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TECHNICAL SPECIFICATIONS FOR LPG TANK TRUCK

LOADING/UNLOADING ARMS
1.0 SCOPE:
This specification outlines the minimum requirements for design, manufacture,
inspection, testing and supply of Loading Arm s for loading/unloading operations of
road tankers.
Scope of Supply:
Vendor scope of supply shall include complete loading arms. Quantity of loading
Arms shall be as per Attachments.
Each loading arm shall essentially be complete with following:
-Outboard & Inboard arm s
-Connecting pipe
-Swivel joints
-Vent Connections
-Shut off valve
-Counter Balance arrangements
-Supporting arrangement
-Locking arrangement
-Emergency release couplings with automatic shutoff valves
-Acme coupling set
Spares for 2 years normal operation.
Extra one set of connecting nozzle with Acme male connector and flanged end
connection for each loading arm.

2.0 CODES & STANDARD

The material of construction of the pipes, flanges, valves, joints etc. shall be in
accordance with relevant ASTM standards. The design and fabrication shall be as
per latest edition of ANSIB31.3 Petroleum Refining Standards.
The specification of the pipes & flanges (ANSI300#WNRF only) shall be in
accordance with relevant ANSI, API standards.
Wherever international standards and codes are not available, vendor may follow
his own proven standards and practices and mention this clearly in the unpriced bid.

3.0 TECHNICALREQUIREMENTS
3.1 GENERAL
Loading Arm s shall essentially consist of outboard arm, inboard arm connecting
pipe or drop pipe, swivel joints, drain and vent connection, shutoff valve, counter
balancing arrangement, supporting arrangement and locking arrangement
emergency release coupling and Acme coupling. The Loading Arms should be
suitable for LPG liquid flow of60 m3/Hr -for 3 (80 mm) NB & 40 m3/Hr - for 2(50
mm) NB Inboard arm connection.
The loading arms shall be designed for the following conditions:
Design temperature: + 70 Deg. C.
Operating Temperature: +45 Deg. C.
Design Pressure: 24 Kgs/sqcm ,
Test Pressure : 36 kgs/sqcm.

3.2 Arms & Pipes


The arms shall be seamless pipes suitable for LPG conforming to ASTM A 106 Gr. B.
The pipe thickness shall be adequate for the specified design pressure and the
bending and torsional stresses encountered in the loading/unloading operations. All
pipes of50 mm dia. and below shall be minimum of schedule 80 and of 65 mm dia.
and above shall be minimum of schedule 40.
Inboard arm shall be of 80 NB size & Outboard arm shall be 50 NB size for both
liquid & Vapour unloading / loading arms.

Connecting pipe/nozzle shall be provided with Acme male connector and flanged
end connection. Acme coupling - male & fem ale connectors shall be of cast steel
and wing nut shall be of gun metal.
A shutoff valve shall be provided in the connecting pipe to minimize product
leakage at the time of disconnection. In case of loading arms with drop pipe, this
valve shall be provided in the outboard arm. The shutoff valve should be a ball valve
of Fire safe type design with full bore and should have API monogram. The arm shall
be balanced throughout its working range with adjustable compression /torsion
/composite spring unit.

3.3 Swivel Joints


The swivel joints shall be designed to make the arm maneuverable with the effort of
a single person and shall be as per A 216 Gr. WCB. Operating torque of any swivel
should not be more than 5 Kg.m. The joints shall have chrome carbon steel balls in
minimum 2 rows fixed in suitably hardened stainless steel guide ways. The seal
materials shall be fitted PTFE with316 Grade SS wear and anti-extrusion rings &
Inconel-X750 energizer springs.
The swivel joints shall be life-lubricated type. If any alternative lubrication is offered,
vendor shall substantiate its superiority with respect to the life lubricated type.
The arrangement of swivel joint shall preferably allow changing of seal without
complete dismantling. The swivel joints shall have corrosion-proof sealing surfaces,
preferably of stainless steel. Seals shall prevent ingress of moisture and
particulates. They shall have leak detection port to enable monitoring of primary
seal for possible leakage. They shall also have a positive back-up seal/ radial O-ring
to protect ball races against harsh operating conditions. The swivel joints shall be
split-flange type.
The strength of the swivel shall be based on the combination of the internal design
pressure for swivels only, and the maximum design equivalent load PCA, which is
based on the most stringent combination of external axial, bending moment and
radial loads.

PCA = FA + 5MT/d + 2.3FR tanA

Where:
FA = Externally applied axial load (N)

MT = Externally applied bending moment (Nm)


D = Raceway diameter (m )
FR = Radial load (N)
= The contact angle (angle between the plane of the balls and the center of contact
at the ball / raceway interface).
The following criteria shall be met:
a. At 1.5 x PCA, plus internal design pressure (for swivels only) the width of any
brinelling shall be a maximum of 8% of the ball /roller diameter.
b. At 2 x PCA, plus internal design pressure there shall be no loss of pressure of
product from a swivel.
Swivel joint design shall be such that non-destructive examination (NDE) of the
hardened thickness of ball races is possible.
Pressure losses for the entire arm assembly shall preferably not exceed 1.0 bar at
maxim um flow rate.
Number of swivel joints provided in each loading arm should result in 5 or 6 degrees
of freedom to ensure the following:

a. Cross connection of liquid/vapor phases


b. Stain free norm al locking / bolting of quick coupler and clamping collar of
breakaway coupler.
The terminal swivel assembly shall be designed to keep the coupling device
horizontal and equipped with a manual handle. Balancing unit shall be adapted
when necessary to maintain this condition.

3.4 Emergency release coupling


Each loading arm shall be provided one emergency release coupling (breakaway
coupler) with self-closing valves on both the sections. It should be of instantaneous
shutdown type to be installed either on the terminal sleeve or on outboard arm
downstream of the shut off valve. The breakaway couplers shall be of 316L SST
construction, seals of Viton, PTFE type, working pressure of 24 barg and working
temperature -46 deg.C to + 100 deg.C. and shall be suitable for re-assembly in 5
minutes. The emergency release coupling should preferably not have any shearing
parts and should not impart any force at the tanker end.

3.5 End Connections


End connections for the Loading Arms will be as follows:
Fixed End
Maneuverable
End

LPG Liquid Line


80mm NB WN RF
300# to ANSI B 16.5
2(50 mm NB)Acme

LPG Vapor Line


50mm NB WN RF300# to
ANSIB 16.5
2(50 mm NB)Acme

Coupling having 2
300# Flange
connection at tanker
end

Coupling along with suitable


adapters for vapor nozzle
connection of 2 300#
Flange connection at
tanker end

Note: All flanges shall be a minimum of 300# rating and shall be weld neck raised
serrated face type.

3.6 Balancing Arrangement


The arms shall be counter balance by a spring balancing device (no torsion spring
permitted) /composite spring type.
The balancing arrangement shall be such that the outboard arm along with the
connecting pipe remains horizontal.

3.7 Supporting Arrangement


The arm shall be self-supporting type or column mounted type with stand post.
The supporting arrangement shall be such that there is complete flexibility in
operation.

3.8 Locking Arrangement


Suitable locking arrangement shall be provided for locking the arm in parked
position. The locking arrangement can be manual or pneumatic.

3.9 Grounding Arrangement


Electrical grounding device shall be provided so that the tank wagons are properly
earthed and electrostatic charges are safely diverted to ground. The arm shall be
equipped with earthing straps min.30mm2 cross-section area made of copper rubber
lined or SST for by-passing a non-conductive junctions, and shall guarantee 0.5
Ohms maximum electrical resistance throughout the life of the arm.

3.10 Loading / Unloading envelope

The length of inboard/outboard arm s and connecting pipes/drop pipes shall be such
as to give adequate flexibility in loading/unloading operations. Inter-distances
between centerline of stand-post location to tank truck bay center varies from 2.25
m. to3.0 m.

The following range of flexibility shall be provided as a minimum:

Loading arms for road tankers

a) Longitudinal direction: +/-1.0 m


(Tanker positioned at center of the bay)

b) Transverse direction:

+/-0.5 m

(Tanker flange(s) and loading arm(s) on same axis).

c) Vertical direction:

+/-0.5 m

(From tanker flange center line / top elevation)

The loading arms shall be designed in such a manner that in all positions of the tank
trucks, the liquid arm should be able to connect to the liquid nozzle on the truck.
Similarly in all positions of the tank trucks, the Vapor loading arm should be able to
connect to the vapor nozzle on the tank truck with or without crossover with liquid
arm.

The loading arm shall have sufficient working range to reach all the filling nozzles of
the tank wagons.

3.11 Liquefied Gases


The loading arm shall be provided with venting system.

4.0 INSPECTION & TESTING


Design and sizing of all components of the LPG loading /unloading arms should be
approved by one of the Third party inspection (TPI) agencies given under. The
materials and specifications mentioned in the tender document are minimum
required and if the design warrants a superior quality / higher sizing of materials,
the same should be included in the scope of this supply.

TPI to cover the following:

1. Visual and dimensional examination of all arms.


2. Checking of radiographs of welds according to ASME V & IX.
3. Review of NDE certificates (radiographic examination & Liquid Penetrant test).
4. Review of hydrostatic test records at 36Kg/cm2/30min.
5. Witness functional test, balancing examination at random.
6. Review of Manufacturers data book including raw materials certificates, WPS/PQR
and welders qualifications, non-destructive examination qualifications of operators,
painting certificate.
HPCL/Authorized representative/Third party shall have access for stage wise & final
inspection. This is in addition to manufacturers own inspection and quality

assurance program. Vendor shall submit Quality Assurance (QA) procedures before
commencement of fabrication. Approved QA procedures shall form the basis for
equipment inspection.
All the weld joints shall be 100% radiographed. The inspection procedure shall
include checking of major dimensions, NDT (radiography etc.) and verification of
materials of construction (through mill test reports) of all components.

After assembly, the arm shall be subjected to tests as per manufacturers standard
test procedure. This shall include the functional test of the swivels, the counter
balance & hydrostatic test of complete arm assembly etc. Manufacturers standard
test procedure shall be submitted along with the offer. If dismantling is required for
improvement of performance after the tests, the above basis tests including
hydrostatic test shall be re-done after reassembly. Surface cleaning and painting to
be inspected by TPI agency.
Any or all the tests, at HPCLs option, shall be witnessed by third party inspection
agency. Acceptance of shop tests shall not constitute waiver of requirements to
meet the field performance under the specified operating conditions.
NDE (Non Destructive Examination) will be applied to all swivel bearing surfaces
without dam age to the swivel body.

Swivels tests
If proof test certificates (for swivels of the type and size proposed and having at
least the same loading) are unavailable or unacceptable, the swivel shall be proof
tested at the Vendors works as follows:

a. After hydrostatic testing at the Vendors works, swivel assemblies shall be partial
vacuum tested at 0.515 bar (abs). The operating pressure shall then be applied to
demonstrate that the seals re-seals re-seat correctly.
b. Swivel assemblies shall be leak tested whilst being rotated at least+/-5 o at0.1 Hz
and at a pressure of10 bar (g), or the specified operating pressure if higher. The
duration of this test shall be30 minutes.
c. The swivel shall be tested at design pressure with tests loads P CT

d. PCT shall be maintained, if increasing other test loads loses internal pressure.

PCT = TLF X PCA

Where
PCT = Test load
TLF = Test load factor
PCA = Combined swivel design load

Test loads shall be applied at ambient temperature as follows:

Stage 1

TLF

2.0

1.5

Acceptance criteria:
a. At test 1, brinelling shall be within acceptable levels
b. At test 2, there shall be no leakage
The swivel shall be disassembled and inspected for brinelling after each of the tests.
The Vendor shall provide a graph of Brinelling vs.P CT as part of the test
documentation.
The material test certificate will comply with EN 10204-3.1B. After assembly, at
least one arm of each type shall be erected at the supplier premises. This will allow
for all inspection parties to check dimensions, balancing, operation and function of
the complete assembly.

Approved third parties are as follows:


1. LloydsRegister 2. Bureau Veritas 3. DNV 4. EIL 5. IRS

5.0 PROTECTION AND PAINTING


All exposed carbon steel parts to be painted shall be thoroughly cleaned from inside
& outside to rem oval scale, rust, dirt and other foreign materials by sand blasting
as applicable. Minimum acceptable standard in case of power tool cleaning shall be
SA 3 and in case of blast cleaning shall be SA2 as per Swedish standard SIS
0559001967.
Primer and finish paints shall be of Polyurethane. Loading nozzle should be painted
with Golden Yellow (Shade 356) color for liquid & International Orange (Shade592)
color for vapor service.
Non-ferrous materials, austenitic stainless steels, plastic or plastic coated materials,
insulated surfaces of equipment and pre-painted items shall not be painted.
Stainless steel surfaces, both inside and outside, shall be pickled and passivated.
Machined and bearing surfaces shall be protected with varnish or a thick coat of
grease.

6.0 PACKAGING AND IDENTIFICATION


All packaging shall be done in such a manner as to reduce the volume. The
equipment shall be dismantled into major components suitable for shipment. All
assemblies shall be properly match marked for site erection.
Attachments, spare parts of the equipment and small item s shall be packed
separately in wooden cases / suitable gunny packing. Each item shall be
appropriately tagged with identification of main equipment, item denomination and
reference number of the respective assembly drawing.
Detailed packing list in waterproof envelope shall be inserted in the package
together with equipment.
Each equipment shall have an identification plate giving salient equipment data,
make, year of manufacture, equipment number, name of manufacturer etc.

7.0 SPARE PARTS


Bidder to attach list of recommended set of spares for two years normal operation.

8.0 DRAWINGS
Three sets of detailed drawings along with bill of material shall be submitted for
approval by HPCL.

9.0 PERFORMANCE TESTING AND GUARANTEE


All equipment and component parts shall be guaranteed by vendor against
defective material, design and work man-ship for a period of one year after being
put in service. The vendor shall carryout the performance test run of the complete
unit at site after satisfactory erection. Training of operators shall be given at site
during erection/commissioning period without any extra cost to owner.