TENDER DOCUMENT FOR SUPPLY OF FIRE FIGHTING PUMPS LONI TERMINAL & TALEGAON DEPOT

Transcription

1 HINDUSTAN PETROLEUM CORPORATION LIMITED TENDER DOCUMENT FOR SUPPLY OF FIRE FIGHTING PUMPS AT LONI TERMINAL & TALEGAON DEPOT Page 1 of 63

2 NAME OF THE WORK: SUPPLY OF FIRE FIGHTING PUMPS AT LONI TERMINAL AND TALEGAON DEPOT AS PER ATTACHED SCHEDULE OF QUANTITIES Sr.No. MASTER INDEX DESCRIPTION 1. TENDER COVER PAGE 2. INDEX 3. PROJECT DESCRIPTION AND SCOPE OF THE WORK 4. TIME SCHEDULE 5. TECHNICAL SPECIFICATIONS A. MAIN & JOCKEY PUMPS 6. SCHEDULE OF QUANTITIES 7. APPROVED LIST OFMAKES 8. SPECIAL PAYMENT TERMS Page 2 of 63

3 SCOPE OF WORK Page 3 of 63

4 INTRODUCTION & BRIEF SCOPE HPCL LONI TERMINAL is existing terminal at LONI KALBHORE, PUNE in Maharashtra State involved in receipt, storage & distribution of petroleum products. HPCL TALEGAON DEPOT is upcoming depot at Talegaon Dabhade which shall be State involved in receipt, storage & distribution of petroleum products. THE SITE ADDRESSES ARE AS GIVEN BELOW: LONI: HINDUSTAN PETROLEUM CORPORATION LTD LONI TERMINAL KADAM WAKVASTI TALUKA HAVELI VILLAGE LONI KALBHORE PUNE SOALPUR ROAD PUNE PH: , TALEGAON: HINDUSTAN PETROLEUM CORPORATION LTD TALEGAON BOOSTER STATION MUMBAI PUNE SOLAPUR PIPELINE ARBOR ACRES ROAD TALEGAON DABHADE MAHARASHTRA PH: Page 4 of 63

5 1.0) THIS TENDER ENVISAGES THE FOLLOWING: 1) Supply, Testing, Supervision services for Erection & Commissioning of Main Fire Fighting Pumps along with Diesel engines and other accessories. The control panel shall be suitable for integration with existing terminal automation system at Loni Terminal and upcoming Automation system at Talegaon. 2) Supply, Testing, Supervision services for Erection & Commissioning of jockey pumps along with electric motors and other accessories 3) Supply of mandatory spares for the Main Pump sets and Jockey Pump sets. 2.0) INSTRUCTIONS TO BIDDERS This specification forms a part of the tender documents and shall be read in conjunction with the same. The bidder shall arrange to transport and deliver on door delivery basis all equipment and accessories to be supplied by the bidder. 3.0) SCOPE OF JOB Design, manufacture / fabrication, procurement, assembly, testing, Third party inspection, packing, transportation, supply & delivery and Supervision of Erection & Commissioning of following: Diesel engine driven Main pumps including prime mover, coupling, base plate and accessories as specified in data sheet. Electrical driven jockey pumps including prime mover, coupling, base plate and accessories as specified in data sheet. Supply of Spare parts for two years operation for Main pumps & prime mover. Supply of Spare parts for two years operation for Jockey pumps & prime mover. Page 5 of 63

6 4.0) QUALIFICATION CRITERIA: APPROVED MAKES FOR MAIN AND JOCKEY PUMPS ARE KIRLOSKAR, MATTHER & PLATT, KSB, FLOWSERVE OR HPCL APPROVED EQUIVALENT. HPCL APPROVED EQUIVALENT SHALL CONFORM TO THE FOLLOWING: 1) PUMP MANUFACTURER SHOULD HAVE SUPPLIED TO EITHER HPCL, BPCL, IOCL, ONGC, OIL INDIA, GAIL, ESSAR OIL OR RELIANCE PETROLEUM AT LEAST FOUR PUMPS OF 680 KL/HR AND 85 M HEAD OR HIGHER DISCHARGE & HIGHER HEAD IN THE LAST SEVEN YEARS ENDING COPY OF PO, DELIVERY CHALLAN AND PHOTOGRAPH SHALL BE SUBMITTED. EXACT CLIENT REFERENCE SHALL BE PROVIDED TO ENBALE HPCL TO VERIFY SAME PHYSICALLY. 2) THE SUBJECT PUMPS (SL.No.1) SHOULD HAVE BEEN FUNCTIONAL FOR AT LEAST 24 MONTHS AS ON CERTIFICATE FROM CLIENT AND EXACT CLIENT REFERENCE SHALL BE PROVIDED TO ENABLE HPCL TO VERIFY SAME PHYSICALLY. 3) PUMP MANUFACTURER SHOULD HAVE SUPPLIED AT LEAST ONE PUMP OF 60 KL/HR AND 110 M HEAD OR HIGHER DISCHARGE & HIGHER HEAD IN THE LAST SEVEN YEARS ENDING ) THE SUBJECT PUMPS (SL. No. 3) SHOULD HAVE BEEN FUNCTIONAL FOR AT LEAST 24 MONTHS AS ON CERTIFICATE FROM CLIENT AND EXACT CLIENT REFERENCE SHALL BE PROVIDED TO ENABLE HPCL TO VERIFY SAME PHYSICALLY. 5.0) DRAWINGS: The following drawings shall be submitted by the vendor for HPCL review and approval after placement of order. i Outline and general arrangement drawings incorporating all principal dimensions and also foundation design data for pump set. ii Sectional drawing of each pump and diesel engine incorporating data on materials of construction. iii Predicted performance curves for pumps. iv Static and dynamic loads. Page 6 of 63

7 All drawings, load data and other information to be furnished for Owner approval shall be progressively submitted in three (3) copies and the entire submission of documents shall be completed within a month s time from the date of issue of LOI/FOI. The approval / comments, if any, of/on the drawings shall be communicated by Owner within a week of receipt of the same. Changes, if any in the drawings have to be incorporated and submitted to HPCL for their approval. It shall be the sole responsibility of the vendor to submit and obtain all drawings approval from HPCL by visiting HPCL Office at Loni, Pune if required by providing all clarifications. Approval of supplier s drawings by HPCL shall not relieve the supplier of any responsibility covered by the requirement of the Contract. The supplier shall get the Supplies inspected by approved Third Party agencies before dispatch in accordance with QAP/ITP approved by HPCL. The approved agencies for Third Party Inspection are DNV, Lloyds, CEIL, IRS, BVQI. The supplier shall supply operation and maintenance manuals along with the equipment. The manuals shall meet the following requirements: i The instruction manuals shall present the categories of information in practical, complete and comprehensive manner prepared for use by operating and/or maintenance personnel. a) Instructions for initial installation. b) Instructions for operation, maintenance and repair. c) Recommended inspection points and periods of inspection. d) Ordering information for all replaceable parts. e) Lubrication chart. ii Drawings and other illustrations shall be included or copies of drawings shall be bound in the manual. Test, adjustment and calibration information as appropriate shall be included and shall be identified to the specific equipment. Safety and warning notices and installation, maintenance and operating cautions shall be emphasized. iii A parts list shall be included showing part nomenclature, manufacturer s part number and/or other information necessary for accurate identification and ordering of replacement parts. Page 7 of 63

8 iv If a standard manual is furnished covering more than the specific requirement purchased, the applicable model No., parts No. and other information for the specific equipment purchased shall be clearly identified. v The instruction manual shall include a list of all special tools and tackles furnished with complete drawings and instructions for use of such tools and tackles. The supplier shall furnish list of special tools required for erection and maintenance. 6.0) SCOPE OF SUPPLY OF THE VENDOR: Diesel engine driven Main pumps including prime mover, coupling, base plate/frame, foundation bolts, shims and accessories as specified in data sheet. The Main pumps shall be straight centrifugal pumps conforming to IS- 9137/1520, Horizontal split casing with glands, inlet & outlet flanges of ASA 150 RF/FF drilled as per ANSI B The Engine shall be supplied with all standard accessories such as Governor, Flywheel with housing, Vibration dampener, Silencer, etc. Electrical driven jockey pumps including prime mover, coupling, base plate/frame, foundation bolts, shims and accessories as specified in data sheet. Spare parts for two years operation for Main pumps & prime mover. Spare parts for two years operation for Jockey pumps & prime mover. Fuel Tank of suitable capacity for each engine. Battery set of suitable capacity for each engine. Hoses required for each engine & pump. Pipes required for each engine & pump. Exhaust pipes required for each engine along with cladding materials and support hangers. Page 8 of 63

9 For each of the Main Pumps & Jockey Pumps: One set of Matching flange (for suction & discharge nozzles) with studs & nuts and gasket has to be supplied by the party. 2 Nos. Pressure gauges with 0-20 kg/cm2 range per pump to be supplied by the party. All other accessories between pump, engine, local panel and fuel tanks which are not mentioned specifically but required for successful commissioning of the system have to be supplied by the party. Commissioning spares for Main pumps & prime mover Commissioning spares for Jockey Pumps & prime mover. Instruction Manual for Main pumps & prime mover Instruction Manual for Jockey pumps & prime mover Control panel for each Main Pump & Prime mover suitable for automation hook-up. Local Push button station for Jockey motor. Also, control panel, suitable for automation hook-up. Cables: Cable from Panel to Batteries to be kept as 2 runs of15 m length (for working and standby battery set) NOTE: WHEREVER PAINTING IS MENTIONED FOR THE PUMPS,ENGINES AND MOTORS,SUBJECT WORK SHALL BE DONE AFTER SURFACE PREPARATION TO SA 2 ½ OR HIGHER; PRIMER WITH INORGANIC ZINC SILICATE OR HIGHER AND FINISH PAINT SHALL BE EPOXY.IN CASE OF CONTRADICTION AT ANY PLACE, SPECIFICATIONS GIVEN IN THIS NOTE ONLY SHALL BE FOLLOWED. 7.0) SCOPE OF SUPPLY OF HPCL: Diesel Lubricating oils Greases Water Electricity Automation Welding of pipes, etc required at Site Civil works Page 9 of 63

10 8.0) SUPERVISION SERVICES FOR ERECTION & COMMISSIONING: - Initial visit of service representative and finalization of pump skid layout, fuel piping routing, fuel tank positioning, panel positioning, cable routing, power cable requirement for panel, exhaust pipe location etc. and other details and freezing of layout plan for pump, engine and accessories and reconciliation of materials received at site to identify missing items, if any. The outcome of the visit shall be communicated by the Suppler to HPCL in writing along with clear advises, if any. During final visit, supervision of erection & commissioning work has to be carried out by the vendor. During the final visit, the vendor s representative shall check & confirm that: (a)the entire installation & piping connections are in accordance with drawings (b)the piping-free and piping-connected alignments are within acceptable limits (c)the Pump-sets are ready for trial and commissioning. The written intimation to the vendor shall be given by owner for commissioning visit and the vendor shall ensure that their personnel is available at site within 3-7 days from the date of intimation. The vendor shall quote his rates assuming that multiple visits would be needed for supervision of erection & commissioning as the Pump sets may be commissioned progressively one after another. Other requirements to be fulfilled by Supplier: - The scope also including brief training of the working personnel at site about predictive maintenance, do s & don ts, daily checks etc. - All other accessories between pump, engine, local panel and fuel tanks which are not mentioned specifically but required for successful commissioning of the system have to be supplied by the party. - The fire water system will be automated by HPCL through a separate agency and hence provision should be kept in the local panel for remote start at full speed, potential free contacts and other contacts for feedback & actuation. Page 10 of 63

11 TIME SCHEDULE Page 11 of 63

12 SUPPLY, SUPERVISION & COMMISSIONING OF FIRE FIGHTING PUMPS MAIN FW PUMPS: 5 (FIVE) MONTHS FROM DATE OF ISSUE O FOI /LOI/ PO, WHICHEVER IS EARLIER JOCKEY PUMPS: 4(FOUR) MONTHS FROM DATE OF ISSUE OF LOI/FOI/PO, WHICHEVER IS EARLIER NOTE: 1) Time for completion shall be reckoned from the date of issue of Fax/ Letter of Intent/Purchase Order by HPCL. 2) Time for completion shall include the time required for Design, Submission & obtaining Drawings & QAP/ITP approval from HPCL, Manufacturing, testing, Inspection and Delivery at Site as per requirements of Contract Document and instructions of HPCL Engineerin-Charge. Page 12 of 63

13 TECHNICAL SPECIFICATIONS Page 13 of 63

14 TECHNICAL SPECIFICATION FOR MAIN Pump-Engine Sets & JOCKEY Pump-motor sets 1) FIRE WATER MAIN PUMPS MATERIALS OF CONSTRUCTION FOR ALL THE PUMP PARTS SHALL BE IN ACCORDANCE WITH IS: (RE-AFFIRMED 2002) AND IS: (REAFFIRMED 2001) 1) Pumps shall be direct-coupled. Belt driven pumps will not be accepted. 2) Parts of pumps like impeller, shaft sleeve, wearing ring etc. shall be of non-corrosive metal. 3) Pumps shall be capable of discharging 150% of its rated discharge at a minimum of 65% of the rated head. The shut-off head shall not exceed 120% of rated head. 4) For diesel engine driven Main fire water pump, the rated horse power of the diesel engine shall be higher of the following two values: (a) 20% in excess of the maximum horsepower required to drive the pump set at its duty point. (b) The BHP required to drive the pump set at 150% of its rated discharge. 5) The pump shall be manufactured, tested and marked in accordance with IS Specification for pumps for firefighting systems. 6) The pump rated capacity, total dynamic head and other performance requirements shall be as per the requirement indicated in the pump data sheet. 7) The pump shall be designed to have the best efficiency at the specified duty point. The pump set shall be suitable for continuous operation at any point within the range of operation wherever specified. Page 14 of 63

15 8) The pump shall have a continuous rising head capacity characteristic from the specified duty point towards the shut-off point, the maximum being shut-off. The horse power characteristic shall preferably be non-over loading type beyond the rated capacity point. 9) The material of construction for components other than those specified in IS:12469 & 5120 shall be as per standard of the pump manufacturer and shall be indicated separately. 10) The pumps shall be suitable for parallel operation. 11) The pump set shall be designed in such a way that there is no damage due to reverse flow through the pump which may occur due to any mal-operation in the system. HPCL will provide NRV on discharge side. 12) Pump along with its drive shall run smooth without undue noise and vibration. 13) The main pump casing shall be horizontally split casing type and the jockey pump shall be end suction back pull out as specified in the data sheet enclosed. 14) Replaceable / renewable wearing rings shall be provided for both the casing and the impeller or for the casing only. 15) The complete assembled unit shall be designed so that all covered parts including shafts and bearings shall be easily accessible for inspection, maintenance and replacement with minimum down time. 16) The rotor assembly with impeller and shaft sleeve shall be dynamically balanced at 150% of operating speed. 17) Pump casing shall be tested at 150% of shut-off head or 200% of rated total head whichever is higher. 18) In case of end suction back pull out type pump, flexible spacer coupling shall be provided. Coupling guard shall be provided for all types of pumps. 19) Suction and discharge flanges shall be drilled in accordance with the standard IS Page 15 of 63

16 20) The gland packing should be easily accessible for changing without having to disassemble the pump. 21) A common base plate mounting both for the pump and drive shall be furnished. The base plate shall be of rigid construction, suitably ribbed and reinforced. Base plate and pump supports shall be so constructed and pumping unit so mounted as to minimize misalignment caused by mechanical forces such as normal piping strain, hydraulic thrust etc. Suitable drip taps and drip lip shall be provided. 22) THE MAIN PUMPS SHALL BE PROVIDED WITH AUTO CUT- IN/ CUT-OFF FACILITY WITH PRESSURE DROP IN FIREWATER NETWORK 2) DIESEL ENGINE The prime mover of the main pump shall be diesel engine as indicated in the data sheet. i General Suitable diesel engine to drive the main fire water pump shall be supplied with all standard accessories. While rating the diesel engine, the site conditions and climatic data of the place of installation shall be taken into account. The engine shall be capable of delivering the rated output continuously. The diesel engine shall be multi-cylinder type four-stroke cycle with mechanical (airless) injection, cold starting type. All parts susceptible to temperature changes shall have tolerance for expansion and contraction without resulting in leakage, misalignment of parts or injury to parts. ii Diesel Engine The Engine shall be: (a) (b) Of the compression ignition mechanical direct injection type, capable of being started without the use of wicks, cartridges, heater plugs or ether, at an engine room temperature of 7 C and shall accept full load within 15 seconds from the receipt of the signal to start. Naturally aspirated, supercharged or turbo-charged and either air or water-cooled. In the case of charge air cooling by Page 16 of 63

17 means of a belt-driven fan or of a belt driven auxiliary water pump there shall be multiple belts such that should half the belts break, the remaining belts would be capable of driving the fan or pump. (c) Provided with an adjustable governor to control the engine speed within 10% of its rated speed under any condition of load up to the full load rating. The governor shall be set to maintain rated pump speed at maximum pump load. (d) Provided with an in-built tachometer to indicate R.P.M. of the engine. Any manual device fitted to the engine that could prevent the engine from starting shall return automatically to the normal position. Engines, after correction for altitude and ambient temperature, shall have bare engine horsepower rating equivalent to the higher of the following two values: (d1) 20% in excess of the maximum brake horsepower required to drive the pump at its duty point. (d2) The brake horsepower required to drive the pump at 150% of its rated discharge. Note: In the case of engines guaranteed by the manufacturers as capable of being overloaded by 10% at the rated speed for one hour in any period of 12 hours consecutive running, the value under (d2) above may be considered as 10% lower than the horse power required to drive the pump at 150% of its rated discharge. iii Cooling System: A heat exchanger, the raw water being supplied from the fire pump discharge (taken off prior to the pump discharge valve) via a pressure reducing device, if necessary, to limit the applied pressure to a safe value as specified by the engine manufacturer. The raw water outlet connection shall be so designed that the discharged water can be readily observed. The water in the closed circuit shall be circulated by means of an auxiliary pump driven from the engine and the capacity of the closed circuit shall not be less than that recommended by the engine manufacturer. If the auxiliary pump is belt driven then there shall be multiple belts so that if half of the belts break, the remaining belts shall be capable of driving the pump. A failure actuated audiovisual alarm shall also be incorporated. iv Lubrication System Page 17 of 63

18 The lubrication system shall be self-contained with the following equipment: (a) Sump: To store sufficient oil for circulation, suitable sump shall be provided in the engine. (b) Pump: Suitable pump shall be provided for forced lubrication. (c) Filter (d) Lubricating oil cooler (e) Interconnecting piping v Air Filtration: The air intake shall be fitted with a filter of adequate size to prevent foreign matter entering the engine. vi Exhaust System: The exhaust shall be fitted with a suitable silencer and the total backpressure shall not exceed the engine maker s recommendation. When the exhaust system rises above the engine, means shall be provided to prevent any condensate flowing into the engine. All the hot parts located at the working level shall be insulated. The exhaust system has to be designed assuming stack height as per PCB norms. The exhaust system shall include: (a) Exhaust manifold. (b) Silencer: Sufficient length of straight pipe shall be provided after the exhaust silencer to leave the gases at sufficient height above the engine room and outside the room. (c) Expansion joint. vii Engine Shut-Down Mechanism: Page 18 of 63

19 The fire water system will be automated, hence the engine should be suitable for starting in a predefined sequence, the shutting down operation shall be manual operated and the engine should return automatically to the starting position after use. viii Fuel System: a) Fuel: The engine fuel oil quality and grade shall be as specified by engine makers. These shall be kept on hand at all times, sufficient fuel to run the engine on full load for six hours, in addition to that in the engine fuel tank. (b) Fuel tank: The fuel tank shall be of welded steel constructed to relevant Indian Standard. The tank shall be mounted above the engine fuel pump to give gravity feed unless otherwise recommended by the manufacturer. The tank shall be fitted with an indicator showing the level of the fuel in the tank. The inside surface of the fuel Tank shall be surface preparation to SA 2 ½ and provided with suitable primer and epoxy finish paint. The capacity of the tank shall be sufficient to allow the engine to run on full load for 8 hrs. Note: There shall be a separate fuel tank and fuel feed pipe for each engine. Fuel feed pipes: Any valve in the fuel feed pipe between the fuel tank and the engine shall be placed adjacent to the tank and it shall be locked in the open position. Pipe joints shall not be soldered and plastic tubing shall not be used. Auxiliary equipment: The following shall be provided: (a) Fuel pump, fuel injection and control system for compression ignition. (b) A sludge and sediment trap. (c) A fuel level gauge and a level switch of approved make to signal fuel less than or equal to 30% of tank capacity. (d) An inspection and cleaning hole. Page 19 of 63

20 (e) A duplex filter between the fuel tank and fuel pump mounted in an accessible position for cleaning. (f) Means to enable the entire fuel system to be bled of air. Air relief cocks are not allowed; screwed plugs are permitted. ix Starting Mechanism Provision shall be made for two separate methods of engine starting viz. (a) Automatic starting by means of a battery powered electric starter motor incorporating the axial displacement type of pinion, having automatic repeat start facilities initiated by a fall in pressure in the water supply pipe to the sprinkler and/or hydrant installation. The battery capacity shall be adequate for ten consecutive starts without recharging with a cold engine under full compression. (b) Manual starting by: Electric starter motor (thru Push Button in Panel or Key in Local start station) Note: The starter motor used for automatic starting may also be used for manual starting provided there are separate batteries for manual starting. x Governing System The engine shall be provided with an adjustable governor capable of regulating engine speed within a range of 10% between shut-off and maximum load conditions of the pumps. The governor shall be set to maintain rated pump speed at maximum pump load. The governor shall be capable of operating without external power supply. xi Instruments: Instrument control and protection required for the safe operation of the engine shall be provided. xii Codes and Standards for the Diesel Engine: Page 20 of 63

21 IS: Specification for performance requirements for constant speed compression ignition (diesel) engines for general purposes (above 20kW). xiii Tools: A standard kit of tools shall be provided with the engine and kept on hand at all times. xiv Name Plate A corrosion resistant nameplate shall be permanently attached to the pump and prime mover. The nameplate shall be stamped with the following information: Manufacturer s name Serial number Model number Rated capacity Rated head Speed in rpm Rating of the prime mover xv Painting The pump and prime mover shall be painted Fire red (Shade No.536 as per IS:5) and suitably marked for identification. xvi Protection Unpainted exterior like machined surfaces shall be coated with suitable rust preventive. All threaded openings shall be plugged and flanged openings shall be provided with full flange dia protective covers. The cover material shall be 4.5 mm thick metal plate bolted to the flange with a gasket in between using a minimum of four bolts. xvii Tags Each pumpset shall be identified by its purchase order number and equipment number by means of a tag. Tags shall be attached to the pumpset with a stainless steel wire. Page 21 of 63

22 xix Packing i) The pumpset shall be packed, securely anchored and protected for domestic shipment by rail or truck. All unmounted components shall be suitably crated and firmly attached to the main pump unit for shipment. ii) One set of shim plates as required for normal alignment iii) The purchase order number and equipment number shall be stenciled on the crate. iv) One complete set of installation, operation and maintenance instruction shall be packed with the pumpset. xx Approved makes: Kirloskar Oil Engines/Greaves/Cummins India 3) PANELS A. DIESEL ENGINE CONTROL PANEL Each diesel engine driven firewater pump shall have an independent control/ panel. 1. The panel shall be provided with 230 V power supply and shall give following Audio (A) and visual(v) alarms. Engine Fails to Start(A&V) Low lube oil Pressure(A&V) High Lube Oil Temperature(A&V) High Water Temperature(A&V) Low Fuel level(a&v) Engine Over speeding(a&v) Engine Running Normal(V) Fuel level Normal(V) Power-On(Battery Fully charged)(v) 2. In case the diesel engine fails to start even after receipt of command from the pressure switch, the succeeding engine should start immediately bypassing its own pressure switch automatically. Page 22 of 63

23 3. In case the preceding engine does not start due to failure of pressure switch and subsequent engine started due to drop in line pressure & actuation of its own switch then, the preceding engine should start automatically. 4. Set of potential free contacts should be provided to connect the panel to REMOTE panel. The panel shall consist of: Push buttons, Auto/manual selector switches circuits with auxiliary contactors and interlocks for starting/stopping/regulating of diesel engine pumps as per technological requirements mentioned elsewhere in the specification. Electronic timers shall be provided for achieving the logic of engine starting (for 3 trial starts) etc. Provision of auto start of engine driven Main pump sensed by pressure loss. Provision of terminals for interlocking for start/stop of engine from header pressure switches Facility to start engine manually by local push button. Panel should be suitable for engine with manual fully shut off arrangement for stopping the engine. Indication lamps and hour run meter. Requisite no. of NO/NC potential free contacts and wire up to terminal block for external interlocking of the jockey pump. Two numbers additional (spare) auxiliary contactors (24v DC 2no. +ve relays) for purchaser s use, fully wired upto terminal block. 1. Battery charger with provision of Boost and trickle charging and SC & O/L protection.two separate battery chargers shall be provided to keep both engine battery and stand by battery under float charge.the charge current should get adjusted automatically depending on the battery condition.the disconnection of any one of the batteries should not affect the system. One set of voltmeter and ammeter shall be provided for each set of battery. Change over facility to be provided for changing over the engine starter motor from main battery to standby battery without the need for reconnecting the cables.the system should withstand 600A min. continuous current and 5000A for short duration. Page 23 of 63

24 Indications and PB viz., Ac Supply on, Start Failure, Low lube oil pressure, High water temperature, Over speed trip, Low fuel level, Pump on demand, water heater on, header pressure normal, hour run meter, engine running, start, stop and reset PB. Switches like AC Supply on/off, Water Heater On/Off, Charge Trickle/Boost,Auto/Off/Manual mode, Hooter On/Off Ammeter for battery 1 & 2 charging and Dc Voltmeter. The control panel shall be floor mounted type sheet steel (2mm thk) enclosed, with hinged door completely wired with terminal block. The wiring shall be carried out with 2.5mm 2 PVC insulated, copper wires. Earthing studs (2 Nos.) shall be provided at two ends of the panel. APPROVED MAKES Metron Eledyne, Firetrol, Achyut, Gem, Sukrut. Battery Each diesel engine pump shall have independent 24 V DC lead acid battery with teak wood stand and accessories, rated for quick starting of diesel engine. All power and control cabling (supply) between diesel engine control panel and Engine/Battery Charger/Batteries (Working and standby) is included in the scope. The Battery shall be 1+1 ( 1 working + 1 standby) with manual changeover facility. 4) FIRE WATER JOCKEY PUMPS MATERIALS OF CONSTRUCTION FOR ALL THE PUMP PARTS SHALL BE IN ACCORDANCE WITH IS: (RE-AFFIRMED 2002) AND IS: (REAFFIRMED 2001) 1) Pumps shall be direct-coupled. Belt driven pumps will not be accepted. 2) Parts of pumps like impeller, shaft sleeve, wearing ring etc. shall be of non-corrosive metal. 3) The pump shall be manufactured, tested and marked in accordance with IS Specification for pumps for firefighting systems. Page 24 of 63

25 4) The pump rated capacity, total dynamic head and other performance requirements shall be as per the requirement indicated in the pump data sheet. 5) The pump shall be designed to have the best efficiency at the specified duty point. The pump set shall be suitable for continuous operation at any point within the range of operation wherever specified. 6) The pump shall have a continuous rising head capacity characteristic from the specified duty point towards the shut-off point, the maximum being shut-off. The horse power characteristic shall preferably be non-over loading type beyond the rated capacity point. 7) The material of construction for components other than those specified in IS:12469 & 5120 shall be as per standard of the pump manufacturer and shall be indicated separately. 8) The pumps shall be suitable for parallel operation. 9) The pump set shall be designed in such a way that there is no damage due to reverse flow through the pump which may occur due to any mal-operation in the system. HPCL will provide NRV on discharge side. 10) Pump along with its drive shall run smooth without undue noise and vibration. 11) The jockey pump shall be end suction back pull out as specified in the data sheet enclosed. 12) Replaceable / renewable wearing rings shall be provided for both the casing and the impeller or for the casing only. 13) The complete assembled unit shall be designed so that all covered parts including shafts and bearings shall be easily accessible for inspection, maintenance and replacement with minimum down time. 14) The rotor assembly with impeller and shaft sleeve shall be dynamically balanced at 150% of operating speed. 15) Pump casing shall be tested at 150% of shut-off head or 200% of rated total head whichever is higher. Page 25 of 63

26 16) In case of end suction back pull out type pump, flexible spacer coupling shall be provided. Coupling guard shall be provided for all types of pumps. 17) Suction and discharge flanges shall be drilled in accordance with the standard IS ) The gland packing should be easily accessible for changing without having to disassemble the pump. 19) A common base plate mounting both for the pump and drive shall be furnished. The base plate shall be of rigid construction, suitably ribbed and reinforced. Base plate and pump supports shall be so constructed and pumping unit so mounted as to minimize misalignment caused by mechanical forces such as normal piping strain, hydraulic thrust etc. Suitable drip taps and drip lip shall be provided. 20) THE PUMPS SHALL BE PROVIDED WITH AUTO CUT- IN/CUT-OFF FACILITY WITH PRESSURE DROP IN FIREWATER NETWORK 5) JOCKEY MOTORS I) GENERAL Motors shall be of squirrel cage TEFC design induction motors conforming to IS: 325. Motors shall be suitable for giving the rated output, without reduction in the expected life span when operated continuously under the following system conditions. 415V+ 10%, 3 Phase, 50 Phase, 50 Hz + 5% and, a combined, voltage and frequency variation of + 10%. Motors shall be suitable for full voltage, direct-on-line starting upto 22 kw or Star-Delta starting for motor ratings above 22 kw. Motors shall be capable of starting and accelerating the load with any of the above mentioned methods of starting, (without exceeding the specified limits of temperature) with applied voltage at its terminals between 80% and 110 % of rated voltage. Page 26 of 63

27 The locked rotor current of motors shall not exceed 600 % of the full load rated current. Motor's vibrations shall be within limits as per applicable standards. Motor's insulation shall be class 'F' with temperature rise limited to class 'B'. The motors shall be given tropical and fungicidal treatment for successful operation of motor in hot, humid and tropical environment. II) CONSTRUCTIONAL FEATURES The stator frame and end shields shall be fabricated steel or cast iron of high quality conforming to IS: 210 (1993). They shall be ribbed externally to maximize heat dissipation. The feet shall be integrally cast with the stator frame, bolted feet construction is not acceptable. The stator and rotor cores shall be of low loss, high permeability steel stampings duly varnished to reduce eddy current losses. The stampings shall be hydraulically pressed, keyed and clamped to ensure rigidity. The motor shaft shall be of cylindrical design made of high carbon steel. The cross section shall be chosen to provide high torsion strength and minimize deflection. The shaft shall be finely machined to ensure fit and eccentricity shall be minimized. Unless specified otherwise, the motor shall be with single shaft extension with slotted keyway. Motor shall be provided with half key. The motor shall be cooled by means of an external fan mounted on the rotor shaft. The fan shall be protected by a cowl which shall be bolted to the stator frame. The fan shall be of cast iron preferably. The body of the fan shall be provided with 2 numbers, diametrically opposite drilled holes to enable removal of fan without breakage. The fan shall be designed to ensure low noise and adequate ventilation. The fan should be suitable for bi-directional rotation. The motor shall be provided with ball/roller bearings with grease lubrication. Greasing nipples and arrangement for drainage of excess/old grease shall be provided as a standard feature. Seals shall be provided to ensure that excess grease does not reach the windings. The L10 life of bearings shall not be less than hour under rated conditions. Bearings shall be suitable for bi-directional rotation. Page 27 of 63

28 The terminal box for motor shall be of sheet steel /cast-iron and shall be mounted on R.H.S when viewed from DE side. The terminal box shall be suitable for rotation in steps of 90º. The design of terminal box shall be spacious to suit termination of armored aluminum conductor cable. Six ends of windings shall be brought to the terminal box and shorting links shall be provided. A) The terminal box shall be provided with gland plate. If required, cable spreader box/trifurcating box shall be provided additionally to facilitate termination of large size cables. Double compression brass cable glands shall be provided along with the motor. B) One no. internal earthing terminal shall also be provided in the terminal box as a standard feature. The terminal box shall also feature a cover plate. The cover plate shall be bolted to the terminal box with Allen bolts. Where space heaters / thermistors are specified, separate TBs for each shall be provided for these accessories. Terminal marking shall conform to IS: 4728 (1975) Phase terminals shall be stud type of FRP material. Terminals for space heaters shall be stud type; terminals for thermistor / RTDs may be clip-on type suitable for 2.5 sq.mm conductor. The rotor shall be dynamically balanced with half key. Other shaft mounted components viz fan, coupling half etc., shall be balanced separately. Balancing shall be carried out at rated r.p.m. of the motor. The balancing weights shall be firmly secured to the rotor. The balance quality grade shall conform to class G2.5 as per IS : 11723, Part I (1992). The motor shall be provided with lifting lugs/eye bolts to facilitate erection/ maintenance requirements. All nuts, bolts, studs shall be based on metric units. The motor shall be provided with a stainless steel rating plate with punched markings. Markings shall be provided as per clause no 20.1 and 20.2 of IS:325 (1996). The painting of motor shall be epoxy-powder-coated type. Final paint shade shall be as indicated in Ordering Data Sheet. Page 28 of 63

29 The overhang of the stator windings shall be given an additional coat of epoxy gel to minimize the effect of end turn forces at switch-on. The vendor shall furnish the details of bracing method employed. Stator slot wedges shall be of non-magnetic material. Rotor shall be of rigid cage design. Rotor bars shall be of high conductivity ETP copper and shall be firmly wedged in the rotor slots. The portion of rotor bars in the rotor slot shall be un-insulated. The rotor bars shall be brazed to the end short-circuiting rings, which shall be of annealed high conductivity copper. If retaining rings are provided in vendor s design, same shall be forged non-magnetic material. Motor rated 30 kw and above shall be provided with single phase anti-condensation heaters as a standard feature. The heaters shall be placed in the lower part of the motor and shall be accessible for easy replacement/maintenance. The main terminal box of the motor shall be rated for 40 ka/ 0.25 sec at 415V. The motor frame shall be provided with two diagonally opposite tapped holes for earthing along with required hardware viz. bolts/screws, plain and spring washers. The hardware shall be electro-galvanized type. III) PERFORMANCE REQUIREMENT i. Motor shall be able to start and accelerate under rated load at 80% of rated voltage, without exceeding the specified temperature. ii. If while running, the voltage drops to 70% the motor shall be capable of delivering rated torque and continue to run without stalling for 3 minutes. iii. The motor shall be capable of withstanding 150% of rated voltage for 2 minutes without damage. iv. The motor shall be designed to provide the required starting torque where speed-torque characteristics of load are included in the specification. Where the specification does not contain the load characteristics, motor shall be designed to provide minimum 160% starting torque. The pull-out torque of the motor shall not be less than 250% at rated voltage and frequency. Page 29 of 63

30 v. Motor shall be suitable for following starting requirements 3 successive cold starts 2 successive hot starts 6 equally spread starts/hour vi. For defining the safe stall time, the rotor temperature shall be limited to 3750 C. vii. The motor vibration in all three axes shall conform to the requirement of Normal class as per IS : 12075(1986). Vibration severity shall be preferably measured as vibration velocity. viii. The motor shall be capable of running at 120% of rated speed for 2 minutes in either direction of rotation. ix. The mean sound power level for motor when tested and measured in conformance to IS: (1987) shall be limited to class Reduced Sound Power as defined in the standard. x. The motor shall be capable of withstanding 1.5 times rated current for 2 minutes. xi. The value of full load speed, full load current and efficiency shall be as set out in IS: 8789 (1996) with tolerances as per Table I of IS : 325 (1996) IV) TEST REQUIREMENT i. All tests shall be carried out at the manufacturing works. Test methods shall be in accordance IS : 4029 (1967) ii. Vendor shall furnish Type Test Certificates. Type tests shall include following optional type tests as per IS : 325 (1996). a) Routine tests as per IS: 325 (1996) shall be carried out on all motors. b) Test for vibration severity. c) Test for noise level d) Temperature rise test at limiting values of voltage and frequency variation as given in this specification. e) Over speed test. Page 30 of 63

31 NOTE :- TPI shall witness the following:- Routine Test of motors. Performance Test. Hydro Tests. Strip Test. V) MOTOR DETAILS i) Design Ambient : 45 Deg. Celsius Temperature ii) Enclosure a) Class of protection : IP 54 b) Location : Inside Firewater Pumpshed iii) Class of insulation : Class F iv) Temperature rise above design : Limited to class B ambient v) Type of cooling : IC 410 (TEFC) vi) Duty type and designation : S1, continuous vii) Starting requirements a) Equally spread / hour 6 starts b) Successive cold : 3 starts c) Successive hot : 2 starts viii) Method of starting : DOL / Star-delta ix) Mounting requirements : a) Shaft Orientation : Horizontal b) Mounting : Foot x) Speed Refer pump specification xi) Terminal box a) Location of main TB (when : R.H.S viewedfrom DE) b) Rating of TB : 40 KA (0.25 sec) at 415V Page 31 of 63

32 xii) Anti-condensation heaters : Required for motors rated 30 kw and higher. Additional TB to be provided. xiii) Temperature sensing : elements Thermistors : For DOL start, 6 nos. to be provided in series for ratings 30 kw and above to 75 kw (excluding 75kw) xiv) Bearing type : Regreasable ball / roller anti friction xv) Bearing insulation : On NDE side for motors rated 75 kw and above. xvi) Vibration Severity : Limited to Normal class as per IS : 12075(1986) xvii) Noise level : Limited to "Reduced sound Power as per IS : (1987) xviii) Final paint shade : Fire red Note: Painting shall be epoxy resin based. xix) Torque characteristics a) Ratio of starting torque to rated : 1.6 torque b) Ratio of pull out torque to rated : 2.5 torque c) Ratio of locked rotor current to : 6.0 rated current xx) Overspeed : 1.2 times rated speed for 2 minutes xxi) Direction of rotation : Bi-directional VI) DOCUMENTATION REQUIREMENT AFTER AWARD OF ORDER i. G.A. drawings of motor, main terminal box, space heater TB, thermistor RTD T.B. Page 32 of 63

33 ii. Wiring diagram for space heater TB, thermistor/rtd T.B. iii. Motor data sheet duly filled up. iv. Routine test certificates v. Quality Assurance Plan for Client s inspection vi. Motor characteristics curves: a) Speed-torque b) Current-time c) Thermal withstand d) P.F. vs. load e) Efficiency vs. load f) Current-speed g) Speed-time VII )APPLICABLE STANDARDS AND CODES i IS : 3-phase induction motors. IS : Specification for Flame proof, ii Re-affirmed 1993 enclosure of electrical apparatus. iii IS : Designation for types of Re-affirmed 1991 construction and mounting arrangement of rotating electrical machines iv IS Re-affirmed 1991 : Degrees of protection provided by Enclosures for rotating electrical machines. v IS : Terminal markings for rotating electrical machines. vi IS : Guide for testing three phase Re-affirmed 1991 vii IS Re-affirmed 1991 induction motors : Guide for Selection of electrical equipment for hazardous area. viii IS : Designation of methods of cooling of rotating electrical Page 33 of 63

34 machines ix IS : Permissible limits of Noise level for rotating Electrical Machines x IS Re-affirmed 1991 xi : Mechanical vibration of rotating electrical machines with shaft heights 56 mm and higher-measurement, evaluation and limits of vibration severity IS 4722 (1992) : Rotating electrical machines xii IS 1231 (1974) : Dimensions of 3 ph. Foot mounted induction motor. xiii IS 8789 (1996) : Values of performance characteristics for 3 ph. xiv IS (1969) VIII) PREFFERED MAKES OF EQUIPMENTS Motors: Crompton GREAVES/Siemens/ABB/Bharat Bijlee Induction Motor. : Type of duty and classes of rating assigned 5.0) MANDATORY SPARE PARTS 5.1) MAIN PUMP-SET The following minimum spares are required are required for each Main pump Set shall consist of the following: SL.NO. PART QUANTITY REQUIRED FOR EACH PUMP ORDERED Page 34 of 63

35 1. Set of gaskets/packing ring/o ring 2. Mechanical seal where applicable 3. Other parts such as coupling bushes, coupling pins, etc. 1 set 1 No. As required 1 set means quantity required for complete replacement in one pump set. The following spare parts shall be offered for each diesel engine. a). Two sets of fuel filters, elements and seals, b). Two sets of lubricating oil filters, elements and seals, c). Two sets of belts (where used), d). One complete set of engine-joints, gaskets and hoses, e). Two injector nozzles f). One complete of set of piston rings for each cylinder g). One inlet valve & one exhaust valve The following spare parts shall be offered for each control panel. 24V 16 A Fuses- Ten Nos. 24V 5 A Relays- Ten Nos. 5.2) JOCKEY PUMP-SET The following minimum spares are required are required for each Jockey pump : SL.NO. PART QUANTITY REQUIRED FOR EACH PUMP ORDERED 1. Set of 1 set Page 35 of 63

36 gaskets/packing ring/o ring 2. Mechanical seal where applicable 3. Other parts such as coupling bushes, coupling pins, etc. 1 No. As required 1 set means quantity required for complete replacement in one pump set. 6.0) INSPECTION i ii The equipment shall be inspected by the Purchaser and/or TPI agency at manufacturer s works prior to dispatch. The equipment will be inspected as per the tests pre-identified in the approved Quality Assurance Plan (QAP), relevant approved drawings, specifications, data sheet etc. The contractor shall finalize the QAP, get it done vetted by TPI (in accordance to the technical specifications attached with this tender document and codal requirements whichever is more stringent) and then obtain HPCL s approval within two weeks after placement of order on this TPI vetted QAP. iii The purchaser shall have free access to the manufacturer s works to carry out any stage inspection to ensure the quality of the equipment being manufactured. iv. The inspection call shall be accompanied by internal inspection/test reports by the manufacturer ensuring that the equipment has been manufactured and tested as per the requirement/approved QAP. v The manufacturer shall furnish all relevant documents and test certificates as required by the inspection agency during inspection. Materials shall be tested only in recognised test houses. vi The contractor/manufacturer shall provide all necessary assistance to the inspection agency during inspection. vii The contractor shall provide all required measuring instruments to carry out the inspection. These instruments shall be having valid calibration certificate. Page 36 of 63

37 viii The inspection agency shall have the right to insist on re-testing of any material / recalibration of instruments. The charges for such tests shall be to the account of the contractor only. ix No equipment shall be dispatched without inspection and receipt of inspection certificate and dispatch clearance from the Third Party Inspection Agency. x In case of waiver category items, the same shall be pre-identified in QAP itself. For such items, the contractor shall furnish necessary certificates as agreed upon. For these items also, the contractor shall obtain inspection waiver certificate and dispatch clearance from the inspection agency before dispatch of equipment. xi Issue of inspection certificate/waiver certificate for any equipment does not absolve the contractor of his contractual obligations towards satisfactory performance of the equipment. Should any equipment be found defective in whole or part thereof after receipt at site or during erection/commissioning the same shall be made good by the contractor free of cost. 7.0) GUARANTEED PERFORMANCE The bidder shall indicate guaranteed performance parameters for the pump, such as rate of flow, delivery pressure, efficiency, specific power consumption etc. The tender shall also indicate guaranteed performance parameters for the diesel engine such as bhp, specific fuel consumption etc. as per IS: The performance factors of the pumps will be checked as per IS: 9137 class C'. 8.0) DATASHEET TO BE SUBMITTED BY VENDOR SHALL COVER THE FOLLOWING DETAILS. (A) FIRE WATER MAIN PUMP & DIESEL ENGINE DATA SHEET A.1 : FOR LONI TERMINAL REVAMPING PROJECT Plant LINE NO. 1 PROJECT LONI TERMINAL REVAMPI NG LINE NO. 3 AMBIENT TEMP Max: 55 deg Min: 8 deg Page 37 of 63

38 Pump Characteristics Pump Construction PROJECT 2 LOCATION LONI, PUNE, MAHARAS HTRA 5 No. of Pumps 6 Capacity of each pump 7 Total Head- Rated 11 Type of Horizontal Pump split casing 12 Casing VENDOR TO DESIGN 4 LOCATION COVERED SHED FOUR(4) 6 Suction Flooded Condition 680Kl/hr 9 Operation Parallel 85 m WC 10 Duty Continuou s 15 Shaft Sleeve VENDOR TO DESIGN Material of Construction 13 Impeller VENDOR TO DESIGN 16 Wearing Ring VENDOR TO DESIGN 14 Shaft VENDOR TO DESIGN 17 Stuffing Box VENDOR TO DESIGN 15 Gland Packing VENDOR TO DESIGN 18 Lantern Ring VENDOR TO DESIGN Liquid Pumped 20 Temp. 55 deg C 21 MS Companion Flange with nuts, bolts & gaskets Accessories & Services Required 19 Gland VENDOR TO DESIGN YES 25 Mandatory spares YES 22 Foundation Bolts YES 26 Erection Supervision YES 23 Common YES 27 Commission YES Page 38 of 63

39 Base Plate 24 Coupling Guard Driver Data 29 Prime Mover ing Supervision YES 28 Paint Fire Red Shade no. 536 as per IS-5 Diesel Engine Diesel Engine Miscellaneous 31 Local Start/stop Station 32 Pressure Gauge (0-20 kg/cm2) 33 Automation Facility in Control Panel 30 Paint Fire Red, Shade No. 536 as per IS-5 Yes 34 Local YES Control Yes ( 2 Nos for each pump) Yes Panel 35 Cabling between batteries and Control Panel YES A.2 : TALEGAON DEPOT PROJECT Plant LINE NO. 1 PROJECT TALEGAO N DEPOT PROJECT LINE NO. 3 AMBIENT TEMP Max: 55 deg Min: 8 deg Pump Characteristics 2 LOCATION TALEGAO N DABHADE 5 No. of Pumps 4 LOCATION COVERED SHED ONE(1) 6 Suction Flooded Condition 6 Capacity of 650Kl/hr 9 Operation Parallel Page 39 of 63