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Specs For NG - MFO Fired Thermal Oil Heater
Specs For NG - MFO Fired Thermal Oil Heater
Specs For NG - MFO Fired Thermal Oil Heater
Project
Mott MacDonald, Sequis Centre, 3rd Floor, Jalan Jenderal Sudirman Kav.71, Jakarta, 12190, Indonesia
T +62 21 252 6588 F +62 21 252 6592 W www.mottmac.com
GCR Oleo Chemicals Project
Specification for NG/IFO/MFO fired Thermal oil Heater
This document is issued for the party which commissioned it and We accept no responsibility for the consequences of this
for specific purposes connected with the above-captioned project document being relied upon by any other party, or being used
only. It should not be relied upon by any other party or used for for any other purpose, or containing any error or omission
any other purpose. which is due to an error or omission in data supplied to us by
other parties.
Contents
1 Introduction 1
1.1 The Client _________________________________________________________________________ 1
1.2 The Project ________________________________________________________________________ 1
1.3 Site particulars _____________________________________________________________________ 1
1.4 Definitions_________________________________________________________________________ 1
2 Scope 3
2.1 Scope of Work _____________________________________________________________________ 3
2.1.1 Vendor’s Scope ____________________________________________________________________ 3
2.1.2 Brief system description ______________________________________________________________ 3
2.2 Owner’s scope _____________________________________________________________________ 4
2.3 Scope of Supply ____________________________________________________________________ 4
2.3.1 Owner’s scope of supply _____________________________________________________________ 4
2.3.2 Vendor’s scope of supply _____________________________________________________________ 4
2.4 Exclusions ________________________________________________________________________ 4
2.5 Mandatory spares and special tools _____________________________________________________ 4
2.6 Commissioning Spares_______________________________________________________________ 4
2.7 Two years operational spares _________________________________________________________ 4
2.8 Scope for Electrical__________________________________________________________________ 4
2.9 Scope for Instrumentation ____________________________________________________________ 5
2.10 Scope for Fire fighting _______________________________________________________________ 5
2.11 Scope of services ___________________________________________________________________ 5
3 Project Information 6
3.1 Battery limits _______________________________________________________________________ 6
3.1.1 Thermal Oil ________________________________________________________________________ 6
3.1.2 IFO/MFO (IFO-Industrial Fuel Oil; MFO-Marine Fuel Oil) _____________________________________ 6
3.1.3 NG ______________________________________________________________________________ 6
3.1.4 Flue gas __________________________________________________________________________ 6
3.1.5 Instrument Air ______________________________________________________________________ 6
3.1.6 Nitrogen __________________________________________________________________________ 6
3.1.7 Compressed Air ____________________________________________________________________ 6
3.1.8 Electrical __________________________________________________________________________ 6
3.1.9 Area Classification __________________________________________________________________ 6
3.2 Conflicting requirements ______________________________________________________________ 6
3.3 Qualification Criteria _________________________________________________________________ 6
3.4 Bid submission _____________________________________________________________________ 7
4 Technical Specifications 8
4.1 General___________________________________________________________________________ 8
4.2 Applicable standards and codes ________________________________________________________ 8
4.2.1 General Material Grades _____________________________________________________________ 9
4.3 General requirements _______________________________________________________________ 10
5 Technical details 14
5.1 Specific details and requirements ______________________________________________________ 14
5.1.1 Multiple Fuel Fired Thermal oil Heaters _________________________________________________ 14
5.1.2 Emission Limits ___________________________________________________________________ 15
5.1.3 Associated equipment / items_________________________________________________________ 15
5.2 General specifications ______________________________________________________________ 19
5.2.1 Thermal oil Heater - Shell and Furnace _________________________________________________ 19
5.2.2 Fuel Firing System _________________________________________________________________ 20
5.2.3 Fuel handling system _______________________________________________________________ 20
5.2.4 Pipes for Thermal oil and Fuel ________________________________________________________ 20
5.2.5 SPM arresting / SOx -NOx monitoring system ____________________________________________ 21
5.2.6 Instruments and Control System ______________________________________________________ 21
5.2.7 Instrument standards and codes ______________________________________________________ 22
5.2.8 Electrical Scope of supply (not limited to) ________________________________________________ 23
5.2.9 Electric Panel _____________________________________________________________________ 23
5.2.10 Electrical standards ________________________________________________________________ 24
6 Safety 26
6.1 LOTO – policy statement ____________________________________________________________ 26
6.1.1 Procedure ________________________________________________________________________ 26
6.1.2 Terms and definition ________________________________________________________________ 26
8 Preparation of shipment 32
8.1 Packing__________________________________________________________________________ 32
8.2 Shipping _________________________________________________________________________ 32
13 Spare requirements 41
1 Introduction
PT Energi Sejahtera Mas (hereafter as Client or Sinar Mas or ESM) is a privately held subsidiary of PT
Ivo Mas Tunggal which in turn is directly owned by Sinar Mas Golden Agri Resources, the flagship
entity of Sinar Mas Group (Sinar Mas) dealing in palm oil plantation and production in Indonesia.
Sinar Mas, through its subsidiaries, is the world’s second largest palm oil plantation company with a
total planted area of 455,800 hectares and has integrated operations focused on the production of
palm-based edible oil and fat.
The factories and plantations under the Group’s plantation division are located in North Sumatera,
Jambi, Riau, Bangka, Central Kalimantan, East Kalimantan and South Kalimantan; while the factories
under the refinery division are located in Surabaya, Medan, Tarjun and Jakarta
Currently, the Group has installed capacity of 1.38 million tonnes of crude palm oil per annum and four
kernel crushing plants with total capacity of 444,000 tonnes of palm kernel per annum
1.4 Definitions
For the purposes of this document, the following definitions shall be used.
Consultant Mott MacDonald Pvt. Ltd who is responsible for project management, engineering,
Procurement assistance
Contractor The party to the Contract with the Company who is responsible for the
Procurement, Construction and other related works specified in the Contract.
Mfg / Supplier The party responsible for design, manufacture and/or supply of equipment/plant
and services to perform the duties specified by the Consultant or company.
Vendor The term “Vendor” is considered to be synonymous with the term Manufacturer /
Supplier.
2 Scope
Thermal oil system (Thermal Oil Heaters) shall be designed keeping in mind flexibility of operation. In
normal conditions both plant shall supply to individual process user plants – Fatty Alcohol and Fatty
Acid plant which need approx. 12,040,000 Kcal/hr energy, while in other likely situation either heater
shall be able to supply any process plant. Hence, it is proposed to install 3 x 14,000 kW
(Approximately 3 x 12,040,000 Kcal/hr) capacity plants (2 w + 1s) all interconnected.
It is important to mention here that it is not the intent of this specification to completely specify
all details of design and manufacture for the packaged system. Nevertheless, the system and its
equipment shall conform to high standards of design, engineering and workmanship in all
respects and shall meet all the requirements of relevant codes. Compliance to this specification
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shall not relieve the equipment manufacturer/supplier of the responsibility of supplying the
equipment’s and auxiliaries of proper design, material and workmanship to meet the operating
requirements specified in the datasheet / design basis. In case of requirements of additional
instruments, controls, safety devices and any other auxiliaries for safe, smooth and trouble free
operation of the equipment, the equipment manufacturer / supplier shall include the same in his
scope of supply.
2.4 Exclusions
Nil
3 Project Information
3.1.3 NG
At the Inlet flange of Natural gas Burner trains for TFH system. The nozzle at battery limits shall be
ASA-150# RF, Drilled to ANSI B 16.5
3.1.6 Nitrogen
At one point in the TFH plant. The nozzle at battery limits shall be 300# RF, Drilled to ANSI B 16.5
3.1.8 Electrical
380±5%,V, 50 ± 3% Hz, 3 phase AC at the terminals of panel
purity and other relevant parameters and at least FIVE (5) of these packages shall have completed the
continuous trouble free operations of a minimum 8000 Hrs. as on the bid due date in the last three (3)
financial years. Vendor to give documentary evidence (confirmation from the purchaser).
The vendor shall have full-fledged service support set-up in Indonesia or have appropriate
arrangements for the same with the established local reputed company.
The offered packages shall be of proven make from the existing production range of package
manufacturer and must meet performance requirement as stated in the specifications.
The vendor shall be required to submit the documentation and proof for above requirements and
purchasers may at his discretion make additional checks for the same.
Vendor to furnish their sub-vendor’s list for components outsourced. Vendor shall obtain prior approval
of Purchaser/ consultant by furnishing Proven Track Record (PTR) of proposed sub-vendors.
Please note that the owner/ purchaser reserve the right to reject any or all the vendors and accept
complete or partial bids without assigning any reasons thereof.
4 Technical Specifications
4.1 General
The package shall be designed, manufactured, tested and supplied strictly in accordance with API/ASME
codes and other applicable standard specifications
Standard Description
IEC-60034 5 Electrical protection
IEC -60034 7 Classification of types of construction, Mounting arrangements and terminal box
position
ISO 5199 Pumps
Indonesian-Earthquake Code Criteria for Earthquake resistant design
ANSI B 31.3 Chemical Plant and Petroleum Piping
API-682 Shaft sealing systems for centrifugal and rotary pumps.
API-671 Special purpose couplings for Refinery service
OSHA Noise control
EPA and EU Regulations Noise control
ISO 1940 Vibration limits for rotating machines
ATEX 94/9/EC Equipment and Protective Systems
Heat exchanger shall include ASME “U” stamp and nameplate certifying compliance with ASME section
VIII, division 1 code for unfired pressure vessels.
Generally, the materials and workmanship of the goods to be supplied in Bills including materials and
equipment which will be purchased shall comply with the appropriate International Standard (ISO) or in
specific cases the German (DIN) or British Standard (BS) or Code of Practice (CP) or Euronorm (EN).
All suppliers of goods and materials that are referred to above shall be certified to ISO 9001 or EN
29001
Other authoritative standards which ensure an equal or higher quality than the standards and code
specified will be subject to the Engineer’s prior review and written approval. Differences between the
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standards specified and the proposed alternative standards must be fully described in writing by the
Contractor and submitted to the Engineer at least 28 days prior to the date when the Contractor
requires the Engineer’s approval.
The Contractor shall obtain and keep on site at least one copy of the standards and codes of practice
that are referred to in the specifications, or approved above, and of each other standard which applies
to materials which are being supplied to, or workmanship which is executed on the Works. Copies of
these codes and standards shall at all times be available for inspection by the Engineer.
All standards used will be the current version as available at the date of signing of the Contract. A
Contractor proposing to use alternative versions of specified codes and standards shall submit the
alternative version to the Engineer for approval in accordance with the requirements outlined in the
above paragraph.
All materials and workmanship not fully specified herein or covered by an approved standard shall be of
such kind as is used in first class work and suitable to the climate in the project area.
Where the requirements of any such standard specification or regulation conflict with the requirements
of this specification or any item on the drawings, then the Contractor should refer to the Engineer for
clarification before proceeding with that section of the works.
Codes and Standards ISO, EN, IEC, BS, ANSI, ASTM, AASHTO or DIN codes and standards of the
latest edition shall be part of this specification. In all cases EC standards will be acceptable. Standards
of other nationalities will be acceptable subject to the approval of the Employer where they can be
demonstrated by the Contractor to be at least equal to, or more stringent than the equivalent specified
standards.
Electric Regulations: The whole of the work shall be carried out in accordance with the latest edition of
the Regulations issued by the Institution of Electrical Engineers.
Where the latter conflict or are inconsistent with the former then the latter shall take precedence.
The Contractor shall also comply with any regulations necessary to enable full insurance cover to be
effected and with any local conditions or by-laws.
4.3.7 Fixing:
With the plant shall be provided all necessary supporting steelwork, holding down bolts, cleats, fixings,
etc., whereby it shall be secured to the structures, the cost of which shall be included in the prices of
the items with which they are associated
to identify them relative to numbers or letters shown on their circuit diagrams. All terminals shall be
numbered with the terminal number or conductor ferrule number as appropriate to the wiring system
adopted so that wires may be correctly reconnected without reference to drawings.
Externals labels shall be engraved on black plastic with light infill and shall be secured by non-ferrous
screws.
Internal labels may be similar to external labels or may be painted and varnished. Adhesive labels shall
not be used.
4.3.13 Samples:
The Contractor shall provide the Engineer with samples of Material necessary for testing in accordance
with the Contract. Unless expressly excused, the Contractor shall also provide samples of all
manufactured items required for the Works.
Alternatively the Contractor shall submit trade literature where the provision of samples, in the first
instance and as agreed by the Engineer, is impracticable. All samples rejected by the Engineer shall be
removed from the Site.
All approved samples shall be stored on Site by the Contractor for the duration of the Contract, and any
materials or manufactured items subsequently delivered to the Site for incorporation in the Works shall
be of a quality at least equal to the approved sample.
4.3.15 Galvanising:
Unless specified otherwise hereafter in the Specifications, where items of plant are required to be
galvanised they shall first have all weld spatters, mill scale, and other adherents removed after
fabrication and then they shall be pickled, washed and hot dipped galvanised. The deposition rate shall
be a minimum 460 gr/m2
All parts shall be treated after galvanising in order to minimise discolouration. Where galvanised items
have been cut or damaged on site, the Contractor shall immediately make good the damage to the
galvanising or to the cut edge by means of an approved zinc-rich cold galvanising paint. the paint shall
be applied strictly in accordance with the manufacturer's instructions and to the approval of the
Engineer.
Repairs to damaged items shall only be carried out with the express permission of the Engineer.
5 Technical details
J Make up pump *
1 Quantity *
2 Make *
3 Capacity *
4 Type *
5 Motor Kw / RPM *
6 Maximum Temperature handling capacity *
7 Mechanical seal *
K Booster Pump
1 Quantity *
2 Make *
3 Capacity *
4 Type *
5 Motor kW / HP *
6 Mechanical seal *
L Temperature control loop for ( Mixing Hot Oil with Cold Oil) to
maintain + 2 Deg.C of Hot Oil at the outlet – independent for each
unit)
1 Type
2 Capacity
3 Maximum Temperature handling capacity
As far as possible Heater unit/equipment shall be skid mounted construction – as ready to install and
hooking up at terminals only.
Thermal oil Heater Unit/ associated equipment shall be so designed that all components are easily and
conveniently accessible for observation/maintenance/replacement.
Maintenance platform with access ladder shall be provided, wherever applicable.
Thermal insulation along with protective covering shall be provided as needed on equipment’s as well
as Thermal oil piping within battery limits.
All interconnecting fuel piping (with heating system) shall be in vendor’s scope.
5.2.6.2 General
Vendor shall supply PLC based system with HMI and PLC-PC interface with Audio-visual alarms and
having compatible hard wares and software.
PLC shall be open platform type. Burner firing sequence and process control shall be through PLC
only(No Black Box Type system control envisaged/accepted)
Redundancy shall be observed regarding Processor, Communication and Power supply w.r.t. control
system.
All I/O controls shall be isolated.
Operation logics and sequence control write up shall be furnished by Vendor.
Control System shall be supplied with software editing/viewing facility.
All control system software licence shall be in Client’s name.
Oxygen analyser at Flue gas outlet shall be considered.
An Integrated system to measure and record Enthalpy flow out of the system with Data Logger
On line Flow recording/measuring system for fuel feeding system to measure and maintain efficiency of
the Thermal oil heating system.
All ID Fan/FD fans shall be provided with VFD which shall be operating through PLC working on
feedback from various pressure transmitters and temperature transmitters for efficient pressure control
within the furnace and throughout the flue gas system and thus saving energy costs.
All control system shall be based on feedback basis.
Integrating voltage shall be 24VDC (redundant).
An efficient fine-tuned temperature control system to maintain Heater outlet oil temperature within the
range of + / - 2 Deg. C. The system shall have PID controller and operate the flow control valve (with
sparger pipe between common inlet header and outlet header)on various inputs from furnace to mix
return cold oil with Thermal oil and thus maintain the Thermal oil temperature within the required band.
This shall be achieved by booster pump integration with control loop.
All necessary controls for safe and efficient operation of the Thermal oil Heater unit.
In addition to above and other standard safety interlocks, following minimum interlocks must be
included:
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– Fuel cut off in case of low oil flow/Circulation pump failure(motor interlock)
– Fuel cut off in case of flame failure
– Heater operations interlock NG transfer.
– Low system pressure switch to shut down the system
– Firing not to start unless Thermal oil circulation is on/Low level in Expansion tank
– Temp controller for Thermal oil and firing control
– High temperature safety switch interlock at heater outlet shutdown and alarm signal
– 2 Nos. Pressure Safety valve at Thermal oil terminals of the heater unit shall be provided.
– Thermal oil dump down system in case of Power failure/no flow situation.
– Redundant Pressure switches for No flow/Low flow condition
– High stack temperature
– Low / High Thermal oil Temperature
Emergency shutdown or Plant Safety Shutdown control system shall be provided.
All the Instruments shall be supplied with proper test certificates/warranty certificates.
All pressure gauges supplied shall be glycerine filled. The minimum gauge size is 6” dial size, 25 NB
end connection and SS-316 bourdon tube.
Mercury filled thermometers are not acceptable. The minimum temperature size is 6” dial size, 25 NB
end connection, and SS-316 bourdon tube.
Thermometers and temperature gauges shall be furnished with 300 series SS solid bar thermo well.
Rota meter shall be Metal Tube Type, flange rating as applicable.
SOV shall be operated by 24V DC, insulation class shall be F, port size of ½”, housing as per area
classification.
Instrument control valves shall be Plug type only.
All Transmitters shall be SMART (FF/HART) type.
All Restriction orifice /Automatic Operated Valves etc. shall be supplied with Test certificates/Sizing
datasheets.
On/Off valve, Control valve shall be designed as per max shut-off and back pressure design.
Pneumatic actuator shall be designed with Instrument Air pressure - 5.0 Kg/cm2 (G) with local Open-
close indication.
The following locally mounted gauges are required, as a minimum:
– Temperature/pressure at strategic locations throughout Thermal oil path.
– Temperature/pressure at strategic locations throughout air/flue gas path.
Relief valves:
– The vendor shall furnish the relief valves that are to be installed on equipment or in piping that the
vendor is supplying. The relief valves shall be ASME certified, and meet the limiting relief valve
requirements defined in API RP 520, Parts I, II, and API STD 526. The vendor's quotation shall list
all relief valves and clearly indicate those to be furnished by the vendor. Relief valves shall be
made of steel only. Relief valves shall be mounted to piping and vessels by extra heavy wall
piping/connections, and the distance between the relief valve and vessel shall be minimized.
Welded braces or gusseting ribs on the extension piping (if any) are required.
– Outlet of all relief valves mounted on Hot Oil Header shall be connected to a common header and
diverted to drain tank for safety reasons.
− (Power cable up to 16 sq. mm shall be of copper conductor and above 16 sq. mm shall be of
Aluminium conductor).
− Power cable shall be sized considering de-rating for ambient, steady state voltage drop of 5% &
starting voltage drop of 15% max.
− Control cables shall be shielded Multicore copper conductor of minimum 2.5 sq.mm.
6 Safety
6.1.1 Procedure
This policy contains procedures for the service and maintenance of equipment and machines where the
unexpected energization or start-up could cause injury to employees/users.
Caution: The following situations are not subject to the procedures outlined in this document:
Work on plug and cord type electrical equipment, for which exposure to the hazards of unexpected
energizing, start up, or the release of stored energy of the equipment is effectively controlled by the
unplugging of the equipment from the energy sources and by the plug being under the exclusive control
of the employee/user performing the servicing or maintenance.
Hot tap operations involving transmission and distribution systems for substances such as gas, steam,
water, or petroleum products when they are performed on pressurized pipelines provided that it is clear
that continuity of service is essential, shutdown of the system is impractical, and documented
procedures and special equipment are implemented which will provide proven and effective protection
for employees/users.
Service or maintenance that takes place during normal production operations, such as lubricating,
cleaning, and making minor adjustments and simple tool changes, except when an employee/user is
required to place any part of his/her body into an area on a machine or piece of equipment where work
is actually performed upon the materials being processed (i.e., point of operation) or where an
associated danger zone exists during a machine operating cycle.
Each unit is responsible for the development of specific energy control procedures for each machine or
other equipment within its respective areas of responsibility.
Authorized Employee/User: A person who locks out or tags out machines or equipment to perform
service or maintenance on that particular item. An affected employee/user becomes an authorized
employee/user when that employee's duties include performing service or maintenance on machines or
equipment covered under this policy.
Blocking Tag - A tag-out device that indicates the use of chains, wedges, key blocks, adapter pins, or
self-locking fasteners for isolating, securing or blocking of equipment from energy sources.
Energy Isolating Device - A mechanical device that physically prevents the transmission or release of
energy, including but not limited to, the following: a manually operated electrical circuit breaker; a
disconnect switch; a manually operated switch by which the conductors of a circuit can be
disconnected from all ungrounded supply conductors, and, in addition, no pole can be operated
independently; a line valve; a block; and any similar device used to block or isolate energy. Push
buttons, selector switches and other control circuit type devices are not energy isolating devices.
Going Through a Tag - A procedure in which a piece of equipment or machinery is started when the
lockout/tag-out procedure is in place.
Hot Tap - A procedure used in repair, maintenance, and service activities that involves welding a piece
of equipment (pipelines, vessels or tanks) under pressure to install connections or appurtenances.
Lockout - The placement of a lockout device on an energy isolating device according to an established
procedure; this ensures that the energy isolating device and the equipment being controlled cannot be
operated until the lockout device is removed.
Lockout Device - A device that uses a lock, either key or combination type, to hold an energy isolating
device in a safe position and prevent the energizing of a machine or other equipment. Included are
blank flanges and bolted slip blinds.
Normal Operations - The utilization of a machine or other equipment to perform its intended function
OSHA – Occupational Safety and Health Administration, an agency in the Department of Labor.
Develops and enforces Occupational safety standards.
Owner's Representative - An individual who represents the Client in all aspects of:1) A project when
dealing with a contractor; 2) A lease agreement when dealing with a vendor. Caution: Some leases
may define these owner's representatives as "contact persons" or "program directors servicing and/or
Maintenance - Work place activities such as constructing, installing, setting up, adjusting, inspecting,
modifying, and maintaining and/or servicing machines or other equipment. These activities include
lubrication, cleaning or unjamming of machines or other equipment and making adjustments or tool
changes, where the employee/user may be exposed to the unexpected energization or start-up of the
equipment or release of hazardous energy.
Tag-out - The placement of a tag-out device on an energy isolating device, according to an established
procedure, to indicate that the energy isolating device and the equipment being controlled may not be
operated until the tag-out device is removed.
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Tag-out Device - A prominent warning device, such as a tag and a means of attachment, which can be
securely fastened to an energy isolating device according to an established procedure, to indicate that
the energy isolating device and the equipment being controlled may not be operated until the tag-out
device is removed.
7.2.1 At shop
Physical inspection, verification of material test certificates etc.
G.A. dimension and visual inspection for quality of workmanship.
Review of inspection & test reports, material T.C. and T.Cs of bought out items.
Witnessing of various pressure / leak testing
Hydrostatic test of all pressure vessel followed by drying of equipments & piping by passing air.
Sequence test of control panel with PLC. Client shall inspect Control system and Panel as and when
ready.
No load test.
Mechanical run of the fan in installed condition to ensure that vibration levels, currents, noise level and
bearing temperatures are within permissible limits
7.2.2 At site
After erection of the Oil Heating System, the performance test of the same shall be taken in accordance
with industry standards and the following parameters are to be checked.
Thermal oil temperature & ∆T
Capacity of Oil Heater (kw)
Power consumption
Performance guarantee test at site as per order specification
Performance run shall be done on non-stop (continuous) basis for 48 hours trouble-free working
without any stoppage. In case of any repair /adjustment in the system, fresh performance runs to be
done.
7.3 Testing
Pressure containing parts such as vessels, heat exchangers, tanks, piping etc. shall be hydrostatically
tested with liquid at a minimum of 1.5 times the maximum allowable working pressure, but not less than
20 psi (1.4 bar gauge). Where applicable, the tests shall be in accordance with ASME code. In case the
inspection and testing is required to be carried out at OEM’s Works, the cost of the same shall be
included in the total price.
all indicators, selectors, controllers, alarm and fault protection equipment shall be demonstrated, if
necessary, by fault simulation. During the run test the unit performance (of flow/ pressure/ temperature/
power), noise and vibration shall be checked.
Mechanical Running Test.
– The Fans shall be operated for 4 hours at rated speed consisting of 2 hours of progressive loading
on a minimum of 2 continuous hours at the rated discharge pressure level and full load.
– All heaters and system joints and connections shall be checked for tightness, and any leaks shall
be corrected prior to the tests.
– All warning, protective, and control devices shall be checked and adjustments shall be made as
required.
– During the running test, the mechanical operation of all equipment being tested shall be as per
design.
– If replacement or modifications of bearings, valves or packing or dismantling of the machine to
replace or modify other parts is required to correct mechanical or performance deficiencies, the
initial test will not be acceptable, and the final shop tests shall be run after these corrections are
made.
All exposed surface shall be appropriately painted to prevent against corrosion / rusting, as applicable.
All opening shall be blanked off suitably before dispatch.
Item tag no. shall be prominently marked / painted.
All loose parts / items shall be provided with proper identification and tag nos.
Items shall be packed suitably to prevent against damage / loss during transit.
Delicate parts (if any) shall be packed separately.
8 Preparation of shipment
8.1 Packing
All packing shall be carried out after satisfactory inspection and testing of the package. In the case of
witnessed inspections' this is subject to receipt by the Vendor of the Release Note for Shipment.
Equipment shall be cleaned and dried before preservation is commenced.
Equipment shall be suitably prepared for the type of shipment specified. The preparation shall make the
equipment suitable for 6 months of outdoor storage from the time of shipment, with no disassembly
required before operation, except for inspection of bearings and seals.
Exterior surfaces, except for machined surfaces, shall be given at least one coat of the manufacturers’
standard paint. Exterior machined surfaces, including shafts, shall be coated with suitable rust
preventive.
All interior areas of crankcases and carbon steel oil systems auxiliary equipment such as reservoir,
vessels, and piping shall be coated with suitable rust preventive. The compressor casing inner diameter
shall be protected by non-combustible rust preventive.
Flanges shall be blanked-off with wooden discs, in which the nuts of the studs are to be embedded
All flanged and threaded openings shall be provided with gasketed metal closures or steel plugs.
The ends of small pipes shall be provided with plastic caps and sealed with tape.
8.2 Shipping
Each unit shall be boxed in a seaworthy close-boarded case with a waterproof lining.
Initial spares shall be packaged in a separate rigid box, which shall be placed in the case containing the
main equipment.
Transport to site will be via truck over extremely rough terrain. Therefore goods shall be packed
/delivered in such a way as to withstand the severe road conditions in Indonesia, which include
unpaved poorly graded roads.
9.1.1 General
This specification describes a general outline for the installation of the equipment involved. The field
circumstances shall be taken into consideration and methods suitable to the site conditions shall be
adopted in consultation with the Engineer-in- Charge. The vendor shall employ only such workers and
supervisors who have considerable experience of similar work and with adequate technical skills.
All bolts, anchor bolts, nuts, lock washers, other fasteners, supports and other miscellaneous items
shall be supplied by the vendor.
Drilling and tapping of holes in base plates, fixing of couplings on shaft after enlarging the pilot bore to
correct size with keyways etc. and doweling including provisions of dowel pins or similar arrangement
for retaining the alignment shall be carried out by the Vendor with utmost care.
All joints shall be assembled without undue stresses. Flanges must be parallel and correctly aligned.
Wherever necessary remove the anti-corrosive coating applied on the machine/equipment by the
vendor, carefully and completely with light oil/ Equivalent.
On the chipped and prepared foundation surface, the vendor shall set up liners for installation and
maintain center of equipment. Liners shall be so arranged that the load of equipment is uniformly and
exactly distributed to the foundation. Liners shall be placed as near as possible to both sides of anchor
bolts. Where distance between anchor bolts is too long additional liner shall be set up in between. The
height of each liner shall be measured on the basis of standard level bench mark. The liners shall be
fixed with appropriate grouting material.
The vendor shall assemble, couple, fix, fit, install, level, align and grout the equipment/materials on
foundations, structures, platforms, floors etc., as the case may be. He shall bolt, weld, cut, drill, rivet
and brace all components and fix them rigidly with one another on the foundation supports, etc.
All necessary shims scaffolding, temporary supports, staging, grouting cement, sand, etc., required for
erection of the equipment shall be kept ready in advance.
Unless specified, 6 copies each of following documents shall be submitted at the stages defined,
except for the bid stage, wherein 2 copies are required.
The bidder would need to specify the timeline when the documents requiring approval would be
submitted in the PERT chart. Bidder also to include timeline for resubmission of final drawings
incorporating all comments.
The contractor to note that any routing of services and axillaries falling in The contractor’s scope of
supply, outside the skid boundary and interfacing with the client facilities, such as cable routing, piping,
etc would need to be first proposed in a general arrangement drawing for client’s approval
Table 12.1:
13 Spare requirements
The Vendor shall include a list of recommended spare parts for following
– Commissioning start up and initial operation
– Normal operations
– Two years trouble free operations
This list shall state the price of all spare parts.
The lists shall be available in advance of shipment in such a time to enable Company to commit for the
required spares in time for being available at site before start-up of the unit. Vendor shall allow 2-month
processing of the list.
The spares procured in the scope of supply shall be as indicated on the data requisition sheet(s).
NOTE: Vendor to obtain prior approval of MM/Client for any other sub-vendors not listed above before
placement of orders on sub-vendors.
Appendix A. Enclosures
Annexure A: Perman LH no. 07 Tahun 2007.
312700-PFC-0010-01.