ANNEXURE- I
TECHNICAL SPECIFICATION AND DESCRIPTION OF WORK FOR SUPPLY OF PACKAGES OF UTILITY AIR SCREW COMPRESSOR AND INSTRUMENT AIR DRYER SKIDS FOR OFFSHORE PLATFORMS
2
1.INTRODUCTION
Oil and Natural Gas Gas Corporation Ltd. Ltd. requires 4 Nos. skid mounted mounted new packages of Instrument and Utility air screw compressors along with compatible and matching air dryer units, associated equipments instrument, piping etc. on FOB basis for replacement of existing packages on following Oil/Gas production platform/water platform/water injection offshore platforms located located in western offshore offshore of India. 1.
ICW platform
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2 Nos Air compressors and 1 no. Air drier
2.
WIN platform
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-do-
3.
BPA platform
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-do-
4.
BPB platform
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-do-
These units shall be installed and commissioned in the same space and location of the platform after removal of the existing equipment. The job of removal of existing equipment, installation installation and commissioning at offshore platform platform shall be carried out through a separate contract to be awarded awarded by ONGC through competitive bidding. 2.SCOPE OF WORK Bidder shall carry out design, manufacturer, inspection, testing, and supervision during installation & commissioning and performance testing at platform in compliance with technical specifications, drawings, data sheets and P&IDs of the package in the bidding document. The interface engineering between the compressors and dryer shall be responsibility of bidder and he shall guarantee outlet condition at skid battery limit. The material required for field installation job shall be covered in the scope of installation contractor. This specification outlines the minimum requirement requirement only for supply of new utility air screw (oil filled type) compressors (one working + one standby) and instrument air dryer package mounted on a skid for for replacement replacement of existing old package at following following offshore platforms as per attached specifications. specifications. Platform / oil field
Equipment Tag Nos.
Differential Pressure Kg/Cm²(g) 11.5
Flow rate Nm³ / Hr
ICW / Mumbai High WIN/ Mumbai High BPA/ Bassein BPB/ Bassein
C-5410/ C-5420
800
Dryer Capacity Nm³ / Hr 640
Exist xistin ing g skid kid size ize /available deck space LxWxH in mm 6400x3740x
C-5410/ C-5420
9 .5
800
640
7200x5200x
C- 2550A/ 2550B C- 1070A/ 1070B
11.5
800
640
4700x3785x3500*
11.5
800
640
7000x3500x3500
* After extension of deck on east side, available deck space shall be 7000x4700x3500 2.1
2.2
Bidder is advised to make pre bid site survey to make himself fully aware with the scope of work, adequacy of deck space, site conditions, material handling equipment facilities on board such as deck crane, mono rails etc. including the availability and access to designated space and shall take care of these aspects while designing & manufacturing the system. Bidder in case needs some additional data/information on the skid, the same shall/can be collected by the bidder from respective platform. ONGC (company) intends to locate new package within the existing deck space only. Bidder shall design the package keeping adequate provision for space required for operations and maintenance. No additional space shall be available. Bidders are advised to check the adequacy of deck space for locating new packages of the compressor and dryer dryer as per the requir requireme ement nt during during pre bid survey survey and confir confirm m the suitabil suitability ity in their their bid .Constraints if any shall be brought to notice of the company during pre bid meeting.
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2.3
2.4 2.5
2.6
2.7
2.8
The package supplied by the bidder shall be skid mounted and some of the accessories may be supplied loose if necessary to be installed at site as per the specifications and drawings. The installation shall be carried out by the installation contractor under separate contract. The bidder shall submit installation drawings of the skid for review of ONGC and the installation contractor which will be finally approved by ONGC. The Installation contractor shall check and verify all the items for completeness of the package as per specification before taking delivery from contractor/supplier. Transportation, insurance, installation & commissioning shall be taken up by the installation contractor. Custom clearance of the packages shall be carried out by Installation contractor and pay order for assessed custom duty applicable on packages shall be arranged by ONGC to be given to installation contractor for payment to the custom department. Proper uniformity and standardisation shall be ensured while selection of make and model of various equipment of the package. Bidder shall design and supply a package considering that these skids shall be installed and commissioned one after another or together at respective platforms if so desired by the Company. Bidder shall design and supply equipment and material up to skid battery limit to facilitate hook up of new package with the existing plant system including modification or any other work necessary for integration with existing piping, electrical, instrumentation and control etc. to make the system complete operable. Adequate space and access shall be available within the skid to facilitate repair maintenance, cleaning on compressors, compressor parts, air filters, coolers, loading and unloading of desiccant from adsorber vessels and their components, parts and instrument with reasonable convenience. Weather protective and sound attenuating painted carbon steel enclosure panels designed and constructed for quick assembly and removable at site as per the operation and maintenance requirements shall be provided for the compressor skids only for their protection from rain water and to ensure sound levels as per specification. Ventilation and lighting shall be provided in side enclosure for safe operation and convenient maintenance. Top side panel of skid enclosure shall be removable type for operation of chain pulley block for removal and maintenance of equipments. Bidder’s scope of supply shall include all new instruments and control items as per the specification and selection of instrument as a minimum shall meet the requirements defined in enclosed Appendix 6 and Appendix 5. All instruments shall be suitable for use in humid and tropical offshore climate. All necessary weather and anti corrosion protection to instruments shall be provided to prevent damage from saline and corrosive process packages. These instrument shall be enclosed in suitable weather proof Nema-4 x enclosures as minimum to protect them from site conditions specified in Appendix 1 of the tender specifications. All out door instruments shall as a minimum be suitable and certified for hazardous area requirements specified elsewhere in the bidding document. For standardisation, make and model of the instruments shall be approved by ONGC before procurement. Bidders shall provide painting of equipment, piping valves, skid base and supports, ladders etc. of the skid and other surfaces as per specifications included in the bidding documents. Bidders shall supply and provide insulation required for personal protection and for repair of damage insulation where ever necessary.
SPARE PARTS 2.9
2.10
2.11
Bidder shall provide commissioning spares required during pre-commissioning, commissioning of the equipment at offshore. Bidder shall provide the list of commissioning spares included in the lump sum quoted prices in his offer. Bidder shall also supply mandatory spares as listed in bid specification and prices for the same shall be quoted as optional in the price format. The prices for mandatory spares shall not be considered for evaluation of the bid. Bidders shall also furnish in their offer recommended list with itemised unit rates of one year operational spares (valid for supply up to two years from the date of successful performance testing at platform) to be ordered separately.
TOOLS 2.12
Bidder as minimum shall supply one set of following special tools & tackles for compressor and dryer package within the quoted lump sum price -Set of torque wrenches -Portable hydraulic operated bearing puller for removal of bearings -Sockets for removal of filter elements / cartridges -Any other special tools & tackles required as per manufacturer’s recommendations.
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2.13
Any other work required for supply, commissioning, performance testing of new skid mounted equipment, operation and smooth function of other associated facilities not specified specifically in this specification but required for completion of the job shall be done by the bidder.
INSPECTION & PERFORMANCE TESTING
The bidder shall arrange inspection of the package equipment from reputed third party inspection agency namely LRS, BV, DNV etc. or any other agency approved by the company. Bidder shall also arrange the witness of the performance test of compressors by third party inspection agency in the premises of manufacturer of screw compressor and air dryer. Bidder shall bear the associated cost and expenses of third party inspection including their fee etc. for the inspection of the packages. 2.15 Bidder shall furnish letter of commitment with the bid from respective equipment manufacturers (compressor, dryer etc.) for providing services during installation and commissioning of the package at each offshore platform. The cost towards this services shall be born by the i nstallation contractor. 2.14
2.16
2.17
2.18 2.19
2.20
2.21
2.22
2.23
2.24
2.25
2.26 2.27 2.28
Bidder shall furnish letter of commitment from respective equipment manufacturers for providing after sales service including supply of spares for a period of minimum fifteen years from the date of commissioning of the equipment. The bidder shall carry out procurement & manufacturing only after approval of design and engineering by ONGC. Bidder shall submit all design data, design calculations and drawings for approval / review by ONGC, same shall also be reviewed by installation contractor. Details of all documents to be submitted shall be finalised during kick off meeting. Bidder shall submit his schedule for design, engineering, procurement, fabrication, assembly, inspection and supply of equipment. Bidder shall furnish pre commissioning, commissioning checks and procedure for performance test to be carried out at offshore platforms. Same shall be reviewed by ONGC and installation contractor. The pre commissioning, commissioning and performance test shall be carried out in association with bidder / representatives of compressor & dryer. The cost towards associations of Bidder, OEM’s of compressor and dryer shall be born by installation contractor. Bidder shall provide their experience record for executing similar contracts for offshore requirement and proposed organisation chart for the execution of such t ype of works along with bids for the purpose of qualification. The bidder / manufacturers shall provide the details of their company setup available in India for providing after sales service of the equipment supplied by them for the packages. Bidder / manufacturers shall provide the name, address and contact phone nos., e - mail addresses etc. of the authorised representative / agency for availing after sales services of the manufacturers of the equipment. Bidder shall furnish make and models of major equipment of the package namely screw compressor with driver, electric motors, air dryer, coolers, filters, PLC and control system etc. Bidder shall also furnish letter of commitment or copy of memorandum of understanding signed with respective sub vendors, of their participation and association with bidder in the execution of this project and to provide assistance in installation / commissioning of the packages at each platform. Commissioning engineers from the respective manufacturer shall be present at platform during the entire period of commissioning and performance run test of compressor and dryer package. Maintenance and operating manuals of the equipment to be provided by the bidder / manufacturers shall be elaborate and descriptive giving full details on equipment operation & maintenance requirement, including checklist and schedules for the preventive maintenance of equipment, equipment part no., part drawings, sequence for assembly and dismantling of parts for maintenance etc, list and quantity of consumables required for the equipments. Bidder shall provide 5 sets of GA drawings, P & ID, in hard and soft copies in a CD, Out of 5 sets two hard copies of drawings should be laminated, licensed copy of Auto Cad software, equipment data sheets, electrical equipment data sheets, instrument data sheets. Bidder shall quote separately for optional scope of work for providing training of operation and maintenance staff in two groups for a minimum period of four days each by compressor & dryer manufacturers separately at respective platform. Equipment manufacturer shall provide certificate to the trainees at offshore. Bidder / manufacturer shall provide brief / copy of typical training module offered by them for training along with the bids. Bidder is required to submit duly filled in data sheets enclosed in the bid document. Bidder shall prepare ‘Bill of Materials’ for the purpose of verifying the items & their quantity by installation contractor and ONGC. Bidder shall submit his bid in hard and soft copy.
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2.29
3.0
The bidder shall supply the units as per specifications on FOB basis and hand over to the installation contractor on FOB basis.
DECK SPACE: 3.1
BPA platform
3.1.1
3.2
Combined existing skid size of utility air compressor (2 nos) and dryer is 4700(L)x3785(W)x3500(H) mm. Platform deck shall be extended towards east side as per enclosed structural drawing to accommodate new separate skids of compressor and air dryer packages. The total deck space available for installing new packages is 7000(L)x4700(W)x3500(H) mm. BPB platform 3.2.1
3.3
Separate existing skid size of two air compressors and one air dryer is 3500 x 2200 x 3000 and 3500 x 1450 x 3115. Thus the total deck space occupied by the compressor & dryer skid on the platform is 3500 x7000x3115. Therefore, total deck space available for locating new package (2 compressor + 1 dryer) is 7000(L)x3500(W)x3500(H) mm.
ICW & WIN platforms 3.3.1 The existing deck space mentioned in the bid shall be used and no extra space or deck extension is permissible.
4.0
OVERHAULING & REPAIR SCHEDULE Vendor recommended overhaul duration / schedule and spare parts requirement for various types of overhaul may be submitted along with operation and maintenance manual.
5.0
COMPLETION SCHEDULE:
5.1
6.0
Delivery of all the packages shall be completed in 8 months from the date of LOI. Partial shipment shall be allowed.
WARRANTY
Warranty for each package shall be 12 months from the date of commissioning of each package on the platform.
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SPECIFICATIONS:
This specification out lines the minimum requirement for design, manufacture, testing, supply, transportation, hookup, installation and association during installation commissioning and performance testing of the screw type (oil flooded) utility air compressors and dryer package at ICW, WIN, BPA and BPB offshore platforms. The installation and commissioning shall be carried out by a separate contract which will be awarded separately by ONGC. 1. PURPOSE: The compressor shall be used for meeting the instrument and utility air requirements of the platform equipment. 2. CODES & STANDARDS: Applicable codes and standards are listed in appendix 11. 3. EQUIPMENT FURNISHED : 3.1. The vendor shall supply all necessary equipment skid mounted as described herein after to make a complete and operable unit. The packaged equipment shall include all but not limited to the following : • •
• • • • • • • • • •
• •
•
Air intake filters and silencers for compressors Utility air screw (oil filled type) compressors with AC driven induction motor for continuous duty. 415 Volts AC 3 Ph 50 Hz. Inter-coolers, after – coolers and oil coolers. Coolers should be air cooled with electric motor driven fan. Oil separators with internal oil removing elements. Set of Coalescer filters Moisture separators and drain traps Air dryer pre filter (duplex Type) Twin tower split flow externally heated No loss No purge type air dryer with required quantity of desiccant. Air dryer after filters (duplex type) Heater, condenser and KO drum Dew point analyzer Inter connecting piping, valves, instrumentation and controls safety devices as described in specification, P&ID and data sheet (s). Vendor standard local PLC based control panel (separate for each compressor and dryer units) for monitoring and fail safe operation of the equipment with minimum attended operation. Weather proof sound attenuating painted carbon steel metal enclosures designed & constructed for quick removal and assembly at site with normal skill and tools and tackles. All necessary items not listed here but required for a complete unattended and safe operation of unit
All above equipments, units and components shall be skid mounted on a common structural skid, fully assembled, piped, with in let and outlet piping terminated at skid edge with appropriately rated flanges, wired, tested and painted for marine environment. 4.2 Acceptance criteria : As a minimum requirement the offered equipment or the equipment of similar design Manufactured by the supplier:
4.3
Shall have been tested and Shall have been in continuous satisfactory service at off shore for a minimum period of one (1) year.
Equipment Qualification Criteria(EQC)
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4.3.1 4.3.2
4.3.3
4.3.4
Unless otherwise specified elsewhere, the Equipment Qualification Criteria (EQC) mentioned below shall be applied for acceptance of the offered compressor model. The vendor for the complete unit (compressor & dryer) shall be an established manufacturer of Rotary-Type Positive Displacement Compressors. The vendor shall also be the manufacturer of the proposed compressors having adequate engineering, manufacturing & testing facilities for the same. The compressor model offered shall be from regular manufacturing range of the manufacturer and shall meet the following minimum service and manufacturing experience requirements. Compressors shall be identical in frame designation and type i.e. oil flooded and validly similar in terms of Frame number, Rotational speed, Inlet and discharge pressures. Inlet temperatures. Actual Inlet flow, Process Gas, Mechanical Design, Type of Rotor, Rotor Dynamics, Materials, Type of shaft seals etc. as compared to at least TWO UNITS designed, manufactured. Tested and supplied form the proposed manufacturing plant and at least ONE of these units shall have successfully operated in the field for at least 8000 hours without any major problems as on the date of issue of inquiry. Proven Track Record (PTR) Compressor vendor shall complete the Experience Record Pro forma as enclosed in the inquiry specifications to amply prove that the Equipments offered meet the EQC for technical acceptance. Compressor vendor may furnish additional information to justify that the EQC is being met. In addition, manufacturer’s catalogue and general reference list for all the above equipments shall also be furnished along with the proposal.
5.0 Design criteria :5.1 Conditions of service : The equipment shall be designed for outdoor location on an off shore platform with site conditions as detailed on the attached appendix 1.
The equipment shall be located in an area classification defined in the attached data sheet / specification /drawings. 5.2 5.2.1 5.2.2
5.3.1 5.3.1
5.3.2 5.3.3 5.3.4 5.3.5 5.3.6
5.4.0
Utilities: Utilities available are indicated in attached data sheet The Vendor shall specify the utilities required along with their rate of consumption in his bids. Safety: It is the intent of the Company that the operational hazards be reduced to minimum. Vendor shall use sound engineering judgment to complete the supply and provide assistance in commissioning that will perform the required process function without compromising this aim. All electrical & instrument devices shall meet the requirements for the area classification in which they are installed. All controls shall operate in a fail safe mode. All couplings, gears and exposed rotating parts shall be provided with adequate guards of non-sparking construction. Drive belts if used shall be antistatic type. Piping shall be arranged in a manner so as to avoid tripping or head room problems. The requirements of equipment vibrations limits as defined in the ISO 2372 and noise limits as defined in data sheet. Conflict: In event of conflict between this specification and other documents listed herein the following order of precedence will govern.
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data sheet(s) this specification General specification attached as appendices 1-22 in Volume III Codes & Standards as per appendix 11
6.0
DESIGN & CONSTRUCTION:
6.1 6.1.1
Compressor : The compressor shall be oil flooded screw compressor heavy duty industrial type, air cooled type with closed circuit cooling water if required to meet the specification requirement of compressed air out let temperature. Industrial mineral oil shall be used for lubrication of the machine. Bidder shall quote for supply of two extra fill of oil as mandatory spares in the attached list of mandatory spares.
6.1.2
8
6.1.3 6.1.4
Compressor shall be designed to meet the requirement defined in attached data sheet. Compressor shall preferably be directly coupled with induction motor. Gear unit when used shall be designed in accordance with AGMA 420 or an equivalent standard and shall have an AGMA service factor of not less than 2, based on the driver nameplate rating when driver is electric motor. For others drives, gearbox manufacturer shall recommend it. Bearings shall be forced-feed lubricated unless otherwise specified in data sheet. Necessary oil cooler shall be provided for cooling of frame lubricating oil.
6.1.5 Coupling and coupling spacer of compressor and driver shall be easily accessible for replacement in case of failure without disturbing the whole unit. 6.1.6
6.1.7 6.1.8
Each compressor unit shall be complete with air cooled, finned tube type oil cooler, inter & after coolers (including fan and fan guard), design for 14ºC approach to maximum ambient in accordance with the applicable standards & codes attached in appendix 11. If located in hazardous area, the fans shall have provision to suppress sparking consistent with AMCA category B. Bidder shall furnish P&ID and general arrangement drawing of screw compressor package along with bids for battery limits details and their scope of supply. Each compressor unit shall be provided with a dry cartridge type air intake filter / silencer with screens. Compressor with drives and its accessories, instrumentation and controls shall be enclosed in weather proof sound attenuating painted carbon steel metal enclosures with single intake and discharge opening suitable for out door location at offshore. The weather protective and sound attenuating enclosures consists of several easily removable access doors for inspection and removal of compressor parts, components and motors etc. Noise level outside the skid shall be as mentioned in compressor data sheet. Enclosures shall be designed and constructed for quick assembly and removal at site with normal skill, tools and tackles.
Removable section of enclosures shall facilitate handling of compressors parts and components maintenance by chain pulley blocks. 6.1.9
6.1.10 6.1.11
6.1.11
6.1.12 6.1.13 6.1.14
Oil separator tank at the discharge of compressor shall be designed as per ASME code. This shall be separate and not integral part or built-in with the compressor casing. Separator tank oil removal efficiency shall be 5 ppm and compressor vendor shall provide details of internals and specify sizing criteria of the oil separator vessel and the internals along with type and material of construction of internals provided for the separator along with bids. Moisture separator with trap shall be provided down stream of inter-cooler and after –cooler for moisture removal. Compressor vendor shall define moisture separation efficiency along with bids. Drain trap shall be provided with automatic drain valve and piped to skid drain header for draining of moisture. A high liquid level switch shall stop the unit should the primary drain ever fail to operate. Design of drainer shall conform to specification and data sheet of continuous drainer included in the bidding document. Two stage Coalescing filters shall be provided to reduce the oil content in air to 0.5 ppm in first stage and further to 0.01 ppm in final phase prior to inlet to air receiver. Bidder shall specify size of filter assembly and shall provide details for filter cartridges / elements including make, size ( diameter x length ) and number of cartridges provided and mono-graph for the cartridges separation efficiency pressure drop, operating life cycle of cartridges and sizing criteria along with bid proposal to check the technical adequacy of the filtration system. Drainage of oil from coalescers(s) shall be by timer controlled solenoid valve. Magnetic filler shall be provided in lube oil circuit for collection of magnetic particles. Material of construction for all filter housings shall be as a minimum stainless Steel 316 series Suitable anti vibration mountings shall be provided for the compressors, Vibration levels of compressor for the following operating conditions shall be provided in the bids by manufacturer • Vibration levels during normal operating range • Vibration limits for setting alarm • Vibration levels requiring shutdown of the machine
Vibration levels shall be measured at site by hand held vibration meter with accelerometer at site. 6.1.15 Control system shall be full load/ no load type operating on signals from pressure sensors. Provision shall be provided in control system such that if idling times become too long w.r.t full load time the compressor should shut down when the maximum pressure is attained as per data sheet and comes in to operation when the minimum pressure is fallen short. In both the cases the idling range is operated at the minimum for the safety of the machine. The switching frequency should not be more than three or four times an hour so that main and the electrical devices are not overloaded. 6.1.16
Lube oil temperature shall be maintained for trouble free operation of compressor through a thermostatically controlled system. Compressor shall shut down at low lube oil temperature to ensure that there is no condensation of water present in oil takes place during operation.
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6.1.17
Compressor shall load or un-load according to the demand as per requirements Specified in attached data sheet. 6.1.18 Selector switch shall be provided to interchange the normal operating compressor with stand by compressor or vice versa. 6.1.19 Compressor unit shall be provided with weatherproof sound attenuating painted carbon steel panels, designed & constructed for quick removal and assembly at site with normal skill and tackles. Noise level out side enclosures shall be as data sheets of compressor. Adequate space / access inside enclosures shall be provided for operation and preventive maintenance of equipments installed in side enclosures. 6.1.20 Lighting shall be provided inside the enclosures as per electrical specification. Temperature inside enclosures shall not increase more than 5º C over the ambient temperature and to maintain this inside condition ventilation fans shall be provided to remove the heat dissipated by the equipment. 6.1.21 Observation and inspection windows, hinged access doors shall be provided in Enclosures for visual observation and routine inspection of equipment and taking Instruments readings without disturbing the enclosures. 6.2.0 Air Dryer unit :-
6.2.1
6.2.2
Air dryer unit shall be twin tower adsorption type with split flow (no loss no purge type) closed circuit regeneration with external electric heating and air-cooling. Air dryer vessels, regeneration heater, unit piping hall be heat insulated. Regeneration shall be by means of heated air as shown on attached P&ID. The unit shall consist of two identical drying vessels, arranged for automatic change
over such that one tower is always under drying and the other under regeneration. Visual indication on local panel to indicate the state of each vessel i.e. drying / Regeneration, shall be provided. 6.2.3
6.2.4
6.2.5 6.2.5
Air dryer unit shall deliver air at the specified dew point. Quantity and pressure as specified on data sheet. Dew point measurement devices with display (on line) shall be provided to check the dew point of instrument air and for energy management system. Duplex type pre-filter for protection against contaminated air and after filter shall be provided to trap the carryover of desiccant to instrument air receiver shall be provided to meet the filtration requirements defined in specification. Control system for the dryer shall be PLC based. Air dryer unit shall be designed and manufactured to meet the requirement as defined in attached specification and data sheet.
6.3.0
Vessels :-
6.3.1
All vessels shall be designed, fabricated and tested in accordance with attached General Specification at appendix 12 and ASME Section VIII Division I. Corrosion allowance of. 3mm shall be applied for carbon steel parts of vessels, exchangers, separator vessels, knock out pots and filter housings etc. ASME Code Stamp shall be provided on all pressure vessels exchangers etc. stated as per General specification at appendix 12. The material of construction of vessel and exchanger shall meet the following requirement as a minimum:-
6.3.2 6.3.4 6.3.5 • •
• •
Boiler quality plates for shell, heads etc shall be supplied in normalized Condition Boiler quality plates over 15mm design thickness shall be ultrasonically examined as per ASTM A – 435. Material specification :Shell, heads reinforcement pads SA-516 Gr. 60 Nozzle SA-106 Gr. B Nozzle flanges SA-105 Vessels shall be designed for spot radiography as a minimum and dish ends to shell circumferential weld joints as partially radiograph. Pneumatic cylinder and linkages provided for the operation of changes over of four way valves shall be stainless steel.
6.4.0 6.4.1
Skid :The skid shall be designed and built to ensure that all equipments stated above along with all accessories, panel, piping, valves, instrumentation are mounted suitably and offer maximum flexibility for installation, convenient operation and
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maintenance of the unit. The skid shall be designed and built in accordance with the attached General specification at appendix 9. 6.5.0
Piping :-
6.5.1
Selection, fabrication and installation of piping work shall be as per enclosed General specification at appendix 7, 8 and 13. Piping shall be arranged adequately supported and connected in such a manner that a minimum number of fittings must be disconnected to remove the compressor. Stainless steel flexible connection shall be used where applicable. Accessory items Including drain trap, pressure regulators, check valves, control and safely devices shall be installed and connected in such a manner that t hey can be readily removed. Replaced or maintained.
6.5.2
6.6.0 6.6.1
6.6.2 6.6.3 6.7.0 6.7.1 6.7.2
Electrical :
All out door equipments shall, as minimum is suitable for hazardous area specified else where in bidding document and shall be BASEEFA, UL or equivalent international testing agency for the service and area in which it is to be used. Electrical equipment and material shall be in accordance with enclosed general specifications at Appendix 2 and design criteria at appendix 3. Power supply: 415 V , 50 Hz. Three phase AC available shall be used. Instrumentation & controls:The selection and installation of instrumentation work, as a minimum shall meet the requirements defined in General specification enclosed at appendix 5 & 6. Instrument / utility air compressor & dryer package shall have separate self-sufficient PLC based vendor standard control & monitoring system for each compressor unit and the air dryer unit separately. All shut down logics interlocks and controls shall be located and performed in these dedicated control systems. Bidder / Contractor shall be responsible for coordination with Engineer-in-charge at site for proper i mplementation of controls. The shut down logics and interlocks shall be designed with fail-safe features as a minimum. All details shall be finalised during detailed engineering after review and approval of ONGC. The control system shall have the following features as a minimum:-
The PLC shall be provided with portable programming unit/ terminal for each package capable of programming, programme storage and programme modification. Auto change over of Lead / Lag of compressor after fixed hours of running to effectively manage running hours with a facility to change over in manual mode also. Vendor / make of PLC shall be chosen from GE Fanuc, Rockwell/ Alan Bradley or Siemens Two sets of loaded software in CD’s CD read and writes facilities All necessary monitoring, indication and alarm for compressor and air dryer as well as selector switches and push buttons shall be available in compressor and dryer control Panel.
The controls & indications that are required to be connected to Company’s remote platform control panel, shall be terminated in a j unction box with terminal strip located at the edge of skid by the manufacturer and shall be interfaced with platform control panel in control room by the installation Contractor/bidder 6.7.3
Modular, single front, skid mounted control panel shall control the operation of the package. SS-316 Panel construction shall be weatherproof NEMA-4 & explosion proof to NEMA-7. The control system and other panel electronics that are required to facilitate control and operation of compressor and dryer units shall be housed in a suitable enclosure certified for the specified area classification by a statutory authority. All signal termination shall be in this panel. Control panel(s) shall be provided with covers/ canopy for protection from rain in case located out side the enclosures.
6.7.4
Vendor standard control system as a minimum shall include the following warning indication and shut downs for the unit:Compressor: -
Automatic start up and shut down of compressor units
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-
Automatic parallel operation of two compressors Automatic loading and unloading of compressor units on demand Compressor air high discharge temperature-Alarm and shut down Compressor air high discharge pressure – unload operation Oil separator differential pressure high – Alarm & shut down Oil separator (air side) discharge temperature high – Alarm and shut down Oil cooler discharge temperature high – Alarm and shut down Oil separator level high – Alarm and shut down Oil pressure low – Alarm and shut down Oil level low in sum or oil separator – Alarm & shut down Coalescer filter(s) differential pressure high – Alarm and shut down Coalescer filter(s) level high – Alarm & shut down Oil filter differential pressure high – Alarm and shut down Main motor over load – Alarm and shut down Fain motor over load – Alarm and shut down Blow of pressure high – Alarm and shut down Emergency stops – Alarm and shut down Re-set /Test
Note :- Control and monitoring of the unit to be read in conjunction with enclosed Compressor data sheet and P&ID. -
All gauges shall be provided in a separate gauge board only.
Air dryer:As a minimum this shall be as per the standard specification included in the bidding document.
Provision shall be made by the bidder for Status signals for Run, trip and common fault alarm for compressor and dryer skids separately to be interfaced with platform control system. 6.7.5 6.7.6
Bidder shall describe the proposed instrumentation and control system along with make/ model and configuration diagram in the proposal / bid for the offered control system. Front of the panel shall be furnished with the following indicator light as a minimum. •
Compressor on Red • Compressor off Green • Compressor Trip Amber 6.7.7. Control panel shall have start & stop push buttons, on & off indication lamps for drive motors of equipment units and components and provisions for interfacing and interlocking with feeders in switchgear room . Front of the panel shall also be furnished with following :• Lamp test • Start & stop from local and stop from remote • Start & stop in manual as well as in auto mode 6.7.8 Alarms & shutdown devices shall be wired through first-out fault indicator. Visual indication for all alarms & shutdowns and common audible alarm shall be provided in control panel. Packager/vendor shall provide extra terminals to allow Contractor to connect common remote alarm in central control panel. The remote alarm shall be provide and wired by the installation contractor. 6.7.9 Instrumentation control panel shall be separate from electrical system control panel in the skid. 6.7.10 All electronics instruments shall be designed for immunity from EM & RF interferences as per IEC-801. 6.7.11 Method of protection to be followed in general for electronic instruments shall be as per the requirements given below. Switches & solenoid valves Transmitters, transducer & Temperature elements
Explosion proof & weather proof Intrinsically safe & weatherproof
All field mounted electronic instruments (transmitters, switches, solenoid Valves ) & junction boxes shall be explosion proof and weather ‘or’ intrinsically safe and weather proof certified by recognized authorities like FM / BASEEFA / CENELEC /CMRI etc for electrical classification NEC class – 1 Division –1 , Group – D as a minimum. Intrinsic safety approval shall be based on entity concepts and the Contractor shall carry out necessary compatibility checks before selecting the instruments, cables and barriers.
12
6.7.12
Power for Instrumentation & control shall be supplied from platform power system at a single point, all further distribution shall be in bidder / contractor scope, platform power system is all follows :-
24V DC +5% negative earthed for all instruments controls & interlock system. 220V AC 50 Hz (Non ups ) for level gauge illumination if required.
Bidder / Contractor shall indicate estimated power consumption for start up & normal operation of instruments and controls along with bids. 6.7.13 Material of construction of instruments, instrument fittings, valves and other related accessories shall be SS-316. Non – stainless steel exposed surfaces shall be painted as per General Specifications at appendix -4. 6.7.14
Make / selection of instrument vendor & instruments shall be subject to Company’s approval. Bidder shall furnish proposed sub vendors list of instruments along with bids. Suggested vendor list for instruments may be provided by the company. 6.7.15 All instruments shall be suitable for use in a humid and tropical offshore climate. All necessary weather and anti corrosion protection to instruments shall be provided to prevent damage from saline and corrosive process atmosphere. All field instruments shall be enclosed in suitable weatherproof NEMA-4X enclosures as minimum to protect them from site conditions specified in General Specifications at appendix 1. Plastic bags shall be provided with all field instruments to protect them during handling installation and commissioning. 6.7.16 Bidder / Contractor’s scope of supply shall include all new instruments and control items as per this specification including all cables, FRP cable / tube trays, trays supports, tubes, junction boxes & cable glands & other material as required for the implementation of the above work within skid battery limits. 6.7.17 Bidder shall furnish list of drawings & documents to be prepared by him and submitted for Company’s review and approval. Instrument specification & data sheet shall be prepared by the bidder / contractor as per typical data sheets attached with specification & submitted for Company’s review and approval. Wherever typical data sheet(S) not available for any instrument bidder/ contractor to prepare as per ISA S.20 The typical instruments data sheets included in this bid package and pertaining to the scope as per this bid package requirement and attached P&ID’s are for establishing a minimum level of quality and service requirements and shall be followed by the bidder/ contractor while making his own data sheet (s). These specifications do not include any detail for the instrumentation required to be supplied by the bidder/ contractor. Contractor shall be responsible for the complete design, installation and workability of instruments and control system. All electronic transmitters shall be microprocessor based non-retro-fit smart type with an accuracy of ± 0.075 of span over a rangability of ± 1:10 Only transmitters (no switches) with indicators and separate transmitters for alarm & shut down shall be provided. Transmitters shall be selected from make like Rose mount, Yokogawa, ITT, Fuji and hand held terminal to be provided for calibration should be make specific. Protective coating: 7.0 Carbon steel surfaces, piping, vessel fittings, supports and structural skids shall be coated in accordance with attached General specification attached at appendix 4
8.0 8.1.0 8.2.0
8.3.0 8.3.1
8.3.2 8.3.3 8.4.0
Inspection & Testing: Vendor shall carry out various tests as per attached equipment data sheet and applicable codes & standards. Test certificates shall be submitted for Company’s approval. Company or it authorized representative or certifying agency shall have access to inspect the equipment at any stage during manufacture. During inspection, material test certificates, shop test data, certificates for bought out components and other relevant information shall be furnished as to ascertain that the specifications and quality are complied with. Vendor shall furnish for company’s approval detailed description of test procedure(s) at least two (2) months prior to scheduled shipment. The following tests shall be performed as a minimum. Equipment shall be performance tested as per enclosed equipment data sheet(s) and specifications in shop. Tests specified as “Witnessed” in data sheets shall be carried out in presence of third party inspection agency. Vessels, piping and the system as a whole shall be hydro statically tested as per the applicable codes in shop. Test pressures shall be in accordance with the maximum working pressure of individual systems. Functional test(s) of control system shall be performed in shop. Functional test shall be carried out in presence of third party inspection agency. Performance test of the compressor and dryer package(s) shall be carried out individually at offshore locations by another Bidder/Contractor on completion of installation and commissioning work for establishing performance/output of the unit as per specification. Bidder shall arrange to co ordinate with offshore installation contractor for all necessary personnel, tools, tackles equipments, spares chemical lubricants etc. as required by
13
8.5.0
him for start up, commissioning and 72 hours uninterrupted performance run test of the package. Any assistance required during performance testing at platforms shall be provided by the installation contractor in terms of manpower, general tools & tackles only. Special tools, instruments, chemicals etc. shall be arranged by the bidder. Q A Plan approved by the third party inspection agency shall be submitted to ONGC for final approval.
9.0
Warranty :
Vendor shall have the final & total responsibility for the design and performance of all equipments supplied under this specification. Vendor shall warrant the equipment furnished by him and the performance of the said equipment in accordance with this specification and attached appendices. The warranty shall be package wise and shall start from the date of commissioning of each package at offshore platform. 10.0
Spares:-
10.1 Vendor shall recommend and provide spare parts needed for start up and commissioning. In addition Vendor shall also furnish separate itemized priced list of recommended spare for one (1) year’s normal operation and maintenance, valid for supply for a period of 2 years after successful commissioning. Recommended spares shall take in to account related factors of equipment reliability, effect of equipment downtime upon production or safety, costs of parts and availability of equipment service facilities. List shall include the requisite quantity of chemical required for the package during one year of normal operation. 10.2 Bidder shall supply two years consumable operation spares as mandatory spares for total package as per attached list at appendix 17. 10.6Spare parts furnished by the vendor shall be wrapped and packaged so that they will be preserved in original as new condition under the normal conditions of storage as anticipated in India and shall be properly tagged and coded so that later identification as to intended equipment usage will be facilitated. They shall be packaged separately, clearly marked as “Spare Parts” and shipped at the same time as the equipment Packing lists shall be furnished so that the parts can be handled without un crating if desired. Start up spares shall packed and identified separately. 11.0
Tools:
Vendor shall provide two sets of special tools required for erection, operation and maintenance of the furnished equipment.
12.0
Packing & Transport:-
The offered equipment along with their accessories shall be shipped packed in wooden crate. They shall be wrapped with polythene sheets before being placed in crates to prevent damage to finish. Crates shall have skid bottom for handling. 13.0
Vendor Data Requirement:-
13.1
With proposal:-
Equipment specifications, catalogues, data sheets, deviation schedule and other relevant data as per attached “Vendor Data Requirement” sheet to facilitate the Company in evaluating the equipment selection. After order placement:13.2 Drawings and data to be furnished by the Bidder/Contractor for Company’s review/approval as outlined in the attached Vendor Data Requirement sheet shall be submitted as a part of Equipment Data Book.
14
STANDARD SPECIFICATION FOR INSTRUMENT AIR DRYER UNIT
CONTENTS
1.0
GENERAL
2.0
CODES AND STANDARDS
3.0
TECHNICAL REQUIREMENT
4.0
INSPECTION AND TESTING
5.0
PROTECTION AND TESTING
6.0
PCKAGING AND IDENTIFICATION
7.0
SPARE PARTS
15
1.0
GENERAL This specification. Outlines the minimum requirements under which the manufacturer shall design, manufacture, test and supply the Instrument Air Dryer Unit complete with all accessories. This specification also lays down the requirements for control and instruments, electrical and associated pipe work.
2.0
CODES AND STANDARDS
2.1
The latest edition of following codes, and standards shall govern: Pressure Vessels
- ASME Sec.VIII Div.I -
Heat Exchangers
-
ASME Sec.IX
TEMA ‘C’ and ASME Sec.VIII Div,I
Piping
-
ANSI-B 31.3
Pressure relieving system
-
API-RP-520 PART I/II
Material specification
-
ASME EC.II & ASTM
Pipe Flange & Fittings
-
ANSI – B 16.5
3.0
TECHNICAL REUIREMENTS
3.1
Type of Unit – Air dryer unit
-
ANSI – B 16.11
-
ANSI B 36.10
The drying process shall be externally heated No loss purge type only
3.2
Operation and Control
3.2.1
The unit shall be fully automatic in operation, with a provision for manual operation in case of timer failure.
3.2.2
All equipment of the package unit shall be hooked up in close circuit with interconnecting pipe work and interlocked in proper sequence of operation for safety.
3.2.3
Following interlocks/alarms indication shall be provided on the skid as a minimum, as applicable for the system. a) b)
Interlock system to ensure that regeneration system is initiated only when the four way valves are switched on in correct position. Very low flow in the regeneration circuit to trip the heater.
16
c) d) e) f) g) h) i)
Audio-visual indication to indicate excessive regeneration air temperature Audio-visual indication to indicate failure to switch over of four way valves. Audio-visual indication to indicate low flow in regeneration circuit.. Indicating lamps for control panel on, absorber under absorption, regeneration or cooling, heater on, timer on etc. Audio visual alarm to indicate high air temperature after regeneration cooler Audio visual alarm to indicate blower motor failure (for blower type only) Interlock between heater and blower shall be provided so that the heater will not start till the blower is started.
3.3
Adsorber
3.3.1
Each adsorber shall be equipped with a suitable corrosion resistant austenitic stainless steel screen for desiccant support. Screen shall be in suitable sections so as to facilitate replacement through manhole. Provision shall be made for replacing and removing desiccant without dismantling the connected pipe work.
3.4
Heater
3.4.1 3.4.2
Heating of re-generation air, wherever applicable shall be by means of Electric Heater. Heater shall have at least 20% excess capacity. The heater may be of internal type, provided on each adsorber for purge type of dryers. For other type of dryers the heater shall be external type. The electric heating elements shall be U-Type and made from Ni-chrome steel, or incolloy material.
3.4.3
The heater shall have 2/3 number of banks depending on the heater capacity.
3.4.4
Safety valve shall be provided, for external type heater.
3.4.5
Suitable arrangement shall be provided to control regeneration air temperature.
3.5
Shell & Tube Heat Exchanger (regeneration cooler)
3.5.1
The heat exchanger shall be horizontal type with carbon steel saddle supports.
3.5.2
Regeneration cooler shall have 20% margin on surface area.
3.5.3
The heat exchanger shall have SA 179 (Carbon steel) cold drawn tubes. The standard type size shall be 20mm O.D. and tube pitch shall be 25mm. Minimum tube thickness shall be 14 BWG. The tube shall be seamless Expanded tube to tube sheet joints shall be provided. U tubes, shall not be used/
3.5.4
Heat exchanger shall be designed and located such that they can be removed or services without disturbing pipe work.
3.5.5
Minimum 20 NB vent shall be provided at the highest point and drain shall be provided at the lowest point on the shell. Safety valve discharge shall be located at the highest point.
3.5.6
Bolting for channel and girth flanges shall consist of continuously threaded studs conforming to SA 193-B7 with nuts in accordance with SA 194-2H. The tube side velocity for cooling water shall be in the range of 1.25 to 2.5m/s at mean temperature.
3.5.7 3.5.8
Fouling factor for air side and cooling water side shall be considered as 0.0004 hr m’°C/keal (each side) unless otherwise specified.
3.6
Pre filter and After filters
3.6.1
A pre filter with isolation and by-pass arrangement shall be provided at the inlet. Pre filter shall be fitted with an automatic drain trap with by-pass arrangement.
3.6.2
The pre filter shall be able to remove water and oil droplets and dust down to 1 microns particle size with an efficiency of 99%.
17
3.6.3
Two numbers after filters-one in operation and one as stand-by shall be provided at the dry air outlet for arresting the desiccant dust particles. The after filter shall be valved to permit each item to be services during normal operation. The after filters shall have 99% efficiency for 5 microns particle size.
3.6.4
The cartridges shall be of PECO/PALL/BEA FILTRI/CUNO/FILTERITE/SCHUMAKER/ULTRAFILTER/CARBORUNDUM make.
3.7
Moisture Separator
3.7.1
Moisture separator with automatic drain trap and by pass arrangement shall be provided after the regeneration cooler. A demister shall be provided in the separator outlet.
3.8
Blower (For Blower Type Only)
3.8.1
Blower shall be complete with drive electric motor, common base frame with foundation bolts, flexible connection, V-belt or flexible coupling and V-belt/coupling guard, damper at outlet etc. Fan casing should have drain plug, inspection door and lifting lug. Noise level shall not exceed 85 dBA at I metre from the fan,.
3.8.2
The rotor assembly shall be statically and dynamically balanced.
3.8.3
Drive motor sizing should have 20% margin in case of V-belt driven fan or 10% margin in case of direct driven fan over max shaft power during operation or under cold start condition.
3.8.4
Blower/fan shall be heavy duty type with ample wearing and bearing surface for continuous operation without excessive vibration. It shall have at least 10% margin on capacity and head. A minimum service factor of 1.6 shall be used for selection of belts.
3.9
Pressure vessels (Absorber, Heater, Regeneration cooler, moisture separator and receiver) All the pressure vessels shall be designed, fabricated, inspected and tested as per ASME SEC. VIII DIV. I with latest addenda. The wall thickness of Vessel shell and heads shall be calculated with design pressure and temperature in accordance with applicable codes. In no case the thickness (in mm) be less than following:
3.9.1 3.9.2
3.9.3 3.9.4
For diameter less than 2400 mm Wall thickness = D/1000 + 1.5 + corrosion allowance. For diameters 2400 mm above. Wall thickness = D/1000 + 2.5 + corrosion allowance. D = Diameter of vessel in mm. Minimum corrosion allowance for carbon steel shall be 3.0 mm, unless otherwise specified. Following guide lines shall be followed for selection of carbon steel material for pressure parts a) Plates From 0º C to + 425º C – SA 516 b)
Forgings From 0º C to + 425º C – SA 105 tested & inspected.
c)
Nozzle pipes From 0º C to + 425º C – SA 106.
d)
Fittings SA 234
Elbows shall be long radius type. e)
f)
Bolting From 0º C to + 425º C – SA 193 GR B7, SA 194 GR 2 H. All internal bolting shall be stainless steel type 304. Gaskets
18
1.5 mm thick compressed asbestos gasket upto 457 mm diameter, 150 lbs RF rating 3 mm thick for sizes over 457 mm. Compressed asbestos 1.5 mm thick gasket shall be used for internal assemblies. 3.9.5
Following guidelines shall be followed for selection of carbon steel material for non pressure parts From 0º C to + 350º C IS: 2062 SA 53, IS 1239
3.9.6
Specification of carbon steel plates
Carbon steel plates used for this job shall conform to latest issue of specifications SA -20 with additional requirements mentioned herein. a) b) c) 3.9.7
One product analysis of each heat shall be carried out & reported chemical analysis shall be as per applicable specifications with carbon content not exceeding 0.23%. Normalised plates with workman like finish shall be used. No reconditioning / repair shall be permitted. Plates of thickness from15 mm to 50 mm shall be examined ultrasonically as per SA – 435.
Manholes/Hand holes and Nozzles
a)
All nozzles, above 3” NB size shall be provided with reinforcement pads. Calculations for reinforcement pads as per ASME shall be submitted. b) Small vessels shall be provided with two pad type inspection opening of 150 NB size. c) For vessels with diameter less than 900 mm and having removable internals, shell flanges shall be provided. d) For vessel with diameter 900 mm and above, man hole of 450 NB shall be provided. Manhole cover shall be provided with davit 3.9.8
3.9.9
Heads Dished ends shall be of seamless construction, torispherical or 2:1 ellipsoidal type and shall be heat treated after forming as per as per ASME SEC –VIII Div.1. However in case hot forming is carried out inside the normalizing range, no stress relieving i s necessary. Flanges a) All flanges shall be as per ANSI B-16.5. Larger flanges not covered by ANSI-B-16.5 shall be to MSS-SP44. b) For nozzles 100 NB and below only weld neck flanges shall be used slip on flanges may be used for nozzles above 100 NB, 150 lbs rating. c) All Flanges above 150 Lbs rating shall be weld neck type.
3.9.10
Welding Welding of all components shall be of a high order as a minimum requirement, welding process, heat treatment details and non destructive quality control testing etc. for piping shall meet the requirements of the welding specification charts (Sht. 14 of 4). Pressure parts joined by “but” welds shall be full penetration. Where both side welding is not accessible, root run by tungsten inert gas process or backing strip may be used to ensure full penetration. Backing strip, if used, is to be removed after welding. 3.9.11 Post Weld Heat Treatment
Vessel shall be heat treated whenever it is required due to service requirement or due to code requirements. Vessels shall be post weld heat treated as a complete unit and no welding is permitted once post weld heat treatment is done. 3.9.12
Radiography A minimum of 10% of the main seam welds and 100% of all ‘T’ junctions shall be radiographed.
Defective welding disclosed by radiography shall be chipped out, reviewed and reradio graphed. Moreover, any other additional radiographs or test required by applicable design/construction code are to be carried out. All fillet welds should be DP/MP tested. 3.9.13
General
a)
Vessel weighing more than 5.0 MT shall be provided with lifting lugs.
19
b) c)
Fabrication tolerances indicated in EIL standard 7-12-001 shall be adhered. Manufacturer shall furnish additional tow sets of gaskets for every manhole and nozzles provided with blind flanges. The final gaskets shall not be used for conducting tests in shop. d) Nozzles up to 50 NB size shall be stiffened with 2 Nos. stiffeners of 40 mm wide x 6 mm thick flats welded at 90ºapart. e) Vessel diameter 300 NB & below shall be made from seamless pipe only f) Rolling of plates for making shell shall be lengthwise.
3.10
Piping Piping within the battery limit shall be carried out as per ANSI B 31.3 and good engineering practice. Piping materials shall be as per EIL standards s[e/ Mo. 6-44-05 A3A & J3A class) The horizontal clearance in front channel or bonnet flange shall be bundle length + 1 meter. Access platform with ladder for desiccant filling on adsorbers shall be provided as required.
3.11
Instrumentation Instrumentation shall be as per General specifications in Appendices 5 & 6
3.12
Electrical Equipment Specifications
3.12.2 3.12.2.1
3.12.2.2
Heating Element Electric Heater shall comprise of required numbers of elements of same KW rating spare capacity as per Cl. No. 3.4.1 shall be provided. The heater’s surface shall be coated with suitable rust resistant point.
3.12.2.3
Skin temperature thermocouple at suitable locations shall be provided if specified elsewhere, to cut off the power supply to heating elements where the set temperature is exceeded/
3.12.2.4
Terminals of individual heater elements shall be brought out to a IP-55 terminal box mounted on the unit and with the help of Heat Resistant wires/copper bus, bars the start point/bank formation shall be done in the terminal box.
3.12.2.5
Two nos. of each studs shall be provided on terminal box for connection to purchaser’s earth grid.
3.12.3
Heater control panel
3.12.3.1 3.12.3.2
Heater control panel shall be in line with Appendix 14. Heater control panel shall comprise of TPN incoming switch fuse and contactor. All hardware required to switch the heater in various combination/groups shall be provided. It shall be possible to isolate different groups individually. DOL starter feeder for blower motor shall also be included in the control panel.
3.12.3.3
Control supply shall be 230 V AC tapped between phase and neutral.
3.12.3.4
If heater control is Thyristor type then its design & supply should be as per Appendix 18.
3.13
Thermal Insulation
The following materials with the corresponding weather protection cladding as specified herein shall be used for all piping/ equipment/vessels etc. Material specification Resin Bonded Mineral Wool Performed pipe insulation as per IS 9842 Metal-mesh covered bonded mineral fibre blanket & blanket type pipe insulation as per IS 8183. Density
Aluminium cladding
Pipe sections density 140 kg/m³ for piping and Mattress (lightly resin bonded) density min. 120 kg/m³ for others.(Above 14’ including pipes vessels etc.) 26 SWG up to 14’ for preformed pipe sections 24 SWG above 14” for lightly resin bonded mineral
20
wool for pipes, vessels, eqpts. Etc. Minimum thickness of insulation shall be as follows: Adsorber
4.0
100mm
Heater
80mm
Piping
40mm
INSPECTION AND TESTING
4.1 Equipment shall be subjected to stage wise expediting, inspection and testing at vendor’s/sub vendor’s works by purchaser/its authorized inspection agency. Vendor shall submit Quality Assurance (QA) procedures before commencement of fabrication. Approved QA procedures shall form the basis for equipment inspection. 4.2.1
Fittings, valves, instruments, other accessories like filters etc. shall be duly tested and manufacturer’s test certificate shall be furnished.
4.2.2
All the pressure vessels shall be hydrostatically tested and inspected as per applicable codes and standards. The total skid shall be hydro tested or pneumatically tested at applicable pressure. Any other tests as per data sheets, standards, codes shall also be performed.
4.2.3
Any or all the tests, at purchaser’s option, shall be witnessed by purchaser/its authorized inspection agency. However, such inspection shall be regarded as check up and in no way absolve the vendor of his responsibility.
4.3
Performance Testing and Guarantees:
4.4.1
The unit shall be performance tested at site after commissioning. The guaranteed parameters shall be checked during the performance test. All instruments necessary for performance testing shall be arranged by the vendor at side. Calibration of all testing equipments shall be done by vendor.
4.4.2
Vendor shall guarantee the following: -
Capacity of the unit.
-
Dew point of air at the outlet through out the cycle including the cycle Change over period.
-
Pressure drop across the unit.
-
Utility consumptions
5.0
PROTECTION AND PAINTING
5.1
All exposed carbon steel parts to be painted shall be thoroughly cleaned from inside and outside to remove scale, rust, dirt and other foreign materials by wire brushing and said blasting as applicable Minimum acceptable standard in case of power tool cleaning shall be St.3 and in case of blast cleaning shall be Sa 2
5.2
5.3
1/12 as per Swedish standard SIS 0055900. Non-ferrous materials, austenitic stainless steels, plastic or plastic coated materials insulated surfaces of equipment and pre painted items shall not be painted. Stainless steel surfaces both inside and outside shall be pickled and passivated
5.4
Machines and bearing surfaces shall be protected with varnish or thick coat of grease.
5.5
Depending on the environment, following primer and finish coats shall be applied.
21
Environment i)
Normal industrial
Description Primer
: 2 coats of Red oxide zinc chromate 25 microns )min.) thick each
Finish coat
ii)
Corrosive industrial
Primer
:
2 coats of synthetic enamel, each 25 Microns (min) thick.
:
2 Coats of Epoxy zinc chromate each 35 microns (min) thick.
iii)
Coastal and marine
Primer
:
2 coats of high build Chlorinated Rubber zinc phosphate, each 50 microns (min.) thick
iv)
All environments
Finish
:
2 coats of heat resistant Aluminium paint suitable for specified temp. each 20 micron thick
(All values refer to dry film thickness) 5.6 6.0
The colour of finish coat shall be intimated to vendor after placement of order PACKAGING AND IDENTIFICATION
6.1
All packaging shall be done in such a manner as to reduce the volume. The equipment shall be dismantled into major components suitable for shipment and shall be properly match marked for site erection.
6.2
Attachment, spare parts of the equipment and small items shall be packed separately in wooden cases. Each item shall be appropriately tagged with identification of main equipment, its denomination and reference number of the respective assembly drawing. Detailed packing list in water proof envelope shall be inserted in the package together with equipment.
6.3
6.4
7.0
Each equipment shall have an identification plate giving salient equipment data, make, year of manufacture, equipment number, name of manufacturer etc. SPARE PARTS
7.1
Vendor shall submit his recommended list of spare parts with recommended quantities and itemized prices for first two years of operation of the equipment. Proper coding and referencing of spare parts shall be done so that later identification with appropriate equipment will be facilitated.
7.2
Recommended spares and their quantities should take into account relate factors of equipment reliability, effect of equipment down time upon production or safety, cost of parts and availability of vendor’s service facilities around proposed location of equipment.
7.3
Vendor shall also submit a list of recommended commissioning spares with quantities and the itemized prices.
22
SAMPLE DATA SHEETS of COMPRESSOR, AIR DRYER & ELECTRIC MOTOR
23
DATA SHEET FOR I/U AIR COMPRESSOR 1. Location
:
2. Tag No.s 3. Nos. required
: C& C2 Nos., 1 No. working,1No. standby
:
Platform
4. Service
:
Utility Air
5. Site
:
Offshore, outdoor
6. Drive
:
Direct couple
7. Duty
:
Continuous
8. Service
:
----
9. Type
:
Flooded screw with separator
10. Gas handled
:
Air
11. NM3/hr. (1.033Kg/cm2 A, 0°C dry)
:
800
12. Pressure (kg/cm2 A)
:
Normal atmospheric rated – 1.033
13. Temperature (Degree C) Min./Max.
:
15/43
Inlet conditions
14. Relative humidity (%) @35°C :
80
15.Molecular weight(M)
29
:
Discharge conditions
16. Pressure (Kg/CM2 g)
:
11.5 min.
17. Temperature(Degree C)
:
55.0
18. Signal source type
:
Electronic
19. Noise specification
:
Applicable to machine, applicable to neighbourhood, acoustic housing required
20. Sound level
:
88 dBA @ 1.0m
21. Painting
:
As per General Specifications in Appendix 4
22. Unusual conditions
:
Saliferrous
23. Bearings Number
:
Male rotor DE NDE Female rotor DE NDE
24Rotation viewed from compressor driven end Remarks
: CW
24
1.
Bidder to submit completely filled in data sheet along with bid to check the technical adequacy of the offer submitted. 2. Air fin cooler shall be sized/thermal designed with ambient temperature of 40°C 3. Both compressors shall shut down when the system pressure is 11.5 Kg/cm2g. 4. System pressure and set pressure requirement shall be harmonized w.r.t. the discharge pressure/set pressure of other Compressors of IC complex during post order stage. 5. Fastening of the compressor blocks, covers etc. shall be with stainless steel hexagonal headed bolts and nuts only. Use of Allen bolts or hex socket head bolts is not permitted. 6. Bidder to specify compressibility, inlet volume (NM3/hr) (wet/dry) at inlet and discharge conditions. 7. Bidder to specify performance parameter – BKW required (all losses included), speed (RPM) pressure ratio ®, volumetric efficiency (%), silencer differential Pr. kg/cm2, 8. Bidder to specify speeds – max. cont. max. (tip speeds, m/s @ max. operating speed, min. allowable speed, vibration – allowable levels peak to peak. 9. Bidder to specify shaft material, casing material and type, cladding material, the type of shaft seals, bearings, housing construction, type of material, max. working pressure, max. design pressure, rotor – material no. of lobes. 10. Bidder to specify coupling – make, model, lubrication, type. Vibration detectors – type, couple, number at each shaft bearing, total number manufactured. Base plate shall have drip rim. 11. Bidder to specify lube oil system, weight of compressor skid and recommended crane capacity.
25
DATA SHEET FOR MEDIUM VOLTAGE SQUIRREL CAGE INDUCTION MOTOR ELECTRICAL DESIGN DATA PLATFORM Description
Specifications
Bidder’s offer
Motor tag No.
1. 2. 3.
Voltage
415 ± 6 %
Frequency (Hz)
50 Hz ± 3 %
Fault level (KA)
4. 5. 6. 7. 8. 9. 10. 11.
Duty
50 KA for 1 sec. for the system Continuous
Phase
3
Connection
Delta
No. of terminals
6
Design Ambient temperature
40 °C
Temp. rise
80 °C
Cable size (mm²)
Later
Type of cable
12. 13. 14.
Enclosure type
PVC sheathed Cu conductor armoured FRLS IP – 55 WP
Cooling
TEFC
Insulation class
15. 16.
Applicable standard
‘F’ with temperature rise limited to that of ‘B’ GS in Appendix 3
Hazardous area classification/Gas group
Zone
18. 19. 20. 21. 22. 23.
Suggested Motor rating in KW / Manufacturer
*
Shaft Kw / Kw at end of curve
*
Speed / rotation of equipment from coupling end
*
Starting / max torque required (mKg)
*
Equipment / coupling type
*
24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.
Manufacturer
*
KW rating
*
No. of poles
*
Frame designation
*
Mounting
*
Full load speed (rpm)
*
Full load torque (mkg)
*
Starting torque as % of full load torque
*
Full load current (A)
*
Starting current at 100 % Voltage (A)
*
Breakdown or pull out torque %
*
Rotation viewed from coupling end
*
Starting time at 80 % V (Sec.)
*
Starting time at 100 %V (Sec.)
*
17.
-2, Gas groupIIA/IIB Temperature class – T3 Type of explosion protection Ex(n) / Ex(e) / Ex d for motors located within compressor enclosure. Ex(d) Ex d / Ex e / Ex n for motors located out door Technical particulars from Driven Equipment manufacturer
Starting condition – On no load / Under loaded * Condition Technical Particulars from Motor manufacturer
26
38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48.
Power factor at 100 % load
*
Power factor at 75 % load
*
Efficiency at 100 % load
*
Efficiency at 75 % load
*
Space heater watts /volts ( for motors rated 3.7 Kw & above /240V, 1 Ph., 50 Hz.) Bearing type /No. DE
*
Bearing type /No. NDE
*
Type of lubrication
*
Weight of motor (Kg)
*
Canopy required / not required
*
*
Notes: 1. Data marked with ‘*’ shall be furnished along with the offer for bid evaluation. 2. Separate datasheet shall be submitted for each of the motors of the package.
27
DATA SHEET - AIR DRYER PLATFORM : Platform
Project No of units
: One
Service
: To dry air delivered by Air Compressor. Suitable for instrument duty
Manufacturer: Type
: Split flow desiccant type
OPERATING CONDITION AND DATA Capacity of unit (outlet), Nm3/hr : 640
Source of air supply Inlet air Pressure, Kg/cm²g Temperature ºC Condition Oil content
From air compressor through pre filters. As per compressor data sheet 30 to 54ºC Saturated with water 0.01 ppm (to) be confirmed by compressor Manufacture
Outgoing air Pressure, Kg/Cm²g Temperature, ºC Condition Dryer System Type
11. 0 55.0 Max Dew point (-) 40º C at atmospheric pressure :Desiccant type (Activated Alumina) : Split Flow, closed circuit system with electrical Heating and air cooling for heated no purge type
Mechanical Design Pressure, Kg.cm²g Temperature ºC
12.5 250
Operating Cycle
4 hours drying & 4 hours regeneration plus cooling
Max. Pressure drop Kg/cm2
0.5
Inlet /Outlet air connection
80 NB
Turn Down
40%, without adjustment in control logic
Controls
Automatic with manual overrides
Dew-Point Analyser
Yes, installed with alarm at Local and main Control panel. Air dryer vessels, Regeneration Heaters and Associated piping shall be heat insulated
Insulation Utilities Available Electric Power
Direction of Air flow Adsorption Heating Cooling
415V ±6%, 3 Phase, 50 Hz +3% 220V ± 6%, Phase, 50 Hz + 3% 24 V DC Top to bottom Bottom to Top Bottom to Top DESICCANT
Type
Activated alumina
28
% dynamic adsorption capacity in the (Company to approve ) design HEATER Design Code ASME SEC.VIII DIV. I (Latest Edition) Corrosion allowance 3 mm Material of heating element Chrome Nickel HEATER CONTROL PANEL 415 v + 5%, 50 Hz + 3 %, TPN AC
Input power supply
MOISTURE SEPARATOR
Design Code
ASME SEC VIII DIV.I (latest Edition )
Corrosion allowance
3mm (minimum)
Continuous drainer
Provided PRE FILTER AND AFTER –FILTER
Filter Cartridge
PRE-FILTER
AFTER-FILTER
Solids in feed
Water & oil droplets
Desiccant dust Particles
Housing Design code Corrosion allowance Construction details Direction of flow Elements cleanable Cleaning procedure Holding and sealing Arrangement
ASME SEC. VIII, DIV.I (Latest Edition) 3 mm (min) 3 mm (min)
Yes/No (Give detailed write up.) As per cartridge manufacturers standard/ recommendation
