Technical Specification for Emergency Scrubber system and Exhaust Blower with HEPA

filter

This technical specification defines the requirements for Planning, design, drawing, material procurement,

testing, fabrication, supply, installation, commissioning, training and related pre and post commissioning

support services for “Emergency Scrubber system and Exhaust Blower with HEPA filter” with all accessories.

1. System Description: Equipment to be supplied shall include, but is not limited to: packed bed

scrubbers, recycle/feed tanks, recycle pumps, blower, motors, instrumentation, control, piping, duct

work, structures, standard accessories & spares for three years.

2. Scope of work: The vendor’s scope of work includes planning, design, materials procurement,

fabrication, testing, installation, commissioning, documentation and guarantee of Emergency Scrubbing

system and HEPA Blower with all accessories at BARC site by the vendor. The total scope of work has

been described in the subsequent paragraphs and appendices.

Planning and scheduling of the entire job including security formalities

Formulation and approval of quality assurance plan and work plan.

Design of the scrubber system based on the data provided and site requirements and approval of design.

Layout finalization for equipment and isometric drawings for ducting.

Preparation of fabrication drawings with all technical details and getting the approval of BARC representatives.

Materials procurement, sampling, testing and certification.

Fabrication of the scrubber system including ducting, blower etc.

Procurement of bought out items and certification by BARC representative.

Inspection and testing at vendor’s works.

Safe delivery of the equipment and accessories to BARC site.

Installation and commissioning of the system including supports at BARC site and testing with actual material.

Documentation.

Guarantee of the system.

3. Scope of supply will include the following:

A) Scrubber

ITEM DESCRIPTION Size/Capacity MOC Quantity Packed columns with all necessary internals (e.g., packing, liquid distributor, nozzles, support grid, support plate, hold down grid etc.)

Packed column with random packing and required amount of mass transfer rate.

The column with internals is to be designed based on data provided.

Column: PP 5mm + FRP 10 mm Wet metallic parts: SS304L Accessories: Suitable MOC for application

I No complete with all internals and accessories based on the specifications and approved design.

Feed Tanks Cylindrical tanks with nozzle. (to be at the bottom of column if found feasible)

1.5 kl PP 5mm + FRP 10 mm

1 No

Blowers with motors, covers and standard accessories

Centrifugal blower As per approved design

Blower- PP/FRP as suitable for application Shaft: SS 304 Foundation bolts: SS 304

2 sets. Both to be attached with column, 1 operational and one standby

Recirculation pumps with motors, covers and standard accessories.

Centrifugal pumps As per approved design

Pump: PP/Teflon/PVDF coated Foundation bolts: SS 304

2 sets

MS Supports and mechanical structure properly painted

Supports for the entire system, ducting, blower and other accessories.

As per approved design

Standard MS channels, angles, I-Beams, Epoxy coated. Foundation bolts: SS-304.

1 set as per approved drawing for all equipments.

Ducting with accessories (damper valves, bends, Tees, hoods, flanges, blinds, gaskets etc).

Ducting for collection and routing of off gas to blower through scrubber

As per Annexure 2 and actual routing.

PP 3mm + FRP 3mm (resin bound & UV protected)

1 complete set as per table below.

Vertical standalone exhaust stack with complete support structure and foundation

Total stack height of 15m

As per approved design.

PP 3mm + FRP 3mm (resin bound & UV protected) stack Support Structure: Standard MS channels, angles, I-Beams, Epoxy coated. Foundation bolts: SS-304.

1 No

Piping PP-FRP piping for feeding and

As per approved

PP-FRP pipes and fittings and PP

1 set

recirculation of scrubbing medium.

design. valves

Electrical cables, Starters, interlocks

Cable and trays are to be provided from control panel (~10m dist) of the equipment. Necessary safety interlocks are also to be provided.

As per requirement

1 set

Instrumentation and control, Control panel

Pressure gauges, level indicators, limit switches, zero speed detectors, Liquid flow meters etc., Control panel with all internal relays and circuitry, starters (for blower and pump), all control cabling

As per Approved design

1 set as per approved design

B) Exhaust Blower with HEPA filter

ITEM DESCRIPTION Size/Capacity MOC Quantity

Blowers with motors, covers and standard accessories

Centrifugal blower As per design Blower- SS 304L as suitable for application Shaft: SS 304L Foundation bolts: SS 304

1 Set as per approved design

Ducting with accessories (damper valves, bends, Tees, flanges, blinds, gaskets etc).

Ducting for collection of dust and maintaining slight negative pressure.

As per layout given in Annexure 2 and actual routing.

PVC ducting 1 complete set as per table below.

HEPA filter and

enclosure

Enclosure should be

split type and ‘clamp

on’ or similar

arrangement for the

easy removal of HEPA

filter. With an

attached U-tube

manometer.

As per approved

design

SS 304L spilt box type

enclosure with

flanged end

connected to PVC

ducting.

Foundation bolts: SS

304

1 Set as per

approved design

Wall supported stack Vertical PVC stack

pipe with Cap. (Wall

support available till

the height of 8 m)

13 m stack height PVC stack pipe

1 set as per approved

design

Instrumentation and

control

Differential pressure

gauge, ON/OFF, zero

speed detectors to

be incorporated with

the main scrubber

control panel.

As per Approved

design

1 set as per approved

design

Annexure 1: All the connection points for Scrubber including the expected generation rate, vent size,

nature of vapour etc.

Drawings: Expected ducting layout of the building (In scale) shown with respective connection points

as per the Drawings BARC/UED/AP/SCBR1 and BARC/UED/AP/SCBR2

New Ducting Length

Equipment Duct Diameter New Ducting Length

Blower with HEPA filter Main Duct 8” 25 m

Sub Duct Length 1”

3”

12 m

3m

Scrubber Main Duct 10”

8”

14 m

28 m

Sub Duct Length 1”

3”

6”

40 m

15 m

12 m

Please refer to Drawings (BARC/UED/AP/SCBR1 and BARC/UED/AP/SCBR2) for the proposed ducting layout. The

ducts marked Yellow, blue and black/white corresponds to the existing scrubber ducting of old scrubber,

existing HEPA blower ducting and proposed ducting respectively. The estimation for ducting quantity and

sizing is lump sum only. The quantity/sizing will vary on actual routing and design Calculation (to be submitted

by vendor). Flanges, bends, dampers and blinds etc (not included in the list) are also to be provided as per the

requirement.

No FIM will be issued by BARC for execution of the job. However, space for temporary storage of materials,

water and electricity required for execution of the job will be made available free of cost at the site for

execution of the job if required and available. The vendor has to arrange for all necessary machines and tools

required for fabrication, installation & commissioning and testing at BARC site.

3. Process parameters for Design

A) Emergency(HF/NOx) scrubbing system:

Type Cylindrical vertical packed bed type scrubbing system Gas load/handling capacity 1800 m3/hr Contents Air + Acidic vapors (HF/NOx) Design load Peak load for which the scrubber has to be designed would

be the maximum of either, (whichever is higher)

1. NOx generation rate of 655 g/hr, OR

2. HF generation rate of 2240 g/hr

Stack Discharge limit of various components

1. HF 5mg/Nm3 2. NOx 150 mg/Nm3 3. NH3 30 mg/Nm3 4. Acetic Acid 75 mg/Nm3

Gas density in kg/m3 1.18 Gas temperature in deg C Ambient Design temperature 40° C (min) Operating pressure 12” WC vacuum ( at the point of suction) Design Pressure 18” WC vacuum Scrubbing liquid To be decided by the vendor Pump head & flow rate To be decided by the vendor Solids present in inlet Negligible Effluent treatment Not necessary Desired scheme for scrubbing liquid Recirculation type Type of column Packed column (Random Packing, type to be selected) Working capacity Vendor to design as per loads Column diameter Vendor to design No of transfer units Vendor to design Height of Packed bed Vendor to design Material of constructions PP/FRP ( 5 mm + 10mm, both minimum) Blower capacity 1800 m3/hr at 18” WC (vacuum) gauge for each blower. No of Blowers and MOC 2 No centrifugal blowers, PP/FRP (impeller, casing, all

contact parts) Caustic recirculation pump 2 No centrifugal pumps, capacity – To be decided by the

vendor. PP/Teflon/PVDF coated

Motors(for blower/pump) RPM:1440 for blowers and for pumps (vendor to confirm) Type: 3 phase non flame proof induction motor, squirrel cage. Power: as per the requirement. Voltage: 440 V, 3 phase, 50Hz Insulation: Class B Standard: As per IS: 325 or other equivalent international standard.

Casing: TEFC flameproof casing as per IS: 2148, Group IIA,IIB gases and vapors. Duty: Continuous. Make: Crompton/Siemens/NGEF or equivalent.

B) Exhaust Blower with HEPA filter

Design Load 600 m3/hr Contents Air + Dust Gas density in kg/m3 1.18 Gas temperature in deg C Ambient Initial pressure drop 1” WC Final pressure drop 3” WC Design Face Velocity 1.3 – 2.5 m/s Material of constructions PP/FRP ( 5 mm + 3mm, both minimum) No of Blowers and MOC 1 No centrifugal blowers, PP/FRP Motors(for blower/pump) RPM:1440 for blowers and for pumps (vendor to confirm)

Type: 3 phase non flame proof induction motor, squirrel cage. Power: as per the requirement. Voltage: 440 V, 3 phase, 50Hz Insulation: Class B Standard: As per IS: 325 or other equivalent international standard. Casing: TEFC flameproof casing as per IS: 2148, Group IIA,IIB gases and vapors. Duty: Continuous. Make: Crompton/Siemens/NGEF or equivalent.

5. Design: Complete design based on BARC requirements will be in vendor’s scope. Based on the data provided

in this specification and actual site conditions, the vendor has to perform all necessary calculations to finalize

the sizing and dimensions as well as internal details of the column. The design and calculations (with references

wherever applicable) is to be forwarded to BARC for checking and approval. The vendor will also have to

prepare the relevant drawings with all necessary technical and fabrication details and submit for approval. The

design will include sizing and detailing of components, layout optimization, mechanical design, fabrication

details, support design, electrical cabling, instrumentation, control strategy, preparation of BOM and list and

technical specifications of bought out items ( motors, pump, blower, valves, instruments etc.). Detailed design

basis have been mentioned in process parameter.

5.1 Design Codes: Following codes/references are to be used for design purpose:

5.1.1 Scrubber & Non Metallic Components:

Item Code/Procedure Design of process Exhaust AIGIH Design of Scrubber Standard design handbooks (Ludwig Vol. II, treybal, Perry’s

handbook, 7th edition).

Non metallic materials Applicable Indian standards (e.g. IS: 6746-1994 for resin materials).

Testing Quality control tests: Hardness, laminate, bond strength, weld strength, ultimate tensile strength, glass content, spark test (@ 10kV etc). Blower performance test: IS 4894

Fabrication: BS: 4994-1987 or ASME section X

5.1.2 Metallic Components: Following codes are to be followed for design:

Item Code/Procedure Hexagonal Nut and bolts

ANSI B18.2

Non metallic Gaskets ANSI B16.21 Pipeline color coding IS 2379 Process Pumps ANSI B 73.1

5.1.3 For structural supports following design codes are to be used:

Item Code/Procedure Design IS 800 Loading IS 875 Properties of steel plates, channels, I-beams etc

SP-6 (1), IS 2062

Member connections (by welding)

IS 813,814,815,816

5.1.4 Blower : The blower should be of centrifugal type, low RPM (1440) for low noise. The impeller, casing and

contact parts should be of SS-304L material for Blower and PP/FRP in the case of Scrubber. All standard

accessories are to be supplied. Design of the blower should be as per given requirement. Balancing (static and

dynamic) of the blower shall be carried out as per ISO:1940. Vibration mount as per ISO:2325 to be provided.

Apart from these, relevant applicable codes and standards and good engineering practices are also to be

followed in design and fabrication.

In case of any conflict between any of the code specification and this technical specification, the more stringent

among the two will be applicable on BARC’s discretion.

5.1.5 HEPA filter and housing

A housing with HEPA filter of suitable dimensions should be fabricated and installed. The HEPA along with the

housing should have DOP test certificate. The HEPA filter housing should be fabricated in GI sheet of suitable

thickness duly epoxy painted or powder coated complete with pressure plates, cleats and dampers etc. It

should also be provided with a DOP port. Proper sealing should be ensured between the filter housing and the

filter.

5.2 Submission of Design and Approval: The vendor has to perform all necessary design calculation based on

the data provided above to finalize various dimensions and parameters of the system. the layout design and

ducting routing etc are to be finalized in consultation with BARC representative. The design should include the

followings:

Process design

Layout preparation

System description and principle of operation. Complete part list with model and part numbers.

Mechanical design

Fabrication details

Electrical cable routing

Instrumentation

Control strategy

All design calculations and engineering drawings with all necessary technical details are to be progressively

submitted to BARC for comments/approval.

5.3 Control Strategy:

Indications and alarms:

Inadequate flow of scrubbing liquid Audio visual alarm Scrubbing liquid Tank liquid level low Alarm Exhaust blower not in operation Indication (local/remote)+alarm Rotameter for scrubbing liquid flow rate Indication (local/remote) + alarm Motor trip (blower/pump) Remote indication + alarm

5.4 Interlocks: The following sequence of operation should be ensured through interlocks:

Recirculation pump ON

Adequate flow rate through scrubber.

Blower is ON.

Relay switches are to be provided for further interlocks of the system with other process that should start only after the scrubbing system has been started up fully.

5.5 Layout Finalization for Equipment and Ducting: The layout of the equipment and ducting is to be prepared

by the vendor and to be submitted for BARC representative’s approval. All necessary care is to be taken to avoid

possible fouling with material and human movement while preparing the layout. The layout is to be optimized

for material, sizing, convenience, performance etc. vendor have to visit site for ducting routing finalization.

6 Materials & Materials testing: All materials (metallic and non metallic) are to be procured from a reliable

source and to be tested and approved from a government approved laboratory for chemical composition,

physical properties, corrosion properties etc. All bought out items should be procured from a reputed supplier

and to be tested and certified by BARC representative.

MATERIALS AND TESTING:

6.1 For Non Metallic Components:

ITEM Testing Materials Applicable Indian standards Quality control tests:

Hardness, Laminate, bond strength, weld strength, ultimate tensile strength, glass content, spark test etc. as per IS/ASTM approved methods

6.2 For Metallic Materials: The materials will be checked for composition, mechanical/physical properties and

corrosion properties (for SS materials only). Applicable codes for testing and acceptance norms are listed

below:

ITEM Testing SS pipes and pipe fittings

Chemical Composition: ASTM A 312 Dimensions: ANSI B16.05,36.10,36.19 Mechanical properties: ASTM A312 Corrosion Properties: ASTM A262 practice A

MS structural items

Dimensions: SP (6)-1

All test reports should be from the manufacturer/ a government approved laboratory.

6.3 Testing of Bought Out Items:

Item Testing Blower Performance tests Pump Performance tests Valves Materials, hydrostatic pressure test Motors No load tests, temperature rise test, IR test Electrical cables IR test, continuity test Instruments Accuracy, repeatability, sensitivity Control panel HV test, IR test Starters IR test

All test reports should be from the manufacturer/ a government approved laboratory.

7. Fabrication: The vendor has to fabricate the equipment and fabricated components based on approved

design and QAP. BARC representative will periodically inspect the job at vendor’s shop as per approved QAP.

8. Testing: After completion of fabrication, the major equipment are to be assembled at vendor’s shop and will

be tested with air & water in presence of BARC representative to ascertain design values of flow rates, pressure

drops etc as well as smooth operation of major components (blower, scrubber, pump, motors, starters,

instruments etc). Detail requirements are provided in section 5.

9. Safe Delivery, Installation, Commissioning and testing: After completion of fabrication work, the equipment

and components, as well as structural materials and bought out items are to be safely delivered to BARC site.

Installation of the scrubbing system at the site including the arrangement for necessary manpower and

machineries for lifting the materials to that height comes under the scope of the vendor. Structural materials

are to be erected as per approved design and site requirements. After completion of installation work the

equipment will be commissioned and tested with air + water with all instruments and control system. Vendor

has to establish all design parameters and control logic in simulated condition and also smooth operations of all

components and instruments.

10. Documentation

Drawings, Design basis report and QAP shall be submitted for evaluation and approval. Fabrication can

be started after receipt of approved drawings. After successful completion of the job, the vendor has to

submit bound volumes (4 sets) including the following documents:

Design basis, calculations, sizing and design of the equipment, components and supports.

Approved QAP.

Approved drawings.

As built drawings & complete technical specifications of the system.

Material testing reports and certificates.

Technical specifications and test reports for all bought out items (including motors, pumps, blowers,

instruments & control panels)

Electrical & control circuit diagram.

All inspection and testing reports (internal, external & joint with BARC)

Commissioning procedure &check list.

Operations & maintenance manual.

Any other relevant information.

INCLUSIONS IN OPERATIONAL MANUAL

Manual to be supplied shall include, but is not limited to the following:

System description and principle of operation

Complete parts list with model and part numbers.

Diagrams, illustrations, and cut sheets.

Performance and nameplate data.

Installation instructions.

Procedures for starting, testing, and operating the system.

Operating parameters and methods for proper adjustments.

Steps required to correct or avoid deviations from operating limits, and consequences of such

deviations.

Procedures to start-up following a turnaround, or after emergency shutdown.

Shutdown instructions; short, long term, and emergency.

Diagnostic procedures and trouble shooting guide to be used in the vent of system shutdown or

malfunction.

Instructions and drawings to facilitate maintenance, lubrication and overhaul of the equipment

and ordering of spare or replacement parts.

List of recommended spare parts.

11. Guarantee: The complete system should be covered by a guarantee not less than 12 months after

commissioning for any defect in design, materials, workmanship, performance etc.

12. Offer: The offer should clearly mention the followings:

Previous experience in similar jobs especially in DAE and other reputed Govt. organisations,

Preference will be given on experience in similar jobs.

Company Profile (staff profile, design and workshop facility, sub vendors, if any, etc.)

Proposed suppliers for bought out items (reputed manufacturers only)

Machineries available for site work.

Proposed laboratory for testing and certification of materials.

13. Notes on planning, design, Fabrication, safe Delivery, Installation, Commissioning and trials.

13.1 Planning: A kickoff meeting is to be held with the BARC representatives for detailed understanding of the

process requirements and routing of the ducting in the existing area. Before starting the actual execution of the

job, vendor has to make a detailed planning for execution of the job and submit the bar chart for approval. Also,

the vendor has to prepare a Quality Assurance Plan (QAP) in consultations with BARC engineers and submit for

approval. The vendor has to depute a suitable team for coordination and execution of the job. Only qualified

and experienced technicians should be deployed for execution of the work.

13.2 Fabrication requirements: All fabrication works are to be carried out by qualified technicians based on

approved design only. All materials that are to be used for fabrication should be tested and certified in a

government approved lab. Applicable codes and standards and good Engineering practices are to be followed.

Maximum possible works are to be carried out at vendor’s works and minimum amount of field work should be

carried out. All necessary tests are to be carried out at various stages of fabrication as per approved QAP in the

presence of BARC representative.

13.3 Safe Delivery, Installation and Commissioning: After completion of fabrication works and testing at

vendor’s shop, the materials are to be safely delivered to BARC site by the vendor. All, materials are to be

supplied with proper tagging and numbering. Loading/unloading of the materials and lifting of the materials to

the site will be totally in vendor’s scope including manpower, tools and tackles, machineries etc. The supports

are to be erected at the site by the vendor. Minor civil works may have to be carried out by the vendor for

erection of the structure. After mechanical erection is over, electrical cabling, instrumentation and control

panel jobs are to be carried out.

13.4 Trials: Initial Trials will be taken at vendor’s shop after completion of fabrication of major components. The

system will be assembled and trial will be taken to check the design performance. Commissioning trials will be

taken after completion of installation work at site with air and water. Smooth and safe functioning of all

components as per design parameters have to be established by the vendor. All alarms and indications will be

checked by simulation of the situation. Vendor has to depute his team for carrying out the trials and for

carrying out the necessary modifications, if required.

14. General Conditions:

11.. All quotations must be accompanied by the following information / documents

ii.. Complete technical details of the equipment being offered along with the basic sketch of the

conceptual equipment indicating approximate dimensions.

iiii.. List of customers to whom similar equipment has been supplied especially to Govt.

organizations.

iiiiii.. Facilities available for fabrication, testing, demonstration etc.

Quotations submitted without the above details are not likely to be considered for the evaluation. The

purchaser shall have the right to visit and evaluate fabrication facilities of the supplier and his sub

contractors.

22.. Prompt after sales service during and after guarantee period has to be provided by supplier.

33.. Anything else not specifically mentioned here but necessary for smooth, safe and trouble free operation

will be in vendor’s scope and should be indicated in the offer.

44.. Any minor modifications during the manufacture or commissioning for smooth and trouble free

operation of the equipment shall be done free of charge. Supplier should also have flexible approach to

accommodate any minor changes for betterment of the system.

Equipme

nt

Locat

ion

Sl. No. Vapour

Type

Volume

of

Tank/Eq

uipment

Temp Breathing

in/out rate

or Exhaust

Rate,Nm3/h

r

ACPH

/Diluti

on

rate,

Nm3/h

r

Release Rate,

g/hr

Exhaust type Design Criterion

Scrubber S88-

G

1 H2O 250L Amb. N.A. N.A N.A. Tank vent-Flanged-2” Peak load for which the

scrubber has to be designed

would be the maximum of

either,

1) NOx generation rate

of 655 g/hr

2) HF generation rate of

2240 g/hr

3) NH3 generation rate of

205.3 g/hr

T.B.D = To be decided by the

manufacturer.

2 2N

HNO3

250L Amb. 1.92 T.B.D 0.345(H2O) Tank Vent-Flanged-2”

3,9 Conc.

HNO3

250Lx2 Amb. 1.92 T.B.D 0.141(HNO3),

0.2856(H2O)

Tank Vent-Flanged-2”

4,5,6,10 n-

dodecan

e

250L x4 Amb 1.92 T.B.D 0.23 Tank Vent-Flanged-2”

8 n-

dodecan

e

3.8 m3

Amb. T.B.D T.B.D 1.55 Enclosed Rectangular hood

with openable doors (Perspex)

2200x 860 x 2000mm

9 NOx 250 L 50°C T.B.D . T.B.D 655 Tank Vent-Flanged-2”

S-

88A

11,12 HF 120L x 2 70°C 1.92 0.06 Tank Vent-Flanged

13,14 HF +

NH3

120L x 2 40°C 1.92 T.B.D 18 Tank Vent-Flanged

15,16 NH3 120L x 2 40°C 1.92 T.B.D 18 Tank Vent-Flanged

17,18 NH3 500mm(

Dia.)x 2

40°C 1.92 T.B.D 18 Open-Circular hood with PVC

strip curtain. Only one

functioning at a time.

19,20 NH3 120L x 2 Amb. 1.92 T.B.D 18 Tank Vent-Flanged

21* HF N.A Amb. T.B.D . T.B.D 2240 Elephant Trunk-3”

22* HF N.A Amb. T.B.D . T.B.D 2240 Elephant Trunk-3”

23,25 Misc N.A N.A . N.A N.A N.A Blind Flanged- 3”

24 HF N.A Amb. T.B.D . T.B.D 96.5 Elephant Trunk-3”

26 NH3 N.A Amb. T.B.D . T.B.D 205.3 Elephant Trunk-3”

S88-

1st

27,28,29 Misc N.A N.A . N.A N.A N.A Blind Flanged- 3”

30,31 NH3 N.A Amb T.B.D . T.B.D 205.3 Elephant Trunk-3”

Annexure 1

Annexure 1 (Contd.)

Equipment Loca

tion

Sl.

No.

Vapour

Type

Volume

of

Tank/E

quipme

nt

Temp Connection Type Design Criterion

Exhaust

blower

(HEPA)

S88-

G

1* Dust 18 m3 Amb. Direct Vent AHU to be designed for an

ACPH of 7.

AHU Load = 581 m3/hr

* = Already existing

connection

(2+3+

4 )*

Dust (10+20

+30)=6

0 m3

Amb. Direct Vent

5 Dust 2m3 Amb. Filter Vent-1”

6 Dust 1m3 Amb. Filter Vent-1”

7 Dust 1.4m3 Amb. Filter Vent-1”

8* Misc. 0.6 m3 Amb. Direct Vent-3”

Total AHU Load 83 m3