Nit 1005 Mab Amd 1

REVAMP OF FCCU & PRU, MATHURA PROJECT
NIT No: LSN/00785/019/MR/1040/01/1005

Page 1 of 2 Rev. 1
NIT FOR MAIN AIR BLOWER
Tag Nos 019-K-101,019-KT-101, 1011-01/000015,101101/000017,1011-01/000021,1011-01/000030,101101/000031,1011-01/000032,1011-01/000034,101101/000036,1011-01/000041,1011-01/000051,101101/000061,1011-01/000071 FOR INDIAN OIL CORPORATION LTD.
AMENDMENT-1 TO NOTICE INVITING TENDER (International Competitive Bidding)
Prepared and issued by:

Technip KT India Ltd., Technip Tower, A 4, Sector 1 Noida 201 301, India

NIT No: LSN/00785/019/MR/1040/01/1005
Page 2 of 2 Rev. 1
AMENDMENT-1 TO NIT NO. LSN/0785/019/MR/1040/01/1005 FOR MAIN AIR BLOWER
Sr. No. 1. 2. 3 4 5 6 7
Description AMENDMENT-1 TO NOTICE INVITING TENDER ( International Competitive Bidding) issued ADDENDUM-1 TO Material Requisition for Main Air Blower issued ( attached) The sale period of bid document is extended up to 08.12.10 The last date of submission of bid is 17.12.10 up to 2.30 P.M. The Last date for receipt of bidder queries is up to 09.12.10 Pg 16 of 19 rev 0 clause 5.0, Third Party Inspection Agency for foreign bidders is M/s Lloyds Register of Shipping only Sr. No. 1.0 of Form SP1 and SP1A Pg 3&4 of 9 of Price Forms Bidders also to furnish detailed list of items for mandatory/commissioning spares separately along with Item Description/Part / Catalogue No./Rate for each item
Please read note 4&5 of Form SP3 Pg 6 of 9 of Price FormsPer Diem rates mentioned above, is based on 8 hours working per day, six days a week (from Monday to Saturday). In case of overstay or working on Sunday, hourly rate shall be applicable as per the refinery rule.
All other Terms & conditions of the original Tender remain unchanged
INDIAN OIL CORPORATION LTD. (REFINERIES DIVISION) NEW DELHI - 110 003
Amendment-1 to NOTICE INVITING TENDER (INTERNATIONAL COMPETITIVE BIDDING) NIT NO. / NAME OF WORK
AMENDMENT Contact Person
1. Techno-commercial Bid Conditions have been amended. 2. The sale period of bid document is Design,Engineering, Manufacturing, Testing and extended upto 08.12.10. Supply of Main Air Blower with steam turbine to 3. The last date of submission of bid is IOCL's 17.12.10 upto 2:30 P.M. Mathura Refinery, for FCCU AND PRU REVAMP 4. Last date receipt of bidders queries is PROJECT at Mathura, U.P, India (Bidding extended upto 09.12.10. Document No: NIT NO.: LSN/00785/019/MR/1040/01/1005 ) All other Terms & Conditions of the Original Tenders remain unchanged.
Mr. L.S. Nagi / Mr. D.K. Dogra Procurement Section M/s TECHNIP KT INDIA LIMITED, A-4, Sector-1, Noida-201301, India Ph. 0120-4301445 / 4301487 email id : lsnagi@technip.com, dkdogra@technip.com
Detailed Tender Notice and Tender Document along with amendment -1 can be download from IOCL website www.indianoiltenders.com
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AADENDUM-1 TO MATERIAL REQUISITION FOR MAIN AIR BLOWER
UNIT PROJECT
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
: FCC UNIT : FCCU AND PRU REVAMP, MATHURA. : IOCL, MATHURA REFINERY.
LOCATION
OWNER
EPCM
TECHNIP KT INDIA LTD.
INDIAN OIL CORPORATION LIMITED.
NOIDA, INDIA.
ADDENDUM-1 TO MATERIAL REQUISION FOR MAIN AIR BLOWER (19-K-101)
ENQUIRY REFERENCE :
00785-019-MR-1040-01 REV-A
REV.
29/11/2010
DATE
ISSUED FOR ENQUIRY

STATUS
NIK
PREPARED BY
DB
REVIEWED BY
RR
APPROVED BY
CSA
PM
DOCUMENT REVISIONS Sections changed in last revision are identified by a line in the right margin
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ADDENDUM-1 TO MATERIAL REQUISITION FOR MAIN AIR BLOWER
ADDENDUM-1 TO REQUISITION FOR ENQUIRY

This Requisition is composed of the documents listed below: Description APPLICABLE DOCUMENTS 1. 2. 3. 4. 5. 6. Engineering Design Basis for Static Equipment List of Mandatory Spare (Piping) Vendor List (Electrical) Vendor List for piping item Addition/Deletion/Modification_ Instrument Scope Annexure-1 to 00785-019-JSS-1514-01 00785-000-JSD-0400-01 00785-000-NM-1305-01 00785-000-NM-1602-01 Refer Attachment Refer Attachment Refer Attachment 0 0 29/11/2010 29/11/2010 29/11/2010 29/11/2010 29/11/2010 29/11/2010 Reference Rev. Date of attachment Date of cancellation
0 -
CLIENT UNIT PROJECT
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INDIAN OIL CORPORATION LIMITED MATHURA REFINERY. FCC UNIT. FCCU AND PRU REVAMP, MATHURA.
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DESIGN BASIS FOR STATIC EQUIPMENT
UNIT PROJECT
LOCATION
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NOIDA, INDIA.
ENGINEERING DESIGN BASIS FOR STATIC EQUIPMENT
0 A
REV.
25.10.2010 04.10.2010
DATE
ISSUED FOR IMPLEMENTATION ISSUED FOR APPROVAL

STATUS
GV GV
PREPARED BY
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REVIEWED BY
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APPROVED BY
CSA CSA
PM
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TABLE OF CONTENTS
SECTION A (Columns, Vessels, Tanks & Heat Exchangers)

SECTION A .................................................................................................................................................... 5 (COLUMNS, VESSELS, TANKS & HEAT EXCHANGERS)............................................................................ 5 1.0 REFERENCED PUBLICATIONS................................................................................................................ 5 2.0 DESIGN PHILOSOPHY / GENERAL CRITERIA ....................................................................................... 7 2.1 MINIMUM SHELL/HEAD THICKNESS ...................................................................................................... 7 2.2 EQUIPMENT END CLOSURES: ................................................................................................................ 8 2.3 DESIGN PRESSURE .................................................................................................................................. 8 2.4 TEST PRESSURE....................................................................................................................................... 9 2.5 DESIGN TEMPERATURE .......................................................................................................................... 9 2.6 CORROSION ALLOWANCE:................................................................................................................... 10 2.7 WIND CONSIDERATION.......................................................................................................................... 10 2.8 EARTHQUAKE CONSIDERATION:......................................................................................................... 11 2.9 SUPPORTS ............................................................................................................................................... 11 2.10 FLANGES................................................................................................................................................ 13 2.11 INTERNALS ............................................................................................................................................ 13 2.12 PIPE DAVIT............................................................................................................................................. 13 2.13 SPARES .................................................................................................................................................. 14 2.14 MP CONNECTION FOR PG/TI............................................................................................................... 15 2.15 IMPORTANT CONSIDERATIONS ......................................................................................................... 16 2.15.1 FOR PRESSURE VESSELS / COLUMNS / REACTORS................................................................... 16 2.15.2 HEAT EXCHANGERS ......................................................................................................................... 17 2.15.3 AIR COOLERS..................................................................................................................................... 18 2.16 LOCAL LOADS....................................................................................................................................... 18 2.17 ANCHOR BOLTS.................................................................................................................................... 19
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3.0 DESIGN CRITERIA / REQUIREMENTS - SPECIFIC APPLICATIONS................................................... 19 3.1 STORAGE SPHERES / MOUNDED BULLETS ....................................................................................... 19 (A) LPG STORAGE SPHERES/MOUNDED BULLETS................................................................................. 19
(B) PROPYLENE STORAGE SPHERES/MOUNDED BULLETS.................................................................. 19 3.2 TALL COLUMNS ...................................................................................................................................... 20 3.3 MOUNDED BULLET................................................................................................................................. 22 3.4 HEAT EXCHANGERS .............................................................................................................................. 24 3.5 AIR COOLERS.......................................................................................................................................... 25 TABLE-I........................................................................................................................................................... 26 DETAILS AND WEIGHT OF COLUMN ATTACHMENT................................................................................ 26
SECTION B (Trays & Tower Internals)
1.0 INTENT...................................................................................................................................................... 28 2.0 PROCESS PARAMETERS, DESIGN CONDITIONS & SELECTION OF INTERNALS.......................... 28 3.0 DESIGN ..................................................................................................................................................... 28 3.1 MATERIALS.............................................................................................................................................. 28 3.2 THICKNESS OF INTERNALS .................................................................................................................. 30 3.3 DESIGN LOADINGS................................................................................................................................. 32 3.4 ALLOWABLE STRESS AND DEFLECTION ........................................................................................... 33 3.5 ARRANGEMENT/DETAILS OF INTERNALS.......................................................................................... 34 4.0 FABRICATION AND SUPPLY ................................................................................................................. 38 4.1 TOLERANCES.......................................................................................................................................... 38 4.2 WELDING.................................................................................................................................................. 39 4.3 MISCELLANEOUS ................................................................................................................................... 40 4.4 SPARES .................................................................................................................................................... 40 5.0 INSPECTION AND TESTING ................................................................................................................... 42
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5.1 GENERAL ................................................................................................................................................. 42 5.2 STAGE INSPECTION DURING FABRICATION...................................................................................... 42 5.2.1 DIMENSIONS ......................................................................................................................................... 42
5.2.2 FABRICATION....................................................................................................................................... 43 5.3 TRIAL ASSEMBLY ................................................................................................................................... 43 5.4 LEAK TESTING ........................................................................................................................................ 44 5.5 DISTRIBUTOR TESTING ......................................................................................................................... 44 6.0 SITE INSTALLATION ............................................................................................................................... 46
SECTION C (Mechanical Equipment)
1.0 SCOPE ...................................................................................................................................................... 47 2.0 CODES & STANDARDS........................................................................................................................... 47 3.0 REFERENCED PUBLICATIONS.............................................................................................................. 48 4.0 GENERAL DESIGN REQUIREMENTS .................................................................................................... 48 5.0 DESIGN REQUIREMENTS FOR SPECIFIC APPLICATIONS ................................................................ 48 6.0 BASKET FILTER ...................................................................................................................................... 48 7.0 CARTRIDGE FILTER................................................................................................................................ 49 8.0 FILTER SEPARATOR/COALESCER....................................................................................................... 49 9.0 FEED FILTERS WITH AUTOMATIC BACKWASH FACILITIES............................................................. 50
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DESIGN BASIS FOR STATIC EQUIPMENT SECTION A (COLUMNS, VESSELS, TANKS & HEAT EXCHANGERS)
1.0 REFERENCED PUBLICATIONS a) The following codes and standards in their latest edition including latest addenda as on the date of first issue of this design basis shall be followed unless otherwise specified in the requisition for the design, fabrication, inspection and testing of Vessels, Columns, Reactors, Spheres, Storage Tanks, Steel Silos, Bins, Hoppers, Steel Flare/Vents Stacks & heat exchangers: ASME SEC. VIII DIV.1 for Pressure Vessels, Heat Exchangers. IS 2825 For Pressure Vessels. ASME SEC. VIII DIV.2 For Pressure vessels and heat exchangers (Selectively for high Pressure/high thickness). ASME SEC. VIII DIV.3 for Very High Pressure. ASME SEC. VIII DIV.2/PD 5500 for Storage Spheres. API 650/IS: 803 for Atmospheric Storage Tanks. API 620 for Low Pressure Storage Tanks. API 620/BS 7777 for Cryogenic Storage Tanks (Double Wall). IS: 9178/DIN 1055 For Silos, hoppers and bins. IS: 6533 for steel vent stacks etc. ASME SEC. VIII DIV.1 For workmanship of Vessels not categorized under any other code. BS: 4994/ASME SEC. X FRP vessels and Tanks. ISO R831/IBR for Steam producing equipment, steam storage, catch water vessels, condensate flash drums and similar vessels and BFW Heaters. OISD-STD 150/ PD 5500/ASME SEC. VIII DIV.2 For Mounded Vessel ASME B 96.1 Welded Aluminum Alloy Storage Tanks ASME SEC. II For material specification. ASTM/IS For material specification. IS: 875/SITE DATA For wind load consideration. IS:1893/SEISMIC DESIGN BASIS For seismic design consideration ASME SEC.V for Non destructive Examination.
: : : INDIAN OIL CORPORATION LIMITED MATHURA REFINERY. FCC UNIT. FCCU AND PRU REVAMP, MATHURA.
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ASME SEC. IX for welding. ASME B 16.5 for flanges. ASME B 16.47 for large diameter flanges.(Series B) ASME B 16.20 for gaskets. TEMA (CLASS-R) for shell and tube Exchanger. API 661 for Air Cooled Exchanger. IS 800 For Air Cooled Exchanger Structural Design AWS for American Welding society for joint specifications and welding electrodes. OISD 116 for Fire Protection facilities for Petroleum Refineries and Oil/Gas Processing Plants OISD 17 for Fire Protection facilities for Petroleum Depots and Terminals and Pipelines Installations. Relevant NFPA rules.
b) STATUTORY PROVISIONS: National laws and statutory provisions such as Indian Boiler Regulation and Department of Explosives, Nagpur, India together with any local by-laws for the state shall be complied with. Static and Mobile Pressure Vessel (SMPV) rules, Petroleum rules, Factory Acts and Rules, Environmental Protection Act & Rules etc. as applicable shall also be complied with. c) PUBLICATIONS: NACE MR 0103 Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining Environments. NACE RP 0296 Guidelines for Detection, Repair and Mitigation of Cracking of Existing Petroleum Refinery Pressure Vessels in Wet H2S Environment. NACE TM 0284 Evaluation of Pipeline and Pressure Vessel Steel for Resistance to Hydrogen Induced Cracking. API-950 Survey of Construction Materials and Corrosion in Sour Water Stripper. API-RP 945 Avoiding Environmental Cracking in Amine Units. NACE TM 0177 Laboratory Testing of Metals for Resistance to Sulphide Stress Cracking in Hydrogen Sulphide Environment. WRC Bulletin #107 Local Stresses in Spherical & Cylindrical Shells due to External Loadings. WRC Bulletin #297 Local Stresses in Cylindrical Shells due to External Loadings on Nozzles.
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DESIGN BASIS FOR STATIC EQUIPMENT NACE-RP-0472 Methods and Controls to prevent in-Service Environmental Cracking of Carbon Steel Weldments in Corrosive Petroleum Refining Environments.
2.0 DESIGN PHILOSOPHY / GENERAL CRITERIA All design calculations shall be performed considering all applicable loads for Erection, Operating and hydrotest conditions. The SI metric system of measurement shall be used in all suppliers drawing and calculation notes, except for pipe and pipe fitting sizes, flange ratings and nozzles dimensions. The SUPPLIER shall indicate the component limiting MAWP (maximum allowable working pressure) for the vessel. Nozzle reinforcement shall not be the limiting factor for the vessel to contain the MAWP in the fully corroded condition.
2.1 MINIMUM SHELL/HEAD THICKNESS Minimum thickness of equipment wall/components shall be as given below: a) For carbon and low alloy steel vessels - 6mm (Including corrosion allowance not exceeding 3.0 mm), but not less than that calculated as per following ; FOR DIAMETERS LESS THAN 2400 mm Wall thickness = (Dia. /1000) + 1.5 + Corrosion Allowance (if any) FOR DIAMETERS 2400 mm AND ABOVE Wall thickness = (Dia. /1000) + 2.5 + Corrosion Allowance (if any) All dimensions are in mm. b) For stainless steel vessels and high alloy vessels - 3 mm, but not less than that calculated as per following for diameter more than 1500mm. Wall thickness (mm) = (Dia. /1000) + 2.5 + Corrosion Allowance (if any)
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c) Vertical vessel with Height (TL to TL) / Diameter ratio greater than 15 shall be considered as tall column and shall be designed accordingly. (Refer Clause 3.2)
d) For carbon steel, stainless steel, low alloy steel columns/towers & high alloy steel columns/tower 5mm (excluding corrosion allowance). e) For shell & tube heat exchangers, minimum thickness shall be as per TEMA. f) For Air Cooled heat exchangers, minimum thickness shall be as per API 661.
2.2 EQUIPMENT END CLOSURES: a) Unless otherwise specified Deep Torispherical Dished End with 80 % crown radius and 15% knuckle radius or alternatively 2:1 semi Ellipsoidal Dished End shall be used for pressure vessels & heat exchangers. b) Hemispherical Ends shall be considered when the thickness of shell exceeds 70 mm. c) Flat Covers may be used for atmospheric Vessels. d) Pipe Caps may be used for vessels diameter <= 600mm having no internals. e) Flanged Covers shall be used for Vessels/Columns of Diameter <= 900mm having no internals. f) All columns below 900 mm shall be provided with intermediate body flanges. Numbers of intermediate flanges shall be decided based on column height and type of internals.
2.3 DESIGN PRESSURE Unless otherwise specified elsewhere design pressure shall be calculated as per the following. a) Design pressure shall be as per process datasheet. b) Design pressure calculated above shall be at the top of vertical equipment or at the highest point of horizontal equipment. c) The design pressure at any lower point is to be determined by adding the maximum operating liquid head and any pressure gradient within the equipment (differential pressure as mentioned in Process Data Sheet and catalyst loadings).
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DESIGN BASIS FOR STATIC EQUIPMENT d) Equipment operating under vacuum/Partial Vacuum shall be designed for an external pressure of 1.055 Kg./cm2g. e) Equipment shall be designed for steam out conditions as specified by process data
sheet/piping. f) Unless otherwise specified Pressure chambers of combination units including heat exchanger shall be designed for testing independently without pressure in the adjacent chamber in corroded condition.
2.4 TEST PRESSURE a) Equipment shall be hydrostatically tested in the fabricator's shop as per design code. b) Equipment open to atmosphere shall be tested by filling with water to the top. c) 1. Pressure Chambers of combination units that have been designed to operate independently shall be hydrostatically tested to code test pressure as separate equipment i.e. each chamber shall be tested without pressure in the adjacent chamber unless otherwise specified in equipment data sheet. 2. When pressure chambers of combination units have their common elements designed for maximum differential pressure, the common elements shall be subjected to test pressure equivalent to the differential pressure multiplied by a factor as per applicable design code. 3. Coils shall be tested separately to code test pressure. d) Unless otherwise specified in applicable design code allowable stress during hydrotest in tension shall not exceed 90% of yield point. e) Storage tanks shall be tested as per applicable code.
2.5 DESIGN TEMPERATURE Unless otherwise specified elsewhere, design temperature shall be as per the following. a) Design temperature shall be as per process datasheet. b) Minimum Metal Design Temperature (MDMT) shall be lower of minimum atmospheric temperature and minimum temperature envisaged during operation.
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DESIGN BASIS FOR STATIC EQUIPMENT 2.6 CORROSION ALLOWANCE: Unless otherwise specified elsewhere, minimum corrosion allowance shall be considered as follows:
Carbon Steel equipment : 3.0 mm * Low alloy steel equipment : 1.5 mm* (3 mm for shell & tube exchangers) Stainless steel equipment : NIL Clad equipment : NIL ( 3 mm cladding minimum) Lined equipment (Refractory): 3.0 mm (plus lining) CS Storage Tank bottom most shell course and bottom plate : 3.0 mm CS Storage Tank shell (other courses) : 1.5 mm Storage tank Fixed roof/ Floating Roof: As specified in process data sheet. CS Burried Vessels (External) : 1.5 mm CS Spheres : 1.5 mm Mounded Bullets : 1.5 mm
* Except for tubes For alloy lined or clad equipment, no corrosion allowance is required on the base metal. The cladding or lining material shall be in no case less than 3.0 mm thickness and the same shall be considered as corrosion allowance for the purpose of stress analysis. For all alloy depositions the minimum undiluted chemistry of 3mm shall be achieved. Corrosion allowance for nozzles and manhole neck shall be at least equal to that specified for the equipment. No Corrosion allowance is required for gasket seating face of girth flanges. However, for non standard blind flanges of channel covers the corrosion allowance will be applied.
2.7 WIND CONSIDERATION Design basis for wind loads shall be as per IS; 875 (Part -3) -Latest with basic wind speed 47m/sec. Values of coefficient K1, K2 , K3(as in IS:875-Part-3) for project site shall be considered as under.
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DESIGN BASIS FOR STATIC EQUIPMENT a. Probability factor K1 The design life of the equipment shall be taken as 50 years. The mean return period of all equipment shall be 50 years. Value of K1 for mean probable life of equipment
shall be 1.0. b. Terrain height and structure size factor K2. These factors are to be taken from IS 875(Part-3) -Latest for relevant class of the structure with respect to the actual height of the structures. Terrain category shall be considered as 3 for the equipment in the units. c. Topography Factor K3 = 1. Surface area of piping, platforms and other attachments fixed to the equipment (vessels/columns) exposed to wind shall be accounted for. Drag coefficient for cylindrical vessels shall be 0.7 minimum. Drag coefficient for spherical vessels shall be 0.6 minimum. Contingency factor of 1.1 shall be used on wind pressure.
2.8 EARTHQUAKE CONSIDERATION: Seismic Zone is IV. Design seismic load shall be calculated in accordance with IS 1893 Part1 & Part4 Latest Edition.
2.9 SUPPORTS 2.9.1 Skirt supports shall be provided for all tall columns {Refer Cl. 2.1 (c)} and reactors. However, equipment may be supported on legs (pipe or structural section) or brackets if following conditions apply; Shell diameter is not more than 1000mm Weight of vessel operating does not exceed 3000 kg. Vessel height-to-diameter ratio is not more than 3 Support height is not more than 1500mm
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DESIGN BASIS FOR STATIC EQUIPMENT Vibration is not expected.
2.9.2 Skirt Thickness

The thickness for the skirts inclusive of corrosion allowance shall be the maximum of following: a) 6 mm. b) Thickness required by analysis. c) 30 mm or 1/3 of the vessel wall thickness whichever is lower. Corrosion allowance of total 1mm minimum shall be considered for skirt unless otherwise specified in the project specifications to achieve final thickness of skirt shell. 2.9.3 All columns with diameter 1000 mm and more shall be self supporting. 2.9.4 All columns with diameter less than 1000 mm shall be supported by superimposed structure around the column covering the entire height. Guy wires are not permitted to be used for supporting any equipment. 2.9.5 In specific cases, columns having diameter less than 1000 mm and total L/D ratio not exceeding 10 may be self supported. 2.9.6 Flare and Vent stacks shall be supported structurally by super imposed structure all around for the entire height. 2.9.7 Storage spheres shall be supported on pipe legs with tie rod bracing and turn buckles. 2.9.8 Buried vessels shall be suitably anchored to prevent the uplift due to under ground water. Anchor bolts shall have corrosion allowance of 6 mm on diameter. Buried vessels shall be rested on concrete saddles with anchoring bracket at the center line of the vessel. 2.9.9 All skirt supported columns/equipments with height 20 m and above (irrespective of
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DESIGN BASIS FOR STATIC EQUIPMENT weight) and weight 50 MT and above (irrespective of height) are to be provided with tailing lug. 2.9.10 The equipment and relevant lifting accessories as tailing lugs, trunnions and lifting lugs shall be designed to withstand the equipment lifting weight considering an impact factor of 2. The design shall be performed considering the equipment in horizontal and vertical position. The lifting weight is defined as shop weight plus insulation, ladders, platforms, main pipelines etc. The internal packing or trays are excluded in lifting weight. 2.9.11 For horizontal equipment the stresses induced by the supports on the shell shall be checked in accordance with the applicable Codes. In case the Codes dont cover this calculation L.P. Zick method or PD 5500 (Annex G) may be used. 2.10 FLANGES 2.10.1 Nozzle flanges up to 600 NB shall be as per ASME/ANSI B16.5 and above 600 NB shall be as per ASME/ANSI B 16.47 (SERIES 'B') except that for high pressure heat exchanger. Non standard flanges shall be designed as per ASME Sec. VIII Div. 1. 2.10.2 Unless otherwise specified, W.N. Flanges shall be used for all classes except for sizes 2 inch and below where LWN type shall be used. 2.11 INTERNALS: Unless otherwise specified removable internals shall be bolted type and material of bolting shall be stainless steel TP 304. For shell & tube heat exchangers, floating head bolting shall be compatible to shell material. Bolting SA 193 Gr. B7M/2HM shall be used as a minimum. 2.12 PIPE DAVIT: i) Vertical Vessel/Column having safety valve size 80 NB and above and or having internals, shall be provided with pipe davit.
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DESIGN BASIS FOR STATIC EQUIPMENT ii) Exchanger davits shall be provided for channel and shell covers only .For stacked exchangers davit shall be provided on top shell only. Davit shall be provided on shell flange instead of channel flange to facilitate channel as well as channel cover removal.
2.13 SPARES: i) Vessels & Columns & Reactors Gaskets : 4 nos. for each installed gasket. Fasteners : 10% (Minimum two in each size) of installed fasteners. Sight/Light Glass : 4 sets for each installed glass.
ii) Shell & tube Exchangers: 400% Gaskets 20% Bolting (Min. 4 studs and 8 nuts per joint) Push rods 100% Lamiflex sealing strips 100%
iii) Air Coolers : 400% gasket for header cover & nozzles with blind flange 200% gaskets for plugs 20% plug 100% belts 20% Bolts & Nuts for all nozzle with BF & Cover plate One set of Diaphragm Actuator with positioner for each type of auto variable pitch fan (for Moore fans) (Alternatively vendor recommended spares for his type of auto variable pitch fans for make other than Moore). One set of blade for each size / type of fan (one set of blades mean total number of blades in one fan). Set of pulleys (fan & motor shall be as follows; o o o 1 set for each type of fan/motor set not exceeding two in number. 2 sets for each type of fan/motor set numbering three and more. 4 For each type of fan upto and including two in number.
Fan clevis bolts shall be as follows:
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DESIGN BASIS FOR STATIC EQUIPMENT o o

8 For each type of fan exceeding two in numbers but upto and including six in number. 12 For fans above six in number. 2+(2)** For fans upto including two in number . 3+(3)** For fans exceeding two in numbers but upto and including six in number. 5+(5)** For fans above six in numbers. 2+(2)** For quantity upto including two in number 3+(3)** For motors exceeding two in numbers but upto and including six in number. 5+(5)** For motors above six in numbers.
Fan bearing set (top + bottom = 1 set ) shall be as follows: o o o
Motor bearings (DE+NDE =1 set) shall be as follows: o o o
VFD 100% or 1 no. whichever is minimum.
( ) ** Indicates commissioning spares : Others are 2 years maintenance spares. (iv) Feed filter / Catrdige Filter / Coalescer; Sets of filtering element 100% Gaskets 100% Nuts and bolts 10%
2.14 MP CONNECTION FOR PG/TI i) Shell & Tube heat exchangers : For Clad Exchangers o o ii) Air Cooler: One on one of the inlet & one on one of the outlets of each header, size 40NB nozzle with BF etc. If it is not possible to provide on process nozzle then it shall be provided on header. Rating shall be same as process nozzle. One no. 50mm ID LWN nozzle with BF on each inlet/outlet nozzle shall be provided. One no. 40NB nozzle with blind on each inlet / outlet . Others (Non Clad)
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DESIGN BASIS FOR STATIC EQUIPMENT 2.15 IMPORTANT CONSIDERATIONS 2.15.1 FOR PRESSURE VESSELS / COLUMNS / REACTORS :
Vessels and columns shall be designed considering maximum operating liquid head in addition to design pressure. All columns and vessels shall be capable of withstanding water full condition during system testing. Minimum platform width shall be 1.2m for all columns and vessels where being provided. Vertical vessels with H/D ratios exceeding 15, where H is the height of the vessel from the point of support to the top tangent line and D is the average diameter in the top third of the vessels, shall be checked for vortex shedding vibrations from wind to insure structural stability. Additionally, vessels with a fundamental natural frequency less than 1 Hz shall also be check regarding vortex-shedding vibrations from wind vibration.
In addition, all vertical vessels, columns and Horizontal vessels shall be designed so as to permit site testing of the equipment with water at the test pressure on the top of the equipment considering 33% of design wind load. The design shall be based on fully corroded condition.
All equipment foundation shall be designed and constructed for water full condition when equipment is new with 33% of design wind load. All nozzle necks, all nozzle flanges and blind flanges shall be of weld deposit construction for clad equipments. Loose liners are not permitted. All vertical equipment shall be provided with two lifting lugs. Lifting lugs shall be designed with impact factor of two. Mechanical design of self supporting Tall Columns /Tower shall be carried out for various load combinations as per Clause 3.2 Projection of vacuum stiffening rings, on insulated vessel shall be less than insulation thickness wherever possible. Alternatively, the stiffening rings shall be covered with insulation & cladding.
Permanent fixed ladders shall be provided inside the skirt of columns/vertical vessels for inspection of bottom dished end.
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All vessels, columns and tanks shall be provided with earthing bosses. Body flanges of equipment shall have provision to provide jumpers for earthing. ODC/very heavy equipments shall be given special consideration for transportation and erection. All equipment requiring insulation shall be provided with insulation support ring/cleat. HIC resistant steels in wet gas section shall be of vacuum degassed steel with sulfur and phosphorus within 0.025 and 0.030 % respectively. Ni shall be less than 1%.
2.15.2 HEAT EXCHANGERS: 2.15.2.1 Testing accessories for shell and tube Heat Exchanger: Test flange shall be provided on all floating 'S' & 'T' head type exchangers. Dummy shell shall be provided for fixing test flange for exchangers such as kettle type or floating head without shell covers (TEMA 'AHT' or 'AKT') or stab in bundle where shell design pressure is higher than tube side pressure. Test ring shall be provided: o o For exchangers with removable bundle and bonnet type channel For exchanger with removable bundle and channel with flat cover if tube side pressure is greater than shell side pressure. Number of test rings/ test flanges/ dummy shells shall be one per each bundle / exchanger. For shell side interconnected and stacked exchangers the minimum number of test rings shall be equal to the number of exchangers in one stack. For 'U' tube & removable bundle exchanger, number of test flanges shall be equal to number of exchangers in one stack. 2.15.2.2 Monorails with chain pulley block shall be provided for all exchangers under structure and for bundle weight greater than 10tons pneumatically operated chain pulley blocks shall be provided. 2.15.2.3 All exchangers shall be shell side or tube side hydrotested at site (without removing opening the Bundle) before commissioning and the job shall be kept under the scope of site installation agency. 2.15.2.4 All coolers and condensers are to be provided with epoxy painting and sacrificial anodes on
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DESIGN BASIS FOR STATIC EQUIPMENT channel and floating head cover to minimize waterside corrosion.
2.15.3 AIR COOLERS

2.15.3.1. Noise level : The noise level shall be limited to 85 dB(A) max. measured at a distance of one meter from the bundle at the header access platform walkways and one meter from the bay limit on motor maintenance platform. The noise level within the air cooler bay shall be 90 dB(A) maximum, at locations defined as per API. 2.15.3.2. Type of Belts : HTD/PGGT of GATES or Torque Drive Plus belts of FENNER, UK or equivalent. 2.15.3.3. Access Platform : Shall be provided wherever possible on all the four sides, (width 900mm) with stairs on one side and ladder on other side. 2.15.3.4. Maintenance Platform : Full steel platform duly interconnected along full length and width of both air coolers for fan/motors etc. 2.15.3.5. Protective Covering (for finned tubes) on bundle top : By heavy duty wire mesh. 2.15.3.6. Hot dip galvanizing of air cooler structurals. 2.15.3.7. Final Painting of header box : All header boxes shall be finally painted at vendors shop. 2.15.3.8. Air cooler fans shall be of FRP type. 2.16 LOCAL LOADS Pressure vessel equipment Local stress in vessel wall resulting from nozzles or attachment loads shall be determined by applying one of the following methods as per the standard TPKTI document. WRC Bulletins 107 and 297. The resulting stresses shall be evaluated using the allowable stress criteria of Appendix 4 of ASME Code, Section VIII, Division 2. If not able to analyse by above FEA shall be done.
Air cooled H.E. (API 661) The nozzles and headers shall withstand thrice the forces and moments indicated on relevant API 661 Figure.
CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED MATHURA REFINERY. FCC UNIT. FCCU AND PRU REVAMP, MATHURA.
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2.17 ANCHOR BOLTS

Allowable anchor bolt stress shall be Tension 1200 kg/cm2. Shear 800 kg/cm2.
3.0 DESIGN CRITERIA / REQUIREMENTS - SPECIFIC APPLICATIONS 3.1 STORAGE SPHERES / MOUNDED BULLETS (A) LPG STORAGE SPHERES/MOUNDED BULLETS - The design pressure shall be established based on the composition and vapour pressure of stored product at design temperature, but in no case it shall be less than 14.50 Kg./cm2g at the top of the sphere for LPG Sphere/Mounded Bullets. - Selection of material of construction for various LPG Storage applications shall be as per following : a) For marketing and similar application: SA-516 Gr 70(Impact tested/SA 537 (where H2S is not present) CL1 (Impact tested)/EQV. b) For refinery and gas processing plants: SA-516 Gr 60 (Impact tested)/EQV.(where H2S presence cannot be ruled out) - All LPG spheres/LPG Bullets shall be post weld heat treated irrespective of storage application and adopted shell thickness.
(B) PROPYLENE STORAGE SPHERES/MOUNDED BULLETS - The design pressure shall be established based on the composition and vapour pressure of stored product at design temperature, but in no case it shall be less than 22.50 Kg./cm2g at the top of Propylene Sphere/Mounded Bullets. - Material of construction of Propylene storage spheres/mounded bullets shall be SA 537 CL.2 (Impact tested)/EQV. All Propylene spheres/Propylene Mounded Bullets shall be post weld heat treated irrespective of storage application and adopted shell thickness.
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DESIGN BASIS FOR STATIC EQUIPMENT 3.2 TALL COLUMNS Mechanical design of self supporting tall column and its anchorage block shall be carried out
considering combination of various loads. 3.2.1 LOADINGS The loadings to be considered in designing a self supporting tall column/tower shall include: (i) Internal and or external design pressure specified on process data sheets. (ii) Self weight of column inclusive of piping, platforms, ladders, manholes, nozzles, trays, welded and removable attachments, insulation and operating liquid etc. The weight of attachments to be considered shall be as per Table-I enclosed. (iii) Other loadings as specified in UG-22 of ASME Code Sec. VIII Div.1, wherever applicable. (iv) Seismic forces and moments shall be computed in accordance with IS 1893 (latest edition) unless otherwise specified in project specification. Unless otherwise specified importance factor and damping coefficient shall be considered as 2 and 2% respectively. Soil /foundation factor shall be considered based on soil/foundation of the equipment. (v) Basic wind pressure and wind velocity (including that due to winds of short duration as in squalls) for the computation of forces/moments and dynamic analysis respectively shall be in accordance with IS 875 (latest edition). Additional wind loading on column due to external attachments like platforms, ladders, piping and attached equipment should be given due consideration. (vi) Loadings resulting in localised and gross stresses due to attachment or mounting of reflux/reboiler, condenser, etc. (vii) If Column Platform of two or more columns put together are interconnected, then foundation design to be made considering this factor. 3.2.2 Loading Condition Analysis shall be carried out for following conditions : (i) Erection Condition Column (uncorroded) erected on foundation, without insulation, platforms, trays etc. but with welded attachments plus full wind on column. (ii) Operating Condition Column (in corroded condition) under design pressure, including welded items, trays, removable internals, piping, platforms, ladder, reboiler mounted on column, insulation and operating liquid etc. plus full wind on insulated column with all other projections
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DESIGN BASIS FOR STATIC EQUIPMENT open to wind, or earthquake forces. (iii) Test Condition : Column (in corroded condition) under test pressure, filled with water plus 33% of specified wind load on uninsulated column including all attachments shall be considered.
(iv) Earthquake And Wind Shall Be Considered Not Acting Concurrently. (v) Cyclic loads if any shall be considered.
3.2.3 Deflection of Column Maximum allowable deflection at top of column shall be equal to height of the column divided by 200 up to a maximum of 300 mm. (i) If the deflection of column exceeds the above allowable limit, the thickness of skirt shall be increased as first trial upto a maximum value equal to the column thickness and this exercise shall be stopped if the deflection falls within allowable limit. (ii) If the above step is inadequate, skirt shall be gradually flared to reduce the deflection. Flaring of skirt shall be stopped if the deflection falls within limits or half angle of cone reaches maximum limit of 9. (iii) If the above two steps prove inadequate in limiting the deflection within allowable limits, the thickness of shell courses shall be increased one by one starting from bottom course above skirt and proceeding upwards till the deflection falls within allowable limits. 3.2.4 Stress Limits The stresses due to pressure, weight, wind/seismic loads shall be combined using maximum principal stress theory for ASME Section VIII Div.I. Thicknesses are accordingly chosen to keep the stresses within limits. 3.2.5 Skirt Support Base Base supporting including base plate, anchor chairs, compression ring, foundation bolting etc. shall be designed based on over-turning moment (greater of seismic or wind). A minimum number of 8 foundation bolts shall be provided. Nos. of foundation bolts shall be in multiple of four. Template shall be provided for all skirt supported equipments. Type of template shall be decided based on the diameter of the skirt. For diameters more than 3000mm box type
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3.2.6 Minimum Hydrotest Pressure Minimum Hydrotest Pressure (in Horizontal position) shall be equal to Q x MAWP x temperature
correction factor, as specified in ASME Code Section VIII Div.I /Div.2, at top of column unless specified otherwise, where Q is a factor depending on code of construction. 3.2.7 Dynamic Analysis of Column/Tower Dynamic analysis of each column shall be carried out for stability under transverse wind induced vibrations as per standard design practice.
3.3 MOUNDED BULLET Mechanical design of mounded bullet shall be carried out considering combination of various loads.
3.3.1 Loading Because of critical relationship between the foundation and vessel design,construction of sand-bed / foundation and settlement shall be strictly monitored during various stages of construction, vessel hydrotest etc. Following loading shall be considered for design: a) Operating Condition: Self weight of vessel (but corroded thickness), mound load, foundation/ sand-bed reaction, liquid weight, earthquake loading, differential settlement, design pressure, longitudinal frictional load due to thermal and pressure expansion, explosion pressure on mound (if specified). b) Hydro Test Condition Self weight of vessel, mound load (in case of health check-up),foundation / sand-bed reaction, water weight, differential settlement, test pressure, longitudinal frictional load due to thermal and pressure expansion. 3.3.2 Stress Analysis
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DESIGN BASIS FOR STATIC EQUIPMENT Detail stress analysis shall be carried out by using finite Element Method, Stiffness matrix method or any other relevant structural mechanics approach. Used software must be properly validated giving references of similar installations for which the package has been used.
3.3.3 Cathodic Protection Sacrificial anode cathodic protection system shall be designed and installed. 3.3.4 Mound Load a) Weight of mound shall be calculated for saturated mound and specific gravity of mound shall be taken not less than 2.0 for this purpose. Load of mound on a vessel shall be calculated with arching effect. b) Mound depth above top of the vessel shall not be less than 1 metre. 3.3.5 Load due to Uneven Settlement a) To make allowance in the design for effect of tolerances in alignment of shell section, unevenness in sand-bed, etc. a maximum/minimum reaction may be assumed as given below.
b) Based on soil investigation along with vessel axis, sub grade modules of soil / bed shall be calculated. Value of Pmax/Pmin may be reduced to 1.30 provided foundation is constructed and differential settlement is ensured by the contractor and demonstrated during hydrotest. c) Sand-bed should be properly prepared and compacted to obtain effective angle of support at least 120 and differential settlement should not be more than 40 mm between mid-point of vessel and
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DESIGN BASIS FOR STATIC EQUIPMENT end-point of vessel. d) During initial hydrotest condition sand bed contact angle may be taken as 60 without mound over vessel if such condition arise during construction and hydrotesting of vessel.
3.3.6 Corrosion Protection Suitable surface treatment ( blast cleaned to SA 2 surface finish) with Polyurethane / PolyUrea coating shall be provided over mounded bullet for corrosion protection. List of applicators / vendor for Polyurethane / Poly-Urea coating are as under; 1) M/s Amchem Products Pvt. Ltd A-79 Sector 58,Phase-III, Noida -201301 Product Name : Purethane. 2) M/s Polybrid Coating, USA Exclusive Licensee M/s. Univest Chemical Pvt Ltd.,Mumbai Product Name : Polybrid 705 3) M/s Vasu Chemicals, Vasu Centre, Military Road, Marol, Andheri (E), Mumbai Product Name : Protegol 100% solid Elastometric Pu Coating from Goldschmidt TIB GmbH 4) M/s Cipy Polyurethane coatings, Bhoisari , MIDC, Pune Product Name : Durathane 100EA The vendor should be given the job as supply and apply basis with necessary guarantees. The vendor shall submit the completion / performance certificate for the job done in the past 5 years. The vendor shall have the necessary application equipment like plural component airless spray equipment and blast cleaning equipment and all suitable inspection instruments. 3.3.7 100% radiography and 100% SR of all pressure part joints on the vessel to be ensured irrespective of thickness as per OISD std. 144 and 150. 3.4 HEAT EXCHANGERS 3.4.1 Mechanical design of heat exchangers shall be done by software which complies with TEMA & ASME Sec. VIII Division 1. 3.4.2 The following mechanical design criteria shall be adhered to during design and engineering of
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DESIGN BASIS FOR STATIC EQUIPMENT heat exchangers: i) Metric bolting shall be used except for nozzles. ii) Bolt loads shall be considered for designing the flange.
iii) Main girth flange shall be of forged (hubbed) construction. iv) Bundle interchangeability shall be considered (in the same unit only) to the extent possible. v) Eye bolts for pulling out of removable bundles shall be provided at both stationary and floating tube sheets. vi) Exchangers shall be designed for full vacuum when partial/full vacuum is specified in data sheet.
3.5 AIR COOLERS 3.5.1 The following mechanical design criteria shall be adhered to during design and engineering of Air Coolers: i) Metric bolting shall be used except for nozzles. ii) Header shall have plate construction. iii) All nozzle flanges shall be of welding neck forged construction.
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TABLE-I
DETAILS AND WEIGHT OF COLUMN ATTACHMENT 1. Shape factor for shell (for wind force calculation) : 2. Weight of trays (with liquid) to be considered. 3. Weight of plain Ladder 4. Weight of caged ladder 5. Equivalent projection to be considered for wind load on caged ladder 6. Distance of platform below each manhole 7. Maximum distance between consecutive platforms 8. Projection of Platform : : : : 300 mm Approx. 1000 mm 5000 mm 900 mm upto 1 meter dia. column and 1200 mm for column dia. >1 meter, from column insulation surface. 9. i) Equivalent height of platform (for wind load computation) ii) Shape Factor for platform 10. Weight of platforms : : : 1000 mm 1.0 170 Kg./m2. 0.7 : : : 120 Kg./m2. 15 Kg./m 37 Kg./m
11. Platform shall be considered all around for top & bottom platforms. All intermediate platforms
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DESIGN BASIS FOR STATIC EQUIPMENT shall be taken as minimum half and platform shall be made available for all nozzle approach including instrument tappings. 12. Supply and fabrication of structure and gratings for platforms, hand railings, toe guard, monkey
ladder shall be in the scope of supply of equipment supplier. Structure & gratings for platform shall be hot dip galvanized. Hand railings, toe guard, monkey ladder shall be supplied with one coat of primer as per painting specification. Assembly of these items shall be carried out by site installation agency.
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SECTION-B
(TRAY & TOWER INTERNALS)
1.0 INTENT 1.1 The intent of this specification is to define basis to be followed for Mechanical Design, engineering, fabrication, inspection/testing, supply and installation (inside the columns at site) of Trays, Packed Column Internals and Tower Packings separately and collectively known as "Internals". For licensed units, in case the requirements specified here are in conflict with licensors specifications, licensors requirements shall govern. 1.2 In case of any conflict between various documents, resolution shall be in accordance with the following order of preference: Data Sheets/P&IDs/Design Basis Job Specifications Standard Specifications/Engineering Standards.
2.0 PROCESS PARAMETERS, DESIGN CONDITIONS & SELECTION OF INTERNALS As per Process Datasheets. 3.0 DESIGN
3.1 MATERIALS 3.1.1 All materials shall conform to those specified in the respective process drawings or data sheets. No substitution of material will be permitted without the written consent of Owner/TPKTI in required formats as per procedure. In case substitution of material is proposed, vendor shall clearly indicate the reasons for requiring such change and give chemical and physical properties of the proposed alternate material with their standard specification number. All the material supplied by vendor shall be
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DESIGN BASIS FOR STATIC EQUIPMENT new and of first quality supported with mill test certificates. Unless specified in data sheets, Material shall be as per clause from 3.1.2 to 3.1.7. 3.1.2 13 Cr Stainless Internals All sheet and plate material shall be in accordance with SA 240 Type 410S or 405 having No.1 finish only for thickness more than 4mm. For thickness up to and including 4 mm, No. 2B/2D finish is also acceptable. All bolting material shall be SA 193 Gr B6X or B6 for bolts and SA 194 Grade 6 for nuts and lock-nuts. 3.1.3 18 Cr - 8 Ni Stainless Internals All sheet and plate material shall be in accordance with SA 240 Type 304 having No.1 finish only for thickness more than 4mm. For thickness up to and including 4 mm, No. 2B/2D finish is also acceptable. All bolting material shall be SA 193 B8 for bolts and SA 194 Gr.8 for nuts and lock-nuts. 3.1.4 Monel Internals All sheet and plate material shall be in accordance with SB127 in hot rolled, annealed and pickled condition. All bolting material shall be Monel, made from rod or bar stock, SB164.
3.1.5 Carbon Steel Internals Unless otherwise specified, sheets and plates shall be procured in hot rolled conditions and shall be free of mill scale. Material shall be suitable for bending. The bend test specimens shall stand being bent cold through 180 degree without cracking on outside of the bent portion, to an inside diameter equal to or less than twice the thickness of the specimen or as per relevant material specification, whichever is severe. All sheet, plate material shall conform to SA285, SA283 or better unless specified otherwise on the data sheets/drawings. All fasteners including clamps, material shall be as per clause 3.1.2 above, unless specified otherwise.
3.1.6 Gaskets
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Trays gasketing material shall be woven tape, fabricated from Asbestos Free Material such as Woven Fiber-glass Tape (Amatex-G36-P752 or equal), Woven Teflon Tape, Woven Expanded Graphite Tape
or Ceramic Fiber Tape etc. and shall be suitable for process fluid and column design temperature, unless specified otherwise in the Data Sheets/Purchase Specifications. The thickness of the woven tape shall be 1.5 mm minimum. The use of Woven Asbestos Tape or Wire shall be subject to TPKTI/Owners prior approval only. 3.1.7 Support Rings/Bolting Bars/Support Cleats Support rings, downcomer or up comer bars and other parts welded to vessel shall be of same metallurgy as that of vessel. Minimum thickness excluding corrosion allowance of welded parts shall be 6 mm for vessel diameter up to 3000 mm and 10 mm for higher diameter. Corrosion allowance as specified in vessel data sheets shall be added on both sides of Support Ring, Bolting Bar and other welded parts. All column tray support fixing inside equipment shall be critically reviewed for accuracy of work before dispatch of equipment.
3.2 THICKNESS OF INTERNALS 3.2.1 Minimum thickness of Internals: Corrosion allowance, wherever specified in the data sheets for Internals in excess of corrosion allowance as indicated in clause 3.2.2 shall be added to the minimum thickness specified below: Alloy i) Deck plates, seal pans, draw-off Pans, weirs/seal plates, other removable Components ii) Welded deck plates, downcomer aprons and other welded components iii) Downcomer/Internal pipes iv) Bubble Caps Risers (fixed) Risers (removable)
: : :
CS 3.5*
2.0
3.0 2.0 1.6 2.0 1.6
3.5* 3.5* 2.0 3.5* 2.0
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DESIGN BASIS FOR STATIC EQUIPMENT v) Valves vi) Structured Packings

1.6 0.15 5.0 5.0
(will not be used) (will not be used) 8.0 8.0
vii) Support Grid for Structured Packings viii) Locating Grid/Retaining Grid/Bed Limiter ix) Grid Packings (a) Bottom-most layer (b) Next Five Layers (c) Balance Layers x) Random Packings xi) Loose Beams xii) Lattice Girders (a) Primary Members (b) Secondary Members (c) Gusset Plates (d) Downcomer bolting bars xiii) Z-Bars (*10 USSG is also acceptable in lieu of 3.5 mm)
5.0 2.0 1.6
8.0 (As per vendors standard) (As per vendors standard)
(As per vendors standard) To suit load 5.0 3.0 10.0 5.0 5.0 To suit load 6.0 4.0 10.0 10.0 8.0
All bolting shall be minimum M10 for Internals and M16 for Lattice Girders. All bolt head/nuts shall be hexagonal. Minimum corroded thickness of the internals for the loading condition as per Clause 3.3.3. (i) and (ii) below, shall be 3.0 mm. 3.2.2 Corrosion Allowance The following corrosion allowance shall be added to calculate thickness of Internals unless otherwise specified on data sheets or bid specification. i) No corrosion allowance is required for Monel or Stainless steel alloy assemblies. ii) The corrosion allowance for all surfaces of floor of Carbon Steel assembly shall be 1.5 mm (total). 3.2.3 Unless specified on the data sheets or bid specifications, corrosion allowance shall be higher of 1.5 mm (total) or one quarter of the vessel corrosion allowance on each surface of trays and its components. 3.2.4 Beams, trusses and other support members shall have total corrosion allowance equal to
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DESIGN BASIS FOR STATIC EQUIPMENT vessel corrosion allowance for removable type construction and twice the vessel corrosion allowance for non-removable type construction through vessel man-hole.
3.3 DESIGN LOADINGS 3.3.1 Design loads for tray assemblies shall be based on a liquid height of 50 mm liquid above weirs plus self weight of deck plates and beams or live load of 150 kg/m2 whichever is severe. In case liquid density is less than water, 1000 kg/m3 shall be considered for purpose of calculating liquid load. 3.3.2 Under-down-flow plates and seal pans shall be designed to withstand a weight of liquid equal to half the normal tray spacing (excluding the locations where tray spacings have been increased to accommodate manholes/feed pipes etc.) or 300 kg/m2 whichever is severe plus self weight of udf plates and beams. In case liquid density is less than water,1000 kg/m3 shall be considered for purpose of calculating liquid load. 3.3.3 Five trays above/below 2-phase feed inlets and in bottom zone of column wherever process steam or two-phase feed is admitted, shall be provided with lock nuts. These trays shall be capable of sustaining a net thrust of i) 1464 kg/m2 and with shear clips for Vacuum Columns (Stripping + Wash + HVGO sections) ii) 1000 kg/m2 and with shear clips for Crude Column/Main Fractionator Columns. iii) 450 kg/m2 for all other services. 3.3.4 One tray above and below the intermediate vapour /liquid feeds shall also be provided with locknuts. 3.3.5 The packing support plate shall be designed to support the maximum expected load of tower packings, liquid hold-up (min 10 percent). In case of liquid density is less than water, 1000 kg/m3 shall be considered for purpose of calculating load due to liquid hold-up. 3.3.6 Bed limiters frame shall be strong enough to take care of surges/uniformly distributed load of 100 kg/m2 and 135 Kgs concentrated load at any point.
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3.3.7 Hold down plate shall exert sufficient static load on the bed to restrict movement of the packing. The hold down plate shall be designed for exerting a load of ~80 kg/m2 minimum on the
packed bed. 3.3.8 Liquid distributors/ Redistributor shall be designed for self weight plus maximum expected liquid load. 3.3.9 All Internals assemblies except cartridge tray assemblies shall be able to withstand the selfweight plus the following number of 135 Kgs concentrated loads (maintenance loads) at ambient temperature. Vessel Diameter Number of 135 kg loads Up to 1200 mm 1 (at center of diameter) Up to 3600 mm 2 (at center and point of diameter) Over 3600 mm 3 (at center and points of diameter)
3.3.10 Design loads for Chimney/Collector trays shall be based on dead weight plus live load of liquid height equivalent to riser height or 50mm more than weir height. In case liquid density is less than water, 1000 kg/m3 shall be considered for purpose of calculating liquid load.
3.4 ALLOWABLE STRESS AND DEFLECTION 3.4.1 Allowable stresses for all Internals shall be as per ASME Sec. II. Part D, latest edition. 3.4.2 The maximum deflection of tray/tower internal assembly shall not exceed 1 mm per meter of column diameter or 7.5 mm, whichever is lower for the design loadings given in clause 3.3.1 and 3.3.2 above. Deflection for distributor assembly shall be limited so that overall liquid maldistribution does not exceed the limit as per clause 3.5.17(v). Deflection for support plate and seal pans shall be limited to L/400, where L is the length of individual component. 3.4.3 Deflection as per clause 3.4.2 may be ignored for trays designed based on design loadings as
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DESIGN BASIS FOR STATIC EQUIPMENT per clause 3.3.3 and 3.3.9. 3.4.4 For large diameter vessels, initial camber may be made in the principal support members of the
assemblies so as to limit the deflection as specified in clause 3.4.2 above.
3.5 ARRANGEMENT/DETAILS OF INTERNALS 3.5.1 All assemblies except one piece cartridge type trays for column ID less than or equal to 750mm shall be of removable type unless otherwise indicated. The general design, number, type and spacing shall be established on the individual vessel drawing/data sheets. Cartridge type trays shall be designed to rest on four support cleats. 3.5.2 Each removable section shall be so dimensioned/sized to permit passage through vessel manhole and shall be suitable for assembly/ dismantling from upper side in so far as structural contingencies permit. Maximum diagonal dimension of the components shall be restricted to vessel manhole ID - 12mm clearance. 3.5.3 Internals support trusses supporting more than one Internal, as are commonly used in large diameter columns and which can not be installed through manholes, shall be split into sections for access through manhole and minimising welding work inside the column. 3.5.4 Internals decks shall have a maximum length of 3000 mm. To achieve this maximum distance between main support beams or girders shall be limited to 3000 mm. However, the main support beams or girders having length more than 3000 mm shall be provided with one butt joint with splice plates of the same thickness as the main member upto 6000 mm length and two butt joints with splice plates of the same thickness as the main member for more than 6000 mm length and so on. The butt joint shall be provided inclined at 45 degrees.
3.5.5 Manways i) One(1) manway in single cross flow decks, two(2) manway in double flow decks and so on shall be provided. These manway shall be freely removable from top and bottom. Manway shall be in the same vertical line for a set of trays. These shall be at such a location and of a shape and size to permit easy
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DESIGN BASIS FOR STATIC EQUIPMENT access to every area of the tray. Manway of different set of trays (about 20 trays) shall be staggered to each other. Minimum clear opening on tray shall be 380mmx450mm. In case same can not be provided due to design conditions, minimum manway size (clear opening) of 360 x 500 or 330 x 550
can be accepted as a special case. ii) Where manway cannot be provided, decks shall be split (turn-up - turndown) to provide suitable access for Inspection and assembly from top as well as bottom. 3.5.6 Unless specified otherwise, support rings, bolting bars, support bracket/cleats when required, shall be designed for welding to the vessel. All other parts shall be designed for bolting or clamping in place. Clamping shall be used on Tray floor and all downcomer/up comer shall be through bolted. Spacing of bolting or clamping shall be close enough to ensure optimum liquid tight construction but shall not exceed 125 mm on deck portion in downcomer area/liquid holding area/downcomer apron bolting etc. and 150 mm in active area. All joints and seams of trays specified to be liquid tight without gasketted joints shall be seal welded at site. Maximum spacing for clamps/bolting for gasketted construction shall be restricted to 100 mm. 3.5.7 Drawings and instructions for installation and fabrication of support ring, bolting bar and support bracket/cleats welded to vessel shall be furnished by Internals supplier. They shall show clearly the type, size and extent of welding. All support rings and bolting bars shall be continuously welded on both sides. All support brackets shall be welded all around. 3.5.8 Casketing need not be used in the design or installation of Internals except for bubble cap trays, all liquid holding portions (e.g. seal pans, draw-offs), collector trays, distributors and redistributors. Fabrication shall provide tight metal-to-metal joints. Metal seal plates shall be used to close construction joints where necessary. 3.5.9 All stiffeners and support members shall be located on the underside of the tray floor with the exception of open type trusses supporting two trays. Stiffeners and support members in bubbling areas shall not exceed 75 mm in width and shall be designed so as not to impede or channel the liquid flow on the tray. Depth of stiffeners and support members transverse and parallel to the liquid flow shall not exceed 20 and 30 percent respectively of tray spacing. 3.5.10 A minimum of 20 mm overlap shall be provided between tray floor section and support members.
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3.5.11 Trays and seal pans not specified to be liquid tight, and of a design which would not easily drain shall be provided with one or more 12mm diameter/square drain holes/slots located in
the outlet weir directly above the tray flow. Size and number of drain hole/slot may be reduced depending upon liquid rate. Draw off sumps shall be located flush with the invert inside of draw off nozzles to allow complete draining of sumps. 3.5.12 All the three (3) and four (4) pass trays shall have pressure equalising pipes (vent tubes) across the downcomers. 3.5.13 Bubble Cap Trays Risers Fixed risers shall be used unless otherwise specified in the data sheets. For deck plates less than 3 mm in thickness, riser shall be expanded into upward flanged opening in the deck plates and then stitch welded to upturned edges of the opening. For deck plate 3 mm thickness and more, the riser shall be continuously welded to the deck plates with the holes in the deck plate being plane, not upturned. Caps shall be attached to the attachments welded to the top of risers. Bubble Cap Bubble caps are to be furnished in Full Annealed and scale free bright condition. 3.5.14 Valve Trays Valve assemblies of proprietary trays shall be provided with following features. i) A means of preventing the orifice covers from adhering to tray floor. ii) A means of preventing the orifice covers with integral guide legs and lift stops from popping out of place during operation. 3.5.15 Sieve Trays All perforations shall be punched and made from top side and burr side on tray decks must be downwards when installed, unless specified otherwise. In case of liquid-liquid extractor column trays, punching direction shall depend on the direction of liquid flow of continuous phase.
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3.5.16 Burrs shall be removed from all perforated areas and edge of Internal sections. 3.5.17 Distributors/Redistributors
Distributors of liquid feed to packed beds, unless otherwise specified in data sheets, shall be gravity flow type (e.g. orifice drip trays, tubed drip trays, trough type, orifice header laterals) in accordance with following requirements: i) Orifice for liquid distributor shall preferably be minimum 8.4 mm diameter and shall be arranged on an approximate equal spacing throughout the distributor. Distributor supports shall be designed and arranged so as not to interfere with flow from orifices. In case orifice diameter calculated is less than 8.4 mm, then antifouling covers shall be provided on each orifice. Orifice below 6mm diameter shall be preferably provided at an elevation in drip tube or in side of trough with guide tubes. ii) Vapour risers shall have a total cross sectional area as per Vendor's design but not less than 15 percent of vessel cross sectional area. Number, size and arrangement of vapour risers shall be such so as not to affect the orifice spacing and liquid distribution to the packings. iii) Distributor joints shall be gasketted to be liquid tight. Gasket material used shall be suitable for service and soft enough for leak tight joint. iv) Distributor shall be capable of performing satisfactorily for the range of loadings specified to cover entire range of plant operation. v) Flow variation from orifice to orifice shall not be more than 10 percent at turndown condition. vi) Feed pipe shall form part of Distributor supply. 3.5.18 Packing Support Plate Packed bed support plate shall be vapour-injection type, providing separate passage for liquid and vapour flow. The support plate shall have at least 90 percent free area based on cross sectional area of vessel. Slot size shall be so selected to avoid any sneak through of packings from slots. 3.5.19 Bed Limiters/Bed Retainers Bed Limiters/Bed Retainers shall be located just above top of packings to avoid fluidizing of bed and shall be fixed in position so as not to be moved by the packings and shall be designed so as not to affect distribution from the liquid distributor to the packings. Bed Limiters/Bed Retainers for use with spray nozzle distributor shall be designed with major structural support on the underside of the
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DESIGN BASIS FOR STATIC EQUIPMENT retainer so as not to affect the spray distribution on the packings. Expanded metal with equal opening area is also acceptable in lieu of wire mesh. 3.5.20 Hold Down Plates Hold down plates shall be provided on the top of ceramic or carbon tower packings. The hold-down plate shall directly rest on the bed without any support cleats. Hold-down plate shall exert sufficient static pressure on the bed to restrict movement of the bed. Care shall be taken not to use hold-down grid with metallic or plastic tower packings. 3.5.21 Flash Feed Distributor Flash feed distributor for flashing or mixed phase, vapour and liquid feeds to packed bed shall be designed to separate the two phases and distribute the liquid phase on distributor/redistributor. If flashing feed gallery is used, riser area shall be 50% of vessel cross sectional area. 3.5.22 Tower Packing If type of packings is not specified in the process data sheets, following shall be taken as guidelines: i) For wash zone of vacuum column, Grid Packings shall be used. ii) For all other applications preferably Pall Rings shall be used. If pall rings are not expected to perform to desired performance, proprietary Random Packings or EIL Structured Packings may be used. 3.5.23 The maximum allowable pressure drop for a packed bed shall include packed bed support, bed limiter and distributor.
4.0 FABRICATION AND SUPPLY
4.1 TOLERANCES All sections shall be truly flat within 2 mm and shall be free from burrs and weld spatters. Tolerances wherever unspecified shall be taken as 1 mm and not to be accumulative, except on thickness and assembly diameter. Tolerances on thickness shall be as per applicable specification and tolerances on assembly diameter shall be as below:
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4.2 WELDING 4.2.1 All welding shall be done by metal arc welding. For welding on thinner gauge sheets TIG welding is preferred. 4.2.2 Gas or Carbon arc welding shall not be used. 4.2.3 Welding electrodes of composition similar to Internals material shall be used except austenitic electrodes of higher chromium and nickel content such as AWS A5.4, ASME SFA 5.4 class E309 and E310 may be used for 12 Cr stainless steel. For dissimilar material welding, electrode composition shall be similar to nobler material being welded. Following electrodes shall be used unless specified otherwise: E 7018 E 308 E 308L E 316 E 316L E Ni Cu7 for all CS materials for all SS 304 to SS 304 for all SS 304L to SS 304L for all SS 316 for all SS 316L for Monel to Monel and Monel to CS/SS.
E 309MoL for SS 410S to SS 410S, SS to CS, SS 410S to SS 304,304L, 316, 316L
4.2.4 Welding wherever specified, is to be done by qualified and approved welders using the suitable fillers and fluxes recommended for the materials in the fabrication drawings. For welding the stud on tray decks and support beams, use of stud welding gun with suitable flux is acceptable. In manually welding the studs, care should be taken to minimise the weld spatter and the outside diameter of the weld so that it should not foul with tray deck or washer. For stud welding, proper welding procedure shall be established. Torque required for welding failure shall be higher than the torque required for failure of the stud.
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4.2.5 A proposed Welding Procedure Specification (WPS) shall be submitted to AIA for his approval. On approval, a Procedure Qualification Test (PQT) shall be conducted which shall be
witnessed by AIA. On acceptance of all tests as per ASME Section IX, a final WPS along with Procedure Qualification Record (PQR) shall be submitted. Production welding shall start only after approval of final WPS/PQR and qualification of welders as per ASME Section IX. AIA may accept previously qualified WPS/PQR at his sole discretion.
4.3 MISCELLANEOUS 4.3.1 All parts fabricated shall be smooth, true, clean and free from burrs, grease and dents. Openings for passage of workman must have exposed edges rounded. 4.3.2 All support rings, bolting bars, beams support brackets and other components which are integral and therefore welded to the column shell inside, shall be supplied and installed by column fabricator. 4.3.3 Total draw-off trays shall be designed for zero leakage construction and may be seal welded (if required) at site to attain zero leakage. 4.3.4 Seal welds shall have a throat thickness at least equal to the specified corrosion allowance. 4.3.5 All stainless steel tray assemblies/internals and their components (e.g. Bubble caps, valves etc.) shall be pickled and passivated. Pickling and Passivation shall be as per ASTM 380. 4.3.6 All parts shall be fabricated in accordance with good shop practice and in uniformity so that all corresponding parts will be inter-changeable.
4.4 SPARES Following spares shall be included as part of the supply: 4.4.1 Constructional Spares The supply shall include the following as constructional spares :
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Bolts/Nuts
10% of total for each size (minimum 10 nos. of each size).
Clamp assemblies
10% of total for each type and size
(minimum 10 nos. of each size). Valves for trays 5% of each type Bubble caps Gasketing or tapes Sealing foils for cartridge trays U-clamps Tower Packings (Only Random Packings) Spray Nozzles Up to 25 Nos. (of each type) - 100% More than 25 (or each type) - 25% (subject to minimum of 25 Nos.) 4.4.2 Vendor shall submit list of spares recommended for two years of satisfactory operation. However, following operational spares as a minimum shall be supplied as Mandatory Spares: i) Valves for Trays ii) Bolts/Nuts iii) Clamp Assemblies iv) Gaskets or Tapes - 10% of each type - 10% of total for each type/size (minimum 10nos. of each size) - - do - 100% of each type and size
5% of each type and size 100% of each type and size 200% of each size
10% of each type and size (minimum 1 nos. of each type &size). 10% for Metallic and Plastic Packings 15% for Carbon and Ceramic Packings
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DESIGN BASIS FOR STATIC EQUIPMENT v) Sealing foils for Cartridge Trays vi) Spray Nozzles
- 200% of each size - 25% subject to minimum 5 Nos. of each type and size. - 5% of each type and size.
vii) Tower Packings (Only Random Packings)
If desired by owner, item wise price for above spares shall be furnished after award of the job. 5.0 INSPECTION AND TESTING
5.1 GENERAL 5.1.1 The materials, fabrication, testing and trial assemblies are subject to inspection by owner/TPI agency/TPKTI, at shop floor before shipment and during installation. 5.1.2 Any rejection made by Inspector shall be final. Approval/Inspection by TPKTI/Owner and/or their designated representative shall in no way relieve the Vendor of his responsibility to meet all the requirements of the Purchase Order. 5.1.3 Owner/TPKTI/Authorized Inspector shall have free entry to the Vendor's shop at all times where and while the work is being performed. The Vendor shall offer the inspectors all reasonable facilities to satisfy them that the materials are being furnished in accordance in accordance with the specifications. 5.1.4 Vendor shall notify the Owner/TPKTI sufficiently in advance of any fabricating operations to permit the Inspector to arrive at the Vendor's shop.
5.2 STAGE INSPECTION DURING FABRICATION
5.2.1 DIMENSIONS The inspector will check that the thickness and the dimensions of all parts for the Decks, Weirs, Seal and Draw off pans, Down comers, Draw off pipes, Supports, Beams, Valves, Bubble caps, Clamps, Studs, Bolts, Nuts, Risers, Washers and Gaskets etc. are as per the approved
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DESIGN BASIS FOR STATIC EQUIPMENT drawings. 5.2.2 FABRICATION

The inspector shall check each individual part of the equipment fabricated as per approved drawings and specifications. For instance, for the Bubble cap dimensions, height, width and number of slots, heights, O.D. and I.D. or riser and cap, shroud ring height, exit and inlet weirs height etc. shall be measured. The inspector will check that all identical parts shall be interchangeable. Inspector shall check that the sharp edges on the Internal components, manway covers,weirs, downcomers etc. are properly removed. Also that all burrs from punched holes and loose weld slags and materials are removed from all components. Stage-wise inspection during fabrication will be thoroughly carried out. Before starting welding, welders' qualification test will be carried out, if required, as per ASME Sec. IX. Where numbers of similar items are to be made, inspector shall give the clearance for the fabrication of the lot only after checking and approving the first sample piece.
5.3 TRIAL ASSEMBLY Trial assembly of one tray of each type and size with its accessories shall be carried out inside the fabricators' shop as floor mock-up. The components for such an assembly will be taken at random from each lot of identical items. The assembled tray will be carefully checked for its dimensions, tolerances, number and arrangement of perforation, the working of the valves in case of valve trays, V-notch or Blocked Weir, adjustability of weir, vent tube details, downcomer clearance, weir heights, downcomer length and width, number of clamps, gaps and potential leakage points etc. The assembly shall also be checked for each type and size of packed tower internals. Inspector will also check the flatness and deflection of the trays, internals, beams, tray edges and beam ends clearance.
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DESIGN BASIS FOR STATIC EQUIPMENT 5.4 LEAK TESTING Bubble cap, Collector trays, Liquid holding portion of other trays such as Seal pans, Recessed
seal pans, Draw off pans, Distributors/Redistributors shall be subjected to leakage test at shop floor (by internals vendor) and in the field (by installation contractor) by filling water up to weir level or up to normal liquid level as the case may be. However, in case site installation of these is also included in internals vendors scope of work, leak testing at shop floor for items in single piece construction is not required. Appropriate ring fixture or a portion of column shell with supports for seal pan/recessed seal pans/draw off box etc. shall be made by Internals Vendor to facilitate leak testing in the shop. Leak testing shall be carried out with service gaskets and drain holes temporarily plugged. All distributors/redistributors shall be leak tested with all holes temporarily plugged. It shall be ensured that leakage is uniform and not from few concentrated places/corners. All plugs shall be removed after leak testing is over. Leakage rate shall not exceed 0.5 percent of design liquid flow rate unless otherwise specified.
5.5 DISTRIBUTOR TESTING 5.5.1 All Vendors Proprietary Liquid distributors/redistributors shall be water tested in the vendors shop only by the following procedure at 50%, 100% and 110% of the design liquid volumetric flow rate. The vendor shall certify to the purchaser at the time of bidding that they believe their equipment can meet the testing requirements listed below: (i) If the distributor contains a pre-distributor, it shall be tested first to ensure that it has a CV of 5 or less at the design flow rate. Each orifice in the pre-distributor shall be tested. The CV is defined as the ratio of the standard deviation to the sample mean, expressed as a percent. (ii) The distributor/re-distributor itself shall be tested and the CV determined. To determine the CV, at least 30 pour points or at least 10% of the pour points (whichever is higher) shall be
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DESIGN BASIS FOR STATIC EQUIPMENT randomly selected and tested. If the CV specified below cannot be met, the vendor will correct the problem at its expense. (a) For orifice pans, tubed drip pans and other similar devices, a CV of 10 or less must be achieved at the design liquid volumetric flow rate. (b) Four orifice parts, tubed drip pans or trough distributors that employ a modular (sectional) design, (wherein many pieces are geometrically identical) all pieces of the same geometry shall be treated as one group or strata. One piece from each strata shall then be tested by the procedure outlined above. (c) The average flow rate per pour point for any grouping of 10 of the tested pour points from a single area should differ by no more than 5% from the average for the group or strata being tested. (d) The test results shall be furnished to TPKTI/Owner in a written report. This report shall also contain a drawing of the distributor in plan view. This drawing shall be broken down into 3 radial zones of equal area and the location of pour points sampled in each zone. In case vendor can demonstrate procedure establishing above quality requirements, performance testing of distributors can be waived off.
5.5.2 SPRAY NOZZLE DISTRIBUTORS Spray nozzle distributors shall not be tested in the vendors shop but must be tested in the tower prior to start-up to ensure that all nozzles are operable and develop the desired spray pattern. This test shall be carried out as close to design rates as possible. SPRAY NOZZLES Apart from the usual material quality tests (chemical analysis and mechanical properties) and manufacturing quality control tests, vendor shall include for & carry out the testing of the spray nozzles with respect to the flow rates for specific .P, spray angle, spray coverage and distribution for the tip distance given in the data sheet. The testing medium shall be water. These results shall be submitted to Owner/TPKTI for review. Tests and acceptance criteria is as below:
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DESIGN BASIS FOR STATIC EQUIPMENT Flow rates Spray angle Flow variation
- 5% for specific .P - 5 - As per vendors Standard. (Data to be reported for Information)
No. of nozzle to be Tested - 10% of each size and type. (Min. 2 nos. of each type & size)
6.0 SITE INSTALLATION Installation of internals at site to be carried out under technical supervision of tray manufacturer. However, the installation works to be done by Mechanical agency.
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SECTION-C (MECHANICAL EQUIPMENT)
1.0 SCOPE This design basis defines the minimum design criteria to be followed for the design of various mechanical equipment.
2.0 CODES & STANDARDS 2.1 The following codes & standards (latest editions) including their latest addenda shall be followed unless specified otherwise. ASTM API ASME BSI BIS AGMA NFPA OCIMF TEMA IS : : : : : : : : : : American Society for Testing and materials American Petroleum Institute American Society of Mechanical Engineers British Standards Institute Bureau of Indian Standards American Gear Manufacturers Association National Fire Protection Association Oil Companies International Marine Forum Tubular Exchangers Manufacturers Association Indian Standards
2.2 Statutory Provisions National laws and statutory provisions such as Indian Boiler Regulation and Department of Explosives, Nagpur, India together with any local by-laws for the state shall be complied with. Static and Mobile Pressure Vessel (SMPV) rules, Petroleum rules, Factory Acts and Rules, Environmental Protection Act & Rules etc. as applicable shall also be complied with.
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DESIGN BASIS FOR STATIC EQUIPMENT 3.0 REFERENCED PUBLICATIONS ABMA

: :
American Boiler Manufacturers Association Heat Exchangers Institute
HEI
4.0 GENERAL DESIGN REQUIREMENTS While specific guidelines pertaining to individual equipment and systems are listed in subsequent sections, the following shall be considered for all items while formulating their specifications and also in downstream procurement engineering activities: - Reliability in service (assessed from vendors relevant track record and improved by incorporating certain minimum design features or requirements in the specification) - Compliance with applicable national or overseas codes and standards as well as any statutory regulations in existence for a specific item. - Ease of operation and maintenance including any necessary measures for ensuring safety of personnel and equipment as well as conducive working environment. - Standardization of components wherever feasible. - Adherence to any limitation of space available for the equipment and its operation/maintenance. - Facility for any known future expansion of plant capacity with a minimum of modification or shutdown.
5.0 DESIGN REQUIREMENTS FOR SPECIFIC APPLICATIONS i) Corrosion allowance for carbon steel vessels shall be minimum 3 mm. ii) All components/equipments shall meet the requirements of respective area classification. iii) Insulation shall be provided for personal protection for all surface temperature higher than 60oC. iv) All couplings, gears and exposed rotating parts shall be provided with adequate protection guards.
6.0 BASKET FILTER 1) Basket filters shall normally be used when particles of around 40 microns or larger size are to be
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DESIGN BASIS FOR STATIC EQUIPMENT filtered from a fluid stream. 2) Filter shall be designed not to exceed the allowable pressure drop in dirty conditions. 3) In order to avoid the possibility of frequent basket cleaning the gross and free areas shall be at
least 20 and 8 times respectively of the filter inlet nozzle area. Basket shall be of straight cylindrical shape. Both concentric and pleated type baskets shall not be accepted. 4) Filter shall be vertical type, unless mentioned otherwise, with facility for removal of the basket from the top after opening the housing cover. 5) Fluid flow shall be from inside to outside of the basket, unless specified otherwise. 6) Filter housing design shall be as per ASME Section VIII, Division 1. For steam jacketed housings, applicable IBR requirements shall also be complied with. 7) For filter top cover weighing more than 15 kg, lifting davit shall be provided.
7.0 CARTRIDGE FILTER 1) Cartridge Filter shall normally be used when particles of less than 40 microns size are to be filtered from a fluid stream. 2) Cartridge material and type of selection shall be consistent with the service conditions. 3) Cartridge elements of throwaway type (meant for depth filtration) shall be used. 4) Cartridge element quantity shall be based on element manufacturer=s data for flow and pressure drop. The pressure drop across the housing (including nozzles and cartridge mounting plate) shall be separately calculated to arrive at the permissible drop through the cartridge. 5) Filter housing design shall be as per ASME Section VIII, Div.1. For steamjacketed housings, applicable IBR requirements shall be complied with. 6) Filter shall be vertical type unless mentioned otherwise. Top covers shall normally be of quick opening type for easy replacement of cartridge elements. 7) Filter shall be vertical type unless mentioned otherwise. For filter top cover weighing more than 15 kg, lifting davit shall be provided. 8) Superficial velocity for charcoal filter in Amine Service shall not exceed 10 M3 / hr/m2 and the minimum height of charcoal bed shall be as indicated in the filter process data sheet.
8.0 FILTER SEPARATOR/COALESCER 1) Material and type of coalescing and separating elements shall be consistent with the service
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DESIGN BASIS FOR STATIC EQUIPMENT conditions as specified in the datasheets. Coalescer pack and or cartridge suppliers recommendations shall be followed for meeting performance requirements, liquid velocity and flux rate established.
2) Coalescing cartridge shall be designed for bursting pressure of 2.0 Kg./cm2 min. 3) Quick opening closure equal to full vessel diameter shall be provided, to meet the process and maintenance requirements, unless otherwise specified. 4) Coalescer vessel shall be designed as per ASME Section VIII Division 1. 5) Coalescer Packs / elements of throw away type shall be used.
9.0 FEED FILTERS WITH AUTOMATIC BACKWASH FACILITIES 1) Filtration system shall ensure continuous uninterrupted filtration of feed. The system shall be capable of removing solid particles of size 20 microns of largest and shall have an automatic back flushing system for instant clearing of filter elements. 2) Back washing media shall be filtered feed or gas assisted or as specified in the process data sheet and shall be designed for a minimum amount of backwash media. Backwash cycle shall be initiated when the set point pressure drop reaches and the cycle shall be complete only, when all filters are cleaned as per the defined sequence of operation. 3) Filter housing design requirements shall be as stated for basket filters above.
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LIST OF MANDATORY SPARES (PIPING)
UNIT PROJECT
LOCATION
OWNER
EPCM
NOIDA, INDIA.
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REV.
19.11.2010
DATE
ISSUED FOR REVIEW

STATUS
MSTK
PREPARED BY
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REVIEWED BY
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APPROVED BY
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PM
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Sr. No.
Part Description
Quantity Required Pipes: 20-24 m (4 Random lengths) Fittings: 2 Nos (each) Pipes: 12 m (2 Random lengths) Fittings: 2 Nos (each) Pipes: 6 m (1 Random length) Nil 2 Nos. Nil 10% 2% 10% 100%
Remarks
1 Pipe and Fittings (1/2 to 1 )
Note 1, 2
2 Pipe and Fittings (2 to 8) 3 Pipe and Fittings (10 to 36) 4 5 6 7 8 9 10 Pipe and Fittings (Above 36) Valves & Flanges (1/2 to 8) Valves & Flanges (10 & Above) Bolts, Nuts & Gaskets Traps (Other than process Traps) Y-Strainers (For -1 size)
Expansion Bellows
Note 1, 2 Note 1, 2 Note 1, 2 Note 1, 2, 3 Note 1, 2, 3 Note 1, 2, 3 Note 1,4
Notes: 1. Percentage/Nos. of quantity required as mandatory spares is for each and every item/size/material consumed in as built; i.e. all items created in plant summary shall be individually considered to calculate spares requirements as per the criteria tabulated above. 2. No substitution in size, rating/schedule and material is allowed. Each type of Material as per PMS 3. Fractional part of quantity shall be converted into nearest upward whole part. 4. Requirement is only for Rubber bellows.
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VENDOR LIST (ELECTRICAL)
UNIT PROJECT
LOCATION
OWNER
EPCM
NOIDA, INDIA.
00
REV.
01.11.2010
DATE
ISSUED FOR REVIEW

STATUS
VV
PREPARED BY
DYS
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DYS
APPROVED BY
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VENDOR LIST (ELECTRICAL) 1) ISOLATORS / LOAD BREAK SWITCHES (HV INDOOR) a) b) c) d) e) f) g) AREVA T&D ASEA BROWN BOVERI LTD. BHARAT HEAVY ELECTRICALS LTD.(BHOPAL) CROMPTON GREAVES LTD. SIEMENS LTD. DRIESCHES PANICKKAR SWITCH GEAR LTD. (PDRP) S & S POWER SWITCH GEAR LTD. (PDRP) INDIA INDIA INDIA INDIA INDIA INDIA INDIA
2) SWITCHGEAR HT (INDOOR) WITH VCB a) b) c) d) e) AREVA T&D ASEA BROWN BOVERI LTD. BHARAT HEAVY ELECTRICALS LTD.(BHOPAL) SIEMENS LTD. CROMPTON GREAVES LTD. (PDRP) INDIA INDIA INDIA INDIA INDIA
3) SWITCHGEAR LT (MCC / PCC / PMCC-DRAWOUT MCC) a) b) c) d) e) f) g) AREVA T&D ASEA BROWN BOVERI LTD. LARSEN &TOUBRO LTD. CROMPTON GREAVES LTD. SIEMENS LTD. CONTROL & SWITCHGEAR LTD. (PDRP) GE POWER CONTROL INDIA LTD. (PDRP) INDIA INDIA INDIA INDIA INDIA INDIA INDIA
4) TRANSFORMERS-DISTRIBUTION (UPTO 5MVA) / LIGHTING TRANSFORMERS a) b) c) d) e) f) g) h) i) AREVA T&D BHARAT BIJLEE LTD. BHARAT HEAVY ELECTRICALS LTD. CROMPTON GREAVES LTD. EMCO LTD. KIRLOSKAR POWER EQUIPMENT LTD. VOLTAMP TRANSFORMERS LTD. SIEMENS LTD. INDO TECH TRANSFORMERS LTD. INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
5) DRY TYPE TRANSFORMERS (LIGHTING)-UPTO 1000 kVA a) b) c) d) e) f)

CLIENT UNIT PROJECT
BHARAT BIJLEE LTD. CROMPTON GREAVES LTD. VOLTAMP TRANSFORMERS LTD. KAPPA ELECTRICALS AUTOMATIC ELECTRIC CO BHEL (JHANSHI)
INDIA INDIA INDIA INDIA INDIA INDIA
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VENDOR LIST (ELECTRICAL) g) INTRA VIDYUT PVT LTD. h) TRANSTON ELECTRICALS PVT LTD. i) INDCOIL PRODUCTS
INDIA INDIA INDIA
6) INSTRUMENT TRANSFORMERS-CT & PT (HV) a) b) c) d) e) f) g) ABB LTD. ELECTRICAL CONTROL & SYSTEMS LTD. AREVA LTD. KAPPA ELECTRICALS PRAGATI ELECTRICALS PVT LTD PRAYOG INSTRANS INDIA INDIA INDIA INDIA INDIA INDIA INDIA
7) INSTRUMENT TRANSFORMERS-CT & PT (MV) a) b) c) d) e) f) g) h) i) j) k) L & T LTD SILKANNS PRECISSION ELECTRICALS KAPPA ELECTRICALS PRAGATI ELECTRICALS PVT LTD PRAYOG INSTRANS AE SIEMENS GILBERT & MAXWELL ELECTRICAL PVT LTD. NARAYANA POWER TECH PVT. LTD. INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
8) NEUTRAL GROUNDING RESISTORS- HV a) b) c) d) e) f) BHARTIA INDUSTRIES LTD NATIONAL SWITCHGEAR RISITECH ELECTRICALS PVT LTD. RSI SWITCHGEAR PVT LTD SR NARKHEEDE ENGINEERING PVT LTD. IRESCO ELECTRICALS PVT. LTD (PDRA) INDIA INDIA INDIA INDIA INDIA INDIA
9) i) CABLE-HIGH VOLTAGE (XLPE) a) b) c) d) e) f) g) h) i)

CLIENT UNIT PROJECT
INDUSTRIAL CABLES LTD. NICCO CORPORATION LTD. TORRENT CABLES LTD. UNIVERSAL CABLES LTD. RPG CABLES CABLE CORPORATION OF INDIA LTD. POLYCAB WIRES PVT. LTD. UNIFLEX CABLES LTD. KEI INDUSTRIES
INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
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VENDOR LIST (ELECTRICAL) 9) ii) HV CABLE ACCESSORIES( END TERMINATION & STRAIGHT THRU. JOINT) HEAT SHRINKABLE TYPE
a) b) c) d)
RAYCHEM 3M CORPORATION LIMITED (Previously known as Mahindra) REPL ENGG. LTD. YAMUNA GASES & CHEMICALS LTD.
INDIA INDIA INDIA INDIA
10) CABLE-CONTROL (PVC) a) b) c) d) e) f) g) h) i) j) k) l) m) n) CORDS CABLE INDUSTRIES LTD. DELTON CABLES LTD. HAVELLS INDIA PVT. LTD. INDUSTRIAL CABLES (I) LTD. KEI INDUSTRIES LTD. NICCO CORPORATION LTD. POLYCAB WIRES PVT. LTD RADIANT CABLES LTD. TORRENT CABLES LTD. UNIVERSAL CABLES LTD. CABLE CORPORATION OF INDIA GLOSTER CABLES LTD. CABLE CORPORATION OF INDIA LIMITED FINOLEX CABLES LTD. INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
11) CABLE-MEDIUM VOLTAGE (POWER- PVC) a) b) c) d) e) f) g) h) i) INDUSTRIAL CABLES (I) LTD. KEI INDUSTRIES LTD. NICCO CORPORATION LTD. POLYCAB WIRES PVT. LTD RADIANT CABLES LTD. TORRENT CABLES LTD. UNIVERSAL CABLES LTD. CABLE CORPORATION OF INDIA LIMITED FINOLEX CABLES LTD. INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
12) JELLY FILLED COMMUNICATION CABLES a) b) c) d) e) f) g) h) DELTON CABLES LTD. ELKAY TELELINKS LTD. KEI INDUSTRIES LTD. RELIANCE ENGINEERS LTD. RPG CABLES LTD. USHA BELTRON LTD. VINDHYA TELELINK LTD. FINOLEX CABLES LTD. INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
13) CABLES- FIRE ALARM AND COMMUNICATION

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a) b) c) d) e) f) g)
DELTON CABLES LTD. ELKAY TELELINKS LTD. KEI INDUSTRIES LTD. RELIANCE ENGINEERS LTD. CMI LTD. VINDHYA TELELINK LTD. CORDS CABLES INDUSTRIES LTD.
INDIA INDIA INDIA INDIA INDIA INDIA INDIA
14) OPTICAL FIRE CABLE a) b) c) d) BIRLA ERRICCON OPTICAL LTD. UNIFLEX CABLES LTD. RPG CABLES STERLITE TECHNOLOGIES LTD. INDIA INDIA INDIA INDIA
15) PLANT COMMUNICATION a) INDUSTRIONIC GMBH & CO. b) NEUMANN ELEKTRONIK GmbH c) SIEMENS AG 16) MOTOR (INDUCTION)- MV (INDL. TYPE SAFE AREA) a) b) c) d) e) f) g) AREVA T&D ASEA BROWN BOVERI LTD.(FARIDABAD) BHARAT BIJLEE LTD. BHARAT HEAVY ELECTRICALS LTD. (BHOPAL) KIRLOSKAR ELECTRIC CO. LTD. CROMPTON GREAVES SIEMENS LTD. INDIA INDIA INDIA INDIA INDIA INDIA INDIA GERMANY GERMANY GERMANY
17) MOTOR (INDUCTION)- MV (FLAMEPROOF) a) b) c) d) e) f) g) h) BHARAT BIJLEE LTD. BHARAT HEAVY ELECTRICALS LTD. (BHOPAL) CEMP INTERNATIONAL CROMPTON GREAVES KIRLOSKAR ELECTRIC CO. LTD. LOHER AREVA T&D ASEA BROWN BOVERI LTD. INDIA INDIA ITALY INDIA INDIA GERMANY INDIA INDIA
18) MOTOR (INDUCTION)- MV (ZONE 2 TYPE e & n) a) b) c) d)

CLIENT UNIT PROJECT
BHARAT BIJLEE LTD. CROMPTON GREAVES LTD. (BHOPAL) SIEMENS LTD. BHEL
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VENDOR LIST (ELECTRICAL) e) KIRLOSKAR ELECTRIC CO. LTD. f) ABB LTD. 19) MOTOR (INDUCTION)- HV (INDL. TYPE SAFE AREA)
INDIA INDIA
a) b) c) d) e) f) g) h) i)
ASEA BROWN BOVERI LTD. FUJI LTD. GEC ALSTHOM HITACHI LTD. LOHER LTD. MITSUBITSHI ELECTRIC CORPORATION BHARAT HEAVY ELECTRICALS LTD. CROMPTON GREAVES KIRLOSKAR ELECTRIC CO. LTD.
SWITZERLAND JAPAN UK JAPAN GERMANY JAPAN INDIA INDIA INDIA
20) MOTOR (INDUCTION)- HV (FLAMEPROOF) a) b) c) d) BHEL CROMPTON GREAVES KIRLOSKAR ELECTRIC CO. LTD. LOHER INDIA INDIA INDIA GERMANY
21) MOTOR (INDUCTION)- HV (ZONE 2 TYPE e & n) a) b) c) d) e) BHEL CROMPTON GREAVES KIRLOSKAR ELECTRIC CO. LTD. MERATHON ELECTRIC MOTOR LTD. LOHER INDIA INDIA INDIA INDIA GERMANY
22) BATTERY CHARGERS a) b) c) d) e) f) g) h) AUTOMATIC ELECTRIC LTD. CALDYNE GREAVES LTD. (BHOPAL) CHHABI ELECTRICALS PVT. LTD. HBL NIFE POWER SYSTEMS LTD. AMARA RAJA POWER SYSTEMS LTD. DUBAS ENGG. PVT LTD. MARS TECH CONTROL PVT LTD. HIND RECTIFIRES LTD. INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
23) UPS SYSTEM (LESS THAN 50 kVA ) a) b) c) d) e) f)

CLIENT UNIT PROJECT
EMERSON NETWORK POWER (INDIA) PVT. LTD. HI-REL ELECTRONICS PVT. LTD. (up to 50kVA) DB POWER ELECTRONICS PVT. LTD. (up to 60kVA) GUTOR ELECTRONIC LLC. CHLORIDE INDUSTRIES SYSTEM FUJI ELECTRIC CO. LTD
INDIA INDIA INDIA SWITZERLAND UK JAPAN
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24) UPS SYSTEM (50 kVA AND ABOVE)

a) b) c) d) e) f)
CHLORIDE POWER ELECTRONICS GUTOR ELECTRONIC LLC. EMERSON SAFT NIFE AB TOSHIBA CORP. FUJI ELECTRONIC CO. LTD
UK SWITZERLAND INDIA SWEDEN JAPAN JAPAN
25) FIRE ALARM SYSTEM a) b) c) d) e) f) g) h) i) TATA HONEYWELL LTD. VIJAY FIRE PROTECTION SYSTEM LTD. SIEMENS EDWARDS INTERNATIONAL NOTIFIER SIMPLEX HONEYWELL INC MATHER & PLATT INDIA LTD. NEW FIRE ENGINEERS PVT. LTD. INDIA INDIA GERMANY CANADA GERMANY INDIA USA INDIA INDIA
26) RELAY & CONTROL PANEL a) b) c) d) e) AREVA T&D ASEA BROWN BOVERI LTD. (BANGALORE) SIEMENS ENPRO ENGG EASUN REYREROLLE LTD. INDIA INDIA INDIA INDIA INDIA
27) CONTROL PANEL (FLP) a) b) c) d) e) f) BALIGA LIGHTING EQUIPMENTS PVT. LTD. FLAMEPROOF EQUIPMENTS PVT. LTD FLAMEPROOF CONTROL GEAR LTD. FLEXPRO ELECTRICALS PVT LTD. SUDHIR SWITCHGEAR PVT LTD FCG POWER INDUSTRIES LTD. INDIA INDIA INDIA INDIA INDIA INDIA
28) LIGHTING FITTINGS & ACCESSORIES (HAZARDOUS) INDIAN a) b) c) d) e) f) BALIGA LIGHTING EQUIPMENT PVT LTD FCG FLAMEPROOF CONTROL GEARS(P) LTD. FCG POWER INDUSTRIES PVT LTD FLAMEPROOF EQUIPMENTS PVT LTD. FLEXPRO ELECTRICALS (P) LTD. SUDHIR SWITCHGEARS PVT. LTD. INDIA INDIA INDIA INDIA INDIA INDIA
29) JUNCTION BOXES (FLAMEPROOF)

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a) b) c) d) e) f)
BALIGA LIGHTING EQUIPMENT PVT LTD FCG FLAMEPROOF CONTROL GEARS(P) LTD. FCG POWER INDUSTRIES PVT LTD FLAMEPROOF EQUIPMENTS PVT LTD. FLEXPRO ELECTRICALS (P) LTD. SUDHIR SWITCHGEARS PVT. LTD.
INDIA INDIA INDIA INDIA INDIA INDIA
30) CONTROL STATIONS (FLAMEPROOF) a) b) c) d) e) f) BALIGA LIGHTING EQUIPMENT PVT LTD FCG FLAMEPROOF CONTROL GEARS(P) LTD. FCG POWER INDUSTRIES PVT LTD FLAMEPROOF EQUIPMENTS PVT LTD. FLEXPRO ELECTRICALS (P) LTD. SUDHIR SWITCHGEARS PVT. LTD. INDIA INDIA INDIA INDIA INDIA INDIA
31) LIGHTNING ARRESTERS a) b) c) d) e) CROMPTON GREAVES LTD. ELPRO INTERNATIONAL LTD. OBLUM ELECTRICAL INDUSTRIES (P) LTD. W.S. INDUSTRIES (I) LTD. SIEMENS INDIA INDIA INDIA INDIA INDIA
32) SIGNAL INTERFACE FOR ECS (Interposing Relays) a) b) c) d) e) f) ABB (RXMSI) ALLEN BRADLEY (Type 700 HG with Magnetic Blowout) POTTER & BRUNFIELD (P&B) OEN (Series 51) ADEPT TECHNOLOGIES AREVA
UK UK UK INDIA INDIA
33) TRANSDUCERS a) b) c) d) ASEA BROWN BOVERI LTD. SOUTHERN TRANSDUCERS AUTOMATIC ELECTRIC ADEPT INDIA INDIA INDIA INDIA
34) SOLID LUBRICATED HDPE PIPE a) BHARAT DURALINE. b) RELIANCE INDIA INDIA
35) TRANSDUCER PANELS / INTERPOSING RELAY PANELS / DUMMY PANELS a) RITTAL GmbH & CO. KG
GERMANY
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00785
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36) A.C. (MV) VARIABLE SPEED DRIVE

a) b) c) d) e) f) g)
ASEA BROWN BOVERI LTD. LARSEN & TUBRO LTD. NELCO LTD. ROCKWELL AUTOMATION INDIA LTD. SIEMENS LTD. HITACHI LTD. BHEL, (BANGALORE)
INDIA INDIA INDIA INDIA INDIA JAPAN INDIA
37) EPABX SYSTEM a) b) c) d) e) f) ALCAD BPL SYSTEMS AND PROJECTS LTD. SIEMENS LTD. TATA TELECOM LTD. ALCATEL-LUCENT ENVOY TECHNOLOGIES SWEDEN INDIA INDIA INDIA INDIA INDIA
38) ALARM ANNUNCIATORS a) b) c) d) e) f) APLAB LTD. DIGICONT ELECTRONIC CORPORATION OF INDIA LTD. INDUSTRIAL INSTRUMENTS & CONTROLS INSTALARM CONTROL PRODUCTS PROCON INSTRUMENTATION (P) LTD. INDIA INDIA INDIA INDIA INDIA INDIA
39) HEATER CONTROL PANELS a) b) c) d) e) AREVA T&D CHEMTEC CHRONALOX LARSEN & TOUBRO LTD. SIEMENS LTD. INDIA SINGAPORE USA INDIA INDIA
40) ELECTRICAL HEATER a) ESCORTS LTD. b) KANTILAL CHUNILAL & SONS APPLICANCES LTD. c) KANTHAL 41) BUS DUCTS MV a) b) c) d)
CLIENT UNIT PROJECT
INDIA INDIA INDIA
LARSEN & TOUBRO LTD. SCHNEIDER ELECTRIC INDIA PVT. LTD. SIEMENS LTD. BRIGHT ENGINEERING LTD.,CHENNAI
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VENDOR LIST (ELECTRICAL) e) f) g) h)

CONTROLS & SWITCHGEAR CO. LTD. STARDRIVE BUS DUCTS PVT.LTD. UNITED ELECTRIC CO. (DELHI) PVT LTD GLOBE ELECTRICAL LTD.
42) CABLE TRAYS & DUCTS a) b) c) d) e) f) g) h) i) j) ANAND UDYOG GLOBE ELECTRICAL INDUSTRIES INDIANA CABLE TRAYS CORPN. METALEMMS BOMBAY PVT LTD. PATNY SYSTEMS (P) LTD. STEELITE ENGINEERING LTD. VATCO ELEC-POWER PVT LTD WEST COAST GRATINGS PVT.LTD. RUKMANI ELECTRICAL COMPONENTS PVT LTD VENUS STEEL PRODUCTS INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
43) GRATINGS a) b) c) d) e) INDIANA GRATINGS PVT LTD. NEHA INDUSTRIES WESTCOAST ENGINEERING GREATWELD GRATING KANADE ANAND UDYOG INDIA INDIA INDIA INDIA INDIA
44) SWITCH BOARDS : MV MCC / ASB / LDB FIXED TYPE a) b) c) d) e) f) g) GE POWER CONTROL INDIA (P) LTD. LARSEN & TOUBRO LTD. SCHNEIDER ELECTRIC INDIA PVT.LTD. SIEMENS LTD. L&T ABB LTD. AREVA LTD. INDIA INDIA INDIA INDIA INDIA INDIA INDIA
45) CAPACITORS HIGH VOLTAGE a) b) c) d) e) f) g) ABB LTD.(BANGALORE) BHARAT HEAVY ELECTRICALS LTD.,BHOPAL KAPSALES ELECTRICALS LTD. SHREEM CAPACITORS PVT LTD. UNIVERSAL CABLES LTD CROMPTON GREAVES LTD. SHAKTI CAPACITORS INDIA INDIA INDIA INDIA INDIA INDIA INDIA
46) BATTERIES NICKEL CADMIUM a) AMCO POWER SYSTEMS LTD.

INDIA
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VENDOR LIST (ELECTRICAL) b) HBL NIFE POWER SYSTEMS LTD. 47) TELEPHONE SET (FLAME PROOF)
INDIA
a) FHS GmbH b) BALIGA LIGHTING EQUIPMENT PVT LTD. c) FLEXPRO ELECTRICALS PVT. LTD. 48) AIR CIRCUIT BREAKER a) b) c) d) L&T SIEMENS LTD SCHNEIDER ELECTRIC INDIA PVT LTD GE INDIA
GERMANY INDIA INDIA
INDIA INDIA INDIA
49) CABLE GLANDS FOR HAZARDOUS AREA a) b) c) d) e) BALIGA LIGHTING EQUIPMENT LTD. FCG POWER IND PVT LTD FLEXPRO ELECTRICALS PVT LTD FLAMEPROOF EQUIPMENTS PVT LTD FCG FLAMEPROOF CONTROL GEARS PVT LTD INDIA INDIA INDIA INDIA INDIA
50) HIGH MAST LIGHTING SYSTEM a) BAJAJ ELECTRICALS LTD. b) PHILLIPS INDIA LTD. c) CROMPTON GREAVES LTD. 51) NUMERICAL RELAYS a) ABB LTD b) AREVA T&D LTD c) SIEMENS LTD 52) AUXILIARY RELAYS a) ABB LTD b) AREVA T&D LTD c) SIEMENS INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
53) ELECTRICAL CONTROL SYSTEM (ECS) (to hook up with existing System) i) UNIT AREA
a) HONEYWELL AUTOMATION INDIA LTD.( on nomination to hook up with existing ECS) ii) FOR TPS AREA
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a) b) c) d) e) f) g) h)
BHEL (MAX DNA) INVENRIS EMERSON PROCESS MAX DNA ROCKWELL SIEMENS ABB LTD. ABB AUTOMATION
INDIA ITALY USA USA GERMANY INDIA INDIA NETHERLANDS
54) CORROSION PROTECTION a) AMCHEM PRODUCTS PVT. LTD.,NOIDA b) POLYBRID COATING (EXCLUSIVE LICENSEE M/S UNIVEST CHEMICAL PVT LTD) c) VASU CHEMICALS,MUMBAI d) CIPY POLYURETHANE COATING,PUNE 55) PACKAGE SUBSTATION a) AREVA b) SIEMENS c) ABB INDIA INDIA INDIA INDIA USA INDIA INDIA INDIA
56) MCC & FEEDER PANEL (Construction Panel Power Supply Purpose Only) a) b) c) d) e) f) g) h) CONTROL & SCHEMATICS INDO ASIAN FUSE GEAR LTD. CONTROL & SWITCH GEAR BHARTIYA INDUSTRIES ELBE ZETA, GHAZIABAD STANDARD ELECTRICALS IMPACT ELECTRICAL CONTROL PVT LTD. B-25 Sector A1, Tronica City, Loni, Ghaziabad. INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
CLIENT UNIT PROJECT
: : :
PIPING
Page 1 of 6
VENDOR LIST - PIPING

VENDOR NAME COUNTRY
1.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
FITTINGS CS/AS/SS (FORGED & SEAMLESS PIPE)

EBY FASTNERS M.S.FITTINGS MFG CO.PVT.LTD TEEKAY TUBES PVT LTD RACCORTUBE GUJRAT INFRA PIPES LTD TUBE PRODUCTS INCORPORATE SCHULX EXPORT TROUVAY & CAUVIN GULF GUJRAT INFRA PIPES LTD TUBE PRODUCTS INCORPORATE TK CORPORATION ALLIED INTERNATIONAL FILMAG TUBACEX INDIA INDIA INDIA ITALY INDIA INDIA GERMANY DUBAI INDIA INDIA KOREA ITALY ITALY SPAIN
2.
1 2 3 4 5 6 7 8 9 11 11 12 13 14
FLANGE CS / AS / SS (FORGED)
CD ENGINEERING CO CD INDUSTRIES (GHAZIABAD) CHAUDHRY HAMMER WORKS LTD. ECHJAY INDUSTRIES LTD. GOLDEN IRON & STEEL WORKS JAV FORGINGS (P) LTD. M.S. FITTINGS MFG. CO. PVT. LTD. THE PUNJAB STEEL WORKS METAL FORGINGS PVT. LTD. PHOCENEE OFFICINE LUIGI GALPERTI SPECIAL FLANGES HYUNDAI FORGING INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA FRANCE ITALY ITALY ITALY KOREA
3.
1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
PIPES (AS-SEAMLESS, CS-SEAMLESS, SS-SEAMLESS +WELDED)

INDIAN SEAMLESS TUBES LTD (AHAMADNAGAR/BARAMATI) JINDAL SAW LTD (NASIK WORKS) MAHALAXMI SEAMLESS LTD RAJENDRA MECHANICAL INDUSTRIES LTD HEAVY METAL & TUBES LTD.(MEHASANA) MAHARASHTRA SEAMLESS LTD RATNAMANI METALS & TUBES LTD. DALMINE SPA (ENQUIRIES TO TENARIS) J FE SUMITOMO V&M ESCO INOXTECH SPA PETROTUB SA SOSTA SEAMLESS SANDVIK TROUVAY & CAUVIN GULF TUBACEX TUBOS VAN LEEUWEN BUIZEN INDIA INDIA INDIA INDIA INDIA INDIA INDIA UAE JAPAN JAPAN FRANCE JAPAN ITALY ROMANIA NETHERLAND INDIA DUBAI FRANCE
page 2 of 6 Pages

VENDOR NAME COUNTRY
4.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
PIPE (IS3589 / ASTM-671/672)

ADVANCE STEEL TUBE LTD. ASIAN MILLS PVT. LTD. INDUS TUBE LTD. JINDAL PIPES LTD. JINDAL SAW LTD. (KOSI) LALIT PROFILES & STEEL INDUSTRIES LTD. LLOYD METALS ENGINEERS LTD. MAHARASHTRA SEAMLESS LTD. MAN INDUSTRIES (I) LTD. MUKAT PIPES LTD. MUKAT TANKS & VESSELS LTD. PRATIBHA PIPES & STRUCTURAL PVT. LTD. PSL INTERNATIONAL LTD. (CHENNAI) RATNAMANI METALS & TUBES LTD. SAW PIPES LTD. SURINDRA ENGINEERING CO. LTD. (MUMBAI) STEEL AUTHORITY OF INDIA LTD. SURYA ROSHNI LTD. SWASTIK PIPES LTD. THE TATA IRON & STEEL CO. LTD. WELSPUN GUJARAT STAHL ROHREN LTD. INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
5.
1 2 3 4 5 6 7 8 9 10 11 12
PIPE (IS1239)
ADVANCE STEEL TUBE LTD. BMW INDUSTRIES LTD. GOODLUCK STEEL TUBES LTD. INDUS TUBE LTD. JINDAL PIPES LTD. LLOYD METALS ENGINEERS LTD. NORTH EASTERN TUBES LTD. SURYA ROSHNI LTD. SWASTIK PIPES LTD. SRI SARBATHI STEEL TUBES PVT.LTD. MAHARASHTRA SEAMLESS LTD. THE TATA IRON & STEEL CO. LTD. INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
6.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
FASTENERS
AEP COMPANY INDUSTRIAL ENGG CORPORATION FIX FIT FASTENERS FASTENER & ALLIED PRODUCTS PVT. LTD. HARDWIN FASTENERS PVT. LTD. J.J. INDUSTRIES MULTI FASTENERS PVT. LTD. NEXO INDUSTRIES PACIFIC FORGING & FASTENERS (ENQ. TO PTD) PIONEER NUTS & BOLTS PVT. LTD. PRECISION AUTO ENGINEERS PRECISION ENGINEERING INDUSTRIES PRESIDENT ENGINEERING WORKS SANDEEP ENGINEERING WORKS SYNDICATE ENGINEERING INDUSTRIES INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
page 3 of 6 Pages

VENDOR NAME COUNTRY
7.
1 2 3 4 5 6 7 8
GASKET - CAF / METTALIC & SOFT IRON / METAL JACKETTED / SPIRAL WOUND
CHAMPION JOINTINGS LTD. IGP ENGINEERS LTD. JAYEM INDUSTRIES MADRAS INDUSTRIAL PRODUCTS MICRO PRECISION PRODUCTS PVT. LTD. STARFLEX SEALING INDIA PVT. LTD. UNIQUE INDUSTRIAL PACKINGS VIRCAP SEALINGTECH PVT. LTD. INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
8.
1 2 3 4 5 6 7 8 9 10
HOSE METALLIC FLEXIBLE SS & RUBBER

AEROFLEX INDUSTRIES PVT. LTD. BENGAL INDUSTRIES PVT. LTD. GAYTRI INDUSTRIAL CORPORATION INSAP ENGINEERS PVT.LTD. PRESIDENCY RUBBER MILLS PVT. LTD. ROYAL INDIA CORPORATION (NASIK WORKS) SENIOR INDIA PVT. LTD. SONI RUBBER PRODUCTS LTD. SRIDHAR RUBBER PRODUCTS PVT. LTD. UNIQUE RUBBER WORKS INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
9.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
HOSE PIPE (STEAM / GAS / AIR / WATER / CHEMICAL)

ASHIT SALES CORPORATION BHARAT RUBBER UDYOG COSMOPOLITE (THE) CROWN RUBBER INDUSTRIES (P) LTD. GAYTRI INDUSTRIAL CORPORATION JYOTI RUBBER UDYOG (I) PVT.LTD. MARKWEL HOSE INDUSTRIES PVT. LTD. PRESIDENCY RUBBER MILLS PVT. LTD. ROYAL INDIA CORPORATION (NASHIK WORKS) SIMPLEX RUBBER PRODUCTS PVT. LTD. SONI RUBBER PRODUCTS LTD. SRIDHAR RUBBER PRODUCTS PVT. LTD. TAURIAN TUBES UNIQUE RUBBER WORKS INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
10.
1 2 3 4 5 6 7
STRAINERS (FAB / CAST / FORGED)

BOMBAY CHEMICAL EQUIPMENTS FILTRATION ENGINEERS (I) PVT. LTD. GRAND PRIX FAB (P) LTD. GUJARAT OTOFILT MULTITEX FILTRATION ENGINEERS (P) LTD. SPIRAX MARSHALL PVT. LTD. VARALL ENGINEERS INDIA INDIA INDIA INDIA INDIA INDIA INDIA
page 4 of 6 Pages

VENDOR NAME COUNTRY
11.
1 2 3 4
STEAM TRAPS BUCKET / TH. DYN. / TH. STAT / FLOAT

ESCO ( DIV. OF JM STEAMCON P.LTD.) PENNANT ENGINEERING PVT.LTD. SPIRAX MARSHALL PVT. LTD. VARALL ENGINEERS INDIA INDIA INDIA INDIA
12.
1 2 3
EXPANSION JOINTS - RUBBER

CORI ENGINEERS PVT. LTD. MADRAS INDUSTRIES LININGS LTD. THE RUBBER PRODUCTS LTD. INDIA INDIA INDIA
13.
1 2 3 4
SPRING SUPPORTS
PIPE SUPPORT (INDIA) PVT. LTD. PIPING & ENERGY PRODUCTS (P) LTD. SARATHI ENGINEERING ENTERPRISES PVT.LTD. SPRING SUPPORTS MFG. CO. INDIA INDIA INDIA INDIA
14.
1 2 3 4 5 6 7 8 9 10 11
VALVE GATE /GLOBE/CHECK (FORGED CAST)

ASSOCIATED TOOLINGS INDIA PVT. LTD. BDK ENGINEERING INDUSTRIES LTD. KSB PUMPS LTD. (COIMBATORE) LARSEN & TOUBRO LTD. LEADER VALVES LTD. NITON VALVE INDUSTRIES LTD.(AURANGABAD) STEEL STRONG VALVES INDIA PVT. LTD. NECO SCHUBERT & SALZER LTD. SAKHI ENGINEERS PVT LTD OSWAL INDUSTRIES LTD. SHALIMAR VALVES PVT. LTD. INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
15.
1 2 3 4 5 6
VALVE BALL
AQUA VALVES PVT. LTD. MICRO FINISH VALVES LTD FLOW CHEM INDUSTRIES LARSEN & TOUBRO LTD. LEADER VALVES LTD. VIRGO ENGINEERS LTD. INDIA INDIA INDIA INDIA INDIA INDIA
16.
1 2 3 4 5 6 7 8 9
VALVE BUTTERFLY
ADVANCE VALVES PVT. LTD. BDK PROCESS CONTROLS PVT. LTD. CRANE PROCESS FLOW TECHNOLOGIES (INDIA) LTD. FOURESS ENGINEERING (I) LTD. (BANGALORE) INSTRUMENTATION LTD.(PALGHAT) INTERVALVE (I) LTD. LARSEN & TOUBRO LTD. LEADER VALVES LTD. TYCO VALVES & CONTROLS INDIA PVT. LTD. INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA INDIA
page 5 of 6 Pages

VENDOR NAME COUNTRY
INDIA INDIA INDIA
17.
1 2 3
VALVE PLUG 4-WAY (NON FIRE SAFE) CSS

FISHER XOMOX SANMAR LTD. CHEMTROLS SAMIL LARSEN & TOUBRO LTD (AUDCO)
18.
1 2 3 4 5 6
VALVE NEEDLE
EXCELSIOR ENGINEERING WORKS LEADER VALVES LTD. SWASTIK ENGINEERING WORKS TECHNOMATIC (I) PVT. LTD. TMT ENGINEERING INDUSTRIES LTD. VARALL ENGINEERS INDIA INDIA INDIA INDIA INDIA INDIA
page 6 of 6 Pages
ADDITION/DELETION/MODIFICATION OF INSTRUMENTATION SCOPE Document Reference S.N. 1 Clause No. 5.1.4-d)
5.2
3 4
5.4.5 5.5.3-
5 6 Job Specification for instrumentation item for Main Air Blower (00785019-JSS-1514-01) 7 8 9 10 11
5.6.3-a) 5.7.3 7.2 7.3 10.2.3 10.2.4 10.3.1.1
12
10.3.2.1
13
10.3.2.3
14 15 16
10.3.3.1 10.3.9 10.4
Temp transmitters shall have accuracy of 0.075% or better of span and the stability shall be better than +/ - 0.25% of upper range limit for 1 year. Addition: For super critical application like the oil drain SOV of MAB failure of which can bring down the entire plant , TMR SOVs shall be used, the same is to be considered for other supercritical application also. Addition: Process connections with spacer rings and drain facility. Addition: d) All PGs shall come with colours marking of 0-30%-Yellow, 31 to 70% green and 71 to 100% Red on dial e) For pump suction and discharge lines, remote seal PG with capillary shall be considered, with installation on a stand. Delete the word - thin Ball valves to be used for shutdown (on/off) applications. Hooter shall be electronic. Annunciator windows shall be LED clusters Addition: Speed lowering and raising facility shall also be on LCP Addition: The 2oo3 over-speed shutdown system. Addition: Only one set of vibration probe (2 nos) shall be connected to one monitor card. Delete: Two probes at 90 degrees apart for each location shall be provided and connected to same dual channel monitor for vibration monitoring. Addition: five independent probes shall be installed for speed. Speed monitoring system shall be Bently Navada 3500 series, equivalent not acceptable. The temperature monitors shall be located in Local control room.. LCR to Main control room is approximately 350 meters. Para 1 Addition: The same shall have independent process sensing mechanism. Para 3, line 4 Addition: The field located
17
10.4
Job Specification for programmable logic controller for package unit (00785-019-JSS1511-02)
18 19
2.9 2.9.2
20 21 22 23 24 25
2.9.4 2.10 13.5 13.6 13.13 14.1
26 27
14.12 14.16
28 29 30
14.17 14.1.1 14.1.2.1
31 32 33 34
14.1.2.2 .3 14.1.2.2 .4 16.3 16.5
35
16.5.1
36
16.5.1.1
37 38 39
16.5.1.1 16.5.1.2 16.5.1.3
emergency switches shall also be with protective cover. The dual redundant link shall be MODBUS Addition: In case of 2oo3 logic inputs, only one input per card shall be considered, hence cards and spares count can be more than 20%. Addition: no power supply shall be loaded beyond 50% in worst case. Addition: commissioned until redundant communication is established. Addition: and shall be installed with single channel diode ORings. Field transmitters shall be powered through IS barriers. Loading of Individual Power supply shall not exceed 50% in worst case. Addition: I/O cards shall be hot standby with automatic changeover in case of failure. Addition: System shall have redundancy at all levels. Addition: provided for modification without bringing down the connected equipment.. Addition: integral SOE shall have a recording of the order of scan time of PLC. PLC shall be TMR configuration. Delete: all other details. Only one ES is required for PLC, operator station not required. PLC shall be interfaced with DCS, required operation shall be through DCS only. PLC shall be of TMR configuration, hence all the processor shall be online. Failure of all three CPU/ Processors shall cause system outputs Delete: second Para Addition: the loading of processors shall not exceed 60% in worst case inclusive of all the installed spare channels. All I/O modules shall be redundant, hot standby with auto change-over in case of failure. Powering: the power to field instruments connected with DCS shall be through IS barriers. Addition: all analog inputs shall be wired through IS barriers. Addition: all analog outputs shall be wired through IS barriers. Addition: all DIs shall be isolated from field
40 41 42 43
16.5.1.4 16.5.1.3 -b) 16.5.1.3 -c) 20.1
by relays. Addition: all DOs shall be isolated from field by relays. Addition: SOE Addition: .to implement all functioning listed in 16.5.1.3-b) Addition: Engineering training shall also be included. Delete: operation training shall be at site. FAT and SAT shall be as per mutually agreed procedure, submitted by bidder and approved by owner. Mandatory spares for instrumentation Addition: a) HART communicator one no for smart transmitters. b) Portable calibrator, Yokogawa make model-CA71 Post warranty Comprehensive AMC for 5 years to be included.
44
22.2
45
Other Items
46
CAMC
INSTRUMENTATION AND ANNUNCIATORS DATA SHEETS FOR COMPRESSOR, AUXILIARIES AND DRIVER TURBINE FOR MAIN AIR BLOWER (Annexure -1 to Doc No. 00785-019-JSS-1514-01) (Also refer Process P & ID No. Job Spec, Equipment & Oil System Data Sheets for additional Details) (For Unit Start/Stop, Monitoring, Protection Etc.) LOCATION OF INDICATORS, SWITCHES AND PUSH BUTTONS S.
No. DESCRIPTION
LOCAL GENERAL A.C.Power On, DC Power ON UPS Power On Control Power ON/OFF Switch Control Indicators lamp Test Push Button Trip Reset Push Button Alarm Unit-Accept, Reset and Lamp Test Push Buttons Selector switch for Auto/Off/Manual Selection of each motor of: a.) Lube Oil Pumps
LOCAL GAUGE BOARD
LOCAL CONTROL PANEL / Panel in LCR
MAIN CONTROL ROOM /DCS
1.A.
1. 2. 3. 4. 5. 6. 7.
V V V V V V
LOCATION OF INDICATORS, SWITCHES AND PUSH BUTTONS S. NO. DESCRIPTION LOCAL LOCAL GAUGE BOARD LOCAL CONTROL PANEL / Panel in LCR MAIN CONTROL ROOM /DCS
b.) 8. 9. 1.B
1.
Condensate Extraction Pumps V (HIC) V HIC)
P
VP (HIC) V (HIC)
Compressor Anti surge control, (HIC) with position -indicator (Hand initiated controller) Woodward Speed Controller CONTROL INDICATORS (LAMPS) Main Driver Turbine RUN/STOP Lube oil Pumps RUN/STOP Lube Oil Standby Pump cutting in (With Alarm at DCS) Condensate Transfer Pumps RUN/STOP Condensate Standby Pump cutting in (With Alarm at DCS) Barring Device Engaged Emergency Lube oil Pump RUN/STOP
V V V V V V V
P P P P P P P
2. 3 4. 5. 6. 7
LOCATION OF INDICATORS, SWITCHES AND PUSH BUTTONS S. DESCRIPTION No. LOCAL LOCAL GAUGE BOARD LOCAL CONTROL PANEL / Panel in LCR MAIN CONTROL ROOM /DCS
I.C. 1.
SWITCHES/PUSH BUTTONS Lube Oil Pumps (Start/Stop) (Push Button) (both for Motor & Turbine) Condensate Pumps (Start/Stop) (Push Button) (both for Motor & Turbine) Main Turbine Start Push Button Main Turbine (Stop Button) Main turbine trip and throttle Valve (ESV open/close) PB Emergency Lube oil Pump START/STOP Blower emergency shutdown EQUIPMENT & PROCESS INSTRUMENTATION V V Manual Trip lever V V V V V V P
2. 3. 4. 5. 6. 7.
II.
S. NO . A. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
LOCATION OF INDICATORS, SWITCHES AND PUSH BUTTONS DESCRIPTION LOCAL Pressure Indicators Compressor Suction (each stage) Compressor Discharge (each stage) Main Turbine Steam Inlet Main Turbine Steam Exhaust Turbine Steam Chest Surface Condenser Pressure Balance Chambers of Compressor Main Turbine Sealing Steam each Seal inlet Sealing Steam Common Outlet Cooling water supply line to surface condenser Steam Supply to each Ejector Inter & After condenser outlet Each Condensate Pump discharge V V V V V V V V VP VP V V V V V V V V P P P P P LOCAL GAUGE BOARD CONTROL PANEL / Panel in LCR MAIN CONTROL ROOM /DCS
LOCATION OF INDICATORS, SWITCHES AND PUSH BUTTONS S. DESCRIPTION No. LOCAL V V V V P LOCAL GAUGE BOARD LOCAL CONTROL PANEL / Panel in LCR MAIN CONTROL ROOM /DCS 14. 15. 16.
14. 15. 16. B. 1. 2. 3. 4. 5. 6. 7.
Auxiliary turbine Steam inlet/exhaust Gland condenser outlet Steam Condensate Return Temperature Indicators Compressor Suction (each stage) Compressor Discharge (each stage) Main driver turbine steam inlet Main driver turbine steam exhaust Surface Condenser Surface Condenser Cooling water return each pass Inter and After condensers each CW return
VP VP V V V V V
V V V V V
P P P P P
.
LOCATION OF INDICATORS, SWITCHES AND PUSH BUTTONS S. DESCRIPTION NO. LOCAL GAUGE BOARD LOCAL CONTROL PANEL / Panel in LCR MAIN CONTROL ROOM /DCS
LOCAL V V V V
8. 9. 10. 11. C. 1. 2. D. 1. 2. E.
Condensate Temp. at condensate pumps inlet Gland steam condenser inlet Auxiliary turbine Steam inlet/exhaust Steam Condensate Return Differential Pressure Indicators/Controllers/Transmitters Differential pressure across inlet filter Compressor balance line Level Indicators / Controllers Surface Condenser Hot well level transmitter and controller Surface Condenser Hot well Level Indicator Flow Indicators & Transmitters
VP V
V (transmitter & Indicator) V
LOCATION OF INDICATORS, SWITCHES AND PUSH BUTTONS S. DESCRIPTION NO. LOCAL VP(Flow element & Transmitter) VP Flow element & Transmitter) VP Flow element & Transmitter) V LOCAL GAUGE BOARD LOCAL CONTROL PANEL / Panel in LCR V V V V MAIN CONTROL ROOM /DCS
1. 2. 3. 4. E. 1. 2. 3. 4. 5. 6.
Compressor suction Compressor discharge blow off Main turbine steam inlet Common condensate Return line Miscellaneous Compressor Speed Indicator All auxiliary drive motors ammeter Annunciator System Solenoid operated inlet ON/OFF valves for Auxiliary Turbines Relief valves on all ,aux. Turbine exhaust lines. Steam Traps
P P (Flow recorder also) P P
V V
P(Speed recorder also) H
V V V V
LOCATION OF INDICATORS, SWITCHES AND PUSH BUTTONS S. DESCRIPTION No, LOCAL LOCAL GAUGE BOARD LOCAL CONTROL PANEL / Panel in LCR MAIN CONTROL ROOM /DCS
7. 8. C. 1. 2. 3. 4. 5.
Pressure/Thermal relief valve on all cooling water return lines of cooler and condensers and safety valve for Surface Condenser Level Control Valve for Surface Condenser Monitors(For Compressor & main Turbine Driver) Vibration Axial Position Thrust bearing metal temp. (Each bearing) Journal bearing metal temp. (each bearing) Key phasor Probe and Proximitor
V V
V V V . V V
P P P P
LOCATION OF INDICATORS, SWITCHES AND PUSH BUTTONS
S. No
DESCRIPTION
LOCAL
LOCALGAUGE BOARD
LOCALCONTROL PANEL / Panel in LCR
MAINCONTROL ROOM /DCS
III
OIL SYSTEM. COOLING WATER AND CONDENSATE SYSTEM INSTRUMENTATION (REFER API 614, OIL SYSTEM DATA SHEET, JOB SPECS & P&IDS ATTACHED FOR ADDITIONAL DETAILS)
A.
Pressure Indicators Main Lube Oil pump suction/ discharge Standby Lube Oil pump suction/discharge Lube Oil header (each level) (Independent pressure gauge for lube oil to compressor and turbine bearings respectively) Governor oil header (each level) Emergency Lube oil Pump discharge Accumulator precharge gas pressure Pressure indicators in each Lube oil supply line from header Condensate pump suction & discharge Cooling water supply/return (Condenser, Gland Condenser, L/O cooler) V V V V V V V V V V V V V P P
1. 2. 3. 4, 5. 6. 7 8. 9.
S. No
LOCATION OF INDICATORS, SWITCHES AND PUSH BUTTONS
DESCRIPTION
LOCAL
LOCALGAUGE BOARD
LOCALCONTROL PANEL / Panel in LCR
MAINCONTROL ROOM /DCS
B. 1. 2. C. 1. 2. 3. 4. 5. 6. 7. 8
Differential Pressure Indicators/ Controllers Lube oil Filter (DP Indication) Lube oil Cooler Temperature Indicators & controller Lube oil (Cooler Inlet) Lube oil (Cooler Outlet) Lube oil after TIC Lube oil Temp. Indicator & Controller Cooling water outlet of each oil cooler & Condensers Lube oil reservoir Journal bearing outlet each bearing (OIL) Thrust bearing outlet each bearing (OIL)
V V
V V V V V V V V P P V P
10
ALARMS S. NO. DESCRIPTION A.V. Annunciation in LCP / Panel in LCR A.V. Annunciation in MCR
TRIPS AN. Annunciation in LCP/ Panel in LCR A.V. Annunciation in MCR
Live Steam to ejector
D. 1. 2. 3. E. 1 2. 3. 4. 5.
Level Indicators: Lube Oil Reservoir Lube Oil rundown tank Condenser Hot well (Split Range) Sight Flow Indicators Thrust bearing drains (each drain) Journal bearing drains (each bearing) Emergency lube oil rundown tank outlet Reservoir (lube oil) purge flow indicators. Lube Oil circulation lines between filters, coolers to tank
V V V
V V V
P P P
V V V V V
11
ALARMS S. NO. DESCRIPTION A.V. Annunciation in LCP/ Panel in LCR A.V. Annunciation in MCR
IV A. 1. 2. 3. 4. 5. 6 7. 8. 9.
ALARM AND TRIP SWITCHES (EQUIPMENT & PROCESS) ALARMS Compressor speed high High turbine exhaust pressure High radial shaft vibration compressor and turbine (for each bearing) High axial displacement compressor as well as turbine (for each bearing) High journal bearings metal temp. (compressor and turbine) (for each RTD) High thrust bearings metal temp. (compressor and turbine) (for each RTD) Compressor suction pressure low (each stage) Compressor discharge temp. high (each stage) Hotwell Condensate Level High (Standby Pump Start) V V V V V P P P P P P P P P
12
ALARMS S. No. DESCRIPTION A.V. Annunciation in LCP A.V. Annunciation in MCR P P P P P P P V

V
.
TRIPS AN. Annunciation in LCP/ Panel in LCR A.V, Annunciation in MCR
10. 11 12. 13. 14. I5. 16 17. 18
Hotwell Condensate Level Low (Standby Pump Stop) Standby Condensate Pump (Running) Condensate Pump Disch. Pressure Low (Standby Pump Start) Gland steam leak pressure high Reverse Rotation Unit shutdown All permissive start switches (connected starting interlock) Common prealarm of all the machine alarms Common prealarm of all the process alarms
13
ALARMS S. NO. DESCRIPTION AV. Annunciation in LCP AN. Annunciation in MCR
B.
TRIP Compressor and turbine radial shaft vibration high high Compressor and turbine axial displacement high high Over speed trip of compressor/turbine Compressor and turbine journal/Thrust bearing metal temperature high high Turbine exhaust pressure High High Compressor disch. temp. high high Common alarm for all machine trips Compressor Suction Pressure low low ALARM AND TRIP SWITCHES (LUBE OIL & CONDENSATE SYSTEM) Alarm V V V V V V V V P P P P P P P P
1. 2. 3. 4. 5. 6. 7. 8.
V.
A.
14
ALARMS S. No. DESCRIPTION A.V Annunciation in LCP A.V. Annunciation in MCR
1.
2. 3. 4. 5 6. 7. 8 9. 10. 11. 12.
Low lube oil reservoir level

Standby Lube oil pumps (Running) Standby lube oil pump start Lube oil rundown tank level Low (standby lube oil pump starts) Lube Oil run down tank level High Compressor permissive start) Low lube oil header pressure (each level) (Standby lube oil pump starts) Low lube oil pressure (compressor permissive start.) Low Control/Governer oil header pressure. High lube oil filter Diff. Pressure High lube oil cooler outlet temp. Condensate pump start/stop Hotwell condenser level high/high
V
V V V V V V V V V V V
P
P P P P P P P P P P V P .
15
S. NO.
13.
ALARMS DESCRIPTION A.V Annunciation in LCP

V
TRIPS
AN. Annunciation in LCP/ Panel in LCR
A.V. Annunciation in MCR
A.V. Annunciation in MCR
Common prealarm for all alarms High outlet oil temp. (Each thrust bearing Compressor and Turbine) Common Trip alarm for all Trips Trip (2 Out of 3 Voting Logic)
14.
15.
P V P
B.
1.
Low low- lube oil header pressure Low low-Control/Governer oil pressure Electrical overspeed trip circuits
V V V
P P P
2. 3.
Legends: A.V : Audio visual LCP : Local control Panel MCR : Main control room LCR : Local control room
V - Vendors supply & Mount

VP- Vendors loose supply & Purchasers amount H - Vendors supply and Purchasers remote amount.
16
M - Mount by vendor of Purchasers item. -C- Cut out for Purchasers item by vendor. S - Switches Vendors supply and Purchasers local mount. Vendor to provide A.V. annunciation in LCP for alarms and trips. P - Signal/contacts to be provided by vendor for interface at Purchasers MCR (DCS). NOTES: 1. For area classification, switch type, enclosure etc., refer to Electrical and Instrumentation Specs. 2. Electrical/Pneumatic instruments shall be connected to common junction box for those instruments mounted on the console. 3. Following shall be Included in vendors scope of supply; a) Electrical connection between local panel and compressor, and between the consoles (Lube Oil) and panel. b) Local panel alarm annunciation. c) Alarm to precede trips and trips with simultaneous alarm. d) Annunciation system with test/acknowledgement push button & first off sequence. e) Instrument, indications, control valves, relief valves, alarm and trip switches for buffer gas system shall be in the scope of vendor and shall be added to the above listing by vendor during detailing and the same shall be subject to approval of the IOCL. 4. Vendor shall submit the fully generated P&IDs (for lube oil, Steam and condensate systems) complete with all instruments, interlocks, annunciations for approval and acceptance by IOCL. 5. For other Instrumentation requirements also refer Instrumentation specs enclosed ..
6. The local control room shall be very near to the compressor on Mezzanine floor. Vendor to check & confirm for the operational point of view which items shall be on the local panel near to compressor and which items are required on panel in Local control room.
17

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REVAMP OF FCCU & PRU, MATHURA PROJECT

NIT No: LSN/00785/019/MR/1040/01/1005

NIT FOR MAIN AIR BLOWER

Tag Nos 019-K-101,019-KT-101, 1011-01/000015,101101/000017,1011-01/000021,1011-01/000030,101101/000031,1011-01/000032,1011-01/000034,101101/000036,1011-01/000041,1011-01/000051,101101/000061,1011-01/000071 FOR INDIAN OIL CORPORATION LTD.

REVAMP OF FCCU & PRU, MATHURA PROJECT

AMENDMENT-1 TO NOTICE INVITING TENDER (International Competitive Bidding)

Prepared and issued by:

REVAMP OF FCCU & PRU, MATHURA PROJECT

AMENDMENT-1 TO NIT NO. LSN/0785/019/MR/1040/01/1005 FOR MAIN AIR BLOWER

AADENDUM-1 TO MATERIAL REQUISITION FOR MAIN AIR BLOWER

INDIAN OIL CORPORATION LIMITED.

ADDENDUM-1 TO MATERIAL REQUISION FOR MAIN AIR BLOWER (19-K-101)

ISSUED FOR ENQUIRY

ADDENDUM-1 TO MATERIAL REQUISITION FOR MAIN AIR BLOWER

ADDENDUM-1 TO REQUISITION FOR ENQUIRY

CLIENT UNIT PROJECT

DESIGN BASIS FOR STATIC EQUIPMENT

INDIAN OIL CORPORATION LIMITED.

ENGINEERING DESIGN BASIS FOR STATIC EQUIPMENT

ISSUED FOR IMPLEMENTATION ISSUED FOR APPROVAL

DESIGN BASIS FOR STATIC EQUIPMENT

SECTION A (Columns, Vessels, Tanks & Heat Exchangers)

CLIENT UNIT PROJECT

DESIGN BASIS FOR STATIC EQUIPMENT

SECTION B (Trays & Tower Internals)

CLIENT UNIT PROJECT

DESIGN BASIS FOR STATIC EQUIPMENT

SECTION C (Mechanical Equipment)

CLIENT UNIT PROJECT

CLIENT UNIT PROJECT

DESIGN BASIS FOR STATIC EQUIPMENT

CLIENT UNIT PROJECT

CLIENT UNIT PROJECT

DESIGN BASIS FOR STATIC EQUIPMENT

CLIENT UNIT PROJECT

CLIENT UNIT PROJECT

CLIENT UNIT PROJECT

CLIENT UNIT PROJECT

DESIGN BASIS FOR STATIC EQUIPMENT Vibration is not expected.

2.9.2 Skirt Thickness

CLIENT UNIT PROJECT

CLIENT UNIT PROJECT

Fan clevis bolts shall be as follows:

CLIENT UNIT PROJECT

DESIGN BASIS FOR STATIC EQUIPMENT o o

Fan bearing set (top + bottom = 1 set ) shall be as follows: o o o

Motor bearings (DE+NDE =1 set) shall be as follows: o o o

VFD 100% or 1 no. whichever is minimum.

CLIENT UNIT PROJECT

CLIENT UNIT PROJECT

DESIGN BASIS FOR STATIC EQUIPMENT

CLIENT UNIT PROJECT

2.15.3 AIR COOLERS

DESIGN BASIS FOR STATIC EQUIPMENT

2.17 ANCHOR BOLTS

CLIENT UNIT PROJECT

CLIENT UNIT PROJECT

CLIENT UNIT PROJECT

DESIGN BASIS FOR STATIC EQUIPMENT

CLIENT UNIT PROJECT

CLIENT UNIT PROJECT

CLIENT UNIT PROJECT

CLIENT UNIT PROJECT