1 general-facilities petrochemicals

Buildings Practice Facilities Plants/Petrochemicals

Chapter 1 General

of 27 2012 Int. P Eng Suraj Singh

An Industrial development- Processing Facility formation

1 It is necessary in interest of economical development that industrial project should be efficiently promoted for Industry being backbone of a nation, keeps nation moving

forward improving quality of life. 2 Sooner is industry created, better would be prospects for economy/nation. 3 Therefore, value engineering should efficiently be applied to product proposed to be

facilitated to enable consumer be delivered with/avail most economic & qualitative products.

4 When we talk of industrial development, we target to achieve potential industries for long term production of intended products that may cost in billions of dollars.

5 Its concept, front end design, design, execution would certainly quantify to considerable

cost & time. 6 All types of major industries require development in line to meet public or economy

requirement of nation/of inter nations. 7 What class of industrial should be promoted for modernization depends on various

relevant criteria as well as, development value engineering.

8 Oil & Gas, Power, Water Resources, Nuclear Energy & many other infrastructures, do require promotion, not only for an exclusive sake of commercial business, but also, for

sake of social, economical development & sustainability. 9 I have tried to include various procedures or steps in common that are required to

promote onshore downstream petrochemical facilities, which is meant for meeting

national & international requirements of natural products. 10 It should be kept in view that promotion of certain potential industrial unit is a national

planning job, which must be based on thorough feasibility studies & research/operational research relevant to long many years.

11 Since, promotion of such development effects to some extent, utilization of natural

resources available in earth store that should not be blindly explored, but a balance must be maintained for future generation to come.

12 It makes adopted decision must be based on certain criteria that available resources may not be exhausted at fast pace by current generation to affirmatively maintain sustainability.

13 Explorations must not be solely destined to just making money out of natural resources.

Policy decision- Authorization-Technology Promotion

1 Government should promptly workout relevant policy in a positive manner for time is extremely important factor that should be used properly to get optimum use of project,

provided adequate funds are available within allocation of budget or institutional financial borrowing should be made.

2 Value engineering should be properly studied by experts to reach a conclusion that proposed product shall be processed imparting no adverse impact to existing environment, shall be most economical in production cost, shall be easy to be

transported to consumer market or end user facility, shall be most beneficial to national society from every aspect/view of cost & economy uplift as well as, shall promote green

technology & provide benefits to all people globally in long run. 3 A right charter must be constituted at very initial stage of conception for a permanent

reference including various information such as, aim, target, policy, political impacts on

area & nation, rehabilitation & other bad effects, requirement of additional infrastructures, generation of employment opportunities in both stages of promotion of

project as well as, its operation & maintenance, technology, stakeholders, current value, earned value, long run value, continuous benefits, expected risks of all sorts, whether or


Chapter 1 General


not, other alternative products could be promoted to achieve better value engineering.

4 Sustainability development means state of art technology that has been developed for application on projects, which technology does not go against existing requirements &

neither, impacts adversely on availability of natural resources, when future generation require all such sources.

5 This means that both, current & future generations should enjoy availability of all

natural resources as well as, friendship with green technologies without compromising with positive effects of nature.

6 Value engineering shall play a significant role to many extents, when use of technologies promotions is concerned.

7 There could be options as far as, technologies are concerned, which options based on

considerable factors & various aspects would decide, which technological application shall deliver better results on proceeds of product in long term as well as, short term.

8 Short term facts could be consideration of land, design considerations, construction cost, product environment friendly impacts, transportation cost, availability of experts & artisans etc. while, long term considerations would be maintenance cost, life of projects

or facility, safety risks involved, public risks involved, future availability of alternate easy & economical technologies that be currently under research stage.

Facility requirement

1 Value Engineering effective application, Effective Technology, Product End User

Requirement Necessity, Approval & Financing, International competition, Cost effectiveness, Safety Health & Environment tenability, Sustainability.

2 Should these points be met by proposal, project may be given a go ahead subject to meeting other criteria.

3 Once Value Engineering factor has been included into plan consideration with full

integrity & incorporation of provisions in line with national & international policy for such evolutionary developments, there remains no meaning to delay projects, but

project’s initiation by Charter authorization by respective stakeholders should be done. 4 Finances have to be allocated to statutory requirements to give a ‘go ahead’ to various

phases or stages of project development, so that delivery be made in defined time for

follow up operations for consumers or end users. 5 Since facilities demand incorporation of inputs from various disciplines, personnel,

materials & equipment with licensed technology, every criterion must be kept in consideration for a final start up.

Facility Justification & Feasibility

1 Environmental sustainability - Cost viability in long term- Nationally beneficial to add

to economic growth - multipurpose approach & creation of employment, casual as well as, regular.

2 Export potential of product.

3 Processing Technology & availability of raw or natural resource materials. 4 Adequacy of availability of terrain & routes.

5 Selection of planning & execution mode. 6 Availability of expertise & experts along with all other inter related professionals. 7 Availability of all human & all other resources, their original sources, international

agreements for bilateral trades with producing nation, finalization of design rights, copyright, process technology license, agreement on various contract forms adoption,

agreement on international workforce migration for projects. 8 Public Private Participation or government responsibility or international joint ventures.


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9 Availability of relevant trade zones based on subsidy for industrial promotion in general

public interest for long term construction & operations. 10 Certainty of return by reliable proceeds after a defined set of years or, an assessed

duration after which, investment is made an asset for remaining life of plant facility. Components Elements of Certain Processing Facility - inclusions in general

1 Availability of natural gas or oil fields, from where, natural resources are being tapped out from offshore locations of various sea beds founded rigging platforms allowing

risers leading pipes to upstream onshore slug tanks. 2 Availability of all well equipped facilities of shipment, platforms, injections & risers for

raw oil delivery from seabed.

3 Availability of land for required downstream processing area onshore with acceptable terrain that may be used for operating complete chemical process engineering

applications used on well designed trains as well as, transportation of processed products & bye products to specifically, located outlets leading to consumers’ locations.

4 Plant /processing scheme & Technology both for green filed & brown field, supported

with authorization by legal license valid for defined period. 5 Liquified Natural Gas tanks made of cryogenic steel, RCC/PSC containments with

spillage & other components etc. for storage purpose at considerable minus temperature. 6 Plant processing trains elements, complete with detailed descriptions of heavy & light

industrial equipment

7 Utilities areas element for integration with plant equipment. 8 Off sites element for sub assistance to aforesaid.

9 Intake piping system arrangement for circulation & delivery into plant equipment for cooling process or application.

10 Seawater basin for storage of seawater to be used for cooling purpose during various

processes, delivery of cooling water to plant & then, recirculation for further cycle of processes cooling.

11 Piping, pipe supports, pipe sleepers & pipe racks for product transportation & relevant handling operational activities.

12 Service air & Instrument air circulation piping

13 Chlorination plant with complete systems package for purpose of chlorinating water for supplies to plant use.

14 Storage & Warehousing for physical handlings of subsidiaries 15 Drainage infrastructure from plant to receiving basin & then, to outfall structure through

discharge channels duly provided with metal lugs & channels

16 Ditches completely lined, to convey out to final discharge, storm water from various catchments areas of plant.

17 Complete Package drainage system for, oily water, acid water, dusty water, sewage etc. that comprises of hundreds of RCC manholes, many kilometers of pipe lines connection, with such manholes & chambers, leading & disposing to sewage treatment plants STPs.

18 Water line for whole site, for various purposes including loss prevention i.e. fire suppression, fire fighting with fresh water as well as, with back up seawater supply from

seawater reservoir or elsewhere. 19 Cooling water line provision throughout whole industrial area zone taking in water from

intake at sea, supplying to industries & then, through return headers, discharging to sea

directly, after being supplied once as well as, employing cooling water system technology to re-circulate used water, while only, make up water to be supplied.

20 Pipe supports, pipe anchors, general anchors, big anchors/thrust blocks at various spacing.


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21 Pipes supports to be connected to sleepers & direct supports using structural steel

connection for both, direct clamping as well as, achieving sliding action to make up for expansion, which supports are often, considerably heavy units for considerable size

pipe. 22 Electrical heat tracing provision for piping system carrying minus temperature liquid or

gas to keep pipe on required temperature, not allowing freezing of material for example,

Sulphur gas can freeze within pipe line. 23 Heat tracing works dedicatedly encompassing pipes, transferring thermal energy to pipe

& then, to internal minus temperature gas, so that gas does not freeze in pipe, but keeps on flowing at specified temperature & velocity.

24 Administration as well as, Amenities buildings elements for facilitating operation &

maintenance as well as, consumer supply/receipt station that should contain various offices with access control.

25 Electrical main station, substations, switchgears, package substations, pump houses, guard houses, visitor’s areas, ring main units, transformers, heavy duty armoured cables, centralised control to all such supporting, on site or off site buildings for electrical

distribution system & security system. 26 Central controlled as well as, Operations building to control whole plants operations

from one single location monitoring all engineering discipline plant surveillance 24 hours 7 days a week.

27 Consumer receipt stations to be used by consumer delivery control.

28 Intake pump houses & other processing Pump houses at various locations, duly integrated for controls all over plant facility.

29 Water retaining structures, such as below ground sumps, receiving basins, drainage channel, out fall discharge to sea.

30 Site security arrangements, fencing, surveillance, by installation of CCTV with state of

art technology. 31 Site telecommunications of all sorts for efficient use by operating personal available in

all security zones spread over entire facility. 32 All loss prevention arrangements including internal & external fire fighting. 33 All arrangements to cater for fire emergency, blast emergency or seismic emergency.

34 Fire tender station is significant to cater for this facility. 35 Adequacy of plant & non plant area of roads & paving, maintenance tracks, road

crossings, utility crossings, road culverts, pipe culverts, transit manholes, controlled defensive traffic movement & circulation etc.

36 Soil erosion protection for all machines & equipment so that all these equipment should

not damaged due to possible negative impact by heavy dust laden storms. 37 Facility bye product plants as extensions & all required elements for that.

38 All related civil engineering disciplinary structures for buildings, sheds, equipment vessels as well as, other processing & non processing equipment.

39 Vessels such as cracking furnace, wash water structures, cracked gas compressor,

propane compressor, ethane compressor, boilers, auxiliary boilers, various types of spheres, steel tanks, fuel towers, rotary equipment, reciprocating equipment etc. shall be

made part of plant with necessary foundations, for these elements or components to be constructed inline/according to defined requirement.

40 Massive concrete blocks shall be required for many such major foundations to found for

heavy vessels. 41 Civil engineering foundations structural requirement shall vary from a simple machine

plinth to independent footings, to combined footings, to strip footings to raft & piles as well as, massive block foundations.


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42 Concrete shall generally, be low heat producing cement based manufactured by using

micro silica or GGBS ground granulated blast furnace slag replacement up to 70% extent and also, pulverized fly ash PFA replacement.

43 Supporting bases of pipe racks may be allowed either by steel structure or RCC construction.

44 Foundations of pipe racks shall generally be of RCC bases / independent footings.

45 Overhead crossing shall be required at many locations for various en route piping to jump over existing plant circulation roads.

46 Such overhead crossings could be constructed using structural steel. 47 Cathodic protection, both critical & non critical requirement for centralised corrosion

control of plant reinforcement, from a central control sacrificial anode station shall also,

be provided for long term corrosion monitoring & controls respecting reinforcing bars. 48 Earthing provision for all individual structures, equipment as well as network.

49 Coloured (Green, Red etc.) Covered Cable trenches RCC walled, buried directly to ground or cable ducts shall also, be included in design forming a major part of certain facility.

50 These ducts shall be coordinated to various interface crossing requiring site resolutions to protect plant supporting services interface clashes.

51 Heavy duty Concrete pavement shall be provided in all plant areas for required purpose of its maintenance respecting machines as well as, movement of heavy vehicles.

52 On other areas, where no pavement is included, stone aggregate shall be spread &

compacted to avoid soil adverse impact effect on all vessels or equipment. 53 In addition, all important administration areas shall be allowed an attractive soft & hard

landscape architectural provision. 54 Access security arrangement shall also, be made with automatic controls using card

readers or finger prints scanning etc. & installation of CCTV for continuous control &

records. 55 Inclusion of flare towers & radio masts is also, contemplated.

B Components brief LNG tanks

1 These components are meant to store Liquefied Natural Gas 80000cum capacity each within steel tank.

2 A RCC with pre-stress arrangement for cables structure of about 80 m dia. 800 mm thick wall as we as, a height of 50 m was included for spillage prevention.

3 Each tank base was allowed soil improvement including many meters depth of granular

fill inlayers not more than 200 mm thick. 4 RCC raft foundation was laid on improved fill pre engineered formation, after ensuring

required design safe bearing capacity. 5 Top of tank was covered with a permanent formed cupola structure raised to level by

compressed air pressure lifting.

6 Cryogenic steel was included to maintain about (–) 60 degrees C temperature of condensed gas.

7 Concrete of circular walls was poured using kwickform proprietary custom designed formwork in 5 m lifts each.

8 A cantilever operational platform was constructed on cupola.

9 An onsite designed plumbing system was erected temporarily for curing activity throughout on full height of tank to cover all vertical areas for curing.

10 Each LNG tank was provided with a RCC spillage below ground tank externally.


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Compressors

1 Compressors are to be installed as a part of various processing trains for Ethylene production unit.

2 Being heavy reciprocating machines to be installed on massive foundations at elevated levels, tabletops would be constructed resting on massive concrete foundation.

3 Foundation concrete for one compressor being 400 cum about 25m long, 12 m wide as

well as, 2 m deep well designed machine foundation for a reciprocating vibratory equipment.

4 This foundation carries thick columns above to support tabletop. 5 Steel plate inserted between equipment & epoxy grout. 6 Tabletops are constructed of thick framed slabs resting on thick columns.

7 Planned arrangements of table top slabs are complicated in all respects regarding civil as well as, mechanical inserts.

8 Such types of thick & massive elements require special type of cement probably with high GGBS replacement, which could also, be pulverized fly ash or Microsilica.

9 Particular arrangements are worked out for curing solutions for such low heat generating

cements to effect thermal curing methods utilizing no direct contact with curing water.

Cracking gas furnaces 1 This meant for purpose of cracking gas received from refinery as bye product for

transmission to compressors for production of ethane as well as, propane.

2 These are tall heavy structures, vertically oriented in group of vessels & founded on a common base.

Other structures

1 Included wash water structures, auxiliary boilers within processing trains.

2 Also, included various vessels, such as spheres to contain gases as well as, tanks for storage

3 Foundations for tanks are generally constructed of RCC ring beams. 4 Other structures are generally, provided with independent footings/ stripped using grade

beams.

Seawater basin

1 A RCC open reservoir meant to continuously collect water from sea through 2 # 84” pipes, store in this reservoir, supply to plant various trains requirement & after cooling installed system, used water to be disposed off from various industrial locations to this

receiving basin & then, further to outfall chamber, should this water may not be reused for process unit system cooling.

2 It is a huge voluminous open structure constructed of RCC base slabs provided various contraction & construction joints during its executive on site construction, peripheral retaining walls up to 12 m high, not more than 9 m length of panels, as well as covered

pump house unit area & baffles. 3 Such structures must be water tight effectively from all locations of water storage

portions, duly tested for water tightness conforming to BS 8007 criteria. 4 Concrete protection is applied for both below ground as well as, above ground RCC

surfaces.

5 Testing would be little cumbersome for many days & factor to be used for computing evaporations losses is complicated since, no pertinent standard data being available.

6 A parallel arrangement as a device has to be arranged to observe real evaporation loss model, result of which could be applied to reservoir evaporation observations.


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7 Many days shall be involved from start of water filling, autonomous healing of surfaces

& then, performing stage wise applicable water tightness testing. 8 It could amount to 2 to 3 weeks for testing performance & if, results being satisfactory,

removal of water from reservoir or otherwise, after removal of water, making repairs of water leakage as recorded, by an application of resin injections to epoxy repairs followed by another water tightness testing for final observation of leakage.

Many other stationary

1 as well as vibratory equipments are included for processing plants for which foundations are constructed accordingly, either as footings bases or combined footings.

2 These horizontal or vertical vessels are erected on these bases connected using anchor

bolts & grouting done between sitting steel plate & top of concrete. 3 For vibratory equipment, epoxy grouting is applied while, for stationary equipment,

cement based grout is suitable.

Sump chambers

1 These covered chambers are used for collection of water from various catchment areas & constructed of RCC underground structures duly tested for water tightness using BS

8007 criteria. 2 Concrete protection is applied for both below ground as well as, above ground surfaces. 3 Manholes, catch basins, rainwater ditches, etc. are constructed using RCC.

4 Manholes are meant for sewerage line, oily manholes for oily discharge, catch basins for rainwater.

5 Generally, these units would be provided in large numbers for certain plant area, making it preferable to produce by pre casting on site for which, all working details for proposed yard are required to be issued to site.

Open ditches are constructed for discharge of storm water.

1 These ditches can also, be used for purpose to give way to fire water disposal during any fire break out on installation.

2 This may also, be used for demanded purpose of intended water line maintenance

discharge from some single loop. 3 At commencement, ditch section is considered shallow, but as it reaches moving within

various catchment areas, ditch section is considerably, deepened like a big city drain.

Piping

1 Carbon steel or Ductile iron or Fiber reinforced plastics family GRP, ERP, GRE etc. are included depending on requirement & structural adequacy to sustain various imposable

stresses. 2 Stress analysis is carried out for various loops giving location of various supports as

well as, anchoring requirement.

3 Various types of supports are designed for varying diameter of pipes for on ground or underground or aboveground use.

FRP (Fiber Reinforced Plastic) Pipes

1 RTRP stands for ‘reinforced thermosetting resin pipe’, a composite material consisting

of a thermosetting polymer, a type of polyster reinforced with glass or other fibers that provide strength & stiffness to a composite material.

2 Different types of resins used for manufacturing GRP, GRV & GRE pipes are ‘Isophthalic resin’, ‘Vinylester resin’ & ‘Epoxy resin’ respectively, that are selected


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according to required properties like chemical resistance, temperature resistance & other

mechanical properties. 3 Resins provide thermal & chemical properties, such as glass transition temperature,

resistance to heat, chemical resistance etc. required for finished product. 4 Properties of GRP pipes can be varied by changing ratio of raw materials as well as,

winding angle.

5 These pipes consist of three layers adherent to each having different characteristics in relation to functional requirement.

Layers 1 Inner Liner-Veil (Glass), Resin: CSM (Glass), Resin 2 Structural wall-Roving (Glass), Resin

3 External liner-Veil (Glass), Resin

Composition 1 Inner Liner-Veil (Glass), Resin: CSM (Glass), Resin a Inner Liner layer is chemical resistant due to being in direct contact with fluid &

therefore, responsible to resist chemical corrosion as well as, permeability. b Internal surface is particularly, smooth to reduce fluid head losses & also, opposes

growth of minerals & algae. c This Liner has two monolithic sub layers. d Inner one in contact with fluid is reinforced with glass veil with resin content 90 %

while, outer one reinforced with CSM glass with resin content 70 % by weight. e Standard liner thickness is about 0.5 to 1.5 mm.

1 Structural wall a Roving (Glass), Resin

b Glass Reinforced layers guarantee mechanical resistance of whole pipe against stresses due to internal & external pressure, external loads as well as, thermal loads.

c For GRP / GRV pipes, this layer is obtained by applying on previous, partly cured inner liner continuous roving of glass, wetted with resin under controlled tension.

d For GRE pipes, structural wall is wound directly on a wet liner.

e This layer can contain aggregates like silica sand if allowed by specifications while, thickness depends on design conditions.

1 External liner- Veil (Glass), Resin a Topcoat or external liner is an outer layer of pipe consisting of pure resin.

b UV protectors may be added if so required, to protect pipe from effects of solar exposure.

c In case of meeting severe exposure condition like aggressive soils or very corrosive environment, this external liner can be reinforced with a surfing veil or added with filters or pigments.

d Fiberglass composites consist of glass fiber reinforcements, thermosetting resins & additives, designed & processed to meet specific functional performance criteria.

General 1 Amount, type & orientation of glass fibers in pipe provide mechanical strength. 2 C Glass, E glass & ECR / Advantex glass, are used commonly depending on pipe

application. 3 Various forms of glass reinforcements are named as surface veil, chopped strand mat

(CSM), chopped roving, filament roving & woven roving (WR). 4 Raw materials like catalyst, accelerators, inhibitors, aggregates & pigments are used


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together with resin & glass reinforcements to achieve desired properties of fiber glass

product. 5 Catalyst is an organic compound, which when added to resin in presence of an

accelerator, determines polymerization reaction at ambient temperature. 6 Accelerator is a chemical compound used together with a catalyst to shorten

polymerization time.

7 Inhibitor is added to resin to reduce reactivity at ambient temperature. 8 There are two manufacturing processes Dual helical filament winding process & another

being Continuous winding process (Drostholm)

Pipe racks

1 Are used for required purpose of running piping from one point to other over ground levels.

2 These are generally constructed of steel structures founding on RCC footings but, RCC frames structures are also, used.

3 Several km of pipes are run over these racks supported & anchored to rack structures.

4 These are fully accessible structures for maintenance purpose. 5 Open steel or plastic flooring is provided on decking.

1 Heat tracing 2 Is applied on piping carrying minus degree gas, which may freeze during flow & block

flow within pipes, for protection of which, heat is continuously, maintained on piping to keep borne/carried gas in condensed form.

3 Various loops are provided on piping routes for various purposes. Pipe supports / sleepers

1 Are used for purpose of carrying pipes at near ground levels. 2 These are RCC units located at defined spacing.

3 For direct support of pipes, steel structural supports are employed remaining either connected or touching pipe by shoes over lengths at various spacing meant for purpose of sliding also.

4 For deciding locations of such supports & their anchorages, stress analysis is conducted that dictates required spacing, dimensions & pipe structural base design.

5 For a pipe of dia. not more than 4 m, not more than 12 m spacing is adopted. 6 For other smaller dia. pipes, spacing depends on standard length of pipes. 7 Pipes that need sliding movement at joints are provided with such a base that allows

movement of pipe in direction of its run. 8 For that purpose, PTFE (Poly Tetra Fluro Ethylene) bearings, fixed on steel plates, duly

designed to withstand imposed forces, are provided. 9 Below pipe support shoe steel portion, a stainless steel plate is provided so that, this

plate slides over PTFE pads.

1 Anchor sleepers, big sleepers, thrust blocks etc. are employed at various

points/locations depending on stress analysis requirement on en route pipeline. 2 These are thick & voluminous structures requiring thousand cum RCC for an individual

sleeper connecting a group of pipes.

3 On pipe loops, various kinds of stresses from all directions are imposed upon during operations or flows, which are resisted by these sleepers.

4 At change in directions of pipe routes as well as, at T locations etc. big sleepers or thrust blocks are provided to resist resultant forces.


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5 These sleepers are constructed as RCC massive blocks.

1 Access platforms are constructed to access to an area above pipe level for maintenance

purpose. 2 EOT cranes are installed for such maintenance as well as, lifting & placing pipes &

other operating items in shops.

3 These also, meet crossing over pipes requirements. 4 Proper ladders, handrails & open floorings are provided for safe access.

1 RCC box culverts 2 Are included for various crossing pipes below roads (road crossing).

3 Pipes culverts are also, included wherever required. 4 For accommodation of spillage tanks, embankment is constructed around to

hold/contain oil during spillage. 5 Pipes are connected to culvert’s base slab using steel connecting arrangements. 6 Enough space is allowed for maintenance purpose for free movement as well as, for

circulation.

1 Receiving basin 2 Is meant for collection of used water from processing units for intended purpose to

further discharge into provided outfall at sea.

3 This basin is also, given a considerable structure size for collecting water from various returning piping headers discharge, letting it accumulate & then dispose into outfall

channel for further permanent discharge into sea. 4 Various types of steel stop logs are installed to control flow according to provided

capacity of channel & receiving basin keeping abreast also, relevant maintenance

function of provided piping. 5 Structure consists of RCC retaining walls in flow direction & RCC base slab.

Flare towers 1 Are required to establish a system to dispose of safely into environment released gases

that cannot be used any further, keeping in view that composition effect of such disposable gas, does not deteriorate existing environment.

2 Height of such towers is kept considerable, so that gases are burnt away into environment safely.

3 Proper arrangements are designed for founding as well as, checking stability of such tall

structure.

Pump houses 1 Are installed as large size & highly elevated steel buildings housing a train of various

pumps, electrical equipment, chlorination plant, rotary drums, intake equipment etc.

2 Piping is routed on ground, vertically as well as, horizontally on various types of supports having complex design.

3 Various types of structural steel access platforms are built for operational & maintenance purpose.

4 Water is pumped into supply manifolds located just outside, where chlorination is

applied & pipes are run to main route on ground up to various industrial users. 5 Hundreds of thousand cum RCC structures are built for supporting bases as well as, for

anchoring arrangements depending on pipe route dictating supporting requirements


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General components for other facilities

1 ‘Train’ indicates separate process trains. 2 ‘String’ indicates parallel process lineups of equipment within a train

3 ‘Common’ to be used for equipment that does not exclusively belong to one train, but serves total complex.

4 Process / Unit:

1 Slug Catcher - Condensate Stabilisation (Column) - Flash Gas Compression - Acid Gas Removal - Dehydration, Mercaptan and - Mercury Removal Unit (Operating +

Regeneration) 2 Sulphur Recovery Unit; Sulphur Degassing - Claus Offgas Treating - OffGas Thermal

Oxidation - NGL Extraction and Fractionation (Overall) - Refrigeration Unit - LPG and

Ethane Treating Unit (LETU) - Field Condensate Treating - Plant Condensate Treating - LIN & LOX Storage & Vapourisation - Air Separation Units (ASU’s) - SGP Reactors -

Syngas Treatment - Steam Methane Reformer SMR Unit - One SMR plus one Pre-reformer 1x 50% One SMR plus one Pre-reformer

3 Hydrogen Manufacturing - One High Temperature Shift (HTS) and PSA unit with

compression 1 x 50% One High Temperature Shift (HTS) and PSA unit with compression - Heavy Paraffin Synthesis - Water Distillation Unit - Catalyst Activation

and Regeneration - Light Ends Stripper - Light Detergent Feedstock 4 Heavy Paraffin Conversion - Synthetic Crude Distiller - High Vacuum Unit 5 Catalytic Dewaxing - Base Oils Re-Distillation

Reliability and availability,

1 Particularly, system uptime, are key project drivers. 2 A ‘systems effectiveness model’ shall be developed for complex, comprising base case

configuration of offshore facilities and GTL (Gas to liquid) plant configuration FEED

for project units, so that required overall system effectiveness of 335 stream days per annum is reached in a cost effective manner.

3 Offshore development concept is based on direct transportation of produced fluids and gas from wells on platforms to shore without any offshore process or treatment.

4 From each platform, shall be multiphase carbon steel trunk line to common slug catcher.

5 Chemical injection and regular pigging shall be applied for corrosion as well as, hydrate formation inhibition to provided carbon steel lines.

6 Produced fluids are received into slug catcher in upstream onshore facilities. 7 Onshore upstream - comprises Slug Catcher - Condensate Stabilisation - Acid Gas

Removal - Sulphur Recovery (Claus Unit) and Storage - SRU Offgas Treating or SCOT

Unit - Dehydration and Mercaptan Removal - NGL Extraction and Fractionation - Final treating for finished NGL products: LPG and Ethane Treating Unit-Field and Plant

Condensate Treating 8 On Onshore Upstream facilities, Condensate and water / kinetic hydrate inhibitor (KHI)

& corrosion inhibitor ex slug catcher are separated.

9 Water is sent to a dedicated effluent treatment, which caters for KHI and possible saline components.

10 Condensate is stabilised and treated (for sulphur removal / conversion) for export sales. 11 Wet feed gas ex slug catcher is routed to gas treatment followed by NGL extraction and

fraction.

12 Gas treating facilities remove sulphur components, water, CO2 and mercury from feed gas.

13 Treating of ethane (ethane recovery and treating facilities shall be installed later) and LPG products to further remove residual traces of sulphur, water and CO2.


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14 Sulphur components so removed shall be converted to elemental sulphur for export as

liquid sulphur. 15 Onshore downstream: Synthesis

Onshore downstream synthesis comprises 1 Gasification Process- Air Separation Units- Heavy Paraffin Synthesis- Catalyst

Activation & Regeneration - Water Distillation - Steam Methane Reformer - Hydrogen

Manufacturing - ASU’s main purpose shall be to produce oxygen for use in SGP as well as, also, produce HP Nitrogen for CAR unit, LP Nitrogen and compressed air for use as

site utilities. 2 In SGP, Syngas shall be produced from natural gas (NG) and oxygen by partial

oxidation.

3 SGP produces majority of Syngas for subsequent conversion to a synthetic heavy paraffin stream in HPS.

4 SGP Syngas requires treatment to remove soot and undesirable byproducts. 5 In SMR, hydrogen rich Syngas shall be produced from NG and steam by a catalytic

reforming process.

6 SMR Syngas has a higher H2 content than SGP Syngas and is used to supplement Syngas feed going to second stage of HPS reactors.

7 Reaction in HPS follows Fischer-Tropsch chemistry and produces significant quantities of process water as a byproduct.

8 WDU shall be used to strip hydrocarbons from process water, which be subsequently,

sent to effluent treatment plant for recovery. 9 CAR Unit shall be used to regenerate HPS reactor catalyst.

10 HMU uses a High Temperature Shift (on a part of SMR Syngas) and a PSA Unit to produce an ultra pure H2 stream mainly for use as a reactant in SMR and Liquids Processing Unit.

Onshore downstream: Liquids processing 1 Onshore downstream liquids processing scope comprises

2 Light Ends Stripper - Heavy Paraffin Conversion - Synthetic Crude Distillation & Stabilisation- Light Detergent Feedstock Units

Base Oil Units: 1 High Vacuum Unit - Catalytic De-Waxing Unit - Base Oils Re-distillation Unit

2 LES, LDF, HPC, SCD & Base Oil (HVU, CDW and RDU) Units shall be also, collectively referred to as Liquids Processing Unit or LPU.

3 In LES Unit water, CO and CO2 to be removed.

4 In LDF Unit, components shall be recovered and after hydrogenation, rundown to storage for sale as a product.

5 Remainder of HPS product shall be routed to HPC, where paraffinic molecules are cracked and isomerised into middle distillate range components, which are subsequently, distilled by SCD into LPG, Naphtha, Kerosene, Gas Oil and an SCD

bottom product stream. 6 In “Base Oil” mode of operation, SCD bottom product stream is routed to HVU for

further separation into Vacuum Gas Oil, a Waxy Raffinate fraction and a residual fraction, that is recycled to HPC.

7 Waxy Raffinate fraction shall be catalytically isomerised in CDW and then separated

into products according to boiling range and viscosity in RDU. 8 In “No Base Oil” mode, SCD bottom product stream shall be recycled to extinction

back to HPC. 9 For no Base Oil case, throughput of complex is limited by capacity in HPC (one single


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maximum size reactor per train).

Supporting facilities: Utilities 1 Utility systems comprise - Boiler Feed Water, Steam & Condensate Systems - Raw,

Demineralised, Potable & Service Water Systems - Power Generation and Distribution - Cooling Water Systems: Cooling Water System, Chilled Water and Closed - Cooling Water System - Instrument and Tool Air System - Nitrogen System - Heat Transfer

Fluid System - Aqueous Ammonia System 2 Utility systems shall be designed to allow standalone operation of GTL complex.

3 Steam and gas turbines shall be provided for shaft power and generation of electrical power.

4 Steam shall be generated in synthesis section thereby, effectively utilising exothermic

heat of process reactions. 5 Auxiliary boilers and gas turbines with Heat Recovery Steam Generators (HRSGs) shall

be included to facilitate black start capability to enhance reliability of steam and power system.

6 Cooling shall be done principally, by air, but cooling water may also, be used where

appropriate. 7 Steam is principal heating medium but, fired heaters and a heat transfer fluid system

shall be provided for specific applications. Supporting facilities:

1 Storage & off-sites - Storage and Offsite Systems comprise Relief & Blow down

System, including flares - Drainage, Collection and Primary Treatment - Effluent Water Treatment - Sour Water Stripper - Flushing Oil System - Storage and Loading Facilities

including onsite product storage - Slops & Intermediate Storage. 2 In general, plant condensate (blended with naphtha) and GTL products shall be stored

on site and transported to RLC harbour for shipping.

3 Field condensate shall be stored in an onsite as well as, an offsite shipping tank prior to export via RLC harbour.

4 LPG shall be transported directly to RLC facilities for refrigeration, storage and export. 5 Liquid sulphur shall be piped to common RLC facilities.

Design Basis – Mechanical Equipment

1 Table Of Contents

1. General, 2. List of Codes, Specifications and Standards, 3. Design Basis – Mechanical Equipment, 4. Equipment Selection, 5. Spare Parts, 6. Shop Testing

Design Basis – Mechanical Equipment Objective

1 Purpose of this part is to provide design basis for all mechanical equipment (rotating equipment + static equipment) on scheme & its various requirements intended to be employed on plant facility for successful operation & functioning of plant processes

during entire life of plant facility. 2 It shall be used for verification of selection and detailing / sizing of equipment for

procurement engineering (while developing EPIC documentation). 3 Plant facility design and installation shall consider 100% equipment redundancy (where

applicable), 100% availability of plant, Equipment selection to ensure 99.7% reliability,

environmental conditions. 4 Packages and equipment shall be suitable for outdoor installation in salt laden,

saliferous and highly corrosive atmosphere prevalent at open Coastal area. 5 Basic Engineering Data developed, shall be applied for development of FEED


Chapter 1 General


documents.

Design Life & Experience

1 Mechanical Equipment and associated auxiliaries shall be suitable for specified operating conditions including certain upset, start up, shutdown and emergency, be designed and constructed for a minimum service life of 30 years with equipment

providing at least 2 years of uninterrupted continuous service, while first major overhaul requirement, should not occur before 10years being a design criterion.

2 Vendor experience for previous supply of at least 2 validly similar design equipment and proven track record of at least two years trouble free running history / experience (in conditions similar to this project conditions) shall be applicable.

List of Codes, Specifications and Standards

1 Main cooling water pumps, associated auxiliaries and other mechanical equipment shall be designed and manufactured in compliance with Requisition, documents listed in Requisition and applicable specification/ datasheets included elsewhere, for

consideration as part of FEED document with compliance to followings. 1 Applicable Codes, Standards and Reference Documents

2 Equipment Specification lists applicable International Codes and Standards. 3 Reference to demanded Standards or Codes shall mean latest edition of that Standard or

Code including addenda or supplements or revisions thereto, as on effective date of

contract. 4 Project Documents, General, Project Design Basis, Technical Specification of Vibration

Monitoring System, Piping Material Specification, Company specifications, Lifting Equipment Technical Regulations, RA Pressure Vessel Design and Fabrication.

5 RA Above ground Welded Storage Tanks, RA Pressure Vessels, RA Air Cooled Heat

Exchanger Design and Fabrication, Plate Heat Exchangers–Design and Construction 6 RA Piping General Design, Diesel Engines, Diesel Engine Driven Generator,

Equipment Identification and Tag Numbering, Standard Specification for Painting and Wrapping of Metal, Surfaces, Company standards applicable to other disciplines shall be listed in individual, Equipment specifications and datasheets included elsewhere, for

consideration as part of FEED documentation.

International Codes and Standards

1 FEM Standards Federation of European Manufacture Standards on Drum Screens, 2 ISO 1940 Mechanical Vibration – Balance Requirements of Rigid Rotors,

3 ISO 2858 End Suction Centrifugal Pumps, 4 Part2, ISO 9001 International Organisation for Standardisation,

5 ISO:3046 Standards for Combustion Ignition Engines, 6 ISO : 10440 (Part 2) Packaged Air Compressors (Oil Free), 7 UBC Uniform Building Codes (Earth Quake Zones),

8 BS CP3, Chapter V Basic Data for Wind loads 9 BS 848 Fans for General Service,

10 BSEN 10204 Types of Inspection Documents – Metallic Product, 11 BSEN 13414 Steel Wire Rope Slings, Safety Standards, 12 HI Standards (HI-2.6) Hydraulic Institute Standards on Centrifugal Pumps,

13 NFPA 20 Standard for Installation of Stationary Centrifugal Fire Pumps for fire Protection,

14 NFPA 24 Standard for Installation of Fire Mains, AWWA American Water Works Association,


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15 API RP 500 Recommended Practice for Classification of Location of Electrical

Installation, 16 API 610 Centrifugal Pumps for Petroleum, Heavy Duty Chemical & Gas Industry

Services (relevant sections shall be applicable), 17 API 520 Sizing Selection & Installation of Pressure Relieving Devices. 18 API 526 Flanged Steel Pressure Relief Valve

19 API 650 Welded Steel Tanks 20 API 2000 Venting Atmospheric and Low Pressure Tanks,

21 API 670 Vibration, Axial Position and Bearing Temperature Monitoring, Systems. 22 API 673 Centrifugal fans for Petroleum, Chemical & Gas Industry Service. 23 ANSI B73.1M Horizontal Centrifugal Pumps,

24 ANSI B73.2M Vertical Centrifugal Pumps, 25 API 675 Positive Displacement Pumps – Controlled Volume,

26 ASME Section VIII Rules for Construction of Pressure Vessels (Div. I), 27 ASME Section II Material Specifications (Part A, B, C & D), 28 ASME Section V Non Destructive Examination,

29 ASME Section IX Welding and Brazing Qualifications, 30 ASME B30 Crane Safety Standards,

31 ASME B16.5 Steel Pipe Flanges and Flanged Fittings, 32 ASME B31.3 Petroleum Refinery Piping, 33 ASME B16.5 Pipe Flanges and Flanged Fittings, ASME B16.47 Large diameter steel

flanges (NPS 26” to NPS 60”). 34 AMCA Air Movement & Control Association,

35 ASTM A370 American Society for Testing and Materials – Standard Test, Method for Mechanical Testing of Steel Products

1 Principles to be adopted during selection & specification of prime equipment & equipment within proposed package can be summarised as follows:

a Design life of facility being 30 years, High availability, Standard/ Proven Equipment Model.

b Safe to operate & Maintain, Typical subjects to be addressed/ considered during

equipment selection & final preparation of purchase requisitions are addressed in following sections.

c Nameplates indicating major design parameters / specified parameters shall be screw attached to equipment.

d Nameplates shall be in SS316 materials.

Equipment Standardization

1 Design of rotating / mechanical equipment shall ensure high equipment availability & maintainability.

2 Effort shall be made to standardise spares stocking by minimising variety of makes &

types of auxiliary equipment used within package. 3 This standardization shall be applied so far as, it does not interfere with selection of an

optimal solution for specified operating conditions & duly considered equipment to minimize spares stocking.

Noise

1 Equipment design shall meet noise level (85 dBA @ 1m) specified in Company standards.

2 It is Supplier’s full responsibility to ensure that noise level of supplied equipment (including drive equipment as a combined unit) shall not exceed maximum allowable as


Chapter 1 General


specified in Project HSE Plan.

3 Effort shall be made to select equipment with low noise level. 4 Where, it is not feasible despite best design available, acoustic enclosures &/ or acoustic

insulation shall be provided. 5 Supplier shall submit estimated noise level & consider/ advise measures that would be

applied, when equipment noise level exceeds to noise level specified at respective

specification & datasheets.

Instrumentation / Controls

1 Equipment Supplier shall include all required package / equipment / auxiliaries’ controls for safe operation of equipment.

2 Instrumentation for communication with DCS shall be included to comply with requirements specified in respective Equipment Specifications, Datasheets & P&ID’s.

Equipment Covered

This design basis covers requirement for following equipment:

1 Main Cooling Water Pumps - Vertically suspended, submerged pump end, mixed flow seawater service Pumps complete with electric motor drive, VSD, Transformer, Local

Control Panel (LCP) & associated auxiliaries. 2 Centrifugal Pumps (General Service) includes hypochlorite dosing pumps/ dilution

pumps etc.

3 Submersible Motor Pumps (Portable) includes sump pumps & drain water pumps. 4 Firewater Pumps (as per NFPA 20)

5 Instrument Air Compressor and Dryer Package 6 Centrifugal Fan (at Hydrogen disengagement Tank of Chlorination Plant) 7 EOT Cranes/ Semi Portal Cranes (Pump house, Mechanical Plant, Receiving Basin,

Workshop/ Warehouse & Piping Manifold area cranes) 8 Fixed Bar Screens cooling water common raking facility

9 Rotating Drum Screens 10 Stop Logs (Intake and Receiving Basin) 11 Emergency Diesel Generator Set.

12 Vessels & Storage Tanks 13 Electro Chlorination Plant Equipment

Equipment Selection

Main Cooling Water Pump Sets

1 By electric motor driven (through VSD), vertically suspended, submerged end mixed flow seawater service line shaft pumps with right angle discharge head shall comply

with Project Specification requirements, HIS Standards & in general compliance to API 610 Standards (where applicable for this service, such as pump rotor dynamics, vibration levels, line shaft & thrust bearing design criteria etc.).

2 Offered vibration monitoring system for pump / motor shall be in compliance with API 670 recommendations.

3 Pump datasheets shall address pump drive train requirements, VSD’s, Local Control Panel (LCP) & complete electrical setup shall be provided by Pump Vendor (single point responsibility for Tender Scope).

4 Vertical centrifugal pumps handling liquids, whose vapour pressure is below atmospheric pressure, can be provided with gland packing suitable for such service.

5 Pumps line shaft bearings shall be service fluid lubricated however, Supplier incorporate pump bearing design or operation strategy that should take care of startup scenario of


Chapter 1 General


standby pumps that would be with dried up bearings.

6 Pumps shall be shop assembled to a maximum possible extent to consider minimum site assembly work & shipment limitations.

7 All pump houses being/located in nonhazardous area while, such pumps are operating in very corrosive environment i.e. salt laden sea mist, dust, wind etc.

8 Flexible coupling shall be selected for every duty by main cooling water pump sets’

Vendor. 9 Coupling guards shall be made from non sparking material.

10 All pumps & auxiliary items located at Pump House shall be designed for outdoor conditions as pump house is only a shelter with partially covered sides.

11 Pumps shall be working in parallel operation with head rising continuously to shutoff is

philosophy requirement. 12 Pump’s right angle discharge head shall be with ‘expansion joint’ to ‘tie in’ with

downstream flanged CCV (Combined Check Valve). 13 In case of blocked discharge, specific unit shall be able to withstand shut off head

condition for at least 5 minutes, without causing any damage to pump and its auxiliary

items. 14 In case of CCV failure, its specific unit shall be able to withstand reverse rotation up to

full speed. 15 Pumps materials for major items / wetted parts shall be specified in Pump datasheets for

required vendor review, intended selection correctness i.e. compatibility to service fluid/

material grades availability etc. would be its Suppliers’ responsibility for providing right pump sets for required service.

16 Pump set items shall be brand new and would be selected by Pump Vendor to provide single point responsibility of meeting specified pump duty requirements & service.

17 Pumps selection shall consider common pump model (to an extent feasible) that

provides stable continuous operating range & includes governing process flow requirements.

18 To achieve this pump model commonality, its pump driver could be of different rating and of different VSD speed range.

19 Pump model testing is required in defined standards.

20 Complete testing requirements shall be conducted as specified in pump specification and datasheets included elsewhere.

Centrifugal Pumps (General Service) 1 Centrifugal pumps for non hydrocarbon service shall comply with Project Specification

and ANSI Standards B 73.1 M or B 73.2 M and ISO 2858 2 Pump construction shall be specified on pump datasheet elsewhere.

3 Two stages overhung and single stage double suction overhung pumps shall not be offered.

4 Maximum allowable flow shall not be less than 120% of best efficiency capacity of its

rated impeller. 5 Pumps shall be selected, so that it is possible to achieve 10% head rise / 5% head

decrease at rated capacity by replacement with new impellers. 6 Pumps shall have head curves rising continuously to shutoff. 7 Shutoff head shall preferably be in preferable range of 110 - 120% of rated head.

8 Pump impellers shall be closed or semi open type, while open impellers are not acceptable.

9 Use of inducers to enhance NPSH is not acceptable. 10 Its mechanical seal, when specified in datasheet shall comply with requirements of API


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682.

11 Mechanical seal design and material selection shall be suitable for proposed service fluid continuous operation with maximum operating temperature.

12 Seal system piping shall be as a minimum in SS 316L or suitable to service. 13 Pump components construction material shall meet intended requirements as specified

in equipment datasheet and compatible to service.

14 Coupling shall be forged steel flexible type with spacer. 15 Removable coupling guards shall be made from non sparking material suitable for very

corrosive environment. 16 As a minimum, its electric motor nameplate rating shall be as below. 17 Motor Nameplate Rating Percentage of Rated Pump Power = 18.5kW 120, 20 – 55kW

110 = 75kW 105. 18 Inspection & Tests shall be carried out per Engineering Standards and as covered in

applicable specification.

Sump Pumps (Portable Submersible Motor Pumps)

1 Portable Submersible Motor Pump shall be utilised for dewatering pump house & receiving basins.

2 When piping sections are to be cleaned from sediments, intended or planned pumps would be required to be compatible with nature of seawater service fluid with sediments/ grits.

3 Proposed Manufacturer’s Standard design shall be acceptable for sump pit installation based on drainage duty portable submersible motor pumps.

4 Pump motor shall be oil filled type and provided with two sets of mechanical seals for double security.

5 Pump shall be fitted with cable & watertight cable connector.

6 Drainage pumps shall be provided with lifting hook for portability & placed/ lowered in sump pits of pump basin/ receiving basin area, whenever basin emptying is planned.

7 For safe custody, these pumps shall be stored in warehouse/ maintenance workshop, when not in use.

8 Tough duty submersible motor pump’s housing & impeller shall be provided in

aluminum bronze (or alternately, in super duplex stainless steel) material & all major components be subject to wear, be coated with polyurethane for longer service life in

fine grain abrasive application. 9 Pump impeller shall be provided semi open type. 10 Pump motor shall be water jacketed to provide cooling to motor by service fluid.

Firewater Pumps

1 Fresh water service Firewater Pumps shall be planned to provide fire protection to equipment by deluge.

2 Planned horizontal centrifugal type Fire Pump sets shall be manufactured in accordance

with NFPA (National Fire Protection Association) 20 design requirements. 3 One pump set shall be provided with an electric motor drive & other, with a diesel

engine driver. 4 An electric motor driven jockey (makeup) pump shall also, be installed to maintain

intended or required header pressure of fire Main Ring.

5 Required fire pump packages shall be provided with listed (UL/ FM approved) pump set items and pump controller for fire protection service auxiliary items, included in

packages, comprise of circulation relief valve, water flow test devices etc. 6 Demanded selected pumps shall be a listed one per Firewater Pumps specifications and


Chapter 1 General


pump requirements in line with NFPA 20.

7 Pumps shall get supply from storage tank/s of adequate capacity for expected duration. 8 Pump capacity selection shall be to NFPA 20 rated provisions and be specified at

respective datasheets. 9 Fire pump shall not furnish less than 150% of rated capacity at a total head of not less

than 65% of rated head and total shutoff head should not exceed 140% of its rated head.

10 Each pump shall have an automatic relief valve listed for relevant fire pump service installed and set below required shutoff pressure at minimum expected suction pressure.

11 Demanded flexible coupling between pump and driver, shall also, be listed for required service.

12 When more than one pump is installed on single suction line, suction pipe layout at

pumps shall be arranged, so that each pump receives its proportional supply. 13 An automatically, controlled Fire Pumps shall be provided with a listed float operated

air release valve (when automatically, controlled deluge system is planned). 14 Required Fire Pump installation shall include water flow test devices to allow test of

intended pump at its rated conditions as well as, at maximum flow condition.

15 Metering devices for pump tests shall be listed one with each pump having its own test loop.

16 Each individual pump shall be tested at its factory to provide detailed performance data and demonstrate compliance to specification.

17 Jockey/ Make up pumps shall have rated capacities not less than any normal leakage

rate and discharge pressure sufficient to maintain system pressure. 18 Fire Pump Driver-Lead fire pump and Jockey pump shall be provided with electric

motor drive, while backup fire pump provided with diesel engine drive. 19 Both diesel engine & drive train components shall comply with as listed items for

intended fire pump service.

20 Controls – Each pump shall have its dedicated driver & each driver have its controller. 21 All controllers for planned motor & diesel engine shall comply with specification of

NFPA 20 Chapter 7 (motor) / Chapter 9 (engine).

Instrument Air Compressor-Dryer Package

1 Planned Air Compressor Dryer Package construction shall be based onto vendor Standards designed for Coastal Area installations.

2 Package units (train of compressor and dryer) shall be installed on single lift skid with compressor unit be located inside its enclosure for sound attenuation.

3 Required plant facility shall be provided with two numbers of packages operating under

lead lag basis. 4 Air Compressor shall be oil free, air cooled, electric motor driven, Screw type Air

Compressor unit complete with its UCP (Unit Control Panel), lube oil console & air cooler for lube oil and compressed air (inter and after cooler of compressor).

5 Package Start/ Stop and lead/ lag operation shall be monitored from skid installed UCP

on pressure level signals. 6 Daily maximum average temperature shall be considered for compressor and its

compressed air cooler sizing. 7 Required oilfield type ‘air to air’ heat exchange cooler in SS316 (SS – Stainless Steel)

or construction with marine installation coating shall be specified to provide rugged

construction in corrosive sea coastal environment. 8 Required compressed air temperature downstream of air cooler, shall be limited to 58°C

(with air cooler sized for ambient temperature of 50°C). 9 Air Dryer unit shall be heatless PSA (Pressure Swing Adsorption) type complete with


Chapter 1 General


twin molecular sieve (aluminum silicate) desiccants towers and timer based controls for

air flow switchover. 10 This unit shall be located downstream of Air Compressor unit and handle specified flow

delivered by upstream air compressor unit. 11 Compressed air shall be stored in Plant’s Service Air Storage Vessel and dried

instrument quality air stored at Instrument Air Storage Vessel sized to cater for required

Plant needs. 12 Package instrumentation (PLC controls) for lead lag controls, shall be in Vendor’s local

control cabinet, DCS communication per package P&ID be achievable as a minimum battery limit pressure, temperature and dew point level, should all be reported besides running status.

13 A common facility delivering complete plant needs including instrument air needed for Chlorination Plant is envisaged in this Phase of project.

14 Fans (Cf Blower) - Fans shall comply with requirements of specifications generally per API 673 and company engineering standard.

15 Fans shall be sized to deliver demanded air flow & differential pressure required for H2

disengagement duty under all operating conditions. 16 Normally two fans (2 x 100%) shall be installed each to run and deliver required

dilution air with an automatic switchover controls to other fan in case, one fan trips. 17 Design power margin for electric motor drivers shall be in accordance with

Specification at rated conditions.

18 Fans shall be provided with barrier type filter systems. 19 Filter shall be suitable for severe sandy & dusty atmosphere with rain hood and bird

screen. 20 Fans shall be shop tested for satisfactory performance and stand by switchover controls.

Electric Overhead Travelling (EOT) Cranes/ Semi Portal Cranes

1 EOT Crane-Planned Pump House is provided with maintenance duty EOT Crane to

handle load lifts during pump overhaul and general lifting needs. 2 Currently Pump House has one 17m span crane with main hook capacity of 60T and

auxiliary hook capacity of 14T.

3 Required power distribution to planned long travel is, by enclosed type bus bars system (with rubber lip seal) while, cross travel/ hoisting power distribution is through power

festoon cable system. 4 In this Project, its possibility of extending planned long travel of installed crane &

certain considerations for additional second crane, shall be reviewed (as a separate

study) & post study recommendations should be implemented to suitability of purpose. 5 Planned crane construction as defined below shall apply for an additional crane

purchase. 6 Proposed EOT Crane shall be top running double girder type, designed for maintenance

duty class 2M (FEM 9.511) & suitable for safe area outdoor location (though installed

in Pump house shelter). 7 Proposed crane shall be provided with operator’s cabin located at one end of crane’s

bridge (girder) & also, provided with remote radio communication setup for crane operator’s use.

8 Complete crane shall be designed to provide access platform/ service walkway for

servicing equipment & floodlights installed to illumine all work area. 9 Required power distribution to its long/ cross travel & hoisting motion shall be Similar

to Phase power distribution system, therefore, crane controls should be compatible to incorporate normal & creep speed motion controls for precise adjustment.


Chapter 1 General


10 Crane load lift capacity per Phase crane & provision for auxiliary hook shall be

maintained as its load lifts provision are with adequate margin.

Semi Portal Crane

1 Planned Mechanical Plant (Screen Yard) is provided with maintenance duty Semi Portal Crane to handle load lifts during drum screen overhaul & general stop log lifting needs.

2 Currently has one semi portal 23m span crane with main hook capacity of 10T. 3 Required power distribution to its cross travel & hoisting motion is through power

festoon cable system & long travel by cable reel. 4 In this Project, possibility of extending its long travel of installed crane & certain

considerations for additional second crane should be reviewed as a separate study.

5 Proposed crane construction as defined below shall be applied, when an additional crane purchase be brought into picture.

6 Planned semi portal Crane shall be top running double girder type electric overhead traveling crane with one end of its crane bridge supported at runway beam while, other end resting on a portal frame.

7 Proposed crane shall be designed for maintenance duty class 2M (FEM 9.511) & would be suitable for safe area outdoor location.

8 Required crane shall be provided with crane operator’s cabin located at one end of its crane bridge (girder).

9 Crane shall also, be provided with remote radio communication setup for crane

operator’s use. 10 Complete crane shall be designed to provide access platform/ service walkway for

servicing equipment & floodlights be attached to crane bridge for work area lighting. 11 Required power distribution to its long travel shall be through enclosed type 7-bus bar

system (with rubber lip seal) while, cross travel/ hoist motion power supply would be

provided through power festoon cable system. 12 A suitable sun shield shall be provided for included festoon cables, when in parked

position. 13 Crane load lift capacity per Phase crane shall be maintained as load lifts provision is

provided with adequate margin.

Other EOT Cranes

1 Maintenance load lift facility e.g. EOT cranes of adequate capacity shall be installed at following Plant Facility areas namely Receiving Basin Area, Plant Workshop/ Warehouse, Electro-Chlorination Plant & Piping Manifold Section.

2 All equipment construction shall be similar as stated in foregoing. 3 Required power distribution for cross travel, long travel and hoist motion shall be

through power festoon cable system. 4 Required crane load lift criteria as detailed in material handling study shall be

accomplished.

Mechanical Plant–Bar Screen and Raking Mechanism

1 Bar screen panel consisting of fixed rectangular steel bar sections with 50 mm spacing shall be installed at pump intake basin (upstream of rotating drum screens).

2 Planned screen bar panel shall be removable type & for facilitating an easy cleaning,

which should be installed with 80 degree angle of installation. 3 Screen panel size similar to PH installation shall be considered for this phase.

4 Planned common raking machine shall be demanded as grab bucket type rake assembly with replaceable tines.


Chapter 1 General


5 Its assembly shall comprise of indicated following main components-an electrically

operated travelling trolley, an over head monorail traverse & a power supply cable festoon, a hydraulically assisted grab bucket complete with associated hydraulic power

pack, a hoist mechanism for grab bucket lowering & a hoisting complete with PLC type Local Control Panel and required pendant controls, a trash/ debris bin (to hold and carry 0.5 T of load) for disposal of rejects etc.

6 Hoisting mechanism & hydraulic power pack shall be attached to traveling trolley. 7 One number rake machine for Pump House & rake machines for Pump House (1 op. +

1 sb.) shall be installed yet to remove trash/ debris/ marine seaweeds/ sea shells etc. duly arrested in bar screens.

8 In addition, one complete warehouse spare suspended grab bucket c/w hydraulic power

pack shall be considered for planned Phase facilities.

Design Basis-Mechanical Equipment

1 An Alternate trash rake machine would also, be reviewed to consider efficient scraping of bars at fixed bar screen panels (availability of traversing trash rake with scrapping in

ascending action for reclamation of attached sea shells and barnacles from bar screen shall be investigated).

Mechanical Plant-Stop Logs

1 Plate gates type Stop Logs (stop gates), similar to existing Phase I installation and

dimensions compatible with civil design shall be planned for pump channels. 2 Guide frame for each stop log shall also, be provided by stop logs supplier to embed in

pump house civil work when, such logs are not in use. 3 Stop log designs construction & supply shall include equalising valve and a common

lifting beam (vendor supplied) with adequately sized slings.

4 Required stop log items supply and construction specification shall include material of construction, coating/painting requirements & any effective corrosion protection system

viz. cathodic protection as applicable.

Rotating Drum Screens

1 Planned double side entry & central rejects disposal type rotating Drum Screen with 3 mm (~ 6 mesh) opening wire mesh panels (removable panels) shall be installed for fine

screening of intake seawater. 2 One screen shall serve 2 #s pump basins. 3 Planned Drum Screen shall consist of a rotating structure for drum & wire mesh panels

attached to drum periphery. 4 Required screen panel backwash setup shall be incorporated in drum screen design for

efficient screening operation. 5 Intended equipment shall be meant for seawater service as such, construction in Duplex

Stainless Steel (DSS) materials (of suitable ASTM grade) is envisaged in Phase II of

project. 6 Proposed sealing between civil work & screen drum to eliminate bypass of fed seawater

shall be achieved per recommendation/ arrangement offered by equipment supplier. 7 Rotating motion to drum screen shall be through rack and pinion drive. 8 Rack shall be in sectors for attachment to drum by bolting.

9 Included drum shall be shaft mounted & supported on bearing block at both its ends. 10 Proposed Drum Screen Supplier shall include Lubrication console for Pillow Blocks

Bearing. 11 Inner periphery of drum shall be provided with elevated plate buckets to lift screenings


Chapter 1 General


up to debris hopper located inside provided screen structure.

12 This debris hopper shall be provided in two separated sections to allow rotation of drum supporting structural members.

13 Included drum screen shall be provided with PLC type local control panel (LCP), interfaced with water differential level instrument and drum screen drive to monitor & control operational speed as well as, interfaced with DCS.

14 Installation shall be provided with service/ inspection platforms & suitable structure for falling object protection to service equipment even in operation.

Vessels and Storage Tanks

1 Pressure Vessels-Pressure vessel shall be designed in accordance with ASME SEC VIII,

DIV-1 ‘Boiler & Pressure Vessels: 2 Rules for Construction of Pressure Vessels’ & shall be code stamped.

3 Pressure vessels shall also, comply with requirements of COMPANY standard & specification.

4 Vessel heads shall be 2:1 ellipsoidal.

5 Minimum shell & head thickness for carbon steel pressure vessels including corrosion allowance shall be 6.0 mm.

6 Minimum internal corrosion allowance for carbon steel & low alloy steel vessels, without any internal coating shall be 3 mm, unless specified otherwise in given datasheets.

7 Minimum corrosion allowance shall be added to both sides of non removable CS internals, when exposed to either corrosive fluid or vapour.

8 Removable CS internal parts shall be provided with corrosion allowance equal to half its specified value on each surface exposed to either corrosion fluid or vapour.

9 All vessel nozzles connections are to be provided with flanged connections.

10 Vessels shall be provided with manholes (24” minimum)/ hand holes (12” minimum) or end flanges as specified on equipment datasheets.

11 These components shall be provided for ease of servicing/operation & be complete with davit.

12 Required structural access platforms for operation/servicing shall be supplied &

installed by others, however attachment clips should be provided on manufactured vessels.

13 All equipment & relevant lifting accessories as tailing lugs, trunnions & lifting lugs, shall be designed to withstand equipment lifting weight considering an impact factor of 1.5, unless otherwise specified on datasheet.

14 Wind & earthquake loadings shall be calculated in accordance with standards. 15 Wind & earthquake loadings shall not to be considered to act simultaneously.

Storage Tanks

1 Design, material fabrication, inspection, erection (where applicable), testing &

preparation for shipment (where applicable) of welded steel tanks shall be in accordance with API-650.

2 Rectangular tanks (if applicable) shall be designed in accordance with “Roark’s Formulas for Stress and Strain” published by author Warren C, Young or similar structural design practices.

3 Tanks shall also, comply with requirements of company standard and specification. 4 Fixed roof tanks shall be of cone roof type.

5 Tank bottoms shall be sloped downward conically (either crown up or crown down), as specified on provided datasheets.


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6 If tank is provided with drainage sumps then sump shall be equipped with a drain pipe

with flanged nozzle. 7 Pressure/ Vacuum relief devices shall also, be provided, if tank is designed for pressure/

vacuum conditions. 8 Wind design loadings shall be in accordance with BS CP3, Chapter V, Part 2. 9 Tank shall be designed for earthquake loadings according to Uniform Building Code

(UBC) with applicable Zone # as 1.

Emergency Diesel Generator Set

1 Emergency Diesel Generator (EDG) set shall comply with requirements of Company standard & specification.

2 Proposed EDG package shall be self contained & would not depend on external utilities for operation.

3 Diesel engine of package shall be 4-stroke, turbocharged type provided with primary battery startup & backup start by compressed service air of plant supply.

4 Engine shall be radiator cooled.

5 Lubrication & cooling systems shall comply with requirements specified in ISO: 3046 and also, meet COMPANY standard.

6 Dedicated diesel fuel system shall be provided with a day tank. 7 Day tank capacity shall be suitable for at least 8 hours running of proposed package at

full load without replenishment.

8 Day tank may be made a part of its diesel engine generator skid or may be, as a separate tank located outside its skid.

9 Provided fuel system shall include spring loaded fuel valve (actuated by fusible plug/ melting fuse) that should shut upon “FIRE”.

10 EDG shall be located indoor, inside acoustically treated & ventilated building to meet its

specified noise levels. 11 EDG Room ventilation shall be achieved by suitably, over sizing included or provided

motor driven radiator fan. 12 Generator & other electrical equipment shall comply with requirements specified on

Company Standard Electrical Specification–Diesel Engine Driven Generator / Electrical

Design Basis. 13 EDG package shall be provided with a control panel, which would be located in

switchgear room away from installed package. 14 It shall be possible to start EDG package from remote systems on failure of mains

supply or manually, from installed package itself.

15 Suitable synchronising hardwired interface shall be provided for same purpose.

Spare Parts

1 Spare parts for main equipment and auxiliaries shall be in line with requirements specified within Project Spare Parts procedure and Company standards referred therein.

2 Generally, spare parts for pre commissioning, commissioning & startup as well as, for demanded defined maintenance period are provided.

Shop Testing

1 Main equipment & auxiliaries shall undergo shop and site testing.

2 Supplier shall prepare test procedures for specified tests & submit same for Company/ Contractor review/ approval.

3 Procedures shall be prepared in line meeting with requirements of contract specification/ applicable international standards as a minimum criterion.


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4 Test procedures shall also, identify suitable methodology of required test, applicable

international standards, acceptance criteria etc. 5 All inspection & test plans & equipment datasheets shall identify Company/ Contractor

witness requirements clearly. 6 Based on above requirements, Supplier shall prepare project specific QA plan/

Inspection & Test plan.

1 Buildings included on facilities plants are of two classes, one being for process

objective, while other being for non process objective. 2 Generally, various buildings designated as Administrative, Amenities, Central control,

Operation, Main & substations, Pump houses, Gatehouses, Security controls etc. are

included. 3 Also, included steel buildings for relevant industrial support purpose namely,

workshops, warehouses etc. 4 These steel buildings are provided with all mechanical furniture, heavy equipment like

lathe machines, forklift, trolleys, steel furniture, tool cabinets, steel racks, lockers etc. &

tools. 5 All buildings require equipments such as office furniture & also, steel furniture, such as

lockers, shelving, benches, racks etc. 6 Buildings located within process areas are designed to sustain blast forces. 7 Buildings located away a distance of more than 610 m from process areas are designed

based on non blast design requirements. 8 All other buildings located within 200 m to 610 m from process areas are designed

based on blast resilience requirements.

Building services

1 Require HVAC chillers, package units, air handling units, ducting, fittings, such as fire dampers, volume control dampers, accessories & other controls.

2 False ceiling, grills & diffusers. 3 Ducts for supply & return run in located plenum between provided false ceiling & RCC

slab soffit.

4 Also, included CCTV, structured cabling, fire fighting, electrical installation of low power as well as, high power, fiber optical cabling, cable cellars, switchgears

transformers, telecommunications, radars controls, Information technology etc. all, whatsoever for smooth functional & support of plant operation.

Electrical supply 1 Is distributed by Main station, sub main stations, transformers etc.

2 Designated areas, where transformers are located should be constructed around by firewalls.

3 Substation comprises of HV & LV areas, wherein, switchgears are accommodated

within. 4 Proper insulation is carried out for on building envelope to reduce its thermal heat flow

into buildings to maintain its required design conditions for economical air-conditioning.

Fire suppression system 1 Is used in process buildings by trade name FM 200 or Inergen etc. to extinguish broken

fire within seconds & minutes. 2 This gas spreads in unventilated or sealed space & extinguishes or suppresses broken


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fire immediately, in seconds.

3 Inergen gas is a mixture of nitrogen, argon & carbon dioxide @ 52, 40 & 8% proportions respectively

4 Inergen gas a nature friendly & does not cause ozone depletion effect 5 Inergen gas requires sealed area to work in seconds to suppress fire 6 Fire suppression is achieved by its property to reduce oxygen percentage in a area

affected by fire in zones A,B & C type of fire 7 Once, oxygen is reduced in percentage, to compensate persons in that area carbon

dioxide assists to respire 8 Inergen gas an, Ansul US product is delivered in alloy cylinders under very high

pressure, but pressure at nozzle is controlled to be within limits

9 Inergen cylinders & can be located inside or outside of protectable areas 10 Inergen can be activated manually as well as automatically

11 Inergen network is installed over area to be protected like a piping network for supplies, depending on engineering based calculations

12 After, application of Inergen, no clouds are visible causing no visibility problems

13 Also, included smoke detection systems along with fire fighting system for internal as well as, for exterior use.

14 Industries within plant area employ their individual systems for firefighting but, preferably one, seawater back up fire fighting system is also, included as stand by.

15 Fresh water system is also, included for all those areas locating within expensive &

strategic equipment for electrical supply as well as, emergency controls.

Cathodic protection 1 Is included to control possible corrosion of included reinforcement by providing

electrode at a designated member of structure, centrally controlled from one location,

where anode sacrificial technology is installed for monitoring & control corrosion. 2 All reinforcing bars are clipped & wired naked maintaining their continuity of included

bars. 3 In such cases, only non coated high strength carbon steel bars are included. 4 All joints are checked for ensuring electrical continuity in such cases.

5 Two types of systems are used, which one is critical cathodic protection & other, is non critical protection.

6 Critical system requires GI rope & C clamps or clips to pass over all steel reinforcing bars & then, connect to electrode.

7 Non critical system is installed only, with one conical boss clamped with binding wire

on columns with later connect to central system.

Cooling towers

1 Are installed, when supplied water is required to be re circulated for many uses or repetitions for concerned industry in which case, only makeup water shall be supplied to

maintain effected or deficient balance of cooling water quantity. 2 For once through system, water is supplied & returned, after cooling various industrial

systems into provided returned headers without any circulations. 3 No cooling tower is provided for such requirement. 4 In some cases, a combination of both systems re circulatory & once through could be

adopted for economical reasons. 5 Cooling towers have been included within process trains for multiple use of cooling

water for purpose of expensive transportation from sea to seawater basin


Chapter 1 General


1 general-facilities petrochemicals

Engineering

Transcript of 1 general-facilities petrochemicals