Documente Academic
Documente Profesional
Documente Cultură
ENGINEERING STANDARD
TC: 3480
CENTRIFUGAL PUMPS
(NON - CRITICAL SERVICES)
TC: 3480
DOCUMENT NO
REV
SHEET 1 OF 8
CENTRIFUGAL PUMPS
(NON - CRITICAL SERVICES)
TC: 3480
DOCUMENT NO
REV
SHEET 2 OF 8
CONTENTS
Sl. No.
SECTIONS
PAGE NUMBER
GENERAL
BASIC DESIGN
3-5
6-7
APPENDIX- I
CHECK LIST
DEVIATION FORM
10
SPECIFIOCATION SHEET
11-14
SPARE PARTS
15-16
17-22
information contained
in the
1.
2.
Specification sheet of particular pump with relevant drawings, if any, for the project in
question.
3.
This document.
4.
Codes & Standards referred in the above mentioned documents and in this document.
CENTRIFUGAL PUMPS
(NON - CRITICAL SERVICES)
1.
2.
TC: 3480
DOCUMENT NO
REV
SHEET 3 OF 8
GENERAL
1.1.
1.2.
1.3.
The pump shall be designed to develop the specified differential head at rated
capacity, suction pressure and specific gravity while running at the rated speed.
Rated speed of pump shall be full load speed of the drive motor. In case the driver
is not in pump vendor's scope, full load speed of the driver shall be furnished to
the pump vendor along with other details after order. The pump characteristics shall
be guaranteed / tested with reference to the full load speed of motor.
1.4.
Guarantee point shall refer to the differential head, rated capacity, specific gravity,
and full load speed of the driver.
1.5.
The pump and accessories shall be suitable for outdoor, unsheltered installation
and continuous duty unless & otherwise specified in specification.
1.6.
The pumps shall be supplied complete with all the accessories as specified in the
respective specification sheets inclusive of necessary appurtenances, auxiliary piping,
special tools, spares etc.
1.7.
1.8.
1.9.
Pumps shall have SI dimensions, comply with applicable ISO standards except for
piping connections which shall be as per ANSI/ASME standard.
1.10.
Reference list of pumps which are in operation for similar service conditions
shall be furnished with the offer indicating broad specifications, purchase order
number, date and name & address of user.
BASIC DESIGN
2.1.
The Pump shall be directly coupled with Driver Motor without any Gear Reducer in
between.
2.2.
2.3.
2.4.
2.5.
Pump inlet, outlet and auxiliary connections shall be flanged. All connections shall be
provided with slip-on type companion flanges, nuts, bolts and gaskets.
CENTRIFUGAL PUMPS
(NON - CRITICAL SERVICES)
TC: 3480
DOCUMENT NO
REV
SHEET 4 OF 8
2.6.
Connections of 11/4, 21/2, 31/2, 5, 7 nominal pipe sizes shall not be used.
2.7.
Pump suction piping shall be as short as possible and shall be arranged with particular
care to avoid vapor pockets.
2.8.
Reducers immediately connected to the pump suction shall be eccentric type flat side
up to avoid the accumulation of gas pocket. For end suction pumps, elbows shall not
be directly connected to the suction flange. A straight piece minimum 3 times the line
size shall have to be provided at the suction nozzle.
2.9.
Pump discharge check valve shall be wafer Type as S pecification GAE-60314 and
shall be installed in horizontal position.
2.10.
When specified, pump shall be provided with drip tray under the stuffing box and
leak-off line with flange, companion flange, nuts, bolts and gaskets. Material
composition of the drip tray should be SS-304 only. L eak - off piping shall be
arranged up to the edge of the base plate.
2.11.
Pump inlet, outlet and auxiliary flanged connections shall confirm to the facing and
drilling requirements of ANSI / ASME B 16.1 or ANSI / ASME B16.5.
2.12.
2.13.
Major parts such as casing components and bearing housings shall be designed
(shouldered or doweled) to ensure accurate alignment on reassembly.
2.14.
Impeller shall be keyed to the pump shaft. Impeller nut shall be used to secure the
impeller and a positive mechanical locking method shall be adopted.
2.15.
2.16.
Shafts for horizontal pumps shall be fitted with deflectors. Deflectors shall be made of
non-sparking material (corrosion resistant material for corrosive service).
2.17.
Renewable wear ring surfaces shall be furnished on impeller and casing. Casing Wear
Ring shall be fitted with non-metallic insert of PEEK material to maintain clearance
between Impeller & casing wear rings.
2.18.
Radial Bearing shall be Sleeve type (white metal Lined) in two halves & thrust
bearings shall be rolling element type. These shall be designed for 24,000 hours
bearing life.
2.19.
For between bearing pumps arrangement, bearing housing shall be cast integral with
the lower half of the pump casing or bolted to it. Bearing housing should be provided
with stiffening brackets and be sufficiently rigid to resist the dynamic loads
during operation.
2.20.
Castings shall be sound and free from shrink holes, blow holes, cracks, scale, blisters
and other similar injurious defects. Ferrous pressure casting shall not be repaired by
peening, plugging, burning in or impregnating. When weld repairs to castings are
authorized by ASTM specification for the material, repair welding shall be carried out
in accordance with that specification. Unless otherwise specified, weld repairs shall
be inspected according to the same quality standards used to inspect the casting.
2.21.
2.22.
Copper and copper alloys shall not be used for pump parts for application in
ammonia and urea plants.
CENTRIFUGAL PUMPS
(NON - CRITICAL SERVICES)
2.23.
TC: 3480
DOCUMENT NO
REV
SHEET 5 OF 8
2.1.
Motor shall have power ratings including service factor at least 115% of pump
rated absorbed power.
2.2.
Pumps shall be provided with shaft sleeve under mechanical seal / gland packing.
2.3.
Shaft sleeves shall be hard chrome oxide coated under flexible member of
mechanical seal.
2.4.
The pumps shall be supplied with mechanical seals of Make Flowserve Sanmar/
Eagleburgmann India only.
2.5.
The mechanical seal on DE Side (Drive End) shall be split type so that replacement /
maintenance of the same can be done without removing coupling & coupling Hub. The
mechanical seal on NDE side may be conventional type.
2.6.
Mechanical seal shall b e inside m ounted, b alanced type with C arbon versus
Silicon Carbide faces. T h e f l u s h i n g p l a n s h a l l b e A P I P l a n 1 1 i . e .
F l u s h i n g w i t h d i s c h a r g e f l u i d shall be provided.
2.7.
Only Metastream / diaphragm type of coupling shall be provided. Coupling guard shall be
non-sparking for pumps located in hazardous area. Coupling make shall be as follows:
Rathi-Discoflex, Euroflex, John Crane (Triveni-Flexibox)
2.8.
2.9.
CENTRIFUGAL PUMPS
(NON - CRITICAL SERVICES)
3.
TC: 3480
DOCUMENT NO
REV
SHEET 6 OF 8
3.2.
3.3.
3.4. Manufacturers standard shall be applied with respect to the tolerances of each
dimension.
3.5. All casting shall be visually inspected before machining for surface defects and
irregularities.
3.6. All repairs of defects found on inspection shall be subjected to prior approval of
purchasers inspector.
3.7.
PERFORMANCE TEST
3.7.1.
Performance test of each pump in the manufacturers shop shall be carried out, unless
specified otherwise.
3.7.2.
Pumps shall be operated in shop for a period sufficient to obtain complete test data.
Unless otherwise agreed, the test speed shall be the rated speed of the pump.
3.7.3.
3.7.4.
3.7.5.
During performance test, pump shall operate without undue heating of bearings,
excessive vibration, noise or other mechanical faults. Such defects if noticed shall
be promptly rectified to the satisfaction of the inspector.
CENTRIFUGAL PUMPS
(NON - CRITICAL SERVICES)
TC: 3480
DOCUMENT NO
REV
SHEET 7 OF 8
3.7.6
3.7.7
When operating fluid has viscosity appreciably higher than test fluid, test values of capacity,
head, efficiency and power input shall be corrected to specified viscosity of operating fluid as
per IS - 5120 / Hydraulic Institute Standard. Characteristic curves shall be plotted accordingly.
3.7.8
Motor to be supplied as driver of Pump shall be used during performance test of Pump at Pump
Vendors works.
3.7.9
3.7.10
Test shall be done at 5 points from shut off to 110% of rated capacity.
3.7.11
3.7.12
3.7.13
Test shall be done at 5 points from shut off to 110% of rated capacity.
3.7.14
Vendor shall compile all the tests & inspection reports relevant to purchase order scope of supply
in folder(s). Following reports must be included:
-
Records of dimensions
Guarantee certificates
Pumps shall be dispatched only after the shop test data and performance test curves are
approved by the inspector.
4.2.
The un-machined exterior surfaces shall be sand blasted, descaled and cleaned. The surface must be
free from foreign material before paint is applied.
4.3.
The external surface subject to atmospheric corrosion shall be painted with two coats of primer and
two coats of epoxy based finish paint.
4.4.
All the internal parts and machined unpainted exterior surfaces shall be protected with suitable rust
preventive.
4.5.
When driver is supplied with pump, the same shall be duly mounted on a common base frame.
4.6.
4.7.
Each unit shall be suitably packed for outdoor storage for at least six months.
VENDORS DATA
5.1.
The pump vendor shall supply the drawings and documents as per Appendix - I.
5.2.
Each drawings / documents shall have the following information in a separate block:
Owners Name
Name of the Project / Plant Purchase Order Number Equipment Code Number / Name
Drawing Number / Revision Number
Supplier Reference Number
CENTRIFUGAL PUMPS
(NON - CRITICAL SERVICES)
TC: 3480
DOCUMENT NO
REV
SHEET 8 OF 8
APPENDIX
DRAWINGS & DOCUMENT SCHEDULE
Bidder shall furnish along with each copy of bid
X
X
X
X
X
X
X
X
X
X
5
6
7
8
9
10
11
12
4
4
6
NOTE:
1.
All the final drawings / documents must be delivered at least one week
before dispatch of the equipment & accessories.
2.
3.
CENTRIFUGAL PUMPS
(NON - CRITICAL SERVICES)
NFVP/CWP/2013 -CL-3480
DOCUMENT NO
REV
SHEET 1 OF 1
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Description
Bidders reply
Completely filled in NFL data sheet for pump including the following:i)
NPSHR, Efficiency, Suction specific speed
ii)
Absorbed power at rated flow and driver rating
iii)
Impeller dia. Rated / min./ max. shut off head
iv)
Percentage possible head increase by Impeller change
v)
Pump minimum operating flow
vi)
Mechanical seal manufacturers recommendation
vii)
Bearing size / make, coupling make, ARC valve (if
provided) make / size / pressure drop and details
viii) Maximum allowable casing pressure and temperature
ix)
Utilities consumption
x)
Constructional details of pump, gear reducer and
mechanical seal etc.
xi)
MOC of all the parts
xii)
Sealing system details
Pump characteristic curve (head, efficiency, power, NPSHR vs. flow)
for Impeller min. / rated / max. dia.
Compliance to scope of supply including instruments, control panel
etc. as per ITB.
Inspection & testing as per ITB. Third party inspection quoted
separately.
List of special tools.
Spares for 2 years operation & commissioning (item wise price).
Reference List
Compliance to technical specifications enclosed with ITB, otherwise
clause wise deviations, if any.
P & I diagram of complete system indicating scope of supply
including capacity control, sealing system, lube oil system etc.
Cross sectional drawing of the pump and mechanical seal with part
list
GA drawing of pump and drive unit
Drawing and documents as per ITB
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
DEVIATION/CONCESSION/
WAIVER PERMIT
NFVP/CWP/2013-DF-3480
DOCUMENT NO
REV
SHEET 1 OF 1
DETAILS
SPECIFIED REQUIREMENTS
REQUESTED MODIFICATION
JUSTIFICATION :
No
Signature:_
No
Name
:_
DEVIATION NUMBER
D W
PDIL JOB NO
APPLICANT NO
APPROVERS NO
Signature:
Name
:
(Disposing Authority)
Ref. No.:
Date
:
DECISION
JUSTIFICATION
CLIENT
NFL, VIJAIPUR
PROJECT :
LOCATION:
VIJAIPUR,
EQUIPMENT
SHEET 1 OF 6
REV.
ITEM NO.
QUANTITY
1 Nos. each
REQUISITION NO.
NFVP/CWP/2013-3480
MANUFACTURER
1.
NOTES :
2.
3.
CLIENT
:
PROJECT :
LOCATION:
NFL, VIJAIPUR
ADDITIONAL C.W. PUMPS
VIJAIPUR, PLANT: AMMONIA-II /UREA-II
SHEET 2 OF 6
REV 0
EQUIPMENT :
ITEM NO-P-3801D/P-4801D
REQ NO:
P.O NO:
MANUFACTURER:
MODEL:
NOS REQUIRED:
PUMP TYPE
INSTALLATION:
ELECTRICAL MOTOR
INDICATES APPLICABLE
HORIZONTAL
VERTICAL
INDOOR/ OUT DOOR
IN-LINE
LIQUID:
COOLING WATER
1000
Kg/M3
AT P.T :
VAPOUR PRESSURE
0.054
Kg/cm a
AT MAX TEMP:
CORROSIV E
PUMPING TEMP
HAZARDOUS
Kg/cm2a
FLAMABLE
NORMAL:
33.5
MIN:
MAX :
VISCOSITY: AT P.T
0.75
TYPE/ SIZE
SOLIDS:
C
O
cP
microns
CONCENTRATION
OPERATING CONDITIONS
CAPACITY:
RATED:
SUCTION PRESSURE :
DISCONTINUOUS
NO
CONTINUOUS
0 .02
Kg/cm2g
PARALLEL OPERATION
YES
MAX ADMISSIBLE PRESSURE AT SHUT OFF
MIN:
MAX:
Kg/cm2g
FLOW CONTROL :
4.2
DIFF HEAD:
NPSHA
M3/hr
DUTY
NOR.
3500
M3/hr
NOR
3700
MIN
Kg/cm2g
40.0
m liq
TYPE:
FLUSHING FLUID
NORM/DES
TYPE:
EST. EFF:
PUMPED LIQUID
WATER
TEMP:
Kg/cm2g
TYPE:
HEATING FLUID
Kg/cm2g
Kg/cm2g
PRESS: NORM/DES
COOLING FLUID
MECH SEAL
PRESS:
STYARTING CONDITION:
RANGE
m liq
SIZE/RATING/FACING
SEAL TYPE:
GLAND PACKED
PROCESS VARIATIONS :
58.5
TYPE
TEMP
Press: Norm/DES
Kg/cm2g
CHARCTRISTIC CURVE NO :
rpm(m3/s) 1/2/m3/4
RATED SPEED:
EFFICIENCY:
NPSHR:
KW
kg-m2
KW
kg-m
m3/hr
RATED
IMPELLER DIAMETER
MIN:
mm
MAX:
mm
Kg
BAL. BY:
MAXIMUM 90
dB(A) AT 1m
CONSTRUCTION
CENTERLINE
FOOT
NEAR CENTER LINE INLINE
AXIAL
RADIAL
SINGLE VOLUTE DOUBLE VOLUTE
DIFFUSER
BARREL
RATING
FACING
POSITION
Kg/cm2g
Kg/cm2g AT
SIZE (NPS)
YES
NO
TYPE
DRAIN
VENT
PRESSURE GAUGE
WARM UP
BALANCE/LEAK-OFF
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION WHICH IS THE EXCLUSIVE PROPERTY OF NFL AND IS LENT TO THE BORROWER ON THE CONDITION THAT
IT SHALL NOT BE REPRODUCED, SOLD, LENT OR OTHERWISE DISPOSED OF NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT IS INTENDED.
CLIENT
NFL, VIJAIPUR
PROJECT :
LOCATION:
CLOSED
IMPELLER
PROJ NO.:
SEMI-OPEN
IMPELLER
BETWEEN BEARINGS
OVERHUNG
NFVP/CWP/2013-002
SPEC. NO:NFVP/CWP/2013-CT-3480
REV 0
SHEET 3 of 6
1ST STAGE SUCTION : SINGLE
DOUBLE
ROTATION VIEWED FROM CPLG. END: CW
CCW
NO.
THRUST
RING OIL
NO.
SPLASH
API 671
API - 610
MODEL
FORCED
SEAL
mm
PRESSURE
CONDENSATE
PRESS.
TYPE
Kg/cm2
FLOW
PUMP HEATING :
m3/h
WATER
kg/cm2g FLOW
STEAM
m3/h
API - 682
SPACER
REAR SIDE
API - 610
MECHANICAL SEAL:
MAKE
MODEL
API CODE
FLUSHING API PLAN
TYPE METASTREAM
COUPLING :
SUCT. SIDE
RADIAL
PRESSURE
FLOW
SIZE
NO. OF RINGS
PACKINGFLUSHING FLUID
Kg/cm2
m3/h PIPING MTRL:
m3/h
IMPELLERS:
ASTM A743 Gr. CA6NM
WEARING RINGS CASING: SA743 Gr. CA6NM WITH PEEK INSERT Gr. WR300
CI (ASTM A48Class30)
SHAFT:
SA322GR. 4140
SHAFT SLEEVES:
INTERSTAGE SLEEVES:
SS316
BALANCING DRUM:
DRIP TRAY:
BASE PLATE:
WEIGHT AND DIMENTIONS
PUMP:
BASE PLATE:
Kg
DIMENSIONS : L x W x H
MOTOR / TURBINE :
GEARBOX:
kg
mm
INSPECTION AND TEST
PERFORMANCE
WITNESS
HYDROSTATIC
NO WITNESS
NPSH
STRIP DOWN
AUX EQUIPMENT
N/A
COMPLETE UNIT
N/A
DRIVER DATA
ELECTRIC MOTOR: ITEM NO
RATED POWER:.
MFR
kw, SPEED
rpm
RATED POWER :.
POWER : VOLTS/PHASE/FREQ
INLET PR
STEAM
MFR.
NA
kw, SPEED
OUTLET PR
rpm
Kg/cm2g, TEMP
2
Kg/cm g, TEMP
SCOPE OF SUPPLY
DRIVER
COUPLINGS
WITH SPACER
COUPLING GUARDS
NON SPARKING
CASING DRAINS
WITH VALVES
MECHANICAL SEALS
CASING VENTS
WITH VALVES
SPECIAL TOOLS & WRENCHES (NOTE 2)
COMPANION FLANGES ( SUC. & DISC.) (NOTE 3)
ARC VALVE
CONTINUOUS BY - PASS ORIFICE ASSEMBLY
SPARE PARTS
CLIENT
PROJ NO.:
NFVP/CWP/2013-002
NFL, VIJAIPUR
SPEC. NO:NFVP/CWP/2013-CT-3480
PROJECT :
ADDITIONAL C. W. PUMPS
LOCATION:
RELIEF VALVE
FLUSHING SEPARATOR
SHEET 4 OF 6
LEVEL INDICATOR
REV.
LEVEL SWITCH
NOTES:
1. NEW PUMPS (1 NO. FOR AMMONIA II COOLING TOWER AND 1 NO. FOR UREA-II) IS REQUIRED
TO BE RUN / WORK IN PARALLEL WITH THE EXISTING PUMPS. PLEASE REFER ATTACHED
EXISTING PUMP PERFORMANCE CURVE. SHUT OFF HEAD SHALL MATCH WITH THE EXISTING
PUMP.
2. IF REQUIRED, LIST IS TO BE PROVIDED ON THE SEPERATE SHEET.
3. COMPANION FLANGES SHALL BE PROVIDED WITH NUTS, WASHERS, GASKETS, BOLTS ETC.
4. BELL MOUTH, SUCTION STRAINER (SS) & VORTEX BREAKER SHALL BE INCLUDED IN THE SCOPE
OF SUPPLY.
5. ALL COMPONENTS MUST BE MANUFACTURED AS PER PREVAILING LATEST INTERNATIONAL
STANDARD AND SHOULD BE DESIGNED AS PER GOOD ENGINEERING PRACTICES.
6. MANUFACTURER SHALL INCLUDE ALL THE NECESSARY INSTRUMENTATION, CONTROL AND
ANY OTHER ITEM REQUIRED IN ADDITION TO WHAT IS SPECIFIED EARLIER, WHICH THEY MAY
FEEL NECESSARY FOR TROUBLE FREE, SMOOTH, RELAIBLE AND HAZARD FREE OPERATION OF
THE SYSTEM.
7. COPPER & COPPER ALLOY NOT ALLOWED.
CLIENT
PROJ NO.:
NFVP/CWP/2013-002
NFL, VIJAIPUR
SPEC. NO:NFVP/CWP/2013-CT-3480
PROJECT :
ADDITIONAL C. W. PUMPS
LOCATION:
SHEET 5 OF 6
REV.
ANNEXURE - A
SPARES PARTS LIST FOR 2 YEARS OF OPERATION & MAINTANENCE
S. No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
DESCRIPTION
Impeller
Impeller Locking Nut
Wearing Rings for Impeller
Wearing Rings for Casing
Shaft with keys
Shaft Sleeve (Mech. Seal)
Set of Seal Faces
Set of O-Rings for Mech. Seal
Constant Level Oiler
Deflectors
Complete Coupling
Bearings (DE + NDE)
Gaskets & O Rings
Labyrinths Bearing Protector
Throat Bushing
Throttle Bushing
Oil Seals (not applicable if provided with
Electrical:
As per document no NFVP/CWP/2013 Annexure E-I
Point 18
INSTRUMENTATION
As per Instrumentation specification enclosed
with enquiry/order specification
QTY
(SETS)
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
UNIT PRICE
(Rs)
TOTAL PRICE
(Rs)
CLIENT
NFL, VIJAIPUR
PROJ NO.:
NFVP/CWP/2013-002
SPEC. NO:NFVP/CWP/2013-CT-3480
PROJECT :
ADDITIONAL C. W. PUMPS
LOCATION:
REV.
ANNEXURE - B
COMMISSIONING SPARES LIST
S. No.
1
2
3
4
5
6
7
QTY
(SETS)
UNIT PRICE
(Rs)
TOTAL PRICE
(Rs)
1
1
NIL
2
1
1
1
2.
Spare parts listed above, with unit price of each set shall be furnished in the above performa.
Bidders are requested to take a Xerox Print of above and fill it up as per requirements. Parts not
applicable in the offered machine shall be marked as "NA". Alternate Part used in place of part "NA"
shall also be quoted.
3.
Above list of parts is minimum requirement. Vendor may recommend number of sets based on his
past experience.
4.
Any additional parts required, based on Vendors experience may also be quoted in the above
fashion on a separate sheet mentioning clearly Additional Spares.
REV0
NFVP/CWP/2013
DOCUMENT NO.:PC-002
SHEET 1 OF 10
0
REV
NFVP/CWP/2013-PIPING
REV
SHEET 2 OF 10
CONTENTS
SECTION
NUMBER
DESCRIPTION
SHEET NUMBER
1.0
2.0
3.0
BIDDERS RESPONSIBILITY
4.0
10
5.0
PACKAGING
10
6.0
10
LIST OF ATTACHMENTS
ATTACHMENT NUMBER
DESCRIPTION
PC65-00-0001_PGR_Amm2_R0
Existing plot plan of ammonia-2 with Proposed location for new C W Pumps &
its Piping
ES-6001
ES-6004
ES-6005
ES-6006
ES-6018
ES-6032
ES-2001
NFVP/CWP/2013QPR
NFVP/CWP/2013-Bellow
PC65ES6002
NFVP/CWP/2013-PIPING
0
REV
SHEET 3 OF 10
1.0
1.1
The detail scope of work includes such as but not limited to complete management,
Design, Detailed Engineering, to provide all the necessary data, drawings, documents
required as per the project requirements, Procurement, Supply, Transportation of
materials, shop & site Fabrication, Erection, Installation, Supporting, Non-Destructive
Testing (NDT) & required Inspection , pr e-heating, dye-penetrant test, Magnetic
Particle Test, post weld heat treatment, radiography , Testing, Flushing, Air drying,
blowing , cardboard-blasting , seal/leak-testing, Pre-Commissioning, Trial run,
Commissioning and Guarantee of all the associated works pertaining to complete
piping system and related facilities for ADDITIONAL COOLING WATER
PUMPS PACKAGE at NFL,VIJAYPUR.
1.2
Design, material, fabrication and erection shall be in accordance with latest edition of
ASME B 31.3 chemical plant and petroleum refinery piping code. The dimensions,
manufacturing tolerances shall conform to applicable standards.
1.3
All works described in this package shall be performed in accordance with the designbasis, specifications, drawings, and other requirements of bid package and shall be
subject to NFLS review and approval.
1.4
MATERIAL OF CONSTRUCTION
Materials as per internationally acceptable code shall be used for piping based on
service requirement. All materials for piping Components shall confirm to ASTM or
API Specifications as per enclosed piping specifications. All piping materials and
valves shall be procured from the reputed approved suppliers/vendors.
1.5
Cost of piping job shall also include the cost of supervision, Labour, overheads /
profits, materials, consumables, scaffolding and all other associated arrangements
required to execute the related activities of this package.
1.6
VALVES:
Hydrostatic & Pneumatic testing shall be carried out for all valves i.e. 100% quantity
as per relevant standard.
All valves shall be operated and checked for 100% trouble free operation.
1.7
NFVP/CWP/2013-PIPING
0
REV
SHEET 4 OF 10
transportation to site , fabrication & erection of all these items shall be in BIDDER
scope.
Since the piping from B.L. of C. W. Pump Package to the Tie-in Points shall be laid
in existing pipe system, the adequacy check of existing pipe rack for new pipe lines
shall be in Bidders scope.
BIDDER to note that tie-in with isolation valves and blind to be erected during next
shut down of the plant tentatively planned in March/April 2014 s o that hook-up of
New C. W. Package with existing system can be done during plant operation.
1.8
2.0
2.1
2.1.1
a)
Complete piping system for C. W. PUMP PACKAGE including all utilities such as
drinking water distribution piping with eye washers cum safety showers shall be
provided at all critical areas.
b)
Carry Out all necessary calculations in accordance with approved design basis,
drawings/documents and requirements of this bid package.
c)
d)
Carrying out Material Take Off for the entire piping system.
e)
The detail design shall take into consideration of all stipulations, practices followed
by various Statutory Regulations/authorities for all types of piping.
NFVP/CWP/2013-PIPING
0
REV
SHEET 5 OF 10
f)
Size of Pipe
Material Code
Fluid Code
Line No.
2.2
2.2.1
BIDDER shall procure and supply all materials whatsoever required for
temporary/permanent installation of piping system in sequence and at appropriate
time. All equipments, materials, components etc shall be suitable for the service and
the design life of the system.
2.2.2
2.2.3
Material take-off with complete description of size, rating, material, thickness and
specifications.
2.2.4
Preparation and finalization of data sheets for all piping materials e.g. all valves etc.
All data-sheets shall be subject to review and approval by NFL.
2.2.5
Preparation of Material requisitions, Request for Quotation & its evaluation and
recommend BIDDERS for NFLS approval. Preparation of purchase requisitions,
review of BIDDERS drawings and calculations, approval of manufacturing
procedures wherever necessary, and the party inspection at manufacturers works of
the materials by reputed agencies as required. Quality control and expediting of all
procured items at BIDDERS shop or at fabrication yard.
2.2.6
2.2.7
Carry out proper documentation of inspection and quality assurance programs for all
equipment and bulk materials duly approved by NFL. BIDDER shall maintain an
accurate and traceable listing of procurement records for the location, quality and
character of all permanent materials in the Project.
2.2.8
BIDDER shall immediately report to the NFL of all changes which will affect
material quality, and take necessary corrective actions. Purchase requisitions
NFVP/CWP/2013-PIPING
0
REV
SHEET 6 OF 10
including Purchase Orders of all major items shall be approved by NFL. For balance
items, records shall be furnished for information only.
Compliance with BIDDERS and suppliers instructions and recommendations for
transportation, handling, installation and commissioning.
2.2.10
Test on pi pe shall be conducted for all mandatory tests conforming the applicable
Material specification .Test reports shall also be furnished for any supplementary test
as Specified in the requisition.
2.2.11
All austenitic stainless steel pipes shall be supplied in solution annealed condition.
2.2.12
Gaskets in the piping shall be used as per relevant piping specifications and in no case
Sheet / Flat Gaskets of CAF / Non-asbestos shall be used.
2.2.13
All materials shall be new materials with all surfaces clean and free from defects,
Weld spatter, arc strike, rust, dirt, sand, scale, paint or any other foreign substance
2.2.14
Each Pipe fitting of thickness and sizes as mentioned below shall be ultrasonically
tested as per ASTM A-388
Size range
Sch./Thk
Upto 4
>Sch 120
> 5
12 mm
2.2.15
Electrodes and Filer Wires to be used at site shall be of Advani Oerlikon, D & H
Secheron, ESAB, Bohler, Thyseen, Kobe, Sandvik, Avesta make only.
2.2.16
Inspection and tests at the Vendor's shop shall be carried out in conformance with the
requirements of the material standards (ASME/ASTM/API) specified on the purchase
order documents.
2.3
2.3.1
All bolting shall be as per ASME/ANSI B18.2.1 for Studs, M/C Bolts and Jack screws, and
ASME/ANSI B18.2.2 for nuts (prefereably in metric units).
2.3.2
Threads shall be unified (UNC for; 1" dia and 8UN for> 1" dia) as per ANSI B1.1 with class
2A fit for Studs, M/C
2.3.3
Stud bolts shall be threaded full length with two heavy hex nuts. Length tolerance shall be in
accordance with the requirement of table F2 of Annexure F of ASME B16.5
2.3.4
The length of the studs/ bolts should be such that minimum two threads should be out of the nut
on either side.
2.4
2.4.1
Supports and/or anchors shall be provided close to changes in direction of lines, branch lines
and, particularly, close to valves to prevent excessive sagging, vibration and strain.
2.4.2
Allowable spans between pipe supports shall be determined to keep the maximum deflection
within 16 mm.
NFVP/CWP/2013-PIPING
0
REV
SHEET 7 OF 10
2.4.3
In cases where periodic maintenance requires removal of equipment, such as pumps and relief
valves, and where lines must be dismantled for cleaning, piping shall be supported to minimize
the necessity of temporary supports.
2.4.4
2.4.5
Suction and discharge lines of rotating equipment shall be supported as close as possible to
equipment nozzles, and shall be relieved of excessive strains by using proper pipe supports.
2.4.6
2.4.7
Expansion joints shall be guided and anchored to the extent necessary for their proper operation
and alignment.
2.4.8
Anchors shall provide sufficient fixation to substantially transmit all load effects into the
foundations.
2.5
UNDERGROUND PIPING
2.5.1
2.5.2
Underground piping passing under loaded areas, such as main roads in the plant, shall be
protected from heavy traffic by casing pipes or covers extending at least 1 m on either side of
the area or having the wall thickness sufficient to bear earth pressure.
2.5.3
Underground piping shall be sloped to all drain points with a downward slope of not less than 1
m in 150 m.
2.5.4
Expansion elbows or joints of underground piping for hot fluids, such as steam or heated heavy
oil, shall be enclosed in a conduit from which they are separated to allow free longitudinal
expansion.
2.5.5
2.5.6
Trenches for piping close to process equipment should be avoided, whenever possible.
2.5.7
2.5.8
Pipes at road crossing shall be under culverts in general. Where culverts are not
2.6
BURIED PIPES
Underground pipe crossing roads, access ways, rails shall have casing pipe (R.C.C
or C.S)
NFVP/CWP/2013-PIPING
0
REV
SHEET 8 OF 10
ii) All underground metallic piping shall be coated and wrapped and provided with cathodic
protection system. If sacrificial metal is used, permanent testing arrangement shall be
provided.
iii) Valve chamber wherever required shall be made of brick or concrete. Valve
chamber should be spacious to attend valves during operation/Maintenance.
iv) All U.G. headers shall clear equipment foundations as far as possible. Under special
cases, the C.W. header may be laid over the footing of foundations.
v) Provide break flange at + 500 MM from floor level connection with cathodic
protection to isolate underground pipe from above ground piping.
vi) Pipes shall be laid below electrical cables if any.
2.7
GROUTING
Grouting of pipe supports, structures, equipments and machineries etc. shall be carried out in
general as per PDIL Engineering standard E-5213, except the following:
A)
i)
ii)
During actual grouting three cubes for testing are to be taken for each batch prepared
and to be tested and must meet the strength required as mentioned.
Contractor shall check and ensure that cement containing calcium chloride is not used for
grouting and all grouting shall be suitably cured so as to achieve full strength. After the
grout has been cured fully, anchor bolts shall be checked for adhesion with the grout by
tightening of nuts.
Instructions for grouting received from equipment vendor shall override specification in this
enquiry.
2.8
MARKING
2.8.1
Each pipe shall be legibly marked using stencilling or etching on the outer surface of pipes in
accordance with the ASTM or API Standard.
For pipes of NFS 3/4 and under, which can be bundled/ the standard marking may be made on a
label or tag securely attached to each bundle. In this case, pipes bundled shall comprise of same
item code only.
2.8.2
In addition to the standard marking of the above, each pipe shall be color marked with
continuous stripe(S) throughout entire length on t he outside surface to identify the material
specification in the same size, e.g. material type or grade, seamless or welded, partial or full
radiograph, wall thickness.
2.9
PAINTING
All the painting material will be bought in accordance with Spec. ES-2001 (Engg.
Standard: Selection and Application of Protective Coating) or equivalent Standard
applicable.
NFVP/CWP/2013-PIPING
0
REV
SHEET 9 OF 10
2.10
CONSTRUCTION
All construction works be carried out as per Approved for Construction drawings,
procedures, specifications and applicable codes and standards. Any changes at site
shall also need prior approval from the NFL and revision of drawings.
BIDDER shall procure and supply all materials whatsoever required for
temporary/permanent installations of piping system in required and at appropriate
time. All equipment, materials, components etc. shall be suitable for the intended
service and the design life of the system. W herever no specification is available in
the contract, the same shall be prepared by the BIDDER and shall be subject to NFL
approval.
3.0
3.1
3.2
3.3
3.4
3.5
3.6
BIDDERS RESPONSIBILITY
All works shall be carried out by Bidder in accordance with the drawings / documents
/ specifications indicated in the subsequent paragraphs.
Specifications:
Standards:
Piping Support Standards:
Flexibility analysis
Drawings:
3D Modelling & Design Review:
Bidder shall submit all proposal designs, analysis, drawings, installation and testing
procedure for review & approval by NFL as mentioned in the scope work. B idder
shall as a minimum, provide above deliverables for NFLS information / records &
review / approval.
3.7
3.8
The BIDDER shall submit separately, the material take off for piping, valves, fittings
and all other accessories as per requirements.
3.9
The BIDDER shall obtain statutory approval from various authorities having
jurisdiction over the area as necessary for construction of the unit package.
3.10
Sizes of various Piping indicated in the Tie-in List & NFVP/CWP/2013- TI-002 are
tentative and final sizes shall be as per designing & recommendation of Vendor.
However, Sizes of existing lines where Tie-in is to be taken are actual.
3.11
Piping specifications enclosed in ITB indicates all the details like Material & Class of
Pipe, Pipe Fitting, Bolting, Valve Type / Tag No. etc.
4.0
NFVP/CWP/2013-PIPING
0
REV
SHEET 10 OF 10
With Bid
Following drawings/documents must be submitted along with the bid.
i) Proposed equipment layout drawing.
ii) Proposed piping Layout drg.
iii) Quality control procedure & plan for piping system.
iv) Completion schedule of piping job in Bar-chart format.
v) List of all construction equipments, tool-tackles & man power resources proposed to
be used.
vi) Clause wise list of deviations / exclusions, if any, to bid requirements shall be
furnished. BIDDER is cautioned that exclusions and deviations listed elsewhere in
bidders offer shall not be considered for evaluation
vii) List of existing drawings for existing plot plan, tentative location/size of C. W.
Pumps package & tie in point location
BIDDER to note that the location/size of CW Package and Tie in points is tentative only & they
have to physically verify all these points at site & quote accordingly.
4.2
With Supply
The pipes shall be supplied with 3 copies of the mill test certificates indicating the following
and duly signed by the inspecting authority along with supply of materials. In addition 8 copies
of these certificates shall be sent to Contractor for final compilation.
PACKAGING
Packaging of piping items shall be as per the guidelines of NFL.
6.0