Tech. Spec - For Propylene Compressor PDF

VISAKH MARKETING INSTALLATION RESITEMENT
PROJECT - LPG TERMINAL
Doc No: 256324-500-RQ-MEC-006 Rev: B Page 1 of 26
MATERIAL REQUISITION
FOR
PROPYLENE COMPRESSOR
Hindustan Petroleum Corporation Ltd Mott MacDonald Consultants (India) Pvt. Ltd.
Visakha Dispatch Station Kothari House, CTS No. 185
VR-ATP Area, Naval Base Post Off Andheri - Kurla Road
Visakhapatnam - 530 014 Andheri (East)
Andhra Pradesh Mumbai 400 059
P:\Andheri\IndiaProject\256324 HPCL- LPG\10 Procurement\TENDER\16 Piping Works Tender\Final\Annexures- Piping Tender\Annexure-

3\MDS,Specs-Mech\Editable\Tech. Spec.for Propylene Compressor.doc
MATERIAL REQUISITION
FOR
PROPYLENE COMPRESSOR
Client HINDUSTAN PETROLEUM CORPORATION LTD.

MMCI Project No. 256324
Issue and Revision Record:
Rev Date Originator Checked Approved Description
A 02/06/09 SVJ SPW PJC Issued for Comments
Issued for Comments LPG

B 06/08/09 SVJ SPW PJC Compressor replaced with LPG
Cylinder Evacuation Compressor.
Group Disclaimer
"This document has been prepared for the titled project or named part thereof and should not be relied upon or
used for any other project without an independent check being carried out as to its suitability and prior written
authority of Mott MacDonald being obtained. Mott MacDonald accepts no responsibility or liability for the
consequences of this document being used for a purpose other than the purposes for which it was commissioned.
Any person using or relying on the document for such other purpose agrees, and will by such use or reliance be
taken to confirm his agreement, to indemnify Mott MacDonald for all loss or damage resulting there from. Mott
MacDonald accepts no responsibility or liability for this document to any party other than the person by whom it
was commissioned.

List of Content Page No
1 Introduction 5
2 Location and Environmental Conditions 6
3 Scope of Supply 6
3.1 Equipment and Materials 6
3.2 Extra for Non Lubricated Construction 7
3.3 Bottles, Accessories, Piping 7
3.4 Instrumentation 7
3.5 Local Control Panel 8
3.6 Motor 8
3.7 Engineering Services 8
3.8 Exclusions 9
4 Applicable Codes, Specifications and Standards 9

4.1 General 9
4.2 Codes and Standards 9
4.3 Other Specifications and Standards 10
5 Design Requirements 10
5.1 Mechanical Requirements 10
5.2 Instrumentation Requirements 10
5.3 Electrical Requirements 11
5.4 Piping Requirements 11
6 Quality Assurance 11
7 Inspection and Testing 11

7.1 Factory Inspection & Testing 11
7.2 Scope of Inspection & Certificates 13
7.3 Vendor Requirements 13
7.4 Performance Testing and Guarantee: 13
7.5 Works Inspection and Notification 14
8 Vendor Documentation 14
8.1 Documents/Information to be supplied with offer 14
8.2 Documents/Information to be supplied After Award of Contract 15
9 Manufacturing Schedule 15
10 Spares and Special Tools 15

10.1 Spares 15
10.2 Special Tools 15
11 Packing and Shipping 15
12 Installation and Commissioning 16
Appendix A: Attachments 17
Appendix B: Requisition of Engineering Documents (Red Form) 18
Appendix C: Table of Compliance 20
Appendix D: Instrumentation Design Requirements 21

1 Introduction
1.1 This specification covers the minimum requirements for the design, engineering, material
procurement, fabrication, painting, assembly, Inspection, supply and shipment of Propylene
Compressor for Resitement of Integrated Marketing Facility at Vishakhapatnam - LPG
Terminal.
The List of Compressors is as follows:
Sr.
Tag No. Quantity Description
No.
1 500C-002 01 no. Propylene Compressor
1.2 The Vendor shall be responsible for the design, engineering, fabrication, assembly, inspection,
co-ordination, testing, delivery and proper functioning of the Compressors.
1.3 The Vendor shall ensure that the design complies with the requirements of this requisition and
its referenced specifications and standards. The data sheets, which form part of this
specification, shall be completed by the Vendor. The Vendor shall highlight any non-
compliance at the offer stage in the Table of Compliance, Appendix C. The Table of
Compliance and filled in data sheets shall form a part of the offer. Not providing completed
compliance table and data sheets can cause rejection of the offer. Failure to clearly identify
specific deviations shall be assumed by the Purchaser to be total compliance with the
requisition.
Only those deviations that are specifically agreed to, by the Purchaser prior to award of the
order will be incorporated into the purchase order. Deviations to the specification will not be
allowed after award of order. Unless referred to in the Table of Compliance (Appendix C), it
will be assumed that all specifications are adhered to and that they do not have implications
with respect to cost, delivery and integrity of the equipment.
1.4 The Vendor shall procure third party material from vendors listed in the approved Vendor List
only, unless the particular type of material is not covered by the list, and a special dispensation
to deviate from the list has been granted in writing by the Purchaser. Company will reject any
materials found at any stage to be out of the approved VENDOR or sub Vendor list.
1.5 Note that lead times will not be considered by the COMPANY as a justifiable reason for
using alternate VENDOR.
1.6 This requisition shall in no way relieve the Vendor from final guarantee as to materials,
apparatus, workmanship and performance of the equipment and services supplied.
1.7 All correspondence and documentation shall be in English. All measurements and units shall
be in SI units.
Where necessary for a specific application, alternative units may be indicated in brackets
behind the SI units.
1.8 The VENDOR shall guarantee the equipment and all component parts against defective
workmanship and improper materials for the agreed period following the date of delivery of
the equipment or from commencement of operation as agreed. The VENDOR shall replace or
repair (the carrying out of all work including uncovering, removal, procurement and
reinstallation and construction as may be necessary) the components that are defective at their

own cost during the guarantee period at a suitable time to the COMPANY. Guarantee period
shall be as per the Contract and to be covered in commercial documentation.
2 Location and Environmental Conditions
For local conditions refer Document no. 256324-500-SP-GEN-001.
3 Scope of Supply
3.1 Equipment and Materials
Scope of supply of each Compressor shall include but not necessarily be limited to following
and mechanical datasheets.
The unit shall be supplied complete in itself including all auxiliaries and accessories required
for normal and safe operation of unit. Major items of supply are listed below.
Vendor shall, however, include any other item that may not be specifically listed but is
considered necessary for the operation of the unit and furnish particulars of the same in bid.
Scope of supply shall include but not be limited to the following:
A) Propylene Compressor (Tag No.500C-002)
Single stage, Air-cooled, Non-Lubricated, Cross-head type, Reciprocating Propylene

Compressor complete with standard equipment including the following (Model No. D291
AM3FDENSNN of CORKEN or Equivalent is preferred).
Gas ends engineered for LPG Service, Heat resistant paint on cylinder heads and in gas
passages to prevent rust.
Gas cushioned A-type channel valves.
Self venting packing case
Two compartment distance piece: Type D as per API -618,5th Edition, 2007.
Suction Filter with silencer
Knock Out drum with drain valves
Full floating Aluminium Alloy bearings.
Full floating, self adjusting, double acting, carbon filled Teflon cylinder & partition
packing rings.
Instruments and skid mounted automation panel.
V belt drive, motor pulley, anti-static V belts.
Completely enclosed non-sparking V belt guard
Foundation bolts fixing bolts, jack screw bolts, shims for compressor and motor
Slide rails for motor.
Electric motors, Local Control Panel.
Cabling and Cable termination within skid.
Base plate with Lifting & Earthing lugs
Commissioning & Start-up Spares. (for more details refer section 11.1)
List of Spares for two years trouble free operation (for more details refer section 11.1)
Inspection and testing as specified in clause 8 of this specification.
Submission of documents as specified in this document (Appendix B).
Painting, preservation, preparation for shipment and delivery at site.
Special tools if required (Bidder to provide list in the bid).
Supervision of Installation & Commissioning (Separate visit for Installation &
commissioning shall be considered).

3.2 Extra for Non Lubricated Construction

Teflon non-lubricating wearing and piston rings.
Teflon full floating piston rod packing.
Specially honed cylinders.
Special wiper rings in partition plate stuffing box.
Heat resistant paint of cylinder heads and in gas passages to prevent rust.
Oil baffle collar on piston rod.
3.3 Bottles, Accessories, Piping
Suction Liquid Separator cum Pulsation Dampner with SS demister as per ASME
Section- VIII Div. 1 with manual drain valve.
Discharge Pulsation Dampner as per ASME Section VIII Div. 1 with manual
drain valve.
1 No. Swing check type Non-return valve on the gas discharge side.
1 No. Safety relief valve full flow type on gas discharge.
Gas piping (MOC - Carbon steel for LPG and LTCS for Propylene) between suction
separator discharge flange and cylinder suction flange.
140 micron inline strainer with spool piece on gas inlet.
3.4 Instrumentation
All instruments shall be Flameproof, suitable for Zone 2 gas Group IIA / IIB.
Dial pressure gauges SS Bourdon type with 1/2 NPT connection. Isolation valves
shall be double block and bleed type and flanged, one each to be located at -
Gas suction
Gas discharge
Lube oil header
Bimetallic Temperature gauges with 2 flanged thermowell in SS 304 bar stock.
Thermo wells, one each to be located at gas suction and discharge.
Low oil pressure shutdown transmitter with flanged isolation valve (double block &
bleed type).
Low suction pressure shutdown transmitter with flanged isolation valve (double block
& bleed type).
High discharge pressure shutdown transmitter with flanged isolation valve (double
block & bleed type).
Temperature transmitter on the compressor body.
Pressure transmitter for Low cooling water pressure for Propylene Compressor.
Liquid level indicator on suction separator.
Flameproof (IIA/IIB) Solenoid valves for 0-50-100% for capacity control (Flanged
Type).
4 way two position pneumatic valve with Solenoid valves, Position Switch, tubing,
etc.
Level Transmitter, Pressure Indicator and Level indicator on KO Drum.
Cabling (to be supplied in free lengths) for field mounted Instruments 30m maximum
per instrument.
Flameproof Junction Box, as required.
Notes:
1) All instruments / piping / cabling to be supplied loose, in free lengths from vendors
works.

2) One Digital Input shall be given by Purchaser per each unit for Emergency Trip
interlock of Compressor. Vendor to provide space for termination and cable entry
into the local panel supplied along the package.
3.5 Local Control Panel

Relay based, Flameproof with solid state alarm annunciation Panel along with Local
Control Panel suitable for use in Zone 2 Gas Group IIA/IIB Area as per IS 2148.
The panel shall have all necessary standard features viz.
Motor on/off push buttons
Test/acknowledge/reset push buttons
Timer to bypass low lube oil pressure switch during start up
Manual Selector switch for 0-50-100% Capacity control
Starting interlock for Auto unloaded starting.
Fault Annunciation Table for Local Control Panel:
Sr. Fault Description Simultaneous

No. Alarm & Trip
1. Low lube oil pressure X
2. Low gas suction pressure X
3. High gas discharge pressure X
4. High liquid level in suction

Separator X
5. Spare X
6. High & Low Level alarms from Evacuation

Vessels 500BOP-052 A/B X
Note: Vendor shall provide one number common fault alarm, compressor run status and position
of 2 nos., 4 way valves (unloading position & depressurizing position) in soft signal form or as
potential free contact, to be wired by others to Client control panel. This is required only for
Propylene Compressor.
3.6 Motor
Squirrel Cage Induction Motor of suitable rating, 4-pole, flameproof ( suitable for Zone 2
Gas Group IIA / IIB )
3.7 Engineering Services

The Vendor shall provide engineering services, which shall include, but not necessarily be
limited to, the following:
Providing/Coordinating detailed design of all equipment and components within the scope
of supply.
Providing Static & Dynamic loads and anchoring plan for the design of Civil foundation
by others.

Resolving engineering queries related to the equipment and components within the scope
of supply.
Performing and coordinating all aspects of design.
Providing progress reports etc.
Providing expediting services for all sub-vendors.
Providing quality assurance including all sub-vendors with respect to ISO 9000 or
equivalent.
Supervision of Erection & Commissioning to be quoted separately.
Any technical document required for statutory approval shall be furnished by vendor.
3.8 Exclusions
The following are excluded from the Vendor's scope and will be provided by others:
Equipment foundations, however design shall be based on Vendor supplied foundation
load data.
Process piping up to Compressor suction and discharge connections.
Interconnecting power cabling and cable trays between motor terminal boxes, and
Purchasers MCC.
Interconnection of earthing bosses and underground earth conductor.
Interconnecting cables for Trip Signal from and to Control room Panel and Local Control
Panel.
4 Applicable Codes, Specifications and Standards

4.1 General
The design, fabrication, assembly, inspection, testing, painting, packing and shipment of
equipment shall be in accordance with the latest edition of the codes, specifications and
standards (including standards / specifications mentioned therein) listed in this requisition.
The Vendor shall provide an itemized list of any comments or exceptions to the specification
and its attachments. Only those comments / exceptions that are accepted by Purchaser will be
incorporated into the requisition at the time of the order.
4.2 Codes and Standards
API 618, 5th Edition,Dec2007 Reciprocating Compressors for Petroleum, Petrochemical

and Natural Gas Industries.
API 520, Part 1, 8th Edition, Sizing and Selection
2008
API 520, Part 1, 5th Edition, Installation
2003
API 521, 4th Edition, 1997 Guide for Pressure-relieving and depressurising systems.
th
API 620, 11 Edition, 2008 Design & Construction of Large welded, low pressure
storage tanks.
ASME Sec. VIII Div. I, 2007 Rules for Construction of Pressure Vessels.
ASME Sec. II Part A, 2007 Ferrous Materials Specification.
ASME B 16.5 (2003) Pipe Flanges and Flanged Fittings.
ISO 9000 (2005) Quality Management and Quality Assurance Standards.
ISO 10474 (1991) Inspection Documents
4.3 Other Specifications and Standards
Appendix - D Specification for Instrumentation in Packaged items.

256324-500-SP-ELE-010 Specification for Electric Motors
Rev. A
256324-500-SP-GEN-001 Local Conditions
Rev.A
5 Design Requirements
5.1 Mechanical Requirements
5.1.1 Compressors shall be supplied as a complete package per the requirements of this
Specification, P & ID nos. 256324-500-PID-A0-1061 (1/1) and 256324-500-PID-A0-1062
(1/1), API618 5th Edition, Dec 2007 and Mechanical Datasheet (Doc. No. 256324-500-DS-
MEC-018).
5.1.2 The compressor shall conform to API 618, as far as possible. The compressor shall be motor
driven, water-cooled type reciprocating compressor. Alternatively Vendor can offer Air-
cooled type compressor.
5.1.3 The frame shall be completely enclosed and provided with gas tight distance piece between
the cylinder frame and the crankcase. The distance pieces shall have ample opening and
shall be provided with gas tight covers for easy access to packing. Metallic and Teflon oil
wiper rings shall be provided to percent oil leakage.
5.1.4 The piston and packings shall be of full floating design. The piston rings and packing
material shall be suitable for Propylene service and shall preferably be of PTFE or
equivalent material.
5.1.5 The cylinder shall be either provided with a liner or designed to provide upto 3 mm
maximum of re-boring without affecting the design pressure of the frame.
5.1.6 The drive unit such as V belt drive shall be of antistatic and non Sparking materials. All
moving parts such as V belts, couplings etc. wherever provided shall be protected by
suitable guards. The valves shall have ample effective areas permitting low gas velocities
across valve opening. The valve shall be renewable and made of hardened steel resistant to
abrasion and corrosion.
5.2 Instrumentation Requirements
All the Instruments shall be as per specification mentioned in Appendix D.
Vendor shall submit the Complete Instrument datasheets with relevant data filled along with
bids.

Vendor to note that Instrument air (Min. 4.5 kg/cm2 and Max. 7.5 kg/cm2) is available at the
battery limit at one point.
5.3 Electrical Requirements
5.3.1 Motors shall be supplied as per attached Motor specification no. 256324-500-SP-ELE-010.
5.3.2 Vendor shall submit the Motor Datasheet with all the data filled by the Motor Manufacturer.
5.4 Piping Requirements
5.4.1 Vendor shall provide General arrangement drawing with co-ordinates for all Tie-ins.
Vendors shall clearly define the space requirement.
5.4.2 Flanged termination/ tie-in points shall be provided with companion flanges.
6 Quality Assurance
The Vendor shall maintain and use a Quality System which is based on ISO 9000 to control
the work. If the Vendor elects to sub-contract part of the work he shall ensure that only those
sub-contractors or suppliers are used who can demonstrate that they operate Quality Systems
based on ISO 9001 or ISO 9002 as applicable.
The Vendor shall give his sub-contractors or suppliers assistance in attaining the required
standard, if necessary. This shall not relieve the Vendor of his responsibility for the quality of
the finished work. The Company / Consultant reserve the right to audit the Vendors Quality
System.
The Vendor shall assign sufficient full time personnel to the project to ensure the Quality
Assurance / Quality Control System, documented in a Quality Assurance / Control Manual, is
maintained and kept up-to-date throughout the duration of any purchase order. The Vendors
Quality Assurance / Control System shall become an integral part of any purchase order.
Vendor shall organize a prefabrication / inspection meeting with the Company / Consultant.
Vendor shall submit QA plan for Purchasers and Consultants review and approval within 15
days weeks from the date of Purchase Order/LOI.
7 Inspection and Testing

7.1 Factory Inspection & Testing
Scope of Inspection:
Approval of Quality assurance plan and Inspection test plan.

Stage wise inspection as per approved quality assurance plan/ Inspection test plan.
Review of material test certificates, Lab. Test reports, etc.
Performance of the equipment.
Review of CCOE / PESO and CMRI approval certificates for the FLP items.
Review of manufacturers test certificates for the bought out items.
Any other specific items as decided by the Consultant/ TPIA to meet the tender
requirements.
Any other requirements as specified in the individual specifications.
The responsibility for inspection, certification, etc. of all materials, parts lies with the Vendor.
The Vendor shall specify all of the inspection and testing requirements in the quality assurance
plan/ Inspection test plan which shall identify the activities requiring the Company /
Consultant's / TPIA approval, review, witnessing etc.
Inspection and testing requirements shall be in accordance with API-618 5th edition, 2007 this
specification and the data sheets.
All equipment shall be inspected for compliance with:

Requirements of the specifications, data sheets and correspondence thereafter.
Applicable Codes, standards and specifications, which shall also include sub-referenced
standards therein.
Quality assurance plan/ Inspection and test plans and Procedures produced by the Vendor,
duly approved by the Owner/ Consultant.
Purchasers/ Consultants Inspectors have the right to request additional inspections or tests to
ensure that the equipment complies with this specification and all relevant codes and
standards.
All equipment shall be presented for inspection in an unpainted state except for the final
inspection. All instruments and other equipment necessary for testing shall be supplied by the
Vendor and the same shall be checked and certified by the Company / Consultants inspector.
Any defects found by the Company / Consultants appointed Inspector shall be rectified in his
presence. Where this is not possible or practical, check lists shall be prepared and signed by
the Inspector stating all pending items. Copies of these lists shall be sent to the
Company/Purchaser to enable their subsequent checking.
Mill and shop inspection shall not relieve the Vendor from his contractual responsibility for
replacing any defective material and for repairing any defective workmanship that may be
discovered in the field.
The Vendor shall be responsible for co-ordinating the inspection and testing of sub-vendor
supplied equipment, and for ensuring that the Company / Consultants representatives are
given the necessary access for inspection, and adequate warning of inspection and tests.
The Vendor (and all sub-Vendors) shall give the Company/ Consultants representatives,
without charge, all reasonable facilities and access for the purpose of inspecting the equipment
to ensure that it is manufactured in accordance with the Specification.
All spare parts shall be subjected to the same inspection standards and full material
certification as the main order.
The equipment shall not leave the Vendors factory before all discovered defects have been
rectified and without the written permission of the Company/Consultant.
Materials for all pressure retaining components & wetted components shall be certified in
accordance with ISO 10474 - 3.1B and that for non-pressure retaining components like
structural components, platforms, ladders, shall be certified in accordance with ISO 10474 -
2.2.
Final hydro test pressure shall be held for a minimum period of 30 minutes. Chloride contents
of water used for hydro test shall not exceed 20 ppm for stainless steel and chloride content
may be permitted up to 250 ppm for carbon steel.

7.2 Scope of Inspection & Certificates

DESCRIPTION CERTIFICATE WITNESS
Compressor:
a. Material test certificate for

Piston rod, connection rod,
Crankshaft and cylinder Yes -
b. Hydro test for Cylinder Yes Yes
c. Ultrasonic / Dye Penetrant

test certificate for piston rod Yes -
d. No Load Mechanical Run Test

of compressor Yes Yes
Accessories:
a. FLP Motor - Routine test

certificate as per IS 2148 ; Yes -
PESO/CCOE /CMRS certificates
b. Volume Bottles:
- Hydro test at Vendors place Yes Yes
- Material Compliance
Certificate Yes -
- Radiography and Mill Test
Certificate Yes -
c. FLP Instruments:
CMRS Certificate Yes
7.3 Vendor Requirements

Any acceptance or release of equipment following an inspection or test activity shall in no way
relieve the Vendor of his responsibility to provide guarantees as to the suitability of the
materials, workmanship and performance of the equipment in accordance with this
Requisition.
7.4 Performance Testing and Guarantee:

Compressors shall demonstrate sustained operation at conditions mentioned in the
datasheets.
All equipment and component parts shall be guaranteed by vendor against defective
material, design and workmanship for a period of one year after being put in service.
The vendor shall carry out the performance test run of the Equipments/ Machine at site
after satisfactory installation. Training of operators shall be given at site during
commissioning period without any extra cost to owner.
The vendor shall be solely responsible for smooth and trouble free performance of the
equipment during the guarantee period .Vendor shall have to carry out any rectifications/
replacement at his own cost.
7.5 Works Inspection and Notification

The supplier shall send inspection notification at least 2 weeks in advance and shall send a
minimum of fifteen (15) working days notice prior to carrying out the Factory Acceptance Test
(FAT). The notification shall contain as a minimum the following information:
Project Title, MMCI project number.
Manufacturers full address, contact name, telex / telefax / telephone numbers.
Purchase Order reference
Date of inspection
Details of equipment to be tested / inspected and the status of the equipment (whether it is
complete).
8 Vendor Documentation
8.1 Documents/Information to be supplied with offer
The Vendor shall provide the Consultant with the following information as a minimum along
with the offer. These documents shall include, but not be limited to the following:
a. The completed Table of Compliance (Appendix C).
b. Completed data sheets (Compressor & Motor), which are attached with this requisition,
with supplier data added.
c. Filled Instrument datasheets with calculations as applicable.
d. A detailed scope of supply that fully describes the equipments offered.
e. Performance curves. These curves shall include the specified duties and design conditions
as required on the enquiry data sheets.
f. Control Panel GA and details.
g. General arrangement drawings with dimensions and Load data for foundation design.
For all equipment whether base plate mounted or not, the outline drawings shall
include approximate weights, overall dimensions, size, rating and approximate
locations of main nozzles, centerline height and shaft extension details, approximate
dismantling clearances and approximate handling weights. They shall also include
the tentaive location of main electrical connections.
h. P & IDs for complete system being offered with Tie-ins identified.
i. Cause and effect diagram for the package.
j. Cross-sectional drawings including main construction features, details of seals, bearings
and other mechanical details
k. Schematics or Flow Diagrams including reasonably accurate gas or fluid flows, lube, seal
oil and control oil, all instrumentation, valves, safety devices and control schemes.
l. Commissioning Spare parts list.
m. 2-Years operation spare part list.
n. Complete list of special tools required, if any.
o. All utility consumptions such as power requirement, utility requirement like Water, Air,
N2, etc. for each Compressor.
p. Experience list as per clause 5 of this requisition.

8.2 Documents/Information to be supplied After Award of Contract

Vendor shall provide Purchaser/Consultant with documents and drawings as described in the
'General Conditions of Contract'. However, document requirements as specified in the
'Requisition for Engineering Documents (RED)' attached with Appendix B shall be followed
as a minimum requirement.
9 Manufacturing Schedule
Within 2 weeks of the receipt of the Purchase Order/ LOI/ FOI the manufacturer shall submit
detail bar chart schedule showing the dates for the following milestone activities, as minimum:
i) Issue of vendor drawings.

a. Issue for comments/approval
b. Issue of final drawings
c. Issue of O&M Manuals
ii) Equipment available for Testing.
iii) Completion of packing and readiness for dispatch.
10 Spares and Special Tools

10.1 Spares
Bidder to quote separately for spares of Compressor in the following format:
The supply of spares for start-up and commissioning
Vendor to recommend two years operation spares and furnish separate price in the offer.
(This list, as a minimum, should include all Gaskets, Complete set of Bearings, Valve
internals, Piston Ring and Packing Ring sets including Instruments as per the quantity built
in one compressor unit.)
The Vendor shall also provide all consumables during erection up to commissioning and
reliability testing. In case of any additional spares if required during commissioning stage, the
same shall be supplied by Vendor free of cost.
The Vendor shall complete and submit SPIR forms 8 weeks after Vendors acceptance of the
Purchase Order. Spare parts for the normal operation shall be selected by the End User from
the electronic version of Spare Parts Lists and Interchange ability Record (SPIR).
10.2 Special Tools

The Vendor shall supply a set of any special tools, which are required for the installation,
commissioning, operation and maintenance of the equipment being supplied. A list of special
tools shall be supplied along with the offer.
11 Packing and Shipping

For Packaging, Shipping and delivery of equipment at site and unloading requirements,
'Agreed Conditions of Contract' shall be referred.

12 Installation and Commissioning

Vendor shall provide qualified personnel to supervise the installation, testing, pre-
commissioning and commissioning. Prices for these services shall be given separately.

Appendix A: Attachments
Equipment Data Sheets
Document No. Rev. Description

A Mechanical Datasheet for Propylene
256324-500-DS-MEC-018
Compressor
Other Documents
Document No. Rev. Description

P & I Diagrams for LPG/Propylene Sick Tank
256324-500-PID-A0-1061(1/1) B
/ Wagon Unloading Compressor
P & I Diagrams for LPG Sick Cylinder
256324-500-PID-A0-1062(1/1) B
Evacuation Facility and Purging Unit.
256324-500-PIP-A0-3000 D Plot Plan
Electric Motor Datasheet (Part of
- - Specification for Electric Motors 256324-
500-SP-ELE-010)
- - Differential Pressure Transmitter (Level)
(Blank Datasheet Format)
- - Pressure Gauge (Blank Datasheet Format)
- - Pressure Transmitter (Blank Datasheet
Format)
- - Temperature Transmitter (Blank Datasheet
Format)
- - Pressure Safety Valve (Blank Datasheet
Format)

Appendix B: Requisition of Engineering Documents (Red Form)
Owner/Purchasers Office Consultants Office
HINDUSTAN PETROLEUM CORPORATION LTD. Mott MacDonald Consultants (India) Pvt. Ltd
Krishna Shree, 2nd Floor, Gandhi Nagar, 1st Main Road-Adyar, Kothari House, CTS No. 185 Off Andheri Kurla Road, Andheri (East)
Chennai 600 020 Mumbai 400 059, India ; Tel 09122 3083 5000
DRAWINGS Required number for TIMING FOR SUBMITTAL
Approval Final issue - for approval 2 weeks after order date
Approval drawings / Final drawings to be submitted Prints Disk Prints - final issue 2 weeks after approval date
under cover of an ADS form / FDS form respectively Transpa Documents shall be submitted to:
rencies
Vendor Doc. Schedule 4 1 3
General arrangement 4 1 3
Foundation loading and bolt location plan 4 1 3
Cross section drawing with BOM and MOC 4 1 3
Completed data sheets of all Main & Auxiliary 4 1 3
equipments
Performance curves for Compressor and motors 4 1 3
Motor Speed/Torque curves 4 1 3
Coupling GA drawings 4 1 3
Motor GA drawing & Terminal Box Drawing 4 1 3
P&ID for the Package with the battery limit 4 1 3
Cause & Effect diagarm 4 1 3
Equipment list 4 3
Utility Consumption list 4 3
Functional Description of Control System 4 1 3
Lay out & Construction details of Local Instrument 4 1 3
Panels
Electrical Cable Schedule 4 3
Wiring & Termination diagram 4 1 3
Instrument & Junction Box Location Plan 4 1 3
Instrument Cable Termination details Junction Boxes 4 1 3
Control Narrative 4 1 3
Lifting beam/frame details along with calculations 4 1 3
List & Drawings of special tools 4 1 3
Instruments Datasheets 4 1 3
Production Schedule 4
Progress Report 4 Monthly Once.
Performance Test Procedure including FAT, NDT 4 1 3
Procedures, WPS, PQR, WPQ
Quality plan satisfying ISO 9000 requirements 4 1 3
Manufacturing, inspection & testing sequence plan 4
SPARE PARTS DOCUMENTS 1 3
SPIR forms including 1 transparency 1 3
Lubrication schedules 1 3
TEST AND INSPECTION DOCUMENTS Prints
Documents to be submitted under transmittal Documents shall be submitted to:
Manufacturing reports 1 3
Material certificates to: ISO 10474 - 3.1B 1 3
Electrical certificates to Cenelec / Baseefa/ATEX Compliance/CMRI 1 3
Static / dynamic balancing certificates 1 3 Purchasing Office via courier service within 4 weeks
Performance test Report & Performance Curves 1 3 of relevant test / inspection.
Heat treatment graphs, if applicable 1 3
Calibration certificates of Instruments 1 3

OPERATING DOCUMENTS Purchasing Office via courier service not later than
time of dispatch of equipment.
Installation instructions 1 3
Operating instructions 1 3 Combine into one manual
Maintenance instructions 1 3
ADDITIONAL REQUIREMENTS:
1. Referenced standards / codes shall be the latest issue unless otherwise stated.
Invoice must certify that the drawings and engineering documents specified Units / dimensions to be used on Engineering documents shall be SI.
above have been dispatched to all parties concerned. The documents shall be in English. Description on drawings and similar
Any deviation from the timing for submittal of documents shall be notified to documents may be in other languages provided English translations are
the Approval / Distribution Offices by fax or E mail. also given.
Shop fabrication shall not be started before the required approval drawings Drawings and documents shall be suitable for microfilming and comply
have been released for construction by the party concerned, unless otherwise with accepted national or international standards for the preparation of
stated on the "Approval Drawing Specification". technical drawings. Only the following standard sizes should be used: A4,
Each document shall bear the item / tag and order reference number and be A3, A2, A1.
dispatched by air mail, unless other instructions are stated on the RED.

Appendix C: Table of Compliance

The Vendor shall confirm below their acceptance of all the clauses contained in the specification or
otherwise make clarifications or exceptions that shall be noted below:-
CLIENT: HINDUSTAN PETROLEUM VENDOR REF. NO.

CORPORATION LTD.
REF. NO.: 256324-500-RQ-MEC-006 Rev. B
CLAUSE CONFORMS ALTERNATIVE CLARIFICATION
NO. Y/N Y/N
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
2.0
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
4.0
4.1
4.2
4.3
5.0
5.1
5.2
5.3
5.4
6.0
7.0
7.1
7.2
CLIENT: HINDUSTAN PETROLEUM VENDOR REF. NO.

CORPORATION LTD.
REF. NO.: 256324-500-RQ-MEC-006 Rev. B
CLAUSE CONFORMS ALTERNATIVE CLARIFICATION
NO. Y/N Y/N
7.3
7.4
7.5
8.0
8.1
8.2
9.0
10.0
10.1
10.2
11.0
12.0
Appendix A
Appendix B
Appendix C
Appendix D
Appendix D: Instrumentation Design Requirements
1.0 Hazardous Area Classification & Protection

Instruments located in hazardous area shall be certified to meet or exceed the electrical
hazardous area defined by Area classification.
All instruments shall comply as per hazardous area classification as mentioned in the
mechanical datasheets. Instruments certified for use in the specified hazardous area
classification shall be recognized by authority like FM, CENELEC, PTB, BASSEFA, ATEX
etc. All solenoid valves and where IS circuits are not available due to higher voltage level shall
be explosion proof and certified for use in specified hazardous area.
Each electrical equipment to be used in Hazardous shall be marked with type of protection, gas
group and temperature class as well.
2.0 Ingress protection / Weather Proof
The Following minimum degree of Protection as per IEC 60529 shall apply to all the
Instrumentation equipment.
Indoor Equipment/Panel - IP 42
Outdoor Equipment/Panel - IP 65
In addition to the above, field Instruments located outdoors, exposed to direct sunlight and not
meeting the plant environmental conditions shall be protected with sunshades.
3.0 General Requirement for Instrument and Control System
Bidder shall provide all transmitter of SMART, two wire type, 4-20 mA output with HART
protocol, 24 VDC loop powered, with local digital indicator.
Transmitter shall have +/- 0.25% of full scale accuracy as minimum & Gauge shall have +/-1%
of full scale accuracy as minimum.
The identifying tag number shall be neatly & clearly marked on each instrument.
Dial size of Pressure gauge shall be 150 mm and Temperature gauge shall be 100mm. The scale
plates shall be aluminium or laminated plastic with white face & black figures.
Pressure gauge and Temperature gauge range shall be within 75% of full scale range. Pressure
Gauge exposed to vacuum shall be capable of withstanding full vacuum.
Instruments shall meet the minimum requirements of IP 65 for ingress protection in accordance
with IEC 60529. In general, no process switches shall be used, instead transmitters with local
indication shall be used.
All instruments shall be individually valved by block and bleed valve at the tap off to allow
depressurization, in-place testing and maintenance of the instrument without shutting down the
equipment/package unit.
Cable entry to all instruments shall be inch NPT. EExd certified adaptors are acceptable
where NPT cable entries are not provided. . Spare cable entries shall be suitably plugged as
per the hazardous area classification with stopping plugs.
Materials of construction for instrument equipment shall be compatible to the corrosion
resistance, pressure and temperature conditions of the process fluids handled. Generally, all
instrument wetted parts, in contact with the process fluid shall be SS316 (minimum), or of a
material equal to or better than that of the related vessel or line.
Solenoid valve coil shall be rated for continuous with class F insulation. In general, Solenoid
valves shall be certified EExd for Zone 1 applications. Solenoid coils shall be of 24V DC, low
power consumption, 12 W maximum. It shall be provided with suppression diode mounted in
solenoid assembly.
Proper access shall be provided from grade or Platform for field devices (Transmitters, Valves,
Temperature sensors etc) for operation & maintenance. If necessary, additional maintenance
platforms specifically for instruments shall be provided.
Normal mode of operation for the unit shall be start/stop from local panel.
For all differential pressure (level and pressure) instruments, single block and bleed type valves
shall be provided for pipe / vessel class up to 600#
Vendor shall provide configuration HART extractor files (DTM) for all HART transmitters.
For the Instrument process connection details refer to the Doc: - 254624-500-SP-INT-002
4.0 The Supplement Requirements for Supply / Services of Instrument and Control
Packaged equipment.
Instrument data sheets shall be prepared by the vendor for all package unit instrumentation as
per MMCI format (Draft format attached) and submitted to the Owner/Consultant for approval.
Instruments on the package unit shall be supplied as per specifications and from Approved
vendor list. Vendor shall submit brief description regarding various controls in the package
along with the offer. The Vendor shall clearly highlight any exceptions to our specifications in
their offer.
Vendor shall include in his scope of supply documentation and calibration certificates for all the
instruments supplied in the package unit.
4.1 Pressure
All pressure gauges shall have 1/2" NPT (M) connections. Process connections at take off point
for pressure transmitters shall be minimum 1/2 for clean Gas/Water/N2 service. The use of
reducing bushings to connect pressure instruments to process lines is not permitted.
Local pressure gauges shall normally have a weather proof stainless steel case with a solid front
and rubber blow-out disc of 25 mm (1") diameter. The lens shall be shatter proof glass.
Pressure gauge pointers shall be balanced and provided with a micrometer adjustment so that
zero shift may be corrected. All gauges shall be provided with Kg/cm2 indication in black letters
on white background.
Pressure gauges for pulsating or vibrating service, and on the discharge of all pumps, shall be
liquid (Glycerine) filled with internal zero adjustment. The full face shall be covered by the
liquid and the filling plug shall act as a blow out seal with internal pressure of 10 psig or greater.
Pressure gauges shall be ranged such that normal operating is between 30 70% of scale; except
on pulsating service where it shall be restricted to 60 % of scale.
All pressure gauges shall have SS 316 bourdon tube and movement as a minimum.
The pressure and differential pressure measuring instruments shall be located below the taps for
liquids and condensable.
Pressure Transmitter shall be 24V DC loop powered, 2 wire, with 4 to 20 mA, HART protocol
output signal.
Over range protection shall be provided for at least 130% the maximum operating pressure.
Also a vacuum protection shall be provided for complete vacuum.
As far as possible all Pressure switches application shall utilize pressure transmitters.
All Pressure and differential pressure measurements in SS 316 construction with block and
bleed facility (e.g. using standard 2-valve, 3-valve or 5-valve instrument manifold as
applicable).
4.2 Temperature
Locally mounted indicators/gauges of process temperatures shall be bimetallic thermometers

with 100 mm dial, every-angle heads and stainless steel cases.

Temperature sensing elements shall be always mounted in thermo well and all Temperature
sensing elements used shall be duplex type.
Material for thermowells shall be minimum ANSI type 316 stainless steel, machined from single
bar stock in a tapered configuration. Better materials and ratings shall be specified as required
by the Piping Material Specification.
3 wire RTD, Pt. 100, shall be used for temperature sensing in Motor bearing / winding
applications. The KW rating of the motor shall be the criteria for determining application of
temperature sensing in motor. For Equipments having high vibrations RTD's with remote
mounted heads shall be provided.
Whenever RTDs are provided for motors, they shall supplied completely with rail mounted
(inside Junction box) temperature transmitters, 2 wire, loop powered, 24 VDC, 4-20mA, which
will be hardwired to OWNER ESD system.
Standard thermo well lengths for piping shall be 230mm ( for pipe size 4 ) or 255 mm ( for
pipe size 6 ). The minimum flange size shall be 2" with pressure rating as per piping class /
design pressure. Standard thermowell lengths for pressure vessels shall be 455 mm. Lagging
shall be standard length, except where insulation thickness is greater, then lagging shall be 1
longer than thickness of insulation. Refer Annexure-B (Drawing no. 256324-500-INT-5975) for
typical Thermowell drawing.
Field indicating type transmitters within the sensor termination assembly shall be used to the
maximum extent possible.
Temperature Transmitter shall be 24 VDC loop powered, 2 wire, with 4 to 20 mA, HART
Protocol output signal. The temperature measuring circuit for transmitters for RTD inputs shall
be the resistance bridge circuit type.
Consideration shall be given to ambient temperature and/or temperature radiation wherever the
in head transmitter is used. If an in head mounting of the transmitter is to be avoided due to
this consideration, the transmitter is to be mounted local to the sensor.
Calculation shall be provided by vendor for thermowell Vortex shedding resonance (WAKE)
frequency to ensure no stress cracking will occur. Wake frequency shall not exceed 80% of the
natural frequency of thermowell at maximum fluid velocity.
4.3 Level
Displacer type instrument gauge with transmitter can be used for level measurements including
liquid to liquid interface.
Level Transmitter shall be 24V DC loop powered, 2 wire, with 4 to 20 mA, HART protocol
output signal.
Top mounted Level Transmitters shall be used based on Owner/Consultant approval.
Other special type of level instruments like ultrasonic type, capacitance type, RF admittance,
nucleonic type shall be used as necessitated by application requirements with prior approval
from Owner/Consultant.
4.4 Safety valves
The overpressure protection devices shall be installed to meet the requirements and sizing of
safety devices for vessels, piping and equipment in accordance with the ASME Pressure Vessel
Code, Section I and VIII, ANSI B31.3, API-RP520 and API-RP521.
Safety and relief valves shall be direct spring loaded type. For liquid service and non-coded
duties i.e. thermal relief they can be semi-nozzle with screw connections. Plain closed bonnets
shall be specified, with a tapped and plugged vent for easy conversion to balanced type valves.
Exposed spring bonnets shall be specified for steam service above 200C as required by ASME
Boiler and Pressure Vessel Code, Section I.

As a minimum all relief valves shall have carbon steel bodies with stainless steel trim, but in all
cases the material shall conform to the piping specification. When the set pressure is within 10%
of the normal working pressure, balanced bellow valve shall be used.
Screwed connections shall be supplied on valves with inlets 3/4" and smaller. Threaded
connections on valves shall be ANSI B1.20.1 pipe threaded ends. Flanged connections shall be
provided on valves, 1" inlet size or larger. Minimum inlet rating shall be ANSI Class 150.
Valve flanges shall match the rating and facing of mating flanges on vessels or piping. Body
flanges shall be in accordance with ANSI B16.5 except for the thickness.
Pressure and vacuum relief valves for storage tanks shall normally be of the weight loaded or
pilot operated type, and sized in accordance with API 620 and API 2000.
4.5 Installation for Instruments
All instruments installation shall follow API 551.

Process tubing between primary pressure connections and instruments or instrument manifolds
shall be inch OD, SS 316 tubes, wall thickness 0.035 inch as a minimum. Double Ferrule
Swagelok/Parker type fittings in ASTM 316 stainless steel must be strictly enforced as a
minimum. Other materials may be used based on process requirement. Where inch OD
connections are required by the instrument or instrument manifold, reducing fitting shall be used
at the instrument.
Instrument process tubing shall conform to ASTM A269, type 316 stainless steel, seamless,
annealed and pickled.
Tubing fittings shall be SS316 Swagelok compression type fittings, or Owner/Consultant
approved. All compression fittings shall be of double ferrule design.
Where SS316 stainless steel is deemed unsuitable, the vendor may propose an alternative, with
justification, for approval by Owner/Consultant.
Instruments located outside of control panels shall be installed as close as practicable to the
process connection and may be surface, yoke, universal 2 inch pipe, or bracket mounted.
Instruments shall not be supported by process piping, handrails or equipment subject to
vibration. Instrument supports shall be welded where possible not bolted, to the platform.
Instrument supports shall not be welded on to the equipment, piping, railings and ladders.
Instrument supports shall be located at an elevation where the centre line of the instrument is
1500mm above grade, walkways or platform and within reasonable reach for servicing.
4.6 Special Tools
Vendor shall identify / supply any special tools required for the package unit equipment as
part of the package wherever required. Programming/configuration tools shall be provided (if
required) & all licensed software / functional / application software shall be included in the
supply.
Any special cables for data communication shall be supplied along with the configuration
tools.
4.7 Spares
The Vendor shall include with the quotation following spares along with relevant cross
sectional drawings and parts list
Mandatory spares recommended by manufacturer
Spare parts for start-up / commissioning.
5.0 Approved Vendors List for Instruments

ELECTRONIC SMART TRANSMITTERS (PT, DPT, LT, TT)

SR.NO. NAME OF VENDOR
1. EMERSON PROCESS MANAGEMENT
2. ENDRESS & HAUSER
3. YOKOGAWA
4. HONEYWELL
PRESSURE GAUGE, LEVEL GAUGE & ACCESSORIES

SR.NO. NAME OF VENDOR
1 WIKA INSTRUMENTS INDIA LTD.
2 PRECISION INDUSTRIES (ASHCROFT )
3 DRESSER PRODUCTS
4 JERGUSON
5 CLARKE-RELIANCE
6 ENDRESS & HAUSER
JUNCTION BOXES & CABLE GLANDS (FLAME PROOF)

SR.NO NAME OF VENDOR
1. BALIGA LIGHTING EQUIPMENTS LIMITED
2. FLAMEPROOF EQUIPMENTS PVT. LTD.
3 SUDHIR SWITCHGEARS
4 CEAG
5 STHAL
6 FLEXPRO ELECTRICALS
7 FCG POWER INDUSTRIES PVT. LTD
SOLENOID VALVES
SR.NO NAME OF VENDOR
ASCO
1.
2. HERION
3. NORGREN
4. ROTEX


Tech. Spec - For Propylene Compressor PDF

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VISAKH MARKETING INSTALLATION RESITEMENT

PROJECT - LPG TERMINAL

Doc No: 256324-500-RQ-MEC-006 Rev: B Page 1 of 26

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Client HINDUSTAN PETROLEUM CORPORATION LTD.

Issue and Revision Record:

Rev Date Originator Checked Approved Description

A 02/06/09 SVJ SPW PJC Issued for Comments

Issued for Comments LPG

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List of Content Page No

2 Location and Environmental Conditions 6

4 Applicable Codes, Specifications and Standards 9

7 Inspection and Testing 11

Doc No: 256324-500-RQ-MEC-006 Rev: B Page 4 of 26

10 Spares and Special Tools 15

11 Packing and Shipping 15

12 Installation and Commissioning 16

Appendix B: Requisition of Engineering Documents (Red Form) 18

Appendix C: Table of Compliance 20

Appendix D: Instrumentation Design Requirements 21

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The List of Compressors is as follows:

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A) Propylene Compressor (Tag No.500C-002)

Single stage, Air-cooled, Non-Lubricated, Cross-head type, Reciprocating Propylene

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3.2 Extra for Non Lubricated Construction

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3.5 Local Control Panel

Fault Annunciation Table for Local Control Panel:

Sr. Fault Description Simultaneous

1. Low lube oil pressure X

2. Low gas suction pressure X

3. High gas discharge pressure X

4. High liquid level in suction

6. High & Low Level alarms from Evacuation

3.7 Engineering Services

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4 Applicable Codes, Specifications and Standards

4.2 Codes and Standards

API 618, 5th Edition,Dec2007 Reciprocating Compressors for Petroleum, Petrochemical

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4.3 Other Specifications and Standards

Appendix - D Specification for Instrumentation in Packaged items.

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7 Inspection and Testing

Approval of Quality assurance plan and Inspection test plan.

Doc No: 256324-500-RQ-MEC-006 Rev: B Page 12 of 26

All equipment shall be inspected for compliance with:

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7.2 Scope of Inspection & Certificates

a. Material test certificate for