Technical Specification Tankage

TANKAGE TECHNICAL SPECIFICATION
TECHNICAL SPECIFICATION CONTENTS Chapter No. I Special Instructions to Tenderers II Technical Specification 01.00 Scope of work 02.00 Scope of Supply of Materials 03.00 Material Specification 04.00 Design and Drawings 05.00 Fabrication and Erection 06.00 Fabrication and installation of underground tanks 07.00 Cathodic protection 08.00 Inspection 09.00 Testing of Tanks 10.00 Calibration of Tanks 11.00 Miscellaneous 12.00 Welding Requirements 13.00 Gauge Pole sleeve 14.00 Data to be furnished by successful bidder 15.00Technical specification for Civil works Annexure I Specification for Nozzles and Pipes Annexure II List of Standards Annexure III Quality Assurance Plan Annexure IV Painting details Annexure V Drawing Index Annexure VI Tank Data Sheet Signature & Seal of Bidder Title Page No. 2 5 5 7 10 11 11 22 24 30 31 33 33 34 35 35 36 50 51 53 58 65 66 Page 1
I. SPECIAL INSTRUCTIONS TO TENDERERS 01.00 GENERAL 01.01 Hindustan Petroleum Corporation Limited (HPCL) is setting up additional storage tanks at Ajmer, Jaipur and Rewari Terminals These Terminals are currently under operation. The tender is being floated for construction of additional tanks for HSD & MS and also Water storage tank.
01.02 The scope of this tender consists of the construction of mild steel tanks required for storing MS ,HSD & Water as under
Details of tanks to be constructed are shown in the Table below:
LOCATION Ajmer
Details of tanks to be constructed 24 M Dia x 14 M Ht- 2 Nos. (FR)-MS 18 M Dia x 12 M Ht- 2 Nos. (FR)- HSD
Design Code
API 650
Jaipur
28 M Dia x 14 M Ht - 1 Nos (FR)- HSD 18 M Dia x 13 M Ht - 2 Nos (FR)-MS API 650
Rewari
17 M Dia x 12 M Ht - 1 No. (FR)-MS 20 M Dia x 14 M Ht - 2 Nos (CR)-HSD 13 M Dia x 14 M Ht 1 No. (OR)Water API 650
FR Floating Roof, CR- Cone Roof, OR-Open Roof
Floating roof shall be of single-deck pontoon type for tanks of dia. more than 12m and up to 60m. Sand pad foundations shall be provided for supporting the vertical storage tanks.
01.03 The materials, design and workmanship shall satisfy the relevant Standards, the job specifications contained herein and codes referred to. Where the job specifications Signature & Seal of Bidder Page 2
stipulate requirements in addition to those contained in the standard codes and specifications, these additional requirements shall also be satisfied. In the absence of any standard / specification / codes of practice for detailed specifications covering any part of the work covered in this tender document, the instruction / directions of Engineer-incharge will be binding on the contractor. 01.04 Wherever it is stated in this Tender document that a particular supply is to be effected or that a particular work is to be carried out, it shall be understood that the same shall be effected/ carried out by the contractor at his cost, unless a different intention is specifically and expressly stated herein or otherwise explicit from the context. 01.05 The tenderer shall visit the site before quoting to get himself acquainted with site conditions, availability of water, power, approach etc, No delay whatsoever shall be entertained on this account. The specification of the products stored will be as per the latest BIS specifications.
01.06
02.00 CONSTRUCTION PROGRAMME 02.01 A detailed bar chart showing various activities shall be prepared by the bidders. The work shall be executed strictly as per the agreed time schedule. The period of completion shall include, the time required for mobilization and testing as well as rectification, if any, testing and completion in all respects to the entire satisfaction of the Engineer-in-charge. 02.02 A joint program of execution of work will be prepared by the contractor in consultation with Engineer-in-charge. 02.03 Monthly / weekly construction program shall be made by the contractor jointly with Engineer-in-charge based on availability of work fronts and the joint construction program. 02.04 The contractor shall scrupulously adhere to these Targets / Program by deploying adequate personnel and construction tools and tackles. He shall also supply all materials in his scope of supply in time to achieve the targets set out in the weekly and the monthly program. 02.05 The contractor shall monitor and report about labour and equipment deployed along with the progress of work done on previous day on daily basis. 03.00 CONSTRUCTION WATER AND POWER Construction water and power (including the requirement for testing and calibration of tanks) will not be made available by the owner and the contractor at his own cost shall Signature & Seal of Bidder Page 3
arrange the same without any liabilities on the part of owner. The rates quoted shall be inclusive of the same. 03.01 The Contractor shall drill the required number of bore wells/ arrange water thru tankers at his cost. 03.02 The Contractor shall arrange his own source of power from their DG set or from SEB directly without any cost to the owner. 04.00 TESTS AND INSPECTION 04.01 The contractor shall carry out the various tests as enumerated in the technical specifications of this tender document and the technical documents that will be furnished to him during the performance of the work. No separate payment shall be made. 04.02 The contractor shall carry out at his cost, all the tests either on the field or through external laboratories, concerning the execution of the work and supply of materials by the contractor. 04.03 The work is subject to inspection at all times by the Engineer-in-charge. The contractor shall carry out all instructions given during inspection and shall ensure that the work is being carried out according to the technical documents and the relevant codes of practice during the performance of the work. 04.04 Any work not conforming to the execution drawings, specifications or codes shall be rejected forthwith and the contractor shall carry out the rectification at his own cost. 04.05 Results of all inspection and tests shall be recorded in the inspection reports, test reports etc., which will be approved by the Engineer-in-charge. These reports shall form part of the completion documents. 04.06 Inspection and Acceptance of works shall not relieve the contractor from any of his responsibilities under this contract. 05.00 SITE CLEANING 05.01 The contractor shall take care to clean the working site from time to time for easy access to work site and for safety. Working site should be always kept cleared to the entire satisfaction of the Engineer-in-charge. 05.02 Before handing over any work to the owner, the contractor in addition to other formalities to be observed as detailed in the document shall clear the site to the entire satisfaction of Engineer-in-charge. 06.00 COORDINATION WITH OTHER AGENCIES Work shall be carried out in such a manner that the work of other agencies operating at the site is not hampered due to any action of the contractor. Proper co-ordination with other agencies will be the responsibility of the contractor. In case of any dispute, the decision of Engineer-in-charge shall be final and binding on the contractor.
Signature & Seal of Bidder
Page 4
07.0 SAFETY PRECAUTIONS AND HOT WORK 07.01 Contractor shall have to take all safety precautions for carrying out hot work in the premises after obtaining hot work permit from location in charge at his own cost as directed by the Engineer-in-charge. Necessary safety equipment such as safety belts, helmet, etc., and other safety instruments are to be positioned by the contractor and the same shall be used by the work force as per work requirement. The contractor has to enforce the same. In addition to the above Contractor shall maintain their own set of Portable fire extinguishers, hose reel & nozzle for necessary hook up with the nearest hydrant point in case of emergency. 07.02 Safety distance as per CCE rules and Oil Industry Safety Directorate shall be maintained strictly. 07.03 All exhaust of vehicle & engines shall be fitted with spark arrestor and all temporary electrical supplies and cabling should have proper Main Isolator, Distribution board, ELCB and temporary shade. All cable joints made at site should be properly covered with insulated. 08.00 Third Party Inspection 08.01 Third Party Inspection will be required for a. Swivel Joints for Articulated Roof Drain b. Primary & Secondary Seal The approved parties for carrying out TPI for a & b are EIL, DNV, BVQI & IRS.
Page 5
II. TECHNICAL SPECIFICATION 01.00 SCOPE OF WORK 01.01 The scope of work of the bidder shall include complete design, selection of materials, preparation of drawings, detailed engineering, supply (except free issue steel plates), obtaining approvals of Engineer in charge/owner, transportation, storage at site, fabrication, installation, erection, testing, calibration, commissioning and establishing the required parameters to the satisfaction of HPCL, of the storage tanks inclusive of all fittings, appurtenances and other attachments there to and sub-assemblies wherever required. The scope also includes construction of sand pad foundation as well as installation of cathodic protection system as enumerated elsewhere in the specification. The complete work shall be done in strict compliance with engineering drawings/ data sheets, specifications from the below mentioned standards/codes. API-650, tenth edition, 2000 for above ground tanks. A list of standards and codes recommended for general guidance is enclosed as Annexure II. 01.02 The scope of work of the bidder is defined in general and shall include the following but not limited to the same. The bidder shall also carry out the jobs that are not listed here but required for completion of the job in all respects as per the specifications, standards, drawings, codes and instructions of Engineer-in-charge whether specifically mentioned in the drawing or not. Loading, handling and transportation of all free issue materials from supply point / store of work site / Contractors store and return the unused / scrap materials to work site storage point after completion of the work including supply of all tools, tackles and accessories etc. Procurement and supply of materials and consumables as indicated in contractors scope of supply. Erection of the tank shell for vertical tanks shall be by hydraulic jacking arrangement. Fabrication of tank bottom, shell, roof, wind girders, etc. including cutting of plates and structural sections to required size, edge preparation, rolling, fitting, welding etc. Design, Supply and fixing of all nozzles, flanges, elbow, bends etc. as per specification drawings and data sheets. Only standard forged pipe fittings shall be used. Fabrication and erection of supports for pipes, instruments etc. on tanks. Design, Supply, fabrication and erection of spiral stairways, catwalk, handrails, platforms, top landing and maintenance platforms, walkway, self leveling type rolling ladder and track, curb angles etc. Design, TPI for design,Supply and installation of distributed anode based impressed current cathodic protection system for tank bottom plates of product tanks at Ajmer & Jaipur. Page 6
01.02.01
01.02.02 01.02.03
01.02.04
01.02.05
01.02.06
01.02.07 Design, Supply and installation of water risers and ring mains (fixed spray system) and spray nozzle arrangement around tank in two/three rows i.e., above and below wind girders. 01.02.08 Radar level gauges for continuous level measurement and RTDs for average temperature measurement are envisaged for all the petroleum storage tanks. Suitable installation provision and mounting arrangements shall be provided for the same as required by the instrument supplier. 01.02.09 Design, Supply and installation of fixed foam fire fighting system as per OISD requirement. Piping , Supply & fixing of foam maker, pourer, deflection board, etc. 01.02.10 Radiography, DP test, MP test and all other tests on tanks as per code, drawings and testing procedures by approved testing agencies apart from routine, visual and dimensional check. The Contractor shall arrange necessary tools and tackles for carrying out the tests. 01.02.11 Carrying out hydrostatic, pneumatic, vacuum and other test as specified in codes/standards using tenderers own equipment. 01.02.12 Calibration of tanks and getting approval from statutory authorities as per IS 2007 1974 and IS 2008 - 1961. Calculations and preparation of calibration charts and submitting to HPCL. 01.02.13 Carrying out roof floatation test for floating roof as per codes/standards. 01.02.14 Design and Supply of appurtenances like nozzles, manholes, vents, hatches, primary roof drains, earth connections, gauge connection with covers etc. and installation of these items on the tanks. 01.02.15 Design, supply and installation of Primary & Secondary Roof seal and its accessories as per specification. 01.02.16 Clearing job sites of all surplus material, debris, scrap, construction equipment etc. as per directions of Engineer-in-charge. 01.02.17 Internal & External painting of Tanks. Accomplishment of any other item of work required for making the storage tank ready for commissioning. 01.02.18 Quantity of steel given is approximate. Payment shall be made for quantities of plates laid / erected duly certified by the Engineer at site. Payment of steel plates will be made basis theoretical weight taken as 7.85g/cc. 01.02.19 Scope of work of the contractor includes construction of tank foundations for all the tanks. The foundation shall be of stone columns overlaid with Sand filling, anticorrosive layer & seal coat. 01.02.20 Design & Preparation of all detailed and working drawings for various components of storage tanks (Cone ,Open Top & FR) and getting the same reviewed / approved by HPCL. Supplying of all drawings and documents as specified. 01.02.21 Supply of spares, wearing parts, consumables for two year trouble free operation where various sizes are involved such as in gaskets, bolts, nuts, studs etc., quantity of spares shall be 10% but not less than 2 number for each size. Signature & Seal of Bidder Page 7
01.02.22 Supply of gauge Pole sleeve for Floating roof tanks. 01.02.23 Excavation, sand filling ,anticorrosive layer, seal coat, PCC/RCC & other misc civil works. Supply & erection of fire screen and temporary wall on Fire wall and dismantling/disposal after completion of work. 01.03 The design, fabrication and installation shall be in conformity with regulations of CCOE, OISD and other statutory bodies. 01.04 Design calculations for complete roof for buoyancy, stability, roof drains, tilting, leg supports, bleeder vents etc. and getting the same approved by TPI and submission of the same for HPCLs review. 01.05 Design, Supply, erection & testing of Articulated Roof Drain for Floating roof tank as per specification. TPI for swivel joints.
02.00 SCOPE OF SUPPLY OF MATERIAL The scope of supply of contractor/ owner is given below and contractors shall quote rates based on this. 02.01 OWNERS SCOPE OF SUPPLY : Only Steel Plates as under: Steel plates of all thickness for bottom, shell, wind girders and floating roof of all tanks. Steel plates for fabrication of reinforcement pad plates for shell and roof nozzles and appurtenances. Steel plates for foam dam and shell extension for deflection for foam pourer. Datum plates under the gauge well pipes, bearing plates for pipe supports. Incase of Rewari, pipes and valves required for piping work will also be supplied by HPCL. However the fabrication of the above plates in the required shape and size is in the scope of the contractor. It may be necessary to change the thickness and size of steel plates before commencement of work or during the progress of work, depending on the availability of steel plates. The contractor shall have no extra claim because of such changes and shall accept final measurement of the finished job without any allowance whatsoever. MS plates in sizes available as indicated below from SAIL/ ESSAR/ LLOYDS/ TISCO/ JINDAL/Others will be supplied to site and the contractor shall prepare fabrication drawings accordingly for approval, prior to commencement of fabrication work. Sl. No. 1 2 Plate Size (LXW) in mm 6300 X 2000 6300 X 1500 Plate thickness in mm 8, 10, 10, 12, 14, 16,18 5, 6, 8 Page 8
3 8000 x 2000 5,6,8,10,12,14,16,18 Basis for procurement of steel plates: 1. API 650 has been adopted for the design of storage tanks. 2. Corrosion allowance of 1.5 mm has been considered. 3. Minimum thickness of Bottom plates shall be 8 mm and annular plate as 10mm. The arrangement of steel plates considered for procurement by the owner for different locations of the storage tanks and the thickness of the same are indicated in the enclosed drawings. The contractor shall confirm the adequacy of the same. 02.02 CONTRACTORS SCOPE OF SUPPLY: All other materials other than steel plates for tanks as under: Materials, consumable/ non-consumable not mentioned under Owners Scope of supply, but required for satisfactory completion of the job shall be supplied by the contractor inclusive of the following but not limited to the same: All the welding rods, erection materials, scaffolding, bending and cutting machine, oxygen, acetylene, grease, oils, labour etc. The procurement and supply in sequence and at the appropriate time of all materials and consumables including structural steel (Plates & sections) required for completion of works as per drawings, specifications and standards except the materials specifically listed in Cl.no 2.01 above shall entirely be the contractors responsibility. The items to be supplied by the contractor are in general but not limited to following: A) All steel plates required for the components other than those listed in Cl.2.1.2. B) All consumables such as electrodes, filler wires, acetylene, grease, oil, gases, electricity etc. C) All structural steel sections wherever required for Cone roof structure,curb angles, Top wind girders Supports/stiffeners/ extensions for stairways, Top wind girder bracings, Secondary wind girders, supports for Fire water Cooling Spray Headers/ risers, supports for Foam system risers, spiral stairways, landings , platforms, handrails, bracing for foam dam, Inlet and Outlet Nozzle Troughs, Gratings(which may be fabricated by the Contractor at a workshop/ factory outside HPCL premises), stiffeners for Shell extension and supports for top platform, etc. D) All pontoon stiffeners for single deck floating roof. E) Rolling Ladder, internal ladders, hand rail for stairways, ladders, platforms,etc. F) All seamless pipes for nozzle necks 200mm NB and below, internal pipes, Nozzle necks for openings more than 200mm,Materials for Inlet/ Outlet Nozzle troughs, floating Page 9
roof supports, bleeder vents, emergency drain, bottom drain extension, extension piping for roof drain, etc. G) All pipe fittings, valves, flanges, matching flanges and blind covers wherever specified for all nozzles, stainless steel wire mesh for emergency drain, brass items and brazing for Auto bleeder vents. H) Primary roof drain after (Third Party Inspection for swivels) with associated rigid piping sections, if any adequately supported on Bottom/ from deck underside, necessary shoes/ guards, etc as per Manufacturers instructions including swivels, brass non return valve, extension piping etc. I) Bolts, nuts and SS spiral wound gaskets for roof & shell manholes, nozzles with blind cover/ matching flange, bolts & nuts for roof structure and other structural works. J) Seals (Primary & Secondary) of approved make, guide rollers, roof stoppers, earthing cable, shunts etc. Primary & Secondary seals for MS & ULMS F/R Tanks. Seals shall be supplied after Third Party Inspection. K) Rim Vent along with relief valves.. L) Gauge well & Gauge Hatch with cover. M) Pipes, fittings, flanges and bolts and nuts and spray Nozzles and orifice plates and structural supports for Piping for Fixed water Cooling spray system. N) Pipes, fittings, flanges, orifice plates, Foam makers/ Pourers and deflectors on point of spray on shell and structural supports for Piping for Foam system O) Support arrangement required for cooling system. P) Internal Bolts & Gaskets. Q) Water including CI for hydrotesting & calibration.Strapping tapes & accessories for calibration. R) Radiographic Films & Consumables for NDT. S) Earth connections, support cleats for pipes, structurals & cables. T) Any Blind flanges, valves, nipples, plugs, bolts, nuts, gaskets, etc required for conducting hydrostatic testing and any other test required by HPCL. U) All primer materials and painting materials, scaffolding, blasting medium and related equipment for Painting.
Page 10
V) Brass Plate for sealing still well annular space, Gasket, Gauge Pole sleeve for still well (W) Providing tools, tackles, hoist/crane, jacks, instruments, supervision etc. required for completion of the work as per drawing, specification and codes. The contractor shall hand over test certificates for all items supplied by him to the owner for verification and approval. (X) All type of appurtenance for floating roof & shell. All types of paints and paintings system for A/G Tanks. (Y) All materials, labor, tools, machinery and accessories required for Civil works related to Tanks. (Z) All materials, labor, equipment & accessories related to CP system for tanks Note: While every effort has been made to list all the supply items, it shall be the sole responsibility of the Contractor to review the list and seek clarifications, if any at the time of Unpriced Bid itself. HPCL undertakes to provide only Free Issue Steel plates for Fabrication, pipes & valves incase of Rewari, and all the other items shall be supplied by the Contractor only. No claims/ disputes by the Bidder/ Contractor shall be entertained by HPCL at a later date. The above items are to be supplied by the party for Floating Roof, Cone roof & OTVT Tank as applicable. The items have been covered in SOR & specification, except 10% spares like studs/nuts/gaskets etc which shall be supplied by the party at the time of handover on the basis of final Bill of quantities, at no extra cost.
02.03 RECOVERY AND INVENTORY OF STEEL PLATES 02.03.01 Steel plates required for the fabrication and erection of tanks as per the owners scope of supply will be issued to the contractor by engineer-in-charge with full measurements. Contractor shall sign and hand over the material receipt to engineer-incharge after thorough checking of the same. 02.03.02 All steel plates thus issued shall be strictly accounted by the contractor. 02.03.03 All off cuts and unused plates shall be property of owner and shall be returned by the contractor to owners store, after weighing all off cuts plates at his cost. 02.03.04 Non-recoverable plates excluding off cuts shall not be more than 0.5% of the erected plate weight. 02.03.05 Off cuts, unused steel plates non-returned and any excess non recoverable plates beyond 0.5% of the weight of erected plates shall be recovered at twice the landed cost of plates from contractors bills.
Page 11
02.03.06 Contractor shall be fully responsible for correctness of sizes of plates indicated in the fabrication drawings to be prepared by him. In case any plate gets damaged/ spoiled by the contractor due to his fault, cost of the same will be recovered at twice the landed cost of plates from contractors bills.
02.04 Civil Works 02.04.01 The civil works required for the tanks included under this tender are included in the scope of the tenderer. Refer to the specification of the civil works part. 03.00 MATERIAL SPECIFICATIONS: Steel plates for tanks shall conform to IS-2062 Gr. A/B, 1999. Man hole neck rings, bolting flanges and cover plates shall be fabricated from MS plates conforming to IS 2062 Gr. A/B 1999. Nozzles of all sizes shall be fabricated from seamless pipelines conforming to specification given in Annexure-I. All slip on and blind flanges shall be fabricated from SA 105 material. Further they shall conform to ASA class 150 with holes drilled as per ANSI B.16.5. All structural steel sections for columns, column bases, beams, girders, rafters, curb angles, hand rails, roof top railings, inter connecting bridges, flat gratings, rolling ladder with track, rollers, axles, rods and bars shall conform to IS-808 latest edition. Gauge well pipes shall be seamless pipes for floating roof tank. Gauge hatches shall be of spark proof aluminium with quick opening cover and locking arrangement. All landing platform floors, spiral staircase steps, self-levelling steps of the rolling ladder, roof top platform floors shall be provided with MS flat gratings in honeycomb pattern. . Metallic Spiral Wound Gaskets for manholes, nozzles, fitted with blind flanges shall conform to specification IS 7719 75. Thickness of gaskets shall be 1.5mm up to 300mm NB nozzle and 3mm above 300mm NB nozzles. However before conducting hydro test the flange joint shall be provided CAF gaskets. There shall be two numbers of spares for each size location wise. Bolts and nuts for all nozzles fitted with blind flanges shall conform to IS 1367 and bolts and nuts for all structurals shall conform to IS 1363 92. Gate valves and non-return valves on pressure relief line shall be of forged steel construction of class 800 conforming to API 602 and BS 5352 respectively. Signature & Seal of Bidder Page 12
Pressure testing shall be done as per API 598/ BS 6755. Pipe fittings shall be of 3000 lbs rating. Welding electrodes for all plates of thickness 14mm and above, annular ring to bottom plates and shell to bottom plate welding shall be of low hydrogen (basic coated) as per AWS classification SFA 5.1. For all other welding high cellulose / rutile type as per AWS specification SFA 5.1 are acceptable. Advani Orlecon / ESAB/ Phillips / D and H Sechron / Hanavar / Mailam / GEE make electrodes only shall be used. Materials listed above shall be considered as minimum qualities for materials. An equivalent or superior quality may be substituted. No substitution shall be made without the written consent of Engineer-in-Charge. All materials shall be new, first class quality and of the type and grade specified. 04.00 DESIGN AND DRAWINGS Floating /Open roof tanks shall be designed in accordance with API 650, 10th Edition, 2000 and applicable Appendix with latest edition and supplement and the horizontal cylindrical tanks shall be as per IS: 10987-92. All basic drawings with design data and material specifications are attached with this tender document for tendering quotation as listed in Annexure-II. Final drawings with revisions if any shall be prepared and submitted for review / approval after award of contract or Purchase order by the contractor. Floating & Cone roof tanks shall be designed by the contractor considering design data given in each drawing and calculations shall be submitted for review / approval / records with regard to following in line with API-650 guidelines. a) Design calculations / data sheets for plate thickness, stability calculations, wind girders etc. b) Buoyancy calculations for roof, calculations for roof drains, bleeder vents etc. c) Structural calculations for roof leg supports, roof rim plates & Structural supports of cone roof tank. Venting size calculation for Roof vent of Cone roof and Auto bleeder vent, rim vent for floating roof tanks. Design calculations of the tank shall be approved by a competent design agency and shall be submitted to HPCL. 05.00 FABRICATION AND ERECTION
Page 13
Before commencing the job all plates shall be squared, diagonally checked, stenciled and stacked in order of execution of work. Plates shall be checked for splitting if any particularly. Split plates or laminated plates shall be rejected. Plates thus prepared shall be offered for inspection to the Engineer-in-Charge. Contractor shall arrange all equipment and labour necessary for inspecting and measuring all the plates. After the plates are approved they shall be stencilled and stacked properly. Plates shall be thoroughly checked for all dimensions and diagonality. Fabrication and erection of the tanks shall be carried out as per drawings reviewed / approved by HPCL. 05.01 BOTTOM The underside of bottom plates shall be blast cleaned to SA 21/2 and painted with two coats of tank mastic paint of approved make before laying. The underside of tank shall be protected for corrosion by cathodic protection technique. Bottom plate shall have a uniform slope of 1:50/100. Plates shall be lap welded and the over lap shall not be less than 5 times the plate thickness unless otherwise specified. For sketch plates/ annular plates, the overlap shall be given as per the code. For all tanks diameter more than 13m annular plates shall be provided and these annular plates shall be butt welded with backing strips. Joints between annular plates and sketch plates shall be lap welded. Datum plate for calibration/ gauging of product level in the tanks shall be welded on to the bottom horizontally to perfect level and directly below the gauge well. Welding sequence to be adopted shall be indicated in the drawings submitted by contractor and this shall be followed so as to cause minimum shrinkage and distortion. Bearing plates of the pipe supports shall be centred under each support for the floating roof and welded to the tank bottom by continuous fillet weld of size equivalent to plate thickness. These bearing plates shall be of sizes 600 x 600 x 10mm. Overlaps in joints of bottom and roof plates will not be measured and paid separately. 05.02 SHELL All the tanks included in this tender shall be constructed by Hydraulic Jacking up arrangement. All vertical and horizontal shell joints shall be full penetration and full fusion welds. The shell joints shall be double welded butt joints using any one of the edge preparation permitted by API 650. Details of the weld and edge cutting shall be shown in the drawings and shall be approved by HPCL.
Page 14
Shell plate arrangement and thickness as planned are as indicated in the enclosed drawings. Top curb angle shall be lap welded to the top course of shell with the flange turned outwards unless otherwise specified. Tank heights that are indicated in the tender are nominal and the actual heights might undergo minor changes to suit the construction. The stiffening ring or wind girder where necessary shall be welded to the tank at the location shown in the drawing duly stiffened with gussets and struts welded to shell. Welding shall be of same quality as used for shell. Primary wind girder shall be provided as a walkway with all around hand railings. Horizontal portion of stiffening rings shall be provided with drain holes of 25mm dia. These holes shall have suitable arrangement so as to avoid rain water from moving to tank shell. Curb angle and stiffening ring joints shall not come in line with the vertical weld joints of the shell plate. These joints shall offset each other by at least 1.0M. First shell course plates shall be so arranged that vertical joints clear the annular ring welds or sketch plate welds by at least 360mm. Vertical joints of shell course shall also clear the nozzle attachment welds or reinforcement pad welds as per API 650. Holes shall not be made on shell plates for erection purpose. Shell plate alignment shall be within the limits specified in API 650. D/P test and Oil chalk test shall be carried out for shell to bottom joint. For shell to bottom joint, low hydrogen electrodes shall be used. Internal weld seams of floating roof tanks shall be smooth and even to allow proper movement of roof without damage to the seals. During fabrication contractor shall provide guy ropes and other means to secure semi finished storage tanks against damage due to wind. Wind girders shall be welded to tanks at the earliest. The lifting of shells should not be commenced without fixing of wind girders.
05.03 FLOATING ROOF Floating roof shall be of pontoon type for diameter more than 12m with multiple compartments and shall be liquid proof to meet the minimum requirements of API 650. Each compartment of floating roof shall be provided with specified manhole with cover. Central deck and pontoons shall be suitably stiffened and calculations for structural Signature & Seal of Bidder Page 15
integrity of floating roof shall be submitted to HPCL for review. Centre deck of the floating roof shall be fabricated out of 5/6mm thick plates. Pontoon bottom shall be of 6mm plates. Pontoon Roof and compartment plates shall be of 5mm thick plate where the same shall be 6 mm. Inner and outer rim plates shall be designed by the contractor and calculations forwarded to HPCL. 16mm and 8mm plates have been considered for the plate procurement for the inner/ outer rim plates respectively. Deck shall have permanent slope to the centre to avoid stagnation of rainwater. When floating roof is in highest position, tank shall be capable of holding its designed capacity. Foam dam shall be provided with 5mm thick plates, for all the tanks as per standard to contain the foam to seal area. Floating roof shall be of low deck (minimum vapour space) type. Central deck of the floating roof shall be provided with two through deck manholes with ladders. Suitable stainless steel leaf springs shall be provided at the bottom rim of the deck @ 2.5 m c/c around the periphery for holding the deck centrally. Necessary stainless steel bolt, nuts, washers, etc, also shall be provided. 05.05 STAIRWAYS, LANDING PLATFORMS AND RAILINGS 05.05.01 Stairways and Platforms Each tank shall be provided with stairway with hand railing and landing platforms for access to the roof. Each step shall be supported by a vertical square rod as specified. The steps shall be fabricated out of MS flats bent in honeycomb pattern. The steps on one side shall be welded to tank shell. Raised platforms as per size indicated in the standard drawing shall be provided at the top of the stairway and shall be extended suitably to permit easy access to the two gauge well pipes for each of the tanks. A self-levelling rolling stairway shall be provided for access from platform to the floating roof. Roller track fixed to the roof shall permit movement of the stairway. Brass rollers for the rolling stairway shall be provided to avoid sparking. The steps for the selflevelling ladder also shall be of MS flat grating in honeycomb pattern. 05.06 TANK APPURTENANCES 05.06.01 Manholes and nozzles All manholes shall be according to API 650. The cut edges of the manhole shall be ground smoothly. The axis connecting both the manholes shall be generally in the direction of the wind prevailing locally. Shell and deck manholes shall be 600mm nominal diameter. Pontoon manholes shall be of 500 mm nominal diameter. The dimensions of the nozzle shall be in accordance with API 650 unless otherwise mentioned in the approved drawings. The out side end of the inlet and outlet nozzles shall be provided with slip-on flanges to facilitate fixing of the gate valve and the inside end shall be provided with a semi-circular MS trough as per drawing. Position of the Signature & Seal of Bidder Page 16
nozzles shall be such as to facilitate easy connection to the main running pipeline in the depot/ installation. Product inlet /outlet nozzle flanges shall be of class 150. Flange holes shall be drilled as per ANSI-B-16.5. Manhole and nozzle reinforcing pad plates shall be provided with 6mm threaded tell tale holes for testing purpose. Nozzles shall be welded to the tank with the same quality electrodes as used for shell welding. Manholes and nozzles shall be provided with gaskets, nut and bolts as specified. 05.06.02 Floating roof supports The number of supports shall be sufficient to ensure non-deformity of the roof and tank bottom when the roof is resting on the legs. The pipe supports shall be provided with cotter pins as specified in the drawing and suitable for two level operations. For this, holes shall be provided on the top portion of the legs to adjust the cotter pin. Leg supports shall be of 80 mm NB seamless SCH 80 pipes and sleeves shall be of 100mm NB seamless SCH 80 pipes. There shall be two operating levels of 2m and 1.2 m from the tank bottom plates. Pipe supports shall rest on the bearing plate after hydro test of tank. These bearing plates shall be stitch welded 50 to 60 mm c/c. Corrosion allowance shall be provided for roof supporting pipes and sleeves also. 05.06.03 Roof drain
1.1
The intent of this specification is to cover the scope of design, supply, erection, testing and commissioning of Swivel Jointed Articulated Roof Drain required for draining rain water from the roofs of Floating Roof Vertical Tanks for the petroleum products viz HSD, ULHSD, MS, ULMS and SKO. Compliance of this specification will not relieve the tenderer of his responsibility for supplying the equipment / items of proper design, material and workmanship to meet the specified operating requirements and also proper workmanship and performance of the facilities under the contract. Any additional material, which are not specifically mentioned in the technical specifications but are required to make the system complete in all respects for safe operation and guaranteed performance, shall be included in the scope of work of the tenderer. All materials supplied shall be new, of best quality and tested in accordance with the latest version of the relevant Indian Standards or relevant International Standard and codes acceptable to HPCL The tenderer shall indicate make and grade of all bought out items for approval from HPCL. Page 17
1.2
1.3
1.1
1.2
Specification of the products are as given below :
Product Density at 15 C Viscosity, cst 20 C Vapour Pressure, kg./cm at 38 C Operation Temperature
HSD 0.87 8 0.1
ULHSD 0.86 8 0.1
MS 0.77 0.7 0.7
ULMS 0.775 0.7 0.7
SKO/ATF 0.84 1.53 0.3
50 C
1.3
All drawings and instructions shall be in English language. Dimensions in drawings; technical data, weights and quantities shall be in metric units.
2.0
SCOPE OF WORK FOR ARTICULATED SWIVEL JOINTED ROOF DRAIN SYSTEM
A.
Design, manufacture / fabrication, testing, supply of roof drain system to work site
B.
Assembling, transportation at work spot, erection, testing and commissioning of the roof drain for the storage tanks as per the details given in Bill of Quantities. The following shall also form scope of work. i) The tenderer shall supply at his cost all equipment / piping, all necessary skilled and unskilled personnel, hoists, tools and tackles, instruments, safety implements and other accessories required for assembly, erection, testing and commissioning of the Roof Drain system for the tanks.
ii)
The tenderer shall give complete calculations for design of drain system, complete technical specification of the equipment offered and general arrangement drawings for the approval of HPCL, sufficiently in advance of the commencement of manufacture. Such approval, when accorded, shall however, Page 18
not relieve the tenderer of his responsibilities towards satisfactory and trouble free performance of the roof drain system.
iii)
All the equipment shall be shop tested according to the relevant standards. The particulars of the proposed tests shall be submitted to HPCL for approval before conducting the tests. HPCL shall be given full access to all the tests. The supplier shall inform HPCL sufficiently in advance so that if HPCL desires, his representative can witness the tests. All the certificates shall be submitted for the approval of HPCL before clearance for dispatch of the equipment can be given.
iv) v) vi)
Tenderer shall furnish certificates for swivel joints, pipes, valves etc forming part of roof drain system. The tenderer shall also additionally supply all necessary spares required during erection and commissioning, free of cost, for roof drain system. The tenderer shall furnish to HPCL the complete drawings, documents, test certificates, etc. as indicated in this technical specification for approval / information and record.
vii)
The tenderer shall guarantee the material, workmanship, and satisfactory performance of the complete roof drain systems for a period of 5 years from the date of completion of work. The completion date as mentioned in the Work Completion Certificate shall be considered as starting date. The party shall give Performance Bank Guarantee equivalent to the cost of Roof drain with a validity of 5 years as above from any Schedule Bank.
3.0
TECHNICAL SPECIFICATION
3.1
The tenderer shall design and size the roof drain system for each tank for a rainfall of 100 mm / hr. The system shall be suitable for draining the water collected at the roof sump through the shell nozzle near tank bottom. For design of roof drain, when the roof is at low leg the height difference between sump drain outlet of roof and at the discharge end at outlet may be considered as 1.5 m. The offered roof drain system shall include / incorporate items / equipment that are well proven, tried and tested for operation in petroleum storage tanks especially in Indian conditions.
Page 19
The satisfactory operation of the roof drain without any damage / leakage shall be ensured, considering the vertical and sideways movements of the roof while in operation. The materials of constructions of Gaskets and seals shall be compatible for operation with the product in the tank. All studs and nuts for roof drain shall be of SS.
3.2
ARTICULATED SWIVEL JOINT ROOF DRAIN :
The roof drain system shall be of swivel jointed type with articulated steel pipes. The system shall include Swivel Joints (ASTM A105 body with viton seals) Split type Design having anti corrosive sealing surface & Hardened Ball races to Min 55HRC, Seamless pipe (ASTM A106 Gr. B Schedule 40), Elbows (ASTM A234 WPB Schedule 40), Flanges including with matching flanges for the roof drain system (ASTM A105 SORF Class 150), SS 304 spiral wound gasket, Flanged Non-return valves at roof sumps (BS 1868, Class 150, Cast steel body, brass lining on flap), Supporting structures / legs, fasteners, chains etc complete in all respects for safe operation of the system. The welding of pipe joints shall be carried out by ASME section IX qualified welders. Makes of Pipes shall be SAIL, Maharashtra seamless ltd, Jindal pipes ltd, TISCO, MAN, Welspun, PSL or any other reputed make with the approval of HPCL. Makes of NRV valves shall be Econo valves Pvt. Ltd., BDK Engineering Industries Ltd., Fouress Engineering (I) Ltd., Steel Strong Valves Pvt. Ltd., NSSL Ltd, Shalimar Valves Pvt. Ltd., Flow Chem Industries, AV Valves Ltd., Audco India Ltd, KSB pumps Ltd or Any other reputed make with the approval of HPCL. Make of Swivel Joint will be Technika, Associate Engineers, PentaTech or any other reputed make with prior approval of HPCL. Assembly of Two Swivel Joints & pipes till flanged ends will be purchased from the Swivel Joint Mfgrs for better concentricity & alignments of the Swivel Joints. Only pipes having flanges at both ends & structures will be made at site. Roof Drain will have sufficient joints to take care of Vertical movement of the roof and other movements such as Rolling, pitching, Rocking about vertical axis or Lateral movements of the roof. This will be achieved by fixing additional Swivel joints Note: The location of drain sump on the deck shall be considered at the centre of the deck. The party should refer the scheme attached with the tender. 8 Nos 6 swivel and 2 Nos 8 swivel has to be provided for the Roof drain per tank. 4.0 INSPECTION & TESTING : Swivel joints along with accessories shall have to be inspected by Third Party agency at bidders cost prior to delivery at site.
Page 20
4.1
The items under the scope of supply of Roof Drain System shall be inspected by HPCL at the manufacturers or his sub contractors works. The tenderer shall furnish, Quality Assurance Plan (QAP) he proposes to follow at the factory and the tests to be conducted. This shall clearly define and identify the stages of inspection, scope of test, list of documents to be furnished. The tests shall include, but not limited to the following :Life cycle test for 20000 cycle of rotation at air / hydraulic pressure of 5 Kg/cm. No indentation mark on ball races shall be there after dismantling the swivel joint (Type test). Swivel joint shall be externally pressure tested at 4 Kg/ cm pneumatically. Bending moment test for base swivel at 1000 cycle of rotation and hydro test for swivel joint with bending moment at 15 Kg/ cm pressure for 10 min. No indentation marks shall be there on ball races after dismantling the swivel joint (Type test). The tenderer shall arrange all facilities required during inspection and testing at his cost. HPCL shall have the right to inspect / witness the tests at various stages of fabrication / manufacture / installation. The inspection shall be carried out at suppliers works / his subcontractors works / site. Inspection of the item shall be done only with a view to ensure that the same is manufactured, tested and supplied as per prescribed specifications. The inspection shall in no way relieve the supplier of his responsibility as per the contract and shall in no way be binding on HPCL Manufacturers test certificate shall be furnished for all bought out materials. Wherever such certificates are not available, the tenderer shall get the items tested at his expense at government recognized laboratories, mutually agreed upon with HPCL. Any defects noticed during the inspection / testing at site shall be rectified by the tenderer at his cost as advised by the site engineer and inspection / testing carried out for fool proof working. The roof drain system shall be pressure tested to 50 PSI after installation in the tank. The contractor shall perform the test in the presence of the engineer-in-charge. Any defects / leakage observed during the testing shall be repaired by the contractor at free of cost to HPCL.
5.0
DRAWINGS / INFORMATION TO BE SUBMITTED Page 21
The following drawings and documents in two copies shall be submitted along with the offer. Data sheets / catalogues / literature / drawings of the items offered indicating : Materials of construction and standards for different components of the roof drain system. b. General arrangement drawings indicating the lay patterns, cross sectional drawings and showing the highest and lowest operating level details. c. Make of Swivel joints, Pipes and NRV. d. Pipe size considered for roof drain system with sizing calculations. List of deviations, if any. 05.06.04 Roof vents Two types of roof vents shall be provided in case of floating roof tank. One is auto bleeder vent and the other is rim vent. For Cone roof tank, single/multiple Roof vent(s) of adequate size shall be provided Automatic bleeder vent of specified size shall be so designed as to open before the roof touches lowest position and to close when the roof rises above this point. Pressure vacuum relief valve ((PVRV) type Rim vents shall be provided for venting the void space between the stored liquid and seal. The connecting pipe shall be fabricated out of MS ERW pipe as specified, with a slip on flange at the top. PVRV shall be of Aluminium construction. 05.06.05 Gauge well Gauge wells with perforations shall be provided from rooftop down to the bottom and have dimensions as indicated in the detailed drawing. The top of the gauge shall be provided with an aluminium gauge hatch with cover and fireproof gasket and a flange for 50mm pipe. Cover shall be spark proof type. The other gauge well diametrically opposite shall be provided with a SORF flange at top. The gauge well shall be fixed in perfect verticality by means of angle sections as shown in the drawing. The well pipe shall extend to the top of stair way platform. 2 Nos. of gauge wells located diametrically opposite shall be provided for each of the tanks. Gauge well shall be of 200mm seamless SCH 40 pipe. The sleeve provided in the pontoon for the gauge well pipe should be of 350 mm diameter. 20 mm thick brass flange shall be provided in the sleeve for the gauge well pipes to pass through. 50 mm SCH 40 pipe with flange shall be provided inside one of the gauge-well pipes for average temperature sensing of products inside the tanks. a.
Page 22
05.06.06 Roof seal Primary Seal Mechanical Shoe Seals comprise a metallic sealing ring, which is held in permanent contact with the tank shell and extends into the product by a system of independent hanger and pusher mechanisms, and with a continuous sealing apron curtain closing the gap between the rim and the top of the Shoe. The product vapors are contained between the shoe , apron curtain and the floating roof. The design of the Mechanical Shoe Seal should be Channel Hanger Type with independent hanger and pusher devices. The design of the Mechanical Shoe Seal should be such that in service installation is enabled with no hot work allowed i.e. no welding or flame cutting. The Mechanical Shoe Seal should conform tightly to shell plate contours adaptable to existing rim and shell configuration, including wide variations in rim gap. The seal is characterized by a shoe-to-shoe slip joint connection, which allows for any variation in the rim space irregularities between the rim and tank shell, while containing the product vapors. It should be custom designed to suit the tank. The Channel hanger type assembly should successfully maintain a constant seal elevation even with a wide rim space. Galvanized shoes shall conform to ASTM A 924 and a G90 coating or equivalent and shall have a minimum nominal thickness of 1.5 mm (16 gauge). Stainless steel shoes shall have a minimum nominal thickness of 1.2 mm (18 gauge). Stainless steel shall conform to the requirements of ASTM A 240/A 240M (austenitic type only). Pusher mechanism should be SS conforming to the requirement of Stainless Steel as given above.Static Shunt to be SS conforming to the requirement of Stainless Steel as given above.All fasteners to be galvanized for seals of galvanized construction & SS for SS construction. Hanger Channels assembly should be minimum 14 gauge.Seal Curtain/ Dip.Curtain should be compatible with stored product, recommended 0.5mm thk PTFE. A protective mechanism should be provided to protect the vapor curtain. VENDOR / MANUFACTURER ELIGIBILTY Vendor shall have proven experience in supplying & installing the mechanical Shoe Seal with necessary documentary proof for having executed such jobs. The seal should meet CPCB requirements
INSPECTION CRITERIA : Maximum seal gap area will be 200 cm2/m of tank diameter.
Page 23
Scope of Third Party Inspection: Seal Curtain: Testing of properties to be witnessed and verified.
Mass of Zinc Coating on Mechanical Seal Components to be witnessed & Verified.Other tests to be carried out at a reputed laboratory and the results shall be furnished for review / approval.
Secondary Seal
Secondary seal shall be of compression plate rim mounted horizontal or vertical (preferably horizontal), made from series of metallic sheet joined together to form a ring with a non-metallic tip that slide on the inside surface of the tank shell. The joints to be bolted or sliding and to incorporate gasket at the point of overlap of the compression plate. Compression plate of the secondary sealing system should be sized to match the existing annular space between the tank shell & the floating roof. The compression plate should be clamped on the Rim flat/angle with channels duly galvanized. The compression plate to have the compression channel gasketing. It should provide Leak tight joint between the plates. Each seal plate should be sealed with the adjacent plate in a fashion to eliminate vapor loss. Galvanized compression plates shall conform to ASTM A 924 and a G90 coating or equivalent and shall have a minimum nominal thickness of 1.5 mm (16 gauge). Stainless steel compression plates shall have a minimum nominal thickness of 1.2 mm (18 gauge). Stainless steel shall conform to the requirements of ASTM A 240/A 240M (austenitic type only). Static Shunt to be SS conforming to the requirement of Stainless Steel as given above.All fasteners to be galvanized for seals of galvanized construction & SS for SS construction.A protective mechanism should be provided to facilitate smooth re-entry of the secondary Seal onto the Tank Shell in the event of Tank overfilling. Secondary seal system shall be tight fitted, rim mounted, with a wiper Tip made of a polymer compatible to the stored product.The Sealing Gasket to be made of a polymer compatible to the stored product. Seal shall have very low coefficient of friction, shall not damage or score the tank shell. Metallic seal components shall have adequate corrosion protection for long life. All material used in the seal manufacturing shall be tested and certified for extended use in hydrocarbon products.
Page 24
It should be custom designed to suit the tank. Additionally, the secondary seal should have the following design features, A. B. C. D. E. F. G. H. I. Safely ground lightening strike. Minimize seal gap and shed water to the extent possible. Capable in operating effectively over irregular rim gaps. To install from above the deck without any hot works. Seal material must be compatible with product stored. Non-metallic parts must resist cracking and tearing. Metallic components must resist corrosion. To be able to dismantle the secondary seal, without affecting evaporative loss control characteristics of primary seal. Secondary seal shall extend from the roof to the tank shell and shall not be attached to the primary seal.
VENDOR / MANUFACTURER ELIGIBILTY

Vendor shall have proven experience in supplying & installing the mechanical Shoe Seal with necessary documentary proof for having executed such jobs. The seal should meet CPCB requirements.
INSPECTION CRITERIA : Maximum seal gap area will be 20 cm2/m of tank diameter Scope of Third Party Inspection. Wiper Tip Material : Testing of properties to be witnessed and verified.
Mass of Zinc Coating on Secondary Seal Components: To be witnessed & Verified.
Tests of other components to be carried out at a reputed laboratory and the results shall be furnished for review / approval.
05.06.09 Settling marker ISA 50 x 50 x 6 and 100mm long settling markers shall be provided on the tank shell 0.5 m above the bottom plate for taking readings of tank settlement during hydrostatic testing. 05.06.10 Tolerance in fabrication Shell plate: Plate cutting: +/- 1.5 mm on length +/- 1.5 mm on width
Page 25
Shell: For the purpose of tanks to have acceptable appearance and to permit proper functioning of floating roof, the tank shall have tolerance strictly as specified in API 650-2000. Floating roof tolerance: Tolerance allowed and annular clearance between shell and floating roof shall be compatible with requirements specified as per API 650-2000. 05.06.11 Electrical & Automation System: The tender envisages supply and installation and commissioning of electrical and automation system of the additional product tankages and integrate with the existing electrical and automation system of the location. All the tanks in the above Terminals are provided with Radar Gauge with tank side indicator ,temperature element with water bottom sensor of Saab make supplied by Automation vendor for the particular location. The all the tank valves are provided with one MOV and one HOV. The contractor shall integrate new MOVs with the help of actuator supplier or thru automation vendor to the existing MOV panels of the system. The existing automation system at Ajmer and Jaipur has been installed and commissioned by M/s L & T ( contact person Mr Wagle09821604718) and in Rewari by M/s Honeywell (contact person Mr Snehal 09860869200) . The contractor is required to supply the same make or equivalent instruments which are already installed in the location for easy maintenance and trouble free operation. 06.00 Underground Tank: Not Applicable 07.00 Cathodic protection for tank bottom of above ground product storage tanks 07.01 Design of the system All materials shall conform to relevant BIS and other standards specified. System shall be complete in all respects to achieve the protection standards specified. These specifications provide only the basic requirements. It shall be responsibility of the Contractor to collect and take into consideration all the parameters to develop acceptable engineering practice for the Impressed Current Cathodic protection system. The Contractors scope of work shall include but not be limited to: 1. Soil/ Sand resistivity survey and soil/sand chemical analysis in Tank Farm area. 2. Submission and acceptance of soil / sand resistivity report. 3. Submission of design calculations and layout plan for the CP system. 4. Certification / approval by a competent authority / agency for the design calculation and installation procedure. 5. Preparation and acceptance of Detailed Engineering Package. 6.Supply and installation of all equipments/materials. 7. Preparation and acceptance of Testing and Commissioning Procedures. Signature & Seal of Bidder Page 26
8. Testing and commissioning of Impressed Current Cathodic protection system. 9. As Built documentation. The major equipment covered under the specification shall include polymeric anodes, reference electrodes, junction boxes (AJB and CJB), test stations / boxes, transformer rectifier units (TRU), power cables, anode header cables, tail cables, cathode header cables, reference cables etc. The installation work shall include necessary insulating joints, backfill, epoxy encapsulations, thermit welding / soldering, cable markers etc. The work of placing the Anodes, connecting the cable etc. shall be carried out along with the other civil works at the right time and with proper co-ordination with the other contractors. 07.02 Design Guidelines The cathodic protection system for the tank bottom shall be specifically engineered to protect tank bottom structure continuously for a minimum period of 30 years. The CP system shall be designed for 100% bare steel. The cathodic protection system shall be ngineered to meet the following protection criteria: 1. The structure to soil potential shall be 0.85V (minimum) to - 1.2 V (maximum) (OFF condition) with reference to Copper/Copper Sulphate Reference Electrode. 2. Minimum polarization shift of 100 mV measured between the tank bottom metallic surface and permanent reference electrode in contact with soil. 3. The minimum requirement of cathodic protection current shall be 10 mA / sq. m for the tank bottom plate. 07.03 Codes and Standards The cathodic protection system shall be engineered, supplied, installed, tested and commissioned in accordance with latest applicable standards / recommended practices of NACE, API, ANSI, BS and IS. In particular, the system shall conform to: API RP 651 1997: Cathodic protection of above ground storage Tanks. NACE RP0193-2001: External cathodic protection of on-Grade Metallic Storage Tank Bottoms. NACE RP0285 : Control of External Corrosion on metallic Buried, Partially buried or Submerged Liquid storage Systems. BS CP-1021 : Code of practice of cathodic protection.In addition the work shall conform to requirements of following regulations. (latestrevision)Indian electricity acts and rules. CCOE regulations, (Nagpur) Chief electrical inspectorate of the respective state. Indian petroleum act. Fire insurance regulation. Equipment and materials shall be engineered, manufactured and selected for use under the following site conditions: Ambient Temperature : 50C to 500C : 00C to 500C Relative humidity : 95% maximum : 95% maximum Climate description : Tropical / Marine normal corrosive or saline soil Signature & Seal of Bidder Page 27
: Tropical normal corrosive soil The cathodic protection system shall be engineered for continuous operation under the above site conditions and fully tropicalized. 07.05 Materials and Construction 07.05.01 General Requirements of major equipments are indicated in these specifications. However contractor shall submit detail specifications of each equipment. All equipments shall be new and procured from approved and reputed manufacturers. Contractor shall offer only equipments which have proven service track record and a reference list of similar make / type shall be provided. As far as possible, all equipments shall be located in safe areas. Any equipment required to be installed in hazardous area shall satisfy all requirements dictated by the hazard classification of area in which the equipment and / or materials are to be installed. It will be ensured that manufacturer of installed electrical equipments, incorporates all statutory safety provisions. Electrical equipment and materials for use in hazardous areas shall be certified by an approved certifying authority such as CCOE/CMRS. 07.05.02 Anode The distributed anode design shall be based on soil resistivity survey data, external bituminous padding / sand padding and other specification of tank foundation. The number and configuration of distributed anodes will be determined by total current requirement of structure to be protected and optimum current density of the anode material selected. It shall be so engineered that a uniform and ample current distribution will be obtained. Anode material shall be carbon based conductive polymer cable (factory packed carbonaceous material) or equivalent of reputed make with proven supply records of use in Storage Tank Bottom plate cathodic protection. It is preferred to avoid splicing of anodes in the sand pad foundation. 07.05.03 Transformer Rectifier Unit Cathodic protection system of each tank shall be in general powered by a separate transformer rectifier unit. In some cases 2 tanks can be combined for a single power source. However, voltage drop shall be checked to be within the tolerance. Transformer will be double wound, air cooled type with electrostatic shield between the windings. The transformer insulation will be F class. It shall be floor mounted, suitable for indoor installation and shall be dust / vermin proof. Transformer rectifier unit shall be sized to cater to the protective current demand required for installation with 100% spare capacity. The DC output voltage of rectifier unit shall not exceed 50V. The rectifier shall have continuous reading flush mounted DC voltmeter and ammeter for measuring output voltage and current. Meters shall be accurate and shall be linear from zero to full scale. Rectifier will be silicon type with adequate cooling arrangement and with Signature & Seal of Bidder Page 28
moisture and humidity resistant finish. It will be mounted on suitable supports. Adequate filtering arrangement will be provided to limit the ripple content to less than 5% at rated output. The Input/ output of rectifier units will be protected by fast acting fuses of suitable ratings. Transient surge suppressors will also be provided across. DC output terminals and AC input terminals to protect the rectifier against surges. Each diode and SCR will be provided with suitable surge suppressors. The TRU shall be equipped with a circuit breaker for the incoming power supply. Power supply to TR units will be drawn from the feeders of PMCC provided in the Terminal / Depot at 415V, 50 Hz. All the CP TR unit panels shall be located in a room earmarked for the panels. A) Auto Mode The unit will be generally working in this mode. The operation of the unit in this mode will be controlled by upto three reference signals, which will be fed simultaneously. The unit will have fully solid state Automatic Reference Selector logic to select the least protected reference out of the three reference signals. The output DC voltage of the unit in this mode will vary right from 0 V to 50V and from 0A to 50 A (or 75 A as the case may be) to maintain all the reference signals within the protected range under all operating conditions. The response of the unit will be instantaneous in order to suppress extremely fast acting external stray currents. The typical reference regulation in this mode will be within + 10 mV under all conditions. In case of failure of any reference signal, the unit will ignore that signal and provided an alarm to indicate failure of that particular reference input. However, the operation of the unit will not be affected in any manner due to failure of any of the reference inputs. The unit will continue maintaining the remaining healthy signals at the protective level. In event of failure of all reference signals, the unit will provide alarm All Reference Fail and output of the unit will be adjusted to preset value which will be operator adjustable from 0 V to rated value. Facility will also be provided for manual selection of any one of the three reference inputs for control. Suitable metering arrangement will also be provided to monitor all the three external reference signals as well as the internal reference signal independently. Independent fast acting electronic current limit circuit will be provided to limit the output current of the unit in Auto Mode to any value from 0 A to rated value as desired by the operator. B) Automatic Voltage Current Control mode (AVCC) mode This will be the second mode of operation. The working of this mode will be independent of the Manual mode and failure of the unit in Auto mode will not affect operation in this mode. The output voltage of the unit will be adjustable to any value from OV to rated voltage by means of step less voltage setter. The set voltage will be maintained within 1% of the set value for change in line voltage from 180V to 270 V and change in load from zero to full load. The output current of the unit will be adjustable to any value from 0A to rated value by means of a step less current setter. The current will be regulated within + 1% of the set value for change in line voltage from 180 Signature & Seal of Bidder Page 29
V to 270V and change in load within the specified limits. The response of both current controller and voltage controller will be ultra fast, instantaneous type there will be no change in output voltage and current even for a step change in load and input. C) Manual mode The control of output in this mode will be without any electronic component. A separate Auto Transformer with tappings will be provided for voltage control in this mode. The output will be adjustable from OV to rated value in steps. Annunciation system Complete annunciation system will be provided to indicate the followings 1. Under protection. 2. Over protection. 3. Over current (Automatically adjustable over complete range). 4. Ref. 1 fail. 5. Ref. 2 fail. 6. Ref. 3 fail. 7. All Ref. Fail. 8. Reference 1 lowest. 9. Reference 2 lowest. 10. Reference 3 lowest. 11. Subsequent reference electrodes The transformer rectifier unit shall be provided with current interrupter to facilitate recording of ON/OFF structure-to-soil potential. 07.05.04 Test station / box The test boxes shall be used for potential measurement. It shall be installed near each tank at four different locations. Test box shall be flameproof, weatherproof, with pushbutton and DC voltmeter suitable for outdoor installation in hazardous area. Test box shall be made of aluminum alloy (LM-6) or stainless steel. Test box shall be suitable for mounting on MS support. A minimum of 30% spare terminals shall be provided in each test box. DC voltmeter with scale 0-3V shall be incorporated in the-test box for taking potential measurement. The accuracy of voltmeter shall be not less than + 1%. The nameplate of test box shall carry following information: Test box number. Test box connection scheme. 07.05.05 Permanent reference cells High purity Copper / Copper Sulphate Reference electrodes with proven high reliability shall be provided for stable structure to soil potential measurement. The permanent reference electrode shall have negligible drift in its lifetime and should have a stability of 0.1%. The life of half cell permanent reference electrode shall be comparable with the design of CP system. Permanent Copper/Copper sulphate reference electrode shall be Stelth 2 of M/s Borin / Harco of USA. A minimum of six permanent reference Signature & Seal of Bidder Page 30
electrodes for tank dia > 30 m and three for tank dia < 30 m shall be located underneath the tank bottom plate at the following locations: - At the center of bottom plate - Near the rim of the bottom plate - In between center and the rim of the bottom plate. 07.05.06 Anode Junction Box Anode Junction Box shall be made of stainless steel or cast aluminum alloy having degree of protection lP55. It shall have arrangement for terminating main positive and negative cables. The anode junction box shall have current divide facility and measuring shunt for current measurement. The anode junction box shall beflameproof/explosion proof, if installed in classified area. 07.05.07 Backfill (If required) The backfill material of anode cable trench shall consist of charcoal/coke powder having minimum carbon content of 80 to 90%. This additional charcoal / coke shall be provided in the trench so that anode cable sets embedded with charcoal / coke. Above it normal soil available in the foundation shall be provided. 07.05.08 Cables All cables used for cathode and anode header circuits (including test leads) shall be 1100 V grade, single core, copper conductor, and PVC insulated GI wire armored cable. The reference electrode cable and anode lead wire cable shall be 1100V grade single core standard copper conductor with a double insulation system. The primary insulation shall be PVC sheathing jacket over the primary insulation. The minimum cross section shall be as follows: Copper conductor:Test Lead cable 6 mm2 Anode and Cathode header cable (for tanks 48 m dia and below)35 mm2 Anode and Cathode header cable (for tanks 64 m dia and below)50 mm2 Anode lead cables 16 mm2 Cathode lead cable 16 mm2 Reference electrode cable 6 mm2 Multi core reference cable 1.5 mm2 07.06. Soil Resistivity survey The contractor shall carry out soil resistivity survey of the tank farm area and shall study the details of all backfill materials used for the entire tank foundation and accordingly judiciously select the design soil resistivity data. To carry out soil resistivity measurement, Wenners 4-pin method shall be used. Contractor shall also carryout tests to check the presence of chlorides and Sulphate Reducing Bacteria. 07.07 Laying and installation 07.07.01 Installation of Anode (Cable) The anode cable is to be installed beneath the tank bottom with normal cable laying technique. A proper coke fill around the anodes has to be ensured. Anode cable shall be Signature & Seal of Bidder Page 31
laid in trench approximately within 1 m depth from the tank bottom. A perforated PE pipe shall be used as a conduit through gravel and concrete foundation ring in order to provide mechanical protection to the cable. The anode cable shall be in individual loops/ single cable with each loop / cable extending outside tank wall. This will help to power each anode cable / loop individually and to access as required. The CP Contractor will provide a detailed methodology of laying the anodes in foundation for owners approval. 07.07.02 Laying of PVC pipe for monitoring of Tank to Soil potential using portable reference electrode A perforated PVC or FRP pipe will be provided for getting a continuous profile of tank to soil potential from the perimeter to the center. The pipe will be laid from the perimeter of the tank to the center of the tank during the period of installation of permanent half cell itself. The pipe will be installed at shallow angle so as to reduce IR drop and perforated in a manner that it allows to be temporarily flooded. The intent of this arrangement is that a submersible Copper / Copper Sulphate electrode can be inserted into the pipe using stiff wire or small diameter pipe to obtain a profile of tank to soil potential across the tank bottom. The open end of the pipe shall have arrangement of plugging through threaded socket. 07.07.03 Installation of Permanent Half Cell Minimum of three nos. of permanent half cells per tank shall be installed at a suitable depth preferably at a depth of 300 mm from the tank bottom plate so as to provide a close measurement of structure (tank bottom) to soil potential. The lead wires from the reference electrodes will be corrosion resistant type and will pass through PE /PVC pipe laid from the tank outer foundation ring to tank center place. These wires will then properly be laid upto the Test box for termination. 07.07.04 Cable to structure connection All cable connections to the tank bottom plate / structure shall be made by an exothermic process, CADWELD, THERMOWELD or equivalent method. 07.07.05 Installation schedule The installation of cathodic protection system shall be broadly grouped in following manner: Laying of main anode cable beneath the tank bottom. This work shall be scheduled to undertake during the tank foundation construction. The jobs may be planned in the following manner: a) During the construction of tank foundation, the construction of foundation is halted when it is at desired height from the level of tank bottom plate for laying the anode cable. b) Laying of anode cable as per engineered configuration will start with normal cable laying technique using manual excavation.
Page 32
c) The cable shall be laid extending the tank concrete foundation ring with cable passing through a perforated PE duct put on the gravel portion and upto the concrete foundation ring of the foundation. d) The cable ends appearing outside the foundation ring shall be properly sealed so as to impede any water or soil ingressing the cable. The protruded cable ends so protected shall be kept temporarily embedded in with proper marking so as to locate afterwards. Similarly laying of permanent half cells, intent to monitoring CP system shall be completed at this stage only. The permanent half cell wires shall be taken though a hard PE pipe similar to the arrangement detailed above. e) Once completed the foundation work of this tank will restart, the cable laying activity, shall resume in other tank in the similar manner as described in the foregoing. f) The other activities like Anode junction box installation, all cable laying work, cathode cable, test lead cable jointing tank body, test lead boxes etc shall be undertaken after completion of tank painting jobs. This measure is considered to avoid any potential damage to cable and other equipment of the CP system intended to install in the Tank Farm Area. g) While details in foregoing para are kept pending, the installation of TR unit in the Tank Farm MCC room/ CP Panel room including all its related civil work and electrical interconnection with MCC shall be taken up consequent to the completion of anode cable laying work. 07.08 Civil Works All civil works associated with complete Impressed Current Cathodic Protection system are included in the scope of contractor. This shall include making cable trenches and foundation of all equipments, Anode junction box, test boxes and minor civil works. etc. 07.09 Commissioning The installed CP system shall be commissioned as per approved testing / commissioning procedures and by following model: Before the energisation of CP unit, natural structure to soil potential value shall be recorded at test station of each tank. After taking natural soil to tank potential, the CP output for the relevant tank shall be switched ON. Output current of the TR Unit shall be adjusted to achieve the maximum potential value of - 1.5V with respect to copper / Copper Sulphate Electrode for at least 48 hours.Output current of anodes shall be adjusted. CP station output of the respective tank shall be set at the designed values. Observation of structure-to-soil potential shall be recorded at each of the installed test station. CP station operating parameters shall be recorded. Utmost care shall be exercised to allow the structure to polarize before structure to soil potential values are recorded across the span for the tank bottoms Structure to soil potential measurement with both ON / OFF potential method shall be repeated after 15 days of polarization using current interruption technique. The maximum OFF potential shall be 1.2 V. As a result of these tests / commissioning if any deficiencies are found in the system, the same Signature & Seal of Bidder Page 33
shall be rectified by the contractor at no extra cost or time effect, to the complete satisfaction of the Owner/ Owners representative. 07.10 Credentials of CP Contractor and Preferred makes The Contractor for carrying out the Cathodic protection system shall have a proven track record of minimum 5 years of designing, installing, testing and commissioning of similar jobs for above ground storage tanks. Relevant documentary proof shall be furnished for verification of the experience. In the absence of these credentials this portion of the tender will not be evaluated. Preferred makes: Polymer anodes : Raychem / Matcor USA TRU : Canara electric controls. Reference electrodes : Borin USA / Harco USA. Polarisation Cells : Kirk. Cables : CCI / Fort Gloster / RPG / Special Cables /Nicco Universal Surge Arresters : Dehn + Sohne Germany. Junction Boxes : FEPL / Sudhir electrical / FCG GEAG / Baliga The tenderer can indicate alternate makes, with process performance for the above items, which will be subject to evaluation / approval by client / consultant. 08.00 INSPECTION 08.01 ACCESS FOR INSPECTION Inspection shall be co-ordinated with the Engineer-in-Charge at all times. All tanks shall be offered for inspection to Engineer-in-Charge in stages as desired by him. In-Charge shall have free access to all works at all times. The contractor shall provide all tools, equipment and labour to the Engineer-in-Charge for proper inspection. All inspections will be carried in accordance with the requirements of this specification. Approval of Engineer-in-Charge shall in no way relieve the contractor of his responsibilities for proper execution of works. 08.02 lnspection and Testing of Cathodic Protection Equipment at Manufacturers Works All components / equipments of Cathodic protection system shall be subjected to minimum testing and inspection requirements, manufacturers works, as per relevant codes and standards in presence of Contractor. Owner reserves right to depute his representative for inspection/testing. The manufacturer/contractor shall furnish all facilities to Owner for entry to respective works and for testing / inspection at his own care and expense. Minimum 15 days notice shall be given for inspection. 08.03 Field Testing of Cathodic Protection system The Contractor shall submit to the Engineer-in-Charge all necessary test certificates for the materials supplied by him. The Engineer-in-charge reserves the right to carry out any / all test either in any Laboratory / Testing facilities and the cost incurred for carrying out such tests shall be borne by the Contractor. The material found not Signature & Seal of Bidder Page 34
conforming to the specifications shall be summarily rejected. The contractor shall furnish all labour, materials, instructions and tools to make all tests and carryout all the specified field tests. The Contractor shall carry out suitable tests to establish to the satisfaction of the Engineer-in-charge / Site Engineer, that all equipments, devices, cables and wiring and connections have been correctly installed, are in good condition and will operate as intended. The Engineer-in-charge / Site Engineer reserves the right to witness all tests and at least two weeks notice shall be given before commencing the tests. 08.04 WELDING SEQUENCE AND WELDER QUALIFICATIONS No welding shall be undertaken without the approval by Site-in-Charge. Test Certificates for welders qualification shall be provided by contractor before deploying any welder for tank welding job. Welding sequence to be adopted shall be indicated in the drawings submitted by the contractor and this shall be followed so as to cause minimum shrinkage and distortion. 08.05 REPAIR OF DEFECTIVE WELDS a. The defective weld shall be removed by chipping or melting out by thermal gouging process from both sides of joint and re-welded. Only sufficient cutting out of the defective joints, as is necessary to correct the defect is required. b. All repaired welds in the joints shall be checked by repeating the original inspection procedure and by repeating the hydrostatic testing / vacuum box testing method. 09.00 TESTING OF TANKS 09.01 BOTTOM TESTING Weld joints of the bottom will be tested by vacuum box / compressed air method. A detailed description of the method to be adopted shall be submitted to the Engineer-inCharge for approval. The weld joints along the periphery shall be tested before erection and welding of the first shell. Contractor shall test the tank bottom for the entire weld length in the presence of Engineer-in-Charge and test certificate shall be issued accordingly. 09.02 SHELL TESTING Procedure and extent of radiographic inspection and testing of radiography shall be as stipulated in API 650. Record of Radiographic Examination: a. The contractor shall make a record consisting of all films with their identification marks on a developed shell plate diagram. b. After completion of inspection, the films shall be handed over to HPCL along with inspection reports for acceptance. Shell hydro testing shall be carried out with floating roof as per API 650. The contractor shall supply all equipment necessary for testing of tanks.. Necessary corrosion inhibitor shall be added to prevent corrosion, wherever required as per manufacturers Signature & Seal of Bidder Page 35
recommendation. The tank inside surface shall be well cleaned with fresh water jet after completion of the test. Bottom to shell joints shall be tested as follows: Inner fillet weld shall be inspected and tested prior to welding the outside fillet weld. Examination for inner fillet toe cracks shall be performed using either liquid penetrant or magnetic particle method. All weld lugs and brackets used for erection process shall be carefully removed from inside and outside surfaces of tank and ground to the satisfaction of Engineer-in-Charge. All openings not used for tests shall be closed by plugs and blind flanges supplied by contractor. Contractor shall hydrostatically test the tank including filling and emptying. Contractor shall follow the procedure given below while carrying out the hydro testing of tanks: a) Check the verticality of the storage tanks with respect to top to bottom shell at an interval of 3-4 m peripheral distance and keep a record. b) Provide required level marker cleats (made out of 75 x 75 x 6mm or 65 x 65 x 6mm) on the tank shell at an interval of approx.4-5 m. These markers are to be provided at a height of 450mm from the bottom plate. Ensure required distance is kept all over uniformly so that variations or settlement can be ascertained without any problem. c) A proper benchmark to be fixed approx. 20-30 m away from the tank so that at all times this benchmark is available for reference. d) Check the level of the tank on the basis of the bench mark and the various cleats being fixed on the tank shell to ascertain the initial tilt if any to the tank prior to carrying out hydro test. This should be recorded in a format. e) Whatever may be the height of the tank, ensure 1/3 height of the tank to be filled with water at the rate of 750 mm at an interval of 24 hours for recording settlement. In case settlement is observed, extend the duration of the observation by another 24 hours and ensure that settlement comes to a halt. Further filling will be carried out only after ascertaining that there is no settlement to the tank at this stage. f) On completion of 1/3 portion of the tank shell filling height will be subsequently reduced to a height of 450 mm and 24 hours settlement period to be kept as it is. With this procedure, the filling height to be continued up to the tank height. g) After completion of 50% height of the tank as stated above the filling rate to be reduced from 450mm to 300mm per day keeping 24 hours settlement period, which is to be considered as firm and there should not be any change as far as the settlement is considered. h) Further filling to be continued at the rate of 300mm per day till maximum level. On observing the settlement reading up to 2/3 of the tank height if found that settlement is not considerable i.e. to the tune of 25 to 50mm only filling rate shall be increased after obtaining confirmation in writing from HPCL. Daily report of filling and settlement to be recorded / furnished HPCL for further handling and comments to expedite testing of tanks. After testing, the tank shall be drained and thoroughly cleaned. Standing water,
Page 36
silt or other dirt left in the tank after testing shall be thoroughly cleaned. All weld repairs shall be done with water level minimum 300mm below the joint being repaired. 09.03 FLOATING ROOF TESTING Testing shall be as recommended in API 650 appendix C and as given below: Lap welds shall be tested with vacuum box. Fillet welds of rim plates and compartment plates and butt welds in rim plates shall be tested with chalk-kerosene. All rim plates and vertical butt welds to a height of 500 mm above lower deck plate shall be tested by DP. Also all lap welds falling within 150 mm length the outer most edge of lower deck shall be tested by DP. The sealing device shall be tested to the satisfaction of Engineer-in-Charge. The contractor will issue necessary test certificates after completion of tests. Floatation tests for roof shall be done as per API 650 along with hydro testing of the tanks. Proof tests simulating conditions with respect to rainfall of 10 inches and deck / pontoon punctured conditions as specified in API 650 Appendix C (Pontoon design) shall be carried out. For floatation test of the floating roof, the filling height shall be so that the secondary seal does not go beyond the curb angle. 09.04 NOZZLES AND REINFORCEMENT PADS TESTING The reinforcing pads shall be tested with soap solution by applying air pressure at 1.05 kg/cm2. The test shall be carried out before filling the tank for hydrostatic testing. No separate payment will be made for this item. 09.05 PRIMARY DRAIN Primary drain pipe in floating roof tanks shall be pressure tested to 3.5 kg/cm2 after installation. Contractor shall perform the test in the presence of the Engineer-in-Charge. Any defects observed during testing shall be repaired by the contractor free of cost. IMPORTANT NOTE: During all the above tests if any leaks are observed contractor shall remove/decant the water up to 300mm below the leaking joint, repair the leak and retest the tank till there are no leaks. Any extra claim by the contractor will not be entertained by HPCL. Contractor may carryout testing several times but all this will be treated as one job only. Testing up to the satisfaction of the Engineer-in-Charge and handing over the tank without leaks shall be the responsibility of the contractor. 10.0 CALIBRATION OF TANKS Calibration shall be done in accordance with IS 2007/2008 latest edition. Calibration tape shall be supplied by Contractor at their cost. All the necessary instruments and implements required for the calibration shall be provided by the contractor. 10.01 BOTTOM CALIBRATION Bottom calibration shall be done physically with a water meter pumping equal volumes of water and then noting the dip with tape. This physical calibration shall be done up to crown starting from the datum plate. The reading shall be submitted in the required
Page 37
format in consultation with the Engineer-in-Charge. All dead wood details shall also be noted. 10.02 SHELL CALIBRATION Calibration of the shell shall be carried out when the tank is at least 3/4th full of water. Tank circumferential readings shall be taken at every top and bottom of each shell strake with the help of a strapping tape by applying sufficient pull at the end by means of a spring balance. All the scaffolding necessary for holding the tape shall be arranged by the contractor at his own cost. Contractor shall ensure perfect horizontality of the tape in this method. Contractor shall be prepared to do by any method. Height of each shell strake shall be noted correct to a mm. All readings thus noted shall be presented in the required format available with the Engineer-in-Charge. 10.03 CERTIFICATION OF CHARTS BY W&M Contractor shall carryout both bottom and shell calibration in the presence of the representatives of W&M Statutory Authorities and HPCL. Calibration charts shall be prepared by the contractor and get the same approved by W&M Statutory Authorities. Contractor shall arrange for certification of tank calibration charts by concerned Central Public Works Department officials. For this purpose, contractor shall arrange visit of W&M/ Statutory Authorities staff. All statutory fees and any other expenses in this regard shall be borne by the contractor. 11.00 MISCELLANEOUS 11.01 TANK EARTHING Each above ground tank shall be provided with independent earthing pits to dissipate static charge developed if any. The earthing pits shall conform to IS: 3043 87 latest edition with all GI parts including the plate and B Class GI pipes of 80 mm dia. The pit shall be covered with GI plate as shown in the drawing attached. A MS earthing boss of 50mm dia shall be provided on the tank at 500mm height above the bottom plate. This boss shall be connected to the nearby earthing pit by of 50 x 6 mm thick MS galvanised strip, After completing all the connections of the earthing system the pits shall be tested for resistance with a megger. A necessary testing certificate shall be obtained from licensed electrical contractor after successful completion of the test. In case of floating roof tanks in addition to the above earthing system the rolling ladder/track and ladder/shell shall be connected by 50 sq. mm braided copper cable. Two such independent connections should exist in parallel. This shall be as per standards. 11.02 PRESSURE RELIEF LINE Tapping of 25mm size with Sch 40 seamless pipe shall be provided on Inlet/outlet nozzle neck with forged flange of 150# rating welded at the free end. Further routing/ connection shall be carried out by different party. 11.03 WATER SPRAY SYSTEM
Page 38
All the tanks shall be provided with water spray system on the shell complete with tank mounted ring mains, tank mounted riser header up to ground level, angle supports on the tank shell, couplings for fixing sprinkler nozzles of spray angle 120 degrees etc. Supply and installation of the system shall be as per the enclosed drawing and shall be in conformity with OISD norm 117. Various fire fighting equipments/ components shall have either BIS certification mark wherever applicable or shall be TAC approved. The minimum pipe size shall be 80mm dia. Medium velocity water spray nozzles shall be used. In the cooling rings, the residual pressure shall be minimum 1.4 kg/sq.cm(g) in the ring based on design pressure of 7 kg/sq.cm(g) available in the fire water header tapping. Suitable orifice plates shall be provided in the vertical risers on the tank. Spray nozzle body shall be made of copper alloy grade II as per IS: 318 and deflector from brass sheet as per IS: 410. Successful tenderer shall submit detailed drawing for the system, along with calculations, bill of quantities with specification/standards, engineering and construction drawings and document submission/ issue schedule to HPCL for review. 11.04 AUTOMATIC FIXED FOAM FLOODING SYSTEM: NOT APPLICABLE 11.05 FIXED FOAM SYSTEM All the above ground tanks shall be provided with fixed foam fire fighting system consisting tank mounted riser line up to ground level, ring main, pourers, foam maker, foam risers, deflection boards etc. in conformity with OISD Norm 117. Various fire fighting equipments/ components shall have either BIS certification mark wherever applicable or shall be TAC approved. Successful tenderer shall submit detailed drawing for the system, along with calculations, bill of Quantities with specification/standards, engineering and construction drawings and document submission/ issue schedule to HPCL for review. The make of foam maker with capacity should be submitted along with the Bid. 11.06 CHAIN BARRIER 20 mm dia. 750 mm long barriers at a height of 1m and 0.5m each at the entrance of rolling ladder for floating roof along with 6 mm dia. MS hooks operable type shall be provided. This is required for safety. 12.0 WELDING REQUIREMENTS IN TANK FABRICATION 12.01 WELDING Welding of steel plates and other structures and accessories shall be carried out in accordance with approved procedures by qualified welders / welding operators. 12.02 WELDING RESPONSIBILITY The contractor is responsible for the welding done by welders employed by him. Tests required to qualify welding procedure and to qualify the welders and if, necessary Signature & Seal of Bidder Page 39
qualification of welders and welding operators shall be conducted with the approval ofthe engineer-in-charge. 12.03 WELDING QUALIFICATIONS 12.03.01 Qualification Requirements Qualification of the welding procedure to be used and of the performance of welders and welding operators shall conform to the requirements of the ASME Section IX. 12.03.02 Procedure Qualification by others a. Engineer-in-charge is responsible for acceptance of any welding procedure that will be used. Welding procedure qualified by others may be used, subject to the specific approval of the Engineer-in-charge / Inspector provided that the following conditions are met. i. The proposed welding procedure specification (WPS) has been prepared, qualified and executed by a responsible, recognised organisation with expertise in the field of welding and ii. The contractor has not made any change in the welding procedure. b. Impact testing is not required c. The materials to be welded are in the thickness range between 5mm to 40mm. Post weld heat treatment is not required. d. The design pressure is atmospheric and the design temperature is in the range -4 Oc to 50 oC. e. The welding process in SMAW or GTAW or a combination thereof. f. The electrodes for the SMAW process shall be E 60 and E 70 classification series (E 6010, E 6013, E 7018) in AWS A 5.1. g. The contractor accepts written responsibility for both i.e. the welding procedure specifications (WPS) and the procedure qualification record (PQR). h. The contractor has at least currently employed welder or welding operator, who have met with the following requirements: i. While in employment, the welder has to satisfactorily pass a performance qualification test using the procedure and the P-Number material specified in the WPS. ii. The performance bend test, required by ASME section IX QW-302, shall be used for this purpose. iii. Qualification by radiography is acceptable. 12.03.03 Performance Qualification of welders a. Site-in-charge may accept a performance qualification made by certified agencies with the specific approval of the Engineer-in-charge. b. The contractor shall obtain a copy from the certified agencies of the performance qualification test record and submit the same to Engineer-in-charge with specific recommendation and approval of Inspector with the following details. i. The name of the agency Signature & Seal of Bidder Page 40
ii. The name of the welder or welding operator iii. The procedure identification iv. The date of successful qualification v. The data regarding individuals last work on tank fabrication 12.03.04 Qualification Records The contractor shall maintain a self-certified record, available to the Engineer-in-charge and the Inspector. The records will have the following details: a. The procedures used. b. The welders and welding operators employed, showing the date and results of procedure and performance qualifications. c. The identification symbol assigned to each welder and welding operator. 12.04 WELDING MATERIALS Filler Metal a. Filler metal shall conform to the requirements of ASME Section IX. b. Filler metal not yet incorporated in ASME section IX, may be used with HPCLs approval, if a procedure qualification test is first successfully made. 12.05 PREPARATION FOR WELDING Cleaning a. Internal and external surfaces to be thermally cut or welded material shall be cleaned. b. They shall be free from paint, oil, rust, scale and other material that would be detrimental to either the weld or the base metal when heat is applied. End Preparation a. End preparations are acceptable only if the surface is reasonably smooth and true and slag from oxygen or arc cutting is cleaned from thermally cut surfaces. b. Discoloration remaining on a thermally cut surface is not considered detrimental oxidation. c. End preparation, for groove welds specified in ASME or as specified which meets the WPS is acceptable. 12.06 ALIGNMENT Circumferential Welds a. Inside surface of steel plate ends to be joined shall be aligned within the dimensional limits in the WPS and the engineering design. b. If the external surfaces of the steel plates are not aligned, the weld shall be tapered between them. 12.07 WELDING REQUIREMENTS Welds Welds, including addition of weld metal for alignment shall be made in accordance with a qualified procedure and by qualified welders or welding operators. Welder's Identification Symbol Each qualified welder and welding operator shall be assigned an identification symbol Signature & Seal of Bidder Page 41
13.0
a. Unless otherwise specified in the engineering design, each weld or adjacent area shall be marked with the identification symbol of the welder or welding operator. b . In addition to marking the weld, appropriate records shall be maintained. Tack Welds a. Tack welds at the root of the joint shall be made with filler metal equivalent to that to be used in the root pass. b. Tack welds shall be made by a qualified welder or welding operator. c. Tack welds shall be fused with the root pass weld, except that those that have cracked shall be removed. Bridge tacks (above the welds) shall be removed. Peening Peening is prohibited on the root pass and final pass or a weld. Climatic Conditions No welding shall be done, if there is impingement on the weld area, of rain, snow, sleet or excessive wind or if the weld area is frosted or wet. Fillet and Socket Welds Fillet welds, including socket welds, may vary from convex to concave. The size of a fillet weld shall be as per engineering design. GAUGE POLE SLEEVE
The Gauge Pole sleeve shall consist of flexible enclosure to be installed over existing slotted gauge pipe along the height of the pipe and can adjust its height depending upon the height of the deck in an external floating roof tank. The flexible enclosing device should completely enclose the slotted gauge pipe while eliminating VOC emission pathway from inside the tank through the gauge pole slots. It should also seal any opening between well cover and any other opening in the gauge well. The detailed specification is as follows: a. It should be custom designed to suit the gauge well of the tank. b. It should have minimum 0.4mm thickness c. The sleeve material shall be non corrosive while handling petroleum hydrocarbons.It should be 100% compatible with all hydrocarbons. d. The material should be of uniform thickness and free from oils, solvents and release agents. e. The sleeve material shall not wick or become brittle during its service life. The gauge pole sleeve material should be resistant to the effects of wind, dust, rain, sand, UV rays & suitable for service upto +80deg C. 14.0 DETAILS TO BE FURNISHED BY SUCCESSFUL TENDERER The successful tenderer shall furnish three sets, unless mentioned other wise, of the following data / documents / drawings for review / approval / information.
Page 42
1. Layout drawings and general arrangement / orientation drawings for different tanks along with cross sectional views, design parameters, nozzle orientation, list of nozzles with sizes, appurtenances etc. 2. Development details, Plate cutting diagrams, edge preparation details etc., of bottom, shell and roof wind girders, stiffeners etc of all tanks including quantities of off-cuts, scrap calculations and scrap percentage. 3. Design calculations / data sheets for plate thickness and stability etc. as per codes for shell, wind girders/ stiffeners, floating roof, inner and outer rim plates of pontoon etc and fabrication and erection procedures, verified and approved by well reputed and experienced design agency. 4. Final Requirement of plates and other auxiliary structures along with detailed specification for all procurement items. 5. Detailed bar chart indicating time schedule for different activities like design, procurement, fabrication / manufacturing, stage inspection. 6. Drawings of pontoon deck, rolling ladder with track, details of self levelling steps and roof legs (long and short) for floating roof tanks with specification, bill of material, etc. 7. Design calculation for floating roof for buoyancy, roof drain, emergency drain, verified and approved by well reputed and experienced design agency. 8. Design calculation for deflection of deck and structural integrity of floating roof, verified and approved by well-reputed and experienced design agency. 9. Fabrication drawings, specifications, connection details, bill of materials etc., of appurtenances with reinforcement plate details with telltale holes etc. 10. Details of roof structural supports. 11. Fabrication drawings of stairway, landing platforms and roof top railings, with specification, bill of material, etc. Drawing for Primary roof drain, venting calculation & structural support for fixed roof etc. 12. Welding procedure and welders qualification report. 13. Drawings showing details and mounting arrangements of cooling water spray system, foam system. 14. Design of stone columns & foam& sprinkler system. 15. Progress report (weekly) for procurement, fabrication / construction, testing and inspection, progress review meeting with owner. 16. Individual tank reports 5 in numbers of hard copies and soft copies (AutoCAD for drawings) containing the following documents for each tank: a. Inspection certificates and test reports b. Material test and analysis certificates c. Radiographic films with inspection reports d. As built drawings / final data / documents with reproducible for all final drawings. e. Operation and maintenance manual of cathodic protection system.
Page 43
f. Sets of As-built drawings, incorporating all changes with respect to approved drawings, will be furnished on completion of work. g. Test reports of field testing and commissioning of cathodic protection. h. Transformer Rectifier settings. i. Structure to soil potential readings. j. Anode circuit resistance. k. Other relevant information / drawings / documents as required by HPCL. Tank brochure for each tank, giving all details and data about the tank, plate thickness, foundation details, nozzles, pipes, operation and maintenance shall be submitted. In all the drawings, the bill of material with specification of each item and the quantity required shall be given. 15.00 TECHNICAL SPECIFICATION FOR CIVIL WORKS FOUNDATION A. Materials Water Water to be used shall conform to IS-456 2000 for all civil works. Bore well water may be used for compaction of sand pad foundation. Generally potable water is considered satisfactory for construction and curing purpose. Cement Cement used shall conform to the following standards:43 Grade Ordinary Portland Cement IS: 8112-1989 53 Grade Ordinary Portland Cement IS: 12269-1987 Aggregates Coarse aggregates for cement concrete works shall be hard broken stone aggregates conforming to IS:383-1970. Fine aggregates shall be naturally occurring river sand with other properties conforming to IS:383-1970. Sand Sand used for plastering purposes shall be hard, durable clean, free from adherent organic matters and shall conforms to IS 1542-1977. Coarse sand shall be sieved at site if sand of IS:1542 quality is not available at site. Sand used for concrete shall conform to Grading Zone II or III of IS 383-1970. For sand pad foundation it shall be conformed to IS456-2000 and IS 383-1970 with Zone II or Zone III. Steel Reinforcing bars for concrete shall be TMT bars conforming to IS :1786-1985 of Grade Fe 415 from SAIL / TISCO / RINL Inserts Steel for preparation of inserts and embedments shall conform to IS:2062-1992. Foundation bolts Bolts to be embedded in concrete shall, unless otherwise detailed in drawings, conform to IS:5624-1970 Specification for Foundation Bolts. Material for bolts, shall, unless Signature & Seal of Bidder Page 44
B.
otherwise mentioned in drawings or the schedule of items, be corrosive resistant/coated steel conforming to IS:2062-1992. Nuts and locknuts shall conform to IS:1363 (Part 1 to 3) 1992 Specification for Black Hexagon Bolts, Nuts and Lock Nuts (Diameter 6-39 mm). Plain washers shall conform to IS:2016 1967 Specification for Plain Washers and spring washers shall conform to IS:3063 1972 Spring Washers for Bolts, Nuts & Screws. Workmanship 1. Earthwork Setting out and making profile Masonry pillars will be erected at suitable points These bench mark shall be connected to standard bench mark. In addition to these pillar center line pillars shall also be erected by the Contractor and footing positions shall be marked with the help of these pillars. The necessary profile shall be set out. The level shall be taken at a interval as directed by Engineer. The levels shall be recorded in field books and plotted on plan before starting the excavation. Excavation for foundation The excavation shall be carried out as per the drawings. Side slopes shoring and strutting if required shall be carried out at contractor own expenses. The bed of the excavation shall be properly dressed and made level. The last 15cm of excavation shall be done by manually just prior to laying of sand. The excavated materials shall not be placed within 1.5m from the edge of any excavated pit. The contractor shall take suitable precautions to prevent ingress of water into excavated areas during construction. The surplus excavated materials and excavated unserviceable materials shall be transported and disposed off by the contractor in spoil dumps/fill areas, as directed by the Engineer. If the contractor excavates to the levels lower than those shown in the drawings, he shall fill up such extra depth at his own cost to the proper level with concrete or such other materials as directed by the Engineer.If the bottom of any excavation appears to be soft, unsound or unsuitable, the contractor shall excavate the same to the required depths and the extra depth shall be filled up by the contractor with concrete or such other material as directed by the Engineer. Every precautions shall be taken by the contractor against slips and falls in the excavation. No extra payment will be made for removal of slips and for back-filling the space with materials approved by the Engineer. If in the opinion of the Engineer there is a possibility of newly constructed work having damaged or disturbed by such collapse, the work shall be laid bare at expense of the contractor for inspection. Any damage shall be made good by the contractor at his own expense. The excavation shall be kept free from water by the contractor at his own expenses by pumping. In small pits water may be bailed out with buckets. Pumping of water shall be carried out either directly from the excavation or from sumps made outside the excavation as directed. Adequate care
Page 45
shall be taken to prevent movement of water through freshly laid concrete or masonry work. If any excavation for foundation gets filled up with water due to rain, seepage or for any other reason, the water shall be removed and bottom of the excavation shall be completely cleared of all silt/slush by the contractor at his own expense. All water pumped or bailed out during de-watering of pits and trenches shall be disposed off suitably through properly laid channels or pipes by the contractor at his own cost. Disposal of water shall be carried out in such a way, so that no inconvenience or nuisance is caused to the work in progress in the area or to other agencies working in the area or cause damage to the property and structures nearby. Backfilling Backfilling of foundations shall be done using suitable soils from excavations. Soil shall be free from organic matter and other materials which would affect the stability of the fill and shall be free from boulders, brick bats wood pieces and other injurious materials, lumps and clods. In case water is encountered during the excavation for foundation or flooding of pits due to any other reasons, the contractor shall arrange for dewatering the same at his own cost. Filling around foundations with earth Before commencement of back filling, the contractor shall remove from the space around foundations all accumulated water and slush, shoring and form work, all debris, brickbats, bits of timber, cement bags and all other foreign materials. Filling shall be carried out in uniform horizontal layers, each layer not exceeding 150mm in thickness. Each layer shall be watered, rammed and thoroughly compacted before the next layer is deposited. 2. Sand filling for tank foundation Filling with sand shall be carried out with uniform horizontal layers of medium to course sand. Each layer shall be watered and compacted with mechanical means like vibro rammers or plate vibrator. The consolidated thickness of each layer shall be 150mm. A relative density of at least 85% shall be achieved in each compacted sand layer and shall be monitored at the rate of 2 tests in each layer. All sand shall conform to IS 456 & IS 383 with grading zone II or III. 3. Murrum The murrum shall not contain cohesive fines (Clay) more than 20% and it shall be taken from approved quarries. Fine quality murrum shall be spread in layers on sand pad sloping portion and it shall be well compacted to the required slope as shown in drawing / directed by the engineer. The top surface shall be finished smooth. 4. Plain cement works Mixing:
Page 46
It shall be done in mechanical mixers. Mixing by hand shall not be permitted unless specific prior permission of the engineer has been obtained in writing. In such a case, proportion of cement shall be increased as per IS:456. Laying The concrete shall be laid gently in layers not exceeding 150 mm. Mechanical vibrators shall be used for compaction. Hand compaction may be carried out if permitted by engineer. Hand compaction shall be done with the help of tamping rods. Next layer of concrete shall be carried out before initial setting starts in the previous layer. When the concreting is suspended, necessary removal of laitance and roughening of surface for jointing shall be done before concrete sets. On the resumption of work the joint shall be thoroughly cleaned, roughened, watered and a grout of neat cement slurry (1 kg of cement in 2 Ltrs of water) shall be applied uniformly. Curing All foundation PCC strips shall be cured by spraying water and keeping the surrounding soil moist. The curing shall continue for minimum 14 days or more as advised by engineer. The masonry work can be started after 48 hours of concreting, but the curing shall continue for minimum 14 days along with masonry. 5. Reinforced cement concrete General The quality of materials and method and control of manufacture and transportation of all concrete work irrespective of mix, whether reinforced or otherwise, shall conform to the applicable portions of this specification. Engineer shall have the right to inspect the sources of materials, the layout and operation of procurement and storage of materials, the concrete batching and mixing equipment, and the quality control system. Such an inspection shall be arranged and Engineers approval obtained, prior to starting of concrete work. Materials for standard concrete The ingredients to be used in the manufacture of standard concrete shall consist solely of a standard type portland cement, clean sand, natural coarse aggregate, clean water and admixtures, if specially called for on drawings or specifications. Cement Contractor will have to make his own arrangements for the storage of adequate quantity of cement. it will be the responsibility of contractor to ensure adequate and proper storage of cement. Cement bags shall be stored in a dry enclosed shed (storage under tarpaulin will not be permitted), well away from the outer walls and insulated from the floor to avoid contact with moisture from ground and so arranged as to provide ready access. Damaged or reclaimed or partly set cement will not be permitted to be used and shall be removed from the site. Not more than 12 bags shall be stacked in any tier. The storage arrangement shall be approved by engineer. Consignment of cement shall be stored as received and shall be consumed in the order of their receipt at site. Cement held in storage for a period of Ninety (90) days or longer shall be tested. Should at any Signature & Seal of Bidder Page 47
time Engineer have reasons to consider that any cement is defective, then irrespective of its origin, date of manufacture and/or manufacturers test certificate, such cement shall be tested immediately at Contractors cost at a national Test laboratory and if such tests are not found satisfactory, it shall not be used in any work. Contractor shall not be entitled to any claim of any nature on this account. Changing of brands or type of cement within the same structure will not be permitted. Consistency The consistency of the concrete shall be such that it flows sluggish into the forms and around the reinforcement without any segregation of coarse aggregate from mortar. The slump tests are mandatory and shall be carried out at regular intervals so that the consistency of concrete can be monitored. Shuttering All shuttering and supports shall be designed by contractor and be subjected to approval of the engineer. The shuttering shall be leak proof. The contractor is responsible for the correctness and strength of formwork including supports intervals. Steel Reinforcement Bending and placing of bars shall be in conformity with IS 2502-1963 Code of practice for Bending & Placing of Bar for Concrete reinforcement and IS 456-2000 Code of practice for plain & reinforcement concrete". Placing of concrete Concreting shall commence only after inspection and written approval by engineer. Shuttering shall be clean and free from deposits of foreign materials and proper de shuttering agent shall be applied to the surface. Proper arrangements shall be provided for conveying the concrete to the place of deposition without disturbing the reinforcement. Compaction The concrete shall be placed and compacted before setting commences and should not be subsequently disturbed. Compaction shall be done using approved mechanical vibrator & never be over vibrated or under vibrated. Concrete shall never be dropped from a height. Curing As soon as the concrete has hardened sufficiently, the curing shall be started. To cure the concrete properly and sufficiently is also the responsibility of the contractor. Minimum 14 days of pond curing or 18 days of spray curing shall be done. Inspection and rectification of defects Immediately on removal of forms, the RCC works shall be examined by the Engg-inCharge before any defects are made good. The work that has sagged or contains honey combing to an extent detrimental to the structural safety or architectural concept shall be rejected Strength test of concrete
Page 48
While placing concrete, the Contractor shall make 6 nos. of 15 cm test cubes from particular batches of concrete as desired by the Engineer. The frequency of taking test cubes shall be either according to clause 15.2.2 of IS 456 2000 or as directed by the Engineer. The cubes shall be prepared, cured and tested according to IS: 516 1959. Out of 6 nos. of test cubes, 3 shall be tested for compressive strength at 7 days after casting and the remaining 3 at 28 days after casting. A register shall be maintained at site by the Contractor with the following details entered and signed by both the Contractor and the Engineer. That register shall be considered as the property of the Owner. Reference to the specific structural member Mark on cubes The grade of concrete The mix of concrete Date and time of casting Crushing strength at 7 days Crushing strength at 28 days Any other information directed by the Engineer. Acceptance criteria for test cubes The acceptance criteria of concrete on strength requirement shall be in accordance with the stipulations under clause 16 of IS: 456 2000. 6. Brick Masonry Providing & laying Brick Masonry using locally available first class brick with minimum compressive strength of 100 kg/cm2 in CM 1:5. Job to include racking of the joints, soaking the bricks in water prior to using & curing for a minimum of 7 days etc complete.Rate to include execution of the job as per latest codal provision & specification. 7. Random rubble masonry: The rubble shall be of the best quality trap / granite / ballast stones obtained from the approved quarry. The sample of the stone, to be used shall be got approved from the Engineer-in-Charge. All stones shall be wetted before laying in masonry. The workmanship of Random Rubble Masonry shall be in conformity with IS-1597 (Part- 1) 1992 8. Plastering The surface shall be thoroughly washed with water, cleaned and kept wet before plastering is commenced. In case of concrete the surface shall be chipped by chiseling and wire brushing, cleaning the surface and erecting scaffolding it required. Plastering shall be done in accordance with provisions of IS:1661 1972. The thickness mentioned in the Schedule of Items shall be minimum thickness. 9. Anti corrosive Layer: The thickness shall be as specified in the SOR. Material Fine aggregate Signature & Seal of Bidder Page 49
Sand for use as fine aggregate in anticorrosive surfacing shall consist of crushed screenings, natural sand or a mixture of both, passing a 2.36 mm sieve and retained on 75 micron sieve conforming to IS383-zoneIII. It shall be clean, hard, durable, uncoated and dry, free from impurity and organic deleterious substances. Course Aggregate Stone aggregate of size 12mm down conforming to IS 383 and it shall be clean, hard, durable, uncoated and dry, free from impurities, soft or flaky pieces and organic deleterious substances. Bitumen It shall conform to IS : 73 1992 and shall be of the specified type and grade. The material shall be homogeneous and shall not foam when heated to 175 degree C. Various properties like specific gravity, flash point, softening point, penetration etc. shall be as given in the above code. The bitumen shall be 80/100 or equivalent grade. Tack coat Bitumen of specified grade heated to a temperature of 177 to 188 degree C shall be spread on the prepared surface uniformly at the rate of 1 kg/sq.m. by means of sprayers. It shall be applied in between two layers of anticorrosive layers and seal coat. Preparation of mix, laying & compaction The 12 mm down graded stone aggregate shall be first screened of dust and measured in boxes and then loaded into the drum mixer. The stone aggregate shall be heated to facilitate mixing with the binder in cold weather, where so directed by the Engineer. The bitumen binder heated in boilers, to a temperature of 149 to 177 degrees C or as specified for the grade used and maintained to the temperature, shall be drawn off from the boiler into a suitable container or in bucket gauged to show the weight of bitumen in it. (8 to 10 % of volume). This shall then be poured over the aggregate in the mixer and mixing started and continued till aggregate is uniformly coated with bitumen. Immediately after applying the tack coat, the hot mix shall be discharged from the mixer, carried to the tank pad foundation and spread to a thickness sufficient to achieve the specified thickness. The anticorrosive layer shall be laid compacted or rolled. Compaction or rolling shall commence from edges and proceed towards the center. Further the prepared finished surface shall be protected for 24 hrs or such period as may be specified by the Engineer. 10. Seal coat The binder shall be heated in boilers of suitable design, to the temperature 170 deg C. The dry sand shall be placed in the mixer of suitable design. Mixing of binder with sand 8 to 10% of volume it shall be continued till the sand are thoroughly coated with binder. The mix shall be immediately transported from the mixing plant to the point of use and spread uniformly on the bituminous surface to be sealed. As soon as sufficient length has been covered the anticorrosive layer , the surface shall be rolled or compacted.
Page 50
Rolling or compacting shall be continued till it seals the voids in the bituminous course and a smooth uniform surface is obtained. C. TESTING OF MATERIALS The contractor shall carryout the following tests at his own expense and as directed by the Engg.-in-charge. Also Engineer-in-Charge reserves their right to ask the contractor to carry out any further tests on any material, which is being used in the project. 1. Water : Suitability for construction / Concreting purposes as per IS 456 2000 Periodicity : One test at the beginning of the project and once in every 3 months as per IS Code. 2. SAND : Tests to be conducted Particle size Lab Silt content Field Bulking of Sand Field Percentage of Deleterious material / Organic impurities Lab. IS code for material: IS -383-1970 IS code for testing: IS-2386 (Part I) to IS-2386 (Part VIII) IS code for Determination of density index (relative density) of cohesionless soils. IS 2720 Part XIV Periodicity of testing:Whenever there is a change in source of supply or as directed by the Engineer-in-Charge. Remarks: Silt content should not exceed 5%. Sand for plastering Tests to be conducted a) Particle size - Lab b) Silt content - Field c) Percentage of Deleterious / organic impurities Lab. IS Code for material IS 1542 IS Code for testing IS - 1727 Periodicity of testing: Same as above, Test shall be repeated for Minimum qty. 500 sq. m of plastering. Remarks: Silt content not to exceed 5% Sand to be sieved in sieve size 4.75 mm. 3. Coarse aggregate Tests to be conducted Percentage of Soft deleterious materials Field (Visual) Particle size distribution Aggregate value : Signature & Seal of Bidder Page 51
Crushing Lab Impact Lab IS code for material - IS-383-1970 IS code for testing - IS-2386 (Part I) to IS 2386 (PartV111) Periodicity of Testing Minimum 45 cum. Tests to be repeated for every 45 cum of coarse aggregate or part thereof. Remarks Percentage of soft deleterious materials. Usually visual inspection shall be carried out. If Engg.-in-Charge has doubts, the same may be tested in Lab. 4. Cement: Tests to be conducted a. fineness - Lab b. Soundness - Lab c. Setting Time Lab Compressive strength Lab Periodicity of Testing: Minimum qty. 20 MT, Tests to be repeated for every 50 MT or part thereof or change of supplier. Remarks: Cement to be tested if supplied by the contractor. Cement to be tested if stored for more than 3 months. 5. Cement concrete: Tests to be conducted a. Slump test - Field b. Cube strength Lab / field Periodicity of Testing: a. Once for minimum 5 cum. Minimum 15 cum of part there of. Remarks: Cube strength to be taken for both 7 days as well as 28 days. Cubes of critical members (decided by Engg.-in-Charge) shall be tested at lab. 6. Reinforcement steel Tests to be conducted a. Free from defects - Field (Visual) b. Weight - Lab c. Size - Lab d. Ultimate tensile stress - Lab e. Yield stress - Lab f. Elongation percentage - Lab Signature & Seal of Bidder Page 52
g. Bend Re-bend test - Lab IS code for material IS-432 for mild steel IS-1786 for Tor steel IS Code for testing IS 1608 Periodicity of Testing: Minimum qty. 10 MT, tests shall be repeated for every 10 MT of each size (dia) or part thereof. Remarks: a. Steel shall be tested if supplied by contractor. b. Steel shall be tested if stored in open yard for more than one year. NOTE : All the testing equipment / machines like Sieve, Compression testing machine etc. required for field tests shall be arranged by the contractor at no extra cost.
Page 53
Seamless pipe upto 8.
Seamless Pipe A106 GrB
Page 54
Page 55
Page 56
1.0
Annexure-III Quality Assurance Plan, ITP GENERAL The enclosed ITPs shall be followed for the works to be performed by the Contractor under this Tender. The provisions indicated for stagewise inspection by HPCL are a minimum and the contractor shall develop a detailed ITP and obtain approval for the same prior to commencement of work. Contractor to carry out 100% examination of all activities. LEGEND HP: Hold point; A point which requires inspection/ verification and acceptance by HPCL before any further processing is permitted. The Contractor shall not process the activity/ item beyond a Hold point without written approval by HPCL. W: Witness Point; activity is performed. Rw: S: An activity which requires witnessing by HPCL when the
2.0
Review of Contractors documentation. Surveillance Inspection by HPCL; Monitoring or making observations to verify whether or not materials/ items or services conform to specified requirements. Surveillance activities may include audit, inspections, witness of testing, review of quality documentation & records, etc.
WC:
100% examination by Contractor.
Responsibility for execution of the inspection/ testing is with the Contractor.
Page 57
S.NO. HPCL III A. 1. 2. STORAGE TANKS
ACTIVITY
CONTRACTOR
PRIOR TO FABRICATION Acceptance of the tanks foundation Incoming Material Owners Supply Contractors supply, including check testing Welding Filler Material Approval/Qualification a) Manufacturing Test Certificate/Documents b) Testing, if any i) Carbon Steel WC WC WC WC* WC Rw HP Rw* W HP
3.
4.
WPS /PQR ( Sample Copy attached from Previous HPCL Site Records) a) Procedure: i) WPS to be written for all the Weld Joints for for Bottom/Shell/Fl. Roof/Appertunance etc WC b) Testing i) Carbon Steel WC c) Approval of Final WPS/PQR WC a) Welder performance Qualification Test b) Certification & Approval of welder Review of joint numbering in drawings mention Reference of 4.a.i) Suitability of plate bending machine WC WC
HP HP HP W HP
5.
6.
WC WC
HP Rw
7.
Page 58
8. B. 1. 2. 3. 4. ___ 5. 6. 7. 8.
Fabrication, erection, testing procedure for job FABRICATION /ERECTION OF BOTTOM Plate size, marking and cutting Blast cleaning & painting of underside of bottom plates. Plate layout, overlap and fit up Sequence of welding Size and positioning of backing plate for annular plates Baking of electrodes Inter-pass cleaning Visual check of welding
WC
HP
WC WC WC WC WC WC WC WC S S W S HP
9. DPT/RADIOGRAPHY of annular plate butt welds and bottom plate butt welds (As Applicable) 10. SHELL 1. 2. 3. Plate size, marking and cutting Plate binding, curvature check, stacking Shell course alignments and fit-up of vertical and Circumferential joints before welding a) Check Shell diameter @0,45,90,135,180,225,270,315,360 & circumference for circularity with strapping tap, perpendicularity, Straight edge before welding and documenting (Each Shellwise & w.r.t precede &ascend ) Visual check of welding and back chipping WC Vacuum box test for bottom plate welding WC
WC HP
HP
WC W
Rw
WC
4.
WC WC
HP W Page 59
5.
6. 6
7.
a)inner side welding visual check WC b) Check Shell diameter @0,45,90,135,180,225,270,315,360 & circumfrancefor circularity with strapping tap , perpendicularity, Straight edge after welding and documenting WC (Each Shellwise & w.r.t precede &ascend ) Location size and alignment of nozzles and other openings WC WC WC WC WC
HP HP W W HP W
8. R.F. pads fit-up/welding 9. PWHT of shell, RF pads, nozzles, manhole etc (If Applicable) 10. 11. 12. Radiography marking (for random radiography only) Curb angle and Wind girders fit-up /welding DPT of Nozzles,etc (as applicable) RF pads pneumatic test Shell to bottom fit-up Shell to bottom I/S welding root run visual/Oil chalk test Shell to bottom O/S welding visual and PT Fabrication and erection of stair ways
WC WC WC WC WC WC
W HP HP HP W S
13. 14. 15. 16. 17.
18.
Radiography a) Radiography interpretation b) Check shot for Radiography
WC WC
HP HP
FLOATING ROOF 1. 2. Temporary staging, spacing and levels Plate size, straightening and cutting WC WC Rw Page 60 Rw
3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17 18. 19. 20. C.
Plate layout, overlap, fit-up welding Availability of approved calculations for design of buoys Buoys/Pantoon fabrications Vacuum testing of roof- plates welds Location of sleeve support Pad Plate welding with roof and sleeve support Fixing and welding of Buoys Initial - Lift Support Fixing through sleeve
WC WC WC WC WC WC WC WC WC
Rw HP S HP S S W W S S HP S WC W HP HP HP HP WC HP
Seal welding of support sleeves from beneath after dewateringWC Air test of Buoys/Pantoons Pontoon welding Location, fixing and welding of man-holes, drains etc Shell to pontoon clearance Air Test of Pontoons for Leakproofness Seal fixing Floating Roof testing, as required e.g. flooding etc. Primary Roof drains installation & testing TESTING WC WC WC WC WC WC
1. Correctness of testing arrangements especially size of blind Flanges/vents/drains/ temporary piping
WC
HP
Page 61
2. 3. 4.
Mechanical / Inspection clearance Earthing of ladder & shell Settlement reading throgh Dumpy Level during water filling Hammer test Air pressure test Vacuum test Roof collapsibility test in case of floating roof tanks Vis--vis to FR Design approved. Calibration of tanks from statutory authorities INSPECTION & TEST DOCUMENTS Review Test and Inspection documents
WC WC
HP W
WC WC WC WC WC WC
HP HP HP HP HP Rw
5. 6. 7. 8. 9.
WC
Rw
Note: Following shall require Third Party Inspection & certification 1. Swivel for Primary Roof Drain 2. Primary & Secondary Seal Third Party vetting is required for CP System Design, Tank Design, Sprinkler system, Foam system & Stone column
Page 62
ANNEXURE-IV
STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING
Page 63
STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING
1.0
GENERAL
1.1
These technical specifications shall be applicable for the work covered by the Contract. It is understood that Contractor shall complete the work in all respects with best quality materials and workmanship, best engineering practice, Manufacturer recommendations and instructions of HPCL.
1.2
All the items covered in this specification are required to be supplied by the Contractor only. SCOPE Scope of work covered in this specification shall include but not limited to the following: Surface preparation for all components of A/G product & U/G Tank Selection, procurement and application of primers, paints and other materials on various metallic surfaces including providing all requisite scaffolding, spray equipment, compressors, applicators, brushes, etc. Lettering, marking as per HPCL requirements and SOR.
2.0
1. 2.
3.
3.0 3.1
CODES AND STANDARDS REFERENCE STANDARDS IS IS : : 5 101
ASTM STANDARDS 3.2 SURFACE PREPARATION STANDARDS SWEDISH STANDARD Signature & Seal of Bidder : SIS-05-5900-1967/ISO-8501-1-1988 Page 64
THIS STANDARD CONTAINS PHOTOGRAPHS OF THE VARIOUS STANDARDS ON FOUR DIFFERENT DEGREES OF RUSTED STEEL. MANUFACTURERS BROCHURES AND INSTRUCTIONS WITH RESPECT TO STORAGE, SURFACE PREPARATION, MIXING AND THINNING, APPLICATION AND CURING INTERVALS. 4.0 EQUIPMENT All tools, brushes, rollers, spray guns, abrasive materials, sand, hand/ power tools for cleaning, scaffolding materials, air compressors, instrument for measuring humidity, etc required for the works shall be supplied by the Contractor.
5.0 5.1 5.1.1
SURFACE PREPARATION, COATING APPLICATION AND DOCUMENTATION GENERAL In order to achieve the maximum durability, blast cleaning with appropriate medium shall be followed. Mill scale, rust, rust scale, etc. shall be fully removed by blast cleaning to SA 2 or equivalent as per SWEDISH STANDARD : SIS-05-5900-1967/ISO-8501-1-1988. Blast cleaning shall not be performed where dust can contaminate surfaces undergoing such cleaning or in conditions where the humidity exceeds 85%. The first coat of primer must be applied on dry surface immediately and in any case within 4 hrs of cleaning of surface. Blasting and painting shall in general be avoided during unfavorable weather conditions. PROCEDURE FOR SURFACE PREPARATION BLAST CLEANING The surface shall be blast cleaned at a pressure of about 7 kg/ sq.cm at appropriate distance and angle using compressed air to give a white metallic luster. Surface profile shall be uniform to provide good key for paint adhesion. The material used for blast cleaning should comply with the stipulations of concerned State Pollution Control Board.
5.1.2 5.1.3 5.1.4 5.1.5 5.2 5.2.1
5.3 5.3.1
COATING PROCEDURE AND APPLICATION Blast cleaned surface upon inspection and clearance by HPCL shall be coated with one complete application of primer as soon as practicable and in no case later than 4 hrs on the same day. Applied paint shall have the required Dry Film Thickness (DFT) after Page 65
drying. 5.3.2 Each coat shall be in a proper state of cure or dryness before the application of succeeding coat. Manufacturers instructions shall be followed for intercoat interval. The type of application may be Airspray or Airless spray or Brush application as per manufacturer recommendation and HPCL instructions for getting satisfactory results. For each coat, the painter should know the WFT corresponding to the specified DFT and standardize the paint application technique accordingly. This has to be ensured in a qualification trial by Contractor.
5.3.3
5.3.4
5.4
SCAFFOLDING Double scaffolding shall be used and all the painters shall be provided with Safety belts for ensuring accident free working.
5.5 1. 2.
DOCUMENTATION A written quality Plan with procedure for qualification trials and for actual work. Daily progress Report with details of humidity, surface preparation, surface profile, Dry film thickness particulars of applications, number of coats applied, type of materials used, methodology-Air or Airless or Brush, progress of work vs programme. Code and Batch numbers of primers and paint materials used. Type of testing equipments and their calibration. Elcometer readings for the various components jointly recorded with HPCL. Paint consumption statement along with the Theoretical consumption requirements.
3. 4. 5. 6.
Page 66
6.0
RECOMMENDED MANUFACTURERS
ASIAN PAINTS BERGER PAINTS GOODLASS NEROLAC JENSON AND NICHOLSON SHALIMAR PAINTS
7.0
HPCL LOGO AND LETTERING HPCL will provide their LOGO with sizing, Flow, coloring and same is to be provided to the Tanks. HPCL will also convey to the Contractor in writing details of the lettering for product and tank details along with the desired color-coding and same has to be arranged by the Contractor. Some of the details have been given in the SOR.
8.0 8.1
INSPECTION AND TESTING All painting materials including primers and thinners brought to site by the Contractor for application shall be directly procured from Approved manufacturers as per specifications and shall be accompanied by Manufacturer Test Certificates. HPCL may call for tests for the primers and paints including verification of batchwise tests for physical and chemical analysis. The Contractor shall carry out the same at his own cost and provide the results to HPCL. The painting work shall be subjected to inspection by HPCL at all times. Stages of inspection are as follows: 1) Surface preparation 2) Primer application 3) Each coat of paint All records of inspection shall be maintained in Registers and jointly signed by HPCL and Contractor. Any defect noticed during the various stages of inspection shall be rectified by the Contractor to the satisfaction of HPCL before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages of work, Contractor shall be fully responsible for making good any defects found during Final inspection or during the Defect Liability period. DFT shall be checked and wherever shot same shall be made up with additional coats.
8.2
8.3
Page 67
8.4
The shades of successive coats should be slightly different in colour in order to ensure application of individual coats in consultation with manufacturer. Calibrated Digital Elcometers, surface profile gauges and any other inspection instrument required by HPCL shall be provided by the contractor at site. The contractor shall arrange expert technical support at site by paint Manufacturer who will cross verify independently regarding surface preparation and DFT and quality and provide a report to HPCL. The type of paint and DFT has been specified in SOR and shall be binding. The shades will be specified by Engineer-in-Charge at Site. Payment shall be made for actual surface of tank shell, bottom, roof measured only once. No separate measurement will be taken for shell/roof appurtenance, foam dams, body valves, tank mounted pipelines, roof top railings, staircases, landing platforms, steel supports, expansion lines, sprinkler/foam lines, rolling ladder, extension plate etc. However, seperate measurement shall be recorded for the walkway (PWG) and secondary wind girders. The specification for blasting and all coats of primer, intermediate and finish coat for sprinkler and Foam line installed on the tank shall be similar to the specification for external paint, only the finish coat shades will be different. ( Fire red for Sprinkler lines and Yellow for Foam lines) The scope of painting against Item No.88 (Black enamel paint) shall be Roof top railing of all above ground tank including vertical posts mid and bottom flats, square rods other exposed steel structures and Stairway including all landing platforms, roof top platforms, all gratings flats, square rods vertical posts and the exposed steel structures
8.5
8.6
8.7
8.8
The classification of tank surface as external or internal depending on the type of tank are as follows Type of Tank FRVT External Outer shell surface along with associated nozzles, stairs, hand rails, structures and supports, wind girders, Top surface of the floating roof deck and pontoon along with associated pipe sleeves, shell/deck Internal Top surface plate. of bottom
Inside shell surface up to 1.0 M from bottom and 1.5 M from curb angle, outer rim and bottom (underneath) surface of the Page 68
appurtenances rolling floating roof deck and ladder, structures & pontoon with fittings & supports fixtures.
OTVT
Outer Shell surface along Complete internal surfaces with associated nozzles, stair, hand rails, structures and supports, wind girders Outer shell surface along Top surface of the bottom with associated nozzles, plate and up to 1.0 M of stairs, hand rails, structures shell surface from bottom. and supports, wind girders, Top surface of the roof .
CRT
Painting to be done for the tank surface shall be as follows: Surface External surface of FRVT,CRT & OTVT a. Blast clean to SSPC-SP-10 or SA 2.5 b. One coat of P-1 @75 micron DFT/coat c. One coat of U-1@ 100 microns DFT/coat d. Two coats of F-2 @2x25 microns DFT/coat Total DFT = 225 microns (minimum) Internal surface of FRVT & CRT a. Blast clean to SSPC-SP-10 or SA 2.5 b. One coat of P-1 @75 micron DFT/coat c. Two coats of F-1 @100micronsDFT/coat Total DFT =275 microns (minimum) Internal Surface of OTVT a. Blast clean to SSPC-SP-10 or SA 2.5 b. One coat of P-2 @60 micron DFT/coat Signature & Seal of Bidder Page 69
c. Two coats of F-3 @100micronsDFT/coat Total DFT =260 microns (minimum)
The external finish paint (F2) shall be of color dark Admirality Grey (IS-632) for shell and other external surface of tank. P-1: Epoxy phenalkamine zinc phosphate primer P-2: Two component polyamide cured epoxy resin medium, pigmented with zinc phosphate.Vol solids~40% P-3: Two component high build amine cured phenolic epoxy primer pigmented with zinc phosphate. Vol solids~63% U-1: A two pack polyamide cured epoxy resin medium suitably pigmented with MIO. Vol. solids ~ 60% U-2: A two pack aliphatic amine cured epoxy resin medium suitably pigmented, Vol. solid~68% F-1: A two pack polyamide /polyamine cured epoxy high build, Vol. solids~ 62% F-2: Two coats of Synthetic enamel (volume of solid should be 38%) F-3: Condensation product of bisphenol A and epichlorohydrin with terminal Epoxide groups, vol solids ~65% (Coal Tar epoxy ) 9.0 Guarantee The party shall guarantee that the chemical and physical properties of paint materials used are in accordance with the specifications. The party shall guarantee the satisfactory performance of the painting provided by him for a period of 6 years. The party shall execute a guarantee deed jointly with paint manufacturer.
Page 70
ANNEXURE- V S.N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 DETAILS Typical General arrangement FR Tank General arrangement of Cone roof tank. General Arrangement Water Tank CP-TR Room Deck Appurtenances Earthing Pit Foam & Water System- FR Tank Gauge Well Pipe Pressure Relief Lines Rolling Ladder (1of2) Rolling Ladder (2 of 2) Sand Pad foundation detail Layout of Ajmer, Jaipur and Rewari Typical drawing of articulated roof drain
The drawings attached with the tender is for reference purpose only, the construction shall be carried out as per the third Party vetted design and detailed drawing approved for construction by HPCL.
Page 71
The weight of tank indicated in the drawing is approximate, the successful bidder has to ascertain the weight as per the tank design for going ahead with the foundation load & settlement. The nozzles sizes indicated in the data sheet may be changed during detailed engineering, the payment will be made as per SOR item.
ANNEXURE-VI DATA SHEET FOR FR TANKS

DESIGN DATA Design Code API 650 Design pressure Full of Water Operating Pressure Atmospheric Design Temperature 55 deg C Operating Temperature 45 deg C Density of Liquid 0.7 Design Density 0.87 at Ajmer & Jaipur, 0.7 at Rewari Wind Pressure As per IS-875 Seismic Data As per IS-1893 Corrosion Allowance 1.5mm shell/bottom 0.5mm roof Radiography As per code Stored Product & Class MS/HSD Capacity As indicated Type Single Deck FR ACCESSORIES
Access to Roof(Spiral stairway) Hand Rail at Roof, PWG Earth Connection Platform at Roof Primary & Secondary Seals Rolling Ladder Gauge hatch Primary Roof Drain Cooling & Foam System LT, TT, PT All structural works By Fabricator By Fabricator By Fabricator By Fabricator By Fabricator By Fabricator By Fabricator By Fabricator By Fabricator By Owner By Fabricator
Page 72
Centre Sump
By Fabricator
MATERIAL SPECIFICATION
Shell-Bottom-FR
Reinf Pad Manhole Neck, flanges, covers Nozzle Necks Nozzle Flanges Gaskets Bolting for Structure Bolting for nozzles etc Structurals External Gussets Internals Fittings Wind girder, support & gussets Stairway, Platform & handrail Pipe support & sleeves Gauge Well Roof Drains Fire water, fixed foam system Annular Plate Primer/Painting Pipe fittings Deflector Plate Foam riser/Dip Pipe
Mark Size Qt y 2 1 1 1 2 1 6 10 3 1 2 3 4 2 1 1
IS-2062 Gr A/B
IS-2062 Gr A/B IS-2062 Gr A/B A 106 Gr.B SA-105 Spiral wound SS-304 IS-1363 IS-1367,Cl.4.6, 4.0 IS-2062 Gr A/B IS-2062 Gr A/B IS-2062/SA106 Gr A/B SA-234, Gr WPB IS-2062 Gr A/B IS-2062 Gr A/B,A53 A106 Gr B A106 Gr.B A106 Gr.B IS-1239 Hvy Gr IS-2062 Gr A/B As per Spec A-234 Gr.WPB IS-2062 Gr A/B A-53/A106 Gr.B/ IS 1978
Service
M1,2 I1 I2 O W1,2 RD FC1-5 EB1-10 PT M3,4 RV1,2 ED1-4 AB1,2 GW1
600 600 400 750 100 200 80 25 50 600 150 100 300 200, 50
SHELL APPURTENANCE S Rtg Typ Faci c # ng h As per API 650 40 40 40 40 40 40 150 150 150 150 150 150 SO SO SO SO SO SO RF RF RF RF RF RF
40 150 SO RF DECK APPURTENANCES 40 As per Std Deck Manhole 40 As per Std Rim Vent 40 As per Std Emergency drain 40 As per Std Auto bleeder vent 40 As per Std Gauge well pipe with temp sensor pipe
Shell M/H with cover Inlet with trough Inlet with trough Outlet with trough Water draw off Roof drain Foam conn Earthing Boss PR Line PT
Page 73
IH
500
40
As per Std As per Std As per Std
Testing: GW2 200 1 40 1. Bottom: By partial vacuum of 2 psig -2 2. Shell Welds: Radiography as per code 3. Nozzle pad: Same as bottom 4. Shell to bottom: By Oil chalk method 5. Floating roof: As per API 650 Electrodes: Upto 14mm Thk: E-6013, for 14mm & above: E-7018
Inspection hatch for pontoon Still well for radar gauge Roof earthing
Primary Wind Girder: Web-8mm, Flange: 8mm, SWG (2 Nos): Web: 8mm, Flange: 8mm DATA SHEET FOR CONE ROOF TANK
DESIGN DATA Design Code API 650 Design pressure Full of Water Operating Pressure Atmospheric Design Temperature 55 deg C Operating Temperature 45 deg C Density of Liquid 0.7 Design Density 0.83 Wind Pressure As per IS-875 Seismic Data As per IS-1893 Corrosion Allowance 1.5mm shell/bottom Radiography As per code Stored Product & Class HSD, Class B ACCESSORIES
Access to Roof(Spiral stairway) Hand Rail at Roof, PWG Earth Connection Platform at Roof Structural By Fabricator By Fabricator By Fabricator By Fabricator By Fabricator
MATERIAL SPECIFICATION
Shell-Bottom-FR
Reinf Pad Manhole Neck, flanges, covers Nozzle Necks Nozzle Flanges Gaskets Bolting for Structure Bolting for nozzles etc Structurals External Gussets Internals Fittings Wind girder, support & gussets Stairway, Platform & handrail Gauge Well Fire water, fixed foam system Annular Plate Primer/Painting Pipe fittings Foam riser/Dip Pipe
Mark Size Qt y 2
IS-2062 Gr A/B
IS-2062 Gr A/B IS-2062 Gr A/B A 106 Gr.B SA-105 Spiral wound SS-304 IS-1363 IS-1367,Cl.4.6, 4.0 IS-2062 Gr A/B IS-2062 Gr A/B IS-2062/SA106 Gr A/B SA-234, Gr WPB IS-2062 Gr A/B IS-2062 Gr A/B,A53 A106 Gr.B IS-1239 Hvy Gr IS-2062 Gr A/B As per Spec A-234 Gr.WPB IS-2062 Gr A/B A-53/A106 Gr.B/ IS 1978
Service
Gauge hatch
By Fabricator By Fabricator
M1,2
600
SHELL APPURTENANCE S Rtg Typ Faci c # ng h As per API 650
Shell M/H with cover
Page 74
Testing: 6. Bottom: By partial vacuum of 2 psig 100 2 40 7. Shell Welds: Radiography as per W1,2 code 8. Nozzle pad: Same as bottom 9. Shell to bottom: By Oil chalk method Electrodes: Up to 14mm Thk: E-6013, for 14mm & above: E-7018
I1 I2 O
600 300 600
1 1 1
40 40 40
150 150 150 150
SO SO SO SO
RF RF RF RF
Inlet with trough Inlet with trough Outlet with trough Water draw off
Primary Wind Girder: Web-8mm, Flange: 8mm, SWG (2 Nos): Web: 8mm, Flange: 8mm DATA SHEET FOR OPEN TOP TANKS Testing: DESIGN DATA 10. Bottom: By partial vacuum of 2 psig Design Code API 650 11. Shell Welds: Radiography as per code Design pressure Full of Water 12. Nozzle pad: Same as bottom Operating Pressure Atmospheric 13. Shell to bottom: By Oil chalk method Design Temperature 55 deg C
Operating Temperature Density of Liquid Design Density Wind Pressure Seismic Data Corrosion Allowance 45 deg C 1.0 1.0 As per IS-875 As per IS-1893 1.5mm shell/bottom
Electrodes: Upto 14mm Thk: E-6013, for 14mm & above: E-7018 Primary Wind Girder: Web-8mm, Flange: 8mm, SWG (2 Nos): Web: 8mm, Flange: 8mm
Radiography As per code Stored Product & Class Water Capacity 3544 KL Type Single Deck FR Approx Empty Wt 84MT Approx wt full of liquid --- MT Approx wt full of water 3627 MT ACCESSORIES
Access to Roof(Spiral stairway) Hand Rail at Roof, PWG Earth Connection Platform at Roof Columnless Roof structure By Fabricator By Fabricator By Fabricator By Fabricator By Fabricator
Page 75

Technical Specification Tankage

Caricato da

Informazioni sul documento

Descrizione originale:

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Technical Specification Tankage

Caricato da

Copyright:

Formati disponibili

TANKAGE TECHNICAL SPECIFICATION

TANKAGE TECHNICAL SPECIFICATION

Details of tanks to be constructed are shown in the Table below:

28 M Dia x 14 M Ht - 1 Nos (FR)- HSD 18 M Dia x 13 M Ht - 2 Nos (FR)-MS API 650

FR Floating Roof, CR- Cone Roof, OR-Open Roof

TANKAGE TECHNICAL SPECIFICATION

TANKAGE TECHNICAL SPECIFICATION

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

TANKAGE TECHNICAL SPECIFICATION

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

TANKAGE TECHNICAL SPECIFICATION

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

TANKAGE TECHNICAL SPECIFICATION

TANKAGE TECHNICAL SPECIFICATION

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

Specification of the products are as given below :

Product Density at 15 C Viscosity, cst 20 C Vapour Pressure, kg./cm at 38 C Operation Temperature

HSD 0.87 8 0.1

ULHSD 0.86 8 0.1

MS 0.77 0.7 0.7

ULMS 0.775 0.7 0.7

SKO/ATF 0.84 1.53 0.3

SCOPE OF WORK FOR ARTICULATED SWIVEL JOINTED ROOF DRAIN SYSTEM

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

ARTICULATED SWIVEL JOINT ROOF DRAIN :

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

DRAWINGS / INFORMATION TO BE SUBMITTED Page 21

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

VENDOR / MANUFACTURER ELIGIBILTY

Signature & Seal of Bidder

TANKAGE TECHNICAL SPECIFICATION

TANKAGE TECHNICAL SPECIFICATION

TANKAGE TECHNICAL SPECIFICATION

TANKAGE TECHNICAL SPECIFICATION

TANKAGE TECHNICAL SPECIFICATION

TANKAGE TECHNICAL SPECIFICATION