technical specifications for liquid ring compressor...

Technical Specifications for Liquid Ring Compressor

Package (280-LZ-01)

Doc No:

FGRU-

TSLC

Flare Gas Recovery Unit Project

0 14.07.2014 14.07.2014 FIRST ISSUE AS ANR GGR

REV REV DATE EFF DATE PURPOSE PREPD REVWD APPD

of 67

TECHNICAL SPECIFICATIONS FOR LIQUID RING COMPRESSOR

PACKAGE (280-LZ-01)

FOR

FLARE GAS RECOVERY UNIT PROJECT

AT

HINDUSTAN PETROLEUM CORPORATION LTD.

VISAKH REFINERY

ENGINEERING CONSULTANT

M/s. PROJECTS & DEVELOPMENT INDIA LIMITED,

VADODARA


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

INTRODUCTION:

For environmental and economic reasons, Visakh Refinery has decided to install a compressor system for

Flare Gas Recovery.

1.0 Vendor’s Scope of Work & Supply; Delivery Schedule:

The Vendor (also referred as “Manufacturer” or “Supplier”) shall be responsible for supply of Liquid

Ring Compressor package as detailed below:

Supply of the complete set of Skid mounted Liquid Ring Compressors (2 Nos.) with electric motor drivers

(2 nos.) along with its auxiliaries as per the relevant API 681 standards (latest edition) and attached

specifications, standards, requirements. The complete package shall be designed for Liquid Ring

Compressors (2 Nos.) with Electric Motor Drivers (2 Nos.) in parallel operation.

The supply shall necessarily include but not be limited to detailed design, procurement, manufacturing,

fabrication, inspection including third party inspection, testing, painting, supply of commissioning spares,

special tools & tackles, Sea worthy export packing for safe transportation including fumigation for safe

inland & ocean transportation. Mechanical, Electrical and Instrumentation Performance Guarantee of the

following equipment in accordance with the requirements of this indent requisition.

Description Q’ty Unit

Liquid Ring Compressors Package complete 1 Lump sum

Accordingly, the Vendor shall be responsible for the supply of the following items:

Liquid Ring Compressors -02 nos.

Electric Driver Motors (2 nos.), push button station(s); Auxiliary Motors (as required) & its push

button station

Seal Water Separator (Common and sized for compressors (2 nos.) working in parallel)

Seal Cooler (Common, type: Shell and tubes and sized for compressors (2 nos.) working in parallel)

Couplings and non-sparking (brass/ brass plated) coupling guards

Mechanical seals and ancillary system

Recycle Valves

Ring Liquid Filters

All instrumentation as required for package operation, monitoring and safeguarding including control

valves, safety valves, emergency valves, PT’s, TG’s, Pressure switches, solenoid valves, temperature

transmitters, PG’s, FT’s etc and compressor seal monitoring. Detailed Instrumentation scope is as per

clause no. 12

All interconnecting wiring within skid (tubing and cables trays with supports)

All auxiliary piping (sealing, lubrication, etc.) - shop fabricated and shop installed


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

All Purchaser’s connections (inlet, outlet, utility, vent, relief and drain, etc.) – flanged, valved and

terminated at skid edge

Steel skid (common) for compressor, driver and all auxiliary equipment

Equipment earthing by externally accessible earthing studs

Bolting and gaskets for all flanges within Vendor’s scope of supply.

Lifting lugs, Anchor bolts/nuts/washers etc. complete requirement.

Special tools and special test equipment (if necessary)

2.0 APPLICABLE CODES, STANDARDS AND SPECIFICATIONS:

Liquid Ring Compressor Packages covered in this indent shall comply with the requirements of the all the

data sheets, drawings, codes, standards, specifications and statutory regulations referred/ listed etc.

Unless specifically designated by date, the latest edition of each publication shall be used, together with

any amendments/supplements/revisions thereto.

2.1 Order of Precedence

In case of conflict between the following documents, the order of precedence shall be as follows. In case

of conflict at same level, more stringent conditions shall be applicable.

Indent Requisition / Mechanical Data Sheets /Attached project drawings / P&ID (if any) (all at same

level)

International standards

3.0 CLARIFICATIONS AND DEVIATIONS

The Vendor shall highlight all clarifications for the ambiguities, conflicts and discrepancies which may be

discovered in the above documents, together with deviations from the requirements therein and propose a

resolution to the Purchaser in separate sheet highlighting the Clarification & Deviation List . The

clarifications and deviations are subject to HPCL Refinery approval. The Vendor shall provide, in

Clarification & Deviation sheet, well explained reasoning or justification as regards the clarifications and

deviations taken for clear understanding by HPCL.

In case the Vendor fails to highlight clarifications prior to PO (Purchase Order) award, the Purchaser’s

interpretation shall be final and the Vendor shall accept such interpretations with no change in delivery

and order amount after PO award. It may please be further noted that during evaluation of bids only the

deviations listed in the list shall be examined and it shall be construed that the bid is in total conformity

with the tender terms – technical as well as commercial, except for the deviations specially listed.

Deviations not listed in “Agreed Technical Terms and Conditions” and listed elsewhere in the bid shall be

ignored and shall not be considered.


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

4.0 INFORMATION REQUIRED

4.1 LIST OF DRAWINGS & DOCUMENTS

The documents and drawings listed below shall be submitted along with supply in bound document

form. The presentation shall be well up to the mark with proper indexing.

SL

DESCRIPTION

With Offer

FOR

APPROVAL OF

OWNER

(AFTER

PLACEMENT

OF PO/FOA,

AND BEFORE

SUPPLY )

WITH FINAL

DOC.

1 Equipment catalogue and experience list

2 Equipment (& accessories) Data / specs sheets 3 General arrangement drawing and foundation plan

4 Cross sectional drawings (typical) of all rotating

equipment

5 Drawing of the couplings and all accessories 6 Compressor performance curve 7 Mechanical seal drawing 8 Recommendation of seal manufacturer

9 Casing drain pipe/ CW arrangement drawing

10 Proposed method for control and protection of the

liquid ring compressor package

11 Clarifications and exceptions to this Requisition

12

PFD (Process Flow Diagram) and P&ID (Piping and

Instrument Diagram) showing major instrument

control points

13 Piping drawing of all the seal plans including

complete sealing system

14 General Arrangement and Fabrication Drawing of

Static Equipment

15 Lube system details (schematics) 16 Estimate of utilities consumption 17 Inspection and test plan 18 Guarantee Certificate 19 Summary sheet of Drg. Nos. 20 Compressor Test Record with performance curves 21 Material Test Certificates


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

4.2 Price Bid Format /Check List (Vendor to indicate Y/N below and the prices to be quoted in Specific

Price Schedule Format Only)

22 Hydrostatic Pressure Test Certificate 23 Dynamic Balancing Certificate 24 Compliance Certificate* 25 Hydro Test Certificate for piping/ equipment 26 Certificate of Non-destructive testing 27 Dimensional reports 28 Motor data sheet and outline drawing 29 Motor Terminal arrangement drawing 30 Motor Thermal withstand characteristics 31 Motor Performance curve and routine test certificate 32 Motor Type Test Certificates 33 Guarantee certificate of Motor 34 Earthing Layout drawing 35 Inspection release note of all equipment /package

36

Equipment /package installation, operation &

maintenance manual with complete spare part list for

the whole package

* Final documents shall be submitted in additional soft form on CD (3 copies) also.

* Certification for testing of all flameproof electrical equipment is to be submitted.

Note :

Five sets of hard bound documents (including inspection and test plan) shall be required as a part

of final documentation. The Final documents shall be submitted in additional soft form on CD

(3 copies) also.

All documents shall be written in the English Language. The standard units for design engineering

shall be based on the SI System, except for pipes, which shall be sized in inches, and flanges,

which shall be rated in pound.

Sr

.

Part description Total

Qty

required

Quoted

(Y/N)

Unit

price (per

set)

Total price

( Rs.)

1. Vendor’s Scope of Work & Supply;

Delivery Schedule:

The Vendor (also referred as “Manufacturer”

or “Supplier”) shall be responsible for

supply of Liquid Ring Compressor package

as detailed below:

Supply of the complete set of Liquid Ring

1

As

indicated

in SP

Forms

As

indicated

in SP

Forms


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

Compressors (2nos.) with electric motor

drivers (2 nos.) along with its auxiliaries as

per the relevant API 681 standards (latest

edition) and attached specifications,

standards, requirements. The complete

package shall be designed for Liquid Ring

Compressors (2 nos.) with Electric Motor

Drivers (2 nos.) in parallel operation.

The supply shall necessarily include but not

be limited to detailed design, procurement,

manufacturing, fabrication, inspection

including third party inspection, testing,

painting, supply of commissioning spares,

special tools & tackles, Sea worthy export

packing for safe transportation including

fumigation for safe inland & ocean

transportation. Mechanical, Electrical and

Instrumentation Performance Guarantee of

the following equipment in accordance with

the requirements of this indent requisition.

Description Q’ty Unit

Liquid Ring Compressors Package complete 1 Lump sum

Accordingly, the Vendor shall be

responsible for the supply of the following

items:

Liquid Ring Compressors -02 nos.

Electric Driver Motors (2 nos.), push

button station(s); Auxiliary Motors (as

required) & its push button station

Seal Water Separator (Common and

sized for compressors (2 nos.) working

in parallel)

Seal Cooler (Common ,type : Shell and

tubes and sized for compressors ( 2 nos.)

working in parallel)

Couplings and non-sparking (brass/ brass

plated ) coupling guards

Mechanical seals and ancillary system

Recycle Valves


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

Ring Liquid Filters

All instrumentation as required for

package operation, monitoring and

safeguarding including control valves,

safety valves, emergency valves, PT’s,

TG’s, Pressure switches, solenoid valves,

temperature transmitters, PG’s, FT’s etc

and compressor seal monitoring.

Detailed Instrumentation scope is as per

clause no. 12

All interconnecting wiring within skid

(tubing and cables trays with supports)

All auxiliary piping (sealing, lubrication,

etc.) - shop fabricated and shop installed

All Purchaser’s connections (inlet,

outlet, utility, vent, relief and drain, etc.)

– flanged, valved and terminated at skid

edge

Steel skid (common) for compressor,

driver and all auxiliary equipment

Equipment earthing by externally

accessible earthing studs

Bolting and gaskets for all flanges within

Vendor’s scope of supply ,

Lifting lugs, Anchor bolts/nuts/washers

etc. complete requirement.

Special tools and special test equipment

(if necessary)

2. Spares

a Double cartridge mechanical seal

1 set As

indicated

in SP

Forms

As

indicated

in SP

Forms

b Complete set of Gaskets for one compressor

(including seal gaskets)

2 set As

indicated

in SP

Forms

As

indicated

in SP

Forms


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

Note:

The word 'Set' means the quantity required for full replacement of that part in one machine.

The cost of Spares, per diem charges, Fixed Trip and Provision of Shut Down valves shall be added to the

'Total Cost' for commercial evaluation of the offer.

5.0 The Procurement Philosophy / Selection Requirement

It is HPCL’s intention to procure equipment vendor’s successful and proven product. The equipment shall

be designed for an intended operating life of 20 years in line with API 681 requirements. The equipment

shall be suitable for long service life and be suited to local operating conditions, which are hot, humid and

corrosive. Selection criteria shall be:

Low maintenance, with ease of operation (user friendly) and ease of service (maintainability) under

local conditions.

Lowest life cycle cost for all operation and maintenance costs, consistent with safety and

environmental requirements.

Equipment will be amenable to predictive monitoring and shall have vibration, temperature and other

sensors connecting points where ever applicable.

c Complete set of coupling shim packing’s 1 set As

indicated

in SP

Forms

As

indicated

in SP

Forms

d Set of gaskets and ‘O’ rings for PSV 1 set As

indicated

in SP

Forms

As

indicated

in SP

Forms

e Complete set of bearings 1 set As

indicated

in SP

Forms

As

indicated

in SP

Forms

3. Per diem charges for supervision As

indicated

in SP

Forms

As

indicated

in SP

Forms

4. Charges for Fixed Trip As

indicated

in SP

Forms

As

indicated

in SP

Forms


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

Vendor to commit uninterrupted supply of spares for the system, as and when required by Owner, at least

for 20 years of operation.

6.0 Functional Design Requirements/ Functional Specifications

6.1. Mechanical Requirements:

6.1.1 Skid Layout: The layout of compressor skid shall afford complete and unconstrained access to all

equipment for operation, maintenance and removal.

The compressor skid shall be as per the available site dimensions. The dimensions of site are 13 meters x

15.7 meters (FGRU Layout drawing attached for reference).

6.1.2. Mechanical Equipment requirements

General

The equipment supports shall be generously designed in order to withstand all induced stresses caused

by transportation, wind loading, operating conditions and pressure testing.

All gaskets fitted shall be new after hydro test.

Equipment shall be insulated for personnel protection wherever temperature exceed 70 deg C.

All removable internals shall be designed to provide easy withdrawal from vessel and shall pass

through vessel Man way. Man way to be of 24 inched NB preferably.

Davits for manhole covers shall be provided.

6.1.3 Ring Liquid Compressor:

The Ring liquid Compressor shall be designed and manufactured / constructed in accordance with API

681 latest edition.. Bearing Brackets to be of nodular cast Iron/ Cast steel. Bearing shall be of SKF / FAG

make with machined brass cages.

Material of construction (MOC) of major parts shall be as below:

Casing ASTM 182 Gr F316L or equivalent ASTM /ASME grade

Impeller A351 Gr CF3M or equivalent ASTM/ASME grade

Cone A351 Gr CF3M or equivalent ASTM/ASME grade

Suction Comp.

Cover

A351 Gr CF3M or equivalent ASTM /ASME grade

Shaft ASTM-A 564 TP 630 / or equivalent ASTM /ASME grade

Service Water will be available for liquid ring make up and mechanical seal flushing at a pressure of

2.5 kg/cm2 at FGRU battery limit. Vendor to check the adequacy of the pressure and provide for pumping

requirement (1 Running + 1 stand by), if required.

The gear box, if considered in the offer, shall conform to API-677.


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

6.1.4 Cooler

Shell and tubes heat exchanger, sized for two compressors, according TEMA R, removable bundle type,

Shell side MOC carbon steel, tube side MOC Cu-Ni 70/30.

6.1.5 Separator

The vessel shell to be provided with demister internals suitable to remove any carry over and level

control to suit operation. Horizontal three-phase gas / liquid separator (sized for two compressors

working) in carbon steel (NACE grade) as per ASME Sect VIII div.1. Provide 24” NB Man-way.

Required instruments shall be provided as per API 681 as a minimum.

Platforms and ladders for separator will be provided by HPCL. Vendor shall provide necessary cleat

arrangement on the vessel. Equipment shall be designed accordingly.

6.1.6 Mechanical Seal:

The Double mechanical seal is to be specifically designed for the compressor. The seals for the

compressor and the ring liquid pump (if applicable) shall be as per API 682. The compressor seal shall

be of cartridge design, C / SiC with Hast Alloy C springs and SS 316 metal parts suitable for HC

applications. Vendor: JOHN CRANE /EAGLE BURGMANN /FLOWSERVE.

1. It is proposed to use API flush plan 32/52 or dry out board seal which is even suitable.

2. Leak detection system.

3. All the “O” rings of the mechanical seal shall be of Kalrez only.

4. For plan 32/52 service water to be used as buffer liquid. Each seal shall preferably be provided with

unpressurized buffer fluid circulation through reservoir and seal leakage detection system. Vendor

may propose alternative seal/sealing system also; accordingly cooling system may also be offered, if

required.

5. a. Duplex filter on the upstream of flushing plan 32 for filter to supply of clean liquid to primary

seal.

b. Duplex filter shall have DP gauge and DP transmitter, upstream and downstream pressure gauges.

c. Duplex filter shall have change over valve for changing of the filter online without affecting the

compressor operation.

It is proposed that vendor shall provide following minimum signals from sealing system.

a. Failure /excessive leakage for individual seals

b. Seal fluid supply pressure indication.

Compressor shutdown or alternative action will be initiated accordingly.

All seal auxiliary system piping shall be of vendor’s standard generous design of SS316 metallurgy.


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

6.1.7 Piping Requirement

1. The following tie-in points (to the HPCL piping) up to skid limit are envisaged.

a. Gas inlet

b. Gas outlet

c. Relief Valve discharge

d. Vessel connection to closed drain

e. Skid connection to open drain

f. Ring liquid make up

g. Cooler connections (vendor to elaborate)

h. Separator connections (vendor to elaborate)

i. N2 purging

j. Instrument air

Vendor to confirm for any other connection.

1. The skid connecting flanges shall be located at the edge of the skid. Vendor shall supply matching

flanges of all tie-in points.

2. All the package piping shall be designed in accordance with ASME B 31.3. All piping layout shall be

designed to provide access to all equipment. The piping to be designed not to exert greater loads than

those allowed for vessel nozzles or those permitted by original manufacturer.

3. Piping supports at tie in locations shall be suitable to withstand loads per the values given by vendor.

Vendor shall furnish their standard allowable loads at tie-in points to be considered by HPCL for

interconnecting piping outside vendor scope of supply

6.1.8 Structural Requirement:

Materials

All structural steel and weld material used in skid fabrication shall be delivered in accordance with ASTM

A6 or equivalent. The primary structural framing shall be carbon steel. Maximum carbon content of steel

sections shall be 0.23% Structural design shall be designed sturdy enough for type of equipment

considering most severe conditions.

6.1.9 Provision of Shutdown valves:

Shutdown valves along with its associated facilities such as PSV shall be provided by the vendor in the

Liquid Ring compressor Package as per the requirement of HPCL in future. Vendor to quote the price

separately for this facility and shall not be included in the Lump sum price of the Liquid Ring Compressor

package.

Skid Fabrication:

Construction: skid shall be of welded construction. Equipment shall be mounted on adequate supports

either mounted directly or attached through structural member on the skid. Floor grating shall not be used

as a mounting surface for equipment or supports.


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

All structural welds on the skids shall be 100% Magnetic Particle Inspected and all the fillet welds shall

be continuous.

Unless otherwise mentioned, equipment shall be attached to skid by bolting. All stainless steel/ carbon

steel interfaces shall have insulation gasket sets. The skid (s) to be designed with a Perimeter beam of one

size extending all the way around the skid to allow the deck plate or grating to be attached to the skid

beam.

Vendor to provide 3 mm steel plate drip pan(s) to cover compressors only. The same shall be sloped

towards a flanged low point drain with tie in flange.

Platforms and ladders:

Platform and ladders for separator vessel will be provided by HPCL. Vendor shall provide necessary Cleat

arrangement on the vessel. Equipment shall be designed accordingly.

6.2. Noise Requirements

Noise level shall be limited to 85 dBA at any position not less than one meter from the equipment surface.

6.3. Piping Design Requirements

Equipment and package piping interface connections shall be flanged to ASME B16.5 for nozzles up to

24”, and ASME B16.47 Series B or MSS-SP-44 for nozzles above 24”. Required ratings and face finish

will be detailed on the PIPING SPECIFICATION. Interfaces for utility/auxiliary services shall be

minimized by the use of manifold piping, where necessary, within the Vendor’s package, and shall be

located at the package skid edge.

The minimum allowable forces and moments shall be as follows:

A. Liquid ring compressor & pump

Compressors and pumps with casing constructed of steel and with nozzles smaller than 16 inch shall be in

accordance with NEMA code as per API 681. Allowable loads on compressor shall be as per API 681

(NEMA SM-23).

For flanges larger than 16”vendor shall design the nozzles with generous strength and the values shall be

sent to HPCL for information.

B. Vessels & Exchanger

External Loads for Nozzle of Vessel & Exchanger to be in accordance to ASME VIII div 1 requirements

and WRC Bulletin.

6.4. Foundation

Design & construction of the skid foundation shall be done by HPCL based on the foundation dimension,

anchor bolts location, static & dynamic loads, GA Drawing etc. of the skid which is to be provided by the

bidder. Bidder shall submit foundation plan with relevant information relevant to foundation dimensions,

anchor bolts location, static and dynamic loads to allow M/s HPCL to provide detailed foundation design

and drawing.

Supply of anchor bolts, washers shall be provided along with the loads (Static and Dynamic).


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

7.0 Hazardous Area Classification

The Liquid Ring Compressor Package will be installed in hazardous area IEC Zone 1, Group IIC & Temp.

Class T3. All electrical equipment shall be in accordance with certification requirements as specified in

the Codes and Standards as per indent.

Equipment Zone-1 Zone-2

Gas Gr II A,

IIB

Gas Gr. IIC Gas Gr.IIA,

IIB

Gas Gr. IIC

MV Motors Ex-d Ex-d Ex-e Ex-e

HV motors Ex-d/Ex-p* Ex-d/Ex-p* Ex-e Ex-e

Push button station Ex-d Ex-d Ex-d Ex-d

Motor starters Ex-d Ex-d Ex-d Ex-d

Plug & socket Ex-d Ex-d Ex-d Ex-d

Welding Receptacle Ex-d Ex-d Ex-d Ex-d

Lighting Fixture Ex-d Ex-d Ex-d Ex-d

i. Lighting fitting

ii. Control Gear Box

Ex-d Ex-d Ex-d Ex-d

Junction Box Ex-d Ex-d Ex-d Ex-d

Hand Lamps

1. Light fitting

2. Transformer

Unit.

3. Plug & Socket

Ex-d Ex-d Ex-d Ex-d

Break Glass Unit (Fire

Alarm Unit)

Ex-d Ex-d Ex-d Ex-d

Lighting panel /Power

panel

Ex-d Ex-d Ex-d Ex-d

*Ex-p motors shall be used only where Ex-d range is not available.

Notes: 1. The electrical equipment for hazardous area shall generally be suitable for gas group IIA/IIB and

temp classification T3 as applicable to the selected type of explosion protection. In case of

hydrogen or hydrogen or hydrocarbon mixtures having more than 30% hydrogen, the gas group to

be considered shall be IIC.

2. As additional safety features, the following requirements for electrical equipment shall be

followed:

A. All electrical motors for agitators / mixtures and metering pumps handling flammable material

shall be flameproof type irrespective of the area being classified as zone-2 or zone-1.


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

B. All electrics motors for vertical oil sump pumps shall be flameproof type.

C. Irrespective of the area classification (Whether zone-1 or zone-2), all lighting fixtures within

the process /storage areas shall be flame proof type.

D. Irrespective of the area classification (Where zone-1 or zone-2) all motors and lighting fittings

within the pump house (station) associated with storage area and within the loading / unloading

gantries shall be of flameproof type.

E. All emergency /critical lighting fixtures and associated junction boxes in hazardous areas

(whether zone-1 & zone-2) shall be flameproof type.

F. Even though fired heaters in process units are not considered for area classification, all

electrical equipments associated with fired heaters in process units shall as a minimum be

suitable for installation in zone-2 area.

G. Where air conditioning system is designed considering ammonia as refrigerant, the room

housing air conditioning equipment shall be adequately ventilated to classify it as safe area.

For additional safety the following shall be considered.

Location of MCC/ local panels in adjacent separate room

Instrumentation to be flame proof type or hermetically sealed.

AC Plant room motors with min. type ‘e’ protection.

Lighting in AC plant room suitable for zone-I area.

8.0 EQUIPMENT DESIGN REQUIREMENT

8.1 Equipment Reliability, Operability and Maintainability

The Vendor shall provide all information on space requirements for layout, handling and removal of

components, to a point on or beyond the confines of the package/skid, where these can be easily lifted and

handled. The Vendor shall also provide all information on any special laydown or handling procedures,

which may be required, and provide all special tools, support cradles, and lifting frames.

9.0 Combined performance in parallel Operation

Liquid Ring Compressors are to be piped for parallel operation. The vendor shall guarantee the combined

performance at the inlet and outlet manifold of the piping as per attached Process Specification, Doc. No.:

PC00078-280-LZ-01, R2.


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

10. Seal Water Quality:

Vendor to refer attached Process Data Sheet for seal water quality available at site.

Vendor to consider suitable strainers, Duplex Basket filter to be provided on the Ring liquid inlet to

compressor.

10.1. Compressor Protection

Vendor shall ensure that the compressor start-up logic inhibits starting of compressor until water seal

system has established water seal minimum flow and appropriate level in the compressor.

Vendor shall provide automated start-up logic for compressor package to ensure proper start-up

procedures, sequences and permissives.

Vendor shall advise, in his bid, suction and discharge protection pressure of compressor. 11.0 ELECTRICAL DESIGN REQUIREMENTS

Motor: Motor shall be supplied as per IEC/IS.

Distribution and Utilization Voltage

Utilization Voltage

Motors:

HV motor voltage = 6.6 KV / 3.3 KV +/- 10% , 3 phase, 50 Hz. +/- 3%

MV motor voltage = 415 V +/- 10% , 3 phase, 50 HZ +/- 3%

Frequency variation = 50 Hz +/- 3%

Control --- 50HZ /110V, DC, 2 wire

Voltage grade of HV motor i.e. 6.6 kV or 3.3 kV shall be confirmed later.

Enclosures and Degree of Protection:

Enclosures

Local panels shall have an enclosure of metal, or of an insulating material of sufficient mechanical

strength and shall be self-supporting, suitable for floor or wall mounting in cubicle or box-type

construction. The design shall include measures to avoid condensation as much as possible.

Degree of protection The degree of protection for equipment except electric motors shall be compliant to the following

enclosure classifications, as a minimum environmental protection according to IEC 60529:

IP 66 for outdoor terminal and junction boxes


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

Accessibility

All components requiring maintenance shall be easily accessible from the front.

The following features for personal and electrical safety shall be incorporated:

- Adequate means shall be provided to ensure the safe removal of fuses, when fitted.

- Adequate insulation or protection shall be provided on all live parts (IP 20) to minimize the risk of

accidental short circuits and to limit their propagation of occurring.

- The insulation shall be capable of providing adequate and lasting protection under specified

normal conditions and recognized over currents and over voltages.

Control Panels, Terminal and Junction Boxes

Control panel power supply shall be 110 V AC 50 Hz, UPS.

Where control devices are grouped in and/or locally mounted control panel, the panel shall be supplied by

the Vendor completely pre-wired to terminal blocks.

Where control devices are grouped in and / or locally mounted control panel, the panel shall be supplied

by the vendor completely pre-wired to terminal blocks.

The local control panel shall be designed for hazardous area classification i.e. Class 1 Division 1 and

temperature classification T3. The panel shall have Z type purge arrangements with + 3 mm or + 5 mm of

WC maintained pressure.

Each Control panel shall be provided with RS 485 (2 wire) Communication port.

Terminal blocks shall be of the locking type construction to prevent wires from vibrating loose. All

terminals shall be tinned plated only accept one wire per terminal and so arranged within the panel to

accommodate all incoming cable cores minimum size 2.5 sq.mm. Removable gland plates shall be

supplied for all incoming cables. Cable Glands of Double Compression Nickel plated Brass, weather

proof to ATEX and Explosion proof to ATEX shall be supplied by the vendor. CMRI test certificate for

cable glands shall be provided.

It is vendor responsibility to hook up all the indication of local panel to DCS control room. Separate

control panels shall be provided with local control panel which shall be plugged with 316 SS plugs.

All terminals shall be numbered. The internal wiring within a panel or box shall be numbered such that

the wire end has the number of the device and / or the terminal, at the other end.

Cable entries to each local control panel should be from bottom only.

Identification of all wires will be achieved by the use of wire markers. Manufacturer’s standard will be

acceptable, however wrap around, adhesive type markers shall not be used.

A minimum of 30% spare terminals shall be provided in each panel.


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

A lamp test individual switch shall be provided for all alarm and indicating lights. Power on lamp to be

provided in front of each panel.

A copper earth bar of adequate cross-sectional area and mechanical strength shall be provided in each

panel to allow convenient connection of all earthing conductors.

All motors shall be equipped with main terminal box. A separate auxiliary terminal box for the space

heater shall be provided when applicable. Each cable entry size of motor terminal box shall be spacious

for cable bending.

It is vendor’s responsibility for cable entry size and terminal block size of each junction box and terminal

box during vendor print review & approval stage. After HPCL approval of submitted document from

vendor, vendor shall incorporate the same.

SWITCHES/LAMPS: BCH/L&T/SIEMENS.

Earthing:

All electrical equipment, the unit frame/structure, equipment for electrical signal transmission, including

the enclosures, as well as the armoring, and screening of cables, shall be properly earthed for personal

safety reasons and for obtaining the maximum possible rejection of interference.

All the equipment being supplied by the bidder shall be properly earthed as per IS: 3043 and the extreme

connection shall be brought up to the earth bus provided by the bidder. Further connection from bidder

earth bus to main Earth grid shall be done by purchaser.

Earth bus shall be of length 350 mm made up of GI of size 50x12mm with 8 to 12 holes.

Earthing of equipment rated 240V and below shall be done by 1Cx10 sq mm (Cu) PVC Cable.

Mechanical Equipment like tanks, vessels, steel structure shall be earthed by 50x6 GI strips.

Motor earthing:

Rating Size

i. Up to 22 KW 1Cx10 sq mm (Cu) PVC

ii. Above 22 KW up to 45 KW 1Cx25 sq mm (Cu) PVC

iii. Above 45 KW 50x6 GI strip or

120 sq mm (A1) PVC cable

All equipment rated above 240 V shall have two external earth connection and those rated below shall

have one external earth connection.

Push button station shall have two external earth connections.

All valves, flanges etc. shall be provided continuity Jumper of size 35 x 6 GI earth strip or 1 x 25 sq mm

(Cu).


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

Minimum size of earthing cable shall be 1C x 10 sq mm (Cu) PVC.

On package equipment with a number of electrical components to be earthed, parallel earthing shall be

employed and not the series looping of equipment.

Two/adequate number of earth bars to which equipment earthing is connected shall be provided at

opposite ends of the skid.

Earth bars to be provided with two additional holes complete with bolts and washers size M10 to

accommodate Purchasers external earth connection to the main earthing grid. The size of the bar shall be

70 mm minimum.

Metal enclosures of electrical equipment, mechanical equipment and construction parts shall be earthed by

an earthing wire of at least 25 mm2 connected to the common earth bar. In case size is not specified, the

same shall be subjected to approval.

All electrical joints made for earthing shall be accessible and checked for tightness and electrical

continuity.

Earthing wires shall be of the stranded copper PVC covered type; the color of the insulation shall be

yellow/green.

Earthing conductors of cables shall be connected to the earthing terminal bolt inside the terminal box and

to the common earth bar.

Vendor shall submit the earthing layout drawings on package equipment for information only.

As per HPCL, the following shall be applicable.

A. Earth electrode : GI pipe

B. Main earth loop material : GI Strip

C. Substation earth loop : GI strip

D. Lightening Conductor: As per IS 2309.

E. Earthing of motors, small equipment shall be done with Al / Cu conductor PVC insulated green

color cable instead of GI rope.

Interconnecting Cabling:

Interconnecting wiring between equipment on a common skid shall be supplied and installed by the

Vendor.

The minimum size of interconnecting cables shall be:

Power cables – 4 mm2

Control cables – 2.5 mm2


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

LV power / control cables used for aboveground wiring shall be stranded copper conductor, XLPE

insulated, galvanized steel wire armored (or braid for sizes up to and including 10 mm2), flame retardant,

PVC over sheathed with FRLS properties.

All power and control cabling to motor remote control stations, heaters, etc. will be connected directly to

the equipment i.e. not via junction boxes, The Vendor shall ensure that the equipment supplied is

completely satisfactory for the termination of Purchaser’s cable(s).

Cabling to controls (not motor control stations), e.g. temperature switches etc, shall be wired to explosion

proof individual junction boxes located on the skid. (Ex-Proof Certificate for junction Boxes and cable

glands from CMRI to be provided).

Where instrument, intrinsically safe and electrical cables are installed on the same skid separate routes

shall be used and due attention shall be given to avoid electromagnetic interference between different

systems.

Conduits, trays, ladders, separators and their supports shall be made of hot-dipped galvanized steel having

galvanizing thickness not less than 100 micron. Cable extensions from cable trays to equipment and other

devices shall be supported and protected from mechanical damage. FRP cable trays minimum 5 mm

thickness shall be used for instrument signal cables and control cables. Nuts & Bolts for FRP cable trays

shall be SS316.

All cable trays, canopies for hazardous area equipment, motors and channels for LCS shall be FRP type.

The thickness of FRP canopy shall be minimum of 3 mm.

All electric devices furnished/installed by the Vendor and requiring external field connections (except

motor power leads) shall be wired by Vendor to terminal blocks in junction boxes located at the edge of

the skid.

Identification of Equipment and Cables

Equipment

All electrical equipment shall be provided with label/tag plates.

A list of labels/tag plates shall be part of Vendor’s drawings for approval before fabrication.

The language to be used on labels/tag plates shall be English.

Cables

The Vendor shall attach cable marker tags to all cables when they are laid. Cable identification shall also

be provided and fixed just below the cable glands at all entries into equipment, junction boxes or through

joints. Markers shall be of 1.5mm thick x 18mm wide lead strip. The circuit identification and cable

schedule numbers shall be stamped on each marker in 6mm high letters and digits.

Alternatively markers in stainless steel or plastic may be used provided that they are attached permanently

to the cable and not subject to deterioration by environment.


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

Motor Starting

Motors less than 800 kW will be designed for full voltage starting; motors 800 kW and above will be

designed for autotransformer reduced voltage starting.

Motors designed for autotransformer reduced voltage starting shall be capable of accelerating the load

with 65 percent rated system voltage applied to the motor terminals.

For low voltage motor (415 V), the locked rotor apparent power shall apply with IEC 60034-12. However,

for machines with a rated output in excess of 55 kW the starting current shall not exceed 6.0 times the

rated current of the machine including IEC/IS tolerance.

For high voltage motor (3.3 kV & 6.6 kV), the starting current shall not exceed 5.5 times the rated current

of the machine including IEC/IS tolerance.

12.0 Design basis of Instrumentation

12.1. General

This document details the basic design criteria for the control and instrumentation for Flare Gas

Recovery Unit of HINDUSTAN PETROLEUM CORPORATION LIMITED, Visakhapatnam,

Andhra Pradesh, India.

12.1.1 Scope

a. This specification covers the minimum requirements for the engineering, design and

supply and installation of instrumentation including package units.

b. This specification provides only the qualitative specifications of commonly used

instruments.

c. In the event of any conflict between these specifications, data sheets, related standards,

codes etc., HPCL shall be consulted for clarification before proceeding with manufacturing/

execution.

12.2. Applicable Codes & Standards

Design and terminology shall comply, as a minimum, with the latest edition prior to the date of purchaser's enquiry with following codes, standard practices and publications:-

AGA American Gas association

Report No.3 - Orifice Metering of Natural Gas & other related hydrocarbon fluids

Report No.7 - Measurement of Gas by Turbine Meters.

ANSI/ASME American National Standards Institute/American Society of Mechanical Engineers.

B 1.20.1 Pipe Threads General Purpose (Inch)

B 16.5 Pipe Flanges and Flanged Fittings

B 16.20 Metallic Gaskets for pipe Flanges, Ring Joint, Spiral wound and Jacketed.

B 16.34 Valves, Flanged, Threaded & Welding Ends

ANSI B16.36 (1996)/B16.36a: Steel orifice flanges

ANSI/FCI American National Standards Institute / Fluid Control Institute

70.2 Control valve seat leakage classification


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

API American Petroleum Institute

API 520 Sizing, selection and installation of pressure relieving devices in Refineries.

Part-I - Sizing and selection

Part-II - Installation

API 521 Guide for pressure relieving and de-pressurizing systems.

API 526 Flanged steel Pressure Relief Valves.

API 527 Seat tightness of Pressure Relief Valves.

API MPMS Manual of Petroleum measurement standards.

API RP 551 Process Measurement Instrumentation

Part I - Process Control and Instrumentation

API 522 Transmission Systems.

S 1101 Measurement of Petroleum Liquid Hydrocarbon by Positive Displacement meter.

S 2000 Venting Atmospheric and low-pressure storage tank non- refrigerated and

refrigerated.

S 2534 Measurement of liquid hydrocarbons by turbine meter systems

S 670 Vibration, Axial-Position and Bearing-Temperature Monitoring Systems

ASME American Society of Mechanical Engineers

ASME Sec-VIII Boiler and Pressure Vessels Code rules for construction of pressure

vessels

ASME Sec-I Boiler and Pressure Vessels Code. Section-I ‘Power Boilers’

ASTM American Society for Testing and Materials.

BIS Bureau of Indian Standards

BS British Standards

BS-5308 Part-II: Specification for PVC insulated cables.

BS-7244 Flame Arrestors.

DIN German Standards

DIN-43760 Temperature Vs Resistance curves for RTD’s.

DIN-19234 Electrical Distance Sensors; DC interface for Distance Sensor and Signal

Converter.

DIN-50049 Document on Material Testing

IBR Indian Boiler Regulations

IEC International Electro technical Commission

IEC 60079 Electrical Apparatus for Explosive Gas atmosphere

IEC 60085 Thermal Evaluation and Classification of Electrical Insulation.

IEC 60332 Test on bunched wires or cables. Part III Cat. A

IEC 60529 Degree of protection provided by enclosures (IP code)

IEC 60534-2 Industrial Process Control Valves-Flow capacity.

IEC 60584-2 Thermocouple Tolerances

IEC 60751 Industrial Platinum Resistance Thermometer Sensors

IEC 60801 Electromagnetic compatibility for Industrial Process measurement and control

equipment.

IEC 61511 Functional safety: Safety Instrumented system for the process industry

sector

IEC 61508 Functional safety of electrical/electronic/programmable electronic safety-

related


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

IS Indian Standards

IS-5 Colours for ready mixed paints and enamels

IS-319 Specification for free cutting Brass bars, rods and sections

IS-1239 Mild steel tubes, tubular and other wrought steel fittings.

IS-1271 Specification of Thermal Evaluation and Classification of Electrical Insulation

IS-1554 PVC insulated (heavy duty) electric cables working Part I -voltage up to and

including 1100 V

IS-2074 Ready mixed paints, air drying, red oxide - zinc chrome

IS-2148 Flame proof enclosures for electrical apparatus for Explosive Gas Atmospheres –

Flameproof Enclosures ‘d’.

IS-3624 Specification for pressure and vacuum gauges

IS-5831 PVC insulation and sheath of electric cables.

IS-7358 Specifications for Thermocouples

IS-8784 Thermocouple compensating cables.

ISA Instrumentation, Systems and Automation Society

S-5.2 Binary logic diagrams for process operations.

S-7.3 Quality standard for instrument air

S-75.01 Flow equations for sizing control valves

ISO 5167 Measurement of fluid flow by means of Pressure differential devices inserted in circular

cross-section conduits running full

S-7.3 Quality standard for instrument air

S-75.01 Flow equations for sizing control valves

NACE National Association of Corrosion Engineers.

NEC National Electric Code.

NEMA National Electrical Manufacturer's Association

ICS-6 Enclosures for Industrial control and systems.

NFPA National Fire Protection Association

NFPA-496 Purged and pressurized enclosures for electrical equipment.

OSHA Occupational Safety and Health Authority.

SAMA Scientific Apparatus Maker’s Association.

12.3 DESIGN PHILOSOPHY

a. Instrumentation shall be complete in all respects and liberal to the extent of providing data on

all operations and variables sufficient for the safe, efficient and easy operation start up and shut

down of the plant.

b. All electronic / electrical Instruments and equipment shall be suitable for area classification as

per IEC codes and shall be certified by any recognized authority like FM, CSA, ATEX

guidelines etc. All electronic / electrical Instruments and equipment shall be finally

approved by statutory authorities in India (Chief Controller of Explosives - NAGPUR).

c. The Design and installation of Instruments shall be generally in accordance with ISA / API

Recommended practices and other applicable standards like BIS, IBR etc. Instrument shall

support availability and reliability of the plant. Material specifications and practices shall, in


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

general, conform to appropriate ASTM or equivalent standards. All standards and code of

practices referred to herein shall be of the latest edition.

d. Material selection for various items shall be as per piping material specification unless

otherwise specified in the data sheets and /or “Specification for Instrumentation”. Material

specification and practices shall conform to appropriate ASTM standards.

e. All instruments and equipment shall be suitable for use in a hot, humid, Coastal and tropical

industrial climate in which corrosive gases and / or chemicals may be present. As a minimum,

all instruments and enclosures in field shall be dust proof and weather proof to IP-65 as per

IEC-529 / IS-2147 and secure against the ingress of fumes, dampness, insects and vermin.

All external surfaces shall be suitably treated to provide protection against corrosive plant

atmosphere. Generally all instrument wetted parts in contact with the process fluid shall be

316 stainless steel as minimum, or better material having corrosion resistant against the

service / process fluid. For Instruments in hydrogen service, special attention shall be given to

possible hydrogen permeation e.g. bellows or diaphragms high nickel alloys to be avoided.

Special attention shall also be given in wet H2S service to avoid hydrogen induced cracking.

Certification to NACE MR-0103 shall be specified for sour service. Considering the site

under lightning prone area, all field transmitters shall be provided with surge Protection

devices.

f. Environment Protection: The following conditions shall be considered on the design in order to

ensure the capability of functions for instrument:

i. All equipment shall be tropicalized to eliminate mildew, fungi, and other detrimental

effects of a tropical environment and shall be suitable for operation in a corrosive, salt

laden, marine atmosphere.

ii. Low ambient temperature: 15 Deg C, High ambient temperature: 45 Deg C.

g. Field mount Electronic instruments with integral LCD indicator and/or remote indicators shall

be 2” pipe mounting. FRP canopy shall be provided & installed for the same. Field switches

shall not be used.

h. Weather Protection: IP 65 minimum for all outdoor instruments, junction boxes & Local Panels.

i. Electrical Connection: 1/2” NPT (F).

j. Pneumatic Tubing: ¼” SS 316 tube (minimum) shall be considered.

k. Impulse Tubing: ½” O/D x 0.065” wall thickness, 316 SS Tube shall only be considered.

l. Steam tracing: Typically ¼” bare copper tube shall be used.

m. In general Intrinsic safe instruments philosophy shall be applicable i.e. EEx-ia IIC T4 for

Instrumentation items, Ex D for junction boxes, .Ex-p for Local panel etc. If intrinsic safe

certification is not available, then flameproof instruments (EExd IIC T4) shall be used and same

shall be brought to the notice of PMC / HPCL. The following are the area classification existing

in the Refinery:

Area classification shall be of IEC CENELEC IIA and IIB, T4 for all application except for H2

application which shall be gas group IIC.


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

n. Standard 4- 20mA (HART) shall be applied for all Analog Instruments.

o. The design of electronic instruments shall be in compliance with the electromagnetic

compatibility requirements as per IEC 801 ‘Electromagnetic compatibility for Industrial Process

measurement and Control equipment’.

p. All line or equipment mounted instruments like control valves, pressure relief valves, thermo

wells, orifice plates, level instruments etc. installed on pipes & vessels under IBR shall be

certified by IBR.

q. Power Supply: 110VAC (±10%) 50Hz UPS power supply for control and instrumentation to be

considered. The details are as mentioned below:

Equipment Electrical Level

Control Panels supplied with Package Units 110 VAC 50Hz

Two wire transmitters (4-20mA) 24 VDC

Discrete inputs and outputs 24 V DC at PLC. However, interrogation voltage to field shall be 110 V AC.

Solenoid Valves( from UPS) 110 V AC

Equipment/instruments located on field with electrical power required in the field

110 VAC 50 Hz (UPS)

Level gauge Illumination & Lighting in Local Control Panel

230 VAC 50 Hz (non Ups)

r. Units of measurements shall be as under:

Measured Variable Unit of Measurement

Temperature Deg C

Pressure & Diff. Pressure mmWC, kg/cm2g

Vacuum pressure mmHg, mmWC, kg/cm2a

Liquid flow m3/hr

Gas flow Nm3/hr

Steam flow kg/hr, T/hr

Level % level, mm

Density kg/m3

Length mtrs, mm

s. Marking

Each instrument shall have a stainless steel nameplate, permanently attached from the

vendor’s factory containing the following data. Manufacturer’s name, Instrument type and

size, Model and serial numbers, Operating condition, e.g. voltage, pressure, Instrument range &

the specified instrument identification numbers or Tag number.


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

t. Connection Details:

INSTRUMENT

SERVICE & / OR RATING

PROCESS TAPPING

SIZE &

TYPE

INSTRUMENT

CONNECTION Flow: D/P Type Pipe Lines 3/4” Welded ½” NPT (F)

Flow: Diaphragm Pipe Lines 3” Flanged 3” Flanged

Level: Guided wave Radar Top mounted

Vessel (300# min.)

4” Flanged

4” Flanged

Level: Guided wave Radar Side mounted

Vessel/Stand Pipe

(300# min.)

2” / 2” Flanged

2” Flanged

Level: D/P TYPE

Vessel/Stand Pipe (300# min.)

3/4”/ 3/4” Flanged

½” NPT (F)

Level: Diaphragm Type D/P

Vessels (300# min.)

3” Flush Flanged

3” Flanged

Level: Magnetic Level Gauge

Vessels/ Stand Pipe (300#min.)

2” / 2”Flanged

2” Flanged

Level: GAUGE GLASS

Vessel/Stand Pipe (300# min.)

3/4” / 3/4” Flanged

3 / 4” Flanged

Pressure: Transmitters Pipe Lines / Vessels 3/4” Welded ½” NPT (F)

Pressure: Diaphragm seal Type Transmitters

Vessels / Pipe Lines

3” Flanged

3” Flanged

Pressure Gauge 3/4” Welded ½” NPT (M)

Diaphragm seal Type gauge

Vessels / Pipe Lines

1 ½” Flanged

1 ½” Flanged

Thermowell

Pipe Lines / Vessels

(300# min.on

vessels)

1 ½” Flanged

½” NPT

Note: These connection sizes will be reconciled with PMS of relevant piping and suitable revisions to

be in consultation with HPCL.

u. Accuracy of Instruments:

Type of Instrument Accuracy

- Differential pressure & Pressure

transmitter - SMART

± 0.075% of span (Note 3)

- Variable area type flow meter with ± 2.0% FS Note (1)

- Vortex flow meter ± 1.0% FS

- Coriolis Mass flow meter ± 0.2 % or ± 0.5 % of Measured value for

liquids depending upon applicability. - Positive Displacement Flow meter

- Raw material and Product

- Others

± 0.2% FS

± 0.5% FS


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

- Turbine meter or Mass Flow meter

- Raw material and Product

- Others

± 0.2% FS

± 0.5% FS

- Magnetic type flow meter ± 0.5% FS

- Ultrasonic type flow meter ± 1.5% OR 0.5 % of FS

- Tank gauge ± 1.0% FS OR ± 1 mm as applicable.

- Servo type tank gauge ± 2 mm OR ± 1 mm

- Radar type tank gauge ± 1 mm or better for custody transfer ± 5 mm or better for normal application

- Draft range Pressure transmitter - SMART ± 0.15% of span within TD ratio of 1: 30

- Diaphragm seal transmitter - SMART ± 0.2% of span within TD ratio of 1: 100

- Pressure gauge ± 1.0 % FS

- Temperature Transmitter ± 0.2% of calibrated span for RTD ± 0.5% of calibrated span for Thermo Couple.

- Filled system / Bimetallic ± 1.0% FS

- Small size pressure gauge ± 3.0% FS

- Draft gauge ± 3.0% FS

- Receiver gauge ± 1.5% FS

- Thermocouple & Resistance Bulb Applicable Codes/Standards

Note: 1. Vendor's standard accuracy is applied to local indicator type

Remarks: 1. Accuracy of instrument and special articles except for the above mentioned instrument shall be in accordance with the applicable codes/standards, or Vendor's standards as approved by Purchaser.

2. FS: Full scale.

3. Overall Turn Down of transmitter except for draft range shall be 1: 100. Draft range

transmitter Turn down shall be 1: 30 for the accuracy indicated above.

12.4 FLOW INSTRUMENTS

12.4.1 The choice of primary differential producing devices will depend on service conditions and on the permanent pressure loss, which can be tolerated. A square edged concentric orifice plate

is the usual selection if conditions permit. Quadrant edge or quarter circle orifice plates shall be used for viscous liquids and for pipe Reynolds number below 10,000 Conical entrance type of orifice plates shall preferably be used for very highly viscous liquids up to throat Reynolds number of 250. These shall be fabricated as per ISO 5167. Vent and drain holes shall be provided wherever necessary.

12.4.2 Corilios mass flow meters shall be used where greater accuracy is required like for custody

transfer, blending, feed flow from battery limit, product flow etc and for highly viscous and


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

fouling fluids like fuel oil etc. In case of Gas flow Turbine type flow meter shall be used. The mass flow meter must have the capability to periodically check the validation of the last calibration through software without dismantling the meter. Indigenous make, Coriolis Mass Flow Meters shall be calibrated at NABL Accredited Lab like FCRI, Palakkad in India and the calibration of Mass Flow Meters shall be certified by Third Party Agencies like EIL/Lloyds/BV. However imported make Coriolis Mass Flow Meters shall be calibrated at the

respective foreign vendor’s works, duly accredited by the respective country’s well known Accreditation Authority like PTB, SGS etc and the same shall be certified by well-known third party agencies like SGS, LRIS, DNV etc. Procurement and Installation for Custody Transfers / Non Custody Transfers shall be strictly as per approved P&IDs. Wherever Jacketing is shown in the P&ID, the same shall be provided for Mass Flow Meter. For Custody Transfer Applications, one spare Mass Flow Meter for each size shall be procured as shop spare.

In case of High turn down applications: For liquids, Mass Flow meter shall be used & for

Gas, Turbine Flow meter shall be used.

Where Mass flow meter is not applicable, Ultra sonic flow meter/Magnetic flow meter can be used. For the measurement of cooling water flow only magnetic flow meter shall be used including for the pipes below the ground level also.

Venturis and flow nozzles may be selected where system requires low pressure drops.

Pitot tube should be an averaging pressure type, and may be selected for clean fluids, low-pressure loss and large quantity measurement.

Vortex meter may be considered for clean liquids, gases and steam measuring application with higher turndown ratio.

Ultrasonic flow meter may be considered for the flow meter on large bore piping such as flare gas measurement.

Variable area flow meters may be used where measurement with low accuracy is accepted.

Flow nozzles, venturies, target meters, magnetic flow meters, ultrasonic flow meters, self- averaging pitot tube etc may be used wherever specified in the data sheet or as required.

12.4.3 Thin Plate Orifices:

Orifice plate shall be thin plate with square-edge concentric orifice. The plate shall be mounted between a pair of weld-neck flanges with flange taps to form orifice plate assembly.

Design calculation of standard type orifice plates shall be as per ISO 5167.

The flow range shall be selected such that normal flow rates are between 50% and 70% of

the flow upper range value.

Beta ratio limits for orifice plates shall be generally 0.3 to 0.7.


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

Material of construction of orifice plate shall be 316 SS except where this material is unsuitable for the service because of corrosion or erosion considerations, in which case an alloy shall be chosen whose corrosion allowance is equal to or better than line material. Orifice plates dimensions, finishing, flatness, tolerances for dimensions and identification information shall be in accordance with ISO standard. Orifice plate shall be provided with tab handle, which is welded on the orifice plate and engraved with following information on the upstream of the tab handle.

- UPSTREAM or UP

- Instrument tag number

- Orifice diameter

- NPS (Nominal Pipe Size) and ANSI flange class

- Material of the orifice plate

- DP range & Meter (Flow) range

12.4.4 Flange taps orifice shall generally be used for line sizes 2” to and including 16”. Above 16” line size, D and D/2 taps shall be used. Integral Orifice assembly with transmitter shall be used for line size 11/2 “or below (as per standard BS-1042).

Orifice assembly shall be provided with two sets of “Flange Taps” located in accordance with latest AGA standards. The orifice assembly shall be provided with jack screw for removal of orifice plate. Instrument tapping connections shall be 1/2”NPT (F).

12.4.5 For multi-transmitter flow installation from a single orifice, separate identical pair of tapping

is to be provided for each Transmitter & no branching from single tapping shall be designed. All tapings emerging from orifices shall be horizontal and shall have sufficient straight length as per standard.

12.4.6 For flow measurements by orifice wherever it is felt difficult to ensure the required upstream & down-stream straight length as per standard, the conditioning orifice plate is to be considered to eliminate the errors due to inadequate straight length.

12.4.7 It is essential that each instrument is having necessary approachable isolation as well as drain valve to check the functionality of the instrument ensuring safety.

12.4.8 Orifice flanges

Orifice flanges shall be in accordance with the ANSI B16.36, ANSI B16.36a and applicable piping specification. The minimum pressure rating of flanges shall be ANSI 300 lbs.

12.4.9 D/P Type Flow Transmitters

Flow transmitters for use with differential producing devices shall be Smart Type. All

transmitters shall be capable of communicating with Hand-Held Communicators. All

Transmitters shall have integral LCD indicator in engineering units and be furnished with test

terminals and bypass diode to facilitate field testing without disconnection of integral

indicator. The transmitters shall have over-range protection. Strain gauge types

Transmitters are not acceptable.


Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

500 mm H2O 2500 mm H2O

750 mm H2O 5000 mm H2O

1250 mm H2O

Separate transmitters shall be used for shutdown & control loops. Range calibration units for

flow measurement shall be mm H2O.

For Anti-surge loops, all transmitters used shall have faster response & high accuracy &

conventional (4-20 mA) transmitter shall be considered for the same. Wherever SIL (Safety

integrity level) loops are identified, min. SIL 2 certified transmitter shall be offered.

The body pressure rating shall be 100 bar minimum and measuring capsules shall be able to

withstand pressure up to the body rating in either direction without damaging the instrument or

shifting the zero more than 0.5% of the span. The body and other wetted parts material shall be

SS 316 minimum. Also other materials such as hastelloy, Monel or tantalum may be used as

per process requirement.

The transmitter electronics shall be capable of monitoring their performance during normal

operation. The transmitter diagnostics shall be able to detect both an input sensor failure and

transmitter electronics failure. The stability shall be better than +/- 0.5% of upper range limit

for 1 year.

Process connections shall be 1/2” (NPTF) and from the side/horizontal to the transmitter. Cable entry shall be 1/2” (NPTF).

Remote Loop Power indicator shall be provided (with separate DCS repeated output) as per

Licensor’s requirement.

In general Transmitter diaphragm shall have 5.7 micron of Gold plating for Hydrogen service.

Five way valve manifold shall be provided in place of isolation & equalizing valves in the impulse piping of flow transmitters for the service up to 600 # rating. However in case of high pressure service and any special requirement, piping manifold with single / double isolation valves and equalizing valve shall be considered.

12.4.10 As far as possible following standard ranges shall be used:

Technical Specifications for Liquid Ring

Compressor Package (280-LZ-01)

Doc No:

FGRU-

TSLC


of 67

12.4.11 Rota meters

Rota meters may be required as indicators or transmitters. Accuracy of measurement shall be within 2% full scale. Rota meters shall be mounted in-line for pipe sizes less than 2 inches. Rotameter Turn Down shall be 10:1. Flow damper shall be provided for pulsating flow. Cooling fins shall be provided for high temperature service (150 deg C & above). Jacket shall be provided for crystallizing fluid at ambient temperature.

Only metal tube Rotameter shall be considered. Glass tube Rotameter shall not be used.

12.4.12 Purge meters

Purge meter units shall consist of a glass / metal tube rotameter with needle valve at the inlet and a built-in check valve at the outlet. A differential pressure regulator shall also be supplied in applications where either the purge supply or process pressures are likely to vary significantly.

The design requirements for Purge meters include: rangeability of 10:1, accuracy

of +/-2% of maximum flow, “O” ring construction, and end connections of 1/4”

N.P.T (F).

12.5 Level Instruments

12.5.1 Selection

Remote diaphragm seal, D/P type level instruments with integral indication

shall be used. For slurries or other difficult services Wafer / flush diaphragm seal

type with extended capillary / Extended Diaphragm seal type shall be considered.

Guided Wave Radar type level instruments shall be used in place of Displacer type

instruments. The guided wave Radar instrument with external cage OR with

internal stilling well shall be considered.

12. 5.2 D/P Type Level Transmitters

Level transmitters for use with differential producing devices shall be Smart type

and be furnished with test terminals and bypass diode to facilitate field testing

without disconnection of integral indicator. The transmitters shall have over-range

protection. Separate transmitters shall be used for shutdown & control loops. Strain

gauge types Transmitters are not acceptable.

Wherever SIL (Safety integrity level) loops are identified, min. SIL 2 certified

transmitter shall be offered.

The body pressure rating shall be 100 bar minimum and measuring capsules shall

be able to withstand pressure up to the body rating in either direction without



Doc No:

FGRU-

TSLC


of 67

damaging the instrument or shifting the zero more than 0.5% of the span. The body

and other wetted parts material shall be SS 316 minimum. Other materials such

as hastelloy, Monel or tantalum may be used as per process requirement

The transmitter electronics shall be capable of monitoring their performance during

normal operation. The transmitter diagnostics shall be able to detect both an input

sensor failure and transmitter electronics failure. The sensor &/or electronics

failure shall be transmitted to the host system (e.g. DCS / PLC). The stability shall

be better than +/- 0.5% of upper range limit for 1 year.


Remote Loop Power indicator shall be provided (with separate DCS repeated

output) as per Licensor’s requirement.

Three valve manifold and oval flange adaptor shall be provided in place of isolation valves in the impulse piping for the service up to 600 # rating.

The D/P type level instruments are to be wafer seal type. It should preferably be direct mounting on the H.P side and capillary in L.P. side.

The wafer seal instruments must have the integral flange along with the diaphragm suitable to process connection.

Remote seal diaphragm type transmitter shall be used for all clean service except in hydrogen service.

In case, the process temperature is more than 200 degree C and the service is congealing, suitable flashing media is to be used along with the wafer seal type level instruments. In case the process temp. is high but not congealing, the impulse length / wafer location is to selected to reduce the process temp. in contact with wafer to about 150 deg C.

For corrosive, acid and alkali services, top mounted non-contact type

level Transmitters shall be used.

Two nos. Pressure Transmitters shall be used in place of Differential Pressure

Transmitter where long impulse piping / tubing is involved. The DP calculation

shall be done at DCS for PT1-PT2.

Separate and independent tapping shall be provided for level gauges and level

transmitters on the vessels. In case of constraint to provide many nozzles on vessel,

stand pipe may be provided to accommodate installation of field transmitters and

gauge. Stand pipes with isolation valves shall be used for LG/LTs. Maximum length

of single standpipes shall be 1500 mm. Standpipe (if required) shall be used for

Level measurements only. Separate nozzle shall be provided for pressure



Doc No:

FGRU-

TSLC


of 67

instruments. Stand pipes shall not be used for Transmitters on shutdown

applications.

12. 5.3 Level Gauge Glasses

Liquid level gauges shall be used for local indication. Gauge glasses shall be made of borosilicate armoured / toughened glass. Gauge glass shall be a single piece forged construction.

The reflex/transparent gauge glass shall be used on all clean service application.

The transparent gauge glass shall be provided with protective shield.

In case of service of crystallizing and viscous fluids, need steam tracing at

ambient temperature, level gauge shall be provided with facility of tracing.

Tubular type gauge glass shall not be used.

Gauge cocks shall be provided for all gauges preferably quick operating lever

operated forged offset ball type. All level gauges shall be supplied with ½” Drain

valve with plug & ½” vent plug. All the fittings shall be welded or screwed & seal

weld. All welding shall be TIG welding.

Transparent type glasses shall have integral illuminators operating at 240 V 50 Hz and suitable for the specified electrical area classification.

Transparent type with mica or Kel-F shield shall be used for treated water, boiler and condensate services and corrosive liquids which will attack glass.

The visible range of level gauge shall be selected to cover the operating level or the operating range of level instruments provided for the vessel.

The maximum visibility length of a single gauge shall not exceed 1500 mm. Normally glass of 300 mm (approx.) section length shall be used.

On low temperature services with liquids having very high vapor pressure at ambient temperatures safety valves shall be provided on the vent connection of the gauge glass.

Frost protection shall be considered for minus temperature fluid application. Bi-color

level gauges may also be provided if indicated by Licensor.

Magnetic level indicators shall be used in the place of gauge glasses for corrosive, dangerous or other difficult services. Maximum length for the single gauge shall not be more than 3 mtrs.

Magnetic Level gauges shall be used for high pressure H2 services. For high pressure services no threaded joints shall be used.



Doc No:

FGRU-

TSLC


of 67

12.5.4 Other level instruments

Other special type of level instruments like ultrasonic type, capacitance type, and nucleonic type shall be used as necessitated by application requirements / process Requirement.

12. 5.5 Steam Drum Level Measurement

For high-pressure steam drum application conductive type (“Hydra step” or equivalent) level instrument shall be preferred.

12.5.6 Solid Level Measurement

For solid level measurement, type of instrument shall be ultrasonic / radio frequency. The actual type selection shall be carried out based on the proven track record of the selected type for the similar type of application.

12.6 Pressure Instruments

12.6.1 General

Gauge Pressure / DP transmitters shall be used for measurement & control of process pressure from DCS. Local indication shall be by means of pressure gauges (bourdon tube, diaphragm or other element) to suit the application.

12.6.2 Pressure Transmitters

Pressure transmitters shall have suitable pressure sensing element and normally be with integral indicator. The pressure transmitters shall have zero and range adjustable, and it shall be specified so that the normal operating pressure is within 40% to 70% of the calibrated range.

Pressure transmitters shall be Smart HART type. All transmitters shall be capable

of communicating with Hand-Held Communicators. All Transmitters shall have

integral LCD indicator in engineering units and be furnished with test terminals and

bypass diode to facilitate field testing without disconnection of integral indicator.

The transmitters shall have over-range protection to 1.3 times the maximum

range of the instrument. Strain gauge types Transmitters are not acceptable.

Separate transmitters shall be used for shutdown & control loops.

For Anti-surge loops, all transmitters used shall have faster response & high accuracy & Conventional (4-20 mA) transmitter shall be considered for the same. Wherever SIL (Safety integrity level) loops are identified, min. SIL 2 certified transmitter shall be offered.

Remote Loop Power indicator shall be provided (with separate DCS repeated output) as per Licensor’s requirement.



Doc No:

FGRU-

TSLC


of 67

The body pressure rating shall be 100 bar minimum and measuring capsules shall be able to withstand pressure up to the body rating in either direction without damaging the instrument or shifting the zero more than 0.5% of the span. The body and other wetted parts material shall be SS 316 minimum. Other materials such as hastelloy, Monel or tantalum may be used as per process requirement.

The transmitter electronics shall be capable of monitoring their performance during normal operation. The transmitter diagnostics shall be able to detect both an input sensor failure and transmitter electronics failure. The sensor &/or electronics failure shall be transmitted to the host system (e.g. DCS / PLC). The stability shall be better than +/- 0.5% of upper range limit for 1 year.


Transmitters in vacuum service shall be capable of withstanding full vacuum regardless of range, without damage or calibration shift.

Flush type diaphragm seal element with capillary shall be used for congealing, corrosive and highly viscous services. The extended capillary shall be minimum 3 meter long.

The process connection shall be flanged 3” ANSI RF. The flange material and rating shall be as per piping specification / SS-316 minimum.

12.6.3 Pressure Gauges

Local indication shall be by means of pressure gauges utilizing a bourdon tube, diaphragm or other element like capsule to suit the application.

Local pressure gauges shall have 150mm dials and shall be quality gauges designed for the process industry.

Ranges of gauges shall be selected such that the normal operating pressure

indication is approximately at mid-scale. Accuracy of local pressure gauges shall be

+/-1.0% of full scale. Pressure gauges shall be capable of withstanding intermittent

overpressures of 1.3 times the maximum scale reading without damage or

calibration shift of more than 1% of the scale reading. Blow out disc shall be

provided for all ranges & solid front shall be provided for ranges of above 60

Kg/cm2g.

Cases for gauges having ranges between 0-2 and 0-20 Kg/cm2g shall have blowout discs in the back of the case. Cases for gauges having ranges above 0-100 Kg/cm2g shall be of the solid front type having blowout backs.

Gauges connections size shall be 1/2” NPT (M). Connection location shall be bottom for local mounting with wrench flats or back for local panel board with mounting flange.

All the gauges shall be equipped with 2 way valve manifold.



Doc No:

FGRU-

TSLC


of 67

The standard measuring element shall be a bourdon tube of AISI 316 stainless steel, except where the process fluid requires the use of special material.

Bourdon tubes shall be welded to socket and tip and stress relieved as required.

The Diaphragm Type & Capsule Gauges shall be used for low pressure applications.

Diaphragm seal type Gauges shall be used where necessary to protect gauges

from Corrosive fluid, crystallizing fluid, fluid including solids and high viscous

fluid.

Diaphragm seals shall be of welded diaphragm type close coupled to the instrument, or connected to it with capillary tubing.

The connection size for diaphragm seal type gauge shall be 11/2” flanged. The diaphragm material shall be minimum 316 SS & flange material and rating shall be as per piping specification / minimum SS 316.

In case, the diaphragm seal type instrument with extended capillary is used extended capillary tube shall be armored with stainless steel, and length shall be as determined individually but minimum 3 meters.

Diaphragm seals shall have flush connection 1/4” NPT with plug and filling

connection.

For viscous fluids, the diaphragm seal shall be clean-out type with removable bottom case

Sockets and tips shall be of the same material as the measuring element and shall be welded to the element using the same filler material. Movements shall be SS 304.

Dial face shall be white with black graduations marked. The gauge pointer shall be

adjustable without removing it from its shaft. All pressure gauges shall be

provided with block and bleed valves securely fastened with identification

tags.

Case shall be of stainless steel, solid front type and weather proof to IP-65

minimum.

12.6.4 Auxiliary components for pressure gauge

Over range protector (gauge saver) shall be provided where a pressure gauge cannot withstand design pressure conditions. Over range protector whenever used shall be of SS 316, as a minimum.



Doc No:

FGRU-

TSLC


of 67

Pulsation dampener shall be provided for all pulsating services e.g. Reciprocating pump discharge piping etc. Pulsation dampeners shall be of minimum SS 316 and have connection 1/2” NPT (F) on both ends. Dampener shall be provided with integral screw head needle valve to adjust aperture externally.

Pigtail type siphon shall be provided for steam service. Siphons shall be made of minimum SS 316 having connections 1/2” NPT (M) Or (F) on both ends as required to suit the PG.

12.7 Temperature Instruments

12.7.1 General For transmission of individual temperature signals, RTD shall be used in conjunction with field mounted temperature transmitters.

Resistance Temperature element (RTD) may be used as temperature primary elements where greater accuracy and better reproducibility are required. RTD shall conform to standard IEC-751.

All temperature elements shall generally be protected by thermo-wells. Class 'A' /

Class ‘1’ tolerance as per IEC 751 / 584-2 shall be specified for RTD /

thermocouple for temperature measurement.

12.7.2 Resistance temperature elements:

In general, Duplex type RTD shall be considered & used up to -200 to 600 Deg C.

- RTD shall conform to be PT-100, 3-wire type.

- RTD shall be spring-loaded, mineral insulated and SS 316 metal sheath type

- The sheath diameter shall be 6.4 mm as a standard unless otherwise

specified.

12.7.3 RTD heads shall be as follows:

- The RTD head shall be connected with thermowell with 3-piece union to

ensure proper contact of RTD junction to thermowell. - Head cover shall be screwed type, with SS retaining Chain fixed to body.

- Head cover shall be weather proof and ex proof suitable to specified hazardous area classification.

- Cable entry shall be 2 nos.1/2” NPT (F) with one entry plugged with SS 304 plug.

- Terminals shall have separate screws for connecting element and extension

cable.

12.7.4 Temperature Transmitters

Temperature transmitters shall be Smart HART type. All transmitters shall be capable of communicating with Hand-Held Communicators. All Transmitters shall have integral LCD indicator in engineering units. Temperature transmitters shall be Remote mounted type (on 2” Pipe), Head mounted transmitters shall not be used.



Doc No:

FGRU-

TSLC


of 67

Separate transmitters shall be used for shutdown & control loops.

For Anti-surge loops, all transmitters used shall have faster response & high accuracy & conventional (4-20 mA) transmitter shall be considered for the same. Wherever SIL (Safety integrity level) loops are identified, min. SIL 2 certified transmitter shall be offered.

All transmitters shall have universal input for thermocouple / RTD. Transmitter output signal shall be linear and directly proportional to the measured temperature with overall accuracy of +/- 0.1% FS.

Transmitter shall have automatic cold junction compensation for thermocouples. Burnout protection (selectable Up Scale / Down Scale) must be provided for temperature transmitters.

The transmitter Cable entry shall be 1/2” NPT (F).

Temperature transmitters shall be furnished with test terminals and bypass diode to facilitate field testing without disconnection of integral indicator. The transmitters shall have over-range protection to 1.3 times the maximum range of the instrument.

12.7.5 Bimetallic element local gauges

Only Bi-metallic elements shall be used. No liquid filled system to be used.

Bimetallic thermometers shall be bimetallic actuated rigid element and dial every-angle type.

Dial size of the gauge shall be 125 mm diameter. The stem and case material of the gauges shall be 316 SS.

Range shall be selected from manufacturer’s standards such that normal operating temperature indication is approximately at midscale.

In vibrating services bimetallic thermometers shall not be used. Other type of gauges can be used with PMC / HPCL approval.

12.7.6 Thermowells

Thermo well shall generally be provided for protection of the primary measuring

element. Thermowells for all services shall be in SS 316 minimum, and drilled in

a single piece from solid bar stock and tapered.

In general Thermowells process connections shall be flanged. Thermowell

connection on Lines shall be 1 1/2" NB, Thermowell connection shall be 1 1/2" NB

for uncladed vessel & minimum 3" NB for claded vessel. The minimum flange

Rating shall be 300 # or higher depending upon the pipe class for equipment /

vessels, however for the thermowells mounted on the pipe line flange rating shall

be as per pipe class. Thermowell and flange material shall be SS 316 minimum

or better as per piping class. Screwed type thermowells are not acceptable.



Doc No:

FGRU-

TSLC


of 67

In general, immersion length of thermowells shall be as follows:

Line Size Immersion length (When nozzle height - 200mm *)

4” 280 mm

6’’ to 8’’ 300

From 10” to 14’’ 350

Vessels / columns As per process requirements

For other nozzle heights, immersion length will be adjusted proportionally.

Other sizes and immersion lengths may be considered based on special

condition / actual requirements.

The design of the wells shall be verified by means of stress analysis, resulting from stream velocity condition. The wake frequency shall not exceed 66% of the thermowell natural frequency.

Pipe line below 3” nominal bore shall be blown to 4” NB size to install thermowell.

Only thermowell (test well) when specified, it shall be provided with the element entry plugged with SS plug and SS chain.

All the thermowells shall be offered for hydro testing at site to PMC/OWNER before installation.

12.8 Control Valves

12.8.1 Control valves shall normally be globe type top guided single seated type or eccentric disc rotary shaft type, except where high pressure drops, high capacity or other adverse conditions require for other type of valve.

The butterfly valves may be used for control and on-off applications with size equal or larger than 8”.

Ball valves may be used for on-off applications. Other valve types like diaphragm valves, rotary plug, angle or 3 way etc. shall be selected as per service / Licensor’s requirements.

12.8.2 Control Valve body shall be flange joint type. Valve body material, flange type,

rating and finish shall conform to the piping specification, however, the body & flange rating shall be minimum 300# for globe valves.

The body metallurgy of control valve shall be minimum as per piping specification. Body material WCB / WCC or equivalent is acceptable. If Piping specification calls for WCC or higher grade material then same shall be followed for selecting the control valve body material.



Doc No:

FGRU-

TSLC


of 67

Trim material shall be SS 316 or better. Trim shall be provided with partial or full stelliting in case of high pressure drops, erosive / slurry / steam / flashing services when recommended by manufacturer.

For all the control/shut down valves in steam / BFW application body metallurgy of the valves shall WCC or equivalent and trim to be properly stellited. All shutdown valves shall have Leakage class VI.

12.8.3 Anti-cavitation trim shall be selected wherever cavitation is expected in the valve.

12.8.4 Sizing of control valves shall be as per ISA-S75-01. Also valve selection to be

made for the manufacturer’s valve “CV” at maximum opening is not less than 160%

of the CV calculated for normal design flow or 110% CV of maximum flow,

whichever is higher.

Valve travel shall be between 20% to 80% for specified minimum & maximum

flow. Minimum body size of the control valve shall be 1”, reduced trim shall be

considered for smaller line size / small flow.

12.8.5 Valve Trim Characteristics

Equal percentage plugs shall normally be used when there are large variations in

valve pressure drop.

Linear characteristic plug shall be selected for

a) Level control

b) Over pressure control in steam or gas service

c) Small variations in valve pressure drop

d) Operation by remote hand controller

e) Split control and parallel control by two valves

f) Small CV and low noise valves as designated by MFR.

Quick opening trim shall be used for ON-OFF and Emergency Shutdown Valves.

For the corrosive & critical services Licensor guidelines shall be followed but in

general Stellite facing / hard facing trim shall be preferred (Plug, Stem, Seat ring).

Licensor’s requirement will take precedence in selecting trim metallurgy. However,

the trim material shall be SS316 with guide bushing of hardened stainless steel like

440C, 17-4PH as a min. up to a pressure drop of 10-12 kg/cm2. For higher pressure

drop, erosive/slurry services hardened surfacing of plug/seat ring etc. are to be

considered. 17-4 PH seat ring, 440C solid plug and other materials like Hastelloy,

Monel etc. should also be considered based on service requirements.

NOTE: Whenever the trim characteristics / material are specified in the Licensor’s data sheets then same shall be followed.

12.8.6 Face to face dimensions of the control valves shall be as per ANSI/ISA-S75.03.



Doc No:

FGRU-

TSLC


of 67

12.8.7 Noise level measured at 1 meter downstream and 1 m upstream of pipe wall shall

not exceed 85 dB. Source treatment of noise shall be preferred by using special

trims like anti-noise trims.

12.8.8 Copper or copper alloys in valves and accessories shall be avoided.

12.8.9 Seat leakage shall be chosen in accordance with process demands, safe operation of the plant and shall conform to ANSI / FCI 70.2

12.8.10 Bonnet shall be provided with cooling fins or extension when the fluid temperature

is 232 Deg C and more and shall be of extension type for low temperature -29 Deg C

below.

12.8.11 Valve packing shall be Teflon for temperature below 200 deg C and graphite for

steam services and temperatures above 200 deg C.

12.8.12 Generally, control valve actuator shall be of the spring and diaphragm, pneumatically actuated type. Standard air control signal to positioner shall be 0.2 to 1.0 kg/cm2g. Piston type actuators with or without fail-safe capacity tanks shall be considered if actuator force requirements fall beyond the normal range of diaphragm actuators. All actuators shall be adequate to fully stroke the valve under the maximum differential pressure specified by the process requirements.

Actuator colour shall be Red for air failure to close type and shall be green for air failure to open type. The valve actuator should be designed based on 4 kg/cm2

air pressure.

12.8.13 Electro-pneumatic valve positioners shall be provided for all control valves except

for On- Off valves. Air filter Regulator filter to be 5 micron. Miniature type, plastic

body & drain assembly etc .as parts of air filter regulator are not acceptable. Control

valves shall be provided with Smart/ HART type positioners. The Control valve and

its valve positioner shall be from same manufacturer. Proper canopy shall be

provided for E/P positioners and other accessories as required.

Necessary software for valve signature should be a part of the smart positioner

supply.

12.8.14 E/P Positioners, solenoid valves, booster relay, air lock relay, limit switches etc shall be supplied wherever required. I/P converter, when used it shall be Electronic feed back type and the enclosures shall be metallic.

Separate air filter regulator shall be used for each E/P Positioners.

12.8.15 In general, all tubing and fittings for control valve pneumatic signal shall be

SS 316 minimum.

12.8.16 Hand wheel shall be considered where the block and by-pass valves are not provided in the process piping or when required by process. In general no by-pass or hand wheel shall be used for shutdown valves unless otherwise specified by licenser.

12.8.17 Limit switches and any other electrical accessories shall conform to the

electrical area classification and environmental conditions.



Doc No:

FGRU-

TSLC


of 67

12.8.18 Limit switches shall be of Proximity type and intrinsically safe certified. Limit switches shall be provided both for close and open positions for all shutdown valves & only for Fail position in case of control valves.

12.8.19 Solenoid valves (Direct acting type) shall be used as the pilot valve to trip a

shutdown valve, On/Off valve. Solenoid valves, wherever used, shall be universal

type and shall be continuous rated type with class H coil insulation as per IEC 85/IS

1271. Wherever SOV are used for control valves in modulating services, SOV shall

be installed between positioner output & actuator & de-energising of SOV shall

bring control valve to failure poison by venting the actuator

Solenoid valve shall be of SS body with SS316 trim, three-way type universal operation as a minimum. Positioners with inbuilt SOV’s are NOT acceptable.

The solenoid valve operating voltage shall be 110V AC and suitable for

specified hazardous area classification. For On-Off valves, all Solenoid valves

shall have Auto Reset for ordinary application and field manual reset (FMR) shall

be provided for critical trip application as per Licensor’s Requirement. Integral

Reset with SOV shall not be provided. The ASCO / HERION / Max Seal make

Solenoid Valves shall be considered. Direct line mounted SOV shall not be

considered.

12.8.20 The guideline to identify the tight shutoff control valves is as follows:

1. Compressor spillbacks

2. High pressure shutoff valves (Depressurising valves )

3. Isolation valves

4. Emergency Shutdown valves

12.8.21 Seat leakage class for single ported and double ported valves or cage guided valves shall be minimum class IV type. All tight shut-off valves specified by Licensor shall meet class V seat leakage class requirements for metal seated valves and class VI requirements for soft seated valves as per FCI 70-2.

Class-VI leakage class with soft seat shall be considered for fuel gas service to flare

below 150 deg.C. and / or below 20 kg/cm2 pressure drop, other than this metal to

metal contact with leakage class-V to be used.

12.8.22 The other auxiliary devices such as lock up relay, pilot relay, booster relay volume tank etc. shall be provided as parts of the actuating system in order to achieve the required stroke-speed, fail safe action etc.

12.8.23 All control valves in service for temperature less than –20 deg. C, shall undergo

cryogenic testing in line with BS-6364.

12.8.24 All control valve castings in H2 service shall undergo Helium leak test

(additionally piping specifications also shall be referred for considering basis of helium leak test)



Doc No:

FGRU-

TSLC


of 67

12.8.25 Tag plates for all Control Valves shall be in SS 316 and necessary information like Tag no, Make, Model no, Service, Cv, Spring Range, Type etc shall be marked in bold font.

12.8.26 On / Off Or shutdown valves (in fire prone Area / As per Licensor’s guidelines) shall have external Fire Proofing Box (K-Mass OR equivalent Type) for actuator & valve assembly. Fire Proofing Box shall be as per API 607 standard. The enclosure material shall be SS304 & it shall withstand Refinery Fire 1100 Deg C for around 15 to 20 minutes. The enclosure shall have adequate openings for entry of Tubes / Cables, which shall be sealed at site after completion of erection.

12.9 Safety Relief Valves

12.9.1 Sizing of safety relief valves shall be in accordance with API RP-520 (latest

edition), Indian Boiler Regulations ASME Section I (Power Boilers) and ASME

code for Pressure Vessels Section VIII’. The code stamps shall be provided for

safety valves in case ASME and Indian Boiler Regulations design.

Safety relief valves shall normally be direct spring loaded types and provided

with full nozzle type. Balanced bellows type safety valves shall be provided when

variable backpressure exceeds 10% of the set pressure or fluid is corrosive. Pilot

operated pressure relief valves shall be used for special services and where set

pressure is closer than 10% of the operating pressure, in general. Thermal relief type

valves shall be used for thermal expansion of liquid or gas. Vacuum relief type

valves shall be used for Storage tank. Steam jacket type safety valves shall be

used for crystallizing fluid at ambient temperature.

12.9.2 ¾ “x 1” threaded (NPT) modified nozzle type valves with typically 0.38 cm2

orifice size shall be specified for thermal relief.

12.9.3 The body material shall, as a minimum, be as per piping specifications. Nozzle and disc material shall be SS316 as a minimum with machined stainless steel guide, and spindle. Whenever semi nozzle designs are unavoidable, body material shall be at least same as nozzle material.

12.9.4 The spring material of pressure relief valves shall be as follows unless

otherwise necessary because of process conditions.

-29ºC to 250ºC : Cadmium / Nickel plated carbon steel

Above 250ºC : Tungsten alloy steel

Below – 29ºC : Stainless steel 316

12.9.5 Flanged connection shall normally be specified for standard sizes 1" or larger with facing and rating in accordance with the piping specification.

12.9.6 Where permissible, screwed connections shall be used on sizes ¾” and below and

for thermal expansion relief valve.



Doc No:

FGRU-

TSLC


of 67

12.9.7 Conventional type safety valves shall have vented bonnets with screwed caps; balanced bellows type safety valves shall be of the yoke type with screw setted caps.

12.9.8 Plain lifting levers shall be provided for steam and air services. Packed lifting levers

shall be used when protection against leakage is required.

12.9.9 All safety relief valves relieving to flare header shall be balanced bellows type only with trims and bellows in SS 316 L.

12.9.10 Pressure relief valves required for liquid service shall have liquid trim with

discharge coefficient certified by ASME.

12.9.11 Pressure relief valve body casting and nozzle casting with inlet rating of 600 # and above in Hydrogen service shall undergo Helium leak test.

12.10 Gas detection system Hydrocarbon gas detectors shall be IR type. The transmitters shall be intrinsically safe with 4~20 mA output superimposed with HART Protocol. All transmitters shall have local LCD display units.

All the mounting accessories, splash guards, junction box etc. shall be included in the scope of supply. Calibration cylinders for 6 months of operation shall be supplied. Gas detectors shall be weatherproof & IS certified.

12.11 Local control panels & Local Gauge Board

12.11.1 Only indication lamps / alarm panels in flameproof or intrinsically safe enclosure shall be installed in local panels.

Field panels shall be Ex-proof / Pressurized panel with purge system considered depending upon the panel size and other criteria for hazardous areas.

12.11.2 Local control panels, in general, shall be of free standing, totally enclosed construction, fabricated from 3.2 mm thick CRCA steel plate. Maximum dimensions shall be 2100 mm (H) x 1200 mm (W) x 1000 mm (D).

The panels shall be pickled / phosphated and shall undergo a seven-tank process

before primer is applied. The panels shall be provided with 2 coats of red oxide

primer and 2 coats of final stove enameled paint. Paint colour shall be any of the

following (to be confirmed).

Opaline green IS 275

Light admiralty gray IS 697

As approved by the OWNER.



Doc No:

FGRU-

TSLC


of 67

12.11.3 Panel doors shall cover the total width and height of a panel section. All doors shall have continuous stainless steel plane hinges. Panels over 1200mm wide shall have double rear doors with heavy duty T-bar latches. Panels less than 1200mm wide shall have single rear door with heavy duty T-bar latch.

12.11.4 Panels shall be provided with 4 lifting lugs at the top. The panels shall be well sealed against ingress of dust and moisture. IP 51 as per IEC 529 for indoor applications and IP 55 for outdoor service.

12.11.5 Local control panel for the package units shall be installed within the battery limit of the package considering operational and maintenance requirements and accessibility. In case of skid mounted package; panel shall be located away from the skid.

In case local control panel is housed outdoor i.e. not in a local control room, it shall be designed to meet IP-55 requirements. In addition, panel must be provided with a rain cum sun shade canopy /shed

12.11.6 It shall be possible to switch off incoming power to panel from panel front. All

such power on/off switches shall be flameproof type.

12.11.7 Local control panels shall be either flame-proof Ex.’d’ type or purged type as per

NFPA-496 Type Y purging. An alarm shall be provided on local panel, whenever the

panel pressurization falls below 2.5 mm of H2O. All hinges, screws and other

non-painted metallic parts shall be of stainless steel material.

Local Control Panel shall have Canopy/ Shed Provision at the top for Monsoon/Sun

Protection and also lighting arrangement outside the Local Control Panel shall be

provided at the top of the Panel in addition to the Lighting arrangement inside the

Local Control Panel. 12.11.8 Analogue signals shall be 4~20 mA DC loop powered by intrinsically safe certified

Isolator repeaters in control panel, wherever required. Vendor shall use isolator

repeaters with single input and dual outputs for repeated signals.

All close & open loops signals required at LCP shall be terminated to DCS/PLC

first & the repeated output from DCS/PLC (using 1 in 2 mA output convertors) shall be wired to LCP for local indication / information to the local operator.

12.11.9 LCP shall have LED cluster type intrinsic safe Alarm Annunciator for alarms &

trips. All instruments like push buttons, lamps, selector switches etc on LCP shall be used in Intrinsic Safe Circuit. The switches / push buttons etc. are preferably to be miniature type and the lamps are to be LED type. All stop push buttons shall be guarded type. It is desirable to have only IS type instruments mounted in the local panel in case it is located in hazardous classified.



Doc No:

FGRU-

TSLC


of 67

12.11.10 Engraved identification plates shall be provided for all instruments on rear of the panel face. Instruments shall have integral nameplate on the panel front. Markers for wires, tubes, terminals, connectors, switches, circuit breakers, panel numbers etc. shall be permanently affixed on them

12.11.11 The panels shall normally be floor mounted on channel base. Channel base and

suitable bolts shall be included in the scope of panel supply.

12.11.12 Cable entry to the panel shall be only from the bottom. Suitable removable cable gland plate with double compression type cable glands shall be supplied along with the panel. All unused cable entries must be plugged.

12.11.13 All panels shall be equipped with an earth bus securely fixed along the inside base

of the panels. Provision shall be made for future extension of the earth bus, if need arises.

12.11.14 The control panel shall be subjected to the following tests and checks:

1. Check of panel alignment and mechanical operation check

2. Verification of degree of protection as per IS 2147.

3. High Voltage Test (2000V for 1 minute)

4. Verification of wiring as per approved drawings

5. Routine tests and checks on all panel accessories

12.11.15 Local Gauge Board : Local gauge board shall be used to install

skid mounted instruments like pressure gauges, temperature gauges and

transmitters. Local gauge boards, when provided shall have easy access at the rear

and front for all instruments and accessories for maintenance and operation.

12.11.16 Gauge board shall be constructed from 3 mm cold rolled cold annealed steel

sheet with other necessary steel supporting structure and shall be painted as per Mfr.

Standard.

12.11.17 Local gauge board shall be supplied with all instruments installed and completely

in tubed/wired condition before shipment.

12.11.18 All pressure gauges shall be provided with block and bleed valves securely

fastened. Identification tags shall be securely fastened for easy identification both at

the front and rear.

12.12 Installation materials

12.12.1 Cables

a) All cables shall have PE insulated primary insulation of 85 Deg C PVC as per IS-

5831 type C and inner and outer jacket shall be 90 Deg C PVC to IS-5831 type

ST-2. Oxygen index of PVC shall be over 30% and temperature index shall be over

250 Deg C.



Doc No:

FGRU-

TSLC


of 67

b) Cables shall be fire retardant (FRLS) as per standard IEC 332 Part III Cat. A.

c) The insulation grade shall be 600 V/1100 V as a minimum and shall meet insulation

resistance, voltage and spark test requirements as per BS-5308 Part-II.

d) All cables shall be twisted & armoured with galvanised steel wire – round as per IS-

standard.

e) Color coding of thermocouple extension cables shall be as per ANSI standard.

Outer colour shall be light green for intrinsically safe cables.

f) Conductors shall be stranded electrolytic annealed copper except for T/C extension

cables Maximum dc resistance of the conductor of the cable shall be as per IS8130.

g) The drain wire resistance including shield shall not exceed 30 ohms / km.

h) A pair of communication wire shall be provided for multipair cables. Each wire

shall be 0.5 mm2 of plain annealed single or multi-stand copper conductor with

0.4 mm thick 85 Deg C PVC insulation. Insulation shall be green and red color coded.

i) Run length of the cable shall be printed at least at every 5-metre interval.

j) Signal / alarm cables

1) Single pair shielded signal cables shall be used between field instruments

and junction boxes/local control panels.

2) Multipair individually and overall shielded signal/alarm cables shall be

used between junction boxes/local control panels and main control room, in

general.

3) Shield shall be aluminum backed Mylar polyester tape bonded with the

metallic side down helically applied with either side having 25% overlap

and 100% coverage. The minimum shield thickness shall be 0.05 mm

in case of single pair/triad and 0.075 mm in case of multipair/triad cable.

4) Drain wire shall be provided for Multipair cables and overall shield, which

shall be 0.5-mm2 multi, stranded bare tinned annealed copper conductor.

The drain wire shall be in continuous contact with aluminum side of the

shield.

5) All multi pair cables shall have 6 pair/12 pairs only while multitriad cable

shall have 6 triads / 8 triads only.

k) Solenoid valve Cables

1) Single pair cables shall be used between field mounted solenoid valves and junction boxes/local control panels.

2) Multi core control cables shall be used between junction boxes, local control

panel and main control room mounted devices in general. These cables shall have overall shielding apart from individual shielding. Specifications for SOV cables shall be same as signal cables except for the outer sheath color which is ‘Black’.



Doc No:

FGRU-

TSLC


of 67

l) Power supply cables

1) All power supply cables shall be as per IS-1554 Part I and shall have

copper conductors. Minimum conductor size shall be 2.5 mm2.The cables

shall be PVC insulated and armoured. The higher size conductors shall be

used in case of long distance power cable where voltage drops more than 3

volts than required supply.

2) Any other special cable required for instruments that should also be supplied

as per requirements. CONTRACTOR shall ensure that these cables are armoured type and shall meet all other requirements.

3) The following table shall be followed for selecting cables for specific application:

Type

No of Cores/ Pairs

Brief Specification

Wire Colour

Coding

Colour of Outer Sheath

Remarks

Non -IS

IS

S1 6, 12 Pairs

Main signals runs (Analogue / Digital signals including SOV) between SRR and field junction boxes shall be FRLS as per IEC 332 Part III Cat A, twisted pair (as per IS std.), multi-stranded 1 mm2 (17 AWG) pair electrolytic annealed copper conductors, 85ºC PVC insulated as per IS-5831 type C, an individually shielded with aluminum-mylar/polyster screen, and an overall aluminum-mylar/polysterscreen over a 0.5 mm2 (20 AWG) (minimum) tinned copper drain wire, 90ºC PVC bedding to IS 5831 type ST-2, galvanised steel wire armoured, 90ºC PVC sheathed overall to IS-5831 type ST-2, an overall shield, 600V/1100 V grade insulation as per BS-5308 Part-II.

Black(-), White(+) (Each pair within a

cable shall be identified

with a unique

number.)

Black Light Blue



Doc No:

FGRU-

TSLC


of 67

S2 1 pair

Individual analogue/digital signal runs between field junction boxes and instruments, shall be FRLS as per IEC 332 Part III Cat A ,twisted pair (as per IS std.), multi-stranded 1.5 mm2 (15 AWG) pair electrolytic annealed copper conductors, 85ºC PVC insulated as per IS-5831 type C, overall aluminum-mylar/polyster tape over a 0.5 mm2 (20 AWG) (minimum) tinned copper drain wire, 90ºC PVC bedding to IS 5831 type ST-2,galvanised steel wire armoured, 90ºC PVC sheathed overall to IS-5831 type ST-2,600V/1100 V grade insulation as per BS-5308 Part-II.

Black(-), White(+)

Black Light Blue

Type

No of Cores/ Pairs

Brief Specification

Wire

Colour Codin

g

Colour of Outer Sheath

Remarks

Non -IS

IS

T1

6, 8

Triad (typica

l)

Main runs between SRR and field junction boxes for three wire devices, shall be FRLS as per IEC 332 Part III Cat A ,twisted Triads (Triple) (as per IS std.), multi-stranded 1 mm2 (17 AWG) electrolytic annealed copper conductors, an individually shielded ,85ºC PVC insulated as per IS-5831 type C with aluminum-mylar/polyster screen and one overall aluminium-polyester screen over a 0.5 mm2 (20 AWG) (minimum) tinned copper drain wire, , 90ºC PVC bedding to IS 5831 type ST-2, galvanized steel wire armoured, 900C PVC sheathed overall to IS-5831 type ST-2, an overall shield, 600V/1100 V grade insulation as per BS-5308 Part-II.

Blue,

Brown, Black

(Each pair within a

cable shall be identified

with a unique

number.)

Black

-

RTD

signal, Vibration measure ment , Axial

Displace ment

measure ment, Gas

Detector



Doc No:

FGRU-

TSLC


of 67

T2

1 Triad

Three (3) wire devices which have individual signal cable runs to field junction boxes or direct to the SRR, twisted Triads (Triple) (as per IS std.), multi-stranded 1.5 mm2 (15 AWG) copper conductors, 85°C PVC insulated as per IS-5831 aluminium-polyester screen over a 0.5 mm2 (20 AWG) minimum) tinned copper drain wire, type-C 90°C PVC bedding to IS-5831 type-ST2 , galvanized steel wire armoured, 90°C PVC sheathed overall to IS-5831 type-ST2 600/1100 V grade insulation.

Blue,

Brown, Black

Black

-

T3

1 pair

Individual signal runs between elements & transmitters, shall be FRLS as per IEC 332 Part III Cat A 1.3 mm2 (16 AWG) pair solid conductor, provided with overall aluminum-mylar / polyster tape over a 0.5 mm2 (20 AWG) (minimum) tinned copper drain wire. The Thermocouple extension wire shall be in accordance with ISA (ANSI) MC96.1.

Yellow / Red

(K-type)

Black

Type of thermocouple

extension cable

shall be compatib le with thermocouple

used. JX type

shall not be used.

P1

3

cores

Power feeder for instruments / Local Panel - 110V AC 50 Hz, shall be FRLS type. The power supplies shall be 2.5mm2 (13 AWG) minimum, copper conductors, PVC insulated, galvanised steel wire armoured, covered by an outer sheath of PVC, 1100V grade min. The power cables shall be designed as per IS-1554 Part-I.

- for 3 core Red (hot),

Black (neutral)

and Green (earth)

Black

-

E1 1 core Earthing, minimum 2.5 mm2 stranded copper conductor

Green with single yellow

strip

m) Cable glands

All cables glands shall be of type 304 SS; double compression type suitable for armoured cables and have PVC shrouds.

Flame proof glands wherever required shall be supplied with applicable

Ex (d) Certification.



Doc No:

FGRU-

TSLC


of 67

12.12.2 Junction boxes

Separate junction boxes shall be used for IS and non IS signals. Further it shall be segregated based on signal types given below;

a) Analogue input/Analogue output

b) Digital input

c) Digital output & SOV d) Power cable.

e) Vibration signal

f) Gas detectors

NOTE: In general direct cables shall be avoided in general but direct cable shall be considered for pulse signals (If any).

a) Junction boxes shall be of die cast aluminum alloy (LM-6) body minimum 5 mm

thick. All JB’s shall have threaded cover wherever applicable. The JB shall be

flameproof Ex (d) as per IS 2148/81 suitable for Installation in required Hazardous

Locations (Gas Group IIA, IIB OR IIC). Protection shall be IP-65 as per IS

13947/93 Part-1. Junction Box shall be CCOE approved, for specified hazardous

area class based on gas group service.

b) Terminal strips required. – 2 rows of 24 nos of terminals each, 2.5 Sq.mm,

Cage Clamp, SS Spring, Screw less Phoenix / Wago make Connector with Front

Entry and numbering strip shall be clearly visible after wiring. All terminals shall

be DIN rail mounted. Each JB shall be provided with external earthing lugs

suitable for 4 mm2 earthing connection.

c) Cross ferruling philosophy to be followed for wiring. Black letters on yellow/white

sleeve to be followed for normal signals. Red color letters on white/yellow sleeve to

be followed for trip related signals.

d) Telephone sockets and plugs shall be provided in junction boxes.

e) No of Entries: For 12 pair cables - Two bottom entries of size 1½” NPT for multipair cable, 12 Nos Side entries (Six entries in each side) each of ½” NPT for single pair signal cables.

f) In each junction box minimum 2 Nos. of ½” NPT branch cable entries & 1 No. of 1 ½” NPT bottom entry shall be kept as spare. All spare entries shall be provided with SS plugs (Ex d). The multi pair cable entry shall be from bottom & branch cable entries shall be from side only.

g) Graphite based grease should be applied to junction box cover and all screw before shipment. Each junction box shall have SS Tag Plate at the center of cover plate.



Doc No:

FGRU-

TSLC


of 67

h) JB Colors shall be as described below

For all IS Boxes: Blue (Epoxy shade) – inside Epoxy Yellow

For Non IS & Power Junction Boxes: Gray (Epoxy shade) – inside Epoxy Yellow

12.12.3 Impulse piping/tubing

a) In general transmitters for hydrocarbon service shall be installed close coupled (as

per Licensor requirement) or with minimum length of impulse tubing.

b) Impulse piping / tubing shall be ½ in. NB impulse lines as per piping specification, however final connection to instrument of impulse piping shall be made using 12mm OD X 0.065” thick ASTM A -269 TP 316 stainless seamless tubes and SS 316 compression fittings. SCH 80 seamless pipe with at least 3000 lb rating fittings should be used as minimum for impulse piping.

c) For long impulse lines wherein process line is not accessible and field transmitter

is accessible from a grade level, following guide lines are to be followed.

d) Impulse line entering to the transmitters which are installed at ground/grid levels shall be done by SS-316 tubing and balance impulse line up to the 1

st isolation

valve shall be done by ½” size piping. The joining of these two impulse lines (Pipe & SS Tube) shall be done by flange joints. However, close coupled type impulse line hookups shall be preferred incase both process lines and the transmitters are accessible from same grade level.

e) Steam tracing shall be 1/4” mm OD bare copper tubes of electrolytic grade copper.

f) Proper accessibility to be provided to installed field devices by providing ladder or platforms, for maintenance.

g) Unique colour (post office red) to be painted to the impulse piping for identification

of instrument used for trip applications (near Transmitter end).

h) MOC of tubes and tube fittings shall be of minimum SS-316.

12.12.4 Pipes and tube fittings

a) Pipes and tube fittings shall be SS 316 double compression tube fitting of three-piece construction of Swagelok / Parker make only. The tube fittings shall be of min.3000 # rating.

b) The fitting/ferrule hardness shall be in the range of RB 85-90 so as to ensure

a minimum hardness difference of 5 to 10 between tube and fittings. The ferrule shall be of stainless steel material, in general.

Socket-weld type forged pipe fittings of suitable material and rating shall be supplied for pipe fittings. The minimum rating shall be 800 lbs. Weld neck fittings shall be used where socket weld types are not allowed by piping class.



Doc No:

FGRU-

TSLC


of 67

c) All threaded fittings shall have NPT threads as per ANSI/ASME B16.11 only. d) All

the pipe fittings shall be of 800 LBS minimum rating. All tubing shall be properly

clamped as per international standard and good engineering practice.

12.12.5 Pneumatic signal tubes

a) Pneumatic signal tubes shall be ¼” OD x 0.028-inch thick SS 3316 tubes as per ASTM A 269 seamless type. Where air supply requirement is more such as large size on/off valves 12 mm OD tube shall be used.

b) Use of intermediate connectors shall be avoided and shall estimate single run

length for each instrument location. Air supply to individual instruments shall be provided with SS 304 full bore ball valves.

12.12.6 Instrument air manifolds, fittings and valves

a) GI Pipe shall be provided from Isolation valve of Air Header up to the Air

manifold. Further distribution will be through the Air manifolds (6 Way Or 10 Way)

b) Instrument air manifolds made out of 2” inch Seamless SS pipe.

c) Double compression type Stainless steel fittings made out of solid bar stock of

3000 lbs rating shall be used.

d) Isolation valves on instrument air service shall be pack less gland type full-bore ball valves and body material shall be SS 316.

e) All isolation and drain valves shall be gate valves. Equalizing valves shall be

globe valves.

f) Body rating and material shall be as per piping class or better and trim material shall

be SS 316. All valves and manifolds shall be forged type only and of minimum

800 LBS rating. g) Superior body and trim material shall be selected if required by process conditions.

Packing material in general shall be of PTFE.

12.12.7 Air filter regulators

a) Instrument air filter regulator of suitable size, range and capacity shall be supplied

for each pneumatic instrument.

b) The body of the filter shall be anodized aluminum.

c) The filter shall have 5 micron sintered bronze/ceramic filter element and shall be provided with manual drain and 2” nominal size pressure gauge.



Doc No:

FGRU-

TSLC


of 67

12.12.8 Cable trays and Ducts

a) All cables on the main pipe rack shall be laid in cable duct. Cable ducts shall be

of FRP construction with cover.

b) All instrument cables in general will be laid over the ground. All branched field cables in the unit area will be laid on machine molded FRP cable tray. The tray shall be of perforated type FRP material. The same will join the cable duct highway above the pipe rack and proper separation between IS / Non IS cables & Power cables in the duct highway shall be maintained. For road crossing and wherever, above ground laying is not possible, cables will be laid underground through cable trench/ Hume pipe.

Instrument cable duct routing should be designed in such a way, that the same

should not get disturbed or damaged during any underneath running mechanical pipe

line replacement

c) The cable ducting sizing should be done in such a way as to provide at least 50%

extra spare capacity for future additions.

d) The vertical drops on the ducts shall be avoided as a general philosophy. Cables shall be made to drop through inclined (45-60 degree) ducts.

e) All FRP trays shall be made of Glass reinforced Flame retardant Isophthallic polyester (minimum Glass content 45 %). It shall be Corrosion resistant and Fire retardant (Class 1, Fire rating) in accordance with the latest ASTM E-84 / IS - 6746. Painting of cable trays shall be as per HPCL painting specifications (Refer attached document no. DSI-G-1.2)

f) An additive is to be mixed with the matrix polyester to make the material Ultraviolet resistant. The FRP Cable Bearers are to be manufactured using the PULTRUSION process. Both sides of FRP trays shall have machine finish.

g) Up to 150 mm width, FRP trays shall be Channel type and above 150 mm width, FRP

trays shall be Ladder type.

h) All FRP trays shall have minimum thickness as per follows.

Up to 100 mm tray- thickness minimum 4 mm

above 100 mm tray- thickness minimum 5 mm

Only SS 316 nuts & bolts shall be used for FRP trays jointing plates.

i) FRP trays for channel type shall have horizontal array of holes of 4 mm diameter at every 300 mm of tray length for cable clamping purpose. Gaps between holes shall be less than 30 mm.

j) Necessary FRP tray bends, tees etc shall be supplied along with the FRP trays.



Doc No:

FGRU-

TSLC


of 67

k) Structural supports used for cable ducts / tray etc should be sufficiently strong to take

care of the load of the fully loaded cable duct.

l) All underground cable trenches wherever required shall be loaded up to 50%

capacity in order to meet future additions

m) Separate cable tray will be used for IS / Non IS cables & Power cables. All cables shall be laid in single layer in case of Trays and all cables shall be identified / marked with SS-316 tag plates with SS-316 wires at every 20 metre intervals. Only 316 SS Bolts/Nuts for FRP Cable Trays and Canopies shall be used

12.12.9 Instrument support/structural steel

Instrument stands, stanchions and other structural steel material required for supporting the cable trays, impulse lines and instruments shall be considered. Structural angles used for cable dropping to Junction Box or to field device shall be preferably galvanized. Stanchions shall be made out of A106 Gr. B 2” size pipe as a minimum. In case application calls for higher grade material, the same shall be supplied by contractor” All the structural steel & stanchion shall be epoxy painted.

All field Instruments shall be adequately supported.

12.13 Painting Specification

a) All the outdoor items shall be tropicalized and epoxy painted. All carbon steel

bolting shall be hot dip galvanized or Cadmium plated and bi-chromated.

b) Screws, rivets, brackets and stiffeners shall be stainless steel.

c) Color of the top coat of panels shall be manufacturer standard / to

be confirmed.

d) Painting for field Instruments, Canopies, Instrument lead lines, gas

detectors, cable ducts, trays shall be as per attached Painting

specifications (Document No. DSI-G-1.2)

12.14 Erection of Field Instrumentation

12.14.1 General

a) All the instruments should have approach for maintenance. All instrument location should be accessible /approachable.

b) The JBs are to be Ex proof as a standard to ensure interchangeability. The cable

entry must be from bottom and branch cable entry shall be from the sides. The incoming multi pair cable shall have minimum 1mtr. of spare loop before glanding & termination. All the power supply JBs are to be earthed locally (through electrical earthing system at field).



Doc No:

FGRU-

TSLC


of 67

c) The power cables are to be laid in different trays and not to be mixed with the signal cables.

d) In general JB’s should not be installed on vibrating body. The location must not have nearby very hot lines, condensate draining arrangement etc. JBs are to be installed in location having approach for maintenance. All the glands are preferably to be double compression type with necessary shrouds

e) The SS tubing for instrument air to control valve, I/P etc. are to be 6 mm O.D

unless otherwise specified. The fittings must be double compression type. Copper tubing should be avoided except for steam tracing.

f) Necessary fire proofing is generally preferred for the complete duct and the venerable

portion of the trays.

g) The supports for the closed couple field instruments are to be taken from the same pipe / equipment (except for wafer seal instruments) only to avoid effect of expansion on account of temperature, pressure etc.

h) The impulse lines are suitably painted if not insulated.

i) Perforated trays are to be used for laying of capillary of wafer seal type instruments.

l) The tapping for level instrument / level stand pipe from vessel / column bottom should be avoided. The impulse for steam / liquid lines must have required slope towards the instruments. However, for gas services the slope must be towards the process i.e. self draining type.

m) It is preferable to use only socket weld (SW) type fittings for impulse piping. Wherever it is difficult (like 150#RF flange etc.), next higher size SW fittings are to be used. The impulse should be sch 80 seamless piping as a minimum.

n) There should be at least one isolation valve & one drain valve in the impulse of each instrument. The remote type impulse piping shall be provided with proper supports.

o) All the impulse fit ups are generally documented with the traceability of

individual fittings / hardware. All the welding joints are subjected to the NDT as per the code/standard as well as hydro tested (Impulse Lines).

p) The Instrument airline after the main header up to Air Manifold is generally made of

GI with heavy schedule of piping, fittings etc. The total instrument air network

is to remain isolated from the header 1st

isolation valve until the same is flushed with water / air etc. and finally charged with instrument air.

q) After completion of the branching of air line pertaining to each tapping, the total branch network is to be flushed. During this period the connection to C/V & other consumers shall be open. The network is to be leak tested and problems rectified. The final connection to the line mounted instruments; C/V etc. are generally made only on final installation after flushing.



Doc No:

FGRU-

TSLC


of 67

r) Normally the field instruments are installed along with the canopy, if specifically

asked to protect the instrument from damage due other erection activities.

12.14.2 SPECIAL INSTRUCTIONS TO VENDOR:

1. Vendor shall supply compressor along with the complete Instrumentation

& control system for start-up, shutdown and for all specified operating

conditions.

2. Instrumentation & installation shall conform to the API standard 681 as

a minimum.

3. All conduits, armored cables and supports shall be designed and installed

so that it can be easily removed without damage and shall be located so

that it does not hamper removal of bearings, seals, or equipment

internals.

4. A free standing local panel shall be provided which shall include all panel

mounted instruments for the driven equipment and the driver. The

instruments on the panel shall be clearly visible to the operator f r o m the

driver control point. A lamp test shall be provided for all the local panel

lamps. LCP shall be suitable for installation in the specified area

classification.

5. Panel shall be c ompletely assembled, piped and wired, requiring only

connections to the external piping or wiring. When more than one

wiring point is required on a unit for control or instrumentation, the

wiring to each switch or instrument shall be provided from a single

terminal box, with terminal posts. Each box shall be mounted on the

unit or its base if any. All leads and posts on terminal strips, switches

and instruments shall be tagged for identification. Wiring inside panel

shall be neatly run in conduits or supported on cable trays.

6. All the transmitters shall be erected, pre-wired to field ex-proof junction

boxes on the skid. All the cables to and from the field instruments shall be

fully wired up to junction boxes, which shall be mounted on the respective

skids, by the vendor. However, hooking up of these junction boxes to the

control room shall be in the scope of HPCL. All interlock/shutdown related

instruments shall be hooked to Vendor supplied PLC. However, parameters

for monitoring & controlling shall be hooked to existing DCS system.

7. Only transmitters shall be used for trip & alarm sensors. No switches shall be

used.



Doc No:

FGRU-

TSLC


of 67

8. There shall be no mixing of signal cables, control cables at junction boxes

used for instrumentation. Separate junction boxes shall be provided for signal

cables and control cables.

9. 2 out of 3 voting shall be provided for critical process parameters as required.

Vendor to consider 2oo3 as per the requirements of Vendor's

standards. 3 nos. transmitters need to be considered wherever 2oo3 logic

is used.

10. Vendor to provide machine monitoring & protection system as per

API681/API670 standards. 4 nos. accelerometers on bearing housing (2 nos.

on each bearing), 1 no. axial probe and 2 nos. RTDs for each bearing shall be

considered as a minimum.

a) Monitoring for Vibration and Axial Displacement shall be through Bently

Nevada System (BN 3500) to be located in Control Room with serial

communication to DCS on MODBUS RTU protocol.

b) Vibration and axial displacement monitoring system shall be based on non-

contacting type sensing probe, unless otherwise specified.

c) Vendor shall furnish requirements for monitoring deemed essential by them

with reasons. Two probes at 90 degree apart for each location shall be

provided and connected to same dual channel monitor for vibration

monitoring at each location.

d) The sensing probe shall be accessible for adjustment, repair and replacement

without dismantling the machine. Sensing elements shall be flexible 304 SS

armored with outer PTFE coating / jacketing.

e) Vibration and displacement monitoring system shall be certified intrinsically

safe for use in Hazardous Area zone-I Gr. IIC Temp. class T3 unless

specified otherwise.

f) Key phasor system shall be provided by vendor for performing analysis of

vibration signals to determine machine malfunctions. It shall consist of

proximity probe and transmitter, extension cable etc. and other accessories

to make the system complete. Vendor shall provide necessary reference on

the shaft to determine one-per-turn occurrence

11. Vendor to consider all the required process as well as machine protection

parameters essential to safeguard the equipment.

12. An alarm & shutdown system shall be provided which will initiate an alarm if

any of the specified process parameters reaches alarm point and will initiate

shutdown of the equipment if any one of the specified parameter reaches

the shutdown point.

13. The alarm & shutdown system shall conform to API standard 681.



Doc No:

FGRU-

TSLC


of 67

14. Alarms & shutdown sequencing is to be achieved using a TUV certified

safety PLC with redundancy at Processor, Power supply, communication &

I/O levels. Vendor scope shall include supply of PLC and its associated

equipment. Vendor to consider dedicated development/engineering system for

PLC for viewing, editing, modifying the logic on-line/off-line. PLC panels

shall be supplied and to be installed in the control room environment.

15. The PLC shall be provided with Serial interface with Modbus RTU protocol.

The serial card shall be configured in ‘Slave’ mode and needs to be connected

to existing DCS system (Yokogawa Centum CS3000 DCS System). Vendor

scope includes co-ordination with DCS vendor during Modbus configuration

& Communication.

16. Vendor to consider PC based ‘Sequence of Events’ Recorder (SOE) for

analysis of events.

17. Vendor to provide the list of documents in the form of DCI (Document

Control Index) for review by client. DCI shall be reviewed by the client for

adding/modifying the documents which are required for the Project.

18. Mandatory Spares: Vendor to provide 10% or minimum 1 for each type of

Instrument, Control valves accessories (like Plug, seat gaskets, O- rings,

diaphragms, capsule, gland packing, AFR ,SOV Limit switches etc.), each type

of PLC card (CPU card, Memory card, Power supply card, I/O cards etc) and

for each type of LCP accessories.

19. Commissioning & Startup spares: vendor to provide commissioning & start-

up spares as required.

20. 2 years O&M Spares: Vendor to provide list of 2 years Operation &

Maintenance spares for all the Instruments, PLC and LCP related equipment.

13.0 SPECIAL REQUIREMENTS

13.1. Paint and Corrosion Protection

The Vendor must ensure that all equipment provided is adequately protected from the

prevailing hot and humid atmosphere at this location, by means of correct material selection,

painting or coating and/or suitable insulation to prevent galvanic corrosion. The Vendor shall

propose and use his standard long life painting/coating system and other protective measures

for approval with provision that final finish colour be agreed with HPCL.

Pre-assembled skids and components shall be supplied with finish paint coat. The Vendor

shall provide necessary paint for field touch-up by the HPCL.

13.2 Equipment Tagging, Labelling And Nameplates

All major items shall be allocated tag numbers. The Vendor must indicate these numbers on

all design documents also.



Doc No:

FGRU-

TSLC


of 67

All tagged items shall have corrosion resistant nameplates or labels permanently attached

which shall include Vendor’s standard identification and together with HPCL’s tag number (if

made available).

All other control and indication devices that operators will need to access and maintain shall

have identification/duty labels permanently attached.

13.3 PACKING AND PRESERVATION

Packing and Preservation shall be suitable for sea transport worhty and movement over

rugged terrain. Also it shall be suitable for storage at site for up to 6 months in an uncovered

and heated location. The Vendor shall provide information for storage at site prior to

installation and for extended periods post installation prior to start-up.

13.4 Special Tools and Special Test Equipment

Vendor to include in his supply any special tool/ tackles and test equipment etc as required for

the maintenance of the equipment. Vendor to mention the same in the offer.

13.5 MONTHLY REPORTING

The Vendor shall, for the duration of the PO execution, provide monthly reporting covering

project management, engineering, procurement, fabrication and testing activities giving full

details of third party inspection activities done. The Vendor shall develop the form of the

reports. The cut-off date shall be 25th day of each month. Vendor shall send the report through

dispatch and also through e-mails.

The reports shall contain details on all aspects of the Vendor and his Sub-Vendor’s

performance over the reporting period and give an up-to-date and clear picture of the project

progress and the overall status of the PO.

14.0 QUALITY ASSURANCE & CONTROL

14.1 Quality Management System

The Vendor shall provide his standard format Inspection and Test Plan (ITP), relating to the

scope of work, for review with the bid submission. However the same shall be in line with

the ITP guideline as enclosed with this indent requisition, as a minimum. The Plan shall include detail descriptions of all tests and inspections and categorize each test

and inspection as below.

Category R–tested by the Vendor. Reports to be reviewed by TPI or Purchaser

Category W – observed by Purchaser or TPI

Category H – witnessed by Purchaser or TPI

For Category W, the TPIA (third party inspection agency) will attend the test at the test

date notified by the Vendor. If Purchaser or his nominee(s) fail to attend the test by any

reason, the Vendor is entitled to carry out the test as scheduled and Purchaser will accept

the test results. (These are no ‘Hold’ points.)



Doc No:

FGRU-

TSLC


of 67

For Category H, the Purchaser / TPIA will agree the test date with the Vendor. If TPI fails to

attend the test by any reason, the Vendor shall hold the test until Purchaser / TPIA attend the

test at a new test date agreed by the parties. (These are ‘Hold’ points.)

The Purchaser shall also have free access to the Vendor and Sub-Vendor’s premises during all

stages of manufacturing and testing.

Regular visits by the Purchaser for the purpose of surveillance and documentation review will

not be carried out as a matter of course. However, should it become apparent that the

Vendor’s or Sub-Vendors’ agreed Manufacturing Quality Control Plan is either inadequate or

not being implemented, the Purchaser reserves the right to increase the level or frequency of

his Quality Control activities or request the Vendor to revise his working practices, as

necessary.

14.2 Testing Testing shall be performed in logical sequence. The vendor’s testing procedure shall be

structured in following manner :

Level 1: Factory testing of individual components by the Vendor or his subvendor.

Level 2: Package factory testing of the completely assembled sub systems at the vendor’s

works.

14.3 Factory Tests

The Vendor shall be responsible for the factory testing for all the equipment covered by this

Requisition, as per the data sheets, codes and standards listed.

The Vendor shall submit guarantee along with sound pressure and sound power level spectra

details, in the Noise Level Data Sheet

14.4 Final Acceptance Test

Final acceptance of factory tests will be made by Purchaser/TPIA after the complete test

sequence has been performed, but shall not constitute a waiver of the Vendor obligation to

provide the equipment which meets all specified operating conditions.

15.0 Third Party Inspection Authority / Agency

A third party authority (TPI) shall inspect at all stages including the final test at and his own

inspection to perform all inspection activities on behalf of HPCL. TPI charges shall be borne

by the VENDOR. However, in case that a scheduled shop or field test will fail and it must be

repeated after the remedy of the failed material or equipment, the additional TPIA’s and

Purchaser’s services shall be at Vendor’s care and cost (travelling an accommodation

expenses plus working time of TPIA’s and Purchaser’s inspectors)



Doc No:

FGRU-

TSLC


of 67

Similarly, Vendor shall bear any additional costs due to delays that may occur, attributable to

the Vendor, e.g., not readiness to perform the test on the agreed date.

The Vendor shall submit in a timely manner to the TPI, all applicable Vendors’

documentation for approval. And the Vendor shall arrange for workshop inspections and tests

witnessing by TPI. Such inspection shall not release the Vendor from performing its own

inspection and quality control programs.

15.1 Scope of Inspection of Third Party agency

Scope of third party inspection agency (TPIA) shall include witness of various tests including

final performance tests, as per QAP.TPIA shall also certify the power consumption of

compressor (refer penalty clause in the specs) during the final performance test.

The scope of TPIA also includes review of procedures/activities, review of tests documents/

inspection test methods/reports/ material identification/ traceability/ QC reports etc required to

ensure strict conformance of material, procedures and testing with specifications, data sheets,

and vendor data requirements etc. as enclosed to the purchase specifications as set out in

enquiry / order, in totality. TPIA shall also endorse the monthly progress report to be prepared

by vendor.

16.0 QA Records

16.1 Inspection and Certification Records

The Vendor shall ensure that all inspection and certification records for equipment and

materials is available on request for a period of 10 years from delivery. The Vendor shall

make such records immediately available to the Purchaser up to completion of his scope of

supply and thereafter within ten days of the Purchaser’s request.

16.2 QA Record Documentation

QA record documentation consisting of collection of original and type test certification,

inspection and test records and final release documentation generated during the approval,

manufacture and testing of the equipment /material shall form part of final documentation to

be submitted to HPCL. All final drawings and manuals including as built documentation must

be supplied prior to the “Release Note”.

16.3 DOCUMENTATION : INFORMATION REQUIREMENTS

Vendor shall submit documentation in accordance with the “List of drawings/ Documents”

(Vendor Data Requirements). In order to reduce the amount of document transmittals, two

types of submission categories will be used;

Category A: Issued to the Purchaser for review/approval. These documents will be

returned to the Vendor with the appropriate action shown on the return label.

Category I: Issued to the Purchaser for information purposes. These documents will only

be returned for subsequent re-submission, if unsatisfactory or incorrect.



Doc No:

FGRU-

TSLC


of 67

The Vendor shall assume a period of twenty (20) working days from receipt for the Purchaser

to review and dispatch documents back to the Vendor. When required, re-submissions are to

be made no later than ten (10) working days

All final drawings and manuals including as built documentation must be supplied prior to the

“Release Note”.

NOTES:-

Approval of Drawings by HPCL shall not relieve vendor from fulfilling his obligation

under this contract and is, in essence, only an acknowledgment of satisfaction with the

general arrangements and general design. HPCL’s approval shall in no event make HPCL

responsible for errors or omission in vendor’s work. Should Purchaser fail to comment, or

only partially comment, upon any Vendor or Sub-Vendor document, this shall not be

construed as an acceptance of the content of such document. Prior to being submitted to

Purchaser, documents shall be developed to the maximum extent.

LOADING, GUARANTEE AND PENALTIES CRITERIA:

THE LOADING CALCULATIONS SHALL BE DONE CONSIDERING TWO NOS.

OPERATING COMPRESSORS.

1. POWER REQUIREMENT : VENDOR SHALL FURNISH THE GUARANTEED VALUES FOR THE FOLLOWING:

MOTOR EFFICIENCY FOR RATED CASE.

BKW OF COMPRESSOR INCLUDING ALL MECHANICAL/LEAKAGE LOSSES

WITH ZERO PERCENT POSITIVE TOLERANCE INCLUDING INSTRUMENT &

MEASUREMENT TOLERANCES, AT RATED OPERATING CASE (SHALL BE

CONSIDERED FOR LOADING/PENALTY, AS DEFINED BELOW).

POWER CONSUMPTION OF MOTOR WHILE DELIVERING POWER REQUIRED AT

COMPRESSOR INPUT SHAFT FOR RATED COMPRESSOR OPERATING CASE WITH

ZERO PERCENT POSITIVE TOLERANCE INCLUDING INSTRUMENT AND

MEASUREMENT TOLERANCES.

NOTE: IN CASE TESTING CONDITIONS DIFFER FROM ACTUAL OPERATING

CONDITIONS AS SPECIFIED, VENDOR SHALL FURNISH IN HIS BID COMPLETE

CONVERSION FORMULAE, CALCULATIONS, CORRECTION CURVES AS

SPECIFIED AND REQUIRED FOR CONVERTING TEST CONDITION RESULTS TO

OPERATING CONDITION RESULTS, ENSURING COMPLIANCE TO GOVERNING

SPECIFICATION, STANDARDS AND CODES.



Doc No:

FGRU-

TSLC


of 67

PROCESS CONDITIONS AS PER RATED GAS IS GUARANTEED THOUGH THE TEST

AT VENDOR SHOP IS CARRIED OUT WITH AIR. DETAILED CONVERSION FROM

AIR TO GAS SHALL BE SUBMITTED BY VENDOR.

2. THE ECONOMIC ANALYSIS FOR ARRIVING AT THE TOTAL COST OF

PACKAGE FOR EVALUATION PURPOSE SHALL BE DONE AS UNDER :

CAPITAL COST (SUM TOTAL OF ALL THE COSTS INDICATED IN THE PRICE

SCHEDULE) OF THE EQUIPMENT PACKAGE ALONGWITH DRIVER MOTOR,

ACCESSORIES & AUXILIARIES INCLUDING SPARES COMPLETE AS PER TENDER

DOCUMENT.

FIVE YEARS DIFFERENTIAL COST BASED ON CRITERIA LAID DOWN UNDER

CLAUSE 3 BELOW SHALL BE ADDED TO ABOVE CAPITAL COST.

3. FIVE(5) YEARS DIFFERENTIAL COST SHALL BE WORKED OUT AS UNDER :

LOWEST OFFERED GUARANTEED BKW OF COMPRESSOR = Cref (SAY)

GUARANTEED BKW (AT RATED CONDITION) OF COMPRESSOR VENDOR UNDER

EVALUATION = C (SAY)

DIFFERENCE IN BKW = C – Cref

5 YEARS. DIFFERENTIAL OPERATING COST FOR VENDOR UNDER EVALUATION

IS AS UNDER,

DIFFERENTIAL COST = (C - Cref) X Cf X 8000 X Df X N

WHERE,

Cf = COST OF ELECTRIC POWER IN TERMS OF RUPEES PER KWH & SHALL BE

CONSIDERED AS RS. 12 PER KWH.

N= NO. OF OPERATING EQUIPMENTS AND SHALL BE TWO IN THE PRESENT CASE.

Df = DISCOUNTING FACTOR TO ARRIVE AT NET PRESENT VALUE (NPV) BASED ON

FIVE YEARS OF OPERATING YEARS AND SHALL BE 2.962



Doc No:

FGRU-

TSLC


of 67

Where

k= Number of operating years for which loading is to be done as specified i.e. 5 years

X=percentage rate of interest = 14.5%.

Df = 2.962

The above formula considers one year time for startup of operation.

THE MAXIMUM DIFFERENTIAL OPERATION COST TO BE LEVIED SHALL NOT

EXCEED 10% OF THE COST OF THE PACKAGE UNDER EVALUATION.

4. DURING THE PERFORMANCE TEST AT VENDOR’S WORKS, IF THE COMPRESSOR

FAILS TO MEET THE GUARANTEED VALUES AS GIVEN BY THE VENDOR, THE

FOLLOWING PENALTIES SHALL BE LEVIED.

FOR EVERY EXTRA KW, CONSUMED OVER AND ABOVE THE GUARANTEED BKW, AS

DESCRIBED IN CLAUSE 1 ABOVE, UPTO A MAX. OF +4% ABOVE THE GUARANTEED

POINT, THE VENDOR SHALL BE PENALISED FOR THE EXTRA POWER CONSUMPTION

FOR A PERIOD OF 5 YEARS AT 8000 HRS. OF OPERATION PER ANNUM AS BELOW:

PENALTY (RS.) = (Ct - Cc) X Cf X 8000 X Df X N

WHERE,

Ct = POWER (COMPRESSOR SHAFT BKW) AS OBTAINED FROM SHOP TEST

VALUES.

Cc = POWER (COMPRESSOR SHAFT BKW) AS GUARANTEED BY VENDOR.

THE MAXIMUM PENALTY TO BE LEVIED SHALL NOT EXCEED 10% OF THE COST

OF THE PACKAGE ON ACCOUNT OF PENALTIES LEVIED ABOVE.

NO ADVANTAGE SHALL BE GIVEN FOR HIGHER PERFORMANCE THAN

GUARANTEED.

5. REJECTION:

HOWEVER, IN CASE DURING SHOP PERFORMANCE TESTS, THE BKW

CONSUMED BY THE COMPRESSOR EXCEEDS THE STIPULATED GUARANTEED

VALUE BY MORE THAN +4% THE ENTIRE PACKAGE STANDS REJECTED.

6. MECHANICAL RUN TEST (MRT): MRT SHALL BE CONDUCTED ON ALL THE LIQUID RING COMPRESSORS.



Doc No:

FGRU-

TSLC


of 67

7. NO NEGATIVE TOLERANCE SHALL BE ALLOWED FOR DISCHARGE PRESUURE.

HOWEVER DISCHARGE PRESSURE MAY INCREASE UP TO A MAXIMUM OF

1 KG/CM2.

8. FIELD TRIAL:

THE COMPRESSOR UNIT SHALL ALSO BE SUBJECTED TO FIELD TRIAL RUN.



Doc No:

FGRU-TSLC


of 67

INSPECTION AND TEST PLAN

FOR LIQUID RING COMPRESSION SYSTEM

Inspect - Activity Inspection - Doc. Type - Remarks -

V Vendor M Manufacturer inspection or activity

CC Conformity certificate

S Supplier W Witness point. The activity cannot proceed without presence of Inspector or his approval to proceed.

MC Mill certificate

P Purchaser H Hold point. The activity cannot proceed without the presence of Inspector

TC Test certificate

IA TPI R Review of document

D Final doc. Dossier

0

Phase

Activity Description

Activity Inspection

Doc. Ref. Documents

Comments

type

V S TPIA

1 LIQUID RING COMPRESSOR

1.1 mill certificates (wetted & pressurized parts + shaft)

R M R -- MC as per code

1.2 mechanical seal R M R -- CC as per code Test report referred to wetted parts material

1.3 visual and dimensional check of M -- -- -- -- detail dwg. -



Doc No:

FGRU-TSLC


of 67

components

1.4 hydrostatic test on head M -- H - TC No leakage or deform.

1.5 balancing test of the impeller M -- R - TC ISO 1940 Gr.2,5

1.6 visual and dimensional. check of assembled compressor

M -- R -- TC Outline dwg.-

1.7 performance test (with to be supplied motor)

M -- H -- TC contr. data and curve - both compressor (s)

1.8 vibration measurement M -- H -- TC ISO 10816 part 1; part 3 / VDI 2056 group G

both compressor (s)

1.9 noise level measurement M -- H - TC ISO 3746 / ISO 9614 part 1 or 2

Type Test

1.10 mechanical test (with to be supplied motor)

M -- H -- TC Verify of sealing. Noise / vibration check list

all compressors (1hour at duty point)

1.11 internal cleanliness and drying inspection

M -- -- -- -- STANDARD MANUFACTURER

1.12 painting check M -- -- - TC STANDARD MANUFACTURER

1.13 name plate data check M -- R - copy Relevant dwg.

1.14 final inspection book M -- R - D STANDARD MANUFACTURER

2.0 Electric Motor

2.1 Routine Test R M R -- TC

2.2 Tagging Check R M R -- --

2.3 Painting check R M R -- --

2.4 Conformity Certificates R M R -- CC