DOC.

ID:

40-0000520

REV/STATUS:

C / Approved

DATE:

10 Sep 2013

MADE/APPROVED:

SIVAKOMA / JONANYLU

PAGE:

1(29)

NAME:

Technical Specification

SUBJECT:

General Project Specification and Project Requirements

GENERAL PROJECT SPECIFICATION

AND
REQUIREMENTS

Revision
A

Made by
Ramaswamy
Neelakantan

Approved by
Jan-Ole
Fagerstrm

Reason for revision

Original revision

B
C

Sivakumar
Komarasamy

Site conditions updated,

Materials in chapter 14.12
updated
(acc to Design Basis)

CITEC OY AB
P.O. Box 109, FI-65101 VAASA, FINLAND, Tel. +358 6 3240 700 Fax +358 6 3240 850
www.citec.com

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TABLE OF CONTENTS

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

GENERAL .................................................................................................................... 3
PROJECT INFORMATION .......................................................................................... 4
EQUIPMENT NUMBERING SYSTEM ........................................................................ 6
GENERAL SCOPE OF CONTRACT ............................................................................. 6
GENERAL SPECIFICATION (COMMON FOR ALL MODULES) ............................... 8
PIPING BASIS & VELOCITY CRITERIA ...................................................................11
GENERAL CODES & STANDARDS COMMON FOR ALL DISCIPLINES .................12
GENERAL ELECTRICAL REQUIREMENTS .............................................................15
I&C SPECIFICATIONS AND REQUIREMENTS .......................................................16
HAZOP ........................................................................................................................22
TIME SCHEDULE ......................................................................................................22
DEVIATIONS ..............................................................................................................23
SPARES, MAIN TOOLS & TACKLES, CONSUMABLES LIST ..................................23
PACKAGING ...............................................................................................................23
MECHANICAL STRUCTURES & PIPING .................................................................24
DOCUMENTATION ....................................................................................................27
QUALITY ASSURANCE .............................................................................................27

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1. GENERAL
Tanzania Electric Supply Company Limited (TANESCO) intends to procure and
install on turnkey basis, a power plant with a total power generation capacity of 150
MW (+5%) using Duel Fuel (Jet A1 and Natural Gas) at Kinyerezi site in Dar - es
Salaam, Tanzania.
Jacobsen Elektro AS (JEL) is awarded as the total EPC contractor for this 150 MW
(+5%) fast track Gas Turbine based power project. In this regard, Citec Engineering
Oy Ab (CITEC) has been engaged by JEL as engineering consultant for Concept,
Basic and Detailed engineering for this proposed Power plant.
GE Energy (GE) will supply 4 Sets of LM6000 PF Dual Fuel Gas Turbine s with
complete Auxiliary power module. JEL will supply the balance of plant for the entire
power plant. The proposed power plant is of simple cycle with all necessary balance
of plant systems. The power plant utilizes both gas (Natural Gas) and Liquid fuel
(Jet-A1).
Citec reserves the right to carry out some limited modifications to the Technical
Details, whilst carrying out the detailed engineering. However, these modifications
would not affect the overall performance of the plant.
Vendor can make suitable offers even if there are minor deviations which do not
affect the efficient functioning of the equipment. However, the deviation mu st be
clearly stated.
All documentation and correspondence shall be in English.

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2. PROJECT INFORMATION
The following table provides the ambient design conditions and other design criteria
to be considered for selection and performance of proposed Power plant.
S.NO
2.1
2.1.1

PARAMETERS
Site Location
Location

2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
2.2
2.2.1

Nearest Port & distance

Nearest Airport & distance
Land Transportation
Nearest Important town
Nearest Railway station
Geographical Data
Geographical Bearing of Site
Latitude
Longitude
Site Characteristics
(Terrain type /Hilly Area
/Plain Area)
Meteorological Data
Climate of Area
Barometric Pressure
Ambient Pressure
Elevation above mean sea
Level
Ambient Temperature
Maximum
Average
Minimum
Relative Humidity
Maximum
Average
Minimum
Wind Data
Wind Velocity
Wind Speed Maximum
Wind Speed Average
Wind Speed Minimum
Wind Direction
Rainfall Data
Annual (mm)Recorded
Maximum
Average
Minimum

2.2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5

2.3.6
C

2.3.7
2.3.7.1

2.3.7.2
2.3.8
2.3.8.1

VALUE
Kinyerezi
Region

site

Dar Es Salaam

Plain Area

Tropical
757.25 mbar
1.00726 Bar
50 m

37C
26C
14C
75%
60%
50%

70 km/h

1100 mm/year

in

Dar-es

Salaam

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2.3.8.2

Maximum recorded in 24 hrs

(mm)
2.3.9
Design intensity for surface
water drainage (mm/hr)
2.3.10
Rainy
Season
(calendar
months)
2.3.11
HFL (Highest Flood Level)
Data for last 20 years and
maximum HFL recorded (m)
2.4
Soil Data
2.4.1
Seismic Design Criteria
2.4.2
Acceleration
2.4.3
Soil Bearing Capacity
2.4.4
Ground Water table level
2.5
Plant Design Life
2.5.1
Operating Hours
2.5.2
Type of Installation
2.6
Electrical Data
2.6.1
Export Voltage
2.6.2
Frequency
2.6.3
Power Factor
2.6.4
Combined
Variation
of
Voltage and Frequency
2.7
Fuel
2.7.1
Main Fuel
2.7.2
Back up fuel
2.8
Water
2.8.1
Source of Water
Note : All the unfilled Datas will be
site survey report

150 mm/hour
March - May

UBC Zone 2A

30 years
Outdoor
220kV & 132kV
50
0.85
+/-10%

Natural gas
Jet A1 Liquid Fuel
Bore well
updated after receipt of site details &

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3. EQUIPMENT NUMBERING SYSTEM

All the Equipment and any other auxiliaries for this Project shall be numbered
according to the KKS numbering system (in documents and on hardware). Refer
to document 40-0000294. All components/equipment shall be tagged as per KKS
tagging philosophy.
4. GENERAL SCOPE OF CONTRACT
The scope of supply of the vendor is intended to cover design, engineering,
manufacture, assembly, painting, inspection, testing at vendors and/or at your
sub-vendors works and transport/delivery of the module to international harbour
with all accessories, site installation supervision, commissioning supervision,
performance guarantee testing, operator training and training material and
handing over of items related to the module as defined in Scope of work,
Technical Specification or elsewhere in this specification.
It is not the intent to specify completely herein all details of design and
construction of the modules and / or structures / works covered under this
contract. However, all equipment and works shall conform in all respects to high
standards of design engineering, materials of construction, workmanship and be
capable of performing in continuous commercial operation.
Modules shall be designed for outdoor condition.
The extent of supply and works under this contract includes all items indicated
in the technical specification, notwithstanding the fact that such items may have
been omitted from the drawings or schedules. Similarly, the extent of supply also
includes all items mentioned in the drawings notwithstanding the fact that such
items may have been omitted in this specifications and / or schedules.
All necessary co-ordination with regard to sub-vendor equipment/system shall be
carried out by the vendor. The communication will be only with the vendor for all
matters pertaining to the Contract.
Bidder shall preferably develop the equipment model and model for structures,
and piping supplied by him in PDMS version.
The following scope will be applicable to the modules in addition to the scope
mentioned in module/skid technical specification:
4.1

Instrumentation shall covers field instruments, Analysers, Instrument

indicator Panel-cum-Junction box, Cabling & cable trays between field
instruments to Instrument indicator Panel cum and junction box, etc.,

4.2

All signals from the field instruments will be first terminated on a

automatic control systems panel and from panel to Junction box (JB). The
JB shall be supplied along with the skid by the vendor.

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4.3

The necessary root valves, Impulse piping, drains cocks, valve manifolds
and all other accessories shall be furnished. The contacts of instruments,
sensors, switches, etc. mounted on equipment shall be wired out in
flexible/rigid conduits independently to suitably located local junction
boxes. Cable entry to instruments and junction boxes shall be properly
sealed.

4.4

The following field Instruments like Pressure gauges, level gauges,

pressure transmitter, pressure switch, temperature elements, flow meters,
analyser, etc., are
minimum
requirement
for
skid, any other
instruments required for easy operation and specific design of the system
shall also be included.

4.5

All accessory equipment such as temperature detector, current

transformers, etc., shall be wired to and terminated in terminal boxes,
separate from and independent of motor (power) terminal box. This box
shall be complete with double compression brass glands and pressure type
terminals to suit Other's cable connections. The terminal box shall be
weather proof, with removable front cover and cable glands for cable
connection.

4.6

The automatic control systems, using PLC control shall be provided. PLC
based Control Panel including all safety interlocks, control tubing and
control equipment for safe operation of module. The control panel shall be
supplied complete with internal wiring and control air tubing as
applicable. A Microprocessor based Master Controller shall be prov ided to
facilitate operation and control of the system from the local control panel
with facility to 'Start / Stop' The microprocessor based Master Controller
will be interfaced with Plant DCS through communication link as well as
hardwiring as required.

4.7

The necessary root valves, Impulse piping, drains cocks, valve manifolds
and all other accessories shall be furnished. The contacts of instruments,
sensors, switches, etc. mounted on equipment shall be wired out in
flexible/rigid conduits independently to suitably located l ocal junction
boxes. Cable entry to instruments and junction boxes shall be properly
sealed.

4.8

All foundation bolts/ anchor bolts, insert plates, pipe sleeves, embedment,
etc required for skid / any equipment/ foundation/ concrete under the
package.

4.9

All cables including special cables, internal wiring shall be supplied within
the terminal point.

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4.10

All required items which ever necessary for the efficient operation shall be
supplied under this contract even though not specified in this technical
specification. A list and specification of these items shall be submitted.

4.11

Bidder shall offer commissioning supervision and necessary assistance

during commissioning of module

4.12

All system oriented items like PLC, Analyzer systems etc. shall undergo
factory testing and integrated factory acceptance test. No such items shall
leave manufacturer works without factory acceptance test. Testing shall be
carried out as per approved procedures.

4.13

Vendor shall make all modification and/or changes found necessary during
loop testing/pre-commissioning/ commissioning

5. GENERAL SPECIFICATION (COMMON FOR ALL MODULES)

5.1

All butterfly, gate, seat, ball and hand valves must be equipped with a
position indicator.

5.2

The valve supplier installation instructions must be observed.

5.3

Double valves must be installed when handling gas to ensure the safety
of the operating and maintenance staff when at work.

5.4

Ball valves must be made so that opening and closing due to vibrations
in the pipe system is prevented.

5.5

Flanged valves must be delivered with flanges drilled according to EN

standards.

5.6

Shut-off valves must be tight for one-sided pressure in both flow

directions.

5.7

Valves with threaded stem sealing must be equipped with a locking

device.

5.8

Pneumatic actuators and positioners : The actuator and positioner must

accept a feed of 4-7 bars. Each actuator must have an individual stop
valve for supply air. If the process requires that the valve moves to safe
position in the event of a fault, the actuator must be single -acting with
spring for opening and closing. In other cases the actu ator must be
double-acting. There must be a local position indicator. The motor-drive
mechanism must be designed so that operation can also be carried out
manually.

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5.9

All rolling bearings for pumps or machines above 10 kW shall be

fitted with SPM nipples for vibration monitoring.

5.10

As per BS EN 12639, Noise Level Guidelines as per EHS, 55 dBA at day

time (7:00 to 22:00) and 45 dBA at Night time (22:00 to 07 :00), for noise
monitoring program, monitors should be located at distance of 1.5 m
above ground and no closer than 3 m to any reflecting surface.

5.11

The panel shall be Outdoor mounted with IP 65 enclosure, free standing

vertical type local panels with 3 mm thick sheet material of cold rolled
steel; anti vibration pads of 15 mm thick; fluorescent light, necessary
incoming switches, selector switches, fuses, relays, timers, control
supply transformer, start-stop push buttons, meters annunciation
system with annunciation windows, hooter, push buttons for silence,
acknowledge, reset and test push buttons and shall have all the
interlocks built-in to the panel to ensure normal operation of the
system as specified in the specification. The components used shall be
of reputed make. All panels to be equipped with a emergency stop
button.

5.12

All field instruments & junction boxes shall be with minimum IP-65 or
equivalent and suitable for the local ambient weather conditions. All
transmitters shall be provided with Instrument isolating valve
manifolds. All pressure and differential pressure transmitters will be
indicating type smart transmitters. Local indicators are envisaged only
at places where remote transmitters are not envisaged. However
adequate test pockets / points will be provided. Tap point/instrument
isolation valves shall be of gate type and drain / ven t valves shall be
provided. Material and pressure rating of valves, impulse piping and
fittings shall be so selected to meet the design requirements. All
incoming and outgoing cables of the junction boxes shall be from the
bottom. No openings will be provided on the top of the junction boxes.
All cable connections shall be provided with glands.

5.13

Pressure gauges dial shall be white, non-rusting plastic with black

figures. Pointers shall have micrometer adjustment. Gauges shall be
weather proof with dial size of 150 mm and shall have features like
screwed bezels, externally adjustable zero, over range protection and
blow out discs. Sensing element shall be of SS-316 and movement of SS304 as a minimum. Pulsation damper shall be of SS-304, floating pin
type, externally mounted and externally adjustable. All connections
shall be 1/2 NPT (M) bottom entry. Cases shall be cast aluminum alloy
and weatherproof to IP-55. Pressure Gauges in Bulk acid storage tank
area shall be diaphragm sealed type.

5.14

Temperature elements shall be spring loaded and shall have stainless

steel sheath. Elements shall have weather proof screw heads & suitable

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cable entry connection. RTD shall be 3 wire platinum element type with
100 ohms resistance at 0 C calibrated as per IEC 751 / DIN 4 3760.
RTD shall have an accuracy of + 0.25% element sensors shall be duplex
with 2 separate cable entries.
5.15

All gate valve shall be of full-way type, when in the full open position,
the bore of the valve shall not be constricted by any part of the gate.
Valves performing similar duties and of same size, rating, material and
type shall be interchangeable with one another. All rising stem valves
shall be provided with back seat to permit repacking (of glands) with
valves in operation.

5.16

Indicators shall be suitable for accessing universal inputs (i.e. 4 to 20

mA, T/C & RTD). It shall have potential free contacts for alarm & other
interlock purposes and also shall have retransmission output. Indicator
shall be 3/2 digit indication with units. SS 316 tubing shall be used for
air tubing and for instrument sensor inlet & outlet tubing.

5.17

Analyser sensor shall be either insertion or flow through cell type.

Sensor shall be selected to suit the operating parameters. Integral cable
of the sensor shall be suitable for remote installation. Analyser
transmitter shall be 2-wire type with indication. Panel mounted
indicator shall also be provided.

5.18

After testing the equipment, all the surfaces and internals shall be
thoroughly cleaned, dried and conserved. All metallic surfaces except
bright parts exposed to whether shall be given a suitable oil resistant
protective coating and then two coats of approved paints (Anti acid
paint). The vendor shall give exact and precise details about the
measures envisaged for surface protection for purchasers Approval
along with this offer.

5.19

While Developing the Skid layout, vendor shall ensure the following
major layout Parameters:

Adequate space shall be provided for the handling/removal of

pumps, strainer, flow meter, etc.

All Valves, Instruments and parts that need maintenance shall be

located in accessible positions, If needed access platform with
handrails, ladder shall be provided.

Module supporting structure shall be designed for transit with any

temporary structures if needed.

Suitable drainage shall be provided to ensure that it should be

possible to drain the module completely.

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5.20

All other safety requirements in addition to EN standards as

required by the factories act and Tanzanian National Electricity
code/law shall be observed while developing the layout.

Suitable lifting legs shall be provided for safe loading & unloading

Equipment installed in indoors Container, wherever specified. The

container may be exposed to rain, high winds (including typhoons),
blowing sand, salt mist or spray and ambient temperatures of 50C .

All external piping connections to/from module shall be at module

border, i.e. close to module frame

All the piping within the Module boundary shall be of suitable EN

material. All equipment, piping, cables and tubing shall be supported
within the module. All nozzles shall be provided with end connections
(Flanges/screwed/welded as indicated in the specification) as per EN
standard.

6. PIPING BASIS & VELOCITY CRITERIA

S.NO

SERVICE

1.

General Service Fluid

(Non-Viscous Fluids)
Pump Suction

2.

General Service (NonViscous Fluids)

Pump Discharge
Viscous Fluid except
Hydrocarbon
Pump Suction
Viscous Fluid Pump
Discharge

PIPE SIZE
mm
<50
80 - <250
300-<450
>500
<250

VELOCITY
MAX. m/sec
0.6
1.0
1.2
1.5
2.4

>300

3.0

<50
80- <200
>250
<150
200- <300
>300

0.3
0.5
1.0
1.0
1.4
1.8
35
2
V (10000 kg/ms2)
35
V2 (10000 kg/ms2)
35
V2(14000 kg/ms2)
30
V2(14000 kg/ms2)
10
15
18

Gas Pressure <20bar

20 bar to 50 bar
50 bar to 80 bar
>80 bar

Compressed Air

<50
80- <150
>200

PRESSURE
DROP bar/100m

0.12

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S.NO

SERVICE

7
8

Nitrogen
Boiler
feed
Suction

Boiler Feed
Discharge

pump
Pump

PIPE SIZE
mm
50- <200
>250
<50
80- <150
>200

VELOCITY
MAX. m/sec
20
0.9

PRESSURE
DROP bar/100m

1.2
1.2
2.1
2.5

7. GENERAL CODES & STANDARDS COMMON FOR ALL DISCIPLINES

Except where otherwise specified, all items under vendors scope shall comply with
the appropriate EN Codes & Standards or agreed internationally accepted codes &
standards as listed in the Technical Specifications.
The list of standards below show examples of standards, this is not an exhaustive
list, i.e. the requirement is not limited to these:
Pressure equipment directive (PED) PED 97/23/EC. Engineering, calculation
and manufacturing
The European directive 89/391/EEG (Working environment directive)
ATEX 95 equipment directive 94/9/EC, Equipment and protective systems
intended for use in potentially explosive atmospheres
EN 12100 Safety of machinery. General principles for design.
EN 13480 Requirements for design, manufacture, installation, testing and
inspection of industrial piping systems
SFS-EN ISO 4126-1 Safety devices for protection against excessive pressure
EN 764 and specially (764-7 Pressure equipment. Part 7: Safety systems for
unfired pressure equipment)
EN 1591 Flanges and their joints. Design rules for gasketed circular flange
connections
EN 60079 Explosive atmospheres. Part 0: Equipment. General requirements
and specially (60079-10 Explosive atmospheres. Part 10-1: Classification of
areas. Explosive gas atmospheres)
EN 12186 Gas supply systems. Gas pressure regulating stations for
transmission and distribution. Functional requirements
EN 1594 Gas supply systems. Pipelines for maximum operating pressure over
16 bar. Functional requirements
EN 13942 Petroleum and natural gas industries. Pipeline transportation
systems. Pipeline valves.
EN 14161 Petroleum and natural gas industries. Pipeline transportation
systems
EN 17292 Metal ball valves for petroleum, petrochemical and allied industries
EN 1349 Industrial process control valves

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ISO 11933-4:2001 Components for containment enclosures Part 4: Ventilation

and gas-cleaning systems such as filters, traps, safety and regulation valves,
control and protection devices
EN ISO 13709 Centrifugal pumps for petroleum, petrochemical and natural
gas industries
EN 12327 Gas supply systems. Pressure testing, commissioning and
decommissioning procedures.

Electrical Codes and standards

IEC 60079 Electrical Installation in Hazardous area

IEC 60529 Degree of Protection provided by Enclosures
IEC 61459 Coordination between fuses & contactors/motor starters
Application Guide.
IEC 61800 Adjustable Speed Electrical Power Drive System
IEC 60287 Calculation of permissible current in cables at steady state
rating
IEC 60027 Letter Symbols to be used in electrical technology
IEC 60502 Power Cables with extruded insulation and their accessories for
rated voltage from 1kV to 30kV

I&C Codes and Standards:

A. International Electrotechnical Commission (IEC)

IEC 60529 Degree of Ingress Protection of Enclosures.

IEC 60079 Installation of Electrical Apparatus in Hazardous Area.
IEC 617
Graphic Symbols for Electronic Diagrams.
IEC 61000-4 Electromagnetic Compatibility (EMC) Part 4: Testing
Measurement Techniques.

and

B. International Society of Automation (ISA)

ISA-S5.1
Instrumentation, Symbols and Identification.
ISA-S5.2
Binary Logic Diagrams for Process Operations.
ISA-S5.3
Graphic Symbols for Distributed Control/Shared Display
Instrumentation, Logic and Computer Symbols.
ISA-S5.4
Instrument Loop Diagrams.
ISA-S5.5
Graphic Symbols for Process Displays.
ISA-S50.1
Compatibility of Analogue Signals for Electronic Industrial
Process Instruments.
ISA-S5 1.1 Process Instrumentation Terminology.
ISA-RP55.1 Hardware Testing of Digital Process Computers.
ISA-RP60.1 Control Center.
ISA-RP60.3 Human Engineering for Control Centers.
ISA-RP60.4 Documentation for Control Centers.

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ISA-RP60.6 Nameplates, Labels and Tags for Control Centers.

ISA-RP60.8 Electrical Guide for Control Centers.
ISA-RP60.11 Crating, Shipping, and Handling for Control Centers.
ISA-S71.01 Environmental Conditions for Process Measurement and
Systems: Temperature and Humidity.
ISA-S71.04 Environmental Conditions for Process Measurement and
Systems: Airborne Contaminants.
ISA S82.03 Safety Standard for Electrical and Electronic
Measurement and Control Equipment.
ISA S84.01 Application of Safety Instrumented Systems for the
Industries.

Control
Control
Process
Process

Where the vendor proposes alternative codes or standards he shall include in his bid
one copy (in English) of each standards to which materials offered shall comply. In
such case, the adopted alternative standard shall be equivalent to or superior to the
standards mentioned in the specification.
The Plant shall conform to various statutory local regulations, Whenever required,
approval from statutory authorities for the equipments supplied under the
specification shall be responsibility of the vendor.
In the event of any conflict between the codes and standards referred, the
requirements that are more stringent shall govern.
In case of any change of code, standards and regulations between the date of award
of contract and the date the vendor proceeds with manufacturing, the customer shall
have the option to incorporate the changed requirement. It shall be the
responsibility of the vendor to advice customer of the resulting effect.

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8. GENERAL ELECTRICAL REQUIREMENTS

8.1

Motor shall be suitably designed for rated frequency and variat ion
given elsewhere in this specification. Motor shall comply to latest
edition of relevant EN codes and standards. Local Push Button Station
(for motors)(Flame proof) shall be provided within the skid. The
specification given in the table below shall be followed.
S.NO
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

PARTICULARS
Type of Motor
Voltage
Phase
Frequency
Cooling Method
Flame proof
Degree of Protection
Insulation
Starting Method
Mounting
Duty
Terminal Box

DESIGN VALUES
Squirrel Cage Induction Motor
400 V10%
Three
50Hz 5%
TEFC
Yes
TEFC-IP-55 (indoor)/IP 65 (outdoor)
F class
DOL
Horizontal
Continuous
Heavy duty

8.2

Generally motor ratings shall be at least 10% above the maximum load
demand of the driven equipment under entire operating range including
voltage and frequency variations. Motor rating shall be selected for
higher value of Density specified.

8.3

Terminal boxes shall be of weatherproof construction designed for

outdoor service, to eliminate entry of dust and water. Gaskets of
neoprene or approved equivalent shall be provided at cover joints and
between box and motor frame. The terminal box shall be suitable for
bottom entry of cables. The terminals shall be of the stud type with
necessary plain washers, spring washers and check -nuts. They shall be
substantially designed for the current carrying capacity and shall
ensure ample phase to phase and phase to ground cl earances.

8.4

Module Vendor to provide Earthing provision at two points on the base

frame for connection with Purchasers earth mat. Any Earthing cable
needed to connect the all equipment within the module to be points in
base frame shall be considered in vendors scope.

8.5

For hazardous area correct Eex class of equipments shall be provided

according to what the specific zone class require per the standard .

8.6

Motors are provided with extension terminal box to receive the

cables to avoid cramping of the cable in the terminal box. Vendor shall
complete the electrical wiring on the skids and complete the necessary

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interconnections among the controls, instrumentation and to the

terminal boxes. Instrument wiring shall no the run through conduit
with power wiring. Terminal boxes and conduit shall be dust -tight,
weather-tight, and corrosion resistant.
8.7

All accessory equipment such as temperature detect or, current

transformers, etc., shall be wired to and terminated in terminal boxes,
separate from and independent of motor (power) terminal box. This box
shall be complete with double compression brass glands and pressure
type terminals to suit Other's cable connections. The terminal box
shall be weather proof, with removable front cover and cable glands for
cable connection.

8.8

LT power cables will be 1100V grade

stranded copper conductor, PVC/XLPE
sheathed, armoured/unarmoured and
shall comply with relevant parts of IEC

8.9

Control cables shall be armoured/unaurmoured multi core copper

conductors, PVC/XLPE insulated according to IEC 60502 standard. If
protective conductors are included in cable it is a conductor with green yellow insulation or the conductor with the highest number.

8.10

Instrumentation cables shall be armoured/unaurmoured single or multi

pair copper cables PVC/XLPE insulated according to EN50288-7
standard.

9. I&C SPECIFICATIONS AND REQUIREMENTS

9.1
I&C
BOP
PLC
LCP
CCR
DCS
I/O
UPS
GPS
IP
IJB

single core or multi core with

insulated, extruded PVC inner
overall PVC sheathed. Cables
60502.

Abbreviations:
Instrumentation & Control System
Balance Of Plant
Programmable Logic Controller
Local Control Panel
Central Control Room
Distributed Control System
Input / Output
Uninterruptible Power Supply
Global Positioning System
Ingress Protection
Instrument Junction Boxe

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9.2

40-0000520
10 Sep 2013
17(29)

Control Philosophy:

Control Philosophy adopted for this Project is that each Package Unit in BOP shall
be controlled by its own standalone Control System PLC supplied by Package
Vendor. PLC shall be installed in LCP located on Package Skid, completely pre wired, integrated with Package Instrumentation, functionally tested with Package
Equipments and supplied by Package Vendor with Package Skid Module. Critical
Signals (Remote Start/Stop, ESD etc..) shall be hard wired to DCS located in CCR.
Less Critical Monitoring Signals shall be transferred to DCS via Modbus TCP/IP
Communication Protocol on Redundant Serial Communication Link.
For DCS interfacing, Package Vendor shall provide dedicated Inst. Junction Box on
Skid for hard wired signals. It shall be pre-wired/connected with LCP at one end for
respective signals. At other end it shall be connected to multi-pair Instrument Cable
coming from DCS Marshalling Cabinet located in CCR.
Any deviations shall be highlighted at bidding stage only, if PLC is not considered
then Package Vendor shall suggest their Proprietary Control System complying the
DCS interfacing requirements. Package Vendor shall submit details about their
Proprietary Control System for approval of the Client.
9.3

Enclosures:

All the field-mounted Instruments shall have degree of protection IP - 65 minimum

as per IEC 60529. Instruments falling under Hazardous Area classification shall be
provided with explosion proof Ex-d housing as per IEC 60079 and certificates shall
be provided for all explosion proof housing.
9.4

Transmitters:

All Temperature, Flow, Pressure and Differential Pressure Transmitters shall be

SMART electronic indicating type, 2-wire signal transmission with 24 VDC power
supply and output signal 4-20 mA with HART protocol.
9.5

Switches

All Process Switches shall have Double Pole Double-Throw (DPDT) micro Switches.
All switches shall be rated for 10 A current rating. All Switches used for interlocking
and/or Protection System shall be blind type.
9.6

Pressure Instruments:

Pressure Gauges shall be of Bourdon Tube type with SS sensing element &
movement and 150mm white dial with black scale marking. Local Gauge board
(panel) Instruments shall have 100 mm dial size.

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Differential Pressure Gauges / Switches shall be bellows or diaphragm type with SS

sensing element.
Pressure / Differential Pressure Transmitters shall have CS/SS body and SS 316
sensor/wetted parts. All Differential Pressure Transmitters shall be provided with
five way valve manifolds.
All Pressure Instruments shall have process connection of 1/2 NPT.
9.7

Temperature Instruments:

Temperature Gauges shall be mercury in steel type with SS 316 Thermo Well. Local
Gauge board (panel) mounting Instruments shall have 100 mm dial size and others
150mm dial size.
Temperature Switches shall be filled system type with SS 316 Thermo Well. All
switches shall be blind.
Temperature Elements shall be Pt 100, 3 wires RTD duplex type for Temperatures
up to 600 C. For Temperatures beyond 600C duplex Thermocouples shall be used.
All test Thermo Wells shall be of SS 316.
All Thermo Wells shall be of bar stock with tapered construction. Thermo Wells
connection shall be 1.5 Raised Flanged type.
Temperature Transmitters shall have CS/SS body.
9.8

Level Instruments:

Level Gauges shall be Transparent / Reflex type with 1 isolation valve and offset
ball check connection.
Level Switches shall be of external cage type, float operated, and with 1 connection
size.
Level Transmitters shall be of Differential Pressure type. However, due
consideration shall be given to Ultrasonic Level Transmitter and Radar L evel
Transmitter as per process requirement and same shall be provided by contractor if
required.
9.9

Flow Instruments:

Flow Elements shall be of Orifice Plate / Flow Nozzle type as per ISO 5167 / BS:
1042. Flow Elements shall be made of SS 316. Manufacturer tolerances and isolation
details for Orifice Plates and Flow Nozzles should comply with ISO standards.
Orifice Plate shall be marked/ stamped with basic design information like Tag No.,

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Flow rate, Flow direction, Pressure and Temperature of the process flu id, Orifice
diameter, and Differential Pressure.
Flow Transmitter shall be generally of Differential Pressure type with local
indicator.
9.10

Indicators:

Local Control Panel Indicators shall be properly grouped with the respective section
or subsection of the Control Panel related to the system that they are indicating.
The Indicators shall be installed on the vertical plane of the Control Panel
preferably at eye level and the associated Hand Switches, Pushbuttons or
Controllers sufficiently close by so that the operator can easily operate the
controlling devices manually while maintaining visual contact with the Indicators.
Vertical scale edgewise indicators shall be used for indication of process variables.
Round type indicators shall be used for indication of electrical variables (MW,
MVAR, Voltage, Current etc.) having a scale length not less than 250 deg of arc.
Accuracy shall be not less than 1% of full scale.
Back lighted, coloured indicating lights shall be provided for all equipment
controlled from the Local Control Panels.
9.11

Control Valves & ON/OFF Valves:

Control Valves shall be electric motor or pneumatic diaphragm actuated type with
electro-pneumatic Positioners, Air Filter Regulators and Position Transmitters.
Control Valves shall be generally of Globe type, Cage guided. Valve characteristics
shall be equal percentage / linear as per system requirement.
ON/OFF Valves shall be Ball / Butterfly type with SS Solenoid Valves and Limit
Switches.
All ON/OFF Valves and Prime Mover Breakers shall be pr ovided with Switches
and/or Relays to indicate status remotely. Valve and Breaker status indication logic
shall be as follows:-

Valve fully closed or Breaker open

- Green Light On
- Red Light Off

Valve fully open or Breaker closed

- Green Light Off

- Red Light On

Valve in mid-travel

- Green Light Flashing

- Red Light Flashing

Abnormal circuit condition

- Amber Light On

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9.12

Instrument Junction Boxes (IJB):

IJBs shall be provided in the field to run Multi-Pair Cables. It shall be made of LM6
material.
It shall be weather proofed to IP 65 minimum. Explosion Proof (Ex-d) IJBs shall be
provided in Hazardous Area. It shall have bottom entry and bottom exit.
Separate IJBs shall be provided for Analogue, Digital, Power, RTD, Thermocouple
Cables.
9.13

Local Control Panel (LCP):

LCP shall be supplied by Package Vendor installed on Skid, completely pre -wired,
integrated with Package Instrumentation, functionally tested with Package
Equipments and supplied with Package Skid Module.
Panel shall be procured pre-fabricated from 3 mm thick cold rolled Steel sheet. Panel
shall be of standard make like Rittal or Package Vendors St andard subject to
approval of the Client.
Panel shall normally be of the totally enclosed cubicle type, Free -Standing floor
mounted or skid mounted, Vertical type and weather proofed to IP 54 minimum for
Outdoor installations. It shall comply with the area classification requirements.
Components inside the Panel shall be mounted on C-Rail. Cable entries/exits shall
be from bottom of the Panel via Metallic Cable Glands. Terminals shall be used for
incoming and outgoing Cables, it is not allowed to conne ct Cable directly on
Components. All Cables shall be marked according to Projects numbering system
(KKS System). All internal wires in the panel shall be marked.
Signs/Nameplates/Tag Nos. provided on the Panel Door and inside the Panel shall be
made of Laminated Plastic, industrially approved types. Language shall be English
for the same.
Colour of Indication Lamps on Panel Door shall be as given below:
-

RED

For ON / Activated

GREEN

For OFF / Deactivated

Outdoor Panels in the field shall be provided with Panel AC. Panel Heater shall be
provided for moisture control. CFL wired with Door Switch for auto ON/OFF with
Door Open/Close shall be provided. Maintenance Receptacle and Drawing Pockets
shall be Provided in the Panel as per the standard / good Engineering Practices.

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40-0000520
10 Sep 2013
21(29)

Programmable Logic Controller (PLC):

Wherever possible, Package Units shall be controlled by PLC. PLC type and
manufacturer shall be subject to approval by Client to ensure that all equipment is
standardised across the Project.
PLC shall be configured to provide the Control and Safety functions for the Package
operation.
The following minimum requirements shall be applied to PLC:
The Processor, Communication to IO racks and the Pow er Supplies must be Hot
Redundant.
Shall have Redundant cross-link Communication with the DCS. Communication
Protocol shall be Modbus ICP/TP.
Shall be Time synchronised with the DCS. GPS based time signal shall be provided
by Client on DCS. It shall be Package Vendors responsibility to synchronise PLC
clock with DCS clock.
CPUs shall be Hot Redundant with simplex I/O modules used for Control
applications. PLC systems shall be of modular design.
Package Vendor shall specify the expansion capabilities of their PLC Systems. PLC
Systems shall allow on line modifications and card replacement.
Transmitter Inputs shall generally be of the 4-20 mA, HART type. Hand held
configurators shall be provided for these devices to assist in factory testing and site
installation.
For each Package Control System, self diagnostic alarms shall be made available in
Central Control Room for hardware failure and maintenance / troubleshooting.
There shall be a provision within the PLC to be connected to a plant wide network
with similar PLC. This network connection shall be separate from that used for DCS
connectivity. The PLC network shall be non-redundant.
Each PLC shall be provided with a programming devise such as a laptop, with
necessary licensed software and HMI display as per the Package requirement.
9.15

Instrument Installation & Erection Hardware:

All Pressure Instruments shall be provided with root isolation, Instrument isolation
and drain / vent valves with caps (2 way manifold).

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All Differential Pressure Instruments shall be provided with root isolation,

Instrument isolation and individual leg drain / vent valves with caps (5 way
manifold).
Level Instruments shall have tank isolation valve, drain and vent valves.
Control Valves shall have inlet / outlet isolation valve, bypass valve and upstream /
downstream drain valves.
All Instruments shall be installed as per the standard / good Engineering Practice.
Wherever Instruments are mounted outside the door, canopies shall be provided.
Instrument implse tubing & fitting shall be done as per the standard / good
Engineering Practice. All impulse tubes / fitting shall be made of SS316 material
and 1/2 size. All fittings shall be minimum of 3000# rating.
Instrument Air tubing & fitting shall be done as per the standard / good Engineering
Practice. All pneumatic tubes shall be made of PVC coated Copper material, fittings
made of Brass material. Pneumatic tubes & fittings shall be of 1/4 size. All internal
tubing of Control Valve shall be of SS.
Separate dedicated Trays shall be provided for Control Signal Cables and Power
Cables. All Cables shall be tied and identified with Tags. Each core / pair of Cable
shall be identified with cross and direct ferrules. All Cable Glands shall be of metal
and Double Compression type.
10. HAZOP
The European directive 89/391/EEG (Working environment directive) determines a
joint approach to safety from EU. At the same time the approach to safety is
harmonized in all product directives (Low voltage directive, machinery directive,
PED directive, ATEX directive etc.)
The purpose of this is that, regardless of supplier, the products, installations,
machines etc. must have equivalent safety requirements.
Vendor must comply to the EN safety requirements.
Purchaser will perform a HAZOP study (hazard and operability study, IEC 61882) to
verify
the
fulfilment
of
the
EN
requirements
for
safety.
Possible
changes/amendments to the design or assembly is to be carried out by the vendor.
The costs are born by the vendor.
11. TIME SCHEDULE
Vendor needs to submit project time schedule along with their offers. Vendor shall
submit a Detailed Master Time Schedule (Level 1 schedule), which shall be approved
by the purchaser. This Level 1 Schedule shall be prepared on a Work Breakdown

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Structure and shall identify milestones of key events, and activities of each modules
in the areas of engineering, procurement, manufacture, despatch, and all other
Project Interfaces.
12. DEVIATIONS
Bidder to furnish the list of deviations. Unless otherwise deviation list submitted it
is understood that Bidder is fully in compliance with the Technical Specification.
13. SPARES, MAIN TOOLS & TACKLES, CONSUMABLES LIST

Mandatory and recommended spare parts and wear parts required for five
years trouble free operation shall be supplied. List of spares shall be
submitted for purchasers Approval along with this offer. In addition, vendor
shall also furnish the list of recommended spares for two and five year
operation.

One set of special tools & tackles required for erection, operation and
maintenance of equipment sets specified in maintenance manual shall be
supplied under this contract. The vendor shall include all nece ssary
maintenance tools required for maintenance of the modules in addition to
other special tools and tackles as required. The tools included by the vendor
shall cover all minimum maintenance tools considered necessary by the
vendor. List of spares shall be submitted for purchasers Approval along
with this offer.

Consumables (if any) required for start up, commissioning and one year
operation from taking over shall be supplied under this contract including
Initial fill of Lubricant / oil for anti-friction bearing / others. List of
consumables shall be submitted for purchasers Approval along with this
offer.

The Vendor shall note that if any other tools are found to be necessary
during the engineering and erection stage of the project, the same shall be
supplied by the Vendor with-out any commercial implication.

14. PACKAGING
Packing has to protect the equipment against all kinds of damages (moisture,
rain, rust, corrosion, shocks, rough treatment, sand etc.) during transportation
by different means of transport as truck, railway, ship (corresponding heights of
stacking in the various types of ocean vessels as well as big stress during sea transport have to be taken in consideration).

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Furthermore, several transhipments and handlings by crane, fork lift, hand

barrow, lift truck, car truck and periods of intermediate storages an d storage on
site have to be considered.
Weather proof, sea worthy package withstanding preservation as a packaged item
at storage yard (outdoor) for a period of 12 months is required.
15. MECHANICAL STRUCTURES & PIPING
14.1

DESIGN DATA
Design shall be as per Euro Code 3

14.2

STRUCTURAL STEEL PROFILE

Structural steel profile shall comply with EN 10025.
All steel shall be new and supported by mill certification.
Generally profiles shall be HEA, IPE having grade S355J2,
Angle, railing profile having grade S235JR.

14.3

MATERIAL SPECIFICATION
Structural steel material shall comply with EN 10025
Use S355J2 grade for all except angle profile and railing profile.

14.4

STRUCTURAL BOLTING
Bolts, nuts and washers shall be grade 8.8 comply with
requirements of bolts as per EN ISO4014, nuts as per EN
ISO4032 & washers as per EN ISO7091.
Bolts, nuts and washers shall be hot dip galvanized.

14.5

WELDING
Welding used in fabrication work shall be the metallic arc
process, in accordance with EN 5817
Welding symbols shall be as per EN ISO 22553
Inspection and testing shall be as per EN970, EN ISO 5817, EN
1712 & 1714

14.6

STEP AND GRATING

Stair treads and grating shall be Weland type.
Steps and grating shall be hot dip galvanized.

14.7

GALVANIZING & PAINTING OF STRUCTURAL STEEL

All structural steel shall be painted in workshop as
transportation protection and on site as surface treatment :
Blasting: FeSa 2.5 7 mic
Painting: The surface treatment will end up with A5M.06 acc.
to ISO 12944-5:2008-1.
Brand: International Protective Coating.
Interzinc 52 / 1 x 70-100 mic (tie coat may be needed)

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Intergard 475HS / 1 x 70 mic

Intergard 475HS / 1 x 110 mic (70mic shop, 110 mic site
painting)
Interthane 990 / 1 x 70 mic (site)
Tot DFT: 320 mic.
For intermediate shop paint layer grey color is sufficient,
different RAL for intermediate and final layer at site.

14.8

ROOF SHEET & FIXING

Roof sheet steel material according to EN 10142
Use load bearing sheets having size RAN120
Sheeting shall be fixed with galvanized self drilling Screw SL2 H15-6.3*20 & hilti bolts ENP - 19 L15 MX

14.9

FABRICATION
Steel structure shall be fabricated in accordance with good
working practice.
For pipe rack all intermediate beams and bracings which are in
between trusses should be cut in proper size and weld at site.
Manufacturing tolerance according to EN 1090-2
Manufacturing certificate will be issued by the vendor and
submitted to JEL.

14.10 DELIVERING AND SITE CONDITION

Transportation size of container length ?m, width ?m and height
?m
To transport all assemblies in container in such way that those
will not get damage.
Delivery of all assemblies at site address which will be given by
Siemens
Again inspection of all assemblies will carry at site, if there is
any damage cost of damage goes to the responsible vendor
decided by Siemens
14.11 PIPING SYSTEMS
NDT; Non Destructive Testing:
Radio graphic examination
Ultrasonic examination
Magnetic particle examination
Liquid penetrant examination
Visual examination
Pneumatic/hydraulic testing acc to PED directive
Pipes:
Fuel gas pipes, design, construction, installation/welding and
testing shall be in accordance with ANSI B31.3 (NB! 100% X -ray)
Fuel oil pipes, design, construction, installation/welding and
testing shall be in accordance with ANSI B31.3

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Piping systems, design, construction, installation/welding and

testing shall be in accordance with ANSI or ISO standards
Welding preparation form shall be according to EN 13480-4
All pressure retaining parts shall be pressure tested according to
EN 13480 and local regulations
Welds not possible to pressure test shall be x-rayed in 10%
V-joint welds 1,2 x wall thickness

Secondary support steel:

Coating/paint on pipe rack steel needs to be grinded off bef ore
welding secondary support steel to it
a=4mm filled weld, unless otherwise specified
measurements to be checked at prefabrication and on
construction site
Painting and protection:
All surfaces to be protected shall be coated in accordance with the
requirements of ISO12944:1988 and preparation grade for
surfaces shall be a minimum of Sa 2
All exterior surfaces, including buried and aboveground pipe
work, shall be of high durability and appropriate to C5-I or C5-M

14.12 DESIGN VALUES FOR PIPING SYSTEMS

Flow media

Max
allowed
pressure
= Design P
[bar(g)]
-1/86

Max allowed
temperature
= Design T

Material

[ C]
150

CS

Fuel
Gas
after
pressure reduction

65

150

CS

Fuel Gas
after GE
BoP filter
Gas venting lines

65

150

SS

5
14

150
75
75
75

SS
CS
CS
SS

15

50

SS

10

100

CS

15

50

SS

Fuel Gas pressure

before reduction

Fuel Oil unloading

Fuel Oil forwarding
Fuel Oil forwarding,
after filtering
Fresh water
Water
drains,
drains, Effluents
Compressed air
Fire water

Oil

14
14

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Flow media

14.13

Max allowed
temperature
= Design T

Material

Hot water & steam

Max
allowed
pressure
= Design P
[bar(g)]
15

[ C]
250

CS

Nitrogen
Deminerized water
Potable water

15
15
15

50
50
50

SS
SS
SS

COLOUR PROGRAM
See document: 40-0000693 Colour Program

16. DOCUMENTATION
Required documentation from vendor is presented in Attachment Requirements
for Documentation.
17. QUALITY ASSURANCE
17.1. Quality Assurance Plan (QAP). The vendor shall prepare within four weeks
of the signing of a contract the QAP which relates his own work and in
which defines the quality control and quality assurance operation at the
fabrication and site construction. QAP must be approved by the Contractor
of authorized representative before starting the work. QAP shall contain at
least the following items:
responsibilities
quality control, inspection and testing plan
site inspections and controls
commissioning tests
documentation and non-conformity plan
Special attention and guarantees should be given for following matters:
The vendor guarantees that only suitable and approved materials are
used and that the used materials are free from defects.
The vendor guarantees that engineering and construction is performed
in such a way that proper functioning of the scope of supply and
services is ensured for a period of three years.
The vendor guarantees that the specified scope of supply fulfils the
criteria of the availability of 8300 h/year.
The vendor guarantees of painted surfaces and hot-dip galvanized
surfaces corrosion protection of minimum 5 years.
The vendor guarantees that the specified technical consumption data for
utilities will not be exceeded during 24h of operation for the scope of
supply. Utilities are power consumption, compressed air, tap and
process water.

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17.2. Acceptance tests, testing & inspections. The whole of the modules and
their assemblies covered by this project shall be inspected and tested by
the purchaser, should he so require, during manufacture, erection and
after completion. The costs of all tests and inspection , excluding the costs
of the Company, shall be borne by the Vendor.
Where no test or inspection standard is specified, the various items of
modules, their equipments and materials shall be tested in accordance
with the relevant EN standards.
Where necessary, the whole module and its components shall be
additionally inspected, tested, marked and certified to the requirements of
the Local Authorities and other relevant statutory authorities.
All
materials used for the construction shall be of tested quality. Materials
shall be tested as per relevant standards and Test certificates are to be
furnished. In case Mill Certificates are not available, vendor shall carry
out physical and chemical tests from Govt. approved Testing Agency at his
own expenses
The purchaser may appoint inspectors of third party to perform the test
and inspection on behalf of him. The tests and inspections shall cover all
aspects of the manufacturing process, including casting, welding, assembly
and their quality assurance.
A notice of the preparation of modules and their components and materials
for test or inspection shall be provided by the Vendor and sub-vendor
thirty (30) days prior to test or inspection as a minimum, to enable the
purchaser to carry out the inspection and witness the test.
No components shall be packed, prepared for shipment, or dismantled for
the purpose of packing for shipment, unless it has been inspected and
approved (or inspection has been waived) and written instructions have
been received from the purchaser. Prior to inspection and testing, their
components and materials shall be cleaned and protected.
The following activities will be included under the inspection and testing
for all modules & their components if applicable:

Inspection and Testing Plan

Non-conformance Report
Quality Supervision
Routine tests not limited to the following shall form part of acceptance
testing:
1. General visual checks, name plate details, mounting location and
cable gland sizes.
2. Measurement of shaft center height dimensions.
3. Measurement of clearances in the Terminal Box.

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4.
5.
6.
7.
8.

Verification of direction of rotation.

Measurement of winding resistance.
Insulation resistance test (before and after high voltage test).
High voltage test.
No load test and measurement of voltage, current, speed and power
input.
9. Locked rotor test at reduced voltage and measurement of voltage,
current and power input.
10. Reduced voltage starting and running.
11. Balance and Vibration Tests

Checking Measuring and Testing Apparatus (Calibration, etc)

Sub-contracting
Inspection and Test at Manufacturers Works
Material Tests
Test Reports and Quality Certificates
Tests at Works of Mechanical Plants and Materials
Welding Standards and Non-destructive Testing of Welds
Hydro
test
shall
be
conducted
under
witness
of
Purchasers/clients personnel
Storage Tanks
PLC/local control system/operation panel FAT test
Tests on Instrumentation and Control Equipment
Painting, Cleaning and Protection
Valves and equipment for which fire safe test has to be carried
out by the vendor and certificate shall be furnished.
Vendor shall compile all the tests & inspection reports relevant to
purchase order, scope of supply. Following reports must be included:
1. Material certificates (chemical analysis, tensile test & impact test)
2. Results of non destructive testing/inspection
3. Results of hydrostatic test
4. Results of dynamic balancing
5. Records of performance test
6. Records of NPSH test
7. Records of dimensions
8. Other tests conducted by vendor as per specification
9. Guarantee certificates
10. Pump Tests