ANNEX 16: Oxy-Fuel Control Equipment Specification

Date: 11 Aug 2016

Revision: E-Rev

This preliminary specification is intended for vendor technical qualification for

procurement of an Oxy-Fuel process system under EU Grant LIFE15 CCM-NL-
000121. It contains the necessary information to assess the scope. A final
specification will be prepared later to allow submitting a detailed quote. The Oxy-Fuel
process equipment will be installed at a glass plant in The Netherlands east of
Rotterdam.

The bidder is requested to quote the following scope and services in compliance with
European standards.

1. Description of Scope
The oxy-fuel process equipment is used to measure and control the flow of Natural
Gas and Oxygen to several use points in an oxy-fuel combuistion process on a glass
furnace. The system includes switching valves that direct the flows to alternating
injection points on the furnace.

1.1. Oxy-Fuel Process Equipment

1. Oxygen and natural gas control skid(s) for operation of OPTIMELT system
a. Connection of all equipment in the BOM to an electrical cabinet
which will be prepared and supplied. Where possible this cabinet
should be pre-mounted and pre-wired. Electrical drawing will be
supplied.
2. Set of operating manuals and purchased equipment documentation for scope
3. Commissioning and startup assistance, optimization
4. Detail mechanical design drawings for the components
5. Detail electrical design drawings for scope
6. Fabrication of system
7. Factory checkout
8. Shipping to customer site
9. Detailed installation drawings, Electrical and Mechanical Installation at
customer site,
10. 1 week commissioning and startup assistance (provide excess pricing)

1.2. Information that is part of this Specification

• Process and Instrumentation Diagram (P&ID) outlining tags of measurement
equipment and limit switches
 • Bill of Material (BOM). Vendor is requested to source these parts in the
European Union according to local codes and indicate exceptions taken to
providing this service

1.3. Codes and Standards

All equipment must comply with CEE directives and local country codes of The
Netherlands. Specifically, the following directives apply. The subcontractor must
guarantee the conformance to all mentioned standards for the equipment build.

• Pressure Equipment Directive (PED) 1997/23 CE

• EN 746-2 concerning combustion equipment
• Low voltage directive 2006/95/CEE for low voltage panels and control panels
• Machine directive 2006/42/CE for HMI and safety
• Electromagnetic emissions and protections 2004/108/CEE
• European standard EN 15001-1 for gas piping.
• EIGA-standard 13/12/E for oxygen pipe line & piping systems.
• EIGA-standard 33/6/E for cleaning of equipment for oxygen service.
• Machine directive (2006/42/EG)
• NEN-EN 13480 Metalen industriele leidingsystemen

Additional standards are:

• NEN-EN-IEC 60204 - Electrical safety for machines.

• NEN-EN-ISO 3834 – Quality requirements for welding - Kwaliteits eisen van
smeltlassen van metalen
• EN ISO 15614-1 Welding procedures
• EN ISO 9606-1 Welder Certification

See attachment: Annex05- Detailed legislations for P&ID.V3

2. Specification Details

Any changes to the P&ID, BOM or use of “non-standard” fabrication practices shall
be communicated to and accepted by buyer and the fabricator via an “engineering
change request” prior to implementation.

2.1. General Requirements

2.1.1. Vendor shall submit detail fabrication design description, drawings,
inspection scope, and list of documents provided for approval prior to
start of fabrication. Vendor shall submit a general arrangement drawing
with their quotation for review. Special attention shall be given to the
orientation of flanges as well as locations and directions of all flanges,
measurement equipment and connecting piping to ensure accessibility
and ease of maintenance.
 2.1.2. Vendor shall submit welding procedures and welder certifications for
buyer’s review and approval.
2.1.3. All components shall be oriented so that they are easy to read and
manual components are easy to access.
2.1.4. All jagged welds and sharp edges are to be ground smooth to prevent
injury.
2.1.5. All bolting, mating flanges, and gaskets for all inlet and outlet process
piping to be supplied unless stated otherwise
2.1.6. All equipment must pass following tests (with certification). Vendor will
repair welds or joints that require rework due to leaks and or improper
quality at no cost to buyer.
− Leak test (according to PED and buyer agreement)
− Pressure test (according to PED and buyer agreement)
− Dry functional test (if applicable)
− Flow test (according to buyer agreement after installation)
2.1.7. CE documents will be by others, tag plate shall be supplied by vendor
2.1.8. The skid shall be tarped for shipment. Flanges shall be capped or
plugged with a fabricated cover, or plastic cap, to prevent damage and
contamination.
2.1.9. All enclosures rated less than NEMA 12 shall be shrink-wrapped prior
to shipping or transport.

2.2. General Frame/Support Steel Fabrication

2.2.1. Vendor is responsible for designing the system pipe supports and the
skid frame. Vendor shall submit design for for approval prior to start of
fabrication. The equipment center of gravity and lifting points shall be
shown on Vendor’s drawings.
2.2.2. Four lifting lugs on the corners are to be included capable to support
the lifting weight of the skid. U-shaped plates or similar must be
included an the base of the skid to allow easy lifting by forklift
2.2.3. Supporting frame members must be made of square profile 40x40 mm,
or larger if required by load analysis. Any frame components or
supports shall be of welded construction throughout with continuous
welds up to 6.3mm on both sides. All frame welds must be cleaned and
brushed (no sharp edges).
2.2.4. All frame components attached to the ground shall have square plates
(min 100 x 100 mm) with four holes of 12 mm diameter to fix the
components to the floor.
2.2.5. Weld spatter is not permitted anywhere on the frame and must be
ground off prior to painting. All frame welds must be cleaned,
passivated and brushed (no sharp edges).
 2.2.6. The frame must include the local electrical panel . Vendor must submit
the chosen location of the panel and the support structure of the panel
for approval prior to fabrication.

2.3. Natural Gas Piping Requirements

2.3.1. Welding procedures in accordance with EN ISO 15614-1 and approval
of welders according to EN ISO 9606-1.
2.3.2. Weld spatter on piping (internal or external) is unacceptable.
2.3.3. For the natural gas piping union type connections or threaded
connections are preferable for DN50 or below. Above this diameter
flanged DIN connections must be used, if not otherwise specified on the
drawings, or specifications for supply.
2.3.4. Carbon steel piping sections for natural gas shall be painted yellow per
Libbey Standard TOALG01 after welding and prior to assembly. Final
touch-up of the paint is to be completed after site installation and
checkout.
2.3.5. All piping is to be PN16, single butt weld construction unless otherwise
noted. Below DN15 or ½” tubing is preferred.
2.3.6. Flange bolting shall adapted to the flange rating and having a minimum
of 3 free treads.
2.3.7. Support of all piping/tubing up to 3” or DN 80 shall be designed with
“Stauf” supports or equal brands
2.3.8. All pipe clamps above 3” or DN 80 are to be of a “heavy-duty” style.
Where pipe expansion is required the supports shall be designed to
allow movement.
2.3.9. Thread-o-lets and weld-o-lets are not to protrude into piping obstructing
the flow of the gas.
2.3.10. All piping/tubing shall be tagged with arrows indicating the flow direction
as well as the fluid on both inlet and outlet.

2.4. Oxygen Piping Requirements

2.4.1. All piping/tubing for oxygen use must be cleaned for oxygen use and
cleaning must to be certified
2.4.2. Cleaning procedures needs to be in accordance of EIGA-standard
33/6/E
2.4.3. All precleaned items needs to be bagged and stored in a dry, dust free
area
2.4.4. After using cleaning agents, purging of the cleaned items will be done
by water followed by nitrogen flow (depending on the type of cleaning
agent).
2.4.5. Weld spatter on piping (internal or external) is unacceptable.
2.4.6. For the natural gas piping union type connections or threaded
connections are preferable for DN50 or below. Above this diameter
 flanged DIN connections must be used, if not otherwise specified on the
drawings, or specifications for supply.
2.4.7. All piping is to be PN16, single butt weld construction unless otherwise
noted. Below DN15 or ½” tubing is preferred.
2.4.8. Flange bolting shall adapted to the flange rating and having a minimum
of 3 free treads.
2.4.9. Support of all piping/tubing up to 3” or DN 80 shall be designed with
“Stauf” supports or equal brands
2.4.10. All pipe clamps above 3” or DN 80 are to be of a “heavy-duty” style.
Where pipe expansion is required the supports shall be designed to
allow movement.
2.4.11. Square T’s and short radius elbows are not to be used in oxygen piping.
2.4.12. Thread-o-lets and weld-o-lets are not to protrude into piping obstructing
the flow of the gas.
2.4.13. All piping/tubing shall be tagged with arrows indicating the flow direction
as well as the fluid on both inlet and outlet.

2.5. Instrument Air Piping Requirements

2.5.1. Below DN15 or ½” stainless tubing is preferred.
2.5.2. Flange bolting shall be adapted to the flange rating and have a
minimum of 3 free treads.
2.5.3. Support of all piping/tubing up to 3” or DN 80 shall be designed with
“Stauf” supports or equal brands
2.5.4. Any instrument air header shall be fabricated using 304 or 316 stainless
steel to prevent rust. The instrument air tubing shall be fabricated with
316SS or 304SS. All fittings, unions, reducers, ect. for instrument air
are to be stainless steel.
2.5.5. The finished instrument air system shall be adequately blown out with
clean air and appropriately cleaned prior to installation of the actuators.
2.5.6. All welds of stainless steel piping are to be wire brushed to
remove/reduce weld heat markings.
2.5.7. Thread-o-lets and weld-o-lets are not to protrude into piping obstructing
the flow of the gas.
2.5.8. When Teflon tape is applied, care shall be taken that no free Teflon will
go into the instrument or the piping. When using liquid sealing material
such as “Loctite” approval shall be given by buyer before the start of
fabrication.
2.5.9. All piping/tubing shall be tagged with arrows indicating the flow direction
as well as the fluid on both in– and outlet
2.5.10. Final placement and routing of instrument air is to be determined during
assembly/installation to minimize interference with other skid
components.

2.6. Electrical Requirements/Panels:

 2.6.1. All electrical requirements are specified in the separate Libbey general
specifications for the engineering of electrical control systems and the
use of components for electric installations “General specifications and
conditions v1.0.6”.
2.6.2. Libbey will place a fully equipped remote I/O cabinet with sufficient
connections in the vicinity of the equipment. Vendor shall supply all
components (sensors, valves) as described in the B.O.M. and
mechanically connect them to the equipment. Vendor shall wire the
electrical components to the Libbey remote I/O cabinet and connect
them according to the Libbey electrical scheme. Connections, wiring,
cable glands and so on shall be done as described in the general
specification mentioned under 2.7.1. Where applicable the electrical
cabinet has to be pre-mounted and pre-wired on the skid at vendors
shop.

3. Documentation
The following documents must been supplied with the equipment/skid at the time of
the FAT. The language of the documents shall be the original language of destination
of the skid and will be confirmed by the buyer.

3.1.1. Technical documentation of each skid component.

3.1.2. Technical documentation of each major electrical cabinet component
3.1.3. List of materials (format to be detailed by buyer), this list will be used to
order parts in the future when necessary and hence must contain all
necessary information of the installed parts such as exact ordering
codes, connections, descriptions, suppliers info, materials, instrument
ranges etc.)
3.1.4. Calibration reports of components (when applicable)
3.1.5. O2 cleaning reports (For components and piping)
3.1.6. General cleaning reports, all inspection reports, material certifications
3.1.7. Pressure testing reports (according to PED when applicable)
3.1.8. As build electrical drawings
3.1.9. Mechanical lay out drawings (3-D, inventor or Solid works)
3.1.10. As build P&ID’s
3.1.11. CE TAG plate
3.1.12. Copy of CE approval file

During the factory acceptance test a punch list will be issued by the buyer, material
will only be released for transport if punch list items have been addressed.