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REPUBLIC OF IRAQ
MINISTRY OF OIL
SOUTH OIL COMPANY
TENDER DOCUMENTS
ENGINEERING, PROCUREMENT AND CONSTRUCTION OF
SUBSTITUTION THE VALVES FOR ZB-1 DEPOT WITH
COMPLETE CONTROL SYSTEM
(TURN KEY PROJECT)
JUNE - 2014
(REV.0)
]1[
1- INTRODUCTION
This project consist of engineering procurements and construction to substitution all the valves,
consist of all control systems accessories and integrated control room building , the proposal must
cover all engineering design details , supply all the valves and control room materials , installation in
zb-1 depot and supervision for startup & commissioning . The battery limits should be covered all
area shown in attached plot plan, The project should be done as (turnkey project) .
Bidder should visit the site (ZB1-Depot) before submitting his offer and consist the technical offer
the max shorten plan to avoidance any shut down .
2- LOCATION
Iraq-Basrah –ZB-1 Depot
3- ENVIRONMENTAL CONDITION
Ambient temp.
Humidity (November to March) %
Max rain fall per day mm
Max wind velocity
Wind velocity for design
:
:
:
:
:
-5 , 60 °c
80 - 90
200
140 km/hr.
160 km/hr.
4- Codes and Standards:
Design, fabrication and installations of the equipment systems shall be in accordance with goods
industrial practices and in compliance with the latest editions and revisions of the following codes
and standards as applicable:
-American national standards institute, ANSI
-American petroleum institute API, API 6D
-American society of mechanical engineers (ASME) B31.3
-AASHTO-ACT-318-2011M-ASTM
- FLANGES MATERIAL .
- FLANGES DIM.
A105 - N
ASME B16.47 SERIES A , ASME B 16.5
- FITTINGS
ASTEM / ASME A 234: GRAD WPB FOR
CARBON STEEL
OR A860 / MSS-SP75: GRAD WPHY ( 42 – 70 )FOR HIGH YIELD STEEL
- STRUCTURE
A – 36
]2[
- STUDS & NUTS
A 193 / 194 H
-
All piping to be acc. to API 5 L
PSL2 ,A1
-
Low voltage switchgear
IEC 60439- 1
-
Low voltage circuit breakers
IEC 60947- 2
-
Low voltage components
IEC 60947- 4
-
Degree of protection
IEC 60529
-
ACI codes ( American Concert Institute ) for concrete works >
-
ASTM –for testing Materials .
-
ASCE , IBC , UBC .
-
‫المواصفات القياسية العراقية‬.
-
MSS-SP44
-
FIRE TEST API 6FA & ISO 10497
-
EN – 10204-3.2 MILL TEST FACTORY
5 - Technical offer requirements
The offer shall include the following documents:123456789-
Process flow diagram for the complete project.
P&I diagram.
Data sheets for all equipment's and device
Necessary catalogue
Execution period
Execution plan and Description
Vendor list according to SOC requirement.
API & ISO certificate
Bidder should submit a three years' experience of similar past Executed projects
as a part of their technical offer
10- Bidder should submit time schedule for procurements, Shipping, Installation and
commission.
11- The bidder should take into consideration a suitable plan to avoid any shut down
which is very important in technical evaluation.
12- The design code for all the valves from the commitment of the contractor to
avoidance as possible to change the inter connecting pipes.
13- The announcement should done as tow stages technical and commercial .
14- Referring to the structural testing materials laboratory that is must be an approved
and international laboratory.
15- Assembly drawing for valves body and gear box include dimensions,
manufacturers names, material list of parts and all standards .
16 . Quality assurance plan for all equipments .
]3[
6- SCOPE OF WORK
The project is an EPC turnkey- lump sum type
The scope of work of zb-1 depot shall include:
1. Basic & detailed design approved by soc .
2. Supply of all materials and equipment.
3. Hazop study, safety integrity level (SIL) & surge analysis shall be carried out by bidder, any
additions required after HAZOP study & surge analysis or during detail engineering shall be
within bidder scope of supply at no additional cost so bidder shall take this into consideration at
bidding stage and we don’t have as built drawing .
4.
5.
Integrated Control room building.
Control panel for each booster pump and tank devices with remote operation( controlling
,operating, alarming and Start / Stop ,Auto / Manual selecting).
6. Station control Panel for control and operation to all booster pumps , All valves in zubair /1
depots operation and select the receiving & pumping rout & auxiliary system .
7. Marshaling penal for connection cable .
8. Each control panel include enunciator showing All Alarm& trip signal( for modern control &
system PLC&HMI touch screen )
9. 4 HMI with monitoring size 26”(PC) for operation
10. Engineering workstation and maintenance laptop, with All PLC s software including a backup
copy &open license .
11. Replace All control cable and Junction box(New cables should be Hydrocarbon Resistance
cable type)
12. Erection & installation shall be done by bidder.
13. Commissioning, start up (including operating procedure) and test run activities to demonstrate
proper performance of the depot and achieve the required performance guarantees.
14. Start-up and commissioning spare parts, chemicals and lubricants first fill for operation after
commissioning shall be provided by the bidder. A price list of recommended spare parts for two
years operation shall be provided by bidder. SOC shall select the required spare parts for the
bidder to procure.
15. . Bidder shall submit a vendor list for each group of equipment and materials & shall subject to
SOC for study and approval.
16. Supply material, Man powers and construct valve support for all project items according
approved drawings and method of statement.
17. Re prepare the site according approved method of statement and repair all damages.
The works include all testing, QA/QC, and safety activity and requirements
18 . All civil work, electrical , instruments and mechanical should be from contractor responsible.
19. All necessary catalogs for spare part and for maintenance.
20. All cable shall be hydrocarbon resistance with armored.
21. Make all survey works that is required.
22-Make all required soil Investigations.
23- Submit calculations and design drawings for each item for approval.
24.
Submit Method of statement for each items of works and no works will be proceed
before get approval ,include QA/QC , Safety Plan , And note that the works includes all damages
that is happening because of the works and re preparing all area that is changes because of the
work items ( Roads , Walkways ….etc )
25.
For any change works complete as built drawings is required.
26.
the responsibility of the contractor is redesigning and construction basins according to
the new valves especially in operation and maintenance . moreover the responsibility of the
contractor is cutting or replace the pipes if required and shouldn’t change the philosophy of the
operation and should be approved by SOC
]4[
SOC can change or refused any items that is not obeying requirements.
27.
Submit rigging Plan for related items.
28- the mobilization of the all valves substituted from the contractor responsibilities to the
yard is fixed later out of zubair depot .
29 . Reducing oil levels in the tanks to the required level in order to replacing valves and desludging
if they are found after our pumps are stopped of the ability of sucking oil that’s from responsibility of
contractors.
30.Dismanting and removing of all the valves from the contractor responsibilities
7) MAIN PROJECT ITEMS:- Supply and install all the valves with all accessories.
- Civil work for valves foundation, pipes and valves supports, walkway, services platforms ,
control room building ....etc.
- Supply and install main Control system and instrumentation.
- Electrical system:, cabling, earth system, motor operating valves panels ..…etc
- All the valves shall be ball valves excluded (drain valves , some of receiving and pumping valves)
8 ) Origin of Materials
Origins for materials to be) USA, west European( UK , GERMANY , FRANCE , ITALY ,
NORWAY , SWEEDN , CANADA, NETHERLAND , BELGIM , AUSTRIA, DANMARK , FINLAND
, and Japan (.
And should be accepted to SOC. related, certificates and catalogue to be
submitted with the offer . and acc. To attached vendor list.
9 ) Third Party Inspection:3rd party activates are obligation of SOC acc. to contract between SOC and the third party
inspection that have the right to inspect all the materials and reject the defected one during the
manufacturing period and all inspection certificate should be acc. EN 10204 type 3.2 table A1
summery of inspection documents and inspection team of SOC should be visited the valves factory
to follow 3rd party activities.
10) Testing
The contractor should submit test plan for all valves and control system equipment's, tests
program before suitable time for study at least two months before the first scheduled test . the
following tests should be witnessed by SOC engineers and 3rd party .( all the cost will be beard by
contractor ).
11) factory test
]5[
All factory testing should be acc. (ITP) inspection test plan which is prepared by manufacturer and
submitted to SOC to approval before manufacturing (by inspection team and 3rd party) and
schedule time.
12) Spare parts :Spare parts for 2 years operation to mechanics, electric and control for all project equipment's (list to
be submitted with technical offer with priced list)
13) Valves
All valves to be ball valve full bore flange type acc. API 6D face to face, Dim. Acc.to international
standard and site Dim. Valves testing - acc. to API 598.
Body : carbon steel RF FLANGED , stem : 17-4 – PH + ENP OR SS 410 ( 13% CR ) + ENP ,Seats&
BALL : A182 F6 + ENPOR A 182 F316 + ENP
All valves should be motorized type and ball valves excluded ( drain valves , some of receiving and
pumping valves …. etc ) with following specification:
Motorized valve 3ph, 380V,50Hz , Pf=0.85-0.9 , Insulation Class :F,
The scope work includes the design , export packing , shipping and delivery to SOC , Replacement
of old valves with all modification that may be need , erection / installation , local testing and
commissioning for all valves including civil works.
The tendered is allowed to visit our site in Zubair/1 , to obtain by himself on his own responsibility all
information that may be necessary for preparing of offer and detailed design.
The cost of visiting our site shall be at the Tenderer's own expense.
The Tenders shall be submit technical offer without commercial in the first stage
The valve operation shall have tow speeds- 0 – 90% fast speed and go to 100%
Dribble slow speed for valve open / closed operation as per process needs this is applicable as service only .
The size, torque, speed and duration for closed and open power (capacity of the actuator) and wiring
diagram of the actuator according to the valve design and specification.
Motorize 3-phase (380 V – 50 Hz) induction type motor syncropack or Automatic actuator valve actuator
ingress protection
: IP68 – I I2 GE EXDIIBT4 / T3
Ambient Temp.
: ( - 20 – 70 oC)
THERMO START TRIP : 132 C
OPERATING CIRCUIT USING REVESRING CONTRACTOR OR SOLID STATE STARTER MODEL UTILIZING
THYRISTER DREIVE AND Their ASSOCIATED CONTRAL ELECTRONIC
Control voltage (24V AC/DC) (110 V AC/DC), for auxiliary limit switch control voltage (240V AC/ 110 V DC),
with (open-close-stop) push-button and (local remote) switch- (full open + full close) limit switch contacts for
indication for control room.
Duty:
Input Signals:
Feedback signal:
Setting:
Open-Close, short-time duty, according to IEC 60034 (S2- 15 min) class A and
B
Open-stop-close
Open-stop-close, selector switch local-remote, collective fault and 4-20mA
position feedback signal
Non-intrusive, settable at motor control without need of special tools
]6[
Explosion certified :
Enclosure:
Anti-condensation
heater:
Lighting suppressions
External earth stud
Valve mounting:
Motors:
Motor protections:
Motor connections:
Local controls:
Hand Wheel:
Corrosion Protection:
Final color :
Internal connection
IECEX, II2G EXd zone 1 group IIC, temperature class T4/ T3
IP 68, according to EN 60529 against submersion up to 9 M head of water for
96 hours allowing 10 operations
Yes
Yes
According to ISO 5210 with plug sleeve connection to valve shaft
3 Phase 380V AC (+/- 10%), 50 Hz (+/- 2%) insulation according to IEC 85 class
F (155oC)
3 thermal monitoring devices or direct embedded thermal trip in the motor
windings
Internal by plug and socket
Type AUMATIC or syneropack motor controls (contactors), push buttons
OPEN-STOP-CLOSE-RESET, lockable selector switch LOCAL-OFF-REMOTE,
Bluetooth interface and LCD graphic display with plain text and in world
languages including Arabic, diagnosis symbols, graphs and five indication
lights for status information.
Side mounted hand wheel for manual operation. Clockwise operation of hand
wheel shall cause clockwise movement of output drive. Hand wheel shall be
marked with an arrow and the word "CLOSE". Hand wheel engagement shall
be of spring loaded push mechanism type and required manual declutching.
Actuator must provide a switch signal when in manual mode. Under manual
operation, hand wheel shall drive the worm shaft. Self-locking shall be
maintained in hand operation. Hand wheel shall automatically disengage
when the electric motor is energized.
According to EN ISO 12944-2, classification of environments C$. actuators
shall be corrosion protected (KS) with a primer coating and a two layer
powder coating consisting of an epoxy primer coating and polyurethane top
coating with thickness at least 140 µM.
Silver grey similar to RAL 7037
Actuators to be connected with SIMA master station or pack scan can operate
240 valves.
-
MOV shall have two stroke speeds.0 to 90% fast speed and 90 to 100% dribble/ slow speed
for valve open/close operation as per process needs. This is only for the liquid service. The
speed shall be adjustable in field with hand held calibrator unit.
-
numbering and marking for each piece acc to API standard including the necessary data
such as current , power, torque , class , type of materials …..etc
]7[
14) Mechanical list ( quantity req. for each) approximately
.
valve to be supplied with flanges. Gaskets and studs with 2 / nuts, designed acc. to API
standard, dimensions acc. to ANSI standards.
 Tanks (1st stage)
.No
Valve
)inch(D
Class
Type
.Qty
1
2
3
4
5
Inlet & outlet
Balance
Agitator
Main
Shared
36
36
32
36
42
150
150
150
150
150
Gate
Gate
Gate
Gate
Gate
10
10
8
5
5
6
7
Drain
Rain
4
6
Total
150
150
Gate
Gate
40
10
8

Notes
For two tanks
For all the tanks 1st and 2nd
stage
88
Tanks (2nd stage)
Notes
Qty.
20
20
20
5
10
20
10
105
Type
Gate
Gate
Gate
Gate
Gate
Gate
Gate
Class
150
150
150
150
150
150
150
D(inch)
Valve
No.
36
Input &outlet 1
36
Balance
2
20 ,18
Agitator
3
36
Main
4
6
Drain
5
4
Drain
6
6
Rain
7
Total
8
• Booster Pumps (1st stage)
Notes
Qty.
5
Type
Gate
]8[
Class
150
D(inch)
42
Valve
Suction
No.
1
5
5
5
20
Gate
Gate
Ball
150
150
150
36
36
16
Total
Discharge
Recycle
Bypass
2
3
4
5
Type
Gate
Gate
Ball
Ball
Class
150
150
150
150
D(inch)
42
36
36
16
Total
Valve
Suction
Discharge
Recycle
Bypass
No.
1
2
3
4
5
Class
600
600
600
300
D(inch)
30
30
12
20
Total
Valve
Suction
Discharge
Recycle
strainer
No.
1
2
3
4
5
• Booster Pumps (2nd stage)
Notes
Include 1st and 2nd dicharge
Qty.
5
11
5
5
26
(1-1)
 Main Pumps (Turbine)
Notes
Qty.
3
3
3
6
15
Type
Gate
Gate
Gate
Gate
 Relief valves
Notes
Qty.
10
39
4
10
13
2
78
Type
Gate &
Ball
Gate
-
 Suggested Valve
]9[
Class
600
150
150
600
150
150
D(inch)
12
12
6
12
12
6
Total
Valve
Relief
Relief
Relief
felexflo
felexflo
felexflo
No.
1
2
3
4
5
6
7
Notes
Qty.
10
10
8
28
Type
Gate
Gate
Gate
Class
150
150
150
D(inch)
36
36
32
Total
Valve
No.
Input &outlet 1
Balance
2
Agitatior
3
4
)2-1(
 Main Valves (Receiving & Pumping)
Notes
hydraulic
Qty.
Type
Class
D(inch)
600
600
150
600
150
600
300
600
600
600
600
300
150
150
600
600
300
600
300
600
300
48
42
42
30
36
36
36
32
30
26
24
24
24
22
20
20
20
18
18
16
16
1
600
14
3
7
600
300
12
12
7
6
7
1
3
8
2
hydraulic
2
2
1
2
1
5
1
7
1
2
1
1
6
3
Gate
or Ball
80
Total
]11[
Valve
No.
1
2
3
4
5
6
7
8
9
10
Receiving 11
&
12
Pumping 13
14
15
16
17
18
19
20
21
22
23
24
25
The final total valves
Notes
Include (felexflo)
Include (felexflo)
Include (felexflo)
Qty.
7
6
22
8
119
2
2
16
9
5
1
2
1
1
8
10
8
10
1
1
6
3
10
1
26
7
52
36
60
440
Class
600
600
150
600
150
300
600
150
600
150
600
600
300
150
600
150
300
150
600
300
600
300
150
600
600
300
150
150
150
D(inch)
48
42
42
36
36
36
32
32
30
24
26
24
24
22
20
20
20
18
18
18
16
16
16
14
12
12
12
6
4
Total
Note : This is not final total valves , it can be changeable (increase or
decrease) .
]11[
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
(-1
Vendor list
item
Body valves
Actuator valves
control valves and self
regulating valves(a)
relief valves
Electric and instruments
vendors
walton weir pacific
Cameron
dafram
alfa valvole
valvitalia
petrol valve
lcm italia
pbv
grove valves
petrol valves
tyco
cort
kit2
Cleveland industrial valve
Mokvold
w.k.m
Rotork ( UK )
AUMA ( GERMANY )
fisher
masoneilan
yamataky
mokveld
alfa valvole
farris
masoneilan
dresser
anderson crosby greenwood
broady
triangle sempell
alfa valvole
mokveld
panalarm
ashcroft
honey well
yamatake
abb
ronan
fisher rosemount
foxboro
siemens
]12[
cables
bicc(uk)
general cable (spain)
delta(uk)
nexans (france)
cic (france)
batt cables (uk)
motor control centre and
m.v. switch gear
abb(italy)
siemens (germeny)
eaton(usa)
schneider (france)
areva (france)
ge (usa)
fuji (japan)
siemens
allen bradly
GE
Schneider
yokogawa(netherland)
prestigious discovery
telemechanics
plc control
]13[
BREAK DOWN LIST
ITEM
1
2
3
4
5
6
7
8
9
10
DESCRIPTION
UNIT
QTY
basic & detailed design engineering, and fabrication
drawing acc. standard. final, data sheets , assembly
details & plant installations to be submitted in 5 hard
copies & 5 electronic copies .
Piping, fitting, valves, complete, list
Inter connecting piping
Electrical system consisting of the followings:- Actuators
- Motor operating valve panels
- Cable
control cabling with accessories
PLC control panel(all control panels are redundant)
Electrical supply system including:
A. factory acceptance test acc to ITP for 8 persons for 5
days. Complete with full accommodation,
transportation and all expenses.
set
1
lot
1
B. training course for 24 trainees for two weeks at
warehouse manufacturers ( including design ,
maintenance ,mechanical ,electrical and instrument ,
operation engineers , inspection team ) complete with
full accommodation , transportation and all expense.
- civil works( all project)
lot
1
lot
1
lot
1
lot
1
lot
1
set
1
-Interconnecting pipe work(for all project)
12
13
14
- demobilizing works for all the project items
- the commissioning for the project
spare parts for two operation years (mechanical,
electrical and instrumenention.) list should be
submitted
total price USD
]14[
set
lot
lot
set
UNIT
PRICE
TOTAL
PRICE
general conditions to be adhered by contenders
1-
Technical & commercial offers to be submitted in duplicate by the
manufactures or through their general manager or their official deputies
commercial manager sales manager at the same time in a sealed separate
envelope which should be offer ref. , batch no. tech. or commercial offer ,
receipt no. , and the closing date .
2-
Contenders should give detailed pricing as per the attached itemized price
list . Failure to do so will lead ignoring the offer .
3-
Commercial offer to be in u.s.d $ and based on :
full supply and manufacturing and equipments outside iraq as per scope of work and
itemized prices list .
4-
Offers to be submitted before or within the closing date period otherwise they
will be neglected.
5-
Offers submitted should be valid for a period not less than (90) days from
closing date.
6-
Offers contender should be clearly such as delivery terms, execution period,
country of origin, port of shipment, entry point, and beneficiaries. Full name and
address, the advising bank and all other necessary information required for
contracting purposes.
7-
Relevant catalogues, diagrams and data sheets to be submitted if necessary
separately but should refer to our enq. no. tender name and offer ref.
89-
Delivery of materials & equipment cip zb-1 depot .
The complete execution period should be submitted from the date of l/c
opening..
10- Performance bond
a performance bond of (5%) of total a mount of supplied equipments under the scope
of supply subjected in the form of bank guarantee to be issued by supplier or
manufacturers bank through the bank nominated later in favor of s.o.c
this performance bond will be effective after (12 months) from commissioning date .
11- Insurance
the contractor is required to insure all the equipments and materials for value of
110% of the total value of the materials and equipments for the sake of the buyer ,
the insurance will allow for a (3) weeks claims after the arrival of this materials
and equipment to um qasser and unloading them .
12- bid bond
the contractor should submit the bid bond from a well known iraqi bank covered
from a foreign bank .
13- all bank charges inside iraq are to the buyers account and all bank charges
outside iraq shall be to the contractors account. Including all the bonds
services.
]15[
]16[