Annexure-B

Document No.
Copy No.

: DRDL/DOAD/ATF/HWT/55
:

No. of pages : 54 (including title page)

TENDER DOCUMENT
FOR
HIGH PRESSURE SYSTEM
OF
HYPERSONIC WIND TUNNEL

Date of issue : Dec, 2011

CONTENTS
1. INTRODUCTION

. 2

2. DESCRIPTION OF THE OVERALL FACILITY AND PROCESS

2.1. DESCRIPTION OF THE FACILITY

2.2. WIND TUNNEL WORKING PROCESS

3. LOCATION AND LAY-OUT OF THE FACILITY ..
3.1. LAY-OUT OF THE FACILITY

..

4
4
5
5
6

4. SYSTEM OBJECTIVES AND CONFIGURATION ..

5. SCOPE OF CONTRACT

...

5.1. SCOPE OF SERVICES BY THE DEPARTMENT

5.2. SCOPE OF WORK BY CONTRACTOR
6. SPECIFICATIONS

..

..

....

8
11
17

6.1. SPECIFICATION FOR AIR COMPRESSOR SYSTEM

..

17

6.2. PRESSURE VESSEL FOR AIR STORAGE SYSTEM

..

23

6.3. PRESSURE VESSEL FOR INSTRUMENT AIR SYSTEM .. 30

6.4. MANUAL VALVES

...............................................................

6.5. ELECTRO-PNEUMATIC VALVES

6.6. PIPES

30

..

32

........................................... ..

34

6.7. GASKET ............................................... 35

6.8. PIPE FITTINGS

.........................

6.9. INSTRUMENTATION AND CONTROL SYSTEM

35

........... 36

6.10. FABRICATION, ERECTION AND COMMISSIONING .. 37

7. DOCUMENTATION

..

40

8. STANDARDS FOLLOWED

..

41

9. LIST OF DELIVERABLES

..

42

10. ACCEPTANCE TEST PLAN ..

44

1. INTRODUCTION
A high pressure pneumatic system to supply compressed dry air for hypersonic wind
tunnel is proposed. The system shall consist of air compressor trains to compress
atmospheric air to 30 MPa(g) pressure with dryer and storage volume of capacity
approximately 80 m3. The system shall be capable of supplying air at maximum mass
flow rate of 180 kg/s. The scope of the contract includes design, engineering of the
system, procurement of various standard components/sub systems, and fabrication of
pipeline etc., erection at site Shamirpet, Hyderabad, and demonstration of the
performance, training and handing over for normal operation.

The High Pressure System (HPS) consists of the following sub-systems:

Feed air compressor

Booster Compressor

Dehydration package in between feed & booster compressors

Highpressure air storage vessels with associated piping, manifold and skid
frame work and interconnecting piping between compressors and storage
vessels

Electrical system

Instrument air system

Instrumentation & control system

Fluid circuits

Cooling water system

Air purification system

Lubrication system

The proposal is requested for establishing on a turnkey basis the entire High pressure
system comprising of the sub-systems mentioned above.

The preliminary Process and Instrumentation Diagrams (P&IDs), along with the
preliminary sizes of the fluid circuits and an indicative layout of the facility are given in
this document. The details of Contractors scope of work shall include the following.
2

Detailed design of all the subsystems and components of the High Pressure
System (HPS).

Detailed engineering of the entire HPS and generation of Purchase specifications.

Purchase of all materials such as equipments, flow components, instruments,

pipes, pipe fittings, etc.

Fabrication, testing and co-ordination for inspection of the system at the

Contractors factory.

Transportation of materials to and storage at the Departments site.

Erection, testing and co-ordination for inspection of the entire system at the
Departments site.

Commissioning

Some of the key words used in this document are defined as follows.

Department shall mean and include the President of India acting through the
Director, DRDL and any representative (s) of the Department duly authorized on his
behalf.

Contractor shall mean the individual or firm or company whether incorporated or

not, chosen by the Department among the bidders to this tender enquiry, undertaking the works and shall include the legal representatives of such individuals or the
persons composing such firm or company, of the successors of such firm or
company and the permitted assignee of such individual or firm (s) or company.

Contract shall mean the formal agreement to be executed between the President
of India and the bidder, whom the Department may choose, based on the
documents forming this tender enquiry and acceptance thereof by the bidder and
together with the documents as referred to therein including the specifications,
designs, drawings and instructions issued from time to time by the Department.

Site shall mean the land and or other places at Hyderabad on which work is to be
executed under the contract, which may be allotted by the Department for the
purpose of carrying out the work.

Materials shall mean all the items required for realizing and forming part of the
HPS, including raw materials, semi-finished & finished products and subassemblies,
which are manufactured by the Contractor or their sub-Contractors or brought-out
3

from their sub-vendors, such as equipments, flow components, pipes, pipe fittings,
instruments, etc.

Facility shall mean the proposed Wind Tunnel Facility.

All the pressure values specified in this document are in absolute scale, unless
specified otherwise.

2. DESCRIPTION OF THE OVERALL FACILITY AND PROCESS

2.1.

DESCRIPTION OF THE FACILITY

The tunnel is of intermittent type and uses air as working fluid. The facility would be
used to carry out aero thermal studies of model at different flow conditions. A block
diagram of the facility is given in Fig 1. The major systems that constitute the facility
are:

High pressure system (HPS)

Wind Tunnel System

Pressure regulating system (PRS)
Air Heating system
Tunnel System
Instrumentation and Control system

Vacuum System(VS)

Civil and Electrical Infrastructure

The High pressure system comprises of air compressor system, high-pressure air
storage, valves, piping and will be used to compress air to required storage pressure
and store to air storage. The pressure regulating system will be used for pressure
reduction from high pressure storage to required test pressure in settling chamber. The
heater is used to heat the air to the required temperature. Without heating, the air
expanding in the tunnel nozzle to high velocity will be cooled to such low temperatures,
which results in air to liquefy. Storage heater is proposed. The heater bed is heated by
combustion products from a burner.

The settling chamber is used to get a low-velocity, homogeneous flow free of

turbulence. A nozzle accelerates the air stream to the specified different speed. To get a
given speed of air stream, a unique nozzle configuration is employed. So, different
nozzles are used to get different speed of air stream. The test section contains the
model to be characterized and associated instrumentation. A diffuser decelerates the air
from test section and air is collected in the vacuum spheres. Vacuum pumps are used
to evacuate the vacuum spheres, before and after the test.

2.2.

WIND TUNNEL WORKING PROCESS

The Typical sequence of operations for one blow-down is as follows: Atmospheric air is
compressed, dried, recompressed and charged into the high-pressure air storage
vessels. Simultaneously the cored bed heater is heated-up with combustion products
from a burner and the vacuum spheres are evacuated by the vacuum pumps. When the
required initial storage pressure is reached in the pressure vessels, the pressure
regulating unit is set for the required test pressure in settling chamber. When all the
systems are ready, the blow-down starts. Air is supplied from the pressure vessels at a
pressure regulated by the pressure regulating system and is heated as it flows through
the heater. When the pressure in the heater reaches a specified value, a valve
downstream of heater is opened and hot air passes through the settling chamber. The
high-pressure, high-temperature air then expands through a nozzle to give the required
controlled environment in the test section. The model to be characterized is injected into
the test section. The air flows around the model in the test section. After the test section
air is decelerated in a diffuser and passes through after cooler and collected into the
vacuum spheres. When the pressure in the vacuum spheres reach a specified level the
blow-down is stopped. The cycle of operations is repeated. The duration of blow-down
is 20 seconds. Four tests are planned per day.

3. LOCATION AND LAY-OUT OF THE FACILITY

The facility will be established at Shamirpet (Badamafi), Hyderabad, Andhra Pradesh
state, India. The nearest seaport is at Chennai, which is 700 km away towards the
south-east.

3.1. LAY-OUT OF THE FACILITY

The Motor control centre (MCC) is available 10 m (approx) away from the maintenance
hall. The size of MCC is 12m x 10m. Water point is available 10m (approx) from water
tank. Compressor room size is 25m x 22m, which is available for compressor housing.
The size of air storage system shed is 30m x 30m. The equipment layout of the facility
is given in Fig 2.

4. SYSTEM OBJECTIVES AND CONFUGURATION

HPS is intended to supply air of specified quality and required flow parameters to the
tunnel. An indicative block diagram of HPS is given in Fig.3. A preliminary P & ID of the
HPS is given in Fig.4. The objectives to be complied with by each of the sub-systems
and the configuration to which they are to be designed are as follows:

4.1.

HIGH PRESSURE AIR COMPRESSOR SYSTEM

The compressor system is intended to fill the high-pressure air storage vessels with dry
air to maximum pressure of 30 MPa (g). The compressor system comprises the
following:

Two high-pressure air compressor trains comprising of Feed & Booster

compressors each with a capacity to deliver 2000 Nm3/hr of dry, oil free air
with discharge pressure sufficient to fill the pressure vessels to 30 MPa(g).

Feed and Booster compressor should have separate driver (Electrical)

Equipment to remove oil and water vapor.

All interconnecting piping, valves, coolers, safety devices, buffer vessels etc.

Complete instrumentation and control package including command and

measurement for the compressor system.

Cooling water system containing cooling water pumps, cooling towers with
associated valves and piping.

4.2.

HIGH PRESSURE AIR STORAGE SYSTEM

The P & ID of a module of air storage system is shown in Fig. 5. This air storage system
stores air at 30 MPa(g) before it is supplied for the downstream operations. The
configuration of the storage system is as follows:

Thirty six pressure vessels of capacity of 2.2m3 water volume each and
maximum operating pressure of 30 MPa (g) constitute the storage system. The
vessels are grouped into six modules and each module consisting of six vessels
is mounted in a structural skid with support for the vessels. The filling ends of the
vessels are connected by piping to a common filling header. The delivery ends of
the vessels are provided with flange and are connected to the delivery manifolds.
The delivery manifolds are connected to the delivery header. Necessary manual
isolation valves are provided in the filling and delivery sides.

Each module is provided with two safety valves. The outlets from the safety
devices are routed to a safe location for discharge to the atmosphere. The filling
and delivery lines for each module are equipped with 1 pressure gauge each.
The delivery line for each module is equipped with 1 pressure transmitter. The
filling header is provided with a manual vent valve. The delivery header is
equipped with 2 pressure transmitters and a temperature transmitter. The
discharge header is provided with an electro-pneumatically operated valve (EP
valves) to vent air from the storage system in case of need.

4.3.

FLUID CIRCUITS

The fluid circuits connect the various subsystems of HPS like compressor and air
storage vessels. Fluid circuits involve various flow components like manual valves,
electro-pneumatic (EP) valves, pressure gauges, safety devices etc. Pipes, fittings and
flow components with stainless steel as materials of construction are planned for air
circuits and the same with carbon steel as material of construction are planned for the
water circuits of HPS.

4.4.

ELECTRICAL SYSTEM

The electrical system is intended to supply electrical power to the various field
equipments like compressors, pumps, fans and blowers etc... Power is fed down from
the state power utility to a substation available in the campus. From MCC, power is fed
to various field equipments. The systems include MCC panels, field panels, starters
(soft starters), circuit breakers, switches, protective devices, cabling, earthing and all
necessary HT & LT switch gear.

4.5.

INSTRUMENT AIR SUPPLY

Instrument air system is intended to provide air to operate EP valves and control valves
and also to supply reference air for dome loaded regulators, if any, in the HPS and other
systems. A single air receiver of 10m3 volume and 1 MPa(g) maximum working
pressure is planned. It is charged by a separate air compressor (1 MPa(g),
~600 Nm3/hour, non lubricated) and air dryer with dew point -400 C. The P & ID of the
instrument air pressure vessel is shown in Fig.6. A fluid circuit to regulate air pressure
and supply to each valve / regulator is a part of instrument air system. In addition to
operate valves the air shall be used for general utility purpose like cleaning of
machineries and operating the pneumatic tools in maintenance workshop. In addition to
the valves of HPS, the valves in the tunnel system are also provided air to operate from
this pressure vessel.

5. SCOPE OF CONTRACT
The scope of the contract and the demarcation of responsibilities between the
Department and the Contractor in realization of HPS are given in this section.

5.1. SCOPE OF SERVICES BY THE DEPARTMENT

In order to realize the HPS, the Department will provide the following services:

5.1.1.

PRELIMINARY DESIGN & DESIGN REVIEW

The conceptual design of the system has been done by the Department. In this
document, the P&ID, along with tentative sizes of the fluid circuits are given. The

specification of the system, along with the list of flow components & instruments, is
given in the document. These details are given only for price estimation. There may be
changes in size etc. based on the design carried out by the Contractor.
The contractor shall carry out the preliminary design of the system within a period of
one month. The design done by the Contractor shall be reviewed and approved by the
Department. Department shall organize the Preliminary Design Review (PDR) meeting
at the Department within 2 weeks from the receipt of design report with all relevant
details from the Contractor. The objective of the design review is to arrive at a
consensus between the Department and the Contractor on the design of HPS and to
freeze the input data for the detailed engineering to be done by the Contractor. The
design review shall primarily address the following issues:

Design of HPS to comply with the specified functional requirements given in

section 6.

Adequacy of the size of fluid circuits, comprising pipe-lines, flow components,

instruments, etc to comply with the specified process parameters.

Adequacy of the in-built safety features.

5.1.2.

EQUIPMENT LAY-OUT

The location plan and equipment lay-out of HPS are given in this document. Based on
this equipment layout and the P&ID, the Contractor shall prepare the pipeline lay-out &
isometric drawings and derive the lengths of the pipe-lines required to connect between
the various inter-faces as per the P&IDs.

5.1.3.

REVIEW OF DETAILED ENGINEERING

Upon award of contract and Preliminary Design Review, the contractor shall carry out
detailed engineering. Document with drawings and all details will be submitted. The
Department will review the detailed engineering done by the Contractor.

5.1.4.

MAJOR CIVIL WORKS

The Department will carry out the following major civil works:

Site preparation and road

Building

Lighting and PH works

Motor Control Center (building only)

However, the Contractor shall provide the details of the area required, foundation, etc.

5.1.5.

SERVICES DURING ERECTION AND COMMISSIONING

During erection and commissioning, the Department will provide the following services:

Electricity for erection on chargeable basis at the tariff rate prevailing at the
time of consumption

5.1.6.

INSTRUMENTATION SYSTEM

The transmitters (TT1, PT1 & PT2) shall be provided by the contractor. The
cabling, signal conditioner and data acquisition / recording for the
transmitters is in the scope of the department.

Command system including cabling and control room equipments only for
EGV 4 control valve is in the scope of department. Controlling of other valve
is in the scope of contractor. However, all the valves shall be supplied by the
contractor.

The instrumentation (measurement/command/control) for the compressor system shall

be responsibility of the Contractor.

5.1.7.

ELECTRICAL SYSTEM

Department will provide a power supply point at the Motor Control Center (MCC). From
this point, proper distribution of power to field equipments like compressors, pumps and
fans/blowers shall be the responsibility of the Contractor. The total power requirement,
voltage/ current rating have to be furnished by the Contractor.

5.1.8.

WATER SUPPLY

The Department will provide water reservoir and pipeline, which will be terminated at a
suitable point near the HPS system. The distribution of water and realization of the

10

cooling water system shall be the responsibility of the Contractor. The contractor has to
specify the quantity and quality of water requirement for Departments planning. A
centralized water softening plant will be planned by the department.

5.2. SCOPE OF WORK BY CONTRACTOR

The scope of work to be executed by the Contractor for the realization of HPS is given
in this section. The bidder is required to submit a complete quotation for the entire
works mentioned herein. If required, the Contractor may engage subcontractors for
executing part of the work. However, Prime contractor will be solely responsible for
executing the work. The bidder shall provide in the quotation, the list of subcontractors
proposed to be engaged for approval by the Department.
Note: For all the components selected, service support and spares shall be
available in India.

5.2.1.

PRELIMINARY DESIGN

The Contractor shall carry out the preliminary design of the HPS and prepare a design
document containing details, with calculations of the sizing of the fluid circuits
comprising the pipe-lines, flow components, instruments, etc. within a period of one
month of awarding the contract. The design shall be generally as per the configuration
given in section 4 and shall meet the objective specification given in section 6. The
design calculations are to be based on the codes/standards mentioned in various
section of this document. In such cases where the Contractor uses alternative codes/
standards, it shall be their responsibility to submit a copy of such codes/ standards in
English language to the Department during design review.

5.2.2.

DETAILED ENGINEERING

Based on the design approved by the Department after Preliminary Design Review
(PDR), the Contractor shall carry out detailed engineering, which shall comprise the
following:
a. Pipe-line lay-out: The detailed lay-out (top view) drawings (indicating skeletal
dimensions to scale) of the pipe-lines of all the process fluid circuits and pipe-

11

lines and impulse tubes of instrumentation system shall be made. A master pipeline lay-out shall be made covering all the pipe-lines over the entire facility area in
a single drawing. For the sake of better legibility, segmental pipe-line lay-out
drawings shall be made in convenient number of segments of any area showing
all the pipe-lines in a magnified scale. The drawings shall be made on
appropriate software and provided in Compact Discs (CDs).
b. Pipe-line isometrics: The 3-dimensional isometric drawings of the individual pipeline segment and the necessary pipe stress analysis shall be made. The
drawings shall be fully dimensioned and show the locations of fittings, flow
components, instruments, pipe supports, etc. Each isometric drawing shall
contain the detailed Bill of Materials (BOM). The drawings shall be made on
appropriate software and provided in compact Discs (CDs).
c. Estimation of pressure drop based on the pipe-line lay-out and isometric
drawings.
d. Cable lay-out: The lay-out of instrument and power cables, including the location
of field junction boxes, cable trays, etc shall be made. The General Arrangement
(GA) drawing of the junction boxes and cable routing shall also be submitted.
e. The detailed Quality Assurance Plan (QAP) for the materials such as pipes, pipe
fittings,

flow

components,

instruments,

etc,

fabrication,

erection

and

commissioning shall be provided.

f.

Detailed procedure and acceptance criteria for fabrication, erection and

commissioning shall be provided.

g. Civil and Electrical requirements: Foundations for the equipments and trenches
for the cabling shall be provided by the contractor. The equipment lay-out
showing details of positioning of subsystems shall be made by the Contractor.
The load details of electrical power to be fed from MCC shall also be provided.
h. The details regarding the space requirement, water equipments shall be given by
the Contractor.
i.

The purchase specification of the materials such as equipments, flow

components, instruments, pipes; pipe fittings, etc shall be provided.

12

j.

The list of sub-vendors along with their company profile, technical catalogues etc.
from whom the Contractor has finalized to purchase the materials such as
equipments, flow components, instruments, pipes, pipe fittings, etc. shall be
provided.

k. The list of spares to be supplied for 2 years operation shall be provided.

The Department shall organize the Detailed Engineering Review (DER) meeting at
DRDL, Hyderabad within 3 months of approval of Preliminary Design. Contractors
representative (s) will participate in DER.
Note-A detailed Quality Assurance Plan (QAP) will be prepared based on mutual
discussion between the vendor and Department.
5.2.3.

SELECTION OF SUB- CONTRACTORS

The list of sub-contractors, if any, through whom the bidder proposes to acquire the
material and services for the execution of work, shall be given in the quotation. The list
of sub-contractors proposed by the bidder is subject to review by the Department during
evaluation of the quotation.
During DER, the Contractor shall submit the final list of sub-contractors with whom they
have finalized the purchase of materials and services.
5.2.4.

PURCHASE OF MATERIALS

All the materials such as equipments, flow components, instruments, pipes, pipe fittings,
etc, for HPS are to be purchased by the Contractor. The specifications are given in
Section 6. The detailed purchase specifications for the individual items of materials to
be purchased shall be made by the Contractor. The purchase specifications of such
materials are subject to review and approval by the Department.
5.2.5.

SUPPLY OF SPARES

The following spares shall be supplied by the Contractor along with the HPS. The
break-up prices of the spares shall be given in the quotation.
a. Spare parts and consumables for erection and commissioning: For the materials
used in the HPS, the Contractor shall supply the spare parts (like seat insert,
body gasket, gland packing, plug/stem assembly, etc for valves) and
13

consumables (like lubricants, oil, greases, PTFE tape, etc) to be replaced/ used
during erection and commissioning (by the Contractor).
b. Spare parts and consumables for operation and maintenance: For the materials
used in the HPS, the Contractor shall also supply the spare parts (like seat insert,
body gasket, gland packing, plug stem assembly with bellows, etc for valves) and
consumables, which are likely to be replaced/ used during operation and
maintenance over a period of 2 years from commissioning. The constituents and
quantity of such spare parts shall be worked out, considering the causative
factors such as normal wear & tear, fatigue cycles, creep, Mean Time Between
Failures (MTBF), etc. The spare parts allocated for this purpose shall not be
consumed by the Contractor during erection and commissioning. A separate set
of spares for 2 years operation and maintenance of the compressor systems
including dryers etc shall also be supplied. The lists of the same shall be
provided with break up price.

5.2.6.

FABRICATION

The system shall be fabricated at the Contractors factory to such an extent that they
can be transported by sea and road. The fabrication shall include testing & cleaning of
the system. All the consumables, tools, tackle; etc required for fabrication shall be
arranged by the Contractor. The detailed specification for fabrication is given in
Section 6.

5.2.7.

INSTRUMENTATION AND CONTROL SYSTEM

The contractor has to design & realize the instrumentation and control system required
for reliable & safe operation of High Pressure System.

This system may include

sensors, signal conditioners, cables, cable conduits, patch panels, instrument racks,
controller with appropriate interface modules, data display terminals, data storage units,
interfacing units etc.. The functional requirements & features are given in section 6.
The contractor has to provide complete training on the application software & test code
to the department personnel.

14

5.2.8.

INSPECTION

All the bought-out materials, fabrication drawings and the works during fabrication at the
Contractors factory and erection at the Departments site shall be inspected by one of
the following reputed Third Party Inspection agencies(TPIA).

Lloyds Register Industrial Services Pvt Ltd (LRIS)

Bureau Veritas Industrial Services Pvt Ltd (BVIS)

Det-Norske Veritas (DNV)

Engineers India Limited, India (EIL)

Any other Government Authorized agency

The broad scope of inspection shall be as follows. However, the detailed scope of
inspection shall be given in the quotation.
a. Review of the fabrication drawings for fluid circuits
b. Identification of the materials such as equipments, flow components, instruments,
pipes, pipe fittings, etc and review of the test and calibration certificates for
compliance with the contract specification.
c. Witnessing of welding procedure qualification and welders performance
qualification tests. If the welders already possess the performance certificate, the
TPIA shall review and authorize the same.
d. Review of X-ray films of radio-graphic tests for possible defects in the weld joints.
e. Inspection at any stage of fabrication to ensure that the methodology employed
for fabrication is in compliance with the requirements of standards/ codes,
practices, contract specification and the approved documents.
f. Witnessing of pressure test, leak test and cleanliness test of the system during
fabrication and erection at site.

It shall be the Contractors responsibility to arrange for and co-ordinate with the TPIA.
Apart from inspection by the TPIA, the Departments representative(s) will also inspect
the system at any stage of fabrication and erection.

15

5.2.9.

TRANSPORTATION

All the fabricated items and bought out materials will be properly packed and
transported to the Departments site at Hyderabad.

5.2.10. ERECTION
The system is to be erected by the Contractor at the Departments site. Apart from
erecting the system fabricated by the Contractor, it shall also be the Contractors
responsibility to erect the major equipments supplied by the Sub-contractor(s). The work
done by the Contractor during erection shall be inspected by the TPIA. The erection
shall also include cleaning & testing, minor civil & structural works (for grounding of
equipments, pipe supports, access bridges, platforms, staircase, etc), and electrical
system in and from MCC.

The Contractors personnel shall not be permitted to reside inside the Departments
premises after the working hours. The Contractor shall arrange for transportation,
accommodation, food, health care, communication, etc for their personnel.

5.2.11. COMMISSIONING
The high pressure system shall be commissioned by the Contractor in two phases as
follows:

In the first phase all the subsystems of HPS shall be tested individually, first in
static (non-flow) condition and then under flow condition.

In the second phase, HPS shall be tested with the rest of the tunnel system in
integrated way.

The detailed specification for commissioning is given in the document in section 6.

5.2.12 TRAINING
The contractor will arrange for training of Departments personnel for operation and
maintenance of the system.

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5.2.12. DOCUMENTATION
The Contractor shall prepare the relevant documents during different phases of he
Contract. All the documents shall be provided in 3 hard copies in English language only.
In the event that the documents by the sub-vendors/ sub-Contractors are in some other
language, it shall be the Contractors responsibility to translate them to English
language. The documents shall also be provided in CDs. besides the 3 hard copies.
These documents are subject to review by the Department. However, the Departments
approval shall not absolve the Contractors responsibility to comply with the
specifications and obligations of the contract. The list of documents to be provided by
the Contractor at different phases of the contract is given in the document in section 7.

5.2.13. SCHEDULE
The total scope of work shall be completed by the Contractor within 20 months from the
date of receipt of order.

5.2.14. LIST OF DELIVERABLES

An Indicative list of deliverables is given in Section 9.
5.2.15 WARRANTY
The Contractor shall give warranty for High Pressure System for a period of 12 months
from the date of commissioning the system.

6. SPECIFICATIONS
6.1. SPECIFICATION FOR AIR COMPRESSOR SYSTEM
Air compressor system shall include air compressor, air dryer units, oil separator,
cooling water system, and electrical power supply to the motors, instrumentation and
control system. The compressor system shall also include lubrication system, lubrication
of pump, intercooler, after cooler, pressure and temperature gauges at suction,
discharge and intermediate stages, pressure and temperature transmitter for all stages,
measurement, switches, alarms, control panels and display for operation and
monitoring, sound level meter, special tools and dew point meter. Each stage shall be
provided with safety relief valve.

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6.1.1.

AIR COMPRESSOR

Number of trains

Two

Fluid medium

Atmospheric air

Ambient temperature

45o C max. With 70% relative humidity

and 10C min. with 95% relative
humidity.

Altitude at location

500 m above Mean sea level

Flow capacity

2000 Nm3/hr of dry, oil free air to

be delivered per train (the FAD capacity
shall be planned accordingly)

Maximum delivery pressure

30 MPa(g) (at storage pressure vessel)

Configuration of compressor

Each train may consist of one feed

Compressor followed by Multi stage
Reciprocating boost compressor.
(the

feed

compressor

should

be

silenced Non-Lub. design.)

Design code

The reciprocating compressor

Shall be as per the API 618
(reciprocating compressor for
general & refinery service)

Driver

Separate Direct couple electric motor

Make

Neuman & Esser / Burckhardt /LMF

/Atlas Copco

Noise level

less than 85 dBA

Air quality at the outlet of Compressor System

Specific (absolute humidity)

Less than 1 x 10 6

(maximum of water vapor/mass of dry

air, equivalent atmospheric dew point is
less than -65C at 40C dry bulb
temperature)

18

Oil content

Less than 1 mg / Sm3

Filtration level

less than 5 micron (multistage filtration)

One

6.1.2.

DRYER UNIT

Number of dryers

Shall be able to handle the total flow rate from both feed compressor units.
(2000 Nm3/hr dry air per train)

The working pressure of the dryer is the discharge pressure of the feed
compressor.

The dryer shall be of heat less type.

One vessel must be always in operation while the other is under

regeneration.

Suitable configuration of dryer system shall be employed to get air with

absolute humidity less than 1 x 10 6.

Additional equipment may be planned for regeneration, independent of

operation of main compressors.

Dryer unit shall be self contained with its own control panel.

Dryer unit vessels shall be designed as per ASME Boiler and pressure
vessel code, section VIII. Division 1 and welding code as per section IX.

6.1.3.

COOLING WATER SYSTEM

The cooling water supply for the compressors shall include industrial type cooling
tower(s), cooling water circulation pumps(s), makeup water line, water supply and return
lines between pumps, compressors and cooling tower.

6.1.4.

ELECTRICAL POWER SUPPLY SYSTEM

The electrical power supply system for the motors of all the equipments under the air
compressor system shall include MCC panels, starter (soft starter), breaker, protective
devices, field panels, all cabling and earthing.

19

6.1.5.

INSTRUMENTATION

Each compressor stage is to be equipped with a pressure gauge of 6/4 dia dial with an
accuracy of 0.5% and safety relief valves set to the required pressures. All safety relief
valves should open within the range of 3 % of set pressure (adjusted to blow at 10%
higher pressure). The gauges are arranged in a compact panel which also contains the
indicating oil pressure gauge. All pressure gauges shall be calibrated and the calibration
reports shall be submitted. One temperature switch monitors the air temperature on the
final stage. Level indicators for crank case oil and condensate receiving tanks are to be
provided. An hour meter shall be provided with the compressor for logging of
compressor running. Digital Pressure Indicator at the delivery of the compressor will
also be provided.

IN BUILT SAFETY DEVICES AND THEIR OPERATION:

i. Audio-visual alarm & Automatic Compressor cut off device
An audio visual alarm along with Automatic Compressor cut off device is to be fitted to
the machine. Audio visual alarm comprises of the following:
a) Annunciator
b) 24 V Hooter
Fault sensing switches described below have to be provided which operate the
annunciator, Hooter and the Automatic Compressor Cut-Off.

ii. High Air Pressure Switch

As soon as the final pressure exceeds design pressure, the pressure switch gives a
signal to the annunciator and hooter. The hooter gives an alarm and the indicator lamp
in annunciator window glows, thus making the operator cautious and the compressor
will be stopped.
iii. Compressor lubricating low oil pressure switch
The switch fitted in the lubricating oil line of the compressor operates in case oil
pressure drops less than the set pressure. This shall give visible indication in
Annunciator, hooter will blow and the compressor will be stopped.

20

iv. Final stage Air temperature switch

If final stage air temperature exceeds the set value, the switch operates. Lamp in
Annunciator window glows, hooter will blow and the compressor will be stopped.
v. Emergency stop switch
An emergency stop switch shall be provided on the control panel to switch off the
compressor.
Electrical safety: Electrical safety in terms of high voltage and phase change shall be
provided.
The make of the safety relief valves shall be FORBES MARSHALL / SWAGELOCK /
HAMLET.

6.1.6.

AUTOMATIC CONDENSATE DRAIN

The stage separators located at the outlet of each stage are regularly drained by means
of diaphragm valves actuated by a timer-controlled solenoid. The condensate and
escaping air are led from the separators into a condensate receiving tank. The unit is
fully piped with high strength flexible hoses for connection on the suction and
discharge side.

6.1.7.

PIPELINES, WELD JOINTS AND SUPPORTS:

Compressor consists of mainly the following of pipe lines:

a) compressed air pipe lines
These pipe lines shall carry the compressed air and shall be of manufacturers
standards. The connections to the valve heads, intercooler, separators, filter,
non-return valve etc. shall be of manufacturers standards.
b) Condensate pipelines: These pipelines shall carry condensate from individual
moisture separators to the common manifold. These shall be of high pressure
flexible hoses.
c) Lubrication pipelines: These pipelines shall carry lube oil form sump to crankshaft
mounted rotor pump to oil cooler and the crankshaft main bearing.

All the weld joints in the pneumatic piping shall be cleared by the TPIA.

21

6.1.8.

TESTS

The following tests shall be carried out and certificates provided for the compressor,
dryer and fluid circuits.

Material tests for physical and chemical properties of all pressure/ load
bearing parts.

Hardness test.

Magnetic particle test & ultrasonic test.

Liquid penetrant examination of welded joints.

Radiographic test (X - ray) of welded joints

Dimensional check

Pressure test & leak test

Balancing

Sound emission test

Functional test

The certificates for bought out components like valve etc.

Motor rating & functional test.

The subsystems will be tested and qualified to the maximum extent possible at the
respective manufacturing facilities and will be witnessed by Department and TPIA. The
compressor performance test shall be demonstrated at both contractors site and
Departments site.

6.1.9.

DOCUMENTATION

The following documents shall be provided at the stages mentioned:

Along with the quotation

Complete description of the configuration of the compressor system

offered.

Deviation, if any, from the technical specification/requirement.

Process flow diagram, over all layout drawing indicating floor space and
other civil requirements.

P & ID diagrams, general arrangement drawings

22

Electrical power requirement in details

Water supply requirement in details.

Lists of sub vendors from whom the Contractor proposes to source all
major equipment like feed compressor, boost compressor, dryer units
cooling towers, cooling water pump, drive motors, MCC panel, control
panel/ system etc. Type/models proposed to be used and relevant
catalogues may be provided.

Soon after entering into contract

Confirmation of all details provided along with quotation, intimation of any

changes and getting clearance from Department.

Quality assurance plan (including the scope of the TPIA)

Electrical single line diagram

P & ID for air piping, isometric, piping layout plan.

Interlocks, trips and control system documents.

Before dispatch of the equipments

Operating manual with complete assembly drawing and spare parts lists.

All tests certificates up to sub system level tests.

Report of TPIA with due certificate and signature.

Guarantee certificates.

After integration and commissioning

6.2.

Certification for tests carried out at site.

As built P & ID and isometric drawing.

PRESSURE VESSEL FOR AIR STORAGE SYSTEM

Each storage system shall comprise 6 pressure vessels mounted in a structural skid
along with associated manifolds, valves, flow components and gauges. Total number of
vessels is 36.

23

6.2.1.

DESIGN DATA
(i)

Fluid medium

Dry Air

(ii)

Water capacity (volume)

2.2 m3 each vessel.

(iii)

Service pressure (filling)

30 MPa (g) Pressure at ambient

temperature ~303 K)

(iv)

Operating air temperature range

170 to 313 K

(v)

Arrangement of pressure vessels

As given in sketch (Fig. 5)

(vi)

Quantity

6 storage skids, each

with 6 pressure vessels

(vii)

Design and material of

As per DOT 3T or

Construction

as per BS 5045 Part 1

(viii) Corrosion allowance

(ix)

Application

As per standard
:

Stationary storage, Horizontal

installation

(x)

Make

Chesterfield Cylinders Ltd /

MCS Cylinder systems

6.2.2.

CONSTRUCTION:

The pressure vessels shall be made of hot rolled seamless tubes for cylindrical shell
and integrally forged hemi-spherical dished ends (without any welding). The pressure
vessels are intended for horizontal installation.

6.2.3.

SURFACE TREATMENT:

The surface treatment of the pressure vessels shall be performed in accordance with
ISO 8501-1:1988 to the following grades.
i.

Internal surface: The internal surface shall be subject to shot blast cleaning to
achieve surface condition as per preparation grade B Sa 2. The treatment shall
be followed by filling with gaseous Nitrogen to 0.2 MPa, which shall be
maintained till receipt of the pressure vessels at out site.

ii.

External surface: The external surface shall be subject to shot blast cleaning to
achieve surface condition as per preparation grade B Sa 2. The treatment shall

24

be followed by painting with Zinc primer and double top coat. The color of paint
shall be white.

6.2.4.

END CONNECTIONS:

The connections for the filling and delivery ends of the pressure vessels of the air
storage systems shall be as follows:
a. Filling end: The filling ends of the pressure vessels shall be fitted with rapid
closure system or equivalent with ID of 10 mm (clear bore for air flow). The
material of construction of the rapid closure system shall be austenitic stainless
steel.

b. Delivery end: The delivery ends for the pressure vessels shall be of female
thread with screwed-in and seam-welded flange of DN 50 mm size (50 mm ID)
with counter-bored seal seat and tapped holes for stud bolt. The material of
construction of the flanges shall be austenitic stainless steel.

6.2.5.

MARKING:

The pressure vessels shall be stamped with permanent and clearly visible identification
marks at an accessible location by steel tamps. The details such as water capacity,
service pressure, hydraulic test pressure, material of construction, manufactures serial
number, date of inspection and inspectors stamp shall be marked.

6.2.6.

MOUNTING:

The pressure vessels shall be mounted in a structural skid to constitute the air storage
systems according to the arrangement specified in Fig. 5. The material shall be
structural steel. The structure shall be provided with lifting lugs for handling. The
structure shall protect the air storage system including the associated flow components
and gauges.

25

6.2.7.

FLOW COMPONENTS AND GAUGES:

Each module shall be instrumented as per Fig. 5. The material of construction of all the
flow components and gauges shall be austenitic stainless steel 316L only.

6.2.8.

MANIFOLD ASSEMBLIES:

The manifold assemblies for the air storage systems shall be as follows: the flow
components, valves and instruments shall be provided in the manifold (P & ID diagram
is shown in Fig. 6). The material of construction of all the flow components and gauges
shall be austenitic stainless steel 316L only.

The filling ends of the pressure vessels shall be connected to manifold. The inlet
of the filling manifold shall be provided with a globe valve (designated as MGV-1)
of size 25 mm. The inlet of the globe valve shall be terminated with a flange.
The delivery ends of the pressure vessels shall be connected to a manifold. The
outlet of the delivery manifold shall be provided with a globe valve (designated as
MGV-2) of size 100 mm. The outlet of the globe valve shall be terminated with a
flange.

The filling and delivery manifold of each skid shall each be provided with
1 pressure gauges (designated as PG-A, and PG - B).

The delivery manifold of each skid shall be provided with one Pressure
Transmitter.

The delivery manifold shall be fitted with two safety valves (designated as SV).
The safety valve shall be the primary safety relief device, set to the maximum
permissible pressure of the vessel. Each of the Safety valves will have same set
pressure (one for redundancy).

All the inter-connecting joints of manifold assemblies, including the valves, but
excluding the end connections of the pressure vessels, filling, delivery and vent
of the manifolds; pressure gauges; and safety valves, shall be made only by butt
welding with Gas-purged Tungsten Arc Welding (GTAW) using gaseous Argon of
99.995 % purity as purge medium. All the butt weld joints shall be qualified by
dye penetrant test and radio-graphic test with X rays to 2T sensitivity. After

26

welding, the internal surfaces of the manifold assembling shall be cleaned by

pickling and passivation.

The flanges on the filling, delivery and vent of each storage system shall be
supplied with companion flanges along with gaskets and fasteners.

6.2.9.

TESTS:

The following tests shall be performed:

a.

Material test for physical and chemical properties

b.

Hardness test

c.

Magnetic particle examination on the dished ends

d.

Liquid penetrant examination on the bore of the dished ends.

e.

Internal and external surface examination

f.

Tare mass measurements

g.

Water capacity measurement.

h.

Hydraulic pressure stretch test as per DOT 173.34 or BS 5430 Part 1.

i.

Ultra sonic test for flaw detection

j.

Dimensional check

k.

Wall thickness measurement by ultra-sonic probe at identified points (the

location of the pressure vessels are sketched on drawing with reference to a
fixed point on the pressure vessels).

l.

Dye penetrant test and radiographic test with x-rays of all butt welded joints in
manifold assembly.

m.

Pressure test of the manifold assembly

6.2.10. INSPECTION:
The in-process (stage) and pre-delivery (final) inspection of the air storage systems
shall be carried out by a reputed Third Party inspection agency (TPIA) .
The scope of inspection shall be as follows:
a. Review and approval of the design calculations and General Arrangement (GA)
drawings.

27

b. Identification of raw materials and review of the material test certificates for
compliance with the relevant requirements.
c. Review of test certificates for compliance with the specification and visual
examination of the bought-out flow components and gauges.
d. Inspection at any stage of fabrication to ensure that the methodology employed
for fabrication is in compliance with the requirements of standard codes and
practices and approved documents.
e. Review of x-ray film of radiographic tests of welded joints.
f. Witnessing of tests given in para 6.2.9
g. Issuance of Pre-Delivery Inspection (PDI) certificate and stamping of on the
pressure vessels.
Apart from inspection by the TPIA, our representative(s) shall also witness and certify
the hydraulic pressure stretch test and any other test as may be deemed necessary.

6.2.11. DOCUMENTATION:
The following documents, in duplicate unless specified otherwise, shall be furnished at
different stages specified thereupon.
(i) Along with quotation: A complete technical description of the system shall be
furnished. The following shall be highlighted.
- Overall documentations of pressure vessels and storage systems.
- Mass of pressure vessels and air storage system
- Wall thickness of pressure vessels
- Mechanical properties and chemical composition of pressure vessels.
- Technical deviation, if any should be highlighted.
(ii) Soon after entering into contract: The following documents shall be prepared
immediately upon receipt of the purchase order. The documents listed in Clauses
a, b & c below shall be reviewed and approved by the Third Party Inspection
agency (TPIA) for compliance with the requirements of the relevant design codes
as specified in the purchase order and statutory regulations. Moreover, it is
suppliers responsibility to submit the documents listed in Clauses a, b & c below
to the Chief Controller of Explosives (CCE), Government of India, Nagpur and

28

get the same reviewed and approved by him. The documents listed in Clauses a,
b & c below duly approved by the TPIA & the CCE along with the documents
listed in Clauses d, e below shall be submitted to the Department within 2 months
from the date of the purchase order. These documents are subject to corrections
by Department and only upon approval of the same by Department, supplier shall
proceed with fabrication. Upon approval by Department, 1 copy of these
documents shall be returned to supplier. However, Departments approval shall
not absolve the supplier responsibility / contractual obligation to comply with the
specification of the system.
a. The overall dimensioned General Arrangement (GA) drawing of the
storage systems shall be provided. The calculations for the pressure
vessels, structural skid, flow components, gauges, etc shall be shown in
the GA drawing.
b. The detailed calculations for the design of the pressure vessels as per the
code shall be provided. The calculations for the sizing of the safety relief
valves as per the relevant code / standard shall also be provided.
c. The detailed dimensioned cross sectional drawing of the pressure vessel
shall be provided.
d. A detailed Quality Assurance Plan (QAP) shall be provided.
e. The make, model number and specifications of the flow components and
gauges along with the catalogues shall be provided.
(iii) Prior to delivery of the consignment: On completion of fabrication, but at least 2
weeks before the expected date of delivery of the consignment, the following
documents shall be sent to the Department. Department shall review the same to
ensure compliance with the specification of the purchase order. On being
satisfied, Department shall issue a dispatch clearance.
a. The certificates of all tests shall be provided. Each page of he
certificates shall be duly counter-signed and stamped by the TPIA.
b. Pre-delivery inspection certificate by the TPIA.
c. As-built GA drawings

29

d. Instruction manual for erection, commissioning, operation, trouble

shooting and maintenance.
e. Guarantee certificate.

6.3.

PRESSURE VESSEL FOR INSTRUMENT AIR SYSTEM

Fluid medium

Dry air

Volume

10 m3

Pressure

1 MPa at ambient temperature ~ 303 K

Number of vessel

The filling end and the delivery end shall be provided with ball valves of
size 50 mm. Each end shall have pressure gauge with its own isolation valve and
vent valves. The delivery end shall have two Safety valves (one for redundancy)
with same set pressure maximum permissible of pressure vessel.

6.4.

MANUAL VALVES

Specification as given in Table 1

Table 1: Specification of manual valves
Operating conditions
valve no.

Temperature
Range, K

MAWP
MPa

tentative
valve
size
mm

Type of
valve

MGV1

233-313

33

25

Globe

MGV2

233-313

33

100

Globe

MGV3

233-313

33

300

Globe

Note: All the valve sizes shall be selected based on the selected pipe sizes
Actuation

Hand operated (manual)

Application

Isolation

Permissible leak rate

1. Class IV as per ANSI Standard for globe

valve
2 Bubble tight as per API 598 or Rate A of BS
6755 part 1 for gate, ball and butterfly valves.

30

Cycle of Operation

10,000

End connection

Flanged; Flanged
ends as per ANSI B16.5

Body

With full port (standard bore)

and in-line end connections

Bonnet

Bolted or screwed to body with

spring-energized seal
seals (Helicoflex, Enerseal. etc)

Stem

Rising stem with Outside

Screw and Yoke (OS & Y)
pattern

Stem (dynamic) seal

By gland packing

Plug

Renewable (replaceable) from

stem

Seat

Renewal from body with seat

insert

Flow direction

Flow to open (for globe valves)

Material of construction

Stainless steel for air and carbon

steel valve for water (details of
material to be given by the
Contractor)

The valves shall be either inherently anti-static or provided with anti-static features.
Design code

1. BS 5352/ BS 6364/ API 6D/

ANSI B 16.34 for globe and
gate valves.

Test Code

BS 6755/ BS 5155/ API 598

Tests:
Material certificate: The material certificates, detailing the physical and chemical
properties, of the principal pressure-bearing parts shall be provided.
Welding joints test: Any butt welding joints in the valve shall be subjected to radio
graphic test with X-rays or gamma rays to 2-T sensitivity.

31

Soundness test for casting: All the casting shall be subject to soundness test with radiographic or ultra-sonic technique for flaw detection.
Hydraulic shell pressure test: The valve, prior to assembly with the bellows, in partially
open position, shall be subject to pressure test with water ( with suitable corrosion
inhibitor) at 1.5 times the maximum rated working pressure of the particular pressure
rating class of the valve. The test procedure and acceptance criteria shall be as per BS
6755 Part 1 or API 598 or ANSI B 16.34.
Pneumatic seat test (for ball valve only): The leak rate across the seat of ball valves
shall be tested with dry air at 0.4 to 0.7 MP by water displacement (bubble) method. The
acceptance criteria shall be as per Rate A of BS 6755 Part 1) or API 598.
Functional test: The valve with all accessories mounted shall be subjected to functional
test to validate the performance.
Marking: All the valves are assigned tag numbers for the sake of identification. The tag
number for each valve, as indicated above, besides size, pressure rating class, material
of construction etc, shall be indelibly engraved on the body of he valves.
Note: For the isolation of pressure transmitters and gauges, 3 port / 2 way manifold
valves are to be used.

6.5.

ELECTRO-PNEUMATIC VALVES

The electro-pneumatic (EP) valve shall comprise the valve, actuator, solenoid valve and
limit switches.
i) VALVE
Actuation

Electro Pneumatically operated

Tag no. working, Temperature range, Size, MAWP

Response time

As given in Table 2

32

Table 2 : Specification of EP valve

Operating conditions
Temperature
Range, K

MAWP
MPa

EGV1

233-313

33

Tentative
valve
size
mm
25

EGV2

233-313

33

25

Globe

<5

EGV3

233-313

33

25

Globe

<5

EGV4

233-313

33

300

Globe

<3

EGV8

233-313

33

100

Globe

<5

valve no.

Type of

Response

valve

Time, Sec

Globe

<5

Note: All the valve sizes shall be selected based on the selected pipe sizes
Other Specification

As specified for manual valves.

And tests
Note: All the valves (EGV, MBV and MGV) shall be of the following Makes:
INSTRUMENTATION INDIA LTD / AUDCO INDIA LTD / MIL CONTROLS / FISHER
SANMAR CONTROL / B.D.K GROUP OF COMPANIES / BHEL / PARKER /
SWAGELOCK / HAMLET/ DMIC
(ii) ACTUATOR
Type

Linear actuator, piston/diaphragm type, single acting,

spring return, fail-safe.

Command gas

Air

Body material

Anodized Aluminum

Piston material

Anodized die cast Aluminum

Test

The response time taken for opening and closing

of the valves shall be evaluated.

(iii) SOLENOID VALVE

Suitable solenoid valve with service gas as air.

Excitation voltage is 24-28 VDC.

Necessary power source shall be supplied by the contractor for solenoids and the limit
switches

33

(iv) LIMIT SWITCHES

It is should have suitable limit switches with proper electrical conduit.

6.6.

PIPES

Type

Seamless pipes

Schedule number

As per P & ID

Length

As required based on the isometrics to be

Nominal pipe size &

prepared by the Contractor.

Material

ASTM A 312 TP 316L for all air circuits.

ASTM A53B / 106B for water circuits

Dimensional standard

ANSI B 36.19/36.10

TESTS
Visual examination: All the pipes shall be visually examined for workmen-like finish.
Dimensional check: One specimen from each lot shall be subjected to dimensional
check.
Chemical analysis: One specimen from each lot shall be subjected to detailed chemical
analysis as per ASTM A 751.
Mechanical Tests: One specimen from each lot shall be subjected to test for mechanical
properties as per ASTM A 370 (including impact test)
Hydraulic pressure test: All pipes shall be hydraulically pressure-tested with Water as
per ASTM A 530.
Ultra-sonic test: All the SS pipes of size DN 25 shall be subject to Ultra-sonic test (100
%) by contact method as per ASTM A 450.
Eddy current test: all the SS pipes of size DN15 shall be subjected to Eddy current
test as per ASTM E 426.
Flattening test: Pieces of pipes of length 63.5 mm (2.5) cut from the ends of 5 % of pipe
lengths per lot shall be subjected to flattening test as per ASTM A 530 to prove ductility
and soundness.
Inter-granular corrosion test (for SS pipe only): One specimen per lot shall be subject to
inter-granular corrosion test as per ASTM A 262 (practice A/E).

34

Cleanliness: The pipes shall be cleaned and dried before dispatch.

Marking: The pipes shall be marked as per ASTM A 700.

6.7.

GASKET

Metallic gasket shall be provided wherever flange joint is coming.

6.8.

PIPE FITTINGS

Size & pressure rating

As required based on P & IDs and

isometric drawings to be prepared
by the Contractors.

Type

Butt welded fittings for fluid circuits of

size DN 50
Socket welded fittings for fluid circuits of
size DN40

Standard

Flanges: ANSI B 16.11

Butt welded fittings: ANSI B16.9
Socket welded fittings: ANSI B16.9

Material for fittings to be used in

SS pipelines

1. Flanges: ASTM A 182 F 316L

2. Butt welded fittings: ASTM A 403 WP 316L
3. Socket welded fittings: ASTM A 182 F 316L

CS Pipeline

1. ASTM A 105
2. ASTM A 234 WPB

Tests
Visual examination: All fittings shall be visually examined for any scratches, dents, and
surface irregularities etc.
Dimensional check: One specimen from each lot shall be subjected to dimensional
check.
Chemical analysis: One specimen from each lot shall be subjected to detailed chemical
analysis.

35

Inter-granular corrosion test: One specimen per lot shall be subject to inter granular
corrosion test as per ASTM A 262 (practice A/E).
Mechanical tests: One specimen from each lot shall be subjected to tests for
mechanical properties.

6.9.

INSTRUMENTATION AND CONTROL SYSTEM

Instrumentation and control system should be designed for meeting following functional
requirements.
1. It is configured as a stand alone system for its safe & reliable operation.
2. It is configured such that system can be operated in either manual or automatic
mode. For manual mode of operation, the necessary provisions like knobs,
process parameters status etc... should be available on the front panel. In the
automatic mode, the controller has to operate the compressor as per the predefined instructions. In case of fault, the controller should automatically detect &
take necessary abort actions.
3. It should have emergency shut down button for stopping of compressor in case
of emergency.
4. All important parameters should have a digital display on the front panel and
necessary interlocks must be incorporated in the control logic. In case of
deviation of any process parameter from its nominal values, the system should
pop up the suitable alert signals to the operator in the form of alarms, LED
display etc.
5. SCADA based GUI environment to be available at the control room.
6. Software (test code) to be developed as per IEEE 12207 standard.
7. It should acquire the data of critical parameters at 10samples/sec during
compressor operation.
8. It should communicate some of the important process parameters (user selected)
using TCP/IP protocol to the master control room of the wind tunnel.

36

Instrumentation system should posses the following features

1. Should be of well proven & rugged system
2. Testability
3. Availability of components in the future (COTS are preferable)
4. Flexibility in modifying the test code (software) as per requirement
5. System should be expandable in terms of channel count
6. Should have a provision for debugging the software.
7. Suitable to the test environment conditions
8. Pass word protection for unauthorized access deny
9. EMI/EMC, CE compliances
The contractor has to perform independent verification & validation on software. The
source code along with the licensed software is to be handed over to department.
Supplying of suitable capacity UPS is in the contractor scope. An industrial PC of latest
processor with touch screen colour monitor, available at the time of installation, shall be
provided.
The contractor has to design & realize complete instrumentation and control system.

6.10.

FABRICATION, ERECTION AND COMMISSIONING

The system shall be fabricated, erected and commissioned as per the following
procedure:

6.10.1 WELDING
The welding procedure qualification and welders performance qualification shall be one
as per section IX, ASME.

6.10.2 TESTS:
The following tests shall be performed after fabrication of pipelines:
a.

Dye penetrate test: All the socket welded joints shall be subjected to Dye
Penetrate Test (DPT) at the root, intermediate and final passes. All the butt and
mitre welded joints shall be subjected to DPT at the root pass.

37

b.

Radio graphic test: All the (full) SS butt welded joints and 10 % (spot) of the CS
butt welded joints shall be subject to radiographic test to 2 T sensitivity.
Generally, the radio graphic films shall be submitted to the Department.

c.

Pressure test: All the fabricated pipe-lines shall be subject to pressure test with
hydraulic medium at 1.5 times the MAWP. Alternatively, in pipe-lines, where the
presence of water is intolerable, the pressure test may be done with pneumatic
medium at 1.1 times the MAWP.

d.

Pneumatic leak test: All the pipe-lines, except those for water medium, shall be
subject to leak test with dry Air at MAWP to validate bubble-tightness.

e.

Surface oil contamination test: The surface oil content of the pipe-line shall be
measured by transferring the oil contaminant into a solvent by mopping the
surface and analyzing with fluorimeter. The permissible surface oil contamination
shall be 200 mg/m2.

6.10.3 CLEANING
The fabricated SS pipe-lines shall be cleaned as per the following procedure:
a. Mechanical cleaning: All the metallic surfaces with scales and newly welded
surfaces shall be cleaned by scrubbing with SS wire brush. The loose
particles generated by mechanical cleaning shall be removed by blowing with
compressed air, sucking or washing with water.
b. Degreasing : The oil and grease adherent to the surface shall be removed
by vapor phase de-greasing with Tri Chloro Ethylene (TCE) or Per Chloro
Ethylene (PCE), followed by liquid phase de-greasing with TCE or PCE.
c. Pickling: In order to remove rusts and scales, the surfaces shall be washed
with water and pickled with a solution containing Hydro-fluoric acid (HF) and
Nitric acid (HNO3). The composition of the pickling solution and duration are
to be adjusted after trial test on a sample piece to remove uniformly less than
25m thick material. Mostly, the composition is as follows;
HF

5% by mass

HNO3

15 to 20 %

Water

Remainder

38

This is followed by rising with water.

d. Passivation : The surfaces shall be passivated with a solution of the following
composition :
HNO3

25% by volume

Water

Remainder

Duration

2h

This is followed by rinsing with De-mineralized water.

6.10.4 PAINTING
All the CS pipe-lines and non-insulated SS pipe-lines shall be pained based on the
colour code scheme. All the pipe-lines, flow components and instruments shall be
provided with identification name plate displaying, in bold letters, their tag numbers. All
the structural materials shall be painted in gray colour and handrails in yellow colour.
The color code scheme shall be provided upon award of the contract. Prior to painting,
the surfaces shall be suitably prepared. The painting shall comprise 2 coats of primer
(like weather protection paint) and 2 coats of synthetic enamel.

6.10.5 ERECTION EQUIPMENTS

All the machineries required for erection such as welding equipments, grinding machine,
drilling machines, radiographic equipments, etc consumables such as Gaseous Argon,
hacksaw blades, etc and tools & tackles, etc. shall be arranged by the Contractor.

6.10.6 ELECTRICAL WORKS

The contractor shall specify the electrical power requirements for the equipments
supplied by them. The Department will provide power source only with open-ended
cables at inlet to the MCC. Supply of MCC along with soft starters for motors, isolators,
fuses, panels, etc and tacking the power from these isolators at MCC with suitable
connectors and cables to the respective electrical points, switches, control elements,
equipments like switch fuse unit, soft starters, etc, wherever required shall be under the
scope of the Contractor. The electrical panels, control elements, etc shall have
provisions for operating the equipments remotely from MCC. The contractor shall also

39

connect the equipments, pipe- lines, flow components, instruments, etc to the earthing
pits through proper earthing strips. The earth pits of 0.5 for instruments and 5 for
mechanical equipments shall be provided by the department.

7 DOCUMENTATION
The list of documents to be provided by the Contractor at the different phases specified
there up on are as follows:

7.1 DESIGN REVIEW

The Contractor shall submit a document listing their comments on the tender document
provided by the Department. If the Contractor proposes any alternative scheme or
sizing, the detailed justification, along with calculation wherever necessary shall be
submitted. In case the Contractor propose to employ alternative codes/standards
followed in their country, different from those specified in this document, the copies of
such codes/ standards in English shall be submitted.

7.2 DETAILED ENGINEERING REVIEW

a.

Pipe-line lay-out drawings

b.

Pipe-lines isometric drawings

c.

Calculations for sizing and positioning of thermal compensators

d.

Design of pipe supports

e.

Estimation of pressure drop

f.

Cable lay-out

g.

QAP

h.

Procedure and acceptance criteria for fabrication, erection and

commissioning

i.

Civil and electrical requirements

j.

Purchase specification of materials

k.

List of sub-vendors/ sub-contractors

l.

List of spares for 2 years operation

40

7.3 FABRICATION
a. As built fabrication drawings.
b. Test certificates and inspection reports of the materials such as equipments,
flow components, pipes, pipefittings, instruments (including the calibration
certificates), etc.
c. Wiring diagram of instrumentation and electrical systems.
d. Test certificates and inspection reports of fabrication (including the radiographic films)
e. Estimation of quantity of fluids to be supplied by the Department during erection
and commissioning.

7.4 ERECTION
At the end of erection, the following documents shall e submitted.
a. As-built pipe-line layout drawings.
b. As-built pipe-line isometric drawings.
c. As-built cable layout drawings.
d. Estimation of pressure drop based on the as-built pipe-line isometric
drawings.
e. Certificates of tests (including radiographic films) done during erection.
f. Inspection report by the Department

8 STANDARDS FOLLOWED
The contractor shall follow the standard for piping, welding, vales etc given in Table 3
Table 3: Standards/codes to be followed.
Sl.No. Description

Standard/code

1.

Piping

ANSI B 31.3/31.1

2.

SS pipes

ANSI B 36.19

3.

CS pipes

ANSI B 36.10

4.

Butt welded fittings

ANSI B 16.9

5.

Socket welded / threaded fittings

ANSI B 16.11

41

6.

Flanges

ANSI B 16.5

7.

Stud (fully threaded), Nuts and

ASTM A 193 B8/ B7, A 194 8/ 2H

Washers
8.

Gaskets

API 601 /ANSI B 16.5

9.

Ball valves

BS 5351/ API 6-D

10.

Globe/Needle valves

ANSI B 16.34 / API 6-D/API 598/ BS

5352/BS 6755

11.

Pressure regulators

Manufacturers standard

12.

Filters

Manufacturers standard

13.

Non return valves

BS 5352/ API 6-D

14.

Safety relief valves

ASME Section VIII Division I/ API RP

520/ API RP 527

15.

Pressure gauges

BS 1780/IS 3624

16.

Hydraulic pressure test of

ASTM A 530

pipelines
17.

Pickling & Passivation

ASTM A 380

18.

NDT

ASME Section V

19.

Welding

ASME Section IX, AWS

20.

Radiography

ASTM E 94

21.

Design & Fabrication

ASME Section VIII, division I

9 LIST OF DELIVERABLES
The contractor shall provide the following list of deliverables as given in Table 4
Table 4: Indicative list of deliverables
Sl.

Description of Item

Qty

- Including feed compressor, Boost compressor with drive

motor, intercooler, aftercooler, and instrumentation etc. - 2
Chains.

1No.

No.
1.

Air compressors

42

2.

Dryer
-

3.

Oil remover
-

4.

Including industrial type cooling tower(s), cooling water

circulation pumps(s), makeup water line, water supply and
return lines between pumps, compressors and cooling
tower.

Including MCC panels, starter (soft starter), breaker,

protective devices, field panels, all cabling and earthing.

1No.

Including pressure gauge, temperature gauge, hour meter, 1 Set

level indictor.

Safety devices
-

Including Audio-visual alarm & Automatic Compressor cut

off device, High Air Pressure Switch, Compressor
lubricating low oil pressure switch, Final stage Air
temperature switch, and Emergency stop switch

.
1 Set

8.

Automatic condensate drain with diaphragm valve, timer

controlled solenoid, flexible hoses etc.

1 Set

9.

Pipeline, & support for compressor system

1 No.

10.

Pressure vessel
-

Including rolled seamless pressure vessel, end connection 36 Nos.

with rapid closure system, safety valve etc.

11.

Air storage mounting skids

6 Nos.

12.

Flow components and gauges

1 Set

13.

Manifold assembly

1 No.

14.

Instrument air compressor with integral dryer

1 Unit

15.

Pressure vessel for instrument air system with safety valve

1 No.

16.

Manual globe valve, size 25 mm , 30 MPag

7 Nos.

17.

Manual globe valve, size 100 mm , 30 MPag

6 Nos.

43

1No.

Instrumentation
-

7.

1No.

Including air filters

Electrical power supply system

-

6.

1No.

Cooling water system

-

5.

Including Dew point meter, dryer column, regeneration

equipment, dryer control panels etc.

18.

Manual globe valve, size 300 mm , 30 MPag

1 No.

19.

Manual ball valve, size 50 mm , 1 MPag

2 Nos.

20.

Manual ball valve, ID > 2 mm , 1 MPag

2 Nos.

21.

Electro pneumatic Globe valve, size 25 mm, 30 MPag

3 Nos.

22.

Electro pneumatic Globe valve, size 100 mm, 30 MPag

1 No.

23.

Electro pneumatic Globe valve, size 300 mm, 30 MPag

1 No.

24.

Instrumentation and control system

- Including SCADA, industrial PC, control software etc

1 No.

25.

Electrical panel with safety devices and accessories

1 No.

26.

UPS for instrumentation & control system of high pressure system 1 No.

10 ACCEPTANCE TEST PLAN:

The system shall be accepted based on ATP Documents. ATP tests shall be conducted
at factory and Departments site. A brief description of ATP is given below. However, a
detailed mutually agreed ATP document will be prepared by the vendor and
Department before erection and commissioning of the system

10.1 COMPRESSOR:
The compressor shall be run for 20 hrs with 15 minutes break after 10 hours at
contractors site and Departments site and performance shall be checked for delivery
pressure, delivery flow rate and quality of the air (dew point).
Leak tests: The inlet and delivery lines of compressor shall be leak tested at 300 bar
outlet pressure.
a) Checking of all safety systems and controls
b) All the safety relief valves shall be tested for their operation and corresponding
feed back to the control panel.
c) Performance tests at various loads
d) Cyclic tests: In one of the 8 hour duration tests at 100 % load, the compressor
shall be run for 1 hr and switched off. After 15 min gap, the compressor shall be
switched on again. This should be repeated for 8 cycles.

44

e) FAD ( Free Air Delivery) / capacity tests shall be carried out as per the IS
standard and conformed to the specifications
f) Oil and Dust content in the compressed air shall be tested at reputed laboratories
to confirm the specifications
g) Working of all pressure/temperature gauges and transmitters

10.2 PRESSURE VESSELS, PIPES AND VALVES:

Tests shall be carried as specified in section 6.2.9 for pressure vessels. Tests for the
valves shall be carried out as per specified in the earlier sections 6.4 and 6.5. Tests for
the pipes shall be carried out as per specified in the earlier sections 6.6 and 6.8.

10.3 INTEGRATED SYSTEM

The following tests shall be carried out for the integrated system( upto EGV4) .
a) Leak test
b) All the safety relief valves shall be tested for their operation and corresponding
feed back to the control panel.
c) Pneumatic test of the vessels and the piping
d) Working of all the pressure gauges and pressure/temperature transmitters

45

46

150m

1.Compressor shed
2.Air storage shed
3.Vacuum pump house
4.Vacuum sphere
5.LPG system
6.Aftercooler
7.Electrical substation
8.MCC
9.HPS workshop
10.Water Pump house
11.Diesel Generator house
12.Water tank
13.Air heating shed

Wind tunnel Hall

300m
Fig. 2 Equipment layout of the Hypersonic Wind Tunnel

47

Air storage

Atmospheric
Air
CT1
FC1
D

CT2
CWP1

CWP2

BC1

FC2

OR
To Tunnel
BC2

Atmospheric
Air
FC1. FC2 - FEED COMPRESSOR
BC1. BC2 - BOOST COMPRESSOR
OR - OIL REMOVER
CT1 ,CT2 - COOLING TOWER
CWP1, CWP2 - COOLING WATER PUMP
D - DRIER

FIG. : 3 INDICATIVE BLOCK DIAGRAM OF HIGH PRESSURE SYSTEM

48

MGV1

2.2m3 x 300 bar x 36 nos.

(Total volume = 79.2 m3)
(Each module consists of 6 cylinders)
EGV8

MGV 2
04-100-18NS-33

MGV 1

EGV1

03-025xxS-33

MGV 1

MGV 2

05-300-45NS-33

02-025xxS-33

MGV 2

EGV4

MGV 2
EGV3

01-025xxS-33

MGV 1

MGV 1

06-300-45NS-33

MGV 2

EGV 2

MGV 1

MGV 2
MGV 1
Module(6-cylinders,3rowsx2columns)

MGV3

INSTRUMENTAL
AIR

C1 = Compressor train 1
C2 = Compressor train 2

FIG.4 P & ID OF HIGH PRESSURE SYSTEM

49

50

vent valve ID >2mm

isolation valve,
ID >2mm

Inst. air
compressor
&dryer

07-50-40S-1.5

10 cu. meter x 10bar(Instrument air)

FIG.6 P & ID OF INSTRUMENT AIR SYSTEM

51

52

53