NUMALIGARH REFINERY LTD.nrl.etenders.in/tnduploads/nrl/pressnotices/PRSN230.pdf · · 2012-11-15numaligarh refinery ltd. (a govt. of india enterprise) project : ... pipe size pipe

NUMALIGARH REFINERY LTD.

(A GOVT. OF INDIA ENTERPRISE)

PROJECT : ADDITIONAL TANKAGES AND

ASSOCIATED FACILITIES AT SMT

IOT DESIGN & ENGINEERING LTD.

SCOPE OF WORK AND SUPPLY DISCIPLINE:

INSTRUMENTATION

REV NO : R2

ISSUE DATE : 17/08/2012

DOC NO : 10096-60-N-111 PAGE NO. 1 OF 4

This document is the property of M/s. IOTDE and must not be copied, used & reproduced without written permission from M/s IOTDE.

SCOPE OF WORK AND SUPPLY







INSTRUMENTATION

REV NO : R2

ISSUE DATE : 17/08/2012

DOC NO : 10096-60-N-111 PAGE NO. 2 OF 4


1.0 GENERAL

1.1 M/s Numaligarh Refinery Limited (NRL) has set up a receipt, storage and dispatch

terminal at Siliguri (Rangapani) for marketing of white oil products. The white oil products

(MS, SKO and HSD) are received from Numaligarh-Siliguri Pipeline to be operated by Oil

India Limited (OIL). The products are received, stored and dispatched through rail and road

loading gantry in the terminal. Now NRL has planned to increase the storage capacity of the

existing terminal by installing 2 nos. of HSD storage tank & 1 no. of MS storage tanks and

associated facilities.

1.2 M/s. IOT Design & Engineering Limited (A 100% owned subsidiary of IOT) has been

engaged as Project Management Consultant (PMC) for the above works.

1.3 In view of the above NRL intends to procure 12 Nos. of Motor Operated Plug Valve of

various size as mentioned in scope of supply.

1.4 This document describes the minimum requirement for the additional Motor Operated Valve

with actuator and necessary accessories to integrate with the existing facilities mentioned

elsewhere in this bid document.

1.5 The scope of this tender shall include Design, Engineering, Supply, Installation, Testing,

Integration with the existing Rotork make Motor Control Station and Commissioning of the

system.

2.0 SCOPE OF SUPPLY

2.1 Vendor scope of supply shall include the following as a minimum:

Sl.

No TAG NO.

PIPE

SIZE

PIPE

MATERIAL

PIPE

RATING SERVICE

1 MOV-1114 24” CS 150# MS

2 MOV-1111 14” CS 150# MS

3 MOV-1112 24” CS 150# MS

4 MOV-1113 8” CS 150# MS

5 MOV-1325 24” CS 150# HSD

6 MOV-1326 24” CS 150# HSD







INSTRUMENTATION

REV NO : R2

ISSUE DATE : 17/08/2012

DOC NO : 10096-60-N-111 PAGE NO. 3 OF 4


7 MOV-1319 14” CS 150# HSD

8 MOV-1320 14” CS 150# HSD

9 MOV-1321 24” CS 150# HSD

10 MOV-1322 24” CS 150# HSD

11 MOV-1323 16” CS 150# HSD

12 MOV-1324 16” CS 150# HSD

3.0 SCOPE OF SUPPLY

Vendor Scope of supply and work shall include but not limited to the following:

a. Design, Engineering, Testing, Third Party Inspection, Packing, Supply and

commissioning of 12 Nos. of Motor Operated Plug Valve of various as mentioned in in

the table above.

b. Configuration and Integration of serial interface cables with the existing network through

the existing Rotork make motor control station..

c. Packing, forwarding, transportation, custom clearance, insurance, storage at site

including unloading, keeping under safe custody and shifting to Site.

d. Documentation, Warranty and post-warranty maintenance etc.

4.0 SPARE PHILOSOPHY

4.1 The bidder shall quote for the spares to cover the various categories of spares for instruments

along with corresponding activity/services as listed below:

a. As part of lump sum quote:-

i) Lump sum Installed engineering spares as part of the additional design & engineering

needed for the expansion project shall be supplied and implemented.

ii) Lump sum commissioning spares including consumable as part of commissioning

activities.

iii) Lump sum mandatory spares.







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REV NO : R2

ISSUE DATE : 17/08/2012

DOC NO : 10096-60-N-111 PAGE NO. 4 OF 4


iv) Lump sum Warranty (2 Years) Spares:

Operational and maintenance Spares as per the recommendations of the respective

equipment manufacturer, for trouble free & uninterrupted operation including consumable

for 24 months.

5.0 EXCLUSIONS

a. Supply of Signal cables,

b. Supply of Power Cables

c. Supply of Control Cables.

d. Engineering at PLC end

e. Laying of Cable and tray

f. Construction of RCC Trenches in the field



PROJECT: ADDITIONAL TANKAGES & ASSOCIATED FACILITIES AT SMT


VENDOR DATA REQUIREMENT DISCIPLINE:

INSTRUMENTATION

REV NO : R0 ISSUE DATE : 19/11/2010

DOC NO : 10096-60-N-112 PAGE NO. 1 OF 2


VENDOR DATA REQUIREMENT FOR

MOTOR OPERATED VALVE

Prepared By Checked By Approved By

SD GP NM





VENDOR DATA REQUIREMENT DISCIPLINE:

INSTRUMENTATION


DOC NO : 10096-60-N-112 PAGE NO. 2 OF 2


SL. NO.

Description With bids

Post order Final documents with equipments For

review For ref/ records

01 Vendor drawing / document submission schedule * *

02 List of deviations, if any ,to MR requirements * 03 Data sheet (dully filled in) * * * 04 G.A drawings and mounting details of Valve

and actuators * * 05 Wiring and connection diagrams * * 06 QA plan of vendor * * 07 Shop inspection plan and testing procedure * * 08 Test records * 09 Type test Certificates for

flameproof/explosion proof equipment * * * 10 Recommended maintenance spares with

prices * 11 Equipment storage procedure at site *

Data Books/ manuals 12 Installation manual and standard * 13 Operating and maintenance manual * 14 Catalogues/brochures indicating complete

technical details and data for actuator selection

* *

15 Details of fire proofing, if specified in data sheet

16 Details of 2 wire control system, if specified in data sheet

# COMPLETE DATA REQUIRED NOTES-

1. Unless agreed otherwise, the number of copies of various drawings and documents shall be as follows: a. With bids : Same as the number of copies of bids b. Post order submission : for review/ records Four copies c. Final documents : Six prints and one electronic file.

2. Vendor shall submit Schedule of Vendor Drawings and Documents within 15 days after placement of FOI/ TOI.

3. Data not submitted with offer to be supplemented.




DATA SHEET FOR PLUG VALVE DISCIPLINE:

INSTRUMENTATION


DOC NO : 10096-60-N-311 PAGE NO. 1 OF 2


DATA SHEET FOR PLUG VALVE




DATA SHEET FOR PLUG VALVE DISCIPLINE:

INSTRUMENTATION


DOC NO : 10096-60-N-311 PAGE NO. 2 OF 2


PLUG VALVE SPECIFICATION

MANUF'S OFFER TAG NO. : SEE LIST PIPING CLASS : A10A, A1A RATING : 150 STANDARD : BS-5353 SIZE RANGE : 0.5" TO 24.0" ENDS : FLGD TO B-16.5 RF/125AARH

STANDARD: MFGRS CAT/FIG: RATING: ENDS:

DESCRIPTION CONSTRUCTION MATERIAL CONSTR. MATERIAL

BODY CAST A 216GR.WCB COVER BOLTED ASTM A 216 GR.WCB PLUG & STEM INVERTED,TAPER A 216GR.WCB, CASE HARDENED & BONDED

WITH LOW FRICTION COATING

GLAND BOLTED A216 WCB STEM SEAL/GLAND PACKING RENEWABLE

GRAFOIL RINGS/GRAPHITED ASBESTOS WITH SACRIFICIAL CORR. INHIBITOR & INCONEL

WIRE REINFORCEMENT

LUBRICANT SCREW WITH CHECK VALVES SS 410 COVER BOLTS ASTM A 193 GR. B7 COVER NUTS ASTM A 194 GR. 2H COVER GASKET SP WND SS316-CA FILLER/GRAFOIL FILLER

OTHERS LUBRICATED,PRESS URE BALANCED TYPE

REQUIREMENT OF GEAR OPERATOR REFER TECHNICAL NOTES FOR PURCHASE OF

VALVES.

REQUIREMENT OF RADIOGRAPHY REFER TECHNICAL NOTES FOR PURCHASE OF

VALVES.

SPECIAL SERVICE CONDITIONS HYDROCARBON, MAX. TEMP 250 DEG. C.

HYDROSTATIC TEST PRESSURE BODY : 450 PSIG SEAT : 325 PSIG

TEST PR. WITH AIR 80 PSIG NOTES 1 THIS VALVE SPEC SHEET SHALL BE READ IN CONJUNCTION WITH TECHNICAL NOTES FOR VALVES. 2 BIDDER SHALL CLEARLY WRITE ALL/ ANY DEVIATION AGAINST EACH PART/ MATERIAL OF VALVE IN THE

SPACE PROVIDED FOR. WHEREVER BIDDER AGREES WITH ABOVE SPEC BIDDER SHALL INDICATE "AGREED". 3 NO CUTTING/ OVERWRITING BY BIDDER ON ABOVE SPEC IS ALLOWED. 4 PLUG VALVES IN ACCORDANCE WITH API-599 / API-6D ARE ALSO ACCEPTABLE.

5 FOR API 6D STD VALVE MIN. BODY WALL THICKNESS SHALL BE AS PER API 599/BS 5353. 6 TESTING SHALL BE AS PER BS 6755(PART-I)/API 598/API 6D AS CALLED OUT IN RESPECTIVE DESIGN

STANDARDS. 7 FOR WRENCH OPERATED VALVES, SEPARATE WRENCH REQUIRED FOR EACH VALVE.

8 VALVE POSITION INDICATOR SHALL BE PROVIDED. 9 VALVES SHALL BE FIRE-SAFE DESIGN AS PER BS-6755(PART-2) / API-607, 4TH EDITION/ API-6FA 10 VENDOR SHALL CONFIRM SUITABILITY OF LUBRICANT WITH RESPECT TO SERVICE AND SERVICE

CONDITIONS SPECIFIED. 11 BIDDER TO SUPPLY LUBRICANT FOR TWO YEARS OF NORMAL OPERATION. 12 5% VALVE CASTINGS SHALL UNDERGO RADIOGRAPIC EXAMINATION FOR SIZES UPTO 24". 13 UNLESS OTHERWISE SPECIFIED IN MR, VALVES SHALL BE SHORT PATTERN TYPE UPTO 12" AND VENTURI

TYPE ABOVE 12" SIZE. 14 GLAND PACKING MATERIAL SHALL BE PROVIDED WITH CORROSION INHIBITOR.




DATA SHEET FOR MOTOR OPERATED ACTUATOR DISCIPLINE:

INSTRUMENTATION


DOC NO : 10096-60-N-312 PAGE NO. 1 OF 3


DATA SHEET FOR MOTOR OPERATED ACTUATOR


SD GP NM





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DOC NO : 10096-60-N-312 PAGE NO. 2 OF 3


Site Conditions

01 Design ambient temperature 65 deg. C 02 Relative Humidity Min-40% max.-87% 03 Operating ambient temperature 10-34 deg. C 04 Project Site Siliguri

05 MOV Tag Nos Will be intimated after award of contract

System Conditions

06 Supply Voltage 415V±10%,3-phase AC for MOV 07 Supply Frequency 50Hz± 3% 08 System Earthing Solidly Earthed

Operating Environment

09 Area Classification Zone 2 10 Gas Group IIA/IIB 11 Temperature Class T3 12 Enclosure Flameproof Ex(d) 13 Ingress Protection IP66 14 Painting Epoxy base

Valve Duty, Mode of

Control and Devices for

Control

15 Fully open and fully closed Yes 16 Control Requirement Local & Remote for all MOVs 17 Local/ Remote selector switch Required 18 Compatibility for interfacing with 2 wire control system

19 Setting of adjustable parameters

From field & remote through Master Control Station/ PLC for 2 wire control(Existing Master control station is of Rotork Make)

20 Continuous position indication :Local Mechanical/ LCD indication required

21 Potentials free contacts for Indication On remote panel and other interlocks

For Valve open position : Required For valve closed position: Required

22 For remote indication of position of Local/Remote selector switch

23 Maximum time of operation - Opening : 120 sec - Closing : 120 sec

24 Make of MOV Actuator Rotork or Equivalent make

26 Double Compression Gland & plugs (for unused entries) , to be supplied With actuator

Flameproof and weather proof

Certificates 27 Submission of type test certificates - Along with the offer Notes: 1.0 Two separate earthing bosses shall be provided in each actuator. All the actuators shall be

controlled through 2 wire control station. The Master station is already available with the owner. The new actuators shall be hooked to the existing Master station. Vendor to quote rates including Internal Field Control Unit (IFCU) for actuators suitable for 2 wire control system.





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DOC NO : 10096-60-N-312 PAGE NO. 3 OF 3


2.0 The purchaser shall provide single point power supply to the actuator as per above. Any other control supply voltage required shall be internally derived by the manufacturer within the actuator.

3.0 In case “Remote continuous position indication” is required as per above, the potentiometer/

transducer required for position indication along with loose remote continuous position indicator shall be included in the quoted prices of respective MOV Actuator and supplied with it.

5.0 Vendor shall furnish complete data as per this data sheet for each MOV Actuator along with the

offer. 6.0 Remote Input signals for opening/ closing/ Stopping the MOV shall be provided through the

momentary closing of separate potential free contacts in owner’s panel. Necessary controls required for running the motor for the complete opening/ closing sequence of the valve using such input signals shall be provided by manufacturer in the actuator.




STANDARD SPECIFICATION FOR PLUG VALVE DISCIPLINE:

INSTRUMENTATION


DOC NO : 10096-60-N-211 PAGE NO. 1 OF 16


STANDARD SPECIFICATION FOR PLUG VALVE


SD GP NM





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DOC NO : 10096-60-N-211 PAGE NO. 2 OF 16


CONTENTS

CLAUSE NO. ITEM PAGE NO.

0.0 Index 2

1.0 Scope 3

2.0 Reference 3

3.0 Materials 3

4.0 Design and Construction 4

5.0 Inspection and Test 5

6.0 Test Certificate 6

7.0 Painting marking and shipment 6

8.0 Spare and Accessories 7

9.0 Documentation 7

10.0 Rejection 8





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DOC NO : 10096-60-N-211 PAGE NO. 3 OF 16


1.0 SCOPE: This specification covers the broad requirements for Design, manufacture, testing, inspection and supply of Carbon steel Plug valves with Motor operated Actuator (Rotork or equivalent) of various sizes as specified in the tender of Class 150# for finished Petroleum product service.

2.0 REFERENCE: 2.1 All the valves covered herein shall be manufactured & supplied in accordance with BS-5353

Specifications. 2.2 Additional requirements over and above BS-5353 requirements if any have been specified in

this Specification. 3.0 MATERIALS: 3.1 Materials for Major components shall be manufactured in accordance with Valve Data Sheet

enclosed. Other components shall be as per Manufacturer’s Standards duly approved vide QAP/ITP by NRL.

4.0 DESIGN AND CONSTRUCTION 4.1 Valves 4.1.1 Valve design shall meet the requirements of BS-5353 Specification and shall be suitable for MS

/HSD service in accordance with conditions stipulated in the Valve Data Sheet. Allowable stress requirements shall comply the provisions of ASME B31.3.The Corrosion allowance indicated in the Valve Data Sheet shall be considered in the valve design and the minimum wall thickness shall not be less than the minimum requirement of ASME B16.34.

4.1.2 Cover shall be bolted to the Body. Screwed connections are not permitted. 4.1.3 All valves shall have the provision for secondary sealant injection under full line pressure for

seat and stem seals through an internal Non-Return Valve. There shall be a provision (viz., Ball type Check valve/ needle Valve) to replace the sealant injector fitting under full line pressure.

4.1.4 Valve design shall ensure repair of gland packing under full line pressure. 4.1.5 Valve ends shall be flanged as per Valve Data sheet. Flanges shall be cast integral with the

Valve Body and Face to face/ end to end dimensions shall conform to BS-5353. 4.1.6 The valves shall be provided with plug Position indicator and stops of rugged construction at

the Open and Fully closed positions.





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DOC NO : 10096-60-N-211 PAGE NO. 4 OF 16


4.1.7 The valves shall have locking devices to lock the valve in LO or LC position. Locking devices shall be permanently attached to the valve operator and shall not interfere with operation of the valve.

4.1.8 Valves shall have a power actuator with manual operator as indicated in the valve data sheet. In

case of manual operator the valves shall be gear operated. Valve design shall be such that damage due to malfunctioning of the operator or its controls will only occur in the operator gear train or power cylinder and that damaged parts can be replaced without the valve cover being removed.

4.1.9 The power actuator shall be in accordance with the specification issued for the purpose.

Operating Time shall be as indicated in Valve Data Sheet. Valve operating time shall be as indicated in Valve Data Sheet. Valve operating time shall correspond to Full Close to Full Open/Full Open to Full Close under maximum differential pressure corresponding to the valve rating. For actuator valves, the actuator rated torque output shall be at least 1. 5 times the break torque required to operate the valve under maximum differential pressure corresponding to the valve class rating.

4.1.10 For the manual operator of all valves, the diameter of the hand wheel or the length of operating

wrench shall be such that under the maximum differential pressure, total force required to operate the valve does not exceed 350 N. Manufacturer shall also indicate the number of turns of hand wheel (in case of gear operator) required to operate the valve from Full Open to Full Close position.

4.1.11 Direction of operation of the hand wheel/ wrench shall be in clockwise direction while closing

the valve. 4.1.12 Gear operators, when provided shall have a self locking provision and shall be fully encased in

water proof/ splash proof enclosure and shall be filled with suitable grease. 4.1.13 Repair by welding is not permitted for fabricated and forged body valves. However, repair by

welding is permitted in case of cast Body valves. Repair shall be carried out before any heat treatment of casting is done.

4.1.14 Valve stem shall be capable of withstanding the maximum operating torque required to operate

the valve against the maximum differential pressure corresponding to applicable class rating. The combined stress shall not exceed the maximum allowable stresses specified in ASME Section 8,divn.1.For power actuated valves, the valve stem shall be designed for maximum output torque of the selected power actuator including gear box, if any at the valve stem.

4.2 Motor Operated Actuator





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DOC NO : 10096-60-N-211 PAGE NO. 5 OF 16


4.2.1 Actuators which are self-contained package units shall be used for electrical operation of valves. Each actuator shall comprise a three-phase electric motor, reduction gearing, reversing contactor starter complete with local controls, turns and torque limitation facilities, electronic logic controls and monitoring facilities.

4.2.2 Actuators shall be suitable for use on 415 volt 3 phase 50 Hz power supply. If required the

actuator motor and starter shall be provided with heaters to prevent condensation. 4.2.3 All actuator shall be O-ring sealed, watertight and dustproof to IP65 and shall at the same

time have an inner watertight and dustproof O-ring seal between the terminal compartment and the internal electrical elements of the actuator, fully protecting the control mechanism, motor and all other internal electrical elements of the actuator from ingress of moisture and dust when the terminal cover is removed on site for cabling.

4.2.4 Enclosure shall be rated explosion proof Ex ‘d’ and suitable for installation in Zone 1IIA/IIB,

Temperature Class T3 electrical area classification. The actuator shall be sized to guarantee valve closure and provide sufficient thrust to position and fully stroke the valve against the maximum differential pressure that may develop under the specified process and/or start-up conditions. Particular attention shall be paid to unbalanced dynamic forces on the valve disc. For actuator sizing, the shutoff differential shall be considered at full differential pressure. The full differential pressure for actuator sizing shall be assumed as the maximum upstream pressure with the valve fully closed and downstream pressure as atmospheric.

4.2.5 The safety margin of motor power available for seating and unseating the valve shall be

sufficient to ensure torque switch trip at maximum valve torque with the supply voltage at 10% below nominal. The operating speed shall be such as to give valve closing and opening rate at approximately 10-12 inches per minute.

4.2.6 The actuator shall be available with mounting base and output drive couplings

conforming to ISO 5210. 4.2.7 A lockable hand/auto lever shall be provided to engage hand wheel operation. Energization of the motor shall automatically re-engage power operation. Two selectors shall

be provided on the actuator, one for Local/Stop/Remote selection, and with pad-lockable for each position and the other for Open, Close and Stop Commands.

4.2.8 Electronic “latching” shall be provided for the torque sensing system to inhibit torque off

during unseating or during starting in mid- travel against high inertia loads. A jammed valve protection circuit shall de-energize the motor after a few seconds, if no movement occurs after receipt of a signal to open or close.

4.2.9 A local display shall give continuous indication of the actuator position





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DOC NO : 10096-60-N-211 PAGE NO. 6 OF 16


4.2.10 A separately sealed compartment containing segregated power and control terminals shall be provided. Earthing terminals shall be provided at the external of MOV. The common connection of the contactor coils at the transformer shall be grounded so that the contactors drop out in the event of a leakage to ground. The primary winding shall be separated from the secondary by a grounded screen. The secondary output shall be protected by a fuse of an easily replaceable cartridge type.

4.2.11 An instruction handbook and wiring diagram shall be enclosed with each actuator. A durable

terminal identification card shall be provided attached to the inside of the terminal box cover indicating the following:

♦ Serial number ♦ External Voltage values ♦ Wiring diagram number ♦ Terminal Layout ♦ Valve Actuator Interface

4.2.12 Actuator Torque Requirement

a. “Actuator design torque” shall be based on maximum valve pressure rating ANSI Class #150 at design temperature and additional safety margin of 25% (1.25x). It actuator shall be capable of opening the valve with the maximum differential pressure across the valve (equal to the maximum specified design pressure on one side and atmospheric pressure on the other side).

b. It shall be based on a valve torque test as defined in API 6D, Appendix-C.

SL. NO. VALVE ACTUATOR

1 (Start-to-close torque)/ (Start-of-stroke torque close)/ (Open-to-close break torque)

Spring-start-torque (SST) A safety margin of 1.25 x shall be applied on top of the valve start-to-close torque. (i.e. 25% more)

2. Running Torque Spring-running-torque (SRT). A safety margin of 1.25 x on top of the required valve running torque shall be maintained. (i.e. 25% more)

3. Reseat Torque/ (Closing torque)/ (End-of-stroke torque)

Spring-end-torque (SET) A safety margin of 1.25 on top of the valve closing torque shall be applied. (i.e. 25% more)

c. The Bidder shall specify maximum actuator torque. The Bidder shall specify and tabulate in his quotation the required torque figures for each valve and the delivered torque figures by the. The torque values shall be expressed in Newton meter (N-m) and shall be given for the following valve positions:





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DOC NO : 10096-60-N-211 PAGE NO. 7 OF 16


i) Start to open torque (breakaway torque) ii) Lowest running torque during opening of the valve iii) End of opening torque (valve fully open) iv) Start to close torque (breakaway torque) v) Lowest running torque during closing of the valve. vi) End of closing torque (reset torque, valve fully closed).

d. Bidder shall mention in the offer the values of the torque for – i. Valve stem shear torque. ii. Maximum torque output of actuators. 4.2.13 MOV control system shall be complete in all respect to execute controls and provide data on

operation variables for the actuator to ensure efficient operation of the Motor operated valves including partial stroke testing.

4.2.14 Actuator shall be suitable for 2 wire control system. Only Open Protocols such as

MODBUS RTU is acceptable. It should be possible to integrate the Actuator with MODBUS RTU protocol with Intermediate Master Station. The Master Station shall then be interfaced with TAS PLC system. Actuator Communication system & TAS PLC shall have seamless interface & shall be redundant.

4.2.15 The paramount reason for MODBUS RTU open protocol is to have seamless interface

communication with various makes of actuators on same loop with out any additional hardware & software. Valve bidders & Actuator vendors shall guarantee the performance of MOV & its MODBUS interface with TAS PLC & with other Actuated valves on same multi drop cabling loop for faster communication.

4.2.16 The system shall basically consist of a central control unit communicating to various field

interface modules (located inside individual Motor operated Valve actuator housing) over a communication network.

4.2.17 The control system shall be capable of controlling a minimum of 200 field devices over a

single or multiple network meeting the performance requirement specified here under. 4.2.18 The MOV control system shall support the quarter turn on/off valves such as plug valves,

ball valves & triple offset butterfly valves. It shall also support the linear control valves. 4.3 Field Control Unit 4.3.1 The field control unit shall be integral to actuator and shall be powered from the actuator

power supply. No separate power supply shall be provided for operation of field unit 4.3.2 The field control unit shall be able to execute the following operational commands





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DOC NO : 10096-60-N-211 PAGE NO. 8 OF 16


• Fully Open/Close the valve. • Inching control • Emergency shut down (Hardwired contacts from TAS PLC shall be provided for ESD actuation) • Emergency shut down (ESD) signal shall over-ride any other signal command including

motor winding temperature bypass. • 2 wire communication with TAS PLC (through master control station as

applicable) 4.3.3 Following signals and alarms shall be transferred by field control unit over the

network: • Continuous valve position • Valve opening • Valve closing • Valve open • Valve close • Valve stopped • Local push button depressed • L/R in remote • Torque switch tripped • Loss of main power • Loss of control power

In addition to above the following diagnostic alarms shall also be transferred: • Actuator fault • Field unit fault • Loss of phase • Thermostat tripped • Torque switch tripped • Valve jammed • Contactor fails to energize

4.3.4 Actuator/ field control station shall accept hardwired contacts for emergency operation or

emergency shutdown operation of the valve in addition to serial two wire signal. 4.4 Master Station (Central Control Unit) 4.4.1 Supply of Microprocessor based Master control station provided to control and monitor all

motor operated valve actuators is in the scope of this tender. Master station shall be housed in panel located in instrument equipment adjacent to main control room and interfaced with plant PLC through redundant communication link. Plant PLC and master station will operate on master/slave mode. Master station shall receive commands like open/close/stop from the PLC and shall operate the valves. All information about all actuators shall be available at PLC





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DOC NO : 10096-60-N-211 PAGE NO. 9 OF 16


through master station. 4.4.2 Master Control Station (MCS) unit shall be complete with a dedicated keyboard and a display

unit. It shall be possible to operate the actuators and configure the network devices from the keyboard/display unit. Protection shall be provided in the MCS for selecting configuration mode.

4.4.3 Master station/Central control unit shall have the following minimum features: - 4.4.3.1 Each Mater station/Central control unit shall have capacity to connect and control

minimum 240 motor. Motor Operated valves. It shall have provision for extending the no. of nodes in case required in future.

4.4.3.2 It shall have REDUNDANCY in communication, processor and power supply and there shall

be bump less transfer in case of failure of any one of the above. Master station/Central control unit shall be with dual redundant configuration in such a way that failure of one processor unit shall automatically transfer the control to the redundant unit.

4.4.3.3 The switch over time shall be of the order of 100 msec. The output shall hold to the last state

during switch over. 4.4.3.4 The system software shall include all software necessary for operation, displays and

configuration of the complete system, along with software for communication with TAS PLC. Software shall also be provided for the detailed diagnostics within the system including in the master control unit and in the network. The system shall also be capable to display all diagnostic alarms including those for field control units, network and of central control unit. Diagnostics shall also identify and display the exact location of network fault. It shall have it's dedicated self-diagnostic features to find out faults like cable fault (for cable open and cable short or grounded), actuator communication is not reached and all actuator faults and alarms, etc) and it shall have real time clock to monitor alarm events/data/faults.

4.4.3.5 It shall have facilities to set parameters like baud rate, address, skipping of few actuators

during maintenance, etc. 4.4.3.6 It shall have capacity to receive at least 25 digital signals and 5 analog signals through

communication link from each valve actuator. 4.4.3.7 The system configuration shall be stored in the retentive memory. 4.4.3.8 It shall be possible to include or delete any of the MOV from the system from Master Control

Station. 4.4.3.9 It shall have capacity to store and display the following events.





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DOC NO : 10096-60-N-211 PAGE NO. 10 OF 16


The memory size shall be 20% extra for future expansion. a) Valve actuator and control signals and its operation status. b) Number of operations of each MOV'S from its normal state. c) Valve and operator position

log d) Actuator control status log e) Statistics f) Historical data/ events g) Actuator failure information. 4.4.3.10 The master station/central control unit shall be connected to each field mounted valve

actuator through redundant communication interface link and back to master station in ring topology. It shall perform tasks of data collecting from each actuator, storing the data's and receiving the command signals from PLC and send the same to respective actuators for it's operation. It shall be possible to operate the valve from the master station. When MOV'S are operated from master station, the command signals form the Plant PLC are ignored and only status signals shall be sent to PLC. Contractor shall include necessary software and hardware to establish communication link. If any special programming tool is required the same shall be supplied.

4.4.3.11 Master station and field units shall be protected against lightening by the provision of

transient suppressor devices on all 2 wire connection ports at 1.5 KV at 1 mS. 4.4.3.12 The cabling, laying, testing, commissioning for MOV’s is included in the scope of the TAS

contractor. The MOV supplier shall assist the TAS contractor in integration of these valves with TAS. Valve bidder shall have co-ordination with TAS contractor for seamless integration of MOV’s with TAS.

4.5 Network Requirements 4.5.1 All field units shall be connected to master control unit using 2 wire network,

consisting of 1 twisted pair, shielded, 1.5 mm2 Cu conductor cable that would be provided by the TAS Contractor. Valve Contractor shall advise the suitability of this cable and inform system performance parameters accordingly, along with the bid.

4.5.2 The network communication protocol shall be Full Duplex type and shall incorporate a robust

mechanism viz. CRC etc. to identify proper data transfer. 4.5.3 The network shall be designed so as to allow uninterrupted data transfer even in case of

network failure (discontinuity in cable failure of one field module etc.) at a single point. 4.5.4 Proper isolation shall be provided for all the network connectors in order to avoid

electrical interface problems.





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DOC NO : 10096-60-N-211 PAGE NO. 11 OF 16


4.6 Performance Requirements 4.6.1 The system shall be designed and engineered so as to provide reliable two way

communication between the TAS, the Master station/Central control station and the Field modules. The communication speed of the network should be selected so as to maintain data integrity even in case of the worst case of data transfer conditions. In any case the Maximum data transfer time for any command from central control unit to field station and vice versa shall not exceed 5 seconds for the network length and no of devices.

4.7 Operational Requirements 4.7.1 All MOVs shall have the provision for wiring the two wire network from Master control

station and additionally shall be capable of accepting hardwired ESD inputs directly from TAS PLC. Normal operational commands, status indications and diagnostic alarms shall be routed to Master Stations over a two-wire system. Whereas ESD inputs shall override any other command and close the MOV on its actuation.

4.8 Motors 4.8.1 The actuator motor shall be three-phase, Class F insulated, squirrel cage motor of special

high torque low inertia design, 15 minute rated at 33% of actuator output rated torque giving a temperature rise not exceeding that permitted for Class B insulation at standard voltage of 415 volts, 3Phase, 50 Hz AC.. Burn-out protection by embedded thermostat shall be provided. Motor shall be capable of 60 starts per hour. Motor shall be certified Ex “d” and be suitable for operating in a Zone 1 IIA/IIB Temperature Class T3 electrical area classification.

4.8.2 The integral power module in the motor shall incorporate a mechanically and

electrically interlocked reversing contactor starter, a control supply transformer fed from two phases of the incoming power supply, an automatic phase rotation correction circuit to ensure that the phase motor is always presented with a correct phase of the power supply and a single phase protector which prevents energizing the contactors if one or more phase of the power supply is lost.

4.8.3 Motor shall have 3 thermostat connected on series, one in each winding of motor for

protection against overheating. 4.8.4 It should be possible to separate motor from the lubricant filled gearing of actuator

allowing easy replacement of motor without losing any lubricant regardless of mounting position.

4.9 Integral Starters with Electronic Control 4.9.1 Integral starter unit shall be with Electronic control logic. Entire unit along with basic





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DOC NO : 10096-60-N-211 PAGE NO. 12 OF 16


Actuator will conform to IP65 Encl Standards. 4.9.2 Electromechanically interlocked contactor are to be offered as starters. 4.9.3 The selection of the following models will be available through DIP switch

programming.

- Tripping by Close torque or close limit switch will be available. - Inching or non-inching (hold-on) for remote command will be field configurable.

4.9.4 A common potential free contact will be available to annunciate the following faults. Thermo switch trip TOLR trip Torque switch trip 4.9.5 Thermal overload relay to trip Actuator in case of overload. 4.9.6 The PCB’s shall be split into different functional modules mounted on a motherboard to

facilitate easy trouble shooting and replacement. The different functional PCB’s will be slot specific and non interchangeable among themselves.

4.9.7 Time delay shall be introduced between tripping of torque switch close and torque switch

open, i.e, torque switch open will be ignored for 3 seconds after tripping of Torque switch close.

4.9.8 Automatic phase correction facility will be available.

5.0 INSPECTION AND TESTS 5.1 The manufacturer shall perform all inspection and tests as per the requirements of this

specification and the relevant codes, prior to shipment at his Works. Such inspection and tests shall include the following:

5.1.1 Visual and dimensional check on all valve shall be carried out as per the Purchaser approved

drawings. 5.1.2 Chemical composition and mechanical properties shall be checked as per relevant material

standards and this specification for each heat of steel used. 5.1.3 Non-destructive examination of individual valve material and components consisting of

castings/forgings shall be carried out by the Manufacturer.





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DOC NO : 10096-60-N-211 PAGE NO. 13 OF 16


5.1.4 Body casting of the valves shall be radio graphically examined as per ASME B 16.34 Procedure and acceptance criteria shall be as per ASME B 16.34. The extent of radiography shall be as follows: ANSI Class 150# - All sizes - Nil All castings shall be wet magnetic particle inspected 100% of the internal surfaces. Method and acceptance shall comply with ASME B16.34.

5.1.5 All valves made by forgings shall be ultrasonically examined in accordance with the procedure and acceptance standard of Annexure E of ASME B16.34.

5.1.6 All valves shall be tested in compliance with the requirements of BS-5353. The sealant lines

shall be either included in the hydrostatic shell test or tested independently. No leakage is permitted during hydrostatic testing.

5.1.7 A supplementary air seat test as per BS-5353 shall be carried out for all valves. No leakage is

allowed. Test pressure shall be held for at least 15 minutes. 5.1.8 Valves shall be subjected to operational torque test as per BS-5353 under hydraulic pressure

equal to maximum differential pressure corresponding to the valve rating. For manually operated valves it shall be established that the force required to operate the valve does not exceed the requirements stated in section 4.8.3 of this specification.

5.1.9 Power actuated valves shall be tested after assembly of the valve and actuator, at the valve

Manufacturer’s works. At least five Open-Close-open cycles without internal pressure and five Open-Close-Open cycles with maximum differential pressure corresponding to valve rating shall be performed on the valve actuator assembly. The time for Full Open to Full Close shall be recorded during testing. If required the actuator shall be adjusted to ensure that the opening and closing time is within the limits stated in Valve data sheet. Hand operator provided on the actuator shall also be checked after the cyclic testing after satisfactory manual over-ride performance. These tests shall be conducted on minimum one valve out of a lot of five(5) valves of the same size, rating and actuator model/type. In case the tests do not meet the requirements, retesting/ rejection of the lot shall be decided by Purchaser’s Inspector.

5.1.10 NRL reserves the right to perform stage wise inspection and witness tests as indicated in Cl. 5.1 above at Manufacturer’s works prior to shipment through the Third party Inspection Agency. Manufacturer shall give reasonable access and facilities required for inspection to the NRL/Third party Inspection Agency. In no case shall any action of NRL/Third Party Inspection Agency relieve the Manufacturer of his responsibility for materials, Design, quality or operation of valves. Inspection and test performed/ witnessed by the Purchaser’s inspector shall in no way relieve the Manufacturer’s obligation to perform the required inspection and tests.





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DOC NO : 10096-60-N-211 PAGE NO. 14 OF 16


6.0 TEST CERTIFICATES

Manufacturer shall submit the following test certificates as a minimum: a) Mill Test Certificates relevant to the Chemical analysis and mechanical properties of the materials used for the valve construction as per relevant standards. b) Test certificates of hydrostatic and pneumatic tests complete with records of timing and pressure of each test. c) Test Reports of Ultrasonic inspection. d) Test Reports on operation of valves as per Cl. 5.1.8 & 5.1.9 of this Document. e) All other test Reports as sought by BS-5353 and this Document. All the above shall be duly certified by manufacturer and Third party Inspection Agency prior to shipment.

7.0 PAINTING, MARKING AND SHIPMENT 7.1 Valve surface shall be thoroughly cleaned, freed from dust and grease and applied with

sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by Shot blasting to SP-6 as per SSPC-VIS-1.

7.2 All valves shall be marked as per BS-5353. 7.3 Valve ends shall be suitably protected to avoid any damage during transit. All threaded and

machined surfaces subjected to corrosion shall be protected by a coat of grease, etc. All valves shall be provided with suitable end protectors for flange faces, securely attached to the valves.

7.4 All sealant lines and other cavities of the valve shall be filled with sealant before shipment. 7.5 Packaging and shipping instructions shall be as per BS-5353. 7.6 On packages, the following must be legibly marked:

a) Order Number. b) Manufacturer’s Name. c) Valve size and rating. d) Tag No. e) Serial No.





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DOC NO : 10096-60-N-211 PAGE NO. 15 OF 16


8.0 SPARES AND ACCESSORIES 8.1 Manufacturer shall quote for Spares and Accessories as per this Document/Schedule of Rates. 9.0 DOCUMENTATION 9.1 At the time of Bidding, Manufacturer shall submit the following documents:

a) General Arrangement drawings showing all features and relative positions and sizes of vents, drains, gear operator/ actuator, painting, coating and other external parts together with overall dimensions.

b) Sectional drawing showing major parts with reference numbers and material specifications. c) Torque curves for the power actuated valves along with break torque and maximum

allowable stem torque. In addition, sizing criteria and torque calculations shall also be submitted for power actuated valves.

d) Reference List of similar Plug valves manufactured and supplied in last five years indicating all relevant details including project, year, client, location, size, rating, service, etc.

e) Descriptive technical catalogs of the manufacturer. f) Copy of Valid BS-5353 Certificates/ License.

9.2 After placement of purchase Order by NRL, the Manufacturer shall submit three copies of the

following documents for NRL’s review and approval: a) Detailed sectional drawings showing all parts with reference numbers and material specification. b) Assembly drawings with overall dimensions and features. Drawing shall also indicate the painting scheme. c) Fabrication details of valves. d) Welding, Heat treatment and Testing procedures. e) Details of corrosion resistant painting. Manufacture of valves shall commence only after approval of the above documents. The Manufacturer shall obtain prior approval from NRL in case any changes/ modifications are proposed to the documents/ drawings approved by NRL. Within 30 days from the approval date, Manufacturer shall submit to NRL one reproducible and six copies of all drawings, documents and specifications as listed in Cl. 9.2.





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DOC NO : 10096-60-N-211 PAGE NO. 16 OF 16


9.3 As part of final documents, Manufacturer shall submit three sets of the following:

a) Test Certificates as per Cl. 1.6 of this document. b) Operation and maintenance Manual.

9.4 All documents shall be submitted in English language only. 10.0 REJECTION

Vendor shall make his offer in detail, with respect to every to item of the puncher’s specifications. Any offer not conforming to this shall be summarily rejected.




STANDARD SPECIFICATION FOR MOTOR OPERATED ACTUATOR DISCIPLINE:

INSTRUMENTATION


DOC NO : 10096-60-N-212 PAGE NO. 1 OF 11


STANDARD SPECIFICATION FOR

MOTOR OPERATED ACTUATOR


SD GP NM





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DOC NO : 10096-60-N-212 PAGE NO. 2 OF 11


CONTENTS

CLAUSE NO. ITEM PAGE NO.

0.0 Index 2

1.0 Scope 3

2.0 Codes and Standards 3

3.0 Bids 4

4.0 Drawing and Documents 5

5.0 General Requirements 5

6.0 Site and System Conditions 5

7.0 Power Supply 6

8.0 Technical Specifications 6

9.0 Spare 8

10.0 Nameplate 9

11.0 Wiring and Terminals 9

12.0 Equipment For Classified Hazardous Areas 10

13.0 Fire Proofing 10

14.0 Inspection, Testing and Acceptance 10

15.0 Packing and Dispatch 11

16.0 Rejection 11





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DOC NO : 10096-60-N-212 PAGE NO. 3 OF 11


1.0 SCOPE

The scope of this specification covers design, manufacture, assembly, shop testing and supply of electrical motor operated valve actuators intended for fully/ partially opening and closing valve duty. This specification does not cover the actuators for flow regulating duty.

2.0 CODES AND STANDARDS 2.1 The equipment shall comply with the requirements of latest revision of the following standards issued

by BIS (Bureau of Indian Standards) unless specified otherwise:

IS 5 Colours for ready mixed paints and enamels IS 325 Three- phase Induction motors IS 2148 Flameproof enclosures for electrical apparatus IS 4691 Degrees of protection provided by enclosure for rotating electrical machinery IS 4722 Rotating electrical machines-Specifications IS 9334 Electric Motor operated Actuators IS 13947 Low Voltage Switchgear and Control gear

2.2 In case of imported equipment, the standards of the country of origin shall be applicable if these standards are equivalent or more stringent than the applicable Indian Standards.

2.3 The equipment shall also conform to the provisions of Indian Electricity Rules and other statutory

regulations currently in force in the country. 2.4 In case Indian standards are not available for any equipment, standards issued by IEC/BS/VDE/

IEEE/NEMA or equivalent agency shall be applicable. 2.5 In case of any contradiction between various referred standards / specifications/data sheets and

statutory regulations, the following order of decreasing priority shall govern:

- Statutory Regulations - Data sheets - Job specifications -This specifications - Codes and Standards





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DOC NO : 10096-60-N-212 PAGE NO. 4 OF 11


3.0 BIDS

Vendor’s quotation shall include a detailed specification sheet for each MOV Actuator which shall provide all the details regarding type, construction materials, capacity etc. and any other accessories.

3.1 All the units of measurement for various items in vendor’s specification sheets shall be to the same

standards those in purchaser’s data sheets.

3.2 All the material specifications for various parts in the vendors specification sheets shall be to the same standards as those in purchaser’s data sheets.

3.3 Vendor shall attach a list of MOV actuator tag number wise, summing up all the deviations, if any,

from the purchase’s data sheets. Also, vendor should provide reasons for these deviations wherever possible.

3.4 Vendor shall provide Performance characteristic viz. Speed vs Current, Speed vs Torque and efficiency /

Power factor vs load.

3.5 Vendor shall provide Thermal withstands curve under hot and cold conditions

3.6 Vender shall enclose catalogues giving detailed technical specifications and other in formations for

each type of actuator covered in the bid.

3.7 Vendor’s quotation, catalogues, drawings, operating and maintenance manuals shall be in English. 3.8 Vender shall enclose cable sizing and Torque calculation for each type of actuator covered in the

bid. 3.9 Vender shall enclose Power supply requirements and consumption details for each type of actuator

covered in the bid

3.10 Vendor shall also quote for the following: a) Two years operational spares for Actuator and its accessories. b) Any special tools needed for maintenance work.

3.11 A copy of the certification of intrinsic safety / flameproof from statutory bodies like BASEEFA, CENELEC, FM, CMRI etc. shall be submitted.





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DOC NO : 10096-60-N-212 PAGE NO. 5 OF 11


4.0 DRAWING AND DATA

4.1 Detailed drawings, data, catalogues and required from the vendor are indicated by the purchaser in vender data requirement sheets. The required number of reproducible and prints should be dispatched to the address mentioned, adhering to the time limits indicated.

4.2 After placement of purchase order, vendor shall submit certified drawings and specification sheets

for Actuator which shall specially include the following:

a) Detailed dimensional drawing of the Actuator. b) Wiring and Interconnection drawing c) Interface details with PLC

d) Height of the completely assembled valve e) Dimensions of clearance space require for maintenance work. f) Weight of the Actuator. g) Location of external supports for vibration, in case they are required.

h) Any other special mounting requirement.

All dimensions shall be given in millimeters

4.3 Vender shall provide test certificates for all test the tests indicated elsewhere in this specification. In addition vendor shall provide the ‘Manufacturer’s certificate of conformity to purchaser’s specifications as per clause 2.2 of DIN 50049.

5.0 GENERAL REQUIREMENTS 5.1 The offered equipment will be brand new with state of the art technology and a proven field track

record. No prototype equipment shall be offered. 5.2 Vendor shall ensure availability of spare parts and maintenance support services for the offered

equipment for at least 15 years from the date supply. 5.3 Vendor shall give a notice of at least one year to Client before phasing out the product/ spares to

enable client to place order for spares and services. 5.4 Vendor shall be responsible for design, engineering and manufacturing of the complete actuator to

fully meet the intent and requirements of this specification and attached data sheet. 6.0 SITE AND SYSTEM CONDITIONS

The electrical motor operated valve actuators shall be suitable for operating under site conditions and system conditions as specified in the requisition and data sheet. If not specifically mentioned therein, a





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DOC NO : 10096-60-N-212 PAGE NO. 6 OF 11


design ambient temperature of 65˚C and an altitude not exceeding 1000m above mean sea level shall be considered.

7.0 POWER SUPPLY

The electrical motor operated valve actuators shall be suitable for power supply at 415 V ± 10%, 50 Hz ± 3%, 3 phases, unless specified otherwise in the data sheet.

8.0 TECHNICAL SPECIFICATIONS

Each MOV actuator shall include the motor, actuator unit, gears, position indicators, limit switches, hand wheel, electrical starter and controls, terminal box etc. as a self-contained unit. The actuator shall be sized to provide adequate torque and/ or thrust to ensure the complete intended travel of the valve under the worst operating and electrical power supply conditions.

8.1 Motor 8.1.1 The motor shall be 3- phase squirrel cage induction type unless specified otherwise in the data sheet. It

shall have totally enclosed non-ventilated construction. 8.1.2 The motor shall be designed for valve actuator service with high starting torque and shall be suitable

for Direct On Line starting. It shall be rated for S2-15 minute duty and shall conform to IS 325 or equivalent international standards.

8.1.3 The motor shall be provided with thermostat(s)/ Thermistor (s) embedded in the hot spots of motor

winding for protecting the motor. 8.1.4 The motor shall be able to operate the actuator at 75% of rated voltage. 8.1.5 The motor shall have class ’F’ insulation with temperature rise limited to class ‘B’ limits. Motor

winding shall be treated to resist corrosive agents and moisture. 8.1.6 Motor rotor shall preferably be of die-cast aluminium and, if brazed, shall be free from phosphorous. 8.2 Integral Starter and Control Transformer

The reversing starter, control transformer and local controls shall be integral with the valve actuator, unless specified other wise in the data sheet. Solid state control of valve actuator and electrically isolated interface for remote control requirement shall be provided, wherever these features exist in manufacturer’s design. The integral starter shall be supplied with following devices:





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DOC NO : 10096-60-N-212 PAGE NO. 7 OF 11


a) Electrically and mechanically interlocked reversing contactors for opening and closing

operations b) Control transformer with necessary tapings with suitable easily replaceable fuses. c) Terminal block for external connection fully prewired for internal devices of valve actuator.

MOV Actuators operating with AC power supply shall be provided with instantaneous phase reversal protection.

8.3 Integral Push Button, Selector Switches, Indicators and Control Devices

The following local control devices shall be providing along with MOV actuators:

a) Push buttons for Opening /Closing/Stop’ or alternatively ‘Open/Close’ selector switch. b) “Local /Off/Remote” selector switch, pad-lockable in each position. c) Local continuous position indication from ‘Valve fully open’ to ’Valve fully closed’

position, which may be analogue or digital type using mechanical indication/ indicating lamps/ LEDs.

8.4 Torque and Travel Limit Switches

Torque limit switches shall be provide to protect the motor from over- loading by cutting –off the power supply to motor during opening and closing operations. The limit switches shall be preset. However, it shall be possible to set the value of maximum torque during closing from 50% to 100% of rated torque actuators. Travel limit switch shall be provided to cut off the power supply to the motor at the end of preset limit of valve travel. The switches shall be provided with requisite number of potential –free contacts for valve actuator operation and for indication on remote panel as specified in the datasheet. Instead of mechanical torque limit switches, magnetic pulse counter to measure and control the stroke of actuator may be provided, wherever this feature exists in manufacture’s design.

8.5 Control Facilities

The internal controls and monitoring circuits shall be incorporated within the integral starter along with transformer and control unit of valve actuator. The remote control circuits shall be powered from internally derived control supply voltage, unless the use of external supply for remote control is specified in data sheet. In order to cater to remote control and indication requirements for ‘Position of Remote/local/Off selector switch’, if specified in the data sheet , an additional Monitoring





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DOC NO : 10096-60-N-212 PAGE NO. 8 OF 11


relay/auxiliary relays shall be provide as the part of the valve actuator. As an alternative, a common status contact indicating the availability of the MOV actuator for remote control may be provided by monitoring the following:

- Loss of one or more phases of power of supply - Loss of control circuit supply - Selector switch in local mode - Local stop push button set to ‘Off’ - Motor thermostat tripped - Any other local fault / abnormal condition

Where applicable, one number hand-held infrared remote programming device required for site commissioning and configuring (with out the need of removal of the MOV cover)shall be supplied for each group of 10 valve actuators(subject to minimum one infra red remote sensing device , even if number of valve actuators are less than ten).

8.6 Hand Operation

A hand wheel with hand/ auto lockable lever shall be provided for emergency operation of the MOV. The energisation of the motor shall automatically reengage power operation.

8.7 The enclosure of complete MOV actuator including motor, integral starter, control transformer unit and all control devices shall have minimum IP-65 degree of ingress protection.

9.0 SPARE

Bidder shall be quoted for two year operational spare separately along with the main offer. Vendor shall consider complete set of commissioning spares (spares which would be necessary during commissioning of the actuator and associated hardware, as envisaged by you). However, a list of such spares shall be provided without price.

10.0 NAMEPLATE

Each motorized valve actuator shall be provided with a stainless steel nameplate furnishing the following details, attached firmly to it at a place convenient for reading:

a) Actuator tag number as per data sheet b) Motor kW rating, motor time rating motor supply voltage, nominal motor phase current,

auxiliary switch rating c) Maximum torque setting d) Actuator enclosure type, lubricant type e) Actuator type , wiring diagram number/ catalogue number , actuator serial number.





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DOC NO : 10096-60-N-212 PAGE NO. 9 OF 11


A separate nameplate shall be provided for hazardous area application.

11.0 WIRING AND TERMINALS

All devices provide in the actuators shall be wired up to the terminal block. The contacts for remote operation and indication shall also be wired up to the terminal block. Minimum 10 % spare terminals shall be provided for future interlocks. Internal wiring for power and control circuits shall be appropriately sized for MOV actuator rating. Each wire shall be identified at both ends using PVC ferrules. The terminal compartment shall be separated from the inner electrical components of the actuator by means of a watertight seal so that the actuator electrical components are protected from the ingress of moisture and foreign materials when the terminal cover is removed during installation and maintenance.

11.1 Vendor shall be solely responsible for the compatibility of the MOV actuator with the valve and for selection and sizing if various electrical devices and components in the actuator.

11.2 The actuator shall be provided with minimum three adequately sized cable entries viz., one for power

cable and two for control cables. Suitable double compression cable glands shall be provided with each actuator for all cable entries and sealing plugs for all control cable entries. The cable glands and plugs shall be made of Nickel-plated brass.

11.3 The type of cable gland along with plugs for unused entries (the cable size for the gland shall be

informed to bidder during detailed engg.) to be supplied by bidder along with each of the valve actuator shall be double compression, flameproof, Ex(d) type

12.0 EQUIPMENT FOR CLASSIFIED HAZARDOUS AREAS 12.1 Actuators meant for hazardous areas shall meet the requirements of IS: 2148, IEC 79 or equivalent

international standards and shall be suitable for Gas groups and Temperature class as specified in the data sheet. Gas group IIB and Temperature class T3 (200˚C) shall be considered if not indicated in the data sheet.

The manufacturer shall possess valid test certificates issued by a recognized independent test house (CMRI/ BASEEFA/ LCIE/ UL/ FM or equivalent) for the offered actuators. All indigenous equipment shall confirm to Indian standards and shall have been tested and certified by Indian testing agencies. All equipment (indigenous and imported) shall also have valid statutory approvals as applicable for the specified hazardous locations from CCE or any other applicable statutory authority. All indigenous flameproof equipment shall have valid BIS license and corresponding marking as required by statutory authorities.





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DOC NO : 10096-60-N-212 PAGE NO. 10 OF 11


12.2 Apart from the name plate indicating the Tag No., a separate nameplate shall also be provided on each actuator to indicate the details of the testing agency(CMRI or equivalent), test certificate number with date, statutory approval number with date , approval agency (CCE/ DGMS/ or equivalent ), BIS license number with date , applicable Gas group and Temperature class etc. The nameplates shall be riveted / fixed with screws and not pasted. In case of any standard details listed above are embossed on the enclosures, the same need not be repeated

13.0 FIREPROOFING 13.1 If specified in the data sheet, the MOV Actuators shall be provided with ‘K-Mass’ type or equivalent

fire proofing. Unless specified otherwise, the fireproofing shall be rated for 30 minutes. The required certificates for the fireproof rating shall be from an independent test laboratory.

13.2 MOV Actuators with fireproofing shall be suitable for termination of mica insulated fire survival type

power and control cables. 14.0 INSPECTION, TESTING AND ACCEPTANCE 14.1 The equipment shall be subject to inspection by Client/Third Party Inspection Agency approved by

Client. Manufacturer shall furnish all necessary information concerning the supply to Client/Third Party Inspection Agency. During the course of manufacturing, Client or his authorized representative shall be free to visit the works and assess the progress of work and the manufacturer shall render him all possible assistance to do so.

14.2 Routine and acceptance tests shall be carried out at the manufacturer’s works under his supervision

and at his own cost. Two weeks’ notice shall be given to Client/Approved Third party Inspection Agency for witnessing the final testing of the complete assembly to ensure satisfactory operation of the MOV actuators. Type test Certificates shall be submitted with bids. Final acceptance of MOVs at site shall be subject to successful testing of the MOV actuators with the valves.

14.3 Type test certificates, original drawings referred in certificates and statutory approval certificates and

BIS license, where applicable, shall be shown to the inspection agency on demand. The certificates and BIS license must be valid at the time of dispatch.

14.4 Test certificates of bought – out components shall be shown to the inspection agency on demand. 15.0 PACKING AND DESPATCH

All the equipment shall be divided into multiple sections for protection and ease of handling during transportation. The equipment shall be properly packed for the selected mode of transportation, i.e. by ship, rail or trailer.





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DOC NO : 10096-60-N-212 PAGE NO. 11 OF 11


The equipment shall be wrapped in polythene sheets before being placed crafts / cases to prevent damage to finish. The crates / cases shall have skid bottoms for handling,, special notations such as ‘Fragile’, ‘This side up’, ’Center of gravity’, ’Weight’, ‘Owner’s particulars’, ‘PO no’ etc. shall be clearly and indelibly marked on the packages together with other details as per purchase order. The equipment may be stored outdoors for long periods before installation. The packing shall be completely suitable for outdoor storage in areas with heavy rains and high ambient temperature unless otherwise agreed . In order to prevent movement of equipment / components within the crates, proper packing supports shall be provided. A set of instruction manuals for erection, testing and commissioning, a set of operation and maintenance manuals and a set of final drawings shall be enclosed in water proof cover along with the shipment.

16.0 REJECTION

Vendor shall make his offer in detail, with respect to every to item of the puncher’s specifications. Any offer not conforming to this shall be summarily rejected.

NUMALIGARH REFINERY LTD. (A GOVT. OF INDIA ENTERPRISE)

PROJECT: ADDITIONAL TANKAGES & ASSOCIATED FACILITIES AT SILIGURI MARKETING TERMINAL


INSPECTION AND TEST PLAN FOR PLUG VALVE DISCIPLINE:

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DOC NO : 10096-60-N-411 PAGE NO. 1 OF 4


INSPECTION TEST PLAN FOR PLUG VALVE





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DOC NO : 10096-60-N-411 PAGE NO. 2 OF 4


1.0 SCOPE: This Inspection and Test Plan covers the minimum testing requirements for Plug Valves. Supplier shall perform all the tests listed under their scope, meeting all the requirement of job PR &IOTDE standard specification 10096-60-N-211. Inspection call to be issued only after satisfactory internal test results.

2.0 REFERENCE DOCUMENTS: PO / PR/ Standards referred there in job specifications / Approved documents. 3.0 INSPECTION AND TEST REQUIREMENTS:

SL. NO. STAGE/ACTIVITY CHARACTERISTICS QUANTUM

OF CHECK RECORD SCOPE OF INSPECTION

SUB SUPPLIER SUPPLIER PMC

1

Incoming material like Forgings & casting for body/bonnet, wetted parts like plug, seat cage, stem. Accessories such as Limit Switches etc.

Material Identification , Chemical & Mechanical properties, Hardness check (for stellited parts), NACE requirements (for valve under NACE application) Make, model no functional check.

100%

Material test

certificates/ Test lab

certificates

P W/R

R

• Radiography of valve casting (if specified) • Bend test and magnetic particle inspection of body and bonnet casting (if specified) • Post welded hit treatment / Radiography /Magnetic particle inspection of weld joints (if specified)

100% Reports P/R R





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DOC NO : 10096-60-N-411 PAGE NO. 3 OF 4


• DP test (if specified) • Solution , Annealing, Pickling (if specified)

2 Machining and components Visual, Dimensional 100% Supplier’s

test records - P -

3

a) Final inspection

• Dimensional test

100% by supplier.

Inspection Witness Record

- P R

• Hydrostatic test for valve bodies • Functional test in including: i) Seat leakage test, lift characteristics iv) Test on accessories. • Helium leak test (if specified)

100% by supplier.

Supplier’s test records P R

b) Final Inspection

• Physical dimensional verification and workmanship. • Hydrostatic test • Helium leak test (if specified) • Check for valve characteristics like stroke. and travel time etc. • Functional tests including: i) Seat leakage test, lift characteristics.

100% by supplier and on

random basis by

PMC/TPI

Inspection witness record

- P W,H

4 Submission of certificates/document.

• Certificate from testing agency like BASEEFA, FM, PTB, CIMFR etc for accessories like Limit switches etc. for use in specified hazardous area.

Prototype for each model

Statutory approval

Certificates/ Type Test

Certificates

- R R





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DOC NO : 10096-60-N-411 PAGE NO. 4 OF 4


• IBR (If applicable) 100%

IBR stamp and IBR from IIIC certificate

- W R

5 Painting and packing

• Visual • Suitable protection to prevent entry of foreign material • Cleaning for oxygen and chlorine services. • Lubrication for valves, which required external lubrication.

100% Packing list / Supplier’s

records - W -

- Supplier to submit internal test reports, type test reports and statutory approval certificates before offering items for inspection to TPI/PMC.

ds: CCE or CCOE- Chief Controller of Explosives, DT-Destructive Testing, HT-Heat Treatment, H-Hold(Do not proceed without approval), IBR- Indian Boiler Regulations, ITP-Inspection and Test Plan, NDT- Not Destructive Testing, P-Perform, PESO-Petroleum Explosive Safety Organization, PO-Purchase Order, PR-Purchase Requisition, PQR-Procedure Qualification Record, QAP-Quality Assurance Plan, Random-10% (min.1 no) of each size and type of bulk item, R- Review, RT- Radiography testing, RW-Random Witness, TC- Test Certificate TPI or TPIA- Third Party Inspection Agency, VDR- Vendor Data Requirement, WPS-Welding procedure Specification, WPQ-Welder Performance Qualification, W- Witness (Give due notice, work may produced after scheduled date).

NOTES: (As applicable) 1. Wherever W/R or H/W is indicated, PMC Inspection engineer shall decide the option to be exercised for the particular stage and supplier. 2. Supplier’s in house Procedures may be accepted in case TPI/PMC is satisfied with adequacy of procedures to comply with purchase order/Specifications requirements. In case of non availability of suitable procedures, fresh procedure may be qualified under TPI/PMC witness. 3. In case of conflict between purchase specification, contract documents and ITP, more stringent conditions shall be applicable. 4. This document describes generally the requirements pertaining to all types of the item. Requirement specific to PO and the item are only applicable. 5. Acceptance norms for all the activities shall be as per PO/PR/STANDARDS referred there in /Job Specification / Approved Document




INSPECTION AND TEST PLAN FOR MOTOR OPERATED ACTUATOR DISCIPLINE:

INSTRUMENTATION


DOC NO : 10096-60-N-412 PAGE NO. 1 OF 6


INSPECTION TEST PLAN FOR MOTOR OPERATED ACTUATOR





INSTRUMENTATION


DOC NO : 10096-60-N-412 PAGE NO. 2 OF 6


1.0 SCOPE:

This Inspection and Test Plan covers the minimum testing requirements for Control Valves. Supplier shall perform all the tests listed under their scope, meeting all the requirement of job PR &IOTDE standard specification 10096-60-N-212. Inspection call to be issued only after satisfactory internal test results.

2.0 REFERENCE DOCUMENTS: PO / PR/ Standards referred there in job specifications / Approved documents. 3.0 INSPECTION AND TEST REQUIREMENTS:

SL. NO. STAGE/ACTIVITY CHARACTERISTICS QUANTUM

OF CHECK RECORD

SCOPE OF INSPECTION SUB

SUPPLIER

SUPPLIER PMC

1

Incoming material like Forgings & casting for body/bonnet, wetted parts like plug, seat cage, stem. Accessories such as positioners, I/P converters, solenoid valves, Limit Switches and Air filter Regulators etc.

Material Identification , Chemical & Mechanical properties, Hardness check (for stellited parts), NACE requirements (for valve under NACE application)

y V-notch impact testing (if specified)

model no functional check.

100%

Material test certificates/

Test lab certificates

P W/R

R

• Radiography of valve casting (if specified)

• Bend test and magnetic particle inspection of

100% Reports P/R R





INSTRUMENTATION


DOC NO : 10096-60-N-412 PAGE NO. 3 OF 6


body and bonnet casting (if specified)

• Post welded hit treatment / Radiography /Magnetic particle inspection of weld joints (if specified)

• DP test (if specified) • Solution , Annealing,

Pickling (if specified)

2 Machining and components Visual, Dimensional 100% Supplier’s

test records - P -

3

a) Final inspection

• Dimensional test • Pneumatic test for all

pneumatic actuator bat a pressure not less than 1.5 times the actual working pressure.

100% by suppli

er.

Inspection Witness Record

- P R

• Hydrostatic test for valve bodies

• Functional test in including:

Seat leakage test, lift characteristics

Test on smart positioners ) Control valve dynamic

testing and response time verification

) Test on accessories.

100% by suppli

er.

Supplier’s test records P R





INSTRUMENTATION


DOC NO : 10096-60-N-412 PAGE NO. 4 OF 6


• Interoperability test for field bus petitioners.

• Helium leak test (if specified)

b) Final Inspection

• Physical dimensional verification and workmanship. • Hydrostatic test • Helium leak test (if specified) • Check for valve characteristics like stroke. Linearity & Hysteresis, and travel time etc. • Functional tests including:

i) Seat leakage test, lift characteristics. ii) Test on smart positioners iii) Control valve dynamic testing and response time verification. iv) Test on Accessories • Pneumatic test on

actuator on representative samples.

• Type test for valves in cryogenic service (if asked)

100% by supplier and on random

basis by PMC/TPI

Inspection witness record

- P W,H





INSTRUMENTATION


DOC NO : 10096-60-N-412 PAGE NO. 5 OF 6


4 Submission of certificates/document.

• Certificate from testing agency like BASEEFA, FM, PTB, CIMFR etc for accessories like solenoid valves, I/P converters, Limit switches etc. for use in specified hazardous area.

Prototype for each model

Statutory approval

Certificates/ Type Test

Certificates

- R R

• BIS approval for explosion proof construction of above accessories manufactured indigenously.

• Statutory approval certificates for instruments from CCOE/PESO for use in specified hazardous area.

• Degree of protection certificate for instrument housing.

• Traceability of record

• IBR (If applicable) 100%

IBR stamp and IBR from IIIC certificate

- W R





INSTRUMENTATION


DOC NO : 10096-60-N-412 PAGE NO. 6 OF 6


5 Painting and packing

• Visual • Suitable protection to

prevent entry of foreign material

• Cleaning for oxygen and chlorine services.

• Lubrication for valves, which required external lubrication.

100% Packing list / Supplier’s

records - W -

- Supplier to submit internal test reports, type test reports and statutory approval certificates before offering items for inspection to TPI/PMC.

ds: CCE or CCOE- Chief Controller of Explosives, DT-Destructive Testing, HT-Heat Treatment, H-Hold(Do not proceed without approval), IBR- Indian Boiler Regulations, ITP-Inspection and Test Plan, NDT- Not Destructive Testing, P-Perform, PESO-Petroleum Explosive Safety Organization, PO-Purchase Order, PR-Purchase Requisition, PQR-Procedure Qualification Record, QAP-Quality Assurance Plan, Random-10% (min.1 no) of each size and type of bulk item, R- Review, RT- Radiography testing, RW-Random Witness, TC- Test Certificate TPI or TPIA- Third Party Inspection Agency, VDR- Vendor Data Requirement, WPS-Welding procedure Specification, WPQ-Welder Performance Qualification, W- Witness (Give due notice, work may produced after scheduled date).

NOTES: (As applicable) 1. Wherever W/R or H/W is indicated, PMC Inspection engineer shall decide the option to be exercised for the particular stage and supplier. 2. Supplier’s in house Procedures may be accepted in case TPI/PMC is satisfied with adequacy of procedures to comply with purchase order/Specifications requirements. In case of non availability of suitable procedures, fresh procedure may be qualified under TPI/PMC witness. 3. In case of conflict between purchase specification, contract documents and ITP, more stringent conditions shall be applicable. 4. This document describes generally the requirements pertaining to all types of the item. Requirement specific to PO and the item are only applicable. 5. Acceptance norms for all the activities shall be as per PO/PR/STANDARDS referred there in /Job Specification / Approved Document