Technical Specification of pressure fed Lubrication system … · 2018-12-20 · INTRODUCTION: Pump...

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Annexure –1

SPECIFICATION FOR AUGMENTATION OF EXISTING PUMP OPERATED

LUBRICATION OIL SYSTEM (LOS) TO FAIL SAFE PRESSURE FED

LUBRICATION OIL SYSTEM

1. INTRODUCTION:

Pump fed lubrication oil system is used in Gear box (5MW) at IPRC,

Mahendragiri. The lubrication oil system has to be supplemented to supply

lubrication oil to the gear box in pressure fed condition for 4 minutes in case of

power failure.

2. SCOPE OF WORK:

The scope of work includes supply, fabrication, installation &

commissioning of pressure fed lubrication oil system consisting of

pressurization system & oil feed system with supply tank, collection tank,

stainless steel pipeline, stainless steel fittings & flanges, manual valves, Electro

Pneumatic (EP) valve, Non-return Valves, pressure regulator, filters, safety

relief valves, rupture disk, pressure transmitter & differential pressure

transmitter. Upon supply the pre fabricated items need to be integrated &

installed in IPRC that includes site fabrication also within the scope of

supplier.

The Process & Instrumentation (P&I) diagram of the pressure fed

lubrication oil system is given in drawing no. SCFT/LOS/P&ID/01/2018 (R0).

The items covered under the portion of P & I diagram shown inside dotted lines

are in the scope of supplier.

The lube oil system is required to supply oil as follows:

Oil flow rate : 5 liter/second

Oil pressure at inlet of gearbox : 2 bar (absolute)

Oil grade : ISO VG 46

Duration : 4 minutes

The isometric piping layout is shown in drawing No.:

SCFT/LOS/PIL/01/2018. Detailed fabrication drawings are to be prepared by

the supplier and submitted to purchaser for approval within 15 days after

placement of purchase order.

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3. MAJOR SPECIFICATIONS OF EQUIPMENTS, COMPONENTS AND

MATERIALS FOR OIL FEED SYSTEM:

Equipments, components and maximum quantity of pipes, pipe fittings,

flanges to be supplied for realization of oil feed system are as follows:

3.1 Supply Tank:

Type : Cylindrical shell with hemispherical end

Capacity : 1700 liter

Material of construction : Carbon Steel

Dimension (approximate) : 1m (dia.) x 1.5m (length of cylindrical segment)

Design pressure : 11 bar (g)

Nozzles : Nozzles necessary for accommodating safety relief valve, rupture disk, oil level indicator, pressure transmitter, differential pressure transmitter, pressure gauge, pressurization circuit with diffuser, feed & drain circuit with vortex breaker, overflow & vent circuit shall be provided in the supply tank.

Design : Design of supply tank is in the scope of supplier. Design shall be as per ASME code. Design calculations shall be submitted to purchaser for review and clearance within 15 days after placement of purchase order.

Supply tank shall be provided with oil level indicator, pressure transmitter,

differential pressure transmitter, safety relief valve, rupture disk, pressure

gauge, vent port & drain port with manual valves, diffuser & vortex breaker.

Suitable structural support for installation of supply tank shall also be

provided.

Supply tank shall be provided with necessary lifting lugs for handling.

3.2 Collection Tank:

Type : Rectangular Cuboid shape Capacity : 1700 liter

Material of construction : Carbon Steel Dimension (approximate) : 1.5m (L) x 0.9m (W) x 1.3m (H) Nozzles : Nozzles necessary for

accommodating breather, oil level indicator, pressure gauge, vent port, drain port, overflow port, nozzle for connecting collection tank with existing storage tank shall be provided in the collection tank.

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Collection tank shall be provided with oil level indicator, breather, pressure gauge, vent port & drain port with manual valves. The collection tank shall be connected with the existing storage tank. Suitable structural support for installation of collection tank shall also be provided.

Collection tank shall be provided with necessary lifting lugs for handling.

3.3 Manual Ball Valves:

Sl. No.

Size Tag No. Flange End Connection

Material Quantity

1 DN15, 150# FVM 803, 805, 811, 819 & 820

SRF Stainless Steel 304

5 Nos.

2 DN25, 150# FVM 807, 813 & 815


3 Nos.

3 DN32, 150# FVM 804 SRF Stainless Steel 304

1 No.

4 DN50, 150# FVM 808, 809, 810 & 814


4 Nos.

Note: SRF - Serrated Raised Face

3.4 Manifold Valve:

Sl. No.

Size Tag No. Type End Connection

Material Quantity

1 DN 15, 150#

FVM 801, 802, 806, 812 & 816

3 port , 2 way

½” NPT Stainless Steel 304

5 Nos.

2 DN 15, 150#

FVM 817 5 port , 3 way

½” NPT Stainless Steel 304

1 No.

3.5 Pipes (Seamless):

Sl. No. Size Material Quantity

1 DN15, 40S ASTM A312 TP 304 10m

2 DN25, 40S ASTM A312 TP 304 10m

3 DN32, 40S ASTM A312 TP 304 15m

4 DN50, 10S ASTM A312 TP 304 35m

3.6 90o Elbow:


1 DN15, 40S ASTM A 403 WP 304 8 Nos.

2 DN25, 40S ASTM A 403 WP 304 2 Nos.

3 DN32, 40S ASTM A 403 WP 304 3 Nos.

4 DN50, 10S ASTM A 403 WP 304 9 Nos.

3.7 Equal Tee:


1 DN50, 10S ASTM A 403 WP 304 4 Nos.

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3.8 Flanges:


1 DN15, 150#, 40S, SRF ASTM A 182 F304 14 Nos.




3.9 Concentric Reducer:


1 DN 32 X DN 25, 40S ASTM A 403 WP 304 1 No.

3.10 Un-equal Tee:


1 DN 25 X DN25 X DN 15, 40S ASTM A 403 WP 304 1 No.

2 DN 32 X DN32 X DN 15, 40S ASTM A 403 WP 304 2 Nos.

3 DN 32 X DN32 X DN 25, 40S ASTM A 403 WP 304 1 No.

3.11 Filter:

Fluid medium : Given in table – 1

Working temperature range : 300 to 318 K

Size : Given in table – 1

Max Allowable Working

Pressure (MAWP)

: Given in table – 1

Fineness of filtration : 25 micron (absolute)

Quantity : Given in table – 1

Inlet pressure : Given in table – 1

Permissible pressure drop : 0.1 bar (max)

Flow rate : Given in table – 1

Leak tightness across the

body (external)

: Bubble-tight

End connection : Given in table – 1

Body : Y or T type with access to replace the filter

element cartridge without removing the

filter body.

Filter element : Wire mesh type, supported on perforated

cartridge

Table – 1

Specification For lubrication oil For pressurization circuit

Tag No. FFL 801 FFL 802

Fluid medium ISO VG 46 lubrication oil Gaseous Nitrogen

Size DN 50 DN 25

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Design Pressure 12 bar (a) 12 bar (a)

Quantity 1 No. 1 No.

Inlet pressure 3 bar (a) 6 bar (a)

Flow rate 5 lit/sec 75 gm/sec

End connection DN50, 150#, 10S, SRF Flange

DN25, 150#, 40S, SRF Flange

Material of construction

Body : Stainless steel 304 / 316 / 321

Mesh : Stainless steel 304 / 316 / 321

Seals : Viton / PTFE

Bolts : ASTM A 320 B 8

Nuts : ASTM A 194 8

Suggested make : a. Puronics System, Bangalore

b. UltraFilters (India) Pvt Ltd, Bangalore

3.12 Electro Pneumatic (EP) valve:

The Electro Pneumatic valve shall be supplied with solenoid valve and status

switches.

Valve

Type : Normally Open

Tag No. : FVP 801

Application : Isolation

Actuation : Electro-pneumatically operated

Pattern : Gate

Fluid medium : ISO VG 46 lubrication oil


Size : DN 50

Max Allowable Working

Pressure (MAWP)

: 12 bar (g)

Quantity : 1 No.

End connection : DN 50, 150#, 10S, SRF flange

Material of construction : Stainless Steel 304

Suggested make : a. Flowserve India Controls Pvt Ltd, Banglore

b. Weir BDK valves, Hubli

c. Instrumentation Ltd, Palakkad

d. MIL Controls Ltd, Thrissur

e. Uniklinger Ltd., Pune

f. Forbes Marshall Pvt. Ltd., Pune

Actuator

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Type : Linear actuator, piston/ diaphragm type, single

acting, spring return

Command gas : GN2 at 6 to 8 bar(a)

Response time (for opening) : 1 sec Maximum

End connection for command

gas mounting

: ½” NPT (F) as per ASME B 1.20.1

Response time test

:

The response time taken for opening and closing of

the valve shall be tested and test report should be

provided.

Status Switches

The Electro Pneumatic valve shall be provided with a pair of non-contact type

proximity status switches to indicate the “open/ close” status of the valve. The status

switches shall be mounted on the valve with such proper arrangement that does not

require any adjustment/ alignment for 50,000 cycles of operation of the valve.

Type : Inductive type, 3-wire configuration

Rated operating distance : 5 mm

Operating voltage : 10 to 30 V DC

Reverse polarity protection : To be provided

Short circuit protection : By pulsing

Voltage drop : 3 V

Operating current : 0 to 200 mA

No-load supply current : ≤ 20 mA

Indication of the switching state

: By all-direction LED

Connection : 2 m long PVC cable

Housing material : Austenitic stainless steel 304L/ 316L/ 304/ 316/

321

Protection class : IP 67

Suggested make : a. Rockwell Automation, USA b. Omron, USA c. Longvale Ltd, England d. Euroswitch, England e. Pepperl + Fuchs, Germany

Solenoid Valve:

Valve Body Type : Three way, Normally closed

Body material : SS 316

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Housing : Die cast Aluminium epoxy painted

Stem : SS 316/ SS304

Seat : Viton

End connection : Threaded, 1/2" NPT (F) conforming to ANSI-B1.20.1.

Solenoid Power supply : 24 Vdc / 300 mA (max)

Solenoid coil : Suitable for continuous energization

Enclosure : IP 65

Coil insulation : Class F as defined in IS: 1271.

Coil pull in voltage : Between 50 to 70% of normal supply voltage

Coil drop out voltage : Between 30% to 50% of nominal supply voltage

Coil temperature rise : Not to exceed 70°C

Single or double coil : Double Coil

Response Time : Less than 100 msec.

Conduit connection : Enclosure shall have 1/2” NPT (F) connection for power Supply cable.

Mode of operation : Direct operated

Manual operation : Provision to open the valve using Lever

Freewheeling Diode : Two diode in series to be provided

Solenoid valve shall be mounted on the EP valve. Command gas tubing from GN2 line to the solenoid valve and to the actuator of EP valve are to be provided. Process condition Fluid : GN2

Pressure rating : 12 bar

Service Life : 50,000 cycles

Operating Temperature : 300K to 318K

Relative humidity : up to 95%

Supply of 2 core cable of minimum 50 meter length for command and 4 core cable of minimum 50 meter length for status of EP valve is in the scope of supplier.

3.13 Non-return valve:

Fluid medium : Given in table - 2

Working temperature range : 300 to 318K

Nominal size : Given in table - 2

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Max Allowable Working Pressure (MAWP) : Given in table - 2

Cracking Pressure (Differential pressure

required to open the valve along intended

flow direction)

: 0. 5 bar

Quantity : Given in table - 2

End connection : Butt Weld with pipe stub, size

and schedule given in table - 2

Leak tightness across body : Bubble-tight as per API 598.

Leak tightness across seat along non-flow

(reverse) direction

: Bubble-tight as per API 598

Lift mechanism : Lift plug type, globe pattern

Cover : Screwed or bolted to body with

suitable seals

Plug : Renewable (replaceable) from

stem with insert

Test : Cracking pressure test for

opening of non-return valve at

0.5 bar pressure in flow direction.

Suggested make : a. Ampo Valves India Pvt Ltd,

Coimbatore

b. Flowserve India Controls Pvt Ltd,

Bangalore

c. Forbes Marshall Co, Pune

d. Instrumentation Ltd, Palakkad

e. MIL Controls Ltd, Thrissur

Table - 2

Specification For lubrication oil For pressurization circuit

Tag No. FVN 802 & 803 FVN 801

Fluid medium ISO VG 46 lubrication oil Gaseous Nitrogen

Nominal Size DN 50, 10S DN 32, 40S

Design Pressure 12 bar (a) 12 bar (a)

Quantity 2 Nos. 1 No.

Flow rate 5 lit/sec 75 gm/sec

End connection Butt welded, DN50, 10S Butt welded, DN 32, 40S

Material of construction

Body, cover : ASTM A 182 F 304/ 316 or

ASTM A351CF8/8M

Stem, plug : ASTM A 479 304/ 316

Pipe stub : ASTM A 312 TP 304/ 316

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Plug insert / trim : PTFE / Glass filled PTFE/PEEK


Nuts : ASTM A 194 Gr 8

3.14 Level indicator:

Level indicators for displaying oil level in supply tank & collection tank shall be

provided.

Quantity : 2 Nos.

Type : Piezometeric type

Working pressure : 11 bar (g) for supply tank & ambient pressure for collection tank

Fluid Medium : ISO VG 46 lubrication oil

Piezometric tube : Transparent

Material : suitable to withstand the working pressure

3.15 Differential Pressure Transmitter:

Differential pressure transmitter for displaying differential pressure at bottom

& top of supply tank shall be provided.

Type : Differential Pressure Transmitter

Measurement range : 0-0.5 bar (g)

Tag No. : FDP 801

Operating pressure : 12 bar (g)

Fluid Medium : ISO VG 46 lubrication oil

Quantity : 1 No.

Output : Two wire 4–20 mA with superimposed Digital communication HART protocol

Power Supply : 12 to 30 V DC

Local Indicator : 4 ½ digit LCD- Local Alpha Numeric Digital display in Engineering unit.

Accuracy : 0.5% of full scale reading

Over pressure limit : 1.25 times of Upper range Limit

Nominal operating temperature

: 300 – 318K

Suggested make : a. Emerson Process Management (India) Pvt. Ltd., Chennai

b. M/s. Honeywell sensing and control, Chennai

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c. Rosemount (M/s. Intellicom Systems Pvt Ltd, Chennai)

d. M/s Yokogawa India Limited, Bangalore

Calibration : Calibration shall be carried out at room temperature in 5 steps ascending and 5 steps descending. Calibration certificate is to be provided

4. MAJOR SPECIFICATION OF COMPONENTS FOR PRESSURIZATION

SYSTEM:

Pressurization system consists of pressure regulator, pressure gauges,

manual valves, filter, non-return valve and associated circuits. The

pressurization system need to pressurize the supply tank to 3 bar (a) pressure

by regulating Gaseous Nitrogen (GN2) at 6 to 12 bar (a) pressure. Supply of

GN2 at 6 to 12 bar (a) pressure is in the scope of purchaser. The pressurization

system is to meet the requirement to supply the lubrication oil (ISO VG 46) at

2 bar (a) pressure and 5 liter/second for 4 minutes continuous operation.

4.1 Pressure regulator & filter:

Inlet pressure range : 6 to 12 bar (a)

Outlet pressure range : 2 to 4 bar (a)

Tag No. : FPR 801

Fluid medium : Gaseous Nitrogen

Flow rate : 75 gm/sec at inlet pressure 6 bar and

minimum differential pressure 2 bar

Quantity : 1 No.

Inlet pipe size : DN 25, 40S

Outlet pipe size : DN 32, 40S

End connection : Threaded with swivel Union


Type of loading : Spring loaded

Venting : Self Venting

Repeatability of Regulation

(Droop)

: • ≤ 1% between the set pressure at minimum & maximum controllable flow rate.

• ≤ 3% between the locked up pressure & the minimum set pressure

Ratio of Variation of Set

pressure to Variation in Inlet

pressure (Decay Ratio):

: ≤ ± 1%

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Leak rate across the seat

(through) in closed condition

: Bubble tight

Leak rate across the body

(External)

: Bubble tight

Suggested make : a. Tescom Europe GmbH & Co KG, Germany

b. IMF sas, France c. Thompson Valves Ltd, England d. Parker Hannifin India Pvt Ltd, Banglore e. Swagelok, Chennai

Materials of Construction

Body, Plug : ASTM A 182 Gr. F 304/ 316

Plug insert / seat : PCTFE (Kel-F)

Seals, O- rings : Viton/ Buna N

Cleaning : All the interior flow surfaces of the pressure

regulator shall be degreased.

4.2 Safety Relief Valve:

Type : Conventional type


Tag No. : FVR 801, FVR 802

Quantity : 2 Nos.

Set pressure : 11 bar (g)

Valve inlet flange size & rating : DN25, 150#, 40S, SRF

Valve outlet flange size & rating : DN50, 150#, 10S, SRF

Flow capacity : 1.2 x Regulator failure flow rate.

Orifice designation : E

Effective orifice area : 0.196 square inch


Over-pressure : 7 ± 3 % of set pressure

Blow-down : 5 % of set pressure

Permissible leakage rate across

seat

: As per API 527

End connection : Serrated Raised Face (SRF) flange

Design code : API 526/ ASME Section VIII, Division 1

Cleanliness : All the interior flow surfaces of the

valve shall be degreased and cleaned.

Suggested make : a. Fainger Leser Valves Pvt Ltd, Mumbai

b. Forbes Marshall Co, Pune

c. Instrumentation Ltd, Palakkad

d. Tyco Sanmar Ltd, Chennai

Material of Construction:

Body, bonnet : ASTM A 351 Gr. CF8/8M

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Nozzle, seat : ASTM A 479 304/ 316/ 321

Spring : Stainless steel 316


Nuts : ASTM A 194 8

4.3 Rupture Disk:

Type : Scored metal, pre-torqued, rupture disc

device along with safety head, studs and

nuts.


Tag No. : FBD 801


Rupture pressure : 12 bar (g)

Disc size : DN25

Quantity : 1 No.

Flow capacity : 1.2 x Regulator failure flow rate.

Ratio of Operating Pressure to

burst Pressure

: 90 %

Orifice diameter : 12mm

Manufacturing tolerance : 0 %

Burst pressure tolerance : ± 5 %

Suggested make : a. BS&B Safety Syetems (India) Ltd, Chennai

b. Fike India pvt. Ltd., Pune

c. Rembe, Germany

d. Zook Enterprises, USA

Material of construction:

Disc : SS 304/316

Safety head : ASTM A 182 Gr. F 304/ 316

Studs : ASTM A 320 B 8

Nuts : ASTM A 194 8

4.4 Pressure gauges:

Type : Bourdon type gauge

Service fluid : Gaseous Nitrogen

Tag No. : FPL 801, 802, 803 & 804

Range : 0 to 20 bar

Dial size : 100mm

Quantity : 4 Nos.

Accuracy : ± 1% of Full Scale

Sensing element

material

: AISI 316

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Movement material : AISI 316

End connection : ½” NPT (M)

Mounting : Direct mounting with bottom connection

Working temperature : 300 to 318 K

Over range protection : 130 % of full scale

Window : Shatter proof

Standard : IS:3624 / EN 837-1

Suggested make : a. Wika Instruments India Pvt Ltd, Chennai

b. Budenberg Gauge Pvt Ltd, Chennai

c. Baumer Technologies India Pvt Ltd, Chennai

d. Swagelok Chennai

e. ASHCROFT India Pvt. Ltd, Gandhinagar

Calibration test: Calibration shall be carried out for all the pressure gauges

and certificate shall be provided.

Each pressure gauges shall be mounted on 3-port, 2-way manifold valve.

4.5 Pressure Transmitter:

Type : Absolute Pressure Transmitter

Measurement Range : 0 to 18 bar

Tag No : FPI 801 Quantity : 1 No.

Service Medium : GN2

Maximum Turndown Ratio

(TD)

: 10:1

Output : Two wire 4–20 mA with superimposed

Digital communication HART protocol.

Power Supply : 12 to 30 V DC.

Local Indication : 4½ digits LCD – Local Alpha Numeric

Digital display in Engineering units.

Accuracy : 0.5% of full scale reading

Over Pressure limit : 1.25 times of Upper range Limit

Nominal operating

temperature

: 300 – 318K

Transmitter Process

connection

: ½ " – NPT (F)

Suggested make : a. Emerson Process Management (India)

Pvt. Ltd., Chennai

b. M/s. Honeywell sensing and control,

Chennai

c. Rosemount (M/s. Intellicom Systems

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Pvt Ltd, Chennai)

d. M/s Yokogawa India Limited, Bangalore

Calibration : Calibration shall be carried out at room

temperature in 5 steps ascending and 5

steps descending. Calibration certificate is

to be provided

5. SPARE ITEMS:

Following spare items shall also be supplied

Sl. No

Description Size Material Quantity

1. Manual Valve (FVM 803S & 805S)

DN15, 150# Stainless steel 304 2 Nos.

2. Manual Valve (FVM 815S)

DN25, 150# Stainless steel 304 1 No.

3. Manual Valve (FVM 804S)


4. Manual Valve FVM (808S)


5. Manifold Valve (FVM 801S)

½” NPT, (3 port, 2 way)

Stainless steel 304 1 No.

6. Manifold Valve (FVM 817S)

½” NPT (5 port, 3 way)

Stainless steel 304 1 No.

7. Non return valve (FVN 801S)

DN32 Stainless steel 304 1 No.

8. Non return valve (FVN 802S)

DN50 Stainless steel 304 1 No.

9. Pressure gauge (FPL 810S & 802S)

0 to 20 bar - 2 Nos.

10. Stainless Steel Pipe DN15, 40S ASTM A312 TP 304 5m




14. 90 o Elbow DN15, 40S ASTM A403 WP 304 2 Nos.

15. 90 o Elbow DN25, 40S ASTM A403 WP 304 1 No.

16. 90o Elbow DN32, 40S ASTM A403 WP 304 1 No.

17. 90 o Elbow DN50, 10S ASTM A403 WP 304 2 Nos.

18. Equal tee DN50, 10S ASTM A403 WP 304 1 No.

19. Flange DN15, 150#, 40S, SRF ASTM A182 F304 4 Nos.




23. Concentric Reducer DN 32 X DN 25, 40S ASTM A403 WP 304 1 No.

24. Un-equal Tee DN25 X DN25 X DN15, 40S

ASTM A403 WP 304 1 No.

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27. Rupture Disk (FBD 801S & 801SS)

DN25 -

2 Nos.

28. Spare filter element & seals for pressurization circuit filter

DN25, 25 micron

- 1 Set

29. Spare filter element & seals for oil feed circuit filter

DN50, 25 micron - 1 Set

30. Spare for pressure regulator along with spare filter elements

- - 1 Set

6. FABRICATION & ERECTION:

Fabrication of pipelines shall be carried out as per the drawings enclosed

herewith; minor changes if any in the routing also shall be carried out. All

machineries, tools, accessories & manpower required for fabrication & erection

is in the scope of supplier. Welding shall be as per ASME sec IX using TIG

process with argon as shielding gas. Prefabrication may be done at supplier’s

site. The prefabricated items along with support structural materials may be

brought to IPRC for final integration. Pressure gauges & pressure transmitter

shall be mounted with 3-port, 2-way manifold valve and differential pressure

transmitter shall be mounted with 5-port, 3-way manifold valve. The works at

IPRC involves tanks erection, piping fabrication and erection with necessary

testing like DP test & radiography. The installation and testing shall be done at

IPRC. The scope of final inspection covers hydro test for integrated circuits,

functional test for flow components and performance test at operating

parameters for the total system. Power supply for fabrication & erection shall

be provided by the purchaser to the supplier at free of cost. Welders, fitters &

helpers required for fabrication & erection shall be arranged by the Supplier.

6.1 Dye Penetrant Test:

All the socket weld joints shall be subjected to Dye Penetrant Test (DPT) at the

root and final passes. All the butt weld joints shall be subjected to DPT at the

root pass.

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6.2 Radio-graphic test:

All the butt weld joints on the supply tank, collection tank & pipelines shall be

subjected to radio-graphic test with X-rays to 2-2T sensitivity. All the

radiographic films shall be submitted to purchaser for review.

6.3 Hydrostatic Pressure test:

The supply tank shall be subjected to hydrostatic pressure test with water at

1.3 times the Maximum Allowable Working Pressure (MAWP) as per ASME Sec

VIII Div. 1 at manufacturer’s works (MAWP of supply tank 11 bar(g)) &

pipelines shall be subjected to hydrostatic pressure test with water at 1.5 times

the Maximum Allowable Working Pressure (MAWP) as per ASME B 31.3 (MAWP

of pipeline 11 bar(g)) after fabrication and installation at IPRC.

6.4 Cleanliness:

The pressure fed lubrication system shall be properly cleaned. Pickling &

passivation shall be carried out for all the stainless steel pipelines before

welding with components

6.5 Painting

The supply tank, collection tank & structural supports of pressure fed

lubrication system shall be painted with two coats of smoke grey color paint

after application of two coats of suitable primer.

7. PRE-DELIVERY INSPECTION (PDI)

The Purchaser will carry out Pre-Delivery Inspection (PDI) of tanks, pipes,

fittings, components, instruments & pre-fabricated items at their discretion

at the Supplier’s works. The scope of inspection includes visual &

dimensional inspection, witness of hydrostatic pressure test and review of

certificate in support of material test, leak test etc as per the specification

document. However, acceptance of the lube oil system will be based on final

inspection after installation & commissioning at IPRC, Mahendragiri. It shall

be the responsibility of the supplier to intimate the Purchaser two weeks in

advance for PDI.

8. INSTALLATION

Installation of total pressure fed lubrication oil system which includes

installation of supply tank, collection tank, pipelines, filters, EP valve along

with supports at IPRC, Mahendragiri is in the scope of supplier. Supply of

stainless steel spiral wound PTFE with inner and outer ring gaskets, stainless

steel fasteners, stainless steel washers, foundation bolts, structural materials

for support fabrication is also in the scope of supplier. Minor civil works

(RCC/PCC) required for installation of above mentioned equipments and

pipelines including excavation of existing PCC floor shall be carried out by

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supplier. All machineries, tools, accessories & manpower required for

installation of total pressure fed lubrication oil system is in the scope of

supplier.

9. COMMISSIONING:

It is the responsibility of supplier to install and commission the pressure fed

lubrication oil system at purchaser’s site and demonstrate its performance &

operation. All machineries, tools, accessories & manpower required for

commissioning of total pressure fed lubrication oil system is in the scope of

supplier. Gaseous nitrogen, lube oil & water for commissioning will be

provided by purchaser. The pressure fed lubrication oil system shall be

inspected for its performance after installation & commissioning at IPRC,

Mahendragiri.

10. CLEANING OF SITE:

After fabrication, erection and commissioning of pressure fed lube oil system at purchaser’s site the supplier shall clean the site.

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SPECIAL CONDITIONS

1) Guarantee/Warrantee: The pressure fed lubrication oil system shall be

guaranteed / warranted for material, workmanship & satisfactory

performance over a period of 12 months from the date of commissioning at

purchaser’s site.

2) Documentation: The following documents (in English) shall be provided by

the supplier at the different stages specified thereupon:

i) Along with Quotation:

• A complete technical description along with drawings &

catalogues of the products featuring the different components

and accessories.

• Deviations, if any, from the tender enquiry specification shall be

explicitly spelt out otherwise it will be presumed that the offer

meets the tender specification.

• The company profile of the supplier highlighting the following:

a) Status as to whether the supplier is a manufacturer, trader,

dealer, stockist, agent, etc.

b) Clientele specifying the clients to whom the supplier has

supplied similar products indicating their address, telephone

number, fax, e-mail, contact person, etc

c) Copies of earlier purchase order as evidence for supply of

similar system shall be submitted along with quotation.

• Price format: Price shall be quoted as per the attached price

format Annexure -2.

• If any of the detail required as per tender is not provided, the

offer will be summarily rejected.

ii) Within 15 days after placement of Purchase Order:

• Detailed fabrication drawings of piping are to be prepared by the

supplier and submitted to purchaser for approval within 15 days

after placement of purchase order.

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• Supplier shall provide design calculations and fabrication

drawings of supply tank & collection tank along with its

supports to the purchaser within 15 days after placement of

purchase order. Only after approval by purchaser the supplier

shall proceed with realization of tanks and supports. Purchaser’s

approval will not absolve the supplier’s responsibility to comply

with purchase order specification.

iii) Along with consignment:

a) A complete technical description, instruction manual along

with drawings & catalogues of the products featuring the

different components and accessories along with operating

instructions.

b) Manuals for operation, maintenance and trouble-shooting.

iv) On commissioning

a) Guarantee certificate.

3) Completion Period:

The total work period, reckoned from the date of award of Purchase Order to the

date of commissioning and final acceptance of the system shall be 6 months as

per the following breakup.

Design calculation, fabrication drawings review & clearance : 1 month

Supply of materials : 4 months

Fabrication, erection & commissioning : 1 month

4) No facilities for transport, canteen and lodging will be provided by IPRC during fabrication, erection & commissioning.

5) Payment Terms:

100% within 30 days after Installation, Commissioning and acceptance of

Lube Oil System at purchaser’s site.

Annexure - 2

20

Price format for augmentation of existing pump operated lubrication oil system (LOS) to fail safe pressure fed lubrication oil system:

Sl. No

Description of Item Size /

Specification Quantity Unit Rate

(Rs.) Total (Rs.)

1. Supply Tank 1m(Ø)x1.5m(l) 1 No.

2. Collection Tank 1.5m(l)x0.9m(w) x 1.3m(h)

1 No.

3. Manifold Valve (3 port, 2 way) ½” NPT 6 Nos.

4. Manifold Valve (5 port, 3 way) ½” NPT 2 Nos.

5. Manual Valve DN15, 150# 7 Nos.




9. Stainless Steel Pipe DN15, 40S 15m




13. 90o Elbow DN15, 40S 10 Nos.

14. 90o Elbow DN32, 40S 4 Nos.

15. 90o Elbow DN25, 40S 3 Nos. 16. 90o Elbow DN50, 10S 11 Nos.

17. Equal tee DN50, 10S 5 Nos.

18. Flange DN15, 150#, SRF 18 Nos. 19. Flange DN32, 150#, SRF 14 Nos.

20. Flange DN25, 150#, SRF 19 Nos.

21. Flange DN50, 150#, SRF 32 Nos.

22.Concentric Reducer DN 32 X DN 25,

40S 2 Nos.

23.Un-equal Tee DN25 X DN25 X

DN15, 40S 2 Nos.


DN15, 40S 3 Nos.


DN25, 40S 2 Nos.

26. Pressure regulator with filter DN25, 25µ 1 No.

27. Safety Relief Valve DN25, 150# 2 Nos.

28. Rupture Disk DN25, 150# 3 Nos.

29. Filter DN50, 150#, 25µ 1 No.

30. EP Valve DN50, 150# 1 No.

31. Pressure gauge with manifold valve 0 to 20 bar 6 Nos.

32. Oil Level Indicator - 2 Nos.

33. Non return valve DN50 3 Nos.

34. Non return valve DN32 2 Nos.

35. Filter DN25, 150#, 25µ 1 No.

36.Pressure transmitter with manifold valve - 1 No.

37.Differential pressure transmitter with manifold valve

- 1 No.

Annexure - 2

21

38.Spare filter element & seals for oil feed circuit filter

DN50, 25µ 1 Set

39.Spare filter element & seals for pressurization circuit filter

DN25, 25µ 1 Set

40.Spare for pressure regulator along with spare filter elements - 1 Set

41. Fabrication & erection - 1 Lot

42. Installation & Commissioning - 1 Lot Sub-total

Taxes

Packing & Forwarding

Freight

Grand Total

Note: Spare items are also included

TITLE: Piping Layout of Pressure Fed Lubrication System

R0Drawing No.: SCFT/LOS/LAYOUT/02/2018 REV.Sheet 01 of 01

NOTE:-

SUPPLYTANK

Page - 24

Technical Specification of pressure fed Lubrication system … · 2018-12-20 · INTRODUCTION: Pump...

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