HINDUSTAN PETROLEUM CORPORATION LIMITED -...

�� HINDUSTAN PETROLEUM CORPORATION LIMITED

TALEGAON DEPOT PROJECT

TECHNICAL SPECIFICATION FOR EFFLUENT TREATMENT PLANT

CONTENTS

Chapter. No. DESCRIPTION

Contents

01. General Instructions to Bidder

02. Scope of Work

03. Technical Specification

04. Site data

05. Inspection

06. Supply and Erection

07. Site testing and painting

08. Commissioning and Performance Guarantee

09. Documents to be furnished

10. Questionnaire

11. List of Tender drawings




01. GENERAL INSTRUCTIONS TO BIDDERS 01.01 The intent of this specification is to entrust the complete work of the effluent

treatment plant as mentioned under “Scope of Work” for execution on a turnkey basis.

01.02 This specification forms a part of the tender documents and shall be read in

conjunction with the same. 01.03 The scope of work covers civil, mechanical, structural, electrical and instrumentation

works. 01.04 The work shall be executed as per the specification. The Bidder shall, however,

include all such items of work whether specifically mentioned or not, which are essential to make the system complete in all respects and for satisfactory working of the proposed scheme.

01.05 The Bidder shall give the lumpsum price as per Price bid of this specification. 01.06 The Bidder shall arrange to transport, unload and store all equipment to be supplied

by him till handing over. 01.07 The Bidder shall remain responsible for the safe custody of all equipment/material till

these are erected, tested, commissioned and handed over to the Purchaser. 01.08 All equipment/materials shall be designed, manufactured, erected and tested in

accordance with the latest Indian Standards, Petroleum rules-2002 or to generally accepted Codes of Practices. They shall also comply with the statutory requirement of the Govt. of India and the Govt. of corresponding states.

01.09 All supplies shall be indigenous, new and best of their kinds and shall be certified by

Third party inspection agency. 01.10 The Bidder shall satisfy himself by a visit to the site to ascertain the actual site

conditions before quoting. Failure to do so shall not absolve him of his responsibilities about proper execution of the job. No claims for extra payments due to any special site conditions will be entertained after the award of contract.

01.11 All documents, drawings, instructions etc shall be in English language and

dimensions, weights etc. shall be in Metric units. 01.12 The site shall be cleared after erection is completed.




01.13 Wherever necessary, the Purchaser reserves the right of selecting the manufacturer of

equipment / equipment components in the interest of standardization. 01.14 The Bidder shall satisfy the Purchaser that he possesses the necessary technical

experience and expertise and has adequate facilities and staff to ensure that the contract shall be of the best quality and workmanship. Necessary particulars in this regard shall be furnished with the tender.

01.15 Delivery and erection schedule shall be submitted along with the tender in the form of

a bar chart. However, the Bidder shall note that the supply, erection & pre-commissioning shall be completed within the period of five months from the date of L.O.I.

01.16 On completion of work, five sets of all drawings with one CD, incorporating all

changes that might have been effected during the course of the execution of the contract and five sets of the test certificates for each item of equipment shall be supplied.

01.17 All moving parts of equipment which can conceivably cause injury to the operator or

other personnel in the vicinity of working area shall be suitably guarded according to the safety regulations.

01.18 Each equipment shall be equipped with suitable lifting attachments such as lifting

lugs, eye bolts etc. to facilitate erection and maintenance. 01.19 All the rotating parts shall be statically and dynamically balanced. 01.20 The Bidder shall provide all drawings, documents & test reports required for

obtaining approval from OISD, CEA, Factory Deptt, PCB & other authorities. 01.21 All electrical equipment to be supplied by the Bidder shall comply with the latest

revision of the Indian Electricity Rules, Petroleum rules-2002 and also with the statutory requirements of the Govt. of India and the Govt. of corresponding states as regards safety, earthing and other provisions specified therein for installation and operation of the electrical equipment.

01.22 The Bidder shall study the specification and satisfy themselves regarding the

workability of the equipment and shall take full responsibility for the guaranteed operation of the equipment as regards output, performance and smooth working.

01.23 If the Bidder desires to deviate from any requirement of the specification, the same

shall be clearly mentioned and the price implication of such deviations shall be clearly indicated.




02. SCOPE OF WORK 02.01 This specification covers design, manufacture / fabrication, procurement, assembly,

testing, packing, transportation, transit insurance, supply, delivery, erection, testing and commissioning of the effluent treatment plant (ETP) for oily water including all accessories and civil works and necessary documentation along with the assistance to M/s HPCL for obtaining approvals of the State Pollution Control Board,CCOE and any other statutory approval concerned for the E.T.P.

02.02 The Supplier shall supply the ETP as described herein and in accordance with the

quantities, size, features, type and accessories as detailed including supply of all motors, instruments and electrics. The ETP operation shall have both manual and automatic mode of operation.

02.03 The following drawings shall be submitted for approval after placement of order:

a) Outline and general arrangement drawings incorporating all principal dimensions.

b) Duly filled Data Sheet along with Sectional drawing of each equipment

incorporating data on materials of construction. c) Predicted performance curves for the pumps. d) Design of Civil Structures. e) Instrument List

02.04 All drawings and other information to be furnished for Owner / Consultant’s approval

shall be progressively submitted in three (3) copies and the entire submission of documents completed within 30 days from the date of Owner’s letter of Intent. Approval of supplier’s drawings by Owner/Consultants shall not relieve the supplier of any responsibility covered by the requirement of the Contract.

02.05 SCOPE OF HPCL APPROVED THIRD PARTY INSPECTION AGENCY 1 TPI will witness all the Hold points as per approved QAP/ITP vetted by TPI and

approved by HPCL. 2 All the Test certificates including the Material test certificate of the supply items shall be certified by the HPCL approved Third party inspection agency as per the respective codes, Tender specification etc. 02.06 The supplier shall supply 3 sets of the following documents for approval before

dispatch of equipment:

a) Material test certificate of all supply items certified by Third party inspection agency as per the respective codes.




b) Static and dynamic balancing test certificates on rotary parts certified by Third

party inspection agency. c) Shop performance data, calibration curves and certified characteristic of

pumps, and other equipment certified by Third party inspection agency. 02.05 The supplier shall supply operation and maintenance manual along with the

equipment. The manuals shall meet the following requirements:

i) The instruction manuals shall present the categories of information in practical, complete and comprehensive manner prepared for use by operating and/or maintenance personnel.

ii) Instructions for initial installation. iii) Instructions for operation, maintenance and repair. iv) Recommended inspection points and periods of inspection. v) Ordering information for all replaceable parts. vi) Lubrication chart.

vii) Drawings and other illustrations shall be included or copies of drawings

shall be bound in the manual. Test, adjustment and calibration information as appropriate shall be included and shall be identified to the specific equipment, Safety and warning notices and installation, maintenance and operating cautions shall be emphasized.

viii) A parts list shall be included showing part nomenclature, manufacturer’s part number and/or other information necessary for accurate identification and ordering of replacement parts.

ix) If a standard manual is furnished covering more than the specific requirement purchased, the applicable model no., parts no. and other information for the specific equipment purchased shall be clearly identified.

x) The instruction manual shall include a list of all special tools and tackles furnished with complete drawings and instructions for use of such tools and tackles.

02.06 The supplier shall furnish list of special tools required for erection and maintenance

of the various equipment supplied by him under this tender. 02.07 Third party inspection shall be done by one of the following agencies

1.LLOYD 2.DNV 3.EIL 4.BV 5.INDIAN REGISTER OF SHIPPING(IRS)




03 TECHNICAL SPECIFICATION 03.01 I) Design parameters

a) Tentative analysis of the effluent at the inlet to ETP

a) Oil content : 3000 ppm

b) Specific gravity : 0.65 to 0.9 b) Analysis of treated effluent required

a) pH : 5.5 to 9

b) Oil & Grease : 5 ppm max.

c) Capacity : 50 m3/hr Treated effluent parameters shall be as per MOEF /CPCB Gazette Notification dt 18th March 2008 (or latest revision). The analysis of treated effluent parameters shall be done by HPCL approved MOEF. certified water testing Labs in presence of approved TPI and HPCL.. II) Suggested scheme of treatment

The flow sheet given in the drawing attached with the tender document which shows the suggested scheme of treatment which broadly consists of the following.

• Primary separation using Bar Screen, plate separator, and oil skimming in RCC inlet sump.

• Low speed Pumps for feeding oil+water mixture to Multimedia filters.

• Filtration using multimedia filter

• Polishing using a coalescer column • Storage and pumping facility for separated Oil and treated effluent.

The flow diagram along with equipments and instruments has been attached with the tender document for reference purpose. Bidders can make minor changes and offer their schemes or arrangement of the equipment subject to condition that a. The performance parameters remain unchanged. b. The major equipments viz. pumps, filter, coalescer, skimmer etc are kept intact in quantity. c. The instrumentation scheme sought for proper control and monitoring are kept. d. The civil structures viz. inlet sump, treated effluent sump and control room are kept intact.




i) Primary Separation

Primary separation of the oil from the effluent shall be achieved in a corrugated plate separator mounted in an RCC tank. The tank shall be divided into three sections: - a) receiving section b) parallel plate section and c) outlet section. The sections shall be divided by RCC walls. The receiving section shall receive oily water from the various units through a closed system of underground OWS pipe. Bar Screen should be provided in this section. Riser pipes shall be provided on the wall between the receiving section and parallel plate section which shall ensure that water from the lower half only of the receiving section gets transferred to the parallel section. The receiving section shall be big enough to provide sufficient residence time for the effluent so that heavier dirt particles start settling down. A diverter wall shall be provided in the receiving section which shall divert the floating oil towards the center of the tank. A floating oil skimmer shall be mounted in the neck created by the diverter wall. The skimmer shall skim off the floating oil and discharge it to an underground oil collecting tank. The parallel plate section shall house a stack of plates. The plate stack shall be made of corrugated plates having flutes at 45°. The stack shall be mounted inside a steel frame which shall be guided into the RCC tank using guide angles provided at four corners of the tank. A wall shall be provided to separate this section from the outlet section. Riser pipes similar to those mounted in the receiving section shall be provided on the wall which shall open into the outlet section. The outlet section shall have sufficient storage volume. Suction of the pumps shall be connected to the outlet section. Float type level control shall be provided in the outlet section for automatic operation of the pumps. Water from outlet section of the plate separators shall be pumped to the filtration unit. ii) Filtration unit

The filter shall have sand as the filter media. The filter shall be down flow pressure sand filter type with inlet at the top and outlet at the bottom. The filter body shall be a pressure vessel constructed out of MS plates as per IS : 2825.




The filter shall be provided with backwashing facilities. The Bidder shall provide a suitable method for disposal of the return back wash water. An oil water interface detection system shall be mounted on the top part for monitoring the oil water interface. DPG should be installed for monitoring the cleanliness of the filter media.

iii) Polishing unit

The filtered water emerging from the pressure filter shall be sent to a polishing unit consisting of a coalescer column incorporating coalescing filters.

The coalescer column shall be built in three parts. The bottom part shall house the coalescing filter and the central and top parts shall act as collecting chambers for the separated oil. An oil water interface detection system shall be mounted on the top part for monitoring the oil water interface. The coalescing filter cartridges shall be made of materials that have the capacity to attract the dispersed oil phase in water. It shall be possible to regenerate the coalescing filter by washing it with water under pressure. III) Accessories required : i) Pumps with drive motor

The separator shall be provided with a low shear low rpm pump. The discharge capacity of the pump shall match the design capacity of the oil water separator.

The pump shall pump from the outlet section of the corrugated plate separator to the dual/media filtration unit.

The operation of the pump shall be automatic based on a float type level control system mounted on the outlet section of the plate separator.

ii) Oil skimmer

The oil skimmer shall be installed in the receiving section of the plate separator. The oil skimmer shall have the following major components.




a) Oil skimmer roller

The oil skimmer roller shall be fabricated out of mild steel plates. The roller shall be sealed from both sides. The roller shall be coated with special oleophyllic material which has the capacity to absorb oil. The roller assembly shall be mounted in such a way that a part of the roller always remains submerged.

b) Scraper with oil receiving tank

A scraper shall be provided for scraping off the oil sticking to the roller. A small tank shall be provided for receiving the scraped oil. The scraper blade shall be teflon coated. Oil from the oil receiving tank shall be led to a bigger underground tank by means of a flexible hose.

c) Prime mover

The oil skimmer roller shall be driven by an electric motor through a gear box.

iii) Oil drain system

The coalescer column and the dual media filtration unit shall be fitted with automatic oil drain systems provided with a sensor and a solenoid valve.

When the level of oil collected in the oil collecting dome of the coalescer column and the dual media filter increases to a preset level, the interface detector shall send a signal to the control panel which shall open the solenoid valve and drain out the oil. When the level of water in the dome goes up to a preset level, the solenoid level shall automatically close.

iv) Control panel

A control panel shall be provided for automatic operation of the plate separator pumps which will pump water from the outlet section of the plate separator to the dual media filter. As mentioned earlier, float type level controls shall be provided in the outlet section of the separator. The control panel shall also have auto/ manual mode selection switch.

03.02 PUMPS Parts of pumps like impeller, shaft sleeve, wearing ring etc. shall be of non-corrosive metal.




The coupling between the prime mover and the pump shall allow each unit to be removed without disturbing the other. The pump shall be manufactured, tested and marked in accordance with IS: 5120 The pump rated capacity, total dynamic head and other performance requirements shall be as per the requirement of the ETP. The pump shall be designed to have the best efficiency at the specified duty point. The pump set shall be suitable for continuous operation at any point within the range of operation selected. The pump shall have a continuous rising head capacity characteristic from the duty point towards the shut-off point, the maximum being shut-off. The horse power characteristic shall preferably be non-over loading type beyond the rated capacity point. The material of construction for components other than those specified shall be as per IS:5120 and shall be indicated separately. The pumps shall be suitable for parallel operation. Pump along with its drive shall run smooth without undue noise and vibration. Replaceable / renewable wearing rings shall be provided for both the casing and the impeller or for the casing only. The power rating of the drive shall be selected such that a minimum margin of 15 % is available over the pump input power required at the duty point. The complete assembled unit shall be designed so that all covered parts including shafts and bearings shall be easily accessible for inspection, maintenance and replacement with minimum down time. The RPM of the pump should not exceed 1500. End suction pumps shall be provided with spacer coupling. The impeller shall be dynamically balanced at operating speed. Pump casing shall be made of cast iron and tested at 150% of shut-off head or 200% of rated total head whichever is higher. Coupling guard shall be provided for the pumps.




Suction and discharge flanges shall be drilled in accordance with the of IS: 6392-1971 / IS:1538. The gland packing should be easily accessible for changing without having to disassemble the pump. A common base plate mounting both for the pump and drive shall be furnished. The base plate shall be of rigid construction, suitably ribbed and reinforced. Base plate and pump supports shall be so constructed and pumping unit so mounted as to minimise misalignment caused by mechanical forces such as normal piping strain, hydraulic thrust etc. Suitable drip taps and drip lip shall be provided.

03.03 PRIME MOVER The prime mover of the pump shall be AC electric motor as indicated under 'Electrics'.

i) Testing at Manufacturer’s Works

Pressure testing of casing, pump assembly etc. upto twice the working pressure or one and half times the shut off head of the pump whichever is higher. The standard to be followed for testing of pumps shall be IS: 9137, 1983 (Code for acceptance tests for centrifugal, mixed flow & axial pumps – Class C) / IS:5120.

ii) Name Plate A corrosion resistant name plate shall be permanently attached to the pump and prime mover. The name plate shall be stamped with the following information:

a) Manufacturer’s name

b) Serial number

c) Model number

d) Rated capacity

e) Rated head

f) Speed in rpm

g) Rating of the prime mover

iii) Packing




a) The equipment of the ETP shall be packed, securely anchored and protected

for domestic shipment by rail or truck. All unmounted components shall be suitably crated and firmly attached to the main pump unit for shipment.

b) The purchase order number and equipment number shall be stenciled on the crate.

c) One complete set of installation, operation and maintenance instruction shall be packed with the equipment.

03.04 Electrics Scope of work for electrics shall include supply, installation, testing and commissioning of all electrical equipment broadly covering the following:

a) Motors (Flame proof)

b) Control panel with DOL starters - / or star delta starters (> 30Kw) / Incoming

SFU unit / control transformers / MCBS required for other loads, auxiliary

contactors, relays required for automatic operation of the plant, located in the

electrical/control/MCC room at a safe distance of 30m from the plant.

c) Power & control cables required for connecting the motors & other electrical

equipment in the ETP.

d) Control Room and ETP area lighting using fittings as per area classification.

e) Flame proof local start / stop push button stations (located near the motors).

f) Earthing system including earth pits and GI earth strip as per IS 3043, earthing

of all equipment & lighting protection if any.

g) Electrical installation accessories required for completion of the plant.

h) Documents to be handed over to owner in required format for obtaining

Clearance from statutory authorities like CEA / electrical inspectorate etc.

i) Complete documentation with test reports etc.

j) Purchaser will make available 415 V +/- 10%, 50HZ+/- 5%, power supply at the incomer of the control panel. All further electrical items as listed above & other control Voltages required shall be in the scope of Bidder.




The control room shall be 3 x 3 m with MCC & control panel located in the room. The MCC shall be complete with switch / starter units for all drives and other equipment. Control panel shall be for auto operation. Flameproof local start – stop stations has to be provided near the motors in the field with necessary canopy. All the power, control and instrumentation cables for the ETP equipment will be in party’s scope. Only 3 ph, power supply at 415V, 50Hz of required rating will be made available at the incomer of his MCC. All outdoor electrical and instrumentation equipment should have protection of IP-55 and additional canopy should be provided. The Yard lighting shall have FLP fixture with HPMV lamps and fixed on MS Poles of suitable height for proper illumination. The illumination should be such that operation of plant and equipment including trouble shooting during night hours should be possible. The control room should have proper illumination (inside and outside). Proper thickness rubber mat should be provided as per IE rules on the front and back of the panel.

i) SPEICIFICATION OF ELECTRIC MOTORS

The Specification for Motors given below shall be read in conjunction with driven equipment specification.

ii) GENERAL

a) Motors shall be flame proof type suitable for Gas group IIA & IIB as per IS 2148 and surface temperature class T3 as per IS 13346 and also confirming to IS 325

b) Motors shall be suitable for giving the rated output, without reduction in the expected life span when operated continuously under the following system conditions.

- 415V+ 10%, 3 Phase, 50 Hz + 5% and, a combined, voltage and frequency variation of + 10%

- Duty cycle 'S1' continuous.

Altitude 950M (above sea level) Ambient temperature 400C R H 100% (However not occurring

simultaneously at max. temperature)

- Motors shall be suitable for full voltage, Direct-on-line starting upto 30 KW or Star-Delta starting for motor ratings above 30 KW




- Motors shall be capable of starting and accelerating the load with any

of the above mentioned methods of starting, without exceeding the specified limits of temperature.

- The locked rotor current of motors shall not exceed 600% of the full load rated current

- Motor's vibrations shall be within limits as per applicable standards.

- Motor's insulation shall be class 'F' with temperature rise limited to class 'B'. The motors shall be given tropical and fungicidal treatment for successful operation of motor in hot, humid and tropical environment.

iii) Enclosure / Certification

(a) Motors shall have flame proof enclosure suitable for gas groups II A & IIB as per IS: 2148 and IP 55 as per IS 4691. Approval certificate from DGMS/Chief controller of explosives, Nagpur for suitability in petroleum industry for the category specified. Type test certificates shall be furnished along with the tender.

(b) Motors (and the driven equipment) shall be supplied with adequately braced common base frames and vibrations and misalignments shall be contained within limits.

• MOTOR DETAILS

i) Design Ambient Temperature : 45º C ii) Enclosure : a) Class of protection : IP 55 (for outdoor application bolted

canopy to be provided additionally) b) Hazardous Area Classification : Gas groups IIA and IIB as per IS 2148

iii) Class of insulation : Class F

iv) Temperature rise above design ambient : Limited to class B

v) Type of cooling : IC 410 (TEFC)

vi) Duty type and designation : S1, continuous

vii) Starting requirements

a) Equally spread / hour : 6 starts

b) Successive cold : 3 starts




c) Successive hot : 2 starts

viii) Method of starting : DOL / Star-delta for 30KW & above

ix) Mounting requirements :

a) Shaft Orientation : Horizontal / vertical

b) Mounting : Foot

x) Speed 1500 rpm

xi) Terminal box

a) Location of main TB (when viewed from DE)

: R.H.S

b) Rating of TB : 40 KA (0.25 secs) at 415V

xii) Anti-condensation heaters : Required for motors rated 30 kw and higher. Additional TB to be provided.

xiii) Temperature sensing elements :

Thermistors : For DOL start, 6 nos to be provided in series for ratings 30 kw and above to 75 kw (excluding 75kw)

xiv) Bearing type : Regreasable ball / roller anti friction

xv) Bearing insulation : On NDE side for motors rated 75 kw and above.

xvi) Vibration Severity : Limited to “Normal class” as per IS : 12075(1986)

xvii) Noise level : Limited to "Reduced sound Power as per IS : 12065 (1987)

xviii) Final paint shade : Shade no.631 as per IS:5

Note: Painting shall be epoxy resin based.

xix) Torque characteristics

a) Ratio of starting torque to rated torque : 1.6

b) Ratio of pull out torque to rated torque : 2.5

c) Ratio of locked rotor current to rated current

: 6.0 (incl. IS tolerance)

xx) Overspeed : 1.2 times rated speed for 2 minutes

xxi) Direction of rotation : Bidirectional




03.05 DOCUMENTATION REQUIREMENT

I.A ALONG WITH BID

a) G.A.drawing of motor, main teminal box, space heater TB, thermistor/RTD T.B.

b) Data sheet for motor

c) Signed list of clause-by-clause deviations

d) Type test certificates

e) List of recommended spares for 2 years normal operation

f) Internal Quality Assurance Plan

I.B AFTER AWARD OF ORDER

a) G.A.drawings of motor, main terminal box, space heater TB, thermistor / RTD T.B.

b) Wiring diagram for space heater TB, thermistor/RTD T.B.

c) Motor data sheet duly filled up.

d) Routine test certificates

e) Quality Assurance Plan/ITP vetted by TPI and approved by HPCL.

f) Motor characteristics curves:

1. Speed-torque

2. Current-time

3. Thermal withstand

4. P.F. vs load

5. Efficiency vs load

6. Current-speed

7. Speed-time

03.06 Applicable Standards and codes 1 IS – 325-1996 : 3-phase induction motors.

2 IS – 2148-1981 Re-affirmed 1993

: Specification for Flame proof, enclosure of electrical apparatus.




3 IS – 2253-1974

Re-affirmed 1991 : Designation for types of construction and mounting

arrangement of rotating electrical machines

4 IS – 4691-1985 Re-affirmed 1991

: Degrees of protection provided by Enclosures for rotating electrical machines.

5 IS – 4728-1975

: Terminal markings for rotating electrical machines.

6 IS – 4029 – 1967 Re-affirmed 1991

: Guide for testing three phase induction motors

7 IS – 5571 – 1979 Re-affirmed 1991

: Guide for Selection of electrical equipment for hazardous area.

8 IS –6362 – 1995 : Designation of methods of cooling of rotating electrical machines

9 IS – 12065-1987 : Permissible limits of Noise level for rotating Electrical Machines

10 IS –12075- 1987 Re-affirmed 1991

: Mechanical vibration of rotating electrical machines with shaft heights 56 mm and higher-measurement, evaluation and limits of vibration severity

11 IS – 4722 (1992) : Rotating electrical machines

12 IS – 1231 (1974) : Dimensions of 3 pH. Foot mounted induction motor.

13 IS – 8789 (1996) : Values of performance characteristics for 3 pH. Induction Motor.

14 IS – 12824 (1969) : Type of duty and classes of rating assigned

15 IS – 12802 (1989) : Temperature rise measurement of rotating electrical machines.




MOTOR TECHNICAL DATA SHEET (To be submitted along with offer) A. MOTOR DETAILS 1. Name of manufacturer : 2. a) Rated voltage : b) Voltage variation : 3. a) Rated frequency : b) Variation in frequency : 4. No. of phases : 5. a) Motor kw at _ º ambient : b) Motor kw at 40º c : 6. Frame size : 7. Rated speed : 8. Enclosure class of protection : IP – 55 9. Hazardous area suitability : 10. Class of Insulation : 11. Temperature rise above _ º C ambient : 12. a)Locked rotor current / rated current : b)Starting torque / Rated torque : c)Pull out torque / rated torque : 13. a)No. of equally spread starts / hour : b)No. of successive starts from cold

condition :

c) No. of successive starts from hot condition : 14. External paint shade : 15. Type of painting : 16. Terminal Box location ( viewed from DE

side) : R.H.S / LHS

17. Space heaters provided : 18. Temperature detectors provided If YES, then a) Type : PTC / Pt-100 b) No.of detectors : B. CONNECTED LOAD DETAILS 1. Connected load type : 2. Connected load tag no : 3. Shaft absorbed kw : 4. Coupling type :




(MOTOR TECHNICAL DATA SHEET) (To be submitted after award of order)

A) GENERAL PARTICULARS 1. Connected equipment tag no : 2. Manufacturer’s Name : 3. Manufacturer’s Model no : B) PRODUCT PARTICULARS 1. Applicable standards : 2. Duty designation : 3. No. of poles : 4. Installation : Outdoor / Indoor 5. Mounting class : IM - 6. Class of Cooling : IC - 7. Enclosure class of protection : IP - C) GUARANTEED PARTICULARS : 1. Rated voltage / no. of phases : 2. Allowable voltage variation : 3. Rated frequency : 4. Allowable frequency variation : 5. Allowable supply voltage imbalance : 6. i)Rated r.p.m ii)Rated slip : 7. Method of starting : 8 i)Kw at º C ambinet ii)Kw at 40º C : 9. Class of insulation : 10. Temperature rise at _ º C ambient : 11. Currents : i) Rated current : ii) Locked rotor / rated current : iii) No load current at rated voltage : 12. Rated Efficiency : 13 Rated power factor : 14. Torque : i) Rated torque : ii) Starting / rated torque : iii) Pull out / rated torque : 15. Minimum voltage required to start and

accelerate under rated load :

16. Starting requirements : i) Equally spread / hour ii) Cold successive




iii) Hot successive 17. Locked rotor current withstand time at rated

voltage :

i) Hot : ii) Cold : 18. Noise level at 1 M (d BA) : 19. Vibration level : D) OTHER PARTICULARS 1. Winding connection : 2. Direction of rotation : 3. Accelerating time at rated load i) At rated voltage : ii) At 110% rated voltage : iii) At minimum voltage : 4. Motor thermal time constant : 5. Slip at : i) 110% rated voltage : ii) 90% rated voltage : 6. Safe stall time : i) At 110% rated voltage - hot : - cold : ii) At minimum voltage - hot : - cold : 7. Motor inertia time constant : 8. Motor main T.B : i) No. of terminals : 3/6 ii) Short circuit level : iii) Location when viewed from DE side : RHS/LHS iv) Cable type & size : 9. i)Space heaters provided : ii)Space heater rating (kw) : iii)Space heater voltage : iv)No. of elements : v) Space heater TB provided separately : 10 i) Winding temperature sensing element : Thermistor ii) Total no of elements : 11 Insulation : i) Tropical & fungicidal treatment : ii) Method : Powerhouse / Trickle impregnation / VPI 12 Bearings : i) Type on DE side : ii) Type on NDE side :




iii) Grease lubrication : iv) Regreasing nipples provided : v) Recommended grease type : vi) Greasing interval : vii) Grease Quantity : viii) Expected bearing life (L 10) : 13 External paint shade : 14 Epoxy based painting : 15 Tinned copper lugs and double compression

brass cable glands for power cable, space heater cable, RTD / BTD cable

:

16 Double earthing provision with electrogalvanised screws / bolts plain and spring washers

:

17 Approx total weight :

03.07 ELECTRICAL CONTROL PANEL

The control panel shall incorporate the DOL starters for the motors and other SFUs required for the ETP. The control panel shall consist of suitably rated incoming Switch fuse unit rated for 415V, 3ph 50 Hz supply.

- Working/stand-by / Local -Remote selector switch

- Outgoing feeders for each motor with SF units, Power and auxiliary contactors,

- Start/stop Push Buttons,

- Auto manual control selector switch if any,

- Voltmeter/ammeter, meter selector switches,

- Bi-metallic Over-load relays with built-in-single phase prevention feature and with manual re-set (accessible from the front of the panel)

- Solid state Alarm annunciation compartments with standard features of Accept/Test/Reset, with hooter mounted on the top of panel.

- The control voltage shall be 110 V AC derived through suitable 415 V/110V control transformer.

- The starter feeders shall have indicating lamps for ON/OFF/TRIP – (RED/GREEN/AMBER) lamps with series resistor/Lens, 7 Watts rated.




- Panel shall be floor/wall mounted type, fabricated out of 2mm thick CRCA

sheet steel with Hinged Doors,

- IP 54 Degree of protection for enclosure.

- Incoming and outgoing feeders shall be compartmentalised.

- The Exterior finish - painted with approved colour.

- Panel wiring shall be carried out using 2.5mm2 PVC insulated copper wires.

- Control circuit shall be designed to take care of logic of automatic operation of pump interlocks from level switches, field limit switches etc.

- Undrilled Gland Plates shall be provided at top and Bottom of the Panel/Cable alley.

Single line diagram, control circuit of pumps etc, shall be approved by HPCL. - At manufacturer's works, the panel shall be tested for routine tests such as, IR

test, HV test functional test and others as per relevant standards and test certificate shall be furnished.

- The Control Panel should have annunciation window. 03.08 Cables

Scope of work will cover supply, erection, terminations, testing and commissioning of power, control and instrumentation cables between all equipment. The power cables shall be 1100 V grade, PVC insulated, Aluminium conductor, PVC sheathed, GI flat wire armoured, PVC overall covered, cable.

The control cable shall be 1100 V grade, PVC insulated, copper conductor, PVC sheathed, GI flat wire armoured, PVC overall covered, cable.




03.09 Local push button stations.

Shall be flame proof / explosion proof designed to gas groups IIA & IIB as per IS: 2148. Shall consist of local / remote selector switch, start/stop push button stations. Flame proof double compression cable glands to be provided for suitable cable size.

03.10 INSTRUMENTATION AND AUTOMATION i. ETP shall be automatic in operation as far as the operation of the belt skimmer and

feed pumps are considered. All drives shall have auto/manual selection so that manual operation is restricted to doing maintenance and checking.

ii. One additional “oil float sensor / switch” shall be provided in the sump tank where

the oil skimmer is provided. This will actuate the belt skimmer even when the ETP is not running. However, the feed pumps shall be interlocked with the skimmer such that whenever pumps are “ON” oil skimmer is also ON. The pumps will operate depending on the level in outlet tanks.

iii. Following “Potential free” relay contacts shall be given for customer’s plant

PLC/MMI station indication (Digital inputs): - a) ETP “ON”: (Pumps + Belt skimmer on) b) ETP “FAULT”: (Trip or other faults in ETP).

iv. For item no. (iii.), the Bidder shall include supply of 300m of YRY (10 x 1.5) cable in his scope of work.

v. All electrical equipment including solenoid valves, etc. shall be CMRS certified.

Solenoid valves shall be from reputed/approved make like ASCO. vi. In addition to pressure gauges at the inlet and outlet of the pressure sand filters, one

number differential pressure gauge also shall be provided. vii. Preferred makes for instrumentation equipment shall be as follows: -

a) Pressure gauge (150mm dia. Size) : AN INSTRUMENTS /GENERAL INSTRUMENTS/INDFOSS.

b) Level probes/switches (capacitance type): SB ELECTROMECHANICAL / NIVO CONTROLS/MONITOR CONTROLS.




� A list of field instruments considered is required to be submitted. The makes of all

components shall be as per preferred makes indicated in the specification.. Details of oil float sensor / switch, considered in the sump tank (where scraper is provided) shall be furnished.

� The control panel shall have window type alarm annunciator. � All field mounted equipment like solenoid valves and instruments shall have

flameproof enclosure or be intrinsically safe.

03.11 ERECTION GUIDELINES General

All electrical equipment shall be erected, tested & commissioned as per relevant Indian standards, codes of practices and good engineering practice. Scope shall include minor civil works like chipping, grouting, etc for erection of the panels and cable trench work for cable laying. The scope includes receiving and storage of equipment at site, transportation, handling, installation, testing and commissioning of all units/items under the scope of supply of the contractor. His scope also includes installation and termination of cables to / between owner's electrical equipment and sealing of cable conduits, floor / slab openings, minor civil works required for erection etc.,

Unpacking shall be properly done at site. Breakage, defects, missing (if any) items shall be made good immediately. All packing materials shall be removed and components shall be thoroughly cleaned. Transportation to respective foundation, after checking and unpacking, shall be done by the contractor. Transportation shall be done systematically using wall/ floor openings, provided exclusively for the purpose, using proper lifting tackles. No part of GI piping, structures, ducts shall be used for lifting equipment without prior consent of owner/engineer. Contractor shall be fully responsible for claiming any damages from insurance company wherever required. Base frames of equipment shall be fixed to foundations by anchor bolts . Equipment/cabling and other electrical system installation shall be carried out in accordance with the latest editions of relevant Indian Standards and codes of practice and the installation shall fully comply, with the requirement of the Indian Electricity Rules and statutory regulations, that are in force, at the place of installation.




Earthing as per IS – 3043 / IE rules including earth pits as required to achieve an earth resistance of not more than 3 ohms for the effluent treatment plant and dual earth connection to all equipment shall be carried out as per standards.

03.12 CLEARANCES All electrical equipment shall have adequate clearances from the point of view of

operation and maintenance and conform to IE Rules. The clearance between the ceiling of the electrical room and top of the tallest

equipment shall not be less than 1 metre.

Back clearance - Minimum 1000 mm Front to front clearance between boards - Minimum 2000 mm Clearance between two panel boards in a row- Minimum 1000 mm Clearances between front of the panel to - Minimum 2000 mm the wall of the room Clearance between the wall & end of - Minimum 1000 mm switchgear/PDB Back to back clearance - Minimum 1500 mm Back to front clearance - Minimum 2000 mm

03.13 Cabling installation

The cables shall be laid in cable trenches / GI pipes / cable trays / directly buried in the ground. In paved area cable shall be laid in GI pipes only. Civil works of RCC cable trenches, excavation of trenches of required width and depth in all types of soil, clearing natural obstructions including rock cutting if any required along the cable routing , laying of cable on 8 cm of riddled sand and covered with 8 cm of riddled sand providing 75mm thick RCC cover slabs, back filling with earth (after cable laying), and finally compacting to original ground level of cable trenches, all other equipment, materials and components required for cable laying are included in the scope of work.

The maximum trench depth shall normally be 1.5m If the trench is to cross railway tracks / roads or any load bearing area the cables shall be taken through suitable GI




conduits/ pipes / ducts. Installation of cables directly buried in ground shall generally conform to the requirements given in IS:255. Cables laid directly in underground trenches ( where permitted by owner/consultant) shall be in one layer only, more than one layer is not permissible.

For crossing the road / rail track, cables shall be laid in concrete cable ducts/ hume pipes/ GI pipes. 25% spare duct /pipe openings / pipes shall be available. The scope includes but not limited to,

i) Cable inspection and handling.

ii)Laying, meggering, termination, dressing and clamping of cables.

iii)Tagging and marking of cables.

iv)HT/LT tests on cable.

v)Identification of phases.

vi)Connection of equipment.

vii)Making of cabling ready for charging after completing all associated works.

03.14 PANELS

The contractor shall follow the following sequence of erection of panels.

1. Erection of base channel and alignment

2. Assembly

3. Alignment

4. Welding and anchoring

5. Installation and wiring of relays, meters etc.,

6. Laying, meggering, termination, dressing and clamping of power and control cables.

7. Tagging and marking of cables

8. Earthing station, earthing strips, earthing equipment and measurement of earth resistance as per IER 1956/IS 3043 with the latest revision.

9. Connection of power and control cables.




10. Checking and testing of all relays, meters, other protective accessories and control and

power circuit wiring, phase sequence connection, checking of all circuit breakers for proper alignment of handles with doors.

11. Using a vacuum cleaner, remove dust, small particles etc.,

12. Clean all insulating surfaces with dry cloth or as indicated by the manufacturer's.

13. Functional tests

14. Submission of completion report to owner's representative.

03.15 TESTING AND COMMISSIONING i. GENERAL

The successful Bidder, based on the broad outline procedure indicated in this specification, shall finalize with owner/engineer, the detailed procedure for testing and commissioning along with Third Party. The contractor shall adhere to the general guidelines given for testing & commissioning of the equipment/items implicitly covered under heading special instructions to contractor general condition of contract and technical specification. On successful completion of erection of each item /equipment, a final inspection will be carried out at site by owner /engineer, for correctness and completeness of erection. The successful Bidder shall provide adequate supervisory/ skilled personnel and all tools and tackles, testing equipment and instruments required for complete checking of installations and testing and commissioning of all equipment and accessories. The Bidder shall furnish with the offer a complete list of equipment, tools and tackles, instruments etc. which he intends to bring to site for erection, start up, testing and commissioning of equipment. The testing and commissioning of all equipment under the scope of the Bidder shall be carried out in accordance with the latest edition of relevant Indian Standards and IE Rules. The testing of all sub systems as well as the equipment as a whole shall be carried out to ensure that the equipment and its components are in satisfactory condition and will successfully perform their functional operation.




Test reports shall be submitted in required number of copies duly signed by the CONTRACTOR,Third party and M/s HPCL. The results of all tests shall conform to the requirements of the specification as well as any specific performance data guaranteed during finalization of the contract. All equipment after testing shall be energized only after certification by the qualified testing engineer that the equipment is ready for energization and with the concurrence of M/s HPCL.

ii. Mechanical Inspection and check up of the equipment

After installation, but before any power supply is connected, the contractor shall make a complete mechanical check and clean all erected electrical equipment and systems. This shall include, but not limited, to the following:

(a) Visually inspect all equipment/item for defects if any and check equipment numbers against drawings to ensure that equipment has been correctly located and proper installation is done.

(b) Check name-plates of individual feeders and others, distribution boards, distribution fuse boards etc., for conformity with data given on the supplier's drawings/standards/specification sheets.

(c) Check that motors turn freely by hand.

(d) Remove, clean and replace if necessary, drain plugs of all motors.

(e) Check connections to all equipment for tightness.

(f) Check correctness of cabling and its terminations.

(g) Check phasing, polarity.

(h) Check all electrical & mechanical interlocks & other equipment for safety and to ascertain that those are functioning as per intention and accomplish their purposes.

(i) Check all plug in contacts for alignment and grip.

(j) Check all contactors for free manual operation

(k) Remove all blocking devices installed for shipment.

(l) Check all the coils for their continuity and proper voltage.

(m) Check that the fuses are correctly rated & installed, are clean, undamaged and fit for operation.




(n) Check, that all disconnect switches are clean, undamaged & operate

properly. Ensure that all contacts are tight/ joints, linkages & contacts properly lubricated (where applicable). Check interlocks and auxiliary devices and also the operation of the circuit breakers with the protection relay circuit connected.

(o) Vacuum clean equipment before energizing.

iii. Panels

Shall be tested for

- Insulation resistance test

- HV withstand for 1 min.

- Functional and operational checks of circuits

- Testing for correct operation of protective relays and calibration if any.

03.16 AC MOTORS i. IR test of stator and rotor windings. ii. Ensure that checking / testing of associated switchboard, cables, relays / meter

interlocking as mentioned in relevant chapters are completed. iii. Check tightness of cable connection iv. Checking continuity of winding v. Check tightness of earth connections vi. Check space heaters and carryout heating of winding (if required) vii. Check direction of rotation in de-coupled condition during kick-start viii. Measure no load current for all phases ix. Check for temperature rise of body in no load and on load conditions. x. Check for tripping of motor from local / remote switches and from electrical /

technological protection including differential protection xi. Checking of vibration xii. Checking of noise level during load running.




xiii. Measurement of stator and bearing temperatures (if applicable) for every Half an hour

interval till saturation comes xiv. Checking tightness of foundation bolts. xv. Check operation of speed switch (if there). xvi. Check continuity of temperature detectors. xvii. Check alignment, paralleling of shafts, level of lubricating oil etc. as per

manufacturer's manual.




03.17 Civil works

DESIGN CRITERIA FOR CIVIL WORKS General Design and construction of buildings, structures etc. shall take into account requirements for operation and maintenance of all equipment and its users. All the design work shall be carried out as per the latest IS codes. The buildings shall have good architectural features. The surrounding areas shall be properly micro levelled and graded. The scope includes complete testing of all construction material as per relevant standards. ANALYSIS AND DESIGN: Analysis and design of civil structures and foundations shall be based on the provisions of IS 456-2000. The loading shall conform to IS 875-1987 and seismic forces as per IS 1893-2002. LOADS AND LOAD COMBINATIONS General All structures shall be designed for the most critical combinations of different loads. All codes and standards referred are the latest editions/ revisions along with amendments if any. Earth pressure loads Earth pressure for all underground structures shall be calculated using coefficients of earth pressure at rest, coefficient of active or passive earth pressure (whichever is applicable). However, for design of sump, receiving tank and underground liquid storage tanks earth pressure at rest shall be considered. In addition to earth pressure and ground water pressure, etc. a minimum surcharge load of 2.0 t/sq.m shall also be considered for the design of all underground structures including channels, sumps, receiving tank and underground liquid storage tanks, etc. to take into account the vehicular traffic in the vicinity of the structure. Wind load




Wind load on structures shall be calculated as per provisions of IS:875 (part 3). The wind shall be assumed to blow in any direction and most unfavorable condition shall be considered for design. In design of structures, wind force on equipment supported on frame including all fixtures, piping, staircases, ladders, handrails, etc. shall also be considered. Seismic loads Seismic analysis using response spectrum method as per IS: 1893 shall be done. Equipment loads Static and dynamic loads of major equipment shall be based on the manufacturer’s data of the specified equipment and shall be considered in design in addition to the live load. Other loads Stresses imparted to structures due to differential settlements, variation of water table, erection and maintenance loads, creep and shrinkage shall also be considered in design of all structures. Load combinations The individual members of the frame shall be designed for worst combination of forces such as bending moment, axial force, shear force and torsion. Permissible stresses for different load combinations shall be taken as per IS:875 (Part-V) and other relevant IS code. Wind and seismic forces shall not be considered to act simultaneously. Criticality of erection / maintenance loads shall also be checked separately in combination with other simultaneously occurring loads for possible design loading. Load combinations for underground structures Following loading conditions shall be considered in addition to the loading from super structure for the design of sub structure of channels, sumps, tanks, trenches and other under ground structures. Only liquid pressure from inside and no earth pressure and ground water pressure and surcharge pressure from outside (applicable only to the structures which are liable to be filled with water or any other liquid). Earth pressure, surcharge pressure and ground water pressure from outside and no water pressure from inside.




Design shall also be checked for buoyancy due to ground water during construction and operation stage. Minimum factor of safety as per IS:3370 against buoyancy shall be ensured considering empty condition ignoring superimposed loads. For design of underground structures, groundwater table shall be considered at 1M below ground level. REINFORCED CONCRETE STRUCTURES AND FOUNDATIONS General All structures, building foundations, machines / equipment foundation, water retaining structures etc. shall be designed as per latest relevant IS codes in general. Construction in general shall follow provisions of IS: 456 – 2000 and IS:3370 for normal and water retaining structures respectively. The walls shall be provided with reinforcement on both faces for sections 150 mm or more, even if not required from design consideration. Foundations and Underground Structures Type of foundation system, i.e. isolated, strip, or raft shall be decided based on the loading arrangement, load intensity and soil strata. Design of foundations at various levels shall be dependent upon the soil bearing capacity at that level. Foundation system adopted shall ensure that settlement / relative settlement is as per provision of IS:1904 and other Indian Standards. However, the settlement shall be restricted to a lower value, if necessary as per the system requirement. All foundations including machine / equipment foundations shall be of RCC construction. All foundations shall be designed in accordance with relevant parts of the latest revisions of Indian standards IS: 2974 and IS:456. Raft foundations shall be designed as per IS:2950. Liquid Retaining Structures RCC water retaining structures like storage tanks shall be leakproof and designed as uncracked section in accordance with IS:3370 (Part 1 to IV) by working stress method. All water retaining / storage structures shall be designed assuming liquid upto the height of wall irrespective of provision of any over flow arrangement. No pressure relieving devices shall be permitted in underground structures.




In all liquid retaining structures, PVC water bar shall be provided at each construction / expansion joint. The sequence of construction shall also be specified on drawings showing construction joints. Stability of Structures Design shall be checked against buoyancy due to the ground water during construction and maintenance stages for structures like under ground storage tanks, pits, trenches, etc. Minimum factor of safety of 1.2 against buoyancy shall be ensured considering empty condition inside and ignoring the superimposed loading. For purpose of calculating downward load due to any overburden, only the mass located vertically above the projected area of the base slab shall be taken in to consideration. All building sub-structures including pump houses / retaining wall shall be checked for sliding and overturning stability during both construction and operating conditions for various combination of loads. Factor of safety for these cases shall be taken as mentioned in IS: 456 and other latest relevant IS codes. However following minimum factor of safety shall be followed: Factor of safety against overturning due to wind, seismic or other lateral load shall be 1.5 minimum. Factor of safety against sliding shall be 1.5 minimum. Factor of safety against uplift due to hydrostatic forces shall be 1.2 and due to any other loads shall be 1.5. In cases where dead load provides the restoring force, only 0.90 times characteristic dead load shall be considered. Imposed loads shall not be considered as restoring force. Min. Thickness of concrete structural elements The following minimum thickness shall be followed: a) Suspended floor / slab / walkways /canopy slabs, etc. : 150mm b) Ground floor slab (non-suspended) : 150mm c) Water retaining slabs / walls : 200mm d) Cable/pipe trenches/underground pits/ : 125mm launder walls and base slab e) All footings (including raft foundations) : 400mm f) Parapets : 125mm g) Sunshades : 75mm at edge h) Precast louvers / fins : 50mm i) Precast trench cover slabs / floor slabs / louvers : 75mm




From fire resistance point of view minimum thickness of reinforced concrete members shall be as per of IS: 456 - 2000. Minimum fire rating of 2 hours shall be considered where fire hazard is expected. Reinforcements Reinforcing bars for concrete shall be “HCR-TMT/ TMT bars with strength requirements conforming to IS :1786-1985” of Grade Fe 415 from SAIL / TISCO / RINL IS CODES AND REFERENCES

All the Indian Standards referred to shall be the latest revision (including all amendments issued thereto) on the date of opening of the price bid. The Codes and Standards listed below are applicable for the design and construction of structures and buildings in general. Field and laboratory testing procedures for materials follow Indian Standard Specifications.

LOADS

IS:875 Code of Practice for design loads (other than earthquake) for Buildings

and structure ( All parts )

IS:1911 Schedule of unit weights of building materials

IS:1893 Criteria for earthquake resistant design of structure

FOUNDATIONS

IS:1080 Code of Practice for design and construction of shallow

foundations on soils ( other than raft, ring and shell )

IS:1904 Code of Practice for design and construction of foundations in soils

general requirement

IS:2950 Code of Practice for design and construction of raft foundations

IS:2974 Code of Practice for design and construction of machine foundations

(all parts )

IS:8009 Code of Practice for calculation of settlement of foundations: (All

parts )

IS:11089 Code of Practice for design and construction of ring foundation




CONCRETE

IS 269 Specification for ordinary, rapid hardening and low heat portland cement.

IS 8112 Specification for high strength ordinary, portland cement.

IS 1489 Specification for portland - pozzolona cement.

IS 383 Specification for coarse and find aggregates from natural source for

concrete.

IS 2386 Methods of test for aggregates for concrete. (Part I to VIII)

IS 516 Method of test for strength of concrete.

IS 1199 Method of sampling and analysis of concrete.

IS 3025 Methods of sampling and test (Physical and chemical) water used in construction.

IS 2645 Specification for integral cement waterproofing compound.

IS 2502 Code of practice for bending and fixing of bars for concrete

reinforcement.

IS 2571 Code of practice for laying in situ cement concrete flooring.

IS 3596 Safety code for scaffolds and ladders. (Part I & II)

IS 1200 Method of measurement of building works.

IS:456- 2000 Code of Practice for plain and reinforced concrete

IS:458 Specification for precast concrete pipes

IS:3370 Code of Practice for concrete structures for the storage of liquids: ( All

parts )

IS:3414 Code of Practice for design and installation of joints in buildings

IS:4326 Code of Practice for earthquake resistant design and construction of

buildings

IS:5525 Recommendation for detailing of reinforced concrete works




IS:1786 Specification for high strength deformed steel bars and wires for

concrete reinforcement

IS:10262 Recommended guidelines for concrete mix design

IS:13920 Ductile detailing of Reinforced concrete structures subjected to

seismic forces – Code of practice

MISCELLANEOUS

IS:1038 Specification for steel doors, windows and ventilators IS:1172 Code of basic requirements for water supply, drainage and sanitation IS:1346 Code of Practice for water proofing of roofs with bitumen felts IS:1742 Code of Practice for building drainage IS:1905 Code of Practice for structural use of unreinforced masonry IS:3067 Code of Practice for general design details and preparatory works for

damp proofing and water proofing of buildings SP:6 Handbook for structural engineers ( all parts ) SP:7 National Building Code of India SP:16 Design Aids for reinforced concrete to IS:456-1978 SP:20 Handbook on masonry design and construction SP:22 Explanatory handbook on codes for earthquake engineering ( IS:1982-

1975 and IS:4326-1976 ) SP:24 Explanatory handbook on Indian Standard code of Practice for plain

and reinforced concrete SP:25 Handbook on causes and prevention of cracks in buildings SP:34 Handbook of concrete reinforcement and detailing (SCIP)




i) Civil - General

Application of Specification This specification shall be read in conjunction with other documents forming the contract.

Baseline and Bench Marks

The Contractor shall establish and maintain to the satisfaction of HPCL Engineer the base line and bench marks based on which the works are set out and shall maintain them throughout the period of construction. He is also responsible for the accuracy of the same. He is to provide all instruments and proper qualified staff with labour for getting his work checked by the HPCL Engineer, if so desired by the HPCL Engineer. Such checking, if any, shall not, however, relieve the Contractor in any way of his responsibility for correct setting out.

ii) Earth work

Scope

This chapter deals with earth work in excavation for foundations, cutting and grading of trenches for drainage, backfilling, levelling and compacting as specified and/or as shown in the drawings.

Excavation for Foundations and Trenches

Side slopes, benching and/or shoring/strutting for excavation work shall be as directed by the HPCL Engineer and prior approval of the HPCL Engineer shall be obtained for a suitable method of protection before excavation work is commenced. The bed of the excavation shall be properly dressed and made level. All mud and slush shall be removed before taking up concreting work. The last 15 cm of excavation shall be done just prior to laying of concrete. The excavated materials shall not be placed within 1.5 m from the edge of any excavation. The Contractor shall take suitable precautions to prevent ingress of water into excavated areas during construction.

The surplus excavated materials shall be transported and disposed of by the Contractor in spoil dumps/fill areas, any royalty payment for the excavation carried out as per Bombay Minor Mineral Extraction rules 1955 for this job will be in the contractors scope.If required suitable documents of royalty payments shall be produced with the Bill.




If the Contractor excavates to levels lower than those shown on the drawings, he shall fill up such extra depth at his own cost to the proper level with PCC M10.

Should the bottom of any excavation appear to be soft, unsound or unstable, the Contractor shall excavate the same to required depths and the extra depth shall be filled up by the Contractor with PCC M10 as directed by the HPCL Engineer.

Every precaution shall be taken by the Contractor against slips and falls in the excavation. No extra payment will be made for removal of slips and for backfilling the space with materials approved by the HPCL Engineer.

The excavation shall be kept free from water by the Contractor at his own expense by

pumping. If any excavation for foundation gets filled up with water due to rain, seepage or for any other reason, the water shall be removed and bottom of the excavation shall be completely cleared of all silt/slush by the Contractor at his own expense.

Backfilling

Suitable materials obtained from excavation of foundations shall be used as far as possible for backfilling. Earth used for filling shall be free from organic and other objectionable matter. All clods of earth shall be broken or removed. If sufficient quantity of suitable materials is not available at site to complete filling work, earth shall be brought to site from outside as directed by the HPCL Engineer. Also the surplus earth shall be carted away.

Before commencement of backfilling, the Contractor shall remove from the space around foundations all accumulated water and slush, shoring and formwork, all debris, brickbats, bits of timber, empty cement bags and all other foreign materials. Filling shall be carried out in uniform horizontal layers, each layer not exceeding 200 mm in thickness. Each layer shall be watered, rammed and thoroughly compacted before the next layer is deposited.

Immediately upon completion of such phase of work, the Contractor shall at his own cost clear the mounds or heaps of earth which may have been raised or made and remove all earth and rubbish which may become surplus in the execution of works

iii) Plain and reinforced concrete work

Scope

This chapter covers the workmanship, special requirements and regulations with which the Contractor must comply to achieve the following objectives.




a)The provision at all locations on the site, of dense workable concrete having the specified characteristic strength.

b)The placing of concrete at all location, well compacting by vibrators in well

fixed and aligned form work ensuring the internal and external dimensions of the structures as per drawing and maintaining the size, shape, number and location of reinforcement, inserts, etc., as per drawings providing the surface finish after stripping off the form work to ensure the structural configuration as per drawings within the specified tolerance limits, curing and guaranteeing the characteristic strength all as specified.

Concrete

Mix Design

Ordinary portland cement conforming to IS:8112-1989 for C-43 grade and IS:12269-1987 for C-53 grade cement of make Ultratech, Lafarge, Grasim,ACC, Rajashree, Rasi, Coromandel or equivalent approved make shall be used for all plain and reinforced works (underground / above ground) with the approval of the HPCL Engineer.

At the commencement of the contract the contractor shall make preliminary tests to determine the proportions by weight of cement, fine aggregates, coarse aggregates and water necessary from an approved laboratory to produce required grades of concrete. The mix proportions shall be selected to ensure that workability of the fresh concrete is suitable for the conditions of handling and placing and when concrete hardens, it shall have the required strength, durability and surface finish. The Contractor shall get approval of HPCL Engineer to such proportions before he starts concreting. However, such approval shall not relieve the Contractor of his responsibility to produce concrete having required compressive strengths.

No departure from the approved proportions will be permitted during the works unless and until the HPCL /Consultant gives written authorisation for any change in proportion. The concrete made by designing the mix is termed hereinafter as “Design Mix Concrete”.

Water / Cement Ratio The water cement ratio, as achieved in the Mix Design, shall be adhered to strictly and shall not be varied without the permission of the HPCL Engineer.




Workabilty

The workability of fresh concrete shall be such that the concrete is just suitable for the conditions of handling & placing so that after compaction it becomes completely consistent and homogeneously surrounds all the reinforcements, corners, angles and completely fills the form work.

The workability of fresh concrete shall be measured by HPCL Engineer and at the

place of disposition by means of slump test. The workability tests shall be carried out in accordance with IS:1199-1959 at the place of pouring concrete.

Durability

The durability of concrete, depending on the exposure condition, is to be taken into account while designing the mix. For given aggregates, the cement content should be sufficient to make sufficiently low water cement ratio and Appendix A of IS:456-2000 shall be taken as guideline for durability considerations.

Concrete grades and Equivalent Nominal Mixes

In particular cases where design mix concrete is not possible following nominal mixes corresponding to the concrete grades indicated may be adopted with prior approval of the HPCL Engineer-in-charge.

Concrete grades and equivalent nominal mixes

Conc.Grade Equivalent Nominal Mix

Max. Nominal size of coarse aggregate

M - 7.5 B 1 : 4 : 8 40 mm (Down Graded) M – 10 C 1 : 3 : 6 20 mm (Down Graded) M – 15 C 1 : 2 : 4 20 mm (Down Graded) M – 20 C 1 : 1½ : 3 20 mm (Down Graded)

Mixing & Transportation of Concrete

Machine mixing

Concrete shall always be mixed in mechanical mixer. Water shall not, normally, be charged into the drum of the mixer until all other ingredients are already in the drum and mixed for at least one minute. Mixing shall be continued until there is uniform




distribution of materials and the mass is uniform in colour and consistency. The mixing time from the time of adding water shall be in accordance with IS:1791-1985 but in no case less than 2 minutes or at least 40 revolutions. If there is segregation after unloading from the mixer the concrete should be mixed again till the mass is uniform in colour and consistency.

Placing and Compaction of Concrete

The concrete shall be placed and compacted before setting commences and should not be subsequently disturbed. No water shall be mixed with the concrete after it has left the mixer. Method of placing should be such as to preclude segregation. Approved mechanical vibrator shall be used for compacting concrete, and concrete shall be vibrated. No concrete shall be placed until the place of deposit has been thoroughly inspected and approved by the HPCL Engineer / Consultant. All inserts and embedments shall be properly secured in position by tack welding or any other approved method and checked and forms properly oiled. No concrete shall be placed in the absence of the HPCL Engineer / Consultant. Concrete shall be placed on clean bed having the designed level. The bed shall be cleaned of all debris and other objectionable materials. Seepage water, if any, shall be controlled or diverted. Concrete shall not be dropped from a height of more than 1.5 m except through a chute, the design and type of which shall be subject to approval of the HPCL Engineer/ Consultant. The concrete shall be placed, spread and compacted by approved mechanical vibrator. Vibrators shall not be used for pushing concrete to adjoining areas. Utmost care shall be taken to avoid the displacement of reinforcements/embedded parts or movement of form work or damage to faces of the form work or transmission of any harmful vibration/ shocks to the concrete which has not yet hardened sufficiently. All members shall be concreted at such a rate that no cold joint is formed and fresh concrete is placed always against green concrete which is still plastic and workable. Should any unforeseen occurrence results in a stoppage of concreting for one hour or such other time as might allow the concrete, already placed, to begin to set before the next batches can be placed, the Contractor shall make at his own cost, suitable tongue, and groove construction joint, as approved by the HPCL Engineer/Consultant. Any additional reinforcement required as directed by the HPCL Engineer / Consultant shall also be provided by the Contractor at his own cost. Before placement of new batches of concrete over that construction joint, the surface




preparation according to this specification stipulated earlier, shall be done by the Contractor at his own cost.

Curing of Concrete by spraying water

Curing is done by spraying water by suitable means at approved time intervals. While spraying, it shall be ensured that the complete area is covered. Alternate wetting and over drying shall be avoided. Curing by spraying water shall be continued at least for 10 days after final setting.

Testing of Concrete General

The Contractor shall carry out entirely at his own cost, all sampling supplemented herein. The Contractor shall get the concrete cube tests done in accordance with the relevant latest IS Codes in approved Laboratory and submit to the HPCL Engineer/Consultant, the test results in triplicate within 3 days after completion of the test.

Frequency of Tests

Unless otherwise specified, for each grade of concrete, 2 sets of test cubes, each set consisting of three (3) twin specimens (i.e. total 6 nos.), shall be taken. The test cubes shall be taken in presence of the HPCL’s representative, who will also sign the record of testing in an agreed performa. The cost of testing of cubes shall be fully borne by the Contractor.

Formwork Shuttering for concrete The term “shuttering” shall include all centerings and formwork required to support the concrete during the process of laying, compacting and setting and all items such as planking, lagging, walling, moulds, covers, cross-bearers, struts, props, bracings etc., shall be covered by the term. Shuttering shall be strong and rigidly constructed so that there should not be any deformation under weight and pressure of wet concrete, construction loads, wind and/or other forces. It shall be constructed in such a manner that it can be easily removed afterwards. The shuttering shall have smooth and even surface and so constructed as to remain sufficiently rigid during the placing and compacting of concrete and shall be sufficiently tight to prevent loss of liquid from the concrete.




The following table gives the minimum period for removing formwork from various concrete members when normal portland cement is used, it being assumed that the work shall not be loaded for several days after the period given. All formwork shall be removed without shock or vibration to concrete. Minimum period for striking Shuttering or forms 1. Walls, columns, vertical sides of : 24 to 48 hours as may be

beams and sides of foundations decided by the HPCL Engineer Supports Formwork shall be so designed that the side of beams and slabs can be removed without disturbing soffit forms and their supports. Props and supports shall allow accurate adjustment of the formwork to line and level and be capable of being removed in an approved sequence without injury to the concrete. Provision shall be made for removal of formwork without disturbing props required for supporting hardening concrete. Reinforcement

Workmanship shall conform to IS: 2502-1963.

All reinforcement bars shall be high strength deformed steel bars conforming to IS 1786-1985.All reinforcement shall be free from loose mill scale, rust, oil, grease and paint. Reinforcement shall not be bent or straightened in a manner that will injure the materials and all bars shall be bent cold.

Reinforcement bars shall be placed and maintained accurately in position as shown in the drawings. The correct cover to the reinforcement shall be maintained by use of precast mortar blocks. Minimum cover to main reinforcement shall be as per relevant IS (456, 3370)

All intersections of longitudinal and transverse bars of stirrups and all laps shall be securely tied together with approved binding wire. The binding wire shall be so placed that it touches all the four corners of the intersection and the two ends shall be looped with pliers and the ends shall be turned into the body of the concrete.

Embedded Parts

All embedded parts shall be accurately set and rigidly fastened. SUPPLEMENTARY SPECIFICATIONS - CIVIL WORKS � The foundation should be located at min. 1.0m below the NGL.




� Mud mat below water retaining structures shall be in PCC 1:3:6, 100mm thick, and

for other foundations it shall be 1:4:8, 75mm thick. � All brickwork shall be carried out with brick having crushing strength not less than 75

kg/cm2. � All brick structures shall be provided with 12 mm thick plaster inside and 20 mm

thick outside in C.M. 1:4. Also the RCC portion of the building shall be plastered 12 mm thk where ever required.

� Brick work in foundation / super structure shall be in C.M. 1:5. � Half brick partition walls shall be constructed in C.M. 1:4 with 2 of 8mm

reinforcement at every 4th course. � Half brick masonry walls used as partition walls shall be directly rested on the ground

floor slab by locally thickening the floor slab. � Concrete grade for all RCC structures shall be M 25. � Minimum thickness of the structural members (slab, walls etc.) for water retaining

structures shall be 200 mm. However, for minor members like launder, baffles etc a thickness of 100 mm shall be provided.

� Floor slab of water retaining structures shall be minimum 200 mm thick and shall be

cast directly over lean concrete M 10. The base slab shall be designed for uplift pressure of ground water.

� Water proofing compound shall be added in M 25 / M 30 concrete mix. for water

retaining structures. However, structures shall be made water tight. � All concrete surface shall be exposed concrete and no plastering shall be done. It shall

be form finished. However, in case of any rough surface, the surface shall be smoothly finished.

� Floor on grade shall have following minimum specifications:

a. 230 mm thick rubble soling / sand filling. b. 50 mm thick PCC (M 7.5) above rubble soling / sand filling. c. 150 thick RCC slab in M 20 grade with one layer reinforcement of 8 � TMT

@ 300 c/c, both ways above PCC M 7.5.




TMT bars of Fe 415 grade from RINL / SAIL / TISCO conforming to IS 1786 - 1985 shall be used as reinforcement for concrete structures and piles.

� Minimum thickness of MS Chequered plate shall be 6 mm and grating shall be 25

mm. Structural steel plates and sections shall be of grade conforming to IS: 2062 and shall be given redoxide primer and painted with synthetic enamel paint.

� Liquid retaining structures shall be designed for their maximum liquid depth

including free board. � RCC underground sump shall be designed for the following conditions:

a. Sump is filled up to design liquid depth and no earth exists outside the sump. b. Sump is empty and outside earth pressure exists with water pressure outside. c. Sump is full up to the top of wall and relief due to outside earth exists.

� For design of underground liquid retaining structures, ground water table shall be

assumed at ground level. � For all underground tanks / sumps, outer walls shall be raised 300 mm above F.G.L. � At construction joints for water retaining structures, 230-mm wide GI water stop

fabricated from 22" gauge sheets, shall be provided. � Water proofing for RCC roof terraces shall be of India water proofing treatment. � The hydrotest for liquid-retaining structures shall be done in accordance with IS:

3370. However, the liquid depth for testing purpose shall be the design liquid depth excluding the free board.

� On walkway and opening, 32 mm dia. (NB medium) MS Tube, top rail and middle

rail in two rows with verticals at 2000 mm centres shall be provided. The RCC inlet sump,Treated effluent sump,Slop oil Tank should have Hand railing all around.

� 110 mm dia. PVC rain water pipes shall be used in buildings as per NBC, appropriate

for 4 kg/cm2 class. � Following architectural features shall be considered in MCC / Control room building

and dosing shed.

a) Floor finishes

i) Floor / skirting: 40 mm thick granolithic flooring with 100mm skirting.




ii) Internal wall / ceiling: Acrylic Emulsion over lime punning. iii) External wall: Exterior emulsion paint.

b) Doors / Windows: Aluminium frame with glazed shutter (sliding window). c) MCC / control room: RCC framed structure with RCC slab. d) All round Plinth protection (750mm wide) with shallow drain (150/200mm)

deep should be provided for the building. � (Site will be handed over after necessary filling in the area). Necessary grading /

micro - grading shall be carried out by the Bidder.




ETP SUPPLEMENTARY SPECIFICATIONS � 4m3 capacity sump for the purpose of collecting treated effluent with a pump of

15m3/hr capacity at 15mWC for TALEGAON is to be included in the scope of work/supply.

� The filters are to be backwashed by reversing the direction of flow through the filter. � Air compressor to be included in the scope of work/supply. � One slop oil (recovery) pump of 5m3/hr capacity is required. However suitable head

of the pump shall be fixed based on the distance between the ETP and slop tanks, given below for various terminals.

� All interconnecting piping within the battery limit is in the Bidder’s scope of

work/supply (upto the discharge flange of treated effluent pump). � The OWS network piping will be 1.2m below the ground at the inlet of ETP at

Talegaon Depot.

� Lifting arrangement for TPI is to be provided (like a beam with a hook over the receiving tank).

� The collected Oil will have to be pumped back into HSD Tank for which provision shall be kept in the Inlet header. The distance from the slop oil pump to the header can be assumed as 50m for the purpose of calculating the discharge head of the pump. The scope of ETP bidder shall be up to NRV installed on the discharge of the pump with a Gate valve and PG. The piping contractor shall extend the pipe from the NRV/Gate valve installed on discharge of Slop Oil pump up to the tank header pipe.

� Similarly, the ETP Bidder shall supply and install Treated Effluent Pump ( with motor, starter and other accessories) with Gate Valve, NRV and Pressure Gauge installed on the discharge side.




05. INSPECTION

The equipment shall be inspected by the Purchaser and / Third party inspection agency at manufacturer’s works prior to dispatch. The equipment will be inspected as per the tests pre-identified in the approved quality assurance plan (QAP) vetted by TPI, relevant approved drawings, specifications, data sheet etc. The Contractor shall finalise the QAP (enclosed) within two weeks after placement of order vetted by TPI and get the same approved from HPCL. The Purchaser and their Third party inspection agency shall have free access to the manufacturer’s works to carry out any stage inspection to ensure the quality of the equipment being manufactured. The Contractor shall give ‘Inspection call’ to the Purchaser and the inspecting agency with a clear notice of 10 days for inspection. The inspection call shall be accompanied by internal inspection / test reports by the manufacturer ensuring that the equipment has been manufactured and tested as per the requirement / approved QAP. In case of any subcontracting, only the main contractor shall give inspection call enclosing internal inspection report of subcontractor verified by the main contractor. The manufacturer shall furnish all relevant documents and test certificates as required by the inspection agency during inspection. Materials shall be tested only in recognised test houses. The Contractor / manufacturer shall provide all necessary assistance to the inspection agency during inspection. The Contractor shall provide all required measuring instruments to carry out the inspection. These instruments shall be calibrated by an agency of national / international recognition. The inspection agency shall have the right to demand re-testing of any material / re-calibration of instruments. The charges for such tests shall be to the account of the Contractor only. No equipment shall be dispatched without inspection and receipt of inspection certificate and dispatch clearance from the inspection agency.




In case of waiver category items, the same shall be pre-identified in QAP itself. For such items, the Contractor shall furnish necessary certificates as agreed upon. For these items also, the Contractor shall obtain inspection waiver certificate and dispatch clearance from the inspection agency before dispatch of equipment.

Issue of inspection certificate / waiver certificate for any equipment does not absolve the Contractor from his contractual obligations towards satisfactory performance of the equipment. Should any equipment be found defective in whole or part thereof after receipt at site or during erection / commissioning the same shall be made good by the contractor free of cost.




FORM No. 11.20(DQM) F-09 REV. 0

CONTRACTOR Reference QUALITY ASSURANCE PLAN FOR

STRUCTURAL & MECHANICAL EQUIPMENT

PROJECT

ORDER No. & DATE

SUB-CONTRACTOR PACKAGE No. ORDER No. & DATE PACKAGE NAME

INSTRUCTIONS FOR FILLING UP: CODES FOR EXTENT OF INSPECTION, TESTS, TEST CERTIFICATES & DOCUMENTS : 1. QAP shall be submitted for each of the equipment separately with break-up of assembly / sub-

assembly & part / component or for group of equipment having the same specification. 2. Use numerical codes as indicated for extent of inspection & tests and submission of test certificates &

documents. Additional codes & description for extent of inspection & tests may be added as applicable for the plant & equipment.

3. Separate identification number with quantity for equipment shall be indicated wherever equipment

having same specifications belonging to different facilities are grouped together. 4. Weight in tonnes (T) must be indicated under column 5 for each item. Estimated weights may be indicated wherever actual weights are not available.

Code Description

1. Visual (Welding etc. ) 2. Dimensional 3. Fitment & Alignment 4. Physical Test (sample) 5. Chemical Test (sample) 6. Ultrasonic Test 7. Magnetic Particle Test (MPI) 8. Radiography Test 9. Dye Penetration Test 10. Metallographic Exam 11. Welder’s Qualification & weld

procedure Test 12. Approval of Test and Repair

procedure 13. Heat Treatment 14. Pressure Test

Code Description

15. Leakage Test 16. Balancing test 17. Vibration Test 18. Amplitude Test 19. Sponge Test 20. Dust / Water Ingress Test 21. Friction Factor Test 22. Adhesion Test 23. Performance Test / Characteristic curve 24. No Load / Free running Test 25. Load / overload Test 26. Measurement of speeds 27. Acoustical Test 28. Geometrical Accuracy 29. Repeatability & Positioning Accuracy

Code Description 30. Proving Test 31. Surface preparation & Painting 32. Manufacturer’s Test Certificates for bought out items 33. IBR / Other Statutory agencies Compliance certificate 34. Internal Inspection Report by Contractor 35. Hardness Test 36. Spark Test for Lining 37. Calibration 38. Safety Device Test 39. Ease of Maintenance

D1. D2.

D3. D4.

D5. D6. D7.

D8.

D9.

DOCUMENTS

Approved GA drawings Information and other reference drg. / stamped drgs. Released for mfg. Relevant catalogues Bill of matl. / Item No. / Identification Match mark details Line / Layout diagram Approved Erection procedures Unpriced sub P. O. with specification and amendments, if any. Calibration Certificates of all measuring Instruments and gauges

ABBREVIATIONS USED : CONTR : CONTRACTOR TPI : THIRD PARTY INSPECTION AGENCY

E Q U I P M E N T D E T A I L S I N S P E C T I O N AND T E S T S Test Certificates &

documents to be submitted to HPCL

Acceptance Criteria Standards/IS/ BS/

ASME/ Norms and Documents

REMARKS/ SAMPLING

PLAN Sl. No.

Description (with equipment heading, place of use & brief specifications)

Identification No.

Quantity Manufacturer’s Name & address

Expected Schedule of Final Inspection

Raw Material and inprocess stage inspection Final Inspection / Test by

No./M T CONTR. TPI HPCL CONTR. TPI HPCL

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16




For HPCL(Stamp & Signature) For CONTRACTOR / SUB-CONTRACTOR (Stamp & Signature)

No. REV.

SHEET OF


E Q U I P M E N T D E T A I L S INSPECTION AND TESTS Test Certificates &




REMARKS/ SAMPLING

PLAN Sl. No.


Identification No.





1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16




For HPCL(Stamp & Signature)

For CONTRACTOR / SUB-CONTRACTOR (Stamp & Signature)

(QAP No.

No. REV.

SHEET OF





CONTRACTOR Reference QUALITY ASSURANCE

PLAN FOR

ELECTRICAL EQUIPMENT

PROJECT

ORDER No. & DATE

SUB-CONTRACTOR PACKAGE No.

ORDER No. & DATE PACKAGE NAME

INSTRUCTIONS FOR FILLING UP: CODES FOR EXTENT OF INSPECTION, TESTS, TEST CERTIFICATES & DOCUMENTS : 5. QAP shall be submitted for each of the equipment separately with break-up of assembly / sub-

assembly & part / component or for group of equipment having the same specification. 6. Use numerical codes as indicated for extent of inspection & tests and submission of test

certificates & documents. Additional codes & description for extent of inspection & tests may be added as applicable for the plant & equipment.

7. Separate identification number with quantity for equipment shall be indicated wherever

equipment having same specifications belonging to different facilities are grouped together. 8. Weight in tonnes (T) must be indicated under column 5 for each item. Estimated weights may be indicated wherever actual weights are not available.

Code

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11.

Description

Visual Dimensional Fitment & Alignment Physical Test (sample) Chemical Test (sample) Ultrasonic Test Magnetic Particle Test (MPI) Radiography Test Dye Penetration Test Measurement of IR value : a) Before HV Test b) After HV Test High Voltage test / Dielectric test

Code

12.

13.

14. 15. 16. 17. 18. 19. 20.

21. 22.

Description

Routine test as per relevant IS / other standard Type tests as per relevant IS / other standard Impulse Test Partial Discharge Test Heat run test / temp. Rise Test Enclosure protection Test Calibration Noise & Vibration Test certificates for bought out components Tank pressure Test Paint shade verification

Code

23. 24.

25. 26. 27.

28.

Description

Short time rating Operational & functional check Over speed Test Flame proof Test Clearance & creepage distance Internal Inspection report

D1. D2.

D3.

D4. D5. D6.

DOCUMENTS

Approved GA drawings Approved single line / schematic diagram Catalogues / Approved data sheet Approved bill of materials Unpriced P.O. copy Calibration Certificates of all measuring instruments and gauges

ABBREVIATIONS USED : CONTR : CONTRACTOR MFR : MANUFACTURER

E Q U I P M E N T D E T A I L S I N S P E C T I O N AND T E S T S Test Certificates &




REMARKS/ SAMPLING

PLAN Sl. No.


Identification No.





1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16




For HPCL (Stamp & Signature)


(QAP No. TO BE ALLOTED BY HPCL)

No. REV.

SHEET OF


E Q U I P M E N T D E T A I L S INSPECTION AND TESTS Test Certificates &




REMARKS/ SAMPLING

PLAN Sl. No.


Identification No.





1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16




For HPCL (Stamp & Signature)


FOR TPI




06. SUPPLY AND ERECTION 06.01 General

The erection of all plants and equipment shall be carried out according to the latest

engineering practices and according to the working drawings, specifications, instructions etc. duly approved by the Owner. The Contractor shall carry out the works in the presence and / or as per the instructions of site engineers/ supervisory personnel deputed by the Owner. The erection shall be carried out by highly skilled workmen.

The Contractor shall take care of the equipment as well as supporting structures

within the required accuracy and tolerance limits. It shall be deemed as a contractual obligation that the pipes are not thrown out of alignment or lifted off during commissioning and subsequent operation.

There may be more than one contractor working in the area at the same time. As such

the work has to be carried out in proper co-ordination and consultation with the M/s HPCL and all other parties concerned with the work. The Contractor shall take due notice of the working conditions, practices and agreements prevalent in the area of the plant site and satisfy himself before quoting.

The Contractor shall be responsible for paying strict attention to statutory regulations

for prevention of accidents and to other safety rules. The regulations for prevention of accidents shall be displayed at appropriate places and should be distinctly visible to all personnel working in the area.

The Contractor shall supply all required consumables, construction and erection

materials, petrol, diesel oil, kerosene, lube oil, solvents, sealing compounds, tapes, brazing and soldering materials, welding sets, pipe bending machines, cables, clamping tools, gauges, erection bolts, nuts and packing sheets/compounds, temporary supports, wooden blocks, spacers, templates, jute and cotton wastes, sand and emery paper etc. as required for satisfactory completion of work.

The Contractor shall make his own arrangement for handling the equipment and pipes

at the stores and transporting it to the site of installation. In addition to the above, the Contractor shall follow all the relevant erection clauses /

conditions stated under various chapters of this specification.




06.02 Pump sets The pump base frame shall be erected on prepared foundation and levelled with shims

and wedges with the help of precision levels and other instruments. After levelling, grouting of foundation bolts shall be completed. When tightening the foundation bolts the base plate levels should not get affected. Final level achieved should be of the order of 0.05 mm per meter.

The pump and driver shall be placed on their respective machined pads ensuring that

the their feet make full contact. Normally a 0.002 inch feeler strip should not pass between the feet and the pad when the pump and motor are freely placed.

The coupling if not supplied fitted with the pump and drive unit, should be carefully

fitted with a pusher or by means of heating in an oil bath of approximately 180 deg F. The coupling shall never be hammered onto the shaft as this may cause serious damage to bearings and mechanical seals. Run-out on a coupling after fitment should be between 0.05 mm and 0.1 mm TIR. Before proceeding with any alignment the pump and driver bearings should be thoroughly cleaned and flushed with recommended grade of lubricant and the individual units should be checked for freeness of rotation. The coupling shall be aligned radially and angularly using two dial gauges.

Connection of suction and delivery pipes shall be made in such a manner that the

connection to the pump flanges does not develop any undue stress and the weight of the pipes is not transmitted to the pump.

After completion of the pipe work, the pumpset shall be grouted upto the flanges of

the base frame. Grouting should be filled from inside the base frame and all cavities filled up. After the grout has set, the alignment should be re-checked and compared with the values recorded prior to grouting.

During manual rotation, it shall be ensured that the shaft assembly moves freely and

no noise develops from bearings. Before coupling the driver to the pump it shall be ensured that the direction of

rotation of the motor corresponds to that of the pump indicated by the manufacturer/supplier.




06.03 Valves

Before erection of valves, it shall be ensured that: - i. All grit and foreign matter are removed from the inside of the valves before

connecting the pipes. ii. All the faces are thoroughly cleaned and coated with a thin layer of mineral grease. iii. It shall be ensured that adequate support is provided for the pipeline and valve. The

valve should never carry the weight of the pipeline. Hangers or supports placed near the valve will provide better supports.

iv. The connecting pipeline should be cleaned and flushed of sediments, sand and other

foreign matter before installing the valves. v. Unless it is operationally critical butterfly valves shall be mounted with the shaft

horizontal and as per the direction of flow indicated on the valve. vi. The valves should be tightly closed when being installed, to prevent any foreign

matter from getting in between the working parts of valves. vii. The gasket shall be lubricated with graphite or other recommended lubricant. viii. It shall be ensured that the joining material sits squarely between the flanges of valves

and pipelines without obstructing the waterway. ix. Valves and other appurtenances shall be so located that they are easily accessible for

operations repairs and maintenance.




06.04 Piping

Laying and joining of pipe lines.

i. The Bidder shall supply/fabricate and install pipes and fittings in strict compliance with the detailed engineering drawings. Deviations if considered necessary to suit site conditions could however, be permitted in consultation with and with prior approval of the M/s HPCL.

ii. All openings in the piping shall be kept effectively closed until assembled in the

system to avoid foreign matter entering into the system. iii. All piping shall follow the general arrangement shown, shall be cut accurately to

measurements established for the work by the Bidder and shall be installed without springing.

iv. All piping shall be installed with adequate clearance for lighting, bracing, doors,

windows and other openings. v. Piping shall be arranged in the straightest possible runs with minimum amount of

fittings. Flanges of the pipelines, fittings, etc., must be so mounted that top bolt holes are symmetrical about the vertical axis of the flange.

vi. Openings provided in the walls for pipelines must be closed with bricks or mortar

with 10 to 20 mm clearance between the brick work and pipe. The clear space must be stuffed with felt or asbestos.

vii. The Contractor shall supply/fabricate and install pipe supports and all that is

necessary to completely support all the piping and piping components including but not limited to beam clamps, pipe clamps, fabricated structural supports, guides and anchors, brackets, saddles, U-bolts, etc. Only approved type of anchor fasteners shall be used for RCC ceiling and walls. Also supporting members required in addition to building structure shall be furnished and installed. Concrete pedestals for supporting the pipes as well as valves are also included in the Bidder's scope of work.

viii. Screwed joints. Pipe sealant shall be used to makeup screwed joints and shall be applied to male threads only. Threaded parts shall be wiped clean of oil or grease using appropriate solvent if necessary and allowing proper time for drying before applying the sealant. Pipe shall be free from fins and burs. Pipe ends shall be reamed or filled out to size of bore and all chips shall be removed.




Mating surfaces shall be coated with white lead. All the joints shall be checked for water tightness. ix. Flanged joints Flanged joint shall be used for connections to vessels, equipment, flanged valves, road crossings and also on suitable straight lengths of pipelines of strategic points to facilitate erection and subsequent maintenance work. x. All above ground piping shall be laid on RCC sleepers excepting below roads where

pipe lines would be underground and laid through RCC hume pipes. Guides have to be provided on every third sleepers. The Contractor shall provide anchor supports / expansion loops wherever necessary.

xi. Underground piping Excavation for pipelines shall be in open trenches to lines and grades shown on the detailed engineering drawings. Excavation of trenches shall be carried out as per the procedure explained under Clause 03.18 (Civil works). Pipelines shall be buried to a minimum depth of 700mm (from top of the pipe). Wherever required, the contractor shall support all trenches of adjoining structures with adequate timber supports. At road crossing the pipes shall be laid in the encasing pipes. RCC NP3 class pipe shall be used as the encasing pipe. The encasing pipe shall project beyond the berm on both sides of the road. xii. On completion of testing and painting of pipelines, trenches shall be refilled as per

the procedure explained under Clause 03.18 (Civil works).




07. SITE TESTING AND PAINTING 07.01 General

After erection at site the plant and equipment shall be subjected to tests to prove satisfactory performance as individual equipment and also as a system on the whole. The Bidder shall include and conduct field tests for all pumps, and piping systems. These tests shall be made after installation is completed and before the systems are placed in service. Field tests covered by ISI and Governmental and local codes shall govern in so far as they exceed corresponding requirements of this specification or cover omissions therein. All tests shall be performed as specified in the presence of M/s HPCL and must be accepted by him. The successful Bidder shall conduct a preliminary test and repair or correct all faulty work before calling M/s HPCL to observe the test for acceptance of the systems. In all cases of tests, the successful Bidder shall provide free of charge, labour, materials, tools, consumables, fuel, stores, apparatus and instruments as may be necessary to carry out such tests efficiently.

07.02 Pipelines Erected pipelines together with fittings shall be tested by hydraulic pressure. The value of test pressure shall be equal to 1.5 times the working pressure. Pipelines to be painted shall be subjected to hydraulic test before painting. Equipment shall be disconnected before the test. Combined tests of equipment with the pipeline is not allowed. Air vents shall be provided at all high points of the piping where the test shall be conducted in order to purge air pockets while the piping system is being filled up. Hydraulic test pressure shall be maintained for a duration which shall be mutually decided upon. At this pressure the pipelines shall be inspected and all welded joints shall be tapped by a 1.5 kg hand hammer. Hydraulic test will be considered satisfactory if during the tests, manometric pressure does not decrease and no leakage or mist is found in the joints, fittings etc. Defective spots found in the joints must be rectified. The joint shall be dismantled and fresh jointing is to be done.




After eliminating all defects, hydraulic tests shall be repeated. Portions in which the same defects are found during repeated tests, must be rejected and replaced by new ones and tested again. The successful Bidder shall arrange at his own expenses all equipment, material, instruments and consumables to conduct the various site tests to demonstrate specified performance of all plant and equipment offered by the Bidder. Representatives of M/s HPCL and the successful Bidder shall make a statement regarding the acceptance of the erected pipelines mentioning defects found during the tests, characteristics of the defects and the method of their elimination.

07.03 Painting I. For Talegaon Depot: Surface preparation: St – 3 according to Swedish Std. SIS 055900. 1. Primer : Two coats of red oxide zinc phosphate primer 30 to 35

microns DFT each. 2. Finish : Two coats of synthetic enamel 30 to 35 microns DFT each. Minimum thickness - 120 microns DFT




08. COMMISSIONING AND PERFORMANCE GUARANTEE 08.01 Commissioning

Testing and commissioning of the plant as well as all the accessories including obtaining approval from the respective state pollution control boards shall be completed within one month from the date of intimation of readiness of the plant by M/s HPCL for successful commissioning. Before preparation for commissioning all the equipment and pipelines shall be certified by the Purchaser for commissioning. The site shall be thoroughly cleaned. All sorts of foreign materials such as welding rod ends, welding beads, metal chips etc., shall be removed by the Contractor from the site before commencement of commissioning. Before commissioning all the pipelines shall be blown with compressed air until the air discharged is free from dust particles etc. The Contractor shall supply all lubricants, oil and other consumables required for commissioning of the system. Commissioning of the various equipment and system shall be carried out by the Contractor as per the accepted procedure and as per the instructions of the supplier of these equipment. On completion of the installation but before energisation of the electrical system, all installations shall be physically checked and properly tested. The Contractor under the supervision of the Purchaser shall conduct these checks and tests. Any defect observed during such checks and tests shall be made good by the contractor before commencement of commissioning.

08.02 Performance Guarantee

The performance and guarantee test shall be conducted in accordance with the conditions specified and as per relevant codes / standards. The parameters guaranteed by the Bidder shall have no tolerance values, except as permitted by Standards / codes. Other testing requirements of individual equipment / item as specified elsewhere in this tender document shall also be complied with. Guarantee certificate is to be submitted from the manufacturer with a Guarantee cover for 12 months from date of commissioning.




09. DOCUMENTS TO BE FURNISHED 09.01 Drawings, Data & Information to be furnished alongwith the Offer

The following drawings / data/ information shall be submitted by the Bidder alongwith his technical offer. In the absence of the minimum drawings / data / information as given below the bid is liable to be rejected.

i) P & I / flow diagram, showing the complete system indicating all field and

panel mounted instruments.

ii) Preliminary layout drawings for the complete scope of work

a) Dimensional General Arrangement Drawing of each equipment b) Quality Assurance Plan and Inspection & Test Matrix c) Data sheets for all instruments and equipment d) Write-up on operation & control philosophy for various systems. e) Leaflets and catalogues etc. covering equipment/ instrument features. f) Information, instruction drawings and all other related data regarding erection

and commissioning of the supplied plant. g) Project schedule with detailed bar chart.

09.02 Drawings,Data & Information to be furnished after award of the Contract

a) The following document/information shall be furnished by the contractor after

award of the contract for Purchaser’s/Owner’s approval/information/record.

b) P & ID/Flow diagram, showing the complete system with associated controls.

c) Detailed equipment layout drawings.

d) Detail design and data for equipment

e) Detailed specification for all procurement items

f) Specification and data sheets for instrumentation items.




g) Loop diagrams.

h) Quality Assurance Plan vetted by Third party.

i) Performance test curves and test certificates for all equipment as per the requirement of technical specifications.

j) Any other data / curve deemed necessary by Purchaser / Consultant.

k) Write-up on specific features of equipment, if any.

l) Instruction manuals for maintenance, overhaul and replacement of parts of

various equipment.

m) Replacement parts list with ordering information.

n) Final Quality Assurance Plan and Inspection & Test Matrix.

o) Leaflets and catalogues etc. covering equipment features.

p) Detailed project schedule for the Contractor’s complete scope of work.

q) Painting specification for all equipment / piping

Electrics The Contractor shall submit General Arrangement Drawings indicating Bill of Material

(rating, makes and quantities of components) Outline dimensions etc., Single Line diagram, control schematic and Power and Control Cable Schedules for the system for approval by Owner/Consultant.

Instrumentation

Process and instrumentation (P & I) diagrams indicating all field and panel mounted instruments using ISA symbols and using suitable tag numbers against each instrumentation equipment. Alarm and interlock functions shall also be indicated in the P & I diagram.

Specification of each instrumentation equipment indicating model no., application, scale range, quantity, tag no, (as per P & I diagram), accuracy, power consumption etc shall be submitted. Data sheets for each instrument as per standard format shall also be submitted with all the required details filled in along with detailed technical literature.




For procedural checking and records.

Hook - up and installation diagrams. Safety interlock scheme. Loop schematic diagrams. Instrumentation layout drawing showing location of sensors, switches etc. and route of cables from these up to the pump panel in the pump house. Cable and pipe schedules. Manufacturer’s test, calibration and guarantee certificates for all the instruments. Operation and maintenance manuals for each instrument. Quality assurance plan for each instrument. The quantity of drawings listed above and to be submitted by the successful Bidder shall be as per the general conditions of contract (GCC)

List of commissioning spares shall also be submitted alongwith the offer.

Instruction Books and Operation Manual for all the equipment The operation and maintenance manuals shall form a pre-requisite for the issue of provisional acceptance certificate for the respective contract.




10. Questionnaire (Details to be furnished by Bidder) I. TECHNICAL PARAMETERS:-

A. PUMP

i.Type : ii.Total head : iii.Capacity :

B. ELECTRICAL MOTOR FOR PUMP

i.Operating Voltage : ii.Insulation class : iii.Type : iv.Rating kW, : v.RPM :

II. MATERIAL OF CONSTRUCTION (MOC)

A. PARALLEL PLATE SEPERATOR

i. Separator : ii. Frame work :

B. ELECTRO PNEUMATICALLY OPERATED VALVES

i. Valve body and working parts : ii. Sealing ring :

C. PUMPS (a) Casing : (b) Impeller : (c) Shaft seal : (d) Shaft : (e) Wearing rings : (f) Gland packing : D. BELT SKIMMER Please indicate MOC of various parts / components




E. MULTI / DUAL MEDIA PRESSURE FILTER Please indicate MOC of various parts / components F. COALESCING FILTER Please indicate MOC of various parts / components.




11. TENDER DRAWINGS

SL. NO. DESCRIPTION

1. SCHEME (FLOW DIAGRAM) FOR TREATMENT OF OILY WATER

HINDUSTAN PETROLEUM CORPORATION LIMITED -...

Documents

Transcript of HINDUSTAN PETROLEUM CORPORATION LIMITED -...