Tender For Vru(Vapour Recovery System) Od Dharmapuri Terminal - Design, Engineering, getting approvals from Purchaser/ Consultant, procurement of raw material, manufacturing, testing & inspection, Supply including packing & forwarding and transportation (on FOT site basis) and commissioning & performance testing of the Skid Mounted Activated Carbon Bed Adsorption Type (with or without membrane) Vapor Recovery System for recovery of Motor Spirit (MS), vapour generated from simultaneously loading of maximum 06 nos. of Trucks (for bottom loading) and 14 No. of rail wagons(top loading) ,meeting stipulated emissionlevel of Hydrocarbon Vapor as per stipulated conditions specified in the Ministry of Environment and Forests guidelines and also as specified in tender document. Supply of Mandatory Spares as per list enclosed and also supply of spares required during commissioning till guarantee/ warranty period. Mandatory Spares may be used by the Vendor during commissioning till guarantee/ warranty period. However, these spares shall be replaced free of cost to HPCL at Dharmapuri Terminal at the end of guarantee/ warranty period. Supply of anchor bolts is included in the Bidders scope. The Vapor recovery system should be designed to meet the maximum concentration of Hydrocarbon in the vapour at the outlet to be 5 g/m3 or as per MOEF guidelines whichever is more stringent. The Vapor Recovery System with maximum capacity 1350 m3/hr. consisting of the following complete as specified but not limited to the same:-:i) Maximum Treatment Capacity of vapour to be 1350 Nm3/hr.ii) Minimum treatment Capacity of Vapour to be 20 Nm3/hr.iii) The normal concentration of Hydrocarbon in the vapour is 40-60 % by volume.iii) Analysis of exhaust vapor is required.iv) The design calculations, drawings, P&I, Data sheet to be vetted by TPI Agency ie DNV/ BV/Lloyds/ IRS/ TUV.1.A MECHANICAL:1.A.1 Primary separating system 2 Set (1W+1S) consisting of Activated Carbon Adsorber (ACAD) with Suction Blower etc. complete as per specification. Exclusion of suction blower shall be subject to TPI clearance with proper technical reason. 1.A.2 ACAD Regeneration system consisting of, but not limited to:a) Absorption column (Packed Column) 1 Set for absorption of Hydrocarbon vapor from saturated ACAD. It is advisable to include demister pad. Exclusion of the demister pad shall be subject to TPI clearance with proper technical reason.b) Dry Vacuum Pump 2 Set (1W+1S) of suitable capacity with suitable head including FLP electrical motor with Variable Frequency Drive (VFD) for removal of HC vapor from ACAD.1.A.3 a) Centrifugal pump 2 Set (1W+1S) (as per API 610 6th edition) set, along-with mechanical seal, of suitable capacity with suitable head including FLP electrical motor, accessories etc. for transfer of MS liquid from Absorption Column to storage tank through Pipeline and valves.b) Centrifugal pump 2 Set (1W+1S) (as per API 610 6th edition) set, along-with mechanical seal, of suitable capacity with suitable head including FLP electrical motor, accessories etc. for transfer of MS liquid to Absorption Column from storage tank through Pipeline and valves. The suction pipeline for this pump shall be design considering NPSHA 4.0 MLC.1.A.4 It is advisable to include Booster Blower 2 Set (1W+1S) of suitable capacity and head including FLP electrical motor to meet the pressure requirement of Absorption Column to be installed downstream of Dry Vacuum Pump. Exclusion of the Booster blower shall be subject to TPI clearance with proper technical reason.1.A.5 Vendor to provide auto-actuated Nitrogen Purging system 1 Set as additional safety measure along with Nitrogen cylinders and valves fittings, Instruments. If required.1.A.6 First fill of lubricants, oils & grease; First fill of all adsorbent. Lot 1NOTES:a) It may be noted that MS, HSD mix vapour is envisaged from Tank Truck gantry in bottom loading at the location.b) The approved TPI Agencies are DNV/ BV/ Lloyds/ IRS/ TUV only. The documents to be vetted by only these TPI agencies as required.1.B ELECTRICAL1.B.1 Motor Control Centre (MCC) 1 Set along with VFD (as required, for each pump) & provision for interlocks for all Electrical drives.1.B.2 Earthing & Lightning protections Lot 11.B.3 Power cables 1 LOT (approx. distance 260 M from VRU skid to existing MCC/ PMCC), Control cables, Cable trays, Supports, Local Control Station (LCS), FLP JBs & accessories inside Battery Limit including UPS DB feeder at MCC and control room. Job includes all cabling jobs to VRU skid from MCC. Vendor to assess requirement of cables by locating existing MCC Room & Control Room and proposed VRU.NOTES:a) Vendor shall confirm that in case any other spare is consumed over and above the ordered commissioning spares related to VRU pumps, drive system or instrumentation, during commissioning, the same shall be replaced/ supplied free of cost by the vendor.b) Mandatory spares: Cost of mandatory spares shall be added to the equipment cost for commercial evaluation.c) Special Tools and Tackles: Bidder shall submit the list of special tools and tackles considered by them along with offer which shall besupplied along with pump. Rates for all these items shall be included in the quoted rates for Pumps and shall not be paid separately.1.C PIPING WORKS1.C.1 Complete work of supply & erection of pipes, fittings, flanges, valves etc. for VRU skid 1 LOT including all taxes, duties, transportation to store and inspection charges but not limited to, the following items in accordance with relevant specifications and instructions of Engineer-in-charge.Civil work is excluded from the suppliers scope. However, design, preparation of civil drawings and stage verification of dimensions of civil structures are included in the present Bidders scope. Structural work for skid installation is included in vendor scope of works i.e. pipe support, guide support, necessary operating platform including supply of the material. Performing all above and or underground piping fabrication works including cutting, edge preparation (inclusive of grinding the edges of pipes, fittings etc. to match with the matching edges of uneven/ different thickness wherever required),fit up, preheating wherever required, welding, threading etc.; erection of pipes of all types and sizes and thicknessover sleepers, overhead on racks and at all elevations; hook-up with equipment nozzles etc. fittings of all sizes i.e. elbows, reducers, tees, o lets, flanges, blind flanges, tapings for sample connections, vents and drains required for process and hydro testing purposes etc. carrying out 10% nondestructive testing of each size such as radiography by gamma ray, magnetic particle, liquid penetration etc. as required. Cleaning and flushing by water/ compressed air, carrying out hydrostatic test at 28.5 kg/cm2 (g) (minimum 1.5 times the design pressure), pneumatic test, valve functional test and any other type of testing as specified, depressurizing, dewatering, drying by compressed air if applicable; cutting/ rebeveling (as required), precommissioning and providing commissioning assistance during commissioning for process piping and commissioning of non-process piping if applicable1.C.2 Design, Supply & installation of bottom loading vapor arms & Top loading vapor arms 08 NOS.required for vapor collection from truck tank along with associated piping work to hook up with main header at TT gantry along with supply of necessary pipe, valves fittings, flame arrestor, end cap, hose, as required to complete the work at TT gantry to make seal proof during loading of MS.1.C.3 Design, Supply & installation of top loading vapour arms 54 NOS. required for vapor collection from wagon along with associated piping work to hook up with main header at TW gantry along with supply of necessary pipe, valves , flame arrestor, fittings, end cap, hose, as required to complete the work at TW gantry to make seal proof during loading of MS .NOTES :1- Product (MS) shall be made available for absorption tower from above ground tanks of the location with a tap off from Common Suction header line of MS TLF (Tank Lorry Filling) pumps and outflow from the absorption tower shall be released to Common suction header of MS TLF pumps. However it shall be ensured by HPCL/MECON that both Tap Offs are taken from the Upstream section of the Common Suction Line whereas Tap Off for VRU Intake shall be prior to the Tap Off for Outflow from VRU so that fresh MS is made available for VRU.2 Maximum height of the existing above ground storage tanks shall be 20.0 M or as per location.3 Supply of pipeline for Absorption tower to common suction header and from common suction header to absorption tower is not included in the vendor scope and piping works for the same shall be done by other. However, piping design for the same is to be in the scope of vendor and same shall be vetted through approved TPI agency. 4 It shall be within the scope of the vendor to design, supply, commission suitable size TOBV : one each at Inlet & Outlet. These TOBVs need to be automated and Synchronized thru suitable actuators with VRU operation to ensure no product intake when VRU is not in operation.5 Vendor shall design proper arrangement to take care of Thermal Expansion by providing proper arrangement of TRVs/ TSVs with suitable piping for the entrapped product when VRU is not in operation.6 Site Survey/visit of the terminal shall be within the scope of the vendor, if required, at the time of construction before procurement of the material.1.D INTRUMENTATION1.D.1 Complete instrumentation 1 LOT which includes field instruments and meters minimum as per P&ID; cables, cable trays with covers, cable glands, junction boxes, lugs, ferrules, plugs, U/G cable trench; SS valves, manifolds, tubes & fittings; PLC System comprises of communication sub-system, power supply, PLC Cabinet, I/O cards, barriers, TBs, fuses, relays, etc., Licensed softwares, development of graphics & logic, operator work station, operator console; structural & civil supports; painting, etc. Required to complete the job as per technical specification attached with the tender. PLC to be located inside Terminal control room. Vendor to assess& supply requirement of all type of cables 1Lump sum Job from the attached layout of the location. Site survey/ visit, if required, needs to be carried out by the vendor for above. Total (1) Inclusive of all items and sub items under (1) i.e. 1.A, 1. B, 1.C & 1.D. Rates to be quoted on lump sum basis for the complete VRU system as per detailed technical specs, Unloading, Storage at site, Site Security of materials, Site Handling, Installation/ Erection, testing, painting, Pre- commissioning and Commissioning of Mechanical, electrical and Instrumentation equipment of Vapor Recovery System. Instrument air of 5-6 Kg/cm2g Pressure, Pipe from TLF Gantry to VRU skid is not included in the present Bidders scope.Notes:1. Requirement of compressed air and corresponding capacity of compressed air to be intimated by the vendor.2. Commissioning of the unit shall be witnessed by HPCL/MECON/TPI. The successful commissioning of the unit shall be reckoned with relevant certification from HPCL approved TPI agency.3. Completion of SAT (Site Acceptance Test) shall be certified by HPCL approved TPI Agency.4. The Vendor shall prepare, submit & participate in the HAZOP study for Skid at consultant office, AMC (After expiry of Guarantee/ Warranty Period) : For 1st year AMC without spares/ items/ parts, AMC (After expiry of Guarantee/ Warranty Period) : For 2nd year AMC without spares/ items/ parts, etc.
