specification for design, realisation and supply of propellant … · 2018-04-11 · page 1 of 22...

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IPRC/ESPSF/RT/01

Specification for Design, Realisation and Supply of

N2O4 Propellant Road Tanker with prime mover

1.0 General:

1.1 A road tanker is required for transportation of N2O4 propellant between

production plant and ISRO work centers. Tank of 8m3 water capacity

made of AISI 304L is mounted over a semi trailer with telescopic front

and rear supports. The semi trailer shall be of double axle type with 18T

pay load capacity. The scope of the supplier includes procurement &

supply of prime mover, trailer and all materials for fabrication and

realization of the tanker (tanks material and components as given in

clause 12). The following details shall be considered during the design

and fabrication of the tanker.

1.2 The fabricator shall have the approval of Chief Controller of Explosives,

Nagpur for the fabrication of pressure vessels under Static and Mobile

Pressure Vessels (unfired) rules 1981 or latest amendment thereafter.

Copy of the current approval shall be submitted along with the Techno

Commercial bid.

1.3 The fabricator shall design the N2O4 propellant tank and water tank

based on the enclosed preliminary dimensional drawings

IPRC/ESPSF/RT/01, 02 & 03.

1.4 The fabricator shall consider the rules and regulations followed by the

state transport authorities.

1.5 The fabricator should get approval for the following

a) Fabrication drawings, mounting drawings and design calculations for

functional aspects and QAP from IPRC.

b) Fabrication drawings, mounting drawings, design calculations and QAP

from Third Party Inspection (TPI) agency.

c) Fabrication drawings and mounting drawings from Chief Controller of

Explosives, Nagpur for N2O4 road tanker.

1.6 Fabrication works shall be taken up only after final approvals.

1.7 The overall height of the tanker (Prime mover and trailer in hauled

condition) shall meet the State Transport Authorities (STA) requirement.

1.8 The supplier should get clearance from State transport authorities for

overall dimensions and road worthiness of the tanker.

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1.9 The supplier is responsible for temporary registration of the tanker

including prime mover in the name of Director, IPRC. Permanent

registration of the tanker including prime mover with State Transport

Authority is the responsibility of IPRC.

1.10 The supplier should arrange to get CCOE license from Nagpur for N2O4

road tanker in the name of Director, IPRC. Obtaining CCOE license for

N2O4 road tanker is the responsibility of the supplier. The supplier shall

obtain CCOE licence for the tanker within 4 months after permanent

registration of the vehicle by IPRC.

2.0 Prime mover Specification

Specification of Prime Mover (GVW: 35 T) with Sleeper cabin

2.1 Make & Model

Prime mover with Sleeper Cabin

(GVW: 35 T; 4x2 Drive)

Prime mover shall be of reputed make such as

ASHOK LEYLAND / TATA / BHARAT BENZ

2.2

Dimensions (mm)

Wheel Base 3000 to 3600

Overall Length 5400 to 6200

Overall Width 2400 to 2600

King Pin Size (inch) 2 inch

2.3 Capacity

Gross Vehicle weight 35000 kg to 40200 kg

2.4

Engine:

Type Diesel Engine meeting BS-IV norms

Power (hp) 170 hp to 235 hp @ rated rpm

Torque (Nm) 600 Nm to 850 Nm @ rated rpm

Exhaust

Exhaust pipe shall be rerouted to front with

spark arrestor OR

Exhaust pipe may be routed to rear; furnish

necessary exemption certificate from Petroleum

and Explosive Safety Organization (PESO), Govt.

of India 2.5 Gear Box: Synchromesh gearbox

2.6 Brake Pneumatic / Hydraulic

2.7 Tyre Suitable tyre size with 6 Nos. on wheel + 1 Spare

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2.8 Steering Power steering

2.9 Cabin All steel SLEEPER CABIN with berth

2.10 Fuel Tank 250 Litre (minimum)

2.11 Electrical system 12 V or 24 V Electrical system

2.12 Fifth Wheel Coupling Suitable for 2 inch King Pin

2.13 Terms & conditions

(i) Sale documents and relevant papers shall be

drawn in favour of `DIRECTOR, ISRO

PROPULSION COMPLEX, MAHENDRAGIRI,

TIRUNELVELI DIST., TAMIL NADU,

PINCODE: 627 133’.

(ii) The vehicle shall be delivered to IPRC,

Mahendragiri with Temporary registration certificate

(iii) The following vehicle documents shall be

furnished along with chassis

a. Sale invoice

b. Form 21, 22, 22A

c. Temporary Registration certificate

d. CMVR tools kit, First Aid kit and suitable fire

extinguishers

e. Operator’s manual, free service folders,

warrantee certificate etc.

3.0 Tank Specification

Type : Horizontal, Cylindrical with 2:1 ellipsoidal dished ends both sides

Design & : i) ASME Boiler and pressure vessel code Construction Sec. VIII Div.1, latest edition.

ii) During design, wind load for survival wind

speed of 200 km/hr considering 3 sec gust;

operating wind speed of 120 km/hr.

Working pressure : 4 kg/cm2(g)

Design pressure : 7 kg/cm2 (g) (Including 3g)

Allowance : Corrosion allowance – 3 mm.

Surface treatment allowance – 1 mm.

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Suitable allowance for thinning during

forming (rolling/spinning/ pressing) is to be

considered.

Thickness (min) : Shell – 10 mm & Dish end – 12 mm

including all allowances.

4.0 Material of construction

Sl. No. Description Material

1 Shell and Dished ends SA 240 GR 304L

2 Nozzle pipes SA 312 TP 304L (Seamless)

3 Nozzle flanges & blind flanges

SA 182 F 304L

4 Man hole flange & blind flange

SA 182 F 304L

5 Baffle plates, reinforcement & pad/wear plates

SA 240 GR 304L

6 Stud bolts/ nuts/ washers SA 193 GR B8/SA 194 GR 8/ SS

7 Gaskets PTFE & SS 304L spiral wound with SS 304L inner and outer rings

8 Man hole cover flange removal assembly/ Davit arm

SS 304L

9 Lifting lugs, Name plate & bracket

SS 304L

10 Man hole cover (Hood), Handles

SS 304L

11 Ladder & platform supports SS 304L 12 Saddle supports IS 2062

13 Platform Aluminium (chequered)

14 Materials having direct contact with tanks & fluids

SS 304L

5.0 General requirements

5.1 During design, the design stress selected shall include an allowance to

enable the vessel to withstand shocks normally encountered by

movements on road such as sudden acceleration and deceleration for a

minimum of 3g provision as per Static and Mobile Pressure Vessels

(unfired) rules 1981 or latest amendment thereafter shall be made for

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distributing localized stress arising from attachments. Two numbers of

baffle plates with stiffeners shall be provided to minimize the sloshing of

fluid during movements. The baffle plates should have openings of 400

mm radius at bottom to connect liquid phase and 200 mm radius at top

to connect vapour phase of the compartments.

5.2 Mounting of the vessel on the trailer chassis shall be done in such a

manner so as to keep the vibration to a minimum by using pads made of

balata material, and take care of the forward and backward movements

of the vessel due to sudden acceleration and deceleration.

5.3 The king pin mounted on the trailer is under the scope of fabricator. The

size of the king pin shall be 51mmx73mm long (std.). The raw material

for the king pin shall be ultrasonically tested for any internal defects. The

manufacturer’s chemical and mechanical test certificates shall be

provided for materials used for king pin. Only defect free material shall

be used for machining the pin.

5.4 The vessel shall be mounted on the trailer so as to get an inclination of

1O along the length of the vessel towards the drain nozzle at the back.

5.5 The vessel shall be electrically continuous with the chassis.

5.6 Earthing shall be done by providing a chain to touch the road while

running.

5.7 The rear of the vessel shall be protected by a robust steel bumper and

this bumper shall be

a) Attached to the back of the chassis so that the collision stress shall be

transmitted to the frame work of the vehicle.

b) Situated at least 7.5cm away from the rear of the rear most part of the

vessel.

5.8 There shall be clear distance of at least 15cm between the back of the

prime mover cabin and front of the vessel.

5.9 Suitable ladder made of Stainless steel pipe shall be fitted on the left side

of the tanker for operation purpose.

5.10 The trailer should have guard on both sides.

5.11 Platform (1m width x 1.5 m length) made of stainless steel with

Aluminium chequered plates of 5 mm thick on both sides of the manhole

shall be provided with sufficient clearance for tightening and loosening of

manhole flange.

5.12 A height barrier made of 1” Stainless steel pipe shall be fabricated and

fitted at the front side of the trailer chassis with proper support. Height

of the height barrier shall be 25mm above the overall height of the tanker

in hauled condition.

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6.0 Fabrication details

6.1 All the plates to be used for the shell and dish should have the original

heat number of the mill. They shall be inspected by third party

inspection agency and inspector’s stamp shall be marked on the plates.

6.2 Pipes and fittings should be procured directly from the manufacturer.

6.3 Material test certificates for all the parts should be provided.

6.4 IGC (practice-E) test should be carried out for each heat lot of shell &

dish plates in Govt. approved lab.

6.5 All SS plates and nozzle pipes should be 100% ultra sonic tested.

6.6 Dished ends should be stress relieved by solution annealing after forming

(Heat treatment process) as per ASME SEC VIII DIV.1

6.7 All nozzles shall be covered with stainless steel blind flanges, stud bolts

& nuts and gaskets.

6.8 Manhole flange should be SORF and other flanges should be WNRF type.

6.9 All flanges should be as per ANSI B 16.5, RF150 lbs rating.

6.10 WNRF flange ID should match with 160 sch. pipe ID.

6.11 Four numbers of lifting lugs equispaced are to be provided.

6.12 Nozzle below 50mm shall be stiffened with 2 Nos. of gussets at right

angles.

6.13 Name plate with bracket shall be provided.

6.14 Equipment shall be provided with two Nos. of earthing boss.

6.15 A sump of one liter capacity with anti vortex arrangement and 25 NB

drain pipe leading from the bottom of the sump to the drain nozzle flange

shall be provided. The drain line shall be properly clamped with the tank

by providing proper supports and no support is permitted from the

chassis. The drain line and its associated valves shall be fitted well

within the chassis.

6.16 A dip pipe of 50 NB size 160 schedule shall be welded with 50 NB weld

neck flange at the top and slip-on flange to fix it over the man hole cover

flange as shown in drawing shall be provided. There shall be a gap of 100

mm between the bottom of the dip pipe and bottom of tank inside

surface.

6.17 The pressurization nozzle should be extended 100 mm inside the man

hole nozzle with proper supports and terminated with horizontal Φ 5mm

perforated pipe having both ends closed.

6.18 A concave pocket arrangement for fixing temperature gauge as shown in

drawing shall be made for housing the gauge without protruding out of

the tank.

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6.19 A flange of 25 NB size 150 lbs rating as per ANSI B 16.5 welded with ½”

NPT female adapter shall be fabricated to mount the pressure gauge.

6.20 Mounting bolts materials for mounting the tank with the trailer should

be of high tension type (EN8 etc).

6.21 Tell tale holes shall be provided for checking the leakage pneumatically

on weld joints of reinforcement/pad plates.

6.22 All nozzle pipes are of seamless, shall be as per design code and a

minimum schedule of 160 to be provided.

6.23 All the flanges shall have serrated finish and shall conform to ASME B

16.5.

6.24 Inside edges of Manholes shall be smooth and rounded off with a

minimum radius of 3 mm.

6.25 Manhole and all nozzle flanges shall be provided with blind flanges of

same material, size and pressure rating with necessary studs & nuts,

washers and gaskets.

6.26 A davit arm shall be provided near manhole used for removal & assembly

of manhole flange. Provision must be made to remove the arm when it is

not in use.

6.27 All studs shall have ISO threading. Studs shall be threaded to full length

and should have standard SS washers.

6.28 All studs shall be provided with double nuts.

6.29 The fabricator shall supply two sets of gaskets other than those used for

testing and/or during transportation. Service gaskets shall be used

during hydrostatic test.

6.30 Saddle supports shall be designed as per IS: 2825. The included angle of

the saddle support shall be 160 deg. Minimum.

6.31 The saddle supports for the tank shall be designed for the density of

Liquid Di Nitrogen Tetroxide (N2O4) i.e., 1.454 gm/cc.

7 Trailer

7.1 The trailer is a double axle skeletal type flat bed semi trailer with

telescope front and rear supports having two speed landing legs. It shall

have a pay load capacity of 18 T over & above the trailer. Trailer axle

shall have wheel hub suitable for the above prime mover. Trailer shall be

of reputed make such as PL HAULWEL / TATA DLT / SATRAC. The

trailer shall have facilities like fail safe brake system, handbrake, brake

light, parking light post of 1.5m height at both end rear corner with park

light, bonding cable, earthing chain, reflectors of white and red colour,

tool box of size 1000mm X 500mm X 300mm made up of 5mm thick SS

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sheet mounted suitably, spare tyre bracket, mud guard, proper electrical

connections for the lighting systems, registration number plates, Fire

extinguisher (10 kg DCP- 2 Nos.) etc. shall be provided. The trailer shall

be painted with two coats of post office red colour synthetic enamel paint

after two coats of red oxide.

7.2 Four numbers of two speed landing gears of suitable capacity (make:

Fuwa/josts/Yoke/BPW) for use in loaded and unloaded condition shall

be provided as described below

- “Two landing legs at front end” of the trailer for mating and de-mating

operations from the prime mover.

- “Two landing legs at rear end” of the trailer platform to relieve the load

on tyres while parked for long duration.

The landing legs consist of two coaxial tubes moving inside the other.

The outer tube is bolted to the trailer through a mounting plate while the

inner tube is free to slide inside the outer tube. The actuation of the

inner tube is through a set of gears (Spur and Bevel gears). Bevel gears

are connected to a shaft with a handle at one end to a threaded rod at

other end. The threaded rod is fitted to a nut. Rotation of the shaft with a

handle causes the inner tube to move relatively. One shaft is directly

connected to the bevel gears and is to be used under no load condition

i.e when the loading leg is relieved of load. This is to be used after the

prime mover and trailers are coupled for lifting the inner tube after it is

lifted off the ground or when the trailer is to be uncoupled from the

prime mover for lowering inner tube before contact with the ground. The

outer shaft is to be used when the landing leg of the trailer is resting on

the ground.

7.3 All the relevant documents for trailer shall be submitted as per the terms

mentioned in clause 2.13.

8 Water tank

A water tank made of SS 304L as per drawing shall be fabricated and it

shall be suitable for mounting on the chassis of each prime mover, back

of the cabin using ‘U’ bolts. Cleaning of the tank shall be done as given in

Para 14 except polishing. Dish end shall be solution annealed.

9. Tank plates

9.1 The number of circular seam weld joints on the cylindrical portion of the

tank shall be minimum.

9.2 Single plate shall be used for longitudinal seam weld joints.

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9.3 Each dome shall be made out of maximum number of two plates only

and shall not be fabricated in petals.

9.4 If the design calls for lower thickness than the minimum thickness

specified in the drawing, the thickness specified in the drawing shall be

provided. But if higher thickness is called for by design than the

minimum thickness specified in the drawing, the higher thickness shall

be provided.

9.5 Welding layout: The welding layout of the tank shell shall be in such way

that either circular seam or Longitudinal seam not to foul with the fillet

weld of R.F pads of saddle supports and Man hole nozzle. A minimum

gap of 100 mm shall be maintained between any two weldments/seams.

9.6 All plates used for the fabrication of tanks shall have traceability with

MIL certificate for Chemical, Mechanical and IGC. All plates used shall

be ultrasonic tested at production MIL itself.

a) All plates shall be procured from a single MIL.

b) The plates should have been rolled within one year of procurement.

c) Plates of age more than one year are not acceptable.

9.7 All butt welds shall be 100% radio graphed (X-ray 2T sensitivity)

10. Welding

10.1 100% by GTAW process shall be followed with high purity (99.99%)

Argon gas purging and shielding, right from root to final passes for all

butt welds (Long seams, ‘C’ seams, nozzles, pipe to flange joints) and all

internal and external welds including fillet welds. Fabricator may also

use Plasma welding.

10.2 Plasma welding in combination with TIG welding is acceptable to reduce

the heat affected zone, weld defects and to improve quality of weld.

SMAW is not acceptable.

10.3 Welding shall be performed only by welders qualified under section IX of

ASME Boiler and Pressure Vessel Code, using procedures mentioned

under Section IX. Welding procedures must be approved and welder

must be qualified by TPI agency.

10.4 Welding consumables (filler wire) shall be used as per AWS classification

/ ER 308L. Filler should be IGC tested.

10.5 All butt welds shall be full penetration welds.

10.6 All butt welds shall be 100% radio graphed (X-ray 2T sensitivity).

10.7 All welds shall be DP tested for root and final welds.

10.8 Hydrostatic test and Pneumatic leak test shall be carried out at 3 bar(g)

before man hole nozzle outside welding with shell plate and welding of

reinforcement plate for checking the inside welding of shell and nozzle.

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10.9 The dye used for Dye-penetrant test shall not have chlorides more than

50 ppm.

10.10 Any re-work / repair have to be carried out as specified in ASME boiler

and Pressure vessel code with the approval of third party/purchaser.

11. Heat treatment

11.1 Solution annealing:

Dished end domes shall be cold formed. After cold forming, solution

annealing shall be done to relieve stresses caused due to cold working as

per code.

Solution annealing shall be as per the following cycle.

a) Loading Temperature : 400 ºC (max.)

b) Rate of heating : 250 ºC/hr (max.)

c) Soaking temperature : 1040 ºC – 1060 ºC

d) Soaking time : 30 minutes (min.)

e) Quenching in water to bring down to temperature 350 ºC within 3

minutes (max.)

The final hardness shall be checked and ensured to be below 201 BHN

11.2 Stress relieving :

The total fabricated tank (full equipment) including saddle to wear plate

welding has to be stress relived at 420 ± 10 ºC as per standard practice

(this operation shall be carried out prior to hydro static test). The

detailed stress relieving cycle is as given below.

Loading Temperature : 300 ºC

Rate of heating : 100 ºC/hr ± 20 ºC

Soaking temperature : 420 ºC ± 10 ºC

Soaking time (min.) : 2 Hrs.

Rate of cooling (min) : 100 ºC/hr

Unloading temperature : 300 ºC (Vessel to be air cooled inside the

furnace by opening furnace doors). Vessel to

be air cooled at atmospheric conditions after

unloading.

11.3 Solution annealing of domes and stress relieving of total tank shall be

carried out in an Electric furnace. Suitable digital photos to be taken in

presence of TPI agency prior & after stress relieving and signed images

shall be sent along with Master Production File.

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11.4 The furnace shall be calibrated prior to taking up stress relieving of the

tanks. The details of the furnace proposed for stress relieving like clear

dimensions, type, number of nozzles, type of fuel used, location and

number of thermocouples proposed for temperature measurement shall

be submitted and approval of TPI agency shall be obtained prior to

performing the stress relieving of entire tanks.

12. Components

12.1 Ball valves: The nozzles for pressurization (25NB), pressure gauge

(25NB), fill line (50NB), and drain line (25NB) shall be provided with one

ball valve each. The specification of the ball valves is given below:

Type : Regular port

Design code : BS EN ISO17292

Construction : Single piece, Antistatic & Fire safe (API 607)

Body material : ASTM A351 Gr. CF8

Ball & stem material : AISI 304

Bolts & Nuts : A 193 Gr.B8 & A 194 Gr.8

Lever material : SS

Body seat : PTFE

Body primary seal : PTFE

Body secondary seal : GFT/Grafoil

Stem primary seal : PTFE

Stem secondary seal : GFT/Grafoil

End connection : Flanged RF with serrated finish as per ANSI B

16.5, 150 lbs Rating

Testing : As per BS EN ISO B 12266

Operation : Lever operated

Heat treatment : Solution annealing of castings as per

ASTM A 351 S 11.1

Radiography : For body castings

Probable suppliers : L&T/ BDK/Micro finish valves/Niton valves

Quantity : 25 NB – 7 Nos. & 50 NB – 1 No.

12.2 Excess flow valves: One number of excess flow valve shall be provided

for each drain line, fill line, pressure gauge line and pressurization line.

The Specification of excess flow valves is given below:

Body material : ASTM A 182 F 304

Bonnet, spindle, seat, spring material : SS 304

End connection : flanged RF as per ANSI B 16.5,

150 lbs rating

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Max. flow rate allowed : 6 lit/sec

Probable supplier : Anil Engineering, Mumbai.

Quantity : 1) 25 NB – 3 Nos.

2) 50 NB – 1 No.

The valves shall be designed for arresting the excess flow which may

happen in case of sudden failure of the downstream connections due to

collision or any other reasons.

12.3 Safety Relief valve: One number of safety relief valve each for two 50 NB

nozzles shall be provided. The orientation of safety relief valve nozzle

should be fixed in such a way that the out let of the safety relief valve

should face towards the platform. The specification of safety relief valves

is given below.

Type : Spring loaded with balanced

bellow and closed bonnet

Nozzle type : Full nozzle

Cap : Screwed, closed

Body, bonnet material : ASTM A 351 F 304

Nozzle, disc, Guide & rings, trim

Spring, bellow, cap material : SS 304

Size : 50NB x 80NB flanged RF as per

ANSI B 16.5 150 lbs rating

Set pressure : 4.5 kg/cm2 (g)

Orifice designation : J

Construction code : ASME SEC VIII div. 1

Sizing basis : API RP 520

Valve testing : API 527

Radiography (100%) : Body & bonnet castings

Solution annealing of castings : ASTM A 351 S11.1

Probable supplier : Tyco Sanmar Pvt. Ltd, Chennai

Quantity : 2 Nos.

12.4 Magnetic level Indicator: One number of Magnetic level indicator

should be fixed on 50 NB nozzle provided on the man hole cover flange.

The specification of magnetic level indicator is given below.

Type : Immersible bullet type magnetic level

indicator

Level range : 0-1300 mm

Mounting : 50 NB RF 150 lbs rating

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ASTM A 182 F 304 L flange

Guide pipe : 25 NB SCH 40

ASTM A 312 TP

304 L seamless pipe.

Float : SS 304 L

Design pressure : 7 kg/cm2 (g)

Working temperature : 15o C to 40o C

Specific gravity : 1.454 for N2O4

Probable supplier : M/s RK Dutt Concerns, Thane

Quantity : 1 No.

12.5 Temperature gauge: Temperature gauge shall be provided as per the

specification given below.

Dial size : 50 mm

Sensing Element : Bimetallic strip

Stem dia. and Material : 8 to 10 mm, SS 304 or SS 316

Case, Bezel and movement : SS 304 / SS 316

Temperature range : 0 – 600 C

Accuracy : 1.5 % of FSD or better

Thermometer stem length : 400 mm

Thermowell MOC : SS 304 L

Thermo well immersion length : 350 mm

Connection size : ¾” screwed

Weather Protection : IP 65 or better

Mounting : Back / Horizontal

Supplier : M/s Vantage Technologies, Bangalore/

M/s Bangalore fluid System

components pvt. Ltd., Bangalore.

Quantity : 1 No.

12.6 Pressure gauge: Pressure gauges shall be provided as per the

specification given below :

Type : Bourdon type

Range : 0 – 7 kg/cm2 (g)

Accuracy : 1.5 % of FSD or better

Material : SS 304L

Dial size : 100 mm

End connection : ½” NPT (M)

Weather Protection : IP 65 or better

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Calibration medium : Air / N2 gas

Make : M/s Odin India pvt Ltd, Chennai/

M/s Kains Instruments India Pvt Ltd,

Bangalore.

Quantity : 2 Nos. (Tanker manhole flange

designation (W) and Water tank

Nozzle, N2)

13. Testing

13.1 Testing of Materials

All materials used shall be tested as per code in the reputed Govt.

approved testing labs before fabrication. All the plates proposed to be

used for fabrication of tank shall be subjected to mechanical, chemical

and IGC tests as per A-262 Practice-E in spite of availability of Mill test

certificates.

The plates used for construction of tank shall also be ensured free from

any lamination and manufacturing defects by 100% Ultrasonic testing as

per Practice A-578 Acceptance criteria Level-B in combination with ASTM

A 577. All nozzle pipes should be 100% ultrasonic tested. The scanning

shall be carried out in four directions during UT test. The test shall be

carried out under TPI at fabrication shop.

Ferrite number in weldment shall be measured by testing and this shall

be within the specified limit of 3% to 12% as per standard code. Test

certificates shall be furnished to purchaser for approval before

fabrication.

13.2 Hydrostatic Test:

13.2.1 Before Hydrostatic test, the inside and outside surfaces of the tanks

shall be mechanically cleaned and buffed.

13.2.2 Hydrostatic test shall be conducted as per code after fabrication and

radiography clearance. The test pressure shall be as per design code

and it shall be done in presence of TPI agency & purchaser.

13.2.3 Clean fresh potable water having chloride content less than 25 ppm

should only be used for Hydrostatic testing.

13.2.4 After Hydrostatic test, the vessel has to be degreased, pickled and

passivated.

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13.3 Pneumatic Leak Test:

After hydro test and pickling & passivation the tank shall be pneumatic

tested at 3 bar (g) by using dry nitrogen gas with dew point of minus 40

ºC or better.

14 Cleaning

14.1 Mechanical Cleaning

All metallic surfaces inside and outside having scales and foreign

materials and all welded surfaces have to be cleaned. This can be done

by scrubbing with metallic brush (Stainless Steel) followed by buffing.

Buffing should be done on the entire inner and outer surface of the total

tank to get a polished surface. The loose scales and powders obtained

from the above process can be cleaned by blowing, sucking or washing

with water. Mechanical cleaning and buffing shall be carried out after

stress relieving, but before hydrostatic test.

14.2 Degreasing

Degreasing has to be done on the inner surface by soaking with hot

detergent solution of Lissapol at 60 ºC to 70 ºC for at least 2 hours till

satisfaction.

14.3 Pickling

Pickling is to be carried out for inner and outer surface with solution

containing Nitric Acid 15% by volume and hydro fluoric acid (HF) 2% by

volume, balance DM water.

Temperature : Ambient

Duration : 1 to 2 hours

Thorough DM water rinsing has to be carried out until all traces of acid

are removed from the surface.

14.4 Passivation

Passivation is to be carried out for inner and outer surface with solution

of Nitric Acid 20-25% by volume, balance DM water.

Temperature : Ambient

Duration : 2 hours

Thorough rinsing with DM water is to be carried out till PH of the final

rinse water is between 6.5 to 7.5 to minimize staining. Surfaces must not

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be permitted to dry between successive steps of the acid cleaning or

passivation and rinsing procedures.

The concentration of iron should not exceed 5% by weight in case of

pickling solution and 2% by weight in case of passivation.

15 Swabbing Method

The pickling and passivation of the tank inner & outer surface shall be

carried out by swabbing method using barium sulphate as carrier

(chloride levels 25 ppm) in the form of paste. For each of pickling and

passivation operations, the paste has to be applied on the surface and

has to be kept for atleast two hours. Paste has to be removed with waste

cotton in each operation and finally the surface has to be rinsed with DM

water.

16 Checking

All the relevant tests shall be carried out to ensure proper pickling and

passivation as per ASTM A 380.

17 Drying

The drying is done to remove water and this is done as given below:

Passing dry Nitrogen / Air having dew point less than -40 ºC and free

from oil and grease (< 10 PPM) 60 ºC till the moisture level at the exit

comes to the inlet concentration value.

18 Sealing

After drying, the tank should be sealed so that ambient moisture never

enters inside. The tank is to be pressurized to 0.5 bar (g) with dry

Nitrogen gas at -40 ºC dew point or better.

19 Documentation

19.1 Three copies of master production files shall be supplied by the

fabricator. Each master production file should contain the following.

19.1.1 Introduction.

19.1.2 Approved design calculation & drawings by TPI /CCOE

19.1.3 As built drawing approved by TPI

19.1.4 All test certificates

19.1.5 TPI inspection certificates

19.1.6 All the brought out components catalogue with datasheets

19.1.7 Statutory approvals

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19.1.8 Final release note

19.1.9 Facsimile of stamping

19.1.10 Guarantee certificate

20 General Conditions

20.1 Information to be given along with quotation:

20.1.1 Complete technical compliance for the specifications and

detailed technical description with make and model of the

proposed prime mover and trailer with technical data sheet

shall be provided.

20.1.2 Delivery terms.

20.1.3 Validity of the offer.

20.1.4 Warranty.

20.1.5 Delivery period:

• The delivery of tanker shall be within one year from the date

of purchase order which includes fabrication drawing

approval from IPRC for functional details, fabrication

drawing approval from TPI agency and CCOE, Mounting

drawing approval from CCOE, temporary registration of

tanker including prime mover and obtaining clearance from

State Transport Authority for overall dimensions and road

worthiness.

• The supplier shall obtain CCOE licence for the tanker within

4 months after permanent registration of the vehicle by

IPRC.

20.1.6 Payment terms & condition:

Final 10 % of the order value shall be payable only after

submission of the CCOE licence to IPRC for the transportation

of N2O4 propellant in the tanker.

20.1.7 Copy of the current approval of Chief Controller of Explosives,

Nagpur for the fabrication of pressure vessels under SMPV

(Unfired) rules, 1991 or latest amendment thereafter shall be

submitted.

20.1.8 Copy of valid NSIC/MSME registration certificate, if applicable,

shall be submitted.

20.1.9 Previous Experience: The supplier shall furnish the client list

to whom similar type of pressure vessel/tank or tanker

fabricated in Stainless Steel and supplied under reputed TPI

agency viz. M/s Lloyds, BVIS with PESO approval etc. during

last seven years along with copy of purchase orders including

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technical specifications and TPI agency release note. This will be

considered as key criteria for evaluation of technical bid and

capability. If these details are not given, the offer may not be

considered.

20.2 The fabricator shall arrange CCOE approved third party inspection

agency like M/s BVIS, Lloyds. The quotation should include third

party inspection charge, charges towards CCOE for approvals /

licences and charges for obtaining temporary registration and road

worthiness certificates from State Transport Authority.

20.3 One set of soft copy of as-built drawings shall be supplied to the

purchaser.

20.4 All radiography films soft copy pertaining to the tanks shall be supplied

to the purchaser.

21 Pre-delivery Inspection:

Inspection shall be carried out by the Purchaser, before dispatch of

tanker at manufacturer’s site.

22 Preparation for Shipment:

Procedures proposed for the preparation of tankers for shipment shall be

intimated to the purchaser and shall generally be in accordance with the

following:

22.1 All shipments shall be protected from damage in transit to site.

22.2 The tankers should be supplied to IPRC, Mahendragiri, Tirunelveli Dist.,

Tamil Nadu State.

23 Form of quotation:

The quotation shall be in two parts tender and shall be submitted in

separate templates:

a. Techno-commercial bid:

Bidders shall comply all the technical and commercial aspects given in

the specification. Techno Commercial bid shall contain all technical

details as well as information and confirmation on all aspects mentioned

in the specification. It shall also contain confirmation on all Commercial

Terms & Conditions, wherever applicable, if any and any additional

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information the bidder would like to provide. Under any circumstances,

the Techno Commercial bid’ shall not mention prices of any items.

b. Price quotation:

The bidder shall quote the price with the individual break-up costs as

given in price bid template. The Techno Commercial bid containing the

technical and commercial aspects shall be opened first. The price

quotation shall be opened only after the evaluation of the Techno

Commercial bid.

Sl. No.

Description Amount in Rs.

1.

Basic product cost (N2O4 Propellant road tanker including tank, water tank, components, trailer, prime mover)

2. P&F charges

3. Freight charges

4. Taxes

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Annexure-I

Scope of Inspection (as per QAP):

The tankers should be fabricated under the inspection of Third party/

Purchaser representative as per QAP.

QUALITY ASSURANCE PLAN

Sl.

No.

Characteristics / type of

check

Ref.

Document

Method of

check

Quantum of check

Manufa

-cturer

QC

Third

party

Purch

-aser

1.a

Identification of plate

material with Mill test

certificates including

Ultrasonic test reports

As per PO Review 100% H 100% R R

1.b

Sample selection for each

heat lot/heat number &

Witness of Chemical,

Mechanical, IGC Test for

plates

As per PO Visual 100% W 100% W W/R

1.c

Witness of Ultrasonic

Testing of plates and pipes

(*refer in specifications)


1.d

Sample selection for each

heat lot/heat number &

witness of Chemical,

Mechanical & IGC Test for

pipes, fittings

As per PO Visual 100% H 100% W R

2

Review of fabrication

drawings and design

calculation

As per PO/

drawing

Material as

per design 100% H 100% R R

3 Review of welding

procedure and qualification AWS Review 100% H 100% R R

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4

Checking of root run & final

weld by Die penetrant test

(Butt welds)

As per PO Visual 100% W 100% R R

4.1 Measuring of Ferrite

number in all weldments As per PO

Checking

with meter 100% W 100% W R

5 Marking of nozzle

orientation

As per

drawing

Location of

nozzle 100% W 100% W R

6 Dye Penetrant test on all

fillet welds As per PO Visual 100% W

100%

R/W R

7 Visual and dimensional

inspection

As per

approved

drawing

Dimension 100% W 100% W R

8 Shell rolling, long seam &

Cir. Seam fit up As per std Visual 100% W 100% W R

9 Back grinding of long and

Cir. Seam welds As per std Visual 100% W 100% R R

10 Circularity of shells after

rolling As per std Visual 100% W 100% W R

11 Forming of dished ends and

solution annealing As per std Visual 100% W 100% W R

12 Fit up of nozzles, saddle

and supports and welding As per std Visual 100% W 100% W R

13 Evaluation of radiography

films of all butt welds As per PO

Film

evaluation 100% W 100% W R

14 Mechanical cleaning and

buffing As per PO Graph 100% W 100% R R

15 Stress relieving of total

fabricated tank As per PO Visual 100% W 100% W R

16 Hydrostatic test of total

vessel as per design code As per PO Pressure

hold 100% W 100% W W

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method

17

Pickling and passivation of

tank internal & external

surfaces

As per PO

Pressure

hold

method

100% W 100% W R

18

Pneumatic leak test at 4.0

bar(g) with nitrogen gas

having dew point of -400C

or better


19

Pressurizing the tank to 0.5

bar(g) with Nitrogen gas

having dew point of -400C

or better

As per PO Gauge

reading 100% W 100% R R

21 Stamping of name plate

and issue of certificates As per PO Visual 100% R 100% W R

22 Verification of Material test

certificates As per PO Review 100% R 100% R R

23 Production master file As per PO Document 100% R 100% R R

Legend: R- Review, W- Witness, H- Hold

Note: 1. The purchaser has rights to participate in the Inspection at any

stage of fabrication & the bidder shall intimate the work progress

periodically.

2. 100% Evaluation of radiography films shall be carried out by

Third Party Inspection Agency.

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