MATERIAL REQUISITION FOR PROPYLENE...

VISAKH MARKETING INSTALLATION RESITEMENT

PROJECT - LPG TERMINAL

Doc No: 256324-500-RQ-MEC-006 Rev: B of 26

P:\Andheri\IndiaProject\256324 HPCL- LPG\10 Procurement\TENDER\16 Piping Works Tender\Final\Annexures- Piping Tender\Annexure- 3\MDS,Specs-Mech\Editable\Tech. Spec.for Propylene Compressor.doc

MATERIAL REQUISITION

FOR

PROPYLENE COMPRESSOR

Hindustan Petroleum Corporation Ltd

Visakha Dispatch Station

VR-ATP Area, Naval Base Post

Visakhapatnam - 530 014

Andhra Pradesh

Mott MacDonald Consultants (India) Pvt. Ltd.

Kothari House, CTS No. 185

Off Andheri - Kurla Road

Andheri (East)

Mumbai 400 059





MATERIAL REQUISITION

FOR

PROPYLENE COMPRESSOR

Client HINDUSTAN PETROLEUM CORPORATION LTD.

MMCI Project No. 256324

Issue and Revision Record:

Rev Date Originator Checked Approved Description

A 02/06/09 SVJ SPW PJC Issued for Comments

B 06/08/09 SVJ SPW PJC Issued for Comments – LPG Compressor replaced with LPG Cylinder Evacuation Compressor.

Group Disclaimer

"This document has been prepared for the titled project or named part thereof and should not be relied upon or

used for any other project without an independent check being carried out as to its suitability and prior written

authority of Mott MacDonald being obtained. Mott MacDonald accepts no responsibility or liability for the

consequences of this document being used for a purpose other than the purposes for which it was commissioned.

Any person using or relying on the document for such other purpose agrees, and will by such use or reliance be

taken to confirm his agreement, to indemnify Mott MacDonald for all loss or damage resulting there from. Mott

MacDonald accepts no responsibility or liability for this document to any party other than the person by whom it

was commissioned.”





List of Content Page No

1 Introduction 5

2 Location and Environmental Conditions 6

3 Scope of Supply 6

3.1 Equipment and Materials 6

3.2 Extra for Non Lubricated Construction 7

3.3 Bottles, Accessories, Piping 7

3.4 Instrumentation 7

3.5 Local Control Panel 8

3.6 Motor 8

3.7 Engineering Services 8

3.8 Exclusions 9

4 Applicable Codes, Specifications and Standards 9

4.1 General 9

4.2 Codes and Standards 9

4.3 Other Specifications and Standards 10

5 Design Requirements 10

5.1 Mechanical Requirements 10

5.2 Instrumentation Requirements 10

5.3 Electrical Requirements 11

5.4 Piping Requirements 11

6 Quality Assurance 11

7 Inspection and Testing 11

7.1 Factory Inspection & Testing 11

7.2 Scope of Inspection & Certificates 13

7.3 Vendor Requirements 13

7.4 Performance Testing and Guarantee: 13

7.5 Works Inspection and Notification 14

8 Vendor Documentation 14

8.1 Documents/Information to be supplied with offer 14

8.2 Documents/Information to be supplied After Award of Contract 15

9 Manufacturing Schedule 15





10 Spares and Special Tools 15

10.1 Spares 15

10.2 Special Tools 15

11 Packing and Shipping 15

12 Installation and Commissioning 16

Appendix A: Attachments 17

Appendix B: Requisition of Engineering Documents (Red Form) 18

Appendix C: Table of Compliance 20

Appendix D: Instrumentation Design Requirements 21





1 Introduction

1.1 This specification covers the minimum requirements for the design, engineering, material

procurement, fabrication, painting, assembly, Inspection, supply and shipment of Propylene

Compressor for “Resitement of Integrated Marketing Facility at Vishakhapatnam - LPG

Terminal.

The List of Compressors is as follows:

Sr.

No. Tag No. Quantity Description

1 500C-002 01 no. Propylene Compressor

1.2 The Vendor shall be responsible for the design, engineering, fabrication, assembly, inspection,

co-ordination, testing, delivery and proper functioning of the Compressors.

1.3 The Vendor shall ensure that the design complies with the requirements of this requisition and

its referenced specifications and standards. The data sheets, which form part of this

specification, shall be completed by the Vendor. The Vendor shall highlight any non-

compliance at the offer stage in the Table of Compliance, Appendix C. The Table of

Compliance and filled in data sheets shall form a part of the offer. Not providing completed

compliance table and data sheets can cause rejection of the offer. Failure to clearly identify

specific deviations shall be assumed by the Purchaser to be total compliance with the

requisition.

Only those deviations that are specifically agreed to, by the Purchaser prior to award of the

order will be incorporated into the purchase order. Deviations to the specification will not be

allowed after award of order. Unless referred to in the Table of Compliance (Appendix C), it

will be assumed that all specifications are adhered to and that they do not have implications

with respect to cost, delivery and integrity of the equipment.

1.4 The Vendor shall procure third party material from vendors listed in the approved Vendor List

only, unless the particular type of material is not covered by the list, and a special dispensation

to deviate from the list has been granted in writing by the Purchaser. Company will reject any

materials found at any stage to be out of the approved VENDOR or sub Vendor list.

1.5 Note that “lead times” will not be considered by the COMPANY as a justifiable reason for

using alternate VENDOR.

1.6 This requisition shall in no way relieve the Vendor from final guarantee as to materials,

apparatus, workmanship and performance of the equipment and services supplied.

1.7 All correspondence and documentation shall be in English. All measurements and units shall

be in SI units.

Where necessary for a specific application, alternative units may be indicated in brackets

behind the SI units.

1.8 The VENDOR shall guarantee the equipment and all component parts against defective

workmanship and improper materials for the agreed period following the date of delivery of

the equipment or from commencement of operation as agreed. The VENDOR shall replace or

repair (the carrying out of all work including uncovering, removal, procurement and

reinstallation and construction as may be necessary) the components that are defective at their





own cost during the guarantee period at a suitable time to the COMPANY. Guarantee period

shall be as per the Contract and to be covered in commercial documentation.

2 Location and Environmental Conditions

For local conditions refer Document no. 256324-500-SP-GEN-001.

3 Scope of Supply

3.1 Equipment and Materials

Scope of supply of each Compressor shall include but not necessarily be limited to following

and mechanical datasheets.

The unit shall be supplied complete in itself including all auxiliaries and accessories required

for normal and safe operation of unit. Major items of supply are listed below.

Vendor shall, however, include any other item that may not be specifically listed but is

considered necessary for the operation of the unit and furnish particulars of the same in bid.

Scope of supply shall include but not be limited to the following:

A) Propylene Compressor (Tag No.500C-002)

Single stage, Air-cooled, Non-Lubricated, Cross-head type, Reciprocating Propylene

Compressor complete with standard equipment including the following (Model No. D291

AM3FDENSNN of CORKEN or Equivalent is preferred).

• Gas ends engineered for LPG Service, Heat resistant paint on cylinder heads and in gas

passages to prevent rust.

• Gas cushioned A-type channel valves.

• Self venting packing case

• Two compartment distance piece: Type ‘D’ as per API -618,5th Edition, 2007.

• Suction Filter with silencer

• Knock Out drum with drain valves

• Full floating Aluminium Alloy bearings.

• Full floating, self adjusting, double acting, carbon filled Teflon cylinder & partition

packing rings.

• Instruments and skid mounted automation panel.

• V belt drive, motor pulley, anti-static V belts.

• Completely enclosed non-sparking V belt guard

• Foundation bolts fixing bolts, jack screw bolts, shims for compressor and motor

• Slide rails for motor.

• Electric motors, Local Control Panel.

• Cabling and Cable termination within skid.

• Base plate with Lifting & Earthing lugs

• Commissioning & Start-up Spares. (for more details refer section 11.1)

• List of Spares for two years trouble free operation (for more details refer section 11.1)

• Inspection and testing as specified in clause 8 of this specification.

• Submission of documents as specified in this document (Appendix B).

• Painting, preservation, preparation for shipment and delivery at site.

• Special tools if required (Bidder to provide list in the bid).

• Supervision of Installation & Commissioning (Separate visit for Installation &

commissioning shall be considered).





3.2 Extra for Non Lubricated Construction

� Teflon non-lubricating wearing and piston rings.

� Teflon full floating piston rod packing.

� Specially honed cylinders.

� Special wiper rings in partition plate stuffing box.

� Heat resistant paint of cylinder heads and in gas passages to prevent rust.

� Oil baffle collar on piston rod.

3.3 Bottles, Accessories, Piping

� Suction Liquid Separator cum Pulsation Dampner with SS demister as per ASME

Section- VIII Div. 1 with manual drain valve.

� Discharge Pulsation Dampner as per ASME Section VIII Div. 1 with manual

drain valve.

� 1 No. Swing check type Non-return valve on the gas discharge side.

� 1 No. Safety relief valve full flow type on gas discharge.

� Gas piping (MOC - Carbon steel for LPG and LTCS for Propylene) between suction

separator discharge flange and cylinder suction flange.

� 140 micron inline strainer with spool piece on gas inlet.

3.4 Instrumentation

All instruments shall be Flameproof, suitable for Zone 2 gas Group IIA / IIB.

� Dial pressure gauges SS Bourdon type with 1/2” NPT connection. Isolation valves

shall be double block and bleed type and flanged, one each to be located at -

• Gas suction

• Gas discharge

• Lube oil header

� Bimetallic Temperature gauges with 2” flanged thermowell in SS 304 bar stock.

Thermo wells, one each to be located at gas suction and discharge.

� Low oil pressure shutdown transmitter with flanged isolation valve (double block &

bleed type).

� Low suction pressure shutdown transmitter with flanged isolation valve (double block

& bleed type).

� High discharge pressure shutdown transmitter with flanged isolation valve (double

block & bleed type).

� Temperature transmitter on the compressor body.

� Pressure transmitter for Low cooling water pressure for Propylene Compressor.

� Liquid level indicator on suction separator.

� Flameproof (IIA/IIB) Solenoid valves for 0-50-100% for capacity control (Flanged

Type).

� 4 way two position pneumatic valve with Solenoid valves, Position Switch, tubing,

etc.

� Level Transmitter, Pressure Indicator and Level indicator on KO Drum.

� Cabling (to be supplied in free lengths) for field mounted Instruments 30m maximum

per instrument.

� Flameproof Junction Box, as required.

Notes: 1) All instruments / piping / cabling to be supplied loose, in free lengths from vendor’s

works.





2) One Digital Input shall be given by Purchaser per each unit for Emergency Trip

interlock of Compressor. Vendor to provide space for termination and cable entry

into the local panel supplied along the package.

3.5 Local Control Panel

� Relay based, Flameproof with solid state alarm annunciation Panel along with Local

Control Panel suitable for use in Zone 2 Gas Group IIA/IIB Area as per IS 2148.

� The panel shall have all necessary standard features viz.

• Motor on/off push buttons

• Test/acknowledge/reset push buttons

• Timer to bypass low lube oil pressure switch during start up

• Manual Selector switch for 0-50-100% Capacity control

• Starting interlock for Auto unloaded starting.

Fault Annunciation Table for Local Control Panel:

Sr. Fault Description Simultaneous

No. Alarm & Trip

1. Low lube oil pressure X

2. Low gas suction pressure X

3. High gas discharge pressure X

4. High liquid level in suction

Separator X

5. Spare X

6. High & Low Level alarms from Evacuation

Vessels 500BOP-052 A/B X

Note: Vendor shall provide one number common fault alarm, compressor run status and position

of 2 nos., 4 way valves (unloading position & depressurizing position) in soft signal form or as

potential free contact, to be wired by others to Client control panel. This is required only for

Propylene Compressor.

3.6 Motor

� Squirrel Cage Induction Motor of suitable rating, 4-pole, flameproof ( suitable for Zone 2

Gas Group IIA / IIB )

3.7 Engineering Services

The Vendor shall provide engineering services, which shall include, but not necessarily be

limited to, the following:

• Providing/Coordinating detailed design of all equipment and components within the scope

of supply.

• Providing Static & Dynamic loads and anchoring plan for the design of Civil foundation

by others.





• Resolving engineering queries related to the equipment and components within the scope

of supply.

• Performing and coordinating all aspects of design.

• Providing progress reports etc.

• Providing expediting services for all sub-vendors.

• Providing quality assurance including all sub-vendors with respect to ISO 9000 or

equivalent.

• Supervision of Erection & Commissioning to be quoted separately.

• Any technical document required for statutory approval shall be furnished by vendor.

3.8 Exclusions

The following are excluded from the Vendor's scope and will be provided by others:

• Equipment foundations, however design shall be based on Vendor supplied foundation

load data.

• Process piping up to Compressor suction and discharge connections.

• Interconnecting power cabling and cable trays between motor terminal boxes, and

Purchaser’s MCC.

• Interconnection of earthing bosses and underground earth conductor.

• Interconnecting cables for Trip Signal from and to Control room Panel and Local Control

Panel.

4 Applicable Codes, Specifications and Standards

4.1 General

The design, fabrication, assembly, inspection, testing, painting, packing and shipment of

equipment shall be in accordance with the latest edition of the codes, specifications and

standards (including standards / specifications mentioned therein) listed in this requisition.

The Vendor shall provide an itemized list of any comments or exceptions to the specification

and its attachments. Only those comments / exceptions that are accepted by Purchaser will be

incorporated into the requisition at the time of the order.

4.2 Codes and Standards

API 618, 5th Edition,Dec2007 Reciprocating Compressors for Petroleum, Petrochemical

and Natural Gas Industries.

API 520, Part 1, 8th Edition,

2008

Sizing and Selection

API 520, Part 1, 5th Edition,

2003

Installation

API 521, 4th Edition, 1997 Guide for Pressure-relieving and depressurising systems.

API 620, 11th Edition, 2008 Design & Construction of Large welded, low pressure

storage tanks.





ASME Sec. VIII Div. I, 2007 Rules for Construction of Pressure Vessels.

ASME Sec. II Part A, 2007 Ferrous Materials Specification.

ASME B 16.5 (2003) Pipe Flanges and Flanged Fittings.

ISO 9000 (2005) Quality Management and Quality Assurance Standards.

ISO 10474 (1991) Inspection Documents

4.3 Other Specifications and Standards

Appendix - D Specification for Instrumentation in Packaged items.

256324-500-SP-ELE-010

Rev. A

Specification for Electric Motors

256324-500-SP-GEN-001

Rev.A

Local Conditions

5 Design Requirements

5.1 Mechanical Requirements

5.1.1 Compressors shall be supplied as a complete package per the requirements of this

Specification, P & ID nos. 256324-500-PID-A0-1061 (1/1) and 256324-500-PID-A0-1062

(1/1), API618 5th Edition, Dec 2007 and Mechanical Datasheet (Doc. No. 256324-500-DS-

MEC-018).

5.1.2 The compressor shall conform to API 618, as far as possible. The compressor shall be motor

driven, water-cooled type reciprocating compressor. Alternatively Vendor can offer Air-

cooled type compressor.

5.1.3 The frame shall be completely enclosed and provided with gas tight distance piece between

the cylinder frame and the crankcase. The distance pieces shall have ample opening and

shall be provided with gas tight covers for easy access to packing. Metallic and Teflon oil

wiper rings shall be provided to percent oil leakage.

5.1.4 The piston and packings shall be of full floating design. The piston rings and packing

material shall be suitable for Propylene service and shall preferably be of PTFE or

equivalent material.

5.1.5 The cylinder shall be either provided with a liner or designed to provide upto 3 mm

maximum of re-boring without affecting the design pressure of the frame.

5.1.6 The drive unit such as V belt drive shall be of antistatic and non Sparking materials. All

moving parts such as V belts, couplings etc. wherever provided shall be protected by

suitable guards. The valves shall have ample effective areas permitting low gas velocities

across valve opening. The valve shall be renewable and made of hardened steel resistant to

abrasion and corrosion.

5.2 Instrumentation Requirements

All the Instruments shall be as per specification mentioned in Appendix D.

Vendor shall submit the Complete Instrument datasheets with relevant data filled along with

bids.





Vendor to note that Instrument air (Min. 4.5 kg/cm2 and Max. 7.5 kg/cm

2) is available at the

battery limit at one point.

5.3 Electrical Requirements

5.3.1 Motors shall be supplied as per attached Motor specification no. 256324-500-SP-ELE-010.

5.3.2 Vendor shall submit the Motor Datasheet with all the data filled by the Motor Manufacturer.

5.4 Piping Requirements

5.4.1 Vendor shall provide General arrangement drawing with co-ordinates for all Tie-ins.

Vendors shall clearly define the space requirement.

5.4.2 Flanged termination/ tie-in points shall be provided with companion flanges.

6 Quality Assurance

The Vendor shall maintain and use a Quality System which is based on ISO 9000 to control

the work. If the Vendor elects to sub-contract part of the work he shall ensure that only those

sub-contractors or suppliers are used who can demonstrate that they operate Quality Systems

based on ISO 9001 or ISO 9002 as applicable.

The Vendor shall give his sub-contractors or suppliers assistance in attaining the required

standard, if necessary. This shall not relieve the Vendor of his responsibility for the quality of

the finished work. The Company / Consultant reserve the right to audit the Vendor’s Quality

System.

The Vendor shall assign sufficient full time personnel to the project to ensure the Quality

Assurance / Quality Control System, documented in a Quality Assurance / Control Manual, is

maintained and kept up-to-date throughout the duration of any purchase order. The Vendor’s

Quality Assurance / Control System shall become an integral part of any purchase order.

Vendor shall organize a prefabrication / inspection meeting with the Company / Consultant.

Vendor shall submit QA plan for Purchaser’s and Consultants review and approval within 15

days weeks from the date of Purchase Order/LOI.

7 Inspection and Testing

7.1 Factory Inspection & Testing

Scope of Inspection:

• Approval of Quality assurance plan and Inspection test plan.

• Stage wise inspection as per approved quality assurance plan/ Inspection test plan.

• Review of material test certificates, Lab. Test reports, etc.

• Performance of the equipment.

• Review of CCOE / PESO and CMRI approval certificates for the FLP items.

• Review of manufacturer’s test certificates for the bought out items.

• Any other specific items as decided by the Consultant/ TPIA to meet the tender

requirements.

• Any other requirements as specified in the individual specifications.

The responsibility for inspection, certification, etc. of all materials, parts lies with the Vendor.

The Vendor shall specify all of the inspection and testing requirements in the quality assurance

plan/ Inspection test plan which shall identify the activities requiring the Company /

Consultant's / TPIA approval, review, witnessing etc.





Inspection and testing requirements shall be in accordance with API-618 5th edition, 2007 this

specification and the data sheets.

All equipment shall be inspected for compliance with:

• Requirements of the specifications, data sheets and correspondence thereafter.

• Applicable Codes, standards and specifications, which shall also include sub-referenced

standards therein.

• Quality assurance plan/ Inspection and test plans and Procedures produced by the Vendor,

duly approved by the Owner/ Consultant.

Purchaser’s/ Consultant’s Inspectors have the right to request additional inspections or tests to

ensure that the equipment complies with this specification and all relevant codes and

standards.

All equipment shall be presented for inspection in an unpainted state except for the final

inspection. All instruments and other equipment necessary for testing shall be supplied by the

Vendor and the same shall be checked and certified by the Company / Consultant’s inspector.

Any defects found by the Company / Consultant’s appointed Inspector shall be rectified in his

presence. Where this is not possible or practical, check lists shall be prepared and signed by

the Inspector stating all “pending items”. Copies of these lists shall be sent to the

Company/Purchaser to enable their subsequent checking.

Mill and shop inspection shall not relieve the Vendor from his contractual responsibility for

replacing any defective material and for repairing any defective workmanship that may be

discovered in the field.

The Vendor shall be responsible for co-ordinating the inspection and testing of sub-vendor

supplied equipment, and for ensuring that the Company / Consultant’s representatives are

given the necessary access for inspection, and adequate warning of inspection and tests.

The Vendor (and all sub-Vendors) shall give the Company/ Consultant’s representatives,

without charge, all reasonable facilities and access for the purpose of inspecting the equipment

to ensure that it is manufactured in accordance with the Specification.

All spare parts shall be subjected to the same inspection standards and full material

certification as the main order.

The equipment shall not leave the Vendor’s factory before all discovered defects have been

rectified and without the written permission of the Company/Consultant.

Materials for all pressure retaining components & wetted components shall be certified in

accordance with ISO 10474 - 3.1B and that for non-pressure retaining components like

structural components, platforms, ladders, shall be certified in accordance with ISO 10474 -

2.2.

Final hydro test pressure shall be held for a minimum period of 30 minutes. Chloride contents

of water used for hydro test shall not exceed 20 ppm for stainless steel and chloride content

may be permitted up to 250 ppm for carbon steel.





7.2 Scope of Inspection & Certificates

DESCRIPTION CERTIFICATE WITNESS

Compressor:

a. Material test certificate for

Piston rod, connection rod,

Crankshaft and cylinder Yes -

b. Hydro test for Cylinder Yes Yes

c. Ultrasonic / Dye Penetrant

test certificate for piston rod Yes -

d. No Load Mechanical Run Test

of compressor Yes Yes

Accessories:

a. FLP Motor - Routine test

certificate as per IS 2148 ; Yes -

PESO/CCOE /CMRS certificates

b. Volume Bottles:

- Hydro test at Vendor’s place Yes Yes

- Material Compliance

Certificate Yes -

- Radiography and Mill Test

Certificate Yes -

c. FLP Instruments:

CMRS Certificate Yes

7.3 Vendor Requirements

Any acceptance or release of equipment following an inspection or test activity shall in no way

relieve the Vendor of his responsibility to provide guarantees as to the suitability of the

materials, workmanship and performance of the equipment in accordance with this

Requisition.

7.4 Performance Testing and Guarantee:

• Compressors shall demonstrate sustained operation at conditions mentioned in the

datasheets.

• All equipment and component parts shall be guaranteed by vendor against defective

material, design and workmanship for a period of one year after being put in service.

• The vendor shall carry out the performance test run of the Equipments/ Machine at site

after satisfactory installation. Training of operators shall be given at site during

commissioning period without any extra cost to owner.

• The vendor shall be solely responsible for smooth and trouble free performance of the

equipment during the guarantee period .Vendor shall have to carry out any rectifications/

replacement at his own cost.





7.5 Works Inspection and Notification

The supplier shall send inspection notification at least 2 weeks in advance and shall send a

minimum of fifteen (15) working days notice prior to carrying out the Factory Acceptance Test

(FAT). The notification shall contain as a minimum the following information:

• Project Title, MMCI project number.

• Manufacturer’s full address, contact name, telex / telefax / telephone numbers.

• Purchase Order reference

• Date of inspection

• Details of equipment to be tested / inspected and the status of the equipment (whether it is

complete).

8 Vendor Documentation

8.1 Documents/Information to be supplied with offer

The Vendor shall provide the Consultant with the following information as a minimum along

with the offer. These documents shall include, but not be limited to the following:

a. The completed Table of Compliance (Appendix C).

b. Completed data sheets (Compressor & Motor), which are attached with this requisition,

with supplier data added.

c. Filled Instrument datasheets with calculations as applicable.

d. A detailed scope of supply that fully describes the equipments offered.

e. Performance curves. These curves shall include the specified duties and design conditions

as required on the enquiry data sheets.

f. Control Panel GA and details.

g. General arrangement drawings with dimensions and Load data for foundation design.

• For all equipment whether base plate mounted or not, the outline drawings shall

include approximate weights, overall dimensions, size, rating and approximate

locations of main nozzles, centerline height and shaft extension details, approximate

dismantling clearances and approximate handling weights. They shall also include

the tentaive location of main electrical connections.

h. P & IDs for complete system being offered with Tie-ins identified.

i. Cause and effect diagram for the package.

j. Cross-sectional drawings including main construction features, details of seals, bearings

and other mechanical details

k. Schematics or Flow Diagrams including reasonably accurate gas or fluid flows, lube, seal

oil and control oil, all instrumentation, valves, safety devices and control schemes.

l. Commissioning Spare parts list.

m. 2-Years operation spare part list.

n. Complete list of special tools required, if any.

o. All utility consumptions such as power requirement, utility requirement like Water, Air,

N2, etc. for each Compressor.

p. Experience list as per clause 5 of this requisition.





8.2 Documents/Information to be supplied After Award of Contract

Vendor shall provide Purchaser/Consultant with documents and drawings as described in the

'General Conditions of Contract'. However, document requirements as specified in the

'Requisition for Engineering Documents (RED)' attached with Appendix B shall be followed

as a minimum requirement.

9 Manufacturing Schedule

Within 2 weeks of the receipt of the Purchase Order/ LOI/ FOI the manufacturer shall submit

detail bar chart schedule showing the dates for the following milestone activities, as minimum:

i) Issue of vendor drawings.

a. Issue for comments/approval

b. Issue of final drawings

c. Issue of O&M Manuals

ii) Equipment available for Testing.

iii) Completion of packing and readiness for dispatch.

10 Spares and Special Tools

10.1 Spares

Bidder to quote separately for spares of Compressor in the following format:

• The supply of spares for start-up and commissioning

• Vendor to recommend two years operation spares and furnish separate price in the offer.

(This list, as a minimum, should include all Gaskets, Complete set of Bearings, Valve

internals, Piston Ring and Packing Ring sets including Instruments as per the quantity built

in one compressor unit.)

The Vendor shall also provide all consumables during erection up to commissioning and

reliability testing. In case of any additional spares if required during commissioning stage, the

same shall be supplied by Vendor free of cost.

The Vendor shall complete and submit SPIR forms 8 weeks after Vendor’s acceptance of the

Purchase Order. Spare parts for the normal operation shall be selected by the End User from

the electronic version of Spare Parts Lists and Interchange ability Record (SPIR).

10.2 Special Tools

The Vendor shall supply a set of any special tools, which are required for the installation,

commissioning, operation and maintenance of the equipment being supplied. A list of special

tools shall be supplied along with the offer.

11 Packing and Shipping

For Packaging, Shipping and delivery of equipment at site and unloading requirements,

'Agreed Conditions of Contract' shall be referred.





12 Installation and Commissioning

Vendor shall provide qualified personnel to supervise the installation, testing, pre-

commissioning and commissioning. Prices for these services shall be given separately.





Appendix A: Attachments

Equipment Data Sheets

Document No. Rev. Description

256324-500-DS-MEC-018 A Mechanical Datasheet for Propylene

Compressor

Other Documents

Document No. Rev. Description

256324-500-PID-A0-1061(1/1) B P & I Diagrams for LPG/Propylene Sick Tank

/ Wagon Unloading Compressor

256324-500-PID-A0-1062(1/1) B P & I Diagrams for LPG Sick Cylinder

Evacuation Facility and Purging Unit.

256324-500-PIP-A0-3000 D Plot Plan

- -

Electric Motor Datasheet (Part of

Specification for Electric Motors – 256324-

500-SP-ELE-010)

- - Differential Pressure Transmitter (Level)

(Blank Datasheet Format)

- - Pressure Gauge (Blank Datasheet Format)

- - Pressure Transmitter (Blank Datasheet

Format)

- - Temperature Transmitter (Blank Datasheet

Format) - - Pressure Safety Valve (Blank Datasheet

Format)





Appendix B: Requisition of Engineering Documents (Red Form)

Owner/Purchaser’s Office Consultant’s Office

HINDUSTAN PETROLEUM CORPORATION LTD. Krishna Shree, 2nd Floor, Gandhi Nagar, 1st Main Road-Adyar,

Chennai – 600 020

Mott MacDonald Consultants (India) Pvt. Ltd Kothari House, CTS No. 185 Off Andheri – Kurla Road, Andheri (East)

Mumbai 400 059, India ; Tel 09122 3083 5000

DRAWINGS Required number for TIMING FOR SUBMITTAL

Approval Final issue - for approval 2 weeks after order date

Approval drawings / Final drawings to be submitted under cover of an ADS form / FDS form respectively

Transpa

rencies

Prints Disk Prints - final issue 2 weeks after approval date Documents shall be submitted to:

Vendor Doc. Schedule 4 1 3

General arrangement 4 1 3

Foundation loading and bolt location plan 4 1 3

Cross section drawing with BOM and MOC 4 1 3

Completed data sheets of all Main & Auxiliary

equipments

4 1 3

Performance curves for Compressor and motors 4 1 3

Motor Speed/Torque curves 4 1 3

Coupling GA drawings 4 1 3

Motor GA drawing & Terminal Box Drawing 4 1 3

P&ID for the Package with the battery limit 4 1 3

Cause & Effect diagarm 4 1 3

Equipment list 4 3

Utility Consumption list 4 3

Functional Description of Control System 4 1 3

Lay out & Construction details of Local Instrument

Panels

4 1 3

Electrical Cable Schedule 4 3

Wiring & Termination diagram 4 1 3

Instrument & Junction Box Location Plan 4 1 3

Instrument Cable Termination details – Junction Boxes 4 1 3

Control Narrative 4 1 3

Lifting beam/frame details along with calculations 4 1 3

List & Drawings of special tools 4 1 3

Instruments Datasheets 4 1 3

Production Schedule 4

Progress Report 4 Monthly Once.

Performance Test Procedure including FAT, NDT

Procedures, WPS, PQR, WPQ

4 1 3

Quality plan satisfying ISO 9000 requirements 4 1 3

Manufacturing, inspection & testing sequence plan 4

SPARE PARTS DOCUMENTS 1 3

SPIR forms including 1 transparency 1 3

Lubrication schedules 1 3

TEST AND INSPECTION DOCUMENTS Prints

Documents to be submitted under transmittal Documents shall be submitted to:

Manufacturing reports 1 3

Material certificates to: ISO 10474 - 3.1B 1 3

Electrical certificates to Cenelec / Baseefa/ATEX Compliance/CMRI 1 3

Static / dynamic balancing certificates 1 3 Purchasing Office via courier service within 4 weeks

Performance test Report & Performance Curves 1 3 of relevant test / inspection.

Heat treatment graphs, if applicable 1 3

Calibration certificates of Instruments 1 3





OPERATING DOCUMENTS Purchasing Office via courier service not later than

time of dispatch of equipment.

Installation instructions 1 3

Operating instructions 1 3 Combine into one manual

Maintenance instructions 1 3

ADDITIONAL REQUIREMENTS:

1. Referenced standards / codes shall be the latest issue unless otherwise stated.

Invoice must certify that the drawings and engineering documents specified

above have been dispatched to all parties concerned.

Any deviation from the timing for submittal of documents shall be notified to

the Approval / Distribution Offices by fax or E mail.

Shop fabrication shall not be started before the required approval drawings

have been released for construction by the party concerned, unless otherwise

stated on the "Approval Drawing Specification".

Each document shall bear the item / tag and order reference number and be

dispatched by air mail, unless other instructions are stated on the RED.

Units / dimensions to be used on Engineering documents shall be SI.

The documents shall be in English. Description on drawings and similar

documents may be in other languages provided English translations are

also given.

Drawings and documents shall be suitable for microfilming and comply

with accepted national or international standards for the preparation of

technical drawings. Only the following standard sizes should be used: A4,

A3, A2, A1.




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3\MDS,Specs-Mech\Editable\Tech. Spec.for Propylene Compressor.doc

Appendix C: Table of Compliance

The Vendor shall confirm below their acceptance of all the clauses contained in the specification or

otherwise make clarifications or exceptions that shall be noted below:-

CLIENT: HINDUSTAN PETROLEUM

CORPORATION LTD.

VENDOR REF. NO.

REF. NO.: 256324-500-RQ-MEC-006 Rev. B

CLAUSE

NO.

CONFORMS

Y/N

ALTERNATIVE

Y/N

CLARIFICATION

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

2.0

3.0

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

4.0

4.1

4.2

4.3

5.0

5.1

5.2

5.3

5.4

6.0

7.0

7.1

7.2






CLIENT: HINDUSTAN PETROLEUM

CORPORATION LTD.

VENDOR REF. NO.

REF. NO.: 256324-500-RQ-MEC-006 Rev. B

CLAUSE

NO.

CONFORMS

Y/N

ALTERNATIVE

Y/N

CLARIFICATION

7.3

7.4

7.5

8.0

8.1

8.2

9.0

10.0

10.1

10.2

11.0

12.0

Appendix A

Appendix B

Appendix C

Appendix D

Appendix D: Instrumentation Design Requirements

1.0 Hazardous Area Classification & Protection






• Instruments located in hazardous area shall be certified to meet or exceed the electrical

hazardous area defined by Area classification.

• All instruments shall comply as per hazardous area classification as mentioned in the

mechanical datasheets. Instruments certified for use in the specified hazardous area

classification shall be recognized by authority like FM, CENELEC, PTB, BASSEFA, ATEX

etc. All solenoid valves and where IS circuits are not available due to higher voltage level shall

be explosion proof and certified for use in specified hazardous area.

• Each electrical equipment to be used in Hazardous shall be marked with type of protection, gas

group and temperature class as well.

2.0 Ingress protection / Weather Proof

The Following minimum degree of Protection as per IEC 60529 shall apply to all the

Instrumentation equipment.

• Indoor Equipment/Panel - IP 42

• Outdoor Equipment/Panel - IP 65

In addition to the above, field Instruments located outdoors, exposed to direct sunlight and not

meeting the plant environmental conditions shall be protected with sunshades.

3.0 General Requirement for Instrument and Control System

• Bidder shall provide all transmitter of SMART, two wire type, 4-20 mA output with HART

protocol, 24 VDC loop powered, with local digital indicator.

• Transmitter shall have +/- 0.25% of full scale accuracy as minimum & Gauge shall have +/-1%

of full scale accuracy as minimum.

• The identifying tag number shall be neatly & clearly marked on each instrument.

• Dial size of Pressure gauge shall be 150 mm and Temperature gauge shall be 100mm. The scale

plates shall be aluminium or laminated plastic with white face & black figures.

• Pressure gauge and Temperature gauge range shall be within 75% of full scale range. Pressure

Gauge exposed to vacuum shall be capable of withstanding full vacuum.

• Instruments shall meet the minimum requirements of IP 65 for ingress protection in accordance

with IEC 60529. In general, no process switches shall be used, instead transmitters with local

indication shall be used.

• All instruments shall be individually valved by block and bleed valve at the tap off to allow

depressurization, in-place testing and maintenance of the instrument without shutting down the

equipment/package unit.

• Cable entry to all instruments shall be ½ inch NPT. EExd certified adaptors are acceptable

where ½” NPT cable entries are not provided. . Spare cable entries shall be suitably plugged as

per the hazardous area classification with stopping plugs.

• Materials of construction for instrument equipment shall be compatible to the corrosion

resistance, pressure and temperature conditions of the process fluids handled. Generally, all

instrument wetted parts, in contact with the process fluid shall be SS316 (minimum), or of a

material equal to or better than that of the related vessel or line.

• Solenoid valve coil shall be rated for continuous with class F insulation. In general, Solenoid

valves shall be certified EEx”d” for Zone 1 applications. Solenoid coils shall be of 24V DC, low

power consumption, 12 W maximum. It shall be provided with suppression diode mounted in

solenoid assembly.

• Proper access shall be provided from grade or Platform for field devices (Transmitters, Valves,

Temperature sensors etc) for operation & maintenance. If necessary, additional maintenance

platforms specifically for instruments shall be provided.






• Normal mode of operation for the unit shall be start/stop from local panel.

• For all differential pressure (level and pressure) instruments, single block and bleed type valves

shall be provided for pipe / vessel class up to 600#

• Vendor shall provide configuration HART extractor files (DTM) for all HART transmitters.

• For the Instrument process connection details refer to the Doc: - 254624-500-SP-INT-002

4.0 The Supplement Requirements for Supply / Services of Instrument and Control

Packaged equipment.

Instrument data sheets shall be prepared by the vendor for all package unit instrumentation as

per MMCI format (Draft format attached) and submitted to the Owner/Consultant for approval.

Instruments on the package unit shall be supplied as per specifications and from Approved

vendor list. Vendor shall submit brief description regarding various controls in the package

along with the offer. The Vendor shall clearly highlight any exceptions to our specifications in

their offer.

Vendor shall include in his scope of supply documentation and calibration certificates for all the

instruments supplied in the package unit.

4.1 Pressure

• All pressure gauges shall have 1/2" NPT (M) connections. Process connections at take off point

for pressure transmitters shall be minimum 1/2” for clean Gas/Water/N2 service. The use of

reducing bushings to connect pressure instruments to process lines is not permitted.

• Local pressure gauges shall normally have a weather proof stainless steel case with a solid front

and rubber blow-out disc of 25 mm (1") diameter. The lens shall be shatter proof glass.

• Pressure gauge pointers shall be balanced and provided with a micrometer adjustment so that

zero shift may be corrected. All gauges shall be provided with Kg/cm2 indication in black letters

on white background.

• Pressure gauges for pulsating or vibrating service, and on the discharge of all pumps, shall be

liquid (Glycerine) filled with internal zero adjustment. The full face shall be covered by the

liquid and the filling plug shall act as a blow out seal with internal pressure of 10 psig or greater.

• Pressure gauges shall be ranged such that normal operating is between 30 – 70% of scale; except

on pulsating service where it shall be restricted to 60 % of scale.

• All pressure gauges shall have SS 316 bourdon tube and movement as a minimum.

• The pressure and differential pressure measuring instruments shall be located below the taps for

liquids and condensable.

• Pressure Transmitter shall be 24V DC loop powered, 2 wire, with 4 to 20 mA, HART protocol

output signal.

• Over range protection shall be provided for at least 130% the maximum operating pressure.

Also a vacuum protection shall be provided for complete vacuum.

• As far as possible all Pressure switches application shall utilize pressure transmitters.

• All Pressure and differential pressure measurements in SS 316 construction with block and

bleed facility (e.g. using standard 2-valve, 3-valve or 5-valve instrument manifold as

applicable).

4.2 Temperature

• Locally mounted indicators/gauges of process temperatures shall be bimetallic thermometers

with 100 mm dial, every-angle heads and stainless steel cases.






• Temperature sensing elements shall be always mounted in thermo well and all Temperature

sensing elements used shall be duplex type.

• Material for thermowells shall be minimum ANSI type 316 stainless steel, machined from single

bar stock in a tapered configuration. Better materials and ratings shall be specified as required

by the Piping Material Specification.

• 3 wire RTD, Pt. 100, shall be used for temperature sensing in Motor bearing / winding

applications. The KW rating of the motor shall be the criteria for determining application of

temperature sensing in motor. For Equipments having high vibrations RTD's with remote

mounted heads shall be provided.

• Whenever RTDs are provided for motors, they shall supplied completely with rail mounted

(inside Junction box) temperature transmitters, 2 wire, loop powered, 24 VDC, 4-20mA, which

will be hardwired to OWNER ESD system.

• Standard thermo well lengths for piping shall be 230mm ( for pipe size ≤ 4” ) or 255 mm ( for

pipe size ≥ 6 ). The minimum flange size shall be 2" with pressure rating as per piping class /

design pressure. Standard thermowell lengths for pressure vessels shall be 455 mm. Lagging

shall be standard length, except where insulation thickness is greater, then lagging shall be 1”

longer than thickness of insulation. Refer Annexure-B (Drawing no. 256324-500-INT-5975) for

typical Thermowell drawing.

• Field indicating type transmitters within the sensor termination assembly shall be used to the

maximum extent possible.

• Temperature Transmitter shall be 24 VDC loop powered, 2 wire, with 4 to 20 mA, HART

Protocol output signal. The temperature measuring circuit for transmitters for RTD inputs shall

be the resistance bridge circuit type.

• Consideration shall be given to ambient temperature and/or temperature radiation wherever the

“in head” transmitter is used. If an “in head” mounting of the transmitter is to be avoided due to

this consideration, the transmitter is to be mounted local to the sensor.

• Calculation shall be provided by vendor for thermowell Vortex shedding resonance (WAKE)

frequency to ensure no stress cracking will occur. Wake frequency shall not exceed 80% of the

natural frequency of thermowell at maximum fluid velocity.

4.3 Level

• Displacer type instrument gauge with transmitter can be used for level measurements including

liquid to liquid interface.

• Level Transmitter shall be 24V DC loop powered, 2 wire, with 4 to 20 mA, HART protocol

output signal.

• Top mounted Level Transmitters shall be used based on Owner/Consultant approval.

• Other special type of level instruments like ultrasonic type, capacitance type, RF admittance,

nucleonic type shall be used as necessitated by application requirements with prior approval

from Owner/Consultant.

4.4 Safety valves

• The overpressure protection devices shall be installed to meet the requirements and sizing of

safety devices for vessels, piping and equipment in accordance with the ASME Pressure Vessel

Code, Section I and VIII, ANSI B31.3, API-RP520 and API-RP521.

• Safety and relief valves shall be direct spring loaded type. For liquid service and non-coded

duties i.e. thermal relief they can be semi-nozzle with screw connections. Plain closed bonnets

shall be specified, with a tapped and plugged vent for easy conversion to balanced type valves.

Exposed spring bonnets shall be specified for steam service above 200°C as required by ASME

Boiler and Pressure Vessel Code, Section I.






• As a minimum all relief valves shall have carbon steel bodies with stainless steel trim, but in all

cases the material shall conform to the piping specification. When the set pressure is within 10%

of the normal working pressure, balanced bellow valve shall be used.

• Screwed connections shall be supplied on valves with inlets 3/4" and smaller. Threaded

connections on valves shall be ANSI B1.20.1 pipe threaded ends. Flanged connections shall be

provided on valves, 1" inlet size or larger. Minimum inlet rating shall be ANSI Class 150.

Valve flanges shall match the rating and facing of mating flanges on vessels or piping. Body

flanges shall be in accordance with ANSI B16.5 except for the thickness.

• Pressure and vacuum relief valves for storage tanks shall normally be of the weight loaded or

pilot operated type, and sized in accordance with API 620 and API 2000.

4.5 Installation for Instruments

• All instruments installation shall follow API 551.

• Process tubing between primary pressure connections and instruments or instrument manifolds

shall be ½ inch OD, SS 316 tubes, wall thickness 0.035 inch as a minimum. Double Ferrule

Swagelok/Parker type fittings in ASTM 316 stainless steel must be strictly enforced as a

minimum. Other materials may be used based on process requirement. Where ¼ inch OD

connections are required by the instrument or instrument manifold, reducing fitting shall be used

at the instrument.

• Instrument process tubing shall conform to ASTM A269, type 316 stainless steel, seamless,

annealed and pickled.

• Tubing fittings shall be SS316 Swagelok compression type fittings, or Owner/Consultant

approved. All compression fittings shall be of double ferrule design.

• Where SS316 stainless steel is deemed unsuitable, the vendor may propose an alternative, with

justification, for approval by Owner/Consultant.

• Instruments located outside of control panels shall be installed as close as practicable to the

process connection and may be surface, yoke, universal 2 inch pipe, or bracket mounted.

• Instruments shall not be supported by process piping, handrails or equipment subject to

vibration. Instrument supports shall be welded where possible not bolted, to the platform.

• Instrument supports shall not be welded on to the equipment, piping, railings and ladders.

• Instrument supports shall be located at an elevation where the centre line of the instrument is

1500mm above grade, walkways or platform and within reasonable reach for servicing.

4.6 Special Tools

Vendor shall identify / supply any special tools required for the package unit equipment as

part of the package wherever required. Programming/configuration tools shall be provided (if

required) & all licensed software / functional / application software shall be included in the

supply.

Any special cables for data communication shall be supplied along with the configuration

tools.

4.7 Spares

The Vendor shall include with the quotation following spares along with relevant cross

sectional drawings and parts list

Mandatory spares recommended by manufacturer

Spare parts for start-up / commissioning.

5.0 Approved Vendors List for Instruments






ELECTRONIC SMART TRANSMITTERS (PT, DPT, LT, TT)

SR.NO. NAME OF VENDOR

1. EMERSON PROCESS MANAGEMENT

2. ENDRESS & HAUSER

3. YOKOGAWA

4. HONEYWELL

PRESSURE GAUGE, LEVEL GAUGE & ACCESSORIES

SR.NO. NAME OF VENDOR

1 WIKA INSTRUMENTS INDIA LTD.

2 PRECISION INDUSTRIES (ASHCROFT )

3 DRESSER PRODUCTS

4 JERGUSON

5 CLARKE-RELIANCE

6 ENDRESS & HAUSER

JUNCTION BOXES & CABLE GLANDS (FLAME PROOF)

SR.NO NAME OF VENDOR

1. BALIGA LIGHTING EQUIPMENTS LIMITED

2. FLAMEPROOF EQUIPMENTS PVT. LTD.

3 SUDHIR SWITCHGEARS

4 CEAG

5 STHAL

6 FLEXPRO ELECTRICALS

7 FCG POWER INDUSTRIES PVT. LTD

SOLENOID VALVES

SR.NO NAME OF VENDOR

1. ASCO

2. HERION

3. NORGREN

4. ROTEX

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