HINDUSTAN PETROLEUM CORPORATION LIMITED MUMBAI REFINERY ...tenders.hpcl.co.in/tenders/tender_prog/TenderFiles/1560/Addendums... · hindustan petroleum corporation limited mumbai refinery

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HINDUSTAN PETROLEUM CORPORATION LIMITED

MUMBAI REFINERY

DHT PROJECT

PART : III

SECTION : B.6.1

TITLE : SCOPE OF WORK - PIPING

( SULPHUR BLOCK )

DOCUMENT NO:

44LK-5100-704/L.02/0105/A4

1 06.04.09 38 Revised as marked &

Issued as Amendment no.1

DRP RMP RMP/PVS

0 23.12.2008 31 Issued for FEED DRP RMP RMP/PVS

Rev No. Issue Date Pages Description Prepared

By

Checked

By

Approved

By

Jacobs

HPCL, Mumbai SCOPE OF WORK – SULPHUR BLOCK Part - III

LSTK Doc. No: 44LK-5100-704/L.02/0105/A4 SECTION – B.6.1

44 LK 5100 Page 2 of 38

TABLE OF CONTENTS

1.0 GENERAL

2.0 ENGINEERING DRAWINGS

3.0 CODES AND STANDARDS

4.0 BASIS OF WORK

5.0 DETAILED ENGINEERING SCOPE OF WORK BY LSTK CONTRACTOR

6.0 SCOPE OF SUPPLY BY LSTK CONTRACTOR

7.0 PIPING CONSTRUCTION

8.0 JOB SPECIFIC REQUIREMENTS FOR ARU & SWS UNIT.

ANNEXURE-I: REQUIREMENTS FOR 3-D MODELLING

ANNEXURE-II: REQUIREMENTS OF FIRE FIGHTING SYSTEM

ANNEXURE-III: TYPICAL HYDRANT AND MONITOR ASSEMBLY DETAILS

ANNEXURE-IV: SPECIFICATIONS FOR HYDRANT ACCESSORIES

ANNEXURE- V: SPECIFICATION FOR HIGH VOLUME LONG RANGE MONITOR 1

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1.0 GENERAL

1.1 Hindustan Petroleum Corporation Limited (HPCL) intends to put up Sulphur Recovery Unit (Sulphur Block) at its Mumbai Refinery in Maharashtra.

The Sulphur Block consists of ARU Unit, SWS Unit, SRU Unit and TGU Unit.

1.2 The Scope of Work shall include complete design, detailed engineering, generation of 3D model using PDS/PDMS software, preparation of drawings and documents, submission of documents and obtaining approvals from Owner/PMC, supply & procurement of all materials and consumables deploying positive material identification, stress analysis, flexibility analysis, fabrication, laying, erection, welding/ PWHT, tie-in and integration with existing system, maintenance provisions as required, chemical cleaning, testing, flushing and pre-commissioning including steam flushing, drying, complete in respects of all piping in accordance with Licensor’s Process Package, which will result in successful commissioning, operation and maintenance of the plant. In addition to the above mentioned piping scope within the battery limit of units as per the process package, the scope shall also include fire fighting / fire protection system, fire proofing, painting, insulation, steam tracing, electrical tracing(if applicable) and steam jacketing(if applicable) of piping as per the P&ID's, line schedule and specifications, coating wrapping of underground piping and also obtaining all statutory approvals and clearance like IBR, CCE, TAC/ LPA, PCB (Pollution Control Board), etc.

Scope of work also includes integration of OWS, CRWS with the existing facilities. LSTK contractor shall study for those hook-ups at site in the existing refinery.

1.3 Total scope of work of Sulphur Block is split into two parts as follows :

ARU and SWS units :

LSTK Contractor shall convert the FEED enclosed with the BID, to AFC (Approved For Construction) package in accordance with requirements of the Engineering Design Basis, Job Specifications, Standard Specifications, Standard drawings, codes, P&IDs and data sheets and other documents enclosed with bid package.

The requirements contained in the equipment layout, specifications, drawings etc. enclosed with the bid document are minimum, which the Contractor has to follow. However, any improvement as a good Engineering is always welcome during detailed Engineering, but at no extra cost to the Owner.

SRU –TGU units : (LEPCC Basis)

LSTK Contractor shall prepare the FEED documents based on Engineering Design Basis, Job Specifications, Standard Specifications; Standard drawings provided with the tender and Process Licensor’s inputs, such as Preliminary Equipment layout, P&ID's and data sheets etc. The requirements contained in this bid document are minimum, which the Contractor has to follow.

Any enabling, shifting, re-routing, modification of existing lines underground lines and facilities shall be carried out within the battery limit (as given in scope of work drawing) by the Contractor without any extra cost to the Owner.

The scopes of work stated in this document are minimum, to be provided by the Contractor. However for smooth running of the plant, any additional work, supply, erection, construction, etc, if required the same shall be carried out by the Contractor without any extra cost to the Owner.

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2.0 ENGINEERING DRAWINGS:

Following drawings are enclosed in the BID, on the basis of which the Contractor shall develop equipment layout and all other drawings & documents required for construction.

1 44LK-5100-00/L.01/0001/A0 Overall plot plan for DHT project and OSBL Facilities

2 44LK-5100-704/L.01/0001/A0 Indicative Equipment Layout – SRU BLOCK

3 44LK-5100-704/L.01/0002/A0 Indicative equipment layout sections – SRU BLOCK

4 44LK-5100-704/L.01/0003/A0 Hazardous area classification – SRU BLOCK

5 44LK-5100-704/L.01/0004/A0 Scope of Work -Piping

3.0 CODES AND STANDARDS:

All piping shall be designed as per ASME B 31.1, ASME B 31.3, except for steam and condensate, which shall meet the requirements of Indian Boiler Regulations also. The Contractor’s work supplies and construction shall comply with all codes/standards, standard specifications and Process Licensor’s package enclosed in the BID document.

The standard drawings provided in the BID are for reference and for conceptual understanding only and thus not exhaustive. Where ever necessary, either for the lack of information or non availability, LSTK shall prepare or develop the required specifications/standard drawings and use the same with prior approval of PMC.

In case of any discrepancy or contradiction either in this Design Basis, or in Standard Drawings / Standard specifications given by PMC, it is deemed mandatory to follow the requirements of the national / International design codes / standards, local statutory rules / OISD guide lines as or client’s standard practice being followed in existing premises, at no additional cost and time.

4.0 BASIS OF WORK:

The following documents enclosed in the bid document form the basis of work for the LSTK Contractor.

i) Overall plot plan Drawing : 44LK-5100-00/L.01/0001/A0

ii) Indicative Equipment layout drawings : 44LK-5100-704/L.01/0001/A0

This shall be developed and converted to IFC drawing(Final Equipment layout), during detailed Engineering, by the Contractor, based on inputs from Process Licensor, vendors, site data and existing facilities around the plot and shall be approved by Owner/PMC

iii) Indicative equipment layout sections : 44LK -5100-704/L.01/0002/A0

iv) Indicative Hazardous area classification drawing : 44LK-5100-704/L.01/0003/A0

v) Scope Drawing for Piping B/L : 44LK-5100-704/L.01/0004/A0

vi) Engineering Design Basis- Piping : 44LK-5100-00/L.02/0003/A4

vii) Design Basis -Stress Analysis : 44LK-5100-00/L.02/0004/A4

viii) Job Specifications : Piping Material Specifications

ix) Standard Specifications

x) Standard Drawings

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5.0 DETAILED ENGINEERING SCOPE OF WORK BY THE LSTK CONTRACTOR

Above-Ground & Under Ground Piping :

Following minimum drawings and documents shall be prepared by the Contractor and submitted to Owner/PMC for approval / review / information as applicable and as decided by PMC. However the Contractor shall also prepare all documents and drawings, required to execute the complete work including statutory approval/ clearance.

1) Overall Plot Plan, Key plan and area division for UNITS.

LSTK Contractor shall revise the Over all plot plans enclosed in the BID, in accordance with final Equipment Layout, Site measurements, Site data and existing facilities around the plot. The required Topography of the site for deciding the co-ordinates and datum levels shall be carried out by the contractor.

Area division for underground piping and above ground piping shall be same however the underground and aboveground piping shall be made in separate drawings.

2) Unit-Equipment layouts:

ARU and SWS Units

The Indicative Equipment Layout enclosed in the BID, shall be developed and converted to IFC drawing(Final Equipment layout – Plans / Sections), during detailed Engineering, by the Contractor, based on inputs from Process Licensor, vendors, site data and existing facilities around the plot.

The layouts shall meet the other requirement such as erection feasibility/ constructability , Lay down area, maintenance /operation accessibility, crane access inside ISBL for maintenance of Equipment (such as Air Coolers located on Pipe rack / technological structure )and for catalyst loading, access roads to unit etc.

SRU and TGU Units:

The enclosed Indicative Equipment Layout shows only the process blocks. Based on Process Licensor’s inputs, LSTK shall prepare Detailed Equipment layouts in plans, elevations, and sections, with unit pipe rack, trenches, monorails, and vendor data incorporated for units/packages. Approaches and roads around the units drop out areas, maintenance areas, construction requirements like hard stands to be clearly marked.

3) Electrical Area Classification Drawing:

ARU and SWS Units :

LSTK contractor shall revise the Indicative Hazardous Area Classification Drawing enclosed in the BID, in accordance with final Equipment Layout and Process Data.

SRU and TGU Units:

Electrical Area classification drawings shall be prepared by LSTK.

4) PMS and VMS :

The PMS (Piping material specifications) provided by PMC are only for reference and indicative and thus may not be exhaustive. LSTK shall update PMS given in the BID and develop detailed piping material specifications (PMS) and Valve Data sheets (VMS) based on process Licensor’s piping specifications, basic material depending upon service conditions (temperature, pressure and corrosively etc.) as spelt in process package, including welding specification for fabrication of piping, welding specification charts, and NDT specification for all piping classes.

5) Piping general arrangement drawings for above ground piping.

6) Piping general arrangement drawings for various underground services like CRWS, OWS, CBD, CWR/CWS, drinking water system, eyewash & safety shower, fire water system,

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storm sewer etc.

Coating and wrapping of underground lines shall be as per document 44LK-5100-00/L.02/0003/A4

7) 3D model using PDS/PDMS (refer Annexure-I)

8) Nozzle Orientation Drawings for all Equipment, showing all nozzles, nozzle schedule and elevation etc. shall be generated by LSTK which will be input to vendor drawing/mechanical datasheets.

9) Piping Isometrics for all lines, system isometrics for steam and Boiler feed water, condensate system falling in the purview of IBR, with Support Marking and Bill of Material as per IBR requirements.

10) Trim drawing with support marking & bill of material for all equipment mountings.

11) Stress Critical Line List, Stress index of critical line list to demonstrate the scope of stress analysis, indicating line number, stress calculation number, line size, material sp ecification, design conditions etc

12) Stress analysis, flexibility analysis reports, flange leakage calculation reports, engineering data for spring supports and pipe rack loading data, engineering data for expansion joints. Composite analysis of lines and calculations to check water hammer. All critical lines including those susceptible to water hammer shall be identified by LSTK.

13) All stress critical lines having a possibility of condensation, high pressure/ high temperature and two phase flow lines shall be adequately supported so as to limit the maximum deflection to 6 mm between two supports.

14) Analog reports for pulsating lines connected to reciprocating compressors/pumps. Dynamic analysis reports for two-phase lines. Any modification in piping as a result of Analog study shall be carried out by the Contractor to ensure vibration free plant.

15) Engineering data/sketches for other miscellaneous items e.g. Fabrication details for clad piping etc.

16) Special support drawings and pipe support cleats on equipment. Pipe support standards/ drawings to cover entire piping. Separate pipe support standards for high-pressure piping.

17) IBR Package as per the requirements of IBR and obtain their clearances and approvals.

18) Quality plan for piping activities

19) Specifications for procurement taking into account the requirements of the PMC’s Technical Notes for Purchase of Piping items contained in general notes to PMS including specific requirement specified by Licensor.

20) “AS BUILT” GA Drgs , Isometrics, Nozzle Orientation, Equipment Layout, Key-plan, Area division plan, as built IBR Package, 3-D model etc.

21) Insulation and painting specifications

22) Bolt tensioning specification

23) Updated specification for fabrication & erection, inspection, flushing & testing, pressure testing of erected piping systems, chemical cleaning spec.

24) Final piping bill of materials/ material summary unit wise.

25) Final support material summary unit wise.

26) Steam jacketing specification & steam tracing specifications. (If applicable)

27) Provide stress sketches / isometric drawings and calculations of all lines as per stress index.

1

1

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28) A composite specification, including all the requirements of the Licensor's package, and valve tag numbers, leading to the development of valve data sheets.

29) Provide a computerised material control system to input the material take-off. Summarise and produce purchase descriptions for requisitioning. The system shall be capable of monitoring and controlling all phases of the piping procurement cycle from enquiry requisition through to delivery on Worksite, including shortages and surplus reports. The material control system shall be capable of demonstrating material availability on specific areas of the work, (e.g.) individual units, accounting day to day variations vis-à-vis utilisation & drawings, giving confidence that material available is equal to material requirements.

30) Special Spacers and Blinds shall be provided at all high pressure (900# and 1500#) nozzles for Reactors, Furnaces, and Exchangers, Vessels to assist in hydro testing of piping systems and for any future isolation / testing of piping / equipment. Special blinds shall have 1½"NB tapped hole from the side of the spacer to only on one side of the blind, for multipurpose use. Special spacer shall be used during normal operation of the plant. Material for spacer shall be as per respective piping class. Standard for special spacers and blinds shall be prepared by the Contractor and shall be submitted for review by PMC.

31) Review and approve the piping design and layout of packaged vendor equipment to ensure compliance with engineering; specifications and codes of practice & PMC approved piping specifications etc.

32) Engineering support services including carrying out of rectification, replacements, for any trouble-shooting service for failure/malfunction during plant operation for two years after handing over.

33) Fire protection/ Fire fighting system (refer Annexure-II) around SRU BLOCK.

34) The Contractor shall finalise tie-in sequence at battery limit for various piping system, in consultation with PMC/Owner.

35) The Contractor has to maintain near zero loads and moments at tie-in points/ battery limits.

36) List of deliverable drawings/ documents along with schedule of drawing/ document/ calculations.

6.0 SCOPE OF SUPPLY BY THE CONTRACTOR

The Contractor shall:

1) Procure, Supply & store all piping materials, consumables including spring supports, bellows, expansion joints, strainers, steam traps, online filters, hoses, couplings, connectors, adaptors, safety showers, eye wash, etc required within the Contractor's B/L along with all material test certificates including photocopies of IBR certificates signed by the IBR Inspector. List of all piping items to be procured and supplied is to be submitted to Owner/PMC for confirmation by the Contractor

2) Prepare Bill of Materials including material summary on the basis of P&ID’s, GAD’s, and Isometrics including fabrication allowance, pre-commissioning and commissioning spares, and mandatory spares.

3) Prepare Material Requisitions, Material Status Reports etc.

4) Place purchase orders for all piping items as per approved Vendor List of Owner/PMC. Furnish final vendor drawings for piping items e.g. bellows, special tagged items etc.

5) Arrange 3rd

party inspection of materials by approved inspecting agencies as per requirements, transport and receive materials at site and store with proper identification tag.

6) All the piping items/components including valves of alloy steel, stainless steel and other

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higher grade materials procured under bulk materials shall be positively identified and checked on three tier basis, first at supplier’s shop, second at the Contractor's stores and third, after fabrication/erection at site. The properly identified material shall be given a distinctive colour by supplier before despatch to avoid mixing with any material and to be certified by the third party inspector.

7) Procure supply insulation materials with all accessories and execute all insulation jobs as per approved specification.

8) Supply paint and execute painting of all piping, and other miscellaneous items as per specifications.

9) Supply of all support materials, pipe supports including material for pipe support pedestals.

10) Four complete sets of bolt torque wrenches & one set of bolt tensioning equipment shall be supplied by the Contractor to owner.

11) Supply of necessary blinds or additional valving not identified in P&ID's to isolate lines to facilitate phased commissioning and start up of the plant.

12) Supply of hoses, couplings and adaptors for each hose station within the battery limit. Confirmation on number of hose stations and its required accessories is to be obtained from Owner/PMC. Length of hose shall be such that it covers 15 m area all around the utility stations.

13) Supply of eyewash & safety shower. Confirmation on number of safety shower is required to be obtained from Owner/PMC.

7.0 PIPING CONSTRUCTION

The Contractor shall provide for:

1) WPS/PQR for Owner/PMC’s review and maintain records for welder qualification and welder testing.

2) Provide for receipt of materials at WORKSITE offloading, checking, warehousing, proper storage and protection and material control facilities, including storage and retrieval of associated certification documentation. The Contractor shall also operate a separate quarantine stores/compound for storage of materials, which arrive without suitable documentation.

3) Fabrication, lifting, laying, erection, bolt tensioning and installation, pre and post weld heat treatment, inspection, non-destructive testing including radiography and hydrostatic and other testing of piping installations, above and below ground. Installation of all valves and other miscellaneous in line/on line items is also included. Open ends of piping, valves shall be protected with wooden blanking plates securely fastened with wire or by plastic insert plugs.

4) The Contractor shall supply all testing apparatus, appurtenances and fittings and the like and specialist testing fluids where required.

5) The Contractor shall arrange suitable numbers of PMI equipment at site to enable Owner/PMC to verify the bulk piping material supplied.

6) Cleaning, pickling, if required, water/steam flushing, air drying disposal of fluids offsite, reinstatement, preservation of piping and miscellaneous items following hydro test, nitrogen purging, cleaning, chemical cleaning, painting, insulation and wrapping coating as per specifications. Any arrangement required inclusive of pumps and laying of lines for carrying out hydro test and drinking water connection to be done by the Contractor. For free issue items like DM water (if agreed by the Owner) etc notice of minimum 4 weeks are to be given to Owner by the Contractor.

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7) Fabrication and installation, setting and commissioning of pipe supports, guides, anchors and spring supports as required, construction of RCC pipe support pedestals independent of floor pavements.

8) Coating and wrapping of underground pipe work

9) Execute all mechanical jobs identified during Owner/Licensors check list, technical audits, pre-commissioning and commissioning, including additional supports required to restrain pipe movement avoiding interference with nearby structural/piping.

10) Set up field engineering cell and execute field engineering, which becomes necessary to resolve problems arising during prefabrication, shop fabrication, field fabrication or erection at site & based on sub vendor data. Necessary field design change drawings shall be prepared by the Contractor and submitted for information/review as the case may be and shall be reflected in the As Built Drawings, Documents, 3D model etc.

11) Obtain clearances and approvals from all applicable statutory/government agencies e.g. IBR, PCB, OISD, CCE, TAC etc. LSTK contractor shall prepare all the Documents / Drgs. needed for these approvals.

12) Supply of all piping materials required for testing, pre-commissioning and commissioning e.g. piping spools, bolting and gaskets, flanges, blinds or any other piping materials for carrying out this activity.

13) Development of a system base for Mechanical completion in agreement with PMC and hand over of sections of the work. The Contractor shall adopt Owner/PMC’s requirements regarding sequence of system completion and hand over.

14) Installation of any necessary blind or additional valving not identified on P&ID’s to isolate lines to facilitate phased commissioning and start-up.

15) The Contractor shall comply with the requirements of Mechanical completion as described in relevant section of the PMC approved FEED Document.

16) Testing of welded/flanged joints not subjected to hydro testing.

17) The Contractor’s scope includes all such activities as required, supply of all materials and components as required, for successful commissioning of the plant as per the requirements of the P&ID’s, line lists, Piping Design Basis and engineering specifications etc. Enclosed in the bid document so as to result in a total safe operable, trouble free and maintainable plant.

18) Scope also includes joint measurements wherever required.

19) The Contractor should clear off all temporary arrangements, sheds, and materials arranged by him after execution of the project.

20) Insulation, painting and protective coatings

21) Co-ordination and liaisoning with other LSTK contractors and with Owner for proper tie-in or hook ups of various existing piping system such as OWS, CRWS or any other underground system emerging from inside SRU BLOCK and for all the B/L piping emerging into and out of DHT project.

22) All approach roads from main road to unit shall be checked for equipment and machinery movements. If any widening or strengthening of the road is required including storm water box, culverts and road crossing, etc are also included in the scope of the Contractor.

23) LSTK contractor should make his own arrangement for ware house/storage of materials.

No fabrication yard shall be provided to contractor at site. No fabrication shall be allowed at site, only field weld to be done at site. All fabricated items brought at site should have 2 coat painting.

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8.0 JOB SPECIFIC REQUIREMENTS:

Following are the job specific requirements (piping) :

8.1 1) The Contractor to develop a detailed equipment layout as per the requirement of process licenser, bid document, OISD and / or Fire Protection Manual -TAC, etc.

2) Any facilities not shown specifically in plot plan drawings as mentioned in item 2.0 above, but required for completion of the job shall be provided by the Contractor.

3) Any implication of piling on equipment placement to be checked before developing the equipment layout.

4) The Contractor shall develop the Heater layout based on thermal design. Heater location shall meet the statutory requirement of 90m from adjacent existing tank farm as per OISD / Petroleum rules.

5) Interconnecting platform to be provided between columns, pipe rack and technological structures, wherever feasible.

6) The location of misc. Equipment (such as neutralisation pits, mobile pumps, ejectors, sample coolers, filters etc) shall be finalised by the Contractor.

7) Each monorail shall be provided with suitable (capacity) chain pulley/ electric hoist for maintenance of equipment as per the bid requirements.

8) Compressor house with overhead crane shall be provided by the Contractor.

9) Exact deck level and size of compressor house shall be finalised by the contractor after receipt of equipment vendor drawings. Lube oil run down tank shall be provided with suitable staircase for access. Minimum two no. access through staircase shall be provided for compressor house deck.

10) The Contractor shall develop complete detail for the hydrocarbon drain (CBD), floor drain systems including the associated sump drums & recirculation pumps to slop. A flare knock out drum will also be included inside battery limits to collect all flare relief's (safety valves and process vents/purges.)

11) Fire proofing requirements as per OISD shall be provided for all equipment structure by the Contractor.

12) The Contractor to decide location of

� Hard stand

� Eye wash and safety shower

� Analyser shed

� Requirement of monorail, chain pulley block, EOT / HOT.

13) Catalyst loading/unloading scheme for wherever required in the plant to be developed by the contractor and submit to Owner / PMC for review. Any supply required for the same is in scope of the contractor.

14) The contractor shall provide the number & location of hydrocarbon sensors, CCTV in the plant if and as indicated in the Instrument job specifications. The contractor shall be responsible for locating the analyser shelter for Chromatograph at suitable location.

15) Fire hydrant / fire fighting system, Fire water monitors, hydrants, deluge valve assembly, sprinkler, Booster pumps if required for tall columns, shall be provided by LSTK contractor in accordance with Fire protection Manual(TAC) and OISD.. All hand operated fire fighting equipment shall be developed by the Contractor as per OISD/ TAC requirements for units/area & hook up with existing system. Booster pump, if required shall be in scope of supply of the Contractor.

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16) Water spray/ sprinkler system shall be provided for all equipment as per OISD/ TAC requirements.

17) The area between plant battery limit and the adjacent road shall be paved by the Contractor for the crane movement.

18) Entire area around SRU BLOCK shall be hard surfaced/paved for crane and fire tender movements.

19) New roads & drains shall be constructed as per civil scope drawing.

20) Ramp shall be provided wherever road & access are marked as applicable for crane fire tender movements.

21) Suitable CRWS/ storm water drain size design, construction, road widening etc is in the scope of the Contractor. Refer civil scope of work given in bid document.

22) Rerouting, enabling modification of existing (UG/AG) lines, services and facilities as a result of placement of new equipment lines & services in existing area is to be taken care by the Contractor. Any additional supply require for the same is to be taken care by the Contractor.

23) MS sleeve pipes of suitable size / culverts to be provided for all u/g pipelines crossing the roads and drains by the Contractor.

24) Provision for isolating equipment from its U/G CBD line by providing break up flanges to be done by the Contractor.

25) All pipe lines shall be routed up to piping battery limit / terminal point as shown in scope of work drawing (Indicative), with valves, matching flange, gaskets, bolts & nuts as per design basis by the Contractor.

26) Modification of existing facilities, such as culvert for existing cables, storm Drain, etc. if required, for clear access path to SRU BLOCK, shall be carried out by the contractor.

27) Existing paving load carrying capacity of approach from any side of SRU BLOCK, plot to be checked for movement of fire tender / crane by the Contractor. Suitable modification to be carried out if not found adequate. Modification of rack & cable trays to be carried out by the Contractor for clear movement of crane / fire tender. Any supply required for the same to be provided by the Contractor

28) RCC Culvert to be provided for the existing wide trapezoidal storm water drain around the plant for main access path by the Contractor & shall be suitable for movement of crane during operation, maintenance & heavy traffic.

29) Any damage to existing structure and services due to upcoming of new plant to be repaired, replaced, tested and commissioned by the Contractor without any extra cost to the Owner/PMC.

30) Any road widening, modification of existing structure to enable transport of equipment and tools for erection at site, the same shall be done by the Contractor at no extra cost. The work shall be carried out in consultation with Owner/PMC. Any permits required for the same shall be obtained by the Contractor

31) Any drawings, documents required for obtaining statutory approvals before starting of the job and during start-up such as TAC, CCOE, IBR, etc is in the scope of the Contractor.

32) The Contractor to carry out 3-D modelling as described in Annexure-I.

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ANNEXURE-I

REQUIREMENTS FOR 3-D MODELLING

1.0 INTRODUCTION

The LSTK Contractor shall carry out Detailed Engineering of the plant/ areas specified in the scope elsewhere using 3D intelligent software.

2.0 SOFTWARE

Any one of the following two software with Oracle database shall be used by the LSTK Contractor.

i) PDS by Intergraph USA on Windows NT with design review through dynamic walkthrough.

ii) PDMS by CAD CENTER UK on Windows NT with design review through dynamic

walkthrough.

Isometrics shall be generated using ISOGEN Software. Latest version of all the software released as on the date of ITB shall be used by the Contractor. The LSTK Contractor shall clearly specify in his bid the software to be used with version number.

3.0 OBJECTIVE

The objective of 3D modelling is to carry out detail engineering and produce deliverables using 3D tools and conduct reviews for obtaining approvals from Owner/PMC. 3D model shall be developed and demonstrated with dynamic walk through facility to check any interference requirements of operation and maintenance for getting the approval of the Owner. LSTK contractor shall deliver to Owner/PMC a complete 3D model which shall be utilised for all future maintenance, operation, revamping and any de-bottlenecking of the plant. The 3D Design Reviews through dynamic walkthrough, through LCD projector system shall assist the Owner’s operation and maintenance personnel in reviewing the project prior to construction and suggest modifications for efficient operation of the plant. Owner/PMC/Licensor shall use it for review of design.

4.0 DEFINITIONS

4.1 EXACT GEOMETRY

The geometry of the object should be exactly as shown in vendor drawings or as per standard drawings as given in codes e.g. Pipes, flanges, valves, beams, etc. the geometry of the items to be modelled should be such that it serves the purpose of clash checking as well as identification of object in 3D.

4.2 NEAR EXACT GEOMETRY

SPECIAL items like bellows, traps, etc does not call for exact geometry. The provision should be made for clash checking and 3D representation of the item. A box, instead of bellows, traps, etc is not acceptable.

4.3 APPROXIMATE GEOMETRY

Items like transmitters, floor stand mounted instruments where boxes instead of exact shape can be shown. The nomenclature of such items should be clearly distinguishable for easy identification.

5.0 EXTENT OF MODELLING/SCOPE OF WORK

5.1 PIPING

5.1.1 All design within each Unit/ Facility battery limit (based on drawings supplied in Process Package), above ground and underground piping inclusive of fire fighting lines and sprinkler system, big bore and small bore, except tubing, for all piping materials shall be modelled.

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Details shall include all pipes, valves, flanges, fittings, reducers, spectacle blinds, drains, temperature/pressure connections, sample points, drip legs jacketed pipes, fittings and flanges etc. All the lines shall be modelled up to the battery limit of unit as indicated in scope of work drawing. (44-LK5100-704/L.01/0004/A1).

5.1.2 All in line instruments like control valves, safety valves, rotameters, orifice plate etc. with near exact geometry.

5.1.3 All piping special items like expansion bellows, slide valves, special valves with purge points, steam traps, strainers etc. with near exact geometry.

5.1.4 Complete vessel trims with level gauges, level switches, level transmitters, equipment/ instrument, vent/drains utility connections, pressure gauges etc. with exact geometry.

5.1.5 Steam supply and condensate recovery stations up to the first valves in tracer lines.

5.1.6 All shop & field welds shall be marked and numbered on the isometrics. Subsequent revisions of the Line/Isometric shall maintain the previously marked and numbered weld nos.

5.1.7 All pipe supports to be modelled in complete details.

a. All spring hangers, roller supports to be modelled with all details.

b. Type of support i.e. X, Y, Z stop Rx, Ry, Rz Rotational stops, anchors to be given in the models so that the information can be interfaced with standard analysis software's like CAESAR II.

c. Details of the spring hanger's i.e. operating load, travel, spring constant should be keyed in as user-defined attributes.

d. Details of expansion bellows i.e. type, axial/lateral deflections, stiffness etc. to be keyed in as user defined attributes.

e. Structural steel members used for the pipe supports to be modelled in complete details.

f. Pipe supports along with concrete pedestals.

5.1.8 All equipment to be modelled with exact geometry including but not limited to: manholes with davits, pipe davits on top platforms, nozzles, stiffener rings, bellows, break flanges, platforms, ladders, handrails, lifting lugs, etc. for all the equipment in the plant like vessels, columns, reactor, receivers, pumps with motors, compressors with details of volume bottles, cylinders etc., blowers, centrifugal compressors, furnaces with soot blowers, fired heaters, burners and peep holes, air coolers with motors and fans, filters, blow down drums, all equipment within packages and heat exchangers etc.

a. Maintenance areas around equipment, davit swing areas, swing elbows sweep areas, tube bundle removal areas for heat exchangers, rotor removal areas, and drop out areas to be modelled as soft envelopes and should be used for clash detections.

b. Equipment supports: skirts, support legs/lugs, saddles to be modelled along with the equipment.

c. Insulation type (hot, cold, tracing, jacketed, etc). Insulation thickness operating/design pressure/temperature, hydro test medium/pressure to be given.

d. Contractor shall get review done by PMC of equipment modelling before nozzle cut outs are made on the equipment. Equipment 3D model shall include all attachments like platforms, nozzles, ladders, pipe supports, etc.

5.1.9 Skid mounted equipment to be modelled with exact geometry.

a. Skid to be tagged as main equipment.

b. All sub-equipment of all skids to have skid tag as a prefix.

c. All sub-equipment to be modelled with exact geometry.

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d. Complete internal Piping of the skid with all inline and online instruments to be modelled as per the details in 5.1.1 to 5.1.7

e. All pipe supports with the skids are to be modelled as per para 5.1.7

5.1.10 Packaged units/modular units are to be treated like the main units and all the requirements of modelling detailed in Para 5.1.1 to 5.1.18 shall be followed for such units.

5.1.11 Tagging of all line nos., Instrument nos., special items, and equipment nos. shall be as marked in the P&ID’s.

5.1.12 Complete underground piping including break flanges, funnels, manholes, manhole vent piping to atmosphere, catch pits, cable trays etc. to be modelled.

a. Envelopes to be modelled on top of manholes and catch pits and shall be used for interference detection.

5.1.13 Material handling equipment e.g. Catalyst loading chutes, drums, etc to be modelled in near exact geometry.

5.1.14 Hard stands, fabrication space for tall columns, erection access for tall structures considering crane boom and movement, crane access, unit approaches from main roads, main roads outside the units shall also be modelled.

5.1.15 Line information required in 3-D model.

The following attributes must be keyed in while modelling:

a. Line operating/design, temperature/pressure in deg. C and kg/cm²g respectively.

b. Liquid state i.e. vapours liquid, 2-phase.

c. Specific gravity

d. Insulation thickness and type i.e. IH/IC/IJ/IC etc.

e. Insulation density

f. Hydro test pressure in kg/cm²g and medium.

g. Line number label should be as per the P&ID with the following attributes: Line size + unit no + line sequence no + sub-line no + piping material specification + insulation type. User Defined Attributes (UDA’s) to be generated for keying in this information in PDMS\PDS.

h. Hydro test loop no.

i. Piping stress analysis system number allocated at the time of generation of critical line list for stress analysis (through UDA’s in PDMS/PDS)

5.1.16 Incorporation of site changes during fabrication and erection with 3D model in order to deliver a complete as built model to Owner.

5.1.17 General Arrangement Drawing Extraction

a. Piping General Arrangement Drawings are to be extracted from the 3D model on A0 size

with a scale of 1:333

1 for UNITS. However in special cases other paper sizes and

scales can be considered. Separate plans shall be made for each level. Dimensions shall be in millimetres while levels and coordinates in meters. Vital installations and battery limits shall be marked with coordinates.

b. All locating dimensions like spacing for equipment, structural columns, pipe-to-pipe etc. shall be marked on the GAD’s. Equipment tag numbers, line numbers, instrument and speciality item tag numbers shall be marked on the GAD’s. Electrical/Instrument ducts shall be marked and labelled. Access ways, maintenance corridors, dropout areas, bundle removal areas catalyst-handling areas shall be marked on the GAD’s.

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5.1.18 Isometric Extraction

All Isometrics within ISBL unit, including those within the package units/vendor packages and LLI units, shall be extracted from 3D model using ISOGEN Software along with Bill of Material, details of pipe supports and issued for fabrication.

5.1.19 Interference Detection shall take care of Hard-Hard clashes and Hard-Soft clashes for all the disciplines.

5.2 STRUCTURAL

The scope of modelling for structural shall include but not limited to the following:

i) Main steel/secondary steel equipment support beams, bracing, columns with footings, stiffener plates, platforms, ladders, pipe racks, stair cases, walkways, wind shield supports, claddings, supporting structure for all coolers with operating platforms and staircase, monorails, EOT support, entire technological structure, lighting mast, etc including fire proofing shall be modelled in exact geometry. Existing structures inside the working battery limit to be modelled.

• Handrails, gratings to be modelled in approximate geometry.

• Skid supports, platforms, ladders & Equipment supports inside skids are to be modelled in exact geometry.

• Welds to be modelled.

ii) Equipment and structure foundations, technological buildings, equipment supporting structure, flue gas stack and any other concrete structure to be modelled in exact geometry with exact locations of all insert plates.

• Foundation and structure for platforms, gratings, handrails etc. for packaged item and skid-mounted items are also included.

5.3 ARCHITECTURAL

i) For applicable Buildings, Control rooms, Analyser rooms, rack rooms, substations, Doors, Ceiling and Floors, compressor house, etc. Modelling of buildings shall include all doors, windows, sheeting, trenches, storm water drains, walls, openings in walls etc. all approach roads around units including culverts.

5.4 INSTRUMENTATION

i) Instrument ducts, cable trays greater than or equal to 300 mm width, Instrument Junction boxes to be modelled in exact geometry.

ii) Transmitters and other floor stand mounted instruments on grade/platform to be modelled in approximate geometry with tag nos. as per P&ID’s.

iii) Instrument control panels inside packaged items with approximate geometry.

iv) Instrument control panels inside rack room and control panel.

5.5 ELECTRICAL

i) Electrical cable trays greater than or equal to 300 mm width. Electrical cable trenches all sizes, junction boxes to be modelled in exact geometry.

ii) Electrical stop/start switches for motors, to be modelled in approximate geometry.

iii) Lighting details, earth pits

iv) Fire alarm system, e.g. fire detection point, hooters, etc.

5.6 HEATING VENTILATION AND AIR CONDITIONING

Ducting, Inline equipment, Sound Attenuators, Fire dampers and balancing dampers to be modelled in exact geometry, both for HVAC ducting and flue gas ducting for Heaters, Air

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blowers, Air intake filter and entire ducting for the process unit section up to the Stack etc.

6.0 MODEL SPLIT

6.1 Separate models to be generated for each discipline.

Discipline Model Identifier

Piping above ground P

Piping under ground U

Equipment M

HVAC H

Structural S

Architectural A

Electrical E

Instrumentation I

6.2 Within each discipline models are to be generated based on the area division in piping key plan. The naming conventions for model in the PDS and Database in PDMS shall be as follows:

X X - XX

Model Identifier as given in 6.1

Levels (given below) Under score Area number from Key Plan

A – Grade B – First Level above grade C - Second Level above grade X – All levels in one model U – Under ground

- Above ground and underground piping shall always be in different models.

6.3 Database Hierarchy in PDMS

i) Piping

a) PIPE NAME:

Line no. Label _ PX _ XX

Specified in 5.1.15) Under score Model no. Under score

Area no. From Piping key plan.

b) Branch Name:

PIPE NAME/ B1, B2

c) TAG NOS. For all Inline Instruments. Special items as component Name in PDMS. Same tag numbering philosophy to be followed in PDS.

XXX - XXX XXXX X

UNIT DASH INST. INST. 1, 2, 3….

No. Type i.e. PSV, FV, PV No./ special item no.

Only if same no. is getting repeated.

- Comments to be written in components S Text attribute.

ii) Other Disciplines

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Basis shall be similar to that given for piping. LSTK Contractor shall develop the Hierarchy and submit it for Owner/PMC approval prior to start of modelling.

7.0 DELIVERABLES

7.1 Complete 3D model along with as built GAD’s, Isometrics, support drawings and MTO reports, all extracted from the model, nozzle orientations for Piping and 3D models for all disciplines as specified in 7.1 to 7.6 with any other document generated from 3D model and naming conventions as per 7.0 to 7.3 with “As built” updates along with complete reference databases, component catalogues for all the size range in the approved specifications shall be furnished by the LSTK Contractor in electronic form.

7.2 Models shall be installed on minimum 2 workstations at site having latest version of software (3D(PDS/PDMS), ISOGEN and design review software and all other pre requisite software like Microstation, Oracle and any other software required for smooth running of 3D system) and minimum configuration as stated in clause 8.1 by the Contractor sufficiently before completion of Mechanical work and shall be continuously updated either through dedicated ISDN link, or through cartridge tapes (up dates once a fortnight for the first 3 months and once a week thereafter). Updation of Model by Cartridge tapes shall only be permitted if other means of wide Area communication like ISDN etc. are not available. Location of these workstations, printer & plotter at site shall be decided in consultation with Owner.

In addition LSTK Contractor to install

� One number of A3/A4 duplex laser printer

� One number of A0 inkjet plotter

7.3 Reference Data Bases.

7.3.1 P.D.S.

The complete reference Data base developed for the FACILITIES by the LSTK Contractor on PDS and delivered shall include but not limited to the following:

7.3.1.1 Piping

1. Piping material class

2. Piping Commodity data files

3. Short or Long material description library

4. Speciality material description library

5. Standard note library

6. Label description library

7. Piping assembly library

8. Graphic commodity library

9. Physical data library

10. Formats files for MTO

11. Isometric set-up (option) files

12. Piping job specification library

13. Write-up of all project specific code lists, which have been, added to the standard code lists.

7.3.1.2 Other disciplines

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Complete reference database with all the libraries. LSTK Contractor shall prepare a comprehensive list of these files separately for each discipline and submit it for PMC review prior to start of 3D modelling.

7.3.2 PDMS

The complete material specifications and component catalogues developed by the LSTK Contractor on PDMS and delivered shall include but not limited to the following:

7.3.2.1 Piping

1. Piping material specifications

2. Insulation specifications

3. Bolt specification

4. Nozzle specifications

5. Complete Piping component catalogues with write-up on naming conventions used for CATALOGUE references, component references for Property Database, Bolt References for single and multibolts.

6. Detail texts along with the symbol keys & R Texts.

7. Material texts with X Texts

8. Any symbol key library developed for special items where Isometric Symbols by CAD Center were not available

9. Property database with nominal bore and outside diameter developed for the project.

7.3.2.2 Other Disciplines

Complete reference database with all the libraries. LSTK Contractor shall prepare a comprehensive list of these files separately for each discipline and submit it for PMC review prior to start of 3D modelling

7.4 During the period of construction the above workstations and software at site shall be manned and maintained by LSTK Contractor personnel up to the completion of the Project.

7.5 Costs for all the above activities at 7.1 to 7.6 along with total hardware, software, networking, model transfers, ISDN link etc shall be borne by the LSTK Contractor. The ISDN link shall be operational until all the as built in the model have been incorporated and complete model transferred to Owner. .

7.6 Review by PMC/Owner/Licensor

LSTK Contractor shall be responsible for arranging 3D review sessions at PMC / OWNER’s office with Dynamic walkthrough with overhead projector system, for comprehensive review of the 3D Models. Simultaneously a Technical Audit of the Reference Database, Component Libraries and Project Database shall be carried out by PMC. PMC / OWNER shall make one workstation available for the entire duration of the Technical Audit to the audit team along with Contractors support team. Incorporation of the comments of the Technical Audit shall be done by the LSTK Contractor without any cost or time impact. LSTK contractor shall send fortnightly updates of the model using latest version of 3D modelling software (compatible to the one at PMC Office) to PMC's office for the review/ status monitoring of the models. LSTK Contractor shall propose the dates and duration at least 4 weeks in advance for these 3D reviews by Owner / PMC..

7.7

REVIEW STAGES

There shall be minimum 5 review stages to be done as follows :

Model Review Matrix, which covers the extent of coverage of modelling as mentioned below, shall be prepared by LSTK contractor and submitted for PMC approval.

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As a minimum requirement, following shall be the extent of coverage for the model reviews :

1. BASIC Model Review

Plot Plan Attached to 3D Models

Battery limits located

All major equipment located

Equipment layout review from lay-down, erection, constructability, operation and maintenance point of view

Major structure shown

Major pipe rack shown

2. 30% Model Review :

Comments from Client BASIC 3D model review incorporated

Large bore critical process & thermal lines studies on the 3D model

Piping studies 15 - 20% complete

Location of unit access ways for mobile maintenance and fire fighting equipment shown

Major platforms, ladders/stairways servicing tall equipments and structures to be modelled.

Comments from Client for operation and maintenance incorporated


Comments from Client 30% 3D model review incorporated

Ready for Client’s comments for operation and maintenance

All equipment located

Complete detailing of all equipments, its platform and ladders using latest vendor data/drawings

Piping studies 70% completed

All large bore process lines and utility mains shown (2 inch and above)

Fire water mains around the unit - modelled

In-line instruments shown for lines installed

Instruments on equipment located. Local panels shown

Final routing for electrical/instrument cable trays as per actual sizes

HVAC ducting and ventilating devices modelled

All structures (concrete and steel), ladders and platforms shown

All pipe racks shown

Start issuing large bore and critical line isometrics (Level-1 only) –IFC, prior to 90% review, in consultation with PMC/client, after incorporating 60% model review comments, stress/support comments

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Comments from Client 60% 3D model review incorporated

Update of all equipments to final status as per latest and final vendor data

All piping shown with supports in compliance with stress mark-up/comments, all in-line/on-line instruments

All major pipe supports located

Safety showers, eye wash, utility stations are shown

Complete Fire fighting system including fire hydrants, monitors, sprinklers, deluge system. Landing valves etc. are modelled

Piping studies 100% complete

Instrumentation, including cable trays - 100% complete.

Electrical cable trays - 100% complete

All major pipe supports located

Issue of large bore / critical lines- isometrics for IFC

5. 100% Model Review

Client’s final comments from 90% 3D model review incorporated

3D model updated to latest issue of PIDs, line list, arrangement drawings and final equipment drawings

8.0 HARDWARE CONFIGURATION: Following configuration is minimum requirement.

8.1 PDS (Intergraph)

1. Configuration for Server: Processor: P4 733 MHz Memory: 512 MB RAM Disk: 4 * 18.2 GB with Raid, Ultra 160 SCSI. Floppy drive, CD ROM, 10/100 Mbps network card, Key Board, Mouse etc. Monitor: 17" colour. OS: Windows NT Server. Back up device: 35/70 GB

2. Only Workstation: Processor: Pentium 4, 1.7 MHz 850 chipset/400 MHz FSB RAM: 512 MB RD RAM Disk: 18.2 GB SCSI 10K RPM Display Card: 32MB Dual display CD Rom, 10/100 Mbps network card, Floppy Drive, Key Board, Mouse etc. Monitor: 2 * 21" colour OS: Windows NT workstation

PDMS

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1. Configuration for Server: Processor: P4 733 MHz Memory: 512 MB RAM Disk: 4 * 18.2 GB with Raid, Ultra 160 SCSI. Floppy drive, CD ROM, 10/100 Mbps network card, Key Board, Mouse etc. Monitor: 17" colour. OS: Windows NT Server. Back up device: 35/70 GB

2. Only Workstation: Processor: Pentium 4, 1.7 MHz 850 chipset/400 MHz FSB RAM: 512 MB RD RAM Disk: 18.2 GB SCSI 10K RPM Display Card: 32MB Dual display CD Rom, 10/100 Mbps network card, Floppy Drive, Key Board, Mouse etc. Monitor: 2 * 21" colour OS: Windows NT workstation

9.0 PROVEN TRACK RECORD

The LEPCC Contractor or his Engineering sub-Contractor must have carried out extensive 3D modelling and data base management for a project of similar nature with the following as a minimum:

i) 1500 lines

ii) 40 GAD’s

iii) 60 piping specification classes

iv) 15 Workstations

v) EPCC Contractor should demonstrate their capability through walk-through of one such 3D model developed by them.

Owner/PMC reserves the right to verify the above at the premises (as applicable) including experience of personnel deployed on the project.

Owner/PMC decision shall be final and binding on the LEPCC Contractor in this regard.

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ANNEXURE-II

REQUIREMENTS FOR FIRE PROTECTION SYSTEM

1.0 SCOPE OF WORK

Contractor shall design, engineer, supply and install the fire protection system inside and around SRU BLOCK, considering the following and as per OISD and / or Fire protection manual (By Tariff advisory Committee), specifications and standard appended hereto and as mentioned below.

LSTK contractor shall hook up the all the fire fighting requirements / piping for ISBL, with the existing Fire water mains-network around the SRU BLOCK. Firewater lines passing through the paved area inside ISBL / Process area shall be laid in sand filled RCC trenches with removable pre-cast RCC slabs. The top of pipes shall be 200mm or more below the bottom of the RCC slab.

Tapping from existing main firewater network including isolation valve on tapping line shall be in the Contractor’s scope. The existing fire water header around the units if required to be dismantled or shifted to enable the work, shall be done by the Contractor, wherever necessary, without any extra claim to the Owner. LSTK contractor shall study at site and confirm such requirements during the BID stage.

2.0 CODES AND STANDARDS

The codes & standards applied on the project will be:

a) OISD 116 (Latest Edition): Fire protection facilities for petroleum refineries and OIL/GAS Processing Plants.

b) Fire Protection Manual (By Tariff Advisory Committee (Latest edition).

c) NFPA codes where ever applicable.

d) IS Codes for fire fighting equipment

3.0 GENERAL

The CONTRACTOR’S design and engineering activities listed below are the minimum requirements to be complied with :

a. Preparation of detailed design basis, specifications, standards and list of codes for each system based on guidelines given in subsequent clauses of scope of work.

b. Preparation of PFD/P&ID’s and equipment data sheets. c. Preparation of material take-off, material requisitions and purchase requisition of

bought out items. d. Design calculations for the respective fire protection system. e. Installation drawings and documents. f. Taking approval from statutory authorities and Tariff Advisory Committee. g. Operating maintenance and spare parts manuals wherever applicable.

In case of any conflicts in this document/specifications/ requirements, then either CCE, OISD, TAC or clients requirement, which ever is more stringent, shall govern

4.0 FIRE PROTECTION SYSTEMS

The following fire protection facilities shall be considered depending upon risk of installation as per OISD and / or TAC requirements.

− Fire water hydrant / Monitor system

− Water spray system (Automatic or Manual as per OISD)

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− Foam system , If applicable

− Clean agent fire extinguishing system, if applicable

− CO2 system, if applicable

− First aid fire fighting equipment

− Smoke detection & manual call point alarm system

− Fire detection and alarm system

− Fire proofing as per OISD

5.0 DESIGN PHILOSOPHY

The following shall be the basic design criteria for providing fire protection facilities for SRU BLOCK.

All hazardous areas / facilities shall be fully covered by fire hydrant system, water spray, monitors , Deluge system, foam systems(if applicable) and designed as per OISD and / or Fire protection manual (By Tariff advisory committee -TAC ), as applicable.

Criteria for providing type of fire protection facilities for various risks and areas inside Process area, shall be as per OISD and / or Fire Protection Manual (By Tariff advisory Committee) and as recommended by process licensor. The design shall meet OISD 116, 118 and 173.

As a guideline, Hydrants/Monitors, Water spray/Sprinklers, Clean Agent protection, Carbon Dioxide protection and Fire fighting equipment shall be provided as applicable. The provision and design of fire fighting system and its components shall be governed by statutory requirements (Fire protection manual –TAC) and applicable OISD standards.

The design and layout of fire protection system shall be such that, maximum rebate in the premium for insurance shall be obtained from Insurance agencies.

6.0

PROCESS UNIT

Following requirements shall be met as a minimum & as per statutory requirements :

a. Tall columns shall be provided with water spray system. Booster pumps, if envisaged, shall be designed and provided for tall columns, wherever necessary in order to meet the required fire water pressure at the highest level.

b. Wet risers, with hose reels and hose boxes for elevated platforms and columns

c. Monitors shall be provided at strategic locations for cluster of columns, fire heaters, gassifiers etc. Minimum 2 nos. of monitors shall be provided for each such area.

d. Water curtain shall be provided to cut off the furnace from rest of the plant. The reformer/fire heater shall be considered as furnace.

e. All the Technological structure shall be provided with fire hydrant valve (Gate valves) with a provision for connecting hose reel.

7.0

FIRE HYDRANT SYSTEM

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Existing firewater headers are running above or underground in closed loops around and near the proposed locations of DHT. Tapings from these headers with an isolation valve shall be taken by the LSTK contractor for the fire hydrant protection of these plants.

The new hydrant mains, if required around the unit as per Fire Protection Manual / OISD, the same shall be normally laid underground or in masonry culverts with removable covers of incombustible construction. Underground mains shall be laid such that the top of pipe is not less than 1m below the ground/grade level and not less than 1.5m under the road with concrete / steel encasement suitable for crane movement. Mains if laid above ground / grade shall be 15m away from the plant B/L .

The fire water mains (ring header ) around ISBL shall be 14” NB minimum.

Contractor to ensure multidirectional flow, by providing Isolation valves in the network and thus enabling isolation of any section of the network without affecting flow in the rest of network. The isolation valves shall (Gate valves only) be located at every 300 m and at crossings (loop junctions) to ensure easy maintenance and uninterrupted water supply in case of break down.

All underground fire water piping within and outside ISBL Unit, shall be externally protected from corrosion by wrapping and coating or as per specifications given in the BID. The extent of coating given to underground CS piping shall extend upto 500 mm above /beyond grade on both sides.

Piping and Valve material shall be as per PMS (Piping material specifications and Valve material specifications) prepared by LSTK contractor based on preliminary PMS provided in the tender. The PMS prepared by LSTK, shall be approved by PMC for Engineering.

All the valves (CS valves) on sea water service (FW,CW) shall be COROCOATED type. PMS & VMS to be updated by LSTK.

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7.1

HYDRANT AND MONITORS

All hydrant out lets shall be 1m above ground level The stand post shall be 80 mm Dia for single headed hydrant and 100 mm Dia for double headed hydrant. Only oblique hydrant conforming to IS: 5290, Type A with outlets angled towards ground shall be used. The hydrant coupling of instantaneous spring-lock (female) type of 63 mm Dia.., and valves shall be of the screw down type. The hydrant couplings shall be of suitable material for fire water (which is sea water). The Double headed hydrant shall consist of two separate landing valves. Double headed hydrants shall be used throughout the system, in case of Oil Refineries, Petrochemical plants. All hydrants and Monitors should be serially numbered. 1. Hydrant shall be BIS approved with following detail :

Outlet : 63mm double headed Pipe Size : 6” CS Capacity : 36 cum/hr Type : Oblique angle type as per TAC requirement Material : SS Hydrant post shall be provided with 4” jumper connection fitted with stainless steel threaded cap. The cap shall have four stainless steel lugs and chain attached to it.

2. Water Monitor Shall be BIS approved with following detail:

Nozzle bore size: 38mm (Aqua fog /foam with arrangement of jet and spray. Pipe Size : 6” CS Capacity : 2580 LPM Material : SS

3. Water Cum foam Monitor:

Nozzle bore size : 38mm (Non aspirating type-Aqua fog / foam with arrangement of jet and spray ) Pipe Size : 6” CS Capacity : 2580 LPM Material : SS Approval : UL

4. Long Range Water cum foam monitor

Capacity : 2000 GPM Horizontal Range : 80m Approval : UL

7.1.1 Hydrants or water monitors shall be located keeping in view the fire hazards at different sections of premises to be protected and to give most effective coverage. Number of hydrants shall be based on one hydrant or water monitor for every 30m of external perimeter of process units and storage tank areas. These shall be generally located on the following:

a) For Hazard areas like Process units 30 m

b) For utility areas, building areas (if applicable) 45 m

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Hydrants/monitors shall be generally located along roadside berms for easily accessibility. The hydrants and monitors shall be provided around the unit at a minimum distance from plant B/L or hazardous equipment as per TAC-fire protection manual / OISD norms.

Hydrant shall be located not less than 7.5 m and not more than 22.5 m from the plant battery limit. in case of High Hazard Occupancy. Monitors should not be installed less than 15 m and not more than 45 m from hazardous equipment.

Hydrants/monitors shall be generally located along roadside berms for easily accessibility. The hydrants and monitors shall be provided around the unit at a minimum distance from plant B/L or hazardous equipment as per TAC-fire protection manual / OISD norms

Double headed hydrants with two separate landing valves of 2- ½” size on 4” stand post shall be used. The height of the hydrant shall be 1.2 m above the ground level.

The water monitors shall have one 4” size monitor. Monitor location shall be given special consideration for protection of cluster of towers, heaters and other high structures, where it may not be possible to approach the higher levels. A minimum of 2 monitors shall be provided for each such area.

The horizontal range & coverage of hydrants and monitors shall be as under:

Hydrants - 30 m

Monitors - 45 m

Hydrants within buildings/ Plants shall be provided as per IS: 3844.

Coverage of Hydrants & monitors shall be checked by drawing circles so as to ensure coverage of all hazardous areas. In case any areas remain uncovered, location of Hydrants/monitors shall be adjusted for complete coverage of the area. It should be possible to direct minimum two water streams from Hydrants/monitors on any hazardous areas for effective protection against fire.

The requirement of elevated/oscillating/ remote operated monitors may become necessary for protection of critical equipment at higher elevation / inaccessible areas. This aspect should be given due consideration. This shall decided during detailed Engineering.

7.1.2

HYDRANT AND MONITOR ASSEMBLY

A typical DRG. for the requirement of Hydrant / Monitor arrangement, being followed at HPCL Mumbai Refinery is attached with this scope work. (Ref Annexure III of this scope of work) LSTK shall study these assembly arrangements at site and accordingly include in the scope.

7..2 HOSE BOXES AND HOSE REELS

7.2.1 Hose Boxes

Fire hose boxes shall be provided, one for every two hydrants. The hose box shall be accessible from two hydrants. Hose box shall be made of carbon steel & painted red. Each box shall contain:

− 4 x 15 M, 2-1/2” fire hose with coupling.

− 2 x 2-1/2” branch pipes with fog/straight jet nozzle with coupling.

− Other accessories to suit connecting two hoses on each hydrant valve.

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7.2.3

Hose Reels

Hose reel shall be 40m 20mm. Hose shall be reinforced rubber line (RRL) 2 Nos 15m each kept in each hose cabinet Hose cabinet shall be BIS/vendor approved installed around process units and at central location

Hose reels shall be considered for location around building and at landings of upper floors near fire hydrants as first aid for fire contingency. These shall be floor-mounted type & shall have water connection from hydrant network.

7.3 SPECIFICATIONS FOR HYDRANT ACCESSORIES AND HIGH VOLUME LARGE RANGE MONITORS :

Refer Annexure IV and V for the specifications.

8.0 FIRE WATER SPRAY SYSTEM

Fixed water spray system equipped with water spray nozzles for specific water discharge is envisaged for hazardous equipment. The piping system shall be connected to the hydrant water supply through an automatically or manually (remote operation) actuated valve, which initiates the flow of water. Water spray pattern & their densities shall be selected according to need.

All the sprinkler system provided for equipment (as applicable) shall have fire water supply from both sides of ISBL.

Provision of flushing shall be provided between strainer & isolation valve on water spray feed lines for all dry piping.

Firewater spray system for exposure protection shall be designed to operate before the possible failure of any containers of flammable liquids or gases due to temperature rise. The system shall therefore be designed to discharge effective water spray within shortest possible time.

8.1 Some specific areas for water spray protection are given below :

8.1.1 Process Units

− Un-insulated vessels with cap. > 50m3

− Vessels / areas inaccessible to fire tender and monitor range.

− Pumps handling class ‘A’ petroleum products under Pipe racks

− Pumps handling products above auto ignition temperature, under pipe rack

− Air fin coolers located above pipe racks

− Water curtain shall be provided around the furnace area to cut off ingress of gas from any direction to the furnace. The curtain shall be auto operated based on gas detection system

− Any other areas as recommended by process licensor shall be provided with water spray system

− Any Equipment / area which needs fire protection and not accessible by Hydrant or Monitors

8.2 WATER SPRAY APPLICATION RATES :

Shall be designed as per OISD and /or TAC.

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9.0 WATER SPRINKLER SYSTEM

Fixed water sprinkler is fixed pipe system to which sprinkler with fusible bulbs are attached in a systematic pattern. Each sprinkler riser/system includes a controlling valve & a device for actuating an alarm on operating of the system. The system consists of a number of zones & separate riser for each zone. In the event of fire, the system gets actuated by heat from fire & the water gets discharged over the fire area automatically. The water for sprinkler system shall be tapped from hydrant system. The design flow rate varies ranging from 6 lpm/m

2 to 10

lpm/m2

depending upon risk category as per NFPA/TAC. Area covered by sprinkler system shall be divided into segments so that a time the affected area would come under sprinkler coverage depending upon fire contingency. The sprinkler systems are used for the extinguishments of fire in hazards located inside buildings. The requirement of water sprinkler system shall be determined during detailed engineering.

Fixed water sprinkler is fixed pipe system to which sprinkler with fusible bulbs are attached in a systematic pattern. Each sprinkler riser/system includes a controlling valve & a device for actuating an alarm on operating of the system. The system consists of a number of zones & separate riser for each zone. In the event of fire, the system gets actuated by heat from fire & the water gets discharged over the fire area automatically. The water for sprinkler system shall be tapped from hydrant system. The design flow rate varies ranging from 6 lpm/m

2 to 10

lpm/m2

depending upon risk category as per NFPA/TAC. Area covered by sprinkler system shall be divided into segments so that a time the affected area would come under sprinkler coverage depending upon fire contingency. The sprinkler systems are used for the extinguishments of fire in hazards located inside buildings. The requirement of water sprinkler system shall be determined during detailed engineering.

10 HYDROCARBON GAS DETECTORS

The following areas should be provided with hydrocarbon gas detectors: - Light hydrocarbon pumps in process units.

- Fuel gas knock out drum - Suction side of forced draft air blowers if located where hydrocarbon vapours may be

present. - Gas compressor

The exact location and number of points should be decided on need basis.

Following areas shall be provided with Smoke/ Flame / Heat detectors with alarm and/or system to actuate relevant fire suppression system:

- Gas compressors

Additionally, following areas may also be provided with suitable detectors:

- Extremely hazardous area in process units (If applicable ) - Unmanned electric substations / MCC rooms (If applicable ) Cable galleries ( If applicable)

11.0 CLEAN AGENT PROTECTION EXTINGUISHING SYSTEM (If applicable) :

Clean agent is liquefied gas, extra ordinarily effective as fire extinguishing agent. The clean agent system broadly consists of clean agent container, feed lines, ring main/lateral, spray nozzles, signalling equipment, cable, heat detection and activation devices. Clean agent fire system can detect, control & extinguish the fire and also give audiovisual indication to the control panel.

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Clean agent is recommended for protection of control rooms & computer rooms.

The system shall be total flooding, single shot & will be designed in accordance with NFPA 2001.

The areas to be protected with clean agent shall be identified & isolated from other areas by firewalls.

Clean agent system shall be operated by use of smoke detectors of two types, located in cross-zone pattern (different loops). The system could be set on manual mode or auto mode. The discharge piping & nozzles shall be designed in order to allow full discharge of clean agent gas in 10 to 60 seconds depending on the type of agents.

The clean agent shall be stored in CCE approved cylinders. 100% reserve cylinders filled with gas shall be kept so that system after use is made operational without loss of time.

12.0 CARBON DIOXIDE PROTECTION ( If applicable):

Carbon dioxide gas fire extinguishing system shall consist of CO2 storage distribution and discharge nozzles. Fixed CO2 system shall be considered for un-manned electric substations, cable gallery. The areas proposed for CO2 protection shall be identified & the use of the system justified. The system shall be designed in accordance with NFPA-12. Minimum effective time of discharge for computing quantities of CO2 shall be 30 seconds.

13.0 FIRST AID FIRE FIGHTING EQUIPMENT

First aid fire fighting equipment shall be provided in process units, offsite, utilities & buildings etc. The general guideline for use & selection of various types of fire extinguishers is given below. However the guidelines specified in OISD/TAC shall govern.

1 D.C.P. Extinguishers 10Kg cap. Process units, pumps areas, truck loading areas, oil separators, substations, workshops, power stations, laboratory, ware house, repair shop etc.

The number shall be determined based on travel distance of 15 M. At least one extinguisher should be provided for every 250 m

2 area.

2 D.C.P. Extinguisher 50Kg – wheeled units

For critical operating areas like sump pump areas. Process units, loading areas, compressor station

The number should be determined based on max.traveling distance of 50M. At least one fire extinguisher should be provided for every 750 m

2 area.

3 CO2 extinguishers – 6.8 Kgs For power stations, substations etc

The number should be determined based on travelling distance of 15 m. At least one extinguisher shall be provided for every 250 m

2 area.

4 Portable water extinguishers To locate in office, laboratory buildings

One extinguisher for every 250 m2 area shall be provided.

First aid equipment selection should be correctly related to type of fire expected in the area and wrong type of extinguisher should not be located which could be accidentally used.

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14.0 APPROVAL Contractor shall prepare all the necessary Drawings and Documents required for TAC / approval / CCE approval and obtain the approval. The CONTRACTOR shall make arrangement for inspection and testing for TAC or concerned Insurance agencies / statutory authorities at various stages of the work. CONTRACTOR shall be responsible for obtaining maximum rebate on the fire protection System from TAC. The CONTRACTOR at no extra cost shall carry out additions required to Meet the requirement of TAC and to obtain maximum rebate.

15.0 RADIOGRAPHY

At least 10% of all welded joints shall be radiographically tested & shall be found in order. At least 50% of welded joints selected for radiography shall be field joints.

A minimum cover of 1.0 M shall be provided in open areas above buried fire water lines.

All firewater piping shall be hydro tested to a pressure of 18.0 kg/cm²g.

Painting & protective coatings as per the requirement or specification shall be provided by the contractor.

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ANNEXURE-III

TYPICAL HYDRANT AND MONITOR ASSEMBLY DETAILS

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ANNEXURE-IV

SPECIFICATION FOR HYDRANT ACCESSORIES

1) Hydrant Flanges 3" X 2 ½"

3" x 2 ½" Male Hydrant Flange fitted with stainless steel (SS 316) facing, and connected to stainless

steel (SS 316) arrangement. The flanges should be suitable for 3" ASA Flat Face rating 150# as per

our requirement. The Male Coupling should be as per IS:903. The flange shall be painted Fire Red.

Notes :

1. Material should be finished surface smooth.

2. Painted internally with corrosion resistive coating of epoxy paint.

Suggested Vendors : HPCL approved vendors.

2) Hydrant Flanges 4" X 4"

4" x 4" Male Hydrant Flanges fitted with Stainless Steel (SS 316) facing, connected to stainless steel

(SS 316) arrangement. Flanges should be suitable for 4" ASA Flat Face rating 150# as per our

requirement. The Male Coupling should be as per IS:903.

Notes :

1. Material should be finished surface smooth.

2. Painted internally with corrosion resistive coating of epoxy paint.


3) Hose Reel :

Supply of Standard hose reel hose along with hose reel drum with facility of installation at the plant

location, swinging wall mounting type, complete with 19 mm bore, 30 meter long, high pressure

braided rubber hose as per IS:444 Type-II, 6mm bore gun metal shut off nozzle and 25 mm G.M. inlet

valve, confirming to IS : 884.The hose reel drum should be Painted with corrosion resistive coating of

epoxy paint and painted Fire Red.

4) Double Female Coupling - 2 ½"

Double Female Coupling confirming to IS: 901-1975 and bearing an IS Mark. The couplings should be

made out of gunmetal or leaded tin bronze and should be of 2 1/2" size.

The coupling should be of robust construction and with sturdy lugs. The lugs should be provided with

phospher bronze plunger springs. Couplings should be provided with Neoprene washers confirming to

IS: 937 - 1965

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5) Double Male Coupling - 2 ½"

Double Male Coupling confirming to IS: 901-1975 and bearing an IS Mark. The couplings should be

made out of gunmetal or leaded tin bronze and should be of 2 1/2" size. The coupling should be of

robust construction.


6) Fire Fighting (Synthetic) Delivery Hose - (63 mm)

Fully synthetic three layered non-percolating flexible Fire Fighting Delivery Hose, provided with unified

lining & cover of special polymer for protection against contact with oil & chemicals. Hose should be 63

mm (2 ½") dia. in 22.5 meter lengths, conforming and bearing IS : 14933-2001 Type B. Hose should

be fitted with gunmetal heavy duty 63 mm male instantaneous coupling at one end and female

instantaneous coupling at other end. The couplings should be as per IS: 903 and bearing IS mark. The

couplings should be riveted and double bound with 16 gauge copper wire. The coupling should be of

robust construction and with sturdy lugs. The lugs should be provided with phospher bronze plunger

springs. Hose should have 50 Kg/cm2 burst pressure, 30 Kg/cm2 proof pressure and 22 kg/cm2

working pressure.


7) Branch pipe, Universal - 2 ½"

The Branch Pipe, Universal of 2 ½" size as per IS:2871, capable of providing atomised spray and wide

angle curtain in addition to straight jet. The branch pipe should be capable of delivering spray over

range varying from 150 degree to complete shut off. The nozzle should be made out of Copper

Alloy/LTB and chrome plated, It should have good workmanship and finish. The forgings and castings

should be free from pits, blowholes, scales, cracks and other imperfections. The Branch pipe should

be provided with 2 ½" Female Instantaneous Coupling with two lugs as per IS:903.


8) Branch Pipe /Straight Nozzle - 2 ½"

The staraight nozzle of 2 ½" size as per IS: 903, made out of Copper Alloy/LTB. The branch pipe

should have Female Instantenous coupling with two lugs as inlet and the out let nozzle diameter

should be 20mm. It should have good workmanship and finish. The forgings and castings should be

free from pits, blowholes, scales, cracks and other imperfections. The internal surface should be made

smooth and highly polished, no machining ridges should be left on internal surfaces.


9) Stand Post Type Water Monitor :

Stand Post Type Water Monitors of 75mm size confirming to type-I of IS 8442 and bearing the IS

mark. Monitor should have capacity of 2580-LPM water flow at 7 Kg/cm2 and nozzle size of 38-mm.

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Horizontal range of 60 meter and vertical reach of 28 meter. The monitor should be suitable for

continuous salt-water use.

1. Base Flange: Flat face ASA 3" x 150# size made out of MS confirming to IS: 6392.

2. Body and Water Barrel: Should be 75mm made out of seamless MS as per BIS:1239 coated

internally with Araldite paint and monitor should be externally painted with Fire Red color shade no

536. The barrel should be provided with internal deflector so as to prevent whirling of water flow.

3. Swivel Joint: Swivel joint should be made out of copper alloy, and should be serviceable. The

copper alloy should confirm to Grade 2/3 of IS 310-1962/ grade 3 of IS 304-1961. The swivel joint

should be water tight and serviceable and provided with grease nipples. Test pressures 30 Kg/cm2.

4. Rotation: The monitor should be capable of rotating 360 Degrees Horizontally and -45 Deg to 80

Deg Vertically.

5. Locking Studs: The locks of the Horizontal and vertical rotation should be made out of brass

confirming to IS: 291-1961.

6. Water Nozzle: The nozzle should be made out of copper alloy confirming to Grade 2/3 of IS: 318

(sand Casting) with orifice diameter of 38 mm. It should be free from any casting defects.

7. Handle: Made out of MS should be threaded & tag welded to the bend in main body.

8. Drain Valve: The drain valve should be made out of brass and should be provided at the base

flange.

Note:

1. The shape of the monitor should be so designed that it will allow free flow of water with minimum frictional loss and maximum stability against nozzle reaction.

2. Material should be finished surface smooth. 3. Painted internally and externally with corrosion resistive coating of epoxy paint and painted Fire

Red.


10) Specifications of 10 Kg DCP Fire Extinguishers

Fabrication and supply of 10 Kg DCP extinguishers from the manufacturer of DCP Fire extinguishers,

conforming and bearing IS:2171-1985 mark. These extinguishers should satisfy following conditions.

1. Extinguisher shall be suitable for fighting Class B & C type of fires, and should be upright operated.

2. The Extinguisher body should be 2mm thick, deep drawn propellant container made up of Mild Steel as per IS: 513 (i.e. extinguisher body without vertical weld joint). The body of extinguisher should have dimensions of out side diameter 175 and overall height 600mm (Approx)

3. CO2 Cartridge inside the extinguisher shall have IS : 4947-1985 certification mark and manufacturers certificates.

4. Discharge Hose, Control (squeeze grip) nozzle and its fittings should be tested at higher pressure of 30 Kg/cm2.

5. Dry Chemical Powder should be Mono Ammonium Phosphate base (ABC Dry Chemical Powder) . Base and IS:14609 marked

6. Anti-corrosive Treatment : The Extinguisher body shall be internally and externally shall be completely coated with lead-tin alloy anti corrosive treatment by electrolytic deposition or hot dipping process to thickness not less than 0.012mm. Extinguisher shall be externally finished with epoxy polyester powder coating of 50 micron thickness to all external surfaces.

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7. Fabrication will be subject to following Stage wise inspection. a. Inspection of raw plates (materials) b. Design drawing of extinguisher to be approved by Manger-Fire & Safety (HPCL) c. Procedure for making body shell stage wise i.e. rolling, weld joints. d. Dye penetration examination of fillet welds of all nozzles and attachments. e. Hydro testing of body shell along with the Extinguisher cap at 30 Kg/sq.cm. without painting. f. Inner container to be tested for workmanship and finish. g. One extinguisher out of the lot of 50 will undergo internal gas pressure test for full assembly,

i.e. when gas cartridge is pierced open with discharge nozzle shut the pressure inside should not exceed 15 Kg/sq.cm.

h. One Extinguisher out of lot of 50 will undergo full performance testing as per IS:2171 i. Spot Radiography of welds on all the cylinders using X-rays/Gamma Rays. 10% of weld

joints to be radio graphed. Interpretation of the radiographs should be as per IS : 2825. j. Overall workmanship and finish to satisfy our inspection.

8. The Stage-wise Inspection will be carried out by Third Party and Performance test will be jointly certified by Third Party & HPCL at the time of delivery.

9. Manufacturer should submit Quality Assurance Plan for review and approval of HPCL. 10. Vendor should have capabilities of manufacture & supply extinguishers in lots larger than 400,

the sufficient proof of such previous supply should be submitted along with Bids. 11. The bids to be submitted in two bid system (Priced & unpriced seperatly) 12. Inspection charges will be bourn by the manufacturer. 13. The Inspection will be carried out by HPCL representative and Third Party Inspection to be

carried out by one of the following agencies M/s LRIS (Lloyds), BVIS (Bueru Veritas), DNV, CEIL (Inspection Agency of EIL).

14. The Extinguisher cap should have chain arrangement to prevent theft. i.e. chain to be fixed. 15. The extinguisher should be labelled as per IS, the label should include

a. Extinguisher operating procedure including picture of man operating Extinguisher. b. Hydro testing date & Pressure c. Manufacturers name and serial number permanently marked. d. Embossing/permanent metal plate with HPCL logo with Mumbai Refinery on each

Extinguisher.


11) Specifications of 6.5 Kg Carbon Dioxide Extinguishers with Trolley (if applicable)

General: Fabrication and supply of 6.5 Kg carbon dioxide extinguisher shall conform and bear IS-

2878-2004 mark. It shall be CCOE approved. Extinguisher shall be mounted on solid rubber trolley

conforming to IS-2878.

Construction :

1. Body: 6.5 kg CO2 extinguisher shall be made out of brand new seamless steel, cylinder as per IS-

7285.

2. Discharge Valve : Shall be wheel type , brass as per IS-3224

3. Safety device : Conforming to IS -5903, shall be in built in discharge valve conforming to IS-3224

4. Syphon Tube: Shall be made of Brass, Alloy No2 of IS-407

5. Hose: It should not be less than 1 meter. Hose should be high pressure wire braided discharge

hose. The minimum bursting pressure shall be 275 kg/cm2 in control discharge and 140 kgf/cm2

without control discharge.

6. Discharge Horn: It shall be made of materials which are non conductor of electricity, like

polyethylene, fiber- glass. Discharge horn with suitable handle shall be provided.

7. Inspection: Fabrication will be subjected to following stage wise inspection.

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a) Inspection of raw plates (Materials). Co-relation checking thickness of plate and witnessing of test

at random sample.

b) Design drawing of extinguishers to be approved by HPCL.

c) Each cylinder shall be examined before final closing in operation for external and internal surface

defects; finished thickness and circularity of the cylindrical shell. All these things will be checked as

per- IS-2804-2004.

d) Mechanical tests will be carried out as per IS-2878:2004

e) Volumetric expansion Testing of seamless containers will be carried out as per IS-2878:2004

8. Anti Corrosive treatment: The external surface of the body shall be completely coated with epoxy

powder of minimum 0.050 mm thickness.

9. Painting:

a) Each extinguisher shall be painted Fire red conforming to shade No 536 of IS-5

b) The picture showing operation of the extinguisher in the correct manner shall be provided on the

body of the extinguisher.

c) Extinguisher shall be marked with letter “B” & “C” indicating their suitability for respective classes of

fire as laid down in IS-2190

10. Performance requirement :

a) 8% of the extinguisher (Randomly selected) will undergo performance testing. 1/3 of the sample will

undergo for discharge duration, 1/3 for intermittent operation and 1/3 for leak test.

b) Extinguisher will be subjected to Class B test, as mentioned in IS-2804:2004.

11. Manufacture shall submit Quality assurance Plan for review and approval of HPCL

12. Third party Inspection to be carried out by one of the following agencies like M/S LRIS (Lloyds);

BVIS (Bueru verities), DNV, CEIL ( Inspection agency of EIL) and

13. The stage wise inspection will be carried out by third party and performance test will be jointly

certified by third party and HPCL at the time of delivery.

14. Manufacturers shall furnish test certificate about conformity of various components.

15. The cylinder shall be fully charged with CO2 gas. CO2 gas shall conform to IS-15222

16. Trolley: The dimension of the trolley shall be 132 mm x 28 mm x 20 mm. Extinguisher shall be

mounted over trolley. Solid rubber trolley wheels conforming to IS-2878 shall be provided.

17. All test certificates from various agencies like Chief controller of explosives; Third party inspection

report has to be submitted at the time of delivery.


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ANNEXURE- V

SPECIFICATION FOR HIGH VOLUME LONG RANGE MONITOR

1. General

Long range of capacity 500-2000 gpm (1900-7600 lpm) Water/Foam monitor complete with nozzle for

mounting on Fire Water Network for Unit equipment protection. The monitor will be mounted on 6”

flange of fire water network. The monitor will be fed with water from fire water network. The monitor

should be able to give non-aspirated hollow jet throw and spray pattern of 0 – 160 Degree.

2. Monitor

A compact duel hand wheel controlled monitor with cast-in turning vanes for flow streamlining, should

have full 4" oval shaped single waterway. The monitor should be forged construction for advantage of

seamless welding for longer life. Monitor should be capable of full 360 Degree horizontal travel and

135 Degree vertical travel, both with adjustable stops. It should have smoother, easier hand wheel

operation of both horizontal and vertical travel. Monitor should be suitable for fixed installation. The

monitor should have wheel handles for horizontal & vertical movement. The swivel joint and control

mechanism should be well protected from dust, water & environment with ingress protection

equivalent of IP65.

a) Inlet : 4” ASA 150#, Flat face flange.

b) Outlet : 3.5” NH

c) Flow : 2000 gpm (7600 lpm)

d) Height : 18” (Max)

e) Material of construction : Brass - suitable for usage in sea water service.

3. Nozzle

Nozzle should be capable of giving 0 to 160 Degree spray pattern. It should have manual pattern

selection from straight stream to wide fog with knurled locking handle for positive positioning. The

nozzle should have two large pattern control handles for easier pattern change and have a 3 ½" swivel

base for connection to monitor. The nozzle should be self pressure balance to automatically adjust the

discharge from 500-2000 gpm according to input pressure & flow, this should allow the monitor to give

maximum reach even when operated at lower discharge/pressure.

a) Inlet : 3.5” NH swivel inlet.

b) Pattern control : Manual with detents on control ring.

c) Flow rate : 500 – 2000 gpm (1900 – 7600 lpm) automatic adjustment

d) Operating pressure : 80 psi.

e) Material of construction : Brass - suitable for usage in sea water service

4. Reach

Straight Stream reach of minimum 75 Mtrs @ 80 psi nozzle pressure with 1000 gpm (3800 lpm) flow in

still wind condition minimum 95 mtrs with 2000 gpm flow.

5. Painting

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The monitor should be painted externally with polyurethane based fire red paint to avoid abrasion &

corrosion.

6. Testing / Inspection

The monitor will be tested at vendor’s manufacturing facility for intended performance in presence of

HPCL approved third party. The cost of inspection will be borne by the vendor. Monitor will not be

accepted if it do not perform as per these specifications.
