Item # 1 : Supply and installation of Secondary Seal

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Attachment
-
II to PR #
10
-
2453





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7

Standing Order for Supply & Installation of Secondary vapour seal & Roof leg covers for
Floating Roof Tanks in FR Offsite Area.


Item # 1 :
S
upply and installation

of Secondary Seal
for 8” Rim Gap Floating Roofs.


Scope of Job :

Supply of Seal with all nec
essary accessories, Removal of weather shields
from the existing tanks, shifting of scrap to the designated scrap yard, Installation of
secondary seal, Inspection, Testing & Commissioning.


The specifications and necessary drawings for the seal are provid
ed by HPCL. However
the vendor should
accept &
return the HPCL dwg or
submit the final dwg of the seal
being supplied by them
along with clear mention of deviations , if any
& get its approval
before
supply
.


Job scope includes Design, Preparation of Draw
ing for HPCL approval, supply,
installation, & testing of Secondary Seal System. The removal of existing seal

/ weather
shield

is in vendor’s scope. Agency shall submit preliminary Seal Drawings, prepared in
AUTOCAD (Latest version), in 2 Sets, individual
ly for each Tank including Dimensions,
Specifications and Bill of Materials, etc. for the specified Rim space
-

within One Week
from the Date of advice
. Agency shall provide the final approved Drawing in
computerized form in a CD, with 1 full Set in non
-
de
gradable Sepia Tracings to HPCL.


Agency shall make necessary Mechanical modifications at Site, while fixing the Seals to
the available Rim Angle, including Holes on the Rim Angle. All the arrangement is in the
scope of the agency.


Design Codes shall con
form to IS & API Codes.

As all jobs should be carried out in stage wise inspection, party must consult the HPCL

MI for all activity before they start.

1) M
OC

of all the seal components should be as per approved drawings.

2) Before installation, offer the

material for visual & Dimensional inspection.

3) Offer Original test certificate of all the material for review.

4) In case of non availability of coordination marks on material, Samples will be tested at
outside laboratory.
















Attachment
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II to PR #
10
-
2453





2

OF

7

SPECIFICATIONS F
OR SECONDARY VAPOUR SEALS


Material of Construction


#

Component

Material

1

Secondary Seal Plates

SS 304
(Minimum 1.2mm Thickness)
,
(1/4
Hard)

2

Secondary Seal Tip

Extruded PVC/Nitrile

3

Secondary Seal Vapor Barrier
Fabric

Reinforced PolyUrethane (0.4
mm thick)
coated Fabric

4

Seal Bolting Channels

SS 304

5

Interface Channels

SS 304

6

All Bolting Components

SS 304

7

Hold down plate

SS 410


Secondary Seal


1.

Secondary Seal shall be designed to be mounted to the Floating Roof Rim Plate,
and completely

cover the annular space between the external Floating Roof and
the Tank Shell Wall and provide contact against the Tank Shell Wall under all
operating conditions. The Secondary Seal shall be independent of the Primary
Shoe Seal in a manner that the Second
ary Seal can be installed, repaired or
removed without impairing operation of the Primary Seal. The Seal should be
tight fitting against the Tank Shell at all levels of the Floating Roof. Any work
carried out on the Secondary Seal shouldn’t affect the Prim
ary Seal.


2.

The Secondary Seal Compression Plates shall be bolted to the Floating Roof Rim;
each Plate overlapping the adjacent Plates by 40mm. The Width of the
Compression Plates shouldn’t exceed 500mm, in order to obtain the maximum
contact between Wiper
Seal and Tank Shell Wall. The adjacent Secondary Seal
Support Compression Plates are not to be bolted, welded or riveted together.
They will be overlapped with each Compression Plate, free to expand and
contract independent of the other Plates. All metall
ic Compression Plates should
be independent and will not be riveted or bolted to each other. They will be
bolted on the Rim Angle.


3.

Secondary Seal shall be designed and pre
-
tensioned to accommodate a variation in
the annular space between the Floating Ro
of and the Tank Shell of +/
-

100mm,
while maintaining a Release Pressure of
15

Kg per Meter of circumference under
normal operating conditions. Design of the Seal, especially size of the
Compression Plates, is decided depending on the ACTUAL Rim Gap observ
ed.
Normally a Survey will be carried out and ACTUAL Rim Gap measurements
will be taken at number of places on the periphery of the Deck at various levels
of the Floating Roof. These readings are fed to the Computer and the Computer
Program decides Height,

Width and Bending Angle of the Compression Plate so
that the Seal, when installed, will be always in contact with the Shell. The


Attachment
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II to PR #
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2453





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7

installed Seal will exert a pressure of
15

Kg per Running Meter on the Tank Shell
with design Rim Gap.


4.

To prevent Vapor leaka
ge between the Support Plates, a continuous Vapor Barrier
of Elastometric material shall be installed under the Support Plates. Vapor
Barrier material is designed for Chemical Resistance of the stored Product
Vapor. Un
-
reinforced Fabrics will not be allowe
d. Vapor Barrier Fabric material
shall be selected to be compatible with the stored Product. Vapor Barrier Fabric
is installed inside the Compression Plates to make the Seal Vapor tight. The
Fabric has to be compatible with the Product stored in the Tank.
It is especially
important that if joints in the Fabric, if unavoidable, should be Vapor tight. There
shall be no holes, tears or other openings in the Seal Fabric.


5.

Secondary Seal Tip system will consist of a PVC/Nitrile extrusion, with an overall
Width o
f not less than 20mm at the point of contact with the Tank Shell. The
adjacent Tip sections are to be butted together with butt joints, protected by
Stainless Steel Cover Strips. The Tip shall be bolted to the end of the
Compression Plates, totally encasin
g the top 70mm of Plate, to provide Sealing at
the point of contact between the Secondary Seal and the Tank Shell. The Seal Tip
is wider at the point of contact with the Tank Shell. Minimum Thickness of the
Tip at this point shouldn’t be less than 20mm. Mi
nimum Length of the Seal Tip
shouldn’t be less than 15 Meters. The Tip should be butt joint and protected with
Stainless Steel Cover Strip to prevent Vapor through the joint.


6.

Secondary Seal shall be designed to be
installed, repaired and replaced with the

Tank remaining in service.

No

Hot Work is allowed during Secondary Seal
installation.

Hence, design of the Secondary Seal should be such that it can be
installed with Tank ‘in service’ and without carrying any Hot Work.


7.

All the Secondary Seal Metallic Co
mponents, including Hold
-
down and Bolting
Hardware shall be SS 304. Compression Plates shall be 1.2mm Thick, SS 304
Stainless Steel. Stainless Steel Compression Plates shall be fabricated from
material to give adequate spring action. ‘C’ Channels are used
to fix the
Compression Plates on the Rim Angle for uniform Pressure on the Compression
Plates. No Flats are allowed.


8.

Secondary Tip is to be attached to the Compression Plates by means of
Thermoplastic Protection Device, with an internal Stainless Steel Bo
lt. In the
event that Secondary Seal protrudes above the top of the Tank Shell (due to over
-
filling of the Tank), the Protection Device shall ensure that the Tip will not
sustain damage when the Roof descends. Protector Clips are provided to fix the
Seal T
ip to the Compression Plates over Vapor Barrier Fabric. In an emergency,
if the Roof needs to be taken above the Safe Filling Height, Secondary Seal may
go beyond the Curb Angle. When the level is reduced and the Deck lowers, these
Protector Clips guide th
e Secondary Seal safely back in to the Shell without
causing any damage to the Seal.




Attachment
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9.

Maximum Spacing between Secondary Seal Tip Bolts shall be 127mm. The
maximum Clips with Bolts are fixed at a maximum distance of 5 Inches. This
reduced distance ensures
proper shape of the Seal Tip and its contact with the
Shell.


10.

Static Shunts shall be incorporated to operate above the Secondary Seal Tip at
Spacing not greater than 3 Meters. These Shunts shall be fabricated from SS 304
Stainless Steel, The Shunts prevent

built up of any Static charge. As the Shunts
are made from Stainless Steel, SS
-
304 , they ensure contact with the Tank Shell.
The Seal Tip is bolted to Compression Plate, using Protector Clip. No rivets are
allowed.


11.

MATERIALS

A)

Metallic Components: The
Secondary Seal Components shall be SS 304
Stainless Steel. Compression Plates shall be 1.2mm Thick SS 304
Stainless Steel.

B)

The Secondary Wiper Seal Electrometric Components shall be:



Secondary Seal Vapor Barrier Fabric

1.

Weld
-
able Polyester Poly
-
Urethane coa
ted on both sides
on a Polyester 500D Base Fabric. Total Finish Thickness
shall be 0.4mm. Finished coated Fabric; weight
approximately 500 gm per M
2

2.

ALTERNATIVELY, TB.20 Reinforced Urethane coated
Fabric, 20 mil Thick, with Aromatic Resistant
characteristi
cs, or Polyurethane coated Fabric.



Secondary Seal Tip

The Wiper Tip material shall be extruded PVC/Nitrile. The material is
to have the overall characteristics of Aromatic and Abrasion
Resistance, Tensile Strength and Weathering Resistance. No Foam
type Wi
per material or Urethane Wiper is allowed. Materials that grip
the Tank Shell are not acceptable.


12.

Vendor to carry out own Inspection, and offer the Test Results/Certificates to
HPCL Inspection/CES Section for review and approval, for the following


A)

Vapo
r Barrier Fabric

B)

Wiper Seal Tip

C)

Compression Plate and other Hardware Chemical & Physical Test

D)

Inspection of installation at HPCL site by HPCL.


13.

Vendor to carry out measurement of the Tank for correct dimensions.


14.

Vendor to provide Sketch of assembly with
cross
-
section view and material of
construction indicating inter
-
distances, Shunt, Protector Clip, Liner Tap, etc.


15.

Maximum Width of Compression Plate is not to exceed 500mm. Minimum
Thickness required is 1.2mm. Material shall conform to ASME SA240M Type
3
04, as per SA666.




Attachment
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II to PR #
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2453





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7

16.

Joints for Vapor Barrier Fabric shall be minimum, depending upon the maximum
available Size of Vapor Barrier Fabric available in the Market. Joining of small
Lengths/Pieces of Fabric is not permitted. Also, Joints must be sealed with
Cor
rections Solution.


17.

Vendor to confirm Test for Vapor Barrier Fabric, as follows:



For 100% Aromatic: Maximum 40% Volume swell is permitted for
Seven Days. No Test Standard is required



Permeability under Toluene Vapor permitted is 0.2 Fl Oz per Ft
2

per
24 H
ours (Maximum). No Test Standard is required



Abrasion Resistance allowed is 50 mg loss per 1000 Cycles. No
Test Standard is required



Finished Thickness: Minimum 0.4mm



Finished Weight: 500 gm per M
2


18.

Vendor to confirm Test for Wiper Seal Tip, as follow
s:



Hardness to be 75 +/
-

IRHD, as per BS 903 A26 Test Standard



Tensile Strength: Minimum 8 Mpa, as per BS 903 A2 Standard



Elongation at break: Minimum 250%, as per BS 903 A2 Standard



Tear Strength: Minimum 25 Nm, as per BS 903 A3 Standard (Angle Tear,
Meth
od B)



Ozone Resistance (50 pphm / 40
O
C / 72 Hours / 100% Strain). No cracks to
be observed within 72 Hours. No Test Standard is required



Wear Resistance with H
-
18 Carbide Wheel: 1000 gm / 2000 Cycles, as per
DIN 53516 Standard



Low Temperature Test is not r
equired



Liquid immersion for 7 Days at 40
O
C as per BS 903 A16 for Toluene


Hardness: Maximum 20, Tensile Strength: Maximum 60%, Elongation at
break: Maximum 65%, Volume Swell: Maximum 100%



Liquid immersion for 7 Days at 40
O
C as per BS 903 A16 for Naphtha



Hardness: Maximum 15, Tensile Strength: Maximum 50%, Elongation at
break: Maximum 65%, Volume Swell: Maximum 100%



Liquid Immersion for 7 Days at 40
O
C as per BS 903 A16 for Fuel B


Hardness: Maximum 10, Tensile Strength: Maximum 35%, Elongation at
brea
k: Maximum 50%, Volume Swell: Maximum 50%


19.

Protector Clip material is Thermo
-
Plastic Alloy of Poly
-
Propylene and
Polyamide, with the addition of Glass Fiber suitable for Gasoline and Hexane.




PRODUCTION SPECIFICATION


Secondary Seal Vapor Barrie
r Fabric


Product Description : Weldable Polyster PU coated on both sides, on a polyester
base fabric.



Attachment
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Base Fabric : Polyester 500 D mesh fabric.

M
aterial

: Poly Urethane coated Polyester Fabric


REQUIREMENTS



COMMENT



TE
ST METHOD/RESULT


100% aromatic


40% vol. Swell max.


ASTMD 543

100% MTBE



11.70%




ASTMD 471/14 days@ 50

Deg.C.

Conductivity



Not applicable

Permeability



0.2 Fl.oz/Ft.Sq./24 hrs.

Toulene Vapour

Fire resistance


No data

Abresion Resistance


50 mg/1000 cycles


DIN 53516

TUV Approval


Yes

Recommended Use


Standard Secondary





seal vapor barrier Fabric


SECONDARY SEAL


Tip Specification :








Value



Test Standard


1. Hardeness (IRED)






75 +/
-

5


BS 903 A26

2. Tensile Strength (Mpa)




8 min



BS 903 A2

3. Elongation at break(%)




250%




4. Determination of Tear strength


25Nm



BS 903 A3(Angle

tear) (Method B)

5. Ozone Resistance



50pphm/40C/72 hrs/100% ext
n.


No Cracks

6. Wear resistance


weight loos (%)

2% Max.


BS 903 A9


H
-
18 acrbide wheel, 1000 grams,

weight loos


2000 cycle

7. Low Temperature : 5
hours@
-
20C

No. Cracks


with 180 deg.bend.

8
. Liquid Immersion : 7 days at





BS 9030 A16

temperature indicated and tested

for hardness, tensile strength,

elongation and volume swell.



TOULENE

40 deg.C


NAPTHA

40 deg.C


Fuel B


40 deg.C



Liquid immersion : 15 days
at





BS 9030A16


Temperature indicated and tested


For hardness, tensile strength,


Elongation and volume swell



MTBE








40 deg.C



Attachment
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9. Drying after immersion in test


fluid placed in oven at 70 deg.C for


72 hours


Weight Loss(%)







15 % Max.





Item # 2 :
Supply & Installation of Roof leg cover for External Floating roof Tanks


Design ,supply, installation and commissioning of
Roof leg cover for External Floating
roof Tanks

for
Crude Oil,
Naphth
a
,

MS
etc.,

mentioned in PR at Offsite FR


SCOPE OF WORK:


The scope work includes the detail design of the sleeve , supply of all types of material ,
installation and commissioning of
Roof leg cover for
with detail drawing fo
r external
floating roof of the Floating roof tanks a
s

mentioned in PR
.
Roof leg cover for External
Floating roof Tanks

are

to be designed to
cover the leg completely above
& including
the
lock pin
. Vendor to visit the site for actual dimension required f
or the job.
Roof leg
cover
shall be
of removable
self adjusting type and can be easily retrofitted on existing
legs
. This shall not create any resistance and defects in normal floatation of tank roof.

Stage wise inspection is in the scope of the vendor.


CONFORMENCE TO SPECIFICATIONS :


The general characteristics of gauge pole sleeve shall comply to the following.


1.

Roof leg cover
material fabric shall be a minimum of 0.4 mm thickness. The material
should be compatible with the product stored and should

be safe for the max storage temp
in the tank.


2.The finished
roof leg

sleeve material shall be free of all oils, solvents and release
agents. The material should be of uniform thickness and be free from any types of
defects.


3.The
roof leg

sleeve materi
al fabric shall not wick or become brittle during its service
life. The m
aterial shall have the resistance

against wind, rain, sand, UV rays and be
suitable for service up to +80 degree Celsius.