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TCE CONSULTING ENGINEERS LIMITED
PROCESS DATA SHEET FOR VESSEL SH 1 OF 1
REV.
NO.GENERAL
REV.
NO.
1 ITEM NUMBER
2 QUANTITY 2
3 CAPACITY (NOMINAL)
4 SERVICE
5 DESIGN CODE
6 LOCATION INDOOR / OUTDOOR
7 FLUID PROPERTIES AT OPERATING TEMP.
8
9 FLUID
10 SPECIFIC GRAVITY
11 VISCOSITY cP
12 VAPOUR PRESSURE kg/cm2(a)
13 (AT 30 DEG.C.)
14
15 DESIGN DATA
16
17 OPERATING TEMPERATURE o C
18 DESIGN TEMPERATURE o
C
19 OPERATING PRESS.AT 32 DEG.C.kg/cm2(g)
20 DESIGN PRESS. kg/cm2(a)
21 INSIDE DIAMETER mm
22 LENGTH mm
23 HEAD TYPE- TOP
24 - BOTTOM
25 CORROSION ALLOWANCE mm
26 SUPPORT SADDLE
27 INSULATION - REQUIRED YES / NO
28 - PURPOSE PERS. PROTEC./CONSER. NOTES :
29 AGITATOR YES / NO 3) This vessel shall be designed, fabricated, manufactured, inspected by Third
29 Party & Testing as per the requirement of "The Static & Mobile Pressure
30 Vessels Rules"(SMPV Rules) .This vessel shall be approved by CCoE Nagpur
31 MATERIAL OF CONSTRUCTION and obtaining approval of CCoE Nagpur and inspection by competent third
32 SHELL party shall be in the scope of vessel vendor
5) A Test & Inspection certificate issued by manufacturer of the vessel
33 JACKET shall be furnished to CCoE, Nagpur.This shall be duly countersigned
34 COIL NA by an Inspector, authorised by CCoE, Nagpur that the vessel meets
35 INTERNALS with the requirements of the code approved by CCoE, Nagpur .
36 GASKET PTFE ENVELOPED CAF
37 ACCESSORIES BY TANK VENDOR
38 AGITATOR YES / NO N14 25 1 NITROGEN INLET (DURING COMMISSIONING)
39 BAFFLES YES / NO N13 50 1 SPARE
40 COIL YES / NO N12 50 1 SPARE
41 DIP PIPES YES / NO N11 500 1 MANHOLE
42 N10 25 1 TEMPERATURE INDICATOR
43 SPECIAL REQUIREMENTS N9 25 1 LEVEL GAUGE
44 RADIOGRAPHY 100% N8 25 1 LEVEL INDICATION TRANSMITTER
45 STRESS RELIEF AS PER CODE N7 25 2 LEVEL INDICATION TRANSMITTER
46 BUFFING NA N6 25 1 PRESSURE TRANSMITTER
47 OTHER NA N5 HOLD 1 PRESSURE GAUGE
48 NOTES : N4 HOLD 1 PRESSURE SAFETY VALVE (PSV)
49 1) Sizes and instrument nozzles are under hold pending instrument N3 HOLD 1 PRESSURE SAFETY VALVE (PSV)
51 finalization. N2 50 1 AMMONIA IN
52 2) All liquid level gauging devices shall be as per "SMPV RULES" N1 50 1 AMMONIA OUTLET (TO NH3 COMPRESSOR)
53 NOZZ. NO. SIZE QTY. SERVICE
54 NOZZLE SCHEDULE
REV NO. : P0 R0 PPD. BY :Sd/- SPP TCE JOB NO. CLIENT : NUCLEAR FUEL COMPLEX
PPD. BY/DATE : Sd/-SPP 31.8.05 Sd/-SPP 11.5.06 CKD. BY:Sd/-MB TCE-4246A PROJECT : NZOSP, PALAYAKAYAL
CKD. BY/DATE : Sd/-MB 31.8.05 Sd/-VAK 11.5.06 DATE :31.08.05 PDS NO. : TCE-4246A-CH-T-PDS-322T441
Liquid NH3
23.55 kg/cm2(a)
0.58
-
322-T-441 A/B
ASME SEC-VIII DIV. 1
45 KL (Water Capacity)
LIQUID NH3 STORAGE
LOW TEMPERATURE CARBON
STEEL
SHELL
3000
AMBIENT
12.7 KG/CM2 (a)
11.89
7250
DISHED END
NA
DISHED END
3 MM
LOW TEMPERATURE CARBON
STEEL
(-) 33 TO 55
SHELL
R1
R0-1
997-0
3-3
1T
CE
.M4-C
H-T
-PD
S-
N10 N3 N6N5N4N2
N1
3.0
m
7.25 m
N11 N7 N8 N13
N12
N9
TCE CONSULTING ENGINEERS LIMITED
PROCESS DATA SHEET FOR VESSEL SH 1 OF 1
REV.
NO.GENERAL
REV.
NO.
1 ITEM NUMBER
2 QUANTITY 2
3 CAPACITY (WORKING)
4 SERVICE
5 DESIGN CODE
6 LOCATION INDOOR / OUTDOOR
7 FLUID PROPERTIES AT OPERATING TEMP.
8 SHELL
9 FLUID 35% NH4OH
10 SPECIFIC GRAVITY 0.85 - 0.94
11 VISCOSITY cP 0.3
12 VAPOUR PRESSURE AT 30oC kg/cm
2(a) 0.75
13
14
15 DESIGN DATA
16 SHELL
17 OPERATING TEMPERATURE o C AMBIENT
18 DESIGN TEMPERATURE o
C 70
19 OPERATING PRESS. kg/cm2(g) ATM.
20 DESIGN PRESS. kg/cm2(g) 10
21 INSIDE DIAMETER mm
22 LENGTH mm
23 HEAD TYPE - TOP
24 - BOTTOM
25 CORROSION ALLOWANCE mm
26 INSULATION - REQUIRED YES / NO
27 - PURPOSE PERS. PROTEC./ CONSER.
28
29
29 MATERIAL OF CONSTRUCTION
30 SHELL SS 304L
31 JACKET
32 COIL NA # indicates as per code
33 INTERNALS SS 304L * indicates minimum for piping
34 GASKET PTFE ENVELOPED CAF
35 ACCESSORIES BY TANK VENDOR
36 AGITATOR YES / NO
37 BAFFLES YES / NO
38 COIL YES / NO
39 DIP PIPES YES / NO N13 25 1 SAMPLING POINT
40 N12 50 1 DRAIN
41 SPECIAL REQUIREMENTS N11 50 1 RECIRCULATION INLET
42 RADIOGRAPHY 100% N10 25 1 NITROGEN BLANKETING
43 STRESS RELIEF AS PER CODE N9 50 1 SPARE
44 BUFFING NA N8 50 1 PVRV
45 OTHER NA N7 500 1 SHELL MANHOLE
46 NOTES : N6 50 1 SPARE
47 1) Sizes and instrument nozzles are under hold pending instrument N5 50 1 PG
48 finalization. N4 25 2 LEVEL INDICATOR TRANSMITTER
49 N3 25 1 TEMPERATURE INDICATOR
51 N2 80 1 AMMONIUM HYDROXIDE OUTLET
52 N1 80 x 40 1 AMMONIUM HYDROXIDE INLET
53 NOZZ. NO. SIZE QTY. SERVICE
54 NOZZLE SCHEDULE
REV NO. : P0 R0 PPD. BY :SPP TCE JOB NO. CLIENT : NUCLEAR FUEL COMPLEX
PPD. BY/DATE : Sd/- SPP 31.08.05 Sd/- SPP 11.05.06 CKD. BY:MB TCE-4246A PROJECT : NZOSP, PALAYAKAYAL
CKD. BY/DATE : Sd/- MB 31.08.05 Sd/-VAK 11.05.06 DATE :31.08.05 PDS NO. : TCE-4246A-CH-T-PDS-322T442
NA
DISHED END
322-T-442 A/B
ASME SEC-VIII DIV. 1
35 KL
NH4OH SOLUTION STORAGE
1 MM
2750
7000
DISHED END
R1
R0-1
997-0
3-3
1T
CE
.M4
-CH
-T-P
DS
-
N10 N3 N8
N5 N6 N9N4N1 N7
N11
N2 N12
7.00 m
2.7
5 m
TCE CONSULTING ENGINEERS LIMITED
PROCESS DATA SHEET FOR VESSEL SH 1 OF 1
REV.
NO.GENERAL
REV.
NO.
1 ITEM NUMBER
2 QUANTITY 1
3 CAPACITY (NOMINAL)
4 SERVICE
5 DESIGN CODE
6 LOCATION INDOOR / OUTDOOR
7 FLUID PROPERTIES AT OPERATING TEMP.
8
9 FLUID
10 SPECIFIC GRAVITY
11 VISCOSITY cP
12 VAPOUR PRESSURE kg/cm2(a)
13 (AT 30 DEG.C.)
14
15 DESIGN DATA
16
17 OPERATING TEMPERATURE o C
18 DESIGN TEMPERATURE o
C
19 OPERATING PRESS.AT 32 DEG.C.kg/cm2(g)
20 DESIGN PRESS. kg/cm2(a)
21 INSIDE DIAMETER mm
22 LENGTH mm
23 HEAD TYPE- TOP
24 - BOTTOM
25 CORROSION ALLOWANCE mm
26 SUPPORT SADDLE
27 INSULATION - REQUIRED YES / NO
28 - PURPOSE PERS. PROTEC./CONSER.
29 AGITATOR YES / NO
29
30
31 MATERIAL OF CONSTRUCTION
32 SHELL
33 JACKET
34 COIL NA
35 INTERNALS
36 GASKET PTFE ENVELOPED CAF
37 ACCESSORIES BY TANK VENDOR
38 AGITATOR YES / NO
39 BAFFLES YES / NO
40 COIL YES / NO
41 DIP PIPES YES / NO
42
43 SPECIAL REQUIREMENTS
44 RADIOGRAPHY NA N8 50 1 SPARE
45 STRESS RELIEF AS PER CODE N7 50 1 SPARE
46 BUFFING NA N6 50 1 SPARE
47 OTHER NA N5 50 1 DRAIN
48 NOTES : N4 25 1 SAMPLING POINT
49 1) Sizes and instrument nozzles are under hold pending instrument N3 500 1 MANHOLE
51 finalization. N2 50 1 PROCESS WATER INLET
52 N1 HOLD 1 AMMONIA INLET
53 NOZZ. NO. SIZE QTY. SERVICE
54 NOZZLE SCHEDULE
REV NO. : R0 PPD. BY :Sd/- SPP TCE JOB NO. CLIENT : NUCLEAR FUEL COMPLEX
PPD. BY/DATE : CKD. BY:Sd/-VAK TCE-4246A PROJECT : NZOSP, PALAYAKAYAL
CKD. BY/DATE : DATE :18.06.07 PDS NO. : TCE-4246A-CH-T-PDS-322T441
LOW TEMPERATURE CARBON STEEL
SHELL
1500
AMBIENT
ATM,
65
SHELL
AMMONIUM HYDROXIDE SOLUTION
LIQUID FULL
1
-
322-T-445
ASME SEC-VIII DIV. 1
5 KL
VENT TANK FOR AMMONIA
-
3500
DISHED END
NA
DISHED END
3 MM
LOW TEMPERATURE CARBON STEEL
R0
R0-1
997-0
3-3
1T
CE
.M4
-CH
-T-P
DS
-
N6N1N8N2
N5
1.5
m
3.5 m
N3 N7
N4
IS
SU
E N
O.
R5
TCE CONSULTING ENGINEERS LIMITED SECTION : D
ENQ.SPEC.NO. DATA SHEET A
TCE.4246-CH-K-PDS-001 LIQUID AMMONIA COMPRESSORS SHEET : 1 OF 6
GE
NE
RA
L
1. DESIGNATION : COMPRESSORS FOR
LIQUID AMMONIA TANKER UNLOADING
DE
SIG
N D
AT
A (
CO
NT
D.)
19.2 FOR INTER-COOLER, AFTER-COOLER
AND OIL-COOLER : WATER
2. NUMBER REQUIRED : 2 NOS (1W+1S) 20. COOLING WATER QUALITY : AS PER
TACO-GYIN SPECS.
3. TAG NUMBERS : 322--K-441 A/B
21. COOLING WATER INLET
4. LOCATION : OUTDOOR TEMPERATURE :** 32 0 C
5. OPERATION : 22. MAXIMUM COOLING WATER OUTLET
INTERMITTENT ~ 1 1/2 hrs. for loading 10
MT Bullet
TEMPERATURE : ** 37 0 C
6. TYPE OF DRIVE : FLAMEPRROF
ELECTRIC MOTOR
23. COOLING WATER PRESSURE AT
AT INLET : ** 2.5 Kg/ cm 2 (g)
7. APPLICABLE STANDARDS : API 618/ 24. MAXIMUM COOLING WATER
API 619 PRESSURE DROP IN THE COMPRESSOR,
INTER-COOLER, AFTER-COOLER AND
8. OIL- COOLER : * Kg/ cm 2
9. 25. COMPRESSOR FRAME LUBRICATION :
DE
SIG
N D
AT
A
10. TYPE : RECIPROCATING- * SPLASH/ PRESSURISED
HORIZONTAL 26. TYPE OF CAPACITY CONTROL : *
NON-LUBRICATED BY SPEED VARIATION/ AT CONSTANT
11. FLUID TO BE COMPRESSED :
LIQUID AMMONIA VAPOR
SPEED
27. METHOD OF CAPACITY CONTROL AT
12. CAPACITY (FAD) : * M3/Hr ( Note 4 ) CONSTANT SPEED : * DUAL TYPE
13. MASS FLOW RATE : * Kg/Hr
( Note 4 )
CONTROL / MOVABLE INLET GUIDE
14. PROPERTIES OF GAS/ GAS COMPO- VANES /
SITION : LIQUID AMMONIA VAPORS 28.
15. SUCTION PRESS. :2.25 ~11.7Kg/cm2 (g) 29.
16. SUCTION TEMPERATURE - MINIMUM /
DU
AL
TY
PE
CO
NT
RO
LS
30. ADJUSTABLE RANGE FOR PRESSURE
MAXIMUM : (-) 33 / 55 0 C SWITCHES : * Kg/ cm
2
17. DISCHARGE PRESSURE : 15 Kg/ cm 2 (g) 31. EXPECTED SETTING OF PRESSURE
18. MAXIMUM COMPRESSOR SPEED : * SWITCHES FOR : *
RPM 31.1 AUTO LOAD-UNLOAD REGULATION :
19. COOLING MEDIUM : * WATER (a) LOAD : * Kg/ cm 2 (g)
19.1 FOR COMPRESSOR:* WATER/ NOTE-1 (b) UNLOAD : * Kg/ cm 2 (g)
REV.NO. PPD. BY: SPP JOB NO. CLIENT: NUCLEAR FUEL COMPLEX
DATE CHD. BY: VAK TCE.
REV. BY DATE : 29.06.07 4246 A PROJECT: NZOSP
TCE FORM NO. 330 R1 FILE NAME : DA10701R5.DOC
ISS
UE
NO
. R
5 TCE CONSULTING ENGINEERS LIMITED SECTION : D
ENQ.SPEC.NO. DATA SHEET A
TCE. 4246-CH-K-PDS-001 LIQUID AMMONIA COMPRESSORS SHEET : 2 OF 6 D
UA
L T
YP
E C
ON
TR
OL
S (
CO
NT
D.)
31.2 AUTO START-STOP REGULATION:
MA
TE
RIA
LS
OF
CO
NS
TR
UC
TIO
N
FO
R C
EN
TR
IFU
GA
L C
OM
PR
ES
SO
RS
(C
ON
TD
.)
44. IMPELLERS : CAST ALUMINIUM ASTM
(a) START : * ~2 Kg/ cm 2 (g) B 26, ALLOY C 355/ CAST SS 410/ CAST
(b) STOP : * ~1 Kg/ cm 2 (g) SS ASTM A 747, TYPE CB7 Cu-1 OR CB7
31.3 VERY LOW RECEIVER PRESSURE Cu-2/ FORGED SS 403/
ALARM : * Kg/ cm 2 (g)
31.4 HIGH RECEIVER PRESSURE 45. BLADES : PLATE STEEL AISI 4130-4140/
ALARM : * Kg/ cm 2 (g) AISI 4320-4340/
32. NUMBER OF STEPS FOR LOAD - 46. GUIDE VANES : CI ASTM A 48 OR A 278,
UNLOAD REGULATION : * 2 / 3 / 4 / CL 30/ CAST STEEL ASTM A 216, GR
33. WCB/ CAST SS ASTM A 743/744 OR
MA
TE
RIA
LS
OF
CO
NS
TR
UC
TIO
N
FO
R R
EC
IPR
OC
AT
ING
CO
MP
RE
SS
OR
S
34. CYLINDER AND CYLINDER LINER : A 351, GR CA15, CF3, CF3M, CF8, CF8M/
* CI
47. SHAFT : FORGED STEEL AISI 1040-
1050
35. PISTON RINGS : * CI OR ASTM A 470, CL 7/FORGED SS ASTM
A 336, GR F6/
36. VALVE SEATS : * EN 8A FORGED 48. COVERS AND HUBS : FORGED STEEL
37. VALVE PLATES : * AISI TYPE 3140/ PLATE STEEL ASTM A
38. VALVE STOPS : * 543/ FORGED SS AISI TYPE 403 OR 410 /
39. VALVE SPRINGS : *
MA
TE
RIA
LS
OF
CO
NS
TR
UC
TIO
N
FO
R S
CR
EW
CO
MP
RE
SS
OR
S
49. CASING : CI IS 210 OR ASTM A 278 CL
40. PISTON : * CI 40/ FABRICATED STEEL ASTM A 353/
CAST STEEL ASTM A 216 GR WCB
41. CRANK SHAFT, CONNECTING ROD NORMALIZED / CAST SS ASTM A 743
AND PISTON ROD : * EN 8A AND 744 CA6-NM/
MA
TE
RIA
LS
OF
CO
NS
T.
FO
R C
EN
TR
IFU
GA
L
CO
MP
RE
SS
OR
S
42. CASING : CI IS 210 OR ASTM A 48 OR 50. ROTOR BODY : CI ASTM A 395/
A 278 / CAST STEEL ASTM A 216 GR FORGED STEEL AISI 1030-1045/ CAST
WCB NORMALIZED/ ALUMINIUM ASTM B 26 ALLOY 355
OR C 355/
43. DIFFUSER : CI ASTM A 536,GR 60-40-
18/ CAST ALUMINIUM ASTM B 26, ALLOY
51. SHAFT : FORGED STEEL AISI 1030-1035/
355.0 / FORGED SS ASTM A151 TYPE 410 SS /
REV.NO. PPD. BY: SPP JOB NO. CLIENT: NUCLEAR FUEL COMPLEX
DATE CHD. BY: VAK TCE.
REV. BY DATE : 29.06.07 4246 A PROJECT NZOSP
TCE FORM NO. 330 R1 FILE NAME : DA10701R5.DOC
IS
SU
E N
O.
R5
TCE CONSULTING ENGINEERS LIMITED SECTION : D
ENQ.SPEC.NO. DATA SHEET A
TCE. 4246A-CH-K-PDS-
001 LIQUID AMMONIA COMPRESSORS SHEET : 3 OF 6
CO
MP
RE
SS
OR
AC
CE
SS
OR
IES
52. INTAKE FILTER TYPE : * PAPER/
INT
ER
-CO
OL
ER
S /
AF
TE
R-C
OO
LE
RS
/ O
IL-C
OO
LE
RS
DE
SIG
N D
AT
A
69. DESIGNATION : * INTER-COOLERS/
OIL WETTED/ CLOTH/ OIL BATH/ AFTER-COOLERS FOR
COMBINED DRY AND WET 70. TAG NUMBERS FOR INTER-COOLERS :
LATER
52.1 MATERIAL OF CONSTRUCTION :
CASING : * MS/ ALUMINIUM 71. AFTER-COOLERS REQUIRED : *NO
NUMBER :
53. SILENCER REQUIRED : * YES
54. DRIVE PULLEYS WITH V-BELT AND 72. TAG NUMBERS FOR AFTER-COOLERS :
BELT GUARDS REQUIRED : * YES LATER
FOR BELT DRIVEN COMPRESSORS 73. CAPACITY OF :
55. COUPLINGS AND COUPLING GUARDS 73.1 INTER-COOLERS : * M3 / Hr
REQUIRED : YES ( non sparking material) 73.2 AFTER-COOLERS : * M3 / Hr
74. TYPE : *HORIZONTAL/ VERTICAL
56. SLIDE RAILS FOR MOTOR REQUIRED: SHELL AND TUBE TYPE WITH
*YES REMOVABLE TUBE BUNDLES/
57. CONTROL CABINET REQUIRED : YES 75. TYPE OF FLOW : COUNTER-CURRENT
58. IMPULSE TUBING : * STAINLESS
STEEL 76. OPERATING PRESSURE FOR AFTER-
COOLERS *
76.1 GAS SIDE :* Kg/ cm 2 (g)
76.2 WATER SIDE : * Kg/ cm 2 (g)
59. MOTOR BY : COMPRESSOR BIDDER 77. DESIGN PRESSURE FOR AFTER-
COOLERS *
60. STARTER BY : COMPRESSOR BIDDER 77.1 AIR/ GAS SIDE : * Kg/ cm 2(g)
77.2 WATER SIDE : * Kg/ cm 2(g)
61. 78. MAXIMUM ACCEPTABLE OUTLET
62. GAS TEMPERATURE : * 0 C
63. 79. ALLOWABLE PRESSURE DROP OF AIR/
64. GAS THROUGH AFTER-COOLER :
65. 0.2 Kg/ cm 2
66. 80. DESIGN CODE : ASME SEC. VIII DIV. 1
67. AND TEMA
68. 81. CORROSION ALLOWANCE : * mm
REV.NO. PPD. BY: SPP JOB NO. CLIENT: NUCLEAR FUEL COMPLEX
DATE CHD. BY: VAK TCE.
REV. BY DATE : 29.06.07 4246a PROJECT: NZOSP
IS
SU
E N
O.
R5
TCE CONSULTING ENGINEERS LIMITED SECTION : D
ENQ.SPEC.NO. DATA SHEET A
TCE4246-CH-K-PDS-001 LIQUID AMMONIA COMPRESSORS SHEET : 4 OF 6
INT
ER
-CO
OL
ER
S/A
FT
ER
CO
OL
ER
S/
OIL
-CO
OL
ER
S –
M O
C
82. SHELL : *
RE
CE
IVE
R D
ES
IGN
DA
TA
90. DESIGNATION : RECEIVERS FOR
83. TUBES : * 91. NUMBER REQUIRED :1
92. TAG NUMBERS :
84. TUBE SHEETS : * CS 93. TYPE : *HORIZONTAL/ VERTICAL/
CYLINDRICAL WITH WELDED DISHED
85. TUBE SUPPORT PLATES : * CS ENDS
94. OPERATING PRESSURE : *
86. Kg/ cm 2 (g)
INT
ER
-CO
OL
ER
S /
AF
TE
R-C
OO
LE
RS
AC
CE
SS
OR
IES
87. MOISTURE AND OIL SEPARATOR 95. DESIGN PRESSURE : * Kg/ cm 2 (g)
WITH AUTO DRAIN TRAP TO BE 96. DESIGN TEMPERATURE : * ° C
PROVIDED WITH EACH INTER- 97. NOMINAL VOLUME : * M 3
COOLER AND AFTER-COOLER TO 98. DIMENSIONS :
DISCHARGE MOISTURE AND OIL TO 98.1 HEIGHT TAN TO TAN : * mm
DRAIN 98.2 DIAMETER : * mm
87.1 TYPE OF MOISTURE AND OIL 99. APPLICABLE CODE : IS 2825/
SEPARATOR : CENTRIFUGAL/
DEMISTER PAD/ BAFFLE 100. CORROSION ALLOWANCE : 1.6 mm
87.2 TYPE OF AUTO DRAIN TRAP : 101. SHELL AND DISHED END MATERIAL :
INVERTED BUCKET / BALL FLOAT / IS 2002/ IS 2062
SOLENOID OPERATED / ELECTRONIC 102. INTERNAL PAINTING : BLACK
LEVEL CONTROLLED BITUMINOUS /
88. MATERIAL OF CONSTRUCTION OF 103. INSULATION : NO
MOISTURE AND OIL SEPARATOR 104.
88.1 BODY/ SHELL : CS
RE
CE
IVE
R
AC
CE
SS
OR
IES
105. SUPPORT LEGS/ LUGS/ SKIRT
REQUIRED : YES
88.2 106. MANHOLE WITH COVER FOR
89. MATERIAL OF CONSTRUCTION OF INSPECTION AND CLEANING
AUTO DRAIN TRAP REQUIRED : YES
89.1 BODY : CI IS 210/ SS 107.
89.2 TRIM : SS/ 108.
REV.NO. PPD. BY: SPP JOB NO. CLIENT: NUCLEAR FUEL COMPLEX
DATE CHD. BY:VAK TCE.
REV. BY DATE : 29.06.07 4246 A PROJECT: NZOSP
TCE FORM NO.330 R1 FILE NAME : DA10701R5.DOC
ISS
UE
NO
. R
5 TCE CONSULTING ENGINEERS LIMITED SECTION : D
ENQ.SPEC.NO. DATA SHEET A
TCE. 4246-CH-K-PDS-001 LIQUID AMMONIA COMPRESSORS SHEET : 5 OF 6 M
ISC
EL
LA
NE
OU
S
109. ALL THE VALVES, SPECIALITIES 123. REFER TCE.M4-907
INSTRUMENTS AND ACCESSORIES
SP
AR
ES
AN
D M
AIN
TE
NA
NC
E T
OO
LS
AN
D T
AC
KL
ES
124. ESSENTIAL SPARES
AS PER ENCLOSED P&I D
TCE.4246- 300-PI-8651
124.1 OIL FILTERS
: REQUIRED 124.2 ALL KINDS AND SIZES OF GASKETS
110. COUNTER FLANGES FOR ALL THE 124.3 ALL KINDS AND SIZES OF O-RINGS
CONNECTIONS AT BATTERY LIMITS 124.4 WEAR RINGS
WITH NUTS, STUDS, BOLTS, GASKETS 124.5 OIL SEALS
AND WASHERS REQUIRED : YES 124.6
110.1 FLANGES : YES 124.7
124.8
111. FOUNDATION BOLTS FOR ALL THE 124.9
EQUIPMENT REQUIRED : YES 124.10
112. ERECTION BY CONTRACTOR :YES/NO T
ES
TS
AN
D I
NS
PE
CT
ION
125. AS PER TCE.M4-904 AND / OR
113. ERECTION SUPERVISION BY TCE.M4-85-01 AND TCE.M4-185-65 OR
CONTRACTOR : YES TCE.M4-186-01, 02, 04, 05, 06, 08, 09, 12
114. AND 26 (NOTE 2)
PA
INT
ING
115. PRIMER : RED OXIDE/ EPOXY 126. PERFORMANCE TEST AT SITE
115.1 NUMBER OF COATS : REQUIRED : YES
115.2 DRY FILM THICKNESS : 127. APPLICABLE STANDARDS : IS 5456 /
116. FINISH PAINT : SYNTHETIC ENAMEL/ API 618 / API 617 / API 672 / API 619 /
EPOXY/ IS 11780 /
116.1. NUMBER OF COATS : 128.
116.2 DRY FILM THICKNESS : 129.
CO
MP
AN
ION
SP
EC
IFIC
AT
ION
S
117. MOTORS : TCE.M4-203-01 AND/ OR
PE
RF
OR
MA
NC
E G
UA
RA
NT
EE
S
130. CAPACITY OF EACH COMPRESSOR :
TCE.M4-203-02 * (+) ( ) M3/Hr
118. TURBINE : TCE.M4-133-01/ 04 / 131. DISCHARGE PRESSURE : *
(+) ( ) Kg/ cm2 (g)
119. PIPING MATERIAL SPECIFICATIONS : 132. POWER CONSUMPTION : *
TCE. (+) ( ) KW
120. INSTRUMENTATION AND CONTROL 133. TEMPERATURE OF AIR AT OUTLET
TCE.M4-107-IC-01 OF AFTER COOLER : * ° C
121. CONTROL CABINET : TCE.M4-219-01 134. COOLING WATER FLOW RATE : *
122. CABLES : TCE.M4-208-01 M3/Hr
REV.NO. PPD. BY: SSP JOB NO. CLIENT: NUCLEAR FUEL COMPLEX
DATE CHD. BY: VAK TCE.
REV. BY DATE : 29.06.07 4246 A PROJECT: NZOSP.
TCE FORM NO. 330 R1 FILE NAME : DA10701R5.DOC
ISS
UE
NO
. R
5 TCE.M4-107-01 TCE CONSULTING ENGINEERS LIMITED SECTION : D
ENQ.SPEC.NO. DATA SHEET A
TCE. 4246-CH-K-PDS-001 LIQUID AMMONIA COMPRESSORS SHEET : 6 OF 6 P
ER
FO
RM
NC
E
GU
AR
AN
TE
ES
(C
ON
TD
.) 135. COOLING WATER OUTLET 139. POWER CONSUMPTION :
TEMPERARURE : 37 ° C Rs. * / KW
136. COOLING WATER PRESSURE DROP : 140. COOLING WATER CONSUMPTION :
0.25 Kg/ cm2 (g) Rs. * / M
3/Hr
137. 141.
138. 142.
LIS
T O
F S
UB
-VE
ND
OR
S F
OR
BO
UG
HT
-OU
T A
ND
CR
ITIC
AL
IT
EM
S
143. BEARINGS
144. MOTORS
145. TURBINE
146. ENGINE
147. COUPLINGS
148. V- BELTS
149. VALVES & SPECIALITIES
150. AUTO DRAIN TRAPS
151. VIBRATION DAMPENING PADS
152. CONTROL PANEL AND INSTRUMENTS : REFER
153. MCC
154.
155.
156.
NOTES
1. FOR COMPRESSORS UPTO MOTOR RATING OF 7.5 KW, BIDDER MAY OFFER AIR COOLED
COMPRESSOR AS AN ALTERNATIVE TO WATER COOLED COMPRESSOR.
2. FOLLOWING ADDITIONAL TESTS INDICATED AS ‘B’ IN TCE.M4-186-01,02, 04, 05, 06, 08, 09, 12
AND 26 SHALL ALSO BE CARRIED OUT WHEN TCE.M4-186-01, 02, 04, 05, 06, 08, 09, 12 AND 26
ARE APPLICABLE
3.. * DENOTES BIDDER TO SPECIFY / CONFIRM.
4. BASIS FOR SIZING : 10 MT LIQUID AMMONIA BULLET TO BE LOADED IN 1-1.5 HOURS. TIME
INCLUDES THE VAPOR RECOVERY FROM ROAD TANKER.
5. ** TO BE CONFIRMED DURING DETAILED ENGG..
6. MOTOR SHALL BE FLAME POOF TEFC , CONFORMING TO GAS GROUP IIA/B, IS 2148, IP
55,CLASS F.
REV.NO. PPD. BY: SPP JOB NO. CLIENT: NUCLEAR FUEL COMPLEX
DATE CHD. BY: VAK TCE.
REV. BY DATE : 4246 A PROJECT: NZOSP
CO
ST
LO
AD
ING
AN
D P
EN
AL
TY
TCE FORM NO. 330 R1 FILE NAME : DA10701R5.DOC
SPECIFICATION NO. TCE CONSULTING ENGINEERS LIMITED SECTION D
DATA SHEET
TCE-4246A-C-300-005 ANALOG SIGNAL ISOLATORS/ MULTIPLIERS SHEET 1 OF 1
REV. NO.
P0 PPD. BY:DMG JOB NO.
CLIENT: NUCLEAR FUEL COMPLEX
DATE CKD. BY:SPA TCE
REV. BY DATE: 17.12.07
4246A PROJECT : NZOSP, PALAYAKAYAL
TCE FORM 330 R1
Make : Bidder to state
Input signal : 4-20 mA DC from process transmitter
Output signal : 4-20 mA DC
No. of outputs : 2 nos.
Quantity : As per P&ID ( for all Analog signals)
Mounting : DIN rail mounted in Marshalling cabinets
Power Supply : 24 V DC
Type of isolation : Transformer Isolated (Preferable)
Accuracy : 0.1% of calibrated span including combined effect of linearity, hysterisis and repeatability
Stability : Calibration shall hold within specified accuracy for a min. period of 1 year
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION : CONTENTS TCE-4246A-C-300-005
CONTENTS
SHEET 1 OF 3
ISSUE R0
TCE FORM NO. 329 R3
SECTION – C (TECHNICAL SPECIFICATIONS)
SEC-TION
SPECIFICATION NO.
ISSUE NO.
TITLE NO OF PAGES
C1 TCE-4246A-C-300-005
R1 CRITERIA FOR ELIGIBILITY FOR EVALUATION OF TENDER DOCUMENT
1
C2 TEC-4246A-950 R1 PROJECT INFORMATION – GENERAL 3
C3 TCE-4246A-951 R0 PROJECT INFORMATION – ELECTRICAL 2
C4 TCE.4246A – 952
RO DOCUMENT & DRAWING SUBMISSION & DISTRIBUTION SCHEDULE
2
C5 TCE-4246A-C-300-005
R1
SCOPE AND GENERAL SPECIFIC TECHNICAL REQUIREMENTS FOR LIQUID AMMONIA AND 35% AMMONIUM HYDROXIDE STORAGE AND TRANSFER SYSTEM
11
C6 TCE-4246A-C-300-05
R1
EQUIPMENT, SYSTEM AND SERVICE TO BE PROVIDED BY CONTRACTOR. SYSTEM DESCRIPTION AND VARIOUS DETAILS FOR LIQUID AMMONIA AND 35% AMMONIUM HYDROXIDE STORAGE AND TRANSFER SYSTEM
12
C6 TCE-4246A-CH-T-PDS-322T441
R1 DATASHEET FOR LIQUID AMMONIA STORAGE VESSEL / BULLET
1
C6 TCE-4246A-CH-T-PDS-322T442
R1 DATASHEET FOR AMMONIUM HYDROXIDE SOLUTION STORAGE VESSEL / BULLET
1
C6 TCE-4246A-CH-T-PDS-322T445
R0 DATASHEET FOR LIQUID AMMONIA VENT TANK
1
C6 TCE-4246A-CH-SM-PDS-322SM101
R0 DATASHEET FOR STATIC MIXER
1
C6 TCE-4246A-CH-X-PDS-001
P0 DATASHEET FOR EXCESS FLOW CHECK VALVES
1
C6 TCE.4246A-CH-K-PDS-001
R5 DATASHEET FOR AMMONIA COMPRESSOR
6
C6 TCE.M4-604-09 R4 DATASHEET-FLOW ELEMENT 3
C6 TCE.4246A-109-TI-04
R0 DATASHEET-TEMPERATURE INDICATOR
2
C6 TCE.M4-601-06 R4
DATASHEET-DIFFERENTIAL PRESSURE TRANSMITTERS
2
C6 TCE.4246A-C-300-005
R0 DATASHEET-ANALOG SIGNAL ISOLATORS/ MULTIPLIERS
1
C6 TCE.4246A-C-300-005
R0 DATASHEET-DIGITAL PANEL METERS
1
C6 TCE.M4-109-UCP-54
R1 DATASHEET-CONTROL PANEL
2
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION : CONTENTS TCE-4246A-C-300-005
CONTENTS
SHEET 2 OF 3
ISSUE R0
TCE FORM NO. 329 R3
SECTION – C (TECHNICAL SPECIFICATIONS)
SEC-TION
SPECIFICATION NO.
ISSUE NO.
TITLE NO OF PAGES
C6 TCE.M4-607-05 R2 DATASHEET-PRESSURE/VACUUM RELIEF 2
C6 TCE.M4-109-CV R0 DATASHEET-CONTROL VALVES 2
MECHANICAL
C7 TCE.M4-107-01 R6 WRITE-UP FOR AMMONIA COMPRESSOR 10
C7 TCE-4246A-300-LS-001
R2 PIPING MATERIAL SPECIFICATION (SA1,CR, CA, CB1, CB2)
18
C7 TCE-4246A-C-300-002
R0 PAINTING SPECIFICATION
2
C7 TCE-M4-102-01 R3 WELDED UNFIRED PRESSURE VESSELS 10
C7 TCE-M4-102-43 R3 EARTHING CLEAT 1
C7 TCE-M4-102-34 R3 GUSSETS FOR NOZZLES 1
C7 TCE-M4-103-99 R3
VALVES AND SPECIALITIES – GENERAL REQUIREMENTS.
4
C8 GENERAL REQUIREMENTS IN ELECTRICAL
TCE.M4-203-01 R8 INDUCTION MOTOR 5
TCE.M4-208-01 R7 CABLES 6
TCE-M4-208-11 R3
CABLING ACCESSORIES, CABLE TRAYS, CONDUITS & PIPES
6
C9 GENERAL REQUIREMENTS IN MECHANICAL
TCE.M4-134-01 R1
WELDING SPECIFICATION FOR CHEMICAL AND INDUSTRIAL PLANT PIPING SYSTEMS
23
TCE.M4-134-06 R1
FABRICATION, ERECTION AND TESTING OF PIPING SYSTEMS FOR CHEMICAL AND INDUSTRIAL PLANTS.
13
TCE.M4-185-01 R3
INFORMATION TO VENDOR ON QUALITY PLANS & GENERAL INSPECTION REQUIREMENTS
3
TCE.M4-186-01 R2
SHOP INSPECTION REQUIREMENTS FOR UNFIRED PRESSURE VESSELS
1
TCE.M4-186-04 R2
SHOP INSPECTION REQUIREMENTS FOR VALVES – METALLIC.
1
TCE.M4-186-05 R2
SHOP INSPECTION REQUIREMENTS FOR PIPES AND PIPE FITTINGS - METALLIC.
1
TCE.M4-186-08 R2
SHOP INSPECTION REQUIREMENTS FOR ROTATING MACHINES – MECHANICAL.
1
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION : CONTENTS TCE-4246A-C-300-005
CONTENTS
SHEET 3 OF 3
ISSUE R0
TCE FORM NO. 329 R3
SECTION – C (TECHNICAL SPECIFICATIONS)
SEC-TION
SPECIFICATION NO.
ISSUE NO.
TITLE NO OF PAGES
C-10 GENERAL TERMS, CONDITIONS AND REQUIREMENTS
TCE.M4-903 R3
DRAWINGS, ENGINEERING DOCUMENTS & INSTRUCTION MANUALS
8
TCE.M4-904 R7 SHOP INSPECTION AND TESTS 8
TCE.4246A -905 R1 GUARANTEE AND PATENT RIGHTS 2
TCE.M4-906 R6
PACKING, MARKING AND TRANSPORT INSTRUCTIONS FOR EQUIPMENT
6
TCE.M4-907 R5 SPARES AND MAINTENANCE TOOLS & TACKLES 3
TCE.M4-908 R4 TRAINING OF PURCHASER’S PERSONNEL 1
TCE.M4-914 R5 PROGRESS SCHEDULE AND REPORTS 3
TCE.M4-915 R4 PERFORMANCE TESTS AT SITE 3
TCE.M4-916 R4 RATING AND NAME PLATES 1
TCE.M4-917 R0
SAFETY CONDITIONS FOR UNDERTAKING SITE WORK
10
ENCLOSURES LIST OF DRAWINGS/DOCUMENT
TCE.4246A-300-PI-8650
R0 LEGEND AND SYMBOLS
1
TCE.4246A-322-PI-8725
R0 P & I DIAGRAM FOR LIQUID AMMONIA STORAGE & TRANSFER
1
TCE.4246A-
322-GA-8595 R0
GENERAL ARRANGEMENT FOR LIQUID AMMONIA STORAGE & TRANSFER 1
TCE.4246A-322-GA-8600
R0 GENERAL ARRANGEMENT FOR AMMONIUM HYDROXIDE STORAGE & TRANSFER
1
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: C1
TCE- 4246A-C-300-005
CRITERIA OF ELIGIBILITY FOR
TECHNICAL EVALUATION OF THE BIDS
SH 1 OF 1
ISSUE R1
TCE FORM 329 R3
1. CRITERIA OF ELIGIBILITY FOR TECHNICAL EVALUATION OF THE BIDS
1.1 Experience of Contractor in similar works / Past Performance
For the purpose of this clause „similar work‟ means the works of “work of one or more types of the system / subsystems alongwith its components, accessories & equipment required as per this tender and including all allied works such as instrumentation, electrical and piping to make the system complete and including erection & commissioning at site”.
The contractor should have the proven technical, commercial and financial capability in terms of having executed turnkey jobs of this nature as required in the tender document.
Bidder shall have satisfactory performance of the works carried out. Bidder shall provide a reference list of previous clients for whom similar work has been carried out and the value of the jobs. Bidder shall to provide letters from them for satisfactory performance, workmanship and delivery of items / system & completion schedules.
1.2 Design, Manufacturing & Quality Control Facilities
Bidder to furnish the details of existing manufacturing (plant and machinery), infrastructural & quality control facilities available with the bidder.
Bidder shall submit the organisation chart and his technical, supervisory & managerial establishment and the technical & managerial staff, CAD / CAM facilities that will be deployed for this project.
1.3 Financial Stability
1.3.1 Turnover :
Average annual financial turnover during last 3 years ending 31st March of the previous financial year. The contractor shall submit TDS certificates or audited balance sheets showing receipts from contracts, profit and loss etc in support of his claim.
SPEC. NO. TCE CONSULTING ENGINEERS LIMITED SECTION D
DATA SHEET
TCE.4356A-C-300-005 DIGITAL PANEL METERS SHEET 1 OF 1
REV. NO. PPD. BY:DMG JOB NO. CLIENT: NUCLEAR FUEL COMPLEX
DATE CKD. BY:SPA TCE
REV. BY DATE: 17.12.07 4246A PROJECT: NZOSP, PALAYAKAYAL
TCE FORM 330 R1
Type : Microprocessor based
Mounting : Front facia of panels
size : 24 mm (H) x 48 mm (W)
Digit height : 12 mm
Enclosure Protection : User Configurable (Universal)
Input : 4-20 mA DC from transmitters
Range : User configurable
Engg. Units : kg/ cm2 for pressure
0C for temperature
Metres for level.
Ampere, Voltage ( User Configurable)
Relay Outputs : 1 changeover (For each high and low alarms,
adjustable over 100% range)
Contact Rating : 2A, 230 V AC
Power Supply : 24 VDC
Accuracy : ± 0.2 % of full scale
Display : 4 ½ digit LED display
Quantity : As per P&ID ( for all Analog signals)
Tests : Calibration & Performance tests
HV test
Type test certificate for protection class
DRAWINGS/ DOCUMENTS
1. Vendor shall submit catalogue & data sheet for review & comments by Purchaser/ Consultant.
2. Vendor shall submit Instruction Manual for Records.
TEST CERTIFICATES
1. Vendor shall submit all routine Test certificates for Purchaser/ Consultant’s review.
2. Vendor shall submit type test certificates for protection class.
NOTES
1. Bidder shall indicate all applicable codes and standards.
SPEC.NO. TCE CONSULTING ENGINEERS LTD. SECTION : C4
TCE.4246A - 952
DOCUMENT & DRAWING SUBMISSION & DISTRIBUTION SCHEDULE
SHEET OF 2 OF 4
1
ISSUE R0
TITLE
TCE FORM 329 R3
The Vendor / Contractor shall submit and distribute to the PURCHASER / OWNER and CONSULTANT / ENGINEER the following number of copies of the required documents and drawings mentioned in the tender.
Sl. No.
Description Vendor / Contractor
Owner Engineer
1. General Correspondence from Vendor / Contractor
a) Commercial S Ori.+ 1 3 (*)
b) Technical S Ori. + 1 3 (*)
2. General Correspondence from :
a) TCE Ori. 2 S
b) NFC Ori. S 3 (*)
3. Vendor / Contractor Manufacturing, fabrication, delivery and erection schedule
S 3 3 (*)
4. Manufacturing Test Reports S Ori. + 3 3
5. Operating, Maintenance and Erection Manuals
a) Preliminary S 4 3 (*)
b) Final S 6 3 (*)
6. Vendor / Contractor Drawings / Documents
a) First submission and subsequent revisions
S 6 6
b) As-Built S R + 6 3 (*)
c) As-Built (on CD) (Soft Copy) S 3 3
7. Draft & Final Reports S 5 4 (*)
(*) : One copy to TCE Site Office. n -- Number of Copies required. Legend : S -- Source, Ori. -- Original, R -- Reproducible
SPEC.NO. TCE CONSULTING ENGINEERS LTD. SECTION : C4
TCE.4246A - 952
DOCUMENT & DRAWING SUBMISSION & DISTRIBUTION SCHEDULE
SHEET OF 2 OF 4
2
ISSUE R0
TITLE
TCE FORM 329 R3
DETAILS FOR CORRESPONDENCE 1. Postal Address :
Nuclear Fuel Complex Department of Atomic Energy,
ECIL Post, Hyderabad – 500 062, Andhra Pradesh, India.
Att’n : Mr. B.Laxminarayana Project Director (NZOSP)
Telephone (040) – 2718 4337 / -- 2718 4971
(thro’ office) Fax (040) -- 2713 5019
E-mail ID [email protected]
2. Postal Address :
TCE Consulting Engineers Ltd. Raj Plaza, 2nd Floor, L. B. S. Marg, Vikhroli (West), Mumbai – 400 083. Att’n : Mr. V.A.Kunte Project Manager
Telephone (022) 6 647 2111 Fax (022) 6 647 2000
E-mail ID [email protected]
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M4-107-01
AIR / GAS COMPRESSORS SHEET 1 OF 10
ISSUE
R6
TCE FORM NO. 329 R3 FILENAME : M410701R6.DOC
1.0 SCOPE
This specification covers the general design, materials, construction features,
manufacture, shop inspection and testing at manufacturer’s works, delivery at
site, handling at site, erection, testing, commissioning, performance testing and
handing over of Air / Gas Compressors and Accessories.
2.0 CODES AND STANDARDS
2.1 The design, materials, construction, manufacture, inspection, testing and
performance of the air/ gas compressors and accessories shall comply with all
currently applicable statutes, regulations and safety codes in the locality where
the equipment is to be installed. The equipment shall also conform to the latest
applicable Indian or equivalent standards. Other international standards are
also acceptable, if these are established to be equal or superior to the listed
standards. Nothing in this specification shall be construed to relieve the
CONTRACTOR of this responsibility.
2.2 The following are some of the important codes and standards relevant to this
specification.
API 617 Centrifugal Compressors for Petroleum, Chemical, and Gas
Service Industry Services
API 618 Reciprocating Compressors for Petroleum, Chemical, and Gas
Industry Services
API 619 Rotary Type Positive Displacement Compressors for
Petroleum, Chemical, and Gas Industry Services
API 672 Packaged, Integrally Geared Centrifugal Air Compressors for
Petroleum, Chemical, and Gas Industry Services
ASME SEC. Boiler and Pressure Vessel Code
VIII DIV.1
TEMA Standards of the Tubular Exchanger Manufacturers Association
IS 2825 Code for Unfired Pressure Vessels
IS 5456 Code of Practice for Testing of Positive Displacement Type Air
Compressors and Exhausters
IS 6206 Guide for Selection, Installation and Maintenance of Air
Compressor Plants with Operating Pressures up to 10 bars
IS 7938 Air Receivers for Compressed Air Installation
IS 11780 Code for Selection and Testing of Rotary Screw Air
Compressors (Oil Flooded)
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M4-107-01
AIR / GAS COMPRESSORS SHEET 2 OF 10
ISSUE
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TCE FORM NO. 329 R3 FILENAME : M410701R6.DOC
IS 13124 Reciprocating Gas Compressors - Technical Supply Conditions
3.0 DESIGN AND CONSTRUCTION FEATURES
The compressor shall be of reciprocating or centrifugal or screw type as
specified in data sheet A.
3.1 RECIPROCATING COMPRESSORS
3.1.1 Frame
The frame shall be a single casting and robust in construction. It shall be
provided with sufficiently large and easily removable inspection doors so that
the bearings and other parts are readily accessible for checking and
adjustments. Inspection doors shall be dust-proof and oil-tight.
3.1.2 Cylinder
The cylinder shall be made of cast iron or stainless steel or as specified in data
sheet A. The cylinder heads and barrels shall be provided with cooling water
jackets. The design of jackets shall be such that low air discharge temperature
and minimum carbon formation are ensured. The water jackets shall be so
constructed that the flow of water is uniform throughout the cooling surface
and no stagnant water pockets are formed. The walls of the cylinder shall have
sufficient thickness suitable for maximum working pressure and temperature
and shall be suitable for reboring. It shall be provided with liberally sized
valve openings and stream-lined passages. The internal surface of the cylinder
shall be highly polished to reduce wear of the piston rings.
3.1.3 Piston and Piston Rod
The piston shall be of such a design and construction that the piston rings exert
equal pressure at all points of the cylinder bore. The piston rod shall be
designed to take up the full thrust acting on the piston. The piston rings for
non- lubricated type compressor shall be of self lubricating type. Piston speed
shall be maximum 300 M/Min for large capacity compressors and 350 M/Min
for small capacity compressors.
3.1.4 Cross Head
The cross head shall be of solid box type with the faces ground to work closely
with the groove of the guides. The cross head pin shall be case hardened and
ground.
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TCE.M4-107-01
AIR / GAS COMPRESSORS SHEET 3 OF 10
ISSUE
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3.1.5 Connecting Rod and Crank Shaft
The connecting rod shall be of I cross-section providing adequate strength and
rigidity. The crank shaft shall be adequately designed so as to ensure smooth
running, without vibrations. It shall be accurately finished to size and shall
have sufficient length so as to be fitted to main bearing and flywheel.
3.1.6 Flywheel
The flywheel shall be designed such that it is well balanced and is of sufficient
weight to give an even turning moment. The wheel shall be of robust
construction. The spokes shall have oval cross-section and the boss shall have
split construction such that the wheel runs true with the shaft. The flywheel
shall be suitable for type of power transmission i.e. flat belt, V-belt, direct
coupling etc. between the driver and compressor.
3.1.7 Main Bearings
The main bearings shall be of robust construction assuring long bearing life
and shall have sufficiently large diameter and adequate length. The bearing at
the crank pin end of connecting rod shall be fitted with bronze lined with best
quality white metal. The bearing at the cross head end shall be fitted with a
bushing made of bronze. The bearings shall be made in halves and shall have
forced feed lubrication.
3.1.8 Valves
The valves shall have straight and uniform lift and maximum effective area so
as to ensure low air velocity and minimum valve clearance. The valve plate
discs shall be heat treated, tempered and ground and the valve seat shall be
case hardened. The valve springs shall be capable of effecting quick opening
and closing and shall also provide the required cushioning effect. The valve
design shall be such that the valve can be easily removed for checking and
maintenance.
3.1.9 Lubrication
(a) Frame Lubrication
Frame lubrication for small compressors with motor rating upto 55 kW
shall be of splash type. The pressurised i.e. forced feed system shall be
used for compressors with higher motor rating. In case of force feed
lubrication, the oil pump shall be either driven by crank shaft of the
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M4-107-01
AIR / GAS COMPRESSORS SHEET 4 OF 10
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compressor or shall be separately driven. The pump shall draw the oil
from the adequately sized oil well.
(b) Cylinder Lubrication
For lubricated type of compressors, multi plunger pump or metering
pump shall be used for cylinder lubrication. In case of non-lubricated
type air compressors, a wiper ring shall be provided such that the crank
case oil is not carried to the cylinder along with the piston rod.
3.2 CENTRIFUGAL COMPRESSORS
3.2.1 Casing
Casing shall be either horizontally split or vertically split type made of cast
iron for moderate pressure applications, cast steel for high pressure
applications or as specified in data sheet A. The thickness of casing shall be
suitable for maximum working and test pressures and shall have a corrosion
allowance of at least 3 mm.
3.2.2 Impellers
Impellers shall be open, semi-open or closed type consisting of disk, hub and
blades. The blades shall be either radial or backward leaning type only. The
material of construction shall be as specified in data sheet A. The design shall
be such as to produce low operating stress levels giving high mechanical
integrity.
3.2.3 Gears
The gears shall be of high speed precision helical type designed as per AGMA
standards. The bull gear shall be directly connected to the driver by a low
speed coupling. The bull gear may be integrally forged with its shaft. In case
bull gear is forged separately, same shall be assembled with an interference fit
on its shaft. The pinion shall be integrally forged with its shaft. It shall be
hardened and precision ground to AGMA 13 quality of AGMA 2000-A88 for
longer life.
3.2.4 Bearings and Seals
The bearings used for pinion and impeller shall be such that high stability and
low vibrations are achieved. Tapered - land thrust bearings shall be provided
for rotor assembly. Bearing shoes shall be pressure lubricated and steel
babbited. Bearings shall be comparatively insensitive to load changes and
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M4-107-01
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variations in oil supply pressure. Hydrostatic squeeze film bearings are also
acceptable. The bull gear shall be supported by horizontally split sleeve journal
bearings and thrust shall be absorbed in either direction by thrust bearings. To
prevent any oil vapour contamination and to ensure oil-free air, mechanical
type air and oil seals shall be provided on the pinion shaft.
3.2.5 Rotor Assembly
Rotor assembly shall consist of pinion shaft to which impellers are attached.
The shaft shall be of forged carbon steel or stainless steel or as specified in
data sheet A. A thrust collar shall be provided on pinion shaft.
3.3 SCREW COMPRESSORS
3.3.1 Casing
Casing shall be of barrel type made of cast iron or fabricated steel for moderate
pressure applications, cast steel or stainless steel for high pressure applications
or as specified in data sheet A. For water injected applications the casing shall
be of stainless steel or as specified in data sheet A. Casing shall have built-in
air passages either as cast or machined.
3.3.2 Rotors
Rotors shall be of asymmetric profile. The material of construction of rotors
shall be as specified in data sheet A. The rotors shall be dynamically balanced
before and after mounting timing gears and thrust collars. The rotors shall be
ultrasonically tested. For non-lubricated screw compressors rotors shall be
lined with PTFE.
3.3.3 Gears
Gear pair shall be used to step up speed of the compressor. Helical gear
hardened to minimum 55 RC shall be used. Gear shall be shrink fit on drive
shaft and shall mesh with pinion mounted on extended portion of male rotor.
Gears shall be designed as per AGMA standards.
3.3.4 Bearings
The rotors shall be carried in heavy duty ball and roller bearings to take radial
and axial loads or journal bearings with thin babbitt metal lining.
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M4-107-01
AIR / GAS COMPRESSORS SHEET 6 OF 10
ISSUE
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3.3.5 Air- Oil Separator
In case of lubricated screw compressors, high efficiency air-oil separation
system shall be provided to ensure removal of oil.
4.0 ACCESSORIES
Accessories such as intake filter, silencer, inter-coolers, after -coolers, oil-
coolers, receivers, control cabinet etc. shall be supplied to make the system
complete in all respects.
4.1 INTAKE FILTER
The intake filter shall be generally as per IS 6206. The type of intake filter
shall be as specified in data sheet A. The filter shall be designed to retain
particles of one (1) micron and above with ninety-seven (97) percent
efficiency. In case of cloth filter, the filter element may be of nylon,
polypropylene or woollen cloth attached to the wire netting.
4.2 INTER-COOLERS
For multi stage compressors, inter-coolers shall be provided. These shall be of
shell and tube type, with removable tube bundles. The tubes shall have
sufficient thickness to withstand the operating pressure and shall be carefully
expanded into the tube sheets. Capacity of inter-coolers shall be twenty (20)
percent more than the compressor capacity or as specified in data sheet A.
Design pressure shall be twenty-five (25) percent more than the working
pressure or as specified in data sheet A. The material of construction and
design shall be as specified in data sheet A.
4.3 AFTER-COOLERS AND OIL-COOLERS
The construction features, design etc. shall be as per inter-coolers described
above. Capacity of after-coolers and oil-coolers shall be twenty (20) percent
more than the compressor capacity or as specified in data sheet A. Design
pressure shall be twenty-five (25) percent more than the working pressure or as
specified in data sheet A.
4.4 RECEIVERS
Receivers shall generally conform to IS 7938. Receivers shall be provided with
two (2) suitably sized safety valves to relieve the full compressor discharge
capacity individually and shall be set at a pressure 1.25 times the operating
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M4-107-01
AIR / GAS COMPRESSORS SHEET 7 OF 10
ISSUE
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pressure. The material of construction and design shall be as specified in data
sheet A.
5.0 MOTOR RATING
Motor shall be of suitable rating considering compressor power requirements.
Motor rating shall be calculated as follows :
(a) If compressor shaft input power requirement is 100 KW and above,
Motor rating in KW shall be = t
SKW10.1
(b) If compressor shaft input power requirement is less than 100 KW,
Motor rating in KW shall be = t
SKW12.1
Where,
SKW = Shaft Power at selected speed in KW
t = Efficiency of transmission
6.0 CAPACITY CONTROL
Capacity control shall be achieved either by speed variation or at constant
speed as specified in data sheet A. In case where capacity control is to be
achieved at constant speed, following methods are generally available. Data
sheet A shall be referred for method to be actually employed.
(a) Automatic start-stop of the compressor
(b) Automatic load-unload of the compressor
(c) Throttling of suction valve
(d) By-passing air or gas from delivery to suction inlet
(e) Increasing clearance volume by a clearance pocket
(f) Variable filling using a by-pass valve.
(g) Movable inlet guide vanes.
6.1 DUAL TYPE CONTROL
Capacity control by start-stop and load-unload of compressors is also known as
‘dual type control’, and same is described below.
6.1.1 The dual type control system shall permit operation of each compressor in
either of the following two regulations:
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M4-107-01
AIR / GAS COMPRESSORS SHEET 8 OF 10
ISSUE
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TCE FORM NO. 329 R3 FILENAME : M410701R6.DOC
(a) Continuous Run-Load-Unload Regulation.
(b) Automatic Start-Stop Regulation.
6.1.2 Under continuous Run-Load-Unload Regulation, the drive motor shall run
continuously while the compressor shall be loaded at pre-set (adjustable) cut-in
pressure as the receiver pressure falls and unloaded at a higher pre-set
(adjustable) cut-out pressure, as the receiver pressure rises. With automatic
Start-Stop Regulation, the drive motor shall automatically start at pre-set
(adjustable) cut-in pressure as the receiver pressure falls and automatically stop
at a pre-set (adjustable) higher cut-out pressure as the receiver pressure rises.
6.1.3 With either system, the compressor shall always be unloaded when the drive
motor starts. The unloaders shall keep the compressor unloaded till the drive
motor comes to full speed.
6.1.4 Each compressor shall be provided with one selector switch having three
positions marked AUTO-OFF-ON for the following functions:
(a) OFF - Stops the motor.
(b) AUTO - Keeps the compressor(s) in load / unload mode as
selected by master selector switch.
- Starts the motor of the compressor in strart-stop
regulation as selected by master selector switch.
(c) ON - For manual start up by push buttons with load /
unload regulation.
6.1.5 Two (2) Compressors Operation
A master selector switch common to both the compressors shall be provided
having two positions marked ‘AB’ and ‘BA’. When the master selector switch
is in position ‘AB’and the individual compressor control switches are in
‘AUTO’ position, compressor ‘A’ shall have continuous run-load-unload
regulation and compressor ‘B’ shall have auto start-stop regulation. In the
other position of the master selector switch ‘BA’, compressor ‘B’ shall have
continuous run-load-unload regulation while compressor ‘A’ shall have start-
stop regulation.
6.1.6 Three (3) Compressors Operation
A master selector switch common for three (3) compressors shall be provided
having three (3) positions marked ‘AB/C’, ‘BC/A’ and ‘CA/B’. When the
individual compressor control switch is in ‘AUTO’ position and the master
selector switch is in position ‘AB/C’, compressors ‘A’ and ‘B’ shall have
continuous run-load-unload regulation and compressors ‘C’ shall have auto
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M4-107-01
AIR / GAS COMPRESSORS SHEET 9 OF 10
ISSUE
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start-stop regulation. Similarly with master selector switch in position ‘BC/A’,
compressors ‘B’ and ‘C’ shall have continuous run-load-unload regulation and
compressor ‘A’ shall have auto start-stop regulation. With master selector in
position ‘CA/B’, compressors ‘C’ and ‘A’ shall have the continuous run-load-
unload regulation while compressor ‘B’ shall have auto start-stop regulation.
6.1.7 Four (4) Compressors Operation
A master selector switch common for four (4) compressors shall be provided
having four (4) positions marked ‘AB/C’, ‘BC/D’, ‘CD/A’, ‘DA/B’. When the
individual compressor control switches are in ‘AUTO’ position and the master
selector switch is in position ‘AB/C’, compressors ‘A’ and ‘B’ shall have
continuous run-load-unload regulation and compressor ‘C’ shall have auto
start-stop regulation. Similarly with master selector switch in position ‘BC/D’,
compressors ‘B’ and ‘C’ shall have continuous run-load-unload regulations
and compressor ‘D’ shall have auto start-stop regulation. With master selector
in position ‘CD/A’ compressors ‘C’ and ‘D’ shall have continuous run-load-
unload regulation while compressor ‘A’ shall have auto start-stop regulation.
With master selector in position ‘DA/B’ compressors ‘D’ and ‘A’ shall have
the continuous run-load-unload regulation while compressor ‘B’ shall have
auto start-stop regulation. Fourth compressor not indicated in the selector
position shall be on manual control.
6.2 Two pressure switches shall be provided to monitor receiver pressure for each
compressor, one for load-unload control and the other for start-stop control
considering two (2) steps regulation for load-unload mode. In case number of
steps are more as indicated in data sheet A, number of pressure switches
provided shall be sufficient to meet the requirement.
6.3 Pressure switches with alarm initiating contacts shall be provided for the
receiver high and low pressures.
6.4 The dual control units shall be complete with pressure switches, solenoid
valves, control air tubing, air filter (if required) and other accessories as
required for the afore-mentioned operations.
6.5 For centrifugal compressors anti-surge control shall also be provided to protect
compressor from surging.
6.6 One potential free contact shall be made available for each compressor for
remote alarm under trip condition and a common contact for compressor auto
start.
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M4-107-01
AIR / GAS COMPRESSORS SHEET 10 OF 10
ISSUE
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6.7 Green and red lamps shall be provided to indicate motor running and stop
conditions respectively.
6.8 Motors shall be provided with motor winding over-heat sensors and bearing
temperature sensors for alarm indication and to trip the motor.
6.9 For compressors driven with turbine, the required turbine control and
instrumentation shall be provided.
6.10 For air / gas compressors, depending on the hazardous area classification,
motors and instrument enclosures shall be explosion-proof certified for the
specific area.
7.0 NOISE AND VIBRATIONS
7.1 Noise level produced by any rotating equipment individually or collectively
shall not exceed 85 dB(A) measured at a distance of 1.5 metres from the
source in any direction.
7.2 The overall vibration level shall be as per zones A and B of ISO 10816-1.
Vibration dampening pads if required, shall be provided.
8.0 PERFORMANCE GUARANTEES
Performance parameters to be guaranteed by the CONTRACTOR and
tolerances permitted shall be as indicated in section C and / or data sheet A.
BIDDER shall confirm acceptance of these by indicating values in data sheet
B. Compressor or any portion thereof is liable for rejection, if it fails to give
any of the guaranteed performance parameters.
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M4-107-01
AIR / GAS COMPRESSORS
SHEET OF 2
1
ISSUE
R4
TCE FORM NO. 329 R3 FILENAME : M410701R6.DOC
DATA SHEET C
DATA TO BE FURNISHED BY THE CONTRACTOR AFTER THE
AWARD OF CONTRACT
1. List of drawings and documents to be submitted for review, approval and
information with scheduled submission dates
2. Quality Assurance Plan (QAP)
3. Calculations for compressor capacity, drive motor rating, selection of speed
reducers and couplings. Torsional vibration analysis for centrifugal and screw
compressors
4. Thermal design calculations for inter-coolers, after-coolers and oil-coolers
5. Detailed P&I diagram showing clearly the scope of supply of equipment,
piping with line sizes and material specifications, valves, specialities,
instrumentation and control and all the accessories. All equipment, lines,
valves, specialities and instruments shall be tagged as per the PURCHASER’s
procedure to be given to the successful BIDDER. All terminal points shall be
clearly identified. All design data and other information furnished in data
sheets A and B shall be covered either in this drawing or other relevant
drawings or documents mentioned below.
6. Detailed equipment list and bill of materials of all items in the
CONTRACTOR’s scope
7. Sub-vendor list for all bought-out items
8. Mechanical design calculations for inter-coolers, after-coolers, oil-coolers,
moisture and oil separator and receivers
9. Characteristic curves of compressors. For centrifugal compressors, in addition
to curves for operating conditions, characteristic curves shall be submitted
considering minimum and maximum ambient temperature, minimum and
maximum humidity and minimum and maximum frequency conditions
10. Dimensioned to-scale equipment layout drawing showing all equipment,
accessories, relevant external dimensions, location and elevation of terminal
points, details of piping and electrical connections to be made by the
PURCHASER, clearances required for erection, dismantling, operation and
maintenance
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M4-107-01
AIR / GAS COMPRESSORS
SHEET OF 2
2
ISSUE
R4
TCE FORM NO. 329 R3 FILENAME : M410701R6.DOC
DATA SHEET C (CONTD.)
11. Dimensioned cross-section drawings of compressors and other proprietary
items with part list and materials of construction
12. Detailed fabrication drawings of all fabricated equipment like inter-coolers,
after-coolers, air receivers etc.
13. Line designation schedule for all lines in the CONTRACTOR’S scope
14. List of valves, specialities and instruments in the CONTRACTOR’S scope
with tag numbers, type, makes, pressure ratings, materials of construction and
ranges for instruments etc.
15. Manufacturer’s drawings, data sheets and catalogues for valves, specialities
and instruments etc.
16. Dimensioned to-scale piping layout drawing for piping in the
CONTRACTOR’s scope with allowable forces and moments on the piping
nozzles and displacement of the nozzles
17. Overall foundation plan, base frame drawing for each equipment, static and
dynamic loads on each of the anchor bolts and dimensional details of pockets
and anchor bolts
18. Motor drawings
19. Electrical control wiring diagrams with all interlocks
20. Control philosophy, interlock description and logic diagrams
21. Dimensional to-scale general arrangement and section drawings of MCC and
instrument control panel with complete bill of materials
22. List of alarms and trip settngs
23. Erection, start-up, operation and maintenance manual complete with
lubrication schedule etc.
TCE CONSULTING ENGINEERS LIMITED
TATA CONSULTING ENGINEER
SECTION
PROCESS DATA SHEET FOR STATIC MIXER SHEET 1 OF 1
RE
V.
NO. GENERAL REV.
NO. CONSTRUCTION DATA
1. 1 ITEM TAG NO.
322-SM-101 A/B INSIDE PIPE DIAMETER mm
2. 2 QUANTITY
02 Nos. SCHEDULE / THICKNESS mm
3. 3 SERVICE Liquid. Ammonia & DM Water LENGTH FLANGE TOFLANGE mm
4. DESIGN CODE ASME SEC.VIII DIV. 1, ANSI B16.5 MIXING ELEMENTS FIXED / REMOVABLE
5. 5 BIDDER / VENDOR
NO.OF ELEMENTS
6. MODEL NO. POSITION HORIZONTAL/VERTICAL
7. 7 LOCATION OUTDOOR / INDOOR JACKET YES / NO
8. 8 DUTY INTERMIT. / CONT. 12hr/day DESIGN TEMP.: PIPE/JACKET 0C 0C
9. 9 DESIGN PRESS.: PIPE/JACKET kg/cm2(g) kg/cm2(g)
10. PHYSICAL PROPERTIES
HYDROTEST PRESS PIPE/
JACKET kg/cm2(g) kg/cm2(g)
11. 1
1 FLUID NAME Ammonia DM water - CORROSION ALLOWANCE :
PIPE / JACKET 3 mm mm
12.
PHASE :
GAS/LIQ./SOLID Liquid Liquid -
SURFACE TREATMENT &
PAINTING REFER NOTE 5
13. DENSITY kg/m3
P
P
580 1000 - MATERIAL OF CONSTRUCTION
14. 1
4 VISCOSITY cP - 1 - HOUSING Low Temp. Carbon Steel
15. SOLIDS : SIZE & % NA NA INTERNALS Low Temp. Carbon Steel
16. 1
6 PERFORMANCE DATA CLADDING / LINING CS
17. FLUID NAME LIQ. NH3 DM Water - FLANGES CS
18. FLOWRATE, kg/hr 200 370 - BOLTS & NUTS CS
19. PRESSURE, kg/cm2g 12.7 2.5 - GASKETS
20. TEMPERATURE,0C AMB AMB - SUPPORTS
21. ACTUAL PRESSURE DROP kg/cm2 NOZZLES
22. ALLOWABLE PRESSURE DROP kg/cm2 JACKET
23. DEGREE OF HOMOGENEITY 100 % NOZZLE SCHEDULE (REFER NOTE 4)
24.
MEASURED PARAMETER FOR
DEGREE OF HOMOGENEITY
COMPOSITION /
TEMPERATURE /
DENSITY
SIZE
NB
RATING
# FACING FINISH
25. PURPOSE OF MIXING BLENDING /
SUSPENDING SOLIDS/ INLET 40
26. DISSOLVING / HEAT
TRANSFER/GAS DISP. OUTLET 40
27. ACCESSORIES BY VENDOR SIDE NOZZLE 40
28. LIFTING LUGS YES / NO JACKET INLET
29. COMPANION FLANGES,
NUTS,BOLTS & GASKETS
AS PER PIPING SPEC. /
NA JACKET OUTLET
30. EARTHING BOSS YES / NO VENT
31. INSULATION YES / NO DRAIN
32. WEIGHT OF STATIC MIXER : INSPECTION & TESTS (REF.NOTE 3, 6)
33. 1) EMPTY kgs. HYDROTEST YES / NO
34. 2) OPERATING kgs. HOMOGENEITY TEST YES / NO
35. 3) FULL OF WATER kgs. PRESSURE DROP TEST YES / NO
36. MATERIAL TEST CERTIFICATE YES / NO
37. 4
0 SPARK TEST ( NOTE 8 ) NA
38. OVERALL SPACE REQUIREMENTS : mm * mm * mm
39. NOTES : 1) - INDICATES BIDDER TO SPECIFY. 2) NA - INDICATES NOT APPLICABLE.
40. 3) - ALL TEST INSTRUMENTS SHALL BE TRACEABLE TO NATIONAL STANDARDS.
41. 4) REFER ATTACHED PIPING MATERIAL SPECIFICATIONS
42. 5) REFER ATTACHED SPECS. FOR SURFACE TREATMENT & PAINTING
43. 6) REFER ATTACHED SPECS FOR SHOP INSPECTION REQUIREMENTS
44. 7) DIRECTION OF FLUID FLOW TO BE MARKED ON DRAWINGS & EQUIPMENT BY BIDDER.
45. 8) SPARK TEST TO BE PERFORMED FOR LINED ITEMS.
REV. NO PPD.BY: SPP TCE JOB NO. CLIENT : NUCLEAR FUEL COMPLEX
PPD. BY
/ DATE
CKDBY: VAK TCE-4246A PROJECT :NZOSP, PALAYAKAYAL
CKD.BY
/ DATE
DATE: PDS NO. :TCE-4246A-CH-SM-PDS-322SM101 R0
R0 2
002
-09
-30
T
CE
.M4
-CH
-X-P
DS
-440
F
ILE
NA
ME
: P
DS
440.D
OC
SPEC. NO. TCE CONSULTING ENGINEERS LTD. SECTION : C2
TCE.4246A - 950
PROJECT INFORMATION – GENERAL
SHEET OF 3
PROJECT INFORMATION GENERAL 4246A_950_R1.doc 21.01.2005
1
ISSUE R2
TITLE
TCE FORM 329 R3
1. Owner / Purchaser Nuclear Fuel Complex, Hyderabad.
2. Consultant / Engineer TCE Consulting Engineers Ltd., Mumbai
3. Project Title New Zirconium Oxide & Sponge Project (NZOSP)
4. Location Palayakayal, Pazhayakayal Post, Tuticorin – Tiruchendur highway, Srivaikundam Taluk, Tuticorin District, Tuticorin – 628 152 Tamil Nadu
5. Altitude (+) 5 m above Mean Sea Level ( MSL )
6.0 Transport
6.1 Railway
Nearest Railway Station Tuticorin (Broad Gauge)
6.2 Road The site is located at Pazhayakayal Post, Tuticorin – Tiruchendur highway, and is approx. 17 km south of Tuticorin.
6.3 Air Port Madurai
6.4 Sea Port Tuticorin
7.0 Ambient Air Temperatures
a) Maximum dry bulb temp. 38.2 Deg. C (in the month of May)
b) Minimum dry bulb temp. 19.5 Deg. C (in the month of January)
c) Average Minimum 24.5 Deg. C
d) Average Maximum 32.3 Deg. C
e) Design wet bulb temp. for cooling tower
26.5 Deg. C
8.0 Design Ambient Temperature for electrical equipment
45 Deg. C
SPEC. NO. TCE CONSULTING ENGINEERS LTD. SECTION : C2
TCE.4246A - 950
PROJECT INFORMATION – GENERAL
SHEET OF 3
PROJECT INFORMATION GENERAL 4246A_950_R1.doc 21.01.2005
2
ISSUE R2
TITLE
TCE FORM 329 R3
9.0 Rainfall
a) Annual Average 500 mm
b) Peak Annual Rainfall 909 mm
c) Maximum Intensity 149.1 mm / hr
d) Design Intensity 75 mm / hr.
e) Period of rainfall Major portion from October to December
10.0 Relative Humidity
a) Maximum 80 %
b) Minimum 40 %
c) Average 60 %
11.0 Wind Data
a) Basic Wind Speed 55 m / sec as per IS : 875 ( Part – 3 ) - 1987
b) Wind Direction Predominantly from North, North-East, West and East
12.0 Seismic Data
a) Zone Zone II as per IS : 1893 - 2002
13.0 Climate Coastal and highly corrosive
14.0 Longitude 780 7’ E (approx.)
15.0 Latitude 80 42’ N (approx.)
SPEC. NO. TCE CONSULTING ENGINEERS LTD. SECTION : C2
TCE.4246A - 950
PROJECT INFORMATION – GENERAL
SHEET OF 3
PROJECT INFORMATION GENERAL 4246A_950_R1.doc 21.01.2005
3
ISSUE R2
TITLE
TCE FORM 329 R3
PROJECT SITE OFFICE DETAILS :
NUCLEAR FUEL COMPLEX -- NZOSP TUTICORIN-TIRUCHENDUR HIGHWAY, PAZHAYAKAYAL POST, SRIVAIKUNDAM TALUK, TUTICORIN- 628 152
ATT’N : EXECUTIVE ENGINEER PHONE (O) : 04630-276200 TELEFAX : 04630- 276111
SPEC.NO. TCE CONSULTING ENGINEERS LTD. SECTION: C3
TCE-4246A - 951
PROJECT INFORMATION - ELECTRICAL
SHEET 1 OF 2 OF 4
PROJECT INFORMATION-ELECTRICAL.doc21.12.2004
ISSUE R0
TITLE
TCE FORM 329 R3
1.0 SUPPLY & DISTRIBUTION
1.1 Primary Power Supply from Grid – Class IV
110 kV, 3-Phase , 50 Hz, Solidly grounded
1.2 Primary Distribution Voltage 11 kV, 3-Phase, 50 Hz, Solidly grounded
1.3 Secondary Distribution Voltage 415V, 3-Phase, 4-WIRE, 50 Hz, Solidly grounded
1.4 Stand by emergency power supply - class III
415 V DG Supply
1.5 UPS POWER SUPPLY FOR CRITICAL MOTORS – CLASS II
415 V , 3-Phase, AC, 50 Hz
2.0 AUXILIARY POWER SUPPY
2.1 Lighting fixtures, space heaters, 1-phase motors, 1-phase receptacles –-- CLASS III / IV
230 V, 1-phase, 50 Hz, AC
2.2 Control Supply
( a ) For substation control and protection – CLASS I
110 V DC, 2 WIRE.
( b ) For Instrumentation and Control - Process & utilities- CLASS II
230 V AC, 1-phase Through UPS
( c ) For MCC control – CLASS IV / III
230 V , 1-phase, AC
3.0 VOLTAGE & FREQUENCY VARIATION : This shall be as follows : -
3.1 AC SUPPLY
VOLTAGE VARIATION: (+) / (-) 10%
FREQUENCY VARIATION (+) / (-) 5%
COMBINED VOLTAGE & FREQUENCY VARIATION
(+) / (-) 10%
SPEC.NO. TCE CONSULTING ENGINEERS LTD. SECTION: C3
TCE-4246A - 951
PROJECT INFORMATION - ELECTRICAL
SHEET 2 OF 2 OF 4
PROJECT INFORMATION-ELECTRICAL.doc21.12.2004
ISSUE R0
TITLE
TCE FORM 329 R3
3.2 DC SUPPLY VOLTAGE VARIATION (+) / (-) 10%
4.0 Each of the above supplies will be made available at one Terminal Point. Vendor shall provide for further distribution of supply. If any other supply is desired by the Vendor, he shall provide for all the necessary hardware to derive this supply from the Control Supply provided by the Purchaser.
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: C5
TCE- 4246A –C-300-005
SCOPE AND GENERAL REQUIREMENTS
OF THE TENDER
SH. 1 OF 11
ISSUE R1
TCE FORM 329 R3
1. SCOPE
1.1 The scope includes the design, preparation of detailed drawings, fabrication, testing, inspection, supply, transportation to site, unloading, safe storage and handling at site, erection, testing & commissioning of the Liquid Ammonia & 35% Ammonium Hydroxide solution Storage & Transfer System and Accessories as given below:
1.1.1 LIQUID AMMONIA & 35% AMMONIUM HYDROXIDE SOLUTION STORAGE & TRANSFER SYSTEM AND ACCESSORIES
SR. No.
Equipment Quantity Details
Liquid Ammonia & 35% Ammonium Hydroxide solution Storage & Transfer System and Accessories
1 Liquid Ammonia Storage vessels / Bullets
02 Nos.
Detailed scope & specifications are given in section C6 – “Technical Specifications of Liquid Ammonia & 35% Ammonium Hydroxide solution Storage & Transfer System”
2 35% Ammonium Hydroxide solution Storage vessels/Bullets
02 Nos.
3 Ammonia vent vessel 1 No.
4 Ammonia Compressors 02 Nos.
5 Online Mixer 02 Nos.
6 Instrumentation For Ammonia Compressor system only
For Safe operation of Ammonia Compressor system.
7 Electrical As per battery limits shown in TCE.4246A-322-PI-8725 „R0 „ issue
Detailed scope given in “Specific Electrical requirements” of section C-6
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: C5
TCE- 4246A –C-300-005
SCOPE AND GENERAL REQUIREMENTS
OF THE TENDER
SH. 2 OF 11
ISSUE R1
TCE FORM 329 R3
1.2 This specification covers the requirements of design, preparation of detailed drawings, supply of materials & accessories, fabrication, manufacture, testing, inspection at Vendor‟s / Sub-Vendor‟s works, packing, forwarding, transportation and delivery at site, safe storage at site, transport to the site of installation, Installation / erection, mechanical completion, testing at site, pre-commissioning, commissioning of the Liquid Ammonia & 35% Ammonium Hydroxide solution Storage & Transfer System and Accessories alongwith its associated sub-systems and accessories complete in all respects, performance testing at site, supply of necessary documentation / calculations / drawings, manuals etc. for comments / approval by purchaser / consultant, supply of as-built documents / drawings described in various sections of this specification.
1.3 It is not the intent to specify completely herein all details of design and construction of equipment or materials to be supplied or of services to be rendered. However, the equipment, materials and services shall conform in all respects to high standards of engineering design, workmanship and be capable of performing in continuous commercial operation in a manner acceptable to PURCHASER who will interpret the meaning of drawings and specifications and shall have the power to reject any work or materials which in his judgement are not in full accordance therewith.
1.4 The scope of work under this contract shall also cover following :
a) Supply of equipment and accessories as specified.
b) Unloading, Safe storage of equipment supplied by CONTRACTOR & Unloading & Safe Storage of equipment and free-issue items wherever required, supplied by PURCHASER.
c) Taking over the equipment from PURCHASER'S storage / unloading area for equipment and free-issue items supplied by PURCHASER.
d) Transfer of material / equipment to CONTRACTOR'S storage area.
e) Maintaining equipment during storage and installation in safe custody.
f) Installation of equipment and carrying out wiring, cabling and earthing to complete the liquid ammonia & 35% ammonium hydroxide solution storage & transfer system as detailed under the technical requirements of the enclosed sections.
g) Installation of equipment at site requiring material handling including hoisting facilities.
h) Testing and commissioning of the equipment within CONTRACTOR'S scope for PURCHASER'S satisfaction.
i) Providing 'As-Built Drawings' and draft and final „Operation & Maintenance‟ manuals.
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: C5
TCE- 4246A –C-300-005
SCOPE AND GENERAL REQUIREMENTS
OF THE TENDER
SH. 3 OF 11
ISSUE R1
TCE FORM 329 R3
j) Obtaining all the clearances/ approvals from external agencies such as CCOE etc.
k) Providing with foundation drawings so as to enable the purchaser to take up with civil contractor. However minor civil works shall be in the scope of the vendor.
l) Supply of essential spares.
2. INSTRUCTION TO BIDDERS
2.1 Bidders shall completely familiarise themselves with the scope of work involved & the job completion schedule. Any clarification required shall be sought from PURCHASER / CONSULTANT, prior to quoting for the Bid.
2.2 Bidder shall ensure that the bids are complete & are prepared in the specified form. Incomplete bids are liable for rejection. Deviation, if any, shall be listed in Section-D; Schedule of Deviations (from Technical Specifications & General conditions). Except for these deviations, it is assumed that BIDDER shall comply with all requirements of the specifications. Any deviation sought at later date will not be entertained.
2.3 While quoting the prices, BIDDER shall quote separately for „supply‟ including all taxes, duties & levies considered and separately for “erection, testing & commissioning” including all taxes, duties & levies considered.
2.4 Bidder shall quote firm price which will be kept firm throughout the duration of the contract.
2.5 The price schedule shall be strictly as per Section E of this specification.
2.6 The make of components shall be as per the “List of approved sub-vendors” of Section – C and / or subject to PURCHASER / CONSULTANT approval. In case, sub-vendors are not mentioned for some items, bidders shall identify the sub-vendor considered for these items and mention in the technical bid documents. In all cases, after placement of the order, the main contractor / main vendor shall submit the list of sub-vendors to Purchaser / Consultant for comments / approval and the order shall be placed onto sub-vendors only approved by Purchaser / Consultant.
2.7 PURCHASER can add / delete items included in scope of work. Unit rates for different items shall prevail under such eventuality.
2.8 Bidder may provide a separate addendum to our price schedule format and submit the unpriced format of the addendum with the technical bid (Section-D) and priced portion of the addendum with the priced bid (Section-E). Description of items offered against such additional unit rates considered by
SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: C5
TCE- 4246A –C-300-005
SCOPE AND GENERAL REQUIREMENTS
OF THE TENDER
SH. 4 OF 11
ISSUE R1
TCE FORM 329 R3
the bidder shall be mentioned in Section D of the bid (unpriced portion) and the rates / prices quoted shall be included in Section E (priced portion of the bid). Purchaser / Consultant shall review these points from technical and commercial considerations and discuss, if required with the bidders at the time of technical bid evaluation. The bid shall be evaluated on lump sum basis including the spares.
2.9 PURCHASER‟S RIGHT:
The PURCHASER does not bind himself to accept the lowest or any Bid and reserves the right to accept or reject any Bid or a portion thereof without assigning any reason thereof.
2.10 ACKNOWLEDGEMENT OF ENQUIRY:
BIDDER shall acknowledge the receipt of enquiry and within two (2) days advise whether he will be quoting or not. If the BIDDER is not quoting, all enclosures to this enquiry must be returned promptly to the issuing authority with „REGRET‟ letter. All specifications and documents enclosed are PURCHASER‟s property and are to be used only for the purpose of this enquiry and any order which may result from it.
2.11 DELIVERY:
Tenderers should note that no tender will be considered by Purchaser unless the Tenderer can meet the delivery schedule specified by the Purchaser. All equipments / machinery / plant / components covered by this tender document should be supplied on or before 24 Weeks or as specified in the tender document from the date of receipt of LOI. The prices quoted by the tenderer should include all charges involved for direct and safe delivery of the items by Road to the Project site of the Purchaser. If a tenderer so desires, separate lumpsum charges for transportation and safe delivery to the Purchaser‟s site at Palayakayal could be furnished. Purchaser will neither undertake responsibility for transit insurance nor pay for it separately. No other, delivery term will be accepted by the Purchaser. The installation and commissioning of the Liquid Ammonia & 35% Ammonium Hydroxide solution Storage & Transfer System shall be carried out within 8 weeks from the date of intimation of site readiness. The vendor will depute personnel to site and carry out joint inspection of site to confirm site readiness.
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2.12 The OWNER reserves the right to :
2.12.1 Increase / decrease the quantities of equipment involved in scope of supply of CONTRACTOR.
2.12.2 The item rates for supply & installation in Section-E shall be applicable for: any increase / decrease in quantities without any ceiling on variation.
2.12.3 Splitting of the order for individual sub-systems / package systems mentioned in the tender.
2.12.4 Calculating the extra price / price reduction on account of any variation.
2.12.5 The prices for new items shall be negotiable.
2.12.6 All site test reports in a specified format maintained by the CONTRACTOR, duly approved by the CONSULTANT / PURCHASER shall be handed over to the PURCHASER/CONSULTANT after completion of job, as per Vendor Distribution Schedule enclosed.
2.12.7 In overall planning of installation work, it shall be the responsibility of CONTRACTOR to minimise wastage of materials and consumables.
2.12.8 The Contractor shall supply all the required documentation / drawings as mentioned in document no. TCE.4246A-952 / R0 enclosed as a part of this tender.
3. GENERAL REQUIREMENTS
3.1 The following definitions shall cover the scope of work and as such the quoted prices shall be based on the same considerations. Payment claims arising out of wrong understanding shall not be entertained or paid for.
3.1.1 Supply, Installation, Testing & Commissioning:
The items are enlisted below in and Section E 'Schedule of Prices' enclosed in this specification. Following works are envisaged for these items under the head of “Supply” and “Installation, Testing and commissioning”.
3.1.1.1 SUPPLY:
This shall include supply of equipment including packing / forwarding, transport and insurance charges complete with all fittings and accessories which form integral part of the equipment for installation purpose to ensure satisfactory commercial operation and timely delivery of the equipment to site. The place of supply shall be “Zirconium Complex” at Palayakayal near Tuticorin, Tamilnadu. Manufacturing, inspection & Testing at vendor's / sub-vendor‟s works of equipment, accessories and items, shall conform to relevant standards and meet statutory approvals.
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3.1.1.2 INSTALLATION, TESTING & COMMISSIONING:
This shall cover:
a) Unloading, handling, storage of equipment, transportation of equipment from CONTRACTOR'S and from PURCHASER'S stores to their proposed locations.
b) Installation of equipment as per Manufacturer's guidelines or specification drawings and / or relevant Indian Standards, Codes of Practice, including supply of materials / fittings / accessories as are necessary for the completion of the installation in all respects, and
c) Testing and commissioning of the equipment as per manufacturer's guidelines, Indian Standards, Codes of practices etc.
The PURCHASER / CONSULTANT may ask for such additional tests at site as in his opinion are necessary for determining that the works comply with the specification. The CONTRACTOR shall be responsible for carrying out the same at no extra cost to the PURCHASER.
d) Preparation of 'AS BUILT' Drawings
e) The VENDOR shall arrange following at his own cost.
i. Adequate quantum of welding electrodes including special
electrodes and welding units required for erection. ii. All consumable items viz. kerosene oil, cotton wool, emery
paper etc. iii. All erection tools and tackles, cranes, hoisting equipment, etc
as required. iv. All skilled, semi-skilled and unskilled labour required for
erection. Any facility, as required, for the labour force such as accommodation, transport, medical facility, insurance etc.
v. First fill of lubricants and grease etc. vi. Chemical cleaning operation for Liquid Ammonia & 35%
Ammonium Hydroxide solution Storage & Transfer System and piping.
vii. Commissioning the Liquid Ammonia & 35% Ammonium Hydroxide solution Storage & Transfer System and accessories and handing over to PURCHASER.
3.2 CODES AND STANDARDS:
All equipment, supply, installation, testing and commissioning shall comply with the requirements of SMPV Rule, latest editions of Indian Standards and Codes of Practices. Where these standards are in conflict with the stipulations of this specification, this specification shall govern.
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3.3 DRAWINGS:
3.3.1 All engineering documents & drawings, construction purpose drawings, cable schedules for execution of contract works, Operation & Maintenance manuals etc. will be prepared & furnished by the Contractor for review, comments, approval by PURCHASER / CONSULTANT.
3.3.2 The drawings attached with this specification, are for the general guidance of the BIDDER. The CONSULTANT / PURCHASER may also issue further drawings and sketches if considered necessary during execution of the work.
3.4 TESTING AND COMMISSIONING:
3.4.1 The performance and commissioning tests shall be carried out as per Section-C of this specification. It is the responsibility of the Contractor to arrange for required test equipment and instruments for such purpose.
3.4.2 The PURCHASER may ask for such additional tests on site, as in his opinion are necessary to determine that the work comply with the specifications, of manufacturer's instruction or IS code of Installation. The CONTRACTOR shall be responsible and bear the cost of such additional tests.
3.4.3 All routine tests shall be conducted in the presence of PURCHASER / ENGINEER on all equipment as per relevant IS standards.
3.4.4 Typical type tests certificate for all equipment of equivalent ratings shall be submitted for scrutiny / approval by PURCHASER / CONSULTANT.
3.4.5 All commissioning tests shall be carried out in the presence of PURCHASER'S representative and approval for the same shall be obtained before commissioning the installations.
3.4.6 All instruments and accessories required for testing and commissioning of the items specified shall be provided by the CONTRACTOR at no extra cost for the duration of Performance Test.
3.4.7 All instruments used for Testing and Commissioning shall have valid calibration certificates, traceable to National / International Standards of repute.
3.4.8 All instruments used for testing at vendor‟s / sub-vendor‟s works or at site shall have valid calibration certificates, traceable to national / international standards of repute. The calibration certificates shall be presented to PURCHASER‟S / CONSULTANT‟S representative.
3.5 MAINTENANCE REQUIREMENTS:
3.5.1 In order to carry out preventive maintenance, it should be possible to readily
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disassemble, repair, re-assemble the equipment in the shortest period and to attend to any defect by a minimum disassembly.
3.5.2 The BIDDER shall furnish one complete set of any special maintenance tools required for normal maintenance of equipment. The prices for the same shall be indicated in Section-E – Format for Submissions of Part-II.
3.5.3 The BIDDER shall confirm that space shown for the equipment is adequate from point of view of access, easy maintenance and for day to day operation.
3.5.4 All system must have convenient maintenance characteristics including :
Minimum disturbance to production during preventive maintenance. Easy access to replacement part which can be installed by personnel with
minimum skill
3.6 INSTALLATION SCHEDULE:
3.6.1 The PURCHASER requires that the CONTRACTOR shall follow schedule for installation, testing and commissioning of the equipment under the scope of this specification which will enable the PURCHASER to commission the project in time.
3.6.2 However, the final installation schedule shall be decided by the CONTRACTOR in consultation with PURCHASER / CONSULTANT.
3.6.3 CONTRACTOR shall submit a 'Bar Chart' indicating the installation schedule and get it approved from the PURCHASER / CONSULTANT. This approved installation schedule shall form the basis of all installation work to be performed by the CONTRACTOR.
3.6.4 For the purpose of overall coordination, CONTRACTOR shall submit the PURCHASER / CONSULTANT, every fortnight, a detailed installation schedule indicating actual progress against planned progress of installation work of individual equipment.
3.6.5 In case of shortfall in actual progress, which shall be clearly brought out by CONTRACTOR, CONTRACTOR shall indicate reasons attributable to it and certify that the equipment installation is being accelerated in order to meet with the 'completion dates'.
3.7 SITE FACILITIES:
3.7.1 This section details various „Site‟ facilities as may be required for execution of „Work‟ under this Contract, their availability and relevant terms and conditions where applicable.
3.7.2 The following facilities will be provided by the OWNER in good faith at terms indicated hereunder. No claims, whatsoever, arising out of use, misuse or
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failure of these facilities will be entertained.
3.7.2.1 Open Space
Open space, free of charge, for the CONTRACTOR‟s site office and storage space for keeping the CONTRACTOR‟s own tools / tackles and other materials for performance of work under this contract. Whereas space will be provided by the OWNER free of cost, the construction of office, their safety and security including safety of materials supplied by the OWNER for erection purpose as well as subsequent removal of the same on completion of „Work‟ under this contract are the responsibility of the CONTRACTOR.
3.7.2.2 Electric Power supply at site and general safety procedure:
a) Electric power supply at medium voltage (415 V, 3 phase, 4 wire) for
construction site lighting, office and stores enclosure lighting and construction machinery will be made available at site or near site of work at the discretion of Purchaser / Engineer-in-charge at one point. The distance will be within a reasonable distance from the building site.
b) Vendor / Contractor shall make his own arrangements for further
distribution of power supply, to lay and maintain further distribution lines and wiring necessary for the work at his own cost. Suitably rated kWh meter will be supplied and installed by the contractor and test certificates as per IS from authorised test lab or manufacturer shall be submitted. Contractor shall ensure at his cost that all electric lines and equipment conform to the Indian Electricity Rules, 1966 and Indian Electricity Act, 1910, with latest amendments. All extensions & distribution by the Contractor shall be executed in an approved manner with prior permission of Purchaser / Engineer-in-charge.
c) Contractor shall submit a list of equipment he proposes to connect for
constructional and general lighting purpose indicating power requirements for approval of Purchaser / Engineer-in-charge. The contractor shall post licensed Electrical staff at site. Double grounding will be provided for all equipment. Power supply will be effected after completion of the above.
d) The contractor shall pay the charges based on his power consumption at the rate of Rs. 7.00 per unit (kWh).
3.7.2.3 Water Supply during erection / installation at site:
a) Water required for construction purposes for the work covered under the
scope of the Contract as well as for drinking purposes and for Contractor's temporary establishment at site shall be arranged by the Purchaser to the
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contractor at one place to be determined by the Engineer-in-charge at available pressure. The distance will be within a reasonable distance from the building site.
b) Contractor shall, at his own expense, make connections and lay and
maintain the pipelines upto the points of consumption, install water meters, provide storage facility etc. as may be necessary. Contractor shall supply & install a tested meter of approved make for metering the water supplied to the contractor. The meter shall be provided with a masonry chamber with a cover and locking arrangement. All installations shall be
subject to approval of Engineer-in-charge. In case, it is observed that the
water meter is out of order, the consumption of water for the period during which the meter was out of order shall be worked out by the Purchaser in consultation with Engineer-in-charge and the amount shall be payable by the contractor.
c) The contractor shall pay the charges based on his water consumption at
the rate of Rs.35.00 per kilolitre. d) In case, Purchaser cannot supply power and water for construction
purpose for any reason, contractors shall make his own arrangement for getting the power & water for using in his work. No extra payment will be
made to the contractor in this regard by the Purchaser. However, no
recovery will be affected in the bill for this quantum of power and water for which contractor/s has/have made his / their own arrangement. Non-availability of construction power and water by the Purchaser will not make the contractors to delay the completion of work or withdraw from the responsibility of carrying out the work. No claim for compensation or extension of time shall be entertained by the Purchaser for any failure or short supply.
3.7.3 Site shall be handed over to the OWNER in a clean and tidy conditions on completion of „Work‟ or as instructed by the OWNER /ENGINEER.
3.7.4 The OWNER will not provide the following facilities and it is the responsibility of the CONTRACTOR to make suitable arrangements for the same.
(a) The CONTRACTOR shall use his own portable compressors, pumps,
temporary piping and accessories as required for cleaning, testing, flushing etc.
(b) No space will be available from the OWNER to accommodate the
CONTRACTOR‟s workmen and supervisory personnel. Necessary residential accommodation, for the same shall have to be arranged by the CONTRACTOR at his own cost.
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(c) Workshop Facilities The CONTRACTOR shall arrange to set up his own workshop to carry out site fabrication as may be required.
(d) Canteen Facilities
The CONTRACTOR shall arrange his own canteen facilities to cater to the requirements of his personnel.
(e) Consumables
The CONTRACTOR shall arrange all consumables and expendables required for work under this contract including necessary welding electrodes.
(f) Lighting
The CONTRACTOR will make his own arrangement for lighting for carrying out work at night as required. Only general lighting of the area as already available shall be maintained by the OWNER.
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1.1. EQUIPMENT, SYSTEM AND SERVICES TO BE PROVIDED BY
CONTRACTOR
1.2. The equipment / system to be supplied and erected under this specification
are shown in the P & I Diagram enclosed with this specification ‘TCE.4246A-
322-PI-8725 ‘R0’’ as detailed in Section C. Any item which may not have
been specifically mentioned herein but are needed to complete the
equipment / system and the process performance equipment / system to
achieve, shall also be treated as included and the same shall also be
furnished and erected, unless otherwise specifically excluded as indicated in
the bid document.
1.3. The Bidder scope also includes the following for Liquid Ammonia and
Ammonium Hydroxide Solution Storage and Transfer
1.3.1. Liquid Ammonia Storage Vessels / Bullets (322-T-441 A/B) - 2 Nos.
1.3.2. 35% Ammonium Hydroxide Solution Storage Vessels / bullets (322-T-442
A/B) - 2 Nos.
1.3.3. Ammonia Compressor (322-K-441 A/B) - 2 Nos.
1.3.4. Ammonia Vent Tank (322-T-445) - 1 No.
1.3.5. Online Mixer 2- nos.
1.3.6. Electrical motor drives for Ammonia Compressors
1.4. Third Party Inspection / Inspection and Testing of equipment / system,
bought-out items etc. at vendor’s and sub-vendor’s shop.
1.5. All foundation bolts, nuts, washers, base plates, for all the equipment /
system. Foundation bolts shall be in SS material.
1.6. Temporary piping, fittings, flanges, strainers, supports, gaskets etc. required
for testing, cleaning, pre-commissioning and commissioning etc. shall be
included in the scope of work.
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1.7. Supply and erection of all the above equipment / system, supply and erection
of auxiliary steel & supporting steel for supporting the equipment / system.
Painting of all the equipment, supports etc.
1.8. The equipment shall be designed, fabricated, manufactured and inspected by
Third Party & Testing as per the requirement of "The Static & Mobile
Pressure Vessels Rules" (SMPV Rules). This vessel shall be approved by
CCoE, Nagpur and obtaining approval of CCoE Nagpur and inspection by
competent third party shall be in the scope of Vendor.
1.9. A Test & Inspection certificate issued by manufacturer of the Liquid Ammonia
storage vessels (bullets) shall be furnished to CCoE, Nagpur. This shall be
duly countersigned by an Inspector, authorised by CCoE, Nagpur that the
vessel meets with the requirements of the code approved by CCoE, Nagpur.
1.10. The Layout for Liquid ammonia storage vessels / bullets shall be approved by
CCoE.
1.11. Supports, platforms, ladders: All the equipment shall be properly supported
and shall be easily accessible for maintenance. Platforms and safe access
ladders to be provided at various locations based on the height of the
equipment as per the requirement.
1.11.1. Design & supply of structural supports for the equipment is in vendor scope
of work. The load details for the structures & equipment shall be provided
by vendor and the specification shall be strictly as per the IS standards.
1.11.2. Fabrication, supply and erection of support structures are in the scope of
the vendor.
1.11.3. Grouting of the equipment etc. and Minor civil works during the erection of
the equipment and supplies are in the vendor’s scope.
1.12. SERVICES BY OTHERS
1.12.1. All piping utilities such as cooling water and instrument air up to battery limit.
1.12.2. Instrument air @ 6.0 kg/cm ², g pressure and (+) 5.0°C dew point shall be
made available at the Battery limits.
1.12.3. Cooling water @ inlet temperature of 32°C & with acceptable temperature
rise of 5°C shall be made available at battery limit.
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2.0 LIQUID AMMONIA AND AMMONIUM HYDROXIDE SOLUTION STORAGE
AND TRANSFER SYSTEM DESCRIPTION AND VARIOUS DETAILS
2.1 The liquid ammonia and Ammonium Hydroxide solution storage system
consists of storage of Liquid Ammonia, preparation of 35% Ammonium
Hydroxide Solution & storage of Ammonium Hydroxide solution. 35 %
Ammonium Hydroxide solution will be prepared by mixing liquid Ammonia
and DM water. This mixing will produce heat of mixing which is removed in
Ammonia dissolver which is a double pipe heat exchanger. This 35%
Ammonium Hydroxide solution is stored in the Ammonium Hydroxide storage
vessel.
2.2 Liquid Ammonia will be transported to site by road tankers. Liquid Ammonia
from road tankers to storage vessel (Ammonia bullet) will be unloaded using
Ammonia compressor 322-K-441 A/B. The time required for unloading 10T of
liquid Ammonia (filled road tanker) will be 1 hour. The capacity of Ammonia
unloading compressor shall be designed for 1 hour unloading of liquid
ammonia and vapour recovery also.
2.3 The DM water from the DM water storage tank is pumped and is online mixed
with liquid Ammonia. This is an exothermic reaction, so heat is being
generated. This heat is removed by means of cooling water in the double
pipe heat exchanger i.e. Ammonia Dissolver 322-R-441 A/B where cooling
water is used to remove the heat of mixing from Ammonium Hydroxide
solution. Cooling water is introduced in the counter current direction in the
Ammonia dissolver. Ammonium hydroxide solution is thus cooled and is
stored into the Ammonium Hydroxide solution Storage Vessels (bullets).
2.4 Ammonium hydroxide solution is transferred by ammonium hydroxide
solution transfer pumps to the Process plant.
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3.0 I & C SYSTEM REQUIREMENTS
The scope of supply for Instrumentation and control will include following two
systems:
1) Ammonia Compressors system
2) Ammonia transfer, dissolution and hydroxide storage & transfer System.
3.1 SCOPE
3.1.1 The scope of supply for Ammonia Compressor System:
3.1.4.1 Supply, installation and commissioning of all field instruments required for
safe and efficient operation of Ammonia compressor is in the vendor’s
scope.
3.1.4.2 Supply, installation and commissioning of local control panel housing
instruments, push buttons, indicating lamps, alarm annunciation and
digital panel indication for local start / stop operation of each Ammonia
compressor and all necessary instrumentation shall be supplied fully
wired for local operation and monitoring of both the compressors.
3.1.4.3 Vendor shall wire all the signals from instruments provided for Ammonia
compressor up to local panel for operation and monitoring. Further
cabling from the Local Control Panel (LCP) to OPF marshalling cabinet in
OPF control room is not in the vendor’s scope.
3.1.4.4 A local / remote selector switch shall be provided on the LCP. In Local
operation, all the equipments/instruments will be operated independently
from the LCP, whereas in the Remote mode, the system will be operated
from PLC. All equipments/instruments individually shall have to accept
remote ON/OFF command from PLC.
3.1.4.5 Supply, installation and commissioning of Cable trays, supports and
conduits for laying cables from field instruments/equipments to Ammonia
compressor local panel shall be in the scope of vendor.
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3.1.4.6 Impulse tubings, fittings, valve manifolds, isolation valves, and other
installation hardware required for mounting of instruments is in the scope
of vendor.
3.1.4.7 All Analog signals shall be multiplied in the LCP using signal multipliers.
One output of the multiplier shall be wired to the Digital panel meter while
another output shall be wired up to local control panel with terminal block
and further cabling from local control panel to OPF marshalling cabinet is
not in vendor’s scope. This will facilitate the remote operation from the
PLC panel.
3.1.2 The scope of supply for Ammonia transfer, dissolution and hydroxide
storage & transfer system:
3.1.2.1 Supply of following field instruments are in vendors’ scope. (Refer section
D for data sheets)
a) FE- 805/806/808(03 nos.)
b) FT- 805/806/808(03 nos.)
c) TI – 801/802/803/804 (4 nos.)
d) PVRV – 801 / 802 (2 nos.)
e) FV – 805(1 no.)
3.1.4.1 Installation and commissioning of all the Field instruments (including the
FIM) in the Ammonia transfer, dissolution and hydroxide storage &
transfer system is in the Vendor’s scope.
3.1.4.2 Supply, installation and commissioning of local control panel housing
instruments, status indicators, push buttons, indicating lamps, alarm
annunciations , digital panel indication ,valve on/off status and drives run
and trip status along with necessary instrumentation and controls shall be
supplied fully wired for local operation and monitoring of the Ammonia
transfer, dissolution and hydroxide storage & transfer system.
3.1.4.3 Supply and termination of cables for all field instruments in the Ammonia
transfer, dissolution and hydroxide storage & transfer system shall
be done up to the junction box. Further cabling from the junction box to
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the Local Control Panel (LCP) is also in the vendor’s scope. Two nos. of
junction boxes shall be supplied as free issue item by NFC (Refer 1.1.3).
3.1.4.4 All Analog signals shall be multiplied in the LCP using signal multipliers.
One output of the multiplier shall be wired to the Digital panel meter while
another output shall be wired up to local control panel with terminal block
and further cabling from local control panel to OPF marshalling cabinet is
not in vendor’s scope. This will facilitate the remote operation from the
PLC panel. Two no. of junction boxes will be supplied as a FIM to vendor
by NFC.
3.1.4.5 A local / remote selector switch shall be provided on the LCP. In Local
operation, the equipment will be operated independently from the LCP,
whereas in the Remote mode, the system will be operated from PLC. All
equipments/instruments individually shall have to accept remote ON/OFF
command from PLC.
3.1.4.6 Impulse tubings, fittings, valve manifolds, isolation valves, and other
installation hardware required for mounting of instruments is in the scope
of vendor.
3.1.4.7 Supply, installation and commissioning of Cable trays, supports and
conduits for laying cables from field instruments/equipments to Ammonia
transfer, dissolution and hydroxide solution storage system local panel
shall be in the scope of vendor. All multiplied signals shall be wired and
terminated in separate terminal block in local control panel and from local
panel to the OPF marshalling cabinet in OPF control room in not in
vendor’s scope.
3.1.3 FREE ISSUE MATERIALS (FIM)
Following items shall be supplied to the Vendor as FIM by NFC.
1. All Field instruments for Ammonia transfer, dissolution and hydroxide
storage & transfer system (except those indicated in Section D)
2. Junction Boxes (100 terminals JB – Analog; 150 terminals JB – Digital)
for termination of cables from field instruments.
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3.1.4 INSTRUMENTATION AND CONTROL CABLES
3.1.4.1 Cables for Analog signals (4 to 20 mA)
660 V/1100V annealed, tinned, high conductivity 1.0 sq.mm. Stranded copper
conductor. Extruded PVC insulated two cores twisted into pair, laid up
collectively, individual pair shielded and overall shielded with aluminium Mylar
tape, 0.5 sq.mm. ATC drain wire run continuously in contact with aluminium
side of the tape, inner sheathed with extruded PVC, with galvanised steel
wire braided, overall sheathed with extruded FRLS PVC, pair identification
number marked at interval of not more than 250mm, confirming to IS 1554,
BS:5308 & IEC:189 part II.
3.1.4.2 Cables for instrument power supply (24 VDC) and digital signals (24
VDC)
660V/1100V grade multicore cables, multistranded high conductivity
annealed 1.0 sq.mm (1.5 sq.mm for 230 V AC). Stranded tinned copper
conductor, overall shielded with aluminium mylar tape, 0.5 sq.mm ATC drain
wire shall run continuously in contact with aluminium side of the tape,
extruded PVC insulated, inner sheathed with extruded PVC, with galvanised
steel wire braided, overall sheathed with extruded FRLS PVC confirming to IS
1554, BS:5308 & IEC:189 part II.
3.1.4.3 Cables for instrument power supply (230 VAC)
660V/1100V grade multicore cables, multistranded high conductivity
annealed 1.5 sq.mm stranded tinned copper conductor, extruded PVC
insulated, inner sheathed with extruded PVC, with galvanised steel wire
braided, overall sheathed with extruded FRLS PVC confirming to IS: 1554.
3.1.5 POWER SUPPLY
All the field instruments shall be suitable for working on 24 VDC. Purchaser
will provide 230 VAC supply at one point in local panel. Further conversion
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and distribution of 230 VAC to 24 VDC in redundant configuration with diode
ORing shall be provided by vendor.
3.2 CODES AND STANDARDS
3.2.1 All equipment, systems and works covered under this specification shall
comply with all currently applicable statutes, regulations, standards and
safety codes in the locality where the equipment will be installed.
3.2.2 In particular, the following standards are applicable (latest editions)
ANSI : American National Standards Institute
70.2 Control Valve Seat Leakage classification.
ASME : American Society for Mechanical Engineers
BS : British Standards
BS-5308 Part-I Specification for Polyethylene insulated cables.
DIN-43760 Temperature Vs Resistance curves for RTD.
IEC : International Electro technical Commission
IEC 79 Electrical Apparatus for Explosive Gas atmosphere
IEC-332 Test on bunched wires or cables.
IEC 529 Classification of degree of protection provided by
enclosures
IEC 584-2 Thermocouple Tolerances
IEC 751 Industrial RTD Sensors.
IEC 801 Electromagnetic compatibility for industrial for industrial
Process measurement and control.
TCE CONSULTING ENGINEERS LIMITED SECTION: C6
TCE.4246A-C-300-005
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ISA : Instrument Society of America
S-5.2 Binary Logic Diagrams for Process Operations.
S-7.3 Quality standard for instrument air
S-75.01 Flow equations for Control Valve Sizing
ISO : Indian Standard Organisation
ISO-5167 Measurement Of fluid flow in closed conduits
NEC : National Electric Code
NEMA : National Electrical Manufacturer’s Association
ICS-6 Enclosures for industrial control system
IS:13947.
Part-1
Low voltage switchgear and control gear : General rules
IEC 326. Printed Circuit Boards
3.2.3 Other national standards established to be equivalent or superior to the
codes and standards specified are also acceptable. The BIDDER shall
furnish English translation of all standards specified in this specification.
3.2.4 In the event of any conflict between the codes and standards referred to in
the specification and the requirements of this specification, the more stringent
of these requirements shall govern.
3.2.5 Unless indicated otherwise, all codes and standards referred to in this enquiry
specification shall be understood to be the latest version on the date of offer
made by the Bidder.
TCE CONSULTING ENGINEERS LIMITED SECTION: C6
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FILE NAME: F120R1
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FORM NO. 120 R1
3.3.0 GENERAL REQUIREMENT FOR INSTRUMENTATION:
3.3.1 For all field instruments, material for the wetted parts shall be stainless steel.
3.3.2 All field instruments shall be weather proof with IP 65 protection class.
3.3.3 Local panel shall be protected under proper shade or canapy arrangement
and panel shall have IP 52 protection class. Local panel make shall be as per
approved vendor list. The panels shall be powder coated, with exterior pebble
grey (RAL 7032 as per DIN standard) and interior glossy white.
3.3.4 All transmitters and gauges shall have at least accuracy of +/- 1.0%.
3.3.5 Instrumentation trays and electrical trays shall be separately laid with
maintaining 300mm of distance between them. All trays shall be properly
covered. Direct run signals shall be laid through GI conduits with proper
supports.
3.3.6 Separate earth shall be provided for power supply, instrument shielding and
for panel.
3.3.7 All makes of various instruments/equipments shall be in line with the list of
approved sub-vendors.
3.3.8 The cable glands shall be of double compression type with high quality
neoprene gaskets. Cable glands shall be of brass with nickel plating.
4.0 SPECIFIC ELECTRICAL REQUIREMENTS:
4.1 The supply, installation, testing and commissioning of the following are
included within the scope of the vendor.
1.0 Drive Motor
2.0 All the power and control cables between vendor supplied
equipments and MCC
3.0 Local Control stations (i.e. Local start / Stop push buttons etc.)
4.0 Earthing of equipment to purchaser’s grid
5.0 Cable tray & accessories.
TCE CONSULTING ENGINEERS LIMITED SECTION: C6
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Electric supply for motors covered under this package shall be 415V, 3
phases, 4 wire. PURCHASER shall make a provision of Motor feeder for
each Compressor motor.
4.2 Induction Motors
4.2.1 Motors shall be provided with enclosures as per data sheet A1.Motors shall
be painted with anti-corrosive epoxy paint. Motors shall conform to the
enclosed specification No. TCE. M4-203-01.
4.3 Cable, Cable Tray & Accessories
4.3.1 1.1 KV grade stranded aluminium / Copper conductor, multi core, XLPE
insulated, extruded FRLS PVC inner sheathed, steel wire armoured, and
FRLS PVC Outer sheathed cable, as per IS : 7098 (Part1).
4.3.2 Up to 6 sq. mm the conductor shall be Copper above 6 sq mm it shall be
Aluminium.
4.3.3 1.1 KV grade stranded copper conductor of 2.5 sq. mm, PVC insulated,
extruded FRLS PVC inner sheathed, steel wire armoured, FRLS PVC
outer sheathed as per IS : 1554 (Part – 1).
4.3.4 Power cable sizing shall be done based on the various derating factors and
site conditions. The voltage drop in the cable at full rated current shall not
exceed 2 % of rated voltage.
4.3.5 The successful Bidders shall submit the cable sizing calculations for review
and approval by the purchaser / consultant along with the details such as
ratings of motors, other electrical load, approximate feeder length etc.
4.3.6 Power and control / Instrumentation cables shall be laid in separate cable
trays. When laid in trenches, the 415 V power cables shall be laid on the
top tier and control and instrumentation cables on the bottom tier.
4.3.7 The supply of the cables shall be as per enclosed specification No. TCE.
M4-208-01.
4.3.8 Cable tray shall be of hot dip GI with ladder type for power cables and
perforated for control cables.
TCE CONSULTING ENGINEERS LIMITED SECTION: C6
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4.3.9 Supply of all cables wherever specified for power, control and
instrumentation, cables system installation work, termination of cables at
both ends, testing and commissioning shall be included in the scope of
BIDDER.
4.3.10 Termination of incoming 415 V cables for power, at the MCC and shall be
in the scope of PURCHASER.
4.3.11 The supply of the cable tray and accessories shall be as per enclosed
specification No. TCE. M4-208-11.
4.3.12 It shall be in the BIDDER’S scope, to supply, install, wire etc. Junction
boxes if required to terminate the control / instrumentation cables. The
junction boxes shall have 20% extra terminals than actual required.
4.3.13 All instruments such as recording and indicating instruments, controller
level switches, pressure switches etc. shall be provided with the suitable
cable glands to suit the selected cable size.
4.3.14 All equipment shall be provided with lugs and cable glands, to suit the
selected cable size. Cable glands shall be of brass metal, double
compression type and lugs shall be of tinned copper type.
4.4 Earthing of equipment
4.4.1 GI shall be used for earthing the equipment as per IS 3043.
4.4.2 The main earthing grid shall be provided by the PURCHASER, the Bidder
scope include providing earthing conductor from individual equipment
supplied by the BIDDER to main grid.
4.4.3 Earthing conductors for equipments shall be brought out and connected
suitably to the earthing grid.
4.4.4 Successful BIDDER shall prepare and submit earthing layout, cabling
layout and other drawings to PURCHASER / CONSULTANT for their
review / approval.