Sie sind auf Seite 1von 52

GCR Oleo Chemicals

Project

Specification for NG/IFO/MFO fired Thermal oil


Heater
December 2013

PT Energy Sejathera Mas


GCR Oleo Chemicals
Project

312700 INC NWI RSD-509 B


C:\Users\PAT33902\Desktop\Specs_for_NG_-
MFO_Fired_Thermal_Oil_Heater.docx
3rd December 2013
Specification for NG/IFO/MFO fired Thermal
GCR Oleo Chemicals Project
oil Heater
Specification for NG/IFO/MFO fired Thermal oil Heater
December 2013

PT Energy Sejathera Mas

Lantal 14,JI M H Thamrin Kay,22,No.51,Jakarta,Indonesia

Mott MacDonald, Sequis Centre, 3rd Floor, Jalan Jenderal Sudirman Kav.71, Jakarta, 12190, Indonesia
T +62 21 252 6588 F +62 21 252 6592 W www.mottmac.com
GCR Oleo Chemicals Project
Specification for NG/IFO/MFO fired Thermal oil Heater

Issue and revision record

Revision Date Originator Checker Approver Description Standard


A 04.09.2013 Murugaraj. A JBP GDS/BKP For Approval

B 03.12.2013 JBP HRS GDS/BKP Revised as per comments and


released for enquiry
C 10.12.2013 AKP JBP/HRS GDS/BKP Revised as per comments and
released for enquiry

This document is issued for the party which commissioned it and We accept no responsibility for the consequences of this
for specific purposes connected with the above-captioned project document being relied upon by any other party, or being used
only. It should not be relied upon by any other party or used for for any other purpose, or containing any error or omission
any other purpose. which is due to an error or omission in data supplied to us by
other parties.

This document contains confidential information and proprietary


intellectual property. It should not be shown to other parties
without consent from us and from the party which
commissioned it..

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
GCR Oleo Chemicals Project
Specification for NG/IFO/MFO fired Thermal oil Heater

Contents

Chapter Title Page

1 Introduction 1
1.1 The Client _________________________________________________________________________ 1
1.2 The Project ________________________________________________________________________ 1
1.3 Site particulars _____________________________________________________________________ 1
1.4 Definitions_________________________________________________________________________ 1

2 Scope 3
2.1 Scope of Work _____________________________________________________________________ 3
2.1.1 Vendor’s Scope ____________________________________________________________________ 3
2.1.2 Brief system description ______________________________________________________________ 3
2.2 Owner’s scope _____________________________________________________________________ 4
2.3 Scope of Supply ____________________________________________________________________ 4
2.3.1 Owner’s scope of supply _____________________________________________________________ 4
2.3.2 Vendor’s scope of supply _____________________________________________________________ 4
2.4 Exclusions ________________________________________________________________________ 4
2.5 Mandatory spares and special tools _____________________________________________________ 4
2.6 Commissioning Spares_______________________________________________________________ 4
2.7 Two years operational spares _________________________________________________________ 4
2.8 Scope for Electrical__________________________________________________________________ 4
2.9 Scope for Instrumentation ____________________________________________________________ 5
2.10 Scope for Fire fighting _______________________________________________________________ 5
2.11 Scope of services ___________________________________________________________________ 5

3 Project Information 6
3.1 Battery limits _______________________________________________________________________ 6
3.1.1 Thermal Oil ________________________________________________________________________ 6
3.1.2 IFO/MFO (IFO-Industrial Fuel Oil; MFO-Marine Fuel Oil) _____________________________________ 6
3.1.3 NG ______________________________________________________________________________ 6
3.1.4 Flue gas __________________________________________________________________________ 6
3.1.5 Instrument Air ______________________________________________________________________ 6
3.1.6 Nitrogen __________________________________________________________________________ 6
3.1.7 Compressed Air ____________________________________________________________________ 6
3.1.8 Electrical __________________________________________________________________________ 6
3.1.9 Area Classification __________________________________________________________________ 6
3.2 Conflicting requirements ______________________________________________________________ 6
3.3 Qualification Criteria _________________________________________________________________ 6
3.4 Bid submission _____________________________________________________________________ 7

4 Technical Specifications 8
4.1 General___________________________________________________________________________ 8
4.2 Applicable standards and codes ________________________________________________________ 8
4.2.1 General Material Grades _____________________________________________________________ 9
4.3 General requirements _______________________________________________________________ 10

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
GCR Oleo Chemicals Project
Specification for NG/IFO/MFO fired Thermal oil Heater

4.3.1 General requirements for Plant and components: _________________________________________ 10


4.3.2 Means for Lifting: __________________________________________________________________ 10
4.3.3 Design and Maintenance: ____________________________________________________________ 11
4.3.4 Wearing parts: ____________________________________________________________________ 11
4.3.5 Suitability for duty: _________________________________________________________________ 11
4.3.6 Access and Safety protection: ________________________________________________________ 11
4.3.7 Fixing: ___________________________________________________________________________ 11
4.3.8 Special Tools: _____________________________________________________________________ 11
4.3.9 Identification Tags / Labels: __________________________________________________________ 11
4.3.10 Protection against corrosion and Erosion: _______________________________________________ 12
4.3.11 Noise (sound) and Vibrations: ________________________________________________________ 12
4.3.12 Approval of Materials: _______________________________________________________________ 12
4.3.13 Samples: ________________________________________________________________________ 12
4.3.14 Materials in contact with water: _______________________________________________________ 12
4.3.15 Galvanising: ______________________________________________________________________ 13
4.3.16 Resistance to Vermin: ______________________________________________________________ 13

5 Technical details 14
5.1 Specific details and requirements ______________________________________________________ 14
5.1.1 Multiple Fuel Fired Thermal oil Heaters _________________________________________________ 14
5.1.2 Emission Limits ___________________________________________________________________ 15
5.1.3 Associated equipment / items_________________________________________________________ 15
5.2 General specifications ______________________________________________________________ 19
5.2.1 Thermal oil Heater - Shell and Furnace _________________________________________________ 19
5.2.2 Fuel Firing System _________________________________________________________________ 20
5.2.3 Fuel handling system _______________________________________________________________ 20
5.2.4 Pipes for Thermal oil and Fuel ________________________________________________________ 20
5.2.5 SPM arresting / SOx -NOx monitoring system ____________________________________________ 21
5.2.6 Instruments and Control System ______________________________________________________ 21
5.2.7 Instrument standards and codes ______________________________________________________ 22
5.2.8 Electrical Scope of supply (not limited to) ________________________________________________ 23
5.2.9 Electric Panel _____________________________________________________________________ 23
5.2.10 Electrical standards ________________________________________________________________ 24

6 Safety 26
6.1 LOTO – policy statement ____________________________________________________________ 26
6.1.1 Procedure ________________________________________________________________________ 26
6.1.2 Terms and definition ________________________________________________________________ 26

7 Inspection, testing, packing and forwarding 29


7.1 Inspection ________________________________________________________________________ 29
7.2 Witnessed inspections, checks and tests ________________________________________________ 29
7.2.1 At shop __________________________________________________________________________ 30
7.2.2 At site ___________________________________________________________________________ 30
7.3 Testing __________________________________________________________________________ 30
7.3.1 Motor test ________________________________________________________________________ 30

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
GCR Oleo Chemicals Project
Specification for NG/IFO/MFO fired Thermal oil Heater

7.3.2 Run test _________________________________________________________________________ 30


7.3.3 Complete Unit Tests ________________________________________________________________ 31
7.4 Final inspection ___________________________________________________________________ 31
7.5 Packing and forwarding _____________________________________________________________ 31

8 Preparation of shipment 32
8.1 Packing__________________________________________________________________________ 32
8.2 Shipping _________________________________________________________________________ 32

9 Erection, commissioning and handing-over 33


9.1 Erection _________________________________________________________________________ 33
9.1.1 General__________________________________________________________________________ 33
9.1.2 Receiving and handling of equipment___________________________________________________ 33
9.1.3 Precautions to be taken by vendor _____________________________________________________ 33
9.1.4 Grouting (As applicable) _____________________________________________________________ 34
9.2 Acceptance tests __________________________________________________________________ 34
9.3 Pre-commissioning and commissioning _________________________________________________ 35
9.4 Handing over _____________________________________________________________________ 35
9.5 Training of owner’s personnel ________________________________________________________ 35

10 Performance, guarantee / warranty 36


10.1 Guaranteed parameters _____________________________________________________________ 36
10.2 Conditions of performance guarantee __________________________________________________ 36

11 Data required from vendor 37

12 Non-material requirements (drawings and documents) 39

13 Spare requirements 41

14 Recommended makes of bought out items 42


Appendix A. Enclosures _______________________________________________________________________ 43

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
GCR Oleo Chemicals Project

1 Introduction

1.1 The Client

PT Energi Sejahtera Mas (hereafter as Client or Sinar Mas or ESM) is a privately held subsidiary of PT
Ivo Mas Tunggal which in turn is directly owned by Sinar Mas Golden Agri Resources, the flagship
entity of Sinar Mas Group (Sinar Mas) dealing in palm oil plantation and production in Indonesia.
Sinar Mas, through its subsidiaries, is the world’s second largest palm oil plantation company with a
total planted area of 455,800 hectares and has integrated operations focused on the production of
palm-based edible oil and fat.
The factories and plantations under the Group’s plantation division are located in North Sumatera,
Jambi, Riau, Bangka, Central Kalimantan, East Kalimantan and South Kalimantan; while the factories
under the refinery division are located in Surabaya, Medan, Tarjun and Jakarta
Currently, the Group has installed capacity of 1.38 million tonnes of crude palm oil per annum and four
kernel crushing plants with total capacity of 444,000 tonnes of palm kernel per annum

1.2 The Project


Sinar Mas intends to set-up a 600 TPD Fatty acid and approximately 1100TPD Fatty alcohol plant. The
project shall have facility for splitting, fractionation and distillation of fatty acids and alcohols along with
Hydrogenation. The project shall also provide for requisite sweet water (Glycerine) purification,
treatment and distillation. A stand-alone 120 TPD Oleic acid plants is also planned on the said facility.
The finished products would be packed either in bulk solids or liquids as well as conventional pack
sizes.

1.3 Site particulars


Particulars Description
Project : GCR Oleo chemical Project
Site address : Dumai, Sumatra, Indonesia
Nearest Port : Dumai
Nearest Airport : Pekanbaru
Ambient air temperature (Max.) : 34 º C
Ambient air temperature(Min.) : 23 º C
Relative humidity : 52% to 96%
Rainfall (annual average) : Max intensity: 100 mm/Hr | Annual average: 3000 mm |
Wet days: 300 / Year
Air Quality : Tropical Hot & Humid, Coastal Air Conditions, Highly Corrosive
Environment
Wind Speed : 36 m/sec average
Seismic Zone : Zone 3

1.4 Definitions
For the purposes of this document, the following definitions shall be used.

Shall the word ‘shall’ is to be understood as mandatory.

Should the word ‘should’ is to be understood as strongly recommended.

May the word ‘may’ is to be understood as indicating a possible course of action.


312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
1
GCR Oleo Chemicals Project

Company/ Owner Sinar Mas (PT Energi Sejahtera Mas)

Consultant Mott MacDonald Pvt. Ltd who is responsible for project management, engineering,
Procurement assistance

Contractor The party to the Contract with the Company who is responsible for the
Procurement, Construction and other related works specified in the Contract.

Mfg / Supplier The party responsible for design, manufacture and/or supply of equipment/plant
and services to perform the duties specified by the Consultant or company.

Vendor The term “Vendor” is considered to be synonymous with the term Manufacturer /
Supplier.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
2
GCR Oleo Chemicals Project

2 Scope

2.1 Scope of Work

2.1.1 Vendor’s Scope


Vendor’s scope shall cover design, engineering, system integration, manufacturing, procurement,
supply, transportation of equipment package at site, inspection, testing and performance testing,
providing mechanical/ performance guarantees and supervision of erection and commissioning of the
Thermal Oil Heating (TOH) system.
The complete packaged system shall include Multiple fuel (Natural gas/IFO/MFO) fired heater units
complete with heater furnace (shell with heat exchanger with multi-pass coils), refractory
bricks/refractory linings, fuels day tanks, fuel feed pumps with preheating system, gas trains, firing
system, necessary heat tracing system, thermal oil storage tank, thermal oil circulation pumps, de-
aeration tank/expansion tank, heat exchangers, Air preheater / waste heat recovery unit (whichever is
applicable considering energy efficiency and shall be quoted optionally), all interconnected flue gas
ducting with requisite dampers/isolators, insulation for system and accessories, chimney, drivers,
auxiliary systems, piping – electrical and instrumentation and control work within battery limits with
accessories and safety devices, PLC control panel etc. as applicable and with all necessary items for
complete package.
Provision of recirculation line for start-up.
Provisions for proper safety system for system protection for pump overpressure, over temperature for
burner, failure case for tubes, system drain and proper venting. All safety valves’ venting shall be
connected to a header which shall be connected to main storage / drain tank.
Provision of proper temperature control system with corresponding calculations for blending Hot
Thermal oil and Cold thermal oil (before furnace) oil for achieving + / - 2 °C temperature variation in the
final temperature of Thermal oil delivered at the Process utilization plants.
Provision of thermal oil for commissioning, performance run, start-up and make-up.
Any additional item/equipment or technical requirement not mentioned hereunder but required to make
the offered system complete in accordance with the specification or required for safe operation, shall be
deemed to be included in the offer and provided by the bidder, without any additional payment.
The vendor (package supplier) shall be responsible for the coordination of the design and for the
satisfactory functioning of the all the components which compose the whole system/ complete unit. In
cases where the vendor supplies equipment that he has not manufactured, he shall be responsible for
ensuring that the design of these items are compatible with each other and with his own equipment in
all respects. In particular, they shall be compatible dimensionally, in performance, in control such that a
fully integrated sturdy unit is provided.

2.1.2 Brief system description

Thermal oil system (Thermal Oil Heaters) shall be designed keeping in mind flexibility of operation. In
normal conditions both plant shall supply to individual process user plants – Fatty Alcohol and Fatty
Acid plant which need approx. 12,040,000 Kcal/hr energy, while in other likely situation either heater
shall be able to supply any process plant. Hence, it is proposed to install 3 x 14,000 kW
(Approximately 3 x 12,040,000 Kcal/hr) capacity plants (2 w + 1s) all interconnected.

It is important to mention here that it is not the intent of this specification to completely specify
all details of design and manufacture for the packaged system. Nevertheless, the system and its
equipment shall conform to high standards of design, engineering and workmanship in all
respects and shall meet all the requirements of relevant codes. Compliance to this specification
312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
3
GCR Oleo Chemicals Project

shall not relieve the equipment manufacturer/supplier of the responsibility of supplying the
equipment’s and auxiliaries of proper design, material and workmanship to meet the operating
requirements specified in the datasheet / design basis. In case of requirements of additional
instruments, controls, safety devices and any other auxiliaries for safe, smooth and trouble free
operation of the equipment, the equipment manufacturer / supplier shall include the same in his
scope of supply.

2.2 Owner’s scope


Open space at site for site storage as per availability of space at site.
All civil works including foundations based on complete loading data (static & dynamic), GA, Elevation
and foundation plan supplied by vendor.
Free water supply for site work at one point
Interfacing with electrical, instrumentation and piping up to battery limits

2.3 Scope of Supply

2.3.1 Owner’s scope of supply


Nil

2.3.2 Vendor’s scope of supply


All materials/equipment/skids for the package system including but not limited to all interconnecting
piping works, valves, foundation bolts etc, instrumentation, electrical works. For detailed scope of
supply of for various disciplines, refer elsewhere in the bid document.

2.4 Exclusions
Nil

2.5 Mandatory spares and special tools


List of mandatory spare and special tools shall be specified in bid document.

2.6 Commissioning Spares


Vendor shall also mention spares required during commissioning.

2.7 Two years operational spares


Vendor shall recommend spares required for two year normal operation along with unit price over and
above insurance spares if any.

2.8 Scope for Electrical


Scope includes complete supply, installation and commissioning of electrical works including panels,
interconnection wiring, cable, cable tray, push button, panel, earthing etc.
All cabling from MCC to all drives shall be in vendor’s scope.
MCC panel for the package shall be located within owner’s premises with other MCCs. Vendor to
consider approximate 250 Mts distance for the same.
Earthing, grounding and lightening protection above ground shall be provided by Vendor and
underground shall be Owner.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
4
GCR Oleo Chemicals Project

2.9 Scope for Instrumentation


Scope includes complete supply, installation and commissioning of instrumentation including panels,
interconnection wiring, cable, cable tray, junction box, PLC, Earthing etc.

2.10 Scope for Fire fighting


Scope includes supply of necessary fire extinguisher as per area requirement.

2.11 Scope of services


The Vendor shall provide, during the course of engineering and execution services, which shall include,
but not necessarily be limited to, the following:
– Providing specifications and details of all equipment and components within the scope of supply.
– Resolving engineering queries related to the equipment and components within the scope of
supply.
– Ensuring that all the equipment and components supplied meet the requirement of this specification
and the specifications, standards and codes detailed therein.
– Performing and coordinating all aspects of design and execution.
– Providing all documentation, drawings, loads, calculations, analysis, design / production schedules,
sub-vendor details etc. for Purchaser’s review and approval.
– Providing progress reports etc.
– Providing expediting services for all sub-vendors.
– Providing quality assurance for all sub-vendors with respect to ISO 9000.
– Inspection and testing and co-coordinating with Consultant/ Consultant appointed TPIA (Third party
Inspection agency) for the same.
– Establishing and following QAP as discussed and mutually agreed upon during final Techno-
commercial discussions.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
5
GCR Oleo Chemicals Project

3 Project Information

3.1 Battery limits

3.1.1 Thermal Oil


IN Hot Oil: At the Inlet Flange of Inlet header of Thermal oil Heater system. The nozzle at battery limits
shall be ASA-300 # RF, Drilled to ANSI B 16.5
OUT Hot Oil: At the flange of Outlet header from system. The nozzle at battery limits shall be ASA-
300 # RF, Drilled to ANSI B 16.5

3.1.2 IFO/MFO (IFO-Industrial Fuel Oil; MFO-Marine Fuel Oil)


At the Inlet flange of IFO/MFO fuel Day tanks for TFH system. The nozzle at battery limits shall be
ASA-150# RF, Drilled to ANSI B 16.5.

3.1.3 NG
At the Inlet flange of Natural gas Burner trains for TFH system. The nozzle at battery limits shall be
ASA-150# RF, Drilled to ANSI B 16.5

3.1.4 Flue gas


Flue Gas at the Outlet of Chimney.

3.1.5 Instrument Air


At one point in the TFH plant. The nozzle at battery limits shall be ASA-150# RF, Drilled to ANSI B 16.5

3.1.6 Nitrogen
At one point in the TFH plant. The nozzle at battery limits shall be 300# RF, Drilled to ANSI B 16.5

3.1.7 Compressed Air


The compressed air will be available at 7.0 barg. The battery limit terminal flanges shall be ASA-150#
RF, Drilled to ANSI B 16.5. All gaskets shall be asbestos free.

3.1.8 Electrical
380±5%,V, 50 ± 3% Hz, 3 phase AC at the terminals of panel

3.1.9 Area Classification


Non Hazardous.

3.2 Conflicting requirements


All conflicts between the requirements of this specification, related specifications, standards, codes,
requisition data sheets and data sheets shall be referred to the Company for clarification before
proceeding with the manufacture of the affected parts.

3.3 Qualification Criteria


The Vendor shall have the single point responsibility for the complete work.
The Vendor shall be a regular manufacturer and supplier of the specified equipment/ package.
Vendor in the last five years should have engineered, manufactured, tested, supplied and
commissioned at least TEN (10) nos. of identical or similar packages in terms of capacity, pressure and
312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
6
GCR Oleo Chemicals Project

purity and other relevant parameters and at least FIVE (5) of these packages shall have completed the
continuous trouble free operations of a minimum 8000 Hrs. as on the bid due date in the last three (3)
financial years. Vendor to give documentary evidence (confirmation from the purchaser).
The vendor shall have full-fledged service support set-up in Indonesia or have appropriate
arrangements for the same with the established local reputed company.
The offered packages shall be of proven make from the existing production range of package
manufacturer and must meet performance requirement as stated in the specifications.
The vendor shall be required to submit the documentation and proof for above requirements and
purchasers may at his discretion make additional checks for the same.
Vendor to furnish their sub-vendor’s list for components outsourced. Vendor shall obtain prior approval
of Purchaser/ consultant by furnishing Proven Track Record (PTR) of proposed sub-vendors.

3.4 Bid submission


Two copies of bid are to be submitted in a single sealed envelope, super scribed with the item and due
date.
The equipment / package shall be offered on lump sum price basis.
The rates for erection and commissioning shall be furnished separately.
The rates for mandatory spares for 2 years shall be furnished separately.
Vendor shall clearly mention whether equipment shall be transported in fully assembled condition or in
a knocked down condition and to be assembled at site. Vendor shall punch match marks to avoid
confusion at site. Vendor shall also furnish “Supply Matrix” together with the offer.
Bids through Telex / Fax/ E-mail are not acceptable.
Vendors are advised to quote strictly as per terms and conditions of the tender documents and clearly
stipulate any deviations / exceptions or alternate design. The deviations / exceptions shall be listed
separately for each specification / document with cross-references and proper reasons for the
deviations / exceptions. In case of any deviation not listed under the ‘List of deviations / exceptions to
the specifications but appears in other part of the bid, the same shall not be considered/ applicable.

Please note that the owner/ purchaser reserve the right to reject any or all the vendors and accept
complete or partial bids without assigning any reasons thereof.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
7
GCR Oleo Chemicals Project

4 Technical Specifications

4.1 General

The package shall be designed, manufactured, tested and supplied strictly in accordance with API/ASME
codes and other applicable standard specifications

4.2 Applicable standards and codes

Table 4.1: Applicable standards and codes


Standard Description
API 520 Sizing, Selection and Installation of Pressure Relieving Devices.
API 526 Flanged Steel Safety-Relief Valves.
API 527 Seat Tightness of Pressure Relief Valves.
API 610 Circulation Centrifugal pump for thermal oil
API 676 Positive Displacement Pumps Rotary.
ASME Section II Materials
ASME Section V Non Destructive Testing
ASME Section VIII, Div. 1 Rules for Construction of Pressure Vessels
ASME Section VIII, Div. 2 Alternate Rules for Construction of Pressure Vessels
ASME Section IX Welding & Brazing Qualifications
ANSI B 16.5 Pipe Flanges and Flanged Fittings.
ASME B16.34 Steel valves, flanges and butt welded ends.
ANSI B 16.47 Large Diameter Steel Flanges NPS 26 Through NPS 60
ANSI B 31.3 Chemical plant and Petroleum refinery piping
ANSI B16.9 Wrought Steel Butt welding Fittings
ANSI B16.20 Metallic Gaskets for Pipe Flanges - Ring Joint, Spiral Wound and Jacketed
ANSI B16.21 Non-metallic Flat Gaskets for Pipe Flanges
WRC 107 Local Stresses in Spherical and Cylindrical Shells Due to External Loading
WRC 297 Local Stresses in Spherical and Cylindrical Shells Due to External Loading -
Supplement to bulletin 107
BS 4360 Skids Design
ISO 9000, ISO 9001 Quality Management and Quality Assurance Standards.
ISO 10474 Material Testing Certificates
ISO 13706 Petroleum and Natural gas industries – Air Cooled Heat Exchangers
ISO 13709 Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries
ISO 14691 Petroleum and Natural gas industries – Flexible couplings for mechanical power
transmission – General purpose applications
IEC 529 Classification of Degrees of Protection Provided by Enclosures
EN 953 Safety of Machinery – Guards – General requirements for the design and
construction of fixed and movable guards
IEC 60034 Rotating Electric Machines
IP15 Hazardous area classification
EEMUA Publication 140 Noise procedure specification
TEMA Tubular Exchangers Manufacturers Association
IEC 534 Industrial control valves
IEC 60034 1 Rotating Electrical machinery
312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
8
GCR Oleo Chemicals Project

Standard Description
IEC-60034 5 Electrical protection
IEC -60034 7 Classification of types of construction, Mounting arrangements and terminal box
position
ISO 5199 Pumps
Indonesian-Earthquake Code Criteria for Earthquake resistant design
ANSI B 31.3 Chemical Plant and Petroleum Piping
API-682 Shaft sealing systems for centrifugal and rotary pumps.
API-671 Special purpose couplings for Refinery service
OSHA Noise control
EPA and EU Regulations Noise control
ISO 1940 Vibration limits for rotating machines
ATEX 94/9/EC Equipment and Protective Systems

Heat exchanger shall include ASME “U” stamp and nameplate certifying compliance with ASME section
VIII, division 1 code for unfired pressure vessels.

4.2.1 General Material Grades

Table 4.2: General Material Grades


Code/Standard Description
ASTM A106 /2010 CS Pipe
ASTM A27 Steel Castings, Carbon
ASTM A36 Structural Steel
ASTM A193 Alloy-Steel and Stainless Steel Bolting Materials
ASTM A194 Carbon and Alloy-Steel Bolting Materials
ASTM A322 Steel Bars, Alloy, Standard Grades
ASTM A536 Ductile Iron Castings
ASTM A775 Epoxy Coated Reinforcing Bars
ASTM B85 Aluminium Alloy Die Castings
ASTM B97 Copper-Silicon Alloy Plate, Sheet, Strip and Rolled Bar
ASTM B179 Aluminium Alloys in Ingot Form
ASTM F467 Nonferrous Nuts for General Use
ASTM F468 Nonferrous Bolts, Hexagon Cap Screw, and Studs for
General Use
Structural steel plate IS-2062
Flanges A 105 / A 182 F 304/316
CS plates SA 285C/SA 515 / SA 516 Plates for high temperature
service

Generally, the materials and workmanship of the goods to be supplied in Bills including materials and
equipment which will be purchased shall comply with the appropriate International Standard (ISO) or in
specific cases the German (DIN) or British Standard (BS) or Code of Practice (CP) or Euronorm (EN).
All suppliers of goods and materials that are referred to above shall be certified to ISO 9001 or EN
29001
Other authoritative standards which ensure an equal or higher quality than the standards and code
specified will be subject to the Engineer’s prior review and written approval. Differences between the
312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
9
GCR Oleo Chemicals Project

standards specified and the proposed alternative standards must be fully described in writing by the
Contractor and submitted to the Engineer at least 28 days prior to the date when the Contractor
requires the Engineer’s approval.
The Contractor shall obtain and keep on site at least one copy of the standards and codes of practice
that are referred to in the specifications, or approved above, and of each other standard which applies
to materials which are being supplied to, or workmanship which is executed on the Works. Copies of
these codes and standards shall at all times be available for inspection by the Engineer.
All standards used will be the current version as available at the date of signing of the Contract. A
Contractor proposing to use alternative versions of specified codes and standards shall submit the
alternative version to the Engineer for approval in accordance with the requirements outlined in the
above paragraph.
All materials and workmanship not fully specified herein or covered by an approved standard shall be of
such kind as is used in first class work and suitable to the climate in the project area.
Where the requirements of any such standard specification or regulation conflict with the requirements
of this specification or any item on the drawings, then the Contractor should refer to the Engineer for
clarification before proceeding with that section of the works.
Codes and Standards ISO, EN, IEC, BS, ANSI, ASTM, AASHTO or DIN codes and standards of the
latest edition shall be part of this specification. In all cases EC standards will be acceptable. Standards
of other nationalities will be acceptable subject to the approval of the Employer where they can be
demonstrated by the Contractor to be at least equal to, or more stringent than the equivalent specified
standards.
Electric Regulations: The whole of the work shall be carried out in accordance with the latest edition of
the Regulations issued by the Institution of Electrical Engineers.
Where the latter conflict or are inconsistent with the former then the latter shall take precedence.
The Contractor shall also comply with any regulations necessary to enable full insurance cover to be
effected and with any local conditions or by-laws.

4.3 General requirements

4.3.1 General requirements for Plant and components:


All components parts of the plant shall be new, unused, in current production and shall comply with the
latest relevant Standard.
All component parts shall be manufactured to strict systems of limits and complete interchange ability
of similar parts shall be achieved.
Where there is no Standards Specification or other the materials and workmanship used shall be
entirely adequate for the purpose and shall not be installed without the written approval of the Engineer.
Uniformity and interchange ability of mechanical and electrical components and accessories which are
common to different parts of the Works shall also be achieved as far as practicable.

4.3.2 Means for Lifting:


All items of plant shall be provided with adequate means for lifting, and heavy covers and other similar
components shall be drilled and tapped for lifting eyes.
Parts having spigotted joints or otherwise likely to be difficult to separate shall be drilled and tapped
for starting screws unless other easy means of separation are provided.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
10
GCR Oleo Chemicals Project

4.3.3 Design and Maintenance:


The general mechanical and electrical design of the plant and particularly that of bearings, glands,
contacts and other wearing parts shall be governed by the need for long periods of operational service
without frequent maintenance and attention being necessary.

4.3.4 Wearing parts:


Parts subject to wear shall be indelibly marked with their part number and maker's name and address
and be easily accessible.
Provision shall be made for taking-up wear in bearings and other wearing parts and for easy
replacement if adjustment is not practicable.
If during the Defects Liability Period any parts show, in the opinion of the Engineer, signs of undue
wear, corrosion or erosion they shall be replaced at the Contractor's expense notwithstanding that they
may be working otherwise in a satisfactory manner.

4.3.5 Suitability for duty:


Except as otherwise specified or approved, all the plant shall be rated for continuous service under the
most onerous duty conditions that may occur under normal circumstances and shall be effectively
protected against damage in the event of overloading arising from the incidence of abnormal working
conditions.
Except as otherwise prescribed or approved, all apparatus and components thereof which comprise the
works shall be of tried and proved design and construction which experience has shown to be entirely
suitable for service according to the Contract.

4.3.6 Access and Safety protection:


The plant shall include such guards, hand-railing, access steelwork, walkways, etc, as may be required
to meet the current relevant regulations for the safety of personnel and of the plant, and to afford
adequate and safe access to all parts of it. All shall be of substantial design and construction.

4.3.7 Fixing:
With the plant shall be provided all necessary supporting steelwork, holding down bolts, cleats, fixings,
etc., whereby it shall be secured to the structures, the cost of which shall be included in the prices of
the items with which they are associated

4.3.8 Special Tools:


Any special tools required for adjustment and maintenance of plant shall be provided. These tools shall
be used during the erection period only for the express purpose for which they are intended.

4.3.9 Identification Tags / Labels:


Each item of plant and each sub-assembly for which spare parts may be required, shall have attached
to it an untarnishable metal or equal approved form of plate showing clearly the manufacture's name,
serial number and basic information as to rating, speed etc, in sufficient detail to allow the component
or assembly to be readily identified in correspondence and when ordering spare parts. The foregoing
information shall be secured by threaded screws and nuts or equal approved method. Self-tapping
screws or soft threaded rivets will not be accepted.
Switchboards and control panels shall bear a title at the top and each component shall bear a smaller
circuit title. Components on the doors shall be grouped as far as possible and each group or single
component labelled to identify its purpose. Internal components and sub-components shall bear labels
312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
11
GCR Oleo Chemicals Project

to identify them relative to numbers or letters shown on their circuit diagrams. All terminals shall be
numbered with the terminal number or conductor ferrule number as appropriate to the wiring system
adopted so that wires may be correctly reconnected without reference to drawings.
Externals labels shall be engraved on black plastic with light infill and shall be secured by non-ferrous
screws.
Internal labels may be similar to external labels or may be painted and varnished. Adhesive labels shall
not be used.

4.3.10 Protection against corrosion and Erosion:


Where corrosion or abrasion of materials may be expected from contact with water or sediment or from
any other cause, the Contractor shall supply suitably resistant materials.
Any material showing signs of corrosion, or pitting before the expiry of the Defects Notice Period shall
be replaced by the Contractor at his own expense with material to the Engineer's approval.

4.3.11 Noise (sound) and Vibrations:


The Contractor shall make all reasonable efforts to reduce noise and vibration to a minimum. All
rotating parts of the plant shall be statically and dynamically balanced so that they operate over all
specified conditions without undue vibration.

4.3.12 Approval of Materials:


Before ordering any Materials of any description intended for the Works, Contractor shall submit for the
approval of the Engineer the names of the supplier or manufacturer proposed, a specification of the
Materials and details of the place of origin or manufacture.
All Materials used in the Works must be new, unless the use of old or refurbished material is expressly
permitted by the Engineer.
The Contractor shall ensure that the provisions of the Technical Consent are strictly adhered to.

4.3.13 Samples:
The Contractor shall provide the Engineer with samples of Material necessary for testing in accordance
with the Contract. Unless expressly excused, the Contractor shall also provide samples of all
manufactured items required for the Works.
Alternatively the Contractor shall submit trade literature where the provision of samples, in the first
instance and as agreed by the Engineer, is impracticable. All samples rejected by the Engineer shall be
removed from the Site.
All approved samples shall be stored on Site by the Contractor for the duration of the Contract, and any
materials or manufactured items subsequently delivered to the Site for incorporation in the Works shall
be of a quality at least equal to the approved sample.

4.3.14 Materials in contact with water:


Materials used in the Works which are, or can be in contact with the untreated or treated water shall not
contain any matter which could impart taste, odour or toxicity or otherwise be harmful to health or
adversely affect the water conveyed.
Materials or equipment shall be according to the specifications from this Project, and when they are
others, prior must be obtained the Engineer's approval.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
12
GCR Oleo Chemicals Project

4.3.15 Galvanising:
Unless specified otherwise hereafter in the Specifications, where items of plant are required to be
galvanised they shall first have all weld spatters, mill scale, and other adherents removed after
fabrication and then they shall be pickled, washed and hot dipped galvanised. The deposition rate shall
be a minimum 460 gr/m2
All parts shall be treated after galvanising in order to minimise discolouration. Where galvanised items
have been cut or damaged on site, the Contractor shall immediately make good the damage to the
galvanising or to the cut edge by means of an approved zinc-rich cold galvanising paint. the paint shall
be applied strictly in accordance with the manufacturer's instructions and to the approval of the
Engineer.
Repairs to damaged items shall only be carried out with the express permission of the Engineer.

4.3.16 Resistance to Vermin:


All plant and equipment supplied under Contract shall be suitably resistant to or protected against
vermin. All seals, grommets, etc shall be made of neoprene or alternative suitable material.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
13
GCR Oleo Chemicals Project

5 Technical details

5.1 Specific details and requirements

5.1.1 Multiple Fuel Fired Thermal oil Heaters

Table 5.1: Multiple Fuel Fired Thermal oil Heater


Sr. No. Description Details
1 Tag No. **
2 Type Natural gas/MFO/IFO Fired, Multi pass,
Thermal oil Heater
3 Construction Horizontal / Vertical Structural Unit
4 Qty. 3 Units
5 Application For heating thermal oil (Therminol-66)
6 Type of fuel used Natural Gas/MFO/IFO (The units shall have
capability to change over to any of one fuel)
7 Approximate calorific value of IFO 10000.48 Kcal/kg (41.87 MJ/Kg)
8 Approximate calorific value of MFO 10008 Kcal/kg (18000 BTU/lb)
9 Approximate calorific value of Natural gas (minimum) 8455 Kcal/m3 (950 BTU/ft3)
10 Thermal oil temp (at outlet of heater) 290 °C
11 Thermal oil temp (at inlet of heater) 255 °C
12 Thermal oil Design temp. 330 °C / *
Design ∆ T = 35 0 C
Operating ∆ T = 250 C
12 Thermal capacity Net Output :3 x 14000 kW
Design Capacity : 3 x ‘* ‘kW
13 Turn down ratio <1:3 (Step less)
14 Thermal efficiency (GCV) for each fuel 85% Minimum
15 Thermal oil trade name Therminol -66
16 Thermal oil Design pressure 15 Kg/cm².g
17 Thermal oil Inlet Pre. - Kg/cm².g (Max.) *
18 Thermal oil Outlet Pre. - Kg/cm².g (Min.) *
19 Location Heater unit- Indoor / Chimney- Out door
20 Inspection door and manhole *
21 Access platform and ladder *
22 Refractory *
23 Insulation bricks *
24 Flue gas Emission Limits As per Indonesian Regulation: PP No.41
Tahun -1999 and Kepmen LH No.21 Tahun
2007
25 Noise Limits Indonesian std.limit as per Indo.Local
regulation: KEP-48/MELH/11/1996

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
14
GCR Oleo Chemicals Project

5.1.2 Emission Limits


As Per attached Annexure A: Perman LH no. 07 Tahun 2007.

Table 5.2: Emission limits for liquid fuels


Parameters Limits
1 Particulate Matter 200 Mg/Mt3
2 SOx 700 Mg/Mt3
3 NOx 700 Mg/Mt3
4 Opacity 15%

Table 5.3Emission limits for Gaseous fuels


Parameters Limits
1 SOx 150 Mg/Mt3
2 NOx 650 Mg/Mt3

5.1.3 Associated equipment / items


S.No Description Details
A Air Preheater or Waste Heat Recovery Unit (for each unit)
1 Quantity 1 No/Unit
2 Type *
3 capacity * Kg/hr @ * Kg/Cm2
4 Max. Working temp. * 0C
5 Design Code *
6 Temp. of Flue gas at I/L *0C
7 Temp. of Flue gas at O/L *0C
8 Overall Dimensions L X W X H * MM
9 Material specification: ASTM 516,Gr.70
10 Shell convection bank ASTM 516,Gr.70
11 Tube Plates BS 3059
12 Tubes BS 3059 Seamless
13 Fuel Heating and Feeding System *

B Fuel Day Tank (For IFO ) 1 No.


1 Capacity/MOC *
2 Size
C Fuel Day Tank (For MFO) 1 No.
3 Capacity/MOC *
4 NG tapping point size *
312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
15
GCR Oleo Chemicals Project

S.No Description Details

D Fuel feed Pumps (common for 3 unit)


1 Quantity 2 nos. (1 Working. +1 standby)
2 Make *
3 Capacity *
4 Type *
5 Motor Kw/RPM *
6 Maximum Temperature .handling capacity *

E NG Gas Train (independent for each unit)


1 Make DUNGS or Equivalent
2 Gas Filter DUNGS or Equivalent
3 Gas Pressure Regulator DUNGS or Equivalent
4 Gas solenoid valves DUNGS or Equivalent
5 Pilot Ignition valve DUNGS or Equivalent
6 Pressure switch DUNGS or Equivalent
7 Valve Proving systems DUNGS or Equivalent

F Thermal oil Main Circulation pump (for each unit)


1 Quantity 1 no. (1 Working + 0 standby)
2 Make *
3 Capacity *
4 Type *
5 Motor Kw / RPM *
6 Maximum Temperature handling capacity *
7 Mechanical seal *

G Thermal oil Emergency circulation pump


1 Quantity 1 No.
2 Make *
3 Capacity *
4 Type *
5 Motor Kw / RPM *
6 Maximum Temperature handling capacity *
7 Mechanical seal *

H Emergency Cooling System (for each unit)


1 Quantity *
2 Make *
3 Capacity *
4 Type *
5 Motor Kw / RPM *
6 Maximum Temperature handling capacity *

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
16
GCR Oleo Chemicals Project

S.No Description Details


I Emergency Venting System (for each unit)
1 Quantity *
2 Make *
3 Capacity *
4 Type of Operation *

J Make up pump *
1 Quantity *
2 Make *
3 Capacity *
4 Type *
5 Motor Kw / RPM *
6 Maximum Temperature handling capacity *
7 Mechanical seal *

K Booster Pump
1 Quantity *
2 Make *
3 Capacity *
4 Type *
5 Motor kW / HP *
6 Mechanical seal *

L Temperature control loop for ( Mixing Hot Oil with Cold Oil) to
maintain + 2 Deg.C of Hot Oil at the outlet – independent for each
unit)
1 Type
2 Capacity
3 Maximum Temperature handling capacity

M Thermal oil De-aerators/expansion tank (independent for each unit


or a common suitably designed and located at suitable location)
1 Capacity *
2 Type *
3 MOC *
4 Design Temp & Pressure *
5 Dimension *

N Fuel Oil Pre-Heater system (for each IFO/MFO unit)


1 Quantity 2 set.
2 Type *
3 Electric heater rating * kw
Accessories provided
- Solenoid valve
- Electric thermostat.
312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
17
GCR Oleo Chemicals Project

S.No Description Details


- Temperature indicator IL/OL.

O Burner System (for each unit) *


1 Make & Model Weishaupt / Riello / *
2 Type of Burner Duel fired /Fully automatic,
pressure atomizing, step less, fully
modulating oil/gas fired burner.
Burner casing with integral air
intake guide, hinged flange,
casing cover with sight glass,
burner motor, air regulation
pressure side, fan, air pressure
switch, servomotor, gas/air
compound regulation with
regulating cam(s), combustion
head, ignition transformer, ignition
cable, ignition electrodes, terminal
strip, flange gasket, fixing screws
3 Atomization method Pressure jet
4 Turn-down Ratio NG – 1:3 *
IFO / MFO – 1:3 / *
5 Air fuel Ratio *
6 Modulation Continuous (step less)
7 Atomized Condition Pressure, kg/cm2 (g) *
Atomized Condition Temp, ° C *

P ID and FD fan (for each unit)


1 Qty. *
2 Type *
3 Capacity in Nm3/hr. *
4 MOC *
5 Pressure *

Q Chimney (Common for 2 units, suitably designed )


1 Qty. 1 No
2 Type Steel chimney – self supported
+with Canopy at top
3 Diameter Vendor to design
4 Height As per design and applicable
Indonesian codes
5 MOC ASTM A 36 + SS 304 at top 4 Mt.
section
6 Design code “”CICIND(International committee
on Industrial chimneys)
“”A Customer's Guide to
Specifying Chimneys"
"Manual for the maintenance and
inspection of brickwork and
concrete chimneys"
Quality System for Industrial
Chimneys"
312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
18
GCR Oleo Chemicals Project

S.No Description Details


"Manual on Chimney Protective
Coatings"
"Model for Thermodynamic
Design of Chimneys and Chimney
Liners"
"Manual for Expansion Joints and
Chimney Seals"
"Metallic Materials Manual"
CICIND Chimney Book
7 Corrosion allowance As per code.
8 Associated accessories Platforms with access ladder,
Aviation Lamp and lightning
arrestor, sample points
9 Interconnecting Flue gas ducting with dampers To be provided
10 Other essential components of the system To be provided according to
[1] Furnace Cleaning/soot blowing system (as applicable) applicable codes/standards
[2] Alternate suitable Heat recovery unit etc.

‘*’ – indicates data to be furnished by the vendor

5.2 General specifications


TOH package shall be designed, manufactured, tested and supplied strictly in accordance applicable
codes & standards.

5.2.1 Thermal oil Heater - Shell and Furnace


The furnace shall be fabricated with CS plates with proper supporting structures, provision for primary
& secondary air, cleaning doors, fire inspection doors.
APH shall consist of fusion welded main shell with jacketing over it for air pre-heating. The flue gas
path shall be multi-pass design to active optimum efficiency level. It shall also have a diverter valve to
control and adjust the flue gas flow.
Furnace volume shall be adequately sized to provide increased residence time and complete
combustion of fuel at low excess air. Also large radiation surface to be designed to give high heat
absorption and keep moderate heat flux and heat release rate.
Pressure parts shall be high temperature resistant quality carbon steel, mainly forming radiant and
convective zones.
Heater shall be with provision of access door for inspection and cleaning purpose.
The system to supply primary/secondary air for the efficient combustion shall be thoroughly compatible
with flue gas handling system at all loading rates, taking into account entire system pressure drops
through dampers and equipment’s in the path up to the chimney, so as to maintain optimum pressure
condition in the furnace at minimum pressure drop. FD fans shall be provided with VFD for efficient
operation control and savings in energy costs.
Air preheater/heat recovery etc. shall be highly efficient in Heat transfer and also in recovering
particulate matter (if any). The nozzle at battery limits shall be ASA-150/300# RF, Drilled to ANSI B
16.5.
Air Pre-heater, other heat recovery units etc. equipment’s shall have proper structural supports with
platform and safety railing for inspection/maintenance and also provision of bypass ducting
arrangement with damper valves for maintaining air/flue gas temperature within limit and adjusting the
pressure drops.
312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
19
GCR Oleo Chemicals Project

As far as possible Heater unit/equipment shall be skid mounted construction – as ready to install and
hooking up at terminals only.
Thermal oil Heater Unit/ associated equipment shall be so designed that all components are easily and
conveniently accessible for observation/maintenance/replacement.
Maintenance platform with access ladder shall be provided, wherever applicable.
Thermal insulation along with protective covering shall be provided as needed on equipment’s as well
as Thermal oil piping within battery limits.

5.2.2 Fuel Firing System


Duel Fuel firing system shall be composed of followings:
– Ball valve
– Gas filter
– Low pressure governor *
– Gas pressure switch
– Double solenoid valves (DMV)
– Gas butterfly valve
– Pressure gauge with push button valve *
– Valve proving VPS *
– Burner
– Pump
– Oil solenoid valve, normally closed
– Oil pressure switch
– Oil regulator
– Nozzles for regulatory control
The firing system shall be VFD/servo based and fully automatic with optimum turn down ratio,
sequence controller and safety interlocks.
The system shall be so designed / selected that residual pollutant in flue gas are minimum and comply
with Indonesian regulatory norms .
Duel fire Burner Assembly shall produce efficient combustion, flame stability and shall maintain
optimum air-fuel ratio throughout the modulating range.
Burner Control:
– Thermal oil heater shall be provided with sequence controller unit with inbuilt flame monitoring
system to ensure safe sequence operations. It shall also start with purge cycle, spark ignition, flame
stabilization and post purge cycle to ensure less soot formation and less corrosion.

5.2.3 Fuel handling system


IFO / MFO day tanks (vendor scope) shall have adequate capacity to allow system to operate and shut
down smoothly in the event of supply system failure.
The limit switches shall be provide and communicate with feed pumps in main storage area
Proper heat tracing shall be provided whenever necessary for IFO/MFO handling system within the
battery limits.

5.2.4 Pipes for Thermal oil and Fuel


For Thermal oil piping it shall be A106 Gr.B and properly design the size and schedule based on the
process requirement.
The flanges shall be of material A105 with dimension as per ANSI B16.5. The minimum rating shall be
class 300#.
Piston valves or Bellow seal valves shall be considered for Thermal oil duty.
312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
20
GCR Oleo Chemicals Project

All interconnecting fuel piping (with heating system) shall be in vendor’s scope.

5.2.5 SPM arresting / SOx -NOx monitoring system


Vendor shall provide adequate facility/equipment to keep the SPM in the outlet flue gases from
chimney as per Indonesian statutory norms/codes.
Online Analysers shall be provided to monitor Excess oxygen /SOx / NOx etc. levels in the flue gas.

5.2.6 Instruments and Control System

5.2.6.1 Instrument scope of supply (not limited to)


Control System
Instrument wiring
Instrument air tubing
Instrument Panel/Marshalling Cabinet
Plant Safety Shutdown /ESD
Burner Control
Field instruments
Analyser Devices
Junction boxes

5.2.6.2 General
Vendor shall supply PLC based system with HMI and PLC-PC interface with Audio-visual alarms and
having compatible hard wares and software.
PLC shall be open platform type. Burner firing sequence and process control shall be through PLC
only(No Black Box Type system control envisaged/accepted)
Redundancy shall be observed regarding Processor, Communication and Power supply w.r.t. control
system.
All I/O controls shall be isolated.
Operation logics and sequence control write up shall be furnished by Vendor.
Control System shall be supplied with software editing/viewing facility.
All control system software licence shall be in Client’s name.
Oxygen analyser at Flue gas outlet shall be considered.
An Integrated system to measure and record Enthalpy flow out of the system with Data Logger
On line Flow recording/measuring system for fuel feeding system to measure and maintain efficiency of
the Thermal oil heating system.
All ID Fan/FD fans shall be provided with VFD which shall be operating through PLC working on
feedback from various pressure transmitters and temperature transmitters for efficient pressure control
within the furnace and throughout the flue gas system and thus saving energy costs.
All control system shall be based on feedback basis.
Integrating voltage shall be 24VDC (redundant).
An efficient fine-tuned temperature control system to maintain Heater outlet oil temperature within the
range of + / - 2 Deg. C. The system shall have PID controller and operate the flow control valve (with
sparger pipe between common inlet header and outlet header)on various inputs from furnace to mix
return cold oil with Thermal oil and thus maintain the Thermal oil temperature within the required band.
This shall be achieved by booster pump integration with control loop.
All necessary controls for safe and efficient operation of the Thermal oil Heater unit.
In addition to above and other standard safety interlocks, following minimum interlocks must be
included:
312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
21
GCR Oleo Chemicals Project

– Fuel cut off in case of low oil flow/Circulation pump failure(motor interlock)
– Fuel cut off in case of flame failure
– Heater operations interlock NG transfer.
– Low system pressure switch to shut down the system
– Firing not to start unless Thermal oil circulation is on/Low level in Expansion tank
– Temp controller for Thermal oil and firing control
– High temperature safety switch interlock at heater outlet shutdown and alarm signal
– 2 Nos. Pressure Safety valve at Thermal oil terminals of the heater unit shall be provided.
– Thermal oil dump down system in case of Power failure/no flow situation.
– Redundant Pressure switches for No flow/Low flow condition
– High stack temperature
– Low / High Thermal oil Temperature
Emergency shutdown or Plant Safety Shutdown control system shall be provided.
All the Instruments shall be supplied with proper test certificates/warranty certificates.
All pressure gauges supplied shall be glycerine filled. The minimum gauge size is 6” dial size, 25 NB
end connection and SS-316 bourdon tube.
Mercury filled thermometers are not acceptable. The minimum temperature size is 6” dial size, 25 NB
end connection, and SS-316 bourdon tube.
Thermometers and temperature gauges shall be furnished with 300 series SS solid bar thermo well.
Rota meter shall be Metal Tube Type, flange rating as applicable.
SOV shall be operated by 24V DC, insulation class shall be F, port size of ½”, housing as per area
classification.
Instrument control valves shall be Plug type only.
All Transmitters shall be SMART (FF/HART) type.
All Restriction orifice /Automatic Operated Valves etc. shall be supplied with Test certificates/Sizing
datasheets.
On/Off valve, Control valve shall be designed as per max shut-off and back pressure design.
Pneumatic actuator shall be designed with Instrument Air pressure - 5.0 Kg/cm2 (G) with local Open-
close indication.
The following locally mounted gauges are required, as a minimum:
– Temperature/pressure at strategic locations throughout Thermal oil path.
– Temperature/pressure at strategic locations throughout air/flue gas path.
Relief valves:
– The vendor shall furnish the relief valves that are to be installed on equipment or in piping that the
vendor is supplying. The relief valves shall be ASME certified, and meet the limiting relief valve
requirements defined in API RP 520, Parts I, II, and API STD 526. The vendor's quotation shall list
all relief valves and clearly indicate those to be furnished by the vendor. Relief valves shall be
made of steel only. Relief valves shall be mounted to piping and vessels by extra heavy wall
piping/connections, and the distance between the relief valve and vessel shall be minimized.
Welded braces or gusseting ribs on the extension piping (if any) are required.
– Outlet of all relief valves mounted on Hot Oil Header shall be connected to a common header and
diverted to drain tank for safety reasons.

5.2.7 Instrument standards and codes

Table 5.3: Instrument standards and codes


Sr. No. Code Details
1 - ISA S 75.1 Flow Equations for sizing control Valve
312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
22
GCR Oleo Chemicals Project

Sr. No. Code Details


- IEC 60534 - 2 -1
2 - ANSI B 1.20.1 Screw Threads and General Purpose
3 - ANSI B 16.36 Orifice flange
4 - IEC 60079-14 Instrument cable
5 - IEC 60751 Ed. 2.0 Industrial Platinum resistance Thermometers and
Platinum Temperature Sensors
6 - IEC 60584 - 2 International thermocouple reference table
Specifications for Thermocouple Tolerances.
7 - API RP 257 Seat tightness of Pressure Relief Valve
8 - ASME PTC 19 03.74-3 Thermo wells for Temperature
9 - IEC 61537 Cable Management - Cable Tray System and cable
Ladder system

5.2.8 Electrical Scope of supply (not limited to)


MCC Panel
Synchronous panel
Switch gear
Trafo distribution
Cable rack
Cable ladder and tray
Local control push button
Lighting
UPS
Battery pack
Cable gland
Grounding and lightning
NGR
Capacitor bank

5.2.9 Electric Panel


All critical loop interlocks (like trip/start/shutdown etc.) shall be displayed on PC-PLC system.
Starter-cum-control panel with dual main incomer isolator, sub isolator(s) for each drive/user shall be
provided.
Control panel shall be with the provision for 24 volts DC supply required for the controls
instrumentation. An annunciator shall be included with the panel with manual reset features.
The power and control section shall be physically isolated with partition plate.
An Ampere meter and voltmeters shall be provided for incoming supply. Energy meter shall be
provided to measure total energy consumption of the system with RS-485 communicators.
Backup power supply for PLC system
Motors and Starters
– All the motors shall be energy efficient TEFC – induction type with protection class IP-55. The
insulation shall be class `F’ with temperature rise restricted to class `B’ insulation.
– As stated earlier all FD fans shall be provided with VFD along with bypass Star Delta Starter.
Cabling & Earthing
− Power cables shall be 1100 volts grade, XLPE insulated with Extruded PVC inner sheath &
overall FRLS – PVC sheath stranded aluminium / copper conductor, steel wire/Flat Armoured.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
23
GCR Oleo Chemicals Project

− (Power cable up to 16 sq. mm shall be of copper conductor and above 16 sq. mm shall be of
Aluminium conductor).
− Power cable shall be sized considering de-rating for ambient, steady state voltage drop of 5% &
starting voltage drop of 15% max.
− Control cables shall be shielded Multicore copper conductor of minimum 2.5 sq.mm.

5.2.10 Electrical standards

5.2.10.1 Technical requirements for Thermal Oil Heater

Table 5.4: Electrical Standards


DC
Sr. No. Item Unit Power AC Power
1 Low voltage Volt - Three Single
Phase phse
2 Medium Voltage K-Volt - 380 +/- 5 220
%
3 Frequency Hz - 50 +/- 3% 50
4 Instrumentation Volt 24 - -
5 mA 4-20 - -
6 Motor Electrical Load Start < 5.5 KW: DOL ( Direct On Line)
system
5.5 KW - 11 KW: Star Delta
> 11 KW: Soft Starter
7 Voltage Classification for Every < 250 KW - 380 V
Motor Load
> 250 KW - 6.6 KV
8 Cable LV: MV
a. Rating 0.6 / 1 KV 7.2 / 12 KV
b. Isolation Double XPLE Double XPLE
c. Resistance 100 1000
d. Outer sheet color Black Red
e. Wire color
- L1 Red Red
- L2 Yellow Yellow
- L3 Black Black
-N Blue Blue
- PE Yellow - Green Yellow - Green
9 Bus bar MOC Tin Copper Aluminium

Table 5.5: Electrical Standards and Codes


Sr. No. Standard and code Details
1 - IEC: For general
2 - IEC 60050 Switch gear, control gear, fuse
3 - IEC 62271 High voltage alternating current circuit breaker
4 - IEC 60255 Electrical relay
5 - IEC 60265 High voltage switch
6 - IEC 60529 Degree of protection (IP)
312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
24
GCR Oleo Chemicals Project

Sr. No. Standard and code Details


7 - IEC 60038 Voltage standards
8 - IEC 60079 Electrical apparatus for explosive gas atmosphere
9 - IEC 60146 semi-conductor converter
10 - IEC 60076 Power transformer
11 - IEC 61537 Cable ladder and tray system for cable management

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
25
GCR Oleo Chemicals Project

6 Safety

6.1 LOTO – policy statement


The vendor shall be responsible to establish and fulfil requirements for affixing the appropriate
lockout/tag-out (LOTO) signage and locks to energy isolating devices and to otherwise disable
machines, equipment or processes to prevent unexpected energizing, start-up, or the release of stored
electrical, hydraulic, pneumatic, chemical, thermal, or other energy.

6.1.1 Procedure

6.1.1.1 Scope of This Policy:


Client wishes to prevent injury to employees/users engaged in service or maintenance activities of
machines, equipment, or processes where the release of energy may put them at serious risk.
Examples of such machinery or equipment include but are not limited to vessel, pumps, motor etc.
Work situations where unexpected energization or start-up can occur include new construction, I
installation or set-up of equipment, and the adjustment, inspection, maintenance, repair, and service of
machines and equipment. Energy types to be considered include electrical, mechanical, hydraulic,
pneumatic, chemical, and thermal.

This policy contains procedures for the service and maintenance of equipment and machines where the
unexpected energization or start-up could cause injury to employees/users.

Caution: The following situations are not subject to the procedures outlined in this document:
Work on plug and cord type electrical equipment, for which exposure to the hazards of unexpected
energizing, start up, or the release of stored energy of the equipment is effectively controlled by the
unplugging of the equipment from the energy sources and by the plug being under the exclusive control
of the employee/user performing the servicing or maintenance.

Hot tap operations involving transmission and distribution systems for substances such as gas, steam,
water, or petroleum products when they are performed on pressurized pipelines provided that it is clear
that continuity of service is essential, shutdown of the system is impractical, and documented
procedures and special equipment are implemented which will provide proven and effective protection
for employees/users.

Service or maintenance that takes place during normal production operations, such as lubricating,
cleaning, and making minor adjustments and simple tool changes, except when an employee/user is
required to place any part of his/her body into an area on a machine or piece of equipment where work
is actually performed upon the materials being processed (i.e., point of operation) or where an
associated danger zone exists during a machine operating cycle.

Each unit is responsible for the development of specific energy control procedures for each machine or
other equipment within its respective areas of responsibility.

6.1.2 Terms and definition


Affected Employee/User : A person whose job requires him/her to operate or use a machine or
equipment on which servicing or maintenance is being performed under lockout or tag-out, or whose
job requires him/her to work in an area in which such servicing or maintenance is being performed.
Affected area within the unit that contains machinery or equipment subject to lockout or tag-out
procedures.
312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
26
GCR Oleo Chemicals Project

Authorized Employee/User: A person who locks out or tags out machines or equipment to perform
service or maintenance on that particular item. An affected employee/user becomes an authorized
employee/user when that employee's duties include performing service or maintenance on machines or
equipment covered under this policy.

Blocking Tag - A tag-out device that indicates the use of chains, wedges, key blocks, adapter pins, or
self-locking fasteners for isolating, securing or blocking of equipment from energy sources.

Energy Isolating Device - A mechanical device that physically prevents the transmission or release of
energy, including but not limited to, the following: a manually operated electrical circuit breaker; a
disconnect switch; a manually operated switch by which the conductors of a circuit can be
disconnected from all ungrounded supply conductors, and, in addition, no pole can be operated
independently; a line valve; a block; and any similar device used to block or isolate energy. Push
buttons, selector switches and other control circuit type devices are not energy isolating devices.

Going Through a Tag - A procedure in which a piece of equipment or machinery is started when the
lockout/tag-out procedure is in place.

Hot Tap - A procedure used in repair, maintenance, and service activities that involves welding a piece
of equipment (pipelines, vessels or tanks) under pressure to install connections or appurtenances.

Lockout - The placement of a lockout device on an energy isolating device according to an established
procedure; this ensures that the energy isolating device and the equipment being controlled cannot be
operated until the lockout device is removed.

Lockout Device - A device that uses a lock, either key or combination type, to hold an energy isolating
device in a safe position and prevent the energizing of a machine or other equipment. Included are
blank flanges and bolted slip blinds.

LOTO – acronym for Lockout/Tag-out.

Normal Operations - The utilization of a machine or other equipment to perform its intended function

OSHA – Occupational Safety and Health Administration, an agency in the Department of Labor.
Develops and enforces Occupational safety standards.

Owner's Representative - An individual who represents the Client in all aspects of:1) A project when
dealing with a contractor; 2) A lease agreement when dealing with a vendor. Caution: Some leases
may define these owner's representatives as "contact persons" or "program directors servicing and/or
Maintenance - Work place activities such as constructing, installing, setting up, adjusting, inspecting,
modifying, and maintaining and/or servicing machines or other equipment. These activities include
lubrication, cleaning or unjamming of machines or other equipment and making adjustments or tool
changes, where the employee/user may be exposed to the unexpected energization or start-up of the
equipment or release of hazardous energy.

Tag-out - The placement of a tag-out device on an energy isolating device, according to an established
procedure, to indicate that the energy isolating device and the equipment being controlled may not be
operated until the tag-out device is removed.
312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
27
GCR Oleo Chemicals Project

Tag-out Device - A prominent warning device, such as a tag and a means of attachment, which can be
securely fastened to an energy isolating device according to an established procedure, to indicate that
the energy isolating device and the equipment being controlled may not be operated until the tag-out
device is removed.

This policy is specifically intended to prevent injuries to employees/users engaged in service or


maintenance activities of machines, equipment, or processes where the release of stored energy may
put them at serious risk. This policy (LOTO) ensures with OSHA 29CFR 1910.147.

6.2 Human factor engineering


Vendor will considered the work around space for all equipments for operation and maintenance. The
location of valves, instruments, push buttons etc., shall be at operating & ease for maintenance.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
28
GCR Oleo Chemicals Project

7 Inspection, testing, packing and


forwarding
7.1 Inspection
The unit shall be offered for inspection by the Company or Company's representative, and all tests
listed below shall be undertaken together with any other tests as necessary to prove satisfactory
operation and full compliance with the Specification. Test procedures shall be submitted to the
Company for review and approval.
In the event that any inspection and witness test is waived, then this shall not release the Manufacturer
from his obligation to supply completely satisfactory equipment of guaranteed performance as
specified.
The Manufacturer shall be required to submit such test certificates in respect of the materials listed, as
specified by the Company.
The test results shall be recorded and three copies of a test report setting out the results in an
approved form shall be made available to the Company.
All equipment shall be presented for inspection in an unpainted state except the final inspection.
Any inspection by the Company or his representative does not relieve the Manufacturer of his
responsibilities as stated in this document.
All equipment, assemblies shall be subjected to inspection prior to despatch as per mutually agreed
Inspection Plan
The customer’s/consultant’s Inspector shall at all times have an access to all parts of shop (s) where
items are being manufactured. All reasonable inspection facilities to be provided by Supplier and his
sub supplier

7.2 Witnessed inspections, checks and tests


Unless waived by the Company, the following inspections, checks and tests shall be witnessed by the
Company or the Company's representative (TPI).
Hydrostatic tests:
– The tests shall be made with clean fluid, for at least 30 minutes and at 1 1/2 times the maximum
allowable casing pressure. (Witnessed test not required, certified test certificates to be submitted.)
Verification of the materials of construction of the package pressure vessels for conformity with the
requirements of the Purchase Order.
Verification that piping and fittings conform with specification for materials and fabrication.
Verification of the Vendor's design calculation for the package pressure vessels.
Verification of the Vendor's welding procedure for the package pressure vessels. Approval of welder's
qualifications.
Spot inspection by radiographic, dye penetrant, magnetic particle, and ultrasonic inspection of the
welds on the pressure retaining parts of package pressure vessels.
Hydrostatic tests of the fabricated pressure retaining pipework and vessels.
Functional test of the package, all alarms, trips, indications, controls and repeat alarms.
Approval of the relief valve settings and witness of their testing after setting.
– A visual check of the assembled package noting:
That the thickness of pressure retaining parts meets or exceeds the quoted design thickness.
– Any repairs.
Internal coatings are complete and have the dry-film thickness quoted in the purchase order.
The general appearance, materials, workmanship and standard of finish are acceptable.
The main dimensions and layout comply with approved drawings.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
29
GCR Oleo Chemicals Project

7.2.1 At shop
Physical inspection, verification of material test certificates etc.
G.A. dimension and visual inspection for quality of workmanship.
Review of inspection & test reports, material T.C. and T.Cs of bought out items.
Witnessing of various pressure / leak testing
Hydrostatic test of all pressure vessel followed by drying of equipments & piping by passing air.
Sequence test of control panel with PLC. Client shall inspect Control system and Panel as and when
ready.
No load test.
Mechanical run of the fan in installed condition to ensure that vibration levels, currents, noise level and
bearing temperatures are within permissible limits

7.2.2 At site
After erection of the Oil Heating System, the performance test of the same shall be taken in accordance
with industry standards and the following parameters are to be checked.
Thermal oil temperature & ∆T
Capacity of Oil Heater (kw)
Power consumption
Performance guarantee test at site as per order specification
Performance run shall be done on non-stop (continuous) basis for 48 hours trouble-free working
without any stoppage. In case of any repair /adjustment in the system, fresh performance runs to be
done.

7.3 Testing
Pressure containing parts such as vessels, heat exchangers, tanks, piping etc. shall be hydrostatically
tested with liquid at a minimum of 1.5 times the maximum allowable working pressure, but not less than
20 psi (1.4 bar gauge). Where applicable, the tests shall be in accordance with ASME code. In case the
inspection and testing is required to be carried out at OEM’s Works, the cost of the same shall be
included in the total price.

7.3.1 Motor test


Each motor will have a witnessed test in accordance with the relevant Indonesian standard. The
Vendor may, as an alternative, with prior approval of the Company, furnish for the approval of the
Company's inspector the Manufacturer's Type Report for the motors supplied, and the Routine
Manufacturing Test Certificate. These certificates shall, as a minimum, cover:
– Verification of nameplate data as compared with the requisition/data sheets.
– Correct assembly of motor components.
– Correct motor winding connections (noting whether motor is star or delta connected).
– Free rotation of uncoupled unit.
– Measured insulation resistance at motor terminals (phase-to-phase and phase-to-earth).
– Measured motor bearing temperature (if recorded) during any test run.
– Measured line voltage and current during any test run.
– Vibration footprint (if recorded).

7.3.2 Run test


A witnessed performance test of the package is required. Each package shall be operated at its rated
capacity for designated hours after the unit temperatures have stabilised. The satisfactory operation of

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
30
GCR Oleo Chemicals Project

all indicators, selectors, controllers, alarm and fault protection equipment shall be demonstrated, if
necessary, by fault simulation. During the run test the unit performance (of flow/ pressure/ temperature/
power), noise and vibration shall be checked.
Mechanical Running Test.
– The Fans shall be operated for 4 hours at rated speed consisting of 2 hours of progressive loading
on a minimum of 2 continuous hours at the rated discharge pressure level and full load.
– All heaters and system joints and connections shall be checked for tightness, and any leaks shall
be corrected prior to the tests.
– All warning, protective, and control devices shall be checked and adjustments shall be made as
required.
– During the running test, the mechanical operation of all equipment being tested shall be as per
design.
– If replacement or modifications of bearings, valves or packing or dismantling of the machine to
replace or modify other parts is required to correct mechanical or performance deficiencies, the
initial test will not be acceptable, and the final shop tests shall be run after these corrections are
made.

7.3.3 Complete Unit Tests


Such components as fans, gears, drivers, and auxiliaries that make up a complete unit shall be tested
together during the mechanical running test. All auxiliaries that make up the package shall be used and
tested jointly with the compressors during the mechanical tests.

7.4 Final inspection


Final inspection before shipment shall be witnessed by Company TPI to ensure satisfactory painting
and preservation, adequate dismantling and bracing for shipment.
Following final inspection the package shall be emptied, dried out, and where necessary, preserved for
shipment and outside storage at site for up to 12 months.
– Inspection Plan (At shop & at Site).

7.5 Packing and forwarding

All exposed surface shall be appropriately painted to prevent against corrosion / rusting, as applicable.
All opening shall be blanked off suitably before dispatch.
Item tag no. shall be prominently marked / painted.
All loose parts / items shall be provided with proper identification and tag nos.
Items shall be packed suitably to prevent against damage / loss during transit.
Delicate parts (if any) shall be packed separately.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
31
GCR Oleo Chemicals Project

8 Preparation of shipment

8.1 Packing

All packing shall be carried out after satisfactory inspection and testing of the package. In the case of
witnessed inspections' this is subject to receipt by the Vendor of the Release Note for Shipment.
Equipment shall be cleaned and dried before preservation is commenced.
Equipment shall be suitably prepared for the type of shipment specified. The preparation shall make the
equipment suitable for 6 months of outdoor storage from the time of shipment, with no disassembly
required before operation, except for inspection of bearings and seals.
Exterior surfaces, except for machined surfaces, shall be given at least one coat of the manufacturers’
standard paint. Exterior machined surfaces, including shafts, shall be coated with suitable rust
preventive.
All interior areas of crankcases and carbon steel oil systems auxiliary equipment such as reservoir,
vessels, and piping shall be coated with suitable rust preventive. The compressor casing inner diameter
shall be protected by non-combustible rust preventive.
Flanges shall be blanked-off with wooden discs, in which the nuts of the studs are to be embedded
All flanged and threaded openings shall be provided with gasketed metal closures or steel plugs.
The ends of small pipes shall be provided with plastic caps and sealed with tape.

8.2 Shipping
Each unit shall be boxed in a seaworthy close-boarded case with a waterproof lining.
Initial spares shall be packaged in a separate rigid box, which shall be placed in the case containing the
main equipment.
Transport to site will be via truck over extremely rough terrain. Therefore goods shall be packed
/delivered in such a way as to withstand the severe road conditions in Indonesia, which include
unpaved poorly graded roads.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
32
GCR Oleo Chemicals Project

9 Erection, commissioning and handing-


over
9.1 Erection

9.1.1 General
This specification describes a general outline for the installation of the equipment involved. The field
circumstances shall be taken into consideration and methods suitable to the site conditions shall be
adopted in consultation with the Engineer-in- Charge. The vendor shall employ only such workers and
supervisors who have considerable experience of similar work and with adequate technical skills.
All bolts, anchor bolts, nuts, lock washers, other fasteners, supports and other miscellaneous items
shall be supplied by the vendor.

9.1.2 Receiving and handling of equipment


All equipment received at site shall be checked by the vendor for the equipment being intact, in the
presence of Engineer-in- Charge and shall be unloaded by contractor and accepted by the vendor for
the storage and safe custody. The equipment shall be stored in the approved manner by
Engineer-in-Charge and the vendor shall be responsible for the storage and safety of the equipment.
Whenever the equipment is received in wooden crates, the vendor shall carefully dismantle these
crates and store all timber and packing materials properly.
It shall be the responsibility of the vendor to study the requirements of installation and instructions for
commissioning of the same prior to supervising the erection and commissioning activities carried out by
contractor by employing skilled personnel experienced in the type of services required. The
responsibility and accountability throughout these activities shall be with Vendor for the safe and
successful completion.
The vendor shall be fully responsible for the safe custody of the equipment during the period from
acceptance of the equipment to commissioning and handing over of the same to the client

9.1.3 Precautions to be taken by vendor


Take adequate care and precautions to prevent loss/damage of material and equipment.
Keep structures, materials and equipment adequately and safely braced by struts, guys, and any other
approved means as required till installation work is satisfactorily completed. Design, provide and erect
the struts, guys, shorting, bracing, planking support in such a way that they do not interfere with other
work and shall not damage or cause distortion to other works executed by him.
Openings for instruments shall be protected during and after erection.
All accessories like pressure gauge, temperature indicators, safety valves, etc. shall be tagged and
separately kept till erection.
All flange connections and openings shall be kept blanked with wooden covers to prevent entry of
foreign matter.
Metallic flange guard shall be considered for all flange connection.
Special care shall be taken for bearings, rotating parts etc., to prevent seizing. Generally, the packages
shall not be opened until required for installation.
Orientation of all the foundations, elevations, lengths, positions of anchor bolt and diameter of holes in
base plates/supporting structure etc. shall be checked by well in advance.
Minor rectification work like chipping of foundation shall be carried out in time.
Rigging procedures of all major lifts above 5 MT and at maximum crane capacity shall be submitted by
Vendor for approval of the Engineer-in-Charge. However, such approvals shall not relieve the vendor
from the responsibility of safe rigging and lifting of the equipment, machinery, etc.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
33
GCR Oleo Chemicals Project

Drilling and tapping of holes in base plates, fixing of couplings on shaft after enlarging the pilot bore to
correct size with keyways etc. and doweling including provisions of dowel pins or similar arrangement
for retaining the alignment shall be carried out by the Vendor with utmost care.
All joints shall be assembled without undue stresses. Flanges must be parallel and correctly aligned.
Wherever necessary remove the anti-corrosive coating applied on the machine/equipment by the
vendor, carefully and completely with light oil/ Equivalent.
On the chipped and prepared foundation surface, the vendor shall set up liners for installation and
maintain center of equipment. Liners shall be so arranged that the load of equipment is uniformly and
exactly distributed to the foundation. Liners shall be placed as near as possible to both sides of anchor
bolts. Where distance between anchor bolts is too long additional liner shall be set up in between. The
height of each liner shall be measured on the basis of standard level bench mark. The liners shall be
fixed with appropriate grouting material.
The vendor shall assemble, couple, fix, fit, install, level, align and grout the equipment/materials on
foundations, structures, platforms, floors etc., as the case may be. He shall bolt, weld, cut, drill, rivet
and brace all components and fix them rigidly with one another on the foundation supports, etc.
All necessary shims scaffolding, temporary supports, staging, grouting cement, sand, etc., required for
erection of the equipment shall be kept ready in advance.

9.1.4 Grouting (As applicable)


Grouting of Anchor bolts, holes, pockets and under base plates or under equipment’s have been
broadly classified into two categories e.g. non-shrinking grout and ordinary grout. Non-shrinking grout
shall consist of 1 part of ordinary Portland cement, 1 part of clean dry well grades sand and 1 part of
Ferro-grout of similar additive (approved by the Engineer-in-Charge). Water should be kept minimum
so that the mix can be applied adequately. The grouting material shall solidly fill the spaces to be
grouted and permanently retain its original volume so that the base plate will be held firmly in the set
position. The amount of water used in mixing shall be kept to a minimum such that the grout shall have
a consistency to stiff to flow. The top of foundation shall be clean and free of all laitance loose particles,
oil, grease, etc. and shall be wetted thoroughly leaving no puddles prior to grouting. All trapped pockets
in the steel structures shall be prepared using ordinary grout. Under no condition neat cement shall be
used for grouting.
All anchor bolts holes shall be completely filled with grout
The finished surface shall be floated smooth and shall slope away from base plate approximately 1:25
After the initial set is over, the grout shall be kept thoroughly wet for a minimum of 5 days
Care is to be taken during grouting so that the base plate level and alignment is not disturbed.
Over and above the grouting clearance shown in foundation drawings, grouting of pockets made by
base frame for machinery, equipment, steel structures etc. shall also be completely filled with grouting
as per direction of Engineer-in- charge.

9.2 Acceptance tests


After the entire erection/ installation work has been completed the vendor shall make necessary
preparations for carrying out site acceptance tests. The site acceptance tests shall be carried out in the
presence of Engineer-in-charge. The test shall be carried out as per the approved QAP and detailed
testing schedule. All tools, tackles, equipment and instruments required for erection, carrying out
acceptance tests and commissioning be arranged by the vendor. Vendor shall also be responsible for
clearing all debris during execution and after completion of work.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
34
GCR Oleo Chemicals Project

9.3 Pre-commissioning and commissioning


The vendor shall inspect equipment within its battery limit after erection, and arrange for pre-
commissioning checks, functional tests of instrumentation and control before trial runs of 72 hours and
commissioning.
On completion of erection and commissioning. The vendor shall arrange for the performance and
guarantee tests run of the package.
The first fill of lubricants and other required consumables for pre-commissioning / commissioning and
guaranteed test run shall be arranged by the vendor.
Also the first change of Lubricants, Filters, gaskets etc. shall be supplied by Vendor.

9.4 Handing over


The vendor shall run the package for 72 hours continuous trouble-free operation in all aspects in
presence of the Owner or the authorised representatives of the Owner before it is handed over to the
owner.
All Nut/Bolts shall be tightened in hot condition.

9.5 Training of owner’s personnel


The vendor has to impart the training to the concerned staff of the owner at the site which shall cover
minimum of following aspects.
Familiarisation with operational procedures and practices
Hands on experience on Operation of Equipment
Routine maintenance activities of the facilities
Knowledge of emergency and manual shut down systems
Immediate and effective isolation of any leak
Accounting of product
Safety regulations and accident prevention

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
35
GCR Oleo Chemicals Project

10 Performance, guarantee / warranty

10.1 Guaranteed parameters


Supplier to furnish the data against following guaranteed performance parameters

S.No Parameter Supplier’s guaranteed parameters


1 Thermal oil temperature 0 C (∆T)
2 Oil Heater Turn down ratio
3 Total Power consumption by/Unit Thermal oil
4 Flue gas outlet SPM/SOx ppm
5 Fuel firing system turn down ratio/Each fuel
6 Total Enthalpy delivered/Hr
7 Thermal Efficiency /Each fuel
8 Noise level 85 dBA @ 1 meter from enclosure
9 Specific fuel consumption/each
10 Pressure drop across the Furnace/Based on each fuel
11 Utility consumption (CA/IA/Power/CW/Nitrogen etc.)

10.2 Conditions of performance guarantee


Performance tests shall confirm to relative standard for testing without negative tolerance on capacity
and temperature
If the equipment / package supplied by the vendor fails to achieve the specified performance under the
given condition, the vendor shall carry out such modifications or replacement of the equipment/
package as necessary to meet the required performance at his own cost within the time as mutually
agreed upon.
The vendor shall guarantee the power consumption at rated point. The guaranteed power consumption
at the fan shaft shall be verified during site testing by measurement of power input to the electric drive
motor multiplied by motor test efficiency. The applicable tolerance on power consumption shall be +/-
1% with instrument tolerance.
The completion of stipulated tests and issue of test certificates shall not relieve the vendor of his
ultimate responsibility of guaranteeing the equipment/ material and its performance.
The vendor shall furnish unconditional guarantee for design, materials, manufacture, construction for
entire life of the package and for workmanship of the package for the 12 months from the date of
commissioning or 18 months from the date of supply whichever is earlier.
All the equipment/items shall be capable of performing the duties specified in this specification without
damage, distortion or failure of any component.
The vendor shall repair/replace any part of the equipment supplied by him at his own expense, in the
event of failure during the guarantee period.
In the event of non-fulfilment of performance guarantees, (up to end of the defect liability period of 12
months from the date of commissioning or 18 months from the date of supply) the vendor, at his own
cost, shall do modification, replacement and rectification to meet the guarantee requirement of the
purchase order. If within reasonable time limit (as agreed to by both the parties), the vendor fails to
make the required corrections in the equipment or its component, the Owner may at his discretion
reject the equipment and can ask the vendor to supply and install new equipment of proper design and
manufacturing to meet the performance guarantees, as per the Purchase Order.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
36
GCR Oleo Chemicals Project

11 Data required from vendor

Table 11.1: Operating and Design data


S.No Description Parameters
1 Thermal Oil Heater Units-Quantity required : 3 No
2 Thermal capacity : Normal: 3 x 14000KW
Minimum: *
Design: *
3 Thermal oil outlet temp : 300° C
Max. Delta T: 25 Deg.C
Min. Delta T: 10 Deg.C
4 Fuel Fired : IFO/MFO/NG
5 Gross calorific value of fuel :
- Natural Gas Approx.* Kcal/kg
- MFO * Kcal/Kg
- IFO * kcal/kg
6 Turn down ratio : <1:3 (Step less)
7 Thermal oil (Trade Name) : Therminol 66
8 Thermal oil circulation rate : 2 x 1050 M³/hr. at 300 ° C
9 Thermal efficiency (Direct/indirect) *
10 Oxygen in flue gas *
11 Total Enthalpy loss *
12 Stack loss *
13 Fuel consumption : *
- Natural Gas in nm3/hr
- MFO in kg/hr
- IFO kg/hr
14 Heating surface in m2 : *
B Equipment Data
1 Type of Thermal Oil Heater : *
2 Construction (Horizontal /Vertical) : *
3 Design Temperature & Pressure : */*
4 Turn down ratio (Step less) : *
5 MOC - Main Shell /Coil/cladding : */*
6 Refractory Type & Make : */*
7 Pre heater / Waste Heat recovery boiler *
8 Fuel Firing System : *
9 Energy balance :
- Total heat, Kcal/hr. : *
- Heat transferred to Thermal oil, Kcal/hr. : *
- Heat loss (with flue gases), Kcal/hr. : *
- Heat loss (Radiation, convection), Kcal/hr. : *
10 MOC
- Heater Coil : *
- Main Shell : *
- Insulation and cladding : *
- Combustion air fan : *
312700/INC/NWI/RSD-509/B 3rd December 2013
C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
37
GCR Oleo Chemicals Project

S.No Description Parameters


- Chimney : *
- Flue gas ducting & dampers : *
- Refractory & Make : */*
- Fuel Handling System : *
11 Utility Requirement
- Total Electrical load –Connected /Absorbed, kw : */*
- Instrument air, NM³/hr : *
- Any other : *
- Chimney -
- Type : *
- Dia , Height & Thk. (mm) : * / * /*
- Shell course thicknesses : *
12 Thermal efficiency : *
- Natural Gas firing in %
- Industrial Fuel Oil firing in %
- Marine Fuel Oil firing in %
13 Furnace pressure drop in kg/cm2(g) : *
- Natural Gas firing
- Industrial Fuel oil firing
- Marine Fuel Oil firing
14 Combustion air consumption in nm3/hr : *
15 Insulation thickness : *
16 Associated equipment’s , as per spec. : *
17 Scope of supply complete as per the technical : *
specification
18 Overall dimension (Main Unit) Lx B x H, Mtrs. : *
19 Erection weight in kg : *
20 Operating weight in kg : *
21 Recommended space requirement : *
22 Schedule of deviations : *

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
38
GCR Oleo Chemicals Project

12 Non-material requirements (drawings


and documents)
Bidders are advised to note that the bids will be considered incomplete if the documents requested for
bid stage are not submitted along with the bid.
All engineering and relevant documents shall be furnished in Hard as well as Soft copies like:
– All drawings like lay outs, views, flow diagram, etc.(Isometrics of all Piping drawings shall be
furnished)
– GA and detailed drawing of each mechanical equipment.
– All drawings for civil construction.
– Data book in 6 copies (hard and soft copies)
Documents as follows:
– Process Flow Diagrams including Process Description
– Mass and Heat balance
– Piping and Instrumentation Diagram
– Fabrication Schedule
– Foundation Plan
– Technical specifications for Instruments
– Electrical and Instrument Diagram
– Control Logic, Interlock and Sequence Diagram
– Assembly Diagram with Part List
– Maintenance Manual including Maintenance schedule
– Operation Manual
– Testing and commissioning Protocol

Unless specified, 6 copies each of following documents shall be submitted at the stages defined,
except for the bid stage, wherein 2 copies are required.
The bidder would need to specify the timeline when the documents requiring approval would be
submitted in the PERT chart. Bidder also to include timeline for resubmission of final drawings
incorporating all comments.
The contractor to note that any routing of services and axillaries falling in The contractor’s scope of
supply, outside the skid boundary and interfacing with the client facilities, such as cable routing, piping,
etc would need to be first proposed in a general arrangement drawing for client’s approval

Table 12.1:

Description Drawing / Document required stage


With Bid After award of Final/As-Built
work
1 A specific statement that the offered package is in strict Yes - -
accordance with data sheet, technical specifications and
applicable standards. In, case of any deviation, specific list
with details and reasons for each deviation.
2 Catalogue details for individual bid items Yes - Yes
3 Utility and their consumption requirement at battery limit Yes Yes Yes
4 Itemised electrical load data Yes Yes Yes
5 Itemised equipment list, listing all the sub-assemblies, - - Yes
capacities, rating and MOC
7 Direct drive, Gearbox, V-belt , pulley with selection chart - - Yes
and calculation
8 Process design calculations of Cold oil blending system in - Yes Yes
Thermal oil

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
39
GCR Oleo Chemicals Project

Description Drawing / Document required stage


9 Thermal and mechanical design calculation - yes Yes
10 Structural loading details with dynamic and static load - Yes Yes
cases.
11 Thermal oil Unit G.A. Drawing indicating overall dimension, Yes Yes -
terminal points and utility requirement in AutoCAD format
A Typical P&ID of the system and other related items Yes Yes Yes
B Process design calculations for Thermal oil heater and - Yes -
Heat recovery system
C Panel G.A. & Wiring Diagram - Yes Yes
D Mounting details - Yes Yes
E Foundation plan for all the items requiring civil foundation - Yes Yes
F Power, Earthing & Lightening protection layout - Yes Yes
G Layout Plan and Elevation drawing in AutoCAD - Yes Yes
H Operation & Control philosophy with Schedule of Interlock - Yes Yes
I Instrument control datasheets - Yes Yes
J Piping specification & Pipe sizing calculations - Yes Yes
K MOC selection - Yes Yes
12 List of Spares Yes Yes Yes
13 Itemized price list of mandatory spares for 2 years of Yes - Yes
operations
14 Overall as well individual assembly quality assurance plan Yes Yes
With Bid After award of Final/As-Built
work
15 Drawing for testing arrangement and test procedure to be Yes - Yes
adopted
16 Test records of following:
A Non-destructive testing - - Yes
B Material composition and physical properties - - Yes
C Mechanical running - - Yes
D Performance test - - Yes
E Material test certificate - -
F Warranty certificate for the Bought-out - -
17 Lubrication schedule along with a statement on oil - - Yes
consumption and minimum allowable oil temp
18 O & M manual - - Yes
19 Control System/Panel Inspection by client - Yes -

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
40
GCR Oleo Chemicals Project

13 Spare requirements
The Vendor shall include a list of recommended spare parts for following
– Commissioning start up and initial operation
– Normal operations
– Two years trouble free operations
This list shall state the price of all spare parts.
The lists shall be available in advance of shipment in such a time to enable Company to commit for the
required spares in time for being available at site before start-up of the unit. Vendor shall allow 2-month
processing of the list.
The spares procured in the scope of supply shall be as indicated on the data requisition sheet(s).

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
41
GCR Oleo Chemicals Project

14 Recommended makes of bought out


items
Table 14.1: Recommended makes of bought out items
S.No Item Approved Make
1 Electric motor Siemens / ABB / TECO
2 Power and Control cables Jembo / Voksel / Sumitomo
3 VFD / Soft Starter ABB /Siemens / Schinder / Telemechaniq
4 Fuse switch Unit Vendor to get approval from Client
5 LV Switchgear ABB /Siemens / Schinder / Telemechaniq
6 HRC Fuses ABB /Siemens / Schinder / Telemechaniq
7 Contactor/O/L relays ABB /Siemens / Schinder / Telemechaniq
8 PBS & Indicating Lamps Vendor to get approval from Client
9 MCC Components as per specs mentioned above
10 Gaskets (Graphite only) Champion / Uniklinger
12 Discharge gas filter Swagelog / Parker / Shavo / Fisher
13 Gas Filter Regulator ABB / Placka / Shavo / V Automat / Fisher
14 Field Transmitter (Pressure, Diff. Emerson / Yokogawa / E & H
Pressure Temperature, Flow,
Level
15 Mass Flow Meters E & H / Emerson
16 Pressure Gauges Ashcroft/GIC/ Wika
17 Pressure Switch Ind-Foss/Denfoss /Switzer
18 Safety Valve Tyco sanmar /Fainger Lesser
19 Self-Actuated Pressure Control Fisher / Dresser / Tyco Sanmar
Valve
20 Solenoid Valves Asco / Parker/ Rotex
21 Control Valve Fisher / Dresser/IL
22 Temp.Element/Indicator Altop/GIC/Wika
23 PLC Mitsubishi/Siemens / Allen Bradley
24 Piston Valves/Bellow seal valves Klinger/SpirexSarco/Tyco
25 Pumps Durco / Gould / Allweiler
26 Mechanical seals Burghman / John Crane / Duramettalic
27 Ball valves Valtalco / keystone/Valtek
28 Globe valve klaus Union /Phonix
29 Butterfly valves Keystone/kitz/Tomoe
30 High Pressure Valves Phonix/Klaus Union/Velan/OMB/Klinger

NOTE: Vendor to obtain prior approval of MM/Client for any other sub-vendors not listed above before
placement of orders on sub-vendors.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
42
GCR Oleo Chemicals Project

Appendix A. Enclosures
Annexure A: Perman LH no. 07 Tahun 2007.
312700-PFC-0010-01.

312700/INC/NWI/RSD-509/B 3rd December 2013


C:\Users\PAT33902\Desktop\Specs_for_NG_-MFO_Fired_Thermal_Oil_Heater.docx
43