chapter 7: technical specifications -...

SPECIFICATION / DATA SHEET

Variable Flow Foam-sum-Water Monitor – Remote Operated

of 26

CHAPTER 7: TECHNICAL SPECIFICATIONS

Equipment: Remote operated Foamcumwater monitor with

Foam Induction Mechanism.

Capacity : Variable flow of 1000, 750 and 500 GPM with single Nozzle.

Type : Nonaspirating.

1.0 SCOPE

This specification covers the requirements regarding design, materials,

fabrication, performance, testing and supply of remote operated foam cum

water monitor to be used for fire fighting. The scope of supply shall include

UL listed or FM approved non-aspirating type foam-cum-water monitor to

be used for fire fighting along with the remote operation mechanism

(remote operated mechanism may or may not be UL listed or FM

approved), Motor Operated Isolation valve & flameproof control panel etc.

to facilitate remote operation of the monitor.

Foam-cum-water monitor is required in the following discharge capacities:

1000 USGPM adjustable to 750 USGPM & 500 USGPM at 7.0Kg/cm2 inlet

pressure with the same single nozzle.

The Monitor shall be designed for mounting on stand posts or elevated

platform /tower at fixed locations.

The monitor shall be capable to give discharge in the form of hollow jet

and spray arrangement.

All the operation of the monitor viz. Horizontal movement, Vertical

Movement, Jet/spray adjustment should be possible manually from

Monitor (without use of power) and remotely from remote control panel.

2.0 MONITOR & FOAM INDUCTION: 2.1 Foam Induction System 2.1.1 Foam feeding shall be by a separate & single aqua powered foam inductor

(JRCP). The induction system shall be UL listed or FM approved for use

along with tendered monitor.

2.1.2 The Foam Inductor should be capable of feeding foam concentrate from a

horizontal distance of minimum 60 meters from the Monitor Nozzle.



of 26

2.1.3 The inlet and outlet of foam Inductor shall be provided with standard male and

female instantaneous couplings as per UL/FM Std.

2.1.4 The length of the foam pick up tube shall be 3-4 Meters. It should be

possible to induct 3% foam for all the flows, however, variation of +20% of

the induction rate is permissible. Manual valve shall be provided at foam

inductor to set foam induction as per 1000 USGPM, 750 USGPM or 500

USGPM water flows. 2.2 Monitor

2.2.1 The monitor shall be able to discharge 1000 USGPM, 750 USGPM and 500 USGPM (depending upon adjustment at the Nozzle) at a pressure of

7.0Kg/CM2 (g) at the mating/mounting flange. The foam compound shall

be AFFF/AR-AFFF. 2.2.2 The nozzle shall produce foam with foam expansion ratio 1:3 to 1:4. 2.2.3 The pattern of the Water/foam jet nozzle shall be adjustable from straight

to 140 deg wide spray. 2.2.4 The monitor shall have traversing mechanism to give 340 deg. in either

direction in horizontal plane and +90 deg. & -15 deg in vertical plane

through swivel joints operated by worm and worm wheel operated geared

unit. There shall be separate hand wheels for horizontal and vertical

movement of the monitor. The arrangement shall be such that monitor

movements can be done by a single person. All the gear mechanisms

shall be sealed by proper enclosure to avoid accumulation of dust on

lubricated parts. Both the traversing mechanisms shall be self locking type.

2.2.5 The Swivel Joints shall have SS ball bearing with efficient sealing. 2.2.6 The monitor shall be variable flow adjustment type and it should be

possible to set all three flow rates easily and quickly at site by the operator. 2.2.7 There shall not be any flanged joint on the monitor body, except one at

base flange. Other Joint between monitor body & nozzle shall be threaded

type. Monitor body shall be single cast without welded joints and tubing.

2.2.8 A pressure gauge to indicate the inlet pressure shall be fitted on the

monitor body near inlet of nozzle. Pressure drop across the monitor shall

be less than 10 PSI. 2.2.9 A drain connection with valve shall be provided near the base flange. 2.2.10 Monitor will be painted with Paint – RAL 3000, two part polyurethane

coating.



of 26

2.2.11 The monitor shall be so designed as to resist the nozzle reaction forces

during operation and shall be capable of being handled by one person. 2.2.12 It should be possible to operate the monitor at 10.5 Kg/cm2 pressure at

Inlet flange. 3.0 MATERIAL OF CONSTRUCTION

Item/Part Material of Construction

Nozzle SS316 L/Brass

Monitor Body SS316 L /Cast Brass

Flange SS316 L /Brass

(150 LBS, ANSI B16.5 rating size 100 mm)

Swivel Joints SS316 L /Brass

Worm SS316 L /Brass

Gear

SS316 L /Brass

Spindle for worm

SS316 L /Brass

Hand-wheels for Nozzle, SS316 L /Brass

horizontal/vertical movement

Pick up tube (3-4 meter length) PVC reinforced with high tensile steel

wire helix as per ASTM D1785 sch.80

Drain connection

SS316 L /Brass

Drain valve

SS316 L /Brass

Foam strainer(removable type) SS316 L / Brass

Foam Inductor SS316 L / Brass

Foam Inductor Couplings(63 mm) SS316 L / Brass

Nuts/bolts at Monitor SS-316 L/Brass

Mounting Brackets for Motors/Limit SS316 L /Brass

switches.

4.0 APPROVAL

The Monitor, Foam Nozzle and Foam Induction device shall be UL Listed

or FM approved with following features:

i) Nozzle : Non-Aspirating type



of 26

ii) Monitor Flow : 1000 USGPM, 750 USGPM & 500 USGPM

foam solution with single nozzle.

iii) Operating Pressure : 100 PSI

iv) Induction : Aqua Powered variable flow Foam Inductor (single)

suitable for all the three flow rates (1000 USGPM,

750 USGPM & 500 USGPM) of monitor.

Instruments certified for use in the specific hazardous area classification shall

have certifications/ approvals from accredited international agencies like FM,

ENELEC, PTB, BASSEFA, ATEX,etc.

All enclosures for electrical equipment shall be suitable for use in Hazardous

are as per Haz. Area Classification and vendor shall submit valid test certificate

issued by CIMFR & PESO. Flameproof enclosures and instruments which are

manufactures outside India and certified by accredited international authorities

shall also have approval of PESO, India. In case bidder has got only

international approval on hand at the time of bid due date and already applied

for PESO approval, then bidder shall be required to get PESO approval before

despatch of materials. Bidder has to submit undertaking along with bid for that

effect and mention timeline of obtaining PESO approval. Decision of HPCL shall

be final and binding on the bidder in this regard.

ALL DOUBLE COMPRESSION FLP CABLE GLANDS AND PLUGS FOR THE

HVLR AND CONTROL PANEL SHALL BE PROVIDED BY THE VENDOR.

UNUSED ENTRIES SHALL BE FITTED WITH FLP PLUGS.

5.0 REMOTE CONTROL SYSTEM

Remote Control System shall be provided for horizontal and vertical

rotation of the monitor from the flameproof control panel to be supplied

along with the monitor. Jet and spray movement of the monitor nozzle

shall also be remotely from the control panel. The remote control system

shall be electrically operated.

5.1 Control Panel shall have minimum following indication and control

functions for each monitor.

a. Joystick / Push Buttons with indication for up, down, right and left

movements on the nozzle.

b. Push button/joystick with indication for adjustment of spray / jet.

c. Push Buttons with indication for Open/Close of Motor Operated

Isolation valve.

d. Indication Lamps for Power available.



of 26

5.2 Control Panel shall be complete with motor starters consisting of required rating

AC-3 motor duty switch, fuse, contactor and bimetal overload relay to suit motor

rating, motor start / stop push button, selector switch, voltmeter etc. and

suitable structural frame for mounting of the panel.

5.3 Controls panel shall be PLC based & mounted in flameproof enclosure. The

control panel shall be minimum Ex-n / Ex-e / Ex-d type in flameproof enclosure

suitable for Zone -2, Gas group – IIA / IIB with GI sheet canopy. Weather

protection for motor enclosure shall be minimum IP55. FM/UL approved

enclosure for Zone 2 environments will also be acceptable. The

monitor movement & controls shall be programmable by solid state

devices.

PLC shall be suitable for installation in flameproof panel installed outdoor. It

shall work & perform satisfactory in hot & humid atmosphere of coastal area.

PLC system shall have processor & power supply redundancy. Shall have 25%

I/O spare (wired). Power On, System Healthy & Common Fault alarm shall be

provided for remote monitoring.

Control of the rotation, elevation and nozzle pattern (fog – jet) of the

RCM shall be by solid state devices housed in general purpose enclosures

and FM/UL approved for Zone 2 environments.

A solid state Motor Drive unit will contain the following features:

Solid state is defined as - silicone based devices (microprocessors, transistors, FET‟s, SCR‟s, etc.)

There are no arcing or sparking components permitted in the solid state Motor Drive Unit.

Directional signal inputs (rotation, elevation & pattern) and corresponding outputs to the motors are short circuit protected.

The electrical power to the monitor motors includes electronic current limiting protection to prevent the motors from operating outside of their design parameters.

A microprocessor is used to process logic signals, monitor motor current and provide motor drive diagnostics.

Power outputs to the RCM motors are handled by solid state relays or equal.

5.3 Input power requirement is 240 VAC, 1 Phase, 50/60 Hz, 15 Amp

5.4 Electrical enclosure is either NEMA 4X, or Flameproof

5.5 FM/UL Approved for NEC Class 1, Div 2, Groups B, C & D Locations



of 26

5.6 Motor shall be minimum Ex-n / Ex-e / Ex-d type suitable for Zone – 2, Gas group

IIA / IIB, temperature class: T3. Weather protection for motor enclosure shall be

minimum IP55. All the motors installed at monitor shall comply with

requirements enclosed as Annexure-A.

5.8 4 inch size Motor operated Isolation valve (MOV) shall be supplied along-

with each monitor . Specifications of Isolation valve to be used for MOV

are enclosed as Annexure-B. 5.9 The electrical motor operated valve actuator for the isolation valve shall be

minimum Ex-n / Ex-e / Ex-d type suitable for Zone – 2, Gas group IIA / IIB

& temperature class: T3. Specifications of the Motor operated valve

actuator are enclosed as Annexure – C.

5.10 Minimum conductor size for power cable for Control panel shall be 4 mm2

copper and all cables between control panel & monitor junction box shall be 1100 V grade PVC insulated, PVC sheathed, armoured fire retardant type. The power cables from monitor junction box to monitor motors and limit/proximity switches shall be flexible fire retardant type.

5.11 Power and Signal cable of 200 meters length for each motor shall

be provided along with the supplies for connection between the monitor

motors and control panel. Flameproof Junction Box, Signal & power cable

of 200 meters length for motor operated isolation valve and common cable

tray for above cables shall be supplied along with each monitor. Power

supply cable from emergency feeder to control panel and shall be under

purchaser‟s scope.

6.0 With pressure of 7 Kg/CM2 (g) at base flange, and Nozzle at 300 to 35 deg. from

horizontal the Monitor shall be capable of giving following performance:

Flow Minimum Horizontal Minimum Horizontal

Unit :USGPM Water Throw Foam Throw

(Unit : Meters) (Unit : Meters)

1000 70 64

750 60 55

500 50 45

Throw to be calculated on the basis of arithmetic average of throws (measured

from monitor base flange to approximate centre of the footprint) in downwind &

upwind directions at prevailing wind speed (maximum 4 KM/hr.) at the time of



of 26

performance test. Flow Variation of + 5% is permissible.

7.0 WORKMANSHIP AND FINISH

All the parts shall have good workmanship and finish. All burrs and sharp

edges shall be removed. Passages for foam/water shall have smooth

finish. 8.0 PAINTING AND MARKING 8.1 All external surfaces shall be properly shot blasted & provided with two

coats of primer followed by two coats of final paint finish of 50 micron. 8.2 Each monitor shall be clearly and permanently marked (embossed on SS

plate) with the following:

a) Manufacturer's/Supplier‟s name b) Year of manufacturer c) Purchaser‟s name and order reference d) Capacity e) UL/FM marking for monitor.

9.0 SITE WORK 9.1 During erection, installation and commissioning of the monitor at site,

vendor shall have to depute their supervisor for two days for each

monitor at vendors cost.

9.2 Vendor shall depute the supervisor for assistance in installation/

commissioning within 10 days of call from the purchaser. 9.3 Vendor shall submit per man-day charges of supervision along with the

priced offer for any requirement of supervision during installation beyond

two days. The per man-day charges quoted by the bidder towards

commissioning assistance shall be inclusive of to and fro transportation,

boarding, lodging, fooding and other logistics charges etc

10.0 EXCLUSION 10.1 Fire water mains up-to inlet base of monitors is excluded from vendor‟s

scope. 10.2 Construction of Elevated platform / Structure. 10.3 Power supply up to the monitor control panel. 10.4 Erection of monitor, MOV & Cables.

11.0 INSPECTION & TESTING



of 26

Prior to dispatch from vendor‟s shop the following acceptance tests shall

be carried out by the vendor to the complete satisfaction of owner‟s

representative/HPCL authorized third party inspection agency(TPIA)

without any extra cost to owner. All consumable (e.g. water, foam

compound etc.) shall be arranged by vendor at his own cost. Vendor shall

arrange all facilities to carry out inspection & testing as follows:

Positive Material Identification (PMI) test for 10% of the monitors.

Visual and dimensional check.- 100%witness by TPIA

• Hydraulic test of each monitor body at minimum 25 Kg/CM 2 or

hydraulic test pressure specified by UL Listing/ FM approval whichever is higher. The pressure shall be held for minimum five minutes without any leakage or distortion of any part. 100% performance by vendor, 20% witness by TPIA

Performance test shall be carried out for minimum 20% monitors.

In case lot size is less than 10 monitors than minimum 2 monitors shall be subjected to performance test. Testing shall be carried out to verify the following performance parameters as per above specification :

a) Measurement of Flow Rates(1000 ,750 & 500 USGPM) at 7 Kg/cm2 pressure at inlet flange.(Variation of +5% is acceptable)

b) Horizontal Movement at 1000 USGPM flow manually by hand wheel & from remote panel.

c) Vertical Movement at 1000 USGPM flow manually by hand wheel & from remote panel.

d) Jet/spray pattern adjustment manually using lugs/handle & from remote panel.

e) Checking operation of all limit/proximity switches. f) Horizontal Throw for foam & water at all the three 1000,

750 & 500 USGPM settings (pressure at inlet flange 7 Kg/cm2)

g) Foam Expansion ratio 1:3 to 1:4. h) Induction rates at all the three1000, 750 & 500 USGPM

settings. i) Smooth functioning of Changeover of flows by single

person without using tools.

Routine test as per applicable Indian Standards for all the

motors. Owner or his representative shall have access at all

reasonable times to vendor‟s works where the appliance or

its accessories are being fabricated and tested.

VALVE: Every valve, its components and auxiliaries must be subjected to all the

mandatory tests and checks called for in the respective codes, datasheets etc. by the



of 26

manufacturer. Vendor shall arrange Inspection by approved third party inspection

(TPI)agency. The inspection plan shall be approved by the purchaser and shall include:

a) Visual and dimensional inspection

b) Review of material test certificates.

c) Review of radiographs/radiographic reports or any other NDT tests wherever

applicable as per data sheet.

d) Strip check is required for 1% of total ordered qty. of valves (min.1No.) Samples for

strip check shall be selected at random and shall generally be in the highest size in the

lot.

e) Functional / operational checks for Motorized operation as per the requirements of

the specifications shall be made on each valve.

ACTUATOR: The actuator shall be subject to inspection by Approved TPIA.

Manufacturer shall furnish all necessary information concerning the supply to Owner.

During the course of manufacturing, the purchaser or his authorized representative

shall be free to visit the works and assess the progress of work and the manufacturer

shall render him all possible assistance to do so.

Following routine and acceptance tests shall be carried out at the manufacturers’

works under his supervision and at his own cost for all the actuators.

a) Functional and calibration test for torque and limit switches

b) Response time test

c) Variation of supply voltage

d) Variation of frequency

e) Tests for motor (As per relevant IS/ IEC)

f) Life test

g) Test on output shaft

Tests listed at Cl. nos. (b), (c), (d), (e), (f) and (g) above arethe acceptance tests.

Type test certificates, original drawings referred in certificates and statutoryapproval

certificates and BIS license, where applicable, shall be shown to theinspection agency

on demand. The certificates and BIS license must be valid atthe time of dispatch.

Test certificates of bought-out components shall be shown to the inspectionagency on

demand.



of 26

12.0 Approved Third Party Inspection Agency: BV / DNV/ CEIL/Lloyd’s/ IRS

/UL/TUV/FM

13.0 INFORMATION/DOCUMENTS REQUIRED FROM VENDOR 13.1 WITH BID

a. Details and drawings of the offered foam cum water monitor with bill of

material of monitor & accessories. Details & Drawings shall be in line

with UL listing or FM approval document of the vendor. b. Performance details like

Projectile curves of both water and foam streams showing horizontal & vertical throw for foam and water for all the three flow rates at Nozzle angles 30, 45, 60 and 75 degree from horizontal planes.

Foot print (shape, size, area) of both streams at landing zone. c. K-factor of the nozzle with supporting calculations. d. Pressure drop across the monitor.

e) Vendor to give details of the proposed foam induction system and

schematic sketch of the monitor with Foam induction and foam source

along with the technical bid.

f) Valid certificates of UL Listing or FM approval of offered manually operated foam-cum water monitor, foam nozzle and foam induction mechanism. NON SUBMISSION OF UL/FM LISTING/APPROVAL SHALL LEAD TO REJECTION OF BID.

g) General Arrangement Plan (GAP) incorporating the stipulated inspection and testing requirements.

h) List of electrical spares for remote panel & all motors for three years of

operation.

i) Power requirement and cable size for cabling between emergency feeder

and Control Panel. ( in owner’s scope)

j) Various Cable incl. sizing between control panel and monitor. ( In

vendor’s scope)

k) Make and model of MOV , Gate Valve & Control Panel.

l) Make and Model of PLCs & I/Os.

13.2 AT THE TIME OF SUPPLIES

Three sets of documents (duly certified) to be provided.

a) As built drawings of monitor assembly. b) Electrical circuit diagrams for junction boxes & remote panel. Cable

termination details & cable schedule. c) Installation procedure. d) All inspection and testing records. e) CMRI/DGMS/PESO/ATEX approval for flame proof enclosures for

motors & panel.



of 26

f) Operating and Instruction manual. g) Testing and maintenance procedure/manual.

14.0 Commissioning Assistance: The owner shall give commissioning call through e-mail/ Fax to the vendor, the vendor shall depute their representative within 10 days of the commissioning call failing which owner may proceed ahead with commissioning through other party at the risk and cost of the vendor. The broad scope of erection and commissioning includes but not limited to the following:

a. Erection Supervision of HVLR and its components

b. Supervision of cable laying ,terminations and earthing. Earthing Boss shall be provided for all electrical equipment as per OISD guidelines.

c. Basic Training to Operating Personnel at Site

d. Checking of mechanical and electrical functionality of HVLR and all its components and providing final clearance for powering up of control panel and commissioning of monitors.

e. Commissioning spares, if applicable has to be provided by the vendor and the same is deemed to be included in the quoted rate.

f. Owner shall arrange for erection team with standard tools and tackles required for erection, cable termination etc. Special commissioning and testing tools, if required shall be arranged by vendor.

g. The PLC functioning shall be demonstrated during commissioning.

h. Commissioning report to be prepared and jointly signed by vendor and owner.



of 26

Annexure-A

Specification for Motors for Monitor Movement 1. Codes and Standards:

The Motor and their components shall comply with the latest editions of

relevant standard issued by BIS (Bureau of Indian Standards).

In case of imported motors, standards of the country of origin shall be

applicable, if these standards are equivalent or stringent than the

applicable Indian Standards.

The motor shall also conform to the provisions of Indian Electricity Rules

and other regulation currently in force in the country.

In case, Indian standards are not applicable or not covering any part , the

standards issued by IEC /BS /VED /IEEE /NEMA or equivalent agency shall

be applicable.

In case of any contradiction between various referred standards /

specifications / Data sheets and statutory regulations the following order

shall be govern. - Statutory Regulation - Tender specification - Code and standards

3. Operating Conditions: 2.1. Ambient Conditions

Motor shall be suitable for operating satisfactorily in humid and corrosive

atmosphere found in refineries, petrochemical plants. Design ambient

temperature of 45º C and an altitude not exceeding 1000M above mean sea

level shall be taken in to consideration. Motor shall be operable under hot &

humid outdoor weather conditions encountered in India. 3. Frequency and Voltage

Unless otherwise agreed motor shall be designed for operation at rated

output under the following conditions:

a) The terminal voltage differing from its rated value by not more than

± 6 % or

b) The frequency differing from its rated value by not more than ± 3 % or

c) Any combination of (a) and (b)



of 26

4. Starting 4.1 Unless otherwise specified, motor shall be designed for on-line starting with

suitable protection. 4.2 Motor shall be designed for reacceleration under full load after a momentary

loss of Voltage with residual voltage being 100 % and is in phase opposition

to the applied Voltage. 4.3 Unless otherwise specified, all motors shall be suitable for starting under

specified load conditions with 75% of the rated voltage at the motor

terminals. 5. Performance

- Motor shall be rated for intermittent duty cycle (S3), unless otherwise

specified.

- Unless otherwise specified, the starting current (as % rated current) shall not exceed 600% subject to tolerance.

- In particular cases, when the starting with reduced voltage is specified,

care shall be taken such that the design values of torque meet the load

requirement while at the same time complying to starting conditions

mentioned above in S.No.4. 6. Construction 6.1 Insulation

Unless otherwise specified the motor shall be with Class „B‟ insulation as a

minimum. In case of motor with class „F‟ insulation the permissible

temperature rise above the specified ambient temperature shall be limited to

those specified in the applicable Indian Standard for class „B‟ insulation.

In case of motors driving equipment with pulsating loads, special care shall

be taken for the joints of rotor bars and end rings to avoid premature failure

due to induced fatigue stress. 6.2 Terminal Box and Cable entries

The terminal box shall be suitable enough to facilitate easy connection of the

cables. The terminal box shall be with necessary clearances, creepage

distances between live parts and between live parts to earth considering air

insulation and without any compound filling.

The terminal box shall be provided with cable lugs and entries for suitable

cable glands corresponding to the size of the specified cable. Nickel plated

brass (or aluminium if specifically required) , double compression type cable



of 26

glands / flame proof cable gland shall be supplied along with the motors for

the specific cable size.

Equipment and accessories shall conform to the hazardous area

classification and the environmental conditions as specified.

The terminal box shall be capable to withstand internal short circuit

conditions without danger to personnel or plant.

Appropriate phase markings as per IS shall be provided inside the

terminal box. The marking shall be non removable and indelible.



of 26

Annexure –B

SPECIFICATION FOR ELECTRICAL MOTOR OPERATED TRIPLE OFFSET BUTTERFLY VALVE

1. Technical Data Sheet For Triple Offset Butterfly Valve

DATA SHEET – VALVE

1 Valve Size As per BQO

DESIGN PARTICULARS

2 Valve Type Triple Offset high performance , metal to

metal seated, non-rubbing, torque seated, double flange end, quarter turn, anti-static,

anti-blow out stem arrangement butterfly valve. Complete actuated valve shall be SIL3

capable certified by third party agencies like

TUV/Exida

3 Mfg. Standard API 609

4 Face to Face As per API 609, Long Pattern

5 Inspection and

Testing

API 598

6 Fire Safe API 6FA/API-607-Vth Edition, Zero leakage

before, during after fire.

7 ANSI Class 150#

8 Rated Travel 90 Degrees

9 Flow direction Bi-directional, tight shut-off in either direction

10 Fire Safe Required

11 Anti Static Device Required

CONSTRUCTION

12 Body Cast (in Single Piece)

13 Disc Cast

14 Stem Bar-forged (No casting)

15 End Connection Double flanged as per ANSI B 16.5RF



of 26

16 Flange & finish 150#, RF, 63-125 AARH, smooth finish

MATERIAL

17 Body ASTM A216 Gr. WCB

18 Disc ASTM A216 Gr. WCB/ASTM A105

19 Seal Ring UNS S 31801 Duplex SS+ Graphite

20 Stem ASTM A182F6a

21 Bushing UNS S31600

22 Disc Retainer

Flange

ASTM A 516

23 Disc and Bottom

Flange

UNS 31600+ Graphite

24 Seat Stellited Gr. 21 Weld Overlay

25 Pin/Nut/Washers SS 316

26 Thrust Bearing SS 316/ Hardfaced /Cobalt based alloy

TESTING

27 Body Hydro-test 1.5 times the flange rating (30 bar #150)

28 Seat Hydro-test 22 bar #150, test duration as per standard

29 Pneumatic Seat Test

NA (6 bar # 150)

30 Leakage Class

required

Zero Leakage/ bubble tight shutoff

2.0 Technical Notes for Triple Offset Butterfly Valve

2.1 General

a) Vendor shall supply valves in accordance with the valve

specification sheets along with auxiliaries, if any, such as gear

operator, bypasses, drains etc. wherever specified in the

specification sheets, subject notes and other enclosures.

b) Vendor shall quote in strict accordance with the valve data /

specification sheets, subject technical notes and all other



of 26

enclosures.

c) All codes and standards for manufacture, testing, inspection etc.

shall be of latest editions.

d) The offered equipment shall be brand new with state of the art

technology and a proven field track record. No prototype

equipment shall be offered.

e) Vendor shall ensure availability of spare parts and maintenance

support services for the offered equipment for at least 15 years

from the date of supply. The vendor shall be responsible for

design, engineering and manufacturing of the complete valve to

fully meet the intent and requirements of this specification and

attached data sheets. 2.2 Documentation

Vendor shall submit the following documents with the offer:

a) Manufacture‟s complete descriptive and illustrative catalogue / literature.

b) Detailed dimensioned cross section drawing with parts / material lists,

weight etc.

c) One copy of the valve specification sheets signed as “Accepted” with all

deviations marked clearly.

The following documents shall be submitted after placement of the order:

a) Material test certificates (physical properties, chemical composition &

heat treatment report) of the pressure containing parts shall be

furnished for the valves supplied. Material test certificates for the other

parts shall also be furnished for verification during inspection.

b) Catalogue/Drawings (3 sets) shall be furnished along with delivery for

Purchaser‟s record for all categories/types of valves. 2.3 Design and Construction

a) Valve shall be designed, manufactured, tested, inspected and marked

as per the manufacturing standards, design codes and standards (latest

editions) indicated in the valve specification sheet.

b) Valves shall have flanges integral with the valves body. Flange face

finish shall be normally specified in the valve specification sheet as

serrated finish, 125 AARH.

c) Valve body / bonnet shall be forged / cast as specified. Forgings are



of 26

acceptable in place of casting but not vice-versa.

d) Material of construction of yoke shall be minimum equivalent to body /

bonnet material.

e) Stem shall be forged or machined from forged / roller bar. No casting is

permitted. However, integral stem of cast stainless steel ball valve is

acceptable.

f) Stencilling / hard-facing by deposition shall be minimum 1.6 mm.

g) Renewable seat rings shall be seal welded to prevent loosening of service.

h) Spiral wound bonnet gaskets are to be provided with inner / outer ring

except when encapsulated gaskets type body-bonnet joints are employed. 2.4 Inspection and Testing

a) Every valve, its components and auxiliaries must be subjected to all the

mandatory tests and checks called for in the respective codes, data sheets

etc. by the manufacturer.

b) Vendor shall arrange Inspection by approved third party inspection (TPI)

agency. The inspection plan shall be approved by the purchaser and shall

include :

i. Visual and dimensional inspection

ii. Review of material test certificates.

iii. Review of radiographs/radiographic reports or any other NDT tests

wherever applicable as per data sheet.

iv. Strip check is required for 1% of total ordered qty. of valves (min.

1No.) Samples for strip check shall be selected at random and shall

generally be in the highest size in the lot.

v. Functional / operational checks for Motorized operation as per the

requirements of the specifications shall be made on each valve. 2.5 Marking

a) Vendor‟s name, valve rating, material designation, nominal size, direction of

flow (if any) etc. shall be integral on the body.

b) Each valve shall have a corrosion resistant tag giving size, valve tag /

code no. securely attached to the valve body.

c) Paint of ink for marking shall not contain any harmful metal or metal salts



of 26

such as zinc, lead or copper which cause corrosive attack on heating.

d) Valves shall be painted with one coat of inorganic zinc silicate (minimum

DFT 65 to 75 microns). 2.6 Packing

a) Valve shall be dry, clean and free from moisture, dirt loose foreign

materials of any kind.

b) Valves shall be protected from rust, corrosion and any mechanical

damage during transportation, shipment and storage.

c) Each end Flange Face of valve shall be protected with Wood or Plastic

Cover.



of 26

Annexure -C

SPECIFICATION FOR ELECTRICAL MOTOR OPERATED VALVE ACTUATOR

1.0 SCOPE

The scope of this specification covers design, manufacture, assembly, shop

testing and supply of electrical motor operated valve actuators intended for

fully / partially opening and closing valve duty. This specification does not

cover the actuators for flow regulating duty. 2.0 CODES AND STANDARDS 2.1 The equipment shall comply with the requirements of latest revision of the

following standards issued by BIS (Bureau of Indian Standards) unless

specified otherwise:

IS 5 Colors for ready mixed paints and enamels

IS 325 Three-phase Induction Motors

IS 2148 Flameproof enclosures for electrical apparatus

IS 4691 Degrees of protection provided by enclosure for rotating

electrical machinery.

IS4722 Rotating electrical machines – Specification

IS 9334 Electric Motor Operated Actuators

IS 13947 Low Voltage Switchgear and Control gear(Parts –1, 3, 4&5) 2.2 In case of imported equipment, the standards of the country of origin shall

be applicable if these standards are equivalent or more stringent that the

applicable Indian standards. 2.3 The equipment shall also conform to the provisions of Indian Electricity

Rules and other statutory regulations currently in force in the country.

2.4 In case Indian standards are not available for any equipment, standards

issued by IEC/ BS/ VDE/ IEEE/ NEMA or equivalent agency shall be

applicable. 2.5 In case of any contradiction between various referred standards / data

sheets and statutory regulations, the following order of decreasing priority

shall govern:

a) Statutory regulations



of 26

b) Tender specification c) Codes and standards

3.0 GENERAL REQUIREMENTS 3.1 The offered equipment shall be brand new with state of the art technology

and a proven field track record. No prototype equipment shall be offered. 3.2 Vendor shall ensure availability of spare parts and maintenance support

services for the offered equipment for at least 15 years from the date of

supply. 3.3 The vendor shall be responsible for design, engineering and

manufacturing of the complete actuator to fully meet the intent and

requirements of this specification. 4.0 TECHNICAL SPECIFICATIONS

Each MOV actuator shall include the motor, actuator unit, gears, position

indicators, limit switches, hand wheel, electrical starter and controls,

terminal box etc. as a self-contained unit. The actuator shall be sized to

provide adequate torque and/ or thrust to ensure the complete intended

travel of the valve under the worst operating and electrical power supply

conditions.

MOV Actuator shall be minimum Ex-n/Ex-e /Ex-d type suitable for Zone–2,

Gas group IIA /IIB, temperature class: T3 & shall meet the requirements of

IS 2148, IEC 79 or equivalent international standards. Weather protection

for motor enclosure shall be minimum IP55. The manufacturer shall

possess valid test certificates issue by a recognized independent test

house (CIMFR/ BASEEFA/ LCIE/ UL/ FM or equivalent) for the offered

actuators. All indigenous equipment shall conform to Indian standards and

shall have been tested and certified by Indian testing agencies. All

equipment (indigenous and imported) shall also have valid statutory

approvals as applicable for the specified hazardous locations from

Petroleum and Explosives Safety Organization (PESO)/ CCE or any other

applicable statutory authority. All indigenous flameproof equipment shall

have valid BIS license and corresponding marking as required by statutory

authorities. 4.1 Motor 4.1.1 The motor shall be 3-phase squirrel cage induction type unless specified

otherwise in the data sheet. It shall have totally enclosed, non-ventilated

construction.



of 26

4.1.2 The motor shall be designed for valve actuator service with high starting

torque and shall be suitable for Direct on line starting. It shall be rated for

S2-15 minute duty and shall conform to IS 325 or equivalent international

standards. 4.1.3 The motor shall be provided with thermister(s) embedded in the hot spots

of motor winding for protecting the motor. 4.1.4 The motor shall be suitable for starting under required torque with 75% of

rated voltage at motor terminals. 4.1.5 The motor shall have class „F‟ insulation with temperature rise limited to

class „B‟ limits. Motor winding shall be treated to resist corrosive agents

and moisture. 4.1.6 Motor rotor shall preferably be of die-cast aluminum and, if brazed, shall

be free from phosphorous. 4.2 Integral Starter and Control Transformer

The reversing starter, control transformer and local controls shall be

integral with the valve actuator. Solid state control of valve actuator and

electrically isolated interface for remote control requirement shall be

provided, wherever these features exist in manufacturer‟s design.

The integral starter shall be supplied with the following devices:

a) Electrically and mechanically interlocked reversing contactors for

opening and closing operations.

b) Control transformer with necessary tapings and protected with suitable

easily replaceable fuses.

c) Terminal block for external cable connection fully prewired for internal

devices of valve actuator.

d) MOV actuators operating with AC power supply shall be provided with

Instantaneous Phase reversal protection. 4.3 Integral Push Button, Selector switches, Indications and Control devices

The following local control devices shall be provided integral with the MOV

actuator:

a) Push buttons for “Opening/ Closing/ Stop” or alternatively “Open/ Close”

selector switch.

b) Local/ Off/ Remote selector switch, pad-lockable in each position.



of 26

c) Local continuous position indication from “Valve fully open” to “Valve

fully closed” position, which may be of analogue or digital type using

mechanical indication/ Indicating lamps /LEDs. 4.4 Torque and Travel Limit Switches

Torque limit switches shall be provided to protect the motor from over-

loading by cutting-off the power supply to motor during opening and

closing operations. The limit switches shall be preset. However, it shall be

possible to set the value of maximum torque during closing from 50% to

100% of rated torque of actuators. Travel limit switch shall be provided to

cut-off the power supply to the motor at the end of preset limit of valve

travel. The switches shall be provided with requisite number of potential-

free contacts for valve actuator operation and for indication on remote

panels. Instead of mechanical torque limit switches, magnetic pulse

counter / encoders to measure and control the stroke of actuator may be

provided, wherever this feature exists in manufacturer‟s design. 4.5 Control Facilities

The internal controls and monitoring circuits shall be incorporated within

the integral starter along with transformer and control unit of valve

actuator.

Remote control facility shall be provided as a standard feature. The remote

control circuits shall be powered from internally derived control supply

voltage.

Common status contact indicating the availability of the MOV actuator for

remote control shall be provided by monitoring the following:

- Loss of one or more phases of power supply

- Loss of control circuit supply

- Selector switch in local mode

- Local stop push button set to “Off”

- Motor thermostat tripped

- Any other local fault/ abnormal condition 4.7 Hand Operation

A hand wheel with auto lockable lever shall be provided for emergency

operation of the MOV. The energisation of the motor shall automatically re-

engage power operation.



of 26

4.8 Nameplate

Each motorized valve actuator shall be provided with a stainless steel

nameplate furnishing the following details, attached firmly to it at a place

convenient for reading:

a) Actuator tag number

b) Motor kW rating, motor time rating, motor supply voltage, nominal motor

phase current, auxiliary switch rating

c) Maximum torque setting

d) Actuator enclosure type, lubricant type

e) Actuator type, wiring diagram number/ catalogue number, actuator

serial number

Apart from the nameplate indicating the Tag Number a separate

nameplate shall also be provided on each actuator to indicate the details

of the testing agency (CIMFR or equivalent), test certificate number with

date, statutory approval

number with date, approval agency for hazardous area application (PESO/

CCE/ DGMS or equivalent), BIS license number with date, applicable Gas

group and Temperature class etc. the nameplate shall be riveted/ fixed

with screws and not pasted. In case any of the standard details listed

above are embossed on the enclosures, the same need not be repeated. 4.9 The enclosure of complete MOV actuator including motor, integral starter,

control transformer unit and all control devices shall have minimum IP-55

degree of ingress protection. 4.10 Wiring and Terminals

All devices provided in the actuator shall be wired up to the terminal block.

The contacts for remote operation and indication shall also be wired up to

the terminal block. Minimum 10% spare terminals shall be provided for

future interlocks. Internal wiring for power and control circuits shall be

appropriately sized for MOV actuator rating. Each wire shall be identified at

both ends using PVC ferrules. The terminal compartment shall be

separated from the inner electrical components of the actuator by means

of a watertight seal so that the actuator electrical components are

protected from the ingress of moisture and foreign materials when the

terminal cover is removed during installation and maintenance.



of 26

4.11 Vendor shall be solely responsible for the compatibility of the MOV

actuator with the valve and for the selection and sizing of various electrical

devices and components in the actuator. 4.12 The actuator shall be provided with minimum three adequately sized cable

entries viz., one for power cable and two for control cables. However, the

actual number of control cable entries in actuator with 2-wire control

system shall be provided based on job requirements as specified in data

sheets/ specification for control systems for MOVs. Suitable double

compression cable glands shall be provided with each actuator for all

cable entries and sealing plugs for all control cable entries. The cable

glands and plugs shall be made of Nickel-plated brass. 5.0 Inspection, testing and acceptance 5.1 The equipment shall be subject to inspection by Owner or by an agency

authorized by the owner. Manufacturer shall furnish all necessary

information concerning the supply to Owner. During the course of

manufacturing, the purchaser or his authorized representative shall be free

to visit the works and assess the progress of work and the manufacturer

shall render him all possible assistance to do so. 5.2 Following routine and acceptance tests shall be carried out at the

manufacturers‟ works under his supervision and at his own cost for all the

actuators.

a) Functional and calibration test for torque and limit switches

b) Response time test

c) Variation of supply voltage

d) Variation of frequency

e) Tests for motor (As per relevant IS/ IEC)

f) Life test

g) Test on output shaft

Tests listed at Cl. nos. 5.2(b), 5.2(c), 5.2(d), 5.2(e), 5.2(f) and 5.2(g) above

are the acceptance tests. 5.4 Type test certificates, original drawings referred in certificates and statutory

approval certificates and BIS license, where applicable, shall be shown to

the inspection agency on demand. The certificates and BIS license must

be valid at the time of dispatch.



of 26

5.5 Test certificates of bought-out components shall be shown to the

inspection agency on demand. 6.0 Packing and dispatch

All the equipment shall be divided into multiple sections for protection and

ease of handling during transportation. The equipment shall be properly

packed for the selected mode of transportation, i.e. by ship, rail or trailer.

The equipment shall be wrapped in polythene sheets before being placed in

crates/ cases to prevent

damage to finish. The crates/ cases shall have skid bottoms for handling. Special

notations such as “Fragile‟. “This side up”, “Center of gravity”, “Weight‟, “Owner‟s

particulars‟, „PO no.‟ etc. shall be clearly and indelibly marked on the packages

together with other details as per purchases as per purchase order. The equipment may be stored outdoors for long periods before installation. The

packing shall be completely suitable for outdoor storage in areas with heavy rains

and high ambient temperature unless otherwise agreed. In order to prevent

movement of equipment/ components within the crates, proper packing supports

shall be provided. A set of instruction manuals for erection, testing and

commissioning, a set of operation and maintenance manuals and a set of final

drawings shall be enclosed in a waterproof cover along with the shipment.

chapter 7: technical specifications -...

Documents