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ANNEXURE 2 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.

6079A-C-266-301
ANNEXURE 2 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 2 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 2 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 2 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 2 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 2 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 2 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 3 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 3 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 3 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 3 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 3 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 3 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 3 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 4 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
SECTION: WRITEUP
TATA CONSULTING ENGINEERS
SHEET 1 OF 3
GALVANISING OF STRUCTURAL STEEL

1. SCOPE

This specification covers the general requirement of Hot dipped galvanising,


Electroplated, Sheardized and Sprayed Zinc coating of the structural
steelwork. It covers the supply of all materials, labour, tools, plant,
equipment, necessary to galvanise the structures in accordance with
specifications.

2. GALVANISING PLANT

2.1 The BIDDER shall indicate in his bid the galvanising plant where galvanising
work will be carried out. Prior approval shall be obtained from OWNER/
ENGINEER if galvanising proposed to be carried out outside Contractor’s
plant.

3. WORKMANSHIP

3.1 After all shop work is complete, all structural material shall be punched with
the erection mark to be hot-dip galvanised. Before galvanising, the steel shall
be thoroughly cleaned of any paint, grease, rust, scale, acid or alkali or such
other foreign matters as are likely to interfere with the galvanising process or
with the quality and durability of the zinc coating as specified in clause 4 of
IS : 2629. Pickling followed by Rinsing shall be carefully and properly done
as specified in IS: 2629.

3.2 Zinc conforming to any grade specified in IS : 209 shall be used for
galvanising. Mass of zinc coating under specified otherwise shall be at least
0.610 kg/sq. m. of total surface area for normal or rural atmosphere. In case of
industrial atmosphere, minimum mass of coating shall be increased as agreed
to between the Galvanizer and Purchaser. Stub members and members for
grillage type footing shall have heavier zinc coating of not less than 0.80
kg/sq. m. Where required by Purchaser, Post Treatment such as Chromating or
Phosphating may be applied to reduce risk of wet storage staining or to assist
subsequent painting, respectively.

3.3 The galvanised surface shall consist of continuous & uniformly thick coating
of zinc, firmly adhering to the surface of steel. The finished surface be cleaned
& smooth & be free from imperfections as flux, ash and bare patches, black
spots, pimples, lumpinch, runs, mist stains, bulky white deposits and blisters.
The presence of any of these defects noticed on visual or microscopic
inspection shall render the material liable for rejection. Sampling and nos. of
test for coating characteristics shall be as specified in IS : 4759. Mass of zinc
coating may be determined in accordance with IS : 6745.

3.4 There shall be no flanking or loosening when struck squarely with a chisel
faced hammer. The galvanised steel member shall withstand minimum four no
of one minute successive dips in copper sulphate solution kept at temp. of 18
ANNEXURE 4 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
SECTION: WRITEUP
TATA CONSULTING ENGINEERS
SHEET 2 OF 3
GALVANISING OF STRUCTURAL STEEL

2 0C as per IS : 2633 unless specified otherwise. If at anytime during the test,


there is any doubt as to presence of exposed base metal as determined by
visual inspection, one or more of supplementary tests as specified in Cl.6.1 or
6.2 of IS: 2633 should be performed. Where practicable, uniformity of
galvanised coating shall be determined by Preece test as described in IS: 2633
Use of Preece test should be agreed to between Purchaser and Galvanizer. For
Hot dipped galvanised steel members, coating shall withstand the Pirotted
hammer and Knife tests as prescribed in IS: 2633 for testing adhesion of zinc
coating on fabricated steel and hardware respectively.

3.5 All galvanised members shall be treated with Sodium Dichromate solution or
an approved equivalent after galvanising, so as to prevent white storage stains.

3.6 Galvanising of each member shall be carried out in one complete immersion.
Double dipping shall not be permitted. When the steel section is removed from
the galvanising kettle, excess spelter shall be removed only by ‘bumping’.

3.7 Whenever galvanised bolts, nuts, locknuts, washers, accessories etc. are
specified, these shall be hot-dip galvanised. Spring washers shall be electro-
galvanised. Excess spelter from bolts, nuts, etc. shall be removed by
centrifugal spinning. Rechasing of bolt threads after galvanising shall not be
permitted. Nuts however may be tapped, but not to cause appreciable rocking
of the nuts on the bolts. Readily available GI nuts, bolts and washers
conforming to galvanising requirements may also be used.

3.8 Defects in certain members indicating presence of impurities in the


galvanising bath in quantities larger than that permitted by the specifications
or lack of quality control in any manner in the galvanising plant, shall render
the entire production in the relevant shift liable to rejection.

3.9 Sufficient care should be exercised while storing, packing and handling.
Contractor shall ensure that galvanising is not damaged in transit. While
storing and transporting, adequate ventilation should be provided as otherwise
‘White rust’ or ‘Wet storage stain’ may result with humidity and atmospheric
gases. In the event of occurrence of any damage, contractor shall at its own
cost adopt scrapping & regalvanizing the member to satisfy the specific
requirements. In many cases, it will be advisable to give a Post-treatment like
Chromatting to minimise chances for formation of white rust.

4. METHOD OF MEASUREMENT

4.1 Galvanising work shall not be measured separately if galvanising is already


included in the scope of item of work of fabrication/erection of steel.

4.2 In case the galvanising is to be carried out on already fabricated steel work, a
separate rate for galvanising shall be quoted as called for in the Schedule of
Quantity. The weight of the actual completed structures including weight of
ANNEXURE 4 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
SECTION: WRITEUP
TATA CONSULTING ENGINEERS
SHEET 3 OF 3
GALVANISING OF STRUCTURAL STEEL

bolts, nuts and washers shall be calculated from the approved drawings for
different items of work and NO ALLOWANCE in weight will be made for
weight of zinc added due to galvanising.
ANNEXURE 5 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
SECTION:
SPEC. NO. TATA CONSULTING ENGINEERS LIMITED Performance
TCE.6079A-C-266- Guarantee
301
FLARE SYSTEM SHEET 1 OF 1

PERFORMANCE GUARANTEE
S. Utilities Units Continuous Intermittent
No Requirement Requirement
1. Water Kg/hr
2. Medium Pressure Steam Kg/hr
3. Fuel Gas Kg/hr
4. Power kWH
5. Noise Level at Stack dBA
Base for full load of
steam only ( <90 dBA
required as per
TCE.6079A-C-266-301
Section Spec Part IIA –
Page 18 of 402)

Note:

Bidder to note that cost loading will be done as per the formula provided below on
guaranteed utility consumption under column titled “Continuous Requirement” for
S.No 1 to 4. The “Continuous Requirement” refers to the operation of flare with
required amount of purge gas only.

Additional Cost Loading will be done as follows:

Utility Cost per Hour (as mentioned in Document No. TCE.6079A-CH-300-DC-01


Part IIA Page 61 of 402 of tender document) x 8000 Hours x 5

In case Bidder fails to meet the Performance Guarantee after award of contract,
Penalty shall be applicable as follows for the utilities mentioned in the table above in
S. No 1 to 4.

(Actual Hourly Utility Consumption) less (Guaranteed Hourly Utility Consumption) x


8000 Hours x 5.

The above formula for penalty will be applied for each utility where “(Actual Hourly
Utility Consumption) less (Guaranteed Hourly Utility Consumption)” is positive and
shall not be applicable if negative. Bidder will not get any benefit for better
performance than the guaranteed values i.e if “(Actual Hourly Utility Consumption)
less (Guaranteed Hourly Utility Consumption)” is negative.

In case Bidder fails to meet the Performance Guarantee after award of contract, for
S.No.5 listed in the table above even after modifications carried to reduce the noise
level, then penalty of 10% of the total contract value shall be levied.

SEAL &
SIGNATURE OF THE BIDDER

ISSUE
R0

FILE NAME: 6079AC266301_PG.DOC TCE FORM NO. 329 R5


ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

TATA CONSULTING ENGINEERS LIMITED SECTION: TITLE


TCE.6079A.590-LS-1001 SHEET i OF iii O
PIPING MATERIAL SPECIFICATION

PIPING MATERIAL SPECIFICATION

PMC SERVICES FOR THE UTILITIES & OFFSITES OF


NHT/CCR

FILE NAME: TCE-6079A-590-LS-1001P1

REV. NO. P0 P1 R0 R1
ISSUE
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD. BY VRP -sd VRP

CHD. BY DSJ -sd DSJ

APD. BY RRP -sd RRP

DATE 07.07.2010 08.11.10


FORM NO. 020R3
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

TATA CONSULTING ENGINEERS LIMITED SECTION: CONTENT


TCE.6079A.590-LS-1001 SHEET ii OF iii
PIPING MATERIAL SPECIFICATION

CONTENTS

SL.NO PIPE CLASS REV SH.NO.

1 LEGEND P0 1

2 PMS FOR ‘CA2’ GRADE P0 2

3 BRANCH CONN. CHART FOR ‘CA2’ GRADE P0 4

4 PMS FOR ‘CB2’ GRADE P0 5

5 BRANCH CONN. CHART FOR ‘CB2’ GRADE P0 7

6 PMS FOR ‘CD2’ GRADE P1 8

7 BRANCH CONN. CHART FOR ‘CD2’ GRADE P1 10

8 PMS FOR ‘CF2’ GRADE P1 11

9 BRANCH CONN. CHART FOR ‘CF2’ GRADE P1 14

10 PMS FOR ‘CC2’ GRADE P0 16

11 BRANCH CONN. CHART FOR ‘CC2’ GRADE P0 18

12 PMS FOR ‘CC3’ GRADE P1 19

13 BRANCH CONN. CHART FOR ‘CC3’ GRADE P1 21

14 PMS FOR ‘SB2’ GRADE P0 22

15 BRANCH CONN. CHART FOR ‘SB2’ GRADE P0 24

16 STEAM DRIP LEG DETAILS P0 25

17 STEAM TRAP ASSEMBLY DETAILS P0 26

18 VENTS AND DRAINS FOR HYDRO TEST P0 27

ISSUE
P1

FORM NO. 120 R1


ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

TATA CONSULTING ENGINEERS LIMITED SECTION: REV.STATUS


TCE.6079A.590-LS-1001 SHEET iii OF iii O
PIPING MATERIAL SPECIFICATION

REVISION STATUS

REV. NO. DATE DESCRIPTION

P0 07.07.2010 ISSUED FOR CLIENTS REVIEW AND COMMENTS

P1 08.11.2010 PMS GRADE CD2, CF2 AND CC3 REVISED

ISSUE
P1

FORM NO. 120 R1


ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION SHEET 1 OF 27

LEGEND
BW - BUTT WELDING
SW - SOCKET WELDING
CS - CARBON STEEL
SS - STAINLESS STEEL
CI - CAST IRON
CL - CLASS
ERW - ELECTRIC RESISTANT WELDED
EFW - ELECTRIC FUSION WELDED
SMLS - SEAMLESS
PE - PLAIN ENDS
BE - BEVELLED ENDS
TE - THREADED ENDS
SO - SLIP-ON
WN - WELDING NECK
LJ - LAP JOINT
RF - FLANGED RAISED FACE
FF - FLANGED FLAT FACE
SCH - SCHEDULE
GALV - GALVANISED
IBR - INDIAN BOILER REGULATION
EPDM - ETHYLENE PROPYLENE DIENE MONOMER
HDPE - HIGH DESNSITY POLYETHYLENE
NPT - AMERICAN STD. PIPE THREAD
Gr - GRADE
PSE- PLAIN SMALL END
BLE - BEVELLED LARGE END
THK - THICKNESS

NOTES:
1. SPECIFIC REQUIREMENTS GIVEN IN PIPING DRAWINGS OR IN ISOMETRICS SUPERSEDES
REQUIREMENTS GIVEN HERE.
0
2. USE PTFE TAPE FOR THREDED JOINTS FOR TEMPERATURE 250 C
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

TATA CONSULTING ENGINEERS LIMITED SECTION : D


SPECIFICATION NO.
TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE :CA2 SHEET 2 OF 27

RATING : 150 #
SERVICE : UTILITIES, COOLING WATER SUPPLY AND RETUREN AT 18 deg C, CHILLED WATER SUPPLY AND RETURN
SERVICE WATER, INSTRUMENT AIR (2” & ABOVE), PLANT AIR, NITROGEN,INERT GAS
DESIGN

TEMP. º F / º C 0 38 65 100 CORR. ALL. inch/ mm 1.5


2
PR. psig/ kg/ cm g 10.55 10.55 10.55 FLANGE FACING RF, CONC. SERR. FINISH
inch
NOM. PIPE SIZE 15 20 25 32 40 50 65 80 100 150 200 250
mm
inch
OUTSIDE DIA. 21.3 26.7 33.4 42.1 48.3 60.3 73.03 88.9 114.3 168.3 219 273
mm
CLASS/ inch
HVY HVY HVY HVY HVY HVY HVY HVY HVY HVY 6.0 6.0
THICKNESS mm
inch
NOM. PIPE SIZE 300 350 400 450 500 600
mm
inch
OUTSIDE DIA. 324 356 406 457 508 610
mm
inch
THICKNESS 6.0 8.0 8.0 8.0 10.0 10.0
mm
40 SW TO ANSI B 16.11
LINE JOINT
50 BW TO ANSI B 16.25
MAINTENANCE
ALL FLANGED. TO BE KEPT MINIMUM
JOINTS
NOMINAL
PIPE MATERIAL DIMENSIONAL
ITEM REMARKS
SIZE RANGE SPECIFICATION STANDARD
inch / mm
PIPES 150 CS, IS 1239 PT-1 IS 1239 PT-1 ERW, BLACK, 40 – PE, 50 - BE
> 150 CS, IS 3589 Gr. 330 IS 3589 ERW, EFW, BLACK, BE
TYPE-E, POE-TOE,PBE,TBE,SCH TO
PIPE NIPPLE 15 TO 40 CS, IS 1239 PT-1 IS 1239 PT-1
MATCH PIPE

ELBOWS, CAPS,
> 40 TO 150 ASTM A 234 Gr. WPB ANSI B 16.9 SCH STD, BW
REDUCERS,TEES
FITTINGS

ELBOWS, CAPS, ASTM A 234 Gr.


> 150 ANSI B 16.9 SCH M, BW
REDUCERS,TEES WPBW
B.W.

40 ASTM A 105 ANSI B 16.11 3000CL.


S.W. FITTINGS

SWAGES( ECC/CONC) 15 TO 80 ASTM A 234 Gr. WPB MSS SP 95 PSE & BLE,THICKNESS TO MATCH PIPE
BRANCH CONNECTION ALL SEE BRANCH CONNECTION CHART
40 ASTM A 105 ANSI B 16.5 SW, 150 CL
FLANGES 50 TO 600 ASTM A 105 ANSI B 16.5 SO, 150 CL

BLIND FLANGES 15 TO 600 ASTM A 105 ANSI B 16.5 150 CL


SPECTACLE BLIND 15 TO 200 ASTM A 105 ANSI B 16.48 150 CL
SPCR & BLIND 250 TO 600 ASTM A 105 ANSI B 16.48 150 CL
MACHINE / STUD BOLTS ALL ASTM A 307 GR.B ANSI B 18.2.1 CL. 2A

REV.NO. PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P0
UTILITIES & OFFSITES OF NHT/CCR
REV. BY DATE: 07/07/10
FILE NAME: F087R0.DOT TCE FORM NO. 087 R0 SH. 1 OF 2
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE:CA2 SHEET 3 OF 27


NOMINAL PIPE
MATERIAL DIMENSIONAL
ITEM SIZE RANGE REMARKS
SPECIFICATION STANDARD
inch / mm
HEAVY HEX.
ALL ASTM A 194, Gr.2 ANSI B 18.2.2 CL.2B REF NOTE 1
NUTS
ANSI B 16.21
GASKETS ALL IS-2712 GR. W/3 SELF-CENTERING RING, 2 MM THK.
CL.150
UNIONS < 40 ASTM A 105 ANSI B 16.11 SW 3000 CL
THREADED
40 ASTM A 105 ANSI B 16.11 3000 CL NPT / IS 554 ( TAPER) AS REQUIRED
FITTINGS

TYPE
TYPE OF SIZE PRESSURE DIM. STANDARD
MATERIAL OF REMARKS
VALVE RANGE RATING OR
ENDS
inch./ mm. BODY TRIM ANSI/ IS TAG NUMBER
CHECK STELLITED BS-5352 C63
GATE 40 ASTM A 105 STEM: 13% 800 SW API-602 G63
GLOBE Cr. STEEL BS-5352 T63

ASTM A 216
BALL 15 TO 400 SS 304 150 RF BS-5351 B23 NOTE-2
Gr.WCB

ASTM A 216 13% Cr.


GLOBE 50 TO 400 150 RF BS-1873 T23
GR WCB STEEL

ASTM A 216 13% Cr. API-609/BS-5155


BUTTERFLY 80 150 WAFER NOTE-3
GR WCB STEEL U23

CHECK ASTM A 216 13% Cr.


50 150 RF BS-1868 C23 SWING
GR WCB STEEL

ASTM A 216 13% Cr.


GATE 50 150 RF API-600 G23
GR WCB STEEL

STRAINER
<40 ASTM A 105 SS 304 150 SW SY23
(Y-TYPE)
STRAINER ASTM A 234
50 TO 150 SS 304 150 BW STT23 MESH 40
(T-TYPE) Gr. WPB
STRAINER ASTM A 234
>200 SS 304 150 BW STT23
(T-TYPE) Gr. WPB-W

NOTES:

1. NUT SHALL BE ALONG WITH WASHER.


2. BALL VALVES SHALL BE GEAR OPERATED FOR 150 NB & ABOVE
3. BUTTERFLY VALVES SHALL BE GEAR OPERATED FOR 250 NB & ABOVE
4. NDT REQUIREMENTS AS PER STANDARD

REV.NO. PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P0
UTILITIES & OFFSITES OF NHT/CCR
REV. BY DATE: 07/07/10
FILE NAME: F087R0.DOT TCE FORM NO. 087 R0 SH. 2 OF 2
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE:CA2 SHEET 4 OF 27

BRANCH CONNECTION CHART


SIZE
(inch/ BRANCH
mm)

100

150

200

250

300

350

400

450

500

550

600

650

700

750

800
15

20

25

32

40

50

65

80
RUN

15 T
20 RT T
25 RT RT T
32 RT RT RT T
40 RT RT RT RT T
50 H H H H H T
65 H H H H H S T
80 H H H H H S S T
100 H H H H H S S S T
150 H H H H H S S S S T
200 H H H H H S S S S S T
250 H H H H H S S S S S S T
300 H H H H H S S S S S S S T
350 H H H H H S S S S S S S S T
400 H H H H H S S S S S S S S S T
450 H H H H H S S S S S S S S S S T
500 H H H H H S S S S S S S S S S S T
550 H H H H H S S S S S S S S S S S S T
600 H H H H H S S SR SR SR SR SR SR SR SR SR SR SR T
650 H H H H H S S SR SR SR SR SR SR SR SR SR SR SR SR T
700 H H H H H S S SR SR SR SR SR SR SR SR SR SR SR SR SR T
750 H H H H H S S SR SR SR SR SR SR SR SR SR SR SR SR SR SR T
800 H H H H H S S SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR T

LEGEND :
T - STRAIGHT TEE
RT - REDUCING TEE
H - HALF COUPLING
TL -THREADOLET
SL - SOCKOLET
WL - WELDOLET
S - STUB –IN
N - NIPOLET SR - STUB-IN WITH R-PAD

REV.NO. PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P0
UTILITIES & OFFSITES OF NHT/CCR
REV. BY DATE: 07/07/10
FILE NAME: F087R0.DOT TCE FORM NO. 087 R0 SH. 1 OF 1
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE:CB2 SHEET 5 OF 27


RATING: 150 #
SERVICE : CONDENSATE NON IBR, NITROGEN (BEYOND CA), LOW PRESSURE STEAM AT 3.4 Kg/CM2,WASTE GAS

CORR. ALL.
DESIGN

TEMP. º F / º C -29 38 93 149 204 260 1.5


inch/ mm

PR. psig/ kg/ cm2 g 20.03 20.03 18.28 16.17 14.06 11.95 FLANGE FACING RF, CONC. SERR. FINISH
inch
NOM. PIPE SIZE 15 20 25 32 40 50 65 80 100 150
mm
inch
OUTSIDE DIA. 21.3 26.7 33.4 42.2 48.3 60.3 73.03 88.9 114.3 168.3
mm
inch SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH
THICKNESS
mm S160 S160 XS XS XS XS STD STD STD STD
inch
NOM. PIPE SIZE
mm
inch
OUTSIDE DIA.
mm
inch
THICKNESS
mm
40 SW TO ANSI B 16.11
LINE JOINT
50 BW TO ANSI B 16.25
MAINTENANCE
ALL FLANGED. TO BE KEPT MINIMUM
JOINTS
NOMINAL
PIPE MATERIAL DIMENSIONAL
ITEM REMARKS
SIZE RANGE SPECIFICATION STANDARD
inch / mm
< 150 ASTM A 106 Gr. B ANSI B 36.10 BLACK, SMLS, 40 – PE, 50 - BE
PIPES

SMLS, POE-TOE,PBE,TBE,SCH TO MATCH


PIPE NIPPLES 15 TO 40 ASTM A 106 Gr. B ANSI B 36.10
PIPE

ELBOWS, CAPS,
> 40 TO 150 ASTM A 234 Gr. WPB ANSI B 16.9 SCH M, SMLS
REDUCERS,TEES
FITTINGS

ELBOWS, CAPS,
REDUCERS,TEES
B.W.

15 TO 20 ASTM A 105 ANSI B 16.11 6000CL.


S. W. FITTINGS
25 TO 40 ASTM A 105 ANSI B 16.11 3000CL.
SWAGES( ECC/CONC) 15 TO 80 ASTM A 234 Gr. WPB MSS SP 95 PSE & BLE,THICKNESS TO MATCH PIPE
MITRES
BRANCH CONNECTION ALL SEE BRANCH CONNECTION CHART
FLANGES ALL ASTM A 105 ANSI B 16.5 WN, 150 CL
BLIND FLANGES ALL ASTM A 105 ANSI B 16.5 150 CL
SPECTACLE BLIND 15 TO 200 ASTM A 105 ANSI B 16.48 150 CL
SPCR & BLIND 250 TO 600 ASTM A 105 ANSI B 16.48 150 CL
MACHINE / STUD BOLTS ALL ASTM A 193 GR.B ANSI B 18.2.1 CL. 2A, FULLY THREADED

REV.NO. PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P0
REV. BY DATE: 07/07/10 UTILITIES & OFFSITES OF NHT/CCR
FILE NAME: F087R0.DOT TCE FORM NO. 087 R0 SH. 1 OF 2
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE:CB2 SHEET 6 OF 27


NOMINAL PIPE
MATERIAL DIMENSIONAL
ITEM SIZE RANGE REMARKS
SPECIFICATION STANDARD
inch / mm

HEAVY HEX. ALL ASTM A 194, Gr.2 ANSI B 18.2.2 CL.2B


NUTS REF .NOTE 1
SP.WOUND SS316 ANSI B 16.20
GASKETS ALL SELF-CENTERING RING, 4.5 MM THK.
WITH GRAFIL FILLED CL.150

THREADED 40 ASTM A 105 ANSI B 16.11 3000 CL NPT


FITTINGS

TYPE OF PRESSUR TYPE OF SPECIFICATION


SIZE RANGE MATERIAL REMARKS
VALVE E RATING ENDS OR
inch./ mm. BODY TRIM ANSI/ IS TAG NUMBER
CHECK BS-5352 C63
GATE STELLITED API-602 G63
40 ASTM A 105 STEM: 13% 800 SW
GLOBE Cr. STEEL BS-5352 T63

ASTM A 216 13% Cr.


CHECK 50 150 RF BS-1868 C23
Gr.WCB STEEL
ASTM A 216 13% Cr. API-609/BS-5155
BUTTERFLY 80 150 WAFER
Gr.WCB STEEL U23
ASTM A 216
BALL 15 SS 304 150 RF BS-5351 B23 SEAT RPTFE,NOTE-3
Gr.WCB
ASTM A 216 13% Cr.
GLOBE 50 150 RF BS-1873 T23
Gr.WCB STEEL
ASTM A 216 13% Cr.
GATE 50 150 RF API-600 G23
Gr.WCB STEEL
STRAINER
<40 ASTM A 105 SS 304 150 SW SY23
(Y-TYPE)
MESH 40
STRAINER ASTM A 234
50 TO 150 SS 304 150 BW ST23
(T-TYPE) Gr. WPB

STEAM TRAPS 25 ASTMA 105 SS 410/420 150 SW SM23 COMPACT TYPE

NOTES:
1. NUT SHALL BE PROVIDED WITH WASHER.
2. PTFE DULY REINFORCED WITH ARAMID FIBRES FOR ALL SERVICE
3. BALL VALVES SHALL BE GEAR OPERATED FOR 150 NB & ABOVE.
4. NDT REQUIREMENTS AS PER STANDARD

REV.NO. PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P0
REV. BY DATE: 07/07/10 UTILITIES & OFFSITES OF NHT/CCR
FILE NAME: F087R0.D TCE FORM NO. 087 R0 SH.2 OF 2
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE:CB2 SHEET 7 OF 27

BRANCH CONNECTION CHART

SIZE BRANCH
inch / mm
RUN 15 20 25 40 50 65 80 100 150
15 T
20 RT T

25 RT RT T

40 RT RT RT T
50 H H H S T
65 H H H H S T
80 H H H H S S T
100 H H H H S S S T
150 H H H H S S S S T

LEGEND :
T - STRAIGHT TEE
RT - REDUCING TEE
H - HALF COUPLING
TL -THREADOLET
SL - SOCKOLET
WL - WELDOLET
S - STUB –IN
N - NIPOLET
SR - STUB-IN WITH R-PAD

REV.NO. PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P0
UTILITIES & OFFSITES OF NHT/CCR
REV. BY DATE: 07/07/10
FILE NAME: F087R0.DOT
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE:CD2 SHEET 8 OF 27


RATING: 150 #
SERVICE : NACE, SOUR WATER CONTAINING H2S &/OR AMMONIUM SALT (NOTES 1-4), ACID FLARE

CORR. ALL.
DESIGN

TEMP. º F / º C -29 38 93 149 204 260 3.0


inch/ mm

PR. psig/ kg/ cm2 g 20.03 20.03 18.28 16.17 14.06 11.95 FLANGE FACING RF, CONC. SERR. FINISH
inch
NOM. PIPE SIZE 15 20 25 32 40 50 65 80 100 150 200
mm
inch
OUTSIDE DIA. 21.3 26.7 33.4 42.2 48.3 60.3 73.03 88.9 114.3 168.3 219
mm
inch SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH
THICKNESS
mm S160 S160 XS XS XS XS STD STD STD STD STD
inch
NOM. PIPE SIZE 250 300 350 400 450 500 600
mm
inch
OUTSIDE DIA. 273 324 356 406 457 508 610
mm
inch SCH SCH SCH SCH SCH SCH SCH
THICKNESS
mm STD STD STD STD STD STD STD
40 SW TO ANSI B 16.11
LINE JOINT
50 BW TO ANSI B 16.25
MAINTENANCE
ALL FLANGED. TO BE KEPT MINIMUM
JOINTS
ITEM NOMINAL
PIPE MATERIAL DIMENSIONAL
REMARKS
SIZE RANGE SPECIFICATION STANDARD
inch / mm
< 350 ASTM A 106 Gr. B ANSI B 36.10 BLACK, SMLS, 40 – PE, 50 - BE
PIPES A672GR.B60 CL.32
400 TO 600 ANSI B 36.10 BE, EFsW
(200 BHN MAX)
SMLS, POE-TOE,PBE,TBE,SCH TO MATCH
PIPE NIPPLES 15 TO 40 ASTM A 106 Gr. B ANSI B 36.10
PIPE

ELBOWS, CAPS,
> 40 TO 350 ASTM A 234 Gr. WPB ANSI B 16.9 SCH M, BW, 1.5D
REDUCERS,TEES
FITTINGS

ELBOWS, CAPS, ASTM A 234 Gr.


400 TO 600 ANSI B 16.9 SCH M, BW, 1.5D
REDUCERS,TEES WPB-W
B.W.

15 TO 20 ASTM A 105 ANSI B 16.11 6000CL.


S. W. FITTINGS
25 TO 40 ASTM A 105 ANSI B 16.11 3000CL.
SWAGES( ECC/CONC) 15 TO 80 ASTM A 105 BS-3799 PSE & BLE,THICKNESS TO MATCH PIPE
MITRES
BRANCH CONNECTION ALL SEE BRANCH CONNECTION CHART
FLANGES ALL ASTM A 105 ANSI B 16.5 WN, 150 CL
BLIND FLANGES ALL ASTM A 105 ANSI B 16.5 150 CL
SPECTACLE BLIND 15 TO 200 ASTM A 105 ANSI B 16.48 150 CL
SPCR & BLIND 250 TO 600 ASTM A 105 ANSI B 16.48 150 CL
MACHINE / STUD BOLTS ALL ASTM A 193 GR.B7M ANSI B 18.2

REV.NO. P1 PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE 08.11.10 CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P1
REV. BY VRP DATE: 07/07/10 UTILITIES & OFFSITES OF NHT/CCR
FILE NAME: F087R0.DOT TCE FORM NO. 087 R0 SH. 1 OF 2
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE:CD2 SHEET 9 OF 27


NOMINAL PIPE
MATERIAL DIMENSIONAL
ITEM SIZE RANGE REMARKS
SPECIFICATION STANDARD
inch / mm

HEAVY HEX. ALL ASTM A 194, Gr.2HM ANSI B 18.2


NUTS REF .NOTE 5
SP.WOUND SS316 ANSI B 16.20
GASKETS ALL SELF-CENTERING RING, 4.5 MM THK.
WITH GRAFIL FILLED CL.150

THREADED 40 ASTM A 105 ANSI B 16.11 3000 CL NPT


FITTINGS

TYPE OF PRESSUR TYPE OF DIM. STANDARD


SIZE RANGE MATERIAL REMARKS
VALVE E RATING ENDS OR
inch./ mm. BODY TRIM ANSI/ IS TAG NUMBER
CHECK BS-5352
GATE STELLITED API-602
40 ASTM A 105 STEM: 800 SW
GLOBE SS316 BS-5352

ASTM B 564,
CHECK 50 TO 600 MONEL400/A MONEL 150 RF BS-1868 SWING TYPE
494, M-30C
ASTM A 216 13% Cr.
GLOBE 50 TO 400 150 RF BS-1873
Gr.WCB STEEL
STELLITED
ASTM A 216
GATE 50 TO 600 STEM: 150 RF API-600
Gr.WCB
SS316
STRAINER
<40 ASTM A 105 SS 316L 150 SW
(Y-TYPE)
STRAINER ASTM A 234
50 TO 350 SS 316L 150 BW MESH 40
(T-TYPE) Gr. WPB
STRAINER ASTM A 234
400 TO 600 SS 316L 150 BW
(T-TYPE) Gr. WPB-W

NOTES:
1. MAXIMUM HARDNESS IN WELD JOINTS SHALL BE LIMITED TO 200 BHN
2. ALL GIRTH WELD JOINTS SHALL BE 100% RADIOGRAPHED & ALL TYPES OF WELDS INCLUDING GIRTH WELD SHALL BE
WET FLOURSCENT MP TESTED
3. FOR ALL WELDED PIPES, THE PLATE SHALL MEETS HIC RESISTENT REQUIREMENTS
4. POST WELD HEAT TREATMENT IS REQUIRED FOR ALL WELD JOINTS IRRESPECTIVE OF THICKNESS
5. NUT SHALL BE PROVIDED WITH WASHER.
6. NDT REQUIREMENTS AS PER STANDARD

REV.NO. P1 PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE 08.11.10 CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P1
REV. BY VRP DATE: 07/07/10 UTILITIES & OFFSITES OF NHT/CCR
FILE NAME: F087R0.D TCE FORM NO. 087 R0 SH.2 OF 2
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE:CD2 SHEET 10 OF 27

BRANCH CONNECTION CHART

SIZE BRANCH
inch / mm
RUN 15 20 25 40 50 80 100 150 200 250 300 350 400 450 500 600
15 T
20 RT T

25 RT RT T

40 RT RT RT T
50 H H H S T
80 H H H H S T
100 H H H H S S T
150 H H H H S S S T
200 H H H H S S S S T
250 H H H H S S S S S T
300 H H H H S S S S S S T
350 H H H H S S S S S S S T
400 H H H H S S S S S S S S T
450 H H H H SR SR SR SR SR SR SR SR SR T
500 H H H H SR SR SR SR SR SR SR SR SR SR T
600 H H H H SR SR SR SR SR SR SR SR SR SR SR T

LEGEND :
T - STRAIGHT TEE
RT - REDUCING TEE
H - HALF COUPLING
TL -THREADOLET
SL - SOCKOLET
WL - WELDOLET
S - STUB –IN
N - NIPOLET
SR - STUB-IN WITH R-PAD

REV.NO. P1 PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE 08.11.10 CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P1
UTILITIES & OFFSITES OF NHT/CCR
REV. BY VRP DATE: 07/07/10
FILE NAME: F087R0.DOT
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE: CF2 SHEET 11 OF 27


RATING : 150 #
SERVICE : HYDROCARBON FLARE
(NOTE-5)

CORR. ALL.
TEMP. º F / º C -29 38 93 149 204 260 3.0
DESIGN

inch/ mm

18.2
PR. psig/ kg/ cm2 g 20.03 20.03 16.17 14.06 11.95 FLANGE FACING RF, CONC. SERR. FINISH
8
inch
NOM. PIPE SIZE 15 20 25 40 50 80 100 150 200 250 300 350 400
mm
i inch 114. 168.
OUTSIDE DIA. 21.3 26.7 33.4 48.3 60.3 88.9 219 273 324 356 406
mm 3 3
inch SC
SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH
THICKNESS H
mm S160 S160 XS XS XS STD STD STD STD STD STD STD
STD
inch
NOM. PIPE SIZE 450 500 600 650 700 750 800 850 900 950 1000 1050 1100
mm
inch
OUTSIDE DIA. 457 508 610 660 711 762 813 864 914 965 1016 1067 1118
mm
inch SCH SC
SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH
THICKNESS STD H
mm STD STD STD STD STD STD STD STD STD STD XS
STD
inch
NOM. PIPE SIZE 1150 1200 1300 1350 1400 1800
mm
inch
OUTSIDE DIA. 1168 1219 1320.8 1371.6 1422 1828.8
mm
inch SCH SCH 12.7
THICKNESS 12.7 12.7 12.7
mm XS STD
40 SW TO ANSI B 16.11
LINE JOINT
50 BW TO ANSI B 16.25
MAINTENANCE
ALL FLANGED. TO BE KEPT MINIMUM
JOINTS
NOMINAL
PIPE MATERIAL DIMENSIONAL
ITEM REMARKS
SIZE RANGE SPECIFICATION STANDARD
inch / mm
< 350 ASTM A 106 Gr. B ANSI B 36.10 SMLS, 40 – PE, 50 - BE
PIPES A672 GR. B60
400 ANSI B 36.10 BE, E.F.W
CL.12(200 BHN MAX)
SMLS, POE-TOE,PBE,TBE,SCH TO MATCH
PIPE NIPPLES 15 TO 40 ASTM A 106 Gr. B ANSI B 36.10
PIPE

ELBOWS, CAPS,
50 TO 350 ASTM A 234 Gr. WPB ANSI B 16.9 SCH M, BW, 1.5D
REDUCERS,TEES
B.W. FITTINGS

ELBOWS, CAPS, 400 TO ASTM A 234 Gr.


ANSI B 16.9 SCH M, BW, 1.5D
REDUCERS,TEES 1200 WPB-W
ELBOWS, CAPS, 1250 TO ASTM A 234 Gr.
MNF’STD SCH M, BW, 1.5D
REDUCERS,TEES 1800 WPB-W
15 TO 20 ASTM A 105 ANSI B 16.11 6000CL.
S. W. FITTINGS
25 TO 40 ASTM A 105 ANSI B 16.11 3000CL.
SWAGES( ECC/CONC) 15 TO 80 ASTM A 234 Gr. WPB BS-3799 PSE & BLE,THICKNESS TO MATCH PIPE
BRANCH CONNECTION ALL SEE BRANCH CONNECTION CHART

REV.NO. P1 PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE 08.11.10 CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P1
UTILITIES & OFFSITES OF NHT/CCR
REV. BY VRP DATE: 07/07/10
FILE NAME: F087R0.DOT TCE FORM NO. 087 R0 SH. 1 OF 3
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE:CF2 SHEET 12 OF 27


NOMINAL
PIPE MATERIAL DIMENSIONAL
ITEM REMARKS
SIZE RANGE SPECIFICATION STANDARD
inch / mm
FLANGES 15 TO 600 ASTM A 105 ANSI B 16.5 WN, 150 CL
650 TO
FLANGES ASTM A 105 ANSI B 16.47-B WN, 150 CL
1500
ASTM A 105/ ASTM A
FLANGES 1550 TO 1800 JOB STD WN, 150 CL, NORMALISED
516 GR.70
BLIND FLANGES 15 TO 600 ASTM A 105 ANSI B 16.5 150 CL
650 TO
BLIND FLANGES ASTM A 516 GR.70 ANSI B 16.47-B 150 CL, NORMALISED
1500
BLIND FLANGES 1550 TO 1800 ASTM A 516 GR.70 JOB STD 150 CL, NORMALISED
SPECTACLE BLIND 15 TO 200 ASTM A 105 ANSI B 16.48 150 CL,FF
SPCR & BLIND 250 TO 600 ASTM A 105 ANSI B 16.48 150 CL,FF
SPCR & BLIND 650 TO 1500 ASTM A 516 GR.70 150 CL,FF
MACHINE / STUD
ALL ASTM A 193 GR.B ANSI B 18.2.1 CL. 2A, FULLY THREADED
BOLTS
ALL ASTM A 194, Gr.2 ANSI B 18.2.2 CL.2B, REF .NOTE 1
HEAVY HEX. NUTS

SP.WOUND SS316 ANSI B 16.20


GASKETS 15 TO 600 SELF-CENTERING RING, 4.5 MM THK.
WITH GRAFIL FILLED CL.150
SP.WOUND SS316
ANSI B 16.20
650 WITH GRAFIL FILLED+ SELF-CENTERING RING, 4.5 MM THK.
CL.150,B 16.47B
I RING

40 ASTM A 105 ANSI B 16.11 3000 CL NPT


THREADED FITTINGS

SIZE PRESSUR TYPE OF SPECIFICATION


TYPE OF VALVE MATERIAL REMARKS
RANGE E RATING ENDS OR
inch./
BODY TRIM ANSI/ IS TAG NUMBER
mm.
CHECK BS-5352 C63
GATE STELLITED API-602 G63
40 ASTM A 105 STEM: 13% 800 SW
GLOBE Cr. STEEL BS-5352 T63

50 TO ASTM A 216 13% Cr.


CHECK 150 RF BS-1868 C23 SWING TYPE
600 Gr.WCB STEEL
80 TO ASTM A 216 13% Cr. API-609/BS-5155
BUTTERFLY 150 WAFER
600 Gr.WCB STEEL U23

650
ASTM A 216 13% Cr.
BUTTERFLY TO 150 RF BS-5155 U23A B16.47B
Gr.WCB STEEL
1200

1250
ASTM A 216 13% Cr.
BUTTERFLY TO 150 RF BS-5155 U23B B16.47B
Gr.WCB STEEL
1300
15 TO ASTM A 216
BALL SS 304 150 RF BS-5351 B23 SEAT RPTFE,NOTE-3
400 Gr.WCB
50 TO ASTM A 216 13% Cr.
GLOBE 150 RF BS-1873 T23
400 Gr.WCB STEEL

REV.NO. P1 PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE 08.11.10 CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P1
UTILITIES & OFFSITES OF NHT/CCR
REV. BY VRP DATE: 07/07/10
FILE NAME: F087R0.D TCE FORM NO. 087 R0 SH.2 OF 3
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE:CF2 SHEET 13 OF 27


SIZE PRESSUR TYPE OF SPECIFICATION
TYPE OF VALVE MATERIAL REMARKS
RANGE E RATING ENDS OR
inch./
BODY TRIM ANSI/ IS TAG NUMBER
mm.
50 TO ASTM A 216 13% Cr. 650 AS PER BS-
GATE 150 RF API-600 G23
1200 Gr.WCB STEEL 1414, FLGD B16.47B
STRAINER (Y-
<40 ASTM A 105 SS 304 150 SW SY23 MESH 40
TYPE)
STRAINER (T- 50 TO ASTM A 234
SS 304 SCH M BW ST23
TYPE) 350 Gr. WPB
STRAINER (T- 400 TO ASTM A 234
SS 304 SCH M BW STT23
TYPE) 600 Gr. WPB-W

NOTES:
1. NUT SHALL BE PROVIDED WITH WASHER.
2. PTFE DULY REINFORCED WITH ARAMID FIBRES FOR ALL SERVICE
3. BALL VALVES SHALL BE GEAR OPERATED FOR 150 NB & ABOVE.
4. NDT REQUIREMENTS AS PER STANDARD
5. PIPE WALL THICKNESS IS CALCULATEDBASED ON ACTUAL DESIGN LINE CONDITIONS ( 200 DEG. C AND 3.5KG/SQ.CM.G)
FOR 800 NB TO 1400 NB AND FOR 1800 NB PIPE.

REV.NO. P1 PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE 08.11.10 CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P1
UTILITIES & OFFSITES OF NHT/CCR
REV. BY VRP DATE: 07/07/10
FILE NAME: F087R0.D TCE FORM NO. 087 R0 SH.3 OF 3
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE: CF2 SHEET 14 OF 27

BRANCH CONNECTION CHART

SIZE
(inch/m BRANCH
m)

100

150

200

250

300

350

400

450

500

550

600

650

700

750

800

850

900
15

20

25

40

50

80
RUN

15 T
20 RT T
25 RT RT T
40 RT RT RT T
50 H H H H T
80 H H H H S T
100 H H H H S S T
150 H H H H S S S T
200 H H H H S S S S T
250 H H H H S S S S S T
300 H H H H S S S S S S T
350 H H H H S S S S S S S T
400 H H H H S S S S S S S S T
450 H H H H SR SR SR SR SR SR SR SR SR T
500 H H H H SR SR SR SR SR SR SR SR SR SR T
550 H H H H SR SR SR SR SR SR SR SR SR SR SR T
600 H H H H SR SR SR SR SR SR SR SR SR SR SR SR T
650 H H H H SR SR SR SR SR SR SR SR SR SR SR SR SR T
700 H H H H SR SR SR SR SR SR SR SR SR SR SR SR SR SR T
750 H H H H SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR T
800 H H H H SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR T
850 H H H H SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR T
900 H H H H SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR T
950 H H H H SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR
1000 H H H H SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR
1050 H H H H SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR
1100 H H H H SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR
1150 H H H H SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR
1200 H H H H SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR
1300 H H H H SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR
1350 H H H H SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR
1800 H H H H SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR SR

REV.NO. P1 PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE 08.11.10 CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P1
UTILITIES & OFFSITES OF NHT/CCR
REV. BY VRP DATE: 07/07/10
FILE NAME: F087R0.DOT SH.1 OF 2
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE: CF2 SHEET 15 OF 27

BRANCH CONNECTION CHART

SIZE
(inch/m BRANCH
m)
1000

1050

1100

1150

1200

1300

1350
1800
950

RUN

950 T
1000 SR T
1050 SR SR T
1100 SR SR SR T
1150 SR SR SR SR T
1200 SR SR SR SR SR T
1300 SR SR SR SR SR SR T
1350 SR SR SR SR SR SR SR T
1800 SR SR SR SR SR SR SR SR T

LEGEND :
T - STRAIGHT TEE
RT - REDUCING TEE
H - HALF COUPLING
TL -THREADOLET
SL - SOCKOLET
WL - WELDOLET
S - STUB –IN
N - NIPOLET SR - STUB-IN WITH R-PAD

REV.NO. P1 PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE 08.11.10 CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P1
UTILITIES & OFFSITES OF NHT/CCR
REV. BY VRP DATE: 07/07/10
FILE NAME: F087R0.DOT SH.2 OF 2
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE: CC2 SHEET 16 OF 27


RATING: 150 #
SERVICE : STEAM SERVICE-IBR (REFER NOTE -1 & 2), CONDENSATE (IBR),BOILER FEED WATER (IBR)
DESIGN

TEMP. º F / º C 38 93 149 204 260 CORR. ALL. inch/ mm 1.5

PR. psig/ kg/cm2 g 20.03 18.28 16.17 14.06 11.95 FLANGE FACING RF, CONC. SERR. FINISH
inch
NOM. PIPE SIZE 15 20 25 32 40 50 65 80 100 150 200 250
mm
inch
OUTSIDE DIA. 21.3 26.7 33.4 42.16 48.3 60.3 73.03 88.9 114.3 168.3 219 273
mm
inch SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH
THICKNESS
mm S160 S160 XS XS XS XS XS STD STD STD STD STD
inch
NOM. PIPE SIZE 300 350
mm
inch
OUTSIDE DIA. 324 356
mm
inch SCH SCH
THICKNESS
mm STD STD
40 SW TO ANSI B 16.11
LINE JOINT
50 BW TO ANSI B 16.25
MAINTENANCE
ALL FLANGED. TO BE KEPT MINIMUM
JOINTS
NOMINAL
PIPE MATERIAL DIMENSIONAL
ITEM REMARKS
SIZE RANGE SPECIFICATION STANDARD
inch / mm
< 350 ASTM A 106 Gr. B ANSI B 36.10 BLACK, SMLS, 40 – PE, 50 - BE
PIPES

PIPE NIPPLES 15 TO 40 ASTM A 106 Gr.B ANSI B 36.10 SMLS, POE-TOE,PBE,TBE,SCH M

ELBOWS, CAPS,
50 TO 350 ASTM A 234 Gr. WPB ANSI B 16.9 BW, SCH M
REDUCERS, TEES
FITTINGS

ELBOWS, CAPS,
REDUCERS
B.W.

15 TO 20 ASTM A 105 ANSI B 16.11 6000CL.


S.W . FITTINGS
25 TO 40 ASTM A 105 ANSI B 16.11 3000CL.
SWAGES( ECC/CONC) 15 TO 80 ASTM A 105 BS-3799 PSE & BLE,THICKNESS TO MATCH PIPE
MITRES
BRANCH CONNECTION ALL SEE BRANCH CHART
15 TO 40 ASTM A 105 ANSI B 16.5 SW, 150 CL
FLANGES 50 TO 350 ASTM A 105 ANSI B 16.5 WN, 150 CL

BLIND FLANGES ALL ASTM A 105 ANSI B 16.5 150 CL


SPECTACLE BLIND 15 TO 200 ASTM A 105 ANSI B 16.48 150 CL
SPCR & BLIND 250 ASTM A 105 ANSI B 16.48 150 CL
MACHINE / STUD BOLTS ALL ASTM A 193 GR.B7 ANSI B 18.2.1 CL. 2A, FULLY THREADED

REV.NO. PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P0
UTILITIES & OFFSITES OF NHT/CCR
REV. BY DATE: 07/07/10
FILE NAME: F087R0.DOT TCE FORM NO. 087 R0 SH. 1 OF 2
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE:CC2 SHEET 17 OF 27


NOMINAL PIPE
MATERIAL DIMENSIONAL
ITEM SIZE RANGE REMARKS
SPECIFICATION STANDARD
inch / mm

HEAVY HEX. ALL ASTM A 194, Gr.2H ANSI B 18.2.2 CL.2B


NUTS REF NOTE 3
SPIRAL WOUND SS
ANSI B 16.20
GASKETS ALL 316 WITH GRAPHITE SELF CENTERING RING, 4.5 MM THK.
CL.150
FILLED

TYPE OF PRESSUR TYPE OF DIM. STANDARD


SIZE RANGE MATERIAL REMARKS
VALVE E RATING ENDS OR
inch./ mm. BODY TRIM ANSI/ IS TAG NUMBER
CHECK BS-5352 C63I
GATE STELLITED API-602 G63I
ASTM A
GLOBE 40 STEM: 13% 800 SW BS-5352 T63I
105
PISTON Cr STEEL MNF’STD K63I

ASTM
13% Cr
CHECK 50 A 216 150 RF BS-1868 C23I
STEEL
Gr.WCB
ASTM A
105/ ASTM
PISTON 50 TO 200 MFR'S STD 150 RF K23I
A 216
Gr.WCB
ASTM
13% Cr.
GLOBE 50 A 216 150 RF BS-1873 T23I
STEEL
Gr.WCB
ASTM
13% Cr.
GATE 50 A 216 150 RF G23I
STEEL
Gr.WCB
STRAINER ASTM A MESH 40
15 TO 40 SS 304 800 SW SY23I
(Y-TYPE) 105
ASTM A MESH 40
STRAINER
50 216 SS 304 150 RF SY23IB
(Y-TYPE)
GR.WCB
COMPACT STEAM
STEAM TRAPS 25 ASTMA 105 SS 410/420 150 SW SM23I
TRAP

NOTES:
1. ALL PIPES, FITTINGS, FLANGES, FLANGED AND WELDED END VALVES SHALL HAVE CARBON 0.25%.
2. PIPES, FITTINGS, FLANGES, VALVES AND SPECIALITIES SHALL BE IBR-APPROVED
3. NUT SHALL BE PROVIDED WITH WASHER.
4. NDT REQUIREMENTS AS PER STANDARD

REV.NO. PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P0
UTILITIES & OFFSITES OF NHT/CCR
REV. BY DATE: 07/07/10
FILE NAME: F087R0.DOT TCE FORM NO. 087 R0 SH. 2 OF 2
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE:CC2 SHEET 18 OF 27

BRANCH CONNECTION CHART

SIZE BRANCH
inch / mm
RUN 15 20 25 40 50 65 80 100 150 200 250 300 350
15 T
20 RT T
25 RT RT T
40 RT RT RT T
50 H H H S T
65 H H H H S T
80 H H H H S S T
100 H H H H S S S T
150 H H H H S S S S T
200 H H H H S S S S S T
250 H H H H S S S S S S T
300 H H H H S S S S S S S T
350 H H H H S S S S S S S S T

LEGEND :
T - EQUAL TEE
RT - REDUCING TEE
H - HALF COUPLING
TL -THREADOLET
SL - SOCKOLET
WL - WELDOLET
S - STUB –IN
N - NIPOLET
SR - STUB-IN WITH R-PAD

REV.NO. PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P0
UTILITIES & OFFSITES OF NHT/CCR
REV. BY DATE: 07/07/10
FILE NAME: F087R0.DOT TCE FORM NO. 087 R0 SH. 1 OF 1
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE: CC3 SHEET 19 OF 27


RATING: 300 #
SERVICE : STEAM SERVICE (IBR), CONDENSATE (IBR), BOILER FEED WATER (IBR)
DESIGN

TEMP. º F / º C 38 260 343 399 427 CORR. ALL. inch/ mm 1.5

PR. psig/ kg/cm2 g 52.02 42.18 37.61 35.5 28.82 FLANGE FACING RF, CONC. SERR. FINISH
inch
NOM. PIPE SIZE 15 20 25 32 40 50 65 80 100 150 200 250
mm
inch
OUTSIDE DIA. 21.3 26.7 33.4 42.16 48.3 60.3 73.03 88.9 114.3 168.3 219 273
mm
inch SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH
THICKNESS S160
mm S160 XS XS XS XS STD STD STD STD STD STD
inch
NOM. PIPE SIZE 300 350 400 450 500 600
mm
inch
OUTSIDE DIA. 324 356 406 456 508 610
mm
inch SCH SCH SCH SCH SCH SCH
THICKNESS STD STD XS XS
mm STD STD
40 SW TO ANSI B 16.11
LINE JOINT
50 BW TO ANSI B 16.25
MAINTENANCE
ALL FLANGED. TO BE KEPT MINIMUM
JOINTS
NOMINAL
PIPE MATERIAL DIMENSIONAL
ITEM REMARKS
SIZE RANGE SPECIFICATION STANDARD
inch / mm
< 350 ASTM A 106 Gr. B ANSI B 36.10 SMLS, 40 – PE, 50 - BE
PIPES ASTM A 672 GR B60
400 TO 600 ANSI B 36.10 BE, EFsW
CL12
PIPE NIPPLES 15 TO 40 ASTM A 106 Gr.B ANSI B 36.10 SMLS, POE-TOE,PBE,TBE,SCH M

ELBOWS, CAPS,
50 TO 350 ASTM A 234 Gr. WPB ANSI B 16.9 BW, SCH M
REDUCERS, TEES
FITTINGS

ELBOWS, CAPS, 400 TO 600 ASTM A 234 Gr.


ANSI B 16.9 BW, SCH M
REDUCERS WPB-W
B.W.

15 TO 20 ASTM A 105 ANSI B 16.11 6000CL.


S.W . FITTINGS
25 TO 40 ASTM A 105 ANSI B 16.11 3000CL.
SWAGES( ECC/CONC) 15 TO 80 ASTM A 105 BS-3799 PSE & BLE,THICKNESS TO MATCH PIPE
MITRES
BRANCH CONNECTION ALL SEE BRANCH CHART
15 TO 40 ASTM A 105 ANSI B 16.5 SW, 300 CL
FLANGES 50 TO 350 ASTM A 105 ANSI B 16.5 WN, 300 CL

BLIND FLANGES ALL ASTM A 105 ANSI B 16.5 300 CL


SPECTACLE BLIND 15 TO 200 ASTM A 105 ANSI B 16.48 300 CL
SPCR & BLIND 250 ASTM A 105 ANSI B 16.48 300 CL
MACHINE / STUD BOLTS ALL ASTM A 193 GR.B7 ANSI B 18.2.1 CL. 2A, FULLY THREADED

REV.NO. P1 PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE 08.11.10 CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P1
UTILITIES & OFFSITES OF NHT/CCR
REV. BY VRP DATE: 07/07/10
FILE NAME: F087R0.DOT TCE FORM NO. 087 R0 SH. 1 OF 2
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE:CC3 SHEET 20 OF 27


NOMINAL PIPE
MATERIAL DIMENSIONAL
ITEM SIZE RANGE REMARKS
SPECIFICATION STANDARD
inch / mm

HEAVY HEX. ALL ASTM A 194, Gr.2H ANSI B 18.2.2 CL.2B


NUTS REF NOTE 3
SPIRAL WOUND SS
ANSI B 16.20
GASKETS ALL 316 WITH GRAPHITE SELF CENTERING RING, 4.5 MM THK.
CL.300
FILLED

TYPE OF PRESSUR TYPE OF DIM STANDARD


SIZE RANGE MATERIAL REMARKS
VALVE E RATING ENDS OR
inch./ mm. BODY TRIM ANSI/ IS TAG NUMBER
CHECK BS-5352 C63I
GATE STELLITED API-602 G63I
ASTM A
GLOBE 40 STEM: 13% 800 SW BS-5352 T63I
105
PISTON Cr STEEL MNF’STD K63I

ASTM
CHECK 13% Cr
50 TO 600 A 216 300 RF BS-1868 C33I
STEEL
Gr.WCB
ASTM
13% Cr.
GLOBE 50 TO 400 A 216 300 RF BS-1873 T33I
STEEL
Gr.WCB
ASTM
50 TO 600 13% Cr.
GATE A 216 300 RF API 600 G33I
STEEL
Gr.WCB
STRAINER ASTM A MESH 40
15 TO 40 SS 304 800 SW SY33I
(Y-TYPE) 105
ASTM A MESH 40
STRAINER
50 TO 600 216 SS 304 300 RF SY33IB
(Y-TYPE)
GR.WCB
COMPACT STEAM
STEAM TRAPS 25 ASTMA 105 SS 410/420 300 SW SM33I
TRAP

NOTES:
1. ALL PIPES, FITTINGS, FLANGES, FLANGED AND WELDED END VALVES SHALL HAVE CARBON 0.25%.
2. PIPES, FITTINGS, FLANGES, VALVES AND SPECIALITIES SHALL BE IBR-APPROVED
3. NUT SHALL BE PROVIDED WITH WASHER.
4. NDT REQUIREMENTS AS PER STANDARD

REV.NO. P1 PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE 08.11.10 CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P1
UTILITIES & OFFSITES OF NHT/CCR
REV. BY VRP DATE: 07/07/10
FILE NAME: F087R0.DOT TCE FORM NO. 087 R0 SH. 2 OF 2
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE:CC3 SHEET 21 OF 27

BRANCH CONNECTION CHART

SIZE BRANCH
inch / mm
RUN 15 20 25 40 50 80 100 150 200 250 300 350 400 450 500 600
15 T
20 RT T
25 RT RT T
40 RT RT RT T
50 H H H RT T
80 H H H H S T
100 H H H H S SR T
150 H H H H SR SR SR T
200 H H H H SR SR SR SR T
250 H H H H SR SR SR SR SR T
300 H H H H SR SR SR SR SR SR T
350 H H H H SR SR SR SR SR SR SR T
400 H H H H SR SR SR SR SR SR SR SR T
450 H H H H SR SR SR SR SR SR SR SR SR T
500 H H H H SR SR SR SR SR SR SR SR SR SR T
600 H H H H SR SR SR SR SR SR SR SR SR SR SR T

LEGEND :
T - EQUAL TEE
RT - REDUCING TEE
H - HALF COUPLING
TL -THREADOLET
SL - SOCKOLET
WL - WELDOLET
S - STUB –IN
N - NIPOLET
SR - STUB-IN WITH R-PAD

REV.NO. P1 PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE 08.11.10 CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P1
UTILITIES & OFFSITES OF NHT/CCR
REV. BY VRP DATE: 07/07/10
FILE NAME: F087R0.DOT TCE FORM NO. 087 R0 SH. 1 OF 1
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

PECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE : SB2 SHEET 22 OF 27


RATING: 150 #
SERVICE : NITROGEN (CRYOGENIC SERVICES )
DESIGN

TEMP. º F / º C -196 38 93 CORR. ALL. inch/ mm NIL

PR. psig/ kg/ cm2 g 19.33 19.33 16.17 FLANGE FACING RF, CONC. SERR.FINISH
Inch
NOM. PIPE SIZE 15 20 25 40 50 80 100 150 200
Mm
inch
OUTSIDE DIA. 21.3 26.7 33.4 48.3 60.3 88.9 114.3 168.3 219
mm
inch SCH SCH SCH SCH SCH SCH SCH SCH SCH
THICKNESS
mm 80S 80S 40S 40S 40S 10S 10S 10S 10S
inch
NOM. PIPE SIZE
mm
inch
OUTSIDE DIA.
mm
inch
THICKNESS
mm
40 SW TO ANSI B 16.11
LINE JOINT
50 BW TO ANSI B 16.25
NOMINAL
PIPE MATERIAL DIMENSIONAL
ITEM REMARKS
SIZE RANGE SPECIFICATION STANDARD
inch / mm
ASTM A 312 Gr.
PIPES 200 ANSI B 36.19 SEAMLESS,BE
TP304
ASTM A 312 Gr.
PIPE NIPPLE 15 TO 50 ANSI B 36.19 SEAMLESS,PE
TP304

ELBOWS, CAPS, ASTM A 403


B.W. FITTINGS

50 TO 200 ANSI B 16.9 SCH M


REDUCERS,TEES Gr. WP 304S

< 40 ASTM A182 Gr.F304 ANSI B 16.11 3000 #


S.W. FITTINGS

BENDS
SWAGES( ECC/CONC) 15 TO 80 ASTM A182 Gr.F304 BS 3799 PSE & BLE,THICKNESS TO MATCH PIPE
BRANCH CONNECTION ALL SEE BRANCH CONNECTION CHART
ALL ASTM A182 Gr.F304 ANSI B 16.5 WN, 150 CL, RF/125 AARH
FLANGES

ALL ASTM A182 Gr.F304 ANSI B 16.5 150 CL, RF/125 AARH
BLIND FLANGES

ASTM A 320 GR.B8


MACHINE / STUD BOLTS ALL ANSI B 18.2.1
CL.2,
SPECTACLE BLIND 15 TO 200 ASTM A182 Gr.F304 ANSI B 16.48 150 CL, FF/125 AARH

REV.NO. PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P0
UTILITIES & OFFSITES OF NHT/CCR
REV. BY DATE: 07/07/10
FILE NAME: F087R0.DOT TCE FORM NO. 087 R0 SH. 1 OF 2
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE:SB2 SHEET 23 OF 27


NOMINAL PIPE
MATERIAL DIMENSIONAL
ITEM SIZE RANGE REMARKS
SPECIFICATION STANDARD
inch / mm

HEAVY HEX. ALL ASTM A 194, Gr.8 ANSI B 18.2.2 REF. NOTE 2
NUTS
SS316+GRAFIL+SS ANSI B 16.20
ALL SPIRAL
GASKETS 316 I/O RING CL.150

ALL ASTM A182 Gr F304 ANSI B 16.11 3000 CL, SW


UNION

TYPE OF PRESSUR TYPE OF DIM. STANDARD


SIZE RANGE MATERIAL REMARKS
VALVE E RATING ENDS OR
inch./ mm. BODY TRIM ANSI/ IS TAG NUMBER
ASTM A182
CHECK < 40 STELLITED 800 SW BS-5352 ,C27A LIFT CHECK TYPE
Gr.F304
ASTM A351
CHECK 50 STELLITED 150 RF BS-1868, C27B SWING CHECK TYPE
Gr.CF8
ASTM A351
BALL ALL PCTFE 150 RF BS-5351, B27A REF. NOTE 3
Gr.CF8
STELLITED
ASTM A182
GLOBE < 40 STEM :SS 800 SW BS-5352 ,T27A
Gr.F304
304
STELLITED
ASTM A351
GLOBE 50 STEM :SS 150 RF BS-1873, T27B
Gr.CF8
304
STELLITED
ASTM A182
GATE < 40 STEM :SS 800 SW API-602 ,G27A
Gr.F304
304
STELLITED
ASTM A351
GATE 50 STEM :SS 150 RF API-600, G27B
Gr.CF8
304
STRAINER ASTM A182
< 40 SS 304 150 SW ST27A
(Y-TYPE) Gr.F304
ASTM A
STRAINER 403
50 SS 304 150 BW ST27B
(T-TYPE) Gr. WP
304S

NOTES:

1. ALL PIPES, FITTINGS, FLANGES OF STAINLESS STEEL SHALL BE SOLUTION ANNEALED, PICKLED AND PASSIVATED
2. WASHER SHALL BE PROVIDED WITH NUT.
3. BALL VALVES SHALL BE GEAR OPERATED FOR 150 NB & ABOVE.
4. NDT REQUIREMENTS AS PER STANDARD
5. VALVES SHALL HAVE EXTENDED BONNET AS PER BS 6364 (NON COLD BOX APPLICATION)

REV.NO. PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P0
UTILITIES & OFFSITES OF NHT/CCR
REV. BY DATE: 07/07/10
FILE NAME: F087R0.DOT TCE FORM NO. 087 R0 SH. 2 OF 2
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION : D

TCE.6079A.590-LS-1001 PIPING MATERIAL SPECIFICATION GRADE:SB2 SHEET 24 OF 27

BRANCH CONNECTION CHART

SIZE BRANCH
inch / mm
RUN 15 20 25 40 50 80 100 150 200
15 T
20 RT T
25 RT RT T
40 RT RT RT T
50 H H H RT T
80 H H H H H T
100 H H H H H S T
150 H H H H H S S T
200 H H H H H S S S T

LEGEND :
T - EQUAL TEE
RT - REDUCING TEE
H - HALF COUPLING
TL -THREADOLET
SL - SOCKOLET
WL - WELDOLET
S - STUB –IN
N - NIPOLET
SR - STUB-IN WITH R-PAD

REV.NO. PPD.BY:VRP JOB NO. CLIENT: BPCL, MUMBAI ISSUE


DATE CHD.BY:DSJ TCE.6079A PROJECT : PMC SERVICES FOR THE P0
UTILITIES & OFFSITES OF NHT/CCR
REV. BY DATE: 07/07/10
FILE NAME: F087R0.DOT TCE FORM NO. 087 R0 SH. 2 OF 2
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 6 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301
ANNEXURE 7 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPEC. NO. SECTION:


TCE.6079A-C-266- TATA CONSULTING ENGINEERS LIMITED Information
301 Flare System – Information Required SHEET 1 OF 1

Bidders to provide the following information:

1. FLARE SYSTEM COMPONENTS :

Bidder to indicate the sub-contractors along with their Proven Track Record
(PTR) for the following activities.

S.No Description Design & Engineering Manufacturing


1. Complete Flare Tips
Assembly with Pilots
2. Molecular Seals
3. Knock out Drums
4. Water Seal Drums

2. Structure for Demountable Flare stacks

Bidder to indicate the sub-contractors along with their Proven Track Record
(PTR) for the following activities.

S.No Description of Activity Name of the Sub- Contractor


1. Design & Engineering of
Structure
2. Fabrication of the Structure
3. Gavanisation of the structure Name of the Size of the
Galvaniser Galvanising Bath

4. Applicable Galvanisation
Standard
5. Life of the Structure

3. Bidder to provide a scheme for erection of Flare considering the present flare in
operation.

4. Bidder to provide the schedule for completion of the contract providing time lines for
Design & Engineering, Manufacturing & Supply, Erection, Commissioning.

5. Bidder to fill in the technical data sheet strictly as per format attached in Attachment
No.1.

SEAL &
SIGNATURE OF THE BIDDER
ISSUE
R0

FILE NAME: 6079AC266301_GALV.DOC TCE FORM NO. 329 R5


Technical Datasheet of Flare System ATTACHMENT 1 TO ANNEXURE 7 OF CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SL.
DETAILS TCE SPEC. BIDDER'S REPLY.
NO.

1 Number Required 1
2 Tag Number (Flare Package) 143 -X-144

A SCOPE OF SUPPLY
MAIN EQUIPMENTS ITEMS
1.0 HC FLARE KOD 3 Nos X 50%
2.0 HC Flare water Seal Drum 3 Nos X 50%
3.0 HC Purge flame front generator with control package 1 Set
4.0 HC Flare Tip 3 No.
5.0 HC Flare molecular seal 3 Nos
6.0 HC flare blow down pump 2 Nos for each KOD (1 W + 1 S)
7.0 Acid Flare KOD 2 Nos X 100%
8.0 Acid flare Purge Flare Ignition Control Package 1 set
9.0 Acid Flare Tip 2 Nos
10.0 Acid Flare molecular seal 2 Nos
11.0 Acid flare blow down pump 2 Nos for each KOD (1 W + 1 S)
PROCESS REQUIREMENTS
1.0 Flow rate HC Flare T/HR 670
2.0 Acid gas flare T/HR 14
3.0 Temperature Normal Operating °C 138 for HC / 150 Acid gas
Mechanical Design °C 300
4.0 Pressure @ KOD inlet ( HC / Acid gas ) kg/cm2 g 0.5 for HC / 0.3 for Acid gas
Design kg/cm2 g 3.5

5.0 Maximum allowable pressure drop (incl. losses)

-(HC Flare ) kg/cm2 g


*
-(Acid gas Flare ) kg/cm2 g
*
6.0 Achievable smokeless flaring flow rate
-HC Flare T/HR
*
134
-Acid flare T/HR NA

7.0 Fraction of heat radiated

HC Flare
*
Acid flare
*
8.0 Steam rate for smokeless flare

HC Flare T/HR *
Acid flare T/HR NA

9.0 Emissivity
HC Flare T/HR
Acid flare T/HR
*
*
10.0 Purge rate
HC Flare NM3/HR/STACK
Acid flare NM3/HR /STACK
*
*
DETAIL DESIGN
1.0 Plot area mXm 35 ( North to South) x 90 ( East to West)
2.0 Header size ( HC Flare / Acid Flare) mm 1800 NB (HC Flare) / 350 NB (Acid Gas Flare)

3.0 Stack

Height
HC Flare m 125 ( Minimum )
Acid flare m 125 ( Minimum )
Design pressure kg/cm2 g 3.5

Design temperature (maximum / minimum) °C 300

Page 1 of 8
Technical Datasheet of Flare System ATTACHMENT 1 TO ANNEXURE 7 OF CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SL.
DETAILS TCE SPEC. BIDDER'S REPLY.
NO.

Corrosion allowance 1
AS PER ATTACHED PMS
Gas pipe material AS PER ATTACHED PMS
Piping for Steam Assist AS PER ATTACHED PMS
Support Structure DERRICK SUPPORT
Earthing protection / earthing lugs REQUIRED

4.0 Riser connection (size / rating / face)

HC Flare inch
*
Acid flare inch
*
Maximum length for erection
HC Flare m
*
Acid flare m
Trial assembly
*
REQUIRED
Match marked REQUIRED
Pipework & steelwork fixings REQUIRED
Ladders REQUIRED
Platforms Top REQUIRED
Intermediate REQUIRED
Utility pipework connections REQUIRED
Thermocouple cable (incl. supports) REQUIRED

Number of stack sections (HC Flare / Acid Flare) *


Length per section (HC Flare / Acid Flare) m *
Flashback Protection (Envisaged) *
5.0 KNOCK OUT DRUM
Particle size > 400 micron (API 521)
Type HC Flare / Acid Flare HORIZONTAL / VERTICAL

Dimension HC Flare / Acid Flare mm *


Thickness HC Flare / Acid Flare mm *
Material HC Flare / Acid Flare *
6.0 Flare Tips
Capacity
HC Flare T/HR *
Acid flare T/HR *
Flame length
HC Flare m *
Acid flare m *
Maximum tip pressure drop
HC Flare Kg/cm2 g *
Acid flare Kg/cm2 g *
Length
HC Flare m *
Acid flare m *
Diameter
HC Flare m(inch) *
Acid flare m(inch) *
Wall thickness
(HC Flare/ Acid flare) mm *
Corrosion allowance AS PER ATTACHED PMS

Page 2 of 8
Technical Datasheet of Flare System ATTACHMENT 1 TO ANNEXURE 7 OF CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SL.
DETAILS TCE SPEC. BIDDER'S REPLY.
NO.

Tip material 1 SPECIFICATION (SS 310)


AS PER ATTACHED TECHNICAL

Flame retention ring material *


Inlet flange size
(HC Flare/Acid gas flare) inches *
7.0 Seal
Type *
Number of baffles *
Gas consumption (HC Flare/Acid gas flare) Nm3/hr *
Dimensions (Dia X Length)

(HC Flare / Acid gas flare ) mm/mm *


Wall thickness

(HC Flare / Acid gas flare ) mm/mm *


Corrosion allowance mm AS PER ATTACHED PMS
Material AS PER ATTACHED PMS (SS 316 L)
Maximum pressure drop of seal at max flow rate
(HC Flare / Acid gas flare ) kg/cm2 g
8.0 Pilots
Operation (intermittent / continuous) CONTINIOUS
Number (per flare tip) AS PER PROCESS DATASHEET

Diameter *
(HC Flare / Acid gas flare ) mm
Schedule / wall thickness

(HC Flare / Acid gas flare ) mm/mm *


Length

(HC Flare / Acid gas flare ) mm *


Material *
Gas flow rate

(HC Flare / Acid gas flare ) kg/hr *


Individual ignition line generated to each pilot No
9.0 Igniters INTERMITTENT

Operation (intermittent / continuous) Intermittent *


Number (per pilot) *
Diameter

(HC Flare / Acid gas flare ) mm/mm *


Schedule / wall thickness

(HC Flare / Acid gas flare ) mm/mm *


Length

(HC Flare / Acid gas flare ) mm *


Material
Gas flow rate

(HC Flare / Acid gas flare ) kg/hr *


STEAM ASSISTED HC FLARE

1.0 Pipe Size mm *


2.0 Schedule/wall thickness mm *
3.0 Steam velocity m/s *
4.0 Steam flowrate kg/s *

Page 3 of 8
Technical Datasheet of Flare System ATTACHMENT 1 TO ANNEXURE 7 OF CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SL.
DETAILS TCE SPEC. BIDDER'S REPLY.
NO.

1
5.0 Minimum Steam Pressure kg/cm2 g *
6.0 Pressure drop kg/cm2 *
SEAL DRUM
1.0 Manufacturer *
2.0 Material (HC Flare / Acid gas Flare) *
Shell *
Head *
Internals *
3.0 Thickness Shell mm *
4.0
Head mm *
1.0 Head configuration *
2.0 Dimensions Diameter mm *
3.0 Tan-Tan mm *
4.0 Design code ASME SEC VIII, DIV 1/2, OISD
5.0 Design pressure kg/cm2 g 3.5
6.0 Design temperature °C 300

7.0 Hydrotest pressure kg/cm2 g *


8.0 Corrosion allowance mm AS PER ATTACHED PMS
9.0 Local instrumentation REQUIRED
10.0 Support REQUIRED
11.0 Footprint area Required REQUIRED
12.0 Lifting Lugs/Trunnions REQUIRED
UTILITY CONSUMPTION
1.0 Fuel gas Flame front generator kg/hr *
Pilots kg/hr / PILOT *
2.0 Instrument air Flame front generator Nm3/hr *
3.0 Control valves kg/hr *
4.0 Enclosure purge kg/hr *
5.0 Fuel gas Continuous runner purge Nm3/hr *
6.0 Burst purge kg/hr *
7.0 Power Flame front generator kW *
8.0 Steam Smokeless Flaring Kg/hr *
9.0 Service water kg/hr *
PIPING
1.0 Design code ANSI B31.3
2.0 Applicable piping specifications REFER ATTACHED STANDARD SPECIFICATION
3.0 Design for thermal expansion REQUIRED
4.0 Radiation protection REQUIRED
5.0 Eccentric reducers for drainage REQUIRED
6.0 Insulation REQUIRED
7.0 Heat tracing REQUIRED
STRUCTURAL & STEELWORKS
1.0 Bolted base ring REQUIRED
2.0 Lifting and tailing lugs (suitable for single lift) per section REQUIRED

Page 4 of 8
Technical Datasheet of Flare System ATTACHMENT 1 TO ANNEXURE 7 OF CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SL.
DETAILS TCE SPEC. BIDDER'S REPLY.
NO.

3.0 Shipping saddles 1


REQUIRED
4.0 Derrick structure REQUIRED
5.0 Access ladders REQUIRED
6.0 Handrails & ladder cages REQUIRED
7.0 Riser hoist winch REQUIRED
8.0 Canting winch REQUIRED
9.0 Sliding winch REQUIRED
10.0 Foundation details and templates REQUIRED
11.0 Heat radiation shields REQUIRED
PIPING & MISCELLANEOUS
1.0 Water seal piping REQUIRED
2.0 Self-inspiriting Pilots REQUIRED
3.0 Flame Front generator panel including piping and fitting REQUIRED
4.0 Individual ignition lines to pilots REQUIRED
5.0 Individual FG lines to pilots REQUIRED
6.0 Manifold connections & valves REQUIRED
7.0 Interconnecting piping/valves/fittings on flare stack REQUIRED
8.0 All gaskets, bolts and nuts within package REQUIRED
GENERAL
1.0 Couplings and guards - all rotating equipment REQUIRED
2.0 Nameplates /tags - all equipment/instruments REQUIRED
3.0 Design standard API RP521 & API 537
4.0 Radiation Maps / Graphs at grade, XXm, XXm, etc. REQUIRED
5.0 Calculations (structural, noise, wind load, etc.) REQUIRED
6.0 Commissioning procedure REQUIRED
7.0 Pre-fabrication / Modularisation REQUIRED

8.0 Burning of condensate *


9.0 Fuel gas blending NA

10.0 Availability / Reliability % *


11.0 Design life 30 yrs
12.0 2 year maintenance-free operation REQUIRED
13.0 Service access (components outside barrier) REQUIRED
14.0 Guarantees Mechanical REQUIRED
Process REQUIRED
Performance REQUIRED
15.0 Maximum allowable nozzle loads (termination flanges) AS PER API 537
16.0 Compliance with codes and standards in Requisition REQUIRED
17.0 Material Certification REQUIRED
18.0 Documentation (per Requisition & General Notes) REQUIRED
19.0 Statement of compliance with Reqn/Specifications REQUIRED
20.0 Drawing showing vessel dimensions, details of internals, REQUIRED
21.0 nozzles and orientation REQUIRED

OTHERS
1.0 Commissioning Spares REQUIRED

2.0 Two year normal operating spares *


3.0 Mandatory spares REQUIRED AS PER ATTACHED LIST
4.0 Special Tools & Tackles REQUIRED
5.0 Consumables - Firstfill REQUIRED
6.0 Preparation, packing and marking for shipment BY CONTRACTOR
3D Modelling of all systems including electrical & instrumentation ( in PDMS compatible
7.0 REQUIRED
environment with all library files)

GUARANTEES
Radiation Intensity at any point on Grade ( Including peak solar radiation) kW/m2 4.7
1.0
2.0 Noise Limitation dBA Continious / Intermittent 90

3.0
Water Consumption m3 / hr Continious / Intermittent *
4.0
Power Consumption kW Continious / Intermittent *

Page 5 of 8
Technical Datasheet of Flare System ATTACHMENT 1 TO ANNEXURE 7 OF CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SL.
DETAILS TCE SPEC. BIDDER'S REPLY.
NO.

1
5.0
Fuel Gas Consumption kg/hr Continious / Intermittent *
6.0
MP Steam Consumption kg/hr *
ELECTRICAL SYSTEM

1.0 SCOPE OF WORK SUPPLY, ERECTION, TESTING AND COMMISSIONING OF LV INDUCTION


FLAMEPROOF DRIVE MOTORS, FLAMEPROOF WINCH MOTOR, FLAMEPROOF
WINCH CONTROL PANEL, MECHANICALLY RETRACTABLE AVIATION WARNINS
LIGHTS (AWL), LIGHTING SYSTEM ACCESSORIES INCLUDING CABLES,
JUNCTION BOXES FOR AWL, LIGHTNING PROTECTION SYSTEM ABOVE
GROUND

2.0 LV INDUCTION MOTORS AS PER SPECIFICATION NO. TCE.6079A-Z-202 AND CORRIGENDUMS


415V, 3 PHASE, ENERGNY EFFICIENT (EFF-1), FLAMEPROOF SQUIRREL CAGE
INDUCTION MOTORS WITH CLASS B TEMPERATURE RISE WITH CLASS F
INSULATION CLASS, TEFC, IP-55, LIGHT GRAY PAINT SHADE, SPACE HEATER
FOR MOTORS ABOVE 30kW, ON LINE GREASING FOR MOTORS ABOVE 37kW,
NOISE LEVEL LESS THAN 85dB FOR MOTORS ABOVE 37kW AND ABOVE

3.0 QUALITY ASSURANCE PLAN FOR MOTORS AS PER CLAUSE NO. 14 OF SPECIFICATION NO. TCE.6079A-Z-202

4.0 AVIATION WARNING LIGHTING SYSTEM MECHANICALLY RECTRACTABLE TYPE, FLASHING, MAINTENED MEDIUM
INTENSITY TYPE ALONG WITH NECESSARY FLAMEPROOF CONTROL PANEL
WITH AUTO/MANUAL FACILITY, JUNCTION BOXES

NO. OF LEVLES AND NO. OF AVIATION LAMPS PER LEVEL AS PER LATEST
ICAO SYSTEM

5.0 LIGHTING SYSTEM FOR STAIRCASE AND PLATFORM FLAMEPROOF LIGHTIING FITTINGS WITH NECESSARY LIGHTING ACCESSORIES

6.0 LIGHTNING PROTECTION EARTH CONTINUITY BONDS FOR FLANGED JOINTS


EQUI-POTENTIAL BONDING BETWEEN FLARE AND DERRICK STRUCTURE

INSTRUMENTATION & CONTROL SYSTEM


1.0 SCOPE OF WORK FOLLOWING SCOPE OF WORK AS PER TENDER DOCUMENT CLAUSE NO 1.1 1 PART IIB, PAGE 51 OF 199.
(A) SUPPLY & ERECTION OF FIELD INSTRUMENTS AND VALVES ALONG WITH ERECTION HARDWARE
AS PER SR. NO.1
(B) SUPPLY & ERECTION OF OPERATOR INTERFACE PANEL WITH ALL INDICATIONS, PUSHBUTTONS
ALONGWITH ALL PANEL MOUNTED ACCESSORIES.
(C) DERIVING ANY OTHER POWER SUPPLY VOLTAGE LEVELS SUCH AS 24VDC ETC AS PER SR. NO.3.
(D) SUPPLY, LAYING, ERECTION, TERMINATION (AT BOTH ENDS) OF ALL CABLES FOR THE COMPLETE
FLARE SYSTEM PACKAGE, ALONGWITH CABLE GLANDS (AT BOTH ENDS), TERMINATION ACCESSORIES
AS PER SR.NO.4
(E) SUPPLY & ERECTION OF JUNCTION BOXES INCLUDING THE JUNCTION BOXES TO WHICH THE SIGNALS PER
SR.NO.5. HARDWARE AS TO DCS/MCC WILL BE WIRED ALONGWITH ALL ERECTION HARDWARE AS PER SR. NO. 5.
(F) SUPPLY & ERECTION OF CABLE TRAYS AND GI CONDUITS WITH ALL ACCESSORIES AND STRUCTURAL
STEEL SUPPORTS AS PER SR. NO.6.
(G) SUPPLY & ERECTION OF ALL ERECTION HARDWARE AS PER SR. NO. 7.
(H) SUPPLY & ERECTION OF ANY SPECIAL TOOLS AS PER SR.NO.8.
(I) FAT & SAT AS PER SR. NO. 9 & 10.
(J) COORDINATION WITH I&C ERECTION CONTRACTOR TO INTERFACE SIGNALS AT PH-5 DCS & MCC
AS PER SR NO. 11.
(K) COORDINATION WITH DCS VENDOR DURING DEVELOPMENT OF SCREENS & ALL CONTROL LOGIC
DEVELOPMENT INCLUDING SEQUENCE & INTERLOCK, LIST OF ALARMS GENERATED, LOOP CHECKING,
COMMISSIONING, OR ANY OTHER PROGRAMMING/ CONFIGURING AS PER THE SYSTEM REQUIREMENT
TO BE IMPLEMENTED IN THE EXISTING DCS.
(L) SUBMISSION OF ALL THE ENGINEERING DOCUMENTS AS LISTED IN CLAUSE NO. 8.2 OF PART IIB,
PAGE 60 OF 199, REQUIRED FOR IMPLEMENTING THE CONTROL & MONITORING IN THE DCS.

2.0 FIELD INSTRUMENTS


2.1 MINIMUM NO OF FIELD INSTRUMENTS AS PER P&ID TCE-6079A-300-PI-8501. ANY OTHER INSTRUMENTS REQUIRED OVER & ABOVE WHAT IS INDICATED
FOR ACHIEVING COMPLETE MONITORING & CONTROL OF THE FLARE SYSTEM SHALL BE PROVIDED BY BIDDER.

Page 6 of 8
Technical Datasheet of Flare System ATTACHMENT 1 TO ANNEXURE 7 OF CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SL.
DETAILS TCE SPEC. BIDDER'S REPLY.
NO.

2.2 MAKE OF FIELD INSTRUMENTS 1


AS PER THE APPROVED VENDOR LIST IN THE TENDER DOCUMENT PART I PAGE 309 OF 391.
2.3 TYPE OF FIELD INSTRUMENTS (BASED ON PRINCIPLE OF OPERATION) AS PER TENDER DOCUMENT CLAUSE NO 3.0, PART IIB,PAGE 54 OF 199.
2.4 SPECIFIC REQUIREMENTS OF FIELD INSTRUMENTS FOR FLARE SYSTEM
2.4.1 HAZARDOUS AREA CLASSIFICATION OF FIELD INSTRUMENTS EX PROOF TO ZONE-2, GR IIC,T4. NECESSARY CCOE SERTIFICATE SHALL BE PROVIDED.
2.4.2 FEATURES OF INSTRUMENTATION FOR HAZARDOUS AREAS AS PER CLAUSE NO. 3.11 OF PART IIB PAGE 68 OF 199
2.4.2 MATERIAL OF CONSTRUCTION OF FIELD INSTRUMENTS FOR ACID FLARE THE MATERIAL OF CONSTRUCTION FOR ALL INSTRUMENTS & ACCESSORIES SHALL MEET THE
GAS APPLICATION FOR ALL INSTRUMENTS & ACCESSORIES REQUIREMENTS FOR SOUR SERVICE SPECIFIED IN NACE MR 01-75 LATEST EDITION. NACE CERTIFICATION
TO BE PROVIDED.
2.4.3 TYPE OF TRANSMITTERS & VALVE POSITIONERS ALL TRANSMITTERS SHALL BE SMART TYPE WITH HART PROTOCOL & VALVE POSITIONERS SHALL BE
NON HART.
2.4.4 MOUNTING OF TEMPERATURE TRANSMITTERS ALL TEMPERATURE TRANSMITTERS SHALL BE PROVIDED ON A SEPARATE BOARD NEAR OPERATOR
INTERFACE PANEL.
2.4.5 SPECIFIC REQUIREMENT FOR THERMOCOUPLE
(A) RETRACTABLE TYPE WITH TERMINATION ONLY IN THE JUNCTION BOX AT REQUIRED
THE BASE OF THE FLARE STACK
(B) TYPE OF THERMOCOUPLE DUPLEX TYPE
(C) THERMOWELL TO BE PROVIDED FOR EACH THERMOCOUPLE
(C) QUANTITY OF THERMOCOUPLES i. 2 NOS. DUPLEX THERMOCOUPLE FOR EACH PILOT FLAME SENSING
ii. DUPLEX THERMOCOUPLE FOR BURN BACK DETECTION AT MIN. 3 POINTS ALONG THE HEIGHT OF THE
FLARE TIP
(D) THERMOCOUPLE THERMOWELL MATERIAL & THERMOCOUPLE SHEATH i. FOR PILOT FLAME SENSING APPLICATION THE MATERIAL SHALL BE SAME AS FLARE TIP MATERIAL.
MATERIAL ii. FOR BURN BACK SENSING, THE MATERIAL OF THE THERMOWELL SHALL BE SS 321.
(E) DUPLEX THERMOCOUPLE WIRING BOTH THE THERMOCOUPLES IN EACH DUPLEX ASSEMBLY TO BE WIRED TO TEMPERATURE TRANSMITTER.
(F) BURNOUT OF THERMOCOUPLES SHALL BE UPSCALE i.e. INITIATE AN ALARM IF THE THERMOCOUPLE BURNS OUT
2.4.6 CABLES, JUNCTION BOXES AT A MIN. OF 15 METRES FROM THE FLARE SHALL BE SUITABLE FOR THE HIGH TEMPERATURE
TIP
2.4.7 PNEUMATIC TUBING SS 316
2.4.8 LEVEL MEASUREMENT IN HYDROCARBON & ACID FLARE KNOCK (A) FOR EACH KNOCK OUT DRUM, 2 NOS LEVEL SWITCH SHALL BE PROVIDED FOR STARTING & STOPPING
OUT DRUM KNOCK DRUM MOTORS BASED ON THE KNOCKOUT DRUM LEVEL.
(B) FOR EACH KNOCK OUT DRUM, 2 NOS LEVEL SWITCH SHALL BE PROVIDED FOR LOW-LOW & HGH- HIGH
LEVEL ALARMS.
(C) FOR EACH KNOCK OUT DRUM, ONE NO. D.P. TYPE LEVEL TRANSMITTER & LEVEL GAUGE SHALL BE
PROVIDED FOR MONITORING OF KNOCKOUT DRUM LEVEL.
2.4.9 FLOW MEASUREMENT IN HC FLARE GAS HEADER (A) INSERTION TYPE ULTRASONIC FLOWMETER TO BE PROVIDED IN THE HC FLARE GAS HEADER LINE
ALONGWITH PRESSURE & TEMPERATURE TRANSMITTER WIRED TO THE FLOWMETER FOR
COMPENSATION .
(B) TYPE: 4-WIRE, SMART WITH LCD INDICATION.
(C) PRINCIPLE: TRANSIT TIME
(D) NO OF PATHS : ONE PATH (I PAIR OF TRANSDUCERS).
(E) ENCLOSURE : EX PROOF TO ZONE-2, GR IIC,T4.
(F) NOZZLES TO BE PROVIDED IN THE FLARE GAS HEADER FOR MOUNTING THE FLOW TRANSDUCERS.
(G) OUTPUTS : 4-20mA FOR THE FOLLOWING:
i. VOLUMETRIC FLOW RATE
ii. MASS FLOW RATE
iii. MOLECULAR WIEGHT
(H) COMMUNICATION PORT: MODBUS
(I) ACCESSORIES SUCH AS SS NAME PLATE, INSERTION- RETRACTION ASSEMBLY WITH BALL VALVE FOR
ONLINE REPLACEMENT OF TRANSDUCER, INTERCONNECTING CABLE BETWEEN TRANSDUCERS &
TRANSMITTER.
2.4.10 MODULATION OF HAND CONTROL VALVE IN THE STEAM LINE HAND CONTROL VALVE IN THE STEAM LINE WILL BE MANUALLY CONTROLLED FROM THE DCS BY THE
OPERATOR, BASED ON VISUALISATION OF SMOKE FROM THE FLARE.

3.0 CONTROL SYSTEM FEATURES


3.1 CONTROL & MONITORING OF THE ENTIRE FLARE SYSTEM INCLUDING SHALL BE DONE IN PURCHASER’S PH-5 DCS.
THE FFG SYSTEM AND UTILITIES FOR FFG SYSTEM
3.2 OPERATOR INTERFACE PANEL TO BE PROVIDED IN THE FIELD WITH NECESSARY INDICATIONS & PUSHBUTTONS TO ENABLE STARTUP
3.3 QUANTITY OF OPERATOR INTERFACE PANELS 1 NO. FOR HC FLARE & 1 NO. FOR ACID FLARE SYSTEM
3.3 HAZARDOUS CLASSFICATION OF OPERATOR INTERFACE PANELS EX PROOF TO ZONE-2, GR IIC,T4.

4.0 ON-OFF VALVES


4.1 PROXIMITY SWITCHES SHALL BE NAMUR TYPE
4.2 OPEN & CLOSE COMMAND FOR THE VALVES SINGLE DIGITAL OUTPUT

Page 7 of 8
Technical Datasheet of Flare System ATTACHMENT 1 TO ANNEXURE 7 OF CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SL.
DETAILS TCE SPEC. BIDDER'S REPLY.
NO.

1
4.0 POWER SUPPLY
4.1 VOLTAGE LEVELS (A) 110 V AC UPS POWER SUPPLY TO OPERATOR INTERFACE PANEL
(B) SOLENOID VALVES & INTERROGATION VOLTAGE-110VAC UPS POWER SUPPLY
(C) 4-WIRE TRANSMITTERS-110VAC, UPS POWER SUPPLY
(D) CONTACT RATING OF POTENTIAL FREE CONTACTS FOR FIELD SWITCHES - 110 V AC, 2A.

5.0 INTERFACE WITH OTHER SYSTEM ALL SIGNALS TO BE WIRED TO PURCHASER'S DCS/MCC SHALL BE WIRED BY BIDDER TO JUNCTION BOXES
PROVIDED IN TH FIELD.

6.0 QUALITY ASSURANCE PLAN ITEMS TO BE INSPECTED BY PURCHASER/CONSULTANT:


(A) ON-OFF VALVES ALONGWITH ACTUATOR & ACCESSORIES.
(B) CONTROL VALVES ALONGWITH ACTUATOR, I/P CONVERTERS & OTHER ACCESSORIES.
(C) OPERATOR INTERFACE PANEL.

7.0 MANDATORY SPARES AS PER GENERAL ENGINEERING SPECIFICATION, PART IIB PAGE 309 OF 391 ANNEXURE-1.

8.0 DATA SUBMITTED ALONGWITH BID ALL DOCUMENTS LISTED IN CLAUSE NO 8.2 OF PART IIB PAGE 60 OF 199 OF TENDER DOCUMENT.

9.0 COORDINATION WITH DCS VENDOR & I&C ERECTION AS PER TENDER DOCUMENT CLAUSE NO 7.8 PART IIB PAGE 60 OF 199.
CONTRACTOR (A) COORDINATION WITH DCS VENDOR FOR CONTROL LOGIC DEVELOPMENT,GRAPHIC SCREEN
DEVELOPMENT, LIST OF ALARMS GENERATED ,LOOP TUNING ,OR ANY OTHER CONFIGURING
AS PER SYSTEM REQUIREMENT.
(B) COORDINATION WITH I&C ERECTION CONTRACTOR FOR WIRING BETWEEN FIELD JUNCTION BOXES
PROVIDED NEAR FLARE SYSTEM & PURCHASER'S DCS,LOOP CHECKING & COMMISSIONING OF THE
FLARE SYSTEM.

10.0 VENDOR LIST AS PER THE LIST OF APPROVED VENDORS IN THE TENDER DOCUMENT

Page 8 of 8
ANNEXURE 7 TO CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SPEC. NO. SECTION:


TCE.6079A-C-266- TATA CONSULTING ENGINEERS LIMITED Information
301 Flare System – Information Required SHEET 1 OF 1

Bidders to provide the following information:

1. FLARE SYSTEM COMPONENTS :

Bidder to indicate the sub-contractors along with their Proven Track Record
(PTR) for the following activities.

S.No Description Design & Engineering Manufacturing


1. Complete Flare Tips
Assembly with Pilots
2. Molecular Seals
3. Knock out Drums
4. Water Seal Drums

2. Structure for Demountable Flare stacks

Bidder to indicate the sub-contractors along with their Proven Track Record
(PTR) for the following activities.

S.No Description of Activity Name of the Sub- Contractor


1. Design & Engineering of
Structure
2. Fabrication of the Structure
3. Gavanisation of the structure Name of the Size of the
Galvaniser Galvanising Bath

4. Applicable Galvanisation
Standard
5. Life of the Structure

3. Bidder to provide a scheme for erection of Flare considering the present flare in
operation.

4. Bidder to provide the schedule for completion of the contract providing time lines for
Design & Engineering, Manufacturing & Supply, Erection, Commissioning.

5. Bidder to fill in the technical data sheet strictly as per format attached in Attachment
No.1.

SEAL &
SIGNATURE OF THE BIDDER
ISSUE
R0

FILE NAME: 6079AC266301_GALV.DOC TCE FORM NO. 329 R5


Technical Datasheet of Flare System ATTACHMENT 1 TO ANNEXURE 7 OF CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SL.
DETAILS TCE SPEC. BIDDER'S REPLY.
NO.

1 Number Required 1
2 Tag Number (Flare Package) 143 -X-144

A SCOPE OF SUPPLY
MAIN EQUIPMENTS ITEMS
1.0 HC FLARE KOD 3 Nos X 50%
2.0 HC Flare water Seal Drum 3 Nos X 50%
3.0 HC Purge flame front generator with control package 1 Set
4.0 HC Flare Tip 3 No.
5.0 HC Flare molecular seal 3 Nos
6.0 HC flare blow down pump 2 Nos for each KOD (1 W + 1 S)
7.0 Acid Flare KOD 2 Nos X 100%
8.0 Acid flare Purge Flare Ignition Control Package 1 set
9.0 Acid Flare Tip 2 Nos
10.0 Acid Flare molecular seal 2 Nos
11.0 Acid flare blow down pump 2 Nos for each KOD (1 W + 1 S)
PROCESS REQUIREMENTS
1.0 Flow rate HC Flare T/HR 670
2.0 Acid gas flare T/HR 14
3.0 Temperature Normal Operating °C 138 for HC / 150 Acid gas
Mechanical Design °C 300
4.0 Pressure @ KOD inlet ( HC / Acid gas ) kg/cm2 g 0.5 for HC / 0.3 for Acid gas
Design kg/cm2 g 3.5

5.0 Maximum allowable pressure drop (incl. losses)

-(HC Flare ) kg/cm2 g


*
-(Acid gas Flare ) kg/cm2 g
*
6.0 Achievable smokeless flaring flow rate
-HC Flare T/HR
*
134
-Acid flare T/HR NA

7.0 Fraction of heat radiated

HC Flare
*
Acid flare
*
8.0 Steam rate for smokeless flare

HC Flare T/HR *
Acid flare T/HR NA

9.0 Emissivity
HC Flare T/HR
Acid flare T/HR
*
*
10.0 Purge rate
HC Flare NM3/HR/STACK
Acid flare NM3/HR /STACK
*
*
DETAIL DESIGN
1.0 Plot area mXm 35 ( North to South) x 90 ( East to West)
2.0 Header size ( HC Flare / Acid Flare) mm 1800 NB (HC Flare) / 350 NB (Acid Gas Flare)

3.0 Stack

Height
HC Flare m 125 ( Minimum )
Acid flare m 125 ( Minimum )
Design pressure kg/cm2 g 3.5

Design temperature (maximum / minimum) °C 300

Page 1 of 8
Technical Datasheet of Flare System ATTACHMENT 1 TO ANNEXURE 7 OF CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SL.
DETAILS TCE SPEC. BIDDER'S REPLY.
NO.

Corrosion allowance 1
AS PER ATTACHED PMS
Gas pipe material AS PER ATTACHED PMS
Piping for Steam Assist AS PER ATTACHED PMS
Support Structure DERRICK SUPPORT
Earthing protection / earthing lugs REQUIRED

4.0 Riser connection (size / rating / face)

HC Flare inch
*
Acid flare inch
*
Maximum length for erection
HC Flare m
*
Acid flare m
Trial assembly
*
REQUIRED
Match marked REQUIRED
Pipework & steelwork fixings REQUIRED
Ladders REQUIRED
Platforms Top REQUIRED
Intermediate REQUIRED
Utility pipework connections REQUIRED
Thermocouple cable (incl. supports) REQUIRED

Number of stack sections (HC Flare / Acid Flare) *


Length per section (HC Flare / Acid Flare) m *
Flashback Protection (Envisaged) *
5.0 KNOCK OUT DRUM
Particle size > 400 micron (API 521)
Type HC Flare / Acid Flare HORIZONTAL / VERTICAL

Dimension HC Flare / Acid Flare mm *


Thickness HC Flare / Acid Flare mm *
Material HC Flare / Acid Flare *
6.0 Flare Tips
Capacity
HC Flare T/HR *
Acid flare T/HR *
Flame length
HC Flare m *
Acid flare m *
Maximum tip pressure drop
HC Flare Kg/cm2 g *
Acid flare Kg/cm2 g *
Length
HC Flare m *
Acid flare m *
Diameter
HC Flare m(inch) *
Acid flare m(inch) *
Wall thickness
(HC Flare/ Acid flare) mm *
Corrosion allowance AS PER ATTACHED PMS

Page 2 of 8
Technical Datasheet of Flare System ATTACHMENT 1 TO ANNEXURE 7 OF CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SL.
DETAILS TCE SPEC. BIDDER'S REPLY.
NO.

Tip material 1 SPECIFICATION (SS 310)


AS PER ATTACHED TECHNICAL

Flame retention ring material *


Inlet flange size
(HC Flare/Acid gas flare) inches *
7.0 Seal
Type *
Number of baffles *
Gas consumption (HC Flare/Acid gas flare) Nm3/hr *
Dimensions (Dia X Length)

(HC Flare / Acid gas flare ) mm/mm *


Wall thickness

(HC Flare / Acid gas flare ) mm/mm *


Corrosion allowance mm AS PER ATTACHED PMS
Material AS PER ATTACHED PMS (SS 316 L)
Maximum pressure drop of seal at max flow rate
(HC Flare / Acid gas flare ) kg/cm2 g
8.0 Pilots
Operation (intermittent / continuous) CONTINIOUS
Number (per flare tip) AS PER PROCESS DATASHEET

Diameter *
(HC Flare / Acid gas flare ) mm
Schedule / wall thickness

(HC Flare / Acid gas flare ) mm/mm *


Length

(HC Flare / Acid gas flare ) mm *


Material *
Gas flow rate

(HC Flare / Acid gas flare ) kg/hr *


Individual ignition line generated to each pilot No
9.0 Igniters INTERMITTENT

Operation (intermittent / continuous) Intermittent *


Number (per pilot) *
Diameter

(HC Flare / Acid gas flare ) mm/mm *


Schedule / wall thickness

(HC Flare / Acid gas flare ) mm/mm *


Length

(HC Flare / Acid gas flare ) mm *


Material
Gas flow rate

(HC Flare / Acid gas flare ) kg/hr *


STEAM ASSISTED HC FLARE

1.0 Pipe Size mm *


2.0 Schedule/wall thickness mm *
3.0 Steam velocity m/s *
4.0 Steam flowrate kg/s *

Page 3 of 8
Technical Datasheet of Flare System ATTACHMENT 1 TO ANNEXURE 7 OF CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SL.
DETAILS TCE SPEC. BIDDER'S REPLY.
NO.

1
5.0 Minimum Steam Pressure kg/cm2 g *
6.0 Pressure drop kg/cm2 *
SEAL DRUM
1.0 Manufacturer *
2.0 Material (HC Flare / Acid gas Flare) *
Shell *
Head *
Internals *
3.0 Thickness Shell mm *
4.0
Head mm *
1.0 Head configuration *
2.0 Dimensions Diameter mm *
3.0 Tan-Tan mm *
4.0 Design code ASME SEC VIII, DIV 1/2, OISD
5.0 Design pressure kg/cm2 g 3.5
6.0 Design temperature °C 300

7.0 Hydrotest pressure kg/cm2 g *


8.0 Corrosion allowance mm AS PER ATTACHED PMS
9.0 Local instrumentation REQUIRED
10.0 Support REQUIRED
11.0 Footprint area Required REQUIRED
12.0 Lifting Lugs/Trunnions REQUIRED
UTILITY CONSUMPTION
1.0 Fuel gas Flame front generator kg/hr *
Pilots kg/hr / PILOT *
2.0 Instrument air Flame front generator Nm3/hr *
3.0 Control valves kg/hr *
4.0 Enclosure purge kg/hr *
5.0 Fuel gas Continuous runner purge Nm3/hr *
6.0 Burst purge kg/hr *
7.0 Power Flame front generator kW *
8.0 Steam Smokeless Flaring Kg/hr *
9.0 Service water kg/hr *
PIPING
1.0 Design code ANSI B31.3
2.0 Applicable piping specifications REFER ATTACHED STANDARD SPECIFICATION
3.0 Design for thermal expansion REQUIRED
4.0 Radiation protection REQUIRED
5.0 Eccentric reducers for drainage REQUIRED
6.0 Insulation REQUIRED
7.0 Heat tracing REQUIRED
STRUCTURAL & STEELWORKS
1.0 Bolted base ring REQUIRED
2.0 Lifting and tailing lugs (suitable for single lift) per section REQUIRED

Page 4 of 8
Technical Datasheet of Flare System ATTACHMENT 1 TO ANNEXURE 7 OF CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SL.
DETAILS TCE SPEC. BIDDER'S REPLY.
NO.

3.0 Shipping saddles 1


REQUIRED
4.0 Derrick structure REQUIRED
5.0 Access ladders REQUIRED
6.0 Handrails & ladder cages REQUIRED
7.0 Riser hoist winch REQUIRED
8.0 Canting winch REQUIRED
9.0 Sliding winch REQUIRED
10.0 Foundation details and templates REQUIRED
11.0 Heat radiation shields REQUIRED
PIPING & MISCELLANEOUS
1.0 Water seal piping REQUIRED
2.0 Self-inspiriting Pilots REQUIRED
3.0 Flame Front generator panel including piping and fitting REQUIRED
4.0 Individual ignition lines to pilots REQUIRED
5.0 Individual FG lines to pilots REQUIRED
6.0 Manifold connections & valves REQUIRED
7.0 Interconnecting piping/valves/fittings on flare stack REQUIRED
8.0 All gaskets, bolts and nuts within package REQUIRED
GENERAL
1.0 Couplings and guards - all rotating equipment REQUIRED
2.0 Nameplates /tags - all equipment/instruments REQUIRED
3.0 Design standard API RP521 & API 537
4.0 Radiation Maps / Graphs at grade, XXm, XXm, etc. REQUIRED
5.0 Calculations (structural, noise, wind load, etc.) REQUIRED
6.0 Commissioning procedure REQUIRED
7.0 Pre-fabrication / Modularisation REQUIRED

8.0 Burning of condensate *


9.0 Fuel gas blending NA

10.0 Availability / Reliability % *


11.0 Design life 30 yrs
12.0 2 year maintenance-free operation REQUIRED
13.0 Service access (components outside barrier) REQUIRED
14.0 Guarantees Mechanical REQUIRED
Process REQUIRED
Performance REQUIRED
15.0 Maximum allowable nozzle loads (termination flanges) AS PER API 537
16.0 Compliance with codes and standards in Requisition REQUIRED
17.0 Material Certification REQUIRED
18.0 Documentation (per Requisition & General Notes) REQUIRED
19.0 Statement of compliance with Reqn/Specifications REQUIRED
20.0 Drawing showing vessel dimensions, details of internals, REQUIRED
21.0 nozzles and orientation REQUIRED

OTHERS
1.0 Commissioning Spares REQUIRED

2.0 Two year normal operating spares *


3.0 Mandatory spares REQUIRED AS PER ATTACHED LIST
4.0 Special Tools & Tackles REQUIRED
5.0 Consumables - Firstfill REQUIRED
6.0 Preparation, packing and marking for shipment BY CONTRACTOR
3D Modelling of all systems including electrical & instrumentation ( in PDMS compatible
7.0 REQUIRED
environment with all library files)

GUARANTEES
Radiation Intensity at any point on Grade ( Including peak solar radiation) kW/m2 4.7
1.0
2.0 Noise Limitation dBA Continious / Intermittent 90

3.0
Water Consumption m3 / hr Continious / Intermittent *
4.0
Power Consumption kW Continious / Intermittent *

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Technical Datasheet of Flare System ATTACHMENT 1 TO ANNEXURE 7 OF CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SL.
DETAILS TCE SPEC. BIDDER'S REPLY.
NO.

1
5.0
Fuel Gas Consumption kg/hr Continious / Intermittent *
6.0
MP Steam Consumption kg/hr *
ELECTRICAL SYSTEM

1.0 SCOPE OF WORK SUPPLY, ERECTION, TESTING AND COMMISSIONING OF LV INDUCTION


FLAMEPROOF DRIVE MOTORS, FLAMEPROOF WINCH MOTOR, FLAMEPROOF
WINCH CONTROL PANEL, MECHANICALLY RETRACTABLE AVIATION WARNINS
LIGHTS (AWL), LIGHTING SYSTEM ACCESSORIES INCLUDING CABLES,
JUNCTION BOXES FOR AWL, LIGHTNING PROTECTION SYSTEM ABOVE
GROUND

2.0 LV INDUCTION MOTORS AS PER SPECIFICATION NO. TCE.6079A-Z-202 AND CORRIGENDUMS


415V, 3 PHASE, ENERGNY EFFICIENT (EFF-1), FLAMEPROOF SQUIRREL CAGE
INDUCTION MOTORS WITH CLASS B TEMPERATURE RISE WITH CLASS F
INSULATION CLASS, TEFC, IP-55, LIGHT GRAY PAINT SHADE, SPACE HEATER
FOR MOTORS ABOVE 30kW, ON LINE GREASING FOR MOTORS ABOVE 37kW,
NOISE LEVEL LESS THAN 85dB FOR MOTORS ABOVE 37kW AND ABOVE

3.0 QUALITY ASSURANCE PLAN FOR MOTORS AS PER CLAUSE NO. 14 OF SPECIFICATION NO. TCE.6079A-Z-202

4.0 AVIATION WARNING LIGHTING SYSTEM MECHANICALLY RECTRACTABLE TYPE, FLASHING, MAINTENED MEDIUM
INTENSITY TYPE ALONG WITH NECESSARY FLAMEPROOF CONTROL PANEL
WITH AUTO/MANUAL FACILITY, JUNCTION BOXES

NO. OF LEVLES AND NO. OF AVIATION LAMPS PER LEVEL AS PER LATEST
ICAO SYSTEM

5.0 LIGHTING SYSTEM FOR STAIRCASE AND PLATFORM FLAMEPROOF LIGHTIING FITTINGS WITH NECESSARY LIGHTING ACCESSORIES

6.0 LIGHTNING PROTECTION EARTH CONTINUITY BONDS FOR FLANGED JOINTS


EQUI-POTENTIAL BONDING BETWEEN FLARE AND DERRICK STRUCTURE

INSTRUMENTATION & CONTROL SYSTEM


1.0 SCOPE OF WORK FOLLOWING SCOPE OF WORK AS PER TENDER DOCUMENT CLAUSE NO 1.1 1 PART IIB, PAGE 51 OF 199.
(A) SUPPLY & ERECTION OF FIELD INSTRUMENTS AND VALVES ALONG WITH ERECTION HARDWARE
AS PER SR. NO.1
(B) SUPPLY & ERECTION OF OPERATOR INTERFACE PANEL WITH ALL INDICATIONS, PUSHBUTTONS
ALONGWITH ALL PANEL MOUNTED ACCESSORIES.
(C) DERIVING ANY OTHER POWER SUPPLY VOLTAGE LEVELS SUCH AS 24VDC ETC AS PER SR. NO.3.
(D) SUPPLY, LAYING, ERECTION, TERMINATION (AT BOTH ENDS) OF ALL CABLES FOR THE COMPLETE
FLARE SYSTEM PACKAGE, ALONGWITH CABLE GLANDS (AT BOTH ENDS), TERMINATION ACCESSORIES
AS PER SR.NO.4
(E) SUPPLY & ERECTION OF JUNCTION BOXES INCLUDING THE JUNCTION BOXES TO WHICH THE SIGNALS PER
SR.NO.5. HARDWARE AS TO DCS/MCC WILL BE WIRED ALONGWITH ALL ERECTION HARDWARE AS PER SR. NO. 5.
(F) SUPPLY & ERECTION OF CABLE TRAYS AND GI CONDUITS WITH ALL ACCESSORIES AND STRUCTURAL
STEEL SUPPORTS AS PER SR. NO.6.
(G) SUPPLY & ERECTION OF ALL ERECTION HARDWARE AS PER SR. NO. 7.
(H) SUPPLY & ERECTION OF ANY SPECIAL TOOLS AS PER SR.NO.8.
(I) FAT & SAT AS PER SR. NO. 9 & 10.
(J) COORDINATION WITH I&C ERECTION CONTRACTOR TO INTERFACE SIGNALS AT PH-5 DCS & MCC
AS PER SR NO. 11.
(K) COORDINATION WITH DCS VENDOR DURING DEVELOPMENT OF SCREENS & ALL CONTROL LOGIC
DEVELOPMENT INCLUDING SEQUENCE & INTERLOCK, LIST OF ALARMS GENERATED, LOOP CHECKING,
COMMISSIONING, OR ANY OTHER PROGRAMMING/ CONFIGURING AS PER THE SYSTEM REQUIREMENT
TO BE IMPLEMENTED IN THE EXISTING DCS.
(L) SUBMISSION OF ALL THE ENGINEERING DOCUMENTS AS LISTED IN CLAUSE NO. 8.2 OF PART IIB,
PAGE 60 OF 199, REQUIRED FOR IMPLEMENTING THE CONTROL & MONITORING IN THE DCS.

2.0 FIELD INSTRUMENTS


2.1 MINIMUM NO OF FIELD INSTRUMENTS AS PER P&ID TCE-6079A-300-PI-8501. ANY OTHER INSTRUMENTS REQUIRED OVER & ABOVE WHAT IS INDICATED
FOR ACHIEVING COMPLETE MONITORING & CONTROL OF THE FLARE SYSTEM SHALL BE PROVIDED BY BIDDER.

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Technical Datasheet of Flare System ATTACHMENT 1 TO ANNEXURE 7 OF CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SL.
DETAILS TCE SPEC. BIDDER'S REPLY.
NO.

2.2 MAKE OF FIELD INSTRUMENTS 1


AS PER THE APPROVED VENDOR LIST IN THE TENDER DOCUMENT PART I PAGE 309 OF 391.
2.3 TYPE OF FIELD INSTRUMENTS (BASED ON PRINCIPLE OF OPERATION) AS PER TENDER DOCUMENT CLAUSE NO 3.0, PART IIB,PAGE 54 OF 199.
2.4 SPECIFIC REQUIREMENTS OF FIELD INSTRUMENTS FOR FLARE SYSTEM
2.4.1 HAZARDOUS AREA CLASSIFICATION OF FIELD INSTRUMENTS EX PROOF TO ZONE-2, GR IIC,T4. NECESSARY CCOE SERTIFICATE SHALL BE PROVIDED.
2.4.2 FEATURES OF INSTRUMENTATION FOR HAZARDOUS AREAS AS PER CLAUSE NO. 3.11 OF PART IIB PAGE 68 OF 199
2.4.2 MATERIAL OF CONSTRUCTION OF FIELD INSTRUMENTS FOR ACID FLARE THE MATERIAL OF CONSTRUCTION FOR ALL INSTRUMENTS & ACCESSORIES SHALL MEET THE
GAS APPLICATION FOR ALL INSTRUMENTS & ACCESSORIES REQUIREMENTS FOR SOUR SERVICE SPECIFIED IN NACE MR 01-75 LATEST EDITION. NACE CERTIFICATION
TO BE PROVIDED.
2.4.3 TYPE OF TRANSMITTERS & VALVE POSITIONERS ALL TRANSMITTERS SHALL BE SMART TYPE WITH HART PROTOCOL & VALVE POSITIONERS SHALL BE
NON HART.
2.4.4 MOUNTING OF TEMPERATURE TRANSMITTERS ALL TEMPERATURE TRANSMITTERS SHALL BE PROVIDED ON A SEPARATE BOARD NEAR OPERATOR
INTERFACE PANEL.
2.4.5 SPECIFIC REQUIREMENT FOR THERMOCOUPLE
(A) RETRACTABLE TYPE WITH TERMINATION ONLY IN THE JUNCTION BOX AT REQUIRED
THE BASE OF THE FLARE STACK
(B) TYPE OF THERMOCOUPLE DUPLEX TYPE
(C) THERMOWELL TO BE PROVIDED FOR EACH THERMOCOUPLE
(C) QUANTITY OF THERMOCOUPLES i. 2 NOS. DUPLEX THERMOCOUPLE FOR EACH PILOT FLAME SENSING
ii. DUPLEX THERMOCOUPLE FOR BURN BACK DETECTION AT MIN. 3 POINTS ALONG THE HEIGHT OF THE
FLARE TIP
(D) THERMOCOUPLE THERMOWELL MATERIAL & THERMOCOUPLE SHEATH i. FOR PILOT FLAME SENSING APPLICATION THE MATERIAL SHALL BE SAME AS FLARE TIP MATERIAL.
MATERIAL ii. FOR BURN BACK SENSING, THE MATERIAL OF THE THERMOWELL SHALL BE SS 321.
(E) DUPLEX THERMOCOUPLE WIRING BOTH THE THERMOCOUPLES IN EACH DUPLEX ASSEMBLY TO BE WIRED TO TEMPERATURE TRANSMITTER.
(F) BURNOUT OF THERMOCOUPLES SHALL BE UPSCALE i.e. INITIATE AN ALARM IF THE THERMOCOUPLE BURNS OUT
2.4.6 CABLES, JUNCTION BOXES AT A MIN. OF 15 METRES FROM THE FLARE SHALL BE SUITABLE FOR THE HIGH TEMPERATURE
TIP
2.4.7 PNEUMATIC TUBING SS 316
2.4.8 LEVEL MEASUREMENT IN HYDROCARBON & ACID FLARE KNOCK (A) FOR EACH KNOCK OUT DRUM, 2 NOS LEVEL SWITCH SHALL BE PROVIDED FOR STARTING & STOPPING
OUT DRUM KNOCK DRUM MOTORS BASED ON THE KNOCKOUT DRUM LEVEL.
(B) FOR EACH KNOCK OUT DRUM, 2 NOS LEVEL SWITCH SHALL BE PROVIDED FOR LOW-LOW & HGH- HIGH
LEVEL ALARMS.
(C) FOR EACH KNOCK OUT DRUM, ONE NO. D.P. TYPE LEVEL TRANSMITTER & LEVEL GAUGE SHALL BE
PROVIDED FOR MONITORING OF KNOCKOUT DRUM LEVEL.
2.4.9 FLOW MEASUREMENT IN HC FLARE GAS HEADER (A) INSERTION TYPE ULTRASONIC FLOWMETER TO BE PROVIDED IN THE HC FLARE GAS HEADER LINE
ALONGWITH PRESSURE & TEMPERATURE TRANSMITTER WIRED TO THE FLOWMETER FOR
COMPENSATION .
(B) TYPE: 4-WIRE, SMART WITH LCD INDICATION.
(C) PRINCIPLE: TRANSIT TIME
(D) NO OF PATHS : ONE PATH (I PAIR OF TRANSDUCERS).
(E) ENCLOSURE : EX PROOF TO ZONE-2, GR IIC,T4.
(F) NOZZLES TO BE PROVIDED IN THE FLARE GAS HEADER FOR MOUNTING THE FLOW TRANSDUCERS.
(G) OUTPUTS : 4-20mA FOR THE FOLLOWING:
i. VOLUMETRIC FLOW RATE
ii. MASS FLOW RATE
iii. MOLECULAR WIEGHT
(H) COMMUNICATION PORT: MODBUS
(I) ACCESSORIES SUCH AS SS NAME PLATE, INSERTION- RETRACTION ASSEMBLY WITH BALL VALVE FOR
ONLINE REPLACEMENT OF TRANSDUCER, INTERCONNECTING CABLE BETWEEN TRANSDUCERS &
TRANSMITTER.
2.4.10 MODULATION OF HAND CONTROL VALVE IN THE STEAM LINE HAND CONTROL VALVE IN THE STEAM LINE WILL BE MANUALLY CONTROLLED FROM THE DCS BY THE
OPERATOR, BASED ON VISUALISATION OF SMOKE FROM THE FLARE.

3.0 CONTROL SYSTEM FEATURES


3.1 CONTROL & MONITORING OF THE ENTIRE FLARE SYSTEM INCLUDING SHALL BE DONE IN PURCHASER’S PH-5 DCS.
THE FFG SYSTEM AND UTILITIES FOR FFG SYSTEM
3.2 OPERATOR INTERFACE PANEL TO BE PROVIDED IN THE FIELD WITH NECESSARY INDICATIONS & PUSHBUTTONS TO ENABLE STARTUP
3.3 QUANTITY OF OPERATOR INTERFACE PANELS 1 NO. FOR HC FLARE & 1 NO. FOR ACID FLARE SYSTEM
3.3 HAZARDOUS CLASSFICATION OF OPERATOR INTERFACE PANELS EX PROOF TO ZONE-2, GR IIC,T4.

4.0 ON-OFF VALVES


4.1 PROXIMITY SWITCHES SHALL BE NAMUR TYPE
4.2 OPEN & CLOSE COMMAND FOR THE VALVES SINGLE DIGITAL OUTPUT

Page 7 of 8
Technical Datasheet of Flare System ATTACHMENT 1 TO ANNEXURE 7 OF CORRIGENDUM 4 TO FLARE SYSTEM TCE.6079A-C-266-301

SL.
DETAILS TCE SPEC. BIDDER'S REPLY.
NO.

1
4.0 POWER SUPPLY
4.1 VOLTAGE LEVELS (A) 110 V AC UPS POWER SUPPLY TO OPERATOR INTERFACE PANEL
(B) SOLENOID VALVES & INTERROGATION VOLTAGE-110VAC UPS POWER SUPPLY
(C) 4-WIRE TRANSMITTERS-110VAC, UPS POWER SUPPLY
(D) CONTACT RATING OF POTENTIAL FREE CONTACTS FOR FIELD SWITCHES - 110 V AC, 2A.

5.0 INTERFACE WITH OTHER SYSTEM ALL SIGNALS TO BE WIRED TO PURCHASER'S DCS/MCC SHALL BE WIRED BY BIDDER TO JUNCTION BOXES
PROVIDED IN TH FIELD.

6.0 QUALITY ASSURANCE PLAN ITEMS TO BE INSPECTED BY PURCHASER/CONSULTANT:


(A) ON-OFF VALVES ALONGWITH ACTUATOR & ACCESSORIES.
(B) CONTROL VALVES ALONGWITH ACTUATOR, I/P CONVERTERS & OTHER ACCESSORIES.
(C) OPERATOR INTERFACE PANEL.

7.0 MANDATORY SPARES AS PER GENERAL ENGINEERING SPECIFICATION, PART IIB PAGE 309 OF 391 ANNEXURE-1.

8.0 DATA SUBMITTED ALONGWITH BID ALL DOCUMENTS LISTED IN CLAUSE NO 8.2 OF PART IIB PAGE 60 OF 199 OF TENDER DOCUMENT.

9.0 COORDINATION WITH DCS VENDOR & I&C ERECTION AS PER TENDER DOCUMENT CLAUSE NO 7.8 PART IIB PAGE 60 OF 199.
CONTRACTOR (A) COORDINATION WITH DCS VENDOR FOR CONTROL LOGIC DEVELOPMENT,GRAPHIC SCREEN
DEVELOPMENT, LIST OF ALARMS GENERATED ,LOOP TUNING ,OR ANY OTHER CONFIGURING
AS PER SYSTEM REQUIREMENT.
(B) COORDINATION WITH I&C ERECTION CONTRACTOR FOR WIRING BETWEEN FIELD JUNCTION BOXES
PROVIDED NEAR FLARE SYSTEM & PURCHASER'S DCS,LOOP CHECKING & COMMISSIONING OF THE
FLARE SYSTEM.

10.0 VENDOR LIST AS PER THE LIST OF APPROVED VENDORS IN THE TENDER DOCUMENT

Page 8 of 8