Tender No: RCC/NR/UPSO-II/ENG/PT-07/19-20

PUBLIC TENDER:- DESIGN, FABRICATION, ERECTION, WELDING, TESTING

AND COMMISSIONING OF 2 NOS. 5000KL IFRVT MOTOR SPIRIT
TANKS (26M DIA. X 14.50M HEIGHT) WITH ALLIED WORKS AT
IOCL MATHURA MARKETING TERMINAL UNDER UTTAR
PRADESH STATE OFFICE-II

8.16 General arrangement drawings and material specification.

8.17 Nozzle orientation drawing.
8.18 Stairway details with orientation.
8.19 Certificate of earthing of tank.
8.20 Calibration charts.
8.21 Radiography films (separately)

ANNEXURE -14
SPECIFICATIONS FOR ALUMINIUM & HYBRID INTERNAL FLOATING ROOF

1.0 GENERAL
This specification defines the minimum requirements for the design, materials, fabrication,
inspection, testing and documentation of an Aluminium Internal Floating Roof as applied to
steel oil storage tanks operating at low pressure
2.0 SCOPE
The Aluminium pontoon type Internal Floating roof shall be of non-contact type as per API
650 Appendix H Section H.2.2.e (latest edition).
3.0 CODES AND STANDARDS
3.1 API Standard 650 Welded Steel Tanks for Oil Storage, Appendix H.
ü API Standard 653 Tank Inspection, Repair, Alteration, and Reconstruction.
ü API Standard 2000 Venting Atmospheric and Low-Pressure Storage Tanks (Non-
refrigerated and Refrigerated)
ü NFPA 11 Low Expansion Foam
ü NFPA 30 Flammable and Combustible Liquids Code.
ü MoEF Guidelines for Controlling Emissions of Volatile Organic Compounds (VOC) from
Aboveground Storage Tanks
4.0 DESIGN
4.1 General
4.1.1 The roof and accessories shall be so designed as to allow the internal floating roof to operate
throughout its normal travel without manual attention and without damage to any part of
the tank or floating roof.
4.1.2 The roof shall be designed and built to float and rest in a reasonably horizontal pattern.
4.1.3 The floating roof shall be naturally buoyant and provide buoyancy to support at least two
times its own weight i.e. 100 % excess buoyancy, and shall remain afloat even in the event of
puncture in 2 adjoining pontoons. Buoyancy is based on a product with a specific gravity of

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 Tender No: RCC/NR/UPSO-II/ENG/PT-07/19-20
PUBLIC TENDER:- DESIGN, FABRICATION, ERECTION, WELDING, TESTING
AND COMMISSIONING OF 2 NOS. 5000KL IFRVT MOTOR SPIRIT
TANKS (26M DIA. X 14.50M HEIGHT) WITH ALLIED WORKS AT
IOCL MATHURA MARKETING TERMINAL UNDER UTTAR
PRADESH STATE OFFICE-II

0.70.
4.1.4 Roof buoyancy shall support at least twice the dead weight of the entire floating roof.
Buoyancy at the rim shall be twice the dead weight at the rim.
4.1.5 All parts shall be sized to pass through a Ø24” diameter tank manhole.
4.1.6 Deck sheets and structural members must be fastened to allow the sheet to be removed
from the topside of the deck.
4.1.7 Pontoons shall not be connected to the support leg system. Pontoons shall be Ø10” or Ø12”
outside diameter. Each pontoon shall be independent & not be connected to another
pontoon.
4.1.8 Pontoons shall have removable/replaceable test plugs. Pontoon sizes of 200 mm only are
desirable.250 mm pontoon sizes may be accepted in exceptional situations.
4.1.9 The Aluminium Internal Floating Roof System shall be offered along with indicative reduction
in Hydro Carbon loss compared to Fixed Roof Tanks and External Floating Roof Tanks
computed as per API approved procedure.
4.1.10 Aluminium Internal Floating Roof should have easy access for operation and maintenance.
Vendor should indicate maintenance procedures, in case of replacement and repairs,
suitable corrosion gauges as per H.6.7 of API 650 Appendix H shall be provided. Complete
description and technical details in form of manuals including detailed operating and
maintenance procedures shall be made available. Vendor shall arrange to attend the entire
checklist / punch list jobs arising out of pre-commissioning activities.
4.1.11 The minimum design point load shall however be kept as per API 650 and thickness of
Aluminum Sheet of Deck should be a minimum 0.51 mm.
4.1.12 All weld joints are to be fully welded and there should not be partial length welding.
Pontoon weld joints to be leak tested with minimum 20 psi (g) air pressure.
4.1.13 Aluminium Internal Floating Roof System should have the following primary features:
a. Provision of centre vent on the fixed roof
b. Roof vents on the fixed roof.
c. Gauge wells
d. Column negotiators
e. Earthing and anti-rotation cable
f. Deck breather valve
g. Man way Approach to top of deck
4.1.14 Vendor to ensure that no where Aluminium should come in contact with tank carbon steel
surfaces. Aluminium shall be isolated from carbon steel by an austenitic stainless steel
spacer, an elastomeric bearing pad or equivalent protection.
4.1.15 Complete design calculations of the internal floating roof calculations for complete roof
buoyancy, stability, tilting, leg supports, bleeder vents etc including QAP and floating roof
testing procedure of Aluminium floating roof tanks shall be got vetted through any one

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 Tender No: RCC/NR/UPSO-II/ENG/PT-07/19-20
PUBLIC TENDER:- DESIGN, FABRICATION, ERECTION, WELDING, TESTING
AND COMMISSIONING OF 2 NOS. 5000KL IFRVT MOTOR SPIRIT
TANKS (26M DIA. X 14.50M HEIGHT) WITH ALLIED WORKS AT
IOCL MATHURA MARKETING TERMINAL UNDER UTTAR
PRADESH STATE OFFICE-II

among the list of consultants attached and additionally the materials required for this item
shall also require Third party inspection / clearance from any agency from the list of
consultants attached.
4.2 SEALS/ ROOF PENETRATION / VAPOUR CONTROL
4.2.1 Columns, ladder, gauge float & tape and other items that penetrate the floating roof shall be
provided with a seal that will permit a local horizontal deviation of plus or minus 4-5 inches
(100 – 125 mm).
4.2.2 The column and vertical ladder negotiator seals shall be fabricated of material that must be
suitable for the product service and operating temperature. Appurtenances shall be plumb
within a tolerance of +3 inches (75 mm).
4.2.3 Gasketed sliding cover plates, which are free to move with the appurtenance relative to the
cover, shall be sized to allow the full movement without exposing product within the
opening i.e. all penetration seals shall be designed to provide a close fit, taking in to account
horizontal and vertical movement of the floating roof deck.
4.2.4 Guide wheels and a hold down device shall be installed on penetration seals to reduce wear
on seal material and increase the effectiveness of the seal.
4.2.5 A peripheral seal that spans the annular space between the internal floating roof deck and
the tank shell shall be provided. Any vertical appurtenances that penetrate the deck are
required to have a seal.
4.2.6 Double seals with a minimum vapour recovery of 96 % shall be provided.
4.2.7 A peripheral seal of vapour mounted Mechanical Shoe type shall be designed to
accommodate +100 mm (4 in) of local deviation between the floating roof and the tank shell.
4.2.8 In line with provisions of Environment (Protection) Amendment Rules 2008, primary seals
shall vapour mounted with a maximum seal gap of 4 cm and a maximum gap area of 200
cm2 / m of Tank diameter.
4.2.9 Secondary seals, shall be rim mounted with a maximum seal gap width of 1.3 cm and
maximum gap area of 20 cm2 / m of tank diameter.
4.2.10 The floating roof shall be equipped with a mechanical shoe type sealing system. Rim space
shall be 6.7 inches (170mm) nominal.
4.2.11 Shoe plate shall be a minimum of 1.2mm thick x 406mm (16”) deep. Type 304 Stainless Steel.
4.2.12 Fabric for the seal vapour barrier and other non-metallic components shall be compatible
with the stored product.
4.3 SUPPORT LEGS
4.3.1 Floating roof shall be provided with two position legs: low and high position shall be at
approximately 1.20 M and 2.1 M respectively. However, the low position can be preset to
other heights.
4.3.2 Changing high/low position must be accomplished from top side of floating roof and while
tank is in service.
4.3.3 Each leg must be capable of vertical adjustment of +3" in the event that the tank bottom

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 Tender No: RCC/NR/UPSO-II/ENG/PT-07/19-20
PUBLIC TENDER:- DESIGN, FABRICATION, ERECTION, WELDING, TESTING
AND COMMISSIONING OF 2 NOS. 5000KL IFRVT MOTOR SPIRIT
TANKS (26M DIA. X 14.50M HEIGHT) WITH ALLIED WORKS AT
IOCL MATHURA MARKETING TERMINAL UNDER UTTAR
PRADESH STATE OFFICE-II

settles after tank is in service. Adjustment to be made from top side of floating roof while
tank is in service.
4.3.4 Legs shall be self-draining (notched or perforated).
4.3.5 Wherever roof legs of the Internal Floating roof lands on the tank bottom, SS shoes is to be
provided.
4.3.6 Support leg housings shall not be attached to the pontoons.
4.3.7 Additional diffuser plates as per design of OEM to be provided on all FR decks as per the
maximum flow rate experienced during jet mixer operations to be provided.
4.4 ROOF LADDER
4.4.1 The floating roof should allow the installation of a fixed ladder from the roof hatch to the
tank floor without reducing the operation levels of the tank. The ladder shall be positioned
adjacent to the gauge well (450 mm NB) through connections between a 150 mm NB slotted
pipe adjacent to the gauge well.
4.5 ANTI-ROTATION DEVICES
4.5.1 The internal floating roof shall be centered and restrained from rotating. A guide pole with
rollers, two or more seal centering cables or other suitable device(s) shall be provided as
required for this purpose.
4.5.2 Anti-rotation cables shall be Ø3/16” minimum diameter Stainless Steel cable and shall
penetrate the deck through a guide tube. The cable will run from the fixed roof to a floor
anchor. The floor anchor will be fitted with a Stainless Steel drawbar spring to compensate
for floor settlement.
4.6 VENT:
4.6.1 Floating Roof: A pressure/vacuum gasketed vent shall be provided on the floating roof to
prevent over stressing of the floating roof or seal. This vent shall be adequate to evacuate
air and gasses from underneath the roof when the roof is on its supports during filling
operations.
4.6.2 It shall also be adequate to release any vacuum generated underneath the roof after it
settles on its supports during withdrawal operations. It shall not open while the roof is fully
afloat due to pressure or vacuum. The roof manufacturer may recommend ideal operating
rates and possibly the installation of an inlet diffuser
4.7 MANHOLES AND INSPECTION HATCHES
4.7.1 The manufacturer shall specify the appropriate number of manholes according to the
application. However, at least one (1) manhole shall be provided with the floating roof to
allow for access to and ventilation of the tank when the floating roof is suspended on its
supports and the tank is empty.
4.8 ANTI-STATIC / GROUNDING DEVICES
4.8.1 Antistatic protection shall be provided with electrical bonding to the tank shell or floating
roof, all conductive parts shall be electrically connected and bonded to the outer tank
structure.

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 Tender No: RCC/NR/UPSO-II/ENG/PT-07/19-20
PUBLIC TENDER:- DESIGN, FABRICATION, ERECTION, WELDING, TESTING
AND COMMISSIONING OF 2 NOS. 5000KL IFRVT MOTOR SPIRIT
TANKS (26M DIA. X 14.50M HEIGHT) WITH ALLIED WORKS AT
IOCL MATHURA MARKETING TERMINAL UNDER UTTAR
PRADESH STATE OFFICE-II

4.8.2 This may be accomplished by electric drains in the seal area or flexible cables from the
external tank roof to the internal floating roof. Flexible cables are preferred. They shall be
1/8-inch (3 mm) diameter stainless steel aircraft cable to insure strength, corrosion
resistance, joint reliability, flexibility, and service life.
4.8.3 Minimum quantities for grounding cables shall be:
Tank Diameter Quantity
< 24 m dia 2
> 24 m < 45 m dia 4
> 45 m < 64 m dia 6
> 64 m dia 8

4.9 ROOF DRAINS

4.9.1 The floating roof shall be provided with roof drains to drain liquid from the top of the roof
into the tank stock. There shall be a minimum of one drain/sheeting run.
4.9.2 Roof drains shall be at least Ø1/2” diameter, extending 4 inches into the stock.
4.10 ROOF MAN WAYS
4.10.1 Roof man ways shall be installed for access from tank bottom to above the internal floating
roof near each tank manway.
4.10.2 Man ways shall be a minimum of Ø600mm ID Manway covers on the floating roof shall be
equipped with gasketed sealing system. Tanks above Ø30m (100ft) shall be fitted with a
minimum of two (2) man ways.
5.0 MATERIALS
5.1 ALUMINIUM IFR (FOR MS SERVICE)
Aluminum Extrusions Alloy : AA 6005/6063/6061–T6/ASTM B221
EQV.

Configuration : Extruded Shapes

Typical UTS : 35-42 Ksi
Deck Sheeting Alloy : AA 3003/3105-ASTM B-209/ EQV.
Thickness : 0.60 mm
Width : 1500 mm
Typical UTS : 18 to 23 Ksi
Pontoons Size Alloy
200 mm OD: AA6063-T6-ASTM B-221/EQV.
250 mm OD: AA 3004/3105

Page 80 of 200
 Tender No: RCC/NR/UPSO-II/ENG/PT-07/19-20
PUBLIC TENDER:- DESIGN, FABRICATION, ERECTION, WELDING, TESTING
AND COMMISSIONING OF 2 NOS. 5000KL IFRVT MOTOR SPIRIT
TANKS (26M DIA. X 14.50M HEIGHT) WITH ALLIED WORKS AT
IOCL MATHURA MARKETING TERMINAL UNDER UTTAR
PRADESH STATE OFFICE-II

Thickness: 1.92 mm extruded for 200 mm dia

1.3 mm fabricated for 250 mm dia
Typical UTS: 18 to 35 Ksi
Seals Composition : Primary SS Mechanical Shoe seal and
Secondary rim vapour mounted wiper
seal
End caps for all pontoons Alloy : AA 5052 H34 /H14 – ASTM B – 209/
EQV.
Configuration : Flanged Plate
Thickness : 3.0 mm
Typical UTS : 25 to 33 Ksi
Anti-rotation cable Material : 18-8 Stainless Steel
Diameter : 6.0 mm
Typ. Breaking 1500 kg
Strength :
End brackets Alloy: AA 5052 H 34 /H14 – ASTM B – 209/
EQV.
Configuration : Welded, Double Gusseted
Thickness : 3.0 mm
Typical UTS : 25 to 33 Ksi
Grounding cables Material : 18-8 Stainless Steel
Diameter : 3.0 mm
Resistance : 0.100 ohm/m approx.
Legs Alloy : AA 6063 – T6-ASTM B-221/ EQV.
Size : Minimum 50.8 mm OD
Configuration : Extruded Tubes
Thickness : 2.03 mm
Typical UTS : 28-35 Ksi
Leg Shoes : S.S.- 300 Series
Fasteners Material : Stainless Steel
Grade : SS Gr. A2, IS:1367

5.2 HYBRID IFR (FOR ETHANOL SERVICE)

Page 81 of 200
 Tender No: RCC/NR/UPSO-II/ENG/PT-07/19-20
PUBLIC TENDER:- DESIGN, FABRICATION, ERECTION, WELDING, TESTING
AND COMMISSIONING OF 2 NOS. 5000KL IFRVT MOTOR SPIRIT
TANKS (26M DIA. X 14.50M HEIGHT) WITH ALLIED WORKS AT
IOCL MATHURA MARKETING TERMINAL UNDER UTTAR
PRADESH STATE OFFICE-II

Aluminum Extrusions Alloy : AA 6005/6063/6061/ASTM B221 EQV.

Configuration : Extruded Shapes

Typical UTS : 35-42 Ksi
Deck Sheeting Alloy : AA 3003/3105-ASTM B-209/ EQV.
Thickness : 0.6 mm
Width : 1500 mm
Typical UTS : 18 to 23 Ksi
Pontoons Size SS304 1.5mm thick 15 inch dia
Seals Composition : Primary SS Mechanical Shoe and Sec
rim mounted wiper seal
End caps for all pontoons and Alloy : SS304
Rim Section
Configuration : Flanged Plate
Thickness : 2.0 mm
Anti-rotation cable Material : 18-8 Stainless Steel
Diameter : 6.0 mm
Typ. Breaking 1500kg
Strength :
End brackets Alloy: SS304
Configuration : Welded, Double Gusseted
Thickness : 2.0 mm
Grounding cables Material : 18-8 Stainless Steel
Diameter : 3.0 mm
Resistance : 0.100 ohm/m approx.
Legs Alloy : SS304
Thickness : 2mm
Fasteners Material : Stainless Steel
Grade : SS Gr. A2, IS:1367
Note: All wetted parts to be SS304.
The dimensions mentioned above represent the minimum specifications.
6.0 COMMISSIONING & WARRANTY
6.1 The manufacturer/ successful bidder shall provide required Cathodic Protection for the
Aluminium & SS IFR decks with sacrificial anode system during the entire period of floatation

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