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ENGINEERING & PROJECTS

TECHNICAL SPECIFICATION

FOR

BOP SUPPLY AND ERECTION OF COKE OVEN GAS FLARE

SYSTEM

Document No: ENG-C/0351-CO12-U-TES-002, REV.: 0

Revision Date Description

Approvals

Prepared by

Checked by

Approved by

0 19-10-2015 Issued SKH AG SBS


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TECHNICAL SPECIFICATION FOR BOPSUPPLY AND ERECTION OF COKEOVEN GAS FLAREING SYSTEM

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C O N T E N T S PAGES

Section-I GENERAL .. 3Section-II PROCESS & MECHANICAL .. 21Section-III ELECTRICS AND AUTOMATION .. 27Section-IV INSPECTION, TESTING AND PG TEST .. 41

ANNEXURES

Annexure-1 - Approved Supplier List Annexure-2 - Tata Steel TPM Standard Annexure-3 - Positive Isolation Procedure Annexure-4 - Project Safety Risk Management Annexure-5 - Pre Start-up Safety Review Annexure – 6A – BOQ and Price Schedule for design, engineering and supply Annexure – 6B –Price Schedule for supervision of erection, testing andcommissioning

Annexure – 6C – BOQ and Price Schedule for spares

DRAWINGS

Drawing No. Title

ENG0351-CO12-U-LAY-001 GA AND SECTION OF CO GAS FLARINGSYSTEM.


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SECTION-1

TECHNICAL SPECIFICATION

FOR

BOP SUPPLY AND ERECTION OF COKE OVEN GAS FLARE SYSTEM

1.0 GENERAL

1.1 The Tata Steel Ltd (TATA STEEL), Jamshedpur intends to set up anew Coke Oven Gas (COG) flaring system near new Coke OvenGasholder area, having adequate capacity.

1.2 The flaring system comprising of a flare stack will be connected tothe existing DN1500 mm COG pipework between CO Gasholder andsuction side of the COG Boosters.

2.0 INTENT OF SPECIFICATION

2.1 This specification covers the scope of supply, assembly, testing,packing, structural work, start-up, commissioning and performanceguarantee test of Balance of Plant packages of COG Flaring systemas per attached lists (Annex-1, 2, 3, 4) and erection of entire COGflaring system (BOP and Main COG Flaring system) at Tata SteelLimited, Jamshedpur including auxiliary system, electricalequipment, cabling and deep bore earthing, interconnecting piping,miscellaneous structures, etc. This specification forms part of thetender documents and shall be read in conjunction with the otherdocuments such as Invitation to Tender, General Conditions ofContract and General Specifications.

3.0 COMPLETENESS AND RESPONSIBILITY OF TENDER

3.1 All items of various equipment shall be complete in all respect andany items not covered in this specification but essential for properinstallation, operation and maintenance shall be included by thetenderer in his offer and the reasons for such inclusion shall beclearly stated.

3.2 The tenderer shall study the specification and satisfy himselfthoroughly, regarding the workability of the equipment and shalltake full responsibility for the guaranteed operation of the


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equipment as regards output, performance and smooth reliable working

3.3 If the tenderer feels that for any items specified hereafter, he is in aposition to submit a more suitable offer, he shall indicate themspecifically and submit an alternative proposal on the basis of thespecification he considers suitable and capable of meeting the dutyrequirements.

3.4 Wherever necessary the Tenderer shall provide handling facilities with required capacity for maintenance purpose of the equipmentsupplied by them.

3.5 The Tenderer shall design his equipment on the basis of givenspecification, unless it is likely to impose some restrictions onoperation and/or equipment capability.

4.0 EQUIPMENT

Specification and other particulars regarding installation, testingand supply of BOP of CO Gas Flaring System shall be as stipulatedin Section-II.

5.0 SCOPE OF WORK

5.1 Supply of plant and equipment

5.1.1 All equipment complete with all accessories as per attached list(Annex-1, 2, 3,4) and below mentioned equipment for smooth andtrouble free operation of the BOP of Flaring System. The same shallat least cover, but not limited to the following:

a)Pipe, valves, fittings etc up to the battery limit as per attachedlist.

b)Fire hydrant pipe, valve, hydrant valves, hoses, hose box etcrequired for hydrant base firefighting system and one noportable fire extinguisher for ECR room.

c)Drinking water pipe, valve, and fittings from battery limit toconsumption point.

d)Service water pipe, valve, and fittings from battery limit toconsumption point.


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e)1.5 T window AC for ECR building.

f)All Electric, illumination as mentioned in electrical chapter.

g)Supply, fabrication and erection of structural items for pipe work, valve platform etc up to the battery limit.

h)Radiation / Heat shield in Junction House of coke conveyor.

i)Special tools and tackles.

j)Any other items not mentioned here but required for successfulinstallation and commissioning of BOP packages shall beincluded into the vendor scope of supply as unit rate basis.

5.1.2 Electrics

This shall include supply, installation, testing and commissioningof all electrical equipment, power distribution, motor control andlighting distribution boards/panels, cables including cabling

accessories, earthing and lightning protection, lighting system etc.up to battery limit and installation of all electrical equipment within battery limit. For details refer section III. Item list are attached inseparate folder.

5.1.3 Instruments

Installation, testing and commissioning of all necessaryinstruments and associated cables including cabling accessories,control equipment etc of entire project and must be complete in all

respect. For details refer section III. Item list are attached inseparate folder.

5.1.3.1 The entire COG flaring system shall be tested, erected andcommissioned under the supervision of flare stack supplier to thesatisfaction of the Purchaser. The tenderer shall supply all erectionand testing hardware as may be necessary for proper installationand functioning of the system.

5.1.3.2 All necessary instruments and accessories for various site tests.


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5.1.4 Any other item, although not specifically mentioned here, butnecessary for smooth and trouble-free operation up to battery limit

of the flare stack system, shall be deemed to be included in thescope of this specification and shall be supplied without anyadditional cost to the Purchaser.

5.1.5 Special embedment & inserts, anchorage etc.

5.1.6 Spares

The tenderer shall submit with his offer quotation for variousspares in accordance with the relevant clauses of the General

Conditions of Contract (GCC) included with this tender enquiry. Thescope of supply shall include the following:

• Commissioning spares: Tenderer shall provide all sparesrequired for commissioning of the equipment as per terms ofGeneral Conditions of Contract (GCC) included with thistender enquiry. The tenderer to enclose a list ofcommissioning spares in the offer.

• Maintenance spare parts for two years normal working:

Tenderer shall indicate maintenance spare parts for two yearsnormal working of the plant as per terms of GeneralConditions of Contract (GCC) included with this tenderenquiry.

5.1.7 Operational Change Parts

The scope of supply will include operational change parts like knifeetc. which tenderer shall feel appropriate for smooth operation ofthe line. Tenderer shall submit a list of operational change parts

included in the scope of supply in their offer.

5.1.8 Tools & Tackles

The tenderer shall include in his offer the special tools and tacklesrequired for normal operation and maintenance as per relevantclauses of General Conditions of Contract (GCC) included with thistender enquiry.

5.2 Testing and Inspection


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Testing and inspection at manufacturer’s works and Acceptance Tests of the BOP packages of CO Gas Flaring System shall be

carried out as per the details given in Section-IV.

5.2.1 All necessary tests shall be carried out by the successful tendererto demonstrate whether the materials and equipment offeredconform to the relevant standards and specifications. The tenderershall include and provide for in his offer all facilities which shallenable inspection by the Purchaser or his authorized representativein accordance with the relevant clauses of the General Conditions ofContract for Supply of Plant, Machinery and Equipment.

5.2.2 The tenderer shall furnish in the quotation a complete list of thetests proposed to be conducted in the factory to demonstrate duringcommissioning. These shall include carrying out the requisite testsat site and procurement of statutory test certificate. The Purchasermay ask for special tests to be carried out for any item.

5.2.3 The equipment shall be shop assembled for checking the accuracyof parts and alignment, except where assembling is to be done atsite. If disassembly is required for shipment/transport, parts shall

be adequately marked where necessary with permanent match

markings to facilitate reassembly at site.

5.2.4 The certificates for bought-out items shall be supplied beforeinspection, to the Purchaser or his authorized representative. Thesetest certificates shall indicate actual test results in relevant unitobtained in such tests.

5.3 Erection and commissioning

5.3.1 The successful tenderer is required to carry out the erection and

commissioning of the entire COG flaring system including BOPpackages at site. The successful tenderer shall, therefore, beresponsible for satisfactory erection, testing and commissioning ofall equipment. Erection shall be carried out as per conditionsspecified in the Invitation to Tender and General Conditions ofContract for Supply of Plant, Machinery and Equipment. Tenderer tofollow thoroughly TISCO-GS-P-02 for erection of all equipment,piping, valves, cables, instruments etc. The same shall at leastcover, but not limited to the following::

• Unloading of materials from rail and other means of transportcarriages.


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• Transportation/shifting of unloaded material to storage area.• Technical assistance for stacking and storing of materials at

site.• Checking of all materials with consignment note, reporting formissing or damaged items, repairing damages and cleaning

before erection.• Maintaining proper record of the materials and place ofstorage for quick identification as and when required.

• Issue of materials from storages and maintaining detailedaccount of the same as required.

• Transportation/shifting of material from storages to erectionsite.

• Final adjustment of foundation levels by chipping anddressing, checking location, elevation etc, of anchor bolts andgrouting of anchor bolts and base plates.

• Construction of site offices and covered storages as required.• Cleaning up of site during and after erection.• Pre-assembly at site after proper checking/overhauling, asrequired.

• Erection and subsequent cleaning/flushing as required, precommissioning checking to ensure correctness of erection.

• Testing and commissioning services as required.• Watch and ward to ensure security and safety of materialsunder the contractor's custody.

5.3.2 DETAILED SCOPE OF ERECTION, TESTING AND COMMISSIONING

General:

The scope of work shall include all activities at site includingplacing of equipment on foundation, levelling and alignment,

grouting of foundation, other miscellaneous minor civil work suchas dressing/chipping of foundation surfaces as required, scraping,drilling, reaming, honing, edge preparation assembly &preassembly, inspection & testing by inspecting authority whereverrequired, refractories and insulation work, minor rectification,

welding, cutting, site adjustments and all other incidental activities.

The contractor shall furnish all labour (supervisory, skilled,unskilled and administrative) all consumable materials, transport

vehicles, mobile cranes, hydraulic jack, required erection tools &tackles & equipment, precision levels including micro levels, dialand other gauges, surface plates, straight edges, testing equipment,special tools like vacuum cleaners, blowers, radiography and stress


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relieving equipment, pumps and other equipment necessary forhydro testing, compressed air testing and all other necessary

implements in sufficient numbers as may be required for timely andefficient execution of the contract. The materials supplied shall beof the best quality, the specification and quality of which have to beapproved by Engineer. Tenderer to follow thoroughly TISCO-GS-P-02for erection of all equipment, piping, valves, cables, instrumentsetc.

Supervision during erection:

The Contractor shall be required to provide, at a proper time, the

necessary supervisory engineers, supervisors and other supervisorypersonnel duly qualified and in sufficient number for transportation, erection, pre-commissioning and post commissioning check-up,start-up, testing and trial operation of plants and equipment.

The Contractor shall keep a competent representative who will beResident Engineer and shall remain as 'In-Charge' of contractor's

work site and also remain answerable to the Purchaser for allactivities of the contractor at site. Before his placement at site, thecontractor shall submit his bio-data to the Purchaser for hisapproval.

The Resident Engineer shall supervise the work of all men of thecontractor working at site. He shall work in complete harmony andcooperation with Purchaser's engineers and manufacturer'sengineers working at site. All statutory rules and labour lawsprevailing in the area must be observed by the Contractor. All safetymeasures against occurrence of accidents must be taken effectively.Resident Engineer shall not be withdrawn without writtenpermission of the Purchaser. If any of the Contractor's personnel isfound unsuitable for the job, the contractor shall remove himforthwith and a suitable replacement shall be posted at site within

a reasonable time. No compensation for withdrawal of unsuitable orunqualified person(s) from site or for posting suitable person(s) tosite at any stage of the project shall be allowed by the Purchaser.

Sequence of Erection Work:

All packing cases and packages shall be opened in the presence ofthe Engineer or his authorized representative. Timber packing casesshall be carefully opened to avoid damage to materials or timber.Nails and packing strips should be pulled out with suitable

appliances and kept separately in a container and not thrown awayat random. All timber of packing cases shall have to be sorted outand stored properly at a suitable place, as directed by the Engineer.


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From time to time packing materials, timber, nails and strips shall be delivered back to the Purchaser or otherwise disposed of, as

directed by the Engineer. The Timber reclaimed from the packing cases or any other materialshall not be used by the contractor for rendering facility in theerection work or any other job, without prior permission of thePurchaser. All timber and packing materials shall remain theproperty of the Purchaser.Each material after stripping from boxes or received loose, shall becarefullyinspected, checked with shipping list and identified witherection drawing, if necessary. Any short supply and/or damagedpart shall be reported forthwith to the Purchaser in writing. The

contractor shall be completely responsible to make all necessaryarrangements , application and follow procedure to process claim onunderwriters, obtain replacement repair/rectify and modify, asrequired on all such damaged/defective/ lost equipment andmaterial at no extra cost to the Purchaser in order to execute the

work in satisfaction to the Purchaser/Engineer within the stipulatedcontract time.Once the materials are inspected, the same shall be preservedproperly and adequately protected from theft and deterioration ordamage by rain, storm, and dust, water, tampering by casual

visitors or workers. The contractor shall prepare and maintainstores, ledgers and bin cards for all materials in his custody.Carrying out all repairs to damages that might have occurredduring transit and in subsequent storage and modifications andrectification work and replacement of all lost parts, are under theContractor's Scope.

Erection:

Erection shall be carried out in the manner and in sequence as may

be directed by respective equipment manufacturer's supervisoryengineers and the Purchaser's engineer.

As erection proceeds, each assembled part before being boxed up with a view to erecting it finally, shall be inspected and approved bythe concerned supervisor. Should any defect be found out duringsuch inspection, the contractor shall make it good as per directivesfrom purchaser's engineer.

All necessary radiography will be included in the scope of work ofthe contractor. Contractor shall furnish all instruments, isotopes,films, etc. for conducting radiography and equip himself fully.

Necessary operators of all testing equipment shall be provided bythe Contractor.Dark-room facilities with air-conditioners for storing and processing


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radiography films and equipment, as necessary, shall have to bearranged by the Contractor.

The equipment shall be placed on respective foundation or support,levelled and aligned with precision measuring instruments, checkedfor proper clearance between moving and stationary parts whereverapplicable and grouted on the foundation.

All fabrication and engineering work incidental to erection, likeScaffoldings, structural framings for pre-assembly, transport anderection etc. shall have to be done by the Contractor at his owncost. The structural steel required for such work shall be arranged

by the contractor. Also, any fabrication work like cutting, grinding, welding, straightening, filling, reaming, drilling, threading, fitting

up, etc., which in the opinion of the Engineer are incidental to theerection at site, shall have to be done by the Contractor. Any defectin the fabrication shall have to be rectified by the contractor at hisown cost.

All piping work shall be done as per Vendor's certified drawings. Fordetails refer specifications.

Welding shall not be carried out on wet surfaces and shall beprotected from high winds.

All pressure vessels should be directly placed on the foundation infully fabricated form.

Particular attention shall be given towards removal of tackles andother forms of distortion.Holes in plate work to assist in erection should be avoided. Lugsrequired for erection shall be removed and projections of weld shall

be chipped and ground flush. All equipment shall be safeguarded from wind or other externalcauses by providing suitable steel cables/guys until completion oferection.

Welding sequence shall be adopted in such a way so as to minimizedistortion due to weld shrinkage and shall be got approved from the

owner's engineer prior to commencement of work. All materials such as welding electrodes, gaskets, bolts, nuts, etc.shall be of reputed make and conforming to relevant Indianstandards. Prior approval of Engineer will have to be obtained beforecommencement of work. Manufacturer's test certificates shall haveto be provided when called for.

Safety regulations:

Tenderer is to follow Tata Steel safety norms strictly. For details

refer anexture-4.

Cleaning:


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The Contractor shall observe strict cleanliness during execution of

the work and shall be in possession of vacuum cleaner for cleaningthe internals of machinery under installation. They shall check thatall the finished surfaces are greased and covered and all pipes andduct ends are covered with plastic or suitable type of cap duringstorage.

The Contractor shall clean inside the internal surfaces of all piping before erection by wire brushing and air lowing. In case of smalldiameter piping for cooling and lubrication, cleaning will have to bedone by pickling if so required. The inside of all equipment shall bethoroughly cleaned before they are installed.

Before boxing up, the Contractor shall examine carefully to ensurethat no foreign materials, such as welding rod ends, metal chips,rope, working tools or other materials are left inside the equipment,piping, and duct.

Pre-commissioning and testing:

After alignment of all equipment, alignment tests shall be carriedout by the Contractor to check level, clearance, eccentricity, etc. Allmeasurements will be witnessed and acceptance will be certified by

the engineer.Hydro testing shall be conducted for all pressure parts afterinstallation at required pressure. All necessary blankingarrangement necessary for such hydro testing shall be furnished bythe Contractor. All necessary test pumps, temporary piping, etc.shall be supplied by the Contractor.

After the hydrostatic tests, the contractor shall carry out thoroughflushing of all lines to ensure removal of foreign materials like

welding rods, metal chips, etc. to the satisfaction of the engineer. After the flushing of the lines, all the water shall be drained and the

cleaned piping surfaces shall be dried by blowing air or by any otherapproved method.Modification/rectifications as felt necessary by theEngineer/Inspector shall be carried out at no extra cost to meet theguarantee and other technical particulars.

Start-up & Trial Runs:

Following the satisfactory completion of inspection, testing andcleaning of a unit, the plant will be placed in trial run under the

super vision of main COG Flare pkg vendor. During this period, alladjustments and repairs, as required, shall be made by theContractor. The plant may be shutdown, if necessary, to carry


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out such adjustments and repairs. On completion of satisfactorytrial operation, the plant will be placed under initial operation.

5.4 Overall Responsibility Matrix

The overall responsibility matrix between TATA STEEL and tenderer isindicated in Table - 1 below:

Table - 1

Sr.

No.Item Purchaser

Successful

Tenderer

1.0

Manufacture and supply of pipe, fittings,

valves including structures, electrics etc up tothe battery limit. - √

2.0 Internal Quality Assurance - √

3.0 Inspection at Manufacturer’s works √ -

4.0Structural work and supply for piping, cabletray etc.

- √

5.0 Civil work and supply of materials. - √

6.0Main Pkg Equipment Foundation bolt, anchor

box, embedded parts, fasteners etc. √ -

7.0Connection of all utilities from TOP to flare

Stack.- √

8.0Interfacing between flare stack to existingsystems of Electrics and Instrumentation.

- √

9.0 Entire COG flare system erection. - √10.0 Trial run and commissioning. - √

11.0 Demonstration of PG Test - √

12.0Supply of all types of spares, operationalchange parts, special tool & tackles, Paintingetc for BOP package.

- √

13.0 Overall project management and monitoring √ -


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Note:Purchaser reserves the right to modify the above scope of work at a later dateas per the requirement with prior intimation to the tenderers.

5.5 BATTERY LIMIT (TAKE OVER POINT)

The tentative battery limit for services is shown in the attacheddrawing.

6.0 SOURCE OF SUPPLY

6.1.1 In case the offer includes item not manufactured by the tenderer,the same shall be clearly indicated in his offer along with the nameof manufacturer of the respective items. It shall be theresponsibility of the successful tenderer to coordinate with the sub-suppliers and execute the contract within the agreed time scheme.

6.1.2 Where found necessary, the Purchaser reserves the right ofselecting the manufacturer of the items covered under thespecification.

6.1.3 A list of preferred makes is enclosed in the specification (Annex-1A

& 1B).

7.0 STANDARDS

7.1 In general, the components shall conform to the relevant standardspublished by the Bureau of Indian Standards, the InterplantStandards for Steel Industry (IPSS) developed by the Steel Authorityof India and Bureau of Indian Standards Oil Industry SafetyDirectorate (OI&SD) wherever available, so that specific aspects

under Indian conditions are taken care of. Wherever suitable IndianStandards are not available, other International Standards such as ASTM and DIN may be adopted with prior approval Section-VI.

7.2 Wherever Indian standards do not exist, the components of allequipment shall be designed, assembled and tested in accordance

with the latest standards of the Standards institution, Institution ofElectrical and Electronics Engineers, USA (IEEE), NationalElectrical and Manufacturers Association, USA (NEMA),International Electro-technical Commission (IEC) or NationalStandards Institution of the country where they are manufactured.


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7.3 All equipment, pipe, fittings valves, accessories, cables electrics etc,covered in the specification shall be designed, manufactured, tested,

erected and commissioned as per latest publication of BIS, IEC, andany other recognized International Standard.

7.4 All equipment, pipe, fittings valves, accessories, cables instrumentsetc, shall comply with the latest regulations and the stipulation ofInspectorate of Factories and other applicable statutory bodies ofthe Government of India and the Government of Jharkhand,

wherever applicable. All costs on this account shall be borne by thesuccessful tenderer.

All electrical equipment and installation shall comply with Indian

Electricity Rules 1956 with amendments.

7.5 The equipment, pipe, fittings, valves, electrics, cables etc. suppliershall provide all assistance to obtain necessary approval fromappropriate statutory authorities for the installation and shallundertake modifications as required by the statutory authorities

without any implication to the TATA STEEL. Wherever required byregulations, the successful tenderer shall have to obtain necessaryapprovals from statutory authorities and other concerned agenciesand any changes required by the said authorities shall be to the

account of successful tenderer. Tenderer to also refer the GeneralConditions of Contract (GCC) enclosed with this tender enquiry forstatutory enactment governing the law.

7.6 In cases where the offer deviates from the specified standards, thetenderer shall indicate clearly in his offer the standards proposed to

be adopted by him along with details thereof and the reasons for thedeviation.

7.7 All work shall conform to the following General

Specifications/Design Basis which form part of the tenderdocument :Specification No. Description

A.PROCESS/ UTILITY

TISCO/GS-P-02 Erection of equipmentENG-C/0351-CO12-U-DBR-001

Design Basis of Pipe work

TISCO/GS-P-01 Painting

B.ELECTRICAL

TISCO/GS-E-03 415 V load centre sub-stations TISCO/GS-E-04 Power & lighting distribution board, (PDBs,


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Specification No. Description

LDB) & misc. electrical equipment. TISCO/GS-E-05 AC motors and controls TISCO/GS-E-07 UPS system TISCO/GS-E-08 Lighting, fittings and accessories TISCO/GS-E-09 Installation, testing and commissioning of

electrical equipment TISCO/GS-E-10 Selection of electrical equipment,cables and

earthing materials TISCO/GS-E-11 Power, control and special cablesC.INSTRUMENTATION, AUTOMATION

TISCO/GS-I-01 Instrumentation & control system TISCO/GS-A-01 Process automation (level-2) system

D.INSPECTION

TSBCRM/GS-INS-01

Inspection & testing requirement of plant &equipment at manufacturer’s premises

7.8 Tenderer to follow TATA STEEL’s TPM (Total productivityMaintenance) standard as given in Annexure-2.

8.0 WORK BY OTHERS

8.1 Work by others shall include main flare stack package with in battery limit and all instruments for entire project :

9.0 LIST OF EXCLUSIONS/ DEVIATIONS

The tenderer shall indicate separate list (as per the format in Table2 given below) of exclusion from their scope of work and alsoindicate specifically list of deviation, if any, from the tenderspecification.

Table – 2

Engineering Scope Supply Scope Erection &

Commissioning Scope


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I t e m N o .

E q u i p

m e n t

g n a t i o n / Q

t y

W e i g h t , a p p r o x . ( T )

B D

B E

D E

S c o p e

L o c a l

F o r e i g n

E r e c t i o n W o

r k

S u p e r v i s i o n o

n a n d

BD = Basic Data P = Purchaser DE = Detail EnggBE = Basic Engg. FS/IP = Foreign Supplier/ Indian Partner IS = Indian Supplier

10.0 PROJECT IMPLEMENTATION SCHEDULE

10.1 The Tenderer shall submit an overall implementation schedule inform of a bar chart for the project indicating the time required tocomplete major activities as follows:

• Structural work and supply of materials.• Manufacture, assembly, inspecting and testing of pipe fittings, valves, electrics, instruments etc.

• Supply of pipe fittings, valves at site.

• Supply of electrics and instruments at site.• Erection of entire plant, shut down period and commissioning

10.2 It is envisaged that the total project implementation period will be“Best total project implementation period”.

10.3 The schedule submitted shall also include the works to be done by“Others”.

10.4 The project implementation schedule shall clearly highlight the

schedule of required availability for power, utilities, water, crane,civil font etc.

11.0 OTHER REQUIREMENTS

11.1 Accessibility and Interchangeability All working parts, as far as possible, are to be arranged forconvenience of operation, inspection, lubrication and ease ofreplacement with minimum downtime.

11.2 Quality and Workmanship


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Workmanship and materials shall be first class quality suitable forthe purpose intended and in accordance with the highest standards

and practices for equipment of the class covered by thespecification.

11.3 Safety and positive isolation

a) All equipment shall be complete with approved safety devices &positive isolation devices for all energy sources and withprovision for safe access of personnel to and around equipmentfor operation and maintenance functions during operation and

during planned & un-planned down time of the facility.

b)The supplier shall incorporate in design all the necessaryequipment that may be required for positive isolation of theenergy sources (electrical, hydraulic, lubrication, pneumatic,mechanical etc.) of the machine before doing maintenance/operation jobs on the machine. The equipment shall satisfy theneeds related to comply with the positive isolation concept asstated in Annexure-3. These items shall include not only thoseusually furnished with elements of machinery, but also the

additional covers, guards, handrails, etc. which are necessary forsafe operation of the plant. Tenderer shall fill the PSI and PHAdocuments in the format given in Annexure-4. Tenderer shallalso to go through the clauses indicated under “Pre Start upSafety Review (PSSR)” given in Annexure-5.

11.4 Painting.

All piping, valves etc shall be given final coat of paint and all thestructural items shall be given prime coat of paint before despatch

to site. All items of equipment and materials shall be thoroughlycleaned and painted in accordance with General Specification forpainting (TISCO/GS/-P-01). The equipment supplied at site withdamaged painting is to be touch up painted at site by the successfultenderer as per the painting standard.

11.5 Noise Abatement

Suitable noise abatement devices shall be provided to restrict thenoise levels in working areas as per the recommendations ofInternational Electro-technical Commission, IEC 179. The methodsof evaluating noise levels shall be as per the International


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Standards Organization (ISO) such as R532 and R1760. Forassessing annoyance of noise, the noise rating curves as per ISO:

R1996 shall be used. For airborne noise emitted by rotatingelectrical machinery, ISO 1680, Part-I may be followed.

12.0 TECHNICAL CAPABILITY OF THE TENDERER

The tenderer shall submit a statement of similar items supplied andinstalled at least 6 references by him during the last ten (10) years.

Tenderer need to provide the various performance parameters in referenceplants along with the contact details.

12.1 The tenderer shall satisfy the Purchaser that he possesses thenecessary technical experience and has at his disposal suitablefacilities and staff to ensure quality and timely completion of work.

The tenderer shall furnish necessary particulars in this connection with the tender.

13.0 INFORMATION TO BE FURNISHED WITH THE OFFER

The tenderer shall furnish in his offer the information called for inthe various parts/sections of the tender documents without whichthe offer is liable to be rejected. The information furnished shallinclude, but not be limited to, the following:

13.1 General description, items offered specifying the importantfeatures and materials of construction for the various componentsincluding safety features, overall control and operation philosophy,manufacturers’ catalogues/ literatures for all bought out items etc.

Valve GA drawing etc.13.2 Itemised list of items/ facilities with brief specification of each item

including their material of construction.

13.3 Requirement of power, water and other utilities.

13.4 Necessary drawings, data etc.

13.5 Each exception to or deviation from or any exclusions from thespecification or the other parts of the tender documents shall belisted in a consolidated list to be submitted with the tenderseparately. If exceptions are not clearly and separately listed, they

will not be considered by the Purchaser at a later date during

execution of the contract. The “Deviation list’ to be submitted bythe tenderer shall include ad seriatim, reference to specificationclause/para, details as per specification, deviation proposed and


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reasons for the same. However, acceptance of any deviation from Technical Specification is subject to acceptance TATA STEEL prior

to order placement.

13.6 Project time schedule in form of bar chart showing various activitiesand milestones as specified above.

13.7 Overall responsibility matrix between purchaser & supplier.

13.8 List of bought out items, if any.

13.9 List of sub-vendors of the bidder.

13.10 Drawing document submission schedule.

13.11 List of special tools & tackles for erection.

13.12 List of commissioning spares, maintenance spare for two years‟normal working.

13.13 Reference list of the past experience in erection of similar flarestack (for the last ten years).

13.14 List of exclusion from scope of work indicated in this technicalspecification and the enquiry.

14.0 DRAWINGS AND DOCUMENTS TO BE FURNISHED AFTER AWARD

OF CONTRACT

14.1 The successful tenderer shall prepare the following drawings andshall submit within two (2) months from the date of placement ofthe letter of intent to Purchaser/Consulting Engineers for theapproval/comments/ information before taking up the manufactureof the equipment.

a)General arrangement drawings of the equipment/valvesindicating list of items with brief specification and scope ofsupply.

b)General arrangement drawings of the electrical items.

c)Any other drawings if required.


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14.2 The following shall be supplied two (2) months before delivery of

equipment:

a)Certified dimensioned drawings including detailed drawings ofall parts subject to wear and breakage.

b)Erection drawings for assembly and erection of all equipment.

14.3 Spare parts lists with drawings, specification and manufacturer’scatalogue.

14.4 Complete list of items detailing individual items with ratings,capacity, services etc.

15.0 PROJECT CO-ORDINATION PROCEDURE

Co-ordination procedure shall be finalized during Kick-off Meeting with the successful tenderer.

16.0 PERFORMANCE AND GUARANTEE

16.1 Functional and performance guarantee tests shall be carried out bythe successful tenderer at Purchaser’s Works in presence of buyer’srepresentative and after commissioning at Purchaser’s Works,respectively, to demonstrate whether performance of the equipmentconforms to the relevant standards and specifications to meet theoperational requirement indicated in the specification.

16.2 All equipment and components shall be guaranteed for workmanship and materials, and satisfactory performance inaccordance with the relevant clause of TATA STEEL-GCC-002.

16.3 Testing shall be carried out by the tenderer after commissioning andthe tenderer shall propose the details of this testing procedure inthe bid including input requirements from Purchaser.

16.4 Tenderer to submit the details regarding the Performance Guarantee(PG) tests to be carried out demonstrate the performance of variousequipment along with the bid.

16.5 The performance tests to be carried out as per stipulation ofSection-IV - Testing and Inspection.


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17.0 PRICES FOR EQUIPMENT AND SERVICES

17.1 The itemised basic prices for design, manufacture, assembly,testing, packing, supply, supervision of erection, start-up,commissioning and performance guarantees of equipment andmaterials shall be quoted as per ITT.

17.2 The itemised basic prices for spare parts and special tools andtackle shall be indicated.

17.3 The basic price of the equipment, spares, special tools and tackles,etc. to be indicated by the tenderer shall be exclusive of all dutiesand taxes. However, itemised taxes, duties, freight, insurance andpacking charges, etc. shall be indicated in the price schedule at theprevailing rate as per ITT.

17.4 Price variation: The prices shall be firm and shall remain so duringthe execution of the contract. Any statutory variation in the taxesand duties will be paid by the Purchaser at actual againstdocumentary evidence.

18.0 DELIVERY

18.1 BOP packages with all accessories except instruments shall becompletely supplied and entire plant to be erected, tested andcommissioned within eight (8) months from the date of LOI. Supplyof equipment shall be completed within Three (3) months from thedate of LOI.

18.2 The offer shall be accompanied by a time schedule showing theindividual time periods required for submission of drawings as wellas the time for erection, start-up, putting into commission andperformance tests. A network diagram incorporating importantactivities shall also be submitted with the offer.

19.0 ADDENDA TO TENDER DOCUMENTS

Purchaser reserves the right to issue addenda to the tenderdocuments to clarify, amend, modify, supplement or delete any of

the conditions, clause or items stated in the tender documentsissued with the tender enquiry. Each addendum so issued shallform a part of the original tender documents.


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SECTION – II

DESIGN DATA AND TECHNICAL REQUIREMENTS- PROCESS & MECHANICAL

1.INTRODUCTION

One (1) No. Coke Oven Gas Flaring system comprising FlareStack /Risers, Flare tips along with all accessories and controls

shall be installed for flaring of excess Coke Oven (CO) Gas duringshutdown of various plants or units which consume these gases.

A Flare stack of capacity 60,000 Nm3/hr is envisaged for CO gasflaring system.

2.DESIGN DATA

2.1 Plant Site

2.1.1 Site Location

The plant site is inside Tata Steel Limited existing steelworks at Jamshedpur in the East Singbhum district of Jharkhand State,India. Altitude from mean sea level is 129 m.

2.1.2 Climatic condition

Maximum mean daily temp. : 33.3 °C

Minimum mean daily temp. : 20.7 °C Absolute maximum temp. : 47.2 °C Absolute minimum temp. : 3.9 °CMaximum wet bulb temperature : 28.9 °CMaximum relative humidity : 84%Minimum relative humidity : 24%

Average relative humidity : 53%Maximum wind velocity : 160 km/hMaximum mean monthly wind velocity : 5.4 km/h.

Wind direction is predominantly from west in winter and from eastin summer.


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2.1.3 Seismic information

The plant is situated in a region falling under Zone II as defined in IS:1893-2002.


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2.2 CO Gas Flaring System

2.2.1For controlling the CO gas pressure in the piping network, one (1)no. of flare stack is being envisaged to take care of the effect offluctuations and sudden closure of major consumers of CO gas

2.2.2The technical parameters of CO Gas Flaring System are as follows:

No. of flare stack One (1)

Capacity of flare stack 60,000 Nm3/hr

Line pressure 300 + 50 mm wc

Tentative Flare Stackdiameter

.. 1100 mm (min)at top of stack

No. Of Flare Tips(StainlessSteel)

.. 03 nos.

Flare Stack height. .. 55 mtrs (min)

FFG panel. .. 1 No.

Independent water seal .. 1 No. at base of stack

Flow control system .. Flare stack system will beprovided with flow measuringand control system to preciselymonitor the quantity of CO gas

being flared for estimation ofthe flow control equipment.

2.2.3Coke Oven Gas Characteristics

COG temperature .. AmbientCOG Calorific Value .. 4000 +/- 200 Kcal/Nm3

Composition (percentage by volume)CO2 .. 2.8 – 3.2CnHm .. 2.5 – 3.4


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O2 .. 0.8 – 1CO .. 8.8 – 9

H2 .. 52 – 55CH4 .. 21 – 23N2 . .. 5.4-6.6

Tar fog .. 8 – 40 mg/NcumNapthalene .. 120-500 mg/ NcumNH3 .. 50-200 mg/Ncum

3.DRAWINGS

3.1 The tentative locations for the proposed Flare Stacks are shown inthe following drawing enclosed with the specification.

Drawing No. Title

ENG0351-CO12-U-LAY-001

GA AND SECTION OF CO GASFLARING SYSTEM.

4.CO GAS PIPELINE

CO gas pipe line of 1500 mm diameter will be taken from the mainrack pipe line and 100 mm CO pilot gas line also will be taken fromsame pipe line. Tentative TOP shown in attached layout drawing.

5.HANDLING FACILITY

The equipment shall be provided with suitable lugs and liftingtackles for ease of handling for erection and maintenance purpose.

The components of the equipment shall be so designed to enablethem to be handled easily with the conventional handling facilities.

6.UTILITIES

6.1 Nitrogen:

Nitrogen of 99.9 % purity will be made available at a pressure of 5-6kscg for purging and instrument uses. Tentative TOP shown inattached layout drawing.

6.2 Compressed Air:


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Compressed Air shall be made available at single point at the battery limit at a pressure of 5-6 kscg. Tentative TOP shown in

attached layout drawing.

6.3 Service water, Fire water and drinking water:

Service water, Fire water and drinking water shall be made availableat single point at the battery limit. Tentative TOP shown in attachedlayout drawing.

6.4 Electrics

Refer Section III.

6.5 Other Requirements

If anything required other than above services, tenderer to supply itupto the battery limt and to install entire line .

6.6 Battery Limit

Refer Section I.

7.EQUIPMENT SPECIFICATION

7.1 When due to some reason the consumers (all or few of them) cannotaccept CO gas, the gas pressure tends to rise which opens a control

valve and the excess gas will be released through a Flare Stack. Atupstream of the control valve, there will be an orifice meter which

will be used as a flow indicator, flow recorder and totaliser.

7.2 Flare stack will mainly consist of two (2) portions, i.e. self-supporting chimney/riser & 03 nos flare tip. These two portionsshall be connected by flanges. This flange connection will be 100%leak proof.

7.3 Flare tip will consist of a number of pilot burners as required. Each burner will mainly consist of Venturi, Nozzle, thermocouple andother necessary instruments/component. Suitable type of Windshield will be provided to protect flame from blow-off. There will besufficient number of flame retention lugs which will act as buffersto the flame. Even if the main flame goes-off, these small lugs willkeep the flames inside them which will again light the main flame.


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Pilot Burners shall be able to withstand any amount of rain and wind without a flame failure, thus ensuring constant availability of

ignition and support flame.

Coke Oven (CO) gas shall be used as pilot fuel to burn the abovegases. Calorific value of CO gas may be considered as 3800kcal/Nm3 minimum and 4200 Kcal/Nm3 maximum for designpurpose.

7.4 Flare stack design have the provision to ignite the burners fromthe respective FFG (Flame Front Generator) Panel which will belocated at ground level near to the Flare stack at a distance of 5

m to 10 m from the Stack inside ECR building.a)Mechanical parts which consist of Ignition Gas Pipelineassembly, Compressed Air Pipeline assembly, IgnitionChamber as required, Pipeline assembly for Pilot Gas (COG),Ignition tubes as well as Pilot Gas pipe line assembly etc.

b)The electrical parts which consists of Electrical circuitry,MCC, requisite number of Power Distribution boards, Ignition

Transformer, Ignition Push Button, necessary Lamps (LED),lighting distribution boards/panels, Hooter, Hooteracknowledgement Push Button, Main switch, Earthing and

Lightning Protection systems, cables including cablingaccessories etc. complete in all respects.

c)Complete instrumentation including pressure transmitter,RTD, temperature indicators and transmitter, Flow element,Flow transmitter, Recorders and Totalizers, Pressurecontroller, solenoid valves, Pressure Gauges, Pressureswitches, Instrument panel with wiring and accessories,signal multipliers, screened/controls/ power supply cables,special cables, impulse pipes and fittings, erection hardware,

cable trays, conduits, Junction boxes, buffer vessels forInstrument air/Nitrogen etc

7.5 To initiate the flaring process the isolation valve will be opened andin case of pilot ignition system for base offer CO Gas will flowthrough the pipeline to pilot. After putting on the main switch, theignition switch will be pushed on and sparking will take place atdownstream of venturi within the ignition pipe and flame willpropagate through the flame pipe and reach the pilot tip.

For base offer the ignition system shall have provision to adjust the

pilot flame length to suit the requirement of stable flame (for astormy day a strong pilot flame is required). There will be athermocouple inside each pilot and the same will be connected to


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the panel through cables. Signal will be received at panel for thepresence/ absence of pilot flame. In case of a flame failure, hooter

will be automatically on and pilot is to be ignited again as describedabove.

Design of Ignition/Flaring system shall be such that there will be no blow-off condition during maximum discharge of gas as well as noinner burning of tip during minimum discharge of gas and hencethere will be always a stable flame.

Tenderer shall be fully responsible for erection of entire plant.

7.6 A Water seal (Liquid seal) will be provided in the CO Gas Inlet ductupstream and as close to the Stack as possible to provide a positivemeans of flash-back prevention, in addition to enabling theupstream flare system header to operate at a slight positivepressure at all times. The Water seal vessel shall be equipped withnecessary accessories for satisfactory working and monitoring ofthe same.

8.SELF SUPPORTING STACK

Stack shall be of mild steel construction and the height of stack is55 mtr.

9.Air Conditioning Ventilation Systems

Ventilation and air-conditioning systems shall be supplied bytenderer.

10. Fire Protection Systems

The Fire Detection & Alarm Systems and portable fire extinguishersto be included in the scope of supply of the tenderer.

11. Electrics, Automation and CCTV system

Electrics, Automation and CCTV system are described in Section-IIIof this specification.


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SECTION III

ELECTRICS & AUTOMATION

1.0 ELECTRICS

1.1 Scope of Work

The scope of supply, installation, testing & commissioning of

equipment and items which are not covered in the main supplypackage shall include but not be limited to the scope of workcovered under this specification & as detailed below. If anyadditional item is found essential during detail engineering forcompletion of works, shall be under scope of work of thesuccessful tenderer without any extra cost.

1.1.1 Design and engineering, supply, installation, testing andcommissioning of cables including cabling accessories, earthing,lighting system including Lighting DB & lighting transformer (for

control room and street lighting including street and arealighting) for CO gas flaring system.

1.1.2 Design, supply and installation of 1.5 T Air ConditioningSystem (Window Type) for proposed control room.

1.1.3 Erection, testing and commissioning of Power distribution board, Aviation lights and lightning protection for chimney andLocal control station supplied by main package supplier.

1.1.4 Testing and commissioning of main package supply itemsshall be done under the supervison of main package supplier.

1.1.5 Fabrication and erection of cable racks/trays/supports,inclusive supply of steel materials, cabling materials, GSpipes/conduits, pipe fittings, road crossing RC/GS pipes etc. asrequired to complete the installation for items in the scope ofsupply & installation of the successful tenderer.

1.1.6Preparation and supply of all necessary construction/erectiondrawings and documents for the entire scope of work.


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1.1.7Obtaining approval from Statutory Government Authorities, ifany.

1.1.8Based on the soil resistivity value, selection of adequate numbersof normal and deep bore earth stations as required to maintainearth resistance value as per IS/IE rules.

1.1.9Excavation and installation of underground cables with supply ofroute marker, sand, bricks etc. embedded underground andfinishing the ground as before, if required.

1.1.10The successful tenderer shall carry out the following: (which are

not specifically mentioned in BOQ) at no extra cost.

a) Supply of drawings (Editable version) of the equipmentcovered in this specification along with allnecessary/specified test reports.

b) Supply of complete list of equipment detailing individualitems with accessories, tools etc.

c) Preparation of installation / erection drawings and obtaining

approval of the purchaser for all items/equipment/cables to be supplied & installed by the successful tenderer.

1.1.11 Submission of As-Built drawings in electronic media (RWCD)along with members of hard copies. The drawings shall be madein proper format and shall incorporate TATA STEEL drawingnumber. The drawing format and numbering system will beindicated to the successful tenderer during engineering meeting.

1.1.12 Testing of all equipment and accessories covered under the

independent supply at manufacturer's works and/or recognisedindependent testing centres before despatch of the same to site as

well as all tests at site before handing over the system complete inall respect to the purchaser prior to inspection report of thepurchaser/consultant as mentioned in General Specification No.

TISCO/GS-O-01(Rev.01).

1.1.13Minor Civil work associated with cabling & earthing installation work.

1.2 Design Basis

1.2.1Standards


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All electrical equipment shall be designed, manufactured andtested in accordance with the latest standards published by theBureau of Indian Standards (BIS), International ElectrotechnicalCommission (IEC) as well as TISCO General Specificationsenclosed with this specification and relevant TISCO Standards.

The equipment/systems offered shall conform to the latest IndianElectricity Rules as regards safety, earthing and other essentialprovisions specified therein for installation and operation ofelectrical equipment. Statutory requirements of the Government

of India and other statutory authorities shall also be complied with.

1.2.2Voltage Levels to be Adopted

LT system : 415 V, 3-phase, 3-wire50 Hz, 50 kA. Systemsolidly grounded attransformer neutral

AC Control Voltage : 110 V AC for contactor with AC coils, auxiliaryrelays

LED indication : 110 V for cluster LEDindication

Solenoids : 110 V AC for normal single/double solenoid valves

1.2.3Electric power will be available at 415 V, 3phase, 3 wire, 50 kAfor 1 sec solidly earthed system from Purchaser’s power source ata single point for each of BF & CO gas flaring system. For anyother voltage to be adopted suitable conversion equipment/ stepdown transformer shall be provided by the Tenderer.

1.2.4All electrical equipment shall be designed for satisfactoryoperation with supply voltage variation of +10% and –15% and

frequency variation of 6%.


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1.2.5Equipment/devices to be located in hazardousatmosphere/location, if required, shall be of flameproof

construction as per requirement of relevant standards.

1.3 EQUIPMENT SPECIFICATION

1.4 LT Power & Control Cables

1.4.1The scope of 415V, 3-phase power and control cabling work shallinclude supply, laying and termination from the PDB to the

various equipments inclusive of instrumentation system withintender’s scope. Supply and installation of incoming feeder cablesupto the incomer of the PDB shall also be included in the scopeof the tenderer considering approximate route length of 250metres.

1.4.2The offer shall include complete LT power and control cables andaccessories as required for interconnection between theequipment in the scope of erection of this tender as well as forstreet and area lighting system and aviation lighting in the scopeof the tenderer inclusive of cable tray installation system.

1.4.3All LT cables shall be 1100 V grade stranded aluminiumconductor armoured PVC type. Control cables shall be strandedcopper conductor, multicore, PVC type of 1100 V grade laid intrays, conduits and ducts and shall be armoured type.

1.4.4The cables shall be designed and manufactured in accordance with the following Indian Standard Specifications as applicable:

IS:1554 (Part-1) for PVC insulated (heavy duty) cables for working voltages upto and including 1100V.

IS:8130 for conductors for insulated electric cables and flexiblecords.

Installation of cables shall conform to the TISCO GeneralSpecifications.

1.4.5After installation of cables fire protection measures shall beprovided conforming to clause 6.1.20 of TISCO/GSE09.


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1.4.6Cable engineering for electrical and instrumentation are in thescope of work of the Tenderer. Following documents shall be

submitted during engineering:

a) Block diagram showing the details, voltage grade, size ofcables etc. related to PDB and field mounted equipment.

b) Interconnection diagram

c) Cable routing showing the list of all types of cables withnumbering system in different types of racks from source todestination.

d) Detail of cable trays carrying power, control & screen cables.

e) Plan & sectional details of cable routes showing all differenttypes cables with proper mounting & clamping arrangement.

f) Cable schedule mentioning cable numbers, sizes, voltagegrade, number of cores & length from source to destination.

g) Bill of materials.

1.5 Earthing Protection System

1.5.1Earthing and lightning protection for the entire scope of workshall be provided in conformity to IE rules and TISCO GeneralSpecification/ Standards.

1.5.2One (1) lot of earthing stations, earthing conductors andaccessories shall be provided for complete earthing of all

equipment, stacks and accessories covered under scope of thisspecification including cable armouring, GS pipes etc to meet thestipulation of IE rules to the full satisfaction of Govt. ElectricalInspector and the Purchaser. Selection of earthing system,earthing strips/wires etc. shall be in accordance with therelevant clauses of the General Specifications and TISCOStandards.

1.5.3Adequate number of earth stations, down conductors andaccessories shall be provided for lightning protection of stack as

per statutory requirements.


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1.5.4The selection of sizes for lightning protection conductors andinstallation of the lightning protection system shall be in

accordance with relevant clauses of the General Specificationsand TISCO Standards.

1.5.5Earth stations for earthing and lightning protection system shall be interconnected by the GS earth strip embedded under ground.

1.5.6Total requirement of earthing and lightning protection system,earth stations and earthing materials and all other accessoriesshall be included in the offer. Tenderer should consider soilearth resistivity value as 150 ohm mt, to be verified by actual site

test by the tenderer during project execution and a combinationof normal earth stations (3.5 mt deep, 40 mm dia pipe electrode)and deep bore earth stations (15 mt deep, 100 mm dia pipeelectrode) shall be taken into consideration to achieve thespecified earth resistance value as per IS/IE rules/ systemsuppliers recommendation. (Power and electronic earthing should

be seperate

1.6 LIGHTING SYSTEM

1.6.1This section of this specification covers the LED lighting systemfor the staircase of the stacks, indoor lighting for control roomand area lighting system including street lighting as per codes ofpractice. This includes complete design, manufacture, assemblyand supply of all items as required to complete the lightingsystem installation conforming to the General Specifications as

well as Aviation obstruction lighting system for stacks.

1.6.2The scope of supply shall generally include but not be limited tothe following:

All lighting fittings (LED Lights) complete with accessories.− All lighting distribution boards comprising MCBs, DP isolatingswitches, DP MCBs, junction boxes etc. as required

− 415V/240V, 1-phase dry type (AN) lighting transformers ofadequate capacity.

− All interconnecting cables, cabling materials, GS pipes/conduits, cable trays, structural supports, earthing materialsetc. as required to interconnect the complete lighting systemand Aviation lighting system.

1.6.3Equipment Specification


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1.6.3.1 All equipment and lighting fittings shall be designed,

manufactured and tested in accordance with the relevant IndianStandard.

1.6.3.2 The lighting MCB distribution boards shall be of 1.6 mm thicksheet steel enclosed with incoming and outgoing DP MCB’s (9 kA)of adequate ratings. Four (4) spare outgoing feeders in each ofthese boards shall be provided. Separate DP MCBs shall beprovided for lighting controls for group of lights/areas. Feedersfor adequate number of 6/16A DP switch socket outlets shall beprovided.

1.6.3.3 Type of lighting fittings to be used in various areas shall be asfollows:

i) Stair case andlanding

: 150W/70W HPSV well glassfittings.

ii) Aviation obstructionlighting system (to

be supplied by main

package supplier)

: As per latest regulation ofInternational Civil AviationOrganisation ICAO)

requirements for AviationObstruction Lights and itscontrol.

1.6.3.4 All cables shall be of 1100V grade stranded aluminium/copperconductor, PVC insulated and sheathed armoured cables. Alongstack/ staircase wiring will be carried out in GS conduits withcables of single core PVC insulated unsheathed copper conductortogether with continuous PVC insulated copper earth wirethroughout the conduit wiring system. The minimum conductor

size shall be 2.5 sq mm for copper. For incoming feeder uptoMCBDB and other installation shall be carried out by 1.1 kV PVCinsulated (Al) armoured cables. All cable shall be installedconforming to relevant IS/codes as well as existing standards of

TATA STEEL.

For tappings from junction boxes/control boxes to the individualfittings, single/2-core, copper conductor PVC insulated flexiblecables shall be used in flexible PVC encased metallic conduits.


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1.6.3.5 All equipment, cable trays, structural supports lighting fittingsand accessories shall be earthed as per IS:3043 as well as

conforming to TATA STEEL Standards.

1.6.4Lighting distribution board (LDB)

1.6.4.1 The lighting distribution board shall be suitable for 240 Vsingle-phase system and shall comprise incoming adequatecapacity double pole switch-fuse units and requisite number ofadequately rated outgoing DP switchfuse units/DP miniaturecircuit breakers with busbars generally conforming to IS:13947and IS:8623 as applicable and designed conforming to relevant

GS.

1.6.4.2 The board shall be of industrial, dust proof, wall/floor mounted,minimum 2 mm thick sheet steel enclosed cubicle design havingIP50 enclosure degree of protection. Separate metalliccompartments shall be provided for busbars, MCBs and cables.

1.6.4.3 The switches of incoming switch-fuse units shall be of load break, heavy duty type with quick make and break mechanism(AC22 category) conforming to IS:13947 (P3). Door interlocking

shall be provided. The fuses shall be of non-deteriorating typeHRC fuses with links complying to IS:13703.

1.6.4.4 The miniature circuit-breakers (MCBs) shall be heat resistantplastic moulded type generally designed, manufactured andtested as per IS:8828. Unless specified otherwise, all MCBs shall

be provided with quick break trip free mechanism and directacting thermal overload and short-circuit trip elements. Theshort-circuit breaking capacity of the MCBs shall not be less than9000 A at 0.8 power factor.

1.6.4.5 The bolted type earthing terminals shall be provided to comply with the requirements of Indian Electricity Rules. Proper dangerplates shall also be provided on each board.

1.6.5Lighting Transformers

1.6.5.1 The lighting transformers shall conform to the followingtechnical requirements, designed, manufactured and tested asper IS:2026 and IS:11171.

- Number One (1) or more asrequired


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- Rated capacity, kVA As required.

- Type Dry, air-cooled (AN)synthetic resin/silicon

varnished, vacuumimpregnated, minimumclass F insulation withtemperature rise limitedto class B

- Number of windingsmaterial

Two (2), electrolyte gradecopper

- Number of phases One (1)

- Rated primary voltage 415 V, phase-phase,2-wire

- Rated secondary voltage

240 V, phase-phase,2-wire

- Rated frequency 50 Hz

- Impedance voltage Less than 2.5%

- Tapping for off-circuittap changer onprimary side above

base voltage of 415 V

: + 2.5% & + 5%

- Primary side terminal Cable box suitable fortermination arrangement

of 2-core, PVC insulated& sheathed armouredaluminium conductorcable

- Secondary side Cable box suitable fortermination arrangementof 2X1-core, PVCinsulated copperconductor cables in

flexible metallic conduit.

- Enclosure 2 mm thick CRCA sheet


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One PLC with Panel mounted HMI screen will be supplied bymain package supplier where the entire flare stack logic will be

implemented. Remote operation of flare stack system is envisagedfrom two places one from New COG Gas Holder PLC and anotherfrom Main booster control room.

2.1.1 Erection, testing and commissioning of FFG Panel, PLC Panel,UPS Panel and all field instrumentation, instrument panels,

valves, Local control station, JBs, Instrumentation cable and anyspecial cables like thermocouple cables supplied by mainpackage supplier.

2.1.2 Testing and commissioning of main package supply items asmentioned in 2.1.1 shall be done by BOP package supplier underthe supervision of main package supplier.

2.1.3 The scope of Erection of the tenderer shall include, but not be limited to the following:a) UPS as supplied by main packager. Necessary DB is in the

scope of BOP package supplier

b) Field mounted instruments and control equipment asrequired.

c) Panel mounted instruments like indicators, recorders,totalizers, annunciators etc as required.

d) Erection of Instrument panels completely pre-wired with allaccessories, and housing display units, alarm annunciators,signal multiplier/isolators, signal conditioning modules as

required for the completeness of the Instrumentation systemof the gas holder.

e) Laying and terminating Screened cable, control cable, specialcables, power supply cables, conduits, cable trays, junction

boxes, cabling materials and accessories, as required.

f) Erection of hardware including impulse pipes and fittings,first root valves, ball valves, piping accessories, fieldinstrument mounting stands, transmitter cubicles, canopies,

installation materials and accessories, as required.Generally, 12 mm OD/ 8 mm ID SS tubes and double


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compression type SS fittings shall be used for impulsepiping.

g) Necessary transformer, conversion, stabilizing anddistribution units apart from the given power system, asrequired for feeding power to various equipment.

h) Necessary filters, pressure regulators etc as required forprovision of instrument grade air for all pneumaticinstruments and valves.

i) Commissioning spares and consumables.

j) Special tools and tackles.

2.1.4 The interfacing signals from FFG at flare stack controlroom & PLC panel at Gas holder control room shall include, butnot limited, to give the following for smooth and efficientoperation, control and Monitoring of Flare Stack system.

a) Flow rate b) Flow recording provisionc) Flow integration (totalizer)d) Presence/absence of pilot flamee) Alarms indicationsf) Temperature of flameg) Pressure Control Valve operation to COG line2.1.5 Interfacing : Flare Stack Signals are required to be controlled

and monitored at the New Gas Holder ECR, FMD and Main booster control room. The interfacing between Flare Stack PLC toNew Gas Holder ECR, FMD and Main booster control room shall

be under scope of BOP Package Supplier.

Bidder to visit the site and study the existing PLC/SCADA systemconfiguration of New CO Gas Holder, FMD and Main BoosterControl Room for the interfacing.

• Interfacing (COG Flare Stack to New Gas Holder ECR):

Flare Stack Signals are required to be controlled andmonitored at the New Gas Holder ECR. Existing PLC(Siemens S7-400) is responsible for new gas holder systemoperation. Bidder to establish the connectivity betweenFlare Stack PLC to New Gas Holder PLC, so that Flarestack remote operation and remote monitoring can be


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done from New gas holder operator station. Existingoperator station of new gas holder to be used for the

operation of Flare Stack.

Design, Engineering, Supply and erection of thecommunication cable, any communication module, powersupply module, repeater/converter module and any otherhardware (if required) for this interfacing shall be underscope of BOP Package supplier. Any modification required to be done in the existing logicof HMI/ PLC of new Gas Holder PLC/SCADA system foroperation, monitoring and data acquisition system from

new COG flare stack, shall also be under scope of bidder(BOP Package supplier).

• Interfacing (COG Flare Stack to Main Booster Control

Room): Flare Stack Signals are required to be controlledand monitored at the Main Booster Control Room.Existing RTU (Honeywell System) is available at Main

booster control room. Bidder to establish the connectivity between Flare Stack PLC to Main Booster Control Room,so that Flare stack remote operation can be done from

Main Booster Control Room. Bidder to provide one push button station at Main Booster Control Room for remoteoperation of Flare stack.Design, Engineering, Supply and erection of thecommunication cable, any communication module, powersupply module, repeater/converter module, push buttonstation and any other hardware (if required) for thisinterfacing shall be under scope of BOP Package supplier.

Any modification required to be done in the existingHoneywell system of main booster control room for

operation, monitoring and data acquisition system fromnew COG flare stack, shall also be under scope of bidder(BOP Package supplier).

• Interfacing (COG Flare Stack to FMD): Flare StackSignals are required to be monitored at the FuelManagement Department (FMD). Existing Honeywell RTU(ML-200) is available at New Gas Holder ECR which isconnected to FMD. Bidder to establish the connectivity

between Flare Stack PLC to the RTU (ML-200) , so that

Flare stack data can be monitored to the FMD also.Existing operator station of FMD may be used for themonitoring the Flare Stack data.


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Design, Engineering, Supply and erection of thecommunication cable, any communication module, power

supply module, repeater/converter module and any otherhardware (if required) for this interfacing shall be underscope of BOP Package supplier.

Any modification required to be done in the existing HMIof FMD PLC/SCADA system for monitoring and dataacquisition system from new COG flare stack, shall also

be under scope of bidder (BOP Package supplier).

2.1.6 For hazardous locations, careful attention shall be paidduring selection of machinery and equipment, method of works

etc in order to ensure safety. The instruments/devices provided inhazardous area shall be either explosion proof or shall haveintrinsically safe circuits.

2.1.7 Quantity and type of field/ panel mounted instruments shall be as per P&I diagram and GA drawing to be finalized duringdetail engineering without any cost implication to TSL.

2.1.8 Any item or accessories not included in this specification butessential for proper functioning of the offered system shall be

included by the tenderer in his offer.

2.1.9 The scope of Supply , Erection , Testing and Commissioningfor Instrumentation & Control part is attached with thisdocument as per following :

b.BOQ-C&I (Annexure-I)c.All equipment and accessories are from approve make list of TSL (Annexure-II)d.Basic system configuration (Annexure-III)


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SECTION – IV

INSPECTION, TESTING AND PG TESTS

1.0 GENERAL

1.1 All equipment covered under this section shall be subjected toinspection and test by Purchaser.

1.2 Material Tests

1.2.1 Whenever tested quality material is specified and wherever calledupon by the applicable design codes, the test pieces are to beprepared and tested to the satisfaction of the Purchaser. In the eventof the Purchaser being furnished with certified records of tests whichhave been carried out by suppliers of materials, the Purchaser mayat his discretion dispense with the tests.

1.3 Inspection / Testing of equipment at Manufacturers’ premises/Shops

1.3.1 Shop tests shall include all tests to be carried out at the works of thesuppliers and sub-suppliers. Tenderer shall furnish a comprehensivelist of the tests to be performed at the supplier's works as a part ofthe offer.

1.3.2 The inspection shall be carried out in accordance with the GeneralSpecification for Inspection and Testing requirement for plant andequipment at Manufacturer’s Premises (TISCO/GS-0-01) and relevantInspection Procedure to be finalised between successful tenderer and

the Purchaser/Engineer.

1.3.3 After placement of order, successful tenderer shall submit proposedInspection Procedure of all Mechanical, Electrical andInstrumentation items, depending on category of items under thescope of supply of relevant Purchase Order, to the ConsultingEngineersfor finalisation.

1.3.4 Works tests are to include electrical, mechanical, performance andhydraulic tests in accordance with the relevant Indian Standards, or

other approved standards or other tests called for, if any by thePurchaser under this specification to ensure that the plant fulfillsthe requirements of the specification. For equipment not covered by


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any Indian or other approved standards, the test to be carried outshall be in accordance with the supplier's quality assurance

programme to be agreed upon between the supplier and thePurchaser.

1.4 Acceptance Tests at Site

1.4.1 On completion of the erection and tests the tenderer shall carry outPreliminary Acceptance Tests (PAT) and Final Acceptance tests (FAT)

for each Flare stack system as per the conditions of the Contract.

1.4.2 The successful tenderer shall conduct performance/ acceptance teststo demonstrate that the equipment supplied is capable of achievingthe performance parameters specified and contracted for.Instruments and gauges installed for the normal operation of the gasholder shall be made use of during the acceptance tests as far aspracticable. However, the tenderer shall provide specialisedinstruments and other accessories, as required, to provide theguarantees and the same shall be included in the offer.

1.4.3 The guarantee parameters shall at least include the following:

a)Checks on the operation of all controls and instruments. b)Testing of proper operation of protection system for FFG panel,

pilot burners, ignition transformer and other accessories.c)Operational check of all individual control loop and inter-relation between each separate control loop.d)Calibration tests of orifices, nozzles in pilot burners, instrumentsand central equipment.

e)Any other functional check as required by the Purchaser.

The tenderer shall also submit a list of tests to be carried out at siteas a part of his offer.

1.4.4 Guarantee tests shall be normally conducted by the tenderer over acontinuous period of 7 days minimum. However, the procedure,programme and time schedule for the tests will have to be mutuallyagreed with the Purchaser. The time of start of the guarantee testsshall be mutually agreed between the Purchaser and Supplier.

1.4.5 Should the tests specified above show that the unit has failed toachieve the guaranteed parameters, the tenderer shall replace the


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items(s) and /or rectify the defects at his own cost and responsibilityfollowed by repetition of the tests after necessary modification /

rectification or replacement as required to establish the Flaringsystem performance satisfactory and acceptable.

2.0 QUALITY ASSURANCE PLAN

2.1 Quality Assurance Plan (QAP) and the scope of actual tests to beperformed to demonstrate performance guarantee will be decidedafter placement of order.


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SECTION – VI

LIST OF APPLICABLE STANDARDS

Sl.

No. Number Title

A. GENERAL

1. OISD Standard – 106 Process Design and Operating Philosophyin Pressure Relief & Disposal System

2. OISD Standard 118 –1995

Layout for Oil and Gas Installation

3. API 520 (Part-1) – 2000 Sizing, Selection & Installation of PressureRelieving Devices in Refineries

4. API 520 (Part-2) – 2003 Sizing, Selection & Installation of PressureRelieving Devices in Refineries

5. API 521 – 1977 Guide for Pressure Relieving &Depressuring Systems

6. IS:6533 (Part-1) – 1989 Code of Practice for Design and

Construction of Steel Chimneys,Mechanical Aspects

7. IS:6533 (Part-2) – 1989 Code of Practice for Design andConstruction of Steel Chimneys, Structural

Aspects

B. MECHANICAL

1. IS:1239-1990, Part-1 Mild steel tube, tubulars and other wrought steel fittings

2. IS:3589-2001 Seamless or electrically welded steel pipesfor water, gas & sewage

3. IS:1978-1982 Line Pipe (Second revision) (Amendment 1)

4. ASTM A-106 – 1999 Seamless carbon steel pipe for hightemperature service

5. ASTM A-182 – 1998 Forged or rolled alloy steel pipe flanges,forged fittings, and valve parts for hightemperature service

6. API 5L-1995 Specification of line pipe

7. IS:1239 (Part II) – 1992 Mild steel tube, tubulars and wrought steel

fittings8. ASME B 16.9 – 2001 Wrought steel butt welding fittings


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9. ASME B16.11 – 2001 Forged steel fittings socket welding andthreaded

10. ASTM A 234 – 1997 Piping fittings of wrought carbon steel andalloy steel for moderate and elevatedtemperatures

11. ASME B 16.5 – 1996 Steel pipe flanges and flanged fittings

12. ASTM A-105 – 1998 Forgings, carbon steel, for pipingcomponents

13. IS:6392-1971 Steel pipe flange

14. IS:778-1984 Copper alloy gate, globe and check valvesfor water works purpose

15. IS:14846-2000 Sluice valve for water works purpose

16. IS:5312(2) – 1986 Swing check type reflux (non-return) valves

17. IS:2712-1998 Compressed asbestos fibre jointing

18. IS:2002-1992 Steel plate for high and mediumtemperature service for boiler use

19. IS:2062-1999 Steel for general structural purpose

Documents

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