NEW ATMOSPHERIC & VACUUM DISTILLATION UNIT (AVU) (EPCC-1 PACKAGE), FOR

BR9 EXPANSION PROJECT, IOCL BARAUNI REFINERY

TABLE-1 to MR NO. EPCC01-LTHE-401-STA-MRQ-000-0003

SCOPE OF WORKS & SUPPLY

REQUISION NO: EPCC01-LTHE-401-STA-MRQ-000-0003 REV. NO.: 0

REQUISION TITLE: Material Requisition for Air Cooled Heat Exchangers

LEGEND: X - Applicable to scope; N.A - Not applicable

BY BY SUPPLIER's CONFIRMATION
Rev. No. SR. NO DESCRIPTION REMARKS
SUPPLIER PURCHASER (YES / NO / N.A.)

Design, Supply, Manufacturing, testing, erection & commissioning assistance, unit

performance guarantee of Air Cooled Heat Exchangers (tag numbers as listed in the
MR), comprising of the following as a minimum

A SCOPE OF WORK - ENGINEERING & DESIGN

Design as per Codes (Latest Editions), Specifications, Standards and datasheets
including;
a. Thermal design & Sizing using (HTRI) Software. (Latest Version).
b. Mechanical Design (ASME Sec. VIII Div.1 &, API 661)
Type of floor considered
c. Structural Design (In STAAD Pro software)
1 X shall be as specified in
d. Electrical & Instrumentation Design
the requisition.
g. Complete Detail Engineering and Interfacing within Package battery limit
h. Resolution to Clarifications/Comments related to Package / Equipment within
the Scope of Engineering and Supply with Purchaser & Client

IBR required for the steam coil for tags 401-AC-007, 401-AC-008, 401-AC-013 &
401-AC-014. Supplier shall be responsible for design, drawings, fabrication,
2 inspection and testing of Steam coils in accordance with latest IBR code.
Obtaining IBR approval is in supplier's scope. Calculations as per IBR code shall
be performed by supplier.

Seismic design & Wind design as per 5.7, 5.8 of IBCE-6373-C00-STA-DEC-000-

3 X
0001 and 3.8, 3.9 of IBCE-6373-C00-CVL-DES-000-0001

Structural Design of Air Cooled Heat Exchanger’s Structures (Structural analysis

using STAAD Version V8i SELECT series 6). Vendor shall submit native file of
4 STAAD analysis. X
Vendor to also supply load data for foundation design.

Bundle frame strength calculation along with Sea /Road Transportation, as

5 X
applicable
6 Lifting attachment calculations with impact factor of 2. X

7 Design of Setting Bolts / Anchor Bolts X

Vibration analysis and natural frequency calculation for air fin cooler support
8 X
structure including Noise Data sheet
Nozzle loads shall be considered 3 times the allowable loads given in of Table-4 of
9 X
API 661.

10 Finite element Analysis for nozzle local loads, as applicable. X

Preparation & submission of engineering documents as per attached

11 X
specifications

12 WPS & PQR as per specification & project documents. X

Compliance of hardness requirement of Plug, Plug-sheet and Gaskets as per

13 X
specification / datasheet

Guarantee for the following:

a. Thermal /Hydraulic design and performance
b. Mechanical, electrical, instrumentation & structural design
c. Noise & Vibration limits
14 d. Specified Utility Consumption( Power, Steam, Air etc.) by the vendor X
e. Material & Workmanship
f. Process fluid outlet temperature
g. Process side Pressure drop
h. Motor Power Consumption
Participation at contractor’s office for following individual meetings like kick-off
15 X
meeting, Design review meeting, Progress review meeting

16 Certification for Electrical & Instrument X

PC2031-006 R1 PAGE NO. 1 OF 6

 NEW ATMOSPHERIC & VACUUM DISTILLATION UNIT (AVU) (EPCC-1 PACKAGE), FOR
BR9 EXPANSION PROJECT, IOCL BARAUNI REFINERY

TABLE-1 to MR NO. EPCC01-LTHE-401-STA-MRQ-000-0003

SCOPE OF WORKS & SUPPLY

REQUISION NO: EPCC01-LTHE-401-STA-MRQ-000-0003 REV. NO.: 0

REQUISION TITLE: Material Requisition for Air Cooled Heat Exchangers

LEGEND: X - Applicable to scope; N.A - Not applicable

BY BY SUPPLIER's CONFIRMATION
Rev. No. SR. NO DESCRIPTION REMARKS
SUPPLIER PURCHASER (YES / NO / N.A.)

B SCOPE OF SUPPLY

Tube bundle assembly including, finned tubes, bundle supports, header box, plug
1 X
sheet, plugs, gaskets, cover plates, etc.

Split headers, wherever applicable, as per code & specification requirement. SS

sliding plates between the split headers for tags having split headers.
2 As per cl.9.12.4 of Process Design Basis (IBCE-6373-C00-PRSDES- X
000-0001) split headers are required for Air Coolers tags. 401-AC-001 & 401-AC-
009 as inlet temperature is more than 180oC.

Minimum thickness as per API 661, however minimum tube sheet thickness shall 5.1.6 of IBCE-6373-C00-
3 X
be 22 mm (excluding corrosion allowance) STA-DEC-000-0001

Refer Paragraph
7.1.9.8.d) of IBCE-6373-
C00-STA-SPC-000-0004
Refer 5.14.4 of IBCE-
6373-C00-STA-DEC-000-
4 Nozzle assembly with Flanges X 0001 for flange rating.
Minimum flange rating to
be as per respective
Piping material
specifications IBCE-6373-
C00-PIP-SPC-000-0001.

5 Steam Coil as per Data Sheet X

MP connections (40 NB nozzles with BF) for PG/TI, one on one of the inlets & one 5.18.2 of IBCE-6373-C00-
6 X
on one of the outlets of each header. STA-DEC-000-0001

7 Blind Flange, Gaskets & Fasteners for Vent, Drain & MP connection Nozzle X

8 Louvers (Manual/ Auto as per Equipment Data Sheet) X

9 Plenum chamber X

10 Fan ring X

11 Fan guard X

12 Pulley Guard X

13 Personal Protection Guard(Burn Guard) X

14 Fin Tube Protection Guard X

15 Motor Guard X

Headers with Cover for Air Cooler tags. 401-AC-004, 401-AC-007, 401-AC-008 &
16 X
401-AC-014. Plugs with gaskets shall be provided for rest of the tags.

17 Fan & its driving parts. (Fan blades in FRP are preferred) X

Speed reducer (HTD/PGGT of Gates or Torque drive plus Belts of FENNER, UK

18 X
up to 40KW, Gear drive above 40 KW)

19 Bearings X

20 Fan assembly mounting frame (support from structure, Not from plenum) X

21 Anti-rotation device for all the fans X

22 Post Weld Heat Treatment of carbon steel headers, as applicable X

PC2031-006 R1 PAGE NO. 2 OF 6

 NEW ATMOSPHERIC & VACUUM DISTILLATION UNIT (AVU) (EPCC-1 PACKAGE), FOR
BR9 EXPANSION PROJECT, IOCL BARAUNI REFINERY

TABLE-1 to MR NO. EPCC01-LTHE-401-STA-MRQ-000-0003

SCOPE OF WORKS & SUPPLY

REQUISION NO: EPCC01-LTHE-401-STA-MRQ-000-0003 REV. NO.: 0

REQUISION TITLE: Material Requisition for Air Cooled Heat Exchangers

LEGEND: X - Applicable to scope; N.A - Not applicable

BY BY SUPPLIER's CONFIRMATION
Rev. No. SR. NO DESCRIPTION REMARKS
SUPPLIER PURCHASER (YES / NO / N.A.)

23 Radiography as per code/project specification X

24 Hydro testing of completed Bundle X

25 Tube bundles shall be dry out with hot air after hydro test. X
Shop run-in test & trail assembly shall be done at shop for below parameters for at
least one bay for each type/tag number of Air fin cooler.
- Vibration test
- Air flow rate check
26 X
- noise level test
- Fan tip clearance and blade angle Check
- Temperature rise of bearing and amperage of motor Check

27 Final Painting - All header boxes shall be finally painted at vendor’s shop X
Air coolers structural shall be hot dip galvanized for the following:
a) Plenum chambers, bundle frames.
b) Motor suspension structure, Fan guards, handrails (with paint) & Gratings for
stairs & platforms.
28 X
c) All bolts / nuts for structures.
d) Wire Mesh for fin tube protection.

All other supporting structure shall be painted as per painting specification.

Pickling & Passivation of Stainless Steel Parts
29 X

30 Painting of Bought-out Items

31 Supply of Touch-up Paint.

Lifting lugs:
a) Four lifting lugs for bundle lifting with bundle side frame (Single point lifting with
32 X
spreader beam)
b) Lifting lugs for lifting header covers as applicable.

33 Earthing Lugs X

Levelling shims ( Settings plates )

34 X
Shim plates for erection
7.3.3.5 of IBCE-6373-
35 Teflon sliding plates below headers X
C00-STA-SPC-000-0004

36 Protective Covering ( for finned tubes) on bundle top -By heavy-duty wire mesh X

Stainless Steel tube connections shall be provided outside the fan guards to permit
lubrication of fan shaft bearings in running condition. Connections shall be
37 X
accessible from grade or platforms. Same provision shall also be made for motor
bearings
38 Fan cage (guard) with hinge type access manway below fan. X

39 Name plate and brackets. X

40 First fill of lubricants X

Required lubricant type, grade and initial volume and Lubricants required for twelve
41 X
(12) months operation.

42 Supply of touch-up paint for paint repair at site X

PC2031-006 R1 PAGE NO. 3 OF 6

 NEW ATMOSPHERIC & VACUUM DISTILLATION UNIT (AVU) (EPCC-1 PACKAGE), FOR
BR9 EXPANSION PROJECT, IOCL BARAUNI REFINERY

TABLE-1 to MR NO. EPCC01-LTHE-401-STA-MRQ-000-0003

SCOPE OF WORKS & SUPPLY

REQUISION NO: EPCC01-LTHE-401-STA-MRQ-000-0003 REV. NO.: 0

REQUISION TITLE: Material Requisition for Air Cooled Heat Exchangers

LEGEND: X - Applicable to scope; N.A - Not applicable

BY BY SUPPLIER's CONFIRMATION
Rev. No. SR. NO DESCRIPTION REMARKS
SUPPLIER PURCHASER (YES / NO / N.A.)

Special tools & tackles (One set) shall be recommended by Vendor for installation
/
maintenance of Air Fin Coolers. Minimum tools & tackled required are 1 set of :
-Inclinometer for fan Cost shall be listed
43 X
-Torque wrench for Plugs separately in the offer.
-Belt Tensioner
-Torque wrench for installation of fan
-Pincer for Fin repair

44 Site Supervision & trial run at site X Based on per DIEM rates

Supervision for fan operating test in field (noise & vibration testing, Air flow &
45 X Based on per DIEM rates
Power consumption)
C ELECTRICAL

1 Medium voltage induction Motor with terminal box. X

2 All fin fan motors shall have preferably roller bearing. X

Motors in compliance with area classification Zone2, Gas Group IIA/IIB, T3, IE2
3 Class (as per 5.3.2(f) of IBCE-6373-C00-ELEDES-000-0001 & 2.1.1(7) of IBCE- X
6373-COO-ELESPC-000-0015).
50% of fans in a section of air cooler bay shall be provided with variable speed
motors as specified in the process datasheets. The hazardous area for LV and HV
4 X
motors fed by variable frequency drives shall be Ex d type only.(as per 5.2(5) of
IBCE-6373-C00-ELEDES-000-0001).
VFD
5 VFD spares shall be supplied as per 8.F of MANDATORY SPARE PART LIST X
(IBCE-6373-C00-PJM-PRC-000-0013).
6 cable Trays X

7 Cleats for Electrical cable tray support for power and control cables X

LCS (local control station), Emergency stop Push button (at grade), safety switch
8 X
as applicable
9 Cable Glands and lugs for all power and control cables. X

10 Power and Control Cables between MCC & VFD and VFD & Cooler X

Plant Lighting (General illumination). For light fixtures required supports will be
11 X
taken from cooler structure.
12 Earthing Strips within Package Battery limit X

13 Earthing Lugs for Equipment & Structures. X

14 Motors rated 55 kW and above shall have space heaters. X

15 Type test certificates for Electric Motor X

PC2031-006 R1 PAGE NO. 4 OF 6

 NEW ATMOSPHERIC & VACUUM DISTILLATION UNIT (AVU) (EPCC-1 PACKAGE), FOR
BR9 EXPANSION PROJECT, IOCL BARAUNI REFINERY

TABLE-1 to MR NO. EPCC01-LTHE-401-STA-MRQ-000-0003

SCOPE OF WORKS & SUPPLY

REQUISION NO: EPCC01-LTHE-401-STA-MRQ-000-0003 REV. NO.: 0

REQUISION TITLE: Material Requisition for Air Cooled Heat Exchangers

LEGEND: X - Applicable to scope; N.A - Not applicable

BY BY SUPPLIER's CONFIRMATION
Rev. No. SR. NO DESCRIPTION REMARKS
SUPPLIER PURCHASER (YES / NO / N.A.)

D INSTRUMENTATION & CONTROLS

Vibration transmitter per fan/driver unit meeting the following Technical

Requirements.
a) The Transmitters shall be 24 VDC Loop Powered, with 4-20 mA HART output
b) The Vibration Transmitter shall have cable entry of 1/2" NPT and shall be
supplied plugged. The required cable gland for the Purchaser cable shall be
supplied by others.
c) The Transmitters used in 'HH' vibration trip of the Air cooler fan shall be certified
SIL-2 min. All other Transmitters used for 'H' alarm in DCS can be Non-SIL
certified. (Refer Attached P&ID for Air Coolers)
d) Irrespective of Area Classification all the Transmitters shall be suitable for Zone-
1 Gr. IIC, T3 with IP-65.
1 e) All Transmitters shall be Intrinsically safe (IS) and shall be suitable for use in X
Zone-1 Gr. IIC, T3 with IP-65 as a minimum. And shall be certified for use in the
specified hazardous area classification ( Zone-1 Gr. IIC, T3) by any recognized
authority like ATEX, CMRI, FM, CENELEC, PTB, BASEEFA etc.
f) The Transmitter make shall be as per the AVL.
g) Vendor to Confirm compliance to OISD 111 & 152
h) All intrinsically safe and explosion proof instruments and accessories, in addition
to the approvals by any of the above agencies shall have approval of Petroleum
and Explosives Safety Organization (PESO), Nagpur, India. This is a mandatory
requirement.)
i) The Vibration Transmitter shall be supplied Pre-Installed to site for Purchaser
connection at site.

2 Junction Boxes for Vibration transmitter. X

3 Cable trays from Transmitter to Purchaser's Junction Box X

4 Cable Trays Support X

5 Interconnecting Cables between accelerometer and Terminal Box/Junction Box X

Structure
E
Structural support including Column & bracing support assembly. Adjacent bays in
the bank shall be supported on common columns. Clearance between the lowest
1 X
portion of the air cooler bundle or fan casing and the upper most pipes/ floor below
Air cooler shall be minimum 2.4m.
Bundles shall be removable without separately supporting or dismantling the fan,
2 X
plenum, or platforms and without disturbing the structure of adjacent bays.
Motor Supporting structure attached with vertical column (Not touching Fan &
3 X
Plenum)
4 Beam at the top of motor with hook to unload the motor during maintenance X

Access Platform Shall be provided, wherever possible on all the four sides with 6.3.6 of BCE-6373-C00-
5 X
grating and handrails, (width – 900 mm) with staircase on both sides. STA-DEC-000-0001
Pipe support
Extension of columns by min.300 mm with top base plate (min.12 thk) for
6 X arrangement for Fire
supporting pipe support arrangement for Fire Fighting Lines.
Fighting Lines by
7 Consideration of nozzle loads in the structural analysis X

Design & Supply of supporting arrangement to support the inlet/outlet piping from
8 X
air cooler structure

9 Structural trial fit up and match marking at shop X

10 Manifold Pipe Support Structure X

Fireproofing material by
11 Fireproofing cleats X
purchaser

12 Anchor Bolts, Nuts, and Washer. X size & qty. by supplier

PC2031-006 R1 PAGE NO. 5 OF 6

 NEW ATMOSPHERIC & VACUUM DISTILLATION UNIT (AVU) (EPCC-1 PACKAGE), FOR
BR9 EXPANSION PROJECT, IOCL BARAUNI REFINERY

TABLE-1 to MR NO. EPCC01-LTHE-401-STA-MRQ-000-0003

SCOPE OF WORKS & SUPPLY

REQUISION NO: EPCC01-LTHE-401-STA-MRQ-000-0003 REV. NO.: 0

REQUISION TITLE: Material Requisition for Air Cooled Heat Exchangers

LEGEND: X - Applicable to scope; N.A - Not applicable

BY BY SUPPLIER's CONFIRMATION
Rev. No. SR. NO DESCRIPTION REMARKS
SUPPLIER PURCHASER (YES / NO / N.A.)

13 Setting Bolts, Nuts, and Washer (Hot dip Galvanized) X

14 Chain & Pulley Block for Motor and Fan removal X

F SPARES

Mandatory spares as per IBCE-6373-C00-PJM-PRC-000-0013. Prices of same

1 X
shall be included in base quote.

Erection and commissioning spares along with main equipment (to be included in
2 quoted price). Also vendor to provide list of Erection and commissioning spares X
recommended by vendor along with offer.

Spares parts list with itemized unit price for two years of normal operation as Cost shall be listed
3 X
recommended by Vendor (apart from mandatory spares) along with the offer. separately in the offer.

G PACKING, PRESERVATION & TRANSPORT

Sea worthy export packing & delivery as per project specifications & standards, as
1 applicable. Tube bundles shall be protected by plywood panel over the top raw of X
finned tubes. Tube bundles shall be double-stacked at a maximum.
Rust prevention :
2 Dry N2 charging with pressure gauge to monitor N2 pressure and ½” non-return X
valve.
H EXCLUSIONS ( i.e. PURCHASER's SCOPE )

1 Foundation /Anchor Bolts X

2 Site Installation X

3 Fire proofing material & work (if applicable) X

4 Connecting pipe work, valves and stand pipes X

5 Electrical Lighting X

6 Unit Control Panel(s) X

7 Third party inspection X

8 Transportation from Vendor’s ex-works to site X

9 Movable Motor Maintenance Trolley. X

I OPTIONAL QUOTES
Cost shall be listed
1 Transportation of Air Coolers to Site
separately in the offer.
2 Unit cost for caged ladder

3 unit cost for staircase

Vendor to submit unit rates for addition/deletion of nozzles (size 1 1/2" to 12",
4
rating #150, #300) with / without blind flange, gasket & bolting.
Optional cost for Design and supply of Third party Certified & witnessed spreader
Cost shall be listed
5 bars / Frame to handle maximum size and weight of air cooler along with supply of
separately in the offer.
all the necessary lifting accessories such as slings, shackles, etc..

PC2031-006 R1 PAGE NO. 6 OF 6