VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - BLACK OIL TERMINAL Doc No: 254625-300-RQ-MEC-004 Rev: D Page 1 of 20 P:\Andheri\IndiaProject\254625 HPCL- Black Oil Terminal\Procurement\ETP\Working\04.09.09-For FLoating\Editable\Mechanical\MR for ETP_Rev.D.doc MATERIAL REQUISITION FOR EFFLUENT TREATMENT PLANT (ETP) Hindustan Petroleum Corporation Ltd Visakha Dispatch Station VR-ATP Area, Naval Base Post Visakhapatnam - 530 014 Andhra Pradesh Mott MacDonald Consultants (India) Pvt. Ltd. Kothari House, CTS No. 185 Off Andheri - Kurla Road Andheri (East) Mumbai 400 059
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VISAKH MARKETING INSTALLATION
RESITEMENT PROJECT - BLACK OIL TERMINAL
Doc No: 254625-300-RQ-MEC-004 Rev: D Page 1 of 20
P:\Andheri\IndiaProject\254625 HPCL- Black Oil Terminal\Procurement\ETP\Working\04.09.09-For
FLoating\Editable\Mechanical\MR for ETP_Rev.D.doc
MATERIAL REQUISITION
FOR
EFFLUENT TREATMENT PLANT
(ETP)
Hindustan Petroleum Corporation Ltd
Visakha Dispatch Station
VR-ATP Area, Naval Base Post
Visakhapatnam - 530 014
Andhra Pradesh
Mott MacDonald Consultants (India) Pvt. Ltd.
Kothari House, CTS No. 185
Off Andheri - Kurla Road
Andheri (East)
Mumbai 400 059
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List of Content Page No
1 Introduction 5
2 Location and Environmental Conditions 6
3 Scope of Supply 6
3.1 Process Description 6
3.2 Equipment and Materials 6
3.3 Engineering Services 8
3.4 Exclusions 8
4 Applicable Codes, Specifications and Standards 8
4.1 General 8
4.2 Codes and Standards 8
4.3 Other Specifications and Standards 9
4.4 Conflicting Requirements 9
5 Design Requirements 10
5.1 Mechanical Requirements 10
5.2 Instrumentation Requirements 10
5.3 Electrical Requirements 10
6 Quality Assurance 11
7 Inspection and Testing 11
7.1 Factory Inspection & Testing 11
7.2 Vendor Requirements 13
7.3 Performance Guarantee 13
7.4 Works Inspection and Notification 13
8 Vendor Documentation 13
8.1 Documents/ Information to be supplied with offer 13
8.2 Document/ Information to be supplied After Award of Contract 14
9 Manufacturing Schedule 14
10 Spares and Special Tools 14
10.1 Spares 14
10.2 Special Tools 14
11 Packing and Shipping 15
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12 Installation and Commissioning 15
Appendix A: Attachments 16
Appendix B: Water Quality 17
Appendix C: Requisition of Engineering Documents (Red Form) 18
Appendix D: Table of Compliance 19
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1 Introduction
1.1 This specification covers the minimum requirements for the design, engineering, material
Vendor : Supplier of Effluent Treatment Package (ETP).
Shall : This is to be understood as a mandatory in relation to the
requirements of this document.
Should : This is to be understood as a strong recommendation to
comply with the requirements of this document
The ETP is as follows:
Sr.
No. Tag No. Quantity Description
1 300ETP-001 ONE Effluent Treatment Plant – 150 m3/h
1.2 The Vendor shall be responsible for the design, engineering, fabrication, assembly, inspection,
co-ordination, testing, delivery and proper performance of the ETP.
1.3 The Vendor shall ensure that the design complies with the requirements of this requisition and
its referenced specifications and standards. The data sheets, which form part of this
specification, shall be completed by the Vendor. The Vendor shall highlight any non-
compliance at the offer stage in the Table of Compliance, Appendix D. The Table of
Compliance and filled in data sheets shall form a part of the offer. Not providing completed
compliance table and data sheets can cause rejection of the offer. Failure to clearly identify
specific deviations shall be assumed by the Purchaser to be total compliance with the
requisition.
Only those deviations that are specifically agreed to, by the Purchaser prior to award of the
order will be incorporated into the purchase order. Deviations to the specification will not be
allowed after award of order. Unless referred to in the Table of Compliance (Appendix D), it
will be assumed that all specifications are adhered to and that they do not have implications
with respect to cost, delivery and integrity of the equipment.
1.4 The Vendor shall procure third party material from vendors listed in the approved Vendor List
only, unless the particular type of material is not covered by the list, and a special dispensation
to deviate from the list has been granted in writing by the Purchaser. Company will reject any
materials found at any stage to be out of the approved VENDOR or sub Vendor list.
1.5 Note that “lead times” will not be considered by the COMPANY as a justifiable reason for
using alternate VENDOR.
1.6 This requisition shall in no way relieve the Vendor from final guarantee as to materials,
apparatus, workmanship and performance of the equipment and services supplied.
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1.7 All correspondence and documentation shall be in English. All measurements and units shall
be in SI units.
Where necessary for a specific application, alternative units may be indicated in brackets
behind the SI units.
1.8 The VENDOR shall guarantee the equipment and all component parts against defective
workmanship and improper materials for the agreed period following the date of delivery of
the equipment or from commencement of operation as agreed. The VENDOR shall replace or
repair (the carrying out of all work including uncovering, removal, procurement and
reinstallation and construction as may be necessary) the components that are defective at their
own cost during the guarantee period at a suitable time to the COMPANY. Guarantee period
shall be as per the Contract and to be covered in commercial documentation.
2 Location and Environmental Conditions
For local conditions refer Document no. 254625-300-SP-GEN-001.
3 Scope of Supply
3.1 Process Description
The treatment scheme shall be designed to treat the waste water collected from Tank Truck
gantry, Tank Wagon Gantry, Pump house and Tank farm area.
The Oily water is passed through a bar screen to remove any bigger size material and collected
in oily water collection sump for 10 minutes. The overflow from this sump is feed to Plate
pack by siphon pipe. The plate pack compartment removes free oil and suspended solids settle
at the bottom. The floating oil on the water surface is removed by rotating belt skimmer and is
collected in the RCC slop oil tank by gravity. The Slop oil shall be pumped to an underground
horizontal Slop oil tank. The sludge collected at the bottom of Plate pack unit is removed
intermittently by using vacuum pump and dried in Sludge drying pits. The Sludge drying pits
are provided by under flow laterals which take away water. The sludge dried in open
atmosphere will be bio remediated.
The de-oiled effluent flows from Plate pack chamber to collection chamber by siphon pipe.
This effluent is pumped through Multi Media filter (MMF) and Coalescer Filter to remove oil
traces. The outlet of the Coalescer filter is disposed vide storm water drains. The Oil collected
in the top chamber of the MMF and Coalescer filter is removed based on the signal from Oil
Level Sensor which opens the Motorized valve and the Oil flow to Slop Oil Tank by gravity.
The provision is made to re-circulate the treated effluent back to the inlet of the treatment
scheme so as to maintain flow during dry period. The Backwash of the MMF is initiated
manually using Fire Water Hydrant. To facilitate the backwash the termination point for
backwash shall have suitable connection to connect Fire hydrant. The backwash water of the
MMF is routed to the Oily water collection sump by gravity.
A brief scheme is shown in the attached sketch no. 254625-300-SKT-MEC-001 Rev. B. All
the drain lines carrying oily water shall be heat traced to avoid slop formation.
3.2 Equipment and Materials
Scope of supply of Effluent Treatment Plant shall include but not necessarily be limited to
following. Any additional equipment required to achieve treated water quality shall be
supplied by the Vendor.
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• Bar screen for installation in the inlet channel.
• Plate pack unit for oil removal.
• Belt Skimmer for floating oil removal.
• Vacuum Pumps with motor for Oily sludge removal.
• Set of under flow laterals and Media for the Sludge drying pit.
• Coalesce filter complete with frontal Piping, Auto valves (Electrically Actuated), Internals,
Interconnecting Piping and Internals. Filter design shall be as per ASME Section VIII Div.
I, latest edition.
• Multi media filter complete with frontal Piping, Auto Valves (Electrically Actuated),
Media, Interconnecting Piping and Internals. Filter design shall be as per ASME Section
VIII Div. I, latest edition.
• Oily Water feed Pumps with Motors mounted on common base plate complete with
flexible spacer type couplings, non-sparking coupling guards, suction and discharge piping
and valves.
• ETP Slop Oil transfer pumps with Motors mounted on common base plate complete with
flexible spacer type couplings, non-sparking coupling guards, suction and discharge piping
and valves. ETP Slop Oil transfer pumps shall be as per API 610, 10th edition. The ETP
slop oil transfer pumps shall be capable of transferring Slop oil of Sp. Gravity 0.95 and
Viscosity of 780 CP (Max). The Capacity of Pump shall be 1.0 m3/h @ 3.0 kg/cm
2g
discharge pressure. The Motor for ETP Slop Oil transfer shall be selected for end of curve.
• Civil design and Construction of Sumps, Pits, Equipment foundations and Control room.
• Motor Control Centre (MCC), Local Control Panel, Supply of cables within the battery
limit and termination in the control panel/ MCC located in safe area near the ETP
(Drawing no. 254625-300-SKT-A3-3786 Rev.A for exact location of control room).
Purchaser shall provide one point power supply in the MCC Incomer.
• All necessary interconnecting piping/tubing and valves within the battery limit of the
package. Purchaser will provide one point Instrument air supply within battery limit.
Vendor to provide the estimated Instrument Air Supply requirement.
• Heat tracing by use of Electrical tracers for oily water carrying lines and drains (By others)
• Instrumentation as required for control and monitoring the quality of treated water.
• Lifting & Earthing lugs for packaged unit, Vessels and Pump sets.
• Anchor bolts, fixing bolts, jack screw bolts, shims, etc.
• First fill of lubricants to be supplied separately along with the pump sets.
• Commissioning & Start-up Spares.
• List of Spares for two years trouble free operation.
• Inspection and testing as specified.
• Submission of documents as specified in this document.
• Painting, preservation, preparation for shipment and delivery at site.
• Special tools if required (Bidder to provide list in the bid).
• Installation & Commissioning.
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3.3 Engineering Services
The Vendor shall provide engineering services, which shall include, but not necessarily be
limited to, the following:
• Providing/Coordinating detailed design of all equipment and components within the scope
of supply.
• Preparing Civil foundation design and drawings for construction at site.
• Resolving engineering queries related to the equipment and components within the scope
of supply.
• Performing and coordinating all aspects of design.
• Providing progress reports etc.
• Providing expediting services for all sub-vendors.
• Providing quality assurance including all sub-vendors with respect to ISO 9000 or
equivalent.
• Erection & Commissioning to be quoted separately.
• Attendance of kick-off meetings, coordination meetings, Design reviews meetings in the
Consultant’s/Purchaser’s office.
• Resolve/incorporate all action points from Design reviews, etc.
• Any technical document if required by Purchaser for statutory approval shall be furnished
by vendor.
3.4 Exclusions
The following are excluded from the Vendor's scope and will be provided by others:
• Piping up to collection tank and beyond the outlet nozzle of last equipment in the
treatment scheme.
• Interconnecting power cabling and cable trays to MCC between ETP control room (in ETP
Vendor’s scope) and Purchaser’s PMCC.
• Cable between Vendor’s Control panel and Purchaser’s Control room.
• Electrical Heat Tracing.
4 Applicable Codes, Specifications and Standards
4.1 General
The design, fabrication, assembly, inspection, testing, painting, packing and shipment of
equipment shall be in accordance with the latest edition of the codes, specifications and
standards (including standards / specifications mentioned therein) listed in this requisition.
The Vendor shall provide an itemized list of any comments or exceptions to the specification
and its attachments. Only those comments / exceptions that are accepted by Purchaser will be
incorporated into the requisition at the time of the order.
4.2 Codes and Standards
ASME Section VIII Divn. I Code for Design and Fabrication of Unfired Pressure vessels
ASME B 16.5 (2003) Pipe Flanges and Flanged Fittings.
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ISO 9000 (2005) Quality Management and Quality Assurance Standards.
ISO 10474 (1991) Inspection Documents
API 610, 10th Edition Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas service.
4.3 Other Specifications and Standards
254625-300-SP-MEC-005 Rev. A
Specification for Centrifugal Pumps - API
254625-300-SP-MEC-006 Rev. B
Specification for Non-API Centrifugal pumps for general services.
254625-300-SP-ELE-010 Rev. A
Specification for Electric Motors
254625-300-SP-PIP-001 Rev.D
Piping Material Specification.
254625-300-SP-GEN-001 Rev.B
Local Conditions
254625-300-SP-CIV-001 Rev.B
Specification for Earthwork.
254625-300-SP-CIV-002 Rev.B
Specification for RCC Work.
254625-300-SP-CIV-004 Rev.B
Specification for Masonry Work.
254625-300-SP-CIV-009 Rev.A
Specification for Flooring.
254625-300-SP-CIV-010 Rev.A
Specification for Painting.
254625-300-SP-CIV-011 Rev.A
Specification for Doors and Windows.
254625-300-SP-CIV-013 Rev.A
Specification for Water proofing.
4.4 Conflicting Requirements
In case of conflict between documents relating to the enquiry or purchase order, the following priority of documents shall apply: First priority : Purchase order and variations thereto Second priority : Data sheets and drawings Third priority : This requisition Fourth priority : Other Specifications Fifth Priority : Referred Codes & Standards
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Note: Should any conflict arise either before or after order placement of order, the
Vendor shall immediately inform the Purchaser for technical resolution of the conflict.
5 Design Requirements
5.1 Mechanical Requirements
5.1.1. Pumps shall be supplied as per the requirements of Specification for Non-API Centrifugal