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Project Specification For Sambu Project R0 20130416 PDF
Project Specification For Sambu Project R0 20130416 PDF
Project Specification For Sambu Project R0 20130416 PDF
PROJECT SPECIFICATION
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TABLE OF CONTENTS
CONTENTS
B2. Building
B3. Utilities
B6. Structure
B8. Electrical
B9. Instrumentation
B11. Painting
C3. Tankage
C4. Piping
A1.1 General
The Contract for the Works consists of, among others, the Conditions of Contract and
this Project Specification. As part of the Contract, the Project Specification, which is
subordinate to the Conditions of Contract, provide the basic information for the facilities
of the Vopak Terminal Merak Project Sambu Expansion Facilities, including Contractor’s
services and technical requirements that Contractor shall satisfy in accomplishing the
work.
The content of the Project Specification is to provide basic information for the Project
Sambu Expansion facilities including requirement applicable to mechanical features,
construction materials and Standard Specifications which defined the minimum
acceptable mandatory technically related requirements for the various parts of the Work.
Vopak Standard Specifications and all Applicable Codes and Standards are considered
an integral part of this Project specification. Contractor can propose better design in order
to achieve most efficient design without compromising safety / maintenance / operation /
reliability / availability.
This Project Specification specifies in general terms of the scope of the Works. Work
items are summarized under various sections but not limited to the same. Contractor’s
scope shall include detailed design engineering, government submission, procurement of
equipment, electrical & instruments and all necessary materials, construction, testing and
commissioning and performance of all other services, works, etc., that are not
categorically listed herein but are required to be carried out by the Conditions of Contract,
Project Specifications, applicable codes and regulations. Contractor is advised to
thoroughly study all documents and specifications to determine the total scope of work.
Contractor shall comply with the Project Specifications, including all applicable codes and
standards, Agreement and all the cross-references therein unless otherwise specified by
Employer. In case of conflicts, deficiencies, omissions, ambiguities in or between the
various specifications, Contractor shall seek Employer’s decision that shall be final.
Contractor shall comply with Employer’s decision at no additional cost to Employer.
Contractor is advised to resolve all ambiguities within and contradictions between the
Project Specifications, including applicable codes, standards and the cross-references
therein with Contractor before signing the Contract.
All Project Specifications and the cross-references therein which are required by the
scope of the Works shall be deemed as applicable and where there are differences, the
more stringent shall apply. Contractor shall comply with these Project Specifications and
the cross references therein with no additional charge to Employer. Contractor is advised
to thoroughly study the scope of the Works and if Contractor finds that the attached
specifications do not sufficiently cover the scope of the project, Contractor must seek
clarification from Employer. All materials, equipment etc. supplied must be suitable for
marine environment.
Where “Future” is marked in the Project specification or Drawings, the item so marked is
not to be included in the Works but planning of layout, additional electrical loads catered
in current design/ calculation and space shall include provision of these future facilities. In
the case of “Future Piping System”, engineering of the piping layout has to include these
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“Future Piping System”. However, in addition to the specific clauses, general allowances
including the size of the items or attachments for future connections through the use of
pipe flanges or structural cleats shall be considered.
The Project Sambu expansion facilities will contain facilities for 1 new chemical tank pit
06. Tank pit 6 will be used for MEG/AA storage tanks. A total of five new tanks will be
3
built adding a total capacity of 11,500 m . There will be 3 tanks for MEG (1x3000 m3
SS304L, 1x2000 m3 SS304L and 1x2000 m3 SS316L). There will be 2 tanks for Acetic
Acid. One Acetic acid tank out of the two will be used as an industrial tank for Amoco
Mitsui Indonesia (AMI). Future expansions for the other 2 tank pits 7 & 8 are catered as
well in the plot plan.
a. Utilities at Terminal
MCC-3 (Existing)
Plant air / Instrument air
Nitrogen
Fresh water
Waste water/ slop system
Fire fighting system
The works to be performed by Contractor shall include but not limited to the following:
b. Procurement including:
Supply of materials, equipment and spare parts for commissioning and start up,
inclusive of consumable for commissioning and testing e.g. fuel, lubricants etc.,
before Employer’s approval.
All costs related to procurement and delivery of equipment and material to the
construction site.
c Construction including:
e. Contractor shall furnish, before the Works are taken over, three (3) sets of operating
and maintenance manuals in English Language, the as-built drawings (in hardcopy as
well as Autocad version software), DCS/PLC logic diagrams and listing (hardcopy
and softcopy) of the works as completed, sufficient detail to enable to operate,
maintain, dismantle, reassemble and adjust all parts of the works. Unless expressly
agreed otherwise, the works is considered to be incomplete for the purpose of taking
over under the terms of contract hereof until such instructions and drawings have
been supplied to Employer.
Contractor shall furnish two (2) sets of CD containing electronic files of all drawings
and technical document related to the Works. The electronic file shall be in both pdf
and native format which is editable by VOPAK such as ACAD, Excel and MS Words.
f. Government Submission
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All necessary application fees to be paid to the Government Authorities in the course
of application and/or obtaining the approval shall be borne by Contractor.
All cost incurred for a resident engineer and/or Registered Technical Officer by
Contractor’s appointed professional engineers shall be borne by Contractor.
Accredited Checker shall be appointed by Contractor and to borne the cost incurred if
required.
g. Contractor shall provide a list of assets value detailed breakdown for all equipment of
the Works upon project completion before Commissioning. The total sum of the
assets breakdown shall be equal to the total EPC lump sum price. VOPAK will
provide the format of Terminal assets breakdown list to Contractor in due course.
Contractor shall be responsible for the establishment and executive of a quality assurance
program to assure quality, reliability, and safety for the duration of the project.
Contractor’s quality assurance program shall apply to the activities for assuring materials,
equipment, and services comply with contractual, regulatory, and related requirements. These
activities include project execution, engineering, procurement, construction and commissioning
commencing with contract award and leading to mechanical completion of the project.
Contractor shall be responsible for maintaining the quality of welding at the required level by
means of having welder’s qualification tests.
The criteria for quality assurance shall include, but not limited to the following:
Drawings, documents etc. furnished by Employer are for the purpose of initially defining the
facilities. Any changes that affect the intent and/or overall configuration of the facilities must be
approved by Employer in writing, before implementation by Contractor. Drawings and data
presented herein, such as but not limiting to equipment sizing, layout, line sizing, to determine
the feasibility or correctness of data nor does the data incorporate final information of vendor’s
supplied equipment. Therefore, details shown are subjected to verification and adjustment by
Contractor as part of Contractor’s scope of work.
Contractor is responsible for its use of the data to the same level of responsibility if the
information was originally created and/or determined by Contractor.
Drawings, documents of similar equipment and facilities are given to the Contractor as
reference to the Work. These documents may be outdated, incomplete or otherwise not
reliable. Contractor is therefore advised to study and confirm at the site all the given information
prior to bidding. Thereafter, Contractor shall be responsible for any discrepancies, errors,
omissions, inaccuracies, etc. in the supplied information and hence, this shall not relieve
Contractor of his liabilities and obligation to perform and complete all works required by the
scope of the project.
Contractor shall at his own expense carry out any alternations or additional work which arise
because of such discrepancies, errors, omissions or inaccuracies, and update the drawings
and/or information accordingly.
Contractor is responsible for ensuring all engineering, procurement, and construction activities
are complete using the latest correct data. Detailed design and incorporation of it into the
construction of the facilities is part of Contractor’s scope of work.
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a. Meteorological Conditions
a.3 Wind
a.4 Rainfall
Peak surface acceleration for return period of 475 years is about 0.25g. Detailed
Analysis Site Response Spectra Report is compiled in separate document.
b Site Condition
b.3 Elevation
Refer to drawing for the relationship between Construction North and Geographic
North.
c. Utility Requirement
Pressure : 6 barg
Temperature : Ambient
Plant air is only utilized for air eductor while tank cleaning is required. Instrument
air is used for the terminal instruments, e.g ESV.
Pressure : 7 barg
Temperature : Ambient
Pressure : 7 barg
Temperature : Ambient
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Description Abbreviations
Area m², mm²
Density Kg/m³
Flow Rate m³/hr
Mass Flow Rate kg/hr
Heat value Joule
Heat transfer coefficient W/(m²)(° C)
Length mm, m
Linear Velocity m/sec
Liquid Concentration Wt%, wt ppm
Temperature °C
Thermal conductivity W/(m)(° C)
Time sec, min, hr
Pressure barg
Pressure (absolute) bar
Standard Gas Volume Nm³ at 0° C, 1.01325 bar
Surface tension N/m
Vacuum mbar
Volume m³, ltr
Weight kg, ton (metric)
Description Abbreviations
Bearing Capacity kN/m²
Force N
Stress N/mm², N/m²
Torque Nm
Description Abbreviations
Current A
Current density A/cm²
Frequency Hz
Power KW
Resistance ohm
Resistivity ohm/m³
Voltage V
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d.4 Language
The new Sambu expansion facilities at Vopak Terminal Merak shall be designed in
accordance with the latest edition of the following codes and standards and the latest
issued laws and regulations applicable in Indonesia.
Standard Specifications, available in this package, are also taken into consideration.
Refer to Appendix A
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This is the additional information for Contractor who might carry out work at site either
during the construction stage or commissioning phase. Contractor is advised to study
and confirm at the site all the given information prior to bidding. Thereafter, Contractor
shall be responsible for any discrepancies, errors, omissions, inaccuracies etc. in the
supplied information and such shall not relieve Contractor of his liabilities and obligations
to perform and complete all works required by the scope of the project after the award of
the project.
Contractor shall at his own expense carry out any alternations or additional work which
arise because of such discrepancies, errors, omissions or inaccuracies, and update the
drawings and/or information accordingly.
Contractor shall use its best efforts to carry out his own Project Management Services to
enable Employer to achieve its objective of economical and timely construction of the
project within the established time, cost, functional and quality requirements.
Employer’s Permit to Work System and other safety regulations shall apply to all the
works within Employer’s existing operational facilities only. None of the foregoing shall be
taken to absolve Contractor of his responsibilities to ensure compliance with this
requirement.
Contractors shall comply with the fire, safety and security regulations in VTS Banyan SHE
Handbook when working in Employer’s premises.
Employer shall have the right to withdraw the work permit and instruct Contractor to
evacuate his personnel from the work site.
Contractor shall carefully support and protect existing services such as piping, electrical
cables, or other services met with and shall notify Employer immediately of any such
services encountered in the course of the Work.
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Contractor shall be responsible for control of his vehicles/ equipment entering or leaving
the site, borrow pits and spoils area including supply and maintenance of traffic controls,
warning signs and lights.
Contractor shall be responsible for overall security of all plants and equipment in his site
against loss, thieves and pilferage.
A6.4.3. Security
Contractor shall provide its own security and guards at the construction site.
A6.4.4 Warehouse
Module units for field toilets with each having its own septic tank and leaching
field for sewage shall be provided by Contractor for use by their own employees
and employees of their sub-contractors. Contractor shall be responsible to
maintain it at acceptable hygiene level.
A6.4.7 Canteen
Contractor shall provide its own catering facilities for his own workers.
Subcontractors are to furnish their own power supply utilities and office facilities.
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A6.4.9 Water
A6.4.10 Fuel
Contractor shall provide diesel fuels and gasoline for construction. Diesel fuel
and gasoline shall be delivered by truck as required by Contractor. The supplier
will provide fuel storage per Indonesian codes. Secondary containment for all oil
products and chemicals shall apply to the site. Contractor must not supply fuel to
other users outside VTM.
Where applicable, Contractor shall submit a fire prevention and fire-fighting plan
for work being carried out at existing area and new area for Employer review. The
plan shall be co-ordinated with Employer existing plans and facilities until
Contractor’s work is turned over to the Employer. The plan includes:
Fire prevention surveillance and fire watch shall be available during ongoing
work that involves welding, burning or use of open flames.
Employer fire and safety personnel may suspend Contractor’s work if Employer
notice any hazardous, unsafe, unhealthy or environmentally unsound condition at
the work site. Work affected by the unsafe conditions shall not be resumed until
necessary steps have been taken to eliminate or rectify the condition.
Electrical power for the site office and lighting will be Contractor’s responsibilities.
Contractor shall provide their own electrical power for construction.
Contractor shall provide bottled gases for welding and testing requirements. At all
times, bottles shall be properly marked with contents and as to whether empty or
filled. Bottles shall be in upright position and secured. Unused bottles shall be
capped.
Contractor shall provide their own compressed air for construction works.
Contractor shall arrange with local haulers for dumpster container and pickup
from the site all combustible waste material. All waste shall be disposed off from
the project site to the mainland periodically periodically at approved dump site.
Construction materials and domestic wastes are to be segregated.
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A6.4.16 Sanitation
Contractor’s shall ensure that the worksite and premises occupied by his
personnel are maintained in a healthy, clean and sanitary condition. The
measures to be taken by Contractor shall include but not limit to the following:
Contractor shall also be responsible for the disposal of all other site wastes (i.e.
sewage, metals, oil, rags, cleaning fluids, aerosol cans etc.). Contractor’s waste
shall be disposed of in the same manner.
Storage, handling and disposal of all site chemicals will be in accordance with
Indonesia and Employer environmental requirements. This may require the
installation of a temporary process sump and disposal contract.
All chemicals brought to the site must be accompanied by Materials Safety Data
Sheet, MSDS. The site safety office will maintain a file of MSDS sheets.
A contract for pest control to comply with the local regulations and pass any
government inspections.
A6.5.1 Pre-Commissioning
When Employer accept custody and control of the systems. A procedure will be
developed by Contractor and Employer to accomplish work boundaries.
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A6.5.3 Commissioning
Contractor shall assist test running of the terminal under partial load conditions.
Contractor shall assist test running of the terminal under operating conditions.
Employer shall put the terminal into commercial operation. During all of the
commissioning, testing and commercial operation, contractor personnel shall
standby and assist Employer throughout the whole process.
The tank storage project systems will be startup by Contractor in this order:
Planning and construction of work during construction will use a Work Breakdown
Structure (WBS). The startup planning will use the following documents for system
startup sequencing:
a. Plot plan
b. P & I Ds
c. Equipment List
d. Piping line Index and Tie-in List
e. Instrument Data Base
f. Cable List
g. Electrical single line diagram
a. Fresh water
b. Nitrogen
c. Plant air/Instrument air
Flushing and cleaning, drying is required for all process lines before the plant introduces
products. All stainless steel tanks and pipelines shall be hydrotested with potable water
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and equipment will be flushed with demineralised water. Contractor shall supply all pre-
commissioning material, equipment, etc. to carry out all the flushing work.
Contractor shall:
a. Verify alignment on pumps and make final alignment check via laser for input into
the plant maintenance database. All flange alignment check for all product lines.
d. Install all fuses and overloads in the presence of the plant checkout group just
before commissioning. Turnover of the electrical systems shall be staged so that all
circuits shall be complete once the local control station is energised. No work shall
be allowed on the energised systems.
e. DCS equipment shall not be energised until all DCS cabinet wiring are completed.
The (+) cable will not be terminated until final loop checkout. When a field loop is
completed and turned over to the operations and checkout group, the loop
checkout is considered completed.
f. Calibration and testing of instruments and relief valves using procedure developed
jointly by Employer and Contractor.
Employer operating personnel will operate valves and switches during checkout as
required at their specific area of responsibility.
A6.8 Definitions
A6.8.2 Commissioning
Testing of the complete facilities before the tank is ready for introduction of
product and other normal operating gases and liquids in the pipelines.
Re-torque of bolts after the lines, vessels or equipment had been subject to heat,
IS NOT ALLOWED.
The point in time when tankage facilities are capable of being operated safely
although some trimming and insulation may still be needed. This occur after pre-
commissioning activities are completed.
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Tanks: within tolerance as per latest edition of API 650, from section 5.51 to
section 5.54.
Foundation: within tolerance as per section 5.5.5 of the latest edition of API
650, while the minimum height above pit level shall be more
than 75 cm measured near the shell of the tank after hydrotest.
Earth electrode test, electrical grounds and continuity check (require written
procedure from Employer’s electrical engineer)
Stroking: Check the operation of control valves and validate their control
room indicators.
Function Test: Verifying that all interlocks and protections programmed or set
is as per design.
Run/Burn in: A bench test of pump motors under load to check bearings.
Service Tests: Use of operating medium to test pipe systems (i.e. water, air).
Mechanical Testing shall be carried out in the presence of and to the satisfaction
of Employer. In the event that any section or portion fails to pass the tests,
Contractor shall promptly remedy the defect and repeat the tests. Upon
completion of these actions, commissioning activity begins.
For the purpose of carrying out the running tests, preliminary operation, normal
maintenance and supervision of the Works or Sections or Portions thereof that
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have been mechanically tested and any other work for preparing the Works or
Sections and Plant available for operation. Employer shall assist Contractor.
A system turnover procedure that identify those systems that now belongs to the
operations group for commissioning activities by attachment of a “BLUE TAG”
which states “FOR OPERATIONS PERSONNEL ONLY”. Construction work will
not permitted on these systems unless directed by operations. In the event, a
WORK PERMIT will be issued and a “GREEN TAG” attached to the system
stating “FOR CONSTRUCTION”. Upon completion of the work, the green tag will
be removed and the blue tag attached for operations.
A6.8.8 Startup
A6.8.9 System
A6.8.10 Turnover
The point in time when the owner accepts care, custody and control of a system
or combination of systems.
Contractor shall organise a system for construction files as construction progresses and
to assume responsibility for these files during the turnover phase. The field files shall be
organised by equipment piece number.
The documents will be accumulated and referenced by pipe line or equipment number.
Various reports shall be submitted on the project status weekly, monthly and overall for
safety, cost, schedule and quality. In addition, the following areas will require monthly
reporting to account for project status:
a. Contractor Reports
Schedule status
Contract cost/extra report
Quality rating/evaluation
Safety issues
Craft productivity measurement
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A6.10 Scheduling
The planning of the construction work shall be carried out jointly with Employer.
A6.12 Consultancy
Part B
The common facilities of the terminal comprise of the utilities (such as potable water, nitrogen,
plant air and dry air ), waste water and slop system, fire fighting system, pipe support, electrical
power supply, instrumentation and control.
B2. Buildings
N/A.
B3. Utilities
B3.1 General
The utility system includes potable water, plant air, nitrogen and instrument air.
The terminal is equipped with potable water piping network and source of potable
water shall be tapped from existing Merak Terminal.
The terminal is equipped with plant air piping network and source of plant air
shall be tapped from existing Merak Terminal.
The terminal is equipped with nitrogen piping network and source of nitrogen
shall be tapped from existing Merak Terminal.
The terminal is equipped with instrument air piping network and source of dry air
shall be tapped from existing Merak Terminal.
.
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B4.1 General
The wastewater refers to oil/chemical contaminated water, including spillage, water drain
from the storage tanks/pump strainer, waste water resulting from washing of tanks,
pipelines, safety shower, pigging station, and scrubber.
In areas where surface water would not be contaminated with, such as rainwater on road,
areas outside tank farm and pump station, etc, drainage system should be provided for
rainwater, domestic wastewater and sewage as per the local requirements.
The contaminated rain water to be checked before discharging into surface drains to the
sea.
Non-polluted rainwater shall be discharged into the surface drain and out to the water
outfall into the sea/river. Rainwater within the terminal could be discharged into the
common rainwater system if it is tested free from contamination.
The ground inside the tank pit shall be provided with scupper drain running along the
center of the main bunded area. The rainwater collected between the main bund wall will
be drained by the scupper drain to the main collection pit. There is a self-priming
horizontal centrifugal pump next to the pit. The pump outlet is connected to two discharge
outlets, namely storm water drainage and to wastewater drums/containers. . Once the
rainwater is tested to be non contaminated, it shall be released to the storm water
drainage. Each tank pit has at least final collection rain pit with the self priming pump. For
tank pit 6, due to the storage of acetic acid, there is an intermediate bundwall separating
the acetic acid from the MEG product. As such, 2 rain pits are catered for Tank Pit 6.
For the loading pump station, the area shall be kerbed to contain the spillage. As there
are pump shelters, the rainwater collected in the sump is minimized. In the event that
there are non contaminated water, it shall be drained directly to the storm water system
via the drain valve.
In areas where surface water may contaminate with oil/chemical, such as within pump
station & pigging station, tank pit area, it shall be provided with drainage facilities in
accordance with the following:
Pump stations must be kerbed to contain any spillage during operation. Any
contaminated water shall be drained to the sump within the pump station and
then transferred via a portable diaphragm pump to the wastewater
drum/containers for disposal. There will be a discharge connection with isolation
valve provided for the portable pump. . For the acetic acid pump, acid resistant
tiles shall be laid to protect the concrete surfaces (floor/wall) and separate sumps
to be provided.
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For the tank pit, all the contaminated water/product will be drained to the
common scupper drain located at the center of the tank pit. The contaminated
water/product will flow to the collection pit. The same self priming pump will be
used to pump the contaminated water/product via the discharge valve to the
wastewater drums/containers located outside the tank pit for disposal. For the
tank pit storing acetic acid, acid resistant tiles shall be laid to protect the concrete
surfaces (floor/wall).
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B5.1 General
The fire fighting system for Vopak Sambu project at Tank Pit 6 includes the firewater and
foam distribution network, fixed water spray system, fixed foam system, firewater
hydrants and fire hose cabinets.
Fire fighting system shall be designed in accordance with the following applicable codes:
Contractor shall be responsible for the following work as described, but not limited to,
including applying and obtaining all necessary government permits / certificates.
Contractor shall be responsible for producing all the detailed design deliverables deemed
necessary for the fire fighting scope of work. Following is a reference list:
Contractor shall provide all vendor documentation for all the vendor item such as fire
water pump, hydrants, monitors, sprinklers etc. in the required hard copies and soft copies
covering but not limited to the following:
QA/QC Plan
General arrangement and dimensional drawings, including as-built documents
Detailed datasheets and specifications
Vendor installation, testing, commissioning and maintenance manuals
Inspection and test certificates
All other documents which are necessary for detailed design shall be provided by the
EPC Contractor.
Details of the tie ins along with the schematics and location should be provided
The design concept of the fire fighting systems for Vopak Sambu project at tank pit 6 are
tabulated below.
Buildings/ Fixed
Foam Foam
S/No Hydrant Water
Tank Farm Monitor Makers
Spray
1 Tank Farm VI -- - --
2 Tanks - - -
To elucidate further the fire fighting facilities shall consist of the following:
The size, capacity and amount of the existing fire protection equipment in the terminal are
based on the assumption that only one worst case fire scenario will occur at any one
time.
Multiple major fire risks shall not be considered. Therefore, the need of the largest single
fire area shall governed the size and capacity of the total fire protection system. The
capacity of the fire water system is determined by the water requirements of the largest
fire case, this includes the cooling requirement of the adjacent tanks potentially at risk.
Carbon steel fire main ring shall be provided outside the reinforced concrete
bund wall of tank pit 6 along the road and tied-in to the new 300mm fire main
ring in at least two locations. Underground fire water main ring shall be
protected by polyken tape wrapping protection system. The size of the fire
main ring is to be designed and calculated taking into account of water
requirement for future tanks.
The pipes shall be equipped with block valves at strategic points of the loop
and for segregation.
Lateral pipe for drenching system shall be installed at least 2.5m above
grade level and sloped continuously towards the bund wall. All drencher lines
shall be self-draining. Drencher ring shall have 3mm drain hole for self
draining every 3m.
There shall be separate risers for tank shell and roof drencher rings
respectively.
Drencher manifolds shall be connected directly to the fire main ring for each
tank, from which the various sections of the tank drencher system are
supplied with water. The requirements of drencher are as follows:
2
Tank shell : 2.0 litre/min.m .
2
Tank roof : 2.0 litre/min.m .
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The fire fighting philosophy is only one tank shall be on fire at any one time.
The tank on fire will have foam extinguishment only and adjacent tanks will
2
have full water spray cover. “Adjacent” is defined as within 10kw/m thermal
radiation contour of the tank on fire.
The valves shall be clearly identified, easily accessible and located outside
the 3kw/m2 contour as per the thermal radiation contour report. In case if this
posed constructional/operational difficulties, then they shall be located
behind a fire wall, valves for the individual tanks should be placed on the side
of the bund wall farthest from the tanks. This distance may be reduced
subject to the provision of a fire barrier – 2.5m high and extend 1.5m from the
2 end valves.
Low point drain valve shall be provided for the branch header.
All fire hydrants shall be equipped with 2 x 2-1/2” female connection and 1 x
5” Storz female connection to BS336. Fire hydrants shall be provided at
suitable interval (60m complying with Vopak Standards) and shall be
minimum 12m away from the protected equipment / structure as per NFPA.
Fire boxes shall be provided along with each hydrant. Exact location of fire
boxes shall be determined during detailed engineering. Content of each fire
box shall be in accordance to Section 3.6 of Employer Standard Specification
SP640-01- Design basis for fire protection.
Terminal
3
The terminal has two (2) nos. of existing 15 m (15,000 litre) foam
concentrate tanks (one containing 3% foam concentrate and the other
containing 6% foam concentrate)
Foam ring shall be provided outside the reinforced concrete bund wall of tank
pit 6 along the road and tied-in to the existing foam ring in at least two
locations. Underground foam ring shall be protected by polyken tape
wrapping protection system. The size of the foam ring is to be designed and
calculated. The foam line shall be hot dipped galvanized and no site welding
is allowed.
The valves shall be clearly identified, easily accessible and located outside
the 3kw/m2 contour as per the thermal radiation contour report. In case if this
poses constructional difficulties then they shall be grouped with a fire wall
2.5m high, valves for the individual tanks should be placed on the side of the
bund wall farthest from the tanks. The valves can share the fire wall for the
fire water line valves. “These distance may be reduced to minimum 7m
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subject to the provision of a fire barrier – 2.5m high and extend 1.5m from
the 2 end valves. “
The foam chamber system are normally dry. Therefore, it shall be executed
in hot dipped galvanized carbon steel piping with flanged connection in line
with the piping class. No field weld is allowed.
When two or more discharge outlets are required, the outlet shall be equally
spaced around the tank periphery.
The minimum pressure of the foam generated from foam chamber shall be
3.5 kg/cm²G.
The foam application rate shall be based on 4.1 litre/min.m². The minimum
discharge time for the foam shall be 55 min as specified in NFPA 11.
Low point drain valve shall be provided for the branch header.
In the vicinity of the storage tank suction and discharge nozzle area, at least
one 9 kg multi purpose dry chemical extinguishers will be provided
The Vopak Sambu plant will be provided with additional fire detection and
alarm system. This is detailed on the electrical portion of this document.
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1 P&I Diagram Foam Tank Area VI Protection System – New Reduced Work Scope 10022-1678-00/H.01HF/0003
2 P&I Diagram Fire Water Tank Area VI Protection System – New Reduced Work Scope 10022-1678-00/H.01HF/0004
3 Calculation of Full Surface Fire New Reduced Scope of Work 10022-1678-00/H.051A/0004
4 Fire Protection Basis of Design New Reduced Work Scope 10022-1678-00/H.01CN/0002
5 Fire Protection System Material Take Off 10022-1678-00/H.021B/0002
B6. Structure
Galvanized steel structures shall be used for the platforms for access to the tank pits
and for operating platforms inside tank pits. All structure flanges connection to have
bitumen sheet in between.
Access platforms from outside the bund wall to the tanks shall be provided for the tank
pit.
The Contractor shall carry out field verifications and submit all necessary calculations
and drawings for pipe supports of new pipelines required at the tank pit area and others.
B6.3 Pavement
The piperack and pipe bridge area shall be paved with 100 mm thick gravel.
Existing truck loading station to be used for accommodating the 4 truck top loading
hoses and accessories. Reinforcement to be provided if deemed inadequate to support
the additional pipes, equipment and other services deemed necessary within the station.
Fall arrestor system shall be used for the personnel accessing the truck manholes. The
structure shall be designed to support the fall arrestor system as well.
Crash barriers should be provided at areas to protect equipment or structures which are
placed closely to truck traffic.
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N/A
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B8. ELECTRICAL
For project Sambu, electrical power shall be fed from existing WTP MCC located in existing
substation building MCC-3. Necessary upgrade for motor feeders & power feeders in WTP
MCC for project Sambu shall be carried out by the Contractor. Empty space in WTP MCC
shall be made available to the Contractor for additional motor & power feeders by Employer.
Contractor shall supply, install, commission the additional motor & power feeders. Make &
model no of WTP MCC feeders shall be same as that of existing panel. For upgrade details
refer attached WTP single line mark up (Drg. No: EL-0002). Existing cable routing shall be
followed with new cable trays for electrical power , control & lighting distribution purpose from
MCC 3 substation to Tank Pit -6 & Pump pit FS-7. Refer attached mark up drawing for cable
routing (Drg. No: EL-0001)
Since the new expansion & existing facility handles and stores chemically hazardous fluids the
process areas are classified as hazardous areas. Contractor shall be responsible for
Hazardous area classification drawings and a risk assessment on all possible sources of
ignition from electrical as well mechanical installations. Hazardous area classification drawings
shall be prepared by Contractor as per the IP-15, 3rd Edition 2005 Area Classification Code
for Installations Handling Flammable Fluids. Electrical equipment shall be selected for the
project as per the area classification drawing. Hazardous area classification drawing/ mark up
provided in project specification document shall be updated/ modified by Contractor during
detail engineering based on the actual equipment layout and process data.
Existing MCC-3 substation building shall be housing the following equipment related to project
Sambu::
Contractor shall undertake necessary site surveys at the execution of detailed design in order
to complete the work satisfactorily.
b) The electrical load list and electrical load summaries to show new equipment
d) New detailed single line diagrams for 400/ 230V Distribution boards
e) CCTV system layout (for new CCTV cameras to be tied in to existing CCTV system)
s) Arrange and perform Factory Acceptance Testing (FAT) of all the major electrical
equipment e.g. LV distribution board, cables, light fittings, etc. and issue release notes.
Inspection and testing shall be carried out as per the requirements of Employer
Engineering standards and/ or specifications.
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t) An electrical installation specification shall be prepared together with bills of quantities and
schedules of rates to enable suitable bids to be obtained for the electrical installation
Contract.
u) Preparation of installation, testing and Pre-commissioning plans, method statements and
test formats for all electrical tests at site (SAT) and these shall be subject to Employer
approval.
v) Preparation of electrical start-up operation and maintenance manuals for Employer review
and acceptance.
x) Supply and installation of all materials, hardware, steelwork, supports, cable, cable
terminating, connection and glanding materials, cable protection tiles, cable markers,
transit blocks and all other items which are necessary for a complete installation of the
electrical system of the Project.
y) Installation of all cable ladders / trays of hot dip galvanized steel / FRP, their supports, and
all brackets and holding down clamps, bolts and hardware accessories.
z) Installation of all conduits, conduit supports and mechanical protection required for cables
installed under this Project.
aa) Installation, termination and connection of all cables necessary to complete the electrical
installation
bb) Installation of field mounted motor control stations and emergency pushbutton stations,
Local Control Stations.
cc) Installation of complete indoor and outdoor lighting installation with supply
ee) Installation of complete earthing & Lightning protection system and lighting system.
ff) Excavation and backfill of cable trenches including removal and reinstatement of floor
tiles, roads and paving required for the direct buried cables.
gg) Installation of all necessary cable protection tiles for the underground installed cables
jj) Installation of all necessary transit blocks in wall and floor cable transit frames wherever
required.
kk) Sealing of all floor / wall openings after completion of electrical installation Work
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ll) Erection, alignment, leveling and installation of distribution boards, control panels, and all
other electrical equipment.
The term electrical equipment used throughout this documentation denotes all distribution
boards, control stations, sockets, light fittings, supports, tray and rack, cables, cable glands,
bolts, studs, nuts, wiring, conduit, and electrical fittings, etc. comprising to form complete
systems for the Project.
The Contractor shall provide materials and services in accordance with the Project
specifications together with labour, equipment, tools, purchasing and expediting services,
consumables and facilities, supervision, transportation, insurance and every item of expense
necessary for the receipt, storage, fabrication, installation, support, inspection and testing,
cleaning of all electrical items in accordance with Project documents, drawings and
specifications. It is the intent that all Work is executed in the best and most workmanlike
manner in accordance with the Project specifications and Approved for Construction drawings
and as described in this document.
The Contractor shall obtain clearance in writing from Employer or his representative prior to
installing electrical equipment or cable trench in any location where development of
interference is possible.
The Contractor shall document all electrical systems installations, inspections, testing and
calibration reports in mechanical completion dossiers.
Electrical
Contractor shall provide all Vendor documentation in the required hard copies and soft copies
covering the following, the following drawings (minimum) as applicable for the specific
equipment shall be furnished. Additional drawings/documents as mentioned in the Project
equipment specification and as required by Employer engineering standards shall also be
provided.
h) Electrical Certificates (FAT & Routine certificates); Type Tests for similar equipment
Contractor shall provide all deliverables for Approval as required and finally “As Built”.
B8.5 Tie-ins
The supply points and infrastructure to support the new equipment associated with the Project
shall be finalized.
A Schedule shall be developed such that any pre -shutdown electrical Work shall not wherever
possible impact existing facilities. Following electrical tie ins are envisaged for sambu project
expansion:
1. Addition of motor & power feeders to WTP MCC
2. Hook up of CCTV camera to existing system.
3. Hook up of earthing network with existing network at 2 points.
Illumination system for the Project shall be designed by Contractor as per Employer’s lighting
& receptacle specification Doc No: VPS860-01, Rev, 1.Illumination calculations shall be
performed by Contractor for various indoor & outdoor areas as per the specification.
Illumination levels defined by Employer shall be followed for lighting calculations. Lighting
layouts for individual area, shall be produced for the new area & existing applicable areas by
Contractor. All outdoor lighting shall be controlled manually as well as through photocell
contact. Lighting Distribution Board shall be located in existing substation building MCC-3.
Fluorescent lighting fixtures shall be used for all indoor & outdoor areas of the plant.
Contractor shall study the option of the LED type light fixtures with detailed cost analysis for in
tank farm areas. Existing Metal halide flood light fixtures shall be used for pump pits & for
truck loading bay for proper illumination
Type of light fixtures & illumination required in various areas shall be clearly identified in the
design basis.
a) Lighting shall be provided for illumination in local stations, tank pits, tank spiral
stairway, tank top, pump stations, utility area, roads, etc.
b) Lighting fixture location shall be selected according to area classification drawing and
convenient for re-lamping and cleaning. In no case shall lighting fixtures be located
directly over equipment having exposed moving parts.
c) Tank spiral stairway and tank top lightings shall be EEx d assembly. Lighting fixture
shall be pendant type with energy saving bulb. Nipple used for the pendant fixture to
be heavy duty Stainless steel material.
d) Average maintained illumination levels for the facility shall be based upon the
recommendation outlined in local code and Employer’s standards/ specifications.
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e) All field lighting shall be controlled by photocell, inclusive of field lighting with on-off
pushbuttons. Switching shall be made on the control circuit and not on the power line.
Switches shall be grouped into operation light and night light for easy management.
f) For lighting circuits, which are provided with local on-off pushbutton, an independent
hour run meter shall be provided, whereas for those without on-off pushbutton, a
common hour run meter shall be provided.
g) Every lighting circuit shall be provided with an RCB and an auto-off-manual selector
switch at the lighting distribution panel.
h) For consistency, the type, height and spacing between lamp poles should be the
same in general depending on the lux level.
a) A 2-pole + earth, 230V 16A receptacle shall be provided for each tank for maintenance
purpose. Receptacle shall be placed in pump stations and jetty platform to facilitator
working areas with 20m extension cord.
b) 2-pole + earth, 230V 16A receptacle shall be provided for Loading pump station FS 7
and loading station.
Earthing shall be designed by Contractor as per the applicable codes and standards.
The earthling system shall consist of a main earth grid loop to tank, lighting fixtures, pumps,
receptacles, motors, process piping and all equipment. The grounding network shall be
formed and connected to the existing earth grid at minimum two locations. The same network
could also be used to assure the safety of personnel and plant operation.
All aboveground pipes shall be static grounded to the grounding network. Flanged pipelines
where the flange and its connection exceeds 100 mega-ohm has to be grounded. Flanges
where flange and its connection may rust over time will also need to be ground.
All earth pits of tank pits/ pump pits shall be outside the bunded area.
Truck loading station shall be provided with grounding system with earth clamp for individual
truck for ensuring the discharge of static electricity properly to ground. Truck Grounding
system shall trip the associated loading pump motors directly for incorrect earthing or loss of
earthing.
Tank farm & other associated structures shall be provided with lighting protection system as
per applicable IEEE/ IEC/ NPFA standards. Employer specification shall be referred for detail
design.
Lightning Protection shall be provided to the tank pit area, loading station & other structures
according to the relevant Code of Practice and applicable standards. The lightning protection
system shall be designed as per NFPA 780 (NEC).
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All metallic storage tanks shall be properly bonded to the individual earth pits. Total no of
earth pits per tank shall be as per the employer’s specifications.
Lightning surge protectors shall be provided for protection of essential systems. All signal
cables, antenna cables, and power supply cables connected with the essential systems shall
be installed with a surge protectors.
Local field control requirement shall be obtained by Contractor based on the instrument I/O list
and P&IDs. Local control station shall be considered as per the applicable hazardous area
classification. Contractor shall develop the detailed specification for local control stations.
Local control push-button stations shall be corrosion resistant and suitable for the area
classification to be installed.
Weather protection : IP65 according to IEC
The enclosure shall be made of impact resistant moulded plastic with corrosion
resistant cover screws, neoprene cover seals and HDG plane cover shield.
The control station can be equipped with the following items:
- On/Off switch
- Auto -O- Manual selector switch
- Push buttons Start/Stop
- Signal lamps (long life type)
All in relation with the necessary control system
Contact rating for switch and push buttons shall be at least:
- for AC - 400V-4A
- for DC - 24V-4A
The new CCTV cameras, miscellaneous accessories and cables shall tie in to the existing
CCTV. Tentative locations for the new CCTV cameras for the expansion project are as
follows:
1 - truck loading bay
1 – FS 7
The recording system shall be modified to accommodate the new cameras. The system shall
including the following components:
Colour camera shall be installed on a tower (8 meters from ground at least) with a sun shade
or in suitable location on the gangway.
Weather proof (meet IP65) and explosion proof type metal junction box shall be provided for
each camera to house video and control signal transmitters and AC/DC transformer. Cable
entries to the junction box shall be at the bottom. Cable entries from top or sides of the
junction box shall avoid.
Signal cable from cameras near tankpit and pump stations shall be run to existing CCTV
panel located in CCR. Existing cable tray route shall be followed for laying cables up to
existing CCR.
Signal cable shall be dedicated. Signal and power supply shall not share in multi cores cable
to avoid interference on signal transmission.
All cameras shall be connected into the existing CCTV system in CCR, and shall be
functioning as the cameras used for common facilities.
All panels shall have one spare circuit breaker installed for every ten, or fraction thereof circuit
breakers used in the final installed design. These spare breakers shall be similar in size and
type to those used in the final design.
All panels shall be indoor type, metal enclosed design, free-standing, standalone or wall
mounting type with front-access and provision for future extension.
All cables shall be cross-linked polyethylene (XLPE) insulated, steel wire armoured, PVC
sheathed and flame retardant comply to IEC 60332-3C standard. Low voltage cable shall be
XLPE/SWA/PVC type. High voltage cables shall be XLPE/ SWA/ PVC/ Screened & shielded
type.
a) All cabling shall be laid aboveground/ underground as per the cable routing
drawings & philosophy finalized. Road lighting shall be laid underground.
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e) Major cable way shall have sufficient capacity for future expansion of the
facilities.
f) Contractor shall lay all cables from MCC-3 to pipe rack or along the
bundwall as indicated the cable tray layout mark up for the Sambu project.
h) Covers for top tier cable trays or ladders shall be provided and at area
where product splashing might occurred.
B 8.6.8 Accessories
i) Stainless steel rain cover/ canopy shall be provided for outdoor junction boxes,
switches and receptacles etc.
ii) All U bolts and screws used shall be stainless steel material.
iii) All relay used shall have LED indicator for easy trouble shooting.
iv) All fuses shall have neon indication for easy trouble shooting.
v) All junction boxes shall have equalization plug & spare opening c/w plug.
FEED drawings & documents are prepared based on the following basis and considerations.
Contractor shall be responsible for capturing changes in the entire system design due to any
alteration/ modification/ addition/ deletion of basis.
Pump pit Motors (4 nos) with YD starter are considered & Slope Pumps (2 nos) with
Direct on Line (DOL) starting. Space heaters are considered for motors 10kW &
above motor ratings.
All electrical loads shall be fed from existing MCC-3 substation location.
Existing cable route shall be followed for new cable tray route from MCC-3 substation
to pump pit 7. Existing steel frame shall be used to generate tray supports. Wherever
required cable trays shall be installed along the bund wall.
The power cable to all Motors is considered 4 core up to 16 Sqmm, the 4th core being
PE conductor. Above 16 Sqmm cable size separate PE conductor shall be
considered.
The lighting circuits to Storage Tank and Loading Bay Shelter are considered single
phase and the main power cable is considered to be 3 core, the 3rd core being PE
conductor.
B9 INSTRUMENTATION
In normal conditions, all electrical or pneumatic driven equipments and actuators shall be
operated in local and manual mode. The instrument system design shall have a provision of
operating all instruments, equipments and actuators via DCS in future.
All essential protection and safety devices shall be designed to fail-safe requirement.
The Instrument Panel room located in the MCC-3 building shall house the ESV Marshalling
Cabinet.
The ESD push buttons shall be hard wired to the dedicated relay based ESD system inside the
existing control room and the ESV field cables shall be terminated at ESV Marshalling cabinet
in existing MCC-3. The communication between ESD push buttons and the ESVs shall be via
cable from the ESV Marshalling cabinet located in existing MCC-3 to ESD System-cum-
marshalling cabinet in existing control room.
Contractor’s scope for detailed engineering and design includes but is not limited to the
following documents and activities:-
Contractor shall provide all Vendor documentation in the required hard copies and soft copies
covering the following. Additional drawings/documents as mentioned in the Project equipment
specification and as required by Employer engineering standards shall also be provided.
Vendor documentation package shall typically include, but not be limited to, the following:-
a) Document list
b) Technical bid documents
c) Instrument catalogues and other vendor documents
d) Installation, Testing and Commissioning manuals
e) Spare part list
f) Instrument/valve outline diagram
g) Instrument/valve technical data sheet
h) Instrument/control valve calculation
i) Instrument/restriction orifice calculation
j) Instruction and operation manual
k) Calibration certificates
l) Performance test reports
m) Declaration of conformity (e.g. ATEX)
n) Certificates for Ex equipment
o) SIL declaration of conformity
p) Material inspection certificate
q) Pneumatic & hydrostatic pressure test certificates
r) Nondestructive test reports (if applicable)
All instrument works shall comply with IEC and ISA standards. All instruments selected
shall have the provision for future tie in to the DCS system if the terminal were to install
the DCS system in future. At this moment, no DCS system will be installed in this project
work scope.
The terminal shall be installed with ESD system. The ESD control circuit shall be deigned as
failure safe. The system will be manually activated when abnormal situation is observed
during operation.
The system shall include individual area ESD. Area ESD means that if the ESD system is
trigged, only that area operations will be shutdown accordingly.
One ESD pushbutton and RESET pushbutton shall be installed for the area on operator
consoles in existing control room.
ESD button shall be red mushroom head, contact normally close, push to lock and turn to
clockwise to release type. Cover shall be provided to prevent accidental activation of the
system.
For project Sambu, SAAB Automatic Tank Gauging System shall be integrated with the
existing tank inventory management system.
The existing SAAB tank inventory system is suit for custody transfer purpose. It consists of
level gauges linked with multiple temperature sensors, communication interface units (CIU),
workstations and printers. The network linked workstations; printers and CIUs is Ethernet.
The existing tank inventory system should be able to accommodate the additional tanks for
Sambu storage facilities; contractor to verify this during clarification.
Still pipe radar gauges (model 3950) shall be provided for all fixed roof tank with internal
floating roof. The level gauges shall be installed on an 8” roof nozzle with RF flange. The
material shall be SS 316L and class of flange shall be similar to the roof nozzle flange.
Radar gauges (model 3930) shall be provided for all fixed roof tank without internal floating
roof. The level gauges shall be installed on a 20” roof manhole nozzle via threaded
connection. See details in existing hookup details provided.
Both kinds of radar gauges shall be suit for real-time inventory measurement and custody
product transfer purpose.
Tank level gauge shall be certified for use in zone 1 hazardous area. The gauge shall be
equipped with slave data acquisition unit interface with multiple temperature elements. The
slave data acquisition unit will communicate with the level gauge and multiple temperature
elements for temperature measurement. The level accuracy and resolution of the gauge shall
not less than ± 1 mm and ± 0.1 mm respectively.
Power supply for the level gauge shall be 230VAC ± 10%, 50Hz.
Gauge used shall have capability to provide redundancy for high level overfill protection. The
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The measurement circuit in the hazardous area shall be intrinsically safe certified according
to EEx-ia IIC T6.
MIT shall be housed in weather proof IP65 cast aluminium housing and suitable for mounting
on top of MIT.
MTT shall be installed in a vertical sealed thermo well of 2” pipe. In order to eliminate the
influence of ambient temperature on the average product temperature measurement, the
thermo well shall be located not less than 600mm from the tank shell. The accuracy cover a
0
range of 100°C shall be ± 0.2 C.
Saab Automatic Tank gauging system for project Sambu area shall be connected to the
existing tank inventory management system. Necessary cabling and software programming
need to be updated for the new installed devices. Contractor shall verify the installation and
tie in during detail engineering. Other instrument items including:
A completed set of flow meter, pneumatic control valve, emergency on-off valve and a batch
controller shall be provided for each dedicated product line that is to be connected with a
truck loading arm.
Batch controller shall be weather proof and designed for use in zone 1 hazardous area. Batch
controller shall be intelligent type with field bus communication features for linking with DCS
in future.
The controller shall have an integrated local display and keypad. All pushbuttons used on the
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The controller shall be provided with the most flexibility on configuration of the loading curve
to achieve the best accuracy of truck loading.
The controller shall have analogue output (4-20mA) and digital outputs for controlling a
pneumatic control valve.
Contractor shall develop a detailed design document package for the installation of LEL Gas
Detectors in outdoor process area. Associated field Work shall be considered by Contractor.
Exact location and quantities of all Gas Detection devices shall be determined during detailed
engineering.
Contractor shall be responsible to develop for the following Project deliverables:
a) Gas Detectors layout drawings indicating location and type of the detection.
b) Provide/ Update Cause and Effect Chart (if applicable)
c) Specifications and Data sheets for Gas Detection system, including detection devices,
control panels and all other necessary hook up material required for complete system
installation and operation, as well as prepare all applicable material requisition
documents necessary to purchase Gas Detection System components/ equipment.
i) Flow Switch
The flow switch shall be based on thermal dispersion design with adjustable response time.
The switch shall be suitable for pipeline that may go dry.
The sensor element shall be suitable for highly viscous, corrosive or contaminated
environment. The sensing portion and its modular electronic package with switch point shall
be mounted in a rugged enclosure suitable for zone 1 hazardous areas. The insertion length
shall depend on the pipe specification.
Switch point shall be field adjustable over a wide 100:1 range. Repeatability shall be less
than 1.0% of full signal at constant temperature and pressure.
Switches shall be relay contact, SPDT and integrated with the flow instrument. Switch rating
shall be 24 VDC. Terminal blocks shall be provided for wiring of switch contacts.
Tank high-high level switch shall be of narrow deadband displacement type with one
displacer. The displacer shall be field adjustable at any point along the defined length.
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Level switch shall be completed with proof-er lever to check the operation of the displacer
control without having to raise the level in the tank or remove the switch. Padlocking facilities
shall be provided.
Level switch shall be of anti-surge design to eliminate the possibility of switch short cycling.
Dial type pressure gauges shall be provided as per P&ID. For details refer to specification
SP723-001.
v) Pressure Transmitter
Diaphragm type pressure transmitters shall be provided for product lines as per P&ID.
Transmitter output shall be linear, 4 to 20 mA DC with local indicator. All wetted parts shall
be compatible with the process environment. Body assembly bolts shall be stainless steel.
Transmitter shall be ranged such that normal operating pressure is at approximately 70% of
full scale.
Conventional pressure transmitter shall be used for water, plant air and instrument air
system.
Mounting brackets for the transmitters to be used in jetty area shall be of stainless steel.
Emergency shutdown on-off ball valve shall be provided for each jetty line at jetty to isolate
the ship and shore in case of fire. Valve specification shall comply with local Standard and
API standard. The valve shall be ball type with double mechanical seal, trunnion type fire
safe design. The valve response time from fully open to fully close shall be set base on
surge study conducted.
Emergency shutdown on-off ball valve shall also be provided on each feed lines to Sambu
plant.
All tank side rundown & filling valves shall be on-off ball valves with pneumatic actuator.
These on-off ball valves and pneumatic actuators shall be fire-safe type.
Accessories supplied with the valve and actuator, like solenoid valve, regulator shall be suit
for using in marine environment.
All solenoid valves shall be rated for Class 1, Division II, Group C & D. The bodies of
solenoid valves should be made of stainless steel. Solenoid design shall have actuator
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Contractor to provide an optional cost for changing all pneumatic on/off valves to MOV.
Mass flow meter and its accessories shall be weatherproof and designed for use in zone 1
hazardous areas. All the wetted parts and the housing materials shall be stainless steel 316.
Flange rating and type shall be according with the process piping.
The sensor shall have at least an accuracy of ±0.05% of rate, repeatability of ±0.05% of rate.
The sensor housing shall be a hermetically sealed case to protect from adverse effects of the
environment. The range ability shall be at least 20:1.
The meter shall be suitable for custody transfer, ability to measure density and concentration.
The transmitter shall be able to convert the low-level signals from the sensor into 4-20mA and
frequency output. The transmitter shall have four outputs – one frequency output, two
independently configured analogue outputs (4-20mA) and one HART protocol with the ability
to detect flow direction. The transmitter shall have explosion-proof housing suited for zone 1.
Power supply to the transmitter shall be 220 VAC, 50Hz.
The transmitter shall have external mounted local display. The display shall be in LCD with at
least 4½ digit for flow and 8 digits for totalizer.
The control valve shall be provided with I/P converter, solenoid valve and necessary
accessories.
All the parts of the actuator shall be similar/compatible with the piping material. The
pneumatic valve shall be provided with two limit switches (open and close) to DCS for future
remote monitoring purpose. The limit switches shall be mounted directly on the actuator
housing and suitable for use in zone 1 hazardous areas. The limit switch shall be SPDT type
with a contact rating 120VAC, 1.0A.
All instrument cables shall be XLPE insulated, steel wire armored, PVC sheathed with
screen protection and flame retardant to IEC 60332-3C standard. Instrument cables shall be
UV resistance type.
All field instrument cables shall be laid above ground and separated from the power cables.
All field instrument cables shall be run aboveground on hot-dip galvanized cable ladder I
tray. Underground cables are only allowed at surrounding areas of existing control room,
substation and LPSs.
If cables are required to across the roads, concrete duct bank shall be installed.
B9.3.8 Accessories
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a) Stainless steel rain cover shall be provided for outdoor junction boxes,
instruments, control switches etc.
b) All U bolts and screws used shall be in stainless steel material.
c) All relay used shall have LED indicator for easy trouble shooting.
d) All junction boxes shall have equalization plug & spare opening c/w plug.
Calibration and certifications for all instruments and equipment shall be provided by
Contractor.
All instruments and instrument systems, including those supplied with equipment packages,
shall be verified and when necessary tested in the instrument workshop prior to installation.
The verification shall consist of a careful comparison of the instruments as supplied, with the
instrument engineering data sheets.
FEED drawings & documents are prepared based on the following basis and considerations.
Contractor shall be responsible for capturing changes in the entire system design due to any
alteration/ modification/ addition/ deletion of basis.
a) Existing control room and MCC-3 Instrument rack room shall be designed large
enough to house electrical and instrumentation equipment for future phase
b) Whenever cable tray is installed it shall have sufficient spare capacity for the future
phase plus the required 20% spare.
c) Spare and future space shall be left in cable cellars
d) Junction boxes shall have minimum 20% of spare terminals
e) Multicore /Multi pair cables shall have minimum 20% of spare cores /pairs
f) IS Barriers shall be installed in the respective cabinet in MCC-3
The following basis is considered for the MTO. Contractor shall re-confirm the following
based on the actual requirement during detail engineering.
Additionally, the following specification for Tank radar system has been provided by VOPAK:
Section A : TGS hardware and software from Rosemount Tank Radar Sweden
(These items are subject to Global agreement discount under Vopak) (22-B1000BR2) Wireless
Description
Thum Adapter
Code: 775-XD11I1WA3WK9-R0
775 : Product Description : Smart Wireless THUM Adapters
X : Output : Wireless
D : Housing : Aluminum
1 : Mounting Connection : 1/2 - 14 NPT
1 :Plantweb Functionality : Hart Data
l1 : Certification : ATEX Intrinsically Safe
WA : Wireless Transmit Rate : User Configurable Burst Rate
3 : Operating Frequency and Protocol
WK : Wireless Antenna : Omnidirectional Integral Antenna
9 : Smart Power (™) Option : Power Scavenging
R : Device Connection : REX
0 : Cable / Conduit Connection : None
B10.1 General
This section covers the engineering and construction requirements for the safety
provision.
All works shall comply to local standard and chemical safety handling requirement. The
works shall include the follows instruments :
- Safety Shower
- Eye Wash Unit
- Gas Detector
All Emergency Showers shall be stainless steel & c/w sign posted.
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B11 PAINTING
B11.1 General
This section covers the requirements for shop and field painting of all equipment, carbon
steel tanks, carbon steel piping, and structure.
The scope of work shall consist of, but not limited to, the supply of painting materials,
labour, supervision, construction equipment and tools, consumable, scaffolding, etc. for
surface preparation, painting, coating and making pipe service and equipment numbers
as required for the following:
a) Piping, and its supports, valves, flanges, fittings, and other items.
b) Fire protection facilities.
c) Mechanical equipment.
d) Structures, platform, walkway and other items that are not hot dipped galvanised.
Contractor shall be responsible for the warranty of the whole painting works, including the
paint material. The protective features of the applied coating system shall be such that
there will be no corrosion equal to or more severe than Re1 as defined in the European
Corrosion Scale during the first two years, and no corrosion equal to or more severe than
Re2 during the next three years, with the exception of corrosion due to mechanical
causes. Should there be any corrosion as stated above, Contractor shall repair such
defects at his own cost.
Contractor shall sign a five year Warranty Contract for Painting Works with Employer.
The draft copy of the Warranty Contract for Painting Works is in the attachment of
Standard Specification VPS620-01 - Specification for Painting
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Part C
The Sambu facility is to be executed in Vopak premises adjacent to its existing Merak site.
The project is envisaged to be executed in two phases. This documents defines the scope for
phase 1 only.
The facilities should be able to receive chemicals (Mono ethylene glycol & Acetic acid) from
the vessel and store in storage tanks. The project will add new pipe lines to the existing jetty
pipework from Jetty 1 and Jetty 2. From the storage tanks, the product will be loaded into the
tanker via loading hose at the truck loading station for distribution to various customers in
Indonesia. For the customer AMI, Acetic Acid will be transferred directly through pipeline via
centrifugal pump.
The Sambu facility consists of one Tank Pit, namely Tank Pit 06 with a total storage capacity of
approx. 11,500m³ with existing loading pump station LP-33 and existing truck loading station
LS-47.
The existing truck loading station LS- 47 will consists of four new loading hose stations.
Chemicals will be received through ship unloading facilities from Jetty 1 and Jetty 2. Ship
unloading facilities would include new pipe lines and modification of the existing pipelines so
that they can be routed to the proposed tank pit 6.
Proposed tank pit 6 will be used for MEG and AA storage tanks. A total of five new tanks will be
3
built adding a total capacity of 11,500 m .
All tanks shall be fixed roof except Acetic acid storage tanks shall be fixed roof with internal
floating roof..
The products from the tanks will be subsequently loaded into the tanker with dedicated truck
loading facilities including pumps and truck top loading hoses except the industrial tank for AMI.
For AMI (TK0637), acetic acid will be transferred through pipeline with dedicated transfer pump
system. Piping to be routed to the two existing pumps. (one in operation and one on standby).
All other accessories to be included as per P&ID.
One vapor scrubber system will be provided for truck loading operation from the loading bay for
acetic acid.
Tank recirculation line shall only be provided for the MEG tank (T0641) for mixing operation.
Vapor Solubility
Specific Flash Boiling Melting
Product Viscosity Pressur In
Gravity Point Point Point
e Water
Mono 0.11
1.115 @ 27.6 cP 190 to
ethylene mbara 111 ºC -13 ºC Miscible
20 ºC @ 20 ºC 240 ºC
glycol @ 20 ºC
15
1.05 @ 1.22 cP
Acetic Acid mbara 39 ºC 118.1 ºC 17 ºC Miscible
20 ºC @ 20 ºC
@ 20 ºC
The respective equipment and piping material selection shall be suitable to handle these
chemicals.
Mono ethylene glycol will be received from vessel at jetty 1 with inbound flow rate of
185 to 325 m3/hr and from vessel at Jetty 2 with inbound flow rate of 270 m3/hr .
MEG shall be stored in 3 nos. of new storage tanks located in new tank pit 06. 3
3 3
tanks shall be of SS304L/SS316L material ( 1 x 2000M SS316L, 1 x 2000M
3
SS304L, 1 x 3000 M SS304L). From these tanks, the dedicated truck loading pumps
each of 80 m3/hr capacity will feed the MEG to trucks through dedicated truck top
loading arms. Jet nozzle facility shall be provided for TK0641.
Acetic acid will be received from vessel at jetty 1 with inbound flow rate of 235 and
from vessel at Jetty 2 with inbound flow rate of 315 M3/hr. Acetic acid shall be
stored in 2 nos. of new storage tanks located in new tank pit 06. Both the storage
tanks shall be of SS316 material. One storage tank (TK0637) of 2500 m3 tank is
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dedicated for direct transfer to AMI and other 2000 m3 tank (TK0638) is dedicated
for trucks loading. From TK0637, acetic acid will be transferred to AMI with dedicated
pipeline by transfer pumps of 25 M3/hr (1 working, 1 standby). Existing AA pumps on
site shall be used and are located at LPS 32. From TK0638, the dedicated truck
loading pump of 80 M3/hr capacity will feed Acetic acid to truck through dedicated
truck top loading hose.
C2.3.2.3 General
Tank feeding flow rates are expected to be controlled by ship control as per agreed
flow rates and monitored by tank ATG system. A pneumatic operated valve (serving
both the purpose of tank inlet on/off valve and ESV) shall be provided at the tank inlet
nozzle and shall be interlocked with the wireless tank ATG and an independent overfill
protection level switch .
Pneumatic operated ESVs at truck loading station and shall be interlocked with the
Truck loading bay’s new ESD.
For MEG, two MEG tanks will be of Stainless Steel SS304L material and one of
SS316L material.
Acetic acid tanks will be Stainless Steel SS316 material with internal floating roof.
Filling diffuser shall be provided for all tanks with internal floating roof design. .
To prevent vapor loss, all the tanks will be provided nitrogen blanketing facilities. The
whole tank pit shall be provided with a dedicated rotameter type flow meter for each
tank and a common mass flow meter to monitor the overall consumption of nitrogen.
Equipment and other facilities connected to each tank shall be according to Product
P&IDs.
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Size of
Tank Design
Type Capacity Design
Tank No. Product Dia. Ht Pressure Material
of Tank (m3) Code
(mbarg)
(m)
Fixed
TK0637 AA 16.0 14.0 Roof 2,500 -5 /100 SS316L API650
with IFR
Fixed
TK0638 AA 12 20.0 Roof 2,000 -5 /100 SS316L API650
with IFR
Fixed
TK0639 MEG 12 20.0 2,000 -5 /100 SS316L API650
roof
Fixed
TK0640 MEG 12 20.0 3,000 -5 /100 SS304L API650
roof
Fixed
TK0641 MEG 14.5 20.0 3,000 -5 /100 SS304L API650
roof
All the feeding and loading pump material selection shall be suitable for the chemical
product properties. The summary of pumps is listed below:
Pump Estimated
Pump Capacity Design
Product Pump Type Head Material Power
No. (m3/hr) Code
(bar.) (kw)
ANSI B
32LP3701 73.1
/02 Acetic Acid Centrifugal 25 9.79 SS316L *
(Existing)
ANSI B
33LP3801 Acetic Acid Centrifugal 80 4.01 SS316L * 73.1
ANSI B
33LP3901 MEG Centrifugal 80 4.01 SS316L * 73.1
ANSI B
33LP4001 MEG Centrifugal 80 4.01 SS316L * 73.1
ANSI B
33LP4101 MEG Centrifugal 80 4.01 SS316L * 73.1
Pneumatic operated ball valve shall be provided for tank suction nozzle and loading
hose/vapor return connection line.
In order to protect the environment, suitable vapor recovery system shall be provided for
the critical chemical product, i.e. acetic acid, for the truck loading operation. The system
capacity shall be based on the maximum product loading capacity.
A dedicated scrubber system is proposed for acetic acid truck loading operation.
The scrubbers shall be located outside the tank pit 6 bund wall. The operating envelope
shall be 0 to 100%.
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C3. Tankage
C3.1 General
This part of the Project Specifications covers the requirements governing the detailed
engineering, material/equipment procurement, fabrication, erection, inspection and testing of
the Sambu storage tanks and its related facilities
The works to be performed by Contractor shall consist of, but not limit to, the following major
items:
(b) Prepare and submit design and engineering documents and drawings.
(c) Contractor shall supply all the steel plates with mill certificates.
The height of each shell course shall be based on 2m or more. Shell thickness shall
be based on API 650, one-foot method.
(d) Material take-off, purchasing and supplying of all remaining materials, tank
accessories and equipment. Contractor shall supply materials with attached mill
certificates. The mill tolerance shall be allowed for plus only.
For TK0641, in view of the critical schedule, the tank plates for the
bottom/annular/shell will be provided by Employer upon contract award. Selected
Contractor shall inform Employer on the location to send the plates upon contract
award. Contractor shall design the tank based on the materials supplied by the
Employer and inform the Employer if there is any excess/shortfall of materials. The
details of the tank plates ordered is as per below:
(e)Welding performance test and welder’s qualification test and welding procedures.
(f) Material handling, storage and transportation of raw materials, equipment, etc.
(g) Perform all testing and inspection required by the relevant specifications, in
accordance with the test procedure. Contractor shall also prepare all test and
inspection procedures to be submitted to Employer for review and approval.
(h) Supply and installation of fire water and foam extinguishing system, including foam
chambers, spray nozzles, etc. for the above mentioned tanks.
(i) Supply and installation of PV-vents (with 100% redundancy), emergency relief valves
and gauge hatches to API 2000.
(j) All shop and field painting work shall be performed in accordance with Employer
Standard Specifications.
(k) Provide calibration tables for the above-mentioned tanks (Contractor shall engage
qualified inspection Company).
(l) Provide stairway, including top platforms, that enables easy access to the level
gauge, temperature element, gauge hatch, roof nozzles, wherever required
(m) Supply and construct supports for internal and external piping and cable conduit.
(n) Tank cleaning and preparation of strapping/ gauging tables for all tanks.
(o) Supply and installation of water spray system for all tanks.
(q) Provide jack-up brackets and anchor chairs for all tanks.
(r) Supply and installation of stainless and carbon steel roof with external rafters.
(s) Supply and installation of internal floating roof (only on the Acetic Acid). The internal
floating roof shall be designed to comply with API 650. The material of the IFR must
be suitable for product and when tank is blanketed with nitrogen. Pigging diffuser
shall be provided.
The contractor shall be responsible for producing all the detailed design deliverables.
A reference list of deliverables to be produced by the EPC contractor is as per below.
All documents not included in the list but may be required for the detailed design of
the project shall be provided by the contractor.
Contractor shall provide all vendor documentation for the tank accessories (e.g. IFR,
Foam chambers, pressure vacuum vents, etc.) in the required hard copies and soft
copies covering but not limited to the following:
QA/QC Plan
General arrangement and dimensional drawings
Detailed datasheets and specifications
Vendor installation, testing, commissioning and maintenance manuals
Inspection and test certificates
All other documents which are necessary for detailed design shall be provided by the
EPC Contractor. Scope of documentation for any other vendor purchased item shall
be similar to above.
(a) All tanks shall be single wall with self-supported carbon steel Cone roof
with external rafters. The Shell to Roof joint shall be a frangible one.
Special care need to be taken in designing the frangible roof with
external rafters
(b) The shell plates shall be butt-welded and the bottom and annular
plates shall be butt-welded with backing strip of same material. The
roof plates shall be lap welded with a minimum lap of 40mm. All welds
shall be with controlled heat input in order to have a good quality on
weld and to prevent carbide formation.
(c) Tank bottom plate shall be cone-down and sloped to tank center at
minmum 1:100 gradient and a sump shall be incorporated at the
lowest point for tank cleaning purposes. Sump plates shall be of the
same thickness as the annular plate.
(d) No corrosion allowance for stainless steel tanks, except its carbon
steel supporting structures shall have a corrosion allowance of 1.0
mm.
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(e) All tanks shall have a spiral stairway with two intermediate platforms to
roof level and connected to the circumferential platform by bolting
connection.
(h) All spiral stairways, platforms and handrails are made of hot-dip
galvanised carbon steel material. For stainless steel tank, stainless
steel clips shall be used to fasten the gratings to the galvanised carbon
steel structures. All handrails are to be fabricated from pipes.
(i) Stainless steel pad plates shall be provided for welding of supports /
brackets to tanks. Direct welding of galvanised supports / brackets to
stainless steel materials are not allowed. Roof plate shall be double
lap welded.
(j) The effects of wind forces and internal pressure shall be checked and
if necessary, anchoring is required.
(k) The tank shell and roof appurtenances shall have provision for future
200mm thick insulation with aluminum cladding.
(l) All root pass of stainless steel plates shall be dye checked.
(m) Seismic load shall be included in tank design calculation. The PGA
shall be considered as 0.25g as per the seismic report.
(n) All stainless steel plates for tank construction shall be free from any
scratches and grinding marks.
(n) Rafters for tank roof shall be external type for ease of inspection.
(a) All tanks shall be equipped with hot dip galvanised foam and drencher
piping. Field welding shall not be allowed.
(b) A caged ladder attached to the shell shall be provided for reaching the
foam chamber or pourers on the tank for maintenance purposes. This
structure shall not be connected to the roof top.
(c) Tank appurtenances on top of the roof shall be localized (located near
to each other) as much as possible.
(d) Hot-dip galvanised cable pipes and supports for mounting cable trays
to the tank shell shall be provided on all tanks.
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(f) The pipe schedule for level gauge well and MTT well shall be similar to
its nozzle.
(g) All shell manholes shall have stud bolts and nuts in accordance with
API 650. Manhole cover flange shall be minimum 18 mm.
(h) A 4” nozzle with pigging diffuser shall be provided for the inlet nozzle
with pigging if IFR installed in tank.
(i) The total length of pigging diffuser, its diameter, number of holes and
the spacing between the holes, etc. shall be advised by the Vendor of
internal floating roof. The pigging diffusers must not interfere with the
legs of the internal floating roof. Details and drawings relating to the
design of the diffusers shall be submitted to Employer for approval.
(j) All tank shell nozzle shall be one schedule higher than the pipe
schedule.
(k) Emergency vent, PV vent and foam chamber for product of acetic acid
tanks shall be in stainless steel material (SS 316L) and for SS MEG
Tanks shall be of SS 304 L/ SS316L.
(d) Painting of stainless steel tank is not required except the carbon steel
accessories and their welds to stainless steel parts.
(a) The tanks shall be equipped with an internal floating roof constructed
with material suitable for the product and shall meet the requirements
of API 650 Appendix H.
(b) The internal floating roof seal shall be suitable for the product to be
stored. A seal shall also be provided for all openings where protrusions
through the floating roof is required. The peripheral seal shall be
stainless steel mechanical shoe seal with Teflon vapour barrier.
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(c) The internal floating roof shall be equipped with adjustable legs. The
legs must not interfere with the filling diffusers.
(d) The internal floating roof shall be equipped with sufficient drains to
ensure that no puddles of product would be left trapped on the roof
during operation and tank cleaning.
(g) The tanks and its internal floating roof shall be grounded.
(h) Details and drawings relating to the design of the internal floating roof
shall be submitted to Employer for approval.
(i) All bolts, washers and nuts used must be stainless steel.
(j) The ladder for accessing of deck manhole shall be installed with a
bracing to avoid dangling, at the top of deck manhole there shall be
handhold to be installed for person to climb up safely.
(a) The sampling hatch nozzle shall be completed with hatch cover. The
material of the hatch cover shall be similar to the material of the roof
plates.
(b) All sampling hatch nozzles shall have stainless steel grounding lug for
gauge tape grounding.
(a) All welds shall be visually inspected, all spatter, slug, sharp edges etc.
must be totally removed / cleaned.
(c) The tanks shall be hydrostatic tested. Contractor shall prepare and
submit for approval the test procedure and test schedule. All SS tanks
shall be chemical cleaned after hydrotest.
C3.3.9 Miscellaneous
Contractor shall measure and calibrate the tanks in accordance with API 2250 (latest
edition) and shall furnish three (3) sets of certified calibration tables. Each set of
tables shall give volume of liquid expressed in litres for every millimetre increment of
the liquid level. The strapping surveyor selected shall be acceptable to the
Directorate of Meteorology Department of Indonesia and approved by Employer.
Contractor shall arrange temporary access to the site for heavy vehicles and
materials.
Contractor shall be responsible for all paper work such as punch list and the
necessary information for the purpose of pre-commissioning and start-up activities.
Contractor shall be responsible to apply and obtain permits and certification from
government and authority for hydrostatic test. All charges payable to the government
and authority shall be borne and be responsible by the Contractor.
C4. PIPING
C4.1 General
This part of the Project Specifications covers the requirements governing the detailed
engineering and construction requirements of the piping system for Sambu storage and
its related facilities.
C4.2.1 Piping
(a) The engineering, procurement and construction of the piping system shall
also include all pipe supports, pipe sleepers, shims, wedges, gusset plates,
temporary supports.
(b) Contractor shall prepare piping specialty item datasheets (e.g. flexible hose,
strainer, pig launcher/receiver) to procure these materials and submit this for
employer approval.
(c) The design of piping routing and layout shall be in accordance with the P&I
Diagrams, the applicable Standard Specifications that form part of this
Project Specification. The line sizes as indicated in the P&IDs are only
preliminary and contractor shall be responsible for the correct line sizing for
all product and utility lines.
(d) Contractor shall prepare drawings to the extent necessary to describe the
piping system, for the material take-off and to install and maintain the
system. The drawings to be produced shall include but not limit to the
following:
(e) All high point vents and low point drains shall be provided accordingly.
(h) Contractor shall provide all labour, materials, consumables, tools and
equipment for execution of testing and inspection of all piping systems,
including spool pieces for hydro test. Testing of the system shall be in full
accordance of the piping design code that is used (ASME B31.3).
(i) After completion of erection, all scales, dirt, slag, welding electrodes, weld
spatters or other foreign materials shall be removed from the piping system.
All piping system shall be flushed after pressure testing.
All painting of the piping system shall be in accordance with the specifications
as described in the Painting Specification.
(k) Walkway, platforms and pipe supports shall be hot dip galvanized and coated
afterwards.
The design of the underground piping for the drainage system shall be in
accordance with Employer Standard Specification VPS530-01 and VPS540-
01.
Pipes routing within Tank Pits shall be run on sleepers. Sleepers shall have
nd
2 tier structural support as shown in drawings. In general, follow the support
scheme shown in drawings for sleepers and also for other structure as pipe
rack or new structural members.
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Contractor shall prepare drawings with the extent necessary to describe the
piping system, for the material take-off and to the system. The drawings to be
produced shall include but not limited to the following:
(a) Product lines shall be provided with a minimum number of high point vents and low
point drains to perform the hydrostatic test.
(b) Sampling points shall be installed as per the details provided in the P&ID
(c) The main valves on the product lines shall be installed according to the P&ID
(d) All main valves at tank side, ESV valves (with pneumatic actuator) on jetty lines and
feed line shall be fire safe type.
(e) The receiving valve connected between the line and tank shall be pneumatic
operated. This valve will be interlocked with ATG and high-high level switch and shut
automatically when the tank is detected at high-high level.
(f) The main valves on the product lines shall be installed according to the P&I D.
(h) Piggable pipelines shall be designed for two-way pigging for all types of pigs.
(i) Special tee connections (Barred Tees) to the piggable line, except 2” and below, shall
be made to permit smooth passage of the pig.
(j) Full bore ball valves shall be used with all existing and new piggable lines.
(k) The arrangement of the pipes on the supports shall be in general as follows:
(l) Stainless steel lines pad plates shall be provided at support point. Pads shall be
500mm long and welding of pad plate shall be full welding with weep hole at the
bottom of pad which shall be seal off by silicon rubber after welding. All SS pipes
shall have pad plates at support.
(m) For product piping, no threaded connection, no slip-on and no socket-weld are
allowed, inclusive of product piping below 2” and all valves shall have flanged
connections. All valves of 2” and below shall be flanged ball type.
Gaskets shall be non-asbestos type and compatibility with product for carbon steel
lines except VAM. Gaskets for VAM service lines shall be PTFE envelope type.
Gaskets for all stainless steel lines shall be PTFE envelope type. Gasket for Acetic
acid shall also be PTFE envelope type.
(n) The pig catcher design shall prevent nitrogen ingress into tanks during pigging
operation.
(o) Contractor shall maximize shop fabrication to accelerate the work at site.
C4.4 Miscellaneous
C4.4.1 Contractor shall measure and calibrate the all pipelines within Battery limits in
accordance with the actual site condition. Contractor is required to furnish
three (3) sets of certified calibration tables. Each set of tables shall give
amounts of liquid expressed in liters for every section of pipe
C5.1 General
This part of the Project Specification covers the requirements governing the detailed
engineering and construction of civil and structural works for Sambu storage and its related
facilities.
The final co-ordinates and layout have to be further developed during the detailed
engineering. In general, it consists of tank location, dykes, pipe racks and roads.
Contractor shall be responsible for the following engineering and construction work required
to be carried out and completed as described, but not limited to, including the supply of all
temporary and permanent material, plant, tool, power, labor and supervision.
Site setting out by local licensed surveyor.
To prepare tank foundation design calculation, rainwater discharge calculation, waste
water discharge calculation and all other calculations that required by for submission to the
local authorities for approval/permit with endorsement of local Professional Engineer if
needed.
Site preparation, soil level cutting and compaction to CD +3.0m for the whole site.
To carry out necessary soil improvement works or piling with reference to the soil
investigation report for tank foundation or other ancillary structures.
Storm water discharge facilities.
Waste water discharge facilities.
Roads.
Concrete bund walls, intermediate dyke and pavement of tank pits.
Modification of Loading Pump Station LP 33 to suit new equipment (Existing)
Modification of Loading Station 47 to suit new equipment (Existing)
Tank foundations.
Verify working load for the existing piles at Tank TK0637. Design & build tank foundation
accordingly to suit the new tank.
Minor foundation works for pipe supports, access platforms, sleepers etc.
Mechanical equipment foundations.
Contractor shall be responsible for producing all the detailed design deliverables deemed
necessary for the C&S scope of work . Following is a reference list:
Calculations and drawings for tank foundations, pump foundations, pipe supports and
sheds for pump station and truck loading, rain water and waste water drainage, bund
wall, roads and all other civil items which are deemed necessary for the construction.
Bill Of Quantities.
All detailed engineering, construction and installation shall be carried out in accordance with
latest version of British Standards, Employer Standard Specifications or relevant local
standards. In cases where more than one code, regulation or standard apply to the similar
condition; the most stringent case shall be followed.
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C5.3.1Soil Investigation
Soil investigation report and Topographical survey report will be supplied by the Employer for
the Vopak Sambu Project
The soil investigation report supplied by the Employer has shown co-ordinates of existing
area of Merak Terminal where the new Sambu facilities will be built. The Contractor shall
finalize the final grading according to the design formation level of the site.The Contractor
shall note that no claims whatsoever for any unforeseeable physical conditions shall
be entertained and the lump sum Accepted Contract Amount shall not be adjusted on
account of this. The Contractor shall be fully responsible and shall be deemed to have
made all allowances in his Accepted Contract Amount for all physical conditions,
including unforeseeable physical conditions that may in any way affect the Works.
The soil investigation report is given to the contractor in good faith. The employer is not
responsible for the accuracy of the report.
The contractor is allowed to carry out his own soil investigation at site at his own cost if
required.
The topographical survey indicates the topography of the project site is approximately at
CD+3.00m to CD+3.50m.
Existing temporary concrete foundations, pavements etc (if any) within the project site shall
be demolished. All debris and unsuitable soil shall be removed from site to a location
approved by the local authorities.
The major earth works in this project involves trimming the platform levels of the proposed
area at to the formation level of the tank farm at CD+3.00m (±100mm). Excavated slope shall
follow a minimum gradient of 1:1.5 for the slope stability requirement. All site preparation and
earthworks shall conform to appropriate local standards.
Road embankment and bund-wall for tank farm shall be filled up to the respective formation
levels and compacted in layers to a maximum dry density of 95% based on Modified
Proctor’s Test (Clause 3.5, BS1377-4, 1990).
The tanks shall be supported on reinforced concrete slab seated on treated ground or piling.
Tank foundation shall be round in shape. The space between the tank bottom and foundation
surface shall be separated by a layer of 70mm sand-bitumen mixture.
The foundation shall have a cone-down slope from tank shell to the centre sump of 1%.
Foundation height shall take into account of tank settlement being hydro-tested.
For TK0637, Contractor is to verify the working load of the existing piles and take that into
consideration when designing the tank foundation. The piling layout is the same as that of T-
36. The new tank, TK0637 (Dia. 16.0m x Height 14.0m) to be constructed is of a similar
dimension as that of T-36 (Dia. 16.0m x Height 13.3m). Additional piles to be added if
necessary to ensure that the tank foundation can support the new tank.
For foundation such as pipe-supports, sleepers etc. which are not sensitive to settlement, it is
acceptable to use shallow foundations. From the soil investigation report, Contractor is to
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design the foundations as per the soil bearing capacity. Contractor shall ensure that sub-
grade beneath the shallow foundations shall be adequately compacted.
The bottom of foundation excavations shall be free from standing water and disturbance due
to construction activities to prevent softening of foundation soils. If local zones of soft soils
are encountered and cannot be improved by compaction, the unsuitable materials shall be
removed and replaced with suitable backfill.
Any foundation excavation remaining open for more than 24 hours shall have a 50mm layer
of lean concrete placed to protect the bottom. This concrete shall not be considered as part
of the foundation.
Bund walls and pit pavement of tank pit 6 shall be reinforced concrete structures for
preventing spillages from the tanks within the tank pit. They shall be liquid tight and designed
to contain 110% spillage of the largest tank inside the tank pit.
The bund wall height is about 1.9 m sized based on the largest tank from tank pit 6. Care has
to be taken when doing the installation work so as to minimize the inconvenience for the
operation of the terminal. Temporary supports/ structure shall be provided if necessary.
For the tank pit, 2 x 10” gate valves shall be installed at the suitable locations on the bund
wall to allow for excess firewater to be empty out after fire water has been applied.
Intermediate reinforced concrete dikes shall be provided to segregate the acetic acid tanks
from rest of product tanks in Tank Pit 6 and shall have minimum height of 500 mm.
The main and intermediate bund wall associated with acetic acid tanks shall be lined with
acid resistant tiles.
Firewater and rainwater from roads and other non-oily areas shall be discharged through
open drains along the road directly to the sea. Material for the open drain shall be either pre-
cast concrete or cast in-situ reinforced concrete. In road crossing section, galvanized gratings
compatible with the loads shall be used. Otherwise buried pipe or culverts should be used.
Drain at operation area shall be covered with gratings.
Controlled storm-water discharge at the tank farm area to the perimeter drains outside the
tank pit shall be by pumping to adjacent sumps/open drains. At occurrence of storms, the
storm-water runoff from tank pit area will be stored by the surrounding bund-walls. Storm-
water at tank pit would only be pumped to the adjacent sumps/open drain after the storm if
they were not contaminated.
Contaminated water from project site shall be routed to the collection sumps provided in the
respective tanks pits, Loading Station (LS) 47, Loading Pump Station (LPS) 33 through
scrupper drains/ drainage channels. Fixed waste water pumps shall be provided for the
sumps inside the tank pits and air operated diaphragm portable pumps shall be provided tank
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for LS 47 and LPS 33 to pump out the contaminated waste water to iso tankers or IBC/
drums.
C5.3.9 Roads
Road shall be constructed around the tank pit. Roads as shown in the civil plot plan are of
6m width Rain water shall be drained to the open ditch on one side of the road.
The normal plant roads shall be of asphalt concrete with a crushed stone sub-bases course
with design condition are as follows:
Life: 30 years
Load: 10 passes per day. (50 m road tanker)
3
At tank truck loading area and on the routes where truck movement is intended
especially in places where the trucks need to do the turning., concrete paving shall be
adopted for as rapid wear off is expected due to turning of trucks. The design conditions for
concrete paving at tank truck loading are as follow:
Life: 30 years
Load: 40 passes per day, axle load: 18 ton (50 m road tanker)
3
The loading pump station 33 shall be modified to accommodate the number of pumps for this
project. The loading pump station shall be kerbed and shall has a sump for waste water
collection and the contaminated water shall be transferred via an air operated portable
diaphragm pump to iso tankers or drums/IBC. Hot dipped galvanized grating with plate
covers shall be provided over the sump. For LPS 33, the acetic acid pump shall be
segregated from the rest of the product pumps and separate sumps for waste water
collection shall be catered. The surrounding area associated with AA pumps shall be tilted
with acid resistant tiles.
The proposed foundation system for loading pump station shall be designed based on the
soil investigation report. Pump shed structures shall also be supported on reinforced concrete
stumps from the raft. Design for the new facilities need to consider on existing site conditions.
Contractor shall verify and add the necessary supports to the existing loading station so as to
accommodate the new truck loading lines and accessories. Current loading station is catered
for one truck loading at any one time. Design for the new facilities need to consider on
existing site conditions.
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PART D
SPARE PARTS
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SPARE PARTS
During the Defects Liability Period, the Contractor shall supply and have available at the site all
required wear and critical spare parts (together with specific tools and instruments required) to
allow for proper operation of all facilities and processes with minimum downtime, not exceeding
the guaranteed number of downtime days per year as specified.
After the completion of the Defects Liability Period, the Contractor shall supply the necessary
wear and critical spare parts to allow for proper operation of all facilities and processes with
minimum downtime for one more year.
The Contractor shall put forward to the Employer a list of spare parts describing such other
spares and special tools, their number, unit price, and where appropriate the anticipated
frequency of replacement as soon as is practicable and not later than 3 months after approval
of Detailed Design. The list shall be sent in sufficient time for the Employer to consider and
instruct the Contractor to provide all or part of such spares and special tools to be available on
the Site before the commencement of the Maintenance Period. The Employer will instruct the
Contractor as to which of the recommended spares and special tools will be required to be
provided.
The spares and special tools ordered shall be as far as is practicable manufactured at the
same time as the plant. All spares shall be tested, calibrated (if required), suitably packed,
labeled and delivered to the Site by the Contractor.
All special tools or instruments required for the maintenance of the equipment shall be supplied
by the Contractor in a suitable locked packaging, unless otherwise agreed by the Employer.
The Defects Liability Period will commence after Taking Over and last for 12 months (with any
extension under Sub-Clause 11.3). After the Defects Liability Period, the Contractor shall hand
over the remaining wear and spare parts and special tools to the Employer.
During the Defects Liability Period, the Contractor shall provide, without charge, labour
and materials for the routine maintenance required to properly maintain all items
installed, and for the provision of 24 hours “call-out” service whereby at any time of day
or night, the Contractor shall dispatch skilled men to attend to defective equipment and
material supplied under the Contract.
At the end of the Deficits Liability Period, the whole installation shall be in “as-new”
condition, taking in account normal wear and tear. The Contractor shall, during the
course of the Contract, protect all plant and equipment, and shall restore/repaint as
necessary before completion of the Contract.
Tender Document
PART E
RESPONSIBILITY MATRIX
Tender Document
RESPONSIBILITY MATRIX
The Responsibility Matrix is attached listing the details of the detail engineering, procurement and
construction necessary and denotes which parties are responsible for each item for execution of
Chang Chun Project. If there are discrepancies between the Responsibility Matrix and Project
Specification, the Responsibility Matrix will take precedence.
NO. DESCRIPTION
A DIRECT WORK EMPLOYER CONTRACTOR
1.2 PROCUREMENT
Supply of Tank Foundation Material X
Supply of other Civil Bulk Material X
1.3 CONSTRUCTION
Demolition of Existing Facilities (if applicable) X
Landfill X
Tank Foundation X
Other Civil Work X
Steel Structure Work including Painting X
Field Inspection X
Tender Document
NO. DESCRIPTION
2 MECHANICAL EQUIPMENT
2.1 Engineering
A Preparation of Specification Sheet & Purchasing Requisition
Loading Pumps X
Utility Pumps X
Scrubber X
2.2 PROCUREMENT
A Product Pump X
B Utility Pumps X
C Scrubber X
D Expediting Shop Inspection X
2.3 CONSTRUCTION
A Field Installation X
B Field Inspection X
C Vendor Assistance for Installation & Commissioning X
3 TANKAGE
3.1 ENGINEERING
A Detailed Design for Tankage X
B Design Information for Piping X
C Design Information for Instrumentation X
D Material take off X
E Preparation of Material Specification & Construction X
Specification
F Material Requisition X
3.2 PROCUREMENT
A1 Tank plates for TK0641 (Bottom/Annular/Shell) X
A2 Material up to First Flange X
B PV Vent & Emergency Vent X
C Foam Chamber X
D Foam Extinguishing System up to 2M above Tank Base Line X
E Fixed Water Spray System up to 2M above Tank Base Line X
F Tank Grounding System X
G Cable Pipe X
F Expediting Shop Inspection X
3.3 CONSTRUCTION
A Shop Fabrication X
B Shop Painting X
C Field Erection X
Tender Document
NO. DESCRIPTION
D Hydrostatic Test X
E Measurement of Foundation Settlement X
F Tank Strapping and Calibration X
G Maintenance of Temporary Access Road Around Tank X
H Field Painting X
I Shop & Field Inspection X
4.2 PROCUREMENT
A Pipe X
B Valve X
C Fitting X
D Bolt & Nut X
E Gasket X
F Pipe Support X
G Expediting Shop Inspection X
4.3 CONSTRUCTION
A Shop Fabrication & Field Installation X
B NDT Test X
C Hydrostatic Test X
D Flushing X
E Field Painting X
F Support Installation X
G Pre-commissioning X
5 PAINTING
5.1 ENGINEERING X
A Preparation of Painting Specification X
Tender Document
NO. DESCRIPTION
B Bill of Quantity X
5.2 PROCUREMENT
A Sand Blasting X
B Painting Material including thinner X
5.3 CONSTRUCTION
A Surface Preparation X
B Shop Painting X
C Field Painting X
6.1 ENGINEERING
A Preparation of Material Specification & Specification
Foam/Water Monitor X
Fire Hose Cabinet X
Fire Extinguisher, Hose Reel X
B Bill of Quantity X
6.2 PROCUREMENT
Foam/Water Monitor X
Fire Hose Cabinet X
Fire Extinguisher, Hose Reel X
6.3 CONSTRUCTION
Installation ( To be included in piping scope) X
D Flow Instrument X
E Pressure Instrument X
Tender Document
NO. DESCRIPTION
F Level Instrument X
G Temperature Instrument X
H MOV Actuator X
I Pneumatic Actuator X
J Control Valves X
K Junction Box X
L Electrical & Instrument Cable X
7.2 Procurement
A Equipment such as LT Panel, MOV Panel, DB panel, ESD X
Panel, etc.
B Cable Termination X
C Lighting Fixture X
D Junction Box X
E Conduit & Accessories X
F Grounding X
G Fire Alarm System X
H CCTV System X
I Minor Civil Work for Electrical Work X
J Flow Instrument X
K Pressure Instrument X
L Level Instrument X
M Temperature Instrument X
N MOV Actuator X
O Junction Box X
P Pneumatic Actuator X
Q Control Valves X
R Electrical & Instrument Cable X
7.3 CONSTRUCTION
Installation X
Continuity & Loop check and precommissioning X
8.0 PROJECT MANAGEMENT & CONSTRUCTION
MANAGEMENT
8.1 Temporary Facilities including Office Furniture, Office
Equipment, Air Conditioners, Fire Protection, Cleaning and
Housekeeping
NO. DESCRIPTION
- Site Development Plan (Laydown, Parking, Subcontractor X
Areas) for all parties at Facility Site
8.4 Storage & Laydown Areas (Purchased & Develop if Outside X
the Property Provided by Employer)
8.5 Contractor Supplied Material Warehouse X
8.6 Contractor Field Fabrication Shop X
8.7 Temporary Road, Open Drainage & Sewer at Facility Site X
including Maintenance till Take Over
8.8 Toilet X
- for Employer Personnel use X
- for Contractor use X
8.9 Utilities Supply from Battery Limit to Facility Site
- Potable Water X
- Electrical Power X
- Water/Power Billing X
- Potable Water for Hydro testing (Pipe /Tank) X
8.10 Communication System X
- Service Line from Battery Limit to Facility Site
NO. DESCRIPTION
4 Topographic Survey: Required for the Performance of the X X
Contract
5 Soil boring & subsurface testing : Detailed, if required for the X
performance of the Contract
6 Environment Impact Assessment X
B INDIRECT WORK