Technical Specification for Vapour Recovery Unit

Order No.
Requisition for Vapour Recovery Unit
73256
This requisition covers the minimum technical requirements for the design, fabrication, assembly,
inspection and vendor documents for the above named equipment, in accordance with the
documents listed below.
Quant.
Name of document
Document no.
Rev.
Date
Technical Specification for Vapour Recovery Unit
2489002
22/04/11
VRU facility site layout plan
1162001
19/04/11
Process & Instruments Diagram
3143408
22/04/11
Specification for Structural Steel Design and Fabrication
1182008
21/10/10
Project Specification for Mechanical Equipment
2111001
27/09/10
Specification for Pipes
2981001
21/10/10
Specification for Valves
2983001
21/10/10
Specification Electrical Requirements for Package Units
4199030
21/10/10
Instrumentation specification for package units
4388001
04/11/10
General Paint Specification for Surface Preparation and Coating
7182001
21/10/10
Required Documents for Vapour Recovery Unit
6551408
14/10/10
22/04/11
Appendix 1 Crude oil physical properties

Appendix 2 Crude oil physical properties
Appendix 3 Figure of Vapour Recovery Unit Working Profiles
22-04-2011 Quotation request
N. Motiejunas
SV
rev.
date
drawn up
ckd.
office:
Kaunas
description/issued for
client:
SC "Klaipdos Nafta"
project:
Crude oil vapour utilization from railway
title:
Requisition for Vapour Recovery Unit
order:
73256
estacada
document:
2499013
rev.:
sheet:
of:
Y:\73256_KN angliavandeniliu garu utilizavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\2489002 Tech Spec rev D.DOC
22-04-2011 Updated chapters
N. Motiejnas
SV
rev.
date
drawn up
ckd.
office:
Kaunas
description / issued for

client:
SC "Klaipdos Nafta"
project:
Crude oil vapour utilization
title:
Technical Specification for
Order:
73256
from railway estacada

Vapour Recovery Unit
document:
2489002
rev.:
sheet:
of:
22
Table of contents
1
Introduction
2
2.1
2.2
2.3
2.4
2.5
Scope of supply
Vendor's responsibility
Battery limits
Exclusions
Spare parts and special tools
Warranty time
3
3
4
4
4
4
3
3.1
3.2
3.3
3.4
Vapour profile
Train gasoline unloading
Train Crude loading
Design case
Vapor recovery operating profiles
4
4
5
5
5
4
Design and material requirements
4.1 General
4.2 Technical
4.3 The vendor scope of project-related services is as follows:
4.4 VRU Equipment Supply Specification
4.5 Specific Specifications
The vendor shall identify the specifics of each of the above in offer, as follows:
4.6 Spare Parts
4.7 Special Tools And Tackles
4.8 Instrumentation
4.9 Control system
4.10 Software
4.11 PERFORMANCE GUARANTEE
4.12 Warranty
4.13 Painting
4.14 Materials
4.15 Utility consumptions
6
6
6
9
9
9
9
15
15
15
18
18
20
21
21
21
21
Codes and standards
21
6
6.1
6.2
6.3
Inspection, factory testing and shipment

Inspection
Factory testing
Shipment
22
22
22
22
Erection, start-up, training of operators and acceptance
22
Quality assurance
22
Vendor documents required
22
client:
project:
title:
office:
Lithuania
page
SC "Klaipdos Nafta"
Crude oil vapour utilization from railway estacada
Order:
73256
document:
2489002
rev.:
sheet:
of:
22
Introduction
SC Klaipdos Nafta intends to install hydrocarbon Vapor Recovery Unit (VRU) in order to
recover VOC (Volatile Organic Compounds) during train loading / unloading operations with
crude and refined products: gasoline, diesel, fuel oil.
Scope of supply
This specification covers the minimum requirements for the design, assembly, testing, supply
and documentation.
The selected vendor will undertake procurement of VRU component raw materials, fabrication
in accordance with the most current standards, inspection at works, assembly, pre-testing at
works, painting, functional testing of the PLC (800xA system) operating and integrated in to
existing 800XA system and all annunciation and operational software, supervision of erection,
commissioning, start-up and training of clients personnel to operate the Vapor Recovery Unit.
The vendor shall provide a Performance Test of complete Vapor Recovery Unit (VRU) at site.
This test shall be conducted in accordance with standard practices and shall prove the
function of the VRU consistent with the emissions specifications, data sheets, local standards,
all drawings, and shall be consistent with the clients original emissions and performance
requirements.
The Vendor shall suggest and offer a proven package for Vapor Recovery Unit. Vendors
scope shall include all equipment, items, piping, structures, electrical, Instrumentation and
controls etc. as required according to the proposed scheme, within the system battery limit.
Vendor shall furnish complete details of their supply in the bid.
2.1
Vendor's responsibility
It is the responsibility of the Vendor to complete the scope of supply and to furnish a complete,
reliable and safe system including all materials, services and documents, except those
specifically indicated in chapter "Exclusions".
The VRU supplied shall be supplied as a complete system, including all required auxiliary
equipment, skidded and assembled where possible, and suitable efficient and satisfactory
operation and maintenance as a whole for the purpose intended. In order to provide for normal
maintenance, all components and subcomponents shall be designed and installed in such a
manner as they are removable/replaceable without the disassembly or removal of other
adjacent components. Vendor shall be responsible for furnishing all documentation, operating
and maintenance manuals (in Lithuanian and English languages), mechanical, electrical,
instrumentation, structural supports, piping, wiring, pressure vessels, software, controls,
PC/PLC operational manuals, VRU training materials/presentation, and other interconnecting
and safety items as may be required to make the system complete.
Part of the scope is support from Vendor specialist during VRU installation, commissioning,
start-up and training of operating personal.
All materials supplied under this specification shall be new, shall be provided with a
performance guarantee and all OEM warranties, and shall be adequate for the proposed
service per this specification. Proper consideration shall be given to their function with regard
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
of:
22
to corrosion, chemical and other processes, fire hazards, and erosion due to the design and/or
the medium being handled.
2.2
Battery limits
The battery limits for the VRU are the connecting flanges and electrical cable connections.
The Vendor shall submit with his quotation assembly drawings showing all Purchasers
connections with detailed information.
2.3
Exclusions
-
2.4
foundations (civil works);

main power supply;
compressed air supply;
steam supply;
Spare parts and special tools

The Vendor shall separately quote for all the necessary spare parts for 2 (two) year operation,
commissioning and special tools required. Also should be included all necessary materials
and tools for VRU start-up operation.
2.5
Warranty time
The delivery should be covered by warranty in a period of 24 months after start-up of the unit
or 30 months after delivery on site.
Vapour profile
Products: Crude, Gasoline, Diesel, Heavy fuel oil, etc.
Crude oil physical properties shown on appendix 1 and appendix 2, included with this
requisition.
3.1
Train gasoline unloading

The vapour will be produced during filling the empty unloading headers and buffer vessels with
product from railcars. The pipes and will contain some product from previous load, so vapour
concentration can be high from the beginning to the end of the process. The duration of
process will be about 10 minutes at capacity of 1700 m3/hour with concentration of up to 60%.
Gasoline data:
Standard:
EN 228:2009
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
of:
22
3.2
Train Crude loading

The railcars will contain some product from previous cargo. The railcars will be loaded by
means of bottom loading arms. The start concentration is estimated to be ~15% with loading
capacity of 1800 m3/hour and will grow to 60% at the end of loading operation, however the
capacity at the end of loading will be reduced to 900 m3/hour.
Crude data:
Type:
Venezuela Santa Barbara
RVP:
7,70 psi @ 100 0F
Sulphur: up to 1,00 % mass
3.3
Design case
Table of VRU unit vapour capacities:
Units
Gasoline
unloading
Crude
loading
Total
simultaneous
m3/h
1700
1800
3000
Maximum 3 minute vapour capacity

from beginning loading/unloading
m3
15
90
Maximum 10 minute vapour capacity

from beginning loading/unloading
m3
152
300
Maximum hour vapour capacity
m3
Maximum 4 hour vapour capacity
m3
Maximum instantaneous vapour flow
Maximum daily vapour capacity

Nominal yearly vapour capacity
1800
300
1800
2100
9000
2 000 000
2 000 000
Maximum vapour flow: 3000 m3/hour.

Maximum design vapour concentration: 55 vol%.
Minimum vapour pressure at inlet point: 20 mbar.
Maximum vapour pressure at inlet point: 80 mbar.
3.4
Vapor recovery operating profiles

Vapor recovery unit working profiles figure shown on appendix 3, included with this requisition.
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
of:
22
4
4.1
Design and material requirements

General
Availability unit: > 98% on annual basis.
Minimum lifetime: 20 years.
Minimum lifetime of carbon bed: 5 years.
The unit is operated intermittently and located outside near the sea.
4.2
Technical
Table of VRU unit main components, utilities and limits:
Adsorber vessel
Number installed
pc
Filled with activated virgin mineral

carbon pellets
Carbon bed adsorber vessels with

adsorbents
proven
not
to
overheat.
vessels suitable for full vacuum;
YES
Absorber column
Number installed (for gasoline and

for crude)
pc
with engineered hydraulic inlet

absorbent distributor, demister
guaranteed to prevent absorbent
carryover, concentrically enlarged
sump designed to prevent overfill,
and complete with sump level
transmitter and dedicated HH and
LL shutdowns level devices.
Vacuum system
Pump type
Number of pumps
pc.
Electric motor with freq. controller
LIQUID RING or SCREW TYPE
*
YES
Absorbent pumps
Crude supply pump
YES
Loose supply.
Tag: P-4/4-4002
Pressure drop in piping 1 bar
Return pumps:
Gasoline
YES
Tag: P-4/4-4003
YES
Tag: P-4/4-4004
Crude
YES
* Vendor to confirm / complete
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
of:
22
Piping
Vapor collection piping
YES
ANSI B-31.3 and 16.5

Battery limit of VRU system shall
have flanged connection with
isolation valves to match with the
outside B/L piping.
Blower
Blower with electric motor drive
YES
YES
to move hydrocarbon vapors from

the source to the VRU.
Other equipment
In-line filter at VRU vapour inlet
YES
Bidirectional
Arrestor
YES
Inlet
Detonation
Continuous emission analyzer
YES
One (1) lot of specialty instruments,

valves, and controls
YES
One industrial PLC (800xA system)

One (1) automation hardware
system (800xA system)
YES
with SIL rating of 1 or higher
YES
Integrated in to the existing ABB

control system 800xA
One (1) automation

system (800xA system)
software
YES

Concentration
YES
Suitable for the ambient conditions

specified
Inlet
analyzer,
temperature
transmitter, and flow meter for the
inlet vapor
YES

Ground
analyzer
Level
Automated valves
Special tools and tackles

operation and maintenance
YES
YES
for
YES
Consumable spares for 12 months

operation
YES
Commissioning spares
Vapor Recovery Unit.
YES
client:
project:
title:
Lithuania

Pneumatically
actuated
Pressure control valves at VRU

inlet:
Gasoline
Crude
office:
Mesh size of filter elements: 10m;

2 pcs connected parrarel or duplex
contruction
for
the
preferable
max. pressure 10 bar

max. pressure 10 bar
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
of:
22
Vendor shall ensure

First fill of lubricants, oil, grease etc.
YES
Absorber cleaning with steam

(180oC, 10 bar), 1 steam inlet
flange
YES
Any additional item or feature

required during detail engineering
for the completeness and troublefree performance of the system
shall be deemed to be included in
the Vendors scope without any cost
and time implication to owner, as
long as the system performance
requirements within the battery
limits of the system are kept
unchanged.
YES
Vapour
Maximum vapour flow
m3/h
3000
Minimum vapour pressure at VRU

inlet
mbar
(g)
20
Max. design vapour concentration
vol %
55
see loading/ unloading schedule

at max. flow rate
Emissions and limits

VOC:
Gasoline
Crude
mg/m3
g/m3
150
10
for any one hour, excluding C1

for any one hour, excluding C1
Noise level
dB(A)
<85
at 1 meter distance of VRU unit
Hazardous zone classification
Gas group
IIB
Temperature rating
T3
Dimensions **
25 x 10,2
LxW
Available utilities
Electrical power
400
Instrument air
bar (g)
3,5 - 8
Steam (for absorber cleaning)
deg. C
bar
185
10
3ph. 50 Hz
** Estimated place, dimensions, VRU facility site layout plan, DWG. No. 1162001
Diagram of vapour and absorbers flows to VRU unit see in Process & Instruments Diagram,
DWG. No. 3143408, included in the Requisition.
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
of:
22
4.3
o
o
o
o
o
o
o
o
o
o
o
o
o
o
The vendor scope of project-related services is as follows:
Process design engineering

Detailed mechanical and electrical design engineering
Documentation for all design engineering and components
Procurement of equipment and materials
Preparation and submission of all drawings and specification sheets for approval by purchaser
Surface preparation, protective coating, and painting as per attached painting specifications
Inspection and testing
Transport to site
Supervision of erection
Commissioning of Vapor Recovery Unit
Start-up of the VRU under normal terminal conditions
Performance test of the complete system at site
Training for clients operating personnel provided at site following commissioning and start-up.
One full day of classroom and one full day of on-site training for owners operating personnel
including PLC and VRU control system functions.
4.4
VRU Equipment Supply Specification

The process description is an automated, self-managing, short cycle, AdAb, activated carbon
based, hydrocarbon vapor recovery system. All pressure vessels shall be designed in strict
accordance with the PED and Machine Directive 89/329/EEG of the European Community which
has been amended by directives 91/363/EEG, 94/44/EEG, and 93/68/EEG. All nozzles 1 and
larger shall be ANSI 150 RF flanges consistent with ANSI standards. All nozzles smaller than 1
shall be full couplings rated at 3000# or greater, or the equivalent Threadolet/Weldolet.
4.5
Specific Specifications
The vendor shall identify the specifics of each of the above in offer, as follows:
Designed Carbon Vessels:
The carbon vessels shall be designed and fabricated in accord with PED. The civil engineering
shall include the bed support and leg beams. The bed support shall be 1 X 3 bar grate suitable
to comply with the dead weight of wet carbon. The carbon shall be supported above the bar
grate on two layers of replaceable stainless steel mesh. Each carbon vessel shall have at least
three 6 carbon fill nozzles in the top head, one ANSI flanged relief valve connection for an
included fire-rated relief valve, one 24 manway above and near the bottom head seam with a
blind and davit, three temperature indicator connections, and appropriately sized ANSI flanged
inlet and outlet. Flow diffusers shall cover both the inlet and outlet openings.
Number to be supplied 2 (two)
Diameter_________
Seam-to-seam shell height_________
Head type_____________
Design working pressure____________
Designed for full vacuum (Yes/No) _____________
MAWP______________
Shell: grade of steel____________
Thickness w/o corrosion allowance_________
Corrosion allowance_____________
Heads: grade of steel____________
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
of:
22
Corrosion allowance 3 mm
Base type (Skirt/Legs) ______________
Foundation contact area/load__________/_____________
Total number of vessel fittings________________
Service designation and size___________
Carbon supplier/manufacturer/processor______________
Carbon brand name________________
Base carbon material (Wood, Coal, Other) ____________
Carbon particle size_____ X ________
Carbon density___________
Total weight of carbon to be supplied for this project______________
Absorber Vessel:
The absorber vessel shall be designed with accordance to PED and at least 90% contact
efficiency. This vessel may be a single piece or two piece vessels. If it is a two-piece vessel,
the two pieces shall be joined by an ANSI RF flange. The Absorber section shall have an
engineered inlet absorbent distributor designed to provide uniform distribution of the sorbent
liquid. It shall be a randomly packed column which shall be designed with a minimum of four
(4) theoretical trays. This section shall include a removable demister, a RF flanged relief
valve connection sized for the fire case and included, a rich-vapor ANSI flanged outlet
nozzle extended into the vessel and up to very near the top of the inside, and a bar grate
and screen support for the IMPT or equal random packing. The absorber sump section shall
be tall enough to provide for adequate NPSH for the absorbent return pump. It shall have
level control and hi/lo shutdown connection, a pressure gauge connection, a coolant
gasoline return ANSI flanged connection, a bottom drain, an anti-vortex ANSI RF flanged
pump suction connection near the bottom, and an ANSI RF flanged vapor inlet. Facility for
absorber column and related piping cleaning by steam (185oC, 10 bar) should be included
by providing an appropriate steam inlet and outlet. The steaming is required when changing
absorber from crude to gasoline.
Number to be supplied 1 (one)
Absorber Section
Diameter_________
Head type_____________
MAWP______________
Demister type__________________
Diameter___________
Depth__________
Material of construction_________
Relief valve size _______X_________
Type______________
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
10
of:
22
Manufacturer________________
Sump Section
Diameter_________
Head type_____________
MAWP______________
Corrosion allowance 3 mm
Base type (Skirt/Legs) ______________
Foundation contact area/load__________ _____________
Total weight of vessel dry______________
Total weight of vessel wet______________
Total weight of vessel flooded___________
Total number of vessel fittings________________
Total weight of vessel dry______________
Total weight of vessel wet______________
Total weight of vessel flooded___________
Vacuum Pump(s):
The vacuum pumps shall be designed and suitable for at least 15,000 of continuous service
run-time hours. The vacuum pump shall be base mounted and coupled to an explosion proof
motor of suitable size and rated for VFD operation (inductance duty), complete with coupling
with one (1) coupling guard per pump. The motor shall be fitted with an internal heat switch
which shall be tied to the PLC to alert the owners operations staff in the event of a heat-up.
The pump and motor shall be Laser aligned by the vendor after installation at the site and
before start-up. The motor shall be fitted with an internal high-temperature switch tied to the
PLC. The base shall be secured to the VRU foundation to prevent the transmission of
vibration back to the carbon beds through the interconnecting piping. At least one bellowstype expansion joint shall be supplied for the inlet side of the pump. The vendor shall provide
for thrust blocks or other pipe supports for the discharge piping, each of which shall be
designed to prevent vibration. The suction of each pump shall be fitted with a cone strainer
with 1/32/0.8mm screen captured between two RF ANSI flanges. All (vapor, coolant) flows
shall be monitored by flow indicating transmitters. The flows shall be adjustable. The vapor
coolant flow shall be stopped during all periods of pump-off time, and shall be reinitiated
during period of pump-on times. This flow shall be managed by two (2) solenoid valves,
each with a discrete open/closed signal from the PLC. Each pump shall be fitted with a RPM
monitor tied to the PLC.
Manufacturer_________________
Model number_____________
Motor HP rating_______________
50Hz
3 Phase (Yes/No) Yes
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
11
of:
22
Suitable for VFD control (Yes/No) Yes

Capacity @ full speed________
Weight______________
Mounting method____________
Maximum Torr rating__________
Hours between overhauls__________
Jacket coolant flow rate_____________
Vapor coolant flow rate_____________
Vibration detection included (Yes/No) Yes
VFD Model and Size _______________and ___________
Maximum current draw______________
Design turndown______________
Minimum turning RPM______________
Coupling model number
Brand______________
Model number________________
Coupling guard included (Yes/No) Yes
Inlet connection size______________
Outlet connection size_______________
Vapor coolant meter type/size________________________/__________
Jacket coolant meter type/size________________________/__________
Absorber Supply Pumps:
The supply pump shall be complete with suitable explosion proof motor fitted on a base to
the pump via a coupling. The motor shall be fitted with an internal high-heat switch tied to
the PLC. It shall be sized to move the absorbent from the owners absorbent storage to the
VRU site. It shall be shipped lose for installation at close proximity to the clients day tank by
others. It shall include, as a minimum:
For Crude:
Manufacturer__________________________
Model number__________________________
Design capacity at full rpm_____________@_______________
Mechanical seal (Yes/No) ________________
Motor Type/Class_______________________
Motor size and HP rating _______________ and ______________
Motor temperature switch included (Yes/No) Yes
Motor VFD rated (Yes/No) ______________
Coupling model number__________________
Coupling guard included (Yes/No) ______________
Base model number________________
Dimension to suction centerline______________
Absorber Return Pumps:

The return pump shall be complete with suitable explosion proof motor fitted on a base
to the pump via coupling. The motor shall be fitted with an internal high-heat switch tied
to the PLC. It shall be sized to move absorbent form the VRU to the owners day tank. It
shall be assembled, mounted and shipped on the same base as all other VRU
equipment. It shall include, as a minimum:
Fro Gasoline:
Manufacturer__________________________
Model number__________________________
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
12
of:
22

Motor Type/Class_______________________
For Crude:
Manufacturer__________________________
Model number__________________________
Motor Type/Class_______________________
Vapor Inlet/Outlet Piping:

All piping shall be designed per the ANSI B31.3 and 16.5 for flows well below turbulent flow
velocities, and large enough to minimize the flowing pressure drop. The vendor will provide
the following:
Vapor Pipe Size(s) ________
Schedule 40
Working Pressure__________
Seamless (Yes/No) Yes
Grade___________
Supply Gasoline Pipe Size(s) ________
Schedule 40
Grade___________
Return Gasoline Pipe Size(s) ________
Schedule 40
Grade___________
Vapor Inlet/Outlet Switching Valves:
All vapor switching valves shall be high performance, bubble tight, lug-type butterfly valves
with replaceable Viton o-ring cushioned Teflon seats, Viton seals, and electric or pneumatic
motor operators. The liquid gasoline circulation valves shall also be MOVs, however these
two valves MUST use fail closed operators, without fail or exception. Vendor shall list vapor
and gasoline valve specifics below.
Brand______________________
Type________________________
Model Number, Size, and Torque:
o Vapor valves_______ _________ _________
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
13
of:
22
o Vacuum valves_____ _________ ___________

o Gasoline circulation line valves________ _______ ___________
Valves are bubble tight, high performance (Yes/No) ________
Valves are lug-type (Yes/No) ________
All valve actuators shall be RCS electrically operated of suitable torque to completely
seat and unseat the valve each is joined with in any temperature or ambient condition.
Each actuator shall be supplied with one coupling kit for joining it properly with its
respective valve. Each actuator shall be supplied with on-off limit switches indicating the
open and closed positions with one pair of installed spare switches
Brand offered____________
Type and size of valve actuators (list all)
o _____________ ________
o _____________ ________
o _____________ ________
o _____________ ________
o _____________ ________
o _____________ ________
Maximum torque of each actuator (list for each size valve)
o _____________ ________
o _____________ ________
o _____________ ________
o _____________ ________
Operating current___________
Maximum operating amperage_____________
o SIL rating_____________
o NEMA rating____________
Maximum design pressure drop across each carbon bed loaded with vendors activated
carbon and ready for service_____
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
14
of:
22
4.6
Spare Parts
4.5.1.
Vendor shall submit recommended list of spare parts with itemized prices for first two years'
of operation of the equipment with bid. Proper coding and referencing of spare parts shall be
done so that later identification with appropriate equipment will be facilitated. Total cost of
spares shall be included in lump-sum price of the system.
4.5.2.
Vendor shall also submit a list of commissioning spares with quantity. Total cost of
commissioning spares shall be included in lump-sum price of the system.
4.5.3.
Vendor shall also guarantee that commissioning spares, if required over and above the
commissioning spares included in the order shall be made available without any cost and
time implication to the owner. If, for any reason during commissioning, Vendor needs to
utilize spares from list of 2 years normal operational spares, he will replenish the same free
of cost duly delivered at site including all freights, insurance, taxes, and duties.
4.5.4.
Mandatory spares shall be supplied per Instrumentation specifications and their price to be
included in the lump sum price of the system.
4.7
Special Tools And Tackles
The Vendor shall provide a set of new, unused special tools and tackles required for operation and
maintenance of the Vapor Recovery system. Price above shall also be included in the basic cost of
the package.
4.8
Instrumentation
All necessary instrumentation, safety interlock & analyzer for measuring inlet and exit Gas
concentration for smooth and safe functioning of the system is considered under the vendors scope
of supply. The instrumentation selected by each vendor is critical to the operational reliability,
efficiency, maintenance, and life of the overall system. Therefore it is necessary for the vendor to use
only devices considered to be standards of the industry, suitably rated, tested, and certified. The
same holds for the automation system as well.
Instrumentation Requirements:
All instruments shall be UL/Cenelec approved for a Class1, Division 2 environment, or equal.
4.7.1. The inlet vapor flow shall be measured at all times. The flow meter shall be a vortex shedding
type with no moving parts and shall be rated for the service it is in. It shall be calibrated to
span the flow of vapor for this application from no flow to the maximum flow with a 20%
overage so it will measure unusually high instantaneous flows. It shall be rated for Class1,
Division 2 service, and shall be locally indicating. It shall be an insert-type, manufactured for
ease of removal from the inlet vapor piping without having to shut the vapor flow off for
instrument extraction. The instrument shall be shielded from all external noise, and shall
generate a 4-20ma linear output consistent with the overall flow rate.
4.7.2. The inlet vapor stream shall be sampled and the sample shall be fed to an inlet vapor
hydrocarbon analyzer to determine the inlet hydrocarbon concentration at all times. This
analyzer shall be in constant communication with the PLC/HMI. The sample shall be collected
from a probe reaching into the center of the pipe being sampled to assure uniformity of
sampling.
4.7.3. The inlet vapor temperature shall be measured at all times. The temperature element used
shall be of the RTD type, and shall generate a linear output signal consistent with the
temperature being measured.
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
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4.7.4. The inlet vapor temperature and pressure shall be indicated locally and/or to the PLC at all
times.
4.7.5. The inlet supply gasoline, crude flow shall be measured at all times using a FIT
communicating with the PLC/HMI.
4.7.6. The exiting return gasoline, crude flow shall be measured at all times using a FIT
communicating with the PLC/HMI.
4.7.7. The inlet jacket coolant gasoline, crude flow to each vacuum pump shall be measured at all
times using a FIT communicating with the PLC/ HMI.
4.7.8. The inlet vapor coolant gasoline, crude flow shall be measured at all times using a FIT
communicating with the PLC/ HMI..
4.7.9. The jacket coolant gasoline, crude temperature shall be measured leaving each vacuum pump
with a TE which communicates constantly with the PLC/ HMI.
4.7.10. The supply gasoline temperature shall be measured as it enters the VRS upstream of the
Absorber Column with a TE which communicates constantly with the PLC/ HMI.
4.7.11. The return gasoline temperature shall be measured as it exits the VRS downstream of the
Absorber Column with a TE which communicates constantly with the PLC/ HMI.
4.7.12. The discharge vapor temperature shall be measured constantly as the vapor leaves the final
pump stage of each vacuum pump with a TE which communicates constantly with the
PLC/HMI.
4.7.13. The true rotating speed of each vacuum pump shall be measured constantly and shall
communicate with the PLC/ HMI.
4.7.14. All motors shall have motor heat switches which shall be monitored by the PLC constantly,
and which will shut down any motor that overheats immediately.
4.7.15. The all flows shall be measured using appropriately sized restriction orifices mounted in
conventional and dedicated orifice flanges with all flow rate signals generated by flow
indicating differential pressure transmitters.
4.7.16. Temperature indicators shall be at least 5 dial face every-angle type. One each shall be
installed on the vapor inlet line, the suction and discharge of each vacuum pump, and on the
vapor outlet line. All temperature indicators shall be supplied with thermowells that reach to
the center of each pipe in which they are fitted.
4.7.17. All pressure indicators shall be at least 5 dial face glycerin filled gauges with the maximum
pressure at or slightly above the MAWP of the pipe or vessel it is fitted into. Each pressure
indicator shall be fitted with an upstream isolation ball valve. These shall be installed on the
vapor inlet line, the vapor vacuum line from each carbon vessel, the supply and return
gasoline,crude lines, the vapor and jacket coolant lines feeding each vacuum pump, and the
Absorber Column.
4.7.18. Each carbon vessel shall be fitted with a vacuum transmitter with a vacuum measurement.
Each vacuum transmitter shall be fitted with an upstream isolation valve.
4.7.19. The outlet vapor stream shall be sampled and the sample shall be fed to an inlet vapor
hydrocarbon analyzer to determine the inlet hydrocarbon concentration at all times. This
analyzer shall be in constant communication with the PLC/ HMI. The sample shall be collected
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
16
of:
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from a probe reaching into the center of the pipe being sampled to assure uniformity of
sampling.
4.7.20. Vendor Shall List All Instruments to be Supplied Below:
o ________________________________________________________________
o ________________________________________________________________
o ________________________________________________________________
o ________________________________________________________________
o ________________________________________________________________
o ________________________________________________________________
o ________________________________________________________________
o ________________________________________________________________
o ________________________________________________________________
o ________________________________________________________________
o ________________________________________________________________
o ________________________________________________________________
o ________________________________________________________________
o ________________________________________________________________
o ________________________________________________________________
o ________________________________________________________________
o ________________________________________________________________
Automatic Vapor and Liquid Valve Requirements:

4.7.21. All automatic valves shall be bubble tight, high performance, lug-type butterfly valves sized
to maintain all flow velocities well below erosion velocity at all times.
4.7.22. Each main automatic vapor switching valve shall be coupled to an RCS or equal electric
actuator sized to assure proper torque considerations when moving the high performance
butterfly valves into and off of their seats. All torque rating shall exceed the torque
requirements of the valves by at least 50%. Each automatic valve shall include:
o Four micro-switches. Two shall indicate the full open and full closed positions of the
valve, and two shall be used as installed spares.
o Each automatic valve actuator shall be fitted with a brake for precise stopping of the
valve at its open and close positions.
o Each actuator shall be rated for Class 1, Division 2 service, or better.
o Each automatic valve shall communicate with the PLC/ HMI constantly.
4.7.23. The system shall be also fitted with dedicated solenoid valves suitable for Class 1, Division 2
service, and rated for the appropriate pressure or vacuum consistent with the application of
each. Each solenoid valve shall be normally closed.
4.7.24. The gasoline supply and return lines shall be fitted with two fail closed bubble tight, high
performance butterfly valves with RCS Sur49 spring closed pneumatic actuators, or equal.
4.7.25.
Vendor Shall List All Instruments to be Supplied Below:

o
o
o
o
o
o
o
o
o
o
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
17
of:
22
o
o
o
o
o
o
o
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
4.7.26. Manual Vapor and Liquid Valve Requirements:

All manual valves shall be bubble tight, high performance full-open ball and fine hand-wheel
adjustment globe valves. Each shall be manufactured from either cast steel or stainless
steel, and shall be specified or pressure and materials of construction consistent with the
service into which each is placed. Only Viton and Teflon elastomers may be supplied.
o Valves smaller than 1 may be NPT threaded.
o Valves 1 and larger shall be ANSI RF flanged consistent with Class 150 as a minimum.
4.7.27. All instruments shall be UL/Cenelec approved for a Class1, Division 2 environment or equal.
4.7.28. The vendor is required to demonstrate operating the VRU during start-up when loading
operation is being carried out.
4.7.29. The vendor is also responsible to commission the VRU and fine tune all controls such that it
operates smoothly. Vendor is to rectify any defect or replace the defective equipment as
required if the need arises within 24 months from the date of commissioning at no cost to the
Owner.
4.7.30. The vendor is to conduct the performance test for the vapor recovery system and prove the
recovery as stipulated in the process data during the start-up process. The VRU shall be
designed to continuously indicate the true instantaneous emissions on the 800xa based on
the inlet mass flow. The vendor shall specify the procedure of the performance test and
submit it to the owner for approval 60 days prior to the planned performance test.
4.9
Control system
Control and monitoring of VRU package unit shall be realized from existing operator work
station (PC). VRU process control equipment shall be integrated with existing process control
800xA system. For that reason all necessary VRU field instrumentation (e.g. sensors, actuator
valves, etc.) shall be integrated to ABB make AC 800M Series controller.
System must be provided with an emergency shut down system which can be connected to the
existing emergency shutdown system.
4.10
4.9.1.
Software
Vendor shall develop VRU operating software to 1) optimize the VRS operation to reduce
energy consumption while maintaining the emissions at or below the target level, and 2)
regenerate only on an as-needed basis using the absorbed mass of hydrocarbons as the
primary regeneration trigger, and emission level as the over-riding trigger.
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
18
of:
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4.9.2.
Vendors operating software shall automatically control the amount of purge air fed to each
carbon bed using a dedicated valve and flow control device. Purge air shall be allowed to
enter each carbon vessel at the conclusion of each regeneration cycle. The PLC logic shall
determine the amount of purge air entering in each cycle based on the mass of
hydrocarbons loaded onto the carbon in the previous bed loading cycle so that the operators
need not make any manual adjustments for the life of the system.
4.9.3.
Vendors operating software and controls system shall automatically control the re-pressure
air system with a dedicated flow control valve and flow control device such that the operators
need not make any manual adjustments for the life of the system.
4.9.4.
In order to prove the energy efficiency of the vendors VRU, vendors operating software shall
calculate the mass of hydrocarbons adsorbed, compare it with the adsorption capacity of the
carbon supplied, and trigger regeneration only when the adsorbed mass reaches a preset
fraction based on the maximum possible adsorbed hydrocarbons.
4.9.5.
Vendors operating software shall make a permanent record of the actual volume of VRU
recovered gasoline and store this data in units of recovered liters daily, weekly, monthly,
annually, and since start-up.
4.9.6.
Vendors operating software and controls system shall be designed to monitor the travel and
position of each vapor flow and liquid flow valve in the VRU and to alarm or shutdown in the
event of any malfunction. Vendor shall identify for the owner which malfunctions are alarms
and which are shutdowns. Vendors HMI shall annunciate each according this schedule.
4.9.7.
Vendors operating software and controls systems shall be developed to monitor, control,
and optimize the absorber pressure during each individual regeneration cycle by varying the
absorber pressure to optimize the adsorption efficiency and minimize the hydrocarbon
loading on the in-service adsorbing carbon.
4.9.8.
Vendors operating software shall be written to allow for 1) logical progressive normal
shutdowns, 2) immediate emergency shutdowns (ESDs), 3) automatic start-up or re-start
after all alarms/shutdowns are reset. Each shall be recorded on discrete HMI logs which
shall stay active in real time for at least 33 days.
4.9.9.
Vendors software shall be designed to operate the supply and return pumps in both the
automatic and manual modes operating via HOA switches. The position of these switches
shall be annunciated on Vendors HMI graphics.
4.9.10. Vendors operating software shall monitor all temperature transmitters continuously, and
shall alarm and/or shutdown the VRS upon published alarm and shutdown temperature
values. These values shall be annunciated on Vendors HMI graphics.
4.9.11. Vendors software shall monitor all motors and pumps for proper and safe operating
conditions. Each shall be annunciated on Vendors HMI graphics.
4.9.12. Vendors operating software shall monitor the HOA status of each motor. Each shall be
annunciated on Vendors HMI graphics.
4.9.13. Vendors operating software and controls system shall measure and monitor the supply and
return liquid flow rates and temperatures, and the vapor inlet flow rate and temperature at all
times. All such values shall be annunciated on Vendors HMI graphics.
4.9.14. Vendors operating software package shall be fully functional with or without the HMI system
in operation.
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
19
of:
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4.9.15. Vendors HMI software and graphics package shall provide for an overview (Main) screen
that continuously reports all real-time flows, temperatures, pressures/vacuum levels,
pumping speeds, loading status lane-by-lane, liquid levels, emissions, loading rates, and
recovered product volumes at all times. All such values shall be annunciated on Vendors
HMI graphics.
4.9.16. Vendors HMI software and graphics package shall include dedicated HMI separate trend
line and separate data screens for real time and historical alarms, historical and real time
shutdowns, historical and real time emissions, real time emissions levels, real time vacuum
pump operating parameters including RPM, coolant flow and temperatures to jacket and
vapor, and vapor discharge temperature.
4.9.17. Original site specific adjustable set-up information so the site personnel with proper security
clearance can make operating parameter adjustments to fine tune the system over time.
4.9.18. A layered security-enabled log-in status record graphic panel.
4.9.19. Vendors HMI and PLC shall be configured with a 24/7 high-speed DSL link to the internet
for secured and continuous off-site monitoring.
4.9.20. Owner shall provide a continuous DSL connection suitable for remote monitoring 24/7.
4.9.21. Vendors shall include off-site monitoring of the in-service system for a minimum of 24
months after start-up at no additional cost to the owner, and shall include an option to renew
the monitoring service thereafter.
4.11
PERFORMANCE GUARANTEE
4.10.1. All equipment and components shall be guaranteed by the Vendor against any defective
material, design, and/or workmanship for the period specified in the commercial document.
4.10.2. After installation and commissioning at site, the system shall be tested for overall
performance as per procedures mutually agreed upon. Vendor shall, at his own cost,
arrange all instruments and controls required for testing at site.
4.10.3. Vendor shall demonstrate the following parameters at site during performance test:
Emission level meets the bid requirements
Document the recovered volumes per unit volume loaded
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
20
of:
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4.12
Warranty
4.11.1. Vendor shall warrant the system to be free of defects and workmanship for a period not less
than 24 months from delivery or 18 months after start-up, whichever shall occur first.
4.11.2. Vendor shall warrant all components of the system for the full period of the warranty period
stated above, and shall replace and component found to be defective during that period at
no cost to the Owner.
4.11.3. Vendor shall warrant the performance of the VRU during the period stated above so long as
it is used for the purpose intended. In the event the unit does not meet the performance
guaranteed emissions level of 150 mg/m3 for gasoline and 10 g/m3 for crude on a two hour
averaged basis, Vendor take whatever actions are necessary at Vendors expense to correct
the situation, and if unable to do so, the following penalties shall prevail:
For gasoline:
o Up to 5 mg/m3 overage = 2% of purchase price
o 6 mg/ m3 up to 10 mg/ m3 overage = 5% of purchase price
o 11 mg/ m3 to 15 mg/ m3 overage = 10% of purchase price
o >15 mg/ m3 overage = 25% of purchase price
For crude:
o Up to 0.3 g/m3 overage = 2% of purchase price
o 0.3 g/ m3 up to 0.7 g/ m3 overage = 5% of purchase price
o 0.7 g/ m3 to 1 g/ m3 overage = 10% of purchase price
o >1 g/ m3 overage = 25% of purchase price
4.13
Painting
All external exposed steel surfaces must be treated with epoxy coating system.
Painting system for absorber should be able to withstand high temperature up to 1850 C.
4.14
Materials
All materials shall be asbestos free.
Designated materials to be supplied with compliance certificate as per EN 10204 3.1
4.15
Utility consumptions
The Vendor shall state in his quotation the consumption of all utilities at the battery limits.
All units of measurement, used to dimension or to specify the capacity, shall be based on the
international system of units (SI).
Codes and standards

The Vendor shall warrant that all aspects of design, fabrication, assembly, testing and intended
use of the equipment to be supplied meet the legal requirements of the National and Local
Authorities.
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
21
of:
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Machine directive
Each equipment item delivered by the Supplier has to be provided with CE-marking, in
accordance with the Machine Directive 89/329/EEG of the European Community which has
been amended by directives 91/363/EEG, 94/44/EEG, and 93/68/EEG.
Therefore a II A Declaration of Conformity for each equipment shall be supplied by the
Supplier, including fulfillment of all requirements as defined in the Machine Directive.
Electrical components and instruments must be in accordance with CENELEC standards.
The supplier has to provide ATEX/CE certification.
Verification of equipment according to PED.
Inspection, factory testing and shipment

6.1
Inspection
Vendor to submit to purchaser for approval an inspection schedule.
6.2
Factory testing
Vendor to submit to purchaser for approval testing schedule (per item).
6.3
Shipment
After inspection and testing, all equipment shall be thoroughly cleaned, dried and touched up
with paint, if necessary. Flanged connections shall be blanked with suitable wooden or metal
covers. Bare screw threads shall be protected by plugs or caps.
Vendor has the responsibility to check the crating in order to prevent any transport damage.
Erection, start-up, training of operators and acceptance

Equipment acceptance on site, erection and installation shall be supervised by the vendor. The
Vendor shall be responsible for the correct installation, connection to existing ancillaries and
commissioning by Purchaser under supervision of Vendor. Approval of installation by vendor
shall be by countersigning a protocol.
On request the Vendor shall make available a specialist engineer to provide training for
Company's Operation/Maintenance personnel during the period of installation and start-up of
the equipment on site.
Quality assurance
Vendor to submit guarantees for performance, service and delivery.
Vendor documents required

The Vendor shall supply all the data and documents in the form, quantities and at the time
stipulated in the Vendor Documents Required, Doc.No. 6551408, included in the Requisition.
client:
project:
title:
office:
Lithuania
SC "Klaipdos Nafta"
Order:
73256
document:
2489002
rev.:
sheet:
22
of:
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Y:\73256_KN angliavandeniliu garu utilizavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\1182008 Structural Steel Spec.doc
21-10-2010 For Comments
rev.
date
office:
Kaunas
N. Motiejunas
SV

drawn up
client:
SC "Klaipdos Nafta"
project:
title:
Order:
73256
document:
1182008
rev.:
ckd.
sheet:
of:
Table of contents
1
1.1
1.2
General
Scope
Codes and standards
3
3
3
Types of Construction
3
3.1
3.2
Steel Structures
Materials
Connections
3
3
3
Fabrication of Steelwork
Access and Maintenance Structures
Flooring
Stairways
Ladders
Handrails and Toe Plates
client:
project:
title:
office:
Kaunas
page
SC "Klaipdos Nafta"
Order: 73256
document:
1182008
rev.:
sheet:
of:
1
1.1
General
Scope
This specification covers the basic requirements for the design and fabrication of structural
steelwork.
1.2
Codes and standards

The design, fabrication and installation shall comply fully with the applicable Lithuanian codes
and standards.
Types of Construction
The specification is directed mainly to the use in structures of hot rolled steel sections, plates
and normalised tubular shapes.
In general, the preferred design shall take account of accessibility for painting and general
maintenance. Lattice type structures, other than trusses and towers, should therefore the
avoided.
Structural steel work generally is to be fabricated in the workshop be welding. Connections
carried out during erection on site shall be bolted in accordance with this specification.
3
3.1
Steel Structures
Materials
All material shall be of new stock.
Structural steel shall be quality FE 60B.
All bolted connections shall be with high tensile bolts of strength grade 8.8.
3.2
Connections
High tensile bolts to NEN 914 grade 8.8 or equal, shall be used for all site connections unless
noted otherwise.
Welding shall be used for shop connections. Except where butt welds are called for, all welds
shall be continuous fillets.
Washers parallel or tapered to suit rolled steel sections shall be provided under each nut.
Lock nuts shall be provided for all bolts securing runway beams to main framing.
All nuts, bolts and washers shall be sherardised.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
1182008
rev.:
sheet:
of:
Fabrication of Steelwork
All members shall be clearly marked and erection drawings shall be furnished clearly showing
the location of all members for ease of erection. In all cases, shop detail numbering system
shall tie-in to the number of the related erection drawing.
All fabricated frames shall be suitably braced to prevent distortion during transit.
Frames, platforms, stairs and handrails shall be shop assembled in the largest units suitable
for handling and transportation.
All boltholes shall be made by drilling. No burning or punching will be permitted.
All sharp edges of structural members shall be rounded to achieve appropriate coating
applications.
Access and Maintenance Structures

Access and maintenance platforms shall have, unless otherwise indicated, a minimum width of
750 mm.
Headroom clearance at all platforms shall preferably be 2.150 m but not less than 2.050 mm,
taking into account electrical fittings and all other obstructions.
Flooring
Steel grating for platforms shall be serrated rectangular open grid type with load bear bars 30
mm deep x 3 mm thick at 30 mm cross centres with twisted cross bars press welded at 30 mm
centres.
Grating shall be attached to the supporting steelwork with clip or other effective means,
minimum of four fixings per panel. Holes or cut-outs in panels shall be made by the flooring
manufacturer and have perimeter stiffening strips welded in. This work is to be carried out
before the final protective coating is applied.
Stairways
Stairs in general shall have a minimum clear width between stringers of 750 mm.
All stairs in the same building or structure shall, if possible, have the same slope and stair
handrails shall be continuous with platform handrails. Stairs shall be arranged with a 45o of
slope.
Stairs shall have maximum vertical step.
Clearance over stairs shall be such that a minimum vertical clearance of 2.100 mm measured
at the nose of a treat shall be maintained.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
1182008
rev.:
sheet:
of:
Treads shall be serrated rectangular pattern open grid type (30 mm x 3 m bearing bars at 30
mm cross centre with twisted bars press welded at 30 mm cross centres) with non skid
abrasive nosings.
Ladders
Ladders shall be provided:
a) For access to platforms not served by stairways;
b) As an emergency escape from platform which is already served by a stairways.
Ladder shall have a width of 450 mm inside stringers
Ladder rungs shall be 20 mm diameter round steel bar. Spacing between ladder rungs shall be
maintained at 30 mm.
Ladder rungs shall be positioned such that the top of the rung is at the same elevation as the
platform served.
All ladders serving platforms or landings shall have side access and shall be equipped with
safety cages. Safety cage shall start at 2.100 mm above grade or landing.
Handrails and Toe Plates

Handrails shall be extended around edges of all platforms, landings, walkways and stairs.
All handrailing shall be pipe material.
Maximum centres of handrail posts shall be 1.500 mm.
All platforms and walkways 1.800 mm or more above grade shall be provided with toe plates.
Toe plates shall also be provided around all pipe penetrations through platforms.
All toe plates shall be 100 mm high unless shown otherwise on the project drawings.
Toe plates shall extend continuously around edges of all platforms, landings, walkways and
openings except at stairs and ladder accesses.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
1182008
rev.:
sheet:
of:
Y:\73256_KN angliavandeniliu garu utilizavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\2111001 Mech Equip Spec.doc
27-09-2010 Quotation request
N. Motiejunas
SV
rev.
date
drawn up
ckd.
office:
Kaunas

client:
SC "Klaipdos Nafta"
project:
title:
Order:
73256
document:
2111001
rev.:
sheet:
of:
Table of contents
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
GENERAL
Purpose
Compliance, exceptions and deviations
Alternative designs
Conflicting requirements
Information required
Engineering coordination
Authority approvals
3
3
3
3
3
3
3
3
2
2.1
PROJECT AND SITE INFORMATION

Site location
2.2
2.3
Project description
Site meteorology
4
4
QUALITY ASSURANCE
4
4.1
4.2
GUARANTEES
Performance
Service
4
4
4
VENDOR DATA AND DOCUMENTS REQUIRED
client:
project:
title:
office:
Kaunas
page
SC "Klaipdos Nafta"
Order:
73256
document:
2111001
rev.:
sheet:
of:
1
1.1
GENERAL
Purpose
This Specification together with other documents of the Requisition covers the minimum
technical requirements for the design, fabrication, assembly, inspection, acceptance test and
Vendor documents for the specified equipment.
1.2
Compliance, exceptions and deviations

Quotations must be fully in accordance with the Specification(s) and other documents of the
Requisition and must contain a written confirmation to this effect.
The Vendor may include in his quotation appropriate exceptions or deviations, provided they
can be shown not to have a negative effect on performance, construction, reliability and
availability of the specified equipment. Such exceptions shall be grouped and listed.
Quotations shall cover all items indicated in the section Scope of Supply. Spare parts and
special tools shall be quoted separately, as indicated.
1.3
Alternative designs
The Vendor may also quote an alternative design with an explanation of the advantages and
disadvantages of his design.
In such case detailed information in respect of performance, construction and reliability is
required.
1.4
Conflicting requirements
All conflicts between the requirements of the Specification(s), Data Sheets or other documents
of the Requisition shall be referred to Purchaser for clarification.
1.5
Information required
All information in the Requisition and the Data Sheets denoted with an asterisks (*) shall be
supplied by the Vendor with the quotation.
A Vendor's nameplate shall be supplied for each item. All relevant information on the
nameplate shall be bilingual in English and Lithuanian. The nameplate data shall be clearly
stamped.
1.6
Engineering coordination
The Vendor is responsible for the engineering coordination of the equipment and all auxiliary
systems included in the scope of his supply.
1.7
Authority approvals
The Vendor is responsible for obtaining authority approvals when applicable included in the
vendors scope.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
2111001
rev.:
sheet:
of:
2
2.1
PROJECT AND SITE INFORMATION

Site location
The address of the job site is:
SC Klaipdos Nafta
Buri str. 19
P.O. Box 81
LT-91003 Klaipda, Lithuania
2.2
Project description
This project consists of technical solutions for hydrocarbon vapors from the rail cisterns
collection and recovery at Klaipdos Nafta Oil Terminal.
2.3
Site meteorology
Climate type
Design ambient temp. range
Design barometric pressure
Relative humidity range
Average rainfall
Maximum rainfall
Maximum wind velocity
Design wind pressure
Direction of wind
Frost design line
UBC seismic zone
Snow load
[ - ]
[Deg C ]
[mbar ]
[ % ]
[mm/year]
[mm/h ]
[m/sec ]
[N/m ]
[ - ]
[ m ]
[ - ]
[ mm ]
marine
Min: -29
1015
Min: 30
625
50
40
1040
s.w.
n.a.
n.a.
1000
Max: +35
Max: 100
QUALITY ASSURANCE
The Vendor shall submit with his quotation (a) document(s) demonstrating that he has an
operational Quality Assurance System, which conforms to the requirements of the International
Standard ISO 9000, or equivalent.
All equipment shall have CE marking and comply to ATEX directive 94/9/EC.
4
4.1
GUARANTEES
Performance
The Vendor shall propose in his quotation a performance guarantee based on the duty and
design requirements given in the Requisition.
4.2
Service
(*) The Vendor shall propose in his quotation a service guarantee based on the mode of
operation given in the Technical Specification.
VENDOR DATA AND DOCUMENTS REQUIRED

(*) The Vendor shall supply all the data and documents in the form, quantities and at the time
stipulated in the list Vendor Documents Required, included in the Requisition.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
2111001
rev.:
sheet:
of:
Y:\73256_KN angliavandeniliu garu utilizavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\2981001 Pipes Spec.doc
N. Motiejunas
SV
rev.
date
author
ckd.
office:
Kaunas

client:
SC "Klaipdos Nafta"
project:
title:
Order:
73256
document:
2981001
rev.:
sheet:
of:
Table of contents
1
General
Certificates
Limitations
Marking
Preservation, painting
Welding, welding procedures
Quality assurance
Shipping, transport
9
9.1
Material specification
Pipe class AC01
5
5
client:
project:
title:
office:
Kaunas
page
SC "Klaipdos Nafta"
Order:
73256
document:
2981001
rev.:
sheet:
of:
General
This specification covers the technical requirements for the design, fabrication, testing and
delivery of carbon steel pipe in accordance with the data as specified in this specification.
Codes, standards and specifications referred to in this specification or in any referenced
document, form a part of the requirements of this specification in the manner and to the extend
specified.
Any deviation from this requisition shall be listed in the quotation and a ruling shall be obtained
by Tebodin before proceeding with the affected portion.
Certificates
Pipe shall be supplied with material certificates EN 10204-3.1B issued by the manufacturer,
stating at least:
Manufacturers name and symbol;
Heat number;
Material specification and grade;
Chemical analysis;
Mechanical test result;
Data with regard to quantity and dimensions, size, schedule etc.;
Hydrostatic test pressures and test results.
Certificates, hydro reports and dimensional check results shall be submitted in one batch
immediately after completion of inspection.
Limitations
Carbon steel material shall have a maximum carbon steel content of 0.23%.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
2981001
rev.:
sheet:
of:
Marking
Pipe diameters 2 inch and larger shall be die-stamped with heat number, material, nominal
pipe size, schedule or wall thickness and Manufacturer's symbol.
Pipe diameters 1.5 inch and smaller shall be low-stress die-stamped with heat number,
material and manufacturers symbol or labelled.
In addition to manufacturer's marking, each tag shall be clearly identified with:
Purchase order no.
Requisition no.
Specification, sheet and item no.
Pipe size 6 inch and larger shall be identified with the applicable tag properly attached to each
pipe.
Pipe size 4 inch and smaller shall be identified with the applicable tag securely attached to the
bundles.
Pipe shall be delivered in an unrusted and clean condition with temporary rust protection.
Welding, welding procedures

Repair, of the material, by welding is not allowed.
For seam welded pipe the weld joint quality factor of 1.0 shall be guaranteed.
Quality assurance
Vendor shall present his quality assurance/control manual, if possible according to BS-5750 or
ISO 9001, 9002, 9003.
Shipping, transport
Pipe size 4 inch and smaller shall be supplied in bundles.
Pipes shall be prepared for shipment in such a manner to avoid damage or atmospheric
corrosion to the inside or outside surfaces during storage or while in transit.
The bevel ends of pipes shall be protected by suitable bevel protectors and/or plastic caps.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
2981001
rev.:
sheet:
of:
Material specification
The choice of pipe type must be carefully evaluated with respect to the available approved
couplings, mechanical-Tees, grooved Tees and elbows.
Carbon steel piping and welding fittings with connections using mechanical couplings and / or
flanged connections.
Counter flanges for equipment with flanged outlets shall be of the same piping class as the
equipment flange.
Branches may be connected to distribution pipes by threaded sockets, welded on the pipe in
prefabrication, or by mechanical-T connections.
Piping shall be prefabricated in reasonable and manoeuvrable lengths to allow easy and
smooth installation.
9.1
Pipe class AC01

Description
1 - pipe c.s., seamless, material ASTM A106B
2-10 - pipe c.s., seamless, material API 5L Gr. B,
12 and more - pipe c.s., seamwelded, material API 5L Gr. B,
150#
Dimensions
Acc. to ASME B 36.10
End preparation
- 1 plain ends
2 and more bevelled ends acc. to ASME B16.25
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
2981001
rev.:
sheet:
of:
Y:\73256_KN angliavandeniliu garu utilizavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\2983001 Valves Spec.doc
N. Motiejunas
SV
rev.
date
drawn up
ckd.
office:
Kaunas

client:
SC "Klaipdos Nafta"
project:
title:
Order:
73256
document:
2983001
rev.:
sheet:
of:
Table of contents
1
General
Certificates
Design
Marking
Testing
Quality assurance
Shipping, transport
client:
project:
title:
office:
Kaunas
page
SC "Klaipdos Nafta"
Order:
73256
document:
2983001
rev.:
sheet:
of:
General
This specification covers the technical requirements for the design, fabrication, testing and
delivery of valves in accordance with the data as specified in this specification.
Certificates
Flanged & welded valves shall be supplied with material certificates EN 10204-3.1, issued by
the valve manufacturer, stating at least:
Manufacturers name;
Heat number;
Material specification;
Chemical analysis;
Mechanical test result;
Data with regard to quantity and dimensions;
Hydrostatic test pressures and test results.
Certificates, hydro reports, NDT reports and dimensional check results shall be submitted in
one batch immediately after completion of inspection.
Design
Flange facing of all valves, shall be furnished with stock finish.
Valves shall be designed and executed in accordance with the design codes and design
features as noted on the attached applicable specification sheets.
Valves shall be supplied with assembly drawings, showing all relevant information, such as
materials of construction, dimensional data, design features, etc.
Marking
Marking shall be in accordance with EN .19:2002
In addition to manufacturer's marking, each tag shall be clearly identified with:
-
Purchase order no.
Requisition no.
Specification, sheet and item no.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
2983001
rev.:
sheet:
of:
Painting shall be according manufacturer's standard.
Testing
The valves shall be inspected and tested in accordance with EN 12569. Seat tightness shall
be according to EN-12266-1, leakage rate A, except for gate valves greater than DN400 (16),
where leakage rate B applies.
Quality assurance
Vendor shall present his quality assurance/control manual, if possible according to BS-5750 or
ISO 9001, 9002, 9003.
Shipping, transport
The valves must be packed in a way that they cannot be damaged during shipment.
Flange facing shall be protected over the gasket seating surface with plastic, cardboard and/or
hardboard covers to avoid mechanical damage.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
2983001
rev.:
sheet:
of:
Specification Electrical Requirements

for Package Units
Y:\73256_KN angliavandeniliu garu utilizavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\4199030 Electrical Spec.doc
21-10-2010 For Information
N. Motiejunas
SV
rev.
date
drawn up
ckd.
client:
SC "Klaipdos Nafta"
project:
Crude oil vapour utilization from railway
title:
Specification Electrical Requirements
estacada
for Package Units

office:
Kaunas
Order:
73256
document:
4199030
rev.:
sheet:
of:
23
Table of contents
Scope
Codes, standards etc.
Area classification
Utilisation voltages
Design and drawings
Equipment
Electric motors
10
Control
11
Wiring and cabling
13
10
Low voltage switchgears and/or motor control centres
15
11
Variable speed control
17
12
Small power distribution boards
21
13
Earthing and lightning protection
21
14
Division of work
22
15
23
client:
project:
title:
office:
Kaunas
page
SC "Klaipdos Nafta"
Specification Electrical RequirementsVapour Recovery Unit
Order:
73256
document:
4199030
rev.:
sheet:
of:
23
Scope
1.1
The requirements outlined herein are for electrical equipment, supplied as part of a
mechanical package. The mechanical specification defines the equipment to be supplied.
Any electrical equipment shall conform to the applicable sections of this specification.
1.2
The electrical installation shall be designed and installed to obtain a maximum of safety and
easy operation with a minimum of maintenance.
1.3
This specification is not intended to cover all the details, however it may be expected that
the Vendor provides all the elements that are inherent to sound engineering practices and
workmanship in order to achieve a completely satisfactory electrical system. It shall be the
Owner's responsibility to advise the Vendor of all clearances, approvals, permits,
documents, etc. required by the several national authorities.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
4199030
rev.:
sheet:
of:
23
Codes, standards etc.

Electrical work must be in compliance with the latest editions of the national or international
codes and governmental requirements.
IEC-Standards as listed in "Catalogue of IEC Publications".
2.1
International Standards
IEC - 34
IEC - 51
Rotating electrical machines.

Direct acting indicating analogue electrical measuring instruments and
their accessories.
IEC standard current rating
Dimensions and output ratings for rotating electrical machines
Thermal evaluation and classification of electrical insulation.
Recommended graphical symbols
Current transformer
Electrical equipment of industrial machines
Low-Voltage fuses.
Push-button switches
Electrical Installation of buildings.
Factory-built assemblies of low voltage switchgear and controlgear
Class 0.5, 1 and 2 alternating-current watt-hour meters
Classification of degrees of protection provided by enclosures.
Limitation of disturbances in electricity supply networks.
Low voltage switchgear and controlgear
Factory-built assemblies of low voltage switchgear and control gear.
IEC - 59
IEC - 72
IEC - 85
IEC - 617
IEC - 185
IEC - 204-1
IEC - 269
IEC - 341
IEC - 364
IEC - 439
IEC - 521
IEC - 529
IEC - 555-2
IEC - 947
IEC - 439
2.2
Other standards
VDE 0875
ISO 1281
2.3
Radio frequency Interference suppression

Rolling bearings: Method of evaluation dynamic load ratings.
Local regulations
In addition to the standards and codes, the electrical system shall be in accordance with the
local regulations and requirements of the following authorities:
the fire-fighting brigade;
the ministry of labour inspectorate;
nuisance act, safety law etc.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
4199030
rev.:
sheet:
of:
23
2.4
EMC (Electromagnetic Compability)

All apparatus, (electrical and electronic appliances together with equipment and installations
containing electrical and/or electronic equipment) liable to cause electromagnetic
disturbance or the performance of which is liable to be affected by such disturbance shall
comply with the local EMC standards and regulations.
Where local EMC standards and regulations are not available, the requirements of the
European EMC-directive and its amendments shall be used which requires that the
apparatus shall be so constructed that:
The electromagnetic disturbance it generated does nor exceed a level allowing radio
and telecommunications equipment and other apparatus to operate as intended.
The apparatus has an adequate level of intrinsic immunity of electromagnetic
disturbance to enable it to operate as intended.
In case of conflict between the European EMC-directive, and its amendments, and the local
EMC standards and regulations the most severe shall rule however it is noted that the
European EMC-directive, and its amendments shall be used as starting point.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
4199030
rev.:
sheet:
of:
23
Area classification
The equipment may be located in an area indoors or outdoors where a potential explosion
hazard may exist if flammable gases or dust are present. Alternatively or in addition, a
corrosive atmosphere may also exist. Each area will be classified with respect to these
conditions.
The area classification will be stated in the mechanical specification or the document
containing the Mechanical Package Requirements.
All equipment and wiring must comply with the applicable standards for the specified
hazardous area.
Electrical equipment finishes and construction materials shall be selected and furnished
which are resistant to the corrosive environment specified.
For equipment installed in a hazardous area the Vendor shall furnish the required
certificates from an official testing laboratory, certifying that the equipment is suitable for
use in that area.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
4199030
rev.:
sheet:
of:
23
Utilisation voltages
4.1
The incoming power supply with over-current protection fuses or circuit breakers at the
utilisation voltages listed below will be supplied by third party.
4.2
Voltages:
400/230V 3-phase
3-wire, TN-S
Application:
Motors, heaters and
total package power earthing system
230V 1-phase
2-wire, TN-S
Lighting and other

single phase loads earthing system
If voltages other than those listed are required, the means for transformation shall be
supplied with the mechanical equipment.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
4199030
rev.:
sheet:
of:
23
Design and drawings
5.1
The complete electrical system shall be designed for a reliable service, highest degree of
flexibility, consistent with good practice, safety to personnel and sound economics with a
maximum interchangeability of equipment.
5.2
Switchgear interrupting capacities, cable sizes etc., shall be calculated and selected in line
with good practice.
A system design shall be prepared containing the short circuit calculation, relay settings and
coordination curves.
The system diagram shall show and define the complete electrical system, circuit breaker
and switch interrupting capacities, short circuit ratings, relay- and metering devices, motor
loads, etc.
5.3
The distribution, installation and utilisation of electricity shall conform to the standards as
mentioned under part. 2.
The distribution system shall be designed and installed to provide a maximum of circuit
reliability consistent with good economics and convenience of operation.
The electrical system switching shall be so arranged to allow sections of switchgears and
feeders to be isolated and de-energized for maintenance with un-interrupted service to
critical areas.
5.4
Drawings shall consist of complete plans and elevations showing equipment locations,
power and control cable lay-out, grounding lay-out and cable schedule in an orderly
numerical sequence, etc.
The drawings shall also include all wiring and elementary diagrams for all items, such as
MCC's, relay cabinets etc. and include all drawings necessary for the proper
interconnection between electrical equipment.
For each motor a motor data sheet shall be filled in.
5.5
All drawings shall be an accurate representation of the electrical system as installed, in such
a manner that they may serve the owner as a convenient guide for future operation and
maintenance.
All drawings, as far as concerned in scope of Vendor, shall contain the complete
information required for installation.
Drawings, symbols etc. shall follow the Vendor's standards and procedures and comply
with the standards as mentioned in part. 2.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
4199030
rev.:
sheet:
of:
23
Equipment
6.1
All equipment for as far as included in contractors scope shall be new, adequate for the
application and comply with the requirements of the codes as specified in part 2.
6.2
All equipment such as switchgear, distribution panels, control panels etc., shall be located
indoors, in a non-hazardous area and shall be in general of the sheet steel enclosure type.
6.3
All operational equipment shall be identified by non-corrosive (resopal, PVC laminated)

nameplates, which shall contain the following:
6.4
All labels, plates, etc. must be either bolted or riveted; glueing by any means whatsoever is
prohibited.
6.5
All parts carrying more than 42V AC shall be protected adequately against live contact.
client:
project:
title:
office:
Manufacturer's name
Serial- and Model no.
Equipment no.
Warning sign if required, etc.
Weight.
Year of manufacture.
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
4199030
rev.:
sheet:
of:
23
Electric motors
7.1
All electric motors shall comply with the standards as mentioned under part 2 and shall be
delivered in standarized types with dimensions and power rates conform to I.E.C.recommendations.
7.2
Electric motors shall be totally enclosed, fan-cooled, non-sparking, weatherproof and

suitable for the classification of area where used.
Enclosure type IP54 with IP55 terminal box or as indicated on the motor data sheet.
7.3
The electric motors shall be of squirrel-cage-induction type, for direct on-line starting.
7.4
The electric motors will perform in such a way that under normal load an overtemperature in
the winding of 80C for L.V.-motors is not exceeded.
7.5
All windings shall be brought out to the terminal box; three phase windings shall be
connected star or delta, according to the data sheet.
7.6
Motors shall be equipped with anti-condensation heaters, when specified on the data
sheets.
7.7
L.V.-electric motors shall be protected against short circuit by means of fuses or circuit
breakers and against overload by means of an adjustable hand re-setting thermal
overcurrent device, connected in 3 phases.
7.8
All protection devices shall be located in starter units, housed in switchgears and/or motor
control centers.
7.9
Motors with frequency converter operation and located within areas classified as hazardous,
shall be provided with 3 PTC thermistors in the windings.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
4199030
rev.:
sheet:
10
of:
23
Control
8.1
Control and alarm circuits shall be designed fail-safe i.e. open circuiting of one wire, shortcircuiting of one wire or failure of a component shall not permit machinery to start-up.
Failures shall trip an overload element, or render equipment inoperative, or sound an alarm.
8.2
Electrical equipment shall be selected on the basis that a 20 % voltage dip of two seconds
duration does not cause the equipment to shutdown.
8.3
Suitable circuit protection shall be supplied for controls so that any one electrical fault does
not affect more than one unit or system. The protection can be accomplished by either
circuit breaker or fuse.
8.4
A disconnecting means shall be provided to permit servicing of individual systems or

control components. The means of disconnection shall be padlocked when in the
disconnected position and shall be near on in sight of the components.
8.5
Where electrically operated circuit breakers or magnetically operated starters are used,
they shall be controlled from a start/stop pushbutton, located in a position providing safe
and convenient operation.
8.6
Motor starter units shall in general provide local control by means of a motor control station.
The motor control station shall be in sight of and near the motor. Each motor will have a
safety switch with provisions for pad locking in the "off" position.
All non-reversing motor starters shall in general provide local control by means of a
pushbutton station.
All reversing motor starters shall in general provide local control by means of a change-over
for left or right direction and a start/stop pushbutton as an integral.
8.7
Units which are controlled by automatic devices and/or for remote control shall be provided
with a 3 position selector switch.
In the auto-position the unit shall be under control of the automatic actuating device and in
the hand-, position the automatic devices shall be disconnected and shall be operated
manually.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
4199030
rev.:
sheet:
11
of:
23
8.8
Units controlled by process switches shall be controlled by means of interposing relays,

which are energized via the shutdown or interlocking systems.
8.9
Where necessary starter units shall be provided with auto-restart features during Voltage
dips of two seconds and where required with automatic change-over switching.
8.10
Motor control stations located in hazardous areas shall be of a certified explosion-proof

design and conform to the standards mentioned under part.3.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
4199030
rev.:
sheet:
12
of:
23
Wiring and cabling
9.1
The design and selection of wiring and cables shall in every respect comply with the
relevant IEC standards.
9.2
The maximum allowable Voltage drops shall be as follows:

a) Main incoming feeders 2%
b) Motor power feeders 5%
c) Lighting circuits 3%
9.3
Cable runs shall be routed around the skid by using cable tray and/or conduits. The
maximum length of unsupported cable runs shall be ten (10) centimetres.
9.4
In general, copper conductor, XLPE insulated, P.V.C. sheated cables shall be used for low
Voltage power cables.
9.5
In general for instrument distribution, lighting etc., copper conductor, XLPE insulated,
P.V.C. sheated cables shall be used.
9.6
The minimum cross sectional area for conductors shall be for power cables 2.5 sq.mm and
for control cables 1.5 sq.mm.
9.7
All cables shall be numbered in a numerical order and shall be sized for the most
economical solution taking into account derating factors and maximum allowable Voltage
drop where applicable.
9.8
Cables leaving cable tray shall be mechanically protected and supported by conduits.
9.9
Cable routes shall be located remote from high temperature process lines or high
temperature surfaces.
9.10
Cable trays shall be close type with expanded metal bottoms or rungs.
9.11
Cable trays shall be designed to withstand a loading of 60 kg/m. without bending.
9.12
Cable tray shall be supported from pipeways, structures or buildings.
9.13
Intrinsically safe cables shall run separately from other power and instrument cables.
9.14
All wiring etc. for external circuits shall be wired to terminals.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
4199030
rev.:
sheet:
13
of:
23
9.15
All wiring and terminals shall be securely fixed and easily accessible. The wiring shall be
adequate for the circuit full load.
9.16
Terminals for external control and alarm circuits shall be suitable for 1.5 sq.mm copper
conductors.
9.17
All cabling and wiring on the package other than main motor connections shall be
terminated at a central location on the package, to enable the buyer to connect the feeder
cable(s) and control cable(s) in a practical manner. Motor feeders will be connected to the
motor terminal box directly.
9.18
Terminal list and electrical devices shall be provided with identification numbers and clearly
marked. All wiring shall be fitted with identification ferrules.
9.19
These identification numbers shall be visibly duplicated on the equipment. They shall also
appear on all vendor wiring and lay out drawings.
9.20
All cable glands shall be of the compression type, suitable for use in the area as stated on
the data sheet which it is to be employed.
Each cable gland shall be provided with a PVC shroud which shall be in addition to the
normal seals in the gland.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
4199030
rev.:
sheet:
14
of:
23
10
Low voltage switchgears and/or motor control centres
10.1
The equipment shall in every respect comply with the relevant national standards and local
electrical supply company regulations.
10.2
The equipment shall comply with the latest edition of I.E.C. publications as mentioned
under part. 2.
10.3
All parts of the equipment shall withstand a rated short circuit current of 20 kA or as
calculated under 5.2 without damage.
10.4
The equipment supplier shall be called upon to present a detailed statement of evidence
supporting the making and breaking capacity of the equipment.
10.5
The equipment shall be cubicle type, free standing, floor mounted, totally enclosed in
accordance with I.E.C. class IP41 min. for indoor and IP55 outside. When equipment is
located in hazardous areas, the enclosure shall meet the requirements of the area
classification.
10.6
The equipment shall be accessible from the front. Wiring spaces and relay compartments
shall be accessible by means of hinged doors.
10.7
Bus bars shall be copper and shall be mounted on supports of high impact, non-tracking
insulating material and shall be braced to withstand the mechanical forces exerted during
the maximum short circuit conditions.
10.8
The main bus shall be continuous without joints, within each shipping section.
10.9
For large equipment with long bus bars, thermal expansion joints shall be provided, in
accordance with the manufacturer's standard practice.
10.10
A ground bus shall be provided for the entire length of the equipment.
10.11
All metal work other than current carrying parts shall be grounded.
10.12
The switchgear shall be labelled in an approved manner.
10.13
All terminals and wiring shall be clearly marked and coloured.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
4199030
rev.:
sheet:
15
of:
23
10.14
Meters shall be flush mounted on the front of the switchboard.

Accuracy class for meter shall be 1.5 according to IEC.
10.15
Current transformers shall have class 1 accuracy for metering and class 5 P for protection
according to IEC. The minimum wire size for current transformer circuits shall be 4.0 mm2.
All current transformer terminals shall have suitable short circuit devices. Secondary current
type relays, if withdrawable, shall have provision for automatically closing the secondary
circuit when the relay is withdrawn. Secondary current rating 5 A. For remote metering 1 A
only is acceptable.
10.16
Before the switchboard is shipped to the construction site, it shall be inspected,

mechanically and electrically tested, to ensure that all equipment, devices, relays and wiring
have been correctly installed and are in a satisfactory working condition.
All tests shall be made in accordance with the relevant IEC standards.
10.17
Incoming air circuit breakers shall be fully interlocked units, electrically operated or
operated by stored energy mechanisms.
10.18
Incoming isolators shall be stationary units housing a load breaker isolator equipped with
H.R.C.-fuses fully interlocked with the compartment door.
10.19
Motor starters shall be a combination of full voltage, direct-on line, non-reversing, magnetic
air break type contactors with adjustable hand resetting thermal overcurrent devices and
circuit breakers or fuse for short circuit protection.
10.20
Free standing switchgear will be provided with permanent heating elements, except those
installed in air conditioned rooms.
10.21
Power distribution panels shall be stationary units housing miniature circuit breakers or
fuses. The compartment door shall not be interlocked with the isolator.
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Order:
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11
Variable speed control
11.1
This part of the specification covers the adjustable speed drive units (for controlling one or
more single direction totally enclosed fan cooled (TEFC) squirrel cage standard motors and
power conversion unit comprising transistors or thyristors with the necessary protective
controls and all required components.
11.2
The equipment shall in every respect comply with the relevant IEC codes and standards of
the latest issue including IEC 439 and all relevant Standards of the country where installed.
Where conflict arises between I.E.C. and standards of the country, the later will prevail.
11.3
The selection of type and size of adjustable speed control is based on the following:
a)
b)
11.4
The adjustable speed drive unit shall be of the AC frequency regulator PWM type. (Pulse
width modulation).
11.5
The unit shall be equipped with the following equipment but not limited to:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
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Technical requirements such as voltage level, current capacity, ambient temperature,

voltage regulations, speed adjusting etc.
Single- or multi motor drives and depending on application.
Kaunas
Ultra rapid fused for transistors/thyristors diode protection against short circuits.
Automatic protective devices for protection against single phasing, overloads,
overvoltage and undervoltage.
Speed accuracy better than 2% in case of 100% load change or 5% feeder voltage
change or 10% temperature change, except when stated otherwise on the Data Sheet.
Variable speed response time between 1,5-4 sec. except when stated otherwise on
the Data Sheet.
Local remote:
speed control (max. and min. speed can be preset)
speed indication
load indication
4-20 mA output signal for remote speed indication
4-20 mA input signal for automatic speed control.
Radio Frequency Interference suppression, as per VDE 0875 group N.
Undesired restart protection, complete with start-up override timer.
Testing provisions for critical signals during operation and at standstill.
Ready to start indication.
Common indication for failure.
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11.6
The enclosures shall be as follows:

When mounted in a control panel:
Control drive panel depending on location shall be designed to a maximum degree of

safety, completely wired and tested, wall mounted.
Front access, hinged single or double doors to be easily removable.
The degree of protection of the panel shall be at least IP-41 when panel door(s)
closed and IP-20 when panel door is open.
The live side terminals of the main switch shall be for safety reasons, be provided with
a pertinax protection cover.
When mounted on a wall:
Front access with easily removable cover.
The degree of protection shall be IP-20.
The live side terminals shall be protected by a pertinax protection cover.
11.7
The following electrical features will apply:

The unit shall have an internal bare copper earth and busbar, directly bolted to the panel
structure.
Earth bolt size as specified.
All internal wiring used for earthing shall have a green/yellow color insulation.
Power circuits shall be rated in such way that thyristors are carrying 60% maximum of
their continuous current at which the nominal operating temperature is reached.
All knife-type fuses shall be installed between partitions of insulation material which
extend 20 mm over the bare parts in all directions.
All knife-type fuses shall be with KEMA approval.
Diazed fuses shall only be acceptable if they are one of the E-27 type and may not be
used for fuses over 25 Amps.
11.8
Cable glands, cable clamping, earth supporting, facilities and terminals shall be provided for
bottom cable entry or as indicated on the data sheets.
11.9
The unit and its components, such as thyristors, diodes, switching devices, protection
relays, instruments, instrument transformers, fuses and fuse holders, shall be individually
identified by means of permanent labels. On withdrawable-type units, identification labels
shall be mounted on both the fixed and withdrawable parts.
11.10
All wires shall be marked at both ends. Also the terminals shall be provided with a
numbering system. Identification shall be in accordance with manufacturers drawings.
Control wiring shall be not less than 1.5 sq mm stranded wire size. Only one conductor is
allowed to be terminated per terminal.
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11.11
The limitation of disturbances in electricity supply networks caused by domestic and similar
appliances equipped with electronic devices shall in every respect comply with EN 50006.
Note: IEC 555-2 and amendment 1985 are identical to EN 50006.
11.12
Control systems shall be provided with radio interference suppression networks to limit any
lineborne interference exceeding a value of suppression grade "N" according to VDE 0875.
The operation of the electronic control system shall not be hampered by radio interference
caused by equipment installed in their vicinity and/or portable telecommunication equipment
(walkie-talkies) having a radio interference class "N" or worse.
11.13
Panel door(s) shall be hinged and provided with suitable door stops.
11.14
Panel door(s) shall be lockable; it shall not be possible to open the panel with a screw driver
or other simple tools.
11.15
Power modules, control electronics, etc. shall be easily accessible to enable. Prevodical
servicing, fault finding and repair.
11.16
All fuses have to be easily accessible for replacement purposes.
11.17
The colour codes of the indication lights shall be as follows:

Common-alarm
Trip
Healthy
"on" status
"off" status
yellow
amber
white
green
red
11.18
Earthing bolt shall be provided on the outside for earth connection with the system, wire
size shall be at least 25 sq mm but not less than 50% of the feeding cable cross-section.
11.19
The maximum noise level generated by the equipment shall be 60 dB measured at a

distance of 1 meter and a height of 1 meter.
11.20
Visual inspection of the board may be required by the Engineer or inspector representing
the principal at any stage of construction or before final packing of boards for shipment.
The requirements for such inspection shall be indicated on the data sheets or
accompanying documents.
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Order:
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11.21
The Vendor shall perform routine factory tests and inspection on each unit.
The principal and/or his appointed representative shall have the option to witness these
tests.
The Vendor shall give at least 5 days notice for these tests.
11.22
After installing and the final adjustments at the site the witnessed tests shall involve the
following test as a minimum:
1.
2.
3.
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Visual inspection.
Control and testing of the by third parties connected cable.
Functional test
3.a check if there is a linear relationship between input signal (4-20 mA) and motor
speed
3.b check if there are no torque pulsations at low frequencies.
3.c check if the VSC is kept in operation at a voltage drop of 80% (time: 0,2 sec.).
3.d check the motor protection switch-off time for each motor.
3.e measure of shaft power of the connected motor at various frequencies and
determine the maximum shaft power.
The following items shall be measured at the input and output of the VSC and at the
motor connection.
current
voltage
power
frequency
The length of the cables to the motors shall be taken into account at these
measurements.
3.f check if there is a linear relationship between output signal 4-20 mA and motor
speed.
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Small power distribution boards
12.1
Small power distribution boards such as heating-, instrument power distribution boards, etc.,
shall in every respect comply with the relevant national standards, local electrical supply
company regulations and all other statutory regulations.
12.2
Distribution boards will be stationary units housing miniature circuit breakers or fuses.
13
Earthing and lightning protection
13.1
All metal parts of electrical apparatus, the steel construction as well as steel construction in
buildings, pipe racks, vessels, tanks, stairways etc. will be bonded to the earth ringmain
cable of the plant.
13.2
The earthing system will also be used as lightning protection and be designed accordingly.
13.3
The earthing system shall in every respect comply with the relevant national standards
and/or IEC standards.
In general the grounding resistance shall not exceed 1 ohm or less if specified.
13.4
Clearly marked grounding terminals must be fixed to on all package units.
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14
Division of work
14.1
The Vendor or his subcontractor is expected to complete all electrical work within the
confines of the package. Where the package does not have a rigid enclosure, everything
that can be shipped in one piece, shall be shipped already assembled and prewired. The
mechanical specification covering the individual item of equipment takes precedence
wherever it specifies exceptions or additions to the following general list.
14.2
The Buyer retains the right to change the by Vendor proposed type and make of the
electrical equipment proposed by the Seller, for standardisation and stock holding
purposes.
14.3
No changes or alteration shall be made to equipment and its installation during the
construction phases without written consent of the Buyer. All agreed changes during
construction phase shall be marked-up on drawings and shall be transferred to the Sellers
originals by the Seller.
14.4
Work by others
a)
b)
14.5
Work by Vendor
a)
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Cabling between the Vendor's equipment and those devices which are furnished by
others.
Cabling between pieces of the equipment which are too large to be shipped
assembled. In these cases where possible, Seller shall furnish a prefabricated
wiring harness to be used.
Testing as defined in part. 15
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15
15.1
Except for low energy and electronic circuits, wiring at all voltage levels shall be checked for
insulation resistance.
15.2
All circuits shall be checked for continuity.
15.3
A functional test shall be performed, in addition to the continuity check, before shipping. A
functional test consists of simulating the Seller's devices with switches, relays, lights or
resistors and of energising each circuit.
15.4
Vendor is responsible for the correct connection of the cables, supplied and connected, by
third parties.
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project:
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Y:\73256_KN angliavandeniliu garu utilizavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\4388001 Instrumentation Spec rev_A.doc
04-11-2010 For comments
N. Motiejunas
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ckd.
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Table of contents
General
1.1
Scope
1.2
Limits of supply
1.3
Applicable codes and standards
1.3.1
1.3.2
1.3.3
General
Local regulations
4
4
5
1.4
Instrument labelling
1.5
Units of measurements
Drawings and documents
Installation design
3.1
Instrument air supply
3.2
Cabling
3.3
Terminal/junction boxes
3.4
Cable trays and trunking
3.5
Mounting of plant instruments
10
3.6
Protection boxes
10
3.7
Fixing materials
10
11
Packing and transport
11
Integration of instrumentation equipment with VRU package unit
11
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1
1.1
General
Scope
This instrumentation specification covers the minimum requirements for the complete design,
fabrication, shipment, delivery to site, erection, testing, commissioning and initial start-up of the
instrumentation part of the package unit where this instrument specification is part.
The design and equipment supplied shall be a complete unit ready to operate and shall include,
but not necessarily be limited to the following:
The preparation and supply of all required documents, manual and drawings.
The preparation and supply of all required documents for obtaining and meeting all
necessary government and local regulations.
Providing electrical and instrumentation specialists for supervisory of installation works.
Check, test, calibrate all instrumentation equipment, which is a part of Vendors scope of
supply.
Commissioning and initial start-up.
Setting of alarms, trips and tuning parameters.
Supply of contract instrument spare parts for testing, commissioning and running during the
guarantee period.
Preparation and submittal of a quotation for itemised spare parts (with prices) for two years
operation after the guarantee period.
Supply, mounting, installation and connection of instrumentation equipment.
The Vendors scope of work shall include, but not be limited to the supply of the following items
and their installation and connection, unless otherwise specified:
All instruments required for safe and efficient automatic operation, such as: indicators,
controllers, switches and proximity switches for open and close position monitoring, locally
mounted push buttons and switches, converters etc.
All the required junction boxes and associated electric cables from these boxes to the
relevant instruments.
All air filters/reducers and air piping between these filters/reducers and the pneumatic
operating instruments.
The connection between the air filters/reducers and Principals main air header.
Supports for field instruments, junction boxes.
Cable trunking and cable support strips for all cables supplied under Vendors scope.
Installation materials, such as valves, fittings, tubing, whenever applicable for the instrument
impulse lines and air piping, bolts, nuts and washers, gaskets, cable glands and entries,
plugs and sockets, mounted brackets, name plates, warning plates.
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1.2
Limits of supply
Junction boxes will be delivered and installed by Vendor at the edge of the package unit for signals
connected to other control systems.
If, in case of safety reasons of operability, the instrumentation control systems should be installed
remote, the instrument signal cables shall run to junction boxes mounted at the edge of the battery
limit of the package unit. Cabling between these junction boxes and the remote control systems is
not part of the Vendors scope.
1.3
1.3.1
Applicable codes and standards

General
The drawings, specifications, instruments, controls and electrical equipment shall be in accordance
with the latest editions and supplements of the national or international codes and governmental
requirements. IEC-Standards as listed in "Catalogue of IEC Publications".
1.3.2
IEC -60034
Rotating electrical machines part 1-3-5
IEC - 60051
Direct acting indicating analogue electrical measuring instruments and

their accessories.
IEC - 60059
IEC standard current rating
IEC - 60072
Dimensions and output ratings for rotating electrical machines part 1-2
IEC - 60085
Thermal evaluation and classification of electrical insulation.
IEC - 60185
Current transformer
IEC - 60204-1
Electrical equipment of industrial machines
IEC - 60269
Low-Voltage fuses.
IEC - 60341
Push-button switches
IEC - 60364
Electrical Installation of buildings.
IEC - 60439
Factory-built assemblies of low voltage switchgear and controlgear
IEC - 60521
Class 0.5, 1 and 2 alternating-current watt-hour meters
IEC -60 529
Classification of degrees of protection provided by enclosures.
IEC - 60555-2
Limitation of disturbances in electricity supply networks.
IEC - 60617
Graphic symbols for diagrams
IEC - 60750
Item designation in electro-technique
IEC - 60947-1
General rules
IEC - 60947-2
Circuit breakers
IEC - 60947-3
Switches, disconnectors and fuse combination units
IEC - 60947-4
Contactors and motor starters
IEC - 606947-5
Control circuit devices and switching elements
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1.3.3
Local regulations
In addition to the standards and codes, the electrical system shall be in accordance with the local
regulations and requirements of the following authorities:
1.4
the fire-fighting brigade;
the ministry of labour inspectorate;
nuisance act, safety law etc.
Instrument labelling
All instruments shall have engraved nameplates showing their tag number and service.
For plant mounted instrumentation equipment the nameplates shall be mounted on a bracket near
the equipment.
Materials for nameplates shall be selected in accordance with the weather data and area
conditions. The text shall be in Lithuanian language.
1.5
Units of measurements
The instrument ranges and scale calibration shall be in metric units, as listed below:
Flow
m3/h
Volume
m3 or l
Level
Pressure
bar gauge
Low pressure, draught or low diff.
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pressure
mbar gauge
Temperature
degr. C
Rotating speeds
rpm
Frequency
Hz
Current
Voltage
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Drawings and documents

Required documents
Vendor shall prepare a set of instrumentation drawings and documents, which shall include, but not
be limited to; those specified in this section.
All documentation, manuals, instructions and other information shall be in Lithuanian.
List of deviations
This shall state details, sections and page numbers of this specifications from which the Vendors
proposal deviates. The Vendor shall justify the deviation.
List of instruments
This shall specify quantity, make, type no., type of input/output signal to the central control system
and give a short service description of all instruments, which Vendor offers in his quotation.
Documentation
Documentation shall be submitted of all instrumentation Vendors proposes to use.
Piping and instrument diagrams

All required instrumentation systems for measurement and control shall be shown on the Piping and
Instrument Diagrams (P&IDs).
Only the basic functions of the instrumentation systems shall be shown. Purchaser will submit
instrument tagnumber during the vendor document control phase afterwards.
Instrument process connection details
Instrument process connections shall be shown on typical drawings.
Special drawings shall be prepared for individual instruments when the application of typical
drawings could cause confusion.
When necessary, a separate location drawing of the routing shall be part of the process connection
details for each individual application.
Consumer, cable and tube lists
Lists shall be prepared indicating consumer, cables and tubes with type, number of conductors or
tubes, locations between which they run and lengths.
Connection diagrams
For each terminal strip in junction boxes etc. a connection list shall be prepared, showing the
internal wiring and the external cables to instruments and interconnecting cabling to other junction
boxes, etc.
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Instrumentation location plans

Drawings shall be prepared, showing all instrumentation points, such as measuring points, location
of instruments, location of junction boxes, location of instrument air supply points, local electrical
power supplies, etc. Each location shall be identified by a tag number, co-ordinates and elevation.
Instrument Index List
- These documents shall list all the required instruments and control elements.
Specifications
Specifications shall be prepared for all components of instrumentation system.
Separate sheets shall be made for each type of instruments and instrument equipment. All relevant
process, construction and engineering data and materials shall be entered on these sheets.
System diagrams
For each instrumentation system a diagrams shall be prepared.
This diagram has to show all components with their tag number, terminal strip numbers, cable
numbers, relevant engineering data and the connection to the instrument electricity/air supply
system.
The drawings shall give a clear picture of the function of the various components.
The drawings shall be divided into the sections: auxiliary room, junction box and field mounted
instruments.
Vendor will only submit the local part of the instrument loop up to including junction box with
terminal No.
List of alarms and trip settings
This list shall show tag number, instrument range, switch point at required process conditions, the
equivalent setting of the relevant instrument etc.
Calculations
Vendor shall prepare all required calculations.
Manuals
Sets of all installation, commissioning and maintenance manuals, applicable to each type of
instrument, including all documents and drawings, shall be made available within the time stated in
the contract. These sets shall contain all information in an as built status.
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3
3.1
Installation design
Instrument air supply
Others will install the main 6 bar instrument air header of carbon steel.
The main air header includes take-off points with a 1 shut off valve on top of the line on
regular distance.
The Vendor shall supply the sub air headers from the shut-off valve to the instruments.
The first connection to the main header shall always be made with a 1 #150 RF carbon steel
flange. The sub air header shall be screwed and carbon steel shall be used.
Per DN15 sub air header a maximum of 5 instruments can be supplied with instrument air and
per take-off point a shut-off valve shall be provided. Each sub air header shall be provided with
a drain valve at the lowest point.
The piping from the sub air header to the instrument shall generally consist of 6 - 4 mm-copper
tubing, PVC covered, and a NPT shut-off valve. If required, each local instrument shall have
its own filter/reducer set installed in a convenient location.
3.2
Cabling
The Vendor is responsible for all instruments cables inside the battery limits and up to the
junction box (es).
220 VAC and 24 VDC power supply cables shall be PE/PE/SWA/PVC mb with a minimu m
conductor size of 2.5 mm2.
Measuring cables, signal cables and cables to solenoid valves will be as follows:
from instrument (transmitter, switch etc.) to a junction box or local cabinet; type:
PE/OSCR/PE/SWA/PVC mb with conductor size of 1.2 mm,
from analog/digital junction box to control/auxiliary room; multicore cable type:
PE/OSCR/PE/SWA/PVC mb 12x2 or 24x2 with conductor size of 0.8 mm,
from solenoid valve to junction box or local cabinet; type: PE/OSCR/PE/SWA/PVC mb with
minimum conductor size of 1.5 mm2.

All conductors shall be terminated.
Cable cores and sheets shall be coloured as follows:
220 V power:
Black (phase), blue (neutral), green/yellow (earth) Grey sheath
24 VDC:
Black (+), blue (-)

Grey sheath (non-intrinsically safe)
Blue sheath (intrinsically safe).
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Approximately 20 % spare shall be available in the junction boxes.

Instrument cables, which are liable to interference from AC sources shall be kept, separated
from other cables.
All cables shall be identified at both ends by means of permanent slip-on sleeves. Cable No. will
be issued by Purchaser later.
3.3
Terminal/junction boxes
All instruments shall be wired to weatherproof junction boxes via a terminal box.
Separate junction boxes shall be used for the following signals:
intrinsically safe analog and digital signals
non intrinsically safe analog and digital signals
signals to solenoid valves.
Terminals and junction boxes shall be polyester, provided with cable glands, material:
Glassreinforced polyamide. Colour of the boxes will be as follows:
Intrinsically safe signals: Blue
Non intrinsically safe signals: Grey
Terminal box provided with 6 terminals.

Junction box provided with earth rail.
Terminal will be coloured as follows:
3.4
Non explosion proof signals: Yellow
Intrinsically safe signals: Blue
Explosion proof signals: Grey
Cable trays and trunking

All the metal materials required from the assembly of cable trays and/or trunking shall be of
galvanised steel.
Metal mounting materials such as supports, hangers, profiles etc. shall be of stainless steel.
Hangers shall be adjustable and mounted in such a way that covering of the trays or trunking
will be possible.
Sharp edges in cable trays or trunking shall be avoided. Bends shall be made by sector pieces.
Corner-, cross and branch pieces shall suitable to cover deviations of dimensions.
Corners shall be constructed in such a way that cables can be laid without space-loss.
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Cable trays and trunking shall be mounted independent of floor and ceiling constructions.
Separate cable trays/trunks shall be installed for:
power cables
intrinsically safe cables and low voltage cables.
Filling grade of cable trays/trunking shall be 70 % maximum.
3.5
Mounting of plant instruments

All instruments shall be installed so that they are not subject to excessive vibration and exposed
to extremely high or low temperature.
To facilitate maintenance, plant mounted instruments shall be yoke mounted on a pipe support
in such a way that the centre of the instrument is approx. 1.35 m above walkways, platforms or
grade.
Plant mounted instruments and their related elements, their sensing elements shall be installed
no more than 0.5 m horizontally away from of no more than 2 m vertically above grade,
platforms of walkways.
When necessary platforms shall be executed or extra platforms shall be provided.
In exceptional cases when it is impossible to comply with the above requirements, it is
acceptable to use temporary access facilities for instruments located no more than 6 m above
grade.
Instruments shall not be installed until heavy construction work adjacent to instruments has
been completed to the extent that there can be no damages to the instrument installation by
such construction work.
When instrument supports are clamped around piping of dissimilar material, isolating barriers,
e.g. tape or gasket material shall be applied to prevent electrolytic action.
3.6
Protection boxes
When required by process or climatic conditions, transmitters shall be mounted in reinforced
polyester protection boxes.
Electrical heating elements mounted inside the protection boxes shall be provided.
3.7
Fixing materials
Fixing materials shall be of stainless steel.
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Prior to the tests of the major instrumentation items of equipment in Vendors workshop, the
Vendor shall inform the Purchaser when testing will start. All instruments shall be tested and
calibrated before being installed
A manufacturers test certificates is required of all instruments.
At least the following system tests shall be carried out during the functional and preliminary test
of the complete package unit on site:
systems
check on correct operational and

optimal
adjustment
of
instruments of Vendors supply

initiating devices
for
alarm
systems
adjustment of switch point under

simulated conditions
The program for the site tests shall be made by the Vendor and is subject to approval by the
Purchaser.
Electrical equipment and cabling shall be subjected to earthfault and continuity tests and full
operational tests, if necessary, by simulating process conditions.
At least one week, prior to site tests of the instrumentation Vendor shall inform the Purchaser
when testing will start to enable the Purchaser to attend the test.
Test and inspection results shall be accurately recorded. These records shall be submitted to
the Purchaser.
Packing and transport

The equipment package shall be adequately protected to prevent damage during transport to its
destination.
In general, instruments should remain as part of the equipment package during shipping and be
removed only if they are outside the confines of the equipment package/skid, or when the
manufacturer requests special packing and shipping facilities.
However, fragile instruments or parts of instrument systems shall be packed and shipped as
separate items.
Integration of instrumentation equipment with VRU package unit

Control and monitoring of VRU package unit shall be realized from operator work station (PC).
VRU process control equipment shall be integrated with existing process control 800xA
system. For that reason all necessary VRU field instrumentation (e.g. sensors, actuator valves,
etc.) shall be integrated to ABB make AC 800M Series controller.
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project:
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SC KLAIPEDOS NAFTA
Order: 73256
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Y:\73256_KN angliavandeniliu garu utilizavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\7182001 Paint Spec.doc
N. Motiejunas
SV
rev.
date
drawn up
ckd.
office:
Kaunas

client:
SC "Klaipdos Nafta"
project:
title:
General Paint Specification for Surface Preparation
Order:
73256
document:
7182001
and Coating
rev.:
sheet:
of:
19
Table of contents
1
1.1
Scope
General
4
4
2
2.1
2.2
Industrial Codes and Standards

Codes and standards
Abbreviations
4
4
4
3
3.1
3.2
3.3
General Requirements
Conformance to manufacturer's recommendations
Surfaces not to be coated
Safety requirements
4
4
5
5
4
4.1
4.2
4.3
4.4
CONTRACTOR Responsibilities
Labour
Equipment
Materials
Miscellaneous
5
5
5
6
6
5
5.1
5.2
5.3
Materials
Packing
Storage
Additives, thinners, solvents, etc.
6
6
6
6
6
6.1
6.2
6.3
6.4
6.5
6.6
Surface Preparation
General
Description of surface preparation methods
Touch-up
Anchor pattern
Blast cleaning
Galvanised steel, aluminium and SS surfaces
7
7
7
7
8
8
8
7
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
7.13
7.14
7.15
Application and Workmanship

Workmanship
Manufacturer's instructions
Application
Relative humidity
Coating sequence
Dry film thickness
Special care
Multiple coats
Subsequent coat
Drying time
Priming
Re-priming
Spot coating
Intercoat contamination
Re-coating
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office:
Kaunas
page
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9
9
9
9
9
9
9
9
10
10
10
10
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10
10
SC "Klaipdos Nafta"
Order: 73256
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7.16
7.17
7.18
7.19
7.20
7.21
7.22
7.23
7.24
7.25
Piping
Touch-up of shop primed surfaces
Inaccessible surfaces after assembly
Platforms, gangways etc.
Area protection and cleaning
Floors and walls
Touch-up and refinish
Stainless steel surfaces
Not covered Items
Doors and windows
10
10
11
11
11
11
11
11
11
11
8
8.1
8.2
8.3
Inspection
General
Acceptance limits and criteria
Primers
12
12
12
13
9
9.1
Selection of Coating System

General
14
14
10 Types of Paint Protection

10.1 Type A (Hot Dip Galvanised)
10.2 Type B (Zinc Rich 2-Pack Epoxy Primer and Heavy Duty Epoxy Coal Tar)
10.3 Type C Multi Layers
10.4 Type D (2-Pack Zinc Rich Epoxy Paint)
10.5 Type E (Epoxy Paint)
10.6 Type F (Epoxy Primer and Chlorinated Rubber Paint)
10.7 Type G (Chlorinated Rubber Paint Brush Application)
10.8 Type H (Chlorinated Rubber Paint)
10.9 Type J (Lead Primer and Epoxy Paint)
10.10Type K (Lead Primer and Epoxy Paint for Galvanised Metal)
10.11Type L (Bitumen Coating)
10.12Type M (Electro Zinc-Plated and Stove-Enamelled)
10.13Type N (Clean and Degrease)
10.14Type P (Lead Primer)
10.15Type Q (Bitumen Enamel or Coal Tar Enamel Wrappings)
10.16Type R (Sealed Sprayed Aluminium Coating)
10.17Type S (Sealed Sprayed Zinc Coating)
10.18Type T (Decorative Painting)
15
15
15
15
15
15
16
16
16
16
16
17
17
17
17
17
17
18
18
11
18
Applications for Different Types of Painting Systems
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
of:
19
1
1.1
Scope
General
This specification is applicable to all field and shop coating, intended to be used for exterior
metal surfaces of equipment, structures, piping, doors and concrete etc. It is intended to
specify the furnishing of materials, labour and equipment, methods for surface preparation and
conditions for workmanship.
Painting work not covered by this specification:
The internal coating or lining of piping and equipment.
The labelling or marking of piping for the indication of the transported media.
The preservation with temporary protectives of piping, steel plates and structures,
equipment and machinery in shipment or in storage.
2
2.1
Industrial Codes and Standards

Codes and standards
In this paint specification reference is made to the following Industrial Codes and Standards:
Industrial Standard - ISO 8501-1 Pictorial Surface Preparation Standards for Painting Steel
Surfaces.
All applicable Lithuanian rules and regulations.
2.2
Abbreviations
3
3.1
M.D.F.T.
M.O.T.
N.O.T.
C.S.
S.S.
means:
means:
means:
means:
means:
Minimum Dry Film Thickness in micro-meter

Maximum Operating Temperature in C
Normal Operating Temperature in C
Carbon Steel, Low Alloy Steel, Cast Iron, Ductile Iron and the like
Stainless Steel
General Requirements
Conformance to manufacturer's recommendations
The
CONTRACTOR
is
responsible
for
conformance
to
coating
Manufacturer's
recommendations defined on product data sheets. In the event of any discrepancies between
coating Manufacturer's recommendations, label instructions and this specification, they are to
be referred to EMPLOYER for adjustment.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
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19
3.2
Surfaces not to be coated

(Unless specified otherwise)
A)
B)
C)
D)
E)
F)
G)
H)
I)
J)
K)
L)
M)
3.3
Stainless steel surfaces;

Aluminium, e.g. insulation protective covering;
Copper and brass surfaces;
Nickel, monel, inconel and other corrosion resistant alloys, FRP and PVC pipe;
Galvanised structural steel, galvanised pipe support steel and galvanised grating;
Galvanised pipe and cable conduit;
Factory finished coated items such as pumps, blowers, motors and other machinery
items, instrument cases, lighting fixtures and other electrical equipment, push buttons,
gauges and other instrument equipment;
Valve stems;
Machined surfaces intended to connect to other items;
however, machines shall be supplied with a rust preventative coating on these surface
which can be removed with a solvet cleaning;
Exposed moving parts and mechanical seal glands;
Capillary tubing of temperature instruments;
Nameplates and markings.
Safety requirements
Coatings, thinners, solvents, soiled rags, waste, etc., shall be kept in tightly closed containers
while at the site and not in use. All materials are subject to fire protection requirements of
applicable codes, standards and EMPLOYERS safety requirements.
4
4.1
CONTRACTOR Responsibilities
Labour
Workmanship shall be of the best quality, performed by skilled workmen. The CONTRACTOR
shall be responsible for a finished product in accordance with Manufacturer's
recommendations and this specification. The finished product shall be free of sags and skips
and present an uniform colour gloss.
4.2
Equipment
All spray equipment shall be inspected and approved by the Construction Management before
any work commences.
Blast cleaning and associated equipment shall be inspected before any work commences.
Suitable moisture traps shall be installed between the air supply and pressure pots and spray
guns. Traps shall be left slightly open to allow continuous bleeding of water and oil.
Regulators and gauges shall be provided by the CONTRACTOR for both pressure pots and
spray guns.
Spray pots must have an agitator for materials which have a tendency to settle rapidly, such
as organic zinc.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
of:
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4.3
Materials
Coatings are to be supplied by the CONTRACTOR.
Consumable supplies are the responsibility of the CONTRACTOR.
4.4
Miscellaneous
The CONTRACTOR shall furnish all inspection equipment. All inspection equipment shall be
calibrated just prior to initial use.
The CONTRACTOR shall protect floors and paved areas against spatter or spillage by use of
drip cloths.
Before acceptance of the works, contractor shall remove coating spots, stains and overspray,
from floors and walls, hardware, fixtures and all other items not intended to be coated. Further
all glass shall be cleaned of all coatings and putty deposits. Special cleaning instructions and
materials shall be applied where necessary. The CONTRACTOR shall consult the EMPLYER
to obtain correct information. Where proper cleaning of spots, stains, etc., is not possible, the
CONTRACTOR shall install protective covering materials and remove these after job is
completed satisfactorily.
The CONTRACTOR shall supply and apply the required coating for all retouching and
refinishing of any work or surfaces which may be damaged or found defective.
5
5.1
Materials
Packing
All materials shall be as made and specified by the Manufacturer and shall be delivered in the
original, unopened packing.
Containers must bear the original Manufacturer's label identifying the actual contents in order
to be accepted.
5.2
Storage
Materials shall be stored in an enclosed area to protect them from temperatures in excess of
coating Manufacturer's recommendations and to prevent fire hazards.
5.3
Additives, thinners, solvents, etc.

The CONTRACTOR shall use only the additives, thinners, solvents, etc., as specified by the
coating Manufacturer. All mixing shall be done in clean metal or plastic containers.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
of:
19
6
6.1
Surface Preparation
General
The CONTRACTOR shall apply coatings only to those surfaces which have been properly
cleaned, prepared and dried, as specified in this Specification.
When a prepared surface has been left uncoated for a long time (i.e. 6 hours) for surface
rusting to occur, the CONTRACTOR shall clean these surfaces again per the specified
requirements.
The time interval between blast cleaning and primer shall under all conditions be such that rerusting or re-contamination cannot occur. Conditions may require a shorter interval than 6
hours. An extension to this interval time is acceptable only if written approval is obtained from
the EMPLOYER.
6.2
Description of surface preparation methods

Solvent cleaning shall precede other methods of surface preparation and the application of any
coating, whenever dirt, oil grease and other substances, harmful to lifetime or appearance of
primers or paints are present.
These agents shall be removed by means of clean solvents (such as white spirit), or suitable
cleaning compounds. After the use of water soluble compounds the surfaces shall be rinsed
with an ample amount of potable water, and then be allowed to dry thoroughly before and
further step is taken. Only clean brushes and rags shall be used.
For the cleaning of SS items only solvents shall be used.
6.3
Touch-up
Touch-up is applicable to field welds, bolting, and damaged, rusted, or otherwise oxidized preprimed surfaces as a first step to field painting. Touch-up shall include all necessary
operations, such as:
Solvent cleaning;
The removal of zinc oxides (as found on zinc-rich primers) by means of potable water
and nylon brushes;
De-rusting of damaged shop primed surfaces, field-welds and bolting (to C-St3
Standard);
Spot priming or painting with the specified materials and to the same number of shop
coats and M.D.F.T. as has been specified.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
of:
19
6.4
Anchor pattern
Blast cleaned surfaces shall provide a good anchor pattern for primers, but shall not show
excessive roughness.
Manufacturers recommendation shall be adhered to.
Power and hand tool cleaned surfaces shall be free of sharp cuts or burrs and shall not be
burnished to a degree detrimental to the adhesion of primers and paints.
6.5
Blast cleaning
Surface preparation shall include the thorough removal of blasting materials and dust, leaving
the prepared surface dry, clean and in all respects fit to be painted.
All field blasting operations shall be performed within the confines of a designated area on site.
All equipment, tools, supplies, etc., must be installed or stored in this area. Any field blasting
not possible within the designated area, e.g. field welds, damaged surfaces, etc. shall be by
means of mechanical tools such as wire brushing. Blast cleaning on the site is only permitted
after written approval of The EMPLOYER.
All steel delivered to the area of operations shall be protected against physical damage before,
during and after blast cleaning.
6.6
Galvanised steel, aluminium and SS surfaces

Galvanised steel, aluminium and stainless steel surfaces may be cleaned and pre-treated in
accordance with the CONTRACTORS standard procedures, however, prior to application, any
procedure shall be sent to the EMPLOYER for review.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
of:
19
7
7.1
Application and Workmanship

Workmanship
Coating applications shall be of first class workmanship, with uniform film thickness, hiding and
appearance, and shall be free of brush marks, laps, sags, runs, crawls, skips, etc.
7.2
Manufacturer's instructions
Coatings shall be applied strictly in accordance with the coating Manufacturer's instructions
and recommendations.
7.3
Application
No coating shall be applied when moisture is present and no coating shall take place when the
air temperature or surface temperature is expected to fall below 5C during the required drying
or curing time.
In any case, coating Manufacturer's recommendations shall govern, if they are more stringent.
Exceptions to the above temperature must be referred to the coating Manufacturer and
EMPLOYER, and are subject to the EMPLOYERS approval in writing.
7.4
Relative humidity
No application of coating shall take place when the relative humidity is above 85%. The
temperature of the steel shall always be at least 3oC above the dew point temperature.
7.5
Coating sequence
The sequence of coating shall be such that a minimum of damage to finished coatings will
result.
7.6
Dry film thickness

Dry Film Thickness (DFT) shall be as specified in the Coating Systems and Schedules; the
acceptance for coating application and actual coating is specified in paragraph 8.0, Inspection.
7.7
Special care
Special care shall be taken when coating is applied on the edges of doors, sharp corners, etc.,
to ensure adequate dry film thickness.
The painting materials shall be applied by the tools as advised by Manufacturer. When spray
application is recommended, supplemental brushing is required to obtain adequate protection
at crevices, bolts, rivets, welds, edges, and all other surfaces where the M.D.F.T. cannot be
reached by spraying only. This brushing shall precede the spray application.
7.8
Multiple coats
Multiple coats of the same colour are not acceptable. Alternating colour coats are required to
distinguish between the base layers, to provide a visual check to ensure complete coverage of
each coat is achieved.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
of:
19
7.9
Subsequent coat
No subsequent coat shall be applied until the preceding coat is dry, has correct dry film
thickness and is in proper condition to receive the subsequent coat.
7.10
Drying time
Extended drying times or airing procedures when recommended by the coating Manufacturer,
shall be followed.
7.11
Priming
All base material shall be primed prior to application of top coats.
7.12
Re-priming
Any damage to a primed surface due to welding, etc., shall be cleaned and re-primed as per
the original coating schedule and allowed to dry before any subsequent coat shall be applied.
7.13
Spot coating
All connecting welds, bolts, rivets, etc., for structural steel framing and miscellaneous steel
work shall be spot-coated with the same material used for the shop coat or an approved
equivalent material, prior to field application. This spot-coating shall be in addition to the
specified number of coats.
7.14
Intercoat contamination
To minimise intercoat contamination, subsequent coats shall be applied with a minimum
elapsed time between coats, as is consistent with the drying time or work and erection
schedules.
When unavoidable contamination does occur, contaminants shall be sufficiently removed to
ensure adequate inter-coat adhesion.
7.15
Re-coating
In case of re-coating, damage to the previous coat shall be repaired with the compatible
coating. The completed coating shall be free from defects.
7.16
Piping
Piping to be installed in the field shall be prepared and primed before installation followed by
final painting after installation.
7.17
Touch-up of shop primed surfaces

Shop primed surfaces shall be touched-up and repaired (damages, field welds, etc.) as soon
as possible after erection. Final painting shall follow immediately after mechanical completion,
or after successfully completed pressure testing.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
10
of:
19
7.18
Inaccessible surfaces after assembly

Surfaces that will be inaccessible after assembly shall receive the complete painting system
before assembling.
Contact surfaces of bolted connections are to be primed only.
7.19
Platforms, gangways etc.

Platforms, gangways and stair beams shall receive the complete painting system before the
gratings or stair treads are mounted.
7.20
Area protection and cleaning

The following areas and similar, but not listed areas, shall be protected against coating, and
after coating work is completed, cleaned by the CONTRACTOR so that all masking agents are
completely removed.
a) Windows, gauge glasses, sight glasses, etc;
b) Globes and reflectors of lighting fixtures;
c) Valve stems, adjusting screws and nuts, and other machined, operating parts or
machinery;
d) Equipment nameplates, plated or polished hardware;
e) Sprinkler heads and fusible links;
f) And all other items as referred to in paragraph 3.2.
7.21
Floors and walls

Floors and exterior metal walls shall be protected against splashes, spills and overspray.
7.22
Touch-up and refinish

The CONTRACTOR shall go over all surfaces and clean-off all coating spots on floors, walls,
glass, etc., touch-up and refinish any part of his work no matter by whom caused, and shall
remove all dirt, rubbish and waste materials resulting from this work.
7.23
Stainless steel surfaces

Special attention is drawn to coating of carbon steel parts attached to or in contact with
austenitic stainless steel parts.
Care shall be taken to prevent contact of zinc containing primer onto austenitic stainless steel
surfaces such as by overspray. If contact cannot be avoided, the CONTRACTOR shall contact
the EMPLOYER prior to applying the primer coat, in order to review the specific application in
detail. The application of a zinc free primer can be agreed upon.
7.24
Not covered Items

Consultation of coating Manufacturer and the EMPLOYER are mandatory for items not
covered herein.
7.25
Doors and windows

Doors and windows are to be left open after coating until they are dry.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
11
of:
19
8
8.1
Inspection
General
All phases of the cleaning, surface preparation and coating shall be subject to the approval of
authorised inspectors of the Paint Manufacturer. No coating shall be applied prior to
Manufacturer's inspector approval of the surface preparation or of subsequent coatings applied
to this surface. All defective work or coating not conforming to this specification shall be
repaired at no additional costs to the EMPLOYER.
Procedures for repairs, not covered by this specification, must be brought to the attention of
the EMPLOYER. Alternative repair procedures must be approved by the EMPLOYER prior to
carrying out the actual repair.
As work progresses, the EMPLOYER is responsible for continuous checking of coverage rate
and wet and dry film thickness. A weekly log shall be maintained, containing the following data
by day: air and steel temperatures, relative humidity, dew point, coating progress, coating Dry
Film Thickness measured and other relevant information pertinent to the work.
At the completion of the works, the contractor is responsible for determining that the correct dry
film thickness is attained, by use of magnetic film thickness gauges or electromagnetic gauges,
such as Magne-Gauge, Mikrotest, Elcometer Gauge or similar for ferrous surfaces.
Some equipment may be delivered with a shop-primer as per vessel, heat-exchanger or tank
specification. The CONTRACTOR shall, after having obtained approval of the paint
Manufacturer's inspector, finish the complete coating of surfaces, on which the surface
preparation and prime coat has been carried out by others, however, the CONTRACTOR shall
take full responsibility to verify that this surface preparation and prime application by others is
complete and in proper condition, all in accordance with this specification.
The CONTRACTOR shall apply all subsequent coats to complete the Coating system and
Schedule applicable for that specific equipment. In the event that the CONTRACTOR is
dissatisfied with the surface preparation and prime coat application, carried out by others, he
shall inform the EMPLOYER in writing immediately after his dissatisfaction has been
established.
The CONTRACTOR shall assign a full-time inspector to the work during the whole period of
coating application.
8.2
Acceptance limits and criteria

The complete coating work and each step such as surface preparation, prime undercoat and
finish coat application shall be subject to inspection.
Surface preparation shall be compared with the specified degree of cleanliness as per this
specification and SIS 05 59 00 and shall be compared with the required anchor pattern
(surface roughness).
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
12
of:
19
8.3
Primers
Acceptance criteria for primers shall be as follows:
Minimum:
90% of all measurements shall have a Dry Film Thickness as specified in the Coating Systems
and Schedules; only 10% of all measurements may have a minimum Dry Film Thickness of
90% of the value specified for the primer as per Coating System and Schedules. Minimum DFT
of an inorganic zinc silicate primer is 60 micrometer.
Maximum:
Acceptance criteria for primers shall be 75% over the value specified in the Coating systems
and Schedules.
Acceptance criteria for primers applied by others
Primer need not to be removed if acceptable for the CONTRACTOR according to 8.1 of this
specification.
Undercoat and Finish Coat
Acceptance criteria shall be as follows:
Minimum:
90% of all measurements shall have a Dry Film Thickness as specified; only 10% may have a
minimum Dry Film Thickness of 90% of the value specified.
Maximum:
Dry Film Thickness shall not exceed more than 75% of the value specified.
If the requirements of the minimum and maximum Dry Film Thickness are not met, the
CONTRACTOR shall be responsible to re-blast and repaint or to repair the paint coat
according to Manufacturer's recommendations as per the original requirements of the Coating
Systems and Schedules. All such required paint work shall be repaired at no additional costs to
the EMPLOYER.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
13
of:
19
9
9.1
Selection of Coating System

General
The CONTRACTOR shall be responsible for the application of the correct painting systems to
the surfaces which must be painted according to this specification.
Section 10 shall be the guide for the selection of the painting system. The selection shall be
based on the Item description and when indicated in the paint system in conjunction with the
Maximum or Normal Operating Temperature (M.O.T. or N.O.T.).
In case the M.O.T. of an item is not known, assume M.O.T. equals design temperature minus
20oC.
Machinery, valves etc. may be painted in accordance with Supplier's Standard Painting
Practice, provided workmanship, quality and the materials used, the number of coats (or
M.D.F.T.) are not less than called for in this specification.
However, each Supplier shall submit for approval full details about his intended painting
practice. The information shall contain at least:
a)
Surface preparation method and standard;
b)
Binder resin type;
c)
Main type of pigment and percentage (e.g. red lead/red oxide 90/10);
d)
Brand name of paint;
e)
Paint Manufacturer's name;
f)
Maximum temperature resistance of paint.
Field painting of machinery as mentioned above shall be executed only when the shop applied
paints have been damaged.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
14
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10
Types of Paint Protection
10.1
Type A (Hot Dip Galvanised)

a) Blast clean to First Quality finish.
b) Hot-dip galvanised to give a minimum coating weight of 610 gm/m2. Finished dry film
thickness shall be not less than 85 microns for metals in interior of building and normally
dry condition, and 140 microns for other conditions.
NOTE: All fastenings including bolts, for use with materials having a Type A finish, shall be
sheradised in accordance with B.S.4921.
10.2
Type B (Zinc Rich 2-Pack Epoxy Primer and Heavy Duty Epoxy Coal Tar)
a) Blast clean to First Quality finish B.S.4232.
b) Within 2 hours of blast cleaning, apply one coat of 2-pack zinc rich epoxy primer, to a
finished dry film thickness of not less than 50 microns.
c) Apply one coat of 2-pack zinc epoxy primer as above to a finished thickness of not less
than 100 microns.
d) Apply two coats of high build epoxy coal tar, to a final finished dry film thickness of not less
than 350 microns.
10.3
Type C Multi Layers

As type B above but with sufficient number of coats in d to give a final finished dry film
thickness of not less than 450 microns.
10.4
Type D (2-Pack Zinc Rich Epoxy Paint)

b) Within 2 hours of blast cleaning, apply one coat of 2-pack zinc rich epoxy primer, as in
Type B Part (b) above.
c) Apply two coats of 2-pack zinc rich epoxy high build matt finish dry film thickness of not
less than 300 microns.
d) Apply final coat of 2-pack epoxy gloss finish of approved shade to produce a total of
finished minimum dry film thickness of 350 microns.
A minimum of 16 hours shall be allowed between coats.
10.5
Type E (Epoxy Paint)

b) Within 2 hours of blast cleaning, apply one coat of high build 2-pack cold cure epoxy resin
primer to give a finished dry film thickness of 125 microns.
c) After a period of not less than 8 hours from the first coat (b above), a finish coat of high
build pure epoxy shall be applied to give a total dry film thickness of not less than 250
microns.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
15
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10.6
Type F (Epoxy Primer and Chlorinated Rubber Paint)

b) Within 2 hours of blast cleaning, apply one coat of 2-pack zinc rich epoxy primer to give a
finished dry film thickness of 50 microns.
c) Apply two coats of 2-pack zinc epoxy high build to a matt finished dry film thickness of 300
microns.
d) Apply one coat of chlorinated rubber paint of approved shade to a gloss finished dry film
total thickness of not less than 350 microns.
10.7
Type G (Chlorinated Rubber Paint Brush Application)

b) Apply 2 coats of chlorinated rubber paint primer to give a finished dry film thickness of 100
microns.
c) Apply 2 coats of chlorinated rubber based high build undercoat to give a finished dry film
thickness of 220 microns.
d) Apply 2 coats of chlorinated rubber base gloss finish of approved shade to give a total dry
film thickness of 280 microns.
10.8
Type H (Chlorinated Rubber Paint)

b) Apply 2 coats of chlorinated rubber based high build primer to give a finished film
c) Apply 2 coats of chlorinated rubber based high build semi-gloss finish of approved shade
to give a total dry film thickness of 300 microns.
10.9
Type J (Lead Primer and Epoxy Paint)

a) Blast clean to First Quality finish B.S. 4232.
b) Within 2 hours of blast cleaning, apply one coat of 2-pack epoxy metallic lead primer to
give a finished dry film thickness of 50 microns.
c) Apply 2 coats of 2-pack epoxy micaceous iron oxide undercoat to give a finished dry film
d) Apply one coat of 2-pack epoxy gloss finish of approved shade to give a total dry film
10.10
Type K (Lead Primer and Epoxy Paint for Galvanised Metal)

a) Thoroughly clean and degrease.
b) Apply one coat of 2-pack epoxy metallic lead primer to give a finished dry film thickness of
50 microns.
c) Apply one coat of 2-pack epoxy micaceous iron ore undercoat to give a finished dry film
d) Apply one coat of 2-pack epoxy gloss finish of approved shade to give a total dry film
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
16
of:
19
10.11
Type L (Bitumen Coating)

a) Blast clean to First Quality finish B.S. 4232 or pickle in hot dilute sulphuric acid.
b) After thorough washing, phosphate coating by immersion in a bath of hot dilute phosphoric
acid.
c) Application of one coat of primer as specified in B.S. 4147:1973.
d) Hot dip bitumen / bitumen coating applied to give a smooth lining having a minimum dry
film thickness of not less than 300 microns.
10.12
Type M (Electro Zinc-Plated and Stove-Enamelled)

a) Blast clean to First Quality finish B.S.4243 or pickle in hot dilute sulphuric acid.
e) After thorough washing, phosphate coating by immersion in a bath of hot dilute phosphoric
acid.
b) Electro-zinc plate.
c) Apply stoved zinc based epoxy primer (incorporating suitable pigments to act as acid
scavengers and counteract the formation of adhesion destroying compounds).
d) Finishing coat(s) of stoved alkyd enamel to give a high standard gloss finish to approved
shade, and not less than 150 microns dry film thickness.
10.13
Type N (Clean and Degrease)

Thoroughly clean by hand, and power tools where available, to remove all mill scale, rust and
grease.
10.14
Type P (Lead Primer)

a) Blast clean to First Quality finish B.S. 4232.
b) Within 2 hours of blast cleaning, apply by brush two coats of metallic lead primer to a
finished thickness of not less than 100 microns.
10.15
Type Q (Bitumen Enamel or Coal Tar Enamel Wrappings)

Apply bitumen enamel wrapping or coal tar enamel wrapping in accordance with B.S. 534:
Clause 5.4
10.16
Type R (Sealed Sprayed Aluminium Coating)

a)
Blast clean to First Quality finish B.S.4232. Surface preparation shall be in accordance
with B.S.2569.
b) Apply suitable primer.
c) Apply sprayed aluminium coating to give a finish dry film thickness of not less than 150
microns.
d) Apply suitable pre-treatment primer (e.g.Two-pack polyvinyl butyral or 2-pack polyvinyl
butyral/ phenolic, containing not less than 85% by weight of zinc tetroxychromate pigment)
e) Apply suitable sealer (e.g.Blend of vinyl chloride / acetete copolymers or 2-pack phenolic
binder or 2-pack epoxy or 2-pack polyurethene).
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
17
of:
19
10.17
Type S (Sealed Sprayed Zinc Coating)

a) As in (a) Type R
b) As in (b) Type R
c) As in (c) Type R but using sprayed zinc coating to give a finished dry film thickness of not
less than 175 microns.
d) As in (d) Type R
e) Apply suitable sealer (e.g. silicone resin containing not less than 95% by weight of
alumunium pigment).
10.18
Type T (Decorative Painting)

Decorative paint (when specified) shall be compatible with the final finish paint or coating.
The final shade shall be advised by the Engineer.
The film thickness of decorative paint shall not be included in the total dry film thickness
specified.
11
Applications for Different Types of Painting Systems
Item
1
Applications
Type
All steel ladders, staircases, guard rail, guard rail standards, safety cages, open
steel flooring, small bore pipework and steel conduit. All small metalwork such as
pipe supports, steel flooring supports and safety chains.
2
All steelwork, castings and other metal surfaces which are immersed in water
(non-potable water) sewage, and other effluents or in contact with liquid or subject
to splashing or buried in the ground.
3
All steel, ductile and cast iron pipes, valves, flow meters and fittings 75 mm and
larger used for the conveyance of sewage and other effluents as in 2 above.
4
All steelwork, castings, pipes, valves, flow meters and other surfaces which are
exposed (exterior) and frequent damp or wet.

5
As 4 above, but in interior of building and normally dry.
D or F
All steelwork and castings which are in contact with potable water.
A,D,E,F or H
All steel pipes, ductile iron pipes, and cast iron pipes and fittings 75 mm and larger
used for the conveyance of potable water.
Internal protection
External protection
E,F,H or L
All steel pipes laid underground
All valves, penstocks, flow meters, tanks and fittings which are in contact with
E,F or H
potable water.
10
Potable water pumping plant installed inside pumping station normally dry
condition.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
18
of:
19
a)
b)
c)
d)
Suction and delivery pipes

Internal protection
External protection
E,F or H
Valves
Internal protection
E or L
External protection
E,F or H
Pump casings
Internal protection
E or L
External protection
E,F or H
Flowmeters (body)
Internal protection
E,F,H or I
External protection
E,F or H
e)
Extension shaft and couplings
E,F or H
f)
Pump motor casing and support steelwork
E,F or H
Potable water pumping plant installed inside pumping station frequently damp or
11
wet condition (External protection).

12
Over-painting of galvanised items not in contact with potable water.
13
Switchboards, multi-motor control panels and other similar enclosures.
14
Metal cable trays, conduits and fixings.
15
Sections of pipe to be built into concrete.
16
High temperature metal surfaces (including radiators):

a)
Temperature up to 200 C
R,S
b)
Temperature up to 500 C
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order: 73256
document:
7182001
rev.:
sheet:
19
of:
19
Y:\73256_KN angliavandeniliu garu utilizavimas is gelezinkelio estakadu\21\Uzsakomoji iranga\VRU\Docs for VRU Purchase\6551408 Req docs.doc
14-10-2010 For Information
N. Motiejunas
SV
rev.
date
drawn up
ckd.
office:
Kaunas
client:
SC "Klaipdos Nafta"
project:
title:
Order:
73256
document:
6551408
rev.:
sheet:
of:
Table of contents
1
General
Required documentation
client:
project:
title:
office:
Kaunas
page
SC "Klaipdos Nafta"
Required DocumentsVapour Recovery Unit
Order:
73256
document:
6551408
rev.:
sheet:
of:
General
Vendor is required to furnish the documents specified herein, in the quantities, within the
periods and in accordance with the instructions and conditions shown below.
1.1
All documents shall be in the Lithuanian language. Documents required by governmental,

provincial or local authorities shall also be made in the language required by the
authorities. The equipment shall be related to a European Directive. The declaration of
conformity and the user manual shall be in Lithuanian language and in the language of the
manufacturer.
1.2
For units of measurement the SI-standard shall be applied.
1.3
All documents shall clearly show the purchase order number and tag numbers (where
applicable) and Purchasers drawing number.
1.4
Drawings shall be prepared in formats A1 thru A4 inclusive.
1.5
Quality/type of documents:
(P) = Prints:
(D) = Digital format:
(on CD-rom) using AutoCad (2D, release 14 or higher).

Miscellaneous lists, text books, usually presented on A4 format
shall be supplied in digital format, using MS Word.
1.6
Not approved documents shall be re-issued in the required quantities after incorporation
of Purchasers comments.
1.7
Prints shall be folded to A4 size, with the title block visible at the front. Prints to be handed
over as originals shall NOT be folded.
1.8
Fabrication is not to start pending approval of all relevant documents.
1.9
Purchaser normally requires 15 working days for document review and approval. In case
extension of this period endangers the delivery date of the equipment/material, the
Vendor shall clearly indicate such on his transmitting letter.
1.10
Approval of documents by Purchaser does not relieve the Vendor from his exclusive
responsibility for their accuracy and/or correctness and does not relieve the Vendor from
his obligation to fully comply with the Contract.
1.11
Specific requirements regarding the documents, if any, have been laid down in the
requisition.
client:
project:
title:
office:
In case of printed matter, originals are required;
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
6551408
rev.:
sheet:
of:
1.12
All documents shall be submitted under cover of a transmittal indicating purchase order
number, document number revision, title and the purpose of submission. For each
document, the appropriate equipment number(s) shall be indicated.
1.13
Document change control:

It is the responsibility of the Vendor to inform Purchaser about changes made to each
document furnished by Vendor. Therefore all re-issued documents shall clearly show
identification and/or description of all changes.
1.14
A live set of documents shall be available at the Vendors shop at all times for use by
Purchasers and/or Clients inspector.
1.15
Vendor shall ensure that, prior to final acceptance of materials and equipment,
Manufacturers data book is complete and presented to Purchaser and/or third party, if so
specified, for their acceptance.
1.16
Manufacturers data book shall be produced by Vendor. Where equipment packages are
involved, data books shall be compiled for each of the components separately as
applicable.
1.17
Vendor shall supply each set of final documentation in file within 2 (two) week after
delivery.
1.18
All documents shall be addressed to:

SC Klaipdos Nafta
Buri str. 19
P.O. Box 81
LT-91003 Klaipda, Lithuania
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
6551408
rev.:
sheet:
of:
Required documentation
2.1
General
Document description
Quantity + type
With
quot.
P
Detailed list of drawings and documents to be
submitted
General company introduction
Photographs and brochures
List of exceptions and deviations to the
specifications
Quality plan
Inspection plan (completed)
Fabrication/inspection schedule
Recommended spares quotation for:
Testing
Commissioning
2 year continuous operation
Sound-level information
List of suppliers
As built documents
Installation/commissioning/operation
manuals in Lithuanian language
Maintenance manuals (1)
Completed specification / data sheets
Manufacturing data report
Submittal period in
weeks
For approval
after award
Final after
approval
For appr.
after
award
Final
after
approval
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
***
**
**
**
(1) in the manual should be included instruction for activated carbon beds cleaning and replacement in
the Vapor Recovery Unit.
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
6551408
rev.:
sheet:
of:
Packaged Units
Quantity + type
With
quot.
Submittal period in
weeks
For approval
after award
Final after
approval
For appr. Final

after award after
approval
3
3
3
3
1
1
1
1
3
3
3
3
1
1
1
1
6
6
6
6
3
3
3
3
3
3
3
3
6
6
3
3
6
6
Dimensions and weights

General arrangement drawings
Assembly drawings
Sectional drawings
Foundation & block-out drawings with
loads
Pipe routing plans
*
*
*
Process
Process diagrams according ISO 33111 rules
Process & Instruments Diagrams
Design, pressure drop and/or heat
balance calculation
Flow & purity registration
Linelist(s)
Specification of equipment and
instruments
Utility consumption & requirements
Emission points + concentration and
quantities per unit time
3
3
3
1
3
3
3
Electrical and instrumentation

Consumers list and electrical load-list
Cable-number list
Connection diagrams / drawings
Installation diagrams / drawings
Instrument index
Alarm & tripsetting-list
Instrument cable-list
Nameplate(s)-list(s)
Applied software description
Cable block schematic
client:
project:
title:
office:
Kaunas
3
3
3
3
3
3
3
3
3
3
1
1
1
1
1
1
1
1
1
1
3
3
3
3
3
3
3
3
1
1
1
1
1
1
1
1
4
6
6
6
6
6
6
6
6
6
3
3
3
3
3
3
3
3
SC "Klaipdos Nafta"
Order:
73256
document:
6551408
rev.:
sheet:
of:
Quantity + type
With
quot.
P
Submittal period in
weeks
For approval
after award
Final after
approval
For appr. Final

after award after
approval
3
3
1
1
3
3
1
1
6
6
3
3
3
3
3
3
1
1
1
1
3
3
3
3
1
1
1
1
6
6
6
6
3
3
3
3
3
3
3
3
1
1
1
1
3
3
3
3
1
1
1
1
6
6
6
6
3
3
3
3
3
3
3
3
3
3
6
6
6
3
3
3
Electrical and instrumentation

(continued)
Junctionbox connection schematics
Installation detail drawings
Drawings of panels and sub-panels:
control diagrams
wiring diagrams
connection diagrams
lay-out drawings
Control systems
PLC-programme (disk-listing)
PC-programme (disk-listing)
Description of PLC-programme
Description of PC-programme
3
3
Pneumatics
Schematic diagrams
Air-consumption calculation
Data sheets
Procedures
Painting procedure
Testing procedure
3
3
3
3
3
6
3
3
3
3
3
3
6
6
3
3
Quality assurance
Coating test reports
*
Welding procedure spec.s (WPS)
*
Weld procedure qualification record
(WPQR)
*
Welders qualifications
*
Test-curves / results
*
Test-certificates
*
Leak test procedure
*
Leak test certificates
*
Material certificates
*
E-motor certificates
*
EXD-certificates
*
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
6551408
rev.:
sheet:
of:
Quantity + type
With
quot.
P
Submittal period in
weeks
For approval
After award
Final after
approval
For appr. Final

after award after
approval
D
M iscellaneous
List of special tools
Fire-risk analysis
Explosion risk analysis
EC Declaration of conformity (IIA
Certificate) in required and original
language
3
3
3
3
3
3
6
6
3
3
**
* In manufacturing report
**With delivery
***After delivery
client:
project:
title:
office:
Kaunas
SC "Klaipdos Nafta"
Order:
73256
document:
6551408
rev.:
sheet:
of:
Appendix 1
Appendix 2
Time, h
24
23,4
22,8
22,2
21,6
21
20,4
19,8
19,2
18,6
18
17,4
16,8
16,2
15,6
15
14,4
13,8
13,2
12,6
12
11,4
10,8
10,2
9,6
8,4
7,8
7,2
6,6
5,4
4,8
4,2
3,6
2,4
1,8
1,2
0,6
Vapour capacity, m3/h
Appendix 3
rev. B, 2011.04.22
VRU working profile
3500
3000
2500
2000
Track 3A
Crude 1800m/h
Track 3B
Gasoline 1200m/h
1500
VRU working capacity
1000
500

Technical Specification for Vapour Recovery Unit

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Order No.

Requisition for Vapour Recovery Unit

Technical Specification for Vapour Recovery Unit

VRU facility site layout plan

Process & Instruments Diagram

Specification for Structural Steel Design and Fabrication

Project Specification for Mechanical Equipment

Specification for Pipes

Specification for Valves

Specification Electrical Requirements for Package Units

Instrumentation specification for package units

General Paint Specification for Surface Preparation and Coating

Required Documents for Vapour Recovery Unit

Appendix 1 Crude oil physical properties

22-04-2011 Quotation request

Technical Specification for Vapour Recovery Unit

22-04-2011 Updated chapters

description / issued for

from railway estacada

Codes and standards

Inspection, factory testing and shipment

Erection, start-up, training of operators and acceptance

Vendor documents required

foundations (civil works);

Spare parts and special tools

Train gasoline unloading

Train Crude loading

Maximum 3 minute vapour capacity

Maximum 10 minute vapour capacity

Maximum hour vapour capacity

Maximum 4 hour vapour capacity

Maximum instantaneous vapour flow

Maximum daily vapour capacity

Maximum vapour flow: 3000 m3/hour.

Vapor recovery operating profiles

Design and material requirements

Filled with activated virgin mineral

Carbon bed adsorber vessels with

Number installed (for gasoline and

with engineered hydraulic inlet

Electric motor with freq. controller

LIQUID RING or SCREW TYPE

* Vendor to confirm / complete

ANSI B-31.3 and 16.5

Electric motor with freq. controller

to move hydrocarbon vapors from

Continuous emission analyzer

One (1) lot of specialty instruments,

One industrial PLC (800xA system)

with SIL rating of 1 or higher

Integrated in to the existing ABB

One (1) automation

Integrated in to the existing ABB

Suitable for the ambient conditions

Integrated in to the existing ABB

Special tools and tackles

Consumable spares for 12 months

Integrated in to the existing ABB

Pressure control valves at VRU

Mesh size of filter elements: 10m;

max. pressure 10 bar

Vendor shall ensure

o Vacuum valves_ _ _______