Page 1
TECHNICAL SPECIFICATION FOR LNG UNLOADING ARM SYSTEM
2
2009.08.10
Deleted Bunker fuel loading arm
1
2009.07.17
Revised as marked
0
2008.10.20
Issued for Construction
P0
2008.08.05
Issued for Approval
REV. NO.
DATE
DESCRIPTION
H.C. Oh JungKwan H.C. Oh JungKwan J.H. Yoon W.J. Choi / H.C. Oh JungKwan J.H. Yoon W.J. Choi / H.C. Oh JungKwan J.H. Yoon DESIGN CHECK Q.A
M.S. Kang M.S. Kang M.S. Kang APPROVED
CLIENT APPROVED
KOREA GAS CORPORATION 통영생산기지 2 단계 6 차 확장공사 TONGYOUNG LNG TERMINAL 6th EXTENSION PROJECT
TECHNICAL SPECIFICATION FOR LNG UNLOADING ARM SYSTEM
SCALE
JOB NO.
PHASE
DOCUMENT NO.
REV.
NONE
3415.OD
II
26 – M - A01 – SP - 004
2
DAEWOO ENGINEERING COMPANY KOREA GAS TECHNOLOGY CORPORATION
Page 2
CONTENTS
1.
General ............................................................................................................................................................4 1.1. 1.2. 1.3. 1.4.
2.
Scope of supply & work ...................................................................................................................................6 2.1. 2.2. 2.3. 2.4.
3.
General .............................................................................................................................................4 Definitions .........................................................................................................................................4 Language and units ..........................................................................................................................4 Design, standardization and interchangeability................................................................................5
Items to be purchased ......................................................................................................................6 Scope of supply ................................................................................................................................6 Scope of work ...................................................................................................................................8 Out of scope .....................................................................................................................................9
Project design data ........................................................................................................................................10 3.1. 3.2. 3.3. 3.4.
LNG process data...........................................................................................................................10 Site data..........................................................................................................................................10 Utility data .......................................................................................................................................12 LNG tanker data .............................................................................................................................14
4.
Applicable codes and standards ....................................................................................................................15
5.
Inspection and tests .......................................................................................................................................18 5.1. 5.2. 5.3. 5.4.
General ...........................................................................................................................................18 Shop inspection ..............................................................................................................................19 Site test...........................................................................................................................................23 Inspection and testing summary.....................................................................................................23
6.
Technical clarification & coordination meeting ...............................................................................................25
7.
Protection for shipment and handling ............................................................................................................25 7.1. 7.2.
8.
Supervision services for installation, test operation and training...................................................................27 8.1. 8.2.
9.
General ...........................................................................................................................................25 Quarantine requirements for wood packaging materials................................................................25
Supervision for installation and test operation................................................................................27 Training ...........................................................................................................................................27
Guarantee and patent infringement ...............................................................................................................27 9.1. 9.2. 9.3.
Guarantee.......................................................................................................................................27 Patent infringement ........................................................................................................................28 Guarantee item list .........................................................................................................................28
10. Spare parts and special tools.........................................................................................................................28 10.1. 10.2.
Spare parts .....................................................................................................................................28 Special tools ...................................................................................................................................29
11. Vendor data requirements..............................................................................................................................29 11.1. 11.2. 11.3. 11.4.
General ...........................................................................................................................................29 List of Vendor document and schedule ..........................................................................................30 Vendor data coordination procedure ..............................................................................................34 Mechanical data book.....................................................................................................................35
12. Technical bid requirement ..............................................................................................................................36 12.1.
Summary of technical specification ................................................................................................36
Page 3 13. Design specification .......................................................................................................................................48 13.1. 13.2. 13.3. 13.4. 13.5. 13.6. 13.7. 13.8. 13.9. 13.10. 13.11. 13.12. 13.13. 13.14. 13.15. 13.16. 13.17.
General ...........................................................................................................................................48 Design and construction .................................................................................................................48 Materials .........................................................................................................................................49 Swivel joints ....................................................................................................................................50 Quick-connect/disconnect cargo coupling (QCDC)........................................................................50 Emergency release system (ERS) .................................................................................................51 Accessories ....................................................................................................................................53 Hydraulic power system .................................................................................................................53 Operating control and emergency system......................................................................................55 General electrical, Instrumentation and control requirements........................................................57 Instrumentation and control requirements ......................................................................................57 Electrical requirements ...................................................................................................................58 Nameplates.....................................................................................................................................59 Painting...........................................................................................................................................59 Noise...............................................................................................................................................59 Material ...........................................................................................................................................60 Welding requirements.....................................................................................................................61
14. Attachments ...................................................................................................................................................62
Attachment #1. Data Sheets for Marine Loading Arms Attachment #2. P & ID and Layout Drawings Attachment #3. Related Technical Specifications Attachment #4. Purchaser’s Standard Forms
Page 4
1.
General
1.1.
General This specification, the associated data sheets and attachments outline the minimum requirements for the design, fabrication, construction, testing, inspection and supply of LNG Unloading Arm System and auxiliary equipment for Phase II - 6th Extension of TongYoung LNG Terminal. TongYoung LNG Terminal is located industrial complex 15 km from the center of TongYoung city, and in the vicinity of Pusan. The Terminal, which is under 4th, 5th & 6th Extension progress, is provided with above ground LNG storage tanks, Vaporizer, utilities and associated facilities.
1.2.
Definitions Purchaser or Owner or KOGAS
Korea Gas Corporation Head office: 215, Jeongja-Dong, Bundang-Gu, Sungnam, Kyunggi-Do, Korea (463-754) TEL : 82-31-7100-114 FAX : 82-31-7100-117/118 TongYoung office: 1179, Anjung-Ri, Kwangdo-Nyon, TongYoung-City, KyungNam, Korea (650-824) TEL : 82-55-640-6000 FAX : 82-55-640-6009
Engineer or DEC
Daewoo Engineering Company, which is the engineering company engaged by KOGAS for terminal detail engineering and supervision services. 9-3, Sunae-Dong, Bundang-Gu, Sungnam, Kyunggi-Do, Korea (463-825) TEL : 82-31-738-0481 FAX : 82-31-738-0465
1.3.
Vendor or Contractor
The person or firm of company whose tender has been accepted by Purchaser and includes the supplier’s duly appointed representatives, successors and permitted assigns.
LNG unloading system
LNG and NG arms with ancillary equipment covered in this specification.
Language and units
1.3.1
Language All documents and drawings to be submitted shall be lettered in English or Korean.
1.3.2
Units Following metric units shall be applied throughout for all documentation, drawings, operating and maintenance manuals etc and for charts and scales on instruments. Glossary
Units
Acceleration
m/s
Area
m
2
2 3
Glossary
Units 2
2 o
Heat transfer coefficient
W/(m .K), W/(m . C)
Illuminance (light)
lx (Lux) (lx = lm/m )
2
Density
kg/m
Length
mm (piping size – inch), cm, m
Electric conductance
mho
Mass
kg, t (Ton)
Electric conductivity
mho/cm
Moment, torque
N.m, kN.m
Page 5 Glossary
Units
Glossary
2
Units
Electric conductor (wire) size
mm
Electric current intensity
A (ampere)
Power
W, kW
Pressure, fluid
Pa, kPa, Mpa
Electric resistance
Ω (ohm)
Pressure, barometric
Pa, kPa
Energy, electrical
kW.h
Sound level
dB(A)
Energy, mechanical
J, kJ, MJ
Stress
N/mm , N/cm
2
2
Energy, thermal
J, kJ, MJ
Temperature
o
Flow, mass
kg/h
Thermal conductivity
W/(m.K), W/(m. C) h (hour), min (minute),
3
C (Celsius), K (Kelvin) o
Flow, volumetric
m /h
Time
Force
N, kN
Velocity
m/s
Viscosity, absolute,
cP (centipoises)
s (second), d (day) Fouling factor
2
2 o
m .K/W, m . C/W
dynamic
1.4.
Frequency
Hz
Heat capacity, specific
J/(kg.K), J/(kg. C)
Heat content or enthalpy
J/kg
o
Voltage
V (Volt)
Volume
m
3
Design, standardization and interchangeability
1.4.1
All parts of the equipment to be designed and manufactured in accordance with the latest acceptable degree of workmanship and modern engineering practice.
1.4.2
The equipment shall be designed to operate satisfactorily under all variations of load, pressure including surge pressure and temperature as may occur during normal operation and local climatic conditions.
1.4.3
The works shall be designed to facilitate inspection, cleaning, maintenance and repair. The design shall incorporate every reasonable precaution and provision for the safety of all those concerned in the operation and maintenance of the works.
1.4.4
Unless otherwise specified all parts of the equipment must be suitable in every respect for continuous operation at maximum output under the climatic and operation conditions peculiar to the erection site.
1.4.5
For the equipment, only those design and machine types that -
have been supplied for Pantograph cable type 16” or more LNG arm with the flow rate equal to or more than 5,000m3/hr, and it’s major components (defined as swivel joint, ERS, and QCDC) have been type approval tested in accordance with OCIMF and certified by third inspection agency (such as LR, DNV, SGS, ABS, TUV and BV) shall be offered. Innovations or proto type cannot be accepted. Vendor shall include all supporting evidence for above eligibility in his proposal. 1.4.6
Parts subject to wear shall be easily accessible and removable. Whenever possible adjustment shall be provided for taking up wear.
1.4.7
All equipment performing similar duties shall be of the same type and manufacture, in order to limit the stock of spare parts required and to maintain uniformity of equipment to be installed.
1.4.8
In case Bidder opposes to the Purchaser’s technical bid evaluation, Bidder may solicit perusal of its own technical bid evaluation sheet only before opening of commercial bid.
1.4.9
Owner reserves the right to ask for coordination of standardization to the extent reasonably possible and no price variation will be allowed for this procedure.
Page 6 1.4.10
Symbol and Legend Standard symbol and legend including line and equipment identification shall be applied to this project for unification in Purchaser. Unless specified in the attachment of this specification, Vendor's standard symbol and legend may be applied with the Purchaser’s approval.
2.
Scope of supply & work
2.1.
Items to be purchased The following item shall be furnished in accordance with the requirements specified in this specification and other related documents. ITEM No.
Q'TY
SERVICE
LA-103A/C
2
LNG unloading arm
LA-103B
1
LNG unloading / Vapour return arm
LA-104
1
Vapour return arm
REMARKS
All the related costs to be incurred by designing, documentation and tests & inspections at the vendor's factory shall be included in the cost of the materials. The Vendor shall include for the supply of all materials, equipment and services for the complete installation within the specified terminal points and battery limits with the exception only of those details specifically stated herein as being supplied by others. 2.2.
Scope of supply Vendor’s scope of supply shall include, but not be limited to: 1)
Two(2) sets of complete LNG unloading arms, one(1) set of complete LNG unloading / Vapour return arm, and one(1) set of complete Vapour return arm with:
Base, riser, inboard arm, outboard arm and counter weight balancing system
Electrical insulation at outboard arm end
Hydraulic operated ERS with two ball valves and one emergency release coupler
Hydraulic operated QCDC
Blind flange of QCDC coupler with safety valve and pressure gauge
Davit for handling for blind flange at outboard swivel joint
Mechanical support jack at outboard swivel joint
Mechanical locking to restrict slewing movement and movement of the inboard arm and outboard arm in stored position, manually operated from operating platform
Maintenance access and ladder
Maintenance platform for swivels
Flanged valve drain installed at shore side of ERS valve to drain outboard arm
Flanged valve drain with protector installed at bottom of outboard swivel joint to drain fluid trapped between the ship’s valve and loading arm valve
Nitrogen purging system for swivel joints with check valve
Cargo purging line from base riser to apex of inboard arm with non-return valve and shutoff valve
Page 7
Centralized greasing system with hand pump which allow grease injection on operating platform
2)
Deleted
3)
All required coupling spool pieces
4)
5)
Coupling spool flanges for LNG unloading arms and Vapour return arm (16”x20”, 4 sets)
Completed hydraulic system necessary for the operation of two (2) LNG Unloading Arms, one (1) LNG Liquid Unloading / Vapour Return Arm and one (1) Vapour Return Arm:
Power packs
Selector valve unit for each arm
Accumulators for ERS of each arm and arm maneuvering
Cylinders
All interconnecting hydraulic piping/tubing, valves, support clamps, etc
Completed electrical and control system consisting of:
Unloading arm control panel of explosion-proof type with: ▪
Arm maneuvering system
▪
Radio control receiver
▪
Microprocessor and display for PMS system
▪
Breaker for UPS power
▪
Purge control unit and filter regulator unit, if required
▪
Intrinsically safe units, if required
▪
All switches, lamps, etc
Local control station of explosion-proof type, installed near hydraulic power unit with switches
Alarm bell, alarm buzzer
Pendant control boxes with control cable (about 50m length)
Radio remote control system by joy stick (2 sets)
Position monitoring system with: ▪
Angle sensors on all arms
▪
All signals from UACP to PMS (refer to Unloading Arm Schematic Diagram and Signal list in Attachment #1.)
▪
Microprocessor and LCD VDU (min. 12”) with key pad for PMS in unloading arm control house(UACH)
All local instrumentation
All interconnecting wiring, cables and cable trays, etc. including electric power terminal boxes between Vendor furnished equipment
Interface with ESD (emergency shutdown system), DCS, MCC and LCS, etc
Minimum requirements for interface are listed in Unloading Arm Signal in section 17 of Attachment #1 6)
Completed access/support structure including all ladders, platforms, etc
7)
One (1) set of nitrogen regulator unit for swivels purge with sight flow indicator at each outlet, pressure indicator at inlet/outlet
Page 8 8)
Nitrogen purge system pipe work completed with all necessary valves and fittings
9)
Two (2) sets of spotting centreline indicator (stainless steel)
10)
One (1) set of dummy manifold flange skid, cradle type with swing casters
11)
All supports and foundation bolting, shims and accessories necessary for the setting, adjustment and anchorage of the equipment supplied
12)
Initial fill of hydraulic oil for hydraulic system, and any special fluid required for flushing the hydraulic system during commissioning
13)
All internal piping required for lubrication, drain, vent and sealing
14)
Vent and drain valves as required
15)
A completed set of all special tools jigs and lifting devices etc. necessary for the site assembly, installation, normal maintenance and repair of the equipment in vendor supply
16)
Spare parts for installation and commissioning
17)
All documents required by this specifications
18)
All necessary components, accessories and appurtenances, as normally provided, whether mentioned in this specification or not
19)
Nameplates
20)
Aircraft warning device of explosion-proof type, if the top of arm is over 60m from M.S.L.
21)
Earth lugs
The Vendor shall provide all the materials needed for site assembly and installation of the arms and their ancillaries (foundation bolts, gaskets, hydraulic pipes, hoses, couplings, electrical interconnecting cables, etc.) according to the layout of the loading platform. Any special tool or equipment needed for assembly and normal maintenance shall also be provided by the Vendor. All components within the LNG unloading arm system shall be completely assembled at Vendor’s shop. Base risers and foundation bolts shall be delivered prior to arm package delivery upon Purchaser’s request. 2.3.
Scope of work 1)
Guaranteed allowable forces and moments on the nozzles which are connected by Purchaser’s piping
2)
Information for foundation design including static & dynamic loading data with various direction
3)
KOSHA (Korean Occupational Safety & Health Agency), KTL (Korea Testing Laboratory) or KGS (Korea Gas Safety Corporation) certificates for explosion proof type electric equipment and instruments (See Section 5.1.6.)
4)
Documents and certificates of pressure vessels and/or high pressure equipment for KGS certificates (See Section 5.1.7)
5)
KGS certificates for safety valve, ball and globe valves for LNG, NG, N2 and fuel gas system (See Section 5.1.8.)
6)
Painting up to finish coating at shop
7)
Coordination meeting
8)
Supervision for installation, commissioning and performance test
9)
Training for Purchaser’s trainees
10)
Packing for export
11)
Inspection and test required by this specification
12)
Performance guarantee
Page 9 13) 2.4.
Performance test at site (Vendor witness)
Out of scope 1)
Detailed design and supply of all materials for site foundations
2)
All construction personnel and plant required for the complete erection of the units.
3)
Plant lighting and earthing
4)
Electrical power supply including Uninterrupted Power Supply (UPS) and wiring to vendor supplied terminal boxes
5)
Nitrogen supplies for Arm Purging
6)
Pipe work and piping up to Arm risers and from drain connections. The latter are to be located local to grade
7)
Unloading arm control house (UACH)
8)
Foundation and civil work
9)
Instrumentation outside battery limit
10)
All external power and control wiring
11)
Motor starter
12)
ESD and DCS
13)
Field installation
14)
Insulation work & material (But insulation support/clips on equipment shall be Vendor’s scope.)
15)
Spare parts for 2 years operation (But, the recommended spare parts list with itemized price shall be submitted for Purchaser’s review.)
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3.
Project design data
3.1.
LNG process data
3.1.1
LNG Component Nitrogen Methane Ethane Propane i-Butane n-Butane i-Pentane n-Pentane
Molecular weight GHV kJ/Nm3* SG Liquid Latent heat kJ/kg
Case 1 Lean 0.00 96.74 1.89 0.68 0.34 0.34 0.01 0.00 100.00
Composition Mol % Case 2 Case 3 Rich Max N2 0.00 1.0 85.12 94.33 8.63 1.97 4.14 2.50 1.10 0.10 0.90 0.10 0.10 0.00 0.01 0.00 100.00 100.00
Case 4 Typical 0.04 89.26 8.64 1.44 0.27 0.35 0.00 0.00 100.00
16.791 41,370 0.434 524.1
19.320 46,734 0.478 526.7
17.924 43,749 0.455 528.8
17.189 41,760 0.448
*Nm3 measured at 1 Atm, 0 °C. 3.2.
Site data
3.2.1
Plot plan MSL (In-chon mean sea level) Sea water intake & B-C tank area LNG tank (#1~#5, #13) area, process area & utility area LNG tank (#6~#12, #17) LNG tank (#14, #15, #16) area & Future space Unloading Arms area
3.2.2
: : : : : :
EL. +0.0 m EL. +4.0 m EL. +5.0 m EL. +9.0 m EL. +9.0 m EL. +6.227 m (DL.+7.5)
General site data 1. 2. 3. 4.
Aircraft warning requirement Air corrosiveness Vibration transmittal precautions Noise precautions
: : : :
5. 6.
Water pollution precautions Tidal data
: :
On structures over 60 m and LNG storage tanks Yes Corrosive coastal sea water environment Yes Earthquake zone in accordance with NFPA 59A and see 8, Earthquake data Yes 85dB(A) max at 1m from equipment except compressor shelter & decompression station 125-135 dB(A) max for relief valves 45 dB(A) max at terminal battery limit 80 dB(A) max for control valves Yes HHW : EL. +0.939 m MSL : EL. +0.0 m LLW : EL. -1.273 m
Page 11
Current
7. 8.
9.
Maximum spring Maximum neap Minimum spring Minimum neap H1/3 = 1.7m T1/3 = 4.88 sec
Max. wave height : Return Period 50 years General earthquake data : a. Operational basis earthquake (OBE) parameters Peak ground acceleration = 0.1 g Peak ground velocity = Refer to UBC 1997 Peak ground displacement = Refer to UBC 1997 b. Safe shutdown earthquake (SSE) parameters Peak ground acceleration = 0.2 g Peak ground velocity = Refer to UBC 1997 Peak ground displacement = Refer to UBC 1997 c. For equipment items that are designed for SSE, allowable stresses are to be determined in accordance with NFPA-59A, 4-1.3.5 as permitted by UBC 1997, sections 1634.1.2 alternative 2, or 1643.4, where I =1.0 for all items. Equipment earthquake data : Item
Facilities
Mechanical
3.2.3
: 19.4 cm/sec : 4.98 cm/sec : ~ 0.0 cm/sec : ~ 0.0 cm/sec
Design Seismic
Unloading arm
Remark
S.S.E 0.2g
Wind and barometer Prevailing direction by height Prevailing velocity (mean) Design velocity Average monthly wind velocity
: : : :
Month
1
2
3
4
5
Wind Vel.
2.6
2.7
2.8
2.9
2.4
Barometric pressure
:
Maximum rate of change of barometric pressure
:
ENE 2.5 m/sec 40 m/sec @ 10m elevation [m/s] 6
7
8
9
10
11
12
2.2
2.7
2.5
2.1
2.0
2.4
2.4
104.03 kPa.a (maximum) 102.48 kPa.a (average) 97.01 kPa.a (minimum) 0.49 kPa/h (Rise) 0.44 kPa/h (Fall)
Page 12 3.2.4
Air temperatures Maximum summer Minimum winter Winter design Mean annual Average monthly temperatures
: : : : :
Month
1
2
3
4
5
Temperature
2.5
3.7
7.9
13.0
17.2
Black body temperature Minimum air relative humidity Maximum air relative humidity Mean air relative humidity Design relative humidity for cold service 3.2.5
6
7
8
9
10
11
12
20.6
24.2
25.7
22.0
17.0
11.5
5.3
: : : : :
65 °C 6.0 % 100 % 68.5 % 82 %
:
Precipitation shall be calculated for a 1 in 50 year return period as:
Precipitation Design rainfall
I 50
755 t 1.81
mm / hr
Design snow loading Paved area runoff Unpaved area runoff 3.3.
36.9 °C -11.6 °C -11.6 °C 14.2 °C °C
Where t= period in minutes : : :
300 kg/m2 100% 10%
Utility data
3.3.1
Electric power utilisation Motors a) above 149.2 kW b) 0.56 kW to 149.2 kW c) below 0.56 kW for process critical service, including lube oil pumps d) below 0.56 kW for non-process service Heaters a) above 7 kW b) above 3.1 kW to 7 kW c) 3 kW and below d) space heaters for panels e) space heaters for 6.6 kV motors f) space heaters for LV motors (if necessary) g) trace heating Instrumentation and communications a) Instrumentation – critical b) Instrumentation – non-critical c) Communications Notes: -
6.6 kV 440 V 440 V
3 ph 3 ph 3 ph
60 Hz 60 Hz 60 Hz
220 V
1 ph
60 Hz
440 V 440 V 220 V 220 V 220 V 220 V 220 V
3 ph ph-ph 1 ph 1 ph 1 ph 1 ph 3 ph
60 Hz 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz
115 V 220 V 115 V
UPS
1 ph 60 Hz 1 ph 60 Hz 1 ph 60 Hz
UPS
Voltage variation ± 10% Frequency variation ± 5% Where equipment requires voltages not listed above the equipment supplier shall provide the appropriate transformers, rectifiers etc.
Page 13 3.3.2
Low pressure fuel gas Pressure, nor. / design Temperature Composition and heating value Component
Case 1 Lean 0.00 96.74 1.89 0.68 0.34 0.34 0.01 0.00 100.00
Nitrogen Methane Ethane Propane i-Butane n-Butane i-Pentane n-Pentane Total
Molecular Weight 16.791 GHV kJ/Nm3* 41,346 SG Liquid 0.434 *Nm3 measured at 1 Atm, 0 °C. 3.3.3
17.189 41,735 0.448
17.924 43,723 0.455
Min. GHV 22.0 78.0 0.0 0.0 0.0 0.0 0.0 0.0 100.0
Max. GHV 0.0 100.0 0.0 0.0 0.0 0.0 0.0 0.0 100.0
18.64 31,413 NA
16.0 39,698 NA
: : : : :
min / nor / max. 0.39 / 0.64 / 0.78 MPa.g Ambient (max 50°C) 0.98 MPa.g 65°C Dew point –40 °C, oil free
: : : : :
0.69 MPa.g Ambient (max 50 °C) 0.98 MPa.g 65°C Oil free, not dried
Plant air Operating pressure Operating temperature Design pressure Temperature Quality
3.3.5
19.320 46,706 0.478
Boil off Gas
Instrument air Operating pressure Operating temperature Design pressure Design temperature Quality
3.3.4
: 0.69 / 0.98 MPa.g : Ambient, Max. 54 oC : HP Fuel Gas Letdown Composition Mol % Case 2 Case 3 Case 4 Rich Max N2 Typical 0.00 1.0 0.04 85.12 94.33 89.26 8.63 1.97 8.64 4.14 2.50 1.44 1.10 0.10 0.27 0.90 0.10 0.35 0.10 0.00 0.00 0.01 0.00 0.00 100.00 100.00 100.00
Nitrogen Liquid nitrogen will be imported by road tankers, and will be supplied through storage tank and vaporizers. Operating pressure : Low pressure N2 : normal 0.784 MPa.g : design 9.8 MPa.g High pressure N2 : normal 19.61 MPa.g : design 21.55 MPa.g Oxygen content : Less than 80ppm Water content : Dry Misc. Impurities : CO2 and oil free
3.3.6
Waste disposal Oily water Oily water discharge limits
: :
To sea via treatment
n-Hexane (mg/l)
Suspended Solids (mg/l)
COD (mg/l)
BOD (mg/l)
pH
<5
< 120
< 130
< 120
5.8 ~ 8.6
Page 14 3.3.7
Notes for utility supply In case lower pressure is required for Purchaser’s utility supply, Vendor shall provide regulator(s) to adjust the pressure as required, unless specifically exempted in this specification.
3.4.
LNG tanker data Ship type Max ship capacity
: :
Max unloading rate Ship BOG rate
: :
Ship pressure Ship LNG pumps
: :
Min. available head at ship manifold
:
Membrane or Moss Rosenberg 138,000 m3 Moss Rosenberg type 270,000 m3 Membrane 15,000 m3/h max 0.25 wt% per day of full ship content min. 0.1 wt% per day of full ship content 175 mbarg (max. saturation) 1,500 m3/h x 150m head x 10 sets or 1,400 m3/h x 165m head x 10 sets 94 m LNG
For detail tanker data, see Section 15 in data sheet, Attachment #1.
Page 15
4.
Applicable codes and standards Reference to standards and codes in this specification and the data sheets shall mean the latest edition thereof plus all amendments ruling at the time of tendering, unless otherwise specified. Vendor shall be ultimately responsible for all aspects of the equipment supplied regardless of source and shall be responsible for ensuring compliance with all applicable regulations, code and standards including followings:
Marine Loading Arms OCIMF, 3rd edition SIGTTO ICS/OCIMF/SIGTTO ICS/OCIMF/SIGTTO ICS/OCIMF/SIGTTO OCIMF SIGTTO SIGTTO OCIMF/SIGTTO SIGTTO OCIMF 11 OCIMF OCIMF BS EN 1474
Design and Construction Specification for Marine Loading Arms Guide to Contingency Planning for the Gas Carrier Alongside and Within Port Limits Guide to Contingency Planning for Marine Terminals Handling Liquefied Gases in Bulk Guide on Marine Terminal Fire Protection and Emergency Evacuation Guidelines and Recommendations for the Safe Mooring of Large Ships at Piers and Sea Islands Guidelines for the Alleviation of Excessive Surge Pressures on ESD Liquefied Gas Handling Principles on Ships and in Terminals Prediction of Wind Loads on Large Liquefied Gas Carriers Recommendations and Guidelines for Linked Ship/Shore Emergency Shut-down of Liquefied Gas Cargo Transfer Safety Guide for Terminals Handling Ships Carrying Liquefied Gases in Bulk Recommendations for Manifolds for Refrigerated Liquefied Natural Gas Carriers (LNG) Effective Mooring Installation and equipment for liquefied natural gas – Design and testing of loading/unloading arms
Unfired pressure vessels and welding ASME Sec. II Material Specification, Part C – Welding Rods, Electrodes and Filler Metals ASME Sec. II Material Specification, Part D – Properties ASME Sec. V Nondestructive Examination ASME Sec. VIII Pressure Vessels’ Division 1 ASME Sec. IX Welding and Brazing Qualification AWS standards Tubular heat exchangers TEMA Piping (cryogenic and non-cryogenic) ANSI B1.20.1 Pipe Threads ANSI B16.5 Pipe Flanges and Flanged Fittings ANSI B16.9 Factory Made Wrought Steel Butt-weld Fittings ANSI B16.10 Dimensions of Ferrous Valves ANSI B16.11 Forged Steel Fittings ANSI B16.28 Wrought Steel Butt-welded, Short Radius Elbows and Returns ANSI B31.3 Chemical Plant & Petroleum Refinery Piping ANSI B36.10 Welded & Seamless Wrought Steel Pipe BS 5351 Ball Valves BS 1873 Globe Valves (1/2” ~ 6") BS 6755 Testing of Valves API 6FA Fire Test for Valves
Page 16 API 606 API 607 ISO 10497
Extended Body Gate Valves (1/2” ~ 2") Fire Test for Soft-seated Quarter-turn Valves Testing of Valves – Fire Type Testing Requirements
Electrical IEC-60034 Rotating Electrical Machines IEC-60079 Electrical Apparatus for Explosive Gas Atmospheres CENELEC NEC NEMA MG-1 Motor and Generators ANSI NFPA Korean Industrial Standard (KS) JIS API IEEE NACE KOSHA, KTL or KGS (for enclosure of hazardous service) Hazardous area Korean regulation, ACT 1993-19, Ministry of Labor, May, 1993 NFPA 59A Standard for Production, Storage and Handling of Liquefied Natural Gas NFPA 497A Classification of Class I Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas IEC 60079-10 Electrical apparatus for Explosive Gas Atmospheres - Classification of Hazardous Areas IP (Institute of Petroleum) Model Code of Safe Practice, Part 15 For Zone 1: IEC 60079-1 or EN 50018 for Flameproof (Ex d) IEC 60079-11 or EN 50020 for Intrinsically Safe (Ex i) IEC 60079-2 or EN 50016 for Pressurized (Ex p) For Zone 2: All above same (The EN designation refers to CENELEC/ Euronorm manufacturing standards.) API RP500 Recommended Practice for Classification of Locations for Electrical Installations Instruments ANSI B1.20.1 ANSI B16.5 API 550 ISA S5.1 ISA S5.2 IEC 60073
Pipe threads Pipe Flanges and Flanged Fittings Manual on Installation of Refinery Instruments and Control Systems Instrumentation in Symbols and Identification Primary Logic Diagrams for Process Operation Colour of Indicator Lights, Push Buttons, Annunciators and Digital Readouts IEC 60079 Electrical Apparatus for Explosive Gas Atmosphere IEC 60529 Classification of Degrees of Protection Provided by Enclosures IEC 60584 Thermocouples for Temperature measurement IEC 60654 Operating Conditions for Industrial Process Measurement & Control Equipment IEC 60751 Industrial Platinum Resistance Thermometer Sensors IEC 60801 Electromagnetic Compatibility for Process Measurement and Control Equipment ISO 8310 Refrigerated Light Hydrocarbon Fluids KGS (for safety valves, ball & globe valve for LNG, NG, N2 & fuel gas system) KOSHA, KTL or KGS (for enclosure of hazardous service) JIS
Page 17 Steel structures AISC UBC Korean Codes and Standards Safety NFPA 59A Relieving systems API RP 520 Part 1 & 2 API RP 521
Standard for Production, Storage and Handling of Liquefied Natural Gas
Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries Guide for Pressure - Relieving and Depressuring Systems
Positive displacement pump API 674 2nd Positive Displacement Pumps - Reciprocating API 675 2nd Positive Displacement Pumps - Controlled Volume Environmental Regulations Korean regulations Earthquake Design UBC ANSI A58.1 NFPA-59A Noise IEC 61260 IEC 60651 ISO 1680 ISO 1996 ISO 3744
ISO 3746 RP 521
Standard for Production, Storage and Handling of Liquefied Natural Gas
Octave-band and fractional-octave-band filters Sound level Meters Test code for the measurement of airborne noise emitted by rotating electrical machinery Description and Measurement of Environmental Noise Acoustics -- Determination of sound power levels of noise sources using sound pressure -- Engineering method in an essentially free field over a reflecting plane Determination of sound power levels of noise sources using sound pressure – Survey Method Guide for Pressure - Relieving and Depressuring Systems
Material ASTM/ASME, KS, JIS Painting & Insulation Purchaser’s specification Note: Korean local regulation shall be applied for all equipment, if applicable. Vendor shall be responsible for determining and complying with the requirements of all applicable local regulations (laws, acts, regulations, etc.) current at the time of proposal.
Page 18
5.
Inspection and tests
5.1.
General
5.1.1
All inspection and tests shall be performed in accordance with this specification, Final documents approved by Purchaser, the applicable codes and standards.
5.1.2
Purchaser or its representatives reserve the right to access freely to all parts of the shop where fabrication is in progress, and to witness and inspect the shop tests and inspections at any time and place including sub-Vendor's works.
5.1.3
The manufacturer shall provide the inspectors with all the means necessary to verify the equipment is being properly executed in accordance with the terms of the order.
5.1.4
Vendor shall conduct, at its own expense and responsibility, the tests and inspections required under contract documents. In the event Purchaser’s or its representative's witnessed inspection is required, the costs, fees and expenses arising therefrom shall be borne by Vendor, with the exception of Purchaser's cost and expenses for dispatching of inspectors.
5.1.5
All inspection and tests required by this specification shall be done by 3rd party inspector(s) for the products or major sub-assemblies irrespective of place/country of manufacture/assembly. The 3rd party inspector(s) shall be one of Lloyd’s Register Verification, TÜV Rheinland Group, DNV, ABSG Consulting INC, BV, HSB and KR (Korean Register of Shipping), subject to approval of Purchaser’s QA/QC department. All cost, fees and expenses for the 3rd party inspector shall be borne by Vendor. The Vendor shall submit the certificate and report of inspection signed by the 3rd party inspector(s) before shipment for Purchaser’s review. Purchaser has the option to replace the 3rd party inspection by Purchaser’s inspection after award. In this case, the price for 3rd party inspection shall be deducted from the contract price. If the inspection and test shall be witnessed by Purchaser, Vendor shall notify Purchaser’s QA/QC team two (2) weeks for the products manufactured in foreign country, and one (1) week for the products manufactured in domestic prior to the actual date of inspection and test.
5.1.6
The below table is shown the typical inspection and test plan by 3rd party inspection agency, and Vendor shall prepare detail inspection and test plan with each item marked with type of activity (“Review”, “Witness” or “Hold”, etc.) and inspection party (Manufacturer, Vendor, Purchaser, 3rd party agency, etc) for Purchaser’s approval. No.
Inspection and Test Item
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Welding check Material inspection Non-destructive examination Visual and dimensional check Hydrostatic test Pneumatic leak test Shop assembly and operational test Hydraulic system Swivel joint test QCDC test ERC test Painting inspection Packing and marking inspection Electric equipment & instrument
Vendor
Activity 3rd Party
KOGAS
V V V V V V V V V V V V V V
R R R SW W W W W W W W W W R (or SW)
R R R R R R W W W W W R R R
Remarks
Page 19 No.
Inspection and Test Item
LEGEND V Vendor to provide R Review of documentation and/or Certificates
5.1.7
Vendor
Activity 3rd Party
H W or SW
KOGAS
Remarks
Hold point Witness or Spot Witness
The facilities are subject to inspection and tests by KGS in accordance with local regulations (High Pressure Gas Control law, instructions by KGS and other ruling regulations). Whole or part of the inspections required by the regulation may be exempted in case the equipment is inspected by authorized foreign inspection agencies admitted by KGS (Korea Gas Safety Corporation), at the discretion of KGS. The inspection and tests shall include visual inspection, material inspection, strength calculation review, radiographic inspection, hydrostatic pressure test, and pneumatic leak test, depending on local regulation. In addition, foreign manufacturer that manufacture high pressure equipment to be imported into Korea shall get manufacturer approval from Korean Authority. For the details, refer to http://www.kgs.or.kr/english/service/service1.asp “Manufactural Approval System”. Application and acceptance by KGS is within the sole responsibility of Vendor, and all cost, fees and expenses for those inspection and tests shall be borne by Vendor.
5.1.8
For instruments and electric equipment located in hazardous area, Vendor shall get KOSHA (Korean Occupational Safety & Health Agency), KTL (Korea Testing Laboratory) or KGS (Korean Gas Safety Corporation) certificates and submit them to Purchaser before site commissioning and performance test. In case the explosion proof type instruments and electric equipment are manufactured in foreign country and not approved by KOSHA, KTL or KGS, Vendor must submit the certificate and test reports by IEC Ex Certification Bodies (Refer to http://www.iecex.com/bodies.htm) to KOSHA, KTL or KGS for approval.
5.1.9
For the safety valves, shut-off (on-off) globe and ball valves of LNG, NG, N2 and fuel gas system, Vendor shall obtain KGS certificates, and those valves shall be stamped on the body by KGS.
5.2.
Shop inspection
5.2.1
Welding check The edge preparation, welding materials, preheat and interpass temperature (if applied) shall be checked during welding in accordance with applicable welding procedure specification and fabrication drawings. Visual inspection of weldments for pressure containing parts shall be made in accordance with ASME Sec. VIII Div.1. Test pieces (per welding process) for pressure containing LNG, NG, N2 or fuel gas system only shall be sampled from production in order to carry out the following tests: Tensile test Guide bend test Impact test (at -196°C)
5.2.2
Material inspection All materials for pressure retaining and structural parts shall be identified. The material applied shall be checked for conformity with the requirements of this specification and applied code and standards. Material of major parts subject to pressure, cyclic loading, power transmission, and parts containing flammables shall be tested for mechanical property and the Vendor shall submit
Page 20 chemical composition and certificate for Purchaser’s review. Pressure casting repairs shall be carried out in accordance with ASTM specification for similar material. All repairs shall be subject to inspector’s approval. 5.2.3
Non-destructive examination The following non-destructive examination shall be performed in accordance with applicable code and standards. Magnetic particle examination Liquid penetrant examination Ultrasonic examination Radiographic examination All butt weld pressure parts of LNG, NG, N2 or fuel gas system shall be subject to 100% radiographic examination. The film shall be submitted for Purchaser’s review. Interpretation and acceptability of welds shall be made as per ASME Sec. VIII, Div. 1, paragraph UW-51. Where radiographic examination is not applicable, all welds shall be subject to dye penetrant or magnetic particle NDT examinations. Acceptance criteria shall be per ASME Sec. VIII, Div. 1, Appendix 8.
5.2.4
Visual and dimensional check Every part shall be inspected and it shall be confirmed that there are no harmful blowholes, dusts, cracks, and cavities. All major dimensions of the loading arms shall be checked, against the fabrication drawings.
5.2.5
Hydrostatic test All pressure containing parts shall be hydrostatic tested at 1.5 times the design pressure for at least 30 minutes at the shop in accordance with applicable code and standards. The hydrostatic test shall be performed in order to confirm that there is no deformation, damage or leakage from welded area, swivel and flange connections. The test shall be carried out in Vendor’s work prior to painting. Following the hydrostatic testing, all subassemblies shall be thoroughly dried, and the swivels shall be disassembled and checked for water penetration between primary and secondary seals. In case of test using water, only clean fresh water of pH value between 6 and 8 shall be used for hydrostatic testing. Chloride content to be less than or equal to 200 ppm for carbon steel, below 10 ppm for austenitic stainless steel (as applicable). Taking into account the design of arms and their operating temperature, the impossibility of perfect drying after testing and the difficulty of freely replacing the water by a more volatile liquid, the pneumatic pressure test may substitute the hydrostatic test.
5.2.6
Pneumatic leak test All pressure containing parts subject to gas pressure shall be pneumatic leak tested at 0.7 MPa.g pressure for a minimum of 30 minutes at the Vendor’s works.
5.2.7
Shop assembly and operational test All parts shall be assembled in the shop to confirm their proper fit with in the limits prescribed in working drawings. Specified number of loading arms (See section 5.4) shall be shop erected using related selector valve units, hydraulic system and instruments. The following tests shall be carried out and recorded on video CDs: Balance Arm envelope and alarm settings QCDC function for each size of adapters and full range of flange sizes
Page 21 -
ERS function test with the arm both empty and full, or simulated full, by moving the dummy manifold through the alarm stages in the envelope for surge and sway Arm manoeuvring back to stored position after ERS release Reconnection of empty arm after ERS release Accumulator test for ERS operation and arm retraction to stowed position after ERS release ERS activation by pushbutton on control panel Swivel N2 purge system The shop test shall demonstrate: Complete hydraulic power system Control and alarm system Operating time of the ERS valves and ERC Operating time of QCDC Safe operation of the arm and the ERS Operation of various interlocks ESD function test (manual pushbutton, automatic action from cause, external signal from temporary for Terminal ESD, Ship ESD) Operation of control panel and pendants Operating envelope at jetty level Automatic pump start-up, for falling accumulator pressure and initiated by the range alarm 5.2.8
Hydraulic system test The main components of the hydraulic system such as cylinders, pressure instruments, accumulators, valves and tubing and hoses shall be flushed and leak tested in the Vendor’s works. Vendor shall propose the extent of hydraulic, leakage and performance testing for the hydraulically powered Equipment and Systems for Purchaser’s approval.
5.2.9
5.2.10
Swivel joint test 1)
All swivel joints shall be subject to hydrostatic pressure test prior to painting to 1.5 times design pressure for not less than 30 minutes.
2)
Swivel joints shall be proof tested at Vendor’s shop as per OCIMF specification section 12.5. See section 5.4 for detail of proof test. In case proof test certificate of authorized third party inspector is available for the identical swivel, same test and same loading, those proof tests may be exempted.
QCDC test 1)
QCDC components, sub-assemblies and assemblies shall be pressure tested prior to painting as follows. No leakage or deformation shall be allowed during the test. ▪
2)
QCDC body, prior to assembly, shall be subject to a hydrostatic pressure test to 1.5 times design pressure for not less than 30 minutes. ▪ Hydraulic components, on completion of assembly, shall be subject to a pressure test of 1.5 times design pressure for not less than 5 minutes. On completion of painting and assembly of the QCDC, it shall be functionally tested by connecting and disconnecting from ANSI B16.5 class 150lb flange. When connected to the flange, the QCDC shall be pressure tested to 1.5 times design pressure for not less than 5 minutes. The QCDC shall engage and disengage from the flange correctly.
3)
QCDC shall be proof tested as follows: ▪ Strength test shall be performed as per OCIMF, section 12.7.2 ~ 12.7.5. ▪ Release performance test shall be performed as per OCIMF, section 12.7.6. See section 5.4 for test details. Hydraulic power pack shall be set at minimum operating pressure during the test. In case test certificate of authorized third party inspector is available for the identical QCDC, same loading and identical test, those strength tests may be exempted.
Page 22 5.2.11
ERC test 1)
ERS components, sub-assemblies and assemblies shall be pressure tested prior to painting as follows: ▪
2)
3)
Ball valve bodies shall be hydrostatic pressure tested at 1.5 times design pressure for 30 minutes. No leakage or deformation is allowed over the duration of the test. ▪ Each ERS ball valve shall be subject to a hydrostatic pressure test of the seat and gland seal to 1.1 times design pressure for not less than 30 minutes. There shall be no leakage over the duration of the test. ▪ Complete ERS assembly including double ball valves shall be subject to pneumatic body pressure test to 0.7MPa.g with nitrogen gas at ambient temperature for not less than 5 minutes. ▪ Hydraulic components, on completion of assembly, shall be subject to a pressure test at 1.5 times design pressure for not less than 5 minutes. There shall be no leakage over the duration of the test. On completion of fabrication, painting and assembly of the ERS including double ball valves, it shall be functionally tested by closing the ball valves and disconnecting the emergency release coupler. It shall be demonstrated that: Ball valves closure time stated in this specification The emergency release coupler cannot be disconnected prior to closure of ball valves. The ball valve cannot be re-opened prior to re-assembly of emergency release coupler. The hydraulic pressure to operate the equipment is within the stated limits. The ERS shall be proof tested as follows: ▪ Strength tested per OCIMF, section 12.6.2 ~ 12.6.4 ▪ Release performance test per OCIMF, section 12.6.5 ▪ ERS valve torque and leakage rate test per OCIMF, section 12.6.6 See section 5.4 for details of the tests. Hydraulic power pack shall be set to minimum operating pressure during the tests. In case test certificate of authorized third party inspector is available for the identical ERS, same loading and identical test, those proof tests may be exempted.
4)
One of the upper ball valve of ERS shall be subject to the additional low temperature test: Seat tightness test Tightness test of the stem seal These tests shall be performed under the following conditions: Center line of valve stem horizontal At minimum cargo temperature (-162 oC) At a pressure of 0.2 MPa.g Holding time shall be 10 minutes. During these test the valve shall be kept closed and no rotation/realigning of the ball or disturbance of the test shall be permitted. In case test certificate of authorized third party inspector is available for the identical ERS and identical test, those ERS ball valve seat/seal tests may be exempted.
5.2.12
Painting Inspection Surface preparation shall be inspected prior to painting. Inspection items such as surface preparation, first and final coat thickness, coating integrity and their allowable limits shall be specified in the procedure. Surface preparation and colour of the coat shall be checked and coat thickness and integrity of the coat shall be examined by suitable gauge. Galvanized parts shall be subject to visual inspection.
Page 23 5.2.13
Packing and Marking Inspection Packing and marking shall be checked with conformity with related specification.
5.2.14
Electric equipment and instrumentation test Vendor shall provide test plan/procedure for electric equipment and instrumentation in accordance with relevant code, attached electric & instrumentation specification and manufacturer’s standard for Purchaser’s approval.
5.3.
Site test Vendor shall prepare site test procedure for Purchaser’s approval prior to execution. Site tests shall be performed by Purchaser under the supervision of Vendor’s supervisor.
5.3.1
Pre-check Pre-check and test operation shall be carried out for all system including piping, instrument, system function, etc. Line flushing, dry-out, purge, cool-down, etc. shall be performed during pre-check stage as required.
5.3.2
Pressure Test Prior to initial operation, the fully assembled arms shall be hydrostatically pressure tested at test pressure or pneumatically leak tested at 0.7 MPa.g for 30 minutes to prove tightness of bolted connections, gaskets and couplings. Either nitrogen or dry air shall be used.
5.3.3
Operational test After installation at site, Vendor shall repeat the shop operational test specified in Section 5.2.7 for specified arm combinations, checking arm envelope, clearance and balance. Vendor shall adjust balance if necessary.
5.3.4
Performance Test Performance test for LNG arms shall be conducted after the completion of commissioning to verify the units meet the performance requirements as defined in Section 9.3.
5.4.
Inspection and testing summary ARM DESIGNATION
1
2
Shop test for arm Pneumatic test Hydrostatic test Leak test for hydraulic system Shop assembly and operational test (See Section 5.2.7) - Hydraulics included - Operating / control / alarm instruments included Site test Test operation Performance test - Pneumatic test @AT - Operational test - ERS shut-down time
LA-103A
LA-103B
LA-103C
LA-104
yes yes yes yes
yes yes yes
yes yes yes
yes yes yes
yes
yes
yes
yes
yes yes yes
yes
yes
yes yes
yes yes
Page 24 ARM DESIGNATION 3
4
5
Swivel test Hydrostatic pressure test - test pressure Proof test per OCIMF, section 12.5 - Hydrostatic test & partial vacuum test per OCIMF, section 12.5.2 @AT - Leakage test per OCIMF section 12.5.3 @AT - Leakage test per OCIMF section 12.5.3 @LT - Load capacity test per OCIMF, section 12.5.4~12.5.6 @AT - Load capacity test per OCIMF, section 12.5.4~12.5.7 @LT - N2 purge test per OCIMF, section 12.5.8 @LT QCDC test required Pressure test - Body hydrostatic test @AT - Hydraulic system pressure test @AT Function test @AT Proof test - Strength test per OCIMF, section 12.7.2 ~ 12.7.4 @AT - Strength test per OCIMF, section 12.7.2 ~ 12.7.5 @LT - Release performance test per OCIMF, section 12.7.6 @ LT Emergency release coupling test required Pressure test - Valve body hydrostatic test @AT - Valve hydrostatic test @AT - Complete ERS assembly pneumatic test @AT - Hydraulic system pressure test @AT Function test @AT Proof test - Strength test per OCIMF, section 12.6.2 ~ 12.6.3 @AT - Strength test per OCIMF, section 12.6.2 ~ 12.6.4 @LT - Release performance test per OCIMF, section 12.6.5 @LT - Valve torque and leakage rate test per OCIMF, section 12.6.6 @LT - Seat/seal test of upper ball valve @LT
Note:
*1)
LA-103A
LA-103B
LA-103C
LA-104
yes 1.5xDP
yes 1.5xDP
yes 1.5xDP
yes 1.5xDP
one unit of each size *1) one unit of each size *1) one unit of each size *1) one unit of each size *1) one unit of each size *1) one unit of each size *1)
yes yes yes
yes yes yes
yes yes yes
yes yes yes
one QCDC *1) one QCDC *1) one QCDC *1)
yes yes yes
yes yes yes
yes yes yes
yes yes yes
yes yes
yes yes
yes yes
yes yes
one ERS *1) one ERS *1) one ERS *1) one ERS *1) one ERS *1)
Test may be exempted if test certificate is available for identical model equipment, same loading and identical test. Abbreviation: AT – ambient temperature LT – low temperature (-162 oC)
Page 25
6.
Technical clarification & coordination meeting The clarification and coordination meetings shall be held upon Purchaser’s request to facilitate communication on technical matters and to check the design and manufacturing process. The meeting shall be held at least three (3) times free of charge to the Purchaser under the spirit of mutual cooperation and for closer future relationship as below. - One (1) time for clarification meeting during technical bid evaluation - Two (2) times for coordination meeting after award. Vendor shall dispatch a sufficient number of qualified personnel to attend the coordination meetings at Purchaser’s office.
7.
Protection for shipment and handling
7.1.
General All gasket surfaces, flange faces and machined or ground metal surfaces shall be thoroughly cleaned, greased & protected with suitable wood, metal, or other substantial-type covering to insure their full protection. All exposed threaded parts shall be greased and protected with metallic or other substantial type protectors. All female threaded connection shall be closed with forged steel pipe plugs or snap-in protection plugs. Cast-iron pipe plugs will not be acceptable. Suitable weather protection, blocking straps and skids shall be provided to protect the equipment from damage in transit and during storage. All loose piping shall be properly protected by an appropriate corrosion inhibiting material and all ends openings shall be closed securely with substantial closures to prevent damage and entry of foreign material. Small loose parts shall be protectively wrapped and packaged cartons and crates and tagged or marked with permanent identification.
7.2.
Quarantine requirements for wood packaging materials All wood packaging materials for all imported consignments shall be subject to quarantine requirements of National Plant Quarantine Service, under the sole responsibility of Vendor. 7.2.1
Regulated articles All non-manufactured wood packaging materials such as pallets, crating, dunnage, packing block, etc
7.2.2
Exempted articles Manufactured wood, packaging materials such as plywood, particle board, oriented strand board, veneer panel, wafer board, fiber board, densified wood, glued laminated wood, agglomerated cork, pulp, wood wool, wood flour, ground cork, etc
7.2.3
Regulated areas All countries
7.2.4
Requirements 1)
All imported wood packaging materials should be treated by one of the following methods, and present the mark, which certifies the approved treatment on two opposite sides of the wood packaging material.
Page 26 2)
Treatment methods (1)
Heat Treatment (HT) Wood packaging material should be heat treated at a minimum wood core temperature of 56 oC for a minimum of 30 minutes.
(2)
Methyl Bromide (MB) fumigation Wood packaging material should be fumigated with methyl bromide as follows. The minimum temperature should not be less than 10 oC and minimum exposure time should be 16 hours. Temperature
Dosage rate
Minimum concentration (g/m3) at 0.5 hrs.
2 hrs.
4 hrs.
16 hrs.
21 oC or above
48
36
24
17
14
16 oC or above
56
42
28
20
17
64
48
32
22
19
o
11 C or above
Provided, Wood packaging material made of Pinus spp., Larix spp., Cedrus spp. from Japan, China, Taiwan, US, Canada, Mexico, Portugal and Wood packaging material made of Pinus spp. from Vietnam should be fumigated with methyl bromide for 24 hours. The treatment standard is as follows. The minimum temperature should not be less than 10 oC and the minimum exposure time should be 24 hours. Temperature
Dosage rate
Minimum concentration (g/m3) at 24 hrs.
21 oC or above
48
24
16 oC or above
56
28
64
32
o
11 C or above 3)
7.2.5
7.2.6
The Mark should contain the valid symbol approved by IPPC, country code, unique number of the producer / treatment facility designated by the National Plant Protection Organization (NPPO) of exporting countries and treatment methods (HT, MB).
Non-compliance measures 1)
Wood packaging material without approved mark : Disposal or Return to the origin
2)
Wood packaging material with approved mark but with live regulated pests : Treatment or Disposal or Return to the origin
Marking for approved measures
XX-000 YY 1)
Symbol
2)
ISO two letter country code followed by a unique number assigned by the NPPO to the producer of the wood producer of the wood packaging material, who is responsible for ensuring appropriate wood is used and properly marked.
3)
IPPC (International Plant Protection Convention) abbreviation for the approved measure used (e.g HT, MB).
Page 27 8.
Supervision services for installation, test operation and training
8.1.
Supervision for installation and test operation The Vendor shall take the full responsibility for proper quality and function of the goods supplied by the vendor. For this purpose, the vendor shall dispatch to the Purchaser's site its qualified supervisor(s) who will provide technical direction and will perform the duties as required to assure proper installation and successful operation of the goods under the conditions of actual operation. The supervisor(s) shall have a good knowledge of instrumentation and control. The manpower requirement for the supervision services including instrument supervisor(s) shall be Five (5) man-months as specified below: Two (2) man-months during the installation period Three (3) man-months during site commissioning and test The Vendor shall include the price for above supervision service in his proposal.
8.2.
Training The Vendor shall provide a comprehensive training program free of charge for the Purchaser’s personnel to be familiarized with designing, operation & maintenance, etc. of the equipment supplied by the Vendor. The training shall be conducted both at the Vendor’s factory and Purchaser’s site as follows: (A) At the Vendor’s factory The training shall be conducted for trainees of Purchaser for a period of two (2) calendar weeks, provided that round-trip air fairs and living allowances to be incurred by the trainees during the training period shall be borne by Purchaser. (B) At the Purchaser’s site The training shall be conducted during the Vendor’s supervision service as specified in 8.1. The Vendor shall submit to the Purchaser the detailed content and schedule of training programs for the Purchaser’s approval at least sixty (60) days prior to the beginning of the training.
9.
Guarantee and patent infringement
9.1.
Guarantee The Vendor guarantee that the equipment furnished is free from fault in design, workmanship, and material, and is of sufficient size and capacity, and is of proper material to fulfill satisfactorily the operating conditions specified. Should any defect in design, material, workmanship or operating characteristics develop for the twenty four (24) months after the goods, or any portion thereof, as the case may be, have been arrived at the final destination indicated in the contract, the Vendor agrees to make all necessary or desirable alterations, repairs, and replacements of defective equipment, free of charge, and shall pay transportation cost involved to and from the Purchaser’s plant and field labour cost. No allowance will be made for alterations or repairs made by others without written consent or approval of Purchaser. If the defect or failure to function cannot be corrected, the Vendor agrees to replace promptly, free of charge, said equipment or to remove the equipment and refund the full purchase price. In no case will the Vendor be responsible for contingent liability. The Vendor shall take full technical and commercial responsibility for all material supplied irrespective of whether it be of the Vendor's own manufacture or not. The Vendor shall guarantee that all equipment supplied shall achieve its individual max/min performance criteria as specified in the data sheet(s), this specification and the referenced specifications herein. All equipment supplied by the Vendor shall be guaranteed to operate under continuous operation, i.e. 99% of 24 hours/day x 7 days/week per year and satisfactorily maintain all functions and capacities within this specification and data sheets under the whole range of operating and climate conditions
Page 28 specified herein. The Vendor shall guarantee all components parts or the LNG liquid marine loading arms in regard to suitability of the design, materials, construction and/or workmanship for the given design/operating conditions. This guarantee is additional to any other guarantee that may be requested in the enquiry document. 9.2.
Patent infringement Vendor shall defend any and all infringement suits in which the Purchaser is made a defendant, alleging patent infringement on equipment purchased from Vendor. Vendor shall pay all costs and expense incident to any such litigation. It being further agreed and understood, however, that Purchaser shall have the right to be represented therein by counsel, of their own selection and paid by them. Vendor shall pay all damages, profits, and costs which may be awarded the plaintiff in any such litigation; and, in general shall defend Purchaser against all claim or demand of every kind to which they may be subjected under the patent laws in connection with equipment purchased under this specification.
9.3.
Guarantee item list The equipment and its supporting systems shall be guaranteed to operate continuously and satisfactorily at all the specified operating conditions as shown on the data sheets. Vendor shall guarantee following performance data at specified conditions specified in Data Sheet in Attachment #1: 1)
Operating range of arms
2)
Pressure drop and flow rate of arms (No negative tolerance shall be admitted.)
3)
Sealing efficiency of arms at working temperature
4)
Loads applied to equipment flange and cross-beams
5)
ERS shut-down time
6)
Noise
7)
Utility consumption (electric power, nitrogen, instrument air, etc)
If the equipment does not meet the guarantee performance values including allowances specified in this specification or applicable codes, Vendor shall provide the performance measuring instruments of good accuracy, and repair the equipment until their performance conditions are fulfilled at free of charge. 10. Spare parts and special tools
10.1.
Spare parts After the initial delivery to Purchaser of spare parts, Vendor shall agree to continue to quote and sell the spare parts to Purchaser at the same price which it is then offering to other commercial customers for similar quantities under similar conditions. In the event Purchaser discovers that Vendor has failed to meet its obligations to Purchaser under this article, Purchaser will be entitled, within one(1) year after the date of sale of any spare parts, to demand and receive a refund in the amount of any excess price Purchaser has paid to Vendor. Vendor shall provide sufficient spare parts for erection and start-up considering unexpected accidents during such period to prevent reordering shortages and to maintain delivery schedule and to avoid delaying target completion date. If any parts including consumable items supplied by Vendor for the erection and start-up purpose are required additionally due to Vendor’s fault prior to completion of the Project, they shall be supplied and/or replaced at Vendor’s cost. And no delay of the Project due to the above shall relieve Vendor’s responsibility under Contract.
Page 29 10.2.
Special tools If any, Vendor shall offer special tools with itemized price for each components of the equipment and all auxiliaries. Special tools are those not commercially available. Special tools shall be purchased with the main equipment. Vendor shall quote by furnishing detail list for special tools, tackles, devices required for lifting, installation, removal and/or maintenance of equipment.
11. Vendor data requirements
11.1.
General 1)
All documentation and drawings including information, calculations, schedules, etc. shall be submitted within the specified due date, as indicated in Section 11.2. Vendor is responsible for submitting all documentation in accordance with a program to be prepared by the Vendor's own allowing all participants sufficient time to check, access, comment, and eventually approve the documents.
2)
The quality of the submitted documents must be in accordance with acceptable international practice and allow a speedy checking procedure. Documents not fulfilling these requirements will be returned to Vendor without comments for Vendor's improvement and resubmission. It is solely at the discretion of Purchaser to decide whether or not documents are acceptable.
3)
All Vendor documentation shall employ Korean or English language, and all units shall be as per Section 1.3.2.
4)
Vendor's subcontractor list shall be approved by Purchaser prior to order.
5)
Technical documentation of Vendor's subcontractor shall be reviewed and cross-checked and approved by Vendor prior to submission to Purchaser for approval.
6)
Vendor's drawings (for layout, outline, assembly or subassembly, arrangement) shall include basically the followings: North direction arrow mark Coordinates Process flow arrow mark and descriptions Descriptions of elevation base Parts list Revision mark and revised description Project title block with full descriptions Vendor's drawings shall be prepared on ISO standard sized drawing sheets of A1, A2, A3 and A4 but one limitation for instrumentation shall be A1, A3, and A4 only.
7) 8)
Vendor's P & I Diagrams and electrical single line diagram shall use symbol and legends prepared by Purchaser.
9)
The numbering system for equipment, piping, instrumentation, correspondences, drawings and documentation for this project shall be informed to the Vendor after contract and shall be followed by the vendor.
10)
Purchaser’s drawing title block (see Attachment #4) shall be used at all Vendor documents.
11)
When submitting revised vendor documents, Vendor shall clearly indicate all revised points with cloud mark and/or revision marks. This is mandatory requirement. Vendor shall be responsible for all possible results caused by omitting revision mark. Any document omitting the revision marks may be returned without comment.
12)
Purchaser’s acceptance, with or without comments, of Vendor’s documents does not relieve Vendor from complying with all terms, conditions, codes, standards, requirements of the order and this specifications. Purchaser reserves the right to review and comment on documents that have previously accepted with or without comments, and Vendor shall incorporate those comments without any cost and delivery impact.
Page 30
11.2.
13)
Purchaser’s comments on submitted documents are not to be considered as authorization to change the scope of purchase order, unless commented as scope change. Changes of scopes shall only be effected via letter or faxes.
14)
Formal clarification, exception and deviation (“deviation” hereinafter) list shall be submitted in Vendor’s proposal. If deviations are specified on some part of proposal, not in formal deviation list, then the deviation shall be not accepted at all. All requirements in this specification shall be deemed accepted by Vendor if specified in deviation list. Any deviation shown on Vendor document after contract award shall not be accepted by Purchaser even though Purchaser overlooks it.
List of Vendor document and schedule
Document
GENERAL DOCUMENTS 1) Vendor prints index / schedule 2) Engineering, fabrication, test & delivery schedule by item 3) Progress report rd 4) Deviation list against OCIMF, 3 edition and/ or BS EN 1474 5) Clarification and deviation list against this specification 6) Sub-vendor list 7) Installation list of similar machines with required data showing conformance with Sec.1.4.5. 8) Narrative description of the system 9) List of guaranteed items and values 10) Spare parts list for installation & commissioning with itemized price list 11) Spare parts list for 2-years operation with itemized price list 12) Special tool list 13) Lubricants list 14) Painting specification 15) Alternative protective coating specification
When bid No. of copies
No. of copies
Due date
No. of copies
Due date
1OR+5C
*1
4w
*2
+3w
1OR+5C
*1
4w
*2
+3w
For Approval
Final Remark
Note 6
monthly 1OR+5C 1OR+5C 1OR+5C
*1
14w
*2
+3w
1OR+5C
*1
10w
*2
+3w
1OR+5C
*1
10w
*2
+3w
Sec. 9.3
1OR+5C
*1
14w
*2
+3w
Note 3
1OR+5C
*1
14w
*2
+3w
Note 3
1OR+5C
1OR+5C
*1
14w
*2
+3w
Note 3
*1
14w
*2
+3w
Note 3
*1
14w
*2
+3w
1OR+5C
Sec. 13.14.2 & 13.14.3
16) 17) 18) 19) 20) 21) 22) 23) 24) 25)
Painting schedule Rust preventive schedule Training program and schedule Installation, operation and maintenance manual Packing specification Shipping schedule & packing list Description of fire proofing for ERS components Fault free analysis for shutdown system Summary of technical specification Technical data requested by Purchaser
MECHANICAL DOCUMENTS 26) Specification & data sheet 27) Equipment noise data sheet 28) Performance curve & data (pressure drop vs flow rate)
*1
14w
*2
+3w
Note 3
*1
14w
*2
+3w
Note 3
*1
24w
*2
+3w
Sec. 8.2
*2
32w
*2
- 4w
*2
- 4w
1OR+5C
Sec. 13.6.18 *1
12w
*2
+3w
1OR+5C
Sec. 13.2.3 Sec. 12
Upon request
1OR+5C
*1
10w
*2
+3w
1OR+5C
*1
10w
*2
+3w
1OR+5C
*1
10w
*2
+3w
Note 3
Page 31
Document
29) 30) 31) 32) 33)
34) 35)
36) 37) 38) 39) 40) 41) 42)
Operating envelope with counter-weight range Arm maintenance attitude drawing Dimensional outline drawing with nozzle list Allowable forces and moments on the nozzle to be connected by Purchaser Assembly & erection drawing including: - Swivel drawings - ERS drawings - QCDC drawings Cross-section drawing with material list Calculation sheet including: - Stress report considering loading combination as defined in OCIMF - Hydraulic calculation Hydraulic piping diagram & schematic Tubing layout drawing with support details BM for piping, insulation and support Special piping support drawing, if necessary Foundation & anchor bolt plan (including conduit layout), loading data Utility consumption list Equipment catalogue
ELECTRICAL DOCUMENTS 43) Electrical single and three line diagram 44) Electric schematic diagram 45) Motor data sheets 46) Motor outline drawing 47) Motor characteristic curve 48) Terminal box drawing 49) Cable list 50) Electric load list INSTRUMENTATION DOCUMENTS 51) System configuration drawing 52) 53) 54) 55) 56) 57) 58) 59) 60)
Instrument list
When bid No. of copies
No. of copies
Due date
No. of copies
Due date
1OR+5C
*1
10w
*2
+3w
*1
10w
*2
+3w
*1
10w
*2
+3w
*1
10w
*2
+3w
*1
10w
*2
+3w
*1
10w
*2
+3w
*1
10w
*2
+3w
1OR+5C
1OR+5C
1OR+5C
*1
10w
*2
+3w
12w
*2
+3w
*1
12w
*2
+3w
*1
12w
*2
+3w
*1
6w
*2
+3w
*1
10w
*2
+3w
*1
10w
*2
+3w
*1
10w
*2
+3w
*1
10w
*2
+3w
*1
10w
*2
+3w
*1
10w
*2
+3w
*1
10w
*2
+3w
*1
10w
*2
+3w
1OR+5C
*1
10w
*2
+3w
1OR+5C
*1
10w
1OR+5C
1OR+5C 1OR+5C
1OR+5C
Instrument & cables layout drawing Instrument loop diagram
*1 *1 *1
I/O list
Interconnecting wiring diagram
Remark
Note 3
1OR+5C
Instrument set point list
Function logic diagram & flow chart
Final
*1
Instrument data sheet
System block diagram with description
For Approval
*1 1OR+5C
*1 *1 *1 *1 *1
10w 10w 12w 10w 10w 10w 12w 12w 12w
*2
+3w
*4
+++2w
*2
+3w
*4
+++2w
*2
+3w
*4
+++2w
*2
+3w
*4
+++2w
*2
+3w
*4
+++2w
*2
+3w
*4
+++2w
*2
+3w
*4
+++2w
*2
+3w
*4
+++2w
*2
+3w
*4
+++2w
*2
+3w
Note 3
Page 32 When bid No. of copies
Document
61) 62) 63) 64) 65) 66) 67) 68) 69) 70) 71) 72)
Instrument process piping hookup Cable specification & schedule Panel layout drawing Panel nameplate schedule Junction box drawing with terminal arrangement Instrument piping & pneumatic hook-up drawing Pneumatic tubing schedule Safety valve & flow element calculation sheet Thermo well vibration & stress calculation Control valve size & noise calculation Instrument catalogues PLC program source and the documentation as below; - Logic diagrams - PLC I/O list - Fully annotated ladder listing - Cross references, memory maps - List of timers and all program listings
Q.A DOCUMENTS 73) Quality control manual 74) Inspection and test plan including 3rd party inspection 75) Inspection and test procedure 76) Shop inspection & test report, certificates 77) WPS, PQR and weld map 78) Heat treatment procedure specification 79) Field check list 80) Site performance test procedure & list of instruments & accuracy 81) Site test report 82) Electrical certificates (including KOSHA , KTL or KGS certificate of electric equipment and instruments) 83) KGS certificates for safety valves, ball and globe valves for LNG, NG, N2 & fuel gas
For Approval No. of copies
Due date
No. of copies
Due date
*1
12w
*2
+3w
*1
12w
*2
+3w
*1
12w
*2
+3w
*1
12w
*2
+3w
*1
12w
*2
+3w
*4
+++2w
1OR+5C
*1 : 9C OR : Original
*2 : 14C
+ : after receiving comment
12w
*2
+3w
*1
12w
*2
+3w
*1
12w
*2
+3w
*1
12w
*2
+3w
*1
12w
*2
+3w
*1
12w
*2
+3w
*2
-4w
*4
+++2w
*1
14w
*2
+3w
1OR+5C
*1
14w
*2
+3w
*1
14w
*2
+3w
*2
-4w
*1
14w
*2
+3w
*1
14w
*2
+3w
*1
24w
*2
+3w
*1
24w
*2
+3w
*2
-4w
1OR+5C
*2
*3
*3 : 4C + 2CD
C : Copy
*1
1OR+5C
MECHANICAL DATA BOOK PACKAGE 84) Mechanical data book package Legend :
Final
-2w
Remark
Sec. 5.1.6
*2
-4w
*4
++2w
Sec.11.3.2
*4 : 17C + 5CD
CD : DVD-ROM - : before shipment ++ : after shipment
+++ : after commissioning (Note 7)
Page 33
Document
1) 2) 3) 4) 5) 6)
7)
When bid No. of copies
For Approval No. of copies
Due date
Final No. of copies
Due date
Remark
Quotation must include cost of above data. Revised drawing and documents shall be submitted within 3 weeks after Purchaser’s comment issue unless otherwise specified in this section. Purchaser’s standard forms in Attachment #4 shall be used. Documents required for proposal as specified in “When bid” column shall be included in the proposal. Omission of any document may cause rejection of the proposal at the discretion of Purchaser. Any document submission schedule that Vendor cannot follow shall be clearly suggested in Bidder’s deviation list in proposal. Vendor shall have the obligation to keep the submission schedule specified in this section. Vendor document list containing all anticipated drawings and data shall be submitted prior to first issue of Vendor documents as soon as possible. This list shall be updated and submitted to Purchaser with each issue of Vendor documents. Specified instrumentation documents shall be updated by Vendor incorporating all field changes, if any, that may happen during installation and commissioning.
Page 34
11.3.
Vendor data coordination procedure
11.3.1
Vendor document distribution and flow schematic Vendor document submission procedure shall be as follows:
1 ST ISSUE W ORK MAY PROCEED. REVISE AND RE-ISSUE FOR APPROVAL
APPROVED ? (NO COMMENT)
W ORK MAY NOT PROCEED.
NOT APPROVED ?
APPROVED W ITH COMMENT ?
NO
NO
YES
YES
YES
ISSUE FINAL (CERTIFIED) REVISE AND RE-ISSUE FINAL
APPROVED ?
NO
YES
PERFORM SHOP INSPECTION AND
11.3.2
ISSUE MECHANICAL DATA BOOK (FOR REVIEW )
ISSUE MECHANICAL DATA BOOK (FOR FINAL)
Document submission procedures Vendor shall submit their technical documents to Purchaser and Engineer (in the address stated in Section 1.2) at the same time in accordance with following schematics:
For Approval/Review documents
Comment
Final documents
Comment
PURCHASER
3 copies VENDOR
PURCHASER
8 copies 1 copy
6 copies
VENDOR
1 copy 6 copies
ENGINEER
This applies to 1st submitted documents or revised document by Purchaser’s comments.
ENGINEER
This applies to documents approved without comment by Purchaser.
Page 35
Mechanical data book package (for Review)
PURCHASER
Comment 2 copies VENDOR
Mechanical data book package (Final)
PURCHASER (TongYoung office) 12copies + 1CD
Comment, if any
if any
if any PURCHASER (Head office)
3copies + 2CD
2 copies + 2 CD ENGINEER
VENDOR
if any
2copies + 2CD ENGINEER
Vendor can enter this process only when all the documents are approved without comment by Purchaser. See section 11.4 for preparation of mechanical data book package.
11.4.
This step is applied when Mechanical Data Book Package for Review is approved by Purchaser. See section 11.4 for preparation of mechanical data book package.
Mechanical data book
11.4.1
Mechanical data book package with all Vendor documents/drawings and inspection/test report shall be submitted after Purchaser’s final approval.
11.4.2
The package shall be binded in hard cover file book of good quality. Each book shall be provided with detail index, dividers, etc. All drawings bigger than A4 size shall be folded and inserted into translucent plastic drawing holder, and compiled in the binders.
11.4.3
Mechanical data book cover format shall be as per Attachment #4.
11.4.4
Soft copies of electronic files contained in CD shall be submitted together with hard copies. The contents and their order shall be strictly same with the hard copies. All documents generated by office software, such as MS Office, Auto Cad, Korean Hangul, shall be submitted in both original source files and converted Acrobat PDF format. All other documents generated by hand-writing, photo and proprietary analysis software, etc. shall be submitted in either Acrobat PDF or TIFF white-black compressed image format with minimum 300 DPI resolution.
Page 36
12. Technical bid requirement In addition to technical bid documents required in Section 11.2, Vendor shall fulfill the bid requirements in this section. 12.1.
Summary of technical specification This form shall be completed by Vendor and submitted with the proposal.
No I
Item General Bid no. Manufacturer / Supplier Korean agent Type Model Delivery condition Delivery period Eligibility (See Section 1.4.5.) 1) Supplied for Pantograph cable type 16” or more LNG arm with the flowrate equal to or more than 5,000m3/hr 2) Swivel, ERS & QCDC type approval tested according to OCIMF rule by 3rd party inspection agency
II II-1
II-2
Bidding document General documents Vendor prints index / schedule Engineering, fabrication, test & delivery schedule by item Deviation list against OCIMF, 3rd edition and/or BS EN 1474 Clarification and deviation list against this specification Sub-vendor list Installation list of similar machines per Section 1.4.5 Narrative description of the system List of guaranteed items and values Spare parts list for installation and commissioning with itemized price list Spare parts list for 2-years operation with itemized price Special tool list Alternative protective coating specification Description of fire proofing for ERS components Summary of technical specification Mechanical documents Specification & data sheet Equipment noise data sheet Equipment performance curve & data (pressure drop vs. flow rate) Operating envelope with counter-weight range
Unit
Required
Required
Required
Sec.11.2 To be submitted with bid “ “ “ “ “ “ “ “ “ “ “ “ “ To be submitted with bid “ “ “
Proposed
Page 37 No
II-3
II-4
II-5
II-6
III
Item Dimensional outline drawing with nozzle list Assembly and erection drawing including swivel, ERS and QCDC drawings Hydraulic piping diagram and schematic Utility consumption list Equipment catalogue Electrical documents Electrical single and three line diagram Motor data sheet Electric load list Instrumentation documents System configuration drawing Instrument list System block diagram with description Panel layout drawing Q.A documents Quality control manual Inspection and test plan including 3rd party inspection Site performance test procedure & list of instruments & accuracy Number of Vendor documents For approval Final Mechanical data book package – for review Mechanical data book package - final Code and standards Marine Loading Arms
Unfired pressure vessels and welding
Tubular head exchangers Piping (cryogenic and non-cryogenic)
Electrical
Hazardous area
Unit
Required “ “ “ “ “ To be submitted with bid “ “ To be submitted with bid “ “ “ To be submitted with bid “ “
9 copies 14 copies 4 copies + 2 CD 17 copies + 5 CD
OCIMF, 3rd edition SIGTTO BS EN 1474 For others see Sec. 4 ASME Sec. II Part. C & D ASME Sec. V ASME Sec. VIII, Div. 1 ASME Sec. IX AWS TEMA ANSI: B1.20.1, B16.5, B16.9, B16.10, B16.11, B16.28, B31.3, B36.10 BS: 5351, 1873, 6755 API: 6FA, 606, 607 ISO: 10497 IEC: 60034, 60079, CENELEC, NEC, NEMA MG-1 ANSI, NFPA, Korean Industrial Standard (KS), JIS, API, IEEE, NACE, KOSHA, KTL or KGS (for enclosure of hazardous service) Korean regulation, ACT 1993-19, NFPA 59A, NFPA 497A,
Proposed
Page 38 No
Item
Instruments
Steel Structures
Safety Relieving Systems Reciprocating Pumps (Metering/Dosing) Environmental Regulations Earthquake Design Noise
Materials Painting & insulation IV IV-1.
Scope of supply & work Scope of supply 1) Two (2) sets of LNG unloading arm, One (1) set of LNG unloading / Vapour return arm, One (1) set of Vapour return arm with: - Base, riser, inboard, outboard and counter weight balancing system - Electrical insulation at outboard arm end - Hydraulic operated ERS with two ball valves and one emergency release coupler - Hydraulic operated QCDC - Blind flange of QCDC coupler with safety valve and pressure gauge - Davit for handling for blind flange at outboard swivel joint - Mechanical support jack at outboard swivel joint
Unit
Required IEC 60079-10, IEC 60079-1 or EN 50018, IEC 60079-11 or EN 50020, IEC 60079-2 or EN 50 016, API RP500 ANSI: B1.20.1, B16.5 API 550 ISA: S5.1, ISA S5.2 IEC: 60073, 60079, 60529, 60584, 60654, 60751, 60801 ISO 8310 KGS (for safety valves, ball & globe valve for LNG, NG, N2 and fuel gas system) KOSHA, KTL or KGS (for enclosure of hazardous service) JIS AISC, UBC Korean Codes and Standards NFPA 59A API RP 520. Part 1 & Part 2 API RP 521 API 674 2nd API 675 2nd Korean regulations UBC, ANSI A58.1 NFPA 59A IEC: 61260, 60651 ISO: 1680, 1996, 3744, 3746 RP 521 ASTM/ASME, KS, JIS Purchaser’s spec
by Vendor
Proposed
Page 39 No
Item
2)
3)
4)
- Mechanical locking to restrict slewing movement and movement of the inboard arm and outboard arm in stored position, manually operated from operating platform - Maintenance access and ladder - Maintenance platform for swivels - Flanged valve drain installed at shore side of ERS valve to drain outboard arm - Flanged valve drain with protector installed at bottom of outboard swivel joint to drain fluid trapped between the ship’s valve and loading arm valve - Nitrogen purging system for swivel joints with check valve - Cargo purging line from base riser to apex of inboard arm with non-return valve and shut-off valve - Centralized greasing system with hand pump which allow grease injection on operating platform All required coupling spool pieces - Coupling spool flange for LNG unloading / Vapour return arms Complete hydraulic system for all unloading arm system - Power packs - Selector valve unit for each arm - Accumulators for ERS of each arm and arm manoeuvring - Cylinders - All interconnecting hydraulic piping/tubing, valves, support clamps, etc. Completed electrical and control system - Unloading arm control panel of explosion-proof type with: - Arm manoeuvring system - Radio control receiver - Microprocessor and LCD VDU for PMS - Breaker for UPS power - Purge control unit, filter regulator unit, if required - Intrinsically safe units, if required - All switches, lamps, etc. - Local control station of explosion-proof type, installed near hydraulic power unit with switches - Alarm bell, alarm buzzer.
Unit
Required
sets
by Vendor 4 (16” x 20”) by Vendor
by Vendor
Proposed
Page 40 No
Item
5)
6)
7) 8) 9)
10)
11) 12) 13) 14) 15) 16) 17)
18) 19) 20) 21)
- Pendant control boxes with control cable (about 50m length) - Radio remote control system by joy stick (2 sets) - Position monitoring system with: - Angle sensors on all arms - Microprocessor and LCD VDU (min. 12”) with key pad for PMS in unloading arm control house (UACH). - All local instrumentation - All interconnecting wiring, cables and cable trays, etc. including electric power terminal boxes between Vendor furnished equipment - Interface with ESD (emergency shutdown system), DCS, MCC and LCS, etc. Completed access/support structure including all ladders, platforms, etc. One (1) set of nitrogen regulator unit for swivel purge with sight flow indicator at each outlet, pressure indicator or at inlet / outlet N2 purge system pipe work Two (2) sets of spotting centerline indicator (stainless steel) One (1) set of dummy manifold flange skid, cradle type with swing casters All supports, foundation bolting, shims, and accessories necessary for the setting, adjustment and anchorage of the equipment supplied Initial fill of hydraulic oil & flushing oil All internal piping required for lubrication, drain, vent & sealing Vent and drain valves as required A completed set of special tools, jig & lifting devices Spare parts for installation and commissioning All documents required by this specifications All necessary components, accessories and appurtenances, as normally provided Nameplates Aircraft warning device of exp-proof type, if required Earth lugs Earlier delivery of risers and foundation bolts
Unit
Required
by Vendor
by Vendor
by Vendor by Vendor by Vendor
by Vendor
by Vendor by Vendor by Vendor by Vendor by Vendor by Vendor by Vendor
by Vendor by Vendor by Vendor upon Purchaser’s request
Proposed
Page 41 No IV-2.
V. V-1
Item
Unit
Scope of work 1) Guaranteed allowable forces and moments on the nozzles 2) Information for foundation design including static & dynamic loading data with various direction 3) KOSHA, KTL or KGS certificates for explosion proof type electric equipment and instruments 4) Documents and certificates of pressure vessels and/or high pressure equipment for KGS certificates 5) KGS certificates for safety valve, ball and globe valves for LNG, NG, N2 and fuel gas system 6) Painting up to finish coating at shop 7) Coordination meeting 8) Supervision for installation, commissioning & performance test 9) Training for Purchaser’s trainees 10) Packing for export 11) Inspection and test 12) Performance guarantee 13) Performance test at site Technical specification General data 1) Arm envelope - Jetty face to center of risers - Jetty face to berthing line - Design sway & surge - Tanker manifold elevation, max - Tanker manifold elevation, min. - ESD-1 limit from max. reach - ESD-2 limit from max. reach - ESD-1 within 80% of max reach - Min. clearance between arms 2) Arm maneuvering speed, fast/slow 3) ERS operation - Action after ERS
4) 5) 6)
7)
- Slewing motion Arm drain Storm lock - Type Stray current protector - Location - Resistance - Safety factor Swivel joint - Type - Lubrication - Repacking without dismantle - No. of primary seal
Required by Vendor by Vendor
by Vendor
by Vendor
by Vendor
by Vendor by Vendor by Vendor by Vendor by Vendor by Vendor by Vendor Vendor witness
m m m m m m m
3.5 4.7 4.6 / 4.0 DL +24.81 DL +18.53
yes mm m/sec
0.15 / 0.075 automatic retraction of outboard arm toward stored position locked by hydraulic gravity, N2 purge mechanical
ohm
min. 10,000 min. 2 Flanged
ea
yes 2
Proposed
Page 42 No
Item
8)
9)
10)
V-2.
- No. of external seal - N2 purge (LNG / NG) - Ball race material - Ball race of NDE - Ball race hardness - Ball race type ERS - Operated by - Type of ball valves - Coupler type - No. of clamps of coupler - Closure time of ball valves - Coupling disconnection time after valve closure - Design ice build-up for coupling disconnection (cryogenic only) - Cylinders for coupling & valves - Cylinder type - Alignment, reassembly bolting system for reassembly - Fireproofing - Strength - ERS parking proximity switch QCDC - Operated by - Aligning and centering device - Design ice load - Manual disconnection by hand pump - Strength Hydraulic system - No. of hydraulic pack - Operating pressure - System design pressure - Pump, q’ty - Pump, type - Pump, min. service life - Pump BHP - Motor, rating - Motor power source - Motor enclosure - Emergency hand pump, q’ty - Oil reservoir, capacity - Suction strainer - Filters - Flow control valves - Accumulator for ERS, capacity - Accumulator for arm manoeuvring, capacity - Cylinder rod material - Tubing size - Tube fitting type
LNG unloading / Vapour return arms 1) Model 2) Type 3) Q’ty
Unit
Required
ea
1 yes must be possible min. 40HRc replaceable Hydraulic
sec sec
3 ~ 40 max. 2
mm
25 separate cylinders double acting yes per ISO 10497 per OCIMF yes Hydraulic yes 25 possible
mm
per OCIMF set MPa.g MPa.g ea
hr
1 working, 1 stand-by min. 50,000
kW kW AC440V, 3ph, 60Hz ea Litres micron micron
150 25, replaceable cartridge fast, slow, return after ERS
Litres Litres hard chromized SS mm
Pantograph cable
Proposed
Page 43 No
Item
4) 5)
6)
7)
8) 9)
10)
11)
12)
13)
14)
15)
- LNG unloading arms - LNG unloading / Vapour return arm - Vapour return arm Design temp Design pressure - LNG unloading arms - LNG unloading / Vapour return arm - Vapour return arm Max. flow rate - LNG unloading arms - LNG unloading / Vapour return arm - Vapour return arm Pressure drop - LNG unloading arms - LNG unloading / Vapour return arm - Vapour return arm Recommended LNG flow rate & time for cool down Connections - Ship connection - Shore connection - N2 cargo purge - N2 swivel purge Size of arm - Riser dia. x height - Inboard arm dia. x length - Outboard arm dia. length Swivel joint - Joint size & Model No. - between riser and inboard arm - between inboard arm and outboard arm - between outboard arm and ERS system - Manufacturer - Certificated by ERS - Valve size - Model No. - Manufacturer - Certificated by - Liquid trapped between valves QCDC - Size - Model No. - Manufacturer - Certificated by Counterweight - Type - Size - Weight Materials
Unit
Required
sets set
Two (2) One (1)
set °C
One (1) -170
MPa.g MPa.g
1.77 1.77
MPa.g m3/hr m3/hr m3/hr
0.35 5,000 5,000 / 15,000
nm3/hr
15,000
kPa kPa
max. 60 max. 60 / max. 2
kPa Liter/min, hours
max. 2
16” or 20” 150# RF 20” 300# RF 150# RF 150# RF inch x m inch x m inch x m
20” x by Vendor 20” x by Vendor 20” x by Vendor
inch
20”
inch
20”
inch
20” or 20”x16”
inch
16” or 20”
Litre inch
16” or 20”
Pantograph cable mm kg
Proposed
Page 44 No
Item
16)
17)
V-3.
- Plate, sheet - Pipe, ~16” - Pipe, 18” ~ 24” - Elbow, fittings - Forging, flanges - Castings - Valves, body - Valves, stem, trim, ball - Valve, seats/seals - Section, bar - Bolts / nuts - Max. carbon content - Hydraulic tubing - Hydraulic reservoir - Cabinet, console - Wire rope Others - Finish coating color for LNG arm - Noise level @ 1m distance Weight - Empty - Operating
Instrumentation and control 1) Unloading arm control panel - Type - Manufacturer - Q’ty - Location Size Materials Enclosure Weather protection grade Operation unit with function key & display - Hard wire and serial communication with Purchaser’s DCS - Annunciator minimum spare windows - Terminal block minimum spare - Panel material PLC - Maker -
2)
- Source program for PLC - Programming tool for PLC
Unit
Required A240-304L A312-304L A358-304L Class 1 A403-WP304L A182-F304L A351-CF8M A182-304L or A351-CF3 AISI 316 PTFE (Virgin) A479-304 A320-B8.Cl.2 / A194Gr.8.MA per ASTM A213-TP316 AISI 316 SS or GRE
dB(A)
to be advised by Vendor max. 85
kg kg
Self standing set
mm
One (1) in Unloading Arm Control House LxWxH Explosion-proof (Zone 1) IP 55 Yes Yes
%
10
%
20
Allen Bradley, Siemens or eq. by Vendor Notebook will Pentium 4, 2GHz CPU, 2GB (1024MB) DDR2 SDRAM, 2BM L2 cash, 80GB hard disk, 15” TFT LCD, Li-Ion battery, DVD/CD multi drive, 128MB Video, optical USB mouse, integrated 56kbps modem & LAN and Korean or English based OS.
Proposed
Page 45 No
Item
3)
4)
5)
6)
VIII VIII-1.
- PLC memory - Power supply and processing cards of PLC Local control station - Type - Manufacturer - Q’ty - Location - Size - Materials - Enclosure - Weather protection grade Pendant control (wired) - Q’ty - Type - Model No. - Manufacturer - Enclosure - Cable length Pendant control (radio) - Q’ty - Type - Model No. - Manufacturer - Enclosure PMS - Microprocessor & LCD VDU (min. 12”) with key pad for PMS in unloading arm control house
Inspection and tests Shop test 1) Welding check - Visual inspection - Production test for LNG, NG, N2 & fuel gas system 2) Material inspection 3) Nondestructive inspection - 100% RT for butt weld of LNG, NG, N2 or fuel gas system - acceptability code for RT - dye penetrant or magnetic particle examination 4) Visual and dimensional check 5) Pneumatic leak test 6) Hydrostatic test
7)
- Test media - Dismantle inspection Shop assembly and operational test - including hydraulics - including instruments - Test items (see Section 5.2.7) - Balance - Arm envelope and alarm setting
Unit
Required EPROM type Redundant
Self standing set mm
LxWxH Explosion-proof (Zone 1) IP 55
set
m sets
One (1) Joy stick
Explosion-proof (Zone 1) about 50 Two (2) Joy stick
Explosion-proof (Zone 1) Explosion-proof (Zone 1)
Tensile, guide bend, impact by material certificates yes ASME Sec. VIII, Div.1 all non-RT welds
MPa.g MPa.g
yes 0.7 for 30 minutes 1.5 x Design pressure for 30 minutes All swivels one unit yes yes yes yes
Proposed
Page 46 No
Item QCDC function ERS function Arm manoeuvring after ERS release - Reconnection after ERS - Accumulator test - ERS activation - ESD input / output action (Refer to Sec. 5.2.7) - Swivel N2 purge Hydraulic system test - Leakage test - Performance test Swivel joint test - Pressure test - Proof test per OCIMF - Hydrostatic test & partial vacuum test @AT - Leakage test @AT - Leakage test @LT - Load capacity test @AT - Load capacity test @LT - N2 purge test @LT QCDC test - Pressure test - QCDC body - Hydraulic components - Function test - Proof test - Strength test @AT - Strength test @LT - Release performance test @LT ERS test - Pressure test - Valve body hydrostatic test - Valve hydrostatic test - Complete ERS assembly pneumatic test - Hydraulic system pressure test - Function test - Proof test - Strength test @AT - Strength test @LT - Release performance test @LT - Valve torque and leakage rate test @LT - Seat/seal test of upper ball valve @LT Painting inspection Packing & marking inspection -
8)
9)
10)
11)
12) 13) VIII-2.
Site test 1) Site performance test procedure 2) Pre-check
Unit
Required yes yes yes yes yes yes yes yes yes yes All swivels, 1.5 x DP certificate required one unit of each size one unit of each size one unit of each size one unit of each size one unit of each size one unit of each size
all QCDC, 1.5 x DP all QCDC, 1.5 x DP all QCDC one QCDC one QCDC one QCDC
All ERS All ERS All ERS All ERS All ERS one ERS one ERS one ERS one ERS one ERS
by Vendor by Purchaser under Vendor
Proposed
Page 47 No
Item 3)
Pressure test
4)
Operational test
5)
Performance test - When the LNG is transferred to both TK-212 tank and TK-216 from LNG ship at the same time with full rate, Purchaser will approve that the performance test is completed and the equipment meet the guaranteed performance values together with all associated testing. - If Vendor could not agree above performance test, Vendor shall provide alternative performance test method, and Vendor shall take full technical and commercial responsibility for verification of the arms. ESD input / output action (Refer to Sec. 5.2.7)
6)
VII-3.
3rd party inspection 1) 3rd party inspection agency
2)
Scope
Unit
Required witness pneumatic 0.7 MPa.g for 30 minutes by Purchaser under Vendor’s witness Vendor witness To be agreed by Vendor
by Vendor, if required
Vendor witness
One of Lloyd’s Register Verification, TÜV Rheinland Group, DNV, ABSG Consulting INC, BV, HSB and KR See Section 5.1.6
Proposed
Page 48
13. Design specification
13.1.
General
13.1.1
The requirements specified are the minimum requirements of the Purchaser but the Vendor shall be ultimately responsible for all aspects of the equipment supplied regardless of source and shall be responsible for ensuring compliance with all relevant local and national codes and regulations, etc.
13.1.2
The specification complements the equipment data sheets in which the operating conditions and other requirements are listed in detail. In case of conflict the order of priority shall be: 1)
Data sheets
2)
The Purchaser’s technical specification including Section 13, Design specification
3)
The piping and instrumentation diagrams (P&ID's)
4)
Other referenced specifications, codes and standards including OCIMF 3rd and/or BS EN 1474
Any conflict in the documents listed above should be reported by the Vendor and should be agreed with Purchaser in writing. 13.1.3
Definition of terms and abbreviations used in this specification related with arms shall be in accordance with OCIMF, 3rd and/or BS EN 1474.
13.1.4
All other requirements specifically not mentioned in this specification shall be in accordance with OCIMF, 3rd and/or BS EN 1474.
13.1.5
The term "Loading Arms or Unloading Arms", as used in this specification, shall mean all arms included in this specification.
13.1.6
All loading arms shall be self-supported marine loading arms with articulated swivel joints inclusive of, where specified, quick connect/disconnect couplings, power system, operating controls, range control system, purge system, emergency release system, jacks and other related accessories required by this specification.
13.1.7
The design pressure as specified in the data sheet is the maximum pressure in the loading arm taking into account occurrence of surge due to quick closing valves be it in the shore piping or in the ship's piping.
13.2.
Design and construction The unloading arms design shall be suitable for unloading LNG liquid from LNG tankers in the capacity range between 123,000 and 270,000 m3 of LNG. Refer to Section 3.4 and the Data Sheets for details of LNG Tankers.
13.2.1
Each loading arm shall be of the pantograph cable type, fitted with self levelling triple swivel assembly and equipped with an emergency release system and a hydraulically powered connect/disconnect coupling. The structural part of the cryogenic arms shall be independent from the one of the product carrying pipe to allow for thermal shrinkage The Loading Arms shall be fitted with inboard and outboard arms counterbalanced empty in all positions.
Page 49 13.2.2
The Loading Arms shall be working at no more than 80% of their safe working range anywhere within the working area specified on the data sheets.
13.2.3
The design of the unloading arm emergency shutoff and release system shall be designed to a high level of reliability. The Vendor shall demonstrate by fault free analysis that the fraction dead-time of the overall loading arm shutdown system shall not exceed 0.001.
13.2.4
The Loading Arms shall be hydraulically operated, slewing/inboard/outboard, dock mounted with articulated ball or roller bearing swivel joints.
13.2.5
The design of each arm is to be such that there is no clash with piping or adjacent structures.
13.2.6
In the stored position no part of the arms shall extend beyond the jetty face.
13.2.7
The range of arm movements shall allow the triple swivel assembly to be positioned on the jetty for maintenance using dummy manifold. Vendor shall indicate the intended location.
13.2.8
The arms will be purged with nitrogen. Vendor shall provide a valve connection with purge lines and flexible hoses to a coupling at the shore end of the loading arm.
13.2.9
Vendor shall supply and guarantee the pressure drop versus flow rate data for all the arms.
13.2.10
All unloading arms are to be designed to permit reverse flow. This will allow LNG transfer from the terminal to a ship at a reduced flow rate via the liquid arms and vapour from/to a ship to pass the terminal vapour recovery system via the vapour arm.
13.2.11
Description of the different components of the loading arm follows in other sections of this specification.
13.2.12
The design and construction of the Loading Arms shall generally be in accordance with the specifications listed in Section 4.
13.3.
Materials
13.3.1
Materials for construction proposed by vendor shall be suitable for the operating and design conditions specified in the Data Sheets and Specifications, Codes and Standards defined in Section 4.
13.3.2
For welding purpose the carbon contents of the carbon and carbon/manganese steels for structural/mechanical loading arm components shall not be higher than 0.23% unless otherwise specified; the carbon equivalent according to:
Ceq C 13.3.3
Mn Cr Mo V Cu Ni 6 5 15
shall not be higher than 0.45
Swivel joints and fluid carrying parts of couplings shall be constructed of materials which do not cause galvanic action with the pipe used in the arm.
Page 50
13.4.
Swivel joints
13.4.1
All swivels and structural bearings, where lubrication is required, shall be capable of being lubricated without dismantling and shall be designed to prevent over-pressurization from lubrication. Cryogenic swivel joints shall be equipped with connections to permit purging with nitrogen. During operation of the arms the cryogenic product swivel joints shall be pressurised with nitrogen.
13.4.2
Except for the outboard joint (triple) swivel, all swivel joint assemblies shall have devices to permit re-packing without dismantling major sections of arms.
13.4.3
The swivel joints shall have ball (minimum two races) or roller bearings. The sealing system of cryogenic swivel joint shall have at least two main seals and one external seal.
13.4.4
The outboard joint (triple) swivel, including the emergency system, hydraulic Quick Connect Disconnect Coupling (QCDC) etc., shall be balanced so that the outboard flange remains in the vertical plane for all arm attitudes.
13.4.5
All swivels in the loading arm shall be designed so that external water cannot penetrate and freeze in the joints between rotating parts of the swivel.
13.4.6
Swivels shall permit temporary vacuum conditions and reseat properly afterwards.
13.4.7
All swivel joint design shall be such that non-Destructive Examination (NDE) of the ball races is possible. Hardness of ball or roller raceways must be over 40HRc.
13.4.8
Heat treatment or surface treatment of the ball races is not acceptable.
13.5.
Quick-connect/disconnect cargo coupling (QCDC)
13.5.1
A hydraulically operated Quick Connect/Disconnect Cargo Coupling shall be provided for each arm to facilitate the loading arm connect/disconnect operations.
13.5.2
Aligning and centering devices shall be furnished for each diameter of flanges to which the coupling must connect.
13.5.3
Vendor to provide arm connection flange as specified in the data sheet.
13.5.4
Lubrication of all moving parts shall be possible without dismantling the coupling.
13.5.5
The coupler mechanism shall ensure that the coupling clamps operate simultaneously and evenly distributed forces are applied to the ships manifold flange during the connection and disconnection operation, thus avoiding overstressing of any part of the flange. This shall be achieved by means of spring support on each hook assembly.
13.5.6
The coupler shall incorporate an overcenter mechanical lock. Couplers relying on friction locks such as cams for primary or secondary locks will not be acceptable.
13.5.7
A single hydraulic double acting cylinder shall operate all the coupler clamps.
13.5.8
The hydraulic cylinder and primary moving parts of the coupler shall be insulated from the fluid carrying body so as to avoid icing of these components.
Page 51 13.5.9
The coupler shall be capable of releasing from the ships manifold flange under maximum unbalanced loads induced by the loading arm and when clamp tips are covered with 25mm solid ice.
13.5.10
The coupler shall be equipped with a blanking plate designed for an internal nitrogen gas pressure of 0.7MPa.g. The blanking plate shall remain attached to the coupler when the coupler is opened accidentally. A suitable lifting davit shall be fitted to the loading arm to support the blanking plate when removed from the coupler.
13.5.11
The coupler design shall include for external centering guides which align on the outside diameter of the ships manifold flange.
13.5.12
It shall be possible to manually disconnect the coupler in the event of electric/hydraulic power failure of the loading arm power pack by means of a portable hand pump.
13.5.13
The strength of coupler shall be based on the requirement of OCIMF.
13.5.14
The coupler shall be designed in order that the interface connection is leak free during full cargo transfer and during cool-down of the loading arm.
13.5.15
As the quick connect/disconnect coupler is utilized in combination with the double ball valve/emergency release coupler then it shall be supplied with the device which disconnect automatically the hydraulic lines to the coupler following an emergency release. There shall be no leakage of hydraulic oil on release.
13.6.
Emergency release system (ERS)
13.6.1
The ERS shall be initiated in the following ways: Automatically
:
by over-extension angle signals (via proximity switches)
Manually
:
by push-buttons at the control station and other defined shore location under healthy power condition.
Manually
:
during total power failure by pulling knob/lever at ERS solenoid. No signal to logic will then be given.
13.6.2
The entire ERS shall be hydraulically operated with separate solenoid valves for the emergency release coupling and operation of ball valves, unless the ball valves and ERC are activated by one cylinder.
13.6.3
The two ball valves shall be mechanically interlocked to guarantee simultaneous closure. The interlocking device shall easily disconnect when the arm is uncoupled at emergency release conditions.
13.6.4
Facilities shall be provided, either hydraulic or manual, for re-opening of the valves after emergency closure. Such facilities, when hydraulically operated, shall be designed as to allow opening of the valves only after the respective ERS components have been re-connected.
13.6.5
Closure time of the ball valves shall lie in the range of 3-40 seconds and be adjustable with tamper-proof flow regulators in the hydraulic system for each valve.
13.6.6
The response time of the electric/hydraulic circuit between initiation of an ESD and the start of the ERS valves closure shall be less than 1 second.
Page 52 13.6.7
The control of the ERS shall guarantee ball valve closure prior to emergency release. The emergency release coupling shall have been disconnected automatically within 2 seconds maximum upon completion of valve closure, during ESD-2. (Refer to Section 13.11.7.)
13.6.8
The emergency coupling shall easily disconnect at the minimum design temperature (frost) and maximum forces exerted by the ship on the outboard arm.
13.6.9
The arrangement of the ERS assembly near the outboard end of the swivel shall be such that parts of the ERS assembly remaining on board of the ship after emergency release will not fall on ship's deck or manifold service platform.
13.6.10
The hydraulic cylinder operating the emergency release coupling shall be of the double acting type. Independent operation of double ball valves and emergency release coupler shall be provided by means of this separable double acting hydraulic actuator.
13.6.11
The emergency release coupler shall be a fully spring energized design to ensure disconnection with a solid ice build up of 25mm minimum around the clamps of the emergency release coupler. The release shall be possible with or without full operating pressure and maximum external design forces.
13.6.12
The emergency release coupler shall incorporate separate clamps to suitable. The clamps shall not fully enclose the flanges.
13.6.13
The emergency release coupler shall incorporate an overcenter mechanical lock. Devices that require tightening of nuts or equivalent item are not acceptable.
13.6.14
The strength of ERS shall be based on the requirements of OCIMF.
13.6.15
The operation of double ball valves & emergency release coupler shall be hydraulically interlocked to prevent disconnection of the emergency release coupler before the ball valves are fully closed. The interlock valve shall meet in full the OCIMF specification.
13.6.16
It shall be possible to fully test the hydraulics of the emergency release system including the actuators without disconnection of the emergency release coupler or dismounting of hydraulic actuators.
13.6.17
The double ball valves shall be provided with an alignment/lifting and reassembly bolting system to assist in the reassembly of the equipment following an emergency release.
13.6.18
Fire Safe Testing of ERS components
13.6.19
1)
The ERS valves and components located around the triple swivel joints such as flexible hoses, cylinders, etc. shall be fireproof so that they remain fully operable when exposed to fire, and shall comply with the requirements of ISO 10497.
2)
Vendor shall submit full details and specification of recommended fire proofing with his bid.
At the swivel between the ball valve and the presentation flange a facility shall be provided to keep the ship side ball valve in an upright position following an emergency decoupling. However, sufficient rotation freedom shall be given to align the loading arm presentation flange and the ship's manifold flange to allow for ships motion. The design of the swivel shall absorb the shock load on the ships manifolds due to the rotation of the bottom part of the ERS unit after a disconnection of the ERS.
Page 53
13.7.
Accessories
13.7.1
Storm locks Storm locks shall be provided for all loading arms designed for the worst wind conditions. The locking mechanism shall be mechanical for inboard arm, mechanical or hydraulic for outboard arm. Detail shall be as per OCIMF, 3rd, 1999. When the arm parking lock is not properly engaged a light shall flash at the control panel.
13.7.2
Support jacks Permanently attached adjustable jack, with two legs, shall be provided for all loading arms to reduce the stress on tanker manifolds.
13.7.3
13.7.4
Stray current protectors 1)
An insulating flange or an integral joint shall be inserted near the triple swivel assembly of the arms to electrically isolate the ship from the loading arms.
2)
The insulating resistance and other details shall be in accordance with OCIMF, 3rd, 1999.
3)
The insulation flange/joint shall be designed to a strength safety factor of at least two.
Dummy manifold Vendor shall provide movable cradle type dummy manifold skid. It shall be equipped with swing casters and retractable feet of copper alloy. Support jacks of triple assembly shall be able to be rested on the cradle skid. Triple assembly shall be fixed by dummy flange and turnbuckles on the cradle skid. All screws, turnbuckles and connecting hardware shall be stainless steel.
13.7.5
Spotting line indicator In front of each loading arm or bank of loading arms a stainless steel instruction plate indicating the spotting centre line shall be provided by Vendor on the jetty head.
13.8.
Hydraulic power system
13.8.1
The hydraulic system shall be designed and sized in accordance with Section 9.1, OCIMF, 3rd with following additional requirement: 1)
Following ERS operation, the released arms shall be retracted inside berthing line
13.8.2
Arm manoeuvring shall be possible in two operating speed modes. The “Fast Speed” shall be 0.15m/s, and the ”Slow Speed“ shall be half the “Fast Speed”.
13.8.3
Separate flow control valves shall be provided to control: -
“Fast" operating speed “Slow" operating speed Return speed after ERS disconnection
13.8.4
Each hydraulic circuit, or section which can be isolated, shall have relief valves of sufficient size to protect the loading arms, including the hydraulic system, from damage during normal operation and emergency release or due to operator error, malfunctioning, and hydraulic or electric power failure.
13.8.5
Hydraulically powered arms shall have an independent flow control valve installed in each cylinder line, each of which shall have a lockable tamperproof cover.
Page 54 13.8.6
Adequate main line pressure protection shall be provided.
13.8.7
Pressure gauges with surge dampeners shall be provided in circuits having different pressures.
13.8.8
Hydraulic power pack
13.8.9
13.8.10
1)
A 25 micron filter with replaceable cartridge shall be provided in the discharge of the pump and in the return line to the reservoir. Strainers capable of removing particles over 150 microns shall be installed in the suction line to the pump.
2)
The power pack shall be supplied with duplicate pump sets. Each pump shall be supplied complete with a motor. The pump sets shall operate as 1 duty/1 standby.
3)
To avoid moisture entering the hydraulic circuit the hydraulic reservoir shall be provided with a diaphragm to accommodate differing oil levels without allowing the ingress of air.
4)
Hydraulics power pack pumps shall be designed and constructed for a minimum service life of 50,000 hours.
Hydraulic piping 1)
Hydraulic lines, including tube and fittings, shall be 316 stainless steel. Minimum bore shall be 10 mm. Suitable flexible hose may be used as required to provide articulation or electrical insulation. Hoses shall be of smooth bore. Oil reservoirs shall be kept to a minimum to reduce the number of places of potential leaks.
2)
The hydraulic piping system shall be assembled by means of compression joints. Welding or threaded joint of pipes will not be allowed in the hydraulic system.
3)
The hydraulic tubing shall be clamped and fitted with synthetic sleeves avoiding SS/CS contact.
Accumulators 1)
For each loading arm an accumulator shall be provided to operate the ERS and QCDC, and shall be located as close as practical to the ball valves and coupling. This accumulator shall be floating on the system and the hold up time of the pressure required to operate the ERS shall be at least 3 hours, when both AC + DC power failure occur.
2)
A separate “manoeuvring" accumulator shall be provided to manoeuvre all arms back to stored position during an AC + DC power failure under all operating conditions. The retention time of pressure required to perform above activities shall be at least 3 hours.
13.8.11
For manoeuvring of the arms cylinders with double rod shall be supplied. Cylinder rod shall be hard chromized stainless steel rods.
13.8.12
The hydraulic directional valves shall be manually operable as well as solenoid operable.
13.8.13
For flushing and venting purposes the hydraulic circuit shall be provided with sufficient drains, vents and temporary by-passes.
13.8.14
To avoid ingress of air in hydraulic circuit, which will affect the response time of the ERS, a pressure control valve shall be installed in the return line to the tank in order to keep the system at all times pressurised to a minimum pressure of 0.3 MPa.g.
Page 55
13.9.
Operating control and emergency system
13.9.1
The control system for the hydraulic manoeuvring operations of the arm may be to manufacturer's standards, subject to Purchaser’s approval.
13.9.2
The control power for the loading arms shall be electro/hydraulic.
13.9.3
Controls for manoeuvring shall be through either the loading arms control panel located in the unloading arm control house (UACH) or through a pendant box (Local control) or through a wireless control (as a subsidiary). The control panel, pendant box and wireless pendant box shall not be operable at the same time. The selector switch for control panel or pendant box or wireless pendant box shall be located at the control panel.
13.9.4
The loading arms control panel (pressurized explosion-proof type) shall contain the following: -
Power to control on/off, key-locked. Hydraulic pump(s) on/off. Loading arm selector switch. Control panel/pendant selector switch. Loading arm manoeuvring controls, including QCDC activation. Slow/fast manoeuvring selector switch. ESD-1 (ESD 111.01) push button, fitted under a red flap-over cover. (I-4.1 Unloading shutdown) ESD-2 (ESD 111.06) push button, fitted under a red flap-over cover. (I-4.2 Marine shutdown) Reset ESD 1 & 2 (111.01 & 111.06) Override selector, key locked. Alarm lamps. Terminal block For ESD (to jetty shutdown system provided by others) For jetty shutdown signal (from jetty shutdown system provided by others) For DCS/ESD For ship valve/pump stop signal with flexible cable and plug Pressure gauge, filter & regulator at panel purge supply line Relay for jetty side solenoid valve Emergency shutdown switch with key-locked (ESD 111.03 I-1 Jetty shutdown) ESD from ship carry on box (ESD 111.07) via ship/shore communication system to unloading shutdown Minimum interface requirements shall be as per Unloading Arm Schematic Diagram and Signal list in Attachment #1.
13.9.5
Electrical contact for ship LNG pump interlocking shall provide electrical signal for immediate trip of cargo pumps on release of ESD system from shore side. The electrical contact shall be provided with the relay installed in local control panel. The working contact of the relay would be wired to two terminals. A flexible cable of flame retardant sheathed 4 x 2 mm2 with shielding and armoured will be connected to these terminals. These internal circuit and terminals will be segregated physically to the others in the local control panel. The free end of this cable is to be equipped with a plug or socket for ship connection. Type and model of plug or socket shall be approved by Purchaser. Electrical contact shall be open when one of the following tripping occurred. First stage overreach of arms ESD switches Jetty shutdown signal (provided by others) Minimum interface requirements shall be as per Unloading Arm Schematic Diagram and Signal list in Attachment #1.
Page 56 13.9.6
The pendant “Carry On” box (local control) and wireless control contains the following controls: -
13.9.7
Each loading arm shall be provided with an Emergency Release System (ERS). The ERS shall consist of: -
13.9.8
Loading arm manoeuvring controls including QCDC activation Slow/fast manoeuvring selection Hydraulic pump on/off Loading arm selector switch
an emergency release coupling two ball valves, one positioned immediately upstream and one positioned immediately downstream of the emergency release coupling, closing prior to emergency release.
The emergency release system (ERS) control conditions will be as follows: 1)
Excess Angle alarm An audio-visual alarm (ESD-1 condition (refer to Section 13.11.7)) shall at all times be initiated when the loading arm crosses its working range limit as specified in the data sheet or working range diagram. This should occur at the jetty control panel and also be transmitted as an alarm to the Central Control Room.
2)
Automatic Emergency Release The ERS of each individual arm shall at all times be automatically activated when the arm travels beyond its working range limit (ESD-2 condition (refer to Section 13.11.7)) reduced with a safety margin as specified in the data sheet or working range diagram. This releasing signal shall be incorporated also with jetty shutdown signal provided by others.
3)
Manual Mechanical Emergency Release A manual emergency release for each individual arm shall be possible in case of vital power failure by pulling/pushing the emergency knob or lever. The emergency release knob or lever shall be protected against accidental operation (e.g. by safety pin or cover). After pulling of the emergency knob or lever the hydraulic valve shall be detained in that position so that operator does not need to hold knob until the arm has been disconnected.
13.9.9
ERS operation 1)
The solenoid operated hydraulic directional valves for the operation of ball valves and emergency coupling shall be leak proof.
2)
When arm is parked and locked by its storm lock the hydraulic power to this arm shall be blocked and the ERS system shall be de-activated.
3)
At the parking lock a proximity switch shall be incorporated which shall cancel any signal which will activate the ERS for that particular arm when the arm is properly parked.
4)
In case of emergency release the loading arms will be automatically retracted towards their stored position. The full retraction must be drived by computed movements using PMS, to achieve a complete and clean disconnection and retraction whatever initial position of arms connected to ship is (inside working range). No risk of clash with the overall structure of the ship and/or the jetty, including fendering installation, must exist.
5)
The outboard arm's hydraulic power system shall automatically retract the outboard arm hydraulically inside berthing line during the release of the emergency coupling. The motion of the outboard arm must be referred to the riser independently from the inboard arm motion. In emergency disconnection condition the outboard arm angle position is relative to the riser axis.
6)
The inboard arm hydraulic power system shall include an adjustable flow regulator or other damping device in order to limit the return velocity of the inboard arm under
Page 57 released conditions. The inboard arm shall be controlled in such a way that the complete arm will be returned towards shore berthing line. 7)
During the release of the emergency coupling the hydraulic power system shall automatically block the slewing movement of the arm due to the wind load and consequently prevent collision of the disconnected arms.
8)
An override in the hydraulic systems for outboard arm and slewing drives shall be provided to limit possible excessive forces exerted by the ship on the release coupling during release.
9)
The system shall be so designed as to allow provision to avoid the accidental operation of the emergency release system unless the loading arm is connected to a tanker manifold flange.
13.10. General electrical, Instrumentation and control requirements 13.10.1
For electrical and instrumentation requirements, see attached P & ID and Instrument Specifications.
13.10.2
Conduit hub size and type for terminal boxes shall be determined by Purchaser and informed to Vendor later. No cost & delivery impact shall be allowed in this matter.
13.10.3
Notebook for the program loader shall be supplied with the PLC made by Allen Bradley, SIEMENS or equivalent. The notebook shall be industrialized type with, as a minimum, Pentium 4, 1.86GHz CPU, 2GB (1024MB) DDR2 SDRAM, 2BM L2 cash, 80GB hard disk, 15” TFT LCD, Li-Ion battery, DVD/CD multi drive, 128MB Video, optical USB mouse, integrated 56kbps modem & LAN and Korean or English based OS. Vendor shall supply source program for PLC programming. PLC memory shall be EPROM type, so that memory shall not be lost in case of power failure, and Power supply and processing cards of PLC shall be redundant.
13.10.4
All control panels and cabinets for installation on exposed area shall be weather proof type, suitable for outdoor hazardous area installation, and shall be made of stainless steel.
13.10.5
Control panel shall be in accordance with attached Instrument Package Specification and General Panel and Wiring Specification.
13.11. Instrumentation and control requirements 13.11.1
All ERS and manoeuvring instruments shall be designed to operate on a DC supply. Full details of the connected load including power distribution board shall be given by the Vendor.
13.11.2
The electric power supply to the ERS instruments will be from an independent uninterrupted power supply (DC battery backed-up). D.C power switches on or momentary power interruption shall not lead to ERS activation, unless ESD-2 has prevailed.
13.11.3
The loading arm Vendor shall list all necessary controls and functions for the safe operation of the arms. All instrument and control components supplied by the Vendor shall be selected from the approved instrument Vendors list.
13.11.4
Each loading arm shall have a dedicated set of solenoid operated valves to operate the ERS.
13.11.5
In order to achieve the desired level of operational security each set of solenoid operated valves, per arm, shall have only one common circuit protection. The failure of this circuit protection shall also initiate an alarm and shall give a potential free contact for connection to other systems. This circuit protection shall be located at the jetty control panel.
Page 58 13.11.6
All solenoid operated valves, forming part of the ERS shall be spring loaded and fail safe.
13.11.7
The ESD control incorporated in the UACP must be repeated in the related system. There will be a two stage alarm system provided as follows: 1)
ESD-1: A first stage overreach alarm system with visual and audible alarm. This shall initiate the closure of ERS ball valves. A pair of voltage free change over contacts shall be provided for closing the jetty side isolating valves and stopping the Unloading Pumps.
2)
ESD-2: A second stage overreach audible and visual alarm shall be actuated prior to the loading arm reaching its design envelope boundary and shall initiate the closure of the ERS ball valves and stopping the ship Unloading Pumps, (if not already actioned during ESD-1) using an independent circuit to the first stage, followed by emergency release coupling actuation.
The objective is to start closing the valves slowly during ESD-1 to avoid surges in the pipe line. If however the valves are not completely shut by the time ESD-2 occurs which indicates that the arm has moved further outside its operating envelope, then the actuator shall take over and shut the valves faster, to ensure effective valve closure before the ERS coupling is released. 13.11.8
Terminals shall be provided to receive signals from the ship carry-on box to activate the ERS.
13.11.9
The low pressure nitrogen back-up signals shall be used to prevent the start-up of the hydraulic pump(s) until an adequate N2 accumulator pre-charge pressure has been established.
13.11.10 All instruments and junction boxes for these instruments shall be safely and permanently accessible from grade, ladder or platform. 13.11.11 Enclosure of all junction boxes shall be suitable for hazardous area classification Zone 1. 13.11.12 Position monitoring system shall be provided to monitor the motion of connected arms. The system shall be capable of self-checking prior to any operation of the arms. Pre-alarms shall be set at the limit of working and drift envelope. ERC alarm shall vary according to the vessel drift speed.
13.12. Electrical requirements 13.12.1
Electrical Equipment shall meet the requirements of attached Electrical Specification.
13.12.2
Equipment used in the loading arms shall comply with the Specifications, Codes and Standards listed in Section 4.
13.12.3
Electrical equipment supplied by the vendor shall be suitable for Zone 1 hazardous area classification.
13.12.4
For the power pack pump sets each motor shall obtain a separate feeder from the power distribution board (distribution board supplied by others).
13.12.5
Motor circuits shall be provided with fuses, contactors, thermal overloads relay (manual reset) with single phase protection and ampere meter (one phase only) in accordance with the applicable specification.
13.12.6
Local control units and isolating switches shall be furnished with padlock facilities in the “OFF" position.
13.12.7
Arm control switches in local control unit shall be momentary contact type.
Page 59 13.12.8
All electrical equipment shall be protected against direct exposure to sunlight. Temperature to be considered as specified in Section 3.2.3.
13.13. Nameplates 13.13.1
Each loading arm shall be furnished with a nameplate stating the following: -
Order number Item number Service (product) Working temperature Test pressure Year of construction
13.13.2
Control components of the loading arms control panel and pendant box shall be provided with function descriptive corrosion resistant nameplates.
13.13.3
All components of the hydraulic system shall be provided with corrosion resistant tag numbers or function descriptive nameplates.
13.14. Painting 13.14.1
The loading arms and ancillaries shall be delivered after surface preparation, priming and finish coating at the Vendor's works in accordance with the attached Purchaser’s standard. Specially, Vendor shall recommend the finish coating colour for LNG unloading arms / Vapour return arm, and submit the detail painting specification for Purchaser’s approval.
13.14.2
Subject to Purchaser’s approval, and compliance with applicable specifications, equipment may be manufacturers standard for the duty and conditions. However, all equipment whether with protective coating or not, supplied under this specification must be resistant to the salty and corrosive atmosphere. Details of any such proposed alternatives shall be submitted by vendor in his Bid.
13.14.3
Stainless steel parts (notably the hydraulic oil tubing) shall be protected from the effects of chlorides in the atmosphere. Vendor is to advise proposed protection of the external surfaces and to consider plastic coated material with his Bid.
13.15. Noise The noise limit is specified in Section 3.2.2 and attached Equipment Noise Data Sheet. Where standard equipment exceeds the required noise levels, Vendor shall take measures to reduce the noise levels to meet the specified limits. Typical measures may be: selection of alternative designs uni-directional, aerofoil section electric motor cooling fans low noise trim on control valves sound insulation on noisy piping systems, and direct lagging of certain equipment. inlet and discharge silencers acoustic enclosures The design and integration of any acoustic device shall not impair the operation of the equipment and will remain within the responsibility of the Vendor The noise level shall be verified by noise test. Noise test procedure shall be approved by Purchaser prior to test. Test procedure shall be based on international standard specified in Section 4.
Page 60
13.16. Material 13.16.1
General All material shall be specified by reference to the ASTM code. In case non-ASTM materials are used, the equivalent ASTM code shall be shown on all relevant documents and drawings. Unless otherwise specified, material of construction for all equipment shall be established on the basis of minimum operating temperatures and shall be, as minimum: Minimum operating temperature above –28.9 oC -45.6 ~ -28.9 oC -198 ~ -45.6 oC
Material carbon steel impact tested carbon steel 300 series stainless steel 9% nickel steel aluminum or aluminum alloy
Corrosion Allowance 3mm 3mm zero 1.2 mm (zero if prime coated) zero
Minimum operating temperature shall be the lowest metal temperature expected during normal operation, start-up, upsets or sudden depressurization, etc. All instrument tubing shall be 316 stainless steel. All carbon steel bolts/nuts (including anchor bolts) and connecting hardware shall be hot dip galvanized. Material specification for piping shall conform to the attached Purchaser’s Piping Material Specification. 13.16.2
Stainless steel Acceptable grades of austenitic stainless steel are 304, 304L, 316, 316L, 317, 317L, 321, 347 and 348. Only 304L or 316L grades of austenitic stainless steel are acceptable for cryogenic parts. Unless approved by Purchaser. Molten zinc causes inter-granular cracking in austenitic stainless steel under high temperature and stress. Hence, welding of galvanized or zinc coated components, or parts containing zinc within conducting distance of the weld, to stainless steel is prohibited. Also, metallic zinc containing paints shall not be used for stainless steel protection. Cold bended austenitic stainless steel U-tubes for heat exchangers shall be heat treated. For heat treated tubes, only low carbon grades 304L and 316L, or stabilized grades 321 or 347 shall be used. Where Super Duplex SS is specified, the only acceptable grades are UNS numbers S32550, S32750 and S32760. Where duplex SS is specified, the only acceptable grades are UNS numbers S31803 and S32205. When 12% Cr SS is specified, only Type 405 SS or Type 410S SS shall be acceptable. All stainless steel surfaces shall be pickled and passivated.
13.16.3
Low temperature materials Austenitic stainless steel castings used for pressure components of valves, pumps and compressors in cryogenic service (below minus 101 oC) shall be impact tested at the minimum design temperature or lower. Each batch/lot and heat of austenitic stainless steel welding (filler) material for services below minus 101 oC shall be pre-qualified at the minimum design temperature or lower. Aluminium alloys such as 5083-0, 8454-0, 5456-0 and 6061-T6 that are approved by the ASME Pressure Vessel Code are acceptable for LNG service. Clad or lined materials shall not be used for cryogenic service.
Page 61 13.17. Welding requirements 13.17.1
WPS and PQR requirement Welding procedures for gas system piping and pressure parts shall be submitted for Purchaser’s approval prior to welding work. They shall accompany by weld maps correlating welds to the appropriate WPS and PQR. The joint design, including root opening, shall be clearly shown in the WPS and PQR. Tolerances for all dimensions shall be included. A separate WPS is required for each group of base metals which require a different AWS classification. Weld repair procedure shall be subject to Purchaser’s approval prior to repair work. All pressure parts weld repair shall be checked by radiograph. Weld repair record shall be submitted to Purchaser’s or 3rd party inspector for acceptance.
13.17.2
Filler metals Filler metals and fluxes shall be completely specified in the WPS and PQR by the use of applicable ASME/AWS specification Use of non AWS filler metals and fluxes shall be subject to Purchaser’s advanced written approval. The product’s relevant physical and mechanical properties and chemical analysis shall be submitted to Purchaser.
13.17.3
Preheat & heat treatment The preheat recommendations of Appendix R of ASME Section VIII, Division 1 shall be mandatory for all carbon and alloy steels. When preheat is a requirement for welding, it is also a requirement for back gouging, electric arc cutting, and flame cutting. If required, postweld heat treatment cycles, method of heat treatment, heating rate, holding temperature (maximum and minimum), holding time, and cooling rate shall be defined in WPS and PQR.
13.17.4
Welding process Welding method not listed in this section shall be subject to the Purchaser’s approval.
Submerged arc welding Welding procedure shall be re-qualified whenever the welding flux or wire is changed from one manufacturer to another, or from one manufacturer’s grade to another grade from the same manufacturer. Alloy, semi-active, active flux or reground fused flux shall not be used. Manual submerged arc welding is not permitted on pressure containing parts. Lincoln 860 flux shall not be used for impact tested weldments with the design temperature below minus 29 oC
Gas tungsten arc (GTAW) and plasma arc (PAW) welding Inert backing gas is required for all materials except carbon steel, 9% nickel steel. For GTAW, SFA 5.18, ER70S-2 is the preferred welding wire for carbon steel.
Shield metal arc welding (SMAW) Electrodes used for the SMAW process shall be of the low hydrogen type.
Page 62 The SMAW shall not be used for root passes unless the backside of the root is ground or back gouged to sound metal and back welded. E6010 or E6011 electrodes may be used for welding the root pass and the subsequent pass in all carbon steel buttwelds, except (1) buttwelds in pipe 2” and smaller and (2) for welding galvanized structural attachment to carbon steel pressure containing components. The SMAW process shall not be used for root pass application in single welded joints of stainless steel or nickel alloys.
Gas metal arc welding (GMAW) Inert backing gas is required for all materials except carbon steel, 9% nickel steel, and similar materials unless the joint is ground or back gouged to sound metal and back welded. 13.17.5
Welding material Stainless steel When “H grade” materials are specified, high carbon electrode, with 0.040% minimum carbon shall be used. The interpass temperature for austenitic stainless steel shall not be greater than 177 oC.
Nickel alloys & 9% nickel steel The interpass temperature for nickel alloys shall not be greater than 177 oC.
Low temperature service To ensure impact properties of austenitic stainless steel welds with design temperature of minus 101 oC or lower, each heat, lot, or batch of filler material and filler material/flux combination shall be “pre-use” impact tested, except following filler materials:
ENiCrFe-2 and E16-8-2-15 or 16 for SMAW
ERNiCr-3 and ER16-8-2 for SAW, GTAW, GMAW, or PAW
ER308, ER308L, ER316, or ER316L for GTAW
The report of “pre-use” impact test shall be attached to the applicable PQR.
14. Attachments Attachment #1. Data Sheets for Marine Loading Arms Attachment #2. P & ID and Layout Drawings Attachment #3. Related Technical Specifications Attachment #4. Purchaser’s Standard Forms
Att #1 - 1
Attachment #1.
Data Sheets for Marine Loading Arms
CONTENTS
1.
Arm design details .................................................................................................................... 2
2.
Product and operational data.................................................................................................... 2
3.
Ship detail and motions............................................................................................................. 3
4.
Manifold details ......................................................................................................................... 3
5.
Berth details .............................................................................................................................. 4
6.
Environmental data ................................................................................................................... 6
7.
Specific requirements................................................................................................................ 6
8.
Envelope details........................................................................................................................ 7
9.
Central control requirement ...................................................................................................... 8
10. Pendant control requirement .................................................................................................... 8 11. Location of pendant control ...................................................................................................... 8 12. Material specification ................................................................................................................ 8 13. Design considerations:.............................................................................................................. 9 14. Notes:...................................................................................................................................... 10 15. LNG Carrier Data .....................................................................................................................11 16. Unloading Arm Schematic Diagram........................................................................................ 15 17. Unloading Arm Signal ............................................................................................................. 16
Att #1 - 2 1.
Arm design details
Berth No.
Arm No.
Arm Dia Inch
2 2
LA-103A LA-103B
16x20 16x20
2 2
LA-103C LA-104
16x20 16x20
2.
Cargo to be Transferred
Single
Arm Operation Combination of Simultaneous Operation
Remark
LNG liquid LNG vapour & LNG liquid LNG liquid LNG vapour
Product and operational data
Berth No.
Arm No.
2
LA-103A
2
LA-103B
2
LA-103C
2
LA-104
Cargo to be transferred
LNG liquid (ship to shore) LNG vapour return and LNG liquid (ship to shore) LNG liquid (ship to shore) LNG vapour return and LNG vapour (ship to shore) N2 (ship to shore)
Density (kg/m3)
Cargo temp, (oC)
Viscosity cSt at oC
Oper. press. (kPa.g)
Des. press. (MPa.g)
Allow. press. drop at design flow (kPa)
Design flow rate (m3/h)
Min. *1)
Max
434 ~ 480
-162
+65
0.145
447
1.77
60
5,000
1.63 ~ 1.86 434 ~ 480
-140
+65
0.004
12.75
0.35
2
15,000
-162
+65
0.145
447
1.77
60
5,000
434 ~ 480
-162
+65
0.145
447
1.77
60
5,000
1.63 ~ 1.86 0.74
-140
+65
0.004
12.75
0.35
2
15,000
Amb.
+65
0.012
8.0
0.35
2
6,800 ~ 10,800
1.14
Amb.
+65
0.019
8.0
0.35
2
4,400 ~ 7,000
Notes : *1) Minimum design temperature : -170oC except as noted.
Att #1 - 3 3.
Ship detail and motions [Unit : m]
TANKER (DWT)
Design Case
Freeboard at ship’s side a. Laden 13.5 b. Unladen 17.8 c. Rail height 1.4 m d. Surge fore 4.0 m e. Surge after 4.0 m f. Sway 4.6 m g. Positive Heave at manifold h. Negative i. List at manifold j. min. 4.1 m Height of manifold above deck k. max. 6.0 m Manifold setback l. min. 3.15 m m max. 3.5 m n. Basic allowable stress of tanker manifold o. Ship’s manifold spacing See Section 15 Notes: Fore and aft surge and sway occur simultaneously. For tanker data, see Section 15 of this data sheet. Arm envelope shall be designed to cover the Design case of above table as well as specific ship data in Section 15 of this data sheet.
Manifold details Cargo to be transferred dia. In in. /AISI rating wall thickness / material
LA-104
Cargo to be transferred dia. In in. /AISI rating wall thickness / material
AL-103B
LA-103A
SHIP TO SHORE LNG Liquid
LA-104 LNG vapour
Vapor return
Cargo to be transferred dia. In in. /AISI rating wall thickness / material
LNG liquid
Vapor return
Cargo to be transferred dia. In in. /AISI rating wall thickness / material
LNG liquid
Cargo to be transferred dia. In in. /AISI rating wall thickness / material
Notes:
SHORE TO SHIP
See Fig. 1 & 3.
See Section 15 of this data sheet for tanker manifold arrangement.
LA-104
SHORE TO SHIP Bow of tankeer
LA-103C
stern of tankeer
Arm Designation
4.
Att #1 - 4 5. a. b. c. d. e. f. g. h. i.
Berth details Distance top of jetty to lowest low water (LLW) Distance jetty face to berthing line (min/max.) Distance jetty face to center line of risers (min/max.) Distance between center line of risers (min/max.) Maximum space available (length) Maximum space available (width) Max. height of obstructions above jetty dock within e and f Maximum allowable unit load on jetty Electric supply
Notes: See Fig. 1 & 2. *1) See Unloading Arm Layout Drawing in Attachment #2.
7.5 4.7 3.5 3.0 / 4.0 *1) *1) *1)
m m m m m m m kN AC440V 3ph 60Hz
Att #1 - 5
``
Att #1 - 6 6.
Environmental data
Maximum wind velocities at 10m above LLW for which the arm should be designed are : - Stored - Manoeuvring / connected - Hydrostatic test / maintenance Earthquake loads (EL) to be considered while arm in stored position and connected attitude - Seismic zone factor, (Z) - Seismic acceleration - Site coefficient for soil characteristics (S) - Importance factor (I) Ambient temperature, min./max. Solar radiation temperature Thickness of ice build-up to be included in self weight (DL) and effect on wind load (WL) - Stored attitude - Manoeuvring / connected attitude Water levels
highest high water (HHW) Mean seal level lowest low water (LLW) Notes : For environmental data, see Section 3.2 of this specification.
7.
40 m/s 15 m/s Yes SSE 0.2g
-11.6 / 36.9 oC 65 oC
25 mm DL +2.212m DL +1.273m DL +0m
Specific requirements
Berth No. / Arm No. Operation Two speed manoeuvring ERS manufacturer & type ERS product valve closure time (seconds) ERS opening time (seconds) ERS product valves - Type - Diameter (inch) - Bore Mechanical interlock Hydraulic interlock QCDC QCDC operation QCDC valve - Operation - Type - Diameter (inch) - Bore Clamp operating time, minimum / maximum (seconds) Piggy back vapour return Flange rating, Jetty side / ship side Diameter (inch) Drives
Control system Vacuum breaker Purge system - Riser - Apex
Slewing Inboard arm Outboard arm Central control Portable
LA-103A/B/C
LA-104
Hydraulic Yes
3 ~ 40 (adjustable)
Ball 16” or 20” Full bore Yes Yes
16” or 20” Full bore
Yes Hydraulic No
No ANSI 300# / 150# 20” / 16” or 20”
Electro-hydraulic Electro-hydraulic Electro-hydraulic Yes Yes No
<-
Yes
Att #1 - 7 Berth No. / Arm No.
LA-103A/B/C
LA-104
Yes
Yes Yes Yes Yes
Yes (by N2) Yes
Yes
Yes
No 20
LA-103A/B/C
LA-104
DL + DL +
DL + DL +
- Manifold end Ladder and platforms Foundation bolts - Specified by Vendor - Supplied by Vendor Base plate template supplied by Vendor Standby electro-hydraulic pump Manual hydraulic pump Swivel purging Jack Lubrication - Grease specification - Cartridge - Local - Central - Other Maintenance dummy manifold Uninterrupted power supply by batteries Flushing connection - Size - Flange Stripping system Design life (years)
8.
Envelope details
Ref. Fig. 4, OCIMF. Berth No. / Arm No. Pre-alarm required a Pre-alarm (m) st b 1 stage alarm (m) c 2nd stage alarm (m) d Maximum reach (m) e Bottom limit operating envelope (m) *1) f Top limit operating envelope (m) *1) g Maximum slew, right surge (m) h Maximum slew, left surge (m) I 2nd stage alarm, slew right (m) j 2nd stage alarm, slew left (m) k 1st stage alarm, slew right (m) l 1st stage alarm, slew left (m) m Pre-alarm, slew right (m) n Pre-alarm, slew left (m) Maximum drift velocity, surge direction (m/s) Maximum drift velocity, sway direction (m/s)
*1) At least 1m allowance shall be provided for both top and bottom limits. Proposed operating envelope shall specify the maximum possible top and bottom limit.
Att #1 - 8 9.
Central control requirement
Power on/off (key locked) Hydraulic pump(s) on/off Arm selector switch Loading arm manoeuvring controls by joy stick Central control / pendant control switch Two speed manoeuvring control switch 1st stage alarm pushbutton, fitted under a red flap-over cover 2nd stage alarm pushbutton, fitted under a red flap-over cover Shutdown reset button Alarm lamps ERS valve closure switches
10.
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Pendant control requirement
Loading arm manoeuvring controls by joy stick QCDC on/off Two speed manoeuvring selection Hydraulic pump on/off Loading arm selector switches ERS valve closure switches
11.
Yes Yes Yes Yes Yes
Location of pendant control
Jetty (one / bank of arms) Triple swivel assembly (one / arm) Wired control Radio control
12.
Yes Yes Yes
Material specification ARM DESIGNATION
Service temperature range, in oC Material group and condition
LA-103A/B/C, LA-104 -170 to 0 ASTM *1) o
Plate, sheet, strip structural nonpressure retaining Pipe 1/2 ~ 16” including seamless Pipe 18” ~ 24” including welded Elbow butt weld Fittings butt weld Forgings, flanges, fittings Castings Valves body
C
KCV J max. Th
A240-304L A312-304L A358-304L class 1 A403-WP304L A182-F304L A351-CF8M A182-304L or A351-CF3 AISI 316 PTFE (virgin) A479-304 A320-B8Cl.2 A194 Gr.8MA according to ASTM A213-TP316 AISI 316 Stainless steel or glass fibre reinforce epoxy (GRE)
stem/trim/ball seats/seals Sections, bars for structural work Boltings for structural bolts work and flanges nuts Maximum carbon content Tube and fittings of hydraulic sys. Hydraulic reservoir Cabinets / consoles etc. Notes: *1) All parts in contact with LNG or cold vapour to be 18%Cr 8Ni stainless steel.
Att #1 - 9 13.
No. 1 2 3 4 5
6
7 8 9 10 11
Design considerations:
Items The design of each arm to be such that there is no clash with piping or adjacent structures The arms will be purged with nitrogen. Vendor to provide a valved connection with purge lines and flexible hoses to a coupling at the shore end of the loading arm. Articulated joints to be sealed to prevent icing in joints. Nitrogen purge connections to be provided on each joint. Each loading arm to be equipped with a powered emergency release coupling (PERC) which isolates the ship from the loading arm using two ball valves and breaks the connection between ship and shore automatically if the loading arm is over extended. Arms are to be equipped with two stage limit switch trip system with visible and audible alarms to prevent over extension of the arm. Connections (for LNG and NG) Jetty side 20” flanged ANSI B16.5 300# RF Ship side to be suitable for connection to LNG tanker manifolds with various flange types (ANSI, BS or DIN). The size range may be accommodated by the use of spool pieces. All unloading arms are to be designed to permit reverse flow. This will allow LNG transfer to a ship at reduced flow rate via the liquid arms and vapour from a ship to pass to the terminal vapour recovery system via the vapour arm. The design of loading arms shall be suitable in all aspects to accommodate the 33% and 20% short term emergency over-pressure allowed by ANSI B31.3. Hazardous area classification for the loading arms shall be zone 1. In the event of a power or hydraulic failure, the coupling shall remain securely fastened to the tanker manifold. Accumulators or other back up devices shall be provided to allow for manual coupling release in this event. “Carry on Box” or equivalent ship/shore link between ship ESD and terminal ESD systems to be provided.
Applicable to LA-103A/B/C
LA-104
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
Att #1 - 10 14.
No. 1 2 3
4
5 6
Notes:
Items Vendor shall supply pressure drop versus flow rate data for arms. Operating envelope to be developed based on LNG tanker dimensions and finalised jetty layout. LNG unloading arms to be compatible, so that a common electro-hydraulic power system can be utilized. The emergency release system (ERS), which is activated on emergency separation of the ship from the jetty, to be interlinked with the ERS of the LNG unloading arms to ensure release of all arms simultaneously. The shutdown system of all the arms to be compatible The vendor shall demonstrate by fault tree analysis that the fractional dead time of the overall loading arm shutdown system shall not exceed 0.001. For painting and protective coating requirement, refer to attached Purchaser’s specification.
Applicable to LA-103A/B/C
LA-104
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
Att #1 - 11 15.
LNG Carrier Data Foreign Ships
National Ships
Ship Golar Spirit
Hoegh Gandria
#1,2,4
#3
#5
#6,9,11,14
#7,13,15
#10,17
#8, 12, 16
HMM(#1,#4)
HS
SKS
HMM
HS
KL
SKS
General data - Operator
*1)
PRONAV
OCTC
TEEKAY
QCTC
Shipping - Ship name / delivery / trade
LWEWAIS
2008.08
(2007.09)
SKS (#2)
HN 1643/44
HN 1675
(2008.04)
(2008.08)
HN 1645
HN 1676
(2008.05)
(2008.10)
Golar Spirit
Hoegh Gandria
#1: Utopia /
Hanjin-
94.06 /
PyeongTaek 99.08 / Qatar Technopia /
Indonesia
/ 95.09 /
99.07/Qatar 99.07 / Oman 00.01 / Oman 00.01 / Qatar
Indonesia
#9:
SK Summit / #6:
#7: Hanjin-
#10:
#8: SK
Muscat /
K.Acacia /
Supreme /
#2: SK
Cosmopia /
#17:
#12: SK
Sovereign /
00.01/Qatar Sur / 00.01 /
K.Freesia /
Splendor /
00.06(?) /
00.03 /
Qatar
Oman
HN 1646
HN 1677
94.12 /
#11:
(2008.06)
(2008.11)
Malaysia
Aquapia /
#13: HanjinOman
00.03/Oman #15: Hanjin#4: Greenpia
#14:
RasLaffan /
#16: SK
/ 96.11 /
Oceanpia /
00.06(?) /
Stellar /
Malaysia
00.07(?) /
Qatar
00.12(?) /
Indonesia - Ship builder
Daewoo
Daewoo
Samsung
Samsung
Hyundai
Hanjin/
Daewoo
Qatar
Hyundai
Hanjin
Daewoo
Samsung
Daewoo - Ship type - Gross tonnage
Membrane
Membrane
Membrane
Membrane
MOSS
MOSS
MOSS
Membrane
Membrane
MOSS
Membrane
Membrane
Membrane
98,205
125,436
101,000
125,600
93,815
95,683
102,000
90,000
95,378
118,000
93,800
95,500
92,866
45,000
40,000
26,700
28,000
40,000
39,000
38.900
40,000
39,500
217,000
266,000
128,997
125,904
126,900
130,000
138,000
138,000
138,300
138,000
138,000
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.15
0.15
0.15
0.15
0.15
0.15
0.15
279
- Shaft horsepower (SHP)
45,000
40,000
- Cargo capacity (m3)
210,100
263,000
- Cargo design press.
0.442
0.442
0.141
0.132
(kg/cm2.g) - BOG gen. rate (%/day)
0.145
0.135
Ship size - LOA (m)
315
345
315
345
280
287.6
274
268
277
288
280
277
- LBP (m)
303
333
302
332
275
274
260
257
266
274
269
266
266
- Breadth (m)
50
55
50
53.8
44.6
43.4
47.2
43.0
43.4
48.2
43
43.4
42.6
- Depth (m)
27
27
27
27
25.0
25.0
26.5
27.0
26.0
26.5
26.2
26.0
26.0
- Draft, full (m)
12
12
12.5
12.2
11.42
11.5
10.95
11.0
11.3
11.25
11.3
11.3
11.3
9.2
10.05
9.7
10.31
9.6
10.08
- Draft, light (m) - Freeboard, full / light (m)
9.4
9.5
9.46
14.953 /
14.822 /
14.5 / 17.54
17.553
17.322
14.8 / 17.8 13.58 / 14.95 13.5 / 15.3 15.55 / 16.19
10.3 16 / 16.7
14.7 / 16.4 15.25 / 16.42
9.8
9.5
9.6
14.9 / 16.4
14.7 / 16.5
14.7 / 16.4
Att #1 - 12 Foreign Ships
National Ships
Ship Golar Spirit
Hoegh Gandria
#1,2,4
#3
#5
#6,9,11,14
#7,13,15
#10,17
#8, 12, 16
1.02
1.23
1.0
1.02
1.4
1.0
1.0
Ship’s rail - Height (m)
1.05
1.05
1.05
1.05
1500 x 150
1500 x 150
1400 x 165
1400 x 165
1400 x 145
1600 x 150
1700 x 155
1500 x 150
1700 x 150
1700 x 155
1700 x 155
10
10
10
10
10
8
8
8
8
8
8
8
8
8,700
9,500
7,200
8,700
8,473
6,333
3,200
4,861
6,036
7,160
6,163
6,037
6,690
560
730
600
600
-
-
350
340
476
350
375
476
594
-
-
-
-
50
25
Nil
Nil
Nil
Nil
Nil
Nil
Nil
4.8
4.8
4.8
4.8
4.95
6
4.198
4.1
4.8
4.198
5.3
4.8
4.8
3.5 / 3.15
3.5 / 3.15
3.5 / 3.15
3.5 / 3.15
-
-
3.15
3.5
3.15
3.15
3.5
3.15
3.15
20”
20”
20”
20”
16” x 4
16” x 4
16” x 4
16” x 4
16” x 4
16” x 4
16” x 4
16” x 4
16” x 4
Cargo pumps - Flow (m3/h) x head (m) - Q'ty (sets)
1100 x 140 1100 x 120
Cargo tanks - Bunker-C tank (m3) - Diesel tank (m3) - N2 tank (m3) Manifold flanges - Height above deck, max/min (m) - Distance to ship side, max/min(m) Manifold connection - LNG liquid - NG vapour
20”
20”
20”
20”
16” x 1
16” x 1
16” x 1
16” x 1
16” x 1
16” x 1
16” x 1
16” x 1
16” x 1
- Bunker-C
10”
10”
10”
10”
8” x 1
14” x 1
10” x 2
12” x 2
12” x 2
12” x 2
12” x 2
12” x 2
12” x 2
- Diesel
4”
4”
4”
4”
3” x 1
3” x 1
4” x 1
4” x 2
4” x 2
4” x 1
4” x 2
4” x 2
4” x 2
- LN2
3”
3”
3”
3”
2-1/2” x 1
1-1/2” x 1
Nil
3” x 1
3” x 1
Nil
3” x 1
3” x 1
3” x 1
- LNG, NG, B-C, Diesel
150# RF
150# RF
150# RF
150# RF
150# RF
150# RF
150# RF
150# RF
150# RF
150# RF
150# RF
- LN2
150# RF
150# RF
150# RF
150# RF
Nil
150# RF
150# RF
Nil
150# RF
150# RF
150# RF
DL +19.765 DL +19.534
DL +19.75
DL +20.01
DL +17.16
DL +17.51
DL +18.40
DL +18.91
DL +18.61
DL +18.63
DL +18.61
DL +18.71
DL +18.61
DL +14.953 DL +14.882
DL +14.50
DL +14.80
DL +13.58
DL +13.5
DL +15.55
DL +16
DL +14.7
DL +15.25
DL +14.9
DL +14.7
DL +14.7
Flange rating & face
Deck elevation
*2)
- Max. (@HHW & light draft) (m) - Min. (@LLW & full draft) (m)
Att #1 - 13 Foreign Ships
National Ships
Ship Golar Spirit Manifold elevation
Hoegh Gandria
#1,2,4
#3
#5
#6,9,11,14
#7,13,15
#10,17
#8, 12, 16
*2)
- Max. (@HHW & light
DL +24.565 DL +24.334
DL +24.55
DL +24.81
DL +22.11
DL +23.51
DL +22.6
DL +23.01
DL +23.41
DL +22.83
DL +23.91
DL +23.51
DL +23.41
DL +19.753 DL +19.682
DL +19.30
DL +19.60
DL +18.53
DL +19.5
DL +19.75
DL +20.10
DL +19.5
DL +19.45
DL +20.2
DL +19.5
DL +19.5
draft) (m) - Min. (@LLW & full draft)
3.0
3.0
3.0
V
D.O
1.25
1.25
D.O
L
0.75
3.0
3.0
L
0.75
L
F.O
H.O
H.O
F.O
F.O
D.O
F.O
D.O
F.O
1.25 0.75 3.0
3.0 3.0
3.0 3.0 3.0 2.0
D.O
L
L
0.3
F.O
1.25 0.75
0.3 3.0
3.0 3.0
0.75
F.O
L
F.O
L
V
L
2.0
D.O
D.O
L
V
3.0
3.0 1.25
L
F.O
L
L
L
L
2.0
0.8 2.0
F.O
3.0
3.0
2.52
F.O
2.0
2.52 F.O
D.O
L
V
L
0.5
2.0
L
1.25 0.75 3.0
2.52
2.52 2.52 2.52
2.52
3.0
2.52
2.52 2.52 2.52
3.0 3.0 0.75
2.0
L
F.O
L
V
L
D.O
L
L
V
L
D.O
L
L
V
F.O
2.52
L
L
L
0.5
F.O
2,0
0.8 2.0
1.22 0.91
0.75 2,0 3.0 3.0
3.0 3.0 D.O
F.O
L
L 3.0
D.O
D.O
V
V
L
D.O
L
L
L
2.0
L
L
L 3.0
3.0 3.0 3.0 3.0 D.O
1.25
L
0.75
D.O
1.25
L
F.O
L
L 3.0
L
D.O
V
V 3.0
V
D.O
L
L 3.0
L
D.O
F.O
L
L 3.0
L
F.O
0.75
2,0
(Unit : m)
F.O 2,0
F.O
0.75
(from bow to stern)
0.75
Manifold arrangement
2,0
(m)
Att #1 - 14
Remark
*1) Operators: *2) Tidal data: HHW MSL LLW
HMM (Hyundai Merchant Marine), SKS (SK Shipping), HS (Hanjin Shipping), KL (Korea Line) : DL +2.212 m : DL +1.273 m : DL +0 m
Att #1 - 15 16.
Unloading Arm Schematic Diagram
UNLOADING ARM SCHEM ATIC DIAGRAM
Att #1 - 16 17.
Unloading Arm Signal
UNLOADING ARM SIGNAL UACP PLT TO PMS (UACH) VIA SERIAL LINK
A
UACP FROM PMS (UACH) HARDWIRED
DBV CLOSE DBV OPEN
INBORD ANGLE >= 30
ERC CLOSE
INBORD ANGLE <= -5
ERC OPEN
INBORD ANGLE <= 8
QCDC CLOSED
OUTBORD ANGLE <= 5
QCDC OPEN
APEX ANGLE > 15
COMMON FAULT ALARM
APEX ANGLE > 150
SOV FUSE FAULT
IN/OUT SENSOR ERROR
APEX ANGLE - HIGH APEX ANGLE - HIGH HIGH SLEW LEFT 'A' - HIGH SLEW LEFT 'B' - HIGH EACH ARM
SLEW LEFT - HIGH HIGH SLEW RIGHT 'A' - HIGH SLEW RIGHT 'B' - HIGH SLEW RIGHT - HIGH HIGH STORM LOCK ENGAGED ARM SELECTED ARM CONNECTED/ERS READY POSITION TX INBOARD(ANALOGUE) POSITION TX OUTBOARD(ANALOGUE) HYD. ACCUMULATOR LOW N2 PRESS. SLEWING ANGLE DATA 1st OVERREACH 2nd OVERREACH HPU COMMOM FAULT ALARM
PMS CPU TROUBLE
COMMOM SOV FUSE FAULT
PMS SENSOR TROUBLE
HPU MOTOR 1 SELECTED
WDT ALARM
HPU MOTOR 2 SELECTED HPU MOTOR AUTO SELECTED HPU MOTOR 1 FAULT COMMON ALL ARM
HPU MOTOR 2 FAULT MANOEUVRING STATION - UCP MANOEUVRING STATION - WIRED REMOTE MANOEUVRING STATION - RADIO REMOTE UAC PLC FAULT PMS FAULT
* IF USED FOR CRITICAL FUCTION IN PMS THESE SIGNAL SHOULD BE HARDWIRED
B
Att #1 - 17
UNLOADING ARM SIGNAL UACP (PMS) TO DCS VIA SERIAL LINK
D
DBV CLOSE
- RPM-111.04A LA-103A POV CLOSE
ERC CLOSE
- RPM-111.04B LA-103B POV CLOSE
ERC OPEN
- RPM-111.04C LA-103C POV CLOSE
QCDC CLOSED
- RVM-616.03 LA-634 POV CLOSE
QCDC OPEN
- RVM-616.15 LA-635 POV CLOSE
SOV FUSE FAULT APEX ANGLE - HIGH APEX ANGLE - HIGH HIGH SLEW LEFT 'A' - HIGH SLEW LEFT 'B' - HIGH SLEW LEFT - HIGH HIGH SLEW RIGHT 'A' - HIGH SLEW RIGHT 'B' - HIGH SLEW RIGHT - HIGH HIGH STORM LOCK ENGAGED ARM SELECTED ARM CONNECTED/ERS READY POSITION TX INBOARD(ANALOGUE) POSITION TX OUTBOARD(ANALOGUE) HYD. ACCUMULATOR LOW N2 PRESS. SLEWING ANGLE DATA 1st OVERREACH 2nd OVERREACH HPU COMMOM FAULT ALARM COMMOM SOV FUSE FAULT HPU MOTOR 1 SELECTED HPU MOTOR 2 SELECTED HPU MOTOR AUTO SELECTED COMMON ALL ARM
POV CLOSE (TAG NUMBER SEE BELOW)
DBV OPEN
COMMON FAULT ALARM
EACH ARM
UCP FROM DCS HARDWIRE
HPU MOTOR 1 FAULT HPU MOTOR 2 FAULT MANOEUVRING STATION - UCP MANOEUVRING STATION - WIRED REMOTE MANOEUVRING STATION - RADIO REMOTE UAC PLC FAULT PMS FAULT
E
Att #1 - 18
UNLOADING ARM SIGNAL
UACP TO ESD
F
ESD TO UACP
G
PERC SLOW & SHIP S/D (ESD I-0, I-1, I-4.1, I-1.11)
ESD LEVEL I-1 (MANUAL_ESD-111.03) ESD LEVEL I-4.1 (MANUAL_ESD-111.01) ALL ARM
ESD LEVEL I-4.2 (MANUAL_ESD-111.06) ESD LEVEL I-4.1 (AUTO) ESD LEVEL I-4.2 (AUTO) ESD P-Ships (ESD-111.07)
ESD TO DCS SERIAL LINK
H
UACP TO DCS HARDWIRED
ESD LEVEL I-1(MANUAL_ESD-111.03) FROM UACP
UACP PURGE COMPLETED_ XA-111.03A
ESD LEVEL I-1 (LOCAL_ESD-110.04, 111.04)
UACP PURGE FAILURE & S/D_ XA-111.03B
ESD LEVEL I-4.1 (LOCAL_ESD-111.08) ESD LEVEL I-4.1 (LOCAL_ESD-111.09) ESD LEVEL I-4.1 (LOCAL_ESD-111.10) ESD LEVEL I-4.1 (LOCAL_ESD-121.01) ESD LEVEL I-4.1 (LOCAL_ESD-616.01) ESD LEVEL I-0 (CCR_ESD-110.02) ESD LEVEL I-1 (CCR_ESD-110.05) ESD LEVEL I-1.11 S/S #4, #6 & #9 ESD LEVEL I-4.1 (MANUAL_ESD-111.01) from UACP ESD LEVEL I-4.1 (AUTO) from UACP ESD LEVEL P-Ship (ESD-111.07) ESD LEVEL I-4.2 (MANUAL_ESD-111.06) from UACP ESD LEVEL I-4.2 (AUTO) from UACP
I
Att #2
Attachment #2.
P & ID and Layout Drawings
P&ID 24-R-A01-32-002, Rev. 2 24-R-A01-32-003, Rev. 1 26-R-A01-32-111, Rev. 4 26-R-A01-32-121, Rev. 5
P & ID for General Notes, Symbols and Abbreviations P & ID for Instrument Symbols and Legend P & ID for LNG Marine Unloading (II) P & ID for Ship-Vapour Return Arm (II)
Equipment Layout Drawing 24-P-A00-01-001, Rev. 2 24-P-A00-01-002, Rev. 0 24-P-A21-02-008, Rev. 1
Piping plan index for Berth and Trestle Area Piping plan index for Berth and Trestle Area 2 Piping plan for Berth Area 2 (8)
Foundation Layout Drawing 2-5-C-M02-11-018, Rev. 0 2-5-C-M02-16-020, Rev. 0
Working platform (WP-1), Unloading Arm Support (1/2) Working platform (WP-1), Unloading Arm Support Detail
Att #3
Attachment #3.
Related Technical Specifications
Piping Material Specifications Class 1R1J Class Z1 Class A1 Class 1P1
for LNG, NG, LN2 for Instrument air for Plant air for Fuel gas, nitrogen gas
Mechanical Specifications 26-M-O00-SP-201, Rev. 0 26-M-O00-SP-203, Rev. 0
Paint and Protective Coatings Standard Specification for Pressure Vessels
Instrumentation Specifications 26-I-M12-SP-2130, Rev. 1 26-I-M12-SP-2140, Rev. 1 26-I-M12-SP-2470, Rev. 1
Instrument General Specification Instrument Package Specification General Panel and Wiring Specification
Electrical Specification 25-E-E00-SP-204, Rev. 0
Technical Specification for Squirrel Case Induction Motors (For Compressor and Pump)
CLIENT : KOGAS PIPING MATERIAL LOCATION : TONGYOUNG, KOREA SPECIFICATION PROJECT : TONGYOUNG LNG TERMINAL DESIGN TEMPERATURE SERVICE DESIGN PRESSURE(gauge) : ㎫(kg/㎠) LNG,NG,LN2 -196˚C TO 65˚C 1.77 (18 ) RATING CORROSION ALLOWANCE MATERIAL BRANCH CHART ANSI CLASS 150, RF 0.0 MM 304SS STD-P-004 SCH/ ITEM SIZE(NPS) ENDS DESCRIPTION CLASS PIPE A312-TP304, SMLS PE 80S 1/2 -1 1/2 A312-TP304, SMLS BE 40S 2 -3 A312-TP304, SMLS BE 10S 4 -6 A312-TP304, EFW, W/100 % RT BE 10S 8 -24 A358-304 CL.1,EFW BE 10 26 -42 NIPPLES A312-TP304, SMLS, 100MM PBE 80 S NIPPLE 1/2 -1 1/2 POE/TOE A312-TP304, SMLS, 100MM 80 S NIPPLE 1/2 -1 1/2 BLE/PSE A403-WP304-S, MSS SP-95 80 S 1/2 -2 SWAGE (CON,ECC) FITTINGS A182-F304, ANSI B16.11 SW 3000LB 90 ELL 1/2 -1 1/2 A182-F304, ANSI B16.11 SW 3000LB 45 ELL 1/2 -1 1/2 A182-F304, ANSI B16.11 SW 3000LB TEE 1/2 -1 1/2 A182-F304, ANSI B16.11 SW 3000LB FULL COUPLING 1/2 -1 1/2 A182-F304, MSS SP-97 SW 3000LB SOCKOLET 1/2 -1 1/2 A182-F304, ANSI B16.11,FOR THERMOWELL SW 3000LB SPECIAL COUPLING 1/2 -1 1/2 A182-F304, ANSI B16.11 SW 3000LB CAP 1/2 -1 1/2 A182-F304, ANSI B16.11 THRD 3000LB CAP 1/2 -1 1/2 A182-F304, ROUND HEAD,ANSI B16.11 THRD 1/4 -1/4 PLUG A182-F304, MSS-SP-79 SW 3000LB REDUCING INSERT 1/2 -1 1/2 A403-WP304-S, ANSI B16.9 BW SAME AS PIPE 2 -12 90 ELL A403-WP304-S, ANSI B16.9 BW '' 2 -12 45 ELL A403-WP304-S, ANSI B16.9 BW '' 2 -12 TEE A403-WP304-S, ANSI B16.9 BW '' 2 -12 REDUCER (CON) A403-WP304-S, ANSI B16.9 BW '' 2 -12 REDUCER (ECC) A403-WP304-S, ANSI B16.9 BW '' 2 -30 CAP A403-WP304--WX, ANSI B16.9 BW '' 14 -42 90 ELL A403-WP304--WX, ANSI B16.9 BW '' 14 -42 45 ELL A403-WP304--WX, ANSI B16.9 BW '' 14 -42 TEE A403-WP304--WX, ANSI B16.9 BW '' 14 -42 REDUCER (CON) A403-WP304--WX, ANSI B16.9 BW '' 14 -42 REDUCER (ECC) A240-304, (2:1 AXIS RATIO) BW SAME AS PIPE 32 -42 ELLIPTICAL HEAD
JOB NO. PAGE
: 3415.99 :6
CLASS
1R1J
DAEWOO ENGINEERING COMPANY KOREA GAS MAIN. & ENG.CO.,LTD. REMARK
TEE: REFER TO STD-P-004 SPECIAL COUPLING: REFER TO STD-P-007
VALVES SS BODY(CF3) 316 SS TRIM, STEL SS BODY(CF3) 316 SS TRIM, STEL, G.O SS BODY(A182-F304L) 316 SS TRIM .STEL SS BODY(CF3) 316 SS TRIM, STEL SS BODY(CF3) 316 SS TRIM, STEL G.O SS BODY&COVER (A182-F304L), 316 SS TRIM,STEL,H OR V SS BODY&COVER (CF3) 316 SS TRIM, STEL H OR V SS BODYW/ 316 SS TRIM, STEL H OR V SS BODYW/ 316 SS DISC/ST, DUAL PLT H OR V SS BODY (CF3) TOP INSPECTION PORT,G.O SS BODY (A182-F304L), 316 SS TRIM, Kel-F ST W/ 2 PBE NIPPLES SS BODY (A182-F304L), 316 SS TRIM, Kel-F ST W/ PBE,POE/TOE NIPPLES SS BODY (CF3) 316 SS TRIM, Kel-F ST. SS BODY (CF3) 316 SS TRIM, Kel-F ST. G.O
GATE GATE GLOBE GLOBE GLOBE PISTON CHECK SWING CHECK NON SLAM CHECK WAFER CHECK BUTTERFLY BALL
2 -4 6 -24 1/2 -1 1/2 2 -4 6 -10 1/2 -1 1/2 2 -24 2 -24 2 -24 8 -36 1/2 -1 1/2
150LB 150LB 800LB 150LB 150LB 800LB 150LB 300LB 300LB 150LB 800LB
BW BW SW BW BW SW BW RF RF BW SW
BALL
1/2 -1 1/2
800LB
SW
150LB 150LB
BW BW
1/2 -1 1/2 2 -24 1/2 -24 26 -42 26 -42
300LB 300LB 300LB 300LB 300LB
RF RF RF RF RF
A182-F304, ANSI B16.5, 125 AARH A182-F304, ANSI B 16.5 125 AARH A182-F304, ANSI B16.5, 125 AARH A182-F304, MSS-SP-44, 125 AARH A182-F304, MSS-SP-44, 125 AARH
1/2 26
-24 -42
300LB 300LB
RF RF
SW(316+GRAP),CENTER RING: 316SS,4.5MM SW(316+GRAP),CENTER RING: 316SS,4.5MM
1/2 26
-24 -42
300LB 300LB
RF RF
A320-B8M CL.2/A194-8MA A320-B8M CL.2/A194-8MA ,MSS-SP-44
300LB 300LB 300LB 300LB 300LB
RF RF RF RF RF
A240-304, 125 AARH,API-590 A240-304, 125 AARH,API-590 A240-304, 125 AARH,API-590 A240-304, 125 AARH,STD-P-016,MSS-SP-44 A240-304, 125 AARH,STD-P-016,MSS-SP-44
BALL BALL FLANGES SOCKET WELD WELD NECK BLIND WELD NECK BLIND GASKETS GASKET GASKET BOLTING STUD BOLTS STUD BOLTS MISCELLANEOUS FIGURE 8 SPACER CIRCULAR BLANK SPACER CIRCULAR BLANK
2 6
-4 -10
1 -1 1/2 1 -24 1 -24 26 -42 26 -42
WAFER CHECK SHALL BE USED ONLY WHERE SHOWN ON P&ID
FOR INST.
MSS-SP-44
SAFTY SYSTEM 에서 FIGURE 8 이용
NOTE : 1.26" & LARGER SHALL BE USED MSS-SP-44(ANSI B16.47 SERIES A) FLANGES. 2. INSPECTION/EXAMINATION/TESTING SHALL BE EXECUTED IN SEVERE CYCLIC CONDITION ACCORDING TO CHAP.Ⅵ OF ANSI B31.3. 3. EXTERNAL COATING FOR U/G PIPING SHALL BE PERFORMED IN ACCORDANCE WITH G01-SP-008.(PIPE, FITTING, FLANGE, WELDING POINT )
CLIENT : KOGAS PIPING MATERIAL LOCATION : TONGYOUNG, KOREA SPECIFICATION PROJECT : TONGYOUNG LNG TERMINAL DESIGN TEMPERATURE SERVICE DESIGN PRESSURE(gauge) : ㎫(kg/㎠) IA -29˚C TO 65˚C 0.98 (10 ) RATING CORROSION ALLOWANCE MATERIAL BRANCH CHART ANSI CLASS 125, FF 1.2 CS STD-P-004 SCH/ ITEM SIZE(NPS) ENDS DESCRIPTION CLASS PIPE A53-B, SMLS, GALV. TE XS 1/2 -1 1/2 A53-B, ERW, GALV. BE STD 2 -4
JOB NO. PAGE
: 3415.99 : 15
CLASS
Z1
DAEWOO ENGINEERING COMPANY KOREA GAS MAIN. & ENG.CO.,LTD. REMARK
NIPPLES NIPPLE SWAGE (CON,ECC)
1/2 -1 1/2 1/2 -2
160 XS
A53-B, SMLS, GALV. 100MM TBE BLE/TSE A234-WPB-S, GALV. MSS SP-95
FITTINGS 90 ELL 45 ELL TEE FULL COUPLING HALF COUPLING CAP REDUCING INSERT UNION (GJ) 90 ELL 45 ELL TEE CAP REDUCER(CON,ECC)
1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 2 2 2 2 2
-1 1/2 -1 1/2 -1 1/2 -1 1/2 -1 1/2 -1 1/2 -1 1/2 -1 1/2 -4 -4 -4 -4 -4
3000 LB 3000 LB 3000 LB 3000 LB 3000 LB 3000 LB 3000 LB 3000 LB SAME AS PIPE '' '' '' SAME AS PIPE
THRD THRD THRD THRD THRD THRD THRD THRD BW BW BW BW BW
A105, GALV., ANSI B16.11 A105, GALV., ANSI B16.11 A105, GALV., ANSI B16.11 A105, GALV., ANSI B16.11 A105, GALV., ANSI B16.11 A105, GALV., ANSI B16.11 A105, GALV.,MSS-SP-79 A105, GALV., MSS-SP-83 A234-WPB-S, GALV., ANSI B16.9 A234-WPB-S, GALV., ANSI B16.9 A234-WPB-S, GALV., ANSI B16.9 A234-WPB-S, GALV., ANSI B16.9 A234-WPB-S, GALV., ANSI B16.9
2 1/2 2 1/2 2 1/2
-4 -1 1/2 -4 -1 1/2 -4 -1 1/2
125 LB 800 LB 125 LB 800 LB 125 LB 800 LB
FF THRD FF THRD FF THRD
CI/MI BODY W/ BRONZE TRIM CS BODY W/ F6 (13CR) TRIM CI/MI BODY W/ BRONZE TRIM CS BODY W/ F6 (13CR) TRIM, H OR V CI/MI BODY W/ BR DISC/ST, DUAL PLT, H OR V CS BODY W/ 304SS B&S PTFE ST W/ 2 TBE NIPPLES
1/2 -1 1/2 1/2 -4 2 -4
150 LB 150 LB 150 LB
FF FF FF
A105, GALV., ANSI B16.5, STD FIN A105, GALV., ANSI B16.5, STD FIN A105, GALV., ANSI B16.5, STD FIN
VALVES GATE GLOBE GLOBE PISTON CHECK WAFER CHECK BALL
FOR INST.
FLANGES THREADED BLIND SLIP ON GASKETS 1/2
-4
150 LB
FF
1.6MM, COMPRESSED NON-ASBESTOS
BOLTING STUD BOLTS
1/2
-4
150 LB
FF
A193-B7/A194-2H GALV.
MISCELLANEOUS FIGURE 8
2
-4
150 LB
FF
A516-70, STD FIN,API-590
NOTE 3
NOTE: 1. 1" GLOBE VALVE WILL BE PROVIDED FOR THE INSTRUMENT AIR DISTRIBUTION ON THE MAIN HEADER PIPING. 2. EXTERNAL COATING FOR U/G PIPING SHALL BE PERFORMED IN ACCORDANCE WITH G01-SP-008.(PIPE, FITTING, FLANGE, WELDING POINT) 3. HOT DIP GALVANIZING METHOD SHALL BE APPLIED TO GALV.
CLIENT : KOGAS PIPING MATERIAL LOCATION : TONGYOUNG, KOREA SPECIFICATION PROJECT : TONGYOUNG LNG TERMINAL DESIGN TEMPERATURE SERVICE DESIGN PRESSURE(gauge) : ㎫(kg/㎠) PA -29˚C TO 65˚C 0.98 (10) RATING CORROSION ALLOWANCE MATERIAL BRANCH CHART CLASS 125, FF 1.2 MM CS STD-P-004 SCH/ ITEM SIZE(NPS) ENDS DESCRIPTION CLASS PIPE A53-B, SMLS PE XS 1/2 -1 1/2 A53-B, ERW BE STD 2 -4 NIPPLES A53-B, SMLS, 100MM PBE 160 NIPPLE 1/2 -1 1/2 POE/TOE A53-B, SMLS, 100MM 160 NIPPLE 1/2 -1 1/2 BLE/PSE A234-WPB-S, MSS SP-95 XS 1/2 -2 SWAGE (CON,ECC)
JOB NO. PAGE
CLASS
: 3415.99 : 14
A1
DAEWOO ENGINEERING COMPANY KOREA GAS MAIN. & ENG.CO.,LTD. REMARK
FITTINGS 90 ELL 45 ELL TEE FULL COUPLING HALF COUPLING CAP CAP REDUCING INSERT UNION (GJ) 90 ELL 45 ELL TEE REDUCER (CON) REDUCER (ECC) CAP
A105, ANSI B16.11 A105, ANSI B16.11 A105, ANSI B16.11 A105, ANSI B16.11 A105, ANSI B16.11 A105, ANSI B16.11 A105, ANSI B16.11 A105, MSS SP-79 A105, INTEGRAL SEAT, MSS SP-83 A234-WPB-S, ANSI B16.9 A234-WPB-S, ANSI B16.9 A234-WPB-S, ANSI B16.9 A234-WPB-S, ANSI B16.9 A234-WPB-S, ANSI B16.9 A234-WPB-S, ANSI B16.9
1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 2 2 2 2 2 2
-1 1/2 -1 1/2 -1 1/2 -1 1/2 -1 1/2 -1 1/2 -1 1/2 -1 1/2 -1 1/2 -4 -4 -4 -4 -4 -4
3000 LB 3000 LB 3000 LB 3000 LB 3000 LB 3000 LB 3000 LB 3000 LB 3000 LB SAME AS PIPE '' '' '' '' SAME AS PIPE
SW SW SW SW SW SW THRD SW SW BW BW BW BW BW BW
2 1/2 2 1/2 2 1/2 1/2
-4 -1 1/2 -4 -1 1/2 -4 -1 1/2 -1 1/2
125 LB 800 LB 125 LB 800 LB 125 LB 800 LB 800 LB
FF SW FF SW FF SW SW
CI/MI BODY W/ BRONZE TRIM CS BODY W/F6 (13CR) TRIM CI/MI BODY W/ BRONZE TRIM CS BODY W/F6 (13CR) TRIM, H OR V CI/MI BODY W/ BR DISC/ST, DUAL PLT, H OR V CS BODY W/ 304SS B&S PTFE ST W/PBE&POE/TOE NIPPLE FOR INST,D&V CS BODY W/ 304SS B&S PTFE ST W/ 2 PBE NIPPLES
1/2 -1 1/2 2 -4 1/2 -4
150 LB 150 LB 150 LB
FF FF FF
A105, ANSI B16.5, STD FIN A105, ANSI B16.5, STD FIN A105, ANSI B16.5, STD FIN
VALVES GATE GLOBE GLOBE PISTON CHECK WAFER CHECK BALL BALL FLANGES SOCKET WELD SLIP ON BLIND GASKETS 1/2
-4
150 LB
FF
1.6MM, COMPRESSED NON-ASBESTOS
BOLTING STUD BOLTS
1/2
-4
150 LB
FF
A193-B7/A194-2H
MISCELLANEOUS FIGURE 8
2
150 LB
FF
A516-70, STD FIN,API-590
-4
NOTE: 1. EXTERNAL COATING FOR U/G PIPING SHALL BE PERFORMED IN ACCORDANCE WITH G01-SP-008.(PIPE, FITTING, FLANGE, WELDING POINT )
CLIENT : KOGAS LOCATION : TONGYOUNG, KOREA PROJECT : TONGYOUNG LNG TERMINAL
ITEM
DESIGN PRESSURE(gauge) : ㎫(kg/㎠) FG, NI:0.98(10) DO, FO:1.37(14)
DESIGN TEMPERATURE -29˚C TO 75˚C MAX
SERVICE FG,NI,BC,DO RATING ANSI CLASS 150, RF
PIPING MATERIAL SPECIFICATION
CORROSION ALLOWANCE 1.2 MM SCH/ SIZE(NPS) CLASS
MATERIAL CS
BRANCH CHART STD-P-004
ENDS
JOB NO. PAGE
CLASS
: 3415.99 :1
1P1
DAEWOO ENGINEERING COMPANY KOREA GAS MAIN. & ENG.CO.,LTD.
DESCRIPTION
REMARK
PIPE -1 1/2 -6 -16
XS STD STD
1/2 -1 1/2 1/2 -1 1/2 1/2 -2
160 160 XS
1/2 2 8
PE BE BE
A53-B, SMLS A53-B, SMLS A53-B,ERW, W/100% RT
NIPPLES NIPPLE NIPPLE SWAGE (CON,ECC)
A53-B,SMLS, 100MM PBE POE/TOE A53-B,SMLS, 100MM BLE/PSE A234-WPB-S, MSS SP-95
FITTINGS 90 ELL 45ELL TEE PLUG FULL COUPLING SOCKOLET SPECIAL COUPLING CAP CAP REDUCING INSERT UNION (GJ) 90 ELL 45 ELL TEE REDUCER (CON) REDUCER (ECC) CAP 90 ELL 45 ELL TEE REDUCER (CON) REDUCER (ECC)
3000 LB 3000 LB 3000 LB 3000 LB 3000 LB 3000 LB 3000 LB SAME AS PIPE '' '' '' '' '' '' '' '' '' SAME AS PIPE
SW SW SW THRD SW SW SW SW THRD SW SW BW BW BW BW BW BW BW BW BW BW BW
A105, ANSI B16.11 A105, ANSI B16.11 A105, ANSI B16.11 A105, ROUND HEAD, ANSI B16.11 A105, ANSI B16.11 A105, MSS SP-97 A105, ANSI B16.11,FOR THERMOWELL A105, ANSI B16.11 A105, ANSI B16.11 A105, MSS SP-79 A105, INTEGRAL SEAT, MSS SP-83 A234-WPB-S, ANSI B16.9 A234-WPB-S, ANSI B16.9 A234-WPB-S, ANSI B16.9 A234-WPB-S, ANSI B16.9 A234-WPB-S, ANSI B16.9 A234-WPB-S, ANSI B16.9 A234-WPB-W, ANSI B16.9, W/100% RT A234-WPB-W, ANSI B16.9, W/100% RT A234-WPB-W, ANSI B16.9, W/100% RT A234-WPB-W, ANSI B16.9, W/100% RT A234-WPB-W, ANSI B16.9, W/100% RT
-1 1/2 -1 1/2 -4 -16 -1 1/2 -4 -16 -1 1/2 -16 -1 1/2 -1 1/2 -4 -16
800 LB 800 LB 150 LB 150 LB 800 LB 150 LB 150 LB 800 LB 150 LB 800 LB 800 LB 150 LB 150 LB
SW T/SW RF RF SW RF RF SW RF SW SW RF RF
CS BODY W/ F6 (13 CR) TRIM CS BODY W/ F6 (13 CR) TRIM CS BODY W/ F6 (13 CR) TRIM CS BODY W/ F6 (13 CR) TRIM, G.O. CS BODY W/ F6 (13 CR) TRIM CS BODY W/ F6 (13 CR) TRIM CS BODY W/ F6 (13 CR) TRIM, G.O CS BODY W/ F6 (13 CR) TRIM, H OR V CS BODY W/ 410 SS DISC/ST, DUAL PLT, H OR V CS BODY W/ 316 SS B&S PTFE ST W/2 PBE NIPPLES CS BODY W/ 316 SS B&S PTFE ST W/PBE,POE/TOE NIPPLE S CS BODY W/ 316 SS B&S PTFE ST CS BODY W/ 316 SS B&S PTFE ST, G.O.
1/2 -1 1/2 1/2 -16 2 -16 1/2 -1 1/2 2 -16
150 LB 150 LB 150 LB 300 LB 300 LB
RF RF RF RF RF
A105, ANSI B16.5, STD FIN A105, ANSI B16.5, STD FIN A105, ANSI B16.5, STD FIN A105, ANSI B16.5, STD FIN A105, ANSI B16.5, STD FIN
1/2 1/2 1/2 1/4 1/2 1/2 1/2 1/2 1/2 1/2 1/2 2 2 2 2 2 2 16 16 16 16 16
-1 1/2 -1 1/2 -1 1/2 -1/4 -1 1/2 -1 1/2 -1 1/2 -1 1/2 -1 1/2 -1 1/2 -1 1/2 -14 -14 -14 -14 -14 -16 -16 -16 -16 -16 -16
1/2 1/2 2 6 1/2 2 6 1/2 2 1/2 1/2 2 6
3000 LB 3000 LB 3000 LB
TEE: REFER TO STD-P-004 SPECIAL COUPLING: REFER TO STD-P-007
VALVES GATE GATE GATE GATE GLOBE GLOBE GLOBE PISTON CHECK WAFER CHECK BALL BALL BALL BALL FLANGES SOCKET WELD BLIND WELD NECK SOCKET WELD WELD NECK
FOR DO,BC INST
FOR NI,FG INST,D&V
NOTE 2
GASKETS 1/2
-16
150 LB
RF
1.6MM COMPRESSED GRAPHITE
STUD BOLTS
1/2
-16
150 LB
RF
A193-B7/A194-2H
MISCELLANEOUS FIGURE 8 SPACER CIRCULAR BLANK
2 14 14
-12 -16 -16
150 LB 150 LB 150 LB
RF RF RF
A516-70, STD FIN,API-590 A516-70, STD FIN,API-590 A516-70, STD FIN,API-590
BOLTING
NOTE: 1. EXTERNAL COATING FOR U/G PIPING SHALL BE PERFORMED IN ACCORDANCE WITH G01-SP-008.(PIPE, FITTING, FLANGE, WELDING POINT) 2. 300 LB RF FLANGES SHALL BE USED ONLY FOR SPEC BREAK POINTS WITH 1R1J CLASS AND IN THIS CASE, GASKETS & BOLT/NUTS OF 1R1J CLASS SHALL APPLIED TO THE SPEC BREAK POINTS.
PAINT AND PROTECTIVE COATINGS
0
2008. 08. 03
REV. NO.
DATE
Issued for Construction DESCRIPTION
H.C. Oh J.K. Lee J.H. Yoon DESIGN CHECK Q.A
M.S. Kang APPROVED
CLIENT APPROVED
KOREA GAS CORPORATION 통영생산기지 2 단계 6 차 확장공사 TONGYOUNG LNG TERMINAL 6th EXTENSION PROJECT
PAINT AND PROTECTIVE COATINGS
SCALE
JOB NO.
PHASE
DOCUMENT NO.
REV.
NONE
3415.99
II
26 – M – O00 – SP – 201
0
DAEWOO ENGINEERING COMPANY KOREA GAS TECHNOLOGY CORPORATION
[Paint] 2
TABLE OF CONTENTS
1.
General ............................................................................................................................................................3
2.
Codes and Standards ......................................................................................................................................3
3.
Extent of painting .............................................................................................................................................3
4.
Specific requirements.......................................................................................................................................4
5.
Surface preparation..........................................................................................................................................5
6.
Rust preventive compounds ............................................................................................................................5
7.
Inorganic and organic zinc rich primers ...........................................................................................................5
8.
Paint application...............................................................................................................................................6
9.
Manufacturers' standard paint system .............................................................................................................7
10. Austenitic stainless steel surfaces ...................................................................................................................7 11. Structural steel .................................................................................................................................................8 12. Buildings...........................................................................................................................................................8 13. Flare stack and support structure ....................................................................................................................8 14. Marking, band & lettering .................................................................................................................................8 15. Repairs.............................................................................................................................................................9 16. Quality assurance ............................................................................................................................................9 17. Procurement of materials and services ...........................................................................................................9 Table No. 1 Surface Preparation .................................................................................................................11 Table No. 2 Paint Type, Color and Thickness .............................................................................................12 Table No. 3 Method of Paint Application .....................................................................................................13 Table No. 4 Final Coat Colors, Marking and MUNSELL & RAL CODE Table .............................................14 Table No. 5 Vessels, Exchangers and Utility Tanks ....................................................................................16 Table No. 6 Pump Casings and Compressors ............................................................................................16 Table No. 7 Structural Steel .........................................................................................................................17 Table No. 8 Electrical and Instrument Equipment .......................................................................................17 Table No. 9 Carbon & Ferritic Alloy Steel Piping & Fittings .........................................................................18 Table No. 10 Austenitic Stainless Steel Piping & Fittings............................................................................18 Table No. 11 Flare Stack and Support Structures .......................................................................................19 Table No. 12 Paint Systems and Codes......................................................................................................19
[Paint] 3 1.
General This specification covers the requirements for surface preparation and application of shop and field protective coatings for equipment, piping and steel structures in TONGYOUNG LNG Receiving Terminal. This specification is modification of Project Design Specification, P30, Rev. 1, of M.W Kellogg, incorporating following KOGAS standards: KOGAS-GSD-0007 Color Standards for Gas Facilities KOGAS-GSD-1021 Painting Standards for Facilities in LNG Terminal KOGAS-GSD-1022 Specification for the Repair of Painting This specification does not cover coatings for internal surface of LNG storage tanks.
2.
Codes and Standards The following latest editions of publications and standards shall be used when referenced in this specification: ASTM A123 BS 729-1971 SIS-055900 ISO-8501-1 SSPC-PA 1 SSPC-SP 1 SSPC-SP 2 SSPC-SP 3 SSPC-SP 5 SSPC-SP 6 SSPC-SP 7 SSPC-SP 8 SSPC-SP10 SSPC-PS 8.01 SSPC-PS 12.00 BS 5493-1977 ANSI A13.1 ANSI Z 53.1 KS KOSHA
3.
Standard Specification for Zinc (Hot galvanized) Coatings on products fabricated from rolled, pressed and forged steel shapes, plates, bars and strip. Pictorial Surface Preparation Standards for Painting Steel Surfaces Preparation of Steel substrates before application of paints and related products. Paint Application Guide, Shop, Field and Maintenance Painting Surface Preparation Specifications, No. 1 Solvent Cleaning Surface Preparation Specifications, No. 2 Hand Tool Cleaning Surface Preparation Specifications, No. 3 Power Tool Cleaning Surface Preparation Specifications, No. 5 White Metal Blast Cleaning. Surface Preparation Specifications, No. 6 Commercial Blast Cleaning. Surface Preparation Specifications, No. 7 Brush-off Cleaning. Surface Preparation Specifications, No. 8 Pickling Surface Preparation Specifications, No. 10 Near-White Blast Cleaning SSPC Paint System Specifications, Rust Preventive Compounds (Thick Film) SSPC Paint System Specifications, Guide to Zinc Rich Coating Systems Code of Practice for Protective Coating of Iron and Steel Structures against Corrosion Scheme for the identification of piping systems Safety Color Code for Marking Physical Hazards KS A 0011, KS A 0062, KS A 0503, KS A 3501 Korea Occupational Safety & Health Agency (former KISCO)
Extent of painting 3.1. Structural steel, equipment (e.g. vessels, heat exchangers, tanks and pumps) and above ground piping, shall be externally painted in accordance with the systems summarized in Table No. 1 to 12. The tables provide a summary of the various items to be painted, surface preparation, type of primer, finish paints, the number of coats required and the final coat color and markings for both ambient, high temperature and low temperature service. 3.2. Electrical equipment, machinery and skid mounted packages shall be painted in accordance with the manufacturers' standard and section 9 of this specification. 3.3. Pressure equipment shall not be painted until after completion of all heat treatment, pressure testing and examinations.
[Paint] 4 3.4. The following items do not require preparation or painting except where otherwise specified in the specific job requirements: 1)
Buried bare steel piping with operating temperatures above 149 oC.
2)
Brickwork, concrete, fireproofing, exterior concrete, building floors, and pavement not subject to attack from corrosive substances.
3)
Asbestos-cement sheeting, brass, copper, slate, glass, tile and similar weather resisting materials.
4)
Aluminum or galvanized metal including insulation weatherproofing. (But, the galvanized metal surface for platform and ladder with handrail shall be painted in accordance with Purchaser’s requirement.)
5)
Screwed items of valves, or gasket contact surfaces.
6)
Finished machined parts of machinery.
7)
Any equipment furnished completely primed and final painted by the manufacturer (e.g. Instruments, Instrument boards, motor) unless specifically required to repair paint damage or to match a color scheme.
8)
Internal surfaces of tanks (except water tanks).
9)
Aluminum pigmented or White insulation coating (fabric reinforcement and mastic).
3.5. Requirements for painting of pipework to suit temperature conditions involved shall include the entire pipework system comprising pipe, fittings, flanges, strainers, traps etc., together with valves where manufacturers' standard finish does not offer sufficient protection for the environmental conditions involved. 3.6. All uninsulated portions of insulated equipment (pressure vessel, nozzles, manway covers, valves, relief valves, etc.) shall be painted to suit temperature conditions involved. 3.7. All supports, including skirts, legs, saddles, etc. shall be coated with the paint system specified for the temperature range up to 80℃. 3.8. The paint system shall generally be based on the maximum operating temperature of the equipment and pipework. This being with the exception of items affected by requirements of paragraph 3.7 and items where high temperatures are involved for steam out, paragraph 3.9 and all predictable nonoperating conditions involving elevated metal wall temperatures for periods of either recurring frequency and/or prolonged duration. Where paint system is applied for low temperature service the effect of lowest temperature shall also be considered. 3.9. Where indicated on piping, exchanger, vessel or any other relevant data sheets, that piping or items of equipment are to be subjected to a pre-commissioning steam cleaning process, the paint system employed shall take into account the designated steam out temperature and shall be suitable for the temperature range 81℃ to 400℃.
4.
Specific requirements 4.1. The specific requirements for surface preparation applicable to both shop and field protective coatings shall be designed in accordance with Table No. 1 and Table No. 5 to 11. 4.2. The specific requirements for paint type, color and thickness applicable to both shop and field protective coatings shall be designed in accordance with Table No. 2 and Table No. 5 to 11. 4.3. The specific requirements for method of paint application to both shop and field protective coatings shall be designed in accordance with Table No. 3 to 4 and Table No. 5 to 11. 4.4. No substitution or modification to materials and methods of application detailed in this Specification is permissible unless prior approval has been obtained from the Purchaser. 4.5. Where conflicts arise between this Specification and any other contract and related document, the Contractor shall obtain a written ruling before proceeding with the work affected.
[Paint] 5 5.
Surface preparation 5.1. Surface preparation and pre-treatment shall be in accordance with the Steel Structures Painting Council descriptive standards listed in column 'A' of Table No. 1. 5.2. The abrasive of spray type air blasting for surface preparation shall generally be steel grit, shot or sand, and they shall be cleaned and dried before use. The type of abrasive, particle size and maximum profile shall be agreed with individual paint manufacturers for each type of paint used, and shall be generally as follows: Type of abrasive Sand
Very fine
Max. particle size (mesh)
Max. profile (µm)
80
40
Fine 40
50
Medium 18
65
Large 12 Grit
SHOT
70
SAE G-80
40
30 ~ 75
SAE G-50
25
85
SAE G-40
18
90
SAE G-25
16
100
SAE G-16
12
200
SAE S-170
20
45 ~ 70
SAE S-230
18
75
SAE S-330
16
85
SAE S-390
14
90
The maximum particle size shall be no larger than that passing through the appropriate mesh screen size to suit the center line profile height requirements. 5.3. For inorganic zinc silicate primed surfaces the abrasive shall be hard sharp and angular, for which reason shot shall not be acceptable. 5.4. Flange faces, valves, and other items which could be damaged by abrasive blasting shall not be abrasive blast cleaned but shall be cleaned by hand or power tools in accordance with SSPC-SP 2 or SSPC-SP. 5.5. In the case of austenitic stainless steel piping or equipment, all surfaces requiring painting shall be lightly blast cleaned with a suitable silica safe abrasive low in chlorides and heavy metal elements such as aluminium oxide or a proprietary abrasive based on inert aluminium silicate. The cleaning process shall result in an appearance resembling pictorial standard Sa 2 of ISO-8501-1 when carried out to a light blast intensity equivalent to the descriptive standard SSPC-SP 6. In cases where blast cleaning is absolutely impossible, an alternative method of surface preparation may be used providing this has the prior approval of the Purchaser. 5.6. Any solvent used for shop or field cleaning of stainless steel surfaces shall be an organic solvent free from metallic elements and have less than 50 ppm chloride content. 5.7. Extreme care must be taken with regard to overcoating times so that pin-holing does not occur.
6.
Rust preventive compounds Rust preventive compounds where used for transit protection shall conform to SSPC-PS 8.01.
7.
Inorganic and organic zinc rich primers Zinc rich primers shall conform to the requirements of Section 3 of SSPC-PS 12.00-82 except that the %Zn by weight in the dry film shall be between 82% and 90% for inorganic coatings, and between 85% and 90% for organic coatings, and shall be no less than 82% and 85% respectively.
[Paint] 6 8.
Paint application 8.1. Unless otherwise specified the application of paint shall be in accordance with SSPC-PA 1 and the paint manufacturers' recommendations. 8.2. The paint applicator shall be responsible for ensuring that he is in possession of the latest available issue of the paint data sheets printed by the paint manufacturer of the particular batch of paint to be applied. Such data shall include specific recommendations and instructions concerning shelf life, pot life, thinners, directions for thinning and mixing, drying time, curing time, recommended spray equipment, safety equipment, cleaning solvent and any other provisions for application of both prime and finish coats. These recommendations shall be considered an inherent part of this Specification and followed accordingly. 8.3. Unless otherwise agreed, materials for succeeding coats on any one surface shall be the products of the manufacturer furnishing the initial priming coat or coats for that particular surface, in accordance with paint types listed in Table No. 2 . All successive coats must however, be compatible with prime coats. 8.4. Unless otherwise specified, paint shall not be applied: 1)
when the ambient or the surface temperature is beyond the range of 10 oC and 40 oC,
2)
when the surface temperature is less than 3 oC below dew point
3)
when the wind velocity is more than 40km/h
4)
when there is rain or snow or fog or dust
5) af
ter sunset
8.5. Contaminated surfaces requiring corrosion resistant paints shall be thoroughly cleaned by washing with clean uncontaminated water or a suitable solvent for the removal of the contaminant. Each applied coat, when dry, shall be similarly cleaned before application of the succeeding coat. In the case of zinc silicate primed surfaces, zinc salts shall be removed by thorough manual scrubbing with stiff brushes in conjunction with a high pressure hose spray of clean uncontaminated water. 8.6. All dry thickness as specified shall be strictly adhered to within a tolerance of -0/+20% unless otherwise agreed by the Purchaser. The film thickness of each coat shall be checked with calibrated film thickness gauges, using the magnetic resistance or eddy currents principle, such as Elcometer, Micro-test, Tinsley, etc. The equipment shall be calibrated at least twice daily in accordance with the Manufacturers' recommendations. 8.7. In order to achieve the specified dry film thickness, frequent checks of wet film thickness shall be carried out during the paint application with film thickness gauges such as the Elcometer wheel or comb type. 8.8. In the event of the film thickness not meeting the specified requirements, additional coat(s) of the paint concerned shall be applied in compliance with the specified requirements. Wet film thickness to get required dry film thickness may be estimated by: Web film thickness = [ dry film thickness / volumetric ratio of solid component ] x 100 8.9. The 1st coat shall be applied within 5 hours after blast cleaning and within 8 hours after other type surface cleaning. 8.10. Drying and curing shall be in made in the atmosphere that is clean without dust, with the temperature above 10 oC and relative humidity less than 90% (20 oC & 90% RH is best condition), with moderate air flow (Too much air flow will result in rough surface.). 8.11. Drying time shall be maintained for sufficient period. General drying time shall be as follows: Under coat Etching primer Zinc rich primer High build zinc rich primer Zinc oil based anti-corrosive paint Zinc phthalic anti-corrosive paint
Upper coat Zinc oil based anti-corrosive paint Epoxy undercoat Epoxy undercoat Zinc phthalic anti-corrosive paint Phthalic middle coat
Drying time (min. ~ max) 1 day ~ 3 months 1 day ~ 10 months 2 days ~ 12 months 2 days ~ 6 months 1 day ~ 6 months
[Paint] 7 Under coat Phthalic anti-corrosive paint Phenolic MIO Polyvinyl rubber under coat Polyvinyl rubber middle coat Epoxy under coat Epoxy under coat Epoxy MIO Epoxy middle coat Epoxy middle coat Tar epoxy Vinylester
9.
Upper coat Phenolic MIO Polyvinyl rubber middle coat Polyvinyl rubber middle coat Polyvinyl rubber top coat Polyvinyl rubber middle coat Epoxy middle coat Epoxy middle coat Polyurethane top coat Fluoric top coat Tar epoxy Vinylester
Drying time (min. ~ max) 2 days ~ 6 months 2 days ~ 12 months 1 day ~ 12 months 1 day ~ 1 month 1 day ~ 7 days 1 day ~ 3 months 1 day ~ 12 months 1 day ~ 7 days 1 day ~ 7 days 1 day ~ 7 days 1 day ~ 7 days
Manufacturers' standard paint system Were the equipment suppliers' standard preparation, priming and finish coat system is permitted, this shall be subject to the following provisos: 1) The coating system is oil resistant, and shall have a life to 1st maintenance of five years minimum in the known environment. 2) For normal operating temperatures up to 80 oC, this is applied in a minimum of three coats to an overall dried film no less than 150 microns, employing two component coatings that are self-curing or chemically curing and not dependent on air drying to attain full hardness. 3) For normal operating temperatures in excess of 80 oC, a heat resisting paint system capable of withstanding these conditions is used. 4) Paint application is over a blast cleaned surface or, in the case of components where blast cleaning is impracticable, a power tool cleaned surface. 5) Information is provided concerning type of touch-up paint to be used in the field in way of damaged areas. 6) The system is approved in writing by Purchaser. 7) Where paint system is used for low temperature service the effect of the lowest temperature shall also be taken into account.
10. Austenitic stainless steel surfaces 10.1. The austenitic stainless steel piping and equipment need not be coated except: 1)
where sea water deluge is used (i.e. ORV area)
2) whe 3)
re surface operating temperature is between 60 oC and 120 oC
where specially required by Owner
All stainless steel surfaces shall be cleaned free from dirt, dust, etc. and shall be passivated at shop where not coated. Passivation procedure shall be submitted for Owner’s review. 10.2. For all priming and or finishing coats applied to austenitic stainless steel, the coating manufacturer shall produce certificates to confirm that the coating is free of contaminants i.e. metallic pigments, sulphur or chlorine which would harmfully affect stainless steel at ambient or elevated temperatures. The certificates shall include a chemical analysis for halogens in accordance with ASTM D808-91 and shall provide confirmation that the halogen content is below 200 PPM. 10.3. For all priming and finishing coats applied to austenitic stainless steel in cryogenic service, the coating manufacturer shall produce certificates in the form of test results to demonstrate that the applied coating will remain stable when subjected to operating temperatures within the range of +120 oC to -170 oC and when subjected to cyclic conditions of temperature and thermal shock.
[Paint] 8
11. Structural steel All structural steel shall be painted in accordance with Table No. 7 of this specification and Construction Specification for Steel Structure provided by Architecture discipline.
12. Buildings Administrative type buildings, control houses, and control rooms shall be painted in accordance with the architectural specifications and drawings. The painting of other types of buildings shall be in accordance with this specification.
13. Flare stack and support structure 13.1. The protective coating systems to be used on flare stack and support structure shall be as detailed for shop and field application respectively in Table No. 11. 13.2. The systems shall be suitable for highly corrosive conditions and for temperature resistance within the radiation temperature zones listed in Table No. 11.
14. Marking, band & lettering 14.1. All equipment shall be stenciled with the equipment number and duty in accordance with Table No. 4 Final Coat Colors, Marking. 14.2. In order to discriminate all equipment, facilities, piping, etc. easily, the relevant items shall be grouped as the same kind. One band shall be used per one group. Color code plate including relevant letter and flow direction shall be attached to the surface in case of piping and the visible surface in case of equipment and facilities. The details of band and lettering shall be as follows; a)
Letter
: Korean or English
b)
Font
: Logotype according to KOGAS C.I.P
c)
Color
: Black or White (excluding, Red for “No Fire”, etc. Warning massage)
d)
The flow mark is as follow (45 oC or 315 o) 315
o
LNG 1.0 [MPa.G]
L
e)
Location of band -
both side of valve and tee, near main fitting
-
near inlet & outlet of piping passing through wall or bridge
-
piping connected to or near equipment / facilities
-
one per 50meter of piping in a straight line
45
o
[Paint] 9 -
pipe rack or support where various kinds of piping gather
- other f)
required
Band and lettering size PIPING SIZE (OD) (INCL. INSULATION TH’K) 2” and below 4” ~ 6” 8” ~ 12” 14” ~ 20” 24” and above
LETTERING SIZE (mm) HEIGHT (H) WIDTH (W) TH’K (T) 30 50 90 140 190
H / 1.3
H / 4.4
LENGTH (mm) 300 500 900 1400 1700
Note) The above may be changed as per site condition.
15. Repairs 15.1. When part of the full protective system has been applied by the equipment manufacturer, the work shall be completed on site making good any damage or deficiency of the general painting. Where the full system has been applied by the equipment manufacturer, additional painting shall be kept to the minimum necessary to obtain uniformity of color. In general, field instruments shall not be repainted. 15.2. Any repairs to damage of abutting property, vehicles, and other portions of the structure due to the painting operations shall be the responsibility of the contractor unless otherwise specifically covered in the special provisions for the painting job.
16. Quality assurance 16.1. The manufacturer of the products specified or the contractor providing the painting of the systems or services shall have quality assurance system and in line with ISO 9000 standards or equivalent schemes. 16.2. Appropriate quality plans shall be presented to the Purchaser for review and approval concerning the products and services provided. Inspection and testing during manufacture shall form the basis of these quality plans, extend of test shall be according to manufacturer's standards. The Purchaser will have the right to witness any relevant tests. 16.3. The contractors and manufacturers shall provide the agreed certification, conformance or guarantees to the Purchaser.
17. Procurement of materials and services 17.1. The supply of materials and services shall be subject to the conditions of the contract at the time of placing the orders, and in conformance to the requirements of the Purchaser. 17.2. The Paint Contractor shall supply all the essential materials and services within the scope of supply and to the standards and specifications outlined in this document. The Contractor's supply shall include the following: 1)
All necessary materials needed for the paint system specified in this document i.e. the basic materials, all accessory materials and application tools.
2)
All services required in the painting and testing of the system, i.e. detailed drawings, documents, procedures, material storage and control, painting, testing, inspection, repair, hand-over documents and data books for records and operational maintenance.
17.3. The materials delivered to construction site shall be completely sealed, properly packed, and identified with necessary information such as manufacturers name, product name, grade, batch number, manufactured date, applicable standards, safety data sheets, and pot life, and checked by Owner’s
[Paint] 10 representative. The delivered materials shall be accompanied with the essential documentation with regard to purchase orders, conformance certification and identification. Materials not conforming to delivery requirements shall be rejected. 17.4. For each type of paint material supplied, the Purchaser will have the right to examine at least two samples (chosen at random) in order to verify conformance to the specifications purchased. The tests will be performed in a test house of the Purchaser's choice at the Vendor's expense. Any nonconformance shall be cause for rejection of the total batch of supply. The vendor shall be responsible for replacing all the rejected materials at his own cost to the standards specified and offered at the time of purchase. The vendor shall provide to the Purchaser the guarantees on the quality and application of the paint. 17.5. Painting material shall be stored in exclusive painting material storage house which is well ventilated at the temperature range of 5 oC ~ 35 oC. The house shall be provided with fire warning message, explosion-proof lights and switches, and away from direct sun, fire and other hazardous risks. Paint materials shall be taken out from the storage house as required by first-in-first-out base.
[Paint] 11
Table No. 1
CODE
A1
Surface Preparation
TYPE SOLVENT CLEAN (PER SECTION 5.5 IN THE CASE OF S.S. SURFACES)
SSPC
ISO-8501-1
DESCRIPTIVE
PICTORIAL
STANDARD 'A'
STANDARD 'B'
SP1- -
A2
HAND TOOL CLEAN
SP 2-
St 2
A3
POWER TOOL CLEAN
SP 3-
St 3
A4
MANUFACTURERS' STANDARD FLASH/ PICKLING FLUXING PRETREATMENT PROCESS
--
A5
WHITE BLAST CLEAN
SP 5-
Sa 3
A6
COMMERCIAL BLAST CLEAN
SP 6-
Sa 2
A7
BRUSH-OFF BLAST CLEAN
SP 7-
Sa 1
SP 8-
-
A8 PICKLING A9 A10 A11 A12 A13 A14 A15
CLEAN DOWN WITH STIFF BRUSHES IN CONJUNCTION WITH CLEAN UNCONTAMINATED H.P. WATER HOSE SPRAY NEAR WHITE BLAST CLEAN VACUUM BLAST WITH PORTABLE EQUIPMENT TO EQUIVALENT STANDARD USED ON ADJOINING SURFACES REMOVE ALL ACCESSIBLE WELD SPATTER REMOVE REMAINING DETRIMENTAL WELD FLUX DEPOSITS LIGHTLY BLAST CLEAN STAINLESS STEEL SURFACES TO REQUIREMENTS OF SECTION 5.5 THOROUGHLY ABRADE WITH COARSE EMERY CLOTH IN CONJUNCTION WITH SOLVENT CLEANING A1
-SP 10-
Sa 2½
-SP 2 (SECTION 3.5) SP 1 (SECTION 3.1.6)
-
SP 6-
Sa 2
-
-
Note Surfaces shall receive the required degree of surface preparation as described in the appropriate S.S.P.C. descriptive standard, Column 'A', when read in conjunction with the quality grade of preparation corresponding in appearance to the pictorial standards presented in ISO8501-01 Standard.
[Paint] 12
Table No. 2
Paint Type, Color and Thickness RAY FILM
CODE
TYPE
MIN VOL
THICKNESS
COLOUR
PER COAT
D 2697-86
MICRONS B1 B2
TWO PACK INORGANIC ZINC SILICATE (SELF CURING) ETHYL SILICATE BASED - AS PARA. 7 TWO PACK ORGANIC ZINC RICH POLYAMIDE CURED EPOXY PRIMER - AS PARA 7
75 65
SOLIDS ASTM
METALLIC GREY METALLIC GREY
58 45
B3
TWO PACK POLYAMIDE CURED EPOXY TIE COAT
40
RED OXIDE
45
B4
TWO PACK POLYAMIDE CURED EPOXY HIGH BUILD COAT
125
OFF-WHITE
60
B5
TWO PACK ALIPHATIC URETHANE
50
NOTE 1
45
B6 B7 B8 B9 B11
TWO PACK ALUMINIUM FILLED MODIFIED EPOXY – CARBOMASTIC 15 OR EQUAL ONE PACK ACRYLIC MODIFIED SILICONE ALUMINIUM HEAT RESISTING TWO PACK POLYURETHANE RED OXIDE PIGMENTED PRIMER (LEIGHS RESISTEX K570 SS) POLY SILOXANE INORGANIC PAINT (AMERON 738) TWO PACK ALUMINIUM FILLED MODIFIED EPOXYCARBOMASTIC 15 OR EQUAL
125 ALUMINIUM 25 ALUMINIUM 35/50 RED 125
TWO PACK POLYAMIDE CURED HIGH BUILD EPOXY/MIO.
125
B13
TWO PACK POLYAMIDE CURED HIGH BUILD EPOXY/MIO
125
B14
COATING
B20
HOT DIP GALVANIZED TO ASTM A123( OR ASTM A153)
B22
ALUMINIUM SPRAY TO BS EN 22063: 94
B23
OXIDE DARK GREY
50 ALUMINIUM
B12
ONE PACK CURE SILICONE ALUMINIUM HEAT RESISTING
37 42/46 93 90
CHARCOAL GREY SILVER GREY
60 60
25 ALUMINIUM 86 (610 g/m2) 300 + 75
MANUFACTURERS STANDARD PREPARATION AND
SELF COLOUR SELF COLOUR
-
NON-BITUMINOUS TRANSIT PROTECTIVE COATING MANUFACTURERS STANDARD CORROSION INHIBITIVE
B24
COMPOUND CAPABLE OF BEING EASILY REMOVED IN THE
-
FIELD B25
RUST PREVENTATIVE COMPOUND IN COMPLIANCE WITH SSPC - PS 8.01
--
B26
TWO PACK AMINE CURED COAL TAR EPOXY
200
DARK BROWN
B27
TWO PACK AMINE CURED COAL TAR EPOXY
200
BLACK
B28 INOR
75
WHITE
43
B29
EPOXY PHENOLIC PRIMER
GANIC SILICATE TOPCOAT
75
WHITE
55
B30
EPOXY PHENOLIC FINISH
100
GREY
55
B31
TWO PACK HIGH BUILD EPOXY AMERON 400C OR
125 NOTE
1
INTERGARD 410 OR EQUIVALENT B32
AMINE ADDUCT EPOXY PRIMER
B33 AMINE B34 B35 W B36
ADDUCT EPOXY
WATERSOLUBE EPOXY PRIMER
100
RED OXIDE
100
WHITE
40
RED OXIDE
ATERSOLUBE EPOXY
100
WHITE
FIREPROOFING COATING
50
MAKER STD
NOTE) 1. B5
& B31 Code colour : R efer to Table No. 4
85
[Paint] 13
Table No. 3
Method of Paint Application
CODE C1
DESCRIPTION PAINT SHALL BE BRUSH APPLIED
C2
PAINT SHALL BE AIR SPRAY APPLIED
C3
PAINT SHALL BE HOT SPRAY APPLIED
C4
AIRLESS OR HIGH PRESSURE SPRAY APPLIED
C5
SPOT CLEAN AND TOUCH-UP DAMAGED AREAS (SEE NOTE C.5)
C6
DO NOT PREPARE PRIME OR PAINT
C7
MANUFACTURERS STANDARD PREPARATION AND FINISH, MEETING REQUIREMENTS OF SECTION 9
C8
LEAVE SELF COLOUR
C9
PAINT IN ACCORDANCE WITH LOCAL STANDARDS
C10
APPLY PRIMING AND FINISHING COAT SYSTEM IDENTICAL TO THAT APPLIED TO ADJACENT SURFACES (SEE NOTE C.10)
C11
NO FINISHING COAT SYSTEM TO BE APPLIED
C12
HEAT CURE SILICONE BASED COATINGS IN ACCORDANCE WITH MANUFACTURERS' RECOMMENDATIONS
Note: (C5)
For C5 where spot clean and touch-up of damaged areas of galvanized surfaces and shop applied inorganic zinc silicate coating o
(B1) is involved, use organic zinc rich polyamide cured epoxy primer (B2) for operating temperatures up to 150 C, and limit the o
use of inorganic zinc silicate (B1) to surfaces having an operating temperature in excess of 150 C. (C10)
For C10 where it is required to apply a priming and finishing coat system identical to adjacent surfaces in way of bolted areas etc., use the specified inorganic zinc silicate primer (B1) where it has been possible to blast clean the surface or where the operating o
o
temperature is in excess of 150 C, and use aluminium filled modified epoxy (B6) as a primer for surfaces up to 150 C where it has only been possible to power tool clean the surface.
[Paint] 14 Table No. 4
Final Coat Colors, Marking and MUNSELL & RAL CODE Table
4-1. Final coat colors and Marking GROUP
APPLIED FACILITIES
Safety
High expansion foam facilities,
device
dry chemical extinguish facilities,
FINISH COLOR
BAND COLOR
(Munsell No)
(Munsell No)
Red (5.0 R 4 / 13)
LETTER’G
--
LETTERING COLOR White (N 9.0)
foam crib, monitor, hydrant Fire water piping
Blue (7.5 B 5 / 9)
FW
Fire extinguishing agent pumps, equipment (fire truck, extinguishers, etc), and switch panel (SPB) Radioactivity equipment &
Yellow (2.5 Y 8 / 14)
storage area
Red Purple (10 RP 4.5/13)
Hot &
LNG
Yellow (2.5 Y 8 / 14)
LNG
Cold
NG, BOG
Yellow Red (7.5 YR 6 /
NG, BOG
Industrial water, Potable water,
Blue (7.5 B 5 / 9)
Silver grey (aluminium)
insulated piping
Black (N1.0)
12) Cooling water, Raw water B-C oil
IW, PW,
White (N 9.0)
CW, RW Silver grey (aluminium)
Red Purple (10 RP
BC
4.5/13) Piping
NG
Green grey (7.5 GY 5.5 / 1)
BOG
Yellow Red (7.5 YR
NG
White (N 9.0)
6/12)
BOG
Black (N1.0)
Fuel gas
Yellow Red (7.5 YR 6 / 12)
Neutral grey (N 7.5)
FG
Nitrogen gas
Neutral grey (N 7.5)
White (N 9.0)
N2
Plant & Instrument air
White (N 9.0)
Green (2.5 G 5.5 / 7)
IA, PA
Odorant
Yellow (2.5 Y 8 / 14)
Neutral grey (N 7.5)
ODOR
Black (N1.0)
Industrial water, Potable water,
White (N 9.0)
Blue (7.5 B 5 / 9)
IW, PW,
White (N 9.0)
Cooling water,
CW
Seawater (for vaporisers)
SW
B-C oil
Silver grey (aluminium)
Red Purple (10 RP
White (N 9.0)
BC
4.5/13) Diesel oil
Red Purple (10 RP 4.5/ 13)
Valves
Valves
Green grey (7.5 GY 5.5/ 1)
Tanks
Nitrogen Tank
White (N 9.0)
Black (N1.0)
HCL storage tank
Red Purple (10 RP 4.5/ 13)
White (N 9.0)
B-C oil storage tank
Silver grey (aluminium)
Black (N1.0)
Diesel oil storage tank
Neutral grey (N 7.5)
Odorant tank
Yellow (2.5 Y 8 / 14)
Industrial water, Potable water,
White (N 9.0)
Neutral grey (N 7.5)
DO
Black (N1.0) White (N9.0)
Fire water Drums
Purge & Cool-down Drum, LNG
Black (N1.0)
Silver grey (aluminium)
drain drum
Pumps
Nitrogen drum
White (N 9.0)
Air Receiver drum
Green grey (7.5 GY 5.5 / 1)
White (N9.0)
LNG pump
Silver grey (aluminium)
-
-
Black (N1.0)
Industrial water, Potable water,
Blue (7.5 B 5 / 9)
-
-
White (N9.0)
Fire water, Cooling water, Rain & Drain water pump Nitrogen pump
Neutral grey (N7.5)
-
-
Black (N1.0)
HCL pump
Red Purple (10 RP 4.5/ 13)
-
-
White (N9.0)
Sea water pump (vaporizer & fire
Neutral grey (N 7.5)
-
-
Black (N1.0)
Odorant pump
Yellow (2.5 Y 8 / 14)
-
-
RGB, BOG comp., Air comp.
Purple blue (2.5 PB 3 / 9)
-
-
sea water) Comp.
White (N9.0)
[Paint] 15 GROUP
APPLIED FACILITIES
FINISH COLOR
BAND COLOR
(Munsell No)
(Munsell No)
LETTER’G
LETTERING COLOR
Heat
ORV, Gas heater, S/W heater,
exchanger
HP & LP nitrogen vaporiser
/ Heaters
Air dryer
Green (2.5 G 5.5/ 7)
-
-
White (N 9.0)
Others
Loading/Unloading arm
White (N 9.0)
-
-
Black (N1.0)
equipment
Cooling tower & Gas filter
Green grey (7.5 GY 5.5 / 1)
-
-
White (N 9.0)
Silver grey (aluminium)
-
-
Black (N1.0)
Crane & Hoist, Elevator
Yellow (2.5 Y 8 / 14)
-
-
Black (N1.0)
Sluice gate
Black (N1.0)
-
-
White (N 9.0) Black (N1.0)
S/W filter
Neutral grey (N 7.5)
-
-
Silencer
Silver grey (aluminium)
-
-
Electric
Emergency generator,
Neutral grey (N 7.5)
--
equipment
transformer, UPS, condenser,
Black (N1.0)
panel Paging system, electric motor,
--
supports (panel & J/B) Steel
Flare stack
White (N 9.0) / Red (5.0 R
-
structure
Vent stack
4 / 13)
--
Pipe rack, Support
Green yellow (10 GY 6 / 5)
-
Platform & Ladder
Green grey (7.5 GY 5.5 / 1)
-
-
Ladder cages, handrail and
Yellow (2.5 Y 8/14)
-
-
Grating
Silver grey (aluminium)
-
-
cable trench cover, valve box
Green grey (7.5 GY 5.5 / 1)
-
-
-
handrail stanchion, kick plate
cover
CON’C
Door & shutter, Gate
Neutral grey (N 7.5)
-
-
Shelter for Fire water pump
Blue (7.5 B 5 / 9)
-
-
Signboard, bulletin board
Neutral grey (N7.5)
HP ORV, LP ORV, Dike for tank
Green (2.5 G 5.5 / 7)
-
-
Sub-station, ware house,
Neutral grey (N 7.5)
-
-
Black (N1.0)
Yellow (2.5 Y 8 / 14) / Black
--
-
Black (N1.0)
COLOR
MUNSELL No.
White (N 9.0)
maintenance shop, air compressor room, bunker-C boiler room Protection wall
(N1.0) Envir.
Waste water treatment system
Note : Tolerance for color is
Neutral grey (N 7.5)
Hue ±2, V alue ±0.3, C hromatism ±1
4-2. MUNSELL& RAL CODE COLOR
MUNSELL No.
RAL CODE
RAL CODE
RED
5.0 R
4 / 13
3000
BLUE
7.5 B 5 / 9
5012
YELLOW RED
7.5 YR 6 / 12
1007
PURPLE BLUE
2.5 PB 3 / 9
5005
YELLOW
2.5 Y 8 / 14
1003
RED PURPLE
10 RP 4.5 / 13
3027
GREEN YELLOW
10 GY 6 / 5
6021
WHITE
N 9.0
9010
GREEN
2.5 G
5.5 / 7
6001
NEUTRAL GRAY
N 7.5
7038
GREEN GRAY
7.5 GY 5.5 / 1
7033
BLACK
N 1.0
9017
ALUMINIUM
- 9006
(SILVER GRAY)
[Paint] 16 Table No. 5
Vessels, Exchangers and Utility Tanks SURFACE PREPARATION AND PAINT INDEX
PORTION OF ITEM
ITEM
(PAINT SYSTEM)
PREPAR’N
PRIMER
2ND COAT
C4/B2
Field welds (S12)
A1+A2+A12+A13
C4/B6
Field erected
Shells & roof, insulated,
A1+ A10
C4/B2
cone roof storage
Amb~93 C (S11)
tanks (External)
Field welds (S12)
A1+A2+A12+A13
C4/B6
Field erected
Bunker-c storage tank
A1+ A10
C4/B2
C4/B26
A9+C5+C4/B26
cone roof storage
Diesel oil storage tank
A1+ A10
C4/B32
C4/B33
A9+C5+C4/B33
tanks (All internal)
Industrial water storage tank
A1+ A10
C4/B3
C4/B12
A9+C5+C4/B13
Potable water storage tank
A1+ A10
C4/B34
C4/B35
A9+C5+C4/B35
Shells & roof, uninsulated,
cone roof storage
Amb~93 C (S11)
tanks (External)
Vessels &
o
o
o
A1+A10
C2 or C4/B1
C4/B3
A9+C5+C4/B13
o
A1+A5
C2 or C4/B1
A9+C5+C4/B7
C4/B7
A1+A5
C2 or C4/B1
A9+C5+C4/B14
C4/B14
Uninsulated –40 C ~93 C (S1) o
Uninsulated 94 C ~200 C (S2)
Carbon and
Uninsulated 201 C~400 C(S3)
construction Vessels &
4TH COAT
A9+C5+C4/B5
o
exchangers ferritic alloy steel
C4/B13
3RD COAT
A1+ A10
Field erected
o
o
o
o
Uninsulated 401 C~538 C(S4)
A1+A10
C2 or C4/B14
C2 or C4/B14
C5+C11+C12
A1+A10
C2 or C4/B1
C4/B28
C5+C11
Uninsulated 60 C ~120 C (S7)
o
o
o
o
o
Insulated -40 C~400 C (S13) o
A1+A14
C2 or C4/B8
A9+C5+C4/B3
A9 + C4/B13
exchangers
*Insulated +60 C ~120 C (S7)
A1+A14
C2 or C4/B8
As above
As above
Austenitic
Uninsulated or insulated
A1 + A14
C2 or C4/B14
C2 or C4/B14
stainless steel
121 C ~538 C (S4) A1+A10
C2 or C4/B1
C4/B3
A9+C5+C4/B13
A1+A10
C2 or C4/B1
C4/B12
C5+C11
B23
A1+A11+C10
B23
A1+A3+C10
o
C4/B5
o
construction Vessels &
Carbon steel skirts & saddles
exchangers
(S1)
supports
Carbon steel skirts & saddles
Carbon steel
to be fireproofed (S14)
Construction
Bolting on vessel / exchanger
C4/B5
flanges etc Bolting on vessel / exchanger flanges where vacuum blasting is not practicable Note
:
*Alternative paint system under insulation for S.S. is (B29 + B30), system S10.
Table No. 6 ITEM
Pump Casings and Compressors SURFACE PREPARATION AND PAINT INDEX
PORTION OF ITEM o
o
PREPAR’N
Pump casings
Uninsulated -170 C ~93 C
and compressors
(SM)
Carbons and
Uninsulated 94 C ~350 C(SM) C7
ferritic alloy steel construction
o
o
Insulated -170 C ~93 C (SM)
C5
C7
C5
Insulated 94 C ~350 C (SM)
C7
C5
Compressor surfaces
C7 C5
o
o
2nd COAT
C7 C5
o
o
PRIMER
including main casings, base plate, air coolers, lube/seal oil filters and piping (SM) Electric motors (SM) o
o
C7
C5
Pump casings
Uninsulated +60 C ~93 C
A1+A14
C2 or C4/B6
A9+C5+ C4/B5
Austenitic
(S15) o o Insulated +60 C ~93 C (S12)
A1+A14
C2 or C4/B6
C5+C11
stainless alloy construction
o
o
Pump casings
Uninsulated –170 C ~93 C
aluminium alloy
(SM)
construction Insulated
o
o
-170 C ~93 C (SM)
B24 A1 B24
A1
3rd COAT
th
4 COAT
[Paint] 17 Table No. 7
Structural Steel
PORTION OF ITEM
ITEM
SURFACE PREPARATION AND PAINT INDEX
(PAINT SYSTEM)
Structural steel
PREPAR’N
Bare structural steel members and
PRIMER
2nd COAT
3rd COAT
A1+A10
C2 or C4/B1
C4/B3
A9+C5+C4/B
A1+A10
C2 or C4/B1
C4/B12
C5+C11
A1+A10
C2 or C4/B1
C4/B3
A9+C5+C4 /
platform supports (S1)
4th COAT C4/B5
13
Structural steel members to be concrete fireproofed (S14), or Structural steel members to be paint fireproofed.
C4/B5
B36
Contact steel surfaces in way of
A1+A10
C2 or C4/B1
C11
A1+A10
C2 or C4/B1
C4/B3
friction type bolted joints (S16) o
o
CS pipe supports 40 C ~93 C (S1)
A9+C5+C4 /
C4+B5
B13 o
o
CS pipe supports 94 C ~350 C (S3)
A1+A10
C2 or C4/B1
A9+C5+C4/
C4+B14
B14 o
o
SS pipe supports -170 C~93 C (S8)
A1+A14
C2 or C4/B8
A9+C5+C4/ B5
Field welds on structural steel
A13+A11
C10
Field welds on galvanised steel
A13 + A11
C5 + C11
Ladder cages, handrail and handrail
A1+A8+A4 B20
C5+A1+A15
stanchion, kick plates, (S23) Open grid flooring, platforms, stair
C11
+ C1 / B31 A1+A8+A4 B20
C5 +C11
assemblies, (S17) Steel piles (S24)
A1+A10
C2 or C4/B26
C2 or C4/B27
Note: The bolts, nuts and washers on painted or galvanised structures may be either hot dip galvanised to ASTM A123 or ASTM A153 as appropriate, or mechanically galvanised in accordance with ASTM B695, Class 50 or higher. Galvanised high strength bolting shall be to ASTM A325 Type 1. The rods, clevises, clamps used in pipe support and guide assemblies, excluding springs and other standard manufactured items, shall be to the above mentioned standards. The galvanised items are unpainted, unless specified for safety markings on other considerations. For the detailed specification and work procedure for the fireproof coating, Refer to Construction Specification for Steel Structure provided by Architecture Discipline.
Table No. 8 ITEM
Electrical and Instrument Equipment SURFACE PREPARATION AND PAINT INDEX
PORTION OF ITEM PREPAR’N A1+A8+A4
PRIMER
Electrical and
Cable trunking (S17)
instrument
Cable trays (S17)
equipment other
Electric motors (SM)
than control
Switches, transforms etc (SM)
C7
C5
valves
Instruments & instrument boxes
C7
C5
2nd COAT
B20
C5+C11
A1+A8+A4
B20
C5+C11
C7
C5
3rd COAT
4th COAT
(SM) Wall type panels (SM)
C7
C5
Console type panels, all surfaces
C7
C5
A1+A10
C2 orC4/B1
incl. cabinets and desks (SM) Instrument support steelwork (S1)
C4/B3
A9+C5+C4/ B13
C4/B5
[Paint] 18 Table No. 9 ITEM
Carbon & Ferritic Alloy Steel Piping & Fittings PORTION OF ITEM o
o
Above ground carbon
Uninsulated -40 C ~93 C
and ferritic steel piping
(S1)
SURFACE PREPARATION AND PAINT INDEX PREPAR’N
PRIMER
A1+A10
C2 or C4/B1
2nd COAT C4/B3(S)
3rd COAT A9+C5+C4/
4th COAT C4/B5
B13 o
o
including nipples, fittings,
Uninsulated 94 C ~200 C
flanges, line blinds
(S2)
A1+A5
C2 or C4/B1
A9+C5+C4/
C4/B7
B7 o
o
Uninsulated 201 C ~400 C
A1+A5
C2 or C4/B1
(S3)
A9+C5+C4/
C4/B14
B14 o
o
Uninsulated 401 C ~538 C
A1+A10
C2 or C4/B14
C2/C4/B14
C5+C11+C1
A1+A10
C2 or C4/B1
C4/2B3
C5+C11
(S4)
2 o
o
Insulated -40 C ~150 C (S5) o
o
Insulated 151 C ~400 C (No)
C6 C6
Weld end speciality
Weld margins 50 mm from
A13+A11 C10
inline components such
each of all pipes and fittings
as strainers where not galvanised o
o
Carbon and ferritic alloy
Uninsulated –40 C ~93 C
steel valves including
(S6)
control valves, flanged
Uninsulated 94 C~400 C(SM)
end speciality inline components such as flow indicators, flanged strainers, steam traps etc.
C7 A1+A3+C4/B
C4/B5 6
o
o
o
o
Uninsulated –40 C ~150 C
C7 C5 C7 C5
(SM) o
o
C7 C5
o
o
Insulated 151 C ~400 C (SM)
C7 C5
Valve handwheels, valves
C7 C5
Insulated –40 C ~150 C (SM)
spindles, flange facings, orifice plates, (SM) Machined surfaces and
B25
A1+C6
threads
Table No. 10 ITEM
Austenitic Stainless Steel Piping & Fittings SURFACE PREPARATION AND PAINT INDEX
PORTION OF ITEM PREPAR’N o
o
Above ground austenitic
Uninsulated 60 C ~120 C
stainless steel piping
*1)
incl. nipples, fittings,
Insulated 60 C ~120 C
flanges, line blinds, weld
*1)
end speciality Inline
Weld margins 50 mm from
components such as
each end of all pipes and
strainers
fittings
Austenitic stainless
Uninsulated -170 C ~80 C
valves incl. control
(S8)
valves, flanged end
Insulated -170 C ~80 C (S9)
A1+A10(S) C2
or
2nd COAT
3rd COAT
C5+C4/B5 C5+C4/B13
C4/B8(S) o
o
A1+A14(S) C2
or
C5+C11 As
C4/B8(S)
o
o
A13+A11 C10
A1+A14(S) C2
or
C5+C4/B5
C4/B8(S) o
o
A1+A14(S)
speciality inline
C2 or
C5+C11
C4/B8(S)
components such as
Valve handwheels, valves
flow indicators, flanged
spindles, flange facings, orifice
strainers etc.
PRIMER
C7(S) C5
plates Machined surfaces, threads
B25(S)
A1+C6
Note: SHOP PREPARATION OR COATING When the letter (S) signifying shop preparation or coating suffixes the code i.e. A3 or C1(S) the required operation shall be carried out in the shop by the Vendor or in a fabrication shop at site. *1) see para. 10.1
for area to be painted.
above
4th COAT
[Paint] 19 Table No. 11 ITEM
Flare Stack and Support Structures
PORTION OF ITEM
SURFACE PREPARATION AND PAINT INDEX PREPR’N
3rd COAT
A1+A14 C2/B7/C12
C2/B7/C12
C5
A1+A14 C2/B14/C12
C2/B14/C12
C5
Stainless steel bolting
B25
A1+A11+C10
Field painting to be
Flare tip
B24
A1+C6
carried out after
steel surfaces of
120 C (s18)
risers and piping
Zone B, radiation temp.
associated with flare
between 121 C and 260 C
C2 or C4/B8
2nd COAT
A9+C5+C4/
Zone A, radiation temp. below
A1+A14
PRIMER
A9+C5+C4/B12
Austenitic stainless
o
4th COAT
B13 o
stacks
(S19)
(Note 1)
Zone C, radiation temp. o
o
o
between 261 C and 540 C (S4)
final tightening of bolts to exposed threads only Carbon steel
Zone A, Radiation Temp.
surfaces of piping,
Below 120 C (S20)
support structures,
Zone B, Radiation Temp. 121
handrail, ladders,
o
ladder cages,
Zone C, Radiation temp. 261
walkways,
o
stairways, grating,
Heads and Nuts of Structural
motors, gearboxes,
Steel and Pipework Bolting
A1+A10
C2 or C4/B1
C4/B3
A9+C5+C4/
o
C4/B13
B12 A1+A5
C2 or C4/B1
A9+C5+C4/B9
C4/B9
C4/B9
C4/B9
o
C ~400 C (S21) A1+A5 B22
C5
o
C ~ 540 C (S22)
winches, coupling
(S16)
and tackle
Threads of Structural Steel
associated with flare stack
A1+A10
C2 or C4/B1
A9+C5+C10
B25
A1+A11+C10
Field painting to be
and Pipework Bolting
carried out after final tightening of
(Note 1)
bolts to exposed threads only
Note 1: In Zones A, B, C, one paint system based on 2 coats of polysiloxane inorganic paint at 125 microns each coat can be considered (S22).
Table No. 12
Paint Systems and Codes
PAINT
PAINT CODES
PAINT
PAINT CODES
SYSTEM
(See Table No. 2 for code description.)
SYSTEM
(See Table No. 2 for code description.)
No NO
S13
B1+B28
S1 B1+B3+B13+B5
PAINT IS APPLIED
S14
B1+B12
S2 B1+B7+B7
S15
B6+B5
S3 B1+B14+B14
S16
B1
S4 B14+B14
S17
B20
S5 B1+B3
S18
B8+B12+B13
S6 B6+B5
S19
B7+B7
S7 B8+B3+B13
S20
B1+B3+B12+B13
S8 B8+B5
S21
B1+B9+B9
S9 B8
S22
B22+B9+B9
S10 B29+B30
S23 B20+B31
S11 B2+B13+B5
S24
B26+B27
SM
Manufacturer’s Standard Approved System
S12
B6
[PV] 1
STANDARD SPECIFICATION FOR PRESSURE VESSELS
0
2008. 08. 03
REV. NO.
DATE
Issued for Construction DESCRIPTION
H.C. Oh J.K. Lee J.H. Yoon DESIGN CHECK Q.A
M.S. Kang APPROVED
CLIENT APPROVED
KOREA GAS CORPORATION 통영생산기지 2 단계 6 차 확장공사 TONGYOUNG LNG TERMINAL 6th EXTENSION PROJECT STANDARD SPECIFICATION FOR PRESSURE VESSELS
SCALE
JOB NO.
PHASE
DOCUMENT NO.
REV.
NONE
3415.99
II
26 – M – O00 – SP – 203
0
DAEWOO ENGINEERING COMPANY KOREA GAS TECHNOLOGY CORPORATION
[PV] 2
TABLE OF CONTENTS 1.
2.
3.
4.
5.
GENERAL .................................................................................................................................................... 4 1.1
Scope ........................................................................................................................................... 4
1.2
Units of Measurement .................................................................................................................. 4
1.3
Codes and Standards ................................................................................................................... 4
DESIGN........................................................................................................................................................ 5 2.1
Shell and Head Seam Layout....................................................................................................... 5
2.2
Reinforcement of Openings.......................................................................................................... 5
2.3
Reinforcement at Cone-to-Cylinder Intersections. ....................................................................... 6
2.4
Torispherical / Toriconical Head Design ....................................................................................... 6
2.5
Nozzle and Connections .............................................................................................................. 6
2.6
Manholes, Handholds, Body Flanges, and Covers ...................................................................... 7
2.7
Corrosion Protection..................................................................................................................... 7
2.8
Vessel Internals ............................................................................................................................ 7
2.9
Linings .......................................................................................................................................... 8
2.10
Wind and Earthquake Design....................................................................................................... 8
2.11
Design Conditions (Loading) ........................................................................................................ 9
2.12
Design Stresses............................................................................................................................ 9
2.13
Supports ..................................................................................................................................... 10
2.14
Lifting Attachments ..................................................................................................................... 10
2.15
Minimum thickness ..................................................................................................................... 10
MATERIALS ................................................................................................................................................11 3.1
General........................................................................................................................................11
3.2
Welding Electrodes......................................................................................................................11
3.3
Bolting..........................................................................................................................................11
3.4
Gaskets .......................................................................................................................................11
3.5
Supplementary Materials.............................................................................................................11
FABRICATION............................................................................................................................................ 12 4.1
Design of Welded Joints............................................................................................................. 12
4.2
Preparation for Welding.............................................................................................................. 12
4.3
Preheat ....................................................................................................................................... 12
4.4
Welding....................................................................................................................................... 13
4.5
Heat Treatment........................................................................................................................... 13
4.6
Tolerances .................................................................................................................................. 14
INPSECTION, REPAIRS, TESTING AND REJECTION ............................................................................ 14 5.1
Code Inspection.......................................................................................................................... 14
5.2
Inspection / Examination – General Requirements.................................................................... 14
5.3
Radiography ............................................................................................................................... 14
[PV] 3 5.4
Surface Examination .................................................................................................................. 15
5.5
Ultrasonic Examination............................................................................................................... 15
5.6
Chemical Analysis ...................................................................................................................... 16
5.7
Hardness Testing........................................................................................................................ 16
5.8
Leak Testing ............................................................................................................................... 17
5.9
Pressure Testing......................................................................................................................... 17
5.10
Report of Defective Welds.......................................................................................................... 17
5.11
Rejection..................................................................................................................................... 17
6.
NAMEPLATE.............................................................................................................................................. 18
7.
PAINTING................................................................................................................................................... 18
8.
MARKING................................................................................................................................................... 18 8.1
General....................................................................................................................................... 18
[PV] 4
1.
GENERAL 1.1 Scop
e
This specification defines mandatory technical requirements for the design, material, fabrication, testing, and inspection of pressure vessels for Tong-young LNG Terminal. 1.2
Units of Measurement Unless otherwise specified, international SI (Metric, Pascal, Celsius and Kilogram, etc) units shall be used for all drawings and documents to be submitted by the vendor.
1.3
Codes and Standards The documents listed below are referenced herein and form part of the order when listed on the Requisition.
Unfired pressure vessels ASME Sec. VIII, Div. 1 Korean local regulation
Pressure Vessel
Piping (cryogenic and non-cryogenic) ANSI B1.20.1 ANSI B16.5 ANSI B16.20 ANSI B16.21 ASME B16.47 series A
Pipe Threads Pipe Flanges and Flanged Fittings Ring Joint Gaskets & Grooves for Steel Pipe & Flanges Non-metallic Gaskets for Pipe Flanges Large Diameter Steel Flanges NPS 26 Through NPS 60”
Welding ASME Sec. II ASME Sec. VIII, Div. 1 ASME Sec. IX AWS standards
Material Specification, Part C – Welding Rods, Electrodes and Filler Metals Pressure Vessels Welding and Brazing Qualification
Material ASTM
Painting Purchaser’s spec.
Insulation Purchaser’s spec.
24-M-O00-SP-201, Paint & Protective Coatings
[PV] 5
2.
DESIGN 2.1
2.2
Shell and Head Seam Layout 2.1.1
Longitudinal seams in adjacent shell rings shall be offset by a minimum of 4 time the plate thickness or 150mm whichever is greater.
2.1.2
Seams in horizontal vessels shall not be located coincident with or across saddle supports.
2.1.3
Plate layout shall be arranged so that to the maximum extent possible, longitudinal and circumferential weld seams clear all nozzles, man ways, and their reinforcing pads by 50mm minimum measured weld edge to weld edge.
2.1.4
When nozzles must penetrate, or when nozzles reinforcing pad must cover weld seams, the seam shall be ground flush and 100% radiographically examined before welding the nozzle. The seam shall be radiography for a distance of 150mm beyond the nozzle or the outside diameter of the reinforcing pad, whichever is greater.
2.1.5
Structural attachment welds such as internal support rings or clips, external stiffening rings, insulation support rings, and ladder, platform or pipe support clips shall clear seams by at least one plate thickness or 25mm, whichever is greater. If overlap of pad type structural attachments and weld seams is unavoidable, the portion of the seam to be covered shall be ground flush and 100% radiographically examined before the attachment is welded on. The seam shall be radiographer for a distance of 150mm beyond the edge of the overlapping attachment. Radiographic examination of weld seams is not required when single plate type attachments such as tray support rings, downcomer bolting bars, stiffening rings, installation support rings, ladder, platform, or pipe support clips cross weld seams.
Reinforcement of Openings 2.2.1
Nozzle reinforcement shall be designed for the maximum allowable working pressure (MAWP) for which the vessel is rated. Nozzle reinforcement shall not limit the vessel’s MAWP.
2.2.2
Vessels 1219mm inside diameter and larger shall have all large openings exceeding the limits defined in Paragraph UG-36 (b) (1) of ASME Section VIII, Division 1, designed in accordance with the paper titled “Design of Radial Nozzles in Cylindrical Shells for Internal Pressure” ASME Transactions, Volume 102, February 1980, page 70. This requirement applies to Division 1 vessels only.
2.2.3
The following nozzle reinforcing requirements shall apply (except as noted below) to vertical vessels having H/D ratios greater than 5, where H is the vessel length between tangent lines and D is the vessel inside diameter (or the smallest diameter of vessels having more than on diameter). These requirements do not apply to NPS 3 and smaller openings that are not required to have reinforcement. The total cross-section area of reinforcement required, A, shall not be less than : A = d x t (mm2), where : d : the diameter of the finished opening in its corroded condition (mm), and t : the nominal thickness of the shall less corrosion allowance (mm), as given on the design drawings at the nozzle location. All metal area within the limits of reinforcement, expect excess shell/head metal area (unless specifically added for that purpose e.g., a thicker insert plate or course), may be considered as having reinforcing value as permitted by the Code.
2.2.4
Each reinforcing pad, or segment if more than one piece is used, shall be provided with one NPS 1/4 NPT threaded hole. Welds in segmented two-piece reinforcing pads on cylinders and cones shall be full penetration butt-welded in the vessel’s circumferential direction. The
[PV] 6 outside edge of reinforcing pads shall be ground or otherwise made reasonably smooth before welding to the vessel. 2.3
Reinforcement at Cone-to-Cylinder Intersections. The reinforcement at junctions of conical reducers with heads, cylinders, or other conical reducers shall be designed for the MAWP for which the vessel is rated (see Paragraph 2.2.1). Cone-tocylinder reinforcement shall not limit the vessel’s MAWP.
2.4
Torispherical / Toriconical Head Design Torispherical and toriconical heads on Division 1 vessels shall be checked for head knuckle wrinkling during hydrotest (future corroded condition) in accordance with Division 2, part AD-204 requirements. Allowable stress shall not exceed 90% of the yield stress.
2.5 No 2.5.1
zzle and Connections Flange bolt hole orientation shall be as follows : (Refer to Figure 1) 1)
When the nozzle axis lies in a plane perpendicular to the longitudinal axis of the vessel, the bolt holes shall straddle the flange centerline parallel to the vessel axis.
2)
When the nozzle axis is parallel to or coincides with the longitudinal axis of the vessel, the bolt holes shall straddle the north-south flange centerline on vertical vessels and the vertical flange face centerline on horizontal vessels.
3)
When the nozzle axis is radial to the vessel head surface, the bolt holes shall straddle the flange face centerline lying in plane containing the vessel axis.
4)
Bolt hole orientation of nozzles not specified above will be shown on the drawings.
FIGURE 1 FLANGE
BOLT HOLE ORIENTATION
2.5.2
Where internal projection will interfere with internals or the flow of process fluids, nozzles and manholes shall be flush with the inside contour of the vessel. Drain and pressure relief valve (PRV) nozzles must be flush. The inside corner of nozzle necks shall be rounded to eliminate all sharp edges.
2.5.3
When tongue and groove facing is used, the groove shall be in the nozzle flange, except when the nozzle is located in the bottom head of a vessel, the groove shall be in the piping flange or blind cover.
2.5.4
Slip-on flanges shall not be used for flange ratings above Class 150. When slip-on flanges are permitted and used, the annulus between the slip-on flange and the nozzle neck shall be vented to the outside by 1/8 inch diameter hole.
[PV] 7 2.5.5
The inside diameter of nozzles shall not be less than the inside diameter of the corresponding size of double extra strong pipe for NPS 1 to NPS 3 nozzles inclusive, Schedule 160 pipe for NPS 4 to NPS 12 nozzles inclusive, and nominal diameter minus 2 inches for nozzles over NPS 12.
2.5.6
Flanges for external nozzles NPS 24 and smaller shall be in accordance with ASME B16.5. Flanges for external nozzles NPS 26 through NPS 60 shall be in accordance with ASME B16.47 Series A. For sizes over NPS 60, flange dimensions will be shown on vessel drawings or data sheets. With prior approval of the Purchaser, special flanges may be designed in accordance with Code rules for the design and test conditions of the vessel.
2.5.7
Pressure flanges shall be furnished to gasket surface finish as defined by Piping Material Specification unless otherwise specified on vessel drawings or data sheets.
2.5.8
Internal flanges for non-pressure connections may be of plate construction with machined flat faces.
2.5.9
External threaded connections shall not be used.
2.5.10 Internal non-pressure threaded connections may be Class 3000 or Class 6000 standard halfcouplings. 2.5.11 All threaded connections shall have NPT threads conforming to ASME B1.20.1 2.6
Manholes, Handholds, Body Flanges, and Covers 2.6.1
All covers and blind flanges weighing over 34kg shall be furnished with davits, hinges, or lifting / handling lugs.
2.6.2
Horizontal manhole openings in vessels shall be furnished with a hand-grip inside the vessel above the manhole.
2.6.3
Manholes, hand-holes, flanged vessel covers, blind flanges or body flanges shall be in accordance with ASME B16.5, ASME B16.47 Series A, or with prior approval of the Purchaser, may be designed in accordance with Code rules for the design and test conditions of the vessel. The final flange thickness shall include the specified corrosion allowance. ASME B16.5 or ASME B16.47 blind flanges may be used on vessels with a corrosion allowance of 1/4 inch or less without further checks.
2.7 Co
rrosion Protection
2.7.1
In alloy, alloy lined, or clad vessels or sections of vessels, all surfaces of pressure parts, and non-pressure parts which are non-removable and exposed to the contained media, shall either be fabricated of or protected by the alloy material (weld overlay or cladding) specified for the vessel.
2.7.2
In unlined vessels or sections of vessels, all surfaces of pressure parts and non-pressure parts welded directly to the pressure parts or those which are otherwise non-removable and are exposed to the contained media, shall have the specified vessel corrosion allowance added to each surface. Corro sion allowance shall not be added to replaceable non-pressure parts.
2.7.3
The minimum corroded thickness of non-removable parts, parts welded directly to the vessel, and the throat of fillet welds shall be 3mm.
2.8 V 2.8.1
essel Internals Removable internal parts shall be designed in units as large as can be withdrawn from the vessel through the nearest manhole or opening indicated for the purpose. When internals are obviously not capable of being removed through a manhole (e.g., NPS 24 internal piping in a vessel with an NPS 24 manhole) they shall have corrosion allowance added in accordance with Paragraph 2.7.2.
[PV] 8 2.8.2
2.8.3
2.8.4
2.9 Lining
Trays and removable tray supports required as internals for vessels shall be fabricated by the tray manufacturer and, unless otherwise noted on the vessel drawings or data sheets, shall be shop-installed by the vessel manufacturer. All welded-in tray supports shall be designed and detailed by the tray manufacturer, but fabricated and installed by the vessel manufacturer. Tray and tray support installation shall be in accordance with the tray manufacturer’s drawings and recommendations. The installer shall exercise sufficient care and make inspections during bolting and packing to provide assurance that leakage tests (bubble cap trays) or levelling required by the applicable standard listed in the Requisition and Order will be met in the field. 1)
The Purchaser shall be notified one week before try installation is started.
2)
Trays shall be installed after any required post weld heat treatment.
3)
Tray manways shall be installed after the Purchaser has completed all inspections. All gaskets shall be installed and bolting fully tightened before shipment.
4)
Adjustable weirs shall be shop-installed at the weir height specified on the tray manufacturer’s drawings.
Internal non-pressure carbon and low alloy (9% Cr maximum) pipe and fittings removable through the vessel manhole shall have the following minimum nominal wall thickness or ratings : 1)
Pipe NPS 12 and smaller
: standard wall
2)
Pipe NPS 14 and larger
: 6.0mm
Internal non-pressure high-alloy (11% Cr and over) pipe and fittings shall have the following minimum nominal wall thickness or ratings : 1)
Pipe NPS 6 and smaller
: Sch. 40S
2)
Pipe NPS 8 and larger
: Sch. 10S
s
2.9.1
Vessels requiring linings shall be either weld overlayed or fabricated from integrally clad plate conforming to ASME SA-263, 264, or 265. Strip-type linings shall not be used unless specified by the Purchaser.
2.9.2
Vessels with integrally clad linings shall be made of plate clad with the required lining material at the steel mill in accordance with the applicable material specifications. Explosion clad material shall not be used without the advance written consent of the Purchaser.
2.9.3
Lining / cladding / weld overlay shall be considered as corrosion allowance and not considered in strength calculations.
2.9.4
Clad or lined materials shall not be used for cryogenic service.
2.10
Wind and Earthquake Design
2.10.1 The design for wind and earthquake shall be based on the requirements set forth on the design drawings. 2.10.2 The effective diameter to be used for vertical vessel wind design shall be : De = [1.1 (ID + 2 (ts + t1) / 1000) + 0.9 + OP] x Sf Where
De
:
is effective wind diameter
(m)
ID
:
is vessel inside diameter
(m)
ts
:
vessel thickness
t1
:
vessel insulation thickness
(mm)
OP
:
insulated diameter of overhead line
(m)
(mm)
[PV] 9 Sf
:
Shape factor, as defined by applicable Wind Code
This effective diameter includes wind loads on platforms, ladders, and piping. The 0.9 factor in the above equation may be deleted for small vessels that do not have platforms or ladders. In addition to the wind loading calculated above on the cylindrical part of the vessel, the top head platform wind load shall be calculated as follows: F = 3.3 W Qf Where
F : is W : is
the wind force on the top head platform the larger of 1.3 or the vessel inside diameter
(N) (m)
Qf : is the wind pressure at the top head platform elevation (N/m2) The wind force on the top head platform is to be applied 0.45 m above the top head. (e.g. on a vessel with a 2:1 elliptical head, the wind force shall be applied at a distance of ID / 4 + 0.45 m above the top tangent line) 2.10.3 Vertical vessels shall be designed for an allowable deflection of 50 mm per meter of vessel height or the deflection specified on the vessel drawing or data sheet. 2.10.4 Vertical vessels with H / D ratios exceeding 15, where H is the length of the vessel from the point of support to the top tangent line and D is the average diameter in the top third of the tower, shall be checked for “vortex shedding vibrations” from winds to ensure their structural stability. 2.11 De
sign Conditions (Loading) Vessels and their supports shall be designed to resist the effects of the following combinations of loads within the limits of allowable stress specified in Article 2.12. Wind, earthquake, or dynamic loads shall not be assumed to occur simultaneously.
2.11.1 Empty erected equipment : The erected dead load of the empty vessel combined with the greater of wind or earthquake load. 2.11.2 Operation : The design pressure, the operating dead load of vessel, the maximum operating contents of the vessel, the operating equipment and external attachment loads, and any other applicable operating effects such as unbalanced pressure, vibration, thermal gradients, or impact, combined with or without wind or earthquake load. The most conservative combination of these loads shall be used. 2.11.3 Test : The test pressure, the test dead load of the vessel and equipment, and the weight of the testing contents of the vessel and any other equipment as may be affected, combined with 1 / 3 of the design wind load with the vessel in corroded condition for future field hydrotest. 2.12 De
sign Stresses For the design conditions given, the calculated stresses shall be maintained within the following limits :
2.12.1 Empty erected vessel : Based on the thickness exclusive of corrosion allowance at ambient temperature, the basic allowable stress increased by 20%. 2.12.2 Operation : Based on the thickness exclusive of corrosion allowance at the design metal temperature, the allowable stresses permitted by the applicable code. 2.12.3 Test : Based on the test thickness at the test temperature, for pressure parts, 90% of specified minimum yield strength, except that Division 1 austenitic stainless steels may be stressed up to 95% of specified minimum yield strength, for non-pressure parts, the basic code allowable stresses increased by 33-1/3%. 2.12.4 All design conditions : the maximum allowable longitudinal compressive stress for support skirts shall be determined in accordance with Division 1, paragraph UG-23.
[PV] 10 2.12.5 Carbon steel anchor bolting shall be designed to an allowable stress of 14kg/mm2 (20,000 psi) based on the root area of the thread (no further increases in stress allowed for wind / earthquake). High strength anchor bolting shall be designed to the allowable stress specified on the vessel drawing or data sheet based on the root area of the thread (no further increase in stress allowed for wind / earthquake). 2.12.6 Welds attaching non-pressure parts to the pressure parts shall be designed to the allowable stress of the weaker of the parts being joined. 2.13 Suppo
rts
2.13.1 Vertical vessels supported by skirts shall conform to the following requirements. 1)
The centerlines of the skirt and the corroded shell plate (bottom course) shall be approximately coincident, except for conical skirts attached to the shells of vertical vessels.
2)
Each skirt opening, NPS 4 and larger on vertical vessels having a height-to-diameter ratio greater than 5, shall have reinforcing sleeves welded to the skirt with double fillet welds and penetration welds as required. The sleeve thickness shall be such that the sleeve replaces the area removed from the skirt unless a reinforcing pad is used for area replacement. Large skirt openings may be reinforced by using other means such as stiffeners.
2.13.2 Horizontal vessels supported on saddles shall have stresses from saddle reactions checked in accordance with the “L. P. Zick” method. 2.14 Lif
ting Attachments
2.14.1 Vertical vessels weighting more than 11,340kg (25,000 lbs) shall be supplied with lifting lugs, trunnions, or covers. When specified in the vessel drawings or data sheets, tailing lugs and any required skirt bracing shall be furnished 2.14.2 Lifting lugs, trunnions, covers, tailing lugs and skirt bracing shall be designed using a 1.5 impact factor. 2.15 Minimum
thickness
2.15.1 The minimum shell or head thickness shall be the greater of the following : 1)
[ vessel inside diameter in mm + 2540 ] / 1000.
2)
4.8mm (3/16 inch) plus corrosion allowance for carbon and low alloy steel vessels.
3)
3.2mm (1/8 inch) for high alloy steel vessels.
4)
9.5mm (3/8 inch) composite thickness for clad plate.
2.15.2 The nominal thickness of alloy cladding shall be 0.42mm (5/64 inch). 2.15.3 The minimum thickness of skirts shall be the greater of 6.0mm or 1/4 of the shell ring thickness where the skirt is attached. (e.g., The bottom shell ring thickness when the skirt is attached to the bottom head.) Unless required by design conditions / loading, the skirt thickness need not be greater than 38mm thick.
[PV] 11
3.
MATERIALS 3.1 Gene
ral
3.1.1
All materials of construction shall be new and as specified on the vessel drawing / data sheet or other document attached to the Requisition.
3.1.2
Substitution of materials for any part shall not be allowed without the Purchaser’s prior written approval.
3.1.3
Backing ring material shall conform to the nominal chemical composition requirements of the base metal material standard.
3.1.4
The heat treatment for clad plate conforming to ASME SA-263 and SA-264 shall be done at the mill.
3.1.5
All clad plate, including explosion clad plate, conforming to ASME SA-263 and SA-264 shall be cold flattened, if required, only after final mill heat treatment and desiccating.
3.1.6
Code requirements (UCS-85 and AT-113) for simulated PWHT of test specimens shall include on extra PWHT cycle for potential future field repair.
3.2 W
elding Electrodes Welding electrodes and rods shall be selected in accordance with ASME / AWS.
3.3 Bolting 3.3.1
Bolting material will be specified on the vessel drawing or data sheet by ASME material specification number.
3.3.2
Unless otherwise specified, stud bolts shall be threaded full length.
3.3.3
Bolt heads for carbon steel bolting shall be of heavy hexagonal (preferred) or regular square series.
3.4 Gasket
s
3.4.1
The type of gasket and material of construction shall be furnished as specified on the vessel drawing / data sheets or other documents attached to the Requisition.
3.4.2
The process of manufacture and any dimensions or tolerance not covered by the dimensional standards shall be in accordance with the manufacturer’s standards.
3.5 Supplem
entary Materials
The vendor shall furnish blind flanges, gaskets, and bolting for manholes, hand-holes, flanged vessel ends, and for all other nozzles indicated on the drawings as requiring closures. 3.5.1
Test gaskets for manholes shall be shipped in place. Other nozzles furnished with permanent blinds or mating flanges shall have new service gaskets installed prior to shipment.
3.5.2
Two spare gaskets shall be furnished for each manhole, hand-hole, and flanged vessel head when vessels are for installation.
[PV] 12
4.
FABRICATION 4.1
Design of Welded Joints 4.1.1
Pressure retaining shell, head, and transition section seam shall be full penetration double welded joints except as noted in Paragraph 4.1.4.
4.1.2
Nozzles and manways shall fully penetrate through the vessel wall except as noted in Paragraph 4.1.3. Nozzle and manways shall be attached to the vessel wall with a full penetration double welded joint except as noted in Paragraph 4.1.4.
4.1.3
When approved in writing by the Purchaser, nozzles NPS 3 and smaller may be installed as follows : 1)
Division 1 vessels
2)
4.2
(1)
Figure UW-16.1 (a) or (b)
(2)
Figure UW-16.1 (v) for thermowell nozzles and other non-load carrying nozzles.
Division 2 vessels (1)
Figure AD-610.1 (a), (b) or (f)
(2)
Figure AD-621.1 © for thermowell nozzles and other non-load carrying nozzles.
4.1.4
When sound back-welding is not feasible due to inaccessibility, single-welded joints which utilize a Gas Tungsten Arc Welding or Gas Metal Arc Welding root pass, shall be used. Permanent backing strips shall not be used.
4.1.5
Temporary backing strips may be used. After welding, they shall be removed and the surface shall be conditioned to meet visual examination criteria. The surface shall be magnetic particle or liquid penetrant examined prior to any radiographic examination or heat treatment.
Preparation for Welding 4.2.1
On clad plates, the cladding shall be stripped back at least 6.0mm (both sides of seam) at all seams prior to welding the base metal. Base material shall not be reduced below the design thickness required by the Code.
4.2.2
Weld metal shall not be used to build up the edges of plates that are too short or those that contain large cavities without advance written approval of the Purchaser.
4.2.3
The maximum allowable gap between reinforcing pads and the surface of the vessel shells or heads before welding shall be 3.0mm.
4.2.4
The weld bevels of stub end nozzles shall be in accordance with ASME Section VIII for the style of bevel specified. The size and schedule or thickness of the adjoining pipe will be specified on the vessel drawing or data sheets.
4.2.5
All weld bevels in material 38mm thick and over shall be examined by the magnetic particle or liquid penetrate method. Any laminations exceeding the limits specified in ASME SA-20, paragraph 9.3 shall be repaired. Welded repairs allowed by ASME SA-20, paragraph 9.3.5 require the Purchaser’s advance written approval.
4.3 Prehe
at
4.3.1
All P-3 and P-4 material shall be preheated to 149 °C minimum.
4.3.2
All P-5 material shall be preheated to 204 °C minimum.
[PV] 13 4.4 W
elding
4.4.1
Welding shall be in accordance with the applicable code.
4.4.2
Fabrication involving welding shall not be sublet to others without advance written approval of the Purchaser.
4.4.3
All welding slag shall be removed from weld deposits by appropriate means.
4.4.4
Temporary attachment welds on pressure parts shall be removed. The surface under such welds which have been removed shall be properly conditioned to eliminate surface stress raisers. Such surfaces shall be examined by either the magnetic particle or liquid penetrate method of examination.
4.4.5
Arc strikes on the pressure shell shall be minimized. Whe n they occur, the surface shall be properly conditioned to eliminate surface stress raisers. Such surfaces shall be examined by either the magnetic particle or liquid penetrate method of examination. Any defects found shall be removed and the surface repaired and re-examined.
4.4.6
Weld Overlay / Clad Restoration Weld overlay shall be applied circumferentially and it shall be relatively smooth with no notches, flaws, or undercuts that would act as stress raisers. Elbows, tees, and small bore nozzles may be overlay welded longitudinally followed by grinding or machining to a smooth surface.
4.5 Heat
Treatment
The solution annealing procedure shall be submitted to Purchaser for review and acceptance prior to heat treatment. 4.5.1
Vessels shall be post weld heat treated when required by the applicable Code or the Purchaser’s vessel drawings or data sheets.
4.5.2
Post weld heat treatment for welds between dissimilar metals shall conform to the requirements of the material having the more stringent requirements and shall be verified by the Welding Procedure Qualification Testes. The proposed post weld heat treatment procedures for these welds shall be reviewed by the Purchaser.
4.5.3
Local post weld heat treatment shall not be performed without advance written approval of the Purchaser.
4.5.4
P-3 materials shall be post weld heat treated at a temperature of 620 °C minimum.
4.5.5
P-4 materials shall be post weld heat treated at a temperature of 677 °C minimum.
4.5.6
The post weld heat treatment temperature shall not exceed the tempering temperature of normalized and tempered or quenched and tempered materials.
4.5.7
If material is “buttered” by depositing weld metal that does not require post weld heat treatment and is subsequently heat treated, welding to the “buttered” weld metal deposit may be done without further post weld heat treatment with prior written approval by the Purchaser.
4.5.8
Carbon and Low alloy steel plate, seamless heads, parts of built-up heads, and similar pressure retaining parts subjected to cold or hot bending and forming shall be heat treated as follows: 1)
As required by the applicable code and the applicable material specification.
2)
The hot forming temperature may be used as the normalizing temperature if the forming temperature is at or above the normalizing temperature at the completion of forming.
3)
Where the code or specification requires normalizing, the hot-formed parts which do not meet the requirements of above 2) shall be normalized after forming.
[PV] 14 4.5.9
4.6 T
Bent or formed austenitic stainless steel parts shall be solution annealed when: 1)
the bending or forming temperature is 482 °C or below and the bend radius is less than 2.5 times the material thickness.
2)
The bending or forming temperature is above 482 °C.
olerances
4.6.1
Unless otherwise noted on the drawings, tolerances shall conform to the requirements of the applicable code or Figure 2, whichever is more stringent.
4.6.2
The tolerances on the specified thickness of the alloy on integrally clad plate shall be as given in Table I. TABLE I - CLADDING TOLERANCES SECTION Flat plate as rolle d, cylindrical and coni cal sectio ns after rolling and other formed sections
5.
TOLERANCE FOR THE CLAD THICKNESS NOMINAL THICKNESS MINIMUM THICKNESS Under Tolerance –2%
Under Tolerance –0%
Over Tolerance (by Vendor)
Over Tolerance (by Vendor)
INPSECTION, REPAIRS, TESTING AND REJECTION 5.1 Cod
5.2
e Inspection
5.1.1
All pressure equipment installed in Tongyoung LNG Terminal shall be constructed in accordance with the requirements of the ASME Boiler and Pressure Vessel Code and Korean Local Regulations.
5.1.2
The Purchaser’s inspector is not to be construed as the Authorized Inspector responsible for performing code inspection.
Inspection / Examination – General Requirements 5.2.1
In addition to any required code inspection, all fabrication, materials, and packaging shall be subject to inspection by the Purchaser at all stages of fabrication and shall conform to the specifications included in the Order. Shop drawings of the vessel shall be available to the Purchaser’s inspector at the time of the inspection. Surfaces shall not be painted nor the vessel shipped until the Purchaser’s inspection is complete.
5.2.2
The production welds attaching pins or studs for external insulation, fireproofing supports shall be tested by tapping with a light hammer.
5.3 Radi
ography
5.3.1
As a minimum requirement, all vessels shall be spot radiographed.
5.3.2
Welds which are subjected to severe working (ratio of thickness to local radius greater than 5%) shall be completely radiographically examined after the completion of the working.
5.3.3
Radiographic film shall be fine grain, high definition, high contrast film (Kodak type AA, equivalent or better). Film density shall be within a range between 2.0 to 3.5 as determined by a calibrated film density strip or densitometer.
[PV] 15 5.4 Surface
Examination
5.4.1
Internal and External finished weld surfaces shall be either magnetic particle or liquid penetrant examined in accordance with Table II using the procedures of ASME Section V, Articles 6 and 7, respectively. Evaluations of indications shall be in accordance with ASME Section VIII. Examination shall be done after completing all require post weld heat treatment, except weld surfaces which will become inaccessible by reason of welded closures which themselves require post weld heat treatment (e.g., nozzle-to-vessel welds covered by reinforcing pads) shall be examined before such closures are welded.
5.4.2
Magnetic particle examination performed after post weld heat treatment shall be done by the AC yoke method to avoid arc strikes.
5.4.3
When liquid penetrant examination is required, it shall be performed on all accessible weld surfaces. Any surface irregularities which interfere with the examination shall be removed by grinding, machining, or wash-blending with Gas Tungsten Arc Welding.
5.4.4
All weld overlay, whether by manual or automatic procedures, shall be liquid penetrant examined in accordance to the methods described in ASTM E165. Where overlay is to be machined, such as inside nozzles and on flange facings, examination shall be performed after machining. If heat treatment is required, the examination shall be done after heat treatment. TABLE II – EXAMINATION OF WELD SURFACES REQUIRED SURFACE EXAMINATIONS (MT or PT) TYPE OF VESSEL MATERIAL
LEVEL OF RADIOGRAPHY (Note 1)
LONGITUDINAL AND GIRTH WELDS
NOZZLE WELDS (Note 2)
ATTACHEMENT WELDS (Note 3)
Not post w eld Heat treated
Spot Full
No No
No Yes
No No
Post weld Heat treated
Spot Full
No No
No Yes
No Yes
Low alloy steels over 1/2% nominal chromium content
Spot or Full
Yes
Yes
Yes
Austenitic steel with design metal Temp. in range of –101 °C to 399 °C Austenitic steel with design metal temperature warmer than 399 °C Austenitic steel with design metal temperature colder than –101 °C
Spot Full Spot or Full Full or Spot
No No
No Yes
No No
Yes Yes
Yes Yes
Yes Yes
Carbon & low al loy steel w ith 1/ 2% (max.) no minal chromium content
NOTES TO TABLE II :
5.5 Ultra 5.5.1
1)
The level of radiography which is specified for longitudinal and circumferential welds
2)
Nozzle welds include the welds between nozzle and the reinforcing pad, vessel and the reinforcing pad, and the nozzle and vessel under the reinforcing pad. Welds under the reinforcing pad shall be examined before the pad is attached.
3)
Attachment welds include structural support, external clips, tray support, and skirt and saddle attachment welds.
sonic Examination Ultrasonic examination of materials shall be performed as follows: 1)
Plate material 100mm thick and greater shall be ultrasonically examined in accordance with SA-435, supplementary requirements S1.
2)
Integrally clad plate with a composite thickness of 100mm and greater shall be ultrasonically examined in accordance with SA-578, supplementary requirements S1 and S6.
3)
Forged products, (except ASME B16.5 and ASME B16.47 flanges), 100mm thick or greater shall be ultrasonically examined in accordance with SA-508 including Supplement
[PV] 16 S2. Thickness of forgings shall be as defined in ASME Section VIII. Division 2, paragraph AM-2000.2. Defects detected during UT may be repaired with the Purchaser’s advance written approval. Failure to obtain approval prior to repair of such defects shall be cause for rejection of the material. 5.6 Che 5.6.1
mical Analysis Samples of production weld overlay shall be taken to confirm chemical analysis to the required depth. Samples shall be taken as follows to represent both manual and automatic overlay welding : 1)
One sample from each automatically overlayed vessel part/section (e.g. each shell ring. head, nozzle, cone, etc.)
2)
Two samples from each manually overlayed vessel part/section and each manually overlayed seam (longitudinal, girth and nozzle welds). One sample is required for nozzles smaller than 150mm diameter.
5.6.2
A quantitative chemical analysis shall report all elements for which specific values are given in ASME Section II, Part C.
5.6.3
Acceptance criteria shall be that the deposited overlay have the chemical composition of the applicable filler metal as specified in ASME Section II. Part C. In the case of low carbon grade stainless steels, the percent carbon shall not exceed 0.045%.
5.7 Ha 5.7.1
rdness Testing Brinell hardness testing shall be performed on the weld and HAZ as follows using portable macro hardness testing equipment; 1)
Testing shall be done on the outside of vessels / components that are clad or overlayed and on the inside of vessels / components that are not clad or overlayed on the inside.
2)
Testing shall be done after post weld heat treatment if post weld heat treatment is required.
3)
Frequency and location of testing; (1)
1 reading from each longitudinal weld and HAZ.
(2)
1 reading from each circumferential weld and HAZ for vessels 1200mm ID and smaller: 2 readings 180 degrees apart for vessels over 1200mm ID.
(3) 5.7.2
1 reading from each nozzle-to-vessel weld and HAZ.
Hardness limitations are in accordance with Table III. TABLE III MATERIAL P NUMBER
MAZIMUM BRINELL HARDNESS
P1 Groups 1, 2, 3 (Note 1)
200
P1 Group 4
250
P3, P4
225
P5 235 P6, P7
240
NOTE TO TABLE III 1. Equipment in wet H2S, amine, or caustic service.
[PV] 17 5.8 Lea
k Testing
5.8.1
Each nozzle reinforcing pad or each segment thereof shall tested at 0.15MPa.g in accordance with ASME Section V, Article T-1031 and T-1032 with air. All welds inside and outside the vessel shall be inspected during the test. Test hoes in pads shall be closed with steel plug after the test.
5.8.2
Attached sleeve-type liners, including cover strips, and nozzle liners shall be tested at 0.1MPa.g in accordance with ASME Section V, Article T-1031 and T-1032 by introducing dry air between the lining and the base metal. The test shall be conducted before post weld heat treatment and before pressure testing of the vessel. Any liquid which may have become trapped between the lining and the base metal shall be completely removed and all test holes drilled in the alloy liner or base metal shall be sealed by welding.
5.9 Pressu
re Testing
5.9.1
Vessels shall be hydrostatically tested in accordance with the applicable code to the test pressure specified on the vessel drawing or data sheet. The test pressure shall be held for at least one hour. The test pressure shall be shown on the manufacture’s drawings.
5.9.2
The temperature of the vessel wall during the test shall be a minimum of 15 °C above the vessel Minimum Design Metal Temperature.
5.9.3
Before the hydrotest, all internal surfaces shall be cleaned by sweeping, vacuum cleaning, or other methods so the vessel will be free of welding slag and flux, weld rod stubs, loose scale, dirt, and debris.
5.9.4
Vessels shall be hydrostatically tested with potable water only ; salt, brackish, or raw river water shall not be used. Vessels or parts of vessels made of austenitic stainless steel or austenitic stainless clad material shall be tested with water having a maximum chloride content of 10 ppm when they have parts that can not be completely drained of the test water. Carbon steel or other material vessels that can be completely drained may be hydrotested with water having a maximum chloride content of 200 ppm.
5.9.5
All water shall be drained after hydrostatic testing. Any standing water in austenitic stainless steel or austenitic stainless clad vessels shall be removed by blowing with air or by swabbing ; heat or hot air shall not be used for drying.
5.9.6
Low alloy steel service bolting and ring joint gaskets to be furnished with the vessel may be used for shop testing. Any material damaged during the test shall be replaced by the manufacturer with new material. Austenitic service bolts shall not be used in the shop test.
5.10
Report of Defective Welds
5.10.1 Welds with defective areas shall have; 1)
The defect removed.
2)
Confirmation of defect removal by magnetic particle or liquid penetrate examination.
3)
Repair welding using qualified welding procedures.
4)
Re-post weld heat treatment if originally requited.
5.10.2 The finished weld-repair shall be radiographed if originally required and the surface shall be reexamined by magnetic article or liquid penetrant examination. If the repair involves serious alterations, the approval of the Purchaser shall be obtained before proceeding with the repair. 5.11 Reje
ction
5.11.1 Completed vessels, parts of vessels, or materials containing defects originating with the manufacturer’s design, materials, or workmanship; or that are not in complete compliance with the requirements of the Order will be rejected.
[PV] 18 5.11.2 Discovery of conditions warranting rejection, after inspection and acceptance of the vessel by the Purchaser, does not relieve the manufacturer of his responsibility to comply with the Order. 6.
7.
8.
NAMEPLATE 6.1
All vessels shall be furnished with a stainless steel nameplate. Required markings shall not be stamped directly on the vessel. Nameplates shall be installed on the manufacturer’s standard nameplate holder of sufficient length to project at least 25mm beyond the vessel insulation.
6.2
The nameplate shall be stamped with the design pressure and design temperature shown on the vessel drawings or data sheets.
6.3
The Purchaser’s equipment item number shall be stamped on the nameplate.
6.4
The nameplates of vertical vessels shall be located on the shell above the lowest manhole. On horizontal vessels, they shall be located in the center of a head or above a manhole in a head. The nameplate location shall be shown on the manufacturer’s drawings.
PAINTING 7.1
Vessels shall be shop painted in accordance with the requirements of Purchaser’s painting specification.
7.2
Machined surfaces shall not be painted.
7.3
Austenitic alloy steel and nickel-iron-chromium alloy material parts shall be kept free of paints containing zinc to avoid the possibility of corrosion at elevated operating temperatures. All traces of zinc containing paints on such parts shall be promptly removed.
MARKING 8.1 Gene
ral
8.1.1
Stamping on all austenitic steel and impact tested materials shall be with “low-stress” steel stamps having round or “U” shaped cross sections or with “interrupted-dot” die stamps.
8.1.2
Marking paint or water insoluble ink for use on austenitic and high nickel alloy steel shall contain no substance (e.g., metallic pigments, sulfur, or chlorides), which would be harmful to these materials at ambient or elevated temperatures.
8.1.3
Internals, clips, lugs or other similar attachments, which are removable and are to be assembled by others shall be marked with piece numbers for identification in assembly and match marked.
8.1.4
Vessels that have been post weld heat treated, shall have the following notation painted on the vessel prior to shipment; “NO WELDING PERMITTED ON THIS VESSEL “ The letters shall be approximately 150mm high painted with a contrasting color. 1)
On vertical vessels, this sign shall be located on two opposite sides near the bottom tangent line and repeated at approximately each 3m of height, but rotated 90 degrees.
2)
On horizontal vessels, the sign shall be located on both sides near the horizontal centerline.
[PV] 19 8.1.5
The North and East orientations shall be center-punched on the outside of each vertical vessel approximately 150mm above the bottom tangent line and 150mm below the top tangent line. The punch marks shall be circled with white paint
HORIZONTAL VESSEL SHALL HAVE THE SAME TOLERANCES FOR CORRESPONDING DIMENSIONS
FIGURE 2 THE NUMBERS SHOWN IN BOXES ON THIS SKETCH CORRESPOND TO THE NUMBERED NOTES BELOW
NOTES FOR FIGURE 2: 1. The tolerance on dimensions not specified herein or specifically shown on the drawings shall be ±6mm. 2. Items not covered b y notes 16, 17 and 18, which have been located on the dra wings by elevation or b y a dime nsion from a tangent or reference line shall be located from the reference plane, within a tolerance of ±6mm. 3. The tolerance on orie ntation from t he reference centerl ine to t he centerlin e of a nozzle or manho le is ±1/2 degr ee, except the circumferential measurement shall have a maximum tolerance of ±6mm. 4. The tolerance on the distance from the face of a nozzle to the vessel surface is ±6mm. 5. The tolerance on the distance from the inside vessel wall to down comer support bars or weirs is as shown on the tray manufacturer’s tower attachment drawing.
[PV] 20 6. The tolerance on the hei ght of do wn c omer boltin g b ars abov e tray sup port ring s is as sho manufacturer’s tower attachment drawing.
wn on the tra
y
7. The tolerance on the len gth of do wn come r bolting bars is as sho wn o n the tray man ufacturer’s to wer att achment drawing. 8. The tolerance on the alignment of a nozzle flange face with the indicated plane is ±1/2 degree in any direction. 9. The tolerance on the distance from the face of a manhole flange to the vessel surface is ±12mm. 10. The maximum deviation of th e actual circ umference (as d etermined by strapping) from the nomi nal circumference is as shown in Column A, Table IV. 11. The tray support rings shall be perpendicular to the lo ngitudinal axis of the vessel within the limits given in Column 8, Table IV. (Dimensions shown in Table represent the total permissible out of level across diameter of vessel.) 12. The top surface of tray support rings shall be perpendicular to the vessel shell within 4mm in the width of the ring. 13. The top of weld-attached weir plates shall be perpendicular to the longitudinal axis of the vessel within the limits given in column C. Table IV. 14. The tolerance on the distance between adjacent tray support is ±3mm. 15. The maximum deviation in elevation between each adjoining clip, bracket, and similar structural attachment located in the same plan is ±3mm. The tolerance on location from the tangent or reference line for each individual clip, bracket, or attachment is shown in Note 2. 16. The tolerance on the distance from the reference plane to support lug is +6mm, -0. 17. The tolerance on the distance from the reference plane to the base is +0, -6mm. 18. The tolerance on the distance from the reference plane to horizontal vessel support (saddle) is +6mm, -0. 19. The tolerance on the distance from the vessel surface to the bottom of horizontal vessel support saddles is +6mm, -0. 20. A reference plane / work line from which dimensions are run shall be located by the manufacturer. The plane shall be punch marked inside and outside at 0, 90, 180, and 270 degree points. Punch marks shall be circled with paint. 21. The tolerance on the specified dimension between two nozzles, connections, or clips is ±3mm. 22. The maximum deviation from a straight line perpendicular to the reference plane / work line of any cylindrical element of the vessel s hell ( including cylindrical or similar su pports exte nding beyond th e she ll of vertical ves sels) sha ll b e 1mm for each 1m of length. 23. The tolerance on the distance from the face of a hillside shell nozzle to the vessel centerline is ±6mm. 24. The tolerance on nozzle bolt hole orientation is ±1.5mm measured at the bolt circle diameter. 25. The tolerance for external clip orientation and clip face alignment is as shown in Notes 3 and 8.
TOLERANCE. Inches
COLUMN / TOWER DIAMETER (m)
A
B
C
1.2m & less
9.0
3.0
3.0
Over 1.2 to 2.4
12.0
6.0
5.0
Over 2.4 to 4.8
25.0
8.0
6.0
Over 4.8m
38.0
9.0
8.0
TABLE IV – VARIABLE TOLERANCES
TECHNICAL SPECIFICATION FOR SQUIRREL CAGE INDUCTION MOTORS (FOR NON-CRYOGENIC TYPE)
0
08/09/03
FOR CONSTRUCTION
REV. NO
DATE
DESCRIPTION
D.H.CHOI S.K.LEE B.S.KO DESIGN CHECK Q.A
M.S.KANG APPROVAL
CLIENT APPROVED
KOREA GAS CORPORATION
통영 생산기지 2단계 6차 확장 건설공사 TONGYOUNG LNG TERMINAL 6th EXTENSION PROJECT TECHNICAL SPECIFICATION FOR SQUIRREL CAGE INDUCTION MOTORS ( FOR NON-CRYOGENIC TYPE ) SCALE
JOB NO.
NONE
3415.OD
PHASE
DOCUMENT NO.
REV.
26-E-E00-SP-204
0
DAEWOO ENGINEERING COMPANY KOREA GAS TECHNOLOGY CORPORATION SONGNAM KOREA
C O N T E N T S
1.
GENERAL
2.
STANDARDS AND REGULATIONS
3.
GENERAL CONDITIONS OF USE
4.
GENERAL CONSTRUCTION REQUIREMENTS
5.
REQUIRED CHARACTERISTICS
6.
TESTS AND VERIFICATIONS
7.
LIMITS OF SUPPLY
8.
MANUFACTURER GUARANTEE
- 1 -
1.
GENERAL
1.1
Scope This specification covers the high and low voltage, squirrel caged induction motors used for the rotating equipment to be installed at TongYong LNG terminal, Korea. Special motors such as for electric fans, ventilators, refrigerators, air conditioners, machine tools, powered hand tools, sirens, testing of experimental equipment or controllers are excluded from the scope of this specification. Motor for cryogenic pumps shall be separately specified.
1.2
Units Unless otherwise specified, metric, celsius and kilogram units shall be used for all drawings and documents to be submitted by the manufacturer.
1.3
Manufacture's drawings and documents Drawings and documents shall be submitted according to the list of vendor document and sch edule. KOGAS approval for such drawings and documents shall not relieve manufacturer of his responsibility to meet all requirement of the purchase order. Manufacturer shall provide a copy of Type Test Certificate including a copy of Type Test Report.
2.
STANDARDS AND REGULATIONS Induction motors shall be constructed and tested in conformity with the following standards and regulations : 1)
National Electrical Manufacturers Association (NEMA) MG-1 : Motors and generators
2)
3)
International Electro-Technical Commission (IEC) 60034
: Rotating electrical machines
60079
: Electrical apparatus for explosive gas atmospheres
American Petroleum Institute (API) ANSI/API standards shall be specifically applied to the driver of relevant rotating machines.
Where two or more references define requirements for the same subject, the more restrictive shall govern.
3.
GENERAL CONDITIONS OF USE
- 2 -
3.1
Supply conditions Squirrel cage electric induction motors are designed to be supplied with : - Low voltage motors for up to 149.2KW
: 440V, 3Ph, 60Hz
- High voltage motors for above 149.2KW : 6.6KV, 3Ph, 60HZ - Space heater, if applied
: 220V, 1Ph, 60HZ
Each motor shall supply its power rating and normal torque without exceeding the overheating limits specified in the standards. These conditions remain mandatory : a) Plus or minus 10 percent of rated voltage with rated frequency. b) Plus or minus 5 percent of rated frequency with rated voltage. c) A combined variation in voltage and frequency of plus or minus 10 percent (sum of absolute value) of the rated values, provided the frequency variation does not exceed plus or minus 5 percent of rated frequency. d) Motors shall be capable of direct full voltage starting or reactor starting. 3.2
Service conditions Motors are required to run in continuous operation for periods of several months. They shall also be capable of starting after being shut down for a month. Service conditions shall take into account climatic conditions.
3.3
Installation conditions In all cases, motor enclosure shall be suitable for service at the location where the motor is installed. The explosion proof protection shall be suitably provided as per the hazardous areas classification indicated on data sheet.
3.4
Climatic and environment conditions
3.4.1
Air temperature
a) Highest
36.9 ℃
b) Lowest
-11.6 ℃
c) Mean d) Black body
14.2℃ 65
℃
3.4.2
Atmospheric pressure average
3.4.3
Wind maximum velocity
3.4.4
Humidity(mean)
3.4.5
Altitude
: 1024.8 mb : 40m/sec at 10M height : 68.5%
: sea level
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4.
GENERAL CONSTRUCTION REQUIREMENTS The general requirements for construction are applicable to all types of enclosure. Special requirements are indicated in sec 5.
4.1
Casing structure
4.1.1
Frame Frames are made of cast iron or welded steel plate. Small frames may be made of pressure cast aluminium. A grounding terminal is provided on the frame.
4.1.2
Cooling Disposition Generally, cooling fluid used is ambient air. A self-contained cooling method i.e. ventilated ribbed frame or tube type frame forming air-air exchanger, shall be preferred. If special cooling method is applied, it shall be approved by KOGAS before manufacturing.
4.2
Bearings
4.2.1
Bearings for all motors 200HP or less, shall be antifriction ball type. Motors above 200HP to 500HP may use antifriction ball or sleeve bearings at manufacturer's option. Bearings for all motors above 500HP will be sleeve bearings.
4.2.2
All motors that are supplied with ball or roller bearings shall have the appropriate AFBMA number stamped on a corrosion proof name plate attached to the motor. The design of these bearing shall be based on AFBMA standard and shall have a design life of not less than 100,000 hours based on the bearing manufacture's rating tables for anticipated loading conditions.
4.2.3
Bearing temperature rise shall be limited to a 40℃ rise over a 40℃ ambient for either self or force-fed lubricated bearing. For motors 1500 HP or higher, the temperature shall be measured by RTD or thermo couple in the bearing metal on each drive and non drive side.
4.2.4
The bearing ends of outdoor-type motors shall be designed and constructed to prevent water creeping along the shaft not to motor housing.
4.2.5
The rotor end play of horizontal-shaft motors provided with sleeve bearings shall be according to NEMA MG 1-20.81, unless otherwise specified
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4.2.6
Bearings for vertical-shaft motors shall be designed to carry not only the thrust of the rotor but also thrust of the load.
4.3
Bearing lubrication Antifriction bearings shall be lubricated by grease, with readily accessible grease inlet and outlet plugs provided in the housings to allow regreasing from the exterior while motor is in service. Ring oil lubrication systems may be furnished for severe duty applications of ball and roller bearing combinations.
4.4
Shaft Shafts are made of steel and to be designed to withstand without deformation stresses due to permanent or transient operating loads in the specified conditions of use. The shaft voltage shall not exceed 0.3V when measured between shaft ends and between shaft and casing of motors operated with no load at rated voltage and rated frequency.
4.5
Rotor Rotor shall be squirrel cage laminated. After fabrication, the entire rotor assembly shall be coated with a suitable corrosion resistant finish.
4.6
Magnetic circuit Magnetic circuit consists of insulated plates tightly bolted together so as to withstand mechanical stresses in the specified conditions of use.
4.7
Stator windings Stator windings are made of copper carefully with material in conformity with the insulation of class B/F in consideration of the ambient temperature of 40℃. F class insulation shall be applied for motors 37 KW and higher. For motors 149.2KW and higher, the winding temperature shall be measured by dual embedded temperature senses in the windings at each phase of the winding. Maximum temperature rise shall be of class B. Windings are treated with the global impregnation method (vacuum, then pressure).
4.8
Ventilation External fans are made of corrosion resisting material to be efficiently protected against corrosion. Fan covers are designed with the same degree of mechanical strength as the frame. External fans are installed at the opposite end to the coupling and shall blow air towards the coupling. Motors with low speed resulted by speed control etc. may be equipped with forced ventilations by means of a motor-fan set. In this case, the principle and the design of auxiliary equipment
- 5 -
of forced ventilation system, are subject to approval of KOGAS. 4.9
Terminal boxes
4.9.1
Terminal boxes are amply dimensioned larger than ANSI C50.41 type II terminal housing and have the protection degree of watertight type 4 enclosures specification in NEMA standard 250 and mechanical strength, as the frame : they can be oriented to all directions in every 90°.
4.9.2
Terminal boxes are equipped with seal female pipe thread for connecting the conduit or packing cable gland. Besides the connection terminals, they shall be equipped with one grounding terminal.
4.9.3
Terminal boxes shall be provided with drain holes having removable threaded plug and shall have gasket cover secured by non-corroding bolts or screws.
4.9.4
For high voltage motors, connections to platinum probes and heating resistors shall be made through separate terminal boxes.
4.9.5
When space heater, temperature detectors and thermocouples are included, each separate terminal boxes shall be provided with drain holes and shall have provision for a conduit connection of not less than 22mm.
4.10
Bolting Internal, external bolting which is not protected by the global impregnation shall be of stainless steel, complying with the climatic conditions of 3.4.
4.11
Identification and name plates Rating nameplates of each motor shall be fixed bearing all information. Separate name plate indicating item No. of each motor with the dimension of 50 x 30mm shall be fixed near the rating plate. Motors installed in hazardous areas are equipped with the regular nameplates required for explosion proof equipments. All identification or regular nameplate shall be made of non-corrosive stainless steel with not less than the minimum information called for the NEMA standard MGI-10.38 or KS.
4.12
Ground Termination Each motor shall have provisions to allow connection of purchaser's grounding cable to the motor frame. Each motor in NEMA frame size 254-445 shall have one(1) 10mm bronze grounding bolt. The Supplier's certified drawings shall show the location and type of grounding
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provisions for each frames size for purchaser's approval. 4.13
Space heater High voltage motors as well as motors to be installed at humidity atmosphere shall be equipped with space heater which is to be operated when motors are stop, in order to prevent moisture condensation. The temperature of these space heater is to be in the limit of temperature required for the explosion proof class of the motor. The heater shall be controlled by the thermostat or similar device to be protected from over heat. The heater control system consist of power contactor shall be equipped inside local panel without purchaser's external control device.
4.14
External protection Motors in principle shall be of totally enclosed fan cooled type. Weather protected type II is to be applicable in case the motor will be installed at out door location. The enclosures shall protect the motor bearings against the entrance of dust and moist air. The air intake filters shall be galvanized steel frames.
4.15
Explosion proof enclosure Motors to be installed at explosive hazardous area shall be of flame proof or pressurized explosion protection type and shall be conformity with the IEC publication 60079. For motors to be installed at Zone 2 hazardous area, the increased safety motor can be used with the prior approval of KOGAS. The temperature indicated on casing shall be lower than the spontaneous ignition temperature of the surrounding hazardous atmosphere depending on the proposed installation. Explosion-proof type motors are selected for the specified hazardous gas group which will be indicated on the data sheet . Explosion proof test certificate shall be submitted in accordance with the related Korean domestic regulations.
5.
REQUIRED CHARACTERISTICS
5.1
Starting, Acceleration and Operation
5.1.1
Motor shall operate satisfactorily during starting, voltage dips of short duration and automatic transfer from a normal to a reserve power supply in accordance with ANSI C50.41 Section 15.
5.1.2
Motors shall be capable of starting from rest and accelerating the load with 80% of motor
- 7 -
name plate voltage applied to the motor terminals. When this requirement makes necessary the use of an increased size of motor, the Supplier shall state so in his proposal. 5.1.3
Squirrel cage induction motors shall be NEMA design B with normal starting torque unless other characteristics are required by the driven equipment. The locked rotor current of all motors shall not exced 6 times full-load current when tested at rated voltage and frequency.
5.1.4
Unless other characteristics are required by the driven equipment, single phase motor shall be split-phase or capacitor start with locked rotor KVA Code G or H.
5.2
Noise level Maximum permissible noise level is the value defined, by IEC 60034-9. By extension, the maximum value shall be taken into account, without power limitation, for the rpm considered.
5.3
Vibration
5.3.1
Balancing of rotating parts shall correspond to the maximum permissible total vibration amplitude defined by IEC 60034-14. By extension, maximum values shall be maintained for power rating higher than those indicated by IEC Rules.
5.3.2
Motors shall be capable of overspeed operation, under emergency conditions, accordance with NEMA standard MG 1-20.44
5.4
Torque a)
For motors up to and including 500KW and having the speed higher than 1500rpm - Locked rotor torque shall be at least equal to full load torque, - Pull-up torque during starting shall be at least equal to full load torque, - Breakdown torque should be at least equal to twice the full load torque.
b) For motors of larger than 500KW or with the speed lower than 1500rpm, values of locked rotor torque, pull-up torque and breakdown torque shall be adapted depending on load torque of the driven machine and on permissible voltage drop in the system. 5.5
Number of starts The motor shall be designed and manufactured in accordance with NEMA MG1-20.43 requirements for successive starts, to start and accelerate the driven load as defined on the driven load speed-torque curve.
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5.6
Locked rotor All the motors shall be capable of enduring the required locked rotor current for the specific start up duration as per the speed-torque characteristics of the connected load.. Minimum duration which motors will be capable of withstanding full voltage with locked rotor is (when starting hot) : - 4 seconds for low voltage motors, - 6 seconds for high volta1ge motors,
5.7
Other characteristics Taking into account that above required characteristics have priority, motors shall have: - Lowest possible starting current surges. - Highest possible power factors and efficiencies.
5.8
Painting More than two coat of painting shall be given with anti-rust paint. All the surface to be painted should be thoroughly cleaned up mil scale, rust and foreign materials, color of the finishing coat shall be Munsell No. N 7.5 The manufacturer shall supply the sufficient quantity of touch-up paint.
6.
TESTS AND VERIFICATIONS Test shall be in accordance to those described by NEMA MG 1-20.
Motors are accepted if
the results of the series tests are in conformity with the characteristics indicated in the specifications
within the tolerance limits :
There are three types of tests : 6.1
Manufacturer tests These are the tests carried out on the different types of motors which the manufacturer performs on prototypes or during fabrication, for which he provides an "as built" certificate with test report.
6.2
Shop acceptance tests Shop acceptance tests are witnessed by a KOGAS inspector or their representative. They are normally restricted to : - Visual inspection - Dielectric tests, high potential test - Stator winding resistance measurements
- 9 -
- Measurement of no-load operating point - Measurement of locked rotor current - Temperature rise test Additional tests may be required, in this case they will be indicated in the purchase order. A test report shall be made of these acceptance tests. Temperature rise and power factor and efficiency at 1/2, 3/4 and 4/4 load tests can be carried out on a selected motor as sampling in a serial of motors at the request of KOGAS inspector. 6.3
Field tests Before being placed in service each motor shall be checked, if possible not coupled to driven machine, for : - Insulation, - Direction of rotation
7.
LIMITS OF SUPPLY The responsibility of the manufacturer of the motor covers the complete machines in proper working order. Unless otherwise specified in the provisions of the specification, supply of a motor is limited to : - Terminal boxes included, - Bare shaft end equipped with shaft key, bolt and washer. Specification may also include auxiliary equipment under the responsibility of the manufacturer and in the limit of his supplies, such as : - Lubrication system, - Air filters and ventilation and/or pressurizing equipment, - Mounting slides, - Thermal sensor equipped with junction box, - Space heater, - Complete accessories of control and regulation for pressurized enclosure of motor - Lifting device and Base - Drain Hole - Accessory Terminal Boxes - Ground Terminal Lug - Name Plate
- 10 -
8.
MANUFACTURER GUARANTEE The following characteristics are in the scope of guarantee of the manufacturer : - Power, - Torque, - Efficiency, - Power factor, - Speed, - Starting current, - Noise level, - Vibration limit
- 11 -
Att #4
Attachment #4.
Purchaser’s Standard Forms
Vendor Prints Index / Schedule Spare parts list for installation and commissioning Spare parts list for 2-years operation Special tool list Lubricants list Electric load list Utility consumption list Painting schedule Rust prevention schedule Equipment noise data sheet Vendor document title block Mechanical data book cover format
Att #4 - 1 TongYoung LNG Terminal 6th Extension Project 3415.OD
Project
VENDOR PRINTS INDEX / SCHEDULE
DEC Project No. Item No. Service
Vendor Vendor Project No. Contract No.
For Approval Vendor Document No.
No.
1 VP-LNGarms_I
Out
I_G-xxxx
VP- LNGarms_II-M-xxxx
Mechanical documents
3
VP- LNGarms_II-E-xxxx
Electrical documents
4
VP- LNGarms_II-I-xxxx
Instrument documents
LNGarms_II-Q-xxxx
In
Rev. No.
Res Out
In
Rev. No.
Res Out
In
Rev. No.
Res Out
In
A S A S A S A
QA docume nts (Includ ed t est report, etc)
S A S
6
A
xxxx : Serial number of each discipline documents
7
S A S
8
A S
9
A S
10
A S
11
A
NOTE :
RESULT (RES) MEAN AS FOLLOWS; S : SCHEDULE,
A : ACTUAL
R : RESUBMIT
For Final
Res Out
S
General documents
2
5 VP-
Rev. No.
Document Title
I : INFORMATION ONLY A : APPROVED N : APPROVED AS NOTED
In
Res
Att #4 - 2
SPARE PARTS LIST FOR INSTALLATION, COMMISSIONING & START-UP
Item no.
Part name
Drawing no.
Part no.
Project DEC Project No. Item No. Service Spec (material)
TongYoung LNG Terminal 6th Extension Project 3415.OD
Installed Q’ty per unit
Recom mended Q’ty
Vendor Vendor Project No. Contract No.
Sketch
Unit price
Total price
Att #4 - 3
RECOMMENDED SPARE PARTS LIST FOR 2-YEARS OPERATION
Item no.
Part name
Drawing no.
Part no.
Project DEC Project No. Item No. Service Spec (material)
TongYoung LNG Terminal 6th Extension Project 3415.OD
Installed Q’ty per unit
Recom mended Q’ty
Vendor Vendor Project No. Contract No.
Sketch
Unit price
Total price
Att #4 - 4
Project
SPECIAL TOOL LIST
No.
Tool name
DEC Project No. Item No. Service Q’ty
TongYoung LNG Terminal 6th Extension Project 3415.OD
Sketch
Vendor Vendor Project No. Contract No.
Unit price
Total price
Att #4 - 5
Project
LUBRICANTS LIST
Equipment
Parts to be lubricated Part
Item no.
Q’ty
Part name
Q’ty per unit
DEC Project No. Item No. Service
TongYoung LNG Terminal 6th Extension Project 3415.OD
Lubricant
Vendor Vendor Project No. Contract No.
Q’ty per unit & interval
Brand Type
Initial charge (L)
Replacement charge Q’ty (L/set)
interval
Make-up Q’ty (L/set)
Interval
Notes
Att #4 - 6 TongYoung LNG Terminal 6th Extension Project 3415.OD
Project DEC Project No. Item No. Service
ELECTRIC LOAD LIST
Power Item no.
source (V/ph/hz)
Rating
BkW
RPM
(kW)
(kW)
at FL
Current (A) ST
FL
LR
Eff. (%) NL
3/4
FL
Power factor 3/4
FL
Time ST
STL
WL
Brg
Fr.
(kg)
lub.
no.
Vendor Vendor Project No. Contract No.
Brg no. Fr.
Re.
RTD No/ph
Mat
Hub
Space heater Ohm
V/Ph/hz
kW
(in) o
C
Att #4 - 7
Project
UTILITY CONSUMPTION LIST
DEC Project No. Item No. Service
TongYoung LNG Terminal 6th Extension Project 3415.OD
Conditions Item no.
Utility name
Consumption
Unit
Pressure (MPa.g)
Temp (oC)
Vendor Vendor Project No. Contract No.
Connection Rating & Size facing
Remark
Att #4 - 8
Project DEC Project No. Item No. Service
PAINTING SCHEDULE
Item no.
Part to be painted
Painting system no.
Max. operating temp (oC)
Insulation Yes / no
TongYoung LNG Terminal 6th Extension Project 3415.OD
Vendor Vendor Project No. Contract No.
Paint name / thickness (micron) Preparation
Primer
2nd
3rd
4th
Net painting area (m2)
Remark
Att #4 - 9
Project
RUST PREVENTION SCHEDULE
Item no.
Parts to be rust prevented
Name of rust preventive
DEC Project No. Item No. Service
TongYoung LNG Terminal 6th Extension Project 3415.OD
Applying procedure
Removing procedure
Vendor Vendor Project No. Contract No.
Protective property
Remark
Att #4 - 10 KOGAS PROJECT Location :
Package No.
EQUIPMENT NOISE DATA SHEET
Page
of
Doc. No.
Tag No.
Location / Module
Unit
No. Req’d
Service
Inquiry No.
Size & Type
Quote No.
Supplier
P.O No.
Manufacturer
Job No.
Model
Serial No.
1 EQUIPMENT DESIGN DATA 2 Calculated L=SWL (Note 1) 3 Efficiency % : 4 Equipment size (L x W x H) m : Driver type : 5 Power kW : Driver speed rpm : 6 Cap acity : Equipment speed rpm : 7 Pressure disch. : Gear tooth contact rate Hz : 8 Pressure suction : Blades / Vanes pass frequency : 9 Equipment weight kg : Number of stator / Number of rotor blade ratio 10 NOISE LEVEL LIMITS FOR THIS EQUIPMENT ARE SET AS SOUND POWER LEVEL LIMITS ONLY 11 COMPANY SPECIFIED DATA Octave band center frequency dB(A) 12 Noise Level Limits SWL (note 1) 31.5 63 125 250 500 1000 2000 4000 13 14 15 16 17 Special Requirement : 18 19 Noise test required : Vibration test required : 20 Y es (X) No ( ) Optional ( ) Y es (X) No ( ) Optional ( ) 21 SUPPLIER DATA Octave band center frequency dB(A) 22 Guaranteed sound power level (note 1) 31.5 63 125 250 500 1000 2000 4000 23 24 25 26 27 28 29 Guaranteed sound pressure Level 30 Narrow band component, Yes / No Frequency / octave band Hz : 31 Method / standard for noise level test : EEMUA PUB #140 Noise Procedure Specification 32 33 Description of implemented noise control measures / other information : 34 35 36 AS BUILT NOISE DATA Octave band center frequency dB(A) 37 Measured noise levels (note 1) 31.5 63 125 250 500 1000 2000 4000 38 39 40 41 S pecial information : 42 43 Note 1 SPL Sound Pressure Level, in dB (re. 20µ Pa) at 1m distance free field conditions. 44 SWL Sound Power Level, in dB (re. 1pW). 45 Note 2 VVL Vibration Velocity Level, in dB (re. 5 x 10^4 m/s) RMS on skid adjacent to support points. REV STATUS BY CHECKED APPROVED DATE
dB
8000
8000
8000
Att #4 - 11 Vendor Document Title Block
REV. NO.
DATE
DESCRIPTION
DRN
DGN
CK
APP
CL. APP
KOREA GAS CORPORATION TONGYOUNG LNG TERMINAL PHASE II – 6th EXTENSION PROJECT DAEWOO ENGINEERING COMPANY KOREA GAS TECHNOLOGY CORPORATION PROJECT NO. ITEM NO.
3415.OD
Vendor Title PROJECT NO.
3415.OD
ITEM NO.
TITLE:
SCALE
DOCUMENT NO. VP – LNGarms_II – G – xxxx
REV.
Att #4 - 12
Mechanical Data Book Cover Format Front View
Side View
KOREA GAS CORPORATION
KOREAGAS CORPORATION TONGYOUNG LNG TERMINAL
TONGYOUNG LNG TERMINAL
PHASE II – 6th EXTENSION PROJECT
th
PHASE II – 6 EXTENSION PROJECT 12 #
50#
MECHANICAL DATA BOOK
MECHANICAL DATABOOK
18#
Transparent Vinyl Pocket 28#
4# P. O NO. EQU IPMENT VOL. NO.
: : :
P. O NO. : EQ UIPMENT : VOL. NO. :
4 cm
3 cm 4 cm
8 cm
7#
DAEWOO ENGINEERING COMPANY KOREA GAS TECHNOLOGY CORPORATION
DAEWOO ENGINEERING COMPANY KOREA GAS TECHNOLOGY CORPORATION VENDOR NAME
VENDOR NAME
Note: Detail of KOGAS logo will be informed upon request.
