Technical submission.

Date : 08-03-2009Client : ADNOCProject : OIL Terminal, SharjahContractor : MISInspection :

Chapter : 01

With Reference To Your Tender For 95 Nos Storage tanks/Silos/Hoppers. M/s SUNIL HITECH Ltd. is Pleased To Submit Technical Proposal For Your Perusal.

The Tanks Will Be Designed As Per API 650 Last Edition. All The Steel Plate Material

Used Will Be Astm A 516 Gr. 70, For Structurals It Will Be SA 36. Flanges Will Be

A105-N, Pipes A 106 Gr. B, Fittings Will Be A 234 Gr. Wpb, Studs & Nuts A 193/194h.

Consumables, Paints & Fastners Will Be Origin From Reputed Indian manufacturers.

Chapter : 2

Scope of Work :

The scope of work shall include Supply of Tanks materials to be prefabricated ready for local erection, and all relevant facilities , including design and fabrication drawings plates and structures, piping, fittings, valves, flexible joints, instrumentation, fire fighting and & all facilities to insure safe and proper operation of tanks.

- The Tank will be Dome Roof Tank with Internal Floating Roof & Fixed Cone Roof.

- The tank shall be designed as per API 650 Add 4.

- Mechanical Design & Drawings

- Providing Fabrication drawing & As built drawing/documents after completion of

work

- Fabrication of Shell, bottom, Annular plates

- Fabrication of Wind girders, curb angle, foam supports.

- Fabrication of erection of Spiral Ladder, Platforms, Roof Handrail

- Fabrication of Structural for Platforms

- Fabrication of Internal & External attachments

- Surface preparation and painting.

- Third Party inspection during pre-fabrication

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1. Reference standards & specification : following standards & specification will

be followed while preparing detail engineering, fabrication, erection and testing of the tanks.

o General specification : as per specification & API 650 Last edition.

o Design & construction : API - 650 ADD 4o Welding : ASME,Sec-IX.o Plate Material : ASTM A 516 Gr. 70

2. Tools & tackles used for fabrication : hydra - crane, hydraulic jacks, chain pulley, welding rectifiers, pug cutting m/c, grinding m/c, rolling m/c etc.

3. Procedure :

A) Engineering : this part contains design calculation and preparation of drawings, based on calculated design, various mentioned specification and standard. Immediate after that 3 sets of each drawing along with Tank design calculation shall be submitted to client / consultant.

B) Softwares : Pvelite, E-Tank, COADE Tank, PDMS, CADWORKS, CODECAL, Autocad 2007.

C) Drawings Drawing under review categoryReview code 1 - no. CommentsReview code 2 - proceed with manufacture / fabrication as per commented

drawings. Revised drawing required.Review code 3 - drawing does not conform to basic requirements as

marked. Resubmit for review.R - retained for record.V - void.

D) Procurement of Raw Material : all the raw material will be indented as well as procured as per specification and code of construction i.e. as per API 650 Last Edition. All incoming material must be correlate with manufacturers / mill test certificate. In case if t.c. Of any lot is not available with in four weeks counting from the date of material received, random sample (s) from the said lot will be check tested from any approved lab. Materials, for which t.c. Is awaited, may be used against positive assurance of contractor. All material related documents should be maintained in the proper format and with client’s / consultant’s approval and signature.

The steel will be procured from :- (1) ALCHEVSK Iron & steel Works - Ukraine; (2) Daval unisor Group - France; (3) Ispat Sidex S. A. - Romania; (4) Salzgitter Handel - GmbH; (5) Oxybel S.A. - Belgium; (6) AG Der Dillinger Huttenwerke -

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Germany; (7) Azovstal Iron & Steel Works - Romania; (8) Arcelor-Mittal - UK; or (9) POSCO Steel - Korea. Mfg. Test Certificates are issued on purchase of the material. Hence we will produce all manufactrurers certificate after confirmation of Purchase Order.

E) WPS/WQR/PQR : as per approved wps, minimum 6 nos. Welders will be engaged for qualification test. At least 4 nos. Welders for 3 g position of plate welding and 2 nos. Welders for pipe welding (6g) will be qualified before commencing welding work and further welder will be engaged as per requirement and instruction of engineer in-charge. Any welder having qualifying certificate (within valid date) may be directed engaged with client’s / consultant’s consent. Either supporting pqr shall be approved by client / consultant or should be established freshly (this shall be done with mutual understanding between stl and client / consultant).

F) Edge preparation & joint fit-up : for butt joint up-to max. Plate thickness of 16mm single vee with 600 angle, root gap 2 –3 mm, max. Mismatch 2 mm shall be maintained. Vee shall be prepared either by pug cutting or by grinding. Single vee butt joint, incase of bottom plate shall be fitted with backing strip. Fit-up joint must be grinded and inspected by both stl and client / consultant before starting welding form o/s. All pipe joints, shell to nozzle joints, bottom to shell joints, shall be inspected by client / consultant.

G) Welding of joint : all single vee butt joint up-to 10mm thick plate shall be completed with one root run (full penetration), one second run and one single / multi pass final run welding from o/s. Root run and second run welding will be done with 3.15 mm electrodes where as final run may be done by 3.15 mm or 4 mm electrodes. Back chipping from i/s, visual inspection and one final run welding must be done for all shell (single vee butt) joints. All weld height must be maintained within 2–3 mm. Roof butt joint shall be one sided full penetration type welding. Sport having lack of fusion / lack of penetration must be back chipped and welded from other side. Roof butt joint root run must be followed by inter pass grinding and d.p. Test as specified in contract under inspection of stl and client / consultant. All weld seam i/s the dm water storage tank shall be flush grinded.

H) Inspection of weld joint :

a) Radiography method: soundness of welded butt joint of roof, bottom shell shall be tested by spot radiograph as per api-650 requirement..

b) Visual examination: during visual checking of weld zone crater cracks / arc strikes in or adjacent to the weld surface cracks under cut beyond 0.4 mm for vertical joints and 0.8 mm horizontal joints, 0.4 for weld that attach nozzle, clean out opening more than one cluster of

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porosity with max. 2.5 mm dia in any 4” of weld length should not be accepted. If any weld fails to meet the above criteria, it shall be repaired.

c) Hydrotest: all weld joints of shell, shell nozzle, shell to bottom joints etc shall be tested as per procedure for hydrotest of tank. If any leakage of water found, the leakage area has to be repaired. (By Site Contractor)

d) Vacuum, pneumatic, chalk diesel test: soundness of bottom plate welding shall be checked by vacuum testing method where as shell to bottom weld shall be tested with chalk diesel test. Soundness of roof weld and r.f. Pad welding shall be tested with pneumatic test. (By site contractor)

I) Repair of weld defects : weld defect shall be removed by grinding from one side or both side of the joint as required and re-welding shall be carried out. All repaired welds shall be checked by repeating the original inspection method.

J) Pre-fabrication : as pre-fabrication yard shall be leveled near to tank foundation (foundation carried out by client)

A site organizing office will be constructed to execute all construction activities. Pre-fabrication of bottom, shell, roof plate, structural parts, nozzle, manhole etc. As per drawing.

NDT of the pre-welded joint. Verification of tank pads with respect to level and co-ordinate shall be done.

K) MECHANICAL CLEARANCE: Mechanical clearance has to be obtained in the proper format after completion of all mechanical work before to start of hydro test.

L) TESTING / INSPECTION: Client / Consultant must be informed for every stage wise inspection. Only after satisfaction of SUNIL HITECH In-house Inspection, Client / Consultant will be offered for the same. All inspection sheets must be signed by SUNIL HITECH and Client’s / Consultant’s Engineer. Procedure for all type of testing shall be submitted to Client / Consultant well in advance for approval.

After completion of all activities hydrotest shall be carried out as per approved procedure. Hydrotesting of tank shall be carried out after mechanical clearance and attending all checklists points if any.Water filling will be done in 4 stages. After 12 hrs. as per procedure of each stage of water filling settlement reading has to be recorded.

If any leakage detected during hydrotest, defect area should be repaired with water level minimum 300mm below the same. Before draining water pneumatic

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test of roof has to be completed as per approved procedure. After testing, water shall be drained at the rate of 3 M water column per day. Care should be taken while draining water that sufficient no. roof nozzle are kept open.

M ) SURFACE PREPARATION & PAINTING: Sand Blasting of entire surface including structure as per specification. Application of first coat primer must be done within 4 hrs of blasting. After completion of first coat primer on entire surface other coats will be followed one by one. Blasting as well as painting must not be carried in humid weather.

Chapter 3.

Scope of Supply : The tanks shall include the following systems as required:

INLET SYSTEM:-

This system is Designed as per API-650 Last edition. This system include, manual valves, expansion joints, nozzle and reinforcements, supports , flanges, elbows and piping with all accessories until limits of scope. From the Tender we understand that the the Inlet size is 36” Dia. The pipe size will 36” NB fabricated from Steel Plate ASTM 516 Gr. 70. The Flange will be SORF Flange size 36” x 150# Gr. A-105. The 36” Dia x 50 mtr long Inlet pipe will be connected with the incoming pipeline. The other end of the 36” Pipeline will be connected to Tank Inlet Nozzle with 36”x150# Expansion Bellow in-between. The Inlet Flow will be controlled using 36”x150# Manual operated Gate Valve. The incoming Line+Inlet Valve+Inlet Nozzle will be Flanged Joint fastened with studs/nuts. All the material used will be of USA, European or Japan origin.

OUTLET SYSTEM :-

This system include manual valves, expansion joints , nozzle and reinforcements, supports, flanges, elbows and piping with all accessories until limits of scope. From the Tender we understand that the the Outlet size is 36” Dia. The pipe size will 36” NB fabricated from Steel Plate ASTM 516 Gr. 70. The Flange will be SORF Flange size 36” x 150# Gr. A-105. The 36” Dia x 50 mtr long Outlet pipe will be connected with the discharge pipeline. The other end of the 36” Pipeline will be connected to Tank Shell Outlet Nozzle with 36”x150# Expansion Bellow in-between. The Outlet Flow will be controlled using 36”x150# Manual Operated Gate Valve. The Discharge Line+Outlet Valve+Outlet Nozzle will be Flanged Joint fastened with studs/nuts. All the material used will be of USA, European or Japan origin.

DRAIN CLEAN OFF SYSTEM / DESLUDGING SYSTEM :-

A method for removing a sludge from a crude oil tank while recovering hydrocarbons from the sludge. The method is carried in the crude oil tank. The sludge is studied to determine a preferred treatment fluid. Once the treatment fluid is in place in the tank, the contents are vigorously mixed and agitated. Subsequently, the contents of the tank

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are sampled and any recovered hydrocarbons are removed, followed by removal of the treatment fluid.

This system consist Draw-Off Sump of size 24” Dia x 24”Ht fabricated flushed to Annular Plate. 10” Draw-off nozzle with a manual valves & expansion joint. The nozzle is connected with pump inlet for sludge removal & discharge.

In this system Leak-Proof Clean Out Door of the size 24” x 24” Rectangular shape fabricated with ASTM A 516 Gr.70 Material for sludge removal & cleaning tank. The section is fabricated with Davit Arm & the complete assembly is PWHT-Post Weld Heat Treated.

RECYCLE SYSTEM :-

The Recycle system is constructed out-of 26” Pipeline. One end of the system is submerged in Sump & the other end is extended out-of Shell thru 26” Nozzle Flange Joint. This system include a manual valves, expansion joint nozzle and reinforcements, supports, flanges, elbows and piping with all accessories until limits of scope .

EXCITING SYSTEM :-

This system include 2 nos 24” Dia. Mixers mounted at the bottom of the tank on First Shell Course with motor and all accessories. The motor capacity will be approx. 25HP explosion proof. Driven by a horizontally foot mounted electric motor which is mounted above the main mixer frame on steel mounting plate connected to the Gear Box.

Tank mixer performance is dependent upon propeller designed and efficiency pitch adjusted propeller is highly efficient, three blade, marine type propeller precision set and permanently fixed at our factory to assure superior mixing performance in each individual application. Standard Material of Construction :-

Impeller – ASTM A-48 Gr. 45 Shaft – AISI 1021. Mounting Flange – ASTM A 515 Gr. 65.

Gear Box – Driven by a vertically flanged mounted electric motor which is mounted on a substantial support bracket. Above the gear box and coupled by all metal flexible coupling enclosed by a guard. The gear box comprises a single reduction hardened high efficiency spiral bevel gear having a min. service factor of 1.52 AGMA Gear Class 2. The gears and all bearings are splash oil lubricated and enclosed in a large gear case for rapid. The mixer bearing have min. B10 life of 44,000 hrs.

The formation of crude oil sludge

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Most crude oils that are stored & then transported for refining have a propensity to separate into the heavier and lighter hydrocarbons from which the crude oil is composed. This problem is often exacerbated by cool temperatures, the venting of volatile components from the crude, and by the static condition of fluid during storage. The heavy ends that separate from the crude oil and are deposited on the bottoms of storage vessels are known as “tank bottoms”, or “sludge”. Tank bottoms are a combination of hydrocarbons, sediment, paraffin and water. Tank bottoms can accelerate corrosion, reduce storage capacity and disrupt operations. Paraffin-based crude oil sludge forms when the molecular orbitals of individual straight-chain hydrocarbons are blended by proximity, producing an induced dipole force that resists separation. These dipole forces are called London Dispersion Forces, or Van der Waal bonds, and are responsible for like molecular aggregation. As the ‘heavier’ straight-chain hydrocarbons flocculate (heavier meaning predominantly the C20+ hydrocarbon molecules), they tend to fall out of suspension within a static fluid, where they accumulate on the tank floor as a viscous gel. Over time, this gel stratifies, as the volatile components within the gel are ‘flashed’ from the gel with changes in temperature and pressure. This departure of the volatile components results in a concentration increase of the heavier fractions within the sludge, resulting in increased density and viscosity and decreased mobility.

Conventional methods of reducing crude oil sludge

Traditionally the cleaning of crude oil storage tanks can be done using one of four methods:

Manual Cleaning Manual cleaning is the most common and historically has been the cheapest method of tank cleaning. The cleaning is completed by entering the tank and using manual labour to move the sludge either out the door or to pumps stationed in the tank. Personnel spend long periods of time working in a toxic, flammable environment. The sludge may contain such harmful compounds as H2S, benzene and lead. This method usually takes a long period of time, costing the tank operator money in lost storage capacity. Using this method, it is difficult to recover the usable hydrocarbons from the sludge that is removed. The majority of the sludge that is removed is usually disposed of as hazardous waste or incinerated. During the clean-out period, the tank is vented to atmosphere and releases vapours that can be harmful to the environment.

Robotic Methods

This is really a variation of the manual cleaning method, except that a remotely controlled robot is used to enter the tank and complete the labour. This method is very expensive and does not solve the venting and disposal problems. This is not a popular method with refinery owners and is primarily used in very dangerous environments only.

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Chemical Cleaning

Chemical cleaning is gaining popularity and credibility as a method of tank cleaning. Various surfactants, solvents or bacteria are used to break down the complex molecules contained in the sludge and render them to their basic constituents – water, crude oil and particulate. This method relies on a chemical reaction and the speed, efficiency and thoroughness of the reaction are proportional the exposed surface area of the sludge. Therefore chemical cleaning methods require some sort of mixing apparatus or method of agitation.

Reduction through re-suspension and shearing by fluid jet

Recently, significant advances have been made in the application of high velocity fluid jets that are introduced into the full crude oil tank for the purpose of re-suspending the accumulated sludge and shearing the paraffin to prolong re-suspension of the heavy hydrocarbon molecules.

The ‘Critical Energy Minimum’

The basis for agitation of static volumes of crude oil lies in the theory that it is possible to introduce sufficient kinetic energy into the system to retard or prevent the formation of the induced dipole (the Van der Waal bond). Preliminary investigations into sludge deposition by Exxon in the 1980’s concluded that light crude oils require a minimum continuous energy input of 190 Watts/100 m3 of volume in order to prevent sludge deposition. Typically, side-entry propeller mixers used for storage tank mixing and agitation are sized using this criteria. More recent empirical evidence suggests that the continuous energy input required to prevent sludge formation in medium and heavy crudes is 280 – 375 Watts/100 m3 of volume. This ‘critical energy minimum’ can be related to a minimum critical velocity for suspension, or VS, which must be maintained throughout the entire fluid volume in order to prevent sludge formation. The majority of crude oil storage tanks in use today are under-serviced in terms of VS, resulting in uneven sludge deposition. This manifests as a sludge-free area immediately surrounding the propeller mixer, with substantial or severe deposition occurring beyond a specific radius, rV, at which the fluid velocity drops below VS.

Submerged Fluid Jet Method.

The ability of a submerged fluid jet to resuspend crude oil “sludge” is dictated primarily by two aspects of the sludge and parent fluid. These properties are the chemical composition of the material (i.e.: what molecules make up the sludge) and the viscosity

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of the material. In relation to the effectiveness of a jet mixer, the temperature-viscosity and composition-viscosity interrelationships and their effects on the efficiency of resuspension and shearing are of primary interest. The ability of the system to “shear” the paraffin molecules depends in part on the viscosity of the fluid, as viscosity is a measure of the energy dissipated by a fluid in motion as it resists an applied shearing force. Fluids can exhibit two types of viscous behavior – Newtonian or non-Newtonian. When a fluid’s resistance to a constantly changing applied shear stress increases as the shear stress increases and retraces the same curve when the shear stress rate change is reversed, that fluid is said to be exhibiting Newtonian behavior. Paraffin-based crude oil sludge (also commonly called “wax”) behaves as a thixotropic non-Newtonian fluid. The behavior of the wax is classified as thixotropic because it physically displays thinning properties when shear stress is applied. This thinning is a result of the shear stress breaking the London Dispersion Forces that exist between. Typical Schematic of Exciting System installed in Large Crude Oil Stoarage Tanks, normally above 40m Dia.

TEST SAMPLING SYSTEM :-

We have considered 1” x 300# NPT Full Coupling fabricated to the tank at 1mtr height. This system include valves at each point for collection of sample parallel to spiral stairway.

DEEP HATCH : -

The Tank shall be fitted with Deep Hatch nozzle made of ALuminium alloy flanged and bolted on top of the Floating Roof Deck of size 8” of the Foot operated type with a

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spark-proof cover plate and flanged connection. The gauge hatch shall be positioned near the top landing of a circumferential stairway.

HEAT SENSORS :-

It should be complete with all accessories, it should be of pnuematic type distributed on the tank roof and connected with a site panel. A sensor is a device which measures a physical quantity and converts it into a signal which can be read by an observer or by an instrument. For example, a mercury thermometer converts the measured temperature into expansion and contraction of a liquid which can be read on a calibrated glass tube. A thermocouple converts temperature to an output voltage which can be read by a voltmeter. For accuracy, all sensors need to be calibrated against known standards.

Sensors are used in everyday objects such as touch-sensitive elevator buttons and lamps which dim or brighten by touching the base. There are also innumerable applications for sensors of which most people are never aware. Applications include automobiles, machines, aerospace, medicine, industry, and robotics.

A sensor's sensitivity indicates how much the sensor's output changes when the measured quantity changes. For instance, if the mercury in a thermometer moves 1cm when the temperature changes by 1°, the sensitivity is 1cm/1°. Sensors that measure very small changes must have very high sensitivities.

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FEATURES :

• Utilizes Hart® protocol for configuration and monitoring; communicates with Hart® communicator or modem• Input-Output isolation – eliminates measuring errors due to ground loops• Long term stability – 0.1% / year• Accepts RTD and T/C inputs• Sensor error correction – compensates for known sensor errors• Customized 50 point linearization – any sensor can be matched• Selectable sensor break function• Full access to all features while in operation• FM & Cenelec approvals • NAMUR compliant

COOLING SYSTEM:-

The characteristics of the cooling system such as layout, diameter & thickness of the pipes as well as flow rate and available head of the cooling water shall be indicated in the tank technical specification. The numberof spray nozzles shall be decided based on the diameter of the tank. The supply shall include all parts as per the system requirements i.e. spray nozzles with appropriate supports. Supply pipes upto the connecting flange positioned at 1mtr from the tank bottom and appropriate guides on the shell. Pipe shall be hot dipped galvanized & may be of the welded type. Provisions laid down in specifications shall be considered in our proposal. The

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distance between shell rings shall be kept constant consequently the external stairway shall be suitably widened to comply with the min. width reqd.

The system is designed to perform cooling action to the tank shell above and under the air girder by rate of ( 5 lit /min/m2) of shell area. The Ring will be 6” dia designed & constructed according to API 650 Last edition & NFPA with flanged joints. The water spray jet nozzles will be appropriately placed to cover the entire shell area & will be made of brass. The cooling ring riser will be supplied with Drain valve at the bottom of the tank 1mtr ht. from ground level. The control valve will be situated outside dyke wall.

The cooling system is designed as per API 650 & NFPA standards. Plz refer our Technical Offer - Construction methodology. The capacity is 5 lit/min/m2. The size of cooling pipe will be 6" Dia & the length of pipe we can provide 6mtrs or 12 mtrs as per clients requirements & approvals. All the pipe segments will be Flanged joints.

FIRE - FIGHTING SYSTEM :-

The supply shall include following :-

Foam maker, Foam Tank, Foam Mixer & Foam distributor nozzles with deflector sections.

Manifolds with appropriate piping, nozzles, supports.

Foam riser fitted 1m from tank with appropriate supports.

The Tank system is designed to automatically detect smoke or fire using addressable Fire/Smoke Alarm system Integrated with automatic fire extinguishing system water & foam spray/flooding and/or one of the following type of environmental friendly fire agent ( CF3i / FE25 / FM-200) covering the complete area. The whole system is designed & fabricated to comply API-650 Last edition & NFPA Std. Worldwide Manufacturers of Cathodic Protection Components Manufactrures from USA, Europe, Japan or equivalent are frunished below :-

B- Fixed Foam Compating Sys.

Fixed Foam consist of Foam Tank , Mixer, Foam Riser & Reflector provided at appropriate orientation of the tank Top subject to the dia. Of the Tank. The entre systemis designed as per API-650 Last edition & comply with nfpa 11-79 Std. The foam discharge rate will be min. 15 Lit/min/m2 covering appropriate risk area. The Foam Pourer is designed at pouring rate on min. 7-8 bars. The entire system is fitted with electrically or pneumatically controlled actuators, & valves. All the electrical wiring will be FRLS & control panels as per IP65. The entire system will be remotely monitored & controlled electronically.

Standards

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All of the traditional recommendations and standards (NFPA, BS, API, VdS, EN, etc.) suggest the use of ‘static tactical rules’ for fighting the fire of hydrocarbon storage tanks. The foam application rate is independent (static) of the respected fire surface. Experience shows poor success rate in extinguishment, while using low foam application intensity values. Technical development, particularly the economical need for large capacity storage tanks over 80–100 metres diameter, brought a new challenge for the firemen. The extinguishment of such fire surfaces is not a simple quantity question that can be solved by increasing the number of the traditional foam generators, foam pourers, etc. New concept of fire extinguishing we developed & Implement is the answer of known problems.

Conventional Foam Systems - In conventional foam systems a number of steps are required to convert foam concentrate, water and air into foam. The foam can subsequently be applied onto the burning surface. In the majority of cases these activities take place close to the scene of the fire. Quite a team of trained manpower is required to set up these relatively complicated systems. In view of the tense situation during any fire, mistakes are likely to be made resulting in mal-performance of the system. The user had, over the past decades, no choice but to accept this complicated and expensive system. The on-going drive to reduce cost in the industry in general, has in many cases resulted in very low manpower levels.

Foam Proportioning - The foam concentrate has to be proportioned into the water. The operating range of the proportioning equipment is always limited. The range giving an acceptable deviation from the set point is even more limited. The response of the proportioner to quick flow variations is, generally speaking, not very good. Proportioning systems range from very simple and not very reliable to electronically controlled sophisticated and complicated devices.

Foam Generation - To make expanded foam, one requires air to be entrained into the foam solution stream. Venturi-type aspirating devices are typically used for this purpose. Proper functioning of such a device is determined by the delicate balance between flow rate, upstream pressure and back pressure. Optimum performance can only be achieved in a rather narrow operating range. Blockage or partial blockage of the small bore of the foam solution nozzle and air inlet, often occurs in fixed systems in locations where maintenance is not optimal, and results in mal-functioning.

Foam Introduction- The foam enters the inside space of the storage tank via foam pourers or foam chambers in a ‘point-like’ pattern. These devices which are sensitive to explosions in the tanks, usually get damaged by such an accident and do not work when there is a need for them.

Conclusion

• The operating range of conventional systems is limited; • foam concentration is seldom at its desired value;

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• system elements require frequent inspections to achieve an acceptable level of reliability; • the foam introduction devices are easily damaged by fire;• the complexity of the systems easily leads to mistakes being made;• a relatively large number of trained men are required to set up the system and operate it;• refresher training at regular intervals is required to maintain competency levels; and• manpower levels in the modern industry are insufficient for reliable use of the labour-intensive conventional systems.

Tank Fire Extinguishing & our New Recommendations, Tactical Rules

The application of the dynamic tactical rules is the answer to the challenge of the large fires. A new foam application on foam supply systems called FoamFatale® realises it.

Design Rules

• The necessary total foam volume shall be determined, which secures a reignition-safe foam blanket spread on the entire liquid surface. A safety factor of three shall be considered in comparison with the sufficient foam volume of successful extinguishment by the dynamic tactical rules.• Two minute maximum foam introduction time is the criterion, the basis of determining the dimensions of the foam distribution pipes by hydraulic calculations. The larger the respected fire surface is, the higher the foam application intensity will be. The foam has to run longer distances when extinguishing larger surfaces, is exposed to fire for a longer period of time and the vastes of foam are bigger. The function of the foam application rate versus fire surface is shown below. The difference between the static (NFPA type) intensity and the a report by

Brief Description of the Foam Fatale System

Preparation of Foam

• Foam Fatale is prepared well in advance under calm and controlled conditions. This eliminates the probability of an off-spec composition of the foam.• The pre-mixed foam is stored in a pressure vessel until the moment of use.• The pressure of the foam is about 16 bar. The pressure level determines the expansion ratio.• The foam remains homogenous for at least 10 years as experience has shown. There is no need for regular replacement in a five-year period as is recommended for the foam solution in the case of conventional foam solution storage.

Dimensions of Foam Solution Vessels

• Static Foam Fatale vessels can be very large, e.g., 100m3. The maximum quantity of stored foam is determined only by the mechanical manufacturing limitations.

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• The maximum size of vessels on vehicles is determined by size and weight. The limiting factor is most probably the maximum allowable dimension of the vehicle as well as the maximum allowable axle load for the road system to be used.

Making Expanded Foam

• On release of the Foam Fatale the pressurized foam will expand. This in turn eliminates the need for aspirating devices.• The release rate of the foam from the vessel is not bound by the conventional limitations, like capacity of fire water system, performance of pump, dimension of proportioner or aspirating devices. • The expansion ratio of the foam is independent of the flow rate, the pressure in the foam is the only factor determining the expansion.

Operation of the System

Operation of the whole system is extremely simple. Only the opening of the isolation valve between the pressurized FoamFatale storage vessel and the foam application/distribution device is required. The simplicity eliminates the need for specialists to operate the system successfully.

Advantages of the FoamFatale System over a Conventional System

The FoamFatale system:

• requires minimum manpower resources to set up and operate at the scene of the fire;• is so simple that making mistakes is unlikely;• uses a foam mixed under calm and controlled conditions;• does not require any aspirating devices;• does have an unlimited flow range;• produces optimum quality foam at all flow rates;• has only a few critical elements requiring regular inspection;• requires considerably lower capital investment; and• requires considerably lower maintenance effort and cost.

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Applications Where FoamFatale Concept Can be Used

• As foam supply for extinguishing systems on fixed roof storage tanks.• As foam supply for rim seal fire-fighting on floating roof tanks.• As foam supply on sites handling flammable liquids, which have no real firewater system.• As foam supply for road car loading facilities handling flammable liquids.• As foam supply for medium and high expansion foam systems.• In portable and wheeled fire extinguishers.• As FoamFatale tanks on vehicles, replacing or complementing conventional fire-fighting vehicles.

Instrumentation Package :-

The entire instrumentation system shall be “SMART” type field instrumentation & will be as per ISO & BS Standards. Electrical & Electronic equipments will explosion proof & comply to IP65, & components will be UL/CE certified. The system includes smart sensors connected to safety systems & shall be write protected to prevent unintentional modification from remote location. All electronic field transmitter shall have cable gland entries of 20mm ISO and have integral mm indicator. Electronic instrumentation will generally be 420mA dc, powered at 24V dc. Switch device shall have a min. rating of 120V, 2A Non-inductive.

Primary Flow Elements – sharp, square edge orifice plates with flange taps shall be used. Where range ability does not exceed 3:1, a single transmitter shall be used. An absolute max. of two differential transmitters, suitable ranged and with overlapping ranges may be connected to single orifice installation. Under this scenario the range shall not exceed 8:1. Orifice plates shall be sized in accordance with ISO 5167 or BS 1042. The Beta ratio d/D range shall be 0.25 to 0.7.

The preferred differential pressure for sizing purpose shall be zero to 12.5, 25, 50, 125, 250 upto 2000 Bar. Appropriate meters shall be used for measurements. Flow transmitters shall be provided with integral square root extraction and integral output meter with square root extraction scale. Process connection shall be of ½ Inch NPT Full coupling. Differential pressure transmitter shall be with integral output meter showing a linear scale. Transmitter shall be able to withstand the max. pressure on either side of diaphragm.

Radar Level Gauging System.

A method and a system for radar-based gauging of a filling level of a filling material is disclosed, wherein the tank has at least one interfering structure. The method comprises: transmitting at a first time moment a microwave signal towards the surface of the filling material; receiving microwave signals as reflected against the surface of the filling material and as reflected against said at least one interfering structure; calculating based on propagation times of the transmitted and reflected microwave signals at least two distances to reflective surfaces in the tank; and repeating at a second time moment

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the transmitting, the detecting and the calculating, wherein said first time moment is timely separated from said second time moment. Based on the several repeated measurements, the distance to the surface of the filling material is determined as the calculated distance that exhibits the greatest change between said first and second time moments. Based on this time difference analysis, it is possible to discinguish moving surfaces very easy and acurate. The method is specifically advantageous in overfill or high level alarm systems.

Our system is designed with SPR-Synthesized Pulse Radar system which enable modulated frequency. The system will have 1 mm level accuracy FMCW range measurement, DSP data extraction via dual FFT algorithm, integrated graphical remote display panel with view select at control room, integrated temperature probe interface with accuracy of 0.1c, water level and density inputs indicators, compatible with NT 5000 tank gauging system maintenance through diagnostic interface tool & gas tight process connection rated to 40 bar. The System Specification comply to high accuracy microwave tank gauge non-intrusive FMCW radar level detection with auxiliary inputs for temperature, density & water interface with Level accuracy of 1 mm, Working pressure of upto 40 bar max. Level measuring range of upto 0-20 meters, temperature accuracy of 0.1 C, Temperature measuring range of- 50 c to + 200 C, having Power supply of 24 VDC.

Displacer shall be used for all normal transmitting and controlling applications, upto and including 60” range. Shutdown functions shall be activated by dedicated instruments. Differential pressure transmitter shall be considered for all level range where presence of viscous, turbulent or flashing conditions preclude the use of displacers and for ESD services to minimize H2S release. Remote measurement shall be in accordance with the specific requirements as optionals. Local indication of of tank level shall be measured by means of guage glass or magnetic indicator. The gauges shell be supplied with shut-off valve at top and bottom with drain valve.

Alarm and trip switch functions shall be derived from analogue level transmitter signals. The level switch considered are LLLS, LLS & HLS. The transmitters will have integral output meter showing linear scale. Pressure gauge shall be Bourdon type SS material, 150mm Dia. Safety pattern with flow out backs with Y2 Inch NPT connections. Pressure switch shall be with diaphragm sensing elements connected with Y2 Inch NPT.

Transmitters – we have considered head mounted transmitter with 3 wire platinum resistance temperature detector (RTD) 100 ohm at 0 Deg. C. with interval of 38.5 Ohms. The transmitters are coupled with thermowells. Local temp. indication is measured using bi-metallic gauges with nominal 100 mm dial.

Typical Schematic of Radar Level Tank Guaging system Designed by our Engineering Team.

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Recommended Mfg. & Vendors for Radar Tank Guaging System :-

Mother well, UK Thermo Scientific, USA VEGA, USA Rosemount, USA KROHNE, Germany SIEMENS, Germany MAGNETROL, France Honeywell, USA L & G Technologies, USA Gauging systems Inc. USA

Thermowells –

Thermowells are used in industrial temperature measurement to provide isolation between a temperature sensor and the environment whose temperature is to be measured. They are intrusive fittings and are subject to static and dynamic fluid forces. These forces govern their design. Vortex shedding is the dominant concern as it is capable of forcing the thermowell into flow-induced resonance and consequent fatigue failure. The latter is particularly significant at high fluid velocities. The ASME Performance Test Code (PTC 19.3) is the most widely used basis for thermowell

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design. It is currently being updated to cover a broader range of thermowell designs and fluid conditions.

Thermowells used shall be 1-1/2 inch on pipe flanged joint. A min rating of 300# with material to suit SS 316, insertion level as per design parameters. Wake frequency will be in accordance to ASME PTC 19.3 subject to velocity criteria. The wake frequency shall not exceed 80% of natural frequency.

Thermowells are among the simplest yet least well publicized accessories used in oil storage temperature measurement applications. There are many variations of two basic kinds; low pressure and high pressure. They are used to provide an isolation between a temperature sensor and the environment, either liquid, gas or slurry. A thermowell allows the temperature sensor to be removed and replaced without compromising either the ambient region or the process.

Illustrations of generic types of metal thermowells are shown below.

Threaded-

Straight

Weldable -

Tapered

Flanged-Tapered Socket-

Tapered

The most complex thermowells are made from drilled molybdenum rods with an internal

sheath of high purity alumina. The annular space between the alumina and metal has a

very slow gas purge of nitrogen+hydrogen to prevent oxidation of the moly surface.

Low pressure, moderate to high temperature environments are routinely provided with a

thermowell variant called a protection tube that can be made of metal or high

temperature glass or ceramic, again according to he conditions. Most high temperature

industrial furnaces use ceramic or metal protection tubes, according tho the conditions.

Thermowell reputed vendors from whom we buy products are :-

Conax Technologies, USA; NOUVA Technologies, USA

WATLOW, USA; BADOTHERM, USA

OMEGA, USA; WIKA, USA

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Italcoppie, Italy

Control Valves –

Control valves are valves used within industrial plants and elsewhere to control operating conditions such astemperature, pressure, flow, and liquid level by fully or partially opening or closing in response to signals received from controllers that compare a "setpoint" to a "process variable" whose value is provided by sensors at monitor changes in such conditions

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The opening or closing of control valves is done by means of electrical, hydraulic or pneumatic systems.

Types of control valve

The different types of control valve may be categorized as shown below:

← Conventional Valve

← Severe Service Valve

The different types of control valve bodies may be categorized as shown below :-

Globe control valve with the pneumatic actuator and smart positioner

← Angle Valves

← Cage-style Valve bodies, DiskStack style Valve bodies

← Angle seat piston valves

← Globe Valves

← Single-Port Valve Bodies, Balanced-Plug Cage-Style Valve Bodies

← High Capacity, Cage-Guided Valve Bodies, Port-Guided Single-Port Valve

Bodies

← Double-Ported Valve Bodies, Three-Way Valve Bodies

← Rotary Valves

← Butterfly Valve Bodies

← V-Notch Ball Control Valve Bodies, Eccentric-Disk Control Valve Bodies

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← Eccentric-Plug Control Valve Bodies.

Valves that we recommend in our design for this project shall comply to ANSI 300 min rating with flanged connection sizes varying from 25mm to 300 mm. For control electro-hydraulic actuators shall be self contained unit comprising of power-pack. Semi rotary actuators shall be fitted with limit switches and potentiometer fro receiving 4-20 OmADc modulating signal. Power supply to actuators shll be 380 V 50Hz, 3 phase. Valves shall be sized in accordance with ISA Std. S75.01. Valve noise shall not exceed 85dBA as measured 1 mtr from valve, when operating at optimum level. The control valve characteristic shall be Linear if level control in gravity service or where range is to be increased or min. flow protection for pumps or pressure drops exceed 2/3 rd in closed position. Otherwise equal percentage characteristic shall be used. If thrust is more than diaphragm actuator then Piston type actuator will be used. SS 316 Electro/Pneumatic positioner’s shall be used. Air regulators shall be provided with valves.

Reputed Vendors we recommend :

Forbes Marshal, France Tyco Flow Control, USA Masoneilan Control Valves, Italy Emerson – Fischer, USA Kaye MacDonald, USA Bermad Control Valves, USA Leslie Control Valves, UK Flow Serve, USA Valtec Controls, USA

Safety Relief Valves – Pressure relieving devices shall be provided to protect the plant against malfunction or fire in accordance with recommended practice included in API RP520, APT RP521. The size shall be designed in accordance of process design & the material will be carbon steel body, SS Nozzle & Dics & spring. Incase pressure relieving device discharge to common relief header, a full area isolation valve shall be placed on discharge side of pressure relieving device. An interlock shall be provided to ensure that both relief routes are not closed or opened simultaneously. Relief valve shall have flanged connection in accordance with requirements of piping.

A safety valve is a valve mechanism for the automatic release of a gas from a boiler, pressure vessel, or other system when the pressure or temperature exceeds preset limits. It is part of a bigger set named Pressure Safety Valves (PSV) or Pressure Relief Valves (PRV). The other parts of the set are named relief valves, safety relief valves, pilot-operated safety relief valves, low pressure safety valves, vacuum pressure safety valves.

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Safety valves were first used on steam boilers during the industrial revolution. Early boilers without them were prone to accidental explosion when the operator allowed the pressure to become too high, either deliberately or through incompetence.

Function and design

Proportional-Safety Valve

The earliest and simplest safety valve used a weight to hold the pressure of the steam, (this design is still commonly used on pressure cookers); however, these were easily tampered with or accidentally released. On the Stockton and Darlington Railway, the safety valve tended to go off when the engine hit a bump in the track. A valve less sensitive to sudden accelerations used a spring to contain the steam pressure, but these (based on Salter spring balances) could still be screwed down to increase the pressure beyond design limits. This dangerous practice was sometimes used to marginally increase performance of a steam engine. In 1856 John Ramsbottom invented a tamper-proof spring safety valve which became universal on railways.

Safety valves also evolved to protect equipment such as pressure vessels (fired or not) and heat exchangers. Safety valve term should be limited to compressible fluid application (gas, vapor, steam).

The two general types of protection encountered in industry are thermal protection and flow protection.

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For liquid-packed vessels, thermal relief valves are generally characterized by the relatively small size of the safety valve necessary to provide protection from excess pressure caused by thermal expansion. In this case a small valve is adequate because most liquids are nearly incompressible, and so a relatively small amount of fluid discharged through the relief valve will produce a substantial reduction in pressure.

Flow protection is characterized by safety valves that are considerably larger than those mounted in thermal protection. They are generally sized for use in situations where significant quantities of gas or high volumes of liquid must be quickly discharged in order to protect the integrity of the vessel or pipeline.

In the petroleum refining, petrochemical and chemical manufacturing, natural gas processing and power generation industries, the term safety valve is associated with the terms pressure relief valve (PRV), pressure safety valve (PSV) and relief valve.

The generic term is or Pressure Relief Valve (PRV) or Pressure Safety Valve (PSV)

Relief Valve (RV): automatic system that relief by static pressure on a liquid. It specifically open proportionally with pressure increasing.

Safety Valve (SV): automatic system that relief by static pressure on a gas. It specifically open almost straight to full lift after a pop sound.

Safety Relief Valve (SRV): automatic system that relief by static pressure on both gas and liquid.

Pilot-Operated Safety Relief Valve (POSRV): automatic system that relief by remote command from a pilot on which the static pressure (from equipment to protect) is connected.

Low Pressure Safety Valve (LPSV): automatic system that relief by static pressure on a gas. The pressure is small and near the atmospheric pressure.

Vacuum Pressure Safety Valve (VPSV): automatic system that relief by static pressure on a gas. The pressure is small, negative and near the atmospheric pressure.

Low and Vacuum Pressure Safety Valve (LVPSV): automatic system that relief by static pressure on a gas. The pressure is small, negative or positive and near the atmospheric pressure.

RV, SV and SRV are spring operated (even said spring loaded). LPSV and VPSV are spring operated or weight loaded.

In most countries, industries are legally required to protect pressure vessels and other equipment by using relief valves. Also in most countries, equipment design codes such as those provided by the ASME, API and other organizations like ISO (ISO 4126) must be complied with and those codes include design standards for relief valves.[1][2]

The main standards, or directives are:

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ASME (American Society of Mechanical Engineers) Boiler & Pressure Vessel

Code, Section VIII, Division 1

API (American Petroleum Institute) Recommended Practice 520 and API

Standard 526, API Standard 2000 (low pressure -Storage tank)

ISO 4126 (originated from from European Union directives)

EN 764-7 (from CEN - European Committee for Standardization - originate from

European Union directives)

PED 97/23/EC (Pressure Equipment Directive - European Union)

Reputed Vendors we recommend for Safety Valves :-

Motherwell Tank Protection systems, UK SARASM RSBD, France, SAPAG, France CROSBY, UK Consolidated, USA Anderson Greenwood, USA FARRIS, Canada ARI-Armaturen, Germany, LASER, Germany, BOPP Reuter, Germany BESA, Italy

Cathodic protection system

Cathodic Protection System is a process for inhibiting corrosion of an aboveground crude oil storage tank comprising of positioning a slotted tubing and at least one impressed current anode within a slotted casing which is beneath an aboveground storage tank, said at least one anode being positioned outside of and adjacent to said slotted tubing; and transmitting electrical current to said at least one anode so as to cathodically protect substantially the entire surface of the bottom of said aboveground storage tank. In this process at least one horizontal bore beneath the storage tank is made and a slotted casing and one anode is positioned within at least one horizontal bore. Petroleum coke breeze is injected into the casing. To prevent drying of anode, water is injected in the slotted tubing. This process is generally implemented for detecting leaks from and cathodically protecting an aboveground storage tank comprising: positioning a slotted tubing within a slotted casing beneath an aboveground storage tank; monitoring fluid transmitted via said slotted tubing to determine leakage of fluid from said storage tank; positioning an impressed current anode within said slotted casing; and transmitting electrical current to said anode to cathodically protect said storage tank.

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Cathodic Protection Design Considerations

•Safety•Codes•Economics•Performance•System Life•Interference•Monitoring and Maintenance•Codes, Regulations and Standards

Types of Cathodic Protection Systems

1) Galvanic (Sacrificial) Anode–Magnesium Anodes in rod or ribbon form–Zinc Anodes in rod or ribbon form

2) Impressed Current System–Consists of a transformer/rectifier and anode system•Mixed Metal Oxide Anodes –linear or grid•Platinum Anodes –linear anode•Conductive polymer –linear anode •Graphite –rod form•High Silicon Cast Iron –tubular form•Scrap metal –mesh or grid

Galvanic Protected AST

Impressed Current System Layouts

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Considerable attention has been directed for preparing optimal design to cathodically protect aboveground storage tanks in addition to monitoring such storage tanks to determine if fluid is leaking or has leaked from such tanks, aboveground storage tanks have been cathodically protected by the use of sacrificial anodes positioned within the ground about the periphery of the storage tank. Where current requirements are significant, impressed current systems have been installed to cathodically protect aboveground storage tanks. Anodes for impressed current systems have conventionally been installed in one of two manners. First, impressed current anodes have been installed in deep well or remote ground bed configurations which may be remote from the storage tank. Deep well designs involve placement of anodes in generally vertical bores at depths of 100 feet or more. Secondly, impressed current anodes are installed at relatively shallow depths about the periphery of the tank either juxtaposed to the tank perimeter or at a site which is distant from the tank.

Typically Cathodic Protection system Consist of Polymeric Anodes, Anode Cable (1 x 35 sq.mm), RE Multi Core Cable, Permanent Typ Cu/CuSO4 Electrodes, Anode Junction Box, with Resistors, Shunts & Fuses, Cathodic Junction Box, Anode Lead Wire, Cathode Lead Wire, End Splices, Inline Splices, Thermit Weld, Epoxy Encapsulation, Marker, PVC Pipes, GI Slotted Tubes etc. The Quantities are calculated on the size of Tank & Scope of Limits. Worldwide Manufacturers of Cathodic Protection Components Manufactrures from USA, Europe, Japan or equivalent are frunished below :-

Cathodic Protection Manufacturers

3-M (www.3M.com) Advance Products & Systems

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Anotec Industries (www.anotec.com) Asbury Carbons (http://www.asbury.com) Borin Manufacturing (www.borin.com) Brance Krachy Co.,Inc. Erico Cadweld (www.erico.com) Carsonite Central Stac Wrap Cygnus UTG Dairyland (www.dairyland.com) DeFelsko Coating Thickness Gauges Denso North America Inc. (www.densona.com) De Nora Tech / Eltech Systems / Eltech Lida (www.eltechsystems.com) Erico Products Fisher Research Laboratories (www.fisherlab.com) Fluke, Inc. Galvotec Alloys Gas Electronics Graphtek LLC Oxbow Calcining (Great Lakes Carbon) (http://www.oxbow.com) JA Electronics (www.jaelectronics.com) J.M. Huber Kalas Mfg. Kris-Tech Wire Kirk Cells Loresco (www.loresco.com) McLaughlin Metrotech Corp. Nilsson Electrical Laboratories Pigs Unlimited Inc. Pro Mark Utility Supply (www.promarksupply.com) Royston Labs Scott Instruments Service Wire & Cable SGL Carbon TELPRO Thermoweld Thunderline Link Seal Tinker & Rasor (www.tinker-rasor.com) Trantex Products Wavetech Wilson Walton

We can provide

(1) Galvanic (Sacrificial) Anode i.e. Magnesium Anodes in Rod/Ribbon Form or (2) Zinc Anodes in Rod/Ribbon Form.

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(2) Impressed Current System : which consist of transformer/rectifier and Anode system, mixed metal oxide anodes-linear or grid, Platinum Anodes - linear anode, Conductive polymer - linear anode, Graphite -Rod form. API Standard 650 Last Edition alongwith :b. API Recommended Practice 1615. c. API Recommended Practice 1621. d. API Recommended Practice 652. e. API Standard 653. f. API Specification 12B. g. API Specification 12D. h. API Specification 12F. i. NACE RP0169. j. NACE RP0193. k. NACE RP0285. l. NFPA 30.

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