7 GAIL (India) Limitedgailtenders.in/writereaddata/Tender/mecon report cheralapally part... · 7...

November 2011

7

GAIL (India) Limited

VSPL – CHERALAPALLY (PART-I)

REPORT FOR DESIGN & DETAILED ENGINEERING FOR UPGRADATION OF EXISTING FIRE WATER SYSTEMS

Report No.: MEC/05/28/23MN/GAIL/07, R-2

MECON LIMITED

(A Govt. of India Enterprise) NEW DELHI- 110092

INDIA

CCOONNTTEENNTTSS

GAIL (INDIA) LTD.

CONSULTANCY FOR DESIGN & DETAILED ENGINEERING FOR UPGRADATION OF EXISTING

FIRE WATER SYSTEMS ALONG JLPL & VSPL NETWORKS

Doc. No.: MEC/05/28/23MN/GAIL/07, R-2

MECON LIMITED

D:\old data\Vijyant\LPG Reports\Final Reports\07-Cheralapally\Contents.doc 00- 1/3 © 2010 MECON Limited. All Rights Reserved

C O N T E N T S

FOR PART-I

CH. NO. DESCRIPTION

01.00 EXECUTIVE SUMMARY

02.00 INTRODUCTION 03.00 DESIGN BASIS

04.00 PROPOSED FACILITIES & RECOMMENDATIONS 05.00 CIVIL, ELECTRICAL & INSTRUMENTATION 06.00 IMPLEMENTATION SCHEDULE

07.00 CAPITAL COST ESTIMATE

ANNEXURES ANNEXURE – I : DATA SHEETS ANNEXURE – II : DRAWINGS & SKETCHES ANNEXURE – III : TECHNICAL SPECIFICATION

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LIST OF DATA SHEET

S. No. Data Sheet Title DS No.

1. Data Sheet for Centrifugal Pumps MEC/23MN/05/21/M/002/DS-081A

2. Data Sheet for Quartzoid Bulb Detector 05/14/23MN/DS/ABU ROAD/01

3. Data Sheet for Landing Valve MEC/23MN/05/21/M/002/DS-081E

4. Data Sheet for T- Type Strainer MEC/23MN/05/21/M/001/DS-010A

LIST OF DRAWINGS & SKETCHES

S. No. Drawing Title Drawing No.

1. Layout of Fire Water System MEC/23MN/05/28/Cheralapally/FF/001

2. Piping & Instrumentation Diagram Fire Water System IP Station – Cheralapally MEC/23MN/05/28/Cheralapally/FF/002

3. Layout & Piping Details of Fire Water Pump House Cheralapally Intermediate Pump Station

MEC/23MN/05/28/Cheralapally/FF/003

4. Installation Details of Fire Water Hydrant MEC/23MN/05/28/Cheralapally/FF/004

5. Installation Details of Water Cum Foam Monitor MEC/23MN/05/28/Cheralapally/FF/005

6. Automatic Operated MVW Spary System Layout for Metering Area MEC/23MN/05/28/Cheralapally/FF/006

7. Automatic Operated MVW Spary System Layout for Scrapper Launcher Area MEC/23MN/05/28/Cheralapally/FF/007

8. Typical Detail off RCC Pavement and Pedestals

MEC/05/11/STD/TERMINAL/002

9. Typical Detail off RCC Road on embankment

MEC/05/11/STD/TERMINAL/009

10. Typical Detail of Valve pit MEC/05/11/STD/TERMINAL/VP-1D

11. Standard Detail of Sleepers, Low supports, Pipe Supports and RCC Pavement

MEC/GAIL/05/11/C/001/STD-III

12. General Arrangement Drawing for Fire Fighting Pump Set

CG17306705 0

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C O N T E N T S

FOR PART-II

LIST OF STANDARD SPECIFICATIONS

S. No. Technical Specification Title TS No.

1. Standard Specification for Centrifugal Pumps for Fire Fighting

MEC/TS/05/21/081A

2. Standard Specification for Diesel Engines for Fire Water Pumps

MEC/TS/05/21/081B

3. Standard Specification for Water monitors MEC/TS/05/21/081C/A

4. Standard Specification for Hose pipes MEC/TS/05/21/081C/B

5. Standard Specification for Landing Valves MEC/TS/05/21/081E

6. Standard Specification for Deluge Valve MEC/TS/05/21/081F/B

7. Standard Specification for Fire Detection and Alarm System

MEC/TS/05/21/081H

8. Standard Specification for Medium Velocity Water Spray System

MEC/TS/05/21/081K

9. Standard Specification for Standpost Type Fire Hydrant MEC/TS/05/21/081N

10. Standard Specification for Pressure Guage MEC/TS/05/21/081Q

11. Standard Specification for Pressure Switch (Electrical) MEC/TS/05/21/081R

12. Standard Specification for Flow Switch MEC/TS/05/21/081S

13. Standard Specification for Y / T Type Strainers MEC/TS/05/21/010

14. Standard Specification for Civil Works – Terminals MEC/S/05/11/01

CChhaapptteerr -- 0011

EEXXEECCUUTTIIVVEE SSUUMMMMAARRYY

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D:\old data\Vijyant\LPG Reports\Final Reports\07-Cheralapally\Chapter-1- Executive Summary.doc 01- 1/21 © 2010 MECON Limited. All Rights Reserved

01.00 EXECUTIVE SUMMARY 01.01 Introduction

M/s GAIL (India) Limited is operating LPG pipeline network starting from Jamnagar in Gujarat State to Loni in Uttar Pradesh State. The pipeline known as “JLPL”, is meant for supply of LPG to various clients enroute such as IOCL, BPCL and HPCL. The total length of the pipeline (mainline & spur lines) is approximately 1355 Km. In order to maintain required flow in the pipeline, LPG Pumping/Booster Stations have been provided along the pipeline at strategic locations.

The other LPG pipeline network is starting from Vizag in Andhra Pradesh State to Secunderabad in Andhra Pradesh State. The pipeline called as VSPL is meant for supply of LPG to various clients enroute such as IOCL, BPCL and HPCL. The total length of the pipeline (mainline & spur lines) is approximately 580 Kms. and to maintain required flow in the pipeline, there is LPG Pumping/Booster Stations at Vizag, TOT Vijayawada and receipt terminal at Cheralapally. The GAIL LPG Jamnagar Loni pipeline & Vizag Secunderabad LPG pipeline was engineered by M/s Engineers India Ltd. The entire system was designed as per the applicable national and international codes and engineering standards prevailing at that point of time, namely, API, ASME, ANSI, B31.3/16.5/16.29, NEMA, OISD 116/117 etc. The material of construction has been selected as per the prevalent engineering codes internationally namely, ASTM, A-285 – Gr.C, A-106-Gr. B, ASTM A182 Gr. F-6, A-216, Gr.WCB, API 5L, etc.

The plant lay out design was carried out as per the then prevailing applicable statutes, OISD Standards/. Fire fighting facilities were provided as per the then applicable OISD standards 116/117.

Due to change in applicable OISD code for fire protection, GAIL vide their LOA No. GAIL/JP10/FL161/5300015379/CP8139/10-11 dated 19.01.2011 have awarded the job of “Consultancy for Design & Detailed Engineering for upgradation of existing fire water system along JLPL & VSPL networks”. The Report covers various outlooks of augmentation recommendations for Jamnagar, Samakhiali, Abu Road, Nasirabad, Mansarampura, Vishakhapattanam and Cheralappaly. The present Report covers various

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outlooks of augmentation recommendations for Receiving Terminal, Cheralapalli.

01.02 Methodology of Study

MECON made visit to the locations, walked through all the units, observed the various fire safety measures provided and added up during various stages of construction of the terminals. In light of the changed OISD code applicable for LPG installations i.e. OISD 214 -2008 & OISD 144, the observations were made and recorded. The design parameters have changed which has been kept in mind and followed while designing the fire protection system. Additionally other relevant norms say NFPA, BIS and TAC available and adopted in India have been checked for this study and more stringent one has been followed.

Following steps have been adopted for report preparation. Existing Designs have been checked and understood for earlier

design philosophy Study and site visit of locations carried out and the available

drawing’s correctness were checked with site measurements. Analysis of collected data & preparation of the scheme As per existing distances between technological units, they were

segregated for medium velocity water spray system. The locations of hydrants and monitors reviewed and required relocation suggested and marked on the fire protection layout drawing.

Capacity of fire water pumps finalised based on single largest fire as per OISD 144.

Network analysis carried out for adequacy of Pipeline diameter in light of enhanced capacity of fire water pumps

Other measures pertaining to safety, layout suggested for implementation or future provisions.

Preliminary System design and approximate Bill of Materials finalised

Approximate Capital cost estimates Financial Appraisal

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STANDARDS / NORMS FOR FIRE PROTECTION FACILITIES IN GAS INDUSTRY

Sr. No.

OISD 214

Clause No.

Description Requirement

1 13.1.1 Design Basis Pump House as Single Largest Risk Area LPG Pumps, Pig Launcher & Receivers, Metering Area, Filtering Area and Receipt & Delivery Manifold to be covered by Medium Velocity Spray System Heat Detectors through Thermal Fuses/Quartz bulbs to blow at 79 Deg Cent/Electro Pneumatic detectors for detection of fire for automatic actuation of sprinkler system The QB/EP detectors to be placed directly overhead or inside the hazard. In area without specific hazard, detectors to be placed evenly across the ceiling or with a maximum spacing of 03 mtrs inside the shed

2 13.1.3 Design Flow Rate

Medium Velocity sprinkler system having remote & local operated DV with spray density of 20.4 LPM per Sq. Mtr to be considered in Pump Shed. Area of Pump shed to be calculated considering outer column distances. For Scrapper area, Metering area/Filteration area and receipt/delivery manifold, medium velocity sprinkler system with spray density 10.2 LPM / Sq. Mtr of surface area to be considered. Pump House to be considered as Single Largest Risk Area. Alternatively, it can be divided into suitable no. of zones with minimum 10 mtr width. The fire water system in the plant be designed to meet the highest fire water flow requirement of a single largest area risk at a time plus 288 Cu. Mtr / hr for operating 02 nos. of fire water monitors/supplementary hose requirements.

3 13.1.4 Fire Water System Design

Fire water pressure system design for a minimum residual pressure of 7.0 Kg/Cm2. Fire water ring to be provided all around perimeter of the plant facilities with hydrants/monitors at intervals not exceeding 30 Mtr. Fire Hydrants/monitors not to be installed with in 15 mtrs from the facilities/equipment to be protected. Fire hydrant network to be in closed loops to ensure multidirectional flow in the system. Isolation valve shall be located near loop junction. Additional isolation valves to be provided where length of pipe section is more than 300 mtr.

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Sr. No.

OISD 214

Clause No.


4 13.1.5 Fire Water storage

Effective cvapacity of tanks above the level of suction point to be minimum 04 hrs aggregate capacity of pumps. If make up water supply is 50% or more, storage capacity may be reduced by 03 hours.

5 13.1.6 Fire water pumps

Fire water pumps to be centrifugal type with flooded suction. Motor driven jockey pumps not more than 10 M3/Hr of water flow to be installed to maintain the fire network pressure at 7.0 Kg/Cm2 at the farthest end of the network. The fire water pumps including the stand by pumps to be diesel driven. Where electric supply is reliable, 50 % of the pumps may be motor driven. Pumps to be capable of discharging 150 % of its rated discharge at a minimum of 65 % of rated head. Each engine to have independent fuel tank for 06 hrs continuous running. Minimum of 50% stand by pumps (minimum 01 no.) of same type & capacity as the main pumps to be provided. Fire water pumps to be provided with automatic starting facilities

6 13.1.7 Fire Hydrant network

Fire water ring to be sized for 120% of design water flow rate. Velocity of water not to exceed 5 m/sec. Fire water ring main to be laid 300 mm to 400 mm above finished ground level. Ring mains to be supported at regular intervals not exceeding 6 mtrs or as per approved design.Ring to be laid underground at road crossings or where above ground piping is likely to get damaged mechanically.. DV to be located at 15 mtrs from risk being protected. A fire wall to be provided for protection of DV and for operational personnel. Fire hydrants can be provided at interval of 30 mtrs or monitors can be provided at interval of 45 mtrs.

7 13.1.8 Medium Velocity

Sprinkler System

MVSS shall have spray nozzles directed radially to the facilities intended for cooling at a distance of 0.6 mtr from the surface of the equipment/facility.

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01.03 System Design 01.03.01 Technological Units

Depending upon the nature of the units to be protected from fire, following types of fire protection systems viz. Fire hydrant and monitor system, Automatic medium velocity water spray system and automatic fire detection-cum-alarm system and portable fire extinguishers are provided.

Sl.

No.

Facility Area

1. Fire Alarm & Detection

System

- Control room, Telecom & VSD rooms (Above & below

false ceiling)

- Switch gear /MCC rooms without flooding system.

2. MWS (Medium Velocity

Water Spray System)

(Automatic & manual)

Filtration and Metering Area, Scrapper launcher area

3. LEL Detectors Strategically located in LPG pump house, Metering &

Filtration Area, Scrapper Launcher Area

4. Hydrant & Monitor System

- Internal

- External

All the units & areas in the plant as per layout drawings.

All the units & areas as per layout drawings.

5. Manual Call Point

- Indoor

- Outdoor



6. Siren (as per OISD 144) One Control Room Building and in Operation and

Maintenance (OMS) Building.

Also 01 no. manual siren available at security guards

entrance gate.

01.04 System Description 01.04.01 Fire Protection facilities as covered under Technological part are existing

for GAIL LPG Receiving Terminal at Cheralapalli. However present Fire Water system designed as per OISD-116/117 needs to be reviewed in line with OISD-214 applicable as on date. For system review following design considerations have been adopted :

a. Fire water design flow rate based on fighting single major fire as per

OISD 214.

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b. The fire water system has been designed for getting a minimum pressure of 7.0 kg/cm2 at the remotest point of application.

c. The required pumping capacity of the fire water tanks are 4 hours aggregate working capacity of pumps.

d. Fire water pumps to be diesel engine driven horizontal centrifugal pumps having capacity 616 m3/hr. Electric motor driven Jockey pumps (1 working + 1 standby) has been there to keep the network pressurized. Existing Diesel engines have an independent fuel tank of (1000 Liters each) for 6 hrs continuous running. The existing fuel tank is also suitable for proposed augmented capacity diesel engine driven pump.

e. The pumps have manual running in addition to auto start. Suitable system for running of main pumps shall also be provided in control room.

f. The fire water network is laid in closed loops to ensue multidirectional flow. Isolation valves are provided in the network to enable isolation of any section of the network without affecting flow in rest of network. The fire water network is laid aboveground at a height of 300 mm to 400 mm above FGL. However, the network piping is laid below ground where aboveground piping is likely to cause obstruction to operation and vehicle movement and get damaged mechanically. Network piping is laid under against corrosion by extend tape coating system.

g. Existing Hydrants and water monitors are located keeping in view the fire hazards at different sections and to give most effective coverage. The required relocation / addition of hydrants / monitors have been suggested and marked on the fire protection layout drawing.

h. Fire hose boxes are provided, one for every two hydrants. The existing hose boxes are accessible from two hydrants.

01.04.02 Fixed Water Spray System

a. The existing fixed water spray system covers LPG mainline pump house

area, scraper area & metering & filtering areas. The proposed spray system has to be modified / amended as per the inforce rules for water spray system OISD:214. Accordingly QBD detection system for MVWSS have been suggested and dia of deluge valve has been recommended based on water spray requirement.

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b. Existing Fixed Water spray system consists of medium velocity water spray nozzles actuated automatically through gas leak detection system and remotely through deluge valve system. Proposed Fixed Water spray system shall consist of medium velocity water spray nozzles to be actuated automatically through heat sensitive quartzoid bulb detectors (QBD ) in addition to the existing activation mechanism through LEL and manually through deluge valve system.

c. The proposed system shall consist of deluge valve trim consisting of

solenoid valve, junction boxes, pressure switches, water motor gong, emergency release valve, test & alarm trim, valves , QBD, control panel with DV actuation push bottom, DV open indicator etc.

d. The existing water spray system has been re-designed for a water

application rate of 20.4 Ipm/m2 over LPG mainline pump house, 10.2 Ipm/m2 over scraper, metering & filtering area. Water supply for the system shall be made available from the main fire water network.

e. In the proposed scheme, all Deluge valve actuations shall be automatic

through QB detectors as well as LEL detectors. LEL gas detectors shall actuate DV at 60% LEL. Remote manual actuation facility shall be provided in the control panel in control room. In addition a local emergency actuation facility shall also be available in the DV trim. At 20% of LEL, operator in control room shall at his discretion operate the push button for operating the deluge valve for the designated areas.

01.05 FIRE WATER DEMAND CALCULATION FOR FIRE PROTECTION SYSTEM

The fire protection system envisaged for the plant calls for early detection of fire and quenching the same by various systems envisaged besides giving out an audio visual alarm. The fire water calculation required for single largest fire has been calculated and indicated below.

The fire water demand is calculated as per the requirements stipulated in OISD-144 & 214

Major Risk: Either Fire in Scrapper Launcher Area (Size 5m x 15m) or Metering & Filtration Area (Size 30m x 14m).

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Further the intermediate distance between Metering Area and scrapper area is more than10m. Fire Water demand shall be calculated area-wise based on single largest fire in any of the area.

Protection to be provided: 1. Water spray system 2. Supplementary Hose stream

01.05.01 1.1A. WATER REQUIREMENT FOR SCRAPPER LAUNCHER AREA

1. Water spray system design density 10.2 lpm /m2 for surface area. 2. Supplementary Hose stream allowance 288 Cu.m/Hr.

Scrapper Launcher area Dimensions : 5mx15m Spray system Water flow requirement : Scrapper Launcher zone Surface Area : 5mx15m : = 75 m2 Design Density : 10.2 lpm/m2 (As per OISD-144 Clause No.10.4.2) Water Spray Required Per Min. : 75x10.2 : 765lpm (45.9Cu.m/Hr.) Total Water Demand for spray system of Scrapper launcher & Filtration area : 46 Cu.m/Hr.---- (1) Water flow requirement for Hose stream Hose stream : 288 Cu.m/Hr.

(As per OISD-214 Clause No. 13.1.3) Total Water Demand for hose stream allowance : 288 Cu.m/Hr.---- (2) Total Water Demand of scrapper : 1 + 2

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Launcher area in case of fire in that = 46 + 288 Particular area : 334Cu.m/Hr. (5567 LPM) Recommended pumping capacity : 334Cu.m/Hr. (5567 LPM)

1.1B. WATER REQUIREMENT FOR METERING AREA

1. Water spray system design density 10.2lpm /m2 for surface area. 2. Supplementary Hose stream allowance 288 Cu.m/Hr. Metering area Dimensions : 30mx14m Spray system Water flow requirement : Metering zone Surface Area : Length x Width : 30m x 14m

: = 420 m2 Design Density : 10.2 lpm/m2 (As per OISD-144 Clause No.10.4.2) Water Spray / Foam Solution Required Per Min. : 420 x10.2 : 4284lpm (257Cu.m/Hr.) Total Water Demand for Spray system of metering area : 257Cu.m/Hr.---- (1) Water flow requirement for Hose stream Hose stream : 288Cu.m/Hr. (As per OISD-214 Clause No.13.1.3) Total Water Demand For hose stream allowance : 288Cu.m/Hr.---- (2)

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Total Water Demand of metering filtration : 1 + 2 area in case of fire in that Particular area : = 257+288 545Cum/Hr (9083LPM) Recommended pumping capacity : 545Cum/Hr(9083LPM)

01.05.02 TOTAL FIRE WATER REQUIREMENT :-

The intermediate distance between scrapper area and Metering / Filtration Area is more than 10m. The recommended pumping capacity shall be highest of the two areas as calculated above which comes to 545Cu.m/hr. for metering & filtration area.

01.05.03 SELECTION OF PUMP:

It is considered that during a prolonged fire fighting operation, the pump selected should be such that, it should be able to cater one single largest possible fire in the terminal alongwith supplementary hose requirement of 288m3/hr.

Based on various options and alternatives, as described below, the suitable pump has been selected.

In the plant there are existing two nos. 410cum/hr. capacity 88m head fire main pumps working as one main and one standby. There are two 15cum/hr capacity 88m head jockey pumps working as one main and one standby.

We should go for 2 nos. 616Cum/hr (TAC approved) diesel engine driven pumps to be working as one main and one standby pumps. We may discard the existing fire main pumps and order for 02 nos. 616 cum/hr diesel pump on buy back basis. This will avoid the civil works required in fire water pump house in case additional pump is recommended to further add the required capacity.

01.05.04 REQUIREMENT OF WATER CAPACITY

The Storage Volume of Fire Water is for four-hour supply at the fire water pumps rated capacity as per OISD-144 Clause no 11.6, OISD-214

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clause no. 13.1.5. Alternately where the make up water supply system is 50% or more, this storage capacity may be reduced to 3 hours aggregate rated capacity of pumps.

There are two nos. 145Cum each capacity raw water sump from where the water is pumped to fire water tanks. Further there is no known source of make up water inside the plant for make up water of 50% or more.

Aggregate rated capacity of Pump (TAC approved) : 616 Cum/hr. Water required for 4 hours : 4 x 616 Cum = 2464 Cum Effective Existing Fire water storage capacity : 2x1250 Cu.M = 2500 Cu.M Recommended Tank capacity : 2500 Cu.M Installed Tank Capacity at site = 2500 Cu. M. Additional Capacity of tank required : NIL Cu. M.

01.05.06 SELECTION OF DELUGE VALVE AREA WISE:

Presently 80NB deluge valve is installed for water spray to metering and filtration area, scrapper launcher area which is insufficient as per the current water spray requirement. The existing deluge valve shall be used exclusively for scrappr launcher area. As per fire water demand calculation, the risk areas have been segregated into three different areas which are:

i. Metering Area ii. Scraper Launcher & Filtration Area and Each deluge valve shall be installed between 2 isolation valves of the network. The area wise water calculation and selection of deluge valve is indicated in the calculation sheet. The calculation indicates that deluge valve of following dia. are to be installed :

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i. Metering & Filtration Area - Deluge valve dia. 150mm 257 m3/hr ii. Scraper Launcher Area - Deluge valve dia. 80mm 46 m3/hr

01.06 FIRE FIGHTING PUMPS 01.06.01 PUMPS: Following pumps shall be installed and replaced with existing

main pumps:-

(i) 80-P-0103- Diesel Engine driven fire fighting pump of 616m3/hr capacity, 88 MWC head.

(ii) 80-P-0104- Diesel Engine driven fire fighting pump of 616m3/hr capacity, 88 MWC head.

Existing Jockey pumps (working / Standby) starts / stops at fire water header pressure 8.5 Kg/cm2 and 9.5 Kg/cm2 respectively.

01.06.02 DETAILS OF PROPOSED PUMPS

Diesel Engine Driven Pump & Diesel Engine

Horizontal multistage / end suction, single outlet pumping set with CI body, bronze impeller, shaft and shaft sleeve SS410, mechanical seal connected by means of a flexible coupling and expansion bellow to a water cooled diesel engine mounted on a common structural base plate with anti-vibration pads and existing foundation complete in all respect as per specifications ready for use.

Pump: i) Type : Multistage - Centrifugal ii) Quantity (Nos.) : 2 iii) Capacity, m3/hr : 616 iv) Head (m) : 88 v) Speed, RPM : 1470 / 1800 vi) Make : Refer list of approved make vii) Model No. : To be specified viii) Casing : Cast Iron ix) Impeller : Bronze x) Shaft : SS 410 xi) Shaft Sleeve : SS 410 xii) Shaft Seal : Mechanical Seal

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Engine: i) Type : Water Cooled Diesel Engine ii) Quantity (Nos.) : 2 iii) Engine Kw (BHP) : To be indicated by the bidder iv) Speed, RPM : 1500 / 1800 vi) Make : Refer list of approved make vii) Model No. : To be specified

01.07 NETWORK ANALYSIS AND TECHNICAL SPECIFICATION FOR

PIPES & VALVES FOR SPRAY MVWS SYSTEM AND QBD NETWORK

The existing Fire water ring main is sized for 120% of the design water flow rate so that Velocity of the water shall not exceed more than 5 m/s in the fire water ring main. The line sizing and corresponding residual pressure network analysis has been done for the existing network and annexed at the end of this chapter. The analysis indicates that the current fire water line size at Cherlapalli is adequate since the delivery header of main pumps are 12” dia.

01.08 Modifications on Fire Water Line a) Installation of Pressure Guage

Presently, the water line net work is charged round the clock and to keep the water line under desired pressure, there are two jockey pumps as narrated earlier in the report.

Pressure gauges have been installed in the Fire Water Network at specific locations including the farthest location to know the pressure in the network.

There is no provision to know the line pressure in normal case and also when the main pumps are running. It is, therefore, recommended to install pressure gauges at certain specific locations as marked on the fire water layout drawing.

b) Installation of Pressure Safety Valves

To restrict line pressure from rising above a set pressure (in this case 12 Kg/cm2) has been presumed), Pressure Safety Valves are to be installed

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at specific locations which are also marked on the fire protection layout drawing. The PSV should also be installed near deluge valve outlet connections.

c) Installation of Air Release Valves

To avoid water hammer effect and fluctuation in pressures, 25mm dia. air release valves at 4 locations has to be provided as marked in the layout drawing.

d) Drainage for outlet of water has to be provided in the fire water line.

01.09 Passive Fire Protection System

Passive Fire Protection System is a very effective means of stopping the spread of fire. It is recommended to use these methods and apply the fire retardant materials, wherever possible in the running terminal.

Various recommended locations, where passive fire protection facilities can be provided are narrated below:

a) Horizontal run of cables - A band of 1m length at every horizontal run of

20m on the bunch of horizontal cables. b) Vertical Run of Cables – Complete vertical run of cables c) Opening through walls – The opening through walls, floors and when

cables entering into panels, the excess space left out are recommended to be fully sealed with fire retardant sealing compounds. These measures do help in stopping the fire propagation in cables. Presently, the water line net work is charged round the clock and to keep the water line under desired pressure, there are two jockey pumps as narrated earlier in the report.

01.10 PROTECTIVE PAINTING

New / existing pipelines wherever required shall be properly cleaned and freed from rust and scale and painted with a primary coat of red oxide zinc chromate primer as per IS: 2074 and final painting shall be done as per the painting specification.

However, galvanized pipes shall be provided with identification bands at regular intervals instead of epoxy painting. All other equipment (wherever applicable & required) shall be painted with epoxy paint.

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01.11 OTHER ASSOCIATED JOBS 01.11.01 Civil Work:

The following Civil Jobs shall be carried out in Receiving Terminal at Cheralapalli : i) Modification of FWP house to accommodate new pumps etc. if so

required. ii) Foundation for Fire Water Pumps and associated facilities. iii) Civil / structural supports for fire water pipes, spray system piping iv) Reconstruction of pavements in equipment areas due to spray

system v) Construction of fire walls etc. for new deluge valves & Valve pits

etc. vi) Shifting of exhaust Stack

01.11.02 SCOPE OF WORK (CIVIL)

The scope of work shall be broadly, but not limited to, the following:

a) Site grading of the area by removing 150 mm top soil including

area development by filling good quality earth as per requirement.

b) 150 mm thick RCC pavement in process area with RCC supports for pipe / equipment as per requirement.

c) 150 mm thick RCC pavement for all external / internal roads, as per requirement

d) Independent RCC foundations for pipe supports, Pump Foundation and other Equipment foundations etc.

e) Laying PCC kerb stones 125mm x 300 mm over 75 thk PCC base as specified.

f) Pipe & Valve support and their foundations. g) Grouting of all base plates/frames of equipment foundations and

structural bases. h) Provision of all inserts, conduits, pre-cast covers, fixing of free

issue items into permanent works etc. i) Provisions of approved quality sand for back filling as per

requirement. j) Clearing all construction debris and handing over completed work

site.

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k) Any other work not specifically mentioned but required to make the terminal functional.

Marking as-built details/drawings on one set of construction drawings and return to owner.

01.11.03 Electrical Work

The following Electrical Jobs shall be carried out in Receiving Terminal at Cheralapalli:

New Deluge valve panel to be installed in deluge valve area and

hook up with existing fire alarm panel. Cabling from DV to Control Room is to be done.

Signal cabling from fire alarm panel to SCADA system

01.10.04 SCOPE OF WORK( ELECTRICAL)

a) For all electrical cables which are laid in directly buried trenches with multiple layers in touching configuration for which derating factor of 0.6 shall be considered for power cables. Junction boxes for terminating 415V power and control cables on to the pump skid shall be provided by the pump vendor on the pump skid.

b) All the related cable glands and lugs as required is included in the

vendor's scope. Cable Laying distance between pumps to power distribution board is 150 mtrs (Approx.). Vendor shall visit site for actual cable length requirement and other necessary details.

c) Cable laying in trenches (making of underground trenches),

excavated under ground trench/trays, pulling through pipes and its proper sealing, cutting of paved area, roads etc.

d) Complete earthing protection system including earthing strips/GI

wires and earth pits etc. shall be in vendor’s scope.

e) Local Control Station {Flame Proof type Ex(d)} with start ,stop push buttons, indication lamps .

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MECON LIMITED


01.11 INSTRUMENTATION FOR FIRE SYSTEM

The Control & Instrumentation system for fire shall ensure safe, efficient and smooth operation of the system and equipment with minimum intervention personnel during normal working of the fire system, load fluctuation / shut down and start-up. A dedicated mini Programmable logic controller (PLC) including closed loop control system, open loop control system is envisagions for logics & safety interlocks (with hot standby redundancy for processor, I/O modules, Interfacing modules, Communication Bus & Communication Controller).

01.11.01 FUNCTIONAL REQUIREMENT OF THE SYSTEM

The PLC-Based System shall be used for interlock, shutdown control & monitoring of fire system. The complete system with all accessories shall work under hot redundant mode. This shall meet the following minimum requirements.

a) Monitoring and Control of Fire system parameters, Data Acquisition. b) Shut Down and Interlocks related to fire system. c) PLC shall have dual redundant processor configuration as a

minimum. d) Additional redundancy for I/O’s , Power Supply , communication

network shall be provided. e) The system shall be supplied with programming tools and related

accessories. f) No two shutdown circuit shall be shared by same I/O module

unless specified otherwise.

01.11.02 Instrumentation Work

Micro PLC is required for logics & safety interlocks having hot standby redundancy with minimum : Digital inputs - 32 Nos. Digital outputs - 16 nos. Analogue inputs - 8 nos. with all inputs and outputs cards.

All cables required for new Deluge Valve shall be in the scope of the executing agency.

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MECON LIMITED


01.12 Implementation Schedule

The overall project comprising the Fire Protection facilities including laying of pipeline, spray system and replacement of fire water pumps at Receiving Terminal, Cheralapalli is envisaged to be implemented over a period of 6 months taking into account planning of phase wise shut-down and supporting infrastructure. Following are the salient points of the Implementation Schedule: The modification of fire water network and water spray system

installation has been taken as an activity to continue during plant operation.

Adequate infrastructure for catering to plant operation

requirement are to be planned considering partial shut down of equipments for installation to ensure no interruption in LPG supply.

The implementation plan envisages achieving following

targets in first six months that is the period of job execution:

The hydrants and monitors shall be relocated. New Hydrants / Monitors shall be installed wherever required. Modification in existing fire water network shall be carried out

for installation of valve pits wherever required for new tapings.

Existing medium velocity water spray system shall be dismantled

New water spray system alongwith detection and spray line shall be installed.

Deluge valves shall be installed of required dia as recommended and the tapings shall be connected with the new / modified spray system.

The modified system shall be integrated with existing fire protection system by doing wiring upto control room and hooking up with existing fire panel.

Final testing and commissioning of the entire system shall be carried out.

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01.13 Manpower 01.13.01 For Project Implementation

The organisational set-up for project implementation for the Project shall be headed by a Senior Manager (Projects) who shall be assisted by Managers, engineers having the required skills to look after the distinct functions assigned to them, operating staff and Finance & Admin.

The project implementation group in Cherlapalli will function under the existing organisational set-up. Services of an Engineering & Project Management Consultant and a Third Party Inspection Agency are also envisaged during project implementation period. There shall also be common set of manpower for the common areas like contracts, procurement, finance, administration etc

01.13.02 For Operation and Maintenance

Not included in this scope

01.14 CAPITAL COST ESTIMATE 01.14.01 General

The augmentation of fire protection system has been planned in the existing LPG terminals / stations which is necessitated due to change in applicable OISD code with respect to initial design from OISD 116/117 to OISD 214/144. The modifications have to be carried phase wise as the plant will be running condition to the extent possible. Capital cost based on the facilities envisaged for creating fire fighting system are estimated as Rs. 69.40 lac. The total cost of project is summarised in Table -07.01.

01.14.02 Major Facilities

The augmentation of fire protection system job has been sub-divided into various heads. The job includes modification in fire water piping networks, relocation of hydrants and monitors, replacement of 2 nos. existing fire water main pumps, installation of new medium velocity water spray system, associated civil, electrical and instrumentation work and system integration with existing fire protection system. Major facilities included in the capital cost estimates are given below:

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Sl. No.

Description Details

I) Fire Water System fire water network of above ground pipe 25 m fire water hydrants & monitors Nil

II) Water Spray System Medium Velocity Water Spray System For - existing Scraper & Launcher Area - existing Metering & Filtration Area

III) Fire Pumps & Accessories 2 nos. IV) Fire Detection and Alarm System V) Associated Civil Works VI) Associated Electrical and Instrumentation Works

Costs toward equipment, associated electrics, spares, erection and civil engineering works are included in the estimate. The estimates are based on the prices for different cost elements prevailing during 2nd quarter of 2011 and do not include any provision for future escalation.

Table-01.01

PROJECT CAPITAL COST (CHERLAPALLY) In Rs.

SL. NO.

DESCRIPTION Amount FC LC TOTAL

A Fire Protection System 1 Fire Water System a) Pipeline of various dia.(25m approx.) 0.00 80,000.00 80,000.00

b) Valves of various dia. (16 nos. approx.), strainers, flanges

0.00850,000.00 850,000.00

c) Hydrants & Monitors 0.00 Nil Nil

d) Pressure gauge, switch & other accessories

0.00100,000.00 100,000.00

2 Medium Velocity Water Spray System a) Scrapper & Launcher Area 0.00 500,000.00 500,000.00 b) Metering Area 0.00 700,000.00 700,000.00

3

Two nos. Fire Pumps of 616 m3/hr capacity & associated accessories without considering salvage value of existing fire water pump

0.00 3,000,000.00 3,000,000.00

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MECON LIMITED


SL. NO.


4 Fire Detection and Alarm System 0.00 200,000.00 200,000.00

5 Electrical & Instrumentation Works including Flow meter

0.00 Nil Nil

6 Associated Civil Works: a) Earth Work 0.00 25,000.00 25,000.00 b) Construction Work 0.00 50,000.00 50,000.00 c) Concrete Pavement 0.00 150,000.00 150,000.00 d) Valve Pit 0.00 50,000.00 50,000.00 e) Kerb Stone Fixing 0.00 50,000.00 50,000.00 f) Plastering & Painting 0.00 25,000.00 25,000.00 g) Road Works 0.00 50,000.00 50,000.00 Sub-total (A) 0.00 5,830,000.00 5,830,000.00B Engineering Costs

1 Detailed engineering, procurement, construction, supervision and project management @ 10% of project cost

0.00 583,000.00 583,000.00

2 Service tax on above @ 10.3% 0.00 60,049.00 60,049.00 Sub-Total ( B ) 0.00 643,049.00 643,049.00C Owner's Cost

2 Owner's management expenses @ 3% of project cost

0.00 174,900.00 174,900.00

Sub-Total ( C ) 0.00 174,900.00 174,900.00

D Other costs

1 Contingency @ 5% of project cost 0.00 291,500.00 291,500.00 TOTAL COST (A to D) 0.00 6,939,449.00 6,939,449.00

Note: The Total Cost includes all applicable Taxes & Duties, Freight Charges.


IINNTTRROODDUUCCTTIIOONN

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MECON LIMITED

D:\old data\Vijyant\LPG Reports\Final Reports\07-Cheralapally\Chapter-2-Introduction.doc 02- 1/13 © 2010 MECON Limited. All Rights Reserved

Chapter – 02

INTRODUCTION

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MECON LIMITED


1.0 BRIEF PROJECT DETAIL

M/s GAIL (India) Limited is operating LPG pipeline network starting from Jamnagar in Gujarat State to Loni in Uttar Pradesh State. The pipeline known as “JLPL”, is meant for supply of LPG to various clients enroute such as IOCL, BPCL and HPCL. The total length of the pipeline (mainline & spur lines) is approximately 1355 Km. In order to maintain required flow in the pipeline, LPG Pumping/Booster Stations have been provided along the pipeline at strategic locations.

The other LPG pipeline network is starting from Vizag in Andhra Pradesh State to Secunderabad in Andhra Pradesh State. The pipeline called as VSPL is meant for supply of LPG to various clients enroute such as IOCL, BPCL and HPCL. The total length of the pipeline (mainline & spur lines) is approximately 580 Kms. and to maintain required flow in the pipeline, there is LPG Pumping/Booster Stations at Vizag, TOT Vijayawada and receipt terminal at Cheralapally.

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The GAIL LPG Jamnagar Loni pipeline & Vizag Secunderabad LPG was engineered by engineering company M/s Engineers India Ltd. The entire system was designed as per the applicable national and international codes and engineering standards prevailing at that point of time, namely, API, ASME, ANSI, B31.3/16.5/16.29, NEMA, OISD 116/117 etc. The material of construction has been selected as per the prevalent engineering codes internationally namely, ASTM, A-285 – Gr.C, A-106-Gr. B, ASTM A182 Gr. F-6, A-216, Gr.WCB, API 5L, etc. The plant lay out design was carried out as per the then prevailing applicable statutes, OISD Standards/guidelines as applicable as well as lay out design concepts as prevalent at that point of time. Fire fighting facilities were provided as per the then applicable OISD standards 116/117. Other safety features namely, control system, interlocks etc., for safe operation as per good practice has also been provided by EIL.

In Major Accident Hazard (MAH) units such as the LPG stations, the locations of facilities inside plants are of strategic importance. The administrative building & fire water pump house and fire water tank locations are complying with the statutes and are as per the OISD guidelines. The fire water pump house as well as fire water tanks should be located far away from areas wherein fire and other emergency incidents can occur. This concept has been taken into consideration for the LPG stations.

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Along these pipelines, following are the Dispatch, Pumping Stations and Receipt Terminals:

1.1 Pumping Stations (JLPL Network):

a) Pumping Station at Dispatch Terminal inside premises of RIL Jamnagar

in Gujarat State b) Pumping Station at Dispatch Terminal inside premises of Essar Oil

Jamnagar in Gujarat State c) Pumping Station at Kandla Dispatch Terminal in Gujarat State d) Intermediate Pumping Station at Samakhiali in Gujarat State e) Intermediate Pumping Station at Abu Road in Rajasthan State f) Intermediate Pumping Station at Nasirabad in Rajasthan State g) Intermediate Pumping Station at Jaipur in Rajasthan State

1.2 Receipt Terminals (JLPL Network): a) Receipt Terminal inside premises of IOCL at Tabiji in Nasirabad,

Rajasthan State b) Receipt Terminal for BPCL & HPCL inside IPS Nasirabad, Rajasthan

State. c) Receipt Terminal inside premises of IOCL at Sanganer in Jaipur,

Rajasthan State d) Receipt Terminal inside premises of BPCL at VKIA, Jaipur, in Jaipur

Rajasthan State. e) Receipt Terminal inside premises of IOCL at Gurgaon, Haryana State. f) Receipt Terminal inside premises of BPCL at Piyala in Haryana State g) Receipt Terminal inside premises of IOCL at Madanpur Khadar in U.P

State h) Receipt Terminal inside premises of IOCL, HPCL & BPCL at Loni in U.P

State

Fire Water Systems at installations along these pipelines have been designed as per OISD-117 (Oil Industry Safety Directorate) which are now required to be upgraded as per OISD-214:2008 Standard. Therefore, GAIL (India) Limited appointed MECON as consultant to carry out the design & engineering of fire water systems for following 05 (Five) locations along JLPL route:

a) Pumping Station at Jamnagar Dispatch Terminal b) Intermediate Pumping Station at Samakhiali c) Intermediate Pumping Station at Abu Road d) Intermediate Pumping Station at Nasirabad

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e) Intermediate Pumping Station at Mansarampura, Jaipur 1.3 Pumping Stations: VSPL

a) Pumping Station at Dispatch Terminal in Vizag in Andhra Pradesh State 1.4 TOT/Receipt Terminals in GAIL's own premises: VSPL –

a) TOT Vijaywada, Andhra Pradesh State. b) Receipt Terminal at Cherlapalli, Hyderabad

1.5 Receipt Terminals in OMC premises: VSPL

a) Receipt Terminal inside premises of IOCL under TOT Vijaywada, Andhra

Pradesh State. b) Receipt Terminal inside premises of BPCL under TOT Vijaywada, Andhra

Pradesh State. c) Receipt Terminal inside premises of HPCL under TOT Vijaywada, Andhra

Pradesh State. d) Receipt Terminal inside premises of IOCL under RT Cherlapalli, Andhra

Pradesh State. e) Receipt Terminal inside premises of BPCL under RT Cherlapalli, Andhra

Pradesh State. f) Receipt Terminal inside premises of HPCL under RT Cherlapalli, Andhra

Pradesh State. This report covers the proposed modifications, detailed design of upgradation of fire water systems of Receiving Terminal at Cherlapalli, Andhra Pradesh as per OISD- 214: 2008.

2.0 SCOPE OF THIS REPORT

GAIL vide their LOA No. GAIL/JP10/FL161/5300015379/CP8139/10-11 dated 19.01.2011 have awarded the job of “Consultancy for Design & Detailed Engineering for up gradation of existing fire water system along JLPL & VSPL networks”. The scope and extent of this report is as mentioned below:

2.1 Field Data Collection

To visit each site to acquaintance with existing system and collection of physical data, drawings & documents etc. required for the purpose of study of existing system.

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MECON LIMITED


2.2 Evaluation

To study in detail about the present system with respect to requirements of OISD 214 standard and find out the deficiencies in existing system. Wherever required, existing design shall be verified before evaluation and final conclusion. To propose the changes/modifications required to upgrade the existing system to fulfill the requirements of OISD-214 and submit the basic design document/report for review by GAIL.

2.3 Detailed Design Engineering

Once system deficiencies are firmed up after review by GAIL, detailed design & engineering for proposed changes in existing system including design calculations for new equipments, piping network sizing, sprinkler system design, QBD (Quartzoid Bulb Detectors) / Heat detection system design, material selection and all Civil works and instrumentation system etc. as required to be carried out.

2.4 Drawings & Documents

Based on design & engineering, to prepare the layout drawings, Process Flow Diagrams (PFD's), Piping General Arrangement drawings (PGA's), Process & Instrument Diagram (P&ID's), Civil structure, foundation & revised pump house drawings (if required) for proposed changes/modifications including new equipments/systems. Drawings for Hook-ups/integration with existing system shall also be in scope of consultant.

2.5 Costing

To work out the cost towards the proposed changes/modifications including cost of new equipments/systems, all Civil & structural works and erection / commissioning cost etc.

2.6 Submission of Draft reports & Final reports Methodology Adopted MECON made visit to the locations, walked through all the units, observed the various fire safety measures provided and added up during various stages of construction of the terminals.

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MECON engineers had meeting with GAIL officials, interacted with key personnel and discussed the problems involved in Fire Safety of the Terminals. The points / suggestions / problems posed by different personnel have been studied and looked into by MECON. Suggestions made during the discussions and meetings have been well taken. This report covers all the suggestions made during the interactions. Various fire protection systems provided in the terminals, have been studied in the light of OISD Fire Safety Norms by which the system was designed and presently applicable codes due to changed guidelines. The fire protection system of the Terminals was designed as per OISD 117. This standard deals with Fire Protection Facilities for Petroleum Depots and Terminals and Pipeline Terminals. Now the OISD code applicable for LPG installations has changed and OISD 214 -2008 & OISD 144 are applicable. As such the design parameters have changed which has been kept in mind and followed while designing the fire protection system. Additionally other relevant norms say NFPA, BIS and TAC available and adopted in India have been checked for this study and more stringent one has been followed. Acknowledgement This Report is a result of extensive study and inter-action between GAIL and MECON. The responsibility has been carried out on behalf of MECON by Shri R K Dutta , the project coordinator and he acknowledges with thanks for the co-operation and assistance he received from the concerned officials and higher management of GAIL, especially Shri. S.N. Kumar, GM, Shri. S.P. Garg, G.M., Shri. Pankaj Patel, DGM, Shri Sunit Verma, Shri R P Singh, Shri A.K. Verma and Shri. D.V. Pant, Shri. Naveen Sinha, Shri. Dharmendra Khatri, Shri. Umesh Akote. MECON is thankful to all other officials of GAIL who have rendered their help / support / advice directly or indirectly in completing the assignment without which it was not possible to accomplish this task. Our thanks are due to JLPL/VSPL Site Heads, in-charges fire & safety who took keen interest in interacting with MECON during the course of action.

3.0 SYSTEM DETAILS (CHERLAPALLI SITE)

Details of Fire water system presently available at the location is as mentioned below:

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3.1 Fire Water Pump House :

The existing fire water scheme consists of one fire water pump house along with two nos. static water tanks. 02 nos. motor driven jockey pumps each of capacity 15 Cu. Mtr per hour flow, head 88m are installed to maintain the fire water system pressure for minor leakages. 02 nos. diesel engines driven pumps each of capacity 410 Cu. Mtr. per hour flow, head 88m. working as main pumps (one working and one standby) are also installed in the pump house making the working capacity of this pump house as 410 m3/hr. Pumps are kept in auto mode and operate at header pressure logic meeting flow requirement from the system. The logic of pump operations is indicated in P&I Diagram. Raw water from the two nos. reservoirs each having storage capacity of 145m3 is being pumped by 02 raw water pumps (01 working and 01 standby) each of capacity 20m3/h to 02 nos. above ground fire water steel storage tanks each of capacity 1310 m3.

3.2 Fire Water Storage

02 nos. cylindrical open roof steel tanks each having effective capacity of 1250 Cu. Mtr. However, the tanks are filled up with 1310 Cu. Mtr of water.

3.3 Fire Water Network:

Fire water network is laid along the roads of the plant. Above ground / underground fire water network of size from 3" to 16" in approx. 1000 mtrs length with monitors & hydrants at prominent locations inside plant premises all around process area and control buildings etc. Generally double headed hydrants are provided at 30m travel distance as per OISD-117 Monitors and hydrants are provided on water line having 7 Kg/cm2 pressure. To combat occurrence of fire in any of the units, design water flow as per OISD-117 is available through existing fire water pumps and tanks. Due to change in fire water demand as per OISD 214, adequacy of pipe sizes and availability of water through revised pumping capacity has been calculated and dealt with separately under chapter in the report and the inadequacy observed is pointed out.

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3.4 Deluge Valve system

01 No. DV of size 80 mm NB to supply feed water for sprinkler system installed over process equipments (filters, flow meters, pig launchers/receivers and valves etc) are installed in open area.

Automatic actuation of DV is provided through LEL detection system; however, manual operation is possible from field and also from control room.

4.0 SYSTEM DEFICIENCY

The Fire Water Systems at installations along these pipelines were designed as per then applicable OISD Code-117. Later OISD-214 :2008 – Cross Country LPG Pipelines came into effect and now the entire fire water system of the installation is required to be designed keeping stipulations and guidelines as per OISD-214 :2008. Wherever required, relevant OISD-144 and TAC (Tariff Advising Committee) guidelines may have to be referred and more stringent norms shall be followed. As per OISD-214:2008, following basic design deficiencies have been observed: i. The calculation of fire water demand philosophy has changed and the

revised calculation has been presented in the relevant chapter of this report.

ii. Due to change in fire water demand calculation, the fire water pump capacity will change which has also been highlighted.

iii. The change in fire water demand may also affect the water storage capacity which has been checked as per the revised recommended capacity of fire water pumps for four hour storage.

iv. Due to change in the water spray area consideration, the water spray quantity will affect the sizing of deluge valves already installed.

v. In the existing installation, the deluge valve operating philosophy is through LEL detectors and manual override. As per the new applicable code, the deluge valve activation philosophy shall be both through LEL detectors as well as Quartzoid Bulb Detectors.

vi. Due to change in water requirement and pumping capacity, piping network sizing may change and network analysis has to be done to suggest the resizing of pipelines in the relevant chapter of the report. It

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is observed that piping network size is adequate for increased flow demand and resizing of network in not required. Details of piping hydraulics carried out for the system is annexed in the report.

vii. The logic interlock for shut down of all technologically strategic units in

case of fire has not been provided. Auto shut off switch which puts off the entire system as well as can make the electrical isolation of the LPG station / terminal in case of emergency has not been provided on fire alarm panel.

vii. Some of the locations in the plant area is not adequately covered with

hydrants / monitors. Suggested augmentation in the quantity of hydrants / monitors is marked in the layout drawing.

5.0 STANDARDS / NORMS FOR FIRE PROTECTION FACILITIES IN GAS

INDUSTRY Govt. of India, Ministry of Petroleum & Natural Gas has set up Oil Industry Safety Directorate, OISD, mainly to look into the safety aspect of industries dealing with petroleum products and Natural Gas. This directorate has developed a number of standards dealing with various aspects of oil industries.

OISD – STD – 144 & 214-2008 deals with Fire Protection Facilities for cross country LPG pipelines and LPG installations.

Tariff Advisory Committee (TAC) of General Insurance Companies and Bureau of Indian Standards (BIS) has categorized various industries depending on the hazard involved.

TAC and BIS has kept oil industry in High Hazard category. 1998 publication, 12th edition of TAC-Manual has further categorized High Hazard (Type A) and High Hazard (Type B) and oil & gas industry is classified under High Hazard (Type B). TAC and BIS have developed their norms / codes for dealing with fire accidents. These norms / codes are taken as guidance because these standards are not mandatory for oil industries. However OISD standards are mandatory.

National Fire Protection Association (NFPA) of USA have also developed various standards including standards for Fire Protection for High Hazard category covering Oil and Natural gas processing plants.

OISD, BIS, TAC, NFPA and other standards / norms are developed by group of people, who are knowledgeable in the field. Group has wide experience and

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they have to strike a balance between the resources to be provided vs. the degree of risk involved. Many a times the entrepreneurs do violate the norms in their favour. There are occasions when the things still go worst during fire accidents, even when all the norms / standards are adopted.

OISD - STD - 214 recommends planning for one major fire occurring at a time in LPG terminals. Accordingly the resources e.g. water, fire water pumps, pipe sizes etc. are designed to cater to such requirements.

Fire Protection Philosophy of OISD is based on Loss Prevention and control. A fire in one part / section of the plant can endanger other sections of the plant as well. If fire breaks out, it must be controlled / extinguished as quickly as possible to minimize the loss of life and property and also to prevent further spread of fire.

Sr. No.

OISD 214

Clause No.


1 13.1.1 Design Basis Pump House as Single Largest Risk Area LPG Pumps, Pig Launcher & Receivers, Metering Area, Filtering Area and Receipt & Delivery Manifold to be covered by Medium Velocity Spray System Heat Detectors through Thermal Fuses/Quartz bulbs to blow at 79 Deg Cent/Electro Pneumatic detectors for detection of fire for automatic actuation of sprinkler system The QB/EP detectors to be placed directly overhead or inside the hazard. In area without specific hazard, detectors to be placed evenly across the ceiling or with a maximum spacing of 03 mtrs inside the shed

2 13.1.3 Design Flow Rate

Medium Velocity sprinkler system having remote & local operated DV with spray density of 20.4 LPM per Sq. Mtr to be considered in Pump Shed. Area of Pump shed to be calculated considering outer column distances. For Scrapper area, Metering area/Filteration area and receipt/delivery manifold, medium velocity sprinkler system with spray density 10.2 LPM / Sq. Mtr of surface area to be considered.

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Sr. No.

OISD 214

Clause No.


Pump House to be considered as Single Largest Risk Area. Alternatively, it can be divided into suitable no. of zones with minimum 10 mtr width. The fire water system in the plant be designed to meet the highest fire water flow requirement of a single largest area risk at a time plus 288 Cu. Mtr / hr for operating 02 nos. of fire water monitors/supplementary hose requirements.

3 13.1.4 Fire Water System Design

Fire water pressure system design for a minimum residual pressure of 7.0 Kg/Cm2. Fire water ring to be provided all around perimeter of the plant facilities with hydrants/monitors at intervals not exceeding 30 Mtr. Fire Hydrants/monitors not to be installed with in 15 mtrs from the facilities/equipment to be protected. Fire hydrant network to be in closed loops to ensure multidirectional flow in the system. Isolation valve shall be located near loop junction. Additional isolation valves to be provided where length of pipe section is more than 300 mtr.

4 13.1.5 Fire Water storage

Effective cvapacity of tanks above the level of suction point to be minimum 04 hrs aggregate capacity of pumps. If make up water supply is 50% or more, storage capacity may be reduced by 03 hours.

5 13.1.6 Fire water pumps

Fire water pumps to be centrifugal type with flooded suction. Motor driven jockey pumps not more than 10 M3/Hr of water flow to be installed to maintain the fire network pressure at 7.0 Kg/Cm2 at the farthest end of the network. The fire water pumps including the stand by pumps to be diesel driven. Where electric supply is reliable, 50 % of the pumps may be motor driven. Pumps to be capable of discharging 150 % of its rated discharge at a minimum of 65 % of rated head.Each engine to have independent fuel tank for 06 hrs continuous running.

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Sr. No.

OISD 214

Clause No.


Minimum of 50% stand by pumps (minimum 01 no.) of same type & capacity as the main pumps to be provided. Fire water pumps to be provided with automatic starting facilities

6 13.1.7 Fire Hydrant network

Fire water ring to be sized for 120% of design water flow rate. Velocity of water not to exceed 5 m/sec. Fire water ring main to be laid 300 mm to 400 mm above finished ground level. Ring mains to be supported at regular intervals not exceeding 6 mtrs or as per approved design.Ring to be laid underground at road crossings or where above ground piping is likely to get damaged mechanically.. DV to be located at 15 mtrs from risk being protected. A fire wall to be provided for protection of DV and for operational personnel. Fire hydrants can be provided at interval of 30 mtrs or monitors can be provided at interval of 45 mtrs.

7 13.1.8

Medium Velocity Sprinkler System

MVSS shall have spray nozzles directed radially to the facilities intended for cooling at a distance of 0.6 mtr from the surface of the equipment/facility.


DDEESSIIGGNN BBAASSIISS

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MECON LIMITED

D:\old data\Vijyant\LPG Reports\Final Reports\07-Cheralapally\Chapter-3-Design Basis-Fire Protection.doc 03- 1/16 © 2010 MECON Limited. All Rights Reserved

DESIGN BASIS

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MECON LIMITED


1.0 INTRODUCTION

The fire fighting measures are of paramount importance to safeguard the material, product / information stored manpower and property from the fire hazards. Fire may occur inside the plot premises consisting of general technological unit areas, buildings (office block, control room, gate areas, non plant building etc.) as per the layout drawing at any location or unmanned rooms due to any mishap, leakage, failure of mechanical items etc. or sudden abnormal rise of temperature due to abnormal operating condition. The main intentions of provision of first aid and inbuilt fire fighting systems are to extinguish the fire at its inception or to control its spread and to assist the fire department in taking required action and thereby reducing the loss suffered as a result of fire.

Water has been considered as the general agent for fire extinguishments / cooling at the proposed installations. This water shall be made to reach at all the strategic points of the installations through a closed pressurized piping network.

In an analysis of this nature, the failure scenario is examined in detail. All possible

outcomes of every possible failure are assessed, taking into account the size and nature of the failure, the process parameters prevalent and the weather conditions. A very important factor to be borne in mind is that volatile petroleum products such as LPG will form substantial amount of vapour if it is allowed to leak for considerable amount of time, and the flammable material will spread further if the leak is allowed to spread beyond dyke to a larger area. Explosion mechanism of inflammable vapors envisages the formation of an “Explosive Mass” which is the quantity of vapour formed within “Lower Flammability Limit” (LFL) and “Upper Flammability Limit” (UFL). The quantity of explosives mass determines the effect of the explosion blast. The time required for forming the explosives mass will be dependent on rate of vaporisation which, in turn will depend on “vapour Pressure of the liquid which “vaporizes” resulting from “loss of containment” and also to an extent on “ nature of loss of containment (rate/velocity of release, direction i.e. horizontal/vertical). Based upon these calculations, effect zones for each of the outcomes are determined, and accordingly zone wise fire protection measures to be taken have been suggested.

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CLASSIFICATION OF POSSIBLE TYPES OF FIRES In a consequence assessment dealing with LPG handling and storage facilities, possible types of fires that may occur have been categorized as follows : 1. Fires

a. Flash Fires b. Pool Fires – Not applicable in this case c. Jet Fires

2. Explosions

a. Unconfined Vapour Cloud Explosions (UVCE) b. Boiling Liquid Expanding Vapour Explosions (BLEVE) – Applicable only where LPG bullets or vessels have been installed.

Flash Fire – A Flash Fire, in effect, is a sheet of flame that moves through a cloud of gaseous or vaporized hydrocarbons, without any accompanying shock-wave. It rarely lasts for more than a few seconds, and causes little damage to equipment and installations, but is fatal to individuals in its path. Pool Fire – A Pool Fire is a fire on a stationary liquid surface, such as that of a pool of liquid hydrocarbon. The nature of the flame depends upon the fuel burning, with more smoke being generated by heavier hydrocarbons on fire. Its thermal radiation can affect all individuals and facilities in its vicinity, but its intensity depends upon the volume available, and the duration of the fire. Jet Fire – A Jet Fire occurs when a hydrocarbon release from a pressurized source is ignited close to the source of the release. It is, for all practical purposes, a jet of flame that will last as long as the supply of fuel lasts under pressure and whose radiation and effect zone, depend as much upon the fuel as on the pressure at which it is released. In addition to damage inflicted by thermal radiation, the flame can also cut through metal, if it were to impinge upon the metallic surface, setting off a domino effect. Unconfined Vapour Cloud Explosion – A UVCE is similar to a flash fire, except that in addition to the flame front, a pressure front, generated by the fire, moves through the cloud, at speeds of 100 m/s or greater. Boiling Liquid Expanding Vapour Explosion – A BLEVE occurs when a liquefied, or occasionally a liquid, hydrocarbon is contained in a vessel exposed to an external

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fire. The fire weakens the shell of the vessel, while also causing the hydrocarbon to boil, thereby pressurizing the vessel. Once the vessel’s pressure exceeds the threshold limit of the metal, the shell would fail spilling out the rest of the hydrocarbon, which would then undergo an explosion or a fireball. The system covers the basic scheme to be implemented to cater fire hazard in the entire area as per OISD: 144, OISD: 214 and TAC / NFPA (National Fire Protection Association) which suggests the following systems / facilities to be installed to provide state of the art fire protection facilities in the area:

a) Fire Water System consisting of hydrants, monitors, hose boxes containing

fire hoses with standard accessories b) High and Medium Velocity Water Spray System c) Pumps, Motors & Diesel Engines d) Automatic Fire detection cum alarm system e) Portable Extinguishers h) Fire Fighting Accessories Technological Part General technological unit areas consist of Filtration and Metering area, scrapper / launcher area etc.

Depending upon the nature of the units to be protected from fire, following types of fire protection systems viz. Fire hydrant and monitor system, Automatic medium velocity water spray system and automatic fire detection-cum-alarm system and portable fire extinguishers are provided.

Sl.

No.

Facility Area

1. Fire Alarm & Detection

System

- Control room, Telecom & VSD rooms (Above & below

false ceiling)

- Switch gear /MCC rooms without flooding system.

2. MWS (Medium Velocity

Water Spray System)

(Automatic & manual)

Filtration and Metering Area, Scrapper launcher area

3. LEL Detectors Strategically located in Metering & Filtration Area,

Scrapper Launcher Area

4. Hydrant & Monitor System

- Internal

- External

All the units & areas in the plant as per layout drawings.


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Sl.

No.

Facility Area

5. Manual Call Point

- Indoor

- Outdoor



6. Siren (as per OISD 144) One Control Room Building and in Operation and

Maintenance (OMS) Building.

Also 01 no. manual siren available at security guards

entrance gate.

2.0 SCOPE

This document covers the fire protection facilities proposed to be provided for Receiving Terminal, Cherlapalli. For fire protection System the requirements of OISD – 214, OISD- 144 and TAC rules, whichever is more stringent shall be followed.

3.0 REFERENCE CODES AND STANDARDS a. Fire Protection Manual TAC

b. IS codes for fire fighting equipments

c. OISD – 117- Fire Protection facilities for petroleum Depots, Terminals & Pipeline installations.

d. National Fire Prevention codes (NFPA)

e. MECON standards & specifications

f. Rules for water spray systems (TAC)

g. OISD-GDN-115 : Guidelines on Fire Fighting, Equipment and appliances in Petroleum Industry

h. OISD-Standard-144 : Design and construction requirements for cross country hydrocarbon pipelines

i. OISD-Standard-214 : Cross Country LPG Pipelines 4.0 LIST OF FACILITIES

The various technological facilities existing at the Receiving Terminal, Cherlapalli are listed below:

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i) Piping Area (Metering Unit, Basket Filter, Meter Prover, Scraper Launcher)

ii) Control Room iii) Sub-Station building iv) Administration building v) Diesel Engine Generator building vi) Diesel Storage Tank and Diesel Transfer Pump vii) Fire water Storage, Fire water Pump House, fire station, Ware House /

Workshop, Guard Room, Drinking water sump & Raw water pump house viii) Parking for mobile flare stack ix) Parking shed for vehicles.

5.0 FIRE PROTECTION SYSTEM

Safety is now a matter of great concern due to faith and choice. It should be our Endeavour to provide the best safety provisions in line with modern technology available in the field. Therefore, it is utmost importance that adequate fire safety measures are provided for protection of life and property. Followings fire protection facilities for GAIL’s Receiving Terminal at various locations inside the plant which are existing alongwith / proposed modifications based on existing technological units:

5.1. Fire Protection facilities as covered under Technological part are existing for GAIL LPG Receiving Terminal at Cherlapalli. However present Fire Water system designed as per OISD-116/117 needs to be reviewed in line with OISD-214 applicable as on date. For system review following design considerations have been adopted

a. Fire water design flow rate based on fighting single major fire as per

OISD 214 (The design calculations shall be dealt in subsequent chapter).

b. The fire water system is designed for getting a minimum pressure of 7.0 kg/cm2 at the remotest point of application.

c. Fire water storage shall be fully dedicated to fire service and is stored in above ground C.S tanks. Fire water make up is directed from raw water sump which shall be fed by tube well network. The required pumping capacity of the fire water tanks shall be 4 hours aggregate working capacity of pumps.

d. Fire water pumps shall be diesel engine driven horizontal centrifugal pumps. Electric motor driven Jockey pumps (1 working + 1 standby) has also been provided to keep the network pressurized. Existing Diesel

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engines have an independent fuel tank of (1000 Liters each) for 6 hrs continuous running. The existing fuel tank is also suitable for proposed augmented capacity diesel engine driven pump.

e. The pumps have manual running in addition to auto start. Suitable system for running of main pumps shall also be provided in control room.

f. The fire water network is laid in closed loops to ensue multidirectional flow. Isolation valves are provided in the network to enable isolation of any section of the network without affecting flow in rest of network. The fire water network is laid aboveground at a height of 300 mm to 400 mm above FGL. However, the network piping is laid below ground where aboveground piping is likely to cause obstruction to operation and vehicle movement and get damaged mechanically. Network piping is laid under against corrosion by extend tape coating system.

g. Existing Hydrants and water monitors shall be located keeping in view the fire hazards at different sections and to give most effective coverage. Numbers shall be based on one hydrant or monitor for every 30 m of external perimeter of process units and 45m for utility areas. Existing Hydrants / monitors shall be generally located along road berms for easy accessibility. Double headed hydrants with two separate landing valves of 2-1/2” size on 4” stand post and water monitor with one 4” size monitor are presently used. If required, existing hydrants and water monitors shall be re-located for complying with OISD-214.

h. Fire hose boxes are provided, one for every two hydrants. The existing hose boxes are accessible from two hydrants. Hose box are made of carbon steel and painted red. Each box contains 2 x 15m 2-1/2” fire hose with coupling, 2 x 2-1/2” branch pipe with fog / straight jet nozzle with coupling & other accessories suiting connecting two hoses on each hydrant valve.

i. Material specification:- Pipes of carbon steel (As Per IS:1239), Isolation valves (CS as per specifications) are used.

5.2 Fixed Water Spray System

a. The existing fixed water spray system covers scraper area & metering &

filtering areas. The proposed spray system shall be modified / amended as per the inforce rules for water spray system OISD:214.

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b. Existing Fixed Water spray system consists of medium velocity water spray nozzles actuated automatically through gas leak detection system and remotely through deluge valve system. Proposed Fixed Water spray system shall consist of medium velocity water spray nozzles to be actuated automatically through heat sensitive quartzoid bulb detectors (QBD ) in addition to the existing activation mechanism through LEL and manually through deluge valve system.

c. The proposed system shall consist of deluge valve trim consisting of

solenoid valve, junction boxes, pressure switches, water motor gong, emergency release valve, test & alarm trim, valves , QBD, control panel with DV actuation push bottom, DV open indicator etc.

d. The existing water spray system shall be re-designed for a water

application rate of 20.4lpm/m2 over LPG mainline pump house, 10.2 lpm/m2 over scraper, metering & filtering area. Water supply for the system shall be made available from the main fire water network.

e. In the proposed scheme, all Deluge valve actuations shall be automatic

through QB detectors as well as LEL detectors. LEL gas detectors shall actuate DV at 60% LEL. Remote manual actuation facility shall be provided in the control panel in control room. In addition a local emergency actuation facility shall also be available in the DV trim. At 20% of LEL, operator in control room shall at his discretion operate the push button for operating the deluge valve for the designated areas.

6.0 Brief Functional Description of proposed facilities

The main intentions of provision of inbuilt fire fighting systems are to extinguish the fire at its inception or to control its spread and to assist the fire department in taking required action and thereby reducing the loss suffered as a result of fire. The existing Fire Water layout for Cherlapalli station having drawing no. MEC/23MN/05/28/M/CHERLAPALLI/001 of the plant and associated facilities are enclosed for ready reference.

The proposed fire protection system shall be envisaged for the plant calls for early detection of fire and quenching the same by various systems envisaged besides giving out an audio visual alarm.

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6.1 Hydrant Service LPG Receiving Terminal at Cherlapalli has a well - designed Hydrant system which is the backbone of entire fire fighting system as it fights fire of all classes of risks. The entire Plant is covered with a water based fire hydrant network. The existing main consists of MS coated /DI pipes, ring mains. Distribution mains form ring around each unit, which is connected to the ring main running in the vicinity, which mainly consist of fire water storage facility, main fire pumps, jockeys pumps, double outlet landing valves, monitors, fixed water spray system etc. The modification works shall be carried out as per OISD: 214 as applicable. In the proposed scheme, water to the hydrant network will be supplied by pumps exclusively envisaged for fire fighting purpose. One number diesel engine operated centrifugal pump of 616 m3/h will be provided as main pump. The delivery pressure at rated capacity will be 8.8kg/cm2. One number diesel engine operated pump of 616m3/h capacity with 8.8 kg/cm2 delivery pressure will be provided as a stand-by, which will start automatically in case of main pump fails to develop desired pressure in the network. For the purpose of starting the diesel engine pump, suitable auto start panel, battery, battery charger etc will also be provided. Two numbers jockey pumps of 15m3/h capacity and 8.8 Kg/cm2 delivery pressure as per TAC are available. All the diesel engine pumps will be installed in the pump house on the existing foundation of discarded 410 m3/hr diesel engine pumps.

The fire water network lines shall be continuously kept pressurized at 9.5 kg/cm2(g) (at the hydraulically remotest point of application pressure shall be 7 Kg/cm2). Any drop in pressure below 8.5 kg/cm2(g) shall be made up with the help of existing 2 nos. of electric driven jockey pumps (one operating + one standby) each of 15m3/h capacity and discharge pressure 8.8 Kg/cm2. If pressure continues to fall below 8.5 kg/cm2(g), there shall be alarm in the pump station and control room at pressure of 7.5 kg/cm2(g). The first fire water pump will start so as to maintain the pressure in the fire water header. However, if the pressure continues to fall further, there shall be an alarm in the pump station & control room at 6.5 kg/cm2g and second fire water pump will start on activation of the system, a signal shall be given in the control room.

Supply of water to the hydrant network will be through a open top steel two numbers fire water reservoir. The total capacity of the existing water reservoir is 2 X 1310m3, where effectively the capacity is 2 x 1250m3. These fire water reservoirs are above ground. The system already has provision to re-circulate the firewater for test run of pumps. The system is equipped with the facility to

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dispose off entire water in the event of contamination. For erection and maintenance in the pump house suitable capacity monorail with chain-pulley block etc. are installed. Distribution mains form ring around each new proposed area, which is connected to the existing ring main running in the vicinity. The existing network is laid generally above ground. Wherever it is laid underground, it is laid at an average depth of 1m below ground level and 1.2M (Min.) below the ground level at road crossings. All such underground pipes are provided with suitable corrosion protection as per IS: 10221. Each area is being covered with adequate numbers of fire hydrants and water monitors. The fire protection system has hose reels, hose boxes, isolation valves, flanges, fittings along with complete electrical and instrumentation work etc. All double headed hydrants, monitors and hose reels are provided with a cut-off gate valve on tapping (stand post) from main fire water header. Hydrants and monitor connections are through 4” line. Double outlet hydrant valves are laid above ground at a height of 1.2M. All welded joints for new DV’s, Pump installation, relocation of hydrants / monitors etc shall be radio graphically tested. Existing Hose boxes with all accessories are provided at locations in line with TAC guidelines and construction of hose box are made as per specifications given in OISD-115. Hose boxes are provided at every hydrant in the network. Each hose box consist of two hoses of 63mm dia. 15m long RRL each with end couplings, 2 nos. jet nozzles with branch pipe two universal branch pipe as per IS: 903. Hoses confirm to IS: 636 type-B. Above ground fire water pipes are painted fire red confirming to shade no. 536 of IS:5. All fire water piping was hydro tested to a pressure of 18 Kg/cm2. Adequate nos. of isolation valves in the fire water network are provided to ensure easy maintenance at the affected part of the network and at the same time uninterrupted water supply to the rest of the network for fire fighting remains available. However, in the proposed scheme, complete fire proofing of equipments in unit shall be carried out as per OISD:164.

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6.2 Automatic Water Spray System

In the existing deluge type water spray network, all modifications wherever necessary shall be designed in accordance with NFPA 15 and API 2030. This system shall be located over the equipment areas and designed to provide water at the net rate as specified. The same existing Medium Velocity Water Spray system is been envisaged for Scrapper Launcher area (5m x 15m) and Metering area (30m x 14m ) to provide cooling and / or exposure protection to such type of risks where extinguishment is always not possible. 6”Φ / 4”Φ tapping is already been taken from the ring mains exclusively for the spray system depending on water requirement. The proposed & existing system in totality shall comprise of piping, valves, deluge valves, sprinkler based detection system alongwith leak detection system, sprayers and other accessories. The temperature rating of the proposed quartzoid detector sprinkler (QBD) shall be 79`C at the site of installation. In case of increase in temperature in and around the area under coverage, the sprinkler bulbs breaks and the pressure is released from priming chamber of deluge valve faster than it is supplied through the restricted priming line. Therefore clapper moves and allows the inlet water supply to flow through the outlet into the system and associated alarm device and water is sprayed through sprayers to combat fire. The mode of actuation of Deluge Valve shall be hydraulic type.

The density of water application by sprayers shall not be less than 10.2 LPM /

M2. For the effective protection of the areas, the risk area shall be divided into several zones of width not less than 10M. Each zone shall be controlled by an individual Deluge Valve and flow shall not be more than 13,500 LPM. Each zone shall be so designed that the pressure at the hydraulically most un-favorable sprayer / sprinkler is not less than 1.4 bars and that the most favorable sprayer / sprinkler is not more than 3.5 bars and that the velocity in distribution pipes shall not exceed 5 m/sec.

The detection network piping shall be similar to the sprayer network however

number of detectors may vary with respect to the number of sprayers depending upon the locations and requirements.

Systems shall comprise of network of pipelines with distribution control, units, open spray nozzles - stainless steel material (capable of spraying water with medium velocity and high velocity), QB detectors automatic fire detection cum alarm facility, deluge valves, Instrumentation (micro-PLC, pressure switches, pressure gauges, cables for solenoid valves / pressure switches) isolation valve & deluge valve housing / dike wall / room. Water required for the system shall be drawn from existing fire water network.

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Design criteria for medium velocity spray system (MVWS) The medium velocity water spray shall be designed as per the stipulation of TAC rules on the subject as well as NFPA’s guidelines. Following salient parameters shall be followed for the design of the system. Water application rate for metering and filtration areas, scrapper / launcher area – 10.2 lpm / m2 of the exposed surface area. The system shall be so hydraulically designed that the pressure at the hydraulically remotest sprayer shall satisfy the pressure, discharge and flow rate conditions. The protected area shall be divided into several zones, each of which shall fed by individual deluge valve. In event of fire water shall be sprayed on the zone concerned (i.e. zone under fire) along with preceding and succeeding zones. Distribution of sprayers: Sprayers shall be providing to spray water on both the top side and bottom side of the process area. Spacing between sprayers shall not be more than 4m. The sprayers shall be installed in rows and spaced at not more than 3 m from each other. Provision for manual operation of the system shall also be made to operate the system in case of failure of the automatic mode. For the protection of deluge valves from mechanical damage and atmospheric conditions civil / structural Dike wall / chain link fencing / rooms shall be provided. Standard fence and door shall be provided in addition to illumination facility.

6.3 Automatic Fire Detection-Cum-Alarm System: Manual Push Button Type

Fire Alarm System

Automatic fire detection-cum-alarm system has been provided for all the electrical premises like switchgear room, control room & administrative building etc. In addition to detection system, manual push button fire alarm system (manual call points) are provided for all the premises / bays. Provision has already been kept in the control panel to repeat the fire signal in the existing fire station. This repeater panel is installed in the fire station. Cablings / connection from main fire

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alarm panel to repeater panels are existing. The alarms are monitored on a 24 x 7 basis. The Fire system is deployed with High Sensitivity Smoke / Heat Detectors (HSSD) to allow swift detection of heat and smoke. The fire alarm is designed to cut power to air-conditioning system. The existing fire detection & alarm system comprise of the following items / equipments: Fire Alarm Panels consisting of:

- Central Fire Alarm Panel with Mimic / Central Processing Unit - Zonal Fire Alarm Panel - Repeat Alarm Panel / Annunciation Panel in Fire Station

Automatic Fire Detectors and Accessories comprising of:

- Heat Detectors - Ionisation Type Smoke Detectors - Photo Electric / Optical Type Smoke Detector

Manual Break Glass Boxes / Manual Call Points (MCP) Response Indicators Exit Signs Hooters Clean Agent Release and Inhibit Switches

Apart from the various signals and control related to fire detection following signal / facilities and control from each of the new deluge valves pertaining to medium velocity water spray shall also be required on the main fire alarm control panel.

Following signals are required to be extended in the existing main fire alarm control panel in the control room.

1 Fire alarm signal through the actuation of individual pressure switches. 2. Low water pressure alarm from each DV trim line / detection line. 3. Alarm from DV to know that it is operated 4. ON/OFF command to operate solenoid valve at water line 5. 24V DC power shall be provided for solenoid valves from the existing

FDA system.

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6.4 Interlocking with A/C & Ventilation system

The existing interlocks trips the A/C system where the fire signal from first detector is operating the audio-visual alarm and the ventilation / air conditioning system is being switched off automatically.

7.0 PROTECTIVE PAINTING

New / existing pipelines wherever required shall be properly cleaned and freed

from rust and scale and painted with a primary coat of red oxide zinc chromate primer as per IS: 2074 and final painting shall be done as per the painting specification.

However, galvanized pipes shall be provided with identification bands at regular

intervals instead of epoxy painting. All other equipment (wherever applicable & required) shall be painted with epoxy paint.

7.1 All above ground pipes, pipe fittings, hose cabinets structural steel work pipe

supports etc. (wherever applicable & required) shall be painted as per specifications given below.

7.2 Painting shall be done only after the completion of fabrication work and testing. 7.3 The instructions of paint manufacturer shall be followed as far as possible

otherwise the work is to be done as directed by Owner. 7.4 All cleaning materials, brushes, tools and tackles, painting, material etc. shall be

arranged by the Contractor at site in sufficient quantity. 7.5 All rust, dust, scales, welding slag or any other foreign materials shall be

removed fully so that a clean and dry surface is obtained prior to painting. Any other oily containment shall be removed by use of a solvent prior to surface cleaning.

7.6 First coat of primer paint must be applied by brush on dry clean surface

immediately or in any case within 3 hours of such cleaning. 7.7 Primer paints - one coat (minimum thickness 100 microns) self-priming epoxy

mastic.

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8.0 COATING WRAPPING FOR UNDERGROUND PIPES 8.1 All underground piping presently are protected by coating and wrapping. 8.2 Cleaning - The pipes (wherever applicable & required) shall be thoroughly

cleaned by dust, rust will scales, oil, grease etc. by stiff wire brush and scrappers. The surface shall be coated with the primer immediately after cleaning.

8.3 Priming – Suitable primer shall be applied as an undercoat. The manufacturers

recommended procedure would be followed for applying the primer. 8.4 Paste Application - Paste shall be applied to fill up uneven surfaces in order to

ensure smoothness for subsequent wrapping with multi-layer tape. 8.5 Tape Wrapping - The tape is to wrap while the second coat of primer is still

tacky. Winding is to be done with 50% overlap so that the total thickness of 2.0mm tape would become 4.0mm. It should be ensured while wrapping that air bubbles are not trapped. The ends of tape shall be secured with nylon binding to ensure that the tape doesn’t get loosened while handling.

8.6 The total thickness including 2 coats of primer, 50% overlap of tape etc. should

not be less than 4.5mm or as per manufacturer recommendations. 8.7 The ‘Holiday Test’ is to be conducted as per IS: 10221 for detecting any

entrapped air or any other defect. The Contractor is to arrange for the Holiday Test and to rectify the defects if found any.

9.0 Leak Detection System - Catalytic Based Gas Detection System

Presently Catalytic based detection system having fixed gas detectors at Pumping station are provided for continuous monitoring of hydrocarbon level in the air in the proximity of Pump House, etc. The basis of location for the existing detectors are based on wind direction, gas component density and coverage of gas detections in Pumping Station & are integrated with SCADA, RTU through serial communication.

Presently at RT Cherlapalli 4 nos. of LEL Detectors are installed in LPG Pump House, 02 Nos in Metering & Filtration area and 01 no in scrapper area. If required, the adequacy of the installed detectors shall be worked out based on the area coverage. If the No. of LEL detectors increase, the existing control panel

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in the control room shall be used for housing the monitor / controller for gas detectors with delays, hooters / annunciates indicating the location.

10.0 Civil Work:

The following Civil Jobs shall be carried out in pumping Station at Receiving Terminal at Cherlapalli :

i) Modification of FWP house to accommodate new pumps etc. if so required. ii) Foundation for Fire Water Pumps and associated facilities. iii) Civil / structural supports for fire water pipes, spray system piping iv) Reconstruction of pavements in equipment areas due to spray system v) Construction of fire walls etc. for new deluge valves & Valve pits etc. vi) Shifting of exhaust Stack

11.0 Electrical Work

The following Electrical Jobs shall be carried out in pumping Station at Receiving Terminal at Cherlapalli:

Necessary modification for providing power supply to higher capacity fire

water pumps. New Deluge valve panel to be installed in deluge valve area and hook up

with existing fire alarm panel. Cabling from DV to Control Room is to be done.

Signal cabling from fire alarm panel to SCADA system

12.0 Instrumentation Work Micro PLC is required for logics & safety interlocks having hot standby

redundancy with minimum : Digital inputs - 32 Nos. Digital outputs - 16 nos. Analogue inputs - 8 nos. with all inputs and outputs cards.

All cables required for new Deluge Valve shall be in the scope of the executing agency.


PPRROOPPOOSSEEDD FFAACCIILLIITTIIEESS && RREECCOOMMMMEENNDDAATTIIOONNSS

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D:\old data\Vijyant\LPG Reports\Final Reports\07-Cheralapally\Chapter-4-Proposed Facilities.doc 04- 1/23 © 2010 MECON Limited. All Rights Reserved

PROPOSED FACILITIES &

RECOMMENDATIONS

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1.0 FIRE WATER DEMAND CALCULATION FOR FIRE PROTECTION SYSTEM

The fire protection system envisaged for the plant calls for early detection of fire and quenching the same by various systems envisaged besides giving out an audio visual alarm. The fire water calculation required for single largest fire has been calculated and indicated below.

The fire water demand is calculated as per the requirements stipulated in OISD-144 & 214

Major Risk: Either Fire in Scrapper Launcher Area (Size 5m x 15m) or Metering & Filtration Area (Size 30m x 14m).

Further the intermediate distance between Metering Area and scrapper area is more than10m. Fire Water demand shall be calculated area-wise based on single largest fire in any of the area.

Protection to be provided: 1. Water spray system 2. Supplementary Hose stream

1.1 Design Basis: 1.1A. WATER REQUIREMENT FOR SCRAPPER LAUNCHER AREA

1. Water spray system design density 10.2 lpm /m2 for surface area. 2. Supplementary Hose stream allowance 288 Cu.m/Hr.

Scrapper Launcher area Dimensions : 5mx15m Spray system Water flow requirement : Scrapper Launcher zone Surface Area : 5mx15m : = 75 m2 Design Density : 10.2 lpm/m2 (As per OISD-144 Clause No.10.4.2)

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Water Spray Required Per Min. : 75x10.2 : 765lpm (45.9Cu.m/Hr.) Total Water Demand for spray system of Scrapper launcher & Filtration area : 46 Cu.m/Hr.---- (1) Water flow requirement for Hose stream Hose stream : 288 Cu.m/Hr.

(As per OISD-214 Clause No.13.1.3) Total Water Demand for hose stream allowance : 288 Cu.m/Hr.---- (2) Total Water Demand of scrapper : 1 + 2 Launcher area in case of fire in that = 46 + 288 Particular area : 334Cu.m/Hr. (5567 LPM) Recommended pumping capacity : 334Cu.m/Hr. (5567 LPM)

1.1B. WATER REQUIREMENT FOR METERING AREA

1. Water spray system design density 10.2lpm /m2 for surface area. 2. Supplementary Hose stream allowance 288 Cu.m/Hr. Metering area Dimensions : 30mx14m Spray system Water flow requirement : Metering zone Surface Area : Length x Width : 30m x 14m

: = 420 m2 Design Density : 10.2 lpm/m2 (As per OISD-144 Clause No.10.4.2) Water Spray / Foam Solution Required Per Min. : 420 x10.2 : 4284lpm (257Cu.m/Hr.) Total Water Demand for Spray system of metering area : 257Cu.m/Hr.---- (1)

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Water flow requirement for Hose stream Hose stream : 288Cu.m/Hr. (As per OISD-214 Clause No.13.1.3) Total Water Demand For hose stream allowance : 288Cu.m/Hr.---- (2) Total Water Demand of metering filtration : 1 + 2 area in case of fire in that Particular area : = 257+288 545Cum/Hr (9083LPM) Recommended pumping capacity : 545Cum/Hr(9083LPM)

2. TOTAL FIRE WATER REQUIREMENT :-

The intermediate distance between scrapper area and Metering / Filtration Area is more than 10m. The recommended pumping capacity shall be highest of the two areas as calculated above which comes to 545Cu.m/hr. for metering & filtration area.

3. SELECTION OF PUMP:

It is considered that during a prolonged fire fighting operation, the pump selected should be such that, it should be able to cater one single largest possible fire in the terminal alongwith supplementary hose requirement of 288m3/hr. Based on various options and alternatives, as described below, the suitable pump has been selected. OPTION-1:

Aggregate rated capacity of Pump (TAC approved) : (410 +96)Cum/hr

: = 506 Cum/hr.

506Cum/hr shall not be able to cater the water requirement of single largest risk area i.e. Metering area for 545Cum/hr. Hence not suitable OPTION-2:


: = 581 Cum/hr.

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581Cum/hr shall not be able to cater the water requirement of single largest risk area i.e. Metering area for 545Cum/hr. Hence not suitable OPTION-3:


: = 683 Cum/hr.

Water required for 4 hours : = 4 x 683 Cum = 2732 Cum

Existing Fire water storage capacity (Effective) : 2x1250 Cu.M = 2500Cu. M

Recommended Tank capacity : 2750 Cu.M

Installed Tank Capacity at site : = 2500 Cu. M.

Additional Capacity of tank required : 250 Cu. M. Additional 250 Cu. M. capacity tank required. Hence not suitable

OPTION-4


: =820 Cum/hr.

Water required for 4 hours : =4 x 820 Cum = 3280 Cum

Existing Fire water storage capacity (Effective) : 2x1250 Cu.M = 2500Cu. M

Recommended Tank capacity : 3300 Cu.M

Installed Tank Capacity at site : 2500Cu. M Additional Capacity of tank required : 800 Cu. M.

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Additional 800 Cu. M. capacity tank required. Hence not suitable OPTION-5: In the plant there are existing two nos. 410cum/hr. capacity 88m head fire main pumps working as one main and one standby. There are two 15cum/hr capacity 88m head jockey pumps working as one main and one standby.

We should go for 2 nos. 616Cum/hr (TAC approved) diesel engine driven pumps to be working as one main and one standby pumps. We may discard the existing fire main pumps and order for 02 nos. 616 cum/hr diesel pump on buy back basis. This will avoid the civil works required in fire water pump house in case additional pump is recommended to further add the required capacity.

4. REQUIREMENT OF WATER CAPACITY

The Storage Volume of Fire Water is for four-hour supply at the fire water pumps rated capacity as per OISD-144 Clause no 11.6, OISD-214 clause no. 13.1.5. Alternately where the make up water supply system is 50% or more, this storage capacity may be reduced to 3 hours aggregate rated capacity of pumps.

There are two nos. 145Cum each capacity raw water sump from where the water is pumped to fire water tanks. Further there is no known source of make up water inside the plant for make up water of 50% or more.

Taking Option-5 as the best suitable Pump

Aggregate rated capacity of Pump (TAC approved) : 616 Cum/hr. Water required for 4 hours : 4 x 616 Cum = 2464 Cum Effective Existing Fire water storage capacity : 2x1250 Cu.M = 2500 Cu.M Recommended Tank capacity : 2500 Cu.M Installed Tank Capacity at site : =2500 Cu. M. Additional Capacity of tank required : NIL Cu. M.

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5.0 SELECTION OF DELUGE VALVE AREA WISE:

Presently 80NB deluge valve is installed for water spray to metering and filtration area, LPG pump house area, scrapper launcher area which is insufficient as per the current water spray requirement. As per fire water demand calculation, the risk areas have been segregated into three different areas which are: i. Metering Area ii. Scraper Launcher & Filtration Area and iii. LPG Pump House Area Each deluge valve shall be installed between 2 isolation valves of the network. The area wise water calculation and selection of deluge valve is indicated in the calculation sheet. The calculation indicates that deluge valve of following dia. are to be installed :

i. Metering & Filtration Area - Deluge valve dia. 150mm 257 m3/hr ii. Scraper Launcher Area - Deluge valve dia. 80mm 46 m3/hr

5.1 Calculation for Automatic Operated MVW Spray System for Metering &

Filtration Area. 5.1.1 DESIGN BASIS:

STANDARD FOLLOWED : TAC Rules For Water Spray Systems I Ed (1998) Design Density : 10.2 lpm/m2 Min. Pressure in the Remotest : 1.4 bar Projector in the Network Velocity in Feed pipes (Max) : 5 m/sec. (as per TAC clause no. 4.8.5.3)

5.1.2 DESIGN CALCULATION

Metering area Dimensions : 30mx14m 1. Equivalent exposed surface area : = Length x Width =30mx14m

: = 420 m2

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2. Basic Water Application Rate : = 10.2 lpm/m2 3. Basic Water Demand : = 420 x10.2

= 4284lpm = 257 Cum/hr.

4. No. of QB Detectors = 53Nos

(As per the design norms coverage area per nozzle, shall not be more than 9m2)

5. No. of MVWS Nozzles = 53 Nos. 6. Discharge Per Projector = Basic Water Demand /No of Nozzles = 4284/53 = 81lpm 7. Referring to H.D. Fire’s diagram of M.V. water spray nozzle, it is seen that, nozzle

size of 8mm with K- factor 64 will give about 90.5lpm (Q = k √P) discharge at a pressure of 2 Kg/cm2.

Selecting nozzle with spray angle as 140` and fitting them at around 6m from the surface of equipment, the coverage shall be sufficient to cater the requirement. K factor selected is = 64x140

It is observed from the nozzle spray pattern diagram for 140` that the circle distribution of sprayers that, The circle diameter of water spray by nozzle is 2 x 3.5 = 7m. Therefore area covered by one nozzle = π (7)2 = 154 m2, whereas as per the design limit, coverage area per nozzle shall not be more than 9m2. Each nozzle covers: As per NFPA, vol-I, page 13.32, clause 4.4.1, spacing of nozzles should not be more than 12 feet. Therefore provision of 53 nozzles , meets the design criteria as per norms.

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8. Actual Water Requirement = 90.5lpm x53 nos. = 4797lpm = 288m3/hr 9. Deluge Valve Selected is : = 150 NB

5.2 Hydraulic calculation Automatic Operated MVW Spray System Layout for Scraper Launcher Area.

5.2.1 DESIGN BASIS:

STANDARD FOLLOWED : TAC Rules For Water Spray Systems I Ed (1998) Design Density : 10.2 lpm/m2 Min. Pressure in the Remotest: 1.4bar Projector in the Network Velocity in Feed pipes (Max) : 5 m/sec. (as per TAC clause no. 4.8.5.3)

5.2.2 DESIGN CALCULATION

1. Equivalent exposed surface area : = Length x Width =5mx15m : = 75 m2 2.Basic Water Application Rate : = 10.2 lpm/m2 3.Basic Water Demand : = 75x10.2

= 765lpm = 46Cum/hr.

4. No. of QB Detectors = 12Nos

(As per the design norms coverage area per nozzle, shall not be more than 9m2)

5. No. of MVWS Nozzles = 12 Nos. 6. Discharge Per Projector = Basic Water Demand /No of Nozzles = 765/12 = 64lpm

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7. Referring to H.D. Fire’s diagram of M.V. water spray nozzle, it is seen that,

nozzle size of 9mm with K- factor 51 will give about 72lpm (Q = k √P) discharge at a pressure of 2 Kg/cm2.

Selecting nozzle with spray angle as 140` and fitting them at around 0.6m from the surface of equipment, the coverage shall be sufficient to cater the requirement.

K factor selected is = 51x140`

It is observed from the nozzle spray pattern diagram for 140` that the circle distribution of sprayers that, The circle diameter of water spray by nozzle is 2 x 3.5 = 7m. Therefore area covered by one nozzle = π (7)2 = 154 m2, whereas as per the design limit, coverage area per nozzle shall not be more than 9m2. Each nozzle covers: Scrapper Launcher Area = 103 sq. mtr. / 12 nozzles = 8.6 m2 of area, which is within the design limit. The spacing of nozzle row and intermediate distances between the nozzles has been planned less than or equal to 3m. With such a configuration, there shall be 2 rows of sprayers in the LPG Scrapper Launcher area each having 6 nos. of sprayers. Water quantity per row = 765/ 2 = 382.5lpm = 23m3/hr, Now since each nozzle gives 72lpm as calculated earlier. No. of nozzles per row = 382.5/72 = 5.3 = 6 nozzles. Nozzles provided 6. As per NFPA, vol-I, page 13.32, clause 4.4.1, spacing of nozzles should not be more than 12 feet. Therefore provision of 18 nozzles , meets the design criteria as per norms.

8. Actual Water Requirement = 72lpm x 12 nos. = 864lpm = 52m3/hr 9. Deluge Valve Selected is : = 80 NB

The existing 80mm dia. Deluge valve already installed at site shall be used exclusively for scrapper launcher area.

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6.0 FIRE FIGHTING PUMPS 6.1 PUMPS: Following pumps shall be installed and replaced with existing main pumps:-

(i) 80-P-0103- Diesel Engine driven fire fighting pump of 616m3/hr capacity, 88

MWC head. (ii) 80-P-0104- Diesel Engine driven fire fighting pump of 616m3/hr capacity, 88

MWC head.

Existing Jockey pumps (working / Standby) starts / stops at fire water header pressure 8.5 Kg/cm2 and 9.5 Kg/cm2 respectively.

6.1.1 80-P-0103 main pump starts at header pressure 7.5 Kg/cm2 and is stopped

manually. The start of this pump shall raise audible alarm in control room. 6.1.2 80-P-0104 Diesel engine driven fire fighting pump starts when header pressure is 6.5

Kg/cm2 and is stopped manually. The start of this pump shall raise audible alarm in control room.

6.1.3 Header pressure of 5.5 Kg/cm2 to give an alarm in Fire station & Control room of

Receiving Terminal Cherlapalli. 6.1.4 Fire water reservoir is filled with water from service water tanks before the start of

process. 6.2 ENGINEERING DESIGN BASIS 6.2.1 Applicable Codes & Standards

The following International Standard/Codes duly modified as per the applicable specifications shall govern the design, manufacture, inspection/ testing of the pumps/ equipment.

Sl. No. Item Standard 1 Centrifugal Pumps IS-5120, 5120, 8414,

IS-9137, BS-5316, ISO-2548, IS-9908, ISO-2858

2 Fire water pumps, Engines, electrics, instrumentation for starting/stopping of Fire water pumps etc.

As per the TAC / OISD stipulations

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6.3 DESCRIPTION OF PUMPS AND DIESEL ENGINE The pump has been elaborated in the equipment details. Pumps are located in the

pump room. The details of pumps are mentioned below and also in the technical specification of centrifugal pumps and in the cost estimate chapter. The working sequence and start stop details along with logistics are also mentioned in the technical specification.

6.3.1 DETAILS OF PROPOSED PUMPS Diesel Engine Driven Pump & Diesel Engine

Horizontal multistage / end suction, single outlet pumping set with CI body, bronze impeller, shaft and shaft sleeve SS410, mechanical seal connected by means of a flexible coupling and expansion bellow to a water cooled diesel engine mounted on a common structural base plate with anti-vibration pads and existing foundation complete in all respect as per specifications ready for use.

Pump: i) Type : Multistage - Centrifugal ii) Quantity (Nos.) : 2 iii) Capacity, m3/hr : 616 iv) Head (m) : 88 v) Speed, RPM : 1470 / 1800 vi) Make : Refer list of approved make vii) Model No. : To be specified viii) Casing : Cast Iron ix) Impeller : Bronze x) Shaft : SS 410 xi) Shaft Sleeve : SS 410 xii) Shaft Seal : Mechanical Seal Engine: i) Type : Water Cooled Diesel Engine ii) Quantity (Nos.) : 2 iii) Engine Kw (BHP) : To be indicated by the bidder iv) Speed, RPM : 1500 / 1800 vi) Make : Refer list of approved make vii) Model No. : To be specified

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Diesel Engine shall be supplied complete with cooling system, Air filters, Exhaust system, Fuel system, Engine shut down mechanism, starting mechanism (auto as well as manual), Batteries, Battery charger, etc. as required and approved by TAC / OISD. The diesel engine shall be mounted on the same existing foundation. Existing Day tanks (1000 ltrs each) for oil storage along with level indicators for minimum 6 hrs running shall be used for proposed diesel engine driven fire pump.

Fire water pumps shall be capable to function at not less than 150% of rated capacity at a head of not less than 65% of the rated head. The shut-off head shall not exceed 120% of rated head. The diesel engine for the fire water main & standby pump shall be complete in all respects as required by TAC and confirm to the stipulations of OISD / TAC.

The pressure setting for the jockey pump shall be such that it starts at approximately 1 kg/cm2 pressure below the normal system pressure and stops at normal system pressure. The pressure setting for the main fire water pumps shall be such that it starts approximately at 2.0 kg/cm2 pressure below the normal system pressure and shall stop only manually at churn pressure. The TAC / OISD-214 stipulations shall be adhered for the design, manufacture, supply of the fire water pumps/engine, motors, control panel, cables etc.

6.3.2 List of Spare Parts and Special Tools for Pumps 6.3.2.1 List of Spares 1 Line Shaft Bearings 1 Set 2 Bearing Bushes / Rubber Bearings 1 Set 3 Shaft Sleeves (at Bearings) 1 Set 4 Stuffing Box / Packing Box Bearings 2 Sets 5 Carbon Bush for Mechanical Seal 2 Nos. 6 Impeller Lock nut 2 Nos. 7 Impeller adjusting nut 2 Nos. 8 Coupling with fixing bolts 1 Set 9 Impeller Shrowd / casing wearing rings 2 Sets 10 Impeller Shaft Sleeves 2 sets 11 Thrust Bearing Pads 1 Set 12 Impeller Rings 4 Nos. 13 Gasket for bottom column pipe 5 Nos. 14 Line Shaft coupling nuts 30 Nos. 15 Line Shaft coupling bolts with nuts 4 Sets 16 Set of gasket for column pipes 8 Sets

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6.3.2.2 List of Special Tools 1 Complete set of column clamps 1 Set 2 Device for checking alignment of coupling etc. If pump is 1 Set Dismantled and re-assembled after maintenance 3 Device for removing bearings 1 Set In addition to above, the manufacturer may include any other special tools for

maintenance / re-erection of the pumps. 7.0 NETWORK ANALYSIS AND TECHNICAL SPECIFICATION FOR PIPES & VALVES

FOR SPRAY MVWS SYSTEM AND QBD NETWORK

The existing Fire water ring main is sized for 120% of the design water flow rate so that Velocity of the water shall not exceed more than 5 m/s in the fire water ring main. The line sizing and corresponding residual pressure network analysis has been done for the existing network and annexed at the end of this chapter. The analysis indicates that the current fire water line size at Abu Road is adequate since the delivery header of main pumps is 12” dia.

7.1 T.S. for Pipes for hydrant system

Pipes and pipe fittings in general shall comply with the requirements of BIS codes and TAC norm. The pipes shall be manufactured/supplied as specified below:

i) Upto 150 mm nominal size - M.S ERW Black pipes conforming to IS-1239- 1984 Part-I (heavy grade) With Plain ends.

ii) 200 mm to 400 mm size - M.S. ERW Pipes conforming to IS-3589 -1973 but thickness as specified below

Nominal Dia O.D X Thickness in mm

DN 200 mm : 219.1 x 6.35 DN 250 mm : 273.0 x 7.14 DN 300 mm : 323.9 x 7.14 DN 350 mm : 355.6 x 7.14 DN 400 mm : 406.4 x 7.14

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7.1 T.S. for Pipes and valves for Spray (MVWS) system

The material of construction and manufacturing standard of pipes, fittings, valves, fasteners, gaskets, etc. shall be as described in table-1 below:-

Table-1

Nominal pressure (PN) - 10 Kg/Cm2 Test Pressure (PT) - 15 Kg/Cm2

S. No.

Items Nominal dia.(mm)

Specification

1. Pipe (M.S. / G.I.) 65 and below 80 100 to 150 200 to 250

250 and above

IS-1239 (Part-1) - '90 Heavy, IS-1239 (Part-1) - '90 Heavy, IS-1239 (Part-1) - '90 Heavy, IS-3589 Gr.410 ERW pipe commercial quality or equivalent. Thickness as specified.

2. Pipe fittings A 234 Gr. IS-1239/3589/2062

2.1 Screwed fittings 65 & below IS-1239 (Part-1) - 90 Galvanised

2.2 Fabricated fittings

Bends 150 and above Mitred bends with radius 1.5 DN from black pipe.

Tees/Crosses 150 and above Fabricated from black pipes by smithing.

Reducers 150 and above Fabricated from black pipes by taper cutting and welding.

3. Bolting All sizes IS – 1367

4. Gaskets All sizes Sheets rubber to IS-635-`79 type-A, 3 mm thick compressed Asbestos to IS-2712-`79 or spiral wind SS 316+CAF as per B 16.20 / ANSI B 16.5

5. Flanges All sizes Slip on flanges to IS-6392 - `71 machined from Carbon Steel plates to IS-2002-`92 Gd. 2 with bore to suit pipe O.D.

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Fittings shall be supplied as per IS:1239-1992 Part II for pipes upto 150 mm dia and shall be fabricated from pipes for dia 200 mm and above. 7.3 Technical specification for valves:

The valves & sluice gates shall be designed, manufactured and tested as per relevant Indian Standards or as per other International standards acceptable to the Purchaser and will be suitable for the duty conditions specified below. All underground valves will be provided with valve chambers with RCC covers. The size of chambers shall be suitable for easy maintenance of the valve. Complete civil work for this is in the contractor's scope.

Table-2

Sl. No. Items Nominal dia.(mm) Specification

1. Isolation Below 50 Forged Carbon steel gate valve, screwed as per API – 602 standard, class 800 # ASTM A-105, trim 13% Cr, Bolt/Nut – B7/2H, Socket end threading as per ANSI B.16.11 Gasket SPW S.S. 304 with CAF Hand Wheel - Cast steel

50 to 300 Cast Carbon Steel flanged gate valve as per standard API-600 class 150 # , Body & bonnet material ASTM A 216 Gr. WCB, Trim 13% Cr S.S, Spindle & Gland bush – A1S1 410. Handwheel C.S, Gasket SW S.S-304 + LAF, flange drilled to ANSI – B.16.5 along with companion slipon welded flange (without hub) drilled as per B.16.5 and gasket, Nut & bolt etc. Hand Wheel - C.S.

2. Throttling 50 and below Gunmetal globe valve, Screwed, as per IS-778-`84 Class-2

NRV used shall be spring loaded double door type.

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BUTTERFLY VALVES Constructional features, materials of construction of various components and testing of butterfly valves shall confirm to IS: 13095 : 1984 (1990) or reputed international standards like BS EN 593 : 1998 or AWWA C 504. Butterfly valves to be installed on delivery lines of pumps and on trunk mains shall be tight shut-off valves as per BS : EN593 : 1998. Butterfly valves up to nominal size DN 150 shall be lugged long wafer type as per BS EN : 593 : 1998 with replaceable liner and lever arrangement for manual operation.

Butterfly valves up to nominal size DN 200 to DN 250 shall be lugged long wafer type with hand wheel and gear arrangement for manual operation.

Valve body with integral seat, disc and hand wheel shall be of cast iron construction to FG 260 grade of IS 210: 1993. The disc shall be designed to withstand full differential pressures across the closed valve disc without exceeding a working stress equivalent to one fifth of the tensile strength of the material used. The shaft shall be stainless steel to AISI 410 and shall consist of a one-piece unit extending completely through the valve disc. Valve seats shall be designed to provide tight shut-off in both directions. Valve seats shall be nitrile rubber and shall be a design that permits removal and replacement at the site of installation. Valves shall be fitted with sleeve type bearings contained in the hubs of the valve body. Valves shall be equipped with thrust bearings which shall hold the valve disc securely in the centre of the valve seat. Sleeves and other bearings fitted into the valve body shall be self-lubricated materials that do not have a harmful effect on water or rubber.

7.2 Technical specification for Spray Nozzles

The Medium Velocity Water Spray Nozzles are open type (non-automatic) nozzles. The nozzles are designed for directional spray application in fixed fire protection system. Medium velocity water spray nozzle has an external deflector, which discharges water in a directional cone shaped pattern of small droplet size. The water is uniformly distributed over the surface to be protected The Nozzles should be effectively designed to apply water to exposed vertical, horizontal, curved and irregular shaped surfaces to

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allow cooling to prevent excessive absorption of heat from external fire and avoid structural damage or spread of fire.

The nozzles should be installed to control or extinguish the fire depending on water design density as per applicable codes. Suitable K factor should be selected based on the discharge required as per spray rate requirement.

These nozzle are being used in deluge water spray system for special hazard fire protection application. The minimum available pressure to achieve the spray pattern for which the system is to be designed is 2.0 Kg./Sq.cm. The nozzles should be selected and installed in such a manner that, change in pressure between 1.4 to 3.5 Kg./sq.cm. does not affect considerable change in spray angle. While designing the system for selection of nozzles, moderate wind velocity must be considered due to outdoor application in Metering & Filtration area and Scrapper area. Field obstruction if any affecting the spray pattern of the nozzle must also be considered. The nozzle may be oriented to any position as deemed necessary to cover the hazard.

While installing, Teflon tape or soft thread sealant on male thread of the nozzle should be used. The nozzles must be hand tightened into the fitting. It is recommended that water spray system be inspected regularly by authorised technical personnel. The nozzle must be checked for corrosion, external and internal obstruction, blockage if any. The nozzle should be cleaned or replaced if required. The system must be operated with optimum water flow at least twice in a year or as per the provisions of NFPA/TAC or local authority having jurisdiction.

7.3 Technical specification for Quartzoid Bulb Detectors

The liquid filled Quartzoid bulbs used in the sprinkler systems are the most common form of heat detector operating on the liquid principle. When heated, the liquid in the bulb expands until it shatters the glass and allows water to spray over the protected area through nozzles fitted separately due to differential pressure created in Deluge Valve. Quartzoid bulb detection devices fitted into a detector line to bring a group of medium velocity water spray open nozzles into action under fire conditions. In the event of a fire, the head nearest to the seat of the fire will activate at a pre-determined temperature. This causes the liquid pressure within the detection line system to drop. The immediate drop in water pressure within the detector line releases the pressure against the Deluge valve diaphragm unit causing the Deluge Valve to open and discharge water through all the open medium velocity waterspray nozzles to rapidly cool, control and extinguish the fire.

Pendent sprinklers have been envisaged for use. The temperature rating is standard response (5 mm. glass bulb) and quick response (3mm glass bulb). The sprinklers

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should be compact design, glass bulb type. Sprinklers visibly damaged, dropped or exposed to temperature in excess of the maximum ambient temperature permitted should never be installed. Never install any glass bulbs sprinkler if the bulb is cracked or if there is a loss of liquid from the Bulb. Detectors should be installed after the piping is in place to prevent mechanical damage. Teflon tape or soft thread sealant on male thread of the detector should be used for leak tight detector joint. Detectors must never be painted, plated or coated.

8.0 Recommendations for Control Room Building, Administrative Building and

other suggestive measures 8.1 Control room building

Control room building is constructed out side the process area and far away from Hazardous units. There are number of control centres covering the vital units. Control room building is protected with • Portable Extinguishers • Fire Hydrant System • Fire Alarm System • Automatic FM200 Flooding System

8.2 Administrative Building Administrative building is planned near to the main gate so that all not concerned with process activities are kept away from the hazardous units / activities. Building is protected against fire with • Portable Extinguishers • Fire Hydrant net work and is very close to the Fire station itself. As such the facilities provided are sufficient to combat any occurrence of fire.

8.3 Other Suggestive Measures

Various measures have been recommended keeping in view that there are a number of installations are existing along JLPL & VSPL pipeline networks where improvements in technical and operational measures can ensure safety and emergency preparedness. This will further enhance the work environment and overall productivity of the organization due to improved confidence of working atmosphere. Such measures include the ensuring of safety back up systems,

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modifications to make human error less likely, making emergency action possible from remote locations ensuring availability and observance of site specific operating procedures through SCADA and linking the system and integration, improving operating discipline, communication facilities and ensuring availability and knowledge regarding the use of Personal Protective Equipment (PPE), mobile equipments and extinguishers.

Other recommendations include enhancing automation levels, installation of LEL detectors, which are already there in place in the LPG process area and CCTV with alarm feature. An important requirement is that for these installations, a quantitative risk assessment exercise should be undertaken and based on the risk assessment; suggestive measures should be undertaken to reduce the risk on human life and assets.

Major areas of recommendations are:

a) Standardization of Fire Protection System for the stations / terminals covering

all aspects including design, construction and operations in line with standards developed for LPG OISD: STD 144.

d) Augmenting fire fighting capabilities/automation and developing as suggested

through this report.

e) Improving human factor through better training, performance evaluation criteria and safety oriented corporate policies.

f) Strengthening the Safety function in the organization by professionalizing its

cadre.

h) Strengthening the internal safety auditing functions by making it cross-functional and providing professional safety auditing training.

i) The recommendations also suggest that a quantitative risk analysis should be

carried out for this purpose.

j) Facilities and installations with inherently high hazards of such nature should incorporate redundancy in safety systems and ensure their upkeep at all times.

k) All terminal operating personnel should be given safety and simulated fire

fighting training based on simulated modules of live fires in tanks, pipeline manifold and pumps, process platforms etc., in reputed training institutes

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equipped with these facilities. Personnel from security services should be trained fully for fire fighting and rescue operations using Personal Protective Equipment.

l) During all operations even after the general shift a dedicated fire fighting

team should be present.

m) There should be a minimum level of manning maintained apart from the security personnel for monitoring the facilities even during non operational hours.

n) The suggestions for layout of the plant keeping in view future expansion /

modifications are as follows:

i) The future proposed process areas which are potential risk should be located far away from existing control room, Fire water tank and fire water pump house as practical. Otherwise, the control room should be made blast proof.

ii) The intermediate distances between the existing process area and proposed process area should be minimum 10m so that the fire water calculation should not get affected.

iii) The size of the proposed process areas should not be more than the existing process areas so that fire water demand should not get increased.

iv) Locate buildings and structures in the upwind direction (for the majority of the year) as far as practicable.

v) Avoid congestion in the plant site because of buildings, structures, pipelines, trees etc. The location of these individual facilities should be decided based on Quantitative Risk Assessment.

vi) All future buildings which are not related to terminal operation which will be planned shall be located outside the plant area.

vii) The emergency exit gate shall be away from the main gate and always be available for use for personnel evacuation during emergency.

o) The Safety related observations are as follows:

a. Auto shut off switch should be provided on fire alarm panel provided

inside the control room, which puts off the entire system as well as

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can make the electrical isolation of the LPG station / terminal in case of emergency.

b. Very high level of security and safety for the terminal should be insured

c. On-the-spot picture of the various operational activities should be clearly displayed.

d. For specific operations, “Standard Operating Procedures” which is a foremost requirement for safe operation of such hazardous facilities, should be available readily.

8.4 Modifications on Fire Water Line

a) Installation of Pressure Gauge

Presently, the water line net work is charged round the clock and to keep the water line under desired pressure, there are two jockey pumps as narrated earlier in the report.

Pressure gauges have been installed in the Fire Water Network at specific locations including the farthest location to know the pressure in the network.

There is no provision to know the line pressure in normal case and also when the main pumps are running. It is, therefore, recommended to install pressure gauges with 3 way isolation valves on the main header at certain specific locations as marked on the fire water layout drawing. Pressure gauges shall be 150mm dial size, calibrated in metric units and accuracy of +/- 0.5% or better. Pressure gauges shall be provided with external zero adjustment facility, over range protection, blow out disc 3-way isolation valves and gauge saver.

Code / Standard : IS3624 Sensing Element : SS 316 Bourdon Tube Dial Size : 150mm dia Range : 0-15 Kg/cm2 Process Connection : ½” NPT, bottom connection

(for direct mounting) b) Installation of Pressure Safety Valves

To restrict line pressure from rising above a set pressure (in this case 12

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Kg/cm2) has been presumed), Pressure Safety Valves are to be installed at specific locations which are also marked on the fire protection layout drawing. The PSV should also be installed near deluge valve outlet connections.

c) Installation of Air Release Valves

To avoid water hammer effect and fluctuation in pressures, 25mm dia. air release valves at 4 locations has to be provided as marked in the layout drawing.

d) Drainage for outlet of water has to be provided in the fire water line.

8.5 Passive Fire Protection System

Passive Fire Protection System is a very effective means of stopping the spread of fire. It is recommended to use these methods and apply the fire retardant materials, wherever possible in the running terminal. Fire retardant coating is a thick flowing liquid which is externally applied on the cables (horizontal or vertical, available in single / bunched lots, laid in cable trays to stop propagation of fire. Various recommended locations, where passive fire protection facilities can be provided are narrated below: a) Horizontal run of cables - A band of 1m length at every horizontal run of 20m

on the bunch of horizontal cables. b) Vertical Run of Cables – Complete vertical run of cables c) Opening through walls – The opening through walls, floors and when cables

entering into panels, the excess space left out are recommended to be fully sealed with fire retardant sealing compounds. These measures do help in stopping the fire propagation in cables.

CChhaapptteerr –– 0055

CCIIVVIILL,, EELLEECCTTRRIICCAALL && IINNSSTTRRUUMMEENNTTAATTIIOONN

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D:\old data\Vijyant\LPG Reports\Final Reports\07-Cheralapally\Chapter-5- Civil, Electrical & Instrumentation.DOC 05- 1/24 © 2010 MECON Limited. All Rights Reserved

Chapter – 05

CIVIL, ELECTRICAL &

INSTRUMENTATION

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PARTICULAR JOB SPECIFICATION (CIVIL)

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CONTENTS

0.0 CIVIL WORKS

1.0 PREAMBLE TO SCHEDULE OF QUANTITIES

2.0 SITE CLEARANCE

3.0 EARTH WORK IN CUTTING & FILLING

4.0 SANDFILLING AND STONE SOLING

5.0 BRICKWORK IN FOUNDATION

6.0 BRICKWORK IN SUPERSTRUCTURE

7.0 PCC WORK

8.0 RCC WORK IN FOUNDATION

9.0 RCC WORK IN SUPERSTRUCTURE

10.0 CONCRETE PAVEMENT

11.0 GROUTING WITH NON-SHRINKABLE COMPOUND

12.0 VALVE PIT

13.0 PCC KERB STONE IN SPECIFIED AREAS

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0.0 CIVIL WORKS I) GENERAL

The scope of work to be performed under this report shall include complete civil works as per plans, equipment layout, drawings & technical specifications for the “CONSULTANCY FOR DESIGN & DETAILED ENGINEERING FOR UPGRADATION OF EXISTING FIRE WATER SYSTEMS ALONG JLPL & VSPL NETWORKS” of M/S GAIL.

II) SCOPE OF WORK The scope of work shall be broadly, but not limited to, the following: a) Site grading of the area by removing 150 mm top soil including area

development by filling good quality earth as per requirement. b) 150 mm thick RCC pavement in process area with RCC supports for pipe

/ equipment as per requirement. c) 150 mm thick RCC pavement for all external / internal roads, as per

requirement d) Independent RCC foundations for pipe supports, Pump Foundation and

other Equipment foundations etc. e) Laying PCC kerb stones 125mm x 300 mm over 75 thk PCC base as

specified. f) Pipe & Valve support and their foundations. g) Grouting of all base plates/frames of equipment foundations and

structural bases. h) Provision of all inserts, conduits, pre-cast covers, fixing of free issue

items into permanent works etc. i) Provisions of approved quality sand for back filling as per requirement. j) Clearing all construction debris and handing over completed work site. k) Any other work not specifically mentioned but required to make the

terminal functional. Marking as-built details/drawings on one set of construction drawings and return to owner.

III) SCOPE OF SUPPLY Contractor shall procure & supply to site all the materials including cement, reinforcing steel, steel sections/plates, pipes, chequered plate, mesh and other accessories, other masonry materials, bitumen/asphalt, admixtures & bonding

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agents, sealants, kerb stones, sand, boulder etc. and any other construction material / item required to complete the civil works.

All costs towards testing/inspection of materials/goods shall be borne by the Contractor. No materials/items shall be supplied by the Owner .

IV) SITE WORK

Complete construction work including supply of labour, construction materials, construction equipment, survey, tools & tackles, dismantling & modification/strengthening, supervision, testing etc. required to complete all the structures, foundations, roads, drains, pavements, finishes, supply, painting, including site grading/earthwork in cutting & filling etc. as specified and required to complete the civil works in all respect. (All enabling works e.g. construction water tank, casting/fabrication yard, electricity, site stores & office, safety and security measures, coordination with other contractors working at site etc. shall be Contractor’s responsibility.

Special permits to such as ‘Hot Permit”, “Fire Safety Permit” to work at terminal shall be contractor’s responsibility.)

1.0 PREAMBLE TO SCHEDULE OF QUANTITIES

The Preamble to Schedule of Items is an integral part of the schedule of quantities and rates and this is to be considered incorporated into the description of items themselves. The Contractor’s rate for any item of work in the schedule of item shall, unless stated otherwise be held to include the cost of all materials including wastage, conveyance and delivery, unloading, storing, fabrication, all consumable materials, like ms bolts, washer, electrodes ,putty, gases, splices paints etc. hoisting, all labour for finishing to required shape and size, tools and plants, power fuel, consumables, all taxes, royalties, other revenue expenses, temporary facilities like roads etc

2.0 SITE CLEARANCE

Complete works for the site clearing so that the site is suitable for construction activity. Brief description of major items shall be as follows: a) Dismantling of all existing structures in brick masonry/stone

masonry/RCC/PCC, road, fence, sheds, cladding, sheets etc. so that the site becomes suitable for construction activity.

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b) Disposal of all material to be cleared from the site to any authorised

disposal site/ storage yard. c) Provide all assistance/co-ordination/liaison between any and all

government/semi government agencies connected with the scope mentioned and also with the body owning/maintaining the access road to the site.

Note: Demolition of RCC/PCC/Brick Masonry, road will be paid in Cu.M and fencing

and steel structure dismantling will be paid in MT. 3.0 EARTH WORK IN CUTTING & FILLING

Complete earthwork in Excavation of earth/municipal waste/ malba etc. & filling with available serviceable earth or borrow earth is included in the scope.

Brief description of major items shall be as follows:

a. Taking pre-work and finished levels. b. Stripping and grubbing the top soil and preparation of sub-grade. c. Dewatering of excessive water. d. Strutting and shoring to retain the earth. e. Disposal of unserviceable and surplus earth to authorized dumping

ground to any lead. f. Borrowing of approved quality good earth from any lead. g. Filling in layers of 150 mm. h. Watering and compaction up to 95% of its MDD with mechanical means.

Note : i) Payments for item no. EW–1, EW–2 shall be based on compacted

volume of earth calculated by taking plan dimensions, initial and final levels of excavation.

ii) Payment for item earthwork in filling shall be compacted volume of filling, calculated by taking plan dimensions, initial and final levels of earth.

iii) No separate payment for excavation for foundation / sewerage / forecourt or roadwork (since cost of earthwork is included in respective items).

iv) Measurement for rock breaking shall be done by stacking. 35% of stack measurement shall be deducted as voids.

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Earthwork shall be done as per approved detailed construction drawings to be issued to the successful tenderer. Offer to be prepared by the tenderer based on the enclosed drawings and on lump sum unit rate (per Cu.M).

4.0 SAND FILLING AND STONE SOLING

Complete works in filling is included in the scope.


a. Taking pre-work and finished levels b. Borrowing of approved quality sand/stone from any lead. c. Filling in layers of 150 mm. d. Providing and laying stone ballast 40-63 mm size in layers of 150 mm

with spreading blinding material like murum, bajri, stone grit and compaction with road roller etc. complete the surface as per specifications including cost of material.

e. Watering and compaction by 10 T roller.

Note : Payments to be done on completed work profiles by considering the plan dimensions only.

Sand filling and Stone soling shall be done as per approved detailed construction drawings to be issued to the successful tenderer. Offer to be prepared by the tenderer based on the enclosed drawings and on lump sum unit rate (per Cu.M).

5.0 BRICK WORK IN FOUNDATION

Complete works in brick masonry in foundation is included in the scope.

Brief description of major civil items shall be as follows:

i) Earth Work in excavation including back filling using serviceable surplus material or approved borrow material and transportation of excess earth beyond plot limits. Preparation of sub-base including dewatering and compaction.

ii) Mud mat in PCC 1:3:6 (M-10) iii) Brick work with 1:4 cement mortar in foundation. iv) 40mm thick DPC in 1:2:4 wherever applicable. v) Plastering on exposed brick surfaces of 15 mm thickness in CM 1:4. vi) Lime wash on plaster.

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vii) Making weep holes of 150x150 with stone filter pack at 1.0 m intervals in both the directions.

Note: Only net brick masonry volume quantity shall be measured for payment purpose. The construction of brick foundation work shall be done as per approved detailed construction drawings to be issued to the successful tenderer. Offer to be prepared by the tenderer based on the enclosed drawings and on lump sum unit rate (per Cu.M) of brickwork done. Complete works in brick masonry foundation is included in the scope.

6.0 BRICK WORK IN SUPERSTRUCTURE

Complete works in brick masonry superstructure is included in the scope.


i) Brick work with 1:4 cement mortars in superstructure at all heights. ii) 15 mm thick plaster in CM 1:4 on the surfaces to be provided. iii) All niches, offsets, pockets etc shall be considered part of the work. iv) Lime wash on plaster. v) Providing shuttering / supports etc. as per requirement. Note : Only net brick masonry quantity excluding plaster thickness shall be

measured for payment purpose.

The construction of brickwork in superstructure shall be done as per approved detailed construction drawings to be issued to the successful tenderer. Offer to be prepared by the tenderer based on the enclosed drawings and on lump sum unit rate (per Cu.M) of brickwork done.

7.0 PCC WORK

Providing and laying PCC M-15 (1:2:4), M-10 (1:3:6) & M-7.5 (1:4:8) in position, construction and handing over of PCC in foundations, substructure, superstructure and under floor including shuttering/ shoring/ stopper and embedment etc complete in all respects as per scope of work detailed construction drawings (to be released to contractor by owner), technical specifications and direction of Engineer-in-charge.

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Brief description of major civil items shall be as follows: i) Preparation of bed including cleaning, leveling, compacting/tamping of

surface and providing support from bottom and sides. ii) Providing shuttering and stoppers. iii) Providing inserts, pockets, recesses, holdfast etc. iv) Curing, rendering, finishes to match with adjoining surfaces etc.

Note : For all these items only net PCC concrete quantity shall be measured for

payment and PCC below brick work and RCC works is included in the respective item.

The construction of PCC work shall be done as per approved detailed construction drawings to be issued to the successful tenderer. Offer to be prepared by the tenderer based on the enclosed typical drawings and on lump sum unit rate (per Cu.M) of PCC work done.

8.0 RCC WORK IN FOUNDATION

Complete works in RCC foundation for equipment foundation, Pipe supports and other RCC works e.g. box culvert, pits, tanks etc. is included in the scope.


a) Earth Work in excavation including back filling using serviceable

surplus/ borrow material.

b) PCC M-10 (1:3:6) mud mat,

c) Providing shuttering and strutting of all types

d) RCC M25

e) Providing and fixing bolts/inserts.

f) Non-shrink grouting over pedestals M-30D for structural base and high strength cementations grout of M-45 grade for Pump foundations, compressor/ D.G. bases. ( Payable in separate item )

g) Plastering on exposed RCC surface and application of two coats of hot bitumen on surfaces in contact with soil. In case of building foundations the anti-termite treatment be applied.

h) Providing and fixing M.S. Structural work fabricated from standard sections e.g. M.S. rounds, angles, channels including cutting to size, drilling, welding, fixing and welding to insert plates in RCC

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structural members including cutting and making good the walls and floors for pipe supports from floor (in plant room), M.S. ladders and manhole covers for water tanks only.

i) Providing and fixing M.S. slotted angle iron 40x40x2 mm thick with stone enamel finish & fixed to brick masonry or RCC walls with 12 mm dia bolts embedded in cement concrete blocks 1:2:4 mix (1 cement: 2 coarse sand: 4 stone aggregate 12.5 mm nominal size) 100x100x100 mm size for masonry walls & with expandable anchor fasteners on RCC spaced not exceeding 600 mm with 15 mm dia G.I. spacer between wall & angle complete.

Note: For all these items only net RCC concrete quantity excluding PCC/Mudmat shall be measured for payment.

The construction of RCC work shall be done as per approved detailed construction drawings to be issued to the successful tenderer. Offer to be prepared by the tenderer based on the enclosed typical drawings and on lump sum unit rate (per Cu.M) of RCC work.

9.0 RCC WORK IN SUPERSTRUCTURE

Complete works in RCC in superstructure for compound wall/retaining wall, columns & beams is included in the scope.


a) Providing shuttering and strutting of all types b) RCC M25 c) Providing and fixing bolts/inserts. d) Providing and fixing M.S. Structural work fabricated from standard

sections e.g. M.S. rounds, angles, channels including cutting to size, drilling, welding, fixing and welding to insert plates in RCC structural members including cutting and making good the walls.

Note: For all these items only net RCC concrete quantity shall be measured for payment (Bolts, inserts, angles, channels will be paid in item structural steel fabrication). The construction of RCC work shall be done as per approved detailed construction drawings to be issued to the successful tenderer. Offer to be prepared by the tenderer based on the enclosed typical drawings and on lump sum unit rate (per CuM) of RCC work done.

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10.0 CONCRETE PAVEMENT


a) Earth Work in excavation including back filling (including using borrow

earth and disposal of surplus earth).

b) 100 Thk. PCC M-10 mud mat.

c) Providing shuttering and strutting of all types.

d) RCC M25 as per drg & specification including reinforcement (supply of cement, coarse aggregate, fine aggregate, reinforcement bars, reinforcement bending, placement, binding/ welding all inclusive & testing of concrete and other materials).

e) Providing and laying 150 mm thick reinforced cement concrete of (M-25 grade) with 20mm and down grade crushed stone aggregate in pavement, including preparation of base (i.e. compacted subgrade, 200 thk sand and 50 thk PCC M-10.

f) Providing pockets if necessary, making recess, trenches with covers projections, fixing inserts conduit pipes (GI, PVC, HDPE, etc.) laying in alternate panels, filling the gaps between the panels with bitumen etc.

g) Making slopes, finishing edges, leaving bars for pedestals & sleepers including providing sand fill isolation.

h) Providing and fixing reinforcing steel (in one / two layers), curing, chipping and modification works etc. as specified in any shape, thickness, position and finishing the top surface smooth as per requirement etc. all complete as per drawings, specifications and directions of the Engineer-in-charge.

i) Application of two coats of hot bitumen on surfaces in contact with soil.

j) Actual work shall be carried out as per certified construction drawings to be issued to successful tenderer.

11.0 GROUTING WITH NON-SHRINKABLE COMPOUND

Brief description of major items shall be as follows: Ready mix non-shrink cementitious grout of compressive strength 30N/mm2 / 45 N/mm2 as per SOR shall be provided and laid manually or by pumping at all positions. This shall include shuttering, compacting, edging, repairing, sealing and curing for shutdown repairs, base grouting of rotating equipment and other

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installation complete. This shall be as per specifications, site sketches/ drawings and direction of the EIC. Minimum coverage as per manufacturers’ recommendations shall be applied in absence of actual field consumption data.

12.0 VALVE PIT


a) Earth Work in excavation (soil or rock) including back filling upto

required level (including using borrow earth and disposal of surplus earth).

b) 100 thk PCC 1:3:6 (M-10) grade. c) Brick work in foundation with not less than M-7.5 grade bricks in 1:4

cement mortar and valve Pit as per drawing. d) Providing shuttering and strutting of all types e) 15mm thick plaster in CM (1:4) on exposed brickwork surfaces. f) Providing 50mm thick high-density rubber pad shall be wrapped around

the pipe in contact with RCC wall. g) PCC coping shall be 1:3:6 h) Application of two coats of hot bitumen on surfaces in contact with soil. i) Filling of Pit with river sand (zone II) j) Dry brick pitching on top. k) Actual work shall be carried out as per sketch attached with tender.

13.0 PCC KERB STONE IN SPECIFIED AREAS

Brief description of major works to be considered in this item is as follows: a) Earth Work in excavation including back filling upto required level

(including using borrow earth and disposal of surplus earth). b) Supplying and fixing Kerb Stone Blocks 125 mm x 300 mm over 75 thk

PCC – M 10 grade. c) Filling joints between the blocks with cement mortar (1:3) d) Actual work shall be carried out as per certified construction drawings to

be issued to successful tenderer. Note: 1) Complete civil works for Kerb Stone including, earth work in excavation,

preparation of base i.e., compacted sub grade, 75 mm thk. PCC, etc. are included in the works & payment shall be made in RM. under Kerb Stone item.

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PARTICULAR JOB SPECIFICATION (ELECTRICAL)

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SCOPE - ELECTRICAL

a) For all electrical cables which are laid in directly buried trenches with multiple layers in touching configuration for which derating factor of 0.6 shall be considered for power cables. Junction boxes for terminating 415V power and control cables on to the pump skid shall be provided by the pump vendor on the pump skid.

b) All the related cable glands and lugs as required is included in the vendor's

scope. Cable Laying distance between pumps to power distribution board is 150 mtrs (Approx.). Vendor shall visit site for actual cable length requirement and other necessary details.

c) Cable laying in trenches (making of underground trenches), excavated under

ground trench/trays, pulling through pipes and its proper sealing, cutting of paved area, roads etc.

d) Complete earthing protection system including earthing strips/GI wires and earth

pits etc. shall be in vendor’s scope.

e) Local Control Station {Flame Proof type Ex(d)} with start ,stop push buttons, indication lamps .

f) Data required with offer from the vendor doing the job at the time of

evaluation–

a. To furnish with offer the tentative outdoor and indoor equipment size and space requirement for all the equipments included in his scope.

b. To furnish with offer the number, location, voltage and wattage rating of

any auxiliary supplies required in the pump starter panel.

c. The rating of various auxiliary motors and electrical devices for the pump package for which switch fuse feeders or any electrical interface are required from the owner shall also be furnished.

d. Datasheet of various power and control cables required for

interconnection between starter panel and power distribution board.

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PARTICULAR JOB SPECIFICATION (INSTRUMENTATION)

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1.0 INSTRUMENTATION FOR FIRE SYSTEM

The Control & Instrumentation system for fire shall ensure safe, efficient and smooth operation of the system and equipment with minimum intervention personnel during normal working of the fire system, load fluctuation / shut down and start-up. A dedicated mini Programmable logic controller (PLC) including closed loop control system, open loop control system is envisagions for logics & safety interlocks (with hot standby redundancy for processor, I/O modules, Interfacing modules, Communication Bus & Communication Controller).

2.0 FUNCTIONAL REQUIREMENT OF THE SYSTEM

The PLC-Based System shall be used for interlock, shutdown control & monitoring of fire system. The complete system with all accessories shall work under hot redundant mode. This shall meet the following minimum requirements.

a) Monitoring and Control of Fire system parameters, Data Acquisition. b) Shut Down and Interlocks related to fire system. c) PLC shall have dual redundant processor configuration as a minimum. d) Additional redundancy for I/O’s , Power Supply , communication network shall

be provided. e) The system shall be supplied with programming tools and related accessories. f) No two shutdown circuit shall be shared by same I/O module unless specified

otherwise.

The system shall have following features:

a. MMI facilities b. System configuration c. Data logging and trending d. Alarm and event printing e. Data retrieving f. Uploading / Downloading program g. Engineering & programming h. Reports, estimates, MIS etc.

2.1 CONTROL FUNCTIONS

Closed loops: The system has to perform combination of P, I, D controller function. The system shall have separate windows for each control loops. The control loop

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windows shall enable the operator to change the P, I, D value independently and to change set point values. The system shall have fast screen update time.

Open loops: The open loops are only meant for indicating and monitoring purposes. The field input to the system is from transmitters, switches, contactors etc. The inputs will be analog or digital in nature. The system shall indicate numerical values of process parameters such us Pressure, Flow, Level, Temperature and alarm conditions as the case may be.

Alarms: Alarm indication, alarm summary and history displays. The following terminology shall be followed for alarm conditions in graphic representation. Normal : Green Alarm : Blinking RED Accept : RED steady.

Latest Alarm message shall be displayed on the top of the page with beep sound and with blinking Red text indicating tag no., description and time irrespective of the page the operator viewing. Until the operator acknowledges it, the alarm condition shall persist. Separate alarm page shall be configured for listing of alarms. The alarm list shall contain the alarm in chronological order with serial number, tag no, description, time & date.

Recording functions: The system shall be programmed for recording of various important process values. In a particular loop page, provision has to be kept for viewing the loop progress as required. Vendor shall furnish the data capture frequency while quote.

Data logging: Data table pages indicating report of volume of flow shall be recorded for Management information system. Trending: Real time and historical trend windows for various process parameters shall be displayed. Screen Navigation: Auto configured operator interface containing overview, process cell, engineering pages, alarm history, trend pages, login and mimic screen navigation buttons.

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Protocols: Any one of the international protocols such as Ethernet, Modbus, etc., shall be followed. All the data in the system shall be available to the telemetry unit through the serial link. Password protection: The operating station shall be provided with lock-key facility and password facility at Operator, Engineer level for security reasons and to avoid un-authorised operation of the system. Reports, Estimates, MIS format etc.: – Prior approval shall be obtained for Formats. Formats shall be user selectable at site. If separate software is required to meet the user requirement, the same shall be supplied

The basic design features of PLC based Control System shall be following:

CPU of 32 bit or higher version bit microprocessor. Redundancy at controller level, field bus, data highways, power supply, all I/Os. Built-in PID with auto tuning. Flash memory / EEPROM memory. Necessary and required common ports. Built in communication port. Programming and diagnostic facility. Memory of adequate capacity with 30% spares capacity under worst loading

condition. Pass-word security. Internal system diagnostic upto card level Communication bus of coaxial / fiber optics cables. Variable / fixed scan. The healthiness of processor shall be continuously monitored by watch-dog

timer. Any hardware or software problem in the system, which shall include CPU, memory, power supply, communication etc. shall cause the watch dog timer to report the failure processor and switch over to the redundant processor.

Communication bus speed 10 mbps as a minimum at all level. Power supply unit shall be built - in and stabilized. Operating platform shall be window based.

PLC-Based System shall comply with NEMA, IEC, ANSI, ISA, IEEE, DIN and VDE

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2.2 SYSTEM CONTROLLER

a) The system shall be provided as a Hot Redundant stand-alone controller with power supply redundancy in each rack to perform logic functions, status monitoring and reporting functions.

b) The system shall comprise of two sets of necessary processors, input/output (I/O)

modules and communication interface modules required to perform the desired functions under Hot Redundant mode.

c) PLC shall have minimum 10” screen panel mounted industrial grade Color Monitors

along with Keyboard and Mouse (or Touch screen type display). The system shall be auto boot-up on power.

d) The system shall have the following attributes as a stand alone controller:

It shall have different functional modules to perform the desired functions. To avoid spurious output because of output module failure, all commands shall

be associated with release signals. Release signals shall include information on healthiness of the hardware; software and power supply modules.

It shall have relays, counter/timer functions, and internal registers/flags,

watchdog timer, set/reset facilities, up-down counter etc. The system shall have a provision for spare input and output modules.

e) In case of system failure or power supply failure all the outputs shall attain pre-

determined fail safe condition. Spurious signals shall not cause equipment operation. Check back before execution features shall be incorporated.

f) The CPU shall have capabilities to handle atleast 20% more I/O’s than the given I/O

counts. g) The CPU shall have scan time less than 5 milli seconds.

h) The processor shall support printer interface, real time clock and serial

communication ports.

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i) The CPU shall have built-in communication port / shall support separate communication interface card.

j) The built-in serial communications - RS-485 for connection to SCADA system & one

RS 232 with USB converter for Laptop. k) The processor shall have both EPROM & RAM memory onboard. l) The memory device should be provided with battery back up for retrieval of data if

main power lost. m) The CPU shall have self-diagnostic on I/O and CPU level. n) The CPU shall have password facility for protection. o) The Central Processing Unit (CPU) shall be high performance processors with

modular configuration suitable for real time process application. High inherent reliability, self-checking, error-recovery and trouble-shooting features shall be source of the features of CPU.

p) Automatic restart of the system on resumption of power shall be provided.

q) CPU shall have functional capabilities like:

Logic function

Sequencing Timing function Control Range: 0-99,999 sec. Least count: 0.01 sec. Others available as standard

r) CPU shall have interfacing capability with:

I/O Moudules Display Modules Printer Main Fire system / SCADA / Laptop

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s) Outputs on process failure:

Freeze Open Close Flunk Engineer Configurable

t) Memory unit shall comprise of highly reliable memory chip which are industry

standard, proven design with fast random access and suitable for operation in process environments. Main memory shall be modular and facility shall be provided for upgradation and expansion of memory to meet future demands.

u) Sufficient program memory and data memory space shall be provided. System

initialization and application software shall be stored in EEPROM or EPROM with necessary hardware. Running data shall be provided and shall be stored in a RAM with internal battery back up. The battery back up provided shall last for at least one month with life of battery a minimum of 3 years. Appropriate programs for application software modification shall be provided.

v) At least 50 % extra memory space shall be provided over the actual requirements.

2.3 INPUT / OUTPUT MODULES

a) Standard rack mounted I/O modules with plug-in Cards shall be provided. Field

wiring shall be terminated in screwed terminal blacks and interconnected to the processor I/O system with pre-fabricated cables and plug in card type connectors.

b) 20% extra I/Os of installed capacity for each type shall be provided as spares and

shall be wired to the terminal block of the control panel. Provision shall be made for future expansion of extra I/O modules of the installed capacity.

Some of the common features of the I/O modules shall be as follows: All inputs shall be terminated with input protective network and necessary isolating barriers if required. Filters for noise rejection. Provision for isolation of faulty channels.

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Test points and fault indication LED’s shall be provided to carry out module testing. Surge withstands facility as per IEEE standards. All the modules shall be of addressable type. Protection for continuous overload upto 200% of all input ranges Fuse protection and fuse failure detection. Internal battery back-up The I/O module shall have own memory in the CPU, and the data shall be automatically updated for every sweep. The I/O module shall have LED’s to indicate the inputs signal status. The I/O module shall have fault indication. The I/O module shall be rack-mounted type. The Bidder shall indicate the number of input points per module. All the inputs shall have optically isolated. Individual power supply shall be provided per I/O rack. INPUT MODULE: Input type: Potential free contact rated, 24 VDC, 1A Analog 4-20 mA intrinsically safe (Two wire) 24 V DC, 2A as required Input interrogation voltage shall be 24 VDC. OUTPUT MODULE: Output type: Potential free contact rated, 24VDC, 1A

Analog 4-20 mA intrinsically safe (Two wire) 24 V DC, 2A as required Input interrogation voltage shall be 24 VDC.

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2.4 SOFTWARE PLC system shall be provided with software suitable to meet the system requirements & HMI software. Prior approval shall be obtained for all the software to be used. All the software used shall be licensed to Client. Necessary authorisation documents shall be furnished.

2.5 CONTROL PANEL CUM MARSHALLING CABINET CUM DISPLAY PANEL

PLC shall have minimum 10” screen panel mounted industrial grade Color Monitors along with Keyboard and Mouse (or touch screen type). The system shall be auto boot-up on power.

The Cabinet shall be provided to house all the system components such as I/O

Modules, Power Supply Modules, Communication Modules, Processor Units of the PLC System along with Isolating Barriers (if required), Signal Repeaters, Relays, etc.

The Cabinet shall be coated to maximum protection against harsh environments. The Cabinet shall be constructed in such a way that to protect electronic devices

from the outside interference.

The Cabinet shall have 30% usable space for future expansion.

3.0 PARTICULAR REQUIREMENTS

SL.NO. DESCRIPTION REMARKS

1. (a) (b)

Item: Quantity

PLC based system 1 Set per unit

2. Mounting Control Panel cum Marshalling Cabinet Cum display Unit

3. Digital Inputs Digital Outputs

32 Nos 16 Nos

4. Analog Inputs Analog Outputs

08 Nos 02 Nos

5. Power Supply to sensor & transmitters From Input cards (loop powered) 6. Type of Input NO/NC – Contacts field selectable

4-20mA – transmitter input 7. Outputs Relay outputs for driving solenoid coils

4-20mA

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SL.NO. DESCRIPTION REMARKS

8. Accessories Minimum 10” Monitor panel mounted with Keyboard, Mouse etc .

9. Serial Communication Port for SCADA & Laptop

1 Nos. RS 485 & 1 Nos RS 232 with USB converter

This is the minimum specification for the system designing; any requirements based on the offered system shall be included by the vendor / contractor and shall be informed at the time of bidding

CChhaapptteerr 0066

IIMMPPLLEEMMEENNTTAATTIIOONN SSCCHHEEDDUULLEE

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D:\old data\Vijyant\LPG Reports\Final Reports\07-Cheralapally\Chapter-06 -Implementation.doc 06- 1/4 © 2010 MECON Limited. All Rights Reserved

01.00 IMPLEMENTATION SCHEDULE 01.01 General

The overall project comprising the Fire Protection facilities including laying of pipeline, spray system and replacement of fire water pumps at IP Station, Samakhiali is envisaged to be implemented over a period of 6 months taking into account planning of phase wise shut-down and supporting infrastructure. Following are the salient points of the Implementation Schedule: The modification of fire water network and water spray system

installation has been taken as an activity to continue during plant operation.

Adequate infrastructure for catering to plant operation

requirement are to be planned considering partial shut down of equipments for installation to ensure no interruption in LPG supply.

The implementation plan envisages achieving following

targets in six months that is the period of job execution:

The hydrants and monitors shall be relocated. New Hydrants / Monitors shall be installed wherever required. Modification in existing fire water network shall be carried out

for installation of valve pits wherever required for new tapings.

Existing medium velocity water spray system shall be

dismantled New water spray system alongwith detection and spray line

shall be installed. Deluge valves shall be installed of required dia as

recommended and the tapings shall be connected with the new / modified spray system.

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The modified system shall be integrated with existing fire protection system by doing wiring upto control room and hooking up with existing fire panel.

Final testing and commissioning of the entire system shall be

carried out.

Indicative implementation schedules as proposed for different activities have been given in Figure 06.01. Activities for all the above areas shall commence from zero date after appointment of project consultant. In other words the major events to be covered in the schedules shall broadly include : i) Submission of basic design and drawings and their approval for

modification in the existing fire water line and pump house. ii) Placement of orders for bought-out equipment, pipes and

materials. iii) Submission of GA drawings for mechanical, electrical and

instrumentation equipment. iv) Manufacture and supply of equipment and pipes. v) Construction of civil and structural works. vi) Pipeline laying schedule. vii) Erection of mechanical, electrical and instrumentation equipment. viii) Testing and commissioning of sub-systems and integrated

systems. ix) Submission of as-built drawings and Operation and Maintenance

manuals. 01.02 Assumptions

a) It is assumed that all the required statutory approvals shall be

obtained as per schedule b) Finalization of engineering consultant shall be considered as the

‘ZERO’ date. c) All statutory approvals shall be taken in time as per schedule.

01.03 Recommendations The proposed project shall be implemented under the overall

responsibility of the owner who shall obtain necessary technical services from an engineering consultant in the areas of basic design, detailed

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MECON LIMITED


engineering, procurement of major equipment and materials, selection of suitable vendors and contractors, construction supervision, commissioning assistance and project management.

The installation of medium velocity water spray system, modification in fire water networks as per drawings along with erection of free issue items which are available shall be given to competent contractors, preferably an EPC agency, who shall complete the works as per project schedule. All major/ critical equipment viz. pumps etc. and materials will be procured by the owners directly, as this shall ensure the quality of equipment / material as well as their availability in time

GAIL (INDIA) LTD.




MECON LIMITED



CCAAPPIITTAALL CCOOSSTT EESSTTIIMMAATTEE

GAIL (INDIA) LTD.




MECON LIMITED

D:\old data\Vijyant\LPG Reports\Final Reports\07-Cheralapally\Chapter-07-Capita Cherlapally.doc 07- 1/7 © 2010 MECON Limited. All Rights Reserved

01.00 CAPITAL COST ESTIMATE 01.01 General

The augmentation of fire protection system has been planned in the existing LPG terminals / stations which is necessitated due to change in applicable OISD code with respect to initial design from OISD 116/117 to OISD 214/144. The modifications have to be carried phase wise as the plant will be running condition to the extent possible. Capital cost based on the facilities envisaged for creating fire fighting system are estimated as Rs. 69.40 lac. The total cost of project is summarised in Table -07.01.

01.02.01 Major Facilities

The augmentation of fire protection system job has been sub-divided into various heads. The job includes modification in fire water piping networks, relocation of hydrants and monitors, replacement of 2 nos. existing fire water main pumps, installation of new medium velocity water spray system, associated civil, electrical and instrumentation work and system integration with existing fire protection system. Major facilities included in the capital cost estimates are given below:

Sl. No.

Description Details

I) Fire Water System fire water network of above ground pipe 25m fire water hydrants & monitors Nil

II) Water Spray System Medium Velocity Water Spray System For - existing Scraper & Launcher Area - existing Metering & Filtration Area

III) Fire Pumps & Accessories 2 nos. IV) Fire Detection and Alarm System V) Associated Civil Works VI) Associated Electrical and Instrumentation Works

Costs toward equipment, associated electrics, spares, erection and civil engineering works are included in the estimate. The estimates are based on the prices for different cost elements prevailing during 2nd quarter of 2011 and do not include any provision for future escalation.

GAIL (INDIA) LTD.




MECON LIMITED


The break up of capital costs under major heads such as equipment, spares, civil engineering works, electrical and instrumentation work, erection, and engineering, supervision, project management etc., for the fire fighting system has been given at Table-07.01.

01.03 Assumptions

Following assumptions have been made for working out the capital costs. 01.03.01 Land and ROW/ ROU Compensation

No provision for land or ROU has been made. 01.03.02 Equipment

The costs of equipment are based on LOA/ budgetary offers. However, generally, in house information for equipment installed in other projects has been used. The cost of equipment under this head is on ex-works basis.

01.03.03 Spares

Provision for spares required for 2 years normal operation has been made equivalent to 5% of equipment cost.

01.03.04 Civil engineering works

Cost estimates for civil engineering works have been worked out based on preliminary layout modifications, road cutting and repair of roads for laying of underground pipelines, pavements, supports and rates generally prevailing for similar work in the area.

01.03.05 Electrical & Instrumentation works

Cost estimates for electrical and instrumentation works have been worked out based on preliminary layout modifications, wiring and other electrical items and accessories, instrumentation PLC and panels etc. Rates generally prevailing for similar work in the area and earlier cost data have been considered for arriving out at the cost estimates.

GAIL (INDIA) LTD.




MECON LIMITED


01.03.06 Erection

Provision towards erection of equipment has been made on the basis of erection rates as prevailing in the region.

01.03.07 Freight, insurance, duties and taxes

For equipment provision for excise duty @10.3%, Central sales tax @12.5%, inland freight & transit insurance @2% has been made. Service tax @10.3% has also been considered on cost of construction, erection, engineering, supervision etc.

01.03.08 Engineering, Supervision and Project Management

A provision has been made towards engineering, supervision and project management services etc., at the rate of 10% of the estimated cost as the value of job is very small. This includes detailed engineering including preparation of drawings, technical specifications, preparation of tender documents, assistance for award of contracts, designer’s supervision, project management services and temporary power and water facilities, etc.

01.03.09 Owner’s Management Expenses Provision towards owner’s management expense has been kept at the rate of

3%. This includes preliminary and pre-operative expenses. 01.03.10 Contingencies

A provision of 5% of the project cost has been made towards contingencies to take care of the unforeseen aspects of the estimate.

GAIL (INDIA) LTD.




MECON LIMITED


Table-01.01 PROJECT CAPITAL COST (CHERLAPALLY)

In Rs. SL. NO.


A Fire Protection System 1 Fire Water System a) Pipeline of various dia.(25m approx.) 0.00 80,000.00 80,000.00

b) Valves of various dia. (16 nos. approx.), strainers, flanges

0.00850,000.00 850,000.00

c) Hydrants & Monitors 0.00 Nil Nil

d) Pressure gauge, switch & other accessories

0.00100,000.00 100,000.00

2 Medium Velocity Water Spray System a) Scrapper & Launcher Area 0.00 500,000.00 500,000.00 b) Metering Area 0.00 700,000.00 700,000.00

3

Two nos. Fire Pumps of 616 m3/hr capacity & associated accessories without considering salvage value of existing fire water pump

0.00 3,000,000.00 3,000,000.00

4 Fire Detection and Alarm System 0.00 200,000.00 200,000.00

5 Electrical & Instrumentation Works including Flow meter

0.00 Nil Nil

6 Associated Civil Works: a) Earth Work 0.00 25,000.00 25,000.00 b) Construction Work 0.00 50,000.00 50,000.00 c) Concrete Pavement 0.00 150,000.00 150,000.00 d) Valve Pit 0.00 50,000.00 50,000.00 e) Kerb Stone Fixing 0.00 50,000.00 50,000.00 f) Plastering & Painting 0.00 25,000.00 25,000.00 g) Road Works 0.00 50,000.00 50,000.00 Sub-total (A) 0.00 5,830,000.00 5,830,000.00B Engineering Costs

1 Detailed engineering, procurement, construction, supervision and project management @ 10% of project cost

0.00 583,000.00 583,000.00

2 Service tax on above @ 10.3% 0.00 60,049.00 60,049.00 Sub-Total ( B ) 0.00 643,049.00 643,049.00C Owner's Cost

GAIL (INDIA) LTD.




MECON LIMITED


SL. NO.


2 Owner's management expenses @ 3% of project cost

0.00 174,900.00 174,900.00

Sub-Total ( C ) 0.00 174,900.00 174,900.00

D Other costs

1 Contingency @ 5% of project cost 0.00 291,500.00 291,500.00 TOTAL COST (A to D) 0.00 6,939,449.00 6,939,449.00

Note: The Total Cost includes all applicable Taxes & Duties, Freight Charges.

Those bidders who meet the following criteria shall be initially short listed for detailed evaluation.

01.04.01 TECHNICAL 1.1.1 The bidder shall be a regular contractor of fire protection system and must

posses proven track record for design, engineering, fabrication, assembly, shop testing, supply, installation & commissioning of such work in totality.

1.1.2 The bidder should have executed under a single contract in the past 5 years,

reckoned from date of submission of bid, at least one project of similar nature consisting of : i) Fire water pumping and distribution system. ii) Fire protection facilities involving hydrants, monitors, medium velocity

water spray system for various process areas, fire alarm system and related instrumentation and controls.

iii) The job completed by the bidder shall consist of multidisciplinary works viz. civil, mechanical, piping and electrical and instrumentation works.

iv) On the date of issue of invitation for bid, the job should have completed and a performance / work completion certificate to this effect shall be submitted by the bidder along with copy of PO.

The bidder should be capable of undertaking job of similar fire protection works as mentioned above at various locations for GAIL terminals.

1.2 Financial 1.2.1 Turnover

GAIL (INDIA) LTD.




MECON LIMITED


The minimum annual turnover achieved by the bidder as per their

audited financial results in at least one of the three preceding financial years shall be as under:

Description Minimum Annual Turnover Requirement (in INR)

Complete Scope of Work 65,00,000/- 1.2.2 Net worth

Net worth of the bidder shall be positive as per audited financial statement of preceding financial year.

1.2.3 Working Capital

The minimum working capital of the bidder as per audited financial statement of preceding financial year as detailed here under :

Description Minimum Working capital

Requirement (in INR) Complete Scope of Work 13,00,000/-

Note: If the bidder's working capital is inadequate, the bidder should

supplement this with a letter from the bidder's bank, having net worth not less than Rs. 100 Crores, confirming the availability of the line of credit at least for working capital requirement (to cover the inadequacy of working capital required as above)

2.0 Completion Schedule

Sl. No.

Name of Work Time of Completion

1. AUGMENTATION OF FIRE PROTECTION SYSTEM, ASSOCIATED CIVIL & ELECTRICAL WORKS FOR EXISTING INSTALLATION AT GAIL RECEIVING TERMINAL, CHERALAPALLI

18 WEEKS FROM THE DATE OF FOI INCLUDING ERECTION, TESTING AND COMMISSIONING.

3.0 BASIS OF OFFER AND PLACEMENT OF ORDER

GAIL (INDIA) LTD.




MECON LIMITED


Bidder must quote for complete scope of work, otherwise bidder’s offer will not be considered for evaluation.

4.0 DOCUMENTS REQUIRED The bidder shall furnish documentary evidence by way of copies of work order,

completion certificate issued by Owner / Consultant and Balance Sheet or Audited Financial Statements including Profit & Loss Account etc. along with the Bid to establish his experience and track record meeting qualification criteria.

5.0 BID SECURITY Bid Security for various item shall be as detailed below:

Description Bid Security (in INR) Complete Scope of Work 1,00,000/-

AAnnnneexxuurree--II

DDAATTAA SSHHEEEETTSS

MECON LIMITED

Delhi

DATA SHEET FOR CENTRIFUGAL PUMPS

MEC/23MN/05/21/M/002/DS-081A MECON LIMITED

DS – CP - 0

DATA SHEET FOR

CENTRIFUGAL PUMPS

MECON LIMITED

Delhi



DS – CP - 1

CENTRIFUGAL PUMP DATA SHEET

I-

PLAN

T

1. PLANT : LPG RECEIVING TERMINAL, CHERLAPALLI, ANDHRA PRADESH, GAIL;2. LOCATION / ADDRESS OUTDOOR / CHERLAPALLI, ANDHRA PRADESH 3. ALTITUDE 6 AMBIENT

TEMP MAX./ MIN.

Max.55`C

Min.(-)5`C

4. ITEM NO. - 7.5. SERVICE DRINKING WATER

FIRE WATER 8.

II-

PU

MP

CHAR

ACTE

RIST

ICS

1 NO. OF PUMPS 1 WORKING + 1 STANDBY

2. CAPACITY RATED m3/hr. 616

7. DIRECTION OF ROTATION FROM COUPLING END

CLOCK WISE /ANTI CLOCK WISE

MAX. m3/hr. *

8. OPERATION PARALLEL / SERIES

MIN. m3/hr. *

9. DUTY CONTINUOUS/ INTERMITTENT

RUN OUT m3/hr. *

10. PUMP EFF *%

3. TOTAL HEAD RATED MWC

11. SHAFT POWER AT DUTY POINT

Kw

SHUT OFF MWC

12. NOISE LEVEL

4. SUC PRESSURE MWC

13. VIBRATION LEVEL

5. NPSH AT CL OF SUC EYE

AVAILABLE MWC

14. RESIDUAL UNBALANCE

REQUIRED MWC

15.

6. MIN SUBMERGENCE MWC

16.

III-

PU

MP

CON

STRU

CTIO

N 1. TYPE OF PUMP SINGLE VOLUTE 13. SHAFT SEAL MECHANICAL

2. MODEL HORIZONTAL CENTRIFUGAL

14. IMPELLER TYPE

3. NO. OF STAGES * 15. SUCTION SINGLE / DOUBLE

4. PREFERRED SPEED *mm 16. SHAFT DISPOSITION HORZ/ VERT5. SUCTION FLANGE DIA

mm * RATING 250# 17. BEARING

6. DELIVERY FLANGE DIA mm * RATING 200 #

18. BEARING LUBE

MECON LIMITED

Delhi



DS – CP - 2

7. IMPELLER DIA RIB/ MAX/MIN. mm

19. WB

8. IMPELLER EYA DIA mm 20. WEIGHT 9. SUCTION POSITION 21. UNDER SIDE OF BASE PLATE TO

SUCTION STRAINER mm

10. DISCHARGE POSITION 22. FLANGE DRILLING RATING kg/cm2

11. BASE PLATE 23.12. COUPLING TYPE 24.

IV-

MAT

ERIA

L

1. CASE OR BOWL 10. MECHANICASL SEAL2. CASING LINER 11.3. IMPELLER BRONZE 12.4. IMPELLER LINER 13.5. SHAFT SS 410 14.6. SHAFT SLEEVE SS 4107. WEARING RINGS 8. STUFFING BOX 9. LANTERN RING

PPD CLIENT CKD APD PROJECT

No. RAT B APD REVISIONS RATE JOB CODEQ6Q9

V-

LIQ

UID

PU

MPE

D

1. COMMERCIAL NAME 12. SEIVE ANALYSIS 2. PH 13.3. S.P. GR 14.4. TEMP. 15.5. VISCOSITY 16.6. VAPOUR PRESSURE 7. CHEM. COMP. 8. SUSP. SOLID BY WT % BY VOL %

9. SHAPE & SIZE OF SOLIDS10. CHARACTERISTICS OF SOLIDS 11. S.P. GR OF SOLIDS

VI-

ACC

ESSO

RIES

&

SERV

ICES

1. DISCHARGE PRESSURE GAUGE YES/ NO

6. COMMISSIONING YES/ NO

2. SUCTION PRESSURE GAUGE YES/ NO

7.

3. COMPANION RANGES WITH YES/ NO NUTS BOLTS GASKETS

8.

4. FOUNDATION BOLTS YES/ NO 9.5. COMMON BASE PLATE YES/ NO

MECON LIMITED

Delhi



DS – CP - 3

10. BASE PLATE PUMP ONLY YES/ NO 25.11. FOOT VALVE WITH STRAINER YES/ NO 26.12. COUPLING GUARD YES/ NO 27.13. PRIMING GUARD YES/ NO 28.14. BEARING TEMP. GAUGE YES/ NO15. MOTOR STARTER YES/ NO16. RECOIL MAINT. TOOLS YES/ NO17. RECOIL SPARES FOR TWO YRS YES/ NO18. PROTABLE TROLLEY YES/ NO19. LEVEL SWITCHES YES/ NO20. LEVEL ALARM YES/ NO21. REFLUX VALVE YES/ NO22. SLUICE VALVE YES/ NO23. PUMP ERECTION YES/ NO24. ERECTION SUPERVISION YES/ NO

VII-

TE

STIN

G

1. HYDROSTATIC TEST CASING WITNESSED/UNWITNESSED/ NOT REQD.

MCKETS / WITNESSED/UNWITNESSED/ NOT REQD. COOLING PASSAGE

2. PERFORMANCE TEST STB. RUNNING TEST WITNESSED/UNWITNESSED/ NOT REQD.

NPSN TEST WITNESSED/UNWITNESSED/ NOT REQD.

3. FIELD TEST NOT REQD. 5. DYNAMIC BAL TEST NOT REQD.4. STATIC BAL TEST NOT REQD. 6. VISUAL INSP. CHECK NOT REQD.


No. RA B APD REVISIONS RATE JOB CODE

VI

II-

D

RIVE

DAT

A

7. PRIME MOVER BY VENDORS/OTHERS

15. WEIGHT

8. DRIVE AS PER SPN. NO. 16. POWER SUPPLY VOLTS HZ AC

9. TYPE ELECT 17.10. RATING HP / Kw 18.11. STARTER BY VENDORS/OTHERS12. SPEED RPM 13. CONTROL PANEL VENDORS/OTHERS

14. CABLING

VENDORS/OTHERS

MECON LIMITED

Delhi



DS – CP - 4

IX-

DEL

IVER

Y D

ATA

1.

X- G

UAR

ANTE

E 1. MONTHS FROM DATE OF SUPPLY MONTHS FROM DATE OF COMMISSIONING


No. RA APD REVISIONS RAT JOB CODE

DATA SHEET

FOR QUARTZOID BULB DETECTOR

Data Sheet No. 05/14/23MN/DS/CHERLAPALLI/01

Rev. : 0

Date : 15.06.2011

Package : Fire Fighting System

1.0 Make HD / EQUIVALENT

2.0 Model No.

3.0 Type Pendent Type

4.0 End Connection ½” NPT

5.0 Operating Temperature 79 Deg. C

6.0 Colour of Bulp Liquid Yellow

Material of Constructions :

1.0 Frame ASTM C37700 B124

2.0 Bulb Glass with Glycerine Solution

3.0 Deflector ASTM C22000 B36

4.0 Lead Screw ASTM C22000 B36

5.0 Seal Belleville Washer Coated on Both Side with Teflon Tape

6.0 Cap Copper

7.0 Bulb Nominal Diameter Standard Response 5.0 mm; Quick Response 3.0 mm

8.0 Catalogue Attached

Project : CONSULTANCY FOR DESIGN & DETAILED ENGINEERING FOR UPGRADATION OF EXISTING FIRE WATER SYSTEMS ALONG JLPL & VSPL NETWORKS

Client : GAIL (India) Limited

MECON LIMITED

Delhi

DATA SHEET FOR LANDING VALVE

MEC/23MN/05/21/M/002/DS-081E MECON LIMITED

DATA SHEET FOR

LANDING VALVE

MECON LIMITED

Delhi

DATA SHEET FOR LANDING VALVE

MEC/23MN/05/21/M/002/DS-081E MECON LIMITED

DS-LV- 1

TECHNICAL DATA SHEET FOR LANDING VALVE AND ACCESSORIES 1.0 Type : Type A Single outlet or Type B Double

outlet 2.0 Code Standard : IS:5290 3.0 Material of construction : 3.1 Body : Leaded Tin Bronze Gr. LTB-2 of IS:318 or

Aluminium alloy of IS designation 4225,4450 and 4600 of IS:617

3.2 Stop Valve : Leaded Tin Bronze to Gr. LTB-2 of IS:318 3.3 Spindle : Brass Rod to IS 320 or IS 319 3.4 Spindle Body : S.S. to IS 6603 3.5 Hand wheel : M.S to IS 1030 or C.I. to IS 210 3.6 Washer, Gasket etc. : Rubber IS:937 or leather to Is 581 3.7 Spring : Phospher Bronze wire to IS:7608 4.0 Inlet flange : Size 100mm (100 NB) the drilling

dimension including O.D. of flange shall be as per ANSI-B-16.5 class 150.

5.0 Working pressure : 3.5 to 12 kg/cm2 6.0 Hydrostatic test pressure : 21 kg/cm2 7.0 Flow/Hydrant : 900 LPM for Type A or 1800 LPM at 7

kg/cm2 for Type B 8.0 Approval : TAC approved

DATA SHEET

1.0 JOB NO. : 23MN ITEM NO. :

2.0 VENDOR : QUANTITY : AS PER SOR

3.0 OPERATING CONDITIONS :

FLUID HANDLED : WATER

FLUID DENSITY@PT, KG/M3 :1000 OPER. TEMP., °C : 15-45

OPER. PR., KG/CM2 :7-11

4.0 MESH

MESH SPECIFICATION 10 MESH 22 SWG OPENING (IN)

SCREENING AREA %

5.0 PR. DROP, KG/CM2, CLEAN/ DIRTY :

MAX. ALLOWABLE PR. DROP, KG/CM2, DIRTY : 0.2

6.0 MATERIAL OF CONSTRUCTION

EQUAL TEE :A-234 Gr. WPB WNRF FLANGES : SA105

BLIND FLANGE : SA 105

GASKET : SS316 SPIRAL WOUND WITH CAF FILLED FASTENER : A193Gr.B7/ A194Gr.2H

FILTER ELEMENT : 304L

7.0 DESIGN AND CONSTRUCTION

TYPE :T-TYPE

DESIGN PR., KG/CM2G :12 DESIGN TEMP., °C :65

HYDROTEST PRESSURE : 18 KG/CM2G

FLANGE TYPE : WNRF FLANGE RATING : 150# FLANGE FINISH : SMOOTH FINISH

CORROSION ALLOWANCE, MM : 3.0

8.0 DIMENSIONAL DETAILS (REF. ATTACHED DRG.)

OVERALL LENGTH (L), MM : OVERALL FILTER ELEMENT SIZE (H1)x(A), MMxMM:

OVERALL HEIGHT (H), MM :

9 INLET/ OUTLET CONNECTION PIPE: 6" & 4" NB

10 DIMENSIONAL STANDARDS

FLANGE & FITTING : ASME B16.5/ B16.9

FASTENERS : B 18.2

GASKET : ASME 16.20 ANSI B16.5 (5 mm . Thickness)

11 PAINTING : AS PER T.S.

ENVIRONMENT FOR PAINTING : CORROSIVE INDUSTRIAL

COLOUR OF FINISH PAINT : FIRE RED

12.0 INSPECTION & TESTING : AS PER T.S. RADIOGRAPHY :100%

NOTE:

1 VENDOR TO SPECIFY

REV. NO. DATE ZONE DESCRIPTIONS BY APPRD

REVISIONS REFERENCES

SECTION OIL & GAS CLIENT : GAIL (INDIA) LIMITED

NAME DATE CHKD DATE PROJECT :CONSULTANCY FOR DESIGN & DETAILED ENGINEERING FOR

DSGN AL RKD UPGRADATION OF EXISTING FIRE WATER SYSTEMS ALONG JLPL & MECON LIMITED

DRWN VSPL NETWORKS

T- TYPE STRAINER SCALE : REV

APPROVED BN BAS TAG NO. : DATA SHEET NO. : MEC/23MN/05/21/M/001/DS-010A 0

This document and the design it covers are the property of MECON and issued for the specific project mentioned therein. This is not to be copied or used for other projects unless expressly permitted by MECON.

FLOW RATE , M3/Hr, Normal/ Max. 90 to 375

THE EFFECTIVE FREE AREA OF BASKET SHALL BE MIN. THREE TIMES THE INLET NOZZLE AREA.

AAnnnneexxuurree--IIII

DDRRAAWWIINNGGSS && SSKKEETTCCHHEESS

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