OCP - AKPPL Bitumen Rev.A

ADANI KATTUPALLI PORT PVT. LTD.
(AKPPL)
PROJECT Liquid Terminal at Kattupali Port
TITLE OF
Operation and Control Philosophy for Bitumen
DOCUMENT
CONTRACTOR Not Applicable
Mott MacDonald Pvt. Ltd.

CONSULTANT Sakar-II, Ellis bridge,
Ahmedabad
CLIENT
DOCUMENT NO.
REV. For Approval
CONTRATOR/
CONSULTANT’S 372479-RSD-523
DOCUMENT NO.
PREPARED CHECKED APPROVED

REV. NO. DATE DESCRIPTION
Init. Sign Init. Sign Init. Sign
ISSUED FOR HRS BAD
A 25-11-2019 JBP
APPROVAL
This Document is the property of AKPPL. It should not be used, copied or reproduced without their written Permission.
Operation and Control
Philosophy
Bitumen
25 November 2019
Confidential
Mott MacDonald
501 Sakar II
Ellisbridge
Ahmedabad
380 006
Gujarat
India
T +91 (0)79 4911 1600

mottmac.com
Operation and Control

AKPPL
Enclosure-3
Kattupalli
Philosophy
Bitumen
25 November 2019
Confidential
Mott MacDonald Private Limited.

Registered office: 101, Nomura,
Hiranandani Gardens, Powai, Mumbai 400
076, Maharashtra, India. CIN
U74210MH1970PTC014650
Mott MacDonald | Confidential | Operation and Control Philosophy
Bitumen
Issue and Revision Record
Revision Date Originator Checker Approver Description

P1 25-11-19 ‘JBP HRS AKS/BAD For Approval
Document reference: 372479-RSD-523 | xx | P1
Information class: Standard
This document is issued for the party which commissioned it and for specific purposes connected with the above-
captioned project only. It should not be relied upon by any other party or used for any other purpose.
We accept no responsibility for the consequences of this document being relied upon by any other party, or being
used for any other purpose, or containing any error or omission which is due to an error or omission in data supplied
to us by other parties.
This document contains confidential information and proprietary intellectual property. It should not be shown to other
parties without consent from us and from the party which commissioned it.
This report has been pr epared sol el y f or us e by the party whic h c ommissi oned it (t he ‘Client’) i n c onnecti on with the capti oned proj ect. It should not be used for any ot her purpos e. N o person other than t he Client or any party who has expressl y agreed ter ms of r eliance with us (t he ‘Reci pient(s)’) may rel y on the c ontent , i nf ormati on or any vi ews express ed i n the repor t. We acc ept no dut y of c are, res ponsi bility or liabilit y t o any ot her r eci pient of thi s doc ument. T his r eport is confi denti al and c ontains pr opri etar y intell ectual property.
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Contents
1 Purpose 9
1.1 IMPORT 9
1.2 Storage at Tank-farm Enclosure-3 9
1.3 Inter Tank Transfer (ITT) 9
1.4 Tanker Loading Facility- (TLF) 10
1.5 DCS / SCADA architecture shall consider following important General Notes: 10
2 Bitumen Import 14
2.1 Operation and Control Methodology for Bitumen Import from Vessel 14
2.1.1 Definition 14
2.1.2 Important considerations 14
2.1.3 General 14
2.2 Scope 15
2.3 Ship docking and unloading 15
2.3.1 Description 15
2.3.2 Bitumen Receipt and Transfer operation 16
2.4 Other essential requirements during Line up for Liquid Transfer from Ship to
Shore 18
2.5 Emergency Shutdown (failure of utility) 18
2.5.1 Failure of Power Supply 18
2.5.2 Failure of Hot Oil supply at Bitumen Storage tanks at Encl.-3 19
2.5.3 Failure of Instrument Air 19
2.6 Emergency Shutdown by ESD enforced. 19
2.7 Normal Operation 19
2.8 Operator’s Routine work 20
2.8.1 Check during transfer 20
2.8.2 When needed 20
2.9 Control System (Logics and Interlocks) 20
2.9.1 In / Out breathing (during import / transfer) 20
2.9.2 Pressure Interlock 20
2.9.3 Level Interlock 20
2.9.4 Emergency Shutdown 20
2.10 Trouble Shooting 21
2.11 Conditions Tables for the Intended Transfer Route for Bitumen Import 21
2.11.1 Bunker Import from Ship to a Single Tank: - Representative line up
from Berth-2 to Single Tank 22
2.11.2 Ship to Many tanks Intra Enclosure (Within a Single enclosure) 25
2.12 Bitumen Import Directly from Berth to TLF area for Road Tankers filling. 34
3 Intermediate Storage and handling of Bitumen in Storage Tank T-31

and T-32 40
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3.1 Description 40
3.1.1 Bitumen Storage Tanks 40
3.1.2 Hot Oil Generation system 40
3.2 Scope 41
3.3 Operation and Control Methodology 41
3.3.1 Preparation of Bitumen Storage tanks for operation readiness 41
3.3.2 Heating Bitumen Storage Tanks 42
3.3.3 Storage Tank Safety Considerations 43
4 ITT 47
4.1 Definition 47
4.2 Operation and control methodology 47
4.2.1 General 47
4.2.2 Scope 47
4.2.3 Other essential requirements during Line up for Liquid Transfer
from One tank to another tank 55
4.7.1 In / Out breathing (during transfer) 56
4.7.2 Pressure interlock 57
5 TLF 58
5.1 Operation and Control methodology 58
5.1.1 General 58
5.1.2 Operation Mode: 58
5.2 Scope 58
5.3 TLF Operation 58
5.3.1 Despatch from Tank Farm Enclosure 60
5.3.2 Other essential requirements during Line up for Liquid export from
enclosure to TLF 60
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Bitumen

5.8.1 In / Out breathing (during transfer) 62
5.8.2 Pressure interlock 62
5.10 Operation Mode Despatch (Bitumen Transfer from Single Tank to TLF) 63
5.10.1 From a Single Tank to TLF (representative line-up for T-31 / T-32
to TLF) 63
5.10.2 From Multiple Tanks to TLF Option-1 (representative line-up for T-
31 and T-32 to TLF) 65
5.10.3 From Multiple Tanks to TLF Option-2 (representative line-up for T-
31 and T-32 to TLF) 67
5.10.4 From a Single Tank to TLF area supplying to Bay-01 and Bay-02
simultaneously 67
5.11 Important considerations 68
6 List of attachments 69
Tables
Figures
Photos
Maps
Charts
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Mott MacDonald | Confidential | Operation and Control Philosophy 9
Bitumen
1 Purpose
This document is prepared with an intention to provide basic data to generate Operation and
Control Philosophy for Bitumen line-up operation at AKPPL Liquid Terminal related
operations.
● Special Note:
– As Bitumen shall be received in liquid state and at temperature above its melting
point (≥ 140 deg. C), entire piping header pathway from receipt at jetty terminal to
storage tanks shall be maintained at desirable elevated temperature till entire parcel
is unloaded. Elect. Trace Heating system shall take care of this requirement.
– Presently, none of the isolation valves (of tanks or headers) be it BV or HOV - shall
be installed with Actuator or shall have Status Feed Back Signal for Open / Close
indication.
– But all applicable Logics and Interlocks shall be built as per approved P&IDs
– Hence all line up operation shall be carried out manually with patience, caution and
double confirmation (for each activity and ultimate status of equipment, tank or
valve) in cascading manner from source to destination for all liquid transfer
operations which may conclude with Pigging operation.
– No portion / component of piping route shall be below the specified temperature till
entire operation is carried out successfully.
1.1 IMPORT
● Line up operation for importing liquid Bitumen from Ship-vessels at Jetty area by a
dedicated header (insulated and having heat tracing provision) to specific tank (s) in Encl.-03
– From Ship-Vessels
○ To a Single Tank
○ To Multiple Tanks Simultaneously
○ To Multiple Tanks Sequential
– From Ship-Vessel directly to Tanker Loading facility (TLF)
1.2 Storage at Tank-farm Enclosure-3

● Storing hot Bitumen in T-31 / T-32 (Insulated tanks having internal hot oil circulation)
– Starting Hot oil Generator and gradual heating of tanks for making them ready for receipt
of hot Bitumen.
– After receiving and filling the tanks up-to safe level Hot oil system shall be operating
on auto mode to maintain required temperature.
– Road tanker filling as per despatch orders.
– Minimum stock level maintenance within storage tanks as recommended.
1.3 Inter Tank Transfer (ITT)

● Line up operation for transferring liquid cargo product (hot Bitumen) from any of the
Tank(s) to another Tank within the Enclosure-3 utilising various line-up options
Intra Enclosure (Within an enclosure) ITT operation as per dedicated enclosure
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○ One tank to One Tank
1.4 Tanker Loading Facility- (TLF)

● Line up operation to enable to supply liquid contents (hot Bitumen) of any tank in Enclosure-
3 towards TLF area to fill the Road Tankers for despatch.
Important consideration for all scenario:

– It shall also be noted here that based on the actual operating scenario, some or any part
of line up sequence may be revised-altered or added after commissioning trials (also
during any point of time during the entire life cycle) and on receiving feedback regarding
ease of operation and (none the less) safe handling procedure from operating
personnel at field and monitoring control Centre
● Other Important Notes:

It may happen sometimes that Bitumen import, or despatch may coincide with other
similar activity / operation being carried out at jetty or tank-farm area. Bitumen
handling operation shall be kept independent of any other tank farm related
operations / activities like Import, ITT or TLF. Operating staff for Bitumen shall be
dedicated and specially trained for operation.
– It shall be ensured that all manual valves along the intended lined up route (valves
without any status feedback to control room) are either in open / close modes so as to
allow the intended operation of liquid transfer in the desired direction starting from
source to final destination. A standard document mentioning SOP (Standard Operating
Procedures) shall be adhered to all the time.
– A schematic Layout for the Chalked-out Line up plan / Route may be generated on
DCS Screen Graphic generated by actual P&IDs. All available information for status
of Tanks and Pumps shall be highlighted while the actual desired (and executed )
status of all Manual Valves (BV / HOV) shall be entered manually by Enforced Status
(as per the COLLECTIVE CHECKLIST - confirmed and verified information as
furnished by field staff) to display Healthy Conditions (of the entire line-up route)
for the desired operation and finally generate “Ready to Start” condition for decision
making authority at Central Control and Monitoring Centre.
– Unless the CHECKLIST from field staff is submitted to Control Room or confirmed at least
through communication (loud and clear) no operation shall be allowed to commence.
1.5 DCS / SCADA architecture shall consider following important General

Notes:
● Though as per present scenario, all BV / HOVs are operated manually, the Status
Feedback for some has been considered. However, it is desirable to keep all in virtual
operating mode to generate Alarms / Flashing status etc. to create actual simulated
required scenario where only corrective action is taken manually at field location and
replicated on DCS by enforced status command
– On activation of ESD, alarm with enunciation shall be popped up with flashing instruction
to stop Bitumen Loading Pump during TLF line up.
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Bitumen
– On activation of ESD, DCS permissive command for Local Operation of Pump shall be
reset.
– After 6 Second of Pump on Command, if discharge pressure is still less than 1.5 Kg /
Cm2 than pump shall be tripped.
– Live and Historic Trends for all available Analogue PVs shall be provided.
– Operator Action Event logging with Value change from ----- to ----- shall be provided.
– All Safety interlocks (including ESD as per Cause and Effect Matrix) shall be applicable
for Operating Bitumen Loading Pump (s) even if they are on Remote Manual Operation
Mode or Local Mode.
– For all Line Up Sequence during any mode (Import / ITT / TLF), there shall be START
Command, PAUSE Command and END / STOP Command available with provision of
Addition / Deletion Logic
– Common Group Alarm Pop Up to be generated to Alert / Inform DCS Operator about
Critical Alarms and operation Faults. Latest Alarm should be Attended First and then
only Older Alarms shall be Re-setted. (LIFO protocol)
– SYSTEM SHALL BE DESIGNED SUCH THAT CHANGE IN ANY KIND OF SET POINT
CHANGE OR MOS / FORCE COMMAND SHALL BE LOGGED IN THE SYSTEM WITH
VALUE OF CHANGE, DATE-TIME AND USER NAME.
– Operational Set Point Change (during any operation mode like Import / ITT / TLF) shall
be Possible to Change during Running Operation Without Interrupting the Current
Operation.
– Events such as Pump / HOV Operation Mode Change, Commands / activities of Pump
Start / Stop, all kinds of Valve Open / Close and Alarm Acknowledgements etc. shall
be logged in the System with facility to have backup for 3 months.
– In case of Critical Alarms Triggering in the field, nearby PTZ Camera and Fixed
Camera shall populate Live Footage in DCS / SCADA in terms of Alarm Pop Up
– DCS Permissive shall be necessary even for Local Operation for any Pump or HOV
valves.
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– All Safety Interlocks (including ESD as per Cause and Effect Matrix) shall be applicable
to all Pumps even if they are on Remote Manual Operation mode.
– Likewise, all safety Interlocks (including ESD as per Cause and Effect Matrix) and
relevant Operational sequence (as per line up operation) shall be applicable to all Pump
even if they are on Remote Auto Operation mode.
– During Operational Line up (whether during start-up or in the course of running

operation) if any discrepancy / mismatch or failure of feedback occurs, Mode Fail Alarm
shall be generated (with particular Tag Blinking with RED colour) with Diagnostic
Help.
– During dormant mode, Tank Leak Alarm shall be generated based on the rate of
change of level.
– Likewise, during the dormant mode, Temperature and Pressure Alarm shall be
generated based on the rate of change of measured value in prescribed time.
– After Auto Operation Line up, all relevant Graphics shall be automatically generated
/ built in a single screen
– All Operational Parameters shall be Resettable as per Operational Demands /

Requirement by User Authorisation
– Provision shall be there to generate L, LL, H and HH Alarms and Trends for all
Pressure and Level Transmitters.
– At no time, H value shall be higher than HH value
– Likewise, L shall not be lower than LL value
– During the course of any operation (ITT / IMPORT / TLF) Operational Set Point
Parameter (applicable for Line up sequence) shall not be higher than HH or lower
than LL
– In case of Very Low Pressure (LL) / Very High Pressure (HH) / Very Low Level (LL) /
Very High Level (HH) or ESD activation, alarms shall be generated, and relevant
pump shall trip (as per Cause and Effect Matrix) but with prescribed time delay. The
time parameter shall be resettable depending upon mode of operation and practical
judgmental decision to avoid damage due to surge pressure wave.
– For all line-up sequence during any mode (Import / ITT / TLF), there shall be START
Command – PAUSE Command and END /STOP Command available.
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Bitumen
– A complete full proof TAS architecture may be designed having all Hardware configurations
of DCS and Safety PLC etc. requirements.
– Manual Override System (MOS) for all applicable controlled equipments with
predefined time shall be provided operative only by User Authorisation.
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Bitumen
2 Bitumen Import
2.1 Operation and Control Methodology for Bitumen Import from Vessel
2.1.1 Definition
● Import means receipt of Liquid Cargo (in our case Hot Liquid Bitumen to storage tanks of
liquid tank farm (Enc.-3) from Barge / Ship-vessel) as a marine cargo.
– T-31 and T-32 tanks have been allocated for receiving / supplying Bitumen in tank farm
Enclosure-3.
● Import of Bitumen from Berth-2 to TLF area directly for filling Road Tankers.
2.1.2 Important considerations

● Hot liquid Bitumen shall be received in previously heated insulated headers up to
dedicated storage tanks T-31 and T-32 in Encl.-3
– Transfer Headers for Import line-up circuit shall be heated by combination of Electrical
heating system supplied and installed by different vendors according to SOP based
on Operational manuals furnished by them.
○ Electrical Skin Trace Heating System (supplied / installed / commissioned by M/s
n-Vent) from Jetty area to system B/L
○ Conventional Parallel Resistance Trace heating system (Supplied / installed /
commissioned by M/s Bartec) starting from own B/L to rest of piping near tank-farm
enclosure and pump-house area covering Tank-transfer pump suction headers and up
to TLF.
● Import operation of Bitumen parcel shall be commenced only after establishment of full
integrity w.r.t. temperature (of proposed path) as set / decided and approved by
importer / custodian.
2.1.3 General
Operation Mode-Bitumen Import
● Line up operation for importing liquid cargo product (Hot Bitumen) from Jetty area via 10”
Ø dock line (P-0201-A21A-10”- IE) connected further to a 12” Ø header (P-0207-A21A-
12”-IE   P-0214-A21A-12”-IE) to the tank (s) in Encl.-03 (T-31, T-32) only.
From Ship-Vessels
– To a Single Tank
○ Berth -2 to Single Tank (T-31 / T-32 of Encl.-3)
– To Multiple Tanks - Simultaneously (Ship to Many Tanks)

○ Berth-2 to Multiple Tanks-Intra Enclosure-Simultaneously (T-31 / T-32)
– To Multiple Tanks - Sequential (Ship to Many Tanks)

○ Berth-2 to Multiple Tanks-Intra Enclosure-Sequentially (T-31 / T-32)
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Bitumen
2.1.3.1 Description of Import Options:

● To a Single Tank: Ship to any single tank (T-31 / T-32) in Enclosure-3
● To Multiple Tanks: Ship to Multiple (Many) tanks
– Sequential (In series, as per lined up tanks following specified logic)
– Simultaneous (to parallel lined up tanks)
Notes:
● Import of Bitumen from Jetty area to Tank Farm Area shall be carried out to Enclosure-3 only.
A typical line up shall be described considering (T-31, T-32) as dedicated storage tanks of
enclosure. In case at later stage other tanks are involved, similar philosophy shall be
applicable.
● Unloading operation from ship-vessel preferably shall be carried out in a single sequence as
desired to avoid losses, considering Import Header heating power cost and minimising the
probability of occurrence of hazardous incidence.
2.2 Scope
● To receive and transfer Bitumen from the Ship Anchored on Berth- 2 at Jetty to any of the
tank(s) T-31 / T-32 of the Enclosures-3 as per the specified lined up options.
● To receive and transfer Bitumen from the Ship Anchored on Berth- 2 at Jetty to directly
TLF area (of Enclosure-3) as per the specified lined up options.
2.3 Ship docking and unloading
2.3.1 Description
● After carrying out necessary formalities and obligatory protocols, the ship carrying Bitumen
shall manage to dock on Liquid Terminal Berth 2 at Kattupali port for unloading the cargo.
● Customer nominated agents shall arrange to provide all necessary documents e.g. NOC from
statutory body etc.to AKPPL for seeking their permission to transfer the Bunker fuel.
● It shall be ensured that Liquid Bitumen shall be having the requisite temperature as
agreed, confirmed and documented.
● If Dock-line header is being put into use for the first time, it shall be ensured that entire
header and piping network has been drained / blown through / dried thoroughly after
final Hydraulic test. Care shall be taken to cross check particularly those portions of
pipe route which form loops at crossings and jump overs. Instant vaporization of water
when coming in contact with liquid Bitumen at very high temperature may result into
hazardous consequences.
● It is expected that the nominated surveyors shall carry out ship-shore inspection (checking
dedicated tank and shore pipelines for temperature readiness, cleanliness, clear any
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Bitumen
doubts about contamination, checkout and verify the capacity of allocated tanks - with
adequate heating facility for storing Bitumen - including physical dips if required) once
the vessel has been brought alongside and tied off before cables are attached for
equipotential bonding (if applicable), communications, and safety.
● Level and temperature / density etc. readings shall be carried out regarding hot liquid
Bitumen in the cargo hold to determine the quantity being carried by the vessel as well as
any residual stored product (if any) at the lined-up tank (T-31 / T-32) inside the enclosure
tank-farm.
● After receiving NOC from the surveyors, tanks and shore pipelines shall be kept ready for
receiving the cargo. Necessary heating arrangements for all piping route shall be carried
out in advance considering Lead-time requirements. All flexible Hose pipes shall be
checked for worn out or damaged portion and transfer operation shall not commence till
the hose is replaced entirely. Hoses shall be devoid of water or any other contaminants.
● Dock line shall be connected by suitable type of coupling with ship delivery with flexible hose
and subsequently purged with air.
● Ship-shore safety tests shall be carried out.
2.3.2 Bitumen Receipt and Transfer operation
2.3.2.1 For transfer to a Single Tank (Ship to Single Tank)

Important Considerations:
● On no account, liquid parcel from ship tanker shall be allowed to unload if the cargo is having
temperature much lower than allowable safe handling limits (exceeding design
allowance of heating capacity) of Electrical Skin Trace Heating system.
● Status of storage tank (being filled as per schedule) at the Enclosure-3 shall be checked
with respect to liquid level and temperature of contents, verified and recorded. It shall be
ensured that in no case overfill takes place.
● In case the lined-up tank has been cleaned in recent past, it shall be ensured at the time
receiving hot liquid Bitumen, tank shall be made totally dry and heating system shall
be commissioned and in operating condition.
● Atmospheric Vent nozzle of the receiving tank shall be inspected beforehand and kept
clean of any congealed material. It would be better if scheduled inspection / cleaning /
replacement is covered under SOP.
● At any given point of time, liquid parcel shall be transferred up to highest permissible level
only (which shall be usable volume as defined keeping margin for piggable volume of the
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Bitumen
transfer line) and transfer operation shall be immediately terminated when contents of
the tank crosses this level. Due care for operational and communication efficiency shall
be taken for immediate action with safety in mind.
● It shall be ensured that under normal course, heating coils inside storage tanks shall
be always covered with minimum depth of liquid contents as recommended. Under
these conditions available capacity shall be calculated subtracting this volume.
● During Import, two isolation valves provision has been identified for stopping the flow of
liquid Bitumen being transferred to storage tanks namely BOVs in tank-pump suction (BOV-
1914 / BOV-1918) within dyke area or dock-line HOVs with pump suction (HOV-31C /
HOV-32C) which need to be operated based on situational demand based on scenario and
safety aspects.
● Above mentioned isolation valves shall be closed manually by field operator (based on
instructions from DCS Panel operator) when level indicator (LI) – reaches HH value or
LS (Level Switch) is activated as per Cause and Effect Matrix. Additionally, they will
also be utilized for closing as per Final level Set Point for an operational demand
requirement for a typical line up operation.
● On activation, high level interlock, audio alarm shall be sounded, DCS panel operator shall
alert Field operator and signal shall be sent (via VHF Transceivers) to stop liquid Bitumen
supply pumps operated by ship vessel. DCS panel operator shall be vigilant always
during import and keep sufficient margin to allow for communication lag and
unavoidable lethargy in manual operations.
● Whenever required all manual valves shall be closed slowly to avoid hammering (or
hydraulic shock / surge due to sudden closing) in a very long supply line.
● On activation of high-pressure interlock, audio alarm shall be sounded, isolation valves shall
be closed and signal / information shall be sent to stop Bitumen supply pumps operated by
ship vessel.
● No transfer shall be initiated if level measuring sensor at any designated storage tank is
malfunctioning or out of action.
● On getting confirmation and after completing formalities, ship’s pump(s) shall be started and
the flow of liquid parcel shall be at low rate initially till minimum level is attained and
then steadily increased to its nominal rate
● Unloading of Bitumen shall continue at the nominal flow rate, with all tank pump(s) operating
at the same time as per pre-decided / agreed sequence.
● Flow shall be gradually decreased when the unloading comes to an end after the ship
authorities declare end of the unloading operation as per contracted transfer.
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Bitumen
● Standard Pigging operation shall be carried out at the end of transfer operation to recover
the dead volume from the header. It shall be ensured that PLR vessel is drained properly
of liquid Bitumen. PLR shall be maintained at elevated temperature matching with
Bitumen carrying header.
● Bitumen supply flexible hose connection and flow circuit shall be purged by Air and
disconnected. It shall be blanked and kept at safe place (to avoid damage by any impact) till
next usage.
● Net volume of liquid Bitumen delivered to desired storage tank shall be calculated (considering
level variance and density corrected to actual temperature) which may be verified physically
by dip and documented.
● At no point of time Field staff shall be on top of tank during Import. A safe distance shall
be always maintained from tank and if any operation is required near tank, operator
shall wear full PPE suit to safeguard against accidental splash /spillage of Hot Bitumen.
2.3.2.2 For transfer to Multiple Tanks (Ship to Many Tanks)

● Liquid parcel transfer to multiple tanks shall be Intra Enclosure -within same enclosure. (In
our case it will be T-31 and T-32 only of Encl.-03)
● Receiving multiple tanks shall be lined up according to Import parcel size and available volume
(tank availability) as distributed among tanks.
● Line up shall be arranged either in sequential mode (as per specified logic for priority
selection and having facility for online addition / deletion of tanks in case of unforeseen
anomalies) or in parallel mode for simultaneous transfer.
2.4 Other essential requirements during Line up for Liquid Transfer from Ship
to Shore
● A single page CHECKLIST depicting status / action taken condition of all linkages for all
possible line up route duly signed by responsible field staff.
● Tested and effective communication network (VHF transceivers / intrinsically safe

Mobiles) among all personnel involved for the transfer of liquid cargo parcel.
2.5 Emergency Shutdown (failure of utility)
2.5.1 Failure of Power Supply
2.5.1.1 Significant impact on Import operation leading to disruption in following cases:

● Power failure at Electrical Skin trace Heating System
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– Emergency power supply as an alternate source may be provided at MCC feeder
● Power failure at Resistance type Heating System

● Power failure at Hot Oil Generator system

● Though Hot Oil flow control valve is motorised, but Hot Oil flow to T-31 / T-32 internal
coils can be regulated by manual bypass valve in case of driver power failure.
● Currently all BV / HOV s have only manual driver to operate, valve operation shall not be
influenced.
2.5.2 Failure of Hot Oil supply at Bitumen Storage tanks at Encl.-3

● Impact will vary depending upon the duration of failure and actual behaviour of Bitumen
storage tank as a heat sink, quality of application of insulation and external atmospheric
temperature at the time of occurrence. Downtime shall be minimised as low as possible.
Alternate source of power supply may be provided to Hot oil Generation system
2.5.3 Failure of Instrument Air

● No significant impact. All valves shall be normally operated by Manual actuator for routine
operation.
● Hot Oil circulation trough Bitumen storage tank is regulated by motor actuated valve.
2.6 Emergency Shutdown by ESD enforced.

● Described elsewhere in a specific document.
2.7 Normal Operation

● Control room staff shall co-ordinate and keep vigilant watch on field activities. They shall also
maintain unbroken communication hub among jetty / Enclosure area, field operators
(busy in lining up) and maintenance wing as per the need.
● All-important instructions and activities of operations shall be logged / recorded and relayed
immediately to the intended destinations.
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Bitumen
2.8 Operator’s Routine work
2.8.1 Check during transfer

● Field staff shall also take frequent rounds and visually inspect entire route of lining up and
report any abnormality or malfunctioning to supervisor/engineer for corrective action.
● Field staff shall monitor transfer operation and look out for any abnormal happening like sound
or smell of product etc. due to leakage or overfill taking place and immediately report to control
room for corrective action.
2.8.2 When needed

● Field operator, with all safety precautions and maintaining communication links shall take
corrective actions for manual intervention if needed.
● Routine oiling and greasing of the required components shall be taken care. Any abnormal
sound emanating from equipments and overheating of gearboxes or motors shall be
immediately reported to supervisor/engineer.
2.9 Control System (Logics and Interlocks)
2.9.1 In / Out breathing (during import / transfer)

● Atmospheric vent through goose neck provided which shall be always ensured to be entirely
clean.
2.9.2 Pressure Interlock

● On exceeding HH Set point all inlet valves should close.
* However, this interlock shall be applicable when actuators are installed on existing
manual valve BV/HOV and at present field staff shall close valve when alarms are
activated and / or relayed to them from main control and monitoring centre.
2.9.3 Level Interlock

● On activating Level switch (LS) or HH set point of Level Indicator (LI) all inlet valves shall
should close as applicable.
However, this interlock shall be applicable when actuators are installed on existing
manual valve BV / HOV and at present field staff shall close valve when alarms are
activated and/or relayed to them from main control and monitoring centre.
2.9.4 Emergency Shutdown

● On activation of ESD mushroom pushbutton, all transfer pumps shall be tripped; HOVs
/ BVs shall be closed immediately.
● However, for valves this interlock shall be applicable when actuators are installed on
BV / HOV and at present field staff shall close valve when alarms are activated and/or
relayed to them from main control and monitoring room.
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
2.10 Trouble Shooting

● It is most imperative for the operators (Control room and Field staff) to coordinate and
communicate with each other continuously.
● Utility operators shall monitor utility (Hot Oil Generator / Instrument air / Electrical heat
tracing system) system operations and coordinate with condition monitoring cell for
preventive maintenance without affecting daily operation schedule.
2.11 Conditions Tables for the Intended Transfer Route for Bitumen Import
Important Notes:
– It is ensured that Electrical Skin Trace Heating has been started as per SOP Manual
of package supplier (n-Vent) and entire header is pre-heated to match receiving
parcel temperature or as suggested by importer / product MSDS. All components of
piping route like valves / fittings / Pig trap / PLR etc. including various Instrument
hook-up shall be having temperature as set and no portion of piping route shall have
lower temperature out of allowable range to avoid dead spots causing congealing
and solid build-up over the period.
– Initial flow rate be at slow rate till minimum level is attained for observation (whether
any water vapour formation or hazardous fumes are observed through vent or any
sound in the tank or unsafe condition is observed) and then after flow rate can be
increased slowly.
– It shall be ensured that all manual valves along the intended lined up route (valves
without any status feedback to control room) are either in open / close modes so as to
allow the intended operation of liquid transfer in the desired direction starting from source
to destination.
– Till actuators and status feedback system are installed on BV / HOV, A FIELD
GENERATED CHECKLIST shall be prepared showing status of all vital links of entire
Line up which shall be filled after double confirmation by physical verification and
submitted to Central monitoring and control centre.
– A standard document mentioning SOP (Standard Operating Procedures) shall be
adhered to all the time.
– At the same time, a common representative CHECK-BOX shall be provided on the Line
/ route on DCS screen (valid for all such Manual Valves which) may be entered
manually enforced status (as per the COLLECTIVE CHECKLIST furnished by field
staff) to detect Healthy Conditions (of the entire line-up route) for the desired operation and
finally generate “Ready to Start” command signal.
– It is recommended that unless the CHECKLIST from field staff is submitted to Control
Room or confirmed at least through communication (loud and clear) no operation shall be
commenced.
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
2.11.1 Bunker Import from Ship to a Single Tank: - Representative line up from Berth-2
to Single Tank
Representative Flow chart - 372479-PFC-0074-01 Rev.P1 – Import to Single Tank- T-31

of Encl.3
Control
Panel
Check Healthy Inst. Tag Ref. line /
Sr. No. point conditions Nos Parameters Ref. PID Tank no Remarks
Line at Headers P-
Dock – 0201-A21A-
Berth-2 10”-IE
1 Header Header 372479-PIA- P- 0201- Manual
depressuris available 0002-01- A21A-10”-IE valve
ed and Rev.-07 opened, and
available Header kept
empty to
receive
product
2 Isolation Open HOV-0201 Open as 372479-PIA- P- 0201- Header
valve status Indicated by 0002-01- A21A-10”-IE ready to
Limit switch Rev.-07 receive
Bitumen
3 Header Header PI-0201 PI-0203 = 0 372479-PIA- P- 0201- Header
depressuris available kg/cm2 0002-01- A21A-10”-IE ready to
ed and Rev.-07 receive
available Bitumen
4 Dock line Header 372479-PIA- P- 0207- Manual
depressuris available 0002-01- A21A-12”-IE valve (BV-
ed and Rev.-07 0234)
available opened, and
Header kept
empty to
receive
product
5 PLR-0207 BV-0224 --- Close as 372479-PIA- P- 0201- PLR-0207
isolation closed confirmed 0002-01- A21A-10”-IE isolated
by Field Rev.-07
Staff
6 Isolation BV-0234 --- Open as 372479-PIA- P- 0201- Header
valve status opened confirmed 0002-01- A21A-10”-IE ready to
by Field Rev.-07 receive
Staff Bitumen
7 Isolation BV-0281 -- Open as 372479-PIA- P- 0207- Header
valve status open confirmed 0002-01- A21A-12”-IE ready to
Staff Bitumen
available Bitumen
9 PLR-0203 Closed HOV-0207 Closed as 372479-PIA- P- 0207- PLR-0203
isolation Indicated by 0002-01- A21A-12”-IE isolated
Limit switch Rev.-07
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Control
Panel
10 Intermediate BV-0251 Open as 372479-PIA- P- 0207- Header

surge valve open confirmed 0002-01- A21A-12”-IE ready to
status by Field Rev.-07 receive
Staff Bitumen
12 Pressure 0 Gauge PI-0207 PI- 372479-PIA- P- 0207- Header
indication of pressure 0207=0kg/c 0002-01- A21A-12”-IE purged and
header m2 kept empty
Rev.-07
13 Temperatur Set as per TI-0203 TI-0203 = -- 372479-PIA- P- 0207- Elect. Trace

e of receiving Deg. C 0002-01- A21A-12”-IE Heating is
receiving parcel on and
Rev.-07
header temp.is
maintained
as per
parcel
Further 372479-PIA- P-0214-
connection 0002-01- A21A-12”-
to dock line IE
Rev.-07
14 Isolation Open HOV-0217 / Open as 372479-PIA- P-0214- Header

valves Indicated by 0002-01- A21A-12”- available
status Limit switch
Rev.-02 IE
15 Isolation Open HOV-0218 Open as 372479-PIA- P-0214- Header

valves confirmed 0002-01- A21A-12”- available
status by Field
Rev.-02 IE
Staff
16 Pressure 0 Gauge PI-2001 PI-2001=0 372479-PIA- P-0214- Header
indication of pressure kg/cm2 0020-01- A21A-12”- purged and
header kept empty
Rev.-04 IE
At 372479-PIA-
Enclosure 0003-01-
manifold-3
Rev.-04
At Pump 372479-PIA- Connection

Manifold-3 0020-01- with P-31
Rev.-04 suction
header to
T-31
17 Isolation HOV-31C Open as 372479-PIA- P- 1911- Dock line to
valve status Open Indicated by 0020-01- A21A-12”-IE P-31
Limit switch Rev.-04 suction
Other Isolation HOV-31B Close as 372479-PIA- P- 1911- Other
isolation valve status Close Indicated by 0020-01- A21A-12”-IE headers
valves Limit switch Rev.-04 isolated
(Encl.-3) from P-31
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Control
Panel
18 Pump P-31 P-31 on SS-P31 / Pump motor 372479-PIA- P-31 P-31 is
status local mode XL-P31 off signal 0020-01- stopped and
and de- Rev.-04 isolated
energised
19 Isolation BV-2008 Close as 372479-PIA- P-2005- P-31 is
valve closed confirmed 0020-01- A21A-10”-IE isolated
by Field Rev.-04
Staff
20 Pressure 0 Gauge PI-T31B PI-T31B=0 372479-PIA- P-1911- Header
indication of pressure kg/cm2 0019-01- A21A-12”- purged and
header kept empty
Rev.-03 IE
21 T-31 inlet Isolation BV- -- Open as 372479-PIA- P- 1911- T-31 inlet

header 1914 fully confirmed 0019-01- A21A-12”-IE header open
open by Field Rev.-03
Staff
22 T-31 inlet Open HOV-T31C Open as 372479-PIA- P- 1913- T-31 inlet
Indicated by 0019-01- A21A-12”-IE header open
Limit switch
Rev.-03
23 T-31 main HOV-T31D Close as 372479-PIA- P- 1911- Main outlet

outlet Closed Indicated by 0019-01- A21A-12”-IE closed
header Limit switch
Rev.-03
24 T-31 HOV-T31E Close as 372479-PIA- P- 1912- Stripping

stripping Closed Indicated by 0019-01- A1M-4”-IE outlet closed
header Limit switch
Rev.-03
Desirable
conditions
for T-31
25 Tank Liquid User defined PI-T31A MMWC 372479-PIA- T-31 shell T-31 is
Static head 0019-Rev.- empty and
03 at
atmospheric
pressure
26 Tank level User defined LT-T31 User defined 372479-PIA- T-31 shell T-31 can be
0019-Rev.- top filled
03
27 Tank level User defined LS-T31 Not 372479-PIA- T-31 shell T-31 can be
switch activated 0019-Rev.- top filled
status
03
28 Re- HOV-T31A ---- Close as 372479-PIA- T-31 shell HOV valve

circulation Closed confirmed 0019-Rev.- closed,
valve status by Field
03
Staff
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
2.11.2 Ship to Many tanks Intra Enclosure (Within a Single enclosure)
Important Notes:
● There shall be separate dedicated teams for manipulating manual valves for each tank.
This is to devote full attention towards operation, avoid time delay, and instruction
confusion which may lead to unsafe operation create hazardous situation like over
filling or spillage.
● For Simultaneous (to parallel lined up tanks) import of Bitumen

– Normally, in this mode, the liquid parcel transfer to multiple tanks shall be (Intra Enclosure)
within multiple tanks of same enclosure.
– Receiving multiple tanks shall be lined up according to Import parcel size and available
volume (tank availability) in an enclosure.
– Line up for Intra Enclosure shall be arranged in parallel mode (simultaneous transfer to
multiple tanks) as per specified logic and having facility for online addition / deletion of
tanks in case of unforeseen anomalies.
– It shall be ensured that following logic functions shall be considered:
○ Liquid path from Jetty up to individual tanks (Tanks with main isolation BV valves)
shall be lined up with header isolation valves in desired open/close position as per
checklist.
○ Main isolation BV valve of parallel lined up tanks shall be kept in open mode.
○ Cargo transfer from Jetty to enclosure shall be commenced when all conditions
including ESD are satisfied.
○ Though all tanks shall be lined to receive liquid simultaneously, incoming flow to tank
shall vary from tank to tank as per local frictional resistance of piping system
components.
○ As soon as any tank among the line-up starts filling and LI crosses desired set point,
field staff shall manipulate the BV valve remaining in close contact with Central
control and monitoring centre.
○ Close communication among jetty staff, field operators and Control room
operator, along with prior capacity margin calculation among tankages shall be
required for efficient operation.
○ At no point of time inlet BVs of multiple tanks shall happen to coincide on “Closed”
status.
– Tanks priority selection shall be reversible and resettable. During liquid parcel transfer
operation, if any anomaly arises, transfer operation shall be suspended by ESD or by field
activity feedback. Secondary planned route for line up shall be chalked out and evaluated
considering safety, contamination factor and ease of line up also taking into account waiting
period of vessel.
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
● For Sequential filling method (In series, as per lined up tanks following specified
logic) for importing Bitumen.
– For liquid parcel transfer to multiple tanks shall be (Intra Enclosure) within multiple tanks
of same enclosure.
– Receiving multiple tanks shall be lined up according to Import parcel size and available
volume (tank availability) as distributed in an enclosure.
– Line up for Intra Enclosure shall be arranged in sequential mode as per specified logic
for priority selection and having facility for online addition / deletion of tanks in case of
unforeseen anomalies.
– It is quite logical that the first tank (as arranged within the lined up set up of tanks) shall
have higher available space to accommodate the liquid parcel to greater extent and spill
over to other tank for maximum utilization of available volume.
– It shall be ensured that for deciding logic functions for change over, following shall be
considered:
○ Liquid path from Jetty up to individual tanks (Tanks and main isolation BV valves)
shall be lined up with header isolation valves in desired open/close position as per
checklist.
○ Main isolation BV of any tank as per priority selection order and line up shall be
kept in respective mode (open / close) for initial line-up.
○ Cargo transfer from Jetty to enclosure shall be commenced when all conditions
including ESD are satisfied.
○ As soon as first tank among the line-up order starts filling and LI crosses desired set
point (considering safe margin of available space which is likely to be filled up
during change over), Field staff shall start opening BV of downstream tank manually
based on feedback / instruction from central control and monitoring centre.
○ LI set point shall be adjusted on practical commissioning feedback of opening time of
BV (as operated manually by field staff) and flow behaviour of liquid parcel on single
tank inlet and multiple tanks inlet scenario.
○ At no point of time inlet BVs of multiple tanks shall happen to coincide on “Closed”
status.
– Tanks priority selection shall be reversible and resettable. During liquid parcel transfer
operation, if any anomaly arises, transfer operation shall be suspended by ESD or by field
activity feedback. Secondary planned route for line up shall be chalked out and evaluated
considering safety, contamination factor and ease of line up also taking into account waiting
period of vessel.
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
2.11.2.1 Bunker Import from Ship to Many Tanks - Representative line up from Berth-2 to
Multiple Tanks Intra Enclo. Simultaneously
Representative Flow chart - 372479-PFC-0075-01 –Rev.P1 Import Bunker to Many

Tanks Simultaneously (T-31 / T-32 of Encl.3)
Control
Panel
Line at Headers P-
Dock – 0201-A21A-
Berth-2 10”-IE
empty to
receive
product
Bitumen
available Bitumen
Header kept
empty to
receive
product
by Field Rev.-07
Staff
Staff Bitumen
Staff Bitumen
available Bitumen
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Control
Panel
Staff Bitumen
Rev.-07

Rev.-07
header temp.is
maintained
as per
parcel
to dock line IE
Rev.-07
14 Isolation Open HOV-0217/ Open as 372479-PIA- P-0214- Header

status Limit switch
Rev.-02 IE

status by Field
Rev.-02 IE
Staff
16 Pressure 0 Gauge PI-2001 PI-2001=0 372479-PIA- P- 0214- Header
indication of pressure kg/cm2 0020-01- A21A-12”-IE purged and
header kept empty
Rev.-03
At Pump Connection
Manifold-3 with P-31/P-
32 suction
header for
T-31 / T-32
For T-31
line up
17 Isolation HOV-31C Open as 372479-PIA- P- 0214- T-31 to P-31
valve status Open Open Indicated 0020-01- A21A-12”-IE suction
Rev.-03 connected
by Limit
switch
Other Isolation Close HOV-31B Close as 372479-PIA- P- 0218- Other
isolation valve status Indicated 0020-01- A21A-4”-IE headers
valves Rev.-03 isolated
by Limit
switch
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Control
Panel
18 Isolation Open HOV-32C Open as 372479-PIA- P- 0214- T32 to P-32
valve status Indicated 0020-01- A21A-12”-IE suction
Rev.-03 connected
by Limit
switch
Isolation Close HOV-32B Close as 372479-PIA- P- 0218- Other
valve status Indicated 0020-01- A21A-4”-IE headers
Rev.-03 isolated
by Limit
switch
energised
20 T-31 inlet Main BV-1914 Open as 372479-PIE- P- 1911- T-31 inlet
header Isolation confirmed 0003-01- A21A-12”-IE header open
valve Rev.-04
by Field
Staff
Limit switch
Rev.-03

header Limit switch
Rev.-03

header Limit switch
Rev.-03
Desirable
conditions
for T-31
03 at
atmospheric
pressure
03
status
03

03
Staff
For T-32
Line up
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Control
Panel
28 T-32 inlet BV-1918 -- Open as 372479-PIA- P- 1916- T-32 inlet
header main fully open confirmed 0019-Rev.- A21A-12”-IE header open
isolation 03
by Field
valve
Staff
Limit switch
Rev.-03

header Limit switch
Rev.-03

header Limit switch
Rev.-03
Desirable
conditions
for T-32
03 at
atmospheric
pressure
03
status
03

03
Staff
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
2.11.2.2 Bunker Import from Ship to Many Tanks – Representative line up from Berth-2 to
Tanks of Intra Enclo. Sequentially
Representative Flow chart - 372479-PFC-0076-01 –Rev.P1 Import Bunker to Many

Tanks Sequentially (T-31 / T-32 of Encl.3)
Control
Panel
Line at Headers P-
Dock – 0201-A21A-
Berth-2 10”-IE
empty to
receive
product
Bitumen
available Bitumen
Header kept
empty to
receive
product
by Field Rev.-07
Staff
Staff Bitumen
Staff Bitumen
available Bitumen
Staff Bitumen
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Control
Panel
Rev.-07

Rev.-07
header temp.is
maintained
as per
parcel
to dock line IE
Rev.-07

status Limit switch
Rev.-02 IE

status by Field
Rev.-02 IE
Staff
header kept empty
Rev.-03
At Pump Connection
32 suction
header for
T-31 / T-32
For T-31
line up
17 Isolation HOV-31C Open as 372479-PIA- P- 0214- T-31 to P-31
Rev.-03 connected
by Limit
switch
valves Rev.-03 isolated
by Limit
switch
18 Isolation Open HOV-32C Open as 372479-PIA- P- 0214- T32 to P-32
Rev.-03 connected
by Limit
switch
Isolation Close HOV-32B Close as 372479-PIA- P- 0218- Other
valve status Indicated 0020-01- A21A-4”-IE headers
Rev.-03 isolated
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Control
Panel
by Limit
switch
energised
20 T-31 inlet Main BV-1914 Open/clos 372479-PIE- P- 1911- T-31 inlet
header Isolation ed as 0003-01- A21A-12”-IE header
valve Open / Rev.-04 open/closed
confirmed
close
by Field
Staff
Limit switch
Rev.-03

header Limit switch
Rev.-03

header Limit switch
Rev.-03
Desirable
conditions
for T-31
03 at
atmospheric
pressure
03
status
03

03
Staff
For T-32
Line up
28 T-32 inlet BV-1918 -- Open/clos 372479-PIA- P- 1916- T-32 inlet
header main fully ed as 0019-Rev.- A21A-12”-IE header
isolation open/closed 03 open/closed
confirmed
valve
by Field
Staff
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Control
Panel
Limit switch
Rev.-03

header Limit switch
Rev.-03

header Limit switch
Rev.-03
Desirable
conditions
for T-32
03 at
atmospheric
pressure
03
status
03

03
Staff
2.12 Bitumen Import Directly from Berth to TLF area for Road Tankers filling.
Important Considerations:
● The gravity and impending Safety Hazard of this operation is higher as liquid is
Bitumen at 150 Deg. C or higher. Enough precautions shall be taken for all activities,
all persons involved shall wear adequate PPE and at no point of time safety shall be
compromised.
● Enough manpower shall be employed for each point of loading to remain attentive and
vigilant during the operation. Timely action for closing manual valve / stopping pump /
pressing ESD button or operating Fire Extinguisher is possible only if dedicated
manpower is allocated per loading point.
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
● Due to combination of various limiting factors like: parcel size-based vessel emptying flow
rate requirement, lesser available pipe size of transfer pump bypass line (indirect line up
route) both P-31 and P-32 shall have to be taken simultaneously in line (in bypass mode)
to utilize Bay- 01 and Bay-02 for maximum utilsation and Tanker loading.
● Though the lineup Flow chart is indicative, the entire operation shall be carried out as per
occasional and rare need.
● Entire operation shall be locally manned operation and supposed to be carried out with
intense communications among all activity holders.
● The purpose of showing line-up is solely to show the status of engagement of line up
equipments-tanks-header-loading bay etc. with reference to other operations for planning
and safety look out.
2.12.1.1 Prime requisites for this operation:
● This option may be needed under the circumstances when,

– Liquid parcel volume is comparatively low.
– Customer does not want to store the product in intermediate storage facility for economic
reasons
– Urgent need for inland despatch.
– Different liquid parcels need to be unloaded simultaneously from the same vessel but
having variable quantum.
● This operation is supposed to be carried out when,

– Strong and efficient communication link between Ship-shore and TLF area has
been established while transfer operation shall be suspended immediately if the
link is severed.
– Ship pumps are operated by either VFD drives or having an efficient bypass system
which has been installed on pump manifold to take care of pressure rise during
changeover of road tankers.
– Enough precautions are taken to avoid surge wave by sudden closing of valves
along the line up to TLF area. A separate empty tanker may be kept connected in
parallel to divert the flow during the changeover of tankers to avoid stopping the
flow altogether. This will help avoid the surge wave generation on long lines.
– Full fleet of road tankers (having sufficient volume) is available round the clock either
owned by customer or charted by the agent.
– It shall be observed that there shall be no violation of prevailing Safety guidelines, CPCB
norms and / or other statutory obligations.
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
2.12.1.2 Import- from Berth to TLF area - (372479-PFC-0077-01-Rev.-P1)
● Representative Flow chart – 372479-PFC-0077-01-Rev.-P1 Ship to TLF-Enclosure-3

(Bay-01 / Bay-02)
Control
Panel
Line at Headers P-
Dock – 0201-A21A-
Berth-2 10”-IE
empty to
receive
product
Bitumen
available Bitumen
Header kept
empty to
receive
product
by Field Rev.-07
Staff
Staff Bitumen
Staff Bitumen
available Bitumen
status Rev.-07
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Control
Panel
by Field receive
Staff Bitumen
Rev.-07

Rev.-07
header temp.is
maintained
as per
parcel
to dock line IE
Rev.-07

status Limit switch
Rev.-02 IE

status by Field
Rev.-02 IE
Staff
header kept empty
Rev.-03
At Pump Connection
32 suction
header
For P-31
line up
17 Isolation HOV-31C Open as 372479-PIA- P- 0214- P-31
Rev.-03 connected
by Limit
switch
isolation valve status Indicated 0020-01- A21A-4”-IE header
valve Rev.-03 isolated
by Limit
switch
18 Isolation Open HOV-32C Open as 372479-PIA- P- 0214- P-32
Rev.-03 connected
by Limit
switch
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Control
Panel
valve Rev.-03 isolated
by Limit
switch
19 T-31 side Main BV-1914 closed as 372479-PIE- P- 1911- T-31 inlet
isolation Isolation confirmed 0003-01- A21A-12”-IE header
valve closed Rev.-04 closed
by Field
Staff
energised
21 T-32 side Main BV-1918 closed as 372479-PIA- P- 1916- T-32 inlet
isolation isolation fully closed confirmed 0019-Rev.- A21A-12”-IE header
closed 03 closed
by Field
Staff
energised
23 P-31 Bypass BV-2022 Open as 372479-PIA- P- 2007- P-31
bypassing Manual confirmed 0020-01- A21A-4”IE Bypassed
valve open Rev.-03
by Field
Staff
24 P-31 Open HOV-P31B Open as 372479-PIA- P- 2006- Del. open
Delivery confirmed 0020-01- A21A-6”-IE
isolation
valve
by Field Rev.-03
Staff
25 Recirculatio Closed HOV-P31A Closed as 372479-PIA- P- 2001- Valve closed
n valve (4”) Closed confirmed 0020-01- A21A-4”-IE
in delivery
by Field Rev.-03
line
Staff
26 P-31 0-gauge PI-P31 0 kg/cm2 372479-PIA- P- 2006-
delivery pressure 0020-01- A21A-6”-IE
header
Rev.-03
empty
27 Batch Batch BC-2101A Manual / 372479-PIA- Bay-01/02 Manual
controller on controller /2102A SOP/ 0021-01- filling by
manual bypassed Checklist Rev.-01 operator
mode
28 Earthing attached ES -2101 / Earthing

sensor 2102 sensor
activated
while filling
29 Overfill Not active LSH2101A / Although
sensor 2102A manual
filling this
will be extra
precaution.
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Control
Panel
30 P-32 Bypass BV-2023 Open as 372479-PIA- P- 2014- P-32
bypassing Manual confirmed 0020-01- A21A-4”IE Bypassed
valve open Rev.-03
by Field
Staff
31 P-32 Open HOV-P32B Open as 372479-PIA- P- 2013- Del. open
Delivery confirmed 0020-01- A21A-6”-IE
isolation
by Field Rev.-03
valve
Staff
32 Recirculatio Closed HOV-P32A Closed as 372479-PIA- P- 2002- Valve closed
n valve (4”) Closed confirmed 0020-01- A21A-4”-IE
in delivery
by Field Rev.-03
line
Staff
33 P-32 0-gauge PI-P32 0 kg/cm2 372479-PIA- P- 2013-
delivery pressure 0020-01- A21A-6”-IE
header
Rev.-03
empty
34 Batch Batch BC-2101B Manual / 372479-PIA- Bay-01/02 Manual
controller on controller /2102B SOP/ 0021-01- filling by
manual bypassed Checklist Rev.-01 operator
mode
35 Earthing attached ES -2101 / Earthing

sensor 2102 sensor
activated
while filling
36 Overfill Not active LSH2101B / Although
sensor 2102B manual
filling this
will be
extra
precaution.
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
3 Intermediate Storage and handling of

Bitumen in Storage Tank T-31 and T-32
3.1 Description
● In ports and liquid terminal / tanks farm area, often some hydrocarbons like Bitumen and
other heavy fuel oils are handled for Intermediate storage, Import and Export (marine
and inland) operations. These products are normally solid or semi-solid / highly viscous
at room temperature hence it becomes imperative to keep them at higher temperature
for easy handling and transportation as follows:
– Marine Transportation
○ Specially built Ships / vessels / barges have onboard heating system to keep the liquid
contents always at recommended elevated temperature from point of loading port
to destination port.
– Import operation from Jetty to Onshore Liquid terminal

○ Often Electrical Trace Heated and Insulated pipelines are employed to maintain the
temperature intact (as received) for liquid parcels
– Dedicated Storage tanks at liquid tank-farm enclosures

○ Insulated tanks having internal coils for Hot Thermic Fluid circulation to maintain
temperature of liquid contents according to client’s instructions or recommendation as
per MSDS
○ Dedicated Hot Oil package (FO/LDO/LG/NG based) with Hot Oil Generation and
circulation system.
– Road Tanker Loading System for inland despatch

○ Transfer pump (to draw and supply hot Bitumen from the storage tank) with Electrical
Trace Heated piping up to Loading Bays.
3.1.1 Bitumen Storage Tanks

● MDS of T-31 and T-32 are attached in annexures
3.1.2 Hot Oil Generation system

● Technical documents (of M/s THERMOTEC who are supplier) for Thermic Fluid Heater are
attached in annexures
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
3.2 Scope
● To receive hot liquid Bitumen from jetty area through dedicated (insulated / heat traced)
dock line into dedicated tanks T-31 / T-32 which are adequately insulated and have internal
coils through which Hot Oil is circulated to maintain required temperature of stored
quantity till despatch activity is commenced through TLF area.
● Maximum operating temperature (lowest usable) shall be specified to avoid the

possibility of flammable atmosphere creation in Ullage space.
3.3 Operation and Control Methodology
3.3.1 Preparation of Bitumen Storage tanks for operation readiness

● Cleaning thoroughly of Bitumen storage tanks at regular intervals is recommended.
Prolonged operations cause char build up on heating coils which reduce heating
efficiency.
● Whenever water jets are used for cleaning purpose, it shall be ensured that no traces of water
or hydrocarbon remain in the tanks after cleaning and before putting into operations.
● Atmospheric vent nozzles shall be inspected and cleaned thoroughly before installing
back on the top.
● It shall be ensured that there shall be no spillage or overflow of hot Bitumen which may
enter into side wall insulation material which may soak up. Therefor closed cell -non-
absorbent Foam glass type insulation material is preferred. Bitumen being hydrocarbon
may ignite and catch fire anytime. While providing insulation-cladding care should be
taken to provide proper sealing to avoid penetration of liquid Bitumen. Make sure to
check Insulation if by any chance spillage occurs and replace old insulation if found
soaked.
● There shall be sufficient Ullage margin as checked and confirmed before start of
operation. It is often found that 90% of spillage / overfill phenomena occurs when safe
working capacity of tank is crossed when one is tempted to go for maximum utilisation
of tank capacity. During operation, special attention shall be provided to High Level alarms
and / or Level Switches while Importing (tank filling operation) followed by (quantity
received during) Pigging at the end of operation.
● For keeping reliability and integrity of instruments, all instruments shall be calibrated at
regular intervals. Level sensors / probes which are prone to Bitumen vapour coating shall be
serviced at predefined intervals.PT based levels shall be provided with accurate specific
gravity (SG) at existing temperature.
● During Import, care shall be taken to convert Mass (Tons) to Volume (Cu. Mt.) as given
mass of Bitumen shall occupy largest volume at its highest storage temperature.
Accurate conversion factor shall help decide volumetric capacity of tank w.r.t. weight
and avoid overfilling the storage tank.
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Bitumen
3.3.2 Heating Bitumen Storage Tanks
3.3.2.1 Before receiving Liquid Bitumen

● Establishing Temperature control by Thermo tech Package control system in tank
empty condition
– It is presumed that Cold start as well as Hot start of the system have been finished.
Consequently, Hot Oil System has been pre-commissioned.
– Entire Forward and Return headers from B/L to T-31 / T-32 shall also be covered
under above mentioned activity.
– Subsequently, NO load trial has been taken and maximum temperature has been
achieved.
– All Interlocks shall be tested and PID controls shall be fine-tuned. Full functionality
of HOG system has been established w.r.t. all controls of Operating system.
– In accordance with the Import schedule, Hot oil package system shall be started
keeping Lead time required for the system to achieve healthy running status.
– Following instructions and guidelines of Thermo tech Package Operation manual, Hot
Oil Temperature set point shall be raised gradually and matching temperature to that of
Bitumen Parcel shall be achieved.
– Hot oil shall be circulating in package system in close circuit at practically No-Load
condition.
– Branch isolation valves of HO supply / return header towards T-31 / T-32 shall be opened
together with manual isolation valves with tank shells. Now internal heating coils of tanks
shall be ready to receive Hot oil from HOG system.
– Subsequently, Temp.control valves (TCV-131 /TCV-132) installed on HOT Oil inlet to
internal heating coils of T-31 / T-32 shall be taken on Manual command mode and opened
100 % but very slowly. A dip in circulating HO temperature shall be observed which shall
be taken care by Burner system to maintain set Point temperature.
– Now Hot Oil shall be kept circulating through entire circuit (TCV-131 / TCV-132 on manual
mode and fully open) waiting for Hot Liquid Bitumen to arrive.
– On receipt of Bitumen, level builds up inside the tanks and Bulk Liquid temperature shall
be indicated by TI-131 / TI-132 which may vary slightly than anticipated based on receipt
at berth.
3.3.2.2 During receipt of Bitumen

● Tank side Temperature control (TIC Loop) shall be included when sufficient liquid
Bitumen level is built up over the heating coils.
– When heating coils are fully submerged TCV-131 / TCV-132 shall be taken in Auto Mode
with Temperature Set Point as agreed before -but minimum as receipt.
– Due to some initial losses to metallic shell and breathing out air, TCV may open more to
provide more enthalpy flow to bring up temperature up to set point.
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Bitumen
– As the Import operation comes to end concluded by final liquid Bitumen quantity as pushed
by Pigging process to empty out dock line, T-31 / T-32 must have been filled up to level not
exceeding Safe Operating Level.
– By this time TCV might have reached to Set Point and some dynamic balance between Hot
Oil package Temp. control system and TCV might have been established.
– It is ideal time to observe and carry out Fine Tuning of PLC controls of HO package and
TCV PID controls.
3.3.2.3 During Bitumen Storage, Transfer and TLF operation

● Long term storage of Bitumen in T-31 / T-32 and temperature maintenance.
– As there is no physical mixing inside the tank by any equipment, heat shall be
diffused by convective thermal currents. Multipoint temperature sensor shall measure
slightly different values across the depth and averaged out value may be utilised for
providing temperature set point for TCV with higher terminal value for shut-off.
– At no time Heating Coils shall be exposed and a minimum pre-decided level of Bitumen
shall be always maintained unless tank needs to be emptied out totally for maintenance or
cleaning purpose.
– Typically, the response time of TCV for such system may be slow / sluggish which shall be
taken care by adjusting PID constants.
– As the heat dissipation inside the tank will be comparatively slower, during raising
of temperature by TCV, RAMP command may be used to avoid higher Delta ‘T’
across both media which may create undesired characteristic of Bitumen on
excessive hot tube surface. RAMP mode will allow to adopt slow rise of temperature
without Bitumen charring on tube surface.
– It is suggested to keep Hot Oil circulation on in T-31 /T-32 (either in a single or both
as per the case) in Auto Mode to maintain the tank inside temperature near to set
point.
– Even if despatch schedule is extended than anticipated, stopping Hot Oil system and
resuming again shall disturb control system as proper temperature feedback shall be
disturbed due to stratification layers formation of different viscosity and temperature zones.
This will hamper the operation with unpredictable behaviour and temperature achieving
time.
– It is to be noted here that the Hot Oil package system has been designed to supply
required Enthalpy (Heat content) to both Bitumen storage tanks together to cater to
demand of raising 1 Deg. C of Bitumen quantity which can be contained in 1 Meter
Height of 18 Mt. Ꝋ tanks.
– Ultimately entire system will operate on more or less constant temperature of Hot oil
as received (from hot oil Package) at TCV inlet from where Flow quantity shall be
controlled to provide required Enthalpy (Heat content) to stored Bitumen quantity.
– Refer TLF for Hot Bitumen transfer to TLF area for Road Tanker filling.
3.3.3 Storage Tank Safety Considerations

● During operations following potential Risks and Hazards are likely to exist:
– Auto ignition at the surface of / within fibrous or porous material impregnated with Bitumen
can occur as low as 100 deg. C. Therefore, overflow of Bitumen contaminating
Insulation should be avoided and Non-adsorbent type insulation should be used.
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Bitumen
– Pyrophoric (solid – may be sometimes Iron sulphide)) deposits which are formed due to
carbonaceous material occur in Oxygen depleted environment and due to condensation of
vapours on roofs/ walls of tank and thermal degradation afterwards. On sudden Oxygen
rich environment evolution due to air blowing through Bitumen piping these
smouldering deposits suddenly self-ignite and can combine with any flammable
atmosphere existing inside to create unsafe conditions.
– Exposure of Bitumen storage tanks to fire - Fog, water mist, well dispersed water
droplets or FFFP (Film Forming Fluro-Protein) foam are best method to control fire. Cooling
to prevent re-ignition is necessary.
– Static Electricity - Though electrical conductivity of bitumen does not cause accumulation
of electrostatic charge during flowing through pipelines, charged fine spray-mist-foam can
be formed due to splash filling and in a large tank it can generate a spark of high magnitude.
– Partial plugging / fouling of atmospheric vents should be avoided. No bird mesh to be
provided. A clear passage to be provided for regular inspection and cleaning. Vent area
should be over designed by 50% considering fouling phenomena. There are chances that
when overfilling occurs due to any reason Bitumen cannot come out from vent (if under
designed or tank designed for another duty is utilised for Bitumen) and tank roof is severely
damaged.
– Boil-over
○ When sinking hot layer comes in to contact of either water at bottom or low boiling point
hydrocarbon layer and ignites, expands and erupts as burning overflow liquid.
– Froth-over
○ Provision to prevent water ingress to be provided by tight opening (inspection hatches
and dip gauge hole etc.) and proper roof drainage provisions. This applies to during
firefighting or emergency tank cooling also.
○ Avoid introducing another grade of Bitumen into a tank having partial load of Bitumen
inside.
○ Frothing phenomena occurs when hot Bitumen comes into contact of water / low boiling
hydrocarbons which causes them to boil and expand pass through Bitumen layers and
overflow from tank with hot Bitumen.
○ Froth over can be avoided if contents are heated at slow rate (between 95 to 120 deg.
C – boiling range of water) if presence of water is suspected.
– Tank internal heating devices over heating shall be avoided always. Localised over
heating of coils causing vaporisation of Bitumen when coils are not covered with sufficient
Bitumen.
– Possibility of Overflow of Bitumen in case of failure of Tank Level Alarms
malfunctioning during Import or ITT operation shall never be overlooked.
– Access to tank roof shall be strictly controlled and avoided as far as practically
possible when Import or Transfer operation is taking place
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Bitumen
● Inspection
– External inspection of tank walls, fittings shall be carried out for leaks during routine
inspection. Findings shall be recorded, and necessary maintenance identified.
– Internal inspection of tank walls, floors, roofs and internal fittings involves total emptying
and cleaning which shall be as per SOP formulated by AKPPL. Findings shall be
recorded, and necessary maintenance identified.
– Bitumen tank vents and pressure relief panels are prone to fouling. A regular inspection
shall be covered under SOP based on operating experience. On filled tank, if required,
inspection / cleaning / replacement of vent shall be carried out with proper Work
Permit issuance and providing PPE to personnel to take care of Hydrogen Sulphide
gas or flammable vapours releasing from vents.
– Thermal Insulation (preferably Non-adsorbent type-sealed) shall be inspected
frequently for contamination by Bitumen spills to avoid Auto-ignition. It shall be replaced
whenever shows signs of Bitumen impregnation or cladding is found damaged.
– Tank Cleaning -
○ During the course of operation, some carbonaceous material deposition invariable takes
place over the period. This happens on heating coils, on walls at some places and roof
area. This becomes evident when working capacity changes, it becomes difficult to
maintain tank temperature and required flow of contents from tank cannot be
maintained. All these problems can be ascertained by visual inspection only but only
possible when tank is emptied, cooled, purged and opened to enter and observe.
○ Deposits which are usually hard, can be removed by chipping manually or by high
pressure water jets. Chipping by mechanical tools may damage the coils hence after
cleaning carful inspection and testing of coil is required before putting into operation
again. While high pressure water jet cleaning is a specialised activity done by a fully
trained, competent and experienced operator taking necessary safeguards. Material
removed from tank can be weathered in Sunlight to remove Hydrogen Sulfides / other
organics and can be sent for land filling.
– Tank Entry
Though empty and cold, Bitumen tank may contain Hydrogen Sulphide, or some
hydrocarbon vapours hence partial or full body entry cannot be allowed without taking
necessary precautionary measures including following:
○ No Bitumen should remain in tank as practically possible.
○ Positive isolation from all connected streams.
○ Isolated from Power and heating source.
○ Cooled to ambient /atmospheric temperature.
○ Ventilated / Purged by fresh air by opening bottom and top openings
○ Tested / checked by GAD by competent person with PPE for absence of H2S and
other flammable vapours and presence of Oxygen.
○ Smouldering -pyrophoric deposits may be doused with water and removed. Care shall
be taken to avoid injury from falling detached pieces of carbonaceous debris from roof
on cooling.
Entry into tank without airline fed RPE (Respiratory Protective Equipment) / SCBA
(Self Contained Breathing Apparatus)
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Bitumen
○ There should be only 0 – 4% LFL flammable vapor

○ Nil H2S (No presence of Hydrogen Sulphide gas)
○ During the period concentration of flammable / toxic vapor shall be continuously
checked as they can be released due to dislodging of deposits.
○ No Hot work shall be allowed in presence of such deposits.
Entry into tank with airline fed RPE / SCBA (Self Contained Breathing Apparatus)
○ Entry shall be for inspection only.
○ When Entry is required in spite of toxic / Oxygen deficient atmosphere inside the tank
○ LFL of flammable shall not exceed 25%
○ A second person with wearing SCBA shall be posted near entry to monitor activity inside
the tank and facility to extend lifeline.
○ When inside person is with airline fed RPE, outside posted person will have control of
air supply from air compressor
○ RPE air compressor shall have intake from fresh and uncontaminated air.
– Taking Bitumen Tank back to Operation

○ Ensure that all free water is removed from tank bottom and connected nozzles / pipe
works.
○ If required carry out mopping and air drying.
○ If possible, introduce Bitumen at 90 Deg. C and cover heating coils with 1 Meter depth
(maximum) and slow heating and raising the temperature up to 120 Deg. C within 24
hrs
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Bitumen
4 ITT
4.1 Definition
● Inter Tank Transfer (ITT) involves the Line-up operation for transferring liquid Bitumen cargo
product from any one of the tanks in Encl.-3 to other tank of the same Enclosure-3
– Intra Enclosure (Within an enclosure)
One tank to One Tank (Singular)
4.2 Operation and control methodology
4.2.1 General
● AKPPL has planned for developing an enclosure (for storing Bitumen) together with TLF and
necessary utility packages etc. Storing typical chemical like Bitumen is always with the
associated responsibility of Optimum Utilization for maximum economic returns. From
dedicated - Insulated and Electrical Trace Heated Jetty dock lines onwards, interconnecting
headers have been provided connections with spool pieces / manual valves etc. to maximise
the extent of manoeuvrability of transferring hot Bitumen liquid contents for intermediate
storing and filling road tankers for inland despatch.
● Inter Tank Transfer mode of operation is likely to be opted due to following probable situations:
– Segregation of same product of same customer in another storage tank of Intra enclosures.
– Transfer of part tank contents of one tank to another tank to make way for accommodating
higher volume liquid parcel import to recently emptied tank.
– Urgent maintenance requirement of a particular tank.
4.2.2 Scope
● Transfer of liquid contents of one tank to another tank employing either of the options as
mentioned below:
One Tank to One Tank

Intra
One Tank to One Tank- through TLF area Encl.-3 (372479-PFC-0078-01-Rev.-P1)
One Tank to One Tank- through TLF Pump and Recirculation Line Encl.-3(372479-
PFC-0079-01-Rev.P1)
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Bitumen
4.2.2.1 Inter Tank Liquid Cargo Transfer operation
● Status of storage tanks (at both ends i.e. Source Tank and Destination Tank at the shall be
checked for actual margin with respect to liquid level and temperature of contents.
● DCS indications for both tanks shall be verified and recorded physically by Dip gauge. It shall
be ensured that in no case overfill at receiving end (destination tank) or starvation of transfer
pump at sending end takes place.
● Main isolation BV is identified as stopping the flow of liquid contents being transferred from
one storage tank to another tank.BV shall be closed (as per instructions relayed from control
room) when level indicator LI – HH reaches 93% tank level and/or level switch LS is activated
(94.5% level) as per prescribed high-level interlock (Resettable)
● On activation of high-level (H) interlock, audio alarm shall be sounded, BV shall be closed
(manually as without actuator)
● No transfer operation shall be initiated if level measuring sensor at either of the storage tank
is malfunctioning or out of action.
● On getting confirmation after completing line up operation, transfer pump shall be started
either in Remote auto mode (from Control room) or locally from field and the flow of liquid
contents shall be steadily increased to its nominal rate
● Transfer shall continue at the nominal flow rate with monitoring level at both the ends and
maintaining communication link. Normally level rise at receiving tank is predictable due to
geometric calculations and hence transfer and pigging recovery operation can be completed
efficiently. Pigging operation shall be carried out at the end of transfer operation to recover the
dead volume from the header.
● Liquid transfer connection and flow circuit may be purged by air and disconnected.
● Net volume of liquid transferred to desired storage tank shall be calculated (considering level
variance and density corrected to actual temperature) which may be verified physically by dip
and documented.
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Bitumen
4.2.2.2 Transfer Mode: ITT - One Tank to One Tank - Intra (within the same enclosure)
representative line-up of T-31 to T-32
● Inter Tank Transfer – via TLF Area Encl.-3 (372479-PFC-0078-01-Rev.-P1)
Control
Panel Check Healthy Inst. Tag Parameter Ref. line /
Sr. No. point conditions Nos s Ref. PID Tank no Remarks
Desirable
conditions
for T-31
1 Tank Liquid User defined PI-T31A MMWC 372479- T-31 shell T-31 is filled
Static head PIA-0019- and at
Rev.-03 atmospheric
pressure
2 Tank level User defined LT-T31 User 372479- T-31 shell T-31 can be
defined PIA-0019- top pumped out
Rev.-03
3 T-31 Main Closed HOV-T31C Close 372479- P- 1913- Inlet closed

inlet valve indication PIA-0019- A21A-12”-
status by close IE
Rev.-03
limit switch
4 T-31 main Opened HOV-T31D Open 372479- P- 1911- Main outlet
outlet valve indication PIA-0019- A21A-12”- valve is open
status by close
Rev.-03 IE
limit switch
5 T-31 Open / close HOV-T31E Closed / 372479- P- 1912- Stripping outlet
stripping Opened as PIA-0019- A21A-4”-IE closed /
valve status indicated opened in case
Rev.-03
by Limit of transferring
Switch entire contents
by stripping
6 T-31 outlet BV-1914 fully ----- Opened as 372479- P- 1911- Tank line-up
valve open confirmed PIA-0019- A21A-12”- done till pump
by Field P-31 suction
Rev.-03 IE
Staff
T-32 Status
7 Tank Liquid User defined PI-T32A MMWC 372479- T-32 shell T-32 is at user
Static head PIA-0019- defined level
Rev.-03 and at
atmospheric
pressure
8 Tank level User defined LT-T32 User 372479- T-32 shell
defined PIA-0019- top
Rev.-03
9 T-32 Main Open HOV-T32C Opened as 372479- P- 1918- Inlet open to

inlet valve Indicated PIA-0019- A21A-12”- receive
status by Limit
Rev.-03 IE
switch
10 T-32 main Close HOV-T32D Closed as 372479- P- 1916- Main outlet
outlet valve Indicated PIA-0019- A21A-12”- valve is closed
status
by Limit Rev.-03 IE
switch
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Bitumen
Control
11 T-32 Close HOV-T32E Closed as 372479- P- 1917- Stripping outlet
stripping Indicated PIA-0019- A21A-4”-IE closed
valve status
by Limit Rev.-03
switch
12 P-31 Suction PI T31B User 372479- P- 1911-

Header defined PIA-0019- A21A-12”-
pressure User defined Rev.-03 IE
13 P-31 suction Closed HOV-31C / Closed as 372479- P- 1911- Other headers

header HOV-31B Indicated PIA-0020- A21A-12”- isolated
Isolation by limit Rev.-02 IE
switches
Suction P-31 Suction DPT P-31 zero DPT P-31 0 kg/cm2 372479- P-2005- P-31 is ready
strainer strainer diff. pressure PIA-0020- A21A-10”- to start
status Rev.-02 IE
14 Pump P-31 P-31 on auto SS-P31 / Pump 372479- P-31 P-31 is lined
status remote XL-P31 motor ready PIA-0020- up and ready
mode/local and to start to start
Rev.-02
energised signal
15 P-31 delivery Closed HOV P31A Closed as 372479- P- 2001-
recirculation Indicated by PIA-0020- A21A-04”-
valve status limit Rev.-02 IE No unexpected
switches recycle
16 Pump User defined HOV-P31B Open/close 372479- P- 2006- Open/close

discharge as Indicated PIA-0020- A21A-6”-IE condition as
valve status by Limit per user
Rev.-02
switches requirement
(manual
bypass open
or start at
closed delivery
and slow
opening)
At TLF area Hose pipe
(BAY-1) shall be
deployed to
connect P-31
line (supply
line) and
receiving P-
32 line with
ball valve
At TLF all LA Isolation Valves closed ----- Closed as 372479- P-2010- Valves shall be
other confirmed PIA-0020- A21A-3”-IE closed and
manual by Field Rev.-2 / P- 2017- Tagged to
valves on Staff A21A-3”-IE avoid cross
Connected contamination/
headers wrong tanker
shall be filling and
closed other hazards
Line up
towards P-
32 delivery
line.
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Bitumen
Control
Pig trap- Isolation BV-2014 closed ----- Closed as 372479- P-2017- Pig trap
isolation confirmed PIA-0020- A21A-6”-IE isolated
by Field Rev.-2
Staff
Del. line of
P-32
17 Delivery Closed HOV-P32A Closed as 372479- P-2002- No sudden

recirculation Indicated by PIA-0020- A21A-4”-IE splash or
valve closed Limit switch Rev.-2 hazards
18 Main del. Open HOV-P32B Opened as 372479- P-2013- P-32 in line

Valve status Indicated by PIA-0020- A21A-6”-IE
Limit switch Rev.-2
19 Pump P-32 P-32 on remote SS-P32 / Pump 372479- P-32 P-32 stopped
status mode and XL-P32 motor PIA-0020- and bypassed
stopped stopped Rev.-2 through
signal bypass line
20 P-32 BV-2023 ----- Opened as 372479- P-2014- P-32 bypassed
bypassing opened confirmed PIA-0020- A21A-4”-IE
by Field Rev.-2
Staff
21 Pig Trap- BV-2011 closed ----- Closed as 372479- P-1916- Pig trap
isolated confirmed PIA-0020- A21A-12”- isolated
by Field Rev.-2 IE
Staff
22 P-32 suction Closed HOV-32B / Closed as 372479- P-1916- Other headers

header 32C Indicated by PIA-0020- A21A-12”- isolated
isolation Limit switch Rev.-2 IE
23 T-32 isolation BV-1918 open ----- Closed as 372479- P-1916- T-32 in line
valve confirmed PIA-0019- A21A-12”-
by Field Rev.-3 IE
Staff
25 T-32 Close HOV-T32E Closed as 372479- P- 1917- Stripping valve
stripping Indicated PIA-0019- A21A-4”-IE is closed.
valve status Rev.-3
by Limit
switch

outlet valve Indicated PIA-0019- A21A-12”- valve is closed
status IE
by Limit Rev.-3
switch
27 T-32 Main Open HOV-T32C Opened as 372479- P- 1918- Inlet open

inlet valve Indicated PIA-0019- A21A-12”-
status by Limit IE
Rev.-3
switch
28 T-32 Close HOV-T32A Closed as 372479- T-32 shell Recir. valve is
Recirculation Indicated PIA-0019- closed.
valve status by limit
Rev.-3
switch
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Bitumen
Control
T-32
desirable
status
29 Tank Liquid User defined PI-T32A MMWC 372479- T-32 shell T-32 is at user
Static head PIA-0019- defined level
Rev.-03 and at
atmospheric
pressure
30 Tank level User defined LT-T32 User 372479- T-32 shell
Rev.-03
31 Tank level Not active LS-T32 Not active 372479- T-32 shell T-32 can
switch PIA-0019- top receive liquid
Rev.-03
● Important Note:
We can also utilise the common line P-2019-A21A-6”-IE which is interconnecting P-31 and
P-32 delivery header, if we want to avoid temporary hose connection at TLF area.
Following valves shall be manipulated:
– Open BV-2024 and BV-2025 (Pump house)
– Close BV-2101, BV-2104, BV-2105 and BV-2108 at TLF area
– Rest line up shall be similar to as mentioned above, P-32 shall be bypassed accordingly.
4.2.2.3 ITT by Transfer pump and Recirculation line representative line up for T-31 to T-32
/T-10
● Inter Tank Transfer –Intra Enclosure Through Pump Recycle Header Encl.-3 (372479-PFC-
0079-01- Rev.-P1)
Control
Desirable
conditions
for T-31
1 Tank Liquid User defined PI-T31A MMWC 372479- T-31 shell T-31 is filled
Static head PIA-0019- and at
Rev.-03 atmospheric
pressure
2 Tank level User defined LT-T31 User 372479- T-31 shell T-31 can be
defined PIA-0019- top pumped out
Rev.-03
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Control
3 T-31 Main Closed HOV-T31C Close 372479- P- 1913- Inlet closed
inlet valve indication PIA-0019- A21A-12”-
status by close IE
Rev.-03
limit switch
4 T-31 main Opened HOV-T31D Open 372479- P- 1911- Main outlet
outlet valve indication PIA-0019- A21A-12”- valve is open
status by close
Rev.-03 IE
limit switch
5 T-31 Open / close HOV-T31E Closed / 372479- P- 1912- Stripping outlet
stripping Opened as PIA-0019- A21A-4”-IE closed /
valve status indicated opened in case
Rev.-03
by Limit of transferring
Switch entire contents
by stripping
6 T-31 outlet BV-1914 fully ----- Opened as 372479- P- 1911- Tank line-up
valve open confirmed PIA-0019- A21A-12”- done till pump
by Field P-31 suction
Rev.-03 IE
Staff
T-31 to P-0214-A21A-
Common 12”-IE
dock line Utilisation
connection
7 T-31 Opened HOV-31C Opened as 372479- P- 1911- Header
connection Indicated PIA-0020- A21A-12”- connected as
with headers by Limit IE per
Rev.-02
switch requirements
pressure User defined IE
Rev.-03
9 P-31 suction Closed HOV-31B Closed as 372479- P- 1911- Other headers

header Indicated PIA-0020- A21A-12”- isolated
Isolation by Limit IE
Rev.-02
switch
10 Pump P-31 P-04 on auto SS-P31 / Pump 372479- P-31 P-31 stopped
status remote XL-P31 motor PIA-0020- and isolated by
mode/local and stopped Rev.-2 closing BV-
de-energised signal 2008
Further Connection
Line-up with P-32
suction header
11 P-32 suction Opened HOV-32C Opened as 372479- P- 1916- Header

header Indicated by PIA-0020- A21A-12”- connected as
connection Limit switch IE per
Rev.-02
requirements
pressure User defined Rev.-03 IE
13 P-32 suction Closed HOV-32B Closed as 372479- P- 1916- Other headers

header Indicated by PIA-0020- A21A-12”- isolated
Isolation Limit switch Rev.-02 IE
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Bitumen
Control
14 P-32 Suction DPT P-32 zero DPT P-32 0 kg/cm2 372479- P-2012- P-32 is ready
strainer diff. pressure PIA-0020- A21A-10”- to start
status Rev.-02 IE
15 Pump P-32 P-32 on auto SS-P32 / Pump 372479- P-32 P-32 is lined
status remote XL-P32 motor ready PIA-0020- up and ready
mode/local and to start to start
Rev.-02
energised signal
16 P-32 delivery Open HOV P32A Opened as 372479- P- 2002-
recirculation Indicated by PIA-0020- A21A-04”-
valve status Limit switch Rev.-02 IE T-31 liquid
contents can
be recycled to
T-32 via
recycle header
17 Pump Closed HOV-P-32B Closed as 372479- P- 2013- Isolated

discharge Indicated by PIA-0020- A21A-06”- towards TLF
valve status Limit switch IE side
Rev.-02
Further line
up
18 T-32 Open HOV-T32A Open as 372479- On T-32 T-32 can

recirculation confirmed PIA-0019- shell receive liquid
valve status by Field Rev.-03 through
Staff recirculation
valve
Desirable
condition
of T-32
19 Tank Liquid User defined PI-T32A MMWC 372479- T-32 shell T-32 is
Static head PIA-0019- filled/empty
Rev.-03 and at
atmospheric
pressure
20 Tank level User defined LT-T32 User 372479- T-32 shell User defined
Rev.-03
21 T-32 Main Close HOV-T32C Closed as 372479- P- 1918- Inlet closed

inlet valve Indicated by PIA-0019- A21A-12”-
status IE

outlet valve Indicated by PIA-0019- A21A-12”- valve is Closed
status IE
23 T-32 stripping Close HOV-T32C Closed as 372479- P- 1917- Stripping outlet

valve status Indicated by PIA-0019- A21A-4” closed
Limit switch
Rev.-03
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Control
24 Tank level Not active LS-T32 User 372479- T-32 shell T-32 can
defined PIA-0019- top receive liquid
Rev.-03
4.2.3 Other essential requirements during Line up for Liquid Transfer from One tank
to another tank
● Volumetric capacity assessment shall be done at both ends prior to lining up to avoid
overfilling and spillage of hot Bitumen at receiving end or starvation at suction line and
pump impellor damage.
● A full CHECKLIST depicting status / action taken condition of all linkages for all possible line
up route duly signed by responsible field staff.
● Tested and effective communication network among all personnel involved for the transfer of
liquid contents from one tank to another.
4.3.1.1 Significant impact on TLF operation leading to disruption in following cases:

● Power failure at Resistance type Heating System / Skin Trace Heating System

● Though Hot Oil flow control valve is motorised, but Hot Oil flow to T-31 / T-32 internal coils
can be regulated by manual bypass valve in case of driver power failure.
influenced.

372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen

operation.


maintain unbroken communication hub among Pumphouse / Bitumen Enclosure area,
field operators (busy in lining up) and maintenance wing as per the need.

4.6.2 When needed

4.7.1 In / Out breathing (during transfer)

clean.
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
4.7.2 Pressure interlock




● Utility operators shall monitor utility (Hot Oil Generator / Instrument air / Electrical heat
tracing system) system operations and coordinate with condition monitoring cell for
preventive maintenance without affecting daily operation schedule.
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
5 TLF
5.1 Operation and Control methodology
5.1.1 General
● Despatch of stored liquid Bitumen parcel via Road Tankers (Onshore disposal) at TLF area
arranged by importers or third-party agents.
● TLF area operation shall be a complete Manual operation at present.
5.1.2 Operation Mode:

● From Single Tank
– From a Single Tank to TLF -Encl.-1 372479-PFC-0080-01-Rev.-P1
● From Multiple tanks (Option-1 by P-31 only)
– From a Multiple tanks to TLF -Encl.-1 372479-PFC-0081-01-Rev.-P1
● From Multiple tanks (Option-2 by dedicated pumps P-31 and P-32)
– From a Multiple tanks to TLF -Encl.-1 372479-PFC-0082-01-Rev.-P1
5.2 Scope
● To supply stored liquid Bitumen contents of any storage tank (T-31 / T-32) by Transfer pump
to Tanker Loading Facility area to fill Road Tanker or ISO tanker as per the schedule for
inland despatch
5.3 TLF Operation

● General Precautions:
– Appropriate training shall be provided to all concerned personnel including drivers
regarding safe Bitumen handling procedure including use of PPE, locations of Fire
Extinguishers, ESD pushbuttons, safety showers and main stop valve.
– A proper loading checklist shall be formulated in which all relevant details shall be
entered before connecting / starting of Tanker Loading operation.
– Tanker loading will be always manned by TWO persons. One person shall be always
monitoring Bitumen level being transferred to Tanker. PPE shall be worn by them.
– Flexible hoses, couplings shall be checked and inspected for cleanliness before putting
into use. Hose shall be as short as practically possible as long hoses vibrate with increased
possibility of leakage. Metallic hoses are preferred as they meet high pressure and
temperature requirements.
– Empty tanker shall be inspected and ensured for total emptiness and not having any
material which may not be compatible with hot liquid Bitumen.
– It shall be ensured that no water or Bitumen Emulsion is inside to avoid violent explosion,
frothing over or boiling over phenomena.
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
– Loading of Road tanker shall be started with Low RPM of Transfer / Loading pump
initially for critical observation of hose for leakage and connection efficiency.
– Discharge extension hose end portion should be below filling manhole.
– Operator should keep a safe distance from hose, but operation shall not be unmanned.
– Before filling outlet valves of tanker shall be checked for closed condition and free
from any solidified Bitumen.
– Proper earthing is provided.
– At least 10% Ullage is left for safety purpose.
– After filling is over, hosepipe shall be removed after ensuring that valves are closed, and
pump is stopped.
– In-between two consecutive loading hosepipe shall be properly drained and put in secured
position so that no foreign matter or water enters into it and cause boil over during second
filling.
● Bitumen Road tanker shall be received at allotted BAY after following all necessary procedure
required for all inbound / outbound traffic as per AKPPL set guidelines.
● Liquid hot Bitumen stored in the tankages shall be sent to TLF (Tanker Loading facility) area
wherein specified Road tankers shall be filled by Loading arms (LA-A/B) located at Bay-01
and Bay-02
● Loading arm assembly (LA-A/B) shall have all the requisite components
– A Batch Controller (BC-2101A / 2101B and BC-2102A /2102B) to take care of safe and
clean filling into the carrier. (Future provision)
– A strainer to arrest contaminant particles. (Shall be considered for present setup and
shall have DPG for indicating operating condition)
– A Flow measuring device for specific filling operation.FI shall also provide cumulative filling
records to generate daily records and cross verify transfer. (Future provision)
– LSH-2101A / 2101B and LSH-2102A/2102B shall detect high level inside the tanker (which
shall be activated to generate High Level alarm only to stop the filling to avoid
overspill.)
– Earthing connection (ES-2101/2102) to detect continuity and to provide feedback to Batch
controller to stop filling by closing FCV-2101A / 2101B and FCV-2102A / 2102B if tanker is
not properly grounded by secured earthing connection.
● To avoid tanker filling Rotary Screw pump (Transfer pump) running idle under closed delivery
or reduced flow condition, a local PT has been provided on pump delivery line to stop the
Pump after a pre-set delay if the idle time between two consecutive fillings is extended.
● Supply / transfer pump shall also trip if:

– If connected tank level goes below LL other than stripping function.
– Zero flow is registered through Batch controller (when Batch controller is
commissioned)
– ESD is activated.
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
5.3.1 Despatch from Tank Farm Enclosure
5.3.1.1 Tanker Loading Area operations

● Empty Road Tankers shall be brought to the loading bays as per SOP and following Standard
Safety Norms,protocols and schedules as laid down by AKPPL.
5.3.1.2 Liquid Cargo Transfer from Single Tank

● Liquid cargo export shall be from source (Single tank) to destination -Road Tankers at TLF
area.
● Storage tank shall be lined up according to Total Liquid volume to be dispatched and available
volume ( no of road tankers) as allocated.
● Line up shll be arranged as per specified logic and having facility for online addition / deletion
of tanks in case of unforeseen anomalies.
● It shall be ensured that following logic functions shall be implemented when full automation is
considered:
– Liquid path from source tank up to TLF shall be lined up with header isolation valves in
desired open/close position as per checklist.
– Liquid Cargo transfer from source tank to TLF shall be commenced when all conditions
including ESD are satisfied as per checklist
– As soon as the Bitumen tank connected as per the line-up starts emptying and LI- crosses
desired set point, isolation BV of that tank shall be started closing manually as per
instructions relayed from Central Control room for Safe Operation.
– Close communication between field staff and Cental Control and Monitoring staff, along
with prior capacity margin calculation among tankages shall be required for efficient
operation and avoiding mechanical damage to transfer pumps.
– At no point of time main outlet BVs of multiple tanks shall happen to coincide on “Closed”
status.
● Tank selection shall be reversible and resettable. During liquid cargo transfer operation, if any
anomaly arises, transfer operation shall be suspended by ESD or by field activity feedback.
Secondary planned route for line up shall be chalked out and evaluated considering safety,
contamination factor and ease of line up also taking into account waiting period of vessel.
5.3.2 Other essential requirements during Line up for Liquid export from enclosure
to TLF
● A CHECKLIST for planned TLF operation depicting status / action taken condition of all
linkages for all possible line up route duly signed by responsible field staff.
● Tested and effective communication network involving all procedures for transfer including
ESD (Emergency Shut Down) method to be followed as per SOP checklist.
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
5.4.1.1 Significant impact on TLF operation leading to disruption in following cases:

● Power failure at Resistance type Heating System
● Though Hot Oil flow control valve is motorised, but Hot Oil flow to T-31 / T-32 internal coils
can be regulated by manual bypass valve in case of driver power failure.
influenced.


operation.


maintain unbroken communication hub among TLF / Bitumen Enclosure area, field
operators (busy in lining up) and maintenance wing as per the need.

372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
5.7.2 When needed

5.8.1 In / Out breathing (during transfer)

clean.
5.8.2 Pressure interlock




372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
● Utility operators shall monitor utility (Hot Oil Generator / Instrument air / Electrical heat tracing
system) system operations and coordinate with condition monitoring cell for preventive
maintenance without affecting daily operation schedule.
.
5.10 Operation Mode Despatch (Bitumen Transfer from Single Tank to TLF)
5.10.1 From a Single Tank to TLF (representative line-up for T-31 / T-32 to TLF)
● Representative flow chart 372479-PFC-0080-01-Rev.P1 for Export from Single tank to TLF
(Encl.-3)
Control
Panel
Desirable
conditions
for T-31
1 Tank User defined PI-T31A MMWC 372479-PIA- T-31 shell T-31 is filled
Liquid 0019-Rev.- and at
Static head 03 atmospheric
pressure
0019-Rev.- top pumped out
03
3 T-31 Main Closed HOV-T31C Close 372479-PIA- P- 1913- Inlet closed

inlet valve indication by 0019-Rev.- A21A-12”-IE
status close limit
03
switch
4 T-31 main Opened HOV-T31D Open 372479-PIA- P- 1911- Main outlet
outlet valve indication by 0019-Rev.- A21A-12”-IE valve is
status close limit open
03
switch
5 T-31 Open / close HOV-T31E Closed / 372479-PIA- P- 1912- Stripping
stripping Opened as 0019-Rev.- A21A-4”-IE outlet closed
valve indicated by / opened in
03
status Limit Switch case of
transferring
entire
contents by
stripping
6 T-31 outlet BV-1914 fully -- Opened as 372479-PIA- P- 1911- Tank line-up
valve open confirmed 0019-Rev.- A21A-12”-IE done till
by Field pump P-31
03
Staff suction
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Control
Panel
7 P-31 PI T31B User defined 372479-PIA- P- 1911-
Suction 0019-Rev.- A21A-12”-IE
Header User defined
03
pressure
8 P-31 Closed HOV-31B / Close 372479-PIA- P- 1911- Other
suction 31C indication by 0020-Rev.- A21A-12”-IE headers
header close limit isolated
02
Isolation switch
9 Pump P-31 P-31 on SS-P31 / Pump motor 372479-PIA- P-31 P-31 is lined
status remote auto XL-P31 ready to 0020-Rev.- up and
mode and start signal 02 ready to
energised start
10 Suction Zero DPT-P31 0 Kg/cm2 372479-PIA- P- 2005- P-31 is lined
strainer differential 0020-Rev.- A21A-10”-IE up and
status pressure for ready to
02
start-up start
11 Pump User defined HOV-P31B Close 372479-PIA- P- 2006- Open/close
discharge (open/ /open 0020-Rev.- A21A-06”-IE condition as
valve closed) per user
Indication 02
requirement
status
by Limit (manual
switch bypass open
or start at
closed
delivery and
slow
opening)
12 P-31 Closed HOVP31A Close 372479-PIA- P- 2001-
delivery indication by 0020-Rev.- A21A-04”-IE
recirculatio close limit No sudden
02 splash /
n valve switch
status hazards
13 Status of ES- Confirmed 372479-PIA- P-2101- Tanker

batch 2101/2102 by Field 0021-Rev.- A21A-3”-IE / earthing
controller relay on, Staff P-2010- done and
00
BC- H>LSH- A21A-3”-IE space
2101A/210 2101A/2102B available for
2A >L filling
14 Manual Road tanker
filling can be filled
done at now at Bay-
present 01/02 /
Encl.-3 TLF
area
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
5.10.2 From Multiple Tanks to TLF Option-1 (representative line-up for T-31 and T-32
to TLF)
● Representative flow chart 372479-PFC-0081-01-Rev.P1 for Export from Multiple Tanks to

TLF (Encl.-3)
Control
Panel
Desirable
conditions
for T-31
1 Tank User defined PI-T31A MMWC 372479-PIA- T-31 shell T-31 is filled
Liquid 0019-Rev.- and at
Static head 03 atmospheric
pressure
03

status close limit
03
switch
03
switch
03
transferring
entire
contents by
stripping
6 T-31 outlet BV-1914 fully -- Opened 372479-PIA- P- 1911- Tank line-up
valve open as 0019-Rev.- A21A-12”-IE done till
pump P-31
confirmed 03
suction
by Field
Staff
Header User defined
03
pressure
8 P-31 Closed HOV-31B Close 372479-PIA- P- 1911- Other
suction indication by 0020-Rev.- A21A-12”-IE headers
02
Isolation switch
Desirable
conditions
for T-32
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Control
Panel
9 Tank Atmospheric PI-T32A 0 MMWC 372479-PIA- T-32 shell T-32 is at
Pressure pressure 0019-Rev.- top atmospheric
03 pressure
03

status close limit
03
switch
03
switch
03
transferring
entire
contents by
stripping
14 T-32 outlet BV-1918 fully -- Opened 372479-PIA- P- 1916- Tank line-up
valve open / close /closed as 0019-Rev.- A21A-12”-IE done till
as per pump P-31
confirmed 03
requirement suction
by Field
Staff
Header User defined
03
pressure
16 P-32 Closed HOV-32B Close 372479-PIA- P- 1916- Other
suction indication by 0020-Rev.- A21A-12”-IE headers
02
Isolation switch
Connection Open HOV-32C Open 372479-PIA- P- 0214- Dock line
to common indication by 0020-Rev.- A21A-12”-IE connected
dock line close limit with P-32
02
switch suction
header.
Liquid from
T-32 can
flow via
HOV-32C to
P-31 suction
status remote auto XL-P32 stopped and 0020-Rev.- isolated
mode and de- idle 02
energised
18 Pump P-31 P-31 on SS-P31 / Pump motor 372479-PIA- P-31 P-31 is lined
status remote auto XL-P31 ready to 0020-Rev.- up and
mode and start signal 02 ready to
energised start
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
Control
Panel
19 Suction Zero DPT-P31 0 Kg/cm2 372479-PIA- P- 2005- P-31 is lined
strainer differential 0020-Rev.- A21A-10”-IE up and
status pressure for ready to
02
start-up start
20 Pump User defined HOV-P31A Closed 372479-PIA- P- 2006- Open/close
discharge (open/ /opened 0020-Rev.- A21A-06”-E condition as
valve closed) per user
as 02
requirement
status
Indicated (manual
by Limit bypass open
Switches or start at
closed
delivery and
slow
opening)
21 P-31 Closed HOVP31A Close 372479-PIA- P- 2001-
delivery indication by 0020-Rev.- A21A-04”-IE
recirculatio close limit No sudden
02 splash /
n valve switch
status hazards
22 Status of ES- Confirmed 372479-PIA- P-2101- Tanker

batch 2101/2102 by Field 0021-Rev.- A21A-3”-IE / earthing
controller relay on, Staff P-2010- done and
00
BC- H>LSH- A21A-3”-IE space
2101A/210 2101A/2102B available for
2A >L filling
23 Manual Road tanker
filling can be filled
done at now at Bay-
present 01/02 /
Encl.-3 TLF
area
5.10.3 From Multiple Tanks to TLF Option-2 (representative line-up for T-31 and T-32
to TLF)
In Option-2, Road Tankers can be filled simultaneously from T-31 and T-32 via dedicated
P-31 and P-32 as shown in representative flow chart 372479-PFC-0082-01 - Rev.P1
5.10.4 From a Single Tank to TLF area supplying to Bay-01 and Bay-02 simultaneously
● Likewise, in Option-3, Road Tankers can be filled simultaneously from T-31 (and its dedicated
P-31) via Interconnection header (P-2019-A21A-6”-IE) provided between P-31 and P-32
delivery lines as shown in representative flow chart 372479-PFC-0083-01 -Rev.P1
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
● In absence of Batch controller which works automatically, this method may turn out to
be perhaps the safest way for filling Road Tankers. As in this Option, if possible, more
Road tankers can be filled simultaneously at comparatively low distributed flow rate
(coupled with VFD of P-31/P-32), changing over at ease and in safe manner when
sufficient manpower (wearing PPE) is employed.
● However, there must be enough space available for movement of tankers and safe
method of loading having provision for immediate closing facility for loading valve and
tripping of pump. It shall be emphasised and drilled into the TLF staff that they are
dealing with very hot liquid which is solid at normal temperature.
5.11 Important considerations
● TLF being entirely manual operation enough field staff shall be provided to carry out line up
operation as per checklist without undue haste and double cross checking for required status
of valves and equipments.
● Where indicated and insisted, all necessary PPE shall be utilised by each and every personnel
including drivers to avoid burns due to unforeseen leakage or splashes of HOT BITUMEN.
● Fire Extinguishers and Safety Shower shall be located within easy reach.
● Safe distance shall be maintained while filling road tankers.
● A general tendency of Overfilling or Maximum Capacity Utilisation approach shall be avoided

all the time.
● Stipulated guidelines for safe filling as per SOP shall be stringently followed.
● Before starting filling operation, empty road tanker shall be verified and cross checked for
absence of WATER or any other hydrocarbons or even residual Bitumen from earlier
transportation duty to avoid hazardous situation. Immediate reporting and rejection shall
be followed if above mentioned contents are found even after tanker has reached into loading
bays.
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
6 List of attachments
● Bitumen Storage Tanks

– Bitumen Tank GA for T-31 / T-32
– Bitumen tank Heating coil layout
● Revised set of P&IDS

– 372479-PIA-0002-01-Rev-08
– 372479-PIA-0019-01-Rev.-05
– 372479-PIA-0020-01-Rev.-03
– 372479-PIA-0021-01-Rev.-01
● Representative PFCs
– 372479-PFC-0074-01-Rev.P1 - IMPORT
– 372479-PFC-0075-01-Rev.P1 - IMPORT
– 372479-PFC-0076-01-Rev.P1 - IMPORT
– 372479-PFC-0077-01-Rev.P1 - IMPORT
– 372479-PFC-0078-01-Rev.P1 - ITT
– 372479-PFC-0079-01-Rev.P1 - ITT
– 372479-PFC-0080-01-Rev.P1 - TLF
– 372479-PFC-0081-01-Rev.P1 - TLF
– 372479-PFC-0082-01-Rev.P1 - TLF
– 372479-PFC-0083-01-Rev.P1 – TLF
● Cause and Effect Matrix

– 372479-PZD-07-Rev.-B
● M/s THERMOTECH (Hot Oil System)

– Manual for TSH-800
– Cause and Effect Matrix
– PID-FO system
– PID-Heater-TSH-800
– PID-Legend
– Control Valve Specification
– Pump Curves
– MDS for expansion tank
– MDS for FO tank
● M/s Bartec (Conventional Elect. trace Heating System)

– Installation, Operation and Maintenance Manual
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
● M/s n-Vent (Elect. Skin Trace Heating System)

– STS Installation and Construction Manuals
– Installation, Operation and Maintenance Manual (STS)
● Bitumen Transfer Pump

– Twin Screw Pump Manual -TUSHACO
– Twin Screw Pump-Motor datasheet -Bharat Bijlee
– Twin screw Pump-Motor GA
372479-RSD-523 | xx | P1 | 25 November 2019

Bitumen
mottmac.com
372479-RSD-523 | xx | P1 | 25 November 2019
tn Tag No : T - 31 & T - 32 Size (Meter) : 20.0 ID x 18.0 Ht Ref. P&ID No. : 372479 - PIA - 0019 - 01 Notes
N26 N28
N23 M3 M4 N29 N10 N6 N13 N12 N9 N11 N30 N24 N25 6Thk. Internal Roof N16 N19 N20 Qty. Reqd. : 2 Nos. (Two) Plant : AKPPL Liquid Terminal Ref. MTDR No. : 26
Truss Support 1. `*' Indicates data to be furnish by the Contractor & `**' by Client.
Service Data
Type : Cylindrical, Vertical Fix Cone Roof Section : Enclosure - 3 Capacity (Normal/Gross) m³ 5000 / 5655
6 Thk
IH - 80 2. All Dimensions are in mm and Elevations are in Meters, unless otherwise specified.
Typ Stored Product / Nature Bitumen Viscosity at Storage Temp cP 250 - 550 3. All Bolt Holes in Nozzle Flanges and Man Holes to be straddle Centre lines of Tank and Nozzle.
Nozzle 4. All Flange Dimensions shall be as per ASME B16.5 Class 150# up to DN600. DN750 Dimensions
1 1 tn Operating Specific Gravity 1.0
12 12 shall be as per ASME B16.47 Class 150# Series `B'. All Manholes shall be as per API - 650.
Working Pressure mmWCg Atmospheric 5. All sharp corners should be rounded off.
17.66 Roof Inside 6. Wherever specified, the Tank Fabricator shall be provided Companion / Blind Flange with Gaskets,
Working Temperature (Min. / Max.) °C 125 / 160 Bolts & Nuts.
Stiffening
7. Nozzle up to DN50 & below shall be provided with 2 (Two) Stiffener Flats of size 50 (W) x 10 Thk
N4 17.45 N5 Ring Code (Design & Fabrication) API 650, 12th Edition, 2013
17.0 HH OD+6.0 mm Hole Wind Load m/Sec 50 & As per API-650
at 90° apart and Provide Reinforcing Pad above DN50.
16.85 H 16.8 8. Reinforcing Pads to have Tell Tale holes of 6 mm. These Pads shall be Air tested at 1 kg/cm²(g)
Min.
100
in Roof Plate Earth Quake Factors / Zone API 650, 12th Edition, 2013, Appendix-E, Zone - III with Liquid soap solution and there after filled with Hard Grease. Tell Tale holes should be Drilled
(Refer Note : 38) tn = Thickness of Nozzle Hazard Class (Area of Classification) Hazardous
& not be Gas Cut.
9. Nozzle Flange gasket face shall have Serrated surface finish of 125 to 250 AARH.
Roof to Nozzle without Design Specific Gravity 1.0 10. Corrosion Allowance on the internals shall be on the thickness.
RF Pad Weld Joint 11. Material test certificates shall be provided prior to fabrication.
Design Temperature (Min. / Max.) °C 175
12. Grounding lug shall not be painted.
6Thk.
6000
tn 1-No. 1
4"
Design Pressure ( Int. / Ext.) mmWCg 350 / 20 13. All nozzle fabricated from plate shall be 100% Radiograph.
14. Nozzle projection shall be measured from Outer surface of Shell / Roof to Flange contact face.
NPT Hole Test Pressure (Hydrotest) Kg/cm²g Full of Water (Refer Note : 28)
Projection shall be as per Table.
6 Thk
Typ RF Flash Point / Pour Point °C ----- 15. All F.P. Weld to be chipped back to sound metal on the second side & re-welded. Where other side
tn Pad is not approachable F.P. Weld may be achieved from one side using TIG Weld.
Design Data
Nozzle Radiography As per Code
16. Three Plates joints on bottom shall not be closer than 300 mm from Each Other as per API - 650.
Weld Joint Efficiency 1.0 17. All Erection Lugs and Cleats to be removed before Hydro Test.
18. Curb Angle joints shall Stagger with Shell joints at least by 300 mm. (If Any)
Corrosion / Erosion Allowance mm Shell 1 / Bottom & annular - 2 / Roof - 1
Roof Inside 19. Structure to be Staggered welded to Roof.
Post Weld Heat Treatment As per Code 20. Vendor's scope include all component shown in this data sheet and as per applicable
6 Thk
Surface Finish (Internal) As per Tender / SOQ Standards / Spec / MR.
21. Tank Accessories such as Spiral stairway, Platform, Handrail, Rim Vents, Foam / Water piping etc.
OD+3mm Hole Internals ------ shall be supplied by Tank Fabricator.
in RF Pad External Accessories Hand Rail, Spiral Stairway, Partial Roof Platform for Nozzle Access 22. Inspection & Testing shall be as per Code / Specifications in Accordance with Approved Inspection
Plan.
OD+6mm Hole Insulation Scope : By Others Cleat Scope : By Fabricator 23. Fabricator have to provide welding sequence for Shell / Roof & Bottom.
Details of Insulation Yes 24. All Staircase and Inter-Connecting Platform shall be furnish after finalization of Equipment Layout.
in Roof Plate Type of Insulation : Hot Insulation Thk : As per Drawing
25. R.F. Pads, internals, cleats etc. shall preferably be away from main seams, in case, it is unavoidable
tn = Thickness of Nozzle Empty Wt : * ~ Refer Table Operating Wt : * ~ Refer Table the main seam portion coming under the attachment plus 150 mm length on both sides shall be
Details of Vessel Weights Tonns.
ground flush, fully radiographed & D.P. examined before welding of any such attachment.
8Thk.
Roof to Nozzle with

2000
2000
Typ.
Hydro test Wt : * ~ Refer Table Max. Erection Wt : * ~

26. The Water shall have Chloride content maximum 250ppm for tanks hydro testing.
RF Pad Weld Joint Shell Plate : IS 2062 Gr. B Roof Plate : IS 2062 Gr. B Annular, Bottom Plate : IS 2062 Gr. B 27. After completion of all testing & inspection, the inside of tank shall be thoroughly drained & dried out
60° Nozzle Pipes : SA106 Gr. B up to 350 DN, more than 350 DN : IS 2062 Gr. B Man Hole Shell / Flange : IS 2062 Gr. B & it must be free from foreign objects like electrodes, slag, tools, oil & grease.
Typ.
2/3t
Typ. 28. Tank shall be filled with water to the top Shell & Design Internal air pressure shall be applied to the
Thk
Thk
Nozzle Flanges : SA105 Internal Flange : SA105 Pipe Fittings (Ext. / Int.) : SA 234 Gr. WPB Enclosed space above the water level & checked with Liquid soap solution for leakages.
Materials
2 Typ. Nozzle & Man Hole Gasket : Non Asbestos Fibre Internal Pipes : SA 106 Gr. B CurbAngle/RoofSupport/Structural:IS2062GrA 29. Service gasket shall not be used for Testing. Hydrotest Gasket shall be similar as Service Gasket.
30. The Tank Dimension " Linear & Geometrical " tolerance as referred in the code API-650 shall be
Internal Gasket : Non Asbestos Fibre Internals : IS 2062 Gr. B Nozzle Fastener : SA 193 Gr.B7 / SA 194 Gr.2H considered half in the construction.
Foundation Bolt : SA 193 Gr. B7 Structure Fastener : IS1367 / IS1363 Cl4.6 & 4 Internal Fastener : SA 193 Gr.B7 / SA 194 Gr.2H 31. Vent Nozzles shall be kept open during water filling for Hydrotest & During Drainage to avoid tank
For Insulation Ring Detail

Damage.
10Thk.
Refer Separate Sketch

2500
2500
Typ.
Reinforcing Pads : IS 2062 Gr. B Name Plate : SS 304 Handrail, Light Support & Bracing : IS 2062 Gr. A 32.
Inside
All Shell Plate of 1Mtr. to 2Mtr. Length should weld with adjacent shell plate before rolling.
1 Typ.
70°
Typ.
18000 Inside Ht.
1/3t
33. All Fittings thickness shall not be less than joining pipe thickness.
Scope of work
Tank Erection / Installation : by Fabricator Companion/Blind Flanges : by Fabricator
Typ.
IH - 80
34. Fitting to fitting joints be avoided.
Tank Testing / Calibration : by Fabricator (As per Approved QAP) Tank Valves Erection/Installation : by Others 35. All "T" joints to be 100% Radiographed.
20/16/14 Thk. Vertical Weld Joint Detail Witness Test : by Client / Consultant (As per Tender/Specification) Tank Instrument Erection/Installation : by Others 36. Shell Nozzle be flushed from inside unless specified.
37. The Secondary Steel Structure like Gratings, Hand Rails etc. shall be hot dip galvanized.
Pipe Fittings/Fasteners/Gasket : by Fabricator Internal/External accessories : by Fabricator 38. Liquid Level Shown Considering upto 1.2 Specific Gravity.
Welding Procedure : As per ASME SEC. IX
Welding Electrodes : As per ASME SEC.II, Part - C
tn
tn External Surface Finish : As per Tender / SOQ
Others
12Thk.
2500
Painting (Internal & External): As per Tender / SOQ. for CBFS, Tank Internal painting shall be done on bottom plate as well as
up to 2 m shell height from bottom plate as per Adani painting specification.
tn+2 Loading Data for Civil Design
Accessories by Fabricator : Spiral Stairway, Hand Rail at Top, Knee & Toe Plate, Top & Mid Landing Platform. Description Remarks
Empty Wt. in MT 235
tn = Thickness of Nozzle
Hold
Flange to Nozzle Neck Weld Joint Hydrotest Wt. in MT 5890 Empty Wt. + Full of Water Wt. of 1.0 Sp. Gravity upto Curb Angle Ht. i.e.18Mtr.
Hydrotest Wt. in MT 6645 Empty Wt. + Operating Liquid Wt. of 1.2 Sp. Gravity upto 17Mtr. Design Liquid Level (HLL)
Shell Appurtenances
14Thk.
2500
6 Reference drawings
20000 I.D. of Shell
DN Thk. / Flanges Nozzle
Nozzle Service Qty. Remarks
mm Sch. Standard Type Class Reinf. Proj.
1) 372479 - FFA - 5001 - 02 Plate Layout
Roof Inside N1 Inlet / Outlet Conn. 300 01 Sch.XS ANSI B16.5 SORF 150# As per API-650 300
2) 372479 - FFA - 5001 - 04 Nozzle Details
30 N2 Inlet / Outlet (Sump) 300 01 Sch.XS ANSI B16.5 SORF 150# As per API-650 300
3) 372479 - FFA - 5001 - 05 Spiral Stairway Details
N3 Inlet / Outlet (Sump) 100 01 Sch.80 ANSI B16.5 SORF 150# As per API-650 250
30 4) 372479 - FFA - 5001 - 07 Heating coil Details
N4/N5 Spare Conn. 150 02 Sch.80 ANSI B16.5 SORF 150# As per API-650 275 Inside Pipe,Deflector,B/F
Grounding Lug
N7 Drain from Sump 100 01 Sch.80 ANSI B16.5 SORF 150# As per API-650 250
N8 Recirculation Conn 100 01 Sch.80 ANSI B16.5 SORF 150# As per API-650 250
Joints in Roof Plate
4 Nos.
N14A/B Coil In 50 02 Sch.80 ANSI B16.5 SORF 150# As per API-650 225 Inside Pipe 150mm
1.5 N15A/B Coil Out 50 02 Sch.80 ANSI B16.5 SORF 150# As per API-650 225 Inside Pipe 150mm
N21
16Thk.
(Refer Note : 38)

2500
N18 1.2 Annular Plate N18 TRV Conn. 25 01 Sch.160 ANSI B16.5 SORF 150# As per API-650 225
1.150
10t
M1 M2 Name Plt N8 N21 TG Conn.@45° 50 01 Sch.80 ANSI B16.5 SORF 150# As per API-650 225
0.9 L 0.8 LL N2 0.535 LAP 50 N22 PT / PI Conn. 50 01 Sch.80 ANSI B16.5 SORF 150# As per API-650 225
N1
D
Nozzle Schedule
0.50 N22 8 M1 / M2 Shell Man Hole 750 02 8 Thk Details As per API-650 200 Cover,Handle,Davit
N3 0.25
0.400 N14A/B N7
1 0.00
0.15 N15A/B Roof Appurtenances
8 Thk. 10t x 2500
IH - 150 Bottom Plate N6 Spare Conn. 150 01 Sch.40 ANSI B16.5 SORF 150# As per API-650 200 with Blind Flange
400
Bottom Plt 10t Annular Plate
8t
1 1
D
73 73 N9 Spare Conn. 40 01 Sch.40 ANSI B16.5 SORF 150# As per API-650 200 with Blind Flange
10t 1220 Sump OD Elevation N10 Spare Conn. 100 01 Sch.40 ANSI B16.5 SORF 150# As per API-650 200 with Blind Flange
Annular Plate to Bottom N11 Cleaning Conn. 200 01 Sch.40 ANSI B16.5 SORF 150# As per API-650 200 with Blind Flange
1235 Base OD
Plate Weld Joint N12 Spare Conn. 150 01 Sch.40 ANSI B16.5 SORF 150# As per API-650 200 with Blind Flange
T N13 Spare Conn. 80 01 Sch.40 ANSI B16.5 SORF 150# As per API-650 200 with Blind Flange
T T Lap 30 Min. for Roof 6 500
10t
20 10 N16 LS Conn. 50 01 Sch.40 ANSI B16.5 SORF 150# As per API-650 200
4 6 Thk Lap 50 Min. for Bot. 30 6t Roof
N19 Spare Conn. 50 01 Sch.40 ANSI B16.5 SORF 150# As per API-650 200 with Blind Flange
Inside Shell
4 Typ 220 Plate

Ø14 Hole Typ Hammer to N20 TE / TI Conn. 50 01 Sch.40 ANSI B16.5 SORF 150# As per API-650 200
t 24 Nos.
t
tn Annular Pl. Annular Pl.
Typ Press 20t N23 Dip Gauge Hatch 150 01 Sch.40 Details As per API-650 Slotted Dip Well
6 Thk. ~726
1 Comp. N24/N25 Spare Conn. 350 02 Sch.40 ANSI B16.5 SORF 150# As per API-650 200 with Blind Flange
Inside Shell
1-No. 4"
45°
tn 50 Gusset
=
NPT Hole 6 Ring M3 Radar 600 01 6 Thk Details As per API-650 200 with Cover
6t
Plate 6
65
M4 Roof Man Hole 600 01 6 Thk Details As per API-650 200 Cover & Handle
Refer Drawing No. : 372479 - CMA - 0002 - 01
t
t
Typ Backing Strip View `V1-V1' 6 t Pad N26 Spare Conn. 25 01 Sch.160 ANSI B16.5 SORF 150# As per API-650 200 with Blind Flange
=
6 Thk
For Details of Internal Truss Roof Structure
tn
OD+3.0 mm
Annular Plate Joint Detail 200Wx300DL ☼ N28 Future LS 50 01 Sch.40 ANSI B16.5 SORF 150# As per API-650 200 with Blind Flange
6 Thk
°
Round & Grind

10
N29 Future Radar 600 01 6 Thk Details As per API-650 200 with Cover
45°
25
45°
R6 La N30 Vent Conn. 250 01 Sch.40 ANSI B16.5 SORF 150# As per API-650 200
Shell to Nozzle without 2 Typ
45°
Bottom Plate p
.
Typ
Typ
75+Insu.Thk. RF Pad Weld Joint
8t
LAP 50 V1 ☼
OD+3.0 mm Hole
Inside Nozzle 8
Typ
Grounding Lug
3
in RF Pad
10°
(Not to be Painted) Round & Grind

p 6 Thk
La 230
Shell to Nozzle with Bottom Plate ☼ 5 101 104 15 5
8t
RF Pad Weld Joint V1 8 Thk

Bottom Plate to Bottom
8
Plate Weld Joint Plate Overlapping Detail
☼ = Backchip to Fab & Erected By
Tack Weld 75 ±5° Sound Metal ☼ Designed By Mott Mac Donald (India) Pvt.Ltd. ForConstruction
20t
16tx320x350 100
2
R25
8
Manufactured for Adani Kattuppalli Port Pvt Ltd

6 (50-100) T T & Reweld 10 Thk
Outside Pad Plate Inspected By ------ HOWE ENGINEERING PROJECTS (INDIA) PVT.LTD
6
120
Typ Shell Inside

30
tn
Code API 650, 12th Edition, 2013

Ø45
250
150
175
tn DRAWING / DOCUMENT REVIEW

Inside Shell
6Ø Item No. Fixed Cone Roof Tank

Hole 70 Detail of 2 ±1 FPW 2 ☼ 12 Thk
1-No. 41"
8
Stiffening
126
136
@3M
Typ.
8 tn = Thickness of Nozzle NPT Hole Tank no. as per Table Product Stored Bitumen 1. APPROVED 3. NOT APPROVED / REJECTED
45°
Name
3
Ring Work can proceed Work cannot proceed
Typ
45° Diameter (mm)
Plate Washer to be
.
6
20000 I.D Year built **
20t
Typical Pipe to Flange & Pipe to Typ Plate 20270 PCD 100 Typ
Bottom Plate 15° 2 Typ.
.
Welded at site After Tank height 18000 Ht. (mm) Manf serial no. **
Pipe Fittings Weld Joint tn
156
136
the Installation ☼ Max fill height 17000 Ht. (mm) 350 / 20 (mmWC)
2. APPROVED WITH COMMENTS 4. FOR INFORMATION ONLY
15°
Design Pre. / vacuum

50 1/3t Typ. Work can proceed subject to Information noted
15°
60° (minimum) 20000 ID Completed. 2/3t Typ. Working volume 5000 (M³ ) Water test Ht. / Int. Pre. 18 / 350 (mtr/mmWC) incorporation of comments
Ø50
2
Thk
Thk
Maximum density 1000 (Kg/M³ ) Max filling rate 120

Shell Typ 14 Thk (M³/hr)
300
20t
OD+13 mm Hole
50
OD+3.0 mm Hole
25
Plate Design metal temp. 175 (C °) Max suction rate 120 (M³/hr)
230 10
Typ
in Shell Plate
35
Inside Nozzle ☼ 16 Thk Specific Gravity 1.0

in RF Pad
10
8
250 This review and approval does not relieve supplier / sub contractor from full compliance with purchase
10 order / contract requirements and also from errors in this drawing / document.
Tank
6Ø Vent Hole
e
Annular Shell to Nozzle with 20132 OD 10 Annular 2 61 30 74 30 31 2

Insid
Back chip RF Pad Weld Joint

Plate 3 Detail of Anchor Chair for Welding Details Plate
2
Backing Strip By: Date:

& Weld for Internal Pipes Detail of Name Plate Bracket Of --------------------- ---------------------
M42 Anchor Bolt (32-Nos)
3D View of Annular Plate Joint Detail 12/10/8/6Thk. Vertical Weld Joint Detail Horizontal Shell Joint Detail of Name Plate MOC : SS304 Project:
-----------------------
Discipline:
-----------------------
Rev Description By Signed Date Consultant Project Management Consultant Client Drawn Check Drawing Title
- - - - -
- - - - -
501
Sakar II
Near Ellisbridge
DPD NG AKPPL Encl-3 DE, Kattupalli
Ahmedabad,380006
- - - - - Designed Verified
- - - - -
India
T +91(0) 79 2657 5550
5000 KL (T-31 & T-32)
F +91(0) 79 2657 5558 NAG KM
-
- - - - - ©Mott MacDonald Limited
W www.mottmac.com
COPYRIGHT
The concepts, diagrams and information IE / PROOF CONSULTANT
General Arrangement CS Storage Tank 20M Dia x 18M Ht.
- - - - - This document is issued for the party which commissioned contained in this document are the sole
it and for specific purposes connected with the captioned property and copyright of AKPPL. Any use,
1 Heating Coil Inlet Elevation Changed as per Heating Coil Drawing. Issued for Construction. DPD NAG 31.05.19 project only. It should not be relied upon by any other party
or used for any other purpose.We accept no responsibility copying, reproduction or disclosure of the
0 Issued for Construction. DPD NAG 08.04.19 Client Drawing No. Consultant/Contractor Drawing No. Rev
for the consequences of this document being relied upon document, whether directly or indirectly, or in
A Issued for Approval. DPD NAG 05.04.19 by any other party, or being used for any other purpose, or whole or in part without the prior written
Last Modified :- Nov 26, 2019 - 11:26am SCALE : N. T. S.
containing any error or omission which is due to an error
or omission in data supplied to us by other parties.
permission of AKPPL is prohibited. - 372479 - FFA - 5011 - 01 1
13° Tag. No. : T - 31 & T - 32 Qty. (No.) : 2 Nos. Plant : AKPPL Liquid Terminal
Item Description : Storage Tank Size (Meter) : 20 ID x 18 Ht. Section : Enclosure - 3
N15A N3 N2 N15B N14B Orientation : Cylindrical, Vertical, Ref. PDS No. : ---- Ref. P&ID No. : 372479 - PIA - 0019 - 01
N14A
N7
850
7 29
1863
R
525
9
R
850
°
1430
106
1475 2779 5 8
3557 1343
Heating Coil Data
470
1008
409 R
12
3000 2
4°
Surface Area 53 M
88
1866 Pipe Size 50 DN Sch. 80
R R Pipe MOC SA 106 Gr. B
Pipe Length ~279 Mtr. Aprx.
3000
3000
4477
Bill of Material for One Tank
00 Sr. Description Size MOC Qnty. Wt.(Kg)
ipe R5
7443
1 Pipe (Seamless) 50DN Sch.80 x ~279Mtr. SA 106 Gr. B Lot 2087
Coil P
50 DN 2 Pipe Supoort Angle ISA 50x50x6 x ~40Mtr. IS 2062 Gr. A Lot 180
P
5838 3 U Clamp+Hex.Nut M8 x ~265 Lg. CS 104 12
ipe
3000
4 Base Plate 6Thk. x 100 Sq. IS 2062 Gr. BR 118 55
3000
1000
Pitch
Total Weight = 2334 Kgs.
6554 Notes :-
500
1200 1. All dimensions are in `mm' unless otherwise specified.
500
6779 = 2. Ù' Bend to be made from pipe. bend shall be free of cracks & buckles, flattening of a bend,
as measured by the diffrence between the max. & min. dia. at any cross section shall not exceed
=
81
° Typ. 8% of the nominal outside diameter.
81
Typ. ° = 3. Heating coil pipe to be butt welded as per available length.
= Typ. 4. If necessary suitable modification in heating coil layout shall be carried out to avoid fouling
Typ. with internals.
500
6554 5. Heating coil shall not have any flange or screwed connection inside the tank.
6. Coil support not to be welded to tank bottom.
2500
Pipe 7. 25% Number of weld joints of heating coil to be radiographed & also all butt weld shall be DP Tested.
Support 7404
2500
8. Heating coil shall be Hydro / Pneumatic tested at pressure of 15.6 kg/cm2. Design Pressure is 12kg/cm2.
9. After hydro test of tank the height of all supports shall be re-adjusted to take care of uneven
settlement of tank bottom by using packing plate, tack welded to support base plate or
6688 by re-adjusting the support height.
10. For Actual location of Heating Coil Inlets, Outlets and Drain Sump location,
6569
refer respective Tank Nozzle Orientation drawing & accordingly change Coil Layout.
0
2500
50 p
Ga
2500
Ø
5327 20
500 ID 000
RR
1500
100Sq.
2716
1500
Blind Plate on Heating Coil

Size & Orientation to Suit
to be Adjust
Height/Slop
3277 500
2 ∠50x50x6 4 ∠50x50x6
50
1 DN50 Pipe Base U Clamp

Plt. 3
6Thk.
Do not weld
Suit
To
with Tank Bottom 100Sq. Tack Weld

Pipe Supports with Plan R - Support Detail with Tank Btm
Suitable Clamp to suit site (7 Nos.)
(104 Nos.) 20000 ID
N7
0.250 Blind Plate
N14A 0.400 on Heating Coil
N14B 0.150 0.275
N15A
N15B
Elevation ISSUED FOR CONSTRUCTION
501
Sakar II
Near Ellisbridge
AKPPL Encl-3 DE, Kattupalli
Ahmedabad,380006
India
T +91(0) 79 2657 5550
F +91(0) 79 2657 5558
©Mott MacDonald Limited

W www.mottmac.com
Heating Coil Layout & Details for 5000 KL
This document is issued for the party which commissioned
it and for specific purposes connected with the captioned
project only. It should not be relied upon by any other party Benchmarking Infrastructure CS Storage Tank (T-31 & T-32)
or used for any other purpose.We accept no responsibility
for the consequences of this document being relied upon
by any other party, or being used for any other purpose, or
- 372479 - FDC - 5012 - 01
Notes
1. For abbreviation & Symbols. Refer drawing no. 372479-PIA-0001-01.
2. All drain valve shall be normally closed.
3. 4" CS line connect all piggable lines to collect piggable material.
4. Barred tee shall be provided. see detail 'A'.
SHIP 5. Reduced bore type.
6. Hose will be used for line connection at Encl manifold -1.
7. Insulated flange has been considered for all dock lines.
8. 2 Nos of 12" x 8" with flange spool piece reducer to be provided for connection to jetty.
9. All flange joints shall be provided with earthing jumpers to avoid static electric charge accumulation.
10. Full bore valve shall be used for all piggable lines.
Berth-2 (Existing) 11. BOQ shall not be considered for future provision connection.
12. All the vertical venting of pipe shall be extended to downwards using goose neck.
LP 13. PSV's pressure setting shall be adjustable as per cargo requirement.
14. PSV end connection shall be flanged end type.
15. Gas detector / UV detector are provided in tank farm area, pump house area and jetty area.
16. Actual number of gas detectors and their location are depicted in fire
Note 8 Note 8 and gas layout drawing.
12"x10"
12"x10"
10"x8"
10"x8"
10"x8"
10"x8"
17. For surge purpose block valve has been shown.
18. 3D & 1.5D type bends has been provided for Cup-pigable and foam-pigable Pipeline.
HOV HOV HOV HOV HOV HOV 19. Presently HOVs are considered as manually operated valve with same tag number & with future
0201 PG 0202
PG
0203 PG 0204 PG 0223 PG 0224 PG provision of Limit switches.
0201 0202 0203 0204 0229 0231
1" 1/2" 1/2" 1/2" 1/2" 1/2"
GV-0232
GV-0236
GV-0235
GV-0239
GV-0278
GV-0285
GV-0215 GV-0210 GV-0226 GV-0220 GV-0277 GV-0284
1/2"
1/2"
1/2"
1/2"
1/2"
1"
V
3/4"
D D D D D D
PG PG PG PG PG PG
0205 0206 0207 0208 0228 0230 SP=HOLD
GD
1" 1/2" 1/2" 1/2" 1/2" 1/2" PANEL
.
P-0220-A21A-10"-IH
3/4"
GV-0229
GV-0233
GV-0234
GV-0237
GV-0276
GV-0283
GV-0211 GV-0214 GV-0225 GV-0221 GV-0275 GV-0282 NOTE-15,16 D
Type - 1 Type - 2
1/2"
1/2"
1/2"
1/2"
1/2"
1"
Barred Tee For Cup Pig Barred Tee for Foam Pig
D D D D D D
2"
PT
1/2"
PT
1/2"
PT
1/2"
PT
1/2"
PT
1/2"
PT
Detail 'A' Detail 'A'
0201 0202 0203 0204 0209 0210
GV-0223 GV-0218 GV-0213 GV-0219 GV-0274 GV-0281
TG HH=13.2 kg/cm2g TG TG HH=13.2 kg/cm2g TG HH=13.2 kg/cm2g TG HH=13.2 kg/cm2g TG HH=13.2 kg/cm2g
0201 PI H=12.1 kg/cm2g 0202 PI 0203 PI H=12.1 kg/cm2g 0204 PI H=12.1 kg/cm2g 0205 PI H=12.1 kg/cm2g 0206 PI H=12.1 kg/cm2g
0201 L=2.5 kg/cm2g 0202 0203 L=2.5 kg/cm2g 0204 L=2.5 kg/cm2g 0209 L=2.5 kg/cm2g 0210 L=2.5 kg/cm2g
IH-065
LL=1.0 kg/cm2g IH-065 LL=1.0 kg/cm2g LL=1.0 kg/cm2g LL=1.0 kg/cm2g LL=1.0 kg/cm2g
IH-90
HH=13.2 kg/cm2g
H=12.1 kg/cm2g
IH-65
IH-65
L=2.5 kg/cm2g
LL=1.0 kg/cm2g Set Set
P-0203-A21A-12"-IH
P-0204-A21A-12"-IH
P-0201-A21A-10"-IE
@ 14.5 kg/cm² g @ 14.5 kg/cm² g

P-0202-A21A-10"
P-0219-A21A-10"-IH
PSV PSV
0205 0206
P-0229-A21A-8"
P-0231-A21A-8"
LO LO
P-0230-A21A-6"
P-0232-A21A-6"
GV-0296 GV-0298
8"x4"
8"x4"
V V HH=14.5 kg/cm2g
H=13.2 kg/cm2g PI TI
HH=80°C
H=75°C
Future Provision
GV-0295
GV-0297
GV-0273
GV-0280
PG L=2.5 kg/cm2g 0208 0204 L=20°C PG Note 11
3/4"
3/4"
LO
LO
0224 LL=1.0 kg/cm2g LL=15°C 0226
10" PLR-0214 2" 10" PLR-0215 2"
PG
PG
0227 GV-02104 GV-02105
BV-0272
BV-0278
BV-0271 BV-0277 0225 TT
GV-0272
GV-0279
GV-0263
GV-0264
GV-0265
GV-0266
PT
BV-0264
PGS 0204 PGS
3/4"
3/4"
4"
4"
1/2"
1/2"
1/2"
1/2"
0208
BV-0269
BV-0275
2"
BV-0259
0210 0211
4"
4"
2"
GV-0270
GV-0271
GV-0268
PGS PGS
GV-0267
BV-0270
BV-0276
N2-2"
1/2"
1/2"
1/2"
HOV D D TE HOV
1/2"
GV-0269
D N2-2" 0216 0212 D
6"x4"
6"x4"
10"
10"
0221 0204 0222
1/2"
N5-2" N4-2" N6-3" N3-1/2" Note 17 N4-2" N6-3" N3-1/2"
Note 17 Note 4
D P-0218-A21A-16"-IH IH-65 D 16"
PLR-0212 Note 18 N1-16" PLR-0213
N1-16"
N7-4" N9-2" N9-2" N7-4"
BV-0283 BV-0267
BV-0260
BV-0261
BV-0265
Note 5 HOV
BV-0266
Set Set 0219
4"
2"
2"
@ 13.2 kg/cm² g @ 13.2 kg/cm² g Stub for
Foam Pigging
PSV PSV
0203 0204
HOV
P-0227-A21A-10"
Note 5 0220
IH-50
P-0225-A21A-10"
6"x8" 6"x8" P-0217-A21A-4"-IH

LO LO
P-0228-A21A-8"
BV-0258 IH-65 P
GV-0292 GV-0294 P-0342-A21A-16"-IH
372479-PIE-0003-01
P-0226-A21A-8"
10"x4"
10"x4"
From Enclosure Manifold 1
V V HH=13.2 kg/cm2g HH=80°C
H=12.1 kg/cm2g PI TI H=75°C
GV-0291
GV-0293
GV-0255
GV-0206
PG L=2.5 kg/cm2g 0205 0201 L=20°C PG
3/4"
3/4"
LO
0209 LL=1.0 kg/cm2g LL=15°C 0219

12" PLR-0209 2" 12" PLR-0210 2"
PG PG
PG
0210 GV-02102 GV-02103 0218
BV-0237
BV-0230
BV-0226 BV-0202 0215 TT

GV-0209
GV-0201
GV-0202
GV-0203
GV-0224
GV-0230
4"x6"
4"x6"
PT
BV-0222
PGS 0201 PGS
3/4"
3/4"
4"
4"
1/2"
1/2"
1/2"
1/2"
0205
2"
BV-0201
0201 0207
10"x4" 10"x4"
2"
GV-0204
GV-0205
GV-0259
GV-0247
GV-0256
GV-0245
PGS 4" PGS
BV-0240
BV-0229
4" N2-2"
1/2"
1/2"
1/2"
1/2"
1/2"
HOV D D TE HOV
1/2"
GV-0250
D N2-2" 0213 0204 D
12"
12"
0205 0201 0208
1/2"
N5-2" N4-2" N6-3" N3-1/2" BV-0242 BV-0228 Note 17 N5-2" N4-2" N6-3" N3-1/2"
Note 17 Note 4 Note 4
D P-0205-A21A-24"-IH IH-080 24"
PLR-0201 N1-24"
Note 18 D D N1-24" PLR-0204
N7-4" N9-2" N9-2" N7-6"
BV-0279 BV-0249
BV-0204
BV-0203
BV-0233
BV-0244
Note 5 HOV Note 5 HOV
0211 0209
4"
2"
2"
6"
Stub for Stub for
Foam Pigging Foam Pigging
Set
@ 13.2 kg/cm² g HOV HOV
Note 5 0212 Note 5 0210
PSV IH-50
0202
P-0210-A21A-6"-IH
BV-0211
6"x8"
P-0223-A21A-8"
LO P-0208-A21A-12"-IH IH-65 P
P-0224-A21A-8"
372479-PIE-0003-01
GV-0290 P-0211-A21A-6"-IH To Enclosure Manifold 1
8"x4"
BV-0212
V P-0209-A21A-12"-IH IH-65 P
372479-PIE-0003-01
NOTES:-
HH=13.2 kg/cm2g HH=80°C
GV-0289
GV-0261
H=12.1 kg/cm2g PI TI H=75°C To Enclosure Manifold 1 ------------------------

3/4"
LO
PG L=2.5 kg/cm2g 0206 0202 L=20°C PG

0211 10" PLR-0208 2" LL=1.0 kg/cm2g LL=15°C 0221
PG GV-02101
PG ------------------------
BV-0239
BV-0225 PG
GV-0207
0212 0220
0216 TT
3/4"
4"
GV-0216
GV-0238
GV-0222
GV-0227
PT
BV-0221
PGS 0202 PGS
------------------------
BV-0241
1/2"
1/2"
1/2"
1/2"
0206
2"
BV-0216
BV-0243
0202 0208
4"
GV-0251
10"
2"
GV-0249
GV-0254
GV-0244
GV-0258
PGS D PGS
GV-0242
1/2"
N2-2"
1/2"
1/2"
1/2"
------------------------
1/2"
GV-0246
HOV TE HOV
1/2"
0214 0205 D
6"x4"
D N2-2"
1/2"
0206 0202 0213
N5-2" N4-2" N6-3" N3-1/2" Note 17 Note 17 N5-2" N4-2" N6-3" N3-1/2"
D Note 4 P-0206-A21A-12" Note 18 D 12" Note 4 D
PLR-0205
N7-4"
PLR-0202
N9-2"
N1-12"
BV-0280 BV-0250
N1-12"
N9-2" N7-4" ------------------------
Set Note 5 HOV
BV-0245
BV-0238
BV-0235
BV-0247
@ 13.2 kg/cm² g 0214
Stub for ------------------------
4"
2"
2"
4"
PSV Foam Pigging
0201 Note-12(Typ.)
HOV
Note 5 0215
6"x8"
HOWE ENGINEERING PROJECTS (INDIA) PVT.LTD
P-0221-A21A-8"
LO P-0213-A21A-4"
P-0222-A21A-8"
GV-0288 BV-0213
P DRAWING / DOCUMENT REVIEW
8"x4"
P-0212-A21A-10"
V HH=13.2 kg/cm2g HH=165°C
372479-PIE-0003-01
H=12.1 kg/cm2g PI TI H=160°C To Enclosure Manifold 1
GV-0287
PG L=2.5 kg/cm2g PG
GV-0260
0207 0203 L=125°C A1 - APPROVED A4 - ADDITIONAL INFORMATION

3/4"
0213 LL=1.0 kg/cm2g 0223

LO
LL=120°C REQUIRED
PG 10" PLR-0207 2" PG
PG 0222
0214 0217 TT
GV-02100
BV-0232
GV-0217
GV-0228
GV-0212
GV-0231
PT
BV-0223
BV-0224
GV-0208
PGS 0203 PGS A2 - APPROVED WITH COMMENTS A5 - FOR INFORMATION ONLY

0207
BV-0236
3/4"
4"
1"
1"
1"
1"
2"
BV-0214
0203 0209
GV-0253
4"
2"
GV-0248
GV-0252
GV-0243
GV-0257
BV-0234
PGS PGS
GV-0241
N2-2"
1"
HOV GV-0240 TE HOV
10"
1"
1"
1"
0215 0206 D
1"
D N2-2"
6"x4"
1"
0207 D 0203 0216 A3 - NOT APPROVED

2"
N5-2" N4-2" N6-3" N3-1" Note 17 Note 17 N5-2" N4-2" N6-3" N3-1"
D 12" P-0207-A21A-12"-IE IH-100 D 12" Note 4 D
Note 18
PLR-0203 N1-12" PLR-0206 N7-4"
N7-4" N9-2" Note 4 N9-2"
Note-19 BV-0281 BV-0251
(Typ.) FB Note 5 HOV This review and approval does not relieve supplier / contractor / sub-contractor from full compliance with purchase
BV-0246
BV-0227
BV-0231
CH-0201 BV-0248
0217
Note-10 Stub for order / contract requirements and also from errors in this drawing / document.
4"
2"
2"
4"
(Typ.)
Foam Pigging
HOV 08 Reviewed By: Signature : ---------------------

P-0216-A21A-4" Note 5 0218 ---------------------
Note 4 Note 18 Note 4
BV-0254 BV-0255 Pigged Oil pipe line BV-0284 BV-0257 Date: Discipline: ----------------------
----------------------
BV-0256
BV-0285
4"
4"
P-0215-A21A-4"-IE IH-75
BV-0252
P-0214-A21A-12"-IE IH-100 P
372479-PIE-0003-01 FORENGINEERING
To Enclosure Manifold 1
Cup Pig Station for Dock Line
Client
- - - - -
08 Revised as per As Built TSC KVD 21.11.19
501
Sakar II
Near Ellisbridge
JBP HRS LIQUID TERMINAL AT KATTUPALLI PORT - PHASE 1
Ahmedabad,380006
07 Revised as per piping requirement JBP HRS 02.04.19 India
06 Revised as per clients comment JBP HRS 22.01.19 T +91(0) 79 2657 5550
F +91(0) 79 2657 5558 SHP/KVD AKS
05 Revised as per clients comment CBP HRS 08.01.19
04 Revised as per clients comment TSC HRS 13.04.18 ©Mott MacDonald Limited
W www.mottmac.com
COPYRIGHT
The concepts, diagrams and information
Terminal Facility & Pig Station, Berth-2 (Existing)
03 Revised as per clients comment CBP HRS 06.04.18 This document is issued for the party which commissioned Benchmarking Infrastructure contained in this document are the sole
02 Revised Berth-2 (existing) instead of Berth-3 JBP HRS 30.03.18
project only. It should not be relied upon by any other party
property and copyright of AKPPL. Any use, -- P & I Diagram
01 Issued for Engineering (Incorporating hazop & clients comments) TSC HRS 12.06.17
0 Issued for Engineering CBP HRS 10.03.17 by any other party, or being used for any other purpose, or whole or in part without the prior written
permission of AKPPL is prohibited. H201-E-LQT-GEN-DP-L-E-003 372479-PIA-0002-01 08
Notes
2. Locate nozzle at minimum height from bottom for complete drain out.
Equipment List : 3. Provide Refensul insulation of thickness 150mm at tank bottom.
Design Design Design 4. Provide tee for pig removal.
Sr. No. Tag N0. Description Qty Capacity MOC Type Sp. Gravity Temperature Pressure 5. For density correction.
6. Local indication at grade. Valve shall be adjusted according to cargo density.
1. T-31/32 Storage Tank 02 5000 KL CS Fixed Cone 1.0 g/cu. cm 175° C Atm 7. All drain valve shall be normally closed.
(20m Ø x18m HT) Roof +350mm WL 8. All vents shall be facilitated with goose neck pipe with cap.
9. All Flanges shall have flange guards.
10. All drain shall be facilitated with end cap.
11. Actual number of leak detection pipes shall be as per civil drawings
of respective tank foundation. Leak detection pipe with cowl cap to prevent
from unwanted foreign materials.
12. Inside cleaning Nozzle-11, provision shall be kept in line with cleaning operation
by suitable machine. A spray nozzle system with flexible hose shall be
employed with pump for cleaning activity.
13. All flange joints shall be provided with earthing jumpers to avoid static electric
charge accumulation.
14. Full bore valve shall be used for all piggable lines.
15. Alarms and Operational Set-points of Radar Type LT and Suction PT shall be
resettable.
16. Cross -over platforms shall be provided near body valve for
ease of manual operation and maintenance purpose.
17. Walkway shall be provided on tank roof for maintenance and operation purpose.
18. TRV end connection shall be flanged end type. A flanged type ball valve(LO)
shall be provided on TRV release to tank nozzle.
19. TRV's pressure setting shall be adjustable as per cargo requirement.
20. Minimum ground level clearance for sampling to kept 300-350mm approximately.
21. Presently HOVs are considered as manually operated valve with same
tag number & with future provision of Limit switches.
Interlock :
I-1 : Pump to trip on low low level of respective tank during TLF and
export operation except stripping.
I-2 : Master Emergency shut-down : On actuation of emergency push button :
Holdx3"GV-1902
Holdx3"GV-1931
GBV-1901
GBV-1902
- All TLF pumps shall be tripped.
NC
NC
- All DCVs in tanker loading facility in TLF area shall be closed.
I-3 : TCV-T31 shall work based on set value of TE/TT-T31.
I I
I-4 : TCV-T32 shall work based on set value of TE/TT-T32.
IH-90
IH-90
HOS-1901-A14A-3"-IH
HOS-1923-A14A-3"-IH
01 01
I I
03 4
I HH=94.5% I HH=94.5%
V-1921-A21A-10"-IH
V-1922-A21A-10"-IH
03 LI H=93% 4 LI H=93%
HH=165°C L=5% HH=165°C L=5%
T31 TCV T32
3"xHold
3"xHold
TCV H=160°C LL=4% TIC H=160°C LL=4%
T31 TIC T32
L=125°C T32 L=125°C
T31 Radar Radar
LL=120°C LL=120°C
Note-6 HH=94.5% Note-6 HH=94.5%
LSA LSA
GV-1901
GV-1932
LT/LI T31 LT/LI T32
T31 T32
TE/TI TE/TI
T31 T32
Future Future
Future LS
Future LS
Radar LS Radar LS
DH DH
IH-65
IH-65
N11-8"
N11-8"
T31 T32
N30-10"
N30-10"
M4-24"
M4-24"
N24-14"
N24-14"
N25-14"
N25-14"
N6-6"
N6-6"
IH -3 IH -3
N10-4"
N10-4"
" "
M3-24"
M3-24"
N26-1"
N26-1"
N12-6" N12-6"
N23-6"
N23-6"
Note-12 Note-12
N20-2"
N20-2"
HOS-1907-A14A-3"-IH
HOS-1903-A14A-3"-IH
N19-2"
N19-2"
N29-24"
N29-24"
N16-2" N16-2"
N9-1½"
N9-1½"
N28-2"
N28-2"
N13-3"
N13-3"
IH-65
IH-65
N4-6" N5-6" N4-6" N5-6"
HOR-1905-A14A-3"-IH
IH -3"
IH -3"
HOR-1909-A14A-3"-IH
HOV HOV
T31A T32A
HOV HOV
N8-4" T31B N8-4" T32B
P-1915-A21A-1"-IE IH-50 Set@ P-1920-A21A-1"-IE IH-50 Set@
T-31 N18-1" 16kg/cm²g T-32 N18-1" 16kg/cm²g
CH-1901 CH-1902
TG TRV TG TRV
T31 N21-2" 5000 KL T31 T32 N21-2" 5000 KL T32
GV-1915
GV-1927
HOV HOV
05 05
LO
LO
IH-65 T31C IH-65 T32C
HOS-1904-A14A-2"-IH HOS-1908-A14A-2"-IH
P-1913-A21A-12"-IE P-1918-A21A-12"-IE
GV-1903 N14A-2" N1-12" GV-1916 N14A-2" N1-12"
GV-1911
GV-1925
HOR-1906-A14A-2"-IH IH-65 HOS-1910-A14A-2"-IH IH-65
M1/M2-30" 3/4" M1/M2-30"
3/4"
PI V PI V
GV-1904 N15A-2" GV-1917 N15A-2"
GV-1909
GV-1922
3"x2" T31A HOV 3"x2" T32A HOV
GV-1914
GV-1926
3/4"
3/4"
HOS-1903-A14A-2"-IH N14B-2" T31D D Note-4 HOS-1907-A14A-2"-IH N14B-2" T32D D Note-4
LO
LO
N2-12" N2-12"
GV-1905 Note-5,6 GV-1918 Note-5,6
HOR-1905-A14A-2"-IH IH-65 N15B-2" HOR-1909-A14A-2"-IH IH-65 N15B-2"
GV-1910
GV-1923
2" N22-2" 2" N22-2"
IH-30
IH-30
PT/PI PT/PI
3/4"
3/4"
HOV HOV
3"x2" GV-1906 T31A T31E 3"x2" GV-1919 T32A T32E
NC GV-1907 N3-4" IH-75 NC GV-1920 N3-4" IH-75
N7-4" D N7-4" D
P-1914-A21A-3/4"-IE
P-1919-A21A-3/4"-IE
Note-2 Note-2
GV-1912
GV-1924
BV-1901 1:73 P-1912-A21A-4"-IE BV-1903 1:73
P-1917-A21A-4"-IE
1"
1"
IH IH
Note-3 D Note-3 D
BV-1918
BV-1914
Leak detection pipe Leak detection pipe NOTES:-

Note-11 Note-11
------------------------
IH-75
HH=13.2 kg/cm2g HH=13.2 kg/cm2g

IH-75
IH-75
IH-75
H=12.1 kg/cm2g 2" H=12.1 kg/cm2g 2"

PI PT PI PT
L=2.5 kg/cm2g T31B T31B
GV-1913
L=2.5 kg/cm2g T32B T32B
GV-1928
------------------------
LL=0.2 kg/cm2g LL=0.2 kg/cm2g
------------------------
IH-100
IH-100
HOR-1902-A14A-4"-IH
HOS-2201-A14A-4"-IH
------------------------
P-2001-A21A-4"-IE
P-2002-A21A-4"-IE
Recirculation Line
Recirculation Line
P-1911-A21A-12"-IE
P-1916-A21A-12"-IE
------------------------
DRAWING / DOCUMENT REVIEW
A1 - APPROVED A4 - ADDITIONAL INFORMATION

REQUIRED
372479-PIC-0022-01
To Distribution
372479-PIA-0020-01
372479-PIA-0020-01
372479-PIC-0022-01
HOR
To P-31
To P-32
372479-PIA-0020-01
372479-PIA-0020-01
P
P
A2 - APPROVED WITH COMMENTS A5 - FOR INFORMATION ONLY
From Distribution
A3 - NOT APPROVED
From P-31
This review and approval does not relieve supplier / contractor / sub-contractor from full compliance with purchase
HOS
order / contract requirements and also from errors in this drawing / document.
P
Reviewed By: Signature : ---------------------

---------------------
Date: Discipline: ----------------------

----------------------
ISSUEDFORENGINEERING
Client
- - - - -
- - - - -
501
Sakar II
Near Ellisbridge
CBP HRS LIQUID TERMINAL AT KATTUPALLI PORT - PHASE 1
Ahmedabad,380006
05 Revised as per As Built TSC KVD 21.11.19 India
04 Revised as per client's comments AGG HRS 05.11.19 T +91(0) 79 2657 5550
F +91(0) 79 2657 5558 SHP/KVD AKS
03 Revised as per client's comments JBP HRS 05.04.19
W www.mottmac.com
COPYRIGHT
Enclosure-3 Tank Area
This document is issued for the party which commissioned Benchmarking Infrastructure contained in this document are the sole
0 Issued for Engineering JBP HRS 22.02.19
B Revised as per client's comments JBP HRS 22.01.19
A Issued for Approval CBP HRS 08.01.19 by any other party, or being used for any other purpose, or whole or in part without the prior written
permission of AKPPL is prohibited. H201-E-LQT-TNK-DP-L-E-101 372479-PIA-0019-01 05
Notes
Equipment List : 1. For abbreviation & Symbols. Refer drawing no. 372479-PIA-0001-01.
2. All pumps shall have local 'Start / Stop 'provision with 'Local / Remote'
Sr. No. Tag N0. Description Qty Capacity Differential MOC Type Design Design Operating Operating selector switch in the field.
Head Temperature Pressure Temperature Pressure 3. Pump base plate drain to be routed to OWS.
1 P-31/32 Bitumen Loading Pump 02 120 M3/hr 55.30 m CS Rotary Screw 175° C 7.0 Kg/cm2g 120° to 160° C 5.10 Kg/cm2g 4. All drain shall be facilitated with end cap.
5.1 Kg/cm2g 5. TRV end connection shall be of flanged end type.
6. All Nitrogen and Air connections shall be quick release type.
372479-PIA-0019-01
372479-PIA-0019-01
From T-31
From T-32
372479-PIA-0019-01
372479-PIA-0019-01
P
P
charge accumulation
8. TRV's pressure setting shall be adjustable as per cargo requirement.
9. Full bore valve shall be used for all pigging lines.
10. Minimum ground level clearance for sampling to kept 300-350 mm
approximately.
To T-31
To T-32
11. All vents shall be facilitated with goose neck pipe with cap.
13. All spectacled blind flange MOC should be SS.
P
14. Curb wall shall be provided in pump house.
15. Internal pigging within tank farm with foam pig.
16. 60 mm mesh considered for pump Strainer.
Recirculation Line
Recirculation Line
17. Presently HOVs are considered as manually operated valve with same
tag number & with future provision of Limit switches.
Interlock :
I-1 : Pump to trip on low low level of respective tank during TLF and
Pump Manifold Enclosure-3 export operation except stripping.
I-2 : Master Emergency shut-down : On actuation of emergency push button :
HOV HOV - All TLF pumps shall be tripped.
31B 32B - All DCVs in tanker loading facility in TLF area shall be closed.
I-3 : Only TLF Pump to trip on zero tanker loading flow.
4" 4"
4" P-2018-A21A-4"-IE IH-75 4"
BV-2019 Pigged Oil Pipe Line BV-2017

BV-2020
BV-2018
HH=13.2 kg/cm2g
2"
4"
PI H=12.1 kg/cm2g
2001 L=2.5 kg/cm2g
LL=1.0 kg/cm2g
PG
2001 PT/PI
2001 HOV HOV ON LOCAL
V XL SS
31C 32C --- ---
OFF REMOTE
GV-2036
03
GV-2034
GV-2033
GV-2035
2"
1"
1"
2"
12" 12" ON
P P-0214-A21A-12"-IE IH-100 12" Pig Trap 2" PB
--- OFF
372479-PIE-0003-01 03
From Jetty BV-2015 GV-2032
GV-2031
I I I
M
CH-2003 BV-2026
3/4"
01 02 03
4"
IH-75
IH-75
4"
Typical Pump Controls and Interlocks
P-2020-A21A-4"-IE
GV-2014
GV-2029
2"
2"
IH-100
Set@ TRV Set@ TRV

5.71 kg/cm2g P31 Note-10 5.71 kg/cm2g P32 Note-10
IH-100
P-2008-A21A-3/4"-IE
P-2015-A21A-3/4"-IE
(Typ.) (Typ.)
Pig Trap
Pig Trap
Note-5 3/4" Note-5 3/4"
P-2009-A21A-1"-IE IH-50 LO D P-2016-A21A-1"-IE IH-50 LO D
P-1916-A21A-12"-IE
GV-2015 GV-2030
GV-2013 GV-2028
P-1911-A21A-12"-IE
GV-2012
GV-2027
HH=165°C HH=165°C
BV-2010
BV-2014
3/4"
3/4"
LO
LO
H=160°C TI TE/TI H=160°C TI TE/TI
6"
6"
HOV HOV
L=125°C P31 P31 L=125°C P32 P32
P31B P32B
LL=120°C LL=120°C
HOV HOV
P31A P-2006-A21A-6"-IE P32A P-2013-A21A-6"-IE
P-2001-A21A-4"-IE IH-75 P-2002-A21A-4"-IE IH-75
Recirculation Line 4" Recirculation Line 4"

NC NC
6" P-2019-A21A-6"-IE 6"
BV-2024 BV-2025
NC NC
4" IH-75 4" P-2014-A21A-4"-IE IH-75
P-2007-A21A-4"-IE
NOTES:-
BV-2022 BV-2023
DPI DPA
H=0.08
Kg/cm2
HH=6.2 kg/cm2g DPI DPA
H=0.08
Kg/cm2
HH=6.2 kg/cm2g ------------------------
PA H=5.61 kg/cm2g PA H=5.61 kg/cm2g
03 P31 P31
P31 03 P32 P32
P32
------------------------
2" IH-75 2" ------------------------
IH-75
DPT PT DPT PT
P31 P31 P32 P32
GV-2011 GV-2026
V V
------------------------
GV-2006
GV-2021
P-2010-A21A-6"-IE
P-2017-A21A-6"-IE
------------------------
3/4"
3/4"
GV-2004
GV-2005
GV-2019
GV-2020
BV-2009
BV-2013
CH-2001
CH-2002
V V
3"
3"
3"
3"
4"
4"
------------------------
GV-2010
GV-2025
3/4"
3/4"
10" PG 10" PG
P31 P32
GV-2003
GV-2018
BV-2008 BV-2012 HOWE ENGINEERING PROJECTS (INDIA) PVT.LTD
BV-2007
BV-2011
3/4"
1" 3/4" 1"

P-2005-A21A-10"-IE STR-P31 P-2012-A21A-10"-IE STR-P32
12"
12"

Holdx10"
Holdx10"
GV-2008 GV-2023
GV-2009
GV-2024
GV-2007
GV-2022
D D
3/4"
3/4"
Holdx6"
Holdx6"
1"
1"
Pig Trap
Pig Trap

REQUIRED
D D D D
GV-2001
GV-2016
372479-PIA-0021-01
372479-PIA-0021-01
To TLF (Enc. 3)
To TLF (Enc. 3)
A2 - APPROVED WITH COMMENTS
3/4"
3/4"
A5 - FOR INFORMATION ONLY

P
P
D D
A3 - NOT APPROVED
GV-2002
GV-2017
2"
2"
ON ON This review and approval does not relieve supplier / contractor / sub-contractor from full compliance with purchase
PB PB order / contract requirements and also from errors in this drawing / document.
P31
P-31 P32
P-32
OFF Note-2,3 OFF Note-2,3 Reviewed By: Signature : ---------------------
---------------------
Date: Discipline: ----------------------

LOCAL LOCAL ----------------------
ON ON
SS XL SS XL
P31 P31 P32 P32
REMOTE OFF REMOTE OFF
Client
- - - - -
- - - -
501
Sakar II
Near Ellisbridge
JBP HRS LIQUID TERMINAL AT KATTUPALLI PORT - PHASE 1
Ahmedabad,380006
03 Revised as per As Built TSC KVD 21.11.19 India
02 Revised as per client's comments JBP HRS 05.04.19 T +91(0) 79 2657 5550
F +91(0) 79 2657 5558 SHP/KVD AKS
01 Revised as per piping requirement JBP HRS 02.04.19
0 Issued for Engineering JBP HRS 22.02.19 ©Mott MacDonald Limited
W www.mottmac.com
COPYRIGHT
Enclosure-3 Pump Area
D Revised as per Client's Comments JBP HRS 29.01.19 This document is issued for the party which commissioned Benchmarking Infrastructure contained in this document are the sole
C Revised as per Client's Comments JBP HRS 24.01.19
B Revised as per Client's Comments JBP HRS 22.01.19
permission of AKPPL is prohibited. H201-E-LQT-GEN-DP-L-E-109 372479-PIA-0020-01 03
Notes
2. Loading Arm assembly shall have all following requisite components:
- FM connected below platform (@ floor level)
- Air/Nitrogen blowing arrangement
- Drain tray for drip containment
3. Connect via spool piece, spare spool piece arrangement to be provided to meet
end connections.
4. Stub for foam pig trap.
P IH-75
P-2017-A21A-6"-IE 5. Internal pigging within tank farm with foam pigs.
372479-PIA-0020-01
6. Flexible Earthing provision for tanker shall be as follows:
From P-32 6"x3" - One direct Earthing connection
- One Earthing connection through relay
P IH-75
- Providing Interlock for preventing loading of tanker if it is not grounded
P-2010-A21A-6"-IE 7. All drain shall be facilitated with end cap.
372479-PIA-0020-01
From P-31 8. All Nitrogen and Air connections shall be quick release type.
6"x3" 9. Piping shall be done in a such away that stub location shall remain at the furthest
point / end point at the line. Therefore foam pig never travels through the tapping.
IH-75
10. Drain, Vent & DPG isolation valve for strainer shall be supplied by vendor.
IH-75
IH-75
charge accumulation.
P-2101-A21A-3"-IE
P-2104-A21A-3"-IE
P-2017-A21A-3"-IE
13. Alarm to be generated on activation of the LSH.
14. Loading Arm assembly shall have all following requisite components:
a) A batch controller with
- Mass Flow Meter (for specific filling and capable of generating daily records to
cross verify with weighbridge)
Note-4
Note-4
- DFCV (Digital flow Control valve)
b) A strainer (to arrest contaminant particles) with Differential PG.
c) A level sensor (to stop overfilling /spillage by generating alarms for closing
BV-2101
BV-2104
BV-2105
BV-2108
manual valve and) having interlock for closing DFCV to stop transfer.
Transfer pump “Off” push button shall be suitably located on TLF common
platform to operate as an Emergency Push Button for stopping pump when DFCV
closes but pump keep on running due to communication link failure..
EFCV-2101
EFCV-2104
EFCV-2105
EFCV-2108
15. Minimum ground level clearance for sampling to kept 300-350 mm approximately.
Note-9
Typ.
16. All vents shall be facilitated with goose neck pipe with cap.
17. 100 mm mesh considered for loading arm strainer.
GV-2101 18. EFCV shall cut off the TLF flow rate at 60 m³/hr flow.
GV-2104
GV-2105
GV-2108
3/4"
3/4"
3/4"
3/4"
D D D D
Note-15(Typ.)
Note-3
Note-3
Note-3
Note-3
PG
2101A
Future Provision Future Provision PG
2101B
PG
21021
Future Provision Future Provision PG
2102B
Interlock :
1" 1" 1" 1" I-2 : Master Emergency shut-down : On actuation of emergency push button :
- All TLF pumps shall be tripped.
GV-2109 01 GV-2117 GV-2125 01 GV-2133
GV-2110
GV-2118
GV-2126
GV-2134
- All DCVs in tanker loading facility in TLF area shall be closed.
1"
1"
1"
1"
I-3 : Only TLF Pump to trip on zero tanker loading flow.
I-4 : Flow control valve (future provision) shall close on high high level in tanker
D D D D attached to respective loading arm (LA).
I-6 : Flow control valve (future provision) shall close on loss of earthing.
DPG DPG DPG DPG
2101A 2101B 2102A 2102B
GV-2111
GV-2112
GV-2120
GV-2119
GV-2127
GV-2128
GV-2136
GV-2135
V V V V
GV-2121
GV-2113
GV-2137
GV-2129
1"
1"
1"
1"
1"
1"
1"
1"
3/4"
3/4"
3/4"
3/4"
STR-21001A STR-2101B STR-2102A STR-2102B
Note-5 Note-5 Note-10 Note-10
GV-2114
GV-2122
GV-2130
GV-2138
3/4"
3/4"
3/4"
3/4"
D D D D
Mass Flow Meter
Mass Flow Meter

Mass Flow Meter
Mass Flow Meter

FI BC FI BC FI BC FI BC
2101A 2101A 2101B 2101B 2102A 2102A 2102B 2102B
FI FI FI FI
210C 2101D 2102C 2102D
FCV FCV FCV FCV NOTES:-

2101A 2101B 2102A 2102B
------------------------
Note-14 Note-14 Note-14 Note-14 ------------------------
------------------------
P-2104-A21A-3"-IE
P-2101-A21A-3"-IE
P-2017-A21A-3"-IE
------------------------
P-2010-A21A-3"-IE
I I I I ------------------------
04 04 04 04
------------------------
V V
V AL AL V AL AL
LSH LSH LSH LSH HOWE ENGINEERING PROJECTS (INDIA) PVT.LTD
GV-2115
GV-2123
GV-2131
GV-2139
Note-14 2101A 2101B Note-14 Note-14 2102A 2102B Note-14
3/4"
3/4"
3/4"
3/4"
I I
06 06
GV-2116
GV-2124
GV-2132
GV-2140
BV-2109 BV-2110 BV-2111 BV-2112 A1 - APPROVED A4 - ADDITIONAL INFORMATION
3/4"
3/4"
3/4"
3/4"
REQUIRED
LA-2101A LA-2101B LA-2102A 2102B-0703B

D D D D
Note-15(Typ.) Tanker Tanker
Note-6 Note-6 A3 - NOT APPROVED
ES ES
2101 2102 This review and approval does not relieve supplier / contractor / sub-contractor from full compliance with purchase
Bay-01 Bay-02 order / contract requirements and also from errors in this drawing / document.

---------------------
Date: Discipline: ----------------------

----------------------
Client
- - - - -
- - - -
501
Sakar II
Near Ellisbridge
CBP HRS LIQUID TERMINAL AT KATTUPALLI PORT - PHASE 1
Ahmedabad,380006
- - - - - India
- - - - - T +91(0) 79 2657 5550
F +91(0) 79 2657 5558 SHP AKS
- - - - -
W www.mottmac.com
COPYRIGHT
TLF Area (Enclosure 3)
01 Revised as per As Built TSC KVD 21.11.19 This document is issued for the party which commissioned Benchmarking Infrastructure contained in this document are the sole
0 Issued for Engineering JBP HRS 22.02.19
B Revised as per Client's Comments JBP HRS 22.01.19
permission of AKPPL is prohibited. H201-E-LQT-TLU-DP-L-E-101 372479-PIA-0021-01 01
Operation Mode : Import Notes:-
Berth-2 (Existing) Berth-2 (Existing) to Single Tank Enclosure - 3 1. All valves shall be either in open or close mode as per requirement
of lineup and operation logic sequence.
2. Presently all BVs & HOVs are considered as manually operated
valve with same tag number & with future provision of motors,
Actuators,Limit switches respectively.
PG
0201
Open
HOV
0201
P-0220-A21A-10''-IH(FL-04B)
P-0203-A21A-12"-IH(FL-03A)
P-0219-A21A-10"-IH(FL-04A)
PG
P-0201-A21A-10"(FL-01)
P-0204-A21A-12"(FL-03B)
0205
P-0202-A21A-10"(FL-02)
Future
Future
D
PT
0201
TG TI
0201 0203
Close
PI 0.0Kg/cm2g
PLR-0207
0201
BV-0224 PG PI 0.0 Kg/cm2g
PG 0.0 Kg/cm2g 0207 TT
0217 0203 PI
0214
Foam Pigging
BV-0234
2001
Open
Stub for
HOV PT TE
0207 0203 Enclosure Manifold-3
0207 PT
P-0207-A21A-12"-IE HOV HOV
PLR-0203 0217 0218 2001
Close BV-0281 BV-0251 PG
Open Open 2001
PG Open Open
BV-2019
Close
0222
P-0214-A21A-12"-IE
PT/PI
Pigged Oil Pipe Line

P-2018-A21A-4"-IE
Close
HOV 2001
0216
TI PI LI <LL PI
T31 T31A T31 2001
PLR-0206
Not Active 0.0 Kg/cm2g
TE/TI LS PT LT
T31 T31 T31A T31 HOV
T31C <LL
HOV PI
T31A T31B HOV HOV
Open
31B 31C
Hot Oil Generation
Hot Oil Generation
Close PT
HOV Close Open
4" T-31 T31B
HOS-1904-A14A-2"-IH T31D 4" 12"
HOS-1901-A14A-3"-IH Open P-1911-A21A-12"-IE
GV-1903 Enclosure-3 P-31
GBV-1901 HOR-1906-A14A-2"-IH Close BV-1914
TCV (Tank farm Area)
T31 3"x2" GV-1904 NOTES:-
HOS-1903-A14A-3"-IH HOV
GV-1902 GV-1901 T31E ------------------------
3"x2" GV-1905
HOR-1905-A14A-3"-IH ------------------------
GV-1906 Close
------------------------
<LL=4.0% ------------------------
TI PI LI
T32 T32A T32 ------------------------
Not Active ------------------------
TE/TI LS PT LT
T32 T32 T32A T32
HOV HOWE ENGINEERING PROJECTS (INDIA) PVT.LTD
T32C <LL
HOV PI DRAWING / DOCUMENT REVIEW
T32A T32B HOV HOV
Close
32B 32C A1 - APPROVED A4 - ADDITIONAL INFORMATION
REQUIRED
Close PT
HOV Close Close
4" T-32 T32B A2 - APPROVED WITH COMMENTS A5 - FOR INFORMATION ONLY
HOS-1923-A14A-3"-IH HOS-1908-A14A-2"-IH T32D 4" 12"

Close P-1916-A21A-12"-IE
GV-1916 Enclosure-3 P-32 A3 - NOT APPROVED
BV-2015
Close
T32 3"x2" GV-1917 This review and approval does not relieve supplier / contractor / sub-contractor from full compliance with purchase
HOS-1907-A14A-3"-IH HOV Pump Manifold Enclosure-3 order / contract requirements and also from errors in this drawing / document.
GV-1931 GV-1932 3"x2" GV-1918 T32E Reviewed By:

---------------------
Signature : ---------------------
HOR-1909-A14A-3"-IH Date: Discipline: ----------------------

----------------------
GV-1919 Close
FORAPPROVAL
Client
- - - - -
- - - - -
501
Sakar II
Near Ellisbridge
AGG HRS/JBP LIQUID TERMINAL AT KATTUPALLI PORT - PHASE 1
Ahmedabad,380006
- - - - -
- - - - -
India
T +91(0) 79 2657 5550
Import
F +91(0) 79 2657 5558 JBP AKS
- - - - -
W www.mottmac.com
COPYRIGHT
Berth-2 (Existing) to Single Tank Enclosure - 3
- - - - -
property and copyright of AKPPL. Any use, Flow Chart
- - - - -
P1 Issued for Approval AGG HRS 15.11.19 by any other party, or being used for any other purpose, or whole or in part without the prior written
permission of AKPPL is prohibited. - H201-E-LQT-GEN-DP-I-E-XXX 372479-PFC-0074-01 P1
Berth-2 (Existing) Import Berth to Multiple Tanks Intra Enclosure Simultaneously Enclosure - 3 1. All valves shall be either in open or close mode as per requirement
PG
0201
Open
HOV
0201
P-0220-A21A-10''-IH(FL-04B)
P-0203-A21A-12"-IH(FL-03A)
P-0219-A21A-10"-IH(FL-04A)
PG
P-0201-A21A-10"(FL-01)
P-0204-A21A-12"(FL-03B)
0205
P-0202-A21A-10"(FL-02)
Future
Future
D
PT
0201
TG TI
0201 0203
Close 2
PI 0.0Kg/cm g
PLR-0207
0201
0217 0203 PI
0214
Foam Pigging
BV-0234 2001
Open
Stub for
HOV PT TE
0207 PT
PLR-0203 0217 0218 2001 PG
Close BV-0281 BV-0251 2001
Open Open Open
BV-2019
PG Open
Close
0222
P-0214-A21A-12"-IE
PT/PI

P-2018-A21A-4"-IE
2001
Close
HOV
0216
PI
TI PI LI <LL
2001
T31 T31A T31
PLR-0206
0.0 Kg/cm2g
Not Active
TE/TI LS PT LT
T31C <LL
HOV PI
T31A T31B HOV HOV
Open
31B 31C
Hot Oil Generation
Hot Oil Generation
Close PT
HOV Close Open
4" T-31 T31B
HOS-1904-A14A-2"-IH T31D 4" 12"
HOS-1901-A14A-3"-IH Open P-1911-A21A-12"-IE
T31 3"x2" GV-1904 NOTES:-
GV-1902 GV-1901 T31E ------------------------
3"x2" GV-1905
HOR-1905-A14A-3"-IH
------------------------
GV-1906 Close
------------------------
<LL=4.0% ------------------------
TI PI LI
T32 T32A T32 ------------------------
Not Active ------------------------
TE/TI LS PT LT
T32C HOWE ENGINEERING PROJECTS (INDIA) PVT.LTD
<LL
HOV PI DRAWING / DOCUMENT REVIEW
T32A T32B HOV HOV
Open
32B 32C A1 - APPROVED A4 - ADDITIONAL INFORMATION
REQUIRED
Close PT
HOV Close Open
4" T-32 T32B A2 - APPROVED WITH COMMENTS A5 - FOR INFORMATION ONLY
HOS-1923-A14A-3"-IH HOS-1908-A14A-2"-IH T32D 4" 12"
Open P-1916-A21A-12"-IE
GV-1916 Enclosure-3 P-32 A3 - NOT APPROVED
BV-2015
HOR-1910-A14A-2"-IH Close BV-1918
Close
GBV-1902
T32 3"x2" GV-1917 This review and approval does not relieve supplier / contractor / sub-contractor from full compliance with purchase
HOS-1907-A14A-3"-IH HOV Pump Manifold Enclosure-3 order / contract requirements and also from errors in this drawing / document.
GV-1931 GV-1932 3"x2" GV-1918 T32E Reviewed By:

---------------------
Signature : ---------------------
HOR-1909-A14A-3"-IH
Date: Discipline: ----------------------
----------------------
GV-1919 Close
FORAPPROVAL
Client
- - - - -
- - - - -
501
Sakar II
Near Ellisbridge
Ahmedabad,380006
- - - - -
- - - - -
India
T +91(0) 79 2657 5550
Import
F +91(0) 79 2657 5558 JBP AKS
- - - - - W www.mottmac.com

COPYRIGHT
Berth to Multiple Tanks Intra Enclosure Simultaneously Enclosure - 3
- - - - -
- - - - -
Berth-2 (Existing) 1. All valves shall be either in open or close mode as per requirement
Import Berth to Multiple Tanks Intra Enclosure Sequentially Enclosure - 3
PG Actuators,Limit switches respectively.
Open
HOV 0201
0201
P-0220-A21A-10''-IH(FL-04B)
P-0203-A21A-12"-IH(FL-03A)
P-0219-A21A-10"-IH(FL-04A)
PG
P-0201-A21A-10"(FL-01)
P-0204-A21A-12"(FL-03B)
0205
P-0202-A21A-10"(FL-02)
Future
Future
D
PT
0201
TG TI
0201 0203
Close
PI 0.0Kg/cm2g
PLR-0207
0201
0217 0203 PI
0214
Foam Pigging
BV-0234
2001
Open
Stub for
HOV PT TE
0207 PT
PLR-0203 2001 PG
0217 0218
Close BV-0281 BV-0251 2001
Open Open
Open Open
BV-2019
PG
Close
0222
P-0214-A21A-12"-IE
PT/PI

P-2018-A21A-4"-IE
2001
Close
HOV
0216
PI
TI PI LI <LL
2001
T31 T31A T31
PLR-0206
0.0 Kg/cm2g
Not Active
TE/TI LS PT LT
T31 T31 T31A T31
HOV
T31C <LL
HOV PI
T31A T31B HOV HOV
Open/Close
31B 31C
Hot Oil Generation
Hot Oil Generation
Close PT
HOV Close Open
4" T-31 T31B
HOS-1904-A14A-2"-IH T31D 4" 12"
HOS-1901-A14A-3"-IH Open/Close P-1911-A21A-12"-IE
T31 3"x2" GV-1904
GV-1902 GV-1901 3"x2" GV-1905 T31E
HOR-1905-A14A-3"-IH NOTES:-
GV-1906 Close ------------------------
------------------------
TI PI LI <LL=4.0%
T32 T32A T32 ------------------------
------------------------
Not Active
TE/TI LS PT LT ------------------------
T32 T32 T32A T32
HOV ------------------------
T32C <LL
HOV PI
T32A T32B HOV HOV
Close/Open HOWE ENGINEERING PROJECTS (INDIA) PVT.LTD
32B 32C
Close PT DRAWING / DOCUMENT REVIEW
HOV Close Close
4" T-32 T32B
HOS-1908-A14A-2"-IH T32D 4" 12"
HOS-1923-A14A-3"-IH Close/Open P-1916-A21A-12"-IE
REQUIRED
BV-2015
HOR-1910-A14A-2"-IH Close
Close
GBV-1902 BV-1918
TCV (Tank farm Area) A2 - APPROVED WITH COMMENTS A5 - FOR INFORMATION ONLY
T32 3"x2" GV-1917

HOS-1907-A14A-3"-IH HOV Pump Manifold Enclosure-3 A3 - NOT APPROVED
GV-1931 GV-1932 3"x2" GV-1918 T32E
HOR-1909-A14A-3"-IH This review and approval does not relieve supplier / contractor / sub-contractor from full compliance with purchase
GV-1919 Close
---------------------
Date: Discipline: ----------------------
----------------------
FORAPPROVAL
Client
- - - - -
- - - - -
501
Sakar II
Near Ellisbridge
Ahmedabad,380006
- - - - -
- - - - -
India
T +91(0) 79 2657 5550
Import
F +91(0) 79 2657 5558 JBP AKS

COPYRIGHT
Berth to Multiple Tanks Intra Enclosure Sequentially Enclosure - 3
- - - - -
- - - - -
Import Berth - 2 (Existing) to TLF Enclosure - 3 1. All valves shall be either in open or close mode as per requirement
Berth-2 (Existing) of lineup and operation logic sequence.
PIC valve with same tag number & with future provision of motors,
P31A
DPI
PG PA
0201 P31 P31A
Open
HOV
0201
Close
PT
BV-2009
Close
Close
DPT P31A HOV HOV
P31 P31A P31B
Open
P-2006-A21A-6"-IE
D P-31
BV-2008 Open
P-0220-A21A-10''-IH(FL-04B)
P-0203-A21A-12"-IH(FL-03A)
P-0219-A21A-10"-IH(FL-04A)
PG
P-0201-A21A-10"(FL-01)
P-0204-A21A-12"(FL-03B)
0205 P-2007-A21A-4"-IE
P-0202-A21A-10"(FL-02)
Enclosure-3 (TLF Area)
Future
Future
Future Provision
D P-2010-A21A-6"-IE
P-2005-A21A-10"-IE
PT 3"x6"
BV-2024
Close
0201
NC
TG TI
0201 PG PG
P-2010-A21A-3"-IE
Close 0203 2102A 2101A
PLR-0207
PI 0.0Kg/cm2g
P-2101-A21A-3"-IE
0201
0217 0203 PI
0214
Foam Pigging
BV-0234
DPG DPG
2001 2102A 2101A
Open
Stub for
HOV PT TE
0207 PT
PLR-0203 0217 0218 2001
Close BV-0281 BV-0251
Open Open PG
Open Open
0222
PG
BV-2019
Close
P-2019-A21A-6"-IE
2001 BC FM BC FM
2102A 2102A 2101A 2101A
Close FCV FCV

2102A 2101A
Close
P-0214-A21A-12"-IE
HOV
Open
Open
BV-2018
0216
P-2020-A21A-4"-IE
PT/PI Not Active

LSH LSH
P-2018-A21A-4"-IE
2001
2102A 2101A
PLR-0206
PI
TI PI LI <LL ES Tanker ES Tanker
2001 2102 Bay-02 2101 Bay-01
T31 T31A T31
2
Close Close 0.0 Kg/cm g
Not Active
TE/TI LS PT LT CH-2003 BV-2026
T31 T31 T31A T31 HOV PIC
T31C P32A
<LL PI
HOV DPI
T31B HOV HOV PA
T31A Close P32
31B 31C P32A
BV-2022
Close
Close
PT
BV-2013
NC
Hot Oil Generation
Hot Oil Generation
Close PT
HOV
Close
Close
4" T31B Close Open DPT P32A HOV
T-31 T31D HOV
HOS-1904-A14A-2"-IH Close 4" 12" Close P32 P32A
HOS-1901-A14A-3"-IH P32B
GV-1903 Enclosure-3 Open
GBV-1901 HOR-1906-A14A-2"-IH Close BV-1914 P-1911-A21A-12"-IE BV-2007 P-32 NC
TCV (Tank farm Area) BV-2012 P-2013-A21A-6"-IE Open
T31 3"x2" GV-1904 BV-2025
HOS-1903-A14A-3"-IH HOV Close
Pump Manifold Enclosure-3

GV-1902 GV-1901 3"x2" GV-1905 T31E
HOR-1905-A14A-3"-IH Enclosure-3 (TLF Area)
GV-1906 Close Future Provision P-2017-A21A-6"-IE NOTES:-
P-2012-A21A-10"-IE
P-2014-A21A-4"-IE
3"x6" ------------------------
TI PI LI <LL=4.0%
T32 T32A T32 ------------------------
PG PG
P-2017-A21A-3"-IE
Not Active 2102B 2101B ------------------------
P-2104-A21A-3"-IE
TE/TI LS PT LT ------------------------
T32C <LL DPG DPG
------------------------
HOV PI 2102B 2101B
T32A T32B HOV HOV ------------------------

Close
BV-2023
32B 32C
Close
NC
Close PT
HOV Close Open
4" T-32 T32D
T32B HOWE ENGINEERING PROJECTS (INDIA) PVT.LTD
HOS-1908-A14A-2"-IH Close 4" 12" Close
HOS-1923-A14A-3"-IH DRAWING / DOCUMENT REVIEW
GV-1916 Enclosure-3
GBV-1902 HOR-1910-A14A-2"-IH Close BV-1918 P-1916-A21A-12"-IE BV-2011
T32 3"x2" GV-1917 BC FM BC FM A1 - APPROVED A4 - ADDITIONAL INFORMATION
REQUIRED
HOS-1907-A14A-3"-IH HOV 2102B 2102B 2101B 2101B
GV-1931 GV-1932 3"x2" GV-1918 T32E A2 - APPROVED WITH COMMENTS A5 - FOR INFORMATION ONLY
HOR-1909-A14A-3"-IH FCV FCV
BV-2015
Close
GV-1919
2102B 2101B
Close
Open
Open
A3 - NOT APPROVED
Not Active
LSH LSH This review and approval does not relieve supplier / contractor / sub-contractor from full compliance with purchase
2102B 2101B
---------------------
ES Tanker ES Tanker Date: Discipline: ----------------------
----------------------
2102 Bay-02 2101 Bay-01
FORAPPROVAL
Client
- - - - -
- - - - -
501
Sakar II
Near Ellisbridge
Ahmedabad,380006
- - - - -
- - - - -
India
T +91(0) 79 2657 5550
Import
F +91(0) 79 2657 5558 JBP AKS

COPYRIGHT
Berth - 2 (Existing) to TLF Enclosure - 3
- - - - -
- - - - -
Operation Mode : ITT Notes:-
Intra Enclosure From One Tank to One Tank by TLF Pump Through TLF Area (Enclosure-3) 1. All valves shall be either in open or close mode as per requirement
Hot Oil Generation 2. Presently all BVs & HOVs are considered as manually operated
Hot Oil Generation
TI PI LI <LL TI PI LI <LL
T31 T31A T31 T32 T32A T32
GBV-1901
GBV-1902
GV-1902
GV-1931
HOS-1901-A14A-3"-IH
HOS-1901-A14A-3"-IH
Not Active Not Active
TCV TE/TI LS PT LT TCV TE/TI LS PT LT
T31 T32
T31 T31 T31A T31 T32 T32 T32A T32
HOV HOV
T31C T32C
HOV HOV
GV-1901
GV-1932
T31A Close T32A Open
Close Close
P-1911-A21A-12"-IE
P-1916-A21A-12"-IE
HOV HOV
4" T-31 T31D 4" T-32 T32D
HOS-1904-A14A-2"-IH HOS-1908-A14A-2"-IH
GV-1903 Enclosure-3 GV-1916 Enclosure-3
HOR-1906-A14A-2"-IH Open HOR-1910-A14A-2"-IH Close
(Tank farm Area) (Tank farm Area)
3"x2" GV-1904 3"x2" GV-1917
HOS-1903-A14A-3"-IH HOV HOS-1907-A14A-3"-IH HOV
3"x2" GV-1905 T31E 3"x2" GV-1918 T32E
HOR-1905-A14A-3"-IH HOR-1909-A14A-3"-IH
GV-1906 Selective GV-1919 Close
HOV TAG NUMBER
BV-1914
BV-1918
Open
Open
AAAA BBBB SIZE
31B 32B 4"
<LL <LL 31C 32C 12"
PI PI
T31B T32B
PT PT
T31B T32B
HOV DPI HOV DPI

AAAA P31 BBBB P32
BV-2009
BV-2013
LOCAL LOCAL
SS SS
Close
Close
Close DPT Close DPT
Pump Manifold Enclosure-3 P31 P31 REMOTE Pump Manifold Enclosure-3 P32 P32 REMOTE
Open P-2005-A21A-10"-IE Open P-2012-A21A-10"-IE
ON ON
XL XL
BV-2008 BV-2012
P31 P32
OFF OFF
NC NC
PB PB
BV-2022 P31 BV-2023 P32
Close Open
BV-2007
BV-2011
P-31 P-32
Close
Close
M M
P-2007-A21A-4"-IE
P-2014-A21A-4"-IE
PA PT PA PT
P31 P31 P32 P32
HOV HOV
P31A P32A
BV-2010
BV-2014
Close
Close
Close Close
4" 4"
NOTES:-
P-2010-A21A-6"-IE
P-2017-A21A-6"-IE
Open
Open
HOV HOV
P31B P32B ------------------------
------------------------
P-2006-A21A-6"-IE P-2013-A21A-6"-IE
------------------------
------------------------
NC P-2006-A21A-6"-IE NC ------------------------
BV-2024 BV-2025 ------------------------
Close Close

P-2104-A21A-3"-IE
P-2017-A21A-3"-IE
P-2101-A21A-3"-IE
P-2010-A21A-3"-IE
REQUIRED
A3 - NOT APPROVED
Close
Close
Open
Open

---------------------
BAY-1 BAY-2 Date:
----------------------
Discipline: ----------------------

FORAPPROVAL
Client
- - - - -
- - - - -
501
Sakar II
Near Ellisbridge
Ahmedabad,380006
- - - - -
- - - - -
India
T +91(0) 79 2657 5550
ITT Intra Enclosure
F +91(0) 79 2657 5558 JBP AKS
- - - - -
COPYRIGHT
From One Tank to One Tank by TLF Pump Through TLF Area (Enclosure-3)
- - - - -
- - - - -
Operation Mode : ITT Notes:-
ITT - Intra Enclosure from One Tank to One Tank by TLF Pump & Recirculation Line Intra Enclosure (Enclosure-3) 1. All valves shall be either in open or close mode as per requirement
Hot Oil Generation
Hot Oil Generation
P-2002-A21A-4"-IE
T31 T31A T31 T32 T32A T32
GBV-1901
GBV-1902
GV-1902
GV-1931
HOS-1901-A14A-3"-IH
HOS-1901-A14A-3"-IH
T31 T32
T31 T31 T31A T31 T32 T32 T32A T32
HOV HOV
T31C T31C
HOV HOV
GV-1901
GV-1932
T31A Close T32A Close
Close Open
P-1911-A21A-12"-IE
P-1916-A21A-12"-IE
HOV HOV
4" T-31 T31D 4" T-32 T31D
HOS-1904-A14A-2"-IH HOS-1908-A14A-2"-IH
HOR-1906-A14A-2"-IH Open HOR-1910-A14A-2"-IH Close
3"x2" GV-1904 3"x2" GV-1917
3"x2" GV-1905 T31E 3"x2" GV-1918 T31E
HOR-1905-A14A-3"-IH HOR-1909-A14A-3"-IH
GV-1906 Selective GV-1919 Close
<LL HOV TAG NUMBER
PI <LL
BV-1914
BV-1918
PI
Close
Open
T31B T32B AAAA BBBB SIZE
31B 32B 4"
31C 32C 12"
PT PT
T31B T32B
P-2002-A21A-4"-IE
Recirculation Line
HOV Pump Manifold Enclosure-3 HOV
31B 32B
Close Close Close Close

BV-2020
BV-2019 BV-2017
Close
HOV HOV
31C 32C
Open Open Close

From Jetty
BV-2015
DPI
P32 LOCAL
SS
BV-2013
P32 REMOTE
DPT
Close
P32 ON
Open XL
P-2012-A21A-10"-IE
P32
OFF
BV-2012 PB NOTES:-
P32 ------------------------
NC
------------------------
BV-2023
P-32 M
------------------------
P-2014-A21A-4"-IE
BV-2007
BV-2011
Close
Close
Close
HOV ------------------------
P32A ------------------------
------------------------
Open
PA PT DRAWING / DOCUMENT REVIEW
P32A P32A
REQUIRED
HOV
P32A A2 - APPROVED WITH COMMENTS A5 - FOR INFORMATION ONLY
Close A3 - NOT APPROVED
4"
HOV order / contract requirements and also from errors in this drawing / document.
P32B
---------------------
Date: Discipline: ----------------------
----------------------
Enclosure-3(TLF Area) FORAPPROVAL

Client
- - - - -
- - - - -
501
Sakar II
Near Ellisbridge
Ahmedabad,380006
- - - - -
- - - - -
India
T +91(0) 79 2657 5550
ITT - Intra Enclosure from One Tank to One Tank by TLF Pump
F +91(0) 79 2657 5558 JBP AKS

COPYRIGHT
& Recirculation Line Intra Enclosure (Enclosure-3)
- - - - -
- - - - -
Hot Oil Generation
Operation Mode : TLF Area Notes:-
One Tank to TLF Area (Enclosure-3) 1. All valves shall be either in open or close mode as per requirement
Hot Oil Generation of lineup and operation logic sequence.
TI PI LI <LL
T31 T31A T31 valve with same tag number & with future provision of motors,
GBV-1901
GV-1902
HOS-1901-A14A-3"-IH
Not Active Actuators,Limit switches respectively.
TCV TE/TI LS PT LT
T31
T31C
HOV
GV-1901
T31A Close
Close
P-1911-A21A-12"-IE
HOV
4" T-31 T31D
HOS-1904-A14A-2"-IH
GV-1903 Enclosure-3
HOR-1906-A14A-2"-IH Open
(Tank farm Area) HOV TAG NUMBER
3"x2" GV-1904 HOV AAAA SIZE
HOS-1903-A14A-3"-IH HOV HOV 31B 4"
3"x2" GV-1905 T31E HOV 31C 12"
HOR-1905-A14A-3"-IH
GV-1906 Selective
BV-1914
Open
<LL PI
T31B
PT
T31B
HOV DPI
AAAA P31
LOCAL
SS
BV-2009
P31 REMOTE
Close DPT
Close
Pump Manifold Enclosure-3 P31
ON
Open P-2005-A21A-10"-IE XL
P31
BV-2008 OFF
PB
P31
P-31 M
NC
PA PT
BV-2022 P31A P31A
Close
BV-2007
Close
HOV
P31A
Close
4"
P-2007-A21A-4"-IE
BV-2010
Close
Open
HOV
P31B
P-2006-A21A-6"-IE

Future Provision
P-2010-A21A-6"-IE
3"x6"
NOTES:-
------------------------
P-2010-A21A-3"-IE PG
2102A
PG
2101A
------------------------
------------------------
P-2101-A21A-3"-IE
DPG
2102A
------------------------
DPG
2101A ------------------------
------------------------

BC FM BC FM
2102A 2102A 2101A 2101A REQUIRED
FCV FCV A2 - APPROVED WITH COMMENTS A5 - FOR INFORMATION ONLY

2102A 2101A
Open
Open
A3 - NOT APPROVED
Not Active
LSH LSH This review and approval does not relieve supplier / contractor / sub-contractor from full compliance with purchase
2102A 2101A order / contract requirements and also from errors in this drawing / document.

---------------------
ES Tanker ES Tanker
Date: Discipline: ----------------------
2102 Bay-02 2101 Bay-01 ----------------------
FORAPPROVAL
Client
- - - - -
- - - - -
501
Sakar II
Near Ellisbridge
Ahmedabad,380006
- - - - -
- - - - -
India
T +91(0) 79 2657 5550
TLF Area
F +91(0) 79 2657 5558 JBP AKS

COPYRIGHT
One Tank to TLF Area (Enclosure-3)
- - - - -
- - - - -
Notes:- Operation Mode : TLF Area
1. All valves shall be either in open or close mode as per requirement Multiple Tanks to TLF Area (Enclosure-3) Option-1 Hot Oil Generation
2. Presently all BVs & HOVs are considered as manually operated Hot Oil Generation
Actuators,Limit switches respectively. T31 T31A T31 T32 T32A T32
GBV-1901
GBV-1902
GV-1902
GV-1931
HOS-1901-A14A-3"-IH
HOS-1901-A14A-3"-IH
T31 T32
T31 T31 T31A T31 HOV T32 T32 T32A T32 HOV
T31C T32C
HOV HOV
GV-1901
GV-1932
T31A Close T32A Close
Close Close
P-1911-A21A-12"-IE
P-1916-A21A-12"-IE
HOV HOV
4" T-31 T31D 4" T-32 T32D
HOS-1904-A14A-2"-IH HOS-1908-A14A-2"-IH
HOR-1906-A14A-2"-IH Open HOR-1910-A14A-2"-IH Open
3"x2" GV-1904 3"x2" GV-1917
3"x2" GV-1905 T31E 3"x2" GV-1918 T32E
HOR-1905-A14A-3"-IH HOR-1909-A14A-3"-IH
GV-1906 GV-1919
BV-1914
BV-1918
Selective Selective <LL
PI <LL
Open
Open
PI
T31B T32B
PT PT
T31B T32B
HOV Pump Manifold Enclosure-3 HOV

31B 32B
Close Close Close Close
BV-2020
BV-2019 BV-2017
Close
HOV HOV
31C 32C
DPI
P31 Close
Open Open
From Jetty
BV-2009
DPT BV-2015
Close
P31
P-2005-A21A-10"-IE Open
BV-2008
NC
P-31 M BV-2022 HOV TAG NUMBER

Close
BV-2007
BV-2011
AAAA BBBB SIZE
Close
Close
PB
31B 32B 4"
P31
ON
PA PT XL
P31A P31A P31
OFF
HOV LOCAL
SS
P31A
P31 REMOTE
BV-2010
Close
4"
Open
HOV
P31B
P-2006-A21A-6"-IE
Enclosure-3 (TLF Area) NOTES:-

Future Provision
P-2010-A21A-6"-IE ------------------------
3"x6"
------------------------
PG PG ------------------------
P-2010-A21A-3"-IE
2102A 2101A
------------------------
P-2101-A21A-3"-IE
DPG ------------------------
2102A
DPG
2101A ------------------------


REQUIRED
BC FM BC FM
2102A 2102A 2101A 2101A
FCV FCV
2102A 2101A A3 - NOT APPROVED
Open
Open
Not Active This review and approval does not relieve supplier / contractor / sub-contractor from full compliance with purchase
LSH LSH order / contract requirements and also from errors in this drawing / document.
2102A 2101A Reviewed By: Signature : ---------------------

---------------------
Date: Discipline: ----------------------
ES Tanker ES Tanker ----------------------
2102 Bay-02 2101 Bay-01

FORAPPROVAL
Client
- - - - -
- - - - -
501
Sakar II
Near Ellisbridge
Ahmedabad,380006
- - - - -
- - - - -
India
T +91(0) 79 2657 5550
TLF Area
F +91(0) 79 2657 5558 JBP AKS

COPYRIGHT
Multiple Tanks to TLF Area (Enclosure-3) Option-1
- - - - -
- - - - -
Multiple Tanks to TLF Area (Enclosure-3) Option-2 1. All valves shall be either in open or close mode as per requirement
Hot Oil Generation
Hot Oil Generation 2. Presently all BVs & HOVs are considered as manually operated
TI PI LI <LL TI PI LI <LL Actuators,Limit switches respectively.
T31 T31A T31 T32 T32A T32
GBV-1901
GBV-1902
GV-1902
GV-1931
HOS-1901-A14A-3"-IH
HOS-1901-A14A-3"-IH
T31 T32
T31 T31 T31A T31 HOV T32 T32 T32A T32 HOV
T31C T32C
HOV HOV
GV-1901
GV-1932
T31A Open T32A Open
Close Close
P-1911-A21A-12"-IE
P-1916-A21A-12"-IE
HOV HOV
4" T-31 T31D 4" T-32 T32D
HOS-1904-A14A-2"-IH HOS-1908-A14A-2"-IH
HOR-1906-A14A-2"-IH Close HOR-1910-A14A-2"-IH Close
3"x2" GV-1904 3"x2" GV-1917
3"x2" GV-1905 T31E 3"x2" GV-1918 T32E
HOR-1905-A14A-3"-IH HOR-1909-A14A-3"-IH
GV-1906 Close GV-1919 Close
<LL
BV-1914
BV-1918
<LL PI
Open
Open
PI T32B
T31B HOV TAG NUMBER
AAAA BBBB SIZE
PT 31B 32B 4"
PT T32B 31C 32C 12"
T31B Pump Manifold Enclosure-3
Pump Manifold Enclosure-3 HOV
DPI HOV DPI BBBB
P31 AAAA P32
LOCAL LOCAL
SS SS Close
BV-2009
BV-2013
DPT Close DPT
Close
Close
P31 REMOTE P32 REMOTE
P31 P32
ON P-2005-A21A-10"-IE Open ON P-2012-A21A-10"-IE Open
XL XL
P31 BV-2008 P32 BV-2012
OFF OFF
PB NC PB P-2014-A21A-4"-IE NC
P31 P32
BV-2022 BV-2023
BV-2007
BV-2011
Close Close
M P-31 M P-32
Close
Close
P-2007-A21A-4"-IE
P-2013-A21A-6"-IE
PA PT PA PT
P31A P31A P32A P32A
HOV HOV
P31A P32A
BV-2010
BV-2014
Close
Close
Close Close
4" 4"
Open
Open
HOV HOV
P31B P32B
NC P-2019-A21A-6"-IE NC
P-2006-A21A-6"-IE BV-2024 BV-2025 P-2006-A21A-6"-IE

Close Close
Enclosure-3 (TLF Area) Enclosure-3 (TLF Area)

Future Provision Future Provision
P-2010-A21A-6"-IE P-2017-A21A-6"-IE NOTES:-
3"x6" 3"x6" ------------------------
------------------------
PG PG PG PG
P-2010-A21A-3"-IE
P-2017-A21A-3"-IE
2102A 2101A 2102B 2101B

------------------------
P-2101-A21A-3"-IE
P-2104-A21A-3"-IE
------------------------
DPG DPG DPG DPG ------------------------
2102A 2101A 2102B 2101B
------------------------

BC FM BC FM BC FM BC FM A1 - APPROVED A4 - ADDITIONAL INFORMATION

REQUIRED
2102A 2102A 2101A 2101A 2102B 2102B 2101B 2101B
FCV FCV FCV FCV
2102A 2101A 2102B 2101B
Open
Open
Open
Open
A3 - NOT APPROVED

LSH LSH LSH LSH order / contract requirements and also from errors in this drawing / document.
2102A 2101A 2102B 2101B
---------------------
ES Tanker ES Tanker ES Tanker ES Tanker Date:

----------------------
Discipline: ----------------------
2102 Bay-02 2101 Bay-01 2102 Bay-02 2101 Bay-01

FORAPPROVAL
Client
- - - - -
- - - - -
501
Sakar II
Near Ellisbridge
Ahmedabad,380006
- - - - -
- - - - -
India
T +91(0) 79 2657 5550
TLF Area
F +91(0) 79 2657 5558 JBP AKS

COPYRIGHT
Multiple Tanks to TLF Area (Enclosure-3) Option-2
- - - - -
- - - - -
Single Tank To TLF Area Utilizing P-31/P-32 Delivery Inter Connection Line (Option-3) 1. All valves shall be either in open or close mode as per requirement
Hot Oil Generation of lineup and operation logic sequence.
Hot Oil Generation
TI PI LI <LL TI PI LI <LL Actuators,Limit switches respectively.
T31 T31A T31 T32 T32A T32
GBV-1901
GBV-1902
GV-1902
GV-1931
HOS-1901-A14A-3"-IH
HOS-1901-A14A-3"-IH
T31 T32
T31 T31 T31A T31 T32 T32 T32A T32
HOV HOV
T31C T32C
HOV HOV
GV-1901
GV-1932
T31A Open T32A Close
Close Close
P-1911-A21A-12"-IE
P-1916-A21A-12"-IE
HOV HOV
4" T-31 T31D 4" T-32 T32D
HOS-1904-A14A-2"-IH HOS-1908-A14A-2"-IH
HOR-1906-A14A-2"-IH Close HOR-1910-A14A-2"-IH Close
3"x2" GV-1904 3"x2" GV-1917
3"x2" GV-1905 T31E 3"x2" GV-1918 T32E
HOR-1905-A14A-3"-IH HOR-1909-A14A-3"-IH
GV-1906 Close GV-1919 Close
<LL
BV-1914
BV-1918
<LL PI
Close
Open
PI T32B
T31B HOV TAG NUMBER
AAAA BBBB SIZE
PT 31B 32B 4"
PT T32B 31C 32C 12"
T31B Pump Manifold Enclosure-3
Pump Manifold Enclosure-3 HOV
DPI HOV BBBB
DPI
P31 AAAA P32
LOCAL LOCAL
SS SS Close
BV-2009
BV-2013
DPT Close DPT
Close
Close
P31 REMOTE P32 REMOTE
P31 P32
ON P-2005-A21A-10"-IE Open ON P-2012-A21A-10"-IE Close
XL XL
P31 BV-2008 P32 BV-2012
OFF OFF
PB P-2007-A21A-4"-IE NC PB P-2014-A21A-4"-IE NC
P31 P32
BV-2022 BV-2023
BV-2007
BV-2011
Close Close
P-31 P-32
Close
Close
M M
P-2013-A21A-6"-IE
PA PT PA PT
P31A P31A P32A P32A
HOV HOV
P31A P32A
BV-2010
BV-2014
Close
Close
Close Close
4" 4"
Close
Open
HOV HOV
P31B P32B
Open P-2019-A21A-6"-IE Open
P-2006-A21A-6"-IE BV-2024 BV-2025 P-2006-A21A-6"-IE
Enclosure-3 (TLF Area) Enclosure-3 (TLF Area)

Future Provision Future Provision
P-2010-A21A-6"-IE P-2017-A21A-6"-IE
NOTES:-
3"x6" 3"x6"
------------------------
PG PG PG PG ------------------------
P-2010-A21A-3"-IE
P-2017-A21A-3"-IE
2102A 2101A 2102B 2101B

------------------------
P-2101-A21A-3"-IE
P-2104-A21A-3"-IE
------------------------
DPG DPG DPG DPG
2102A 2101A 2102B 2101B ------------------------
------------------------

BC FM BC FM BC FM BC FM A1 - APPROVED A4 - ADDITIONAL INFORMATION
2102A 2102A 2101A 2101A 2102B 2102B 2101B 2101B REQUIRED
FCV FCV FCV FCV A2 - APPROVED WITH COMMENTS A5 - FOR INFORMATION ONLY
2102A 2101A 2102B 2101B
Open
Open
Open
Open
A3 - NOT APPROVED
LSH LSH LSH LSH
2102A 2101A 2102B 2101B order / contract requirements and also from errors in this drawing / document.

ES Tanker ES Tanker ES Tanker ES Tanker ---------------------
2102 Bay-02 2101 Bay-01 2102 Bay-02 2101 Bay-01 Date:

----------------------
Discipline: ----------------------
FORAPPROVAL
Client
- - - - -
- - - - -
501
Sakar II
Near Ellisbridge
Ahmedabad,380006
- - - - -
- - - - -
India
T +91(0) 79 2657 5550
Single Tank To TLF Area Utilizing P-31/P-32 Delivery
F +91(0) 79 2657 5558 JBP AKS

COPYRIGHT
Inter Connection Line (Option-3)
- - - - -
- - - - -
Project Liquid Terminal at Kattupalli Port – Phase - 1
Project No. 372479
Originating Company Mott MacDonald
Document Title Cause and Effect Diagram
Document Number 372479
Document Revision B
Document Status APR
Document type Report
Originator / Author DJM
Issue Date 4/4/2019
B 4/4/2019 Issued for Engineering DJM HRS BAD

A 22/03/2019 Issued for Engineering DJM HRS BAD
Rev # Issue Date Description/Reason for Change Originator Reviewer Approver
red signal,Manual Action to

Alarm in DCS & hooter will

be triggered in field with

Motor Oprated Valve
Motor Oprated Valve
Motor Oprated Valve
Motor Oprated Valve
Flow Control Valve
Flow Control Valve
Flow Control Valve
Flow Control Valve

Description
be taken
be taken
be taken
be taken
Pump
Pump
Enclosure - 3
Effect
Control Room Hooter

Shall be Close
Shall be Close
Shall be Close
Shall be Close
Shall be Close
Shall be Open
Shall be Open
Shall be Open
Pump House Hooter

Shall Stop
Shall Stop
Action
Jetty Hooter
TLF Hooter
Siren
FCV- FCV- FCV- FCV-
Cause Tag No. P-31 P-32 MOV T31 MOV T32 MOV T31 MOV T32
2101A 2101B 2102A 2102B
Sr.No. Description Tag No. Setpoint Location
DCS / PLC
Tank Farm
1 Level Switch LS-T031 HH Of tank Level T-031 X X
2 Level Switch LS-T032 HH Of tank Level T-032 X X
3 Level Transmitter High - High LT/LI-T031 HH Of tank Level T-031 X X
4 Level Transmitter High - High LT/LI-T032 HH Of tank Level T-032 X X
5 Level Transmitter Low - Low LT/LI-T031 LL Of Tank Level T-031 X X X X
6 Level Transmitter Low - Low LT/LI-T032 LL Of Tank Level T-032 X X X X

HH Of tank
7 Temparature Transmitter High - High TT-T31 T-031 X X
Temparature
HH Of tank
8 Temparature Transmitter High - High TT-T32 T-032 X X
Temparature
LL Of Tank
9 Temparature Transmitter Low - Low TT-T31 T-031 X X
Temparature
LL Of Tank
10 Temparature Transmitter Low - Low TT-T32 T-032 X X
Temparature
11 Manual Call point MCP-03-01 - - X
Pump House
12 Emergency Push Button XS_01 - - X X X X X X X X X
TLF
14 Level Switch LSH-2101A HH Of tank Level Bay-01 X
15 Level Switch LSH-2101B HH Of tank Level Bay-01 X
16 Level Switch LSH-2102A HH Of tank Level Bay-02 X
17 Level Switch LSH-2102B HH Of tank Level Bay-02 X
18 Flow meter BC 2101A/B No Flow Bay-01 X X
19 Flow meter BC 2102A/B No Flow Bay-02 X X
20 Emergency Push Button XS_02 - - X X X X X X X X X
Master ESD - Control Room
22 Control Room- Master ESD XS_01 - - X X X X X X X X X X X

Notes:
1) MCP - Manual Call Point,LPBS-Local Push Button Station
2) TLF - Tanker Loading Facility.
3) ESD - Emergency Shutdown.
4) All set points and alarm limits may be revised based on actual performance parameters.
5) Cause and Effect related with Maintenance schedule for individual Tank or Enclosure will be finalized along with AKPPL.
6) In case of the Radar or Vibrating Level High High, the Corresponding Pump House hooter to be ON and Control room Hooter to be ON.
7) In case of the Jetty ESD operated, corresponding Jetty Hooter to be On (with strobe flash lights) & Control room hooter to be ON, In case of the Pump house lined up, the corresponding Pump House Hooter to be On.
8) In case of the the Pump House ESD activated, the corresponding Pump House Hooter to be ON and Control Room & TLF Hooter to be ON.
9) HH value for LS shall be finalised after tank liquid level calibration.
10) Jetty hooter shall be activated on pressing of emergency push button during Export and Import operation only.
11) TLF hooter shall be activated on pressing of emergency push button during TLF operation only.
12) The ESD of pump/motor shall be located LPBS of respective pump/motor.
13) Green color highlighted consider in future Scope.
INSTRUCTION MANUAL
FOR
THERMIC FLUID HEATER
(OIL FIRED)
MODEL: - TSH-800
1 TSH – 800
CONTENTS
SECTION 1 : INSTALLATION MANUAL
SECTION 2 : OPERATION MANUAL
SECTION 3 : THERMIC FLUID CHARACTERISTICS &

PUMP FLOW DISRTIBUTION
SECTION 4 : MAINTENANCE AND SPARES
2 TSH – 800
SECTION I
INSTALLATION MANUAL
FOR
(OIL - FIRED )
3 TSH – 800
: INDEX:
CHAPTER 1. INTRODUCTION …
a. CORPORATE PROFILE ..
CHAPTER 2. TECHNICAL SPECIFICATION …
CHAPTER 3. DO’S AND DON’TS FOR T.F.H. INSTALLATION
CHAPTER 4. TRANSPORTATION …
a. UNLOADING ..
b. RECEIVING AND INSPECTION ..
c. STORAGE ..
d. FOUNDATIONS ..
e. HANDLING ..
f. GROUTING AND LEVELLING ..
CHAPTER. 5. HEATER ROOM …

a. THERMIC FLUID CIRCULATING PUMP ..
b. COMBINED DEAERATOR & EXPANSION TANK ..
a. SEPARATE DEAERATOR TANK ..
b. SEPARATE EXPANSION TANK ..
c. COMPARISION BETWEEN COMBINED D & E TANK ..
CHAPTER. 6. UTILISATION CIRCUIT …

a. PNEUMATIC TESTING OF PIPELINES ..
CHAPTER. 7. FUEL OIL SUPPLY …

a. TFH WORKING ON LDO ..
b. THF WORKING ON FO ..
a. ELECTRICAL HEATING ..
b. STEAM HEATING ..
c. FURNACE OIL (FO) STORAGE FORMALITIES ..
CHAPTER. 8. DRAUGHT SYSTEM ...

a. CHIMNEY (STACK) ..
b. FLUE GAS DUCTING ..
c. USING EXISISTING OR COMMON CHIMNEY ..
d. CHIMNEY – DIA / HEIGHT CALCULATION ..
e. DO’S AND DON’TS FOR CHIMNEY ..
CHAPTER. 9. ELECTRICAL SYSTEM …

a. EARTHING OF THE EQUIPMENT ..
b. DO’S AND DON’TS FOR ELECTRICAL SYSTEMS ..
CHAPTER. 10. COMMISSIONING OF THE SYSTEM …

a. WARMING UP THE SYSTEM ..
4 TSH – 800
CHAPTER: 1
 INTRODUCTION
The ‘THERMOTECH’ liquid phase heating system essentially comprises of fully automatic packaged
Oil / Gas fired Thermic Fluid Heater available in Horizontal & Vertical models, where in thermic
fluid can be heated upto 3000C at near atmospheric pressure. The hot thermic fluid is circulated
through appropriate heat exchanger in the users equipment circuit, through a combined De-
aerator and expansion tank, which effectively removes any liberated gases to prevent cavitation
in the pump and accommodates expansion of thermic fluid oil.
This Manual is prepared with a view to.
 Assist you in making ideal installation.

 Assist you in understanding construction, function and operation of Thermic Fluid
Heater.
 Assist you in starting and stopping the Thermic Fluid Heater.
 Proper guidance on routine maintenance repair and fault finding and setting it right.
The manual is design in different section deals with Installation, Operation, Maintenance, and
Fault finding etc. for smooth operation of unit.
In addition to this our Service Engineers are always available to guide you in proper installation of
Thermic Fluid Heater and to help in solving any operating or maintenance problem, and also we
have Franchise all over country for assistance to you.
5 TSH – 800
COMPANY PROFILE – THERMOTECH SYSTEMS LIMITED
We introduce ourselves as a leading manufacturer of process heating equipment’s & turnkey

industrial solutions, with manufacturing facilities in Gujarat & Marketing, service network across
India with offices in Delhi, Mumbai, Indore, Chennai, Bangalore, Hyderabad, Calcutta, Rajasthan,
etc & abroad with representative in Turkey, UAE, Srilanka, Bangladesh, Etc…..
We had exported to countries like Srilanka, Bangladesh, Nepal, Kenya, Nigeria, UAE, Saudi
Arabia, New Zealand, Turkey, etc.
We feel pleasure in introducing our company THERMOTECH SYSTEMS LIMITED, a leading

engineering company steered by technology & values in core.
OUR VISION
To be leaders in providing solutions for PROCESS HEATING & ENGINEERING through consistent
quality products & complete customer satisfaction.
THE PRODUCTS
Thermotech, an eco-energy company is one of the few companies in the world that
offers integrated solution in energy & ecosystem management. Thermotech is a
solution provider for complete process heating systems & its ancillaries.
THERMOTECH’S wide range of heating solution envelop:
1. Thermic Fluid Heater : Range up to 15 M Kcal/hr
2. Hot Water / Air Generator : Range Up to 10 M Kcal/hr
3. Air Heaters : Range up to 4 M Kcal/hr
Fuel For Above Systems: OIL / GAS / SOLID FUEL
MAJOR ACHIEVEMENTS & CREDENTIALS.
3.5 M Kcal/hr x 4 Nos. : Dual Gas Fired Thermic Heater by GPS-DUBAI for Ukraine Gas
Treatment Plant – Hazardous Zone
6.0 M Kcal/hr x 3 Nos. : Diesel fired TFH for DNO – Iraq project.
We had commissioned 10 M Kcal/hr Thermic Heater – fully automatic Coal Fired in

Turkey, which is First of its kind to be manufactured by any Indian Company other than
Thermax.
We had executed orders up to 12 M Kcal/hr Thermic Fluid Heater.

The customer base of more than 1500 in India & abroad.
6 TSH – 800
Thermotech has tie-up with consultants for detail engineering of specialized projects, pipeline
engineering & major structural work of complete system.
CORPORATE PROFILE
The motivating power behind the phenomenal success of the Company since its inceptions is a
sole motto to provide a wide range of quality products maintenance free, which are manufactured
with the latest state of the art technology.
Guided by the dedicated philosophy of technical perfection, Thermotech Systems

Limited has earned nationwide high reputation for its exclusively superior quality
products. Needless to say that this well pursued motto has made the Company a
distinctly outstanding entity in a highly competitive field.
THE COMPANY TODAY
Today, the Company by its continuous quality encroachment had earned a

recognition, which ensures quality management services & hence an improved
product quality. Thermotech enjoys a wide spread satisfied client base of around 1500,
also that the company’s products are being exported to neighboring countries. All
the product are very well received and commands high rate of preference in the
market.
The Company is promoted and backed up by a team of highly qualified and experienced
technocrats and professionals fully devoted to their respective field- Production, Marketing,
Administration etc., besides, it is heavily banking on its trump card, a prompt and efficient after
sales service. All these put to gather have led us to what we are today.
APPLICATION OF THERMOTECH PRODUCTS
Thermotech’s products are widely used in following industries:
■ CHEMICALS ■ PLYWOOD ■ SOLAR

■ TEXTILE ■ PAINT ■ FOOD
■ GARMENTS ■ RUBBER ■ DISTILLERY
■ LEATHER ■ PAPER ■ AUTO

■ CERAMICS ■ MARINE ■ TANK HEATING
7 TSH – 800
TECHNICAL SPECIFICATION OF THERMIC FLUID HEATER
Heater Model TSH-800

Heater Configuration Horizontal
Heating Requirement 0.8 M Kcal/hr.
Heater Efficiency, Calculated 91 % on NCV as per BS 845
Burner Heat Release 0.9 M Kcal/hr
Combustion Air Required 1300 Kg/hr
Stack Flow Rate 1850 M3/hr
Required Stack Diameter x Stack ø0.35 m x 31 m for 1 No. 0.8M TFH
Height
Flue Gas Outlet Temp. @ Coil Outlet 40 °C above Forward Temp.
Flue Gas Outlet Temp. @ TF outlet of 175 – 185 °C
250 C
Heater Surface Area of Coils 46 m²
Coil Holdup of Thermic Oil 0.6 M3
Total Thermic Oil Holdup (Process+ 23 M3 (Assumed)
Pipeline + TFH)
Expansion Tank Capacity 2700 Ltrs
Average Heat Flux Density 17390 kcal/m²hr
Pressure Drop Across Heater 22 mlc (1.6 – 1.8 Kg/cm2)
Pressure Available for Process 60 mlc (4.8 – 5.0 Kg/cm2)
Thermic Pump Flow Rate 66 m³/hr
Thermic Pump Differential Head 82 mlc
Thermic Pump motor required 22.3 KW
Heater Coil Design Temperature / 310 °C / 12.0 barg
Pressure
Design Heater Outlet Temperature 250 °C
Calculated Return Temperature 225 °C @ Load of 0.8 M Kcal/hr
F.D. Fan Capacity & Pressure in MM of 1600 m³/hr & 500 mm WC
WC
F.D. Fan motor 3.7 KW X 2880 RPM
Primary Fuel Furnace Oil (FO)
Fuel Consumption @ 9650 Kcal/nm3 92 nm3/Hr
of NCV (Assumed)
Secondary Fuel High Speed Diesel (HSD)
Fuel Consumption @ 11,500 Kcal/kg of 77 Kg/hr
NCV
Nitrogen Gas Supply (required for Not required for <300 Deg.C operating
Expansion Tank)
Electrical Supply 420/3/50
System Elevation <600 ft. msl
Location of Unit & Heat Exchangers Under Shed Structure - Enclosed
Area of Classification of Unit & Heat General
Exchangers
Unit Instruments Classification Safe Area
Thermic Oil Therminol 55 / equivalent
HSD Pump motor capacity Existing to be used
Total Connected Load in KW 40 KW Appx.
8 TSH – 800
Chapter 3
 DO’S AND DON’TS FOR THERMIC FLUID HEATER INSTALLATION
OIL FIRED THERMIC FLUID HEATER
1. All fuel and thermic fluid piping should be thoroughly be flushed or blown out (
cleaned ) before being connected to the system. This will prevent foreign matter from
blocking or damaging the piping system. Never use second hand pipes and fittings.
2. Use only Cast Steel Globe valves and not Cast Iron valves in the thermic fluid line.
Cast Iron cannot withstand the high temperature.
3. Use raised face flanged in the thermic fluid piping.
4. Use flanged connections with valves only.
5. Use 1/16” thick oil quality gaskets for all flanges in the thermic fluid piping.
6. Do not use elbows and sharp bends in water, fuel oil and thermic fluid lines as far
as possible to reduce frictionless losses. Use Shoe bend and Y bend wherever required to
divert oil flow.
7. Do not use smaller diameter pipes than those specified for the thermic fluid lines, as
this pipe may not be capable of handling the quantity of thermic fluid being circulated
in the process.
8. Do not use screwed connection anywhere in the thermic fluid piping. Use only welded
construction and use a minimum number of flanged joints.
9. Provide a rise of about 3 mm/meter in the thermic fluid outlet piping from the heater
towards the user equipment and a similar slope from the user equipment to the heater in
the return line.
10. Do use expansion bends / bellows in the horizontal plane after every 30 meters of
the straight run of piping or as specified by the expansion bellow manufacturer.
11. Do use vents to let out air and gases at all high points of pipeline. Air is a contaminant
for the thermic fluid at high temperatures.
12. Use drain valves at one or more low points in the installation.
13. Do provide adequate size strainer before the thermic fluid pump in the return line to filter
the thermic fluid.
14. Keep the Expansion Tank vertically above the Deaerator tank as far as possible in case the
Expansion and Deaerator tanks are separate.
15. Make sure that the vent pipe in the expansion tank is free of obstruction and is open to
the atmosphere. It should also prevent entry of water or foreign particles.
9 TSH – 800
16. Select fuel oil storage and service tank of adequate capacity. Consider delivery schedule,
price breaks and adequate oil reserve. Keep in mind the regulations involved. Keep the
fuel oil service tank at the height specified in the manual. Otherwise, there will be
improper flow of oil to the fuel pump. Use as few fitting as possible in the fuel oil line
17. Use MS Black Class “C” pipes and NEVER GI pipes for fuel oil lines as the pipes will get
corroded due to the presence of Sulphur in fuel oil.
18. Use outflow heaters and tracers for furnace oil lines wherever the ambient temperature is
below 25C and lag the pipe lines to reduce heat loss
19. Use chimney of correct cross sectional area as specified in the manual. Never reduce the
diameter as this will pose combustion problems due to frictional resistance offered.
CONSULT SMOKE NUISANCE INSPECTOR WHEREVER THE ACT IS IN FORCE.
20. Never test the heater, piping or any heat exchanger hydraulically. Test them only
Pneumatically with an air pressure of about 6 kg / cm2 ( 90 psig ). Testing can be
done with an inert gas like Nitrogen also. Ensure that water does not mix with thermic
fluid.
21. Lag the lines and equipment after they have been tested completely.
22. Do get the Thermic Fluid tested and verified before filling it in the system and ensure that
its properties are as specified by the manufacturer.
10 TSH – 800
Chapter 4
 TRANSPORTATION
The THERMIC FLUID HEATER dispatched from our factory is normally unpacked. During
transportation, care should be taken to keep the unit always in vertical position. The units
should never be turned to horizontal position.
a. UNLOADING.
The unit should be lifted for loading and unloading or shifting from one position to
another, by means of lifting hooks provided on the top plate of the unit only. If lifting
tackles are not available, rollers should be placed beneath the chassis of the unit and it
should be guided to the position of installation. Under no circumstances, should the weight
of the unit, be borne on the control panel, or other structural members.
The Thermic Fluid Heater main unit and other accessories should be lifted for loading,
unloading or shifting from one place to another, only by means of lifting hooks provided
on the top of the unit / case by crane or gantry.
If lifting tackles are not available, rollers, wooden slabs or some skid should be placed
beneath the frame of the Thermic Fluid Heater and cases and it should be carefully guided
for unloading and shifting, Under no circumstance the Thermic Fluid Heater and
accessories should be dropped or turned to any other position other then marked on the
cases / equipment.
It is advisable to unload the Thermic Fluid Heater as close as possible to the Heater Room
preferably just out side the main door of the room, on some skids or pipes, so that
pushing the Thermic Fluid Heater in the heater room for positioning it on the foundation is
easier. The soil at the place of unloading should be hard enough to bear the weight of the
Thermic Fluid Heater to prevent it from sinking the approach road to the heater house
should also be made of hard ground.
b. INSPECTION.
On receipt of Thermic Fluid Heater at site please, check that all items are as per delivery
challan have been received. For ease of checking one set of PACKING SLIP is sent along
with the transport copy of Invoice with truck driver.
By care full inspection, determine weather any damage / loss has occurred in transit in
spite of proper checking and loading of equipment and accessories at our works before
dispatch.
Thermotech office / Insurance co-office must be informed / notified immediately in case of

any lost or undelivered parts or transit damage for Corrective action as the case may be.
c. STORAGE.
If the installation of Thermic Fluid Heater is delayed and storage is made open to sky,
provide reasonable weather protection as detected by the climate and period of exposure.
Please note that the packing case life is maximum 3 Months.
11 TSH – 800
Electrical Components, Motors, bearings should be tightly covered by polythene or
laminated cloth to prevent ingress of water / moisture and if the equipment or its parts
are to be stored outdoor for any length of time, it should be completely covered with a
tarpaulin. Periodically the unit should be inspected to make sure no damage, such as
corrosion is occurring.
When a equipment is stored or installed within a building under construction, the entrance
of the dirt and construction material to the Motors, Fan, Bruner, Electrical components,
should be prevented. The critical components should be stored in covered portion of
building.
When ever an assembled rotating equipment such as fan, pump, gear box, is to remain in
idle condition for any extended number of days, extra precaution should be taken to avoid
rusting and jamming of the bearing the equipment can be rotated manually ones in a
week in the following sequence to prevent jamming.
180 degrees then 90 degrees, then 180 degrees.
d. FOUNADATION.
A rigid level foundation is vitally essential for smooth, quite operation, good performance
and low maintenance cost of the TFH and other equipment. An improperly constructed or
inadequate foundation may cause vibration and possible misalignment of the equipment.
Special attention must be given to insure a permanently solid support for the rotating
equipment and bearing supports.
ALL FOUNDATIONS MUST BE FLAT, LEVEL AND RIGID
The height of any foundation should be minimum 100 mm above the finish floor level
unless otherwise specified in foundation drawing of your heater. This is to prevent the
structure of equipment from spilled water, oil, corrosive chemicals etc. which may corrode
and reduce the life of equipment and foundation bolts.
An allowance must be made for a minimum of (25mm) one inch of shimming and grouting
when determining the top surface of the foundation.
Generally speaking, concrete foundation should have a minimum weight of six to eight
times the total weight of the equipment. Consult your Civil engineering expert for
designing the foundations based on soil condition of your plant and live weight on the
foundation.
The foundation layout and floor loading for designing foundations of various equipments
are given in foundation details / general arrangement drawing of the TFH.
PREFER THE FOUNDATION WORK SHOULD BE COMPLETED

PRIOR TO ARRIVAL OF TFH TO SAVE TIME IN INSTALLATION.
e. HANDLING.
If a hoist/crane is employed in handling the equipments, extreme care should be taken to

prevent distortion or damage to any part of the equipment. The handling of large sized
equipment will require extra precaution in this respect. Use lifting hooks or eyes where
provided. It is advisable to use a spreader type sling when handling equipments.
12 TSH – 800
TFH requires careful assembly and alignment at site. Each equipment should be moved to
its foundation as a unit, with care being taken to prevent distortion of the equipment.
After the foundation holes in the unit are lined up with anchor bolts in the foundation, the
equipment should be lowered over the anchor bolts.
Since the TFH and fan is mounted on separate foundations much care and attention to
alignment is required to match their inlets and outlets.
Prior to placing the TFH and fan on the foundation, the location of anchor bolts should be
checked against the drawing to ensure that these bolts are placed correctly. During
erection all parts should be carefully checked to see that they physically match and are in
a correct position as indicated in the general arrangement drawing.
f. GROUTING AND LEVELING
For preventing the rotating equipment from vibration etc. proper care needs to be taken
on selection on anchor bolts, its size, shape and length and on proper leveling.
Anchor bolts in concrete should be L or T-shaped, and should be placed in pipe or sheet
metal sleeves approximately in to (50mm) 2” larger diameter then the anchor bolts to
allow for adjusting the bolts in case they move slightly when concrete is poured.
Where some adjustment is required to level the unit, leveling should be done taking top
plate and heater shell as reference.
For leveling large area shims should be placed under the heater frame/pedestal before
tightening the anchor bolts. Distortion of the equipment may occur when the bolts are not
tightened equally or if short thick shims providing only limited surface contact are used.
13 TSH – 800
Chapter-5
a. HEATER ROOM.
The heater being compact and light, can be installed anywhere in the plant. However, if a
separate room is planned, the minimum space required is indicated in General
Arrangement with Terminal points and Foundation details drawing. A RCC base slab of
about 100 mm (4”) above FFL is shown on which the unit rests. This platform prevents
any oil or water drippage going underneath the unit. The unit and its surroundings can be
kept clean if the installation is done on a raised slab or platform, the dimension ‘E’ of
which is shown in drawing. The slab must be cast out of a non- combustible material like
concrete and properly levelled.
If the unit is viewed from the front, the left hand side clearance, as shown, is 1000 mm
(3.3’). (A minimum clearance of 1000mm (3.3’) is required for any machinery as per
FACTORY ACT.). The front clearance should be at least 1200mm (4’) to allow adequate
room for movement, operation and maintenance.
The vertical clearance above the unit, required for coil removal is also indicated. ‘H” as
indicated in the drawing stands for the distance from the room ceiling to the point of
maximum height to which the lifting hook can be raised. This decision shall, therefore,
depend on the type and make of the lifting device proposed to be installed. If sufficient
height in this room is not available, shifting the entire unit to a place with adequate
vertical clearance may be considered. Coil removal in such a case can be done with the
help of the tripod and a chine pulley block.
Alternatively, a trap door can be provided in the roof and an “I” beam can be fixed above
it for lifting the coil. This however, is an exception. Generally, an “I” beam and a chain
pulley, as shown in the drawing are preferred.
This room should be properly ventilated, preferably by large windows on all sides in order
that the surrounding temperature does not exceed 45c to 50c. For this purpose, it is also
necessary to insulate the chimney inside the room. It is to be noted that in case of
artificial ventilation, extraction of air by exhaust fans is not recommended as this may
create negative pressure in
the room, which can be detrimental to the proper operation of the unit.
Please make sure that while installing the unit, regulations of Fire Insurance Association,
Factory act smoke nuisance act.
a. THERMIC FLUID CIRCULATING PUMP
The Thermic Fluid Heater and Thermic fluid circulating pump should be placed side by
side. The circulating pump should be placed on the same side as close as possible to the
thermic fluid inlet of the unit, so as to minimize pipe length, fittings, friction losses and
pressure drop. While installing the circulating pump please ensure that no part of the fan
is at a distance less than 1mtr (1000 mm ) from any of the wall. In the general
arrangement drawings, the unit and circulating pump are shown mounted on separate
slabs, this slabs must be of a non-combustible material like concrete and properly levelled.
Please note that the circulating pump foundation has to be sturdy to avoid vibrations
during working and for longer life of components of blower fan.
14 TSH – 800
b. COMBINED DEAERATOR AND EXPANSION TANK
The thermic fluid in the complete circuit expands in volume, when it is heated. The
rate of expansion in volume is 7% per 100oC rise in temp. of the thermic fluid, thus the
selection of size of expansion tank depends upon fluid content of total system.
Expansion tank capacity should be minimum 20% of the total volume of oil to be
filled in the system. The deaeration vessel capacity depends upon the flow rate. Its size
can be roughly decided considering 2.5 to 3 m/s fluid velocity at its inlet nozzle.
The standard de-aerator cum expansion tanks supplied is suitable for most of the
standard processes. In case the volumetric expansion of thermic fluid of the system
is more then the higher capacity of expansion tank provided, otherwise a separate
extra tank needed to be incorporated. The thermic fluid also contains some
fractions, which flash off at elevated temperature while commissioning. These are
to be driven out of the system to have proper functioning of the equipment. The
combined expansion and deaerator tank is so designed as to take care of the
expansion of thermic fluid and also to drive away the gases or entrapped air. This
tank should be installed at least 1500mm (5’) above the highest point in the thermic
fluid pipeline. It is also necessary to confirm that the NPSH available at pump
suction is more, by at least 0.5m, than the NPSH required for your pump. Supports
are welded to the tank, with the help of which the tank can be fixed and bolted to the
structure ( refer deaerator drawing for details ).
The drain tank kept on the ground as shown in Drawing No. TS-02 page no. 18, has to be
of a capacity at least equal to the capacity of the combined deaerator and expansion tank.
The drain and overflow from the expansion cum deaerator tank are connected to this tank
as shown in drawing.
While installing the thermic fluid circulating pump, arrangement should be made to install
a small pump for charging the system with thermic fluid, when required. The head and
capacity of this pump will depend on the thermic fluid circuit. It is necessary to have such
an arrangement because it is not advisable to use the thermic fluid circulating pump for
charging thermic fluid in the system.
Thermic fluid returning from the user equipment enters this tank from a side entry and
passes on to the circulating pump. Gases and air are separated from the thermic fluid at
the top of this tank, close to the point of entry of thermic fluid. These gases are let out to
the atmosphere through a pipe connected between the top of the deaerator tank & top of
the expansion tank. In the line leading from the deaerator tank to the circulating pump, a
valve should be provided with the help of which the circulating pump can be easily isolated
from the rest of the system when repairs of the pump are to carried out.
a. SEPARATE DEAERATOR TANK
The deaerator tank, if supplied separately can be installed at any suitable place in the
plant. The expansion tank should be installed at least 600 mm above the highest point in
the thermic fluid pipeline but in no case less than 2000 mm from the floor level. The
deaeration line is connected between the top of the deaerator tank & the top of the
expansion tank. A non-return valve should be incorporated in this line to prevent the
atmospheric air entering the system, which leads to oxidation of the thermic fluid. It is
necessary that the vertical distance between the non-return valve and the top of the
expansion tank is one third of the vertical distance between the top of the expansion tank
& inlet of the deaerator tank. Avoid bends in this line as far as possible. The expansion
pipeline is connected between the bottom of the deaerator tank & the bottom of the
expansion tank. The outlet of the deaerator tank from its side is connected to the inlet of
the thermic fluid circulating pump. The deaerator tank should be lagged to only one third
15 TSH – 800
height of the tank from the top of the tank as the bottom portion is the place where the
thermic fluid cools down before going into the expansion tank.
SEPARATE DEAERATOR TANK IS NEEDED WHEN :-
1. Installation has more than one heater. Common deaerator & expansion tank is not a
good solution, especially if number of heaters operating at any time varies.
2. Hold up of entire system is not known while sizing.
SITE INSTALLATION INSTRUCTION: -
1. Deaerator is to be fitted at ground level & close to suction of pump.

2. Expansion tank sizing is to be done based on system hold up. It can be done by
customer also.
3. Deaerator is to be insulated.
4. Deaeration & expansion lines not to be insulated, to permit cooling.
b. SEPARATE EXPANSION TANK
The average volume coefficient of thermal expansion of mineral oils used as heat transfer
fluids is about 0.00076 per Deg. C. hence, between room temperature and 3000C, a total
expansion by volume of around 20% occurs. It is therefore necessary to make provision
for this increased volume by incorporating an expansion tank. The total volume of tank
should be at least twice the calculated expansion of the total volume of oil. This tank
should be highest point in the circuit and connected to the suction side of the pump
through a U-bend in order to reduce convective currents.
The design of the expansion tank is critical as it is the only equipment in the entire system
where oil surface is exposed to air, thus presenting a major source of risk of oxidation.
The tank should preferably be tall & narrow to present minimum surface area. This area
can then be still further protected by the use of an inert gas blanket such as nitrogen. In
case of such a blanket, it is advisable to seal the tank to maintain a low overpressure
controlled by a pressure relief valve. In normal cases, valves should not be fitted in the
expansion line as accidental closure could have serious consequences.
16 TSH – 800
c. COMPARISION OF COMBINED & SEPARATE DEAERATOR &
EXPANSION TANK
COMBINED D&E TANK SEPARATE D&E TANK

Introduces for product differentiation, no more a Traditional & well proven with installations of
strong USP European makes of Thermic Fluid Heater.
Only deaerator can be supplied. Later,
At sales stage, fluid hold up is not known, hence
customer can decide holdup & make
too early to fix D&E tank size then
expansion tank.
Bulky & heavy Expansion tank lighter
D&E tank sizes are standard for each model, but Only deaerator needed to be standardized
non-standard flow requires special order for each model
In case of one more unit added to an installation New units can be added without any
& existing D&E tank replaced by a common one, if problem. Surges are absent. By adding an
flow is lower than rated, due to one unit being extension tank; expansion capacity can be
shut off, surge through deaerator riser pipe enhanced.
causes overheating in expansion tank.
In multiple unit installations, different levels are Easy to select separate deaerators & a
seen. To solve this, expansion vessels are common expansion tank. Problem of level is
sometimes connected. This causes fluid absent.
overheating & severe oxidation, leading to costly
downtime & fluid replacement
Fluid surface temperature stays low as large
Fast heating up causes oxidation due to high fluid
distance between deaerator & expansion
surface temperature in expansion vessel.
tanks permit cooling.
Even while in normal operation, surface Surface temperature is close to ambient.
temperature is at 60-700C Oxidation is negligible
Fabrication cost is very high, due to complex Lower costs. Can give pricing advantage or
internals. better margins
Must be made by selected vendors Can be made in field, if required
Location recommended above pump, often not Expansion tank can be installed anywhere,
convenient Deaerator on pump suction.
Overflow due to steaming when topping up with Overflow not possible as venting is taken
fluid containing water, fire hazard above the fluid.
Cleaning difficult due to complex construction Easy to clean
Cross flow between heating & cooling circuits
No cross-flow safe
causes overflow, fire hazard
17 TSH – 800
Chapter 6
UTILISATION CIRCUIT.
In order to utilize maximum heat in the user equipment, it is important that complete
circuit is properly designed taking in to consideration the site condition and applications.
This done by our process design section and necessary schematic and layout drawings are
generally prepared and passed to the customer on demand and feed back from plant level.
In order to help the client we undertake complete erection jobs on turnkey basis or
provide facilities for supervision by our experienced erection engineer at extra cost. In
such cases more detailed drawings are made to facilitate working at site. However if you
like to carry out erection of equipment and installation of pipelines by yourselves, we shall
provide all relevant information on request.
We also undertake erection jobs on turnkey basis. If you like to carry out erection of
the equipment and installation of pipelines, etc yourselves, we shall be glad to endow
all the applicable information to you, on request. Some important precautions should be
borne in mind before installation of unit as given in “Do” s and “Don’t”s.
The pneumatic pressure testing of pipelines is carried out after completing the
installation of pipelines.
a. PNUEMATIC TESTING OF PIPELINES
To carry out the pneumatic test, following procedure can be adopted.
1. Blank out suction and outlet points of the circulating pump.
2. Isolate combined expansion cum deaerator tank by blanking inlet and outlet flanges. It
is emphasized here that expansion cum de-aerator tank is not to be subjected to hydraulic
test.
3. Blank out Thermic Fluid Heater inlets and outlets so that the coil is isolated.
4. Close all vent and drain valves.
5. Check all the flanged joints for ring gaskets and clamp the flanges tightly.
After the above points are checked upon, a compressor can be connected to one of
the drain or vent valves with a flexible air hose and the compressor switched on. After
some time, a pressure build up will occur, which can be observed on a separate pressure
gauge which is installed on the line.
In case the pressure fails to build up one should check possible leakage points such as
flanges, vent valves and gland packing of the valves, etc. which are the points for major
leakage. Once these are found to be correct, and yet the pressure fails to build up then
one should look out for a major leakage. If observed minutely, the source of leakage
can be determined easily by a hissing sound of escaping air. The source of leakage
should be repaired after the system is depressurized. Once again pressurise the
system and minor leakages can be determined with the help of soap solution test.
18 TSH – 800
Pressurise the system again and this time check the repaired joints first and also the
other joints afterwards. Maintain the air pressure in the system for at least one hour
with compressor switched off and the air inlet valve closed. The test pressure can be
between 5 to 6 kg/cm2. The pressure drop after one hour should not exceed 10% of the
set pressure. 10% of air pressure drop will not occur in case glands are leak proof. Once
satisfied with the pneumatic test, the balanced out points should be removed and ring
gaskets fitted in the flanged joints. Now the system is ready for filling Thermic Fluid Oil.
19 TSH – 800
Chapter-7
 FUEL OIL SUPPLY.
a. THERMIC FLUID HEATER WORKING ON LDO (LIGHT OIL FUEL).
A Service tank for LDO is erected at a height of not less than 2.4 meters (8’) above the
unit room floor level. LDO from the main storage tank can be pumped to this through a
pipe, either by a hand oil transfer pump or an electrically driven oil transfer pump. Oil
companies can be consulted for the selection of the size of the pipe. In any case, its
diameter should not less than 40 mm (1 ½”) NB. Installation of the main storage tank and
oil service tank must confirm to statutory regulations, as applicable.
The oil service tank should also have various accessories namely a hinged or tight lid, a
vent, a drain with a valve, an overflow and a calibrated level indicator. The outlet pipe of
the tank leading to boiler should have a minimum size of 25 mm (1”). The outlet from the
service tank should be 100 mm (4”) above the bottom level of tank. One mesh type filter
of 80x 80 mesh must be provided just at the outlet of the main storage tank. The unit is
supplied with a separate filter duly fixed at the inlet of the fuel pump.
Recommended capacities of oil service tanks are given in a separate table at the end.
Wherever ambient temperature is below 20c, an outflow heater should be provided in the
tank to heat the out flowing oil to about 30c. For this heater a pipe of about 150 mm (6”)
NB is welded to the tank and the oil flows out from bottom of this heater pipe. An electric
immersion type, single phase, heater with a thermostat is inserted in the pipe and the
thermostat is set at about 35C. Capacity of this heater should be at least 3 KW. The fuel
pump bypass should be connected back to the service tank with a 20 mm (3/4”) pipe.
b. THERMIC FLUID HEATER WORKING ON F.O. (FURANCE OIL).
A horizontal cylindrical furnace oil storage tank with enclosure wall, etc. should be erected
at a minimum distance of 6.1 (21 feet) from the boiler house. The tank could be placed
underground.
TANKS OF CAPACITIES ABOVE 4546 LITERS (1000 GALLONS) MUST

CONFIRM TO STATUTORY REGULATIONS
Oil suppliers should be consulted for the mode of installation and storage of the furnace oil
storage tank. The formalities to be observed for storage of furnace oil given separately.
Oil from this tank should be pumped through a pipe either by a hand oil transfer pump or
by an electrically driven gear oil transfer pump into a furnace oil service tank. The gear
pump installed should have an output capacity of 2000 Liters/hr against 50 psi delivery
pressure. The pump may be installed either inside or outside the boiler house. Oil
companies should be
consulted for selection of the size of the pipe from storage tank to the service
tank. In any case, the diameter of this pipe should not be less than 40 mm (1 ½”) NB.
IT IS IMPORTANT THAT ALL OIL PIPES ARE OF M.S. BLACK CLASS “C” AND NEVER OF G.I.
The Sulphur in the oil eats up the Zinc in the G.I. pipes and chokes the strainers and the
burner nozzle.
20 TSH – 800
The fuel oil service tank should have various accessories namely, a hinged or tight lid, a
vent, a drain with a valve, an overflow and a calibrated level indicator. The outlet should
be about 100 mm (4”) above the bottom level of the tank.
An outflow heater (in the service tank) and line heaters (or heating cords) should be
incorporated to maintain a temperature of 40C throughout the fuel feed pipe. It should be
noted that a strainer or mesh type filter of 40 mesh should be provided in the pipeline
before the outlet of storage tank. Additional filter is fitted separately on the unit. In the
case of units operating continuously for 24 hours, it is suggested that an additional filter
may be provided in the line parallel to the one of the unit, with necessary valves, so that
one filter will always be in operation while the other one can be cleaned and kept ready.
a. ELECTRICAL HEATING.
A pipe of about 150 mm (6”) NB is welded to the tank and the oil supply pipe is taken at
the bottom of this pipe. An electric immersion type single-phase heater with a
thermostatic inserted in pipe. Capacity of this heater depends on the model of the unit
but should be at least 3 KW.
The thermostat is set to about 45C. For details refer Drawing No. 8 See Page no. 39. An
electric heating cord should be used to heat the oil in the pipe from the tank to the boiler.
For pipe lengths of less than 20 feet, heating cords of 220 V, A.C., 2 KW capacities should
be wound. For longer pipes, the cords should be of 3 KW capacity.
b. STEAM HEATING.
An alternative arrangement, in case steam is available, is to tap out a small amount of

steam from the steam main pipeline by a 12.7 mm (1/2”) NB pipe and to connect the pipe
to the heaters steam inlet through a ½” solenoid valve. Supply for the solenoid valve
should be given through a thermostat fitted on the heater. The valve will remain open as
long as the temperature of outgoing oil is less than the present temperature, i.e. 45c. The
outlet of the steam heating coil may be connected to a tracer pipe of 12.7 mm (1/2”) NB
running all along the pipe touching the oil pipelines from the service tank to the fuel filter
on the unit. This will heat the oil in the pipe to the required temperature. A steam trap
should be fitted at the end of tracer pipe. The tracer pipe and the oil pipe then may be
legged to together for better heat transfer to the oil. For details of this type of heating
arrangement, refer Drawing No. TS-09 See Page 40.
As the steam consumption may not be very high, a steam outflow heater is preferable. If
is suggested that heating cords may be used in the bypass line to prevent the fuel oil from
cooling down. The recommended capacities of oil storage tanks and service tanks are
shown in table.
Heating cords may be used in the fuel oil by pass and burner circulation return line to
prevent the fuel oil from cooling down. It should be noted that the fuel pump bypass and
the ball valve and circulation return lines should not be combined.
c. FURANCE OIL STORAGE FORMALITIES.
The Department of Explosive prohibits the storage of furnace oil inside the boiler house, if
it exceeds 1000 gallons. The following procedures may be followed for storage of furnace
oil.
Storage below 4546 liters (1000 Gallons).

21 TSH – 800
No formalities required, if the storage tank is erected outside.
Storage over 4546 liters but less than 45460 liters (10000 gallons).
No Storage License is required but prior approval of the Controller of Explosive should be
obtained. For this purpose, three copies of layout plan showing the proposed tankage
should be sent to the Controller of Explosives of the area in question. They will return one
copy duly signed in token of approval and then only the installation of the tank should be
carried out as per the approved plan.
While preparing the plan for the installation of the tank, the following precautions should
be taken:
1. There should be no structure within 10 feet from the tank.
2. Entire area has to be fenced with 4-½ feet barded wire.
3. The tank has to be installed in an earth pit and the top area should be covered with
thick and 6” high kerbing.
4. There should be no structure within a radius of 15 feet from the fill point on tank
lorry unloading platform.
5. Fill pipeline, suction pipeline, gear rotary or hand operated pump vent Pipe, Dip,
etc. should be clearly shown.
6. In one corner of the plan, the cross-section of the tank should be shown with
fabrication details.
7. In another corner, the site plan of the factory showing the tank and entire Pipeline
should be shown.
8. In case a tank kept above ground, apart from the above regulations, the following
additional measures should be adopted:
The tank should be fitted on a proper pedestal.
An enclosure wall has to be built around the tank, which should be less than 5 feet away
from the tank. The height of such a wall depend on the capacity of the tank. It should be
high so as to contain the entire product in the tank in case the whole product leaks out of
the tank.
There should not be any structure within 10 feet from the enclosure wall.
Tank over 45460 Liters (10000 gallons).
For Storage over 45460 Liters, a storage License should be obtained form the Explosives
Department. For this purpose, an approval should be obtained from the controller of
Explosives as per the details given above. Simultaneously, an application should be made
to the District Magistrate with five copies of the plan for this “No Objection Certificate:
Only after this certificate is obtained, the installation should be carried out as per plan.
22 TSH – 800
The Storage License will be issued after the application is submitted in “ Form D” along
with the original No Objection Certificate, Safety Certificate from the suppliers and the
Storage License Fees.
For your guidance, a model layout plan for the installation of a tank has been attached
(Refer Model Drawing TS-07) which be helpful in preparing the plan.
NOTE:
INSTALLATION CARRIED OUT WITHOUT OBSERVING ANY OF THE FORMALITIES
MENTIONED ABOVE ARE LIABLE FOR PROSECUTION.
23 TSH – 800
Chapter 8
 DRAUGHT SYSTEM
The THERMIC FLUID HEATER is supplied with a suitable Forced Draught combustion air fan
with motor. The fan is erected close to the unit for providing combustion air. The outlet of
this fan is connected to air inlet of outer jacket assembly, which is at the rear end of the
unit. For the units provided with modulation, a damper is provided is provided at fan’s
suction for adjusting the air quantity required for proper combustion.
The Flue gas outlet of the unit, which is at the rear bottom side, is to be connected to
chimney to discharge the product of fuel combustion by properly sized flue gas duct.
The fresh air for combustion is supplied by blower fan ( at the rear end, of the outer jacket
). The air is heated as it passes through the gap between outer and inner jacket before
entering the burner for fuel combustion. The hot flue gases after giving its heat to Thermic
Fluid in unit, get discharged to chimney. This system is called the Forced Draught System.
The FD fan dampers are adjusted during commissioning of TFH, such that the flame is
bright yellow ( for oil ) & the flue gases are almost colourless. The FD fan motor set should
be properly sheltered to protect it against sun, rain, etc.
a. CHIMNEY.
In view of pollution control norms, a tall chimney of suitable diameter and height is
provided to discharge the products of combustion. For sizes, refer Table 9.1. Chimney and
flue gas ducting plays a vital role in TFH performance, hence it should be designed
properly to discharge the products of combustion with minimum resistance and back
pressure in combustion chamber, which affects flame configuration and efficient
combustion of fuel. Guy ropes not shown in the drawing may be used, if the chimney
design calls for it. Chimney of smaller diameter, chimney with more than two bends and
chimney with long cross connections should not be used.
WHEREVER SMOKE NUISANCE REGULATIONS ARE PREVALENT, IT IS

NECESSARY TO CONSULT THE SMOKE NUISANCE INSPECTOR.
IN GNERAL FOR THE DESIGN, FABRIACTION AND ERECTION OF

CHIMENYS THE INDIAN STANDARD SPECIFICATION IS: 6533 CAN BE
FOLLOWED AND IS ACCEPTED.
Generally, the following procedure is followed for fabrication and erection of chimney:
1. The Smoke Nuisance Inspector should be informed and consulted.
2. The chimney height is decided by the smoke Nuisance Regulation / Air pollution
prevention department applicable for that site.
3. The diameter of chimney is primarily decided by the flow rate, temperature of gas
through it, and the height of chimney. Velocity of gas can be about 7 to 9 m/s at
24 TSH – 800
full load. In absence of any other criteria, use the average velocity for deciding the
diameter.
4. In some states the chimney drawings and strength calculations are to be approved
prior to starting the fabrication. Check this with the smoke nuisance inspector
concerned for your area.
5. Prior to getting the approval of smoke Nuisance Inspector, the “No Objection
Certificate” has to be obtained from the Air Pollution Prevention Department.
6. After the chimney is fabricated, it is offered for ground inspection and is allowed to
be erected only if the Inspector is satisfied.
7. The “No Objection Certificate” has to be obtained from the Civil Aviation authority
also, before the erection of the chimney.
Refer chimney typical drawing. The duct connection between TFH and chimney is also
indicated. The main chimney is erected on ground outside the TFH house with proper
foundation bolts.
b. FLUE GAS DUCTING.
The chimney are designed to take care if it’s own pressure drop considering the draught
created by it due to density difference between hot flue gases and air. This ensures that
the draught available at chimney base is either Zero or slightly negative when the TFH is
in operation.
The combustion air fan selection is done to ensure availability of either zero or slightly
positive pressure at the flue gas outlet. When the equipment is operating at full load.
Therefore duct connection between equipment and chimney should be designed such that
the pressure drop is minimum. It should also be insured that the flue gas velocity is kept
between 8 to 10 mtrs/sec.
Following precautions should also be taken.
(a) Chimney with smaller diameters and chimneys with long duct piece between the
flue gas outlet of equipment and the main chimney should not be accepted.
(b) The duct connection between equipment outlet and chimney should be connected
at an angle not less then 45 degree. A lower angle of 30 degree may be accepted.
(c) A removable distance piece should be provided immediately after the equipment.
The short removable distance piece can be removed whenever required without
disturbing the main chimney, the equipment, the equipment house walls or
neighboring machines. All the connections should be with flanges and bolts.
(d) Two nos. 1/2" sockets with plugs should be provided for testing purpose in each
flue gas duct at a distance of One meter from the equipment.
CHIMENY OF SMALLER DIAMETER, CHIMNEY WITH MORE THAN

TWO BENDS AND CHIMENY WITH DUCT PIECE SHOULD BE
AVOIDED.
NOTE: Please consult the concerned authorities (i.e. civil aviation

department, Air pollution, control department etc.) Applicable in
your state / area before fabrication and erecting the chimney.
25 TSH – 800
c. USING EXISTING OR COMMON CHIMNEY.
If existing chimney or a common chimney for two or more equipment is required to be

connected, following precautions should be taken and ensured.
(a) Cross section area of chimney should be checked for it’s capacity to
handle additional flue gases after connection.
(b) Any two flue gas duct connection to chimney should be away from
each other by minimum 1 meter in vertical plane.
(c) If the flue gas outlet of each equipment is connected to common duct,
the area/size of duct should be suitably increased / modified to take
care of increased flue gases.
d. CHIMENY – DIAMETER / HEIGHT CALCULATION.
The Graphs are prepared by using the following equations:
Height = 4.3282 x (% S x ff) ^0.3
Diameter=  13.5 x ff x {(HAG + 273) / 273} x 4

V x 3600 
Where:
% S = % of sulphur in fuel.
Ff = fuel firing rate in kg/h
HAG = stack temperature in *c.
A = area C.S. of chimney in m^2
V = velocity of flue gas in stack in m/s
e. DO’S AND DON’TS FOR CHIMENY.
DO’s DON’TS
* Use smoother bends to connect * Never reduce the dia. of the chimney
equipment and chimney.
* Use expansion joint at the * Never use short bends in the flue gas
out let of the equipment. duct.
* Insulate the flue gas duct and * Never reduce the dia. of flue gas duct
part of chimney inside the TFH other than suggested for connecting
house, for safety purposes. Equipments to chimney.
26 TSH – 800
* The angle at which the duct of
equipment gets connected to
chimney should not be less than 45C.
* Provide a removal duct pieces

immediately after the Equipment
for ease of maintenance.
* Provide two nos. ½” socket with plugs

for testing purpose in flue gas duct at a
distance of one meter from the TFH.
27 TSH – 800
CHAPTER: 9
 ELECTRICAL SYSTEM
The starters for all motor and switchgear for the TFH along with control contactors are
mounted inside this control panel box. Hence no need to install any starter for any motors
separately. The electrical cabling between circulating fan motor to control panel, and field-
mounted instruments to control panel are to be completed at site. The details of Control
and Power cables are given in the attached cable schedule.
Three phase, 4 wires A.C. Electric supply of 415 Volts, 50 Hz with neutral and earth is
required for operating the TFH. The supply to the TFH control panel should be given
through a main switch fuse having adequate capacity. The back up fuse capacity to suit
the total electric loading should also be maintained.
For details of control logic and cables refer the electrical circuit diagram and cable
schedule attached.
a. EARTHING OF THE EQUIPMENT
Earthing wires of adequate cross-section should be provided to link the TFH, the electrical
control panel box, various motors, etc. to a suitable earth plate, as per Indian electricity
Act.
Following size of earthing conductors can be used:
Up to 3.75 Kw 8 SWG GI wire

5.5 Kw to 30 Kw 3/8” GI fine wire rope
37 Kw to 55 Kw 5/8” GI fine wire rope
WHILE INSTALLING THE ELECTRICAL CABLES KEEP IN MIND THE RULES

AND REGULATION INVOLVED.
b. DO’S AND DON’T’S FOR ELECTRICAL SYSTEMS
DO’S DON’TS
* Provide adequate size switch fuse unit * Never increase or decrease the
and cables. back up fuse capacity.
* Provide proper lugs to terminate the cables.

also provide ferrule numbers on cable for
identification, maintenance and ease of
locating faults.
* Provide proper sized glands for the cable at

the entry to control panel and at motor
terminal box.
* Use cable trays or trenches for laying the
28 TSH – 800
cables.
CHAPTER: 10
 COMMISSIONING OF THE SYSTEM
Once the unit is pneumatically tested ( as discussed earlier ) and all the connections
are completed, commissioning of the system is done as following :-
a. The Thermic Fluid which customer purchases directly, has to be sent to us for analysis
and is confirmed fit for use by us. This will ensure that the quality of the Thermic Fluid is
OK and is fit for use in the unit. If the thermic fluid is of bad quality, it may crack at
higher temperatures and carbonize and choke the system piping and the coil of the unit.
OR
a. Customer should draw sample from 2 – 3 drum about 1 ltr. in a clean bottle. Mark on
bottle the make and batch no. of sample, keeping record with you and send the sample
to STANDARD LABORATORY for analysis report as shown in table ‘A’. Confirm the test
report with us before charging
b. Before charging oil, check that the flanges used for Blanking the circulating pump, de-
aerator cum expansion tank, etc. for pneumatic testing is removed and joints are
tightened properly in order to prevent leakage.
c. Make arrangement of separate pump for charging oil in the system capable of
pumping 1000 liters of oil per hour against a head of 40 to 50 meters of liquid
depending upon the highest point in the circuit viz. Expansion cum De-aerator Tank.
d. To ensure that all the air escapes through vent points and no air remains trapped in
the circuit, the Thermic Fluid must always be pumped into the circuit from the lowest
point in the circuit. The suction can be connected to the oil drums through charging
pump.
e. Open all the vent points to the atmosphere.
f. Before starting pump, check water circulation for pump gland cooling is properly circulated
at rated rate.
g. Start pumping the Thermic Fluid and watch closely the vent valves. Observe the user
equipment vent / drain at the outlet. The moment oil starts coming out of these point,
close down the vent / drain valves at respective points and open the outlet valve so that
the filling of oil starts in that part of the system.
It will be observed that as the oil starts reaching the various levels in the circuit,
respective vent valves will start overflowing and these have to be shut and the process
continued till the last valve is shut. Now, one will have to observe closely the level in
the expansion tank, the desired level in the expansion tank is about 50mm above the
level of the bottom gauge glass valve, but since the system is being filled up for first
time, the possibility of air pockets is not ruled out and with the first circulation of oil
the level might fall down drastically and hence it is advisable to fill the liquid to a
level of 150 to 200 mm in the expansion tank. After this level has been reached, the
filling of oil should be stopped and the system be left for half an hour for oil to settle
and the circulation of oil in cold should be started. The oil should be passed through
the strainer circuit in the piping for separating the unwanted solids in the piping. If the
strainer is not suitable for high temperature, this should be done at ambient temperature
29 TSH – 800
only. Note the pump pressure and circuit pressure. There should be practically no
fluctuation of the needles of respective pressure gauges.
If fluctuation of these needles is observed, it is evident that either trapped air is present
or air is being sucked in through flanged joints or through glands of the valves. In case
of trapped air, this will be removed gradually by cold circulation through de - aerator
unit. The cold circulation should be continued until all the trapped air is removed.
The flanged joints and the glands of the valves should be further tightened if found
leaking and a stage of constant pressure reached. In this process it might be necessary
to start refilling of the thermic fluid in case the level in the expansion tank falls below
the required minimum level of 50mm. Once the system is balanced and the level is
maintained for half an hour, remove strainer from the filter and clean it, then after the
system is ready to be warmed up. Check that the level switch in the tank operates
properly.
a. WARMING UP THE SYSTEM
After the Thermic Fluid Heater has been fired, the temperature of oil should be gradually
increased. The warming up should be done in following stages.
1. Set the outlet temperature to 110oC
2. Fire the unit following the starting instruction given in the Manual for operation and
Maintenance.
3. Maintain return temperature for one hour.
4. Increase the outlet temperature controller settings to 120oC after making sure that
there is no cavitation in the system. If cavitation starts, stop the firing and switch off
the system and immediately vent out the gases from vent points by opening the vent
valves. Steam and hot gases may come out of these valves and when oil starts coming
out, the vent valves should be shut and circulation of oil be commenced. When the
pressure readings stabilize the unit can be re-fired.
5. Maintain the return temperature for at least one hour so that all the vapours are
removed and observed that no cavitation occurs.
6. Increase the outlet temperature settings by 20oC and repeat the same procedure detailed
above until temp. of 160oC at the outlet is achieved.
7. Maintain the temperature of 160oC for at least one hour and closely observe for
minute
fluctuation in the pump pressure and also the level in the expansion tank. The
level in expansion tank should rise only as a result of expansion of oil, which is 7 litres
per 100 litres of oil per 100oC rise. If it is greater than this, then it should be concluded
that some abnormal phenomena is on, such as back pressure due to presence of
moisture, trapped gases, etc. and these should be vented out. In order to remove some
ingredients of oil, the temperature between 160oC and 250oC should be gradually
achieved and sufficient time lag should be provided. After reaching the temperature of
250oC, further increase in the temperature up to 300oC at the outlet of Thermic Fluid
Heater can be done directly.
30 TSH – 800
It should be noted here that the above procedure of warming up is only required in the
initial run of the unit and not every day. The temperature can be raised next day
directly up to 300oC.
8. It is necessary to check flanged joints for leakage at high temperature of 200oC and
above. If still found to be existing, then the flanged should be further tightened with
even pressure on diagonally opposite bolts. It might be necessary to add gland packing
to valves, to stop any leakage.
CAUTION :
The warming up procedure should be closely followed every time, when the system is
recharged with new thermic fluid or when thermic fluid is topped, while
recommissioning after cleaning, repairing or altering the heat exchanger coil.
31 TSH – 800
SECTION II
OPERATIONAL MANUAL
FOR
(OIL - FIRED )
32 TSH – 800
:INDEX:
CHAPTER 1. THERMIC FLUID HEATER IN GENERAL …

a. OIL FIRED UNIT..
b. OPERATIONAL FEATURES ..
c. SEQUENCE OF OPERATIONS FOR OIL FIRED UNITS..
d. AUTO CONTROLS AND SAFETIES..
CHAPTER. 2. OPERATIONTING INSTRUCTIONS …
a. Starting ..
b. Running Attention ..
c. Stopping ..
33 TSH – 800
CHAPTER: 1
 THERMIC FLUID HEATER WORKING
The ‘THERMOTECH’ liquid phase heating system essentially comprises of fully automatic Oil /
Gas fuel fired 3 start – 3 flue gas pass, forced draught, packaged type Thermic Fluid Heater
available in Horizontal & Vertical models. The helical coil fabricated out of high heat resistant
boiler quality BS 3059 M.S. tube to form the combustion chamber i.e. inner coil and radiant
zone by outer coil. The two concentric assembly placed at the center of tube shells; one inside
the other in case of vertical models & coil assembly placed in center of horizontal shell duly
insulated with mineral wool. In case of horizontal models, the imported burner is mounted on
front door & is fully openable on hinge along with burner for ease of coil inspection & cleaning.
In case of vertical models, the top plate bolted to shell is to be removed for inspection of coil
& to take out for cleaning. Thermic fluid oil circulated through coil by a centrifugal pump
through expansion cum deaerator tank in the system.
a. OIL FIRED UNIT :
The fuel burner is situated at the top center of the helical coil. The burner is down firing,
forced draught type with direct electric spark ignition. The combustion air fan and fuel pump
are at the front base of the unit in case of vertical models. A monoblock imported burner is
situated the front door of mounting plate in case of horizontal models.
THERMIC FLUID CIRCULATION PUMP :
A high heat resistance centrifugal pump coupled with electric motor supplied with Thermic
Fluid Heater is mounted separately near to unit in boiler house.
ELECTRIC CONTROL PANEL :
A dust proof prewired electric control panel board fitted at front top of the shell in case of
vertical unit and floor mounted near to unit in case of horizontal unit incorporated all switch
gears, contactors, controls & safety devices for safe & smooth operation of Thermic Fluid
Heater.
b. OPERATIONAL FEATURES :
The centrifugal type high temperature process pump, near the unit, circulates the thermic
fluid through the unit and the system. The thermic fluid returning from the user equipment is
fed to the circulating pump through a combined deaerator and expansion tank. Vapours,
gases, etc. are separated from the thermic fluid in this tank. The deaerator tank is connected
to the expansion tank by pipes. The function of the expansion tank is to accommodate the
increased volume of the thermic fluid, when it is heated. Thermic fluid expands by about 7%
of its total volume for every 1000C rise in temperature.
Heat liberated by burning fuel in the combustion chamber is utilized for heating the thermic
fluid in the coil. The product of combustion, after they exchange their heat with the thermic
fluid in the coil, are let out of the unit through the flue gas outlet. Insulation of the unit and
combustion air preheating are achieved by circulating the fresh air for combustion through a
double jacket formed by the inner shell and the outer shell surrounding the combustion
34 TSH – 800
chamber. A high degree of combustion air preheating ensures high thermal efficiency. After
the rotary switch is put in “BURNER ON” position, the burner starts and the temperature of
the thermic fluid goes on increasing to the required degree. The return temperature combistat
keep the thermic fluid temperature under control by making the burner to work either ON-OFF
or on modulation, as the case may be.
c. SEQUENCE OF OPERATIONS FOR OIL FIRED UNITS :
Sequence of operation for Thermic Fluid Heater is as follows :-
1. When the electric main switch is put on, supply comes to the panel box.
2. fuel oil preheating starts, when the Rotary Switch is put on. ( applicable to F.O. operated
unit s only. The fuel oil temperature combistat indicates and controls the fuel oil
temperature. The black pointer indicates the actual temperature. The green pointer is set
to control the minimum temperature and the red pointer is set to control the maximum
temperature. Normally the green pointer is set at 1050C & the red pointer at 1200C. The
burner can be fired only when the fuel oil temperature is above 1050C. TS-100 & TS-200
operates only on LDO/HSD. For other units two oil preheating tanks can be provided, one
electrically operated and other thermic fluid operated as optional ).
3. On making sure that the furnace oil temperature reaches 900C, the push button switch for
fuel oil circulation kept pressed. The blower motor which also drives the fuel pump, starts
and circulation of fuel oil starts through the fuel oil preheating tank and the burner rod.
The fuel oil temperature increases. Simultaneously, the Rotary Switch / Push Button for
thermic fluid pump is also put on. Thermic fluid circulating pump starts and the flow of
thermic fluid is established in the coil and circuit.
4. On observing that the pump pressure gauge and circuit pressure gauge is showing steady
pressure and after the fuel oil temperature crosses the minimum temperature mark of
1050C, the rotary switch is put in “BURNER ON” position.
5. The blower motor starts. The blower pushes air through the combustion chamber, driving
away combustible gases, if any, from the combustion chamber. This is known as
“Prepurging”. At the same time, fuel oil pressure is also developed, as the blower and the
fuel pump are driven by the same motor.
Note :- For units operating on Light Diesel Oil, portions explaining the working of the
fuel oil preheating system above, are not applicable
6. After prepurging.
a. Sparking starts.
b. Burner solenoid valve energises and oil is sprayed into the combustion chamber.
c. Flame is established and sparking stops.
d. Heating of thermic fluid starts.
d. AUTO CONTROLS AND SAFETIES:
 High Fluid Temperature Switch (Return) :
Digital temperature indicator cum controller cut off burner at preset temperature and
indicate return oil temperature and restart burner at preset differential temperature to
maintain system temperature.
35 TSH – 800
 High Fluid Temperature Switch (Outlet) :
Digital Temperature indicator cum controller on outlet of the thermic fluid cut off burner
and sound an alarm if temperature exceed to preset temperature and put the burner in
electrical lock out.
 Stack Temperature Switch :
A blind temperature controller cut of burner, put in electrical lock out and sound an alarm
if the stack (flue gas) temperature exceed to preset temperature.
 Liquid Level Switch :
A Magnetic float level switch cut-off burner actuated indicator lamp and sound an alarm in
case of low level of Thermic Fluid in the expansion tank.
 Flame Sensor
Photocell resistor actuated indicator lamp audio-visual alarm and burner cut off in case of
flame failure.
 Low Fluid Pressure Switch :
Differential pressure switch actuated indicator lamp, sound alarm and put the burner in
electrical lock out in case of no-flow or low fluid pressure of Thermic Fluid Oil.
 Fuel Oil Temperature Switch :
Thermostat automatically cut off electric heater at preset temperature to maintain furnace
oil fuel temperature and interlocking with burner allows burner to start only at preset
temperature of fuel.
 Spring Loaded Relief Valve :
Spring loaded Relief valve assembly at second third pass of flue gas automatically lift up
and make passage to escape flue gases in case of back firing of burner and prevent
damage to coil.
 Bottom Drain :
In case of vertical models drain point provided at bottom of combustion chamber drain out
unburnt fuel oil to avoid back firing.
 Circulating Pump Motor Interlock :
Thermic Fluid Oil circulating pump motor electrically interlocked, do not allow burner to
start till complete oil circulation take place in the system.
36 TSH – 800
Chapter 2
 OPERATING INSTRUCTIONS :
a. STARTING
1. check that fuel oil service tank is full of fuel oil for oil fired unit.
2. Ensure that fuel filters, strainers and burner nozzle are clean.
3. Open fuel oil / gas inlet valve.
3. (FO fired unit) : Put the Rotary Switch on to start fuel pre-heating. Press FUEL
CIRCULATION switch occasionally (For about ten seconds every five minutes ) to heat
up the burner rod and the fuel return line. Observe the fuel temp indicator. This
heating takes about 20-30 minutes.
4. Start cooling water supply to the thermic fluid circulating pump. In case of pump fitted
with mechanical seals, open the valves for the Heat Exchanger also.
5. Open the vent valves provided in the thermic fluid line to remove any air entrapped.
Close them after all the air has been vented out.
6. Check the level of thermic fluid in the expansion tank. Never start the unit sufficient
quantity of thermic fluid is not there in the expansion tank.
7. Press the Push Button switch after the fuel oil reaches 900C. The fuel oil temperature
will increase as the blower motor drives the fuel oil pump, starting the fuel oil
circulation through the oil preheating tank and the burner rod. Simultaneously, put on
the Rotary Switch for the thermic fluid pump. Check the pump and circuit pressures.
The pressure gauge pointers should be steady. If the pointers are flickering too much,
make only the thermic fluid pump to work till all the air entrapped in the column of
thermic fluid is driven out.
8. Ensure that the setting of all controls and safeties are not altered. After the fuel oil
temperature crosses the minimum temperature setting on the fuel oil switch, put
Rotary Switch in “BURNER ON” position. Burner firing sequence will start and flame will
be established. The sequence of operation will start only if the flow of thermic fluid
through the coil of the unit is sufficient. If the rat of flow is less than the specified rate,
the sequence will not start.
9. For oil fired unit : Check the oil pressure as indicated on the oil pressure gauge.
Check that its setting is not altered.
10. For Gas fired unit : Check the current on the Micro ammeter after a steady flame has
been established.
11. The circulating pump will keep on working all the time, even when the burner is off by
the action of any the switches.
b. RUNNING ATTENTION :
 The attention of the plant while in working is necessary and operator undertakes the
job. The operator must take care of following things.
37 TSH – 800
 Unit is not getting overheated.
 All valves and joints are leak-tight.
 No excessive noise and undue vibrations are there from motor or any moving parts.
 Appropriate flow of cooling water and thermic fluid is maintained.
 Electrical contacts must not be loose, so as sparking is avoided.
 Rise in temperature of glands cooling water is not more than 35oC.
 Pump & circuit pressure needles are steady and not flickering.
 Flame in combustion chamber are steady and not flickering
 Chimney exhaust is normal.
 Required temperatures are being maintained in the user equipment and the working of
temperature control valves in the thermic fluid circuit is satisfactory.
 A level of about 2” of thermic fluid is maintained in the gauge of expansion tank.
 Temperature difference between forward & return temperature is almost constant

throughout the working of the equipment.
 In “ON-OFF” operation, the unit starts and stops smoothly without excessive vibrations or
smoke.
c. STOPPING
 Put the Rotary Switch from “BURNER ON TO BURNER OFF” position. Let the thermic fluid
circulating pump keeps on working till the outlet temperature drops down to 80oC.
 Put off the Rotary switch for oil preheating (for FO operated units only)
 Put off the Rotary switch / Push Button for thermic fluid pump.
 Close the fuel inlet valve.
 Put off the main electric switch.
 Circulate cooling water for thermic fluid circulating pump for 15 minutes.
 Close the necessary valves in the water lines for thermic fluid circulating pump.
38 TSH – 800
SECTION III
THERMIC FLUID CHARACTERISTICS &

PUMP FLOW DISRTIBUTION MANUAL
FOR
(OIL - FIRED)
39 TSH – 800
:INDEX:
CHAPTER 1. THERMIC FLUID …

a. PROPERTIES OF THERMIC FLUID ..
b. SPECIFICATION OF NEW THERMIC FLUID ..
c. DETERIORATION OF THERMIC FLUID ..
d. WHEN TO REJECT THE OIL IN USE ..
CHAPTER 2. CLEANING OF THERMIC FLUID SYSTEM …
CHAPTER 3. PUMPS, PIPING & FLOW DISTRIBUTION …

a. SYSTEM RESISTANCE ..
b. RESISTANCE OF PIPING & FITTINGS ..
c. PIPING NETWORK RESISTANCE & FLOW ..
d. NPSH..
e. ESTIMATING FLOW RATE IN OPERATING SYSTEM ..
f. EFFECT OF LIQUID VISCOSITY ..
g. PUMPS IN SERIES & PARALLEL ..
CHAPTER 4. FACTORY ACT FOR THERMOPAC …
40 TSH – 800
Chapter 1
 THERMIC FLUID
a. PROPERTIES OF THERMIC FLUID
A quality thermic fluid retains following properties :-
a. Thermic fluid must be thermally stable.
b. The oil must possess adequate stability to oxidation.
c. Oil must possess low pour point, about 20oC.
d. The fluid if derived from paraffin base, should be well de-waxed, while refining process, so
that at low winter temperature, it does not get wax clogged.
e. It should have specific heat of about 0.45, at ambient conditions, and this value should
not exceed 0.7 at the highest working temperature about 300oC.
f. The fluid must be free from any acidic reaction, to avoid corrosion.
g. The fluid must be completely free from water and other insoluble contaminants.
h. The oil must not be too viscous at the ambient temperature.
i. The fluid must not loose its viscosity during its hot run, to avoid physical instability by
increase in temperature.
j. The fluid must have high boiling point at atmospheric pressure i.e. low vapour pressure in
order to ensure lower circulation pressure and lesser possibility of vapour lack effects in
the system.
b. SPECIFICATIONS OF NEW THERMIC FLUID
In addition of the above mentioned requirements of thermic fluid, other specifications of

new thermic fluid are as follows :- substantiate
a. Boiling point less than 320oC to 340oC.
b. No foreign insoluble contaminants.
c. Specific gravity in range of 0.88 – 0.93 at room temperature.
d. Specific heat not more than 0.7 at 300oC.
e. Thermal conductivity K, at temperature toC should substantiate the relation.
41 TSH – 800
0.101 ( 1 – 0.00054 t )
K = ˙˙˙˙˙˙˙˙˙˙˙˙
Specific gravity
(kcal per meter hour per oC)
f. The viscosity index figure of new oil should not be preferably lower than 100
g. Pour point below 20oC is preferred.
h. Thermal expansion in range of 0.00076 to 0.0008 per oC.
i. The ash and water contents in oil must be less, to guard against corrosion.
j. High resistance to oxidation i.e. the oil that shows no insoluble, with hexane and benzene
shows high resistance to oxidation.
k. Flash point in range of 200 – 240oC.
c. DETERIORATION OF THERMIC FLUID.
The deterioration of thermic fluid id due to following reasons :-
a. The emulsion by water into the system reduces the life of fluid and induces rapid
corrosion of tubes.
b. The small quantity of water present into the system will change to steam under pressure
and push out thermic fluid through the expansion tank.
c. Acidity in fluid.
d. Insolubles in hexane and benzene.
e. The thermic fluid has tendency to absorb oxygen from air. The max. volume of oxygen it
can dissolve, within oil, is 10% of the total oil volume.
A good thermic fluid oil, is well refined so that the unstable hydrocarbon are removed,
which otherwise, would have got oxidized, with the dissolved oxygen. Thus, there
should be no danger of any oxidation, with such good oil. However, as temperature
increases, the resistance of even stable hydrocarbons decreases.
For every 10oC rise, the resistance gets reduced by half its original resistance. De-
aeration is provided in the system to push out as much oxygen as possible, from the
system. If there be any overheating of oil, the resistance to oxidation gets considerably
reduced and so whatever little oxygen that may be in dissolved state, will attack
hydrogen atoms to form unstable peroxides, which produces acidic products soluble in
oil. Moreover, due to insoluble and gummy deposits, the viscosity of oil increases. We
need, therefore, to carry out tests to gauge.
f. Overheating of thermic fluid, as a result of which hot spots on pipe results in film
temperature of oil film, above the cracking temperature. Such cracking results in release
of higher and inflammable hydrocarbons. Flash point of the fluid thus gets reduced so
also the viscosity and serves as warning, indicating that the oil has started cracking down
and thus its thermal instability sets in. thus due to progressive overheating ultimately the
42 TSH – 800
tube passage gets chocked and cracking is faster, tube puncture may take place and fire
may broke out.
d. WHEN TO REJECT THE OIL IN USE
If the degree of deterioration exceeds the following limits, then it is necessary to replace
the oil by fresh new oil.
1. Flash point below 170oC.
2. Insoluble exceeds 1%.
3. Viscosity index below 95.
4. Any acidity beyond 0.0015 gram of KOH neutralization per gram of oil.
5. There should be no water or ash and sediments.
Also if the oil has been subjected to severe oxidation and hence increased deposits and
gumming state, so long the flash point is maintained above 170oC we need not change the
oil for entire system, we can effectively filter off the oil, to remove all sediments, water,
etc. and reuse the same oil.
43 TSH – 800
CHAPTER: 2
 CLEANING OF THERMIC FLUID SYSTEM
Two proven methods of Cleaning the Partially / Fully Chocked Thermic Fluid Systems are
explained hereunder. While carrying out the cleaning operation, it is advisable to take utmost
precaution as recommended by the chemical manufacturer.
Method 1. : Using “ GREESKILLA “ compound made by castrol :
1. Drain out the thermic fluid from the system.
2. Open any bend or pipe to check the extent of carbon deposition.
3. Make solution of “ GREESKILLA “ with water at 5% concentration by weight. Preferably,

use DM or condensate water.
4. Pump the solution in the system with separate charging pump.
5. Replace Graphoil gland packing of the thermic fluid pump with ordinary gland packing, to
avoid leakage from the gland of the thermic fluid pump.
6. Start circulation of solution with Thermopac circulating pump.
7. The thermic fluid system without the utility should be cleaned first. Further, take up
individual utilities. This procedure is adopted to avoid checking of pipelines and utility.
8. Maintain solution at 70-80oC with low pressure steam.
9. Circulate the solution for 12 hrs. in the system.
10. Inspect the system pipeline at any convenient point to check the effectiveness of
cleaning.
11. After ensuring cleaning, drain out the solution from the system.
12. Recharge fresh solution of “ GREESKILLA “ at 2.5 to 3% concentration by weight.

Maintain temperature of solution at 70-80oC and circulate for 24 hrs. and drain out the
solution.
13. Rinse the system with water 6 to 8 times to remove traces of “ GREESKILLA “. Each
circulation of water should be for a duration of 6 to 8 hrs. However, the rinsing should
be continued till the pH of inlet and outlet water coincides.
14. Inspect the pipeline again. Get all the air vents and valves cleaned.
15. Dry the system with low pressure steam and compressed air and bet circulating pump
overhauled.
16. Charge new oil, carry out normal checks and recommission the unit.
44 TSH – 800
CHAPTER: 3
 PUMPS, PIPING AND FLOW DISTRIBUTION
The total system resistance is the total head to be developed by pump. In order to ensure
sufficient flow rate from pump, the system resistance should be minimum. Due to the
drooping characteristic of centrifugal pump, when the head increases, the flow rate
reduces.
a. SYSTEM RESISTANCE
The system resistance consists of following :-
 Discharge velocity head

 Resistance valves, bends, fittings and total length of piping.
 Altitude of open discharge point from suction point.
b. RESISTANCE OF PIPING AND FITTINGS.
Pressure Drop :-
Pressure drop (mlc) = f * L * v2 / ( 2 * g * di )
= K * Q2 ………………………………………..(1)
where,
K = f * L / ( 12.1 * di5 ) ………………………………………..(2)

F = Darcy’s friction factor ( Moody’s Diagram )
v = Fluid velocity in given section (m/s)
L = Equivalent length of given section (m), including equivalent length of fittings.
di = Piping ID (m)
Q = Fluid flow rate (m3/s)
g = 9.81 (m/s2)
c. PIPING NETWORK RESISTANCE AND FLOW
Method for Piping Network Resistance and Flow Distribution
a. Draw a schematic diagram of piping network to represent parallel and series connections
b. Convert the resistance of valves, fittings, bends etc. to the equivalent lengths of
respective branches.
c. Indicate the path resistance of different sections of network by variables Ki (i = 1,2,……n)

on the respective lines of diagram.
45 TSH – 800
d. Calculate the values of each of the path resistances ( Ki ) using equation (2). In case of
coils, multiply K by coil resistance factor.
e. Calculate the resultant (K’s) of various groups of network as follows :-
K9 = K2 + K3
1/√K10 = 1/√K9 + 1/√K4
K11 = K10 + K5
1/√K12 = 1/√K11 + 1/√K6
K13 = K1 + K12 + K7 + K8
f. If the total flow rate is not known accurately, then, it can be calculated by rearranging
equation (2)
Q = √( ∆Pa – e/K13 )
∆Pa-e is the difference between pressures at suction (Hs) and outlet (Ho) of the pump.
Thus, ∆Pa-e = Ho – Hs.
g. Calculate the flow rates through different branches as follows :-
∆Pb-d = K12 * Q2
Q3 = √(∆Pb-d/K6)
∆Pb-c = K10 * (Q-Q3)2
Q2 = √(∆Pb-c/K4)
Q1 = √(∆Pb-c/K9) or Q1 = Q – ( Q3 + Q2 )
d. NPSH
The cavitation formed due to suction head created by the pump impeller at its entry if
more than the vapour pressure of liquid at the pumping temperature has many adverse
effects.
To avoid cavitation the available “ net positive suction head “ (NPSH) should be more than
that required by the pump, which is normally about 2 to 3 meters.
NPSHa = Atm. Pressure + Suction static head + Suction line resistance − Vapour pressure of
liquid
at pumping temperature.
46 TSH – 800
e. ESTIMATING FLOW RATE IN OPERATING SYSTEM
For estimating the flow rate by Motor Power consumption or current :
Power consumed by pump = Power supplied by motor
Q*H*S = √3V * 1 * Cos * Em

367 * EP 1000
Where,
Q = Pump flow rate (m3/hr)
H = Head developed by pump (mlc)
S = Specific gravity of liquid at pumping temperature
EP = Pump efficiency (fraction)
V = Existing voltage (V)
I = Current drawn by motor (Amp)
Cos = Power factor ( at actual load )
Em = Motor efficiency (at actual load )
f. EFFECT OF LIQUID VISCOSITY
The pump is started in the system at room temperature when the liquid viscosity is around
60 cst. When firing is started, the liquid temperature increases and viscosity reduces,
hence at 100oC, viscosity is nearly 5 cst and at 250oC is nearly 1 cst (equal to water).
Effects of viscosity: -
 Viscosity is higher, system resistance is higher.

 Viscosity is higher, pump flow rate and efficiency reduces.
 Viscosity is higher, reduces flow and increases motor power.
g. PUMPS IN SERIES AND PARALLEL
 Pumps in series :
In case of two or more pumps in series the total discharge pressure of the last pump is the
sum of the individual discharge pressures of the individual pumps. For identical pumps, the
capacity is that of one pump, and the discharge pressure of the last pump is the sum of the
individual heads of each pump acting as a single unit. Thus, for two identical pumps the
discharge head is twice that of the rated pressure of one pump at the designated flow rate.
The pump casing of each stage must be of sufficient pressure rating to withstand the
developed pressure.
47 TSH – 800
 Pumps in parallel :
In case of parallel pumps i.e. when more than one pump discharges into the same pipeline,
the resultant discharge pressure is the sum of the individual flow rates at the same head.
Also by drawing a horizontal line through established operating point for parallel operation, it
is possible to find flow rates if individual pumps and efficiencies. Operating point is the
intersection of resultant Q-H with system resistance curve. Each pump will not have to carry
the same flow, but it will operate at its own characteristic curve and must deliver the
required head. At a common tie point on discharge of all pumps, the head will be the same
for each pump, regardless of its flow.
48 TSH – 800
CHAPTER: 4
 FACTORY ACT FOR THERMOPACS

(M.S. GOVERNER’S GASSETTE DECEMBER 1, 1994)
RULE ’73-AA : SAFETY PREAUTIONS FOR THERMIC FLUID HEATERS’:-
1. In respect of any factory where Thermic fluid heater has been installed (hereafter called
“heater”) and following provisions shall be compiled with.
2. All heater shall be of such construction that, the coils shall be removable for periodic
cleaning, visual inspection and hydraulic test.
3. Suitable arrangement shall be made for cooling the furnace effectively in case of power
failure to the heater.
4*. Before restarting the furnace of heater it shall be effectively purged.
5. The Thermic fluid used for heater shall be circulated in a closed circuit formation with an
expansion cum deaerator tank. This tank shall be located outside the shed where the
heater is installed.
6*. Every heater shall be provided with a photo-resistor actuated audio-visual alarm to
indicate flame failure and automatic burner cut-off.
7. The stack temperature monitor-cum-controller with audio-visual alarm shall be provided to

the heater so as to warn the operator in case the outlet temperature exceeds the specified
maximum.
8. Where inspection doors are provided on the furnace of heater they shall be inter-locked
with the burner itself, so that they cannot be opened until burner is shut off and furnace is
cooled sufficiently.
9. All heater shall be provided with following devices and the same be maintained in efficient
working order :-
a. Level indicator in the expansion tank ;

b. Temperature indicator of Thermic fluid ;
c. Differential pressure switch on the outlet line of the heater tubes ;
d. Temperature control device for the fuel oil supply to the burner.
10. All devices mentioned in paragraph 9 above, for heater shall have inter-locking
arrangement with burner, so that in case of any pre-determined limits being crossed, the
supply of fuel and air to burner shall automatically cut-off.
11. All safety inter-locks when operated shall be indicated of on the control panel of the
heater by a suitable audio-visual alarm.
12. Electric panel for the heater shall be located near the heater but not so close as to be
exposed to spilling or leaking oil.
13. The heater shall be located in place segregated from other manufacturing activities.
49 TSH – 800
14. Explosion vent for heater shall be so installed that, the release takes place at safe
location.
15. The heater coil including the coil connected to it in the user’s equipment shall be
subjected to pressure, shall be tested by competent person once at least in every 12
months. The test pressure shall not be lass than twice the operating pressure.
16. If repairs are carried out to the heater, furnace oil, it shall be tested before taking it into
use.
17. Maximum temperature of Thermic fluid in the heating of heater coil shall not exceed the
figure specified by the manufacturer. The Thermic fluid used in heater shall confirm to
specifications prescribed by the manufacturers and shall be tested by competent person
for suitability at least once in every 3 months period, such test shall include test for
acidity, suspended matter, ash content, viscosity and flash point.
18. Cleaning of the internal surface of the heater for removing soot and check up the
refractory surface on the inside shall be carried out every month or as often as required
depending upon working conditions. The coil of heater shall be removed and surface of
the coils cleaned thoroughly once at least in a period of six months. The burner, nozzles,
oil filters and pumps shall be cleaned once a week during the period of use.
19. A separate register containing the following information for the heater shall be
maintained :
a. Weekly checks carried out confirming the effectiveness of inter-lock ;

b. Weekly checks confirming that all accessories are in good state of repairs ;
c. Information regarding fuel oil temperature, pressure , Thermic fluid inlet/outlet
pressure and temperature, fuel gas temperature, recorded at four hourly interval ;
20. The heater when in operation shall be always be kept in charge of a trained operator. “
By order and in name of the Governor of Maharashtra.
A. V. SULE
Desk Officer
Note:-
*applicable to oil/gas fired units
50 TSH – 800
SECTION - IV
MAINTENANCE & SPARES MANUAL
FOR
(OIL - FIRED)
51 TSH – 800
:INDEX:
CHAPTER 1. MAINTENANCE …
a. TRAINING ..
b. LOG BOOK ..
52 TSH – 800
CHAPTER: 1
 MAINTAINANCE
The better performance and efficiency of the unit depends principally upon the
maintenance carried out. It is necessary to check out whether all the parts of the unit are
working properly. The maintenance must be carried out periodically.
THERMIC FLUID
Thermic fluid must be clean and not contaminated with any other oil. It should be kept in a
clean container. In order that the thermic fluid is clean, it is advisable to circulate it through the
strainer provided in the return line, each time the level in the expansion tank is topped up and
also in any case once a week.
The thermic fluid leaked out from the system should not be reused, unless it is made sure that
it is uncontaminated. Thermic fluid barrels should be stored in shelter in horizontal position to
protect from rain water.
a. TRAINING
Training is important to comprehend the product completely and carry out schedule
maintenance.
Apart from the first-rate After Sales Service offered to the customers through our branches all
over India, a brief training and guidance is imparted to the customers by the Service Engineers
while installing and commissioning the unit.
b. LOG BOOK
Record of daily checks and servicing operation as well as other checks and servicing
operation must be kept in an operating log book and signed daily by the responsible operating
personal.
The operator’s superior must convince himself at least weekly of proper operation and
servicing of the Thermic Fluid Heater installation and other accessories and must note this on
the operating log book along with his signature and date. Recurring test carried out by the
technically competent person must also be entered in operating log book.
The log books are to be maintained dutifully and regularly, so that variation and digression, if
any can be sorted out immediately and a major breakdown of the unit can be avoided.
53 TSH – 800
SPECIMAN FORMAT FOR LOG BOOK.
THERMIC FLUID HEATER – Model & Sr. No.:

______________________________
Fuel Used. : ______________________________
Date of Receipt. : ______________________________
Date of Commissioning. :
______________________________
DETAILS OF USER EQUIPMENT.
SR. NO. Description. Energy Consumption
T1
T2
T3
T4
T5
54 TSH – 800
1.1 OVERHAULING CHECK LIST.
Date:
_____________
Sr. Activity Observation OK Not OK Action Action Remarks

No. Taken Proposed
1. Cleaning of Coil/
Jacket.
2. Descaling.
3. Inner/Outer Jacket.
4. Al. Radiator.
5. Top refractory.
6. Bottom refractory.
7. Burner assembly.
8. Air / Wegman cone.
9. Pneumatic test.
10. Thermic Fluid circulation pump.
11. Fuel pump.
12. Mountings and Valves.
55 TSH – 800
DATA SHEET FOR ANALYSIS OF THERMIC FLUID
1. Company Name & Address:
2. Model & Serial No. of Thermic Fluid Heater :
3. Quality / Brand Name of Thermic Fluid sent :
4. Date on Which Sample was Drawn:
5. Report No. & Date of the Last Sample of thermic Fluid Tested:
6. When was last Thermic Fluid Replace? State its Brand Name:
7. Unit Inlet Temperature:
8. Unit Outlet Temperature:
Note: -
Sample should be sent in a leakproff plastic container with identification marks by Regd. Post
Parcel or Courier. Minimum 1 Liters of Thermic Fluid is needed for testing. Invoice / bill will not be
raised. We will issue you receipt after receiving testing charges. Please send-testing charges in
advance by Demand Draft.
Date: _________ Signature: ____________
56 TSH – 800
THANK YOU
57 TSH – 800
REV.
04
04
04
04
04
04
04
04
04
04
04
04
04
04
REF.DOCUMENT
521 008 21 01
521 008 21 01
521 008 21 01
521 008 21 01
521 008 21 01
521 008 21 01
521 008 21 01
521 008 21 01
521 008 21 01
521 008 21 01
521 008 21 01
521 008 21 01
521 008 21 01
521 008 21 01
EFFECT
THERMOTECH SYSTEMS LIMITED
THERMIC FLUID HEATER ‐ CAUSE & EFFECT CHART
THERMIC CIRCULATION PUMP‐1
THERMIC CIRCULATION PUMP‐2
THERMIC FLUID CHARGING PUMP‐1
THERMIC FLUID CHARGING PUMP‐2
COMBUSTION AIR BLOWER‐1
COMBUSTION AIR BLOWER‐2
F O CHARGING PUMP
PRESURE CONTROL VAVLE
DESCRIPTION
ELECTRIC HEATER‐1
ELECTRIC HEATER‐2
F O PUMP ‐ 2
FO PUMP ‐1
BURNER
BURNER
TAG NO.
CAUSE
E10A
E13A
E10B
E13B
E5A
E2A
E9A
E5B
E2B
E9B
E14
E11
T40
REV. REF.DOCUMENT DESCRIPTION TAG NO. SYSTEM TYPE (PLC) INTERLOCK NO. ALARM
THERMIC FLUID HEATING SYSTEM
04 521 008 21 01 EXPANSION TANK LEVEL LOW LSLL‐1‐15 PLC I12 √ C C C C
04 521 008 21 01 FUEL OIL DAY TANK LEVEL HIGH‐HIGH LSHH‐8‐7 PLC ‐‐ √
04 521 008 21 01 FUEL OIL DAY TANK LEVEL HIGH LSH‐8‐8 PLC I15 √ C
04 521 008 21 01 FUEL OIL DAY TANK LEVEL LOW LSL‐8‐9 PLC I14 √ O
04 521 008 21 01 FUEL OIL DAY TANK LEVEL LOW‐LOW LSL‐8‐10 PLC I13 √ C C C C C C
C
04 521 008 21 01 THERMIC FLUID FLOW LOW DPT‐1‐13 PLC ‐‐ √
04 521 008 21 01 THERMIC FLUID FLOW LOW‐LOW DPT‐1‐13 PLC I11 √ C C C C
04 521 008 21 01 THERMIC FLUID PRESSURE HIGH‐HIGH PT‐1‐21 PLC ‐‐ √ T TIME DELAY (>1 SEC.)
04 521 008 21 01 DIFFRENTIAL PRESSURE HIGH ACROSS E2A DPSL‐1‐3 PLC I4 √ C C C CLOSE / STOP
04 521 008 21 01 DIFFRENTIAL PRESSURE HIGH ACROSS E2B DPSL‐1‐10 PLC I9 √ C C O OPEN / START
04 521 008 21 01 F O HEATING TANK PRESSURE HIGH PS‐8‐2 PLC I17 √ C C C C C C C √ MESSAGE / ALARM
04 521 008 21 01 FORWARD TEMP HIGH (E2A) TT‐1‐5 PLC ‐‐ √
04 521 008 21 01 FORWARD TEMP HIGH‐HIGH (E2A) TT‐1‐5 PLC I2 √ C C
04 521 008 21 01 RETURN TEMP HIGH (E2A) TT‐1‐1 PLC ‐‐ √
04 521 008 21 01 RETURN TEMP HIGH‐HIGH (E2A) TT‐1‐1 PLC I3 √ C C
04 521 008 21 01 FORWARD TEMP HIGH (E2B) TT‐1‐11 PLC ‐‐ √
04 521 008 21 01 FORWARD TEMP HIGH‐HIGH (E2B) TT‐1‐11 PLC I7 √ C C
04 521 008 21 01 RETURN TEMP HIGH (E2B) TT‐1‐7 PLC ‐‐ √
04 521 008 21 01 RETURN TEMP HIGH‐HIGH (E2B) TT‐1‐7 PLC I8 √ C C
04 521 008 21 01 STACK TEMP HIGH (E2A) TT‐3‐1 PLC I5 √ C C
04 521 008 21 01 STACK TEMP HIGH (E2B) TT‐3‐3 PLC I10 √ C C
04 521 008 21 01 F O TEMPERATURE HIGH TT‐8‐3 PLC I16 √ C
04 521 008 21 01 F O TEMPERATURE HIGH‐HIGH TT‐8‐3 PLC ‐‐ √ CLIENT : ADANI
04 521 008 21 01 F O TEMPERATURE LOW TT‐8‐3 PLC ‐‐ √ S CONSULTANT : HOWE BENCHMARKING INFRASTRUCTURE
04 521 008 21 01 F O TEMPERATURE LOW‐LOW TT‐8‐3 PLC ‐‐ √ C C C C SUPPLIER : THERMOTECH SYSTEMS LTD.
04 521 008 21 01 F O CHARGING PUMP TRIP E13A/E13B PLC I17 √ C C C C C C PROJECT : STAND BY THERMIC FLUID HEATER INSTALLATION
04 521 008 21 01 COMBUSTION AIR BLOWER TRIP E5A PLC I18 √ C C DOCUMENT NAME : THERMIC FLUID HEATER ‐ CAUSE & EFFECT CHART
04 521 008 21 01 COMBUSTION AIR BLOWER TRIP E5B PLC I19 √ C C DOCUMENT NO. : TSL‐HOWE‐C&E_001
04 521 008 21 01 THERMIC CIRCULATION PUMP TRIP E10A/E10B PLC I20 √ C C C C C C SHEET NO. : 1 OF 1 REV. NO : 00
Note‐1 : E2A BURNER WILL HIGH‐LOW ON TT‐1‐6.
2. E2B BURNER WILL HIGH‐LOW ON TT‐1‐12.
3. T40 PRESSURE CONTROL VALVE WILL CONTROLLING ON PT‐1‐21.
PAGE NO.: 1 of 1
E2B
E11
CAP.:990 LTR.
E2A
E12
E13A
E14
CAP.: 225 Ltr.
E13B
ISSUE FOR APPROVAL
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Near Ellisbridge
Ahmedabad,380006
India
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VENDOR: THERMOTECH SYSTEMS LTD. contained in this document are the sole
R
property and copyright of AKPPL. Any use,
copying, reproduction or disclosure of the
document, whether directly or indirectly, or in
whole or in part without the prior written
RText (RText) permission of AKPPL is prohibited.
E6
CAP.:2700 LTR.
CAP.:240 LTR.
E7
PROCESS
E2B E3B
E1B E5B
E8
CAP.:4000 LTR.
F.F.L.
E2A E3A
.
E10A
E1A E5A
E9A E4
.
E10B
.
.
P & I DIAGRAM
E9B FOR THERMIC FLUID HEATER - 8 Lac Kcal / hr. - 2 Nos.
MODEL : TSH-800
R4
R4
ISSUE FOR APPROVAL
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India
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Ltr.R4R4
225
LTR.E14CAP.:
LTR.CAP.:240
LTR.CAP.:2700
LTR.CAP.:4000
TSH-800E10AE3AE4E5AE1AE2AE3BE5BE1BE2B....E9BE10BE11E13AE13BE12E2AE2BCAP.:990
:
Nos.MODEL
2
-
hr.
/
Kcal
Lac
8
-
HEATER
FLUID
THERMIC
DIAGRAMFOR
I
&
E8E9AF.F.L.E6E7PROCESSP
ISSUE FOR APPROVAL
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R
Control Valve
Technical Specification
Customer THERMOTECH SYSTEMS LIMITED Project Offer No PVQ-1920-1782 Sheet No
Enq. Ref E mail date 22/07/2019 Date 22-07-2019 1 of 1
1 Item No. | TagNo 1 -
2 Quantity (Nos) 4 INSPECTION Pneucon
3 Line Fluid |State Thermic Fluid Liquid Additional Notes
4 Flow Unit | Pressure Unit M3/Hr Kg/Cm2 (G) As discussed we have considered max.
SERVICE CONDITION
Inlet pressure 7 kg/cm2 G.

5 Flow Rate 66 - -
6 Pressure Inlet 7 - - We have considered 10% pressure drop
for Cv calculations.
7 Outlet 6.3 - -
8 ΔP 0.7 - -
9 Inlet Temperature °C 280 - -
10 Sp. Gravity | MW 0.91 -
11 Z Factor | Viscosity(CP) - -
12 Vapour | Critical Pr. KSC - -
13 Δ P Actuator Sizing 7 kg/cm2 G
14 Line Size In | Out | Sch. 3" (80 mm) 3" (80 mm) Sch 40
15 Valve Lift % 85 - -
16 Predicted SPL (dBA) <70 dBA - -
17 Calculated Cv 87.86 - -
18 Body Form | Model No Globe-2 Way 110
19 Valve Size | Port Size | Cv 3" (80 mm) 3 118
VALVE SPECIFICATION
20 End Connections Style Flanged RF ANSI 150

21 Rating 150 #
22 Type Of Bonnet Finned
23 Gland Packing Grafoil
24 Body Material A216 Gr WCC
25 T No Of Seats | Design One Cage Balanced Guide
26 R Type | Rings V-Ported Carbon Ring
27 I Characteristic|Flow Direction Equal % Under
28 M Material AISI - 304 (CF8) -
29 Leakage Class (FCI 70.2) IV
30 IBR Certification No
31 Others - - -
32 Type | Size (inÂ²) Motorised -
ACTUATOR
33 Actuator Model No. SD-2000-200-1 + 2Nos Limit

- switches
34 Spring Range | Voltage - 230 V AC Single Phase
35 On Supply Failure Valve Stayput
36 Supply Con.| Tubing & Fittings - -
37 Hand Wheel | Travel Yes -Side Mounted 28 mm
38 Air Pressure (Min/Max) - -
39 POSITIONER Make | Type - -
40 Model -
41 Input | Output - -
42 Enclosure -
ACCESSORIES
43 AIR SET Make | Model - - Rev. Revision By Date

44 MOC | Qty - -
45 Solenoid Valve Make | Model - -
46 MOC | Voltage - -
47 Enclosure -
48 SERVO CONTROLLER Yes-Input Signal - 4 to 20 mA, Output Signal- 4 to 20 mA.
49
50 Checked By Approved By
51
52
Doc No: PV4MKT04-01
PUMP : 50/250
FLOW : 66M3/HR
HEAD : 82 MLC
MOTOR HP : 30
IMPLELLER DIA: 252
N5 MH
À'
N3 N4
N2 N4
N1 N2
N1 N3 N5 MH
N11A
N6 N11A
N15 N6 N15
X
X
N14 N14
N13 N13
N9 N9
N12 N12
N8 N7 N11B N7 N8
N11B
N10
N10
À'
ISSUE FOR INFORMATION
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Ahmedabad,380006
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COPYRIGHT
R
BARTEC India P Private Limitted
56/45, 1ST Flo
C‐5 oor, Priska To
ower Sector‐‐62, Noida‐20
01 309
U. P. (India)
PR
ROJECT LIQ
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TUPALLI PO
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TS (INDIA) PVT. LTD.
EPC
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ACTOR
BARTEC India P Private Limitted
56/45, 1ST Flo
C‐5 oor, Priska To
ower Sector‐‐62, Noida‐20
01 309
CO NSULTAN T
MOT
TT MACDO
ONALD
TIT
TLE OF INSTALLATION
N, OPERATIO
ON AND MA
AINTENANCEE MANUAL
DO
OCUMENT
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ETH-DE-W-E-001
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OCUMENT NO. Rev..
CO
ONTRATOR// 00
No.
ONSULTANT’S DOCUM
CO MENT PR-18-1757--2-003
NO
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PREPARED CHE
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REV. NO. DATE D
DESCRIPTIO
ON
Initt. Sign Init. Sign Init. S
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019 For Review
w MK SR S
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This
s Document is the properrty of AKPPL
L and B&R. It should no
ot be used, copied
c or rep
produced witthout their written
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mission. 1 of 1
Page 1
Installation and Operation
Self-Limiting Parallel Circuit Heating Tapes and Installation systems on Pipes
Introduction
This BARTEC instruction manual for installation and operation is intended to give you important
information on electric trace heating systems for pipes. Reference is made here only to the use
of BARTEC self-limiting parallel circuit tapes. The contents of this manual are intended mainly
for persons who are familiar with the plans, installation, operation and maintenance of electric
trace heating systems.
Reservation
Technical data are subject to change without notice. Changes, errors and printer’s errors do
not justify claims for damages. For safety components and systems the relevant standards and
regulations are to be observed, as well as the corresponding operating and installation
instructions.
Contents
1. Important instructions 2
2. Selection of heating tape and project planning 2
3. Storage 3
4. Installation 3 - 11
4.1 Preparation for installation 3

4.2 Installation of the parallel circuit heating tape 4-8
4.3 Installation of accessories 9 - 10
4.4 Acceptance and testing 10 - 11
5. Temperature regulation 12
6. Thermal insulation 13
7. Voltage supply and electrical protective equipment 14
8. Tests and putting into operation 15 - 16
9. Operation and maintenance 16 - 17
10. Procedure when faults occur 18
10.1 Automatic circuit breaker triggered 19

10.2 Fault current protective switch (FI) triggered 19
10.3 No, or too low heat output 20
10.4 Heat output appears to be correct, but pipe temperature is 20
under the required temperature
1
The BARTEC guarantee is valid only if all 1. Important instructions for installation and operation
the instructions and recommendations
in this manual, and the installation and It is absolutely essential to observe the following instructions under all circumstances during the
assembly instructions accompanying the installation and maintenance of BARTEC self-limiting heating tapes and their installation systems.
product, are followed exactly. This Disregard of these instructions can lead to serious danger for personnel and equipment of the
applies particularly to the instructions installation.
given below. During installation and maintenance of electrical trace heating systems the relevant national regulations,
such as DIN VDE 0100 and DIN VDE 0105, as well as the respective currently applicable safety
regulations, e. g. BGV A2 must be observed.
■ For industrial use DIN VDE 0721 part 1 and part 2 A3 and DIN VDE 0253 must be observed. For
potentially explosive areas the relevant applicable regulations must be observed.
For potentially explosive areas the applicable regulations must be observed.
- For the Federal Republic of Germany:
DIN VDE 0165, DIN VDE 0100, DIN VDE 0105, Elex V, EX-RL
- For Europe:EN 50014, EN 50019, EN 60079-14 (Appendices)
■ Improper installation of the electric trace heating system and the adjoining installation components,
or damage to the heating tape, can cause short-circuiting and a fire risk in the operating state.
■ Never connect the two supply conductors of the heating tape together. Danger of short circuit !
■ Protect the self-limiting heating element surrounding the two supply conductors from environmental
influences. This black plastic element is electrically conducting and must therefore be treated
accordingly.
■ Do not use PVC/VC-containing self-adhesive tape for fixing self-limiting heating tapes.
■ BARTEC connections, tape-to-tape splice connections and remote end terminations are to be used
for correct installation of BARTEC heating tapes. These have been specially developed for BARTEC
heating tapes and have been tested and approved by various testing institutes.
2. Selection of heating tape and project planning

Before installing any electric trace heating system the installer should check whether correct planning
and design of the trace heating system has been carried out. Checking of the following points in
particular is recommended:
■ Is exact documentation of the project planning available?

■ Does the selected trace heating system fulfil the prevailing requirements?
This applies particularly with reference to:
- calculated heat losses
- the temperature class stipulated in the test certificates
- max. permissible operating temperature
- max. permissible ambient temperature
■ Have the max. permissible heating circuit lengths been taken into account?
■ Has a connection and remote end termination technique been selected which is suitable for the
requirements?
■ Does the other material included in the trace heating system or the adjoining installation fulfil the
- electrical
- mechanical
- thermal and
- chemical requirements?
■ Has electrical equipment with an EC type test certificate or certificate of conformity been selected for
installation in potentially explosive areas?
■ If suitable project planning documentation is missing, we recommend that the points mentioned
above are checked on the basis of the BARTEC product documentation.
■ If any points are unclear when checking the project planning documentation please contact us.
2
3. Storage
Incoming goods inspection
■ Compare the delivery note with the delivered goods.
■ Inspect the delivered heating tapes and accessories for possible transport damage.
■ Insulation measurement must be carried out on the heating tapes.
Storage
■ The heating tapes and connecting components must be stored in a clean, dry place.
■ During storage contact with chemicals and petrochemical products in particular must be effectively
avoided.
■ It should be ensured that the heating tapes are protected against mechanical damage during storage.
■ The storage temperature must not exceed +60 °C or drop below -40 °C.
■ If heating tapes and connecting components are stored only for a short time in damp rooms, or on
the construction site, it is essential that they are effectively protected from moisture (e. g. by
mounting a remote end termination).
4 . Installation
4.1 Installation and preparation
4.1.1 Time schedule
■ Time scheduling of installation of the electric trace heating system must be coordinated with other
installation work, particularly with work on the tank or vessel, electrical installation and thermal
insulation.
■ All installation work on the pipe system must have been completed.
■ Pressure tests and material tests on the pipe system should have been completed before starting
installation of the electric trace heating system.
4.1.2 Tests before installation

■ Measure the insulation resistance of the heating tape shortly before beginning with the installation.
■ Check whether the material which you require for installing the electric trace heating system is all
available on the construction site, and is undamaged.
■ It is particularly important to check whether the marking on the heating tape and components agrees
with the project planning documents (material list) and test certificates.
■ With the aid of the installation instructions accompanying the product check whether all the tools
required are completely available.
■ Plan installation of the heating tapes by inspecting the pipe system to be heated.
■ At the same time pay attention to sharp edges and unevenness which could damage the heating tapes,
and remove these.
■ Lacquered and painted pipes and surfaces must be completely dry before beginning the installation.
Complete drying throughout and ending of gas evolution is not completed until after approx.
3 weeks.
3
4.2 Installation of the self-limiting parallel circuit heating tape
4.2.1 Handling the heating tape
■ Use a stable holding device for unwinding the heating tape from the coil.
■ Remove the heating tape in a straight line from the coil.
■ Do not bend or pinch the heating tape, or pull it over sharp edges.
■ Do not tread on or drive over the heating tape; do not use it as a loop for stepping on.
■ The ends of the heating tape are always fitted with a protective cap.
correct wrong
4.2.2 Installation of the heating tape

■ Always install the heating tape in a straight line round the pipe. This way you save valuable
installation time, help to avoid installation mistakes through complicated spiral installation and
prevent damage to the heating tape during the thermal insulation work. Furthermore with straight line
installation the heating tape can be easily localised later on.
■ The heating tape should be installed spirally only if this is expressly specified in the project
planning.
■ In order to ensure good heat transmission the heating tape must have a flat, flush fit over the whole
length. If necessary the distances between the fixing points should be reduced.
■ Do not cut the heating tape until it has been installed and fastened on the pipe. The specific heating
power (W/m) is not affected by cutting to the correct length on site. After cutting, the ends must be
effectively protected against moisture (e.g. by self-adhesive tape or a blanking cap).
■ When installing allow for an additional length of heating tape for assembling tape-to-tape splice
connections, tee branches and remote end terminations (approx. 0.5 metres for each).
■ When installing heating tape on plastic pipes or plastic tanks it is advisable to line these with
aluminium foil before installation. This measure improves heat distribution and protects the plastic from
damage.
4
4.2.3 Fastening
■ Fasten the heating tape with self-adhesive tape at intervals of at least 200 mm.
■ For selecting the correct fastening material please observe the following instructions:
Fasten the heating tape preferably with BARTEC self-adhesive tapes (see self-adhesive tape
selection table).
When using cable ties make sure that they have adequate temperature resistance and
resistance to chemicals.
Do not use metal fixtures
Never use PVC insulating tape or self-adhesive tapes containing PVC or VC.
Use aluminium self-adhesive tape only if this is specified in the project planning. Use of
aluminium self-adhesive tape improves the heat transmission. Glueing over the heating tape
with aluminium self-adhesive tape increases its heating power.
Heating tape Aluminium self-adhesive tape Self-adhesive tape
When heating plastic pipes aluminium self-adhesive tape or aluminium foil should be used
under, or under and over the heating tape in order to improve heat transmission and
distribution.
Selection chart self-adhesive tape

Self-adhesive tape/for heating tape type1 max. Temperatur Rollenbreite Rollenlänge Bestellnummer
Aluminium self-adhesive tape/PSB 80°C 50 mm 50 m 02-5500-0003

Aluminium self-adhesive tape/HSB 150°C 50 mm 55 m 02-5500-0014
Fabric self-adhesive tape/PSB 130°C 12 mm 50 m 02-5500-0001
Polyester self-adhesive tape/PSB 100°C 19 mm 50 m 02-5500-0005
Glass-fibre self-adhesive tape//up to HSB 60 180°C 12 mm 50 m 02-5500-0035
Aluminium foil/HSB3 1000 mm 100 m 02-2430-0002
Aluminium foil/HSB 1000 mm 10 m 02-2430-0003
1
Details of the heating tape types refer to their max. possible operating temperature. At lower holding temperatures self-adhesive tapes with a
correspondingly lower temperature resistance can be used.
2
For steam-purged pipes use self-adhesive tape 02-5500-0035.
3
It is recommended that aluminium foil is wrapped round plastic pipes before installing the heating tape in order to protect the pipes and improve heat
distribution.
5
4.2.4 Straight line installation

■ Install the heating tape on the pipe approximately in the “half past four“ or “half past seven“ position.
■ Do not install the heating tape at the lowest point on horizontal pipes.
■ Do not install the heating tape on the upper half of horizontal pipes either, unless this has been
specified in the project planning. This prevents mechanical damage to the heating tape, e.g. when
installation personnel walk along the pipe. Furthermore installation of the heating tape on the upper
half of the pipe is disadvantageous for the heat distribution and only meaningful in certain
applications.
4.2.4 Installation of fittings, flanges and pumps

■ When installing the heating tape always ensure that the minimum permissible bending radii
(PSB = 25 mm/HSB = 25 mm) are observed.
Bending the heating tape on edge is not allowed.
■ Always install the heating tape on fittings, valves etc in such a way that these are easily accessible
and replaceable during maintenance and repair work, and heating circuits do not have to be cut up.
This is most easily achieved using a sufficiently large heating tape loop.
■ Through the higher heat losses from fittings, valves, flanges etc a greater length of heating tape is
required. This additional requirement is given in the project planning documents.
■ The following illustrations show typical types of installation
Installation on flanges
Installation on fixed points
6
Installation on valves
Installation on bends
Installation on pressure gauges
Installation on pumps
7
Basic construction
Heating tape Self-adhesive tape Aluminium foil Identification plate
Insulation bushing
5 12
6, 7, 8, 9
1
13 10 11 3
4
1 Parallel circuit heating tape
2 2 PLEXO terminal connection
3 PLEXO remote end termination
4 EEx e junction box
5 Temperature monitor BSTW
6 Mounting bracket
7 Mounting panel
8 Clamping ring for mounting bracket
9 Turnbuckle for clamping ring
10 Glass fibre self-adhesive tape
11 Identification plate “Electrically heated“
12 Temperature monitor BSTW for extra alarm (optional)
13 Mounting bracket (illustrated = stainless steel, optional)
8
4.3 Installation of accessories
■ Use only original BARTEC accessories to ensure that existing technical regulations and permits are
observed.
■ Please note that the use of original BARTEC accessories is a precondition for possible guarantee
claims.
■ Follow exactly the installation and technical instructions on the enclosed instructions for use for the
particular accessory. This is absolutely essential for fault-free installation.
Caution - Do not connect the two supply conductors together –

otherwise this will cause short-circuiting.
4.3.1 BARTEC system accessories

For complete installation of a heating circuit the following system accessories are normally required in
addition to the heating tape:
■ Powered end connection
■ Power supply cable
■ Remote end termination
■ Fixing accessories for the heating tape
■ Heat insulation bushings
■ Identification plate “Electrically heated“
The following further system accessories may also be required:

■ Tape-to-tape splice connection
■ Heating tape tee branch
■ Junction box/tee branch junction box
■ Mounting bracket and mounting panel for junction box or tee branch junction box
■ BARTEC automatic controllers
4.3.2 Further installation instructions

■ Install the heating tape remote end termination and tape-to-tape splice connection before you install
the power supply connection.
■ Mount the junction box so that it is easily accessible.
■ When positioning the junction box ensure that the box bushings with threaded glands for cable and
heating tape do not point upwards.
■ When installing the connections establish whether existing cable routes can be used.
■ Keep the junction box closed for as long as possible during installation, in order to prevent
penetration of dirt and moisture.
■ Check whether installation of the remote end termination, tape-to-tape splice connection, tee branch
and connection have been carried out correctly by subsequently measuring the insulation resistance.
9
After installing junction boxes check:

whether correctly fitting and approved glands and blanking plugs have been used and that these
have been mounted properly,
firm fitting of glands and blanking plugs
firm fitting of the junction box on the mounting bracket
Make sure that the requirements given in the test certificates have been fulfilled
4.4 Acceptance and acceptance testing
Caution - The installed heating circuits must be tested before fitting the thermal insulation.
Procedure
■ Make sure that the heating tape has been correctly installed, in particular that
the heating tape has a flat, flush fit on the pipe or tank,
a sufficient additional length of heating tape has been installed on flanges, valves, pumps
and other fittings,
the heating tape is not damaged and has not been laid under pipe clips.
■ Check that connections, remote end terminations, tee branches and junction boxes, as well as
temperature regulators and sensors, have been properly installed (visual check).
■ Supplement the pipe system documentation by adding the position of heating tape, connections,
remote end terminations, tape-to-tape splice connections and tee branches.
■ Measure the insulation resistance of all heating circuits before installing the thermal insulation.
■ The correct installation and functioning of the electric trace heating system should be confirmed by
an acceptance test report (see following sample form).
10
Installation
Acceptance report and Operation
Electric trace heating systems Page
Electric trace heating systems for tanks and vessels Heating circuit
Customer Date
Order comm. no.
Project plant
BARTEC order no.
Production no.
Heating circuit no.
Pipe/tank no.
Building
Product
Heating cable
Type
Installation number
Heating cable length m m m

Voltage V V V
Current Switch on A A A
Operation A A A
Power W/m W/m W/m
Resistance cold Ω Ω Ω
warm Ω Ω Ω
Insulation resistance Set value: ≥ 5 MΩ

at 1000 V measuring voltage > MΩ > MΩ > MΩ
Temperature setting Functional test Functional test Functional test
yes no yes no yes no
Regulator °C °C °C
Limiter °C °C °C
Insufficient temperature °C °C °C
Explosion-proof design Ex Ex Ex
Temperature class T T T
Comments:
Above data checked by:
Place/date Installer Customer
BARTEC GmbH Max-Eyth-Straße 16 D-97980 Bad Mergentheim Tel: +49 (0) 7931 597-0 Fax: +49 (0) 7931 597-119
11
5. Temperature regulation
Selection of temperature regulator
■ Use of a temperature regulator is always recommended. The data given in the project planning
documents are decisive for this.
■ If exact requirements are set on the temperature use of a regulator is esential.
■ When selecting a suitable temperature regulator the following technical data in particular must agree
with the respective application:
Operating voltage
Rated current
Temperature regulating range
Max. permissible temperature/max. permissible sensor temperature
IP protection
Explosion protection, if necessary
Certification
■ Use of a regulator with contact sensor is always to be recommended, since this is most economical
with regard to energy utilisation.
■ Before installation make sure that the temperature regulator used fulfils the technical requirements
and agrees with the project planning documentation.
Temperature regulator with sensor cable
■ In pipe trace heating systems the temperature sensor should not be mounted in the immediate
vicinity of the heating tape.
■ When fixing the temperature sensor care should be taken that there is good heat transmission
between the sensor and pipe (e.g. by using aluminium self-adhesive tape or a heat conducting
paste).
■ As a rule the temperature sensor is fitted at a distance of at least 2 metres from valves, flanges, pumps
and supports.
■ Observe the installation instructions for the respective temperature regulator.
■ If the position of the temperature regulator is not specified in the project planning you should
contact your BARTEC technical office. Our staff will give you expert advice.
Further installation instructions

■ Keep the enclosure of temperature regulators closed for as long as possible during installation, in
order to prevent penetration of dirt and moisture.
■ Ensure that the enclosure cover is fitted perfectly and properly sealed.
■ Use fitting threaded glands and blanking plugs, according to the technical requirements and test
certificates, and make sure that they are properly sealed.
12
6. Thermal insulation
Important note
Before fitting the thermal insulation check whether an acceptance test for the insulation has been
carried out and a test report made.
Installation of the thermal insulation

Reliable functioning and effectiveness of an electric trace heating system depends to a considerable
extent on correct, expert installation of the thermal insulation.
Particular attention should be paid to the following factors:
■ Check that the thermal insulation (type, thickness of insulation) agrees with the project planning
documentation. Thermal insulation deviating from the project planning documentation must on no
account be installed, since otherwise correct functioning of the trace heating system is no longer
guaranteed.
■ Install the thermal insulation immediately following installation of the trace heating system if
possible, in order to minimise the potential risk of damaging the heating tape.
■ Use only dry insulating material since this loses its efficiency through moisture and therefore
impairs functioning of the trace heating system.
■ When installing the thermal insulation always take care that the heating tape is not damaged.
■ Use only BARTEC thermal insulation bushings for lead-through of heating tapes and power supply
cables.
■ Seal the thermal insulation at all seams of the steel sheet jacket and at bushings (valve bushings,
suspension brackets). The complete insulation must be reliably waterproof.
■ After installing the thermal installation measure the insulation resistance of each heating circuit
again, in order to ensure that the heating tape has not become damaged during installation.
Marking
■ Mark the outside casing of the thermal insulation with identification plates “Electrically heated“ at
intervals of maximum 3 metres, in order to warn maintenance personnel of the electric trace heating
system.
13
7. Voltage supply and electrical protective equipment
Rated voltage
■ BARTEC heating tapes are available for various rated voltages. Information on this is obtainable from
the BARTEC technical literature and from your BARTEC technical office.
■ Operate the respective heating tape only at the specified rated voltage.
Overcurrent protection
■ For overcurrent protection please use only automatic circuit breakers in agreement with the project
planning and technical documents of BARTEC. Deviations from this can lead to faulty triggering of
automatic circuit breakers or to impairment of the effectiveness of the overcurrent protection device.
■ If fuse protective devices other than those given in the project planning or the technical documentation
of BARTEC are to be used, please contact your BARTEC technical office.
Fault current protective system

■ For limiting heating up as a result of abnormal earth terminating currents and earth discharge
currents the following protective system must be installed, in addition to overcurrent protection:
In a TT or TN system a fault current protective system must be used, the rated current, minimum
operating current of which does not exceed fault current of 300 mA. Fault current protective systems
with 30 mA are preferable. The maximum switch-off time of the system must not exceed 5 sec for
rated current, minimum operating current fault current and 0.15 sec for 5 times the rated curent,
minimum operating current fault current (see EN 60079-14, 1997 and IEC 60755).
■ To make this protective measure effective a heating tape with protective braiding should generally
be used. This protective braiding should be included in the protective system. This applies
particularly to all trace heating systems on non-electrically conducting pipes (plastic pipes, coated
pipes) and surfaces.
Caution
■ When carrying out electrical protective measures the respective national technical regulations
should be observed.
In the Federal Republic of Germany:

VDE- regulations, particularly DIN VDE 0100 and DIN VDE 0721, part 1 and 2/A3 as well as
VDE 0254.
14
8. Tests and putting into operation

Tests
Progressive tests on the trace heating system during installation and operation serve to avoid additional
costs through not recognising installation and assembly faults early enough. Since the installation
costs for the trace heating system and thermal insulation exceed the costs for the heating tape to a
considerable extent, the following test sections should be strictly observed.
Measurement of the insulation resistance is carried out at the following times:
a) Preliminary test
Shortly before beginning installation of the heating tape on the construction site
b) Acceptance test
Following complete installation of the heating circuit or fitting of the thermal insulation
c) Final inspection
Immediately after completion of work on the thermal insulation
d) Commissioning
Before switching on the installation
Measurement of the insulation resistance

■ This test method is used to determine damage to the heating tape and possible installation faults in
connections, remote end terminations, tape-to-tape splice connections and tee branches
■ An insulating test apparatus with a minimum testing voltage of DC 500V and a maximum testing
voltage of DC 2000V is used. The insulation resistance should be at least 50 MOhm per heating
circuit, irrespective of the length.
■ Measurement is carried out as follows:
Heating tape with protective braiding and outer jacket
Measurements are carried out between each supply conductor of the heating tape and the
protective braiding, as well as between the protective braiding and the earthed pipe.
Acceptance and acceptance test report

■ After completion of the installation work (before fitting the thermal insulation) each heating circuit
must be accepted, if possible in the presence of the client. Acceptance must be documented
(acceptance test) according to the enclosed sample acceptance report.
■ All tests going beyond this must also be documented in an acceptance test report.
■ After completion of work on the thermal insulation final inspection and acceptance of the individual
heating circuits is recommended. As a rule carrying this out is incumbent on the client or the final
customer (= final inspection).
Putting into operation

■ Each trace heating system can be put into operation only if
the acceptance test reports for each heating circuit are available and the perfect state of the trace
heating system has been confirmed,
the thermal insulation has been completely installed and is in a dry condition
it has been ensured that the heating circuit is operated within the data specified by BARTEC.
Note
Additional heating power, which is required for heating up empty or already filled tanks/pipes, is
normally not taken into consideration in the project planning. Therefore for cold starting of the
system you should allow sufficient time so that the pipe can reach the required temperature.
15
Caution
Electrical equipment may be put into operation in potentially explosive areas only if
■ an EC type test certificate from the Physikalisch-Technischen Bundesanstalt (Physical
Technical Federal Institute) (PTB), Bergbau-Versuchsstrecke (Mining Testing Track)
(DMT) or another testing authority named according to directive 94/9/EC is available.
■ the following marking according to directive 94/9/EC has been fitted on the equipment by
the manufacturer:
protective type
Device group
Device category
Manufacturer’s name
marking
In parag. 12 of the (German) ElexV directive it is stipulated that the operator must arrange for
testing of the satsifactory condition of the electrical installation by an electrician, or under
supervision of an electrician, before putting into operation for the first time (= commissioning
test).
9. Operation and maintenance

Operation
■ During operation of the electric trace heating system it must be ensured that all components of the
system are operated within the operating data specified by BARTEC. This applies particularly to
observation of the maximum temperature. Operation within these operating data is a precondition
for possible later guarantee claims.
System documentation
■ Complete documentation must be carried out for each system, from the project planning stage,
through installation and putting into operation up to periodic maintenance of the trace heating
system.
■ This documentation should include the following:
Project planning documents
Heat loss calculation
Selection of the heating tape
Piping plans with division of heating circuits
Circuit diagrams
Up to date piping plans
Acceptance reports
Reports on repair work and any operations carried out on the tank/pipe system, trace
heating system and thermal insulation
Inspection reports
Maintenance
For optimum safety and reliability of a trace heating system BARTEC recommends the introduction of
a maintenance plan which provides for visual, functional and electrical inspection at specified intervals.
Important instructions in this respect are given below:
16
Visual and functional inspection

■ Check the thermal insulation for possible damage, missing seals, cracks, damage to the outer jacket,
missing thermal insulation bushings for heating tapes and cables, penetrated water or chemicals.
If the thermal insulation is damaged the heating tape should be checked for possible damage.
Damaged heating tapes should be replaced by new ones.
Parts subject to wear should be replaced (e.g. seals, locking plates etc).
■ Check the junction box, connection enclosure and enclosures of temperature regulators for
corrosion damage and possible mechanical damage. Make sure that all enclosure covers are
properly closed.
■ Check the temperature regulator connecting cables and capillary tube systems for damage and that
their installation is protected against mechanical damage.
■ Check temperature regulators for operatability.
Electrical inspection
■ Measurement of the insulation resistance should be seen as a permanent part of regular maintenance.
Inspection intervals
■ For frost protection installations inspections should be carrried out annually before the heating
period begins.
■ For plants designed to maintain process temperatures, inspections should be carried out at regular
intervals, but at least twice a year.
Personnel training courses

■ Regular maintenance should be carried out by trained, experienced maintenance personnel.
■ It is recommended that maintenance personnel are supported in learning new developments in
application technology and maintenance by regular training.
BARTEC Service
■ Apart from the installation of complete heating circuits, BARTEC also offers its experienced service
personnel for maintenance work.
Repair work on thermal insulation or piping

■ Ensure that the plant is isolated for safety before all repair work.
■ Take care that the trace heating system is not damaged during repair work on the pipe system or
thermal insulation.
■ Ensure that at the end of all repair work the heating circuits plus thermal insulation are properly
installed again in accordance with the project planning documentation.
■ Carry out a visual, functional and electrical check on the trace heating system at the end of all repair
work.
■ Remember that self-limiting heating tapes are designed only for installing once.
Note
For operation, and therefore also for maintenance of explosion protected equipment and
installations DIN VDE 0105, part 1 “General Stipulations“ and part 9 “Additional Stipulations
for Potentially Explosive Areas“ is applicable.
Electrical installations in potentially explosive areas are included under installations requiring
surveillance (according to parag. 2 of the equipment safety law).
The operator must arrange that the electrical installations are tested before putting into
operation for the first time, and then at definite intervals – at least every 3 years.
Testing, which must be provable, is to be carried out by a electrician, or under the supervision
and direction of an electrician.
17
10. Procedure when faults occur

Damage to the heating circuit
■ On no account should you try to repair a damaged heating tape. Replace the damaged section of the
heating tape immediately by a new one (fire risk!)
■ Use only BARTEC original components for repairing a heating circuit (e.g tape-to-tape splice
connections, connections and remote end terminations, seals etc).
Instructions for remedying faults

■ If faults occur in a trace heating system we recommend that fault finding is carried out according to
the instructions below and, if necessary, the fault then remedied.
■ If the attempt to remedy the fault according to the instructions below is not successful, please contact
your BARTEC technical office immediately.
Note
For potentially explosive areas the following applies

Maintenance work on and modifications to electrical installations in which an explo
sive atmosphere can be ignited may be carried out only with the permission of the
works manager or his representative.
The most important safety measure is to make the system dead before beginning work,
and to ensure that this state is maintained (DIN VDE 0105, part 1, section 7)
A hot work permit is required, or suitable protective measures must be taken, if work
has to be carried out with a hot surface/flame.
18
10.1 Automatic circuit breaker is triggered
Possible causes Measures
1. Automatic circuit breaker is under Check current loading, check overcurrent

dimensioned protection and max. current-carrying capacity
of the power supply cable.
2. Heating circuit is too long
3. Switch on at too low temperatures
(See project planning data)
4. Defective FI protective switch Replace FI protective switch
5. Short circuit/earth fault at connections, Defective connections, remote end

tape-to-tape splice connections, remote termination, localise connection and repair or
end termination or power supply cables localise defective heating tape and replace.
6. Short circuit/earth fault on heating tape
7. Supply conductors of heating tape have Shorten defective remote end termination,
been connected together at the remote end check remaining heating circuit for possible
termination (short circuit/earth fault) further damage, install a new remote end
termination.
10.2 Fault current circuit breaker (FI) is triggered
1. Automatic circuit breaker is under- Check current loading, overcurrent protection

dimensioned and max. current-carrying capacity of the
electric power supply cable.
2. Defective FI protective switch
3. Short circuit/earth fault at connection, tape
to-tape splice connections, remote end
termination or power supply cables
4. Short circuit / earth fault on heating tape
through damage
5. Supply conductors of heating tape have
been connected together at the remote end
termination (short circuit / earth fault)
6. Excess moisture in the connection, Localise moist parts, renew terminal block
remote end termination or tape-to-tape and dismantle affected parts. First check the
splice connections through improper enclosure part outside the thermal insulation,
installation and, if necessary, repair this – then the part
below the heat insulation.
7. Damage to heating tape or power supply Localise damaged parts and replace with new
cable heating tapes or power supply cable.
19
10.3 No, or too low heating power
1. No, or too low supply voltage Check the mains voltage at the supply point of
the heating circuit and remedy any faults here.
2. Heating circuit length is shorter than Check heating circuit distribution, installation
specified in the project planning and length, recalculate required heating power.
documentation – recalculate. a) Connect tape-to-tape splice connections and
a) Supply cables or tee branches have branches, and recheck heating power.
not been connected. b) Localise interruption and remedy this, then
b) Heating tape is disconnected (interrupted). recheck the heating power.
3. High transition resistance through faulty Reinstall affected connection, supply cable,
connection, supply cable tape-to-tape splice connection and at the same
time ensure that connecting or crimping is
correct.
4. Temperature regulator has been incorrectly Correct wiring or position sensor correctly.
connected, incorrectly adjusted or the sensor
has been positioned incorrectly.
5. The maximum permissible temperature of the Check pipe temperature.

pipe has been exceeded.
6. Heating tape has become too moist Replace faulty components

(e.g. faulty supply cable or damage to
heating tape).
7. Heating tape has been subjected to too high Replace connection, remote end termination,
temperatures. heating tape
10.4 Heating power appears to be correct, but pipe temperature is below

the required value
1. Moist thermal insulation Replace moist thermal insulation with dry

insulation and make sure that sealing is
correct.
2. Inadequate covering with heating tape on Install additional heating tape using tape-to-
flanges, valves and fittings tape splice connections, but do not exceed the
max. permissible heating circuit length.
3. Incorrect adjustment of temperature Correct regulator setting

regulator
4. Inadequate thermal design concept Check project planning documentation

together with your BARTEC office, and follow
the recommendation of the BARTEC project
planning department.
5. Cross-section of power supply cable is Use power supply cable with approved cross-
below the permissible value (too high section
voltage drop)
6. Sensor wrongly positioned Position sensor correctly
20
BARTEC protects
people and the
environment
by the safety
of components,
s y s t e m s
and plants.
D-UK-BEH151203-01/04-BARTEC WerbeAgentur-221846
BARTEC GmbH Max-Eyth-Straße 16 Phone: +49 7931 597-0 E-mail: info@bartec.de

D-97980 Bad Mergentheim Fax: +49 7931 597-494 Internet: http://www.bartec.de
6th Floor, Jolly Board Tower,
D-Wing, i-Think Techno Campus, Kanjurmarg (East),
Mumbai-400042, Maharashtra, India.
PROJECT LIQUID TERMINIAL TANK FARM AT KATTUPALLI, PHASE- I
OWNER
ADANI KATTUPALLI PORT PVT. LTD. (AKPPL)
CLIENT
HOWE ENGINEERING PROJECTS (INDIA) PVT. LTD.
EPC CONTRACTOR
NVENT THERMAL INDIA PRIVATE LTD.
CONSULTANT NA
INSTALLATION, OPERATION & MAINTENANCE MANUAL (STS)

TITLE OF DOCUMENT
NA
CLIENT
DOCUMENT NO.
Rev.
QD08_1002 0
CONTRATOR/ No.
CONSULTANT’S DOCUMENT NO.

0 05-Nov-19 IFR MRI GCJ BNP
This Document is the property of HOWE. It should not be used, copied or reproduced without their written Permission.
Page 1 of 1
ADANI HOWE KATTUPALLI STS PROJECT
Installation, Operation & Maintenance Manual

SKIN-EFFECT HEATRACING SYSTEM ( STS)
0 5-Nov-19 lssued for Documentation

Rev Date Purpose of Issue Prepared By Checked By Approved By
STS O & M Manual
0 5-Nov-19 Issued for Documentation

Rev Date Reason for issue Made by Disc. check Proj. appr. Client appr.
Initial Start-up, Operation and Maintenance Instructions
Section Contents
1.1 General Commissioning Procedure
1.2 Initial Start-up Data
1.3 Normal Start-up Procedure
1.4 STS Troubleshooting Guide
1.5 Recommended Maintenance
Document Title:
Project No. P.IN190021
Installation, Operation &
Maintenance Manual (STS)
12” Bitumen Pipeline

ADANI HOWE KATTUPALLI STS PROJECT
Safety Warnings
Safety Warning: Always follow Adani HOWE approved Tag and Lock-out
procedures before working on any of the STS transformers, control panels
or connection boxes.
Safety Warning: Insulation Resistance Test - Very high-test voltages are

used. Take appropriate measure to assure that no personnel can come in
contact with the STS wire while it is under test.
Safety Warning: Insulation Resistance Test - The STS wire and heat
tube act like a large capacitor and will hold the test voltage for a considerable
length of time after turning the test equipment off. Be sure to leave the test
equipment connected and off until the residual charge has dissipated, and
the voltage has returned completely to ZERO.
Confidential Property of Nvent Thermal

1.1 General Commissioning Procedure
The proceeding steps are followed during the commissioning of a typical STS
system.
1. Review Quality Control records for the installation of the heat tube, wire
and splices (wire and splice records include the dielectric test results, as
specified in the STS Installation/Construction Manual). The wire and
splice dielectric tests are required for review before energizing the
system; the heat tube records may be reviewed at any time, but preferably
before energizing the system for maintenance (step 5 below).
2. A thorough inspection of the pipeline installation is performed as per

nVENT STS Heat Tracing and RTD Inspection format. This includes a
visual inspection of the whole pipeline (preferably via a walk-along of the
entire length for above ground pipe line sections), paying particular
attention to the power connections, end terminations and RTDs. The
purpose is to check insulation completion and its integrity, heat sinks,
grounding and electrical connection boxes. If possible then power and
end connection boxes should be opened for inspection of the
connections. One or two splice boxes should be opened for inspection of
the splices, if possible.
3. Inspection of the panel and transformer installation, as per the STS

System Commissioning Data sheet, is next. This includes initial power
up of the panel and verification of basic control functions.
4. Apply power to the heater, observing voltages and currents carefully.

System currents should be within the range specified in the STS design.
For mid-feed systems, the heater currents must be balanced within 15%.
Any transformer tap adjustments that may be required to obtain proper
operating parameters, is made at this time.
5. Allow the system to maintain temperature, monitoring and logging

performance on the STS System Commissioning Report log sheet
For the following STS system configurations:
∉ Scott T connected heater (3 phase power supply, 2 phase heater)
6. Allow system to operate on Automatic control overnight. Log performance

on the STS System Commissioning Report again the following morning.

1.2 Initial Start-up Data
During the initial start-up/commissioning of the skin effect tracing system,
operational and performance data are recorded. The actual start up data is
listed on the following pages.
Initial Start-up Procedure
This procedure should be followed during the initial commissioning of the system,
anytime that the system is being restarted after having been out of service
for extended periods or having modifications or repairs made to it.
1. A dielectric test must be performed on the wire after pulling and splicing, but
before terminating. It may be helpful to test after each section is pulled, so
that any faults can be more easily found. In any event, a final DC dielectric
test at the following voltages must be performed. Table 1 lists the test
voltages to be applied for each STS wire type. An STS tracing wire & splice
inspection & test report form is provided at the end of installation &
construction manual. Each STS wire must be inspected, tested and reported.
Copies of completed forms must be available for the nVent Thermal field
engineer to review. A final pre- commissioning test must also be performed
and witnessed by the nVent Thermal field service engineer.
Table 1: STS Wire Test Voltages

STS Wire STS Wire Types Dielectric Test
Voltage Rating Voltage (DC)
600 and 1000 FSE, 600V and 1000V 2.5 kV
2500 STS-HT 7.5 kV (hipot)
5000 STS-MT 15 kV (hipot)
Increase the test voltage gradually, from 0 to the specified value. Hold the
test voltage for 1 minute and record the final meg-ohm (MK) or micro-amp
(µA) reading on the report form. The minimum acceptable insulation
resistance is 100 meg-ohms per km of wire under test, although most
systems will read approximately 1500 meg-ohms per km. Investigate low
readings and review carefully prior to energizing the system. The source of
the low reading should be investigated and corrected. A common cause of
low megger readings is water in the heat tube or splice boxes.
Safety Warning: Very high-test voltages are used. Take appropriate

measure to assure that no personnel can come in contact with the STS wire
while it is under test.

Safety Warning: The STS wire and heat tube act like a large capacitor and
will hold the test voltage for a considerable length of time after turning the
test equipment off. Be sure to leave the test equipment connected and off
until the residual charge has dissipated, and the voltage has returned
completely to ZERO.
2. All power connections should be verified per the system schematics. Ensure
that the transformer secondaries are connected to the proper skin effect
circuit (this is especially critical for unbalanced mid-feed systems!) Verify
that the feed box is properly grounded and that there are no ground
connections made at the transformer secondary terminals. Check all power
connections and terminations for tightness.
3. Open the Off-Load Isolators (located in the STS Panel), turn the Heat Trace
selector switch to the “OFF” position, and power up the control panel. Using
the simulated RTD and AC current inputs, check the operation of the control
system. Test the control system in “Hand” and “Auto” modes. Verify that all
alarm circuits are functional.
4. Adjust Over current relays to 100%, close the Off-Load Isolators, and switch
Heat Trace selector to the “Hand” position. Ensure that heat trace power is
applied to the pipeline, and that tracing circuit currents are within reasonable
limits. Record the tracing system voltages and currents and verify the panel
meters using a hand-held instrument.
5. Measure the line voltage feeding the transformer. If necessary, power off
the system and adjust the transformer primary taps to match the measured
line voltage (refer to the transformer wiring diagram for tap settings.)
6. Perform either step 6a or step 6b, depending on the type of system being
started. Keep in mind that the tracing circuit currents will start at a higher
(inrush) value and will taper off toward the steady state value over a period
of several minutes. After 10 or 15 minutes of on-time, the currents should be
near the lower end of the target range, which is 3.5% above or below the
design value.
a. MID-FED and DUAL TUBE SYSTEMS: If the measured current falls

below the target range for the measured pipe temperature, power off the
system and adjust the transformer secondary taps to the next higher
voltage. Energize the heat tracing and repeat this step until the measured
current falls within the target range. Once both currents are within the
target range, calculate the current balance using CB=I(higher)/I(lower). If
CB is between 1.10 and 1.15, move on to step 7.

If CB is greater than 1.15, adjust one of the transformer secondary taps
one position: either lower the tap on the higher current side, or raise the
tap on the low current side. Repeat step 6a to verify the currents are still
within range.
b. END-FED SYSTEMS: Referring to the Operational Characteristics

section, compare the measured tracing circuit current to the steady state
STS current. If the measured current falls 3.5% below the design value
for the measured pipe temperature adjust the transformer secondary taps
to the next higher voltage. If the measured current rises 3.5% above the
design value, adjust the transformer secondary taps to the next lower
voltage. Energize the heat tracing and repeat this step until the
measured current falls within the target range.
7. Adjust the over-current relays to the specified value of Itrip. Verify this setting
using a simulated input current, as described under the Over-current Relay
Setup section of this manual.
8. De-energize the tracing for 15 minutes, then re-energize it in “Auto” mode

and monitor its performance in accordance with the Start-up Performance
section of the STS System Commissioning Report. Record the initial inrush
current and starting pipe temperature, and then record the currents and
temperatures at the time intervals specified on the Start-up Performance
table.
9. Once the maintenance temperature has been reached, monitor the system’s
operation through several on/off cycles, recording the temperatures
(measured and setpoint) and on/off times for each cycle. Calculate the total
cycle period (on time+ off time for 1 cycle) and duty cycle (on time ÷ total
cycle period). Record this information in the Temperature Maintenance
Performance table on the STS System Commissioning Report

1.3 Normal Start-up Procedure
This procedure applies to restarting of the system after a short duration of down
time, such as after a plant turn-around. If down time becomes long (several
months), it is recommended that a more thorough startup procedure be used.
1. Set the Heat Trace selector to the “OFF” position; open the Off-Load Isolators
and power up the control panel. Verify that all instruments power up
successfully and operate normally. Verify that all temperature controller
settings are correct.
2. Close the OFF-LOAD ISOLATORS and set the Heat Trace selector to
“AUTO” mode. Monitor the heat trace currents for the first ½ hour in
accordance with step 8 of the Initial Start-up Data section. Verify that the
currents are in line with those measured during initial startup.

1.4 STS Troubleshooting Guide
High Temp Alarm
Panel indicates high temperature alarm and will not energize the heater.
Normally, a high temperature alarm will trip the lockout relay in the STS panel,
turning off power to the heater. Investigate why the high temp alarm occurred
before restoring power to the heater.
Low Temp Alarm

1) Panel indicates low temp alarm; heater is energized continuously but
pipe does not seem to heat up properly.
Check the following items:
∉ Is temperature sensor properly installed and firmly against pipeline?

∉ Is insulation well packed and sealed around temperature sensor?
∉ Is insulation dry around temperature sensor?
∉ Are there any other heat sinks near the temperature sensor (see note
below)?
∉ Check the operating current of the STS system; make sure it is within
the design criteria.
Note that heat sinks, such as valves, pipe supports, uninsulated or wet sections
of piping, and other high heat loss items can affect the pipe temperature for a
distance of up to 10 times the diameter of the pipe. For a 10-inch pipe, this
means that the cooling effect of a valve could be a problem anywhere within 8
feet (2.5 meters) from the valve itself.
Warning: If a low temperature alarm is caused by heat sinks or sensor problems,

it is quite possible that other sections of the pipeline have heated to excessively
high temperatures. This can cause damage to the STS wire in some cases,
particularly when high temperature maintenance is required.

2) Panel indicates low temperature alarm; heater is not energized
Check the following items:
∉ Check the status of the primary power supply to the STS system.
∉ Check the status of the lockout relay in the STS panel. If it is tripped,
investigate why it tripped.
∉ Check for indication that a high temperature trip might have occurred.
∉ Check for indication of an electrical fault trip.
∉ Check for indication of a transformer fault or problem.
∉ Check the operating current of the STS system; make sure it is within
the design criteria.
Primary Power Supply

Primary circuit breaker or fuse trips when operated to energize the STS
transformer
All power transformers have an inrush current when energized. This inrush
current can be as high as 10 or 20 times the normal full load current of the
transformer, but only lasts for a few cycles of the AC power line. It is critical that
all of the upstream (i.e., primary supply) protective devices be properly selected
and coordinated to prevent nuisance tripping when the system is energized.
As a general rule, the primary circuit breaker or fuse just ahead of the
transformer should be sized 25% larger than the full load current rating of the
transformer. For instance, if the transformer primary current rating is 100 Amps,
then a 125 Amps fuse or CB should be installed. If there is an additional circuit
breaker or fuse ahead of that (for example, if we have supplied a primary CB in
our equipment, and the customer has also supplied a CB in his switchgear that
feeds our equipment), then the additional CB must be sized or set to a slightly
higher current rating than the one closest to the transformer.
Many large circuit breakers have adjustable trip settings. These will usually
include separate thermal (time delayed) and magnetic (instantaneous) trip
settings. Check these settings, particularly the magnetic trip, to ensure that it
will allow for the transformer inrush.
Sometimes, particularly where oil filled transformers are used, the transformer
will be provided with a number of alarms (oil pressure, temperature, etc.). These
alarms are sometimes connected back to the primary switchgear. If this is the
case, check the status of the alarms and verify that they are properly
connected to the primary switchgear.

STS Heater Faults
1) Locating faults in the STS heater - initial assessment
The first step toward locating a fault in the STS heater is to identify the nature
of the fault (open or shorter circuit). This can be done either from the STS panel
or from the power connection box at the pipeline. The following basic steps can
be followed:
1. Familiarize yourself with the STS panel and identify all external power
sources connected into it.
2. For safety, de-energize and lock out the power supply to the STS system
and any other external power sources that may represent a possible
safety risk.
3. Using a 5000 V (or higher) DC insulation tester (Megger), check the STS
wire. A shorter circuit indication at this stage could mean a short circuit
fault in the wire, or it could simply mean that the STS wire has not
opened as a result of the fault. A high reading at this stage means that
the STS wire is open-circuited.
If the megger test indicates a short circuit, follow instructions for "Locating short
circuit faults in the STS heater".
If the megger test indicates an open circuit, follow instructions for "Locating
open circuit faults in the STS heater".
2) Locating faults in the STS heater - 'brute force' method
This method uses the “guess, divide and average” approach to narrow down
the location of a fault by testing the STS wire from pullboxes. Once the general
nature of the fault has been identified, the location of the fault is determined
through a process of elimination. An ordinary megger can be used for this
procedure.
1. Prepare the system according to the type of fault you are searching for:
∉ If the fault is an open circuit fault, then make a temporary short circuit
between the STS wire and the heat tube at the power connection box.
∉ If the fault is a short circuit fault, then disconnect the STS wire from
the heat tube at the end termination box.
2. Locate the pullbox that is most nearly in the center of the pipeline section
being searched and open the STS wire at that point. Test the wire in both
directions. The fault lies in the direction which yields the same or similar
reading as was obtained in the initial assessment

3. Referring only to the section of the pipeline containing the fault, repeat
Step 2. Continue his process until the location of the fault has been
identified within a few hundred meters.
This approach will typically locate a fault on a 5 km pipeline to within 160

meters after 5 tries. For a 10 km pipeline, 6 tries would be required.
3) Locating open circuit faults in the STS heater using capacitance

measurements
Capacitance measuring instruments are available which can be used to measure

the capacitance of a length of STS wire installed in a heat tube. For this
purpose, an STS heater is basically a long tubular capacitor; the longer a
section of STS heater is, the higher the capacitance it will exhibit. The procedure
for using this approach is listed below.
1. Disconnect and isolate the STS wire at the power connection and end
termination boxes
2. Measure the capacitance between the STS wire and the heat tube at the
power connection end. This value will be called Cp
3. Measure the capacitance between the STS wire and the heat tube at the
end termination. This value will be called Ce
4. Calculate the approximate location of the open circuit using the formula:
X = TotalPipeLength * Cp / (Cp + Ce)
where X is the distance from the power connection to the open circuit.
It should be noted that high resistance faults (between the STS wire and the
tube) can skew the capacitance measurements leading to location error.
4) Locating short circuit faults in the STS heater
There are different ways to approximate the location of a short circuit fault in an
STS heater.
One approach is the low-tech “guess, divide and average” method (see Section
2 above).
Another approach is the “resistance ratio” method. This method gives a very
rough approximation of the location of a STS heater short and only requires the
use of an ohmmeter (see Note below). The procedure for using this method is
as follows:
1. Disconnect and isolate the STS wire at the power connection and end
termination boxes

2. Measure the resistance between the STS wire and the heat tube at the
power connection end. This value will be called Rp
3. Measure the resistance between the STS wire and the heat tube at the
end termination. This value will be called Re
4. Calculate the approximate location of the short circuit using the formula:
X = TotalPipeLength * Rp / (Rp + Re)
where X is the distance from the power connection to the short circuit.
Note: Some times a short in an STS system will cause the wire to burn open
downstream of the fault, making resistance ratios difficult. Also, taking a DC
resistance measurement can be inaccurate since you wind up reading
through the pipe itself, with elbows, valves, ground points, etc all affecting
the reading. This method may still be useful as a rough gauge though.
Time Domain Reflectometry (TDR) can also be used to find short circuits in
STS systems. TDR's might be useful, although the use of heavy duty models
may be required due to the size of the heater and amount of capacitance and
reactance.
There are some other types of equipment for fault locating in power cables that
can also be used (various signaling type units).

1.5 Recommended Maintenance
Performance data should be recorded periodically to ensure that the system is

operating and performing correctly. The STS System Commissioning Report
found in this section serves this purpose.
Approximately once a month, record the operating parameters using the “HAND”
mode, or while the system is cycled ON. Allow 10 to 15 minutes of operation
before recording the values. At least once per year, record the temperature
maintenance performance data (STS System Commissioning Report).
It is also recommended that the tracing wire dielectric be checked using a 2500
volt megger once per year.
There are several other maintenance items that should be made part of your
preventative maintenance program. The frequency of inspection listed is a
minimum recommendation; greater frequency is certainly desirable, and may
be dictated if any performance problems occur.
Item Frequency
Check control system for proper
Monthly
operation.
Check operation of OFF-LOAD
Monthly
ISOLATORS .
Check all power connections for
Semi-annually
tightness and oxidation.
Perform dielectric test on tracing wire. Semi-annually
Inspect STS transformer for signs of

over heating. Clean vents to assure Semi-annually
proper ventilation.
In accordance with mfg.
Verify all instrumentation – calibration recommendations (refer to included
and setpoints. instrument manual) but not less than
bi-annually.
Inspect all power component contacts
Monthly
and terminals.

6th Floor, Jolly Board Tower,
D-Wing, i-Think Techno Campus, Kanjurmarg (East),
Mumbai-400042, Maharashtra, India.
PROJECT LIQUID TERMINIAL TANK FARM AT KATTUPALLI, PHASE- I
OWNER
ADANI KATTUPALLI PORT PVT. LTD. (AKPPL)
CLIENT
HOWE ENGINEERING PROJECTS (INDIA) PVT. LTD.
EPC CONTRACTOR
NVENT THERMAL INDIA PRIVATE LTD.
CONSULTANT NA
TITLE OF DOCUMENT STS INSTALLATION AND CONSTRUCTION MANUALS
NA
CLIENT
DOCUMENT NO.
Rev.
QD08_1001 01
CONTRATOR/ No.
CONSULTANT’S DOCUMENT NO.

01 8-Aug-19 IFR MRI GCJ BNP

This Document is the property of HOWE. It should not be used, copied or reproduced without their written Permission.
Page 1 of 1
STS SKIN-EFFECT HEAT TRACING SYSTEMS
STS Installation and Construction Manual
INDUSTRIAL HEAT TRACING SOLUTIONS Raychem-IM-H58914-STSInstandConstruction-EN-1610

STS Installation and Construction Manual
Revision Record:
8 Sept-2016 General Revision MC, JF, GS MA

7 Oct-2015 Crimp and Crimper Tool Revision IF/GS/DEC MA
6 Mar-2014 Hazardous Location Approval Update DT, WW KS/GS MA
5 Feb-2013 General Revision WW DEC/GS FC
4 Aug-1998 Original Manual DP
Rev. Date Reason for Issue Made by Reviewed by Approved by
INDUSTRIAL HEAT TRACING SOLUTIONS Raychem-IM-H58914-STSInstandConstruction-EN-1610 ii/23

Throughout the guide the following symbol: WARNING: identifies particularly
important safety warnings that must be followed.
WARNING: Shock Hazard

Electrical testing of the STS system can create a risk of shock due to the high voltages
being used. Be sure to observe all local safety precautions and the recommendations of
the test equipment manufacturer. In addition, follow all the instructions and warnings
contained in this manual.
Take appropriate measures to ensure that no personnel can contact the STS wire while
it is under test. Be sure to discharge the test equipment or leave it connected and off
until the residual charge has dissipated and the voltage has returned to zero.
IMPORTANT:
Ensure that the carrier pipe is in good condition prior to welding the heat tube. Always
verify that existing pipes are empty and purged prior to welding the heat tube and
always obtain any necessary permits from plant operations.
IMPORTANT:
When welding, be careful not to undercut, pit or burn through either the heat tube or the
carrier pipe. Undercutting, pitting and burn through are not allowed and can result in
pipeline leakage or STS system failure.
IMPORTANT:
Once the wire is installed, no further welding may be performed on the carrier pipe or
heat tube, as damage to the wire will result. Ensure that all pipeline and heat tube
inspection and testing has been completed and accepted prior to wire installation.
IMPORTANT:
Be careful to obey any maximum exposure temperature limits that apply to the system.
Steam cleaning, or any other high temperature pre-commissioning operations that may
be required and would potentially exceed the exposure temperature limits, should be
performed prior to installing the STS wire.

Very high test voltages (up to 15 kV) are used. Take appropriate measures to assure that
no personnel can come into contact with the STS wire while it is under test!

The STS wire and heat tube act like a large capacitor and will hold the test voltage for a
considerable length of time after turning the test equipment off. Be sure to leave the
test equipment connected and off until the residual charge has dissipated and the
voltage has returned completely to ZERO.
INDUSTRIAL HEAT TRACING SOLUTIONS Raychem-IM-H58914-STSInstandConstruction-EN-1610 iii/23

CONTENTS
1. GENERAL INFORMATION 5
1.1 Use of the Manual 5
1.2 Electrical Codes and Standards 5
1.3 Safety Guidelines 5
1.4 Approvals and Codes 5
1.5 STS Specifications 6
1.6 Fiber Optic Temperature Monitoring 6
1.7 Custom STS Heating Applications 6
2. MATERIAL STORAGE AND HANDLING 6
3. INSTALLATION AND QUALITY CONTROL SEQUENCE 6
3.1 Mechanical and Pipeline Electrical Work 6
3.2 Electrical Equipment Work 7
3.3 Completion and Commissioning 7
4. INSTALLATION OF HEAT TUBE 7
4.1 Carrier Pipe Preparation for Existing Pipelines 7
4.2 Heat Tube Preparation 7
4.3 Heat Tube Joints (Couplings) 8
4.4 Heat Tube Attachment 10
4.5 Heat Tube Installation on Elbows 12
4.6 Heat Tube Bending 12
5. PULL, SPLICE, AND JUNCTION BOX INSTALLATION 13
5.1 Pull and Splice Boxes 13
5.2 Junction Boxes (Power Connection, Jumper, and End Termination) 14
6. HEAT TUBE INSPECTION AND TESTING 14
6.1 Heat Tube Pigging 14
6.2 Air Test 15
7. INSTALLATION AND TESTING OF STS TRACING WIRE 15
7.1 Wire Pulling 16
7.2 Wire Splicing and Termination 17
7.3 Wire Testing 20
8. STS ELECTRICAL EQUIPMENT INSTALLATION AND TESTING 20
9. STS HEAT TUBE INSPECTION RECORD 21
10. STS HEAT TRACING WIRE AND SPLICE INSPECTION REPORT 22
INDUSTRIAL HEAT TRACING SOLUTIONS Raychem-IM-H58914-STSInstandConstruction-EN-1610 iv/23

1. GENERAL INFORMATION
1.1 USE OF THE MANUAL

This manual covers Pentair Industrial Heat Tracing Solutions STS Skin-effect Tracing
Systems for long pipelines installed above ground or underground in ordinary or Zone 1;
Class I, Division 2; or Class I, Zone 2 hazardous locations.
Follow the installation instructions included with the project specific engineering
documents and drawings. For the Pentair warranty and agency approvals to apply, you
must follow the instructions in this manual, and all project-specific engineering drawings
and documents. In the event that there is a conflict between details and procedures
shown on the project-specific engineering drawings and documents and the details and
procedures shown in this document, contact Pentair for clarification.
1.2 ELECTRICAL CODES AND STANDARDS

Applicable sections of Articles 426 and 427 of the US National Electrical Code (NEC), and
ANSI/IEEE Standard 844, apply in particular to skin-effect systems. Other international or
local codes may apply to the STS System installation. Be sure to follow all applicable
codes and standards. If there is any question regarding the applicability of certain codes
or standards, please contact Pentair.
1.3 SAFETY GUIDELINES

The safety and reliability of any heat-tracing system depends on both the quality of the
products selected and the manner in which they are designed, installed and maintained.
Incorrect handling, installation, or maintenance of any of the system components can
cause insufficient heating, overheating of the pipe, or damage to the heat tracing system,
which may result in system failure, electric shock, or fire. The information, warnings, and
instructions contained in this guide are important. Read and follow them carefully to
minimize these risks and to ensure that the system performs reliably.
Throughout the guide the following symbol: WARNING: identifies

particularly important safety warnings that must be followed.
1.4 APPROVALS AND CODES

Conditions for Safe Use: Refer to Hazardous Area certification.
Certificate No. and Coding
INDUSTRIAL HEAT TRACING SOLUTIONS Raychem-IM-H58914-STSInstandConstruction-EN-1610 5/23

All heat-tracing-systems must be installed in compliance with all national or local
electrical regulations and codes of practice.
1.5 STS SPECIFICATIONS
STS Wire Rated Voltage Max. Exposure Temperature Classification

Temperature
STS-HT 2500 V 250°C (482°F) Application dependent.
Established using principles of
stabilized design. Contact Pentair
STS-MT 5000 V 150°C (302°F) for assistance.
1.6 FIBER OPTIC TEMPERATURE MONITORING

If fiber optic temperature monitoring is used with the skin-effect system, refer to the
Installation, Testing, and Operational Instruction Manual and the data sheets and
drawings issued as project specific documents.
1.7 CUSTOM STS HEATING APPLICATIONS

If subsea, structural, or custom modifications are required with the skin-effect system,
refer to the Installation, Testing, and Operational Instruction Manual and the data sheets
and drawings issued as project specific documents.
2. MATERIAL STORAGE AND HANDLING
Store the heat tube off the ground in a location that will not be subject to flooding or
physical damage. Keep the heat tube dry and free from dirt and debris. Ensure that the
heat tube ends are capped at all times to prevent any debris from entering the tube, as it
is much easier and less costly to keep the tube clean than to have to clean out mud,
stones or other debris after installing it on the pipe.
STS tracing wire should be handled with care. DO NOT lift reels using a fork lift between
the flanges of the reel as this will damage the tracing wire. The two options are to either
secure the reel to a pallet and to lift the pallet, or to secure a reel arbor to the reel and to
lift the arbor.
STS transformers and control systems must likewise be handled with care, as dropping
or rough handling will cause damage to the equipment.
Store the STS electrical materials in a secure, dry storage facility. Protect the
equipment from physical damage caused by traffic through the storage area, flooding,
or other causes.
STS electrical equipment such as switchgear and control panels, transformers, and load
balancing units shall be stored as directed by the equipment supplier or in Pentair’s
project specific Operation and Maintenance Manual.
3. INSTALLATION AND QUALITY CONTROL SEQUENCE
Installation of an STS system must proceed in a sequence, in order to ensure

that the installation work of one component does not result in damage of another
(previously installed) component. Shown below is a progression of how the installation
should proceed.
3.1 MECHANICAL AND PIPELINE ELECTRICAL WORK

• Installation and inspection of the heat tube, coupling, and pullbox
• Testing the heat tube
• Installation and inspection of the power, jumper, and end boxes
• Installation of the STS wire, wire splices and terminations
• Testing of the STS wire

3.2 ELECTRICAL EQUIPMENT WORK
• Installation of the control / switchgear panel, transformer, and load balancer
• Installation of the RTD
• Installation of the interconnection wiring
3.3 COMPLETION AND COMMISSIONING

• Pre-commissioning inspections
• Commissioning
Note: Depending on the project, the mechanical and electrical work can proceed in
parallel; however it is critical to ensure that wire installation does not begin until the
applicable sections of the pipeline and heat tube have been installed, inspected, tested,
and signed-off.
4. INSTALLATION OF HEAT TUBE
The heat tube installation method required for each system will be shown on the system
specific drawings supplied by Pentair. Depending on the design requirements, the heat
tube may be strapped or welded to the carrier pipe. The spacing between the straps or
weldments is shown on the Heat Tube Installation Details sheet of the engineering
drawings.
4.1 CARRIER PIPE PREPARATION FOR EXISTING PIPELINES
IMPORTANT:
Ensure that the carrier pipe is in good condition prior to welding the heat tube.
Always verify that existing pipes are empty and purged prior to welding the
heat tube and always obtain any necessary permits from plant operations.
4.2 HEAT TUBE PREPARATION

The heat tube must be checked and prepared prior to installation on the carrier pipe.
Failure to do so may result in complications during the installation of the STS tracing wire,
and may cause damage to the tracing wire.
Check each piece of heat tube to be certain that it is the proper size as per the
specification in the design sheet. It is important to ensure that each tube is clean and dry
on the inside. If any water or debris is found in the heat tube, clean it out while the tube is
still on the ground and easily accessible.
The inside edges of both ends of the heat tube must be de-burred using a reamer. This
should be done at all ends of all tube pieces, just prior to installation on the pipe.

Figure 1: Cutaway view of heat tube end preparation
4.3 HEAT TUBE JOINTS (COUPLINGS)

The heat tube joints are joined by welding the heat tube to specially made socket weld
sleeves (couplings). The coupling welds must be air tight, in order to ensure adequate
electrical conductivity and protection from water ingress.
There are two types of heat tube joints. For a typical field installation, or when installing
two short lengths of tube on a longer length of pipe (as in shop pre-fabrication), only
a coupling is necessary to join tube sections, see Figure 2. In cases where the heat
tubes are already fixed to the pipeline prior to tube joining (as when making field joints
of pre-fabricated pipe sections), an additional part called a Heat Tube Guide is required,
see Figure 3.

Figure 2: Cutaway view of heat tube coupling (no guide used)
Note: Orbital welding can be used to make heat tube joints if approved by Pentair
and the customer.
Figure 3: Cutaway view of heat tube coupling with guide

4.4 HEAT TUBE ATTACHMENT
Welded Attachment
A 3 mm (1/8") fillet weld is used to attach the heat tube to the carrier pipe. DO NOT weld
directly over the carrier pipe butt welds or ERW seam welds. In all cases where welding of
the heat tube to the carrier pipe is required, the weld length and skip length dimensions
and specific weld details will be specified on the Pentair project drawings.
Note: Figures 4 and 5 display the proper heat tube attachment welds.
IMPORTANT:
When welding, be careful not to undercut, pit or burn through either the heat
tube or the carrier pipe. Undercutting, pitting and burn through are not
allowed, and can result in pipeline leakage or STS system failure.
Figure 4: Heat tube attachment with skip weld
Figure 5: Heat tube attachment with continuous weld

The procedure for a welded heat tube attachment is:
1. Position the heat tube in the correct orientation on the pipeline. Be sure to check the
end offset (or cut back) dimensions when shop fabricating pipe spool pieces.
End offset dimensions will be given on the Pentair project drawings.
2. Temporarily fix the heat tube to the pipeline using straps or clamps, or apply a tack
weld every 3 meters (10') between the heat tube and pipeline along the opposite side
from the main welding.
3. Weld couplings in place (not required for shop pre-fabrication, unless short lengths of
tube need to be joined on a single pipe spool).
4. Weld the heat tube in accordance with the dimensions shown on the Pentair project
drawings.
Strap-On Attachment
When the Pentair Project drawings call for strapping on the heat tube (instead of welding),
use the following procedure. Be sure to use the proper strapping material and spacing as
specified on the Pentair project drawings.
1. Position the heat tube in the correct orientation on the pipeline. Be sure to check the
end offset (or cut back) dimensions when shop fabricating pipe spool pieces. End
offset dimensions will be given on the Pentair project drawings.
2. Temporarily fix the heat tube to the pipeline using straps or clamps.
3. Weld couplings in place (not required for shop pre-fabrication, unless short lengths of
tube need to be joined on a single pipe spool).
4. Tightly apply permanent strapping, observing the spacing requirements shown on the
Pentair project drawings. Heat tube must be pulled tight against the pipeline at each
strap.
Figure 6: Heat tube strap-on attachment

4.5 HEAT TUBE INSTALLATION ON ELBOWS
One of the more difficult areas of heat tube installation involves pipe fittings (most
commonly elbows). It is important that the tube be kept in contact, or very nearly in
contact, with the carrier pipe at all times. Accomplishing this on elbows, tees or other
fittings requires planning and care. Failure to maintain contact will result in insufficient
heat transfer from the heat tube to the pipe, resulting in cold spots on the carrier pipe and
potential failure of the heat tracing system.
Note: The heat tube must be tight against the pipeline at all points. Gaps of more than 10
mm (1/2") between the heat tube and the pipeline are not allowed unless explicitly shown
on the Pentair project drawings for the system. Gaps between the heat tube and the
pipeline that are less than 10 mm (1/2") shall be corrected as follows:
1. Where the gap between the heat tube and the carrier pipe is less than 3 mm (1/8") fill
the gap by welding so that the welded and un-welded lengths are within those
specified for the system.
2. Where the gap between the heat tube and the carrier pipe is greater than 3 mm (1/8"),
insert a mild steel filler material (such as a steel rod or plate) and weld in place to
both the carrier pipe and the heat tube (if the heat tube is strapped on, then only weld
the filler material to the heat tube).
Depending on the orientation of the heat tube, it may be necessary to sweep the tube to a
different orientation on an elbow. Generally speaking, the tube should run along the side
or back of an elbow. DO NOT run the tube through the throat of the elbow if the bend
radius of the tube will be less than the minimum value listed in Table 1, since it will be
virtually impossible to maintain contact between the tube and the carrier pipe elbow.
When approaching an elbow where the tube’s orientation will run it into the throat of the
fitting, begin sweeping the tube to the side a few feet ahead of the elbow.
4.6 HEAT TUBE BENDING

Always maintain at least a 5 times bending radius on the heat tube and take care not to
deform the tube when bending. The ID of the heat tube must not become significantly
restricted or the STS tracing wire may not be able to be pulled in. Table 1 lists the
minimum bending radius for the most common heat tube sizes.
Table 1: Minimum heat tube bending radius
Tube size Min. center-line bend radius

19 mm (3/4” NPS) 95 mm (3-3/4”)
25 mm (1” NPS) 125 mm (5”)
32 mm (1-1/4” NPS) 160 mm (6-1/4”)
38 mm (1-1/2” NPS) 190 mm (7-1/2”)
50 mm (2” NPS) 250 mm (10”)

5. PULL, SPLICE, AND JUNCTION BOX INSTALLATION
Note: Always keep the lids of pull, splice and junction boxes in place and closed during
installation in order to prevent the entry of water and debris into the heat tube.
5.1 PULL AND SPLICE BOXES
Figure 7: Typical pull box installation (welded heat tube attachment)
WARNING:
Painted Enclosures require these additional instructions:
For fixed installations, minimize the risk of electrostatic discharge of painted
enclosures by conforming to the following recommendations.
a. Remove the explosive atmosphere prior to contact or cleaning.
b. Make certain the enclosure is grounded to the pipe.
c. Avoid friction with surfaces. Only clean with wet cloth moistened
with de-ionized water.
d. Avoid contact in low relative humidity environments.
Locate pull boxes as shown on the Pentair project drawings for the STS system. These
boxes are typically provided every 75 m (250 ft.) of straight pipe or every 180 degrees of
elbows. The boxes are intended to fit under the thermal insulation, providing minimal heat
loss. A “PULL BOX” or “SPLICE BOX” label should be permanently affixed to the outside of
the insulation jacketing in a location where it can be readily seen by maintenance
personnel. These labels are available through Pentair.
The heat tube must be welded to the pull boxes, as is done at heat tube couplings. Ensure
that the tube ends do not extend more than 3 mm (1/8”) past the inside of the box end
plate. Welding must be done on the OUTSIDE of the box, as shown in Figure 7, no welding
is allowed on the inside of the box. Specific installation details are found on the Pentair
project drawings.

5.2 JUNCTION BOXES (POWER CONNECTION, JUMPER, AND END TERMINATION)
Junction boxes are provided for making power connections, end terminations and jumper
connections. These boxes are typically designed to provide access to the electrical
connections inside without removal of thermal insulation, in order to facilitate easy
preventative maintenance procedures. The exact size and configuration of these boxes will
vary somewhat depending on the application. Refer to Pentair specific drawings for further
details and box locations.
The heat tube must be welded to the box entry couplings, as is done at heat tube
couplings. Ensure that the tube ends do not extend more than 3 mm (1/8”) past the inside
end of the box entry coupling. Welding must be done on the OUTSIDE of the box. No
welding is allowed on the inside of the box.
It is typically required that a filler plate be installed between the heat tube and the
pipeline, at the heat tube entry to the STS junction box. This is detailed on the Pentair
project drawings.
All pull, splice, power connection, end termination, and jumper boxes for STS systems
operating over 600V should have a “HIGH VOLTAGE” label installed on the OUTSIDE of the
insulation jacketing.
6. HEAT TUBE INSPECTION AND TESTING
After installing the heat tube, several tests must be performed. These tests are designed
to ensure the electrical continuity, water tightness and physical quality of the installed
tube. Performing these tests will ensure that the STS tracing wire can be installed without
the risk of damage, and that the electrical current will be contained within the heat tube.
The STS Heat Tube Inspection Report form is provided at the end of this manual. Each
heat tube section must be inspected and reported. Copies of completed forms must be
available for the Pentair Field Service engineer to review.
6.1 HEAT TUBE PIGGING

Blow a jet line through the tube then pull the proper size conduit mandrel / scraper (or
ball) through the tube. A cloth swab attached to the end of the scraper should be used to
help clean and dry the tube. If the mandrel will not pass through the tube, locate the
source of the problem and correct it. Common problems are typically linked to tube
deformation at elbows and bends.
Table 2: Special Tools for Heat Tube Testing
Description Item Part No.

Heat tube ID scraper mandrel, ¾” STS-SCRAPER-19 990199-000
Heat tube ID scraper mandrel, 1” STS-SCRAPER-25 302807-000
Heat tube ID scraper mandrel, 1¼” STS-SCRAPER-32 T1012693
Heat tube ID scraper mandrel, 1½” STS-SCRAPER-38 T0000902
Heat tube ID scraper mandrel, 2” STS-SCRAPER-51 T1012694

6.2 AIR TEST
The tube must be air tested in order to verify water tightness and electrical continuity. In
addition, failure to hold air pressure indicates a poor coupling weld, or a burn through in
the welding of the heat tube. These problems may prevent the use of a jet line for wire
pulling, and may ultimately result in premature electrical failure of the tracing system.
Plug one end of the tube section under test (typically, between two boxes), then pressurize
the tube to 1034 millibar (15 PSIG). Hold a static pressure for at least 5 minutes. If the
pressure will not hold, inspect the tube couplings and joints with soap to find the leak.
Note: Pull, splice, and junction boxes are not air tight. It will not be possible to include
these boxes in the test section.
Note: Test plug dimensions should match the heat tube nominal size.
Table 3 contains a list of special tools that are required for air testing of the heat tube.
Table 3: Air Testing

3/4" ported air test plug STS-PATP-19 743287-000
3/4" bolt grip test plug STS-BGTP-19 848751-000
1" ported air test plug STS-PATP-25 028081-000
1" bolt grip test plug STS-BGTP-25 216999-000
1¼” ported air test plug STS-PATP-32 T1012689
1¼” bolt grip test plug STS-BGTP-32 T1012690
1½” ported air test plug STS-PATP-38 T0000903
1½” bolt grip test plug STS-BGTP-38 T0000904
2" ported air test plug STS-PATP-51 T1012691
2" bolt grip test plug STS-BGTP-51 T1012692
7. INSTALLATION AND TESTING OF STS TRACING WIRE
The STS Tracing Wire is a critical element of the tracing system. It is of the utmost
importance that the proper wire be used in each system. The conductor size, temperature
and voltage ratings must be as specified on the Pentair project specifications and
drawings. Failure to use the proper wire will result in unacceptable system performance
and may result in unsafe operating conditions or system failure. Use only Pentair STS
tracing wire.
Table 4 provides a listing of special tools that may be required for installation of the STS
wire and splices.
Table 4: Special Tools Required for STS Wire and Splice Installation

Jet line, 240# x 5200 FT pkg. STS-JETLINE 217859-000
Conduit piston for 3/4" tube STS-PM-19 151447-000
Conduit piston for 1" tube STS-PM-25 637457-000
Conduit piston for 1 ¼” tube STS-PM-32 T1012695
Conduit piston for 1 ½” tube STS-PM-38 T1012696
Conduit piston for 2" tube STS-PM-50 T1012697
Twisted poly-propylene rope, STS-PULL-ROPE 003185-000
1/4x600' pkg
STS Field Crimping Kit STS-CRIMP-KIT T1015912

7.1 WIRE PULLING
IMPORTANT:
Once the wire is installed, no further welding may be performed on the carrier
pipe or heat tube, as damage to the wire will result. Ensure that all pipeline
and heat tube inspection and testing has been completed and accepted prior to
wire installation.
IMPORTANT:
Be careful to obey any maximum exposure temperature limits that apply to the
system. Steam cleaning, or any other high temperature pre-commissioning
operations that may be required and would potentially exceed the exposure
temperature limits, should be performed prior to installing the STS wire.
WARNING:
Painted Enclosures require these additional instructions:
For fixed installations, minimize the risk of electrostatic discharge of painted
enclosures by conforming to the following recommendations.
a. Remove the explosive atmosphere prior to contact or cleaning.
b. Make certain the enclosure is grounded to the pipe.
c. Avoid friction with surfaces. Only clean with wet cloth moistened
with de-ionized water.
d. Avoid contact in low relative humidity environments.
Wire pulling should commence from either an end termination box or power
connection box, and then proceed to the other end or power connection. Station people at
intermediate pull boxes as required. DO NOT use lubricants since they may break down
when exposed to higher temperatures and cause degradation of the heat tube or wire. The
use of mechanical pulling equipment is not allowed. Do not, under any circumstances,
exceed the maximum pulling forces listed in Table 5. This can be accomplished by use of a
breakaway device.
Table 5: Maximum Wire Pulling Tension
Wire Gauge Maximum Pulling

mm2 (AWG) Force, kg (lb.)
13 (6) 90 (200)
21 (4) 90 (200)
33 (2) 90 (200)
During pulling, be sure to use an appropriate reel stand and arbor. Guide the wire
carefully into the heat tube. Avoid dragging the wire across sharp or abrasive edges.
Visually inspect the wire as it pays off the reel to ensure that no damage has occurred.
If damage to the wire is found, report the condition to Pentair.
DO NOT install any damaged STS tracing wire. Cut out the damaged section at the
previous pull box and continue with the remaining undamaged cable.

7.2 WIRE SPLICING AND TERMINATION
Splicing and terminating procedures may vary, depending on the application. STS wire
splices are to be made in pull boxes unless there are other specific splicing details
provided in the Pentair project drawings. Be sure to locate the appropriate project specific
details and follow them.
To ensure high reliability STS tracing wire splices and terminations, Pentair requires the
use of special nickel plated connectors and lugs. Use only the long barrel compression
butt connectors and lugs as supplied by Pentair. DO NOT use standard, off-the-shelf
connectors or lugs. Connectors and lugs may be re-ordered from Pentair if necessary.
Pentair provides an STS Field Crimping Kit which includes a battery operated hydraulic
crimping tool, crimping dies and wire stripping tools necessary to perform splices and
terminations in the field. This kit is required by Pentair to ensure high quality STS tracing
wire splices and terminations. A force gauge is included in the kit to verify that the
hydraulic crimping tool is applying sufficient force during crimping, thus ensuring a good
connection.
The approved splice connectors and termination lugs are provided in Tables 6 and 7.
These tables also identify which crimping die set and wire stripping head to use with the
various Pentair STS tracing wires. Be sure to follow the specific splice and termination
instructions provided in the project documents to use these tools correctly.
Figure 8: STS Field Crimping Kit
Note: Suitable Crimping tools shall be used as per project

requirement

Terminal Lug Crimping Die Cable Stripper
Stud Stud Cable

Tongue Die Stripping
Part Hole Hole Embossed Die Strip
STS Tracing Wire Description Width Color Tool
Number Size Spacing Die Index Number Length
(mm) Code Head
(mm) (mm) (mm)
STS-MT/33.50- 401207- STS-HT-TERM- 1/4" 5/8" 0.68" 1-7/16"
10 Brown U2CRTW Blue, #2
WIRE, #2AWG 000 LUG33, 2GA (6) (16) (17) (37)
STS-MT/21.50- 778245- STS-HT-TERM- 1/4" 5/8" 0.55" 1-5/16"
8 Grey U4CRTW Blue, #4
WIRE, #4AWG 000 LUG21, 4GA (6) (16) (14) (33)
STS-MT/13.50- 735123- STS-HT-TERM- 1/4" 5/8" 0.48" 1-5/16"
7 Blue U5CRTW Blue, #6
WIRE, #6AWG 000 LUG13, 6GA (6) (16) (12) (33)
STS-HT/33.25- 401207- STS-HT-TERM- 1/4" 5/8" 0.68" 1-7/16"

10 Brown U2CRTW Red, #2
WIRE, #2AWG 000 LUG33, 2GA (6) (16) (17) (37)
STS-HT/21.25- 778245- STS-HT-TERM- 1/4" 5/8" 0.55" 1-5/16"
8 Grey U4CRTW Red, #4
WIRE, #4AWG 000 LUG21, 4GA (6) (16) (14) (33)
STS-HT/13.25- 735123- STS-HT-TERM- 1/4" 5/8" 0.48" 1-5/16"
7 Blue U5CRTW Red, #6
WIRE, #6AWG 000 LUG13, 6GA (6) (16) (12) (33)
Table 6: Termination Lug and Crimping Equipment Cross Reference.

Splice Connector Crimping Die Cable Stripper
Cable
Die Stripping
Part L B Embossed Die Strip
STS Tracing Wire Description Color Tool
Number (mm) (mm) Die Index Number Length
Code Head
(mm)
717219- STS-HT-SPLICE- 2.89" 1.35" 1-7/16"

STS-MT/33.50-WIRE, #2AWG 10 Brown U2CRTW Blue, #2
000 CONN13, 6GA (73) (34) (37)
127577- STS-HT-SPLICE- 2.62" 1.22" 1-5/16"
STS-MT/21.50-WIRE, #4AWG 8 Grey U4CRTW Blue, #4
000 CONN21, 4GA (67) (31) (33)
137961- STS-HT-SPLICE- 2.62" 1.22" 1-5/16"
STS-MT/13.50-WIRE, #6AWG 7 Blue U5CRTW Blue, #6
000 CONN13, 6GA (67) (31) (33)
717219- STS-HT-SPLICE- 2.89" 1.35" 1-7/16"

STS-HT/33.25-WIRE, #2AWG 10 Brown U2CRTW Red, #2
000 CONN13, 6GA (73) (34) (37)
127577- STS-HT-SPLICE- 2.62" 1.22" 1-5/16"
STS-HT/21.25-WIRE, #4AWG 8 Grey U4CRTW Red, #4
000 CONN21, 4GA (67) (31) (33)
137961- STS-HT-SPLICE- 2.62" 1.22" 1-5/16"
STS-HT/13.25-WIRE, #6AWG 7 Blue U5CRTW Red, #6
000 CONN13, 6GA (67) (31) (33)
Table 7: Splice Connectors and Crimping Equipment Cross Reference

7.3 WIRE TESTING

Very high test voltages are used. Take appropriate measures to assure that no
personnel can come into contact with the STS wire while it is under test!

The STS wire and heat tube act like a large capacitor and will hold the test
voltage for a considerable length of time after turning the test equipment off.
Be sure to leave the test equipment connected and off until the residual charge
has dissipated and the voltage has returned completely to ZERO.
A dielectric test must be performed on the STS tracing wire after pulling and splicing, but
before terminating. It may be helpful to test the wire after each section is pulled so that
any faults can be more easily identified. In any event, a final DC dielectric test must be
performed at the voltages listed in Table 8 for each corresponding wire type.
A STS Tracing Wire and Splice Inspection and Test Report form is provided at the end of
this manual. Each STS wire section must be inspected, tested and reported. Copies of the
completed forms must be available for the Pentair Field Service engineer to review. A
final, pre-commissioning test must also be performed and witnessed by the Pentair Field
Service Engineer.
Table 8: STS Wire Test Voltages
STS Wire Voltage Rating STS Wire Types Test Voltage Test Voltage
(Acceptance) (Maintenance)
2500 STS-HT 10kV, DC 8kV, DC
5000 STS-MT 15kV, DC 12kV, DC
Note: If approved by Pentair, the dielectric properties of STS wires operating below 2000
Volts can be tested using a 5 kV insulation resistance tester (Megger™).
Increase the test voltage gradually, from 0 to the specified value. Hold the test voltage for
1 minute and record the final megohm (MΩ) or microampere (μA) reading on the report
form. The minimum acceptable insulation resistance is 10 megohm·km of wire under
test, although most systems will read approximately 1500 megohm·km. Investigate low
readings and review carefully prior to energization of the system.
Note: Refer to the Pentair project specific Operations and Maintenance manual for
troubleshooting guidelines.
8. STS ELECTRICAL EQUIPMENT INSTALLATION AND TESTING
STS electrical equipment such as switchgear and control panels, transformers, and load
balancing units must be installed, inspected, and tested on site as directed by the
equipment supplier or in Pentair’s project specific Operation and Maintenance Manual.

9. STS HEAT TUBE INSPECTION RECORD
Pentair Industrial Heat Tracing Solutions Report
Project Number: Number:
Revision
Project Name: Number:
Drawing Numbers:
Pipe Spool Numbers:
Test RESULT
Inspection Item Remarks
Criteria Accept Reject
1 Heat Tube Material A-106 SMLS
Grade B
2 Heat Tube Cutting Length
Per Drawings
3 Heat Tube End de-burring No Burrs,
Slight Bevel
4 Heat Tube Coupling Centered
and Welded
5 Heat Tube Attachment
Per Drawings
dimensions
6 Heat Tube pigging Mandrel /
Scraper (or Ball)
Must Pass Freely
7 5 minute Static Air Test 1034 mb /
15 PSIG
8 Close box or cap tube end
Comments:
Performed by: Witnessed by: Approved by:
Sign/Date Sign/Date Sign/Date

10. STS HEAT TRACING WIRE AND SPLICE
INSPECTION REPORT
Pentair Industrial Heat Tracing Solutions Report
Project Number: Number:
Revision
Project Name: Number:
Drawing Numbers:
Pull box Ref. Numbers:
Circuit Number:
Length of wire under test: km
Test RESULT
Inspection Item Remarks
Criteria Accept Reject
1 Confirm STS wire type Pentair drawings (Record wire markings here)
and size
k
2 Confirm proper splice Per Drawings
materials and procedure
used
3 Check wire ends for 1. Safety check!
clearances for testing 2. Cap or tape to prevent arcing
4 Apply test voltage (Record test voltage here) (Record MΩ or μA reading
for 1 minute here - circle units used)
kV MΩ / μA
5 Remove test voltage and
ground STS conductor for
5 minutes
6 Is Insulation Resistance R must be more than 10 MΩ Minimum insulation resistance of
Acceptable 10 MΩ is recommended by
IEEE844
7 Terminate STS wire
(if all testing is complete)
8 Close boxes
Measured / Calculated Insulation Resistance (use method 1 or 2, depending on the type of data recorded):
1: R = ________ M Ω (if a Megger is used) 2: R = 1000kV = ________ M Ω (if μA were recorded)

μA
Performed by: Witnessed by: Approved by:
Sign/Date Sign/Date Sign/Date

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Fax: +1.800.527.5703 Fax: +32.16.213.603 Fax: +86.21.5426.2937 Fax: + 1.713.868.2333
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specifications without prior notice.
© 1997–2016 Pentair.

SERIES 246 TUSHACO®
Pump Sr no - 1775085
Page | 1
TABLE OF CONTENTS 1.0
1. TABLE OF CONTENTS…….……………………… 1.0
2. INTRODUCTION…………………………………………. 2.0
... Description………………………………………………… 2.0
... Application……………………………………………..… 2.0
... Advantages…………………………………………….… 2.0
... Relief valve……………………………………………..… 2.1
... Shaft sealing arrangement……………………………… 2.1
... Heating of pump casing………………………………… 2.1
... General pump data……………………………………… 2.1
... Available designs…………………………………..…… 2.1
3. INSTALLATION………………………..…………….… 3.0
... Preparation for installation…………………………….. 3.0
... Transport…………………………………………………… 3.0
... Location…………………………………………………… 3.1
... Foundation……………………………………………..… 3.1
... Aligning of pump and motor…………………………… 3.2
... Horizontal alignment………………………………….… 3.2
… Alignment - sub 1,2,3…………………………………… 3.2.1
... Piping design……………………………………………… 3.3
... Pipe accessories………………………………………… 3.3
... Suction strainers………………………………………… 3.3
... Check valve………………………………………………. 3.3
4 OPERATION…………………………………………..… 4.0
... General…………………………………………………… 4.0
... Before start-up…………………………………………… 4.1
... Start-up…………………………………………………… 4.1
... After the pump is in operation……………………….… 4.2
... After long term shut down……………………………… 4.2
... Fault find chart…………………………………………… 4.3
5. MAINTENANCE………………………………………… 5.0
... Schedule…………………………………………………. 5.0
... Bearings…………………………………………………… 5.1
... Timing gear………………………………………………… 5.1
... Spare parts…………………………………………….… 5.1
... Lubrication table……………………………………….… 5.2
... Lubrication chart………………………………………..… 5.3
... Bearing chart…………………………………………..… 5.4
6. LONG TERM STORAGE……………………………… 6.0

... Conservation prescription……………………………… 6.0
Page | 2
7. DOCUMENTS AND DRAWINGS………………………… 7.0
… Cross Sectional View ………….………………………... 7.1
… Dismantling instructions 246--/40 .……………………….. 7.2
... Assembly……………………………………………………. 7.3
Page | 3
INTRODUCTION 2.0
TUSHACO TWIN SCREW 246 series is a Positive Displacement screw pump with a
pair of timing gears - a unique construction that prevents metal to metal contact of
rotating elements while in operation - Thus preventing serious damages - and
considered as an ideal choice for many duties where dry running can occur
sometimes.
TWIN SCREW pumps - as in case of other screw pump class - deliver uniform
pulsation free - smooth flow conveying the product gently without agitation/churning
or shearing.
TWIN SCREW pump is a double flow design - the liquid enters from both the ends of
screw pairs and travels towards the center where it is discharged. NPSHR is low,
pump is capable of handling a wide range of viscosities and run direct at motor speed
for most applications.
Description ... Screws with timing gears
Application ...
The screw pumps, series 246 are specially designed for According to material and
pump construction all kind of non-lubricating viscous, neutral,
poisonous, aggressive, cold or hot liquid can be pumped, also fluids with a certain
contents of gas or air. In the chemical, petro-chemical and tar industry as:
 Burner feed pump at refineries  pumping low viscosity oils or residues  Crude oil,
gathering pumps  Mainline pumps  Tank storage pumps.
Liquid handled
 ASPHALT
 BITUMEN
 CRUDE OIL
 FUEL OIL
 VACUUM RESIDUE
 CHEMICAL
 POLYMERS
Advantages ...
A High efficiency.
B No metal to metal contacts between the screws shaft
C High suction lift capability
D Can handle a wide range of fluids with superior volumetric efficiency
E The pump is capable of DRY running for short periods.
Page | 4
F High speed operation - direct motor speeds eliminate the need
for gear reduction.
G The pumps are self priming.
H The pump can handle air in the suction line without loss of prime.
I Non-Pulsating Flow
J No emulsification of the fluid being pumped.
K Very low noise and vibration levels.
Page | 5
INTRODUCTION 2.1
Relief Valve...
The safety valve connects discharge and the suction side of the pump to protect the
pump against over pressure if ordered with the pump. If not, separate line mounted
Relief Valve should be fitted.
Relief valve can be utilized to reduce the starting torque. Hand wheel feature permits
opening of the valve to lower the pressure and the starting torque during start-up.
Shaft Sealing Arrangement...

Due to their specific design, these pumps can be supplied with mechanical seals or
stuffing box packing. The selection of these seals depends on temperature and
nature of the liquid handled as well as on the specific operating conditions.
Heating of Pump Casing...
- Heating the pump prior to its use in order to protect the hot product from cooling
down when entering the pump. According to the application the pump can be supplied
With fully jacket casing
- It is necessary to start heating at least one hour prior to starting the pump.
This system is not intended for heating the liquid, but to keep it hot when the pump is
not in use to prevent congealing/solidifying of product within the casing. It is thus
necessary that the product to be pumped is heated to the required temperature
beforehand, so that it is pumped in the best possible conditions.
Once the pump is started, product temperature will be such that it may not be
necessary to continue heating the pump.
General pump data...
TUSHACO Twin screw 246 Series pumps are offered with the following limitations:
Performance data
Capacity Q up to 525 m3/h
Viscosity range ν 0.6 to 100000cST
Temperature of
Pumped liquid t up to 400 ° C
Inlet pressure ps up to 10 bar
Outlet pressure pd up to 16 bar
Differential pressure Δp up to 16 bar
Speed n up to 3600 rpm
Flanges according to DIN or ANSI
Available designs...
Pumps with external bearing, mechanical seal or horizontal foot mounted with fully
jacket without built in relief valve. Standard construction Fabricated steel - screws
AISI C1045/4140/420 or 431.
Page | 6
API design for special applications with above features. Vertical designs
for space saving applications. The screws are supported and axially held in position by ball
bearings. Due to the double
suction design the hydraulic axial forces are eliminated, therefore the axial bearings are
only for fixing the position of screw shafts only. The transmission of torque from main screw
to short screw is effected by timing gears which are located in separate housing and are oil
splash lubricated.
Page | 7
INSTALLATION 3.0
Preparation for Installation...
After receipt of the pump, it should be stored in a dry area.
The shipping crate is only suitable to protect the pump for maximum of 90 days after
shipment from the factory. The period may be shorter in the case of poor atmospheric
conditions. Special packing for long term storage can be supplied upon request. After
receipt, each pump should be thoroughly checked. Damage must be reported to the
TUSHACO office or representative, and the transportation company immediately.
Any claims for damage must be known within one week after receipt of the goods.
Transport...
Take care when moving the pump. Rough treatment or lifting in an unsuitable way
may cause permanent damage. The safe lifting methods are illustrated below. The
pump should never be lifted by the shaft end. Relief valve hand wheel may have to
be removed to accommodate the lifting straps.
Page | 8
INSTALLATION 3.1
Location...
Position the pump as close as possible to the tank. Ideally the pump should be
located in a well-ventilated room with sufficient space on all sides for easy
maintenance. If it is necessary to place the pump in a pit, care should be taken to
prevent flooding.
Foundation...
The foundation should be designed in such a way that it can support the weight of
pump and motor.
When concrete is poured, holes should be kept open at the positions indicated on the
base plate drawing for placing the bolts later.
The surface of the concrete should be left rough in order to permit the application of a
thin layer of mortar, which serves to support the entire baseplate. After the concrete
has set hard, place the pump unit together with the bolts in its place. With levelling
wedges the unit can be levelled. The holes can now be filled, and this goes also for
the void between the base plate and the concrete. If a concrete floor is already
available, use can be made of wedge bolts.
Page | 9
INSTALLATION 3.2
Aligning of pump and motor...
The accuracy of aligning of pump and motor is of great importance for the working life
of coupling and bearings. A flexible coupling is not designed to absorb a mis-
alignment. The purpose of the coupling is to permit some radial movement between
pump and motor shafts during power transfer.
A major mis-alignment will cause a shorter life for the coupling and excessive bearing
wear. It will also result in vibration. Alignment is best done with a dial gauge. Axial or
radial deviations may not exceed 0.25 mm/0.010”. After having the pump in operation
for about a week, it is essential to recheck the alignment. This should take place after
switching off the motor before the pump has had time to cool down.
For good operation it is necessary to mount the pump securely. Nuts must be
tightened evenly to prevent distortion.
Alignment can be carried out as follows.
Procedure for horizontal mount pumps...

1) Align motor shaft abd pump shaft vertically by using shims.
2) Now align motor shaft and pump shaft horizontally by pushing.
3) Align the coupling halves.
Page | 10
INSTALLATION 3.2.1
Sub 1) Horizontal Alignment [dismounted coupling piece(s)].
Connect the dial gauge to the coupling half of the motor.
A Rotate the shaft through a 1/4 revolution.
B Adjust the gauge to zero.
C Rotate the shaft through a 1/2 revolution. The difference between the gauge
reading now and before should not exceed 0.25. If the deviation is larger, the
motor shaft is to be adjusted and the check should be carried out again.
Sub 2) Check of horizontal alignment [dismounted coupling piece(s)].

Connect the dia gauge to the coupling half of the motor.
A Rotate the shaft several times through 90 Deg. and read the gauge.
B The two readings in opposite position should not differ more than 0.25 mm.
C If it is more, the parallellity of the pump-motor combination must be realigned.
Sub 3) Alignment of coupling [mounted coupling piece(s)].
A The next thing to be done is to check whether the coupling halves are
parallel. A micrometer should be placed at 4 places between the coupling
halves; at top, bottom and at both sides. If the variation in reading is less than
0.25 mm the pump motor combination can be considered parallel and the
motor can be anchored down.
B If the variation is larger than 0.25 mm the motor must be adjusted.
Page | 11
INSTALLATION 3.3
Piping design...
Because the screw pump has close clearance between its working parts, it is
essential that the suction line is carefully and thoroughly cleaned before the
connection is made. If the pump has a suction lift, the suction line should be
adequately sized to reduce friction losses. Errors in the pipe layout, such as
excessively long or small diameter suction lines, too may bends, valves, and elevated
parts in the line cannot be overcome by the pump since the limiting factor is the
atmospheric pressure. This pressure is a physical phenomenon independent of any
pump. The result will inevitably be cavitation, noise, vibration, and faulty operation.
After installing the pump unit on foundation, the pipelines can be connected. For
correct location of pipes, refer to the pump drawing. Pipe adaptors should be short
and direct.
Bends should be laid out with the largest possible radius. All pipes should be fixed
independent from the pump flanges. Pipelines which may have to withstand elevated
temperature must be provided with expansion joints to absorb expansion of the pipe.
Tensional or compressing loads on the pump could result in distortions causing wear
or even seizure.
To check whether the pipes are correctly aligned, bolts should be inserted through the
bolt holes of pump flange and pipe flange. If these bolts can be pushed by hand and
the flanges are parallel, the pipelines are fitted stress free. Some clearance between
the pump and the pipe flange should be maintained to allow for the flange gaskets.
Pipe Accessories...
Suction Strainers...
TUSHACO recommends the use of a strainer at the suction side to ensure that no dirt
or welding beads remain in the system. The strainer should be made of reinforced 30
Mesh wire (~ 500 Microns). The total free flow area must be 4 to 5 times bigger than
the cross sectional free flow area of the suction line. If the medium has a viscosity
above 20 CST, the area should be enlarged to 5 or 6 times the size of the pipe.
Manometers should be placed before and behind the strainer to check when cleaning
is to be carried out.
The pressure loss over the strainer should be no more than 0.5 BAR. In general,
suction strainers can be used with any liquid except when the viscosity is very high. In
these cases, the strainer should be eliminated and careful cleaning of the suction line
is advised to remove all foreign particles.
Check Valve...
If the discharge head is high and the viscosity of the liquid is low, it is recommended
to install a check valve in the discharge line. This is to protect the pump from reverse
rotation in the event of backflow when the pump is shut down. This also allows
parallel operation of another pump in the same system.
Page | 12
OPERATION 4.0
General...
For all TUSHACO TWIN-SCREW pumps, the operating principle remains the same.
The TUSHACO twin screw pump series is a Rotary Positive Displacement pump
which consists of two counter-rotating screws. The screws mesh together with very
small clearance between flanks (due to precision timing gears) and rotate freely in the
casing bores. Before start up, the pump is filled with liquid. The air in the suction line
will be removed by the pumping action.
This creates a vacuum (negative pressure) enabling the liquid to enter into the pump.
The fluid gets trapped between the thread profiles and moves axially from one end to
the other with least turbulence. Internal pressure losses is the lowest in Twin screw
pumps thus giving excellent suction capability. Opposed screw construction eliminates
axial thrust.
Both shafts are supported by bearings and are fixed axially at the driven end of the
shafts.
Shaft sealing can be accomplished by two methods:
- Soft packed stuffing boxes External bearings and long shaft (L)
- Mechanical seals Short or long shaft (S) or (L)
A variety of designs and/or materials can be offered for both versions.
Page | 13
OPERATION 4.1
Before start-up...
A Inspect all pipelines, check for any leakage or stress in the system. Clean
all pipes, valves, tanks and filters to be sure all foreign materials have been
removed. Check all valves and meters. All casing bolts should be tightened.
B Check to be sure the pump shaft can rotate without difficulty; if not, the cause
of blockage or friction should be corrected. Each pump is tested before
leaving the factory, but transport could have some effect.
C Resistance in turning the shaft must be expected with pumps equipped with
mechanical seals. The pumps equipped with soft packed stuffing boxes will
not have this resistance.
D Check the direction of rotation of pump and motor to be sure they are the
same. An arrow to indicate the direction of rotation is always fixed on the
pump.
E In case the pump has external bearings; fill the timing gear box with oil.
Refer to the lubrication table for type and quality of the oil. The pumps should
always be filled with liquid before starting.
F If the pump is fitted with mechanical seals it is most important to fill the pump
before start-up either with the pumped liquid or with a neutral compatible
liquid to protect the seal faces from running dry. This is very important.
G Auxiliary flushing or lubrication lines should be examined for any damage or

distortions.
H Open all valves.
I Read the driver instruction manual to determine if a special coupling is

required.
J If the pump has a suction lift, the deairation valve in the discharge line should
be opened and the pipe filled with liquid. This is only necessary for new
installations or for reinstalled pumps.
Start-up...
A If the pump is provided with a heating feature, this heating should be turned
on until pump has reached its normal operation temperature, after that
heating must be turned off and motor can be started.
B As soon as the pump has reached the rated speed, the safety valve should
be closed.
C The absorbed power and the suction and discharge pressure should be
checked against the data sheet.
Page | 14
OPERATION 4.2
After the pump is in operation...
A If the pump has soft packed stuffing boxes, tighten the packing gland bolts,
until the leakage is reduced to 40 - 60 drops per hour, per box. If it is not
possible to reduce the leakage by tightening the gland bolts, the soft packing
must be worn and should be replaced.
Mechanical seal usually do not require any attention. Slight seepage/leakage

after 1st commissioning may eventually stop after a few hours of running
when the seal faces get beded in.
B Check the temperature of bearings, timing gearbox and soft packing if

provided. It is to be expected that this temperature will be high in these areas
at start-up, and after a short period of time the temperatures will settle down
to the product temperature.
C If the pump is part of a closed system, the discharge line should be

derated during operation.
After long term shut down...
The pump should not stand unused for long periods. The pump should be
operated once a week if possible. If the pump will be idle for longer periods, it
is advisable to rotate the shaft by hand if possible, on a weekly schedule.
It is easy to detect if any of the internal parts are contacting by rotating the
shaft by hand.
When starting, let the pump run for a short period without pressure to allow
proper wetting of all rotating parts.
Page | 15
OPERATION 4.3
Fault finding chart
Pump fails to prime

Lack of output
Hydraulic noise
Motor overloading
Irregular delivery
Pump Seizes
Pump becomes warm
Cause:
 Rotation incorrect
 Pump is not filled
   Air leaks in suction system
   Shaft seal(s) leaking
   Vacuum too high
    Relief valve leaking
      Viscosity too high
 Motor speed too low
  Vapour pressure of the medium too high
   Suction pipe too close to the tank bottom
   Retention time of fluid in tank too short
to separate the air
   Incorrect alignment
   Motor speed too high
 Velocity in pipeline too high
  Discharge pressure too high
 Foreign matter in screw clearances
   Damaged ball bearings
   Pipe work incorrectly aligned
to pump casing
 Suction pipe too small
Page | 16
MAINTENANCE 5.0
Schedule...
Daily (only for pumps with external bearings):
1. Check the level of the oil in the timing gearbox (it should cover half the sight
glass.
2. Check the leakage from the stuffing boxes if these are applied; it should
remain at 40 to 60 drops per hour per box.
Mechanical seal do not require routine maintenance.
Weekly:
1. Let unused pump run for 30 minutes at full load.
2. Check any automatic controls and/or regulating valves.
Yearly:
1. Check the alignment of the coupling halves, preferably immediately after

ending the pumping operation, while the temperature is still at operating level.
2. Check capacity and absorbed horse power. Capacity - and power loss will
indicate wear.
3. Check the screw flank clearance, as well as the play between the timing
gears.
Page | 17
MAINTENANCE 5.1
Bearings...
After every 4000 to 5000 working hours the axial clearance of the bearings is to be
checked. The axial clearance of the shafts should not exceed 0.2 mm.
Timing gears ...
If the clearance is more than 0.5 mm the timing gears should be replaced.
For pumps with external bearings:
Refer to the lubrication table and chart (pages 5.5 and 5.6) for the quantity and quality
of lubricating oil to be used and the schedule for changing the lubrication (page 5.1).
After the first 50 working hours of pump operation the lubrication oil should be
changed. Subsequent renewals are to be made in accordance with the lubrication
chart.
Spare parts...
In order to reduce the time the pump is out of order in case of break down, it is
advisable to keep the following parts in stock.
- 1 Set of screwshafts complete with timing gears

- 1 Set of bearings
- 1 Set of gaskets
- 1 Set of mechanical seals or
- 1 Set of stuffing box packing.
When ordering spare parts, the following information should be indicated on the
purchase order:
- Pump serial number (see title page).

- Pump type (see title pate).
- Code number of required spares as given in the parts list (page 7.1)
Page | 18
MAINTENANCE 5.2
Lubrication …
Pump series 246 (External Bearing)
Lubrication of gears and ball bearings driven side: oil (forced lubrication)
Lubrication of gears and ball bearings non driven side: greased for life
PUMP SERIES 246 API design
Required amount of oil in gear box in liters.
Series 246
088 1.3
105 1.7
118 2.1
135 2.3
150 3.7
165 4.2
180 5.7
195 6.3
210 8.3
Page | 19
MAINTENANCE 5.3
Lubrication ONLY FOR EXTERNAL BEARING CONSTRUCTION
chart.....
Recommend
ed Oils
Temp. of the 100° C 160° C 240° C 300° C 350° C

pumped liquid
Max. Temp. 80° C 120° C 160° C 200° C 250° C
of the gear
box
Drain interval 4000 4000 2000 1000 500
for working
hours
ISO standard VG 100 VG 150 VG 680 VG 680 1000
Make
BP Energol OE Energol OE Energol OE Energol OE
175 225 225 325 Energol
Energol CS Energol CS Energol CS Energol CS CS 550
200 300 300 425
CHEVRON OC Turbine OC Turbine Cylinder Cylinder Cylinder
Oil 24 Oil 36 Oil 90 Oil 190 Oil 190
ELF Orites 125 MS Orites 125 MS Orites 270 MS Orites 270 MS Orites
270 MS
ESSO Marine Tromar 30 Tromar 30
ESSO Teresso 100 Teresso 150 Cyclesso 680 Cyclesso 680 Cyclesso
Industrial 680
GULF Marine Veritas V9 Veritas HDV

17
GULF Harmony 61 Harmony 97 Harmony 204 Harmony 204
Industrial
MOBIL DTE Oil No 3 DTE Oil HH Glygoyle 30 Glygoyle 30

DTE Oil Extra
heavy
SHELL Omala 150 Omala 220 Omala 320 Trivela WA
TOTAL Carter EP 100 Carter EP 220 Carter EP 220 Cortusa SY Cortusa

N 150 SY 150
IOCL Servo System Servo System Servo System Cyndol 680 Cyndol
121 220 220 680
HPCL Enklo 120 Enklo 220 Enklo 220
BPCL Hydrol 150 Hydrol 220 Hydrol 220 Engoil 680
ccccccccc
Page | 20
MAINTENANCE 5.4
Shaft dimensions repair purposes series 246
216/236 D d1 tolerance Single row Double row

bearing bearing
d2 tolerance d3 tolerance d4 tolerance L
Bearings and seal sizes: see cross sectional drawings enclosed
Page | 21
LONG TERM STORAGE 6.0
When pumps are stored or unused for long periods, rust may occur. Since rust has
an adverse effect on the working life of the pump, it is advisable to apply protection to
the bare metal surfaces.
Conservation prescription...
The inside of the timing gearbox, the bearings, and pump casing and screw shafts
should be filled with:
Exxon RS 335
Shell Ensis Oil 1
Valvoline Ritzol R6
Mobil Arma 523/524
The shaft seals should be greased with grease, which can be removed later. The
internal machined parts must be protected with for example:
Exxon RS 335
Shell Ensis Oil 1
Valvoline Ritzol R6
Mobil Arma 523/524
All drilled holes and screw taps are to be plugged. Flanges are to be covered with
blanks. Periodical checks of the stored pump should be made. The screw shafts are
to be turned once per 14 days. After rotation, the position of the shafts must be
different from what they were before the rotation.
Page | 22
DRAWINGS 7.0
Cross Sectional View... 7.1
Enclosed:
= Cross sectional view no.:
Dismantling: Tick  any one, as per customer requirement
 External bearing, 4 mechanical seal 246 _ _ / 40
See attached drawings
Page | 23
Page | 24
DISMANTLING INSTRUCTION FOR 246 _ _/40 7.2

External bearing with four mechanical seals. Refer drawings attached in the manual
Dismantling a twin screw pump requires clean open space as in a workshop rather
than at the place where the pump is installed and connected to piping system.
The pump will have to be removed from the base frame after disconnecting power
supply and shutting off inlet/outlet/steam in/condensate out valves and disconnecting
the pipelines.
Drain all the fluid from the pump and clean the pump externally. All bolts/screws and
fasteners are in metric sizes - keep standard tools - Spanner sets, Allenkey sets and
other conventional maintenance tools like puller, hammer etc.
DISMANTLING PROCEDURE
 Keep the above referred drawings ready for quick reference.

 First remove the coupling from the shaft and also shaft key (133).
 Mark for identification on all covers and parts with respect to one another by
numbers/letters.
 Drain the lube oil from gear box by opening drain plug 443.
 Remove bolts (434) and pull out gear box. The timing gears are visible for
inspection as well as to check the backlash.
 Remove cover non drive end (407) together with bearings (103) by removing bolts
(310). The cover can be removed by using jack screws using threaded holes.
Now remove bolts.
 Now unscrew bolts (310) drive end and jack off cover drive end (401) carefully.
The entire screw assembly along with shafts bearings (105) etc. will come off as a
cartridge. There will be a tendency for the assembly to drop in the bores as soon
as screws are out of the bores while pulling out the assembly. This will damage
the shafts.
 If further disassembly is required then you may proceed.
 Remove lock nuts (110) and lock washer (111). The timing gears (108) can be
pulled out. Make sure to mark the timing gears with respect to the shafts and
positions.
 Distance piece (124) (very important) can also be removed but positions must be
marked to prevent interchanging of locations as these spaces determine the
clearance between screws and timings.
 The bearings (105) can also be removed and also the oil seal (721).
 Similarly bearings (103) and oil seal (721) from cover (407) can also be removed.
 Rotating parts mechanical seals (702) see makers drawing, can be pulled out of
shaft stationery part of seal will be in segment (498 and 494) and can be
removed. Replace seals if damaged.
 Clean all parts thoroughly by kerosene/solvent.
Page | 25
ASSEMBLY OF TWIN SCREW SERIES ‘246’ 7.5
For assembly follow reverse procedure.
The assembly should start with screw sets assembled on drive end cover as a
cartridge. See diagram.
Rotate the drive screw and check the clearances.
Page | 26
Axial clearances can be adjusted by putting shims between the bearing (105) and
cover (401) so as to make the clearances uniform. The clearance should be checked
on the convex flanks.
After the axial adjustments are carried out the timing gears can be locked with lock
nut (110). Now turn the driven long shaft screw in the direction of rotation. Check for
the clearances between flanks while rotating.
 Make sure, however, that the convex flank clearance remains sufficiently large.
The clearance between the convex flanks must always be larger than the
clearance between the sharp edges.
 If the sharp edges touch in some areas, some filing may be carried out until a
play of 0,05mm is obtained.
 After assembly fill lubricating oil for the level by the recommended grade for
External bearing execution.
 Check that the pump is free to rotate by hand.
 If everything is OK the pump may be put back into operation after following the
instruction in the manual for installation and operation.
 Contact manufacturer for any help or assistance.
Page | 27
Page | 28
Data sheet for motors
Manufacturer Bharat Bijlee Ltd. Customer ALLWEILER INDIA PRIVATE LTD
Type of motor 3 phase Induction Motor AWRNO 1775085

Quantity 2 End Customer ADANI PORT LIMITED, MUNDRA
Application PUMP Ref no AIPL/PUR/BBL/RFQNO-0087/2019-2020/7.5.2019
Tag no. Output kW / pole 45 / 4P

BBL type Ref. 2J25M433 Frame size MJ250
Installation details Applicable standards (latest edition)
Area classification (Safe / Hazardous) Hazardous area Performance: IS/IEC 60034-1 Maintenance IS:900 FLP Motors: IS/IEC 60079-1
Location: indoor/outdoor/deck Indoor Dimensions: IS 1231/IS 2223/IS:8223 VFD FED MOTORS :
Altitude (meters) 1000 or less Vibrations: IS 12075 Application guide: IS 15880
Noise level: IS 12065 Specification : IS 15881
Hazardous area details Supply conditions and permissible variations (grid supply)
Area classification GAS (Zone 1/Zone 2) ZONE I Number of phases Three
Gas group IIA, IIB Voltage (Volts) and permisible variation 415 ±10%
Temp.class T4 Frequency (Hz) and permissible variation 50 ±5%
Type of Explosion protection (FLP/Type 'e'/Type
Ex d Combined variation (absolute sum) ±10%
'n')
If Coal Mine application then
Approving authority for hazardous area
DGMS else PESO
Electrical parameters
Starting performance
Method of starting VFD Starting current (%FLC) 650
Load speed (rpm) CUSTOMER TO FURNISH Starting torque (%FLT) 250
Motor GD2 (kgm2) 2.78 Pull out torque (%FLT) 260
Load GD2 (kgm2) CUSTOMER TO FURNISH Locked rotor withstand time (hot/cold) (sec) DOL 15 / 30
Number of consecutive starts (hot/cold) (nos.)
Load torque-speed curve Parabolic TS curve 2/3
provided Load GD2 = Motor GD2
PLEASE FURNISH ALL ABOVE
Starting time at rated voltage (sec)
DETAILS
Running Performance
Efficiency class IE2 Duty and designation Continuous (S1)
Ambient temp./temp.rise by resistance (deg.C) 50 / 70 CDF/Equivalent starts per hour/FI -
TEFC (TOTALLY ENCLOSED
Enclosure Insulation class / utilisation class on DOL F/B
FAN COOLED)
Full load current (FLC) amps. 79.1 Rotor type (Squirrel Cage/ Slip ring ) Squirrel Cage
Full load speed (rpm) 1480 Rotor voltage/rotor current (RV/RA) (Volts/Amps) Not applicable
Full load torque (FLT) kg-m 29.6 Stator/rotor time constant (min) 108/146
Efficiency in % at FL/0.75FL/0.5FL 93.1 92.5 91.0 Power factor at FL/0.75FL/0.5FL 0.85 0.79 0.70
Mechanical parameters
Mounting B3 Mounting dimensions Refer GA drawing
Shaft extention Single cylindrical Direction of rotation viewed from DE Clockwise
Degree of protection IP 55 Suitable for bidirectional rotation Yes
Method of cooling (TEFC/forced cooled/TESC) TEFC (IC 411) Paint type Acid Alkali Proof
Net weight of motor (kgs) 590 Paint shade RAL 7035
Earthing provision (two terminals on stator body) Yes
Bearings Terminal box
Coupling (Direct/flexible/Belt & Pulley/Gearbox) Direct Terminal box location when viewed from DE As per GA drawing
Dimenssions of pulley (OD x width) mm - Direction of cable entry As per GA drawing
Bearings (roller/ball/angular contact) Ball /Ball Cable size and type(Aluminium) 2R X 3C X 120 SQ MM
Bearing size DE/NDE 6215 C3 / 6215 C3 Earthing provision (one terminal in TB) Yes
No of phases/Winding connection/number of
Type of lubrication GREASE/SKF LGMT3 3 / DELTA / 6
terminals
Accessories
RTDs - 3 numbers simplex (w/o controller) Arrow plate for direction of rotation
BTDs - 1 number per bearing (w/o controller) Double compression glands (main cable) YES
Double compression glands (Space
Space heaters - single phase 50z, 230V YES YES
heater/Thermisters/RTDs)
Thermisters - PTC 1 number per phase Brake (Type/voltage/torque)
Additional T-Box for Accessories YES
Additional nameplate
Notes:
1) All performance values are subject to IS/IEC 60034-1 tolerances, unless otherwise specified.
2) Performance values are at rated voltage and rated frequency condition and for DOL starting condition.
3) Motor GD2 = Load GD2 assumed wherever not mentioned.
4) Where starting time is more than 10 seconds, provision of heavy duty relays is mandatory.
5) Kilowatt rating is mandatory and HP is approximate.
6) Accessories provided are marked as "YES"
Notes for motors run on VFD supply
1) Motors suitable to run on VFD supply are designed with an insulation system suitable for withstanding voltage of 1.56 kV (peak phase to phase) and rise time > = 0.1
micro sec. (for motors with rated voltage up to 415V).
2) The customer/ his system integrator have to ensure that the voltage does not exceed above limit by properly selecting cable length preferably 5 to 10 meters long. For
higher cable lengths, dv/dt filters or sine filters may be required
3) Switching frequency should not exceed 5.0 kHz. Prepared by SSD
4)For constant torque application, voltage boost is necessary for frequencies <= 17Hz. Approved by MCG
Revison R0
Project: Contractor/Client
Date: 08.05.2019
Consultant Package
DRG. N0.
SPEED Vs T0RQUE & CURRENT CHARACTERISTICS
CUSTOMER: ALLWEILER INDIA PRIVATE LTD

Enquiry No. W.O.No./SAP No.:
kW: 45 POLE : 4P VOLTS : 415 QTY : 2
CURRENT SPEED CHAR AT 100% VOLTAGE

700
CURRENT SPEED CHART AT 80% VOLTAGE
T Vs N at 100% V
T Vs N at 80% V
600
500
F
U
L 400
L
L
O
A
D
T 300
O
R
Q
U
E
&
C
U 200
R
R
E
N
T
100
0
0 10 20 30 40 50 60 70 80 90 100
% SYNCHRONUS SPEED
PREP SSD
APPD MCG
REVISION R0 DATE 08.05.2019 SIGN
DRG. NO.
LOAD Vs EFF., P.F.,

Enquiry No. W.O.NO./SAP NO :
kW 45 Pole 4P VOLTS : 415 QTY : 2
100.00 1.00
EFFICIENCY
95.00
90.00 0.90
85.00
POWER FACTOR
80.00 0.80
Z
75.00
70.00 0.70
65.00
60.00 0.60
% EFFICIENCY
55.00
P.F.P.U
50.00 0.50
45.00
40.00 0.40
35.00
30.00 0.30
25.00
20.00 0.20
15.00
10.00 0.10
5.00
0.00 0.00
0 10 20 30 40 50 60 70 80 90 100
% LOAD
PREP. SSD
APPD. MCG
DRG.No.
STARTING CURRENT VS STARTING TIME AND THERMAL WITHSTAND TIME.

ENQ.NO W.O.NO./SAP NO:
kW : 45 POLE : 4P VOLTS : 415 QTY : 2
10000
T start AT 80%V
TWT-HOT
TWT-COLD
1000
T start AT 100%V
100
THERMAL WITHSTAND
TIME (sec)
10
0.1
0 100 200 300 400 500 600 700
% FULL LOAD CURRENT
L. R.Current at 100% voltage : 650 % OF FLA THERMAL WITHSTAND TIME(sec):

Starting time at 100% voltage=
PLEASE FURNISH ALL ABOVE
sec DETAILS AT100% RATED VOLTAGE (HOT) : 15
Starting time at 80% voltage= 2 sec AT100% RATED VOLTAGE (COLD): 30
PREP SSD
APPD MCG
4 3 2 1
A L L D IM E N S IO N S ARE IN MM UNLESS O T H E R W IS E S P E C IF IE D SC ALE - N .T .S .
M in im u m d is ta n c e fo r e ffic ie n t c o o lin g
± 10 o f m o to r (T o be m a in ta in e d by u s e r)
L
AC
F q O1 F
LV
S 2 - (2 N o 's)
d5
HD
E
A E
m6
V
HC
D
+ 0 .5 2 0
HA
- 0 .5
A K
H
E a rthing
l BC B A1 AA te rm ina l
BA
± 0 .7 5 ± 0 .7 5 (M 1 2 - 2 N o s)
E C B A
B1 AB
BB
D D
Fixing G e ne ra l
IE C
P o le A B B1 C H K AB BB AA BA BC BA1 HA HC HD L LV AC
Fra m e
250M 4& 6 406 349 - 168 250 24 506 425 100 115 49 - 42 495 688 915 100 489
S ha ft GA
C T Box C
F
V O O1 q S2 D E F GA l d5
6 0 1 2 8 7 2 4 2 4 7 4 M 5 0 x1 .5 P 6 5 1 4 0 18 69 130 M20
T B o x a rra n g e m e n t
S e c tio n A - A w ith s e a lin g b o x
N o te s :-
1) R in g e d d im e n s io n s a re as p e r IS :1 2 3 1 / IE C 6 0 0 7 2
2) T e rm in a l b o x can be ro ta te d in 360 deg in s te p s of 90 deg.
B B
C ustom er P ro je c t
P .O . N o . C o n s u lt a n t
k W / P o le C lie n t / C o n t ra c t o r
F ra m e Package
SO No. T a g n o 's
NAME DATE
T IT L E :
A DRN YCJ 0 7 .0 4 .2 0 1 5 DIMENSION DRAWING A
CHD
3 P H S Q U IR R E L C A G E , TE F C (F O O T M O U N TE D ) F L A M E P R O O F (E x 'd ') IN D U C TIO N M O TO R
APPD
DRG. No:
D25M431TC
A IR O L I, N A V I M U M B A I
4 3 2 1

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ADANI KATTUPALLI PORT PVT. LTD.

PROJECT Liquid Terminal at Kattupali Port

CONTRACTOR Not Applicable

Mott MacDonald Pvt. Ltd.

PREPARED CHECKED APPROVED

T +91 (0)79 4911 1600

Operation and Control

Mott MacDonald Private Limited.

Issue and Revision Record

Revision Date Originator Checker Approver Description

Document reference: 372479-RSD-523 | xx | P1

Information class: Standard

372479-RSD-523 | xx | P1 | 25 November 2019

3 Intermediate Storage and handling of Bitumen in Storage Tank T-31

372479-RSD-523 | xx | P1 | 25 November 2019

372479-RSD-523 | xx | P1 | 25 November 2019

5.5 Emergency Shutdown by ESD enforced. 61

372479-RSD-523 | xx | P1 | 25 November 2019

1.2 Storage at Tank-farm Enclosure-3

1.3 Inter Tank Transfer (ITT)

372479-RSD-523 | xx | P1 | 25 November 2019

○ One tank to One Tank

1.4 Tanker Loading Facility- (TLF)

Important consideration for all scenario:

● Other Important Notes:

1.5 DCS / SCADA architecture shall consider following important General

372479-RSD-523 | xx | P1 | 25 November 2019

372479-RSD-523 | xx | P1 | 25 November 2019

– During Operational Line up (whether during start-up or in the course of running

– All Operational Parameters shall be Resettable as per Operational Demands /

– At no time, H value shall be higher than HH value

– Likewise, L shall not be lower than LL value

372479-RSD-523 | xx | P1 | 25 November 2019

372479-RSD-523 | xx | P1 | 25 November 2019

2.1.2 Important considerations

– To Multiple Tanks - Simultaneously (Ship to Many Tanks)

– To Multiple Tanks - Sequential (Ship to Many Tanks)

372479-RSD-523 | xx | P1 | 25 November 2019

2.1.3.1 Description of Import Options:

2.3 Ship docking and unloading

372479-RSD-523 | xx | P1 | 25 November 2019

● Ship-shore safety tests shall be carried out.

2.3.2 Bitumen Receipt and Transfer operation

2.3.2.1 For transfer to a Single Tank (Ship to Single Tank)

372479-RSD-523 | xx | P1 | 25 November 2019

372479-RSD-523 | xx | P1 | 25 November 2019

2.3.2.2 For transfer to Multiple Tanks (Ship to Many Tanks)

● Tested and effective communication network (VHF transceivers / intrinsically safe

2.5 Emergency Shutdown (failure of utility)

2.5.1 Failure of Power Supply

2.5.1.1 Significant impact on Import operation leading to disruption in following cases:

372479-RSD-523 | xx | P1 | 25 November 2019

– Emergency power supply as an alternate source may be provided at MCC feeder

● Power failure at Resistance type Heating System

● Power failure at Hot Oil Generator system

2.5.2 Failure of Hot Oil supply at Bitumen Storage tanks at Encl.-3

2.5.3 Failure of Instrument Air

2.6 Emergency Shutdown by ESD enforced.

2.7 Normal Operation

372479-RSD-523 | xx | P1 | 25 November 2019

2.8 Operator’s Routine work

2.8.1 Check during transfer

2.8.2 When needed