VRU_technical_requirements_EN.pdf

Requisition for Vapour Recovery Unit

C 22-04-2011 Quotation request N. Motiejunas SV rev. date description/issued for drawn up ckd.

client: SC "Klaipėdos Nafta" project: Crude oil vapour utilization from railway estacada title: Requisition for Vapour Recovery Unit

office: Kaunas order: 73256

document: 2499013

rev.: C

sheet: 1

of: 1

Order No.

73256

This requisition covers the minimum technical requirements for the design, fabrication, assembly,

inspection and vendor documents for the above named equipment, in accordance with the

documents listed below.

Quant. Name of document Document no. Rev. Date

1

Technical Specification for Vapour Recovery Unit VRU facility site layout plan Process & Instruments Diagram Specification for Structural Steel Design and Fabrication Project Specification for Mechanical Equipment Specification for Pipes Specification for Valves Specification Electrical Requirements for Package Units Instrumentation specification for package units General Paint Specification for Surface Preparation and Coating Required Documents for Vapour Recovery Unit Appendix 1 – Crude oil physical properties Appendix 2 – Crude oil physical properties Appendix 3 – Figure of Vapour Recovery Unit Working Profiles

2489002

1162001

3143408

1182008

2111001

2981001

2983001

4199030

4388001

7182001

6551408

D

A

P 0 0 0 0 0

A 0 0

B

22/04/11

19/04/11

22/04/11

21/10/10

27/09/10

21/10/10

21/10/10

21/10/10

04/11/10

21/10/10

14/10/10

22/04/11

Y:\73256_KN angliavandeniliu garu util izavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\2489002 Tech Spec rev D.DOC

D 22-04-2011 Updated chapters N. Motiejūnas SV rev. date description / issued for drawn up ckd.

client: SC "Klaipėdos Nafta" project: Crude oil vapour utilization from railway estacada title: Technical Specification for Vapour Recovery Unit

office: Kaunas Order: 73256

document: 2489002

rev.: D

sheet: 1

of: 22

Technical Specification for Vapour Recovery Unit


office: Lithuania Order: 73256 document: 2489002 rev.: D sheet: 2 of: 22

Table of contents page

1 Introduction 3

2 Scope of supply 3 2.1 Vendor's responsibility 3 2.2 Battery limits 4 2.3 Exclusions 4 2.4 Spare parts and special tools 4 2.5 Warranty time 4

3 Vapour profile 4 3.1 Train gasoline unloading 4 3.2 Train Crude loading 5 3.3 Design case 5 3.4 Vapor recovery operating profiles 5

4 Design and material requirements 6 4.1 General 6 4.2 Technical 6 4.3 The vendor scope of project-related services is as follows: 9 4.4 VRU Equipment Supply Specification 9 4.5 Specific Specifications 9 The vendor shall identify the specifics of each of the above in offer, as follows: 9 4.6 Spare Parts 15 4.7 Special Tools And Tackles 15 4.8 Instrumentation 15 4.9 Control system 18 4.10 Software 18 4.11 PERFORMANCE GUARANTEE 20 4.12 Warranty 21 4.13 Painting 21 4.14 Materials 21 4.15 Utility consumptions 21

5 Codes and standards 21

6 Inspection, factory testing and shipment 22 6.1 Inspection 22 6.2 Factory testing 22 6.3 Shipment 22

7 Erection, start-up, training of operators and acceptance 22

8 Quality assurance 22

9 Vendor documents required 22



1 Introduction

SC “Klaipėdos Nafta” intends to install hydrocarbon Vapor Recovery Unit (VRU) in order to

recover VOC (Volatile Organic Compounds) during train loading / unloading operations with

crude and refined products: gasoline, diesel, fuel oil.

2 Scope of supply

This specification covers the minimum requirements for the design, assembly, testing, supply

and documentation.

The selected vendor will undertake procurement of VRU component raw materials, fabrication

in accordance with the most current standards, inspection at works, assembly, pre-testing at

works, painting, functional testing of the PLC (800xA system) operating and integrated in to

existing 800XA system and all annunciation and operational software, supervision of erection,

commissioning, start-up and training of client’s personnel to operate the Vapor Recovery Unit.

The vendor shall provide a Performance Test of complete Vapor Recovery Unit (VRU) at site.

This test shall be conducted in accordance with standard practices and shall prove the

function of the VRU consistent with the emissions specifications, data sheets, local standards,

all drawings, and shall be consistent with the client’s original emissions and performance

requirements. The Vendor shall suggest and offer a proven package for Vapor Recovery Unit. Vendor’s scope shall include all equipment, items, piping, structures, electrical, Instrumentation and controls etc. as required according to the proposed scheme, within the system battery limit. Vendor shall furnish complete details of their supply in the bid.

2.1 Vendor's responsibility

It is the responsibility of the Vendor to complete the scope of supply and to furnish a complete,

reliable and safe system including all materials, services and documents, except those

specifically indicated in chapter "Exclusions".

The VRU supplied shall be supplied as a complete system, including all required auxiliary

equipment, skidded and assembled where possible, and suitable efficient and satisfactory

operation and maintenance as a whole for the purpose intended. In order to provide for normal

maintenance, all components and subcomponents shall be designed and installed in such a

manner as they are removable/replaceable without the disassembly or removal of other

adjacent components. Vendor shall be responsible for furnishing all documentation, operating

and maintenance manuals (in Lithuanian and English languages), mechanical, electrical,

instrumentation, structural supports, piping, wiring, pressure vessels, software, controls,

PC/PLC operational manuals, VRU training materials/presentation, and other interconnecting

and safety items as may be required to make the system complete.

Part of the scope is support from Vendor specialist during VRU installation, commissioning,

start-up and training of operating personal.

All materials supplied under this specification shall be new, shall be provided with a

performance guarantee and all OEM warranties, and shall be adequate for the proposed

service per this specification. Proper consideration shall be given to their function with regard



to corrosion, chemical and other processes, fire hazards, and erosion due to the design and/or

the medium being handled.

2.2 Battery limits

The battery limits for the VRU are the connecting flanges and electrical cable connections.

The Vendor shall submit with his quotation assembly drawings showing all Purchasers’

connections with detailed information.

2.3 Exclusions

- foundations (civil works);

- main power supply;

- compressed air supply;

- steam supply;

2.4 Spare parts and special tools

The Vendor shall separately quote for all the necessary spare parts for 2 (two) year operation,

commissioning and special tools required. Also should be included all necessary materials

and tools for VRU start-up operation.

2.5 Warranty time

The delivery should be covered by warranty in a period of 24 months after start-up of the unit

or 30 months after delivery on site.

3 Vapour profile

Products: Crude, Gasoline, Diesel, Heavy fuel oil, etc.

Crude oil physical properties shown on appendix 1 and appendix 2, included with this

requisition.

3.1 Train gasoline unloading

The vapour will be produced during filling the empty unloading headers and buffer vessels with

product from railcars. The pipes and will contain some product from previous load, so vapour

concentration can be high from the beginning to the end of the process. The duration of

process will be about 10 minutes at capacity of 1700 m3/hour with concentration of up to 60%.

Gasoline data:

Standard: EN 228:2009



3.2 Train Crude loading

The railcars will contain some product from previous cargo. The railcars will be loaded by

means of bottom loading arms. The start concentration is estimated to be ~15% with loading

capacity of 1800 m3/hour and will grow to 60% at the end of loading operation, however the

capacity at the end of loading will be reduced to 900 m3/hour.

Crude data:

Type: Venezuela Santa Barbara

RVP: 7,70 psi @ 100 0F

Sulphur: up to 1,00 % mass

3.3 Design case

Table of VRU unit vapour capacities:

Units

Gasoline

unloading

Crude

loading

Total

simultaneous

Maximum instantaneous vapour flow m3/h 1700 1800 3000

Maximum 3 minute vapour capacity

from beginning loading/unloading m3 15 90

Maximum 10 minute vapour capacity

from beginning loading/unloading m3 152 300

Maximum hour vapour capacity m3 1800

Maximum 4 hour vapour capacity m3 300 1800 2100

Maximum daily vapour capacity m3 9000

Nominal yearly vapour capacity m3 2 000 000 2 000 000

Maximum vapour flow: 3000 m3/hour.

Maximum design vapour concentration: 55 vol%.

Minimum vapour pressure at inlet point: 20 mbar.

Maximum vapour pressure at inlet point: 80 mbar.

3.4 Vapor recovery operating profiles

Vapor recovery unit working profiles figure shown on appendix 3, included with this requisition.



4 Design and material requirements

4.1 General

Availability unit: > 98% on annual basis.

Minimum lifetime: 20 years.

Minimum lifetime of carbon bed: 5 years.

The unit is operated intermittently and located outside near the sea.

4.2 Technical

Table of VRU unit main components, utilities and limits:

Adsorber vessel

Number installed pc 2 Carbon bed adsorber vessels with

adsorbents proven not to

overheat.

vessels suitable for full vacuum;

Filled with activated virgin mineral

carbon pellets

YES

Absorber column

Number installed (for gasoline and

for crude)

pc 1 with engineered hydraulic inlet

absorbent distributor, demister

guaranteed to prevent absorbent

carryover, concentrically enlarged

sump designed to prevent overfill,

and complete with sump level

transmitter and dedicated HH and

LL shutdowns level devices.

Vacuum system

Pump type * LIQUID RING or SCREW TYPE

Number of pumps pc. *

Electric motor with freq. controller YES

Absorbent pumps

Crude supply pump

YES Loose supply.

Tag: P-4/4-4002

Pressure drop in piping 1 bar

Return pumps:

Gasoline

Crude

YES

YES

Tag: P-4/4-4003


Tag: P-4/4-4004



* Vendor to confirm / complete



Piping

Vapor collection piping YES ANSI B-31.3 and 16.5

Battery limit of VRU system shall

have flanged connection with

isolation valves to match with the

outside B/L piping.

Blower

Blower with electric motor drive YES to move hydrocarbon vapors from

the source to the VRU.


Other equipment

In-line filter at VRU vapour inlet YES Mesh size of filter elements: 10µm;

2 pcs connected parrarel or duplex

contruction

Bidirectional Inlet Detonation

Arrestor

YES

Continuous emission analyzer YES Integrated in to the existing ABB

control system 800xA

One (1) lot of specialty instruments,

valves, and controls YES

One industrial PLC (800xA system) YES with SIL rating of 1 or higher

One (1) automation hardware

system (800xA system) YES Integrated in to the existing ABB


One (1) automation software

system (800xA system) YES Integrated in to the existing ABB


Ground Level Concentration

analyzer YES Suitable for the ambient conditions

specified

Inlet analyzer, temperature

transmitter, and flow meter for the

inlet vapor

YES Integrated in to the existing ABB


Automated valves Pneumatically

actuated

preferable

Pressure control valves at VRU

inlet:

Gasoline

Crude

YES

YES

max. pressure 10 bar

max. pressure 10 bar

Special tools and tackles for

operation and maintenance YES

Consumable spares for 12 months

operation

YES

Commissioning spares for the

Vapor Recovery Unit.

YES



Vendor shall ensure

First fill of lubricants, oil, grease etc. YES

Absorber cleaning with steam

(180oC, 10 bar), 1” steam inlet

flange

YES

Any additional item or feature

required during detail engineering

for the completeness and trouble-

free performance of the system

shall be deemed to be included in

the Vendor’s scope without any cost

and time implication to owner, as

long as the system performance

requirements within the battery

limits of the system are kept

unchanged.

YES

Vapour

Maximum vapour flow m3/h 3000 see loading/ unloading schedule

Minimum vapour pressure at VRU

inlet

mbar

(g)

20 at max. flow rate

Max. design vapour concentration vol % 55

Emissions and limits

VOC:

Gasoline

Crude

mg/m3

g/m3

150

10

for any one hour, excluding C1

for any one hour, excluding C1

Noise level dB(A) <85 at 1 meter distance of VRU unit

Hazardous zone classification I

Gas group IIB

Temperature rating T3

Dimensions ** m 25 x 10,2 L x W

Available utilities

Electrical power V 400 3ph. 50 Hz

Instrument air bar (g) 3,5 - 8

Steam (for absorber cleaning) deg. C

bar

185

10

** Estimated place, dimensions, VRU facility site layout plan, DWG. No. 1162001

Diagram of vapour and absorbers flows to VRU unit see in Process & Instruments Diagram,

DWG. No. 3143408, included in the Requisition.



4.3 The vendor scope of project-related services is as follows:

o Process design engineering

o Detailed mechanical and electrical design engineering

o Documentation for all design engineering and components

o Procurement of equipment and materials

o Preparation and submission of all drawings and specification sheets for approval by purchaser

o Surface preparation, protective coating, and painting as per attached painting specifications

o Inspection and testing

o Transport to site

o Supervision of erection

o Commissioning of Vapor Recovery Unit

o Start-up of the VRU under normal terminal conditions

o Performance test of the complete system at site

o Training for clients’ operating personnel provided at site following commissioning and start-up.

o One full day of classroom and one full day of on-site training for owner’s operating personnel

including PLC and VRU control system functions.

4.4 VRU Equipment Supply Specification

The process description is an “automated, self-managing, short cycle, AdAb, activated carbon

based, hydrocarbon vapor recovery system”. All pressure vessels shall be designed in strict

accordance with the PED and Machine Directive 89/329/EEG of the European Community which

has been amended by directives 91/363/EEG, 94/44/EEG, and 93/68/EEG. All nozzles 1” and

larger shall be ANSI 150 RF flanges consistent with ANSI standards. All nozzles smaller than 1”

shall be full couplings rated at 3000# or greater, or the equivalent Threadolet/Weldolet.

4.5 Specific Specifications

The vendor shall identify the specifics of each of the above in offer, as follows:

Designed Carbon Vessels:

The carbon vessels shall be designed and fabricated in accord with PED. The civil engineering

shall include the bed support and leg beams. The bed support shall be 1” X 3” bar grate suitable

to comply with the dead weight of wet carbon. The carbon shall be supported above the bar

grate on two layers of replaceable stainless steel mesh. Each carbon vessel shall have at least

three 6” carbon fill nozzles in the top head, one ANSI flanged relief valve connection for an

included fire-rated relief valve, one 24” manway above and near the bottom head seam with a

blind and davit, three temperature indicator connections, and appropriately sized ANSI flanged

inlet and outlet. Flow diffusers shall cover both the inlet and outlet openings.

Number to be supplied 2 (two)

Diameter_________

Seam-to-seam shell height_________

Head type_____________

Design working pressure____________

Designed for full vacuum (Yes/No) _____________

MAWP______________

Shell: grade of steel____________

Thickness w/o corrosion allowance_________

Corrosion allowance_____________

Heads: grade of steel____________




Corrosion allowance 3 mm

Base type (Skirt/Legs) ______________

Foundation contact area/load__________/_____________

Total number of vessel fittings________________

Service designation and size___________








Carbon supplier/manufacturer/processor______________

Carbon brand name________________

Base carbon material (Wood, Coal, Other) ____________

Carbon particle size_____ X ________

Carbon density___________

Total weight of carbon to be supplied for this project______________

Absorber Vessel:

The absorber vessel shall be designed with accordance to PED and at least 90% contact

efficiency. This vessel may be a single piece or two piece vessels. If it is a two-piece vessel,

the two pieces shall be joined by an ANSI RF flange. The Absorber section shall have an

engineered inlet absorbent distributor designed to provide uniform distribution of the sorbent

liquid. It shall be a randomly packed column which shall be designed with a minimum of four

(4) theoretical trays. This section shall include a removable demister, a RF flanged relief

valve connection sized for the fire case and included, a rich-vapor ANSI flanged outlet

nozzle extended into the vessel and up to very near the top of the inside, and a bar grate

and screen support for the IMPT or equal random packing. The absorber sump section shall

be tall enough to provide for adequate NPSH for the absorbent return pump. It shall have

level control and hi/lo shutdown connection, a pressure gauge connection, a coolant

gasoline return ANSI flanged connection, a bottom drain, an anti-vortex ANSI RF flanged

pump suction connection near the bottom, and an ANSI RF flanged vapor inlet. Facility for

absorber column and related piping cleaning by steam (185oC, 10 bar) should be included

by providing an appropriate steam inlet and outlet. The steaming is required when changing

absorber from crude to gasoline.

Number to be supplied 1 (one)

Absorber Section

Diameter_________


Head type_____________



MAWP______________







Demister type__________________

Diameter___________

Depth__________

Material of construction_________

Relief valve size _______X_________

Type______________



Manufacturer________________

Sump Section

Diameter_________


Head type_____________



MAWP______________



Corrosion allowance 3 mm




Base type (Skirt/Legs) ______________

Foundation contact area/load__________ _____________

Total weight of vessel dry______________

Total weight of vessel wet______________

Total weight of vessel flooded___________

Total number of vessel fittings________________









Total weight of vessel dry______________

Total weight of vessel wet______________

Total weight of vessel flooded___________

Vacuum Pump(s):

The vacuum pumps shall be designed and suitable for at least 15,000 of continuous service

run-time hours. The vacuum pump shall be base mounted and coupled to an explosion proof

motor of suitable size and rated for VFD operation (inductance duty), complete with coupling

with one (1) coupling guard per pump. The motor shall be fitted with an internal heat switch

which shall be tied to the PLC to alert the owner’s operations staff in the event of a heat-up.

The pump and motor shall be Laser aligned by the vendor after installation at the site and

before start-up. The motor shall be fitted with an internal high-temperature switch tied to the

PLC. The base shall be secured to the VRU foundation to prevent the transmission of

vibration back to the carbon beds through the interconnecting piping. At least one bellows-

type expansion joint shall be supplied for the inlet side of the pump. The vendor shall provide

for thrust blocks or other pipe supports for the discharge piping, each of which shall be

designed to prevent vibration. The suction of each pump shall be fitted with a cone strainer

with 1/32”/0.8mm screen captured between two RF ANSI flanges. All (vapor, coolant) flows

shall be monitored by flow indicating transmitters. The flows shall be adjustable. The vapor

coolant flow shall be stopped during all periods of pump-off time, and shall be reinitiated

during period of pump-on times. This flow shall be managed by two (2) solenoid valves,

each with a discrete open/closed signal from the PLC. Each pump shall be fitted with a RPM

monitor tied to the PLC.

Manufacturer_________________

Model number_____________

Motor HP rating_______________

50Hz

3 Phase (Yes/No) Yes



Suitable for VFD control (Yes/No) Yes

Capacity @ full speed________

Weight______________

Mounting method____________

Maximum Torr rating__________

Hours between overhauls__________

Jacket coolant flow rate_____________

Vapor coolant flow rate_____________

Vibration detection included (Yes/No) Yes

VFD Model and Size _______________and ___________

Maximum current draw______________

Design turndown______________

Minimum turning RPM______________

Coupling model number

Brand______________

Model number________________

Coupling guard included (Yes/No) Yes

Inlet connection size______________

Outlet connection size_______________

Vapor coolant meter type/size________________________/__________

Jacket coolant meter type/size________________________/__________

Absorber Supply Pumps:

The supply pump shall be complete with suitable explosion proof motor fitted on a base to

the pump via a coupling. The motor shall be fitted with an internal high-heat switch tied to

the PLC. It shall be sized to move the absorbent from the owner’s absorbent storage to the

VRU site. It shall be shipped lose for installation at close proximity to the client’s day tank by

others. It shall include, as a minimum:

For Crude:

Manufacturer__________________________

Model number__________________________

Design capacity at full rpm_____________@_______________

Mechanical seal (Yes/No) ________________

Motor Type/Class_______________________

Motor size and HP rating _______________ and ______________

Motor temperature switch included (Yes/No) Yes


Motor VFD rated (Yes/No) ______________

Coupling model number__________________

Coupling guard included (Yes/No) ______________

Base model number________________

Dimension to suction centerline______________

Absorber Return Pumps:

The return pump shall be complete with suitable explosion proof motor fitted on a base

to the pump via coupling. The motor shall be fitted with an internal high-heat switch tied

to the PLC. It shall be sized to move absorbent form the VRU to the owner’s day tank. It

shall be assembled, mounted and shipped on the same base as all other VRU

equipment. It shall include, as a minimum:

Fro Gasoline:

Manufacturer__________________________

Model number__________________________






Motor Type/Class_______________________








For Crude:

Manufacturer__________________________

Model number__________________________




Motor Type/Class_______________________








Vapor Inlet/Outlet Piping:

All piping shall be designed per the ANSI B31.3 and 16.5 for flows well below turbulent flow

velocities, and large enough to minimize the flowing pressure drop. The vendor will provide

the following:

Vapor Pipe Size(s) ________

Schedule 40

Working Pressure__________

Seamless (Yes/No) Yes

Grade___________

Supply Gasoline Pipe Size(s) ________

Schedule 40



Grade___________

Return Gasoline Pipe Size(s) ________

Schedule 40



Grade___________

Vapor Inlet/Outlet Switching Valves:

All vapor switching valves shall be high performance, bubble tight, lug-type butterfly valves

with replaceable Viton o-ring cushioned Teflon seats, Viton seals, and electric or pneumatic

motor operators. The liquid gasoline circulation valves shall also be MOVs, however these

two valves MUST use fail closed operators, without fail or exception. Vendor shall list vapor

and gasoline valve specifics below.

Brand______________________

Type________________________

Model Number, Size, and Torque:

o Vapor valves_______ _________ _________



o Vacuum valves_____ _________ ___________

o Gasoline circulation line valves________ _______ ___________

Valves are bubble tight, high performance (Yes/No) ________

Valves are “lug-type” (Yes/No) ________

All valve actuators shall be RCS electrically operated of suitable torque to completely

seat and unseat the valve each is joined with in any temperature or ambient condition.

Each actuator shall be supplied with one coupling kit for joining it properly with its

respective valve. Each actuator shall be supplied with on-off limit switches indicating the

open and closed positions with one pair of installed spare switches

Brand offered____________

Type and size of valve actuators (list all)

o _____________ ________

o _____________ ________

o _____________ ________

o _____________ ________

o _____________ ________

o _____________ ________

Maximum torque of each actuator (list for each size valve)

o _____________ ________

o _____________ ________

o _____________ ________

o _____________ ________

Operating current___________

Maximum operating amperage_____________

o SIL rating_____________

o NEMA rating____________

Maximum design pressure drop across each carbon bed loaded with vendor’s activated

carbon and ready for service_____



4.6 Spare Parts

4.5.1. Vendor shall submit recommended list of spare parts with itemized prices for first two years'

of operation of the equipment with bid. Proper coding and referencing of spare parts shall be

done so that later identification with appropriate equipment will be facilitated. Total cost of

spares shall be included in lump-sum price of the system.

4.5.2. Vendor shall also submit a list of commissioning spares with quantity. Total cost of

commissioning spares shall be included in lump-sum price of the system.

4.5.3. Vendor shall also guarantee that commissioning spares, if required over and above the

commissioning spares included in the order shall be made available without any cost and

time implication to the owner. If, for any reason during commissioning, Vendor needs to

utilize spares from list of 2 years normal operational spares, he will replenish the same free

of cost duly delivered at site including all freights, insurance, taxes, and duties.

4.5.4. Mandatory spares shall be supplied per Instrumentation specifications and their price to be

included in the lump sum price of the system.

4.7 Special Tools And Tackles

The Vendor shall provide a set of new, unused special tools and tackles required for operation and

maintenance of the Vapor Recovery system. Price above shall also be included in the basic cost of

the package.

4.8 Instrumentation

All necessary instrumentation, safety interlock & analyzer for measuring inlet and exit Gas

concentration for smooth and safe functioning of the system is considered under the vendor’s scope

of supply. The instrumentation selected by each vendor is critical to the operational reliability,

efficiency, maintenance, and life of the overall system. Therefore it is necessary for the vendor to use

only devices considered to be standards of the industry, suitably rated, tested, and certified. The

same holds for the automation system as well.

Instrumentation Requirements:

All instruments shall be UL/Cenelec approved for a Class1, Division 2 environment, or equal.

4.7.1. The inlet vapor flow shall be measured at all times. The flow meter shall be a vortex shedding

type with no moving parts and shall be rated for the service it is in. It shall be calibrated to

span the flow of vapor for this application from no flow to the maximum flow with a 20%

overage so it will measure unusually high instantaneous flows. It shall be rated for Class1,

Division 2 service, and shall be locally indicating. It shall be an insert-type, manufactured for

ease of removal from the inlet vapor piping without having to shut the vapor flow off for

instrument extraction. The instrument shall be shielded from all external “noise”, and shall

generate a 4-20ma linear output consistent with the overall flow rate.

4.7.2. The inlet vapor stream shall be sampled and the sample shall be fed to an inlet vapor

hydrocarbon analyzer to determine the inlet hydrocarbon concentration at all times. This

analyzer shall be in constant communication with the PLC/HMI. The sample shall be collected

from a probe reaching into the center of the pipe being sampled to assure uniformity of

sampling.

4.7.3. The inlet vapor temperature shall be measured at all times. The temperature element used

shall be of the RTD type, and shall generate a linear output signal consistent with the

temperature being measured.



4.7.4. The inlet vapor temperature and pressure shall be indicated locally and/or to the PLC at all

times.

4.7.5. The inlet “supply” gasoline, crude flow shall be measured at all times using a FIT

communicating with the PLC/HMI.

4.7.6. The exiting “return” gasoline, crude flow shall be measured at all times using a FIT

communicating with the PLC/HMI.

4.7.7. The inlet “jacket coolant” gasoline, crude flow to each vacuum pump shall be measured at all

times using a FIT communicating with the PLC/ HMI.

4.7.8. The inlet “vapor coolant” gasoline, crude flow shall be measured at all times using a FIT

communicating with the PLC/ HMI..

4.7.9. The jacket coolant gasoline, crude temperature shall be measured leaving each vacuum pump

with a TE which communicates constantly with the PLC/ HMI.

4.7.10. The supply gasoline temperature shall be measured as it enters the VRS upstream of the

Absorber Column with a TE which communicates constantly with the PLC/ HMI.

4.7.11. The return gasoline temperature shall be measured as it exits the VRS downstream of the

Absorber Column with a TE which communicates constantly with the PLC/ HMI.

4.7.12. The discharge vapor temperature shall be measured constantly as the vapor leaves the final

pump stage of each vacuum pump with a TE which communicates constantly with the

PLC/HMI.

4.7.13. The true rotating speed of each vacuum pump shall be measured constantly and shall

communicate with the PLC/ HMI.

4.7.14. All motors shall have motor heat switches which shall be monitored by the PLC constantly,

and which will shut down any motor that overheats immediately.

4.7.15. The all flows shall be measured using appropriately sized restriction orifices mounted in

conventional and dedicated orifice flanges with all flow rate signals generated by flow

indicating differential pressure transmitters.

4.7.16. Temperature indicators shall be at least 5” dial face every-angle type. One each shall be

installed on the vapor inlet line, the suction and discharge of each vacuum pump, and on the

vapor outlet line. All temperature indicators shall be supplied with thermowells that reach to

the center of each pipe in which they are fitted.

4.7.17. All pressure indicators shall be at least 5” dial face glycerin filled gauges with the maximum

pressure at or slightly above the MAWP of the pipe or vessel it is fitted into. Each pressure

indicator shall be fitted with an upstream isolation ball valve. These shall be installed on the

vapor inlet line, the vapor vacuum line from each carbon vessel, the supply and return

gasoline,crude lines, the vapor and jacket coolant lines feeding each vacuum pump, and the

Absorber Column.

4.7.18. Each carbon vessel shall be fitted with a vacuum transmitter with a vacuum measurement.

Each vacuum transmitter shall be fitted with an upstream isolation valve.

4.7.19. The outlet vapor stream shall be sampled and the sample shall be fed to an inlet vapor

hydrocarbon analyzer to determine the inlet hydrocarbon concentration at all times. This

analyzer shall be in constant communication with the PLC/ HMI. The sample shall be collected



from a probe reaching into the center of the pipe being sampled to assure uniformity of

sampling.

4.7.20. Vendor Shall List All Instruments to be Supplied Below:

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

Automatic Vapor and Liquid Valve Requirements:

4.7.21. All automatic valves shall be bubble tight, high performance, lug-type butterfly valves sized

to maintain all flow velocities well below erosion velocity at all times.

4.7.22. Each main automatic vapor switching valve shall be coupled to an RCS or equal electric

actuator sized to assure proper torque considerations when moving the high performance

butterfly valves into and off of their seats. All torque rating shall exceed the torque

requirements of the valves by at least 50%. Each automatic valve shall include:

o Four micro-switches. Two shall indicate the full open and full closed positions of the

valve, and two shall be used as installed spares.

o Each automatic valve actuator shall be fitted with a brake for precise stopping of the

valve at its open and close positions.

o Each actuator shall be rated for Class 1, Division 2 service, or better.

o Each automatic valve shall communicate with the PLC/ HMI constantly.

4.7.23. The system shall be also fitted with dedicated solenoid valves suitable for Class 1, Division 2

service, and rated for the appropriate pressure or vacuum consistent with the application of

each. Each solenoid valve shall be normally closed.

4.7.24. The gasoline supply and return lines shall be fitted with two fail closed bubble tight, high

performance butterfly valves with RCS Sur49 spring closed pneumatic actuators, or equal.

4.7.25. Vendor Shall List All Instruments to be Supplied Below:

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________



o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

o ________________________________________________________________

4.7.26. Manual Vapor and Liquid Valve Requirements:

All manual valves shall be bubble tight, high performance full-open ball and fine hand-wheel

adjustment globe valves. Each shall be manufactured from either cast steel or stainless

steel, and shall be specified or pressure and materials of construction consistent with the

service into which each is placed. Only Viton and Teflon elastomers may be supplied.

o Valves smaller than 1” may be NPT threaded.

o Valves 1” and larger shall be ANSI RF flanged consistent with Class 150 as a minimum.

4.7.27. All instruments shall be UL/Cenelec approved for a Class1, Division 2 environment or equal.

4.7.28. The vendor is required to demonstrate operating the VRU during start-up when loading

operation is being carried out.

4.7.29. The vendor is also responsible to commission the VRU and fine tune all controls such that it

operates smoothly. Vendor is to rectify any defect or replace the defective equipment as

required if the need arises within 24 months from the date of commissioning at no cost to the

Owner.

4.7.30. The vendor is to conduct the performance test for the vapor recovery system and prove the

recovery as stipulated in the process data during the start-up process. The VRU shall be

designed to continuously indicate the true instantaneous emissions on the 800xa based on

the inlet mass flow. The vendor shall specify the procedure of the performance test and

submit it to the owner for approval 60 days prior to the planned performance test.

4.9 Control system

Control and monitoring of VRU package unit shall be realized from existing operator work

station (PC). VRU process control equipment shall be integrated with existing process control

800xA system. For that reason all necessary VRU field instrumentation (e.g. sensors, actuator

valves, etc.) shall be integrated to ABB make AC 800M Series controller.

System must be provided with an emergency shut down system which can be connected to the

existing emergency shutdown system.

4.10 Software

4.9.1. Vendor shall develop VRU operating software to 1) optimize the VRS operation to reduce

energy consumption while maintaining the emissions at or below the target level, and 2)

regenerate only on an as-needed basis using the absorbed mass of hydrocarbons as the

primary regeneration trigger, and emission level as the over-riding trigger.



4.9.2. Vendor’s operating software shall automatically control the amount of purge air fed to each

carbon bed using a dedicated valve and flow control device. Purge air shall be allowed to

enter each carbon vessel at the conclusion of each regeneration cycle. The PLC logic shall

determine the amount of purge air entering in each cycle based on the mass of

hydrocarbons loaded onto the carbon in the previous bed loading cycle so that the operators

need not make any manual adjustments for the life of the system.

4.9.3. Vendors operating software and controls system shall automatically control the re-pressure

air system with a dedicated flow control valve and flow control device such that the operators

need not make any manual adjustments for the life of the system.

4.9.4. In order to prove the energy efficiency of the vendors VRU, vendors operating software shall

calculate the mass of hydrocarbons adsorbed, compare it with the adsorption capacity of the

carbon supplied, and trigger regeneration only when the adsorbed mass reaches a preset

fraction based on the maximum possible adsorbed hydrocarbons.

4.9.5. Vendor’s operating software shall make a permanent record of the actual volume of VRU

recovered gasoline and store this data in units of recovered liters daily, weekly, monthly,

annually, and since start-up.

4.9.6. Vendor’s operating software and controls system shall be designed to monitor the travel and

position of each vapor flow and liquid flow valve in the VRU and to alarm or shutdown in the

event of any malfunction. Vendor shall identify for the owner which malfunctions are alarms

and which are shutdowns. Vendors HMI shall annunciate each according this schedule.

4.9.7. Vendor’s operating software and controls systems shall be developed to monitor, control,

and optimize the absorber pressure during each individual regeneration cycle by varying the

absorber pressure to optimize the adsorption efficiency and minimize the hydrocarbon

loading on the in-service adsorbing carbon.

4.9.8. Vendor’s operating software shall be written to allow for 1) logical progressive normal

shutdowns, 2) immediate emergency shutdowns (ESDs), 3) automatic start-up or re-start

after all alarms/shutdowns are reset. Each shall be recorded on discrete HMI logs which

shall stay active in real time for at least 33 days.

4.9.9. Vendor’s software shall be designed to operate the supply and return pumps in both the

automatic and manual modes operating via HOA switches. The position of these switches

shall be annunciated on Vendor’s HMI graphics.

4.9.10. Vendor’s operating software shall monitor all temperature transmitters continuously, and

shall alarm and/or shutdown the VRS upon published alarm and shutdown temperature

values. These values shall be annunciated on Vendor’s HMI graphics.

4.9.11. Vendor’s software shall monitor all motors and pumps for proper and safe operating

conditions. Each shall be annunciated on Vendor’s HMI graphics.

4.9.12. Vendor’s operating software shall monitor the HOA status of each motor. Each shall be

annunciated on Vendor’s HMI graphics.

4.9.13. Vendor’s operating software and controls system shall measure and monitor the supply and

return liquid flow rates and temperatures, and the vapor inlet flow rate and temperature at all

times. All such values shall be annunciated on Vendor’s HMI graphics.

4.9.14. Vendor’s operating software package shall be fully functional with or without the HMI system

in operation.



4.9.15. Vendor’s HMI software and graphics package shall provide for an overview (Main) screen

that continuously reports all real-time flows, temperatures, pressures/vacuum levels,

pumping speeds, loading status lane-by-lane, liquid levels, emissions, loading rates, and

recovered product volumes at all times. All such values shall be annunciated on Vendor’s

HMI graphics.

4.9.16. Vendor’s HMI software and graphics package shall include dedicated HMI separate trend

line and separate data screens for real time and historical alarms, historical and real time

shutdowns, historical and real time emissions, real time emissions levels, real time vacuum

pump operating parameters including RPM, coolant flow and temperatures to jacket and

vapor, and vapor discharge temperature.

4.9.17. Original site specific adjustable set-up information so the site personnel with proper security

clearance can make operating parameter adjustments to fine tune the system over time.

4.9.18. A layered security-enabled log-in status record graphic panel.

4.9.19. Vendor’s HMI and PLC shall be configured with a 24/7 high-speed DSL link to the internet

for secured and continuous off-site monitoring.

4.9.20. Owner shall provide a continuous DSL connection suitable for remote monitoring 24/7.

4.9.21. Vendor’s shall include off-site monitoring of the in-service system for a minimum of 24

months after start-up at no additional cost to the owner, and shall include an option to renew

the monitoring service thereafter.

4.11 PERFORMANCE GUARANTEE

4.10.1. All equipment and components shall be guaranteed by the Vendor against any defective

material, design, and/or workmanship for the period specified in the commercial document.

4.10.2. After installation and commissioning at site, the system shall be tested for overall

performance as per procedures mutually agreed upon. Vendor shall, at his own cost,

arrange all instruments and controls required for testing at site.

4.10.3. Vendor shall demonstrate the following parameters at site during performance test:

• Emission level meets the bid requirements

• Document the recovered volumes per unit volume loaded



4.12 Warranty

4.11.1. Vendor shall warrant the system to be free of defects and workmanship for a period not less

than 24 months from delivery or 18 months after start-up, whichever shall occur first.

4.11.2. Vendor shall warrant all components of the system for the full period of the warranty period

stated above, and shall replace and component found to be defective during that period at

no cost to the Owner.

4.11.3. Vendor shall warrant the performance of the VRU during the period stated above so long as

it is used for the purpose intended. In the event the unit does not meet the performance

guaranteed emissions level of 150 mg/m3 for gasoline and 10 g/m3 for crude on a two hour

averaged basis, Vendor take whatever actions are necessary at Vendor’s expense to correct

the situation, and if unable to do so, the following penalties shall prevail:

For gasoline:

o Up to 5 mg/m3 overage = 2% of purchase price

o 6 mg/ m3 up to 10 mg/ m3 overage = 5% of purchase price

o 11 mg/ m3 to 15 mg/ m3 overage = 10% of purchase price

o >15 mg/ m3 overage = 25% of purchase price

For crude:

o Up to 0.3 g/m3 overage = 2% of purchase price

o 0.3 g/ m3 up to 0.7 g/ m3 overage = 5% of purchase price

o 0.7 g/ m3 to 1 g/ m3 overage = 10% of purchase price

o >1 g/ m3 overage = 25% of purchase price

4.13 Painting

All external exposed steel surfaces must be treated with epoxy coating system.

Painting system for absorber should be able to withstand high temperature up to 1850 C.

4.14 Materials

All materials shall be asbestos free.

Designated materials to be supplied with compliance certificate as per EN 10204 – 3.1

4.15 Utility consumptions

The Vendor shall state in his quotation the consumption of all utilities at the battery limits.

All units of measurement, used to dimension or to specify the capacity, shall be based on the

international system of units (SI).

5 Codes and standards

The Vendor shall warrant that all aspects of design, fabrication, assembly, testing and intended

use of the equipment to be supplied meet the legal requirements of the National and Local

Authorities.



Machine directive

Each equipment item delivered by the Supplier has to be provided with CE-marking, in

accordance with the Machine Directive 89/329/EEG of the European Community which has

been amended by directives 91/363/EEG, 94/44/EEG, and 93/68/EEG.

Therefore a II A Declaration of Conformity for each equipment shall be supplied by the

Supplier, including fulfillment of all requirements as defined in the Machine Directive.

Electrical components and instruments must be in accordance with CENELEC standards.

The supplier has to provide ATEX/CE certification.

Verification of equipment according to PED.

6 Inspection, factory testing and shipment

6.1 Inspection

Vendor to submit to purchaser for approval an inspection schedule.

6.2 Factory testing

Vendor to submit to purchaser for approval testing schedule (per item).

6.3 Shipment

After inspection and testing, all equipment shall be thoroughly cleaned, dried and touched up

with paint, if necessary. Flanged connections shall be blanked with suitable wooden or metal

covers. Bare screw threads shall be protected by plugs or caps.

Vendor has the responsibility to check the crating in order to prevent any transport damage.

7 Erection, start-up, training of operators and acceptance

Equipment acceptance on site, erection and installation shall be supervised by the vendor. The

Vendor shall be responsible for the correct installation, connection to existing ancillaries and

commissioning by Purchaser under supervision of Vendor. Approval of installation by vendor

shall be by countersigning a protocol.

On request the Vendor shall make available a specialist engineer to provide training for

Company's Operation/Maintenance personnel during the period of installation and start-up of

the equipment on site.

8 Quality assurance

Vendor to submit guarantees for performance, service and delivery.

9 Vendor documents required

The Vendor shall supply all the data and documents in the form, quantities and at the time

stipulated in the Vendor Documents Required, Doc.No. 6551408, included in the Requisition.

Y:\73256_KN angliavandeniliu garu util izavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\1182008 Structural Steel Spec.doc

0 21-10-2010 For Comments N. Motiejunas SV rev. date description / issued for drawn up ckd.

client: SC "Klaipėdos Nafta" project: Crude oil vapour utilization from railway estacada title: Specification for Structural Steel Design and Fabrication


document: 1182008

rev.: 0

sheet: 1

of: 5

Specification for Structural Steel Design and Fabrication


office: Kaunas Order: 73256 document: 1182008 rev.: 0 sheet: 2 of: 5


1 General 3 1.1 Scope 3 1.2 Codes and standards 3

2 Types of Construction 3

3 Steel Structures 3 3.1 Materials 3 3.2 Connections 3

4 Fabrication of Steelwork 4

5 Access and Maintenance Structures 4

6 Flooring 4

7 Stairways 4

8 Ladders 5

9 Handrails and Toe Plates 5



1 General

1.1 Scope

This specification covers the basic requirements for the design and fabrication of structural

steelwork.

1.2 Codes and standards

The design, fabrication and installation shall comply fully with the applicable Lithuanian codes

and standards.

2 Types of Construction

The specification is directed mainly to the use in structures of hot rolled steel sections, plates

and normalised tubular shapes.

In general, the preferred design shall take account of accessibility for painting and general

maintenance. Lattice type structures, other than trusses and towers, should therefore the

avoided.

Structural steel work generally is to be fabricated in the workshop be welding. Connections

carried out during erection on site shall be bolted in accordance with this specification.

3 Steel Structures

3.1 Materials

All material shall be of new stock.

Structural steel shall be quality FE 60B.

All bolted connections shall be with high tensile bolts of strength grade 8.8.

3.2 Connections

High tensile bolts to NEN 914 grade 8.8 or equal, shall be used for all site connections unless

noted otherwise.

Welding shall be used for shop connections. Except where butt welds are called for, all welds

shall be continuous fillets.

Washers parallel or tapered to suit rolled steel sections shall be provided under each nut.

Lock nuts shall be provided for all bolts securing runway beams to main framing.

All nuts, bolts and washers shall be sherardised.



4 Fabrication of Steelwork

All members shall be clearly marked and erection drawings shall be furnished clearly showing

the location of all members for ease of erection. In all cases, shop detail numbering system

shall tie-in to the number of the related erection drawing.

All fabricated frames shall be suitably braced to prevent distortion during transit.

Frames, platforms, stairs and handrails shall be shop assembled in the largest units suitable

for handling and transportation.

All boltholes shall be made by drilling. No burning or punching will be permitted.

All sharp edges of structural members shall be rounded to achieve appropriate coating

applications.

5 Access and Maintenance Structures

Access and maintenance platforms shall have, unless otherwise indicated, a minimum width of

750 mm.

Headroom clearance at all platforms shall preferably be 2.150 m but not less than 2.050 mm,

taking into account electrical fittings and all other obstructions.

6 Flooring

Steel grating for platforms shall be serrated rectangular open grid type with load bear bars 30

mm deep x 3 mm thick at 30 mm cross centres with twisted cross bars press welded at 30 mm

centres.

Grating shall be attached to the supporting steelwork with clip or other effective means,

minimum of four fixings per panel. Holes or cut-outs in panels shall be made by the flooring

manufacturer and have perimeter stiffening strips welded in. This work is to be carried out

before the final protective coating is applied.

7 Stairways

Stairs in general shall have a minimum clear width between stringers of 750 mm.

All stairs in the same building or structure shall, if possible, have the same slope and stair

handrails shall be continuous with platform handrails. Stairs shall be arranged with a 45o of

slope.

Stairs shall have maximum vertical step.

Clearance over stairs shall be such that a minimum vertical clearance of 2.100 mm measured

at the nose of a treat shall be maintained.



Treads shall be serrated rectangular pattern open grid type (30 mm x 3 m bearing bars at 30

mm cross centre with twisted bars press welded at 30 mm cross centres) with non skid

abrasive nosings.

8 Ladders

Ladders shall be provided:

a) For access to platforms not served by stairways;

b) As an emergency escape from platform which is already served by a stairways.

Ladder shall have a width of 450 mm inside stringers

Ladder rungs shall be 20 mm diameter round steel bar. Spacing between ladder rungs shall be

maintained at 30 mm.

Ladder rungs shall be positioned such that the top of the rung is at the same elevation as the

platform served.

All ladders serving platforms or landings shall have side access and shall be equipped with

safety cages. Safety cage shall start at 2.100 mm above grade or landing.

9 Handrails and Toe Plates

Handrails shall be extended around edges of all platforms, landings, walkways and stairs.

All handrailing shall be pipe material.

Maximum centres of handrail posts shall be 1.500 mm.

All platforms and walkways 1.800 mm or more above grade shall be provided with toe plates.

Toe plates shall also be provided around all pipe penetrations through platforms.

All toe plates shall be 100 mm high unless shown otherwise on the project drawings.

Toe plates shall extend continuously around edges of all platforms, landings, walkways and

openings except at stairs and ladder accesses.

Y:\73256_KN angliavandeniliu garu util izavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\2111001 Mech Equip Spec.doc

0 27-09-2010 Quotation request N. Motiejunas SV rev. date description / issued for drawn up ckd.

client: SC "Klaipėdos Nafta" project: Crude oil vapour utilization from railway estacada title: Project Specification for Mechanical Equipment


document: 2111001

rev.: 0

sheet: 1

of: 4

Project Specification for Mechanical Equipment




1 GENERAL 3 1.1 Purpose 3 1.2 Compliance, exceptions and deviations 3 1.3 Alternative designs 3 1.4 Conflicting requirements 3 1.5 Information required 3 1.6 Engineering coordination 3 1.7 Authority approvals 3

2 PROJECT AND SITE INFORMATION 4 2.1 Site location

4 2.2 Project description 4 2.3 Site meteorology 4

3 QUALITY ASSURANCE 4

4 GUARANTEES 4 4.1 Performance 4 4.2 Service 4

5 VENDOR DATA AND DOCUMENTS REQUIRED 4



1 GENERAL

1.1 Purpose

This Specification together with other documents of the Requisition covers the minimum

technical requirements for the design, fabrication, assembly, inspection, acceptance test and

Vendor documents for the specified equipment.

1.2 Compliance, exceptions and deviations

Quotations must be fully in accordance with the Specification(s) and other documents of the

Requisition and must contain a written confirmation to this effect.

The Vendor may include in his quotation appropriate exceptions or deviations, provided they

can be shown not to have a negative effect on performance, construction, reliability and

availability of the specified equipment. Such exceptions shall be grouped and listed.

Quotations shall cover all items indicated in the section Scope of Supply. Spare parts and

special tools shall be quoted separately, as indicated.

1.3 Alternative designs

The Vendor may also quote an alternative design with an explanation of the advantages and

disadvantages of his design.

In such case detailed information in respect of performance, construction and reliability is

required.

1.4 Conflicting requirements

All conflicts between the requirements of the Specification(s), Data Sheets or other documents

of the Requisition shall be referred to Purchaser for clarification.

1.5 Information required

All information in the Requisition and the Data Sheets denoted with an asterisks (*) shall be

supplied by the Vendor with the quotation.

A Vendor's nameplate shall be supplied for each item. All relevant information on the

nameplate shall be bilingual in English and Lithuanian. The nameplate data shall be clearly

stamped.

1.6 Engineering coordination

The Vendor is responsible for the engineering coordination of the equipment and all auxiliary

systems included in the scope of his supply.

1.7 Authority approvals

The Vendor is responsible for obtaining authority approvals when applicable included in the

vendors scope.



2 PROJECT AND SITE INFORMATION

2.1 Site location The address of the job site is:

SC “Klaipėdos Nafta”

Burių str. 19

P.O. Box 81

LT-91003 Klaipėda, Lithuania

2.2 Project description

This project consists of technical solutions for hydrocarbon vapors from the rail cisterns

collection and recovery at “Klaipėdos Nafta” Oil Terminal.

2.3 Site meteorology

Climate type [ - ] marine

Design ambient temp. range [Deg C ] Min: -29 Max: +35

Design barometric pressure [mbar ] 1015

Relative humidity range [ % ] Min: 30 Max: 100

Average rainfall [mm/year] 625

Maximum rainfall [mm/h ] 50

Maximum wind velocity [m/sec ] 40

Design wind pressure [N/m² ] 1040

Direction of wind [ - ] s.w.

Frost design line [ m ] n.a.

UBC seismic zone [ - ] n.a.

Snow load [ mm ] 1000

3 QUALITY ASSURANCE

The Vendor shall submit with his quotation (a) document(s) demonstrating that he has an

operational Quality Assurance System, which conforms to the requirements of the International

Standard ISO 9000, or equivalent.

All equipment shall have CE marking and comply to “ATEX” directive 94/9/EC.

4 GUARANTEES

4.1 Performance

The Vendor shall propose in his quotation a performance guarantee based on the duty and

design requirements given in the Requisition.

4.2 Service

(*) The Vendor shall propose in his quotation a service guarantee based on the mode of

operation given in the Technical Specification.

5 VENDOR DATA AND DOCUMENTS REQUIRED

(*) The Vendor shall supply all the data and documents in the form, quantities and at the time

stipulated in the list Vendor Documents Required, included in the Requisition.

Y:\73256_KN angliavandeniliu garu util izavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\2981001 Pipes Spec.doc

0 21-10-2010 For Comments N. Motiejunas SV rev. date description / issued for author ckd.

client: SC "Klaipėdos Nafta" project: Crude oil vapour utilization from railway estacada title: Specification for Pipes


document: 2981001

rev.: 0

sheet: 1

of: 5

Specification for Pipes




1 General 3

2 Certificates 3

3 Limitations 3

4 Marking 4

5 Preservation, painting 4

6 Welding, welding procedures 4


8 Shipping, transport 4

9 Material specification 5 9.1 Pipe class AC01 5



1 General

This specification covers the technical requirements for the design, fabrication, testing and

delivery of carbon steel pipe in accordance with the data as specified in this specification.

Codes, standards and specifications referred to in this specification or in any referenced

document, form a part of the requirements of this specification in the manner and to the extend

specified.

Any deviation from this requisition shall be listed in the quotation and a ruling shall be obtained

by Tebodin before proceeding with the affected portion.

2 Certificates

Pipe shall be supplied with material certificates EN 10204-3.1B issued by the manufacturer,

stating at least:

- Manufacturers name and symbol;

- Heat number;

- Material specification and grade;

- Chemical analysis;

- Mechanical test result;

- Data with regard to quantity and dimensions, size, schedule etc.;

- Hydrostatic test pressures and test results.

Certificates, hydro reports and dimensional check results shall be submitted in one batch

immediately after completion of inspection.

3 Limitations

Carbon steel material shall have a maximum carbon steel content of 0.23%.



4 Marking

Pipe diameters 2 inch and larger shall be die-stamped with heat number, material, nominal

pipe size, schedule or wall thickness and Manufacturer's symbol.

Pipe diameters 1.5 inch and smaller shall be low-stress die-stamped with heat number,

material and manufacturers symbol or labelled.

In addition to manufacturer's marking, each tag shall be clearly identified with:

- Purchase order no.

- Requisition no.

- Specification, sheet and item no.

Pipe size 6 inch and larger shall be identified with the applicable tag properly attached to each

pipe.

Pipe size 4 inch and smaller shall be identified with the applicable tag securely attached to the

bundles.

5 Preservation, painting

Pipe shall be delivered in an unrusted and clean condition with temporary rust protection.

6 Welding, welding procedures

Repair, of the material, by welding is not allowed.

For seam welded pipe the weld joint quality factor of 1.0 shall be guaranteed.

7 Quality assurance

Vendor shall present his quality assurance/control manual, if possible according to BS-5750 or

ISO 9001, 9002, 9003.

8 Shipping, transport

Pipe size 4 inch and smaller shall be supplied in bundles.

Pipes shall be prepared for shipment in such a manner to avoid damage or atmospheric

corrosion to the inside or outside surfaces during storage or while in transit.

The bevel ends of pipes shall be protected by suitable bevel protectors and/or plastic caps.



9 Material specification

The choice of pipe type must be carefully evaluated with respect to the available approved

couplings, mechanical-Tees, grooved Tees and elbows.

Carbon steel piping and welding fittings with connections using mechanical couplings and / or

flanged connections.

Counter flanges for equipment with flanged outlets shall be of the same piping class as the

equipment flange.

Branches may be connected to distribution pipes by threaded sockets, welded on the pipe in

prefabrication, or by mechanical-T connections.

Piping shall be prefabricated in reasonable and manoeuvrable lengths to allow easy and

smooth installation.

9.1 Pipe class AC01

Description

½” – 1½”” - pipe c.s., seamless, material ASTM A106B

2”-10” - pipe c.s., seamless, material API 5L Gr. B,

12” and more - pipe c.s., seamwelded, material API 5L Gr. B,

150#

Dimensions

Acc. to ASME B 36.10

End preparation

½” - 1½” – plain ends

2” and more – bevelled ends acc. to ASME B16.25

Y:\73256_KN angliavandeniliu garu util izavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\2983001 Valves Spec.doc


client: SC "Klaipėdos Nafta" project: Crude oil vapour utilization from railway estacada title: Specification for Valves


document: 2983001

rev.: 0

sheet: 1

of: 4

Specification for Valves




1 General 3

2 Certificates 3

3 Design 3

4 Marking 3

5 Preservation, painting 4

6 Testing 4


8 Shipping, transport 4



1 General

This specification covers the technical requirements for the design, fabrication, testing and

delivery of valves in accordance with the data as specified in this specification.

2 Certificates

Flanged & welded valves shall be supplied with material certificates EN 10204-3.1, issued by

the valve manufacturer, stating at least:

- Manufacturers name;

- Heat number;

- Material specification;

- Chemical analysis;

- Mechanical test result;

- Data with regard to quantity and dimensions;

- Hydrostatic test pressures and test results.

Certificates, hydro reports, NDT reports and dimensional check results shall be submitted in

one batch immediately after completion of inspection.

3 Design

Flange facing of all valves, shall be furnished with stock finish.

Valves shall be designed and executed in accordance with the design codes and design

features as noted on the attached applicable specification sheets.

Valves shall be supplied with assembly drawings, showing all relevant information, such as

materials of construction, dimensional data, design features, etc.

4 Marking

Marking shall be in accordance with EN .19:2002

In addition to manufacturer's marking, each tag shall be clearly identified with:

- Purchase order no.

- Requisition no.

- Specification, sheet and item no.



5 Preservation, painting

Painting shall be according manufacturer's standard.

6 Testing

The valves shall be inspected and tested in accordance with EN 12569. Seat tightness shall

be according to EN-12266-1, leakage rate A, except for gate valves greater than DN400 (16”),

where leakage rate B applies.

7 Quality assurance

Vendor shall present his quality assurance/control manual, if possible according to BS-5750 or

ISO 9001, 9002, 9003.

8 Shipping, transport

The valves must be packed in a way that they cannot be damaged during shipment.

Flange facing shall be protected over the gasket seating surface with plastic, cardboard and/or

hardboard covers to avoid mechanical damage.

Y:\73256_KN angliavandeniliu garu utilizavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\4199030 Electrical Spec.doc

0 21-10-2010 For Information N. Motiejunas SV rev. date description/issued for drawn up ckd.

client: SC "Klaipėdos Nafta" project: Crude oil vapour utilization from railway estacada title: Specification Electrical Requirements for Package Units


document: 4199030

rev.: 0

sheet: 1

of: 23

Specification Electrical Requirements

for Package Units

client: SC "Klaipėdos Nafta" project: Crude oil vapour utilization from railway estacada title: Specification Electrical RequirementsVapour Recovery Unit



1 Scope 3

2 Codes, standards etc. 4

3 Area classification 6

4 Utilisation voltages 7

5 Design and drawings 8

6 Equipment 9

7 Electric motors 10

8 Control 11

9 Wiring and cabling 13

10 Low voltage switchgears and/or motor control centres 15

11 Variable speed control 17

12 Small power distribution boards 21

13 Earthing and lightning protection 21

14 Division of work 22

15 Inspection and testing 23



1 Scope

1.1 The requirements outlined herein are for electrical equipment, supplied as part of a

mechanical package. The mechanical specification defines the equipment to be supplied.

Any electrical equipment shall conform to the applicable sections of this specification.

1.2 The electrical installation shall be designed and installed to obtain a maximum of safety and

easy operation with a minimum of maintenance.

1.3 This specification is not intended to cover all the details, however it may be expected that

the Vendor provides all the elements that are inherent to sound engineering practices and

workmanship in order to achieve a completely satisfactory electrical system. It shall be the

Owner's responsibility to advise the Vendor of all clearances, approvals, permits,

documents, etc. required by the several national authorities.



2 Codes, standards etc.

Electrical work must be in compliance with the latest editions of the national or international

codes and governmental requirements.

IEC-Standards as listed in "Catalogue of IEC Publications".

2.1 International Standards

IEC - 34 Rotating electrical machines.

IEC - 51 Direct acting indicating analogue electrical measuring instruments and

their accessories.

IEC - 59 IEC standard current rating

IEC - 72 Dimensions and output ratings for rotating electrical machines

IEC - 85 Thermal evaluation and classification of electrical insulation.

IEC - 617 Recommended graphical symbols

IEC - 185 Current transformer

IEC - 204-1 Electrical equipment of industrial machines

IEC - 269 Low-Voltage fuses.

IEC - 341 Push-button switches

IEC - 364 Electrical Installation of buildings.

IEC - 439 Factory-built assemblies of low voltage switchgear and controlgear

IEC - 521 Class 0.5, 1 and 2 alternating-current watt-hour meters

IEC - 529 Classification of degrees of protection provided by enclosures.

IEC - 555-2 Limitation of disturbances in electricity supply networks.

IEC - 947 Low voltage switchgear and controlgear

IEC - 439 Factory-built assemblies of low voltage switchgear and control gear.

2.2 Other standards

VDE 0875 Radio frequency Interference suppression

ISO 1281 Rolling bearings: Method of evaluation dynamic load ratings.

2.3 Local regulations

In addition to the standards and codes, the electrical system shall be in accordance with the

local regulations and requirements of the following authorities:

• the fire-fighting brigade;

• the ministry of labour inspectorate;

• nuisance act, safety law etc.



2.4 EMC (Electromagnetic Compability)

All apparatus, (electrical and electronic appliances together with equipment and installations

containing electrical and/or electronic equipment) liable to cause electromagnetic

disturbance or the performance of which is liable to be affected by such disturbance shall

comply with the local EMC standards and regulations.

Where local EMC standards and regulations are not available, the requirements of the

European EMC-directive and its amendments shall be used which requires that the

apparatus shall be so constructed that:

• The electromagnetic disturbance it generated does nor exceed a level allowing radio

and telecommunications equipment and other apparatus to operate as intended.

• The apparatus has an adequate level of intrinsic immunity of electromagnetic

disturbance to enable it to operate as intended.

In case of conflict between the European EMC-directive, and its amendments, and the local

EMC standards and regulations the most severe shall rule however it is noted that the

European EMC-directive, and its amendments shall be used as starting point.



3 Area classification

The equipment may be located in an area indoors or outdoors where a potential explosion

hazard may exist if flammable gases or dust are present. Alternatively or in addition, a

corrosive atmosphere may also exist. Each area will be classified with respect to these

conditions.

The area classification will be stated in the mechanical specification or the document

containing the Mechanical Package Requirements.

All equipment and wiring must comply with the applicable standards for the specified

hazardous area.

Electrical equipment finishes and construction materials shall be selected and furnished

which are resistant to the corrosive environment specified.

For equipment installed in a hazardous area the Vendor shall furnish the required

certificates from an official testing laboratory, certifying that the equipment is suitable for

use in that area.



4 Utilisation voltages

4.1 The incoming power supply with over-current protection fuses or circuit breakers at the

utilisation voltages listed below will be supplied by third party.

Voltages: Application:

400/230V 3-phase Motors, heaters and

3-wire, TN-S total package power earthing system

230V 1-phase Lighting and other

2-wire, TN-S single phase loads earthing system

4.2 If voltages other than those listed are required, the means for transformation shall be

supplied with the mechanical equipment.



5 Design and drawings

5.1 The complete electrical system shall be designed for a reliable service, highest degree of

flexibility, consistent with good practice, safety to personnel and sound economics with a

maximum interchangeability of equipment.

5.2 Switchgear interrupting capacities, cable sizes etc., shall be calculated and selected in line

with good practice.

A system design shall be prepared containing the short circuit calculation, relay settings and

coordination curves.

The system diagram shall show and define the complete electrical system, circuit breaker

and switch interrupting capacities, short circuit ratings, relay- and metering devices, motor

loads, etc.

5.3 The distribution, installation and utilisation of electricity shall conform to the standards as

mentioned under part. 2.

The distribution system shall be designed and installed to provide a maximum of circuit

reliability consistent with good economics and convenience of operation.

The electrical system switching shall be so arranged to allow sections of switchgears and

feeders to be isolated and de-energized for maintenance with un-interrupted service to

critical areas.

5.4 Drawings shall consist of complete plans and elevations showing equipment locations,

power and control cable lay-out, grounding lay-out and cable schedule in an orderly

numerical sequence, etc.

The drawings shall also include all wiring and elementary diagrams for all items, such as

MCC's, relay cabinets etc. and include all drawings necessary for the proper

interconnection between electrical equipment.

For each motor a motor data sheet shall be filled in.

5.5 All drawings shall be an accurate representation of the electrical system as installed, in such

a manner that they may serve the owner as a convenient guide for future operation and

maintenance.

All drawings, as far as concerned in scope of Vendor, shall contain the complete

information required for installation.

Drawings, symbols etc. shall follow the Vendor's standards and procedures and comply

with the standards as mentioned in part. 2.



6 Equipment

6.1 All equipment for as far as included in contractors scope shall be new, adequate for the

application and comply with the requirements of the codes as specified in part 2.

6.2 All equipment such as switchgear, distribution panels, control panels etc., shall be located

indoors, in a non-hazardous area and shall be in general of the sheet steel enclosure type.

6.3 All operational equipment shall be identified by non-corrosive (resopal, PVC laminated)

nameplates, which shall contain the following:

− Manufacturer's name

− Serial- and Model no.

− Equipment no.

− Warning sign if required, etc.

− Weight.

− Year of manufacture.

6.4 All labels, plates, etc. must be either bolted or riveted; glueing by any means whatsoever is

prohibited.

6.5 All parts carrying more than 42V AC shall be protected adequately against live contact.



7 Electric motors

7.1 All electric motors shall comply with the standards as mentioned under part 2 and shall be

delivered in standarized types with dimensions and power rates conform to I.E.C.-

recommendations.

7.2 Electric motors shall be totally enclosed, fan-cooled, non-sparking, weatherproof and

suitable for the classification of area where used.

Enclosure type IP54 with IP55 terminal box or as indicated on the motor data sheet.

7.3 The electric motors shall be of squirrel-cage-induction type, for direct on-line starting.

7.4 The electric motors will perform in such a way that under normal load an overtemperature in

the winding of 80°C for L.V.-motors is not exceeded.

7.5 All windings shall be brought out to the terminal box; three phase windings shall be

connected star or delta, according to the data sheet.

7.6 Motors shall be equipped with anti-condensation heaters, when specified on the data

sheets.

7.7 L.V.-electric motors shall be protected against short circuit by means of fuses or circuit

breakers and against overload by means of an adjustable hand re-setting thermal

overcurrent device, connected in 3 phases.

7.8 All protection devices shall be located in starter units, housed in switchgears and/or motor

control centers.

7.9 Motors with frequency converter operation and located within areas classified as hazardous,

shall be provided with 3 PTC thermistors in the windings.



8 Control

8.1 Control and alarm circuits shall be designed fail-safe i.e. open circuiting of one wire, short-

circuiting of one wire or failure of a component shall not permit machinery to start-up.

Failures shall trip an overload element, or render equipment inoperative, or sound an alarm.

8.2 Electrical equipment shall be selected on the basis that a 20 % voltage dip of two seconds

duration does not cause the equipment to shutdown.

8.3 Suitable circuit protection shall be supplied for controls so that any one electrical fault does

not affect more than one unit or system. The protection can be accomplished by either

circuit breaker or fuse.

8.4 A disconnecting means shall be provided to permit servicing of individual systems or

control components. The means of disconnection shall be padlocked when in the

disconnected position and shall be near on in sight of the components.

8.5 Where electrically operated circuit breakers or magnetically operated starters are used,

they shall be controlled from a start/stop pushbutton, located in a position providing safe

and convenient operation.

8.6 Motor starter units shall in general provide local control by means of a motor control station.

The motor control station shall be in sight of and near the motor. Each motor will have a

safety switch with provisions for pad locking in the "off" position.

All non-reversing motor starters shall in general provide local control by means of a

pushbutton station.

All reversing motor starters shall in general provide local control by means of a change-over

for left or right direction and a start/stop pushbutton as an integral.

8.7 Units which are controlled by automatic devices and/or for remote control shall be provided

with a 3 position selector switch.

In the auto-position the unit shall be under control of the automatic actuating device and in

the hand-, position the automatic devices shall be disconnected and shall be operated

manually.



8.8 Units controlled by process switches shall be controlled by means of interposing relays,

which are energized via the shutdown or interlocking systems.

8.9 Where necessary starter units shall be provided with auto-restart features during Voltage

dips of two seconds and where required with automatic change-over switching.

8.10 Motor control stations located in hazardous areas shall be of a certified explosion-proof

design and conform to the standards mentioned under part.3.



9 Wiring and cabling

9.1 The design and selection of wiring and cables shall in every respect comply with the

relevant IEC standards.

9.2 The maximum allowable Voltage drops shall be as follows:

a) Main incoming feeders 2%

b) Motor power feeders 5%

c) Lighting circuits 3%

9.3 Cable runs shall be routed around the skid by using cable tray and/or conduits. The

maximum length of unsupported cable runs shall be ten (10) centimetres.

9.4 In general, copper conductor, XLPE insulated, P.V.C. sheated cables shall be used for low

Voltage power cables.

9.5 In general for instrument distribution, lighting etc., copper conductor, XLPE insulated,

P.V.C. sheated cables shall be used.

9.6 The minimum cross sectional area for conductors shall be for power cables 2.5 sq.mm and

for control cables 1.5 sq.mm.

9.7 All cables shall be numbered in a numerical order and shall be sized for the most

economical solution taking into account derating factors and maximum allowable Voltage

drop where applicable.

9.8 Cables leaving cable tray shall be mechanically protected and supported by conduits.

9.9 Cable routes shall be located remote from high temperature process lines or high

temperature surfaces.

9.10 Cable trays shall be close type with expanded metal bottoms or rungs.

9.11 Cable trays shall be designed to withstand a loading of 60 kg/m. without bending.

9.12 Cable tray shall be supported from pipeways, structures or buildings.

9.13 Intrinsically safe cables shall run separately from other power and instrument cables.

9.14 All wiring etc. for external circuits shall be wired to terminals.



9.15 All wiring and terminals shall be securely fixed and easily accessible. The wiring shall be

adequate for the circuit full load.

9.16 Terminals for external control and alarm circuits shall be suitable for 1.5 sq.mm copper

conductors.

9.17 All cabling and wiring on the package other than main motor connections shall be

terminated at a central location on the package, to enable the buyer to connect the feeder

cable(s) and control cable(s) in a practical manner. Motor feeders will be connected to the

motor terminal box directly.

9.18 Terminal list and electrical devices shall be provided with identification numbers and clearly

marked. All wiring shall be fitted with identification ferrules.

9.19 These identification numbers shall be visibly duplicated on the equipment. They shall also

appear on all vendor wiring and lay out drawings.

9.20 All cable glands shall be of the compression type, suitable for use in the area as stated on

the data sheet which it is to be employed.

Each cable gland shall be provided with a PVC shroud which shall be in addition to the

normal seals in the gland.



10 Low voltage switchgears and/or motor control centres

10.1 The equipment shall in every respect comply with the relevant national standards and local

electrical supply company regulations.

10.2 The equipment shall comply with the latest edition of I.E.C. publications as mentioned

under part. 2.

10.3 All parts of the equipment shall withstand a rated short circuit current of 20 kA or as

calculated under 5.2 without damage.

10.4 The equipment supplier shall be called upon to present a detailed statement of evidence

supporting the making and breaking capacity of the equipment.

10.5 The equipment shall be cubicle type, free standing, floor mounted, totally enclosed in

accordance with I.E.C. class IP41 min. for indoor and IP55 outside. When equipment is

located in hazardous areas, the enclosure shall meet the requirements of the area

classification.

10.6 The equipment shall be accessible from the front. Wiring spaces and relay compartments

shall be accessible by means of hinged doors.

10.7 Bus bars shall be copper and shall be mounted on supports of high impact, non-tracking

insulating material and shall be braced to withstand the mechanical forces exerted during

the maximum short circuit conditions.

10.8 The main bus shall be continuous without joints, within each shipping section.

10.9 For large equipment with long bus bars, thermal expansion joints shall be provided, in

accordance with the manufacturer's standard practice.

10.10 A ground bus shall be provided for the entire length of the equipment.

10.11 All metal work other than current carrying parts shall be grounded.

10.12 The switchgear shall be labelled in an approved manner.

10.13 All terminals and wiring shall be clearly marked and coloured.



10.14 Meters shall be flush mounted on the front of the switchboard.

Accuracy class for meter shall be 1.5 according to IEC.

10.15 Current transformers shall have class 1 accuracy for metering and class 5 P for protection

according to IEC. The minimum wire size for current transformer circuits shall be 4.0 mm2.

All current transformer terminals shall have suitable short circuit devices. Secondary current

type relays, if withdrawable, shall have provision for automatically closing the secondary

circuit when the relay is withdrawn. Secondary current rating 5 A. For remote metering 1 A

only is acceptable.

10.16 Before the switchboard is shipped to the construction site, it shall be inspected,

mechanically and electrically tested, to ensure that all equipment, devices, relays and wiring

have been correctly installed and are in a satisfactory working condition.

All tests shall be made in accordance with the relevant IEC standards.

10.17 Incoming air circuit breakers shall be fully interlocked units, electrically operated or

operated by stored energy mechanisms.

10.18 Incoming isolators shall be stationary units housing a load breaker isolator equipped with

H.R.C.-fuses fully interlocked with the compartment door.

10.19 Motor starters shall be a combination of full voltage, direct-on line, non-reversing, magnetic

air break type contactors with adjustable hand resetting thermal overcurrent devices and

circuit breakers or fuse for short circuit protection.

10.20 Free standing switchgear will be provided with permanent heating elements, except those

installed in air conditioned rooms.

10.21 Power distribution panels shall be stationary units housing miniature circuit breakers or

fuses. The compartment door shall not be interlocked with the isolator.



11 Variable speed control

11.1 This part of the specification covers the adjustable speed drive units (for controlling one or

more single direction totally enclosed fan cooled (TEFC) squirrel cage standard motors and

power conversion unit comprising transistors or thyristors with the necessary protective

controls and all required components.

11.2 The equipment shall in every respect comply with the relevant IEC codes and standards of

the latest issue including IEC 439 and all relevant Standards of the country where installed.

Where conflict arises between I.E.C. and standards of the country, the later will prevail.

11.3 The selection of type and size of adjustable speed control is based on the following:

a) Technical requirements such as voltage level, current capacity, ambient temperature,

voltage regulations, speed adjusting etc.

b) Single- or multi motor drives and depending on application.

11.4 The adjustable speed drive unit shall be of the AC frequency regulator PWM type. (Pulse

width modulation).

11.5 The unit shall be equipped with the following equipment but not limited to:

a) Ultra rapid fused for transistors/thyristors diode protection against short circuits.

b) Automatic protective devices for protection against single phasing, overloads,

overvoltage and undervoltage.

c) Speed accuracy better than 2% in case of 100% load change or 5% feeder voltage

change or 10% temperature change, except when stated otherwise on the Data Sheet.

d) Variable speed response time between 1,5-4 sec. except when stated otherwise on

the Data Sheet.

e) Local remote:

speed control (max. and min. speed can be preset)

speed indication

load indication

4-20 mA output signal for remote speed indication

4-20 mA input signal for automatic speed control.

f) Radio Frequency Interference suppression, as per VDE 0875 group N.

g) Undesired restart protection, complete with start-up override timer.

h) Testing provisions for critical signals during operation and at standstill.

i) Ready to start indication.

j) Common indication for failure.



11.6 The enclosures shall be as follows:

When mounted in a control panel:

− Control drive panel depending on location shall be designed to a maximum degree of

safety, completely wired and tested, wall mounted.

− Front access, hinged single or double doors to be easily removable.

− The degree of protection of the panel shall be at least IP-41 when panel door(s)

closed and IP-20 when panel door is open.

− The live side terminals of the main switch shall be for safety reasons, be provided with

a pertinax protection cover.

When mounted on a wall:

− Front access with easily removable cover.

− The degree of protection shall be IP-20.

− The live side terminals shall be protected by a pertinax protection cover.

11.7 The following electrical features will apply:

The unit shall have an internal bare copper earth and busbar, directly bolted to the panel

structure.

− Earth bolt size as specified.

− All internal wiring used for earthing shall have a green/yellow color insulation.

− Power circuits shall be rated in such way that thyristors are carrying 60% maximum of

their continuous current at which the nominal operating temperature is reached.

− All knife-type fuses shall be installed between partitions of insulation material which

extend 20 mm over the bare parts in all directions.

− All knife-type fuses shall be with KEMA approval.

− Diazed fuses shall only be acceptable if they are one of the E-27 type and may not be

used for fuses over 25 Amps.

11.8 Cable glands, cable clamping, earth supporting, facilities and terminals shall be provided for

bottom cable entry or as indicated on the data sheets.

11.9 The unit and its components, such as thyristors, diodes, switching devices, protection

relays, instruments, instrument transformers, fuses and fuse holders, shall be individually

identified by means of permanent labels. On withdrawable-type units, identification labels

shall be mounted on both the fixed and withdrawable parts.

11.10 All wires shall be marked at both ends. Also the terminals shall be provided with a

numbering system. Identification shall be in accordance with manufacturers drawings.

Control wiring shall be not less than 1.5 sq mm stranded wire size. Only one conductor is

allowed to be terminated per terminal.



11.11 The limitation of disturbances in electricity supply networks caused by domestic and similar

appliances equipped with electronic devices shall in every respect comply with EN 50006.

Note: IEC 555-2 and amendment 1985 are identical to EN 50006.

11.12 Control systems shall be provided with radio interference suppression networks to limit any

lineborne interference exceeding a value of suppression grade "N" according to VDE 0875.

The operation of the electronic control system shall not be hampered by radio interference

caused by equipment installed in their vicinity and/or portable telecommunication equipment

(walkie-talkies) having a radio interference class "N" or worse.

11.13 Panel door(s) shall be hinged and provided with suitable door stops.

11.14 Panel door(s) shall be lockable; it shall not be possible to open the panel with a screw driver

or other simple tools.

11.15 Power modules, control electronics, etc. shall be easily accessible to enable. Prevodical

servicing, fault finding and repair.

11.16 All fuses have to be easily accessible for replacement purposes.

11.17 The colour codes of the indication lights shall be as follows:

Common-alarm – yellow

Trip – amber

Healthy – white

"on" status – green

"off" status – red

11.18 Earthing bolt shall be provided on the outside for earth connection with the system, wire

size shall be at least 25 sq mm but not less than 50% of the feeding cable cross-section.

11.19 The maximum noise level generated by the equipment shall be 60 dB measured at a

distance of 1 meter and a height of 1 meter.

11.20 Visual inspection of the board may be required by the Engineer or inspector representing

the principal at any stage of construction or before final packing of boards for shipment.

The requirements for such inspection shall be indicated on the data sheets or

accompanying documents.



11.21 The Vendor shall perform routine factory tests and inspection on each unit.

The principal and/or his appointed representative shall have the option to witness these

tests.

The Vendor shall give at least 5 days notice for these tests.

11.22 After installing and the final adjustments at the site the witnessed tests shall involve the

following test as a minimum:

1. Visual inspection.

2. Control and testing of the by third parties connected cable.

3. Functional test

3.a check if there is a linear relationship between input signal (4-20 mA) and motor

speed

3.b check if there are no torque pulsations at low frequencies.

3.c check if the VSC is kept in operation at a voltage drop of 80% (time: 0,2 sec.).

3.d check the motor protection switch-off time for each motor.

3.e measure of shaft power of the connected motor at various frequencies and

determine the maximum shaft power.

The following items shall be measured at the input and output of the VSC and at the

motor connection.

• current

• voltage

• power

• frequency

The length of the cables to the motors shall be taken into account at these

measurements.

3.f check if there is a linear relationship between output signal 4-20 mA and motor

speed.



12 Small power distribution boards

12.1 Small power distribution boards such as heating-, instrument power distribution boards, etc.,

shall in every respect comply with the relevant national standards, local electrical supply

company regulations and all other statutory regulations.

12.2 Distribution boards will be stationary units housing miniature circuit breakers or fuses.

13 Earthing and lightning protection

13.1 All metal parts of electrical apparatus, the steel construction as well as steel construction in

buildings, pipe racks, vessels, tanks, stairways etc. will be bonded to the earth ringmain

cable of the plant.

13.2 The earthing system will also be used as lightning protection and be designed accordingly.

13.3 The earthing system shall in every respect comply with the relevant national standards

and/or IEC standards.

In general the grounding resistance shall not exceed 1 ohm or less if specified.

13.4 Clearly marked grounding terminals must be fixed to on all package units.



14 Division of work

14.1 The Vendor or his subcontractor is expected to complete all electrical work within the

confines of the package. Where the package does not have a rigid enclosure, everything

that can be shipped in one piece, shall be shipped already assembled and prewired. The

mechanical specification covering the individual item of equipment takes precedence

wherever it specifies exceptions or additions to the following general list.

14.2 The Buyer retains the right to change the by Vendor proposed type and make of the

electrical equipment proposed by the Seller, for standardisation and stock holding

purposes.

14.3 No changes or alteration shall be made to equipment and its installation during the

construction phases without written consent of the Buyer. All agreed changes during

construction phase shall be marked-up on drawings and shall be transferred to the Sellers

originals by the Seller.

14.4 Work by others

a) Cabling between the Vendor's equipment and those devices which are furnished by

others.

b) Cabling between pieces of the equipment which are too large to be shipped

assembled. In these cases where possible, Seller shall furnish a prefabricated

wiring harness to be used.

14.5 Work by Vendor

a) Testing as defined in part. 15



15 Inspection and testing

15.1 Except for low energy and electronic circuits, wiring at all voltage levels shall be checked for

insulation resistance.

15.2 All circuits shall be checked for continuity.

15.3 A functional test shall be performed, in addition to the continuity check, before shipping. A

functional test consists of simulating the Seller's devices with switches, relays, lights or

resistors and of energising each circuit.

15.4 Vendor is responsible for the correct connection of the cables, supplied and connected, by

third parties.

Y:\73256_KN angliavandeniliu garu util izavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\4388001 Instrumentation Spec rev_A.doc

A 04-11-2010 For comments N. Motiejunas SV rev. date description / issued for drawn up ckd.

client: SC “KLAIPEDOS NAFTA” project: Crude oil vapour utilization from railway estacada title: Instrumentation specification for package units


document: 4388001

rev.: A

sheet: 1

of: 11

Instrumentation specification for package units


office: Kaunas Order: 73256 document: 4388001 rev.: A sheet: 2 of: 11


1 General 3

1.1 Scope 3

1.2 Limits of supply 4

1.3 Applicable codes and standards 4 1.3.1 General 4 1.3.2 International Standards 4 1.3.3 Local regulations 5

1.4 Instrument labelling 5

1.5 Units of measurements 5

2 Drawings and documents 6

3 Installation design 8

3.1 Instrument air supply 8

3.2 Cabling 8

3.3 Terminal/junction boxes 9

3.4 Cable trays and trunking 9

3.5 Mounting of plant instruments 10

3.6 Protection boxes 10

3.7 Fixing materials 10

4 Inspection and testing 11

5 Packing and transport 11

6 Integration of instrumentation equipment with VRU package unit 11



1 General

1.1 Scope

This instrumentation specification covers the minimum requirements for the complete design,

fabrication, shipment, delivery to site, erection, testing, commissioning and initial start-up of the

instrumentation part of the package unit where this instrument specification is part.

The design and equipment supplied shall be a complete unit ready to operate and shall include,

but not necessarily be limited to the following:

• The preparation and supply of all required documents, manual and drawings.

• The preparation and supply of all required documents for obtaining and meeting all

necessary government and local regulations.

• Providing electrical and instrumentation specialists for supervisory of installation works.

• Check, test, calibrate all instrumentation equipment, which is a part of Vendors scope of

supply.

• Commissioning and initial start-up.

• Setting of alarms, trips and tuning parameters.

• Supply of contract instrument spare parts for testing, commissioning and running during the

guarantee period.

• Preparation and submittal of a quotation for itemised spare parts (with prices) for two years

operation after the guarantee period.

• Supply, mounting, installation and connection of instrumentation equipment.

The Vendors scope of work shall include, but not be limited to the supply of the following items

and their installation and connection, unless otherwise specified:

• All instruments required for safe and efficient automatic operation, such as: indicators,

controllers, switches and proximity switches for open and close position monitoring, locally

mounted push buttons and switches, converters etc.

• All the required junction boxes and associated electric cables from these boxes to the

relevant instruments.

• All air filters/reducers and air piping between these filters/reducers and the pneumatic

operating instruments.

• The connection between the air filters/reducers and Principals main air header.

• Supports for field instruments, junction boxes.

• Cable trunking and cable support strips for all cables supplied under Vendor’s scope.

• Installation materials, such as valves, fittings, tubing, whenever applicable for the instrument

impulse lines and air piping, bolts, nuts and washers, gaskets, cable glands and entries,

plugs and sockets, mounted brackets, name plates, warning plates.



1.2 Limits of supply

Junction boxes will be delivered and installed by Vendor at the edge of the package unit for signals

connected to other control systems.

If, in case of safety reasons of operability, the instrumentation control systems should be installed

remote, the instrument signal cables shall run to junction boxes mounted at the edge of the battery

limit of the package unit. Cabling between these junction boxes and the remote control systems is

not part of the Vendor’s scope.

1.3 Applicable codes and standards

1.3.1 General

The drawings, specifications, instruments, controls and electrical equipment shall be in accordance

with the latest editions and supplements of the national or international codes and governmental

requirements. IEC-Standards as listed in "Catalogue of IEC Publications".

1.3.2 International Standards

IEC -60034 Rotating electrical machines part 1-3-5

IEC - 60051 Direct acting indicating analogue electrical measuring instruments and

their accessories.

IEC - 60059 IEC standard current rating

IEC - 60072 Dimensions and output ratings for rotating electrical machines part 1-2

IEC - 60085 Thermal evaluation and classification of electrical insulation.

IEC - 60185 Current transformer

IEC - 60204-1 Electrical equipment of industrial machines

IEC - 60269 Low-Voltage fuses.

IEC - 60341 Push-button switches

IEC - 60364 Electrical Installation of buildings.

IEC - 60439 Factory-built assemblies of low voltage switchgear and controlgear

IEC - 60521 Class 0.5, 1 and 2 alternating-current watt-hour meters

IEC -60 529 Classification of degrees of protection provided by enclosures.

IEC - 60555-2 Limitation of disturbances in electricity supply networks.

IEC - 60617 Graphic symbols for diagrams

IEC - 60750 Item designation in electro-technique

IEC - 60947-1 General rules

IEC - 60947-2 Circuit breakers

IEC - 60947-3 Switches, disconnectors and fuse combination units

IEC - 60947-4 Contactors and motor starters

IEC - 606947-5 Control circuit devices and switching elements



1.3.3 Local regulations

In addition to the standards and codes, the electrical system shall be in accordance with the local

regulations and requirements of the following authorities:

• the fire-fighting brigade;

• the ministry of labour inspectorate;

• nuisance act, safety law etc.

1.4 Instrument labelling

All instruments shall have engraved nameplates showing their tag number and service.

For plant mounted instrumentation equipment the nameplates shall be mounted on a bracket near

the equipment.

Materials for nameplates shall be selected in accordance with the weather data and area

conditions. The text shall be in Lithuanian language.

1.5 Units of measurements

The instrument ranges and scale calibration shall be in metric units, as listed below:

Flow m3/h

Volume m3 or l

Level %

Pressure bar gauge

Low pressure, draught or low diff.

pressure

mbar gauge

Temperature degr. C

Rotating speeds rpm

Frequency Hz

Current A

Voltage V



2 Drawings and documents

Required documents

Vendor shall prepare a set of instrumentation drawings and documents, which shall include, but not

be limited to; those specified in this section.

All documentation, manuals, instructions and other information shall be in Lithuanian.

List of deviations

This shall state details, sections and page numbers of this specifications from which the Vendor’s

proposal deviates. The Vendor shall justify the deviation.

List of instruments

This shall specify quantity, make, type no., type of input/output signal to the central control system

and give a short service description of all instruments, which Vendor offers in his quotation.

Documentation

Documentation shall be submitted of all instrumentation Vendor’s proposes to use.

Piping and instrument diagrams

All required instrumentation systems for measurement and control shall be shown on the Piping and

Instrument Diagrams (P&ID’s).

Only the basic functions of the instrumentation systems shall be shown. Purchaser will submit

instrument tagnumber during the vendor document control phase afterwards.

Instrument process connection details

Instrument process connections shall be shown on typical drawings.

Special drawings shall be prepared for individual instruments when the application of typical

drawings could cause confusion.

When necessary, a separate location drawing of the routing shall be part of the process connection

details for each individual application.

Consumer, cable and tube lists

Lists shall be prepared indicating consumer, cables and tubes with type, number of conductors or

tubes, locations between which they run and lengths.

Connection diagrams

For each terminal strip in junction boxes etc. a connection list shall be prepared, showing the

internal wiring and the external cables to instruments and interconnecting cabling to other junction

boxes, etc.



Instrumentation location plans

Drawings shall be prepared, showing all instrumentation points, such as measuring points, location

of instruments, location of junction boxes, location of instrument air supply points, local electrical

power supplies, etc. Each location shall be identified by a tag number, co-ordinates and elevation.

Instrument Index List

- These documents shall list all the required instruments and control elements.

Specifications

Specifications shall be prepared for all components of instrumentation system.

Separate sheets shall be made for each type of instruments and instrument equipment. All relevant

process, construction and engineering data and materials shall be entered on these sheets.

System diagrams

For each instrumentation system a diagrams shall be prepared.

This diagram has to show all components with their tag number, terminal strip numbers, cable

numbers, relevant engineering data and the connection to the instrument electricity/air supply

system.

The drawings shall give a clear picture of the function of the various components.

The drawings shall be divided into the sections: auxiliary room, junction box and field mounted

instruments.

Vendor will only submit the local part of the instrument loop up to including junction box with

terminal No.

List of alarms and trip settings

This list shall show tag number, instrument range, switch point at required process conditions, the

equivalent setting of the relevant instrument etc.

Calculations

Vendor shall prepare all required calculations.

Manuals

Sets of all installation, commissioning and maintenance manuals, applicable to each type of

instrument, including all documents and drawings, shall be made available within the time stated in

the contract. These sets shall contain all information in an “as built” status.



3 Installation design

3.1 Instrument air supply

Others will install the main 6 bar instrument air header of carbon steel.

The main air header includes take-off points with a 1” shut – off valve on top of the line on

regular distance.

The Vendor shall supply the sub air headers from the shut-off valve to the instruments.

The first connection to the main header shall always be made with a 1” #150 RF carbon steel

flange. The sub air header shall be screwed and carbon steel shall be used.

Per DN15 sub air header a maximum of 5 instruments can be supplied with instrument air and

per take-off point a shut-off valve shall be provided. Each sub air header shall be provided with

a drain valve at the lowest point.

The piping from the sub air header to the instrument shall generally consist of 6 - 4 mm-copper

tubing, PVC covered, and a ¼” NPT shut-off valve. If required, each local instrument shall have

it’s own filter/reducer set installed in a convenient location.

3.2 Cabling

The Vendor is responsible for all instruments cables inside the battery limits and up to the

junction box (es).

220 VAC and 24 VDC power supply cables shall be PE/PE/SWA/PVC mb with a minimum

conductor size of 2.5 mm2.

Measuring cables, signal cables and cables to solenoid valves will be as follows:

• from instrument (transmitter, switch etc.) to a junction box or local cabinet; type:

PE/OSCR/PE/SWA/PVC mb with conductor size of 1.2 mm,

• from analog/digital junction box to control/auxiliary room; multicore cable type:

PE/OSCR/PE/SWA/PVC mb 12x2 or 24x2 with conductor size of 0.8 mm,

• from solenoid valve to junction box or local cabinet; type: PE/OSCR/PE/SWA/PVC mb with

minimum conductor size of 1.5 mm2.

All conductors shall be terminated.

Cable cores and sheets shall be coloured as follows:

220 V power: Black (phase), blue (neutral), green/yellow (earth) Grey sheath

24 VDC: Black (+), blue (-)

Grey sheath (non-intrinsically safe)

Blue sheath (intrinsically safe).



Approximately 20 % spare shall be available in the junction boxes.

Instrument cables, which are liable to interference from AC sources shall be kept, separated

from other cables.

All cables shall be identified at both ends by means of permanent slip-on sleeves. Cable No. will

be issued by Purchaser later.

3.3 Terminal/junction boxes

All instruments shall be wired to weatherproof junction boxes via a terminal box.

Separate junction boxes shall be used for the following signals:

• intrinsically safe analog and digital signals

• non intrinsically safe analog and digital signals

• signals to solenoid valves.

Terminals and junction boxes shall be polyester, provided with cable glands, material:

Glassreinforced polyamide. Colour of the boxes will be as follows:

• Intrinsically safe signals: Blue

• Non intrinsically safe signals: Grey

Terminal box provided with 6 terminals.

Junction box provided with earth rail.

Terminal will be coloured as follows:

• Non explosion proof signals: Yellow

• Intrinsically safe signals: Blue

• Explosion proof signals: Grey

3.4 Cable trays and trunking

All the metal materials required from the assembly of cable trays and/or trunking shall be of

galvanised steel.

Metal mounting materials such as supports, hangers, profiles etc. shall be of stainless steel.

Hangers shall be adjustable and mounted in such a way that covering of the trays or trunking

will be possible.

Sharp edges in cable trays or trunking shall be avoided. Bends shall be made by sector pieces.

Corner-, cross and branch pieces shall suitable to cover deviations of dimensions.

Corners shall be constructed in such a way that cables can be laid without space-loss.



Cable trays and trunking shall be mounted independent of floor and ceiling constructions.

Separate cable trays/trunks shall be installed for:

• power cables

• intrinsically safe cables and low voltage cables.

Filling grade of cable trays/trunking shall be 70 % maximum.

3.5 Mounting of plant instruments

All instruments shall be installed so that they are not subject to excessive vibration and exposed

to extremely high or low temperature.

To facilitate maintenance, plant mounted instruments shall be yoke mounted on a pipe support

in such a way that the centre of the instrument is approx. 1.35 m above walkways, platforms or

grade.

Plant mounted instruments and their related elements, their sensing elements shall be installed

no more than 0.5 m horizontally away from of no more than 2 m vertically above grade,

platforms of walkways.

When necessary platforms shall be executed or extra platforms shall be provided.

In exceptional cases when it is impossible to comply with the above requirements, it is

acceptable to use temporary access facilities for instruments located no more than 6 m above

grade.

Instruments shall not be installed until heavy construction work adjacent to instruments has

been completed to the extent that there can be no damages to the instrument installation by

such construction work.

When instrument supports are clamped around piping of dissimilar material, isolating barriers,

e.g. tape or gasket material shall be applied to prevent electrolytic action.

3.6 Protection boxes

When required by process or climatic conditions, transmitters shall be mounted in reinforced

polyester protection boxes.

Electrical heating elements mounted inside the protection boxes shall be provided.

3.7 Fixing materials

Fixing materials shall be of stainless steel.



4 Inspection and testing

Prior to the tests of the major instrumentation items of equipment in Vendor’s workshop, the

Vendor shall inform the Purchaser when testing will start. All instruments shall be tested and

calibrated before being installed

A manufacturer’s test certificates is required of all instruments.

At least the following system tests shall be carried out during the functional and preliminary test

of the complete package unit on site:

systems - check on correct operational and

optimal adjustment of

instruments of Vendor’s supply

initiating devices for alarm

systems

- adjustment of switch point under

simulated conditions

The program for the site tests shall be made by the Vendor and is subject to approval by the

Purchaser.

Electrical equipment and cabling shall be subjected to earthfault and continuity tests and full

operational tests, if necessary, by simulating process conditions.

At least one week, prior to site tests of the instrumentation Vendor shall inform the Purchaser

when testing will start to enable the Purchaser to attend the test.

Test and inspection results shall be accurately recorded. These records shall be submitted to

the Purchaser.

5 Packing and transport

The equipment package shall be adequately protected to prevent damage during transport to its

destination.

In general, instruments should remain as part of the equipment package during shipping and be

removed only if they are outside the confines of the equipment package/skid, or when the

manufacturer requests special packing and shipping facilities.

However, fragile instruments or parts of instrument systems shall be packed and shipped as

separate items.

6 Integration of instrumentation equipment with VRU package unit

Control and monitoring of VRU package unit shall be realized from operator work station (PC).

VRU process control equipment shall be integrated with existing process control 800xA

system. For that reason all necessary VRU field instrumentation (e.g. sensors, actuator valves,

etc.) shall be integrated to ABB make AC 800M Series controller.

Y:\73256_KN angliavandeniliu garu util izavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\7182001 Paint Spec.doc


client: SC "Klaipėdos Nafta" project: Crude oil vapour utilization from railway estacada title: General Paint Specification for Surface Preparation and Coating


document: 7182001

rev.: 0

sheet: 1

of: 19

General Paint Specification for Surface Preparation and Coating




1 Scope 4 1.1 General 4

2 Industrial Codes and Standards 4 2.1 Codes and standards 4 2.2 Abbreviations 4

3 General Requirements 4 3.1 Conformance to manufacturer's recommendations 4 3.2 Surfaces not to be coated 5 3.3 Safety requirements 5

4 CONTRACTOR Responsibilities 5 4.1 Labour 5 4.2 Equipment 5 4.3 Materials 6 4.4 Miscellaneous 6

5 Materials 6 5.1 Packing 6 5.2 Storage 6 5.3 Additives, thinners, solvents, etc. 6

6 Surface Preparation 7 6.1 General 7 6.2 Description of surface preparation methods 7 6.3 Touch-up 7 6.4 Anchor pattern 8 6.5 Blast cleaning 8 6.6 Galvanised steel, aluminium and SS surfaces 8

7 Application and Workmanship 9 7.1 Workmanship 9 7.2 Manufacturer's instructions 9 7.3 Application 9 7.4 Relative humidity 9 7.5 Coating sequence 9 7.6 Dry film thickness 9 7.7 Special care 9 7.8 Multiple coats 9 7.9 Subsequent coat 10 7.10 Drying time 10 7.11 Priming 10 7.12 Re-priming 10 7.13 Spot coating 10 7.14 Intercoat contamination 10 7.15 Re-coating 10



7.16 Piping 10 7.17 Touch-up of shop primed surfaces 10 7.18 Inaccessible surfaces after assembly 11 7.19 Platforms, gangways etc. 11 7.20 Area protection and cleaning 11 7.21 Floors and walls 11 7.22 Touch-up and refinish 11 7.23 Stainless steel surfaces 11 7.24 Not covered Items 11 7.25 Doors and windows 11

8 Inspection 12 8.1 General 12 8.2 Acceptance limits and criteria 12 8.3 Primers 13

9 Selection of Coating System 14 9.1 General 14

10 Types of Paint Protection 15 10.1 Type A (Hot Dip Galvanised) 15 10.2 Type B (Zinc Rich 2-Pack Epoxy Primer and Heavy Duty Epoxy Coal Tar) 15 10.3 Type C Multi Layers 15 10.4 Type D (2-Pack Zinc Rich Epoxy Paint) 15 10.5 Type E (Epoxy Paint) 15 10.6 Type F (Epoxy Primer and Chlorinated Rubber Paint) 16 10.7 Type G (Chlorinated Rubber Paint – Brush Application) 16 10.8 Type H (Chlorinated Rubber Paint) 16 10.9 Type J (Lead Primer and Epoxy Paint) 16 10.10Type K (Lead Primer and Epoxy Paint for Galvanised Metal) 16 10.11Type L (Bitumen Coating) 17 10.12Type M (Electro Zinc-Plated and Stove-Enamelled) 17 10.13Type N (Clean and Degrease) 17 10.14Type P (Lead Primer) 17 10.15Type Q (Bitumen Enamel or Coal Tar Enamel Wrappings) 17 10.16Type R (Sealed Sprayed Aluminium Coating) 17 10.17Type S (Sealed Sprayed Zinc Coating) 18 10.18Type T (Decorative Painting) 18

11 Applications for Different Types of Painting Systems 18



1 Scope

1.1 General

This specification is applicable to all field and shop coating, intended to be used for exterior

metal surfaces of equipment, structures, piping, doors and concrete etc. It is intended to

specify the furnishing of materials, labour and equipment, methods for surface preparation and

conditions for workmanship.

Painting work not covered by this specification:

• The internal coating or lining of piping and equipment.

• The labelling or marking of piping for the indication of the transported media.

• The preservation with temporary protectives of piping, steel plates and structures,

equipment and machinery in shipment or in storage.

2 Industrial Codes and Standards

2.1 Codes and standards

In this paint specification reference is made to the following Industrial Codes and Standards:

• Industrial Standard - ISO 8501-1 Pictorial Surface Preparation Standards for Painting Steel

Surfaces.

• All applicable Lithuanian rules and regulations.

2.2 Abbreviations

• M.D.F.T. means: Minimum Dry Film Thickness in micro-meter

• M.O.T. means: Maximum Operating Temperature in °C

• N.O.T. means: Normal Operating Temperature in °C

• C.S. means: Carbon Steel, Low Alloy Steel, Cast Iron, Ductile Iron and the like

• S.S. means: Stainless Steel

3 General Requirements

3.1 Conformance to manufacturer's recommendations

The CONTRACTOR is responsible for conformance to coating Manufacturer's

recommendations defined on product data sheets. In the event of any discrepancies between

coating Manufacturer's recommendations, label instructions and this specification, they are to

be referred to EMPLOYER for adjustment.



3.2 Surfaces not to be coated

(Unless specified otherwise)

A) Stainless steel surfaces;

B) Aluminium, e.g. insulation protective covering;

C) Copper and brass surfaces;

D) Nickel, monel, inconel and other corrosion resistant alloys, FRP and PVC pipe;

E) Galvanised structural steel, galvanised pipe support steel and galvanised grating;

F) Galvanised pipe and cable conduit;

G) Factory finished coated items such as pumps, blowers, motors and other machinery

items, instrument cases, lighting fixtures and other electrical equipment, push buttons,

gauges and other instrument equipment;

H) Valve stems;

I) Machined surfaces intended to connect to other items;

J) however, machines shall be supplied with a rust preventative coating on these surface

which can be removed with a solvet cleaning;

K) Exposed moving parts and mechanical seal glands;

L) Capillary tubing of temperature instruments;

M) Nameplates and markings.

3.3 Safety requirements

Coatings, thinners, solvents, soiled rags, waste, etc., shall be kept in tightly closed containers

while at the site and not in use. All materials are subject to fire protection requirements of

applicable codes, standards and EMPLOYER’S safety requirements.

4 CONTRACTOR Responsibilities

4.1 Labour

Workmanship shall be of the best quality, performed by skilled workmen. The CONTRACTOR

shall be responsible for a finished product in accordance with Manufacturer's

recommendations and this specification. The finished product shall be free of sags and skips

and present an uniform colour gloss.

4.2 Equipment

All spray equipment shall be inspected and approved by the Construction Management before

any work commences.

Blast cleaning and associated equipment shall be inspected before any work commences.

Suitable moisture traps shall be installed between the air supply and pressure pots and spray

guns. Traps shall be left slightly open to allow continuous bleeding of water and oil.

Regulators and gauges shall be provided by the CONTRACTOR for both pressure pots and

spray guns.

Spray pots must have an agitator for materials which have a tendency to settle rapidly, such

as organic zinc.



4.3 Materials

Coatings are to be supplied by the CONTRACTOR.

Consumable supplies are the responsibility of the CONTRACTOR.

4.4 Miscellaneous

The CONTRACTOR shall furnish all inspection equipment. All inspection equipment shall be

calibrated just prior to initial use.

The CONTRACTOR shall protect floors and paved areas against spatter or spillage by use of

drip cloths.

Before acceptance of the works, contractor shall remove coating spots, stains and overspray,

from floors and walls, hardware, fixtures and all other items not intended to be coated. Further

all glass shall be cleaned of all coatings and putty deposits. Special cleaning instructions and

materials shall be applied where necessary. The CONTRACTOR shall consult the EMPLYER

to obtain correct information. Where proper cleaning of spots, stains, etc., is not possible, the

CONTRACTOR shall install protective covering materials and remove these after job is

completed satisfactorily.

The CONTRACTOR shall supply and apply the required coating for all retouching and

refinishing of any work or surfaces which may be damaged or found defective.

5 Materials

5.1 Packing

All materials shall be as made and specified by the Manufacturer and shall be delivered in the

original, unopened packing.

Containers must bear the original Manufacturer's label identifying the actual contents in order

to be accepted.

5.2 Storage

Materials shall be stored in an enclosed area to protect them from temperatures in excess of

coating Manufacturer's recommendations and to prevent fire hazards.

5.3 Additives, thinners, solvents, etc.

The CONTRACTOR shall use only the additives, thinners, solvents, etc., as specified by the

coating Manufacturer. All mixing shall be done in clean metal or plastic containers.



6 Surface Preparation

6.1 General

The CONTRACTOR shall apply coatings only to those surfaces which have been properly

cleaned, prepared and dried, as specified in this Specification.

When a prepared surface has been left uncoated for a long time (i.e. 6 hours) for surface

rusting to occur, the CONTRACTOR shall clean these surfaces again per the specified

requirements.

The time interval between blast cleaning and primer shall under all conditions be such that re-

rusting or re-contamination cannot occur. Conditions may require a shorter interval than 6

hours. An extension to this interval time is acceptable only if written approval is obtained from

the EMPLOYER.

6.2 Description of surface preparation methods

Solvent cleaning shall precede other methods of surface preparation and the application of any

coating, whenever dirt, oil grease and other substances, harmful to lifetime or appearance of

primers or paints are present.

These agents shall be removed by means of clean solvents (such as white spirit), or suitable

cleaning compounds. After the use of water soluble compounds the surfaces shall be rinsed

with an ample amount of potable water, and then be allowed to dry thoroughly before and

further step is taken. Only clean brushes and rags shall be used.

For the cleaning of SS items only solvents shall be used.

6.3 Touch-up

Touch-up is applicable to field welds, bolting, and damaged, rusted, or otherwise oxidized pre-

primed surfaces as a first step to field painting. Touch-up shall include all necessary

operations, such as:

- Solvent cleaning;

- The removal of zinc oxides (as found on zinc-rich primers) by means of potable water

and nylon brushes;

- De-rusting of damaged shop primed surfaces, field-welds and bolting (to C-St3

Standard);

- Spot priming or painting with the specified materials and to the same number of shop

coats and M.D.F.T. as has been specified.



6.4 Anchor pattern

Blast cleaned surfaces shall provide a good anchor pattern for primers, but shall not show

excessive roughness.

Manufacturers recommendation shall be adhered to.

Power and hand tool cleaned surfaces shall be free of sharp cuts or burrs and shall not be

burnished to a degree detrimental to the adhesion of primers and paints.

6.5 Blast cleaning

Surface preparation shall include the thorough removal of blasting materials and dust, leaving

the prepared surface dry, clean and in all respects fit to be painted.

All field blasting operations shall be performed within the confines of a designated area on site.

All equipment, tools, supplies, etc., must be installed or stored in this area. Any field blasting

not possible within the designated area, e.g. field welds, damaged surfaces, etc. shall be by

means of mechanical tools such as wire brushing. Blast cleaning on the site is only permitted

after written approval of The EMPLOYER.

All steel delivered to the area of operations shall be protected against physical damage before,

during and after blast cleaning.

6.6 Galvanised steel, aluminium and SS surfaces

Galvanised steel, aluminium and stainless steel surfaces may be cleaned and pre-treated in

accordance with the CONTRACTOR’S standard procedures, however, prior to application, any

procedure shall be sent to the EMPLOYER for review.



7 Application and Workmanship

7.1 Workmanship

Coating applications shall be of first class workmanship, with uniform film thickness, hiding and

appearance, and shall be free of brush marks, laps, sags, runs, crawls, skips, etc.

7.2 Manufacturer's instructions

Coatings shall be applied strictly in accordance with the coating Manufacturer's instructions

and recommendations.

7.3 Application

No coating shall be applied when moisture is present and no coating shall take place when the

air temperature or surface temperature is expected to fall below 5°C during the required drying

or curing time.

In any case, coating Manufacturer's recommendations shall govern, if they are more stringent.

Exceptions to the above temperature must be referred to the coating Manufacturer and

EMPLOYER, and are subject to the EMPLOYER’S approval in writing.

7.4 Relative humidity

No application of coating shall take place when the relative humidity is above 85%. The

temperature of the steel shall always be at least 3oC above the dew point temperature.

7.5 Coating sequence

The sequence of coating shall be such that a minimum of damage to finished coatings will

result.

7.6 Dry film thickness

Dry Film Thickness (DFT) shall be as specified in the Coating Systems and Schedules; the

acceptance for coating application and actual coating is specified in paragraph 8.0, Inspection.

7.7 Special care

Special care shall be taken when coating is applied on the edges of doors, sharp corners, etc.,

to ensure adequate dry film thickness.

The painting materials shall be applied by the tools as advised by Manufacturer. When spray

application is recommended, supplemental brushing is required to obtain adequate protection

at crevices, bolts, rivets, welds, edges, and all other surfaces where the M.D.F.T. cannot be

reached by spraying only. This brushing shall precede the spray application.

7.8 Multiple coats

Multiple coats of the same colour are not acceptable. Alternating colour coats are required to

distinguish between the base layers, to provide a visual check to ensure complete coverage of

each coat is achieved.



7.9 Subsequent coat

No subsequent coat shall be applied until the preceding coat is dry, has correct dry film

thickness and is in proper condition to receive the subsequent coat.

7.10 Drying time

Extended drying times or airing procedures when recommended by the coating Manufacturer,

shall be followed.

7.11 Priming

All base material shall be primed prior to application of top coats.

7.12 Re-priming

Any damage to a primed surface due to welding, etc., shall be cleaned and re-primed as per

the original coating schedule and allowed to dry before any subsequent coat shall be applied.

7.13 Spot coating

All connecting welds, bolts, rivets, etc., for structural steel framing and miscellaneous steel

work shall be spot-coated with the same material used for the shop coat or an approved

equivalent material, prior to field application. This spot-coating shall be in addition to the

specified number of coats.

7.14 Intercoat contamination

To minimise intercoat contamination, subsequent coats shall be applied with a minimum

elapsed time between coats, as is consistent with the drying time or work and erection

schedules.

When unavoidable contamination does occur, contaminants shall be sufficiently removed to

ensure adequate inter-coat adhesion.

7.15 Re-coating

In case of re-coating, damage to the previous coat shall be repaired with the compatible

coating. The completed coating shall be free from defects.

7.16 Piping

Piping to be installed in the field shall be prepared and primed before installation followed by

final painting after installation.

7.17 Touch-up of shop primed surfaces

Shop primed surfaces shall be touched-up and repaired (damages, field welds, etc.) as soon

as possible after erection. Final painting shall follow immediately after mechanical completion,

or after successfully completed pressure testing.



7.18 Inaccessible surfaces after assembly

Surfaces that will be inaccessible after assembly shall receive the complete painting system

before assembling.

Contact surfaces of bolted connections are to be primed only.

7.19 Platforms, gangways etc.

Platforms, gangways and stair beams shall receive the complete painting system before the

gratings or stair treads are mounted.

7.20 Area protection and cleaning

The following areas and similar, but not listed areas, shall be protected against coating, and

after coating work is completed, cleaned by the CONTRACTOR so that all masking agents are

completely removed.

a) Windows, gauge glasses, sight glasses, etc;

b) Globes and reflectors of lighting fixtures;

c) Valve stems, adjusting screws and nuts, and other machined, operating parts or

machinery;

d) Equipment nameplates, plated or polished hardware;

e) Sprinkler heads and fusible links;

f) And all other items as referred to in paragraph 3.2.

7.21 Floors and walls

Floors and exterior metal walls shall be protected against splashes, spills and overspray.

7.22 Touch-up and refinish

The CONTRACTOR shall go over all surfaces and clean-off all coating spots on floors, walls,

glass, etc., touch-up and refinish any part of his work no matter by whom caused, and shall

remove all dirt, rubbish and waste materials resulting from this work.

7.23 Stainless steel surfaces

Special attention is drawn to coating of carbon steel parts attached to or in contact with

austenitic stainless steel parts.

Care shall be taken to prevent contact of zinc containing primer onto austenitic stainless steel

surfaces such as by overspray. If contact cannot be avoided, the CONTRACTOR shall contact

the EMPLOYER prior to applying the primer coat, in order to review the specific application in

detail. The application of a zinc free primer can be agreed upon.

7.24 Not covered Items

Consultation of coating Manufacturer and the EMPLOYER are mandatory for items not

covered herein.

7.25 Doors and windows

Doors and windows are to be left open after coating until they are dry.



8 Inspection

8.1 General

All phases of the cleaning, surface preparation and coating shall be subject to the approval of

authorised inspectors of the Paint Manufacturer. No coating shall be applied prior to

Manufacturer's inspector approval of the surface preparation or of subsequent coatings applied

to this surface. All defective work or coating not conforming to this specification shall be

repaired at no additional costs to the EMPLOYER.

Procedures for repairs, not covered by this specification, must be brought to the attention of

the EMPLOYER. Alternative repair procedures must be approved by the EMPLOYER prior to

carrying out the actual repair.

As work progresses, the EMPLOYER is responsible for continuous checking of coverage rate

and wet and dry film thickness. A weekly log shall be maintained, containing the following data

by day: air and steel temperatures, relative humidity, dew point, coating progress, coating Dry

Film Thickness measured and other relevant information pertinent to the work.

At the completion of the works, the contractor is responsible for determining that the correct dry

film thickness is attained, by use of magnetic film thickness gauges or electromagnetic gauges,

such as Magne-Gauge, Mikrotest, Elcometer Gauge or similar for ferrous surfaces.

Some equipment may be delivered with a shop-primer as per vessel, heat-exchanger or tank

specification. The CONTRACTOR shall, after having obtained approval of the paint

Manufacturer's inspector, finish the complete coating of surfaces, on which the surface

preparation and prime coat has been carried out by others, however, the CONTRACTOR shall

take full responsibility to verify that this surface preparation and prime application by others is

complete and in proper condition, all in accordance with this specification.

The CONTRACTOR shall apply all subsequent coats to complete the Coating system and

Schedule applicable for that specific equipment. In the event that the CONTRACTOR is

dissatisfied with the surface preparation and prime coat application, carried out by others, he

shall inform the EMPLOYER in writing immediately after his dissatisfaction has been

established.

The CONTRACTOR shall assign a full-time inspector to the work during the whole period of

coating application.

8.2 Acceptance limits and criteria

The complete coating work and each step such as surface preparation, prime undercoat and

finish coat application shall be subject to inspection.

Surface preparation shall be compared with the specified degree of cleanliness as per this

specification and SIS 05 59 00 and shall be compared with the required anchor pattern

(surface roughness).



8.3 Primers

Acceptance criteria for primers shall be as follows:

Minimum:

90% of all measurements shall have a Dry Film Thickness as specified in the Coating Systems

and Schedules; only 10% of all measurements may have a minimum Dry Film Thickness of

90% of the value specified for the primer as per Coating System and Schedules. Minimum DFT

of an inorganic zinc silicate primer is 60 micrometer.

Maximum:

Acceptance criteria for primers shall be 75% over the value specified in the Coating systems

and Schedules.

Acceptance criteria for primers applied by others

Primer need not to be removed if acceptable for the CONTRACTOR according to 8.1 of this

specification.

Undercoat and Finish Coat

Acceptance criteria shall be as follows:

Minimum:

90% of all measurements shall have a Dry Film Thickness as specified; only 10% may have a

minimum Dry Film Thickness of 90% of the value specified.

Maximum:

Dry Film Thickness shall not exceed more than 75% of the value specified.

If the requirements of the minimum and maximum Dry Film Thickness are not met, the

CONTRACTOR shall be responsible to re-blast and repaint or to repair the paint coat

according to Manufacturer's recommendations as per the original requirements of the Coating

Systems and Schedules. All such required paint work shall be repaired at no additional costs to

the EMPLOYER.



9 Selection of Coating System

9.1 General

The CONTRACTOR shall be responsible for the application of the correct painting systems to

the surfaces which must be painted according to this specification.

Section 10 shall be the guide for the selection of the painting system. The selection shall be

based on the Item description and when indicated in the paint system in conjunction with the

Maximum or Normal Operating Temperature (M.O.T. or N.O.T.).

In case the M.O.T. of an item is not known, assume M.O.T. equals design temperature minus

20oC.

Machinery, valves etc. may be painted in accordance with Supplier's Standard Painting

Practice, provided workmanship, quality and the materials used, the number of coats (or

M.D.F.T.) are not less than called for in this specification.

However, each Supplier shall submit for approval full details about his intended painting

practice. The information shall contain at least:

a) Surface preparation method and standard;

b) Binder resin type;

c) Main type of pigment and percentage (e.g. red lead/red oxide 90/10);

d) Brand name of paint;

e) Paint Manufacturer's name;

f) Maximum temperature resistance of paint.

Field painting of machinery as mentioned above shall be executed only when the shop applied

paints have been damaged.



10 Types of Paint Protection

10.1 Type A (Hot Dip Galvanised)

a) Blast clean to First Quality finish.

b) Hot-dip galvanised to give a minimum coating weight of 610 gm/m2. Finished dry film

thickness shall be not less than 85 microns for metals in interior of building and normally

dry condition, and 140 microns for other conditions.

NOTE: All fastenings including bolts, for use with materials having a Type A finish, shall be

sheradised in accordance with B.S.4921.

10.2 Type B (Zinc Rich 2-Pack Epoxy Primer and Heavy Duty Epoxy Coal Tar)

a) Blast clean to First Quality finish B.S.4232.

b) Within 2 hours of blast cleaning, apply one coat of 2-pack zinc rich epoxy primer, to a

finished dry film thickness of not less than 50 microns.

c) Apply one coat of 2-pack zinc epoxy primer as above to a finished thickness of not less

than 100 microns.

d) Apply two coats of high build epoxy coal tar, to a final finished dry film thickness of not less

than 350 microns.

10.3 Type C Multi Layers

As type B above but with sufficient number of coats in “d” to give a final finished dry film

thickness of not less than 450 microns.

10.4 Type D (2-Pack Zinc Rich Epoxy Paint)


b) Within 2 hours of blast cleaning, apply one coat of 2-pack zinc rich epoxy primer, as in

Type B Part (b) above.

c) Apply two coats of 2-pack zinc rich epoxy high build matt finish dry film thickness of not

less than 300 microns.

d) Apply final coat of 2-pack epoxy gloss finish of approved shade to produce a total of

finished minimum dry film thickness of 350 microns.

A minimum of 16 hours shall be allowed between coats.

10.5 Type E (Epoxy Paint)


b) Within 2 hours of blast cleaning, apply one coat of high build 2-pack cold cure epoxy resin

primer to give a finished dry film thickness of 125 microns.

c) After a period of not less than 8 hours from the first coat (“b” above), a finish coat of high

build pure epoxy shall be applied to give a total dry film thickness of not less than 250

microns.



10.6 Type F (Epoxy Primer and Chlorinated Rubber Paint)


b) Within 2 hours of blast cleaning, apply one coat of 2-pack zinc rich epoxy primer to give a

finished dry film thickness of 50 microns.

c) Apply two coats of 2-pack zinc epoxy high build to a matt finished dry film thickness of 300

microns.

d) Apply one coat of chlorinated rubber paint of approved shade to a gloss finished dry film

total thickness of not less than 350 microns.

10.7 Type G (Chlorinated Rubber Paint – Brush Application)


b) Apply 2 coats of chlorinated rubber paint primer to give a finished dry film thickness of 100

microns.

c) Apply 2 coats of chlorinated rubber based high build undercoat to give a finished dry film

thickness of 220 microns.

d) Apply 2 coats of chlorinated rubber base gloss finish of approved shade to give a total dry

film thickness of 280 microns.

10.8 Type H (Chlorinated Rubber Paint)


b) Apply 2 coats of chlorinated rubber based high build primer to give a finished film


c) Apply 2 coats of chlorinated rubber based high build semi-gloss finish of approved shade

to give a total dry film thickness of 300 microns.

10.9 Type J (Lead Primer and Epoxy Paint)

a) Blast clean to First Quality finish B.S. 4232.

b) Within 2 hours of blast cleaning, apply one coat of 2-pack epoxy metallic lead primer to

give a finished dry film thickness of 50 microns.

c) Apply 2 coats of 2-pack epoxy micaceous iron oxide undercoat to give a finished dry film


d) Apply one coat of 2-pack epoxy gloss finish of approved shade to give a total dry film


10.10 Type K (Lead Primer and Epoxy Paint for Galvanised Metal)

a) Thoroughly clean and degrease.

b) Apply one coat of 2-pack epoxy metallic lead primer to give a finished dry film thickness of

50 microns.

c) Apply one coat of 2-pack epoxy micaceous iron ore undercoat to give a finished dry film


d) Apply one coat of 2-pack epoxy gloss finish of approved shade to give a total dry film




10.11 Type L (Bitumen Coating)

a) Blast clean to First Quality finish B.S. 4232 or pickle in hot dilute sulphuric acid.

b) After thorough washing, phosphate coating by immersion in a bath of hot dilute phosphoric

acid.

c) Application of one coat of primer as specified in B.S. 4147:1973.

d) Hot dip bitumen / bitumen coating applied to give a smooth lining having a minimum dry

film thickness of not less than 300 microns.

10.12 Type M (Electro Zinc-Plated and Stove-Enamelled)

a) Blast clean to First Quality finish B.S.4243 or pickle in hot dilute sulphuric acid.

e) After thorough washing, phosphate coating by immersion in a bath of hot dilute phosphoric

acid.

b) Electro-zinc plate.

c) Apply stoved zinc based epoxy primer (incorporating suitable pigments to act as acid

scavengers and counteract the formation of adhesion destroying compounds).

d) Finishing coat(s) of stoved alkyd enamel to give a high standard gloss finish to approved

shade, and not less than 150 microns dry film thickness.

10.13 Type N (Clean and Degrease)

Thoroughly clean by hand, and power tools where available, to remove all mill scale, rust and

grease.

10.14 Type P (Lead Primer)

a) Blast clean to First Quality finish B.S. 4232.

b) Within 2 hours of blast cleaning, apply by brush two coats of metallic lead primer to a

finished thickness of not less than 100 microns.

10.15 Type Q (Bitumen Enamel or Coal Tar Enamel Wrappings)

Apply bitumen enamel wrapping or coal tar enamel wrapping in accordance with B.S. 534:

Clause 5.4

10.16 Type R (Sealed Sprayed Aluminium Coating)

a) Blast clean to First Quality finish B.S.4232. Surface preparation shall be in accordance

with B.S.2569.

b) Apply suitable primer.

c) Apply sprayed – aluminium coating to give a finish dry film thickness of not less than 150

microns.

d) Apply suitable pre-treatment primer (e.g.Two-pack polyvinyl butyral or 2-pack polyvinyl

butyral/ phenolic, containing not less than 85% by weight of zinc tetroxychromate pigment)

e) Apply suitable sealer (e.g.Blend of vinyl chloride / acetete copolymers or 2-pack phenolic

binder or 2-pack epoxy or 2-pack polyurethene).



10.17 Type S (Sealed Sprayed Zinc Coating)

a) As in (a) Type R

b) As in (b) Type R

c) As in (c) Type R but using sprayed zinc coating to give a finished dry film thickness of not

less than 175 microns.

d) As in (d) Type R

e) Apply suitable sealer (e.g. silicone resin containing not less than 95% by weight of

alumunium pigment).

10.18 Type T (Decorative Painting)

Decorative paint (when specified) shall be compatible with the final finish paint or coating.

The final shade shall be advised by the Engineer.

The film thickness of decorative paint shall not be included in the total dry film thickness

specified.

11 Applications for Different Types of Painting Systems

Item Applications Type

1 All steel ladders, staircases, guard rail, guard rail standards, safety cages, open

steel flooring, small bore pipework and steel conduit. All small metalwork such as

pipe supports, steel flooring supports and safety chains.

A

2 All steelwork, castings and other metal surfaces which are immersed in water

(non-potable water) sewage, and other effluents or in contact with liquid or subject

to splashing or buried in the ground.

C

3 All steel, ductile and cast iron pipes, valves, flow meters and fittings 75 mm and

larger used for the conveyance of sewage and other effluents as in 2 above.

B

4 All steelwork, castings, pipes, valves, flow meters and other surfaces which are

exposed (exterior) and frequent damp or wet.

B

5 As 4 above, but in interior of building and normally dry. D or F

6 All steelwork and castings which are in contact with potable water. A,D,E,F or H

7 All steel pipes, ductile iron pipes, and cast iron pipes and fittings 75 mm and larger

used for the conveyance of potable water.

Internal protection

External protection

L

E,F,H or L

8 All steel pipes laid underground Q

9 All valves, penstocks, flow meters, tanks and fittings which are in contact with

potable water.

E,F or H

10 Potable water pumping plant installed inside pumping station – normally dry

condition.



a) Suction and delivery pipes

Internal protection

External protection

L

E,F or H

b) Valves

Internal protection

External protection

E or L

E,F or H

c) Pump casings

Internal protection

External protection

E or L

E,F or H

d) Flowmeters (body)

Internal protection

External protection

E,F,H or I

E,F or H

e) Extension shaft and couplings E,F or H

f) Pump motor casing and support steelwork E,F or H

11 Potable water pumping plant installed inside pumping station – frequently damp or

wet condition (External protection).

D

12 Over-painting of galvanised items not in contact with potable water. J

13 Switchboards, multi-motor control panels and other similar enclosures. M

14 Metal cable trays, conduits and fixings. A

15 Sections of pipe to be built into concrete. N

16 High temperature metal surfaces (including radiators):

a) Temperature up to 200 °C R,S

b) Temperature up to 500 °C S

Y:\73256_KN angliavandeniliu garu utilizavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\6551408 Req docs.doc

0 14-10-2010 For Information N. Motiejunas SV rev. date description/issued for drawn up ckd.

client: SC "Klaipėdos Nafta" project: Crude oil vapour utilization from railway estacada title: Required Documents for Vapour Recovery Unit


document: 6551408

rev.: 0

sheet: 1

of: 8

Required Documents for Vapour Recovery Unit

client: SC "Klaipėdos Nafta" project: Crude oil vapour utilization from railway estacada title: Required DocumentsVapour Recovery Unit



1 General 3

2 Required documentation 5



1 General

Vendor is required to furnish the documents specified herein, in the quantities, within the

periods and in accordance with the instructions and conditions shown below.

1.1 All documents shall be in the Lithuanian language. Documents required by governmental,

provincial or local authorities shall also be made in the language required by the

authorities. The equipment shall be related to a European Directive. The declaration of

conformity and the user manual shall be in Lithuanian language and in the language of the

manufacturer.

1.2 For units of measurement the SI-standard shall be applied.

1.3 All documents shall clearly show the purchase order number and tag numbers (where

applicable) and Purchaser’s drawing number.

1.4 Drawings shall be prepared in formats A1 thru A4 inclusive.

1.5 Quality/type of documents:

(P) = Prints: In case of printed matter, originals are required;

(D) = Digital format: (on CD-rom) using AutoCad (2D, release 14 or higher).

Miscellaneous lists, text books, usually presented on A4 format

shall be supplied in digital format, using MS Word.

1.6 Not approved documents shall be re-issued in the required quantities after incorporation

of Purchasers’ comments.

1.7 Prints shall be folded to A4 size, with the title block visible at the front. Prints to be handed

over as originals shall NOT be folded.

1.8 Fabrication is not to start pending approval of all relevant documents.

1.9 Purchaser normally requires 15 working days for document review and approval. In case

extension of this period endangers the delivery date of the equipment/material, the

Vendor shall clearly indicate such on his transmitting letter.

1.10 Approval of documents by Purchaser does not relieve the Vendor from his exclusive

responsibility for their accuracy and/or correctness and does not relieve the Vendor from

his obligation to fully comply with the Contract.

1.11 Specific requirements regarding the documents, if any, have been laid down in the

requisition.



1.12 All documents shall be submitted under cover of a transmittal indicating purchase order

number, document number revision, title and the purpose of submission. For each

document, the appropriate equipment number(s) shall be indicated.

1.13 Document change control:

It is the responsibility of the Vendor to inform Purchaser about changes made to each

document furnished by Vendor. Therefore all re-issued documents shall clearly show

identification and/or description of all changes.

1.14 A “live” set of documents shall be available at the Vendor’s shop at all times for use by

Purchaser’s and/or Client’s inspector.

1.15 Vendor shall ensure that, prior to final acceptance of materials and equipment,

Manufacturer’s data book is complete and presented to Purchaser and/or third party, if so

specified, for their acceptance.

1.16 Manufacturer’s data book shall be produced by Vendor. Where equipment packages are

involved, data books shall be compiled for each of the components separately as

applicable.

1.17 Vendor shall supply each set of “final” documentation in file within 2 (two) week after

delivery.

1.18 All documents shall be addressed to:

SC “Klaipėdos Nafta”

Burių str. 19

P.O. Box 81

LT-91003 Klaipėda, Lithuania



2 Required documentation

2.1 General

Document description Quantity + type

Submittal period in

weeks

With

quot.

For approval

after award

Final after

approval

For appr.

after

award

Final

after

approval

P P D P D

Detailed list of drawings and documents to be

submitted

3 2

General company introduction 3

Photographs and brochures 3

List of exceptions and deviations to the

specifications

3

Quality plan 3 3 3 3

Inspection plan (completed) 3 3 3 3

Fabrication/inspection schedule 3

Recommended spares quotation for:

• Testing 3 3

• Commissioning 3 3

• 2 year continuous operation 3 3

Sound-level information 3

List of suppliers 3

As built documents 3 1 ***

Installation/commissioning/operation

manuals in Lithuanian language

3 **

Maintenance manuals (1) 3 **

Completed specification / data sheets 3

Manufacturing data report 4 **

(1) in the manual should be included instruction for activated carbon beds cleaning and replacement in

the Vapor Recovery Unit.



Packaged Units


Submittal period in

weeks

With

quot.

For approval

after award

Final after

approval

For appr.

after award

Final

after

approval

P P D P D

Dimensions and weights

General arrangement drawings * 3 3 1 3 1 6 3

Assembly drawings * 3 1 3 1 6 3

Sectional drawings * 3 1 3 1 6 3

Foundation & block-out drawings with

loads

3 1 3 1 6 3

Pipe routing plans * 3 1 3 1 6 3

Process

Process diagrams according ISO 3311-

1 rules

3 1 3 1 6 3

Process & Instruments Diagrams 3 1 3 1 6 3

Design, pressure drop and/or heat

balance calculation

3 3 6 3

Flow & purity registration 3 3 6 3

Linelist(s) 3 1 6

Specification of equipment and

instruments

3

Utility consumption & requirements 3

Emission points + concentration and

quantities per unit time

3 3 6

Electrical and instrumentation

Consumers list and electrical load-list 3 3 1 4

Cable-number list 3 1 6

Connection diagrams / drawings 3 1 3 1 6 3

Installation diagrams / drawings 3 1 3 1 6 3

Instrument index 3 1 3 1 6 3

Alarm & tripsetting-list 3 1 3 1 6 3

Instrument cable-list 3 1 3 1 6 3

Nameplate(s)-list(s) 3 1 3 1 6 3

Applied software description 3 1 3 1 6 3

Cable block schematic 3 1 3 1 6 3




Submittal period in

weeks

With

quot.

For approval

after award

Final after

approval

For appr.

after award

Final

after

approval

P P D P D

Electrical and instrumentation

(continued)

Junctionbox connection schematics 3 1 3 1 6 3

Installation detail drawings 3 1 3 1 6 3

Drawings of panels and sub-panels:

• control diagrams 3 1 3 1 6 3

• wiring diagrams 3 1 3 1 6 3

• connection diagrams 3 1 3 1 6 3

• lay-out drawings 3 1 3 1 6 3

Control systems

PLC-programme (disk-listing) 3 1 3 1 6 3

PC-programme (disk-listing) 3 1 3 1 6 3

Description of PLC-programme 3 3 1 3 1 6 3

Description of PC-programme 3 3 1 3 1 6 3

Pneumatics

Schematic diagrams 3 3 1 3 1 6 3

Air-consumption calculation 3 3 6 3

Data sheets 3 1 3 1 6 3

Procedures

Painting procedure 3 3 3 3

Testing procedure 3 3 6 3

Quality assurance

Coating test reports *

Welding procedure spec.’s (WPS) * 3 3 6 3

Weld procedure qualification record

(WPQR) *

3 3 6 3

Welders qualifications * 3 3 6 3

Test-curves / results *

Test-certificates *

Leak test procedure *

Leak test certificates *

Material certificates *

E-motor certificates *

EXD-certificates *




Submittal period in

weeks

With

quot.

For approval

After award

Final after

approval

For appr.

after award

Final

after

approval

P P D P D

Miscellaneous

List of special tools 3

Fire-risk analysis 3 3 6 3

Explosion risk analysis 3 3 6 3

EC Declaration of conformity (IIA

Certificate) in required and original

language

3 **

* In manufacturing report

**With delivery

***After delivery

Appendix 1

Appendix 2

Appendix 3 rev. B, 2011.04.22

VRU working profile

0

500

1000

1500

2000

2500

3000

35000

0,6

1,2

1,8

2,4 3

3,6

4,2

4,8

5,4 6

6,6

7,2

7,8

8,4 9

9,6

10

,2

10

,8

11

,4 12

12

,6

13

,2

13

,8

14

,4 15

15

,6

16

,2

16

,8

17

,4 18

18

,6

19

,2

19

,8

20

,4 21

21

,6

22

,2

22

,8

23

,4 24

Time, h

Vap

ou

r cap

ac

ity, m

3/h

Track 3ACrude 1800m³/h

Track 3BGasoline 1200m³/h

VRU working capacity

VRU_technical_requirements_EN.pdf

Documents

Transcript of VRU_technical_requirements_EN.pdf