Professional Documents
Culture Documents
Document No.
Copy No.
: DRDL/DOAD/ATF/HWT/55
:
TENDER DOCUMENT
FOR
HIGH PRESSURE SYSTEM
OF
HYPERSONIC WIND TUNNEL
CONTENTS
1. INTRODUCTION
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4
4
5
5
6
5. SCOPE OF CONTRACT
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11
17
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8. STANDARDS FOLLOWED
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9. LIST OF DELIVERABLES
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1. INTRODUCTION
A high pressure pneumatic system to supply compressed dry air for hypersonic wind
tunnel is proposed. The system shall consist of air compressor trains to compress
atmospheric air to 30 MPa(g) pressure with dryer and storage volume of capacity
approximately 80 m3. The system shall be capable of supplying air at maximum mass
flow rate of 180 kg/s. The scope of the contract includes design, engineering of the
system, procurement of various standard components/sub systems, and fabrication of
pipeline etc., erection at site Shamirpet, Hyderabad, and demonstration of the
performance, training and handing over for normal operation.
Booster Compressor
Highpressure air storage vessels with associated piping, manifold and skid
frame work and interconnecting piping between compressors and storage
vessels
Electrical system
Fluid circuits
Lubrication system
The proposal is requested for establishing on a turnkey basis the entire High pressure
system comprising of the sub-systems mentioned above.
The preliminary Process and Instrumentation Diagrams (P&IDs), along with the
preliminary sizes of the fluid circuits and an indicative layout of the facility are given in
this document. The details of Contractors scope of work shall include the following.
2
Detailed design of all the subsystems and components of the High Pressure
System (HPS).
Erection, testing and co-ordination for inspection of the entire system at the
Departments site.
Commissioning
Some of the key words used in this document are defined as follows.
Department shall mean and include the President of India acting through the
Director, DRDL and any representative (s) of the Department duly authorized on his
behalf.
Contract shall mean the formal agreement to be executed between the President
of India and the bidder, whom the Department may choose, based on the
documents forming this tender enquiry and acceptance thereof by the bidder and
together with the documents as referred to therein including the specifications,
designs, drawings and instructions issued from time to time by the Department.
Site shall mean the land and or other places at Hyderabad on which work is to be
executed under the contract, which may be allotted by the Department for the
purpose of carrying out the work.
Materials shall mean all the items required for realizing and forming part of the
HPS, including raw materials, semi-finished & finished products and subassemblies,
which are manufactured by the Contractor or their sub-Contractors or brought-out
3
from their sub-vendors, such as equipments, flow components, pipes, pipe fittings,
instruments, etc.
All the pressure values specified in this document are in absolute scale, unless
specified otherwise.
The tunnel is of intermittent type and uses air as working fluid. The facility would be
used to carry out aero thermal studies of model at different flow conditions. A block
diagram of the facility is given in Fig 1. The major systems that constitute the facility
are:
Vacuum System(VS)
The High pressure system comprises of air compressor system, high-pressure air
storage, valves, piping and will be used to compress air to required storage pressure
and store to air storage. The pressure regulating system will be used for pressure
reduction from high pressure storage to required test pressure in settling chamber. The
heater is used to heat the air to the required temperature. Without heating, the air
expanding in the tunnel nozzle to high velocity will be cooled to such low temperatures,
which results in air to liquefy. Storage heater is proposed. The heater bed is heated by
combustion products from a burner.
2.2.
The Typical sequence of operations for one blow-down is as follows: Atmospheric air is
compressed, dried, recompressed and charged into the high-pressure air storage
vessels. Simultaneously the cored bed heater is heated-up with combustion products
from a burner and the vacuum spheres are evacuated by the vacuum pumps. When the
required initial storage pressure is reached in the pressure vessels, the pressure
regulating unit is set for the required test pressure in settling chamber. When all the
systems are ready, the blow-down starts. Air is supplied from the pressure vessels at a
pressure regulated by the pressure regulating system and is heated as it flows through
the heater. When the pressure in the heater reaches a specified value, a valve
downstream of heater is opened and hot air passes through the settling chamber. The
high-pressure, high-temperature air then expands through a nozzle to give the required
controlled environment in the test section. The model to be characterized is injected into
the test section. The air flows around the model in the test section. After the test section
air is decelerated in a diffuser and passes through after cooler and collected into the
vacuum spheres. When the pressure in the vacuum spheres reach a specified level the
blow-down is stopped. The cycle of operations is repeated. The duration of blow-down
is 20 seconds. Four tests are planned per day.
4.1.
The compressor system is intended to fill the high-pressure air storage vessels with dry
air to maximum pressure of 30 MPa (g). The compressor system comprises the
following:
All interconnecting piping, valves, coolers, safety devices, buffer vessels etc.
Cooling water system containing cooling water pumps, cooling towers with
associated valves and piping.
4.2.
The P & ID of a module of air storage system is shown in Fig. 5. This air storage system
stores air at 30 MPa(g) before it is supplied for the downstream operations. The
configuration of the storage system is as follows:
Thirty six pressure vessels of capacity of 2.2m3 water volume each and
maximum operating pressure of 30 MPa (g) constitute the storage system. The
vessels are grouped into six modules and each module consisting of six vessels
is mounted in a structural skid with support for the vessels. The filling ends of the
vessels are connected by piping to a common filling header. The delivery ends of
the vessels are provided with flange and are connected to the delivery manifolds.
The delivery manifolds are connected to the delivery header. Necessary manual
isolation valves are provided in the filling and delivery sides.
Each module is provided with two safety valves. The outlets from the safety
devices are routed to a safe location for discharge to the atmosphere. The filling
and delivery lines for each module are equipped with 1 pressure gauge each.
The delivery line for each module is equipped with 1 pressure transmitter. The
filling header is provided with a manual vent valve. The delivery header is
equipped with 2 pressure transmitters and a temperature transmitter. The
discharge header is provided with an electro-pneumatically operated valve (EP
valves) to vent air from the storage system in case of need.
4.3.
FLUID CIRCUITS
The fluid circuits connect the various subsystems of HPS like compressor and air
storage vessels. Fluid circuits involve various flow components like manual valves,
electro-pneumatic (EP) valves, pressure gauges, safety devices etc. Pipes, fittings and
flow components with stainless steel as materials of construction are planned for air
circuits and the same with carbon steel as material of construction are planned for the
water circuits of HPS.
4.4.
ELECTRICAL SYSTEM
The electrical system is intended to supply electrical power to the various field
equipments like compressors, pumps, fans and blowers etc... Power is fed down from
the state power utility to a substation available in the campus. From MCC, power is fed
to various field equipments. The systems include MCC panels, field panels, starters
(soft starters), circuit breakers, switches, protective devices, cabling, earthing and all
necessary HT & LT switch gear.
4.5.
Instrument air system is intended to provide air to operate EP valves and control valves
and also to supply reference air for dome loaded regulators, if any, in the HPS and other
systems. A single air receiver of 10m3 volume and 1 MPa(g) maximum working
pressure is planned. It is charged by a separate air compressor (1 MPa(g),
~600 Nm3/hour, non lubricated) and air dryer with dew point -400 C. The P & ID of the
instrument air pressure vessel is shown in Fig.6. A fluid circuit to regulate air pressure
and supply to each valve / regulator is a part of instrument air system. In addition to
operate valves the air shall be used for general utility purpose like cleaning of
machineries and operating the pneumatic tools in maintenance workshop. In addition to
the valves of HPS, the valves in the tunnel system are also provided air to operate from
this pressure vessel.
5. SCOPE OF CONTRACT
The scope of the contract and the demarcation of responsibilities between the
Department and the Contractor in realization of HPS are given in this section.
5.1.1.
The conceptual design of the system has been done by the Department. In this
document, the P&ID, along with tentative sizes of the fluid circuits are given. The
specification of the system, along with the list of flow components & instruments, is
given in the document. These details are given only for price estimation. There may be
changes in size etc. based on the design carried out by the Contractor.
The contractor shall carry out the preliminary design of the system within a period of
one month. The design done by the Contractor shall be reviewed and approved by the
Department. Department shall organize the Preliminary Design Review (PDR) meeting
at the Department within 2 weeks from the receipt of design report with all relevant
details from the Contractor. The objective of the design review is to arrive at a
consensus between the Department and the Contractor on the design of HPS and to
freeze the input data for the detailed engineering to be done by the Contractor. The
design review shall primarily address the following issues:
5.1.2.
EQUIPMENT LAY-OUT
The location plan and equipment lay-out of HPS are given in this document. Based on
this equipment layout and the P&ID, the Contractor shall prepare the pipeline lay-out &
isometric drawings and derive the lengths of the pipe-lines required to connect between
the various inter-faces as per the P&IDs.
5.1.3.
Upon award of contract and Preliminary Design Review, the contractor shall carry out
detailed engineering. Document with drawings and all details will be submitted. The
Department will review the detailed engineering done by the Contractor.
5.1.4.
The Department will carry out the following major civil works:
Building
However, the Contractor shall provide the details of the area required, foundation, etc.
5.1.5.
During erection and commissioning, the Department will provide the following services:
Electricity for erection on chargeable basis at the tariff rate prevailing at the
time of consumption
5.1.6.
INSTRUMENTATION SYSTEM
The transmitters (TT1, PT1 & PT2) shall be provided by the contractor. The
cabling, signal conditioner and data acquisition / recording for the
transmitters is in the scope of the department.
Command system including cabling and control room equipments only for
EGV 4 control valve is in the scope of department. Controlling of other valve
is in the scope of contractor. However, all the valves shall be supplied by the
contractor.
5.1.7.
ELECTRICAL SYSTEM
Department will provide a power supply point at the Motor Control Center (MCC). From
this point, proper distribution of power to field equipments like compressors, pumps and
fans/blowers shall be the responsibility of the Contractor. The total power requirement,
voltage/ current rating have to be furnished by the Contractor.
5.1.8.
WATER SUPPLY
The Department will provide water reservoir and pipeline, which will be terminated at a
suitable point near the HPS system. The distribution of water and realization of the
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cooling water system shall be the responsibility of the Contractor. The contractor has to
specify the quantity and quality of water requirement for Departments planning. A
centralized water softening plant will be planned by the department.
5.2.1.
PRELIMINARY DESIGN
The Contractor shall carry out the preliminary design of the HPS and prepare a design
document containing details, with calculations of the sizing of the fluid circuits
comprising the pipe-lines, flow components, instruments, etc. within a period of one
month of awarding the contract. The design shall be generally as per the configuration
given in section 4 and shall meet the objective specification given in section 6. The
design calculations are to be based on the codes/standards mentioned in various
section of this document. In such cases where the Contractor uses alternative codes/
standards, it shall be their responsibility to submit a copy of such codes/ standards in
English language to the Department during design review.
5.2.2.
DETAILED ENGINEERING
Based on the design approved by the Department after Preliminary Design Review
(PDR), the Contractor shall carry out detailed engineering, which shall comprise the
following:
a. Pipe-line lay-out: The detailed lay-out (top view) drawings (indicating skeletal
dimensions to scale) of the pipe-lines of all the process fluid circuits and pipe-
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lines and impulse tubes of instrumentation system shall be made. A master pipeline lay-out shall be made covering all the pipe-lines over the entire facility area in
a single drawing. For the sake of better legibility, segmental pipe-line lay-out
drawings shall be made in convenient number of segments of any area showing
all the pipe-lines in a magnified scale. The drawings shall be made on
appropriate software and provided in Compact Discs (CDs).
b. Pipe-line isometrics: The 3-dimensional isometric drawings of the individual pipeline segment and the necessary pipe stress analysis shall be made. The
drawings shall be fully dimensioned and show the locations of fittings, flow
components, instruments, pipe supports, etc. Each isometric drawing shall
contain the detailed Bill of Materials (BOM). The drawings shall be made on
appropriate software and provided in compact Discs (CDs).
c. Estimation of pressure drop based on the pipe-line lay-out and isometric
drawings.
d. Cable lay-out: The lay-out of instrument and power cables, including the location
of field junction boxes, cable trays, etc shall be made. The General Arrangement
(GA) drawing of the junction boxes and cable routing shall also be submitted.
e. The detailed Quality Assurance Plan (QAP) for the materials such as pipes, pipe
fittings,
flow
components,
instruments,
etc,
fabrication,
erection
and
g. Civil and Electrical requirements: Foundations for the equipments and trenches
for the cabling shall be provided by the contractor. The equipment lay-out
showing details of positioning of subsystems shall be made by the Contractor.
The load details of electrical power to be fed from MCC shall also be provided.
h. The details regarding the space requirement, water equipments shall be given by
the Contractor.
i.
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j.
The list of sub-vendors along with their company profile, technical catalogues etc.
from whom the Contractor has finalized to purchase the materials such as
equipments, flow components, instruments, pipes, pipe fittings, etc. shall be
provided.
The Department shall organize the Detailed Engineering Review (DER) meeting at
DRDL, Hyderabad within 3 months of approval of Preliminary Design. Contractors
representative (s) will participate in DER.
Note-A detailed Quality Assurance Plan (QAP) will be prepared based on mutual
discussion between the vendor and Department.
5.2.3.
The list of sub-contractors, if any, through whom the bidder proposes to acquire the
material and services for the execution of work, shall be given in the quotation. The list
of sub-contractors proposed by the bidder is subject to review by the Department during
evaluation of the quotation.
During DER, the Contractor shall submit the final list of sub-contractors with whom they
have finalized the purchase of materials and services.
5.2.4.
PURCHASE OF MATERIALS
All the materials such as equipments, flow components, instruments, pipes, pipe fittings,
etc, for HPS are to be purchased by the Contractor. The specifications are given in
Section 6. The detailed purchase specifications for the individual items of materials to
be purchased shall be made by the Contractor. The purchase specifications of such
materials are subject to review and approval by the Department.
5.2.5.
SUPPLY OF SPARES
The following spares shall be supplied by the Contractor along with the HPS. The
break-up prices of the spares shall be given in the quotation.
a. Spare parts and consumables for erection and commissioning: For the materials
used in the HPS, the Contractor shall supply the spare parts (like seat insert,
body gasket, gland packing, plug/stem assembly, etc for valves) and
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consumables (like lubricants, oil, greases, PTFE tape, etc) to be replaced/ used
during erection and commissioning (by the Contractor).
b. Spare parts and consumables for operation and maintenance: For the materials
used in the HPS, the Contractor shall also supply the spare parts (like seat insert,
body gasket, gland packing, plug stem assembly with bellows, etc for valves) and
consumables, which are likely to be replaced/ used during operation and
maintenance over a period of 2 years from commissioning. The constituents and
quantity of such spare parts shall be worked out, considering the causative
factors such as normal wear & tear, fatigue cycles, creep, Mean Time Between
Failures (MTBF), etc. The spare parts allocated for this purpose shall not be
consumed by the Contractor during erection and commissioning. A separate set
of spares for 2 years operation and maintenance of the compressor systems
including dryers etc shall also be supplied. The lists of the same shall be
provided with break up price.
5.2.6.
FABRICATION
The system shall be fabricated at the Contractors factory to such an extent that they
can be transported by sea and road. The fabrication shall include testing & cleaning of
the system. All the consumables, tools, tackle; etc required for fabrication shall be
arranged by the Contractor. The detailed specification for fabrication is given in
Section 6.
5.2.7.
The contractor has to design & realize the instrumentation and control system required
for reliable & safe operation of High Pressure System.
sensors, signal conditioners, cables, cable conduits, patch panels, instrument racks,
controller with appropriate interface modules, data display terminals, data storage units,
interfacing units etc.. The functional requirements & features are given in section 6.
The contractor has to provide complete training on the application software & test code
to the department personnel.
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5.2.8.
INSPECTION
All the bought-out materials, fabrication drawings and the works during fabrication at the
Contractors factory and erection at the Departments site shall be inspected by one of
the following reputed Third Party Inspection agencies(TPIA).
The broad scope of inspection shall be as follows. However, the detailed scope of
inspection shall be given in the quotation.
a. Review of the fabrication drawings for fluid circuits
b. Identification of the materials such as equipments, flow components, instruments,
pipes, pipe fittings, etc and review of the test and calibration certificates for
compliance with the contract specification.
c. Witnessing of welding procedure qualification and welders performance
qualification tests. If the welders already possess the performance certificate, the
TPIA shall review and authorize the same.
d. Review of X-ray films of radio-graphic tests for possible defects in the weld joints.
e. Inspection at any stage of fabrication to ensure that the methodology employed
for fabrication is in compliance with the requirements of standards/ codes,
practices, contract specification and the approved documents.
f. Witnessing of pressure test, leak test and cleanliness test of the system during
fabrication and erection at site.
It shall be the Contractors responsibility to arrange for and co-ordinate with the TPIA.
Apart from inspection by the TPIA, the Departments representative(s) will also inspect
the system at any stage of fabrication and erection.
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5.2.9.
TRANSPORTATION
All the fabricated items and bought out materials will be properly packed and
transported to the Departments site at Hyderabad.
5.2.10. ERECTION
The system is to be erected by the Contractor at the Departments site. Apart from
erecting the system fabricated by the Contractor, it shall also be the Contractors
responsibility to erect the major equipments supplied by the Sub-contractor(s). The work
done by the Contractor during erection shall be inspected by the TPIA. The erection
shall also include cleaning & testing, minor civil & structural works (for grounding of
equipments, pipe supports, access bridges, platforms, staircase, etc), and electrical
system in and from MCC.
The Contractors personnel shall not be permitted to reside inside the Departments
premises after the working hours. The Contractor shall arrange for transportation,
accommodation, food, health care, communication, etc for their personnel.
5.2.11. COMMISSIONING
The high pressure system shall be commissioned by the Contractor in two phases as
follows:
In the first phase all the subsystems of HPS shall be tested individually, first in
static (non-flow) condition and then under flow condition.
In the second phase, HPS shall be tested with the rest of the tunnel system in
integrated way.
5.2.12 TRAINING
The contractor will arrange for training of Departments personnel for operation and
maintenance of the system.
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5.2.12. DOCUMENTATION
The Contractor shall prepare the relevant documents during different phases of he
Contract. All the documents shall be provided in 3 hard copies in English language only.
In the event that the documents by the sub-vendors/ sub-Contractors are in some other
language, it shall be the Contractors responsibility to translate them to English
language. The documents shall also be provided in CDs. besides the 3 hard copies.
These documents are subject to review by the Department. However, the Departments
approval shall not absolve the Contractors responsibility to comply with the
specifications and obligations of the contract. The list of documents to be provided by
the Contractor at different phases of the contract is given in the document in section 7.
5.2.13. SCHEDULE
The total scope of work shall be completed by the Contractor within 20 months from the
date of receipt of order.
6. SPECIFICATIONS
6.1. SPECIFICATION FOR AIR COMPRESSOR SYSTEM
Air compressor system shall include air compressor, air dryer units, oil separator,
cooling water system, and electrical power supply to the motors, instrumentation and
control system. The compressor system shall also include lubrication system, lubrication
of pump, intercooler, after cooler, pressure and temperature gauges at suction,
discharge and intermediate stages, pressure and temperature transmitter for all stages,
measurement, switches, alarms, control panels and display for operation and
monitoring, sound level meter, special tools and dew point meter. Each stage shall be
provided with safety relief valve.
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6.1.1.
AIR COMPRESSOR
Number of trains
Two
Fluid medium
Atmospheric air
Ambient temperature
Altitude at location
Flow capacity
Configuration of compressor
feed
compressor
should
be
Driver
Make
Noise level
Less than 1 x 10 6
18
Oil content
Filtration level
One
6.1.2.
DRYER UNIT
Number of dryers
Shall be able to handle the total flow rate from both feed compressor units.
(2000 Nm3/hr dry air per train)
The working pressure of the dryer is the discharge pressure of the feed
compressor.
Dryer unit shall be self contained with its own control panel.
Dryer unit vessels shall be designed as per ASME Boiler and pressure
vessel code, section VIII. Division 1 and welding code as per section IX.
6.1.3.
The cooling water supply for the compressors shall include industrial type cooling
tower(s), cooling water circulation pumps(s), makeup water line, water supply and return
lines between pumps, compressors and cooling tower.
6.1.4.
The electrical power supply system for the motors of all the equipments under the air
compressor system shall include MCC panels, starter (soft starter), breaker, protective
devices, field panels, all cabling and earthing.
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6.1.5.
INSTRUMENTATION
Each compressor stage is to be equipped with a pressure gauge of 6/4 dia dial with an
accuracy of 0.5% and safety relief valves set to the required pressures. All safety relief
valves should open within the range of 3 % of set pressure (adjusted to blow at 10%
higher pressure). The gauges are arranged in a compact panel which also contains the
indicating oil pressure gauge. All pressure gauges shall be calibrated and the calibration
reports shall be submitted. One temperature switch monitors the air temperature on the
final stage. Level indicators for crank case oil and condensate receiving tanks are to be
provided. An hour meter shall be provided with the compressor for logging of
compressor running. Digital Pressure Indicator at the delivery of the compressor will
also be provided.
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6.1.6.
The stage separators located at the outlet of each stage are regularly drained by means
of diaphragm valves actuated by a timer-controlled solenoid. The condensate and
escaping air are led from the separators into a condensate receiving tank. The unit is
fully piped with high strength flexible hoses for connection on the suction and
discharge side.
6.1.7.
All the weld joints in the pneumatic piping shall be cleared by the TPIA.
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6.1.8.
TESTS
The following tests shall be carried out and certificates provided for the compressor,
dryer and fluid circuits.
Material tests for physical and chemical properties of all pressure/ load
bearing parts.
Hardness test.
Dimensional check
Balancing
Functional test
The subsystems will be tested and qualified to the maximum extent possible at the
respective manufacturing facilities and will be witnessed by Department and TPIA. The
compressor performance test shall be demonstrated at both contractors site and
Departments site.
6.1.9.
DOCUMENTATION
Process flow diagram, over all layout drawing indicating floor space and
other civil requirements.
Lists of sub vendors from whom the Contractor proposes to source all
major equipment like feed compressor, boost compressor, dryer units
cooling towers, cooling water pump, drive motors, MCC panel, control
panel/ system etc. Type/models proposed to be used and relevant
catalogues may be provided.
Operating manual with complete assembly drawing and spare parts lists.
Guarantee certificates.
6.2.
Each storage system shall comprise 6 pressure vessels mounted in a structural skid
along with associated manifolds, valves, flow components and gauges. Total number of
vessels is 36.
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6.2.1.
DESIGN DATA
(i)
Fluid medium
Dry Air
(ii)
(iii)
(iv)
170 to 313 K
(v)
(vi)
Quantity
(vii)
As per DOT 3T or
Construction
Application
As per standard
:
(x)
Make
6.2.2.
CONSTRUCTION:
The pressure vessels shall be made of hot rolled seamless tubes for cylindrical shell
and integrally forged hemi-spherical dished ends (without any welding). The pressure
vessels are intended for horizontal installation.
6.2.3.
SURFACE TREATMENT:
The surface treatment of the pressure vessels shall be performed in accordance with
ISO 8501-1:1988 to the following grades.
i.
Internal surface: The internal surface shall be subject to shot blast cleaning to
achieve surface condition as per preparation grade B Sa 2. The treatment shall
be followed by filling with gaseous Nitrogen to 0.2 MPa, which shall be
maintained till receipt of the pressure vessels at out site.
ii.
External surface: The external surface shall be subject to shot blast cleaning to
achieve surface condition as per preparation grade B Sa 2. The treatment shall
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be followed by painting with Zinc primer and double top coat. The color of paint
shall be white.
6.2.4.
END CONNECTIONS:
The connections for the filling and delivery ends of the pressure vessels of the air
storage systems shall be as follows:
a. Filling end: The filling ends of the pressure vessels shall be fitted with rapid
closure system or equivalent with ID of 10 mm (clear bore for air flow). The
material of construction of the rapid closure system shall be austenitic stainless
steel.
b. Delivery end: The delivery ends for the pressure vessels shall be of female
thread with screwed-in and seam-welded flange of DN 50 mm size (50 mm ID)
with counter-bored seal seat and tapped holes for stud bolt. The material of
construction of the flanges shall be austenitic stainless steel.
6.2.5.
MARKING:
The pressure vessels shall be stamped with permanent and clearly visible identification
marks at an accessible location by steel tamps. The details such as water capacity,
service pressure, hydraulic test pressure, material of construction, manufactures serial
number, date of inspection and inspectors stamp shall be marked.
6.2.6.
MOUNTING:
The pressure vessels shall be mounted in a structural skid to constitute the air storage
systems according to the arrangement specified in Fig. 5. The material shall be
structural steel. The structure shall be provided with lifting lugs for handling. The
structure shall protect the air storage system including the associated flow components
and gauges.
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6.2.7.
Each module shall be instrumented as per Fig. 5. The material of construction of all the
flow components and gauges shall be austenitic stainless steel 316L only.
6.2.8.
MANIFOLD ASSEMBLIES:
The manifold assemblies for the air storage systems shall be as follows: the flow
components, valves and instruments shall be provided in the manifold (P & ID diagram
is shown in Fig. 6). The material of construction of all the flow components and gauges
shall be austenitic stainless steel 316L only.
The filling ends of the pressure vessels shall be connected to manifold. The inlet
of the filling manifold shall be provided with a globe valve (designated as MGV-1)
of size 25 mm. The inlet of the globe valve shall be terminated with a flange.
The delivery ends of the pressure vessels shall be connected to a manifold. The
outlet of the delivery manifold shall be provided with a globe valve (designated as
MGV-2) of size 100 mm. The outlet of the globe valve shall be terminated with a
flange.
The filling and delivery manifold of each skid shall each be provided with
1 pressure gauges (designated as PG-A, and PG - B).
The delivery manifold of each skid shall be provided with one Pressure
Transmitter.
The delivery manifold shall be fitted with two safety valves (designated as SV).
The safety valve shall be the primary safety relief device, set to the maximum
permissible pressure of the vessel. Each of the Safety valves will have same set
pressure (one for redundancy).
All the inter-connecting joints of manifold assemblies, including the valves, but
excluding the end connections of the pressure vessels, filling, delivery and vent
of the manifolds; pressure gauges; and safety valves, shall be made only by butt
welding with Gas-purged Tungsten Arc Welding (GTAW) using gaseous Argon of
99.995 % purity as purge medium. All the butt weld joints shall be qualified by
dye penetrant test and radio-graphic test with X rays to 2T sensitivity. After
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The flanges on the filling, delivery and vent of each storage system shall be
supplied with companion flanges along with gaskets and fasteners.
6.2.9.
TESTS:
b.
Hardness test
c.
d.
e.
f.
g.
h.
i.
j.
Dimensional check
k.
l.
Dye penetrant test and radiographic test with x-rays of all butt welded joints in
manifold assembly.
m.
6.2.10. INSPECTION:
The in-process (stage) and pre-delivery (final) inspection of the air storage systems
shall be carried out by a reputed Third Party inspection agency (TPIA) .
The scope of inspection shall be as follows:
a. Review and approval of the design calculations and General Arrangement (GA)
drawings.
27
b. Identification of raw materials and review of the material test certificates for
compliance with the relevant requirements.
c. Review of test certificates for compliance with the specification and visual
examination of the bought-out flow components and gauges.
d. Inspection at any stage of fabrication to ensure that the methodology employed
for fabrication is in compliance with the requirements of standard codes and
practices and approved documents.
e. Review of x-ray film of radiographic tests of welded joints.
f. Witnessing of tests given in para 6.2.9
g. Issuance of Pre-Delivery Inspection (PDI) certificate and stamping of on the
pressure vessels.
Apart from inspection by the TPIA, our representative(s) shall also witness and certify
the hydraulic pressure stretch test and any other test as may be deemed necessary.
6.2.11. DOCUMENTATION:
The following documents, in duplicate unless specified otherwise, shall be furnished at
different stages specified thereupon.
(i) Along with quotation: A complete technical description of the system shall be
furnished. The following shall be highlighted.
- Overall documentations of pressure vessels and storage systems.
- Mass of pressure vessels and air storage system
- Wall thickness of pressure vessels
- Mechanical properties and chemical composition of pressure vessels.
- Technical deviation, if any should be highlighted.
(ii) Soon after entering into contract: The following documents shall be prepared
immediately upon receipt of the purchase order. The documents listed in Clauses
a, b & c below shall be reviewed and approved by the Third Party Inspection
agency (TPIA) for compliance with the requirements of the relevant design codes
as specified in the purchase order and statutory regulations. Moreover, it is
suppliers responsibility to submit the documents listed in Clauses a, b & c below
to the Chief Controller of Explosives (CCE), Government of India, Nagpur and
28
get the same reviewed and approved by him. The documents listed in Clauses a,
b & c below duly approved by the TPIA & the CCE along with the documents
listed in Clauses d, e below shall be submitted to the Department within 2 months
from the date of the purchase order. These documents are subject to corrections
by Department and only upon approval of the same by Department, supplier shall
proceed with fabrication. Upon approval by Department, 1 copy of these
documents shall be returned to supplier. However, Departments approval shall
not absolve the supplier responsibility / contractual obligation to comply with the
specification of the system.
a. The overall dimensioned General Arrangement (GA) drawing of the
storage systems shall be provided. The calculations for the pressure
vessels, structural skid, flow components, gauges, etc shall be shown in
the GA drawing.
b. The detailed calculations for the design of the pressure vessels as per the
code shall be provided. The calculations for the sizing of the safety relief
valves as per the relevant code / standard shall also be provided.
c. The detailed dimensioned cross sectional drawing of the pressure vessel
shall be provided.
d. A detailed Quality Assurance Plan (QAP) shall be provided.
e. The make, model number and specifications of the flow components and
gauges along with the catalogues shall be provided.
(iii) Prior to delivery of the consignment: On completion of fabrication, but at least 2
weeks before the expected date of delivery of the consignment, the following
documents shall be sent to the Department. Department shall review the same to
ensure compliance with the specification of the purchase order. On being
satisfied, Department shall issue a dispatch clearance.
a. The certificates of all tests shall be provided. Each page of he
certificates shall be duly counter-signed and stamped by the TPIA.
b. Pre-delivery inspection certificate by the TPIA.
c. As-built GA drawings
29
6.3.
Dry air
Volume
10 m3
Pressure
Number of vessel
The filling end and the delivery end shall be provided with ball valves of
size 50 mm. Each end shall have pressure gauge with its own isolation valve and
vent valves. The delivery end shall have two Safety valves (one for redundancy)
with same set pressure maximum permissible of pressure vessel.
6.4.
MANUAL VALVES
Temperature
Range, K
MAWP
MPa
tentative
valve
size
mm
Type of
valve
MGV1
233-313
33
25
Globe
MGV2
233-313
33
100
Globe
MGV3
233-313
33
300
Globe
Note: All the valve sizes shall be selected based on the selected pipe sizes
Actuation
Application
Isolation
30
Cycle of Operation
10,000
End connection
Flanged; Flanged
ends as per ANSI B16.5
Body
Bonnet
Stem
By gland packing
Plug
Seat
Flow direction
Material of construction
The valves shall be either inherently anti-static or provided with anti-static features.
Design code
Test Code
Tests:
Material certificate: The material certificates, detailing the physical and chemical
properties, of the principal pressure-bearing parts shall be provided.
Welding joints test: Any butt welding joints in the valve shall be subjected to radio
graphic test with X-rays or gamma rays to 2-T sensitivity.
31
Soundness test for casting: All the casting shall be subject to soundness test with radiographic or ultra-sonic technique for flaw detection.
Hydraulic shell pressure test: The valve, prior to assembly with the bellows, in partially
open position, shall be subject to pressure test with water ( with suitable corrosion
inhibitor) at 1.5 times the maximum rated working pressure of the particular pressure
rating class of the valve. The test procedure and acceptance criteria shall be as per BS
6755 Part 1 or API 598 or ANSI B 16.34.
Pneumatic seat test (for ball valve only): The leak rate across the seat of ball valves
shall be tested with dry air at 0.4 to 0.7 MP by water displacement (bubble) method. The
acceptance criteria shall be as per Rate A of BS 6755 Part 1) or API 598.
Functional test: The valve with all accessories mounted shall be subjected to functional
test to validate the performance.
Marking: All the valves are assigned tag numbers for the sake of identification. The tag
number for each valve, as indicated above, besides size, pressure rating class, material
of construction etc, shall be indelibly engraved on the body of he valves.
Note: For the isolation of pressure transmitters and gauges, 3 port / 2 way manifold
valves are to be used.
6.5.
ELECTRO-PNEUMATIC VALVES
The electro-pneumatic (EP) valve shall comprise the valve, actuator, solenoid valve and
limit switches.
i) VALVE
Actuation
As given in Table 2
32
MAWP
MPa
EGV1
233-313
33
Tentative
valve
size
mm
25
EGV2
233-313
33
25
Globe
<5
EGV3
233-313
33
25
Globe
<5
EGV4
233-313
33
300
Globe
<3
EGV8
233-313
33
100
Globe
<5
valve no.
Type of
Response
valve
Time, Sec
Globe
<5
Note: All the valve sizes shall be selected based on the selected pipe sizes
Other Specification
And tests
Note: All the valves (EGV, MBV and MGV) shall be of the following Makes:
INSTRUMENTATION INDIA LTD / AUDCO INDIA LTD / MIL CONTROLS / FISHER
SANMAR CONTROL / B.D.K GROUP OF COMPANIES / BHEL / PARKER /
SWAGELOCK / HAMLET/ DMIC
(ii) ACTUATOR
Type
Command gas
Air
Body material
Anodized Aluminum
Piston material
Test
Necessary power source shall be supplied by the contractor for solenoids and the limit
switches
33
6.6.
PIPES
Type
Seamless pipes
Schedule number
As per P & ID
Length
Dimensional standard
ANSI B 36.19/36.10
TESTS
Visual examination: All the pipes shall be visually examined for workmen-like finish.
Dimensional check: One specimen from each lot shall be subjected to dimensional
check.
Chemical analysis: One specimen from each lot shall be subjected to detailed chemical
analysis as per ASTM A 751.
Mechanical Tests: One specimen from each lot shall be subjected to test for mechanical
properties as per ASTM A 370 (including impact test)
Hydraulic pressure test: All pipes shall be hydraulically pressure-tested with Water as
per ASTM A 530.
Ultra-sonic test: All the SS pipes of size DN 25 shall be subject to Ultra-sonic test (100
%) by contact method as per ASTM A 450.
Eddy current test: all the SS pipes of size DN15 shall be subjected to Eddy current
test as per ASTM E 426.
Flattening test: Pieces of pipes of length 63.5 mm (2.5) cut from the ends of 5 % of pipe
lengths per lot shall be subjected to flattening test as per ASTM A 530 to prove ductility
and soundness.
Inter-granular corrosion test (for SS pipe only): One specimen per lot shall be subject to
inter-granular corrosion test as per ASTM A 262 (practice A/E).
34
6.7.
GASKET
6.8.
PIPE FITTINGS
Type
Standard
CS Pipeline
1. ASTM A 105
2. ASTM A 234 WPB
Tests
Visual examination: All fittings shall be visually examined for any scratches, dents, and
surface irregularities etc.
Dimensional check: One specimen from each lot shall be subjected to dimensional
check.
Chemical analysis: One specimen from each lot shall be subjected to detailed chemical
analysis.
35
Inter-granular corrosion test: One specimen per lot shall be subject to inter granular
corrosion test as per ASTM A 262 (practice A/E).
Mechanical tests: One specimen from each lot shall be subjected to tests for
mechanical properties.
6.9.
Instrumentation and control system should be designed for meeting following functional
requirements.
1. It is configured as a stand alone system for its safe & reliable operation.
2. It is configured such that system can be operated in either manual or automatic
mode. For manual mode of operation, the necessary provisions like knobs,
process parameters status etc... should be available on the front panel. In the
automatic mode, the controller has to operate the compressor as per the predefined instructions. In case of fault, the controller should automatically detect &
take necessary abort actions.
3. It should have emergency shut down button for stopping of compressor in case
of emergency.
4. All important parameters should have a digital display on the front panel and
necessary interlocks must be incorporated in the control logic. In case of
deviation of any process parameter from its nominal values, the system should
pop up the suitable alert signals to the operator in the form of alarms, LED
display etc.
5. SCADA based GUI environment to be available at the control room.
6. Software (test code) to be developed as per IEEE 12207 standard.
7. It should acquire the data of critical parameters at 10samples/sec during
compressor operation.
8. It should communicate some of the important process parameters (user selected)
using TCP/IP protocol to the master control room of the wind tunnel.
36
6.10.
The system shall be fabricated, erected and commissioned as per the following
procedure:
6.10.1 WELDING
The welding procedure qualification and welders performance qualification shall be one
as per section IX, ASME.
6.10.2 TESTS:
The following tests shall be performed after fabrication of pipelines:
a.
Dye penetrate test: All the socket welded joints shall be subjected to Dye
Penetrate Test (DPT) at the root, intermediate and final passes. All the butt and
mitre welded joints shall be subjected to DPT at the root pass.
37
b.
Radio graphic test: All the (full) SS butt welded joints and 10 % (spot) of the CS
butt welded joints shall be subject to radiographic test to 2 T sensitivity.
Generally, the radio graphic films shall be submitted to the Department.
c.
Pressure test: All the fabricated pipe-lines shall be subject to pressure test with
hydraulic medium at 1.5 times the MAWP. Alternatively, in pipe-lines, where the
presence of water is intolerable, the pressure test may be done with pneumatic
medium at 1.1 times the MAWP.
d.
Pneumatic leak test: All the pipe-lines, except those for water medium, shall be
subject to leak test with dry Air at MAWP to validate bubble-tightness.
e.
Surface oil contamination test: The surface oil content of the pipe-line shall be
measured by transferring the oil contaminant into a solvent by mopping the
surface and analyzing with fluorimeter. The permissible surface oil contamination
shall be 200 mg/m2.
6.10.3 CLEANING
The fabricated SS pipe-lines shall be cleaned as per the following procedure:
a. Mechanical cleaning: All the metallic surfaces with scales and newly welded
surfaces shall be cleaned by scrubbing with SS wire brush. The loose
particles generated by mechanical cleaning shall be removed by blowing with
compressed air, sucking or washing with water.
b. Degreasing : The oil and grease adherent to the surface shall be removed
by vapor phase de-greasing with Tri Chloro Ethylene (TCE) or Per Chloro
Ethylene (PCE), followed by liquid phase de-greasing with TCE or PCE.
c. Pickling: In order to remove rusts and scales, the surfaces shall be washed
with water and pickled with a solution containing Hydro-fluoric acid (HF) and
Nitric acid (HNO3). The composition of the pickling solution and duration are
to be adjusted after trial test on a sample piece to remove uniformly less than
25m thick material. Mostly, the composition is as follows;
HF
5% by mass
HNO3
15 to 20 %
Water
Remainder
38
25% by volume
Water
Remainder
Duration
2h
6.10.4 PAINTING
All the CS pipe-lines and non-insulated SS pipe-lines shall be pained based on the
colour code scheme. All the pipe-lines, flow components and instruments shall be
provided with identification name plate displaying, in bold letters, their tag numbers. All
the structural materials shall be painted in gray colour and handrails in yellow colour.
The color code scheme shall be provided upon award of the contract. Prior to painting,
the surfaces shall be suitably prepared. The painting shall comprise 2 coats of primer
(like weather protection paint) and 2 coats of synthetic enamel.
39
connect the equipments, pipe- lines, flow components, instruments, etc to the earthing
pits through proper earthing strips. The earth pits of 0.5 for instruments and 5 for
mechanical equipments shall be provided by the department.
7 DOCUMENTATION
The list of documents to be provided by the Contractor at the different phases specified
there up on are as follows:
b.
c.
d.
e.
f.
Cable lay-out
g.
QAP
h.
i.
j.
k.
l.
40
7.3 FABRICATION
a. As built fabrication drawings.
b. Test certificates and inspection reports of the materials such as equipments,
flow components, pipes, pipefittings, instruments (including the calibration
certificates), etc.
c. Wiring diagram of instrumentation and electrical systems.
d. Test certificates and inspection reports of fabrication (including the radiographic films)
e. Estimation of quantity of fluids to be supplied by the Department during erection
and commissioning.
7.4 ERECTION
At the end of erection, the following documents shall e submitted.
a. As-built pipe-line layout drawings.
b. As-built pipe-line isometric drawings.
c. As-built cable layout drawings.
d. Estimation of pressure drop based on the as-built pipe-line isometric
drawings.
e. Certificates of tests (including radiographic films) done during erection.
f. Inspection report by the Department
8 STANDARDS FOLLOWED
The contractor shall follow the standard for piping, welding, vales etc given in Table 3
Table 3: Standards/codes to be followed.
Sl.No. Description
Standard/code
1.
Piping
ANSI B 31.3/31.1
2.
SS pipes
ANSI B 36.19
3.
CS pipes
ANSI B 36.10
4.
ANSI B 16.9
5.
ANSI B 16.11
41
6.
Flanges
ANSI B 16.5
7.
Washers
8.
Gaskets
9.
Ball valves
10.
Globe/Needle valves
11.
Pressure regulators
Manufacturers standard
12.
Filters
Manufacturers standard
13.
14.
15.
Pressure gauges
BS 1780/IS 3624
16.
ASTM A 530
pipelines
17.
ASTM A 380
18.
NDT
ASME Section V
19.
Welding
20.
Radiography
ASTM E 94
21.
9 LIST OF DELIVERABLES
The contractor shall provide the following list of deliverables as given in Table 4
Table 4: Indicative list of deliverables
Sl.
Description of Item
Qty
1No.
No.
1.
Air compressors
42
2.
Dryer
-
3.
Oil remover
-
4.
1No.
Safety devices
-
.
1 Set
8.
1 Set
9.
1 No.
10.
Pressure vessel
-
11.
6 Nos.
12.
1 Set
13.
Manifold assembly
1 No.
14.
1 Unit
15.
1 No.
16.
7 Nos.
17.
6 Nos.
43
1No.
Instrumentation
-
7.
1No.
6.
1No.
5.
18.
1 No.
19.
2 Nos.
20.
2 Nos.
21.
3 Nos.
22.
1 No.
23.
1 No.
24.
1 No.
25.
1 No.
26.
UPS for instrumentation & control system of high pressure system 1 No.
10.1 COMPRESSOR:
The compressor shall be run for 20 hrs with 15 minutes break after 10 hours at
contractors site and Departments site and performance shall be checked for delivery
pressure, delivery flow rate and quality of the air (dew point).
Leak tests: The inlet and delivery lines of compressor shall be leak tested at 300 bar
outlet pressure.
a) Checking of all safety systems and controls
b) All the safety relief valves shall be tested for their operation and corresponding
feed back to the control panel.
c) Performance tests at various loads
d) Cyclic tests: In one of the 8 hour duration tests at 100 % load, the compressor
shall be run for 1 hr and switched off. After 15 min gap, the compressor shall be
switched on again. This should be repeated for 8 cycles.
44
e) FAD ( Free Air Delivery) / capacity tests shall be carried out as per the IS
standard and conformed to the specifications
f) Oil and Dust content in the compressed air shall be tested at reputed laboratories
to confirm the specifications
g) Working of all pressure/temperature gauges and transmitters
45
46
150m
1.Compressor shed
2.Air storage shed
3.Vacuum pump house
4.Vacuum sphere
5.LPG system
6.Aftercooler
7.Electrical substation
8.MCC
9.HPS workshop
10.Water Pump house
11.Diesel Generator house
12.Water tank
13.Air heating shed
300m
Fig. 2 Equipment layout of the Hypersonic Wind Tunnel
47
Air storage
Atmospheric
Air
CT1
FC1
D
CT2
CWP1
CWP2
BC1
FC2
OR
To Tunnel
BC2
Atmospheric
Air
FC1. FC2 - FEED COMPRESSOR
BC1. BC2 - BOOST COMPRESSOR
OR - OIL REMOVER
CT1 ,CT2 - COOLING TOWER
CWP1, CWP2 - COOLING WATER PUMP
D - DRIER
48
MGV1
MGV 2
04-100-18NS-33
MGV 1
EGV1
03-025xxS-33
MGV 1
MGV 2
05-300-45NS-33
02-025xxS-33
MGV 2
EGV4
MGV 2
EGV3
01-025xxS-33
MGV 1
MGV 1
06-300-45NS-33
MGV 2
EGV 2
MGV 1
MGV 2
MGV 1
Module(6-cylinders,3rowsx2columns)
MGV3
INSTRUMENTAL
AIR
C1 = Compressor train 1
C2 = Compressor train 2
49
50
isolation valve,
ID >2mm
Inst. air
compressor
&dryer
07-50-40S-1.5
51
52
53