REQUEST FOR PROPOSAL FOR · 2017-06-27 · REQUEST FOR PROPOSAL FOR REALIZATION OF CRYOGENIC FLUID CIRCUITS FOR CRYOGENIC TURBO PUMP TEST FACILITY Volume 2 June 2017 ISRO Propulsion

REQUEST FOR PROPOSAL

FOR

REALIZATION OF

CRYOGENIC FLUID CIRCUITS FOR

CRYOGENIC TURBO PUMP TEST FACILITY

Volume 2

June 2017

ISRO Propulsion Complex Indian Space Research Organization

Department of Space, Government of India

Mahendragiri 627133

Tirunelveli District, Tamil Nadu State, India

Request For Proposal (RFP) for Cryogenic Fluid Circuits (CFC) of

Cryogenic Turbo Pump Test Facility (CTPT)

2.2

CONTENTS SL No Title Page

No 2.1. Introduction 2.4

2.2. Facility Layout 2.4 2.2.1 Climatic condition 2.5 2.3 Description of cryogenic fluids circuits: 2.6 2.3.1 Design parameters 2.8 2.3.2 Liquid Oxygen (LOX) System 2.10 2.3.3 Liquid Hydrogen (LH2) System 2.23

2.3.4 Liquid Nitrogen System 2.38 2.3.5 Gaseous Hydrogen System 2.41 2.4 Design & Engineering 2.44 2.5 Fabrication 2.53 2.6 Erection and Commissioning 2.56 2.7 Documentation 2.61

Annexure Annexure 2-A Equipment layout 2.63 Annexure 2-B Process & Instrumentation Drawings

(Total Nos:4) 2.64

Annexure 2-C

A2.C Specification of cryogenic fluid circuits:

2.68

A2.C.1 Stainless Steel Pipes 2.68 A2.C.2 Super-Insulated (SI) piping 2.72 A2.C.3 Pipe Fittings & Flanges 2.88

A2.C.4 Super Insulated Flexible Hoses 2.91 A2.C.5 Manual valves 2.100 A2.C.6 EP valves 2.116 A2.C.7 Control valves 2.128 A2.C.8 Filters 2.137 A2.C.9 Non-return valves 2.145

A2.C.10 Safety Relief valves 2.154 A2.C.11 Rupture Discs 2.161 A2.C.12 2 Valve Manifold 2.166 A2.C.13 Pressure Gauges 2.169 A2.C.14 Fasteners 2.174

Annexure 2-D Interfaces for cryogenic fluid circuits 2.175 Annexure 2-E Tentative piping layout 2.185

Annexure 2-F Standards Followed 2.186 Annexure 2-G Sub-vendor Directory 2.187



2.3

List of Figures Fig. 2.1 Scheme of Line number 2.9 Fig. 2.2 Scheme of Tag number 2.9 Fig. A2.C.2.1 General arrangement of fluid temperature

sensor assembly in Cryo SI circuits. 2.87

Fig. A2.C.2.2 General arrangement of surface temperature sensor assembly in Cryo SI circuits.

2.87

Fig. A2.C.3.3 Interface of flexible hose. 2.93



2.4

2.1 INTRODUCTION

The Request for Proposal (Volume 2) to establish Cryogenic Fluid Circuits of Cryogenic Turbo Pump Test Facility (CTPT) at IPRC, ISRO, Mahendragiri contains:

Outline of the facility equipment layout Descriptions of fluid systems of the facility, including CFC Specifications for Engineering, procurement, fabrication, erection &

commissioning, with Quality Assurance Plans Process and Instrumentation Diagrams (P&IDs), preliminary piping layout,

detailed list of components and sub-vendor directory, are also given in this document. The Contractors’ scope of work specified in volume 1 is elaborated further in this volume.

2.2 FACALITY LAYOUT

The facility layout showing the major equipments, test bays and buildings is given

in Annexure 2-A drawing No. TSE/CSSTF/CTTF/CTPT/EQL-CFC.

The test facility is configured with four test bays, catering to the requirements of

testing different test articles viz Turbo-Pump, OBTP, FBTP and HTPM. The test

bays are covered on three sides with a blast proof wall to a height of 4.5 m to

protect the other equipments/ installations outside the bay due to incidents if any

in test articles during testing. The size of the bay is 30 x 13 m in plan and an EOT

crane of 2T capacity is planned only for CE25 bay. The test bays are housed in a

shed of RCC portal structure construction/ structural column with Galvalume

sheet roofing. Blast proof walls is planned to cover both sides of the shed.

The LH2 high pressure run tank (DTK 200) and LOX high pressure run tank (DTK

100) are located behind the blast proof wall and separated by a distance of 26 m

from each other. The LH2 & LOX low pressure run tanks (DTK 230 & DTK 130)

are located adjacent to the high pressure run tanks respectively. Dike walls are

planned on 3 sides of these tanks for avoiding inter-mixing, in case of inadvertent

spillage of these propellants. Sufficient area is provided in the paved area for

easy movement and parking of the cryogenic liquid tankers.

The LN2 storage tank (DTK 300) is located at rear side of LN2 vaporizer bank

intended to supply Nitrogen gas for driving the ejectors. GH2 cooler for supplying

cold GH2 is mounted to the North of LH2 tanks.

The GH2 and GN2 & GHe gas cylinders kept in the cylinder yard located in the

test facility. The pressure regulation of the gases is done in the regulation sheds



2.5

located in front of cylinder yard. The sides of pressure regulation shed are

provided with galvalume sheet louvers for adequate ventilation. The pressure

regulation shed on the LH2 side is to handle GH2 and the one on the LOX side to

handle GN2 & GHe.

Vacuum pumps to evacuate the jackets of the cryogenic tanks and pipe-lines are

housed in Vacuum Pumping Station.

LOX/ GO2 vented/ dumped from the LOX system is safely disposed in a pit of 7 x

7 m area, located about 80 m from the test bay.

GH2 from the intentional vent circuits at low flow rates as well as from the

spontaneous vent circuits of the LH2 and GH2 systems is disposed of through

non-flare stacks located about 75 m away from the test bay. LH2/ GH2

intentionally dumped/ vented from LH2 system at high flow rates is safely

disposed in a burning yard located about 100 m from the test bay.

2.2.1. CLIMATIC CONDITION

The climatic condition at Mahendragiri is tropical and windy with gusts.

Normal monsoon period is June-July and October-November. The typical

climatological data of Mahendragiri are as follows:

Rainfall

Maximum daily rainfall: 50 mm

Maximum monthly rainfall: 120 mm

Average annual rainfall: 550 mm

Temperature

Maximum temperature in shade: 311 K

Minimum temperature: 293 K

Humidity

Maximum relative humidity: 80 %

Minimum relative humidity: 25 %

Climate: Tropical

Seismic Zone

All the systems shall be designed for seismic load conforming to Zone 3

as per IS:1893 latest edition. The Importance factor (I) shall be considered

1.5.



2.6

Wind Load

All the systems shall be designed for wind load as per IS:875 Part 3 latest

edition. The following data shall be considered:

Basic wind speed (Vb) = 39 m/s

Probability factor (Risk coefficient) (k1) = 1.08 (50 years mean probable

design life, 33 % risk level)

Terrain, height & structure size factor (k2) shall be considered for

Terrain category 1 specific to width & height of structure

Topography factor (k3) = 1.36

2.3 DESCRIPTION OF CRYOGENIC FLUID CIRCUITS

The Cryogenic Fluids Circuits form part of the following fluid systems of Cryogenic Turbo Pump Test Facility (CTPT):

• Liquid Oxygen System

• Liquid Hydrogen System

• Liquid Nitrogen system

• Gaseous Hydrogen system Process & Instrumentation Diagrams

The Process & Instrumentation Diagrams (P&IDs) of these systems are given in Annexure 2-B.

System Drawing No. of P&ID

Liquid Oxygen System CTPT/CFC/P&ID/100/R0 Liquid Hydrogen System CTPT/CFC/P&ID/200/R0 Liquid Nitrogen system CTPT/CFC/P&ID/300/R0 Gaseous Hydrogen system CTPT/CFC/P&ID/500/R0

The symbols used in the P&IDs for pipes/ flow components are as per the following description.



2.7

The scheme of line number and tag number for components, used in the P&IDs, are shown in figures2.1 & 2.2 respectively.

Figure 2.1 The schematic of line number used in the facility fluid system.

Figure 2.2. The schematic of tag number used in the facility fluid components.



2.8

2.3.1 Process design Parameters:

The process design parameters of the various fluids to be serviced to the various utilities so as to comply with the objectives are given in the following table 2.3.1.1

Table 2.3.1.1 DESIGN PARAMETERS

S. No

Line designation Line description Process Design Parameters

Strength design parameters

Pressure (MPa)

Temperature ( K)

Flow rate (kg/s)

Pressure (MPa)

TemperatureRange ( K)

1.0 LOX circuits

1.1 110-50-10S-1.4

LOX fill circuit for LP & HP run tank

0.5 92 4.00 1.4

75-350

1.2 120-50-XXS-36 LOX feed circuit from HP run tank to OBTP turbine

28.6 92 4.20 36

1.3 121-40-XXS-36 LOX feed circuit from HP run tank to CE20 gas generator

9.67 92 1.20 36

1.4 150-100-10S-1.4 LOX feed circuit from LP run tank to LOX catch tank

0.18 92 22.80 1.4

1.5 160-150-10S-1.6 LOX feed circuit from LP run tank to LOX Turbo pump

1 92 62.80 1.6

2.0 LH2 circuits

2.1 210-50-10S-1.4 211-50-10S-1.4

LH2 fill circuit for LP & HP run tank

0.2 22 0.30 1.4

15-350

2.2 220-50-80S-17 LH2 feed circuit from HP run tank to CE20 gas generator

13 30 1.36 17

2.3 250-100-10S-1.6 LH2 feed circuit from LP run tank to LH2 catch tank

0.25 22 6.00 1.4



2.9

Table 2.3.1.1 DESIGN PARAMETERS

S. No

Line designation Line description Process Design Parameters

Strength design parameters

Pressure (MPa)

Temperature ( K)

Flow rate (kg/s)

Pressure (MPa)

TemperatureRange ( K)

2.4 260-150-10S-1.6 LH2 feed circuit from LP run tank to LH2 Turbo pump

1.0 23 12.04 1.6

15-350 3.0 LN2 circuits

3.1 310-40-10S-1.4 LN2 fill circuit 0.5 79 3.6 1.4

77-350 3.2 311-65-10S-2.5 LN2 feed to vaporisers 0.5 79 9.0 2.5

3.3 320-40-10S-1.4 LN2 fill to OBTP & FBTP catch tanks, GH2 cooler

0.5 79 3.6 1.4

4.0 GH2 circuits

4.1 555-25-160-31 GH2 feed circuit to FBTP turbine 21 310 0.20 31

4.2 555-25-160-31 GH2 feed circuit to HTPM -Case1 7.5 310 0.21 31

80-350 4.3 555-25-160-31 GH2 feed circuit to HTPM-Case2 16 310 0.04 31

4.4 560-25-10S-3.7 GH2 chill circuit to LH2 HP run tank

0.7 220 0.04 3.7



2.10

2.3.2 LIQUID OXYGEN SYSTEM The P&ID of LOX system is given in drawing No. CTPT/CFC/P&ID/100/R0. The major constituents of the system are cryogenic run tanks, catch tank, LOX road tanker and fluid circuits including pipelines, instruments and flow components. This system is used to supply LOX at the required pressure, flow rate, and temperature to the test articles for testing. The LOX system is intended to perform the following functions:

• Chilling & Filling of LOX run tank DTK130 from LOX tanker

• Filling of LOX run tank DTK100

• Chill-down of circuits connecting tanks to test articles

• Chill-down of LOX feed system of test article.

• Feeding LOX to Test Articles from run tanks.

• Disposal of LOX from test articles to Disposal pit.

• Dumping of LOX from run tanks to Disposal pit. Circuits for safety devices, pressurization, venting and evacuation of tanks are also included. The LOX road tanker, run tanks DTK100 and DTK130, catch tank DTK150) are under Department’s scope. All the fluid circuits are to be realized by the Contractor. Flow meters, fluid temperature sensors and surface temperature sensors in the circuits are free-issued by the Department. These instruments are to be installed in the circuits by the Contractor. Pressure & vacuum transmitters are not shown in P&ID and these will be provided & connected by the Department during erection at site. LOX TANKS

Details of the tanks are as follows:

Sl. No

Description Designation Purpose MAWP (MPa)

Capacity (m3)

1. High Pressure Run tank

DTK100 feed to GG, OBTP Turbine drive

36 3

2. Low Pressure Run tank

DTK130 Feed to LOX Pump and catch tank

1.6 35

3. Catch tank DTK150 To mount and feed OBTP unit

1.3 1

These tanks per se, along with instruments (not shown in P&ID) mounted on the tanks for pressure, temperature & level measurement,



2.11

are realized by the Department and erected on the foundations. Contractor shall realize all fluid circuits connected to the tanks. LOX TANKER

The facility has the provision for parking and connecting LOX road tanker for supplying LOX. The tanker is under the Department's scope. LOX DISPOSAL PIT The LOX dumped / vented from various locations of the LOX system is disposed at the O2 disposal pit to facilitate proper vaporization. LOX disposal pit shall be realized by the Department. Disposal circuits from the point of dump/vent in the process line to the disposal pit shall be realized by the Contractor ONLY to the extent given in the piping layout. Remaining length of the disposal lines will be realized by the Department. JACKET VACUUM SYSTEM A vacuum system (not shown in the P&ID) to evacuate the jackets of SI tanks and pipe-lines of the LOX system shall be realized by Department. Contractor shall provide, during Detail Engineering Review, the locations at which vacuum pump-out ports / valves are installed in the SI LOX circuits. Department will plan the vacuum system accordingly.

2.3.2.1 FILL CIRCUIT FOR DTK100 AND DTK130

The fill circuit has two SI pipelines designated as 110-50-10S-1.4 and 111-50-10S-1.4, meant for LOX transfer from road tanker to the low pressure and high pressure run tanks DTK130 & DTK100. The fill circuit is of DN 50 size, 1.4 MPa MAWP and is provided with SI. The LOX tanker is connected to the fill circuit through the interface DIF110, using a flexible hose. The circuit 110-50-10S-1.4 has an isolation EP valve DVP110 and the normally open EP valve DVP111. The circuit is provided with a filter

DFL110 of 5µm (absolute) rating. The flow rate of Liquid Oxygen in the circuit is measured by orifice flow meter DOP110. Chill down of the circuit for filling DTK 130 is monitored by fluid temperature sensor DTI110 and surface temperature sensor DTC110. Chill down of the circuit for filling DTK 100 is monitored by fluid temperature sensor DTI111 and surface temperature sensor DTC11. Pressure transmitters DPI110, DPI111 and a pressure gauge DPL110 (with process isolation valve DVM110A and two valve manifold - DVM110B/C) are used to monitor pressure in the line.. The pressure transmitters are isolated with process isolation manual valve DVM110E and DVM111E. In order to protect the line segment upstream of valve DVP110 from excessive



2.12

pressure, a safety circuit with a safety relief valve DVR110 is provided. The circuit has a common EP valve DVP719 and a non return valve DVN719 to provide GN2 purging for pipe segments both the upstream and downstream of DVP110. The branches are isolated with independent manual valves DVM 112 and DVM113 respectively. An independent manual valve DVM110 with a non-return valve DVN110 in series is provided in the vent circuit for venting and maintaining a positive pressure in the fill circuit. A gas sample port is provided with a manual valve DVM111S. To protect the segment between valve DVP110 and DVP111(NO) from excessive pressure, a safety circuit with a safety relief valve DVR111 & burst disc DBD111 in series is provided. A pressure gauge DPL111 with isolation valve (two valve manifold - DVM111B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. The outlet of the vent circuit and spontaneous safety relieving circuit is connected to LOX Disposal pit. Downstream of DVP111(NO) the circuit leads up to fill isolation valve DVP112 of tank DTK130.The LOX from the tanker is admitted initially to chill the circuit through the vent valve DVP11) by monitoring the temperature using DTI110 & DTC110. The vent valve is closed after the circuit is sufficiently chilled. The isolation valve DVP112 is opened and liquid Oxygen is fed through the isolation valve DVP13) in to the run tank DTK130. The total pressure drop in this circuit between the inter-face (DIF110) and inlet of the valve (DVP 112) for the flow rate of 3.4kg/s shall not exceed 0.108 MPa. Fill line 111-50-10S-1.4 has a manual valve DVM112E for isolation of pressure transmitter DPI112. An EP vent valve DVP114 with a orifice DOP111-Department scope) is provided in the chill vent circuit for venting the vapours during chilldown. A manual valve DVM115 and a non-return valve DVN115 in series are provided in the spontaneous vent circuit for venting and maintaining a positive pressure in the fill circuit after filling. A gas sample port is provided with a manual valve DVM 114S. In order to protect the segment between valve DVP111(NO) and DVP113 from excessive pressure, a safety circuit with a safety relief valve DVR112 & burst disc DBD112 in series is provided. A pressure gauge DPL112 with isolation valve (two valve manifold - DVM112B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. The outlet of the chill vent, spontaneous vent circuit and safety circuit is connected to LOX Disposal pit. The LOX from the tanker outlet is admitted initially to chill the circuit through the vent valve DVP114 by monitoring the temperature using DTI111 &, DTC111. The vent valve is closed after the circuit is sufficiently chilled. The isolation valve DVP113 is opened and liquid Oxygen is fed through the valve DVP100 to the run tank DTK100. The total pressure drop in this circuit between the inter-face (DIF110) and inlet of the valve (DVP113) shall not exceed 0.112MPa. , for a flow rate of 3.4kg/s .



2.13

2.3.2.2 ASSOCIATED CIRCUITS FOR RUN TANK DTK130

The circuits connected with run tank DTK130 are detailed below.

2.3.2.2.1 DUMP CIRCUIT

The circuit 137-100-10S-1.4 is used to carry out the emergency dumping of LOX or for draining the remnant quantity of LOX in the run tank DTK130 before warming-up. This circuit is branched off from the withdrawal circuit of the tank. The dump circuit is isolated by valve DVP137 from the withdrawal circuit. The initial portion of the circuit up to non return valve DVN132 is provided with SI and is realized by the Contractor. The dump circuit has GN2 purging provision with an EP valve DVP758 and a non return valve DVN 758.

2.3.2.2.2 VENT / PRESSURISATION CIRCUIT

This SI circuit 130-150-10S-1.6 is a common circuit to carry out the processes like intentional venting during tank chilling, tank pressurization to achieve the required LOX pressure for the test articles, spontaneous venting cum preservation during warming up after test, and sub-cooling of the LOX using the ejector. This has a normally open control valve DVC130(NO) and EP valve DVP132 in series and these valves are used for venting / depressurization of the tank. The balance part of the vent circuit from interface DIF131V leading to disposal pit will be realized by Department. The circuit segment sandwiched between the valves is provided with a safety circuit with a safety relief valve DVR434 & burst disc DBD434 in series. A pressure gauge DPL434 with isolation valve (two valve manifold - DVM434B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. A manual valve DVM131 and a non return valve DVN131 in series are provided in the spontaneous vent circuit for venting and maintaining a positive pressure in the tank during LOX storage before / after test. This segment has a GN2 purging provision with EP valve DVP718. The outlet of the spontaneous vent circuit and safety circuit are connected to LOX Disposal pit. A sampling port with manual valve DVM 132S is provided to collect gas sample from the run tank top for analysis. Manual valve DVM 132E is used to isolate a Pressure transmitter. Upstream of control valve DVC130(NO) in main circuit, two branches for connecting the pressurization circuit and sub-cooling circuit are provided. The tank pressurization branch 730-40-40S-7.4 is provided with EP valve DVP730 and has the interface DIF730-Pr for the nitrogen gas supply from GN2 system. The uninsulated, pressurization gas supply circuit beyond DIF 730-Pr is under Department scope.



2.14

2.3.2.2.3 SUBCOOLING CIRCUIT

This SI circuit 135-150-10S-1.4 is branched off from the vent circuit. The circuit has an EP valve DVP135 and the ejector DEJ430. The ejector is used to evacuate the inner vessel of the tank for sub-cooling LOX in the tank down to 75K. It uses GN2 as active fluid(drive gas). The drive gas supply circuit (terminating at DIF EJ774D) is under Department’s scope. The interface DIF EJ774D is provided in the ejector for connecting gas supply line from GN2 system. The ejector circuit is provided with vacuum pressure measurement DPV131 with process isolation manual valve DVM131H. The circuit is SI till ejector inlet. Ejector shall be realized by the Department.

2.3.2.2.4 SAFETY CIRCUIT

This circuit 133-50-10S-1.6 is provided for connecting safety relieving system to the tank, for limiting the excess pressure in case of any exigency. The circuit has a 3-port/ 2-way manual change-over valve DVM434 to connect the tank to any one group of safety devises at a time. This facilitates replacement of rupture disc even when the tank contains LOX. Two pairs of rupture disc devices DBD430 & DBD432 and DBD 431 & DBD433 are provided on either side of manual change-over valve DVM434. The safety relief valves DVR430 & DVR432 and DVR431 & DVR433 are provided downstream of the rupture disc devices to ensure re-sealing feature so that atmospheric air does not enter into the tanks in the event of the rupture disc opening. Pressure gauges DPL430, DPL431, DPL432 , DPL433 with isolation valves (two valve manifold - DVM430B/C, DVM431B/C, DVM432B/C, DVM433B/C) are mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. The primary safety relief devices DBD430/DBD431 and DVR430/DVR431 are set at 100 % of MAWP of the tank and sized to take care of the “loss of vacuum” condition in the insulation jacket. The supplementary safety relieving devices DVR432/DVR433 and DBD432/DBD433 are set at 110 % of MAWP of the tank and sized to take care of “loss of vacuum” condition in the insulation jacket, compounded with “fire engulfing” condition in the environment. The disposal circuit from outlets of the relieving devices, beyond interface DIF 132-V, is realized by the Department.

2.3.2.3 LOX FEED CIRCUIT TO LOX TP & CATCH TANK DTK150

The LOX withdrawal / feed circuit has SI pipelines designated 160-150-10S-1.6, 150-100-10S-1.4 meant to feed LOX from run tank DTK130 to LOX Turbo pump and LOX catch tank DTK150 respectively. Upstream section of this circuit has tank isolation valve DVP130, feed isolation valve DVP160 and a small, bypass valve



2.15

DVP131. The segment sandwiched by valves is given with a safety circuit with a safety relief valve DVR130 & burst disc DBD130 in series. A pressure gauge DPL131 with isolation valve (two valve manifold - DVM131B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. A manual valve DVM135 and a non return valve DVN130 in series are provided in the spontaneous vent circuit for venting and maintaining a positive pressure in the feed circuit after test. A liquid sample port is provided with a manual valve DVM133. LOX is filled in the tank through fill circuit and the valves DVP112 & DVP130. LOX in DTK130 is withdrawn to the feed line through the valve DVP130 and DVP160. The bypass line with valve DVP131 is used for low flow chilling and pressure equalization. This circuit has a common flow measuring segment with two stage chilling arrangement and is then branched-off to feed LOX Turbo pump and LOX catch tank DTK150. The pipeline of common segment is of DN 150 size, 1.6 MPa MAWP. The branches for chill vents are of DN40 size, 1.6 MPa MAWP. The common segment has GN2 purging provision with an EP valve DVP734 and a non return valve DVN734.

A filter DFL160 of 16 µm (absolute) rating is used to control particulate contamination in LOX fed to test articles. A differential pressure transmitter DPD160 is used to monitor filter clogging. The flow rate, temperature and pressure of Oxygen in the flow measuring segment of the circuit are measured by turbine type flow meters DFQ160, DFQ161 & DFQ162, fluid temperature sensors DTI161, DTI162 & DTI163 (all mounted in one vertical plane), and pressure transmitter DP161. The flow meters are of welded end connection. Flow meters are free-issued by Department. These are to be installed by the Contractor in the inner process pipe of the feed circuit, with required spacing upstream & downstream of each flow meter. The flow meters are to be provided with SI. An isolation valve DVP161 is provided just upstream of the flow meters in the main feed line. It has a bypass line of DN15 size with a valve DVP162(NO) for low flow chilling of flow meters. A pressure gauge DPL166 (with process isolation valve DVM166A and two valve manifold - DVM166B/C) and pressure transmitters DPI 160 & DPI 161 (with process isolation valves DVM160E & 161E) are also provided in the line. The segment up to inlet of EP valves DVP161/DVP162 is cooled down by venting vapours through the vent EP valve DVP164 and control valve DVC161(NO), by monitoring DTC160. The downstream segment is cooled down by venting vapours through the vent EP valve DVP166 and control valve DVC162(NO), by monitoring DTC161. The control valve in the vent circuit ensures optimal utilization of LOX by regulating the flow rate during chill-down. The segments in the circuit sandwiched



2.16

between isolation/control valves are provided with 4 safety circuits, comprising rupture disc devices DBD160, DBD161, DBD164, DBD165 and safety relief valves DVR160, DVR161, DVR164, DVR165 in series. Pressure gauges DPL 160, DPL161, DPL164 , DPL165 with isolation valves (two valve manifold - DVM160B/C, DVM161B/C, DVM164B/C, DVM165B/C) are mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. A manual valve DVM160 and a non-return valve DVN160 in series are provided in the spontaneous vent circuit for venting and maintaining a positive pressure in the feed circuit after test. Gas sample ports are provided in the segments upstream and downstream, with manual isolation valves DVM161S & DVM162S. The outlet of the spontaneous vent circuit and safety relieving circuits are connected to LOX Disposal pit.

a. The branch-off circuit to CE20 LOX TP:

This SI DN150 size, 1.6MPa MAWP pipeline extends the circuit to LOX TP inlet interface DIF163. This circuit has an EP

isolation valve DVP163, a terminal filter DFL161 of 70 µm (absolute) rating [with a differential pressure transmitter DPD161 to monitor clogging] and a SI Flexible hose DFH160. A pressure transmitter DPI162 is provided with a manual valve DVM162E. The provision for helium purging is given with an EP valve DVP617 and a non return valve DVN617. The circuit between isolation valve DVP163 and LOX TP is provided with a safety circuit with a safety relief valve DVR162 & burst disc DBD162 in series. A pressure gauge (DPL162) with isolation valve (two valve manifold - DVM162B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. LOX from the low pressure run tank DTK130 is used initially to chill the feed circuit. After the circuit is sufficiently chilled, DVP163 is opened and liquid Oxygen is fed to LOX TP. The total pressure drop in this circuit between the tank inter-face DIF131 and inlet inter-face of the LOX TP DIF163 shall not exceed 0.345 MPa for for flow rate of 62.88kg/s.

b. The branch-off circuit to Catch Tank DTK150:

This pipeline (150-100-10S-1.4) SI DN100 size, MAWP 1.4MPa extends the feed circuit to Catch tank DTK150 inlet interface DIF155. This circuit has EP isolation valve DVP153

and a filter DFL151 of 70 µm (absolute) rating [with a differential pressure transmitter DPD151 to monitor clogging], At the downstream of valve DVP153, a branch line from LN2 system is connected through an interface DIF330 and a Manual valve DVM330. This circuit has a SI Flexible hose



2.17

DFH150 and a fluid temperature sensor DTI155 at the end. LOX from the low pressure run tank DTK130 is admitted through isolation valve DVP153 and fed to the Catch tank DTK150. The total pressure drop in this circuit between the tank inter-face DIF131 and inlet of the catch tank DTK150 interface DIF155 shall not exceed 0.450 MPa for flow rate of 22.80kg/s.


The circuits connected to run tank DTK100 are detailed below.

2.3.2.4.1 DUMP CIRCUIT This SI circuit 107-65-10S-1.4 is used to carry out the emergency dumping of LOX or for draining the remnant quantity of LOX in the run tank DTK100 before warming-up. This circuit is branched off from the withdrawal circuit of tank. The dump circuit is isolated from the withdrawal circuit by EP valve DVP107. The initial portion of the circuit up to non return valve DVN100 is provided with SI and is realized by the Contractor. The circuit has GN2 purging provision with an EP valve DVP724 and a non return valve DVN724


This SI circuit 100-65-XXS-36 is a common circuit to carry out the processes like intentional venting during tank chilling, tank pressurization to achieve the required pressure of LOX to feed the test articles, spontaneous venting cum preservation after test and sub-cooling of the LOX using the ejector. This circuit has a normally open control valve DVC100 (NO) and EP valve DVP102 in series. The remaining part of the circuit from interface DIF101V leading to disposal pit will be realized by Department. The circuit segment sandwiched between valves DVC100 (NO) and DVP102 is provided with a safety circuit with a safety relief valve DVR404 & burst disc DBD404 in series. A pressure gauge DPL404 with isolation valve (two valve manifold - DVM404B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. A manual valveDVM101 and a non return valve DVN101 in series are provided in the spontaneous vent circuit for venting and maintaining a positive pressure in the tank during LOX storage before / after test. A venting circuit with EP valve DVP104 and orifice (DOP101) mounting interface DIF108 to carry out controlled venting during the depressurization of the tank is provided parallel to the spontaneous vent circuit. The outlet of the spontaneous vent circuit, depressurization circuit and safety relieving circuits are connected to LOX disposal pit. Disposal line downstream of interface DIF 102V is realized by the Department.



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This circuit has a GN2 purging provision with EP valve DVP717. A sampling port with manual valve DVM 102S is provided to collect gas sample from the run tank top for analysis. Manual valve DVM 102E is used to isolate a Pressure transmitter. Upstream of control valve DVC100(NO), the circuit has two branches for connecting the pressurization circuit and sub-cooling circuit. The tank pressurization branch is provided with EP valve DVP700 and has the interface DIF700-Pr for the pressurization gas supply from GN2 system. The pressurant GN2 supply circuit under GN2 system is realized by Department.


This SI circuit 105-100-10S-1.4 is branched off from the vent circuit. It has an EP valve DVP105 and the ejector DEJ400. The ejector is used to evacuate the inner vessel of the tank for sub-cooling LOX in the tank down to 75K. It uses GN2 as active fluid (drive gas). The drive gas supply circuit is under Department’s scope. The interface DIF EJ773D is provided in the ejector for drive gas supply connection from GN2 system. The ejector suction is provided with vacuum pressure transmitter DPV101 with process isolation manual valve DVM101H. The circuit is SI till ejector inlet. Ejector shall be realized by the Department.


This circuit 103-50-XXS-36 is provided for spontaneous safety relieving system for limiting the excess pressure in the tank in case of any exigency. The line is connected to tank at the interface DIF102. The circuit has a 3-port/ 2-way manual change-over valve DVM404 which enables line-up of safety devises on any one side of the change over valve to the process. It facilitates replacement of rupture disc even when the tank contains LOX. Two pairs of rupture disc devices (DBD400 & DBD402 and DBD401 & DBD403) are provided on either side of a 3-port/ 2-way manual change-over valve DVM404. The safety relief valves DVR400 & DVR402 and DVR401 & DVR403 are provided downstream of the rupture disc devices to ensure re-sealing feature so that atmospheric air does not enter into the tanks in the event of the rupture disc opening. Pressure gauges DPL400, DPL401, DPL402 , DPL403 with isolation valves (two valve manifold - DVM400B/C, DVM401B/C, DVM402B/C, DVM403B/C) are mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. The main safety relief devices DBD400/DVR400 and DBD401/DVR401 are set at 100 % of MAWP of the tank and sized to take care of the “loss of vacuum” condition in the insulation jacket. The supplementary safety relieving devices DBD402/DVR402 and DBD403/DVR403 are set at 110 % of MAWP of the tank and sized to



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take care of “loss of vacuum” condition in the insulation jacket, compounded with “fire engulfing” condition in the environment.

2.3.2.4.5 CHILLDOWN CIRCUIT

The chill down circuit 104A-25-XXS-36 is connected at the tank interface DIF104. It is used to chill the run tank from ambient to about 100K using Liquid nitrogen. This circuit has an EP valve DVP340. LN2 supply circuit No. 321-25-10S-1.4 (Refer P&ID No. CTPT/CFC/ /P&ID/300/R0) is connected to interface DIF 340.

2.3.2.5 LOX FEED CIRCUIT TO GAS GENERATOR AND OBTP TURBINE

DRIVE

The LOX feed circuit has SI pipeline designated as 120-50-XXS-36 & 121-40-XXS-36 meant for feeding LOX to Gas Generator (GG) and OBTP turbine drive respectively, from the run tank DTK100. This circuit is of DN 50 size, 36MPa MAWP has two stage chilling arrangement branched are of DN25 size and 36 MPa MAWP. This circuit has tank isolation EP valve DVP100 and feed isolation valve DVP120. DVP100 has a bypass line of DN15 size with valve DVP101 for low flow chilling and pressure equalization. The circuit sandwiched between valves is provided with a safety circuit with a safety relief valve DVR113 & burst disc DBD113 in series. A pressure gauge DPL113 with isolation valve (two valve manifold - DVM113B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. A manual valveDVM119 and a non return valve DVN112 in series are provided in the spontaneous vent circuit for venting and maintaining a positive pressure in the feed circuit after test. A liquid sample port is provided with a manual valveDVM103. LOX from the fill line is supplied to the tank through the valves DVP113, DVP100 and tank interface DIF101. LOX in Tank DTK100 is withdrawn to the feed line through the valves DVP100 and DVP120. Upstream part of the circuit has GN2 purging provision with an EP valve DVP736 and a non return valve DVN736. This circuit has 2 filters

DFL120 of 16µm (absolute) rating at the upstream and DFL121 of

70µm (absolute) rating at the downstream end, with a differential pressure transmitters DPD120 & DPD121to monitor clogging. The flow rate, temperature and pressure of Oxygen in the circuit are measured by turbine type flow meters DFQ120, DFQ121 & DFQ123; fluid temperature sensors DTI120, DTI121, DTI122, DTI123 & DTI125; surface temperature sensors DTC120, DTC121 & DTC123; pressure transmitters (DPI120, DPI121& DPI122; and a pressure gauge DPL126 with process isolation valve DVM126A and two valve manifold - DVM126B/C. The flow meters are of welded end connection. Flow meters are free-issued by Department. These are to be installed by the Contractor in the inner process pipe of the feed circuit, with required



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spacing upstream & downstream of each flow meter. The flow meters are to be provided with SI. The pressure transmitters are isolated with process isolation manual valves DVM120E, DVM121E & DVM122E. An isolation valve DVP121 is provided at the upstream of the flow meters with a bypass line of DN15 size. The bypass line has a valve DVP122(NO) for low flow chilling and pressure equalization. Further downstream, the circuit has a normally open control valve DVC120(NO) and an isolation EP valve DVP123. The segment up to inlet of EP valve DVP121 is cooled down by venting vapours through the vent EP valve DVP124 and control valve DVC 121(NO), by monitoring DTC120. The downstream segment is cooled using the vent EP valve DVP126 and control valve DVC122(NO), by monitoring DTC121. The control valves in the vent circuit ensure optimal utilization of LOX by regulating the flow rate during chill-down. The segments in the circuit sandwiched by isolation/control valve are provided with safety circuits, comprising rupture disc devices DBD120, DBD121, DBD123, DBD124, DBD125 and safety relief valves DVR120, DVR121, DVR123, DVR124, DVR125 in series. Pressure gauges DPL120, DPL121, DPL123, DPL124, DPL125 with isolation valves (two valve manifold - DVM120B/C, DVM121B/C, DVM122B/C, DVM124B/C, DVM125B/C) are mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. Manual valves DVM120 & DVM128 and non-return valves DVN120 & DVN128 in series are provided in the spontaneous vent circuits for venting and maintaining a positive pressure in the feed circuit after test. Gas sample ports are provided in the upstream and downstream locations with a manual isolation valves DVM121S & DVM122S. The outlet of the spontaneous vent circuit and safety relieving circuits are connected to LOX disposal pit. The circuit has an interface DIF123A that can be connected either with (i) the GG LOX feed inlet segment through the interface DIF123C or (ii) with OBTP turbine drive feed segment through interface DIF123B. The GG LOX feed inlet segment has a SI flexible hose DFH120 to connect with the GG interface DIF124. OBTP turbine feed inlet has a branch with an EP valve DVP127 to carry out the chilling of the segment and has a SI flexible hose DHF121 to connect with the OBTP interface DIF154. LOX from the high pressure run tank DTK100 is admitted initially to chill the circuit. The vent valve is closed after the circuit is sufficiently chilled. The isolation valve DVP123 is opened and liquid Oxygen is fed to GG / OBTP. The total pressure drop in this circuit between the inter-face DIF 101 and inlet inter-face of GG DIF124 shall not exceed 0.635MPa. for flow rate of 3.8kg/s. The total pressure drop in this circuit between the inter-face DIF 101 and inlet inter-face of OBTP



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turbine feed DIF154 shall not exceed 0.409MPa. for flow rate of 3.8kg/s.

2.3.2.6 ASSOCIATED CIRCUITS FOR CATCH TANK DTK150

Other circuits associated with catch tank DTK150 are detailed below.

2.3.2.6.1 DUMP / VENT CIRCUITS

The SI circuit 153-40-10S-1.4 is used to carry the emergency dumping of LOX or for draining LOX from the tank. It is interfaced with tank at DIF152 with SI flexible hose RFH 152. It has EP isolation valve DVP151 and connects to overflow line. The SI circuit 151-50-10S-1.4 is used for intentional venting during catch tank chilling and draining overflow from the tank during OBTP testing. This circuit is connected to the catch tank at interface DIF156 using a flexible hose DFH151. The circuit has an EP valve DVP150 and a normally open control valve DVC150(NO) in series. The downstream of DVC151(NO) is connected with the LOX pump delivery circuit leading to LOX disposal pit. The segment sandwiched by isolation valve DVP150, DVP151 and control valve DVC150(NO) is provided with a safety circuit comprising rupture disc device DBD151 and safety relief valve DVR151 are in series. Pressure gauge DPL151 with two valve manifold DVM151B/C is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. The temperature of overflowing LOX is measured using the fluid temperature sensor DTI156. A Gas sample port is provided with a manual valve DVM150S in dump line.

2.3.2.6.2 SAFETY/ PRESSURISATION CIRCUIT

The SI circuit 152-25-10S-1.4 is used for connecting safety devises for tank overpressure protection. It has a safety circuit comprising rupture disc device DBD450 & DBD451 and safety relief valve DVR450 & DVR451 in series. Pressure gauges DPL450 & DPL451 with isolation valves (two valve manifold - DVM450B/C, DVM451B/C) are mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. The spontaneous vent circuit has a manual valve DVM450 and a non-return valve DVN450 in series. The spontaneous vent and safety relieving circuit outlets are connected to LOX disposal pit. The tank has GN2 pressurizing provision with an EP valve DVP720 to supply GN2 at 0.5MPa.



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2.3.2.7 TEST ARTICLE OUTLET CIRCUITS

The pump delivery / chill vapour disposal circuits from test articles are detailed below.

2.3.2.7.1 LOX TURBO-PUMP DELIVERY

The CE20 LOX pump delivery circuit has SI pipeline designated as 161-65-80S-18.6 and 162-150-10S-1.6. This circuit has a normally open control valve DVC160 (NO) and EP valve DVP167 in series. The test article interface DIF164 is connected with the 161-65-80S-18.6 using a SI flexible hose DFH161. LOX pump outlet temperature and pressure are measured by fluid temperature sensor DTI165, surface temperature sensor DTC163 and pressure transmitter DPI164. The pressure transmitter is isolated with a process isolation manual valve DVM164E. The segment sandwiched by control valve DVC160(NO) and isolation valve DVP167 is provided with a safety circuit with a safety relief valve DVR163 & burst disc DBD163 in series. A pressure gauge DPL163 with two valve manifold DVM163B/C is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. A spontaneous vent provision is given using an EP valve DVP168(NO) and manual valve DVM163 with DN15 SI line.

2.3.2.6.2 GG LOX CHILL VENT DISPOSAL

The GG LOX chill vent disposal circuit has SI pipeline designated as 122-40-10S-1.4 meant for dispose the LOX during GG line chilling and venting before opening the GG injection valve. The test article interface DIF125 is connected with the circuit using a SI flexible hose DFH122. LOX temperature and pressure are measured by fluid temperature sensors DTI126, surface temperature sensor DTC126 and pressure transmitter DPI123. The pressure transmitter is isolated with a process isolation manual valve DVM123E.This circuit has a manual valve DVM124. This segment is provided with a safety circuit with a safety relief valve DVR126 & burst disc DBD126 in series. A pressure gauge DPL127 with isolation valve (two valve manifold - DVM127B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. This line is connected with LOX pump delivery disposal circuit with isolation manual valve DVM 124.

2.3.2.6.3 OXYDIZER BOOSTER PUMP DELIVERY/DISPOSAL This SI circuit 180-80-10S-1.4 is used to dispose LOX from LOX booster turbo pump delivery. The test article interface DIF153 is connected with the circuit using a SI flexible hose DFH180. This SI circuit has a common section up to the flow measuring segment and then branched-off for the purposes of connecting to LOX disposal pit and also to ejector system to maintain vacuum at the LOX booster



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pump outlet. The flow rate, temperature and pressure of Oxygen in the segment is measured using turbine type flow meters DFQ180, DFQ181 & DFQ182; fluid temperature sensors DTI180 & DTI181; surface temperature sensors DTC180, DTC181, DTC182 & DTC183; and pressure transducers DPI180 & DPI181 respectively. The pressure transducers are isolated with a process isolation manual valve DVM180E. The flow meters are of welded end connection. Flow meters are free-issued by Department. These are to be installed by the Contractor in the inner process pipe of the feed circuit, with required spacing upstream & downstream of each flow meter. The flow meters are to be provided with SI. In order to protect this circuit from excessive pressure a safety circuit with a safety relief valve DVR180 & burst disc DBD180 in series is provided. A pressure gauge DPL180 with isolation valve (two valve manifold - DVM180B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. The spontaneous vent circuit for venting and maintaining a positive pressure in the feed circuit after test is provided with EP valve DVP182(NO), independent manual valve DVM180 and a non-return valve DVN180 in series. A gas sample port is provided in the segment with a manual isolation valves DVM180S. The outlet of the spontaneous vent circuit and safety relieving circuits are connected to LOX disposal pit. This segment has a GHe purging provision with an EP valve DVP647 and a non return valve DVN647.

a. The branch-off circuit to Disposal pit This branch circuit has an EP isolation valve DVP181 and an interface DIF181 to mount the orifice DOP181 (Department scope). A pressure transducer DPI183 is provided for pressure measurement at the downstream of DVP181. The pressure transducer is isolated with a process isolation manual valve DVM183E. The segment at the downstream of orifice is connected with the LOX pump outlet segment by the Department.

b. The branch-off circuit to ejector system This branch circuit has an EP isolation valve DVP180, and the manual isolation valves DVM182E for pressure transmitter DPI182. The segment has an interface DIFEJ180 to connect the ejector DEJ180. Ejector will be realized by Department.

2.3.3 LIQUID HYDROGEN SYSTEM

The P&ID of LH2 system is given in drawing No. CTPT/CFC /P&ID/200/R0. The major constituents of the system are cryogenic run tanks, catch tank, LH2 road tanker and fluid circuits including pipelines, instruments and flow components.



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This system is used to supply LH2 at the required pressure, flow rate, and temperature to the test articles for testing. The LH2 system is intended to perform the following functions:

Chilling & Filling of LH2 run tank DTK230 from LH2 tanker Filling of LH2 run tank DTK200 Chilldown of circuits connecting tanks to test articles Chill-down of LH2 feed system of test article. Feeding LH2 to Test Articles from run tanks. Disposal of LH2 from test articles to Disposal system. Dumping of LH2 from run tanks to Disposal system.

Circuits for safety devices, pressurization, venting and evacuation of tanks are also included. The LH2 road tanker, run tanks DTK200 and DTK230, catch tank DTK 250) are under Department’s scope. All the fluid circuits are to be realized by the Contractor. Flow meters, fluid temperature sensors and surface temperature sensors in the circuits are free-issued by the Department. These instruments are to be installed in the circuits by the Contractor. Pressure & vacuum transmitters are not shown in P&ID and these will be provided & connected by the Department during erection at site. LH2 TANKS

The major specifications and purpose of LH2 tanks are given below:

Sl. No

Description Designation Purpose MAWP (MPa)

Capacity (m3)

1. High Pressure Run tank

DTK200 feed to GG 17 9.5

2. Low Pressure Run tank

DTK230 Feed to LH2 Pump and FBTP

1.6 85

3. Catch tank DTK250 To mount and feed FBTP

1.3 1

These tanks per se, along with instruments (not shown in P&ID) mounted on the tanks for pressure, temperature & level measurement, are realized by the Department and erected on the foundations. Contractor shall realize all fluid circuits connected to the tanks. LH2 TANKER

The facility has the provision for parking and connecting LH2 road tanker for supplying LH2. The tanker is under the Department's scope.



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LH2 / GH2 DISPOSAL SYSTEM LH2 / GH2 dumped or intentionally vented from the LH2 system is disposed at the Hydrogen burn yard which facilitates full burning of Hydrogen using igniters. LH2 burn yard shall be realized by the Department. GH2 from outlets of safety devises is disposed off by venting through non-flaring stacks. These stacks are also realized by Department. Disposal circuits from the point of dump/vent in the process line to the disposal system shall be realized by the Contractor ONLY to the extent given in the piping layout. Remaining length of the disposal lines will be realized by the Department. JACKET VACUUM SYSTEM A vacuum system (not shown in the P&ID) to evacuate the jackets of SI tanks and pipe-lines of the LH2 system shall be realized by Department. Contractor shall provide, during Detail Engineering Review, the locations at which vacuum pump-out ports / valves are installed in the SI LH2 circuits. Department will plan the vacuum system accordingly.

2.3.3.1 FILL CIRCUIT FOR DTK200 AND DTK 230

The fill circuit has two SI pipelines designated as 210-50-10S-1.4 and 211-50-10S-1.4, meant for LH2 transfer from mobile tanker to the low pressure and high pressure run tanks DTK230 & DTK200. The fill circuit is of DN 50 size, 1.4 MPa MAWP and is provided with SI. The LH2 tanker is connected to the fill circuit through a SI flexible hose DFH 210 with the LH2 tanker interface DIF214. The circuit 210-50-10S-1.4 has an isolation EP valves DVP210 and the normally open EP valve DVP 211. The circuit is provided with a filter

DFL210 of 5 µm (absolute) rating. The flow rate Liquid Hydrogen in the circuit is measured by orifice flow meter DOP210 (installed at DIF 209). Chilldown of the circuit for filling DTK 230 is monitored by fluid temperature sensor DTI 210 and surface temperature sensor DTC210. Chilldown of the circuit for filling DTK 200 is monitored by fluid temperature sensor DTI 211 and surface temperature sensor DTC211. Pressure is measured by transmitters DPI 210 & DPI 211 and a pressure gauge DPL210 with isolation valve DVM 210A and two valve manifold - DVM210B/C. The pressure transmitters are isolated with manual valves DVM 210E and DVM 211E. In order to protect the line segment upstream of valve DVP210 from excessive pressure a safety relief valve DVR 210 is provided. The circuit has a common EP valve DVP625 and a non return valve DVN625 to provide helium purging for line segments both upstream



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and downstream of DVP210 and isolated with independent manual valves DVM212 and DVM213 respectively. An independent manual valve DVM 210 and a non-return valve DVN 210 in series is given in the vent circuit for spontaneous venting and maintaining a positive pressure in the fill circuit. A gas sample port is provided with a manual valve DVM211S. The outlet of the vent circuit and safety circuit is connected to stack. To protect the segment between valve DVP210 and DVP211(NO) from excessive pressure, a safety circuit with a safety relief valve DVR 211 & burst disc DBD211 in series is provided. A pressure gauge DPL 211 with isolation valve (two valve manifold - DVM211B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. The outlet of safety circuit is connected to stack. Just downstream of DVP211(NO) the circuit is bifurcated with one leading to tank DTK230 through fill isolation valve DVP212. LH2 from the tanker is admitted initially to chill the circuit through the vent valve DVP214 by monitoring the temperature using DTI210 & DTC210. The vent valve is closed after the circuit is sufficiently chilled. The isolation valve DVP212 is opened and liquid Hydrogen is fed through the valve DVP230 to the run tank DTK230. The total pressure drop in this circuit between the inter-face DIF 214 and inlet of the valve DVP212 shall not exceed 0.014 MPa for flow rate of0.3kg/s. Fill line 211-50-10S-1.4 to tank DTK 200 has a pressure transmitter DPI212 which is isolated with manual valve DVM212E. A manual valve DVM215 and a non-return valve DVN211 in series are provided in the spontaneous vent circuit for venting and maintaining a positive pressure in the fill circuit after filling. A gas sample port is provided with a manual valve DVM214S. In order to protect the segment between valve DVP211(NO) and DVP213 from excessive pressure, a safety circuits with a safety relief valve DVR212 & burst disc DBD212 in series is provided. The outlet of the spontaneous vent circuit and safety circuit is connected to stack. A pressure gauge DPL 212 with isolation valve (two valve manifold - DVM212B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. LH2 from the tanker outlet is admitted initially to chill the circuit through the vent valve DVP214 by monitoring the temperature using DTI211 & DTC211. The vent valve is closed after the circuit is sufficiently chilled. Tank fill isolation valve DVP213 is opened and liquid Hydrogen is fed through the valve DVP200 to the run tank DTK200. The total pressure drop in this circuit between the inter-face DIF 214 and inlet of the valve DVP213 shall not exceed 0.015 MPa for flow rate of 0.3kg/s.



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The circuits connected to run tank DTK230 are described below.


This SI circuit 237-100-10S-1.4 is used to carry out the emergency dumping of LH2 or for draining the remnant quantity of LH2 in the run tank DTK230 for warming-up. This circuit is branched off from the withdrawal circuit of tank. The dump circuit is isolated by valve DVP237 from the withdrawal circuit. The non return valve DVN232 is provided at the downstream end of the circuit. The dump circuit has GN2 purging provision with an EP valve DVP759 and a non return valve DVN 759.


The SI circuit 230-150-10S-1.6 is a common circuit to carry out the processes like intentional venting during tank chilling, tank pressurization to achieve the required pressurized LH2 for the test articles and spontaneous venting cum preservation during warming up after test. This has a normally open control valve DVC230 (NO) and EP valve DVP232 in series. The circuit sandwiched between valves is provided with a safety circuit with a safety relief valve DVR534 & burst disc DBD534 in series. A pressure gauge DPL534 with isolation valve (two valve manifold - DVM534B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. A manual valve DVM231 and a non return valve DVN231 in series are given in the spontaneous vent circuit for venting and maintaining a positive pressure in the tank circuit after test. The outlet of the spontaneous vent circuit and safety circuits are connected to stack. This segment has a GH2 purging circuit with the EP valve DVP517 and the GN2 purging circuit with the manual valve DVM752 and Non return valve DVN752. Pressure transmitter DPI232 is isolated using a manual valve DVM232E. A Gas sample port with a manual isolation valve DVM233S is also provided. Upstream of control valve DVC230 (NO) has two branches for connecting the pressurization circuit and sub-cooling circuit. The tank pressurization branch is provided with EP valve DVP535 and has the interface DIF535-Pr for the gas supply from GH2 system. Gas supply circuit is realized by Department. Vent GH2 disposal circuit between interface DIF 237V and the hydrogen burning yard is realized by Department.



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The sub-cooling SI circuit 234-150-10S-1.4 is isolated from the vent circuit by an EP valve DVP235. The circuit has an ejector DEJ530. The interface DIF EJ776D is provided in the ejector for drive gas supply from GN2 system. The ejector line is provided with vacuum pressure transmitter DPV231. The vacuum pressure transmitter is isolated with process isolation manual valve DVM 231H. The ejector and the drive GN2 gas supply circuit are realized by Department.


This circuit 533-100-10S-1.6 is provided for spontaneous safety relieving system for limiting the excess pressure in case of any exigency. The circuit has a 3-port/ 2-way manual change-over valve DVM534 enabling line-up of safety devises on either side to the tank. This arrangement facilitates replacement of rupture disc even when the tank contains LH2. Two pairs of rupture disc devices DBD 530 & DBD532 and DBD531 & DBD533 are provided on either side of change-over valve DVM534. The safety relief valves DVR530 & DVR532 and DVR531 & DVR533 are provided downstream of the rupture disc devices to ensure re-sealing feature so that atmospheric air does not enter into the tanks in the event of the rupture disc opening. Pressure gauges DPL 530, DPL531, DPL532 , DPL533 with isolation valves (two valve manifold - DVM530B/C, DVM531B/C, DVM532B/C, DVM533B/C) are mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. The primary safety relief devices DVR530 / DVR531 and DBD530 / DBD531 are set at 100 % of MAWP of the tank and sized to take care of the “loss of vacuum” condition in the insulation jacket. The supplementary safety relieving devices DVR532/DVR533 and DBD532/DBD533 are set at 110 % of MAWP of the tank and sized to take care of “loss of vacuum” condition in the insulation jacket, compounded with “fire engulfing” condition in the environment. The outlets of the relieving devices are connected to vent stack by disposal header. Disposal header beyond DIF232V is realized by the Department.

2.3.3.3 LH2 FEED CIRCUIT TO TURBOPUMP & CATCH TANK DTK250

The LH2 feed circuit has SI pipelines designated 260-150-10S-1.6 and 250-100-10S-1.4 meant to feed LH2 from the run tank DTK230 to LH2 Turbo pump and LH2 catch tank DTK250 (used to test Fuel Booster Turbo Pump. Upstream part of the circuit has a tank isolation valve DVP230, feed isolation valve DVP260 and dump valve DVP237. The circuit sandwiched between these valves is provided with a safety circuits with a safety relief valve DVR230 & burst disc DBD230 in series. A pressure gauge DPL231 with isolation valve (two valve manifold - DVM231B/C) is mounted in the tell tale port between the



2.29

safety relief valve and burst disc to know the integrity of burst disc. A manual valve DVM233 and a non return valve DVN230 in series are given in the spontaneous vent circuit for venting and maintaining a positive pressure in the feed circuit after test. A liquid sample port is provided with a manual valve DVM234. LH2 from the fill line is fed to the tank through the valves DVP212 and DVP230. LH2 in Tank DTK230 is fed to the feed line through the valve DVP230 and DVP260. This circuit has common flow measuring segment with two stage chilling arrangement and is then branched-off to feed LH2 Turbo pump and LH2 catch tank DTK250. The main pipeline of common segment is of DN 150 size, 1.6 MPa MAWP. The branched chill down circuits are of DN40 size, 1.6 MPa MAWP. The circuit has helium purging provision with an EP valve DVP612 and a non return valve DVN 612.

A filter DFL260 of 16 µm (absolute) rating is used to limit particulate contamination, with a differential pressure transmitter DPD260 to monitor clogging. The flow rate, temperature and pressure of Hydrogen in the flow measuring segment of the circuit are measured by turbine type flow meters DFQ260, DFQ261 & DFQ 262; fluid temperature sensors DTI261, DTI262 & DTI263 (mounted in a vertical plane; and pressure transmitter DPI 261. pressure transmitter DPI 261 and pressure gauge DPL 266 with isolation valve (process isolation valve DVM266A and two valve manifold - DVM266B/C) are also mounted in the line. The pressure transmitters are isolated with process isolation manual valve DVM 260E and DVM261E. 3 flow meters are provided in series for the sake of redundancy. The flow meters are of welded end connection. Flow meters are free-issued by Department. These are to be installed by the Contractor in the inner process pipe of the feed circuit, with required spacing upstream & downstream of each flow meter. The flow meters are to be provided with SI. An isolation valve DVP261 provided at the upstream of the flow meters has a bypass line of DN15 size. The bypass line has a valve DVP262(NO) for low flow chilling and pressure equalization. The segment up to inlet of EP valves DVP261/DVP262 is cooled down by venting vapours through the vent EP valve DVP264 and control valve DVC 260(NO). Progress of cooling is monitored by surface temperature sensor DTC260 & liquid temperature sensor DTI 260. The downstream segment is cooled down through the vent EP valve DVP266 and control valve DVC 261(NO), with temperature sensor DTC 261 for monitoring progress. The control valves in the vent circuit ensure optimal utilization of LH2 by regulating the flow rate during chill-down. Disposal lines from interfaces DIF 261 and DIF 262 to burning yard are realized by Department. The segments in the circuit sandwiched by isolation/control valve are provided with a safety circuit, comprising rupture disc devices DBD260, DBD261, DBD264, DBD265 and safety relief valves DVR260, DVR261, DVR264, DVR265 in series. Pressure gauges DPL 260, DPL 261 , DPL 264 , DPL 265



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with isolation valves (two valve manifold - DVM260B/C, DVM261B/C, DVM264B/C, DVM265B/C) are mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. A manual valve DVM260 and a non-return valve DVN260 in series are provided in the spontaneous vent circuit for venting and maintaining a positive pressure in the feed circuit after test. Gas sample ports are provided in the upstream and downstream locations with a manual isolation valves DVM261S & DVM262S. The outlet of the spontaneous vent circuit and safety relieving circuits are connected to stack.

a. The branch-off circuit to LH2 Turbo Pump: This SI DN150 size, MAWP 1.6MPa pipeline leads to LH2 TP inlet interface DIF263. This circuit has an EP isolation valve

DVP263, a filter DFL261 of 70 µm (absolute) rating with a differential pressure transmitter DPD261to monitor clogging and a SI Flexible hose DFH260. A pressure transmitter DPI262 is given with a manual valve DVM 262E. The provision for helium purging is given with an EP valve DVP613 and a non return valve DVN613. The circuit between isolation valve DVP263 to LH2 TP is provided with a spontaneous safety relieving circuit with a safety relief valve DVR 262 & burst disc DBD262 in series. A pressure gauge DPL 262 with isolation valve (two valve manifold - DVM262B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. LH2 from the low pressure run tank DTK230 is admitted initially to chill the feed circuit. The vent valve is closed after the circuit is sufficiently chilled. The isolation valve DVP263 is opened and liquid Hydrogen is fed to LH2 TP. The total pressure drop in this circuit between the inter-face DIF 231 and inlet inter-face of LH2 TP DIF 263 shall not exceed 0.250 MPa, for flow rate of12.04kg/s.

b. The branch-off circuit to Catch Tank DTK250

This SI, DN100 size, 1.6MPa MAWP pipeline leads to Catch tank DTK250 inlet interface DIF256. This circuit is isolated from the circuit 260-150-10S-1.6 by an EP isolation valve DVP253.

A filter DFL250 of 70 µm (absolute) rating is employed with a differential pressure transmitter DPD250 to monitor clogging, At the downstream of valve DVP253 a branch line from LN2 system is connected through Manuel valve DVM250. The circuit has a SI Flexible hose DFH250 & a fluid temperature sensor DTI255. The provision for helium purging is given with an EP valve DVP626 and a non return valve DVN626. LH2 from the low pressure run tank DTK230 is admitted through isolation valve DVP253 and fed to the Catch tank DTK250. The total pressure drop in this circuit between the inter-face DIF230



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and inlet of the catch tank DTK250 interface DIF256 shall not exceed 0.161MPa, for flow rate of 6kg/s.


The circuits associated with run tank DTK200 are detailed below. 2.3.3.4.1 DUMP CIRCUIT

This SI circuit 207-50-10S-1.4 is used to carry out the emergency dumping of LH2 or for draining the remnant quantity of LH2 in the run tank for warming-up. This circuit is branched off from the withdrawal circuit of tank. The dump circuit is of size DN50 from the dump isolation valve DVP207 to non return valve DVN202. The circuit has GN2 purging provision with an EP valve DVP754 and a non return valve DVN754.


This SI circuit 200-65-80S-17 is a common circuit to carry out the processes like intentional venting during tank chilling, tank pressurization to achieve the required pressurized LH2 to feed test articles, spontaneous venting cum preservation during warming up after test and sub-cooling of the LH2 using the ejector. This circuit has a normally open control valve DVC200(NO) and EP valve DVP202 in series. The remainder of the circuit from interface DIF 201V to burn yard will be routed by Department. The circuit sandwiched between valves DVC200 (NO) and DVP202 is protected with a safety circuit with a safety relief valve DVR504 & burst disc DBD504 in series. A pressure gauge DPL504 with isolation valve (two valve manifold - DVM504B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. A manual valve DVM201 and a non return valve DVN201 in series are provided in the spontaneous vent circuit for venting and maintaining a positive pressure in the tank after test. A venting circuit with interface DIF208 for mounting orifice DOP201 and EP valve DVP204 is used to carry out controlled venting during the warming up of the tank. The outlet of the spontaneous vent circuit, warm up vent circuit and safety relieving circuits are connected to stack. This segment has a GH2 purging circuit with the EP valve DVP516 and GN2 purging circuit with the manual valve DVM751, Non return valve DVN751 and a pressure indicator DPI202 which is isolated using a manual valve DVM202E. A Gas sample port with a manual isolation valve DVM202S is also provided. Circuit upstream of control valve DVC230 (NO) has two branches for connecting the pressurization circuit and sub-cooling circuit. The tank pressurization branch is given with EP valve DVP506 and has the interface DIF506-Pr for the gas supply from GH2 system. GH2 supply circuit for tank pressurization is realized by Department.



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The sub-cooling SI circuit 204-100-10S-1.4 is isolated from the vent circuit by EP valve DVP205. The circuit has the ejector DEJ500. The interface DIFEJ775D is provided in the ejector for drive gas supply from GN2 system. The ejector suction is provided with vacuum pressure measurement DPV201. The vacuum pressure transmitter is isolated with process isolation manual valve DVM 201H. The ejector and the drive gas GN2 supply circuit are realized by Department.


This circuit 503-65-80S-17 is provided for tank safety system for relieving the excess pressure in case of any exigency and is at the tank interface DIF202. The circuit has a 3-port/ 2-way manual change-over valve DVM504 which enables line-up of safety devises on either side of manual valve to the process side (tank). This arrangement facilitates replacement of rupture disc even when the tank contains LH2. Two pairs of rupture disc devices DBD 500 & DBD502 and DBD501 & DBD503 are provided on either side of change-over valve. The safety relief valves DVR500 & DVR502 and DVR501 & DVR503 are provided downstream of the rupture disc devices to ensure re-sealing feature so that atmospheric air does not enter into the tanks in the event of the rupture disc opening. Pressure gauges DPL 500, DPL501, DPL502 , DPL503 with isolation valves (two valve manifold - DVM500B/C, DVM501B/C, DVM502B/C, DVM503B/C) are mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. The primary safety relief devices DVR500/DVR501 and DBD500/DBD501 are set at 100 % of MAWP of the tank and sized to take care of the “loss of vacuum” condition in the insulation jacket. The supplementary safety relieving devices DVR502/DVR503 and DBD502/DBD503 are set at 110 % of MAWP of the tank and sized to take care of “loss of vacuum” condition in the insulation jacket, compounded with “fire engulfing” condition in the environment. The outlets of the relieving devices are connected to vent stack through disposal header.

2.3.3.4.5 CHILLDOWN CIRCUIT

The chill circuit 560A-25-40S-17 is used to chill the run tank from ambient temperature to about 50K using cold GH2 from the GH2 system. This circuit has a EP valve DVM560 and an interface DIF560 at its downstream. Cold GH2 circuit from GH2 system is to be connected to this interface by the Contractor.



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2.3.3.5 LH2 FEED CIRCUIT TO GG

The LH2 feed circuit has SI pipeline designated as 220-50-80S-17, meant to feed LH2 to Gas Generator (GG) from the high pressure run tank DTK200. This circuit is of DN 50 size, 17 MPa MAWP and it’s two stage chilling arrangement branches are of DN25 size, 17MPa MAWP. The circuit has a tank isolation valve DVP200, feed line valve DVP220 and dump valve DVP207. The segment sandwiched between valves is provided with a safety circuit with a safety relief valve DVR200 & burst disc DBD 200 in series. A pressure gauge DPL 201 with isolation valve (two valve manifold - DVM201B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. A manual valve DVM203 and a non return valve DVN200 in series are given in the spontaneous vent circuit for venting and maintaining a positive pressure in the segment after test. A liquid sample port is provided with a manual valve DVM204. LH2 from the fill line is fed to the tank through the valves DVP213, DVP200 and tank interface DIF201. LH2 in Tank DTK200 is fed to the feed line through the valve DVP200 and DVP220. The upstream part of this circuit has a helium purging provision with an EP valve DVP 610 and a non return valve DVN 610. This circuit has

filters DFL220 of 16µm (absolute) rating at the upstream and DFL221

of 70µm (absolute) rating at the downstream end, with differential pressure transmitters DPD220 & DPD221 to monitor clogging. The flow rate, temperature and pressure of Hydrogen in the circuit is measured by turbine type flow meters DFQ220, DFQ221 & DFQ222; fluid temperature sensors DTI221, DTI222, DTI223; and pressure transmitter DPI221. The flow meters are of welded end connection. Flow meters are free-issued by Department. These are to be installed by the Contractor in the inner process pipe of the feed circuit, with required spacing upstream & downstream of each flow meter. The flow meters are to be provided with SI. Additionally, pressure transmitters DPI220 (in upstream section) & DPI 222 (at the end) and a pressure gauge DPL226 with isolation valve (two valve manifold - DVM226B/C) are provided. The pressure transmitters are isolated with process isolation manual valve DVM 220E, DVM221E & DVM222E. An isolation valve DVP221 is provided at the upstream of the flow meters with a bypass line of DN15 size. The bypass line has a valve DVP222(NO) for low flow chilling and pressure equalization. There is final isolation EP valve DVP223. The segment up to inlet of EP valve DVP221/DVP222(NO) is cooled down by venting vapours through the vent EP valve DVP224 and control valve DVC 220(NO). Chilldown is monitored by surface & fluid temperature sensors DTC220 & DTI220. The downstream segment is cooled down by venting through the EP valve DVP226 and control



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valve DVC 221(NO), by monitoring DTC 221. Control valves in the vent circuit ensure optimal utilization of LH2 by regulating the flow rate during chill-down. Chilldown vent disposal lines from interfaces DIF 221 & DIF 222 to burning yard are realized by Department. The segments in the circuit sandwiched by valves are provided with a safety circuit, comprising rupture disc devices DBD220, DBD221, DBD222, DBD224 & DBD225 and safety relief valves DVR220, DVR221, DVR222, DVR224 & DVR225 in series. Pressure gauges DPL220, DPL221,DPL222, DPL224 & DPL225 with isolation valves (two valve manifold - DVM220B/C, DVM221B/C, DVM222B/C, DVM224B/C, DVM225B/C) are mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. A manual valve DVM220 and a non-return valve DVN220 in series are provided in the spontaneous vent circuit for venting and maintaining a positive pressure in the feed circuit after test. Gas sample ports are provided in the upstream and downstream locations with manual isolation valves DVM221S & DVM222S. The outlet of the spontaneous vent circuit and safety relieving circuits are connected to stack. The LH2 feed inlet of GG has a SI flexible hose DFH220 to connect with the GG interface DIF223. LH2 from the run tank DTK230 is admitted initially to chill the circuit. The vent valve is closed after the circuit is sufficiently chilled. Then, necessary isolation valves are opened and liquid Hydrogen is fed from tank DTK 200 to GG. The total pressure drop in this circuit between the inter-face DIF201 and inlet inter-face of the CE20 GG DIF223 shall not exceed 0.350 MPa, for flow rate of 1.36kg/s

2.3.3.6 ASSOCIATED CIRCUITS FOR CATCH TANK DTK250

The associated circuits of LH2 catch tank DTK250 are detailed below.

2.3.3.6.1 VENT/ SAFETY/ PRESSURISATION CIRCUIT

This SI circuit 251-50-10S-1.4 is used to carry intentional venting during catch tank chilling, spontaneous safety relieving of excess pressure in case of any exigency and pressurization of the tank for FBTP testing. This circuit is connected using a flexible hose DFH251 with the catch tank interface DIF255. This circuit has an EP valve DVP251 and a common normally open control valve DVC250 (NO) in series. The circuit downstream at DIF257 is connected with the FBTP pump delivery circuit leading to LH2 burning yard. The segment sandwiched by valves is protected with a safety circuit, comprising rupture disc device DBD552 and safety relief valve DVR552 in series. Pressure gauge DPL552 with isolation valves (two valve manifold - DVM552B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. The segment



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upstream of valve DVP251 has a branch with manual valve DVM550 and a non-return valve DVN550 in series as spontaneous vent circuit for venting and maintaining a positive pressure in the tank after test. Provision for GH2 pressurization of the tank is given with EP valve DVP 518. The tank has a safety circuit 253-25-10S-1.4, comprising rupture disc devices DBD550 & DBD551 and safety relief valves DVR550& DVR551 in series. Sizes of these two sets of rupture discs and safety valves are specified by the Department. These are procured and installed by the Contractor. Pressure gauges DPL550& DPL551 with isolation valves (two valve manifold - DVM550B/C, DVM551B/C) are mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. The spontaneous vent and safety relieving circuit outlets are connected to stack. The temperature at the top of vent / overflow circuit is measured using the fluid temperature sensor DTI256.


This SI circuit 252-40-10S-1.4 is used to carry out the emergency dumping of LH2 or for draining the remnant quantity of LH2 in the catch tank DTK250 during warming-up. This circuit has a isolation EP valve DVP252. The outlet of the isolation valve is connected with the branch provided in the main vent line. A sample port is provided in the upstream location with a manual isolation valves DVM551.

2.3.3.7 TEST ARTICLE DELIVERY / CHILL DISPOSAL CIRCUITS

The circuits for Turbo Pump discharge, GG chill vent and FBTP delivery are detailed below.

2.3.3.7.1 LH2 TURBO PUMP DELIVERY CIRCUIT

The LH2 turbo pump delivery circuit has SI pipelines designated 261-65-80S-18.6 & 262-150-10S-1.6 meant to dispose LH2 from LH2 turbo pump outlet. This circuit has a normally open control valve DVC262 (NO) and EP valve DVP268 in series. The test article interface DIF264 is connected with the 261-65-80S-18.6 using a SI flexible hose DFH261. Pump outlet temperature and pressure are measured by fluid temperature sensor DTI265 and pressure transmitter DPI263 respectively. The pressure transmitter is isolated with a process isolation manual valve DVM263E. Surface temperature sensor DTC263 is used to monitor chilling prior to test. A gas sample port is provided in the segment with a manual isolation valve DVM264S. The segment upstream of valve DVC262(NO) has a manual valve DVM263 and a non-return valve DVN261 in series in the spontaneous vent circuit for venting and maintaining a positive pressure in the segment



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after test. The segment sandwiched by control valve DVC264(NO) and isolation valve DVP268 is protected with a safety circuit with a safety relief valve DVR263 & burst disc DBD263 in series. A pressure gauge DPL263 with isolation valve (two valve manifold - DVM263B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. The downstream circuit is of DN 150 size, 1.6MPa MAWP and has a pressure transmitter DPI264 which is isolated with a process isolation manual valve (DVM264E). Disposal circuit beyond interface DIF 266 is realized by Department.

2.3.3.7.2 GG LH2 CHILL VENT DISPOSAL CIRCUIT

The GG LH2 chill vent disposal circuit has SI pipeline designated as 222-65-10S-1.4 meant for dispose the GH2 during GG chilling and venting the LH2 before opening the GG injection valve. This circuit has a manual valve DVM224 with status switch. The test article interface DIF224 is connected with the 222-65-10S-1.4 using a SI flexible hose DFH222. The GG LH2 chill vent temperature and pressure are measured by fluid temperature sensor DTI225, surface temperature sensor DTC223 and pressure transmitter DPI223 respectively. The pressure transmitter is isolated with a process isolation manual valve DVM223E. A manual valve DVM223 and a non-return valve DVN221 in series are given in the spontaneous vent circuit for venting and maintaining a positive pressure in the segment after test. This segment is protected with a safety circuit with a safety relief valve DVR223 & burst disc DBD223 in series. A pressure gauge DPL223 with isolation valve two valve manifold - DVM223B/C is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. The circuit is connected to LH2 pump delivery disposal line.

2.3.3.7.3 FUEL BOOSTER PUMP DELIVERY CIRCUIT

This circuit 270-80-10S-1.4 is used to dispose the LH2 from LH2 turbo pump delivery. The test article interface DIF254 is connected with the line using a SI flexible hose DFH270.This SI circuit is common in the flow measuring segment and subsequently branched-off to LH2 disposal to burn yard and ejector system to maintain vacuum at the LH2 booster pump outlet. The flow rate, temperature and pressure in the circuit is measured by turbine type flow meters DF270, DFQ271 & DFQ272, fluid temperature sensors DTI270 & DTI271, surface temperature sensors DTC270, DTC271, DTC272 & DTC273 and pressure transducers DPI270 & DPI271 respectively. The pressure transducers are isolated with a common process isolation manual valve DVM270E. The flow meters are of welded end connection. Flow meters are free-issued by Department. These are to be installed by the Contractor in the inner process pipe of the feed circuit, with required spacing upstream & downstream of each flow meter. The flow meters are to be provided with SI.



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In order to protect this circuit from excessive pressure a safety circuit with a safety relief valve DVR270 & burst disc DBD270 in series is provided. A pressure gauge DPL270 with isolation valve (two valve manifold - DVM270B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. A spontaneous venting circuit with normally-open EP valve DVP 272(NO), manual valve DVM271 and a non-return valve DVN270 in series are provided in the circuit for venting and maintaining a positive pressure after test. Gas sample port is provided in the segment with a manual isolation valves DVM270S. The outlet of the spontaneous vent circuit and safety circuits are connected to stack. This circuit has a GHe purging provision with an EP valve DVP622 and a non return valve DVN622.

c. The branch-off circuit to burn yard

This circuit has an EP isolation valve DVP271, a manual valve DVM273E for pressure transducer DPI273 isolation and an interface DIF276 to mount the orifice DOP276-Departments scope. The segment at the downstream of orifice is connected with the TP discharge circuit.

d. The branch-off circuit to ejector system

This circuit has an EP isolation valve DVP270, and an interface DIF277 to mount the orifice (DOP277-Departments scope). The manual isolation valve DVM272E for pressure transducer DPI272 isolation. The segment has an interface DIF270 to connect the ejector DEJ270, will be mounted by Department.

2.3.3.7.4 FUEL BOOSTER PUMP BEARING COOLANT DISPOSAL

This circuit 273-40-10S-1.4 is used to dispose the LH2/GH2 from LH2 booster pump bearing coolant. The test article interface DIF253 is connected with the circuit using a SI flexible hose DFH271. The temperature and pressure measurement of Hydrogen in the segment of the circuit is carried out by fluid temperature sensor DTI273, surface temperature sensors DTC274 & DTC275 and pressure transducer DPI274. The pressure transducer is isolated with process isolation manual valve DVM274E. The segment has an interface DIF275 to connect the circuit with the ejector DEJ272, which will be mounted by Department. Provision for GHe purging is made with EP valve DVP 623 and check valve DVN 623.

2.3.3.7.5 FUEL BOOSTER TURBINE EXHAUST DISPOSAL: This circuit 570-40-10S-1.4 is used to dispose the GHe/GH2 from LH2 booster turbine exhaust. The test article interface DIF252 is connected with the line using a SI flexible hose DFH570. The temperature and pressure of GHe/GH2 in the circuit is measured by fluid temperature



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sensor DTI570 and pressure transmitter DPI570. The pressure transmitter is isolated with process isolation manual valve (DVM570E). This segment has a GHe purging provision with an EP valve DVP624 and a non return valve DVN624.The segment has an interface DIF570 to connect an ejector, which will be realized by Department.

2.3.4 LIQUID NITROGEN SYSTEM This system is used to supply LN2 at the required pressure and flow rate to the equipments at CTPT. The LN2 system is intended to perform the following functions: a. Filling of LN2 storage tank DTK300 from LN2 tanker. b. Feed to LN2 vaporizer bank. c. Filling of GH2 cooler DHX530 from LN2 storage tank DTK300. d. Chilling of FBTP and OBTP catch tanks (DTK150 &DTK250) e. Chilling of LOX high pressure storage tank DTK100 from LN2

storage tank DTK300 / LN2 tanker.

The Process & Instrumentation Diagram (P&ID) of the system is given in CTPT/CFC/P&ID/700/R0. The major constituents of the system are LN2 storage tank DTK300 and fluid circuits including pipelines, instruments and flow components. The cryogenic circuits are to be realized by the Contractor. Fluid & surface temperature sensors are free-issued by Department and shall be incorporated by the Contractor in the circuits. LN2 STORAGE TANK A vacuum jacketed, perlite insulated tank DTK300 (75m3, 2.5MPa MAWP) is used to store and supply LN2 for various utilities. The tank per-se [with certain instruments (not shown in P&ID) for pressure & level measurement] is realized by the Department and erected on it’s foundation.

LN2 TANKER

The facility has the provision for parking and connecting LN2 road tanker. The tanker is under the Department's scope. JACKET VACUUM SYSTEM A vacuum system (not shown in the P&ID) to evacuate the jackets of SI tanks and pipe-lines of the GH2 system shall be realized by Department. Contractor shall provide, during Detail Engineering Review, the locations at which vacuum pump-out ports / valves are installed in the SI GH2 circuits. Department will plan the vacuum system accordingly.



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Description of fluid circuits to be realized by the contractor is as

follows.

2.3.4.1 FILL CIRCUIT FOR LN2 TANK

The fill circuit has SI pipelines designated 310-40-10S-1.4 & 311-65-10S-2.5 meant for LN2 transfer from mobile tanker to the LN2 storage tank DTK300. The fill circuit sections are of DN 40 size, 1.4 MPa MAWP and DN 65 size, 2.5 MPa MAWP is provided with SI. The LN2 tanker is connected to the fill circuit through the LN2 tanker interface DIF310. This circuit has manual isolation valve DVM310 at the upstream and

EP valve DVP300 at the downstream. A filter DFL310 of 5 µm (absolute) rating is provided at supply end. The temperature and pressure of Liquid Nitrogen in the circuit is measured by fluid temperature sensor DTI310, surface temperature sensor DTC310, pressure transmitters DPI310, DPI728 and a pressure gauge DPL310 with isolation valve (process isolation valve DVM310A, two valve manifold - DVM310B/C). The pressure transmitters are isolated with process isolation manual valve DVM310E and DVM728E. In order to protect the tanker-end segment from excessive pressure a safety relief valve DVR728 is provided. The circuit has a manual valve DVM728 and a non return valve DVN728 in series to provide common GN2 purging for circuit segments both the upstream and downstream of DVM310 and isolated with independent manual valves DVM728T and DVM728F respectively. An independent manual valve DVM728V and a non-return valve DVN728V in series is provided in the vent circuit for venting and maintaining a positive pressure in the fill circuit. A gas sample port is provided with a manual valve DVM310S. To Protect the segment at the downstream of DVM310 from excessive pressure a safety relief valve DVR310 is provided. An independent manual valve DVM311 and a non-return valve DVN310 in series is provided in the vent circuit for venting and maintaining a positive pressure in the segment. The outlet of the vent circuit and safety circuit is connected to Local vent. This downstream segment of DVP300 leads up to DTK300 tank fill/drain interface DIF303. The tank-end segment near EP valve DVP 300 has a branch to LN2 vaporizers with isolation valve DVP315. A liquid sample port with the manual valve DVM304 is given. Another branch from the line has EP valve DVP320 to isolate circuit 320. The LN2 from the tanker is admitted initially to chill the circuit through the vent valve DVM311 by monitoring the temperature using DTI310, DTC310 then the vent valve is closed after the circuit is sufficiently chilled. The isolation valve DVP300 is opened and Liquid Nitrogen is fed to the storage tank. The total pressure drop in this circuit between the inter-face DIF310 and



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inlet of storage tank shall not exceed 0.180 MPa, for flow rate of 3.6kg/s.

2.3.4.2 ASSOCIATED CIRCUITS FOR STORAGE TANK

The associated circuits of storage tank DTK300 are detailed below. 2.3.4.2.1 VENT / PRESSURISATION CIRCUIT

This SI circuit 312-100-10S-2.5 is a common circuit to carry out the processes like intentional venting during tank chilling, tank pressurization to achieve the required pressurized LN2 for the equipments and spontaneous venting cum preservation during warming up after test. This has an EP valve DVP301 and a spontaneous venting provision with manual valve DVM302 and a non return valve DVN302 in series for venting and maintaining a positive pressure in the feed circuit after test. The outlets of are connected in the common interface DIF301V and leading to local vent. In the upstream of valve DVP301 there is a DN50 branch with interface DIF732-Pr for GN2 pressurization. Pressurization GN2 supply line will be realized by Department.


This circuit 313-25-10S-2.5 is provided for spontaneous safety relieving system for relieving the excess pressure in case of any exigency. The circuit has a 3-port/2-way manual change-over valve DVM301 with which safety devises on one side can be connected to tank. This also facilitates replacement of rupture disc even when the tank contains LN2. One each of safety relief valves DVR301 & DVR302 and rupture disc devices DBD301 and DBD302 are provided on either side of manual change-over valve. The safety relief valves are set at 100 % of MAWP of the tank and sized to take care of the “loss of vacuum” condition in the insulation jacket. The rupture disc device is set at 110 % of MAWP of the tank and sized to take care of “loss of vacuum” condition in the insulation jacket, compounded with “fire engulfing” condition in the environment. The outlet of the safety circuit will be connected in the common interface DIF302V.

2.3.4.3 LN2 FEED CIRCUIT TO VAPORIZER The LN2 feed circuit has SI pipeline designated as 315-65-10S-2.5 meant to feed LN2 to vaporizer bank from storage tank DTK300. This circuit emerges from the feed isolation valve DVP315 and routed up to the inlet interface DIF312 of the vaporiser bank. This segment has a GN2 purging circuit with manual valve DVM727 and a non-return valve DVN727. The vaporizer banks are under Department’s scope.



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2.3.4.4 LN2 FEED CIRCUIT TO FPTP CATCH TANK DTK250, OBTP CATCH TANK DTK150 AND GH2 COOLER DHX350

The LN2 feed circuit has SI pipeline designated as 320-40-10S-1.4 meant for feed the LN2 to FPTP catch tank DTK250, OBTP catch tank DTK150 and GH2 cooler DHX350 from storage tank DTK300. This circuit from the feed isolation valve DVP320 has to be extended to each of these utility points. Upstream part of this circuit has a GN2 purging circuit with EP valve DVP726 and a non-return valve DVN726 and has a fluid temperature sensor DTI320 and a pressure transmitter DPI320. The pressure transmitter is isolated with process isolation manual valve DVM320E. The circuit has a GH2 cooler fill isolation valve DVP350 at the cooler-end of the circuit. The circuit has a spontaneous venting provision with manual valve DVM321 and a non return valve DVN321 in series for venting and maintaining a positive pressure in the circuit. To protect the segment from excess pressure, a safety relief valve DVR321 is provided. The outlet of the valves DVR321 and DVN321 are connected in the interface DIF301V and DIF321S respectively and leading to local vents. .A gas sampling port is provided in this segment with an isolation valve DVM320S. A fluid temperature sensor DTI321 is provided at downstream of the circuit to monitor the chilling of the circuit. This circuit has 3 branched off lines with the interfaces DIF330, DIF340 and DIF 360 to connect to the equipments. The interface DIF330 is for the OBTP catch tank DTK150 and is connected using the flexible hose DFH330, interface DIF340 is for the LOX high pressure run tank DTK100 chilling and is connected using the flexible hose DFH340 and interface DIF360 is for the FBTP catch tank DTK250 and is connected using the flexible hose DFH360.

2.3.5 GASEOUS HYDROGEN SYSTEM

The Process & Instrumentation Diagram of cold GH2 system is given in the drawing CTPT/CFC/P&ID/500/R0. The cold GH2 system is intended to cater to the following requirements:

• To feed cold GH2 for FBTP turbine drive

• To feed cold GH2 for flow test of HTPM Module

• To supply cold GH2 for chilling of high pressure LH2 run tank DTK200

The major constituents of the system are GH2 cooler DHX530 and fluid circuits including pipelines, instruments and flow components. The entire fluid circuits are to be realized by the Contractor. Flow meters and fluid & surface temperature sensors are free-issued by Department and these are to be incorporated in the circuits by the Contractor.



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GH2 COOLER The GH2 cooler DHX530 is an LN2 bath type heat exchanger used to

cool GH2 from ambient temperature to the required low temperature for supplying to the three utilities given above. Volume of the cooler is about 8m3 and the MAWP is 0.1MPa. The cooler is realized by Department.

JACKET VACUUM SYSTEM A vacuum system (not shown in the P&ID) to evacuate the jackets of SI tanks and pipe-lines of the GH2 system shall be realized by Department. Contractor shall provide, during Detail Engineering Review, the locations at which vacuum pump-out ports / valves are installed in the SI GH2 circuits. Department will plan the vacuum system accordingly.

Description of fluid circuits to be realized by the contractor is as

follows. 2.3.5.1 GH2 FEED CIRCUIT TO HTPM AND FBTP TEST BAYS

The circuit 556-25-160-31 is used to feed cold GH2 at high pressure from the cooler to HTPM and FBTP test bays. This SI circuit is initially common including the flow measuring segment and then branched-off to FBTP and HTPM test bays. The mass flow rate of hydrogen is known from volumetric flow, temperature and pressure of Hydrogen in the circuit from vortex type flow meters DFQ555, DFQ556 & DFQ557, fluid temperature sensors DTI 557 & DTI 558 & DTI559 and pressure transmitter DPI 558 respectively. The flow meters are of welded end connection. Flow meters are free-issued by Department. These are to be installed by the Contractor in the inner process pipe of the feed circuit, with required spacing upstream & downstream of each flow meter. The flow meters are to be provided with SI. The pressure transmitter is isolated with a process isolation manual valve DVM 558E. In order to prevent this circuit from excessive pressure a safety circuit with a safety relief valve DVR 556 & burst disc DBD556 in series is provided. A pressure gauge DPL 557 with isolation valve (two valve manifold - DVM557B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc.

a. The branch-off circuit to HTPM test bay This branch circuit has a fluid temperature sensor DTI 561, an EP isolation valve DVP 558, a manual valve DVM 562E for pressure transmitter DPI 558 isolation and a control valve DVC 558. The provision for helium purging is given with an EP valve DVP 630 which is common for both the FBTP and HTPM test bays and isolated with independent manual valve DVM 631



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and a non return valve DVN 632.The cold GH2 from the cooler outlet is fed through the control valve to the HTPM test bay for testing HTPM at different inlet pressures. The total pressure drop in this circuit between the inter-face DIF 558-O and inlet of the control valve DVC 558 shall not exceed 1.58 MPa, for flow rate of 0.21kg/s.

b. The branch-off circuit to FBTP test bay

This branch circuit has a fluid temperature sensor DTI560, an EP isolation valve DVP557 & an EP vent valve DVP559 , a manual valve DVM 561E for pressure transmitter DPI 561 and a control valve DVC 557. The provision for helium purging the circuit is made with manual valve DVM630 and a non return valve DVN630. A gas sample port is provided with a manual valve DVM 556S. The circuit is initially chilled through the vent valve DVP559 by monitoring the temperature using DTI560 then the vent valve is closed after the circuit is sufficiently chilled. The isolation valve DVP557 is opened and cold Hydrogen is fed through the control valve to the FBTP test bay for testing FBTP at different inlet pressures. The total pressure drop in this circuit between the inter-face DIF 558-O and inlet of the control valve DVC 557 shall not exceed 0.55 MPa, for flow rate of 0.2kg/s.

2.3.5.2 GH2 CIRCUIT TO PRE-CHILL THE LH2 RUN TANK

This low pressure SI circuit 560-25-10s-3.7 is branched-off from the parent high pressure circuit 556-25-160-31 at the downstream of flow measuring segment and then isolated by a high pressure terminal isolation valve DVM 560. A flanged joint with flexible hose DFH560 is provided to connect the low pressure circuit with the high pressure circuit. The low pressure circuit has a gas sample analysis port and a pressure measurement port isolated with manual valves DVM 560S and DVM 560E respectively. In order to protect this low pressure circuit from high pressure circuit a safety circuit with a safety relief valve DVR 560 & burst disc DBD 560 in series is provided. A pressure gauge DPL 560 with isolation valve (two valve manifold - DVM560B/C) is mounted in the tell tale port between the safety relief valve and burst disc to know the integrity of burst disc. The terminal isolation valve DVM 560 will be opened and the low pressure cold GH2 from the cooler outlet is fed to the High pressure LH2 run tank for its pre-chilling process. The total pressure drop in this circuit between the inter-face DIF558O and the high pressure LH2 run tank interface DIF560 shall not exceed 0.02 MPa, for flow rate of 0.04kg/s.



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2.4 DESIGN & ENGINEERING

The Cryo Fluid Circuits (CFC) of CTPT have to meet the stringent requirements of test article servicing and to perform at wide range of temperatures (from cryogenic to ambient temperature) and pressures (from vacuum to very high pressures). Contractor shall consider these thermal & pressure variations in Design, Analysis & Engineering of CFC. Climatic and environmental conditions given are also to be factored in Design, Engineering & Analysis. The requirements of Design & Engineering are detailed in this section.

2.4.1 PROCESS DESIGN

The Process design of the fluid systems has been done by the Department. Contractor shall study the documents given by Department in this regard, Process and Instrumentation Diagrams (P&ID), piping layout & Process Design report. Contractor shall participate in the Design review and discuss all aspects with Department so that a mutually-agreed basic design is finalized to start Detail engineering by Contractor. P&IDs of all fluid systems indicating the sizes of circuits, location of major components such as valves, filters, hoses, measurements etc are given Annexure 2-B;

Also a preliminary piping layout of critical & essential pipe circuits is given in Annexure 2-E. The specification of the flow components of CFC, along with the list of flow components is given in detail in Annexure 2-C.

2.4.2 Hazards and Operability (HAZOP) study

Contractor’s representatives shall participate in Hazard and Operability (HAZOP) study to be organized by the Department at Mahendragiri for one week. The recommendations of the HAZOP study, upon review & approval by Department, shall be incorporated in the scope of CFC. Accordingly, the Contractor shall update the P&IDs and design documents.

2.4.3 Detail Engineering

Based on the approved design evolved during design review and the recommendation of HAZOP study, the Contractor shall carry out Detail Engineering, which shall comprise the following:



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2.4.3.1 Pipeline layout

In addition to equipment layout, a preliminary piping layout, showing routing of pipelines for major cryogenic fluid circuits has been prepared by the Department and is given in Annexure 2-E. The actual piping layout shall be finalized by the Contractor based on Detail engineering. Flow components such as valves, filters, safety relieving systems etc., shall be suitably grouped as modules based on function/ location/ fluid. The flow components thus grouped as modules can be with independent vacuum jacket or cold box configuration and shall be finalized during DER with approval Department. A single drawing of pipeline layout shall be made covering all the cryogenic pipelines in CTPT. Also, for the sake of better legibility, pipeline layout drawings at various areas of test stand shall be made in convenient numbers of segments showing all the pipelines in a magnified scale. The drawings shall be made on latest AutoCAD-based software and provided in Compact Discs (CDs). Minimum flow capacity of Safety Reliving Devices for SI circuits shall be designed as per CGA-1.2-2009 with consideration of conduction through insulating material, radiation, convective heat transfer rate through annular space saturated with gaseous lading or air whichever is greater.

2.4.3.2 Pipeline isometrics

The 3-dimensional isometric drawings of the individual pipeline segments shall be made. The drawings shall be fully dimensioned (not to scale) and show the locations of the fittings, flanges, flow components, instruments, bellows compensators, pipe supports, etc. Each isometric drawing shall contain the detailed Bill Of Materials (BOM). The drawings shall be made on latest AutoCAD-based software and provided in Compact Discs (CDs). While preparing the piping layout & isometrics, location of valve modules and the interferences due to structural members & civil structures shall be considered.

The valves, flow meters and associated flow components in a particular location are to be clustered into valve units mounted on structured skid. The valve units may be configured in either of 2 schemes as follows:

• Individual valves & flow components are to be vacuum jacketed and arranged on skid.



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• The cluster of valves & flow components (without individual vacuum jacket) are to be accommodated in a vacuum chamber / cold box and the chamber can be kept under vacuum.

• The filters in SI piping circuit may be purchased either as vacuum-jacketed filters from the Sub-vendors listed in contract or bare filters may be purchased and the vacuum-jacketing shall be done along with the piping.

2.4.3.3 Flexibility Analysis

Complete piping stress and flexibility analysis of the fluid circuits shall be done by the Contractor using appropriate software as per the Design code. In general, all the cryogenic pipelines shall be provided with bellows either in inner pipeline or outer jacket based on analysis to compensate for thermal contraction upon chill-down. The use of specific U-bends for thermal compensation can be employed especially for high-pressure cryogenic circuits. The arrangement shall not pose hindrance to working personnel. The detailed calculations for the sizing and positioning of the thermal compensators such as bellows and U-bends based on flexibility analysis shall be provided. The supports are to be appropriately designed taking into account of forces & moments due to thermal effect, pressure, seismic forces etc. Loads / movements at interfaces between equipment under Department scope and circuits designed by Contractor shall be properly accounted.

2.4.3.4 Chill down analysis

The chill down analysis of the cryogenic pipelines including detailed calculations shall be provided. The calculations for arriving at the optimum flow rates at different instants of time and the controlling process variables such as tank pressure, vent control valve opening, etc to achieve the same shall be provided. The analysis shall generate profiles of pipeline wall temperature and optimum flow rates at different instants of time during chill down. The analysis shall be done specifically for every cryogenic circuit, based on the pipeline layout and isometric drawings. The results of the analysis shall be presented in CD along with hard copy document.

2.4.3.5 The routing of the pipelines shall also address the Geyser effect (“lock” in flow of cryogenic fluid through pipeline due to accumulated vapour, resulting from prolonged two phase flow, entrapped at higher level). The design and location of pipe supports shall address, apart from fluid dynamic forces, the bowing effect (bending of pipeline due to non-uniform contraction in semi-filled condition during chill down) for cryogenic pipelines.



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2.4.3.6 The pressure drop in the circuits under operating flow conditions shall be estimated based on the pipeline layout and isometric drawings. Also, the temperature rise in feed circuits to test articles shall be estimated considering the heat-in-leak & pressure drop.

2.4.3.7 The static earthing scheme for pipelines shall be prepared and

submitted.

2.4.3.8 Design of joints

The drawings of removable joints (threaded unions, flanges, etc) along with the seals (gaskets, O-rings, etc) planned in various circuits shall be provided. The drawings of bayonet couplings wherever specified as interface also shall be provided. The adequacy of such joints to ensure leak tightness of 1E-06 m3Pa/s shall also be established.

2.4.3.9 The Quality Assurance Plan (QAP) for pipes, pipe fittings, flow components, instruments, etc, fabrication, erection and commissioning shall be worked out and submitted by the Contractor.

2.4.3.10 A Detailed procedure and acceptance criteria for fabrication, erection and commissioning of CFC including the safety procedures to be followed during erection shall be prepared by the Contractor.

2.4.3.11 Civil requirements

The foundations required for pipe supports, platforms and other minor civil works related with piping system is under scope of Contractor. The Contractor shall consider details like forces, moments acting on foundations for design.

2.4.4 Purchase of materials

All the materials such as flow components, instruments, pipes, pipe fittings, etc, [except the Free Issue materials (FIM)] are to be purchased by the Contractor. The general specifications of these items are given in Annexure 2C. The detailed purchase specifications for the individual items to be purchased including the make, model no., technical catalogues etc. shall be made by the Contractor. The purchase specifications of such materials and the sub-vendors from whom such materials are to be purchased are subject to review & approval by the Department.

2.4.5 Selection of sub-vendors: Refer Annexure2G.



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2.4.6 Supply of spares:

The following spares shall be supplied along with the CFC.

a. Spare materials for augmentation: Over and above the quantity required for the realization of CFC as per the requirements given in the contract, the spare materials such as flow components, pipes, pipe fittings, flexible hoses, etc shall be supplied as fully assembled (wherever applicable) stand-alone pieces. These spare materials are meant to be stored in the Department’s inventory for facilitating augmentation (not under the scope of the Contractor) to CFC so as to comply with unforeseen requirements in future. The spare materials shall also be subjected to the same tests specified for the like materials in this document. The spare materials of the flow components are listed in the respective Tables with suffix ‘SP’ in the tag number (e.g. DVP 100SP).

b. Spare parts and consumables for erection and commissioning: For the materials used in the CFC, the Contractor shall provide spare parts (like seat insert, body gasket, gland packing, plug stem assembly with bellows, seals for end fittings etc) and consumables (like PTFE tapes, etc.) to be replaced/ used during erection and commissioning (by the Contractor). It is the responsibility of the Contractor to account the required quantity till the completion of commissioning.

c. Spare parts and consumables for operation and maintenance: For the materials used in CFC, the Contractor shall also supply the spare parts (like seat insert, body gasket, gland packing, plug stem assembly with bellows, etc for valves, rupture discs, filter element, gaskets for flange joints and consumables, which are likely to be replaced/ used during operation and maintenance over a period of 2 years after commissioning and acceptance. The constituents and quantity of such spare parts shall be worked out, considering the factors such as normal wear & tear, fatigue cycles, creep, Mean Time Between Failures (MTBF), etc. However, the quantity of such spare parts shall be at least as 10% of the total requirement (rounded off to next higher integer) of each type of flow components required. For example, if in CFC one EP valve of globe pattern, stem extension, vacuum jacket, bellows seal, DN 150 size, 3.7 MPa MAWP, 77 to 350 K working temperature range, stainless steel material, then one set of spare parts such as seat, disc, body gasket, gland packing, plug stem assembly with bellows etc shall be supplied. For each type (size, burst pressure, etc.) of burst disc assembly, 3 numbers of spare discs shall be supplied. For each filter unit, one



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number of spare filter cartridge shall be supplied. The quantity of spares for the elastomeric seals used in the fluid lines shall be of 2 times of each seal and for spring energized metal rings (such as Helicoflex, Enerseal, etc.,) shall be of 2 times of each gasket. For bellows, the quantity shall be of 20% of each size of bellows used in SI circuits,. The spare parts allocated for this purpose shall not be consumed by the Contractor during erection and commissioning.

2.4.7 Instrumentation: The procurement of field Instruments like pressure transmitter, temperature sensors and flow meters required for monitoring and controlling process parameters of Cryo Fluid circuits of CTPT facility will be under the scope of Department. The mounting of pressure transmitter will be carried out by Department. The mounting of Flow meters, Surface & Fluid Temperature sensors shall be by the Contractor in the appropriate location as per the Detailed Engineering documents approved by the Department. The Department will free issue Flow meters, Surface & Fluid Temperature sensors to the Contractor. The contractor shall carry out necessary wiring between sensors and the vacuum feed through connector of outer jacket of SI piping. The required vacuum feed through connectors including supply of mating connector shall be the responsibility of contractor. The necessary suiting parts/ adaptors to install these instruments shall be fabricated by the Contractor. Department shall review the procedure prepared by the Contractor for the Installation of temperature sensors and flow meters with SI piping. Temperature during welding of the temperature sensors and flow meters with SI piping should be controlled to prevent them from overheating.

2.4.8 Free-issue material (FIM):

The Department will free issue the Flow meters, Fluid temperature

sensors and Surface temperature sensors (as per listing given in table

2.4.8.1, table 2.4.8.2, and table 2.4.8.3.) to the contractor for mounting

in the SI piping to be fabricated at Contractor's works. Contractor shall

arrange to collect the materials from Department’s Stores at

Mahendragiri (after submission of Bank Guarantee for equivalent

amount) and transport the materials to their factory. If any free-issued

material is damaged due to the Contractor, the value of it shall be

recovered by Department from the Contractor. However, replacement

for damaged material will be provided by Department.



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Table 2.4.8.1 Flow meters(Departments scope)

Sl. No

Tag number Line No. Fluid

medium Size Type

Unit Cost INR

Liquid Oxygen[LOX] System (Ref P&ID: Drawing CTPT/CFS/P&ID/100/R0)

1 DFQ 120 120-50-XXS-36 LOX DN25 Turbine 3,35,000

2 DFQ 121 120-50-XXS-36 LOX DN25 Turbine

3 DFQ 122 120-50-XXS-36 LOX DN25 Turbine

4 DFQ 160 160-150-10S-1.6 LOX DN100 Turbine 5,20,000

5 DFQ 161 160-150-10S-1.6 LOX DN100 Turbine


7 DFQ 180 180-80-10S-1.4 LOX DN65 Turbine 4,45,000



Liquid Hydrogen[LH2] System (Ref P&ID: Drawing CTPT/CFS/P&ID/200/R0)

10 DFQ 220 220-50-80S-17 LH2 DN65 Turbine 4,45,000

11 DFQ 221 220-50-80S-17 LH2 DN65 Turbine

12 DFQ 222 220-50-80S-17 LH2 DN65 Turbine

13 DFQ 260 260-150-10S-1.6 LH2 DN150 Turbine 10,50,000

14 DFQ 261 260-150-10S-1.6 LH2 DN150 Turbine


16 DFQ 270 270-80-10S-1.4 LH2 DN100 Turbine 5,20,000



Gaseous Hydrogen [GH2] System (Ref P&ID: CTPT/CFS/P&ID/500/R0)

19 DFQ 555 556-25-160-31 GH2 DN25 Vortex 1,20,000

20 DFQ 556 556-25-160-31 GH2 DN25 Vortex

21 DFQ 557 556-25-160-31 GH2 DN25 Vortex

Table 2.4.8.2 Fluid Temperature indicators (Departments scope)

S. No Tag number Line No. Fluid

medium Unit Cost

INR Liquid Oxygen[LOX] System (Ref P&ID: Drawing CFS-TD/LOX/P&ID)

1 DTI 110 110-50-10S-1.4 LOX

45,000

2 DTI 111 111-50-10S-1.4 LOX

3 DTI 120 120-50-XXS-36 LOX

4 DTI 121 120-50-XXS-36 LOX

5 DTI 122 120-50-XXS-36 LOX

6 DTI 123 120-50-XXS-36 LOX

7 DTI 125 120-50-XXS-36 LOX

8 DTI 126 122-40-10S-1.4 LOX

9 DTI 156 150-100-10S-1.4 LOX

10 DTI 160 160-150-10S-1.6 LOX

11 DTI 161 160-150-10S-1.6 LOX

12 DTI 162 160-150-10S-1.6 LOX

13 DTI 163 160-150-10S-1.6 LOX

14 DTI 165 161-65-80-18.4 LOX

15 DTI 180 180-80-10S-1.4 LOX 45,000



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Table 2.4.8.2 Fluid Temperature indicators (Departments scope)


medium Unit Cost

INR 16 DTI 181 180-80-10S-1.4 LOX

17 DTI 400 105-100-XXS-36 LOX

18 DTI 430 135-150-10S-1.4 LOX

Liquid Hydrogen[LH2] System (Ref P&ID: Drawing CFS-TD/LH2/P&ID) 19 DTI 210 210-50-10S-1.4 LH2

45,0000

20 DTI 211 211-50-10S-1.4 LH2

21 DTI 220 220-50-80S-17 LH2

22 DTI 221 220-50-80S-17 LH2

23 DTI 222 220-50-80S-17 LH2

24 DTI 223 220-50-80S-17 LH2

25 DTI 225 222-50-10S-1.4 LH2

26 DTI 255 250-100-10S-1.4 LH2

27 DTI 256 251-50-10S-1.4 LH2

28 DTI 260 260-150-10S-1.6 LH2

29 DTI 261 260-150-10S-1.6 LH2

30 DTI 262 260-150-10S-1.6 LH2

31 DTI 263 260-150-10S-1.6 LH2

32 DTI 265 261-65-80S-186 LH2

33 DTI 270 270-80-10S-1.4 LH2

34 DTI 271 270-80-10S-1.4 LH2

35 DTI 273 271-40-10S-1.4 LH2

36 DTI 500 204-100-10S-1.4 LH2

37 DTI 530 234-150-10S-1.4 LH2

38 DTI 570 570-40-10S-1.4 LH2

Gaseous Hydrogen [GH2] System (Ref P&ID: Drawing CFS-TD/GH2/P&ID) 39 DTI 558 556-25-160-31

GH2 45,000

40 DTI 559 556-25-160-31 GH2

41 DTI 560 556-25-160-31 GH2

42 DTI 561 556-25-160-31 GH2

43 DTI 557 556-25-160-31 GH2

Liquid Nitrogen [LN2] System (Ref P&ID: Drawing CFS-TD/LN2/P&ID) 44 DTI 310 310-40-10S-1.4 LN2 45,000

45 DTI 320 320-40-10S-1.4 LN2

46 DTI 321 320-40-10S-1.4 LN2

Table 2.4.8.3 Surface Temperature Indicators (Departments scope)


medium Unit Cost

INR Liquid Oxygen[LOX] System (Ref P&ID: Drawing CFS-TD/LOX/P&ID)

1 DTC 110 110-50-10S-1.4 LOX

45,000 2 DTC 111 111-50-10S-1.4 LOX

3 DTC 120 120-50-XXS-36 LOX

4 DTC 120 120-50-XXS-36 LOX 45,000



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Table 2.4.8.3 Surface Temperature Indicators (Departments scope)


medium Unit Cost

INR 5 DTC 121 120-50-XXS-36 LOX

6 DTC 123 120-50-XXS-36 LOX

7 DTC 126 122-40-10S-1.4 LOX

8 DTC 160 160-150-10S-1.6 LOX

9 DTC 161 160-150-10S-1.6 LOX

10 DTC 163 161-65-80-18.4 LOX

11 DTC 180 180-80-10S-1.4 LOX

12 DTC 181 180-80-10S-1.4 LOX

13 DTC 182 180-80-10S-1.4 LOX

14 DTC 183 180-80-10S-1.4 LOX

Liquid Hydrogen[LH2] System (Ref P&ID: Drawing CFS-TD/LH2/P&ID) 15 DTC 211 211-50-10S-1.4 LH2

45,000 16 DTC 220 220-50-80S-17 LH2

17 DTC 221 220-50-80S-17 LH2

18 DTC 223 222-5010S-1.4 LH2

45,000

19 DTC 260 122-40-10S-1.4 LH2

20 DTC 261 260-150-10S-1.6 LH2

21 DTC 263 261-65-80S-18.6 LH2

22 DTC 270 270-80-10S-1.4 LH2

23 DTC 271 270-80-10S-1.4 LH2

24 DTC 272 270-80-10S-1.4 LH2

25 DTC 273 270-80-10S-1.4 LH2

26 DTC 274 271-40-10S-1.4 LH2

27 DTC 275 271-40-10S-1.4 LH2

Liquid Nitrogen [LN2] System (Ref P&ID: Drawing CFS-TD/LN2/P&ID) 28 DTC 310 310-40-10S-1.4 LN2 45,000



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2.5 FABRICATION

2.5.1 Shop fabrication

SI piping in segments shall be fabricated at the Contractor’s/ factory to the extent possible. Considering P&ID, piping layout and equipment layout, valves shall be grouped as modules based on function/location/fluid with proper structural support. All such valve modules shall be fabricated, tested at Contractor’s site and brought to Department site. Adequate space shall be provided between each valve for easy access. All the weld joints in the fluid circuits shall be of Butt welded type and no Socket weld type is permitted except for outer pipes of Insulated lines. Only qualified welders and procedures as per code shall be employed. All the Butt welded joints in the inner lines of SI segments fabricated at Contractor’s factory shall be radiographed with X-ray to 2% sensitivity. The fabrication, testing, inspection, etc. of SI pipes at manufacturer’s factory shall be as per the technical specification given under Section A2.8.2 of Annexure 2-C. All the fabrication of adapters or pressure bearing parts in the CFC, shall be done only by using tested raw material such as rod/bar or plate. The material test certificate for the raw material used shall be provided to the Department and shall be traceable to the component used in the circuit.

2.5.2 Inspection:

All the bought-out materials, works during fabrication at the Contractor’s factory and fabrication & erection at the Department’s site shall be inspected by Third Party Inspection (TPI) agency. as given in Volume 1 section 1.6.7.

The broad scope of inspection shall be generally as follows. However, the detailed scope of inspection shall be given in the QAP to be provided by the Contractor.

a. Bought-out Materials

1. Review of the material test certificates.

2. Witnessing/review of tests given in QAP of specification of

individual components

3. Issue of inspection report and release note.

4. Stamping of all items.

b. Fabrication of SI pipe segments at the Contractor’s

factory



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1. Review and approval of the design calculations and

fabrication drawings.

2. Identification of raw materials and review of the material test

certificates for compliance with the relevant requirements.

3. Witnessing of welding procedure qualification and welder’s

performance qualification tests. If the welder already

possesses the performance qualification certificate, the TPI

agency shall review and authorize the same.

4. Witnessing / review of tests given in specification of these

items

5. Review of X-ray films of radio-graphic tests to find out the

defects in the weld joints.

6. Inspection at any stage of fabrication to ensure that the

methodology employed for the fabrication is in compliance

with the requirements of standards/ codes, practices, contract

specification and the approved documents.

7. Witnessing of Hydro/ Pneumatic pressure test, leak test and

cleanliness test .

8. Verification of health check of instruments installed in the SI

piping.

9. Issuance of Pre-Delivery Inspection (PDI) certificate and

stamping.

Upon completion of fabrication, the Contractor shall organize Pre-Shipment Review (PSR) meeting at their office/ factory, in which the Contractor, the Department’s representative(s) and the TPI agency shall participate. Upon satisfactory review of the test certificates and inspection reports of fabrication, the Department will accord the shipment clearance.

The Department shall have the right to waive their participation in the Pre-shipment Review by a notification to the Contractor within 2 week of the receipt of intimation from the Contractor. In such case, the documents mentioned in Section 2.7.d shall be sent to the Department. Upon review of the documents, the Department will issue the shipment clearance.

c. Fabrication & Erection at Department site

1. Identification of the materials such as pipes, pipe fittings, etc and review of the test certificates for compliance with the contract specification.

2. Verification of health check of instruments installed in the SI piping.



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3. Witnessing of welding procedure qualification and welder’s performance qualification tests. If the welder already possesses the performance qualification certificate, the Department will review and authorize the same.

4. Review of X-ray films of radio-graphic tests to find out the defects in the weld joints.

5. Inspection at any stage of fabrication to ensure that the methodology employed for the fabrication is in compliance with the requirements of standards/ codes, practices, contract specification and the approved documents.

6. Witnessing of Hydro/ Pneumatic pressure test, leak test and cleanliness test of the system during fabrication and erection.

It shall be Contractor’s responsibility to arrange & co-ordinate with the TPI agency. The price towards TPI charges shall be included in the cost of CFC. Apart from inspection of works by TPI agency, the Department shall have the right to conduct inspection of works carried out by the Contractor at the Contractor’s/ Sub- vender’s works and also during erection & commissioning at Department site.

2.5.3 Transportation, Storage and Handling

Refer Section 1.3.3.8 of Volume 1.



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2.6 ERECTION AND COMMISSIONING AT DEPARTMENT SITE

SI pipeline segments and valve modules shall be fabricated at Contractor’s site as far as possible and erected & commissioned at Department site. The site erection involves fabrication works primarily by welding. The other joints such as flanges, threaded unions, etc. may be resorted to in such cases where removal of the joints becomes inevitable like pressure gauges, safety relief valves, burst disc devices, etc. All the works including inspection applicable to site (like erection of pre-fabricated SI pipeline segments, joining of SI segments by carrying out field-welded joints, providing supports, etc.) shall be carried out by the Contractor.

2.6.1 Site Fabrication

All the items including flow components, pipes etc. shall be checked for foreign matter and purged. The site fabrication mainly involves the following woks;

2.6.1.1 Welding

All the welding of SS pipelines & materials shall be performed by Gas purged Tungsten Arc Welding (GTAW) with gaseous Argon (99.995% purity) as the purge medium. In case of welding very thick SS pipelines, welding up to the initial 15 mm thickness shall be performed by GTAW and for the remaining thickness by Shielded Metal Arc Welding (SMAW) with gaseous Argon/ Gaseous Argon-Nitrogen (2-3%) mixture as the purge medium. The welding processes shall comply with the requirements of ASME Section IX. All the welding should be done only by qualified welders for both pipelines and structural works. The welding procedure qualification and welder’s performance qualification shall be done as per ASME SectionIX.

2.6.1.2 Tests

The tests for SI piping segment & flow components are given under specification of individual items under section A2.C.2 of Annexure-2C. The following tests shall be performed during fabrication of pipelines and wherever applicable.

a. Dye penetrant test:All the butt and mitre welded joints shall be

subjected to DPT at the root pass.

b. Radio-graphic test: All the weld joints in the fluid circuits shall be of Butt welded type and no Socket weld type is permitted except for outer pipes of Insulated lines.



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The requirements of radiography of butt welded joints shall be as follows:

100% radiography for all the butt joints including inner lines of SI circuits for LH2, LOX, LN2 & Cold GH2.

No radiography for outer-jackets of SI piping. Note: Generally, the radio-graphic tests shall be done with

X-rays to 2% sensitivity. Alternatively, the gamma rays may be used in locations where the joint is inaccessible to X-ray equipments with the approval of the Department. The Department’s discretion as to whether a joint is inaccessible to X-ray shall be final. All the radio-graphic films shall be submitted to the Department along with joint identification numbers marked on the films after review by TPI. The isotope for gamma ray shall be stored in a temporary shed as per AERB guidelines.

c. Pneumatic pressure test: All the pipelines after final assembly

with flow components shall be subject to pressure test with GN2 at 1.1 times the MAWP. During pressure test, care shall be taken to protect the bellows from expanding by welding half jackets & SS strips.

d. MSLD leak test: All the pipelines (including the jacket pipes of SI pipelines) shall be subject to leak test with GHe Mass Spectrometer Leak Detector (MSLD) to validate leak tightness of 1E-07 Pa m3/s.

e. Vacuum Retention test: After evacuation of the jacket of SI pipelines to < 1 Pa, the stabilised vacuum pressure shall be periodically recorded over 72 hrs. The permissible rise in vacuum pressure shall not exceed the value predicted by the specified permissible leak rate.

f. Internal Surface oil contamination test: The surface oil content of the pipelines shall be measured by mopping the surface and transferring the oil contaminant to a solvent like heptane/acetone/IPA and the contamination measured in fluorimeter shall be 200 mg/m2.

2.6.1.3 Super Insulation

The SI piping circuits, after fabrication & ambient testing of the core pipe, the multi layer shall be wrapped, suitable adsorbents placed at appropriate locations and the jacket pipe fabricated. The vacuum valves & seal-off valve shall be welded on the jacket pipe. After leak test, the jacket shall be evacuated with proper baking (by heating the outside surface of the jacket pipe by electrical heater tapes and by passing hot Air through the core pipe).



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2.6.1.4 Painting

All the pipelines shall be painted with identification bands of 100mm width at 2m span based on the following colour code scheme: LH2: Brick red; LOX: Black; LN2: Olive green; GH2: Signal red; All the SS pipelines, flow components and instruments shall be provided with identification name plate displaying, in bold letters, their tag numbers. All the structural materials shall be painted in grey colour and hand rails in yellow colour. Prior to painting, the surfaces shall be suitably prepared. The painting shall comprise 2 coats of primer (like red oxide) and 2 coats of chlorine-free synthetic enamel paint.

2.6.2 Erection The pre- fabricated SI segments & valve modules shall be erected by the contractor at Purchaser’s site. Before installation, all the pipelines and flow components shall be visually inspected for any entry of foreign particles. The pipelines shall be purged to remove the foreign particles. All piping circuits shall be connected, if required by welding and installed by Contractor at site as per approved layout. All the machineries required for erection such as welding equipments, grinding machine, drilling machines, radiographic equipments, etc, consumables such as Gaseous Argon, Gaseous Argon – Nitrogen(2-3%) mixture, hacksaw blades, etc and tools & tackles, etc. shall be arranged by the Contractor. The fasteners, washers, gaskets, etc. to be used shall be of SS 304 material and of relevant ASME standard.

2.6.2.1 Minor Structural Works

The structural works under CFC to be done by the Contractor shall include design, supply of materials, fabrication, assembly and erection of all types of structures like pipe supports, pipe line cross over bridges etc. Design & scheme shall be submitted to Department for approval.

2.6.2.2 Minor Civil Works

The civil works under CFC shall be done with Plain Cement Concrete (PCC), Reinforced Cement Concrete (RCC) and brick masonry, as required. The minor civil works are required for:

a) Grouting of pipe supports, structural works, etc b) Breaking and making holes across walls for laying pipelines c) Providing RCC pedestal for pipe supports wherever needed as

mutually agreed by the Contractor and Department.



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All the materials such as HYSD steel reinforcement rods, binding wires, brick, cement, sand, gravel, etc shall be arranged by the Contractor. The composition of concrete shall be as follows:

a) PCC – Cement: Fine aggregate: Coarse aggregate (20mm) = 1:3:6

b) RCC – Cement: Fine aggregate: Coarse aggregate (20mm) = 1:1.5:3

2.6.3 COMMISSIONING After completion of erection and ambient testing of all the fluid circuits, the following commissioning tests shall be carried out. The contractor shall prepare the systems and generate the operating procedure. The readiness of the systems and the procedure would be reviewed and approved by the Department. The fluid circuits shall be commissioned in two phases jointly by the Department and the Contractor. The fluids such as LH2, LOX, LN2, GH2, GHe and GN2 shall be provided by the Department free of cost.

2.6.3.1 Functional Tests The individual sub-systems of CFC shall be validated independently in static condition (without flow) using Liquid Nitrogen (LN2). The procedure shall comprise the following:

a. Medium substitution with GN2 and analysis to comply with the following specification:

- Moisture : < 20 ppm

- Oil : < 3 mg/ Nm3

- Particulate contaminants : Class 6 of SAE 4059E b. Functional check of all flow components (including evaluation of

response time of EP and control valves) c. Verification of all instruments d. Chilling & Filling of Cryo Fluid Circuits of CTPT with the

simulating fluid and pressurizing to 80% of Maximum Allowable Working Pressure (MAWP) to validate thermal and structural integrity.

e. Post test global leak check of inner pipeline of CFC at 80% MAWP using MSLD (at ambient temperature)

2.6.3.2 Performance Validation Trial Run (PVTR)

The Cryo Fluid Circuits of CTPT facility shall be qualified together with other systems of CTPT in dynamic (flow) condition with the actual working fluids. The procedure shall comprise the following:



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a. Chilling & Filling of the CFC along with other systems with the respective working fluids and pressurizing to 80% of MAWP to validate thermal and structural integrity.

b. Flow trial to evaluate the flow characteristics of the circuits such as pressure drop and temperature rise at the working flow rates.

c. Functional validation of all flow components and instruments.



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2.7 DOCUMENTATION:

The following documents are to be provided by the Contractor in English at different phases specified thereupon. Also soft copies of all documents shall be provided in CDs.

a. Process design review:

The Contractor shall submit a document listing their comments on the design document provided (On award of contract) by the Department. If the Contractor proposes any alternative scheme or sizing, the detailed justification, along with calculation wherever necessary, shall be submitted. In case the Contractor proposes to employ alternative codes/standards, different from those specified in this document, the copies of such codes/standards in English shall be submitted.

b. Detail Engineering review: The detail engineering documents shall be submitted to Department in advance for perusal. The date of DER meeting shall be mutually agreed upon. Contractor shall organize the DER meeting at their office/factory, in which the Department’s representative(s) will participate. The level of information to be provided in these documents shall be considering the requirements given in this section A2.C.3.

a. Design calculations, GA drawings and fabrication drawings approved by TPI agency for SI pipelines.

b. Pipeline layout drawings c. Pipeline isometric drawings d. Report on piping stress and flexibility analysis including

Calculations for sizing and positioning of thermal compensators

e. Design of pipe supports including bowing effect f. Chill-down analysis g. Estimation of pressure drop h. Estimation of temperature rise i. Calculation for sizing of safety devices, control valves, burst

discs, etc. j. Design of joints k. Purchase specification of flow components, etc l. List of sub-vendors for each item m. Quality Assurance Plan (QAP) n. Procedure and acceptance criteria for fabrication at

Contractor’s premises. o. Civil works requirements p. Procedure and acceptance criteria for fabrication, erection and

commissioning at Department site. q. List of spares r. Safety procedure s. Static earthing scheme.



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All the design documents & updated PI&Ds based on detail engineering review shall be provided.

c. Pre Shipment Review During the Pre-Shipment Review (PSR), the following documents shall be submitted:

1. As-built GA and fabrication drawings 2. Test certificates and inspection reports of the materials such

as flow components, pipes, pipe fittings, instruments (including the calibration certificates), etc. Each page of the certificate shall be duly counter-signed and stamped by the TPI agency.

3. Test certificates and inspection reports of fabrication (including the radiographic films)

4. List of spares 5. PDI certificate by the TPI agency 6. Estimation of quantity of fluids to be supplied by the

Department during erection and commissioning 7. Instruction manuals for installation, operation, maintenance

and troubleshooting of all flow components of CFC. 8. Safety procedures for fabrication, erection and

commissioning works at Department’s site. d. Before start of Fabrication and Erection at Department site

The following documents shall be submitted:

1. Procedure & acceptance criteria for fabrication & erection 2. Welding Procedure Specification (WPS) and Procedure

Qualification Record (PQR) 3. As-built pipeline layout drawings 4. As-built pipeline isometric drawings 5. List of spares 6. Certificates of tests (including radio-graphic films) done

during erection

7. Inspection report byTPI agency 8. Warranty certificate along with performance guarantee.

e. Commissioning At the end of commissioning, the following documents shall be submitted 1. Certificates of tests done during commissioning

2. Inspection report by the Department 3. Final acceptance report (jointly between the Department and

the contractor) 4. Warranty certificate along with performance bank guarantee.

5. Detailed documents for;

- Operation to comply with the specified test objectives.

- Maintenance (routine, preventive and break-down)

- Trouble-shooting



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Annexure 2A

A2.A EQUIPMENT LAYOUT



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Annexure 2B

A2.B.1 PROCESS AND INSTRUMENTATION DIAGRAM FOR LOX SYSTEM



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A2.B.2 PROCESS AND INSTRUMENTATION DIAGRAM FOR LH2 SYSTEM



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A2.B.3 PROCESS AND INSTRUMENTATION DIAGRAM FOR GH2 SYSTEM



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A2.B.4 PROCESS AND INSTRUMENTATION DIAGRAM FOR LN2 SYSTEM



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Annexure 2C

A2.C SPECIFICATION OF FLOW COMPONENTS OF CFC

Cryo Fluid Circuits consist of Super Insulated (SI) pipelines and Flow components such as; EP valves, Control valves, Manual valves, Safety relieving systems (Safety Relief Valves & Burst Disc) , Filters, Flexible hoses, pipes & fittings etc. The specifications of these SI pipe lines and flow components that have to be procured, fabricated and installed by the contractor as part of scope of CFC are detailed in this section.

A2.C.1 TECHNICAL SPECIFICATION OF STAINLESS STEEL PIPES

Type : Seamless pipes

Nominal pipe size

: DN10 to DN250

Schedule number : As per P&ID

Total length : As given P&ID

Length of individual pipe pieces

: In random lengths ranging from 3 to 6 m

Material : ASTM A 312 TP 304L/ 316L /321 or equivalent

Dimensional standard

: ASME B 36.19 up to SCH 80S/ ASME B36.10 above SCH 80S

TESTS

a. Visual

examination

: All the pipes shall be visually examined for workmen-like finish.

b. Dimensional

check

: All the pipes shall be subject to dimensional check.

c. Chemical

analysis

: One specimen from each heat shall be subject to detailed chemical analysis as per ASTM A 751.

d. Mechanical tests : One specimen from each lot shall be subject to tests for mechanical properties as per ASTM A 370.

e. Pressure test : All the pipes shall be hydraulically pressure-tested with Water as per ASTM A 530.



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f. Ultra-sonic test : All the pipes of size ≥ DN 25 shall be subject to Ultra-sonic test (100 %) by appropriate method as per ASTM E 213.

g. Eddy current test/

Ultra-sonic test

: All the pipes of size ≤ DN 20 shall be subject to Eddy current/Ultrasonic test as per ASTM E 426/ ASTM E 213.

h. Flattening test : Pieces of pipes of length 63.5 mm (2.5”) cut from the ends of 5 % of pipe lengths per lot shall be subject to flattening test as per ASTM A 530 in 2 steps to prove ductility and soundness.

i. Inter-granular

corrosion test

: One specimen per lot shall be subject to inter-granular corrosion test as per ASTM A 262 (practice A/E).

j. Cleanliness : The pipes shall be pickled, passivated and dried before delivery. The ends shall be blanked off by dust-tight plastic caps.

k. Marking : The pipes shall be marked as per ASTM A 700.

QAP: The QAP is given in Table A2.C.1.1



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Table A2.C.1.1: QUALITY ASSURANCE PLAN FOR PIPES

S No

Test Object tested

Characteristic sought for

Sample size

Test procedure

Acceptance criterion

Form of record

Pre-Delivery Inspection (PDI) Test performed by

Test witnessed by

Record reviewed by

1. Visual examination

Pipes Surface finish

100 % Visual examination

Workmen-like finish

Inspection report

Vendor - Inspector

2. Chemical analysis

Specimen from pipes

Chemical composition

1 per heat ASTM A 751

ASTM A 312

Material certificate

Vendor’s or Third party laboratory

- Inspector

3. Mechanical test

Specimen from pipes

Mechanical properties

1 per lot ASTM A 370

ASTM A 312



- Inspector

4. Dimensional check

Pipes Dimensions

100 % Metrology ASME B 36.10/ 36.19

Inspection report

Vendor - Inspector

5. Pressure test

Pipes Structural integrity under stress

100 % ASTM A 530

ASTM A 530

Test certificate

Vendor Inspector Inspector

6. Ultra-sonic test

Pipes of size ≥ DN 25

Internal flaw detection

100 % ASTM E 213

ASTM E 213

Test certificate


7. Eddy current test

Pipes of size ≤ DN 20


100 % ASTM E 426

ASTM E 426

Test certificate


8. Flattening test

Specimen from pipes

Ductility and soundness

5 % ASTM A 530

ASTM A 530

Test certificate

Vendor - Inspector



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Table A2.C.1.1: QUALITY ASSURANCE PLAN FOR PIPES

S No

Test Object tested


Sample size

Test procedure


Form of record


Test witnessed by

Record reviewed by

9. Inter-Granular Corrosion test

Specimen from pipes

Susceptibility to corrosion

1 per lot ASTM A 262 (practice A/ E) /

ASTM A 262 (practice A/ E)

Test certificate


- Inspector

10. Cleanliness

Pipes Cleanliness for Oxygen service

100 % CGA G-4.1/ ASTM G 93

CGA G-4.1/ ASTM G 93

Certificate Vendor - Inspector

Notes 1. Inspector: Third party inspection agency



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A2.C.2 TECHNICAL SPECIFICATION OF SUPER INSULATED (SI) PIPING

DESIGN DATA

1. Type of circuits : Pipe lines of double walled construction with Super insulation (SI) as shown in Process & Instrumentation Diagrams.

2 Insulation : Evacuated multi-layer Insulation (Super Insulation) with Aluminised Mylar /Aluminum foil with Glass fiber. Spacers, suspensions shall be of suitable low-thermal-conductivity materials.

3 Service fluid : As given Table A2.C.2.1

4 Working temperature : As given Table A2.C.2.1

5 Design Pressure : As given Table A2.C.2.1

6 Design code : ASME B 31.3 (Process Piping Code)

7 Heat-in leak rate from ambient to fluid through insulation in straight pipe section (referred to conditions of Liquid Nitrogen (LN2) in inner pipe line)

: Pipeline size

Heat influx (W/m length)

DN 25 0.5 DN 40 0.7 DN 50 0.8 DN 65 1 DN 80 1.2

DN 100 1.3 DN 150 1.7

The detailed design calculation for Heat-in-leak rate for each segment shall be provided by the Contractor

8 Nominal size and thickness of inner pipe

: As given in Table A2.C.2.1 for S.I pipe line segments.

9 Nominal size and thickness of jacket (outer) pipe

: The size of outer pipe for S.I pipe line segments shall be designed and specified by the Contractor. The outer pipe shall be designed for 2



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bar (a) external pressure with full vacuum inside.

10 Length : Approximate length is given in Table A2.C.2.1. Actual length will be based on the piping layout & detailed isometric piping fabrication drawings to be prepared by the Contractor during detail engineering.

11 The relief pressure of vacuum seal-off cum safety valve in the vacuum jacket of the each piping segment

: As per Manufacturer's standard (> 0.05 MPa, g) & the value shall be provided to Department during detail engineering for approval.

12 Pipes & Pipe fittings : Seamless pipes for size ≤ DN250 & Longitudinal seam-welded pipes for nominal pipe size ≥ DN 300 For the outer jacket pipes, Seamless pipes shall be selected for straight lengths. Other outer jackets may be of seam-welded type.

Helium Leak Tightness

I) Individual joints/bellows of SI pipe lines:

a) Inner pipe & Jacket pipe weld joints

: ≤1 x 10-8 Pa m3/s

b) Thread / flange joint, etc (other than weld joint)

:

≤1 x 10-6 Pa m3/s

c) Bellows : ≤1 x 10-8 Pa m3/s

II) Global leak of each pipe line segment (Each vacuum cavity):

a) Atmosphere to vacuum jacket

: ≤1 x 10-8 Pa m3 /s

b) Inner pipe to vacuum jacket

: ≤1 x 10-8 Pa m3/s



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c) Stabilized vacuum level in jacket (insulation) at atmospheric temp.

: <1 Pa

Material of construction:

Pipes (Core and jacket pipes)

Bellows

: :

ASTM A 312 TP 304 L / 316L / 321 SS 321/316 Ti /Hastalloy /Inconel

Ferrite index of Bellows : ≤ 8 Bellow Sleeves,

pipe stubs : SS304L / 316L/ 321

Butt weld fittings : ASTM A 403 WP 304 L / 316L Flanges and socket weld

fittings : ASTM A 182 F 304 L / 316L

Bolts : ASTM A 193 B 8 Nuts : ASTM A 194 Gr 8

Dimensional standards:

Pipes : ANSI B 36.19/ ANSI B 36.10 Flanges : ANSI B 16.5 Socket weld pipe fittings : ANSI B 16.11 Butt weld pipe fittings : ANSI B 16.9 Welding Process:

• All the welding both in the inner pipe as well as in the outer vacuum jacket pipe shall be performed by Gas purged tungsten arc welding (GTAW/TIG) with gaseous Argon (better than 99.99% purity) purging.

• All the weld joints in the fluid circuits shall be of Butt welded type and no Socket weld type is permitted except for outer pipes of Insulated lines.

• All the welding at Contractor’s works as well as at Department's work site shall be performed by qualified welders. The welding processes shall comply with the requirements of Section IX, ASME BPV code. Welding Procedure Specifications (WPS) shall be provided by the Contractor. The welding procedure qualification and welders’ performance qualification (WPQ) shall be done as per Section IX, ASME BPV code. The welder’s performance qualification (WPQ) certificate issued by a competent authority shall be furnished.



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• During welding of the flow components, temperature control near the weld joints needs to be emphasized (i.e. temperature shall be ≤ 350K at the distance of 100 mm from the joint being welded) in such a way that any part of components (Eg. valve seat, flow meters) in the pipeline next to the welding spot are not affected. The details of the same shall be provided by the Contractor during DER.

• During welding of the instruments such as temperature sensors and flow meters, temperature control near the weld joints needs to be controlled by providing proper measurements (i.e. temperature shall be precisely controlled ≤ 350K at the specified locations approved by Department). The detailed temperature controlled welding procedure shall be provided by the Contractor during DER.

• Welding rods shall be chosen in accordance with the relevant standards. Welding rods chosen shall be suitable for material of free issue materials also. Contractor shall provide the details of welding rods chosen during detail engineering phase to the Department for approval.

Bellow compensators:

The thermal compensation of the inner pipes for chill-

down shall be provided by bellows in the inner or outer pipe for low pressure circuits and the same will be finalized during Detail Engineering Review. U bends are allowed for this purpose in high pressure circuits only. The ends of vacuum jackets shall be connected to the inner pipe line with heat bridges. The bellows shall be provided with stainless steel sleeves both inside (to reduce fluid frictional pressure drop) and outside (to provide axial guide). The bellows in the inner line shall be provided with stopper arrangement with SS fasteners to prevent it from expanding axially more than the stipulated value. Bellows cyclic life shall be more than 5,000 cycles. Calculations for positioning of bellows in the inner pipes shall be provided during detail engineering review. Bellows shall be bought from reputed manufacturers; approval of the same shall be got from Department during detail engineering. Drawings & Detailed design calculations with details such as Axial expansion, length, no. of plies, cycles of operation, Axial spring rate, Lateral spring rate, Torsional spring rate, Limiting internal design pressure based on column instability, Limiting design pressure based on in plane instability, Bellows effective area, stresses etc (based



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on EJMA / relevant standards) for each type & size of bellows shall be submitted to the Department for approval during detail engineering. Ferrite index shall be less than or equal to 8 for the bellows.

Individual segment & it’s Outer Jacket of SI pipe lines Overall SI pipeline shall be divided in to individual segments. Each segment of SI pipelines shall be of suitable length and provided with Vacuum valves and vacuum seal off valve. The exact segment length & Number of segments will be finalized during detail engineering. The segments which can be fabricated in full at the factory shall be done at the Contractor’s site / factory itself and rest of the segments will be partly fabricated at Contractor’s site and completed in full at site. All the pre-fabricated segments shall be erected, installed & acceptance tested at Department’s site.

In the fabrication of every segment, after the fabrication

of the core pipe, the multi layer insulation materials shall be wrapped, spacers & suitable adsorbents placed at appropriate locations and the jacket pipe fabricated. The manual vacuum valves and seal off valve shall be welded suitably in every segment of the jacket. After leak test, the jacket shall be evacuated with proper baking (by heating the outside surface of the jacket by electrical heater tapes and by passing hot dry Air through the core pipe/vessel). After achieving stabilized vacuum pressure, the jacket shall be sealed.

Configuration of spacer (to support inner pipe line within

outer pipe line) & its material of construction shall be provided by the Contractor during detail engineering review. Also the location of fixed stoppers at discrete points in SI lines shall be finalized during DER. Details of MLI materials, its layer density, properties like thermal conductivity, etc, shall be provided by the Contractor during detail engineering.

Vacuum seal- off cum safety valve Every segment of the vacuum jacket of the SI pipe-lines shall be provided with a welded vacuum seal off cum safety valve for relieving pressure > 0.05 MPa (g). The specification of vacuum seal off valve shall be as follows; Helium leak tightness: ≤1 x 10-9 Pa m3/ s. Material of construction: Austenitic Stainless Steel Vacuum seals : Viton/Neoprene



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Detailed specifications & drawing of Vacuum seal off valve indicating its manufacturer shall be provided to the Department for approval during detail engineering. The seal off valves used on all the piping segments shall be of the same dimension.

Manual Vacuum valves : Every segment of the vacuum jacket of the SI pipe-lines shall be provided with a welded manual vacuum valve (size : DN25 for SI line size of ≤ DN50 & DN50 for SI line size of > DN50) for evacuation and another valve of size DN15 for vacuum measurement with brief specifications given below. Specifications: Leak rate (Body, seat) < 1 x 10-9 Pa m3/s Type Bellow sealed manual valve Pressure range 1 x 10-9 to 200 KPa

( absolute) Service life 100000 cycles Operating temperature 250 to 350 K Materials of Construction

Body ASTM A182F 304 L / 316L / 321 For ≤DN40 ASTM A351 CF3 /CF3M For ≥DN50

Bellows SS 321/316 Ti /Hastalloy /Inconel

Seat To be suitably selected and specified by the bidder during DER

End connection DN 50 ISO KF for DN50 size DN25 ISO KF for DN25 size & DN16 ISO KF for DN15 size valve with suitable end fittings like centering ring, O rings, C clamps, SS fasteners and mating flange

Testing The following are the tests to be performed. A detailed Quality Control Plan (QAP), in line with the following, shall be prepared by the Contractor and submitted for review & approval by Department during detail engineering.



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1. Tests to be carried out for raw materials & bought out

components required for fabrication at Contractor’s works & Department site:

a) Pips & Pipe fittings: All the SS pipes and pipe fittings used in fabrication of SI circuits shall be tested as per Specification given for SS pipes & pipe fittings under A2.C.2.1 & A2.C.2.3.

b) Bellow compensators:

• Chemical & Material test • Pressure test: All the bellows shall be subjected

to pneumatic pressure test with dry air or gaseous Nitrogen at 1.1 times MAWP of the SI pipeline.

• MSLD leakage test: The global leakage rate across individual bellows before installation shall be measured by sniffer probe method with gaseous Helium Mass Spectrometer Leakage Detector (MSLD) at MAWP with 80% GN2 + 20% GHe mixture.

• Welding joint test (wherever applicable): All butt welding joints in the bellows shall be subjected to radiographic test with X-rays or gamma rays to 2% equivalent sensitivity as per Section IX, ASME. All the socket welding joints shall be subjected to dye-penetrant test.

• Cyclic life test: Bellows with 5000 cycles which are in standard manufacturing range of the Manufacturer shall be used. Manufacturers compliance certificate based on Prototype test shall be provided

• Ferrite index: shall be measured and it should be less than 8. The same shall be included in test certificates provided.

• Cleanliness: All the interior flow surfaces of the bellows assembly shall be degreased and cleaned to Oxygen service standards.

c) Relief pressure test for seal off valve: Shall be relief pressure tested as per relevant standards.

Manufacturer’s test certificates for all the above tests certified by the Third Party Inspection Agency shall be submitted to Department for review.



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2. Tests to be carried out for all the S.I pipe line segments fabricated at Contractor’s works.

a. Weld joint tests 1. For Inner(core) pipe:

All the butt weld joints shall be subjected to DP test at the root weld run and 100% radio-graphic test with X-rays to 2% sensitivity at the final weld.

2. For outer (jacket) pipe:

All the weld joints shall be subjected to DP test.

Note: For the radiographic tests on the piping segments at Contractor’s works, Department reserves the right to have full access to examine and verify the X-ray films. All the x-ray films shall be handed over to the Department.

b. Mechanical cleaning:

All the metallic surfaces with scales and newly welded surfaces shall be cleaned by scrubbing with SS wire brush. The loose particles generated by mechanical cleaning shall be removed by blowing with compressed dry air and sucking.

c. Pneumatic Pressure test: All the piping segments fabricated at Contractor's works shall be subjected to pneumatic pressure test at 1.1 times MAWP using Dry Air (or) Gaseous Nitrogen (GN2). There shall be no pressure drop during the hold period. Extra care should be taken for preventing expansion of bellows while testing.

d. Leak test (at ambient temperature):

d1. The weld joints in the inner line before providing vacuum jacketing, shall be leak checked by sniffer probe method using He MSLD by providing a shroud over the individual weld joints and charging the inner line with 20% GHe + 80% GN2 at its MAWP. The leak tightness shall be better than 1 x 10-8 Pa m3/s.

d2. After providing the vacuum jacket, while conducting the

global leak check, the internal volume shall be charged to its MAWP with a mixture of 80 % GN2 + 20 % Gaseous Helium and the annular volume between the inner pipeline and the outer pipeline be evacuated and connected to MSLD. The leak tightness shall be better than 1 x 10-8 Pa m3/s.



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d3.While leak-testing the outer jackets, either shroud method or Helium spray method shall be used. In shroud method, the exterior surface of the outer pipeline shall be shrouded by synthetic bag and charged to 1.5 bar,(a) with Gaseous Helium and the annular volume between the inner pipeline and the outer pipeline shall be evacuated and connected to MSLD. In Helium spray method, GHe shall be sprayed on to the weld joints and the annular volume between the inner pipe line and the outer pipeline shall be evacuated and connected to MSLD. The leak tightness of individual joints shall be better than 1 x 10-8 m3Pa/s.

e. Vacuum Retention test:

After evacuation of the jackets of each segment of SI pipe-lines, the stabilized vacuum pressure shall be periodically recorded over 72hrs. There shall be no deterioration in vacuum level and it should stabilize at < 1 Pa (at atmospheric temperature).

f. Cold shock test:

After successful completion of vacuum retention test, all the piping segments (which are evacuated and sealed at Contractor’s site) shall be subjected to cold shock test with LN2 to observe for any structural defects or sweating/ frosting on the jacket. The vacuum pressure in annular space shall be checked before and after (on completion of warming up to atmospheric temperature) cold shock test and there shall be no deterioration in vacuum level.

g. Cleaning for Oxygen service:

All the pipelines that are pre-fabricated at Contractor’s premises shall be cleaned to Oxygen service standards as per CGA G-4.1 or ASTM G 93 prior to dispatch to Department’s site.

h. Preservation:

The ends shall be blanked off properly during transportation and storage. The pipe-lines shall be kept pressurised with GN2 or dry Air at ~ 0.15 MPa (a) during transportation and storage.

Test certificates for all the tests mentioned above, approved by Third Party Inspection Agency shall be provided to Department for review before despatch.



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INSPECTION: Inspection at Contractor’s site: Inspection of all the raw materials, bought-out materials required for fabrication at both Contractor’s & Department’s site, fabrication work at Contractor’s site, tests & cleaning performed at Contractor’s works shall be inspected and certified by Third Party Inspection (TPI) agency. The broad scope of inspection shall be as follows.

a. Identification of all the materials such as equipments, flow

components, instruments, gauge head, pipes, pipe fittings, bellows, etc, and review of the test and calibration certificates for compliance with the order specifications.

b. Witnessing of welding procedure qualification and welder’s

performance qualification tests. If the welders already possess the performance certificate, the Quality Inspector of Contractor Quality Control division shall review WPS, PQR & WPQ and authorize the same.

c. Review of all X-ray films of radio-graphic tests for possible

defects in the weld joints. d. Inspection at any stage of fabrication to ensure that the

methodology employed for fabrication is in compliance with the requirements of standards/ codes, practices, purchase order specification and the approved documents.

e. Witnessing of DP tests, pressure test, leak test (inner & outer

lines), vacuum stabilisation test, cold shock test, cleanliness & other tests carried out by the Contractor.

f. Witnessing of weld joint set up at random. g. Verification of cleaning for oxygen service for the pipeline to a

procedure accepted by the Department. h. Inspection report and final release note for all raw materials,

bought out components, etc and fabricated segments of SI pipelines shall be issued by the Third Party Inspection Agency.

Apart from inspection by TPI agency, the Department‘s representative(s) shall inspect the system at any stage of fabrication. Upon completion of fabrication, the Contractor shall organise Pre-Shipment Review (PSR) meeting at their office/



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factory, in which the Contractor, the Department’s representative(s) and the TPI Inspector shall participate. Upon satisfactory review of the test certificates and inspection reports of fabrication, the Department will accord the shipment clearance.

SITE WORKS: The Contractor shall transport, unload and store the pre-fabricated SI pipeline segments safely at Department’s site. The erection of pre-fabricated SI pipeline segments, completion of fabrication of SI piping circuits by carrying out field-welded joints, providing supports and inspection & quality control shall be the Contractor’s responsibility. 1. Erection & Site fabrication: All the works applicable to erection and fabrication at

Department’s site shall be carried out by the Contractor. All the technical requirements delineated above for fabrication & testing (Weld joint test, Pressure test, leak test & vacuum retention test, etc) at Contractor’s premises shall also apply to the works done at Department’s site. During erection at the Department’s site, the pre-fabricated segments shall be joined (by welding) and vacuum jacket (joint box) to be made around the joint. Appropriate Nos. of joint boxes shall be looped and provided with common vacuum seal-off cum safety valve, vacuum evacuation valve and a vacuum measurement isolation valve.

2. Cleaning:

The cleanliness of the pipeline for LOX service during welding at the Department site will be checked by taking sample using calico cloth wetted in Iso-Propyl Alcohol/Heptane and the contamination must be less than 200 mg/m2. The spectro-fluorimeter required for checking contamination level will be provided by the department.

Inspection at Department’s site: a. During Erection and fabrication

All Inspection and Quality control of works to be carried out during erection and fabrication of CFC at Department’s site shall be carried out by TPI agency arranged by the Contractor.



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b. During Acceptance tests

The necessary Inspection works during performance test at Department’s site shall be done by Department’s Quality Control Division.

3. Acceptance Tests:

The following Acceptance tests are to be carried out for CFC after its final fabrication and erection at Department site. The necessary fluids such as GHe, GN2, LN2, LOX and LH2 required for conducting acceptance tests will be provided by Department.

3.1 Pressure test with LN2: All the SI piping assembly shall be

subjected to static pressure test with LN2 at its 80% of MAWP. During this test, no frosting should occur on the outer pipe. The vacuum pressure in annular space shall be checked before and after (on completion of warming-up to atmospheric temperature) this test and there shall be no deterioration in vacuum level. On successful completion of pressure test with LN2, the leak tightness across inner pipe in all SI pipeline assembly shall be tested with GHe MSLD at 80% of MAWP and the leakage rate shall be ≤ 1 x 10-7 Pa m3/s.

3.2 Performance test with actual working fluids:

The Cryo Fluid Circuits (CFC) will be commissioned (final acceptance test) at site by carrying out Chilling & filling of the SI pipelines with the respective working fluids and conducting flow tests at nominal flow rates and working pressure. The main objective shall be as follows;

a. To verify conformance with thermal, structural and functional specification.

b. To validate heat in - leak rate and pressure drop

specification. c. To verify performance of all instruments with respect to

specification. d. There shall be no sweating/ frosting on the outer pipe

surface.



2.84

Note:

1. Detailed procedure for conducting performance test shall be jointly prepared by the Contractor and Department.

2. The necessary Inspection works during performance test at Department’s site shall be done by Department’s Quality Control Division.

PAINTING

All the SI pipe-lines (over the jacket pipe) shall be painted with identification bands of 100 mm width at 2 m span based on the colour code scheme as follows: LH2: Brick Red; LOX: Black; LN2: Olive Green, GH2-Signal Red

Prior to painting, the surfaces shall be suitably prepared. The painting shall comprise 2 coats of primer (like red oxide) and 2 coats of synthetic enamel. Line number shall be clearly marked on the outer jackets. The weld joints of the outer jackets shall also be painted.

TECHNICAL SPECIFICATION OF INSTRUMENTATION

1. The Department on free of cost will issue the required fluid temperature sensor (500 Ω RTD), surface temperature sensor (500 Ω RTD) and flow meters (turbine & vortex) to the contractor. The contractor shall install these instruments in the Super Insulated (SI) piping segments of CFC. The vacuum feed through connectors with the matting connectors shall be the scope of Contractor.

2. The fluid and surface temperature measurements in the SI pipeline shall be provided with a redundant sensor adjacent to the main sensor and the cable shall be terminated in the common vacuum feed through connector. This measurement will be used only on failure of the main sensor. The general arrangement is shown in Fig. no. A2.C.2.1 & A2.C.2.2.

3. The Contractor shall fabricate all the adapters, interface elements, etc., required for integration of these instruments with SI pipelines. The fabrication drawings of adaptors & interfaces and wiring diagram connecting temperature sensors with vacuum feed through are to be prepared by Contractor & shall be submitted to Department for approval before starting fabrication.



2.85

4. The specification of Vacuum feed through (VFT) for temperature sensors/flow meters shall be as follows: Specification of 20/10-Pin vacuum feed through connector Make : Insulator seal INC, USA or

equivalent Application : Instrumentation, Low power

Leak tightness Tightness : <1E-8 m3.Pa/s Type : UHV Connector (Air side plug) Type : MIL-C-5015 Grade Voltage : 700 VDC Contact amps : 10A/Contact AWG of contacts : 18/20/22 No. of contacts : 10/20-Pins

Material Body : SS 304 Temperature range : 0 to +125˚C Contact air side : Solder cup contacts Insulator : Alumina ceramic Socket Type : MIL-C-5015 Grade Voltage : 700 VDC No. of contacts : 10/20-Pins

Material Body : SS 304 Contacts : Alumel Installation : NW 35 CF Temperature range : -40 to +125˚C Contact vacuum side : Gold plated crimp

contact with Ceramic spacer

Note: Approval for specification & make of the vacuum feed through connectors shall be obtained from Department during detail engineering review (DER).



2.86

Table A2.C.2.1 List of SI circuits

SL.

No

Nominal

pipe Size

Fluid

Medium Schedule

Design

pressure

Total

length

mm - - MPa m

1 DN 40 LOX Sch 10S 1.4 11.5

2 DN 40 LOX Sch XXS 36 10

3 DN 50 LOX Sch 10S 1.4 47

4 DN 50 LOX Sch XXS 36 25

5 DN 65 LOX Sch 80S 18.6 7

6 DN 65 LOX Sch XXS 36 7.5

7 DN 80 LOX Sch 10S 1.4 10

8 DN 100 LOX Sch 10S 1.6/1.4 29.5

9 DN 150 LOX Sch 10S 1.6/1.4 51

10 DN 40 LH2 Sch 10S 1.4 12

11 DN 50 LH2 Sch 10S 1.4 55.5

12 DN 50 LH2 Sch 80S 17 38

13 DN 65 LH2 Sch 80S 18.6 13.5

14 DN 80 LH2 Sch 10S 1.4 11

15 DN 100 LH2 Sch 10S 1.6/1.4 25

16 DN 150 LH2 Sch 10S 1.6/1.4 56.5

17 DN 25 GH2 Sch 10S 3.7 20

18 DN 25 GH2 Sch 160 31 22.5

19 DN 25 LN2 Sch 10S 1.4 28

20 DN 40 LN2 Sch 10S 1.4 90

21 DN 65 LN2 Sch 10S 2.5 17 The lengths of pipelines are based on preliminary piping layout. The actual length has to be worked out by contractor based on isometrics after Detail Engineering Review (DER). Changes in lengths of the SI circuits from those given above, due to detail engineering, should not have any commercial implications after award of contract. The bidder shall suitably consider this aspect while submitting the quote.



2.87



2.88

A2.C.3 TECHNICAL SPECIFICATIONS OF PIPE FITTINGS AND FLANGES

Type : Seamless pipe fittings for nominal

pipe size ≤ DN 250 Longitudinal seam-welded pipe

fittings for nominal pipe size ≥ DN 300

Type of fitting : Fittings: BW type / Threaded

Flanges: ≤Class 1500, WNRF ≥Class 2500, WNRJ or Equivalent Special flanges/ connectors: for high pressure and Flow meter Interfaces.

Nominal size

: To be selected according to the Pipe circuits

Pressure rating class

: According to MAWP of the Pipe circuits

Quantity : The quantity has to be worked out by contractor based on isometric drawing and equipment layout.

Standard for dimensions : Flanges: ASME B 16.5 Butt welding fittings: ASME B 16.9 Pipe nipples: ASME B 36.19/

36.10 Material :

Elbows, Tees, crosses, Concentric/eccentric reducers/enlargers

ASTM A 403 WP 304L/316L for SS ASTM A234 for CS

Flanges ASTM A 182 F 304L/316L for SS ASTM A 105 for CS



2.89

TESTS

Visual examination: All pipe fittings and flanges shall be visually examined for any scratches, dents, surface irregularities, etc. Dimensional check: All the pipe fittings and flanges shall be checked for dimensions as per the standard. Chemical analysis: One specimen from each heat shall be subject to detailed chemical analysis as per ASTM A 751. Mechanical properties: One specimen from each lot shall be subject to mechanical test to verify mechanical properties as per ASTM A 370. Inter-granular corrosion test (for stainless steel pipe fittings and flanges only): One specimen per lot shall be subjected to inter-granular corrosion test as per ASTM A 262 (practice A/E).

Marking: The nominal size, pressure rating class, material, heat number, manufacturer’s name, etc shall be indelibly marked on the pipe fittings and flanges.

QAP: As given in Table A2.C.3.1.

The supply of blind flanges required for the pressure/leak test is under the scope of the contractor.



2.90

Table A2.C.3.1: QUALITY ASSURANCE PLAN FOR PIPE FITTINGS AND FLANGES

S No

Test Object tested


Sample size

Test procedure


Form of record

Pre-Delivery Inspection (PDI)

Test performed by

Test witnessed by

Record reviewed by

1. Visual examination

Pipe fittings

Surface properties

100 % Visual examination

No scratch, dent, surface irregularity, etc

Inspection report

Vendor - Inspector


Pipe fittings

Dimensions

100 % Metrology Relevant standard

Inspection report

Vendor - Inspector,

3. Chemical analysis

Specimen from pipe fittings and flanges

Chemical composition

1 per heat ASTM A 751

Relevant standard



- Inspector

4. Mechanical test


Mechanical properties

1 per lot ASTM A 370

Relevant standard



- Inspector

5. Inter-granular corrosion test


Susceptibility to corrosion

1 per lot ASTM A 262 Practice A/ E

ASTM A 262 Practice A/ E



- Inspector

Note 1. Inspector: Third party inspection agency



2.91

A2.C.4 TECHNICAL SPECIFICATION OF SUPER-INSULATED FLEXIBLE

HOSES

Quantity : As given Table A2.C.4.2

Tag number : As given Table A2.C.4.2

Type (of process/ core/ inner flexible hose)

: Parallel corrugated, bellows type, stainless steel wire-braided, all-metallic, flexible hose, except as below.

Insulation : Double-walled construction with multi-layer

(Aluminized Mylar) vacuum insulation

Process fluid medium

: As given Table A2.C.4.2

Working temperature range of process flexible hose


Inside diameter of process flexible hose

: To be specified by the bidder based on the size given in Table A2.C.4.2

Inside diameter of jacket/ outer flexible hose

: To be specified by the bidder

Maximum allowable working pressure (MAWP) of process flexible hose


MAWP of jacket flexible hose

: 0.1 MPa external pressure (atmosphere) with full vacuum in the jacket. 0.05 MPa(g) internal pressure in the jacket with atmospheric pressure outside.

Overall length (including end fittings)

: As given Table A2.C.4.2 (Actual length of the hoses shall be finalized during Detail Engineering Phase)

Minimum bend radius : To be specified by the bidder

Permissible leakage rates

: 1E-8 Pa-m3/s from process flexible hose to jacket flexible hose



2.92

1E-8 Pa-m3/s from atm. to jacket flexible hose

1E-6 Pa-m3/s from end fittings to

atmosphere

Permissible heat influx rate (referred to the condition of liquid Nitrogen in process flexible hose)

: process flexible

hose size in mm

Across corrugation,

W/m

Across each end fitting, W

DN 25 0.5 3.5

DN 40 0.7 4.6

DN 50 0.8 5.4

DN 65 1.0 6.5

DN 80 1.1 7.5

DN 100 1.3 8.8

DN 150 1.7 11.7

Vacuum pressure in jacket flexible hose (at atmospheric temperature)

: ≤ 1 Pa (pre-evacuated and sealed at the vendor’s factory)

End connection

: As given Table A2.C.4.2. The acronyms shall be read as follows:

BW: Pipe stubs (Seamless) as per ASME B 36.19/ 36.10 of 150 mm length each shall be butt-welded to the flexible hose on either side, the ends of which shall be prepared for butt welding as per ASME B 16.9/ 16.25.

NSF-Type-1 (Non standard Flange Type-1): A typical configuration is

provided Fig. no. 2.4. The fabrication drawings with dimensions for each hose will be provided by the Department on award of contract.

Bayonet-1: 2” x 15” Cryenco type bayonet coupling (M/s. Gardner, USA make.



2.93

Material of corrugation & braids

: Austenitic stainless steel grade 321 / 316Ti

Material of end fittings : ASTM A 312 TP 304L/ 316L/ 321 for pipe stubs

ASTM A 182 F 304L/ 316L/ 321 for flanges

and bayonet couplings

ASTM A 182 F 304/304L/ 316L/ 321 for Cryenco bayonet couplings

Material of seals : PTFE/ Glass-filled PTFE for maximum



2.94

allowable working pressure ≤ 15 MPa and lower limit of working temperature range ≥ 75 K

PCTFE/Polycarbonate for maximum

allowable working pressure ≤ 15 MPa and lower limit of working temperature range < 75 K

Spring-energized, pressure-assisted,

metallic seals for maximum allowable working pressure > 15 MPa

Viton/Neoprene for vacuum pressures

The corrugation of the flexible hose shall be joined with the end fittings by Gas Tungsten Arc Welding (GTAW/ TIG) process with gaseous Argon as the purge medium. Vacuum jacket: The outer pipe shall be provided with following:

• Stainless steel bellow sealed angle vacuum valve of size DN25 for evacuation.

• Seal-off valve to relieve pressures in vacuum space above 0.05 MPa (g)

• SS bellow sealed angle vacuum valve of size DN15 for vacuum measurement.

Tests a. Material certificates: The material certificates, detailing the physical and

chemical properties, shall be provided. b. Flaw detection test for pipe stubs (wherever applicable): All the pipes of

nominal pipe size ≥ DN 25 shall be subject to Ultra-sonic test (100 %) by pulse echo or contact probe method as per ASTM E 213. All the pipes of nominal pipe size ≤ DN 20 shall be subject to Eddy current test as per ASTM E 426.

c. Welding joint test (wherever applicable): All butt welding joints in the

flexible hose (including the joints between the corrugation and the pipe stubs) shall be subject to radio-graphic test with X-rays or gamma rays to 2% equivalent sensitivity as per Section IX, ASME.

d. Pressure test: The process hoses shall be subject to pressure test with

pneumatic medium at 1.1 times the respective maximum allowable working pressure.



2.95

e. MSLD leakage test:

The global leakage rate of process flexible hose & end fittings to jacket flexible hose shall be measured with MSLD by pressurizing the process hose to a pressure of 80% of MAWP.

The leak rate of jacket flexible hose (from atmosphere to jacket flexible hose) shall be checked by hood technique as per Article 10, Section V, ASME.

f. Vacuum hold test: The hoses after attaining stabilized vacuum level in

the annular space, shall be tested for vacuum hold for a period of 48 hrs. Accessories The end connections (flanged/ bayonet coupling) of each flexible hose shall be provided with proper blank-off closures. The hoses with NSF-Type-1 ends shall be supplied with conical gaskets of SS321 material and high tensile fasteners. The butt welding ends shall be provided with proper dust free plastic closures. Cleanliness All the interior flow surfaces of the flexible hoses shall be degreased and cleaned to Oxygen service standards as per CGA G-4.1 or ASTM G 93. The ends shall be blanked off properly after cleaning to required levels. Marking All the flexible hoses are assigned tag numbers for the sake of identification. The tag number for each flexible hose, as indicated above, besides manufacturer, size, maximum allowable working pressure, material of construction, etc, shall be legibly and indelibly engraved on the end fittings of the flexible hoses. Quality assurance plan: As given in Table A2.C.4.1



2.96

Table A2.C.4.1: QUALITY ASSURANCE PLAN FOR SUPER-INSULATED FLEXIBLE HOSES

S No

Test Object tested


Sample size

Test procedure


Form of record


Test witnessed by

Record reviewed by

1. Material test Specimen from raw materials

Chemical composition and physical properties

1 per heat/ lot

Relevant standard

Relevant material specification


Sub-vendor/ vendor or Third party laboratory

- Vendor, Inspector,

2. Ultrasonic test for pipe stub (wherever applicable)

Pipe of size ≥ DN 25


100 % ASTM E 213 ASTM E 213 Test certificate

Sub-vendor/ Vendor

- Vendor/ Inspector,

3. Eddy current test for pipe stub (wherever applicable)

Pipe of size ≤ DN 20


100 % ASTM E 426 ASTM E 426 Test certificate

Sub-vendor/ vendor

- Vendor/ Inspector,

4 Welding joint test (wherever applicable)

Butt welding joint

Absence of defect

100 % Radiographic test

ASME, Section IX

Test certificate

Vendor - Inspector,



2.97

Table A2.C.4.1: QUALITY ASSURANCE PLAN FOR SUPER-INSULATED FLEXIBLE HOSES

S No

Test Object tested


Sample size

Test procedure


Form of record


Test witnessed by

Record reviewed by


Flexible hose

Dimensions 100 % Metrology Relevant standard/ Department-approved drawing

Test report

Vendor - Inspector,

6. Pressure test

Flexible hose

Structural integrity under stress

100 % Relevant standard

Relevant standard

Test certificate


7. MSLD leakage test

Flexible hose

Leakage-tightness

100 % Article 10, Section V, ASME

Purchase order specification

Test certificate


8. Vacuum Hold

Flexible hose

Leakage-tightness

100 % Purchase order specification


Test certificate


9. Cleanliness (if applicable)

Flexible hose

Cleanliness for Oxygen service

100 % CGA G-4.1/ ASTM G 93


certificate Vendor - Inspector

Notes Inspector: Third party inspection agency



2.98

Table A2.C.4.2 SI Flexible Hoses

Sl. No


medium Size

(metric) Length (mm)

MAWP (MPa)

Process temp. (K)

End connection

End 1 End2


1 DFH 120 121-40-XXS-36 LOX DN 40 1000 36 75 to 350 NSF-Type-1 BW

2 DFH 121 120-50-XXS-36 LOX DN 50 1000 36 75 to 350 BW BW

3 DFH 122 122-40-10S-1.4 LOX DN 40 1000 1.4 75 to 350 BW BW




7 DFH 160 160-150-10S-1.6 LOX DN 150 2000 1.6 75 to 350 NSF-Type-1 BW

8 DFH 161 161-65-80-18.6 LOX DN 65 1000 18.6 75 to 350 BW BW



10 DFH 220 220-50-80S-17 LH2 DN 50 1000 17 15 to 350 NSF-Type-1 BW

11 DFH 222 222-65-10S-1.4 LH2 DN 65 1000 1.4 15 to 350 BW BW

12 DFH 250 250-100-10S-1.4 LH2 DN 100 300 1.4 15 to 350 BW BW

13 DFH 251 251-50-10S-1.4 LH2 DN 50 300 1.4 15 to 350 BW BW

14 DFH 252 252-40-10S-1.4 LH2 DN 40 500 1.4 15 to 350 BW BW

15 DFH 260 260-150-10S-1.6 LH2 DN 150 2000 1.6 15 to 350 NSF-Type-1 BW

16 DFH 261 261-65-80S-18.6 LH2 DN 65 1000 18.6 15 to 350 BW BW

17 DFH 270 270-80-10S-1.4 LH2 DN 80 1000 1.4 15 to 350 BW BW

18 DFH 271 273-40-10S-1.4 LH2 DN 40 1000 1.4 15 to 350 BW BW

19 DFH 570 570-40-10S-1.4 GH2 DN 40 1000 1.4 77 to 350 BW BW



2.99

Table A2.C.4.2 SI Flexible Hoses

Sl. No


medium Size

(metric) Length (mm)

MAWP (MPa)

Process temp. (K)

End connection

End 1 End2

Liquid Nitrogen [LN2] System (Ref P&ID: Drawing CTPT/CFS/P&ID/300/R0)

20 DFH 330 322-25-10S-1.4 LN2 DN 25 1000 1.4 15 to 350 NSF-Type-1 BW

21 DFH 340 321-25-10S-1.4 LH2 DN 25 1000 1.4 15 to 350 NSF-Type-1 BW

22 DFH 360 323-25-10S-1.4 LN2 DN 25 1000 1.4 15 to 350 NSF-Type-1 BW

Gaseous Hydrogen [GH2] System (Ref P&ID: Drawing CTPT/CFS/P&ID/500/R0)

23 DFH 560 560-25-10S-3.7 GH2 DN 25 1000 3.7 290 to 350 NSF-Type-1 NSF-Type-1



2.100

A2.C.5 TECHNICAL SPECIFICATION OF MANUAL VALVES

Tag No, pattern,

configuration of

ports/ ways, fluid

medium, working

temperature range,

size, MAWP,

Pressure rating class

:

As given in Table A2.C.5.2

Actuation

:

Hand operated (manual)

Application : Isolation

Valve coefficient : To be specified by the bidder in the quotation

Permissible leakage rate across body

: 1E-07 Pa-m3/s for bellows-sealed globe valves.

1E-06 Pa-m3/s for gland packing globe valves

Permissible leak rate across seat

: 1E-06 Pa-m3/s for resilient-seated globe valves

1E-05 Pa-m3/s for hard-seated globe valves

Permissible leak rate from atmosphere to jacket in case of vacuum-jacketed globe valves

: 1E-08 Pa-m3/s

Guaranteed cycles of operation

: 5,000

Length of stem extension (applicable to valves with Vacuum jacket and Extended stem)

: As per BS 6364



2.101

Allowable heat in-leak rate referred to the condition of LN2 (applicable to vacuum jacketed valves)

: 0.9 W for DN 15 2.0 W for DN 25 4.2 W for DN 40 6.1 W for DN 50 9.3 W for DN 65 13.1 W for DN 80 18.8 W for DN 100 27.1 W for DN 125 36.5 W for DN 150

End connection

:

BW: Butt welding ends as per ASME B 16.9/ 16.25. In case of valves with resilient seat, pipe stubs as per ASME B 36.19/ 36.10 of 150 mm length each shall be butt-welded to the body on either side, the ends of which shall be prepared for butt welding.

Style of construction: Body : With full port (standard bore) and in-line

end connections

Bonnet

: Bolted or screwed to body with spring-energised seals (Such as Helicoflex, Enerseal, etc) For cryogenic valves, the body-bonnet joint shall be located on top of the stem extension such that the seal experiences near-ambient temperature. The vacuum jacket collar shall be located below the body-bonnet joint (to preclude the possibility of vacuum in the jacket collapsing due to leakage of process fluid through body-bonnet joint). The stem extension for cryo application shall be as per design Code. The stem shall be of non-rotating type.

Stem (dynamic) seal : By bellows with redundant gland packing for globe valves of LH2, LOX, LN2 and GH2 media

By gland packing for GN2 media (As given in Table A2.C.5.2 )



2.102

Plug : Renewable (replaceable) from stem

Seat : Renewable from body with seat insert

Flow direction : Flow to open and all the valves shall

have bi-directional shut-off. Material of construction: Note: For Oxygen service Pressure >15MPa: All internals (like stem, seat, plug, trim, etc.,) shall be made of compatible materials such as Monel, bronze & other copper alloys.

Body and Bonnet : ASTM A182F 304 L / 316L / 321 For

≤DN40 ASTM A351 CF3 /CF3M For ≥DN50

Stem, plug, seat : ASTM A479 304L/ 316L/ 321

Bellows : Stainless steel 316L/ 316Ti/ 321/ Hastealloy C 276/ Inconel 600/ 625/ Incoloy

Gland packing

: PTFE/ Glass-filled PTFE

Plug and seat inserts : PCTFE (Kel-F) / Poly-carbonate for MAWP ≤ 250 bar

ASTM A 479 304L/ 316L with # 6 stelliting for MAWP > 250 bar.

Vacuum jacket pipe : ASTM A 312 TP 304L/ 316L/321

Pipe stub

: ASTM A312 TP 304L/ 316L

Bolts : ASTM A 193 B 8

Nuts : ASTM A 194 8

Note: 1. The valves shall be either inherently anti-static or provided

with anti-static features. 2. Dual grade (SS304/304L or 316/316L) is also acceptable

wherever applicable.

Design code : BS 5352/ BS 6364/ API 6-D/ ANSI B16.34

Test code : BS 6755/ API 598



2.103

TESTS a. Material certificates:

The material certificates, detailing the physical and chemical properties, of the principal pressure–bearing parts shall be provided.

b. Bellows cyclic life test:

3 sample bellows drawn from a batch of the same size and type shall be subject to (destructive) cyclic life (proto-type) test as per BS 5352. If the manufacturer of the bellows has already performed such test, copy of the certificate may be produced.

c. Welding joint test: Any butt welding joint in the valve shall be subject to radio-graphic test with X-rays or gamma rays to 2-T sensitivity.

d. Soundness test for castings: All the castings shall be subject to soundness test with radio-graphic or ultra-sonic technique for flaw detection.

e. Hydraulic shell pressure test: The valve, prior to assembly with the bellows, in partially open position, shall be subject to pressure test with Water (with suitable corrosion inhibitor) at 1.5 times the maximum rated working pressure of the particular pressure rating class of the valve. The test procedure and acceptance criteria shall be as per BS6755 Part 1 or API 598 or ANSI B 16.34.

f. Pneumatic shell pressure test The valve, upon final assembly including the bellows, in partially open position, shall be subjected to pressure test dry air or GN2 at 1.1 times the maximum rated working pressure of the particular pressure rating class. The test procedure and acceptance criteria shall be as per BS 6755 Part 1 or API 598 or ANSI B 16.34.

g. Hydraulic seat pressure test: The valve, in closed position, shall be subject to pressure test with Water (with suitable corrosion inhibitor) at 1.1 times the maximum rated working pressure of the particular pressure rating class of the valve. The test procedure and acceptance criteria shall be as per Rate A of BS 6755 Part 1 or API 598 or ANSI B 16.34.

h. MSLD shell leak test: The global leak rates across body shall be measured with



2.104

GHe MSLD to establish the Leak tightness values specified above by hood technique as per Article 10, Section V, ASME. The leak test shall be performed by shrouding the entire outside surface of the valve with a plastic bag to hold GHe at a positive pressure and by evacuating and connecting the inlet/ outlet port to MSLD. Leak test by detector probe or tracer probe technique is not acceptable.

i. MSLD jacket leak test (for vacuum-jacketed valves only): The global leak rates across jacket shall be measured with GHe MSLD to establish the Leak tightness values specified above by hood technique as per Article 10, Section V, ASME. Suitable temporary blank-off shall be used to seal the annular gap between the process (core) pipe and the jacket pipe for performing this test. The leak test across the jacket shall be performed by shrouding the entire outside surface of the jacket with a plastic bag to hold GHe at a positive pressure and by evacuating and connecting the annular space between the valve and the jacket to MSLD. Leak test by detector probe or tracer probe technique is not acceptable.

j. MSLD seat leak test: The global leak rates across seat shall be measured with GHe MSLD to establish the Leak tightness values specified above by hood technique as per Article 10, Section V, ASME. The leak test shall be performed by pressurising the inlet with GHe and by evacuating and connecting the outlet to MSLD. Leak test by detector probe or tracer probe technique is not acceptable.

k. Cleanliness All the interior flow surfaces of the valve shall be degreased and cleaned to O2 service standards as per CGA G-4.1 or MIL-C-52211.

l. Marking : All the valves are assigned tag numbers for the sake of identification. The tag number for each valve, as indicated above, besides size, pressure rating class, material of construction, etc, shall be legibly and indelibly engraved on the body of the valves.

m. QAP: As given in Table A2.C.5.1.



2.105

Table A2.C.5.1: QUALITY ASSURANCE PLAN FOR MANUAL VALVES

S No Test Object

tested

Characteristic

sought for

Sample

size

Test

procedure

Acceptance

criterion

Form of

record


Test

performed

by

Test

witnessed

by

Record

reviewed

by

1. Material test Specimen

from raw

materials

Chemical

composition

and physical

properties

1 per lot Relevant

standard

Relevant

material

specification

Material

certificate

Vendor or

Third

party

laboratory

- Vendor,

Inspector

2. Bellows

cyclic life

test

(wherever

applicable)

Bellows Cyclic life

under fatigue

3 per

batch of

same

size and

type

BS 5352 BS 5352 Test

certificate

Sub-

vendor

- Vendor,

Inspector

3. Welding

joint test

(wherever

applicable)

Butt welding

joints

Absence of

defects

100 % Radiographi

c test

ASME,

Section IX

Test

certificate

Vendor - Inspector

Socket

welding

joints

Absence of

surface

defects

100 % Dye

penetrant

test

Relevant

standard

Test

certificate

Vendor - Inspector



2.106


S No Test Object

tested

Characteristic

sought for

Sample

size

Test

procedure

Acceptance

criterion

Form of

record


Test

performed

by

Test

witnessed

by

Record

reviewed

by

4. Soundness

test for

castings

(wherever

applicable)

Castings Absence of

defects

100 % Radiographi

c or

ultrasonic

test

Relevant

standard

Test

certificate

Vendor - Inspector

,

5. Dimensional

check

Valve Dimensions 100 % Metrology Relevant

standard/

Department-

approved

drawing

Test

report

Vendor - Inspector

,

6. Pre-

assembly

hydraulic

shell

pressure

test

Valve

before

assembly

with bellows

Structural

integrity under

stress

100 % 1.5 times

maximum

rated

working

pressure

BS 6755

Part 1/

API 598/

ASME B

16.34

Test

certificate




2.107


S No Test Object

tested

Characteristic

sought for

Sample

size

Test

procedure

Acceptance

criterion

Form of

record


Test

performed

by

Test

witnessed

by

Record

reviewed

by

7. Final hshell

pressure

test

Valve after

assembly

with bellows

Structural

integrity of

body under

stress

100 % 1.1 times

maximum

rated

working

pressure

BS 6755

Part 1/

API 598/

ASME B

16.34

Test

certificate


8. Hydraulic

seat

pressure

test

Valve in

closed

position

Structural

integrity of

seat under

stress

100 % 1.1 times

maximum

rated

working

pressure

BS 6755 Part 1/

API 598/

ASME B 16.34

Test

certificate


9. MSLD shell

leakage test

Valve in

open

position

Leakage rate

across body

100 % ASME,

Section V,

Article 10

Purchase

order

specification

Test

certificate


10. MSLD

jacket

leakage test

Vacuum

jacket

Leakage rate

across jacket

100 % ASME,

Section V,

Article 10

Purchase

order

specification

Test

certificate




2.108


S No Test Object

tested

Characteristic

sought for

Sample

size

Test

procedure

Acceptance

criterion

Form of

record


Test

performed

by

Test

witnessed

by

Record

reviewed

by

11. MSLD seat

leakage test

Valve in

closed

position

Leakage rate

across seat

100 % ASME,

Section V,

Article 10

Purchase

order

specification

Test

certificate


12. Cleanliness Valve Cleanliness

for Oxygen

service

100 % CGA G-4.1/

ASTM G 93

CGA G-4.1/

ASTM G 93





2.109

Table A2.C.5.2 Manual valves

SL. No


medium Siz

e

(metr

ic)

MA

WP

(M

Pa)

Pre

ssu

re

rati

ng

cla

ss

Valv

e

Co

eff

. C

v Process

temp. (K)

Type


1 DVM 101 100-65-XXS-36 LOX DN25 36 4500 4 75 to 350 BS-ES

2 DVM 103 120-50-XXS-36 LOX DN15 36 4500 1 75 to 350 BS-ES-VJ

3 DVM 110 110-50-10S-1.4 LOX DN15 1.4 150 4 75 to 350 BS-ES

4 DVM 112 110-50-10S-1.4 LOX DN15 1.4 150 4 75 to 350 BS

5 DVM 113 110-50-10S-1.4 LOX DN15 1.4 150 4 75 to 350 BS




9 DVM 122S 120-50-XXS-36 LOX DN15 36 4500 1 75 to 350 BS-ES

10 DVM 124 122-40-10S-1.4 LOX DN40 1.4 150 30 75 to 350 BS-ES-VJ








18 DVM 330 150-100-10S-1.4 LN2 DN25 1.4 150 13 75 to 350 BS-ES-VJ

19 DVM 404 103-50-XXS-36 GO2 DN50 36 4500 25 75 to 350 BS-ES (3WAY, 2PORT)

20 DVM 434 133-50-10S-1.6 GO2 DN50 1.6 300 51 75 to 350 BS-ES (3WAY, 2PORT)

21 DVM 450 152-25-10S-1.4 GO2 DN25 1.4 150 13 75 to 350 BS-ES



2.110


SL. No


medium Siz

e

(metr

ic)

MA

WP

(M

Pa)

Pre

ssu

re

rati

ng

cla

ss

Valv

e

Co

eff

. C

v Process

temp. (K)

Type

22 DVM 110A 110-50-10S-1.4 LOX DN15 1.4 150 4 75 to 350 BS-ES

23 DVM 126A 120-50-XXS-36 LOX DN15 36 4500 1 75 to 350 BS-ES

24 DVM 166A 160-150-10S-1.6 LOX DN15 1.6 300 4 75 to 350 BS-ES

25 DVM 102E 100-65-XXS-36 GO2

6mm PORT

40 -

1

270 to 350 BS-Needle type globe

valve

26 DVM 120E 120-50-XXS-36 GO2

27 DVM 121E 120-50-XXS-36 GO2

28 DVM 122E 120-50-XXS-36 GO2

29 DVM 164E 161-65-80-18.4 GO2

30 DVM 120P 120-50-XXS-36 GO2

31 DVM 120Q 120-50-XXS-36 GO2

32 DVM 121P 120-50-XXS-36 GO2

33 DVM 121Q 120-50-XXS-36 GO2

34 DVM 102S 100-65-XXS-36 GO2

35 DVM 121S 120-50-XXS-36 GO2

36 DVM 110E 110-50-10S-1.4 GO2

6mm PORT

10

-

1

270 to 350

BS-Needle type globe valve

37 DVM 111E 110-50-10S-1.4 GO2

38 DVM 112E 110-50-10S-1.4 GO2

39 DVM 123E 122-40-10S-1.4 GO2

40 DVM 132E 130-150-10S-1.6 GO2

41 DVM 160E 160-150-10S-1.6 GO2

42 DVM 161E 160-150-10S-1.6 GO2

43 DVM 162E 160-150-10S-1.6 GO2

44 DVM 180E 180-80-10S-1.4 GO2



2.111


SL. No


medium Siz

e

(metr

ic)

MA

WP

(M

Pa)

Pre

ssu

re

rati

ng

cla

ss

Valv

e

Co

eff

. C

v Process

temp. (K)

Type

45 DVM 182E 180-80-10S-1.4 GO2

6mm PORT

10 - 1 270 to 350 BS-Needle type globe

valve

46 DVM 183E 180-80-10S-1.4 GO2

47 DVM 101H 105-100-10S-1.4 GO2

48 DVM 131H 135-150-10S-1.4 GO2

49 DVM 151P 150-100-10S-1.4 GO2

50 DVM 151Q 150-100-10S-1.4 GO2

51 DVM 160P 160-150-10S-1.6 GO2

52 DVM 160Q 160-150-10S-1.6 GO2

53 DVM 161P 160-150-10S-1.6 GO2

54 DVM 161Q 160-150-10S-1.6 GO2

55 DVM 111S 110-50-10S-1.4 GO2

56 DVM 114S 111-50-10S-1.4 GO2

57 DVM 132S 130-150-10S-1.6 GO2

58 DVM 150S 151-40-10S-1.4 GO2

59 DVM 161S 160-150-10S-1.6 GO2

60 DVM 162S 160-150-10S-1.6 GO2

61 DVM 180S 180-80-10S-1.4 GO2


62 DVM 201 200-65-80S-17 LH2 DN 25 17 1500 10 15 to 350 BS-ES

63 DVM 203 220-50-80S-17 LH2 DN 15 17 1500 3 15 to 350 BS-ES

64 DVM 204 220-50-80S-17 LH2 DN 15 17 1500 3 15 to 350 BS-ES-VJ

65 DVM 210 210-50-10S-1.4 LH2 DN 15 1.4 150 4 15 to 350 BS-ES

66 DVM 212 210-50-10S-1.4 LH2 DN 15 1.4 150 4 15 to 350 BS



2.112


SL. No


medium Siz

e

(metr

ic)

MA

WP

(M

Pa)

Pre

ssu

re

rati

ng

cla

ss

Valv

e

Co

eff

. C

v Process

temp. (K)

Type

67 DVM 213 210-50-10S-1.4 LH2 DN 15 1.4 150 4 15 to 350 BS

68 DVM 215 211-50-10S-1.4 LH2 DN 15 1.4 150 4 15 to 350 BS-ES

69 DVM 220 220-50-80S-17 LH2 DN 15 17 1500 3 15 to 350 BS-ES

70 DVM 223 222-65-10S-1.4 LH2 DN 15 1.4 150 4 15 to 350 BS-ES

71 DVM 224 222-65-10S-1.4 LH2 DN 65 1.4 150 76 15 to 350 BS-ES-VJ

72 DVM 231 230-100-10S-1.6 LH2 DN 25 1.6 300 13 15 to 350 BS-ES

73 DVM 233 260-150-10S-1.6 LH2 DN 15 1.6 300 4 15 to 350 BS-ES



76 DVM 260 260-150-10S-1.6 LH2 DN 15 1.6 300 4 15 to 350 BS-ES

77 DVM 263 261-65-80S-18.6 LH2 DN 15 18.6 1500 3 15 to 350 BS-ES

78 DVM 271 270-80-10S-1.4 LH2 DN 15 1.4 150 4 15 to 350 BS-ES

79 DVM 504 503-65-80S-17 GH2 DN 50 17 1500 41 15 to 350 BS-ES (3 way valve)

80 DVM 534 533-100-10S-1.6 GH2 DN 80 1.6 300 117 15 to 350 BS-ES(3 way valve)

81 DVM 550 253-25-10S-1.4 GH2 DN 25 1.4 150 13 15 to 350 BS-ES

82 DVM 551 252-40-10S-1.4 GH2 DN 15 1.4 150 4 15 to 350 BS-ES-VJ

83 DVM 751 200-65-80S-17 GH2 DN 15 1.4 150 4 270 to 350 BS

84 DVM 752 230-150-10S-1.6 GH2 DN 15 1.4 150 4 270 to 350 BS

85 DVM 210 A 210-50-10S-1.4 GH2

6mm PORT

10 - 1 270 to 350

BS-Needle type globe

valve

86 DVM 266 A 260-150-10S-1.6 GH2

87 DVM 210 E 210-50-10S-1.4 GH2

88 DVM 211 E 210-50-10S-1.4 GH2

89 DVM 212 E 211-50-10S-1.4 GH2



2.113


SL. No


medium Siz

e

(metr

ic)

MA

WP

(M

Pa)

Pre

ssu

re

rati

ng

cla

ss

Valv

e

Co

eff

. C

v Process

temp. (K)

Type

90 DVM 232 E 230-150-10S-1.6 GH2

6mm PORT

10 - 1 270 to 350

BS-Needle type globe

valve

91 DVM 260 E 260-150-10S-1.6 GH2

92 DVM 261 E 260-150-10S-1.6 GH2

93 DVM 262 E 260-150-10S-1.6 GH2

94 DVM 264 E 262-150-10S-1.6 GH2

95 DVM 270 E 270-80-10S-1.4 GH2

96 DVM 272 E 270-80-10S-1.4 GH2

97 DVM 273 E 271-40-10S-1.4 GH2

98 DVM 274 E 273-40-10S-1.4 GH2

99 DVM 570 E 570-40-10S-1.4 GH2

100 DVM 231 H 234-150-10S-1.4 GH2

101 DVM 250 P 250-100-10S-1.4 GH2

102 DVM 250 Q 250-100-10S-1.4 GH2

103 DVM 260 P 260-150-10S-1.6 GH2

104 DVM 260 Q 260-150-10S-1.6 GH2

105 DVM 261 P 260-150-10S-1.6 GH2

106 DVM 261 Q 260-150-10S-1.6 GH2

107 DVM 211S 210-50-10S-1.4 GH2

108 DVM 214S 211-50-10S-1.4 GH2

109 DVM 233S 230-150-10S-1.6 GH2

110 DVM 261S 260-150-10S-1.6 GH2

111 DVM 262S 260-150-10S-1.6 GH2

112 DVM 270S 270-80-10S-1.4 GH2



2.114


SL. No


medium Siz

e

(metr

ic)

MA

WP

(M

Pa)

Pre

ssu

re

rati

ng

cla

ss

Valv

e

Co

eff

. C

v Process

temp. (K)

Type

113 DVM 201 H 204-100-10S-1.4 GH2 6mm PORT

10 - 1 270 to 350 BS-Needle type globe valve 114 DVM 223 E 222-65-10S-1.4 GH2

115 DVM 226 A 220-50-80S-17 GH2

6mm PORT

40 4500 1 270 to 350 BS-Needle type globe

valve

116 DVM 202E 200-65-80S-17 GH2

117 DVM 220 E 220-50-80S-17 GH2

118 DVM 221 E 220-50-80S-17 GH2

119 DVM 222 E 220-50-80S-17 GH2

120 DVM 263 E 261-65-80S-18.6 GH2

121 DVM 220 P 220-50-80S-17 GH2

122 DVM 220 Q 220-50-80S-17 GH2

123 DVM 221 P 220-50-80S-17 GH2

124 DVM 221 Q 220-50-80S-17 GH2

125 DVM 202S 200-65-80S-17 GH2

126 DVM 221S 220-50-80S-17 GH2

127 DVM 222S 220-50-80S-17 GH2

128 DVM 264S 261-65-80S-18.6 GH2

Liquid Nitrogen [LN2] System (Ref P&ID: Drawing CTPT/CFS/P&ID/300/R0) 129 DVM 301 313-25-10S-1.4 LN2 DN80 2.5 300 117 75 -350 GS-ES (3way valve)

130 DVM 302 312-100-10S-2.5 LN2 DN 25 2.5 300 13 75 -350 GS-ES

131 DVM 304 311-65-10S-2.5 LN2 DN 15 2.5 300 4 75 -350 GS-ES-VJ

132 DVM 310 310-40-10S-1.4 LN2 DN40 1.4 150 30 75 -350 GS-ES-VJ

133 DVM 311 310-40-10S-1.4 LN2 DN 15 1.4 150 4 75 -350 GS-ES

134 DVM 321 320-40-10S-1.4 LN2 DN 15 1.4 150 4 75 -350 GS-ES



2.115


SL. No


medium Siz

e

(metr

ic)

MA

WP

(M

Pa)

Pre

ssu

re

rati

ng

cla

ss

Valv

e

Co

eff

. C

v Process

temp. (K)

Type

135 DVM 727 311-65-10S-2.5 GN2 DN 15 2.5 300 4 75 -350 GS-ES

Gaseous Hydrogen [GH2] System (Ref P&ID: CTPT/CFS/P&ID/500/R0)

136 DVM 560 560-25-10S-3.7 GH2 DN 25 31 2500 13 80-350 BS-ES-VJ

137 DVM 630 556-25-160-31 GHe DN 15 31 2500 2 270-350 BS

138 DVM 631 556-25-160-31 GHe DN 15 31 2500 2 270-350 BS

139 DVM 560E 560-25-10S-3.7 GH2 6mm PORT

10 - 1 270 to 350 BS-Needle type globe valve 140 DVM 560S 560-25-10S-3.7 GH2

141 DVM 558E 556-25-160-31 GH2

6mm PORT

40 - 1 270 to 350 BS-Needle type globe valve

142 DVM 561E 556-25-160-31 GH2

143 DVM 562E 556-25-160-31 GH2

144 DVM 556S 556-25-160-31 GH2

145 DVM 728 310-40-10S-1.4 GN2 DN 15 1.4 150 4 75 -350 GS-ES

146 DVM 728F 310-40-10S-1.4 GN2 DN 15 1.4 150 4 75 -350 GS-ES

147 DVM 728T 310-40-10S-1.4 GN2 DN 15 1.4 150 4 75 -350 GS-ES

148 DVM 728V 310-40-10S-1.4 GN2 DN 15 1.4 150 4 75 -350 GS-ES

149 DVM 310S 310-40-10S-1.4 LN2 DN 15 1.4 150 4 75 -350 GS-ES

150 DVM 320S 320-40-10S-1.4 LN2 DN 15 2.5 300 4 75 -350 GS-ES

151 DVM 750S 320-40-10S-1.4 LN2

6mm PORT

10

-

1 270 -350 Needle type globe

152 DVM 310E 310-40-10S-1.4 GN2

153 DVM 320E 320-40-10S-1.4 GN2

154 DVM 728E 310-40-10S-1.4 GN2

155 DVM 310A 310-40-10S-1.4 GN2

Note: GS-Gland sealed, BS- Bellow sealed, ES-Extended stem, VJ-Vacuum jacketed



2.116

A2.C.6 TECHNICAL SPECIFICATION OF ELECTRO-PNEUMATIC VALVES

Quantity : As given in Table A2.C.6.2

Tag number : As given in Table A2.C.6.2

VALVE

Pattern : Globe type

Application : Shut-off/ isolation/ on-off

Actuation

:

By pneumatic actuator

Fluid medium : As given in Table A2.C.6.2

Working temperature range

: As given in Table A2.C.6.2

Nominal size : As given in Table A2.C.6.2

Pressure rating class : As given in Table A2.C.6.2

Valve coefficient : To be specified by the bidder in the quotation

Other specifications related to valve

: As specified for manual valves in Section A2.C.5

ACTUATOR

Type : Linear actuator, piston/ diaphragm type, single acting, spring return, fail-safe

Normal position : As given in Table A2.C.6.2

Command gas

: Gaseous Nitrogen at 0.55 to 0.6 MPa(g). Where ever the command gas is less than 0.55 MPa(g) suitable filter regulator shall be installed for each valve. Note:If the given response time is not able to meet then the actuator shall be designed to operate with command pressure of Gaseous Nitrogen at 4.3 – 4.9 MPa (g)



2.117

Response time (for both opening and closing strokes)

:

As given Table A2.C.6.2 If required, flow (volume) booster and quick exhaust valve shall be incorporated to achieve the specified response time.

End connection for command gas

: DN 8 (¼”) NPT(F) to ASME B 1.10.1.

Material : Carbon steel (enamel-painted)

Test : The response time taken for opening and closing of the valve shall be evaluated.

STATUS SWITCHES The valve shall be provided with a pair of non-contact type proximity status switches to indicate the “opened/ closed” status of the valve. The status switches shall be mounted on the valve with such proper arrangement that does not require any adjustment/ alignment for the specified cycles of operation of the valve.

Type : Cylindrical Inductive Type

Proximity Sensor (switch) in

accordance with NAMUR

Sensing Distance : 1.5, 2, 4, 5 mm (The sensing

distance shall be suitably

selected by the valve

manufacturer according to

the valve stroke length)

Electrical configuration : DC, 2 wire

Nominal voltage : 8 V

Operating voltage : 5 – 24V

Switching frequency : > 500 Hz

Reverse polarity : Shall be Protected against

reverse polarity

Short circuit protection : Shall be Protected for short

circuit



2.118

Current

Consumption

Not

sensing

: ≥ 3mA

Sensing : ≤ 1mA

Indication of switching

state

: LED

Connection Type : 2 m long PVC cable

Ambient Temperature : -240 C to 800 C

Housing material : Stainless steel

Protection Degree : IP 67

Hazardous area

certification

: The switches shall be

intrinsically safe for Hydrogen

environment in conformance

with Ex ia IIC T6, Zone 1 of

IEC/ ATEX. The certificate of

conformance to this effect from

the accredited agency shall be

provided.

Make and model : To be specified by the bidder in

the quotation.

Suggested make : a. IFM electronic b. Omron, USA c. Pepperl + Fuchs, Germany d. Rockwell Automation – USA e. LongVale ltd – UK f. Cario Gavazzi g. Euroswitch – UK

Command

solenoid valve

: Solenoid valve for the

command purpose is not under

the scope of the Contractor.

Hence the solenoid valve need

not be supplied along with the

Pneumatic valve. It will be

provided by IPRC.

Quality

assurance plan




2.119

Table A2.C.6.1: QUALITY ASSURANCE PLAN FOR PNEUMATICALLY-ACTUATED VALVES

S No

Test Object tested


Sample size

Test procedure


Form of record


Test witnessed by

Record reviewed by



1 per heat/ lot

Relevant standard



Vendor or Third party laboratory


2. Bellows cyclic life test (wherever applicable)

Bellows Cyclic life under fatigue

3 per batch of same size and type

BS 5352 BS 5352 Test certificate

Sub-vendor


3. Welding joint test (wherever applicable)

Butt welding joints

Absence of defects


ASME, Section IX

Test certificate

Vendor - Inspector,

Socket welding joints

Absence of surface defects

100 % Dye penetrant test

Relevant standard

Test certificate

Vendor - Inspector,

4. Soundness test for castings (wherever applicable)

Castings Absence of defects

100 % Radiographic or ultrasonic test

Relevant standard

Test certificate

Vendor - Inspector,


Valve Dimensions 100 % Metrology Relevant standard/ Department-approved drawing

Test report

Vendor - Inspector,



2.120


S No

Test Object tested


Sample size

Test procedure


Form of record


Test witnessed by

Record reviewed by

6. Pre-assembly hydraulic shell pressure test

Valve before assembly with bellows


100 % 1.5 times maximum rated working pressure

BS 6755 Part 1/ API 598/ ASME B 16.34

Test certificate


7. Final hydraulic shell pressure test

Valve after assembly with bellows

Structural integrity of body under stress


BS 6755 Part 1/ API 598/ ASME B 16.34

Test certificate


8. Hydraulic seat pressure test

Valve in closed position

Structural integrity of seat under stress


BS 6755 Part 1/ API 598/ ASME B 16.34

Test certificate


9. MSLD shell leakage test

Valve in open position

Leakage rate across body

100 % ASME, Section V, Article 10


Test certificate


10. MSLD jacket leakage test

Vacuum jacket

Leakage rate across jacket



Test certificate


11. MSLD seat leakage test


Leakage rate across seat



Test certificate




2.121


S No

Test Object tested


Sample size

Test procedure


Form of record


Test witnessed by

Record reviewed by


Valve Cleanliness for Oxygen service

100 % CGA G-4.1/ ASTM G 93



13. Response time test

Valve Response time

100 % Vendor’s standard


Test certificate

Vendor - Inspector

14. Hazardous area certification (if applicable)

Electrical and electronic parts

Compatibility with environment

IEC/ ATEX

IEC/ ATEX IEC/ ATEX and purchase order specification

Test certificate

Accredited agency


Notes 1. Inspector: Third party inspection agency.



2.122

Table A2.C.6.2 Electro Pneumatic [EP] valves

Sl. No Tag

number Line No.

Flu

id

med

ium

No

min

al

Siz

e

(metr

ic)

MA

WP

(M

Pa)

Pre

ssu

re

rati

ng

cla

ss

No

rmal

po

sit

ion

Valv

e

co

eff

icie

nt

CV

Resp

on

se

tim

e (

sec)

Working temp. range

(K)

Type


1 DVP 100 120-50-XXS-36 LOX DN 50 36 4500 NC 25 ≤4 75 to 350 BS-ES-VJ



4 DVP 104 100-65-XXS-36 LOX DN 15 36 4500 NC 1 ≤2 75 to 350 BS-ES



7 DVP 110 110-50-10S-1.4 LOX DN 50 1.4 150 NC 51 ≤4 75 to 350 BS-ES-VJ

8 DVP 111 110-50-10S-1.4 LOX DN 50 1.4 150 (NO) 51 ≤4 75 to 350 BS-ES-VJ






14 DVP 122 120-50-XXS-36 LOX DN 15 36 4500 (NO) 1 ≤2 75 to 350 BS-ES-VJ









2.123


Sl. No Tag

number Line No.

Flu

id

med

ium

No

min

al

Siz

e

(metr

ic)

MA

WP

(M

Pa)

Pre

ssu

re

rati

ng

cla

ss

No

rmal

po

sit

ion

Valv

e

co

eff

icie

nt

CV

Resp

on

se

tim

e (

sec)

Working temp. range

(K)

Type



23 DVP 137 160-150-10S-1.6 LOX DN 100 1.6 300 NC 200 ≤5 75 to 350 BS-ES -VJ






29 DVP 162O)

160-150-10S-1.6 LOX DN 15 1.6 300 (NO) 4 ≤2 75 to 350 BS-ES-VJ

30 DVP 163 160-150-10S-1.6 LOX DN 150 1.6 300 NC 445 ≤1.5 75 to 350 BS-ES-VJ






36 DVP 182 180-80-10S-1.4 LOX DN 15 1.4 150 NC 4 ≤2 75 to 350 BS

37 DVP 340 104A-25-XXS-36 LOX/ LN2

DN 25 36 4500 NC 4 ≤2

75 to 350 BS-ES-VJ

38 DVP 617 160-150-10S-1.6 GHe DN 15 1.6 300 NC 4 ≤2 75 to 350 BS

39 DVP 645 120-50-XXS-36 GHe DN 15 36 4500 NC 1 ≤2 75 to 350 BS


41 DVP 700 100-65-XXS-36 GN2 DN 65 44 4500 NC 35 ≤5 75 to 350 BS-ES

42 DVP 717 100-65-XXS-36 GN2 DN 25 36 4500 NC 4 ≤2 75 to 350 BS



2.124


Sl. No Tag

number Line No.

Flu

id

med

ium

No

min

al

Siz

e

(metr

ic)

MA

WP

(M

Pa)

Pre

ssu

re

rati

ng

cla

ss

No

rmal

po

sit

ion

Valv

e

co

eff

icie

nt

CV

Resp

on

se

tim

e (

sec)

Working temp. range

(K)

Type

43 DVP 718 130-150-10S-1.6 GN2 DN 40 1.6 300 NC 31 ≤4 75 to 350 BS

44 DVP 719 110-50-10S-1.4 GN2 DN 15 1.4 150 NC 4 ≤2 75 to 350 GS

45 DVP 720 152-25-10S-1.4 GN2 DN 15 1.4 150 NC 4 ≤2 75 to 350 BS-ES


47 DVP 724 107-65-10S-1.4 GN2 DN 15 1.4 150 NC 4 ≤2 75 to 350 GS


49 DVP 734 160-150-10S-1.6 GN2 DN 15 3.7 300 NC 4 ≤2 75 to 350 GS

50 DVP 736 120-50-XXS-36 GN2 DN 15 36 4500 NC 1 ≤2 75 to 350 GS

51 DVP 758 137-100-10S-1.4 GN2 DN 15 1.4 150 NC 4 ≤2 75 to 350 GS


52 DVP 200 220-50-80S-17 LH2 DN 50 17 1500 NC 41 ≤4 15 to 350 BS-ES-VJ



55 DVP 204 200-65-80S-17 LH2 DN 15 17 1500 NC 3 ≤2 15 to 350 BS-ES



58 DVP 210 210-50-10S-1.4 LH2 DN 50 1.4 150 NC 51 ≤4 15 to 350 BS-ES-VJ

59 DVP 211 210-50-10S-1.4 LH2 DN 50 1.4 150 (NO) 51 ≤4 15 to 350 BS-ES-VJ








2.125


Sl. No Tag

number Line No.

Flu

id

med

ium

No

min

al

Siz

e

(metr

ic)

MA

WP

(M

Pa)

Pre

ssu

re

rati

ng

cla

ss

No

rmal

po

sit

ion

Valv

e

co

eff

icie

nt

CV

Resp

on

se

tim

e (

sec)

Working temp. range

(K)

Type

65 DVP 222 220-50-80S-17 LH2 DN 15 17 1500 (NO) 3 ≤2 15 to 350 BS-ES-VJ














79 DVP 263 260-150-10S-1.6 LH2 DN 150 1.6 300 NC 445 ≤1.5 15 to 350 BS-ES-VJ







86 DVP 506 506-40-XXS-44 GH2 DN 40 44 4500 NC 13 ≤4 15 to 350 BS-ES

87 DVP 516 200-65-80S-17 GH2 DN 15 17 1500 NC 3 ≤2 15 to 350 BS-ES



2.126


Sl. No Tag

number Line No.

Flu

id

med

ium

No

min

al

Siz

e

(metr

ic)

MA

WP

(M

Pa)

Pre

ssu

re

rati

ng

cla

ss

No

rmal

po

sit

ion

Valv

e

co

eff

icie

nt

CV

Resp

on

se

tim

e (

sec)

Working temp. range

(K)

Type

88 DVP 517 230-150-10S-1.6 GH2 DN 15 1.6 300 NC 4 ≤2 15 to 350 BS

89 DVP 518 253-25-10S-1.4 GH2 DN 15 1.4 150 NC 4 ≤2 15 to 350 BS

90 DVP 535 230-150-10S-1.6 GH2 DN 80 7.4 600 NC 103 ≤5 15 to 350 BS-ES

91 DVP 560 560A-25-40S-17 GH2 DN 25 17 1500 NC 12 ≤2 15 to 350 BS-ES-VJ

92 DVP 610 220-50-80S-17 GHe DN 15 17 1500 NC 3 ≤2 15 to 350 BS

93 DVP 611 220-50-80S-17 GHe DN 15 17 1500 NC 3 ≤2 15 to 350 BS








101 DVP 754 207-50-10S-1.4 GN2 DN 15 1.4 150 NC 4 ≤2 15 to 350 BS

102 DVP 759 237-100-10S-1.4 GN2 DN 25 1.4 150 NC 13 ≤2 15 to 350 BS


103 DVP 300 311-65-10S-2.5 LN2 DN 40 2.5 300 NC 30 ≤4 75 -350 BS-ES-VJ

104 DVP 301 312-100-10S-2.5 GN2 DN 100 2.5 300 NC 200 ≤5 75 -350 BS-ES

105 DVP 302 312-100-10S-2.5 LN2 DN 25 2.5 300 NC 13 ≤2 75 -350 BS-ES




109 DVP 726 320-40-10S-1.4 GN2 DN 15 1.4 150 NC 4 ≤2 75 -350 BS-ES



2.127


Sl. No Tag

number Line No.

Flu

id

med

ium

No

min

al

Siz

e

(metr

ic)

MA

WP

(M

Pa)

Pre

ssu

re

rati

ng

cla

ss

No

rmal

po

sit

ion

Valv

e

co

eff

icie

nt

CV

Resp

on

se

tim

e (

sec)

Working temp. range

(K)

Type


110 DVP 557 556-25-160-31 GH2 DN 25 31 2500 NC 7 ≤2 80-350 BS-ES-VJ



113 DVP 630 556-25-160-31 GHe DN 15 31 2500 NC 7 ≤2 273-350 BS

Note: GS-Gland sealed, BS- Bellow sealed, ES-Extended stem, VJ-Vacuum jacketed



2.128

A2.C.7 TECHNICAL SPECIFICATION OF CONTROL VALVES

The control valve shall comprise valve, Smart positioner and actuator. Quantity : As given in Table A2.C.7.2

Tag number : As given in Table A2.C.7.2 VALVE

Pattern : Globe

Application : Orifice with opening variable from 0 to 100 % / Proportional Control

Actuation

:

By pneumatic actuator

Configuration of ports/ ways





Valve co-efficient (kv)

: To be specified by manufacturer

Inlet nominal pipe size x schedule number


Outlet nominal pipe size x schedule number


MAWP Rangeability

: :

As given in Table A2.C.7.2

1:50

Design code : ASME B 16.34

Test code : ASME B 16.34, ASME B 16.104/ FCI 70.2.

Permissible leakage rate across seat

: Class VI as per ASME B 16.104/ FCI 70.2 for resilient-seated valves

Class IV as per ASME B 16.104/ FCI 70.2 for hard-seated valves



2.129


: 5,000

End connection : As given in Table A2.C.7.2 The acronyms shall be read as given in Manual Valves specifications

The other specifications and tests shall be the same as those given for Manual valves in section A2.C.5 ACTUATOR

Type : Linear actuator, piston/ diaphragm type, single acting, spring return, fail-safe

Normal position : As given in Table A2.C.7.2

Command gas

: Gaseous Nitrogen at suitable pressure supplied by the positioner.

Response time (for both opening and closing strokes)

:

As given in Table A2.C.7.2 If required, flow (volume) booster and quick exhaust valve shall be incorporated to achieve the specified response time.

End connection for command gas

: DN 8 (¼”) NPT(F) to ASME B 1.10.1.

Material : Carbon steel (enamel-painted)

Cv type test: : CV type test shall be carried out for all control valves and CV type test certificate shall be provided

Instrumentation: The specification of valve positioner which is part of control valve shall be as per specification given below. Type : Microprocessor-based smart valve

positioner integrated with valve

position transmitter (Feed back

module)

Travel length : 3 to 100 mm for linear motion



2.130

Position sensing : Contact type / Inductive type

Auto positioning : The positioner shall have

provision to carry out auto tuning,

which is selectable by hand-held

communicator or by local

switches.

Positioner input:

Input : 4 to 20 mA, 2 wire

Power supplied by the 4 to 20 mA

current only. No external power

supply.

Input range : Range shall be configurable

through hand held communicator

or by local switches

Voltage drop : 10 V DC maximum at 20 mA

Minimum current : 3.6 mA

Communication : HART protocol, digital signal

superimposed on the 4 to 20 mA

current signal

Reverse polarity protection : Reverse polarity shall not damage

the positioner.

Command gas supply : Gaseous Nitrogen at 0.55 ± 0.1

Mpa(g). (If the positioner or

actuator is designed for lesser

pressure, suitable pressure

regulator along with filter shall be

integrated with control valve by

the Contractor.

Positioner output:

Output to actuator : 0 to 100 % command gas

pressure

Indication : 4 1/2 digit LCD indicator

Feedback : 2-wire, 4 to 20 mA output



2.131

corresponding to valve position.

Output range : Shall be configurable through

hand-held communicator or by

local switches

Flow characterization : Equal Percentage

Gain : Selectable through hand-held

communicator or locally adjustable

Travel time : Adjustable through hand-held

communicator or locally

adjustable.

Performance specification:

Resolution (A/D

conversion)

: > 4000 steps

Sample rate : 20ms

Repeatability : 0.1% of full scale

Hysterisis : 0.2% of full scale

Command gas

consumption

: < 0.25 Nm3/h

Tolarence band/dead band : 0.3 – 10% adjustable

Operating temperature : 233 to 358 K (-40 to 85°C)

Vibration effect : ≤ 0.1% upto 10g and 80Hz

EMI effect : Comply with IEC60801

Physical specification:

Electrical connection : DN15 (1/2 NPT) as per ASME B

1.20.1

Pressure gauge : Pressure gauges for supply and

output command gas to be

provided along with Air filter

regulator.

Mass : 3 kg approximate



2.132

Ingress protection class : IP 67

Hazardous area

certification

: The positioner shall be intrinsically

safe for Hydrogen environment in

conformance with EEx ia IIC T6,

Zone 1 of IEC/ ATEX. The

certificate of conformance to this

effect from the accredited agency

shall be provided.

Make and model number : To be specified by the bidder in

the quotation

Safe integrity level : SIL 2

Suggested make : a. Smar, Brazil b. ABB, Germany c. Fischer

Quality assurance plan: As given in Table A2.C.7.1



2.133

Table A2.C.7.1: QUALITY ASSURANCE PLAN FOR CONTROL VALVES

S No

Test Object tested


Sample size

Test procedure


Form of record


Test witnessed by

Record reviewed by



1 per heat/ lot

Relevant standard





2. Bellows cyclic life test (wherever applicable)


3 per batch of same size and type

BS 5352 BS 5352 Test certificate

Sub-vendor



Butt welding joints

Absence of defects


ASME, Section IX

Test certificate

Vendor - Inspector




Relevant standard

Test certificate

Vendor - Inspector




Relevant standard

Test certificate

Vendor - Inspector



Test report

Vendor - Inspector



2.134


S No

Test Object tested


Sample size

Test procedure


Form of record


Test witnessed by

Record reviewed by

6. Pre-assembly hydraulic shell pressure test

Valve before assembly with bellows



BS 6755 Part 1/ API 598/ ASME B 16.34

Test certificate


7. Final hydraulic shell pressure test

Valve after assembly with bellows

Structural integrity of body under stress


BS 6755 Part 1/ API 598/ ASME B 16.34

Test certificate


8. MSLD shell leakage test





Test certificate


9. MSLD jacket leakage test

Vacuum jacket

Leakage rate across jacket



Test certificate


10. Pneumatic seat leakage test



100 % ASME B 16.104/ FCI 70.2


Test certificate




100 % CGA G-4.1/ ASTM G 93



12. Response time test

Valve Response time

100 % Vendor’s standard


Test certificate

Vendor - Inspector



2.135


S No

Test Object tested


Sample size

Test procedure


Form of record


Test witnessed by

Record reviewed by

13. Hazardous area certification (if applicable)

Electrical and electronic parts

Compatibility with environment

IEC/ ATEX

IEC/ ATEX IEC/ ATEX and purchase order specification

Test certificate

Accredited agency





2.136

Table A2.C.7.2 Control valve

Sl No

Tag number Line No.

Flu

id

med

ium

Size (metric)

Line Pipe size

Flo

w r

ate

(k

g/s

)

Valv

e

co

eff

. C

v

MA

WP

(M

Pa)

Resp

on

se t

ime

(sec)

Pro

cess

tem

p. (K

)

Type Inlet outlet


1 DVC 100(NO) 100-65-XXS-36 LOX DN 65 DN 65 DN 65 1.5 35 36 ≤5 75 to 350 BS-ES-VJ

2 DVC 120(NO) 120-50-XXS-36 LOX DN 50 DN 50 DN 50 4 25 36 ≤4 75 to 350 BS-ES-VJ

3 DVC 121(NO) 120-50-XXS-36 LOX DN 25 DN 25 DN 25 1.5 6.8 36 ≤2 75 to 350 BS-ES-VJ

4 DVC 122(NO) 120-50-XXS-36 LOX DN 25 DN 25 DN 25 1.5 6.8 36 ≤2 75 to 350 BS-ES-VJ

5 DVC 130(NO) 130-150-10S-1.6 LOX DN 100 DN 150 DN 150 1.8 200 1.6 ≤5 75 to 350 BS-ES-VJ

6 DVC 150(NO) 151-50-10S-1.4 LOX DN 50 DN 50 DN 50 1.5 42.6 1.4 ≤4 75 to 350 BS-ES-VJ

7 DVC 160(NO) 161-65-80S-18.6 LOX DN 65 DN 65 DN 150 60 42.6 18.6 ≤5 75 to 350 BS-ES-VJ




10 DVC 200(NO) 200-65-80S-17 LH2 DN 65 DN 65 DN 65 0.260 57.4 17 ≤5 15 to 350 BS-ES-VJ



13 DVC 230(NO) 230-100-10S-1.6 LH2 DN 100 DN 150 DN 150 0.30 170.5 1.6 ≤5 15 to 350 BS-ES-VJ






18 DVC 557 556-25-160-31 GH2/GHe DN 25 DN 25 DN 25 0.16 5.5 31 ≤2 80-350 BS-ES-VJ

19 DVC 558 556-25-160-31 GH2/GHe DN 25 DN 25 DN 25 0.17 5.5 31 ≤2 80-350 BS-ES-VJ



2.137

A2.C.8 TECHNICAL SPECIFICATION OF FILTERS





Nominal inlet and outlet pipe size


Maximum allowable working pressure


Degree of filtration (absolute)


Nominal inlet temperature


Nominal inlet pressure : As given in Table A2.C.8.2

Nominal flow rate : As given in Table A2.C.8.2

Permissible pressure drop at working flow rate


Filtration area : To be specified by the bidder in the quotation along with the relevant calculations for 50% clogging condition

End connection : BW: Butt welding ends as per ASME B 16.9/ 16.25. In case of filter with internal resilient seals, pipe stubs as per ASME B 36.19/ 36.10 of 100 mm length each shall be butt-welded to the body on either side, the ends of which shall be prepared for butt welding. The butt welding ends shall be suitable to mate with the interfacing pipe of schedule number as given in Table A2.C.8.2

Permissible leakage rate across the body (external)

: 1E-7 Pa-m3/s for filters for fluid medium of liquid Hydrogen, liquid Oxygen, liquid Nitrogen, gaseous Hydrogen

Insulation (for those filters indicated in Table )

: Double-walled construction with multi-layer (Aluminised or Silverised Mylar) vacuum insulation



2.138

Permissible heat in-leak rate referred to the standard condition of liquid Nitrogen

: 4.2 W for DN 40 6.1 W for DN 50 9.3 W for DN 65 18.8 W for DN 100 36.5 W for DN 150

Style of construction: Body : Y or T type with access to replace the

filter element cartridge without removing the filter en-masse from pipeline. The vacuum jacket of filter assembly shall be provided with a suitable flange for access to filter element. For sizes ≤DN50, Filters are preferred in bi-directional type.

Filter element : Sintered wire mesh type, supported on perforated cartridge

Material of construction: Body : ASTM A182F 304 L / 316L / 321

For ≤DN40

ASTM A351 CF3 /CF3M For ≥DN50 Alternatively, the material of housing of filters of size ≥ DN50 may be fabricated using standard pipes, caps, pipe fittings, etc of material SS 304L/ 316L subject to following:

a. Pipes of size ≤ DN 300 shall be seamless and sizes ≥ DN 350 shall be of welded or seamless.

b. The parent/ raw materials (pipes, caps, pipe fittings, etc) used shall be subject to 100 % ultrasonic test. c. The welding joints (including longitudinal seam joint of welded pipes) shall be subject to 100 % radiographic test.



2.139

d. The drawings are to be specifically reviewed the Department before fabrication.

Mesh : Stainless steel 304L/ 316L/ 321

Internal seals : PTFE/ Glass-filled PTFE for filters with lower limit of working temperature range ≥ 75 K

PCTFE/ Poly-carbonate for filters

with lower limit of working temperature range < 75 K

Viton/ PTFE for filters with working temperature range 290 to 350 K

Bolts : ASTM A 320 B 8 Nuts : ASTM A 194 8 Tests: a. Material certificates: The material certificates, detailing the

physical and chemical properties, of the principal pressure–bearing parts shall be provided.

b. Welding joint test (wherever applicable): All butt welding joints in

the filter shall be subject to radiographic test with X-rays or gamma rays to 2% equivalent sensitivity as per Section IX, ASME. All the socket welding joints shall be subject to dye-penetrant test.

c. Soundness test for castings (wherever applicable): All the

castings shall be subject to soundness test with radiographic or ultrasonic technique for flaw detection.

d. Hydraulic shell pressure test: The filter, upon final assembly shall

be subject to pressure test with Water (with suitable corrosion inhibitor) at 1.3 times the maximum allowable working pressure.

e. MSLD shell leakage test (for filters with fluid medium gaseous

Hydrogen, gaseous Helium and Vacuum): The global leakage rate across body shall be measured with gaseous Helium Mass Spectrometer Leakage Detector (MSLD) to establish the permissible leakage rate values specified above by hood technique as per Article 10, Section V, ASME. The leakage test shall be performed by shrouding the entire outside surface of the filter with a plastic bag to hold gaseous Helium + gaseous Air mixture at a positive pressure and by evacuating and connecting the inlet/ outlet port to MSLD. Leakage test by detector probe or tracer probe technique is not acceptable.



2.140

f. MSLD jacket leakage test: The global leakage rate across jacket

shall be measured with gaseous Helium MSLD to establish the permissible leakage rate values specified above by hood technique as per Article 10, Section V, ASME. Suitable temporary blank-off shall be used to seal the annular gap between the process (core) pipe and the jacket pipe for performing this test. The leakage test across the jacket shall be performed by shrouding the entire outside surface of the jacket with a plastic bag to hold gaseous Helium + gaseous Air mixture at a positive pressure and by evacuating and connecting the annular space between the valve and the jacket to MSLD. Leakage test by detector probe or tracer probe technique is not acceptable.

g. Degree of filtration test: One sample filter element cartridge from

each batch of the same size shall be subject to “micron rating” prototype test by bubble point method and microscopic examination to evaluate minimum and maximum pore size of the filter element in Government-approved laboratory.

Cleanliness All the interior flow surfaces of the filter shall be degreased and cleaned to Oxygen service standards as per CGA G-4.1 or ASTM G 93. Marking All the filters are assigned tag numbers for the sake of identification. The tag number for each filter, as indicated above, besides manufacturer, size, maximum allowable working pressure, degree of filtration, material of construction, etc, shall be legibly and indelibly engraved on the body of the valves. Quality assurance plan: As given in Table A2.C.8.1



2.141

Table A2.C.8.1: QUALITY ASSURANCE PLAN FOR FILTERS

S

No

Test Object

tested

Characteristic

sought for

Sample

size

Test

procedure

Acceptance

criterion

Form of

record


Test

performed

by

Test

witnessed

by

Record

reviewed

by

1. Material test Specimen

from raw

materials

Chemical

composition

and physical

properties

1 per

heat/ lot

Relevant

standard

Relevant

material

specification

Material

certificate

Vendor or

Third

party

laboratory

- Vendor,

Inspector

,

2. Welding joint

test (wherever

applicable)

Butt welding

joints

Absence of

defects

100 % Radiographi

c test

ASME,

Section IX

Test

certificate

Vendor - Inspector

,

Socket

welding

joints

Absence of

surface

defects

100 % Dye

penetrant

test

Relevant

standard

Test

certificate

Vendor - Inspector

,

3. Soundness

test for

castings

(wherever

applicable)

Castings Absence of

defects

100 % Radiographi

c or

ultrasonic

test

Relevant

standard

Test

certificate

Vendor - Inspector

,



2.142


S

No

Test Object

tested

Characteristic

sought for

Sample

size

Test

procedure

Acceptance

criterion

Form of

record


Test

performed

by

Test

witnessed

by

Record

reviewed

by

4. Dimensional

check

Filter Dimensions 100 % Metrology Relevant

standard/

Department-

approved

drawing

Test

report

Vendor - Inspector

,

5. Hydraulic

shell pressure

test

Filter Structural

integrity under

stress

100 % Section VIII,

Division 1,

ASME

Section VIII,

Division 1,

ASME

Test

certificate


,

6. MSLD shell

leakage test

Filter Leakage rate

across body

100 % ASME,

Section V,

Article 10

Purchase

order

specification

Test

certificate


,

7. MSLD jacket

leakage test

Vacuum

jacket

Leakage rate

across jacket

100 % ASME,

Section V,

Article 10

Purchase

order

specification

Test

certificate


,



2.143


S

No

Test Object

tested

Characteristic

sought for

Sample

size

Test

procedure

Acceptance

criterion

Form of

record


Test

performed

by

Test

witnessed

by

Record

reviewed

by

8. Degree of

filtration test

Filter

element

Degree of

filtration

1 per lot Bubble point

method and

microscopic

examination

Relevant

standard

Test

certificate


,

9. Cleanliness (if

applicable)

Filter Cleanliness

for Oxygen

service

100 % CGA G-4.1/

ASTM G 93

CGA G-4.1/

ASTM G 93


,

Notes: 1. Inspector: Third party inspection agency



2.144

Table A2.C.8.2 SI Filters

Sl. No

Tag number Line No.

Flu

id

med

ium

Siz

e

(metr

ic)

MA

WP

(M

Pa)

Pre

ssu

re

dro

p (

MP

a)

Pro

cess

tem

p. (K

)

Deg

ree o

f fi

ltra

tio

n

No

min

al

Flo

w r

ate

(k

g/s

)

No

min

al

Inle

t P

ressu

re

MP

a

No

min

al

Inle

t t

em

p.

(K)


1 DFL 110 110-50-10S-1.4 LOX DN 50 1.4 <0.05 75 to 350 5 3.4 0.5 92

2 DFL 120 120-50-XXS-36 LOX DN 50 36 <0.03 75 to 350 16 4.19 28.6 92

3 DFL 121 120-50-XXS-36 LOX DN 50 36 <0.015 75 to 350 70 4.19 28.6 92

4 DFL 151 150-100-10S-1.4 LOX DN 100 1.4 <0.015 75 to 350 70 22.8 0.18 92

5 DFL 160 160-150-10S-1.6 LOX DN 150 1.6 <0.05 75 to 350 16 62.88 1 92

6 DFL 161 160-150-10S-1.6 LOX DN 150 1.6 <0.015 75 to 350 70 62.88 1 92


7 DFL 210 210-50-10S-1.4 LH2 DN 50 1.4 <0.05 15 to 350 5 0.3 0.2 22

8 DFL 220 220-50-80S-17 LH2 DN 50 17 <0.03 15 to 350 16 75.52 13 30

9 DFL 221 220-50-80S-17 LH2 DN 50 17 <0.015 15 to 350 70 75.52 13 30

10 DFL 250 250-100-10S-1.4 LH2 DN 100 1.4 <0.015 15 to 350 70 68.96 0.25 22

11 DFL 260 260-150-10S-1.6 LH2 DN 150 1.6 <0.05 15 to 350 16 68.96 1.0 23

12 DFL 261 260-150-10S-1.6 LH2 DN 150 1.6 <0.015 15 to 350 70 68.96 1.0 23


13 DFL 310 310-40-10S-1.4 LN2 DN40 1.4 <0.05 75 -350 5 3.6 0.5 79



2.145

A2.C.9 TECHNICAL SPECIFICATION OF NON-RETURN VALVES

Tag number : As given in Table A2.C.9.2.

Type Plug Type

Fluid medium : As given in Table A2.C.9.2.


: As given in Table A2.C.9.2.

Nominal size : As given in Table A2.C.9.2.

MAWP : As given in Table A2.C.9.2.

Cracking pressure (minimum pressure required to open the valve along intended flow direction)

: As given in Table A2.C.9.2.

End connection : BW: Butt welding ends as per ASME B 16.9/ 16.25. In case of

valves with resilient seat, pipe stubs as per ASME B 36.19/ 36.10 of 100 mm length each shall be butt-welded to the body on either side, the ends of which shall be prepared for butt welding. The butt welding ends shall be suitable to mate with the interfacing pipe of schedule number as given in Table A2.C.9.2.

Flanged: Raised Face (RF) flanges with serration for pressure

rating class ≤ PN 250 and Ring Joint (RJ) flanges for pressure rating class ≥ PN 420 as per ASME B 16.5.


: 1E-6 Pa-m3/s for valves for fluid medium of liquid Hydrogen, liquid Oxygen, liquid Nitrogen, gaseous Hydrogen and gaseous Helium

Bubble-tight as per API 598 or Rate A as per BS 6755 Part 1 for valves for other fluid media

Permissible leakage rate across seat at a pressure differential of 50 % of the cracking pressure along flow (forward) direction

: Bubble-tight as per API 598 or Rate A as per BS 6755 Part 1



2.146

Permissible leakage rate across seat at a pressure differential of 0.2 MPa(d) along non-flow (reverse) direction

: Bubble-tight as per API 598 or Rate A as per BS 6755 Part 1

Style of construction: Lift mechanism

: Lift plug type, globe pattern for valves of nominal size ≤ DN 100

Swing/ butterfly/ dual plate type

for valves of nominal size > DN 100

Cover

:

Screwed or bolted to body with suitable seals

Plug : Renewable (replaceable) from stem with insert

Material of construction

Note: For Oxygen service Pressure >15MPa: All internals shall be

made of compatible materials such as Monel, bronze & other copper

alloys.

Body, cover :

ASTM A 182 F 304L/ 316L/ 321 for nominal size ≤ DN 40

ASTM A 351 CF 3/ 3M for

nominal size ≥ DN 50

Stem, plug : ASTM A 479 304L/ 316L/ 321

Plug insert/ trim : PCTFE (Kel-F)/ Poly-carbonate

for working temperature < 75 K and pressure rating class ≤ PN 250

ASTM A 479 304L/ 316L/ 321

for pressure rating class ≥ PN 420.




2.147

Nuts : ASTM A 194 8

Tests: a. Material certificates: The material certificates, detailing the


b. Welding joint test (wherever applicable): All butt welding joints in

the valve (including the joints between the body and the pipe stubs) shall be subject to radiographic test with X-rays or gamma rays to 2% equivalent sensitivity. All the socket welding joints shall be subject to dye-penetrant test.

c. Soundness test for castings (wherever applicable): All the castings

shall be subject to soundness test with radiographic or ultrasonic technique for flaw detection.

d. Hydraulic shell pressure test: The valve, upon final assembly, shall

be subject to pressure test with Water (with suitable corrosion inhibitor) at 1.5 times the maximum rated working pressure of the particular pressure rating class of the valve.

e. MSLD shell leakage test (for valves for fluid medium of liquid

Hydrogen, liquid Oxygen, liquid Nitrogen, gaseous Hydrogen): The global leakage rate across body shall be measured with gaseous Helium Mass Spectrometer Leakage Detector (MSLD) to establish the permissible leakage rate values specified above by hood technique as per Article 10, Section V, ASME. The leakage test shall be performed by shrouding the entire outside surface of the valve with a plastic bag to hold gaseous Helium + gaseous Air mixture at a positive pressure and by evacuating and connecting the inlet/ outlet port to MSLD. Leakage test by detector probe or tracer probe technique is not acceptable.

f. Seat leakage test: The leakage rates across seat in flow and non-

flow directions shall be measured with gaseous nitrogen / dry Air to establish the permissible leakage rate values specified above by bubble emission method.

Cleanliness All the interior flow surfaces of the valve shall be degreased and cleaned to Oxygen service standards as per CGA G-4.1 or ASTM G 93. Marking



2.148

All the valves are assigned tag numbers for the sake of identification. The tag number for each valve, as indicated above, besides size, pressure rating class, material of construction, etc, shall be legibly and indelibly engraved on the body of the valves. Quality assurance plan: As given in Table A2.C.9.1.



2.149

Table A2.C.9.1: QUALITY ASSURANCE PLAN FOR NON-RETURN VALVES

S No

Test Object tested


Sample size

Test procedure


Form of record


Test witnessed by

Record reviewed by



1 per heat/ lot

Relevant standard






Butt welding joints

Absence of defects


ASME, Section IX

Test certificate

Vendor - Inspector,




Relevant standard

Test certificate

Vendor - Inspector,




Relevant standard

Test certificate

Vendor - Inspector,



Test report

Vendor - Inspector,

5. Hydraulic shell pressure test




BS 6755 Part 1/ API 598/ ASME B 16.34

Test certificate

Vendor Inspector Inspector,



2.150

Table A2.C.9.1: QUALITY ASSURANCE PLAN FOR NON-RETURN VALVES

S No

Test Object tested


Sample size

Test procedure


Form of record


Test witnessed by

Record reviewed by

6. MSLD shell leakage test (wherever applicable)





Test certificate


7. MSLD seat leakage test (wherever applicable)





Test certificate


8. Pneumatic seat leakage test (wherever applicable)



100 % Water displacement method


Test certificate




100 % CGA G-4.1/ ASTM G 93


Certificate Vendor - Inspector,




2.151

Table A2.C.9.2 Non Return Valves [NRV]

Sl. No


medium Size

(metric)

Cracking pressure

(MPa)

MAWP (MPa)

Process temp. (K)


1 DVN 100 107-65-10S-1.4 LOX DN 65 0.15 1.4 75 to 350

2 DVN 101 100-65-XXS-36 LOX DN 25 0.2 1.4 75 to 350

3 DVN 110 110-50-10S-1.4 LOX DN 15 0.2 1.4 75 to 350

4 DVN 111 111-50-10S-1.4 LOX DN 15 0.2 1.4 75 to 350

5 DVN 112 120-50-XXS-36 LOX DN 15 0.2 1.4 75 to 350

6 DVN 120 120-50-XXS-36 LOX DN 15 0.2 1.4 75 to 350

7 DVN 128 120-50-XXS-36 LOX DN 15 0.2 1.4 75 to 350

8 DVN 130 160-150-10S-1.6 LOX DN 15 0.2 1.6 75 to 350

9 DVN 131 130-150-10S-1.6 LOX DN 25 0.2 1.6 75 to 350

10 DVN 132 137-100-10S-1.4 LOX DN 100 0.15 1.4 75 to 350

11 DVN 160 160-150-10S-1.6 LOX DN 15 0.2 1.4 75 to 350

12 DVN 180 180-80-10S-1.4 LOX DN 15 0.2 1.4 75 to 350

13 DVN 450 152-25-10S-1.4 GO2 DN 25 0.15 1.4 75 to 350

14 DVN 617 160-150-10S-1.6 GHe DN 15 0.15 1.6 75 to 350

15 DVN 645 120-50-XXS-36 GHe DN 15 0.15 36 75 to 350

16 DVN 647 180-80-10S-1.4 GHe DN 15 0.15 1.4 75 to 350

17 DVN 719 110-50-10S-1.4 GN2 DN 15 0.15 1.4 75 to 350

18 DVN 721 150-100-10S-1.4 GN2 DN 15 0.15 1.4 75 to 350

19 DVN 724 107-65-10S-1.4 GN2 DN 15 0.15 1.4 75 to 350

20 DVN 734 160-150-10S-1.6 GN2 DN 15 0.15 3.7 75 to 350

21 DVN 736 120-50-XXS-36 GN2 DN 15 0.15 36 75 to 350

22 DVN 758 137-100-10S-1.4 GN2 DN 15 0.15 1.4 75 to 350



2.152


Sl. No


medium Size

(metric)

Cracking pressure

(MPa)

MAWP (MPa)

Process temp. (K)

Liquid Hydrogen[LH2] System (Ref P&ID: Drawing CTPT/CFS/P&ID/200/R0))

23 DVN 200 220-50-80S-17 LH2 DN 15 0.2 1.4 15 to 350

24 DVN 201 200-65-80S-17 LH2 DN 15 0.2 1.4 15 to 350

25 DVN 202 207-50-10S-1.4 LH2 DN 50 0.15 1.4 15 to 350

26 DVN 210 210-50-10S-1.4 LH2 DN 15 0.2 1.4 15 to 350

27 DVN 211 211-50-10S-1.4 LH2 DN 15 0.2 1.4 15 to 350

28 DVN 220 220-50-80S-17 LH2 DN 15 0.2 1.4 15 to 350

29 DVN 221 222-65-10S-1.4 LH2 DN 15 0.2 1.4 15 to 350

30 DVN 230 260-150-10S-1.6 LH2 DN 15 0.2 1.6 15 to 350

31 DVN 231 230-100-10S-1.6 LH2 DN 25 0.2 1.6 15 to 350

32 DVN 232 237-100-10S-1.4 LH2 DN 100 0.15 1.4 15 to 350

33 DVN 260 260-150-10S-1.6 LH2 DN 15 0.2 1.6 15 to 350

34 DVN 261 261-65-80S-18.6 LH2 DN 15 0.2 1.4 15 to 350

35 DVN 270 270-80-10S-1.4 LH2 DN 15 0.2 1.4 15 to 350

36 DVN 550 253-25-10S-1.4 LH2 DN 15 0.15 1.4 15 to 350

37 DVN 610 220-50-80S-17 GHe DN 15 0.15 17 15 to 350

38 DVN 611 220-50-80S-17 GHe DN 15 0.15 17 15 to 350

39 DVN 612 260-150-10S-1.6 GHe DN 15 0.15 1.6 15 to 350

40 DVN 613 260-150-10S-1.6 GHe DN 15 0.15 1.6 15 to 350

41 DVN 622 270-80-10S-1.4 GHe DN 10 0.15 1.4 15 to 350

42 DVN 623 273-40-10S-1.4 GHe DN 10 0.15 1.4 15 to 350

43 DVN 624 570-40-10-10S-1.4 GHe DN 10 0.15 1.4 15 to 350

44 DVN 625 210-50-10S-1.4 GHe DN 15 0.15 1.4 15 to 350

45 DVN 626 250-100-10S-1.4 GHe DN 15 0.15 1.4 15 to 350



2.153


Sl. No


medium Size

(metric)

Cracking pressure

(MPa)

MAWP (MPa)

Process temp. (K)

46 DVN 751 200-65-80S-17 GN2 DN 15 0.15 1.4 15 to 350

47 DVN 752 230-150-10S-1.6 GN2 DN 15 0.15 1.6 15 to 350

48 DVN 754 207-50-10S-1.4 GN2 DN 15 0.15 1.4 15 to 350

49 DVN 759 237-100-10S-1.4 GN2 DN 15 0.15 1.4 15 to 350


50 DVN 302 312-100-10S-2.5 GN2 DN 25 0.15 2.5 77 -350

51 DVN 310 310-40-10S-1.4 LN2 DN 15 0.2 1.4 77 -350

52 DVN 321 320-40-10S-1.4 LN2 DN 15 0.2 1.4 77 -350

53 DVN 726 320-40-10S-1.4 GN2 DN 15 0.15 1.4 77 -350

54 DVN 727 311-65-10S-2.5 GN2 DN 40 0.15 3.7 77 -350

55 DVN 728 310-40-10S-1.4 GN2 DN 15 0.15 1.4 77-350

56 DVN 728V 310-40-10S-1.4 GN2 DN 15 0.15 1.4 77-350


57 DVN 630 556-25-160-31 GHe DN 15 0.15 31 80-350

58 DVN 632 556-25-160-31 GHe DN 15 0.15 31 80-350



2.154

2.8.10 TECHNICAL SPECIFICATION OF SAFETY RELIEF VALVES


Type : Balanced bellow type

Extent of lift : Full lift




Set pressure : As given in Table A2.C.10.2

Flow temperature : As per design standard

Minimum required gas flow capacity

: To be sized by the contractor

Orifice designation (area)


Over-pressure : ≤ 10 % of set pressure

Blow-down :

≤ 7 % of set pressure

Permissible leakage rate across seat

:

As per API 527

End connection : Raised Face (RF) flanges with concentric serrations for pressure rating class ≤ 1500 as per ASME B 16.5 and

Ring Joint (RJ) flanges for

pressure rating class ≥ 2500 as per ASME B 16.5

NPT as per 1.20.1 for

screwed valves (The bidder shall specify in the quotation the nominal size and pressure rating class of the flanges at inlet and outlet)



2.155

Material of construction: Body, bonnet :

ASTM A 351 CF3/3M/8/8M (for conventional & bellow balanced valves) ASTM A 182F304/304L/316 / 316L (for screwed valves)

Nozzle

:

ASTM A182F304/304L/316/ 316L (for set pr.≤ 15 MPa) ASTM A182F304/304L/316/ 316L stellited (for set pr.> 15 MPa)

Disc

: Viton (for set pr.≤1 MPa & op. temp. 300 K) PTFE (for set pr.1 to 15 MPa & op. temp. 75 to 300 K) PCTFE (for set pr.< 15 MPa & op. temp. <75 K) ASTM A182F304/304L/ 316/316L stellited (for set pr.> 15 MPa)

Guide : ASTM A 297 Gr HE

Bellows (for valves of balanced bellow construction)

: Stainless steel 316L/ 316Ti/ 321/

Spring : Stainless steel 316L


Nuts : ASTM A 194 8

Design code : API 526/ ASME Section VIII, Division /CGA-S-1.2, 2009



2.156



b. Soundness test for castings (wherever applicable): All the

castings shall be subject to soundness test with radiographic or ultrasonic technique for flaw detection.

c. Bellows cyclic life test (wherever applicable): Sample bellows drawn from each batch of the same size and type shall be subject to (destructive) cyclic life (prototype) test as per relevant standard. If the manufacturer of the bellows has already performed such test, copy of the certificate may be produced.

d. Seat leakage test: As per API 527 e. Cold differential set pressure test: To validate set pressure

f. Hydrostatic test of nozzle: All the nozzles / base of the

valves shall be subject to hydrostatic test as per Code. Cleanliness All the interior flow surfaces of the valve shall be degreased and cleaned to Oxygen service standards as per CGA G-4.1 or ASTM G 93. Marking All the valves are assigned tag numbers for the sake of identification. The tag number for each valve, as indicated above, besides manufacturer, set pressure, size & pressure rating class of inlet & outlet connections, material of construction, etc, shall be legibly and indelibly engraved on the body of the valves. Quality assurance plan: As given in Table A2.C.10.1



2.157

Table A2.C.10.1.: QUALITY ASSURANCE PLAN FOR SAFETY RELIEF VALVES

S No

Test Object tested


Sample size

Test procedure


Form of record

Pre-Delivery Inspection (PDI) Test perform by

Test witnessed by

Record reviewed by



1 per lot Relevant standard





2. Soundness test for castings



Relevant standard

Test certificate

Vendor - Inspector, Department

3. Bellows cyclic life test (if applicable)


Relevant standard

Relevant standard

Relevant standard

Test certificate

Sub-vendor




Test report

Vendor - Inspector

5. Seat leakage test

Valve Leakage rate across seat

100 % API 527 API 527 Test certificate


6. Cold differential set pressure test

Valve Set pressure, resealing pressure

100 % ASME, Section VIII, Division 1

ASME, Section VIII, Division 1

Test certificate




100 % CGA G-4.1/ ASTM G 93





2.158

Table A2.C.10.1.: QUALITY ASSURANCE PLAN FOR SAFETY RELIEF VALVES

S No

Test Object tested


Sample size

Test procedure


Form of record

Pre-Delivery Inspection (PDI) Test perform by

Test witnessed by

Record reviewed by

8. Hydrostatic test of Nozzle/base

Nozzle/base Structural integrity under stress

100% As per Code As per Code certificate Vendor - Inspector




2.159

Table A2.C.10.2 Safety Relief Valves [SRV]

Sl. No

Tag number Line No.

Flu

id

med

ium

No

min

al

Siz

e

(metr

ic)

Set

Pre

ssu

re (

MP

a)

Working temp.

range (K)


1 DVR 110 110-50-10S-1.4 LOX DN 15 1.4 75 to 350

2 DVR 111 110-50-10S-1.4 LOX DN 25 1.4 75 to 350

3 DVR 112 111-50-10S-1.4 LOX DN 25 1.4 75 to 350

4 DVR 113 120-50-XXS-36 LOX DN 25 36 75 to 350

5 DVR 120 120-50-XXS-36 LOX DN 25 36 75 to 350

6 DVR 121 120-50-XXS-36 LOX DN 25 36 75 to 350

7 DVR 122 121-40-XXS-36 LOX DN 25 36 75 to 350

8 DVR 123 120-50-XXS-36 LOX DN 25 36 75 to 350

9 DVR 124 120-50-XXS-36 LOX DN 25 36 75 to 350

10 DVR 125 120-50-XXS-36 LOX DN 25 36 75 to 350

11 DVR 126 122-40-10S-1.4 LOX DN 25 1.4 75 to 350

12 DVR 130 160-150-10S-1.6 LOX DN 25 1.6 75 to 350

13 DVR 151 150-100-10S-1.4 LOX DN 25 1.4 75 to 350

14 DVR 160 160-150-10S-1.6 LOX DN 25 1.6 75 to 350

15 DVR 161 160-150-10S-1.6 LOX DN 25 1.6 75 to 350

16 DVR 162 160-150-10S-1.6 LOX DN 25 1.6 75 to 350

17 DVR 163 162-150-10S-1.6 LOX DN 25 1.6 75 to 350

18 DVR 164 160-150-10S-1.6 LOX DN 25 1.6 75 to 350

19 DVR 165 160-150-10S-1.6 LOX DN 25 1.6 75 to 350

20 DVR 180 180-80-10S-1.4 LOX DN 25 1.4 75 to 350

21 DVR 400 103-50-XXS-36 GO2 DN 25 36 75 to 350

22 DVR 401 103-50-XXS-36 GO2 DN 25 36 75 to 350

23 DVR 402 103-50-XXS-36 GO2 DN 25 39.6 75 to 350

24 DVR 403 103-50-XXS-36 GO2 DN 25 39.6 75 to 350

25 DVR 404 100-65-XXS-36 GO2 DN 25 36 75 to 350

26 DVR 430 133-50-10S-1.6 GO2 DN 50 1.6 75 to 350

27 DVR 431 133-50-10S-1.6 GO2 DN 50 1.6 75 to 350

28 DVR 432 133-50-10S-1.6 GO2 DN 50 1.76 75 to 350

29 DVR 433 133-50-10S-1.6 GO2 DN 50 1.76 75 to 350

30 DVR 434 130-150-10S-1.6 GO2 DN 25 1.6 75 to 350

31 DVR 450 152-25-10S-1.4 GO2 DN 25 1.3 75 to 350

32 DVR 451 152-25-10S-1.4 GO2 DN 25 1.3 75 to 350


33 DVR 200 220-50-80S-17 LH2 DN 25 17 15 to 350

34 DVR 210 210-50-10S-1.4 LH2 DN 15 0.6 15 to 350

35 DVR 211 210-50-10S-1.4 LH2 DN 25 1.4 15 to 350

36 DVR 212 211-50-10S-1.4 LH2 DN 25 1.4 15 to 350

37 DVR 220 220-50-80S-17 LH2 DN 25 17 15 to 350

38 DVR 221 220-50-80S-17 LH2 DN 25 17 15 to 350

39 DVR 222 220-50-80S-17 LH2 DN 25 17 15 to 350



2.160

Table A2.C.10.2 Safety Relief Valves [SRV]

Sl. No

Tag number Line No.

Flu

id

med

ium

No

min

al

Siz

e

(metr

ic)

Set

Pre

ssu

re (

MP

a)

Working temp.

range (K)

40 DVR 223 222-65-10S-1.4 LH2 DN 25 1.4 15 to 350

41 DVR 224 220-50-80S-17 LH2 DN 25 17 15 to 350

42 DVR 225 220-50-80S-17 LH2 DN 25 17 15 to 350

43 DVR 230 260-150-10S-1.6 LH2 DN 25 1.6 15 to 350

44 DVR 260 260-150-10S-1.6 LH2 DN 25 1.6 15 to 350

45 DVR 261 260-150-10S-1.6 LH2 DN 25 1.6 15 to 350

46 DVR 262 260-150-10S-1.6 LH2 DN 25 1.6 15 to 350

47 DVR 263 262-150-10S-1.6 LH2 DN 25 1.6 15 to 350

48 DVR 264 260-150-10S-1.6 LH2 DN 25 1.6 15 to 350

49 DVR 265 260-150-10S-1.6 LH2 DN 25 1.6 15 to 350

50 DVR 270 270-80-10S-1.4 LH2 DN 25 1.4 15 to 350

51 DVR 500 503-65-80S-17 GH2 DN 50 17 15 to 350

52 DVR 501 503-65-80S-17 GH2 DN 50 17 15 to 350

53 DVR 502 503-65-80S-17 GH2 DN 50 18.7 15 to 350

54 DVR 503 503-65-80S-17 GH2 DN 50 18.7 15 to 350

55 DVR 504 200-65-80S-17 GH2 DN 25 17 15 to 350

56 DVR 530 533-100-10S-1.6 GH2 DN 80 1.6 15 to 350

57 DVR 531 533-100-10S-1.6 GH2 DN 80 1.6 15 to 350

58 DVR 532 533-100-10S-1.6 GH2 DN 80 1.76 15 to 350

59 DVR 533 533-100-10S-1.6 GH2 DN 80 1.76 15 to 350

60 DVR 534 230-100-10S-1.6 GH2 DN 25 1.6 15 to 350

61 DVR 550 253-25-10S-1.4 GH2 DN 25 0.6 15 to 350

62 DVR 551 253-25-10S-1.4 GH2 DN 25 0.6 15 to 350

63 DVR 552 252-50-10S-1.4 GH2 DN 25 1.4 15 to 350


64 DVR 301 313-25-10S-2.5 LN2 DN 25 2.5 75 -350

65 DVR 302 313-25-10S-2.5 LN2 DN 25 2.5 75 -350

66 DVR 310 310-40-10S-1.4 LN2 DN 25 1.4 75 -350

67 DVR 321 320-40-10S-1.4 LN2 DN 25 1.4 75 -350

68 DVR 728 310-40-10S-1.4 LN2 DN 15 1.4 75 -350


69 DVR 556 556-25-160-31 GH2 DN 40 31 80-350

70 DVR 560 560-25-10S-3.7 GH2 DN 25 3.7 80-350

Note: Size of the safety relief valve (SRV) of SI piping given in this table is indicative.

The size of SRV may change during detail engineering to be done by the contractor. The changes shall be accommodated without any commercial implications.



2.161

A2.C.11 TECHNICAL SPECIFICATION OF RUPTURE DISCS



Type : 1. Scored metal, pre-torqued, rupture

disc devices, along with safety heads, studs and nuts. 2. Scored metal, pre-torqued, rupture disc devices, with hinge design to withstand full vacuum, along with safety heads, studs and nuts.

Mode of buckling : To be specified by the bidder in the quotation (forward/ reverse)




Burst pressure : As given in Table A2.C.11.2

Flow temperature : As per design standard

Minimum required flow gas capacity


Orifice diameter : To be sized by the contractor

Manufacturing range

: 0 %

Burst tolerance : ± 5 %


Disc : Austenitic Stainless Steel

Safety head : ASTM A 182 F 304L/ 316L/ 321

Studs : ASTM A 320 B 8

Nuts : ASTM A 194 8



2.162



b. Burst test: As per UG-127, Section VIII, Division 1, ASME. c. MSLD leak test: The burst disc assemblies meant for Liquid

Hydrogen, Liquid Oxygen & Gaseous Hydrogen systems shall be leak tested with Gaseous Helium at an inlet pressure of 80% of burst pressure using He Mass Spectrometric Leak Detector (MSLD) and it shall be leak tight to a value better than 1 x 10-6 m3 Pa/s.

The outlet flange of the safety head shall be provided with a tell tale indicator provision required for checking in-situ the burst disc integrity. The end connection of the tell tale indicator shall be ¼” NPT(F). A bourdon type pressure gauge with suitable range of dial size 50 mm shall be connected in the tell-tale port. Cleanliness All the interior flow surfaces of the device shall be degreased and cleaned to Oxygen service standards as per CGA G-4.1 or ASTM G 93. Marking All the devices are assigned tag numbers for the sake of identification. The tag number for each device, as indicated above, besides nominal size, burst pressure, pressure rating class of the safety heads, material of construction of disc, etc, shall be legibly and indelibly engraved on the body of the devices.

QAP: As given in Table A2.C.11.1



2.163

Table A2.C.11.1: QUALITY ASSURANCE PLAN FOR RUPTURE DISC DEVICES

S No

Test Object tested


Sample size

Test procedure


Form of record


Test witnessed by

Record reviewed by








2. Burst test Rupture disc

Burst pressure

1 per lot UG-127, Section VIII, Division 1, ASME

UG-127, Section VIII, Division 1, ASME

Test certificate



Rupture disc device

Dimensions 100 % Metrology Approved drawings

Report Vendor - Inspector


Rupture disc device


100 % CGA G-4.1/ ASTM G 93



Notes: 1. Inspector: Third party inspection agency



2.164

Table A2.C.11.2 Rupture Discs

Sl. No

Tag number Line No.

Flu

id

med

ium

Siz

e

(metr

ic)

MA

WP

(M

Pa)

Process temp. (K)


1 DBD 111 110-50-10S-1.4 LOX DN 25 1.4 75 to 350

2 DBD 112 111-50-10S-1.4 LOX DN 25 1.4 75 to 350

3 DBD 113 120-50-XXS-36 LOX DN 15 36 75 to 350

4 DBD 120 120-50-XXS-36 LOX DN 25 36 75 to 350

5 DBD 121 120-50-XXS-36 LOX DN 25 36 75 to 350

6 DBD 122 121-40-XXS-36 LOX DN 25 36 75 to 350

7 DBD 123 120-50-XXS-36 LOX DN 25 36 75 to 350

8 DBD 124 120-50-XXS-36 LOX DN 15 36 75 to 350

9 DBD 125 120-50-XXS-36 LOX DN 15 36 75 to 350

10 DBD 126 122-40-10S-1.4 LOX DN 25 1.4 75 to 350

11 DBD 130 160-150-10S-1.6 LOX DN 15 1.6 75 to 350

12 DBD 151 150-100-10S-1.4 LOX DN 25 1.4 75 to 350

13 DBD 160 160-150-10S-1.6 LOX DN 25 1.6 75 to 350

14 DBD 161 160-150-10S-1.6 LOX DN 25 1.6 75 to 350

15 DBD 162 160-150-10S-1.6 LOX DN 25 1.6 75 to 350

16 DBD 163 162-150-10S-1.6 LOX DN 25 1.6 75 to 350

17 DBD 164 160-150-10S-1.6 LOX DN 15 1.6 75 to 350

18 DBD 165 160-150-10S-1.6 LOX DN 15 1.6 75 to 350

19 DBD 180 180-80-10S-1.4 LOX DN 25 1.4 75 to 350

20 DBD 400 103-50-XXS-36 GO2 DN 25 36 75 to 350

21 DBD 401 103-50-XXS-36 GO2 DN 25 36 75 to 350

22 DBD 402 103-50-XXS-36 GO2 DN 25 39.6 75 to 350

23 DBD 403 103-50-XXS-36 GO2 DN 25 39.6 75 to 350

24 DBD 404 100-65-XXS-36 GO2 DN 15 36 75 to 350

25 DBD 430 133-50-10S-1.6 GO2 DN 50 1.6 75 to 350

26 DBD 431 133-50-10S-1.6 GO2 DN 50 1.6 75 to 350

27 DBD 432 133-50-10S-1.6 GO2 DN 50 1.76 75 to 350

28 DBD 433 133-50-10S-1.6 GO2 DN 50 1.76 75 to 350

29 DBD 434 130-150-10S-1.6 GO2 DN 15 1.6 75 to 350

30 DBD 450 152-25-10S-1.4 GO2 DN 25 1.3 75 to 350

31 DBD 451 152-25-10S-1.4 GO2 DN 25 1.3 75 to 350


32 DBD 200 220-50-80S-17 LH2 DN 25 17 15 to 350

33 DBD 211 210-50-10S-1.4 LH2 DN 25 1.4 15 to 350

34 DBD 212 211-50-10S-1.4 LH2 DN 25 1.4 15 to 350

35 DBD 220 220-50-80S-17 LH2 DN 25 17 15 to 350

36 DBD 221 220-50-80S-17 LH2 DN 25 17 15 to 350

37 DBD 222 220-50-80S-17 LH2 DN 25 17 15 to 350

38 DBD 223 222-65-10S-1.4 LH2 DN 25 1.4 15 to 350

39 DBD 224 220-50-80S-17 LH2 DN 25 17 15 to 350



2.165

Table A2.C.11.2 Rupture Discs

Sl. No

Tag number Line No.

Flu

id

med

ium

Siz

e

(metr

ic)

MA

WP

(M

Pa)

Process temp. (K)

40 DBD 225 220-50-80S-17 LH2 DN 25 17 15 to 350

41 DBD 230 260-150-10S-1.6 LH2 DN 25 1.6 15 to 350

42 DBD 260 260-150-10S-1.6 LH2 DN 25 1.6 15 to 350

43 DBD 261 260-150-10S-1.6 LH2 DN 25 1.6 15 to 350

44 DBD 262 260-150-10S-1.6 LH2 DN 25 1.6 15 to 350

45 DBD 263 261-150-10S-1.4 LH2 DN 25 1.6 15 to 350

46 DBD 264 260-150-10S-1.6 LH2 DN 25 1.6 15 to 350

47 DBD 265 260-150-10S-1.6 LH2 DN 25 1.6 15 to 350

48 DBD 270 270-80-10S-1.4 LH2 DN 25 1.4 15 to 350

49 DBD 500 503-65-80S-17 GH2 DN 50 17 15 to 350

50 DBD 501 503-65-80S-17 GH2 DN 50 17 15 to 350

51 DBD 502 503-65-80S-17 GH2 DN 50 18.7 15 to 350

52 DBD 503 503-65-80S-17 GH2 DN 50 18.7 15 to 350

53 DBD 504 200-65-80S-17 GH2 DN 25 17 15 to 350

54 DBD 530 533-100-10S-1.6 GH2 DN 80 1.6 15 to 350

55 DBD 531 533-100-10S-1.6 GH2 DN 80 1.6 15 to 350

56 DBD 532 533-100-10S-1.6 GH2 DN 80 1.76 15 to 350

57 DBD 533 533-100-10S-1.6 GH2 DN 80 1.76 15 to 350

58 DBD 534 230-100-10S-1.6 GH2 DN 25 1.6 15 to 350

59 DBD 550 253-25-10S-1.4 GH2 DN 25 0.6 15 to 350

60 DBD 551 253-25-10S-1.4 GH2 DN 25 0.6 15 to 350

61 DBD 552 252-50-10S-1.4 GH2 DN 25 1.4 15 to 350


62 DBD 301 313-25-10S-2.5 LN2 DN 25 2.75 75 -350

63 DBD 302 313-25-10S-2.5 LN2 DN 25 2.75 75 -350


64 DBD 556 556-25-160-31 GH2 DN 25 31 80-350

65 DBD 560 560-25-10S-3.7 GH2 DN 25 3.7 80-350

Note: Size of the Rupture Disc (Burst Disc - BD) of SI piping given in this table is indicative. The size of BD may change during detail engineering to be done by the contractor. The changes shall be accommodated without any commercial implications.



2.166

A2.C.12 TECHNICAL SPECIFICATION OF 2 VALVE MANIFOLDS


Fluid Medium : As given in Table A2.C.12.2

Actuation

:

Hand operated (manual)

Size : DN 12 (6mm port)

Application : For the isolation of pressure gauges.

MAWP : 41.3 MPa

Working Temperature :

290 to 350 K


: 1E-07 Pa-m3/s

Permissible leak rate across seat

: 1E-06 Pa-m3/s


: 5,000

End connection

: ½” NPTF / Face seal fitting for inlet & outlet port, ¼” NPTF for vent port.


Body and Bonnet : ASTM A 479 304L/ 316L/ 321

Stem : ASTM A 479 304L/ 316L/ 321

Stem Seal : PTFE

Tests: Refer Section A2.C.5. on specification of manual valves.

Quality assurance plan: Refer Section A2.C.5 on specification of manual valves.



2.167

Table A2.C.12.2 Two Valve Manifold

Sl. No


medium MAWP (MPa)

Process temp. (K)

Type


1 DVM 110 B/C

110-50-10S-1.4 LOX

10 75 to 350


2 DVM 111 B/C

110-50-10S-1.4 LOX

3 DVM 112 B/C

111-50-10S-1.4 LOX

4 DVM 127 B/C

122-40-10S-1.4 LOX

5 DVM 131 B/C

160-150-10S-1.6 LOX

6 DVM 151 B/C

151-100-10S-1.4 LOX

7 DVM 160 B/C

160-150-10S-1.6 LOX

8 DVM 161 B/C

160-150-10S-1.6 LOX

9 DVM 162 B/C

160-150-10S-1.6 LOX

10 DVM 163 B/C

162-150-10S-1.6 LOX

11 DVM 164 B/C

160-150-10S-1.6 LOX

12 DVM 165 B/C

160-150-10S-1.6 LOX

13 DVM 166 B/C

160-150-10S-1.6 LOX

14 DVM 180 B/C

180-80-10S-1.4 LOX

15 DVM 430 B/C

133-50-10S-1.6 GO2

16 DVM 431 B/C

133-50-10S-1.6 GO2

17 DVM 432 B/C

133-50-10S-1.6 GO2

18 DVM 433 B/C

133-50-10S-1.6 GO2

19 DVM 434 B/C

130-150-10S-1.6 GO2

20 DVM 450 B/C

152-25-10S-1.4 GO2

21 DVM 451 B/C

152-25-10S-1.4 GO2

22 DVM 113 B/C

120-50-XXS-36 LOX

40 75 to 350


23 DVM 120 B/C

120-50-XXS-36 LOX

24 DVM 121 B/C

120-50-XXS-36 LOX

25 DVM 122 B/C

121-40-XXS-36 LOX

26 DVM 123 B/C

120-50-XXS-36 LOX

27 DVM 124 B/C

120-50-XXS-36 LOX

28 DVM 125 B/C

120-50-XXS-36 LOX

29 DVM 126 B/C

120-50-XXS-36 LOX

30 DVM 400 B/C

103-50-XXS-36 GO2

31 DVM 401 B/C

103-50-XXS-36 GO2

32 DVM 402 B/C

103-50-XXS-36 GO2

33 DVM 403 B/C

103-50-XXS-36 GO2

34 DVM 404 B/C

100-65-XXS-36 GO2


35 DVM 210 B/C

210-50-10S-1.4 LH2

10 75 to 350


36 DVM 211 B/C

210-50-10S-1.4 LH2

37 DVM 212 B/C

211-50-10S-1.4 LH2

38 DVM 223 B/C

222-50-10S-1.4 LH2

39 DVM 231 B/C

260-150-10S-1.6 LH2

40 DVM 260 B/C

260-150-10S-1.6 LH2

41 DVM 261 B/C

260-150-10S-1.6 LH2



2.168

Table A2.C.12.2 Two Valve Manifold

Sl. No


medium MAWP (MPa)

Process temp. (K)

Type

42 DVM 262 B/C

260-150-10S-1.6 LH2

10 75 to 350


43 DVM 263 B/C

261-150-10S-1.4 LH2

44 DVM 264 B/C

260-150-10S-1.6 LH2

45 DVM 265 B/C

260-150-10S-1.6 LH2

46 DVM 266 B/C

260-150-10S-1.6 LH2

47 DVM 270 B/C

270-80-10S-1.4 LH2

48 DVM 530 B/C

533-100-10S-1.6 GH2

49 DVM 531 B/C

533-100-10S-1.6 GH2

50 DVM 532 B/C

533-100-10S-1.6 GH2

51 DVM 533 B/C

533-100-10S-1.6 GH2

52 DVM 534 B/C

230-100-10S-1.6 GH2

53 DVM 550 B/C

253-25-10S-1.4 GH2

54 DVM 551 B/C

253-25-10S-1.4 GH2

55 DVM 552 B/C

251-50-10S-1.4 GH2

56 DVM 201 B/C

220-50-80S-17 LH2

40 75 to 350


57 DVM 220 B/C

220-50-80S-17 LH2

58 DVM 221 B/C

220-50-80S-17 LH2

59 DVM 222 B/C

220-50-80S-17 LH2

60 DVM 224 B/C

220-50-80S-17 LH2

61 DVM 225 B/C

220-50-80S-17 LH2

62 DVM 226 B/C

220-50-80S-17 LH2

63 DVM 500 B/C

503-65-80S-17 GH2

64 DVM 501 B/C

503-65-80S-17 GH2

65 DVM 502 B/C

503-65-80S-17 GH2

66 DVM 503 B/C

503-65-80S-17 GH2

67 DVM 504 B/C

200-65-80S-17 GH2


68 DVM 310B/C 310-40-10S-1.4 GN2 10 75 to 350


Gaseous Hydrogen (Ref P&ID: Drawing CTPT/CFS/P&ID/500/R0)

69 DVM 557B/C 556-25-160-31 GH2 40 75 to 350 BS-Needle type globe valve BS-

70 DVM 560B/C 560-25-10S-3.7 GH2 10 75 to 350



2.169

A2.C.13 TECHNICAL SPECIFICATION OF PRESSURE GAUGES



Type : Bourdon tube



: 290 to 350 K

Range : As given in Table A2.C.13.2

Unit : MPa(g) and bar(g)

Dial size : To be specified by Contractor during DER

Scale : Concentric

Accuracy : ±1 % of FSD

Over-range protection

: 130 % of FSD

Material of construction of sensing element, movement, socket, case, bezel

: Stainless steel 304L/ 316L/ 321

Window : Shatter-proof

Process connection : DN 8 (¼”) NPT(M) for gauges with 50 mm dial and DN 15 (½”) NPT(M) for other gauges OR ¼” Face Seal Fittings for gauges with 50 mm dial and ½” face seal fittings for other gauges

Mounting : Direct mounting, bottom entry

Case and bezel : Weather-proof housing with screwed outer bezel

Extra fitments : Micro-type adjustable pointer Blow-out-proof disc



2.170

Joints : Gas Tungsten Arc Welding (GTAW)

with gaseous Argon purge

Code : IS 3624

Tests a.Material certificates: The material certificates, detailing the physical and chemical properties, of the principal pressure–bearing parts shall be provided. b.Calibration: The pressure gauges shall be calibrated with IPA as per Code. All other tests shall be carried out as per Code IS 3624. Cleanliness All the interior flow surfaces of the pressure gauge shall be degreased and cleaned to Oxygen service standards as per CGA G-4.1 or ASTM G 93. Marking All the pressure gauges are assigned tag numbers for the sake of identification. The tag number for each pressure gauge, as indicated above, besides size, pressure rating class, material of construction, etc, shall be legibly and indelibly engraved on the body of the pressure gauges. QAP: As given in Table no. A2.C.13.1



2.171

Table A2.C.13.1: QUALITY ASSURANCE PLAN FOR PRESSURE GAUGES

S No

Test Object tested


Sample size

Test procedure


Form of record


Test witnessed by

Record reviewed by




Relevant material specn.


Vendor or Third party lab.

- Vendor, Inspector

2. Calibration Pressure gauge

Accuracy 100 % IS 3624 IS 3624 Calibra-tion certificate

Vendor - Inspector


Pressure gauge


100 % CGA G-4.1/ ASTM G 93






2.172

Table A2.C.13.2 Pressure gauges


medium Range MPa(g)

Temp. (K)

Liquid Oxygen[LOX] System (Ref P&ID: Drawing CFS-TD/LOX/P&ID) 1 DPL 110 110-50-10S-1.4 GOX 0 - 2 280 to 350

2 DPL 111 110-50-10S-1.4 GOX 0 - 2 280 to 350

3 DPL 112 111-50-10S-1.4 GOX 0 - 2 280 to 350

4 DPL 113 120-50-XXS-36 GOX 0 - 40 280 to 350

5 DPL 120 120-50-XXS-36 GOX 0 - 40 280 to 350

6 DPL 121 120-50-XXS-36 GOX 0 - 40 280 to 350

7 DPL 122 121-40-XXS-36 GOX 0 - 40 280 to 350

8 DPL 123 120-50-XXS-36 GOX 0 - 40 280 to 350

9 DPL 124 120-50-XXS-36 GOX 0 - 40 280 to 350

10 DPL 125 120-50-XXS-36 GOX 0 - 40 280 to 350

11 DPL 126 120-50-XXS-36 GOX 0 - 40 280 to 350

12 DPL 127 122-40-10S-1.4 GOX 0 - 2 280 to 350

13 DPL 131 160-150-10S-1.6 GOX 0 - 2 280 to 350

14 DPL 151 151-100-10S-1.4 GOX 0 - 2 280 to 350

15 DPL 160 160-150-10S-1.6 GOX 0 - 2 280 to 350

16 DPL 161 160-150-10S-1.6 GOX 0 - 2 280 to 350

17 DPL 162 160-150-10S-1.6 GOX 0 - 2 280 to 350

18 DPL 163 162-150-10S-1.6 GOX 0 - 2 280 to 350

19 DPL 164 160-150-10S-1.6 GOX 0 - 2 280 to 350

20 DPL 165 160-150-10S-1.6 GOX 0 - 2 280 to 350

21 DPL 166 160-150-10S-1.6 GOX 0 - 2 280 to 350

22 DPL 180 180-80-10S-1.4 GOX 0 - 2 280 to 350

23 DPL 400 103-50-XXS-36 GO2 0 - 40 280 to 350

24 DPL 401 103-50-XXS-36 GO2 0 - 40 280 to 350

25 DPL 402 103-50-XXS-36 GO2 0 - 40 280 to 350

26 DPL 403 103-50-XXS-36 GO2 0 - 40 280 to 350

27 DPL 404 100-65-XXS-36 GO2 0 - 40 280 to 350

28 DPL 430 133-50-10S-1.6 GO2 0 - 2 280 to 350

29 DPL 431 133-50-10S-1.6 GO2 0 - 2 280 to 350

30 DPL 432 133-50-10S-1.6 GO2 0 - 2 280 to 350

31 DPL 433 133-50-10S-1.6 GO2 0 - 2 280 to 350

32 DPL 434 130-150-10S-1.6 GO2 0 - 2 280 to 350

33 DPL 450 152-25-10S-1.4 GO2 0 - 2 280 to 350

34 DPL 451 152-25-10S-1.4 GO2 0 - 2 280 to 350

Liquid Hydrogen[LH2] System (Ref P&ID: Drawing CFS-TD/LH2/P&ID) 35 DPL 201 220-50-80S-17 GH2 0 - 20 280 to 350

36 DPL 210 210-50-10S-1.4 GH2 0 - 2 280 to 350

37 DPL 211 210-50-10S-1.4 GH2 0 - 2 280 to 350

38 DPL 212 211-50-10S-1.4 GH2 0 - 2 280 to 350

39 DPL 220 220-50-80S-17 GH2 0 - 20 280 to 350

40 DPL 221 220-50-80S-17 GH2 0 - 20 280 to 350

41 DPL 222 220-50-80S-17 GH2 0 - 20 280 to 350

42 DPL 223 222-65-10S-1.4 GH2 0 - 2 280 to 350

43 DPL 224 220-50-80S-17 GH2 0 - 20 280 to 350



2.173

Table A2.C.13.2 Pressure gauges


medium Range MPa(g)

Temp. (K)

44 DPL 225 220-50-80S-17 GH2 0 - 20 280 to 350

45 DPL 226 220-50-80S-17 GH2 0 - 20 280 to 350

46 DPL 231 260-150-10S-1.6 GH2 0 - 2 280 to 350

47 DPL 260 260-150-10S-1.6 GH2 0 - 2 280 to 350

48 DPL 261 260-150-10S-1.6 GH2 0 - 2 280 to 350

49 DPL 262 260-150-10S-1.6 GH2 0 - 2 280 to 350

50 DPL 263 262-150-10S-1.6 GH2 0 - 2 280 to 350

51 DPL 264 260-150-10S-1.6 GH2 0 - 2 280 to 350

52 DPL 265 260-150-10S-1.6 GH2 0 - 2 280 to 350

53 DPL 266 260-150-10S-1.6 GH2 0 - 2 280 to 350

54 DPL 270 270-80-10S-1.4 GH2 0 - 2 280 to 350

55 DPL 500 503-65-80S-17 GH2 0 - 20 280 to 350

56 DPL 501 503-65-80S-17 GH2 0 - 20 280 to 350

57 DPL 502 503-65-80S-17 GH2 0 - 20 280 to 350

58 DPL 503 503-65-80S-17 GH2 0 - 20 280 to 350

59 DPL 504 200-65-80S-17 GH2 0 - 20 280 to 350

60 DPL 530 533-100-10S-1.6 GH2 0 - 2 280 to 350

61 DPL 531 533-100-10S-1.6 GH2 0 - 2 280 to 350

62 DPL 532 533-100-10S-1.6 GH2 0 - 2 280 to 350

63 DPL 533 533-100-10S-1.6 GH2 0 - 2 280 to 350

64 DPL 534 230-100-10S-1.6 GH2 0 - 2 280 to 350

65 DPL 550 253-25-10S-1.4 GH2 0 - 2 280 to 350

66 DPL 551 253-25-10S-1.4 GH2 0 - 2 280 to 350

67 DPL 552 251-50-10S-1.4 GH2 0 - 2 280 to 350

Gaseous Hydrogen [GH2] System (Ref P&ID: Drawing CFS-TD/GH2/P&ID) 68 DPL 557 556-25-160-31 GH2 0 - 40 80-350

69 DPL 560 560-25-10S-3.7 GH2 0 - 5 80-350

Liquid Nitrogen [LN2] System (Ref P&ID: Drawing CFS-TD/LN2/P&ID) 70 DPL 310 310-40-10S-1.4 GN2 0 - 2 280-350



2.174

A2.C.14 Specifications for Fasteners

a) SS Hexogonal Bolt & Nut with plain washer and spring washer. b) SS Stud & Hexogonal nut with two plain washers and two spring

washers

Material Bolt & Stud : ASTM A193 Gr.B8 Nut : ASTM A194 Gr.8 Washers : SS Note :

1. The fasteners required for the assembly of various interfaces such as Safety Relief Valves & Burst Disc, pipe flanges, flexible hoses, etc. shall be supplied by the contractor.

2. The type, size, length and Quantity shall be worked out by the contractor and to be finalized during Detailed Engineering Review.

Request For Proposal (RFP)

Cryogenic Turbo Pump T

A2.D

A2.D.2 Liquid Oxygen system

Sl. No

Interface

1 DIF 101 11

2 DIF 102 103

3 DIF 103 10

4 DIF 104 104A

5 DIF 105 104

6 DIF 106 104

7 DIF 107 107

8 DIF 108 102

9 DIF 109 110

10 DIF 110 110

11 DIF 111 111

12 DIF 124 121

13 DIF 125 122

14 DIF 129 120

15 DIF 131 160

16 DIF 132 133

17 DIF 133 130

18 DIF 134 134

19 DIF 135 134

20 DIF 137 137

21 DIF 152 151

22 DIF 153 180

23 DIF 154 120

24 DIF 155 150

25 DIF 156 151



A2.D Interfaces for Cryogenic Fluid Circuits:

Liquid Oxygen system

Line No. Location

111-50-10S-1.4 DTK100 run tank fill

103-50-XXS-36 DTK100 run tank safety

100-65-XXS-36 DTK100 run tank vent

104A-25-XXS-36 DTK100 run tank LN2 chill

104-25-XXS-36 DTK100 run tank over flow

104-25-XXS-36 DTK100 overflow

107-65-10S-1.4 DTK100 run tank dump line (Downstream of DVN 100)

102-100-10S-1.4 For orifice DOP101 (Downstream of DVP104)

110-50-10S-1.4 For Orifice flow meter DOP110 (Downstream of DFL 110)

110-50-10S-1.4 LOX Road tanker outlet

111-50-10S-1.4 For orifice DOP111 (Downstream of DVP 114)

121-40-XXS-36 GG Article inlet

122-40-10S-1.4 GG Article outlet

120-50-XXS-36 Downstream of DVP127

160-150-10S-1.6 DTK130 run tank fill

133-50-10S-1.6 DTK130 run tank safety

130-150-10S-1.6 DTK130 run tank vent

134-25-10S-1.6 DTK130 run tank overflow

134-25-10S-1.6 Downstream of DVM134

137-100-10S-1.6 Downstream of DVN132

151-40-10S-1.4 OBTP catch tank drain

180-80-10S-1.4 OBTP catch tank pump outlet

120-50-XXS-36 OBTP turbine inlet

150-100-10S-1.4 OBTP catch tank fill

151-50-10S-1.4 OBTP catch tank vent

for Cryogenic Fluid Circuits (CFC) of

Page 2.175

Annexure 2D

Interfaces for Cryogenic Fluid Circuits:

Interface description

Butt-weld inter face

DTK100 run tank safety Butt-weld inter face


DTK100 run tank LN2 chill Butt-weld inter face

DTK100 run tank over flow Butt-weld inter face

1/2" NPT Male with closure

DTK100 run tank dump line (Downstream of DVN 100)


(Downstream of DVP104) Flange interface

(Downstream of Butt-weld inter face

Flange interface

DVP 114) Flange interface

Non std. Flange interface


Downstream of DVP127 Butt-weld inter face




DTK130 run tank overflow Butt-weld inter face

Downstream of DVM134 Butt-weld inter face

Downstream of DVN132 Butt-weld inter face


OBTP catch tank pump Non std. Flange interface Non std. Flange interface Non std. Flange interface

Non std. Flange



Sl. No

Interface

26 DIF 163 160

27 DIF 164 161

28 DIF 165 162

29 DIF 166 160

30 DIF 181 181

31 DIF 330 150

33 DIF 340 321

34 DIF 101V 100

35 DIF 102V 100

36 DIF 110V 110

37 DIF 111V 110

38 DIF 112V 111

39 DIF 113V 120

40 DIF 121V 120

41 DIF 122V 120

42 DIF 123V 120

41 DIF 123A 120

42 DIF 123B 120

44 DIF 123C 121

45 DIF 123V 120

46 DIF 126V 122

47 DIF 127V 120

48 DIF 128V 120



Line No. Location

160-150-10S-1.6 CE20 LOX TP article inlet interface

161-65-80S-18.6 CE20 LOX TP article outlet interface

162-150-10S-1.6 CE20 LOX TP Pump outlet to Disposal pit

160-150-10S-1.6 Downstream of DVR 162

181-25-10S-1.4 Orifice DOP181 (downstream of DVP181)

150-100-10S-1.4 LN2 feed toDTK150 from LN2 system

321-25-10S-1.4 LN2 chill inlet to DTK100 from LN2 system

100-65-XXS-1.4 Downstream of DVP102

100-65-XXS-1.4 Downstream of DVN101

110-50-10S-1.4 Downstream of DVN 110

110-50-10S-1.4 Downstream ofDVR111


120-50-XXS-36 Downstream of DVN 112

120-50-XXS-36 Downstream of DVC 121 (Chilling segment)

120-50-XXS-36 Downstream of DVC 122 (Chilling segment)

120-50-XXS-36 LOX HP feed to OBTP safety

120-50-XXS-36 LOX HP feed process change over

120-50-XXS-36 LOX HP feed to OBTP

121-40-XXS-36 LOX HP feed to GG inlet

120-50-XXS-36 GG inlet circuit (Downstream of DVR 123)

122-40-10S-1.4 GG outlet circuit (Downstream of DVR 126)




Page 2.176


interface

CE20 LOX TP article inlet Non std. Flange interface

CE20 LOX TP article outlet Non std. Flange interface

CE20 LOX TP Pump outlet Butt-weld inter face


(downstream of DVP181) Flanged interface

toDTK150 from Non std. Flange interface

LN2 chill inlet to DTK100 Non std. Flange interface

DVP102 Butt-weld inter face

of DVN101 Butt-weld inter face

Downstream of DVN 110 Butt-weld inter face


Downstream of DVR 112 Butt-weld inter face


Downstream of DVC 121 Butt-weld inter face




Non std. Flange

interface

LOX HP feed to GG inlet Non std. Flange

interface

(Downstream of DVR 123) Butt-weld inter face






Sl. No

Interface

49 DIF 131V 130

50 DIF 132V 130

51 DIF 134V 160

52 DIF 161V 160

53 DIF 162V 160

54 DIF 163V 162

55 DIF 180V 180

56 DIF 450V 152

57 DIF 617-P 160

58 DIF 645-P 120

59 DIF 647-P 180

60 DIF 700-Pr 700

38 DIF 717P 100

61 DIF 718-P 130

62 DIF 719-P 110

63 DIF 720-P 152

64 DIF 721-P 151

65 DIF 724-P 107

66 DIF 730-Pr 730

67 DIF 734-P 160

68 DIF 736-P 120

69 DIF 758-P 137

70 DIF EJ180 180

71 DIF EJ400I 105

72 DIF EJ400V 105

73 DIF EJ430I 135

74 DIF EJ430V 135

75 DIF EJ773D 105

76 DIF EJ774D 135



Line No. Location

130-150-10S-1.6 Downstream of DVP 132



160-150-10S-1.6 Downstream of DVC 161 (chilling segment)

160-150-10S-1.6 Downstream of DVC 162 (chilling segment)

162-150-10S-1.6 CE20 LOX TP outlet circuit (Downstream of DVR 163)

180-80-10S-1.4 OBTP Pump outlet circuit (downstream of DVR 180)

152-25-10S-1.4 OBTP catch tank safety

160-150-10S-1.6 Upstream of DVP 617

120-50-XXS-36 Upstream of DVP 645


700-65-XXS-44 Pressurization of LOX HP run tank DTK100 Upstream of DVP700

100-65-XXS-36 Upstream of DVP717




151-50-10S-1.4 OBTP catch tank dump (Upstream of DVP 721)


730-40-40S-7.4 Pressurization of DTK130 (Upstream of DVP730)


120-50-XXS-36 Upstream of DVP 736


180-80-10S-1.4 Ejector for OBTP pump outlet

105-100-10S-1.4 Upstream of Ejector DEJ400

105-100-10S-1.4 Downstream of Ejector DEJ400



105-100-XXS-36 Drive gas for Ejector 400 interface

135-150-10S-1.4 Drive gas for Ejector DEJ430


Page 2.177


Downstream of DVP 132 Butt-weld inter face





CE20 LOX TP outlet circuit (Downstream of DVR 163)


OBTP Pump outlet circuit (downstream of DVR 180)



Flanged interface

Flanged interface

Flanged interface

Pressurization of LOX HP run tank DTK100 Upstream Butt-weld inter face

Flanged interface

Flanged interface

Flanged interface

Flanged interface

OBTP catch tank dump

Flanged interface

Flanged interface

Pressurization of DTK130


Flanged interface

Flanged interface

Flanged interface

Ejector for OBTP pump Flanged interface

Upstream of Ejector DEJ400 Flanged interface

Flanged interface



Drive gas for Ejector 400 Flanged interface

Flanged interface



Sl. No

Interface

77 DIF PD-120 120

78 DIF PD-121 120

79 DIF PD-151 150

80 DIF PD-160 160

81 DIF PD-161 160

82 DIF PI-102 100

83 DIF PI-110 110

84 DIF PI-111 110

85 DIF PI-112 111

86 DIF PI-120 120

87 DIF PI-121 120

88 DIF PI-122 120

89 DIF PI-123 122

90 DIF PI-132 130

91 DIF PI-160 160

92 DIF PI-161 160

93 DIF PI-162 160

94 DIF PI-164 161

95 DIF PI-180 180

96 DIF PI-181 180

97 DIF PI-182 180

98 DIF PI-183 181

99 DIF PV-101 105

100 DIF PV-131 135



Line No. Location

120-50-XXS-36 Across filter DFL 120

120-50-XXS-36 Across filter DFL 121

150-100-10S-1.4 Across filter DFL 151

160-150-10S-1.6 Across filter DFL160

160-150-10S-1.6 Across filter DFL161

100-65-XXS-36 Downstream of DVM102E

110-50-10S-1.4 Downstream of DVM110E







130-150-10S- 1.6 Downstream of DVM132E




161-65-80-18.4 Downstream of DVM164E





105-100-10S-1.4 Downstream of DVM101H



Page 2.178


1/2" NPT Male

1/2" NPT Male

1/2" NPT Male

1/2" NPT Male

1/2" NPT Male

stream of DVM102E 1/2" NPT Male




DVM120E 1/2" NPT Male













stream of DVM101H 1/2" NPT Male

stream of DVM131H 1/2" NPT Male



A2.D.2 Liquid Hydrogen system

S. No

Interface

1 DIF 201 220

2 DIF 202 503

3 DIF 203 200

4 DIF 204 560A

5 DIF 205 205

6 DIF 206 205

7 DIF 207 207

8 DIF 208 200

9 DIF 209 210

10 DIF 211 211

11 DIF 214 210

12 DIF 221 220

13 DIF 222 220

14 DIF 223 220

15 DIF 224 222

16 DIF 231 260

17 DIF 232 533

18 DIF 233 230

19 DIF 234 235

20 DIF 235 235

21 DIF 237 237

22 DIF 251 252

23 DIF 252 570

24 DIF 253 273



Liquid Hydrogen system

Line No. Location

220-50-80S-17 DTK200 run tank fill

503-65-80S-17 DTK200 run tank safety

200-65-80S-17 DTK200 run tank vent

560A-25-40S-17 DTK200 run tank Chilling

205-25-40S-17 DTK200 run tank overflow

205-25-40S-17 DTK200 overflow

207-50-10S-1.4 DTK200 run tank dump line

200-65-80S-17 For orifice DOP201 (Downstream of DVP204)

210-50-10S-1.4 For Orifice flow meter DOP110 (Downstream of DFL 110)


210-50-10S-1.4 LH2 road tanker interface to LH2 fill line

220-50-80S-17 Downstream of DVC 220

220-50-80S-17 Downstream of DVC 221

220-50-80S-17 CE20 GG inlet

222-65-10S-1.4 GG HVV outlet

260-150-10S-1.6 DTK230 Run tank fill

533-100-10S-1.6 DTK230 Run tank safety

230-150-10S-1.6 DTK230 Run tank vent

235-25-10S-1.6 DTK230 Run tank overflow

235-25-10S-1.6 DTK230 overflow line


252-40-10S-1.4 DTK250 catch tank dump

570-40-10S-1.4 DTK250 catch tank turbine outlet

273-40-10S-1.4 DTK250 catch tank bearing coolant


Page 2.179



DTK200 run tank safety Butt-weld inter face


hilling Butt-weld inter face

DTK200 run tank overflow Butt-weld inter face

1/2" NPT Male with closure

DTK200 run tank dump line Butt-weld inter face

(Downstream of DVP204) Flanged interface

DOP110 (Downstream of Butt-weld inter face


LH2 road tanker interface to Bayonet type-1 coupling






DTK230 Run tank safety Butt-weld inter face


DTK230 Run tank overflow Butt-weld inter face



DTK250 catch tank dump Non std. Flange

interface DTK250 catch tank turbine Non std. Flange

interface DTK250 catch tank bearing Non std. Flange

interface



S. No

Interface

25 DIF 254 270

26 DIF 255 251

27 DIF 256 250

28 DIF 257 251

29 DIF 261 260

30 DIF 262 260

31 DIF 263 260

32 DIF 264 261

33 DIF 266 262

33 DIF 275 27

34 DIF 276 27

35 DIF 277 270

36 DIF 550 253

37 DIF 570 570

38 DIF 201V 200

39 DIF 202V 200

40 DIF 204V 220

41 DIF 210V 210

42 DIF 211V 210

43 DIF 212V 211

44 DIF 220V 220

44 DIF 221V 220

45 DIF 222V 220

46 DIF 223V 222

47 DIF 232V 230



Line No. Location

270-80-10S-1.4 DTK250 catch tank pump outlet

251-50-10S-1.4 DTK250 catch tank vent

250-100-10S-1.4 DTK250 catch tank fill

251-50-10S-1.4 Downstream of DVC250

0-150-10S-1.6 Chilling segment (downstream of DVC 260)

0-150-10S-1.6 Chilling segment (downstream of DVC 261)

260-100-10S-1.6 CE20 LH2 TP article inlet

261-65-80S-18.6 CE20 LH2 TP article outlet

2-150-10S-1.6 Downstream of DVP268

273-40-10S-1.4 For orifice DOP272 (bearing coolant outlet)

271-40-10S-1.4 For orifice DOP271 FBTP Pump outlet circuit

270-80-10S-1.4 For orifice DOP270 FBTP Pump outlet circuit

253-25-10S-1.4 LH2 catch tank vent (Downstream of DVN 550)

570-40-10S-1.4 FBTP turbine outlet

200-65-80S-17 LH2 HP run tank vent (downstream of DVP202

200-65-80S-17 LH2 HP run tank vent (downstream of DVR 504)

220-50-80S-17 Upstream of DVR 200




220-50-80S-17 Downstream of DVN 220

220-50-80S-17 Downstream of DVR 221

220-50-80S-17 Downstream of DVR 222

222-65-10S-1.4 Downstream of DVR223



Page 2.180


DTK250 catch tank pump Butt-weld inter face

DTK250 catch tank vent Non std. Flange

interface Non std. Flange

interface

Downstream of DVC250 Butt-weld inter face

(downstream of DVC 260) Butt-weld inter face

(downstream of DVC 261) Butt-weld inter face

CE20 LH2 TP article inlet Non std. Flange

interface

CE20 LH2 TP article outlet Non std. Flange

interface


For orifice DOP272 (bearing Flanged interface

FBTP Pump outlet circuit Flanged interface

FBTP Pump outlet circuit Flanged interface

(Downstream of DVN 550) Butt-weld inter face


P202) Butt-weld inter face

(downstream of DVR 504) Butt-weld inter face








Downstream of DVR223 Butt-weld inter face




S. No

Interface

49 DIF 234V 260

50 DIF 237V 230

51 DIF 260V 260

52 DIF 261V 260

53 DIF 262V 26054 DIF 263V 262

56 DIF 264V 261

57 DIF 270V 270

58 DIF 506-Pr 506

59 DIF 535-Pr 536

60 DIF 550V 253

61 DIF 552V 251

62 DIF 516-P 20063 DIF 517-P 230

64 DIF 518-P 253

39 DIF 610-P 220

65 DIF 611-P 220

66 DIF 612-P 260

67 DIF 613-P 260

68 DIF 624-P 570

69 DIF 622-P 270

70 DIF 623-P 273

71 DIF 625-P 210

72 DIF 626-P 250

73 DIF 754-P 207

74 DIF 759-P 237

75 DIF EJ500I 204

76 DIF EJ500V 204

77 DIF EJ530I 234

78 DIF EJ530V 234



Line No. Location


230-150-10S-1.6 LH2 LP run tank vent (Downstream of DVP 232)



260-150-10S-1.6 Downstream of DVR 262262-150-10S-1.6 Downstream of DVR 263



506-40-XXS-44 Pressurisation for LH2 HP run tank (Upstream of DVP 506)

536-80-40S-7.4 Pressurisation for LH2 LP run tank (Upstream of DVP 535)

253-25-10S-1.4 LH2 catch tank safety


200-65-80S-17 Upstream of DVP 516 230-150-10S-1.6 Upstream of DVP 517


220-50-80S-17 Upstream of DVP 610

220-50-80S-17 Upstream of DVP 611






210-50-10s-1.4 Upstream of DVP 625

250-100-10S-1.6 Fill line to FBTP catch tank (upstream of filter DFL 250)



4-100-10S-1.4 Upstream of Ejector DEJ

204-100-10S-1.4 Downstream of Ejector DEJ500




Page 2.181



(Downstream of DVP 232) Butt-weld inter face


1 Butt-weld inter face

Downstream of DVR 262 Butt-weld inter face Downstream of DVR 263 Butt-weld inter face



Pressurisation for LH2 HP run tank (Upstream of DVP Butt-weld inter face

Pressurisation for LH2 LP run tank (Upstream of DVP Butt-weld inter face



Flanged interface Flanged interface

Flanged interface

Flanged interface

Flanged interface

Flanged interface

Flanged interface

Flanged interface

Flanged interface

Flanged interface

Flanged interface

Fill line to FBTP catch tank (upstream of filter DFL 250)

Flanged interface

Flanged interface

Downstream of DVP 759 Flanged interface


Flanged interface





S. No

Interface

79 DIF EJ775D 204

80 DIF EJ775D 234

81 DIF PD-220 220

83 DIF PD-221 220

84 DIF PD-250 250

85 DIF PD-260 260

86 DIF PD-261 260

87 DIF PI-202 200

88 DIF PI-210 210

89 DIF PI-211 210

90 DIF PI-212 211

91 DIF PI-220 220

92 DIF PI-221 220

93 DIF PI-222 220

94 DIF PI-223 222

95 DIF PI-232 230

96 DIF PI-260 260

97 DIF PI-261 260

98 DIF PI-262 260

99 DIF PI-263 261

100 DIF PI-264 262

101 DIF PI-270 270

102 DIF PI-271 270

103 DIF PI-272 270104 DIF PI-273 27

105 DIF PI-274 27

106 DIF PI-570 570

107 DIF PV-201 204

108 DIF PV-231 234



Line No. Location

204-100-XXS-36 Drive gas for Ejector 500 interface

234-150-10S-1.4 Drive gas for Ejector DEJ

220-50-80S-17 Across filter DFL 220

220-50-80S-17 Across filter DFL 221




200-65-80S-17 Downstream of DVM202E
















270-80-10S-1.4 Downstream of DVM272271-40-10S-1.4 Downstream of DVM273






Page 2.182


00 Flanged interface

Drive gas for Ejector DEJ530 Flanged interface

1/2" NPT Male

1/2" NPT Male

1/2" NPT Male

1/2" NPT Male

1/2" NPT Male

of DVM202E 1/2" NPT Male
















2E 1/2" NPT Male 3E 1/2" NPT Male

4E 1/2" NPT Male

570E 1/2" NPT Male

201H 1/2" NPT Male

31H 1/2" NPT Male



A2.D.3 Liquid Nitrogen system

Sl. No

Interface

1 DIF 300 312-

2 DIF 301 313

3 DIF 303 311

4 DIF 310 310

5 DIF 311 310

6 DIF 312 311

7 DIF 330 322

8 DIF 340 321

9 DIF 350 320

10 DIF 360 323

11 DIF 301V 312-

12 DIF 302V 313

13 DIF 321V 320

14 DIF 321-S 320

15 DIF 350-P 312-

16 DIF 726-P 320-

17 DIF 727-P 311

18 DIF 728-P 310

19 DIF 728-V 310

20 DIF 729-V 310

21 DIF PI-310 310

22 DIF PI-320 320-

23 DIF PI-728 310-



Liquid Nitrogen system

Line No. Location

-100-10S-2.5 LN2 run tank vent

313-25-10S-2.5 LN2 run tank safety

311-65-10S-2.5 LN2 run tank fill

310-40-10S-1.4 LN2 road tanker inlet


311-65-10S-2.5 LN2 vaporizer inlet

322-25-10S-1.4 To OBTP catch tank

321-25-10S-1.4 To DTK100 tank

320-40-10S-1.4 LN2 inlet to GH2 cooler

323-25-10S-1.4 To FBTP catch tank

-100-10S-2.5 Downstream of DVP301

313-25-10S-2.5 Downstream of DVR301



-150-10S-1.4 Upstream of DVP 301

-40-10S-1.4 Upstream of DVP 726

311-65-10S-2.5 Upstream of DVM 727

310-40-10S-1.4 Upstream of DVM 728


310-40-10S-1.4 Downstream of DVN 728V

310-40-10S-1.4 Downstream of DVM 310E

-40-10S-1.4 Downstream of DVM 320E

-40-10S-1.4 Downstream of DVM 728


Page 2.183





Flanged interface











Flanged interface

Flanged interface

Flanged interface

Flanged interface


Downstream of DVN 728V Butt-weld inter face

Downstream of DVM 310E 1/2" NPT Male

Downstream of DVM 320E 1/2" NPT Male

728E 1/2" NPT Male



A2.D.4 Gaseous Hydrogen system

SL. No

Interface

1 DIF 558-O 556

2 DIF 557 556

3 DIF 558 556

4 DIF 560 560

5 DIF 561 560

6 DIF 555V 556

7 DIF 556V 556

8 DIF 560V 560

9 DIF 630-P 556

10 DIF PI558 556

11 DIF PI560 560

12 DIF PI561 556

13 DIF PI562 557



Gaseous Hydrogen system

Line No. Location

556-25-160-31 GH2 cooler outlet

556-25-160-31 Cold GH2 to FBTB turbine inlet

556-25-160-31 Cold GH2 to HTPM

560-25-10S-3.7 Chilling of DTK 200

560-25-10S-1.4 Downstream of DVM 560

556-25-160-31 Downstream of DVP 559

556-25-160-31 Downstream of DVR 556


556-25-160-31 Upstream of DVP 630

556-25-160-31 Downstream of DVM274E





Page 2.184



Cold GH2 to FBTB turbine Butt-weld inter face



Downstream of DVM 560 Butt-weld inter face





Downstream of DVM274E 1/2" NPT Male








A2.E PIPING LAYOUT:


Page 2.185

Annexure 2E



2. 187

Annexure 2-F

A2.F STANDARDS FOLLOWED

The following standards are used for component design, material selection and fabrication. However, the equivalent standards/ codes in force in the country of the manufacturer are also acceptable at the discretion of the Department.

Sl.No Description Standard/Code

1. Tanks Inner vessel: ASME section VIII Div.1 Outer vessel: CGA 341.2002/EN13458-

2:2002

2. Piping ASME B 31.3/ 31.1

3. SS pipes ASME B 36.19

4. CS pipes ASME B 36.10

5. Butt welded fittings ASME B.16.9

6. Socket welded/ threaded fittings

ASME B16.11

7. Flanges ASME B 16.5

8. Bolts, Nuts and Washers ASTM A 193 B 8/ B7, A 194 8/ 2H

9. Gaskets API 601/ ASME B16.5

10. Ball valves BS 5351/ API 6-D/equivalent

11. Globe/ needle valves ASME B.16.34/ API 6-D/ API 598/ BS 5352/ BS 6755/equivalent

12. Filters Manufacturer’s standard

13. Non-return valves BS 5352/ API 6-D/equivalent

14. Safety Relief valves ASME Section VIII Division I/ API RP 520/ API RP 527

15. Rupture disc devices ASME Section VIII Division 1

16. Pressure gauges BS 1780/ IS 3624

17. Flexible hoses Manufacturer’s standard

18. Control valves ASME B 16.34/ ASME B 16.104/ FCI 70.2/ISA

19. Hydraulic pressure test of

pipelines

ASTM A 530

20. Pickling & passivation ASTM A 380

21. NDT ASME Section V

22. Radio-graphy ASTM E 94

23. Structural materials IS 808/ IS 2062

24. Particulate contamination

SAE 4059E



2.188

Annexure 2-G

A2.G SUB-VENDOR DIRECTORY

A2.G.1 Pipes & Pipe Fittings

A2.G.1.1 SS pipes

1 M/s REMI Edalstahl tubulars Ltd., Mumbai

2 M/s Ratnamani Metals & Tubes Ltd., Ahmedabad

3 M/s Nuclear fuel Complex,

ECIL, (PO), Hydrabad

4 M/s Maharastra Seamless Ltd.

Jindal group company, Sukeli

5 M/s Sandvik Asia Ltd.,

Mumbai, Pune Road, Dapedi, Pune

6 M/s. Tubacex Prakash India Pvt Ltd, Mumbai

A2.G.2 Pipe Fittings

1 M/s Arvind Pipes & Fitting Industries Pvt. Ltd.,

Mumbai.

2 M/s Amforge Industries,

Mumbai

3 M/s Echjay Industries,

Rajkot

4 M/s Eby Industries, Rajghat,

Gujarat

5 M/s J.K.Forge Industries,

Mumbai

6 M/s Mechwell fittings Pvt. Ltd.,

Chhatral mehsana (Dist.), India

7 M/s Sanghvi Forge Industries,

Mumbai

8 M/s Chowdhary hammer works,

Faridhabad.

9 M/s. Gujarat Infrapipes Pvt Ltd,

10 M/s. Metal Forge (India), Mumbai

11 M/s. Tube Products Incorporate, Vadodara



2.189

A2.G.2 Flow Components

A2.G.2.1 Globe Valves (Manual, EP operated, Control & Check Valves)

1 M/s Ireland S.A.S, France

2 M/s Flow serve India Controls Pvt. Ltd. Whitefield, Bangalore

(Except LH2 &GH2 service)

3 M/s VELAN , France

4 M/s VELAN , Coimbatore,India (Except LH2 &GH2 service)

5 M/s Samson Aktiengesellschaft, Germany,

6 M/s Samson Controls Pvt Ltd, Pune, India.


7 M/s Weka, AG., Switzerland

8 M/s FX Stohr GmbH & Co., Germany


9 M/s JSC Cryogenmash

67, Lenin Avenue, Balashikha-7, Moscow Region, Russia

10 M/s R&DIME, Russia

11 M/s MIL control Ltd., Aluva P.O., Cochin

(Except LH2 & GH2 service)

12 M/s Splav Modernizatsiya (Closed Joint Stock Company)

13 M/s Herose valves, Germany


14 M/s. ARCA-Regler GmbH, Germany

M/s. B.O.M. Robinetterie Industrielle, France


15 M/S. GE Energy (Dresser Valve India Pvt Ltd), Coimbatore.


16 M/S. Emerson Process Management Chennai Pvt Ltd, India


17 M/S. Svern Glocon, England


18 M/S. FEMA s.r.l, Italy

A2.G.2.2 Needle Valves

1 Parker

2 Swagelok



2.190

A2.G.2.3 Burst-Discs

1 M/s BS &B System (India) Ltd. 9 Cathedral Road,

Chennai

2 M/s Fike Corporation, USA

3 M/s Rembe GmbH, Germany

A2.G.2.4 Safety Relief Valves

1 M/s Tyco Sanmar Ltd.,Chennai.

2 M/s Fainger Leser Valves Pvt. Ltd.Andheri, Mumbai

3 M/s Anderson Greenwood & Co. Stafford, Texas, USA

4 M/s Crossby Valve & Engg. Co. Ltd.,England

5 M/s Instrumentation Ltd.,Palakkad.

6 M/s Motoyama Engg Works Ltd, Japan

7 M/s IMI Bailey Birkitt Ltd, Manchester, England

8 M/s Bopp & Reuther, Germany

9 M/s Herose, Germany

10 M/S. Weir BDK Valves Pvt Ltd, Hubli, India.

11 M/S. FEMA s.r.l, Italy

A2.G.2.5 Filters

1 M/s Puronics System

3rd Phase Peeniya Industrial Area, Bangalore

2 M/s Ultra Filters (India) Pvt. Ltd

Basva Nivas, 29/2 K.H Road, Bangalore

3 M/s Milliipore Gesellschaft GmbH

A-1130 Wien, Austria

4 M/s Cryo diffusion SA, France

5 M/s Novintec Filters,

Paris, France

6 M/s JSC Cryogenmash , Russia

7 M/s R&DIME, Russia



2.191

A2.G.2.6 Pressure Gauge

1 M/s Wika Instrument Limited, Pune

2 M/s Bourdon, France.

3 M/s Budenburg, Germany

4 M/s. Baumer Technologies India Pvt Ltd, Chennai

5 M/s. Budenberg Gauge Pvt Ltd, Chennai

6 M/s. ASHCROFT India Pvt. Ltd, Chhatral

7 M/s. Swagelok, Chennai

A2.G.2.7 Bellows

1 M/s Calorstat Industries, France

2 M/s Witzenmann Gmbh, Germany

3 M/s Bird Precision Bellows Ltd. England

4 M/s Powerflex, England

5 M/s Boa Lucerne, Switzerland

6 M/s Witzenmann, Kolkata. (For MAWP ≤ 4MPa)

A2.G.2.8 Cryenco bayonet coupling

A2.G.2.9 Super-insulated Flexible Hoses

1 M/s Cryogenmash, Russia

2 M/s Air Liquide DTA, France.

3 M/s Demaco, Netherlands

4 M/s ACME cryogenics, USA

5 M/s Bergofer GmbH., Germany

6 M/s Techniflex Witzenmann, France

7 M/s Cryo Diffusion SA, France

8 M/s Nexans Deutschland Industries, Gmbh, Germany

9 M/s Cryolor SA, France

1 M/s. Gardner cryogenics, USA

2 M/s. DeMaco, Netherlands

REQUEST FOR PROPOSAL FOR · 2017-06-27 · REQUEST FOR PROPOSAL FOR REALIZATION OF CRYOGENIC FLUID CIRCUITS FOR CRYOGENIC TURBO PUMP TEST FACILITY Volume 2 June 2017 ISRO Propulsion

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