MR for TW Loading arms - HPCLtenders.hpcl.co.in/tenders/tender_prog/TenderFiles/2114/Tender... · 5 400LATW-193 TO 240 48 MS Wagon Loading Arm Package 1.2 The Vendor shall be responsible

VISAKH MARKETING INSTALLATION RESITEMENT

PROJECT - WHITE OIL TERMINAL

Doc No: 254624-400-RQ-MEC-008 Rev: B Page 1 of 19 abcabcabcabc

P:\Andheri\IndiaProject\254624 HPCL- White Oil Terminal\06 Mechanical\Documents\Rotating & Packages\MR's\TW

Loading arms\Rev B (09.07.2009)\MR for TW Loading arms.doc

MATERIAL REQUISITION

FOR

TANK WAGON LOADING ARMS

Mott MacDonald Consultants (India) Pvt. Ltd.

Kothari House, CTS No. 185

Off Andheri - Kurla Road

Andheri (East)

Mumbai 400 059

Hindustan Petroleum Corporation Ltd

Krishna Shree, 2nd

Floor, Gandhi Nagar

1st Main Road - Adyar

Chennai 600 020






List of Content Page No

1 Introduction 5

2 Location and Environmental Conditions 6

3 Scope of Supply 6

3.1 Equipment and Materials 6

3.2 Engineering Services 7

3.3 Exclusions 7

4 Applicable Codes, Specifications and Standards 7

4.1 General 7

4.2 Codes and Standards 8

4.3 Other Specifications and Standards 8

4.4 Conflicting Requirements 8

5 Design Requirements 9

6 Quality Assurance 10

7 Inspection and Testing 11

8 Vendor Requirements 13

9 Performance Guarantee 13

10 Vendor Documentation 13

11 Manufacturing Schedule 14

12 Spares and Special Tools 14

12.1 Spares 14

12.2 Special Tools 14

13 Packing and Shipping 14

14 Installation and Commissioning 14






Appendix A: Attachments 15

Appendix B: Table of Compliance 16

Appendix C: Instrument Data sheets 18

1) Loading Arm Position Sensor 18

2) Overfill Sensor 19






1 Introduction

1.1 This specification covers the minimum requirements for the design, engineering, material

procurement, fabrication, painting, assembly, Inspection, supply and shipment of Tank Wagon

Loading Arms for “Resitement of Integrated Marketing Facility at Vishakhapatnam -White

Oil Terminal.

Definitions:

Company/End User/ Owner : Hindustan Petroleum Corporation Ltd (HPCL)

Purchaser : Hindustan Petroleum Corporation Ltd (HPCL)

Engineer / Consultant : Mott MacDonald Consultants (India) Pvt. Ltd.

Vendor : Supplier of Tank Wagon Loading Arms

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 List of Tank Wagon Loading Arms is as follows:

Sr.

No. Tag No. Qty Description

1 400LATW-001 TO 048 48 HSD Wagon Loading Arm Package

2 400LATW-049 TO 096 48 SKO Wagon Loading Arm Package

3 400LATW-097 TO 144 48 ATF Wagon Loading Arm Package

4 400LATW-145 TO 192 48 Naphtha Wagon Loading Arm Package

5 400LATW-193 TO 240 48 MS Wagon Loading Arm Package

1.2 The Vendor shall be responsible for the design, engineering, fabrication, assembly, inspection,

co-ordination, testing, delivery and proper functioning of the Tank Wagon Loading Arms.

1.3 The Vendor shall ensure that the design complies with the requirements of this specification

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 B. 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 in total compliance with the

specification.

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 B), 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.




P:\Andheri\IndiaProject\254624 HPCL- White Oil Terminal\Procurement\Mechanical\TW Loading

Arms\Working\Mechanical\10.07.09\MR for TW Loading arms.doc

1.5 Note that “lead times” will not be considered by the COMPANY as a justifiable reason for

using alternate VENDOR.

1.6 This specification shall in no way relieve the Vendor from final guarantee as to materials,

apparatus, workmanship and performance of the equipment and services supplied.

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. 254624-400-SP-GEN-001.

3 Scope of Supply

3.1 Equipment and Materials

Scope of supply of each loading arm shall include but not necessarily be limited to following

• Complete loading arms with all accessories as per the data sheets

• Instrumentation as specified

• Study and confirmation of the location of the loading arm on the gantry based on the

operating envelope.

• 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

• Commissioning & Start-up Spares.

• List of Spares for two years trouble free operation






3.2 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.

• Providing Static & Dynamic loads and anchoring plan for the design of Civil foundation

by others.

• 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.

• Attendance of kick-off meetings, coordination meetings, Design reviews, HAZOP,

meetings in the Consultant’s/Purchaser’s office.

• Resolve/incorporate all action points from HAZOP & Design reviews.

• Any technical document required for statutory approval shall be furnished by vendor

3.3 Exclusions

The following are excluded from the Vendor's scope and will be provided by others:

• Platforms and Ladders.

• Process piping up to loading arm connection.

• Interconnection of earthing bosses and underground earth conductor.

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 specification.

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 specification at the time of the order.






4.2 Codes and Standards

ASME Section VIII-2007 Pressure Vessels Division I and II

ASME Section IX-2007 Welding Qualifications

ASME Section V-2008 Non Destructive Examination

ASME B16.5-2003 Pipe Flanges and Flanged Fittings

ASME B31.3-2008 Process Piping

4.3 Other Specifications and Standards

254624-400-SP-PIP-001 Piping Material Specification

254624-400-SP-PIP-003 Specification for Painting: Piping & Equipments

254624-400-SP-GEN-001 Local Conditions

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 specification

Fourth priority : Other Specifications

Fifth Priority : Referred Codes & Standards

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 General

5.1.1 This specification covers the minimum requirements for the manufacture, testing and supply of

tank wagon loading arms.

5.1.2 Loading arms shall be designed and constructed for a minimum service life of 20 years and at

least two years of uninterrupted operation.

5.1.3 The vendor shall assume unit responsibility for loading arms and all auxiliary system including

but not limited to arm position proximity switch, over spill switch, etc. included in the scope.

Any other items which are not specified but required for safe and proper functioning of loading

arms shall be included in Vendor’s scope.

5.1.4 Earthing relay will be procured along with TAS tender. Earthing Bond is required to be

supplied by Loading arm Vendor.

5.1.5 Vacuum breaker shall be pre-installed on loading arms.

5.1.6 The vendor shall ensure maximum standardization and interchangeability of components.

5.1.7 The manufacture of loading arms shall be in accordance with a proven design of satisfactory

and safe operation for this equipment.

5.1.8 The design shall demonstrate easy operation combined with a minimum of maintenance and

space requirements, with a proven successful swivel joint design.

5.1.9 Due consideration shall be given for the maximum expected elevation of wagons due to its

different capacity/sizes.

5.1.10 Hazardous area classification for rail wagon loading arms gantry shall be as specified in the

data sheets.

5.1.11 Loading arms shall be provided with 2 nos. earthing lugs. Wherever required earthing jumpers

shall be provided to maintain earthing continuity.

5.1.12 Vendor shall guarantee for stability of the complete unit in operation and emergency

disconnection scenario of loading arm.

5.1.13 In the stored position no part of the arm shall extend beyond the loading bay.

5.1.14 Loading arms shall be designed to permit easy in situ inspection, maintenance and replacement

of vital swivel and structural bearing components, without having to dismantle major sections

of the loading arm.

5.1.15 The lengths of the arm sections, the number and type of pivotal connections and the general

configuration of the arms shall be selected to ensure that arms shall be in safe condition for any

position in the envelope of movement of the wagon.

5.1.16 All materials of construction including the seals shall be suitable for handling fluids at the

design temperature range as marked on data sheets.

5.1.17 Swivel joints of the arm shall be of split flange design, enabling ease of maintenance, with

double row ball construction. Carbon Steel swivel joints shall be forged.

5.1.18 The joints shall have chrome steel / stainless steel ball rows in suitably hardened carbon tracks,

as dictated by the product to be handled. The joints shall be complete with packing (seals, ‘O’

rings) of proven design.

5.1.19 The arrangement of swivel joint shall facilitate changing of seals without dismantling the

complete joint. The complete joints shall be able to withstand the design pressure.



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5.1.20 Vendor shall furnish drawings for swivel joints, showing materials of construction, working

and design pressure and temperature, and test pressure, temperature for each item.

5.1.21 Loading/Unloading envelope

The length of inboard arm, outboard arms and connecting pipe or drop pipes shall be such as

to give adequate flexibility in loading or unloading operations. The following range of

flexibility shall be provided, as a minimum.

a) Loading arms for rail wagon

(When rail wagon is parked with centre line of folding platform and wagon nozzle on the same

axis, in plan view).

Top Loading i. Longitudinal direction (In-line with rail wagon movement)

Atmospheric loading ±1 m

ii. Transverse direction (Perpendicular to rail wagon movement)

Atmospheric loading ±0.25m

iii. Vertical direction (From rail wagon filling nozzle centre

line / top elevation)

Atmospheric loading 0.25 m

5.2 Instrumentation Requirements

5.2.1 For instrumentation requirements, refer to Appendix C (Instrument Data Sheets).

6 Quality Assurance

The Vendor shall maintain and use a Quality System which is based on ISO 9000 to control

the work. If the Vendor elects to sub-contract part of the work he shall ensure that only those

sub-contractors or suppliers are used who can demonstrate that they operate Quality Systems

based on ISO 9001 or ISO 9002 as applicable.

The Vendor shall give his sub-contractors or suppliers assistance in attaining the required

standard, if necessary. This shall not relieve the Vendor of his responsibility for the quality of

the finished work. The Company / Consultant reserve the right to audit the Vendor’s Quality

System.

The Vendor shall assign sufficient full time personnel to the project to ensure the Quality

Assurance / Quality Control System, documented in a Quality Assurance / Control Manual, is

maintained and kept up-to-date throughout the duration of any purchase order. The Vendor’s

Quality Assurance / Control System shall become an integral part of any purchase order.

Vendor shall organize a prefabrication / inspection meeting with the Company / Consultant.

Vendor shall submit QA plan/Inspection Test Plan & Factory/Site Acceptance Test procedure

for Purchaser’s/Consultant’s review within 2 weeks from the date of Purchase Order/LOI/FOI.




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7 Inspection and Testing

The responsibility for inspection, certification, etc. of all materials, parts lies with the Vendor.

The Vendor shall specify all of the inspection and testing requirements in the quality control

plan / Inspection test plan which shall identify the activities requiring the Company /

Purchaser's approval, review, witnessing etc.

Inspection shall be in accordance with ASME B31.3, ASME Section V & Section IX, other

applicable standards as listed in this requisition and the data sheets and vendor quality

assurance plan / inspection test plan approved by Purchaser and Consultant with 100% X rays

radiography of butt-welded joints.

All equipment shall be inspected for compliance with:

• Requirements of the Company’s / Consultant’s specification and correspondence

thereafter.

• Applicable Codes, standards and specifications, which shall also include sub-referenced

standards therein.

• QAP/Test and Inspection Plans produced by the Vendor duly approved by Purchaser /

Consultant.

Purchaser’s / Consultant’s Inspectors have the right to request additional inspections or tests to

ensure that the equipment complies with this requisition and all relevant codes and standards.

All equipment shall be presented for inspection in an unpainted state except for the final

inspection. All instruments and other equipment necessary for testing shall be supplied by the

Vendor and the same shall be checked and certified by the Company / Purchaser’s /

Consultant’s inspector.

Any defects found by the Company’s / Consultant’s appointed Inspector shall be rectified in

his presence. Where this is not possible or practical, check lists shall be prepared and signed by

the Company’s / Consultant’s Inspector stating all “pending items”. Copies of these lists shall

be sent to the Company / Consultant to enable their subsequent checking.

Shop/Factory inspection shall not relieve the Vendor from his contractual responsibility for

replacing any defective material and for repairing any defective workmanship that may be

discovered in the field.

The Vendor shall be responsible for co-coordinating the inspection and testing of sub-vendor

supplied equipment, and for ensuring that the Company / Purchaser’s / Consultant’s

representatives are given the necessary access for inspection, and adequate warning of

inspection and tests.

The Vendor (and all sub-Vendors) shall give the Company / Consultant and its’

representatives, without charge, all reasonable facilities and access for the purpose of

inspecting the equipment to ensure that it is manufactured in accordance with the

Specification.

All spare parts shall be subjected to the same inspection standards and full material

certification as the main order.




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The equipment shall not leave the Vendor’s factory before all discovered defects have been

rectified and without the written permission of the Company/Purchaser/Consultant.

Welding shall be in accordance with the requirements of the Manufacturing welding

specifications (based on ASME Section IX) submitted and approved by Purchaser/Consultant.

Where radiography is not possible or applicable, welds shall be 100% tested by DP or any

other non-destructive method, to be approved by Purchaser/Consultant.

Mechanical properties shall be verified by carrying out tension and hardness tests in

accordance with ASTM A 370.

7.1 Shop Test The shop tests shall demonstrate / show the following:

• Material certificates.

• Non-Destructive Test.

• Hydrostatic Test of the assembled arm in accordance with ASME B 31.3.

• Operation Test (including manoeuvring inside the operating envelope, and swivels for

each arm).

• Dimensional Check and Visual Inspection.

• Painting Inspection.

• Control and alarm systems test.

• Safe operation of the loading arm.

• Operation of the various interlocks.

7.2 Site Test Site tests after installation of the arms shall be carried out to ensure correct performance. Site

test procedure shall be submitted to purchaser/Consultant for approval.

The following tests are required as a minimum:-

• Working range and clearance check

• Electrical earthing resistance measurement.

• A complete hydrostatic test at 1.5 times the design pressure for a minimum period of 30

minutes shall be performed at site, with the arm fully assembled.

• Operation test including automation.

• Final Painting (Touch up of painting etc.)




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8 Vendor Requirements

Any acceptance or release of equipment following an inspection or test activity shall in no way

relieve the Vendor of his responsibility to provide guarantees as to the suitability of the

materials, workmanship and performance of the equipment in accordance with this

Specification.

9 Performance Guarantee

Unless otherwise agreed, all equipment shall be guaranteed as follows:

All equipment shall perform satisfactorily under the operating conditions in this Specification

and shall be fit for the purpose intended.

The Vendor shall guarantee following as a minimum at site conditions:

• Sustained operation at the conditions outlined in the data sheets,

• The mechanical and structural integrity, workmanship and the materials of construction

used.

Also refer to guarantee clause under general conditions of contract.

10 Vendor Documentation

10.1 Documents / Information to be supplied with offer

The Vendor shall provide the Consultant with the following information as a minimum along

with the offer. These documents shall include, but not be limited to the following:

a. The completed Table of Compliance (Appendix B).

b. Completed data sheets (which are attached with this specification, with supplier data

added.

c. A detailed scope of supply that fully describes the equipments offered.

d. General arrangement drawings with dimensions and Load data

e. Commissioning Spare parts list

f. 2-Years operation spare part list

g. Complete list of special tools required, if any.

10.2 Documents / Information to be supplied After Award of Contract

a) Manufacturing schedule

b) Drawing and document schedule

c) Completed data sheets

d) General arrangement drawings with dimensions and Load data

e) Quality Assurance Plan (QAP) / Inspection Test Plan

f) Inspection and test procedures / Factory Acceptance Test Procedure

g) Material test certificates




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h) Inspection and test reports

i) Lubrication schedules

j) Installation, operation and maintenance manual

11 Manufacturing Schedule

Within 2 weeks of the receipt of the Purchase Order/LOI the manufacturer shall submit detail

bar chart schedule showing the dates for the following milestone activities, as minimum:

i) Issue of vendor drawings.

a. Issue for comments/approval

b. Issue of final drawings

c. Issue of O&M Manuals

ii) Equipment available for Testing.

iii) Completion of packing and readiness for dispatch.

12 Spares and Special Tools

12.1 Spares

For requirements of spares refer General Conditions of Contract. However, as a minimum

spares shall include the following:

• The supply of spares for start-up and commissioning.

• Vendor to recommend two years operations spares & furnish the separate price in the offer.

The Vendor shall also provide all consumables during erection up to commissioning and

reliability testing. In case of any additional spares if required during commissioning stage, the

same shall be supplied by Vendor free of cost.

12.2 Special Tools

The Vendor shall supply a set of any special tools, which are required for the installation,

commissioning, operation and maintenance of the equipment being supplied. A list of special

tools shall be supplied along with the offer.

13 Packing and Shipping

For Packaging, Shipping and delivery of equipment at site and unloading requirements,

'General Conditions of Contract' shall be referred.

14 Installation and Commissioning

Vendor to provide qualified personnel to check and clear the installation done by other party.




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Appendix A: Attachments

Equipment Data Sheets

Document No. Rev. Description

254624-400-DS-MEC-62 B HSD Wagon Loading Arm Package

254624-400-DS-MEC-63 B SKO Wagon Loading Arm Package

254624-400-DS-MEC-64 B ATF Wagon Loading Arm Package

254624-400-DS-MEC-65 B Naphtha Wagon Loading Arm Package

254624-400-DS-MEC-66 B MS Wagon Loading Arm Package

Other Documents

Document No. Rev. Description

254624-400-SKT-A1-3726 (sht

1&2) A

Conceptual Layout for Wagon Loading Arm (Rail

Wagon Gantry)

MMCI/STD/IND/ITP/M-020 0 Indicative Inspection And Test Plan

254624-400-SP-PIP-001 A

Piping Material Specification

254624-400-SP-PIP-003 A

Specification for Painting: Piping & Equipments

254624-400-SP-GEN-001 B

Local Conditions

254624-400-PID-1053 C P&ID for White Oil Tank Wagon Gantry - Segment 1








254624-400-PID-1042 C P&ID for HSD Tank Wagon filling Pumps

254624-400-PID-1047 C P&ID for SKO/ATF Tank Wagon filling Pumps

254624-400-PID-1045 C P&ID for MS/Naphtha Tank Wagon filling Pumps




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Appendix B: Table of Compliance

The Vendor shall confirm below their acceptance of all the clauses contained in the specification or

otherwise make clarifications or exceptions that shall be noted below:-

CLIENT: HINDUSTAN PETROLEUM

CORPORATION LTD.

VENDOR REF. NO.

REF. NO.: 254624-400-SP-MEC-008

CLAUSE

NO.

CONFORMS

Y/N

ALTERNATIVE

Y/N

CLARIFICATION

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

2.0

3.0

3.1

3.2

3.3

4.0

4.1

4.2

4.3

4.4

5.0

5.1

5.2

6.0

7.0

7.1

7.2

8.0

9.0

10.0

10.1




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CLIENT: HINDUSTAN PETROLEUM

CORPORATION LTD.

VENDOR REF. NO.

REF. NO.: 254624-400-SP-MEC-008

CLAUSE

NO.

CONFORMS

Y/N

ALTERNATIVE

Y/N

CLARIFICATION

10.2

11.0

12.0

13.0

14.0

Appendix A

Appendix C




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Appendix C: Instrument Data sheets

1) Loading Arm Position Sensor

Technical point Description

Function To detect the position of loading arm

Type Proximity Switch

Supply Voltage 24VDC

Operating Temperature 0 to 55 Deg. C

Hazardous

Approval Intrinsically Safe or Explosion Proof and

confirming to IP-65

Area Classification Zone 1, Gr. IIA / IIB, T3

Repeatability +/- 1%

Material Housing / Sensing Face Stainless Steel

Output Potential free contact to Batch Controller

Mounting On the loading arm

Proximity Range STS

Function To detect the position of loading arm

Type Proximity Switch


Approval / Certification CCOE




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2) Overfill Sensor

Technical point Description

Function To detect overfilling.

Type Suitable for very viscous fluid of Black Oil category,

VTA


Operating Temperature 0 to 55 Deg. C

Hazardous

Approval Intrinsically Safe or Explosion Proof and

confirming to IP-65

Area Classification Zone 1, Gr. IIA / IIB, T3

Repeatability +/- 1%

Material Housing / Sensing Face Stainless Steel

Output Potential free contact to Batch Controller

Mounting On the loading arm

Proximity Range VTA

Function To detect the overfilling level & spill protection for

TW

Approval / Certification CCOE