Air Separation Unit

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This docum en t wit h all its r ights is th e pr ope rt y of BU PC and m u st be h e ld in conf idence . No disclosur e, repr oduc ti on or o ther us e o f the docu m ent in wh ole o r p a rt s is to be m a d e w it hout th e p ri or conse n t o f B UPC DE EXT INQ R

Eng. Phase Purpose of Distribution (POD) Purpose of Issue (POI) Owner's Action

03 28.05.2014 Issued for Inquiry B.Hamidi M.Hashemi M.Hashemi M.Jalali

02 _05.05.2014 _{Issued for Inquiry} _{B.Hamidi M.Hashemi}_{M.Hashemi M.Jalali}

01 26.01.2014 Issued for Inquiry B.Hamidi M.Hashemi M.Hashemi M.Jalali

00 07.10.2013 Issued for Inquiry D.Zeidani M.Hashemi M.Hashemi M.Jalali

Rev. Date Description Prepared by Checked by Approved by Project

This Requisition is issued to obtain quotation for supply and delivery of:

AIR SEPARATION UNIT

as per this Requisition and its attachments.

REQUISITION CONTENTS 1. Scope of Work 2. Scope of Supply 3. Requisition Notes 4. List of Attachments

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This docum en t wit h all its r ights is th e pr ope rt y of BU PC and m u st be h e ld in conf idence . No disclosur e, repr oduc ti on or o ther us e o f the docu m ent in wh ole o r p a rt s is to be m a d e w it hout th e p ri or conse n t o f B UPC 1. SCOPE OF WORK

Vendor’s scope of work includes but not limited to the following items with requirements stated in the requisition and all its attachments.

1.1 GENERAL

Main

Quotation Options

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1.1.1 Design & Engineering

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1.1.2 Fabrication /Manufacturing

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1.1.3 Assembly

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1.1.4 Shop test and inspection as per attachment No.6

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1.1.5 Painting ( Primer and Intermediate coating )

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1.1.6 Packing (Including N2 filling)

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1.1.7 Marking

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1.1.8 Site supervision and start up services

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1.1.9 Training

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1.1.10 Mechanical guarantee

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1.1.11 Performance guarantee

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1.1.12 Erection

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1.1.13 Commissioning 1.2 OTHERS

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1.2.1 Documentation

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1.2.2 Instrumentation and Control

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1.2.3 Wiring and tubing for instrument within skid

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1.2.4 Internals such as internal piping, baffles, inlet distributors and their support, vortex breakers and wire screen around VB or in the inlet of nozzle (if any), impingement plates, internal rungs, support for packing/ hold down & grid support, internal flanges and etc.

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1.2.5 All external welded attachments, including reinforcement pad around nozzles, lifting and tailing trunnion / lugs, clips (for

piping, ladder, platform, insulation, earthing), pipe davit and etc.

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1.2.6 Ladders and platforms complete with bolting.

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1.2.7 Review of PIDEC’s related drawings such as (foundation _{drawings etc.)}

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1.2.8 Skid ( Steel structure for the equipment such as compressors, _{driver, auxiliary equipment and systems )}

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1.2.9 HAZOP and SIL study (The HAZOP and SIL study meeting shall _{be held in presence of Owner, Contractor, and third party.).}

03

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1.2.10 Engineering for Fire Fighting and F&G system related to ASU Plant

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Vendor’s scope of supply shall include but not limited to the followings with all accessories and as required according to this requisition, its attachments and references:

2.1 GENERAL

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2.1.1 Items and quantities as stated in the material summary list. (point 2.3)

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2.1.2 Installation / Mounting accessories

03

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2.1.3 Spare parts for erection, pre-commissioning, commissioning and

start-up

03

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2.1.4 Spare parts for two years operation

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2.1.5 Capital spare parts ( if any )

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2.1.6 Consumables for site erection

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2.1.7 Chemical and lubricants

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2.1.8 Special erection and maintenance tools ( if any )

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2.1.9 Special calibration tools ( if any )

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2.1.10 Test equipment ( during shop test )

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2.1.11 Name Plate (s)

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2.1.12 Documents as per the attached RFD ( requirements for documents) _form

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2.1.13 Final Vendor data book

2.2 OTHERS

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2.2.1 Local Instruments

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2.2.2 Junction boxes

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2.2.3 Cabling bulk materials including cable glands, conduit pipes, _etc.

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2.2.4 Instrument air supply line piping material including valves, _{fitting, flanges, bolts & nuts, gasket, etc.}

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2.2.5 Air line tubing materials including fittings

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2.2.6 Installation and support material for above

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2.2.7 All steel structures including supporting structures , shelters , _{T-supports and their accessories & attachments}

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2.2.8 Platform, stairway, ladder and hand rail on equipment.

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2.2.9 Piping material including valves, flanges, bolts, nuts, pipe _{supports, pipe hangers and etc.}

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2.2.10 Ducting material, if any.

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2.2.12 Deleted

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2.2.13 Painting material for touch-up, Concrete coating & painting

(where needed)

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2.2.14 One layer of final coating material at site.

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2.2.15 Initial charge of column packing (filter elements, etc.).

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2.2.16 Equipment, apparatus and consumable for analysis and test _{required for normal operation and guarantee test run}

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2.2.17 Welding electrode

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2.2.18 Transportation saddle

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2.2.19 Gasket, bolt & nut for reducing and blind flanges and internal _nozzles.

03

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2.2.20 Sliding plates, templates, liners, insert plate & shims.

03

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2.2.21 Insulation material

03

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2.2.22 Lubricant for initial fill and two years operation.

03

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2.2.23 Resin/Catalyst/absorbent for initial fill and two years operation.

03

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2.2.24 All required facilities for Fire fighting and F&G system related

to ASU Plant.

NOTE :

1. The package (all equipment, devices & etc.) shall be seaworthy packed and shall be

protected from any corrosion during manufacturing, transportation, site store before erection and start up.

2. Vendor shall supply all relevant equipment, instruments, etc. to make the package complete in all respect even-though it is not listed in the specifications and requisition or in the Vendor’s offer.

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2.3 MATERIAL SUMMARY LIST

2.3.1 EQUIPMENT

The following list of equipment is as minimum requirement and Vendor shall provide all the necessary equipment, piping and valves to meet the requirements.

SR. ITEM NO. ITEM DESCRIPTION QTY UNIT

(m/kg/set/...) 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 30-PU-6101 (Note 5,6)

AIR SEPARATION UNIT that includes two cold boxes equipped with three air compression trains mainly composed of :

Main air compressors Booster air compressors Air pre-cooling systems

Molecular sieves absorbent vessels

Each condensing steam turbines (for each main air compressor and booster air compressor train) including condensation unit Cold Box

Expansion turbine

Exchangers Cold Box

1 2(W)+1(St.by) 2(W)+1(St.by) 2 (one stand by pump to be considered for each set of pumps) 1(W)+1(St.by) (for each train of

compressor)

2(W)+1(St.by)

2 1(W)+1(St.by) (for each train of cold box)

One complete set (for each

train) Set Set Set Set Set Set Set Set Set

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Rectification Cold Box

Liquid nitrogen storage tanks and vaporizer

Liquid oxygen storage tank and vaporizer

Independent instrument air and plant air package

Control and ESD system Spare parts for erection

commissioning and start-up (for SR. 1,2,3,4,5)

Spare parts for two years operation (for SR. 1,2,3,4,5)

Capital spares (for SR. 1,2,3,4,5)

One complete set (for each

train) 1 1 1 1 1 1 1 Set Set Set Set Set Set Set Set NOTE :

1. TAG No. of equipment and Instruments will be specified according to project numbering procedure.(Attachment 10)

2. Any other equipment/system not included in the above list, but necessary for right and satisfactory operation of the unit shall be considered in the scope of this requisition designed and supplied by Vendor without any price impact.

3. Number of required equipment besides their detailed specifications to be specified by Vendor.

4. W: Working , St.by: Stand by

5. Vendor of ASU shall consider the future expansion provisions for the third train of ASU and related main air compressor(s) in the design of package. Moreover the hydraulic design of all common facilities and interconnections including utility, feed and products piping and etc shall be performed and supplied for three similar trains of ASU and its air compressor(s). 6. The optimum number of air compressor trains to be proposed by Vendor considering the

quantity of available steam in the site.

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2.3.2 INSTRUMENT AND ELECTRICAL

Vendor shall provide all necessary instrumentation, internals and electrical to meet the requirement.

2.4 EXCLUSION

2.4.1 Foundation works (Anchor bolts calculation is by Vendor & supply by others) 2.4.2 Structural/ detail design of buildings (including G.A and Foundation, HVAC

design, Plumbing Design, F&G, etc). 2.4.3 Site erection

2.4.4 MV line feeder cables

2.4.5 Underground conduits for power and instrument cables

2.4.6 Fire detection and alarm system related to buildings are excluded, although all signal related to F&G of the buildings shall be implemented in ASU Plant F&G Panel by Vendor.

2.4.7 Supply of hydrant/monitor/hose reels connected to fire water network. (Fire water system to be designed by Vendor).

2.4.8 Installation of insulation materials for equipment and piping off skid 2.4.9 Loading of adsorbents and catalyst

2.4.10 Filling of perlite for thermal insulation chambers 2.4.11 Utilities from Out Side Battery Limits (OSBL) 2.4.12 Underground piping , trench and open ditch 2.4.13 HVAC

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This docum en t wit h all its r ights is th e pr ope rt y of BU PC and m u st be h e ld in conf idence . No disclosur e, repr oduc ti on or o ther us e o f the docu m ent in wh ole o r p a rt s is to be m a d e w it hout th e p ri or conse n t o f B UPC 03 3. REQUISITION NOTES 3.1 GENERAL

3.1.1 Design and construction of the Air Separation Unit (ASU) shall be in

accordance with this specification. In addition, Vendor shall comply with all applicable codes, laws and regulations of the jurisdiction in which the equipment is to be operated.

3.1.2 Vendor shall design and fabricate the package to meet the

requirements mentioned in air separation unit process specification in item 3.2.

3.1.3 If any discrepancy is found during procuring, design and fabrication

stages, Vendor shall immediately inform PIDEC and shall obtain necessary clarification / approval before proceeding with the job any further.

3.1.4 Vendor shall complete/sign the attached letter of conformity and list

his probably deviations from this requisition clearly in his quotation

3.1.5 Equipment covered by this requisition shall be supplied in accordance

with the requirement set forth herein and attached reference documents that are to be considered as an integral part of this requisition.

3.1.6 Compliance with the provisions of this requisition does not relieve the

Vendor of the responsibility of furnishing the equipment of proper design, mechanically suited to meet performance guarantees at the specified operating condition.

3.1.7 Package shall be designed to be operable down to 60% of normal

flow rate for each train.

3.1.8 Vendor shall fill out all equipment data sheets and submit for PIDEC

and Owner review and approval. 3.1.9 Deleted

3.1.10 Material and corrosion allowances shall be considered for a minimum

of 25 years safe operation.

3.1.11 Material selection shall be made based on the referenced specifications as per American codes and standards.

3.1.12 Drawings, calculations and documents shall be submitted as indicated on the attached RFD sheets (attach. No.3).

3.1.13 All drain lines from drums / filters, etc. inside the package shall be

grouped together as far as possible and shall be routed to drain into a common drain funnel.

3.1.14 Vendor shall furnish details of anchor bolts (i.e. size, number, material

and setting plans ) according to 1210-00-ST-ESS-746 (attached to this requisition).

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This docum en t wit h all its r ights is th e pr ope rt y of BU PC and m u st be h e ld in conf idence . No disclosur e, repr oduc ti on or o ther us e o f the docu m ent in wh ole o r p a rt s is to be m a d e w it hout th e p ri or conse n t o f B UPC 03 03

3.1.15 Air Separation Unit including all accessories shall be shop painted as

per project painting specification 1210-00-PI-ESS-406 (attached to this requisition). Surface preparation as per SA 2 ½ and one coat proper primer and one coat proper intermediate and one finish coat as 1210-00-PI-ESS-406 (attached to this requisition).

3.1.16 This package shall be suitable for operation under out-door conditions

as per attached ambient and site condition and utility data 1210-00-PR-ESS-101 (attached to this requisition).

3.1.17 Vendor shall tabulate foundation loads including shear and axial

moment loads in erection, operation and test conditions for seismic loads and wind load as per UBC97.

3.1.18 Default nozzle loads should be as per: 1210-00-PV-ESS-242 (attached to this requisition). Vendor shall submit supporting calculations showing that the above loading data are exact, neither short nor conservative, any time when the PIDEC requests.

3.1.19 Material for pressure vessels, and piping shall procured as per project

requested codes & Standards.

3.1.20 Vendor should submit the HAZOP and SIL study for ASU package at

his own cost based on PFD, P&ID, Plot Plan and Equipment data sheets and safety-related equipment checklist. Vendor should provide information about the reported accidents in similar Plants in the world during HAZOP meetings.

The HAZOP and SIL study meeting should be held in presence of Owner, PIDEC and third party.

Vendor should introduce at least three qualified and internationally well known companies as third party of HAZOP and SIL study and the selected third party for HAZOP study is subject to Owner/PIDEC approval.

Vendor is responsible for implementation of any required modification and changes based on HAZOP and SIL study recommendations at his own cost.

3.1.21 Sub Vendors/suppliers shall be approved by Owner /PIDEC prior to placement of sub-orders. List of sub-Vendors shall be submitted at proposal stage.

3.1.22 Before start of fabrication Vendor shall submit QC plan and ITP to BUPC and PIDEC for approval.

3.1.23 Vendor shall submit the design calculations (based on attachment No.3) for PIDEC approval prior to fabrications. Fabrication shall not commence prior to PIDEC’s approval of documents.

3.1.24 For shipping of the equipment and materials, please refer to the document No. BU-00-GE-000-MEC-PRC-002-00, “Packing, Marking and Shipping Instruction” (attached to this requisition).

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This docum en t wit h all its r ights is th e pr ope rt y of BU PC and m u st be h e ld in conf idence . No disclosur e, repr oduc ti on or o ther us e o f the docu m ent in wh ole o r p a rt s is to be m a d e w it hout th e p ri or conse n t o f B UPC 03 03 3.1.25 Design Requirements: 3.1.25.1 Codes, Rules and Standards

The supply shall be in compliance with this specification, Codes, Rules, and Industrial Standards listed here below or elsewhere in the requisition or its attachments:

• Rotating Equipment:

- Air compressors: API Std 672 / API Std 617, 7th edition, July 2002

and specification 1210-00-MC-MSS-301 (attachment no.12.18)

- Steam turbines: API Std 612, 6th edition, November 2005, and specification 1210-00-MC-MSS-305 (attachment no. 12.19)

- Expanders: API Std 617 7th. edition, July 2002 - Process pumps: API 610, 11th edition and specification

1210-00-MC-MSS-307 attached to this requisition. I specification 1210-00-MC-MSS-308 for general service (attachment no. 12.21) for cooling water pumps - Cryogenic pumps: API 610, 11th edition and specification

1210-00-MC-MSS-307 (attachment no. 12.20).

-Vibration Monitoring Systems: API Std 670 • Air coolers: API Std 661

• S&T heat exchangers: TEMA I API Std 660 I ASME VIII Div. 1 or 2 • Auxiliary S&T heat exchangers

For rotating equipment: Mfr Std

• Plate exchangers: API Std 662 I Mfr Std • Welded type heat exchangers: Mfr Std

• Pressure vessels and

pressurized tanks: ASME VIII Div. 1 or 2 • Materials: ASTM Std. Code • Material quality certificate: EN 10204-3.1 • Piping: ASME B.31.3 • Flanges: ASME B.16.5

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• Threaded connections: ASME B1.1 and 8.20.1 • Safety relief valves: API RP 520- 527 / ASME VIII

• Electrical equipment: IEC / NEC / NEMA / ISO / ANSI / EN / CENELEC / BS

• Instruments: ISO / ISA / IEC

• Design of structural steel: AISC / ACI / U8C / BS

• UBC 97: For Wind & Seismic Design Load

The latest edition for all above Specifications, Codes, Rules and Standards shall be in effect at date of purchase order.

3.1.25.2 In case of doubts of interpretation or conflicts among the specifications, the

following decreasing order of priority shall be applied: 1. Duty specifications and data sheets

2. Client's specifications and documents mentioned or attached to this specification

3. This Specification (3.1.25.1)

4. National and International applicable standards and codes as listed in this Specification

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3.1.26 Following specifications should be considered for ASU plant.

Design Service Life Time Year 25

Continuous Operation between Deriming(Defrosting)

Year >2

Time Required for Clean up Liquid/Warming/Deriming

hr 24 Start-up Time (Start of

Turbo-Expander to O2 Purity)

hr Vendor To

Advise Start-up Time (Start of

Turbo-Expander, With Liquid to O2 Purity)

hr Vendor To

Advise Start-up Time (After

Temporary Stop to O2 Purity)

hr Vendor To

Advise Regeneration time for

Molecular Sieves hr 4

ASU Technology Internal

Compression

3.1.27 The Vendor shall specify the delivery time of ASU package. 3.1.28 The Vendor shall deliver equipment at BUPC site.

3.1.29 Vendor shall supply a list of proposed Sub-Vendors for each component such as motors, instruments, bearings, etc. indicating Sub-Vendor's model number, type, etc. along with their catalogues, drawings, etc, with first revision of offer for Owner/ PIDEC approval. Vendor shall not be free to substitute any other manufacturer or model unless so accepted by the PIODEC/ Owner.

3.1.30 For all purchased items, the overall responsibility as to their suitability and performance shall be of Vendor scope. Vendor shall ensure that all requirements of inspection, testing, drawings and documentation are complied by Sub-Vendors.

3.1.31 Vendor's service charges for erection and commissioning supervision and training for each section of the package will be separate and on daily basis. 3.1.32 Vendor shall fill out the Lubrication Schedule form, for lubrication details covering initial fill and two years normal operation (if applicable).

3.1.33 Bidder shall complete/sign the attached letter of conformity and list his probably deviations from this requisition clearly in his quotation.

3.1.34 UBC 97 to be followed for importance factor selection, in this regard based on table 16-K, equipment of ASU package could be categorized as “3. Special

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occupancy structures” except for Oxygen system/storage which shall be categorized as “2.hazardous facilities”.

Related importance factor to be selected by Vendor. 3.2 PROCESS SPECIFICATION

3.2.1 The present process specification has the purpose of providing the required

performances of the Air Separation Unit for the 5’000 MTD Methanol Plant and 1515.2 MTD MEG Plant in Assaluyeh (IRAN).

The ASU plants will provide:

 pure gaseous oxygen

 pure gaseous nitrogen

 liquid nitrogen buffer reservoir as well as evaporator for evaporation liquid nitrogen

 liquid oxygen buffer reservoir as well as evaporator for evaporation liquid oxygen

 independent instrument air and plant air package which will be located inside of ASU

The total required design capacity will be delivered by two units (cold boxes) equipped with three air compression trains (each train including one Main Air Compressor, Booster Air compressor , electric motor and steam turbine drivers). During normal operation, two air compression trains will be on stream, working in parallel, while one will be in stand-by. Each of air compressor trains on stream will have 55% normal capacity.

The package will be provided with two parallel lines (2 cold boxes) each line shall be designed for 60500 Nm3/h gaseous oxygen.

The provision for the third train of ASU and its related air compressor train(s) shall be considered in the design and supply of common facilities such as piping of feed air and products.

As the steam with specification mentioned in this document is available for the driving of steam turbine, so the Vendor shall consider in its design the maximum consumption of steam in the steam turbine as driver of the air compressors. Then shortage of power for the air compressors can be supplied by electric motor.

The steam turbine driver is a medium pressure steam condensation type. Liquid Nitrogen production shall be considered for the first filling of LIN storage tank and compensation of evaporation loss of the LIN storage tank (the capacity of LIN production to be recommended by Vendor).

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3.2.2 Expected performances and Technical Requirements

The unit shall be designed to deliver 2 x 60500 Nm3/h of gaseous oxygen ( with a minimum purity of 99.8%) at B.L of ASU plant; capacity related to oxygen liquefaction to be added to total capacity of the ASU plant in order to keep constant flow of gases oxygen at B.L of the package.

The Oxygen shall be available at B.L in two pressure level as per item 3.2.3.1of this requisition.

The unit shall deliver 14000 Nm3/h of gaseous nitrogen normal flow rate and 25000 Nm3/h as maximum flow rate, with purity higher than 99.95%. The turndown capacity of each ASU unit shall be 60% of its normal flow rate.

The three air compressors trains (two in operation and one stand by) for supplying feed air to two ASU trains shall be driven each by a condensation type steam turbine running on medium pressure steam.

Two trains will work in parallel during the normal operation.

A liquid nitrogen buffer tank (350 m3 capacity) shall be foreseen within unit battery limits and connected to the gaseous nitrogen network after evaporation in the vaporiser dedicated for this function. The nitrogen evaporator will be designed for 14000 Nm3/h. The type of evaporator is recommended to be water bath.

A liquid oxygen buffer tank (700 m3 capacity) (to be confirmed later) shall be foreseen within unit battery limits and connected to the gaseous oxygen network after evaporation in the vaporiser dedicated for this function. The oxygen evaporator will be designed for 60500 Nm3/h. The oxygen evaporator type is preferred to be water bath.

Medium pressure steam available at unit battery limits shall be used also for the molecular sieves regeneration and liquid Nitrogen Vaporizer (if the steam has to be de-pressurized and de-superheated all facilities should be considered by Vendor inside the package). The Vendor should consider necessary facilities for uninterruptible nitrogen supply in case of ASU shutdown and for cooling down of the liquid nitrogen and oxygen transfer pumps.

The Vendor shall provide detailed Process Flow Diagram plus the Heat & Material Balance table with expected figures for all streams.

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Sparing philosophy for ASU package is as following:

Main Air Compressor : 2W+1St.by

Booster Air Compressor : 2W+1St.by

Expander turbine : 1W+1St.by (for each train)

Cryogenic pumps : 1W+1St.by (for each train and for each

stream of liquid oxygen and liquid nitrogen)

Cooling pumps : 1W+1St.by (for each train)

Chilling pumps : 1W+1St.by (for each train)

Molecular sieves absorbent vessels: 1W+1St.by (for each train)

Future expansion space and design for the third train of ASU and related air compressors to be considered.

An independent separate package for IA (Instrument Air) and PA (Plant Air) should be considered inside the ASU package and supplied by the Vendor. Electrical driver compressors should be considered for the IA/PA package. Sparing philosophy for IA/PA package:

Main compressor: 2+1 (3 x 55%)

ASU Vendor shall design the plant in order to provide instantaneously back up N2 and O2 from relevant storage tanks in case of unit shut down. ASU will have a dedicated control system that shall be designed and supplied by ASU Vendor.

Vendor shall suggest cooling system by two options and shall report these options in his offer:

A : cooling system by usage air media for cooling.

B : cooling system by usage cooling water media for cooling.

Consumption figures and requirements for both alternatives should be proposed by Vendor for Owner / PIDEC verification and finalizing.

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This docum en t wit h all its r ights is th e pr ope rt y of BU PC and m u st be h e ld in conf idence . No disclosur e, repr oduc ti on or o ther us e o f the docu m ent in wh ole o r p a rt s is to be m a d e w it hout th e p ri or conse n t o f B UPC 3.2.3 Products characteristics

3.2.3.1 Oxygen Demand and characteristics: Design Flowrate (as 100% O2) for Methanol and MEG Plants

Nm3/ h

2 x 60500 Nm3/h Normal Flowrate (as 100% O2) for

Methanol and MEG Plants

Nm3/ h

2 x 55000 Nm3/h (2)

Temperature °C 15 (1)

MP GOX Operating / Design bar g 50/57

LP GOX Operating /Design bar g 29/31.5

Mechanical Design Temperature °C 85

Composition

O2 % 99.80 (min)

N2 + Ar % 0.20(split by Vendor)

total % 100.00

(1) Minimum Temperature to be confirmed by Vendor.

(2) Maximum normal flow rate for MeOH Plant : 75530 Nm3/h Maximum normal flow rate for MEG Plant : 36733 Nm3/h 3.2.3.2 Gaseous Nitrogen Demand:

Service Normal Peak

Total for design purpose of BUPC

Nm3/h 14000 25000

3.2.3.3 Gaseous Nitrogen characteristics:

Temperature °C Ambient (1)

Pressure at ASU B.L. bar g 7.5 min/ 8.5 normal/ 9 max

Mechanical Design Temperature °C 85 Mechanical Design Pressure bar g 10.5

Dew point at atm. °C -70

Composition

N2 % 99.9

O2 ppm (vol) 2 max

CO ppm (vol) 10 max

CO2 ppm (vol) 1 max

Oil ppm (vol) 0.5 max

S ppm (wt) 0.2 max

H2O ppm (wt) 1 max

H2 ppm (wt) 1 max

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This docum en t wit h all its r ights is th e pr ope rt y of BU PC and m u st be h e ld in conf idence . No disclosur e, repr oduc ti on or o ther us e o f the docu m ent in wh ole o r p a rt s is to be m a d e w it hout th e p ri or conse n t o f B UPC 03 03 3.2.3.4 Liquid Nitrogen:

Buffer Tank capacity m3 350 (2)

Liquid nitrogen continuous production to be minimized and should be adequate to compensate storage losses for self-cooling.

(1) Buffer tank filling max capacity flow rate: 5 m3/h (min), 10 m3/h max, Vendor to optimize.

(2) Buffer tank shall be completed with Nitrogen Evaporator which shall be able to produce 14000 Nm3/h (minimum) of gaseous nitrogen as per para 3.2.3.2.

(3) Nitrogen temperature shall be not more than 20°C below site

temperature.(Min. operating temperature related to vaporized nitrogen shall not be less than 5 °C)

.

3.2.3.5 Instrument Air Demand from Independent Instrument air and Plant air

package:

Service Normal Peak

Methanol Plant (ISBL) Nm3/h 800 900

Storage Tanks Nm3/h

65 215

Polishing Unit Nm3/h

Flare Unit Nm3/h

Bushehr Petrochemical Complex (excluding above units)

Nm3/h 5135 6885

Nm3/h 6000 8000

3.2.3.6 Instrument Air characteristics:

Pressure at ASU B.L. bar g 6.5 min / 8.5 normal / 9 max

Mechanical Design Pressure bar g 10.5

Dew Point °C - 40 / Oil Free

Max particle size µm 5

(1) To be confirmed by Vendor.

(2) Any required facility for purification and drying of air including internals, molecular sieves, interconnection piping, manual/ automatic valves, instrumentation, regeneration system and etc. should be provided by Vendor of the package.

(3) Instrument Air/ Plant Air receiver to be considered in the independent instrument air and plant air package. Buffer volume, which will supply instrument air to the instrument air main header, shall be designed for, at

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least, 30 minutes of normal consumption of whole Bushehr Petrochemical complex.

(4) Instrument Air back-up in case of ASU shut-down and buffer volume consumption to be provided by OSBL. This is necessary for the safe shut-down of Bushehr Petrochemical Complex in case no instrument air will be available from ASU.

3.2.3.7 Plant Air demand from Independent Instrument air and Plant air package:

Service Normal Peak

Methanol Plant (ISBL) Nm3/h 200 500

Storage Tanks Nm3/h NNF 420 Polishing Unit Nm3/h Flare Unit Nm3/h Bushehr Petrochemical Complex (excluding above units) Nm3/h 2000 3600

Nm3/h 2500 5000

3.2.3.8 Plant Air characteristics:

Pressure at ASU B.L. bar g 6.5 min / 8.5 normal / 9 max

Mechanical Design Pressure bar g 10.5

Max particle size µm 5

(1) To be confirmed by Vendor.

3.2.4 Vendor shall indicate the expected consumption for all utilities. 3.2.4.1 Medium pressure steam

The available Medium Pressure Steam (MPS) to be used, during normal operation, as motive fluid for compressors steam turbines will have the characteristic summarized in the following table.

The available MPS flow rate from Methanol Plant will be 250 t/h.

The Vendor shall consider in his design the maximum consumption of MPS for the steam turbine drivers of air compressors. Then the rest of drivers shall be considered as electric motor.

Minimum Normal Maximum Mechanical Design Pressure (bar g) 47 49 50.5 57&FV

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Vendor to state the possibility to start-up the unit and run it in case of Methanol Plant upset having MPS (the relevant flow rate to be given by the Vendor and to be confirmed by the purchaser) at the following conditions:

Minimum Normal Maximum Mechanical Design Pressure (bar g) 38 40 42 47&FV

Temperature (°C) 400 410 430 470

3.2.4.2 Cooling water

Open loop cooling water will be available at process plant B.L.

Thermal design Mechanical Design

Supply Pressure (bar g) 4.5 8.5

Supply Temperature (°C) 35 85

Max. allowed T within process plant BL: 10°C (return temperature 45°C)

Max. allowed P within ASU plant BL: 1 bar (return pressure 3.5 bar g)

Chloride content (as Cl-): 150 ppm wt (max) 3.2.4.3 Electricity

Electric power supply at ASU BL is 20000 V, 3ph, 3 wires, 50 Hz. The standard voltage rating for various utilization loads are as follows:

No. Item AC/DC

Rated Voltage (V) Phase/Wire 1 2500 kW and above AC 11000 3/3 150 kW and above AC 6000 3/3 0.2 kW to 150 kW AC 400 3/3 below 0.2 kW AC 230 1/2 2 Construction and Maintenance AC 230 - 400 1/2 - 3/4 3 Lighting Fixtures AC 230 1/2 4 Emergency Lighting AC 230 1/2 5 Instruments AC 110 1/2 6

Controls for H.T. Boards+

H.V. Motors DC 110 ---

7 Controls for L.T. Board AC 230 ---

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This docum en t wit h all its r ights is th e pr ope rt y of BU PC and m u st be h e ld in conf idence . No disclosur e, repr oduc ti on or o ther us e o f the docu m ent in wh ole o r p a rt s is to be m a d e w it hout th e p ri or conse n t o f B UPC 03 3.2.5 Site Information 3.2.5.1 Plant Location

The Plant is located at Bandar Assaluyeh, Iran. 3.2.5.2 Site Climatic Condition

3.2.5.2.1 Air Temperatures

- Max. recorded temperature 52°C

- Min. recorded temperature 5°C

- Max wet bulb temperature 33°C

- Dry bulb design temperature 50°C

- Max temperature for mechanical, civil and

structural design 55°C

- Max. temperature for equipment exposed to

sunlight (design value) 85°C

- Minimum Design Metal Temperature 5°C

3.2.5.2.2 Air Humidity

- Max. relative humidity in summer 76%

- Min. relative humidity in winter 74%

- Design relative humidity and temperature 76% at 48°C

- Design relative humidity for Electrical equipment 80%

3.2.5.2.3 Barometric Pressure and Altitude

The barometric pressure at site is ranging from 990 to 1'100 mbar. 3.2.5.2.4 Wind

a) Max wind velocity - 125 km/h at 10 m above ground for

structural design

- 16 m/s at 10 m above ground for flare thermal radiation

b) Prevailing wind direction North-West

For mechanical and civil structures design purpose, wind shall be considered from all directions.

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3.2.5.2.5 Rainfall and Snow Precipitation

a) Design Rainfall precipitation values

in 3 minutes: 17 mm

in 10 minutes: 24 mm

in 1 hour: 40 mm

in 1 day: 70 mm

b) Rainfall value for sewer design 40 mm/hr

c) Design snow load 25 kg/m2

3.2.5.2.6 Other Climatic Phenomena to Consider a) Sand storm – to be considered

b) Thunder and lightning – to be considered c) Sea breeze – to be considered

3.2.5.2.7 Earthquake (Seismic Factor)

Earthquake shall be considered for ZONE 4 as per UBC. 3.2.5.2.8 Other Data

Transportation : Provisional and national roads

capacity

 Max. weight : up to 96 ton

 Max load per axle : 12 ton

 Max height : 5.2 m

 Max width : 5 m

 Max length : 50 m

Transportation by sea: No limitation by size or weight.

3.2.5.2.9 Available Unit Area

The available plant area for Air Separation Unit corresponds to 140 m(fixed) x 80 m (Vendor to confirm)

Two trains and INA/PA packages shall be located in available area. The third train should be arranged in additional area (if required).

3.3 EQUIPMENT

Each train of the Air Separation Unit shall be complete with all the accessories and auxiliaries necessary for safety and satisfactory operation and shall include, but shall not be limited to, the main equipment listed below:

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03 3.3.1 Process Main Air Compressor (MAC)

Each MAC will include the following main components:

• Inlet filter, self cleaning type, suitable for the site environment conditions • Centrifugal multistage integrally geared compressor oil free

• Shaft sealing system

• Automatic flow regulation system by Inlet Guide Vane (IGV) • Automatic anti-surge control and protection system

• Blow off valve and blow off silencer

• Safety relief valve (inter stage and final stage) • Speed gear

• Flexible coupling/s

• Vibration and axial position probes I transducers for compressor bearings • Compressor Inter-cooler

• Compressor After-cooler

• Steam turbine driver (common for MAC and BAC(Booster Air Compressor))

The steam turbine shall mainly include:

- Steam chest

- Trip & throttle valve

- Electronic governor

- Speed sensors

- Emergency trip device

- Over speed trip device - Exhaust shutoff valve

- Shaft seals including gland vacuum system with condenser and ejectors

- Vibration and axial position probes I transducers for turbine bearings

- Turning device

• Steam turbine exhaust condensing unit

- Each train with air or water cooled condenser

• Common Lube Oil system for turbine, gears and centrifugal compressors

bearings

• Electric Motor drivers for remaining MAC and BAC (in case that MPS to be insufficient for all the MAC and BAC)

• Skid assembly including compressors, driver, auxiliary equipment and systems, instrumentation, junction boxes and local control station

3.3.2 Air pre-purifying and drying unit dual vessel type, including internals, molecular sieves, interconnection piping, manual I automatic valves, instrumentation and regeneration system.

3.3.3 Booster Air Compressor (BAC) centrifugal multistage integrally geared. The BAC will be part of a common train with the MAC.

MAC and BAC will be driven by a common steam turbine(for steam turbine driven air compressors only). For the motor driven compressors, each MAC and BAC shall have its own electric motor driver..

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• Centrifugal multistage integrally geared compressor • Shaft sealing system

• Automatic flow regulation system • Automatic anti-surge control system • Blow off valve and blow off silencer

• Safety relief valve (inter stage and final stage) • Speed gear

• Flexible coupling/s

• Vibration and axial position probes I transducers for compressor bearings • Compressor Intercooler (see point 3.3.17)

• Compressor Aftercooler (see point 3.3.17)

3.3.4 Expansion turbine and auxiliary booster compressor integral unit, including automatic speed control device (two units shall be provided, one in operation + one in standby) for each train.

3.3.5 Heat exchangers cold box including: • Process heat exchangers

• Internal interconnecting piping and supports • Manual and automatic valves

• Instrumentation • Drain facilities

• External shell and self-supported steel structure

• Insulation materials (perlite, rockwool panels and cover sheets) • External and internal stairs and maintenance platforms

3.3.6 Rectification cold box including:

• Medium and low pressure columns complete of internals • Condenser I reboiler

• Sub-cooler

• Internal interconnecting piping and supports • Manual and automatic valves

• Instrumentation • drain facilities

• External shell and self-supported steel structure

• Insulation materials (perlite rockwool panels and cover sheets) • External and internal stairs and maintenance platforms

3.3.7 LIN (Liquid Nitrogen) and LOX (Liquid Oxygen) cryogenic pumps. Two pumps for each service (one in operation+ spare) shall be provided. LIN back up system shall be quick response type, so that no interruption taken place in the gaseous nitrogen supply to header (specially during the time for cooling down of the LIN pumps).

3.3.8 LIN 350 m3 volume buffer tank with pressure built up vaporizer and LIN vaporizer for GAN network feed.

3.3.9 LOX 700 m3 (to be confirmed later) volume buffer tank and LOX vaporized for GOX network feed shall be supplied by the Vendor.

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3.3.10 Main and booster air compressors shall comply with API 672 or API 617.” 3.3.11 Expanders shall comply with API 617, 7th. edition, July 2002.

3.3.12 The permissible speed range of the centrifugal compressors for continuous operation shall be clearly stated by the manufacturer.

3.3.13 The performance of the compressor units and the mechanical requirements shall be specified by the ASU Vendor.

3.3.14 The performance test of the compressor units shall be carried out by Vendor according to ASME PTC-10 or ISO 5389, latest edition)

3.3.15 The compressors shall be considered as a packaged units including at least: - Air intake

- Inlet filter - Main Driver

- Lubrication unit (common for compressor and driver) - Oil cooling system

- Machinery monitoring system for compressors and drivers, including vibration probes, temperature probes and vibration monitors in suitable control panel.

- Safety and control instrumentation - Anti surge device

- Local panel

3.3.16 The compressors packages shall be designed and fabricated in accordance with all the rules of good engineering practice and taking into account any unusual condition peculiar. As a minimum, the following features shall be provided:

• Suitable protection of the equipment to ensure the safety of personnel during operation and maintenance

• Maximum reliability • Ease of maintenance

3.3.17 Below philosophy for the process air compressors intercoolers and aftercoolers to be considered as separate option:

• MAC intercooler:

- Cool down by air or water cooled heat exchangers • MAC aftercooler:

- Cool down by air or water cooled heat exchangers • BAC intercoolers and aftercooler:

- Cool down by air or water cooled heat exchangers

3.3.18 For expansion turbine and auxiliary booster compressor magnetic bearings are required.

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3.3.19 Steam turbines shall be horizontal design, multistage, condensing type. Medium pressure steam for steam turbine is available with the following characteristics: - Pressure (Minimum I Normal I Max): 47 I 49 I 50,5 barg

- Temperature (Minimum I Normal I Max): 370 I 396 I 410 °C Exhaust steam condensation shall be as follows:

- Steam turbines trains : operating pressure related to surface condenser to be modified / confirmed by Vendor

3.3.20 Steam Turbine selected for Compressors as a driver shall comply with API 612, 6th edition, November 2005, and specification 1210-00-MC-MSS-305 (attached to this requisition).

3.3.21 Special provisions for emergency lube oil supply to bearings and gears shall be made in case of turbine shut-down. This shall require overhead reserve oil tank to supply lube oil at adequate pressure when there is breakdown of power. Necessary control circuit shall also be provided for this system.

3.3.22 The turbine and auxiliary equipment shall be designed for outdoor operation. 3.3.23 Local control panel shall be adjacent to turbine for easy operation.

3.3.24 Vendor shall supply if any expansion joints or adaptor required between steam turbine and air or water cooled condenser.

3.3.25 The Lube oil system for Compressor package shall be designed and manufactured according to API 614, 5th edition, April 2008, and relevant specification (attached to this requisition).

3.3.26 Lube oil pumps shall comply with API 676, 2nd edition, December 1994. 3.3.27 Cryogenic Centrifugal pumps shall comply with API 610, 11th edition and

specification 1210-00-MC-MSS-307 (attached to this requisition).

3.3.28 Centrifugal pumps for cooling water shall comply with specification for centrifugal pumps for general service 1210-00-MC-MSS-308 (attached to this requisition). 3.3.29 Vendor shall furnish complete information about pump characteristics: head,

efficiency, power, NPSH vs. capacity for the fluid pumped and head vs. capacity for Max. and Min. Sizes of impeller.

3.3.30 Complementary Equipment /Materials Required for the complete ASU:

• Interconnecting piping for process lines according to project piping classes inside the ASU BL, including supports and accessories

• Interconnecting piping for utilities lines according to project piping classes inside the ASU BL, including supports and accessories

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• Set of control valves, on-off valves, solenoid valves, isolation valves, manual valves, etc for process and utilities lines.

• PSV's including piping connection to relief points in safe location. • Warm and cold insulation for piping and equipment as necessary.

For equipment installed on skid the insulation must be, as far as possible, installed in supplier workshop; otherwise, as for the equipment supplied loose and the interconnecting piping, insulation materials in bulk shall be provided.(Vendor to provide specification for cold insulation as per operating condition of system .MTO for insulation should be provided by Vendor.) • Acoustic insulation and additional measures (acoustic hoods, silencers, baffles etc),as necessary to meet the noise limitation requirements.

• The noise level to be respected is 85 dBA maximum at 1 meter from the edge of each skidded equipment or single equipment installed alone.

• In case of exceeding the specified noise level, Vendor has to solve the noise exceeding problems providing all additional measures and materials at own cost.

• During engineering design, Vendor shall indicate the overall sound power level of the whole package unit in operation. This information shall be considered for evaluation of the total noise impact of whole plant at the fence limit.

• Vendor shall submit the expected noise data sheet.

• Prefabricated structural steel for main structures and pipe racks, including erection materials

• Platforms, stairs, ladders, handrail and grating, where necessary for accessing to the equipment, according to Mfr Std.

• Surface preparation and painting according to the Project Technical Specification for Painting attached to this requisition.

• Cable glands for instruments and junction boxes

• First charge of adsorbents and I or catalysts, including provision for losses (quantities at least for two years operation).

• First charge of lubricants (quantities at least for two years operation). • Flushing fluids - if any

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• HAZOP and SIL study (The HAZOP and SIL study meeting shall be held in presence of Owner, Contractor, and third party).

3.4 PROCESS CONTROL

3.4.1 It is Vendor responsibility to design its package as required to permit safe and orderly start-up, shutdown and operation.

3.4.2 Vendor’s recommended start-up, shutdown and operating procedure, will be reviewed by PIDEC.

3.4.3 The above procedure shall be included in the package “operating and maintenance manual”.

3.5 INSTRUMENTATION ‘General’

3.5.1 The control and monitoring of ASU unit will be considered in a dedicated control

room/building. Additionally, provisions shall be taken into account to perform data communication with offsite ITR. It should be noted that offsite DCS operator stations and cabinets (if any) will be installed in ASU control room.

3.5.2 Control room design (including CCR, auxiliary room, Eng. room, ...) and relevant

documents such as Control room layout, Cabinets & Operator/Engineering stations arrangement, cable ladder arrangements and etc. shall be provided by Vendor.

3.5.3 Vendor shall calculate and supply required power supply (110 V AC, 50 Hz, UPS)

for control systems and field instruments (redundant feeders shall be considered for control systems of all packages).

3.5.4 Vendor shall design and supply “Safety & Instrument Grounding” requirements.

3.5.5 Vendor shall design and supply all the instrumentation necessary for the safe and

efficient operation of the Air Separation Unit (ASU) to fulfill the process requirements specified in this requisition. This includes, but not limited to all the instruments and control required for safe and satisfactory start up, control and shut down of the package units.

3.5.6 All instruments in hazardous area shall be of intrinsically safe (IS) type. Using of

explosion proof devices are only acceptable if IS type is not commercially available. Signals from/to MCC’s shall be considered as non-IS.

All panels, enclosures and junction boxes shall be explosion protected according to their area classification.

All field mounted instruments, enclosures and junction boxes shall be protected to IP-65.

3.5.7 SIL STUDY shall be performed for packages based on IEC- 61508 and ESD loops

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study shall be considered for PLC and instruments.

3.5.8 The process override or maintenance override switches shall be shown on relating

diagram (if required) and the required facilities shall be foreseen as per Vendor’s common practice.

3.5.9 Air supply to pneumatic instruments and instrument air distribution inside ASU is in

Vendor scope of supply and work.

3.5.10 All instruments and control systems shall be calibrated/ configured, programmed and debugged completely before delivery to minimize field works. PLC system and related equipments, barriers, power distributions etc. as well as cabinets, local panels shall be shop fabricated and wired up to the terminals, ready for installation and interconnection at site.

3.5.11 Vendor shall recommend spare parts for commissioning and 2-year operation. 3.5.12 All instruments and devices shall be supplied with nameplates indicating tag no.,

type, model no., serial no., range, type of protection, certifying authority, etc.

3.5.13 For FCS and respective cabinets, please refer to document No. 1210-00-IN-MSS-601, “Material Standard Specification for Fieldbus Control System” (attached to requisition).

3.5.14 For instruments selection and control / safety systems design, please refer to document No. 1210-00-IN-ESS-603, “Engineering Standard Specification for Package Instrumentation” (attached to requisition).

3.5.15 For PLC-based control / shutdown system and respective cabinets, please refer to documents No.1210-00-IN-MSS-673, "material standard specification for programmable logic controllers" (attached to requisition) and 1210-00-IN-MSS-672, "material standard specification for cabinets" (attached to requisition).

3.5.16 For MMS, please refer to document No. 1210-00-IN-MSS-676, “Material Standard Specification for Machine Monitoring System” (attached to requisition).

3.5.17 For electrical interface with MCC’s, please refer to document No. 1210-00-IN-SKT-005, “Instrument/Electrical Connection Details” (attached to requisition).

3.5.18 For Vendor documentation, please refer to document No. 1210-61-PR-RFD-104, “Requirement for Documents” (attachment No. 3).

‘Control System’

3.5.19 The PLC’s used for shutdown of ASU shall be fully redundant (CPU, bus, communication modules, power supply, I/O cards, etc).

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3.5.21 The PLC’s shall have the capabilities to integrate and work with the main instrumentation and control and shall have the communication capabilities to exchange data from and to other external PLC based control equipments and FCS. 3.5.22 Each PLC system shall communicate with Plant FCS (if any) by redundant

bi-directional Modbus RTU through RS 485 physical layer. FCS will act as the master. Coordination with FCS Vendor has to be carried out by Vendor.

3.5.23 The PLC’s shall be provided with all required system software including application/utility programs, engineering/configuration tools, checking and self-diagnostic fault detection capabilities.

3.5.24 The required shut-down, start-up and inter-lock diagrams, based on IEC 61131, shall be provided and implemented in ASU’s control system by Vendor.

3.5.25 The system logic shall be ‘fail safe’. All instruments shall be considered for fail to safe action upon loss of instrument air or electrical power. The input contacts to alarm, interlock and emergency shutdown system shall be close (make contact) during normal operation and open on alarm or trip. The solenoids shall be energized during normal operation and de-energized to trip.

The status of all switches in normal operating conditions shall be logic high “1”. 3.5.26 Comprehensive system status information shall be available on standard displays.

The PLC shall be capable of on-line replacement of any faulty module without requiring system shutdown.

3.5.27 Sensors for shutdown shall be separated from sensors provided for measurement, control or pre-alarms.

3.5.28 PLC control system shall receive synchronization signal from Plant FCS, at predefined periods and make synchronized with Plant FCS.

3.5.29 Provision shall be made to facilitate Machine Monitoring interface to Machine Condition Monitoring (where applicable).

3.5.30 All the system hardware (including monitoring, control, protection, communications, communication with FCS, etc.) complete with all software (including application software) installed and loaded on the corresponding hardware, are subject to Factory Acceptance Test (FAT). FAT procedure shall be prepared by Vendor, approved by Owner and used as the guideline for performing FAT. Owner reserves the right to modify Vendor’s standard procedure.

‘Field Instruments’

3.5.31 The instrumentation shall be rated to withstand the tropical, dust, humid environmental conditions.

3.5.32 Design and supply of all instruments, including process / air tubing and cabling are within Vendor’s scope of supply.

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3.5.33 All instruments shall be cabled up to auxiliary room through relevant junction boxes / local panels.

3.5.34 All instruments installation materials including fittings, isolation and drain valves, manifolds, junction boxes, cable ladders/trays, glands, instrument support, etc. are in Vendor’s scope of supply.

3.5.35 Vendor shall provide 4-20 mA, HART transmitters with integral indicator and potential free contacts switches. Solenoid valves shall be IS with 24 VDC voltage rating.

All limit switches for automatic valves shall be proximity (NUMOR) type and intrinsically safe.

3.5.36 All instrument/automatic valves wetted parts and process/air tubing materials shall be S.S. 316 as minimum, other materials as per process conditions.

3.5.37 All cable entries shall be M20X1.5 with explosion-proof cable glands.

3.5.38 Isolating valves shall be provided for all instruments. Multi port gauge valves for pressure switches and gauges and 5-valve manifold for DP transmitters shall be considered.

3.5.39 Guidelines for selection of Spare parts for commissioning/ start up and two years operation are listed below:

Erection, pre-commissioning, commissioning and start-up spare parts For Control Panel

Siganl Lamp Fuse Elements 50% 50% Field Transmitters: Gasket 30% Field Instruments: Air Pressure Regulators Temperature Indicators Pressure Gauges Solenoid Valves Valve Positioners Cable – Single Pair Cable – Multi Pair Cable Glands

Junction Boxes – Large Pipe and Tube

Fittings, all Type Valves

Manifold Valves Cable Tray

10%

20% each type (min one ) 20% each type (min one ) 15% each type (min. one Set) 15% each type (min. one Set) 20% 20% 20% 1 min. 10% 15% each size 20% min. one valve 10% each type 20%

DCS:

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This docum en t wit h all its r ights is th e pr ope rt y of BU PC and m u st be h e ld in conf idence . No disclosur e, repr oduc ti on or o ther us e o f the docu m ent in wh ole o r p a rt s is to be m a d e w it hout th e p ri or conse n t o f B UPC Fuse Elements Printer Paper Printer Ribbon 50%

4 Boxes Each Type 10 sets each type Gas Chromatograph:

Filter Elements

Calibration Gas Cylinders Standard Gas Cylinders Other Gas Cylinders

20%

1 Cylinder (100 litres) each type 1 Cylinder (100 litres) each type 1 Cylinder (100 litres) each type Other Analysers:

Filter Elements

Calibration Gas Cylinders Standard Gas Cylinders Other Gas Cylinders

20%

1 Cylinder (100 litres) each type 1 Cylinder (100 litres) each type 1 Cylinder (100 litres) each type Guidelines for selection of two years operation spare parts Flow Instruments Level Instruments Temperature Instruments Pressure Instruments Analyzers To be determined in conjunction with the equipment Vendor (based on Vendor’s experience on similar type of plant) Control Valves: Valve Bodies Valve Plugs Seat Rings Actuator Valve Stems Steam packing Grease Diaphragms

None unless service is corrosive or erosive.

For corrosive or erosive service, shall be determined in conjunction with the Vendor.

1 of each size/min. 15% or 1 2 of each size/min. 25% or 2 10% (min. one per type/size) 1 of each diameter-

These vary in length depending on valve size. Purchase the longest of each dia. These can be cut to the correct size.

3 boxes of each size used/min.30% 3 boxes of each type used/min.20% 2 of each size used min. 20%

Pressure Gauges 15% each type (min two)

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Valve Positioners 15% each type

Thermocouples 15% each type (min two)

Blank Orifice Plates Manual Loading Stations

Instrument Air Filters (Regulation sets) Pressure Switches

Plug-in Assemblies for Elect. Instr.

Plug-in Assemblies for Pneum. Instr. 10%

Seal, Condensate and Vent Pots (for all)

Solenoid and Trip Valves

Thermowells Signal Lights

I/P Converters

FCS/DCS/ESD/PLC (for each system) the Following Items:

I/O Cards Main Cards

Power Supply (AC, if any) Power Supply (DC, if any) Barrier Cards

20%, min. one for each type 1 set

1 set 1 set

20% for each type (min. 1 for each type)

On-Line Gas Chromatographs:

Main Mother Cards One set

Column One per type

Barrier Cards 20% for each type

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This docum en t wit h all its r ights is th e pr ope rt y of BU PC and m u st be h e ld in conf idence . No disclosur e, repr oduc ti on or o ther us e o f the docu m ent in wh ole o r p a rt s is to be m a d e w it hout th e p ri or conse n t o f B UPC 03 3.6 ELECTRICAL

Furthermore to the items listed in table of scope of work/ supply below list to be considered as well: S/N Description Scope of design (layout, calculation, MTO...) Scope of supply of equipment 1 CCTV SYSTEM V V 2 TELEPHONE SYETEM P V

3 CALCULATION FOR SHORT CIRCUIT STUDIES V N/A

4 CALCULATION FOR LOAD FLOW STUDIES V N/A

5 CALCULATION FOR LARGE DRIVE STARTING STUDIES V N/A

6 CALCULATION FOR RELAY SETTING SCHEDULE &

COORDINATION STUDIES V N/A

7 CALCULATION FOR ELECTRICAL LOAD BALANCE SUMMARY V N/A

8 SWITCHGEARS V V 9 PDCS V V 10 TRANSFORMER V V 11 NGR V V 12 CABLE V V 13 D/G V V

14 EQUIPMENT ARRANGEMENT LAYOUT IN BUILDINGS V V

15 SUBSTATION CABLE ROUTING LAYOUT IN BUILDINGS V V

16 LIGHTNING PROTECTION LAYOUT P V

17 EARTHING IN BUILDINGS P V

18 EARTHING IN AREA V V

19 LIGHTING AND SMALL POWER IN BUILDINGS P V

20 LIGHTING AND SMALL POWER IN AREA V V

21 PAGING IN BUILDINGS P V

22 PAGING IN AREA V V

23 RADIO SYETEM V V

24 HEAT TRACING V V

25 FIRE ALARM IN BUILDINGS P V

26 FIRE ALARM IN AREA V V

27 CATHODIC PROTECTION V V

28 UPS V V

29 DC CHARGER V V

30 HAZARDOUS AREA CLASSIFICATION DRAWING V N/A

31 UNDERGROUND CABLE ROUTING P N/A

32 CABLE TRAY/LADDER/GLAND/ACCESSORIES V V

33 LIGHTING & DISTRIBUTION PANEL IN BUILDINGS P V

34 LIGHTING & DISTRIBUTION PANEL IN AREA V V

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36 LOCAL CONTROL STATION V V

V: By Vendor P: By PIDEC N/A: Not Applicable

3.6.1 Selection, sizing and supply of electrical equipments should be as per the below project specifications:

a. 1210-00-EL-MSS-502: Material standard specification for MV

switchgears.

b. 1210-00-EL-MSS-503: Material standard specification for LV

switchgears.

c. 1210-00-EL-MSS-504: Material standard specification for power and

distribution transformers.

d. 1210-00-EL-MSS-505: Material standard specification for PDCS.

e. 1210-00-EL-MSS-506: Material standard specification for AC UPS.

f. 1210-00-EL-MSS-507: Material standard specification for DC battery

charger.

g. 1210-00-EL-MSS-508: Material standard specification for electrical

panel boards.

h. 1210-00-EL-MSS-509: Material standard specification for electrical

cables and wires.

i. 1210-00-EL-MSS-510: Material standard specification for cathodic

protection.

j. 1210-00-EL-MSS-515: Material standard specification for electrical

heat tracing.

k. 1210-00-EL-MSS-517: Material standard specification for LV variable

speed drives.

l. 1210-00-EL-MSS-519A: Material standard specification for MV

capacitor banks.

m. 1210-00-EL-MSS-519B: Material standard specification for LV

capacitor banks.

n. 1210-00-EL-MSS-520: Material standard specification for

aircraft warning lights.

o. 1210-00-EL-MSS-521: Material standard specification for LV

induction motors.

p. 1210-00-EL-MSS-522: Material standard specification for MV

and HV Motors.

q. 1210-00-EL-MSS-528: Material standard specification for local

control stations.

r. 1210-00-EL-MSS-534: Material standard specification for MV

variable speed drives.

3.6.2 Electrical installation/electrical design should be as per the below project specifications:

a. 1210-00-EL-ESS-501: Engineering standard specification for

electrical system design.