PROCESS DESCRIPTION of 2 X 33 MT MOUNDED ...

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

&

DESIGN DATA

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


ROV-8108.02


ROV-8109.01


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)


To overcome the pressure drop in fire

hydrant line.

12 PS-8119.05

Press. Switch for Main Pumps (Elect. Pump-2)


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


19 GLDS- 8110-11

Gas Leakage Detector near Vapouriser Area


20 GLDS-6 (8112)

Gas Leak Detector near PRS


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


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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


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.



~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.

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