bbu-80-b-000-ma-spc-008-02 - copy.docx

8/10/2019 BBU-80-B-000-MA-SPC-008-02 - Copy.docx

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KANAZ LOGO

PROJ .NO:

PROJECT TITLE Owner:

OWNER NAME

SPECIFICATION

FOR

FIRE WATER PUMPS

KANAZ Doc No.: Owner Doc No.: Rev: 00 MC:

SPECIFICATIONFOR

FIRE WATER PUMPS

TOTAL PAGES:25

00 Jan 2014 Issued for comment

Rev Date Description Prepared Checked Approved Authorized


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SPECIFICATION

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OWNER NAME

SPECIFICATION

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1. SCOPE ............................................................................................................................. 5

2. DEFINITIONS ................................................................................................................... 5

3. PROJECT REFERENCED DOCUMENTS/DRAWINGS .................................................... 6

4. SCOPE OF SUPPLY ........................................................................................................ 6

4.1 BASICSCOPEOFSUPPLY 6

4.2 OPTIONS TO SCOPE OF SUPPLY 8

4.3 EXCLUSIONS TO SCOPE OF SUPPLY 9

4.4 BOUNDARY LIMITS 9

5. FUNCTIONAL DESIGN REQUIREMENTS ................................................................... 10

5.1 GENERAL 10

5.2 MECHANICAL 12

6. INSPECTION AND TESTING ......................................................................................... 19

6.1 GENERAL 19

6.2 QUALITY PLAN 20

6.3 SCOPE OF INSPECTION AND TESTING 20

6.4 CERTIFICATION 22

7. ACCEPTANCE CRITERIA AND GUARANTEES ........................................................... 23

7.1 ACCEPTANCE CRITERIA 23

7.2 GUARANTEES 23

8. SITE SERVICES ............................................................................................................. 23

8.1 PACKING, PRESERVATION AND TRANSPORTATION 23

8.2 SPARE PARTS 24


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OWNER NAME

SPECIFICATION

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8.3 MAINTENANCE 24

9. DOCUMENTATION ........................................................................................................ 24


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SPECIFICATION

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FIRE WATER PUMPS


1. SCOPE

1.1. This specificationcovers the minimum requirements for the design andmanufacturing of firewater pumps in accordance with API 610 and NFPA 20 inrenovation of fire water systems Project. The specification shall be read inconjunction with the material requisition and all attachments thereof.

1.2. The VENDOR shall include, in his quotation, a list of any specific exclusion tothis specification and all the referenced specifications, otherwise the quotationwill be considered to be fully in accordance with the enquiry documents andsubsequent claims for extras arising out of non-compliance with this specificationwill not be considered.

1.3. Compliance by the VENDOR with the provisions of this specification does notrelieve him of his responsibility to furnish equipment and accessories of asuitable and safe design to meet the specified service conditions, and therequirements of international and local codes and standards.

2. DEFINITIONS

PROJECT: XXXXXXXXXXXXXXXXXXX

OWNER/PURCHASER: XXXXXXXXXX

CONTRACTOR: KANAZ Moshaver Company

VENDOR / SUPPLIER / MANUFACTURE: The party which manufactures or supplies

equipment and services to perform the duties specified by the Contractor.

CONSTRUCTION CONTRACTOR: means the person or persons , firm or company to

whom/which the construction contract is awarded by the owner and includes his/its

representatives, successors or assignees

INSPECTOR: Person assigned by the Purchaser or Owner to inspect the specified

services, equipment or system being provided by the Vendor

SHALL:Indicates a mandatory requirement.


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3. PROJECT REFERENCED DOCUMENTS/DRAWINGS

All work shall be completed in accordance with engineering codes and standards

listed in the followings:

4. SCOPE OF SUPPLY

4.1 BASICSCOPEOFSUPPLY

4.1.1 Fire Water Pumps:Horizontal centrifugal pumps are required on the site, which take suction from the Fire

Water Tank. Pumps shall comply with the NFPA 20 and be able to operate across the

full flow range through to 150 % of the Rated Flow.Preference, for the main pumps is for

horizontal centrifugal pumps between bearings, compliant with NFPA.The maximum

shaft speed is 1800 rpm. The number of diesel driven pumps as well as

lectricmotordrivenpumpwill be specified in relevant data

sheets.TheVENDOR'Sscopeofsupplyforeachpumpshallinclude,butnotbe limitedto:

ElectricMotorDrivenHorizontalFirewaterPumps.

Horizontal,centrifugalpump.

Electric motor driver.

Couplings and non-sparking coupling guards

Local Firewater pump controller in accordance with NFPA 20requirements andproject P&ID (Located adjacent to pump)

Local gauge board (if required)

Anti-vibrationmountsforthefirewaterpumpcontrollerandgaugepanels.

Fabricated steel baseplate for pump, motor driver and all auxiliaries.

Baseplate leveling bolts and shims

Baseplate earthingbosses, welded to diametrically opposite corners

All electrical and instrumentation cabling within the confines of thebaseplate.

All required cable trays within the confines of the baseplate

Diesel Engine Driven Horizontal Centrifugal Pumps.

SPECIFICATION FOR INDUCTION LV/MV MOTOR Will be issued laterPIPING MATERIAL SPECIFICATION Will be issued laterSPECIFICATION FOR PAINTING Will be issued laterUTILITY AND SITE CONDITION Will be issued laterPACKING , MARKING & SHIPPING PROCEDURE Will be issued later


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SPECIFICATION

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Horizontal centrifugal firewater pumps

Diesel engine driver furnished complete with lubricating oil system,

Closed circuit cooling water system, fuel injection system and allotherauxiliaries to form a complete unit.

Universal joint type shaft coupling and non-spark coupling guards

Lubrication systems for pump, diesel engine.

Desalinated water cooling system complying with NFPA 20requirements.Desalinated water shall be taken from pump discharge

D.C. electric starting system. With 2 sets of Ni-Cad batteries

Combustion air filtration system

Exhaust system including silencer and spark-arrestor and exhaust

Duct/stack.

Fuel system day tank

Anti-vibration mounts under the diesel engine and for the firewater pumpcontroller and gauge panels.

Local Firewater pump controller in accordance with NFPA 20requirements and project P&ID

Local gauge board

Fabricated steel baseplate for pump, diesel engine driver and allauxiliaries except the fuel day tank.

Baseplate leveling bolts and shims

Baseplate earthing bosses, welded to diametrically opposite corners

All interconnecting piping, valves and fittings within the confines of thebaseplate, including flexibles between the engine and fixed piping.

All electrical and instrumentation cabling within the confines of thebaseplate.

All required cable trays within the confines of the baseplate. Funnel.

Relief valve.

Common(Applicabletodieselenginedrivenandmotordrivenfirepumps)

All instrumentation and electrical equipment required for safe, trouble freeand efficient operation of each firewater pump.

All instrumentation and control components comply with NFPA 20requirements and project P&IDsuch as pressure sensing line

Suction & discharge gauges with isolating cocks

Automatic air release valve (if required)

All electrical and instrumentation junction boxes.


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Interface with plant DCS

Special tools for installation and maintenance.

Foundation bolts, nuts, shims and washers

Spare parts for start-up and commissioning, including a minimum of 5%spare bolting and gaskets for the pump columns.

Lifting beams and slings, c/w certification, for transportation, installationand erection

Packing including suitable protection for both sea transport and road

transport on rough tracks Painting of all items

Preservation suitable for 18 months at site

Drawings, Documentation and Certification in accordance with MaterialRequisition..

Design, engineering, fabrication, assembly, inspection, testing,certification and provision of all services and equipment necessary toprovide firewater pump packages fit for the intended purpose andmeeting the requirements of this specification. This shall include but notlimited to

Review of CONTRACTOR'S design/documents in connection with interfacing

equipment, as specified herein.

Torsional and lateral vibration analysis of the complete driver, transmission unit

and pump train.

Preparation and submission of documentation necessary for engineering,

installation, commissioning, operation, maintenance and trouble shooting for all

items of equipment within the package.

Performance and mechanical guarantees Flushing oil and first fill of lubricant charges shall be supplied by Vendor.

4.1.2 Jockey Pumps:Single-stage, horizontally mounted type with driver mounted on same base and connected

with coupling completed with all required piping, instrument and electrical components as

per NFPA 20.

Jockey Pump Controller:

A suitable model jockey pump controller shall be supplied in accordance with NFPA 20.

Pressure sensing line per NFPA 20 to the controller on the discharge to be considered.

4.2 OPTIONS TO SCOPE OF SUPPLY

Separate support for pump and gearbox including inter-connecting pipingand cabling between the pump and the diesel engine power unit.


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Sacrificial anode bracelets sized for 3 years service.

Electrolytic type anti-fouling system.

Secondary (black) starting system.

Equipment sun canopy(s)

Two Years Operating spares

Insurance spares

Services of a Commissioning Engineer to be based at site

4.3 EXCLUSIONS TO SCOPE OF SUPPLY

Lighting

Maintenance access ladders, walkways and platforms

Piping between the fuel tank and the firewater pump package baseplate.

Cabling between the electric motor driven pump and its associatedcontroller

Start/stop push buttons

Personnel protection insulation and cladding

Winterization

Installation and Commissioning labor

4.4 BOUNDARY LIMITS

The VENDOR shall indicate all piping, electrical and instrument terminalpoints on GALayout drawings.

The GA Drawing shall include a table showing all the piping terminalpoints with the nozzle identification, size, rating and facing and shallinclude but not limited to the following items:

Summary:

Pump discharge nozzle

Air release- vacuum breaker valve

Diesel fuel supply and return piping

Equipment/instrument junction boxes

Local fire water pump controller Underside of baseplate

Vent and drain flanges (valved)

Terminals for hard wired connections to the F&G and ESD

Also refer to Section 5.2.10 of this Specification


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PROJ .NO:


OWNER NAME

SPECIFICATION

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FIRE WATER PUMPS


5. FUNCTIONAL DESIGN REQUIREMENTS

5.1 GENERAL

5.1.1 The firewater pump packages shall be designed for the process duties and ratedperformance as defined on the equipment data sheets. The supplied equipmentshall be designed for continuous service and shall perform satisfactorily over theentire range of operating and environmental conditions.

5.1.2 The rated (100% duty) operating and design conditions shall be as stated on the

pump data sheets. The VENDOR shall add to the stated capacities the coolingwater requirements for the transmission system, i.e., electric motor driver or dieselengine/gearbox plus any other auxiliary cooling demands.

5.1.3 The equipment shall be heavy-duty type, designed and constructed for aminimum service life of 20 years. The pumps, drivers, transmissions, and controlsystems forming the package shall be preferably UL listed and FM approved forfire pump service.

5.1.4 The supplied equipment shall include all the necessary instrumentation to permitfully automated, unattended and safe operation of the package.

5.1.5 Cooling of the diesel engine driven firewater pumps shall be via a closed loopcooling system via a coolant to seawater heat exchanger. Seawater shall besupplied from thepump discharge.

5.1.6 The diesel engine, gearbox, pump discharge head and all auxiliaries shall bemounted on a common baseplate to maximize factory assembly, testing andsimplify installation. The baseplate shall be designed to resist all forces that maybe imposed during sea transportation, road transportation and lifting duringinstallation. The baseplate shall also be designed to accommodate thermal ormechanical loads imposed during normal operation

5.1.7 The VENDOR shall advise the overall skid dimensions, weight and position ofcenter gravity in his quotation.

5.1.8 All drainage points shall be piped to a common low point drain, terminating in ablock valve and a flanged connection at the edge of the baseplate, for connectionto the plant closed drains system.

5.1.9 The supplied equipment shall be designed to ensure the safest possibleoperation and shall be supplied with all safeguards and warning notices required toprotect personnel.

5.1.10 Safety requirements covered under referenced International Codes and

Standards shall be strictly complied with.


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OWNER NAME

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FIRE WATER PUMPS


5.1.11 The VENDOR shall ensure that all equipment and associated ancillary systemsare pressure rated for all operating and upset conditions.

5.1.12 The surface temperature of any exposed surface shall not exceed 55C. TheVENDOR shall identify areas likely to exceed this temperature, so that personnelprotection facilities can be installed by the site sub-contractor.

5.1.13 The equipment shall be designed and fabricated to take into account the effect ofdirect exposure of the equipment to solar radiation; VENDOR shall identify anyrequirement for sun canopies over the equipment and/or the need for a roof, full or

partial over the package.

5.1.14 Sun canopies, if required shall be supplied by the VENDOR and included as anoption within the quotation. If full or partial roofing over the package is required thePURCHASER and VENDOR shall mutually agree the arrangement andresponsibility for the supply of the roof.

5.1.15 All electrical, controls and instrumentation equipment and devices shall meet therequirements of the appropriate project specification with regard to hazardous areaclassification and certification.

5.1.16 All rotating and moving parts shall be provided with adequately sized rigid non-sparking guards.

5.1.17 Equipment shall be located andorientated on the baseplate so as to permitadequate, safe access for operation and maintenance activities. Attention shall bepaid to potential tripping and overhead hazards.

5.1.18 The VENDOR shall confirm all the utility requirements with his quotation.

5.1.19 Control of the sound pressure level of all equipment shall conform to therequirementsof IPS-G-SF-900 General Standard for Noise Control and Vibration.Unless otherwise specified another values in relevant data sheet, the pump and

electric motor driver noise shall be not more than 85 dBA at 1 meter from theequipment surface. For diesel engine driven set, the noise level shall be limited to110 dBA.

5.1.20 The VENDOR shall submit the guaranteed noise levels for thefirewaterpump package and its component parts, e.g., pump, gearbox, driver at theengine air intake and engine exhaust etc., with the quotation.

5.1.21 All layouts and outline drawings shall show the dimensions of major subassemblies as well as clearances required for lifting and withdrawal.

5.1.22 Details of pump, diesel engine, gearbox and major component removal

procedures and required clearances shall be provided. This shall include requiredaccess, lifting devices and weights of sub-assemblies.


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PROJ .NO:


OWNER NAME

SPECIFICATION

FOR

FIRE WATER PUMPS


5.1.23 Main equipment items - pump, diesel engine, gearbox and coolers - shall besupplied fitted with a stainless steel nameplate. The VENDOR shall submitNameplate Drawings for approval. The drawings shall show the proposed material,dimensions, thickness, and content.

5.2 MECHANICAL

5.2.1 Modes of Operation.

5.2.1.1 Except for routine operations such as checking oil levels and filters on the dieselengine, the packages shall be designed for uninterrupted operation at designconditions for 10,000 hours or intermittent duty (1 hour per week for the service lifeof the package) without attention, whichever is more onerous. During this time theflow rate may be vary between zero and 150% of rated capacity, as required bythe fire ring main system. At 150% flow rate the pump head shall comply with theNFPA20 requirement.

5.2.1.2 Apart from fire duty and a test run once per week for approximately one hour, thepackages of fire pumps(El. Motor & Diesel driven) will generally be at rest butconnected to a normally pressurized firewater ring main by means of Jockeypumps. However, they shall be designed such they may be kept in a state of

readiness for emergency/rapid supply of firewater.

5.2.1.3 Normal Standby Status:

The fire pump will normally be held at rest but available for instant start-up,immediately a hazard (fire or gas escape) is detected. When at rest, thosefunctions/parameters that affect its readiness to operate shall be continuouslymonitored and should a fault occur, that fact shall be alarmed at the local firewaterpump controller and the remote control station(s). The remote control station (byothers) is situated in plant CCR.

5.2.1.4 NormalAutomaticStart

Whenahazardoussituationoccurs,thefirepumpshallstartautomaticallybymeansofasignalfromtheplantfireandgaspanel.Operatorinitiationcanbemadebymanualsignalfromtheremotecontrolstationoremergencypushbuttonpointsaroundtheplantviatheplantfireandgaspanel

5.2.1.5 Shutdown

Shutdown of the fire pump shall be normally affected manually from the localcontroller, or automatically by the engine over speed controls on engine drivenpumps. In normal operation (i.e. when the pump is in the "automatic" or "manual"modes) an engine driven fire pumps shall only shutdown automatically if it over

speeds. All other malfunctions shall initiate an alarm only

5.2.1.6 Test Mode


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When the controller is switched to TEST MODE certain alarm functions shallinitiate shutdown. Engine driven pumps will shut down via the fuel shut-offsolenoid only.

If a hazardous situation occurs (whilst the controller is in TEST MODE) whichrequires the firepump to start, then the controller logic shall automatically overridethe additional trips and start the pump. The pump and controller shall then functionas though it was in AUTOMATIC MODE.

5.2.1.7 StartingSequence

The fire water ring main is a permanently pressurized by two (one main and onestand-by) electrically driven jockey pumps. The jockey pumps and the mainfirewater pumps are controlled by low pressure signals from the firewaterdistribution network.

After a suitable delay, should for any reason the fire water ring main pressure bebelow its set point, indicating the demand is not being satisfied by the selectedjockey pump, the logic shall initiate in sequence the starting of the main lead firepump. This shall normally be the electrically driven main fire pump followed bythe diesel driven pumps as the ring main continues to fall in pressure due to

failed to start or not available pumps.

5.2.2 General Pump Characteristic and Requirements

5.2.2.1 The rated operating condition as shown in the data sheets shall be the specifiedguaranteed operating condition against which the pump will be purchased. Therated condition shall include capacity, head, NPSH, specific gravity, power,speed and viscosity.

5.2.2.2 Maximum suction pressure, liquid specific gravity, impeller diameter and pump

speed should be considered at the pump shut-off condition, to establish themaximum pump discharge pressure condition.

5.2.2.3 The pump shall have a stable head-capacity characteristic, decreasing head withincreasing flow. The head-flow characteristic shape shall be in accordance withNFPA 20 as a minimum requirement. The shut-off head shall not exceed 140%of the head at 100% duty point capacity including any head rise due to off-loadoperation of the equipment.

5.2.2.4 Generally the pumps will draw from a dedicated storage tank located close to thepumps. The water in the tank will be desalinated water. Alternative waters orsupply sources will be detailed in the Material Requisition. Sea water is available

as a secondary source, Suppliers shall confirm the suitability of the equipment tohandle this water in an emergency case, also the post operation activities thatshould be carried out to return the equipment to operation on desalinated water.


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5.2.2.5 The pumps shall be designed to operate continuously at 150% of the ratedoperating speed.

5.2.2.6 Pumps, transmissions and drivers shall be suitable for start-up with the pumpdischarge valve open and a pressure in the discharge header equal to pump rateddischarge pressure.

5.2.2.7 The impellers shall be individually dynamically balanced in accordance with ISO

1940-1 Grade 2.5, sleeved and keyed to the shaft.

5.2.2.8 Impellers shall be made in one piece and have solid hubs.

5.2.2.9 The sizing of the driver should be based on the maximum pump shaft power atany point on the pump curve up to 150% of the rated flow, including the relevanttest tolerances, gear losses and auxiliary losses.

5.2.2.10 Pump shall develop not less than 65 percent of rated total head whendischarging at 1-1/2 times (i.e.150%) rated capacity.

5.2.2.11 The VENDOR shall provide pump torque/speed curves showing both open andclosed discharge valve pump start-up characteristics. The driver torque/speedcharacteristic(s) shall be superimposed on the pump characteristics.

5.2.2.12 It is the responsibility of the pump VENDOR to ensure that all necessary criticalspeed calculations and/or tests are carried out (for lateral and torsional conditions)as may be necessary to ensure satisfactory operation of the complete driver/pumppackage.

5.2.2.13 In order to ensure that cavitation of the pumps will not occur. The minimumNPSH Available shall exceed the NPSH required by at least 1.5metres. Thisrequirement shall be met across the full flow range up to rated point and could bechanged to 1m (at least) up to the 150% rated flow.

5.2.2.14 The pump shall be suitable for parallel operation.

5.2.3 Primary Starting System

5.2.2.15 Two 100% sets of batteries shall be provided for each engine complete withcharging facilities in accordance with NFPA 20. The VENDOR shall include anunder-voltage monitoring (alarm) relay per battery set. Batteries shall be sealednickel cadmium type with a system output voltage of24 Volts DC.

5.2.2.16 Each set of batteries shall be sized in accordance with NFPA 20 requirements.


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5.2.2.17 The automatic start sequence shall be arranged in accordance with NFPA20.The engine starter motor(s) shall be of sufficient rating to undergo the abovestarting cycle without damage or overheating.

5.2.2.18 Batteries shall be substantially secured against displacement, excessivetemperature, vibration, and mechanical damage and flooding with water. Theyshall be readily accessible for servicing.

5.2.2.19 Battery charger control logic shall provide the required protection circuitry to

prevent overload in the event that the engine cranking sequence commencesduring a battery charging period.

5.2.2.20 The VENDOR shall provide all cables between the controller, batteries andengine starter motor(s).

5.2.4 Secondary (Black) Starting System

5.2.4.1 The vendor shall offer as an option within the quotation a secondary (black)start facility for each engine. This may achieved by hydraulic or pneumaticmeans, as recommended by the VENDOR.

5.2.4.2 The complete secondary start system shall be mounted within the confines ofthe firewater pump package baseplate.

5.2.4.3 The VENDOR shall ensure that all piping, hoses, etc., are adequatelysupported and protected from damage. Hoses shall be restrained fromsnaking into access ways.

5.2.4.4 The hydraulic system shall comprise but not limited to an engine mountedcharge pump, a hand charge/top-up pump, starter control valve complete withclosed loop tubing system, accumulators, hydraulic start motor(s),oil reservoir, filters, cooler, piping, valves, instrumentation and ancillaries. TheSupplier shall propose a design code for the accumulators within the quotationfor the CONTRACTORS approval.

Based on site minimum ambient temperature, the system shall be sized toprovide a minimum of three start attempts of 15 seconds duration each,without recharging.

5.2.4.5 The pneumatic starting shall be accomplished via direct air injection into theengine cylinder, where the vendor has a proven system for doing so, or via anair motor. The system shall include but not be limited to the following:

An engine mounted air compressor for priming the pneumatic starting

system, and for maintaining readiness to start of the firewater pumpduring normal operation.


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An air receiver each sized for a minimum of three start attempts, each of15seconds duration. Unless otherwise agreed with the CONTRACTOR the airreceiver shall be designed in accordance ASME VIII Div 1.

Air starter motor (if necessary).

Air dryers (if necessary).

All piping, valves, filters/strainers, pressure safety/relief valves,silencers, instrumentation and ancillaries.

A quick connect coupling (VENDOR to provide both halves of the coupling)shall be provided on the system to permit connection of an external air supplyor bottle (air or nitrogen).

The air compressor for pneumatic systems shall be capable of charging theair receiver from atmospheric in not more than 30 minutes.

5.2.5 Couplings and Guards

5.2.5.1 A flexible spacer type coupling capable of absorbing torsional vibration andshaft misalignment include non-sparking metal coupling with a minimum servicefactor of 2.0 shall be provided.

Initial alignment between engine and gearbox shall be in accordance with thecoupling manufacturer's recommendation. VENDOR shall advise maximumallowable offset and angularity for use in field installation alignment

5.2.5.2 All couplings shall be supplied by the VENDOR and be statically anddynamically balanced in accordance with 6.9.4 of API 610 11

th. Edition.

Grade G2.5 dynamic balancing for all rotating components is required as per6.9.4.1 of API 610 11

th. Edition.

5.2.5.3 The coupling between the engine and gearbox shall absorb the variations inangular momentum from the driver and shall resist shock loading due to startup, maximum torque, overspeed, etc. The torsional stiffness over the possible

range of the engine/pump power shall be compatible with the torsionalcharacteristics of the connected system to avoid resonant conditions within theoperating speed range.

5.2.5.4 Cast iron couplings are not permitted. Coupling hubs shall be removablewithout the applicationof heat.

5.2.5.5 Coupling guards shall be non-sparking, rigid, ventilated, and removable. Theguard design shall comply with local/national regulations and/or standardsfor guarding of machinery and personnel protection.

5.2.6 MATERIALS OF CONSTRUCTION


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5.2.6.1 Materials of construction used shall be in accordance with those shown on theequipment data sheets. The VENDOR is responsible for ensuring that allmaterials used are suitable for the operating and ambient conditions specified.

5.2.6.2 ASTM designation of materials shall be specified on the equipment data sheets.If the VENDOR is unable to offer these materials, he shall submit, with hisproposal, his material specification including the physical properties andthechemical composition. Where materials of construction arenotspecified, the VENDOR should offer his standard and proven materials forapproval.

5.2.6.3 Stainless steel materials generally, shall not be used in a saliferous coastalenvironment at operating temperatures in excess of 50C to avoid chloride attackand stress corrosion cracking that are known to occur at highertemperatures.THE VENDOR shall specify within the quotation, the measurestaken to mitigate such effects on the package equipment/systems for theCONTRACTOR'S approval.

5.2.6.4 All materials shall be new and of first quality.

5.2.6.5 No substitution of material may be made without the written consent of theCONTRACTOR.

5.2.6.6 Structural quality steels are not acceptable for pressure containing parts.

5.2.6.7 Unless agreed otherwise by the CONTRACTOR, pipes for nozzles or internalsshall be seamless.

5.2.6.8 Non pressure parts attached to pressure parts by welding shall be of the samegeneral type of material as the pressure part.

5.2.6.9 Should any materials prove unsatisfactory during fabrication, they shall berejected, even if there is certification to prove previous satisfactory examinationor tests.

5.2.6.10 Material certification shall be provided in accordance with BS EN 10204, type3.1 for all pressure containing parts and type 2.2 for all non-pressure parts.

5.2.7 LIFTING

5.2.7.1 Lifting attachments shall be provided, where required, to facilitate handlingduring transportation and erection at site. The baseplate and its lifting pointsshall be designed to enable a single point lift, such that slings do not foul anypart of the equipment. The lift weight shall be factored by 2.0 for the design ofthe lift points.


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5.2.7.2 Where a single point lift is not possible a lifting beam or lifting frame shall besupplied. All lifting devices shall comply with the requirements of the local andnational standards at the points of loading and unloading. All lifting equipmentshall be proof tested (witnessed) by a recognized competent authorityinaccordance with a recognized code.

5.2.7.3 Where mechanical aids are required to remove equipment components formaintenance, these equipment components shall be equipped with liftingattachments. Typically this shall be for all items weighing more than 25kg.

5.2.8 ELECTRICAL

5.2.8.1 Motors shall be in accordance with the requirements of project MotorSpecification

5.2.8.2 The electrical equipment shall be in accordance with theproject electricalspecification-:Specification For Electrical Requirements For Packages, andSpecification For Electrical Installation.

5.2.8.3 Electric motors shall be suitable for direct on-line starting. The VENDOR shallconfirm that the motor's starting torque capability exceeds the speed torque

requirement of the driven equipment.

5.2.8.4 Motor terminal boxes shall have minimum ingress protection to IP 56requirements, and be suitable for outdoor installation.

5.2.8.5 In accordance with NFPA 20, the motor starter shall be supplied by theVENDOR and fitted into the Local Controller.

5.2.8.6 All metal to metal parts of the supplied equipment shall be earth bonded

5.2.8.7 The VENDOR shall provide motor terminal boxes with cable glands for theCONTRACTOR'S power cables. Cable glands and terminals shall also besupplied for motor anti-condensation heaters and thermistor pairs, if specifiedon the Motor Specification.

5.2.8.8 The VENDOR shall provide separate terminal boxes at the skid edge for theCONTRACTOR'S power and instrumentation/control cables. Bottom entryconnections are required for all skid-mounted terminal boxes.

5.2.9 INSTRUMENTATION

5.2.9.1 The VENDOR shall supply instrumentation to ensure safe and economic

operation of the equipment.


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5.2.9.2 Instrumentation equipment and devices shall have a minimum ingressprotection in accordance with IP 66 requirements, and be suitable for outdoorinstallation.

5.2.9.3 Instrumentation shall comply with the requirements of the Project InstrumentSpecification. Specification For Instrument & Control Systems On PackagedUnits.

5.2.10 PIPING

5.2.10.1 The VENDOR shall provide all necessary piping components within theconfines of the baseplate. Auxiliary piping Carrying external services shallterminate with block valves at the edge of the baseplate and shall be designedto permit ready disconnection of the external piping from the skid.

5.2.10.2 All piping shall be welded; flangedjoints shall be provided only wheredisassembly is necessary for maintenance purposes.

5.2.10.3 Piping shall conform to piping material specification

5.2.10.4 All piping shall be adequately supported for service and shipment conditions.Supports installed for shipment shall be painted red for easy identification andremoval after installation. These temporary supports shall be identified on a GAdrawing. For shipment, all openings must be blanked by suitable cover.

5.2.10.5 The piping arrangement shall provide adequate clearances for installation,removal, access or maintenance of equipment components or pipingaccessories.

5.2.10.6 All piping interfaces, including vents and drains, shall be terminated with aflanged connection to ASME Bl6.5 at skid edge. Facings, size and ratings shallbe stated on the Pump Data Sheets. Minimum connection size shall be 20mm(3/4") diameter.

5.2.10.7 All flange bolt holes shall be equidistant from the flange centerlines (x/y axes),unless stated otherwise. This practice is also known as two hole square.

6. INSPECTION AND TESTING

6.1 GENERAL

6.1.1 The equipment shall be subject to inspection at all stages of manufacture by theCONTRACTOR'S inspector.

6.1.2 Access shall be made available to the CONTRACTOR'S representatives at anytime during the manufacture of the equipment. For all witnessed tests VENDORshall give the CONTRACTOR the agreed notice period.


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6.1.3 Inspection and witnessed tests by the CONTRACTOR and third parties shall notrelieve VENDOR of any guarantees, responsibilities or obligations to providesatisfactory equipment.

6.2 QUALITY PLAN

6.2.1 The VENDOR shall implement a Quality Management System compliant withISO 9001:2008

6.2.2 The VENDOR shall provide a quality/inspection and test control plan, which setsout specific quality practices and activities relevant to his entire scope of supply.The requirements regarding the format and content of the quality plan shall beagreed with the OWNER. It shall include as a minimum; inspection and testactivities, procedure references, acceptance criteria, documentation andcertification to be provided.

The above shall also apply to major sub-vendors.

6.2.3 The final inspection and test plan will be developed jointly between the VENDORand the OWNER. The OWNER will define the extent of his participation on the

plan.

6.2.4 The OWNER'S and VENDOR'S representatives shall confirm compliance withthe inspection and test plan by initialing and dating against completed activities,before shipment of the package. The plan may be supplemented by otherinspection checklists and outstanding work lists.

6.2.5 The requirements for dossier compilation shall be agreed with theCONTRACTOR.

6.3 SCOPE OF INSPECTION AND TESTING

6.3.1 Inspection and testing shall be performed in accordance with written proceduresprepared by the VENDOR and approved by the OWNER. The test proceduresshall include a schematic of the proposed testing arrangement.

6.3.2 The following tests are required as a minimum:

Hydrostatic test of equipment including skid piping(For piping according torelevant specification and for pump acc. To API 610 11

th. Edition)

Pump performance test to be carried out on all pumps and sparerotors(See6.3.4 below)

Diesel engine test (See 6.3.5 below)

NPSH test if required (see 6.3.8 below)

Gearbox mechanical run and over speed tests (if any)


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Motor Tests - in accordance with theproject motor specification.

Local Controller testing (See 6.3.6 below)

Posttests strip inspection - at discretion of the OWNER

Functional checks of all supplied controls and instrumentation

Pump package string test (See 6.3.7 below)

6.3.3 The VENDOR shall advise whether any additional tests are recommended.

6.3.4 Performance testing shall be carried out in accordance with ISO 9906 (2012) orThe Hydraulic Institute standard and the results shall satisfy the tolerances withinin Table 16 of API 610. Test points shall be as per clause 8.3.3.3 of API 610 11

th.

Edition. End of allowable operating margin shall be 150% rated point.

6.3.5 The diesel engine shall be subjected to performance and mechanical runningtests in accordance with ISO 3046. Testing shall demonstrate the engine outputpower, fuel consumption and the correct function of auxiliary systems andinstrumentation. Power output and fuel consumption shall meet theguaranteed values stated on the data sheets.

If any part of the test is unacceptable or engine parts are replaced due to defects,the tests shall be repeated in its entirety until a successful test is achieved.6.3.6 Each gearbox shall be subjected to mechanical running and overspeedtests.

6.3.6 Each local controller shall be subject Factory Acceptance Test (FAT) asfollows

Full input/output (I/0) point testing. Full functional test including starting logic checks. Power consumption tests. Power up tests. Fusing tests (sample only to check discrimination).

After assembly the Controller shall be subjected to a 72 hour heat soak testimmediately prior to the FAT. Throughout the heat soak test input and outputsignals shall be verified.

6.3.7 Each complete firewater package shall be subjected to the following witnessedtesting.

Each firewater pump package shall be fully assembled with all utilities

connected to undergo an extended run performance and functional


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string test at the VENDORS works. The test shall include at least 4 hours

operation at the 100% DUTY point and at least 2 hours operation running

at the 150% duty point.

The head-flow characteristic curve for each pump shall be generated.

The VENDOR shall record sufficient parameters during the test to verify

the mechanical/electrical integrity of the complete package.

As a minimum, the following checks shall be undertaken during the

string test:

All controls, alarms and trips shall be checked for correct set point and

function. Functionality shall be verified by simulating the fault on the

equipment concerned.

Noise level measurements in accordance with EEMUA Publication 140.

Baseplate vibration survey at full load.

Over speed tests.

Primary and secondary (black) start system tests to confirm correct

operation and that the specified number of starts and duration can be

obtained without the starter motor(s) showing signs of duress or

overheating.

Cold start capability shall demonstrate. This shall be achieved by leaving

the engine stationary for a period of 12 hours (preferably overnight) priorto testing

All remote hardwired signals to/from controller shall be

simulated and function tested.

Cable insulation and continuity testing.

6.3.8 A NPSH test shall be carried out if the requirements of NPSH margin stated in5.2.2.13 could not be met. In this case, NPSHR data shall be taken at the followingfour points: minimum continuous flow, 75% of rated flow, rated flow and 150% ofrated flow. The NPSH test shall be in accordance with the test code of theStandards of Hydraulic Institute.

NOTE:The liquid fuel on test shall be similar to that to be used during

normal operation

6.4 CERTIFICATION

6.4.1 The VENDOR shall provide quality records appropriate to all inspection and testactivities. The records shall be referenced against appropriate activities within theinspection and test plan.

6.4.2 VENDOR shall collect and collate all such quality records and certification for

submission to the CONTRACTOR as a certification dossier. Note that, wherenecessary,certificates shall be stamped as approved by the OWNERs inspector.


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7. ACCEPTANCE CRITERIA AND GUARANTEES

7.1 ACCEPTANCE CRITERIA

The acceptance criteria for the manufacturing, fabrication, construction and NDT ofcomponent parts, sub-assemblies and the fully assembled units shall, in order ofprecedence be; as stated on the data sheets; in accordance with this specification; or inaccordance with specified design codes. The acceptance criteria shall be confirmed in thequality plan.

7.2 GUARANTEES

7.2.1 The VENDOR shall guarantee that the pump shall meet the various performanceguarantees as required by the agreed governing national codes and standards anddetailed elsewhere in this specification and on the Pump Data Sheet.

7.2.2 The VENDOR shall guarantee the suitability of the materials of construction forthe duties required, even if the CONTRACTOR has specified the type and gradeof material to be used.

7.2.3 All equipment and component parts shall be warranted by the vendor against

defected materials, design and workmanship for 12 months after start-up or 18months after shipment, whichever is longer.

8. SITE SERVICES

8.1 PACKING, PRESERVATION AND TRANSPORTATION

8.1.1 The equipment shall be painted in accordance with the VENDOR'S standard

which shall be proven and established for the service conditions and shall takeaccount of the CONTRACTOR'S paint specification.Specification for Painting

8.1.2 Packaging and protection for shipment shall be performed in accordance with theproject procedure:Packing & Marking Procedure Shipping & Material DeliveryProcedure : Material Handling Procedure:. Particular attention shall be given to theprotection of flanges, which shall have substantial wood, metal or plastic blanksbolted on. If the CONTRACTOR gives a concession allowing the use of screwedterminations then the termination shall be plugged or capped. Transport to site willbe by road and sea. Some of the journey will be on rough tracks.

8.1.3 The VENDOR shall submit details of his standards and procedures for anynecessary temporary corrosion protection to the CONTRACTOR for review.

Equipment may be stored at site for up to 18 months.


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8.2 SPARE PARTS

Any required spares comprising commissioning and 2 years shall be submitted by vendor

and supplied after client approval .

8.3 MAINTENANCE

8.3.1 The VENDOR shall submit a Maintenance Schedule, including recommendedlubricants and quantities, with his quotation.

8.3.2 SPECIAL TOOLS

The VENDOR shall submit, with his quotation, his recommendations for one set ofspecial tools required for installation and maintenance of the supplied equipment.

9. DOCUMENTATION

9.1 Relevant drawings and documentation shall be provided by the VENDOR in

accordance with the requirements of the CONTRACTOR'S "VENDOR

Documentation Requirement Schedule" (VDRS), contained in the Material

Requisition. The documentation shall be submitted strictly in accordance with the

timings indicated on the VDRS.

9.2 The VENDOR document type catalogue, which forms part of the VDRS,

describes specific requirements regarding content, format and submission

details for drawings, data sheets and manuals etc.

9.3 Review of VENDOR'S drawings, calculations and other documents by the

CONTRACTOR does not relieve the VENDOR of the responsibility for

correctness under the terms of the order.

9.4 In addition to the number of installation and operating instructions specified in the

VDRS, one approved copy of these documents shall packed with the pump

package for delivery to the jobsite. The equipment manifest shall include these

documents.

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