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Table of ContentsDocument Number Rev. Document Title Page

NumberA133-000-WB-MR-3115

C MOTOR OPERATED VALVES 2

6-44-0052 6 Technical notes for valves. 86-78-0001 0 Specification for Quality Mgt. System Requirements from Bidders 286-78-0003 0 Specification for Documentation Requirement from Suppliers 37A133-000-16-43-ATR-3115

D ADDITIONAL TECHNICAL REQUIREMENTS 49

A133-000-16-43-DS-3115

B MOV SCHEDULE 55

A133-000-16-43-VDR-3115

A VENDOR DATA REQUIREMENTS 56

A133-000-16-43-TCL-3115

A TECHNICAL COMPLIANCE FORMAT 58

A133-6-44-0006-3115

B VMS FOR MOV MR 60

44NC- 4600-Q-0002-A4

A PROPOSAL INPUT 82

A133-00-000--ITP-0010A

A INSPECTION AND TEST PLAN (JOB SPECIFIC) 89

A133-000-16-50-SP-3115

B JOB SPECIFICATION 91

A133-000-16-50-DS-3115

A DATA SHEET 94

A133-000-16-50-VR-3115

A VENDOR DATA REQUIREMENTS 98

44NC4600ESS037 0 MOTORISED VALVE ACTUATOR 101A133-86-02-DS-2950 1 MOV Datasheets MOV Datasheets 109A133-086-16-47-DS-20

1 DATA SHEET FOR MOV 126

A133-00-000--ITP-0101


A133-00-000--ITP-0102


A133-000-16-43-SK-3115

A PORT DETAIL FOR 3-WAY VALVE 129

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ENGINEERS INDIA LIMITED

NEW DELHI

Project:

Client:

COKER BLOCK (LSTK 1)

CPCL

Requisition No. Rev

A133-000-WB-MR-3115 C

Page 1 of 5

MATERIAL REQUISITION (TOP SHEET)

ITEM: MOTOR OPERATEDVALVES

Issue Status 1. -> Entire Requisition Issued

2. -> Only Revised Pages are Issued

(Fill 1 or 2 from below in this bracket)

DOCUMENT NUMBER(Always quote this document number given below as reference)

A133 000 WB 3115MR 20/10/2014 16/43C

JOB NO. UNIT/AREA

COST CENTRE

DOCCODE

SR.NO. REV DATE ORIGINATINGDIVN./DEPT

VENDOR NAME VENDOR CODE

Material to be delivered at (job site) CPCL, CHENNAI within the delivery period specified in the "Request For Quotation"

(RFQ).

Notes :

This page is a record of all the Revisions of this Requisition.

The nature of the Revision is briefly stated in the "Details" column below, the Requisition in its entirety shall beconsidered for contractual purposes.

When a Requisition is revised, only the revised pages may be issued.

When revised pages only are issued, the revised pages shall form part of the original Requisition. The original requisition alongwith the revised pages shall be considered in its entirety for contractual purposes.

REV. DATE BY CHK. APPD. A

B

C

12/09/2014

19/09/2014

20/10/2014

ISSUED FOR BIDS

REVISED & ISSUED FOR BIDS

REVISED & ISSUED FOR BIDS

DETAILS

[ ]

Vendors are required to quote strictly as per technical specifications / notes stipulated in the material requisition. Theoffers with deviations are likely to be summarily rejected.

1.

2.

3.

4.

5.

MR Category :II

NK

NK

NK

KB

KB

KB

UC

UC

UC

This is a system generated approved document and does not require signature

Page 2 of 129

B636

Review

B636

Typewritten Text

PMC DOC. CONTROL CODE: L15

B636

Rectangle

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NEW DELHI

Project:

Client:


CPCL

Requisition No. Rev

A133-000-WB-MR-3115 C

Page 2 of 5

LIST OF ATTACHMENT

DOCUMENT TITLESR. NO DOCUMENT NO.REVISION

NO. DATE 1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

TECHNICAL NOTES FOR VALVES

SPECIFICATION FOR QUALITYMANAGEMENT SYSTEM REQUIREMENTSFROM BIDDERS

SPECIFICATION FOR DOCUMENTATIONREQUIREMENTS FROM SUPPLIERS

ADDITIONAL TECHNICALREQUIREMENTS

CO-RELATION OF SPECIFICATIONSFOR MOTOR OPERATED VALVES

VENDOR DATA REQUIREMENTS FORMOTOR OPERATED VALVES

PIPING TECHNICAL COMPLIANCEFORMAT

VALVE MATERIAL SPECIFICATION

STANDARD SPECIFICATION FORPOSITIVE MATERIALIDENTIFICATION AT VENDOR'SWORK.

INDICATIVE ITP FOR AGTE, GLOBE& CHECK VALVES

JOB SPECIFICATION (ELECTRICAL)FOR MOV ACTUATORS

DATA SHEET FOR MOTORISED VALVEACTUATOR (MOV)

VENDOR DATA REQUIREMENTS FORMOV'S

STANDARD SPECIFIACTION FORMOTORISED VALVE ACTUATORS

MOV PROCESS DATASHEETS

MOV PROCESS DATASHEET

CONCESSION REQUEST

NON-CONFORMANCE REPORT (NCR)

PORT DETAILS FOR 3-WAY VALVE

6-44-0052

6-78-0001

6-78-0003

A133-000-16-43-ATR-3115

A133-000-16-43-DS-3115

A133-000-16-43-VDR-3115

A133-000-16-43-TCL-3115

A133-6-44-0006-3115

44NC-4600-Q-0002-A4

A133-00-000-ITP-010A

A133-000-16-50-SP-3115

A133-00-16-50-DS-3115

A133-000-16-50-VDR-3115

44NC-4600:ESS 037

A133-86-02-DS-2950

A133-086-16-47-DS-20

A133-00-000-ITP-0101

A133-00-000-ITP-0102

A133-000-16-43-SK-3115

6

0

0

D

B

A

A

B

0

B

A

A

0

1

1

A

04/08/2010

04/06/2009

04/06/2009

22/10/2014

20/10/2014

12/09/2014

11/09/2014

20/10/2014

13/04/2010

04/09/2014

27/07/2014

01/08/2014

03/05/2010

01/07/2014

09/09/2014

11/09/2014

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NEW DELHI

Project:

Client:


CPCL

Requisition No. Rev

A133-000-WB-MR-3115 C

Page 3 of 5

MR ATTACHMENTSR.NO. DETAIL DESCRIPTION QTY. U. RATE TOT.VALUE CDD

086-MOV-1201, BALL VALVE, 16.0", 150 CLASS RF, SHEETNO.54301 , LINE NO. 16"-WF-086-0207-A33A.

086-MOV-1202, BALL VALVE, 14.0", 150 CLASS RF, SHEET NO.54396, LINE NO. 14"-P-086-1201-A9A-IT

086-MOV-1501, BALL VALVE, 6.0", 300 CLASS RF, SHEETNO.54498 , LINE NO. 6"-P-086-1503-B4G-IT.

086-MOV-1601, BALL VALVE, 8.0", 300 CLASS RF, SHEETNO.54496 , LINE NO. 8"-P-086-1605-B9A-IH.









086-MOV-1801, BALL VALVE, 14.0", 600 CLASS RF, SHEETNO.54599 , LINE NO. 14"-P-086-1801-D4G-IT.

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

*PS1600MV1201A33A

*PS1400MV1202ZA9A

*PS0600MV1501ZB4G

*PS0800MV1601ZB9A

*PS0600MV1602ZB9A

*PS0800MV1603ZB9A

*PS0600MV1604ZB9A

*PS0800MV1605ZB4G

*PS1600MV1701ZB4G

*PS1400MV1702ZB4G

*PS1600MV1703ZB4G

*PS1400MV1704ZB4G

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1

2

3

4

5

6

7

8

9

10

11

12

ITEMCODE

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NEW DELHI

Project:

Client:


CPCL

Requisition No. Rev

A133-000-WB-MR-3115 C

Page 4 of 5





086-MOV-2601, 3-WAY VALVE, 4.0", 300 CLASS RF, SHEETNO.66491 , LINE NO. 4"-P-086-2603-B9A-IT.

086-MOV-2602, 3-WAY VALVE, 14", 300 CLASS RF, SHEETNO.66491, LINE NO. 14"-P-086-2607-B9A-IT.

086-MOV-2901, BALL VALVE, 12.0", 150 CLASS RF, SHEETNO.54391 , LINE NO. 12"-P-086-2804-A26A.


086-MOV-3001, BALL VALVE, 24.0", 150 CLASS RF, SHEETNO.54391 , LINE NO. 24"-P-086-2801-A26A-IT.

086-MOV-3002, BALL VALVE, 16.0", 150 CLASS RF, SHEETNO.54391 , LINE NO. 16"-P-086-3001-A26A-IS.

086-MOV-3003, BALL VALVE, 14.0", 150 CLASS RF, SHEETNO.54391 , LINE NO. 14"-P-086-3109-A26A-IT.

086-MOV-3004, BALL VALVE, 10.0", 300 CLASS RF, SHEETNO.54491 , LINE NO. 10"-P-86-3002-B26A-IS.

086-MOV-3005, BALL VALVE, 10.0", 600 CLASS RF, SHEETNO.54593 , LINE NO. 10"-SVH-086-3001-D2D-IH.


Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

*PS1400MV1801ZD4G

*PS1200MV1802ZD4G

*PS1400MV1803ZD4G

*PS1200MV1804ZD4G

*PS0400MV2601ZB9A

*PS1400MV2602ZB9A

*PS1200MV2901A26A

*PS0600MV2902A26A

*PS2400MV3001A26A

*PS1600MV3002A26A

*PS1400MV3003A26A

*PS1000MV3004B26A

*PS1000MV3005ZD2D

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

13

14

15

16

17

18

19

20

21

22

23

24

25

ITEMCODE

Page 5 of 129

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NEW DELHI

Project:

Client:


CPCL

Requisition No. Rev

A133-000-WB-MR-3115 C

Page 5 of 5


086-MOV-3201, BALL VALVE, 10.0", 300 CLASS RF, SHEETNO.54491 , LINE NO. 10"-P-086-3201-B26A.



086-MOV-4511, BALL VALVE, 12.0", 2500 CLASS RTJ, SHEETNO.54891 , LINE NO. 12"-WP-086-4502-G9A-IS.

086-MOV-4512, BALL VALVE, 8.0", 2500 CLASS RTJ, SHEETNO.54891 , LINE NO. 8"-WP-086-4503-G9A-IS.

086-MOV-4513, BALL VALVE, 12.0", 2500 CLASS RTJ, SHEETNO.54891, LINE NO. 12"-WP-086-4501-G9A-IS.

086-MOV-4514, BALL VALVE, 8.0", 2500 CLASS RTJ, SHEETNO.54891, LINE NO. 8"-WP-086-4504-G9A-IS.

086-MOV-5301, BALL VALVE, 4.0", 150 CLASS RF, SHEETNO.54301 , LINE NO. 4"-P-086-5305-A9A-IH.

086-MOV-5401, BALL VALVE, 6.0", 150 CLASS RF, SHEETNO.54301 , LINE NO. 6"-P-086-5402-A9A-IH.

MANDATORY SPARES FOR ACTUATORS (DOC. NO. A133-000-16-50-SP-3115). PRICES TO BE PROVIDED WITH DETAILED BREAKUP

VENDOR RECOMMENDED SPARES (VALVES & ACTUATORS)-PRICES TOBE PROVIDED WITH DETAILED BREAKUP.

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

Item Description:

*PS0300MV3101A26A

*PS1000MV3201B26A

*PS1200MV3701ZB9A

*PS0800MV3801A19A

*PS1200MV4511ZG9A

*PS0800MV4512ZG9A

*PS1200MV4513ZG9A

*PS0800MV4514ZG9A

*PS0400MV5301ZA9A

*PS0600MV5401ZA9A

*PS0000MANSPRZA1A

*PS0000VDRESPZA1A

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

1 NOS

26

27

28

29

30

31

32

33

34

35

36

37

ITEMCODE

Page 6 of 129

SUMMARY SHEET OF CHANGES

Date:22.10.2014

Page 1 of 1

With reference to the MR for MOTOR OPERATED VALVES (A133-000-WB-MR-3115 Rev B), following are the changes:

Sl. No. Document Document no. Document Added (A)/ /Revised (R)

Affected Contents

1.

MATERIAL REQUISITION A133-000-WB-MR-3115 R

A. Changes in List of attachments

1. Revision details (Rev No. & Date) Changed for SR. No. 4, 5 & 8.

B. Changes in MR attachment

1. Item Description are changed for item SR. NO. 2, 4, 5, 6, 7 & 28.

2. CO-RELATION OF

SPECIFICATIONS FOR MOTOR

OPERATED VALVES MR No. A133-

000-WB-MR-3115

A133-000-16-43-DS-3115 R VMS Sheet no. are changed for MOV tag nos. 086-

MOV-1202, 086-MOV-1601, 086-MOV-1602, 086-

MOV-1603, 086-MOV-1604 &086-MOV-3701.

Remarks changed for MR item sl. No. 21, 22, 23, 24,

25, 29 & 35. 3. VALVE MATERIAL SPECIFICATION A133-6-44-0006-3115

R VMS Sheet No. 54396 & 55496 are added.

VMS Sheet No. 54401 is deleted.

4. ADDITIONAL TECHNICAL

REQUIREMENTS

A133-000-16-43-ATR-3115 R 1. Clause No. 21 & 25 are modified.

2. Clause No. 26 & 27 are added.

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ADDITIONAL TECHNICAL

REQUIREMENTS

DOCUMENT No.

A133-000-16-43-ATR-3115 Rev. D

Page 1 of 6

D 22/10/2014 REVISED & ISSUED FOR BIDS NK KB UC / MI

C 20/10/2014 REVISED & ISSUED FOR BIDS NK KB UC / MI

B 19/09/2014 REVISED & ISSUED FOR BIDS NK KB UC / MI

A 11/09/2014 ISSUED FOR BIDS NK KB UC / MI

Rev. No Date Purpose Prepared by Checked by Approved by

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

ADDITIONAL TECHNICAL REQUIREMENTS

MOTOR OPERATED VALVES

CAT-II

Page 49 of 129


REQUIREMENTS

DOCUMENT No.

A133-000-16-43-ATR-3115 Rev. D

Page 2 of 6


ADDITIONAL TECHNICAL REQUIREMENTS MOVs - CAT-II

1. Bidder to note that bid evaluation may be carried out without any post bid correspondence.

2. Bidder shall furnish quotations only for those items which he can supply as per

MR specifications including fulfillment of Qualification criterion as per MR.

3. If the bid does not include complete scope and technical/performance data, proven track record etc, required to be submitted with the bid, the offer shall be liable for rejection.

4. The submission of prices by the Bidder shall be construed to mean that he has confirmed compliance with all technical specifications of the corresponding item(s).

5. Bidder shall categorically confirm compliance to all the attachments listed in the “List of attachment” sheet of the MR, A133-000-WB-MR-3115.

6. MOVs shall be provided with MOV Tag No. in addition to standard marking as per Technical notes for Valves, 6-44-0052, Rev 6.

7. Bidder shall confirm compliance to the following:-

a. All MOVs and accessories (including actuators) etc. shall comply with

Process Data Sheet for MOVs. b. Bidder shall be solely responsible for selection of suitable actuators &

actuator control system. Bidder shall be single point responsible for the complete system (i.e. valves, actuators, actuators control system etc.).

c. All Valves with motorized actuators shall be suitable for installation in horizontal/vertical lines.

8. Bidder to note that the offered opening/closing time for the Motor-operated Ball Valves shall be in line with the MR Requirements. Bidder to ensure compliance

9. For flanged valves with ring joint flange the hardness of grooves for 9% Cr.

flange material shall be minimum 150BHN.

10. Bidder shall submit the following documents with the offer:

a. Manufacturer’s complete descriptive and illustrative catalogue/ literature. b. Detailed dimensioned cross section drawing with parts/ material lists,

weight etc. c. Drawings for valves with accessories like gear operator, hydraulic/

pneumatic operator, motor, bypass etc. giving major salient dimensions.

d. One copy of the valve specification sheets signed as “Accepted” by the manufacturer. Deviations, if any shall be marked as applicable on the valve specification sheet.

Page 50 of 129


REQUIREMENTS

DOCUMENT No.

A133-000-16-43-ATR-3115 Rev. D

Page 3 of 6


11. Co-relation of all specifications for Motor Operated Valves (Doc. No. A133-086-16-43-DS-3115) shall be referred for applicable specifications against subject tag number.

12. Bidder to ensure that complete testing of valves with the actuators etc. shall be done at shop before shipping the valves.

13. Bidder shall refer to attached MOV Process data sheet (Doc. No. A133-086-02-

DS-2950 & A133-086-16-47-DS-20) for Process parameters.

14. Bidder shall quote for mandatory spares as per requirements of the MR for actuators.(Refer document no. A133-000-16-50-SP-3115)

15. Bidder to furnish the list of recommended maintenance and commissioning

spares with unit rate, for 2 years normal operation of all the valves & actuators.

16. Bidder to ignore following specifications as mentioned in different clauses of Technical notes for piping items attached with MR:

S. No. Technical Notes Clause No. Specification No. to be ignored

1. Technical notes for Valves (6-44-0052) 10.0 6-44-0052-A1




5. Technical notes for Valves (6-44-0052) 11.0 6-81-0001

6. Technical notes for Valves (6-44-0052) 11.0 6-81-0004

17. Clause 2.1.6 of Technical notes for Valves (6-44-0052), shall be read as

following: “For subject notes, if there is any deviation, the same shall be listed clause wise. Even clauses which are acceptable shall be categorically confirmed as “Accepted”.

18. Type of gear for clause 4.2 of Technical notes for valves(6-44-0052) shall be as under :

For Gate / Globe / Diaphragm Valves

Totally enclosed bevel gear in grease case with grease nipples / plugs.

For Ball / Plug / Butterfly Valves Totally enclosed helical worm or combination of helical worm and spur gear in grease case with grease nipples / plugs.

19. Torque details for MOV’s shall be furnished by bidder in the Data Sheet for

Torque values of MOV’s format (Format No. 1-1643-0091) attached with the MR.

20. Bidder to ignore format no. 5-0000-0180-F1 (Concession/deviation Permit) as mentioned in Specification for Quality Management System Requirements from

Page 51 of 129


REQUIREMENTS

DOCUMENT No.

A133-000-16-43-ATR-3115 Rev. D

Page 4 of 6


Bidders, Doc. No. 6-78-0001. Instead Concession/deviation request (if required) must be made by bidder in the Concession Request & Non-Conformance Report (NCR) as attached with MR elsewhere.

21. Process parameters for MOV tag nos. 086-MOV-3005 shall be confirmed after

receipt of WGC Turbine vendor data. Process parameters shall for MOV tag nos. 086-MOV-4511, 4512, 4513 & 4514, shall be confirmed after receipt of Coke cutting pump data.

22. MOV’s specified with the requirements of “LUM1” shall meet the requirements of “NACE” specified in MR-0103 and Sulphur content in the material is to be restricted to 0.01% (max). Hardness shall be below BH No. 200 for CS material. Carbon equivalent (CE) shall be limited to 0.43.

23. Bidder to ensure that the port shall be designed as per Port detail for 3-way

valve (Doc. No. A133-000-16-43-SK-3115).

24. Valves specified with LO/ LC provision shall be supplied with arrangement suitable for locking in open as well as in closed position. Lock is included in bidder’s scope of supply. Lock Open/ Lock Closed arrangement with chain is not acceptable.

25. Bidder shall furnish PTR as given below and shall meet the following

requirements for MR Sr. Nos. 2 to 18, 25, 28 & 30 to 33 (for alloy steel ball

valves/ 3-way ball valves):-

For Trunnion mounted Fire Safe Alloy Steel Ball valves / 3-way ball valves (for MR. Sr. Nos. 2 to 18, 25, 28 & 30 to 33)

i. The bidder should be enlisted in EIL under Trunnion Fire Safe Ball valves.

ii. The bidder shall have manufactured & supplied Forged/Cast Alloy Steel (1.25%Cr/ 5%Cr/ 9%Cr) Fire Safe Trunnion Ball valves in the last 7 years to be reckoned from the bid due date. Bidder shall submit copy of the Purchase Order/Purchase Requisition / Inspection Release Note for the same.

iii. PTR of submitted rating shall qualify items of same rating and below. (e.g. PTR of 300 rating shall qualify items in 300 rating and 150 rating)

iv. PTR of submitted size shall qualify items of same size and below (e.g. PTR of 6” size shall qualify items sizes 6” and below).

v. Bidder to submit duly signed & stamped PTR proforma (Annexure-I) attached with ATR.

26. MOV’s specified with TSO requirements shall meet the maximum allowable leakage of Rate A.

27. All valves shall be of full bore construction.

D

D

Page 52 of 129


REQUIREMENTS

DOCUMENT No.

A133-000-16-43-ATR-3115 Rev. D

Page 5 of 6


Page 53 of 129


REQUIREMENTS

DOCUMENT No.

A133-000-16-43-ATR-3115 Rev. D

Page 6 of 6


Bidder’s proven track record proforma (Annexure-I)

Item : Motor operated valves MR No. : A133-000-WB-MR-3115

Sr. No.

Name of Client & location

Contact person and address, Ph. No. & email ID

Year of Supply

Size & rating of valves supplied

Remarks

NOTE:

1. Bidder to submit duly signed & stamped this proven track record proforma with the bid.

2. Bidder to submit copy of purchase order/ purchase requisition/ IRN in support of the references being submitted.

3. Incorrect information furnished in this proforma shall render the bid liable for rejection.

Bidder’s seal & signature with date

Page 54 of 129

CO-RELATION OF SPECIFICATIONS FOR MOTOR OPERATED VALVES

B 20.10.2014 REVISED & ISSUED FOR BIDS NK KB UC A133-000-16-43-DS-3115

A 11.09.2014 ISSUED FOR BIDS NK KB UC Rev. B

REV NO. DATE PURPOSE BY CHK APPROVALS

CO-RELATION OF SPECIFICATIONS FOR MOTOR OPERATED VALVES MR No. A133-000-WB-MR-3115

Item Code MOV TAG No. LINE No. PIPING CLASS Valve Type VMS Sheet No. Process Data Sheet No. Electrical Data Sheet No. P&ID NO Remarks

1 *PS1600MV1201A33A 086-MOV-1201 WF-086-0207 16 A33A Ball 54301 A133-086-16-47-DS-20 A133-000-16-50-DS-3115 A133-086-16-47-003022 *PS1400MV1202ZA9A 086-MOV-1202 P-086-1201 14 A9A Ball 54396 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1112-23 *PS0600MV1501ZB4G 086-MOV-1501 P-086-1503 6 B4G Ball 54498 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-11154 *PS0800MV1601ZB9A 086-MOV-1601 P-086-1605 8 B9A Ball 54496 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-11165 *PS0600MV1602ZB9A 086-MOV-1602 P-086-1607 6 B9A Ball 54496 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-11166 *PS0800MV1603ZB9A 086-MOV-1603 P-086-1606 8 B9A Ball 54496 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-11167 *PS0600MV1604ZB9A 086-MOV-1604 P-086-1608 6 B9A Ball 54496 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-11168 *PS0800MV1605ZB4G 086-MOV-1605 P-086-1601 8 B4G Ball 54498 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-11169 *PS1600MV1701ZB4G 086-MOV-1701 P-086-1701 16 B4G Ball 54498 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1117

10 *PS1400MV1702ZB4G 086-MOV-1702 P-086-1703 14 B4G Ball 54498 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-111711 *PS1600MV1703ZB4G 086-MOV-1703 P-086-1702 16 B4G Ball 54498 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-111712 *PS1400MV1704ZB4G 086-MOV-1704 P-086-1704 14 B4G Ball 54498 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-111713 *PS1400MV1801ZD4G 086-MOV-1801 P-086-1801 14 D4G Ball 54599 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-111814 *PS1200MV1802ZD4G 086-MOV-1802 P-086-1804 12 D4G Ball 54599 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-111815 *PS1400MV1803ZD4G 086-MOV-1803 P-086-1803 14 D4G Ball 54599 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-111816 *PS1200MV1804ZD4G 086-MOV-1804 P-086-1808 12 D4G Ball 54599 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-111817 *PS0400MV2601ZB9A 086-MOV-2601 P-086-2603 4 B9A 3 Way Ball 66491 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-112618 *PS1400MV2602ZB9A 086-MOV-2602 P-086-2607 14 B9A 3 Way Ball 66491 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-112619 *PS1200MV2901A26A 086-MOV-2901 P-086-2804 12 A26A Ball 54391 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1129 LUM120 *PS0600MV2902A26A 086-MOV-2902 P-086-2906 6 A26A Ball 54391 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1129 LUM121 *PS2400MV3001A26A 086-MOV-3001 P-086-2801 24 A26A Ball 54391 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1130 LUM122 *PS1600MV3002A26A 086-MOV-3002 P-086-3001 16 A26A Ball 54391 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1130 LUM123 *PS1400MV3003A26A 086-MOV-3003 P-086-3109 14 A26A Ball 54391 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1130 LUM124 *PS1000MV3004B26A 086-MOV-3004 P-086-3002 10 B26A Ball 54491 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1130 LUM125 *PS1000MV3005ZD2D 086-MOV-3005 SVH-086-3001 10 D2D Ball 54593 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1130 IBR, TSO Valve (Rate A) , Refer HOLD in PDS26 *PS0300MV3101A26A 086-MOV-3101 P-086-3101 3 A26A Ball 54391 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1131 LUM127 *PS1000MV3201B26A 086-MOV-3201 P-086-3201 10 B26A Ball 54491 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1132 LUM128 *PS1200MV3701ZB9A 086-MOV-3701 P-086-3701 12 B9A Ball 54496 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-113729 *PS0800MV3801A19A 086-MOV-3801 P-086-3801 8 A19A Ball 54313 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1138 TSO Valve (Rate A)30 *PS1200MV4511ZG9A 086-MOV-4511 WP-086-4502 12 G9A Ball 54891 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1145 Refer HOLD in PDS31 *PS0800MV4512ZG9A 086-MOV-4512 WP-086-4503 8 G9A Ball 54891 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1145 Refer HOLD in PDS32 *PS1200MV4513ZG9A 086-MOV-4513 WP-086-4501 12 G9A Ball 54891 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1145 Refer HOLD in PDS33 *PS0800MV4514ZG9A 086-MOV-4514 WP-086-4504 8 G9A Ball 54891 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1145 Refer HOLD in PDS34 *PS0400MV5301ZA9A 086-MOV-5301 P-086-5305 4 A9A Ball 54301 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-115335 *PS0600MV5401ZA9A 086-MOV-5401 P-086-5402 6 A9A Ball 54301 A133-86-02-DS-2950 A133-000-16-50-DS-3115 A133-02-41-86-1154 TSO Valve (Rate A)

MR SL. NO.

SIZE (INCH)

B

B

B

B

B

B

Page 55 of 129

VENDOR DATA REQUIREMENTS

FOR

MOTOR OPERATED VALVES

A 12-SEP-2014 ISSUED WITH MR NK KB UC

Rev.No.

Date Purpose Prepared by Checked by Approved by

VENDOR DATA REQUIREMENTSFOR

MOTOR OPERATED VALVES of 2

Document No.A133-000-16-43-VDR-3115

Rev. A

Page 1

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

Page 56 of 129


The following drawings/documents marked " " shall be furnished by the bidder.

Notes :

1. "TICK" denotes applicability.

2. Post order, drawing / document review shall commence only after approval of Document Control Index (DCI).

3. All post order documents shall be submitted / approved through EIL eDMS portal.

4. Final documentation shall be submitted in hard copy (Six prints) and soft ( two CDs/DVDs ) in addition to

submission through EIL eDMS.

5. Refer - 6-78-0001: Specification for quality management system from Bidders.

6. Refer - 6-78-0003: Specification for documentation requirement from Suppliers.

7. All drawings & documents shall be submitted in A4 or A3 paper sizes. Documents in higher paper size shall

be submitted in exceptional circumstances or as indicated in the MR/Tender.

8. Post order- The schedule of drawing / data submission shall be mutually agreed between EIL & the bidder /

contractor / supplier during finalization of Document Control Index (DCI).

9. Bill of Material shall form part of the respective drawing.

10. Also refer other department's VDR :-

11. Electrical

S.NO.

DESCRIPTION WITHBID

POST ORDERREMARKSFOR

REVIEWFOR

RECORD

WITHDATABOOK

(FINAL)

1. Document Control Index

2. Detailed Dimensioned Cross Section Drawingwith parts / material list, weight etc.

3. Drawing for valves with accessories like gearoperator, hydraulic / pneumatic operator, motor,bypass etc. giving major salient diemnsions.

4. Test reports for all mandatory tests as per theapplicable codes.

5. Inspection & Test Plan (ITP)- For review byInspection Dept.


MOTOR OPERATED VALVES of 2


Rev. A

Page 2


Page 57 of 129

TECHNICAL COMPLIANCE FORMAT PIPING

FOR MISC. COKER VALVES

Document No.

A133-000-16-43-TCL-3115 Rev A

Page 1 of 2

A 11.09.14 ISSUED WITH BID NK KB UC

Rev. No


Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

TECHNICAL COMPLIANCE

DISCIPLINE: PIPING

DOCUMENT No.: A133-000-16-43-TCL-3115

PROJECT: RESID UPGRADATION PROJECT-DCU

MR: MOTOR OPERATED VALVES

OWNER: CPCL

EIL JOB No.: A133

BIDDER: _____________________________________________

Notes:

1. The bidder shall indicate their reply in the space provided in the Technical Questionnaire. In

case space provided is not adequate, the reply may be furnished separately under suitably

numbered annexes/ attachments duly referred against the comment/ query.

2. The Compliance Statements/ Queries are required to be categorically confirmed/ answered by

the bidder and the completely filled in technical questionnaire shall be submitted together with

the BID.

Bidder’s Signature

& Stamp

Page 58 of 129

TECHNICAL COMPLIANCE FORMAT PIPING

FOR MISC. COKER VALVES

Document No.

A133-000-16-43-TCL-3115 Rev A

Page 2 of 2

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

SI. No. COMMENT / QUERY BIDDER’S CONFIRMATION / ANSWER

1. Bidders offer evaluation shall consider confirmation

/ deviation marked by bidder on respective valve

data sheets. Valve drawings/ Vendor Catalogue

enclosed, in the offer are considered for reference

only. Any deviation specified therein with respect to

above referred filled up Valve data sheets/ MR

requisitions shall not be considered applicable.

Bidder shall note and confirm.

2. Bidder to submit complete descriptive and

illustrative catalogue, detailed dimensional cross

sectional drawing with accessories giving major

salient dimensions.

3. Bidder to categorically confirm compliance to the

Additional technical requirements (Doc. No. A133-

000-16-43-ATR-3115), various technical

specifications & documents attached with the MR.

4. Bidder to submit signed & stamped copy of valve

material specification sheet for quoted valves &

Additional technical requirements (A133-000-16-

43-ATR-3115), as a token of their acceptance for

the same

Page 59 of 129


CPCLClient :

COKER BLOCK (LSTK 1)Project :

CHENNAILocation :

16/43Dept./Sect. :

JOB SPECIFICATION NO.

A133-6-44-0006 Rev. A

Copyright EIL-All rights reservedTemplate No. 5-0000-0001-T2 Rev. 1

Page 1 of 22

54301

54301

TAG NO. :

SHEET REV. NO.

DATE 07/10/2013 11/09/2014

0 1

NOTES

4

5

6789

VALVES CAN ALSO BE SUPPLIED IN ACCORDANCE WITH API-6D. FOR API 6D VALVES,MIN BODY WALLTHICKNESS SHALL BE PER ASME B16.34. ALL VALVES SHALL BE FIRE SAFE DESIGN.FIRE SAFE TEST SHALL BE AS PER (API 607 IV EDITION/ (API 607/ISO 10497))/ (BS 6755(PART II)/ BS EN ISO 10497)/API RP 6FA. TESTING SHALL BE AS PER BS EN 12266-1/API 6D. FOR TRUNNION MOUNTED BALL,BODY SEAT SHALL BE SPRING LOADED.ALL VALVES SHALL BE BIDIRECTIONAL.10 % VALVE CASTINGS SHALL UNDERGO RADIOGRAPHIC EXAMINATION.

BODY

STEM

BALL

BODY SEAT

GLAND

STEM SEAL

BODY SEAL

BODY STUD

BODY NUT

OTHERS

REQUIREMENT OFGEAR OPERATOR

REQUIREMENT OFRADIOGRAPHY

SPECIAL SERVICECONDITIONS

SPRING

HYDROSTATIC TESTPRESSURE

TEST PRESSUREWITH AIR

FORGD/CAST

ANTI BLOWOUT

SOLID

BOLTED/ RETAINEDBY NUT & WASHER

RENEWABLE WITHVALVE OPEN ONSTREAM

BODY : 450 PSIG

80 PSIG

ASTM A 105 / A 216GR.WCB

13% CR.STEEL/SS316; (NO CASTING)

13% CR.STEEL/SS304/SS316

RPTFE WITH SECONDARY METAL TO METAL

ASTM A105/13% CR STEEL/SS 316/SS 304

GRAFOIL/PTFE V-RINGS+GRAFOIL

GRAFOIL/PTFE

ASTM A193 GR.B7

ASTM A194 GR 2H

REFER TECHNICAL NOTES FOR PURCHASE OFVALVES.


MAX TEMP 204 DEG C.

INCONEL X-750

SEAT : 325 PSIG

150 BS EN ISO 17292RATING :SIZE RANGE : ENDS :

12

3

THIS VALVE SPEC SHEET SHALL BE READ IN CONJUNCTION WITH TECHNICAL NOTES FOR VALVES.ONLY IN THE CASE OF CATEGORY - II MRs,BIDDER SHALL CLEARLY WRITE ALL/ ANY DEVIATION AGAINSTEACH PART/ MATERIAL OF VALVE IN THE SPACE PROVIDED FOR AND WHEREVER BIDDER AGREES WITHEIL'S SPEC BIDDER SHALL INDICATE "AGREED".NO CUTTING/ OVERWRITING BY BIDDER ON EIL'S SPEC IS ALLOWED.

STANDARD:MFGRS CAT/FIG:

RATING: ENDS:

SIGNATURE&

SEALOF MANUFACTURER

BALL VALVE SPECIFICATION MANUF'S OFFER

DESCRIPTION CONSTRUCTION CONSTRUCTION MATERIALMATERIAL

STANDARD : 0.5" TO 16.0" FLGD TO B-16.5 RF/125AARH

PIPING CLASS : A11A, A1A, A33A, A9A

Tag No: 54301

(For category -II MRs only )

Sheet No. 1 of 2

Page 60 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 2 of 22

54301SHEET REV. NO.

DATE 07/10/2013 11/09/2014

0 1

NOTES

10

1112

BIDDER'S STAMPING ON THE VALVE SPECIFICATION SHEET SHALL BE CONSTRUED TO MEAN BIDDER'SACCEPTANCE OF SUITABILITY OF VALVE AND VALVE SHEETS FOR SERVICE AND 'SPECIAL SERVICECONDITIONS' MENTIONED IN THE VALVE SPECIFICATION SHEETS.STEM SEAL/BODY SEAL MATERIALS SHALL BE PROVIDED WITH CORROSION INHIBITOR.VALVES AS PER BS-5351 AND TESTING AS PER BS 6755 (PART-1) IS ALSO ACCEPTABLE.

Sheet No. 2 of 2

Page 61 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 3 of 22

54313

54313

TAG NO. :

SHEET REV. NO.

DATE 18/09/2013 24/01/2014

0 1

NOTES

4

5

6789

VALVES CAN ALSO BE SUPPLIED IN ACCORDANCE WITH API-6D. FOR API 6D VALVES,MIN BODY WALLTHICKNESS SHALL BE PER ASME B16.34. ALL VALVES SHALL BE FIRE SAFE DESIGN.FIRE SAFE TEST SHALL BE AS PER (API 607 IV EDITION/ (API 607/ISO 10497)) / (BS 6755(PART II)/ BS EN ISO 10497) /API RP 6FA. TESTING SHALL BE AS PER BS EN 12266-1/API 6D. FOR TRUNNION MOUNTED BALL,BODY SEAT SHALL BE SPRING LOADED.ALL VALVES SHALL BE BIDIRECTIONAL. 100 % VALVE CASTINGS SHALL UNDERGO RADIOGRAPHIC EXAMINATION.

BODY

STEM

BALL

BODY SEAT

GLAND

STEM SEAL

BODY SEAL

BODY STUD

BODY NUT

OTHERS




SPRING



FORGD/CAST

ANTI BLOWOUT

SOLID



BODY : 450 PSIG

80 PSIG


SS 304/SS 316; (NO CASTING)

SS 304/SS 316



GRAFOIL/PTFE V-RINGS+GRAFOIL

GRAFOIL/PTFE

ASTM A193 GR.B7

ASTM A194 GR 2H



AMINE; MAX TEMP 204 DEG.C

INCONEL X750

SEAT : 325 PSIG


12

3



RATING: ENDS:

SIGNATURE&

SEALOF MANUFACTURER




PIPING CLASS : A19A

Tag No: 54313


Sheet No. 1 of 2

Page 62 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 4 of 22

54313SHEET REV. NO.

DATE 18/09/2013 24/01/2014

0 1

NOTES

10

111213

BIDDER'S STAMPING ON THE VALVE SPECIFICATION SHEET SHALL BE CONSTRUED TO MEAN BIDDER'SACCEPTANCE OF SUITABILITY OF VALVE AND VALVE SHEETS FOR SERVICE AND 'SPECIAL SERVICECONDITIONS' MENTIONED IN THE VALVE SPECIFICATION SHEETS.STEM SEAL/BODY SEAL MATERIALS SHALL BE PROVIDED WITH CORROSION INHIBITOR.VALVES AS PER BS-5351 AND TESTING AS PER BS 6755 (PART-1) IS ALSO ACCEPTABLE.FLOATING BALL VALVES SHALL BE PROVIDED WITH PRESSURE EQUALISATION SEATS TO RELIEVE THEBODY-BONNET CAVITY PRESSURE TO THE UPSTREAM SIDE.

Sheet No. 2 of 2

Page 63 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 5 of 22

54391

54391

TAG NO. :

SHEET REV. NO.

DATE 16/12/2013 11/09/2014

0 1

NOTES

4

56789

10

ALL VALVES SHALL BE FIRE SAFE DESIGN.FIRE SAFE TEST SHALL BE AS PER (API 607 IV EDITION/ (API 607/ISO10497)) / (BS 6755(PART II)/ BS EN ISO 10497) /API RP 6FA.TESTING SHALL BE AS PER BS EN 12266-1/API 6D.FOR TRUNNION MOUNTED BALL,BODY SEAT SHALL BE SPRING LOADED.ALL VALVES SHALL BE BIDIRECTIONAL.100 % VALVE CASTINGS SHALL UNDERGO RADIOGRAPHIC EXAMINATION.BIDDER'S STAMPING ON THE VALVE SPECIFICATION SHEET SHALL BE CONSTRUED TO MEAN BIDDER'SACCEPTANCE OF SUITABILITY OF VALVE AND VALVE SHEETS FOR SERVICE AND 'SPECIAL SERVICECONDITIONS' MENTIONED IN THE VALVE SPECIFICATION SHEETS.STEM SEAL/BODY SEAL MATERIALS SHALL BE PROVIDED WITH CORROSION INHIBITOR.

BODY

STEM

BALL

BODY SEAT

GLAND

STEM SEAL

BODY SEAL

BODY STUD

BODY NUT

OTHERS




SPRING



FORGED / CAST

ANTI BLOWOUT

SOLID



NACE (NOTE-14)

BODY: 450 PSIG

80 PSIG

ASTM A 105 / ASTMA A216 GR.WCB

SS316L (NO CASTING)

SS316L


SS 316L

GRAFOIL / PTFE V-RINGS + GRAFOIL

GRAFOIL / PTFE

ASTM A193 GR.B7M

ASTM A194 GR.2HM



SOUR SERVICE, MAX TEMP 204 DEG.C

INCONEL X750

SEAT: 325 PSIG


12

3



RATING: ENDS:

SIGNATURE&

SEALOF MANUFACTURER




PIPING CLASS : A26A

Tag No: 54391


Sheet No. 1 of 2

Page 64 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 6 of 22

54391SHEET REV. NO.

DATE 16/12/2013 11/09/2014

0 1

NOTES

1112

131415

VALVES AS PER BS-5351 AND TESTING AS PER BS 6755 (PART-1) IS ALSO ACCEPTABLE.VALVES CAN ALSO BE SUPPLIED AS PER API-6D. FOR API 6D VALVES, MIN. BODY WALL THICKNESS SHALL BEAS PER ASME B 16.34.NACE REQUIREMENT SHALL BE AS PER MR 0103.SULPHUR CONTENT TO BE RESTRICTED TO 0.01% MAX .CARBON EQUIVALENT (CE) SHALL BE LIMITED TO 0.43. HARDNESS SHALL BE BELOW BH NO. 200 FOR CSMATERIAL.

Sheet No. 2 of 2

Page 65 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 7 of 22

54396

54396

TAG NO. :

SHEET REV. NO.

DATE 14/10/2014

0

NOTES

4

5

6789

VALVES CAN ALSO BE SUPPLIED IN ACCORDANCE WITH API-6D. FOR API 6D VALVES,MIN BODY WALLTHICKNESS SHALL BE PER ASME B16.34. ALL VALVES SHALL BE FIRE SAFE DESIGN.FIRE SAFE TEST SHALL BE AS PER (API 607 IV EDITION/ (API 607/ISO 10497))/ (BS 6755(PART II)/ BS EN ISO 10497)/API RP 6FA. TESTING SHALL BE AS PER BS EN 12266-1/API 6D. FOR TRUNNION MOUNTED BALL,BODY SEAT SHALL BE SPRING LOADED.ALL VALVES SHALL BE BIDIRECTIONAL.10 % VALVE CASTINGS SHALL UNDERGO RADIOGRAPHIC EXAMINATION.

BODY

STEM

BALL

BODY SEAT

GLAND

STEM SEAL

BODY SEAL

BODY STUD

BODY NUT

OTHERS




SPRING



FORGD/CAST

ANTI BLOWOUT

SOLID

METAL TO METAL



BODY : 450 PSIG

80 PSIG




13% CR.STEEL/SS304/SS316 + STELLITED


GRAPHITE

GRAPHITE

ASTM A193 GR.B7

ASTM A194 GR 2H



MAX TEMP 371 DEG C.

INCONEL X-750

SEAT : 325 PSIG


12

3



RATING: ENDS:

SIGNATURE&

SEALOF MANUFACTURER




PIPING CLASS : A9A

Tag No: 54396


Sheet No. 1 of 2

Page 66 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 8 of 22

54396SHEET REV. NO.

DATE 14/10/2014

0

NOTES

10

1112

BIDDER'S STAMPING ON THE VALVE SPECIFICATION SHEET SHALL BE CONSTRUED TO MEAN BIDDER'SACCEPTANCE OF SUITABILITY OF VALVE AND VALVE SHEETS FOR SERVICE AND 'SPECIAL SERVICECONDITIONS' MENTIONED IN THE VALVE SPECIFICATION SHEETS.STEM SEAL/BODY SEAL MATERIALS SHALL BE PROVIDED WITH CORROSION INHIBITOR.VALVES AS PER BS-5351 AND TESTING AS PER BS 6755 (PART-1) IS ALSO ACCEPTABLE.

Sheet No. 2 of 2

Page 67 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 9 of 22

54491

54491

TAG NO. :

SHEET REV. NO.

DATE 16/12/2013 11/09/2014

0 1

NOTES

4

56789

10

ALL VALVES SHALL BE FIRE SAFE DESIGN.FIRE SAFE TEST SHALL BE AS PER (API 607 IV EDITION/ (API 607/ISO10497)) / (BS 6755(PART II)/ BS EN ISO 10497) /API RP 6FA.TESTING SHALL BE AS PER BS EN 12266-1/API 6D.FOR TRUNNION MOUNTED BALL,BODY SEAT SHALL BE SPRING LOADED.ALL VALVES SHALL BE BIDIRECTIONAL.100 % VALVE CASTINGS SHALL UNDERGO RADIOGRAPHIC EXAMINATION.BIDDER'S STAMPING ON THE VALVE SPECIFICATION SHEET SHALL BE CONSTRUED TO MEAN BIDDER'SACCEPTANCE OF SUITABILITY OF VALVE AND VALVE SHEETS FOR SERVICE AND 'SPECIAL SERVICECONDITIONS' MENTIONED IN THE VALVE SPECIFICATION SHEETS.STEM SEAL/BODY SEAL MATERIALS SHALL BE PROVIDED WITH CORROSION INHIBITOR.

BODY

STEM

BALL

BODY SEAT

GLAND

STEM SEAL

BODY SEAL

BODY STUD

BODY NUT

OTHERS




SPRING



FORGED / CAST

ANTI BLOWOUT

SOLID



NACE

BODY: 1125 PSIG

80 PSIG

ASTM A 105 / ASTMA A216 GR.WCB

SS316L (NO CASTING)

SS316L


SS 316L

GRAFOIL / PTFE V-RINGS + GRAFOIL

GRAFOIL / PTFE

ASTM A193 GR.B7M

ASTM A194 GR.2HM



SOUR SERVICE, MAX TEMP 204 DEG.C

INCONEL X750

SEAT: 825 PSIG


12

3



RATING: ENDS:

SIGNATURE&

SEALOF MANUFACTURER




PIPING CLASS : B26A

Tag No: 54491


Sheet No. 1 of 2

Page 68 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 10 of 22

54491SHEET REV. NO.

DATE 16/12/2013 11/09/2014

0 1

NOTES

1112

131415

VALVES AS PER BS-5351 AND TESTING AS PER BS 6755 (PART-1) IS ALSO ACCEPTABLE.VALVES CAN ALSO BE SUPPLIED AS PER API-6D. FOR API 6D VALVES, MIN. BODY WALL THICKNESS SHALL BEAS PER ASME B 16.34.NACE REQUIREMENT SHALL BE AS PER MR 0103.SULPHUR CONTENT TO BE RESTRICTED TO 0.01% MAXCARBON EQUIVALENT (CE) SHALL BE LIMITED TO 0.43. HARDNESS SHALL BE BELOW BH NO. 200 FOR CSMATERIAL.

Sheet No. 2 of 2

Page 69 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 11 of 22

54496

54496

TAG NO. :

SHEET REV. NO.

DATE 14/10/2014

0

NOTES

4

5

6789

VALVES CAN ALSO BE SUPPLIED IN ACCORDANCE WITH API-6D. FOR API 6D VALVES,MIN BODY WALLTHICKNESS SHALL BE PER ASME B16.34. ALL VALVES SHALL BE FIRE SAFE DESIGN.FIRE SAFE TEST SHALL BE AS PER (API 607 IV EDITION/ (API 607/ISO 10497))/(BS 6755(PART II)/ BS EN ISO 10497) /API RP 6FA. TESTING SHALL BE AS PER BS EN 12266-1/API 6D. FOR TRUNNION MOUNTED BALL,BODY SEAT SHALL BE SPRING LOADED.ALL VALVES SHALL BE BIDIRECTIONAL.BIDDER'S STAMPING ON THE VALVE SPECIFICATION SHEET SHALL BE CONSTRUED TO MEAN BIDDER'SACCEPTANCE OF SUITABILITY OF VALVE AND VALVE SHEETS FOR SERVICE AND 'SPECIAL SERVICECONDITIONS' MENTIONED IN THE VALVE SPECIFICATION SHEETS.

BODY

STEM

BALL

BODY SEAT

GLAND

STEM SEAL

BODY SEAL

BODY STUD

BODY NUT

OTHERS




SPRING



FORGD/CAST

ANTI BLOWOUT

SOLID

METAL TO METAL



BODY : 1125 PSIG

80 PSIG




13% CR.STEEL/SS304/SS316 + STELLITED


GRAPHITE

GRAPHITE

ASTM A193 GR.B7

ASTM A194 GR 2H



MAX TEMP 427 DEG C.

INCONEL X-750

SEAT : 825 PSIG


12

3



RATING: ENDS:

SIGNATURE&

SEALOF MANUFACTURER




PIPING CLASS : B9A

Tag No: 54496


Sheet No. 1 of 2

Page 70 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 12 of 22

54496SHEET REV. NO.

DATE 14/10/2014

0

NOTES

101112

20% VALVE CASTINGS SHALL UNDERGO RADIOGRAPHIC EXAMINATION.STEM SEAL/BODY SEAL MATERIALS SHALL BE PROVIDED WITH CORROSION INHIBITOR.VALVES AS PER BS-5351 AND TESTING AS PER BS 6755 (PART-1) IS ALSO ACCEPTABLE.

Sheet No. 2 of 2

Page 71 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 13 of 22

54498

54498

TAG NO. :

SHEET REV. NO.

DATE 18/09/2013

0

NOTES

4

5

678

VALVES CAN ALSO BE SUPPLIED IN ACCORDANCE WITH API-6D. FOR API 6D VALVES,MIN BODY WALLTHICKNESS SHALL BE PER ASME B16.34.ALL VALVES SHALL BE FIRE SAFE DESIGN.FIRE SAFE TEST SHALL BE AS PER (API 607 IV EDITION/ (API 607/ISO10497))/(BS 6755(PART II)/ BS EN ISO 10497) /API RP 6FA.TESTING SHALL BE AS PER BS EN 12266-1/API 6D. FOR TRUNNION MOUNTED BALL,BODY SEAT SHALL BE SPRING LOADED.ALL VALVES SHALL BE BIDIRECTIONAL.

BODY

STEM

BALL

BODY SEAT

GLAND

STEM SEAL

BODY SEAL

BODY STUD

BODY NUT

OTHERS




SPRING



FORGED / CAST

ANTI BLOWOUT

SOLID

METAL TO METAL



METAL TO METAL

NOTE 13

BODY : 1125 PSIG

80 PSIG

ASTM A 182 GR.F9/ASTM A 217 GR.C12 (NORM &TEMP)

13% CR.STEEL//SS304/SS316; (NO CASTING)

9%CR1%MO/13%CR.STEEL/SS304/SS316+STELLITED/COATEDWITH CHROME CARBIDE

9%CR1%MO/SS410/SS304/SS316 +STELLITED/COATED WITH CHROME CARBIDE

SS 316 / SS 304

GRAPHITE

GRAPHITE

A193 GR.B16

A194 GR.4/7



MAX TEMP 538 DEG C.

INCONEL X-750

SEAT : 825 PSIG


12

3



RATING: ENDS:

SIGNATURE&

SEALOF MANUFACTURER




PIPING CLASS : B4G

Tag No: 54498


Sheet No. 1 of 2

Page 72 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 14 of 22

54498SHEET REV. NO.

DATE 18/09/2013

0

NOTES

910

111213

100% VALVE CASTINGS SHALL UNDERGO RADIOGRAPHIC EXAMINATION.BIDDER'S STAMPING ON THE VALVE SPECIFICATION SHEET SHALL BE CONSTRUED TO MEAN BIDDER'SACCEPTANCE OF SUITABILITY OF VALVE AND VALVE SHEETS FOR SERVICE AND 'SPECIAL SERVICECONDITIONS' MENTIONED IN THE VALVE SPECIFICATION SHEETS.STEM SEAL/BODY SEAL MATERIALS SHALL BE PROVIDED WITH CORROSION INHIBITOR.VALVES AS PER BS-5351 AND TESTING AS PER BS 6755 (PART-1) IS ALSO ACCEPTABLE.VALVES SHALL BE STEAM PURGED WHEREVER REQUIRED AS PER PROCESS DATA SHEET .

Sheet No. 2 of 2

Page 73 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 15 of 22

54593

54593

TAG NO. :

SHEET REV. NO.

DATE 11/09/2014

0

NOTES

4

56789

10

VALVES CAN ALSO BE SUPPLIED IN ACCORDANCE WITH API-6D. FOR API 6D VALVES,MIN BODY WALLTHICKNESS SHALL BE PER ASME B16.34.VALVES TO COMPLY WITH DESIGN REQUIREMENTS OF IBR ALSO. TESTING SHALL BE AS PER BS EN 12266-1/API 6D & IBR.ALL VALVES SHALL BE BIDIRECTIONAL.100% VALVE CASTINGS SHALL UNDERGO RADIOGRAPHIC EXAMINATION. ALL VALVES TO BE SUPPLIED WITH IBR CERTIFICATE IN FORM-III C. ALL VALVES SHALL BE PAINTED RED ON BODY-BONNET JOINT.

BODY

STEM

BALL

BODY SEAT

GLAND

STEM SEAL

BODY SEAL

BODY STUD

BODY NUT

OTHERS




SPRING



FORGED/CAST

ANTI BLOWOUT

SOLID

METAL TO METAL



I.B.R.

BODY : 2250 PSIG

80 PSIG

ASTM A182 GR.F11 CL2/A217 GR.WC6 (NORM &TEMP



13% CR.STEEL/SS304/SS316 + COATED WITHCHROME CARBIDE

13% CR STEEL/SS 316/SS 304

GRAFOIL

GRAFOIL

ASTM A193 GR.B16

ASTM A194 GR 4/GR.7



HIGH PRESSURE STEAM, MAX. TEMP 538DEG.C.

INCONEL X-750

SEAT : 1650 PSIG


12

3



RATING: ENDS:

SIGNATURE&

SEALOF MANUFACTURER




PIPING CLASS : D2D

Tag No: 54593


Sheet No. 1 of 2

Page 74 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 16 of 22

54593SHEET REV. NO.

DATE 11/09/2014

0

NOTES

11

121314

BIDDER'S STAMPING ON THE VALVE SPECIFICATION SHEET SHALL BE CONSTRUED TO MEAN BIDDER'SACCEPTANCE OF SUITABILITY OF VALVE AND VALVE SHEETS FOR SERVICE AND 'SPECIAL SERVICECONDITIONS' MENTIONED IN THE VALVE SPECIFICATION SHEETS.STEM SEAL/BODY SEAL MATERIALS SHALL BE PROVIDED WITH CORROSION INHIBITOR.VALVES AS PER BS-5351 AND TESTING AS PER BS 6755 (PART-1) & IBR IS ALSO ACCEPTABLE.FOR TRUNNION MOUNTED BALL, BODY SEAT SHALL BE SPRING LOADED .

Sheet No. 2 of 2

Page 75 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 17 of 22

54599

54599

TAG NO. :

SHEET REV. NO.

DATE 11/09/2014

0

NOTES

4

5

678

VALVES CAN ALSO BE SUPPLIED IN ACCORDANCE WITH API-6D. FOR API 6D VALVES,MIN BODY WALLTHICKNESS SHALL BE PER ASME B16.34.ALL VALVES SHALL BE FIRE SAFE DESIGN.FIRE SAFE TEST SHALL BE AS PER (API 607 IV EDITION/ (API 607/ISO10497))/(BS 6755(PART II)/ BS EN ISO 10497) /API RP 6FA.TESTING SHALL BE AS PER BS EN 12266-1/API 6D. FOR TRUNNION MOUNTED BALL,BODY SEAT SHALL BE SPRING LOADED.ALL VALVES SHALL BE BIDIRECTIONAL.

BODY

STEM

BALL

BODY SEAT

GLAND

STEM SEAL

BODY SEAL

BODY STUD

BODY NUT

OTHERS




SPRING



FORGED / CAST

ANTI BLOWOUT

SOLID

METAL TO METAL



METAL TO METAL

BODY : 2250 PSIG

80 PSIG

ASTM A 182 GR.F9/ASTM A 217 GR.C12 (NORM &TEMP)

13% CR.STEEL//SS304/SS316; (NO CASTING)

9%CR1%MO/13%CR.STEEL/SS304/SS316+STELLITED/COATEDWITH CHROME CARBIDE

9%CR1%MO/SS410/SS304/SS316 +STELLITED/COATED WITH CHROME CARBIDE

ASTM A 217 GR.C12 (NORM. & TEMP.)/13%CR.STEEL / SS304 / SS316

GRAPHITE

GRAPHITE

ASTM A193 GR.B16

ASTM A194 GR.4/7



MAX TEMP 566 DEG C.

INCONEL X-750

SEAT : 1650 PSIG


12

3



RATING: ENDS:

SIGNATURE&

SEALOF MANUFACTURER




PIPING CLASS : D4G

Tag No: 54599


Sheet No. 1 of 2

Page 76 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 18 of 22

54599SHEET REV. NO.

DATE 11/09/2014

0

NOTES

910

1112

100% VALVE CASTINGS SHALL UNDERGO RADIOGRAPHIC EXAMINATION.BIDDER'S STAMPING ON THE VALVE SPECIFICATION SHEET SHALL BE CONSTRUED TO MEAN BIDDER'SACCEPTANCE OF SUITABILITY OF VALVE AND VALVE SHEETS FOR SERVICE AND 'SPECIAL SERVICECONDITIONS' MENTIONED IN THE VALVE SPECIFICATION SHEETS.STEM SEAL/BODY SEAL MATERIALS SHALL BE PROVIDED WITH CORROSION INHIBITOR.VALVES AS PER BS-5351 AND TESTING AS PER BS 6755 (PART-1) IS ALSO ACCEPTABLE.

Sheet No. 2 of 2

Page 77 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 19 of 22

54891

54891

TAG NO. :

SHEET REV. NO.

DATE 11/09/2014

0

NOTES

45678

910

TESTING SHALL BE AS PER BS EN 12266-1/API 6D.FOR TRUNNION MOUNTED BALL,BODY SEAT SHALL BE SPRING LOADED.ALL VALVES SHALL BE BIDIRECTIONAL.100% VALVE CASTINGS SHALL UNDERGO RADIOGRAPHIC EXAMINATION.BIDDER'S STAMPING ON THE VALVE SPECIFICATION SHEET SHALL BE CONSTRUED TO MEAN BIDDER'SACCEPTANCE OF SUITABILITY OF VALVE AND VALVE SHEETS FOR SERVICE AND 'SPECIAL SERVICECONDITIONS' MENTIONED IN THE VALVE SPECIFICATION SHEETS.STEM SEAL / BODY SEAL SHALL BE PROVIDED WITH CORROSION INHIBITOR.MIN. BODY WALL THICKNESS SHALL BE AS PER ASME B-16.34.

BODY

STEM

BALL

BODY SEAT

GLAND

STEM SEAL

BODY SEAL

BODY STUD

BODY NUT

OTHERS




SPRING



FORGED/CAST

ANTI BLOW OUT

SOLID

METAL TO METAL

BOLTED / RETAINEDBY NUT & WASHER


COKE CUTTINGWATER

BODY: 9275 PSIG

80 PSIG


13% CR.STEEL/ 17-4 PH SS; (NO CASTING), 32RMS FINISH

13%CR.STEEL/SS304/SS316+STELLITED/COATEDWITH CHROME CARBIDE

SS410/SS304/SS316 +STELLITED/COATED WITHCHROME CARBIDE

ASTM A 105 / 13% CR.STEEL / SS304 / SS316

GRAPHITE

GRAPHITE

ASTM A193 GR B7

ASTM A194 GR 2H



MAX. TEMP.-100 DEG. C;MAX. PRESS.- 380kg/cm2g

INCONEL X-750

SEAT: 6690 PSIG

2500 API-6DRATING :SIZE RANGE : ENDS :

12

3



RATING: ENDS:

SIGNATURE&

SEALOF MANUFACTURER



STANDARD : 0.5" TO 12.0" FLGD TO B-16.5 RTJ/63AARH

PIPING CLASS : G9A

Tag No: 54891


Sheet No. 1 of 2

Page 78 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 20 of 22

54891SHEET REV. NO.

DATE 11/09/2014

0

NOTES

11

12

ALL VALVES SHALL BE FIRE SAFE DESIGN.FIRE SAFE TEST SHALL BE AS PER (API 607 IV EDITION/ (API 607/ISO10497))/(BS 6755(PART II)/ BS EN ISO 10497) /API RP 6FA.VALVE TESTING AS PER BS 6755 (PART-1) IS ALSO ACCEPTABLE

Sheet No. 2 of 2

Page 79 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 21 of 22

66491

66491

TAG NO. :

SHEET REV. NO.

DATE 03/09/2014

0

NOTES

45

6789

1011

TESTING SHALL BE AS PER BS EN 12266-1/API 6D.ALL VALVES SHALL BE FIRE SAFE DESIGN.FIRE SAFE TEST SHALL BE AS PER (API 607 IV EDITION/ (API 607/ISO10497))/(BS 6755(PART II)/ BS EN ISO 10497) /API RP 6FA.VALVE SHALL BE T-SHAPED FULL PORT DESIGN TO ALLOW CHANGEOVER.100% VALVE CASTINGS SHALL UNDERGO RADIOGRAPHIC EXAMINATION.VALVE SHALL BE PROVIDED WITH LIMIT STOPS TO ENSURE POSITIVE ALIGNMENT OF BALL WITH PORT.VALVE SHALL BE PROVIDED WITH BALL POSITION INDICATOR.FLOW DIRECTION SHALL BE CLEARLY MARKED ON ALL VALVES.FOR TRUNNION MOUNTED BALL,BODY SEAT SHALL BE SPRING LOADED.

BODY

STEM

BALL

BODY SEAT

GLAND

STEM SEAL

BODY SEAL

BODY STUD

BODY NUT

OTHERS

REQUIREMENT OFGEAR OPERATION


THRUST WASHER


SPRING



CAST / FORGED

ANTI BLOWOUT

SOLID( T PORT)

METAL TO METAL



3-WAY, 2 PORT (TSHAPE), FULL PORT

BODY : 1125 PSIG

80 PSIG


13% CR.STEEL/SS304/SS316; (NO CASTING)

13%CR.STEEL/SS304/SS316+STELLITED/COATEDWITH CHROME CARBIDE

SS410/SS304/SS316 +STELLITED/COATED WITHCHROME CARBIDE

ASTM A 105/ 13% CR. STEEL/SS304/SS316

GRAPHITE

GRAPHITE

ASTM A193 GR B7

ASTM A194 GR 2H


SEE NOTE-7

GRAPHITE

MAX TEMP 427 DEG.C.

INCONEL X-750

SEAT : 825 PSIG

300 ANSI-B-16.34RATING :SIZE RANGE : ENDS :

12

3



RATING: ENDS:

SIGNATURE&

SEALOF MANUFACTURER

3 WAY BALL VALVE SPECIFICATION MANUF'S OFFER



PIPING CLASS : B9A

Tag No: 66491


Sheet No. 1 of 2

Page 80 of 129


CPCLClient :


CHENNAILocation :

16/43Dept./Sect. :


A133-6-44-0006 Rev. A


Page 22 of 22

66491SHEET REV. NO.

DATE 03/09/2014

0

NOTES

12

13

BIDDER'S STAMPING ON THE VALVE SPECIFICATION SHEET SHALL BE CONSTRUED TO MEAN BIDDER'SACCEPTANCE OF SUITABILITY OF VALVE AND VALVE SHEETS FOR SERVICE AND 'SPECIAL SERVICECONDITIONS' MENTIONED IN THE VALVE SPECIFICATION SHEETS.STEM SEAL/BODY SEAL MATERIALS SHALL BE PROVIDED WITH CORROSION INHIBITOR.

Sheet No. 2 of 2

Page 81 of 129

Page 1 of 7

CHENNAI PETROLEUM CORPORATION LIMITED MANALI REFINERY, CHENNAI

RESID UPGRADATION PROJECT

LSTK-1 : COKER BLOCK : DELAYED COKER UNIT & LPG CFC TREATING UNITS

PART I

SECTION : 5

STANDARD SPECIFICATION FOR POSITIVE MATERIAL IDENTIFICATION AT VENDOR’S WORKS

(PMI)

DOCUMENT NO : 44NC-4600-Q-0002-A4

0 13.04.2010 7 Issued for Feed APK PKB SBN

Rev No. Issue Date Pages Rev Description Prepared

By

Checked

By

Approved

By

Page 82 of 129

Jacobs CPCL – CHENNAI INSPECTION, MONITORING PART-I 44NC - 4600 FOR LSTK CONTRACTOR SECTION-5 LSTK – 1 COKER BLOCK Doc.No.44NC-4600-Q-0002-A4 Rev.0 Page 2 of 7

TABLE OF CONTENTS

1.0 SCOPE 2.0 DEFINITIONS 3.0 PMI EXAMINATION 4.0 ACCEPTABLE METHODS FOR PMI 5.0 EXTENT OF PMI EXAMINATION 6.0 RECORDING AND DOCUMENTATION 7.0 MARKING 8.0 ATTACHMENTS

8.1 TYPICAL POSITIVE MATERIAL IDENTIFICATION REPORT FORM – ALLOY STEEL BULK MATERIAL

Page 83 of 129


1.0 SCOPE

1.1 This specification applies to the requirements for Positive Material Identification (PMI) to be performed at vendor’s works on Metallic Alloy Materials procured either directly by Vendor or indirectly through their sub-vendors. Any deviations from this specification must be approved by Purchaser in the deviation / Waiver permit format. This specification shall also be read in conjunction with positive material identification at site.

1.2 This Specification covers the procedures and methodology to be adopted to assure that the chemical composition of alloy material is consistent with the material specification as specified in purchase documents using alloy analyser at the time of final inspection before despatch.

1.3 The scope of this specification shall include but not limited to Positive Material identification (PMI) to be performed on Alloy Piping Materials listed below :

However all grades of piping materials including stainless steel are subjected to PMI verification / test after receipt at site.

− Alloy Steel Pipes − Alloy Steel Flanges & Forgings − Alloy Steel Fittings − Alloy Steel Fasteners − Alloy Cast & Forged Steel Valves − Alloy Steel Instrumentation items (Control Valve, Safety Valves etc.) − Equipment, Pipe & Fittings Welds. − Gaskets (Ring Type Joints)

Following items shall be excluded from scope of PMI examination

− Gasket other than Ring Type Joints − Valve internal Components

2.0 DEFINITIONS

2.1 Vendor : Any supplier or manufacturers on whom an order is placed for supply of referred piping items. This definition shall also include any sub-vendor or manufacturers on whom a sub-order is placed by the vendor.

2.2 Inspection Lot : A group of items offered for Inspection covered under same size,

heat and heat treatment lot.

2.3 Alloy Material : Any metallic material (including welding filler materials) that contains alloying elements such as chromium, nickel, molybdenum, vanadium, etc which are intentionally added to enhance mechanical or physical properties and/or corrosion resistance.

Page 84 of 129


3.0 PMI EXAMINATION

3.1 The Vendor shall submit a procedure of PMI to comply with the requirements of this Specification. Approval of PMI procedure shall be obtained from Purchaser prior to commencing manufacturer / inspection of product.

3.2 PMI examination of alloy materials is independent of any certification, markings of

colour coding that may exist and is aimed at verifying that the alloy used are as per specified grades.

3.3 The Vendor shall identify all incoming alloy materials and maintain full traceability of

all alloy materials, including all off-cuts. Transfer of identification marks shall be undertaken prior to cutting to ensure maintenance of identification on off-cuts.

3.4 The Vendor shall ensure that all materials are segregated and stored in separately

identified locations to prevent the mix-up of materials of different alloy specifications or alloy material with carbon steel. Non-ferro-magnetic materials shall be segregated at all times from ferro – magnetic materials.

3.5 PMI examination is subject to surveillance inspection by Vendor / Third Party

Inspection Agency / Purchaser as specified in Quality Assurance Plan.

4.0 ACCEPTABLE METHODS FOR PMI

4.1 The Method used for PMI examination shall provide a quantitative determination of the alloying elements like Cr, Mo, Ni, V in Alloy Steel items. For Non-Ferrous alloys quantitative determination of appropriate alloying elements shall be verified.

4.2 Instruments or methods used for PMI examination shall be of those that will provide

quantitative, recordable, elemental composition results for positive identification of alloying elements present.

4.3 The acceptable instrument for alloy analyser shall be either “Portable X-ray

fluorescence” or “Optical Emission Spectro Analyser” type capable of verifying the percentage of alloy elements within specified range.

4.4 Chemical spot testing, magnets, alloy sorters and other methods using eddy current

methods are not acceptable for PMI examination.

4.5 The PMI instrument used shall have the sensitivity to detect the alloying elements in the specified range.

4.6 Each analyser must be calibrated according to the manufacturer’s specification at the

beginning and end of each shift. Instrument must be checked against known standard for each alloy type to be inspected during the shift.

4.7 Certified samples with full traceability of “known” alloy materials shall be available for

use as a random spot check on the instrument calibration.

4.8 The surface to be examined shall be prepared by light grinding or abrasive paper and solvent cleaner. Evidence of arc burn resulting from examination shall be removed by light grinding or abrasive paper.

Page 85 of 129


4.9 Alloy steel type joint gaskets shall only be inspected by using portable X-ray fluorescence instrument.

4.10 Testing shall be done as per the procedures outlined by the manufactures of alloy

analyser being used. Modification of these procedures if any, must be approved by Purchaser.

4.11 The persons performing PMI shall demonstrate their capabilities to the satisfaction of

Owner/PMC/Third Party Inspection Engineer. If the vendor has qualified operator in his rolls, he may perform the examination. Otherwise PMI examination shall be sub contracted to an independent testing agency.

4.12 Whenever materials, items and welds are identified as not meeting requirements by

the visiting engineer a rejection note shall be issued. The above shall be marked with a red “R” pending resolution.

5.0 EXTENT OF PMI EXAMINATION

Following sampling plans shall be applicable for PMI examination of various alloy items.

A. Flanges, Fittings, Valves, RTJ Gaskets

: 100%

B. Pipes : 100% (for pipes procured from traders).

10% random samples (minimum 2 Nos.) drawn from each size/Heat/Lot (for pipes procured directly from mills).

C. Tubes for heat transfer service : 100% (for tubes procured from traders).

Spot checking by sampling 1% of the tubes or 25 nos. whichever is less (for tubes procured directly from mills.

D Fasteners

:

Lot Size Sample Size

Upto 100 2% (Min 2)

101 to 500 1% (Min 3)

501 and above 0.5% (min 5) 6.0 RECORDING AND DOCUMENTATION

The results of PMI examination shall be recorded in the PMI Report Form as enclosed with this specification.

Page 86 of 129


7.0 MARKING

7.1 All alloy materials tested by PMI shall be identified using either of the following methods by indicating “AV”

a) Electro – etching b) A low stress stamp marking c) Hologram Sticker d) Vibro – etching e) Colour Coding

Location of markings will be near to vendor’s monogram, material specification, heat number / cast number, welders stamp, etc as applicable.

8.0 ATTACHMENTS

Page 87 of 129


PMI REPORT FORM – ALLOY BULK MATERIAL

ATTACHMENT 8.1

TYPICAL POSITIVE MATERIAL IDENTIFICATION REPORT : ALLOY STEEL BULK MATERIALS Page ….of ….

Project : Client : Job No. :

PMI Report No. : Vendor / Sub-Vendor :

Purchase Order No. : Testing Agency :

Purchase Requisition No. PMI Location :

Bulk Item Type (as per Requisition)

Material Specification / Grade :

Number of items in Lot :

Requisition Item No. Description : Alloy Content Weight Percent Remarks Accept/Reject

Cr. Mo Ni V

Instrument Type / ID

Source Age Source dt.

Last Service Date :

PMI Examination by :

Approved by Vendor Witnessed by

Company

Page 88 of 129

APPENDIX - A

INDICATIVE INSPECTION & TEST PLAN** PROJECT : 44NC-4600 : CPCL MANALI REFINERY, CHENNAI : RESID UPGRADATION

PROJECT

SHEET 1 OF 2

DOC. NO: A133-00-000-ITP010A EQUIPMENT/ITEM DESCRIPTION : GATE, GLOBE, CHECK

AND BALL VALVE EQUIPMENT / ITEM TAG NO. : TEST & INSPECTION AS PER : (CODES & SPECIFICATIONS) :

EQUIPMENT INSPECTION CODE : A

VENDOR : P.O. NO. :

PR/PS NO. DRG. NO.

A C

T

I

V

I

T

Y

1 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY OWNER / PMC

2 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY THIRD PARTY INSPECTION AGENCY (TPIA) / STATUTORY AUTHORITY

3 WITNESS INSPECTION BY SUB VENDOR,VENDOR Rev.1

4 CERTIFICATES / DATA TO BE SUBMITTED BY LSTK CONTRACTOR / VENDOR FOR APPROVAL / REVIEW OF TPI A / OWNER / PMC

1 A A R X DETAILED INSPECTION & TEST PLAN AFTER ISSUE OF PO/PR/PS

2 A R X INSPECTION & TEST PROCEDURES INCLUDING NDT, PWHT PROCEDURES, ETC.

3 - R X Rev. 1

4 A X PACKING PROCEDURE Rev.1

5 R R X WPS/PQR QUALIFICATION / WELDER PERFORMANCE RECORDS FOR OVERLAY / STELLITING INCLUDING WELD REPAIR PROCEDURE

6 R R X MANUFACTURERS’ TEST CERTIFICATES FOR BODY / BONNET / TRIM MATERIAL,ETC.

7 R R X FIRE SAFE TEST CERTIFICATES FOR BALL VALVES

8 R

W X NDT (RT-Film review , UT, PT, MT – AS APPLICABLE) EXAMINATION Rev.1

9 R R X HEAT TREATMENT RECORDS / CHARTS

10 R R X HARDNESS CHECK / CORROSION TEST, IF APPLICABLE

11 H W X HYDROSTATIC / PNEUMATIC TEST FOR BODY, SEAT AND BACK SEAT.(100% BY VENDOR & AT RANDOM BY TPI AGENCY)

12 H W X STRIP CHECK ON SAMPLE VALVES TO VERIFY COMPONENTS (ONE VALVE PER SIZE / TYPE / ORDER, IF REQUIRED AS PER DATASHEET) Rev. 1

13 H W X FUNCTIONAL / OPERATIONAL CHECK FOR GEAR / ACTUATOR OPERATED VALVES

14 H W X VISUAL AND DIMENSIONAL INSPECTION INCLUDING COATING CHECK(100% BY VENDOR & AT RANDOM BY TPI AGENCY) Rev.1

15 W/R

W X VERIFICATION OF MARKING (100% BY VENDOR & AT RANDOM BY TPI AGENCY) & REVIEW OF VENDOR’S FINAL CERTIFICATES & REVIEW OF IBR CERTIFICATES, AS APPLICABLE. Rev.1

16 H W X PMI INSPECTION FOR AS / SS VALVES(100% BY VENDOR & AT RANDOM BY TPI AGENCY) Rev.1

17 R R X FINAL DOCUMENTATION

18 H X PACKING & LOADING OF ITEMS AS PER SHIPPING DRAWING

Page 89 of 129

INDICATIVE INSPECTION & TEST PLAN** PROJECT : 44NC-4600 : CPCL MANALI REFINERY, CHENNAI : RESID UPGRADATION

PROJECT

SHEET 2 OF 2

DOC. NO: A133-00-000-ITP010A

EQUIPMENT/ITEM DESCRIPTION : GATE, GLOBE, CHECK AND BALL VALVE

EQUIPMENT / ITEM TAG NO. : TEST & INSPECTION AS PER :(CODES & SPECIFICATIONS) :

EQUIPMENT INSPECTION CODE : A

VENDOR : P.O. NO. :

PR/PS NO. DRG. NO.

A C

T

I

V

I

T

Y

1 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY OWNER / PMC

2 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY THIRD PARTY INSPECTION AGENCY (TPIA) / STATUTORY AUTHORITY

3 WITNESS INSPECTION BY SUB VENDOR,VENDOR Rev.1

4 CERTIFICATES / DATA TO BE SUBMITTED BY LSTK CONTRACTOR / VENDOR FOR APPROVAL / REVIEW BY TPI A / OWNER / PMC

19 H H INSPECTION RELEASE CERTIFICATE

LEGENDS : H – HOLD, W – WITNESS, R - REVIEW, A – APPROVAL, I - INFORMATION, X – SUBMIT

PO – PURCHASE ORDER, PR – PURCHASE REQUISITION, PS – PURCHASE SPECIFICATION

** NOTE : THIS IS AN INDICATIVE INSPECTION AND TEST PLAN IDENTIFYING SCOPE OF INSPECTION

/REVIEW OF DOCUMENTS AS A MINIMUM REQUIREMENT, DETAILED INSPECTION AND TEST PLAN INDICATING ALL SPECIFIED REQUIREMENTS AFTER ISSUE OF PO / PR TO BE GENERATED BY VENDOR AND SAME DULY APPROVED BY TPI A TO BE SUBMITTED TO OWNER/PMC FOR APPROVAL.

Note : Following modification has been made from the original ITP attached with Bid Document.

1. In activity :scope of Inspection LSTK contractor has been deleted

2. Activity 3: Summary of all supplimentary requirements as specified in the order/PS/PR deleted

3. Activity 4 : Shipping drawings of completed equipments has been deleted

4. Activity 8: NDT( UT,RT,PT,MT) has been modified as R

5. Activity 12: Strip check has been has been modified as H for TPI if applicable as per data sheet.

6. Activity 14: Visual and Dimensional including has been modified as 100 % for vendor & at random by TPI

7. Activity 15: Verification of Marking has been modified as W at random for TPI and balance as R for TPI.

8. Activity 34:Surface preparation painting /pickling etc has been modified as R for TPI

9. Activity 36:Spares and packing list check has been modified as W for TPI

10. Activity : TPI A TO CARRY OUT INSPECTION AT SUB-VENDORS’ WORKS. has been deleted

11. Activities in respect of QAP / ITP and IRN /IC for categories will be as below:

For PMC category A : QAP/ITP approval by EPC , TPIA & PMC.

IRN/IC issued by TPIA and to be endorsed by PMC

APPENDIX - A

OWNER/PMC RESERVES RIGHT TO WITNESS INSPECTION OF ANY ITEM AT ANY STAGE WHICH SHALL BE INDICATED ON QAP / INSPECTION & TEST PLAN AT THE TIME OF APPROVAL AND SAME TO BE COVERED AS PART OF PURCHASE ORDER

CONDITION ISSUED BY CONTRACTOR.

Page 90 of 129

JOB SPECIFICATION FOR

MOV ACTUATORS

DOCUMENT No.

A133-000-16-50-SP-3115 Rev B

Page 1 of 3

B 04.09.14 Revised & Issued with MR VB ANPS SA

A 01.08.14 Issued with MR VB ANPS SA

Rev. No



JOB SPECIFICATION

(ELECTRICAL)

FOR

MOV ACTUATORS (MR No. A133-000-WB-MR-3115)

PROJECT : COKER BLOCK (EPCC-1) RESID UPGRADATION PROJECT, CPCL, CHENNAI OWNER : CHENNAI PETROLEUM CORPORATION LIMITED PMC : JACOBS ENGINEERING INDIA PRIVATE LIMITED CONTRACTOR : ENGINEERS INDIA LIMITED JOB NO. : A133

Page 91 of 129


MOV ACTUATORS

DOCUMENT No.

A133-000-16-50-SP-3115 Rev B

Page 2 of 3


1. GENERAL REQUIREMENTS

In addition to the standard specification ESS 037 and data sheet, the following specific requirements shall also be met:

i. MOVs shall be provided with an integral control box consisting of reversible starter, local/ remote

selector switch, start/ stop switches or push buttons, torque switches, limit switches etc., and shall be suitable for installation in classified areas. The mechanical design shall be such that in case of torque or limit switch failure, the motor shall be protected. Anti-condensation heater shall be provided for the actuator. The power supply for the control circuit shall be AC.

ii. MOV shall be designed to start with 75% of the motor terminal voltage.

iii. MOV actuator shall be complete with motor, integral reversing starter, necessary control, protections and terminals for remote control and indications. The actuator shall include a device to ensure that motor runs with correct rotation for required direction of valve travel with either phase sequence of 3-phase power supply.

iv. Area classification for the MOVs shall be as under:

S. No. Tag No. Area Classification 1. 086-MOV-1201 Zone-2, Gas group IIA/IIB, Temp. Class T3

2. 086-MOV-1202 Zone-2, Gas group IIC, Temp. Class T3

3. 086-MOV-1501 Zone-2, Gas group IIA/IIB, Temp. Class T3

































Page 92 of 129


MOV ACTUATORS

DOCUMENT No.

A133-000-16-50-SP-3115 Rev B

Page 3 of 3


v. Fire safe requirement for MOVs shall be as defined in Process datasheets attached with the MR. Actuators with fire-proofing shall be provided for fire safe MOVs. Fireproofing shall be rated for 30 minutes. Arrangement shall be made by Intumescent paint (brand name: K-mass/ ERS/ equivalent). The required certificates for fireproof rating shall be furnished from independent testing agency. MOVs with fireproofing shall be suitable for mica insulated fire survival power and control cables.

vi. All MOVs shall have provision for remote OPEN and CLOSE command from Control room (DCS/ PLC) and OPEN/ CLOSE indication in DCS.

vii. Remote input signals for Opening/ Closing/ Stopping the MOV shall be provided through the

momentary closing of separate potential-free contacts in Purchaser’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 the manufacturer in the actuator.

viii. One actuator of each type is required for motor operated valves as mandatory spare. ix. Vendor shall quote for Maintenance spares for two years’ trouble free operation of the MOV

actuators, indicating recommended quantity and unit prices. Vendor shall also identify a list of such spares along with quantity, required for commissioning the MOVs.

x. For all motors, the winding shall be suitably treated for corrosive atmosphere with epoxy gel

treatment on winding overhang. 2. LIST OF ATTACHMENTS

S. No. Description Doc. No.

1. MOV Actuator Data Sheet A133-000-16-50-DS-3115 Rev. A

2. Vendor Data Requirements A133-000-16-50-VR-3115 Rev. A

3. Standard Specification for Motorized Valve Actuator

44NC-4600: ESS 037

Page 93 of 129

Page 1 of 4

DATA SHEET FOR

MOTORISED VALVE ACTUATOR (MOV)

DOC. NO. A133-000-16-50-DS-3115 REQN. NO. A133-000-WB-MR-3115

APPD. BY SA

PROJECT NO A133 CHKD. BY ANPS PROJECT LOCATION MANALI PRPD. BY VB PROJECT TITLE RESID UPGRADATION PROJECT DATE 27.07.14 CLIENT CPCL REV. A

A APPLICABLE SPECIFICATION & STANDARD REFER STANDARD SPECIFICATION NO. E SS 037

B GENERAL 1 VALVE REF. NO. * 2 VALVE TYPE / VALVE SIZE * 3 APPLICABLE SPECIFICATION & STANDARDS AS PER ESS-037 4 VALVE TAG NOS. REFER VALVA DATA SHEET

C SERVICE CONDITIONS 1 AMBIENT (MAX/MIN) 45

OC

2 DESIGN AMBIENT TEMP. 45 OC

3 ALTITUDE ABOVE M. S. L 3.5 MTRS. 4 RELATIVE HUMIDITY (MAX.) 80% 5 ENVIRONMENT CORROSIVE 6 ANNUAL RAINFALL 1378 mm

D SYSTEM CHARACTERISTICS 1 SYSTEM VOLTAGE, FREQUENCY, PHASES 415V, 50Hz, 3 PHASE 2 VOLTAGE VARIATION 10% 3 FREQUENCY VARIATION 3% 4 COMBINED VARIATION 10% 5 FAULT LEVEL 50 kA for 1 SEC.

6 NEUTRAL EARTHING Solidly earthed

E AREA CLASSIFICATION

i) UNCLASSIFIED SAFE / ZONE 1 / ZONE 2

ii) GAS GROUP OF ENCLOSURE: I / IIA / IIB / IIC

iii) TEMPERATURE CLASS : T1 / T2 / T3 / T4 / T5 / T6

F ACTUATOR TYPE AND RATING 1 MODEL AND SIZE * 2 TYPE AND MAKE OF ACTUATOR * 3 RATED SPEED (SYN.) * RPM 4 CLASS OF INSULATION CLASS `F' WITH TEMPERATURE RISE LIMITED TO CLASS `B' 5 WINDING TREATMENT MOISTURE PROTECTION VARNISH / ANTI CORROSIVE TREATMENT 6 OPENING TIME * MINIMUM : MAXIMUM : AS PER VALVE DATA SHEET 7 CLOSING TIME * MINIMUM : MAXIMUM : AS PER VALVE DATA SHEET 8 STARTER WITH ALL NECESSARY CONTROLS INTEGRAL / REMOTE 9 MAX. POWER CONSUMPTION / KW RATING OF MOTOR *

10 MAXIMUM OPERATION CYCLES PER HOUR / 24 HOURS : 11 TYPE OF DUTY S2-15 MINUTES (IS 325 - LATEST CODE) OR AS SPECIFIED ELSEWHERE

12 VALVE TRAVEL LIMIT SWITCHES

REQUIRED/ NOT REQUIRED 13 VALVE POSITION INDICATION INTEGRAL/ REMOTE 14 VALVE POSITION INDICATION CLOSE POSITION / OPEN POSITION / CONTINUOUS / INTERMEDIATE 15 LOCK ROTOR CURRENT * A 16 POWER FACTOR OF STARTING CURRENT WITH * %

FULL VOLTAGE * - Information to be furnished by vendor APPLICABLE STANDARD SPECIFICATION : E SS 037

Page 94 of 129

Page 2 of 4

DATA SHEET FOR



APPD. BY SA

PROJECT NO 44NC - 4600 CHKD. BY ANPS PROJECT LOCATION MANALI PRPD. BY VB PROJECT TITLE RESID UPGRADATION PROJECT DATE 27.07.14 CLIENT CPCL REV. A

F ACTUATOR TYPE AND RATING (CONTD.) 17 TEMP. RISE OVER -

oC AMBIENT * O

C 18 NO LOAD CURRENT * A 19 ACCELERATION TIME * SEC. 20 STARTING TORQUE / FULL LOAD TORQUE * 21 STALLING TORQUE * 22 EFFICIENCY : 50% LOAD * %

: 75% LOAD * % : 100% LOAD * %

23 POWER FACTOR : 50% LOAD * : 75% LOAD * : 100% LOAD *

24 SAFE STALL TIME WITH MOTOR IN `HOT' CONDITION * 25 NO. OF STARTS PER HOUR WITH ALLOWABLE *

MINIMUM INTERVAL BETWEEN STARTS 26 DETAILS OF RATING OF SPACE HEATERS * 27 TORQUE REQUIREMENTS (% OF FULL LOAD TORQUE) * BREAK-AWAY : % PULL OUT : % 28 TORQUE SWITCHES : OPEN & CLOSE REQUIRED / NOT REQUIRED 29 VOLTAGE FOR LAMP / INDICATION CIRCUIT/ *

CONTROL CIRCUITS 30 HANDWHEEL REQUIRED / NOT REQUIRED 31 REMOTE OPERATION REQUIRED / NOT REQUIRED 32 REMOTE INDICATION REQUIRED / NOT REQUIRED 33 REMOTE INTERLOCKING PROVISION REQUIRED / NOT REQUIRED 34 EARTH TERMINALS TWO NOS. - EXTERNAL 35 GREASING ARRANGEMENT GREASE NIPPLES WITH GREASE RELIEF VALVE / PLUG 36 MAIN NAME PLATE STAINLESS STEEL 37 AUXILIARY NAME PLATE REQUIRED / NOT REQUIRED 38 MODULATING / ON - OFF MOTOR THRMISTORS REQUIRED/ NOT REQUIRED (AS PER STD. SPEC. ESS 037) 39 ANY OTHER IMPORTANT PARAMETER FOR *

SATISFACTORY OPERATION OF MOV (VENDOR TO SPECIFY)

G ENCLOSURE 1 FEATURE OF PROTECTION FLP (Exd) /INCREASED SAFETY (Exe) / NON SPARKING (Exn)/ TEFC/ SPDP

(W. R. T. AREA CLASSIFICATION) 2 DEGREE OF PROTECTION IP 68 3 CANOPY REQUIRED / NOT REQUIRED (NON-INTEGRAL FRP)

H TERMINAL BOX REQUIREMENTS 1 TERMINAL NOS. SIX NOS. TERMINALS TO BE BROUGHT OUT FOR MOTOR OF 7.5 kW & ABOVE 2 SIZE OF TERMINALS : POWER SUITABLE FOR CABLE SIZE SPECIFIED

CONTROL 2.5 mm2

3 LOCATION OF TERMINAL BOX SEEN FROM RHS DRIVEN END

4 SEPARATE TERMINAL BOX FOR SPACE HEATER REQUIRED / NOT REQUIRED AND PTC THERMISTORS

APPLICABLE STANDARD SPECIFICATION : E SS 037

Page 95 of 129

Page 3 of 4

DATA SHEET FOR



APPD. BY SA


I EXTERNAL CABLE: TYPE SIZE AND NO. NO. OF POWER AND CONTROL CABLE ENTRIES SHALL BE AS PER ESS 037 1 POWER CABLE LATER

2 CONTROL CABLE FOR REMOTE INDICATION/ LATER INTERLOCKING

J MOTOR BEARINGS 1 TYPE OF BEARING BALL / ROLLER / SLEEVE 2 BEARING LUBRICATION

K OPTIONS 1 MICROPROCESSOR BASED INTEGRAL CONTROL REQUIRED / NOT REQUIRED

CIRCUIT & INTELLIGENT ACTUATOR 2 ANTI- CONDENSATION HEATER WITH MOTOR REQUIRED / NOT REQUIRED 3 EXTRA AUXILIARY LIMIT SWITCHES FOR INTERMEDIATE REQUIRED / NOT REQUIRED

POSITION INDICATION 4 STABLE CURRENT SIGNAL, PROPORTIONAL TO REQUIRED / NOT REQUIRED

VALVE POSITION, FOR DCS 5 DCS CONTROL / FEEDBACK REQUIRED / NOT REQUIRED 6 LOCAL-OFF-REMOTE SELECTOR SWITCH REQUIRED / NOT REQUIRED 7 AUTO-OFF MANUAL SELECTOR SWITCH REQUIRED / NOT REQUIRED 8 OPEN-CLOSE-STOP PUSH BUTTONS REQUIRED / NOT REQUIRED 9 TORQUE SWITCH TRIPPED ALARM REQUIRED / NOT REQUIRED

10 CONTACTLESS TRANSMITTERS FOR GIVING 4-20 mA REQUIRED / NOT REQUIRED ANALOGUE SIGNALS

11 FIREPROOFING WITH 30 MINUTES RATING REQUIRED / NOT REQUIRED (FOR MOVs AS DEFINED IN MR ELSEWHERE)

L INDICATING LAMPS LOCAL ON VALVE REMOTE ON DCS

1 POTENTIAL INDICATIONS : R Y B

2 MOTOR RUNNING 3 VALVE OPEN

4 VALVE CLOSE 5 INTERMEDIATE POSITION 6 LOCAL / REMOTE SWITCH POSITION INDICATION 7 AUTO / MANUAL SWITCH POSITION INDICATION 8 INDICATION OF VALVE MOVEMENT (BLINKING LAMP) 9 VALVE STOPPED IN MID TRAVEL

10 VALVE TRIPPD ON TORQUE SWITCH OPERATION 11 VALVE TRIPPED ON THERMISTOR OPERATION

M BODY (TO BE FILLED IN BY VALVE MANUFACTURER) 1 TYPE OF BODY & VALVE CODE 2 BODY SIZE & PORT SIZE 3 END CONNECTION SIZE AND RATING 4 BODY MATERIAL 5 BONNET TYPE 6 TRIM MATERIAL 7 REQUIRED SEAT TIGHTNESS


Page 96 of 129

Page 4 of 4

DATA SHEET FOR



APPD. BY SA


N SERVICE (TO BE FILLED BY VALVE MANUFACTURER) 1 VALVE DETAILS:

FLOW KG/HR PRESSURE KG/ CM

2G

TEMPERATURE OC

2 FLUID 3 VALVE SIZE 4 PRESSURE MAXIMUM : OPERATION : DESIGN : 5 TEMPERATURE MAXIMUM : OPERATION : DESIGN : 6 MAXIMUM SHUT OFF PRESSURE 7 LINE NO. 8 LINE SIZE / SCHEDULED / INSULATION THICKNESS 9 PIPING & INSTRUMENTATION DIAGRAM

10 VALVE MANUFACTURER 11 VALVE MODEL NO.

O DRAWINGS AND DATA SHALL BE AS SPECIFIED ELSEWHERE.

P PAINTING - TYPE - SHADE

Q INSPECTION AS PER VENDOR QUALITY PLAN

R ROUTINE TEST WITNESS REQUIRED YES / NO

S ADDITIONAL REQUIREMENTS: MAKE OF ACTUATOR: AUMA INDIA LTD/ LIMITORQUE IND LTD/ ROTORK CONTROLS IND LTD DOUBLE COMPRESSION CABLE GLANDS & PLUGS FOR UNUSED ENTRIES (TO BE SUPPLIED ALONG WITH MOV ACTUATOR)

REQUIRED (FLAMEPROOF AND WP TYPE)

TEST AND APPROVAL CERTIFICATES FOR FLAMEPROOF ACTUATORS

- FOR INDIGENOUS MOV ACTUATORS CIMFR TEST CERTIFICATES, APPROVALS OF PESO/ CCOE/ OTHER APPLICABLE STATUTORY AUTHORITY AND VALID BIS LICENSE

- FOR IMPORTED MOV ACTUATORS CERTIFICATES FROM AUTHORISED CERTIFICATION AGENCY OF COUNTRY OF ORIGIN OF ACTUATORS AND APPROVALS OF PESO/ CCOE/ OTHER APPLICABLE STATUTORY AUTHORITY

- SUBMISSION OF TYPE TEST CERTIFICATES ALONG WITH OFFER

YES (CERTIFICATE NUMBERS AND VALID DATE TO BE INDICATED)

NOTES:

1. AREA CLASSIFICATION ZONE, GAS GROUP AND TEMPERATURE CLASS INDICATED AT SL. NO. E ABOVE REFER TO IS/ IEC STANDARDS.

2. WHEREVER ‘REMOTE CONTINUOUS POSITION INDICATION’ IS REQUIRED, THE TRANSDUCER REQUIRED FOR THE SAME, ALONG WITH LOOSE REMOTE CONTINUOUS POSITION INDICATOR, SHALL BE INCLUDED IN THE QUOTED PRICE OF RESPECTIVE MOV ACTUATOR AND SUPPLIED WITH IT.

3. VENDOR SHALL FURNISH COMPLETE DATA AS PER THIS DATA SHEET FOR EACH MOV ACTUATOR SEPARATELY.

4. UNUSED CABLE ENTRIES, IF ANY, SHALL BE PROVIDED WITH FLAMEPROOF TYPE PLUGS. PLASTIC PLUGS ARE NOT ACCEPTABLE.


Page 97 of 129


FOR

FOR MOVS

A 01-AUG-2014 Issued for Bids VB ANPS SA

Rev.No.



FOR MOVS of 3


Rev. A

Page 1


Page 98 of 129


The following drawings/documents marked " " shall be furnished by the bidder.

MOV ACTUATOR

Notes :

1. "TICK" denotes applicability.

2. Post order, drawing / document review shall commence only after approval of Document Control Index (DCI).

3. All post order documents shall be submitted / approved through EIL eDMS portal.

4. Final documentation shall be submitted in hard copy (Six prints) and soft ( two CDs/DVDs ) in addition to

submission through EIL eDMS.

5. Refer - 6-78-0001: Specification for quality management system from Bidders.

6. Refer - 6-78-0002: Specification for documentation requirements from Contractors.

7. Refer - 6-78-0003: Specification for documentation requirement from Suppliers.

S.NO.

DESCRIPTION WITHBID

POST ORDERREMARKSFOR

REVIEWFOR

RECORD

WITHDATABOOK

(FINAL)

1. Schedule of Vendor Documents

2. Data Sheets (Duly filled-in)

3. G.A.Drawings and mounting details ofactuators

4. Wiring and Connection diagrams

5. Inspection & Test Plan (ITP) -For review byInspection Dept.

6. Test Records

7. Type Test Certificates for Flameproof/Explosionproof equipment

8. List of Maintenance Spares

9. List of Special Tools & Tackles

10. Equipment storage procedure at site

11. Data Books/ Manuals : Installation Manual andStandards

12. Data Books/ Manuals : Operating/ MaintenanceManual

13. Data Books/ Manuals : Catalogues/ Brochuresindicating complete technical details and datafor actuator selection

14. Details of fireproofing, if specified in data sheet

15. Details of 2-Wire control system, if specified indata sheet

16. List of mandatory spares


FOR MOVS of 3


Rev. A

Page 2


Page 99 of 129

8. All drawings & documents shall be submitted in A4 or A3 paper sizes. Documents in higher paper size shall

be submitted in exceptional circumstances or as indicated in the MR/Tender.

9. Post order- The schedule of drawing / data submission shall be mutually agreed between EIL & the bidder /

contractor / supplier during finalization of Document Control Index (DCI).

10. "@" indicates submission of documents to Inspection Agency.

11. Bill of Material shall form part of the respective drawing.

12. Also refer other department's VDR :-

13. Electrical

14. Piping


FOR MOVS of 3


Rev. A

Page 3


Page 100 of 129

Page 1 of 8

STANDARD SPECIFICATION FOR

MOTORISED VALVE ACTUATOR

DOCUMENT NO: 44NC-4600 : ESS 037

Rev No.

Issue Date Pages Rev Description Prepared

By

Checked

By

Approved

By

0 03 May 2010 8 Issued for Engineering VSL PPP RBD

Page 101 of 129

STANDARD SPECIFICATION : 44NC-4600: ESS 037 DATE : 03 May 2010 MOTORISED VALVE ACTUATOR PAGE : 2 OF 8 REVISION NO : 0

TABLE OF CONTENTS

1.0 SCOPE 3

2.0 STANDARDS 3

3.0 CLIMATE 3

4.0 ELECTRICAL SYSTEM 3

5.0 ACTUATOR SIZING 3

6.0 CONSTRUCTION 4

7.0 MOTOR 4

8.0 MOTOR & ACTUATOR PROTECTION 4

9.0 GEARING 4

10.0 HAND WHEEL 5

11.0 TORQUE & POSITION LIMIT SWITCH 5

12.0 INTEGRAL STARTER & CONTROL TRANSFORMER 5

13.0 CABLING, WIRING & TERMINALS 6

14.0 ENCLOSURE 7

15.0 TOOLS 7

16.0 SPARES 7

17.0 DRAWINGS / DOCUMENTATION 7

18.0 TESTING AND INSPECTION 7

19.0 QUALITY ASSURANCE 8

20.0 DEVIATIONS 8

Page 102 of 129


1.0 SCOPE

This specification covers design, manufacture, testing and supply of Motorised Valve Actuators for Voltages up to 415 V, 3 phase, 50 Hz. The actuator shall be complete with motor, integral reversing starter, necessary control and protections and terminals for remote control and indications. The actuator shall include a device to ensure that motor runs with correct rotation for required direction of valve travel with either phase sequence of 3-phase power supply.

2.0 STANDARDS

All materials, equipment and accessories used in the manufacture shall conform to the latest editions of relevant Indian / International standards including amendments and Addenda, some of which are listed below :

IS 13947 (Part IV) : AC Contactors of Voltage not exceeding 1000 Volts

IS 9224 (Part II) : HRC Cartridge Fuse up to 650 Volts.

IS 694 (Part I & II) : PVC Insulated Cables (for Voltages up to 1100V with Copper & Aluminium Conductors)

IS 325 : Specification for three Phase Induction Motors

IS 2148 : Flame proof enclosure for electrical apparatus

IS 4691 : Degree of protection provided by enclosure for rotating electrical machinery

IS 4722 : Rotating electrical machines

IS 9334 : Electric Motor Operated Actuators

In absence of Indian Standards Specifications, International Electro-technical Committee Specifications shall be followed.

3.0 CLIMATE

Climatic conditions and other environmental conditions shall be as specified in the data sheets.

It should be, however, noted in general that the MOV shall be suitable for use in tropical climate with high humidity, heavy rainfall and/or conducive to fungus growth and corrosion.

4.0 ELECTRICAL SYSTEM

4.1 The electrical system voltage, frequency, fault level and circuit ratings shall be as stated in the data sheets.

4.2 Three Phase, 4- wire supply shall be made available for the MOV at one point. Any other necessary voltage inside the starter unit if required, shall be derived by using suitable transformer inside the starter by vendor.

5.0 ACTUATOR SIZING

5.1 The actuator shall be sized to guarantee valve closure at the specified differential pressure. The safety margin of motor power available for sealing and unsealing the valve shall be sufficient to ensure torque switch trip at maximum valve torque with the supply voltage 10% below normal. The operating speed shall be such as to give closing and opening at approximately 10-12 inches per minute unless otherwise stated in the job specification.

Page 103 of 129


5.2 The actuator shall be furnished with drive bushing easily detachable for matching to suit

the valve stem or gearbox input shaft. The drive bush shall be positioned in the base of the actuator to facilitate the use of standard length valve stems.

6.0 CONSTRUCTION

6.1 MOV body construction shall be as per the requirement.

6.2 Actuator enclosure shall have a minimum degree of protection – IP68, to ensure complete protection of the motor and the internal electrical circuitry from the ingress of moisture and dust.

7.0 MOTOR

7.1 The motor of the actuator shall be `High Torque, Low Inertia’ single speed, 3 phase squirrel cage induction motor , with a winding insulation of class - `F’ and Temperature rise limited to Class - `B’.

7.2 The motor shall be provided with thermister(s) embedded in hot spot of motor windings.

7.3 The motor shall be rated for S2 – 15 minute duty at design ambient temperature or twice the valve stroking time, whichever is longer, at an average load of at least 33% of maximum valve torque. The motor shall conform to IS:325 or equivalent international standard. The stall torque of motor shall be atleast 25% greater than maximum torque required for operation of valve.

7.4 The motor shall be able to operate the actuator at 75% of rated voltage. 7.5 Approximate enclosure for motor shall be used if the MOV is located in hazardous area. 7.6 The motor shall be provided with space heater with thermostat etc. 7.7 Two nos. earthing terminals shall be provided on the body.

8.0 MOTOR & ACTUATOR PROTECTION

8.1 Following minimum protections shall be offered for motor: Valve Jamming Motor Winding Over – Heating Single phasing Protection against incorrect connection of power supply / valve damage due to incorrect motor rotation / phase rotation correction compatibility Antihammer protection

8.2 Any additional protection for satisfactory operation of motor / MOV shall be specified and included by the Bidder in his offer.

8.3 The Actuator shall be protected against instantaneous reversal.

8.4 The mechanical design of Actuator shall be adequate to trip the motor without damage in case end limit switch fails.

9.0 GEARING

9,1 The actuator gearing shall be totally enclosed in an oil-filled gear-case suitable for operation at any angle. All main drive gearing shall be of metal construction. Where the actuator operates gate valves or large diameter ball or plug valves, the drive shall incorporate a lost motion hammer blow feature. For rising spindle valves, the output shaft shall be hollow to accept a rising stem, and incorporate a thrust base with lubricated bearings of ball or roller type. The design shall be such as to permit the gear-case to be

Page 104 of 129


opened for inspection or dissembled without releasing the stem thrust on taking the valve out of service.

10.0 HAND WHEEL

10.1 A Hand wheel shall be provided for emergency operation and it should be possible to select hand operation with Hand / Auto selection lever. Hand/Auto selection lever shall be provided with locking facility for both positions.

10.2 Hand wheel shall get engaged when the motor is declutched, and the drive shall be restored to power automatically by starting the motor. Hand wheel drive shall be mechanically independent of the motor drive and any gearing shall be such as to permit emergency manual operation in a reasonable time. Clockwise rotation of the hand wheel shall give closing movement of the valve, unless otherwise stated elsewhere.

11.0 TORQUE & POSITION LIMIT SWITCH

11.1 Both torque and limit switches shall be provided in the Actuator. These limit switches shall have at least 1 `NO’ & 1 `NC’ contacts for indication and interlocking. The additional contacts shall be provided for remote indication / interlocking.

11.2 The Actuator shall not trip during starting / in mid-travel against high inertia loads.

11.3 The actuator shall be sized to provide 30% margin over the required torque.

11.4 A digital position indicator shall be included in actuator, which gives a display from fully open to fully closed position. Also illuminated mechanical dial position indicator shall be provided to indicate valve position. Coloured lights corresponding to open, close and intermediate positions shall be included. Continuous monitoring of valve position (open or close) shall also be possible. Additional set of limit switches (min. 2 nos) shall also be provided for any intermediate valve position.

11.5 Provision shall be made for the addition of 2 contact less transmitters to give 4-20mA analogue signal corresponding to valve travel and output torque for remote indication.

12.0 INTEGRAL STARTER & CONTROL TRANSFORMER

12.1 MOV shall be provided with emergency shut down push button, integral reversible starter. Starter shall consist of necessary fuse/fuse switch units, mechanically and electrically interlocked reversible contactors, auxiliary contactors, overload relays, local-off-remote and auto-off-manual selector switch, open-close-stop push buttons, torque limit switches and end limit switches with necessary indication lamp. Solid state reversing controls may be used where feasible.

12.2 Local – off – Remote / Auto – off – Manual selector switch shall be lockable type. Also start control only shall be selective. Stop / Emergency stop control shall be irrespective of mode of operation. Remote control circuit shall use an opto isolator interface.

12.3 MOV shall be suitable for remote operation & wiring remote interlock indication.

12.4 Microprocessor based, intelligent actuator may be offered as an option and shall be provided with facility for serial communication using MODBUS or any other open type communication protocol.

12.4.1 Microprocessor based, communicable type control system may be offered for these actuators. The entire control system network shall consists of generally following:

− Microprocessor based control for valve actuators and other field devices which communicates with Master controller,

− Master station which provides control and monitoring functions for devices connected to control system network.

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− Signal converters / modbus or any other suitable communication protocol for control

system network.

− Two wire twisted pair cables connecting field units to controllers and to each other (maximum up to 300 units).

− PC based SCADA with GUI to interface with Master station, which in turn communicates with number of field units of various types.

12.4.2 The GUI shall be windows NT based (or higher) and shall communicate with Master Station by sending / receiving requested information or information request along with the field unit network address. Master station shall be in a continuous polling mode with all field units. The master station shall send reply or status information to GUI, which in turn shall display retrieved information on screen. In the event of an alarm, GUI shall generate alarm even though relevant screen is not open on system screens. The field units shall be identified serially which GUI shall use as a network address. The GUI system shall be user friendly. All critical screens like diagnostic screens, individual status, alarms etc. can be accessed by single click to enable to see the information required and take corrective actions. The PC’s / Printers and other items used for two wire control system shall be of latest configuration as of date of supply.

12.5 Control transformer with necessary ratings, and tapping and protected with easily replaceable type HRC fuses also shall be provided. Control circuit shall operate on 110 volts AC, 1 PH – N, 2 wire supply.

12.6 Cable entries for power and control cable shall be separate. 2 no. entries for control cable and 1 no. for power cable shall be provided of appropriate size as specified in the data sheets..

12.7 Starter shall be suitable for 60 starts per hour and of rating appropriate to motor size.

12.8 Facility for connecting external interlocks to inhibit / enable valve closing / opening operation during local / remote control shall also be provided.

12.9 Following monitoring facilities, as a bare minimum, shall be provided:

Motor stalled / Single phasing / ESD operated.

Actuator running / open.

Actuator running / closed.

Actuator tripped due to high temperature of motor windings.

Actuator tripped due to overload / any other electrical / mechanical faults.

Remote control selected.

Mains failure.

4 – 20 ma signal proportional to actuator torque output..

12.10 Electrical components including PCB’s shall be mounted on withdrawable chassis.

13.0 CABLING, WIRING & TERMINALS

13.1 MOV shall be complete with all internal wiring and ready for external cable connection at the outgoing terminals.

13.2 All control wiring inside the MOV shall be carried out with tropical grade PVC insulated wires. All wiring shall be ferruled at both ends for easy identification and tracing during maintenance.

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13.3 Minimum size of conductor for power circuits shall be 2.5 mm2 copper or 6 mm2 aluminium. Control wiring shall be done by 2.5 mm2 copper.

13.4 The terminal compartment shall be separated from the inner electrical components of the actuator by means of watertight seal.

13.5 Durable terminal identification card showing terminal plan, serial number, wiring diagram, terminal layout etc. shall be provided attached to inside of terminal box cover.

14.0 ENCLOSURE

14.1 Actuator shall be O-ring sealed, water tight to NEMA 6, IP 68, and shall at the same time have an inner water tight and dust proof O-ring seal between the terminal compartment and the internal electrical elements of the actuator, fully protecting the motor and all other internal electrical elements of the actuator from ingress of moisture and dust when the internal cover is removed on site for cabling.

14.2 The actuator shall be designed so that all turns and torque output settings and calibrations during commissioning can be effected without access to the actuator main control gear enclosure.

14.3 Enclosures for actuators for hazardous area application shall be suitable for the area classified.

14.4 Anti-condensation space heaters shall also be provided inside the enclosure.

15.0 TOOLS

15.1 One complete set of all special tools, Electrical wiring diagrams, sufficient spare cover screws, seals to make good site losses during installation / commissioning, installation manuals shall be provided per MOV for installation, operation and maintenance of MOV.

16.0 SPARES

The manufacturer shall furnish with his quotation separate priced list of recommended operation and maintenance spares. Lube oil of Indian Oil grade shall be supplied.

17.0 DRAWINGS / DOCUMENTATION

The Vendor shall furnish following drawings / documents as a bare minimum:

Actuator GA drawing with part lists / bill of materials for each actuator.

Electrical wiring diagrams / terminal plans for each type / size of valve.

Catalogues / test certificates for all bought out items.

Installation, commissioning, operation and maintenance manual for actuators.

18.0 TESTING AND INSPECTION

After completion of all work at the manufacturer’s works, MOV shall be inspected by the purchaser’s representatives. However, stage inspection may be carried out from time to time to check progress of work and workmanship.

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The following minimum tests shall be carried out during inspection:

All routine tests specified in the relevant Indian Standard for LT AC squirrel Cage induction motor.

Insulation test with 500V volts megger.

Earth continuity test with a low voltage (6 volts) tester.

Operational tests, current / torque at maximum torque setting.

Actuator output speed / operating time

The vendor shall provide all facilities such as power supply, testing instruments and apparatus required for carrying out the tests. Required copies of certificates for all tests carried out along with copies of type test certificates and certificates from sub-vendor for the components procured from them are to be submitted before despatch of the MOV.

19.0 QUALITY ASSURANCE

19.1 Quality assurance shall follow the requirements of Jacobs Q.A. Documents as applicable

19.2 Q.A. involvement will commence at enquiry and follow through to completion and acceptance. Thus ensuring total conformity to purchaser’s requirements.

20.0 DEVIATIONS

20.1 Deviations from the specifications must be stated in writing at the quotation stage.

20.2 In absence of such a statement, it will be assumed that the requirements of the Specifications are met without exception.

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MOTOR OPERATED VALVE

Document No.A133-086-16-47-DS-20

PROCESS DATA SHEET Rev. No. 1Page 1 of 1

PROJECT EPCC-1, RESID UPGRADATION PROJECT CLIENT CPCL

UNIT COKE BLOCK JOB NO. A133 UNIT NO. 86

ITEM NO. MOV-1201

SERVICE FIRE WATER

LOCATION OSBL

OPERATING CONDITIONS

OPERATING PRESSURE KG/CM2G 7.12

OPERATING TEMPERATURE DEG C 40

TIME FOR FULL OPENING/ CLOSING SECONDS 60-90

DESIGN DATA

DESIGN PRESSURE KG/CM2G 13.54

DESIGN TEMPERATURE DEG C 65

KG/CM2 6.42

LINE SIZE/SPEC FULL BORE 16 "/ A33A

VALVE BORE REDUCED BORE FULL BORE

NOTE NO.

NOTES

1 MOV and Accessories to be fire safe2 Motor to be suitable for outdoor installation in process area3 Emergency power to be provided4 Valve shall have provision for hand operation

5

6 Ball Valve to be considered

1 09.09.2014 REVISED FOR EGINEERING RR NS AK0 05.09.2014 ISSUED FOR ENGINEERING RR NS AKA 14.08.2014 ISSUED FOR COMMENTS RR NS AK

Rev. No. Date Purpose

Format No. 3-0241-1034 Rev. 0 Copyrights EIL - all rights reserved

DP SHUTOFF

Open/close switches for MOV's shall be provided locally with the valve. MOV to have OPEN/CLOSE indication in DCS.Additional switch to close to be provided from control room

Prepared By

Reviewed By

Approved By

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CONCESSION REQUEST

Part A - To be Completed by LSTK Contractor / Vendor :

Project No. 1.Name of LSTK Contractor / Vendor & Location 2. CR No. 3. Issue No.

Client : C P C L Dt.:

5. P.O.NO. 6. Description

7. P.O.Item No. 8. LSTK Contractor / Vendor Ref. No. 9. Sub-Order No.

10. Tag/Equipment No. 11. Sub-Vendor 12. Sub Assembly Part No.

13. Drawing & Documents affected by Request :

14. Description of Request 15. Attachments Wt Control state wt in excess

� Yes � No. of 500 kg for complete PO

List :- ..........................kg.

16. Justification

Signature (Contractor / Vendor) Position

17. Effect on delivery : 18. Effect on cost if granted

______________ if Granted

______________ if not Granted � Increase ? � Decrease ? � Unchanged ?

OTHER FACTORS AFFECTED : Tick as applicable

� Strength � Function � Code Compliance � Integrity / Reliability

� Maintenance � Performance � Interchangeability � QA/QC

� Contractual � Approval by CA � Safety / Fitness � Item Life

PART B : To be completed by Jacobs Engineering India Pvt. Ltd.

1. Resolution Category 2. Amendment to P.O. 3. Design Change 4. CA Approval

Requirement

Level 1 � - Engineering, Yes No Yes No Yes No

Procurement & Client

Level 2 � - Level 1 + Cert. Reference No. Reference No. Letter No.

Authority

5. Conditions of Acceptance / Usage / Reason for rejection

6. Decisions Approved Signature Date 7 CR Close out

Engg. Discipline Yes No Name

Purchase Manager Yes No Signature

Inspection Manager Yes No Date

Procurement ED * Yes No Inspection Report Ref :

Yes No

Yes No

Note :- 1. Add extra page for additional comments. * In case of commercial implication

Client

Project Manager

2. In case of any deviation/addition to the approved vendor list, CR alongwith PTR or approval of construction sub-contractor

format as per Appendix-3 to SCC as applicable shall be submitted..

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NON-CONFORMANCE REPORT (NCR)

Project No. : NCN NO.

Client:

Location: Issue Date :

Project Name:

PO/ SC No. : Main Supplier :

Sub - Order No. : Sub-Supplier:

Equipment No. / Item No.

Non-Conformity Description : Spec./Drg. No.

Supplier/Sub-contractor Representative :……...………………Date Date. Jacobs Representative …………….Date:

Root cuuase of the problem and actions to prevent recurrence (to be complted by

Supplier/sub-contractor)

Corrective Action Proposed by Supplier/Subcontractor;

Supplier/Subcontractor Representative Signature : ……………………………………….Date………………

Corrective Action Required by Jacobs :

Per Supplier/Subcontractor Proposal: Yes/No

Other (Sate):

Inspectior / Filed Engineer /

Originating Engineer's approval:…………….Date……… PM / CM Approval ………………………Date………….

Verified Complete by Jacobs Client Acceptance Certifying Authority Acceptance

(if required) (if required)

Distribution Supplier Surveillance Co-ordinator Expeditor

(as applicable) Requisition Enngineer / Discipline Lead Construction Manager

Project Manager

Form No. :S305/fA(1)doc.Page 128 of 129

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