VAPOUR RECOVERY SYSTEM TO COMPLY EMISSION NORMS AT TALEGAON

Transcription

1 BOTTOM LOADING ARM SHALL HAVE FOLLOWING FEATURES:- 1.Design should be such that arms can fully cross over within the API RP1004 specific loading envelope. 2.Every Bottom Loading Arm should be fitted with API Coupler conforming to API RP All API Couplers should be easy to maintain with automatic latching and ergonomic ball type handle. 4.Bottom Loading System are designed around using 4 (100 mm ) bore Pipe, Valves, Meters, Strainers, Hoses etc. 5.Loading Rate of Bottom Loading Arms can be up to a maximum of 2400 LPM for a 4 piping system. 6.Bottom Loading Facility for MS will have a 4 Vapour Recovery Arm as well. Vapour recovery arm will be complete with poppeted vapour coupler to comply with API RP1004 standard. Coupler should also have a sight glass for visible warning of liquid in vapour line. 7.Bottom loading rack will require overfill and grounding assurance system with gantry plug and intrinsically safe signaling to truck connection as per API RP With Bottom Loading System the Tank Truck Driver should be able to carry out the following basic tasks:- (i) Park the Bottom Loading Tanker in correct location in the loading Area (ii) Connect the grounding and overfill gantry plug to the truck mounted overfill and Grounding system to enable the pumping system to achieve a permissive state (iii) Connecting the Vapour arm to the Vapour recovery connection on the truck for loading MS (iv) Connect Bottom Loading Arm API Coupler to the Tanker (v) Open Tanker Foot Valves / Emergency Valves and Compartment Vapour Vents (vi) Set the Flow Meter and start loading (vii) When loading is completed the Driver disconnects the Bottom Loading Arm and vapour recovery arm (after loading MS) and closes the Tanker Foot Valves Vapour Vents provided on the Manhole Covers on the Top of the Tankers. Page 1 of 15

2 GENERAL TECHNICAL SPECIFICATIONS This specification outlines the minimum requirement under which the manufacturer shall design, manufacture, test and supply the Bottom loading arm for loading / unloading operations of road tanker with bottom loading arrangement. In the event of failure, the spring must be contained in a heavy duty cylinder to avoid any injury to the operator. CODES AND STANDARDS The material of construction of the pipes, flanges, valves, joints etc. shall be in accordance with relevant ASTM standards. The specification of the pipes and flanges shall be in accordance with relevant ASME, ANSI, TTMA (Tank Truck Manufacturers Association), and API standards. Wherever international standards and codes are not available, vendor may follow internationally proven standards and practices with prior approval of owner. TECHNICAL REQUIREMENTS Bottom loading arm shall generally consist of base (input) riser, inboard arm, outboard arm with flexible hose, swivel joints, balancing arrangement, supporting arrangement and arrangement for parking position dummy Adapter for parking stand post Inboard The arms shall be of seamless pipes suitable for the hydrocarbon service. It shall be of seamless Carbon steel material to ASTM A106/Aluminium pipe material to ASTM B- 345(6061/6063T3) to avoid sparking. The material of construction of input riser shall be CS/Aluminium and inboard onwards aluminium alloy. The arm pipe thickness shall be selected for the specified design pressure, and the bending and torsional stresses encountered in the loading operations. Outboard Arm Drop hose stainless steel with braided hose conforming to AISI-321 equivalent with coupler end with the following features. 1. Stiffener at the end of hose pipe to be provided. 2. Corrugated inside hose shall be SS External braided shall be SS Both side of braided steel shall be SS 5. Continuous electrical continuity Page 2 of 15

3 API Coupler: VAPOUR RECOVERY SYSTEM TO COMPLY EMISSION NORMS Loading coupler automatic self latching type shall conform to API standards as per RP 1004 with 5/4 cams drip less design a Seal material should be compatible with petrol and diesel(ptfe or approved equivalent).coupler body shall be Aluminum Hard Anodized. API couplers to be supplied by manufacturers who can give the service for the couplers as and when required and should have trained service personnel in India. Approved makes: OPW/ LIQUIP/ ALFONS-HARR/ EMCO WHEATON/FORT VALE Balancing Arrangement The arms shall be counter balanced by compression spring assembly, torsion spring box and or gas strut with integrated locking spring, Oil-impregnated bronze bearing for carrying spring load to eliminate ferrous-to-ferrous contact, minimizes wear, ensures smooth operation, pneumatic cylinder or hydraulic cylinder. The balancing arrangement shall be such that the outboard arm remains horizontal in filled condition for pressure bottom loading arm and in empty condition for atmospheric loading arm. Balancing arrangement should have five year warranty from the date of commissioning or 6 years from the date of supply whichever is earlier. Approved makes: OPW/ LIQUIP/ ALFONS-HARR/ EMCO WHEATON/WOODFIELD Supporting Arrangement The arm shall be self supported on base riser location. The supporting arrangement shall be such that there is complete flexibility in operation. The supporting arrangement shall be such that no load or force due to bottom loading arm is transferred to piping. Grounding Arrangement Each bottom loading arm shall be electrically continuous, otherwise earthing conductors shall be provided across the non-insulating joints to make it electrically continuous and input will be given to the grounding unit. Vendor shall integrate and power on the grounding unit with the loading arm. Monitor Multi-purpose monitors per gantry to provide overfill protection, position sensor combined with ground assurance connector compatible with all common probes. The system shall also be compatible with the terminal automation software being provided by Page 3 of 15

4 another vendor and bottom loading arm vendor shall provide assistance to the terminal automation vendor to integrate the system for ensuring such protection. Suitable mechanism shall be available in the monitor to communicate with the optic sensor available in the Tank Truck to detect any overfill and in such an event the monitor shall immediately communicate with TAS and stop. vendor shall arrange to lay power cable (cable shall be FRLS type) from junction box to each monitor (one monitor per bay) proposed to be located on each bay. The power cable shall be laid in GI cable tray with proper clamping arrangement. Necessary communication cable from the monitor to each batch controller (supplied by the TAS vendor appointed by owner) shall be supplied and laid on vendor supplied GI trays. The communication cable shall also be FRLS type. All cable terminations shall be thru double compression flame proof glands (with CMRS, CCOE and BIS certification) of approved make. Output from the monitor is a single triple-ganged relay signal to provide a go or no-go control for operation of the gantry or tank farm. Indication is by red or green lamp and a lockable by-pass switch. Truck plugs may be standard or optic style. Ground assurance connector may be via truck plug, or ground ball socket, or crocodile clamp. The monitor shall be explosion proof housing for Class 1 Zone 1 and weather proof (IP65), monitoring signals intrinsically safe Class 1 Zone 0 suitable for operation with power supply 240V AC. Output (control) relay shall be triple-ganged for reliability and shall be normally open. Lockable by-pass switches to enable loading in emergency. Shutdown response time 0.5 seconds for all fault conditions. The primary swivel joint shall have the following specification SPECIFICATION FOR SWIVEL JOINT OF CARBONS STEEL MATERIAL SWIVEL JOINT MAKE : REMARK 1. DESIGN SPLIT TYPE It should allow replacement of main seals without removal of bearing balls and dismantling of swivel joint. Flanged swivels with two rows of rollers(balls and/or needles) and with viton type B seals are also acceptable 2. MATERIAL FORGED CARBON STEEL ASTM A 105 or CAST STEEL conforming to ASTM A 216 Gr WCB 3. SEAL Viton type B/Approved equivalent 4. BALL RACES INTIGRAL DESIGN HAVING HARDNESS OF MINIMUM 50 HRC SHOULD HAVE SMOOTH FINISH MACHINED ON CNC MACHINE. IT SHOULD HAVE MINIMUM 2 BALL/roller Page 4 of 15

5 RACES. 5. BALLS /ROLLERS HIGH CARBON STEEL HARDENED 6. SEALING SURFACE ANTI CORROSIVE LAYERED 7. INTERCHANGABILITY SHOULD BE 100% 8. DESIGN APPROVAL Design should be approved by Third party inspection agency for static and dynamic load of loading arm. 9. TYPE TEST Cyclic testing of Oscillations of min 270 degree & should be checked for pressure testing at 15 Kg under rotation after the same. Approved Makes: OPW/LIQUIP/ALFONS-HARR/EMCO WHEATON/WOODFIELD The intermediate swivel joint shall have the following specification SPECIFICATION FOR SWIVEL JOINT ALUMINIUM SWIVEL JOINT MAKE : REMARK 1 DESIGN SPLIT TYPE It should allow replacement of main seals without removal of bearing balls and dismantling of swivel joint. Flanged swivels with two rows of rollers(balls and/or needles) and with viton type B seals are also acceptable. 2 MATERIAL ALUMINIUM ALLOY OF I m GRADE AS PER BS SEAL Viton type B/ Approved equivalent 4 BALL RACES IT SHOULD HAVE REPLACEABLE BALL RACES OF STEEL AND SHOULD HAVE SMOOTH FINISH IT SHOULD HAVE MINIMUM 2 BALL RACES. 5 BALLS HIGH CARBON STEEL HARDENED 6 INTERCHANGABILITY SHOULD BE 100% 7 DESIGN APPROVAL Design should be certified by Third Party Inspection Agency for static & dynamic load of loading arm 8 TYPE TEST Cyclic testing of Oscillations of min 270 degree & should be checked for pressure testing at 15 Kg under rotation after the same. Approved Makes: OPW/LIQUIP/ALFONS-HARR/EMCO WHEATON/WOODFIELD Page 5 of 15

6 Non Return Valves Non-Sparking type non-return valve (Check Valve to ensure no reverse flow) shall be provided at the end of each Vapour Loading Arm before the same is connected to the vapour loading header provided in the gantry. The check valve shall be supplied as per the following Data Sheet: Sl.no Description Requirement 1 Standard, Rating and service API6D, 150#, MS vapour 2 Size 4 NB 3 Ends Flanged conforming to ANSI B16.5 with raised face having serrations 125 AARH 4 Valve Port Reducing Port 5 Body Cast Steel conforming to ASTM A 216 Gr WCB/ Forged conforming to ASTM A Cover Bolted with material conforming to ASTM A 216 Gr WCB/ ASTM A Disc Material conforming to ASTM A 216 Gr WCB/ ASTM A 105 with 13% Cr. Steel Facing 8 Body seat ring Renewable with Material conforming to ASTM A 216 Gr WCB/ ASTM A 105 with facing of suitable non-sparking material 9 Disc Hinge Material conforming to ASTM A 216 Gr WCB/ ASTM A 105 with facing of suitable non-sparking material 10 Hinge stud Bolt ASTM A 193 Gr B7 11 Cover nuts ASTM A 194 Gr 2H 12 Bonnet Gasket Spiral wound SS 316 with soft iron filler 13 Hydrotest pressure Body: 450 psi, Seat:315 psi 14 Pneumatic pressure 80 psi 15 Seats Shall be non-renewable integral type or Non-Integral seat ring seal welded type 16 Installation position Suitable for horizontal/vertical installation 17 Testing As per API 6D with zero leak 18 Approved makes Audco/KSB Pumps Ltd/ BHEL/Leader Valves/ BDK Industries/ Niton/ Steel Strong/ Associated Toolings India Page 6 of 15

7 DATA SHEETS FOR BOTTOM LOADING ARM ITEM NO. DESCRIPTION REQUIREMENT 1 Quantity As per Bill of Quantities 2 Model To be specified by Vendor 3 Ambient temperature 5 to 50 deg c Service MS Design pressure 10.5 Kgf/sqcm Operating pressure 7 Kgf/sqcm Flow rate Type Size and rating Battery limit connections Product feed direction 2400LPM Self supporting, high profile, over head (top to bottom) bottom loading arm suitable for above mentioned product service 4 suitable for connecting with battery limit connection 4 Flanged ends with raised face as per ANSI B 16.5, class 150 From below Balancing type Cross over function Inboard Arm/Primary Arm Out-Board Arm/Secondary Arm No. of swivels 4 Primary/Base swivel Spring Type (Torsion/Compression) / Gas Strut In the event of failure the Spring/Strut must be contained in a heavy duty cylinder to avoid any injury to the operators Shall have simple adjustment to balance the Arms. Required Schedule 40 seamless pipes carbon steel A106 / Aluminum pipe of ASTM B-345 to avoid sparking 4, seamless Aluminum pipe of ASTM B-345, Flexible Hose Pipe having SS convoluted with TTMA flanges as per AISI 321 with SS Braid. To act as electrically continuous. Inside corrugation of braided hose shall be of SS 321 and external braiding shall be of SS Flanged end with raised face and with holes drilled as per B16.5, 150#, Forged Carbon Steel conforming to ASTM A105 of Cast Carbon Steel conforming ASTM A 216 Gr WCB. - Double Ball race type with 3 Seal Design and Page 7 of 15

8 Intermediate swivel Interchangeability of intermediate swivel Coupler for connection to Tank Truck Working envelope Leak detection port, High Carbon Steel Hardened balls / Flanged Swivels with two row of rollers (balls and/ or needles), 3 seal design -The swivel design shall allow replacement of main seals without removal of bearing balls and dismantling of swivel joint - Grease relief system shall have a grease entry nipple and a pressure relief nipple to allow old grease to exit to prevent over pressurization of the swivel - Anti corrosive layer -Seals shall be viton type B or approved equivalent - Parking lock shall be provided -Flanged, 150# TTMA, Al alloy of LM grade as per BS Double Ball race type with 3 Seal Design and Leak detection port, -High Carbon Steel Hardened balls / Flanged Swivels with two rows of rollers (balls and/ or needles), 3 seal design -The swivel design shall allow replacement of main seals without removal of bearing balls and dismantling of swivel joint -Grease relief system shall have a grease entry nipple and a pressure relief nipple to allow old grease to exit to prevent over pressurization of the swivel -Anti corrosive layer - Seals shall be viton type B or approved equivalent Required 4 size as per API coupler (RP1004), 5/4 cams drip-less design, material shall be Aluminum Hard anodized Automatic push and latch type dry break coupler as per API RP 1004 type 5ml allowable spillage 4/5 nos Interlocking type (unable to open the valves unless the latches are triggered) latches Cast stainless/aluminium collar Aluminium Hard Anodized body End connections shall be as per TTMA As per API, The connector must be movable over a volume ("envelope") 8 feet long and 3.5 Page 8 of 15

9 Accessories Painting feet high, with the centerline of the connector 2.25 feet above grade, and at a distance of 6 feet to 10 feet laterally from the center line of a standpipe on the island Dummy adaptor with parking post for loading arm API coupler with position Sensor. Position sensor provided in parking adaptor is also acceptable Primer 2 coats of high build epoxy Zinc Phosphate, each coat of 50 microns (min) thickness Finish coat 2 coats of chlorinated rubber, each coat of 35 microns (min) thickness Page 9 of 15

10 DATA SHEETS FOR VAPOUR RECOVERY ARM ITEM NO. DESCRIPTION REQUIREMENT 1 Quantity As per Bill of Quantities 2 Model To be specified by Vendor 3 Ambient temperature 5 to 50 deg c Service MS vapour during loading operation Design pressure 10.5 Kgf/sqcm Operating pressure 7 Kgf/sqcm Flow rate 2400 LPM Density(Min/Max) 0.70/.86 gm per cc Viscosity(Min/Max) 0.9 cst / 5 38 deg C Maximum pressure drop Should conform to CEN regulations Type Self supporting, high profile, over head (top to bottom) bottom loading arm suitable for above mentioned product service Size and rating 4 suitable for connecting with battery limit connection Battery limit connections 4 Flanged ends with raised face as per ANSI B 16.5, class 150 Vapour feed direction From below Balancing type Cross over function Inboard Arm/Primary Arm Out-Board Arm/Secondary Arm Spring Type (Torsion/Compression) / Gas Strut In the event of failure the Spring/Strut must be contained in a heavy duty cylinder to avoid any injury to the operators Shall have simple adjustment to balance the Arms. Required Schedule 40 seamless pipes carbon steel A106 / Aluminum pipe of ASTM B-345 to avoid sparking with TTMA flanges 4, seamless Aluminum pipe of ASTM B-345, Flexible Hose Pipe having SS convoluted with TTMA flanges as per AISI 321 with SS Braid. To act as electrically continuous. Inside corrugation of braided hose shall be of AISI 321 Page 10 of 15

11 and external braiding shall be of SS 304. No. of swivels 4 Primary/Base swivel - Flanged end with raised face and with holes drilled as per B16.5, 150#, Forged Carbon Steel conforming to ASTM A105 of Cast Carbon Steel conforming ASTM A 216 Gr WCB. - Double Ball race type with 3 Seal Design and Leak detection port, High Carbon Steel Hardened balls / Flanged Swivels with two row of rollers (balls and/ or needles), 3 seal design -The swivel design shall allow replacement of main seals without removal of bearing balls and dismantling of swivel joint - Grease relief system shall have a grease entry nipple and a pressure relief nipple to allow old grease to exit to prevent over pressurization of the swivel - Anti corrosive layer -Seals shall be viton type B or approved equivalent - Parking lock shall be provided Intermediate swivel -Flanged, 150# TTMA, Al alloy of LM grade as per BS Double Ball race type with 3 Seal Design and Leak detection port, -High Carbon Steel Hardened balls / Flanged Swivels with two rows of rollers (balls and/ or needles), 3 seal design -The swivel design shall allow replacement of main seals without removal of bearing balls and dismantling of swivel joint -Grease relief system shall have a grease entry nipple and a pressure relief nipple to allow old grease to exit to prevent over pressurization of the swivel -Anti corrosive layer - Seals shall be viton type B or approved equivalent Interchangeability of Required intermediate swivel Coupler for connection to 4 ( 3 x 4 as per API coupler RP1004 Tank Truck(API coupler) standards compatible with tank truck adaptors) hinged poppet design with body having MOC Aluminum Hard anodized Sight glass to check Vapour condensation and reverse flow of Page 11 of 15

12 Working envelope Accessories Painting liquid in vapour arm. End connections shall be as per TTMA.Coupler shall be designed to ensure pressure drop as per CEN Regulations As per API, The connector must be movable over a volume ("envelope") 8 feet long and 3.5 feet high, with the centerline of the connector 2.25 feet above grade, and at a distance of 6 feet to 10 feet laterally from the center line of a standpipe on the island Dummy adaptor with Parking post for loading arm API coupler with position Sensor. Position sensor provided in parking adaptor is also acceptable. Primer 2 coats of high build epoxy Zinc Phosphate, each coat of 50 microns (min) thickness Finish coat 2 coats of chlorinated rubber, each coat of 35 microns (min) thickness Erection of all equipments supplied by the vendor as per this Tender shall be carried out by the vendor including testing wherever applicable as per the rates quoted in the price bid. The equipment shall also be commissioned by the vendor. SCOPE OF INSPECTION AND TESTING Equipment shall be subjected to stage wise expediting, inspecting and testing at vendor s/ sub vendor s works by owner or its authorized Inspection Agency (TPIA). Vendor shall submit Quality Assurance (QA) procedures before commencement of fabrication. Approved QA procedures shall form the basis for equipment inspection. Inspection and Testing at Vendor s / Sub Vendor s works shall include but not be limited to the following: Sr.No. Material Specification HPCL Requirement Vendor s Confirmation 1 Visual inspection of loading arms 2 Dimensional inspection of loading arms 100% 100% as per approved Drawing 3 Hydrotest 100 % Hydrostatic test of Page 12 of 15

13 complete bottom loading arm assembly at 1.5 times of design pressure for minimum 30 minutes with full assembly 4 Movement of complete Loading Arm 100% movement / operation of complete bottom loading arms by a single person and recorded easiness of operation for the complete working envelope 5 After assembly, the arms shall be subject to the following tests: A Balancing test This is conducted in loading arms to demonstrate that the arms are mechanically counter balanced. B Performance test (Maneuverability test of swivel ) Rotate the swivel joints for three cycles in forward and three cycles in reverse direction to demonstrate that swivels joints can be easily Operated. Torque required for operating the Swivel joint shall be measured Quantum of check 100% C All test certificates, indicating details of materials for inboard arm, out board arm and drop pipe and scope of inspection indicated above, shall be provided along with supplies. Also Page 13 of 15

14 verification of material of construction (thru. Mill Test report) of all components.all the above certificates shall be vetted by Third party inspection agency Quantum of check 100% D Life cycle testing of swivel joint of each type shall be done and the certificates shall be offered for verification during inspection. E Quantum of check Bending moment test for Springs and Base Swivel Joint Quantum of check 1 No. of each type of swivel Joint It shall be done and the certificates shall be offered for verification during inspection. Additionally bending moment. test shall be done for split flange type of swivel joint and witnesses by TPIA 1 No. of each type of swivel Joint F Forces required for movement of loading arms: Vendors shall arrange to provide a Force testing arrangement, such that the force is applied perpendicular to arm. The self weight of the mechanism shall be accurately measured prior to applicable of force Quantum of check 100% G Certificates for chemical Page 14 of 15

15 analysis of seal ring material from approved lab. Quantum of check 100% H Type test for pressure drop across the loading arms Shall be carried out though any approved reputed institute for one loading arm I Spring life cycle test It is to be carried for more than 2 lakh cycles and certificates to be offered for verification during inspection J Testing of O - Ring and SEALS 1 sample from each lot/ batch and internal certificates to be offered for verification during inspection Vendors to prepare QAP based on above Scope of inspection and get the same approved through TPIA and final approval of HPCL shall be obtained on it. In case vendor is unable to accept any of the above clauses then reasons for the same shall be provided in the vendor s confirmation column. However vendors to note that the bid may be liable for rejection in case of non-acceptance of any of the above clauses. NOTE:- 1. The bottom loading equipments as per BOQ should have compatibility to performance as per RP 6004 in meeting the point of tank truck equipments of terminal and party to confirm the same. 2. All the equipments shall have the approval from chief controller of explosive, Nagpur. 3. Comissioning spares for Bottom loading arm and vapour recovery arm shall be in the vendors scope. Recommended spares shall be listed separately and will be under vendor scope Page 15 of 15