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Jspl-Refilling Station
Jspl-Refilling Station
Jspl-Refilling Station
Dear Sir,
M/S U3S Engitech Private Limited is pleased to submit you with offer for Centralized
Oil Refilling System.
We assure our commitment to fulfill your expectation in terms of quality, price and delivery.
We trust you will find our offer in line with your requirement and now look forward to
the receiving your valued order, which will receive our prompt and best attention at all times.
Thanking you.
Yours faithfully,
SITE PRE-REQUISITES
SITE CONDITION
SITE AMBIENT TEMPERATURE 45 Deg C
SITE HUMIDITY (RH %) 89%
NOISE AT SITE(in dB) 86 dB
ENVIRONMENT (GASES TYPE & PPM) Possible Mild Presence of Corrosive Gasses
SCOPE OF PROJECT
The Scope of Work shall consists of design, engineering, manufacture, fabrication, inspection, assembly,
shop testing, painting at shop, supply to site including packing, loading, transportation supply at site, Commissioning
Supervision, of Hydraulic system complete with hydraulic power pack, Valves, Valve stands, interconnecting
hydraulic piping and fittings from power pack to valve stands including all auxiliaries of hydraulic system.
The scope of work of the supplier shall include but not limited to the following:
MATERIAL OF CONSTRUCTION
TANK ASSEMBLY
The Capacity of the Reservoir shall be 20000Lts. The Material od Construction shall in Steel as per MS IS 2062
with thickness greater than of 14 mm. The reservoir shall be designed to prevent the ingress of any foreign
materials including water and dust with adequate stiffeners for reinforcement shall have nozzle connections;
clean out doors, drain connections and mounting accessories as given in the drawing.Glass type local level
indicator and 100 mm dial gauge type thermometer shall be considered by supplier for oil Tank for local
indication.
Air breathers shall be of 3 micron absolute rating and 2 nos of desiccant air breather with silica gel type, consisting
of desiccant crystals and absolute filter for tanks, of adequate capacity to be provided.
After manufacturing of the tank weld test shall be carried out on all welded joints by application of chalk & kerosene
swab. Filling water to check rigidity of tank for bulging shall carry out hydrostatic test.
• Main pumps inlet isolation valve (manual type) shall be consider with limit switches for open/close position.
• Main Motor shall be IE-3 type.
• All Seals will be Nitrile Seals
FILTERATION SYSTEM
• REFILLING FILTER
Duplex filter tank top type capable of handling 55 LPM of prefilter pump capacity at a pressure drop of 0.3 kg/cm2 in
clean condition. Degree of filtration shall be as per hydraulic circuit / BOQ and the filter shall be fitted with necessary
change over valves. The Recirculation Filter will be equipped with 5 Micron Filters. Working pressure shall be 8
kg/cm2. Mechanical clogging indicator to be provided to give signal in case differential pressure exceeds 1.2kg/cm2.
By - pass valve to be provided to by-pass in case differential pressure exceeds 1.7 kg/cm2.
Clogging indicator(Mechanical & Electrical) shall be considered across the filters of refilling for Hyd. System.
One (1) set of Main filter at the delivery line of each pump of suitable capacity with Beta micron rating (β5≥200)
suitable for system pressure with electrical & mechanical clogging indicator. The Filter Rating Shall be 5 Microns.
Filter media provided shall be Microglass III. The Pressure Line Filter shall be Provided with Bypass Valve set at 3.5
Bar.
The Filters will be Mounted with Duplex Configuration Manifold mounted Option. All Filter Units shall be
Fatigue Tested for 69 Bars. The Filters have been designed considering Nominal Flow of 228 LPM. The Seals provided
will be Nitrile.
Total Initial Pressure Drop (Housing + Element) for 46 cSt Oil @ 228 Lpm <0.5 Bar
REFILLING PUMP
Electrical Motor operated Barrel Mounted Refilling Pump Set will be provided as per the following
specifications.
Power : 1 HP
The Pump will have internal relief Setting & Oil level Switch for automatic Pump shutoff.
CONTROL VALVES
Lockable type valves shall be provided to prevent tampering. All hydraulic valves, accessories and devices shall be
provided with identification metal tags. As per hydraulic circuit given in this specification. Necessary relief valves
shall be provided to protect the hydraulic system from excessive pressure. The fluid leaked though the relief valve
shall be suitable carried to the reservoir. Ball Valve Shall be provided with handle & locking Arrangement.
• Limit Switch along with Ball Valves on Suction Line of Each Pump.
• Level Switch : One level switch assembly float type for level alarms / main pump tripping. The level switch
shall be selected such that level setting can be made throughout the height of level switch.
• Pressure Gauge : These shall be glycerin filled, heavy duty 100 mm dial size, of suitable range bar, complete
with bourdon movement and snubber of AISI 316 SS, in die cast aluminum alloy, moisture proof case, heavy
enameled black and equipped with zero adjustment mechanism suitable for mineral oil service. Pressure
gauge shall be installed with Minimess hoses and Minimess coupling
• TEMPERATURE CONTROL
Suitable Temperature switch shall be provide in the Oil Tank. Temperature switch shall have 2 nos.
of contact “High” and “High High”. High contact for alarm and High High contact for tripping of the Hyd.
System.
• Thermostat :One (1) no. having 25-90 deg C range & 2.4 to 10° C adjustable differential range with armoured
3 meters long capillary, thermo well & socket.
• Temperature gauge : One (1) direct mounting back entry type temperature gauge of 100 mm dial size, 0-100
deg. C range, "mercury in steel" type with SS bulb & thermo well having immersion length 105 mm length
SAFETY/RELIEF VALVE
Each Main pump station unit shall be Fitted with Individual Safety Relief Cum Unloading Valves to regulate
the System Pressure and to ensure safety of the System in case of any hydraulic failures. We have selected Pilot
Operated Sub Plated mounted Valve of Size NG 16 considering the Nominal Flow of 228 LPM. The Pressure Setting
on each valve is adjustable through a Hand Knob.
VALVE STANDS
The valve stands of adequate dimension shall be of manifold construction. The valve stand shall primarily consists of
various types of control valves mounted on vertically arranged manifold blocks. Material of manifold block shall be
forged steel / GGG 40.
All the electrical connection shall be wired to a common junction box mounted on each valve stand.
All necessary equipment onboard piping between various units i.e. tank, accumulator stand, pumping unit and valve
stands and between valve stands and equipment shall be provided. The onboard piping shall complete with high
pressure hoses, pipes/tubes, welded nipple type with O-ring type fittings, SAE flanges, heavy duty PP clamps, etc as
required.
Electrical
General
Voltage: 415 V ±10%, 3 Phase
Frequency: 50 Hz +3%, -6%
Aux voltage: 110 v AC (Normal Supply) UPS voltage – 230 V AC
For Instruments – 24 v DC
Electric motors
LCS shall be fabricated from 2 mm thick sheet mild steel, powder coated and shall be suitable to install on walls,
structures, columns etc. Local control panel have indication lamp, amp. Meter, isolation transformer for control
supply.
They shall be dust & vermin proof and protected against rain with minimum IP-55 protection class. LCS to be
installed in outdoor areas shall be provided with canopy arrangement.
LCS shall have start Push button (PB), stop push button (Lockable type). (In case of RDOL motors, forward and
reverse start push buttons)
- START PB - GREEN
- STOP PB ( Lockable type) - RED
- Indicating Lamp – On - RED
- Indicating Lamp – OFF - GREEN
- Indicating Lamp – TRIP - ORANGE
20% extra Terminal Box (TB) shall be considered, all TB shall be Push/Pull type and indication shall be LED. TB shall be
made of polyamide material. STOP PB 2 NC Element and START PB 2 NO+2NC type shall be considered.
I. Flow Meter
2. Internal Test Certificate(Certificate of Conformance) for Tank Assembly, using Kerosene& Chalk Swab /
Water Check for Bulge & Hydrostatic Test / Radiographic Weld Test Report
3. Test Certificate for Manifold Block
4. Test Certificate for Coupling
5. Internal test Certificate for Flow & Pressure for Pump
6. Internal Test Certificate for Electric Motor
7. Pressure Test Certificate for all Interconnect Hoses
8. Commissioning spares and list of 2 years of normal operation spares
9. Bill of Materials with Make List
10. Complete GA and detail drawings of interconnecting piping
11. Operation & Maintenance Manuals
12. Spares Manual/Product Catalogues for Components
13. Material Test Certificate of Hoses/Pipes/Forgings/Castings
INSPECTION AND TESTING
Inspection and testing of equipment/ items shall be carried out by the Customer or an authorized
representative of the Customer at the workshop of supplier during manufacturing and on final product to ensure
conformity of the same with the acceptable criteria of technical specification, approved drawings, authenticated
manufacturing drawings and reference national / international standards.
Customer or authorized representative of customer, shall have the right to visit our premises to check the
physical progress of work, inspection, testing etc., of the contract items or any part thereof at any time during all
stages of manufacturing. We shall extend all necessary facilities for carrying out such inspection and check of
progress of work.
Inspection of equipment/ item by customer/ authorized representative of customer shall be only with a view
to ensure that the equipment/ item is being fabricated / manufactured, assembled, tested as per approved drawings
and prescribed specifications.
Manufacturer’s test certificates shall be furnished by us for all bought out materials, components etc.We
shall furnish certificates for material test, heat treatment test, Physical & Chemical test reports for all Fabricated /
Casted / Forged items, & other records of internal quality control (whichever is applicable) along with the
InspectionCall.
After assembly the complete Hydraulic System shall be tested for the following parameters:
i. Visual inspection
The following specification shall be applicable for all equipment covered under this document unless
separate painting specification is elaborated in the respective attachments.
This specification covers the facilities and quality requirement for surface preparation and painting of
structures, equipment, piping, etc. The term "painting" referred herein covers rust preventive, preventive and
decorative coating along with surface protection.
Surfaces made of aluminum brass, bronze, stainless steel, cast iron and other corrosion resistant alloys are
not required to be painted unless specified except for aesthetic purposes or for identification bands. All machined
mating surfaces (e.g. flanges) shall be properly cleaned, greased and rust preventive before dispatch.
General compatibility between primer and finishing paints shall be certified by the paint manufacturer
supplying the paints.
Areas which become inaccessible after assembly shall be painted before assembly (after painting clearance
has been given by the inspecting authority) after requisite surface cleaning as specified.
The machine finished surfaces shall be coated with white lead and covered before shipment or before being
put out into the open air.
The colour code to be followed for the final coat shall be intimated to the successful supplier.
The complete paint system for any item includes the following activities
Surfaces which cannot be painted but require protection shall be given a coat of rust inhibitive grease according to
standards. The general guideline followed for painting is asfollows:
Preparation
Painting scheme
Total DFT
Surface
Sl.
Description
No.
At shop At shop
2coats of a two pack air drying Epoxy 2 coats of a single pack synthetic
polyamide with zinc dust of at least rubber based aluminium paint.
Equipment with {Air drying time - 2 hours (touch
92% zinc dust on the dry film.{Epoxy
SP-Sa 2 1/2
hot surfaces BASED), Total solid (3 wt) - 84 ±2, drying time - 3 to 4 hours (touch
3 (temp. up to dry), 24 hours (hard dry), 180
Density- 3.07 ±0.005, Air drying
400°C) time- 16 hours, DFT/Coat - 60 DFT/Coat - 20 microns (min),
microns, Temperature resistance - up Temperature resistance
to 450°C dry heat} - up to 400°C dry heat, Colour
- smooth aluminium
BILL OF MATERIAL / BILL OF QUANTITY
2. Replacement of the Hand Operated DC Valve and Valve Unit (42,43,44,45) with Automated Oil
Management System
The Existing System design has the following shortcomings:
• Flowmeter only provides transient value of Flow on each line and doesn’t indicate important
parameters like total oil input in the system.
• The amount of oil to be filled cannot be predetermined and needs to be manually controlled. This
may lead to overflow of Oil.
• No central control of the system, each time a Power Unit must be refilled, the ball valves must be
opened and closed manually
• Ball Valves/DC Valves are prone to leakages if not closed properly
We Suggest the replacement of the following units with the BOM as follows :
1. Centralized Operation(Either from Panel or SCADA in Control Room) of the Entire Refilling Station
2. Logs of Exact amount of Oil Filled in Each Hydraulic System over past 1000 Times.
3. Instant Operation without physical access to different power units.
4. Exact amount of Oil as desired can be poured into the System without manual oversight.
5. Minimizes chances of Leakages due to Ball Valves.
6. One Totalizer required instead of 5 separate flowmeters.
The Scope of Supply does not Include:
Notes :