Bom

SABARMATI GAS LIMITED (A Joint venture with GSPCL & BPCL)

CITY GAS DISTRIBUTION PROJECT

BID DOCUMENT FOR

PROCUREMENT OF COMPRESSOR PACKAGE

VOL II OF II – TECHNICAL

(BID DOCUMENT NO 11/0353/WGI/SGL/01-R0)

LIMITED INTERNATIONAL BIDDING

ISSUED BY

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SABARMATI GAS LIMITED


CLIENT JOB NO. - SPECIFICATIONS FOR ELECTRIC MOTOR DRIVEN

CNG COMPRESSOR PACKAGES TOTAL SHEETS 64

DOCUMENT NO 11 0353 02 09 02 007

0 02.05.11 ISSUED FOR TENDER MH RM RC

C 26.04.11 RE-ISSUED FOR CLIENT APPROVAL MH RM RC

B 11.04.11 ISSUED FOR CLIENT APPROVAL SS RM RC

A 07.04.11 ISSUED FOR IDC SS RM RC

REV. DATE DESCRIPTION PREP CHKD APPD

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SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR

PACKAGE

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CONTENTS

1.0 GENERAL ...................................................................................................................................................3

2.0 UTILITIES & BATTERY LIMITS ..................................................................................................................9

2.1 UTILITIES ...................................................................................................................................................9

2.2 BATTERY LIMITS ......................................................................................................................................10

3.0 BASIC DESIGN..........................................................................................................................................10

4.0 CONTROL PHILOSOPHY..........................................................................................................................20

5.0 INSTRUMENTATION.................................................................................................................................23

6.0 EARTHING / CABLING ..............................................................................................................................25

7.0 INSPECTION AND TESTING ....................................................................................................................25

8.0 PERFORMANCE GUARANTEES, LOADING AND PENALTIES ...............................................................27

9.0 PAINTING AND PROTECTION.................................................................................................................29

10.0ERECTION, TESTING AND COMMISSIONING AT SITE..........................................................................30

11.0FIELD TRIAL RUN/ SITE PERFORMANCE TEST....................................................................................30

12.0SPARE PARTS, SPECIAL TOOLS AND TACKLES..................................................................................30

13.0MAINTENANCE PHILOSPHY: ..................................................................................................................30

14.0WARRANTY SERVICING AND SPARE PARTS.......................................................................................30

15.0DATA AND DRAWING..............................................................................................................................31ANNEXURE – I: GAS COMPOSITION.............................................................................................................33

ANNEXURE-II : GUARANTEED PARAMETERS ..............................................................................................34ANNEXURE – III: LIST OF RECOMMENDED THIRD PARTY INSPECTION AGENCY...................................35ANNEXURE – IV: APPROVED BIDDER LIST..................................................................................................36ANNEXURE-V: BIDDER DATA REQUIRED ....................................................................................................39ANNEXURE-VI: M.R. COMPLIANCE SCHEDULE...........................................................................................49ANNEXURE – VII : EXPERIENCE RECORD PROFORMA .............................................................................53

ANNEXURE- VIII : PARAMETERS REQUIRED FOR SCADA .........................................................................64

DATA SHEETS FOR COMPRESSOR (1200 SCMH)

DATA SHEETS FOR COMPRESSOR (650 SCMH)

DATA SHEET FOR LT MOTOR

DATA SHEETS FOR HEAT EXCHANGER

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1.0 GENERAL

Sabarmati Gas Limited (SGL) is a joint venture of GSPCL & BPCL & it proposes to install refuelling outlets in Gandhinagar,Mehsana & Sabarkanta district of Gujarat. SGL is inviting tenders on Competitive Bidding basis for procurement of CNG COMPRESSORS for CNG Stations.

1.1 SCOPE

This specification along with applicable codes as referred describe the minimum requirements for Design, engineering, manufacturing, inspection, testing, packaging, supply & delivery at site , erection & commissioning including Field Performance Test at site along with 1st year operation and maintenance during warranty period & next 3 Years operation & comprehensive maintenance of "ELECTRIC MOTOR DRIVEN” RECIPROCATING CNG COMPRESSOR PACKAGES as required for dispensing CNG to vehicles in Gandhinagar, Mehsana & Sabarkanta district of Gujarat. The CLIENT/CONSULTANT at his sole discretion may order all the packages on one bidder or split the order among two or more bidders. The packages ordered on one packager shall be identical in all technical aspects. Various parts of this specification shall be read in conjunction with each other and in case where the different parts of this specification differ the more stringent requirement shall govern.

Any additional work/equipment or technical requirement not mentioned in the specification but required to make the offered system complete in accordance with the specification or required for safe operation, shall be deemed to be included in the offer and provided by the bidder, without any additional payment.

1.1.2 THE DESCRIPTION OF TOTAL SUPPLY OF PACKAGED COMPRESSOR IS AS UNDER:

Sl. No. Description Quantity

1. Electric Motor driven 1200 SCMH Packaged Reciprocating Compressor Unit

03 Nos.+ 2 Nos Optional

2. Electric Motor driven 650 SCMH Packaged Reciprocating Unit

01 Nos.+ 1 Nos Optional

1.2 CODES & STANDARDS

The design, construction, manufacture, supply, testing and other general requirements of the compressor package equipment shall be strictly in accordance with the data sheets, applicable API Codes, and shall comply fully with relevant National/ International standards.

Any modification suggested by the statutory bodies either during drawing approval or during inspection, if any shall be carried out by the bidder without any additional cost and delivery implications.

The following codes and standards (versions/revisions valid on the date of order) are referenced to & made part of specification: API-11P (Second edition), API 618

NFPA-37, OISD 179, NFPA-52: 1992

NFPA-12, IS: 6382, Gas Cylinder Rule-2004

IS: 5571, IS: 5572, IS: 5580

ANSI, ASTM, NEC, NEMA

Indian Electricity Rules 1956 and updates thereafter, Indian Explosives Act, Factory Rules, 1950

Australian and New Zealand Refuelling Standards (AG 901/NZS 5425)

Any internationally recognised standard.

OISD rules should be followed be complied as this falls under hazardous Gas Area classifications.

1.3 PRECEDENCE In case of any conflict among the various documents of this requisition the following preferential order shall govern:

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1. Data sheets/drawings 2. Technical Specification

3. Indian Standards / codes applicable

4. International standards/codes as applicable

Compliance with these specifications shall not relieve the bidder of the responsibility of furnishing equipment and accessories of proper design, material and workmanship to meet the specified operating conditions.

No deviations to the technical requirements and to the scope of supply specified in this enquiry document shall be accepted and offers not in compliance to the same shall be rejected.

1.3.1 Bidder shall necessarily furnish the following along with the bid without which the offer shall be

considered incomplete: (1) Proven Track Record Formats duly filled in along with general reference list shall be submitted for

the earlier supplied CNG packages as per BEC requirement. One similar package, which is in operation and number of hours of operation as on due date, shall be clearly indicated in the format by the Bidder.

(2) Checklist duly filled in with regards to scope of supply. (3) Completely filled in Data Sheets of compressor, electric Motor & Heat exchanger. (4) Tentative Lay out/key plan/General Arrangement indicating size of skids, centre distance between

skids and space required along with maintenance requirements. (5) (a) Utilities requirements

(b) Electrical Load summary (6) Catalogues of compressor, Electric Motor, Instrumentation and controls.

1.4 SCOPE OF SUPPLY FOR EACH COMPRESSOR PACKAGE

The scope of work/services to be provided by the bidder shall be inclusive of but not limited to: Design, Engineering, Manufacture, assembly, testing at manufacturer’s works erection, commissioning, and field trial runs along with Equipment performance test along with associated electricals, instrumentation etc. as per bid document.

Each compressor Package shall be complete with:

- Lubricated Compressor (Lubrication includes: Cylinder Lubrication, Frame Lubrication, Piston & Piston-Rings Lubrication, Packing’s Lubrication) with suction/discharge volume bottles for each stage (separators) with manual & automatic drain system, lube oil system, and lubricated connecti-

-ng rod.- SGL will provide 3 KVA UPS for power back up.

- Air Compressor with receiver & drier of suitable capacity to cater compressor and 4 nos.

dispenser (For 1200SCMH Compressor) & 3 Nos. Dispenser for 650 SCMH Compressors).

- Provision for overhead mounting of 3000 WL capacity stationary cascade to be included in bidder’s scope. The overhead structure required for putting Cascade (3000WL capacity of 75 cylinders which have approximate weight 5.5 Tonne) should be of enough strength having

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working space & along with ladder arrangement.Design of such structure shall be approved by SGL.

- Mounting of Cascade on the structure shall be in the scope of bidder however cascade shall be

provided by owner. - Mass flow meter to measure the Natural Gas consumption at packages inlet, package discharge.

- Instrumentation and control system as specified on data sheets, P&ID including Local panel,

Console/Local gauge boards, PLC. - Common structural steel skid for the compressor – Electric Motor combination and for all

auxiliary systems with foundation bolt.

- Duplex Suction gas filters with oil drain and temporary suction inline strainer at the compressor package inlet.

- Air-cooled heat exchanger for inter-stage and discharge gas.

- Suction, interstage and discharge Knockout Drums (KOD) with solenoid valve operated auto &

manual drains. Demisters to be provided for each KOD. Bidder to ensure that KOD & coalescent filter shall be provided after the final discharge and before the mass flow meter. All drain lines shall be provided with level operated / time based auto drain valves and NRV’s.

- Priority Panel at Package Discharge. Priority panel shall be kept outside in a separate enclosure

preferably mounted on compressor side walls.

- All interconnecting oil, gas, water, air piping within the compressor package.

- Impulse and pneumatic piping/Tubing for all valves, fittings as specified & required for mounting the instruments. Block & bleed valves to be provided for Pressure gauges and pressure Transmitters.

- Separate junction boxes for different type of signals like intrinsically safe signals, alarm,

shutdowns, thermocouples, RTDs etc. for interfacing to local panel.

- NRV at final discharge.

- Structural supports within the compressor package for all piping, instruments etc.

- One no. safety relief valve at suction, discharge, Blow down Vessel (BDV) and in priority panel banks shall be provided.

- Y- type strainers, valves, sight flow indicators, check valves, auto & manual drain traps etc. as

required for various auxiliary systems i.e. frame lube oil, cylinder lubrication system, air cooled systems etc.

- Coupling/Pulleys

- Acoustic enclosure for both Compressor and Electric Motor assembly with two number L.E.L

detectors and two UV detectors in the enclosure.

- Common CO2 extinguishing system consisting of two cylinders for Motor driven, piping, valves and control systems (details are given at s.no.1.5.8).

- Flame proof (FLP) electrical motors and Flame Proof control panel and other panels. The soft

starter to be placed in the electrical panel room. Cable from starter to electric motor is in compressor bidder’s scope.

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- Inlet and outlet automatic and manual isolating valves for maintenance & emergency.

- Package should be so designed that there should be sufficient space for operation and maintenance.

- Complete Erection, Testing & Commissioning of compressor packages.

- Supply of all spares as required for erection & commissioning.

- As built drawings and Operation & Maintenance catalogue with each compressor package.

- Training of six personnel in two batches at Packager’s works. The travelling, boarding and

lodging of SGL’s engineers shall be borne by SGL. Each training module shall span for one week and shall cover the equipment constructional features, operational and maintenance procedures, practical hands on experience on assembling, dismantling etc.

- Bidder shall provide necessary provision in control panel (located in hazardous area) provision of

availability of operating and fault condition data on PLC through SCADA system .The system shall be compatible with SGL’s system.

- Maintenance and operation of compressor shall be for 365 days 24 hrs per day basis. - Any item which is not included in the BOM/ Scope but required for commissioning/operation of

the system shall be made available by the bidder without any extra cost & time implication. - Temperature element shall be of INSERTION TYPE NOT SKIN TYPE. - Foundation Drawings/ Equipment drawings of SYSTEM offered shall be submitted along with

Technical bid. - Load Torque Graph and the speed torque graph should be provided for electrical motor. - Power consumption Vs. Suction Pressure Graph to be submitted by bidder along with Technical

Bid. Exclusions

The following are excluded from the scope of the bidder:

- All civil works and foundation design, however the bidder shall furnish all the relevant data for design of any pedestal if required.

- All piping beyond battery limits except piping from CO2 cylinders up to the enclosure. The CO2 piping shall be of seamless CS pipe.

- Foundation structural work. 1.5 SAFETY 1.5.1 All controls shall operate in a fail-safe mode i.e. failure of any control shall not lead to running of

equipment in unsafe mode.

1.5.2 The hazardous area classification Class-I, Division 2, Group D as per NEC or Zone II, Group II A/ II B as per IS/ IEC for compressor and Electric Motor. Certificate from recognized agency to the effect that equipment supplied and/or installed conform to above area classification. All Devices shall meet the requirement for the specified area classification in which they are installed, including instrumentation leads.

1.5.3 All exposed rotating parts shall be provided with adequate guards of non-sparking type. 1.5.4 Necessary hazard identification signs to be displayed on each equipment inside the package.

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1.5.5 Piping shall be arranged in a manner so as to provide clear headroom and accessibility within the package. Adequate clearances shall be provided for all the engineered components so as to have sufficient space for carrying out maintenance.

1.5.6 Each package ENCLOSURE shall have two L.E.L detectors (IR Type) and two Ultra Violet (UV) fire

detectors to cover the enclosure effectively as already spelt in the scope of supply. 1.5.7 All material used in the package shall be flame retardant. 1.5.8 Relief Valves shall be provided at interstage/compressor discharge with setting as per Cl. 7.20.3 of API –

11P with R.V. venting as per Cl. 7.20.4 of API-11P. Suction separator at first stage inlet shall also be provided with Relief Valve.

1.5.9 CO2 Flooding System:

The package shall be protected by automatically operated CO2 flooding system designed as per NFPA-12 which should have minimum following features: - 1. Gas Detection by installation of hydrocarbon gas detector (IR type) with self check function and

transmitter with adjustable alarm levels (0-100%) with preset of 10%, 20% and 50%. Each enclosure should have at least 2 nos. gas detectors. -The local panel of CO2 flooding system shall be flame proof type.

2 Installation of flame detector (UV-IR type) with self check function and transmitter, alarm on detection of flame. Each enclosure should have at least 2 nos. flame detectors.

3. CO2 flooding system will consist of 2 nos. of adequately sized CO2 cylinders. One cylinder will act as main cylinder & other as stand by, which shall have identical arrangement and connected to the system. The cylinders shall be placed in a shed to protect from weather and direct sunrays as per Gas Cylinder Rules, 2004. Cylinders shall be fitted with automatic actuated Valves, Solenoid valves etc. No extra utility as air, inert Gas shall be made available by SGL/used by the supplier to operate the system other than the UPS.

4. The System shall be designed to operate on 24 V DC supply. FRLS (Fire resistant low smoke) Copper cables with glanding on both the ends shall be used for the wiring of the system.

All the wires /cables used/installed inside the compressor should be tagged on both sides.

5. Interlock of CO2 Flooding system with compressor as per following sequence: -

i. Compressor shall trip on detection of gas at preset level. ii. Compressor shall trip on detection of flame at preset level and automatic discharge of CO2 gas

shall take place from the main cylinder simultaneously. iii. Compressor shall not start if the CO2 Flooding System is faulty, not working, Switched OFF etc.

The compressor shall be able to start only when the CO2 Flooding System is in healthy working condition.

iv. Maintenance Override Switch shall be provided to keep the system off during maintenance. This

feature shall be in compliance to the point no. 5 (iii) as above. v. Selector switch shall be provided to put Main/Stand by Cylinder in line at the turn of a switch as

per requirement.

6. Alarm panel for CO2 Flooding System shall be integral with the main compressor panel. Necessary displays as system ON, OFF, FAULT, RESET, Gas/ Flame indication, Remote actuation of solenoid valve, distinguished hooter etc., shall be provided for CO2 flooding system. The remote push button shall be installed in the control room at site. Bidder to include all cabling etc. up to remote actuator

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7. CO2 Cylinders shall be provided outside the package at a safe place, minimum 4.5 meters away

(aerial distance), where it is not exposed to fire in case of fire in the compressor. Facility shall be made to operate the system both manually from remote with the help of a switch/ call point and with help of pull down lever on cylinders.

8. Bidder shall provide suitable weighing arrangement to facilitate weighing of the cylinders without

requiring the cylinders to be detached from the installation. For this, lever operated lifting arrangements shall be provided along with alarm system.

9. All installation shall be compatible for hazardous area Class 1, Division 1, Group-D for Methane Gas

as per NACE.

10. The system designed by the supplier shall be duly approved by SGL.

11. Technical specifications, Operation and Maintenance Manual, CCOE Certificate, Approval/ Manufacturing certificates for cylinders and cylinder valves, gas detectors, flame detectors, solenoid valves etc. shall be furnished by the supplier along with system. Necessary tools (1 set per package) shall be provided with the system.

12. Warning and Operating instructions to be displayed at equipments as per the statutory/ safety

regulations. 1.6 AMBIENT CONDITIONS.

Complete compressor package shall be suitable to work under the following climatic conditions:

Wind velocity km/hr (max.) 13

Amb. Temperature (Min./Max.) 4oC / 47oC

Design Wet bulb Temp. 27oC

Design Relative Humidity 95%

Altitude, M above MSL 110 meters

Air Cooler design oC 47oC DBT, 27oC WBT & 94% RH

2.0 UTILITIES & BATTERY LIMITS

2.1 UTILITIES

2.1.1 Bidder shall make his own provision for Instrument and starting air with an electric motor driven air compressor receiver system. Air Compressor with receiver & drier of suitable capacity to cater compressor and 4 nos. dispenser (For 1200SCMH Compressor) & 3 Nos. Dispenser for 650 SCMH Compressor) instrument air requirements shall be provided by the Bidder.

- The connectivity for instrument air for dispensers from the air compressor shall be in bidder’s scope.

2.1.2 Cooling water is not available as utility and the package shall be provided with air cooled heat exchanger.

2.1.3 All electrical and instrumentation terminals shall be as specified.

2.1.4 For motor driven compressor package, SGL shall provide the required control supply for LCP (230 V, 1 phase (2 wire), 50 Hz A.C.) through UPS and supply of (230 V, 1 phase (2 wire), 50 Hz A.C.) for lighting at single point in the Local Control Panel mounted on the package.

Electric Power (a) SGL shall supply 415 V 3 phase, N, AC 50 Hz electrical power at the incomer of the Soft Starter

panel supplied by the contractor. All further distribution of electric power shall be carried out by the contractor.

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(b) SGL shall supply 230 V AC, 50 Hz electrical power for instrumentation through UPS at the inlet of the

Soft Starter panel supplied by the contractor. All further distribution of electric power shall be carried out by the contractor.

2.1.5 ELECTRICAL SUPPLY PARAMETERS (For Electric Motor Driven Compressor Package)

All electrical shall be suitable for the following supply conditions Electrical operating voltage: AC, 3 phase, Neutral 415 V, 50 Hz Electrical control voltage: 240V AC, 50 Hz (under supplier’s scope) Tolerance of voltage: + 10% Tolerance of frequency: + 3%

1) CLIENT shall provide 415V, 3 phase, Neutral electrical connection at only 1 designated point for electric driven compressor package. Bidder shall distribute electric power to all equipments and control systems, by providing a suitable switch gear distribution panel. Suitable flameproof double compression gland shall be provided for termination of main cable in main electrical panel. Exact size and specification of the cable gland will be indicated to successful bidder within 2 weeks of order placement and receipt of electric signal line diagram from bidder.

2) All solenoid coils power contactor etc. shall have operating voltage of 240V AC and 50 Hz. The control

supply of power contractor and PLC unit should be different. 2.2 BATTERY LIMITS

2.2.1 All customer interface connections (i.e. Gas Inlet & Gas Outlet) shall be brought out to the package edge. Gas inlet shall be terminated in nozzles with isolation valves having flange connections and Gas outlet (priority panel outlet connection) shall be terminated through high pressure ¾” full flow ball valves with ¾” Tube OD End Connections.

2.2.2 As and where specified on the data sheets all vents (i.e. Relief valve, distance piece, packing and starting air) shall be manifolded and terminated at skid edge outside the enclosure and vented to safe height of 3m from working platform of cascade.

2.2.3 All drains from different process equipments, distance piece and packing shall be manifolded and terminated as single point for customer interface duly flanged with isolation valve. Drains should be through a common header and discharge to be allowed in a pit to avoid spillage around compressor package. Metallic collecting pot to be provided by the bidder suitable for collecting and disposal of drained oil.

3.0 BASIC DESIGN

3.1 General

3.1.1 The Compressor shall meet all the technical requirements as specified in:

i. Data Sheets ii. Technical Specification iii. Code and specification API-11P, OISD 179, NFPA 37, NFPA 52, ANSI, ASTM, NEC, NEMA,

Indian Electricity Rules and Indian Explosives Act are referenced to & made part of specification. Compressor, motor and auxiliaries design shall be in conformity with API 11P, second edition

3.1.2 Minimum Three stage Compressor configuration is envisaged. Gas composition given under design

Case shall be used for Compressor selection, sizing and performance guarantee estimates. However

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compressor shall be suitable for continuous operation with the indicated gas composition range and operating parameters given in the data sheet.

3.1.3 Suction line pressure may vary from 14 kg/cm2G to 19 kg/cm2G with discharge pressure remaining

constant at 250 kg/cm2G. A suction pressure regulator shall be installed to limit the suction pressure to 19 kg/cm2G. The suction pressure of 16 kg/cm2G shall be used for compressor sizing/selection. However, compressor shall operate at maximum available pressure at any time.

Bidder to provide filter cum regulating skid with PCV at inlet. The pressure regulator at inlet should be of approved make with slam shut off valve of 300# rating. The inlet pressure range of the regulator shall vary between 20 to 35 bar pressures. Outlet pressure should be in the range of 14 to 19 bars. However, sizing of the compressor shall be carried out at 16 kg/cm2.

3.1.4 Bidder’s offer shall be based on firm and final compressor models on which basis the offer shall be

evaluated. All bidders shall take full cognizance of this matter before submitting the bid. 3.1.5 Note that the pressures given on the data sheet are at the compressor package battery limits, bidder

shall consider all pressure losses at suction, interstage and discharge at the specified capacity (with no -ve tolerance) for compressor/motor and indicate the same on the data sheets.

No venting of the gas is allowed at any point during operation.

3.1.6 The compressor Driver shall be suitable to start the compressor against the stabilized pressure (35 Kg/cm²g) of the system. A gas recovery vessel of suitable capacity shall be provided to collect the gas of 1st, 2nd & 3rd stage of compression. The operating pressure of gas recovery vessel shall be 35 kg/cm²g maximum. No venting of gas is allowed.

3.1.7 The compressor driver shall be capable of running the compressor under loaded condition with each

stage pressurized to its respective specified pressure and final pressure upto PRV set pressure. 3.2 Allowable speeds, temperature and vibration levels

3.2.1 The rotational speed of both compressor & Electric motor (driver) shall be limited to maximum of 1500 rpm.

3.2.2 The linear piston speed shall be limited to 4 m/sec for non-lubricated compressors and 4.5 m/sec for

lubricated compressor.

3.2.3 The maximum discharge gas temperature for each stage shall be limited to 150ºC before cooler. 3.2.4 Compressor maximum vibrations of cylinders shall not exceed 7.5 mm/sec. of unfiltered peak velocity.

Maximum Vibration level of installed compressor frame shall not exceed an unfiltered peak velocity of 5 mm/sec. or 200 micron unfiltered peak to peak vibration whichever is less. The Bidder shall provide for all structural support within the package so that these levels can be achieved.

3.3 Piston Rod, Bearings and Cross Heads

3.3.1 The surface hardness of Rockwell C 50 minimum is required on piston rods in the areas that pass through the packing.

3.3.2 Crosshead shall be as per manufacturer’s standard material and designs. Adequate openings for removal of the crossheads shall be provided.

3.3.3 Piston rod and cross head pin loading at any specified operating condition including the relief valve set

condition shall not exceed 80% of the maximum design rod load of the offered compressor. Rod loads shall have sufficient reversals in direction for all specified operating conditions including PSV Settings and part load operation. The calculation for rod loading at various conditions needs to be submitted.

3.4 Packing Cases and Pressure Packing

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3.4.1 All oil wiper intermediate gas cylinder pressure packing shall be segmental rings with stainless Steel garter springs. The pressure packing case shall be provided with a common vent and drain routed outside the package enclosure.

ERW steel, seamless steel tubing conforming to ASTM A-192 or series 300 SS tubing conforming to ASTM A-269 with minimum thickness as specified in Cl. 7.11 of API-11P shall be used for vent piping.

3.4.2 Packing vent piping inside of the distance piece shall be designed for the maximum allowable working pressure of the cylinder. Gas flow direction to be marked on all internal pipes carrying Natural Gas.

3.4.3 Bidder to indicate the allowable packing vent in their designs in SCMH along with the bid. Methodology of demonstration of packing losses shall also be submitted & should be demonstrated at the time of performance test.

3.5 Compressor Frame Lubrication

3.5.1 Compressor frame lubrication shall be pressurized system, with main oil pump driven directly by the compressor shaft.

3.5.2 All lube oil piping after oil filter shall be 300 series stainless steel conforming to ASTM A 269. 3.5.3 Heating shall be provided for reservoir when the minimum ambient temperature is less than the Bidder's

required minimum start up temperature. 3.6 Distance Pieces 3.6.1 Compressor manufacturer’s standard Type–1 or Type-2 of API 11 P shall be provided as a minimum. 3.7 Cylinder and Packing Lubrication

3.7.1 Single plunger per point force feed mechanical lubricator or divider block system shall provide lubrication to compressor cylinders.

3.7.2 Lubricators shall be driven by crankshaft and bidder shall highlight any pre lubrication requirements of

the cylinders and the method of achieving the same. 3.7.3 Lubricators shall have a sight flow indicator for each lubricator point and a stainless steel double ball

check valve shall be provided at each lubrication point.

3.7.4 Digital no flow switch shall be provided to stop the compressor in case of loss of cylinder lubrication in

any stage/ packing. 3.7.5 Lubricator reservoir capacity shall be adequate capacity & to be topped up 7 days of normal operation,

and shall be equipped with low-level alarm. 3.7.6 Bidder shall furnish along with their bids the details of the recommended Lubricating oil type,

International Grades & Specifications along with their quantity and changing frequency/ schedule. The recommended oil shall be compatible with gaskets, ‘O’ rings, seals, packing, lubricating parts and other parts coming into contact.

3.8 Cooling System

3.8.1 Compressor Cylinder

Compressor cylinders shall be air cooled,

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3.8.2 Inter/After Gas Coolers

Air-cooled Interstage and Final stage discharge coolers shall be provided which shall limit the gas temperature after the cooler to 52oC. For calculating the surface area of the air cooler, the ambient air temperature of 47OC and 95% RH shall be considered. Bidder to indicate the motor ratings with the bid. Cooler design shall be on the basis of 20% extra margin on the heat load at most severe condition corresponding to suction pressure. Gas sections of coolers shall be designed as per API-11P requirements and shall be inspected by any approved 3rd party inspection agency.

3.9 Separators & Oil Removal System

3.9.1 Carbon Steel separators / KOD at suction and interstage and with SS 300 series, mist extractors, auto and manual drain system (level/time based) shall be provided for the capacity as required.

3.9.2 All pressure vessels shall be designed as per ASME VIII Div 1 practice. 3.9.3 The offered scrubber and mist removal shall restrict the oil level to < 5 ppm in the discharge gas of

compressor and the equipment shall be designed accordingly.

All vessels including pulsation dampers shall be fully (100 %) radiographed as per ASME VIII UW (a). Minimum design temperature for separators shall be 100OC and minimum design pressure shall be maximum operating pressure plus 15% for interstages and plus 10% for final stage.

3.9.4 Gas Recovery System: Bidder shall provide gas recovery system with gas recovery vessel of sufficient

capacity (however, operating BDV pressure should not exceed 35 Kg/cm2g) so as to limit the gas pressure inside vessel to 35 kg/cm2g after tripping of compressor at PSV trip set pressure of final stage discharge. The gas recovery vessel shall be provided with pressure relief valve and necessary instrumentation to avoid cold flaring of gas. Gas recovery vessel shall be designed as per the ASME code and will be inspected by Third Party Inspection Agency approved by WGI.

3.9.5 All pressure vessels shall be provided with 3 mm corrosion allowance. 3.10 Pulsation, Vibration Control and Analog Study

3.10.1 Bidder shall provide pulsation, suppression devices at each suction and discharge of compressor cylinders.

3.10.2 The design of pulsation suppressing devices shall be based on the acoustic and mechanical evaluation

carried out as per API 618-design approach 3. 3.10.3 These devices must reduce pressure pulsation in piping within 3%. These pulsation dampers shall be

designed to limit pressure drop to 1%. %. The minimum acceptable volume of pulsation suppression device shall be 10 times the cylinder swept volume

3.10.4 Bidder shall get the acoustic and mechanical evaluation study carried out for one compressor package

(from inlet flange to discharge on skid edge) by an agency who should have conducted TEN such simulation studies. The compressor Bidder shall be totally responsible for all the coordination with the agency carrying out the study. Bidder shall submit acoustic and mechanical evaluation report to WGI for review.

3.11 Electric Motor 3.11.1 Motors shall be capable of starting and accelerating the load with the applicable method of starting

without exceeding permissible winding temperature, when the supply voltage is 75% of the rated motor voltage.

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3.11.2 The motor design shall normally allow at least 3 starts in quick succession from cold against full load

torque (motor coasting to rest in between starts) without injurious heating of the insulated windings. (Two consecutive starts shall be possible within 6 minutes after final steady working temperature. Further one additional (hot) start shall be possible after an interval of 30 minutes form the previous hot start.)

3.11.3 Motors shall be designed for restart under full load, after momentary loss of voltage and with possibility

of restoration in few cycles. Supply voltage being 100% out of phase with motor residual voltage, motors shall be capable of withstanding transient torque’s associated under such reaccelerating conditions. Constructional details 1. The rotor shall be of squirrel cage type, dynamically balanced to provide a low vibration level and

a long service life for the bearings. The accepted values of peak to peak vibration amplitudes for a motor at rated voltage and speed on a machined surface bedplate with the motor levelled and with a half-key or coupling fitted shall not exceed those given in IS:12075.

2. Windings -insulation and bracing.

3. Motors shall be provided with Class ‘F’ insulation with temperature rise limited to Class ‘B’.The permissible temperature rise above the specified ambient temperature by thermometer method shall be limited to these specified in the applicable Indian standards for class ‘B’ insulation.

4. The windings shall be treated so as to resist the action of corrosive agents or substances(solids,

liquids or gases) as may be present in the atmosphere of chemical, petrochemical and natural gas plants which may tend to adversely affect the insulation. Sulphur vapour may be present in the atmosphere. The windings shall be tropicalised. The windings shall be suitably varnished, baked and treated with epoxy gel for operating satisfactory in humid and corrosive atmosphere.

5. The windings shall be adequately braced to prevent any relative movement during operation and,

in this respect, particular attention is drawn to the stator windings of full voltage started squirrel cage motors insulation shall be provided between coils of different phases which lie together.

6. In case of motors driving equipment with pulsating loads, special attention shall be paid to the

joints of rotor bars and end rings to avoid failure due to induced fatigue stress. 7. Phase connections.

(a) The windings shall preferably be connected in delta. However, for motors rated 1.5KW and below, star connection may be accepted.

b) If star-delta starting is required, this will be specified in the data sheet and the motor

windings shall be fully insulated for delta connection. 8. Winding terminations

(a) The ends of the windings shall be brought out into a terminal box. They shall be terminated by means of terminals mounted on an insulating base made of non-hygroscopic and non-flammable material.

(b) Preferably, all motors shall be with six terminals and suitable links to connect them in

star or in delta. However, motors rated up to and including 2.2KW may be accepted with three terminals.

(c) The terminals shall be adequately designed and thoroughly insulated from the frame

using material resistant to tracking. 9. Terminal box and cable entries

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(a) The terminal box shall be located on the right hand side viewed from the driving (coupling) end. It shall be routable in steps of 900 to allow cable entry from any direction.

(b) The terminal box shall be of sturdy construction and large enough to facilitate easy

connection of the cables.

(c) An adequately sized earth terminal shall be provided in the motor terminal box for termination of the fourth core of cables.

(d) The terminal box shall be provided with bolted terminals, Cu cable lugs and entries for

suitable cable glands corresponding to the number and size of specified cables. If specified in the requisition, nickel-plated brass (or aluminium if specifically required) double compression type cable glands and pin type lugs shall be supplied along with the motor for the mentioned cable sizes.

(e) Equipment and accessories provided should conform to the area classification and the

environmental conditions specified in the motor data sheet.

(f) The terminal box shall be capable of withstanding the full internal short-circuit conditions without danger to personnel or plant from the emission of hot gases or flame or due to excessive distortion or damage to the terminal enclosure. Unless otherwise specified, the fault level to be considered shall be 31 MVA for 415V System, (For motors rated below 55KW, the fault energy to be considered shall depend upon the back-up fuse rating).

(g) A separate terminal box shall be supplied for space heater as specified.

10. Phase marking

(a) Appropriate phase markings as per IS: 4728 shall be provided inside the terminal box.

The Markings Shall be non-removable and indelible. Other Details :

Motor shall be TEFC squirrel cage type in standard frame size as per IS/IEC rated for continuous duty with high efficiency and designed for soft starting. Motor shall be suitable for starting under specified load conditions with 75% of rated voltage at the terminals. Motor torque shall be compatible with the speed torque curve of the compressor. Motor winding shall be Class F insulated with temperature rise limited to Class B. Minimum degree of protection of enclosure shall be IP55 as per IS. Motor for use of hazardous shall have flameproof protection ex (d) as per area classification. The main motor starter should be soft starter and all accessories motor above 5.5kW should have start-delta except main compressor motor. Adequate space shall be provided along/ around the motor for maintenance purpose. The motor name-plate rating (exclusive of service factor) shall be minimum 110% of the greatest kW/ HP required under any of the specification operating conditions. All motor shall be tested in accordance with IS/IEC. Each motor shall be compulsorily be protected with thermal magnetic over-current relay. Electric power supply distribution panel switchgear panel and starter panels shall be skid mounted construction, weather and vermin proof suitable for installation in the compressor package. There shall be FLP push button panel available at the compressor skid. The switchgear shall have 1 incomer and adequate no. of outgoing feeders. The incomer shall be provided with suitable rated switch fuse unit, ammeter, voltmeter with selector switch, energy meter, pf meter, etc. Motor feeder shall be provided with heavy duty dwitch. HRC link type fuses, contractors (Ac 3 duty) bimetallic relays, single phase prevented, ammeter, pushbutton, earth leakage relay and indication lamp for start/stop/trip etc. Adequate nos. of MCB feeders for control and lighting shall be provided. Supplier shall furnish single line diagram of panel with the bid. The switch for change over of phase shall be provided inside the panel.

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Multi functional digital energy meter preferably HPL socomac CT2emfA1- basic version with maximum demand in kVA and kW with suitable fuse protection required within the panel. There shall be separate panel for main incoming switch (MCCB) and starter for main motor. There shall be minimum clearance of 30mm between the 2 power contactor. The compressor panel shall have phase reversal relay to detect electric supply phase sequence and trip the compressor on wrong phase sequence. Supplier shall make provision for earthing of the complete package as required as per IS All electrical shall comply with latest IS/ IEC. Epoxy base paint shall be applied on all electrical equipments. Supplier’s scope shall include obtaining statutory approvals for all complete package, wherever necessary. Bidder to note that all control electronics/ electrical, instrumentation shall be capable of withstanding voltage fluctuation within+ 15% of rated voltage (240 VAC). In case the card/components are not capable of withstanding above voltage fluctuation, the scope of supply of compressor package shall include an UPS/ voltage stabilizer (VS) / voltage conditioner(VC) so as to take care of voltage fluctuation. In such condition each compressor packager shall be provided with individual UPS / VC / VS. along with necessary interconnecting cable. Bidder shall also be responsible for lying of such cable, installation and commissioning of UPS. Pre-lubricated sealed bearing for all motors may be considered provided a full guarantee is given for 4- 5 years of trouble, free service without necessity of lubrication. Various Data’s Curves & Design calculation for selection of Driver i.e. Electrical Motor to be submitted by bidder. Superimposed Torque-Speed characteristics of motor & compressor. Starting time calculation at 100%, 80% & 58% of rated voltage. Motor casing and type of enclosure 1. Motors for use in safe areas shall be normal industrial types meeting the specified ambient

conditions and operating requirements. The minimum degree of motor enclosures, including terminal boxes and bearing housing, shall be IP-44 as per IS: 4691 for motors meant for indoor use and IP-55 for outdoor duty motors.

2. Motors for use in hazardous area (Zone 1 or Zone 2) shall have type of protection Ex (d) or ex (p)

or Ex (e) or ex (n) as specified in the data sheet and shall meet the requirements of applicable Indian standards. The minimum degree of motor enclosure, including terminal boxes and bearing housings, shall be IP-55 as per IS: 4691 for all motors, used in hazardous areas.

3. Motors for outdoor use shall be suitable for installation and satisfactory operation without any

protective shelter or canopy. In case of manufacturer’s view that the motors for outdoor duty should have a canopy at any particular site, the same shall be deemed to be included in manufacturer’s scope of supply. Motor casing shall be provided with a suitable drain for removal any of condensed moisture.

4. Vertical motors with downward shaft shall be provided with fully covering rain canopies. Vertical

motors with upward shaft, e.g. on fin-fan coolers, shall be adequately protected, (such as with cowls/canopies) against ingress of water into the enclosure or the bearing housing, even when standing still for long periods of time.

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5. All internal and external metallic parts which can come into contact with cooling air, (piping, air

supply and discharge conduit, protective grills, air deflectors, filters and supports) shall be of corrosion-resistant material or appropriately treated to resist the corrosive agents which may be present in the atmosphere. Screws and bolts shall be hot- dip galvanised or zinc passivated to protect against corrosion.

6. Unless otherwise agreed, industrial and non-sparking type Ex (n) motors shall have standard

frame sizes for various output ratings as stipulated in IS:1231. 7. Acoustic enclosure should be fabricated in such that it is completely sealed so that gas or fire

should not travel from one enclosure to another. Two number L.E.L detectors and two UV detectors in each enclosure shall be provided.

Bearings and lubrication

1. Motors shall have grease-lubricated ball or roller bearings. In all cases, the bearings shall be chosen to provide a minimum operating life of 40,000 hours. Unless otherwise specified the bearing shall be adequate to absorb axial thrust in either direction produced by the motor itself or due to shaft expansion. Vertical motors shall be provided with thrust bearings suitable for the load imposed by the driven equipment. In cases such as pumps for hot liquids, the driven machine operates at high temperatures and the bearings, particularly of vertical motors, which are exposed to high temperature, shall be cooled by an impeller fan mounted on the shaft. This shall ensure efficient ventilation of the bearing and disperse the heat transmitted from the driven object by conduction or convection.

2. Bearings shall be capable of grease injection from outside without removal of covers with motors

in the running condition. The bearing boxes shall be provided with required seals, to prevent loss of grease or entry of dust or moisture, where grease nipples are provided, these shall be associated, where necessary, with appropriately located relief devices which ensure passage of grease through the bearing. Pre-lubricated sealed bearings will be considered provided a full guarantee can be given for 4 to 5 years trouble-free service without the necessity of re-lubrication.

COOLING SYSTEM

1. All motors shall be self ventilated, fan cooled. The fans shall be of bronze, brass, aluminium, mild steel, stainless steel or of plastic. Plastic fans shall be “antistatic” type. i.e. they shall not permit the accumulation of electric charge on the fan surface. Brass or bronze fans shall not be used for motors installed in fertiliser plants. In all cases fans shall be corrosion-resistant or appropriately protected against corrosion. They shall be suitable for rotation in either direction without affecting the performance of the motor. If this is not possible for large outputs, it shall be possible to reverse the fan without affecting the balancing of the motor.

2. Motors for installation in dusty atmospheres or in the presence of sand, fuel or other solid

particles in suspension in the air, shall be fitted with filters for the cooling air. The filters shall be easily accessible for inspection and removable for cleaning and re-use.

3. The material of the filter and support trays shall be rustproof or protected against oxidation or

corrosion. Other requirements

1. Anti-condensation heaters

(a) All motors rated above 75KW shall be provided with 240V anti-condensation heaters, sized and located so as to prevent condensation of moisture during shutdown periods. Motors meant for humid locations such as cooling tower fans, sump pump, etc. shall be provided with space heaters irrespective of the motor rating. The heaters shall

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permanently remain ‘ON’ when the motor is not in service and as such shall not cause damage to the windings.

(b) For motors installed in hazardous atmospheres (Zone 1 or Zone 2) such heaters shall

conform to the provision of applicable Indian standards and temp. Classification specified in the data sheet.

(c) The heater leads shall be brought out to a separate terminal box of the same

specification and grade of protection as the main power terminal box excepting that the cable glands provided shall be suitable for three core 2.5 Sq.mm. copper conductor, armoured cable.

2. Motors shall be provided with a single shaft extension with keyway and full key. 3. All motors above 25Kg of weight shall be provided with lifting hooks of adequate capacity to

facilitate safe lifting. 4. Two earth terminals located preferably on diametrically opposite points shall be providing for

each motor. Necessary nuts and spring washers shall be provided for earth connection. 5. A warning with indelible red inscription shall be provided on the motor to indicate that isolation of

the power line alone is not sufficient and that the heater supply should also be isolated before carrying out any work on the motor.

6. Fixing bolts: All motors shall be supplied with fixing bolts. 7. Special tools and spanners

(a) Each motor shall be provided with a set of spanners and special tools, required for dismantling and maintenance of the motor.

(b) Triangular spanners required for explosion-proof or increased safety motors are

considered as special tools. 8. A name plate as required under specification IS: 325 shall be provided on each motor in addition

to the motor rating plate. A separate motor plant equipment number plate shall be fixed in readily visible position. This number is indicated on the attached data sheets. Additional information as stipulated in applicable Indian standards shall be included in the nameplate for motors meant for use in hazardous atmospheres.

9. The permissible noise level shall not exceed the stipulations laid down in IS: 12065. 10. Motor vibrations shall be within the limits of IS: 12075 unless otherwise specified for the driven

equipment. 11. Internal and external parts of the casing and all metal parts likely to come in contact with the

surrounding air shall be protected with anti-acid paint that will resist the particular ambient condition. All external surfaces shall be given a coat of epoxy based paint.

Performance

1. The pull out torque at the rated voltage shall be not less than 175% of the rated load torque with no negative tolerance. In the case of motors driving equipment with pulsating loads (e.g. reciprocating compressors) the minimum value of pull out torque at 80% of the rated voltage shall be more than the peak value of the pulsating torque. Unless otherwise agreed, the pull out torque shall not exceed 300 % of the rated load torque.

2. The minimum value for product of efficiency and power factor for motors rated up to and including 37KW shall be as per IS: 8789

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3.13 Coupling

The first preference is for directly coupled driver-compressor arrangement.

3.14 Enclosure of CNG Compressor Package

3.14.1 The Compressor package shall be housed in an acoustic leak proof enclosure. The equipment shall be mounted on one common skid. Enclosure shall restrict maximum noise level to 75 dBA at 1 meter from the enclosure.

The maximum temperature within the enclosure shall be limited to 52ºC based on the ambient temperature of 47ºC. Adequate ventilation fans shall be provided to meet the above and also to account for heat dissipation of the coolers as well as maintaining the positive pressure inside enclosure.

Suitable interlocks shall be built in for clearing the entrapped gases (if any) within the enclosure before the start up of the compressor package. The CLIENT/CONSULTANT shall review the vent requirements to meet the above & interlocks during detailed engineering.

3.14.2 Enclosures shall provide a degree of protection equivalent to IP 54 as defined in AS 1939 and provided with adequate ventilation system.

3.14.3 The enclosures shall have doors for normal access and removable wall panels for ease of maintenance.

The acoustic material should be fire resistant with fire retardant rating of 30 min. UL approval/IS certification shall be applicable for acoustic material..

3.14.4 All the pressure, temperature, gas flow meter, oil level, lube oil pressure, coolant temperature, coolant

level indicators shall be visible from outside of enclosures. 3.14.5 Enclosure shall have internal flame proof lighting arrangement. 3.14.6 For handling of all heavy parts for maintenance purpose lifting arrangement i.e. beam fitted with chain

hoist shall be provided in the enclosure. The beams should be properly centered over the heavy equipments. Certificate of chain hoist is to be provided.

3.14.7 All Coolers, Cooling System, lubrication system along with interconnecting piping shall be inside the

enclosure. Enough headroom shall be made available for easy access and maintenance of all equipment in the enclosure.

- Components such as pressure gauges, temperature and pressure switches etc., which require in-site adjustment and reading, shall be easily accessible.

- Conduits and tubing shall be arranged in orderly and systematic manner and shall be routed

neatly to enter the back of display or monitoring panels.

- Routine service item such as, but not limited to, crank case oil filters, inter stage gas filters, inlet and outlets gas filters shall be located to facilitate easy one-man servicing.

- One person should be able to access crank case oil inlet and drains to allow addition or drainage of oil without removing panels or adjacent components and without the need of the pump.

- Items which must be operated & monitored during operation shall be readily accessible without

opening the door.

- Suitable gradients shall be provided on the enclosure roof for rain drainage and to avoid water pockets.

3.15 Piping

3.15.1 All gas piping shall be designed, fabricated & tested in accordance with ANSI B 31.3.

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3.15.2 Gas piping shall be seamless carbon steel manufactured in accordance with ASTM A- 53 Gr. B or ASTM A - 106 Grade B. All Gas piping shall be flanged connections.

3.15.3 All rigid piping, tubing & other components of compressor package shall be designed for full range of pressure & temp and loading to which they may be subjected with a factor of safety of at least 4 based on minimum specified tensile strength at specified ambient temperature.

3.15.4 All rigid piping shall be continuous between their respective components & free of connections except

welded joints. All high pressure joints shall be welded unless otherwise not feasible. 3.15.5 The instrument air tubing material shall be Stainless Steel series –316 conforming to ASTMA269. 3.15.6 All high-pressure double ferrule fitting & 2/3 way valves shall be from SWAGELOK or PARKER makes &

shall be SS 316L material only. 3.15.7 Bidder shall furnish a temporary start up conical strainer fitted with adequate size mesh at the gas inlet

before the filter. 3.15.8 All lube oil piping down stream of filter shall be series 300 Stainless Steel.

3.15.9 External drain & vent piping shall be Carbon Steel and not less than 1" nominal size.

3.15.10 Mercaptan/THT dosing is envisaged hence all materials coming in contact with gas shall be compatible

to such gas with Mercaptan/THT dosing and be of compressor manufacturer's standard. The use of SA 515 material is prohibited.

3.15.11 All gas piping after coalescent filter at compressor discharge shall be of SS 316 of Sandvik/Tubacex make

and hardness less than Rb 80.

4.0 CONTROL PHILOSOPHY

4.1 The compressor package control system shall be designed for unattended operation in automatic mode and in case of any fault it will go in a safe mode. Compressor Package shall be provided with a PLC based LCP of approved make (i.e. Siemens- /ABB/GE Fanuc/Tata Honeywell/Allen Bradley), which shall be weatherproof to IP55 and shall be certified suitable for specified hazardous area classification. PLC should be integral with the package with necessary Hazardous Area Certificate (HAC) compliance. HMI shall be of text display type. PLC shall incorporate all process parameters (specified elsewhere) and status of compressor, engine & priority panels and shall be modular in construction with 100% redundancy with respect to CPU, Power supply, Interface. PLC components/system shall be tropicalised, MIL standard adopted with complete wiring and necessary terminals. Wiring to be colour coded with cross ferruling in position. PLC shall be capable of carrying out on line routines for at least ten separate loops without affecting the scan, cycle & up dating time etc. PLC shall be capable for display of flow meter data (i.e. Gas suction, Gas Discharge), various trips/abnormal conditions, compressor running hour etc. in following manner: a) Shift wise (for 3 shift operation i.e. 06:00-14:00, 14:00-22:00 & 22:00-06:00)- shall be available for at least last 96 hours. b) Daily basis- shall be available for at least last 31 days. c) Fortnightly basis- shall be available for at least last 3 fortnights. d) Monthly basis- shall be available for at least last 2 months.

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PLC shall be configured as a remote terminal unit of supervisory computer and data acquisition system

complete with dial up connectivity. One card for transferring and accessing data from minimum twenty devices with RS 485 port shall be provided. PLC SCADA connectivity is required as per the attached specification at Annexure-IX.

PLC would be provided with integral keyboard and display for configuring, programming and to view process & machine parameters. Suitable communication port for connectivity to PC with RS 485 card shall be provided to download programs etc from PLC through a Laptop. Laptop not included in Bidder’s scope.

All source & object codes including logic flow chart, ladder diagram etc are to be furnished by the

Packager and PLC shall be capable of incorporating function Block diagram, sequence function chart, ladder diagram and structural text as per IEC 61131. Bidder shall provide individual application software. Programming software one set usable for all machines is to be supplied.

4.2 The compressor package control system shall be so designed that the first item to go into alarm condition shall lock out to indicate the cause of the trip though the cause of the trip may have disappeared. The lock out condition shall be manually reset. A change over set of contacts shall be provided for SGL’s use to give a remote indication of alarm and trip.

4.3 In auto mode, compressor shall start automatically in case high bank storage pressure falls below 200

kg/cm2 and stop as soon as pressure of stationery cascade reaches 250 kg/cm2. 4.4 The priority fill system (In bidder’s scope) shall ensure the filling of vehicle, storage cascade and mobile

cascade in correct order. Priority fill system shall be necessarily of actuator type. Following Priorities are envisaged for supply of compressor packages:

With (5) bank priority panel:

Break up:

1st - Direct to dispenser unit

2nd – High Bank cascade

3rd - Medium bank cascade

4th - low bank cascade

5th - Mobile bank (LCV)

Priority panel shall of high bank and pneumatic actuated type consisting of inlet and outlet valves and NRV, safety valves, pressure transmitter in each bank and should be controlled through PLC.

Each line must be complete with necessary NRV and Full flow control trunion mounted ball valve, inter connected NRV and ball valves required for smooth operation and shall have ¾” full flow ball valve at the battery limit of equipment. Bidder shall provide P & ID along with offer indicating battery limit condition.

4.5 Control system shall be designed such that in case of any fault, discrepancy or abnormality, it will go in

safe mode. All controls shall be made in fail-safe mode & failure of any control shall not lead to operation of equipment/ system in unsafe condition.

4.6 In case of fault, a warning hooter shall operate, the sound of which should be audible at distance of at least 15 meter. Further the fault alarm and emergency stop PB shall be duplicated in the CNG station control room. Acknowledgement/resetting of fault shall be possible only from compressor panel. Emergency stop PBs shall be mushroom head turn lockable type.

4.7 Once the fault is acknowledged or the engine and/or compressor are under normal maintenance, the valves of priority panel shall take the position so that gas available in the stationary CNG storage cascade can be dispensed.

4.8 The pressure in each bank shall be monitored from down stream of priority panel.

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4.9 Bidder shall provide emergency shut down (ESD) system in the control room as well as locally mounted on the compressor panel and one no. on the enclosure. Total 3 nos. of ESD switches to be provided as a minimum.

4.10 Fail-safe system shall be designed and incorporated to isolate cascade storage from dispenser, stop

compressor, isolate the compressor suction line on activation of ESD switch. ESD switch shall have to be manually reset to restart the compressor package again. 4.11 Bidder shall provide individual Application program for PLC, HMI (Human Machine Interface) on LCP

(one set) along with all interfacing adaptors and cables. Bidder shall also provide one set of source & object codes for PLC, HMI on LCP (in both forms, hard & soft). Programming software one set usable for all machines is to be supplied.

4.12 All pressure and temperature at compressor inlet, outlet, at each stage before and after cooling, to be available on the PLC.

4.13 Suction gas filter with oil drain, differential pressure gauge and temporary suction inline strainer at the compressor package inlet before PRV and Slam Shut off valve.

4.14 All material use in the package should be flame retardant.

4.15 The maximum discharge temperature for each stage shall be limited to 150 degree centigrade before cooler and 52 degree centigrade after cooler.

4.16 The motor selected should be for continuous duty operation.

4.17 The motor bearing should guarantee for minimum of 40000 hours of trouble free operations.

4.18 Winding temperature sensor of the motor to be interlocked with emergency shutdown system for tripping in case of winding temperature increases above the limit.

4.19 Enclosure shall be flameproof and provided with forced ventilation system.

4.20 All the pressure, temperature, gas flow meter, oil level, lube oil pressure shall be visible from outside of enclosures.

4.21 Enclosure shall have flame proof (internal/external) lighting arrangements.

4.22 Bidder shall furnish a temporary start up conical strainer fitted with adequate size mesh at the gas inlet before filter.

4.23 Priority panel should be at package discharge, however priority panel should be kept outside the package preferable mounted on the walls of the compressor enclose covered with additional doors.

4.24 The compressor package should trip if any of the doors is kept open.

4.25 The enclosure shall have doors for normal access and removable wall panels for east of maintenance. The acoustic materials should be fire resistant with fire retardant rating of 30 min. the materials used should be UL approved. Necessary documents to be submitted for the material selected.

4.26 Priority panel shall be by PLC based.

4.27 The pressure in each bank should be monitored downstream of priority panel.

4.28 PLC shall incorporate all process parameter (specified elsewhere) and status of compressor, priority panels and shall be modular in construction with 100% redundancy. PLC components/ system shall be tropicalised, MIL standard adopted with compete wiring and necessary terminals. Wiring to be colour coded with cross ferruling in position.

4.29 Type approval for compressor package including all instrument items from PESO is needed.

4.30 The bidder shall have servicing facility in India existing since, last six months. Proof of the same has to be submitted.

4.31 Compressor foundation size with all projected portion should not exceed 6.0mm in length and 3.5m in width in all direction.

4.32 Basis for calculation of venting loss/ KWH (Loading factor) to be demonstrated. Quoted valve shall be demonstrated at site by successful bidder.

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4.33 RPM meter shall be in package

5.0 INSTRUMENTATION

5.1 All Instruments shall be suitable for an area classification of “Class 1, Division 2, Group D as per NEC” OR “Zone II, Group IIA/IIB as per IS/IEC”.

5.2 All package mounted transmitters/transducers & temperature element shall be intrinsically safe" i.e." as

per IEC 79-11 and solenoid valves, switches and related junction boxes shall be certified flame proof (Eexd) as per IEC 79-1 by a statutory body viz. FM, BASEEFA etc. for the specified hazardous area classification. Other special equipment’s/instruments, where intrinsic safety is not feasible or available the same shall be flame proof (Eexd) certified suitable for the specified hazardous area by a statutory body as per IEC 70-1. All analog as well as digital input to PLC shall be connected through barriers. All analog barrier shall be isolator type.

5.3 The compressor package instrumentation & control is to be configured for manual as well fully automatic

control system including starting, shutdown as applicable for unattended operation. Control system shall be PLC based with make & model no. duly approved by CLIENT/CONSULTANT.

5.4 Instrumentation electronics shall be certified by a recognized authority such as BASEEFA, PTB, LCIE,

CESI, INIEX, and CMRS. 5.5 All the instrumentation shall be capable of operating for full range of operation.

5.6 Separate junction boxes shall be provided for each type of signal i.e., analog, digital, solenoids, RTD thermocouple and power supply. Instrument junction boxes should not have any high voltage connection.

5.7 All pressure gauges and pressure transmitters shall be provided with common isolation valve and have

accuracy of + or – 1 % of Full Scale Deflection (FSD). 5.7.1 The temperature gauge shall be generally mercury in steel filled type, weatherproof & with capillary

extension. Capillary tubing shall be min CS with CS flexible armouring. The gauge shall have accuracy of + or - 1% Full Scale Deflection (FSD). The range shall be 1.5 times of operating temperature.

5.8 All field instruments power shall be limited to 24 VDC. Power conversion unit if required shall be in the

scope of the bidder. All instruments and enclosures shall be dust proof and weather proof to IP 65 as per IEC-529/ IS 2147.

5.9 Units of measurement shall be:

GAS FLOW - Kg/hr & SM3/hr PRESSURE - Kg/cm2 g TEMPERATURE - 0C

5.10 Following points to be noted regarding Mass Flow meter – Coriolis type: 5.10.1 Each Mass Flow meter shall include a sensor with integral transmitter i.e. meter electronics certified

intrinsically safe/explosion proof by statutory authority suitable for the required hazardous area as per IS-2148 /IEC-79. Also the offered sensor and the transmitter shall be weather proof to IP 65 as per IS-2147/IEC-529. Statutory authority for local installation is CCOE.

5.10.2 Allowable pressure drop for the flow meter at the inlet and outlet of the compressor shall be 1.0 kg/ cm2. Offered mass flow meter shall be necessary for Custody Transfer application but not exceeding 0.5% of span.

5.10.3 Calibration for the offered mass flow meter shall be in Kg/hr and SM3/hr. Pressure, Temperature

compensation shall be provided by the meter.

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5.10.4 Flying lead type electrical termination is not acceptable. All electrical connections shall be ½” NPTF. Cable glands shall be provided for electrical power, signal and control connections. Cable glands shall be double compression type and certified weatherproof and explosion proof for the required area classification as per IS-2147 and IS-2148.

5.10.5 Offered Mass flow meter shall be completely free from corrosion of measuring tube due to alternating

stresses continuously occurring in the tube. Also measuring tube shall be completely free from erosion, which may result due to fluid velocity.

5.10.6 The design of meter electronics shall be in compliance with the electromagnetic compatibility

requirements as per IEC-801. Meter Electronics shall include all the associated pre-amplifiers converters lineariser etc.

5.10.7 Installation details like straight run requirements, recommendation for horizontal /vertical installation,

minimum distance between upstream and downstream pipe bends from Mass flow meter to be provided. 5.10.8 Bidder shall calibrate each Mass Flow meter at his shop or any recognized test house with the fluid (Use

design process conditions) for which it is to be used as per Clause no.9 of MPMS (Draft standard Nov. 2000). In case it is not possible to calibrate the Mass Flow meter with actual fluid, Bidder must indicate:-

a) Fluid used for calibration b) Correction factor/Adjustment required for actual process fluid. In any case, inaccuracy when

extended to actual process shall not exceed the specified limits (as per manufacturer’s standard). 5.10.9 Bidder shall submit the following test certificates and test reports for purchaser’s review: -

a) Material test certificate with detailed chemical analysis from foundry (MIL Certificate).

b) Certificate of radiography / x-ray for any welded joint.

c) Hydrostatic test report with pressure of 1.5 times the design pressure.

d) Calibration report including calibration factors for each Mass flow meter certificate from statutory body for offered sensor and transmitter for required area classification.

5.11 CERTIFICATION:

The requirement of statutory approvals for usage of equipment/instruments/system in electrically hazardous areas shall be as follows: a) The bidder shall be responsible for obtaining all statutory approvals, as applicable for all instruments

and control systems.

b) Equipments/instruments/systems located in electrically hazardous areas shall be certified for use by statutory authorities for their use in the area of their installation. In general, the following verification shall be provided by the bidder. - Bidder shall provide certificates (from BASEEFA, FM, UL, PTB, LCIE etc.) from country of origin

for all intrinsically safe/flameproof protected by other methods equipment/instrument/systems, which are manufactured outside India. Bidder shall provide necessary certification/approvals/authentication, for all such intrinsically safe/flameproof equipment/instrument/systems, by the Indian authority–Chief Controller of Explosive (CCOE), Nagpur, India & BIS.

- For all flame proof equipment manufactured within India, the testing shall be carried out by any of

the approved testing houses- Central Mining Research Institute (CMRI)/ERTL etc. The item shall in addition bear the valid certification from CCOE and also the manufacturer shall hold a valid Bureau of Indian Standards (BIS) licence.

- For all intrinsically safe equipment manufactured within India the testing shall be carried out by

any of the approved testing houses – Central Mining Research Institute (CMRI)/ERTL etc. The item shall in addition bear the valid certification from CCOE & BIS.

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6.0 EARTHING / CABLING

Metallic part of all equipment not intended to be live shall be connected to earth as per provisions of IS: 3043/IEC recommendation. Grounding of all electronics shall be separately connected to earth using insulated copper wire. Grounding of electronic equipment shall not be connected to earthing for electrics or equi-potential bonding.

6.1 Cabling 6.1.1 Cables for Power & Control inside as well as outside the enclosure shall be minimum 2.5 Sqmm (copper)

and 1.5 Sqmm (copper) respectively. 6.1.2 Cables shall be 1100-volt grade, stranded copper conductor, PVC insulated PVC sheathed, steel round

wire armoured. FRLS cables. 6.1.3 Cables shall be terminated using double compression type metallic flameproof cable glands and copper

lugs. 6.1.4 Spare cores to be kept in each control cable. 6.1.5 All Junction Boxes (JBs) shall have metallic enclosure 6.1.6 Cables for control circuits shall be single phase (2 wire), 240 V, 50Hz A.C. supply from UPS. 6.1.7 All cables shall be of armoured type. 7.0 INSPECTION AND TESTING

7.1 General

a) Inspection and Test Requirements have been spelled out in respective Equipment Data Sheets & Technical Specification.

b) Bidder shall confirm compliance to all inspection and testing requirements stipulated therein and include the inspection charges in the lump sum cost.

c) All tests which are required to be witnessed stagewise as per data sheet and this specification shall

be witnessed by a TPI duly appointed by the bidder. For major tests and inspection points as per data sheet and specification shall be witnessed by CLIENT/CONSULTANT. The bidder shall notify the timing of such inspection and testing to CLIENT/CONSULTANT one week before the schedule Inspection date.

d) Bidder shall submit detailed Test Procedure for Approval of the CLIENT/CONSULTANT one week in

advance of the actual date of conducting each test.

7.2 Mechanical running test (MRT)

7.2.1 The MRT for the each compressors shall be carried out with job or shop driver including complete job driving system i.e., job pulleys etc., for 4 hours continuously at shop of compressor manufacturer. During this test following shall be recorded at agreed intervals.

- Vibration levels measured on cylinders and frame - Bearing temperature - Oil cooler inlet and outlet temp Subsequent to satisfactory run the compressor shall be examined as per standard procedure & following shall be examined as minimum: - Bore & other parts by opening a valve

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- Piston & cylinder clearance - Visual examination of piston rod, cylinder guide bore without dismantling

If any of part found damaged, all similar components shall be stripped for inspection. The MRT test shall be repeated after replacement of such parts.

7.3 Motor Performance

1. Tests on the completely assembled motor shall be carried out in the presence of CLIENT/CONSULTANT or his representative. The results shall be tabulated and signed by both contractor and owner or their representatives. Though the motors shall be accepted on the basis of the satisfactory results of the tests at the works, it shall not absolve the contractor from liability regarding the proper functioning of motor coupled to the driven equipment at site.

2. General Inspection

(a) Check for installation according to drawings. (b) Check equipment for clean and dry conditions, proper lubrication of bearings, earthing and

terminations. 3. The motors shall be tested in accordance with IS:325 and IS:4029. Type tests including any specific

test to ascertain compliance with these specifications shall be carried out if necessary, on one sample from each kW rating and frame size. Routine tests shall be carried out on all motors which are as follows:

(a) Insulation resistance test. (b) High voltage test. (c) No load running of motor and reading of current in three phases and voltage. (d) Locked rotor test at a suitable voltage. (e) Reduced voltage running up test. (f) Temperature rises test.

1. Before connecting power cables to motor, the insulation resistance of all motor windings shall be

measured with 500 Volts megger for 415 Volts systems and with 5 KV megger for H.V system. Minimum megger reading shall be 10 Mega ohms. Measurements shall be repeated after power cable terminations are completed.

2. After checking the direction of rotation, all motors shall be run uncoupled for a minimum period of 4

hours before the driven equipment is placed in regular service.

7.4 Mechanical String Test

Mechanical String Test for 4 hrs is a mandatory requirement to be performed at packager’s shop before despatch in presence of CLIENT/CONSULTANT representatives (or a third party as arranged by SGL). This test can be clubbed up with the Mechanical Run Test of compressor as specified above, provided the job driver & lube Oil system is used for the test. At least 25% of the packages ordered shall be string tested.Mechanical run test however is a mandatory requirement.

7.5 Package Performance Test

Bidder shall send fully assembled package including auxiliary systems, instrumentation, safety devices within the enclosure to the site and carry out the performance test for 72 hours duration at site or works. Full load performance test shall be carried out at site/work for 4 hours. Field trial run shall be carried out for 72 hours duration added with interval after full load performance test.

In case the bidder has the facility to carry out the complete field performance test satisfactorily at their works then the bidder need not repeat the field performance test. This shall be in addition to tests carried out as per clause nos. 8.2, 8.3 & 8.4.

Complete package shall be performance tested as a module whereby along with motor & compressor performance bidder shall demonstrate all controls, shutdown, trips/alarms etc.

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The test shall be the basis of assigning penalties on the bidder, acceptance/rejection of the package thereon. Bidder shall submit the detail test procedure for the same including methodology of demonstration of venting losses, which shall be approved by SGL. The test for the package shall be witnessed by SGL’s representative.

8.0 PERFORMANCE GUARANTEES, LOADING AND PENALTIES

8.1 This section describes the guaranteed parameter, which the CNG compressor package must fulfill, the penalty for shortfall in guaranteed parameters and rejection of compressor package by the CLIENT/CONSULTANT.

8.2 The guaranteed parameter shall be adjusted to account for variation in gas composition and prevailing

ambient condition during testing. 8.3 Necessary calculations correction curves shall have to be furnished by Bidder along with bid, which shall

be final & no deviation shall be permitted afterwards. 8.4 In case of any inconsistency in manufacture and/or operation of supplied compressor package, Bidder

shall at his own risk and cost, eliminate the defects to the satisfaction of CLIENT/CONSULTANT. Bidder shall furnish guaranteed value as per Annexure – II enclosed with this specification.

8.5 Compressor Capacity

8.5.1 Bidder shall guarantee 1200 SCM/hr capacity of compressor with design case gas composition, at suction pressure of 16 kg/cm2g, suction temperature of 19oC, discharge pressure of 250 kg/cm2g.

Since the compressor suction pressure varies from 14 kg/cm2g to 19 kg/cm2g the compressor shall be sized / selected for specified capacity of 1200 SCM/Hr at 16 kg/cm2g (with no –ve tolerance) whereas the driver shall be selected on the basis of compressor BkW with either 14 kg/cm2g or 19 kg/cm2g whichever is higher.

8.5.2 Bidder shall guarantee 650 SCM/hr capacity of compressor with design case gas composition, at suction pressure of 16 kg/cm2g, suction temperature of 190 C, discharge pressure of 250 kg/cm2g with the negative tolerance for errors in instruments and measurements. Since the compressor suction pressure varies from 14 kg/cm2g to 19 kg/cm2g the compressor shall be sized / selected for specified capacity of 650 SCM/Hr at 16 kg/cm2g (with no -ve tolerance) whereas the driver shall be selected on the basis of compressor BkW with either 14 kg/cm2g or 19 kg/cm2g whichever is higher. The Total connected load of 650 SCMH compressors should not exceed 98 KW.The same shall be used to establish the capacity at test bed during package performance test. Bidder to note that a separate filtering cum regulating skid to be provided at the inlet with pressure range of 20-35 bar to feed the compressor at 14-19 bar.

8.6 Loading & Penalty Criteria

8.6.1 Loading

Bidder shall indicate the Power Consumption and/or BHP as guaranteed value in the offer.

Bidder shall also indicate the venting losses due to leakages from packings in percentage of total throughput of the package.

The offers shall be loaded for the fuel/electricity consumption as given under:-

The loading per package shall be the differential cost evaluated as follows;

Total cost of the package for evaluation purpose (A+C1+C2)

Where

A: Capital cost of each package including cost of erection, commissioning, special tools and commissioning spares

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C1: Differential operating cost for power consumption as defined hereunder

C2: Differential operating cost for vent/packing losses as defined hereunder

Differential operating cost (C1)

C1 (in Rs) = Nop x (Fe - Fr) x Cp X Dp

Where

Nop: 8000 Hrs

Fe: Guaranteed power consumption in KW by the bidder.

Fr: Lowest Guaranteed power consumption KW (amongst technically accepted bidders)

Cp: Cost of power as Rs 3.85 / KWH

Dp: discounting factor to arrive at Net Present Value (NPV) based on 5 years i.e. 3.274

Differential operating cost (C2)

C2 (in Rs) = Nop x (Fv - Fr) x Cf X Df

Where

Nop: 8000 Hrs

Fv: Estimated venting/packing losses in percentage of throughput of package by the bidder.

Fr: Lowest venting/packing losses in percentage of throughput (amongst technically accepted bidders)

Cf: Cost of fuel as Rs 14 / SCM

Df: discounting factor to arrive at Net Present Value (NPV) based on 5 years i.e. 3.274

Maximum loading shall be limited to 10% of the total quoted Cost i.e. A as defined above.

8.6.2 Penalty

During compressor package performance test, in case the compressor package fails to meet the guaranteed values, the following penalties shall be imposed.

A. In case during shop performance test of compressor package the power consumed in terms of KW, to achieve the guaranteed compressor capacity of 1200 SCM/Hr or 650 SCM/Hr as the case may be is found more than 10% the entire package shall stand rejected. However, for every extra KW consumed over and above the guaranteed value upto a maximum of ten percent the Bidder shall be penalized for extra power consumption.

The penalty per package shall be the differential cost calculated as follows:

PY (in Rs) = (FT-FG) X CP X 8000 X DP

Where,

PY = Penalty Cost

FT = Power consumption as obtained from performance test in terms of KW

FG = Guaranteed power consumption in KW

CP = Rs. 3.85 / KWH

DP = 3.274 (Discounting factor based on 5 years of operating years)

B. In shop performance test if the venting/ packing losses in percentage of throughput of 1200 SCM/Hr or 650 SCM/Hr are found to be in excess of the guaranteed value the bidder shall be penalized for excess venting losses.

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The penalty per package shall be the differential cost calculated as follows:

PY (in Rs) = (FT-FG) X CF X 8000 X DF

Where,

PY = Penalty Cost

FT = Venting/packing loss as obtained from performance test in terms percentage of throughput

FG = Estimated venting/packing loss in percentage of throughput

CF = Rs. 14 /SCM

DF = 3.274 (Discounting factor based on 5 years of operating years)

The total penalty to be charged for non-conformance of guaranteed parameter shall not exceed 10% of the ordered value i.e. A+B as defined above.

No advantage shall be given for higher performance than the guaranteed.

Bidder shall indicate the Guaranteed parameter in his offer as per Annexure–I of this specification.

8.6.3 Penalty for Non-Performance during Period of Operation & Maintenance

8.6.3.1 Details of Penalty for non performance of equipments

(a) On normal day (i.e. the day other than the schedule maintenance day):

(i) The party has to ensure that the equipments are available for operation for minimum 20 hours per day and on an average the equipment availability has to be 98% in a month.

(ii) If the equipment is down for more than 4 hours on any day or availability is less than 98% in a month. Penalty would be applicable as follows:

Upto 12 hours: Rs. 10,000/- per day.

Beyond 12 hours: Rs. 25,000/- per day.

(b) On schedule maintenance day:

(i) The party would be required to carry out the recommended schedule/preventive maintenance of the equipments for which the party has to indicate the time required for each type of schedule maintenance.

(ii) If the equipment is down for more than 4 hours & upto 12 hours beyond the time indicated for the agreed schedule maintenance, the party would be penalized Rs. 10,000/- and for more than 12 hours Rs. 25,000/- per day.

8.6.3.2 In any case, the maximum penalty imposed in a month for non-performance of the equipment would be limited to 50% of the amount of O&M charges to be paid to the party per month per compressor (a complete cost break up of O&M charges need to be furnished by the bidder during bid).

9.0 PAINTING AND PROTECTION

9.1 Packing shall be sufficiently robust to withstand rough handling during ocean shipment & inland journey. Sling points shall be clearly indicated on crates.

9.2 The external steel surfaces of equipment & piping shall be painted. The paint shall be chosen, primed and applied as to have a service life of atleast two years. The exterior of equipment and container is required to be corrosion free for atleast two years and to have faded free life without oxidation of paint surface for atleast two years in an environment of bright sunlight with an intense UV content. The Packager to specify the Grade of the paint intended to be used.

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9.3 The headers of air-cooled exchanger shall be zinc sprayed.

10.0 ERECTION, TESTING AND COMMISSIONING AT SITE

10.1 Bidder shall be responsible for erection commissioning; performance test, field noise level test and field trial run of all compressor packages at site.

10.2 Bidder shall be liable to pay all local taxes, levies applicable and comply with rules, laws prevailing in

India. 11.0 FIELD TRIAL RUN/ SITE PERFORMANCE TEST

Bidder shall conduct a field trial run of each compressor package for minimum 72 hours continuous duration at guaranteed points in which satisfactory operation of complete package together with all accessories/auxiliaries controls shall be established for specified operating conditions prior to the start of 1st year operation and maintenance during warranty period & next 3 Years operation & comprehensive maintenance period as defined in the contract. Full load performance test shall be carried out at site/work for 4 hours. Field trial run shall be carried out for 72 hours after full load performance test. During the field trial run the bidder will be allowed a maximum of THREE attempts to complete the above-specified test. The Equipment shall be considered commissioned after the successful completion of Field Trial Run. All punch points raised by CLIENT/CONSULTANT should be completed before performing the FTR/ Site PT. The above conditions are also applicable in case the bidder carries out the performance test and trial run at their works.

12.0 SPARE PARTS, SPECIAL TOOLS AND TACKLES

12.1 All spare parts, special tools & tackles for erection and commissioning and spare parts required for 1(One)+ Three (03) Year Operation and maintenance of compressor package shall be arranged by the Packager and shall form his scope of supply. The bidder has to provide the list of spares, tools & tackles for erection and commissioning and spare parts required for operation & maintenance along with the bid. These tools and tackles and any spare parts left after work completion shall be the property of Client. Bidder shall maintain sufficient spares to fulfill the warranty period requirements.

12.2 A brand new separate set of Special Tools & Tackles per compressor as required for preventive maintenance as well as breakdown maintenance beyond the contractual One Year Operation Period shall be supplied by the Packager, which shall form the property of CLIENT/CONSULTANT.

13.0 MAINTENANCE PHILOSPHY:

Bidder shall provide maintenance philosophy and schedule of maintenance along with offer. First year of operation, when equipment is in warranty period, bidder shall arrange and store all necessary spares to avoid any loss in operating times.

Bidder also intimate the list of recommended spares envisaged for maintenance and shall store in the custody.

14.0 WARRANTY SERVICING AND SPARE PARTS

The supplier should provide a warranty for a period of 12 months after commissioning or 24 months from the date of shipment, whichever expires first inline with GCC. All necessary spare parts during warranty period shall be provided by bidder free of cost for which bidder shall provide sufficient stock of spares at CT of installation.

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15.0 DATA AND DRAWING

a) Drawings and Data shall be furnished in conformity with the Bidder Data Requirements Forms attached with Enquiry Specifications. b) Bidder shall furnish all the information at the time of bidding as specified in the relevant Bidder Data Requirement (BDR) forms. c) The data requirement after placement of Fax of Intent (FOI) is indicated in the Bidder Data

Requirement Forms for the respective equipment, including the number of weeks within which this data is to be provided. Bidder shall confirm that all data as required shall be furnished by him and shall indicate the Bidder’s promised data in the columns provided.

d) After the placement of FOI, a conference (kick off meeting) will be held at such place, as may be

mutually agreed upon between the Bidder and the CLIENT/CONSULTANT within 15 days from the date of placement of FOI. The intent of this conference shall be to discuss / clarify various requirements and finalize the modus operandi for execution of the contract within the scheduled delivery period.

e) Bidder shall furnish the Drawings/Documents for CLIENT/CONSULTANT’s Review / approval as

per the Bidder Data Requirement (as specified in the Specifications/Bidder Data Requirement forms). The review comments for major and critical drawings (such as system P&ID’s, General Arrangement Drawings, Foundation Drawings, Performance characteristics, Pulsation and Vibration Study Reports, Torsional Analysis etc.) shall be discussed across the table at such date and place as may be mutually agreed between the CLIENT/CONSULTANT and the Bidder.

f) Along with the supply of compressor packages, the supplier shall provide application software for PLC & HMI, ladder logic. Programming software one set usable for all machines is to be supplied.

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ANNEXURES

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ANNEXURE – I: GAS COMPOSITION

Component

% mole

Methane

94.5189

Ethane 4.3663

Propane 0.5405

i-Butane 0.0877

n-Butane 0.1227

i-Pentane 0.0057

n-Pentane 0.0020

Nitrogen

0.2863

Carbon dioxide

0.0663

C6+

0.0037

Total 100

Oxygen : Not more than 0.5 mole% Total Non Hydrocarbon : Not more than 2.0 mole% Total Sulphur including H2S : Not more than 10 ppm by weight expected H2S content not more than

4 ppm by volume Water Content : <112 Kg per MMSCM Specific Gravity (SG) : 0.55 - 0.63 Net Calorific Value : 8485.096 Kcal/SCM

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ANNEXURE-II: GUARANTEED PARAMETERS

GUARANTEED PARAMETERS – II (A) 1200 SCMH (Electric Motor Driven with suction pressure 14 - 19 kg/cm2G)

Sr. No. Parameter Bidder’s Data

1 Compressor Capacity in SM3/Hr (required 1200 SM3/Hr)

2 Compressor BKW in KW @ Rated Conditions (No +ve tolerance)

3 Compressor BKW in KW @ RV Set Conditions (No +ve tolerance)

4 Net of all auxiliaries/package ventilation loads in KW

5 Site rated BKW of Motor (No –ve tolerance)

6 Vent/packing losses in package in percentage of throughput(Basis of loading and penalty)

7 Noise level 75 dBA @ 1 meter from enclosure (required 75 dBA max)

GUARANTEED PARAMETERS – II (B) 650 SCMH (Electric Motor Driven with suction pressure 14 - 19 kg/cm2G)

Sr.No. Parameter Bidder’s Data

1 Compressor Capacity in SM3/Hr (required 650 SM3/Hr)

2 Compressor BKW in KW @ Rated Conditions (No +ve tolerance)

3 Compressor BKW in KW @ RV Set Conditions (No +ve tolerance)

4 Net of all auxiliaries/package ventilation loads in KW

5 Site rated BKW of Motor (No –ve tolerance)

6 Vent/packing losses in package in percentage of throughput(Basis of loading and penalty)

7 Noise level 75 dBA @ 1 meter from enclosure (required 75 dBA max)

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ANNEXURE – III: LIST OF RECOMMENDED THIRD PARTY INSPECTION AGENCY

LIST OF RECOMMENDED THIRD PARTY INSPECTION AGENCY

S.NO ITEM NAME OF VENDOR ADDRESS PHONE NO FAX NO

1 Tata Projects Ltd. 22,Sarvodaya Society,Nizampura,Baroda-390002

0265-2392863

0265-2785952

2 Indian Register of Shipping

52 AAdi Shankaracharya Marg Opp. Powai Lake , Powai,MUMBAI,400 072

022-30519400

022-25703611

3 Bax counsel Insepection

Bureau Pvt. Ltd.

303, Madhava,Bandra Kurla Complex, Bandra(E),Mumbai-400051

022-26591526,

022-26590236

022-26591526

4 Bureau Veritas Ql The Leela Galleria,5th floor,Andheri-

Kurla Road,Andheri(E),Mumbai-400059

022-26956300

022-26956309

5 Germanischer Lloyd

304-305, Anna Salai,Teyanampet,Chennai-600018

044-24320335

044-24328186

6 Velosi

Certification Serrvices,Mumbai

Velosi Certification Services(I)Pvt.Ltd.,212,Shivkrupa

Complex Centre,Off Ghokhale Road,Navpada Thane(W)-400602

022-25376770

022-25426777

7 ABS Industrial

Verification Ltd., Mumbai

404,Mayuresh Chambers,Sector-11,CBD Belapur(E),Navi Mumbai-

400614

022-27578780 /1

/2

022-27578784 /

5

8

Certification Engineers

International Ltd.

EIL Bhavan,5th floor,1,Bhikaji Camma Place,New Delhi-110066

011-26167539,26

102121

011-26101419

9 Dalal Mott MacDonald

501, Sakar -II, Ellisbridge,Ahemedabad-380006

079-26575550

079-6575558

10 International Certification

Systems

E-7,Chand Society, Juhu Road, Juhu, Mumbai-4000049

022-26245747

022-226248167

11

Third Party

Inspection Agency

SGS SGS India Pvt. Ltd.,SGS

House,4B,A.S.Marg,Vikhroli(W),Mumbai-400083

022-25798421 to

28

022-25798431 to

33 Note: The details of Vendors indicated in this list are based on the information available with WGEIL, BIDDER shall verify the capabilities of each vendor for producing the quantity with proper quality. Purchaser or purchaser representative does not take any responsibility on the performance of the vendor.

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ANNEXURE – IV: APPROVED BIDDER LIST

ITEM CODE / DESCRIPTION AIR FILTER REGULATORS BIDDER NAME REMARKASEA BROWN BOVERI LTD.

BLUE STAR LTD DIVYA CONTROL ELECMENTS PVT. LTD. JANATICS INDIA PVT. LTD. P.RAI AND COMPANY PLACKA INSTRUMENTS & CONTROLS PVT. LTD SHAH PNEUMATICS SHAVO NORGREN (I) PVT. LTD V AUTOMAT & INSTRUMENTS PVT. LTD. VELJAN HYDRAIR PVT. LTD. ITEM CODE / DESCRIPTION FIELD INSTRUMENTS (P, DP, F,L,T) BIDDER NAME REMARKSABB AUTOMATION LTD. BROWN BOVERT LTD. ASCHROFT MURPHY CCS WAREE FISHER ROSEMOUNT INDIA LIMITED FISHER ROSEMOUNT SINGAPORE PTE LTD. FUJI ELECTRIC CO. LTD. HONEYWELL INC. TATA HONEYWELL YOKOGAWA ELECTRIC CORPORATION YOKOGAWA BLUE STAR LTD. WIKA DRUCK ITEM CODE / DESCRIPTION MASS FLOW METERS BIDDER NAME REMARKENDRESS & HAUSER CMBH & COMPANY CORIOLIS TYPE, MANUFACTUER,

ENDRESS + HAUSER FLOWTEC AG, REINACE, SWITZERLAND

EMERSON PROCESS MANAGEMENT CORIOLIS TYPE RHEONIK MESSGERATE GMBH CORIOLIS TYPE ITEM CODE / DESCRIPTION PRESSURE GAUGES BIDDER NAME REMARKSAN INSTRUMENTS PVT. LTD. BADOTHERM PROCESS INSTRUMENTS B. V. BOURDON HAENNI S.A BRITISH ROTOTHERM CO . LTD BUDENBERG GUAGE CO. LTD. DRESSER INC GENERAL INSTRUMENTS CONSORTIUM MANOMETER (INDIA) PVT. LTD. NAGANO KEIKI SEISAKUSHO LTD. WAAREE INSTRUMENTS LIMITED WALCHANDNAGER INDUSTRIES LTD. WIKA ALEXANDER WIEGAND & CO GMBH WIKA INSTRUMENTS INDIA PVT. LTD. DRUCK ITEM CODE / DESCRIPTION PRESSURE RELIEF VALVE BIDDER NAME REMARKS

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ALSTHOM FLUIDS SAPAG ANDERSON GREENWOOD CROSBY BHEL (TRICHY ) DRESSER INC. FUKUI SEISAKUSHO CO. LTD. INSTRUMENTATION LTD. (PALGHAT) NAKAKITA SEISAKUSHO CO LTD. NUOVO PIGNONE SPA (ITALY) PARCOL SPA SAFETY SYSTEMS UR LTD. SARASIN RSBD SEBIN VALVES INDIA PVT. LTD. TAI MILANO SPA TYCO SANMAR LTD. TYCO VALVES & CONTROLS INDIA PVT. LTD NIRMAL INDUSTRIES ITEM CODE / DESCRIPTION SELF ACTUATED PR. CONTROL VALVE BIDDER NAME REMARKDANIEL INDUSTRIES INC DRESSER PRODUITS INDUSTRIES ESME VALVES LTD. FISHER ROSEMOUNT SINGAPORE PTE LTD. FISHER EXMOX SANMAR LIMTED GORTER CONTROLS B.V. INSTROMET INTERNATIONAL NV KEYE & MACDONALD INC NUOVO PIGNONE SPA (ITALY) PIETRO FIORENTINI SPA RICHARDS INDUSTRIES (FORMERLY TRELOAR) RMG REGEL + MESSTECHNIK GMBH ITEM CODE / DESCRIPTION SOLENOID VALVES BIDDER NAME REMARKALCON ALEXANDER CONTROLS LIMITED ASCO (INDIA) LIMITED JEFFERSONS ASCO JOUCOMATIC LTD. ASCO JOUCOMATIC SA AVCON CONTROLS PVT. LTD. BARKSDALE INC. BLUE STAR LTD. HERION WERKE SCHRADER SCOVILL DUNCAN LIMITED ITEM CODE /DESCRIPTION SPECIAL CONTROL VALVES BIDDER NAME REMARKFISHER ROSEMOUNT SIGAPORE PTE. LTD. FLOWSERVE PTE. LTD. (FORMERLY DURIRON) HOPKINSONS LIMITED METSO AUTOMATION PTE LTD. (FORMERLY NELES) NUOVO PIGNONE SPA (ITALY) SPX VALVES & CONTROLS (FORMERLY DEXURIK ) ITEM CODE /DESCRIPTION FLAME DETECTOR MAKE REMARKDETECTION INSTRUMENT(I)PVT LTD MEGGITT AVIONICS SPECTREX DETRONICS HONEYWELL

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ITEM CODE /DESCRIPTION GAS DETECTOR (IR TYPE) MAKE REMARKDETECTION INSTRUMENT(I)PVT LTDCROWCON DETRONICS GENERAL MONITORS SIEGER ITEM CODE /DESCRIPTION PLC MAKE REMARKSIEMENS-POSITRONICS ALLAN BRADLEY, ROCKWELL ABB GE FENUC HONEYWELL MITSUBHISHI TELEMECANIQUE ITEM CODE /DESCRIPTION FLP MOTOR MAKE REMARKABB CGL KIRLOSKAR SIEMENS ITEM CODE /DESCRIPTION FLP SWITCHGEAR MAKE REMARKBALIGA FCG FPE STERLING FLEX PRO ITEM CODE /DESCRIPTION SWITCHES/FUSES/ CONTACTORS MAKE REMARKL&T GEC SIEMENS SCHNEIDER ITEM CODE /DESCRIPTION UV FLAME DETECTOR MAKE REMARKGENERAL MONITORS CROWCON SEIGER MAGGIT DETRONICS ITEM CODE /DESCRIPTION SOFT STARTER MAKE REMARKSCHNEIDER ALLEN BRADLEY ITEM CODE /DESCRIPTION START-DELTA STARTER AND

ELECTRICAL SWITCHGEAR MAKE REMARKL&T SCHNEIDER

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ANNEXURE-V: BIDDER DATA REQUIRED

(A) BIDDER DATA REQUIRED

(For 1200 SCMH (Electric Motor Driven) with suction pressure 14 – 19 kg/cm2)

CERTIFIED INFORMATION REQUIRED AFTER PURCHASE ORDER

S. NO

DESCRIPTION PRINTS WITH BID

FOR REVIEW FOR RECORDS A GENERAL 1 PROJECT SCHEDULE YES 2 DULY FILLED-IN

“CHECKLIST FOR COMPLETENESS OF BID”

YES

3 DULY FILLED-IN “CHECKLIST FOR SCOPE OF SUPPLY”

YES

4 DEVIATION LIST (IF ANY) TO THE APPLICABLE SPEC., DATASHEETS

YES

5 UTILITIES REQUIREMENT SUMMARY

YES YES

6 FLANGE DETAILS OF PIPING CONNECTION WITH CONNECTION AT BATTERY LIMIT

YES

7 DULY FILLED IN EXPERIENCE RECORD PROFORMA

YES

8 GUARANTEE PARAMETERS AS SPECIFIED

YES YES

9 TENTATIVE LOAD DATA FOR FOUNDATION DESIGN

YES

10 LIST OF SUB-BIDDERS FOR ALL BOUGHT OUT ITEMS INCLUDING ELECTRICAL & INSTRUMENTATION ITEMS

YES

11 LEAFLET, CATALOGUES FOR ALL ITEMS

YES YES

12 O & M MANUAL YES B COMPRESSOR 1 DATASHEETS FOR THE

FOLLOWING YES YES

A - COMPRESSOR YES YES B - HEAT EXCHANGERS YES YES C - PRESSURE VESSELS YES YES D - MOTOR YES YES 2 CATALOGUE FOR

COMPRESSOR YES YES

3 TYPICAL CROSS SECTIONAL DRAWING AND LITERATURE TO FULLY DESCRIBE THE DETAILS OF OFFERING

YES

A - COMPRESSOR YES B - SUCTION VALVE YES C - DISCHARGE VALVE YES

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D - PISTON ROD GLAND PACKING & PISTON RINGS

YES

E - LUBE OIL PUMP YES 4 PULLEY WITH SELECTION

CHART & CALCULATION YES

5 COOLER DATA / DRG WITH THERMAL & MECH DESIGN CALCULATION

YES

6 DESIGN CALCULATION, GA DRGS FOR PULSATION DAMPNER

YES

7 PIPING & INSTRUMENTATION DIAGRAMS FOR THE FOLLOWING

YES YES

A - PROCESS GAS YES YES B - LUBE OIL YES YES C - AIR START UP / VENT YES YES 8 TORQUE ANGLE DIAGRAM,

PISTON ROD LOAD VS CRANK ANGLE

YES

9 TORQUE SPEED CHARACTERISTICS

YES

10 ACOUSTIC / MECHANICAL EVALUATION REPORT

YES

11 DRG. FOR TESTING ARRANGEMENT & TEST PROCEDURE TO BE ADOPTED

YES

12 CERTIFICATE FOR FOLLOWING:

YES

A HYDRAULIC TESTING YES B NON DESTRUCTIVE

TESTING YES

C MATERIAL COMPOSITION & PHYSICAL PROPERTIES

YES

D LEAK PROOFNESS TEST OF FRAME

YES

E LUBE PUMP, FRAME OIL PUMP, HYD OIL PUMP

YES

13 DESIGN / ACTUAL ASSEMBLY CLEARANCE CHART

YES

14 TEST RECORDS OF FOLLOWING

A MECHANICAL RUNNING S YES B PERFORMANCE TEST /

PACKAGE TEST YES

C NOISE LEVEL TEST YES YES 15 LIST OF SPECIAL TOOLS &

TACKLES FOR INSTALLATION & MAINTENANCE

YES YES

C ELECTRIC MOTOR 1 PERFORMANCE CURVES YES YES 2 TECHNICAL LITERATURE / YES YES YES

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CATALOGUE, SELECTION CHARTS, NOMOGRAPHS ETC.

3 CONTROL SCHEMATICS 3 YES YES 4 TYPICAL COMPONENT

CROSS SECTIONAL DRAWING AND LITERATURE TO FULLY DESCRIBE THE DETAILS OF OFFERING

YES

5 TEST PROCEDURE YES 6 FINAL ACCEPTANCE

TESTING AND PERFORMANCE TESTED RECORDS

YES

7 SCHEMATIC DIAGRAM WITH START UP & SHUT DOWN PROCEDURE & LOGIC

YES

D INSTRUMENTATION 1 G.A. OF INSTRUMENT

PANEL WITH BILL OF MATERIAL & WIRING DIG. FOR LCP

YES

2 INSTRUMENT DATASHEET YES 3 LOGIC DIAGRAM / LADDER

DIAGRAM / FUNCTIONAL DIAGRAM

YES

4 LOOP SCHEMATIC YES 5 INTER CONNECTING

DIAGRAM YES

6 OPERATING / CONTROL WRITE UP

YES

7 ALARM / SHUT DOWN LIST7

YES

8 WIRING DIAGRAM / INTER CONNECTING PIPING

YES

9 START UP AND SHUT DOWN WRITE UP

YES YES

10 START UP AND SHUT DOWN INLET LOCK DIAGRAM

YES YES

11 ALARM AND SHUTDOWN LIST WITH SET POINT

YES YES

12 LOAD CONTROL PANEL LAYOUT

YES

13 TERMINATION DIAGRAM, PANEL WIRING DETAIL

YES


DIAGRAM YES

16 CABLE SCHEMATIC YES 17 BILL OF MATERIAL YES 18 TEST / INSPECTION

CERTIFICATE YES

19 LIST OF RELIEF VALVES WITH SETTINGS

YES

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1.1.1 Document Distribution Schedule

1.1.2 Documents and drawings under column no. 3 shall be submitted with each copy of the bid.

1.1.3 Documents listed under column 4 are to be submitted in 4 copies

1.1.4 Documents listed under column 5 are to be submitted in 4 copies.

1.1.5 Documents listed in Clause 1.2 below are to be submitted as hard bound indexed book containing the following details in Twelve (12) copies & 2 AutoCAD software set and to be submitted within 4 weeks of release note/dispatch of materials/ equipment from bidder's works.

1.2 Details to be included in Final Documents Books

1.2.1 Copy of P.O. and all amendments.

1.2.2 Copy of Purchase Requisition and all amendments.

1.2.3 Manufacturing Data Book containing all test certificates of components, raw materials, stage manufacturing tests and inspections, final tests & inspection documents including welders' qualification & welding procedure qualification, repairs & reworking carried out in shops. All raw material test certificates must be correlated to the P.O. Item No. & component to which they relate by clear notings on the certificates.

1.2.4 Spares details including assembly drawings, part numbers, delivery, prices and ordering information.

1.2.5 All design calculations carried out by the bidder.

1.2.6 Final Drawing Index and all as-built drawings reduced to A3/ A4 size and wherever reduction is not possible, full size copies duly folded and placed in plastic pockets.

1.2.7 Catalogues/leaflets of sub-bidders/suppliers of various bought out components highlighting the components actually supplied correlated to P.O.Item Numbers.

1.2.8 Operating and maintenance instructions including lubrication schedules with details of suppliers for procurement by OWNER for subsequent needs.

1.2.9 Release Note and Packing List.

1.2.10 Any other documents asked for in the Purchase Requisition.

1.2.11 All final drawings shall also be given to purchaser in digitized form on CD-ROM compatible to AUTOCAD software (2 sets).

1.3 Special instructions for submission of Dwgs./Documents:

1.3.1 Fold all prints to 216 MM x 279 MM size & roll transparencies.

1.3.2 Contractor to forward the drawings and documentation to SGL (Attention bidder prints control department) clearly specifying purchasers Job no. & Req. No.

1.3.3 The drawing/Document no. with Rev. No. is essential. The number may be up to a maximum of 28 characters in length.

1.3.4 Each Drawing/Document submitted to SGL must be checked and signed/stamped by contractor before it is submitted to SGL.

1.3.5 Revision number must change during subsequent submission of bidder document.

1.3.6 Multi-sheet documents other than drawings must be submitted in their entirety in the event of a re-submission even if only a few sheets are revised.

1.3.7 Final submission in bound volumes shall necessarily have a cover page giving project title, Item name, P.O.No. particulars of owner & bidder and an index giving list of drawings & documents included (with revision no.

1.3.8 All bidder drawings to be provided with a blank space measuring 75 mm W x 38 mm H for marking of review codes etc. by SGL.

1.3.9 The review of the bidder drawings shall be done by SGL, as applicable, under the following review codes:

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Review Code A No comments.

Review Code B P Proceed with manufacture/fabrication as per commented drawings.

Revise drawings required

Review Code C Document does not conform to basic requirements.

Review code D For information

1.3.10 Review of bidder drawings by SGL would be only to check compatibility with basic designs & concepts & would in no way absolve the contractor/bidder of his responsibility to meet applicable codes, specifications & statutory rules/regulations.

Bidder shall submit within 10 days after placement of FOI, the complete list of drawings/ documents with submission dates against each. Critical drawings, only, the list of which will be agreed during kick-off meeting shall be reviewed jointly at SGL's office.

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(B) BIDDER DATA REQUIRED

(For 650 SCMH (Electric Motor Driven) with suction pressure 14 – 19 kg/cm2)

CERTIFIED INFORMATION REQUIRED AFTER PURCHASE ORDER

S. NO

DESCRIPTION PRINTS WITH BID

FOR REVIEW FOR RECORDS A GENERAL 1 PROJECT SCHEDULE YES 2 DULY FILLED-IN

“CHECKLIST FOR COMPLETENESS OF BID”

YES

3 DULY FILLED-IN “CHECKLIST FOR SCOPE OF SUPPLY”

YES

4 DEVIATION LIST (IF ANY) TO THE APPLICABLE SPEC., DATASHEETS

YES

5 UTILITIES REQUIREMENT SUMMARY

YES YES

6 FLANGE DETAILS OF PIPING CONNECTION WITH CONNECTION AT BATTERY LIMIT

YES

7 DULY FILLED IN EXPERIENCE RECORD PROFORMA

YES

8 GUARANTEE PARAMETERS AS SPECIFIED

YES YES

9 TENTATIVE LOAD DATA FOR FOUNDATION DESIGN

YES

10 LIST OF SUB-BIDDERS FOR ALL BOUGHT OUT ITEMS INCLUDING ELECTRICAL & INSTRUMENTATION ITEMS

YES

11 LEAFLET, CATALOGUES FOR ALL ITEMS

YES YES

12 O & M MANUAL YES B COMPRESSOR 1 DATASHEETS FOR THE

FOLLOWING YES YES

A - COMPRESSOR YES YES B - HEAT EXCHANGERS YES YES C - PRESSURE VESSELS YES YES D - MOTOR YES YES 2 CATALOGUE FOR

COMPRESSOR YES YES

3 TYPICAL CROSS SECTIONAL DRAWING AND LITERATURE TO FULLY DESCRIBE THE DETAILS OF OFFERING

YES

A - COMPRESSOR YES B - SUCTION VALVE YES C - DISCHARGE VALVE YES D - PISTON ROD GLAND YES

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PACKING & PISTON RINGS E - LUBE OIL PUMP YES 4 PULLEY WITH SELECTION

CHART & CALCULATION YES

5 COOLER DATA / DRG WITH THERMAL & MECH DESIGN CALCULATION

YES

6 DESIGN CALCULATION, GA DRGS FOR PULSATION DAMPNER

YES

7 PIPING & INSTRUMENTATION DIAGRAMS FOR THE FOLLOWING

YES YES

A - PROCESS GAS YES YES B - LUBE OIL YES YES C - AIR START UP / VENT YES YES 8 TORQUE ANGLE DIAGRAM,

PISTON ROD LOAD VS CRANK ANGLE

YES

9 TORQUE SPEED CHARACTERISTICS

YES

10 ACOUSTIC / MECHANICAL EVALUATION REPORT

YES

11 DRG. FOR TESTING ARRANGEMENT & TEST PROCEDURE TO BE ADOPTED

YES

12 CERTIFICATE FOR FOLLOWING:

YES

A HYDRAULIC TESTING YES B NON DESTRUCTIVE

TESTING YES

C MATERIAL COMPOSITION & PHYSICAL PROPERTIES

YES

D LEAK PROOFNESS TEST OF FRAME

YES

E LUBE PUMP, FRAME OIL PUMP, HYD OIL PUMP

YES

13 DESIGN / ACTUAL ASSEMBLY CLEARANCE CHART

YES

14 TEST RECORDS OF FOLLOWING

A MECHANICAL RUNNING S YES B PERFORMANCE TEST /

PACKAGE TEST YES

C NOISE LEVEL TEST YES YES 15 LIST OF SPECIAL TOOLS &

TACKLES FOR INSTALLATION & MAINTENANCE

YES YES

C MOTOR 1 PERFORMANCE CURVES YES YES 2 TECHNICAL LITERATURE /

CATALOGUE, SELECTION YES YES YES

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CHARTS, NOMOGRAPHS ETC.

3 CONTROL SCHEMATICS 3 YES YES 4 TYPICAL COMPONENT

CROSS SECTIONAL DRAWING AND LITERATURE TO FULLY DESCRIBE THE DETAILS OF OFFERING

YES

5 TEST PROCEDURE YES 6 FINAL ACCEPTANCE

TESTING AND PERFORMANCE TESTED RECORDS

YES

7 SCHEMATIC DIAGRAM WITH START UP & SHUT DOWN PROCEDURE & LOGIC

YES

D INSTRUMENTATION 1 G.A. OF INSTRUMENT

PANEL WITH BILL OF MATERIAL & WIRING DIG. FOR LCP

YES

2 INSTRUMENT DATASHEET YES 3 LOGIC DIAGRAM / LADDER

DIAGRAM / FUNCTIONAL DIAGRAM

YES


DIAGRAM YES

6 OPERATING / CONTROL WRITE UP

YES

7 ALARM / SHUT DOWN LIST7

YES

8 WIRING DIAGRAM / INTER CONNECTING PIPING

YES

9 START UP AND SHUT DOWN WRITE UP

YES YES

10 START UP AND SHUT DOWN INLET LOCK DIAGRAM

YES YES

11 ALARM AND SHUTDOWN LIST WITH SET POINT

YES YES

12 LOAD CONTROL PANEL LAYOUT

YES

13 TERMINATION DIAGRAM, PANEL WIRING DETAIL

YES


DIAGRAM YES

16 CABLE SCHEMATIC YES 17 BILL OF MATERIAL YES 18 TEST / INSPECTION

CERTIFICATE YES

19 LIST OF RELIEF VALVES WITH SETTINGS

YES

1.1.1 Document Distribution Schedule

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1.1.2 Documents and drawings under column no. 3 shall be submitted with each copy of the bid.

1.1.3 Documents listed under column 4 are to be submitted in 4 copies

1.1.4 Documents listed under column 5 are to be submitted in 4 copies.

1.1.5 Documents listed in Clause 1.2 below are to be submitted as hard bound indexed book containing the following details in Twelve (12) copies & 2 AutoCAD software set and to be submitted within 4 weeks of release note/dispatch of materials/ equipment from bidder's works.

1.2 Details to be included in Final Documents Books

1.2.1 Copy of P.O. and all amendments.

1.2.2 Copy of Purchase Requisition and all amendments.

1.2.3 Manufacturing Data Book containing all test certificates of components, raw materials, stage manufacturing tests and inspections, final tests & inspection documents including welders' qualification & welding procedure qualification, repairs & reworking carried out in shops. All raw material test certificates must be correlated to the P.O. Item No. & component to which they relate by clear notings on the certificates.

1.2.4 Spares details including assembly drawings, part numbers, delivery, prices and ordering information.

1.2.5 All design calculations carried out by the bidder.

1.2.6 Final Drawing Index and all as-built drawings reduced to A3/ A4 size and wherever reduction is not possible, full size copies duly folded and placed in plastic pockets.

1.2.7 Catalogues/leaflets of sub-bidders/suppliers of various bought out components highlighting the components actually supplied correlated to P.O.Item Numbers.

1.2.8 Operating and maintenance instructions including lubrication schedules with details of suppliers for procurement by OWNER for subsequent needs.

1.2.9 Release Note and Packing List.

1.2.10 Any other documents asked for in the Purchase Requisition.

1.2.11 All final drawings shall also be given to purchaser in digitized form on CD-ROM compatible to AUTOCAD software (2 sets).

1.3 Special instructions for submission of Dwgs./Documents:

1.3.1 Fold all prints to 216 MM x 279 MM size & roll transparencies.

1.3.2 Contractor to forward the drawings and documentation to SGL (Attention bidder prints control department) clearly specifying purchasers Job no. & Req. No.

1.3.3 The drawing/Document no. with Rev. No. is essential. The number may be up to a maximum of 28 characters in length.

1.3.4 Each Drawing/Document submitted to SGL must be checked and signed/stamped by contractor before it is submitted to SGL.

1.3.5 Revision number must change during subsequent submission of bidder document.

1.3.6 Multi-sheet documents other than drawings must be submitted in their entirety in the event of a re-submission even if only a few sheets are revised.

1.3.7 Final submission in bound volumes shall necessarily have a cover page giving project title, Item name, P.O.No. particulars of owner & bidder and an index giving list of drawings & documents included (with revision no.

1.3.8 All bidder drawings to be provided with a blank space measuring 75 mm W x 38 mm H for marking of review codes etc. by SGL.

1.3.9 The review of the bidder drawings shall be done by SGL, as applicable, under the following review codes:

Review Code A No comments.

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Review Code B Proceed with manufacture/fabrication as per commented drawings. Revisedrawings required

Review Code C Document does not conform to basic requirements.

Review code D For information

1.3.10 Review of bidder drawings by SGL would be only to check compatibility with basic designs & concepts & would in no way absolve the contractor/bidder of his responsibility to meet applicable codes, specifications & statutory rules/regulations.

Bidder shall submit within 10 days after placement of FOI, the complete list of drawings/ documents with submission dates against each. Critical drawings, only, the list of which will be agreed during kick-off meeting shall be reviewed jointly at SGL's office.

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ANNEXURE-VI: M.R. COMPLIANCE SCHEDULE

ANNEXURE VI (A): 1200 SCMH ELECTRIC MOTOR DRIVEN CNG COMPRESSOR

ITEM: CNG COMPRESSOR

Bidder:

S. No. Requirements Compliance By Bidder (To Be Answered By Bidder)

1.0 Confirm compliance individually to following clauses of Job Specification.

SECTION: A

Clause no 1.0

Clause no 2.0

Clause no 3.0

Clause no 4.0

Clause no 5.0

Clause no 6.0

Clause no 7.0

Clause no 8.0

Clause no 9.0

Clause no 10.0

Clause no 12.0

Clause no 13.0

Clause no 14.0

Clause no 15.0

Clause no 16.0

2.0 Confirm that you have filled-up the following Schedules/ Annexure and enclosed these with the Bid

Gas Composition (Annexure-I)

Guarantee Parameters (Annexure-IIA)

List of Recommended Third Party Inspection Agency (Annexure-III)

Approved Vendor List (Annexure-IV)

Bidder Data Required (Annexure-VA)

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Experience Record Schedule for CNG Compressors Package (Annexure-VIA)

Material Requisition Compliance Schedule (Annexure-VIIA)

3.0 Confirm that you have filled-up the Data Sheet and enclosed with the Bid.

Compressor Data Sheet

Electric Motor Data Sheet

Inter cooler Data Sheet

Heat Exchanger Data sheet

Mass Flow Meter Data Sheet

Control Valves

Solenoid Valves

Self Actuated Pressure Control Valves

Pressure Relief Valve

Pressure Instruments

Pressure Gauges

4.0 Confirm that following Documents have been enclosed with Bid.

List of components of CNG Compressor with Make & Specification of components alongwith Technical Catalogues of components.

Battery Limit (Interface) drawing/ information.

Process flow diagrams (PFDs) and Piping & Instrumentation diagrams (P & IDs) of sub systems and complete system with write-up on operation

Utility requirement

Detail of control wiring diagram, interlock/shutdown/ control scheme with write up on operation. Sizing calculation for instrument items.

G.A. drawing of Compressor showing maintenance clearances required.

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ANNEXURE VI (B): 650 SCMH ELECTRIC MOTOR DRIVEN CNG COMPRESSOR

ITEM: CNG COMPRESSOR

Bidder:

S. No. Requirements Compliance By Bidder (To Be Answered By Bidder)

1.0 Confirm compliance individually to following clauses of Job Specification.

SECTION: A

Clause no 1.0

Clause no 2.0

Clause no 3.0

Clause no 4.0

Clause no 5.0

Clause no 6.0

Clause no 7.0

Clause no 8.0

Clause no 9.0

Clause no 10.0

Clause no 12.0

Clause no 13.0

Clause no 14.0

Clause no 15.0

Clause no 16.0

2.0 Confirm that you have filled-up the following Schedules/ Annexure and enclosed these with the Bid

Gas Composition (Annexure-I)

Guarantee Parameters (Annexure-IIB)

List of Recommended Third Party Inspection Agency (Annexure-III)

Approved Vendor List (Annexure-IV)

Bidder Data Required (Annexure-VB)

Experience Record Schedule for CNG Compressors Package (Annexure-VIB)

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Material Requisition Compliance Schedule (Annexure-VIIB)

3.0 Confirm that you have filled-up the Data Sheet and enclosed with the Bid.

Compressor Data Sheet

Motor Data Sheet

Inter cooler Data Sheet

Heat Exchanger Data sheet

Mass Flow Meter Data Sheet

Control Valves

Solenoid Valves

Self Actuated Pressure Control Valves

Pressure Relief Valve

Pressure Instruments

Pressure Gauges

4.0 Confirm that following Documents have been enclosed with Bid.

List of components of CNG Compressor with Make & Specification of components along with Technical Catalogues of components.

Battery Limit (Interface) drawing/ information.

Process flow diagrams (PFDs) and Piping & Instrumentation diagrams (P & IDs) of sub systems and complete system with write-up on operation

Utility requirement

Detail of control wiring diagram, interlock/shutdown/ control scheme with write up on operation. Sizing calculation for instrument items.

G.A. drawing of Compressor showing maintenance clearances required.

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ANNEXURE – VII : EXPERIENCE RECORD PROFORMA

ANNEXURE VII (A): EXPERIENCE RECORD PROFORMA OF ELECTRIC MOTOR DRIVEN COMPRESSOR PACKAGE FOR GAS KCAL / SCM = 8485.096 COMPRESSOR CAPACITY 1200 SM3/H

(SUCTION PRESSURE 14 - 19 kg/cm2G)

SR. NO DESCRIPTION INFORMATION OFFERED

COMPRESSOR INFORMATION OF

EXISTING COMPRESSOR

REQUIREMENT AS PER TENDER Cap 1200 sm3/h

1 Status of bidder a) Compressor manufacturer b) Motor manufacturer c) Packager 2 COMPRESSOR Name of compressor manufacturer Place of compressor manufacturer Compressor model Anticipated Life in running hours Compressor max frame BKW

Comp Manufacturing code API - 11P 2nd edition

Lubricated or non lubricated Nos of stages "3" Max stage temperature oC (150oC ) Compressor max RPM

Compressor operating RPM (max RPM - 1500)

Piston speed m/s

Vibrations at comp cylinders <10 mm / sec. Unfiltered peak velocity Vibration comp frame : Unfiltered peak velocity of 7.5 mm/sec or 250 micron unfiltered peak to peak vibration whichever is less

Material for all stages Cylinder as per datasheet Piston Rings (PTFE/PEEK) Rider Rings (PTFE/PEEK) Piston Rod (Forged steel)

Valve (Rings / plates / spring) : (SS/PEEK)

3 PERFORMANCE OF COMPRESSOR

CASE - L

Performance of compressor at 19 kg/cm2 suction pr, 250 kg/cm2 discharge pr and 35oC suction temp

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CASE - G GUARANTEED POINT:

Performance of compressor at 16 kg/cm2 suction, 250 kg/cm2 discharge pr and 35 o C suction temp

CASE -L

a) Capacity Sm3/h

CASE-G

CASE -L

b) BKW required by compressor including compressor's lube oil pump BKW CASE-G

CASE -L

c) BKW required by compressor including compressor's lube oil pump BKW at RV set pr CASE-G

d1) Gas cooler (heat exchanger ) fans; nos required (W+S)

CASE -L

d2) Power required for all fans in KW

CASE-G

e) Ventilation fans for enclosure No of fans Type of fans (included or forced draft) Power required for all fans in KW

Site Capacity of Motor

Piston rod and cross head pin loading at any specified operating condition including the relief valve set condition shall not exceed 80% of the maximum design rod load of the offered compressor

---- Piston rod : max design

--- Piston rod: calculated at safety set pr condition

--- Max cross head pin loading : Design

--- Cross head pin loading : calculated at safety set pr condition

Guaranteed gas loss through rod deals ; sm3/h

Other information of compressor

a) Year of manufacturing of the compressor

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b) Name and address of user with FAX no, phone no, E-mail address

c) Nos of hours the compressor have clocked on bid due date (Enclose certificate from user)

4 Motor

Make and model Anticipated Life in running hours

Power (ISO power) & corresponding Max RPM

Site power (KW) at operating RPM after deration

KW of motor with availability of 10% overload for one hour within a period of 12 hrs operation with no negative tolerance

240V anti-condensation heaters, sized and located so as to prevent condensation of moisture during shutdown periods

Lifting hooks of adequate capacity to facilitate safe lifting.

Other information of electric motor

a) Year of manufacturing of the motor


c) Nos of hours the motor has run as on bid due date (Enclose certificate from user)

5 PACKAGE

Name of Packager

Place of Packaging

Name of Enclosure Manufacturer

Palace of enclosure manufacturer

Sound level at 1 m distance from package in db (A) 75

Make and model LEL detector - 2 nos each comp

Make and model fire detector - 2 nos each comp

2 no min 45 kg C02 cylinder with weighing arrangement

Volume of enclosure in m3

Nos of explosion proof tube light in each enclosure

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PACKAGES

SHEET 55 OF 64

Coupling Direct

Mass flow meter to measure the Natural Gas consumption at packages inlet, package discharge.

Separators between inter stage of compressor

Other information of complete package

a) Year and place of manufacturing of the package


c) Nos of hours the complete package (including engine and compressor) have clocked on bid date (enclose certificate from user)

6 Gas inlet train

Inlet relief valve

Inlet-gas pressure gauge

Non return valve

Inlet duplex gas filter

Temporary suction filter after mail filter

Inlet manual isolation valve

Inlet automatic isolation valve

Suction Skid: PRV shall be designed for pressure range from 20-35 bar to 14-19 bar

7 Gas recovery system

Gas recovery system with pr relief valve, pr regulator, pr gauge, manual & automatic drainage system

8 Gas Delivery system

High pr piping with SS 316, tubing, compression fittings, NRV

KOD

Coalescent filter

PLC based Priority panel with full bore ball valve. Priority panel shall be kept

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SHEET 56 OF 64

outside in a separate enclosure preferably mounted on compressor side walls.

Final gas outlet connection from priority panel 3/4" SS valves WITH 3/4" Tube OD end connections.

9 ESD system

10 Volume bottles / dampers at each compressor stage of compressor

Vessels

Drainage system

11 Manual double isolation valve

12 Automatic valves

13 Heat exchanger

14 Code of construction API 11 P

15 Gas sections of coolers shall be as per API - 11P requirements

16 Tube material SA-179

17 Piping between stages shall be continuous with flange connection

18 Gas recovery vessel provided

19 Area classification; " class 1, group D, division 1 as per NEC " OR " Zone 1, group IIA / IIB as per IS/IEC"

20 The size of the complete package

21 Chain pulley block and beam for chain pulley block

22 Acoustic and pulsation study

23 Acoustic enclosure for package

24 Instrumentation as indicated in TS

25 Human - machine interfacing unit (HMI)

26 String test as shop

27 Field trial run for 72 hours

28 Electric power requirement (purchaser will give electric power for air compressor and compressor controls)

29 Cabling - Double compression type cable glands and copper lugs

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30 Junction box with metallic enclosure

ANNEXURE VII (B): EXPERIENCE RECORD PROFORMA OF ELECTRIC MOTOR DRIVEN

COMPRESSOR PACKAGE FOR GAS KCAL / SCM = 8485.096 COMPRESSOR CAPACITY 650 SM3/H (SUCTION PRESSURE 14 – 19 kg/cm2)

SR. NO DESCRIPTION INFORMATION OFFERED

COMPRESSOR INFORMATION OF

EXISTING COMPRESSOR

REQUIREMENT AS PER TENDER Cap 650 sm3/h

1 Status of bidder a) Compressor manufacturer b) Motor manufacturer c) Packager 2 COMPRESSOR Name of compressor manufacturer Place of compressor manufacturer Compressor model Anticipated Life in running hours Compressor max frame BKW

Comp Manufacturing code API - 11P 2nd edition

Lubricated or non lubricated Nos of stages "3" Max stage temperature oC (150oC ) Compressor max RPM

Compressor operating RPM (max RPM - 1500)

Piston speed m/s

Vibrations at comp cylinders <10 mm / sec. Unfiltered peak velocity Vibration comp frame : Unfiltered peak velocity of 7.5 mm/sec or 250 micron unfiltered peak to peak vibration whichever is less

Material for all stages Cylinder as per datasheet Piston Rings (PTFE/PEEK) Rider Rings (PTFE/PEEK) Piston Rod (Forged steel)

Valve (Rings / plates / spring) : (SS/PEEK)

3 PERFORMANCE OF COMPRESSOR

CASE - L

Performance of compressor at 19 kg/cm2 suction pr, 250 kg/cm2 discharge pressure and 35oC suction temp

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CASE - G GUARANTEED POINT:

Performance of compressor at 16 kg/cm2 suction, 250 kg/cm2 discharge pressure and 35 o C suction temp

CASE -L

a) Capacity Sm3/h

CASE-G

CASE -L

b) BKW required by compressor including compressor's lube oil pump BKW CASE-

G

CASE -L

c) BKW required by compressor including compressor's lube oil pump BKW at RV set pr CASE-

G

d1) Gas cooler (heat exchanger ) fans; nos required (W+S)

CASE -L

d2) Power required for all fans in KW

CASE-G

e) Ventilation fans for enclosure No of fans Type of fans (included or forced draft) Power required for all fans in KW

Site Capacity of Motor

Piston rod and cross head pin loading at any specified operating condition including the relief valve set condition shall not exceed 80% of the maximum design rod load of the offered compressor

---- Piston rod : max design

--- Piston rod: calculated at safety set pr condition

--- Max cross head pin loading : Design

--- Cross head pin loading : calculated at safety set pr condition

Guaranteed gas loss through rod deals ; sm3/h

Other information of compressor

a) Year of manufacturing of the compressor

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c) Nos of hours the compressor have clocked on bid due date (Enclose certificate from user)

4 Motor

Make and model Anticipated Life in running hours

Power (ISO power) & corresponding Max RPM

Site power (KW) at operating RPM after deration

KW of motor with availability of 10% overload for one hour within a period of 12 hrs operation with no negative tolerance

240V anti-condensation heaters, sized and located so as to prevent condensation of moisture during shutdown periods

Lifting hooks of adequate capacity to facilitate safe lifting.

Other information of electric motor

a) Year of manufacturing of the motor


c) Nos of hours the motor has run as on bid due date (Enclose certificate from user)

5 PACKAGE

Name of Packager

Place of Packaging

Name of Enclosure Manufacturer

Place of enclosure manufacturer

Sound level at 1 m distance from package in db (A) 75

Make and model LEL detector - 2 nos each comp

Make and model fire detector - 2 nos each comp

2 no min 45 kg C02 cylinder with weighing arrangement

Volume of enclosure in m3

Nos of explosion proof tube light in each enclosure

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SHEET 60 OF 64

Coupling Direct

Mass flow meter to measure the Natural Gas consumption at packages inlet, package discharge.

Separators between inter stage of compressor

Other information of complete package

a) Year and place of manufacturing of the package


c) Nos of hours the complete package (including engine and compressor) have clocked on bid date (enclose certificate from user)

6 Gas inlet train

Inlet relief valve

Inlet-gas pressure gauge

Non return valve

Inlet duplex gas filter

Temporary suction filter after mail filter

Inlet manual isolation valve

Inlet automatic isolation valve

Suction Skid: PRV shall be designed for pressure range from 20-35 bar to 14-19 bar

7 Gas recovery system

Gas recovery system with pr relief valve, pr regulator, pr gauge, manual & automatic drainage system

8 Gas Delivery system

High pr piping with SS 316, tubing, compression fittings, NRV

KOD

Coalescent filter

PLC based Priority panel with full bore ball valve. Priority panel shall be kept

Page 61 of 129

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SHEET 61 OF 64

outside in a separate enclosure preferably mounted on compressor side walls.

Final gas outlet connection from priority panel 3/4" SS valves WITH 3/4" Tube OD end connections.

9 ESD system

10 Volume bottles / dampers at each stage of compressor

Vessels

Drainage system

11 Manual double isolation valve

12 Automatic valves

13 Heat exchanger

14 Code of construction API 11 P

15 Gas sections of coolers shall be as per API - 11P requirements

16 Tube material SA-179

17 Piping between stages shall be continuous with flange connection

18 Gas recovery vessel provided

19 Area classification; " class 1, group D, division 1 as per NEC " OR " Zone 1, group IIA / IIB as per IS/IEC"

20 The size of the complete package

21 Chain pulley block and beam for chain pulley block

22 Acoustic and pulsation study

23 Acoustic enclosure for package

24 Instrumentation as indicated in TS

25 Human - machine interfacing unit (HMI)

26 String test at shop

27 Field trial run for 72 hours

28 Electric power requirement (purchaser will give electric power for air compressor and compressor controls)

29 Cabling - Double compression type cable glands and copper lugs

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30 Junction box with metallic enclosure

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SHEET 63 OF 64

ANNEXURE- VIII : Parameters Required for SCADA

Hardware Details: Connector Type, Communication Standard, Communication port Pin details, Communication Port Configuration: Baud Rate, data bits, stop bit, parity Polling Constraints: Minimum time period between two consecutive poll cycles. Protocol Details: Protocol name and message structure for different read / write functions. Function codes for reading digital and Analog inputs Function code for writing analog values in the IED registers List of parameters available in the IED which can be accessed from the IED through serial port. Register address of each parameter in the IED. A Sample of the details is given below for understanding: PROTOCOL DETAILS:

Sr.No. Description Content/Details 1 Protocol MODBUS RTU2 Connection Type FCC -68 RJ45 3 Communication standard RS232D4 Signals supplied Tx, Rx, GND5 Baud Rate(Speed) 300, 600,1200,4800,9600,192006 Format Software configurable

7 Port Configuration

Speed : 19,200, 9,600 & 115,200 bpsData Bits: 8 BitsStop Bit : 1 BitParity : None

8 Min. Time period between consecutive Query 2 Sec.

PORT PIN Details:

Example: RS232 Pin Details: IED SCADARJ45 GND DTR RTS TX RX RX TX CTS DCR DCD � Function Code & Message Structure: Function Code: 3 - Read Output RegisterPoll Format: Address 1 Byte Function 1 Byte Start Item 2 Byte

No. Item 2 Byte Response Format: Address 1 Byte Function 1 Byte Length 1 Byte Date Item 1 4 Byte

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Date Item n 4 Byte � Function Code & Message Structure: Function Code: 2 - Read Input Status Poll Format: Address 1 Byte Function 1 Byte Start Item 2 Byte

No. Item 2 Byte Response Format: Address 1 Byte Function 1 Byte Length 1 Byte Date Item 1 2 Byte . . Date Item n 2 Byte Memory Mapping, Data Type & Parameter Information: A) Digital Parameters:

Sr. No. Description Address 1 Flow computer malfunction Alarm 82472 Mass Flow Low alarm 82453 Mass Flow High alarm 8246

B) Analog Parameters:

Parameter Register details

Engineering Range and Unit

GC Register Register

Format Remarks

Density Kg/m3 (500-600)

8655-56 Float

Pressure 8657-58 Float Temperature 8659-60 Float Mass Flow Rate 8661-62 Float Totalized mass flow 8663-64 Float Yesterday’s Total Mass flow 8665-66 Float Today's Total Mass Flow 8667-68 Float Corrected volumetric Flow rate 8669-70 Float

Yesterday's Total corrected Volumetric Flow

8671-72 Float

Totalized Mass Flow at 6 AM (Snapshot of cumulative)

8673-74 Float

Page 65 of 129

1



CLIENT JOB NO. - DATASHEET- COMPRESSOR (1200 SCMH)

TOTAL SHEETS 28

DOCUMENT NO 11 0353 02 09 03 101

0 02.05.11 ISSUED FOR TENDER MH RC RC


B 11.04.11 ISSUED FOR CLIENT APPROVAL SS RM SB

A 07.04.11 ISSUED FOR IDC SS RM SB


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SHEET 2 OF 29

Datasheet-Compressor

1

GENERAL

2

PROJECT: PROCUREMENT OF CNG COMPRESSORS

3

OWNER: M/S SABARMATI GAS LIMITED

SITE: GANDHINAGAR

4

SERVICE: COMPRESSOR FOR CNG MOTHER STATION

5

NO. REQD.: 3no.+2no. optional (1200 SCMH)

DRIVER: ELECTRIC MOTOR

6

NOTE: � SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER � INFORMATION REQUIRED FROM VENDOR

7

� MANUFACTURER:

� MODEL NO.:

8

� PLACE OF MANUFACTURE:

9

� NO. OF STAGES: THREE.

� CYLINDER ARRANGEMENT:

10

CYLINDER LUBRICATION: � LUBRICATED � MINIMUM LUBRICATED � NON LUBRICATED

11

� DRIVER TYPE: ELECTRIC MOTOR

12

� DRIVE: � DIRECT WITH COUPLING

13

� DIRECTION OF ROTATION(FACING DRIVEN END): � CLOCKWISE � COUNTER CLOCKWISE

14

� SITE / INSTALLATION DATA

15

SITE DATA: AMBIENT TEMP. (0C): MAX: 47.0 MIN: 4.0

16

RELATIVE HUMIDITY (%): MAX: 95

17

ALTITUDE (M): 110

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18 EARTH QUAKE ZONE III BASIC WIND SPEED(m/sec) 47

19 INSTALLATION: �OUTDOOR

20

� MOUNTED ON A COMMON SKID ALONGWITH DRIVER, ENCLOSED IN AN ACOUSTIC ENCLOSURE

21

� ELECTRICAL AREA HAZARD:

22

CLASS I, DIVISION I, GROUP D AS PER NEC OR ZONE I, GROUP II A/ II B AS PER IS/ IEC

23

APPLICABLE CODES AND STANDARDS

24 COMPRESSOR : API 11P, 2ND

EDN./PISTON TRUNK

PIPING: ASME/ANSI B 31.3

25

PRESSURE VESSELS: ASME SEC-VIII, DIV-1.

GAS COOLER: API 11P /API 661

26

OIL COOLER: TEMA `C’.

SOUND: 75 DBA @ 1M FROM ENCLOSURE

27

�AUX. ELECT. MOTORS:

28

CONTROL PANEL & INSTRUMENTATION REFER:

29

UTILITIES DATA

30 � Cooling Water (Not Available)

31

� Type: � Supply temperature (0C): � Max return temperature (0C):

32

� Fouling Factor: � Supply pressure (kg/cm²G): � Min. return pressure (kg/cm²G):

33

� Design pressure (kg/cm2A): � Design temperature (0C):

34

� Water Flow Rates (m3/hr)

35

� Electricity

36

Auxiliary Motors: V Ph Hz

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37 Oil Heaters: V Ph Hz

38

Solenoid Valves: A.C/D.C V Ph Hz

39

Instruments: A.C/D.C V Ph Hz

40

Local Panel INDI./Alarm/Ann : A.C/D.C V Ph Hz

41

Local Panel Trip Circuit: A.C/D.C V Ph Hz

42

UPS: KVA, V Ph Hz

43

� Total Utility Consumption

44

� Cooling Water (Make UP) (m3 /hr)

45

� Power (Auxiliaries) (kW)

46

� Power (Heaters) (kW)

47

REMARKS:

48

Vendor/Bidder shall estimate the requirement for all the Utilities and indicate the same in tabular form.

49

� CONSTRUCTION / DESIGN FEATURES

50

Nomenclature

Unit

Stage#1

Stage#2

Stage#3

51

Cylinders

52

No of Cylinders –

53

Single Acting (SA) / Double Acting (DA)

54

Cylinder Bore / Stroke

mm / mm

55

Rotational Speed

RPM

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56 Linear Average Piston Speed

m/sec

57

Piston Displacement

m3/ hr

58

Cylinder Liner (Yes / No)

59

Type of Cylinder Liner : Dry/Wet –

60

Clearance Pockets Yes / No

61

Max. Allow. Working Pressure, Cylinder

kg/cm²a

62

Max./Min Allow. Working Temp., Cylinder

0C

63

M.A.W.P, Cylinder @ Amb. Temp.

kg/cm²a

64

Safety Valve Set Pressure, Cylinder

kg/cm²a

65

Helium Test Pressure, Cylinder

kg/cm²a

66

Hydrostatic Test Pressure, Cylinder

kg/cm²a

67

Cylinder Jacket Cooling Type As reqd.

68

Cooling Media, Cylinder Jackets Water /AIR

69

Max. Allow. Working Pressure, Cyl. Jacket

kg/cm²a

70

Hydrostatic Test Pressure, Cyl. Jacket

kg/cm²a

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71 Suction Nozzle Size/Rating/Position

72

Discharge Nozzle Size/Rating/Position

73

Suction Valve Number

74

Average gas Velocity

m/sec

75

Discharge Valve Number

76


m/sec

77

Type of Suction valve –

78

Type of Discharge valve –

79

Suction Valve Unloaders Yes / No

80

Clearance Pockets Unloaders Type

81

Piston Rod Diameter

mm

82

Rod Reversal at Crosshead Pin (min.)

Deg.

83

Piston Rod Runout Operating

84

Max. Allow. Rod Load Comp.

kg

85

Tension

kg

86

Rod Load Comp.

Kg

87

(Inertia Alone) Tension

kg

88

Rod Load Rated Pr. (Gas+Inertia) Comp.

kg

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89 Tension

Kg

90

Rod Load at R.V Set Comp.

kg

91

(Gas + inertia) Tension

Kg

92

Distance piece / Packing

93

Type of Packing

94

Packing Vent Connected to ##

95

Packing Cooling

96

Type of Distance Piece

97

Cyl. Side Compartment Purged

98

Frame Side Compart. Pressurised

99

Distance Piece purge gas Pressure

mm H2O

100

Distance Piece purge gas Flow

Nm3 /hr

101

Distance Piece Vent to

Safe Height

Safe Height

Safe Height

102

Distance Piece Hydrostatic Test Pressure

kg/cm²G

103

## Packaging shall be connected to vent header Ref 7.19.4 of API-11 P

104

Frame

105

Frame Explosion proof Relief device

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106 Flame Arrestor Yes / No

107

Replaceable Crosshead Shoes Yes / No

108

Crosshead Guide Integral / Separate

109

Maximum Frame Rating

kW

110

Speed - Maximum/ Minimum

Rpm

111

�Lubrication Systems

112

Type of lube system

Piping material

113

Carbon Steel

114

Main Oil Pump Driven By :

Stainless Steel (all piping & valves Trims)

115

Standby Oil Pump, Driven By :

Auxiliary oil tank

116

Hand Operated Prelube/Priming Pump:

Oil Grade :

117

Suction Strainer

Lube Oil Consumption

118

Pressure Control Valve

Main Pump Make : Model : Type : Material :

119

Level Sight Glass on the Crankcase

Standby Pump Make : Model : Type : Material :

120

Type of Oil Cooler :

121

Size of Filter:

122

Oil Heater (if required).

123

Electric Heater with thermostat (Kw)

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124

Thermostatic Valve

125

Type of Cylinder Lubrication

Lubricator Equipped With : level sight glass

126

Lubricator Type : Manzel or Equivalent .

127

Single plunger per feed

oil heater electric with thermostat

128

Divider blocks type.

Electric Heater (Kw) (if required)

129

Lubricator Driven By :

Auxiliary Oil Tank (if required)

130

Compressor Shaft

Oil Grade :

131

Electric Motor KW

Oil System Capacity: (min 150 Hrs.)

132

All tubing and valves in SS

Oil Consumption rate

133

Double Ball Check valve on each lubrication point

134

�Cooling System

135

�Static filled coolant system for

136

All Stage Cylinders � 1 Stage Cylinder/s � 2 Stage Cylinder/s � 3 Stage Cylinder/s

137

Including expansion chamber, Vents, Drains, Level Gauge, Pipings, etc.

138

All Piping prefabricated� Material

139

�Atmospheric thermosyphon cooling system for

140


141

Including expansion tank, Vents, Drains, Coolers, Level & Temp. indicators, Pipings, etc.

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142 All Piping prefabricated. � Material

143

�Forced Cooling Water System

144


145

�Packings � Oil Coolers � Gas Coolers

146

�Including drains, Vents, flow & temp. Indicators, regulating & Isolation valves, complete piping to provide one

147

�Common inlet and one common outlet connections for purchaser's interface terminated by a flanged block valve

148

�Block valve.

149

� Each isolatable circuit to be provided with thermal relief valve.

150

All Piping prefabricated. � Material

151

�Self contained, forced circulation, closed circuit Cooling Water System (if reqd.)

152

All Stage Cylinders � 1 Stage Cylinder/s � 2 Stage Cylinder/s x 3 Stage Cylinder/s

153

�Packing� Oil Coolers � Gas Coolers

154

�Including drains, Vents, flow & temp. indicators, Temp. Control Valve, Regulating & Isolation valves, complete piping

155

�Main circulating pumps with drivers & suction strainers � Single Coolers

156

�Reservoir (Make Up) � Heater (if required)

157

�Pumps, Reservoirs, Coolers etc. to be mounted on a common skid as to make a separate console.

158

�Material of piping:

159

�Type of coolant:

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160

�Jacket cooling

161

�Gas Piping System

162

�Vendor's Supply Includes:�Suction Separator

163

�Pulsation suppression equipment as per ‘next’ page

164

�Suction Filter:

165

�Temporary Strainer on Compressor Suction

166

�Type of Strainer:

167

� Relief Valves: on compressor � suction � Inter-stage � on compressor discharge

168

�Check Valve on Discharge Line (compressor valve design, and suction line)

169

�Process Gas Coolers Complete With Manual Drain Valve

170

�Separators Complete With Manual/ Automatic Drain Values

171

�Process Gas Piping

172

�Supply starts at inlet flange of CNG PACKAGE

173

�Terminates after priority panel with isolation valve

174

�Materials:

175

�By-Pass Line Piping

176

�Between 3rd stg. discharge and 1 st stg. Suction

177

�Gas cooler

178

�Interconnecting Piping Between Packing Vents, PSV Relief terminating to Vent Recovery System.

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179

�Interconnecting piping between distance piece terminating to Vent Recovery System upto package B/L

180

�Interconnecting piping between Drains terminating as a single point

181

�Interconnecting piping between Instrument Air terminating

182

�Pulsation Suppression Equipment

183

Stage #:

Stage#1

Stage#2

Stage#3

184

Suction

185

Puls. Equipment Required Yes/No

YES

YES

YES

186

Inlet Pressure

187

Residual Peak to Peak Pulsation % As per API 618, Cl 3.9.2.7

188

Inlet Nozzle Size / Rating/Position

189

Discharge Nozzle Size / Rating/Position

190

Design Pressure Kg/cm²a

191

Design Temperature 0C

192

Volume

193

Material : vessels

SA 516 Gr.60/70”

SA 516 Gr.60/70”

SA 516 Gr.60/70”

194

Internals

195

Corrosion

3

3

3

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Allowance mm

196

Hydrostatic test Pressure kg/cm²g

1.3XMAWP

1.3XMAWP

1.3XMAWP

197

Discharge

198

Puls. Equipment Supplied Yes/No

YES

YES

YES

199

Inlet Pressure

200

Residual Peak to Peak Pulsation %

As per API 618, Cl 3.9.2.7

201


202


203


204


205

Volume

206

Material : vessels

SA 516 Gr.60

SA 516 Gr.60

SA 516 Gr.60

207

Internals

208

Corrosion Allowance mm

3

3

3

209


1.3XMAWP

1.3XMAWP

1.3XMAWP

210

Pulsation Suppressors are complete and installed on the Skid with supports & anchor bolts

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211 Design Code : . ASME SECT. VIII DIV. 1

212

Analog Piping Study / Accoustic Simulation, As per Approach 3, Cl. 3.9.2.6 API618, 4th edition

213

Upstream / downstream Inter-stage

214

Performed By: �Vendor � Any other agency having similar experience

215

Piping Mechanical Analysis

216


217

�Automatic Drain Valves For Each Stage suction KOD

218

�Capacity Control

219

�Start / Stop, based on discharge receiver pressure: Fully Automatic

220

Unloading for Start up/Shut down :Automatic Through � Valve Unloader � Recycle Valve

221

�Interlock against loaded start

222

� Automatic Control based on

223

�Suction Pressure� Discharge Pressure � Flow Manual Signal

224

� Type of Actuator � Actuation fluid to load � Actuation fluid to unload

225

� On Power / Actuation fluid failure : Compressor to � Load � Unload

226

� At 0 % capacity through Valve Unloader, Compressor shall run

227

� Continuously � Maximum Hrs.

228


229


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230

� At All other capacity, Compressor shall run continuosly

231

Vendor's scope Shall Include :

232

� Pilot Devices (pressure / temperature / Flow devices ,Controllers & Switches)

233

� Intermediate Devices (Solenoid Valves | Pneumatic Relay / Valves)

234

� Actuators

235

� Recycle valves

236

� Control Logic and System for Complete Capacity Control

237

� Inter Connecting Tubing, Piping, Cabling & Wiring

238

�Protection against extended unloaded operation (Trip)

239

�valve unloaders are required as such Compressor shall start / stop at specified receiver pressures.

240

�Purchaser's Interface

241

Type of Interface (Single Point)

Size

Rating

Face

Position/Location

242

Main Gas Piping Inlet

243

Main Gas Piping Outlet

244

Relief Valves discharge

245

Distance Piece Vent

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246

Packing Vent

247

C.W. Inlet

248

C.W. Outlet

249

N2 Inlet Supply

250

N2 Vent (Safe location)

251

Drains

252

MATERIALS

253

Cylinder Materials

254

Stage

1 Stage

2 Stage

3 Stage

255

Cylinder

NODAL CAST IRON / F.S



256

Liner

257

Piston

258

Piston Rings

PTFE/PEEK

PTFE/PEEK

PTFE/PEEK

259

Rider Rings

PTFE/PEEK

PTFE/PEEK

PTFE/PEEK

260

Piston Rod

Forged steel/ AISI 4142



261

Packings Rings

262

Valve Seats

Page 81 of 129

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SHEET 17 OF 29

263

Valve Stops

264

Valve Rings / Plates

CS /plate should be MT or PEEK.”



265

Valve Springs

SS

SS

SS

266

Cylinder Head

267

Motion Work Materials :

268

Material / ASTM Grades

269

Top Cover

� Cast � Fabricated

270

Crankcase

� Cast �Fabricated

271

Crankshaft

� Die Forged � Open Forged � Cast

272

Connecting Rods

� Die Forged �Open Forged � Cast

273

Cross heads

� Cast � Fabricated �

274

Cross Head Shoes

275

Cross Head Guide


276

Main Bearings Type

� Split Precision � Bush

277

Cross Head Pin Bearings Type


278

Connecting Rod Bearings Type


279

Cross Head Pin Type


280

Notes :

Page 82 of 129

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SHEET 18 OF 29

281 Each package shall be provided with two number drain lines, one from Suction KOD and second drain as common drain line from intermediate and discharge KOD routed to drain vessels through gas recovery vessels

282

�CONTROLS & INSTRUMENTATION

283

� AC Power On/Off Switch With Indication Lamp

284

� Control Power On/Off Switch With Indication Lamp YES

285

� Selector Switch A/M Station For L/O Pump Motor

286

� Selector Switch A/M Station For CW Pump Motor

287

� Emergency Stop Push Button

288

� Start Push Button For Air Compressor Motor

289

� Emergency Stop Push Button for Main Motor

290

� Lamp Test Push Button

291

�Alarm/Trip Acknowledge /Reset Push Button

292

� Frame Oil Heater ON (Indicating lamp)

293

� Lubricator Oil Heater ON (Indicating lamp)

294

� Driver Interlocked against loaded start

295

� Driver Interlock against start without pre-lubrication

296

Notes :

297

Minimum required indications, alarms & trips are shown herewith. Bidder shall provide any additional instrumentation for safe operation.

298

Compressor shall start stop at pre determined receiver pressure as specified. Bidder shall include

Page 83 of 129

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SHEET 19 OF 29

in his

299

Scope includes the necessary hardware for the same.

300

All inter-stage / discharge and suction scrubber shall be provided with high / low level operated auto drain solenoid valves.

301

INSPECTION AND TESTS

302

Material Composition and Physical Properties Certificates Required For/Compliance certificate:

303

� Cylinder and Liner � Piston

304

� Crankshaft � Connecting Rod

305

� Pressure Vessels � Heat Exchangers

306

� X-Ray Examination for components: Pressure Vessels (certificates to be furnished).

307

� Ultrasonic Testing for components: Piston Rod, Crankshaft, Big End Bolts, Main Bearing Studs.

308

� Magnaflux Testing for components: Crankshaft, Piston Rod, Connecting Rod.

309

� Dye Penetration Testing for : Cylinder, Liner, Piston.

310

Required

Observed

Witnessed

311

� Shop inspection by Purchaser during manufacture

�

�

�

312

� Cylinder Hydrostatic

�

�

�

313

� Cylinder Pressure Test By Helium

�

�

�

314

� Hydrostatic Test of Pressure Vessels

�

�

�

315

� Hydrostatic Test of Distance Piece.

�

�

�

316

� Leak Proof Test of Crank case for 24 Hrs

�

�

�

Page 84 of 129

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SHEET 20 OF 29

317 � Barring over to check clearance / Rod run out

�

�

�

318

� Mech. Running Test with shop Driver ( 4 Hours min.)

�

�

�

319

� Performance Test at Works as per IS 5456/PTC9/BS 726 (*).

�

�

�

320

� Partial Stripping and internal inspection

�

�

�

321

� Functional/Continuity Tests - Control Panel.

�

�

�

322

� Field Trial Run 72 Hrs. under Vendor's Supervision (Package)

�

�

�

323

� Valve Leak Test

�

�

�

324

� Lube Oil Console Run test

�

�

�

325

� Closed Circuit C.W. System test

�

�

�

326

*: During package performance test

327

Test Certificates Required For:

328

� Auxiliary Motor & Pumps � Safety Relief Valves

329

� Safety Switches �Solenoid Valves

330

� WEIGHTS

331

Overall supply (excluding driver and gear box, if any) Kg. approx.

332

Maximum erection weight Kg. approx.

333

Maximum maintenance weight Kg. approx.

Page 85 of 129

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SHEET 21 OF 29

334

Gear Box Kg. approx.

335

Driver Kg. approx.

336

SCOPE OF SUPPLY

337

� Compressor Assembly complete with frame, cylinders, cross head etc.

338

� Motion work lubrication system

339

� Cylinder and packing lubrication system

340

� Cooling system

341

� Process Gas system

342

� Local instrumentation

343

� Local Gauge Board

344

� Local Control Panel � PLC Panel � Man Machine Interface located in Control Room

345

� Main driver (Electric motor)

346

�Barring Device : � Manual �Electric . pneumatic

347

� Flywheel

348

349

�Couplings

350

� Driver Compressor

351

� Guards for moving parts �

352

� Base plate Common for Compressor and Driver

353

� Fabricated Steel skid Common for compressor, driver and accessories

Page 86 of 129

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354 �Ladders and platforms

355

� Special Tools - One Set for each package

356

� Anchor Bolts for Complete Package

357

�Piping supports and brackets : � prefabricated for piping in Vendor's Scope

358

� Supports For Cylinders & Auxiliaries, Prefabricated & fitted in the Package

359

� Commissioning Spares, erection and commissioning spares

360

�Train Torsion Analysis Study and Report

361

�Acoustic Simulation Study & Report

362

� Vendor Data as specified

363

NOTE : Refer checklist for scope of supply

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DATA SHEET- INSTRUMENTATION & CONTROLS FOR COMPRESSOR

INDICATION ANNUNCIATION & PRE ALARM

TRIP & A/V ALARM ANNUN.

S. NO DESCRIPTION

GU

AG

E –

LOC

AL

GU

AG

E

BO

AR

D

IND

ICA

TOR

LO

CAL

P

AN

EL

(PLC

) DIS

PLA

Y

LOW

LO

CA

L PA

NE

L D

ISP

LAY

HIG

H L

OC

AL

PA

NE

L D

ISPL

AY (P

LC)

LOW

–LO

CAL

PA

NE

L -

PLC

-DIS

PLA

Y

HIG

H L

OC

AL

PA

NE

L P

LC- D

ISP

LAY

1 Frame Oil Sump/Reservoir Level

� yes

2 Main L/O Pump Disch. Pr (supply header).

� yes � yes � yes � yes

3 Oil Flow 4 Oil Pressure at Main Bearing 5 Supply Header Temp. 6 Oil cooler Oil Inlet Temp. 7 Stand by Pump Start 8 Compressor Main bearing

metal Temp.

9 Cylinder & Packing Oil 10 Lubricator Oil Level � yes 11 Lubricator Oil Flow 12 Lubricator Failure � yes

13 Aux. Oil

14 Lub. Oil Supply Pr. to Electric Motor Driver

15 Lub. Oil return from Electric Motor Driver

16 Elec. Motor bearing metal temp.

17 Coolant System 18 Each cylinder CW outlet

temp.

19 Inter/After/Oil Cooler CW outlet temp.

20 CW Supply header flow 21 For Closed Circuit Cooling 22 Coolant standby pump disch.

Pr.

23 Coolant stand by pump start

24 Coolant supply header Pr. 25 Coolant supply header temp 26 Coolant reservoir Level � yes � yes 27 Cylinder Coolant Outlet temp. 28 Cylinder Coolant Outlet temp.

Page 88 of 129

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SHEET 24 OF 29



S. NO DESCRIPTION

GU

AG

E –

LOC

AL

GU

AG

E

BO

AR

D

IND

ICA

TOR

LO

CAL

P

AN

EL

(PLC

) DIS

PLA

Y

LOW

LO

CA

L P

AN

EL

DIS

PLA

Y

HIG

H L

OC

AL

PA

NE

L D

ISPL

AY (P

LC)

LOW

–LO

CAL

PA

NE

L -

PLC

-DIS

PLA

Y

HIG

H L

OC

AL

PA

NE

L P

LC- D

ISP

LAY

29 Diff. Pr. Across packing coolant filter

30 Process Gas System 31 Each stage inlet Pressure 32 Each stage inlet temp. 33 Each stage Outlet Pressure � yes � yes � yes � yes 34 Each stage Outlet temp.

(before air cooler and after cooler)


35 After Cooler Gas Outlet temp. � yes � yes � yes � yes 36 Ist stage pressure low / high � yes � yes � yes � yes � yes � yes 37 Cylinder Packing Vent

Pressure

38 Suction Pressure, low � yes � yes � yes 39 Blow Down vessel level � yes 40 Piston Rod Drop Indicator 41 Distance piece diff. Purge

pressure

42 Common process parameters 43 Common machine

parameters

44 Blow Down vessel Pressure � yes � yes � yes 45 Vibration Measurement � yes 46 Temperature Instrument

(shall be Insertion type but Not skin type)

47 Winding Temperature 48 RPM meter � yes

Such as Amperes, voltage, flow rate, total quantity of gas compressed, inlet – outlet pressure, inlet –outlet temperature, Kilo Watt Hour (KWH), electric power (electric driven compressor).

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1 OPERATING CONDITIONS (EACH MACHINE) / PERFORMANCE 2 Operating Case: SUCTION PRESSURE: 14 kg/cm² g 3 Units Stage 1 Stage 2 Stage 3 4 � Gas Handled (See Analysis) 5 � Corrosion Due to NONE NONE NONE 6 Suction Conditions 7 � Pressure (@ Vendor's

B/L) Kg/cm² g 14

8 �Temp. (+@ Vendor's B/L)

0C 35

9 Discharge Conditions (Vendor's Battery Limit: 10 �Pressure (@ Vendor's B/L Kg/cm² g 250 11 Pressure @ Cylinder Flg. Kg/cm² g 12 Temp.,Adiabatic @Cyl.

Flange 0C <150 < 150 < 150

13 Temp.,Actual @Cyl.Flange 0C 14 Temp.,After AfterCooler 0C < 52 15 Cp/Cv Ratio 16 Compr. Factor (Z2 ) or (Z

avg )

17 Operating Characteristics 18 Capacity (wet) SM3 /Hr 19 Mfr's Rated Cap. (Design) (No -ve tol.) 20 Actual Inlet Flow (wet) AM3 /Hr 21 Specific Gravity 22 Coupling Losses kW 23 Volumetric Efficiency % 24 Valve Lift Suction / mm / mm 25 Valve Lift Area Suction/

Discharge mm2 / mm2

26 Valve Velocity m/sec 27 Speed RPM 28 Compressor Shaft Power

KW

29 Power consumed @ RV Set Pr.

KW

30 Driver Power KW 31 Guaranteed Point 32 GAS ANALYSIS- Gas Composition attached as Annexure-I.

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1 OPERATING CONDITIONS (EACH MACHINE) / PERFORMANCE 2 Operating Case: SUCTION PRESSURE: 16 kg/cm² g 3 Units Stage 1 Stage 2 Stage 3 4 � Gas Handled (See Analysis) 5 � Corrosion Due to NONE NONE NONE 6 Suction Conditions 7 � Pressure (@ Vendor's B/L) Kg/cm² g 16 8 �Temp. (+@ Vendor's

B/L) 0C 35


Flange 0C <150 < 150 < 150

13 Temp.,Actual @Cyl.Flange 0C 14 Temp.,After AfterCooler 0C < 52 15 Cp/Cv Ratio 16 Compr. Factor (Z2 ) or (Z avg

)


Discharge mm2 / mm2

26 Valve Velocity m/sec 27 Speed RPM 28 Compressor Shaft Power KW 29 Power consumed @ RV Set

Pr. KW

30 Driver Power KW 31 Guaranteed Point 32 GAS ANALYSIS - Gas Composition attached as Annexure-I.

Page 91 of 129

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SHEET 27 OF 29


B/L) 0C 35


Flange 0C <150 < 150 < 150


)


Discharge mm2 / mm2


Pr. KW


Page 92 of 129

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SHEET 28 OF 29

DATA SHEET INTER COOLER

1 GENERAL 2 PROJECT: PROCUREMENT OF CNG COMPRESSORS 3 OWNER: SABARMATI GAS LIMITED SITE: GANDHINAGAR 4 Item No. : Service : Intercooler / Aftercooler for Compressor Package 5 NOTE: � SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER � INFORMATION

REQUIRED FROM VENDOR. 6 � Manufacturer: Type: � Forced Draft �Induced Draft 7 �Bundle Size: m x m x m Bundles/Section Number

of Units: 8 Bundles/Unit: In Parallel / Series Section Size: 9 Surface/Bundle: m² Bare Tube: m² Section/Unit:

10 Surface/Unit: m² Bare Tube: m² Plot Area/Unit: 11 PERFORMANCE (Of One Unit) 12 Heat Exchanged: kcal/hr MTD (Corrected): 0C 13 Transfer Rate: kcal/hr m² 0C (Finned Surface) (Bare

Surface) 14 TUBE SIDE 15 Fluid Circulated GAS Gravity: Liquid

API SG @ 15.4EC 16 Total Entering Gas kg/hr Enthalpy / Latent

Heat kcal/kg 17 Operating Temperature In: Out: Fouling Resistance hr m² 0C/kcal 18 Operating Pressure Passes / Bundle kg/cm² 19 AIR SIDE 20 Temperature In:47 Out: Altitude m 21 Total Flow/Unit kg/hr Static Pressure kg/cm² 22 Quantity/Fan kg/hr Power/Fan kW 23 Face Velocity m/sec Power/Unit kW 24 CONSTRUCTION (Each Bundle) 25 Design Pressure: kg/cm²g Test Pressure: kg/cm²g Design Temperature: 0C 26 Code Requirements: 27 Type of Tubing: Tube Material: SA 179 Fin Material: Al 28 Tube Bare Tubes (no's) : No. of rows: O.D.

BWG/Thk Length 29 Fins : Spacing /inch. O.D. Root Dia

Thickness: 30 Header Type: Plug / Cover No. of Splits: Material : 31 Plugs/Gaskets Side Frame : C.S. Inside Zinc Protected 32 Nozzles In : Out : 33 Couplings Vent: Drain : 34 CONSTRUCTION (Each section) 35 Structure CS Sec./Gr. No. Design Wind

Load : kgf/m 36 Plenum Chamber CS inside Zinc Protected Type : 37 Fans No. Dia. RPM Mfr. 38 Blades Material : No./Fan Pitch Angle(Design) : 39 Hubs Material : Pitch : Autovariable / Adjustable (No. ) 40 Louvers Material : Type : Mfr. 41 Weights kg Each Section(Dry) : Full of Water: 42 Each Bundle (Dry) : Full of Water: 43 APPLICABLE SPECIFICATIONS API Standard 661 44 REMARKS 1. Air coolers shall be designed for 20% excess capacity than required normally. 45 Exchanger shall be designed with air side temperature of 47.5 0C.

Page 93 of 129

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SHEET 29 OF 29

46 Separate data sheet shall be filled by the bidder for each service i.e. Inter cooler and After cooler

Page 94 of 129

1

SABARMATI GAS LIMITED CITY GAS DISTRIBUTION

CLIENT JOB NO. - DATA SHEET FOR LT MOTOR

TOTAL SHEETS 4

DOCUMENT NO 11 0353 02 10 03 004






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SHEET 2 OF 4

DATASHEET-LT MOTOR

1 GENERAL

2 PROJECT: PROCUREMENT OF MOTOR DRIVEN COMPRESSORS

3 OWNER: M/S SABARMATI GAS LIMITED SITE: Mehsana & Sabarkanta Dist of Gujarat

4 SERVICE: DRIVER FOR CNG COMPRESSOR

5 NO. REQD. 3+ 2 Optional for 1200SCMH & 1 + 1 Optional for 650 SCMH

6 NOTE: � SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER

� INFORMATION REQUIRED FROM VENDOR.

7 SITE / INSTALLATION DATA

8 SITE CONDITIONS:

9 LOCATION: � OUTDOOR � CLOSED ROOM WITH FORCED AIR VENTILATION

SYSTEM.

10 SITE DATA: AMBIENT TEMP. (0C): MAX:40 MIN: 5


11 ELECTRICAL AREA CLASSIFICATION

CLASS 1, DIVISION II, GROUP D AS PER NEC

ZONE II GROUP IIA/IIB AS PER IS/IEC

12 DUTY

13 MANUFACTURER

14 TYPE

15 FRAME DESIGNATION

16 OUTPUT (KW)

17 VOLTAGE (VOLT)

415 ± 10% V

18 FULL LOAD CURRENT (AMP)

19 FULL LOAD SPEED (RPM)

20 ENCLOSURE

21 TYPE OF PROTECTION

22 GAS GROUP

CLASS 1, DIVISION II, GROUP D AS PER NEC ZONE II GROUP IIA/IIB AS PER IS/IEC

23 MOUNTING

24 AMB. TEMP/TEMP RISE ( °C)

Page 96 of 129

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SHEET 3 OF 4

25 FULL LOAD TORQUE (KGM)

26 APPLICABLE CODE

27 STARTING TORQUE AS (%FLT)

28 EFFICIENCY AT : %EFF @100% LOAD

29 %EFF @75% LOAD

30 %EFF @50% LOAD

31 BEARING TYPE

32 TYPE OF LUBRICATION

33 NET WEIGHT (APPR.) (KG)

34 TYPE OF COUPLING

35 CABLE SIZE TYPE (Sq. mm)

36 PHASE - CONN. - NO OF TERMINAL -

3 Phase

37 FREQUENCY (Hz)

50 ± 5% Hz

38 INSULATION

CLASS ‘F’ (Temp. rise limited to class ‘B’) as standard

39 No. OF POLES

40 LOCKED ROTOR CURRENT %FLC

41 LR WITHSTD TIME HOT/COLD

42 STATOR THERMAL TIME CONST MIN

43 POWER FACTOR : PF @-100% LOAD

PF @ 75% LOAD

PF @- 50% LOAD

44 PULL OUT TORQUE - %FLT

45 SPACE HEATERS - WATTS/VOLTS

46 ACCESSORIES

47 PAINT SHADE

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SHEET 4 OF 4

48 TERMINAL BOX POSITION

49 LOAD GD SQ. (KG-M²)

50 MOTOR GD SQ. (KG-M²)

51 STARTING TIME @100% V SEC

52 TYPE OF STARTING

53 NOISE LEVEL

54 VIBRATION

55 SEPERATE ACCOUSTIC

ENCLOSURE WITH VENTILATION

FAN

56 REMARKS

NOTE: 1) ALL PERFORMANCE FIGURES ARE SUBJECT TO IS 325 - 1996 TOLERANCES. .

Page 98 of 129

1



CLIENT JOB NO. - DATASHEET- COMPRESSOR (650 SCMH)

TOTAL SHEETS 28

DOCUMENT NO 11 0353 02 09 03 102






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DATASHEET-COMPRESSOR

SHEET 2 OF 28

Datasheet-Compressor

1

GENERAL

2

PROJECT: PROCUREMENT OF CNG COMPRESSORS

3

OWNER: M/S SABARMATI GAS LIMITED

SITE: GANDHINAGAR

4

SERVICE: COMPRESSOR FOR CNG MOTHER STATION

5

NO. REQD.: 1+1 optional (650 SCMH)

DRIVER: ELECTRIC MOTOR

6

NOTE: � SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER � INFORMATION REQUIRED FROM VENDOR.

7

� MANUFACTURER:

� MODEL NO.:

8

� PLACE OF MANUFACTURE:

9

� NO. OF STAGES: THREE.

� CYLINDER ARRANGEMENT:

10

CYLINDER LUBRICATION: � LUBRICATED � MINIMUM LUBRICATED � NON LUBRICATED

11

� DRIVER TYPE: ELECTRIC MOTOR

12

� DRIVE: � DIRECT WITH COUPLING

13

� DIRECTION OF ROTATION(FACING DRIVEN END): � CLOCKWISE � COUNTER CLOCKWISE

14

� SITE / INSTALLATION DATA

15

SITE DATA: AMBIENT TEMP. (0C): MAX: 47.0 MIN: 4.0

16


17

ALTITUDE (M): 110

18

EARTH QUAKE ZONE III BASIC WIND SPEED(m/sec) 47

Page 100 of 129

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SHEET 3 OF 28

19

INSTALLATION: �OUTDOOR

20

� MOUNTED ON A COMMON SKID ALONGWITH DRIVER, ENCLOSED IN AN ACOUSTIC ENCLOSURE

21

� ELECTRICAL AREA HAZARD:

22

CLASS I, DIVISION I, GROUP D AS PER NEC OR ZONE I, GROUP II A/ II B AS PER IS/ IEC

23

APPLICABLE CODES AND STANDARDS

24 COMPRESSOR : API 11P, 2ND

EDN./PISTON TRUNK

PIPING: ASME/ANSI B 31.3

25

PRESSURE VESSELS: ASME SEC-VIII, DIV-1.

GAS COOLER: API 11P /API 661

26

OIL COOLER: TEMA `C’.

SOUND: 75 DBA @ 1M FROM ENCLOSURE

27

�AUX. ELECT. MOTORS:

28

CONTROL PANEL & INSTRUMENTATION REFER:

29

UTILITIES DATA

30 � Cooling Water (Not Available)

31

� Type: � Supply temperature (0C): � Max return temperature (0C):

32

� Fouling Factor: � Supply pressure (kg/cm²G): � Min. return pressure (kg/cm²G):

33

� Design pressure (kg/cm2A): � Design temperature (0C):

34

� Water Flow Rates (m3/hr)

35

� Electricity

36

Auxiliary Motors: V Ph Hz

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SHEET 4 OF 28

37

Oil Heaters: V Ph Hz

38

Solenoid Valves: A.C/D.C V Ph Hz

39

Instruments: A.C/D.C V Ph Hz

40

Local Panel INDI./Alarm/Ann : A.C/D.C V Ph Hz

41

Local Panel Trip Circuit: A.C/D.C V Ph Hz

42

UPS: KVA, V Ph Hz

43

� Total Utility Consumption

44

� Cooling Water (Make UP) (m3 /hr)

45

� Power (Auxiliaries) (kW)

46

� Power (Heaters) (kW)

47

REMARKS:

48

Vendor/Bidder shall estimate the requirement for all the Utilities and indicate the same in tabular form.

49

� CONSTRUCTION / DESIGN FEATURES

50

Nomenclature

Unit

Stage#1

Stage#2

Stage#3

51

Cylinders

52

No of Cylinders –

53

Single Acting (SA) / Double Acting (DA)

54

Cylinder Bore / Stroke

mm / mm

55

Rotational Speed

RPM

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SHEET 5 OF 28

56 Linear Average Piston Speed

m/sec

57

Piston Displacement

m3/ hr

58

Cylinder Liner (Yes / No)

59

Type of Cylinder Liner : Dry/Wet –

60

Clearance Pockets Yes / No

61

Max. Allow. Working Pressure, Cylinder

kg/cm²a

62

Max./Min Allow. Working Temp., Cylinder

0C

63

M.A.W.P, Cylinder @ Amb. Temp.

kg/cm²a

64

Safety Valve Set Pressure, Cylinder

kg/cm²a

65

Helium Test Pressure, Cylinder

kg/cm²a

66

Hydrostatic Test Pressure, Cylinder

kg/cm²a

67

Cylinder Jacket Cooling Type As reqd.

68

Cooling Media, Cylinder Jackets Water /AIR

69

Max. Allow. Working Pressure, Cyl. Jacket

kg/cm²a

70

Hydrostatic Test Pressure, Cyl. Jacket

kg/cm²a

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SHEET 6 OF 28

71 Suction Nozzle Size/Rating/Position

72

Discharge Nozzle Size/Rating/Position

73

Suction Valve Number

74


m/sec

75

Discharge Valve Number

76


m/sec

77

Type of Suction valve –

78

Type of Discharge valve –

79

Suction Valve Unloaders Yes / No

80

Clearance Pockets Unloaders Type

81

Piston Rod Diameter

mm

82

Rod Reversal at Crosshead Pin (min.)

Deg.

83

Piston Rod Runout Operating

84

Max. Allow. Rod Load Comp.

kg

85

Tension

kg

86

Rod Load Comp.

Kg

87

(Inertia Alone) Tension

kg

88

Rod Load Rated Pr. (Gas+Inertia) Comp.

kg

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SHEET 7 OF 28

89 Tension

Kg

90

Rod Load at R.V Set Comp.

kg

91

(Gas + inertia) Tension

Kg

92

Distance piece / Packing

93

Type of Packing

94

Packing Vent Connected to ##

95

Packing Cooling

96

Type of Distance Piece

97

Cyl. Side Compartment Purged

98

Frame Side Compart. Pressurised

99

Distance Piece purge gas Pressure

mm H2O

100

Distance Piece purge gas Flow

Nm3 /hr

101

Distance Piece Vent to

Safe Height

Safe Height

Safe Height

102

Distance Piece Hydrostatic Test Pressure

kg/cm²G

103

## Packaging shall be connected to vent header Ref 7.19.4 of API-11 P

104

Frame

105

Frame Explosion proof Relief device

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SHEET 8 OF 28

106 Flame Arrestor Yes / No

107

Replaceable Crosshead Shoes Yes / No

108

Crosshead Guide Integral / Separate

109

Maximum Frame Rating

kW

110

Speed - Maximum/ Minimum

Rpm

111

Lubrication Systems

112

Type of lube system

Piping material

113

Carbon Steel

114

Main Oil Pump Driven By :

Stainless Steel (all piping & valves Trims)

115

Standby Oil Pump, Driven By :

Auxiliary oil tank

116

Hand Operated Prelube/Priming Pump:

Oil Grade :

117

Suction Strainer

Lube Oil Consumption

118

Pressure Control Valve

Main Pump Make : Model : Type : Material :

119

Level Sight Glass on the Crankcase

Standby Pump Make : Model : Type : Material :

120

Type of Oil Cooler :

121

Size of Filter:

122

Oil Heater (if required).

123

Electric Heater with thermostat (Kw)

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SHEET 9 OF 28

124

Thermostatic Valve

125

Type of Cylinder Lubrication

Lubricator Equipped With : level sight glass

126

Lubricator Type: Manzel or Equivalent

127

Single plunger per feed

oil heater electric with thermostat

128

Divider blocks type.

Electric Heater (Kw) (if required)

129

Lubricator Driven By :

Auxiliary Oil Tank (if required)

130

Compressor Shaft

Oil Grade :

131

Electric Motor KW

Oil System Capacity: (min 150 Hrs.)

132

All tubing and valves in SS

Oil Consumption rate

133

Double Ball Check valve on each lubrication point

134

Cooling System

135

�Static filled coolant system for

136


137

Including expansion chamber, Vents, Drains, Level Gauge, Pipings, etc.

138

All Piping prefabricated� Material

139

�Atmospheric thermosyphon cooling system for

140


141

Including expansion tank, Vents, Drains, Coolers, Level & Temp. indicators, Pipings, etc.

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SHEET 10 OF 28

142 All Piping prefabricated. � Material

143

�Forced Cooling Water System

144


145

�Packings � Oil Coolers � Gas Coolers

146

�Including drains, Vents, flow & temp. Indicators, regulating & Isolation valves, complete piping to provide one

147

�Common inlet and one common outlet connections for purchaser's interface terminated by a flanged block valve

148

�Block valve.

149

� Each isolatable circuit to be provided with thermal relief valve.

150

All Piping prefabricated. � Material

151

�Self contained, forced circulation, closed circuit Cooling Water System (if reqd.)

152

All Stage Cylinders � 1 Stage Cylinder/s � 2 Stage Cylinder/s x 3 Stage Cylinder/s

153

�Packing� Oil Coolers � Gas Coolers

154

�Including drains, Vents, flow & temp. indicators, Temp. Control Valve, Regulating & Isolation valves, complete piping

155

�Main circulating pumps with drivers & suction strainers � Single Coolers

156

�Reservoir (Make Up) � Heater (if required)

157

�Pumps, Reservoirs, Coolers etc. to be mounted on a common skid as to make a separate console.

158

�Material of piping:

159

�Type of coolant:

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SHEET 11 OF 28

160

�Jacket cooling

161

�Gas Piping System

162

�Vendor's Supply Includes:�Suction Separator

163

�Pulsation suppression equipment as per ‘next’ page

164

�Suction Filter:

165

�Temporary Strainer on Compressor Suction

166

�Type of Strainer:

167

� Relief Valves: on compressor � suction � Inter-stage � on compressor discharge

168

�Check Valve on Discharge Line (compressor valve design, and suction line)

169

�Process Gas Coolers Complete With Manual Drain Valve

170

�Separators Complete With Manual/ Automatic Drain Values

171

�Process Gas Piping

172

�Supply starts at inlet flange of CNG PACKAGE

173

�Terminates after priority panel with isolation valve

174

Materials:

175

�By-Pass Line Piping

176

�Between 3rd stg. discharge and 1 st stg. Suction

177

�Gas cooler

178

�Interconnecting Piping Between Packing Vents, PSV Relief terminating to Vent Recovery System.

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SHEET 12 OF 28

179

�Interconnecting piping between distance piece terminating to Vent Recovery System upto package B/L

180

�Interconnecting piping between Drains terminating as a single point

181

�Interconnecting piping between Instrument Air terminating

182

�Pulsation Suppression Equipment

183

Stage #:

Stage#1

Stage#2

Stage#3

184

Suction

185

Puls. Equipment Required Yes/No

YES

YES

YES

186

Inlet Pressure

187

Residual Peak to Peak Pulsation % As per API 618, Cl 3.9.2.7

188


189


190


191


192

Volume

193

Material : vessels

SA 516 Gr.60/70”

SA 516 Gr.60/70”

SA 516 Gr.60/70”

194

Internals

195

Corrosion

3

3

3

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SHEET 13 OF 28

Allowance mm

196


1.3XMAWP

1.3XMAWP

1.3XMAWP

197

Discharge

198

Puls. Equipment Supplied Yes/No

YES

YES

YES

199

Inlet Pressure

200

Residual Peak to Peak Pulsation %

As per API 618, Cl 3.9.2.7

201


202


203


204


205

Volume

206

Material : vessels

SA 516 Gr.60

SA 516 Gr.60

SA 516 Gr.60

207

Internals

208

Corrosion Allowance mm

3

3

3

209


1.3XMAWP

1.3XMAWP

1.3XMAWP

210

Pulsation Suppressors are complete and installed on the Skid with supports & anchor bolts

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211 Design Code: ASME SECT. VIII DIV. 1

212

Analog Piping Study / Accoustic Simulation, As per Approach 3, Cl. 3.9.2.6 API618, 4th edition

213

Upstream / downstream Inter-stage

214


215

Piping Mechanical Analysis

216


217

�Automatic Drain Valves For Each Stage suction KOD

218

�Capacity Control

219

�Start / Stop, based on discharge receiver pressure: Fully Automatic

220

Unloading for Start up/Shut down :Automatic Through � Valve Unloader � Recycle Valve

221

�Interlock against loaded start

222

� Automatic Control based on

223

�Suction Pressure� Discharge Pressure � Flow Manual Signal

224

� Type of Actuator � Actuation fluid to load � Actuation fluid to unload

225

� On Power / Actuation fluid failure : Compressor to � Load � Unload

226


227


228


229


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SHEET 15 OF 28

230

� At All other capacity, Compressor shall run continuosly

231

Vendor's scope Shall Include :

232

� Pilot Devices (pressure / temperature / Flow devices ,Controllers & Switches)

233

� Intermediate Devices (Solenoid Valves | Pneumatic Relay / Valves)

234

� Actuators

235

� Recycle valves

236

� Control Logic and System for Complete Capacity Control

237

� Inter Connecting Tubing, Piping, Cabling & Wiring

238

�Protection against extended unloaded operation (Trip)

239

�valve unloaders are required as such Compressor shall start / stop at specified receiver pressures.

240

�Purchaser's Interface

241

Type of Interface (Single Point)

Size

Rating

Face

Position/Location

242

Main Gas Piping Inlet

243

Main Gas Piping Outlet

244

Relief Valves discharge

245

Distance Piece Vent

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SHEET 16 OF 28

246

Packing Vent

247

C.W. Inlet

248

C.W. Outlet

249

N2 Inlet Supply

250

N2 Vent (Safe location)

251

Drains

252

MATERIALS

253

Cylinder Materials

254

Stage

1 Stage

2 Stage

3 Stage

255

Cylinder




256

Liner

257

Piston

258

Piston Rings

PTFE/PEEK

PTFE/PEEK

PTFE/PEEK

259

Rider Rings

PTFE/PEEK

PTFE/PEEK

PTFE/PEEK

260

Piston Rod




261

Packing Rings

262

Valve Seats

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SHEET 17 OF 28

263

Valve Stops

264

Valve Rings / Plates




265

Valve Springs

SS

SS

SS

266

Cylinder Head

267

Motion Work Materials :

268

Material / ASTM Grades

269

Top Cover

� Cast � Fabricated

270

Crankcase

� Cast �Fabricated

271

Crankshaft

� Die Forged � Open Forged � Cast

272

Connecting Rods

� Die Forged �Open Forged � Cast

273

Cross heads


274

Cross Head Shoes

275

Cross Head Guide


276

Main Bearings Type


277

Cross Head Pin Bearings Type


278

Connecting Rod Bearings Type


279

Cross Head Pin Type


280

Notes :

Page 115 of 129

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SHEET 18 OF 28

281 Each package shall be provided with two number drain lines, one from Suction KOD and second drain as common drain line from intermediate and discharge KOD routed to drain vessels through gas recovery vessels

282

CONTROLS & INSTRUMENTATION

283

� AC Power On/Off Switch With Indication Lamp

284

� Control Power On/Off Switch With Indication Lamp YES

285

� Selector Switch A/M Station For L/O Pump Motor

286

� Selector Switch A/M Station For CW Pump Motor

287

� Emergency Stop Push Button

288

� Start Push Button For Air Compressor Motor

289

� Emergency Stop Push Button for Main Motor

290

� Lamp Test Push Button

291

�Alarm/Trip Acknowledge /Reset Push Button

292

� Frame Oil Heater ON (Indicating lamp)

293

� Lubricator Oil Heater ON (Indicating lamp)

294

� Driver Interlocked against loaded start

295

� Driver Interlock against start without pre-lubrication

296

Notes :

297

Minimum required indications, alarms & trips are shown herewith. Bidder shall provide any additional instrumentation for safe operation.

298

Compressor shall start stop at pre determined receiver pressure as specified. Bidder shall include in his

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SHEET 19 OF 28

299 Scope includes the necessary hardware for the same.

300

All inter-stage / discharge and suction scrubber shall be provided with high / low level operated auto drain solenoid valves.

301

INSPECTION AND TESTS

302

Material Composition and Physical Properties Certificates Required For/Compliance certificate:

303

� Cylinder and Liner � Piston

304

� Crankshaft � Connecting Rod

305

� Pressure Vessels � Heat Exchangers

306

� X-Ray Examination for components: Pressure Vessels (certificates to be furnished).

307

� Ultrasonic Testing for components: Piston Rod, Crankshaft, Big End Bolts, Main Bearing Studs.

308

� Magnaflux Testing for components: Crankshaft, Piston Rod, Connecting Rod.

309

� Dye Penetration Testing for: Cylinder, Liner, Piston.

310

Required

Observed

Witnessed

311

� Shop inspection by Purchaser during manufacture

�

�

�

312

� Cylinder Hydrostatic

�

�

�

313

� Cylinder Pressure Test By Helium

�

�

�

314

� Hydrostatic Test of Pressure Vessels

�

�

�

315

� Hydrostatic Test of Distance Piece.

�

�

�

316

� Leak Proof Test of Crank case for 24 Hrs

�

�

�

Page 117 of 129

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SHEET 20 OF 28

317

� Barring over to check clearance / Rod run out

�

�

�

318

� Mech. Running Test with shop Driver (4 Hours min.)

�

�

�

319

� Performance Test at Works as per IS 5456/PTC9/BS 726 (*).

�

�

�

320

� Partial Stripping and internal inspection

�

�

�

321

� Functional/Continuity Tests - Control Panel.

�

�

�

322

� Field Trial Run 72 Hrs. under Vendor's Supervision (Package)

�

�

�

323

� Valve Leak Test

�

�

�

324

� Lube Oil Console Run test

�

�

�

325

� Closed Circuit C.W. System test

�

�

�

326

*: During package performance test

327

Test Certificates Required For:

328

� Auxiliary Motor & Pumps � Safety Relief Valves

329

� Safety Switches �Solenoid Valves

330

� WEIGHTS

331

Overall supply (excluding driver and gear box, if any) Kg. approx.

332

Maximum erection weight Kg. approx.

333

Maximum maintenance weight Kg. approx.

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SHEET 21 OF 28

334 Gear Box Kg. approx.

335

Driver Kg. approx.

336

SCOPE OF SUPPLY

337

� Compressor Assembly complete with frame, cylinders, cross head etc.

338

� Motion work lubrication system

339

� Cylinder and packing lubrication system

340

� Cooling system

341

� Process Gas system

342

� Local instrumentation

343

� Local Gauge Board

344

� Local Control Panel � PLC Panel � Man Machine Interface located in Control Room

345

� Main driver (Electric Motor)

346

�Barring Device : � Manual �Electric . pneumatic

347

� Flywheel

348

349

�Couplings

350

� Driver Compressor

351

� Guards for moving parts �

352

� Base plate Common for Compressor and Driver

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SHEET 22 OF 28

353 � Fabricated Steel skid Common for compressor, driver and accessories

354

�Ladders and platforms

355

� Special Tools - One Set for each package

356

� Anchor Bolts for Complete Package

357

�Piping supports and brackets : � prefabricated for piping in Vendor's Scope

358

� Supports For Cylinders & Auxiliaries, Prefabricated & fitted in the Package

359

� Commissioning Spares, erection and commissioning spares

360

�Train Torsion Analysis Study and Report

361

�Acoustic Simulation Study & Report

362

� Vendor Data as specified

363

NOTE : Refer checklist for scope of supply

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SHEET 23 OF 28

DATA SHEET- INSTRUMENTATION & CONTROLS FOR COMPRESSOR



S. NO DESCRIPTION

GU

AG

E –

LOC

AL

GU

AG

E

BO

ARD

IND

ICAT

OR

LO

CA

L PA

NE

L (P

LC) D

ISP

LAY

LOW

LO

CAL

PA

NEL

D

ISP

LAY

HIG

H L

OC

AL

PA

NE

L D

ISP

LAY

(PLC

)

LOW

–LO

CA

L P

AN

EL

-PL

C-D

ISPL

AY

HIG

H L

OC

AL

PA

NE

L P

LC- D

ISP

LAY

1 Frame Oil Sump/Reservoir Level

� yes

2 Main L/O Pump Disch. Pr (supply header).


3 Oil Flow 4 Oil Pressure at Main Bearing 5 Supply Header Temp. 6 Oil cooler Oil Inlet Temp. 7 Stand by Pump Start 8 Compressor Main bearing

metal Temp.

9 Cylinder & Packing Oil 10 Lubricator Oil Level � yes 11 Lubricator Oil Flow 12 Lubricator Failure � yes

13 Aux. Oil

14 Lub. Oil Supply Pr. to Electric Motor Driver

15 Lub. Oil return from Electric Motor Driver

16 Elec. Motor bearing metal temp.

17 Coolant System 18 Each cylinder CW outlet

temp.

19 Inter/After/Oil Cooler CW outlet temp.

20 CW Supply header flow 21 Sight Flow CW return each

cylinder, Cooler & Header � yes

22 For Closed Circuit Cooling

23 Coolant main pump disch. Pr. � yes � yes

24 Coolant standby pump disch. Pr.

25 Coolant stand by pump start 26 Coolant supply header Pr. 27 Coolant supply header temp

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SHEET 24 OF 28



S. NO DESCRIPTION

GU

AG

E –

LOC

AL

GU

AG

E

BO

AR

D

IND

ICA

TOR

LO

CAL

P

AN

EL

(PLC

) DIS

PLA

Y

LOW

LO

CA

L P

AN

EL

DIS

PLA

Y

HIG

H L

OC

AL

PA

NE

L D

ISPL

AY (P

LC)

LOW

–LO

CAL

PA

NE

L -

PLC

-DIS

PLA

Y

HIG

H L

OC

AL

PA

NE

L P

LC- D

ISP

LAY

28 Coolant cooler Outlet Temp. � yes 29 Coolant reservoir Level � yes � yes 30 Cylinder Coolant Outlet temp. 31 For Static/Thermosyphon

System

32 Cylinder Coolant Outlet temp. 33 Diff. Pr. Across packing

coolant filter

34 Process Gas System 35 Each stage inlet Pressure 36 Each stage inlet temp. 37 Each stage Outlet Pressure � yes � yes � yes � yes 38 Each stage Outlet temp.

(before air cooler and after cooler)


39 After Cooler Gas Outlet temp. � yes � yes � yes � yes 40 Ist stage pressure low / high � yes � yes � yes � yes � yes � yes 41 Cylinder Packing Vent

Pressure

42 Suction Pressure, low � yes � yes � yes 43 Blow Down vessel level � yes 44 Piston Rod Drop Indicator 45 Distance piece diff. Purge

pressure

46 Common process parameters 47 Common machine

parameters

48 Blow Down vessel Pressure � yes � yes � yes 49 Vibration Measurement � yes 50 RPM meter � yes

Such as Amperes, voltage, flow rate, total quantity of gas compressed, inlet – outlet pressure, inlet –outlet temperature, Kilo Watt Hour (KWH), electric power (electric driven compressor).

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SHEET 25 OF 28

1 OPERATING CONDITIONS (EACH MACHINE) / PERFORMANCE 2 Operating Case: SUCTION PRESSURE: 14 kg/cm² g 3 Units Stage 1 Stage 2 Stage 3 4 � Gas Handled (See Analysis) 5 � Corrosion Due to NONE NONE NONE 6 Suction Conditions 7 � Pressure (@ Vendor's

B/L) Kg/cm² g 14

8 �Temp. (+@ Vendor's B/L)

0C 35


Flange 0C <150 < 150 < 150

13 Temp.,Actual @Cyl.Flange 0C 14 Temp.,After AfterCooler 0C < 52 15 Cp/Cv Ratio 16 Compr. Factor (Z2 ) or (Z

avg )


Discharge mm2 / mm2

26 Valve Velocity m/sec 27 Speed RPM 28 Compressor Shaft Power

KW

29 Power consumed @ RV Set Pr.

KW

30 Driver Power KW 31 Guaranteed Point 32 GAS ANALYSIS- Gas Composition attached as Annexure-I.

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SHEET 26 OF 28


B/L) 0C 35


Flange 0C <150 < 150 < 150


)


Discharge mm2 / mm2


Pr. KW


Page 124 of 129

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SHEET 27 OF 28


B/L) 0C 35


Flange 0C <150 < 150 < 150


)


Discharge mm2 / mm2


Pr. KW


Page 125 of 129

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SHEET 28 OF 28

DATA SHEET INTER COOLER

1 GENERAL 2 PROJECT: PROCUREMENT OF CNG COMPRESSORS 3 OWNER: SABARMATI GAS LIMITED SITE: GANDHINAGAR 4 Item No. : Service : Intercooler / After cooler for Compressor Package 5 NOTE: � SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER � INFORMATION

REQUIRED FROM VENDOR. 6 � Manufacturer: Type: � Forced Draft �Induced Draft 7 �Bundle Size: m x m x m Bundles/Section Number

of Units: 8 Bundles/Unit: In Parallel / Series Section Size: 9 Surface/Bundle: m² Bare Tube: m² Section/Unit:

10 Surface/Unit: m² Bare Tube: m² Plot Area/Unit: 11 PERFORMANCE (Of One Unit) 12 Heat Exchanged: kcal/hr MTD (Corrected): 0C 13 Transfer Rate: kcal/hr m² 0C (Finned Surface) (Bare Surface) 14 TUBE SIDE 15 Fluid Circulated GAS Gravity: Liquid

API SG @ 15.4EC 16 Total Entering Gas kg/hr Enthalpy / Latent

Heat kcal/kg 17 Operating Temperature In: Out: Fouling Resistance hr m² 0C/kcal 18 Operating Pressure Passes / Bundle kg/cm² 19 AIR SIDE 20 Temperature In:47 Out: Altitude m 21 Total Flow/Unit kg/hr Static Pressure kg/cm² 22 Quantity/Fan kg/hr Power/Fan kW 23 Face Velocity m/sec Power/Unit kW 24 CONSTRUCTION (Each Bundle) 25 Design Pressure: kg/cm²g Test Pressure: kg/cm²g Design

Temperature: 0C 26 Code Requirements: 27 Type of Tubing: Tube Material: SA 179 Fin Material: Al 28 Tube Bare Tubes (no's) : No. of rows: O.D.

BWG/Thk Length 29 Fins : Spacing /inch. O.D. Root Dia

Thickness: 30 Header Type: Plug / Cover No. of Splits: Material : 31 Plugs/Gaskets Side Frame : C.S. Inside Zinc Protected 32 Nozzles In : Out : 33 Couplings Vent: Drain : 34 CONSTRUCTION (Each section) 35 Structure CS Sec./Gr. No. Design Wind

Load : kgf/m 36 Plenum Chamber CS inside Zinc Protected Type : 37 Fans No. Dia. RPM Mfr. 38 Blades Material : No./Fan Pitch Angle(Design) : 39 Hubs Material : Pitch : Autovariable / Adjustable (No. ) 40 Louvers Material : Type : Mfr. 41 Weights kg Each Section(Dry) : Full of Water: 42 Each Bundle (Dry) : Full of Water: 43 APPLICABLE SPECIFICATIONS API Standard 661 44 REMARKS 1. Air coolers shall be designed for 20% excess capacity than required normally. 45 Exchanger shall be designed with air side temperature of 47.5 0C. 46 Separate data sheet shall be filled by the bidder for each service i.e. Inter cooler and After cooler

Page 126 of 129

1



CLIENT JOB NO. - DATA SHEET – AIR COOLED HEAT EXCHANGER

TOTAL SHEETS 03

DOCUMENT NO 11 0317 02 09 03 301






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DATA SHEET - HEAT EXCHANGER

SHEET 2 OF 3

28 Plug/Gaskets

Side Frame: C.S.Inside Zinc Protected

DATA SHEET –AIR COOLED HEAT EXCHANGERS

1 Service: Intercooler / After cooler for Compressor Package

2 NOTE: Scope option / information specified by Purchaser * Information Required From Vendor

3 Manufacturer Type Forced

Draft Induced Draft

4 Bundle / Unit : m x m x m

Bundles / Section Number of Units

5 Bundles/Unit:

In Parallel / Series Section Size

6 Surface / Bundle: m2

Bare tube: m2

Section / Unit

7 Surface / Unit: m2 bare Tube: m2 Plot Area / Unit 8 Performance (of

one unit)

9 Heat Exchanged: kcal/hr

MTD (Corrected:0C

10 Transfer Rate: kcal/hr/m2°C

(Finned Surface) (Bare Surface)

11 Tube Side

12 Fluid Circulated: Gas Gravity: Liquid [email protected]

13 Total Entering Gas kg/hr

Enthalpy/Latent Heat kcal/kg

14 Operating /Temperature In: Out:

Fouling Resistance hrm2°C/kcal

15 Operating Pressure Passes/Bundle kg/cm2

16 Air Side 17 Temperat

ure In: 47 Out: Altitude (m): 110

18 Total Flow/Unit Kg/hr

Static Pressure kg/cm2

19 Quantity / Fan kg/hr Power / Fan kW 20 Face Velocity

m/sec Power / Unit kW

21 Construction (Each Bundle) 22 Design Pressure :

kg/cm2g Test Pressure : kg/cm2g

Design Temperature : 0°C

23 Code Requirements:

24 Type of Tubing: Tube material : CS (SA-179)

Fin material: AI

25 Bare Tubes (nos.) No. of rows: O.D BWG/Thk Length

36 Fins: Spacing/inch.OD

Root Dia Thickness

27 Header Type: Plug/Cover

No. of Splits:

Material:

Page 128 of 129

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DATA SHEET - HEAT EXCHANGER

SHEET 3 OF 3

29 Nozzles In: Out: 30 Couplings Vent Drain 31 Construction (each Station) 32 Structure CS Sec/Gr.N

o. Design Wind Load: kgf/m

33 Plenum Chamber Cs inside Zinc Protected

Type

34 Fans No. Dia RPM Mfr. 35 Blades Materia

l No/Fan Pitch Angle

(Design) 36 Hubs Materia

l Pitch L Auto variable / Adjustable (No.)

37 Louvers Material

Type Mfr.

38 Weights kg Each Section (Dry):

39 Each Bundle (Dry) 40 Applicable Specifications API

Standard 11P

41 Remarks 1. Air coolers should be designed for 10% excess capacity than required normally.

42 Exchanger should be designed with air side temperature of 48°C

43 Separate data sheet should be filled by the bidder for each service i.e. Inter cooler and after cooler.

Page 129 of 129

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