Petroleum Development Oman Version:1

Petroleum Development of Oman

Specification for Fire Water Pumps/Package

Document ID SP-2167

Document
Specification
Type

Security Unrestricted

Discipline Mechanical-Rotating

Owner UEP1R

Issue Date August 2015

Revision 1

Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the whole nor
any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or
transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise)
without prior written consent of the owner.

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Table of Contents

1. Introduction 6

1.1 Scope 6
1.2 Definitions 6
1.3 Responsibility of the Vendor 6
1.4 Abbreviation 7

2. Applicable standards 8

2.1 Company Standards & Specifications 8

2.2 International Standards & Codes (Latest) 10
2.3 Conflicting Requirements 11
2.4 Adherence to Specifications 11

3. General Site Conditions 11

3.1 Local and Environmental Conditions 11

3.2 Area Classification 12
3.3 Available Utilities 12
3.4 Interfaces of Vendor Supplied Equipment with Other Facilities 12

4. Scope of supply 13

4.1 General 13
4.2 Diesel Engine Driven Fire Water Pump 13
4.3 Electric Fire Water Pump 15
4.4 Jockey pumps 16
4.5 Instrumentation & Electrical 16
4.6 Civil 17
4.7 Piping 17
4.8 Engineering Services 17
4.9 Site Services 18
4.10 Exclusions 18

5. Design Requirements 19

5.1 General 19
5.2 Fire Water Main Pump 19
5.3 Jockey Pumps 20
5.4 Diesel Engine 20
5.5 Fuel Day tank, Engine Fuel & Lubrication System 21
5.6 Engine Air Intake, Exhaust & cooling system 22
5.7 Governor and Over Speed device 23

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5.8 Engine starting system 23

5.9 Battery charging system 24
5.10 Coupling and Guard 25
5.11 Base Plate & Equipment Layout 25
5.12 Piping 25
5.13 Noise Control 25
5.14 Electrical 26
5.15 Instrumentation & Controls 26

6. Materials 30

7. Quality Assurance 30

8. Inspection And Testing 31

8.1 General 31
8.2 Factory Acceptance Tests (FAT) 32
8.3 Site Acceptance Test (SAT) 33
8.4 Final Acceptance 33
8.5 Electrical Equipment 33
8.6 Instrumentation 33

9. Preparation for Shipment 34

9.1 Packing Requirements 34

9.2 Crating Identification 34

10. Documentation Requirments 35

11. Installation and Commissioning 36

11.1 Site Supervisions 36

11.2 MANUALS 37
11.3 E-SPIR FORMS FOR SPARE PARTS 37
11.4 SAP 37

12. Training 37

APPENDIX 1-LIST OF PDO APPROVED VENDORS 38

APPENDIX 2- LIST OF SPARES & SPECIAL TOOLS (typical) 39

APPENDIX 3: Table of Compliance 40

APPENDIX 4: Typical Controller arrangement for fire water pump package 42

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1. Introduction
1.1 Scope
This standard specification covers the minimum requirements for the design, engineering,
fabrication, assembly, inspection, testing, painting, transportation to port of entry in Oman and
supervision of erection and commissioning of Fire water pumps/packages with driver
(Engine/Motor) and other auxiliaries. These Fire Water pumps/Package (includes Motor driven
Jockey Pumps, Motor driven fire water pumps, Diesel engine driven fire water pumps along with
controllers, diesel day tank & auxiliaries as minimum) shall be installed at various onshore fields
for Petroleum Development Oman LLC (PDO).
Note: This specification does not covers, the requirements for offshore fire water package installations.

1.2 Definitions
COMPANY : Petroleum Development Oman LLC (PDO)
CONTRACTOR / PURCHASER : Any EPC or EMC/EPCC Contractor / PDO
VENDOR : Supplier of Fire Water Pumps/Packages

1.3 Responsibility of the Vendor

The Vendor shall ensure that the design fully complies with the requirements of this
specification and standards mentioned and shall highlight non-compliances if any, at the tender
stage.
The Vendor shall be responsible for:
 The selection, design, engineering, fabrication, assembly, painting, inspection, testing,
delivery and proper functioning of fire water pumps/packages at site.
 Supervision of installation/ pre commissioning activities.
 Vendor shall ensure that the design of the Fire water pumps/package control algorithms
is clearly documented in an accurate way.
 An effective, unproblematic and efficient interfacing of all necessary subsystems of the
pump packages under the scope of supply.
 The quality control of all sub-orders.
 The Vendor shall submit project quality plan including QA/QC procedure for all stages
of the project.
 The Vendor shall implement and maintain a quality system that complies with ISO
9001:2008, as described in section 7.0 of this specification.
 The Vendor shall select sub-vendors from the Company approved Vendor’s list (AVME)
as per appendix 1(Vendor to consider latest version as available at the time of issuing
requisition/PO).
 All correspondence and documentation shall be in English and all measurements and
units shall be in SI system.
 This specification shall not relieve the Vendor by any means from taking full
responsibility in providing NFPA compliant fire water pump/packages along with the
agreed quality and performance characteristics with PDO.

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1.4 Abbreviation
The words and expressions listed below shall have the meaning hereby assigned to them
respectively for all purposes related to this specification and related documents.

ANSI American National Standard Institute

API American Petroleum Institute
ARM Availability, Reliability and Maintainability
ASME American Society of Mechanical Engineers
AVME Approved Vendors Material & Equipment
BFD Basis for Design
CP PDO Standard Codes of Practice
CQP Contract quality plan
CMS Condition Monitoring system
DCS Distributed Control system
DEM-1 Shell Design Engineering Manual-1
DEP Design and engineering practice (Shell International Petroleum
Technical standards and specifications)

EPC Engineering, Procurement and Construction

EPCC Engineering, Procurement, Construction & Commissioning
EMC Engineering and Maintenance Contracts
E-SPIR Electronic spare parts and interchange ability record
FAT Factory Acceptance Test
FACT Final Acceptance Certificates Test
FCS Field bus Control System (DCS)

FGS Fire & Gas Detection System

GU PDO Standard Guidelines
IEC International Electro-technical Commission
HSE Health, Safety and Environment
HART Highway Addressable Remote Transducer
IPS Instrumented Protective system
ISO International Organisation for Standardization
ITP Inspection and test plan
JB Junction Box
LCP Local Control Panel
LPI/PT Liquid penetration inspection
LV Low Voltage
MCC Motor Control Room
MPI Magnetic particle inspection
MTBF Mean Time Between failure
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MTTR Mean Time To Repair

MV Medium voltage
MT Magnetic Particle Examination
NDE Non destructive examination
NFPA National Fire Protection Association
NPSH Net Positive Suction Head
PAS Process Automation System
PDO Petroleum Development Oman LLC
PEFS Process Engineering Flow Scheme
PFS Process Flow Scheme
PGSC Product Group Services Codes (AVME list)
PR PDO Standard Procedures
PWHT Post weld heat treatment
QA Quality Assurance
QC Quality Control
RCS Remote Control System
RCU Remote Control Unit
RT Radiography test
SAP System application and products
SAT Site Acceptance Test
SP Engineering Specification
SPIR Spare parts and interchange ability record
TPI Third Party Inspector
UEFS Utility Engineering Flow Scheme
UL/FM Underwriters Laboratories/Factory Mutual
UT Ultrasonic testing
VTA Vendor to Advice

2. Applicable standards

2.1 Company Standards & Specifications

The pump package shall be designed, manufactured, inspected, tested and supplied in
accordance with this SP and the latest revision of the following Company Standards,
Specifications, Codes and any project specific requirements.

General

Doc/Spec. No. Description

GU-556 Vendor Documentation.
PDO-SP-2047 Preparation and Contents of Engineering drawings

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PDO-SP-1131 Specification for Handover and As-built documentation

PDO -SP-1246 Painting and Coating of Oil and Gas Production Facilities
PDO-SP-1171 Specification for Quality Assurance of Design, Construction and
Engineering
PDO-UEQ-QCP-035 Guideline for Preparation of ITP
DEP 00.00.20.10-Gen. The use of S.I. Quantities

Civil

DEP 34.28.00.31-Gen Steel structures

Electrical

PDO-SP-1109 Specification for Earthing and Bonding

PDO-SP-1119 Electric Motors-Cage Induction type
PDO-SP-1120 Specifications for High Voltage Switchgear and Control Assemblies
PDO-SP-1121 Specifications for Low Voltage Switchgear and Control Assemblies
DEP 33.66.05.31-Gen. Electric Machines, Cage-Induction Type.
DEP 33.67.01.31-Gen Low voltage switchgear and control gear assemblies
DEP 33.67.51.31-Gen High voltage switchgear and control gear assemblies
STD-4-0302-001 Earthing Detail Skid Base Frame
STD-4-0303-001 Earthing Detail : Earth Bus bar
STD-4-0304-001 Earthing Boss for Steel Structures, Tanks, Vessels etc.
S35.409 RTD installation

Instrumentations

PDO-SP-1206 C&A Standard drawings

PDO-SP-1090 Instrument Signal Lines
DEP 32.31.09.31- Gen Instrumentation for Equipment Packages
DEP 32.10.03.10- Gen Instrument symbols and identification on Process Engineering
Flow Schemes.
DEP 32.37.10.11- Gen Installation of on line instruments
S37.601 Instrument name plates

Mechanical

DEP 30.10.02.35-Gen Technical requirement for the supply of components in 6Mo

Austenitic, 22Cr Duplex and 25Cr Super Duplex Stainless Steel
DEP 30.48.00.31-Gen Protective coating for onshore facilities
DEP 31.29.80.30-Gen Diesel Engines

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DEP 82.00.10.10-Gen Project quality assurance

DEP 31.38.01.10-Gen. Piping Classes, Basis of design
DEP 31.38.01.11-Gen. Piping General Requirements
DEP 31.38.01.15-Gen. Piping Classes – Exploration & Production
DEP 39.01.10.12-Gen. Selection of Materials
DEP 70.10.90.11-Gen. Spare Parts.
DEP 80.47.10.30 Assessment of the Fire Safety of Onshore Installations
DEP 80.47.10.31 Active Fire protection Systems and Equipment for Onshore
facilities

2.2 International Standards & Codes (Latest)

Standard Description
ISO 9001 Quality Systems
ISO 13709 / API 610 Centrifugal Pumps for Petroleum, Petrochemical and Natural
gas Industries
ISO 21049 / API 682 Shaft Sealing Systems for Centrifugal and Rotary Pumps
ISO 5199 Technical Specification for pumps Class-II
ISO 14691 Petroleum and Natural gas industries – Flexible couplings for
mechanical power transmission – General purpose applications
ISO 10474 International Standards. Steel and steel products. Inspection
Documents
API RP 686 Recommended Practice for Machinery Installation and
Installation Design
NFPA 20 Standard for installation of stationary pumps for fire protection
NFPA 70 National Electrical Code, Article 695 of pumps
UL 1247 UL Standard for Safety Diesel Engines for Driving Stationary Fire
Pumps
UL 448 UL Standard for Safety Centrifugal Stationary Pumps for Fire-
Protection Service
FM 1311 Centrifugal Fire Pumps Split-Case Type (Axial or Radial)
HIS 1.6 Rotodynamic Pumps for Hydraulic Performance Acceptance
Tests
ASME B 73.1 /B 73.2 Specification Centrifugal Pumps for Chemical Process
ASME B 16.5 Pipe Flanges and Flanged Fittings
ASME B 31.3 Process Plant Piping Code
IEC 60034 Rotating Electrical machines
IEC60529 IP code for Degree of protection provided by enclosures
IEC60801 Electromagnetic compatibility for industrial process
measurement and control equipment

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IEC 60871 Shunt capacitors for A.C. power systems having rated voltage
above 1000 V Part 1- General
IEC 61439 Low Voltage Switchgear and Control Assemblies
IEC 62271 High Voltage Switchgear and Control Assemblies

EN 953 Safety of Machinery – Guards – General requirements for the

design and construction of fixed and movable guards

2.3 Conflicting Requirements

In case of any conflict between documents relating to this specification or any subsequent
purchase order, the following priority of documents shall be applied:
a) Local laws, decrees and statutory instruments
b) Project specifications and data sheets
c) PDO SPs
d) NFPA 20
e) Design and Engineering Practice (DEP)
f) International Standards
Note: Should any conflict arise either before or after order placement, the Vendor shall
immediately inform the Purchaser/Company for technical resolution of the conflict.

2.4 Adherence to Specifications

The VENDOR shall provide an itemized list of any additional projects specific comments or
exceptions to this specification and its appendices and any referenced standards / DEPs. These
shall be listed on the Table of Compliance provided in Appendix 3 for review by PURCHASER.
Unless referred to in these listings, it will be assumed that all specifications are adhered to and
that they do not have implications with respect to cost, delivery and integrity of the plant. Only
those comments/exceptions that are accepted by the PURCHASER shall be incorporated into
the Project Purchase requisition.
(Specifications referred inside other specifications but not included in section 2.0 are considered Not
Applicable)
3. General Site Conditions
3.1 Local and Environmental Conditions
The following general environmental data shall be used for the equipment design in general
(Refer to specific project conditions for exact details, Below is typical extracted data) .

Ambient Air Temperature

Maximum shade temperature 60°C
Continuous ambient temperature 55°C
Minimum average ambient temperature 5°C
Maximum black bulb temperature 82°C
Maximum daily variation in temperature 25°C
Relative Humidity Max 100%

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Min 4%
Barometric Pressure Maximum 97.7 kPa(a)

Wind Speed
Design wind speed (twice/month) Max 18 m/s
Maximum wind speed (1 hour duration) Min 22 m/s
Maximum gust (3 second duration) 46 m/s
Rainfall
Rainfall design 25 mm/h
Average annual Negligible
Soil thermal resistivity Average 240 °C cm/W
Note: The above maximum shade temperature occurs for short intervals only. Equipment shall
be designed to achieve rated capacity with a shade temperature of 55°C. It shall also be
designed to function safely with a shade temperature of 60°C, but not necessarily at its rated
capacity.

3.2 Area Classification

The fire water equipment shall be installed only in safe (non-classified) area.

3.3 Available Utilities

Available utilities are as follows:
Electrical power supply shall be in accordance with the details specified in motor data sheet.
The following data is provided for design purpose.
HV Power Supply
Electric motor voltage : 6600V AC, +/- 5%, 3 ph, Resistance earthed.
Rated frequency : 50Hz +/- 2%
LV Power supply
Electric motor voltage : 415V AC, +/- 5%, 3 ph, solidly earthed.
Rated frequency : 50Hz +/- 2%
All associated auxiliaries : 240V AC (1Phase+neutral)
Controller power supply
Voltage : 240V AC, +/- 10% UPS supply (1Phase+neutral)
Rated frequency : 50Hz +/- 2%
3.4 Interfaces of Vendor Supplied Equipment with Other Facilities
Mechanical/Process
- Main and Jockey fire Water Pumps : Suction and Discharge flanges
- Pumps casings drain : Drain valves
- Engine Jacket Water cooling : Engine cooling water supply & drain
connections.

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- Engine Diesel Fuel day Tank : Inlet to tank, supply and return of the engine
flanges and drain flanges of the tank.
- Pressure sensing lines : Fire Water Network tap points.

Electrical
- Terminals of LCP (Controller)
- Earth boss or earth bus on Vendor supplied equipment skid
- Terminals of Main and Jockey fire Water Pumps

Control & Instrumentation

- Motor-Pumps/Engine/ Controllers.

Civil
- The foundation of the package will be constructed by others in accordance with design
data supplied by the vendor.

4. Scope of supply
4.1 General

The Vendor shall supply complete Fire Water package, assembled and tested, as defined in
this section.

4.2 Diesel Engine Driven Fire Water Pump

The unit shall comprise all necessary equipment including LCP (controller), valves,
instrumentation, pipe work and fittings in accordance with the documents listed in section 2 fully
mounted and packaged on the skid base plate. The scope of supply for each of the Diesel
engine driven Firewater Pumps shall include, but not be limited to the following

• Horizontal Centrifugal** Firewater Pump.

(** Pump can be radial split (OH) or horizontal split between bearing construction (BB))

• Pump vent with automatic air release valve, terminated above pump base.

• Pressure safety relief valve (Loose supply) at pump discharge with waste cone integral with
sight glass as per NFPA 20.

• Diesel engine driver.

• Flexible coupling/Flexible connecting shaft.

• Guards protecting all rotating items on the package.

• Diesel engine fuel system including loose supply of day tank

• Diesel engine main (24V DC electric) and back-up self-contained starting systems as per
clause 5.8 and 5.9.

• Diesel engine shutdown system.

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• Diesel engine inlet air system with filter/silencer.

• Diesel engine exhausts system including silencer, spark arrester, ducting and all necessary
couplings and supports (The final position of exhaust shall be decided during detail design
based on layout of area).

• Diesel engine self-contained forced feed oil lubrication system including dual thermostat
(control and shutdown) controlled pre-lube and pre-start electric heater.

• Diesel engine cooling loop (i.e Cooling water from pump discharge itself).

• Diesel engine gauge board.

• Diesel engine driven unit fire pump LCP (controller).

• Structural steel skid base plate(s) complete with full length drip pan and flange walled 2”
drain connection or suitable provision for draining of leakage.

• On skid interconnecting piping, pipe supports, filters, valves and fittings for lube oil, drains
and vents terminating and at skid edge with flanged connections. All skid edge
terminations shall be fully anchored.

• On skid interconnecting instrument cabling, instrument cable trays and supports within the
skid limits, instrument cabling terminated at skid edge for Company interface.

• Access and maintenance platform gangways with all associated access ladders and
walkways, all with safety hand rails.

• Instrumentation including isolation/bleed valves, fittings and tubing.

• Thermal Insulation for personnel protection

• Lifting Lugs.

• On skid interconnecting electrical power and control cabling including cable trays, supports
within the skid limits and electrical single point power supply at Controller terminals for
Company interface.

• On skid Earthing and Bonding.

• Special Tools.

• Inspection & Testing (including factory and site acceptance tests).

• Painting and Protective Coating.

• Commissioning and start-up spare parts.

• Packing, Marking and Preservation.

• Documentation as detailed in this specs, NFPA 20 & project specs as applicable.

• Performance and Mechanical Guarantees.

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4.3 Electric Fire Water Pump

The electric motor driven horizontal centrifugal** pump shall be supplied for the Electric
Firewater Pump. The unit shall comprise all necessary equipment including LCP (controller),
valves, instrumentation, pipe work and fittings in accordance with the documents listed in
section 2 fully mounted and packaged on the skid base plate.
(** Pump can be radial split (OH) or horizontal split between bearing construction (BB))
The scope of supply for the Electric Firewater Pump shall include, but not be limited to the
following:

• Horizontal Centrifugal Firewater Pump

• Pump vent with automatic air release valve, terminated above pump base.

• Pump circulation relief valve (Loose supply)

• Electric motor driver

• Flexible coupling

• Guards protecting all rotating items on the package.

• Electric motor driven unit fire pumps LCP (controller) as per clause 5.15

• Structural steel skid base plate(s) complete with full length drip pan and flange walled 2”
drain connection or suitable provision for draining of leakage.

• On skid interconnecting piping, pipe supports, valves and fittings for drains and vents
terminating at skid edge with flanged connections. All skid edge terminations shall be fully
anchored.

• On skid interconnecting instrument cabling, instrument cable trays and supports within the
skid limits, instrument cabling terminated at skid edge for Company interface.

• Instrumentation including isolation/bleed valves, fittings and tubing.

• Lifting Lugs.

• On skid interconnecting electrical power and control cabling including cable trays, supports
within the skid limits.

• On skid Earthing and Bonding.

• Special Tools.

• Inspection & Testing (including factory and site acceptance tests).

• Painting and Protective Coating.

• Commissioning and start-up spare parts.

• Packing, Marking and Preservation.

• Documentation as detailed in this specs, NFPA 20 & project specs as applicable.

• Performance and Mechanical Guarantees.

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4.4 Jockey pumps

The scope of supply for the Firewater Jockey Pumps shall include, but not be limited to the
following:

• Centrifugal Jockey Pump.

• Pump vent with automatic air release valve, terminated above pump drain base

• LV electric motor driver.

• Flexible coupling for horizontal pumps & rigid for vertical Pumps.

• Guards protecting all rotating items on the package.

• Electric motor driven fire water jockey pumps LCP (controller) as per clause 5.15.

• Structural steel skid base plate(s) complete with full length drip pan and flange walled 2”
drain connection or suitable provision for draining of leakage.

• On skid interconnecting piping, pipe supports, valves and fittings for drains and vents
terminating at skid edge with flanged connections. All skid edge terminations shall be fully
anchored.

• On skid interconnecting instrument cabling, instrument cable trays and supports within the
skid limits, instrument cabling terminated at skid edge for Company interface.

• Instrumentation including isolation/bleed valves, fittings and tubing.

• Lifting Lugs.

• On skid interconnecting electrical power and control cabling including cable trays, supports
within the skid limits.

• On skid Earthing and Bonding.

• Special Tools.

• Inspection & Testing (including factory and site acceptance tests).

• Painting and Protective Coating.

• Commissioning and start-up spare parts.

• Packing, Marking and Preservation

• Documentation as detailed in this specs, NFPA 20 & project specs as applicable

• Performance and Mechanical Guarantees.

4.5 Instrumentation & Electrical

Vendor shall provide all skid-mounted field Instrumentation for pumps, motors, engine and
auxiliaries, for the safe and reliable operation of the fire pumps, along with required Junction
boxes, Field Cabling up to Junction Boxes, individual Controllers and Instrument hook-ups.

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Refer Section 5.14 & 5.15 for further design details for electrical & instrumentation
requirements.

4.6 Civil
Civil foundations shall be provided by the Purchaser, based on Vendor’s design information.
The foundation bolts shall be designed by Vendor and supplied by purchaser/contractor.

4.7 Piping
Design, Engineering, procurement of on skid piping, fittings including pipe supports and field
instrument, Fabrication, inspection, hydro testing, certification and guarantee of the piping for
each equipment. Piping shall be terminated with flange connection at skid limit for all tie-in.

4.8 Engineering Services

The pump vendor shall assume overall responsibility for the design and engineering of
equipment supplied, as indicated in this specification. This shall include, but not necessarily be
limited to:

 Design, engineering, selection, inspection and testing, QA/QC, and supply of the
complete scope of supply as per specification and standards.
 Any technical document required for statutory approval shall be furnished by vendor
 Resolve engineering queries related to equipment within scope.
 Providing all documentation for tie-in of mechanical, electrical and instrumentation and
as required by this specification and standards referred to herein.
 Engineering coordination with the Purchaser for package safeguarding, start-up and
control functionality.
 Engineering co-ordination with sub vendors.
 Inspection and testing as specified in this specification and relevant codes and
standards.
 Participation in Purchaser’s design review & HAZOP, operation study & classification
review meetings in Muscat or designated purchaser’s contractor office. The Purchaser
will organize these reviews of the pump package after award of individual purchase
orders or after award of contract. Participation by Vendor’s technical representative and
providing necessary drawings/ documents/ layouts shall be mandatory.
 Resolve/incorporate all action points from Design reviews and HAZOP.
 Performing / coordinating all calculations, analysis etc., as specified in this specification
and the referenced specifications and standards, and / or the equipment data sheets
and where deemed necessary to support technical, engineering decisions.
 Vendor shall provide foundation loading details for the foundation design. Fire water
package GA drawing shall include foundation bolt /Jack plate location & details, centre
of gravity of the equipment, thickness & type of grout.
• Vendor shall provide the maximum maintenance weight.
• Providing requirement for platform and staircase for the access of all the elevated parts
such as Diesel Oil Tank, Engine Muffler, etc.
• Vendor coordination meeting / kick-off meeting.
 Coordinating with the detail design consultant on all design/technical matters.

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 Providing installation and testing guidelines prior to commissioning.

 Certificate for conformity for Electric Motors issued by a recognized authority
 Incorporating and closing out all comments from HAZOP and Design reviews to
company satisfaction without any price implication
 Vendor shall include the design of control, monitoring and safeguarding requirement of
the Fire Water package in their scope.
 Vendor shall provide the electrical load list along with the offer.
 Providing spare parts information as required by PDO

4.9 Site Services

Vendor shall provide the following services:
 Supervise unpacking and installation of vendor supplied items if requested
 Supervise pre-commissioning, commissioning and start-up of the units.
 Supervision of performance and acceptance tests at site.

4.10 Exclusions
The following are excluded from the vendor's scope of work:
 Concrete foundations and all concrete work and grouting
 On-Site installation and grouting of the Base plates.
 Fire water piping up to packages inlet and outlet connections.
 Supply and installation of access platforms, and ladders/staircases for non skid items.
However, Vendor shall indicate all the access requirements in his GA drawing so that
Contractor can supply them.
 Connecting pipe work from the station drains system to the vendor's skid edge
connections for the package drain header.
 HV and LV Switchboard in Switchgear building
 HV and LV cabling from switch gear up to the Motor terminals / Fire water pump
controller and between Motor terminals and the Fire Pump Controllers.
 UPS Unit
 Earthing connection from the 'Earth Boss' or 'Earth bus' on the skid / controller to the
plant main earthing system.
 Instrument cabling from Fire Pump Controllers to the system cabinets for FGS systems
located in the Control Room.
 Sun shelter with overhead lifting facilities above the package skids (Vendor to state
maximum maintenance weights of package components on the drawing)
 Site erection and commissioning.
 Shed lighting

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5. Design Requirements

5.1 General
Fire water Pumps, diesel engine, controller and all associated auxiliaries (e.g. Diesel day tank,
pressure relief valves as applicable, suction and discharge pressure gauges, circulation relief
valve, Automatic vent valve, test flow meter etc, shall be UL Listed or FM approved for fire
pump service in accordance with NFPA 20. The equipment, including auxiliaries shall be
heavy-duty type, designed and constructed for service life of 20 years. The equipment shall be
suitable for emergency operation over its entire service life and shall be designed for immediate
start-up when required. Prototype equipment/components shall not be offered.
If the vendor’s design requires special suction and/or discharge piping arrangements i.e.
straight run requirements etc. in terms of nominal diameter of pipe or nozzle size, the same
shall be informed in advance for review & acceptance.

5.2 Fire Water Main Pump

• Pumps shall be selected so as to furnish the flow not less than 150 % of rated capacity at a
total head of not less than 65 % of the total rated head. The pump and driver shall be suitable
for parallel operation with a minimum continuous head rise of 110% to shut-off. Shut off head
shall not exceed 140% of rated head for any type of pumps. Maximum pressure rating of the
pump shall be considered prior to selection of the pump.
• The Pump shall operate under positive suction head at all times. The margin between NPSHA
and Net Positive Suction Head required (NPSH3) shall be at least 1.5 m at rated flow and at
least 0.5m over the entire specified operating range.
• The circulation relief valve shall be provided for motor driven main Fire Water Pump to
prevent overheating.
• Diesel Fire Water pump shall be equipped with Discharge Pressure Safety Relief Valve for
Engine Speed Control Failure.

• Diesel engine driven pump shall be fitted with mechanism for preventing reverse rotation.

• All cable trays to be manufactured from 316L stainless steel.

• The pumps shall be provided with Gland packing arrangement as a shaft seal.
• The packing material shall be graphite-based with good self-lubricating qualities such that the
integrity of the packing is preserved during start-up of the pumps. Whilst the pumps are
running, the packing lantern rings shall be supplied with an adequate flow of water to preserve
the packing. Minor gland leakage shall be piped to drain and not allowed to drip onto base
plate.
• The Pump bearings shall be self-lubricated by lubricant oil. Vendor to provide PDO/SHELL
equivalent of Lubricant oil during bid. The grease lubricated pump bearings require
Company/CFDH approval.
• The external pressurized lubrication system, if required, shall be provided and mounted by
vendor within the pump skid, inclusive of as a minimum, an oil reservoir, main oil pump, oil
filters, oil cooler, necessary valves, piping and instrumentation.
• Pump pressure retaining parts shall be hydro-tested at 1.5 times the maximum casing design
pressure irrespective of the fire ring main design pressure or 1.5 times the sum of the
pressure developed at the pump’s shutoff head (shut off pressure) plus its maximum
allowable suction pressure, whichever is higher, but in no case shall it be less than 17 barg.

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• In case pump is not self-venting design, The Pump shall be provided with a casing vent and
Casing vent shall be supplied with an automatic air release valve which is used to remove any
trapped air from the pump casing, and the connection to be terminated a skid edge.
• Fire water pump shall be maintained primed full at all times. Automatic air release valve shall
keep the pump and system free of air accumulation in order to minimize corrosion and risk of
damage to pump during start-up thrust and poor pump performance due to air trapped in the pump
casing.
• Pump shall be provided with a casing drain connection with an isolation valve and flange
terminated at the skid edge.
• Pump shall be suitable for remote and automatic starting without operator intervention.
• The Firewater pump package with driver (Electric motor or Diesel Engine) shall be provided
with individual controllers.

5.3 Jockey Pumps

• The design of Jockey pump shall confirm to ASME B73.1/ ISO 5199/Alternatively bidders may
quote for API 610, OH2 type, for the specified “pressure maintenance pump” services & also
the design shall fully comply with NFPA 20. Jockey pumps shall normally be one working and
one installed spare. Alternative designs for jockey pumps such as vertical multistage type pump
of proven vendor specific design can be accepted with Company approval.

• The jockey pumps shall be capable of frequent start and stop as required to maintain the
pressure and shall be able to run continuously. A jockey pump shall start automatically based
on ring main pressure header. The rated flow of each jockey pump shall be the stated flow plus
the specified minimum continuous flow. The jockey pumps shall be fitted with a mechanical
seal. Each jockey pump with electric motor driver shall be mounted on a common base plate.

• The design of Jockey Pump shall be normally be self venting design.

• Single Mechanical seals with necessary seal flushing system shall be used for the jockey
pumps.
• For all jockey pumps, each controller shall have its own individual pressure sensing line
.

5.4 Diesel Engine

• Diesel Engine drivers shall conform to the requirements of NFPA 20 and UL listed and FM
approved diesel engines shall be provided.

• Diesel engine shall be capable of continuous operation at the rated power and speed and at
any speed within the operating range.

• Ambient air temperature and Altitude (atmospheric pressure) affect Diesel engine’s
performance. Hence, appropriate deductions from diesel engine performance rating shall be
made for the environmental conditions specified in project specifications/datasheets, if nothing
is specified, engine de-rating to be considered for 50 deg C ambient.

• Diesel Engine shall have a de-rated power rating of not less than 110% of the maximum pump
demand at rated speed. The maximum pump demand is the sum of

i) Maximum pump absorbed power for the complete operating range including the
test tolerances

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ii) Transmission losses

iii) Auxiliary power take-off.

• Anti-vibration mounting pads shall be provided between the engine and skid.

• The controller must have visual indications and annunciations locally and common fault
FGS/FCS to make personnel aware of occurrence of each of these problem conditions.
• The Diesel driven pumps is controlled from local control & engine control panel. The diesel
driven pump can also be started from FGS.
• For Diesel driven pumps, The controller shall have its own individual pressure sensing line for
auto start-up.

5.5 Fuel Day tank, Engine Fuel & Lubrication System

• Off-skid Double Wall Diesel Oil day tank, shall be supplied, sized & manufactured in
conformance with NFPA 20, UL-142. Fuel day tank shall be adequately sized to store the
engine fuel for minimum of 8 hours continuous operation at rated power. Fuel supply tank(s)
shall have a capacity at least equal to 5.07 L/kW, plus 5% volume for expansion and 5%
volume for sump.
The tank shall be separate from the fire water pump skid. The tank shall be complete with the
following:

i) Its own free supporting steel structure, elevated with suitable fuel supply point
height above engine fuel pump centreline based on engine Manufacturer
recommendations Supply and return piping to the engine fuel system

ii) 2” screened fuel filing connection & additional 2” flange with blind truck filing
connection with isolation valve.

iii) Fuel filter at the inlet of the fill connection of the tank.

iv) Instrument connections for Fuel low level switch and transmitters etc.

v) Vent connection with flame / spark arrestor

vi) 1” ASME flanged supply valve & 1” drain valve with blind flange.

vii) Bolted & Gasketed access Man-way(s).

viii) Cleanout point

ix) Interconnecting wiring between tank level switch and pump controller

In case larger capacity tanks are required if determined by vendor due to prevailing conditions,
such as refill cycle and fuel heating due to recirculation, Before considering larger capacity tank
for diesel oil in vendor’s scope, vendor to provide suitable justification for same.

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• Engine shall be supplied with a fuel oil system complete with pumps (1 Working + 1 standby),
day tank, filters etc. as per vendor standard scheme. Fuel oil system shall include the following
as a minimum:

i) Water and sediment trap cleanout drain

ii) Shaft driven fuel feed pump with pressure relief valve
iii) Fuel feed pump suction strainers and discharge filter (Duplex type)
iv) Shaft driven fuel injection pump
v) Fuel day tank with level indication, alarm

• The engine shall be lubricated by a self contained pressure lubrication system which shall
include the following as a minimum:
i) Shaft driven positive displacement oil pump with external pressure relief valve.
ii) Lube oil coolers shall be sized for continuous rating, where cooling water is not
available, air cooled lube oil coolers shall be provided.
iii) An integral oil reservoir with level indications, fill filter, vent with demister and
flanged drain connection.
iv) Duplex oil filters with replaceable cartridge elements and full flow transfer
valve. The filters shall be equipped with a differential pressure gauge.
v) Lube oil heater, if applicable
• Crankcase Lubrication: The crankcase shall be supplied with breather

• Fuel feed pump suction strainers shall be replaceable, cartridge element type. Filtration of the
fuel shall be capable of protecting the fuel feed pump from any entrained particles that may be
present in the fuel oil.

• Fuel feed pump discharge filters shall be of duplex type with replaceable cartridge element with
full flow transfer valve. A differential pressure gauge shall be provided across the filter to
monitor the filter condition.

• Vendor shall guarantee the engine performance based on the specified diesel fuel quality
provided in the equipment datasheet.

5.6 Engine Air Intake, Exhaust & cooling system

• The diesel engine shall be supplied with an air intake and exhaust system which shall include,
but not limited to the following:

i) Intake air filters

ii) Air Intake silencer to meet the specified noise level.
iii) An automatic combustion air shut-off valve actuated by engine over-speed to be
fitted in the air intake manifold. Operation of the valve shall be independent of
external power sources and shall be capable of manual operation.
iv) Engine exhaust shall be complete with silencer to meet the noise level and equipped
with flame / spark arrestor and rain cap. Vendor shall route the exhaust out of the
Engine shelter to a safe height to comply with local environmental regulations.

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v) All necessary thermal insulation/cladding for personal protection.

vi) Turbocharger
vii) Inlet and exhaust flexible connections, as required.
viii) Emission control equipment shall be an integral part of the engine package. Control
of nitrogen and carbon oxides and un-burnt hydrocarbons in the engine exhaust
should be achieved by the design of the engine combustion system. Catalytic
converters in the engine exhaust should be regarded only as a last resort to meet
the emission requirements and shall be installed only with the agreement of the
Principal.

• Heat exchanger for cooling of engine may be either shell & tube or Plate type. Water for cooling
shall be considered from pump discharge. The additional water to be included for the fire water
duty & returned hot water shall be routed to open drain only.

• Air cooling may be an alternative option. Cooling shall be achieved by an air blast radiator. A
radiator, an engine jacket temperature regulating device, and an engine-driven fan for providing
positive movement of air through the radiator from the diesel engine and the fan mounted on
the engine shaft. Cooling method adopted shall be adequate to remove waste heat from internal
parts of engine. It should also be capable of removing entrapped air from coolant, allow for
coolant expansion, allow for a specific volume of coolant loss, and maintain minimum flow
under varying conditions.

• The engine coolant system shall be provided with filling connections, coolant level checking
facility, sampling connection for coolant and adding makeup water when necessary. The system
shall have a complete drain facility and provision for complete venting.

• Cooling medium shall contain anti-freeze protection.

5.7 Governor and Over Speed device

• Engines shall be provided with a governor capable of regulating engine speed within a range of
10 percent between shutoff and maximum load condition of the pump.

• The engine shall be provided with an over-speed shutdown device. The over speed device shall
be arranged to shut down the engine at speed 20% above rated engine speed.

5.8 Engine starting system

5.8.1 Electric Starting.

• Two (2) sets of nickel-cadmium type batteries shall be supplied for each engine along with
independent individual chargers. Each battery set shall have twice the capacity, at maximum
specified ambient temperature conditions, sufficient to maintain cranking speed through a three
(3) minute attempt to start cycle which is six (6) consecutive cycles of 15 seconds of cranking
and 15 seconds of rest. Thus, the battery set shall have capacity for 12 such consecutive
attempts.

• In operation the two sets of batteries shall be used alternately with changeover being automatic,
except for Manual start. The batteries shall normally be on a continuous charge with the charger

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maintaining the batteries in fully charged condition at the same time supplying any continuous
standby load.

• Batteries shall be sized on a calculated capacity of 72 hours of standby power followed by three
15–second attempt-to-start cycles per battery unit, without ac power being available for battery
charging. Battery shall be protected against the effects of over voltage, under voltage and over
charging in accordance with the battery manufacturer’s recommendation. Each battery unit shall
be rated for 125% of the maximum expected load. Batteries shall have a life expectancy of not
less than 10 years under the specified service condition. The date of manufacture shall be
clearly marked on the exterior surface of each battery. Batteries shall be adequately secured
against displacement, excessive temperature, vibration and mechanical damage or flooding
with water and shall be readily accessible for servicing.

• Batteries shall be sized for the rated performance at the end of the battery design life based on
IEEE 1115, design temperature, de-rating factors as per manufacturer’s recommendation for
above sizing criteria.

• The battery sizing calculation shall be subjected to review by the Principal.

• Diesel engines shall not require any preparation for start-up and shall be capable of quick
starting (immediate start-up to rated duty).

• The starting system shall be able to start the engine when coupled with the driven equipment.
All wiring on the engine, including starting circuitry shall be sized on a continuous duty basis.

5.8.2 Other starting systems-Optional

If necessary, vendor shall recommend alternative starting system after due consideration to the
design data, extreme site ambient conditions and with his proven experience / reference from
the following alternatives as per NFPA 20.
a) Backup Hydraulic starting system

b) Direct Air Injection starting system

The acceptance to optional starting systems shall subject to Company (CFDH) approval.

5.9 Battery charging system

• Battery chargers shall be specifically listed for Fire water pump service.
• Two means for recharging storage batteries shall be provided as below

a) One shall be the generator or alternator furnished with the engine whilst unit is
running.

b) The other shall be an automatically controlled charger taking power from the
single point 240V AC supply provided by the purchaser for the controller.

• The charger shall be rated to recharge the battery to 85 % of nominal capacity within 10 hours
and to 100% in 24 hours, following a discharge at rated load for the specified autonomy time.
The charger shall be sized for supplying the maximum battery charging current while supplying
the connected DC load.

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• An ammeter with an accuracy of 5 percent of the normal charging rate shall be furnished to
indicate the operation of the charger.

• The charger shall be designed such that it will not be damaged or blow fuses during the cranking
cycle of the engine when operated by an automatic or manual controller.

5.10 Coupling and Guard

Flexible spacer type coupling shall be provided for the pumps. Guards shall be provided on all
the moving parts which could be hazardous to the personnel. The coupling guards shall be
removable and made of non-sparking materials.

5.11 Base Plate & Equipment Layout

The pump sets shall have a common base plate for pump, driver and auxiliary equipments.
Base plate shall be provided with lifting lugs for single point lift, a drip tray and a flanged drain
connection. Diagonally opposite earthing connections shall be provided on the base plate.
Vendor also shall provide the package base plate with drip pans for collection of liquids and
spillages if any. The drip pans shall be sloped with continuously sloping drainage piping to the
skid edges for connection (by others) to the site drainage system
Vendor shall provide adequate access (Platforms, ladders, grating, non-skid decking etc) to all
items of equipment on the Package that require access for normal operation and maintenance.
Design and layout of the equipment shall take into account, removal and replacement of major
items of equipment without the need for removal of other equipment items on or adjacent to the
Package.

5.12 Piping
• Piping and appurtenances shall be designed, fabricated, installed, inspected and tested in
accordance with applicable standards SP-1173, DEP 31.38.01.10-Gen., DEP 31.38.01.11-
Gen., DEP 31.38.01.15-Gen., ASME B16.5 and this specification.
• Vendor shall carry out Pickling & Passivation for SS and high alloy steel pipe works including all
pipes with relevant flanges, fittings and elbows.
• Drain and vents shall be manifolded with valve and flanged connection so that there is only one
termination for each type duly supported at the skid edge for connection by others.
• Tie-in points shall be clearly marked on the vendor’s piping general arrangment and elevation
drawings.
• Non Ferrous, stainless steel and CRA pipework shall be suitably protected at pipe supports
against crevice and galvanic corrosion. Connection between dissimilar metals shall be avoided..
• All valves shall be accessible from a safe operating position.

5.13 Noise Control

Noise levels for pumps and ancillaries shall not exceed the limit as stated on the equipment
datasheets. Any treatment required to meet the requirements shall be vendor’s responsibility
and shall be subject to Purchaser’s approval.

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5.14 Electrical

The motor starter modules including the protection and metering for HV and LV electric motors
will be located inside the Controller to be provided by pump package vendor. All control logic
shall be built in the respective controller.

The control supply for the controllers shall be fed by redundant 240V AC UPS supply (by
purchaser). The controller shall be designed with suitable changeover arrangement for the non-
synchronized incoming UPS control supplies. Further control supply distribution including any
other voltage required shall be derived by the vendor within the controller.

Electrical power and control supply cabling and termination at motor and controller terminals
respectively shall be provided by the Purchaser.

The voltage at the contactor(s) load terminals to which the motor is connected shall not drop
more than 5 percent below the voltage rating of the motor when the motor is operating at 115
percent of the full-load current rating of the motor. The starter unit, motor and the power cable
shall be sized accordingly.

All interconnecting power and control cables for the fire water system laid above ground shall
be protected by rigid or liquid tight flexible metal conduits.

The name plate tag for power circuit for fire water starter module shall be clear visible red
colour.

No RCU or emergency push buttons shall be provided for motors in the field. If there is any
requirement for testing, same shall be built in the controller located in field.

5.15 Instrumentation & Controls

The control and monitoring of the entire Fire Water Pumps Package shall be through Plant
FGS (Fire & Gas System) and/or FCS (Field bus Control System). All the Pumps shall be
designed to accept remote Start Command (Hardwired) from Plant Fire and Gas System
and/or FCS.

Reliability is a prime consideration to ensure a safe and economic operation of the unit and
therefore industrial high quality instruments that have been well proven in similar application
shall be used. Particular attention shall be paid to the effects of corrosion, vibration and
environmental conditions in the selection and installation of instruments.

The fire water system shall ensure un-interrupted availability of water for automatic extinction
of fire where demanded by the FGS cause and effect diagrams.

5.15.1 Pump Control Panels (Controller)

These are required to monitor the performance of the pump units during duty and standby
conditions and annunciate back to the Control Point for operator information or action.

Each Fire Water Pump as well as Jockey Pump shall be controlled with a dedicated Controller
as required by NFPA and UL/FM. All the Pump Controllers shall be interfaced with Plant FGS
and/or FCS through hardwired cables. The coordination amongst the pumps for start on
demand and automatic pump start on low pressure in the Main Fire Water Headers shall also
be managed by the Plant FGS and/or FCS Systems.

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All controllers shall be of an approved type and shall be in accordance with NFPA 20.
Controller shall be enclosed in a stainless steel cabinet with an ingress protection of at least
IP65 and shall be fitted with an anti-condensation heater.

Working Clearances around Controllers and wiring shall comply with NFPA 70.

The Local Control Panel shall comprise of all pushbuttons, switches, lights for status
indication, matrix type annunciator lamp box, audible alarm, junction boxes, anti-condensation
heater, etc. as required by NFPA requirement. UL/FM requirement shall be approved.

All the Controllers shall be mounted in close vicinity of Fire water Pump skid.
(..............this line deleted by Author, Refer "Errata at last page of this document.......)

For diesel engine driven Fire Water Pump Control, all relays shall be hermetically sealed and
be suitable for 15 to 40 V DC (nominal 24 V DC) to ensure normal operation in the event of
voltage dips during engine cranking.

In designing the controller, due consideration should be given to access for operation and
maintenance, both internally and externally.

The controller design shall be such that even when the engine is started manually, all engine
monitoring channels function, and the over speed protection device is operative.

As a minimum the following functions shall be provided on the controllers: (Refer Appendix 4
for arrangement)

1. UL/FM Approved Diesel driven fire pump controller

a. Crank on battery #1 push button

b. Crank on battery#2 push button
c. Hydraulic/Pneumatic start push button (if applicable)
d. Stop push button
e. Break glass window for emergency start (Completely bypass automatic and manual
controls on emergency)
f. Manual - Off - Auto selector switch (behind the window)
g. Alarm accept / reset push button
h. Annunciation test push button
i. Unit available indication lamp
j. Pump running indication lamp
k. Panel heater on indication lamp
l. Low pressure indication lamp
m. Audible alarm
n. Charging indication & charging failure alarm
o. Engine speed (over-speed Alarm/Trip)
p. Engine Jacket and exhaust Temperature High
q. Engine Coolant level low
r. Engine oil pressure low
s. Engine (fuel level low, fuel filter pressure high)
t. Common fault
u. Weekly Test due

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2. UL/FM Approved Electric motor driven Jockey pump controller with built in motor starter
module

a. Start/Stop push button

b. Break glass window for emergency start (Completely bypass automatic and manual
controls on emergency)
c. Manual - Off - Auto selector switch (behind the window)
d. Alarm accept / reset push button
e. Annunciation test push button
f. Duty/Standby selector switch (as applicable)
g. Motor available indication lamp
h. Control supply available indication lamp
i. Common electrical fault indication lamp
j. Unit available indication lamp
k. Pump running indication lamp
l. Panel heater on indication lamp
m. Low pressure indication lamp
n. Audible alarm

3. UL/FM Approved Electric motor (HV/LV) driven fire pump controller with built in motor
starter module

a. Start/Stop push buttons

b. Pump Start (from FGS and/or FCS)
c. Break glass window for emergency start (Completely bypass automatic and manual
controls on emergency)
d. Duty/Standby selector switch (if applicable)
e. Manual - Off - Auto selector switch (behind the window)
f. Alarm accept / reset push button
g. Annunciation test push button
h. Motor available indication lamp
i. Control supply available indication lamp
j. Common electrical fault indication lamp
k. Unit available indication lamp
l. Pump running indication lamp
m. Panel heater on indication lamp
n. Low pressure indication lamp
o. Audible alarm
p. Weekly Test due

Vendor shall provide list of Interface signals, complying NFPA 20 requirements, between the pump
controllers and Plant FGS and/or FCS.

5.15.2 Package Instrumentation

The Instrumentation design requirements of the Package Panel and the Package
Instrumentation are briefed as below and for reference purpose only. However, detailed
requirements shall be developed by detail design CONSULTANT/CONTRACTOR in their
Purchase Specifications for Fire Water Pump Package.

It is VENDOR’s responsibility to identify the instrumentation required for the safe, efficient and
reliable operation of package.

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All instrumentation and control design shall conform to:

• Project Specific Control & Automation Philosophy

• Specifications for Instrumentation/Interface for Package Units (if applicable)
• Project specific individual specification for all applicable Instruments (if any)
• Applicable SHELL DEPs.
• International standards referenced in the above referred specification and other
documents referenced in the Purchase Specifications.

The instrumentation shall be designed for automatic operation with minimum operator
intervention and with all Instruments & Instrument Systems necessary to operate the
equipment Package. The following criteria shall be applied in the design:
• VENDOR shall supply the entire required Package Instrumentation with necessary
installation items such as Junction Boxes, Cables, Cable Trays & Instrument Piping/
Tubing with associated Fittings etc. installed within the battery limit of Skid.
• All indications, alarms and trip inputs (outside of Pump Skid) shall be derived from
Transmitters.
• All Instruments, Automated Valves and Instrument accessories, etc. supplied in this
Package (outside of Pump Skid) shall be from the PDO’s approved vendors list
(PGSC). All Instrumentation and control devices shall be technically acceptable to
CONTRACTOR/PURCHASER. VENDOR shall submit a list of all selected
Instrument manufacturers, Instrument model numbers and specification sheets for
approval by CONTRACTOR/PURCHASER.
• No process switches (such as pressure, temperature, level and flow switches) shall
be used, except where recommended by VENDOR, and have been specifically
approved by CONTRACTOR/COMPANY.
• All Package instruments shall be mounted for easy accessibility.
• All required gauge boards, junction boxes shall be mounted at edge of the skid.
VENDOR shall discuss and agree exact location of skid edge Junction Boxes during
Detailed Engineering stage.
• Package instrumentation equipment shall be of the electronic type except for
mechanical gauges and pneumatically actuated valves
• All Plant-mounted Instruments, e.g. Transmitters, Converters, Control Valves, etc.
and Junction Boxes shall be provided with nameplates. The nameplate shall be
properly secured to the Instrument or its support. The preferred method is by means
of SS316 screws.
• Cable trays wherever required, shall be made of heavy-duty, galvanized mild steel.
The size of the cable tray shall be suitable for the number of cables, which they
intend to carry, including spare space. Trays shall be supported by structures. The
strength and spacing shall take into account the weight of cables they are designed
to carry.
• All cable ties shall be of plastic coated SS material.
• Process connection for Instruments (outside of Pump Skid) shall be in line with DEP
32.37.10.11. Instrument impulse lines & fittings shall be as per DEP 32.31.00.32
Gen. Standard.

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Equipment and components installed within the Panels shall not be mounted directly on the
enclosure walls. The location and grouping of components and auxiliary equipment shall permit
easy identification and access (between AC and DC wiring) for operation, maintenance and
repair. Suitable partitioning between AC power and control sections shall be provided where
necessary to allow adjustment and inspection to be carried out safely.

All panel components shall be installed in such a way that they are clearly visible.

Components requiring inspection or adjustment shall be accessible from floor level.

Control circuit shall use 24VDC/12VDC (as per Vendor’s NFPA approved package) and
Vendor shall derive the 24VDC/12VDC from the Single Point Power Supply made available at
the skid.

The controller shall be suitable for bottom cable entries.

Two earthing points shall be provided for each controller for external body earthing.

All Instrumentation and Controls (including Controller / HMI) shall be designed for the stated
environment condition. Vendor to provide details of the Protective Coatings applied on
Instrumentation/Controller/HMI Electronics. All Electronic Circuits, which are falling outside of
the Pump Skid, shall be tropicalized.

UL listing and FM approval is mandatory.

6. Materials
Pump package material of construction shall be as specified by DEP 39.01.10.12 (SELECTION
OF MATERIALS). Contractor/Vendor shall review the materials and confirm its suitability for the
operating data, fluid characteristics and site ambient conditions. Material of construction shall
normally be specified in datasheets. However, vendor/contractor can select material as per
DEP 39.01.10.12 based on water quality, subject to acceptance from Company or alternatively
vendor to confirm/endorse suitability for Company specified material of construction.

7. Quality Assurance
The VENDOR shall maintain and use a Quality System, which is based on ISO 9001, to control
the work and assure the quality. In addition an approved PDO QA/QC document should be
used and followed.
The VENDOR selected sub-contractors, or suppliers-shall demonstrate that they operate
Quality Systems based on ISO 9001 as applicable to the work.
The VENDOR shall give his sub-contractors or suppliers assistance in attaining the required
standard if necessary. This shall not relieve the VENDOR of his responsibility for the quality of
the finished work.
The PURCHASER reserves the right to audit the VENDOR’s Quality System and this can be
carried out by the PURCHASER or its nominee.
The VENDOR shall assign sufficient full time personnel to the project to ensure the Quality
Assurance / Quality Control System, documented in a Quality Assurance / Control manual, is
maintained and kept up-to-date throughout the duration of any purchase order. VENDOR’s
Quality Assurance / Control System shall become an integral part of any purchase order.
A coordination meeting or a Pre-Inspection meeting (if required) between the VENDOR and
PURCHASER, purchaser’s nominated TPI shall be held after the first stage of drawing
approvals and prior to start of manufacturing.

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8. Inspection And Testing

8.1 General
Inspection and testing requirements shall be in accordance with applicable PDO, DEP and
NFPA/API standards, with the relevant sections of this specification and the data sheets. The
specific tests required for a particular pump shall be specified on its datasheet based on a
Criticality Rating established for the application in use. A full String test (if identified in the
project data sheet) shall be generally required for one unit only in case of similar units
(pump/package) of the order. The Vendor shall furnish elaborated ITP and Purchaser shall
review and approve the same for each project.
The PURCHASER reserves the right to inspect every component or item, which will form part of
the pump package. Inspection will be performed by PURCHASER and / or his nominated
representative.
The responsibility for the inspection, certification, etc. of all materials, parts, etc. lies with the
VENDOR.
The PURCHASER shall be given a minimum of 15 working days notice prior to carrying out any
tests on the equipment covered by this specification.
VENDOR (and all sub vendors) shall give the PURCHASER and / or its nominated
representative, without charge, all reasonable facilities and access for the purpose of inspecting
the equipment to ensure that it is manufactured in accordance with the requisition, drawings,
technical specification and QA / QC procedures and practices.

The package shall be inspected for compliance with:

• “Approved for Construction” (AFC) drawings, latest revision. Requirements of the

PURCHASE requisition and correspondence thereafter.
• Applicable standards, which shall also include the sub-referenced standards therein
• Test and inspection plans produced by the VENDOR as part of the contract Quality
Plan.
• Verification of the quoted efficiency values and pump operating characteristics during
performance test.
• All measuring instruments required for shop testing shall be furnished by the VENDOR,
and be supported by valid calibration certification.

All spare parts shall be subject to the same inspection standards and full material certification
as the main order.
All major inspections shall be shown in the ITP plan, Vendor to refer to standard PDO-UEQ-
QCP-035 as guideline for preparing project specific ITP’s.

The inspection shall meet the requirements as per inspection class II of API 610 & below table.

Sr. Part Description Inspection Class

No
I II & III
ISO 10474 (Certificate Type)
1. Pressure Casing (Including bolting) 3.1B 3.1B

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2. Auxiliary piping (including all pressure 3.1B 3.1B

containing components such as fittings,
valve bodies etc.)
3. Impeller/Shaft 3.1B 3.1B
4. Sleeves 3.1B 3.1B
5. Wear Rings 2.1 2.1
6. Throttle bushings 2.1 2.1
7. Mechanical Seals 2.1 2.1
8.. Diffusers 2.1 2.1

Any defects found by the PURCHASER’S inspector shall be rectified in his presence. Where
this is not possible or practical, check lists shall be prepared and signed by PURCHASER’S
inspector stating all ‘pending items’. Copies of these lists shall be sent to the PURCHASER to
enable their subsequent checking.
The pumps and ancillaries shall not be tested or leave the factory, unless the FAT report has
shown to be successful test and before all punch lists are addressed, discovered defects have
been rectified, inspected and approved by PURCHASER’S Representative / Inspector (TPI).

8.2 Factory Acceptance Tests (FAT)

Following FAT requirement to be considered for fire water package with full compliance to
NFPA 20 requirements,

 Hydrostatic test
 Pump performance test
 NPSH Test (If specified in datasheet)
 Diesel engine running test as per ISO 3046 Part 1 (Certified) complying
NFPA 20 Rules
 Diesel engine over speed protection system test
 4-hr complete unit mechanical running test
 Vibration test
 Sound level test
 Control panel function test.
 Electric motor routine test
 Type (Motor) test (Certified)
 Others as per datasheets

All inspections and tests shall be shown in the agreed Inspection and test plan (ITP). ITP shall
be reviewed by rotating, technical safety & QC engineers from the COMPANY.
The other main components such as main driver motor / Engine, the controllers, Day Tank,
loose supplied items and Spare parts shall be inspected as per applicable specifications &
standards at respective manufacturing facilities prior to the final assembly at pump vendor’s
shop

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As a minimum the following shall be guaranteed,

• The pump flow shall be maintained at the flow as specified on the data sheet for the
guarantee point .The head and efficiency shall have zero negative tolerance at this
guarantee point.

• The noise level emissions from the Package shall comply with the noise level
limitations as per data sheets.

• Demonstrate satisfactory Performance of all components with auxiliaries /

accessories.

8.3 Site Acceptance Test (SAT)

The site acceptance test (SAT) must satisfactorily demonstrate that the equipment performs at the
Company’s site in the same manner as demonstrated by the FAT in accordance with the
provisions of NFPA 20. After installation and commissioning at the Company’s site, the SAT shall
be executed for the minimum 4 hours (or to be agreed with purchaser during bid) without any
interruptions. If the SAT is unsuccessful during the determined period, it has to be re-started from
the beginning.

8.4 Final Acceptance

The Vendor shall, following the successful completion of shop performance test and SAT, notify the
Company in writing requesting that the Final Acceptance Certificate to be signed. The application
shall include the signed copies of the FAT documents and SAT results. The Final Acceptance
Certificate shall be signed by the Company or the Company's site representatives who will have to
confirm that the system has successfully passed the Performance Test. Copies of the Final
Acceptance Certificate are required in support of the final system invoice.

8.5 Electrical Equipment

All electrical equipments shall be tested generally in accordance with NPFA 20, relevant SPs and
DEPs listed in this specification. Vendor shall supply the purchaser with the performance, type and
routine test certificates.

8.6 Instrumentation
To ensure that the package performs to specification and is constructed to specification, regular
inspection visit by Company/ Company contractor nominated instrumentation inspector and / or
engineer shall be considered. Final inspection, including witnessing of function tests, shall be
conducted by the Company nominated engineer and the instrumentation inspector. Vendor shall
provide a factory acceptance test (FAT), System integration Test (SIT) and Site acceptance test
(SAT) procedure for the entire Fire Water Pumps package for owner’s approval. All instruments
and systems shall be functionally tested by simulating the final operating conditions of the Fire
Water Pumps package and shall be checked against the vendor schematics and manufacturer's
specifications.
All instrumentation and ancillary equipment shall be verified and tested in accordance with DEP
62.10.08.11-Gen., prior to installation. All instrumentation calibration sheets to be provided.
Following installation, all instrumentation shall be inspected and tested for correct operation as part
of the overall system in accordance with DEP 62.10.08.11-Gen.
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9. Preparation for Shipment

9.1 Packing Requirements

All open ends on the skid and all open ends of loose shipped interconnecting piping shall be
treated with the suitable preservation material and closed off by wooden or plastic blanks and
taped. Small bore connections shall be taped over. Preservation of the packages shall be
suitable for a storage period of at least 6 months.

Pump/package skid shall be packed in a seaworthy close boarded case with a waterproof lining.
The case shall be sufficiently strong to withstand handling and storage.

All precautions shall be taken to prevent ‘brinelling’ of the bearings.

The spare rotor supplied as insurance spares (if specified) shall be packed in a steel container.
The equipment shall be arranged on the skids such that the centre of gravity of the units
coincides as near as possible with the geometric centre. All lifts should be single point unless
adequately demonstrated by the VENDOR that single point lifts are not possible. Adequate
lifting accessories such as lifting beam/frame, slings, shackles etc. (as part of the shipment)
shall be included in the VENDOR’s scope of supply if requested at the enquiry stage.
Completeness of shipment shall be witnessed by the Third Party Authority and a certificate of
complete shipment issued by the VENDOR will be verified against the packing lists. A detailed,
itemized packing list shall be sent to the PURCHASER prior to dispatch. A copy of the same
signed packing list shall be included with the freight. Any shortages at site shall be air freighted
by VENDOR at his expense.

Initial spares shall be packaged in a separate rigid box placed in the case containing the main
equipment.

In general, within Oman, all items shall be transported to site by truck. The majority of roads are
rough, corrugated, dusty desert graded roads. The equipment and packing must be able to
withstand rougher than normal treatment, with greater use made of shock absorbent materials.

The preparation for shipment of equipment and materials shall be in accordance with project
specifications and additional requirements as defined in this section. Special care shall be taken
for the packaging of delicate equipment e.g. the equipment control panel.

9.2 Crating Identification

The exterior of all crated equipment shall be identified in accordance with the purchase order
and, as a minimum, shall include the following:
 Crate dimensions and gross weight.
 Specific lifting and/or storage instructions.
 Crate identification.
 Supplier and Purchaser details.

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 Brief material specification.

 Purchase order number
 Final destination.
A complete packing list in a waterproof sleeve shall be firmly attached to the outside of each
crate. An identical list shall be attached to the inside of the crate.

10. Documentation Requirments

The English language shall be used throughout all the engineering documentation. All
documents shall also be made available electronically to the maximum extent. S.I. units shall
be used throughout. The Vendor shall provide all drawings, design details, commissioning,
operation and maintenance manuals, and other information necessary for the design, erection,
operation and maintenance of the installation. The manuals for operation and maintenance
shall be clear and not open to misinterpretation and shall apply specifically to the installation
supplied. Vendor shall maintain all records at least for a period 15 years in his own archives.
All drawings, purchase orders, manuals, reports, etc. produced by the Vendor under the
conditions of the purchase order are to be recorded on standard schedules which shall include
dates for document submissions to contractor and registers in a format to be agreed by the
Vendor and the Contractor and Company. Engineering documents shall include the
requirements of relevant DEP and/or NFPA 20 standards. Engineering documents submittal
procedure shall be in accordance with standard specification GU 556 & SP-2065.
Operations and maintenance data and installation instructions (including long term storing
procedure), Technical design data (including bearing and wear parts clearances) and FAT test
results (Manufacturer’s design data book), Certification data book including Material
certificates, electrical/instrument certificates, Test certificates.
All manuals shall also be provided in electronic form on CD ROM compatible with Acrobat
Reader, Word for Windows 2007 and all drawings on AutoCAD version 14.0.
In addition to the Vendor's data and drawings required by NFPA 20. The following shall be
provided, as applicable:-

a) Filled-in Table of Compliance

b) ITP
c) Equipment data sheet (Pumps / Motors / Engine / Day Tank / Mech. Seals/ Instruments)
d) Pump performance curve
e) Pump cross sectional drawing
f) Pump set outline drawing
g) Casing relief valve data
h) Air release valve data
i) Pressure relief valve data
j) Pump speed – torque curve
k) Coupling drawing
l) Engine de-rating calculation
m) Engine speed – torque curve
n) Engine outline drawing
o) Muffler drawing

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p) Noise level data sheet

q) Foundation loading data for foundation design
r) Fuel tank general arrangement drawing
s) Utility/ Lubrication list
t) Electrical Load list
u) Battery and charger sizing calculation
v) Electrical motor documentation requirements as per SP-1119
w) UEFS & System PEFS (Supported by Package Vendor)
x) Control description & Philosophy of operation
y) UL/FM name plate drawing for major components
z) Controller GA drawing
aa) Controller wiring schematic diagram
bb) Terminal block diagram for controller
cc) Pump and other auxiliaries test procedures
dd) Material certificates
ee) Pump, Engine and Motor test report, certificates and procedures
ff) Installation operating and maintenance manual
gg) Spare part list
hh) List of alarm and trip settings (Supported by Package Vendor)
ii) Manufacturer record book (MRB)
jj) PDMS Compatible 3D Model files of the Fire Water Pumps package with all accessories for the
plant design review (Supported by Package Vendor).
kk) A production schedule of the complete packages showing delivery dates for all sub Vendors
equipment
ll) Full description and specification of all piping and instrumentation incorporated within the
package.
mm) As applicable, vendor/contractor to provide Detailed Control and Shutdown narrative
(Functional Design Specification), C&E Diagrams, IO list, Logic Diagram, Block diagram and all
other input required by PAS/F&G System to configure / implement the package requirements in
respective system.

nn) Engineering Deliverables format shall conform to CONTRACTOR’s/COMPANY’s format and

VENDOR to obtain the same during Detailed Design.
11. Installation and Commissioning

11.1 Site Supervisions

It is intended the Purchaser will install and commission the Fire Water Pumps package.
Optionally, the Vendor may be requested to supervise the installation, commissioning and start
up in order to satisfy himself that the installation and pre-commissioning activities are carried
out as per his requirements. The Vendor’s supervision shall not be part of scope of supply as
detailed in this specification but will be ordered separately at a later stage by means of a
separate purchase order. Vendor shall provide as an option, supervisory services to check the
installation and commissioning of the pump unit including the guarantee test run. Vendor shall

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indicate the minimum notice that should be provided by Purchaser for undertaking supervision
services at site. The commissioning procedure shall be developed by the Vendor.

11.2 MANUALS
For field commissioning, the Vendor shall provide the results of Fire Water Pumps package
shop tests executed prior to shipment. The Vendor shall provide full installation, start-up,
commissioning and maintenance instructions for the complete package, including details on
settings control and mechanical seal arrangements. Vendor shall provide electronic copy of
manual on CD.

11.3 E-SPIR FORMS FOR SPARE PARTS

Electronic copy of SPIR forms shall be completed by the Vendor for each part included in the
Fire Water Pumps package and shall confirm to the requirements of DEP 70.10.90.11-Gen.
Original part numbers / ordering numbers shall be used. E-SPIR forms shall be issued to
include:
Commissioning spares.
Two Years/Normal operating Spares
Insurance Spares, if specified.

11.4 SAP
Vendor shall submit all as-built information on a SAP compatible format for ease of
downloading the information. Such information would be:
Tag number
Functional description and location
Spare parts
Maintenance strategy/frequency
Reference information/documents
PM check list
Manufacturer Country of Origin

12. Training
If requested the Vendor shall provide training courses including manuals to the owner’s staff on
the installation, start-up, operation and maintenance of the package. Training courses will be
generally held on site.

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APPENDIX 1-LIST OF PDO APPROVED VENDORS

(Refer to PGSC for Fire Pumps)

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APPENDIX 2- LIST OF SPARES & SPECIAL TOOLS (typical)

(Minimum Requirement)
Vendor to recommend his list of spares, however the following list of spares shall be considered as
the minimum acceptable (per each package).
The Vendor shall include these spares within their estimation / Technical submission.
Ref ITEM DESCRIPTION Qty

1 COMMISSIONING AND START UP SPARES- To be endorsed by supplier

also

1.01 Set of pump gaskets. 1 Set/pkg

1.02 Engine fuel filter 1 Set/pkg
1.03 Engine oil filter 1 Set/pkg
1.04 Engine air intake filter 1 Set/pkg
1.05 Engine Fuel Solenoid Valve 1 Set/pkg
2 INITIAL OPERATING SPARES(Two years)- To be endorsed by supplier
2.01 Bearings for each Pump 1 Set/pkg
2.02 Bearings for each Driver Motor 1 Set/pkg
2.03 Set of Packing rings for Main and standby Fire Water Pumps 2 Sets/pkg
2.04 Mechanical seal set for each Jockey Pump 1 Set/pkg
2.05 Engine fuel filter 4 Sets/pkg
2.06 Engine oil filter 8 Sets/pkg
2.07 Engine air intake filter 4 Sets/pkg
2.08 Engine Belts 4 Sets/pkg
Set of pressure and Temperature indicators /Switches/ transmitters
2.09 1 Sets/pkg
for different systems (fuel, air, oil, etc.).
3 OPERATING SPARES - To be endorsed by supplier
3.01 Vendor to Recommend
4 Special Tools- To be endorsed by supplier
4.01 Barring device complete with related wrenches. 1 Sets/pkg
4.02 All special size spanners of open, socket box head, etc. 1 Sets/pkg
4.03 Piston ring compression tool. 1 Sets/pkg
4.04 Adjustable torque wrench with meter covering the range of torque 1 Sets/pkg
wrench values encountered in engine overhauls.
4.05 All special size hub pullers required for engine major overhauls. 1 Sets/pkg
4.06 Any other special tools recommended by Vendor. 1 Sets/pkg
Notes: 1) Here; set stands for full requirement/replacement of packaged unit. (i.e The packaged unit are consisting of
Fire Pumps, Jockey Pumps, applicable motors, engine with their controllers & Associated Accessories)

2) Spares for other items like electrical & instrumentation spares shall be as per manufacturer's recommendation.
3) Operating Spares- for normal operation and day-to-day maintenance during the lifetime of the equipment after the
initial operating period.

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APPENDIX 3: Table of Compliance

The Vendor shall confirm below that the offer complies with all the clauses contained in this
specification or otherwise highlight deviation / exceptions under the clarification column. Vendor can
use separate sheets if space provided in the clarification column is insufficient. Words such as “Noted”
shall not be used.

Client : Petroleum
Development Oman
(PDO) Vendor :
Client Ref. No. : SP 2167 Vendor Ref. No :

Specification Reference Conforms Alternative Clarification

Section Yes / No Yes / No
1.1
1.2
1.3
1.4
2.1
2.2
2.3
2.4
3.1
3.2
3.3
3.4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
5.1
5.2
5.3

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5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
6.0
7.0
8.1
8.2
8.3
8.4
8.5
8.6
9.1
9.2
10
11
11.1
11.2
11.3
11.4
12
APPENDIX 1
APPENDIX 2
APPENDIX 3
APPENDIX 4

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APPENDIX 4: Typical Controller arrangement for fire water pump package

All UL listed Main Fire pump/Jockey Pump controllers to be located as close as practical to the motors
they control and shall be within sight of the motors. Applicable for all HV and LV controllers/Motors.

Typical Sketch

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ERRATA (SP 2167)

1. 9th Line deleted from page 27 of SP-2167 (Version 1).