SPECIFICATION / DATA SHEET

Variable Flow Foam-sum-Water Monitor – Remote Operated

CHAPTER 7: TECHNICAL SPECIFICATIONS

Equipment: Remote operated Foam-cum-water monitor with

Foam Induction Mechanism.

Capacity : Variable flow of 1000, 750 and 500 GPM with single Nozzle.

Type : Non-aspirating.

1.0 SCOPE
This specification covers the requirements regarding design, materials,
fabrication, performance, testing and supply of remote operated foam cum
water monitor to be used for fire fighting. The scope of supply shall include
UL listed or FM approved non-aspirating type foam-cum-water monitor to
be used for fire fighting along with the remote operation mechanism
(remote operated mechanism may or may not be UL listed or FM
approved), Motor Operated Isolation valve & flameproof control panel etc.
to facilitate remote operation of the monitor.

Foam-cum-water monitor is required in the following discharge capacities:

2
1000 USGPM adjustable to 750 USGPM & 500 USGPM at 7.0Kg/cm inlet
pressure with the same single nozzle.
The Monitor shall be designed for mounting on stand posts or elevated
platform /tower at fixed locations.
The monitor shall be capable to give discharge in the form of hollow jet
and spray arrangement.
All the operation of the monitor viz. Horizontal movement, Vertical
Movement, Jet/spray adjustment should be possible manually from
Monitor (without use of power) and remotely from remote control panel.

2.0 MONITOR & FOAM INDUCTION:

2.1 Foam Induction System

2.1.1 Foam feeding shall be by a separate & single aqua powered foam inductor
(JRCP). The induction system shall be UL listed or FM approved for use
along with tendered monitor.

2.1.2 The Foam Inductor should be capable of feeding foam concentrate from a
horizontal distance of minimum 60 meters from the Monitor Nozzle.

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2.1.3 The inlet and outlet of foam Inductor shall be provided with standard male and
female instantaneous couplings as per UL/FM Std.

2.1.4 The length of the foam pick up tube shall be 3-4 Meters. It should be
possible to induct 3% foam for all the flows, however, variation of +20% of
the induction rate is permissible. Manual valve shall be provided at foam
inductor to set foam induction as per 1000 USGPM, 750 USGPM or 500
USGPM water flows.

2.2 Monitor

2.2.1 The monitor shall be able to discharge 1000 USGPM, 750 USGPM and
500 USGPM (depending upon adjustment at the Nozzle) at a pressure of
2
7.0Kg/CM (g) at the mating/mounting flange. The foam compound shall
be AFFF/AR-AFFF.

2.2.2 The nozzle shall produce foam with foam expansion ratio 1:3 to 1:4.

2.2.3 The pattern of the Water/foam jet nozzle shall be adjustable from straight
to 140 deg wide spray.

2.2.4 The monitor shall have traversing mechanism to give 340 deg. in either
direction in horizontal plane and +90 deg. & -15 deg in vertical plane
through swivel joints operated by worm and worm wheel operated geared
unit. There shall be separate hand wheels for horizontal and vertical
movement of the monitor. The arrangement shall be such that monitor
movements can be done by a single person. All the gear mechanisms
shall be sealed by proper enclosure to avoid accumulation of dust on
lubricated parts. Both the traversing mechanisms shall be self locking type.

2.2.5 The Swivel Joints shall have SS ball bearing with efficient sealing.

2.2.6 The monitor shall be variable flow adjustment type and it should be
possible to set all three flow rates easily and quickly at site by the operator.

2.2.7 There shall not be any flanged joint on the monitor body, except one at
base flange. Other Joint between monitor body & nozzle shall be threaded
type. Monitor body shall be single cast without welded joints and tubing.

2.2.8 A pressure gauge to indicate the inlet pressure shall be fitted on the
monitor body near inlet of nozzle. Pressure drop across the monitor shall
be less than 10 PSI.

2.2.9 A drain connection with valve shall be provided near the base flange.

2.2.10 Monitor will be painted with Paint – RAL 3000, two part polyurethane
coating.

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2.2.11 The monitor shall be so designed as to resist the nozzle reaction forces
during operation and shall be capable of being handled by one person.

2.2.12 It should be possible to operate the monitor at 10.5 Kg/cm2 pressure at

Inlet flange.

3.0 MATERIAL OF CONSTRUCTION

Item/Part Material of Construction
Nozzle SS316 L/Brass
Monitor Body SS316 L /Cast Brass
Flange SS316 L /Brass
(150 LBS, ANSI B16.5 rating size 100 mm)

Swivel Joints SS316 L /Brass

Worm SS316 L /Brass
Gear SS316 L /Brass

Spindle for worm SS316 L /Brass

Hand-wheels for Nozzle, SS316 L /Brass

horizontal/vertical movement
Pick up tube (3-4 meter length) PVC reinforced with high tensile steel
wire helix as per ASTM D1785 sch.80
Drain connection SS316 L /Brass

Drain valve SS316 L /Brass

Foam strainer(removable type) SS316 L / Brass

Foam Inductor SS316 L / Brass
Foam Inductor Couplings(63 mm) SS316 L / Brass
Nuts/bolts at Monitor SS-316 L/Brass
Mounting Brackets for Motors/Limit SS316 L /Brass
switches.

4.0 APPROVAL
The Monitor, Foam Nozzle and Foam Induction device shall be UL Listed
or FM approved with following features:
i) Nozzle : Non-Aspirating type

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Variable Flow Foam-sum-Water Monitor – Remote Operated

ii) Monitor Flow : 1000 USGPM, 750 USGPM & 500 USGPM
foam solution with single nozzle.
iii) Operating Pressure : 100 PSI
iv) Induction : Aqua Powered variable flow Foam Inductor (single)
suitable for all the three flow rates (1000 USGPM,
750 USGPM & 500 USGPM) of monitor.

Instruments certified for use in the specific hazardous area classification shall
have certifications/ approvals from accredited international agencies like FM,
ENELEC, PTB, BASSEFA, ATEX,etc.

All enclosures for electrical equipment shall be suitable for use in Hazardous
are as per Haz. Area Classification and vendor shall submit valid test certificate
issued by CIMFR & PESO. Flameproof enclosures and instruments which are
manufactures outside India and certified by accredited international authorities
shall also have approval of PESO, India. In case bidder has got only
international approval on hand at the time of bid due date and already applied
for PESO approval, then bidder shall be required to get PESO approval before
despatch of materials. Bidder has to submit undertaking along with bid for that
effect and mention timeline of obtaining PESO approval. Decision of HPCL shall
be final and binding on the bidder in this regard.

ALL DOUBLE COMPRESSION FLP CABLE GLANDS AND PLUGS FOR THE
HVLR AND CONTROL PANEL SHALL BE PROVIDED BY THE VENDOR.
UNUSED ENTRIES SHALL BE FITTED WITH FLP PLUGS.

5.0 REMOTE CONTROL SYSTEM

Remote Control System shall be provided for horizontal and vertical

rotation of the monitor from the flameproof control panel to be supplied
along with the monitor. Jet and spray movement of the monitor nozzle
shall also be remotely from the control panel. The remote control system
shall be electrically operated.

5.1 Control Panel shall have minimum following indication and control
functions for each monitor.

a. Joystick / Push Buttons with indication for up, down, right and left
movements on the nozzle.
b. Push button/joystick with indication for adjustment of spray / jet.
c. Push Buttons with indication for Open/Close of Motor Operated
Isolation valve.
d. Indication Lamps for Power available.

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5.2 Control Panel shall be complete with motor starters consisting of required rating
AC-3 motor duty switch, fuse, contactor and bimetal overload relay to suit motor
rating, motor start / stop push button, selector switch, voltmeter etc. and
suitable structural frame for mounting of the panel.

5.3 Controls panel shall be PLC based & mounted in flameproof enclosure. The
control panel shall be minimum Ex-n / Ex-e / Ex-d type in flameproof enclosure
suitable for Zone -2, Gas group – IIA / IIB with GI sheet canopy. Weather
protection for motor enclosure shall be minimum IP55. FM/UL approved
enclosure for Zone 2 environments will also be acceptable. The
monitor movement & controls shall be programmable by solid state
devices.

PLC shall be suitable for installation in flameproof panel installed outdoor. It

shall work & perform satisfactory in hot & humid atmosphere of coastal area.
PLC system shall have processor & power supply redundancy. Shall have 25%
I/O spare (wired). Power On, System Healthy & Common Fault alarm shall be
provided for remote monitoring.

Control of the rotation, elevation and nozzle pattern (fog – jet) of the
RCM shall be by solid state devices housed in general purpose enclosures
and FM/UL approved for Zone 2 environments.

A solid state Motor Drive unit will contain the following features:

 Solid state is defined as - silicone based devices (microprocessors,

transistors, FET‟s, SCR‟s, etc.)

 There are no arcing or sparking components permitted in the solid state

Motor Drive Unit.

 Directional signal inputs (rotation, elevation & pattern) and corresponding

outputs to the motors are short circuit protected.

 The electrical power to the monitor motors includes electronic current

limiting protection to prevent the motors from operating outside of their
design parameters.

 A microprocessor is used to process logic signals, monitor motor current

and provide motor drive diagnostics.

 Power outputs to the RCM motors are handled by solid state relays or
equal.

5.3 Input power requirement is 240 VAC, 1 Phase, 50/60 Hz, 15 Amp

5.4 Electrical enclosure is either NEMA 4X, or Flameproof

5.5 FM/UL Approved for NEC Class 1, Div 2, Groups B, C & D Locations
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5.6 Motor shall be minimum Ex-n / Ex-e / Ex-d type suitable for Zone – 2, Gas group
IIA / IIB, temperature class: T3. Weather protection for motor enclosure shall be
minimum IP55. All the motors installed at monitor shall comply with
requirements enclosed as Annexure-A.

5.8 4 inch size Motor operated Isolation valve (MOV) shall be supplied along-
with each monitor . Specifications of Isolation valve to be used for MOV
are enclosed as Annexure-B.

5.9 The electrical motor operated valve actuator for the isolation valve shall be
minimum Ex-n / Ex-e / Ex-d type suitable for Zone – 2, Gas group IIA / IIB
& temperature class: T3. Specifications of the Motor operated valve
actuator are enclosed as Annexure – C.
2
5.10 Minimum conductor size for power cable for Control panel shall be 4 mm
copper and all cables between control panel & monitor junction box shall
be 1100 V grade PVC insulated, PVC sheathed, armoured fire retardant
type. The power cables from monitor junction box to monitor motors and
limit/proximity switches shall be flexible fire retardant type.

5.11 Power and Signal cable of 200 meters length for each motor shall
be provided along with the supplies for connection between the monitor
motors and control panel. Flameproof Junction Box, Signal & power cable
of 200 meters length for motor operated isolation valve and common cable
tray for above cables shall be supplied along with each monitor. Power
supply cable from emergency feeder to control panel and shall be under
purchaser‟s scope.

6.0 With pressure of 7 Kg/CM2 (g) at base flange, and Nozzle at 300 to 35 deg. from
horizontal the Monitor shall be capable of giving following performance:

Flow Minimum Horizontal Minimum Horizontal

Water Throw Foam Throw
Unit :USGPM
(Unit : Meters) (Unit : Meters)

1000 70 64

750 60 55

500 50 45

Throw to be calculated on the basis of arithmetic average of throws (measured

from monitor base flange to approximate centre of the footprint) in downwind &
upwind directions at prevailing wind speed (maximum 4 KM/hr.) at the time of

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performance test. Flow Variation of + 5% is permissible.

7.0 WORKMANSHIP AND FINISH

All the parts shall have good workmanship and finish. All burrs and sharp
edges shall be removed. Passages for foam/water shall have smooth
finish.
8.0 PAINTING AND MARKING
8.1 All external surfaces shall be properly shot blasted & provided with two
coats of primer followed by two coats of final paint finish of 50 micron.
8.2 Each monitor shall be clearly and permanently marked (embossed on SS
plate) with the following:
a) Manufacturer's/Supplier‟s name
b) Year of manufacturer
c) Purchaser‟s name and order reference
d) Capacity
e) UL/FM marking for monitor.

9.0 SITE WORK

9.1 During erection, installation and commissioning of the monitor at site,
vendor shall have to depute their supervisor for two days for each
monitor at vendors cost.

9.2 Vendor shall depute the supervisor for assistance in installation/

commissioning within 10 days of call from the purchaser.
9.3 Vendor shall submit per man-day charges of supervision along with the
priced offer for any requirement of supervision during installation beyond
two days. The per man-day charges quoted by the bidder towards
commissioning assistance shall be inclusive of to and fro transportation,
boarding, lodging, fooding and other logistics charges etc

10.0 EXCLUSION
10.1 Fire water mains up-to inlet base of monitors is excluded from vendor‟s
scope.
10.2 Construction of Elevated platform / Structure.
10.3 Power supply up to the monitor control panel.
10.4 Erection of monitor, MOV & Cables.

11.0 INSPECTION & TESTING

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Variable Flow Foam-sum-Water Monitor – Remote Operated

Prior to dispatch from vendor‟s shop the following acceptance tests shall
be carried out by the vendor to the complete satisfaction of owner‟s
representative/HPCL authorized third party inspection agency(TPIA)
without any extra cost to owner. All consumable (e.g. water, foam
compound etc.) shall be arranged by vendor at his own cost. Vendor shall
arrange all facilities to carry out inspection & testing as follows:
 Positive Material Identification (PMI) test for 10% of the
 monitors. 
  Visual and dimensional check.- 100%witness by TPIA 
2
• Hydraulic test of each monitor body at minimum 25 Kg/CM or
hydraulic test pressure specified by UL Listing/ FM approval
whichever is higher. The pressure shall be held for minimum
five minutes without any leakage or distortion of any part.
100% performance by vendor, 20% witness by TPIA

 Performance test shall be carried out for minimum 20% monitors.

In case lot size is less than 10 monitors than minimum 2 monitors
shall be subjected to performance test. Testing shall be carried
out to verify the following performance parameters as per above
 specification : 
a) Measurement of Flow Rates(1000 ,750 & 500 USGPM)
at 7 Kg/cm2 pressure at inlet flange.(Variation of +5% is
acceptable)
b) Horizontal Movement at 1000 USGPM flow manually
by hand wheel & from remote panel.
c) Vertical Movement at 1000 USGPM flow manually by hand
wheel & from remote panel.
d) Jet/spray pattern adjustment manually using lugs/handle
& from remote panel.
e) Checking operation of all limit/proximity switches.
f) Horizontal Throw for foam & water at all the three 1000,
750 & 500 USGPM settings (pressure at inlet flange 7
Kg/cm2)
g) Foam Expansion ratio 1:3 to 1:4.
h) Induction rates at all the three1000, 750 & 500 USGPM
settings.
i) Smooth functioning of Changeover of flows by single
person without using tools.
 Routine test as per applicable Indian Standards for all the
motors. Owner or his representative shall have access at all
reasonable times to vendor‟s works where the appliance or
its accessories are being fabricated and tested. 

VALVE: Every valve, its components and auxiliaries must be subjected to all the
mandatory tests and checks called for in the respective codes, datasheets etc. by the

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manufacturer. Vendor shall arrange Inspection by approved third party inspection

(TPI)agency. The inspection plan shall be approved by the purchaser and shall include:

a) Visual and dimensional inspection

b) Review of material test certificates.

c) Review of radiographs/radiographic reports or any other NDT tests wherever

applicable as per data sheet.

d) Strip check is required for 1% of total ordered qty. of valves (min.1No.) Samples for
strip check shall be selected at random and shall generally be in the highest size in the
lot.

e) Functional / operational checks for Motorized operation as per the requirements of

the specifications shall be made on each valve.

ACTUATOR: The actuator shall be subject to inspection by Approved TPIA.

Manufacturer shall furnish all necessary information concerning the supply to Owner.
During the course of manufacturing, the purchaser or his authorized representative
shall be free to visit the works and assess the progress of work and the manufacturer
shall render him all possible assistance to do so.

Following routine and acceptance tests shall be carried out at the manufacturers’
works under his supervision and at his own cost for all the actuators.

a) Functional and calibration test for torque and limit switches

b) Response time test

c) Variation of supply voltage

d) Variation of frequency

e) Tests for motor (As per relevant IS/ IEC)

f) Life test

g) Test on output shaft

Tests listed at Cl. nos. (b), (c), (d), (e), (f) and (g) above arethe acceptance tests.

Type test certificates, original drawings referred in certificates and statutoryapproval

certificates and BIS license, where applicable, shall be shown to theinspection agency
on demand. The certificates and BIS license must be valid atthe time of dispatch.

Test certificates of bought-out components shall be shown to the inspectionagency on

demand.

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12.0 Approved Third Party Inspection Agency: BV / DNV/ CEIL/Lloyd’s/ IRS

/UL/TUV/FM

13.0 INFORMATION/DOCUMENTS REQUIRED FROM VENDOR

13.1 WITH BID
a. Details and drawings of the offered foam cum water monitor with bill of
material of monitor & accessories. Details & Drawings shall be in line
with UL listing or FM approval document of the vendor.
b. Performance details like
 Projectile curves of both water and foam streams showing
horizontal & vertical throw for foam and water for all the three
flow rates at Nozzle angles 30, 45, 60 and 75 degree from
 horizontal planes. 
  Foot print (shape, size, area) of both streams at landing zone. 
c. K-factor of the nozzle with supporting calculations.
d. Pressure drop across the monitor.

e) Vendor to give details of the proposed foam induction system and

schematic sketch of the monitor with Foam induction and foam source
along with the technical bid.
f) Valid certificates of UL Listing or FM approval of offered manually
operated foam-cum water monitor, foam nozzle and foam induction
mechanism. NON SUBMISSION OF UL/FM LISTING/APPROVAL SHALL
LEAD TO REJECTION OF BID.
g) General Arrangement Plan (GAP) incorporating the stipulated
inspection and testing requirements.
h) List of electrical spares for remote panel & all motors for three years of
operation.
i) Power requirement and cable size for cabling between emergency feeder
and Control Panel. ( in owner’s scope)
j) Various Cable incl. sizing between control panel and monitor. ( In
vendor’s scope)
k) Make and model of MOV , Gate Valve & Control Panel.
l) Make and Model of PLCs & I/Os.

13.2 AT THE TIME OF SUPPLIES

Three sets of documents (duly certified) to be provided.
a) As built drawings of monitor assembly.
b) Electrical circuit diagrams for junction boxes & remote panel. Cable
termination details & cable schedule.
c) Installation procedure.
d) All inspection and testing records.
e) CMRI/DGMS/PESO/ATEX approval for flame proof enclosures for
motors & panel.
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f) Operating and Instruction manual.

g) Testing and maintenance procedure/manual.

14.0 Commissioning Assistance: The owner shall give commissioning call through e-
mail/ Fax to the vendor, the vendor shall depute their representative within 10
days of the commissioning call failing which owner may proceed ahead with
commissioning through other party at the risk and cost of the vendor. The broad
scope of erection and commissioning includes but not limited to the following:

a. Erection Supervision of HVLR and its components

b. Supervision of cable laying ,terminations and earthing. Earthing Boss shall be

provided for all electrical equipment as per OISD guidelines.

c. Basic Training to Operating Personnel at Site

d. Checking of mechanical and electrical functionality of HVLR and all its

components and providing final clearance for powering up of control panel and
commissioning of monitors.

e. Commissioning spares, if applicable has to be provided by the vendor and the

same is deemed to be included in the quoted rate.

f. Owner shall arrange for erection team with standard tools and tackles required
for erection, cable termination etc. Special commissioning and testing tools, if
required shall be arranged by vendor.

g. The PLC functioning shall be demonstrated during commissioning.

h. Commissioning report to be prepared and jointly signed by vendor and owner.

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Annexure-A

Specification for Motors for Monitor Movement

1. Codes and Standards:

The Motor and their components shall comply with the latest editions of
relevant standard issued by BIS (Bureau of Indian Standards).

In case of imported motors, standards of the country of origin shall be

applicable, if these standards are equivalent or stringent than the
applicable Indian Standards.

The motor shall also conform to the provisions of Indian Electricity Rules
and other regulation currently in force in the country.

In case, Indian standards are not applicable or not covering any part , the
standards issued by IEC /BS /VED /IEEE /NEMA or equivalent agency shall
be applicable.

In case of any contradiction between various referred standards /

specifications / Data sheets and statutory regulations the following order
shall be govern.
- Statutory Regulation
- Tender specification
- Code and standards

3. Operating Conditions:

2.1. Ambient Conditions

Motor shall be suitable for operating satisfactorily in humid and corrosive

atmosphere found in refineries, petrochemical plants. Design ambient
temperature of 45º C and an altitude not exceeding 1000M above mean sea
level shall be taken in to consideration. Motor shall be operable under hot &
humid outdoor weather conditions encountered in India.

3. Frequency and Voltage

Unless otherwise agreed motor shall be designed for operation at rated

output under the following conditions:
a) The terminal voltage differing from its rated value by not more than
± 6 % or
b) The frequency differing from its rated value by not more than ± 3 %
or
c) Any combination of (a) and (b)

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4. Starting

4.1 Unless otherwise specified, motor shall be designed for on-line starting with
suitable protection.
4.2 Motor shall be designed for reacceleration under full load after a momentary
loss of Voltage with residual voltage being 100 % and is in phase opposition
to the applied Voltage.

4.3 Unless otherwise specified, all motors shall be suitable for starting under
specified load conditions with 75% of the rated voltage at the motor
terminals.
5. Performance

- Motor shall be rated for intermittent duty cycle (S3), unless otherwise
specified.

- Unless otherwise specified, the starting current (as % rated current)

shall not exceed 600% subject to tolerance.
- In particular cases, when the starting with reduced voltage is specified,
care shall be taken such that the design values of torque meet the load
requirement while at the same time complying to starting conditions
mentioned above in S.No.4.

6. Construction

6.1 Insulation

Unless otherwise specified the motor shall be with Class „B‟ insulation as a
minimum. In case of motor with class „F‟ insulation the permissible
temperature rise above the specified ambient temperature shall be limited to
those specified in the applicable Indian Standard for class „B‟ insulation.
In case of motors driving equipment with pulsating loads, special care shall
be taken for the joints of rotor bars and end rings to avoid premature failure
due to induced fatigue stress.
6.2 Terminal Box and Cable entries

The terminal box shall be suitable enough to facilitate easy connection of the
cables. The terminal box shall be with necessary clearances, creepage
distances between live parts and between live parts to earth considering air
insulation and without any compound filling.

The terminal box shall be provided with cable lugs and entries for suitable
cable glands corresponding to the size of the specified cable. Nickel plated
brass (or aluminium if specifically required) , double compression type cable

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glands / flame proof cable gland shall be supplied along with the motors for
the specific cable size.

Equipment and accessories shall conform to the hazardous area

classification and the environmental conditions as specified.

The terminal box shall be capable to withstand internal short circuit

conditions without danger to personnel or plant.
Appropriate phase markings as per IS shall be provided inside the
terminal box. The marking shall be non removable and indelible.

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Annexure –B

SPECIFICATION FOR ELECTRICAL MOTOR OPERATED TRIPLE

OFFSET BUTTERFLY VALVE

1. Technical Data Sheet For Triple Offset Butterfly Valve

DATA SHEET – VALVE

1 Valve Size As per BQO

DESIGN PARTICULARS

2 Valve Type Triple Offset high performance , metal to

metal seated, non-rubbing, torque seated,
double flange end, quarter turn, anti-static,
anti-blow out stem arrangement butterfly
valve. Complete actuated valve shall be SIL3
capable certified by third party agencies like
TUV/Exida

3 Mfg. Standard API 609

4 Face to Face As per API 609, Long Pattern

5 Inspection and API 598

Testing

6 Fire Safe API 6FA/API-607-Vth Edition, Zero leakage

before, during after fire.

7 ANSI Class 150#

8 Rated Travel 90 Degrees

9 Flow direction Bi-directional, tight shut-off in either direction

10 Fire Safe Required

11 Anti Static Device Required

CONSTRUCTION

12 Body Cast (in Single Piece)

13 Disc Cast

14 Stem Bar-forged (No casting)

15 End Connection Double flanged as per ANSI B 16.5RF

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16 Flange & finish 150#, RF, 63-125 AARH, smooth finish

MATERIAL

17 Body ASTM A216 Gr. WCB

18 Disc ASTM A216 Gr. WCB/ASTM A105

19 Seal Ring UNS S 31801 Duplex SS+ Graphite

20 Stem ASTM A182F6a

21 Bushing UNS S31600

22 Disc Retainer ASTM A 516

Flange

23 Disc and Bottom UNS 31600+ Graphite

Flange

24 Seat Stellited Gr. 21 Weld Overlay

25 Pin/Nut/Washers SS 316

26 Thrust Bearing SS 316/ Hardfaced /Cobalt based alloy

TESTING

27 Body Hydro-test 1.5 times the flange rating (30 bar #150)

28 Seat Hydro-test 22 bar #150, test duration as per standard

29 Pneumatic Seat NA (6 bar # 150)

Test

30 Leakage Class Zero Leakage/ bubble tight shutoff

required

2.0 Technical Notes for Triple Offset Butterfly Valve

2.1 General

a) Vendor shall supply valves in accordance with the valve

specification sheets along with auxiliaries, if any, such as gear
operator, bypasses, drains etc. wherever specified in the
specification sheets, subject notes and other enclosures.

b) Vendor shall quote in strict accordance with the valve data /

specification sheets, subject technical notes and all other

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enclosures.

c) All codes and standards for manufacture, testing, inspection etc.

shall be of latest editions.
d) The offered equipment shall be brand new with state of the art
technology and a proven field track record. No prototype
equipment shall be offered.

e) Vendor shall ensure availability of spare parts and maintenance

support services for the offered equipment for at least 15 years
from the date of supply. The vendor shall be responsible for
design, engineering and manufacturing of the complete valve to
fully meet the intent and requirements of this specification and
attached data sheets.
2.2 Documentation

Vendor shall submit the following documents with the offer:

a) Manufacture‟s complete descriptive and illustrative catalogue / literature.

b) Detailed dimensioned cross section drawing with parts / material lists,

weight etc.

c) One copy of the valve specification sheets signed as “Accepted” with all
deviations marked clearly.

The following documents shall be submitted after placement of the order:

a) Material test certificates (physical properties, chemical composition &

heat treatment report) of the pressure containing parts shall be
furnished for the valves supplied. Material test certificates for the other
parts shall also be furnished for verification during inspection.

b) Catalogue/Drawings (3 sets) shall be furnished along with delivery for

Purchaser‟s record for all categories/types of valves.
2.3 Design and Construction

a) Valve shall be designed, manufactured, tested, inspected and marked

as per the manufacturing standards, design codes and standards (latest
editions) indicated in the valve specification sheet.
b) Valves shall have flanges integral with the valves body. Flange face
finish shall be normally specified in the valve specification sheet as
serrated finish, 125 AARH.
c) Valve body / bonnet shall be forged / cast as specified. Forgings are

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acceptable in place of casting but not vice-versa.

d) Material of construction of yoke shall be minimum equivalent to body /

bonnet material.

e) Stem shall be forged or machined from forged / roller bar. No casting is

permitted. However, integral stem of cast stainless steel ball valve is
acceptable.

f) Stencilling / hard-facing by deposition shall be minimum 1.6 mm.

g) Renewable seat rings shall be seal welded to prevent loosening of service.

h) Spiral wound bonnet gaskets are to be provided with inner / outer ring
except when encapsulated gaskets type body-bonnet joints are employed.

2.4 Inspection and Testing

a) Every valve, its components and auxiliaries must be subjected to all the
mandatory tests and checks called for in the respective codes, data sheets
etc. by the manufacturer.
b) Vendor shall arrange Inspection by approved third party inspection (TPI)
agency. The inspection plan shall be approved by the purchaser and shall
include :

i. Visual and dimensional inspection

ii. Review of material test certificates.

iii. Review of radiographs/radiographic reports or any other NDT tests

wherever applicable as per data sheet.
iv. Strip check is required for 1% of total ordered qty. of valves (min.
1No.) Samples for strip check shall be selected at random and shall
generally be in the highest size in the lot.

v. Functional / operational checks for Motorized operation as per the

requirements of the specifications shall be made on each valve.
2.5 Marking

a) Vendor‟s name, valve rating, material designation, nominal size, direction of

flow (if any) etc. shall be integral on the body.

b) Each valve shall have a corrosion resistant tag giving size, valve tag /
code no. securely attached to the valve body.
c) Paint of ink for marking shall not contain any harmful metal or metal salts

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such as zinc, lead or copper which cause corrosive attack on heating.

d) Valves shall be painted with one coat of inorganic zinc silicate (minimum
DFT 65 to 75 microns).
2.6 Packing
a) Valve shall be dry, clean and free from moisture, dirt loose foreign
materials of any kind.

b) Valves shall be protected from rust, corrosion and any mechanical

damage during transportation, shipment and storage.
c) Each end Flange Face of valve shall be protected with Wood or Plastic
Cover.

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Annexure -C
SPECIFICATION FOR ELECTRICAL MOTOR OPERATED VALVE
ACTUATOR

1.0 SCOPE

The scope of this specification covers design, manufacture, assembly, shop

testing and supply of electrical motor operated valve actuators intended for
fully / partially opening and closing valve duty. This specification does not
cover the actuators for flow regulating duty.
2.0 CODES AND STANDARDS

2.1 The equipment shall comply with the requirements of latest revision of the
following standards issued by BIS (Bureau of Indian Standards) unless
specified otherwise:

IS 5 Colors for ready mixed paints and enamels

IS 325 Three-phase Induction Motors

IS 2148 Flameproof enclosures for electrical apparatus

IS 4691 Degrees of protection provided by enclosure for rotating

electrical machinery.

IS4722 Rotating electrical machines – Specification

IS 9334 Electric Motor Operated Actuators

IS 13947 Low Voltage Switchgear and Control gear(Parts –1, 3, 4&5)

2.2 In case of imported equipment, the standards of the country of origin shall
be applicable if these standards are equivalent or more stringent that the
applicable Indian standards.

2.3 The equipment shall also conform to the provisions of Indian Electricity
Rules and other statutory regulations currently in force in the country.

2.4 In case Indian standards are not available for any equipment, standards
issued by IEC/ BS/ VDE/ IEEE/ NEMA or equivalent agency shall be
applicable.
2.5 In case of any contradiction between various referred standards / data
sheets and statutory regulations, the following order of decreasing priority
shall govern:
a) Statutory regulations

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b) Tender specification
c) Codes and standards

3.0 GENERAL REQUIREMENTS

3.1 The offered equipment shall be brand new with state of the art technology
and a proven field track record. No prototype equipment shall be offered.

3.2 Vendor shall ensure availability of spare parts and maintenance support
services for the offered equipment for at least 15 years from the date of
supply.

3.3 The vendor shall be responsible for design, engineering and

manufacturing of the complete actuator to fully meet the intent and
requirements of this specification.
4.0 TECHNICAL SPECIFICATIONS

Each MOV actuator shall include the motor, actuator unit, gears, position
indicators, limit switches, hand wheel, electrical starter and controls,
terminal box etc. as a self-contained unit. The actuator shall be sized to
provide adequate torque and/ or thrust to ensure the complete intended
travel of the valve under the worst operating and electrical power supply
conditions.

MOV Actuator shall be minimum Ex-n/Ex-e /Ex-d type suitable for Zone–2,
Gas group IIA /IIB, temperature class: T3 & shall meet the requirements of
IS 2148, IEC 79 or equivalent international standards. Weather protection
for motor enclosure shall be minimum IP55. The manufacturer shall
possess valid test certificates issue by a recognized independent test
house (CIMFR/ BASEEFA/ LCIE/ UL/ FM or equivalent) for the offered
actuators. All indigenous equipment shall conform to Indian standards and
shall have been tested and certified by Indian testing agencies. All
equipment (indigenous and imported) shall also have valid statutory
approvals as applicable for the specified hazardous locations from
Petroleum and Explosives Safety Organization (PESO)/ CCE or any other
applicable statutory authority. All indigenous flameproof equipment shall
have valid BIS license and corresponding marking as required by statutory
authorities.
4.1 Motor

4.1.1 The motor shall be 3-phase squirrel cage induction type unless specified
otherwise in the data sheet. It shall have totally enclosed, non-ventilated
construction.

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4.1.2 The motor shall be designed for valve actuator service with high starting
torque and shall be suitable for Direct on line starting. It shall be rated for
S2-15 minute duty and shall conform to IS 325 or equivalent international
standards.
4.1.3 The motor shall be provided with thermister(s) embedded in the hot spots
of motor winding for protecting the motor.

4.1.4 The motor shall be suitable for starting under required torque with 75% of
rated voltage at motor terminals.
4.1.5 The motor shall have class „F‟ insulation with temperature rise limited to
class „B‟ limits. Motor winding shall be treated to resist corrosive agents
and moisture.
4.1.6 Motor rotor shall preferably be of die-cast aluminum and, if brazed, shall
be free from phosphorous.
4.2 Integral Starter and Control Transformer

The reversing starter, control transformer and local controls shall be

integral with the valve actuator. Solid state control of valve actuator and
electrically isolated interface for remote control requirement shall be
provided, wherever these features exist in manufacturer‟s design.

The integral starter shall be supplied with the following devices:

a) Electrically and mechanically interlocked reversing contactors for

opening and closing operations.
b) Control transformer with necessary tapings and protected with suitable
easily replaceable fuses.

c) Terminal block for external cable connection fully prewired for internal
devices of valve actuator.

d) MOV actuators operating with AC power supply shall be provided with

Instantaneous Phase reversal protection.
4.3 Integral Push Button, Selector switches, Indications and Control
devices

The following local control devices shall be provided integral with the MOV
actuator:
a) Push buttons for “Opening/ Closing/ Stop” or alternatively “Open/ Close”
selector switch.

b) Local/ Off/ Remote selector switch, pad-lockable in each position.

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c) Local continuous position indication from “Valve fully open” to “Valve

fully closed” position, which may be of analogue or digital type using
mechanical indication/ Indicating lamps /LEDs.
4.4 Torque and Travel Limit Switches

Torque limit switches shall be provided to protect the motor from over-
loading by cutting-off the power supply to motor during opening and
closing operations. The limit switches shall be preset. However, it shall be
possible to set the value of maximum torque during closing from 50% to
100% of rated torque of actuators. Travel limit switch shall be provided to
cut-off the power supply to the motor at the end of preset limit of valve
travel. The switches shall be provided with requisite number of potential-
free contacts for valve actuator operation and for indication on remote
panels. Instead of mechanical torque limit switches, magnetic pulse
counter / encoders to measure and control the stroke of actuator may be
provided, wherever this feature exists in manufacturer‟s design.
4.5 Control Facilities

The internal controls and monitoring circuits shall be incorporated within

the integral starter along with transformer and control unit of valve
actuator.
Remote control facility shall be provided as a standard feature. The remote
control circuits shall be powered from internally derived control supply
voltage.
Common status contact indicating the availability of the MOV actuator for
remote control shall be provided by monitoring the following:
- Loss of one or more phases of power supply

- Loss of control circuit supply

- Selector switch in local mode

- Local stop push button set to “Off”

- Motor thermostat tripped

- Any other local fault/ abnormal condition

4.7 Hand Operation

A hand wheel with auto lockable lever shall be provided for emergency
operation of the MOV. The energisation of the motor shall automatically re-
engage power operation.

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4.8 Nameplate

Each motorized valve actuator shall be provided with a stainless steel

nameplate furnishing the following details, attached firmly to it at a place
convenient for reading:
a) Actuator tag number

b) Motor kW rating, motor time rating, motor supply voltage, nominal

motor
phase current, auxiliary switch rating

c) Maximum torque setting

d) Actuator enclosure type, lubricant type

e) Actuator type, wiring diagram number/ catalogue number, actuator

serial number
Apart from the nameplate indicating the Tag Number a separate
nameplate shall also be provided on each actuator to indicate the details
of the testing agency (CIMFR or equivalent), test certificate number with
date, statutory approval
number with date, approval agency for hazardous area application (PESO/
CCE/ DGMS or equivalent), BIS license number with date, applicable Gas
group and Temperature class etc. the nameplate shall be riveted/ fixed
with screws and not pasted. In case any of the standard details listed
above are embossed on the enclosures, the same need not be repeated.

4.9 The enclosure of complete MOV actuator including motor, integral starter,
control transformer unit and all control devices shall have minimum IP-55
degree of ingress protection.
4.10 Wiring and Terminals

All devices provided in the actuator shall be wired up to the terminal block.
The contacts for remote operation and indication shall also be wired up to
the terminal block. Minimum 10% spare terminals shall be provided for
future interlocks. Internal wiring for power and control circuits shall be
appropriately sized for MOV actuator rating. Each wire shall be identified at
both ends using PVC ferrules. The terminal compartment shall be
separated from the inner electrical components of the actuator by means
of a watertight seal so that the actuator electrical components are
protected from the ingress of moisture and foreign materials when the
terminal cover is removed during installation and maintenance.

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4.11 Vendor shall be solely responsible for the compatibility of the MOV
actuator with the valve and for the selection and sizing of various electrical
devices and components in the actuator.

4.12 The actuator shall be provided with minimum three adequately sized cable
entries viz., one for power cable and two for control cables. However, the
actual number of control cable entries in actuator with 2-wire control
system shall be provided based on job requirements as specified in data
sheets/ specification for control systems for MOVs. Suitable double
compression cable glands shall be provided with each actuator for all
cable entries and sealing plugs for all control cable entries. The cable
glands and plugs shall be made of Nickel-plated brass.
5.0 Inspection, testing and acceptance

5.1 The equipment shall be subject to inspection by Owner or by an agency

authorized by the owner. Manufacturer shall furnish all necessary
information concerning the supply to Owner. During the course of
manufacturing, the purchaser or his authorized representative shall be free
to visit the works and assess the progress of work and the manufacturer
shall render him all possible assistance to do so.

5.2 Following routine and acceptance tests shall be carried out at the
manufacturers‟ works under his supervision and at his own cost for all the
actuators.

a) Functional and calibration test for torque and limit switches

b) Response time test

c) Variation of supply voltage

d) Variation of frequency

e) Tests for motor (As per relevant IS/ IEC)

f) Life test

g) Test on output shaft

Tests listed at Cl. nos. 5.2(b), 5.2(c), 5.2(d), 5.2(e), 5.2(f) and 5.2(g) above
are the acceptance tests.

5.4 Type test certificates, original drawings referred in certificates and statutory
approval certificates and BIS license, where applicable, shall be shown to
the inspection agency on demand. The certificates and BIS license must
be valid at the time of dispatch.

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5.5 Test certificates of bought-out components shall be shown to the

inspection agency on demand.
6.0 Packing and dispatch

All the equipment shall be divided into multiple sections for protection and
ease of handling during transportation. The equipment shall be properly
packed for the selected mode of transportation, i.e. by ship, rail or trailer.
The equipment shall be wrapped in polythene sheets before being placed in
crates/ cases to prevent
damage to finish. The crates/ cases shall have skid bottoms for handling. Special
notations such as “Fragile‟. “This side up”, “Center of gravity”, “Weight‟, “Owner‟s
particulars‟, „PO no.‟ etc. shall be clearly and indelibly marked on the packages
together with other details as per purchases as per purchase order.
The equipment may be stored outdoors for long periods before installation. The
packing shall be completely suitable for outdoor storage in areas with heavy rains
and high ambient temperature unless otherwise agreed. In order to prevent
movement of equipment/ components within the crates, proper packing supports
shall be provided. A set of instruction manuals for erection, testing and
commissioning, a set of operation and maintenance manuals and a set of final
drawings shall be enclosed in a waterproof cover along with the shipment.

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