anex-1

TCE CONSULTING ENGINEERS LIMITED

PROCESS DATA SHEET FOR VESSEL SH 1 OF 1

REV.

NO.GENERAL

REV.

NO.

1 ITEM NUMBER

2 QUANTITY 2

3 CAPACITY (NOMINAL)

4 SERVICE

5 DESIGN CODE

6 LOCATION INDOOR / OUTDOOR

7 FLUID PROPERTIES AT OPERATING TEMP.

8

9 FLUID

10 SPECIFIC GRAVITY

11 VISCOSITY cP

12 VAPOUR PRESSURE kg/cm2(a)

13 (AT 30 DEG.C.)

14

15 DESIGN DATA

16

17 OPERATING TEMPERATURE o C

18 DESIGN TEMPERATURE o

C

19 OPERATING PRESS.AT 32 DEG.C.kg/cm2(g)

20 DESIGN PRESS. kg/cm2(a)

21 INSIDE DIAMETER mm

22 LENGTH mm

23 HEAD TYPE- TOP

24 - BOTTOM

25 CORROSION ALLOWANCE mm

26 SUPPORT SADDLE

27 INSULATION - REQUIRED YES / NO

28 - PURPOSE PERS. PROTEC./CONSER. NOTES :

29 AGITATOR YES / NO 3) This vessel shall be designed, fabricated, manufactured, inspected by Third

29 Party & Testing as per the requirement of "The Static & Mobile Pressure

30 Vessels Rules"(SMPV Rules) .This vessel shall be approved by CCoE Nagpur

31 MATERIAL OF CONSTRUCTION and obtaining approval of CCoE Nagpur and inspection by competent third

32 SHELL party shall be in the scope of vessel vendor

5) A Test & Inspection certificate issued by manufacturer of the vessel

33 JACKET shall be furnished to CCoE, Nagpur.This shall be duly countersigned

34 COIL NA by an Inspector, authorised by CCoE, Nagpur that the vessel meets

35 INTERNALS with the requirements of the code approved by CCoE, Nagpur .

36 GASKET PTFE ENVELOPED CAF

37 ACCESSORIES BY TANK VENDOR

38 AGITATOR YES / NO N14 25 1 NITROGEN INLET (DURING COMMISSIONING)

39 BAFFLES YES / NO N13 50 1 SPARE

40 COIL YES / NO N12 50 1 SPARE

41 DIP PIPES YES / NO N11 500 1 MANHOLE

42 N10 25 1 TEMPERATURE INDICATOR

43 SPECIAL REQUIREMENTS N9 25 1 LEVEL GAUGE

44 RADIOGRAPHY 100% N8 25 1 LEVEL INDICATION TRANSMITTER

45 STRESS RELIEF AS PER CODE N7 25 2 LEVEL INDICATION TRANSMITTER

46 BUFFING NA N6 25 1 PRESSURE TRANSMITTER

47 OTHER NA N5 HOLD 1 PRESSURE GAUGE

48 NOTES : N4 HOLD 1 PRESSURE SAFETY VALVE (PSV)

49 1) Sizes and instrument nozzles are under hold pending instrument N3 HOLD 1 PRESSURE SAFETY VALVE (PSV)

51 finalization. N2 50 1 AMMONIA IN

52 2) All liquid level gauging devices shall be as per "SMPV RULES" N1 50 1 AMMONIA OUTLET (TO NH3 COMPRESSOR)

53 NOZZ. NO. SIZE QTY. SERVICE

54 NOZZLE SCHEDULE

REV NO. : P0 R0 PPD. BY :Sd/- SPP TCE JOB NO. CLIENT : NUCLEAR FUEL COMPLEX

PPD. BY/DATE : Sd/-SPP 31.8.05 Sd/-SPP 11.5.06 CKD. BY:Sd/-MB TCE-4246A PROJECT : NZOSP, PALAYAKAYAL

CKD. BY/DATE : Sd/-MB 31.8.05 Sd/-VAK 11.5.06 DATE :31.08.05 PDS NO. : TCE-4246A-CH-T-PDS-322T441

Liquid NH3

23.55 kg/cm2(a)

0.58

-

322-T-441 A/B

ASME SEC-VIII DIV. 1

45 KL (Water Capacity)

LIQUID NH3 STORAGE

LOW TEMPERATURE CARBON

STEEL

SHELL

3000

AMBIENT

12.7 KG/CM2 (a)

11.89

7250

DISHED END

NA

DISHED END

3 MM

LOW TEMPERATURE CARBON

STEEL

(-) 33 TO 55

SHELL

R1

R0-1

997-0

3-3

1T

CE

.M4-C

H-T

-PD

S-

N10 N3 N6N5N4N2

N1

3.0

m

7.25 m

N11 N7 N8 N13

N12

N9



REV.

NO.GENERAL

REV.

NO.

1 ITEM NUMBER

2 QUANTITY 2

3 CAPACITY (WORKING)

4 SERVICE

5 DESIGN CODE



8 SHELL

9 FLUID 35% NH4OH

10 SPECIFIC GRAVITY 0.85 - 0.94

11 VISCOSITY cP 0.3

12 VAPOUR PRESSURE AT 30oC kg/cm

2(a) 0.75

13

14

15 DESIGN DATA

16 SHELL

17 OPERATING TEMPERATURE o C AMBIENT


C 70

19 OPERATING PRESS. kg/cm2(g) ATM.

20 DESIGN PRESS. kg/cm2(g) 10


22 LENGTH mm

23 HEAD TYPE - TOP

24 - BOTTOM



27 - PURPOSE PERS. PROTEC./ CONSER.

28

29

29 MATERIAL OF CONSTRUCTION

30 SHELL SS 304L

31 JACKET

32 COIL NA # indicates as per code

33 INTERNALS SS 304L * indicates minimum for piping



36 AGITATOR YES / NO

37 BAFFLES YES / NO

38 COIL YES / NO

39 DIP PIPES YES / NO N13 25 1 SAMPLING POINT

40 N12 50 1 DRAIN

41 SPECIAL REQUIREMENTS N11 50 1 RECIRCULATION INLET

42 RADIOGRAPHY 100% N10 25 1 NITROGEN BLANKETING

43 STRESS RELIEF AS PER CODE N9 50 1 SPARE

44 BUFFING NA N8 50 1 PVRV

45 OTHER NA N7 500 1 SHELL MANHOLE

46 NOTES : N6 50 1 SPARE

47 1) Sizes and instrument nozzles are under hold pending instrument N5 50 1 PG

48 finalization. N4 25 2 LEVEL INDICATOR TRANSMITTER

49 N3 25 1 TEMPERATURE INDICATOR

51 N2 80 1 AMMONIUM HYDROXIDE OUTLET

52 N1 80 x 40 1 AMMONIUM HYDROXIDE INLET


54 NOZZLE SCHEDULE

REV NO. : P0 R0 PPD. BY :SPP TCE JOB NO. CLIENT : NUCLEAR FUEL COMPLEX

PPD. BY/DATE : Sd/- SPP 31.08.05 Sd/- SPP 11.05.06 CKD. BY:MB TCE-4246A PROJECT : NZOSP, PALAYAKAYAL

CKD. BY/DATE : Sd/- MB 31.08.05 Sd/-VAK 11.05.06 DATE :31.08.05 PDS NO. : TCE-4246A-CH-T-PDS-322T442

NA

DISHED END

322-T-442 A/B


35 KL

NH4OH SOLUTION STORAGE

1 MM

2750

7000

DISHED END

R1

R0-1

997-0

3-3

1T

CE

.M4

-CH

-T-P

DS

-

N10 N3 N8

N5 N6 N9N4N1 N7

N11

N2 N12

7.00 m

2.7

5 m



REV.

NO.GENERAL

REV.

NO.

1 ITEM NUMBER

2 QUANTITY 1

3 CAPACITY (NOMINAL)

4 SERVICE

5 DESIGN CODE



8

9 FLUID

10 SPECIFIC GRAVITY

11 VISCOSITY cP

12 VAPOUR PRESSURE kg/cm2(a)

13 (AT 30 DEG.C.)

14

15 DESIGN DATA

16

17 OPERATING TEMPERATURE o C


C

19 OPERATING PRESS.AT 32 DEG.C.kg/cm2(g)

20 DESIGN PRESS. kg/cm2(a)


22 LENGTH mm

23 HEAD TYPE- TOP

24 - BOTTOM


26 SUPPORT SADDLE


28 - PURPOSE PERS. PROTEC./CONSER.


29

30

31 MATERIAL OF CONSTRUCTION

32 SHELL

33 JACKET

34 COIL NA

35 INTERNALS




39 BAFFLES YES / NO

40 COIL YES / NO

41 DIP PIPES YES / NO

42

43 SPECIAL REQUIREMENTS

44 RADIOGRAPHY NA N8 50 1 SPARE

45 STRESS RELIEF AS PER CODE N7 50 1 SPARE

46 BUFFING NA N6 50 1 SPARE

47 OTHER NA N5 50 1 DRAIN

48 NOTES : N4 25 1 SAMPLING POINT

49 1) Sizes and instrument nozzles are under hold pending instrument N3 500 1 MANHOLE

51 finalization. N2 50 1 PROCESS WATER INLET

52 N1 HOLD 1 AMMONIA INLET


54 NOZZLE SCHEDULE

REV NO. : R0 PPD. BY :Sd/- SPP TCE JOB NO. CLIENT : NUCLEAR FUEL COMPLEX

PPD. BY/DATE : CKD. BY:Sd/-VAK TCE-4246A PROJECT : NZOSP, PALAYAKAYAL

CKD. BY/DATE : DATE :18.06.07 PDS NO. : TCE-4246A-CH-T-PDS-322T441

LOW TEMPERATURE CARBON STEEL

SHELL

1500

AMBIENT

ATM,

65

SHELL

AMMONIUM HYDROXIDE SOLUTION

LIQUID FULL

1

-

322-T-445


5 KL

VENT TANK FOR AMMONIA

-

3500

DISHED END

NA

DISHED END

3 MM

LOW TEMPERATURE CARBON STEEL

R0

R0-1

997-0

3-3

1T

CE

.M4

-CH

-T-P

DS

-

N6N1N8N2

N5

1.5

m

3.5 m

N3 N7

N4

IS

SU

E N

O.

R5

TCE CONSULTING ENGINEERS LIMITED SECTION : D

ENQ.SPEC.NO. DATA SHEET A

TCE.4246-CH-K-PDS-001 LIQUID AMMONIA COMPRESSORS SHEET : 1 OF 6

GE

NE

RA

L

1. DESIGNATION : COMPRESSORS FOR

LIQUID AMMONIA TANKER UNLOADING

DE

SIG

N D

AT

A (

CO

NT

D.)

19.2 FOR INTER-COOLER, AFTER-COOLER

AND OIL-COOLER : WATER

2. NUMBER REQUIRED : 2 NOS (1W+1S) 20. COOLING WATER QUALITY : AS PER

TACO-GYIN SPECS.

3. TAG NUMBERS : 322--K-441 A/B

21. COOLING WATER INLET

4. LOCATION : OUTDOOR TEMPERATURE :** 32 0 C

5. OPERATION : 22. MAXIMUM COOLING WATER OUTLET

INTERMITTENT ~ 1 1/2 hrs. for loading 10

MT Bullet

TEMPERATURE : ** 37 0 C

6. TYPE OF DRIVE : FLAMEPRROF

ELECTRIC MOTOR

23. COOLING WATER PRESSURE AT

AT INLET : ** 2.5 Kg/ cm 2 (g)

7. APPLICABLE STANDARDS : API 618/ 24. MAXIMUM COOLING WATER

API 619 PRESSURE DROP IN THE COMPRESSOR,

INTER-COOLER, AFTER-COOLER AND

8. OIL- COOLER : * Kg/ cm 2

9. 25. COMPRESSOR FRAME LUBRICATION :

DE

SIG

N D

AT

A

10. TYPE : RECIPROCATING- * SPLASH/ PRESSURISED

HORIZONTAL 26. TYPE OF CAPACITY CONTROL : *

NON-LUBRICATED BY SPEED VARIATION/ AT CONSTANT

11. FLUID TO BE COMPRESSED :

LIQUID AMMONIA VAPOR

SPEED

27. METHOD OF CAPACITY CONTROL AT

12. CAPACITY (FAD) : * M3/Hr ( Note 4 ) CONSTANT SPEED : * DUAL TYPE

13. MASS FLOW RATE : * Kg/Hr

( Note 4 )

CONTROL / MOVABLE INLET GUIDE

14. PROPERTIES OF GAS/ GAS COMPO- VANES /

SITION : LIQUID AMMONIA VAPORS 28.

15. SUCTION PRESS. :2.25 ~11.7Kg/cm2 (g) 29.

16. SUCTION TEMPERATURE - MINIMUM /

DU

AL

TY

PE

CO

NT

RO

LS

30. ADJUSTABLE RANGE FOR PRESSURE

MAXIMUM : (-) 33 / 55 0 C SWITCHES : * Kg/ cm

2

17. DISCHARGE PRESSURE : 15 Kg/ cm 2 (g) 31. EXPECTED SETTING OF PRESSURE

18. MAXIMUM COMPRESSOR SPEED : * SWITCHES FOR : *

RPM 31.1 AUTO LOAD-UNLOAD REGULATION :

19. COOLING MEDIUM : * WATER (a) LOAD : * Kg/ cm 2 (g)

19.1 FOR COMPRESSOR:* WATER/ NOTE-1 (b) UNLOAD : * Kg/ cm 2 (g)

REV.NO. PPD. BY: SPP JOB NO. CLIENT: NUCLEAR FUEL COMPLEX

DATE CHD. BY: VAK TCE.

REV. BY DATE : 29.06.07 4246 A PROJECT: NZOSP

TCE FORM NO. 330 R1 FILE NAME : DA10701R5.DOC

ISS

UE

NO

. R

5 TCE CONSULTING ENGINEERS LIMITED SECTION : D


TCE. 4246-CH-K-PDS-001 LIQUID AMMONIA COMPRESSORS SHEET : 2 OF 6 D

UA

L T

YP

E C

ON

TR

OL

S (

CO

NT

D.)

31.2 AUTO START-STOP REGULATION:

MA

TE

RIA

LS

OF

CO

NS

TR

UC

TIO

N

FO

R C

EN

TR

IFU

GA

L C

OM

PR

ES

SO

RS

(C

ON

TD

.)

44. IMPELLERS : CAST ALUMINIUM ASTM

(a) START : * ~2 Kg/ cm 2 (g) B 26, ALLOY C 355/ CAST SS 410/ CAST

(b) STOP : * ~1 Kg/ cm 2 (g) SS ASTM A 747, TYPE CB7 Cu-1 OR CB7

31.3 VERY LOW RECEIVER PRESSURE Cu-2/ FORGED SS 403/

ALARM : * Kg/ cm 2 (g)

31.4 HIGH RECEIVER PRESSURE 45. BLADES : PLATE STEEL AISI 4130-4140/

ALARM : * Kg/ cm 2 (g) AISI 4320-4340/

32. NUMBER OF STEPS FOR LOAD - 46. GUIDE VANES : CI ASTM A 48 OR A 278,

UNLOAD REGULATION : * 2 / 3 / 4 / CL 30/ CAST STEEL ASTM A 216, GR

33. WCB/ CAST SS ASTM A 743/744 OR

MA

TE

RIA

LS

OF

CO

NS

TR

UC

TIO

N

FO

R R

EC

IPR

OC

AT

ING

CO

MP

RE

SS

OR

S

34. CYLINDER AND CYLINDER LINER : A 351, GR CA15, CF3, CF3M, CF8, CF8M/

* CI

47. SHAFT : FORGED STEEL AISI 1040-

1050

35. PISTON RINGS : * CI OR ASTM A 470, CL 7/FORGED SS ASTM

A 336, GR F6/

36. VALVE SEATS : * EN 8A FORGED 48. COVERS AND HUBS : FORGED STEEL

37. VALVE PLATES : * AISI TYPE 3140/ PLATE STEEL ASTM A

38. VALVE STOPS : * 543/ FORGED SS AISI TYPE 403 OR 410 /

39. VALVE SPRINGS : *

MA

TE

RIA

LS

OF

CO

NS

TR

UC

TIO

N

FO

R S

CR

EW

CO

MP

RE

SS

OR

S

49. CASING : CI IS 210 OR ASTM A 278 CL

40. PISTON : * CI 40/ FABRICATED STEEL ASTM A 353/

CAST STEEL ASTM A 216 GR WCB

41. CRANK SHAFT, CONNECTING ROD NORMALIZED / CAST SS ASTM A 743

AND PISTON ROD : * EN 8A AND 744 CA6-NM/

MA

TE

RIA

LS

OF

CO

NS

T.

FO

R C

EN

TR

IFU

GA

L

CO

MP

RE

SS

OR

S

42. CASING : CI IS 210 OR ASTM A 48 OR 50. ROTOR BODY : CI ASTM A 395/

A 278 / CAST STEEL ASTM A 216 GR FORGED STEEL AISI 1030-1045/ CAST

WCB NORMALIZED/ ALUMINIUM ASTM B 26 ALLOY 355

OR C 355/

43. DIFFUSER : CI ASTM A 536,GR 60-40-

18/ CAST ALUMINIUM ASTM B 26, ALLOY

51. SHAFT : FORGED STEEL AISI 1030-1035/

355.0 / FORGED SS ASTM A151 TYPE 410 SS /



REV. BY DATE : 29.06.07 4246 A PROJECT NZOSP


IS

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R5



TCE. 4246A-CH-K-PDS-

001 LIQUID AMMONIA COMPRESSORS SHEET : 3 OF 6

CO

MP

RE

SS

OR

AC

CE

SS

OR

IES

52. INTAKE FILTER TYPE : * PAPER/

INT

ER

-CO

OL

ER

S /

AF

TE

R-C

OO

LE

RS

/ O

IL-C

OO

LE

RS

DE

SIG

N D

AT

A

69. DESIGNATION : * INTER-COOLERS/

OIL WETTED/ CLOTH/ OIL BATH/ AFTER-COOLERS FOR

COMBINED DRY AND WET 70. TAG NUMBERS FOR INTER-COOLERS :

LATER

52.1 MATERIAL OF CONSTRUCTION :

CASING : * MS/ ALUMINIUM 71. AFTER-COOLERS REQUIRED : *NO

NUMBER :

53. SILENCER REQUIRED : * YES

54. DRIVE PULLEYS WITH V-BELT AND 72. TAG NUMBERS FOR AFTER-COOLERS :

BELT GUARDS REQUIRED : * YES LATER

FOR BELT DRIVEN COMPRESSORS 73. CAPACITY OF :

55. COUPLINGS AND COUPLING GUARDS 73.1 INTER-COOLERS : * M3 / Hr

REQUIRED : YES ( non sparking material) 73.2 AFTER-COOLERS : * M3 / Hr

74. TYPE : *HORIZONTAL/ VERTICAL

56. SLIDE RAILS FOR MOTOR REQUIRED: SHELL AND TUBE TYPE WITH

*YES REMOVABLE TUBE BUNDLES/

57. CONTROL CABINET REQUIRED : YES 75. TYPE OF FLOW : COUNTER-CURRENT

58. IMPULSE TUBING : * STAINLESS

STEEL 76. OPERATING PRESSURE FOR AFTER-

COOLERS *

76.1 GAS SIDE :* Kg/ cm 2 (g)

76.2 WATER SIDE : * Kg/ cm 2 (g)

59. MOTOR BY : COMPRESSOR BIDDER 77. DESIGN PRESSURE FOR AFTER-

COOLERS *

60. STARTER BY : COMPRESSOR BIDDER 77.1 AIR/ GAS SIDE : * Kg/ cm 2(g)

77.2 WATER SIDE : * Kg/ cm 2(g)

61. 78. MAXIMUM ACCEPTABLE OUTLET

62. GAS TEMPERATURE : * 0 C

63. 79. ALLOWABLE PRESSURE DROP OF AIR/

64. GAS THROUGH AFTER-COOLER :

65. 0.2 Kg/ cm 2

66. 80. DESIGN CODE : ASME SEC. VIII DIV. 1

67. AND TEMA

68. 81. CORROSION ALLOWANCE : * mm



REV. BY DATE : 29.06.07 4246a PROJECT: NZOSP

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TCE4246-CH-K-PDS-001 LIQUID AMMONIA COMPRESSORS SHEET : 4 OF 6

INT

ER

-CO

OL

ER

S/A

FT

ER

CO

OL

ER

S/

OIL

-CO

OL

ER

S –

M O

C

82. SHELL : *

RE

CE

IVE

R D

ES

IGN

DA

TA

90. DESIGNATION : RECEIVERS FOR

83. TUBES : * 91. NUMBER REQUIRED :1

92. TAG NUMBERS :

84. TUBE SHEETS : * CS 93. TYPE : *HORIZONTAL/ VERTICAL/

CYLINDRICAL WITH WELDED DISHED

85. TUBE SUPPORT PLATES : * CS ENDS

94. OPERATING PRESSURE : *

86. Kg/ cm 2 (g)

INT

ER

-CO

OL

ER

S /

AF

TE

R-C

OO

LE

RS

AC

CE

SS

OR

IES

87. MOISTURE AND OIL SEPARATOR 95. DESIGN PRESSURE : * Kg/ cm 2 (g)

WITH AUTO DRAIN TRAP TO BE 96. DESIGN TEMPERATURE : * ° C

PROVIDED WITH EACH INTER- 97. NOMINAL VOLUME : * M 3

COOLER AND AFTER-COOLER TO 98. DIMENSIONS :

DISCHARGE MOISTURE AND OIL TO 98.1 HEIGHT TAN TO TAN : * mm

DRAIN 98.2 DIAMETER : * mm

87.1 TYPE OF MOISTURE AND OIL 99. APPLICABLE CODE : IS 2825/

SEPARATOR : CENTRIFUGAL/

DEMISTER PAD/ BAFFLE 100. CORROSION ALLOWANCE : 1.6 mm

87.2 TYPE OF AUTO DRAIN TRAP : 101. SHELL AND DISHED END MATERIAL :

INVERTED BUCKET / BALL FLOAT / IS 2002/ IS 2062

SOLENOID OPERATED / ELECTRONIC 102. INTERNAL PAINTING : BLACK

LEVEL CONTROLLED BITUMINOUS /

88. MATERIAL OF CONSTRUCTION OF 103. INSULATION : NO

MOISTURE AND OIL SEPARATOR 104.

88.1 BODY/ SHELL : CS

RE

CE

IVE

R

AC

CE

SS

OR

IES

105. SUPPORT LEGS/ LUGS/ SKIRT

REQUIRED : YES

88.2 106. MANHOLE WITH COVER FOR

89. MATERIAL OF CONSTRUCTION OF INSPECTION AND CLEANING

AUTO DRAIN TRAP REQUIRED : YES

89.1 BODY : CI IS 210/ SS 107.

89.2 TRIM : SS/ 108.


DATE CHD. BY:VAK TCE.

REV. BY DATE : 29.06.07 4246 A PROJECT: NZOSP

TCE FORM NO.330 R1 FILE NAME : DA10701R5.DOC

ISS

UE

NO

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TCE. 4246-CH-K-PDS-001 LIQUID AMMONIA COMPRESSORS SHEET : 5 OF 6 M

ISC

EL

LA

NE

OU

S

109. ALL THE VALVES, SPECIALITIES 123. REFER TCE.M4-907

INSTRUMENTS AND ACCESSORIES

SP

AR

ES

AN

D M

AIN

TE

NA

NC

E T

OO

LS

AN

D T

AC

KL

ES

124. ESSENTIAL SPARES

AS PER ENCLOSED P&I D

TCE.4246- 300-PI-8651

124.1 OIL FILTERS

: REQUIRED 124.2 ALL KINDS AND SIZES OF GASKETS

110. COUNTER FLANGES FOR ALL THE 124.3 ALL KINDS AND SIZES OF O-RINGS

CONNECTIONS AT BATTERY LIMITS 124.4 WEAR RINGS

WITH NUTS, STUDS, BOLTS, GASKETS 124.5 OIL SEALS

AND WASHERS REQUIRED : YES 124.6

110.1 FLANGES : YES 124.7

124.8

111. FOUNDATION BOLTS FOR ALL THE 124.9

EQUIPMENT REQUIRED : YES 124.10

112. ERECTION BY CONTRACTOR :YES/NO T

ES

TS

AN

D I

NS

PE

CT

ION

125. AS PER TCE.M4-904 AND / OR

113. ERECTION SUPERVISION BY TCE.M4-85-01 AND TCE.M4-185-65 OR

CONTRACTOR : YES TCE.M4-186-01, 02, 04, 05, 06, 08, 09, 12

114. AND 26 (NOTE 2)

PA

INT

ING

115. PRIMER : RED OXIDE/ EPOXY 126. PERFORMANCE TEST AT SITE

115.1 NUMBER OF COATS : REQUIRED : YES

115.2 DRY FILM THICKNESS : 127. APPLICABLE STANDARDS : IS 5456 /

116. FINISH PAINT : SYNTHETIC ENAMEL/ API 618 / API 617 / API 672 / API 619 /

EPOXY/ IS 11780 /

116.1. NUMBER OF COATS : 128.

116.2 DRY FILM THICKNESS : 129.

CO

MP

AN

ION

SP

EC

IFIC

AT

ION

S

117. MOTORS : TCE.M4-203-01 AND/ OR

PE

RF

OR

MA

NC

E G

UA

RA

NT

EE

S

130. CAPACITY OF EACH COMPRESSOR :

TCE.M4-203-02 * (+) ( ) M3/Hr

118. TURBINE : TCE.M4-133-01/ 04 / 131. DISCHARGE PRESSURE : *

(+) ( ) Kg/ cm2 (g)

119. PIPING MATERIAL SPECIFICATIONS : 132. POWER CONSUMPTION : *

TCE. (+) ( ) KW

120. INSTRUMENTATION AND CONTROL 133. TEMPERATURE OF AIR AT OUTLET

TCE.M4-107-IC-01 OF AFTER COOLER : * ° C

121. CONTROL CABINET : TCE.M4-219-01 134. COOLING WATER FLOW RATE : *

122. CABLES : TCE.M4-208-01 M3/Hr

REV.NO. PPD. BY: SSP JOB NO. CLIENT: NUCLEAR FUEL COMPLEX


REV. BY DATE : 29.06.07 4246 A PROJECT: NZOSP.


ISS

UE

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TCE. 4246-CH-K-PDS-001 LIQUID AMMONIA COMPRESSORS SHEET : 6 OF 6 P

ER

FO

RM

NC

E

GU

AR

AN

TE

ES

(C

ON

TD

.) 135. COOLING WATER OUTLET 139. POWER CONSUMPTION :

TEMPERARURE : 37 ° C Rs. * / KW

136. COOLING WATER PRESSURE DROP : 140. COOLING WATER CONSUMPTION :

0.25 Kg/ cm2 (g) Rs. * / M

3/Hr

137. 141.

138. 142.

LIS

T O

F S

UB

-VE

ND

OR

S F

OR

BO

UG

HT

-OU

T A

ND

CR

ITIC

AL

IT

EM

S

143. BEARINGS

144. MOTORS

145. TURBINE

146. ENGINE

147. COUPLINGS

148. V- BELTS

149. VALVES & SPECIALITIES

150. AUTO DRAIN TRAPS

151. VIBRATION DAMPENING PADS

152. CONTROL PANEL AND INSTRUMENTS : REFER

153. MCC

154.

155.

156.

NOTES

1. FOR COMPRESSORS UPTO MOTOR RATING OF 7.5 KW, BIDDER MAY OFFER AIR COOLED

COMPRESSOR AS AN ALTERNATIVE TO WATER COOLED COMPRESSOR.

2. FOLLOWING ADDITIONAL TESTS INDICATED AS ‘B’ IN TCE.M4-186-01,02, 04, 05, 06, 08, 09, 12

AND 26 SHALL ALSO BE CARRIED OUT WHEN TCE.M4-186-01, 02, 04, 05, 06, 08, 09, 12 AND 26

ARE APPLICABLE

3.. * DENOTES BIDDER TO SPECIFY / CONFIRM.

4. BASIS FOR SIZING : 10 MT LIQUID AMMONIA BULLET TO BE LOADED IN 1-1.5 HOURS. TIME

INCLUDES THE VAPOR RECOVERY FROM ROAD TANKER.

5. ** TO BE CONFIRMED DURING DETAILED ENGG..

6. MOTOR SHALL BE FLAME POOF TEFC , CONFORMING TO GAS GROUP IIA/B, IS 2148, IP

55,CLASS F.



REV. BY DATE : 4246 A PROJECT: NZOSP

CO

ST

LO

AD

ING

AN

D P

EN

AL

TY


SPECIFICATION NO. TCE CONSULTING ENGINEERS LIMITED SECTION D

DATA SHEET

TCE-4246A-C-300-005 ANALOG SIGNAL ISOLATORS/ MULTIPLIERS SHEET 1 OF 1

REV. NO.

P0 PPD. BY:DMG JOB NO.

CLIENT: NUCLEAR FUEL COMPLEX

DATE CKD. BY:SPA TCE

REV. BY DATE: 17.12.07

4246A PROJECT : NZOSP, PALAYAKAYAL

TCE FORM 330 R1

Make : Bidder to state

Input signal : 4-20 mA DC from process transmitter

Output signal : 4-20 mA DC

No. of outputs : 2 nos.

Quantity : As per P&ID ( for all Analog signals)

Mounting : DIN rail mounted in Marshalling cabinets

Power Supply : 24 V DC

Type of isolation : Transformer Isolated (Preferable)

Accuracy : 0.1% of calibrated span including combined effect of linearity, hysterisis and repeatability

Stability : Calibration shall hold within specified accuracy for a min. period of 1 year

SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION : CONTENTS TCE-4246A-C-300-005

CONTENTS

SHEET 1 OF 3

ISSUE R0

TCE FORM NO. 329 R3

SECTION – C (TECHNICAL SPECIFICATIONS)

SEC-TION

SPECIFICATION NO.

ISSUE NO.

TITLE NO OF PAGES

C1 TCE-4246A-C-300-005

R1 CRITERIA FOR ELIGIBILITY FOR EVALUATION OF TENDER DOCUMENT

1

C2 TEC-4246A-950 R1 PROJECT INFORMATION – GENERAL 3

C3 TCE-4246A-951 R0 PROJECT INFORMATION – ELECTRICAL 2

C4 TCE.4246A – 952

RO DOCUMENT & DRAWING SUBMISSION & DISTRIBUTION SCHEDULE

2

C5 TCE-4246A-C-300-005

R1

SCOPE AND GENERAL SPECIFIC TECHNICAL REQUIREMENTS FOR LIQUID AMMONIA AND 35% AMMONIUM HYDROXIDE STORAGE AND TRANSFER SYSTEM

11

C6 TCE-4246A-C-300-05

R1

EQUIPMENT, SYSTEM AND SERVICE TO BE PROVIDED BY CONTRACTOR. SYSTEM DESCRIPTION AND VARIOUS DETAILS FOR LIQUID AMMONIA AND 35% AMMONIUM HYDROXIDE STORAGE AND TRANSFER SYSTEM

12

C6 TCE-4246A-CH-T-PDS-322T441

R1 DATASHEET FOR LIQUID AMMONIA STORAGE VESSEL / BULLET

1


R1 DATASHEET FOR AMMONIUM HYDROXIDE SOLUTION STORAGE VESSEL / BULLET

1


R0 DATASHEET FOR LIQUID AMMONIA VENT TANK

1

C6 TCE-4246A-CH-SM-PDS-322SM101

R0 DATASHEET FOR STATIC MIXER

1

C6 TCE-4246A-CH-X-PDS-001

P0 DATASHEET FOR EXCESS FLOW CHECK VALVES

1

C6 TCE.4246A-CH-K-PDS-001

R5 DATASHEET FOR AMMONIA COMPRESSOR

6

C6 TCE.M4-604-09 R4 DATASHEET-FLOW ELEMENT 3

C6 TCE.4246A-109-TI-04

R0 DATASHEET-TEMPERATURE INDICATOR

2

C6 TCE.M4-601-06 R4

DATASHEET-DIFFERENTIAL PRESSURE TRANSMITTERS

2

C6 TCE.4246A-C-300-005

R0 DATASHEET-ANALOG SIGNAL ISOLATORS/ MULTIPLIERS

1

C6 TCE.4246A-C-300-005

R0 DATASHEET-DIGITAL PANEL METERS

1

C6 TCE.M4-109-UCP-54

R1 DATASHEET-CONTROL PANEL

2


CONTENTS

SHEET 2 OF 3

ISSUE R0

TCE FORM NO. 329 R3


SEC-TION

SPECIFICATION NO.

ISSUE NO.

TITLE NO OF PAGES

C6 TCE.M4-607-05 R2 DATASHEET-PRESSURE/VACUUM RELIEF 2

C6 TCE.M4-109-CV R0 DATASHEET-CONTROL VALVES 2

MECHANICAL

C7 TCE.M4-107-01 R6 WRITE-UP FOR AMMONIA COMPRESSOR 10

C7 TCE-4246A-300-LS-001

R2 PIPING MATERIAL SPECIFICATION (SA1,CR, CA, CB1, CB2)

18

C7 TCE-4246A-C-300-002

R0 PAINTING SPECIFICATION

2

C7 TCE-M4-102-01 R3 WELDED UNFIRED PRESSURE VESSELS 10

C7 TCE-M4-102-43 R3 EARTHING CLEAT 1

C7 TCE-M4-102-34 R3 GUSSETS FOR NOZZLES 1

C7 TCE-M4-103-99 R3

VALVES AND SPECIALITIES – GENERAL REQUIREMENTS.

4

C8 GENERAL REQUIREMENTS IN ELECTRICAL

TCE.M4-203-01 R8 INDUCTION MOTOR 5

TCE.M4-208-01 R7 CABLES 6

TCE-M4-208-11 R3

CABLING ACCESSORIES, CABLE TRAYS, CONDUITS & PIPES

6

C9 GENERAL REQUIREMENTS IN MECHANICAL

TCE.M4-134-01 R1

WELDING SPECIFICATION FOR CHEMICAL AND INDUSTRIAL PLANT PIPING SYSTEMS

23

TCE.M4-134-06 R1

FABRICATION, ERECTION AND TESTING OF PIPING SYSTEMS FOR CHEMICAL AND INDUSTRIAL PLANTS.

13

TCE.M4-185-01 R3

INFORMATION TO VENDOR ON QUALITY PLANS & GENERAL INSPECTION REQUIREMENTS

3

TCE.M4-186-01 R2

SHOP INSPECTION REQUIREMENTS FOR UNFIRED PRESSURE VESSELS

1

TCE.M4-186-04 R2

SHOP INSPECTION REQUIREMENTS FOR VALVES – METALLIC.

1

TCE.M4-186-05 R2

SHOP INSPECTION REQUIREMENTS FOR PIPES AND PIPE FITTINGS - METALLIC.

1

TCE.M4-186-08 R2

SHOP INSPECTION REQUIREMENTS FOR ROTATING MACHINES – MECHANICAL.

1


CONTENTS

SHEET 3 OF 3

ISSUE R0

TCE FORM NO. 329 R3


SEC-TION

SPECIFICATION NO.

ISSUE NO.

TITLE NO OF PAGES

C-10 GENERAL TERMS, CONDITIONS AND REQUIREMENTS

TCE.M4-903 R3

DRAWINGS, ENGINEERING DOCUMENTS & INSTRUCTION MANUALS

8

TCE.M4-904 R7 SHOP INSPECTION AND TESTS 8

TCE.4246A -905 R1 GUARANTEE AND PATENT RIGHTS 2

TCE.M4-906 R6

PACKING, MARKING AND TRANSPORT INSTRUCTIONS FOR EQUIPMENT

6

TCE.M4-907 R5 SPARES AND MAINTENANCE TOOLS & TACKLES 3

TCE.M4-908 R4 TRAINING OF PURCHASER’S PERSONNEL 1

TCE.M4-914 R5 PROGRESS SCHEDULE AND REPORTS 3

TCE.M4-915 R4 PERFORMANCE TESTS AT SITE 3

TCE.M4-916 R4 RATING AND NAME PLATES 1

TCE.M4-917 R0

SAFETY CONDITIONS FOR UNDERTAKING SITE WORK

10

ENCLOSURES LIST OF DRAWINGS/DOCUMENT

TCE.4246A-300-PI-8650

R0 LEGEND AND SYMBOLS

1

TCE.4246A-322-PI-8725

R0 P & I DIAGRAM FOR LIQUID AMMONIA STORAGE & TRANSFER

1

TCE.4246A-

322-GA-8595 R0

GENERAL ARRANGEMENT FOR LIQUID AMMONIA STORAGE & TRANSFER 1

TCE.4246A-322-GA-8600

R0 GENERAL ARRANGEMENT FOR AMMONIUM HYDROXIDE STORAGE & TRANSFER

1

SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: C1

TCE- 4246A-C-300-005

CRITERIA OF ELIGIBILITY FOR

TECHNICAL EVALUATION OF THE BIDS

SH 1 OF 1

ISSUE R1

TCE FORM 329 R3

1. CRITERIA OF ELIGIBILITY FOR TECHNICAL EVALUATION OF THE BIDS

1.1 Experience of Contractor in similar works / Past Performance

For the purpose of this clause „similar work‟ means the works of “work of one or more types of the system / subsystems alongwith its components, accessories & equipment required as per this tender and including all allied works such as instrumentation, electrical and piping to make the system complete and including erection & commissioning at site”.

The contractor should have the proven technical, commercial and financial capability in terms of having executed turnkey jobs of this nature as required in the tender document.

Bidder shall have satisfactory performance of the works carried out. Bidder shall provide a reference list of previous clients for whom similar work has been carried out and the value of the jobs. Bidder shall to provide letters from them for satisfactory performance, workmanship and delivery of items / system & completion schedules.

1.2 Design, Manufacturing & Quality Control Facilities

Bidder to furnish the details of existing manufacturing (plant and machinery), infrastructural & quality control facilities available with the bidder.

Bidder shall submit the organisation chart and his technical, supervisory & managerial establishment and the technical & managerial staff, CAD / CAM facilities that will be deployed for this project.

1.3 Financial Stability

1.3.1 Turnover :

Average annual financial turnover during last 3 years ending 31st March of the previous financial year. The contractor shall submit TDS certificates or audited balance sheets showing receipts from contracts, profit and loss etc in support of his claim.

SPEC. NO. TCE CONSULTING ENGINEERS LIMITED SECTION D

DATA SHEET

TCE.4356A-C-300-005 DIGITAL PANEL METERS SHEET 1 OF 1

REV. NO. PPD. BY:DMG JOB NO. CLIENT: NUCLEAR FUEL COMPLEX

DATE CKD. BY:SPA TCE

REV. BY DATE: 17.12.07 4246A PROJECT: NZOSP, PALAYAKAYAL

TCE FORM 330 R1

Type : Microprocessor based

Mounting : Front facia of panels

size : 24 mm (H) x 48 mm (W)

Digit height : 12 mm

Enclosure Protection : User Configurable (Universal)

Input : 4-20 mA DC from transmitters

Range : User configurable

Engg. Units : kg/ cm2 for pressure

0C for temperature

Metres for level.

Ampere, Voltage ( User Configurable)

Relay Outputs : 1 changeover (For each high and low alarms,

adjustable over 100% range)

Contact Rating : 2A, 230 V AC

Power Supply : 24 VDC

Accuracy : ± 0.2 % of full scale

Display : 4 ½ digit LED display

Quantity : As per P&ID ( for all Analog signals)

Tests : Calibration & Performance tests

HV test

Type test certificate for protection class

DRAWINGS/ DOCUMENTS

1. Vendor shall submit catalogue & data sheet for review & comments by Purchaser/ Consultant.

2. Vendor shall submit Instruction Manual for Records.

TEST CERTIFICATES

1. Vendor shall submit all routine Test certificates for Purchaser/ Consultant’s review.

2. Vendor shall submit type test certificates for protection class.

NOTES

1. Bidder shall indicate all applicable codes and standards.

SPEC.NO. TCE CONSULTING ENGINEERS LTD. SECTION : C4

TCE.4246A - 952

DOCUMENT & DRAWING SUBMISSION & DISTRIBUTION SCHEDULE

SHEET OF 2 OF 4

1

ISSUE R0

TITLE

TCE FORM 329 R3

The Vendor / Contractor shall submit and distribute to the PURCHASER / OWNER and CONSULTANT / ENGINEER the following number of copies of the required documents and drawings mentioned in the tender.

Sl. No.

Description Vendor / Contractor

Owner Engineer

1. General Correspondence from Vendor / Contractor

a) Commercial S Ori.+ 1 3 (*)

b) Technical S Ori. + 1 3 (*)

2. General Correspondence from :

a) TCE Ori. 2 S

b) NFC Ori. S 3 (*)

3. Vendor / Contractor Manufacturing, fabrication, delivery and erection schedule

S 3 3 (*)

4. Manufacturing Test Reports S Ori. + 3 3

5. Operating, Maintenance and Erection Manuals

a) Preliminary S 4 3 (*)

b) Final S 6 3 (*)

6. Vendor / Contractor Drawings / Documents

a) First submission and subsequent revisions

S 6 6

b) As-Built S R + 6 3 (*)

c) As-Built (on CD) (Soft Copy) S 3 3

7. Draft & Final Reports S 5 4 (*)

(*) : One copy to TCE Site Office. n -- Number of Copies required. Legend : S -- Source, Ori. -- Original, R -- Reproducible

SPEC.NO. TCE CONSULTING ENGINEERS LTD. SECTION : C4

TCE.4246A - 952

DOCUMENT & DRAWING SUBMISSION & DISTRIBUTION SCHEDULE

SHEET OF 2 OF 4

2

ISSUE R0

TITLE

TCE FORM 329 R3

DETAILS FOR CORRESPONDENCE 1. Postal Address :

Nuclear Fuel Complex Department of Atomic Energy,

ECIL Post, Hyderabad – 500 062, Andhra Pradesh, India.

Att’n : Mr. B.Laxminarayana Project Director (NZOSP)

Telephone (040) – 2718 4337 / -- 2718 4971

(thro’ office) Fax (040) -- 2713 5019

E-mail ID [email protected]

2. Postal Address :

TCE Consulting Engineers Ltd. Raj Plaza, 2nd Floor, L. B. S. Marg, Vikhroli (West), Mumbai – 400 083. Att’n : Mr. V.A.Kunte Project Manager

Telephone (022) 6 647 2111 Fax (022) 6 647 2000

E-mail ID [email protected]

mailto:[email protected]

mailto:[email protected]

SPEC.NO. TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP

TCE.M4-107-01

AIR / GAS COMPRESSORS SHEET 1 OF 10

ISSUE

R6

TCE FORM NO. 329 R3 FILENAME : M410701R6.DOC

1.0 SCOPE

This specification covers the general design, materials, construction features,

manufacture, shop inspection and testing at manufacturer’s works, delivery at

site, handling at site, erection, testing, commissioning, performance testing and

handing over of Air / Gas Compressors and Accessories.

2.0 CODES AND STANDARDS

2.1 The design, materials, construction, manufacture, inspection, testing and

performance of the air/ gas compressors and accessories shall comply with all

currently applicable statutes, regulations and safety codes in the locality where

the equipment is to be installed. The equipment shall also conform to the latest

applicable Indian or equivalent standards. Other international standards are

also acceptable, if these are established to be equal or superior to the listed

standards. Nothing in this specification shall be construed to relieve the

CONTRACTOR of this responsibility.

2.2 The following are some of the important codes and standards relevant to this

specification.

API 617 Centrifugal Compressors for Petroleum, Chemical, and Gas

Service Industry Services

API 618 Reciprocating Compressors for Petroleum, Chemical, and Gas

Industry Services

API 619 Rotary Type Positive Displacement Compressors for

Petroleum, Chemical, and Gas Industry Services

API 672 Packaged, Integrally Geared Centrifugal Air Compressors for

Petroleum, Chemical, and Gas Industry Services

ASME SEC. Boiler and Pressure Vessel Code

VIII DIV.1

TEMA Standards of the Tubular Exchanger Manufacturers Association

IS 2825 Code for Unfired Pressure Vessels

IS 5456 Code of Practice for Testing of Positive Displacement Type Air

Compressors and Exhausters

IS 6206 Guide for Selection, Installation and Maintenance of Air

Compressor Plants with Operating Pressures up to 10 bars

IS 7938 Air Receivers for Compressed Air Installation

IS 11780 Code for Selection and Testing of Rotary Screw Air

Compressors (Oil Flooded)


TCE.M4-107-01


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IS 13124 Reciprocating Gas Compressors - Technical Supply Conditions

3.0 DESIGN AND CONSTRUCTION FEATURES

The compressor shall be of reciprocating or centrifugal or screw type as

specified in data sheet A.

3.1 RECIPROCATING COMPRESSORS

3.1.1 Frame

The frame shall be a single casting and robust in construction. It shall be

provided with sufficiently large and easily removable inspection doors so that

the bearings and other parts are readily accessible for checking and

adjustments. Inspection doors shall be dust-proof and oil-tight.

3.1.2 Cylinder

The cylinder shall be made of cast iron or stainless steel or as specified in data

sheet A. The cylinder heads and barrels shall be provided with cooling water

jackets. The design of jackets shall be such that low air discharge temperature

and minimum carbon formation are ensured. The water jackets shall be so

constructed that the flow of water is uniform throughout the cooling surface

and no stagnant water pockets are formed. The walls of the cylinder shall have

sufficient thickness suitable for maximum working pressure and temperature

and shall be suitable for reboring. It shall be provided with liberally sized

valve openings and stream-lined passages. The internal surface of the cylinder

shall be highly polished to reduce wear of the piston rings.

3.1.3 Piston and Piston Rod

The piston shall be of such a design and construction that the piston rings exert

equal pressure at all points of the cylinder bore. The piston rod shall be

designed to take up the full thrust acting on the piston. The piston rings for

non- lubricated type compressor shall be of self lubricating type. Piston speed

shall be maximum 300 M/Min for large capacity compressors and 350 M/Min

for small capacity compressors.

3.1.4 Cross Head

The cross head shall be of solid box type with the faces ground to work closely

with the groove of the guides. The cross head pin shall be case hardened and

ground.


TCE.M4-107-01


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3.1.5 Connecting Rod and Crank Shaft

The connecting rod shall be of I cross-section providing adequate strength and

rigidity. The crank shaft shall be adequately designed so as to ensure smooth

running, without vibrations. It shall be accurately finished to size and shall

have sufficient length so as to be fitted to main bearing and flywheel.

3.1.6 Flywheel

The flywheel shall be designed such that it is well balanced and is of sufficient

weight to give an even turning moment. The wheel shall be of robust

construction. The spokes shall have oval cross-section and the boss shall have

split construction such that the wheel runs true with the shaft. The flywheel

shall be suitable for type of power transmission i.e. flat belt, V-belt, direct

coupling etc. between the driver and compressor.

3.1.7 Main Bearings

The main bearings shall be of robust construction assuring long bearing life

and shall have sufficiently large diameter and adequate length. The bearing at

the crank pin end of connecting rod shall be fitted with bronze lined with best

quality white metal. The bearing at the cross head end shall be fitted with a

bushing made of bronze. The bearings shall be made in halves and shall have

forced feed lubrication.

3.1.8 Valves

The valves shall have straight and uniform lift and maximum effective area so

as to ensure low air velocity and minimum valve clearance. The valve plate

discs shall be heat treated, tempered and ground and the valve seat shall be

case hardened. The valve springs shall be capable of effecting quick opening

and closing and shall also provide the required cushioning effect. The valve

design shall be such that the valve can be easily removed for checking and

maintenance.

3.1.9 Lubrication

(a) Frame Lubrication

Frame lubrication for small compressors with motor rating upto 55 kW

shall be of splash type. The pressurised i.e. forced feed system shall be

used for compressors with higher motor rating. In case of force feed

lubrication, the oil pump shall be either driven by crank shaft of the


TCE.M4-107-01


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compressor or shall be separately driven. The pump shall draw the oil

from the adequately sized oil well.

(b) Cylinder Lubrication

For lubricated type of compressors, multi plunger pump or metering

pump shall be used for cylinder lubrication. In case of non-lubricated

type air compressors, a wiper ring shall be provided such that the crank

case oil is not carried to the cylinder along with the piston rod.

3.2 CENTRIFUGAL COMPRESSORS

3.2.1 Casing

Casing shall be either horizontally split or vertically split type made of cast

iron for moderate pressure applications, cast steel for high pressure

applications or as specified in data sheet A. The thickness of casing shall be

suitable for maximum working and test pressures and shall have a corrosion

allowance of at least 3 mm.

3.2.2 Impellers

Impellers shall be open, semi-open or closed type consisting of disk, hub and

blades. The blades shall be either radial or backward leaning type only. The

material of construction shall be as specified in data sheet A. The design shall

be such as to produce low operating stress levels giving high mechanical

integrity.

3.2.3 Gears

The gears shall be of high speed precision helical type designed as per AGMA

standards. The bull gear shall be directly connected to the driver by a low

speed coupling. The bull gear may be integrally forged with its shaft. In case

bull gear is forged separately, same shall be assembled with an interference fit

on its shaft. The pinion shall be integrally forged with its shaft. It shall be

hardened and precision ground to AGMA 13 quality of AGMA 2000-A88 for

longer life.

3.2.4 Bearings and Seals

The bearings used for pinion and impeller shall be such that high stability and

low vibrations are achieved. Tapered - land thrust bearings shall be provided

for rotor assembly. Bearing shoes shall be pressure lubricated and steel

babbited. Bearings shall be comparatively insensitive to load changes and


TCE.M4-107-01


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variations in oil supply pressure. Hydrostatic squeeze film bearings are also

acceptable. The bull gear shall be supported by horizontally split sleeve journal

bearings and thrust shall be absorbed in either direction by thrust bearings. To

prevent any oil vapour contamination and to ensure oil-free air, mechanical

type air and oil seals shall be provided on the pinion shaft.

3.2.5 Rotor Assembly

Rotor assembly shall consist of pinion shaft to which impellers are attached.

The shaft shall be of forged carbon steel or stainless steel or as specified in

data sheet A. A thrust collar shall be provided on pinion shaft.

3.3 SCREW COMPRESSORS

3.3.1 Casing

Casing shall be of barrel type made of cast iron or fabricated steel for moderate

pressure applications, cast steel or stainless steel for high pressure applications

or as specified in data sheet A. For water injected applications the casing shall

be of stainless steel or as specified in data sheet A. Casing shall have built-in

air passages either as cast or machined.

3.3.2 Rotors

Rotors shall be of asymmetric profile. The material of construction of rotors

shall be as specified in data sheet A. The rotors shall be dynamically balanced

before and after mounting timing gears and thrust collars. The rotors shall be

ultrasonically tested. For non-lubricated screw compressors rotors shall be

lined with PTFE.

3.3.3 Gears

Gear pair shall be used to step up speed of the compressor. Helical gear

hardened to minimum 55 RC shall be used. Gear shall be shrink fit on drive

shaft and shall mesh with pinion mounted on extended portion of male rotor.

Gears shall be designed as per AGMA standards.

3.3.4 Bearings

The rotors shall be carried in heavy duty ball and roller bearings to take radial

and axial loads or journal bearings with thin babbitt metal lining.


TCE.M4-107-01


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3.3.5 Air- Oil Separator

In case of lubricated screw compressors, high efficiency air-oil separation

system shall be provided to ensure removal of oil.

4.0 ACCESSORIES

Accessories such as intake filter, silencer, inter-coolers, after -coolers, oil-

coolers, receivers, control cabinet etc. shall be supplied to make the system

complete in all respects.

4.1 INTAKE FILTER

The intake filter shall be generally as per IS 6206. The type of intake filter

shall be as specified in data sheet A. The filter shall be designed to retain

particles of one (1) micron and above with ninety-seven (97) percent

efficiency. In case of cloth filter, the filter element may be of nylon,

polypropylene or woollen cloth attached to the wire netting.

4.2 INTER-COOLERS

For multi stage compressors, inter-coolers shall be provided. These shall be of

shell and tube type, with removable tube bundles. The tubes shall have

sufficient thickness to withstand the operating pressure and shall be carefully

expanded into the tube sheets. Capacity of inter-coolers shall be twenty (20)

percent more than the compressor capacity or as specified in data sheet A.

Design pressure shall be twenty-five (25) percent more than the working

pressure or as specified in data sheet A. The material of construction and

design shall be as specified in data sheet A.

4.3 AFTER-COOLERS AND OIL-COOLERS

The construction features, design etc. shall be as per inter-coolers described

above. Capacity of after-coolers and oil-coolers shall be twenty (20) percent

more than the compressor capacity or as specified in data sheet A. Design

pressure shall be twenty-five (25) percent more than the working pressure or as

specified in data sheet A.

4.4 RECEIVERS

Receivers shall generally conform to IS 7938. Receivers shall be provided with

two (2) suitably sized safety valves to relieve the full compressor discharge

capacity individually and shall be set at a pressure 1.25 times the operating


TCE.M4-107-01


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pressure. The material of construction and design shall be as specified in data

sheet A.

5.0 MOTOR RATING

Motor shall be of suitable rating considering compressor power requirements.

Motor rating shall be calculated as follows :

(a) If compressor shaft input power requirement is 100 KW and above,

Motor rating in KW shall be = t

SKW10.1

(b) If compressor shaft input power requirement is less than 100 KW,

Motor rating in KW shall be = t

SKW12.1

Where,

SKW = Shaft Power at selected speed in KW

t = Efficiency of transmission

6.0 CAPACITY CONTROL

Capacity control shall be achieved either by speed variation or at constant

speed as specified in data sheet A. In case where capacity control is to be

achieved at constant speed, following methods are generally available. Data

sheet A shall be referred for method to be actually employed.

(a) Automatic start-stop of the compressor

(b) Automatic load-unload of the compressor

(c) Throttling of suction valve

(d) By-passing air or gas from delivery to suction inlet

(e) Increasing clearance volume by a clearance pocket

(f) Variable filling using a by-pass valve.

(g) Movable inlet guide vanes.

6.1 DUAL TYPE CONTROL

Capacity control by start-stop and load-unload of compressors is also known as

‘dual type control’, and same is described below.

6.1.1 The dual type control system shall permit operation of each compressor in

either of the following two regulations:


TCE.M4-107-01


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(a) Continuous Run-Load-Unload Regulation.

(b) Automatic Start-Stop Regulation.

6.1.2 Under continuous Run-Load-Unload Regulation, the drive motor shall run

continuously while the compressor shall be loaded at pre-set (adjustable) cut-in

pressure as the receiver pressure falls and unloaded at a higher pre-set

(adjustable) cut-out pressure, as the receiver pressure rises. With automatic

Start-Stop Regulation, the drive motor shall automatically start at pre-set

(adjustable) cut-in pressure as the receiver pressure falls and automatically stop

at a pre-set (adjustable) higher cut-out pressure as the receiver pressure rises.

6.1.3 With either system, the compressor shall always be unloaded when the drive

motor starts. The unloaders shall keep the compressor unloaded till the drive

motor comes to full speed.

6.1.4 Each compressor shall be provided with one selector switch having three

positions marked AUTO-OFF-ON for the following functions:

(a) OFF - Stops the motor.

(b) AUTO - Keeps the compressor(s) in load / unload mode as

selected by master selector switch.

- Starts the motor of the compressor in strart-stop

regulation as selected by master selector switch.

(c) ON - For manual start up by push buttons with load /

unload regulation.

6.1.5 Two (2) Compressors Operation

A master selector switch common to both the compressors shall be provided

having two positions marked ‘AB’ and ‘BA’. When the master selector switch

is in position ‘AB’and the individual compressor control switches are in

‘AUTO’ position, compressor ‘A’ shall have continuous run-load-unload

regulation and compressor ‘B’ shall have auto start-stop regulation. In the

other position of the master selector switch ‘BA’, compressor ‘B’ shall have

continuous run-load-unload regulation while compressor ‘A’ shall have start-

stop regulation.

6.1.6 Three (3) Compressors Operation

A master selector switch common for three (3) compressors shall be provided

having three (3) positions marked ‘AB/C’, ‘BC/A’ and ‘CA/B’. When the

individual compressor control switch is in ‘AUTO’ position and the master

selector switch is in position ‘AB/C’, compressors ‘A’ and ‘B’ shall have

continuous run-load-unload regulation and compressors ‘C’ shall have auto


TCE.M4-107-01


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R6


start-stop regulation. Similarly with master selector switch in position ‘BC/A’,

compressors ‘B’ and ‘C’ shall have continuous run-load-unload regulation and

compressor ‘A’ shall have auto start-stop regulation. With master selector in

position ‘CA/B’, compressors ‘C’ and ‘A’ shall have the continuous run-load-

unload regulation while compressor ‘B’ shall have auto start-stop regulation.

6.1.7 Four (4) Compressors Operation

A master selector switch common for four (4) compressors shall be provided

having four (4) positions marked ‘AB/C’, ‘BC/D’, ‘CD/A’, ‘DA/B’. When the

individual compressor control switches are in ‘AUTO’ position and the master

selector switch is in position ‘AB/C’, compressors ‘A’ and ‘B’ shall have

continuous run-load-unload regulation and compressor ‘C’ shall have auto

start-stop regulation. Similarly with master selector switch in position ‘BC/D’,

compressors ‘B’ and ‘C’ shall have continuous run-load-unload regulations

and compressor ‘D’ shall have auto start-stop regulation. With master selector

in position ‘CD/A’ compressors ‘C’ and ‘D’ shall have continuous run-load-

unload regulation while compressor ‘A’ shall have auto start-stop regulation.

With master selector in position ‘DA/B’ compressors ‘D’ and ‘A’ shall have

the continuous run-load-unload regulation while compressor ‘B’ shall have

auto start-stop regulation. Fourth compressor not indicated in the selector

position shall be on manual control.

6.2 Two pressure switches shall be provided to monitor receiver pressure for each

compressor, one for load-unload control and the other for start-stop control

considering two (2) steps regulation for load-unload mode. In case number of

steps are more as indicated in data sheet A, number of pressure switches

provided shall be sufficient to meet the requirement.

6.3 Pressure switches with alarm initiating contacts shall be provided for the

receiver high and low pressures.

6.4 The dual control units shall be complete with pressure switches, solenoid

valves, control air tubing, air filter (if required) and other accessories as

required for the afore-mentioned operations.

6.5 For centrifugal compressors anti-surge control shall also be provided to protect

compressor from surging.

6.6 One potential free contact shall be made available for each compressor for

remote alarm under trip condition and a common contact for compressor auto

start.


TCE.M4-107-01


ISSUE

R6


6.7 Green and red lamps shall be provided to indicate motor running and stop

conditions respectively.

6.8 Motors shall be provided with motor winding over-heat sensors and bearing

temperature sensors for alarm indication and to trip the motor.

6.9 For compressors driven with turbine, the required turbine control and

instrumentation shall be provided.

6.10 For air / gas compressors, depending on the hazardous area classification,

motors and instrument enclosures shall be explosion-proof certified for the

specific area.

7.0 NOISE AND VIBRATIONS

7.1 Noise level produced by any rotating equipment individually or collectively

shall not exceed 85 dB(A) measured at a distance of 1.5 metres from the

source in any direction.

7.2 The overall vibration level shall be as per zones A and B of ISO 10816-1.

Vibration dampening pads if required, shall be provided.

8.0 PERFORMANCE GUARANTEES

Performance parameters to be guaranteed by the CONTRACTOR and

tolerances permitted shall be as indicated in section C and / or data sheet A.

BIDDER shall confirm acceptance of these by indicating values in data sheet

B. Compressor or any portion thereof is liable for rejection, if it fails to give

any of the guaranteed performance parameters.


TCE.M4-107-01

AIR / GAS COMPRESSORS

SHEET OF 2

1

ISSUE

R4


DATA SHEET C

DATA TO BE FURNISHED BY THE CONTRACTOR AFTER THE

AWARD OF CONTRACT

1. List of drawings and documents to be submitted for review, approval and

information with scheduled submission dates

2. Quality Assurance Plan (QAP)

3. Calculations for compressor capacity, drive motor rating, selection of speed

reducers and couplings. Torsional vibration analysis for centrifugal and screw

compressors

4. Thermal design calculations for inter-coolers, after-coolers and oil-coolers

5. Detailed P&I diagram showing clearly the scope of supply of equipment,

piping with line sizes and material specifications, valves, specialities,

instrumentation and control and all the accessories. All equipment, lines,

valves, specialities and instruments shall be tagged as per the PURCHASER’s

procedure to be given to the successful BIDDER. All terminal points shall be

clearly identified. All design data and other information furnished in data

sheets A and B shall be covered either in this drawing or other relevant

drawings or documents mentioned below.

6. Detailed equipment list and bill of materials of all items in the

CONTRACTOR’s scope

7. Sub-vendor list for all bought-out items

8. Mechanical design calculations for inter-coolers, after-coolers, oil-coolers,

moisture and oil separator and receivers

9. Characteristic curves of compressors. For centrifugal compressors, in addition

to curves for operating conditions, characteristic curves shall be submitted

considering minimum and maximum ambient temperature, minimum and

maximum humidity and minimum and maximum frequency conditions

10. Dimensioned to-scale equipment layout drawing showing all equipment,

accessories, relevant external dimensions, location and elevation of terminal

points, details of piping and electrical connections to be made by the

PURCHASER, clearances required for erection, dismantling, operation and

maintenance


TCE.M4-107-01

AIR / GAS COMPRESSORS

SHEET OF 2

2

ISSUE

R4


DATA SHEET C (CONTD.)

11. Dimensioned cross-section drawings of compressors and other proprietary

items with part list and materials of construction

12. Detailed fabrication drawings of all fabricated equipment like inter-coolers,

after-coolers, air receivers etc.

13. Line designation schedule for all lines in the CONTRACTOR’S scope

14. List of valves, specialities and instruments in the CONTRACTOR’S scope

with tag numbers, type, makes, pressure ratings, materials of construction and

ranges for instruments etc.

15. Manufacturer’s drawings, data sheets and catalogues for valves, specialities

and instruments etc.

16. Dimensioned to-scale piping layout drawing for piping in the

CONTRACTOR’s scope with allowable forces and moments on the piping

nozzles and displacement of the nozzles

17. Overall foundation plan, base frame drawing for each equipment, static and

dynamic loads on each of the anchor bolts and dimensional details of pockets

and anchor bolts

18. Motor drawings

19. Electrical control wiring diagrams with all interlocks

20. Control philosophy, interlock description and logic diagrams

21. Dimensional to-scale general arrangement and section drawings of MCC and

instrument control panel with complete bill of materials

22. List of alarms and trip settngs

23. Erection, start-up, operation and maintenance manual complete with

lubrication schedule etc.


TATA CONSULTING ENGINEER

SECTION

PROCESS DATA SHEET FOR STATIC MIXER SHEET 1 OF 1

RE

V.

NO. GENERAL REV.

NO. CONSTRUCTION DATA

1. 1 ITEM TAG NO.

322-SM-101 A/B INSIDE PIPE DIAMETER mm

2. 2 QUANTITY

02 Nos. SCHEDULE / THICKNESS mm

3. 3 SERVICE Liquid. Ammonia & DM Water LENGTH FLANGE TOFLANGE mm

4. DESIGN CODE ASME SEC.VIII DIV. 1, ANSI B16.5 MIXING ELEMENTS FIXED / REMOVABLE

5. 5 BIDDER / VENDOR

NO.OF ELEMENTS

6. MODEL NO. POSITION HORIZONTAL/VERTICAL

7. 7 LOCATION OUTDOOR / INDOOR JACKET YES / NO

8. 8 DUTY INTERMIT. / CONT. 12hr/day DESIGN TEMP.: PIPE/JACKET 0C 0C

9. 9 DESIGN PRESS.: PIPE/JACKET kg/cm2(g) kg/cm2(g)

10. PHYSICAL PROPERTIES

HYDROTEST PRESS PIPE/

JACKET kg/cm2(g) kg/cm2(g)

11. 1

1 FLUID NAME Ammonia DM water - CORROSION ALLOWANCE :

PIPE / JACKET 3 mm mm

12.

PHASE :

GAS/LIQ./SOLID Liquid Liquid -

SURFACE TREATMENT &

PAINTING REFER NOTE 5

13. DENSITY kg/m3

P

P

580 1000 - MATERIAL OF CONSTRUCTION

14. 1

4 VISCOSITY cP - 1 - HOUSING Low Temp. Carbon Steel

15. SOLIDS : SIZE & % NA NA INTERNALS Low Temp. Carbon Steel

16. 1

6 PERFORMANCE DATA CLADDING / LINING CS

17. FLUID NAME LIQ. NH3 DM Water - FLANGES CS

18. FLOWRATE, kg/hr 200 370 - BOLTS & NUTS CS

19. PRESSURE, kg/cm2g 12.7 2.5 - GASKETS

20. TEMPERATURE,0C AMB AMB - SUPPORTS

21. ACTUAL PRESSURE DROP kg/cm2 NOZZLES

22. ALLOWABLE PRESSURE DROP kg/cm2 JACKET

23. DEGREE OF HOMOGENEITY 100 % NOZZLE SCHEDULE (REFER NOTE 4)

24.

MEASURED PARAMETER FOR

DEGREE OF HOMOGENEITY

COMPOSITION /

TEMPERATURE /

DENSITY

SIZE

NB

RATING

# FACING FINISH

25. PURPOSE OF MIXING BLENDING /

SUSPENDING SOLIDS/ INLET 40

26. DISSOLVING / HEAT

TRANSFER/GAS DISP. OUTLET 40

27. ACCESSORIES BY VENDOR SIDE NOZZLE 40

28. LIFTING LUGS YES / NO JACKET INLET

29. COMPANION FLANGES,

NUTS,BOLTS & GASKETS

AS PER PIPING SPEC. /

NA JACKET OUTLET

30. EARTHING BOSS YES / NO VENT

31. INSULATION YES / NO DRAIN

32. WEIGHT OF STATIC MIXER : INSPECTION & TESTS (REF.NOTE 3, 6)

33. 1) EMPTY kgs. HYDROTEST YES / NO

34. 2) OPERATING kgs. HOMOGENEITY TEST YES / NO

35. 3) FULL OF WATER kgs. PRESSURE DROP TEST YES / NO

36. MATERIAL TEST CERTIFICATE YES / NO

37. 4

0 SPARK TEST ( NOTE 8 ) NA

38. OVERALL SPACE REQUIREMENTS : mm * mm * mm

39. NOTES : 1) - INDICATES BIDDER TO SPECIFY. 2) NA - INDICATES NOT APPLICABLE.

40. 3) - ALL TEST INSTRUMENTS SHALL BE TRACEABLE TO NATIONAL STANDARDS.

41. 4) REFER ATTACHED PIPING MATERIAL SPECIFICATIONS

42. 5) REFER ATTACHED SPECS. FOR SURFACE TREATMENT & PAINTING

43. 6) REFER ATTACHED SPECS FOR SHOP INSPECTION REQUIREMENTS

44. 7) DIRECTION OF FLUID FLOW TO BE MARKED ON DRAWINGS & EQUIPMENT BY BIDDER.

45. 8) SPARK TEST TO BE PERFORMED FOR LINED ITEMS.

REV. NO PPD.BY: SPP TCE JOB NO. CLIENT : NUCLEAR FUEL COMPLEX

PPD. BY

/ DATE

CKDBY: VAK TCE-4246A PROJECT :NZOSP, PALAYAKAYAL

CKD.BY

/ DATE

DATE: PDS NO. :TCE-4246A-CH-SM-PDS-322SM101 R0

R0 2

002

-09

-30

T

CE

.M4

-CH

-X-P

DS

-440

F

ILE

NA

ME

: P

DS

440.D

OC

SPEC. NO. TCE CONSULTING ENGINEERS LTD. SECTION : C2

TCE.4246A - 950

PROJECT INFORMATION – GENERAL

SHEET OF 3

PROJECT INFORMATION GENERAL 4246A_950_R1.doc 21.01.2005

1

ISSUE R2

TITLE

TCE FORM 329 R3

1. Owner / Purchaser Nuclear Fuel Complex, Hyderabad.

2. Consultant / Engineer TCE Consulting Engineers Ltd., Mumbai

3. Project Title New Zirconium Oxide & Sponge Project (NZOSP)

4. Location Palayakayal, Pazhayakayal Post, Tuticorin – Tiruchendur highway, Srivaikundam Taluk, Tuticorin District, Tuticorin – 628 152 Tamil Nadu

5. Altitude (+) 5 m above Mean Sea Level ( MSL )

6.0 Transport

6.1 Railway

Nearest Railway Station Tuticorin (Broad Gauge)

6.2 Road The site is located at Pazhayakayal Post, Tuticorin – Tiruchendur highway, and is approx. 17 km south of Tuticorin.

6.3 Air Port Madurai

6.4 Sea Port Tuticorin

7.0 Ambient Air Temperatures

a) Maximum dry bulb temp. 38.2 Deg. C (in the month of May)

b) Minimum dry bulb temp. 19.5 Deg. C (in the month of January)

c) Average Minimum 24.5 Deg. C

d) Average Maximum 32.3 Deg. C

e) Design wet bulb temp. for cooling tower

26.5 Deg. C

8.0 Design Ambient Temperature for electrical equipment

45 Deg. C


TCE.4246A - 950


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TCE FORM 329 R3

9.0 Rainfall

a) Annual Average 500 mm

b) Peak Annual Rainfall 909 mm

c) Maximum Intensity 149.1 mm / hr

d) Design Intensity 75 mm / hr.

e) Period of rainfall Major portion from October to December

10.0 Relative Humidity

a) Maximum 80 %

b) Minimum 40 %

c) Average 60 %

11.0 Wind Data

a) Basic Wind Speed 55 m / sec as per IS : 875 ( Part – 3 ) - 1987

b) Wind Direction Predominantly from North, North-East, West and East

12.0 Seismic Data

a) Zone Zone II as per IS : 1893 - 2002

13.0 Climate Coastal and highly corrosive

14.0 Longitude 780 7’ E (approx.)

15.0 Latitude 80 42’ N (approx.)


TCE.4246A - 950


SHEET OF 3


3

ISSUE R2

TITLE

TCE FORM 329 R3

PROJECT SITE OFFICE DETAILS :

NUCLEAR FUEL COMPLEX -- NZOSP TUTICORIN-TIRUCHENDUR HIGHWAY, PAZHAYAKAYAL POST, SRIVAIKUNDAM TALUK, TUTICORIN- 628 152

ATT’N : EXECUTIVE ENGINEER PHONE (O) : 04630-276200 TELEFAX : 04630- 276111

SPEC.NO. TCE CONSULTING ENGINEERS LTD. SECTION: C3

TCE-4246A - 951

PROJECT INFORMATION - ELECTRICAL

SHEET 1 OF 2 OF 4

PROJECT INFORMATION-ELECTRICAL.doc21.12.2004

ISSUE R0

TITLE

TCE FORM 329 R3

1.0 SUPPLY & DISTRIBUTION

1.1 Primary Power Supply from Grid – Class IV

110 kV, 3-Phase , 50 Hz, Solidly grounded

1.2 Primary Distribution Voltage 11 kV, 3-Phase, 50 Hz, Solidly grounded

1.3 Secondary Distribution Voltage 415V, 3-Phase, 4-WIRE, 50 Hz, Solidly grounded

1.4 Stand by emergency power supply - class III

415 V DG Supply

1.5 UPS POWER SUPPLY FOR CRITICAL MOTORS – CLASS II

415 V , 3-Phase, AC, 50 Hz

2.0 AUXILIARY POWER SUPPY

2.1 Lighting fixtures, space heaters, 1-phase motors, 1-phase receptacles –-- CLASS III / IV

230 V, 1-phase, 50 Hz, AC

2.2 Control Supply

( a ) For substation control and protection – CLASS I

110 V DC, 2 WIRE.

( b ) For Instrumentation and Control - Process & utilities- CLASS II

230 V AC, 1-phase Through UPS

( c ) For MCC control – CLASS IV / III

230 V , 1-phase, AC

3.0 VOLTAGE & FREQUENCY VARIATION : This shall be as follows : -

3.1 AC SUPPLY

VOLTAGE VARIATION: (+) / (-) 10%

FREQUENCY VARIATION (+) / (-) 5%

COMBINED VOLTAGE & FREQUENCY VARIATION

(+) / (-) 10%

SPEC.NO. TCE CONSULTING ENGINEERS LTD. SECTION: C3

TCE-4246A - 951

PROJECT INFORMATION - ELECTRICAL

SHEET 2 OF 2 OF 4

PROJECT INFORMATION-ELECTRICAL.doc21.12.2004

ISSUE R0

TITLE

TCE FORM 329 R3

3.2 DC SUPPLY VOLTAGE VARIATION (+) / (-) 10%

4.0 Each of the above supplies will be made available at one Terminal Point. Vendor shall provide for further distribution of supply. If any other supply is desired by the Vendor, he shall provide for all the necessary hardware to derive this supply from the Control Supply provided by the Purchaser.


TCE- 4246A –C-300-005

SCOPE AND GENERAL REQUIREMENTS

OF THE TENDER

SH. 1 OF 11

ISSUE R1

TCE FORM 329 R3

1. SCOPE

1.1 The scope includes the design, preparation of detailed drawings, fabrication, testing, inspection, supply, transportation to site, unloading, safe storage and handling at site, erection, testing & commissioning of the Liquid Ammonia & 35% Ammonium Hydroxide solution Storage & Transfer System and Accessories as given below:

1.1.1 LIQUID AMMONIA & 35% AMMONIUM HYDROXIDE SOLUTION STORAGE & TRANSFER SYSTEM AND ACCESSORIES

SR. No.

Equipment Quantity Details

Liquid Ammonia & 35% Ammonium Hydroxide solution Storage & Transfer System and Accessories

1 Liquid Ammonia Storage vessels / Bullets

02 Nos.

Detailed scope & specifications are given in section C6 – “Technical Specifications of Liquid Ammonia & 35% Ammonium Hydroxide solution Storage & Transfer System”

2 35% Ammonium Hydroxide solution Storage vessels/Bullets

02 Nos.

3 Ammonia vent vessel 1 No.

4 Ammonia Compressors 02 Nos.

5 Online Mixer 02 Nos.

6 Instrumentation For Ammonia Compressor system only

For Safe operation of Ammonia Compressor system.

7 Electrical As per battery limits shown in TCE.4246A-322-PI-8725 „R0 „ issue

Detailed scope given in “Specific Electrical requirements” of section C-6


TCE- 4246A –C-300-005


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ISSUE R1

TCE FORM 329 R3

1.2 This specification covers the requirements of design, preparation of detailed drawings, supply of materials & accessories, fabrication, manufacture, testing, inspection at Vendor‟s / Sub-Vendor‟s works, packing, forwarding, transportation and delivery at site, safe storage at site, transport to the site of installation, Installation / erection, mechanical completion, testing at site, pre-commissioning, commissioning of the Liquid Ammonia & 35% Ammonium Hydroxide solution Storage & Transfer System and Accessories alongwith its associated sub-systems and accessories complete in all respects, performance testing at site, supply of necessary documentation / calculations / drawings, manuals etc. for comments / approval by purchaser / consultant, supply of as-built documents / drawings described in various sections of this specification.

1.3 It is not the intent to specify completely herein all details of design and construction of equipment or materials to be supplied or of services to be rendered. However, the equipment, materials and services shall conform in all respects to high standards of engineering design, workmanship and be capable of performing in continuous commercial operation in a manner acceptable to PURCHASER who will interpret the meaning of drawings and specifications and shall have the power to reject any work or materials which in his judgement are not in full accordance therewith.

1.4 The scope of work under this contract shall also cover following :

a) Supply of equipment and accessories as specified.

b) Unloading, Safe storage of equipment supplied by CONTRACTOR & Unloading & Safe Storage of equipment and free-issue items wherever required, supplied by PURCHASER.

c) Taking over the equipment from PURCHASER'S storage / unloading area for equipment and free-issue items supplied by PURCHASER.

d) Transfer of material / equipment to CONTRACTOR'S storage area.

e) Maintaining equipment during storage and installation in safe custody.

f) Installation of equipment and carrying out wiring, cabling and earthing to complete the liquid ammonia & 35% ammonium hydroxide solution storage & transfer system as detailed under the technical requirements of the enclosed sections.

g) Installation of equipment at site requiring material handling including hoisting facilities.

h) Testing and commissioning of the equipment within CONTRACTOR'S scope for PURCHASER'S satisfaction.

i) Providing 'As-Built Drawings' and draft and final „Operation & Maintenance‟ manuals.


TCE- 4246A –C-300-005


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SH. 3 OF 11

ISSUE R1

TCE FORM 329 R3

j) Obtaining all the clearances/ approvals from external agencies such as CCOE etc.

k) Providing with foundation drawings so as to enable the purchaser to take up with civil contractor. However minor civil works shall be in the scope of the vendor.

l) Supply of essential spares.

2. INSTRUCTION TO BIDDERS

2.1 Bidders shall completely familiarise themselves with the scope of work involved & the job completion schedule. Any clarification required shall be sought from PURCHASER / CONSULTANT, prior to quoting for the Bid.

2.2 Bidder shall ensure that the bids are complete & are prepared in the specified form. Incomplete bids are liable for rejection. Deviation, if any, shall be listed in Section-D; Schedule of Deviations (from Technical Specifications & General conditions). Except for these deviations, it is assumed that BIDDER shall comply with all requirements of the specifications. Any deviation sought at later date will not be entertained.

2.3 While quoting the prices, BIDDER shall quote separately for „supply‟ including all taxes, duties & levies considered and separately for “erection, testing & commissioning” including all taxes, duties & levies considered.

2.4 Bidder shall quote firm price which will be kept firm throughout the duration of the contract.

2.5 The price schedule shall be strictly as per Section E of this specification.

2.6 The make of components shall be as per the “List of approved sub-vendors” of Section – C and / or subject to PURCHASER / CONSULTANT approval. In case, sub-vendors are not mentioned for some items, bidders shall identify the sub-vendor considered for these items and mention in the technical bid documents. In all cases, after placement of the order, the main contractor / main vendor shall submit the list of sub-vendors to Purchaser / Consultant for comments / approval and the order shall be placed onto sub-vendors only approved by Purchaser / Consultant.

2.7 PURCHASER can add / delete items included in scope of work. Unit rates for different items shall prevail under such eventuality.

2.8 Bidder may provide a separate addendum to our price schedule format and submit the unpriced format of the addendum with the technical bid (Section-D) and priced portion of the addendum with the priced bid (Section-E). Description of items offered against such additional unit rates considered by


TCE- 4246A –C-300-005


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SH. 4 OF 11

ISSUE R1

TCE FORM 329 R3

the bidder shall be mentioned in Section D of the bid (unpriced portion) and the rates / prices quoted shall be included in Section E (priced portion of the bid). Purchaser / Consultant shall review these points from technical and commercial considerations and discuss, if required with the bidders at the time of technical bid evaluation. The bid shall be evaluated on lump sum basis including the spares.

2.9 PURCHASER‟S RIGHT:

The PURCHASER does not bind himself to accept the lowest or any Bid and reserves the right to accept or reject any Bid or a portion thereof without assigning any reason thereof.

2.10 ACKNOWLEDGEMENT OF ENQUIRY:

BIDDER shall acknowledge the receipt of enquiry and within two (2) days advise whether he will be quoting or not. If the BIDDER is not quoting, all enclosures to this enquiry must be returned promptly to the issuing authority with „REGRET‟ letter. All specifications and documents enclosed are PURCHASER‟s property and are to be used only for the purpose of this enquiry and any order which may result from it.

2.11 DELIVERY:

Tenderers should note that no tender will be considered by Purchaser unless the Tenderer can meet the delivery schedule specified by the Purchaser. All equipments / machinery / plant / components covered by this tender document should be supplied on or before 24 Weeks or as specified in the tender document from the date of receipt of LOI. The prices quoted by the tenderer should include all charges involved for direct and safe delivery of the items by Road to the Project site of the Purchaser. If a tenderer so desires, separate lumpsum charges for transportation and safe delivery to the Purchaser‟s site at Palayakayal could be furnished. Purchaser will neither undertake responsibility for transit insurance nor pay for it separately. No other, delivery term will be accepted by the Purchaser. The installation and commissioning of the Liquid Ammonia & 35% Ammonium Hydroxide solution Storage & Transfer System shall be carried out within 8 weeks from the date of intimation of site readiness. The vendor will depute personnel to site and carry out joint inspection of site to confirm site readiness.


TCE- 4246A –C-300-005


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TCE FORM 329 R3

2.12 The OWNER reserves the right to :

2.12.1 Increase / decrease the quantities of equipment involved in scope of supply of CONTRACTOR.

2.12.2 The item rates for supply & installation in Section-E shall be applicable for: any increase / decrease in quantities without any ceiling on variation.

2.12.3 Splitting of the order for individual sub-systems / package systems mentioned in the tender.

2.12.4 Calculating the extra price / price reduction on account of any variation.

2.12.5 The prices for new items shall be negotiable.

2.12.6 All site test reports in a specified format maintained by the CONTRACTOR, duly approved by the CONSULTANT / PURCHASER shall be handed over to the PURCHASER/CONSULTANT after completion of job, as per Vendor Distribution Schedule enclosed.

2.12.7 In overall planning of installation work, it shall be the responsibility of CONTRACTOR to minimise wastage of materials and consumables.

2.12.8 The Contractor shall supply all the required documentation / drawings as mentioned in document no. TCE.4246A-952 / R0 enclosed as a part of this tender.

3. GENERAL REQUIREMENTS

3.1 The following definitions shall cover the scope of work and as such the quoted prices shall be based on the same considerations. Payment claims arising out of wrong understanding shall not be entertained or paid for.

3.1.1 Supply, Installation, Testing & Commissioning:

The items are enlisted below in and Section E 'Schedule of Prices' enclosed in this specification. Following works are envisaged for these items under the head of “Supply” and “Installation, Testing and commissioning”.

3.1.1.1 SUPPLY:

This shall include supply of equipment including packing / forwarding, transport and insurance charges complete with all fittings and accessories which form integral part of the equipment for installation purpose to ensure satisfactory commercial operation and timely delivery of the equipment to site. The place of supply shall be “Zirconium Complex” at Palayakayal near Tuticorin, Tamilnadu. Manufacturing, inspection & Testing at vendor's / sub-vendor‟s works of equipment, accessories and items, shall conform to relevant standards and meet statutory approvals.


TCE- 4246A –C-300-005


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3.1.1.2 INSTALLATION, TESTING & COMMISSIONING:

This shall cover:

a) Unloading, handling, storage of equipment, transportation of equipment from CONTRACTOR'S and from PURCHASER'S stores to their proposed locations.

b) Installation of equipment as per Manufacturer's guidelines or specification drawings and / or relevant Indian Standards, Codes of Practice, including supply of materials / fittings / accessories as are necessary for the completion of the installation in all respects, and

c) Testing and commissioning of the equipment as per manufacturer's guidelines, Indian Standards, Codes of practices etc.

The PURCHASER / CONSULTANT may ask for such additional tests at site as in his opinion are necessary for determining that the works comply with the specification. The CONTRACTOR shall be responsible for carrying out the same at no extra cost to the PURCHASER.

d) Preparation of 'AS BUILT' Drawings

e) The VENDOR shall arrange following at his own cost.

i. Adequate quantum of welding electrodes including special

electrodes and welding units required for erection. ii. All consumable items viz. kerosene oil, cotton wool, emery

paper etc. iii. All erection tools and tackles, cranes, hoisting equipment, etc

as required. iv. All skilled, semi-skilled and unskilled labour required for

erection. Any facility, as required, for the labour force such as accommodation, transport, medical facility, insurance etc.

v. First fill of lubricants and grease etc. vi. Chemical cleaning operation for Liquid Ammonia & 35%

Ammonium Hydroxide solution Storage & Transfer System and piping.

vii. Commissioning the Liquid Ammonia & 35% Ammonium Hydroxide solution Storage & Transfer System and accessories and handing over to PURCHASER.

3.2 CODES AND STANDARDS:

All equipment, supply, installation, testing and commissioning shall comply with the requirements of SMPV Rule, latest editions of Indian Standards and Codes of Practices. Where these standards are in conflict with the stipulations of this specification, this specification shall govern.


TCE- 4246A –C-300-005


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SH. 7 OF 11

ISSUE R1

TCE FORM 329 R3

3.3 DRAWINGS:

3.3.1 All engineering documents & drawings, construction purpose drawings, cable schedules for execution of contract works, Operation & Maintenance manuals etc. will be prepared & furnished by the Contractor for review, comments, approval by PURCHASER / CONSULTANT.

3.3.2 The drawings attached with this specification, are for the general guidance of the BIDDER. The CONSULTANT / PURCHASER may also issue further drawings and sketches if considered necessary during execution of the work.

3.4 TESTING AND COMMISSIONING:

3.4.1 The performance and commissioning tests shall be carried out as per Section-C of this specification. It is the responsibility of the Contractor to arrange for required test equipment and instruments for such purpose.

3.4.2 The PURCHASER may ask for such additional tests on site, as in his opinion are necessary to determine that the work comply with the specifications, of manufacturer's instruction or IS code of Installation. The CONTRACTOR shall be responsible and bear the cost of such additional tests.

3.4.3 All routine tests shall be conducted in the presence of PURCHASER / ENGINEER on all equipment as per relevant IS standards.

3.4.4 Typical type tests certificate for all equipment of equivalent ratings shall be submitted for scrutiny / approval by PURCHASER / CONSULTANT.

3.4.5 All commissioning tests shall be carried out in the presence of PURCHASER'S representative and approval for the same shall be obtained before commissioning the installations.

3.4.6 All instruments and accessories required for testing and commissioning of the items specified shall be provided by the CONTRACTOR at no extra cost for the duration of Performance Test.

3.4.7 All instruments used for Testing and Commissioning shall have valid calibration certificates, traceable to National / International Standards of repute.

3.4.8 All instruments used for testing at vendor‟s / sub-vendor‟s works or at site shall have valid calibration certificates, traceable to national / international standards of repute. The calibration certificates shall be presented to PURCHASER‟S / CONSULTANT‟S representative.

3.5 MAINTENANCE REQUIREMENTS:

3.5.1 In order to carry out preventive maintenance, it should be possible to readily


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disassemble, repair, re-assemble the equipment in the shortest period and to attend to any defect by a minimum disassembly.

3.5.2 The BIDDER shall furnish one complete set of any special maintenance tools required for normal maintenance of equipment. The prices for the same shall be indicated in Section-E – Format for Submissions of Part-II.

3.5.3 The BIDDER shall confirm that space shown for the equipment is adequate from point of view of access, easy maintenance and for day to day operation.

3.5.4 All system must have convenient maintenance characteristics including :

Minimum disturbance to production during preventive maintenance. Easy access to replacement part which can be installed by personnel with

minimum skill

3.6 INSTALLATION SCHEDULE:

3.6.1 The PURCHASER requires that the CONTRACTOR shall follow schedule for installation, testing and commissioning of the equipment under the scope of this specification which will enable the PURCHASER to commission the project in time.

3.6.2 However, the final installation schedule shall be decided by the CONTRACTOR in consultation with PURCHASER / CONSULTANT.

3.6.3 CONTRACTOR shall submit a 'Bar Chart' indicating the installation schedule and get it approved from the PURCHASER / CONSULTANT. This approved installation schedule shall form the basis of all installation work to be performed by the CONTRACTOR.

3.6.4 For the purpose of overall coordination, CONTRACTOR shall submit the PURCHASER / CONSULTANT, every fortnight, a detailed installation schedule indicating actual progress against planned progress of installation work of individual equipment.

3.6.5 In case of shortfall in actual progress, which shall be clearly brought out by CONTRACTOR, CONTRACTOR shall indicate reasons attributable to it and certify that the equipment installation is being accelerated in order to meet with the 'completion dates'.

3.7 SITE FACILITIES:

3.7.1 This section details various „Site‟ facilities as may be required for execution of „Work‟ under this Contract, their availability and relevant terms and conditions where applicable.

3.7.2 The following facilities will be provided by the OWNER in good faith at terms indicated hereunder. No claims, whatsoever, arising out of use, misuse or


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failure of these facilities will be entertained.

3.7.2.1 Open Space

Open space, free of charge, for the CONTRACTOR‟s site office and storage space for keeping the CONTRACTOR‟s own tools / tackles and other materials for performance of work under this contract. Whereas space will be provided by the OWNER free of cost, the construction of office, their safety and security including safety of materials supplied by the OWNER for erection purpose as well as subsequent removal of the same on completion of „Work‟ under this contract are the responsibility of the CONTRACTOR.

3.7.2.2 Electric Power supply at site and general safety procedure:

a) Electric power supply at medium voltage (415 V, 3 phase, 4 wire) for

construction site lighting, office and stores enclosure lighting and construction machinery will be made available at site or near site of work at the discretion of Purchaser / Engineer-in-charge at one point. The distance will be within a reasonable distance from the building site.

b) Vendor / Contractor shall make his own arrangements for further

distribution of power supply, to lay and maintain further distribution lines and wiring necessary for the work at his own cost. Suitably rated kWh meter will be supplied and installed by the contractor and test certificates as per IS from authorised test lab or manufacturer shall be submitted. Contractor shall ensure at his cost that all electric lines and equipment conform to the Indian Electricity Rules, 1966 and Indian Electricity Act, 1910, with latest amendments. All extensions & distribution by the Contractor shall be executed in an approved manner with prior permission of Purchaser / Engineer-in-charge.

c) Contractor shall submit a list of equipment he proposes to connect for

constructional and general lighting purpose indicating power requirements for approval of Purchaser / Engineer-in-charge. The contractor shall post licensed Electrical staff at site. Double grounding will be provided for all equipment. Power supply will be effected after completion of the above.

d) The contractor shall pay the charges based on his power consumption at the rate of Rs. 7.00 per unit (kWh).

3.7.2.3 Water Supply during erection / installation at site:

a) Water required for construction purposes for the work covered under the

scope of the Contract as well as for drinking purposes and for Contractor's temporary establishment at site shall be arranged by the Purchaser to the


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contractor at one place to be determined by the Engineer-in-charge at available pressure. The distance will be within a reasonable distance from the building site.

b) Contractor shall, at his own expense, make connections and lay and

maintain the pipelines upto the points of consumption, install water meters, provide storage facility etc. as may be necessary. Contractor shall supply & install a tested meter of approved make for metering the water supplied to the contractor. The meter shall be provided with a masonry chamber with a cover and locking arrangement. All installations shall be

subject to approval of Engineer-in-charge. In case, it is observed that the

water meter is out of order, the consumption of water for the period during which the meter was out of order shall be worked out by the Purchaser in consultation with Engineer-in-charge and the amount shall be payable by the contractor.

c) The contractor shall pay the charges based on his water consumption at

the rate of Rs.35.00 per kilolitre. d) In case, Purchaser cannot supply power and water for construction

purpose for any reason, contractors shall make his own arrangement for getting the power & water for using in his work. No extra payment will be

made to the contractor in this regard by the Purchaser. However, no

recovery will be affected in the bill for this quantum of power and water for which contractor/s has/have made his / their own arrangement. Non-availability of construction power and water by the Purchaser will not make the contractors to delay the completion of work or withdraw from the responsibility of carrying out the work. No claim for compensation or extension of time shall be entertained by the Purchaser for any failure or short supply.

3.7.3 Site shall be handed over to the OWNER in a clean and tidy conditions on completion of „Work‟ or as instructed by the OWNER /ENGINEER.

3.7.4 The OWNER will not provide the following facilities and it is the responsibility of the CONTRACTOR to make suitable arrangements for the same.

(a) The CONTRACTOR shall use his own portable compressors, pumps,

temporary piping and accessories as required for cleaning, testing, flushing etc.

(b) No space will be available from the OWNER to accommodate the

CONTRACTOR‟s workmen and supervisory personnel. Necessary residential accommodation, for the same shall have to be arranged by the CONTRACTOR at his own cost.


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(c) Workshop Facilities The CONTRACTOR shall arrange to set up his own workshop to carry out site fabrication as may be required.

(d) Canteen Facilities

The CONTRACTOR shall arrange his own canteen facilities to cater to the requirements of his personnel.

(e) Consumables

The CONTRACTOR shall arrange all consumables and expendables required for work under this contract including necessary welding electrodes.

(f) Lighting

The CONTRACTOR will make his own arrangement for lighting for carrying out work at night as required. Only general lighting of the area as already available shall be maintained by the OWNER.

TCE CONSULTING ENGINEERS LIMITED SECTION: C6

TCE.4246A-C-300-005

LIQUID AMMONIA AND AMMONIUM HYDROXIDE SOLUTION STORAGE AND TRANSFER SYSTEM

SHEET 1 OF 12

FILE NAME: F120R1

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FORM NO. 120 R1

1.1. EQUIPMENT, SYSTEM AND SERVICES TO BE PROVIDED BY

CONTRACTOR

1.2. The equipment / system to be supplied and erected under this specification

are shown in the P & I Diagram enclosed with this specification ‘TCE.4246A-

322-PI-8725 ‘R0’’ as detailed in Section C. Any item which may not have

been specifically mentioned herein but are needed to complete the

equipment / system and the process performance equipment / system to

achieve, shall also be treated as included and the same shall also be

furnished and erected, unless otherwise specifically excluded as indicated in

the bid document.

1.3. The Bidder scope also includes the following for Liquid Ammonia and

Ammonium Hydroxide Solution Storage and Transfer

1.3.1. Liquid Ammonia Storage Vessels / Bullets (322-T-441 A/B) - 2 Nos.

1.3.2. 35% Ammonium Hydroxide Solution Storage Vessels / bullets (322-T-442

A/B) - 2 Nos.

1.3.3. Ammonia Compressor (322-K-441 A/B) - 2 Nos.

1.3.4. Ammonia Vent Tank (322-T-445) - 1 No.

1.3.5. Online Mixer 2- nos.

1.3.6. Electrical motor drives for Ammonia Compressors

1.4. Third Party Inspection / Inspection and Testing of equipment / system,

bought-out items etc. at vendor’s and sub-vendor’s shop.

1.5. All foundation bolts, nuts, washers, base plates, for all the equipment /

system. Foundation bolts shall be in SS material.

1.6. Temporary piping, fittings, flanges, strainers, supports, gaskets etc. required

for testing, cleaning, pre-commissioning and commissioning etc. shall be

included in the scope of work.


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1.7. Supply and erection of all the above equipment / system, supply and erection

of auxiliary steel & supporting steel for supporting the equipment / system.

Painting of all the equipment, supports etc.

1.8. The equipment shall be designed, fabricated, manufactured and inspected by

Third Party & Testing as per the requirement of "The Static & Mobile

Pressure Vessels Rules" (SMPV Rules). This vessel shall be approved by

CCoE, Nagpur and obtaining approval of CCoE Nagpur and inspection by

competent third party shall be in the scope of Vendor.

1.9. A Test & Inspection certificate issued by manufacturer of the Liquid Ammonia

storage vessels (bullets) shall be furnished to CCoE, Nagpur. This shall be

duly countersigned by an Inspector, authorised by CCoE, Nagpur that the

vessel meets with the requirements of the code approved by CCoE, Nagpur.

1.10. The Layout for Liquid ammonia storage vessels / bullets shall be approved by

CCoE.

1.11. Supports, platforms, ladders: All the equipment shall be properly supported

and shall be easily accessible for maintenance. Platforms and safe access

ladders to be provided at various locations based on the height of the

equipment as per the requirement.

1.11.1. Design & supply of structural supports for the equipment is in vendor scope

of work. The load details for the structures & equipment shall be provided

by vendor and the specification shall be strictly as per the IS standards.

1.11.2. Fabrication, supply and erection of support structures are in the scope of

the vendor.

1.11.3. Grouting of the equipment etc. and Minor civil works during the erection of

the equipment and supplies are in the vendor’s scope.

1.12. SERVICES BY OTHERS

1.12.1. All piping utilities such as cooling water and instrument air up to battery limit.

1.12.2. Instrument air @ 6.0 kg/cm ², g pressure and (+) 5.0°C dew point shall be

made available at the Battery limits.

1.12.3. Cooling water @ inlet temperature of 32°C & with acceptable temperature

rise of 5°C shall be made available at battery limit.


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FORM NO. 120 R1

2.0 LIQUID AMMONIA AND AMMONIUM HYDROXIDE SOLUTION STORAGE

AND TRANSFER SYSTEM DESCRIPTION AND VARIOUS DETAILS

2.1 The liquid ammonia and Ammonium Hydroxide solution storage system

consists of storage of Liquid Ammonia, preparation of 35% Ammonium

Hydroxide Solution & storage of Ammonium Hydroxide solution. 35 %

Ammonium Hydroxide solution will be prepared by mixing liquid Ammonia

and DM water. This mixing will produce heat of mixing which is removed in

Ammonia dissolver which is a double pipe heat exchanger. This 35%

Ammonium Hydroxide solution is stored in the Ammonium Hydroxide storage

vessel.

2.2 Liquid Ammonia will be transported to site by road tankers. Liquid Ammonia

from road tankers to storage vessel (Ammonia bullet) will be unloaded using

Ammonia compressor 322-K-441 A/B. The time required for unloading 10T of

liquid Ammonia (filled road tanker) will be 1 hour. The capacity of Ammonia

unloading compressor shall be designed for 1 hour unloading of liquid

ammonia and vapour recovery also.

2.3 The DM water from the DM water storage tank is pumped and is online mixed

with liquid Ammonia. This is an exothermic reaction, so heat is being

generated. This heat is removed by means of cooling water in the double

pipe heat exchanger i.e. Ammonia Dissolver 322-R-441 A/B where cooling

water is used to remove the heat of mixing from Ammonium Hydroxide

solution. Cooling water is introduced in the counter current direction in the

Ammonia dissolver. Ammonium hydroxide solution is thus cooled and is

stored into the Ammonium Hydroxide solution Storage Vessels (bullets).

2.4 Ammonium hydroxide solution is transferred by ammonium hydroxide

solution transfer pumps to the Process plant.


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3.0 I & C SYSTEM REQUIREMENTS

The scope of supply for Instrumentation and control will include following two

systems:

1) Ammonia Compressors system

2) Ammonia transfer, dissolution and hydroxide storage & transfer System.

3.1 SCOPE

3.1.1 The scope of supply for Ammonia Compressor System:

3.1.4.1 Supply, installation and commissioning of all field instruments required for

safe and efficient operation of Ammonia compressor is in the vendor’s

scope.

3.1.4.2 Supply, installation and commissioning of local control panel housing

instruments, push buttons, indicating lamps, alarm annunciation and

digital panel indication for local start / stop operation of each Ammonia

compressor and all necessary instrumentation shall be supplied fully

wired for local operation and monitoring of both the compressors.

3.1.4.3 Vendor shall wire all the signals from instruments provided for Ammonia

compressor up to local panel for operation and monitoring. Further

cabling from the Local Control Panel (LCP) to OPF marshalling cabinet in

OPF control room is not in the vendor’s scope.

3.1.4.4 A local / remote selector switch shall be provided on the LCP. In Local

operation, all the equipments/instruments will be operated independently

from the LCP, whereas in the Remote mode, the system will be operated

from PLC. All equipments/instruments individually shall have to accept

remote ON/OFF command from PLC.

3.1.4.5 Supply, installation and commissioning of Cable trays, supports and

conduits for laying cables from field instruments/equipments to Ammonia

compressor local panel shall be in the scope of vendor.


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FORM NO. 120 R1

3.1.4.6 Impulse tubings, fittings, valve manifolds, isolation valves, and other

installation hardware required for mounting of instruments is in the scope

of vendor.

3.1.4.7 All Analog signals shall be multiplied in the LCP using signal multipliers.

One output of the multiplier shall be wired to the Digital panel meter while

another output shall be wired up to local control panel with terminal block

and further cabling from local control panel to OPF marshalling cabinet is

not in vendor’s scope. This will facilitate the remote operation from the

PLC panel.

3.1.2 The scope of supply for Ammonia transfer, dissolution and hydroxide

storage & transfer system:

3.1.2.1 Supply of following field instruments are in vendors’ scope. (Refer section

D for data sheets)

a) FE- 805/806/808(03 nos.)

b) FT- 805/806/808(03 nos.)

c) TI – 801/802/803/804 (4 nos.)

d) PVRV – 801 / 802 (2 nos.)

e) FV – 805(1 no.)

3.1.4.1 Installation and commissioning of all the Field instruments (including the

FIM) in the Ammonia transfer, dissolution and hydroxide storage &

transfer system is in the Vendor’s scope.

3.1.4.2 Supply, installation and commissioning of local control panel housing

instruments, status indicators, push buttons, indicating lamps, alarm

annunciations , digital panel indication ,valve on/off status and drives run

and trip status along with necessary instrumentation and controls shall be

supplied fully wired for local operation and monitoring of the Ammonia

transfer, dissolution and hydroxide storage & transfer system.

3.1.4.3 Supply and termination of cables for all field instruments in the Ammonia

transfer, dissolution and hydroxide storage & transfer system shall

be done up to the junction box. Further cabling from the junction box to


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the Local Control Panel (LCP) is also in the vendor’s scope. Two nos. of

junction boxes shall be supplied as free issue item by NFC (Refer 1.1.3).

3.1.4.4 All Analog signals shall be multiplied in the LCP using signal multipliers.

One output of the multiplier shall be wired to the Digital panel meter while

another output shall be wired up to local control panel with terminal block

and further cabling from local control panel to OPF marshalling cabinet is

not in vendor’s scope. This will facilitate the remote operation from the

PLC panel. Two no. of junction boxes will be supplied as a FIM to vendor

by NFC.

3.1.4.5 A local / remote selector switch shall be provided on the LCP. In Local

operation, the equipment will be operated independently from the LCP,

whereas in the Remote mode, the system will be operated from PLC. All

equipments/instruments individually shall have to accept remote ON/OFF

command from PLC.

3.1.4.6 Impulse tubings, fittings, valve manifolds, isolation valves, and other

installation hardware required for mounting of instruments is in the scope

of vendor.

3.1.4.7 Supply, installation and commissioning of Cable trays, supports and

conduits for laying cables from field instruments/equipments to Ammonia

transfer, dissolution and hydroxide solution storage system local panel

shall be in the scope of vendor. All multiplied signals shall be wired and

terminated in separate terminal block in local control panel and from local

panel to the OPF marshalling cabinet in OPF control room in not in

vendor’s scope.

3.1.3 FREE ISSUE MATERIALS (FIM)

Following items shall be supplied to the Vendor as FIM by NFC.

1. All Field instruments for Ammonia transfer, dissolution and hydroxide

storage & transfer system (except those indicated in Section D)

2. Junction Boxes (100 terminals JB – Analog; 150 terminals JB – Digital)

for termination of cables from field instruments.


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FORM NO. 120 R1

3.1.4 INSTRUMENTATION AND CONTROL CABLES

3.1.4.1 Cables for Analog signals (4 to 20 mA)

660 V/1100V annealed, tinned, high conductivity 1.0 sq.mm. Stranded copper

conductor. Extruded PVC insulated two cores twisted into pair, laid up

collectively, individual pair shielded and overall shielded with aluminium Mylar

tape, 0.5 sq.mm. ATC drain wire run continuously in contact with aluminium

side of the tape, inner sheathed with extruded PVC, with galvanised steel

wire braided, overall sheathed with extruded FRLS PVC, pair identification

number marked at interval of not more than 250mm, confirming to IS 1554,

BS:5308 & IEC:189 part II.

3.1.4.2 Cables for instrument power supply (24 VDC) and digital signals (24

VDC)

660V/1100V grade multicore cables, multistranded high conductivity

annealed 1.0 sq.mm (1.5 sq.mm for 230 V AC). Stranded tinned copper

conductor, overall shielded with aluminium mylar tape, 0.5 sq.mm ATC drain

wire shall run continuously in contact with aluminium side of the tape,

extruded PVC insulated, inner sheathed with extruded PVC, with galvanised

steel wire braided, overall sheathed with extruded FRLS PVC confirming to IS

1554, BS:5308 & IEC:189 part II.

3.1.4.3 Cables for instrument power supply (230 VAC)

660V/1100V grade multicore cables, multistranded high conductivity

annealed 1.5 sq.mm stranded tinned copper conductor, extruded PVC

insulated, inner sheathed with extruded PVC, with galvanised steel wire

braided, overall sheathed with extruded FRLS PVC confirming to IS: 1554.

3.1.5 POWER SUPPLY

All the field instruments shall be suitable for working on 24 VDC. Purchaser

will provide 230 VAC supply at one point in local panel. Further conversion


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FORM NO. 120 R1

and distribution of 230 VAC to 24 VDC in redundant configuration with diode

ORing shall be provided by vendor.

3.2 CODES AND STANDARDS

3.2.1 All equipment, systems and works covered under this specification shall

comply with all currently applicable statutes, regulations, standards and

safety codes in the locality where the equipment will be installed.

3.2.2 In particular, the following standards are applicable (latest editions)

ANSI : American National Standards Institute

70.2 Control Valve Seat Leakage classification.

ASME : American Society for Mechanical Engineers

BS : British Standards

BS-5308 Part-I Specification for Polyethylene insulated cables.

DIN-43760 Temperature Vs Resistance curves for RTD.

IEC : International Electro technical Commission

IEC 79 Electrical Apparatus for Explosive Gas atmosphere

IEC-332 Test on bunched wires or cables.

IEC 529 Classification of degree of protection provided by

enclosures

IEC 584-2 Thermocouple Tolerances

IEC 751 Industrial RTD Sensors.

IEC 801 Electromagnetic compatibility for industrial for industrial

Process measurement and control.


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FORM NO. 120 R1

ISA : Instrument Society of America

S-5.2 Binary Logic Diagrams for Process Operations.

S-7.3 Quality standard for instrument air

S-75.01 Flow equations for Control Valve Sizing

ISO : Indian Standard Organisation

ISO-5167 Measurement Of fluid flow in closed conduits

NEC : National Electric Code

NEMA : National Electrical Manufacturer’s Association

ICS-6 Enclosures for industrial control system

IS:13947.

Part-1

Low voltage switchgear and control gear : General rules

IEC 326. Printed Circuit Boards

3.2.3 Other national standards established to be equivalent or superior to the

codes and standards specified are also acceptable. The BIDDER shall

furnish English translation of all standards specified in this specification.

3.2.4 In the event of any conflict between the codes and standards referred to in

the specification and the requirements of this specification, the more stringent

of these requirements shall govern.

3.2.5 Unless indicated otherwise, all codes and standards referred to in this enquiry

specification shall be understood to be the latest version on the date of offer

made by the Bidder.


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FORM NO. 120 R1

3.3.0 GENERAL REQUIREMENT FOR INSTRUMENTATION:

3.3.1 For all field instruments, material for the wetted parts shall be stainless steel.

3.3.2 All field instruments shall be weather proof with IP 65 protection class.

3.3.3 Local panel shall be protected under proper shade or canapy arrangement

and panel shall have IP 52 protection class. Local panel make shall be as per

approved vendor list. The panels shall be powder coated, with exterior pebble

grey (RAL 7032 as per DIN standard) and interior glossy white.

3.3.4 All transmitters and gauges shall have at least accuracy of +/- 1.0%.

3.3.5 Instrumentation trays and electrical trays shall be separately laid with

maintaining 300mm of distance between them. All trays shall be properly

covered. Direct run signals shall be laid through GI conduits with proper

supports.

3.3.6 Separate earth shall be provided for power supply, instrument shielding and

for panel.

3.3.7 All makes of various instruments/equipments shall be in line with the list of

approved sub-vendors.

3.3.8 The cable glands shall be of double compression type with high quality

neoprene gaskets. Cable glands shall be of brass with nickel plating.

4.0 SPECIFIC ELECTRICAL REQUIREMENTS:

4.1 The supply, installation, testing and commissioning of the following are

included within the scope of the vendor.

1.0 Drive Motor

2.0 All the power and control cables between vendor supplied

equipments and MCC

3.0 Local Control stations (i.e. Local start / Stop push buttons etc.)

4.0 Earthing of equipment to purchaser’s grid

5.0 Cable tray & accessories.


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FORM NO. 120 R1

Electric supply for motors covered under this package shall be 415V, 3

phases, 4 wire. PURCHASER shall make a provision of Motor feeder for

each Compressor motor.

4.2 Induction Motors

4.2.1 Motors shall be provided with enclosures as per data sheet A1.Motors shall

be painted with anti-corrosive epoxy paint. Motors shall conform to the

enclosed specification No. TCE. M4-203-01.

4.3 Cable, Cable Tray & Accessories

4.3.1 1.1 KV grade stranded aluminium / Copper conductor, multi core, XLPE

insulated, extruded FRLS PVC inner sheathed, steel wire armoured, and

FRLS PVC Outer sheathed cable, as per IS : 7098 (Part1).

4.3.2 Up to 6 sq. mm the conductor shall be Copper above 6 sq mm it shall be

Aluminium.

4.3.3 1.1 KV grade stranded copper conductor of 2.5 sq. mm, PVC insulated,

extruded FRLS PVC inner sheathed, steel wire armoured, FRLS PVC

outer sheathed as per IS : 1554 (Part – 1).

4.3.4 Power cable sizing shall be done based on the various derating factors and

site conditions. The voltage drop in the cable at full rated current shall not

exceed 2 % of rated voltage.

4.3.5 The successful Bidders shall submit the cable sizing calculations for review

and approval by the purchaser / consultant along with the details such as

ratings of motors, other electrical load, approximate feeder length etc.

4.3.6 Power and control / Instrumentation cables shall be laid in separate cable

trays. When laid in trenches, the 415 V power cables shall be laid on the

top tier and control and instrumentation cables on the bottom tier.

4.3.7 The supply of the cables shall be as per enclosed specification No. TCE.

M4-208-01.

4.3.8 Cable tray shall be of hot dip GI with ladder type for power cables and

perforated for control cables.


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FORM NO. 120 R1

4.3.9 Supply of all cables wherever specified for power, control and

instrumentation, cables system installation work, termination of cables at

both ends, testing and commissioning shall be included in the scope of

BIDDER.

4.3.10 Termination of incoming 415 V cables for power, at the MCC and shall be

in the scope of PURCHASER.

4.3.11 The supply of the cable tray and accessories shall be as per enclosed

specification No. TCE. M4-208-11.

4.3.12 It shall be in the BIDDER’S scope, to supply, install, wire etc. Junction

boxes if required to terminate the control / instrumentation cables. The

junction boxes shall have 20% extra terminals than actual required.

4.3.13 All instruments such as recording and indicating instruments, controller

level switches, pressure switches etc. shall be provided with the suitable

cable glands to suit the selected cable size.

4.3.14 All equipment shall be provided with lugs and cable glands, to suit the

selected cable size. Cable glands shall be of brass metal, double

compression type and lugs shall be of tinned copper type.

4.4 Earthing of equipment

4.4.1 GI shall be used for earthing the equipment as per IS 3043.

4.4.2 The main earthing grid shall be provided by the PURCHASER, the Bidder

scope include providing earthing conductor from individual equipment

supplied by the BIDDER to main grid.

4.4.3 Earthing conductors for equipments shall be brought out and connected

suitably to the earthing grid.

4.4.4 Successful BIDDER shall prepare and submit earthing layout, cabling

layout and other drawings to PURCHASER / CONSULTANT for their

review / approval.

anex-1

Documents

nuclear fuel

ammonium hydroxide

tank vendoryes

opf marshalling

ptfe enveloped

opf control

extruded frls

moderate pressure