Technical Specification

for
Supply, Fabrication and installation of VSD
Type Screw Air Compressor
 Technical Specification:

1 Introduction
Typical Scope includes: “Fabrication & Installation of Screw Air Compressor system for Process Plant. A fully
packaged compact variable speed drive (VSD), single stage, oil injected rotary screw air compressor
system is required at BARC for supply of compressed air for different instrumentation/valve applications.
Here, this compressor system means, it should include all components that are needed to suck air from
ambient up to the terminal point where compressed pure air (oil, moisture and dusts are removed as per
specifications of this document) is delivered, which can be taken by pipe line to different
applicationsthrough buffer tank. This compressor system should be designed for easy to install, simple to
operate and should deliver rated compressor performance. The enclosure should be designed to manage the
environment of the internal components and the cooling ventilation system with suitable fan, at the same
time it should, significantly, reduce the sound level emitted from the machine into the installation
environment. The complete package should be designed to be located on an adequate flat floor without any
special foundations and fixtures on the ground. The fully packaged compressor unit should have sufficient
leak proof components/elements to avoid air and oil leakage. The compressor should have high reliability
for uninterrupted operation for at least 6 months. It should have sufficient instruments & sensors for
monitoring and fault diagnosis and appropriate controls with interlocks for safe operations. This air
compressor system will be used for instrumentation air purpose. For pneumatic control of valves,
instrumentation air is required to have compressed air at 7.5 bar (gauge) pressure and 25 -45degrees
Celsius temperature with flow rate 55 to 300 CFM(cubic feet per minute) at 7.5bar(g)as nominal
requirement. At the outlet of the compressor system, delivered compressed air should be pure and
lubricating oil content in this compressed air should be less than 0.001 PPM (parts per million) by volume.
Detailed requirements and specifications are given below.

2. Main Design Data

Main data required for supply of oil injected air screw compressor system. Only screw type compressor
will be considered as this can provide high flow rate at the pressure required here.
Sr. No. Description of Parameter Requirement
1. No. of compressor systems required :One number

2. Compressor Type : Oil injected/oil flooded screw type

3. Cooling type for cooling of oil and Air cooled (compact coolers must be sized for the load
air corresponding to higher torque load of motor shaft which is
also equal to the minimum required motor capacity)

4. Nominal discharge Pressure of air 7.5 bar(g) or higher

required at the end (or terminal
point) of compressor system

5. Single Stage or Double Stage Single stage coupled to internal magnetic motor of oil cooled
compression bearing.

6. Lubricating oil content in air at the ≤ 0.001 PPM By volume (Activated carbon bed may be used
end of compressor system with oil to achieve this. If this is used, a filter should be used at the
removal system. downstream of it to filtrate 10 micron or bigger size carbon
particles coming from this bed). Suitable oil removal system
shall be included.
7. Moisture content in terms of PDP ≤ PDP (pressure dew point) 5 0C.The inbuilt air dryer heat
in terminal point (end of exchanger system shall be included along with filter.
compressor system) discharge air. Automatic condensate /moisture drain valve system also be
included.

8. Air volume flow control or Part Variable Speed Drive / VFD (variable frequency Drive) (it
Load Control method should be able to vary flow at least down to 30% and on
higher side up to 100% of nominal flow rate).

9. Volume Flow rate in cfm (cubic 55 to 300 CFMand as per standard capacity of supplier
feet per minute) at suction
condition (atmospheric pressure
and temperature)

10. Shaft torque /power:Motor of 20 % more than standard requirement for the 100 % nominal
having suitable internal permanent compressed air delivery.SelectedMotor Kw/HP with
magnets preferred. specification shall be given with proposal.

11. Air Temperature at the Outlet of < ambient (Mumbai, atmospheric temperature should be taken
whole compressor unit at any time into account for designing the air coolers) which varies from
in the year 20 0 C to 420 C in Mumbai.

12. Type of delivery pipe end Bolted SS (stainless steel) flange type. Standard flanged end
connection to the application at the pipe with holes for bolting and counter mating flange should
outlet of whole unit be provided by the supplier.

14. Air receiver tank
A Single vertical tank of 1000 litreswith following specs
should be supplied connecting two airdischarge of
twocompressor system (one is existing at site) along with
valving for isolation.
Design pressure-12.75 bar (g), working pressur-7.5 bar (g),
maximum tank height-2.5.m ,
Tank construction material: SS304L.
Pressure gauge and pressure relief valve with burst disc along
with burst pressure indicator should be provided. leak
tightness at any location: As per ASME design code/standard

15. Design, fabrication and tests ASME VIII Div-I standard. Design, fabrication and tests
code/standard document along with test record shall be submitted if order is
placed.

17. Noise level < 70db at a distance of 1 meter from the unit.
16. Instrumentation & control Necessary instrumentation and controls for all variable
parameter should have local display with control cabinet.
Three (potential free contacts for remote indication “PLC” for
machine status) shall be provided record parameters in main
control room of plant should give a list of instrumentations
and controls, with make, specifications included in the
supply. This should be also uploaded with quotations for
technical evaluations. Advance microprocessor based controls
will be preferred.
17. Safety and alarm system Necessary safety equipment and alarm provisions shall be
provided. Its list should be given by the supplier along with
quotations/proposals for technical evaluation.

18. Foundation requirement
To support the buffer tank on the concrete floor it should have
provision of fixing with anchor-fastener. It should not require
special concrete flooring. Supplier must upload the weight
and dimensions of components/systems along with proposal
for technical evaluation. The available space in which two
compressors is to be installed is width: 1.5 m, length:2 M &
Height: 1.9 M.

19. Flow meter for acceptance test Supplier should provide calibrated flow meter in addition
with standard package to measure air volumetric or mass flow
rate during acceptance test. This should be included as part of
the supply and be integrated in piping by supplier.

20. Power supply available 415 V ± 10%, 50 Hz ± 5% , 3 phase, 5 wire (without back up)
for heavy loads and b) 230 V ± 1%, 50 Hz ± 1Hz , single
phase, 3 wire.

21. Electrical Motor Electrical condition: 400/50/3/

Type of motor: Interior permanent Magnet motor,
Type of motor cooling: oil cooled.
IP protection: IP 66.
Motor Efficiency: IE 4 (96.8%).
Oil lubricated motor bearing hence no greasing needed.
Cable size: 25 sq. mm. copper cables.
Main fuse: 100 amps.

3 Scope of work, supply material & fabrication.

3.1 Scope of Work:
The offer must include the following works:
1. Fabrication and assembly of components of compressor unit with all accessories & Piping work.
2. Appropriate quality assurance and quality control, inspection and tests.
3. Pre-dispatch inspection tests at factory site.
4. Installation, interconnection of piping if any, acceptance tests and commissioning at site.
5. Documentations related to quality controls and quality assurance and tests done at vendor’s site and tests
and commissioning done at site.
6. Documentations related to design, drawing, codes and standards used for different components,
instrumentations, control units.
7. Documentations and drawings required for trouble shooting during operation, maintenance and repair. A
separate preventive/ breakdown maintenance manual shall also be supplied.
3.2 Scope of Material Supply & Fabrication:
The offer must include the following components/elements to supply & fabrication.
1. One Compressor unit with electrical motor and VFD for variable speed of coupled motor.
2. An air receiver tank with all accessories.
3. Oil removal system which includes bulk oil separator, oil cooler, filters and coalescers.
4. Enclosure with support frame for compressor system’s main components to reduce noise level outside of
it and to safeguard from atmospheric dust and other harmful elements.
5. Electric Control cabinet along with compressor - motor unit / Combined unit cabinet
6. Instrumentation and Control System which should include sufficient valves, instruments and safety
equipment, graphical depiction of P & ID, air flow meter and operators window console.
7. Electrical armoured copper cable FRLS, XLPE 3.5 core, 25 sq. mm.
8. Documentations related to quality controls and quality assurance and tests done at vendor’s site and tests
and commissioning done at site.
9. Documentations related to design, drawing, codes and standards used for different components,
instrumentations and control units.
10. Documentations and drawings required for trouble-shooting during operation, maintenance and repair.
A separate preventive/ breakdown maintenance manual shall also be supplied.

Free Issue material: No Free issue materials.

4. Documents for Approvalbefore Manufacturing

Following documents must be provided by the supplier for approval by (user/ Indenter) before
manufacturing of compressor system including air receiver tank.
1. GA (General Arrangement) drawing, P&ID (Process instrumentation drawing) and ES (Electric
schematic) drawing with relevant specification for compressor system except air receiver tank.
2. GA and volume calculations for air receiver tank.
3. QA (quality assurance) and QP (quality plan) documents.

5. Tests, Commissioning, Acceptance and spare parts

5.1 Factory Acceptance Tests (FAT)
FAT should include following tests and inspections at Vendor’s factory before dispatch to (user/ indenter)
under the witness of (user/ indenter) and/or (user/ indenter) representatives. These will be considered as
pre=dispatch inspection.
1. A final hydro & pneumatic pressure test shall be carried out at the factory site for air receiver tank as per
design code.
2. Leak test of air receiver tank as per design code.
3. Operation and checking of health of all parts.
4. Measurement of pressure, temperature and volume flow rate of compressed air near final delivery point
(or terminal point) of the whole system.
5. Measurement of oil content in compressed air near final delivery (or terminal point) of whole system. If
supplier can’t do, it should get it done by a third party under the witness of purchaser’s representative. Or,
supplier should give relevant design data for verification and approval before manufacturing.
6. Measurement of vibration/noise level at full load.
7. Measurement of power consumption at different part load operations (30%, 60% and 100% of full load)
8. Checking of all design, drawing and fabrication documentations.
9. Checking of all inspection and test reports.
10.Test report of pressure relief valve with burst disc on receiver tank.
10. All results should conform to that specified by the supplier within +/- 10 % deviation.
11. Vendor should intimate at least 15 days in advance about the dates of above mentioned FAT

5.2 Installation, Commissioning and site acceptance tests (SAT) at site

Installation and interconnecting piping work, if any will be done by the supplier at site, Mumbai. All
required tools and equipment for this purpose is in the scope of supplier. All performance tests and
commissioning runs for acceptance must be carried out by the personnel and under the responsibility of the
supplier. The detailed test procedure will be defined jointly by the customer and the supplier.
During commissioning, following tasks will be performed:
1. Test of all the sequential procedures for starting the compressor unit, nominal operations for at least 1
day continuously and shut down of the compressor unit.

2. Measurement of pressure, temperature and volume flow rate of compressed air near final delivery point
(or terminal point) of the whole system

3. Power consumption at full load and part load.

4. Local oil leaks will be checked visually. There should not be any visible oil leakage.

5. All results should conform to that specified by the supplier within +/- 10 % deviation.

6. On successful completion of site performance tests and reception of all specified documents, the
purchaser will issue a certificate of acceptance.

7. Receiver installation on flooring with anchor fastening.

8. Piping fabrication from receiver outlet to our external existing dryer inlet, length of piping is 10mtr.
(8000mm), size of pipes 2.5” (63.5mm).
9. Fittings Bend 4 nos., “T” Joint 1 no., Ball Valves 4 nos., size 2.5” (63mm)
10. Piping fabrications for air compressor from machine outlet (size25mm NB) by using necessarily filter
drier and pipe fittings up to receiver inlet connections.
11. All piping Fabrication by using SS304material.

12. Electrical armoured copper cable FRLS, XLPE 3.5 core, 25 sq. mm. Laying & fitting between machine &
MCC panel.

13. Requirement of civil work, if any for the erection of the unit, to be mentioned in the quotation.

5.3 Terms & condition for Fabrication, Supply and Installation:

1. After supply of all the material in BARC Central Stores, vendor shall be asked to carry out installation
work. After receipt of suitable Work Permit, party shall start work at site as per instruction of Site
Engineer.
2. Vendor should take all safety precaution of their employee while execution of the job.
3. Vendor shall follow the safety rules & regulations while executing the job.
4. Vendor shall regularly carry out housekeeping of the working area.
6. Sales after Service
After selling their equipments, over the guarantee period for services authorized service centre
must be available within the Mumbai with suitable service engineers & technicians and also
required spares from OEM.

7. Other Requirements:
Safety feature should be incorporated for safety of operator and the machine.
Anti Vibration Mountings should be provided on the compressor frame for vibration isolation
from Screw element, Motor and Oil Separator Tank.

8. Documents and Drawings:

The Bidder shall deliver to the Purchaser a detailed time schedule covering the various phases
involved. The bidder shall submit three copies (3) of assembly and individual part drawings along
with a soft copy in CD. Four sets of Design, Operation and Maintenance Manuals documents along
with a soft copy in CD are to be supplied along with the unit, without any additional charges.
Detailed electrical circuit should also be supplied along with the air compressor.

9.Criteria for Vendor Selection:

i. Vendor should have an experience of minimum 5 years in the field of fabrication & installation of
system as per code / standard.........
ii. Vendor should have qualified and experienced workmen like welder, fitter, rigger etc. for
fabrication and installation work.

10.Submission of Offer:
1. Vendor should submit their offer on or before the tender due date. Before submission of offer,
vendor can do site visit. Incomplete / Partial offers will not be considered for evaluation of the
offer.
For site visit contact person: Name: K. P. Paradkar , HWD, Engg. Hall-8, Room No. F-3, Trombay,
BARC, Mumbai – 4000085, Off. Ph.: 25596428, Email: kpparad@barc.gov.in
2. Vendors have to submit the following documents along with their offer:
i) Necessary Material Test Certificates and.
ii) Work experience certificates regarding the fabrication.

11.General Requirements:
1. The Vendor to whom this contract will be awarded will have to carry out certain formalities with BARC
Security department for the entry of their manpower inside the company premises. Contractor shall make
sure that each person being deployed for execution of the job at site should possess a valid PVC (Police
Verification Certificate) issued by Mumbai Police; Subsequently necessary photo passes will be issued to the
vendor’s personals by security department till the period of execution of the job.
2. The contractor has to sign “Industrial Safety Undertaking” before starting the job at BARC premises.
3. Vendor will be liable to compensate the workmen, in case of any accidents or injury at work site.

12. Delivery & Completion Period:

PO / WO shall be placed on party for supply of material & execution of job as defined in scope of work. The
entire scope of work as stipulated in the tender document shall be completed in 90 working days from the
date of acceptance letter of WO.
13. Safety & Cleanliness:
I. Contractor shall insist the concerned departmental officer to take "Safely Work Permit (SWP)" (if applicable)
during work inside BARC campus and shall follow all recommendations specified in that SWP
ii. Contractor shall bring all "Personal Protecting Equipment (PPE)" (viz.,safety shoes,
safety belt, hand gloves etc.) required for the work (insideBARC campus) under the scope of WO / PO.
iii. Contractor shall follow safe work procedure approved by the department.
iv. During the work, contractor shall maintain general cleanliness of the workplace on daily basis.
v. Contractor will be responsible to remove debris, scrap materials, (if
any)generated during the work, on regular (daily / weekly etc., as appropriate) basis from the work place to
the place designated by the department.
vi. On completion of the work, Contractor shall take a cleanliness certificate from the concerned BARC
Swachhta Monitoring Officer (BSMO).

14. Annexure –III Technical Data Sheet:

All technical and quantitative information regarding the system / work shall be provided.
Technical data: Those all fabricated piping installation at our new ms angle supports with arc welding or
clamping fasteners.

Technical Specification
Type Air Cooled
Compressor VSD
Capacity Screw Type
Pressure rating 55-300CFM
Drive Type Direct
Required Pressure 7.5 KG/CM ²(g) Pressure can be adjusted 4 -7 bar
Control Panel Microprocessor based / GRAPHICS monitoring system
Electrical Motor 37KW (50HP) Permanent Magnet Electric Motor Variable speed
drive along with Variable speed Starter (i. e. starting amps never
reaches to full load current at starting….starting torque)
Sound Level 69dB (A) +/- 3dB (A)
Air Filters Supply & Installation of HIGH EFFICIENCY coalescing filter,
40% less pressure drop then tandem filters. For Dust, Foreign
particles Removal, Nautilus design Coalescing Filter (Fibers Glass
Filter) UD 140+ suitable for above flow and remove Liquid water,
dust particles up to 0.001 Micron and aerosol to 0.0009mg/m3,
(0.001ppm)
Air Dryer Refrigerated type Air Dryer CFC free R410A
Quantity 1nos.
Air Receiver Tank AIR RECIVER of capacity 1M3 as per ASME STD and standard
fittings like pressure gauge, Make: Wika or equivalent with test
calibration certificate, size: 1/2’’ NPT threaded, siphon pipe SS304
with cock & coupling size:1/2’’NPT or 1”NPT threaded , safety
valve with test calibration certificate and auto drain valve. (For 10
kg/cm2)
Electronic Drain Valve Capacity 1M3 at 9kg/cm²
Drain Valves Auto Operated
Overall Size, Foundation 1mtr.(L) x 1 mtr.(W) x 100mm(H)