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CLP-PSP-020-003-A4
PT. PERTAMINA (PERSERO)
JASA KONSULTANSI PENYUSUNAN
FRONT END ENGINEERING DESIGN (FEED)
UNTUK PEMBANGUNAN TERMINAL LPG
PRESSURIZED
DEPOT LPG CILACAP
Revision:
2
Status:
IFB
Discipline:
MECHANICAL
OWNER
PROJECT
LOCATION
REV
DATE
07/01/2015
04/02/2015
DESCRIPTION
Issued For Approval
(IFA)
Re-Issued For Approval
(Re-IFA)
Chkd
Apvd
FRL
AND
KS
FRL
AND
KS
PT. PERTAMINA
Chkd
Apvd
Document No. :
CLP-PSP-020-003-A4
Status :
Revision : 2
Re-IFA
Date
Dicipline : MECHANICAL
: 04/02/2015
Page : 2 of 37
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Document No. :
CLP-PSP-020-003-A4
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: 04/02/2015
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TABLE OF CONTENTS
REVISION HISTORICAL SHEET.................................................................................2
TABLE OF CONTENTS................................................................................................3
1.0 INTRODUCTION..................................................................................................5
2.0 GENERAL SCOPE...............................................................................................5
3.0 DEFINITIONS.......................................................................................................6
4.0 REFERENCES.....................................................................................................6
4.1 Code & Standards......................................................................................7
4.2 Project Specifications................................................................................7
5.0 GENERAL REQUIREMENTS..............................................................................8
6.0 SCOPE OF SUPPLY...........................................................................................11
6.1 Fire Pump..................................................................................................11
6.2 LPG Filling Pump.....................................................................................12
7.0 EXECUTION.......................................................................................................12
8.0 FIRE PUMP DESIGN REQUIREMENTS...........................................................12
8.1 General......................................................................................................12
8.2 Prime Mover..............................................................................................14
8.3 Electrics.....................................................................................................19
9.0 LPG FILLING PUMP DESIGN REQUIREMENTS.............................................24
9.1 General......................................................................................................24
9.2 Design........................................................................................................25
9.3 Mechanical Shaft Seal..............................................................................26
9.4 Vibration....................................................................................................27
9.5 Base Plate.................................................................................................28
9.6 Lubrication................................................................................................28
9.7 Electric Motor & Drive..............................................................................28
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9.8 Performance..............................................................................................29
9.9 Noise..........................................................................................................30
9.10 Material......................................................................................................30
10.0 SPARE PARTS FOR THE PUMP ORDERED...................................................31
11.0 SPARE PARTS FOR ENGINE ORDERED........................................................31
12.0 INSPECTION AND TESTING.............................................................................31
12.1 Fire Pump..................................................................................................31
12.2 LPG Filling Pump.....................................................................................32
13.0 PERFORMANCE GUARANTEE........................................................................34
14.0 NAME PLATE.....................................................................................................34
15.0 PREPARATION FOR SHIPMENT......................................................................35
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CLP-PSP-020-003-A4
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1.0 INTRODUCTION
PT. Pertamina (Persero) Directorate of Marketing and Commerce, intends to
carry out the construction of pressurized LPG terminal in line with the
government's program to reduce fuel subsidies of land for household tumble to
LPG.
By the conversion of fuel from kerosene to LPG, the LPG demand in the future
will continue to increase while the facility receiving, storage and distribution of
liquefied petroleum gas (LPG terminal) available is not sufficient, so it should be
added hoarding LPG facility, to anticipate the needs of LPG in the future in
order to avoid a crisis availability of LPG in the community.
Prior to the development activities conducted prior Pre-Project activities and
preparation of Front End Engineering Design (FEED) for the construction of
LPG Terminal pressurized LPG Depot Cilacap.
Document No. :
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: 04/02/2015
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Work
Consultant
MIGAS
Third Party
QA / QC
Issuer
Project Documents
SITE
4.0 REFERENCES
The following applicable section of the latest edition of the code and standards,
including addenda and referenced documents, project's specification shall form
an integral part of this specification.
Document No. :
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Where the requirement of the subject is defined by two or more references, the
more stringent reference shall govern.
4.1
ASME
B 73.1
: Specification
for Horizontal
End
Centrifugal Pumps for Chemical Process
Suction
ASME
B 73.2
ASME B16.5
ASTM
API RP 7B-11C
: American
Petroleum
Institute
Internal
Combustion Engines for Offshore Facilities
BS 5265
EEMUA 140
HI
ISO 1940
ISO 5199
ISO 9906
ISO 2017
: Vibration Isolators
4.2
ISO 13709:2009
OSHA
: Safety Regulation
Project Specifications:
CLP-PSP-040-001-A4
CLP-PSP-040-003-A4
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CLP-PSP-030-001-A4
CLP-PSP-030-006-A4
CLP-DSH-020-005-A4
CLP-DSH-020-007-A4
CLP-DSH-020-008-A4
Document No. :
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l. The supplier shall get the equipment inspected by approved Third Party
agencies before dispatch of the equipment to site. The approval / comments,
if any, of/on the drawings shall be communicated by PTM within 10 days of
receipt of the same. Changes, if any in the drawings have to be incorporated
and submitted to PTM for their record.
m.Approval of suppliers drawings by PTM shall not relieve the supplier of any
responsibility covered by the requirement of the Contract.
n. The supplier shall supply operation and maintenance manuals along with the
equipment. The manuals shall meet the following requirements:
The instruction manuals shall present the categories of information in
practical, complete and comprehensive manner prepared for use by
operating and/or maintenance personnel.
Drawings and other illustrations shall be included or copies of drawings
shall be bound in the manual. Test, adjustment and calibration
information as appropriate shall be included and shall be identified to
the specific equipment. Safety and warning notices and installation,
maintenance and operating cautions shall be emphasized.
A parts list shall be included showing part nomenclature, manufacturers
part number and/or other information necessary for accurate
identification and ordering of replacement parts.
If a standard manual is furnished covering more than the specific
requirement purchased, the applicable model No., parts No. and other
information for the specific equipment purchased shall be clearly
identified.
The instruction manual shall include a list of all special tools and tackles
furnished with complete drawings and instructions for use of such tools
and tackles.
o. Other miscellaneous works:
Foundation drawing, bolt size and numbers, grouting method, etc.
should be advised in advance after order placement. The scope of
supply includes supply of foundation bolts.
The scope also including brief training of the working personnel at site
about predictive maintenance, dos & donts, daily checks etc.
Matching flange with studs, nuts and gasket has to be supplied by the
Vendor.
2 (two) Nos. of pressure gauges per pump (on suction and discharge)
have to be supplied by the Vendor as per pressure range as specified
on each data sheet of pumps.
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Fire Pump
Fire Water pump package shall include the following listed major components
which shall be assembled and fully shop tested prior to shipment from the
Vendor facilities:
a. Centrifugal pump as per NFPA standard
b. Pump Driver (Electric motor as per NEMA standard or Diesel Engine as
per UL/FM).
c. Driver and pump coupling connection.
d. Fire pump controller (as per UL/FM standard)
e. Non sparking coupling guard.
f. Structural skid.
g. Gland packing and seal system
h. For Diesel Engine: Fuel system including fuel storage tank, Lube oil
system, Cooling water system, batteries, exhaust system with silencer
and engine mounting with anti vibration.
6.2
7.0 EXECUTION
Unloading and installation of pump sets along with all accessories; fuel piping from
tank to engine, extension of exhaust pipe from silencer/flexible element onwards
at site has been excluded from the scope of work of the Contractor. However
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General
- The pump shall be manufactured, tested and marked in accordance with
NFPA 20.
- Pumps shall be capable of developing not less than 150% of rated capacity
at a head of not less than 65% of the rated head. The shut-off head shall not
exceed 120% of rated head. The pump shall have a continuous rising head
capacity characteristic from the specified duty point towards the shut-off
point, the maximum being shut-off. The horse power characteristic shall
preferably be non-over loading type beyond the rated capacity point.
- The pump rated capacity, total dynamic head and other performance
requirements shall be as per the requirement indicated in the pump data
sheet.
- The pump shall be designed to have the best efficiency at the specified duty
point. The pump set shall be suitable for continuous operation at any point
within the range of operation wherever specified.
- The pump shall have a continuous rising head capacity characteristic from
the specified duty point towards the shut-off point, the maximum being shutoff. The horse power characteristic shall preferably be non-over loading type
beyond the rated capacity point.
- For diesel engine driven fire water pump, the rated horse power of the diesel
engine shall be higher of the following two (2) values:
- 20% in excess of the maximum horsepower required to drive the pump set at
its duty point.
- The BHP required driving the pump set at 150% of its rated discharge.
- The main pump casing shall be horizontally split casing type. End suction
centrifugal pump and multi stage centrifugal jockey pump shall be end
suction back pull out as specified in the data sheet enclosed.
- The fire water system will be automated by other agency; hence provision
should be kept in the local panel for remote start at full speed, potential free
contacts and other contacts for feedback & actuation.
- The shaft sealing of Fire pump shall be Gland Packing type. The gland
packing should be easily accessible for changing without having to
disassemble the pump and suitable of gland packing material.
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- Suction and discharge flanges shall be drilled in accordance with the NFPA
20 standard.
- Pumps shall be direct-coupled. Belt driven pumps will not be accepted.
- Others additional required information should be refer to Data sheet
- Parts of pumps like impeller, shaft sleeve, wearing ring etc. shall be of noncorrosive metal as specified in the data sheet.
- The coupling between the prime mover and the pump shall allow each unit to
be removed without disturbing the other.
- The material of construction for components other than those specified shall
be as per standard of the pump manufacturer and shall be indicated
separately
- The pump set shall be designed in such a way that there is no damage due
to reverse flow through the pump which may occur due to any mal-operation
in the system.
- Pump along with its drive shall run smooth without undue noise and vibration.
- The main pump casing shall be horizontally split casing type and the jockey
pump shall be end suction back pull out as specified in the data sheet
enclosed.
- Replaceable / renewable wearing rings shall be provided for both the casing
and the impeller or for the casing only.
- The complete assembled unit shall be designed so that all covered parts
including shafts and bearings shall be easily accessible for inspection,
maintenance and replacement with minimum down time.
- The rotor assembly with impeller and shaft sleeve shall be dynamically
balanced at 150% of operating speed.
- Pump casing shall be made of cast iron and tested at 150% of shut-off head
or 200% of rated total head whichever is higher.
- Suction and discharge flanges shall be drilled in accordance with the
standard NFPA 20.
- The gland packing should be easily accessible for changing without having to
disassemble the pump.
- A common base plate mounting both for the pump and drive shall be
furnished. The base plate shall be of rigid construction, suitably ribbed and
reinforced. Base plate and pump supports shall be so constructed and
pumping unit so mounted as to minimize misalignment caused by mechanical
forces such as normal piping strain, hydraulic thrust etc. Suitable drip taps
and drip lip shall be provided.
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: 04/02/2015
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Prime Mover
The prime mover of the pump shall be diesel engine and/or AC electric motor as
indicated in the data sheet.
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8.2.1. AC Electric
Refer to clause 8.4
8.2.2. Diesel Engine
a. General
Suitable diesel engine to drive the main fire water pump shall be supplied
with all standard accessories. Diesel engine supplied shall be provided by
removable enclosure. Suitable anti-vibration mounting (type, quantity and
size) for diesel engine shall be required to ensure there will be no
execessive vibration occured during operation of the fire water pump. While
rating the diesel engine, the site conditions and climatic data of the place of
installation shall be taken into account. The engine shall be capable of
delivering the rated output continuously. The diesel engine shall be multicylinder type four-stroke cycle with mechanical (airless) injection, cold
starting type. All parts susceptible to temperature changes shall have
tolerance for expansion and contraction without resulting in leakage,
misalignment of parts or injury to parts.
b. The Engine
Engine heater shall be provided. The Engine shall be:
Compression ignition mechanical direct injection type, capable of
being started without the use of wicks, cartridges, heater plugs or
ether, at an engine room temperature of 2C and shall accept full load
within 15 seconds from the receipt of the signal to start.
Naturally aspirated, supercharged or turbo-charged and either air or
water-cooled. In the case of charge air cooling by means of a beltdriven non metallic fan or of a belt driven auxiliary water pump there
shall be multiple belts such that should half the belts break, the
remaining belts would be capable of driving the fan or pump. Driving
belt shall be from anti static material.
The diesel engine as fire pump driver shall be started and brought up
to rated speed without interruption within 20 seconds.
Provided with an adjustable governor to control the engine speed
within 10% of its rated speed under any condition of load upto the full
load rating. The governor shall be set to maintain rated pump speed at
maximum pump load.
Provided with an in-built tachometer to indicate the speed (rpm) of the
engine. Any manual device fitted to the engine that could prevent the
engine from starting shall return automatically to the normal position.
Engines, after correction for altitude and ambient temperature, shall
have bare engine horsepower rating equivalent to the higher of the
following two values
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designed assuming stack height as per PCB norms. The exhaust system
shall include:
Exhaust manifold.
Exhaust piping material shall be non corrosive material for high
temperature above 300 oC.
Silencer: Sufficient length of straight pipe shall be provided after the
exhaust silencer to leave the gases at sufficient height above the
engine room and outside the room.
Expansion joint.
f.
g. Fuel System
Fuel: The engine fuel oil quality and grade shall be as specified by
engine makers. These shall be kept on hand at all times.
Fuel tank: The tank shall be mounted above the engine fuel pump to give
gravity feed unless otherwise recommended by the manufacturer. The
tank shall be fitted with an indicator showing the level of the fuel in the
tank. The capacity of the tank shall be sufficient to allow the engine to run
on full load for 6 hours operation. Fuel tank sizing shall be as per NFPA
20 standard: 5.07 liter/kW plus 5% for expansion plus 5% for sump.
There shall be one fuel tank per engine. The tank should also have level
switch for low fuel level and tripping of pump / alarm. Each tank should
be fitted with isolation valve. Fuel tank shall have venting, drain and filling
connection.
Any valve in the fuel feed pipe between the fuel tank and the engine shall
be placed adjacent to the tank and it shall be locked in the open position.
Pipe joints shall not be soldered and plastic tubing shall not be used. The
following shall be provided:
- Fuel pump shall be gear pump type, fuel injection and control
system for compression ignition.
- Manual priming pump.
- A sludge and sediment trap.
- A fuel level gauge and a level switch of approved make to signal
fuel less than or equal to 30% of tank capacity.
- An inspection and cleaning hole.
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- A duplex filter between the fuel tank and fuel pump mounted in an
accessible position for cleaning.
- Means to enable the entire fuel system to be bled of air. Air relief
cocks are not allowed; screwed plugs are permitted.
h. Starting Mechanism
Provision shall be made for two separate methods of engine starting.
Automatic starting by means of a battery powered electric starter motor
incorporating the axial displacement type of pinion, having automatic
repeat start facilities initiated by a fall in pressure in the water supply pipe
to the sprinkler and/or hydrant installation. The battery capacity shall be
adequate for ten consecutive starts without recharging with a cold engine
under full compression and 15 seconds of cranking and 15 seconds of
rest in six (6) consecutive cycles as per NFPA 20 standard.
Manual starting by electric starter motor (thru Push Button in Panel or
Key in Local start station). The starter motor used for automatic starting
may also be used for manual starting provided there are separate
batteries for manual starting.
Battery shall be placed in battery rack for and shall be provided with
battery isolation for protection any short circuit.
i.
Governing System
The engine shall be provided with an adjustable governor capable of
regulating engine speed within a range of 10% between shut-off and
maximum load conditions of the pumps. The governor shall be set to
maintain rated pump speed at maximum pump load.
j.
Instruments
Instrument control and protection required for the safe operation of the
engine shall be provided. Instrument panel on engine shall consist of
(minimum):
Starter Switch
Lube Oil Temperature Gauge
Water temperature Gauge
Lube Oil Pressure Gauge
Ammeter
Tacho meter and
Hour meter
k. Tools
Document No. :
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A standard kit of tools shall be provided with the engine and kept on hand at
all times.
l.
Name Plate
A corrosion resistant nameplate shall be permanently attached to the pump
and prime mover. The nameplate shall be stamped with the following
information:
Manufacturers name
Serial number
Model number
Rated capacity
Rated head
Speed in rpm
Rating of the prime mover
m. Protection
Unpainted exterior like machined surfaces shall be coated with suitable rust
preventive. All threaded openings shall be plugged and flanged openings
shall be provided with full flange protective covers. The cover material shall
be 4.5 mm thick metal plate bolted to the flange with a gasket in between
using a minimum of four (4) bolts.
n. Packing
The pump set shall be packed, securely anchored and protected for
domestic shipment. All unmounted components shall be suitably crated and
firmly attached to the main pump unit for shipment. The purchase order
number and equipment number shall be stenciled on the crate. One
complete set of installation, operation and maintenance instruction shall be
packed with the pumpset.
8.3 Base Plate
a. The pump, driver and electric motor shall be mounted on a rigid base
plate suitable for full grout support.
b. Grouting holes of 4 inch in diameter with raised edges shall be
provided.
c. A pan under the pump shall drain leakage to a 1 inch diameter flange
connection at the pump end of the base plate, as well as a 1 inch drip
rim around the skid.
d. Jacking bolts shall be provided for all motors 45 kW and greater, to
enable axial and transverse positioning. Stainless steel shims shall be
provided for height adjustment.
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Battery charger with provision of boost & trickle charging and SC &
O/L protection. Two separate battery charger should be provided to
keep both engine battery &stand by battery under float charge. The
charge current should get adjusted automatically depending on the
condition of the battery. The disconnection of any one of the
batteries should not affect the system. One set of voltmeter &
ammeter should be provided for each set of battery. Change over
facility to be provided for changing over the engine starter motor
from main battery to stand by battery without the need for
reconnecting the cables. The system should withstand 600 Amps
minimum continuous current & 5000 Amps for short duration.
Battery charger with provision of boost & trickle charging and SC &
O/L protection.
Indication lamps and hour run meter.
Indications and PB viz. AC supply On, Start failure, Low lube Oil
pressure, high water temperature, over speed trip, low fuel level,
pump on demand, water heater ON, header pressure normal, hour
run meter, engine running, start, stop and reset PB.
Switches like A/C supply On/Off, Water heater On/Off, Charger
trickle/boost, Auto/Off/Manual mode, Hooter On/Off
Ammeter for Battery-1 & 2 charging and DC voltmeter
Provision of terminals for interlocking for start/stop of engine from
header pressure switches
Requisite no. of NO/NC potential free contacts and wire up to
terminal block for external interlocking of the jockey pump.
Two numbers additional (spare) auxiliary contactors (24 VDC 2 No.
+ ve relays) for Contractor use, fully wired up to terminal block.
e. The control panel shall be floor mounted type sheet steel (2 mm thick)
enclosed, with hinged door completely wired with terminal block. The
wiring shall be carried out with 2.5mm2 PVC insulated, copper wires.
Earthing studs (2 Nos.) shall be provided at two ends of the panel.
f. Diesel engine pump shall has independent 24 VDC lead acid battery
(SMF) with teak wood stand and accessories, rated for quick starting
of diesel engine. All power and control cabling (supply) between diesel
engine control panel and engine/battery charger/batteries (working
and standby) is included in the scope. The Battery shall be 1+1 (1
working + 1 standby) with manual change-over facility.
8.4.2. Motors
a. General.
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The Contractor shall furnish type Test Certificates along with the
bid.
Test for vibration severity.
Test for noise level
Temperature rise test at limiting values of voltage and frequency
variation as given in this specification.
Over speed test.
e. Documentation Requirement
GA drawings of motor, main terminal box, space heater thermistor
RTD.
Wiring diagram for space heater TB, thermistor/RTD.
Motor data sheet duly filled up.
Type test certificates
Quality Assurance Plan for PTMs inspection.
Motor characteristics curves.
8.5
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opened with the handle in the ON position except by a hidden tool operated
defeater mechanism.
g. The fire pump controller operator interface shall be capable of displaying true
RMS digital motor voltage and current measurements for all three phases
simultaneously.
h. Diesel Engine and Electrical Motor Fire Pump Controller screen operator
interface shall visually indicate the following alarms and differentiate the
criticalness:
Engine run
Main switch in Hand, Off or Auto
AC present / failure
Battery #1 and battery #2 failure
Battery charger #1 and battery charger #2 failure
Low oil pressure
High engine temperature
Over-speed Fail to start
Fail when running
Periodic test
System overpressure
Water reservoir low
Low system (discharge) pressure
Periodic test cut-in not reached
Run test solenoid valve check
Faulty pressure transducer
Pump on demand
Over pressure and Under pressure
Low pump room temperature
Low fuel level
Power Available
Alarm
System Pressure Low
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Remote Start
Transfer Switch Normal
Transfer Switch Emergency
Phase Failure
Phase Reversal
Interlock On
Fail To Start
Motor Overload Emerg. Iso. Switch Off
Automatic Shutdown Disabled
Overvoltage and Undervoltage
i. The controller shall feature a RS485 serial communications port for use with
2 or 4 wire Modbus RTU communications.
j. The controller shall not start the fire pump motor under a single-phase
condition.
k. A 4 alarm bell rated for 85dB at 10ft (3m) shall sound during boot up and
internal communication error.
9.0 LPG FILLING PUMP DESIGN REQUIREMENTS
9.1
General
a. All centrifugal pumps shall be met with the PTM standard design amended in
accordance with the additional requirements called for by this specification.
b. LPG Filling pumps shall be design, manufactured, tested and installed as per
API 610 latest edition. The pumps shall be design for minimum 20 years of
service life and at least 3 years of uninterrupted operation.
c. Preference will be given to pumps running close to the best efficiency point at
the design conditions.
d. Pumps shall be designed to minimize wear of components in contact with the
fluid and to resist the chemical environment described on the data sheets.
e. All pumps shall be self-venting without the need for external bleed valves.
f. The pumps shall not be selected to operate at the fastest speed of the pump
impeller range, not shall the smallest or largest impeller diameters be used.
g. All bolts & nuts, shafts, screw on rotating parts shall be correctly tightened
and locked in position with the appropriate tools and parts or product.
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h. All pump casings and their components shall be furnished with corrosion
resistant bolts, nuts and washers.
i. Pumps shall be suitable for uncovered outdoors installation under the
specified ambient conditions.
j. Materials shall conform to appropriate standards for chemical analysis and
mechanical properties.
k. All exposed moving parts shall be fitted with appropriately painted guards to
prevent contact, by accident or intent, of personnel with the moving parts.
The seal space shall be covered to prevent accidental splashing of harmful
fluids in the event of seal failure.
l. All safety guards shall be fully removable during maintenance activities.
m.Electrical components and installation shall be suitable for the area
classification and grouping specified in the Data Sheets.
n. All pumps shall be have a stabile curve (the head and capacity curve) with
continue increment until the pump is shut off.
o. Pressure design of casing shall be design for at least 10% bigger than
maximum discharge pressure.
p. Alarm and shutdown of pumps are happen in case of condition:
- The inlet pressure is too low.
- Excessive motor power (overload)
9.2
Design
a. The impeller diameter selected to meet the specified duty point shall be no
more than 90% of the maximum impeller size of the pump. Where this
requirement is deemed impractical, full details shall be provided in the
proposal and PTM approval obtained prior to award purchase order.
b. The pump shaft shall be machined all over with fine finish ground surfaces
and large radius fillets. Shaft deflection shall not exceed the more stringent
of either 0.05 mm at the shaft seal or the seal manufacturers requirement.
Locking of impeller to shaft shall tighten with normal pump rotation.
c. A renewable shaft sleeve shall be provided. The sleeve shall be positively
fastened to the shaft with expansion provision to cater for any temperature
variations.
d. Ball or roller type anti-friction bearings shall be provided. These shall have a
L10 service life of not less than 50,000 hours.
e. Bearings shall be sealed against entry of foreign matter or moisture, but with
provision for lubrication. Rolling element bearings shall not have plastic
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h. Where applicable, a shoulder at least 0.125 inch wide shall be provided in the
seal gland to prevent the stationary element of the mechanical seal from
dislodging as a result of chamber pressure.
i. Specified seal and pump connections shall be identified by symbols
permanently marked into the components (such as stamped, cast, or
chemically etched) and shown on the seal drawing.
j. Mechanical seals and glands for all pumps shall be installed in the pump
before shipment and shall be clean and ready for initial service. On pumps
whose seals require final adjustment or installation in the field, the Vendor
shall attach a tag warning of this requirement.
k. The seal gland plates shall have a throttle bushing (0.125 inch thickness) to
restrict the flow to atmosphere in the event of seal failure. The throttle
bushing shall be of non-sparking material, and shall be shouldered to prevent
blowout. Seal glands plates shall be provided with quench and drain
connections (1/2 inch diameter NPT minimum).
l. Special tools and accessories required for mechanical seal servicing shall be
supplied by the Vendor.
m.The Vendor shall nominate a seal liquid system and the PTM shall confirm
the system suitability for the given application.
n. Seal fluid inlet and outlet connections shall be located in the seal cartridge
housing, with the outlet connection above the upper seal face for proper
venting of seal cavity air.
o. Unless otherwise noted, O rings shall be used to seal the shaft sleeve to
the shaft. The O rings shall be located so as to minimize the effects of heat
from the duty fluid.
9.4
Vibration
All pumps shall be designed not to produce excessive vibrations that would be
harmful to the equipment as a whole and surrounding and supporting, as a
result of hydrodynamic forces, both:
a. In operation, during opening and closing of flow and for all flow rates up to
and including maximum flow, and
b. When stationary including partial opening position.
c. Vibration limits for overhung and between-bearings API 610 pumps are
specified as :
Measured Overall velocity < 3,0 mm/sec Root Mean Square (RMS)
Discrete frequently velocity (measured with Fast Fourier Transform)
< 2.0 mm/sec RMS.
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: 04/02/2015
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Base Plate
a. The pump, driver and electric motor shall be mounted on a rigid base plate
suitable for full grout support.
b. Grouting holes of 4 inch in diameter with raised edges shall be provided.
c. A pan under the pump shall drain leakage to a 1 inch diameter flange
connection at the pump end of the base plate, as well as a 1 inch drip rim
around the skid.
d. Jacking bolts shall be provided for all motors 45 kW and greater, to enable
axial and transverse positioning. Stainless steel shims shall be provided for
height adjustment.
e. Lifting lugs shall be provided on the base plate.
9.6
Lubrication
a. Pump bearings shall preferably be lubricated by a rotary flinger picking up oil
from below bearing level. A sight glass and fill cap shall be provided. Oil
lubricated components shall be sealed to prevent both leakage of oil and
entry of fumes and dust. Lip seals are not preferred and the option of rotating
labyrinth or magnetic seals shall be provided. Where a breather is fitted, it
shall be designed to prevent spray water ingress.
b. The Vendor shall lubricate all components requiring lubrication prior to testing
and delivery.
9.7
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g. Enclosure, motor shall be of the totally enclosed fan cooled (TEFC) type and
the enclosure shall be cast iron up to frame 315 or welded steel corrosion
resistant.
h. All motors over than 20 kgs, shall have adequate lifting and hoisting
provisions.
i. Drivers shall be foot mounted, refer to PTMs specification CLP-PSP-030006-A4, Specification for Induction Motor
j. The Vendor shall supply a flexible coupling, selected to suit the power output
of the motor and able to transmit the design starting torque with a service
factor of 1.2, in accordance with the coupling manufacturers
recommendations.
k. Couplings shall be manufactured from materials such that the coupling is
classified as non-sparking.
l. Drivers shall have a continuous rating at least equal to the most stringent of:
The highest power requirement along the pump characteristic curve
containing the specified operating conditions.
9.8
Performance
a. Selection of pumps shall be in accordance with the specified LPG Filling
Pump Data Sheets. All flow and pressure conditions influencing reliability
shall be nominated by the Vendor in the proposal submission. This shall
include the conditions to avoid suction recirculation and cavitation, the
minimum flow conditions and any specific installation requirements (e.g.
piping and valve).
b. Standard NPSHReq data provided by the Vendor shall be presumed to be for
3% head drop and this shall be at least 1.0 m less than the available NPSH
at the maximum specified flow at the highest specified temperature.
c. Balancing of pump rotating parts shall be in accordance with grade G2.5 of
ISO 1940. Vibration of the bearing housing at design conditions shall not
exceed 2.8 mm/s RMS at 1800 rpm and 4.5 mm/s RMS at 3600 rpm.
d. The pump and drive components shall be selected so that the pump cannot
be run at a speed more than 80% of the first critical speed of the pump
rotating assembly.
e. To improve reliability, the value of L3 / D4 shall not exceed 2 mm-1, where L
is the length from the bearing centre to the impeller centreline, and D is the
solid shaft diameter (under sleeve) at the seal.
9.9
Noise
a. Noise limitations shall comply with requirements of IEC 60034-9.
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b. Combined pump and driver noise at all operating conditions shall not exceed
a sound pressure level of 85 dB(A) at 1 meter periphery from the surface of
the equipment.
c. When equipment has a noise level expectation above this, attenuation
devices including shields or enclosures shall be offered as an option. Low
noise fans shall be fitted to motors if the standard fans do not meet the noise
specification.
d. An acoustic enclosure, where required, shall be suitable for outdoor
installation in the specified environmental condition.
e. The Vendor shall provide all additional ancillary equipment necessary to
ensure the efficient operation of the pump within the enclosure under the
specified environmental conditions. These may include ventilation fan,
temperature gauges and instrumentation as recommended by the Vendor.
f. The enclosure shall incorporate a sufficient number of hinged or readily
removable access panels to provide convenient access for inspection and
maintenance.
g. The enclosure shall also be designed so that it can be readily removed.
Lifting lugs shall be provided for this purpose.
h. All grease lubrication points shall be extended to externally mounted grease
nipples and all pressure and temperature gauges shall be mounted external
to the enclosure.
9.10 Material
The materials shall be new, free from defects and in accordance with the
following:
a. Pump casing, impeller, wear ring, and mechanical seal parts shall be in
accordance with LPG Filling Pump Data Sheet, CLP-DSH-020-005-A4
b. Seal flush lines shall be 316 stainless steel tubing and tubing fittings.
c. Pump/motor skid shall be in accordance with CLP-PSP-030-006-A4,
Specification for Induction Motor.
d. All wetted pump parts must be inert to the process fluids. No corrosion /
erosion products are permitted to enter the product stream. Materials offered
by the Vendor to perform the stated duty shall be clearly defined in the
proposal.
e. Pump materials must have a proven history in process duties similar to those
specified in the Data Sheet.
f. Viton elastomers shall not be used. AFLAS is considered an acceptable
alternative.
g. Asbestos materials shall not be used.
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If it is necessary to dismantle any pump after the shop test for the sole
purpose of machining impellers to meet the tolerances on differential head,
no retest shall be required unless the reduction in diameter exceeds 5% of
the original diameter. The diameter of the impeller at the shop test, together
with the final diameter of the impeller, shall be recorded on a certified shop
test curve sheet showing the operating characteristics on test and the
calculated characteristic after the diameter of the impeller has been reduced.
If it is necessary to dismantle the pump because of some other correction,
such as improvement of efficiency, NPSH, or mechanical operation, a further
performance test shall be run after corrections are made.
Following the performance test each pump and motor unit shall be run
continuously for four hours under full load conditions.
c. NPSH Test
This test is optional and is only required if specified in the requisition.
Testing by vacuum tank suppression test is preferred; however an
arrangement where the pump is installed above a suction pit in which the
level can be lowered is also acceptable. The Manufacturer shall state the
method of NPSH testing (if specified) in the proposal.
Data shall be taken at the same points as the performance test. The NPSH
test shall be subject to the approval of the Principal.
A drop in head of 3% at the first-stage shall be interpreted as an indication of
performance impairment. Where identical impellers are installed the total
head rise shall be divided by the number of stages to approximate the firststage head rise. Where a different impeller is used for the First stage, the
head rise of the first stage shall be similarly estimated from the total head rise
by proportioning the theoretical relative impeller head rises for each stage
accordingly.
d. Motor Test
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Manufacturer
Serial Number
Date of Manufacture
b. Motor
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