Post on 16-Jan-2023
PROCESS DESCRIPTION
of 2 X 33 MT MOUNDED
PROPANE/LPG BULLET
AT
INSILCO LIMITED , GAJRAULA ,
UTTAR PRADESH
Insilco Ltd.
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Synopsis of project Insilco Limited
A group company of Evonik Industries Germany, is one of the leading producers of precipitated
silica in South Asia. The Company was incorporated in the year 1988 and commenced commercial
production in January 1993. The Company’s registered office and plant is situated at Gajraula,
Uttar Pradesh. There are being held 73.11% Equity Shares of the Company with Evonik Degussa
GmbH, Germany and the rest 26.89% Equity Shares are widely distributed among public. The
Equity Shares of the Company are listed on the Bombay Stock Exchange.
Organisation
The Corporate Office of the Company is located at Noida. The corporate functions like Controlling, Finance, Secretarial, Legal and IT are based here.
The Plant management including Plant Head, the Engineering function, ESHQ, Project, Commercial and HR and Centralised Accounting function are based at Gajraula.
The Sales and Marketing of Insilco’s products are handled through Evonik India Private Limited, with headquarters in Noida and regional offices in Noida, Noida, Chennai and Kolkata. Insilco also has a dealer network in various cities all over India.
Culture: Guiding Principles
All operations are carried out in accordance with the international standards of Evonik Industries to ensure quality and consistency of products.
In accordance with the guiding principles of Evonik, we adhere to the following principles:
Focus on our customers Treat people fairly, with consistency and respect different opinions Respect diversity in culture, gender, nationality and race Take responsibility and lead by example Support innovation and initiative, learn from mistakes, strive for excellence Set clear goals, empower employees and encourage open feedback Be open, honest and share information Encourage learning, develop people, foster teamwork Act with passion for the business
The tenets of Evonik Global Social Policy and Evonik Code of Conduct for Employees are applicable to Insilco operations and these are followed in practice.
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Site Description
M/s INSILCO LIMITED (IL) are setting up the '2X33 MT PROPANE/LPG MOUNDED BULLET’ Project
and has retained INDIAN OIL CORPORATION LTD (IOCL) as project management Consultant inter-
alia for recommending to Owner (IL), suitable Contractor for Works Contract. IL, a group company
of EVONIK LIMITED located at Gajraula, Dist. Amroha, UP. The nearest airport is Indira Gandhi
International Airport, New Delhi(2.5 hr Drive).
Site location
Plant Location
A-5, UPSIDC, Industrial Estate Bhartiyagram, Gajraula-244223 Uttar Pradesh, Phone: 09837923893
Nearest Railway Station Gajraula
Nearest Airport New Delhi
Nearest National Highway NH-24
Barometric pressure 750 mm Hg
Air temperature 50C to 42 0C
Relative humidity 30% to 90 %
Maximum Rain fall 200-300 mm
Seismic Factor As per IS: 1839 ZONE
Average Wind Speed 8 MPH
Maximum Wind Speed 13 MPH
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Brief description/Scope of the project
INSILCO LIMITED, GAJRAULA, Distt : AMROHA, UP, desires to construct a Mounded Storage facility
for LPG which will be compatible for PROPANE as well.
Presently HSD as fuel (Maximum 13 KL/day) are being used for Hot Air Generator. The purpose of
converting the existing HSD Installation, for use in Hot Air Generator with Propane/LPG, is to
achieve the Huge Saving in fuel cost.
LPG/Propane being cheaper and having better calorific value will also improve the end product
quality, besides recurring benefit in fuel cost.
The Payback period (ROI) is calculated as 7-8 months. Besides fuel cost saving, the proposed
Propane/LPG installation will also contribute to the environment. The Green Fuel Propane/LPG
will help in getting Carbon Credit also, which will be added advantage.
Mounded Bullets provide intrinsically passive & safe environment & eradicates the possibility of
Boiling Liquid Expanding Vapour Explosion (BLEVE) as compared to Exposed LPG Bullet Installation.
Though LPG handling possess many challenges, due to its inherent dangerous properties, modern
state of art safety features and mitigations have been taken into consideration while designing the
facilities using OISD codes, PESO norms and good engineering practice.
One Mound consisting Two (2) LPG/Propane bullets each 12.8m long & 2.8m dia. (approx.), with
Net LPG storage capacity of 33MT shall be constructed.
Liq. LPG/Propane from bottom outlet of Bullets will be taken to Water Bath Type Vapourisers
(1W+1S) of Capacity 800 Kgs/Hr. LPG/Propane Vapour so obtained will be taken to the Hot Air
Generator through Pipelines after regulating the pressure and flow in PRS (1W + 1S) installed in
the battery limit
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Plant Design Basis of LPG Mounded Storage Facility System overall design - As per recommendations of OISD Std. 150 and SMPV Rules
Single mound consist of 2 LPG Bullets with capacity of 33 MT each bullet.
Mounded storage shall be designed for a maximum outflow of 700 Kgs/Hr.
LPG will be Unloaded through LPG “Liquid Transfer – Vapour Recovery” Compressor
(1W+1S).
Special Unloading Arms having Swivel Joints and Emergency Release Coupling will be
used in place of Conventional Hoses.
Bullets are equipped with various instruments and interlocks through PLC.
Magneto restrictive type Automatic Tank Gauging will be provided in both the bullets to
know the instantaneous level of LPG. The Remote level displays will be available both in
SCADA/HMI room and at Unloading Location to know the content of product in each
bullet at any instant. ATG will also be used as back-up to HLS having interlocks with
Unloading LPG Compressor at high high level.
The HLS provided in bullets will have interlock with Unloading Compressor (Corken Model
291/Equivalent Blackmer Model) to avoid overfill of bullets. PT and PS will also have
interlock with Unloading Compressor. RTD will have interlocks with main power supply to
all equipment and will also open the Solenoid Valves of MV Sprinklers to cool the various
equipment in case of high temperature.
Gas Leak detection system with Alarm indication in HMI/SCADA : The Smart Type, 3-wire
Gas Transmitter having Digital display (both local and at panel) with Main and Remote
Panel having compatibility with PLC/HMI/SCADA will be provided in fenced area at
strategic locations as shown in P&ID (Enclosed).
Fire water monitors (4 Nos.) will be provided just outside fence area for easy access in case
of emergency.
The Proposed Mounded LPG installation will have its own fire fighting facility, Fire Water
Storage Tank (1, 50,000 Ltr. Cap.) with dedicated electrically driven fire water pumps (1620
LPM/70 Mtr Head) and engine driven pump (1620 LPM/70 Mtr Head). One jockey pump
will also be provided to maintain the desired pressure of 7 bar in hydrant line.
MV water sprinkler system are provided at TLD, over the Manholes of the Bullets, in LPG
Compressor shed, Vapouriser Shed and in the Inspection tunnel of each bullet.
Although Vapourisers are having various (in built) safety interlocks, still upstream and
downstream of the Vapourisers are provided with additional safety by providing ROV,
Pressure Transmitter and RTD to ensure the smooth operation.
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ROVs with flameproof limit switches to be provided at strategic locations to combat the
emergency from HMI Room. These ROVs to have interlocks with all possible undesirable
outcome from the instruments.
The Proportionate Remote Operated Valves with flameproof positioners are provided at
downstream of each PRS to control the LPG Flow as per varying requirement.
The entire system operations will be available live in HMI Room and will be monitored
round the clock by skilled instrumentation engineer.
Besides various interlocks the ESDs (Emergency Shut Down/MCP) switches to be
provided at three locations.
The battery Area will also be under continuous vigil of Security Guard and surveillance
of CCTV Camera.
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Operational Philosophy for the LPG/Propane plant
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The list of equipment of the plant are listed below
LPG related equipment :
Major Equipment :
1. Compressor-1 : For unloading of LPG from the Road Tanker
2. Compressor-2 : For unloading of LPG from the Road Tanker
3. Bullet-1 : LPG Storage tank (35 MT gross capacity)
4. Bullet-2 : LPG Storage tank (35 MT gross capacity)
5. Vapouriser-1: For converting LPG liquid to LPG vapour.
6. Vapouriser-2: For converting LPG liquid to LPG vapour.
7. PRS -1: For Pressure and Volume Control.
8. PRS -2: For Pressure and Volume Control.
Remote Operated Valves
S.No. Location of Remote Operated Valves Equipment
1 LPG Liquid Inlet line near the Road Tanker ROV-8113.01
2 LPG Vapour Balance/Inlet line near the Road Tanker ROV-8113.02
3 Compressor-1 Inlet/Outlet based on 4-way Directional Valve position
ROV-8108.01
4 Compressor-1 Inlet/Outlet based on 4-way Directional Valve position
ROV-8108.02
5 Compressor-2 Inlet/Outlet based on 4-way Directional Valve position
ROV-8109.01
6 Compressor-2 Inlet/Outlet based on 4-way Directional Valve position
ROV-8109.02
7 Compressor -1 Bye pass. ROV-8108.03
8 Compressor-2 Bye pass. ROV-8109.03
9 Vapour-Liquid Interconnecting line downstream of C-1 & C-2. ROV-8113.05
10 LPG Vapour Outlet from Bullet-1 ROV-8106.04
11 LPG Vapour Inlet to Bullet-1 ROV-8106.05
12 LPG Liquid Inlet to Bullet-1 ROV-8106.03
13 LPG liquid outlet from Bullet-1 ROV-8106.08
14 LPG Vapour Outlet from Bullet-2 ROV-8107.04
15 LPG Vapour Inlet to Bullet-2 ROV-8107.05
16 LPG Liquid Inlet to Bullet-2 ROV-8107.03
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17 LPG liquid outlet from Bullet-2 ROV-8107.08
18 LPG Liquid Inlet to Vapouriser-1 ROV-8110.01
19 LPG Liquid Inlet to Vapouriser-2 ROV-8111.01
20 LPG Vapour common outlet from Vapouriser to PRS ROV-8113.07
21 Proportionate Valve at PRS-1 PROV-8112.01
22 Proportionate Valve at PRS-1 PROV-8112.02
Fire fighting related equipment
1 Jockey Pump For maintaining the line pressure at
6 bar
2 Main Electrically driven pump-1 For water discharge in fire situation
– 5 bar
3 Main Electrically driven pump-2 For water discharge in fire situation
– 5 bar
4 Diesel Engine pump-1 For water discharge if Elec. Pump
fails to start
5 Manual Call Point-1 Near LPG Compressor area-
Unloading point
6 Manual Call point-2 Near Vapouriser area – On the
outside wall
7 Manual Call point-3 Near HMI/SCADA Room – On the
outside wall
8 SOV-8119.01 A 8119.01 B
Solenoid Valve on Water Sprinkler line for i) Bullet top, ii) Inspection Tunnel, iii) LPG Compressor shed
and Vaporizer Shed. (both SOVs are healthy
provided with bye-pass).
100.00%
Will start the sprinkler for cooling, the
moment air pressure drops to 1bar due to heat detection by QB
detectors, which are to be provided.
9 SOV-8119.02 A 8110.02 B
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10 PS-8119.03
Press. Switch for Jockey Pumps
6 bar (Falling), 7 bar (Rising)
To overcome the pressure drop in fire hydrant line.
11 PS-
8119.04 Press. Switch for Main Pumps (Elect. Pump-1)
5 bar (Falling), 8 bar (Rising)
To overcome the pressure drop in fire
hydrant line.
12 PS-8119.05
Press. Switch for Main Pumps (Elect. Pump-2)
5 bar (Falling), 8 bar (Rising)
To overcome the pressure drop in fire
hydrant line.
13 PS-8119.06
Press. Switch Spare (Jockey Pump) 6 bar (Falling), 7
bar (Rising)
NA
14 PS-8119.07
Press. Switch Spare (Main Pump) 5 bar (Falling), 8
bar (Rising)
NA
15
GLDS-8113.10
Gas Leakage Detector near Custody Transfer Area
Switch at set LEL To attend the Gas
Leakage at particular location.
16 GLDS-8106.10
Gas Leakage Detector near Bullet-1
Switch at set LEL To attend the Gas
Leakage at particular location.
17 GLDS-8107.10
Gas Leakage Detector near Bullet-2
Switch at set LEL To attend the Gas Leakage at particular location.
18
GLDS-8108-09
Gas Leakage Detector near Compressor Area
Switch at set LEL To attend the Gas Leakage at particular location.
19 GLDS- 8110-11
Gas Leakage Detector near Vapouriser Area
Switch at set LEL To attend the Gas Leakage at particular location.
20 GLDS-6 (8112)
Gas Leak Detector near PRS
Switch at set LEL To attend the Gas Leakage at particular location.
21 SOV-8120.01
Near Air Drier Solenoid Valve for supply air
cut-off
To maintain air supply at constant pressure
22 SOV-8120.02,03
Near Air Compressor. For auto
changeover of Air Compressor
To maintain air supply at constant pressure
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23 PT-8120.04,05
In QB Detector line For auto
operation of water sprinkler
To cool the area affected
24 PS- 8120.06,07
At outlet of each Air Compressor.
For auto changeover of
Air Compressor
To maintain air supply at constant pressure
The system is designed to operate in three modes:
1. Remote Auto mode
2. Remote Manual Mode
3. Locally Operated mode
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LPG Decantation Procedure
Ensure all the preliminary manual checks for the Road Tanker as listed out in Annexure.
Before starting the unloading of the LPG from the Road Tanker, the selection of the
Compressor and the selection of the Bullet are to be made from the HMI.
The unloading of the LPG from the Road Tanker to the Bullets is possible in any one of the
following combinations :
a) Compressor-1 and Bullet-1
b) Compresssor-1 and Bullet-2
c) Compressor-2 and Bullet-1
d) Compressor-2 and Bullet-2
Once any of the Compressor/Bullet combination is selected, the operator has to ensure the
position of all the corresponding manual valves for the respective combination as detailed
at Annexure-1, 2, 3 & 4.
If the manual valve positions as per the unloading combination is verified by the operator,
a button in the HMI for the same is to be pressed. Unless this button is pressed, Unloading
will not start (Neither manually nor Automatically).
Each Bullet can be in any of the following states :
a) Standby Mode (Default Mode)
b) Loading Mode (When Decantation is in progress)
c) Discharge Mode (When Discharging is in progress)
One of the Bullets is required to be selected and the status of the Bullet is displayed as
‘Loading’ in the HMI to indicate that the Decantation is possible to that Bullet. The second
Bullet will automatically be deselected and will be in ‘Standby’ mode.
Each compressor can be in any of the following states :
a) Standby Mode (Default Mode)
b) Working Mode (If compressor is selected)
Once any of the compressor is selected to ‘Working’ mode, the other compressor
automatically goes into ‘Standby’ mode.
In the Standby mode, the Inlet and Outlet valves of the corresponding compressor will be
closed and the compressor cannot be started.
Once the working mode is selected for a compressor, the Inlet and Outlet valves will
immediately open, and the compressor will be ready for decantation.
If any of the compressor is started, the system should not allow the other compressor to go
into ‘Working’ mode and consequently not allowing it to start.
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Decantation/Unloading Process
The decantation process can happen in any of the following modes :
a) Liquid Unload without compressor
b) Liquid Unload with compressor
c) Vapour Recovery with compressor
Once the Road tanker is placed and the Unloading arms are connected, and the operator
has to select the Compressor and Bullet combination
Liquid Unload without Compressor
The transfer of liquid LPG will initially take place because of the pressure difference
between the Road Tanker and the Bullet (First Unloading).
The pressure in the Road Tanker will generally be higher than that of the pressure inside
the Bullet.
The operator after ensuring the manual valve positions as per Annexure-1,2,3,4 depending
on the unload combination, will press a button ‘Manual Valves OK’ in the HMI. This is the
first check for the system to start the unloading process in any of the modes.
Once the ‘Manual Valves Ok’ button is pressed, the operator has to press the ‘Liq. Unload’
button in the HMI. The ROVs pertaining to the Compressor/Bullet selection, as detailed in
Annexure, will have to be in Auto mode. Otherwise the auto unloading will not start.
Once the ‘Liq. Unload’ button is pressed, the ROVs will automatically be selected as per the
preconditions of Annexure.
The transfer of the liquid LPG should be manually monitored by the operator at site with
the help of the view-glass (liquid Flow Indicator) provided. The liquid transfer is assumed to
be completed if there is no more liquid flow inside the view glass. The Liquid Level in
bullets to be read at HMI and at Unloading point.
Liquid Unload with Compressor
The operator after ensuring the manual valve positions as per Annexure-04 depending on
the unload combination, will press a button ‘Manual Valves OK’ in the HMI. This is the
first check for the system to start the unloading process in any of the modes
The entire liquid transfer from the Road Tanker into the Bullet is not completed if there is
still liquid inside the view-glass. The operator should now intimate the operator in the
control room to start the compressor, keeping the ‘Liq. Unload’ button pressed.
The operator in the control room should ensure that the ‘Liquid Unload is in progress’ and
start the compressor in manual mode.
Once the compressor start button is pressed, the respective ROVs for the unloading
combination as per Annexure-03 will automatically be set and then start the compressor.
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The liquid transfer with compressor will be in progress and the operator at the site should
be continuously monitoring the view-glass. The Control room should be informed when
there is no more liquid transfer observed at site.
The operator in the Control room should stop the compressor first and then press the
‘Liq. Stop’ button in the HMI.
The ‘Liq. Stop’ button will reset the position of the valves to the default positions (All
close except the Vapour Outlet valves of the Bullet).
The manual valves should be set to the normal positions.
Vapour Unload with Compressor
The operator after ensuring the manual valve positions for Vapour Unloading as per
Annexure-04 depending on the unload combination, will press a button ‘Manual Valves
OK’ in the HMI. This is the first check for the system to start the unloading process in any
of the modes.
The transfer of the vapour from the Tanker to the Bullet in the Auto mode will happen
only through Liquid Inlet to the Bullet to ensure that there is no sudden rise of
temperature because of the transfer. Hence, the Liquid- Vapour interconnection Valve
will have be opened and the same is brought out in Annexure-04 for Manual valves.
The operator will press the ‘Vapour Unload’ button and the ROVs as per the combination
selected as brought out in Annexure-03 will be automatically set. The ‘Vapour unloading
is in progress’ will be displayed in the HMI.
If any of the ROVs is not in Auto mode, the vapour unloading will not start.
Once the feedbacks from all the respective ROV as per the Annexure-03 are set, the
compressor will be ready to start.
The compressor should be started in manual mode. Once the transfer is completed,
checked by the operator at site based on the pressure of the Road Tanker, the operator in
the control should be informed of the same.
The compressor should be turned off manually. Press the ‘Vap. Stop’ button. This will
reset all the corresponding ROVs to the normal positions.
The manual valves should be set to the normal positions
Locally Operated Mode
In the locally operated mode, the Remote/Local switch in the MCC panel for the corresponding
Compressors will be in the Local position. The operator will not be able to start/stop the
compressor from the HMI. All the HMI controls shall be disabled if the Local/Remote selection
switch is kept in Local mode. However all interlocks will remain active and unloading
compressor will be turned off automatically by any interlock in case of undesirable outcome
from the instruments.
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Discharging the LPG from the Bullet to the Vapouriser
There are two outlets from Both Bullet to the Vapourisers common inlet :
I. Liquid LPG Outlet a) Bullet-1 : ROV-8106.08
b) Bullet-2 : ROV-8107.08
The Bullet in the ‘Standby’ mode will change the status to ‘Discharge’ mode if the operator
presses the Discharge Button of the selected Bullet, and the Liquid outlet ROV is opened
automatically.
Discharge of the liquid LPG from the Bullet is done in Remote manual mode only. The
operator has to select the ROV corresponding to the selection of the Bullet. However the
following interlocks are to be considered for the operation of these valves.
a) The ROVs are to be closed if the corresponding Bullet is not in the Decantation
mode.
b) These ROVs should be closed if the pressure upstream of Vaporiser (PT-1008)
drops to 2.5bar, indicating that the Bullet needs replenishment and a popup in
the HMI for the operator to be provided.
II. Vapour LPG Outlet
a) Bullet-1 : ROV-8106.04
b) Bullet-2 : ROV-8107.04
These ROVs are single acting with fail safe Close Position. If the pressure at the Consumer
point is high, i.e.PT-8113.09 reaches 1.5 bar , the ROVs for the above Vapour Outlet are
closed.
The discharge of the LPG from the Bullet to the Vapouriser is directly by gravity.
Pressure at the consumer point (PT-8113.09) is set at 1bar (Low SP) to 1.5bar (High SP).
On Low value of PT-8113.9, Popup to the operator for necessary action.
On High value of PT-8113.9, Outlet of Vapourisers (ROV-8113.07) should be closed.
Pressure Control Valves at the Consumer point :
PROV-8112.01 : 700 Kg/hr
PROV-8112.02 : 700 Kg/hr
i. PROV-8112.01 : Working, PROV-8112.02 : Standby
ii. PROV-8112.01 : Standby, PROV-8112.02 : Working
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Vapouriser Operation
There are two vapourisers each of 800 kg/hr, with local controls independent from the PLC. Only
command to the breaker ON/OFF is provided in the HMI. Each vapouriser consists of heaters
whose supply is controlled locally, based on the following interlocks :
I. Water Temperature Interlock – Heater will be auto ‘ON’ when the temperature of the
water falls below 70 deg. and auto’OFF’ when the temperature reached 80 deg. The
inlet LPG liquid to the vapouriser will also be stopped by shutting off the locally
controlled Solenoid Valve.
II. Level of the LPG inside the Vapouriser – Inlet LPG SOV OFF
III. Pressure at the outlet of the Vapouriser – Inlet LPG SOV OFF
IV. ROVs corresponding to the selected Vapouriser should be in open position – both
Liquid LPG Inlet/Outlet.
V. Inlet ROV and Solenoid Valves of any of the Vapouriser should close as soon as RTD
8113.06 at Vapouriser common outlet indicates Low Temperature (below +30 degree
C).
VI. LLS-8110.04/8111.04 are water level sensor provided in both the vapourisers. If water
level goes below minimum level it will trip the vapourisers if in operation or not allow
to start when in cold condition.
Fire Fighting System
The LPG plant is to be provided with Fire Fighting system consisting of the equipment as
mentioned earlier. The line pressure in the Hydrant is to be maintained at 7 bar during normal
condition.
I. The function of the Jockey pump is to maintain the constant pressure at 7 bar in Fire
Water main Ring. This pump will automatically start if the pressure (PS-8119.03 or PS-
8119.06) in the line drops to 6 bar and automatically turned off at 7 bar.
II. If the pressure (PS-8119.04, 8119.05, 8119.07) drops below 5 bar, the Main Electrically
Driven pump-1 or pump-2 automatically starts. (The standby pump will start in case the
Working pump fails to start) .However, once started the Main Electrical Pump should
be either stopped in Remote manual from HMI or Local Manual from MCC.
III. If both the Main Electrically driven pumps fail to start, a popup to the operator for
indicating the same should appear in HMI.
IV. Diesel Pump is to be started manually.
V. QB detectors are provided at, i) top of the bullets, ii) LPG compressor shed, iii) LPG
Vaporizer shed, iv) LPG Unloading Shed. In the presence of undesirable heat, these
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QBburst and Nitrogen pressure drops in the line, consequently SOVs 8119.01
(A&B)/02(A&B) open and auto sprinkling starts simultaneously at all locations.
VI. Separate Nitrogen Cylinder Manifold (fitted with NRVs, High Pressure hoses etc) with
2 Nitrogen Cylinders, pipelines, necessary control devices like pressure regulators
(1W+1S), Isolation valves at strategic locations and pressure transmitters to be
provided. The pressure transmitter will give two output (i. when pressure drops to 2
bar - Hooter in HMI Room, ii. When pressure drops to atmosphere automatically
opens the SOV 8119.01 (A&B)/8119.02(A&B)of sprinkler line)
VII. There is one separate line also for manual sprinkler operation only at Tanker Lorry
Unloading location.
VIII. 4 Nos Water Monitors are provided on all four sides (just outside fence area) for fire
fighting operation.
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Basic design data and equipment specification
Design Data I. HSD is presently used for Hot Air Generator.
INSILCO LTD intends to replace HSD with Propane/LPG and use the same for
theexisting Project. ‘IL’accordingly intends to install a new 2X33 MT Capacity
Propane/LPG Mounded storage system along with Propane/LPG unloading,
storage and distribution system for meeting the requirement of HOT AIR
GENERATOR.Tenderer to note that proposed Propane/LPG supply shall be
installed independent of the existing HSD system
II. Propane/LPG will be received by means of road tankers. After ensuring proper
earthing of the system and coupling of Unloading Arm and other connections
to the tanker, compressors shall be run to draw Propane/LPG vapour from
storage tanks outlets and increase the pressure of vapour in tanker. Due to
generated pressure differential between tanker and storage tank, the liquid
content in the tanker shall be discharged into the storage tanks. After
withdrawal of the entire liquid content of the tanker, the residual vapour shall
be recovered by means of compressors and shall be discharged into the
storage tank. The vapour recovery process shall continue till the vapour
pressure in the tanker falls to about 1.5 kgf/Cm2 (g).
Propane/LPG from the storage tank shall be drawn into electrically heated
water bath type vapourisers and the Propane/LPG vapour sent to the plant
through piping network after necessary pressure reduction.
The design of the system shall be such that, continuous supply of
Propane/LPG vapour can be carried out from one (1) bullet while the other
(bullet 2) is being filled from the road tanker and vice versa.
Tenderer to note that all equipment shall be as designed that Propane or
LPG may be used depending on availability.
Tenderer to note that in case of fire/leakage of Propane/LPG (100% LEL),
the electrical power system of LPG station may get switched off except the
emergency lighting.
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III. Total storage capacity of the system envisaged shall be around 66 tons of
Propane/LPG. The above storage shall be achieved by means of two (2) nos.
storage tanks of 72 m3 water capacity each . The Propane/LPG compressors,
vapourisers and fire water pumps shall be designed considering the total
storage capacity of 66 tons of Propane/LPG.
IV. From the vapouriser Propane/LPG shall be supplied to the
consumer at a maximum withdrawal rate of 700kg/hr. The equipment shall be
capable of operation from 0 to 100% range of the above requirement .
a. A typical flow scheme of Propane/LPG unloading,
storage and distribution shall be as per drawing no.–UTL/INS/LPG-38.
b. The layout of the Propane/LPG installation is shown in the
enclosed layout drawing no UTL/INS/LPG-31.
V. All safety norms pertaining to handling of Propane/LPG, other utilities,
electricity etc. in plants are to be followed by the Contractor while erecting,
testing and commissioning the plant.
VI. Composition and characteristics of Propane/LPG are given in Table-1.
TABLE- 1
TYPICAL COMPOSITION AND CHARACTERISTICS OF PROPANE/LPG
Characteristics Specification
Sr.No. TYPE PROPANE LPG
1 Vapour pressure Kg/Cm² 23 at 65ºC 10.5 at 45ºC
2 Volatility : Evaporation temperature
in ºC. For 95% by volume at 760 mm
Hg Pressure, max .
2.0 2.0
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3 Total volatile sulphur % by weight 0.02 0.002
4 Copper strip corrosion Not worse than
No.1 of IS: 1448
(1960), Test
Method “ P: 15”
Not worse than
No.1 of IS: 1448
(1960), Test
Method “ P: 15”
5 Hydrogen sulphide Absent Absent
6 Dryness No free
entrained
water content
No free entrained
water content
Properties of Propane / LPG are given below:Based on a typical Analysis
TYPE PROPANE LPG
Boiling Point at atmospheric pressure - 42ºC - 18ºC
Specific gravity of liquid 0.56 0.58
Specific gravity of gas (air=1) 1.6 1.8
Flash point(ºC) -60 - 60
Heat of combustion per unit wt of liquid at
N.T.P.
23500
Kcal/Ncum
25000
Kcal/Ncum
Flammable range,
percentage of gas in
gas/ air mixture
At Lower Limit 2.1 1.5
At upper Limit 10.10 99.0
Volume of air required to burn unit volume
of gas
20 31
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Note:Figures given above are only approximate and would vary depending upon the
proportions of the mixture .
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Equipment
Storage Tanks Two (2) nos. Propane/LPG storage tanks of net LPG capacity 33
tons each shall be provided. The mounded storage tanks shall be complete with all
nozzles, minimum two manholes (Not less than 600 mm) , safety relief valves, excess
flow check valves, level indicators, pressure and temperature indicators, RTD, ATG, HLS,
Rochestor Gauge, other instruments, fittings etc as necessary. The tanks shall be
designed for a design pressure of 21.5 Kgf/Cm2 at top of the vessel and a design
temperature of –42OC to +55 OC and a working pressure of 19 kgf/Cm2 and working
temperature of 550C. Material of construction of the storage tanks as follows:
Shell and dish ends SA 516 Gr.70/537 Class-I
Saddle Support IS 2062 on RF Pad of SA 516 Gr.70/537
Class-I
Accessories like ladders, railing, supports etc. shall be provided.
Level gauge systems as required, pressure indicators and
temperature indicators, with instrument piping, valves, fittings, supports etc
including audio-visual annunciation at the control room shall be provided.
Encasement of structural steel columns of the storage
tanks with suitable resisting materials of approved quality as per IS 6044 (Part II)
shall be indicated.
Vapour Compressors Compressors shall be two (2) nos. proven for Propane/LPG Service (Model 291 of
Corken/Equivalent Blacker Model) for unloading from road tankers. In this connection,
the tenderer shall furnish along with his offer the calculations for the time required for
liquid unloading and vapour unloading under varying suction conditions .
The compressors shall operate on varying suction
conditions from 1.0 Kgf/Cm2 to 12.5 Kgf/Cm2 and for a delivery pressure of 13.0
Kgf/Cm2. The compressors shall be stationary, non-lubricated, reciprocating type
driven by electric motor. The compressor shall generally meet the requirement of
the code API 618 - Reciprocating Compressors for General Refinery Services.
The compressor shall be complete with suitable drive,
necessary interconnecting pipework with a knock-out drum on suction line and
safety relief devices. All safety interlocks (factory built) for the compressors
should be considered.
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All component parts of the compressors shall be designed to withstand a vapour
pressure of 23.0 Kgf/Cm2 at 750C
Vapourisers a) Two (2) nos. Propane/LPG vapourisers each of 800 kg/hr
capacity shall be provided to generate around 700 kg/hr of Propane/LPG vapour
from 01 working and 01 no. Vapouriser as standby. The vapouriser shall be
designed for operation from 0-100% of the rated capacity and for a minimum
ambient temperature of 5oC. The pressure of vapour from the vapouriser outlet
shall be adjustable by suitable pressure reducing valves to match the requirement
of the consumers.
b) The vapourisers shall be designed and will be of flame and
explosion proof construction and constructed suitable for continuous operation,
wherever, necessary. Vapouriser shall be designed to withstand a vapour pressure
of 23.0 bar of Propane/LPG at 65OC.
c) Vapouriser shall be indirectly heated type using electrical
coil immersed in water bath as heating medium.
d) Necessary precaution shall be taken to prevent liquid
Propane/LPG passing through the vapouriser to the gas discharge piping. Suitable
demisters, if necessary, made of CS/SS steel shall be fitted..
e) The heat input to the vapouriser shall be suitably
controlled to prevent the pressure in the vapouriser reaching the set pressure of
the relief valve. Necessary regulating valves, controls and instruments etc shall be
provided for this purpose.
f) The vapouriser shall be provided with strainer at the liquid
Propane/LPG inlet, automatic pressure regulators at the Propane/LPG vapour
outlet, pressure relief valves at the vapour discharge and other accessories as safe
and satisfactory operation.
g) The vapourizers shall be approved by CCE and will consistof all essential safety and
control feature to prevent over temperature, over pressure and passing of liquid
Propane/LPG downstream.
Unloading Gantry A. One (1) unloading station for unloading Propane/LPG from road tankers shall be
provided
B. The unloading gantry shall be complete with Unloading Arm having Swivel Joints
and Emergency Release Coupling, necessary
pipes for conveying liquid and gaseous Propane/LPG from road tankers to storage
tanks, excess flow check valves, isolating valves, non-return valves, pressure
gauges, liquid flow indicators etc. The tenderer shall provide for all structural
work. Necessary earthing provisions, supports for pipes and Unloading Arm shall
be provided.
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Pipework, Insulation and Painting
1) All piping required for unloading Propane/LPG from road
tankers, compressor house, storage tanks, in the yard, storage tanks to
vapourisers and all interconnecting piping shall be provided. The tenderer shall
also include all piping for the medium velocity water spray pr otection system, fire
hydrant system from/to fire water pump house to/from the Propane/LPG
installation. The tenderer shall also include the Compressed Air Piping for ROV
operation from Two Nos 5.0 HP Air Compressors kept in MCC Panel Shed. The
tenderer shall also include the Nitrogen Piping with two Nitrogen cylinders and
other necessary accessories for QB detectors to be provided on bullet tops, inside
inspection tunnel, in vapouriser/PRS Shed, in Unloading Compressor shed and in
Unloading Gantry Shed.
2) The design, material, construction, assembly, inspection
and testing of piping shall generally conform to the requirement of the
Specification with specific references to ASME B31.2 and ASME B31.4 for
Propane/LPG piping and ASME B31.3 for other services .
Product Piping – CS Seamless Sch-80 as per ASTM A106 GrB.
Fire Hydrant Piping – MS “C” Class ERW.
Compressed air piping - MS “C” Class Galvanised ERW.
Nitrogen (downstream of PRS of Nitrogen Manifold) Piping – GI
“C” Class ERW. SS-316 Sh-80 or as suitable piping will be used
Upstream of PRS in Nitrogen Manifold System.
3) The LPG piping system for the complete installation shall be
suitably earthed to discharge stray charges developed. Wherever necessary, safety
relief valves shall be provided for releasing excess pressure generated. The piping
system provided shall be complete with isolating valves, check valves, control
valves, safety shut-off valves etc. Necessary expansion joints shall be provided in
the piping system if required.
4) Utility service headers will be terminated at the supply
limit of Propane/LPG installation i.e. upto the proposed fire water tank of the
installation. The tenderer shall tap his water headers from purchaser’s headers by
employing appropriate branching method. Suitable valves , in an accessible
position to isolate his headers from other headers , shall be provided.
5) Pipework and associated equipment shall be over pressure
protected as per recommendation of codes API.TP.520 and BS: 5500.
6) All valves used in Propane/LPG service shall be specifically
designed for Propane/LPG service, antistatic fire safe design class#300. All ROV
isolation valves shall be pneumatically and remotely operated from control room.
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ROVs will be,single acting and fail safe CLOSE design, provided with Flameproof
Limit switch.
7) All vent gas lines shall be piped to a safe distance from the
operating area. All vent/drain lines shall be fitted with Two Isolation Valves.
8) For safe operation of the installation, excess flow check
valves necessary flame arrestors/flash back arrestors, safety valve shall be
installed in Propane/LPG piping wherever required by the safety requirement.
9) All plant drains shall discharge into Percolation Pit. Storm water drain and plant
drains shall be separated.
10) Piping within the Propane/LPG installation shall run on
concrete pedestals/ structure at a height of about 500 mm from the finished
ground level.
11) All Propane/LPG piping shall be subject to radiographic
examination of not less than 25% of the total number of joints.
12) Wherever required and possibility of occurrence of low
temperature/freezing of Propane/LPG pipelines exists, the same shall be properly
insulated.
13) One (1) number wind sock with digital indicators for wind speed and wind
direction will be installed (Electronic Wind Detection System).
14) Necessary 3-wire Smart type Digital Type Gas Transmitter Propane/LPG detectors
at suitable height, in fenced area will be provided so as to give alarm in case of
leakage of Propane/LPG is beyond the preset value. The necessary control panel
and hooter shall be located in the HMI/SCADA Room. The Propane/LPG detector
shall be in flame proof construction and approved by CMRI/CCE for use in
Propane/LPG area.
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Fire protection system The facilities envisaged in the Fire Protection Systems are:
I. Fire Hydrant system for the Propane/LPG storage facility comprising bullets, compressor, vapouriser, unloading gantry etc.
II. Supplementary protection of bullets by medium velocity water spray system alongwith detection system
III. Fire extinguishers, sand buckets shall be installed at point of access to the storage installations as per IS:2190.
IV. The system shall be designed as per stipulation of OISD and TAC regulations.
Source of Water Supply
Water supply for the proposed fire protection system shall be from industrial make -
up water pipeline available near the Fire Water Tank of Propane/LPG ins tallation.
The storage reservoir and the pump house for fire water pumps shall be suitably
located as per OISD/TAC regulations.
The reservoir shall have two (2) compartments with suitable interconnection to
facilitate cleaning and repairing. Supply and erection of valve on the inlet to the water
storage reservoir shall be included in the scope of work of the tenderer.
1. Design Data
1) Medium Velocity water spray system shall be provided mainly to extinguish the
fire involving liquids withflash points of below 65 degree. Three principles of
extinguishment are employed in the system for emulsification, cooling and
smothering.
2) ONE (1) standby diesel operated pump will be provided in addition to two (2) nos.
electrically operated pumps. (1W +1S) Pumps shall be p rovided to supply water for
the purpose of fire fighting system considering individual demands of various
detached blocks within the risk. The pumping capacity required shall be
equivalent to the highest of the demands. Battery of diesel pumps shall be
complete with trickle charger.
3) The pumps shall be horizontal split casing type with closed
impeller. Impeller shall be statically and dynamically balanced.
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4) The pumps shall directly be coupled with the drive through
flexible coupling. Removable coupling guards shall be supplied and mounted.
Speed of the pumps shall not exceed 1500 rpm.
5) Suction piping with valves, strainer and fittings and
delivery piping with non-return valves, stop valve, drain valve, pressure gauges,
and other accessories as specified in Fire Protection Manual shall be provided. If
required, suitable priming arrangement also is to be included.
6) The diesel engine shall be directly coupled with flexible
coupling to the pump. The coupling between the engine and the pump shall allow
each unit to be removed without disturbing the other.
7) The diesel engine after correction for altitude and ambient
temperature shall have bare engine horse power rating at least 20% greater than
the maximum brake horse power required to drive the pump at its duty point
and in no case less than the brake horse power(BHP) required to drive the pump at
150% of the rated discharge.
8) The engine shall be capable of operating continuously on
full load at the site elevation for a period of four hours.
9) The engine shall be of the compression ignition mechanical
direct injection type capable of being started without the use of wicks, cartridges,
heater plugs or either, at an engine room temperature of 70oC and shall accept
full load within 15 seconds from the receipt of the signal to start.
10) The engine shall be suitable for electrical starting over a
battery. The electrical starting system shall comprise starting motor, battery, and
dynamo for charging the battery together with all necessary accessories.
11) The performance testing of the diesel engine shall conform to the standards ISO
3046 (Parts I, II, III, & IV).
12) The storage reservoir and the pump house for fire water
pumps shall be suitably located as per OISD/TAC regulations.
13) The reservoir shall have two compartments with suitable interconnection to
facilitate cleaning and repairing.
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Fire equipment
Equipment related to High Velocity Water Spray system will include but not be limited to
the following.
Sr.No. ITEMS
1 Electric Motor driven pumps
2 Diesel Engine driven pump
3 Jockey pump
4 Compressors
5 Spray Nozzles ( Open type )
6 Pipe & Fittings
7 Gate Valves, Non-return Valves, Isolating Valves etc.
8 Piping Network including supports, instruments etc.
9 Detection system
10 Reservoir (Concrete)
11 Pump House
12 Battery and battery chargers
13 Pylon Support etc.
14 MCC Control Panel including all electrics
15 Instruments
Fire hydrant & Medium Velocity Water Spray System
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The system would consist of pumpsets along with jockey pump, quartzoid bulb detectors,
water spray nozzles, nitrogen piping, & Mild steel piping for spray nozzles, underground
Mild steel hydrants, monitors etc. as required for systems.
The design of the system shall be carried out to meet the requirement of OISD and shall
also meet the requirement of Rules for water spray systems of TAC. All components of
the system such as pumpsets, detectors, spray nozzles, hydrants monitors, etc shall be of
TAC approved type
Spray Nozzles
Open type spray nozzles with suitable angle of discharge and other discharge
characteristics designed to provide an effective water spray ,shall be used. The nozzles
shall be fitted in independent overhead pipework above exposed area of the storage
tanks, inspection tunnel, vapouriser shed, compressor shed & tanker lorry unloading
shed. The protection network shall be fabricated in the form of horizontal rows of
sprayers connected by piping in rings. The number of rows required shall be governed by
the diameter of the vessel as per sprayer application charts of TAC.
Quartzoid bulb Detectors
Quartzoid bulb detectors approved by the Tariff Advisory Committee only shall be used.
These bulb detectors shall be connected to pneumatically charged pipelines, fitted
around exposed surface of tanks, Vapouriser & LPG compressor shed, TLC Shed Etc.
Detectors shall be spaced according to the approved standards for quick and effective
detection. Detectors shall be so positioned that they will not interfere with the spray
pattern of the sprayers anywhere.
Solenoid Valve Assembly
Required number of automatically operated Solenoid Valves (1W+1S) shall be provided.
In the event of fire, the PT fitted on QB detector pipe will give command to Solenoid
Valve(through PLC)to open automatically when the pressure is reached to atmosphere
and Solenoid valve shall come into operation allowing the water to enter the sprayers.
Pressure gauge and line strainer shall also be provided.
Jockey Pumps
ONE Nos. jockey pump shall be supplied with motor on commonbase plate and shall be
complete in all respects
Pump shall be supplied with one gate valve on the suction side and one gate valve along
with one check valve on the delivery side.
Controls for the Pumpsets
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Pump described above shall be automatically started, whenever there is a drop in
pressure in delivery lines. Suitable pressure gauges with adequate electrical contacts
shall be provided on both the delivery lines to enable automatic starting of the pump.
During power failure diesel engine driven pump shall be run. The diesel engine driven
pump shall be started manually in the event of a power failure/shut down and a pressure
drop signal from the pressure gauges/switches mounted on the delivery lines
Aboveground/Underground Firewater Mains
The firewater ring main shall be above ground throughout the installation site in closed
ring. The Ring main will be laid underground only at road crossing. The mains shall be of
Mild steel pipes. The sizes of the main shall be suitably selected as per the codes of Fire
Protection Manual. Isolation valves shall be provided at the required points to obtain the
best possible (Sizes are shown in hydrant lay out drawing).Isolation valves shall be
provided at the required points. The isolation valves shall be of cast iron / CS conforming
to IS 14846/or as applicable and shall be approved by the Committee. Isolation valves
shall be of right hand type. Valves wheels / lever must have an arrow head engraved or
cast showing direction for turning 'open' and 'close'.
Laying, testing and commissioning of the pipes and fittings shall be done strictly as per
the approved standards.
Erection of pipework along with all accessories, supports, etc shall include the following:
a) Supply of all bolts, studs, nuts, washers and gaskets as required, other than those
supplied with valves.
b) Flushing, cleaning and purging of the piping components and erected pipework
c) Corrosion protection coating and wrapping for UG pipes.
The successful tenderer shall carry out necessary excavation and back-filling for laying of
pipes, making foundation for pipe supports. He shall also construct all platform for
operating the Water Monitor.
Gas Detection System
Suitable gas detectors (as explained above) shall be provided at identified critical
locations inside the Propane/LPG installations. Audio-visual alarms as per requirement of
OISD standard shall also be provided at the instrument panel. Provision should b e kept
so that these alarms can be retransmitted to Purchaser’s central control panel located at
500 Mtr away from Installation site.
Corrosion Protection for UG Pipes.
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The successful tenderer shall include for supply and application of necessary corrosi on
protection. Coating and wrapping shall be of the following specification and the total
thickness of the coating shall not be less than 4.0 mm.
a)One coat of Shalimar Platicised coal tar primer cold application
b) A flood coat of hot pipeline coating of plasticised coal tar with inner wrap of fibre
glass Resin Polyester tissue followed by a second flood coat of hot pipeline coating of
plasticised coal tar with inner wrap of fibre glass Resin Polyester tissue.
Air Conditioning and Ventilation System
Air Conditioning System
Split type Air conditioners of suitable capacity (2 X 50% capacity) shall be provided for
the HMI/SCADA Control Room to maintain the room temperature within 23+2°C.
Ventilation System:
Wall mounted exhaust fan of suitable capacity shall be provided in the fire pump house
and toilet. Ceiling Fan should be provided in Office (HMI/Scada Room), Security Guard
room.
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Electricals
1. Scope 1. The scope of electrics shall include design and engineering, manufacture, testing
at works, packing, forwarding, supply, unloading, transport to work site,
installation, commissioning and performance testing of electrical system for the
entire work on a Discrete Turnkey package concept.
2. The scope of work shall include but not be limited to the
requisite number of 415 V, 3 ph, 50 Hz, AC squirrel cage
induction motors along with the main equipment, Motor control centre, local
control stations, soft starters, UPS, Lighting distribution boards/panels, 415 V &
240 V socket outlet, power and control cables including cabling accessories,
earthing and lighting system etc. complete in all respects for Propane/LPG storage
system.
3. The motor control centre (MCC) and other panels shall be
located at separate electrical panel shed and will feed power to pump house
equipment as well as Propane/LPG storage facility equipment. The supp ly and
installation of power and control cables from the MCC to the drive/motors
equipment and other panels, field instruments/devices limit switches etc. shall be
within the scope of work of the successful tender. Employer will terminate the
incoming power cable from two source to the MCC.
4. Power supply will be available from two source from
Employer.
5. Fabrication and erection of cable racks/trays/supports,
inclusive supply of steel materials, cabling materials, GS pipes/conduits, pipe
fittings, road crossing RCC/GS pipes etc. as required to complete the installation
for items shall be in the scope of the successful tenderer.
6. Obtaining approval from Statutory Government Authorities.
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7. All civil works inside electrical room, pump house,
Propane/LPG handling area as required and excavation and installation of
underground cables with supply of route marker, sand, bricks etc. embedded
underground and finishing the ground as before.
Successful tenderer shall carry out the following: (which are not speci fically
mentioned in BOQ)
1. Supply of complete list of equipment detailing individual items with accessories,
tools etc
2. Supply of drawings (both hard and soft copies) of the
equipment covered in this specification along with all necessary/specified test
reports.
a. Preparation of installation/erection drawings and obtaining approval of the
Employer for all items/ equipment/cables to be supplied & installed by the
successful tenderer.
b. Submission of As-Built drawings in electronic media (Read only CD) along
with requisite numbers of hard copies. The drawings shall be made in
proper format and shall incorporate INSILCO drawing number.
3. The successful tenderer shall supply al l operational spares as well as
commissioning spares and necessary tools for 2 years trouble free operation.
4. SMC mats, shock treatment charts, danger boards etc. as
required.
5. Any electrical item/equipment/component which has not been specifically called
for, but essential for the satisfactory operation/maintenance of the equipment
shall be provided.
6. Testing of all equipment and accessories covered under
the independent supply at manufacturer's works and/or recognised independent
testing centres before despatch of the same to site as well as all tests at site
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before handing over the system complete in all respect to the Employer prior to
inspection report of the Employer/consultant.
7. Make of all items under tenderer’s scope of supply shall be as per INSILCO List of
preferred make.
2. Design basis
Standards
All electrical equipment shall be designed , manufactured
and tested in accordance with the latest standards published by the Bureau of Indian
Standards (BIS), International Electro technical Commission (IEC)
The equipment/systems offered shall conform to the latest
Indian Electricity Rules as regards safety , earthing and other essential provisions
specified therein for installation and operation of electrical equipment . Statutory
requirements of the Government of India and other statutory authorities shall also be
complied with.
1. Two(1w+1S)Electric power from factory substation, will be made availableby
purchaser at one location near MCC Panel Shed from source at 415 V, 3phase,
4wire, solidly earthed system. For any other voltage to be adopted suitable
conversion equipment/ step down transformer shall be provided by the Tenderer.
2. All electrical equipment shall be designed for satisfactory
operation with supply voltage variation of +6% and frequency variation of + 3%
and fault level of 50kA.
3. The electrical equipment shall be suitable for operation at 45 0 C at indoor area and
at 500 C at outdoor area.
4. The following ambient conditions will be maintained in various premises:Electrical
MCC Panel Shed : Ambient
HMI/Scada PLC Control room : 25 +/- 20 C,
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Controlled atmosphere will be maintained in HMI/SCADA room.
5. Equipment/devices to be located in hazardousatmosphere/location shall be of
flameproof (ZONE-1, Gr II A/B T3) construction as per requirement of relevant
standards.
3. Equipment Specification
415V, 3-PH, 50 HZ AC Squirrel Cage Induction Motors
1. All 415 V AC motors shall be squirrel cage induction type
and shall conform to relevant IS and shall have standardised dimension. In case of
hazardous locations, Viz. Propane/LPG installation area, flame proof motors
suitable for Zone-1 Gas group II A/B T3 shall be provided. The flameproof motors
shall have acceptance certificate issued by Central Mining Research Station,
Dhanbad and CCOE Certified. Flame proof motors shall be supplied complete with
flame proof terminal box and flameproof cable glands.
2. All motors shall be energy efficient type as per relevant
IS. The degree of protection shall be IP:54 . For outdoor locations degree of
protection IP 55 with canopy shall be considered
3. The motor terminal box, located generally on top shall be preferred.
4. Standard motors below 75 kW rating and all flame proof
motors shall have direct cable connection whereas all motors rated 75kW and
above, power junction box shall be provided. Flexible 1.1 kV PVC copper cable
connection shall be considered in between junction box and motor terminal box
5. Anti-condensation heater shall be provided for motor of frame size 280 and above
and outdoor motors viz. cooling towers.
6. Other details of the motors may be obtained from relevant code.
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I. The tenderer shall submit the technical catalogue and general arrangement
drawings for all motors on award of contract and shall also furnish the following
technical information on each of the motors offered by him.
II. Thermal withstand characteristics - hot and cold. III. Load curves showing current, efficiency, power factor and percent slip with
respect to output. IV. Safe stall time V. Torque and current curve with respect to speed
VI. Current vs. time characteristics 7. The name plate of the motors shall contain the following information:
a) Motor type
b) Serial Number
c) Connection
d) Voltage, No of phases, frequency
e) Rated output at 40oC and at specified ambient temperature, KW/HP
f) Rated curren
g) Duty
h) RPM
i) Power factor and efficiency
j) Class of insulation
MotorControl System Requirement
1. The electrical controls for equipment comprising
group of motors shall be done from one composite motor control centre to meet
the operational requirement. It should be possible to control each drive either
through PLC/HMI or from local control stations Local/remote selector switches
shall be provided in the MCC. Combined MCC shall be considered for Propane/LPG
storage area and pump house equipment and shall be located at separate
electrical room near pump house.
2. The MCCs shall be of totally enclosed, floor mounted,
cubicle type construction in multi-tier compartmentalised(TYPE 4B) single / double
front non-draw out design with degree of protection IP-50.
3. The MCC shall have double bus coupler (with
mechanical castle key interlock) of ACB/MCCB depending on current rating as per
requisite number of outgoing motor and power feeders with MCCBs. Air circuit
breakers shall be electrically operated (motorised spring charged). MCCBs shall be
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of 50 kA short circuit rating with electronic adjustable O/C, S/C releases (E/F
release for crane feeders only). For motors rated 37kW and below, MPCBs can be
used in place of MCCBs.
4. Motor control feeders shall generally comprise of MCCBs,
magnetic contactor and overload relay (thermal overload or electronic type.Type -2
coordination shall be ensured while select ing the motor feeder components. Each
feeder shall have ‘ON’, ‘OFF’ & ‘TRIP’ indicating lamps.
5. Outgoing 415 V motor feeders rated 15 kW and above as
well as essential feeders rated below 15 kW shall be provided with digital ammeter
having RS 485 port. The ammeter circuit shall have provision for connection of one
additional remote ammeter.
6. The MCCs shall have TPN busbars of aluminium alloy
conforming to relevant IS. Rating of the busbars shall not be less than the derated
rating of the incoming feeder.
7. The control power 240V AC shall be fed from two full capacity control
transformers with automatic changeover arrangement and individual DP MCBs for
each outgoing feeder.
8. MCC shall have two (2) nos. spare motor feeders, one for
the highest rated motor and the other of mostly used motor rating . MCC shall also
have two (2) nos. 100 A and two (2) 63A TPN MCCB (50 kA fault level) feeders . Two
blank compartment shall be kept in MCC for future addition of motor feeder of 15
kW rating (minimum).
9. The protection circuit for each motor feeder shall be wired
in such a manner that this will be effective in all modes of operation and
stop the motor even in case of PLC malfunctioning . All safety features shall be
directly hardwared in MCC with necessary feedback to PLC.
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10. Digital type kWh meters (communicable type) as well as
panel mounted analog type 3-Ph voltmeter with selector switch & 3-Ph digital
ammeter with CTs shall be provided for the incomer of MCCs .
11. All other features shall be strictly in conformity to the standard Specification.
12. All drive motors shall be provided with local control station
containing Start-Stop push buttons for local isolation and maintenance purpose.
13. Tenderer shall consider control of all drives/heaters,
valves, etc. from PLC/HMI for remote operation. Adequate
indications/annunciations shall be included to fulfil the requirements of the
process in all respects.
14. The fire pumps shall be automatically started whenever
there is a drop in pressure in the delivery lines. Suitable pressure switches with
adequate electrical contacts shall be provided on the delivery lines to enable
automatic starting of the pumps. During power failure, diesel e ngine driven pump
shall be run manually.
15. The Propane/LPG compressors shall be controlled by local
control stations containing Start-Stop push buttons (mushroom headed stop push button,
press to lock-turn to release type) to be installed near the compressors. In addition the
Propane/LPG compressors shall have ON-OFF control facility in the PLC/HMI. The local
control stations located near the compressors and heaters shall be of flameproof
construction(Zone-1 Gr II A/B T3). The compressors shall have factory fitted control panel
for compressor protection.
16. All local control stations, junction boxes, cable glands,
welding socket outlets etc. to be located in the hazardous area shall be of flame
proof design conforming to Zone-1 Gr II A/B T3.
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Soft-starter Units (Digital Microprocessor based)
1. Soft starter shall be provided for motors rated 150kW and above
2. The unit shall have fully digital microprocessor based control and protectio n unit.
3. The unit shall comprise incoming MCCB unit (similar to
that specified for MCCs), three phase thyristors/triac based bridges.
4. One adequately rated by-pass contactor shall be provided
to by-pass the soft starter unit after the motor is accelerated to full speed.
5. The control electronics shall be accommodated in sub -rack away from power
handling devices.
6. The soft starter shall have the feature to inject current during starting for starting
feeder with higher inertia.
7. The soft starter unit shall be housed in a sheet steel
enclosed free standing design with ingress protection class IP -4X (minimum).
8. The soft starter unit shall have potential free contacts for signal exchange with the
PLC/Automation system.
Uninterrupted Power Supply System (UPS)
1. The uninterrupted power supply system shall be suitable
for duplicate power supply, microprocessor based solid state design complete with
all controls, protective devices, power distribution board, storage battery bank
etc. to make the system complete with all respects.
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2. Current sharing type parallel redundant (100%) stand by
configuration shall be provided with 30% reserve capacity. The battery shall be
sealed maintenance free type suitable to supply rated current for emergency
period of 30 minutes to meet the total power requirement of programmable
controllers and other electronic equipment like gas detectors, emergency lighting
etc pertaining to instrumentation system.
3. Tenderer shall indicate KVA rating of UPS unit along with complete technical
details in his offer.
4. One (1) no. outgoing feeder of UPS DB shall be utilised for emergency lighting in electrical
and control room, security room and toilet..
5. The UPS system shall also supply uninterrupted power to Gas Detectors and
detectors monitoring panel.
Switch socket outlet
The offer shall include all power control instrumentation and specials cables required for
completion of the job in all respects. These shall include cabling accessories such as
racks, trays, supports, hooks, conduits and fittings, gland, lugs, etc to make the
installation complete in all respects. Cable selection and installation shall conform to
relevant codes and specifications. All power and control cables shall be 1100 Volts grade,
heavy duty type, PVC insulated and PVC sheathed, armoured type. The cable installation
in Propane/LPG storage area shall be generally as per normal practices followed in
Petroleum Refineries and Propane/LPG installation and is subject to Employer's approval .
Earthing
1. The offer shall include one lot of earth stations, GI earth
conductors and accessories required for complete equipment earthing, including
storage tanks, unloading gantry, Unloading Compressors, Lightings, Fire Hydrant
Pumps, Pipelines, vapourisers, Pamels etc.. The earthing shall be as per relevant IS
code and OISD. Any modification demanded by the Government electrical
inspector will have to be carried out without extra cost to the Employer. The
general requirements of the earthing installation shall be as follows:
2. Earthing of non-current carrying parts of the equipment
which includes MCC, instrumentation control panel, local control stations, motors,
instruments etc as required.
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3. Structural frame work not associated with power system
such as steel structures of the building, storage tanks, Vapourisers, unloading
platform, Propane/LPG wagons and trucks shall be earthed as required.
4. Separate earthing system shall be considered for electronic equipment earthing.
Lightening Protection
Tenderer shall include lightning protection as required outside the fenced area.
LIGHTING SYSTEM
The lighting system covers general lighting within the
scope
The scope shall generally include but not be limited to
the following:
1. All lighting fittings complete with accessories & poles etc .
2. All lighting distribution boards comprising MCCBs, DP
MCBs, junction boxes etc. as required.
3. All interconnecting cables, cabling materials, GS
pipes/conduits, cable trays, structural supports, earthing materials etc. as required
to interconnect the complete lighting system.
4. The LDB shall generally comprise incoming TPN MCCB of
adequate rating and requisite number of 32/16 A DP outgoing MCBs (9kA) as well
as adequately rated busbars. The MCB DBs shall generally comprise incoming 32A
DP miniature circuit breaker isolator and requisite number of outgoing 10/16 A
miniature circuit breakers. 2 spare feeders in LDB and 2 spare feeders in MCBCB
shall be provided.
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5. For automatic switching of road/area lighting, necessary
power contactor, synchronous timer (L&T type TSQ-100-T or equivalent, 0-24 hrs),
auxiliary relay (if required for multiplication of auxiliary contact s), auto/manual
selector switch, start/stop push buttons, ON/OFF lamps, control fuses and other
accessories shall be provided on the outgoing feeder from lighting distribution
board.
6. Type of lighting fittings to be used in various areas shall be
as follows:
i) Within Propane/LPG
storage and handling
area
250W HPMV non-integral type
Flameproof light fittings
ii) Electrical room and
control room
2 x 40W/1 x 40W fluorescent
fittings. In case of rooms without
false ceiling these shall be of rail
type and for control room/offices
with false ceiling mirror optics
recessed type fittings are to be
adopted
iii) Pump house 70W/150W HPSV well glass fittings
having separate or built-in control
gear box.
iv) Emergency/Escape
Lighting for Electrical
and control room
9/11 LED Lamps fed from UPS
v) Road/area lighting LED lighting (100W), to be
mounted on buildings, structures
as well as on 5 M mounting height
single reach galvanised
tubular/road lighting poles and
straight tubular flood light poles of
adequate numbers.
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7. Selection of light fittings and accessories and lighting
installation shall conform to standard technical specification.
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Instrumentation & automation GENERAL
1. This Section covers design, supply, erection, testing and
commissioning of Instrumentation and control system complete with all
accessories as required for the Propane/LPG Storage Installation to achieve
maximum automatic and remote manual operation.
2. All the items of equipment as covered in the specification
shall be complete in all respect and any equipment not covered in this Section but
essential for proper installation, operation and maintenance of the
Instrumentation and control system shall be deemed to be in the scope of supply
of the Tenderer.
1. Scope
1. The tenderer’s scope of supply for instrumentation and control system for
Propane/LPG storage system shall generally include but not limited to the
following:
a) Field mounted instruments comprising primary measuring elements,
transmitters, Local pressure gauges with 3way isolation valves
temperature gauges level switches ATG, temperature switches, pressure switches, Pressure/Temperature transmitter, pressure relief valves, automatic flow control valves, RTDs etc.
b) PLC for execution of various monitoring, control, alarm annunciation , sequencing and interlocking functions for the above system. PLC shall have redundant CPU, power supply module and communication processor with required number of input/output modules. Any changes in one program of One CPU will automatically get upgraded in other CPU.
c) Three (3) Nos. PC based Visualization system (HMI), for operation, monitoring of status, fault alarms, real time trends, historical trends etc., Out of which two (2) nos. operator stations and one (1) No. Engineeri ng station. Operator station shall have HMI runtime software and Engineering
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station shall have HMI runtime cum development and programming software.
d) One (1) set of redundant Ethernet switch with 20% spare ports after installation of complete system.
e) Two (2) nos. Laser printers of A3 size and one (1) No. laser printer for alarm and event logging.
f) Dust proof operator console - Ergonomically designed console - for housing HMI PC, Servers etc. and Power Distribution Panel comprising set of double pole MCBs for Powering of field instruments and Level -1 Automation System.
g) Pre-wired PLC cabinets which shall contain power supply units, marshalling racks and other relevant system hardware.
h) One (1) number local panel with required electrical accessorie s for truck unloading.
i) For signal exchange with Plant Supervisory Control and Data Acquisition (SCADA) system, available with INSILCO, OPC connectivity over Ethernet shall be kept in the automation system, to be supplied by the ‘tenderer’
j) Flow, pressure and temperature of all utility services provided by INSILCO at the battery limit shall be measured and monitored in Level-1 automation system. Suitable provision shall be kept to transmit these signals and necessary electrical signals, if any, to SCADA/DCS system OF INSILCO through OPC.
k) All necessary power, signal, control and special cables including accessories as may be required for cable laying and termination as per standard norms.
l) Supply and installation of electronic earthing stations including su pply of earthing wires and accessories for the instrumentation and automation system.
m) Supply and erection of field instruments mounting strand and other installation materials, instrument and impulse pipes and fittings, cable
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trays, conduits, junction boxes, earthing hardware and cabling and piping accessories as required.
n) All impulse pipes, instrument air lines shall be of 2mm wall thickness.
o) Supply and installation of GI cable trays, GI /MS conduits, pull boxes etc wherever required shall be included in the scope.
p) The data of LPG station shall be hooked up to intranet as a report on line for monitoring the position of the plant from a remote place.
2. One (1) set UPS system for power supply to PLC, HMI
stations and instrumentation system along with sealed maintenance free battery
for powering upto 30 min.
3. Field proven multi-tasking operating system, diagnostic
programmes, application and communication software packages for the functions
to be executed by PLCs and the engineering and operator stations.
2. Design Basis
The instrumentation and Level-1 automation system for Propane/LPG Storage system
shall perform various interlocking, monitoring and alarm generating functions to achieve
safe and hazard free operation.
The proposed measuring and control instruments for the
Propane/LPG Storage system shall include, but not limited to the following: -
a) Flow indicationtantalisation complete with flow measuring elements (MASS FLOW METER) with transmitters at the outlet of Propane/LPG header.
b) Automatic Level Gauge, High Level switch, local temperature & pressure indicator at Propane/LPG vessels.
c) Pressure reducing station at downstream of Vapourisers to consumer point.
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d) Local temperature & pressure indicator, High level switches at EntrainmentSeparator
e) RTD downstream of Vapouriser,
f) Factory fitted interlocks at Unloading Compressor with factory fitted Starter panel .
g) Pressure transmitter, Digital Temperature controller, LLS for water level, Temperature Indicator & pressure indicators in the vapouriser unit.
Audiovisual alarmannunciation shall be provided for the following abnormal
conditions
i) Propane/LPG vessel level high
ii) Propane/LPG vapouriser pressure high
iii) Vapouriser heating liquid temperature high and low
iv) ES drum level high
v) High and low pressure of Propane/LPG at downstream pressure control station
vi) Compressor discharge pressure high
vii) Compressor discharge temperature high
viii) Vapouriser outlet temperature low.
ix) Gas leakage at various locations
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Safety Interlocks
I. The compressor will trip at the following condition a. Very low suction pressure b. Very high discharge pressure c. Very high discharge temperature d. Low lube oil
II. Stopping of Propane/LPG to Vapourisers due to following conditions
a. High pressure at downstream of vapouriser b. Low temperature of vapouriser heating water c. Failure of electric power d. Liquid Level high in ES. e. Low temperature in downstream of vapouriser. f. Very high temperature in downstream.
III. ONOFF type temperature control forvapouriser water immersion heater .
IV. Automatic stoppage of Propane/LPG in the event of high pressure (more than 1.5
bar) atdownstream of pressure reducing valve .
3. Equipment Specification
1. For guideline concerning the design and manufacture of Instrumentation
equipment refer P&ID (Enclosed).
2. For guide line concerning the design and manufacture of Level -1 Automation
system refer P&ID (Enclosed).
3. Instrument panelfield mounted instrumentselectric
actuator shall be of industrial flameproofexplosion proof construction and shall
be suitable for installation in hazardous area Zone-1 Gr II A/B T3.
4. Make of all items for instrumentation and Level1
automation system shall be as per approved make list.
5. Quantity and type of field instruments shall be as per P&I
diagram to be finalized during detail engineering by successful bidder.
6. All control JBs shall have door hinged at the bottom with retainer chain. Protection
class shall be IP 54 with canopy suitable for Zone-1 Gr II A/B T3 for inside fenced
area.
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7. Signals having different voltage levels shal l not be mixed
up in same cable or same tray.
8. 20% spare cores shall be provided for all multi-core cables.
9. Terminals at the marshalling cabinets of PLC shall be
fuse protected with LED indication.
Telecommunication system
1. Scope The scope of work of tenderer shall include but not be
limited to the design, manufacture, supply, installation, testing and commissioning of
Telephone network within the Propane storage area.
2. Design basis Telephone Cable Network
Telephone connection shall be provided from P lant
Telephone system for communication inside as well as outside the Plant. For providing
telephone connection at required locations, following shall be provided.
a) One (1) no. Krone make Main Cable termination (CT) box with Krone connectors having 20 pair termination capacity shall be installed inside battery limit of Propane storage area. Incoming telephone cable from Plant telephone cable network and distribution telephone cables from Propane storage area will be terminated in the above main CT box and cross jumpered as per requirement.
b) Required quantities of armoured Jelly filled / unarmoured Dry core Telephone Cables. For each telephone connection, two (2) pair unarmoured telephone cable shall be provided from above CT box to subscriber location.
c) Rossette Blocks (RJ11 type) suitable for termination of two (2) pair cable with mounting arrangement.
d) All cabling accessories
e) Require nos. of telephone sets
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.
3. Equipment specification
All telecommunication system equipment shall conform to
the ‘General specification for Telecommunication system’
Tenderer to include the following .
a) Plant Telephone System
b) 2 Sets of telephones in HMI/SCADA Room.
c) 1 Set in Security room.
d) 1 Set in Fire Pump room.
e) 1 Set in MCC Panel shed
PAINTING
Painting shall be done as per standard engineering practice .
UTILITY SERVICES
The following utilities will be provided by the Purchaser .
Electric Power
a) Electric power available in the MCC panel shed shall be as 415V, 3-phase, 4-
wire, 50 Hz with system fault level of 50 KA.
b) If any equipment is designed for a voltage different from
the above, necessary transformers and conversion equipment shall be provided.
c) The control circuit voltage adopted shall be
240 V AC for contactors with AC coils, auxiliary relays etc. For solenoid valves,
operating voltage shall be 24 V DC.
Water
Industrial quality water shall be available from the
make-up water circuit at a temperature of 350C maximum and a pressure of 1.0
Kgf/Cm2 at the fire water tank of LPG/Propane Installation site by purchaser.
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Cathodic protection system
1. Scope The impressed current Cathodic Protection System should provide a uniform Cathodic current
density to the target bullet structure in order to maintain the steel at a potential between -0.85 V
and -1.2 V w.r.t. a Cu/CuSO4 reference electrode.
Steel ( off ) potential needs to be greater than -0.85 V to avoid corrosion and less than ( off ) -1.2V
to avoid excessive hydrogen evolution which Induces hydrogen embrittlement of high carbon
steels used in the fabrication of bullet tanks. The protected structure thus needs to be maintained
within a narrow window of 0.35 V.
The type of Anode and its positioning relative to the bullet tank has a critical influence on both
achieving the uniform current density and maintaining the potential of the structure within the -
0.85V to -1.2V potential range. In addition, the relative positions of the associated pipes and tanks
have to be considered.
The above critical issues for selecting a suitable Cathodic Protection System should be addressed
by the CP Contractor.
2. Design basis
For designing the system, the following parameters should be considered:
Sr.No. Item Specification
1 Soil Resistivity Min 10,000 ohm-cm(*)
2
CP current
density
Bare Steel 10mA/sqmt
Painted Steel 5 mA / sqmt
Bitumen Coated 3 mA / sqmt
Polyethylene
Coated
125 A/sqmt
Polyurethane 75 A/sqmt
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3 Propane Bullet Dia 2.8 Mtrs. (Approx)
4 Propane Bullet length 12.5 Mtrs (Approx)
5 %age bare steel 30%
6 Design Life 30 years
7 No. of Vessels 2 Nos.
(*)Exact measurements should be taken at site.
Based on the above design parameters, the tenderer shall design a suitable system taking
particular care with the positioning of the ANODES and the Cu/CuSO4 reference cells.
MONITORING
Reference electrode shall be provided 3, 6, 9 and 12 O’ Clock position at two places for each
tank (refer OISD-150). One Zinc electrode for each tank shall also be provided. Permanent CU
CuSO4 Reference electrode shall be of make M/s.Borin Manufacturing, California, Trade name
“Stelth 2” Stationary Reference electrode/ equivalent. Provision shall also be made for installing
reference electrode in 12 O’Clock position so that in future it could be retrieved and replaced from
top of mound for each tank.
TRANSFORMER RECTIFIER UNIT
The transformer rectifier shall be automatically controlled C.P. rectifier natural air cooled, of rating
- Single Phase (~ 220 V) – 25 V/25 A with auto/manual override facility. The ampere rating is a
function of the type of coating used on the tank.
Control:Constant Voltage/Current
Construction :Outdoor type – IP 55/dust proof with an additional canopy.
This TR unit will be located in the safe and outside the licensed area which is approx 125
mtrs away from the mounded vessel.
Transformer rectifier shall be floor mounted natural air cooled, weather proof and dust proof type. The transformer Rectifier Unit shall be installed in non-hazardous area.
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The power supply to the transformer rectifier shall be AC 220 V single phase, 50 Hz. As TR
unit is being provided outdoor, suitable enclosure with covered roof to be made for its
protection as per advise of Site in charge/IOCL.
POTENTIAL CONTROL
The C.P. system shall be provided with automatic potential control. A switch shall be provided to
switch the system between automatic and manual operation. Automatic reference selector logic
with 3 Nos. reference inputs located in the TR unit will be capable to control the current output
such that the structure to soil potential at the connected reference cell is maintained within 10
millivolts of the set value.
The potential measuring circuit shall be capable of working with both Cu/CuSO4 and Zinc
reference cells. At any given time the system shall be controlled by one type of reference cell and
other type shall be kept on the standby mode. The changeover, if required, shall be effected
manually at site in the TLP (Test Lead Point).
The TR unit shall be provided with the following Visual annunciation and alarm :
~Under Protection
~Over Protection
~Reference 1 Failure - Bullet 1.
~Reference 2 Failure - Bullet 2.
~Reference 3 Failure - Bullet 3.
~All Reference Failure
~Over Current.
A panel-mounted meter to read the bullet-to-soil potential at the selected control reference cell
through a selector switch shall be provided.
ELECTRICAL SEPARATION.
The cathodically protected mounded vessel shall be isolated from the unprotected
structures/surfaces by installing monolithic joints i.e. one each on liquid and vapour lines. A
suitable isolation shall also be provided on utility pipelines etc (such as air line to ROV)
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EARTHING.
The Mounded Vessel shall be connected to the central earthing system through two
polarisation cells.
Cathodic protection system shall be designed meeting with the latest edition of the
following standards/publications:
NACE
a. Control of External corrosion on underground submerged metallic system RP-0169-96.
b. Design, installation, operation and maintenance of impressed current Deep ground bed. RP-05-72-95.
c. Control of External Corrosion on Metallic buried, partially buried or submerged liquid storage system RP-02-85-95.
OISD 150
The design of the Cathodic Protection system for the tank bottom shall be effected considering the
protection of tank bottom plate for a prolonged duration compatible with design service life of
tank.
Anode Junction Box The anode junction box (flame proof) shall be installed in hazardous area classified as Zone I Group 2A & 2B T3.
Prior to Energising the CP System
A. Before the energization of TR unit, vessel to soil potential value shall be recorded at test
stations of each vessel.
B. After taking natural soil to vessel potential, the CP output for the relevant tank is switched
on. Output current of the T/R unit shall be adjusted step by step so as to achieve a max.
structure to soil potential reaches the maximum allowable value of 1.2 Volt (w.r.t.Cu-
CuSo4 electrode) for at least 48 hrs.
C. Output current of anodes shall be adjusted using shunts in circuits.
D. CP station output of respective vessel shall be set at the designed values
E. Observation of vessel to soil potential shall be recorded at each of the installed test station.
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F. CP station operating parameter shall be recorded.
G. Care shall be exercised to allow the vessel to polarise before vessel to soil potential values
are recorded across the span of the vessel bottoms.
H. Vessel to soil Potential measurement with both ON/OFF potential method shall be
repeated after 15 days of polarisation using current interruption technique. The max. off
potential shall be 1.1 volt.
ASSOCIATED CIVIL WORK.
3. Tank mound materials T
he area to be covered by the mound shall be cleared of all trees , stumps, roots, bushes and other
objectionable matter.
We will take precautions to prevent the excavation and the sub-grade formation level being
flooded by rain or surface water.
FILL UNDER TANKS AND SAND BED
a. A geo-textile layer of Terram 1,000 or equivalent (approved by TPIA) shall be laid directly
on the top of the gravel material prior to the commencement of the sand bed.
b. The tank bed material shall be sand 200 mm layers and compacted to 98% maximum dry
density in accordance with BS:1377 :1900
c. The sand bed shall be laid to the falls and to the levels and full depth as denoted on the
drawings and the bed for the tanks shall be excavated out of the fully compacted bed using
a template formed to the exact shape and size of the tanks.
d. If welding trenches are to be used they shall be backfilled with sand, and compacted in
accordance with the above clauses. The trenches shall be adequately propped and braced
to ensure that there is no loss of compaction of the adjacent sand bed.
SAND SURROUND/FILLING BETWEEN TANKS
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The sand surround to each tank shall be material in compliance with standard clause laid around
the tanks during the mound filling operation to a 300 mm minimum thickness and shall be hand
compacted into position.
Filling material between tank surrounds shall be sand in compliance with laid in maximum 200 mm
layers.
Sand filling placed between tanks and a line extending out at 45o from the centre of the tank
above the tanks centre line shall be hand compacted and fill placed outside this line shall be light
machine compacted (both to minimum of 93% maximum dry density).
Compaction shall be sufficient to avoid significant settlement of the sand filling/mound surface but
shall be such as not to impose undue stresses on the tanks.
The sand filling shall be placed equally, in maximum 200 mm layers (uncompact depth), on each
side of the tanks so as to avoid any lateral displacement/rotation of the tanks during compaction.
Sand filling shall be brought up to the levels and slopes as denoted on the drawings to/ below the
drainage layer.
DRAINAGE LAYER ABOVE TANKS
A 1,000 micron PVC sheet (approved by TPIA) to be laid on top of the compacted sand fill, to falls
and levels denoted on the drawings, with a 1,000 mm minimum lap at joints and with the upper
sheet overlapping the lower sheet.
A Terram 1,000 sheet or equivalent (to be approved by TPIA) shall be laid on top of the
waterproof membrane to protect if from the stone layer over.
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A perforated PVC drain shall be laid as denoted on the drawings and between the Terram and the
UPVC membrane and shall be surrounded by pea gravel and overlaid by a 5 mm to 50 mm stone
layer. The UPVC drainage pipe shall be to BS4962:1989, where the drainage pipe to BS:5911.
MATERIAL SPECIFICATION
The gravel fill wherever required/below the tank sand bed shall consist of material within the
following range of grading; to be determined in accordance with BS 1377.
BS Sieve Size % By Mass Passing
75 mm 100
37.5 mm 85-100
10.0 mm 45-100
5.0 mm 25-85
600 micron 8-50
63 micron 0-25
The sand for the tank bed , tank surround and filling between tanks shall consist ofmaterial
complying with the following specification :
A. Good quality clean, non-aggressive sand with a maximum organic Material content of 3%
by weight.
B. Maximum silt content of 10% by weight (particles smaller than 0.063 mm).
C. Maximum particle size of 5 mm.
D. Grain size distribution Uniformity Coefficient (D60/D10) of between 2 and 8.
I. The pea gravel shall consist of clean washed, single sized, 8mm round stone free from all
organic matter, sulphates or any other deleterious material and laid as surround to the
perforated PVC drain, minimum 150 mm thickness.
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II. The stone layer to the top of the mound shall consist of clean, well graded stone free from
all organic material, sulphates or any other deleterious material, and with a particle size of
5mm to 50 mm. Depth varies from 150 mm minimum to 350 mm maximum.
III. The side slopes to the mound shall be protected by good quality stone pitching constructed
out of stones of size 225 average and grouted together to form am impermeable finish, all
as denoted on the drawings with 1:4 cement mortar ( with 50 mm depth ) for joints.
Raised pointing of pitching is to be carried out with 1:2 cement mortar.
SUMMARY TABLE
A summary of the proposed materials, gradings and compaction requirements for the tank mound
is given in the following Table :
ITEM GRADING COMPACTION
Sub-Grade
(undisturbed ground)
N/A
93% of maximum dry density,
if possible.
Fill to underside of sand bed
Gravel material
98% of maximum dry density.
Tank sand bed
Clean sand
98% of maximum dry density
Tank sand surround, 300 mm
Clean sand
Hand compacted to
minimum 93% maximum dry
density.
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Mound filling between tanks
Clean sand or other
suitable material
Hand compacted or light
machine compacted to
minimum 93% maximum dry
density.
Pea Gravel
Clean stone to
N/A
Stone Drainage Layer
Clean stone
N/A
Stone Pitching
Stone to
N/A
I. with pot holes. The drain shall be suitable designed to connect with the Percolation Pit.
II. Barricading for isolation of mound during construction.
III. Dressing and cleaning off areas.
IV. Fencing and Gates as shown on lay out drawing.
V. HMI/SCADA Room as shown on lay out drawing.
VI. Security guard room
VII. Fire Water Tank.
VIII. Fire Pump House.
IX. MCC Panel Shed.
X. Toillet.
XI. Unloading gantry shed, Vapouriser & PRS Shed, Unloading Compressor shed.
XII. Pavit Interlocking Tiles within fenced area.
XIII. RCC Hard Stand for Road Tanker.
XIV. RCC Road as shown on Lay out drawing.
XV. Removal, Transportation & disposal of surplus material, debris & unserviceable material at
designated area outside or inside factory premises as per discretion of Engineer-in-Charge/Owner.