ATTACHMENT A: Technical Attachments

Supply, Installation & Commissioning of Automatic actuated Rim seal Fire Detection
& Foam based Fire extinguishing System for External Floating Roof Storage Tanks
(EFRT)

1.0 Scope

This specification covers design, engineering, fabrication, calibration, testing supply,

installation and commissioning of automatic Rimseal fire detection and suppression system
of external floating roof tanks (EFRT) in line with OISD standard 116. The automatic Rim
seal fire protection system shall consist of:
a) Linear Heat Hollow metallic tube type detection system duly certified by any of the
international certifying agencies like UL, FM, VdS or LPC.
b) Foam based Fire suppression system
c) Local Field PLC for monitoring and control of rim seal fire protection system.
d) Associated piping and cabling
HPCL proposes to connect the local control panel over Modbus TCP-IP protocol to a PLC
located at Asphalt control room and repeat the signals for fire alarm annunciation to Fire and
Safety control room.

• Automatic Fire Protection system is to be installed on product tanks. No hot job is

permitted on the tank. The detection and actuation shall be immune to the effects of
lightening.
• Agency should take high precaution while working in the tank area as the tanks are in
operation. It is the sole responsibility of the agency for safety requirements
considering the hazardous location and should work according to the safety
regulations of the refinery. Agency shall co-ordinate with the fire & safety dept. &
operation dept. of the refinery for dismantling existing ones and installing the new
equipments.

• The entire job of replacement and providing fire protection systems shall be carried
out on Lumpsum turnkey basis. Agency shall use the existing standards for
installation of the new fire protection. No hot work permitted on the tank. Agency shall
ensure the new system fits to the existing supports on the tank. Agency shall follow
the attached HPCL specifications for instrument erection & commission job or
control/signal cable as applicable. Vendor may visit the site before quoting by taking
permission with concerned authorities.

• Agency shall provide all technical information/ brochure on capabilities of the

proposed system i.e. detection time, extinguishing time etc along with offer for an
evaluation. Agency shall provide all references on whether the system was
previously offered in any reputed company with & performance along with offer for
supply. Job shall be completed as per Refinery safety & regulations as shown in
Attachment. The system shall be commissioned to the satisfaction of F&S dept. &
operation dept. Agency shall provide a certificate of warranty for the system for a
minimum period of 1year from the date of installation.

2.0 Objective

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The overall purpose of the system is to detect and extinguish the Rim seal fire at the
incipient stage and simultaneously alert the personnel at the facility so that they can respond
to the incident.

• Pre bid meeting and site visit will be arranged& date will be intimated.

3.0 APPLICABLE CODES AND STANDARDS

(a) OISD standard 116 (latest edition)

(b) NFPA 11 2001: Standard for low expansion Foam
(c) Factories Rules – for applicable States.
(d) Indian Electricity Rules
(e) Bureau of Indian standards
(f) ASME Section VIII Div. I

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(g) ASME 31.3
(h) Cylinder rules and Static and Mobile Pressure Vessels (unfired) rules
(i) Petroleum Explosives and Safety Organizations (PESO) Rules
(j) UL/FM/VdS/LPC
(k) Relevant EN standards
(l) Any other applicable codes and standards
Where edition number of standards referred are not indicated, latest editions shall apply.

4.0 Basic System Description

The Rim seal protection system shall consist of a microprocessor based, site configurable
Hollow Metallic Tube type Linear Heat Detection (LHD) system monitoring the rimseal area
over the whole tank circumference. The detection tubing, which shall be laid around the
whole circumference in the rim seal area of the floating roof tank, shall rapidly detect the fire
at its incipient stage (within 10 secs of its occurrence), raise an alarm at manned location/s
and automatically discharge low expansion foam over the rimseal area of the tank.. The
system shall be modular type with each module protecting a defined length of rimseal area
and all modules shall discharge simultaneously on detection of fire at any location on the rim
seal area. The detection system shall have programmable self-diagnostic facility with
annunciation of status displayed at manned location/s.
The system shall be such that after any Rim-seal fire event it can be quickly reinstated by
trained site personnel without the need for specialist engineers.
The necessary alarms like system pressure low, fire alarm, foam discharge etc. are to be
provided in the system. The main panel shall be located outside the Tank Dyke with field
PLC giving MODBUS output

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5.0 Bidder‟s Scope of Supply/work:
This section covers the minimum requirements for the Design, Engineering, Fabrication,
Calibration, Testing, Supply, Installation, and Commissioning, of Automatic fire detection &
Foam based extinguishing system for Rim Seal fire protection of Floating Roof Tanks for
Gasolene (Motor Spirit) Storage at various Depots/Terminals. Only those Rim seal protection
systems, which use the linear heat hollow metallic tube type detectors in line OISD-116 with
foam based extinguishing media shall be used.
Automatic Rim Seal Fire detection and foam based extinguishing system shall consist of
highly sensitive & field configurable fire protection system based on principles of Heat
detection using air filled hollow tube and activation of foam flooding for fire extinguishing
(Foam Flooding System).
Supply of rim seal fire protection system shall include heat detection and activation system
complete so as to have the desired function of the automatic rim seal fire protection. Supply
shall also include storage of fire extinguishing medium (foam), activation, discharging and
control of fire fighting system, rim seal fire alarm panel, local control panels (LCP), power,
signal and instrumentation cables, junction boxes, interface with terminal automation system
etc.

The provision and installation of the Rimseal Fire Protection by the Bidder shall be based on
site specific requirements & shall consist of:

a) Visit the location, prepare engineering drawing along-with bill of material & submit for
approval of the Owner.
b) Provide necessary loading data for the owner to verify suitability of load of the rimseal fire
protection system for the floating roof of the tank. The Vendor shall provide details of the
equipment to be mounted on the tank roof and the total weight with foam solution charge.
c) Design, Engineering, Fabrication, calibration, testing and Supply of all the components of
Rimseal Fire Protection system as per the specification.
d) Installation of the Rimseal fire protection system on the tank roof deck.
e) Supply and installation of all required signal cables, power cables, control cables,
interface cables & junction boxes from tank top.
f) Provision of potential-free contacts at Rimseal Main Fire Alarm Panel for Fire and Fault
Signals for each tank for necessary hook up with main fire alarm system at the location.
g) Provision of RS485/RS232 or equivalent communication links up-to Rim Seal Main Fire
Alarm Panel at control room/operator cabin for connection with laptop computer.
h) Power distribution from UPS to rimseal main fire alarm panel, Local panel outside the
dyke, rim seal fire protection system at tank & repeater panel shall be designed, supplied &
installed by the Bidder.
• Supply and installation of all required signal cables, power cables, interface cables &
junction box (as per attached specifications) from tank top up to Rim seal Fire Alarm
Panel outside the Dyke Area(local PLC to be used). The Cable length from tank top
to Main control panels will vary from approx. 500 meter to 3000 meters, required site
survey for length & routing of cable to be done by vender separately for each tank.

• Supply and installation of all local PLC in Ex proof JB outside the dyke which shall
have CPU(scan time less than 250 msec), required I/O cards, barriers/isolators for
intrinsically safe I/O, redundant power supply unit, redundant Modbus output unit,
relays etc.

• Separate PLC to be considered for each tank.

• Supply & installation of Customized Fire Alarm Panel dedicated to the Rim seal system
of each tankin the relevant locations (Outside Tank Dyke).

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 • Provision of potential-free contacts at Rim seal Main Fire Alarm Panel for Fire and
Fault Signals for each tank for necessary hook up with HPCL PLC. All scope related
to connection of relay output to HPCL PLC shall be in the scope of HPCL..

• Power distribution from Fire Alarm Panel at outside Tank shall be designed, supplied
& installed by the vendor.

• Provision of manual simulation from local field PLC.

• Common audible / visual alarm for fire at Local junction box outside the dyke audible
up to 200 m radial distance.

p) Water supply arrangement for re-filling foam modules from water line. Piping shall be laid
from tank top upto road side with standard 63 mm instantaneous male hose coupling fitted at
the end.
q) Portable trolley mounted N2 filling kit including cylinder, & hose reel to facilitate
pressurizing the foam modules.
r) Supply of Manuals containing Operating and Maintenance procedures, as built drawings,
technical documents & approvals in Hard copies & CD form.
s) Supply of all software on CD alongwith required software licenses.
t) Factory acceptance test as per clause 14.0 of the specification.
u) Site acceptance test as per clause 15.0 of the specification.
v) Commissioning of the system.
w) Training of the Owner‟s personnel on functional, operational & routine maintenance
aspects of the system.
x) All civil, mechanical, electrical & instrumentation work required for completion of the job.

Any other component and software required for completion and commissioning of Rimseal
Fire Protection system shall be supplied & installed by the Bidder except the items
mentioned under the Owner‟s scope under clause 5.0.

• Foam: First fill shall beas per the spec. shown as Annexure-2

6.0 Owner‟s Scope

Owner shall provide either 230 V/ 110 V (+ 10%), 50 Hz (+ 3%) AC Power at control room &
at repeater panel room as a single point source by the owner. The system proposed to be
supplied by the bidder shall be compatible based on the power source supplied by the owner
for the location. Further power distribution to Local panel outside the dyke & rim seal fire
protection system at tank shall be designed, supplied & installed by the Bidder. Bidder shall
indicate the maximum and normal operating power loads along with the bid.
HPCL proposes to connect the local control panel through Modbus TCP-IP protocol to a PLC
located at Asphalt control room and repeat the signals for fire alarm annunciation to Fire and
Safety control room. Provision of all hardware items like PLC, Fibre optic connectors,
interfacing with Honeywell system at Fire Control room is in HPCL scope.

7.0 Operating Conditions

The detection and control system shall be suitable for operating in humid and corrosive
atmospheres found in oil terminals, refineries & petrochemical plants in India. The system
shall be suitable for working in relative humidity upto 95% (non-condensing) & temperature

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range of +1 deg C to +65 deg C. The system shall be tolerant to influences such as
electromagnetic interference, Radio Frequency Interference (RFI), aggressive or corrosive
vapour, UV radiation, and heavy rainfall & electrical surge. The system should be certified for
response behavior on Class – 1 as per EN 54/5 standard by UL / FM / Vds/LPC.
All enclosures for electrical equipment shall be suitable for use in Zone 1, Gas group IIA/IIB
as per hazardous area classification & approved by PESO India. Bidder shall submit valid
test certificates issued by PESO,India. The test certificate for enclosure shall contain details
of the components installed in it. As a minimum all enclosures and instruments in the field
shall be dust proof & weather proof to IP65.

8.0 FAIL SAFE PHILOSOPHY

The system should have features that ensure fail safe operation of the rim seal fire
protection system on floating roof storage tanks even under abnormal conditions.
To ensure the fail safe operation of the rim seal fire protection system, the system should be
designed in such a way that in the event of any failures within the system due to any reasons
like cable damage, power failure, mechanical damage due to excavation, movement of
heavy machinery or adverse environmental conditions, the system should function as per
details provided in Annexure I.
Rim seal fire protection system should have following features to overcome any abnormal
conditions as described in Annexure – 1

8.0 Approvals & Authorization:

8.1 Following approvals shall be required along with the bid:
a) Linear Heat Detector system along with evaluation unit & metallic sensor tube shall be
certified by any of the international certifying agencies like UL, FM, VdS or LPC. Evaluation
unit shall either be FLP / intrinsically safe by itself or shall be housed in a FLP box having
PESO approvals mentioning details of components housed inside the FLP box, including
sensor tube entering the FLP box.

b) UL listing for 3% type AFFF as per Annexure 2.

c) Foam spray Nozzles to be UL listing or FM approved.

8.2 All flameproof junction boxes, cable glands, electrical equipments, instruments & its
accessories shall have PESO approval or in case any electrical equipments which are not
flame proof shall be housed in a flame proof enclosure which shall be approved by PESO for
use in hazardous area classification (Zone 1 gas group IIA/IIB). The bidder shall submit the
approval to TPI/owner before factory acceptance test.

9.0 Linear Heat Detection (LHD)

9.1 Principle of Operation
Linear Heat Detection Systems shall work on the principle of change in pressure of gases /
air caused by rise in temperature in a close circuit sensor tube. The system shall be able to
sense the rapid rate of rise as well as preset maximum temperature.Thepneumatically tight
system is formed by the sensor tube, which is sealed at its one end and connected to a
detector box which contains pressure sensor, device for artificial pressure generation for de-
bugging and microprocessor based evaluation unit at its other end. Normal air at ambient
pressure is present in the total pneumatic volume of tube.
If the pressure in the sensor tube increases due to rise in temperature of the protected area
beyond the threshold values the system should trigger an alarm and actuate an
Extinguishing System. A non-pressurized sealed stainless steel tube should be laid above

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the rim seal as recommended by the manufacturer. The sensor tube shall be reusable type
even after direct exposure to several hydrocarbon fires.
9.2 LHD Mounting
LHD tube shall be securely fixed as close as possible to the highest point of the seal
assembly. The maximum distance from the sensor to the top of the seal shall be 150mm.
The sensor shall be located on the external face of the weather shield so that it can be
inspected without the need for removal of any seal components.
LHD tube mounts shall be such that they can accommodate tank flexing and movement
without causing chafing or other damage to the tube. The Bidder shall supply all necessary
fixing brackets, sleeves, clamps or other devices required to install the sensor tube on the
tank roof.
9.3 Detection system requirements
a) The sensor (metallic tube) element shall be reusable after exposure to and rapid
extinguishment of associated hydrocarbon fires and shall be resettable after actuation.
The detection system shall be restored for service after event occurrence from the Control
Room without the need for access to the protected area.
b) The Sensor tube shall be hollow metallic tube of suitable diameter and thickness in line
with UL listing/VdS/FM/LPC approval, free from glass, fiber, and rubber & plastic for its long
and dependable service.
c) The LHD evaluation unit shall be housed in a flameproof enclosure and installed
alongside one of the extinguishing systems (Foam Module) installed on the tank pontoon.
The flame proof enclosure opening cover shall be so designed so as that power to the
evaluation units is cut off automatically when the cover is removed.
d) The detection system shall be self-testing by means of automatic pressurisation at preset
regular intervals.
e) When the entire length metallic detection tube (Min 80 M) is kept at a height of 300 mm
above the centre line along the length of 300 mm wide and 6.0 M meter long fire tray
containing motor spirit & fuel is set on fire, the fire alarm & actuation of foam suppression
system should not start later than 10 seconds from the inception of fire.
f) The detection system shall provide fire alarm/fault signals separately for each tank at the
rim seal main fire alarm panel at Control Room/security cabin.
g) The Detection system shall be site configurable for rate of rise and maximum temperature
at two different alarm thresholds at Graphic console, rimseal main fire alarm panel and LCP.
h) The Detection system shall be of decentralised type i.e. individual detection system
(sensor tube with evaluation unit) for individual tank shall be independent & shall be
mounted on the tank roof itself.
i) The system shall have the facility for interface to the owner supplied Laptop for
configuration at rimseal main fire alarm panel and LCP and setting the parameters of the
system. Suitable port connectivity with Laptop at Control Room shall be provided for tank
diagnosis.
j) All field junction boxes/instruments/electrical equipment shall be provided with
prefabricated canopy.
k) Software for the detection system shall have site specific graphics with authorisation for
use of the software for life at a particular facility.The documented authorisation shall
accompany the software at the time of supply.
l) The system shall be fail safe as per the criteria given in Annexure-1.

9.4 Installation requirements:

The LHD & automatic foam suppression system is required to be installed on the tank roof
as per approved drawings & after obtaining confirmation of the tank roof being capable of
holding the subject system. No modification or alterations will be allowed on the main tank
shell or on the floating roof. Rim seal fire protection system design shall be suitable in
accordance with the individual tank design.

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It is recognised that installation may be required whilst the tank is in service. In this case the
complete system shall be designed such that it can be installed without the need for welding
or any kind of hot work on the tank. In case, the installation is required at the tank in service,
the following condition shall apply:
a) Bidder shall comply fully with all safe working practices and Permit to Work system of the
owner.
b) No hot work shall be allowed on the tank.
c) No work shall be allowed to be performed during receipt and dispatch of material from the
tank.
d) Continuous monitoring of vapour levels shall be done on the tank roof when personnel are
present on the roof.
e) All persons working on the roof shall use required personal protective equipment &
retractable type fall arrestor system.

f) The SS sensor tube shall be securely laid using SS clips and screws with provision for
linear expansion
g) While working on tank roof, non-sparking tools only shall be used.

10.0 Foam Fire Suppression System

10.1 Design
The Rimseal fire suppression system shall include the appropriate number of equally spaced
identical modular foam units mounted adjacent to but outside the containment area of the
foam dam so as to protect the entire rim seal area. The foam units shall be charged with pre-
mixed foam solution pressurised with nitrogen as an expellant gas. All modules on a tank
shall be actuated simultaneously in the event of automatic detection of fire from any detector
(in case of more than one linear detector) on the tank roof or by actuation of a manual
release station outside the bund. The system shall be designed for a minimum foam
application rate of 18 lpm /m2 of rim seal area. An application period of minimum 40 seconds
shall be considered.
The system shall be modular in design with each section of foam distribution manifold
protecting the equal length of Rimseal area. In order to ensure full foam coverage in the
entire rimseal area, the placement of the nozzle shall be such that foam application shall be
uniform including the area at the ends of the manifold. The nozzle shall be made of SS-316
material.
Foam concentrate to be used in the rimseal fire protection system shall be UL listed 3%
concentrate Aqueous film forming foam (AFFF) or 3% type Film Forming Flouro Protein
(FFFP) or 3%/3% Alcohol Resistant-Aqueous Film Forming Foam (AR-AFFF).
10.2 Foam solution modules
a) Stainless Steel (SS316) Foam solution storage tank (foam module) shall be designed to
meet foam application rate of minimum 18 lpm/m2 of protected rim seal area for an
application period of minimum 40 seconds. However, the maximum capacity of each foam
solution storage tank shall not exceed 250 litres. The specification of Stainless steel and
fabrication of Foam solution modules shall be as per attached specifications. (Annexure 5)

b) Foam solution storage tank shall be manufactured to ASME-VIII, Div-1 requirements and
indicative drawings attached to this specification.

c) Foam Discharge Manifold and distribution pipe work with semi aspirating foam spray
nozzles (expansion ratio 1:3 to 1:6) shall be made of SS-316 and evenly spaced to cover
one segment of rim seal up-to maximum length 50 meters. This shall be designed for 18
lpm/m2 and extinguishing of fire within 40 secs of detection.

d) Automatic Foam Discharge actuation valve shall be provided at discharge outlet.

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e) Instrumentation Panel containing nitrogen charging port, Distribution Manifold, pressure
switch to monitor foam module pressure, etc.shall be installed on each foam module.

f) Pre-coated canopy shall be provided on each foam module for protection from direct
impingement by sunlight & rain water.

g) Clearly legible schematic and operating instruction plate shall be permanently fixed on
each foam module.

h) Suitable sized filling and draining facilities shall be provided for operation and
maintenance of modules.

i) Each foam module shall be fitted with a pressure gauge to manually identify module
pressure. Additionally, the signal from the pressure switch shall terminated into the Local
junction box and a common signal for “Module pressure low” shall be transmitted for each
tank to the Rimseal fire alarm panel at the control room, Repeater Panel and LCP.
j) One Test discharge connection with nozzle shall be provided to allow testing of system
without discharging foam into Rimseal area.

10.3 Foam system general requirements

a) The discharge nozzles shall be mounted above the Primary seal and aligned such that the
discharge pattern shall be directed at the tank shell above the primary seal around the
complete circumference of the tank.
b) The suppression system shall be capable of actuation without any signal from the Fire
Alarm Panels outside the tank dyke.
c) The foam discharge nozzles shall be UL listed / FM Approved.
d) All the piping coming in contact with foam solution shall be of SS 316.
e) Pipe supports shall be designed and located to effectively sustain the weight and thermal
effects of piping system and to prevent its vibration.
f) The piping shall be provided with the required number of valves, bends, and fittings for the
efficient functioning of the system.
g) Module Pressure Low signal shall be available from the unit.

10.4 AQUEOUS FILM FORMING FOAM-AFFF (UL LISTED)

10.4.1 Aqueous film forming foam (AFFF) 3% concentrate should have UL Listing
(Underwriters Laboratories Inc.) under UL 162, the standard for foam equipment and foam
Concentrate. In addition the AFFF should have spreading co-efficient of +4.5 as per OISD
Specification No.115. The AFFF shall also have IS mark. Foam shall be supplied by the
bidder for the purpose of SAT and thereafter for first fill. The specifications shall be as per
Annexure 2

11.0 Alarm & Control Panel

11.1 Local Control Panel (LCP):

The requirement of various alarms & signals has been summarized as under:

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 Main Rim
Graphic Repeater
Alarm /signal LCP seal fire
console panel
alarm panel
Fire - flashing light and
√ √ √ √
sounder
Detector Fault – flashing
√ √ √
light and sounder
Cable Fault – flashing light
√ √ √
and sounder
Foam Module pressure low
(common per tank) – √ √ √
flashing light and sounder
Total system is healthy –
Constantly illuminated √ √ √
green light
Manual Actuation point √
Volt & Ammeter √
Power On √

12. Following signals shall be configured for MODBUS output

i. System pressure low
ii. Foam vessel low level
iii. Fire condition
iv. Foam discharge
v. Lamp / LED test Switch
vi. Any other alarm for effective operation and maintenance of the system.

13.0 Connection Cables/Junction boxes (Flameproof) as per Annexure 6:

13.1 General requirement:

13.1.1 The connection cable onto and from the tank roof shall:
a) Consist of stranded copper conductor of minimum 2.5mm2 or higher according to power
requirements and approved design.
b) Have a working temperature range of -40 deg C to +95 deg C.
c) Have length and mounting suitable for tank roof movement over the entire height.
d) Cables between tank roof to Dyke wall and control room/operator cabin to Dyke wall shall
be armoured FRLS. All cables shall be XLPE as per IS 7098.
e) Cable Joints shall not be used for signal and control cables.
f) There shall not be any cable joints for power cables inside the tank dyke.
g) All cable glands shall be provided with PVC shrouds to prevent ingress of moisture and
rain water inside the enclosures.
h) Each cable shall not be loaded more than 35%, so that in case of failure of one power
supply, the total load shall not exceed 70%.

13.1.2 All main multi-core / multi-pair cables having more than three cores shall have a
minimum of 20% spare cores / pair.

13.1.3 Power distribution network shall be designed in such a way that single point failure
shall not cause tripping of the total system. Each distribution point shall be provided with a
separate MCB of power rating for isolation of the system.

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13.2 Cable routing onto the tank
Provision shall be made to prevent snagging of the cable. It shall take account of tank roof
movement and wind conditions. Routing shall be done along the rolling ladder with
necessary arrangement to ensure that the cable does not snag under the ladder wheels.
Cables laid aboveground shall be in GI trays.
13.3 Cable routing between tank dyke panel & main fire alarm panel/repeater panel:
All the above ground cables shall be laid in galvanised metallic cable trays.
Underground cables shall be laid in armored HDPE conduits as per ASTM F2160 (Standard
Specification for Solid Wall High Density Polyethylene Conduit)

13.4 INSTRUMENTATION SPECIFICATIONS (Also refer Annexure 3)

13.4.1 Unless specified otherwise Solenoid Operated Valve (SOV) shall be stainless Steel
body and shall be intrinsically safe /explosion proof as per requirement and shall have
approval of PESO. Refer Annexure7
13.4.2 Canopies shall be used along with all field instruments in general. Wherever used,
these shall be prefabricated and pre-coated type. The colour of the canopies shall be „Red‟
for instruments connected to interlocks / shutdown. The local panel shall also be provided
with canopies.
13.4.3 Specification of control cable, signal cable shall be as per enclosed specification.
Signal / Alarm cables (1 pair / 6 pair / 12 pair) shall be shielded (individual as well as overall
shielding) and armoured with conductor size 1.5 mm2 minimum for single pair and 0.5 mm2
for multi-pair cable.
13.4.4 Control cables (1 Pair / 6 Pair/ 12 Pair) shall be overall shielded and armoured with
conductor size 1.5 mm2 minimum. Only 12 pair/8 Triad multi cables shall be used. However,
higher conductor sizes shall be considered based on distance. Signaling system shall work
on 2 wires and 4 wire based communication and 30% spare core shall be provided for all
signal and communication cables above 2 cores.
13.4.5 All signal and control cable shall be fire resistant as per IEC-60331 and flame
retardant as per IEC-60332 Cat.-A.
13.4.6 The cable trays and accessories required for interconnecting above ground cables
between all bidders supplied field instruments and junction boxes / local gauge board / local
control panel, shall be supplied by bidder. Cable trays shall be of Galvanized Iron (GI)
material. Cables upto control room and security room/pipeline control panel is also in
bidder‟s scope. Refer Annexure 5
13.4.7. All tubes shall be of SS 316 L and its OD shall be in mm. All tubes fittings shall be of
SS- 316, double compression, suitable for tubes in mm OD.
13.4.8 All field instruments, junction boxes, etc. shall be as per enclosed specifications. All
wetted parts shall be minimum SS 316.

14.0 Factory Testing

14.1 Bidder shall arrange following inspections in presence of owner‟s representative/ Third
Party Inspection (TPI) agency approved by the owner. Third party Inspection Charges shall
be borne by the Bidder.
a) Based upon the specification, bidder shall develop detailed Quality Assurance plan (QAP)
& submit to the owner for approval thru TPIA. QAP should also include detection, foam
suppressant system and its control mechanism.
b) Approval of design & engineering documents of the entire system.
c) Positive Material Identification (PMI) test of 10% material of all piping, vessel and
fasteners and
other pressure components and witness by TPI.
d) 100% Review of certification for electrical enclosures to be mounted in classified
hazardous areas.
e) 100% Review of certificate of approval / listing of Linear Heat Detection.

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f) 100% welding joints of pressure vessel and piping shall be radiographed and reports will
be reviewed.
g) Inter granular corrosion test as per ASTM A-262 Practice-E (IGC) sampling and stamping
to be done.
h) Weld joint fit up to 10 % will be witnessed randomly.
i) Review of WPS (Welding Procedure Specification) & witness of WPQ (Welder‟s
Performance Qualification) as per ASME Sec-II – Part-C & ASME-Sec-IX, QAP ( Quality
assurance plan ) and mill test certificate of raw material and test certificate marking.
j) TPI shall witness 100% of the following manufacturing activities of pressure vessel and
piping besides other inspection as per applicable codes :
 Weld joint hardness test after PWHT if any
 Final Visual and dimensional inspection
 Air testing of nozzle pads
 Hydro testing (Water quality should be monitored and shall not contain more than 25 PPM
chlorides)
k) Measurement of expansion ratio of the foam produced from nozzle at 7 KG/CM2

14.2 Factory Performance/Acceptance Test (FAT)

Factory Performance test shall be carried out using the test simulator. Simulation Test shall
comprise of:
a) 2 nos of linear heat detection units with full length of sensor tube (min 80m)
b) 2 nos foam suppressant system consisting of foam modules and foam discharge piping
manifold
c) Local Control panel
d) Rimseal main fire alarm Panel
e) Graphic Console &
f) Repeater panel

The following two tests shall be carried out:

(i) For detection: The detection tube of any one of the heat detection units shall be placed
300 mm above Six meter long and 300 mm wide tray along the centre line of the length of
the tray. The test fuel shall be a liquid hydrocarbon such as motor spirit, or kerosene. The
detection system shall detect the fire within 10 seconds of start of fire.
(ii) For extinguishing: The set up shall be prepared as above expect that 6M length of the
tray shall be replaced by 50 M (max) long tray or length as per approved design. After
detection of the fire, the fire in the tray shall be extinguished in approx 40 secs. The module
and discharge Manifold with Nozzles for carrying out the test shall be selected by the
owner/Third Party Inspection Agency.

15.0 Site Acceptance Test:

Bidder shall arrange following Site Acceptance Test in presence of owner‟s representative at
no extra cost to the owner:
a) Simulation of discharge of two Foam modules on each tank shall be done from the panel
at control room. In case simulation, Bidder shall demonstrate the simulation of all Foam
Modules for that particular tank. Foam required for the simulation/testing shall be supplied by
the Bidder.
b) Actuation of foam discharge valve by operation of manual Fire call point outside the dyke.
c) Functioning of All signals at the control panels & Junction box outside the dyke.
d) Demonstration of resetting of Detection system after simulation from control room itself.
e) Demonstration of Site specific graphic console.
f) UL listed 3% type AFFF/FFFP or 3%/3% type AR-AFFF foam suitable for foam nozzles
required during testing & commissioning shall be supplied by the owner.
g) For new/decommissioned tanks entire functioning of the entire rim-seal fire protection
system shall be tested using rim-seal simulator as mentioned in FAT.

12
Site Acceptance Test (SAT) as given above shall be conducted for each tank within
maximum 15 days of completion of installation.
Based upon the above test requirement, Bidder shall develop detailed Site Acceptance Plan
& submit it to the owner for approval.

16.0 Testing and maintenance during operation

Both the detection and the extinguishing system shall have a manual or automatic simulation
facility to test system integrity and function during operation. A discharge test nozzle and
appropriate valve shall be provided so that the system can be discharged without the need
for discharging foam into the seal area.

17.0 Documentation:
A) Documents to be furnished with offer / bid:
i. Detailed P&ID indicating the complete scheme of instrumentation and controls
ii. Control and Interlocking Philosophy
iii. Power supply requirement for field instruments along with consumption
iv. List of spares during commissioning and during 2 year warranty.
v. Indicative Bill of Material for one no tank each of dia 16M, 32M, 48M & 64M
vii. UL Listing/ VdS/FM/LPC certification for detection system
vi. UL listing approval for nozzle
vii. Procedure for calibration of rim-seal detection system, solenoid valves, etc.
viii. UL Certificate of foam manufacturer and foam container manufacturer from whom the
bidder proposes to procure the foam.
ix. Detailed procedure for calibration of detection and control system.
x. Proven track record of the offer system along with satisfactory performance proof of at
least for a period of 6 months.

B) Documents to be submitted for approval after order placement as minimum

i. Detailed design of the system which should include detection, control, monitoring, foam
suppressant system.
ii. Detail specification (completely filled up data sheets) with make and model no. before
placement of order to sub-vendor
iii. Logic diagram with detailed logic write up
iv. General Arrangement Drawings of panels and internal layout with dimensions
v. Power supply distribution
vi. P&ID & cable schedule
vi. Bill of material after site survey
vii. Instrument tray layout
viii. Instrument location plan
ix. Wiring and termination drawings for panels and junction boxes
x. PESO approval for electrical system

C) Documents to be submitted after commissioning

i. Operating and Maintenance manuals for all offered instruments (2 sets per location)
ii. As built Wiring and termination drawings for panels and junction boxes (2 sets per
location)
iii. All relevant test certificates
iv. As built drawings (tank farm) showing the location of systems and associated
alarm/control equipment.
v. Data sheets providing technical details of all Major components.
vi. PESO Certificates for Electrical Enclosure mounted in classified hazardous areas.
vii. UL listing approval document for the Nozzle.
viii. UL listing or FM/VdS/LPC approval for linear heat detector.

13
All manuals shall be provided in hard bound A4 size folders with clear printed labels on it. In
addition to the hard copies following software shall be supplied after the commissioning
a) Soft copies of the documents/drawings placed in the manual.
b) CD for Software to be used with the rim seal fire detection system along-with the
authorization.

18.0 Training:
Bidder shall impart training to site personnel for routine operation & maintenance of the rim-
seal fire protection system. The training shall be imparted at owners‟ site for minimum two
days immediately after commissioning.

19.0 Warranty
The warranty shall be come into vogue after commissioning of entire rim seal protection
systems as per specifications all the tanks in a location.
Bidder shall offer performance guarantee for satisfactory and trouble free operation of the
entire Rimseal protection system for a minimum period of 1 year from the date of
commissioning of the system.
The Bidder shall repair any defect or replace any defective part during the warranty period
within two weeks of receiving such information from the owner.
During the warranty period the bidder shall also provide the following services:
a) Once in six month, complete checking, validation of measuring instruments and detailed
reporting.

b) Once in a year calibration of detection system, solenoid valves, pressure gauges/pressure

switches & cleaning of the foam nozzles.

20.0 Post Warranty Maintenance:

The bidder shall submit annual post-warranty AMC for 3 years in line price bid schedule. The
following shall be covered under post warranty maintenance:
a) The Bidder shall provide non comprehensive maintenance excluding supply of spares for
period of three years after the expiry of the warranty period.
b) The travel, boarding & lodging of service engineer/technician shall be borne by the Bidder.
The Bidder shall also bring tools & tackles as required for maintenance of the system.
c) The bid shall be made year-wise for three years & price validity shall be available for the
entire period of the contract (including AMC period).
d) The service under post warranty maintenance shall include :

(i) Once in three month, complete checking, site acceptance test as per the specification,
repair/replacement of defective part/components, and detailed reporting.
(ii) Once in a year calibration of detection system, solenoid valves, pressure
gauges/pressure switches & cleaning of the foam nozzles.
(iii) Emergency maintenance:

In the event of any malfunction of the system, experienced service engineer shall be made
available at site with-in one week on the receipt of such information from the owner & the
system must be brought to the Normal within 24 hrs after reporting at site. Vendor has to
supply/replace all the required parts/equipments free of cost.

14
Annexure -1
FAIL SAFE REQUIREMENT
CASE 1: Power failure from mains to the fire alarm panel in the control room/rim seal
protection system:
Power supply to all components of the Rimseal fire protection system including panels shall
be taken from Un-interrupted Power Supply (UPS) source. In case of failure of AC Power,
UPS should be rated to supply continuous power for minimum 2 hours.
CASE 2: Any hardware/software problem in functioning of fire alarm panel in control
room:
System should independently be able to actuate the extinguishing system locally on the tank
upon detection of fire without any support from the fire alarm panel in the control room. This
feature should be of de-centralized and independent for each tank.
CASE 3: Failure / cut of any or all signal cables communicating to / from tank to
control room or vice versa:
The system should have the feature whereby it would still remain functional locally on the
tank i.e. detect fire, give alarm (actuation signal) locally and actuate the extinguishing
system. Cable fault signal should be displayed on the fire alarm panel in control room.
CASE 4: Failure / cut of any/or all power cables supplying power to the local unit of
the tank:
The system shall provide fault alarm/signal at fire alarm panel in control room and repeater
panel.
CASE 5: Failure of detection system installed on the tank
The system should give „detection fault‟ alarm signal at fire alarm panel.
CASE 6: Leakage / damage in detection Tube:
Fault indication / alarm should be displayed on the fire alarm panel
CASE 7: Pressure in the Foam module low:
Low module pressure indication & alarm should be displayed on the fire alarm panel. Rim
Seal Fire

15
Annexure 2

1. GENERAL

1.1. This specification covers the requirements for aqueous film forming foam (AFFF) liquid
concentrate fire fighting agents consisting of fluorocarbon surfactants, foaming agents,
stabilisers and other compounds, as required, to conform to this specification.
1.2. The concentrate should conform to Type-3 of IS:4989-2008 and bear IS mark. In
addition the foam should have UL Listing (Underwriters Laboratories Inc) under UL 162, the
Standard for Foam Equipment & Foam Concentrates. The foam concentrate must have UL
approval marking. The manufacturer should have ISO-9001 certified production facilities.
1.3. At the time of use, the concentrate shall be diluted to form a fire extinguishing solution
for the fire extinction of hydrocarbon fuels
1.4. The AFFF concentrates shall be suitable for use in foam generating equipments with
fresh water or seawater with no loss in its performance.
1.5. In addition to being suitable for use at low expansion, the foam concentrate should have
film formation characteristics that allow it to be used through non-aspirating
nozzles/monitors.
1.6. The produced foam should be essentially have a quick control time, good burn-back
resistance, effective vapour sealing properties and low critical application rates.

2. TYPE OF FOAM CONCENTRATE

The foam concentrates shall be.
Type - 3 : To be used as 3 parts of concentrate in 97 parts of water v/v.
3. CONCENTRATE CHARACTERISTICS :
The concentrate shall conform to the physical requirements shown in Table
Concentrate requirements
Viscosity, at 27 / 1 o C 40 - (Centistokes)
Hydrogen ion concentration 6.5 to 8.5 to 6.5 (pH) for both original and conditioned sample.
Specific Gravity for both 1 to 1.15 original & conditioned sample
Miscibility with water Miscible /sea water
Sludge contents ( % v/v) 0.25%
Freezing Point Shall flow at -50 C
Film Formation Forms Aqueous Film
Spreading coefficient minimum 3
Expansion at 27/1 oC 3.6 to 10
25% drainage time minimum 90 Sec at 27¿1oC
Fire test extinction time 90 Sec (maximum)
Fire control time 60 sec (maximum)
Resistance to burn back - 8 Min (thermal stability)
Sealability- Shall pass the test
3.1. Storage
The concentrate shall be capable of being stored in sealed containers within India for a
period not less than 15 years at local ambient temperatures and conditions encountered
without deterioration by chemical or bacterial action.
3.2. Homogeneity
The concentrate shall be homogeneous. No solidification or separation of crystals or
stratification shall take place under the conditions stated in 3.1.
3.3. Compatibility
The foam produced from the concentrate shall be compatible with dry chemical powder.

4. Test Methods / Procedures

4.1. Viscosity
Viscosity shall be determined by method described in IS:1206 (Part 3) - 1978, using viscosity
meter Sl no iv of Table 2.

16
4.2. pH value
pH shall be determined using a pH meter with glass electrode and reference electrode as
per method specified in Appendix A of IS:4989 -2008.
4.3. Specific Gravity.
Specific gravity shall be determined as per procedure prescribed in IS:4989 - 2008.
Appendix B.
4.4. Miscibility with water / Sea water (Optional)
Miscibility with water shall be determined as per procedure prescribed in IS:4989 -2008
4.5. Sludge contents
Sludge contents shall be determined as per procedure prescribed in IS:4989 -2008.
Appendix D.
4.6. Freezing point (Optional)
Freezing shall be determined as per procedure prescribed in IS:4989 -2008. Appendix E.
4.7. Film formation
Film formation test shall be conducted as per procedure prescribed in IS:4989-2008.
However, details of nozzle and method of foam generation shall be as described in Appendix
F of IS:4989 -2008
4.8. Spreading coefficient
Spreading coefficient shall be determined as per formula / method described in IS:4989 -
2008. Appendix H.
4.9. Expansion
Expansion test of the foam shall be determined as per procedure described in IS:4989 -
2008. Appendix J.
4.10. 25% drainage Time.
25 % Drainage Time shall be determined as per procedure described in IS:4989 -2008.
Appendix K.
4.11. Fire Test Extinction Time
Fire test extinction time shall be determined as per procedure described in IS:4989 -2008.
Appendix L.
4.12. Resistance to Burn-Back.

Resistance to burn back shall be determined as per procedure described in IS:4989 -2008.
Appendix M.

QUALITY ASSURANCE

5.1. The foam manufacturer shall have all test facilities to carry out quality control tests of the
foam produced in his premises.

5.2. The foam manufacturer should also get the dispatch ready material tested and certified
by UL India Private Limited, Bangalore as a Third Party inspection. The foam manufacturer
will have to provide all facilities for testing and will bear the cost of all the testing including
cost of third party. Before acceptance of the ordered foam, the manufacturer shall arrange
for conducting all the tests specified in this specification and tests as per UL 162 (on a
randomly drawn sample from dispatch ready lot of the ordered foam) for ensuring quality of
the foam being supplied. The above testing shall be done at no extra cost. The testing shall
be carried out in presence of third party and HPCL Representative for joint certification. The
vendor shall submit the calibration certificates of all foam/water equipments, measuring
equipments and gauges to HPCL.

17
Annexure 3

TECHNICAL SPECIFICATION FOR INSTRUMENTATION ITEMS

1. ALARM ANNUNCIATOR
 Mounting - Solid state plug in type
 Power supply – (To be provided by the bidder)
 Legend size - 4mm
 Flasher/horn driver – One audible upto 500 M

Module
 Sequence module - Sequence ISA-S18.1 F2M-1 for all the points
 Indication - LED Array per point replaceable from front,
 Legend - black letter on white translucent background
 Fault indicating alarm - break to alarm
 The annunciator shall be of solid-state type having first out sequence with manual reset.

2. PRESSURE GAUGE
 Instrument ref.No.:
 Qty.: As reqd. for safe and efficient operation of the system
 Fluid: Water / Air
 Working pressure:
 Pressure range:
 Ring type: Screwed
 Element: Bourden
 Location/size: Bottom ½ “ NPT (M)
 Connection type and rating: Screwed NPT (M)
 Mounting: Local
 Element: SS316
 Case: SS316
 Movement: SS316
 Accessories: S NUMBER – SS 316
 Accessories material: Bidder to specify
 Accessories connection: ½ “ NPT (M)
 Size/type: Blow out disc micrometer pointer
 Accuracy: 1% calibration at site in presence of Engineer-in-charge
 Enclosure type: Weatherproof, IP 55

3. PRESSURE SWITCH
 Instrument ref.No. :
 Qty. required: As reqd. for safe and efficient operation the system
 Service Fluid: Water /Air
 Working pressure:
 Working temperature: Ambient

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 Element type: Bellows
 Element material: SS 316
 Connection size and type: ½ “ NPT(F)

Location: Bottom
 Over range (max.op.pr):
 Set point:
 Switch type: Snap acting micro switch
 Switch action: Opens on low pressure condition
 Accuracy: 0.5%
 Cable entry/size: ½ “ NPTF
 Enclosure type: Weather proof, IP 65, Ex (d)
 Setting adjustment: 10% to 90%
 Gland type: Weather proof
 Mounting: Direct with brackets
 Alarm contacts, rating: SPDT, 5A
 Case material: Die cast Aluminium
 Calibration: Calibration at site in presence of engineer-in-charge
4. JUNCTION BOX SPECIFICATION
 Type: For connecting cables from individual instruments
 Enclosure: Explosion proof (Ex(d)), W/P IP65
 Mounting: Bracket / pedestal mounting
 Entries: As per requirement
 Cable glands: Adequate double compression cable glands to be provided
 Earthing terminal: Required
 Drain fittings: Required
 Tag plate: Non corrosive SS tag plate

5. SOLENIOD VALVE
 Coil Voltage: To be provided by the Bidder
 Coil insulation: Class H
 Enclosure: Weather proof to IP 65
 Ex. Proof required: Yes, Ex(d) required
 Body of the valve: SS 316
 Seat: SS 316
 Disc: Teflon
 Seal: Teflon
 Port type: 3 way
 No. of coil: single
 Pneumatic connection: ¼” NPT(F)
 Cable entry: ½”NOT(F)
 Accessories: Bug proof on vent port SS cable gland

19
Annexure 4

APPROVED SUB-VENDOR
LIST
Serial No EQUIPMENTS APPROVED VENDOR

1. ALARM ANNUNCATOR Applied Electronics

Bangalore
Procon Instrumentation
IIC , Mumbai
Minilek
Toyo Electronic Corporation
Japan
2 PRESSURE GUAGE Switzer Instruments
H.Guru Instruments
Odin India
Wika Instruments
Wellwin Industries
Manometer(I)Ltd.
Spirana Italy
Wyka Germany
3 PRESSURE SWITCH Switzer
Danfos
Honeywell
UE through Chemtrols
4 INSTRUMENT PANEL Waves Electronics, Kochi
Megatech Controls
Rittal
Pyrotech
Chemin Controls, Pondichery
5 SIGNAL CABLES Lapp Cables
TCL cables
Nicco Corporation
Associated Cables
Delton Cables
Associated Flexibles & wires
Ltd
Brooks Cable works,
Polycab, Radiant, Universal,
Incab
6 CONTROL CABLES TCL cables
Nicco Corporation
Associated Cables
Delton Cables
Brooks Cable works
CCI, KEI, Torrent, Finolex,
Polycab, Universal,
Gemscab, Golster cables
7 SOLENOID VALVE ASCO
HERION
8 FRP CABLE TRAYS PATNY & CO / TECHNOFAB
/ INDIANA
/ SADHANA/ IDS

20
 Composites/ National
Galvaniser/Vatco/Steelite/Rat
an Engineering
9 EXPLOSION PROOF Baliga Lightings
JUNCTION BOX Flexpro Electricals
CEAG Flameproof Controls
Ex-Protecta/ Bajaj/ Sudhir
Switchgears
10 UPS Emerson, HiRel, Aplab, DB
Electronics

11 PLC Invensys, Honeywell, Rockwell,

Siemens, Schneider, OMRON, Emerson, Yokogawa.

In case the bidder intends to provide any alternate makes then prior approval of owner is
required. The bidder shall provide documents for proper functioning of such equipments for the
intended use from the end user.

21