all the items at LPSC, Valiamala. The payment shall be released on receipt of all the items and invoice (commercially certified) from the Supplier. The following documents shall accompany the invoice while claiming this

milestone payment: a. Joint declaration by the Purchaser and the Supplier of having successfully

completed the Pre-Delivery Inspection and subsequent clearance certificate.

c. The Purchaser shall pay to the Supplier 10 % of the total price, upon erection

& commissioning of the all the items at Purchaser’s premises. The payment shall be released after commissioning and receipt by the Purchaser of invoice

(commercially certified) from the Supplier. The following documents shall accompany the invoice while claiming this milestone payment: a. Purchaser’s certification of having successfully completed erection and

commissioning of all the units. b. Warranty certificate

c. Performance bank guarantee for 10% of the total price valid over the warranty period

d. Operation and Maintenance Manuals.

5. Delivery: The overall completion period reckoned from the date of release of

purchase order to the date of completion of erection & successful commissioning of the items at LPSC, Valiamala shall be 8 months.

6. The Supplier shall warrant all the items against any faulty material or

workmanship for a period of 12 months from the date of commissioning at the Purchaser’s site.

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7. Spares and service support for 10 years from the date of supply/ installation of the system to be ensured by the party.

8. PERFORMANCE BANK GUARANTEE

The Supplier shall guarantee the successful and satisfactory performance/

operation of all the items under the conditions and for the services specified. As

a performance security, the Supplier shall furnish a performance bank guarantee

for 10 % of the Purchase Order price to guarantee the faithful performance of all

the items with all the specifications and terms specified herein valid for the

warranty period as specified above. On due performance, the performance bank

guarantee shall be automatically cancelled and returned to the Supplier within

30 days after expiry of the warranty period.

annexure 1 water expulsion test facility...page 1 of 47 annexure 1 water expulsion test facility...

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