GAIL GAS LIMITED - gailtenders.ingailtenders.in/writereaddata/Tender/vol -ii of ii...

$Page 1: GAIL GAS LIMITED - gailtenders.ingailtenders.in/writereaddata/Tender/vol -ii of ii web_20131128... · GAIL GAS LIMITED {A wholly owned subsidiary of GAIL Gas Limited}$
GAIL GAS LIMITED {A wholly owned subsidiary of GAIL Gas Limited}

NOIDA, UTTAR PRADESH (INDIA)

TAJ TRAPEZIUM ZONE (TTZ) PROJECT

BID DOCUMENT OF

GAS ENGINE DRIVEN CNG COMPRESSORS

OPEN INTERNATIONAL COMPETITIVE BIDDING

E-Tender no. 6000000251

Bid Document No.: 05/51/23N0/GAIL GAS/031

VOLUME – II OF II

PREPARED AND ISSUED BY

MECON LIMITED (A Govt. of India Undertaking)

Delhi, India

1 of 103

GAIL GAS LIMITED

TENDER FORGAS ENGINE DRIVEN

CNG COMPRESSORS FORTAJ TRAPEZIUM ZONE (TTZ) PROJECT

Bid Document No.: 05/51/23N0/GAILGas/031 MECON LIMITED

Page 2 of 103

UC O N T E N T

USl.No.U U DescriptionU

SECTION-I MATERIAL REQUISITION

SECTION-II TECHNICAL SPECIFICATION FORCNG COMPRESSOR

SECTION-III DRAWINGS

GAIL GAS LIMITED




Page 3 of 103

SECTION – IMATERIAL REQUISITION

GAIL GAS LIMITED




Page 4 of 103

PROJECT : TAJ TRAPEZIUM ZONE (TTZ) PROJECTMR NO. : MEC/MR/05/25/23N0/031CLIENT : GAIL GAS LIMITEDITEM : GAS ENGINE DRIVEN CNG MOTHER COMPRESSORS

ItemNo.

DESCRIPTION UNIT QTY Destination/Remarks

1.1(a)

Design, Engineering, Manufacturing,Supply (including packaging andforwarding, insurance, customclearance, handling and unloading atport as well as at GAIL Gas’s site (atKosi Kalan, Firozabad, in Uttar Pradesh(UP); Ludhiana and Jalandhar inPunjab; Dewas in Madhya Pradesh(MP) & Bharatpur in Rajasthan of Skidmounted gas engine driven CNGCompressor Package with explosionproof electric & control panel of 1200Sm3/h at suction pr. of 17.5kg/cm2(g)(range 14 to 19 kg/cm2(g) withdischarge pr. 255 kg/cm2(g) with 8bank Priority panel.

Nos. 10 1(One) out of 10 (Ten)packages required atLudhiana, Punjab.

1(One) out of 10 (Ten)packages required atJalandhar, Punjab.

4(Four) out of 10 (Ten)packages required atFirozabad, UP

2(Two) out of 10 (Ten)package required at Kosikalan,UP

1(One) out of 10 (Ten)package required atBharatpur, Rajasthan

1(One) out of 10 (Ten)packages required at Dewas,MP.

1.1(b)

Cost of providing one priority or takeaway one priority from abovecompressor.

Nos 5

1.2 String test of complete compressorpackage along with gas engine andaccessories at packagers' factory

Nos. 10

1.3 Special tools & tackles required forerection and commissioning (list of tools& tackles to be furnished by the bidder)

Set 10

1.4 Design, Engineering, Manufacturing,Supply (including packaging andforwarding, insurance, customclearance, handling and unloading atport as well as at GAIL Gas’s site (atKosi Kalan, Firozabad, in Uttar Pradesh(UP); Ludhiana and Jalandhar inPunjab; Dewas in Madhya Pradesh(MP) & Bharatpur in Rajasthan of aircompressor of capacity approx 7.5 kW,discharge pressure approx 16 kg/cm

2g,

1000 water litre capacity air receiverand air dryer along with all accessoriesand auxiliaries and air compressor of

Nos. 10

GAIL GAS LIMITED




Page 5 of 103

capacity approx 1.5 kW, dischargepressure approx 7 kg/cm

2g, 500 water

litre capacity air receiver and air dryeralong with all accessories andauxiliaries.

1.5 Installation, commissioning & Fieldperformance test of CompressorPackages including air compressors atvarious sites.

Nos. 10

1.6 Non Comprehensive maintenance for01 year within warranty period includingall lubricant, consumables andreplacement of parts/components if any.

Nos. 10

1.7 Mandatory Spares as per list enclosed Lumpsum

01

Notes:

1. Cost of air Compressor installation and O&M shall also be included in above relevantheads.

2. Evaluation Basis: Lump Sum overall basis.3. Delivery location will be intimated before despatch of the compressor packages and

in case of Jalandhar/ Ludhiana the same may be used at other location of TTZ asdecided by the owner.

Mandatory Spares List for 1200 SCMH CNG Compressor, Gas Engine & AirCompressor

S.No. Item Description Units Qty.

A CNG Compressure

1 All compressor bearing / bushes (main, connecting rod big end.Connecting Rod small end, Cross Head etc.) Set 10

2 Crosshead Set 5

3 Crosshead Shoes Set 5

4 Piston rings / Rider Ring (sealing wear rings) for all cylinders. Set 5

5 Piston Rods Set 5

6 Piston for all stages Set 5

7 Piston for all cylinders. Set 5

8 Complete valve assembly, Suction, for all stages Set 5

GAIL GAS LIMITED




Page 6 of 103



9 Complete valve assembly, Discharge, for all stages Set 5

10 Valve internals consisting of valve springs, valve plates etc. Set 6

11 Replaceable parts of main packing, partition packing, all scrapper ring,o-rings, gaskets etc. Set 4

12 Complete Lubricator assembly Set 4

13 Digital No flow Transmitter, if applicable Set 2

14 complete coupling/ pulley Set 4

15 Idler pulley, if applicable Set 4

16 Belt, if applicable / bended Belt Set 10

17 Cooling fan bearing Set 6

18 Cooling fan shaft Set 6

19 Cooling fan blades with hub Set 6

B Gas Engine

20 All engine bearings/ bushes (main, Connecting rod big end, connectingcylinder end etc.) Set 6

21 Complete Cylinder head assembly Set 4

22 Piston rings (all types) Set 6

23 Piston Set 4

24 Liners Set 4

25 Connecting Rod Set 4

26 Ignlition System (Transformer / Contractor / Distributor etc.) Set 6

27 Spark Plug Set 6

28 Carburettor assembly Set 4

29 Fuel Pressure regulator Set 5

30 Diaphragm kit for fuel pressure regulator Set 6

31 Starter motor Set 5

GAIL GAS LIMITED




Page 7 of 103



32 Starter motor repair kit Set 6

33 Complete Coolant pump Set 6

34 Coolant pump repair kit Set 6

C Instrumentation

35 Display Set 4

36 PLC (CPU/ Interfce card / Others) Set 4

37 Isolators Set 6

38 Pressure Transducer Set 6

39 Temperature Element Set 6

40 Gas / Fire / Smoke / Detectors Set 6

41 Pressure Gauge Set 6

42 Temperature Gauge Set 6

43 Solenold Colls Set 6

D Package Spares

44 NRV Set 6

45 Coalescing Filter Element Set 18

46 Suction Gas Filter Element Set 18

47 Lube Oil Filter Element Set 18

E Air Compressor

48 Piston Rings Set 6

49 Air Filter Set 18

50 V-Belts Set 18

51 Master control Valve for CO2 Cylinder Nos. 05

GAIL GAS LIMITED




Page 8 of 103

SECTION – IITECHNICAL SPECIFICATION

FORGAS ENGINE DRIVEN CNG COMPRESSOR

(MEC/TS/05/25/23N0/031)

MECON LimitedDELHI 110 092

GAIL GAS LIMITED




Page 9 of 103

C O N T E N T SU

Sl No. DESCRIPTION1. GENERAL

2. UTILITIES & BATTERY LIMITS

3. EQUIPMENT QUALIFICATION CRITERIA

4. BASIC DESIGN

5. ELECTRICS AND INSTRUMENTATION CONTROL

6. INSPECTION AND TESTING

7. PRICE LOADING AND COMPENSATION FOR UNDER PERFORMANCE

8. PAINTING AND PROTECTION

9. ERECTION, TESTING AND COMMISSIONING AT SITE

10. FIELD TRIAL RUN

11. SPARE PARTS, SPECIAL TOOLS AND TACKLES

12. DATA AND DRAWING

13. OPERATION & MAINTENANCE SERVICES

14. GUARANTEED PARAMETERS OF COMPRESSOR

15. GAS COMPOSITION.

16. CLIMATE

17. DATA SHEET OF COMPRESSOR

18. DATA SHEET OF GAS ENGINE

19. DATA SHEET OF DETECTORS

20. OPERATING CONDITIONS & EXPERIENCE RECORD OF GAS ENGINE

DRIVEN COMPRESSOR21. EXPERIENCE RECORD PROGRAMME OF GAS ENGINE DRIVEN

COMPRESSOR

22. LIST OF INSTRUMENTATION & CONTROLS23. QUALITY ASSURANCE PLAN

24. MAKES OF BOUGHT OUT ITEMS

25. CHECKLIST

26. FORMAT OF DEVIATION TO THE TECHNICAL SPECIFICATION.

GAIL GAS LIMITED




Page 10 of 103

1.0 GENERAL

GAIL Gas Ltd., a wholly owned subsidiary of M/s GAIL (India) Limited, has been set upto provide CNG (Compressed Natural Gas) as fuel to commercial and private vehiclesthrough filling stations and PNG (piped Natural Gas) to household, commercial andindustrial consumers in Taj Trapezium zone (including Kosi Kalan, Firozabad, Vrindavanetc. in UP; Bharatpur in Rajasthan) and various locations across the country.

1.1 Scope of work

This specification along with applicable codes as referred, describe the minimumrequirements for design, engineering, manufacturing, inspection, testing, supplyincluding packaging, forwarding, insurance, custom clearance, handling and unloading atport as well as at PURCHASER stores/ site at Kosi Kalan, Firozabad, in UP; Ludhianaand Jalandhar in Punjab; Dewas in (MP) & Bharatpur in Rajasthan , package string testat Bidder 's shop, supply, erection & commissioning at site of "GAS ENGINE DRIVENRECIPROCATING GAS COMPRESSOR PACKAGES" as required for dispensing CNGto vehicles at various locations in Ludhiana and Jalandhar in Punjab; Dewas in MP;Firozabad, Kosi kalan in UP and Bharatpur in Rajasthan. Various parts of thisspecification shall be read in conjunction with each other and in case where the differentparts of this specification differs the more stringent requirement shall govern.

Any additional work/equipment or technical requirement not mentioned in thespecification but required to make the offered system complete in accordance with thespecification and for safe and proper operation, shall be deemed to be included in thescope of work by the Bidder .

1.2 Codes & Standards

The design, construction, manufacture, supply, testing and other general requirementsof the compressor package equipment shall be strictly in accordance with the datasheets, applicable API codes, and shall comply fully with relevant National/ Internationalstandards, Indian Electricity Act, Indian Electricity Rules, regulations of InsuranceAssociation of India and Factories Act while carrying out work as per this specification.

Any modification suggested by the statutory bodies either during drawing approval orduring inspection, if any, shall be carried out by the Bidder without any additional costand delivery implications.

The following codes and standards (versions/ revisions valid on the date of order) arereferenced to & made part of specification:

API-11P, Second edition, API 618NFPA-37, OISD 179, PNGRB T4s, NFPA-52: 2006, NFPA-496, NFPA-68, NFPA-70ANSI, ASTM, NEC, NEMA

GAIL GAS LIMITED




Page 11 of 103

Indian Electricity Rules, Indian Explosives Act., Gas cylinder rules, code for SS tube andforged fittings

1.3 Precedence

In case of any conflict among the various documents of this requisition the followingpreferential order shall govern:

1. Data sheets/drawings2. This Technical Specification3. International standards/codes as applicable4. Indian Standards / codes applicable

Compliance with this specification shall not relieve the Bidder of the responsibility offurnishing equipment and accessories of proper design, material and workmanship tomeet the specified operating conditions.

No deviations to the technical requirements and to the scope of supply specified in thisenquiry document shall normally be accepted and offers not in compliance to the sameshall be rejected summarily. In case a deviation is required due to inherent design of theequipment offered, the Bidder shall list all such deviations at one place giving reasonsthereon.

1.4 DOCUMENTS/DATA REQUIRED ALONG WITH BID U

Bidder shall necessarily furnish the following along with the bid without which the offershall be considered incomplete:

1. Proven Track Record Formats duly filled in2. Checklist duly filled in with regards to scope of supply3. Completely filled in Data Sheets of compressor, gas engine and electric motors.4. Deviations if any to this Technical Specification5. Tentative Lay out / key plan/ General Arrangement indicating size of skids, center

distance between skids and space required along with maintenance requirements6. (a) Utilities requirements (b) Electrical Load summary7. Catalogues of compressor, gas engine and instrumentation items.8. Other details are given in VDR.

1.5 SCOPE OF SERVICES

1. Engineering, design and manufacturing.

2. Procurement of raw materials etc., from sub-vendors.

3. Preparation of documentation for design, approval by Purchaser/consultant.

4. Inspection and testing as per T.S.

GAIL GAS LIMITED




Page 12 of 103

5. Surface preparation, protective coating and painting as per T.S.

6. Packaging for transportation to site and supply.

7. Erection, testing & commissioning as per T.S.

8. Field trial run and performance test at site.

9. Post commissioning annual maintenance with all spares and consumables.

1.6 SCOPE OF SUPPLY FOR EACH COMPRESSOR PACKAGE

Each compressor Package shall be complete with:

Lubricated or non-lubricated two throw balanced opposed reciprocating compressorwith lube oil system and cooling system (console type) as required.

Gas engine as compressor driver.

Gas meter (3 nos.): Mass flow meter (Model CNG 50 with integral local display)based on Coriolis principle of Micro motion, USA with F-series 2700 transmitter atcompressor discharge, F-series with 1700 transmitter at compressor suction and gasengine fuel consumption. Installation and manufacturing of mass flow meter shall beas per as per AGA-11.While installing special care shall be taken to isolate the massflow meter from piping vibration.

Instrumentation and control system as specified on data sheets, P&ID includingLocal panel, Console/Local gauge boards, PLC

Electrical equipment / Instruments indicated in the Compressor package.

Separate junction boxes for different type of signals like analog, digital signals,alarm, shutdowns, and thermocouples, RTDs etc. for interfacing to local panel. Sameis not applicable for direct run cable upto PLC panel.

All cables and accessories shall be as per cl. No. 5.7

Common structural steel skid for the compressor- gas engine and for all auxiliarysystems.

Structural supports within the compressor package for all piping, electrical andinstruments etc

Inlet twin suction gas filter with oil drain valve & DP gauge and temporary suction linestrainer at 1P

stP stage and at other stage if required, Inter-stage and discharge gas, air

cooled heat exchangers.

Inter-stage and discharge gas, air cooled heat exchanger.

Exhaust fan in the enclosure in addition to the cooling fan of the heat exchanger.

Separator/ Knockout drums with solenoid valve operated auto & manual drains asrequired.

Priority Panel at Package Discharge as per Priority fill system.

GAIL GAS LIMITED




Page 13 of 103

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

Impulse and pneumatic piping/Tubing for all valves, fittings as specified & requiredfor mounting the instruments.

NRV at gas suction, final discharge point, LCV and priority panel as required.

Over ride facility in LCP to fill LCV in priority panel of compressors shall be provided.

Y- type strainers, valves, sight flow indicators, check valves, manual drain/ traps etc.as required for various auxiliary systems i.e. frame lube oil, cylinder lubricationsystem, cooling water systems, fuel supply/conditioning system etc.

Coupling/V-belt/pulleys.

Single Acoustic enclosure for both Compressor and gas engine as specified, withtwo number L.E.L detectors and two UV detectors in enclosure.

COB2B extinguishing system consisting of two cylinders, piping and valves.

Inlet and outlet manual & automatic isolating valves.

Piping from air compressor and CO2 cylinders up to enclosure.

Complete Erection, Testing & Commissioning including Co2 flooding system ofcompressor packages.

Annual O&M during one year warrantee period with spares, consumables, manpower and lubricants.

Training of 4 persons (2 supervisors + 2 operators) at packager’s workshop and atsub-vendors workshop. The traveling, boarding and lodging of Purchaser’s engineersshall be borne by PURCHASER. Training module shall span for one week and shallcover the equipment constructional features, operational and maintenanceprocedures etc. (Bidder to indicate separate price, if any).

Exclusions

The following are excluded from the scope of the Bidder:

All civil works and foundation design. However the Bidder shall furnish all therelevant data for design of compressor foundation. However, grouting ofequipment including supply of material is a part of erection.

CNG storage cascade.

Bidder to note piping from air compressor and COB2B cylinders up to enclosures inthe scope of bidder.

1.7 Safety

GAIL GAS LIMITED




Page 14 of 103

1.7.1 All controls shall operate in a fail-safe mode i.e. failure of any control shall not lead torunning of equipment in unsafe mode. Fail safe control shall be available through bothsoftware and hardware for all trips.

1.7.2 Area Classification :The hazardous area classification Class-I, Division I, Group D as perNEC or Zone I, Group II A/ II B as per IS/ IEC. Certificate from recognized agency to theeffect that equipment supplied and/or installed conform to above area classification. AllDevices shall meet the requirement for the specified area classification in which they areinstalled, including instrumentation leads.

1.7.3 All exposed rotating parts shall be provided with adequate guards of non-sparking type.

1.7.4 Drive belt if used shall be of fire retardant and anti-static type.

1.7.5 Piping shall be arranged in a manner so as to provide clear headroom and accessibilitywithin the package. Adequate clearances shall be provided for all the engineeredcomponents for O&M point of view.

1.7.6 Package enclosures shall have two IR type L.E.L detectors and two Ultra Violet (UV)/IRfire detectors in each enclosure to cover the enclosures effectively.

1.7.7 All material used in the package shall be flame retardant.

1.7.8 The Compressor Package shall trip if any of the enclosure is opened while the machineis running.

1.7.9 Relief Valves shall be provided at suction and discharge and in between inter stages ofcompressor with setting as per cl. 7.20.3 of API – 11P with R.V. venting as per cl. 7.20.4of API-11P. All vented lines to be connected to common relief valve header.

1.7.10 CO2 flooding system:

The package shall be protected by automatically operated CO2flooding system designed

as per NFPA-12 which should have minimum following features: -

1. Gas Detection by installation of hydrocarbon gas detector (IR type) andtransmitter with adjustable alarm levels (0-100%) with preset of 10%, 20% and50%. Package should have at least 2 nos. gas detectors.

2. Installation of flame detector (UV-IR type) and transmitter, alarm on detection offlame. Package should have at least 2 nos. flame detectors.

3. CO2 flooding system shall consist of 2 nos. of min 45 kg CO2 cylinders. Howeveractual size of the cylinder shall be as per compressor enclosure size. Necessarycalculation shall be submitted by the bidder during detailed engineering. Onecylinder will act as main cylinder & other as stand by, which shall have identical

GAIL GAS LIMITED




Page 15 of 103

arrangement and connected to the system. The cylinders shall be protected fromweather and direct sunrays as per Gas Cylinder Rules, 2004. Cylinders shall befitted with actuated Valves, Solenoid valves etc. for automatic actuation. Controlphilosophy shall be such that in case main cylinder fails the standby cylindershall discharge automatically. For this the vendor shall provide suitable devicesuch as pressure switch (intrinsically safe type) to detect the failure of maincylinders failure. One manual switch / call point shall be provided to operate theCO2 cylinder from remote control room. Pull down lever on cylinder valve formanual operation shall be provided.

4. The System shall be designed to operate on 24 V DC supply. FRLS (Fireresistant low smoke) cables shall be used for the wiring of the system.

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 automaticdischarge of CO2 gas shall take place from the main cylinder simultaneously.

iii. Maintenance Override Switch shall be provided to keep the system off duringmaintenance.

iv. Compressor shall not start if the CO2 Flooding System is faulty, not working,Switched OFF during maintenance etc.

v. Selector switch shall be provided to put Main/Stand by Cylinder in line at theturn of a switch as per requirement.

6. CO2 Cylinders shall be provided outside the package at a safe place, minimum4.5 meters away (aerial distance), where it is not exposed to fire in case of fire inthe compressor. Facility shall be made to operate the system both manually fromremote with the help of a switch/ call point and with help of pull down lever oncylinders.

7. Online weight (CO2) loss indication device to be provided to ascertain the health

of the CO2flooding system.

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

9. Technical specifications, Operation and Maintenance Manual, CCOE Certificate,Approval/ Manufacturing certificates for cylinders and cylinder valves, gasdetectors, flame detectors, solenoid valves etc. shall be furnished by the bidderalong with system. Software and hardware, calibration procedure shall beprovided by the bidder along with the supply sufficient enough to handle thesystem independently.

10. System shall be tested by the bidder after commissioning at site by creating firesignal and actual discharge of CO2 Gas from the Cylinders. The cylinders haveto be refilled by the vendor at no extra cost to purchaser after testing. If the

GAIL GAS LIMITED




Page 16 of 103

system fails during testing, subsequent testing and refilling would be at vendor’scost.

11. Warning and Operating instructions to be displayed at equipments as per thestatutory/ safety regulations.

2.0 UTILITIES & BATTERY LIMITS

2.1 Utilities

2.1.1 Bidder shall make his own provision for air required for starting the compressor.

2.1.2 Air compressor of capacity approx 7.5 kW preferably of IR/KPCL/Elgi/CP make ofapprox 16 kg/cm

2(g) discharge pressure with PRV, and 1000 water litre capacity air

receiver shall be supplied for each CNG compressor package for gas engine startingpurpose. Air dryer suitable for automatic operation shall also be supplied along with allaccessories. Electric power will be arranged by purchaser for driving the air compressor.The air compressor shall be kept off the package in safe area or in electrical room.Piping, electrical & instrumentation cabling shall be in bidder’s scope as per cl. No. 2.1.3.The air receiver shall be connected to existing instrumentation air dryer for emergencypurpose through NRV, PRV (set at 7 kg/cm2) and isolation valve. Air receiver shall beprovided with, SRV, pressure gauge and drains. Manual drains and automatic moisturetraps shall be provided in the system.

2.1.3 Air compressor with discharge pressure of 7 kg/cm2 suitable for1.5 KW electric motorrating with dryer shall be supplied by the bidder. Compressor to be supplied should bepreferably of IR/KPCL/ElGI/CP make; air receiver of 500 water liter capacity shall beprovided. Air dryer suitable for automatic operation shall also be supplied along with allaccessories. Air compressor, drier and air receiver for instrument air, shall be kept off thepackage in safe area or client’s building. Piping, electrical & instrumentation cabling shallbe in bidder’s scope. Necessary FR unit shall be provided as per requirement. Manualdrains and automatic moisture traps shall be provided in the system. Air receiver shall beprovided with SRV, pressure switch, pressure gauge and drains. Pressure switch andpressure gauge shall have isolation valve. Air dryer shall be with bypass arrangement.One ½” tapping with isolation valve for dispenser and one 1” tapping with isolation valve(spare) from each air receiver shall be provide.

2.1.4 Bidder will make piping connection from existing instrumentation air receiver forinstrumentation air requirement. Necessary FR unit shall also be provided as perrequirement

2.1.5 Cooling water is not available as utility and the package shall be provided with selfsufficient cooling water system for Compressor, as required, with make up tank. Howevercooling water for make up tank is available.

2.1.6 All electrical and instrumentation terminals shall be as specified.

2.1.7 Electric power shall be made available by Owner.

GAIL GAS LIMITED




Page 17 of 103

2.1.8 For running the Air compressor, Exhaust fan and illumination, 415 Volt (10 %) 3-phases4 Wire, 50 Hz (5%) shall be provided by Owner at a single point (feeder inPDB) inside the electrical room. Bidder shall indicate power/Feeder (KW/Amp)requirement in the offer.

2.1.9 Purchaser shall provide UPS (240 1 % V, 50 1 % Hz) for control supply requirementsat a single point (feeder in UPS ACDB) inside the electrical room. Bidder shall indicatepower/ feeder (KW/Amp) requirement in the offer. Surge protection devices ofapproved make shall be provided for all incoming supply to Bidder’s end.

2.1.10 Battery limits.

2.1.10.1 All customer interface connections , gas Inlet shall be brought out to the packageedge and terminated in nozzles with isolation valves having flange connection

2.1.10.2 As and where specified on the data sheets all vents (i.e. Relief valve, distance pieceand packing) shall be manifolded and terminated at skid edge outside the enclosureand vented to safe height of 2.5 m at package roof.

2.1.10.3 All drains from different process equipment, distance piece and packing shall bemanifolded and terminated at single point for customer interface duly flanged withisolation valve.

2.1.10.4 UPS and Non UPS power shall be made available from power distribution board(PDB) in the electrical room. Supply, Erection and termination of all cables andaccessories from feeder in electrical room shall be in the bidder’s scope

2.1.10.5 Electronics earth pit shall be made available at a distance of about 5 meters fromcompressor package. Cable from this earth pit shall be in the bidder’s scope.Owner’s earthing main ring shall be made available at compressor foundation. Cableto control panel body earth inside the compressor package shall be in the bidder’sscope.

3.0 EQUIPMENT QUALIFICATION CRITERIA

3.1 The Gas Compressor model offered shall be from the existing regular manufacturingrange of the Gas Compressor manufacturer. At least one identical or higher capacitycompressors must have been manufactured, tested and supplied from the proposedmanufacturing plant in the last seven years. The compressor supplied must havebeen operating satisfactorily in the CNG field for a period of 8000 hours eachwithout any major break down as on the bid due date.

3.2 The Gas Engine model offered shall be from the existing regular manufacturingrange of the gas engine manufacturer. At least one identical or higher capacity

GAIL GAS LIMITED




Page 18 of 103

engine must have been manufactured, tested and supplied from the proposedmanufacturing plant in the last seven years. The gas engine supplied must havebeen operating satisfactorily in India in the CNG field for a period of 8000 hours eachwithout any major break down as on the bid due date.

.

4.0 BASIC DESIGN

4.1 General

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

1. Data Sheets: As enclosed

2. Technical Specification:

3. Code and specification API-11P, API-61, OISD 179, NFPA, ANSI, ASTM, NEC,NEMA, Indian Electricity Rules, and Indian Explosives Act are referenced to & madepart of specification.

4. Compressor and its auxiliary’s design shall be in conformity with API 11P, secondedition, API 618, piston trunk design.

4.1.2 Gas composition given under Design Case shall be used for Compressor selection,sizing and performance guarantee estimates. However compressor shall be suitable forcontinuous operation with the indicated gas composition range and operatingparameters given in this tender.

4.1.3 Suction line pressure varies from 14 to 19 Kg/cm2 for MR item no.1.1. Bidder to notesuction pressure regulator is not required. However, suction pr transmitters shall beprovided to protect the compressor from very high and low pressure.

4.1.4 Bidder's offer shall be based on firm and final compressor / gas engine make andmodels on which basis the offer shall be evaluated and no alternate compressor / gasengine make and models or change of make and models to lower frame shall beentertained.

4.1.5 Note that the pressures given on the data sheet are at the compressor packageboundary limits and not at compressor cylinder, Bidder shall consider all pressure lossesat suction, inter-stage and discharge at the specified capacity (with no -ve tolerance) forcompressor and indicate the same on the data sheets.

4.2 Allowable speeds, temperature and vibration levels

GAIL GAS LIMITED




Page 19 of 103

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

4.2.2 The maximum discharge gas temperature for each stage shall be limited to 150 degree C.

4.2.3 Compressor maximum vibrations at cylinders and at frame shall not exceed 10 mm /sec.And 5 mm/s respectively unfiltered peak velocity. The Bidder shall provide for all structuralsupport within the package so that these levels can be achieved.

4.3 Piston Rod, Bearings and Cross Heads

4.3.1 The surface hardness of Rockwell C 50 minimum is required on piston rods in the areasthat pass through the packing. Rolled threads shall be provided on the rods with threadrelief area as polished.

4.3.2 Crosshead shall be manufacturer standard material and designs. Adequate openings forremoval of the crossheads shall be provided.

4.3.3 Piston rod and cross head pin loading at any specified operating condition at the reliefvalve set pressure shall not exceed 80% of the maximum design rod load of the offeredcompressor. Rod loads shall have sufficient reversals in direction for all specified operatingconditions including RV Settings and part load operation.

4.3.4 Frame rating as published in catalogues of the offered compressor model shall be min1.1 times the required rating corresponding to max severe operating conditions takinginto account temperature correction factor.

4.4 Packing Cases and Pressure Packing

4.4.1 All oil wiper intermediate gas cylinder pressure packing shall be a segmental ring withstainless steel garter springs. The pressure packing case shall be provided with a commonvent and drain below the piston rod tube to the outside of the Package enclosure.

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

4.4.3 Packing vent piping inside of the distance piece shall be designed for the maximumallowable working pressure of the cylinder.

4.5 Compressor Frame Lubrication

4.5.1 Compressor frame lubrication shall be pressurized system, with a main oil pump drivendirectly by the compressor shaft.

GAIL GAS LIMITED




Page 20 of 103

4.5.2 If required the Bidder shall provide an air/electric motor driven pre-lubrication pump.Crankcase shall be fitted with lube oil temp & level indicator.

4.5.3 All lube oil piping after oil filter shall be 300 series stainless steel conforming to ASTMA269.

4.5.4 Heating shall be provided for reservoir when the minimum ambient temperature is lessthan the Bidder’s required minimum start up temperature.

4.5.5 Heater besides meeting the area classification requirements specified in the Tender shallbe star connected if designed for operation on 3-phase (4 wire), 440V, 50 Hz supply.

4.6 Distance Pieces

4.6.1 Distance piece as per API-11P with cylinder side compartment vented to safe location isspecified.

4.6.2 Distance pieces shall be provided with gasketted, solid covers and shall be suitable for aminimum differential compartment pressure of 1.75 kg/cm²g.

4.7 Cylinder and Packing Lubrication

4.7.1 Single plunger per point force feed mechanical lubricator shall provide lubrication tocompressor cylinders.

4.7.2 Lubricators shall be driven by crankshaft and bidder shall highlight any pre lubricationrequirements of the cylinders and the method of achieving the same.

4.7.3 Lubricators shall have a sight flow indicator for each lubricator point and a stainless steeldouble ball check valve shall be provided at each lubrication point.

4.7.4 Digital no flow timer shall be provided to stop the compressor in case of loss of cylinderlubrication.

4.7.5 Lubricator reservoir capacity shall be adequate for 100 Hrs of normal flow, and shall beequipped with low level alarm.

4.7.6 Bidder along with the proposal shall furnish the recommended lubricating oil type,International Grades & Specification along with their quantity and frequency of change.The recommended oil shall be compatible with gaskets, O-rings, seals, packing, lubricatorparts and other parts coming into contact.

4.8 Cooling System

4.8.1 Compressor Cylinder

GAIL GAS LIMITED




Page 21 of 103

Compressor cylinders may be air-cooled or water-cooled. The CW shall be cooled by anair-cooled heat exchanger.

4.8.2 Inter / After Gas Coolers

Air-cooled inter-stage and final stage discharge coolers shall be provided which shall limitthe gas temperature after the after cooler to 50 degree C. For calculating the surface areaof the air cooler the ambient air temperature of 44oC and 80% RH shall be considered.Cooler design shall be on the basis of 20% excess capacity than required correspondingto suction pr of 19 kg/cm2. Gas sections of coolers shall be designed as per API-661requirements. Vibration switch shall be provided on the heat exchanger to trip thecompressor on high vibration limit. Bidder shall indicate vibration level in the offer. Forcooling of the Heat Exchangers a cooling fan shall be provided inside the enclosure(s).Cooling system shall be preferably installed on the same skid as the compressor due tospace constraints. Bidder shall submit cooler sizing calculation for review.

4.9 Separators & Oil Removal System

4.9.1 Carbon Steel separators / KOD at auto and manual drain system shall be provided forthe capacity as required.

4.9.2 All pressure vessels shall be designed as per ASME VIII Div 1 or equivalent.

4.9.3 Scrubber service class - B shall be used for Inter-stage / discharge scrubbers. ServiceClass - C shall be used for suction scrubber. (Refer API -11P)

The offered scrubber and mist removal shall restrict the oil level to < 5 ppm in thedischarge gas of compressor. SS mesh pad shall be used in the scrubbers.

All vessels including pulsation dampers shall be fully (100 %) radiographed as perASME VIII UW (a) or equivalent.

Minimum design temperature for separators shall be 71OC and minimum designpressure shall be maximum operating pressure plus 15% for inter-stages and plus10% for final stage.

NRV shall be provided on suction, 1st stage, 2nd stage and 3rd stage scrubber drains.

4.9.4 Gas recovery system: Bidder shall provide blow-down tank to act as:

A buffer tank during start-up.

Gas flow dampener during compressor operation

Surge tank for depressurization of each of the compressor stage piston cylindersduring shutdown.

GAIL GAS LIMITED




Page 22 of 103

Blow-down tank size should be to manufacturer’s design standards. The gasrecovery vessel shall be provided with pressure relief valve and necessaryinstrumentation to avoid cold flaring of gas.

Capacity shall be suitable to prevent any venting.

Suction damper and gas recovery vessel shall preferably not to be combined andone pressure regulator with isolation valve shall be provided to connect gas recoveryvessel with compressor suction.

If suction damper and gas recovery vessel are combined, pressure regulator aftergas recovery vessel will not be allowed due to high pressure drop during compressoroperation.

One vent line from gas recovery vessel with double isolation valves shall beprovided.

4.9.5 All separators / KOD's shall be provided with 3 mm corrosion allowance.

4.9.6 Oil from all drains shall be collected into the oil recovery pot. Oil recovery pot shall beprovided with double isolation manual valve, safety relief valve and level gauge.Capacity shall be min 15 water liter.

4.9.7 Coalescent super fine filters (preferably two stages) for removal of liquid e.g. water & oil)and solid particles down to 0.1 microns out of compressed natural gas shall be provided.Residual Oil Contents shall be less than 1 PPM. Manual drains with double isolationvalves with oil collecting pot shall be provided. The filter should be sized to flow min200% of the maximum flow at 255 kg/cm2g. However mechanical design shall be basedon safety set pressure.

4.9.8 Pulsation, Vibration Control and Analog Study

4.9.8.1 Suitable arrangement for inter-stage pulsation damping shall be provided in confirmationto API 618 and API 11P.

4.9.8.2 Bidder shall get the acoustic and mechanical evaluation study carried out for onecompressor package (from inlet flange to discharge on skid edge as per API-618approach-3) by an agency or in house experts. The compressor Bidder shall be totallyresponsible for all the coordination with the agency carrying out the study. Bidder shallsubmit acoustic and mechanical evaluation report to GAILGas/CONSULTANT forreview. If bidder has conducted such study previously, the same may also beconsidered.

4.10 Gas Engine

GAIL GAS LIMITED




Page 23 of 103

4.10.1 The gas engine offered shall be gas fired 4-stroke, spark ignited type. The integral gasengine & compressor type design is not acceptable.

4.10.2 The site rating of engine shall be max of the following two conditions;

a) 110% of greatest BKW required by compressor including cooling fan, other auxiliariesand the losses at any of the compressor operating conditions corresponding to suction prof 14, 17.5 or 19 kg/cm2(g) with suction valve fully opened and discharge pressure 255kg/cm2(g) for desired MR package as per sr. no.1.1.

b) 105% of greatest BKW required by compressor including cooling fan , other auxiliariesand the losses at any of the compressor operating conditions corresponding to suction prof 14, 17.5 or 19 kg/cm2(g) with suction valve fully opened and discharge pressure atrelief valve ( RV) set pressure for desired MR package as per sr. no.1.1.

4.10.3 The site rating of engine shall be worked out considering the derating specified under thelatest edition of British Standard 5514/ISO 3046 and deducting the power absorbed byall the engine driven auxiliaries, as conceived by the Packager. The site rating of engineshall be based on 45.0oC ambient temperature, RH 80% and an altitude of 165 metertaking design case gas composition as specified, the site rating so arrived shall besuitable for the maximum Compressor BkW as arrived at and which can be applied 24Hrs a day seven days a week with a overrating capability of up to 10%. Bidder isrequested to submit site-rating calculation along with de-rating calculation in their bid.Note that the Design Gas specified for the compressor shall be used as engine fuel.

4.10.4 All the auxiliary equipment including the cooling fans shall be engine driven.

4.10.5 The engine shall be provided with the shielded ignition system of breaker less type, low-tension solid state having vapour proof enclosure with a high-tension coil at each powercylinder. The spark plug shall be shielded and all low-tension wiring shall be enclosed ingrounded steel conduits. But the spark plug connecting cables shall be enclosed ingrounded, metal shielded flexible conduits.

4.10.6 Constant speed hydraulic/electronic governor preferably of WOOD WORD makeadjustable for speed setting over the operating range.

4.10.7 The engine silencer shall be residential type mounted on the roof of the engineenclosure.

4.10.8 Bidder shall supply fuel gas conditioning system to condition the fuel gas so as to makeit suitable for use in offered gas engine. The fuel gas-conditioning skid shall mainlyconsist of fuel gas filter, interconnecting piping, fittings, valves, pressure regulator, safetyvalve, mass flow meter and necessary instrumentation etc as required shall beincorporated by the bidder.

GAIL GAS LIMITED




Page 24 of 103

4.10.9 Bidder shall provide suitable provision in the exhaust including catalytic converter orsome other suitable device so that the exhaust gas meets the emission norms of CPCB.

4.11 Enclosure of CNG Compressor Package

4.11.1 The maximum allowed temperature within the enclosure shall be 5°C above ambienttemperature. Adequate ventilation fans shall be provided to meet the above and also toaccount for heat dissipation of the coolers. Interlock shall be provided to start the exhaustfan to vent out any entrapped gases in the enclosure before starting the main compressor.

4.11.2 The compressor package shall consist of single enclosure for Compressor and gasengine. The equipment shall be mounted on one common skid. The Enclosure to restrictmaximum noise level to 75 dB (A) at 1 meter from the enclosure.

4.11.3 Enclosures shall be provide with a degree of protection equivalent to IP 54 as defined inAS 1939, shall be flame proof and provided with ventilation system.

4.11.4 The enclosures shall have doors for normal access and removable wall panels for ease ofmaintenance.

4.11.5 All the pressure, temperature, gas flow meter, oil level, lube oil pressure, coolanttemperature, coolant level indicators shall be visible from outside of enclosures.

4.11.6 Enclosures shall have internal flame proof lighting arrangement.

4.11.7 The Compressor shall be located inside an acoustic enclosure. All Coolers, Knock outDrums, Scrubbers, Cooling System, lubrication system along with interconnecting pipingshall be inside an enclosure. Enough headroom shall be made available for easy accessand maintenance of all equipment. The piping layout with respect to the compressor,intercoolers, KOD and auxiliaries location shall be subject to Purchaser’s approval duringdetailed engineering stage.

Components such as pressure gauges, temperature , pressure switches, filterautomatic ball valves, safety valves etc., which require in-situ adjustment,maintenance and reading, shall be easily accessible..

Conduits and tubing shall be arranged in orderly and systematic manner and shall berouted 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 gasfilters, inlet and outlets gas filters and drive belt shall be located to facilitate easyone-man servicing.

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

GAIL GAS LIMITED




Page 25 of 103

Items which must be operated & monitored during operation shall be readilyaccessible without opening the door.

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

4.12 Piping

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

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

4.12.3 All rigid piping, tubing & other components of compressor package shall be designed forfull range of pressure & temp and loading to which they may be subjected with a factor ofsafety of at least 4 based on minimum specified tensile strength at specified ambienttemperature.

4.12.4 All rigid piping shall be continuous between their respective components & free ofconnections except welded joints. All high pressure joints shall be welded unlessotherwise not feasible. In case welding of gas piping from Ist stage to 2nd stage, 2nd stageto 3rd stage and 3rd stage to coalescent filter is not possible, the material of gas pipelineshall be SS316 as per ASTM A269.

4.12.5 The instrument air tubing material shall be SS316 as per ASTM A269.

4.12.6 All high-pressure double ferrule fitting and 2/3 way valves shall be of S.S. material only.

4.12.7 Bidder shall furnish a temporary start up conical strainer fitted with adequate size mesh.

4.12.8 All lube oil piping down stream of filter shall be series 300 Stainless Steel.

4.12.9 External drain & vent piping shall be Carbon Steel and not less than 1" nominal size.However, all the internal drains shall be SS 300 series material.

4.12.10 Mercaptan / THT dosing is envisaged hence all materials coming in contact with gas shallbe compatible to such gas with Mercaptan / THT dosing and be of compressormanufacture's standard. The use of SA 515 material is prohibited.

4.12.11 All piping after coalescent filter at compressor discharge shall be of SS 316.

4.12.12 The instrument air header upto compressor enclosure and Co2 piping shall be seamlessCS

4.13 Coupling

GAIL GAS LIMITED




Page 26 of 103

4.13.1 V-Belt drive upto 150 KW gas engine rating is acceptable. Direct drive shall be offered bythe Bidder if power requirement is > 150 KW. Gear drive is not acceptable.

5.0 ELECTRICS & INSTRUMENTATION CONTROL:

5.1 Starter/Control Panel/ Control philosophy

5.1.1 Doors shall be interlocked isolator. Panel shall be complete with start and stop pushbuttons, hours run meter, power on and fault indication lamps, fault reset button. Allnecessary timers and intrinsically safe relays to control the system on an automaticstarting and stopping basis shall be provided. The compressor package control systemshall be designed for unattended operation in automatic mode and in case of any fault itwill go in a safe mode.

5.1.2 Compressor Package shall be provided with a PLC based LCP, which shall be mountedon the package enclosure. PLC shall be housed inside flameproof IIA/IIB (Ex’d’)enclosure. Local operator panel shall also be provided on the flameproof enclosure. Allthe interlock, monitoring and controlling of the CNG compressor package shall be donethrough PLC based control system which will be of proven type and make. PLChardware shall be in accordance with IEC-61131-2 and PLC programming shall be madeonly in ladder diagram, however PLC shall be capable to convert programmed in flowchart, functional block diagram, structural text etc in accordance with IEC-61131-3. PLCshall be provided display & scrolling facilities to view process & machine parameters. Allsource & object codes including logic flow chart, ladder diagram etc is to be furnished bythe Packager during detailed engineering. Two nos. of Laptop shall be in the Bidder’sscope. PLC shall be suitable for recording of compressor parameters as indicated ininstrumentation and all other parameters that are recommended by the compressormanufacturer for recording on hourly basis for the last 24 hours. PLC shall be suitablefor interfacing with printer (HP Laser printer) for getting the printout of the parametersrecorded (as mentioned above) for the last 24 hours through remote HMI PC (ifprovided). The units of measurement for flow shall be Kg/hr, for pressure shall beKg/cm2(g) or and for temperature shall be degree C. PLC shall be of modular inconstruction with redundant CPU with EEPROM, redundant interface module, redundantpower supply for CPU and HMI, redundant power supply for load , non redundant I/Os ,communication cards for connecting mass flow meter, communication card card/port forfuture SCADA connectivity. The selected I/O shall have 40 % spare capacity for futureuse. Diagnosis feature shall be available in CPU and I/O used in PLC. Mounting of PLCcomponents such as CPU, HMI, I/Os in one JB and power supply relay barriers/isolators,fuses, MCB, electrical earthling bus bar in other JB... PLC components / system shall betropicalised, adopted with complete wiring and necessary terminals. Wiring to be color-coded with cross printed ferruling in position. Mass to volume calculation is not required;however, bidder shall provide a soft tag for entering standard density upto 2 decimal pointwith the help of external push button in PLC for converting mass flow rate to volume flowrate. PLC shall be configured as a remote terminal unit of supervisory computer and dataacquisition system complete with dial up connectivity. PLC shall be capable of carryingout on line routines for at least ten separate loops without affecting the scan, cycle & up

GAIL GAS LIMITED




Page 27 of 103

dating time etc. The PLC System offered shall be supplied with monitor and shall becapable of:

a) Compressor Control & Emergency Shut downb) Fire and gas detection and monitoringc) Data acquisition, monitoring & logging, viewing, modifying set point and range of all

process parameters for which transmitters are provided.d) Record the last 20 Alarms of abnormal operations on separate page.e) Viewing process diagram with on line data on line.f) Viewing trend of min 10 critical parameters.g) Shall have historical as well as event recording system for atleast last 200 eventsh) PLC shall be capable for display of flow meter data for flow rate and flow tantalizer

(i.e. Gas Suction, Gas Discharge, Gas consumed by the engine), compressorrunning hour etc. in following manner:

1) Shift wise (for 3 shift operation i.e. 06:00-14:00, 14:00-22:00 & 22:00-06:00)- shall beavailable for at least last 96 hours with date stamping

2) Daily basis - shall be available for at least last 31 days with date stamping

5.1.3 The compressor package control system shall be so designed that the first item to go intoalarm condition shall lock out to indicate the cause of the trip though the cause of the tripmay have disappeared. The lock out condition shall be manually reset. A change over setof contacts shall be provided for Owner’s use to give a remote indication of alarm and trip.Where three bank cascade has been envisaged ; in auto mode, compressor shall startautomatically in case high bank storage pressure falls below 220 kg/cm2(g) and stop assoon as pressure in all three banks of stationery cascade and mobile cascade reaches255 kg/cm2(g). Where only one bank cascade has been envisaged; in auto mode,compressor shall start automatically in case storage pressure falls below 220 kg/cm2(g)and stop as soon as pressure in cascade and mobile cascade reaches 255 kg/cm2(g). Inmanual mode the compressor shall also stop at 255 kg/cm2(g) pressure. The priority fillsystem (In Bidder’s scope) shall ensure the filling of vehicle, storage cascade and mobilecascade in correct sequence. Control system shall be designed such that in case of anyfault, 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 inunsafe condition. In case of fault, a warning hooter shall operate, the sound of whichshould be audible at distance of at least 15 meter. Further the fault alarm and emergencystop PB shall be duplicated in the CNG station control room. Acknowledgement/resettingof fault shall be possible only from compressor panel. There shall be red and greenindication at top of enclosure to indicate code no of alarm/trip in red color. List of alarmwith code no shall be indicated on SS plate and to be fixed at compressor enclosure.Acknowledgement/resetting of fault shall be possible only from compressor panel.Emergency stop PBs shall be mushroom head turn lockable type. Once the fault isacknowledged or compressor is under normal maintenance, the valves of priority panelshall take the position so that gas available in the stationary CNG storage cascade can bedispensed.

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

GAIL GAS LIMITED




Page 28 of 103

- Pressures in each bank of stationary storage cascades.- Pressure at outlet for dispenser.- Pressure at outlet for mobile cascades.- Control Air Pressure- Indicators, Alarms and Trips as per Equipment Data Sheets

5.2 The priority fill systems: the priority panel shall ensure the filing of vehicle, storagecascades & LCV in correct sequence. The priority fill system shall ensure 200-kg/cm2gpressure in CNG dispenser outlet port. Design of priority fill system shall be aimed toachieve maximum flow rate through combined flow from compressor and cascadearrangement. All priorities shall be with full bore ball valves having high CV. Bidder shallindicate flow rate achievable through proposed priority fill system design. All tubing andvalves shall be ¾” size for 1200 SM3/h compressor. One isolation valve at outlet of eachline shall be provided. After isolation valve tube dia for bus dispenser and bus cascadesshall be 1” OD. Sheeting work of priority panel shall be SS construction.

The priority fill panel shall be designed to deliver the CNG and priorities shall be asfollows:

5.2.1 TYPE –1 FOR MOTHER STATION: 9 LINE :

A: When compressor is running

1 Priority no one: Car dispenser Low bank2 Priority no two: Car dispenser Medium bank3 Priority no three: Car dispenser High bank4 Priority no four: Bus dispenser (Single bank filling)5 Priority no five: High bank of storage cascade6 Priority no six: Medium bank of storage cascade7 Priority no seven: Low bank of storage cascade8 Priority no eight Bus cascade (Single bank filling)9 Priority no Nine Mobile cascades mounted on Light commercial vehicle

(single bank filling).B: When compressor is not running:

When the compressor is not running, the valves of priority panel shall take the positionso that gas available in the stationary car cascade and bus cascade can be dispensed.The priority of dispensing from car cascade shall be as follows;

Priority no One: Low bank of storage cascadePriority no Two: Medium bank of storage cascadePriority no Three: High bank of storage cascade

5.2.2 TYPE –2 FOR ON LINE STATION: 8 LINE :

GAIL GAS LIMITED




Page 29 of 103


1 Priority no one: Car dispenser Low bank2 Priority no two: Car dispenser Medium bank3 Priority no three: Car dispenser High bank4 Priority no four: Bus dispenser (Single bank filling)5 Priority no five: High bank of storage cascade6 Priority no six: Medium bank of storage cascade7 Priority no seven: Low bank of storage cascade8 Priority no eight Bus cascade (Single bank filling)

B: When compressor is not running:

When the compressor is not running, the valves of priority panel shall take the positionso that gas available in the stationary car cascade and bus cascade can be dispensed.The priority of dispensing from car cascade shall be as follows;Priority no One: Low bank of storage cascadePriority no Two: Medium bank of storage cascadePriority no Three: High bank of storage cascadePriority no Four: Bus cascade (Single bank filling)



1 Priority no one: Car dispenser Low bank2 Priority no two: Car dispenser Medium bank3 Priority no three: Car dispenser High bank4 Priority no four: High bank of storage cascade5 Priority no five: Medium bank of storage cascade6 Priority no six: Low bank of storage cascade






GAIL GAS LIMITED




Page 30 of 103

(1) Priority no one: Car dispenser Low bank(2) Priority no two: Car dispenser Medium bank(3) Priority no three: Car dispenser High bank(4) Priority no four: Bus dispenser (Single bank filling)(5) Priority no five: High bank of storage cascade(6) Priority no six: Medium bank of storage cascade(7) Priority no seven: Low bank of storage cascade




5.3 Human machine interface (HMI)

HMI shall be provided with touch screen and operating system software (with minimumall the features of operator panel MP277B 10” graphic display of siemens orequivalent), software’s for interlocking, monitoring and control. All operational buttonsshall be on touch screen except the Emergency stop button. Touch screen displaysystem shall be weather proof to IP65. This should be provided in the flame proof panelwith HMI mounted on the door of the panel. The HMI screen shall be back side of thetoughened glass. During running of the compressor the HMI should be assessablethrough the external push button provided on the panel. The PLC shall be interfaced withSCADA in future. All the parameters on the PLC shall be available on the HMI. Biddershall provide Application program for PLC, HMI on LCP (licensed one set) along with allinterfacing adaptors and cables. Bidder shall also provide one set of source & objectcodes for PLC, HMI on LCP (in both forms, hard & soft).

5.4 Emergency Shut Down

Bidder shall provide emergency shut down (ESD) system in the control room as well aslocally mounted near the Compressor. Fail-safe system shall be designed andincorporated to isolate cascade storage from dispenser, stop compressor, and isolatethe compressor suction and discharge lines. ESD switch shall have to be manually resetto restart the compressor package again. ESD shall activate either on pressingemergency push button ( red button ) or on fire detection. Red ESD button ( 5 nos )shallbe located near dispenser, control room, control panel and at two sides of compressor.Separate ESD push button shall be provided in LCP other than the packagedemergency push button. This push button shall be directly wired with fuel shut off valve

GAIL GAS LIMITED




Page 31 of 103

and engine ignition grounding system by passing PLC /engine governing system. Onpressing the button it shall immediately cut off the fuel supply and ground the ignitionsystem for immediate stop of the machine. A spare contact from the emergency pushbutton shall be connected in PLC to initiate other auxiliaries shut down and indicatealarm as “hard ware emergency push button press”.

5.5 Electric and control panel :

5.5.1 The electrical panel shall be flameproof construction and located on the compressorpackage. The electrical power supply distributions panels, switchgear panels and starterpanels shall have flame proof construction. There shall be FLP push button panelavailable at the compressor skid suitable for hazardous area classification. Theswitchgear shall have one incomer and adequate number of outgoing feeders. Theincomers shall be provided with suitably rated fuse switch unit (AC – 23), ammeter,voltmeter with selector switch, energy meter, PF meter, Phase reversal relay, Earth faultrelay, indication lamps etc. Adequate number of MCB feeders for control and lightingshall be provided. Bidder shall furnish single line diagram of the panel with the bid.

5.5.2 Push button for fault accept, fault reset, ESD, comp start, comp stop, scroll up, scrolldown, enter, increment, decrement, back, hooter test, 4 nos spares shall be provided.Switch for main over ride, auto manual selection, Co2 cylinder main /Co2 cylinderstandby, 415 VAC supply on/off ,230 VAC supply on/off, tube light on/off, enclosure doorby pass and 2 nos spares shall be provided. Lamp for 415 VAC, 230 VAC on, 24 VDCPLC supply on , ready to start , running & trip and 5 nos spares shall be provided

5.5.3 Electrical Power supply for electrical control panel:

All electrical equipments shall be suitable for the following supply conditions.

Power supply for electrical control panel: Electrical operating voltage: AC, 3phases, 415 + 10%V, 50 + 5%Hz.. Bidder to note that all control electronic / electricsshall be capable of with standing voltage fluctuation specified.

Power supply for PLC based Control Panel : Electrical control voltage: 230 5 %V, 50 1 % Hz. Control supply through UPS shall be provided by the purchaser

5.5.4 All auxiliaries and , power contactors in electrical panel etc. shall have operating voltageof 230 volt AC

5.6 Electric Motor for Air compressors

a) Type of drive totally enclosed fan ventilated (TEFV) high efficiency as per IEEMAstandard-19-2000

b) Protection By bidderc) Insulation Class “F” with Class “B” temperature rise

GAIL GAS LIMITED




Page 32 of 103

d) Mounting Horizontal foot mountinge) Specification Standard By Bidderf) Supply Voltage (assumed) 415 + 10% volt, 3 phases, 50 + 5%Hzg) Synchronous Speed By Bidderh) Motor rating By Bidderi) Motor efficiency % By Bidderj) Power factor By Bidderk) Speed of motors By Bidderl) Coupling type By Bidder

5.6.1 Motor accessories

a) Compressor grooved flywheelb) Motor grooved drive pulleyc) Drive vee beltsd) Flexible coupling for direct drivee) Drive guardf) Adjustable motor slide rails for vee belt tensioningg) Starter

5.6.2 The motor name plate rating (exclusive of service factor) shall be minimum 115% of thegreatest HP required under any of the specification operating conditions. All motors shallbe tested in accordance with IS/IEC.

5.6.3 Pre-lubricated sealed bearings for all motors may be considered provided a fullguarantee is given for 4 to 5 years of trouble – free service without necessity of re-lubrication.

5.7 CABLING (all suitable for hazardous area applications)

5.7.1 Control Cable inside the compressor package shall be of 1.5 Sq. mm and for outsidecompressor package shall be 2.5mm.

5.7.2 Cables shall be 1100-volt grade, stranded copper conductor, PVC insulated, PVCsheathed, round wire armoured, FRLS cables.

5.7.3 Cables shall be terminated using double compression type metallic frame proof glandsand copper lugs.

5.7.4 Spare cores to be kept in each control cable.

5.7.5 All JB’s shall have flame proof metallic enclosure.

5.7.6 All the signal cables shall be screened armoured cables.

5.7.7 All the control and power cables shall be armoured cables.

5.7.8 All the communication cables shall be screened and shall be terminated to JB throughthreaded GI conduits only.

GAIL GAS LIMITED




Page 33 of 103

5.8 Electrical cables:5.8.1 Following cables shall be supplied and laid by purchaser for flame proof control panel:

a) From PDB to compressor control panel

b) From compressor to hooter and upto ESD push button in control room.

c) From compressor to ESD push button near dispenser.

d) Form PDB to air compressor.

5.8.2 Following cables shall be supplied, laid and terminated by bidder:a) Power and signal communication cables from compressor to trailer panel, if trailer is

indicated in SOR (distance 20 m approx).

b) Cables inside the compressor package

5.8.3 Termination of cables in compressor control panel including cable lugs and doublecompression cable glands etc. is in bidder’s scope.

5.8.4 Bidder shall furnish following electrical data along with bid:

S NO. DESCRIPTION TO BE FILLEDBY BIDDER REMARKS

1 CABLES FORPROCUREMENT ANDERECTION BY CLIENT

3.5X---- SQMMAYFY

Note:If bidder revises the cables sizebeing procured by client, it shallbe supplied, erected andterminated by him free of cost.

a) From PDB to compressorcontrol panel (three phase)b) From UPS ACDB tocompressor control panel(single phase)

3.5X---- SQMMYFY

c) From compressor to hooterand upto ESD push button incontrol room.

3.5X---- SQMMAYFY

d) From compressor to ESDpush button near dispenser.

3.5X---- SQMMAYFY

e) From PDB to airCompressor.

3.5X---- SQMMAYFY

2 FEEDER RATING IN PDBPANEL

for providing feeder in PDB byclient

b)FOR AUXILIARY LOAD(lights inside enclosure,exhaust fan etc.) ---- AMPc)FOR AIR COMPRESSOR ---- AMP

3 UPS LOAD ----- KW

GAIL GAS LIMITED




Page 34 of 103

4 NON UPS LOAD ----- KW

5.9 INSTRUMENTATION

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

5.9.2 All package mounted transmitters & temperature element shall be intrinsic safe "ib" as perIEC 79-11 and solenoid valves, switches and related junction boxes shall be flame proof“D" as per IEC 79-1. Other special equipment's/instruments, where intrinsic safety is notfeasible or available, shall be flame proof as per IEC 79-1.

5.9.3 The compressor package instrumentation & control is to be configured for manual as wellfully automatic control system including starting, shutdown as applicable for unattendedoperation. Control system shall be PLC based of a reputed make and proven type.

5.9.4 Electrical instrumentation shall be certified by a recognized authority such as BASEEFA,PTB, LCIE, CESI, INIEX, CMRS or any agency approved by Indian Government.

5.9.5 All the instrumentation shall be capable of operating for full range of operation.

5.9.6 Separate junction boxes shall be provided for each type of signal i.e., analog, digital,solenoids, RTD thermocouple and power supply.

5.9.7 RTD shall be 3 wire PT-100 and duplex type, thermocouple shall be K type and solenoidvalve shall be 24 V DC operated.

5.9.8 Power cable, analog signal cable, digital signal cable shall be separately laid and properlytagged.

5.9.9 All pressure gauges and pressure transmitters shall be provided with isolation valves andhave accuracy of + or - 1% of FSD and. + or - 0.25% of FSD respectively.

5.9.10 Pressure transmitters shall be fixed range type with 2 wire 4 to 20 mA transmitter of piezoresistive suitable for CNG applications except at suction and discharge which is 2 wiresmart type 4 to 20 mA transmitter with integral display and IP 67 certified & ex-proof.

5.9.11 The temperature gauge shall be generally mercury in steel filled type, weatherproof & withcapillary extension. Capillary tubing shall be min Carbon Steel with CS flexible armoring.The gauge shall have accuracy of + or - 1% FSD. The range shall be 1.5 times ofoperating temperature.

5.9.12 Units of measurement shall be:

GAS FLOW: SM3/hr & kg/hr

PRESSURE: kg/cm2 (g)

GAIL GAS LIMITED




Page 35 of 103

TEMPERATURE: 0C

5.9.13 Two nos. Of RS 485/RS232 Serial Communication Ports shall be provided for Hooking Upthe PLC to SCADA & Laptop PC at PLC end in Future. Necessary adopter if required shallbe under scope of vendor. Also, Vendor shall include one set of all licensed relevantSoftware (Windows XP/ Windows 2000 based system configuration software andapplication program) for accessing the PLC, HMI and mass flow meter through ownersupplied Laptop PC or laptop supplied by the bidder. All the parameters available on thePLC through SCADA system are required. The detail requirement of SCADA will becommunicated to successful vendor during detailed engineering. For selection ofequipment, compatibility of SCADA system vendor shall consider the Modbus RTUprotocol, FCC-68 RJ 45 connection type RS 232 communication standard, Baud rateupto 19.2 K with configurable software.

5.9.14 Following points to be noted regarding Mass Flow meter – Coriolis type.

Each Mass Flow meter shall include a sensor with integral transmitter i.e. meterelectronics certified intrinsically safe/explosion proof by statutory authority suitable forthe required hazardous area as per IS-2148 /IEC-79. Also the offered sensor and thetransmitter shall be weather proof to IP 65 as per IS-2147/IEC-529. Statutory authorityfor local installation is CCOE.

Offered mass flow meter shall be necessary for Custody Transfer application but notexceeding 0.5% of span.

Calibration for the offered mass flow meter from the authority of country of origin andshould be valid at the time of supply. If the validity expired then the same shall becalibrated from FCRI. The display shall be in Kg/hr for cumulative flow and M3/hr forvolumetric flow.

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

Offered Mass flow meter shall be completely free from corrosion of measuring tubedue to alternating stresses continuously occurring in the tube. Also measuring tubeshall be completely free from erosion, which may result due to fluid velocity.

The design of meter electronics shall be in compliance with the electromagneticcompatibility requirements as per IEC-801.

Meter Electronics shall include all the associated pre-amplifiers converters line riser etcand shall have enough diagnostic facility to correct live zero, variation, meter factor etc

GAIL GAS LIMITED




Page 36 of 103

with help of Laptop. Output of the mass flow meter RS 485 type/ RS 232 to PLC shallbe utilized. Mass flow meter shall be powered by 24 V DC only.

Installation details like straight run requirements, recommendation for horizontal/vertical installation, minimum distance between upstream and downstream pipebends from Mass flow meter to be provided.

Vendor shall calibrate each Mass Flow meter from the statutory authority of country oforigin or any recognized test house (for India from FCRI) with the fluid for which it is tobe used. In case it is not possible to calibrate the Mass Flow meter with actual fluid.Vendor 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).

The calibration certificate should be valid for at the time of supply. The validity ofcalibration will be considered one year from the date of calibration. If the same isexpired then the recalibration has to be done from FCRI as per the latest NABL/ISstandards with the fluid.

Vendor shall submit the following test certificates and test reports for purchaser’sreview:-

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

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 metercertificate from statutory body for offered sensor and transmitter for required areaclassification.

5.9.15 CERTIFICATION:

The requirement of statutory approvals for usage of equipment/instruments/system inelectrically hazardous areas shall be as follows:

a) The vendor shall be responsible for obtaining all statutory approvals, as applicablefor all instruments and control systems.

b) Equipments/instruments/systems located in electrically hazardous areas shall becertified for use by statutory authorities for their use in the area of their installation. Ingeneral, the following verification shall be provided by the vendor.

GAIL GAS LIMITED




Page 37 of 103

Bidder shall provide certificates (from BASEEFA FM, UL, PTB, LCIE etc.) fromcountry of origin for all intrinsically safe/flameproof protected by other methodsequipment/instrument/systems, which are manufactured outside India. If required,bidder shall provide necessary certification/approvals/authentication, for all suchintrinsically safe/flameproof equipment/instrument/systems, by the Indian authority–Chief Controller of Explosive (CCOE), Nagpur, India.

For all flame proof equipment manufactured within India, the testing shall be carriedout by any of the approved testing houses- Central Mining Research Institute(CMRI)/ERTL etc. The item shall in addition bear the valid certification from CCOEand also the manufacturer shall hold a valid Bureau of Indian Standards (BIS)license.

For all intrinsically safe equipment manufactured within India the testing shall becarried out by any of the approved testing houses – Central Mining ResearchInstitute (CMRI)/ERTL etc. The item shall in addition bear the valid certification fromCCOE.

5.10 Earthing of equipment:

5.10.1 Bidders shall make provisions for earthing of the complete package as required as per IS(Earth pits are not in Bidder’s scope). All electrics shall comply with latest IS/IEC. Epoxybased paints shall be applied on all electrical equipments. Bidder’s scope shall includeobtaining statutory approvals for the complete package, wherever necessary.

5.10.2 Metallic part of all equipment not intended to be alive shall be connected to earth as perprovisions of IS: 3043/IEC recommendation. Grounding of all electronics shall beseparately connected to earth using insulated copper wire. Grounding of electronicequipment shall not be connected to earthing for electrics or equi-potential bonding

6.0 INSPECTION AND TESTING

6.1 General

a) Inspection and Test Requirements have been spelled out in respective EquipmentData Sheets and this Technical Specification.

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

c) Owner/consultant shall witness tests as per data sheet and this specification. TheBidder shall notify the timing of such inspection and testing at least 15 days in advanceto PURCHASER/CONSULTANT. PURCHASER/ CONSULTANT shall depute theirrepresentative for witnessing the tests.

GAIL GAS LIMITED




Page 38 of 103

d) Bidder shall submit detailed Test Procedure for Approval of the Purchaser two monthsin advance of the actual date of conducting each test.

e) Cost towards third party inspection including fees payable and arranging the sameshall be borne by bidder. Approved 3rd party inspection agencies are EIL, BVQ, DNV,MECON and Lloyd’s reg. Over and above, Owner/Consultant will carry out Inspectionand testing as per QAP.

.

6.2 Mechanical running test (MRT)

6.2.1 The MRT for the each compressors shall be carried out by bidder with job or shop driverincluding complete job driving system i.e., job driven V-belt, job pulleys etc., for 4 hourscontinuously at shop of compressor manufacturer. The compressor need not be pressureloaded for MRT test. 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

Sound level

Subsequent to satisfactory run the compressor shall be examined as per standardprocedure & following shall be examined as minimum:

Strip test is limited to open Crank Case cover, X-Hd guide & Dist.pc. Cover and openingof bore & other parts, piston, one valve per cylinder. Visual examination of position rod

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

6.3 Mechanical String Test

Mechanical String Test for 4 hrs shall be performed at packager’s shop before dispatchin presence of Purchaser/Consultant. This test can be clubbed up with the MechanicalRun Test of compressor as specified above, provided the job driver, lube Oil system isused for the test. Air/N2 can be used for string test purpose if natural gas is not availablein the shop. All parameters including discharge pressure shall be demonstrated. Stringtest at unload condition is not acceptable.

6.3.1 Compressor capacity during string test for MR item no. 1.1

The string test for the compressors shall be performed at suction pressure 14, 17.5 and19.0 kg/cm2 for 4 hrs continuously and the capacity shall be recorded. In case the

GAIL GAS LIMITED




Page 39 of 103

capacity is found to be not meeting the requirement, the compressor shall not beaccepted.

6.3.2 Methodology /Calculation and Charts for the Suction pr with varied temp and varied Gascomposition and accordingly the Discharge Pressure and resulted SCMH must beattached along with the tender for calculation purpose

6.4 Package Performance Test (PT)

Bidder shall assemble the complete package including auxiliary systems,instrumentation, safety devices within the enclosure at his shop and dispatch. Durationof PG test shall be min 4 hours continuously. Complete package shall be performancetested as a module along with gas engine & compressor as per Performa given inAnnexure-I. Bidder shall demonstrate all controls, shutdown, trips & alarms etc.Pressure and temperature of gas shall be considered at purchaser’s boundarylimit and bidder shall install necessary pressure and temp measuring devices. Allinstrument duly calibrated, tools & tackles, any modification required for conducting PTshall be in the scope of bidder.

6.4.1 The PT shall be conducted only after 30 days’ running of the machine after successfulcommissioning or after 30 days from the date of commercial operation, but not later than90 days from the date of commercial operation of the machine. The delay inconducting PT beyond 90 days shall be liable for PRS unless such delays aresolely attributable to the owner (i.e, due to inadequate load, ie, non-availability ofCNG vehicles for conducting PT).

6.4.2 The test shall be the basis of assigning penalties on the Bidder. The test shall beconducted as per format attached as annexure-I. The PT shall be witnessed byPURCHASERL/CONSULTANT.

6.4.2 Bidder to note that prime mover speed correction shall not be allowed below guaranteedspeed. Temperature and pressure will be considered at purchaser’s boundarylimit.

7.0 PRICE LOADING AND COMPENSATION FOR UNDER PERFORMANCE

a) This section describes the guaranteed parameter, which the CNG compressor packagemust fulfill and the penalty for shortfall in guaranteed parameters.

b) The guaranteed parameter shall be adjusted to account for variation in gas compositionand prevailing ambient condition during testing.

c) Necessary calculations shall have to be furnished by Bidder, which shall be final and nodeviation shall be permitted afterwards.

GAIL GAS LIMITED




Page 40 of 103

d) In case of any inconsistency in manufacture and/or operation of supplied compressorpackage, Bidder shall at his own risk and cost, eliminate the defects to the satisfaction ofOwner.

Bidder shall furnish guaranteed values as per cl. 14 of this specification.

7.1 Compressor Capacity

i) For MR item no.1

Bidder shall guarantee 1200 SCMH capacity of compressor with given gas composition,at suction pressure of 17.5 kg/cm

2(g) and at suction temperature of 30

0C, discharge

pressure of 255 kg/cm2(g) with no negative tolerance for errors in instruments and

measurements.Since the compressor suction pressure varies from 14 kg/cm

2g to 19 kg/cm

2g, the

compressor shall be suitable to operate at full range of pressures..

In both the above cases the driver shall be selected corresponding to max capacity.Mechanically the compressor shall be suitable to operate from min to max suctionpressure without throttle and suction valve full open condition. Bidder should note thatthe suction pressure and temperature shall be measured at vendor’s boundarylimit and not at compressor cylinder.

Bidder shall guarantee compressor capacity in SCMH as per MR item no. for designcase gas composition, suction pressure and suction temperature as specified againstguaranteed condition with discharge pressure of 255 kg/cmP

2Pg with no negative tolerance

for errors in instruments and measurements. Mechanically the compressor shall besuitable to operate from min to max suction pressure without throttle and suction valvefull open condition.

7.2 Loading & Compensation Criteria

7.2.1 Price loading for fuel consumption of gas engine driven compressor

Bidder shall indicate the specific fuel consumption kg/hr/BHP and the total fuelconsumption (above defined compressor capacity) in SCMH as guaranteed value in theoffer. The guaranteed value of fuel consumption of gas engine in SCMH shall bebetween 44 and 49 SCMH corresponding to flow of 1200 SCMH for the given gas.Bidder shall not be given any credit/advantage for quoting fuel consumption below thelower limit. But in case the fuel consumption quoted by the bidder exceeds theupper limit, the bid will be rejected. Therefore bidders are requested to indicatethe fuel consumption very carefully.

Fuel consumption of all the techno-commercially qualified Bidders shall becompared with respect to the lowest SCMH quoted by any Bidder within the range

GAIL GAS LIMITED




Page 41 of 103

44 to 49 SCMH. Even if any bidder quotes less than 44 SCMH as fuel consumptionby engine for running the package, 44 SCMH will be considered as fuelconsumption by packager for price loading purpose. All other bidders shall beloaded as per differential cost evaluated as per following formula over and abovethe total evaluated price.

Differential operating cost (in Rs) = Top x (FQ – FL) x Cf X Df

Where:

Top = Operating Time in hours = 6570 Hrs

FQ = Guaranteed fuel consumption in SCMH quoted by a bidder under evaluation.

FL = Lowest Guaranteed fuel consumption SCMH (amongst the techno-commerciallyaccepted bidders)

Cf =Cost of fuel as Rs 40/- per SCM

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

The financial loading on account of fuel consumption shall not exceed 5 % of basiccompressor supply cost on FOT basis.

For loading calculations purpose fuel consumption as indicated in the original bid shallbe taken. If any bidder fails to indicate the fuel consumption, highest fuel consumptionfigure from the techno-commercially accepted bidders shall be considered for evaluationpurpose and the same shall be considered for demonstration by the supplier at site.

7.2.2 Compensation for fuel consumption of gas engine in excess of guaranteedvalue.

During compressor package performance test, in case the compressors package fails tomeet the guaranteed values, the compensation (calculated as per formula given underhere) shall be claimable by the owner and the same shall be recovered by the ownerfrom any payment due to the bidder. In case such claims are not fully recovered, thenbidder will pay the balance amount to the owner.

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

PY (in Rs) = 2 x Top (FT- FQ) X CF X DF

Where,

PY = Differential Cost

GAIL GAS LIMITED




Page 42 of 103

Top= Operating Time in hours = 6570 Hrs

FT = Fuel consumption as arrived from PT in SCMH

FQ = Guaranteed fuel consumption in SCMH as quoted by the bidder during bidding.

CF = Rs. 40/- per 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 onaccount of fuel consumption shall not exceed 10 % of basic compressor supply cost onFOT basis.

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

Bidder shall indicate the Guarantee parameter in his offer as per Annexure–II of thisspecification.

Fuel consumption shall be adjusted for actual gas at site for density and C.V.

7.3 Compensation (Penalty) against Package Loss.

Bidders are to ensure that the package loss (excluding Engine consumption)should not exceed 0.5% of the capacity of the machine. In case the above lossexceeds 0.5% of the capacity of the machine (established in PT), the purchaser shallbe compensated @ Rs 65/- per kg for 3 years for the gas leakage. The amount will bededucted from O&M monthly running bill.

7.4 Compensation (Penalty) due to non performance of compressor

Over and above the penalty due to fuel consumption, If during PG test, the compressorcapacity is found to be less than tender requirement (as per 7.1 above), penalty for thereduction in capacity shall be imposed on the Bidder on pro-rata basis based onthe FOT cost of compressor (supply cost only) without any upper limit. FurtherMethodology for capacity and fuel consumption (with sample calculation), if suction anddischarge pressure and suction and discharge temperature and gas composition aredifferent then as indicated in the tender, shall be submitted.

8.0 PAINTING AND PROTECTION

8.1 SURFACE PREPARATION

GAIL GAS LIMITED




Page 43 of 103

(a) Rust, rust scale and foreign matter shall be removed fully to ensure that a clean anddry surface is obtained. The minimum acceptable standard for blast cleaning shall beSa 2-1/2 or equivalent as per Swedish Standard SIS-055900-1967 or equivalent.

(b) Blast cleaning shall not be performed where dust can contaminate surfacesundergoing such cleaning or during humid weather conditions having humidityexceeding 85%.

(c) The first coat of primer must be applied by brush on dry surface. This should be doneimmediately after cleaning.

(d) Surface shall be inspected by Purchaser/ third party before application of primer.

8.2 PAINTING (PRIMER & FINISH COAT)

Following primer and finish coats to be applied on the canopy and all structural parts asa minimum:-

a) Primer Two component epoxy zinc phosphate primer with minimumvolume solids of 59%, an initial cure of 75 minutes at 25 deg. Cand a weight of around 2.52 kg/litre.

No. of Coats: 1

DFT 75 (micron) µ each

b) Primer Two component intermediate coat with epoxy high build MIO(micaceous iron oxide) of minimum volume solids of 80%, aninitial cure of 60 minutes at 25 deg. C and a weight of around2.1 kg/ litre.

No. of Coats 1

DFT 100 micron

c) Finish Coat :Acrylic Polyurethane paint

No. of Coats: 2

DFT 50 (micron) each coat

Total DFT 100 µ

Total DFT after application of primer and paint shall be 275 µ (micron) minimum.

GAIL GAS LIMITED




Page 44 of 103

8.3 The vendor to ensure that exterior steel surface of equipment and piping painted shallhave a fade free life without oxidation of paint surface for atleast 5 years in anenvironment of bright sunlight with an intense UV content.

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

8.5 Packing shall be sufficiently robust to withstand rough handling during ocean shipment &in-land journey. Sling points shall be clearly indicated on crates.

9.0 ERECTION, TESTING AND COMMISSIONING AT SITE

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

9.2 Bidder shall be liable to pay all local taxes, levies applicable and comply with rules, lawsprevailing in concerned state.

10 FIELD TRIAL RUN

Bidder shall conduct a field trial run of each compressor package for minimum 72 hourscumulative or 6 hours continuous duration near the guaranteed points in whichsatisfactory operation of complete package together with all accessories/auxiliariescontrols shall be established for specified operating conditions prior to the start of oneyear operation and maintenance period as defined in the contract. During the field trialrun the bidder will be allowed a maximum of THREE attempts to complete the above-specified test. The Equipment shall be considered commissioned after the successfulcompletion of Field Trial Run.

11 SPARE PARTS, SPECIAL TOOLS AND TACKLES

11.1 All spare parts as required, special tools & tackles with toolbox for erection andcommissioning and one year operation and maintenance of compressor package shall besupplied by the packager and shall form his scope of supply.

11.2 A brand new separate set of min 15 nos special tools and tackles ( such as tool forextraction of fly wheel, key to hold crank shaft for loosing & tightening mech seal/bush ,special key to install and uninstall bush for mech seal, piston nut wrench, valve installationtool, rod nut wrench, valve adjusting wrench, engine timing light, engine barring tool ,spark plug removal tool, etc ) as required for Normal maintenance beyond the contractualoperation & maintenance period shall be supplied by the packager, which shall form theproperty of PURCHASER. Special tools & tackles used by bidder in during O&M periodshall not be considered as new. Supply shall be before one month of completion of O&Mperiod

12 DATA AND DRAWING

GAIL GAS LIMITED




Page 45 of 103

a. Drawings and Data shall be furnished in conformity with the Bidder Data RequirementsForms attached with Enquiry Specifications.

b. Bidder shall furnish all the information at the time of bidding as specified in therelevant Bidder Data Requirement (VDR) forms

c. The data requirement after placement of Telex of intent is indicated in the Bidder Datarequirement Forms for the respective equipment, including the number of weeks withinwhich this data is to be provided. Bidder shall confirm that all data as required shall befurnished by him and shall indicate the Bidder’s promised data in the columnsprovided.

d. After the placement of TOI, a conference (kick off meeting) will be held at such dateand at such place, as may be mutually agreed upon between the Bidder and thePurchaser. The intent of this conference shall be to discuss / clarify variousrequirements and finalize the modus operandi for execution of the contract within thescheduled delivery period.

e. Bidder shall furnish the Drawings/Documents for Purchaser’s Review / approval as perthe Bidder Data Requirement (as specified in the Specifications/ Bidder datarequirement forms). The review comments for major and critical drawings (such assystem P&ID’s, operation philosophy , General Arrangement Drawings, FoundationDrawings, Performance characteristics, Pulsation and Vibration Study Reports,Tensional Analyses etc.) shall be discussed across the table at such date and place asmay be mutually agreed between the Purchaser and the Bidder.

DRAWINGS AND DATA REQUIRED FROM BIDDER(All drawings & Documents shall be in English Language only and shall be

submitted in three sets)

DESCRIPTION Requiredwith bid

Certified Information Required afterPurchaser order

Printsfor

review

For records&

Information

Time fromFOI in weeks

(To beindicated by

vendor)(1) (2) (4) (5) (6)A GENERALA.1 Schedule for furnishing the vendor

data

GAIL GAS LIMITED




Page 46 of 103



Printsfor

review

For records&

Information


(To beindicated by

vendor)(1) (2) (4) (5) (6)A.2 A specific statement that CNG

compressor package is in strictaccordance with data sheet ,technical specification & applicablestandards, In case of any deviation,specific list with details & reasons foreach deviation.

Yes Yes

A.3 General arrangement (GA) indicatingbattery limit for electric and pipingconnection & schematic diagram.

Yes Yes

A.4 A statement on oil consumption andminimum allowable oil temp.

Yes Yes

A.5 Flange details of piping connectionwith connection at battery limit.

Yes

A.6 Duly filled in experience recordprogram

Yes Yes

A.7 Tentative load data for foundationdesign.

Yes Yes

A.8 List of sub-vendors with address /phone/ fax no. For all bought outitems including electrical &instrumentation items.

Yes

A.9 Leaflet, catalogues for all items. Yes YesA.10 O & M manual YesB CompressorB.1 Data Sheet duly filled in. Yes YesB.2 Catalogue of compressor Yes YesB.3 Typical cross sectional drg. and

literature to fully describe the detailsof offering.

Yes Yes

- Compressor Yes Yes- Suction Yes Yes- Discharge valve Yes Yes- Piston rod gland packing

& piston rings.Yes Yes

- Lube oil pump Yes Yes

GAIL GAS LIMITED




Page 47 of 103



Printsfor

review

For records&

Information


(To beindicated by

vendor)(1) (2) (4) (5) (6)B.4 V-belt & pulley with selection chart &

calculationYes

B.5 Cooler data / drg with thermal &mech. design calculation

Yes Yes

B.6 Design calculation, GA drgs forpulsation dampner.

Yes Yes

B.7 Gas hydraulic oil, lube oil piping &instrument diagram

Yes Yes

B.8 Torque angle diagram, piston rodload VS crank angle.

Yes Yes

B.9 Torque speed characteristic. Startingtorque of engine and compressor tobe superimposed over each other.

Yes Yes

B.10 Acoustic / mechanical evaluationreport

Yes

B.11 Itemized price list of spares Yes YesB.11 Itemized list with price of spares for

erection / commissioning.Yes Yes

B.12 Item list of spares for one yearwarrantee period

Yes Yes

B.13 Drg. For testing arrangement & testprocedure to be adopted.

Yes Yes

B.14 Quality Assurance Plan (QAP) andQuality Procedure

Yes

B.15 Certificate for following Yesa) Hydraulic testing Yesb) Non destructive testing Yesc) Material composition &

physical properties.Yes

d) Leak proofness list of frame Yese) Lube pump, frame oil pump,hyd. Oil pump

Yes

B.16 Design / Actual assembly clearancechart

Yes Yes

B.17 Test records of following Yesa) Mechanical running Yesb) Performance test Yes

GAIL GAS LIMITED




Page 48 of 103



Printsfor

review

For records&

Information


(To beindicated by

vendor)(1) (2) (4) (5) (6)

c) Noise level test YesB.18 List of special tools & tackles for

installation & maintenanceYes Yes

B.19 Filled in air cooler data sheet Yes YesC Electric equipment and motors Yes YesC.1 Performance curves of motor Yes YesC.2 Technical literature/catalogue,

selection charts, nomographs etc.for motors

Yes Yes

C.3 Filled in data sheet of motor and Gasengine and UV detection system

Yes Yes

C.4 Control schematics of motors Yes Yes

C.5 Performance curves for auxiliarieslike fan, pump along with motor

Yes Yes

C.6 Typical component cross sectionaldrawing and literature to fullydescribe the details of offering.

Yes Yes

C.7 Test procedure of motor YesC.8 Mill test report of motors YesC.9 Manufacturer's test report of motors YesC.10 Stage inspection and test report YesC.11 Final acceptance testing and

performance tested records.Yes

C.12 Schematic diagram with start up &shut down procedure & logic

Yes

C.13 Inter connection & wiring diagram YesD INSTRUMENTATION AND

ELECTRICSD.1 Drawing & document index YesD.2 Instruments and electric motor data

sheetsYes Yes

D.3 Start up and shut down write up Yes YesD.4 Start up & shut down inlerlock

diagramYes Yes

D.5 Alarm & shut down list with set point Yes YesD.6 Control panel layout Yes

GAIL GAS LIMITED




Page 49 of 103



Printsfor

review

For records&

Information


(To beindicated by

vendor)(1) (2) (4) (5) (6)D.7 Termination diagram, panel writing

detailYes

D.8 Loop schematic YesD.9 Inter connecting diagram YesD.10 Cable schematic YesD.11 Bill of material YesD.12 Inspection & test procedure YesD.13 Test / Inspection certificate YesD.14 List of relief valves with settings YesD.15D-17

P & ID of priority panel. Yes Yes

D-16 Electrical Load summary YesPower required from UPS Supply(230 V AC Single Phase)

Yes

D-18 Power required from Non UPSSupply (415V TPN)

Yes

D-19 Combined Speed-TorqueCharacteristic curve of engine andCompressor starting at rated inletpressure.

Yes

D-20 Methodology of Calculation ofdischarge pressure, SCMH for thevariation in Suction pressure,temp., Gas composition.Yes

Note:

1) The above documents shall be given by bidder after placement of order and approval ofdrawings/ document as explained above.

a) 1 CD – of all documents/drawing in editable form;b) 6 sets of prints;c) one set of transparencyd) One set of CD of software for compressor PLC.

For consultant : 1 CD – of all documents/drawing in editable form; b) 2 sets of prints

GAIL GAS LIMITED




Page 50 of 103

The drawing submitted with bid will not be considered as final. Successful Bidder shallsubmit final drawing as per scope defined in tender for approval.

13.0 OPERATION & MAINTENANCE SERVICES

The date of successful performance test (PT) at site (which shall be conducted within 90days from the date of successful commissioning of the machine) will be considered asdate of start of the annual maintenance contract. However, bidder shall be paid only50% of O&M charge for operation and maintenance of the compressor from the date ofcommercial operation upto the date of performance test as part payment against O&Mtill the capacity and other guaranteed parameters of the package are establishedthrough PT. The balance 50% of O&M charge (from the date of commercial operationupto the date of PG test) shall be released to the bidder subsequent to successful PT(ie, after establishing all the guaranteed parameters as per tender) In case the PT isnot successful or PT is accepted with > 5% penalty, the balance 50% shall beforfeited in addition to provision of cl. 7.2.2 and 7.4 of this Section. The bidder mustfollow the ‘OPERATION & MAINTENANCE REQUIREMENT’ as stated below but notlimited to and ensure to provide trouble free services to the satisfaction of the owner.

13.1 Accommodation/transportation/medical

The bidder shall make his own arrangement for the accommodation of his personnel atrespective locations and subsequent transportation arrangement for them from theirplace of residence to work place or any other place as required and company shall haveno obligation in this respect. The company shall not be responsible for providing anymedical assistance to the bidder personnel.

13.2 Discipline:

The bidder shall be responsible for the discipline and good behavior of all his personneldeployed in the services contracted out and should any complaint be received againstany of his employee, he shall arrange to replace such persons within 24 hours of noticeissued by the Engineer-in-Charge. The decision of the Engineer –in-Charge in thismatter shall be final and binding on the Bidder.

13.3 Gate pass/identity card

The contract shall arrange to supply / renew identity card to his workforce at his owncost, if so required by the Purchaser for security or for any other reasons. ThoseBidder’s personnel shall be required to carry their respective identity cards while on dutyand produce on demand.

13.4 Right to get services carried out through other agencies.

GAIL GAS LIMITED




Page 51 of 103

Nothing contained herein shall restrict Purchaser from accepting similar service fromother agencies, at its discretion and at the risk and cost of the Bidder, if the bidder failsto provide the said services any time.

13.5 Sub-letting of contract

Sub-letting of contract: The bidder may sub let/ assign the installation and O&M services toan agency having experience of CNG compressor installation and O&M for minimum oftwo years. However, complete responsibility including composite bank guarantee shall befurnished by the bidder. Bank guarantee for O&M shall start from the date ofcommercial operation by the purchaser which will be 10% of total cost of O&Mservices.

13.6 Compliance of laws

The bidder deploying 20(twenty) or more workmen as contract labour shall have toobtain license from appropriate licensing authority, if required. The bidder (which shallinclude the Contracting firm / company) shall be solely liable to obtain and to abide by allnecessary licenses from the concerned authorities as provided under the various labourlaws legislation’s including labour license from the competent authority under theContract Labour (“Regulation & Abolition”) Act or similar act applicable to land of law.

The Bidder shall be responsible for necessary contributions towards PF, FamilyPension, ESIC or any other statutory payments to Government Agencies if applicableunder the laws in respect of the contract and personnel deployed by the bidder forrendering services to PURCHASER and shall deposit the required amount with theconcerned statutory authorities on or before due dates.

The bidder shall not engage /deploy any person of less than 18 years under this contractand the persons to be deployed should be physically and mentally fit.

The installations where job is to be carried out are live and have hydrocarbonenvironment. Bidder shall comply with all safety and security rules and regulations andother rules laid down by PURCHASER for its operation. It shall be theduty/responsibility of the bidder to ensure the compliance of fire, safety, security andother operational rules and regulations by his personnel. Disregard to these rules by theBidder’s personnel will lead to the termination of the contract in all respects and shallface penal/legal consequences.

The bidder shall arrange for insurance of all this workers engaged on the job as per therelevant Acts, rules and regulations, etc. In case by virtue of provisions of worker’scompensation Act, or any other law in force. PURCHASER has to pay compensation fora workman employed by the bidder due to any cause whatsoever the amount so paidshall be recovered from the dues payable to the bidder and /or security deposit.

13.7 The officer in charge shall have power to

GAIL GAS LIMITED




Page 52 of 103

i) Issue the bidder from time to time during the running of the contract such furtherinstructions as shall be necessary for the purpose of proper and adequateexecution of the contract and the bidder shall carry out and bound by the same.

ii) During the currency of this contract, PURCHASER can increase and/or decreasethe number of the services / technicians to meet contractual requirements.

iii) Order the bidder to remove or replace any workman whom the companyconsiders incompetent or unsuitable and opinion of the company representativeas to the competence of any workman engaged by the bidder shall be final andbinding on the Bidder.

13.8 Repatriation and termination

PURCHASER shall reserves the right at any time during the currency of the contract, toterminate it by giving 30 days notice to Bidder, and upon expiry of such notice period thebidder shall vacate the site/office occupied by him immediately.

13.9 Indemnity agreement

Bidder shall exclusively be liable for non-compliance of the provision of any act, laws,rules and regulations having bearing over engagement of workers directly or indirectlyfor execution of work and the bidder hereby undertake to indemnify the company againstall actions, suits, proceedings, claims, damages demands, losses, etc. which may ariseunder minimum wages act, payment of wages act, workman compensation act,personnel injury (compensation insurance) act ESI Act, Fatal Accident Act, IndustrialDispute Act, Shops and Establishment Act, Employees Provident Fund Act, FamilyPension and deposit Linked Insurance Scheme or any other act or statutes not hereinspecifically mentioned but having direct or indirect application for the persons engagedunder this contract. (A certificate to this effect shall be submitted by the bidderimmediately on receipt of LOA).

13.10 Compensation for non-fulfillment of obligation under Annual Maintenance Contract(AMC)

During the AMC in warranty period of 1 year, the bidder must ensure that thecompressor is available for a minimum of 18 continuous hours a day and 365 days ayear for performing the required services as defined in the tender document. The timingof 18 hours will be decided by client. If the bidder fails to provide the required servicesfor any day, the bidder shall compensate the owner @ Rs 3000/- per hr. for the defaultperiod. For calculation of default period will be recorded jointly by the bidder and owneron daily basis. However, compensation will be on monthly cumulative basis rounded tonearest hour. During 6 hours bidder can carryout cleaning and preventive maintenance.Bidder in consultation with owner can club these 6 hours for two consecutive days for 2times a month only without any penalty. In case bidder has utilized less down time of the

GAIL GAS LIMITED




Page 53 of 103

compressor package than that allowed, the bidder can carry forward only max unutilized9 hours downtime to immediate next month.

13.11 Bidder’s responsibility

The bidder shall depute his Supervisor for supervision of the services to receiveinstructions from Engineer-in-Charge or his representative.

13.12 Employment liability of Bidder

The bidder shall ensure and will be solely responsible for payment of wages and otherdues latest by 7P

thP of the following month to the personnel deployed by him in the

presence of the Company’s representative.

The bidder shall be directly responsible and indemnify the company against all charges,claims, dues etc. arising out of disputes relating to the dues and employment ofpersonnel deployed by him.

The bidder shall indemnify the company against all losses or damages caused to it onaccount of acts of the personnel deployed by the Bidder. The bidder shall ensure regularand effective supervision of the personnel deployed by him.

The bidder shall be liable for making good all damages/losses arising out of loss or theftof each handled, leakage, pilferage of any office, furniture equipment fitting and fixtureswhat-so-ever as may be caused directly or indirectly by the engaged persons throughhim/work carried out by them.

13.13 General

The operation and maintenance services shall be provided in terms of shift pattern onthe round the clock basis as mentioned in the tender document.

i) The bidder shall deploy adequate number of technicians / supervisors /Engineers / helpers as well as tools & equipment for smooth and properoperation & maintenance of the compressors supplied in terms of the contract. Incase required to meet operational requirements, the bidder shall augment thesame as per direction of Engineer –in-Charge.

ii) The bidder is required to carry out all services as mentioned in the Scope ofServices and Schedule of Rates on all the 365 days including Sunday and allHoliday & around the clock.

iii) The bidder shall allow weekly rest and daily working hours to his workmen as perthe relevant Act/Law/and Rule made there under. However, no work shall be leftincomplete/unattended on any holiday/weekly rest. Technician/operatorsprovided shall have minimum qualification of ITI. Contract in person or hisauthorized representative shall provide the services on daily basis to interact withEngineer-in-charge and deployed workman

GAIL GAS LIMITED




Page 54 of 103

iv) The work force deployed by the bidder for O&M services at CNG installation shallbe of sound relevant technical professional expertise which is otherwise alsoessential from the safety point of view of the personnel of the bidder as well asfor the installation.

v) Bidder has to ensure the safety of man and machine all the times. Damages ofequipment due to negligence will be recovered as per the decision of Engineer-in-Charge, which will be final.

vi) Regarding work completion, the decision of the Engineer-in-Charge will be finaland binding.

vii) The bidder shall make his own arrangements to provide all facilities like boardingand transport etc. to his workmen.

viii) All personnel of the bidder entering on work premises shall be properly andneatly dressed and shall wear uniform, badges while working on premises of thecompany including work sites.

ix) Bidder shall maintain proper record of his working employee’s attendance andpayment made to them.

x) The Bidder’s representative/supervisor shall report daily to the Shift-in-Charge forday to day working.

xi) All the safety rules and regulations prevailing and applicable from time to time atthe installations as directed by PURCHASER will be strictly adhered to by theBidder.

xii) The rates quoted by the Bidder must be inclusive of all the taxes, duties, servicestax, work contract tax and any other levies, Bidder’s share of P.F. and insurancecharges, Bidder’s profit and any other expenditure etc.

xiii) It will be the responsibility of the bidder to pay as per the minimum wages of theappropriate government applicable under the Minimum Wage Act.

xiv) The services shall be provided in terms of shift pattern on the round the clockbasis. The bidder is responsible to provide effective and efficient services in allshifts and assure that there is no disruption in the services for want of anyresources.

xv) The bidder shall establish a central control room to operate 24 hours, seven daysa week where complaint regarding non-performance of the compressors in termsof the contract can be lodged. Further, the bidder shall deploy adequate numberof technicians/ supervisors / engineers at various site offices in consultation withEngineer-in-Charge to provide trouble free operation & maintenance of thecompressors.

xvi) All arrangements for communication from control room to the contract personworking on job under the services shall be the responsibility of the Bidder, vizpagers / walky-talky.

xvii) All the jobs mentioned under scope of services shall be carried out as per soundengineering practices, work procedure documentation, recommendation of themanufacturer and as per the guidelines/direction of engineer-in-charge ofauthorized representative.

GAIL GAS LIMITED




Page 55 of 103

13.14 Operation and Maintenance of compressor packages during one year warrantyperiod.

13.14.1 Scope of supply during one year warranty period:

All spares, consumables, lubricants, lubricating oil, coolant, sealant etc. required forcarrying out the Operation and maintenance of the complete compressor package duringthe warranty period, including periodic, breakdown maintenance for continuous anduninterrupted operation of the compressor packages shall be in scope of the Bidder andshall be kept in stock. If any equipment got fire or broken due to accident the same shallbe replaced or rectified by the bidder. Electricity shall be supplied free of cost to theBidder.

13.14.2 Scope of services:

The Bidder shall have to keep all the spares, consumables, lubricants, coolant, etcrequired for carrying out periodic, breakdown, emergency maintenance etc of thepackage so as to minimize the down time of the compressor. Non-availability ofcompressor package for non-availability of spares shall be liable for compensation.

13.14.3 All tools, tackles and fixtures required for carrying out the above maintenance of thecompressor shall be in scope of the Bidder. The scope will also include handlingequipment like crane, forklift, chain pulley block, etc required during the anymaintenance activity.

13.14.4 Any expert services required from principal company or OEM shall be arranged by thebidder or his agent at his own cost. All arrangements like phone, fax, computer, Internetetc required for correspondences with above personnel shall be arranged by the Bidder.

13.14.5 The periodic maintenance required to be done as per OEM recommendation shall betaken up promptly. The Bidder shall provide the detailed preventative maintenanceschedule along with

a) Estimated down time required for each type of maintenance schedule.b) List of spares and their quantities required for each type of maintenance

schedule per compressor.c) Type and number of man days required for each type of maintenance

schedule per compressor.

The bidder shall plan such maintenance during non-peak hours and in consultationwith the Engineer In Charge (EIC) of PURCHASER. Any maintenance that needs tobe taken up shall be well planned in advance with due approval of the EIC.

13.14.6 The Bidder shall use only OEM’s certified spares during maintenance. In case, theschedule maintenance of the OEM manual recommends checking and replacing parts

GAIL GAS LIMITED




Page 56 of 103

like valve spring, valve plates, piston rings etc. after certain time interval, same shall bereplaced or used further only on approval from the PURCHASER representative.However any untoward consequences for non-replacement of such parts shall be theresponsibility of the Bidder.

13.14.7 All routine and periodic checks / inspections required to be done as per OEMrecommendation shall be done by the Bidder. Instruments required for above inspectionlike venire caliper, micrometer screw gauge, fill gauges, bore gauge etc shall be in scopeof the Bidder and these instruments shall be calibrated every year.

13.14.8 All parts replaced by the Bidder during the above contract period shall be properlypacked and handed over to PURCHASER, on replacement.

13.14.9 The bidder shall submit a copy of the daily / weekly / fortnightly / monthly / bimonthly /quarterly and yearly performance report to the EIC in both soft and hard form. Allstationery including the printed material shall be in scope of the Bidder.

13.14.10 All the maintenance / inspection job carried out by the Bidder shall be recorded and thereport of the same shall be jointly signed by PURCHASER representative.

13.14.11 The EIC will be final authority to take decision with regards to maintenance orreplacement of parts or any disagreement between the Bidder and PURCHASER,during the execution of the contract.

13.14.12 The Bidder shall carryout calibration of gas detectors and flame detectors every sixmonths or earlier as per requirement or instruction of EIC of PURCHASER. Also yearlycalibration of all instruments such as pressure gauges, transmitters, switches, mass flowmeters etc shall be in the scope of the Bidder. In addition to the above all safety reliefvalves shall also be tested and calibrated every year.

13.14.13 Calibration shall be done from government-approved laboratories and shall be carriedout at least 15 days prior to the calibration due date.

13.14.14 The Bidder shall keep 1 set of safety relief valves in spare for the purpose of calibration.

13.14.15 The Bidder shall carry out retesting of pressure vessels periodically as per GasCylinder rules 1981 or Static & Mobile Pressure Vessels Rules.

The periodic maintenance required to be done as per OEM recommendation shall betaken up promptly. The Bidder shall plan such maintenances during non peak hours andin consultancy with the Engineer In Charge (EIC) of PURCHASER. Any maintenance thatneeds to be taken up shall be well planned in advance with due approval of the EIC. Thescope shall include preparation of maintenance schedule for carrying out themaintenance during the contract period.

GAIL GAS LIMITED




Page 57 of 103

13.14.17 In case, the schedule maintenance of the OEM manual recommends checking andreplacing parts like valve spring, valve plates, piston rings etc. after certain timeinterval, same shall replaced in the presence of PURCHASER’s representative. If topoverhauling and major overhauling of the compressor and prime mover is required asper compressor and prime mover manufacturer’s O&M manual recommendation, thesame shall be in bidder’s scope.

13.14.18 Insurance of free issue items upto 15 days beyond commercial operation by purchaseror two months from the date of supply of equipment at site whichever comes earlierwill be in the scope of bidder. The risks that are to be covered under the insuranceshall include, but not be limited to the loss or damage in handling, transit, theft,pilferage, riot, civil commotion, weather conditions, accidents of all kinds, fire, war risketc.

14.0 GUARANTEED PARAMETERS:

14.1 SUCTION Pressure 14KG/CM2 (g); COMPRESSOR CAP by BIDDER

SL NO DESCRIPTION By bidder

1 Compressor capacity in SCMH at suction pr 14kg/cm2(g)disch pr 255 kg/cm2(g) and gas inlet temp 300 C (No -vetolerance):

2 Compressor BKW excluding (engine cooling fan , aftercooler and inter cooler fan, lube oil pump, water pumpetc. if applicable ) at guaranteed condition in Kw (No +vetolerance

3 Auxiliaries load (engine cooling fan , after cooler and intercooler fan, lube oil pump, water pump etc. if applicable )in Kw (No +ve tolerance)

4 Gas engine heat rate in Kcal/ kW hr (No +ve tolerance)5 Site rated BKW of gas engine at operating RPM (No –

ve tolerance)6 Over all transmission efficiency %

7 Kcal required by gas engine to drive compressorpackage per hour sl no {( 2+3)*4/6)}

8 Net CV of gas considered in Kcal/Sm3 :

9 Fuel gas consumed by gas engine in SCMH (basis ofLoading and Penalty) : (No +ve tolerance)

10 Noise level at 1 meter from enclosure (required 75 dBAmax)

GAIL GAS LIMITED




Page 58 of 103

14.2 SUCTION PR 17.5 KG/CM2 (g); COMPRESSOR CAP REQUIRED = 1200SCMH


1 Compressor capacity in SCMH at suction pr17.5kg/cm2(g) disch pr 255 kg/cm2(g) and gas inlet temp300 C (No -ve tolerance):

2 Compressor BKW excluding (engine cooling fan , aftercooler and inter cooler fan, lube oil pump, water pumpetc. if applicable ) at guaranteed condition in Kw (No+ve tolerance

3 Auxiliaries load (engine cooling fan , after cooler andinter cooler fan, lube oil pump, water pump etc. ifapplicable ) in Kw (No +ve tolerance)

4 Gas engine heat rate in Kcal/ kW hr (No +ve tolerance)5 Site rated BKW of gas engine at operating RPM (No –

ve tolerance)6 Over all transmission efficiency %





14.3 SUCTION PR 19 KG/CM2 (g); COMPRESSOR CAP by BIDDER


1 Compressor capacity in SCMH at suction pr 19kg/cm2(g) disch pr 255 kg/cm2(g) and gas inlet temp300 C (No -ve tolerance):

2 Compressor BKW excluding (engine cooling fan , aftercooler and inter cooler fan, lube oil pump, water pumpetc. if applicable ) at guaranteed condition in Kw (No+ve tolerance

3 Auxiliaries load (engine cooling fan , after cooler andinter cooler fan, lube oil pump, water pump etc. ifapplicable ) in Kw (No +ve tolerance)

4 Gas engine heat rate in Kcal/ kW hr (No +ve tolerance)

GAIL GAS LIMITED




Page 59 of 103

5 Site rated BKW of gas engine at operating RPM (No –ve tolerance)

6 Over all transmission efficiency %





Note:1) For evaluation purpose average fuel consumption for Guarantee case shall be calculated

corresponding to 1200 SCMH basis.

2) For penalty purpose average fuel gas consumption for above three cases or availablesuction pressures shall be calculated corresponding to 1200 SCMH.

3) Methodology /Calculation and Charts for the Suction pr with varied temp and varied Gascomposition and accordingly the Discharge Pr and resulted SCMH must be attachedalong with the tender for calculation purpose.

15.0 GAS COMPOSITION: The gas composition at Taj Trapezium Zone (TTZ) and at otherplaces is as shown below:

Component Range mole % Design Case Mole%

Methane 90 92 91.2703Ethane 3.5 4.5 4.29Propane 0.4 0.7 0.59I Butane 0.02 0.03 0.022N Butane 0.01 0.02 0.015I Pentane 0.002 0.007 0.0053N Pentane 0.0001 0.0007 0.0004CO2 2.0 4.0 3.7Nitrogen 0.1 0.2 0.107Total 100 100 100

NOTES:

Total non hydrocarbon content not more than 1.0%.

GAIL GAS LIMITED




Page 60 of 103

Total S including H2S should not be more than 10 PPM by weight. H2S should not be more than 4 PPM by volume. Moisture content should be in the range 112 to 114 Kg/MMSCM. Specific gravity- to be calculated from gas composition Net CV – to be calculated from gas composition Temp of gas shall be 20 to 40 C. for guarantee purpose take 30 C.

16.0 CLIMATE Height above Mean sea level: 165m Max. site temp.: 470C Minimum site temp.: 40C Max. RH: 81% in the month of August. Min. RH : 36% in the month of March.

GAIL GAS LIMITED




Page 61 of 103

17.0 DATA SHEET OF COMPRESSOR

17.1 Data Sheet of Main Compressor:

1 GENERAL: ■ Means required □ Means bidder shall indicate; if not indicated shall bein bidders scope

2 PROJECT: : .3 OWNER: GAIL Gas Limited4 SERVICE: PROCUREMENT OF CNG COMPRESSORS

SITE:NO. REQD :

5 COMPRESSOR CAPACITY : DRIVER: Gas engine6 NOTE: ■ SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER □

INFORMATION REQUIRED FROM VENDOR.7 □ MANUFACTURER: □ MODEL NO.:8 □ PLACE OF MANUFACTURE:9 □ NO. OF STAGES: by Bidder □ CYLINDER ARRANGEMENT:

10 CYLINDER LUBRICATION: □ LUBRICATED □ MINIMUM LUBRICATED□ NON LUBRICATED

11 ■ DRIVER TYPE: Gas Engine12 □ DRIVE: □V – BELTS (ANTI-STATIC TYPE) □ DIRECT

WITH COUPLING13 □ DIRECTION OF ROTATION (FACING DRIVEN END): □ CLOCKWISE □

COUNTER CLOCKWISE14 ■ SITE / INSTALLATION DATA15 SITE

DATA:16 AMBIEN

TTEMP.(P

0PC):

MAX:MIN:

RELATIVEHUMIDITY (%):

17 MAX:

ALTITUDE (M):

18 EARTH QUAKE ZONE V WIND VELOCITY (KM/HR) 160(MAX)

19 INSTALLATION: ■OUTDOOR20 ■ MOUNTED ON A COMMON SKID ALONGWITH DRIVER, ENCLOSED INSIDE A

ACOUSTIC ENCLOSURE21 ■ ELECTRICAL AREA HAZARD:22 CLASS/ZONE: CLASS I ZONE I DIVISION: I GAS GROUP: D, GROUP

IIA, IIB23 APPLICABLE CODES AND STANDARDS24 COMPRESSOR: Preferably PIPING: ASME/ANSI B 31.3

GAIL GAS LIMITED




Page 62 of 103

API 618API 11P2nd ed25 PRESSURE VESSELS:

ASME SEC-VIII, DIV-1.GAS COOLER: Preferable API 661

26 OIL COOLER: TEMA `C’. SOUND: 75 DBA @ 1M FROM ENCLOSURE27 □AUX. ELECT. MOTORS:28 CONTROL PANEL & INSTRUMENTATION REFER: TECHNICAL SPECIFICATION29 UTILITIES DATA30 □ Cooling Water (Not Available)31 □ Type: □ Supply temperature (P

0PC): □ Max

return temperature (P

0PC):

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

33 □ Design pressure (kg/cm A): □ Designtemperature (P

0PC):

34 □ Water Flow Rates (m3/hr)35 □ Electricity36 Auxiliary Motors: V Ph

Hz37 Oil Heaters: V Ph Hz38 Solenoid Valves: A.C/D.C V Ph

Hz39 Instruments: A.C/D.C V Ph

Hz40 Local Panel INDI./Alarm/Ann : A.C/D.C V Ph

Hz41 Local Panel Trip Circuit: A.C/D.C V Ph

Hz42 UPS: KVA, V Ph Hz43 □ Total Utility Consumption44 □ Cooling Water (Make UP) (m P

3P /hr)

45 □ Power (Auxiliaries) (kW)46 □ Power (Heaters) (kW)47 REMARKS:48 Vendor/ Bidder should estimate the requirement for all the Utilities and

indicate the same in tabular form.49 □ CONSTRUCTION / DESIGN FEATURES50 Nomenclature Unit Stage#1 Stage#

2Stage# 3

51 Cylinders52 No of Cylinders -53 Single Acting (SA) /

Double Acting (DA)54 Cylinder Bore / Stroke mm / mm55 Rotational Speed RPM56 Linear Average Piston

SpeedM/sec

57 Piston Displacement MP

3P/ hr

58 Cylinder Liner (Yes /No)

GAIL GAS LIMITED




Page 63 of 103

59 Type of Cylinder Liner: Dry/Wet -

60 Clearance PocketsYes / No

61 Max. Allow. WorkingPressure, Cylinder

kg/cm²a

62 Max./Min Allow.Working Temp.,Cylinder

P

0PC

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

kg/cm²a

64 Safety Valve SetPressure, Cylinder

kg/cm²a

65 G Helium TestPressure, Cylinder

kg/cm²a

66 Hydrostatic TestPressure, Cylinder

kg/cm²a

67 Cylinder JacketCooling Type As reqd.

68 Cooling Media,Cylinder JacketsWater /AIR

69 Max. Allow. WorkingPressure, Cyl. Jacket

kg/cm²a

70 Hydrostatic TestPressure, Cyl. Jacket

kg/cm²a

71 Suction NozzleSize/Rating/Position

72 Discharge NozzleSize/Rating/Position

73 Suction Valve Number74 Average gas Velocity M/sec75 Discharge Valve

Number76 Average gas Velocity M/sec77 Type of Suction valve -78 Type of Discharge

valve -79 Suction Valve

Unloaders Yes / No80 Clearance Pockets

Unloaders Type81 Piston Rod Diameter Mm82 Rod Reversal at

Crosshead Pin (min.)Deg.

83 Piston Rod Run outOperating

84 Max. Allow. Rod LoadComp.

Kg

85 Tension Kg

GAIL GAS LIMITED




Page 64 of 103

86 Rod Load Comp. Kg87 Tension Kg88 Rod Load at R.V Set

Comp.Kg

89 Distance piece /Packing

90 Type of Packing91 Packing Vent

Connected to ##92 Packing Cooling93 Type of Distance

Piece94 Cyl. Side

Compartment Purged95 Frame Side

CompartmentPressurized

96 Distance Piece purgegas Pressure

Mm HB2BO

97 Distance Piece purgegas Flow

Nm P

3P /hr

98 Distance Piece Vent to SafeHeight

SafeHeight

SafeHeight

99 Distance PieceHydrostatic TestPressure

kg/cm²G

100 ## Packaging should be connected to vent header Ref 7.19.4 of API-11101 Frame102 Replaceable

Crosshead Shoes Yes/ No

103 Crosshead GuideIntegral / Separate

104 Maximum FrameRating

KW

105 Speed - Maximum/Minimum

Rpm

106 □ Lubrication Systems107 Type of lube system Piping material108 Carbon Steel109 Main Oil Pump Driven By : Stainless Steel (all piping & valves Trims)110 Standby Oil Pump, Driven By : Auxiliary oil tank111 Hand Operated Prelube/Priming

Pump:Oil Grade :

112 Suction Strainer Lube Oil Consumption113 Pressure Control Valve Main Pump Make : Model :114 Level Sight Glass on the

CrankcaseType : Material :

115 Type of Oil Cooler : Standby Pump Make : Model :

GAIL GAS LIMITED




Page 65 of 103

116 Size of Filter: Type : Material :117 Oil Heater (if required).118 Electric Heater with thermostat

(Kw)119 Thermostatic Valve120 Type of Cylinder Lubrication Lubricator Equipped With :121 Lubricator Type: Manzel or

Equivalent.Level sight glass

122 Single plunger per feed Oil heater electric with thermostat123 Divider blocks type. Electric Heater (Kw) (if required)124 Lubricator Driven By : Auxiliary Oil Tank (if required)125 Compressor Shaft Oil Grade :126 Lube oil Electric Motor KW Oil System Capacity: (min 30 Hrs.)127 All tubing and valves in SS Oil Consumption. Rate128 Double Ball Check valve on each

lubrication point129 □ Cooling System130 □ Static filled coolant system for131 All Stage Cylinders132 Including expansion chamber, Vents, Drains, Level Gauge, Piping, etc.133 All Piping prefabricated□ Material134 □Atmospheric thermosyphon cooling system for135 All Stage Cylinders □136 Including expansion tank, Vents, Drains, Coolers, and Level & Temp. indicators,

Piping, etc.137 All Piping prefabricated. □ Material138 □Forced Cooling Water System139 All Stage Cylinders140 □ Packings □ Oil Coolers □ Gas Coolers141 □ Including drains, Vents, flow & temp. Indicators, regulating & Isolation valves,

complete piping to provide one142 □ Common inlet and one common outlet connections for Purchaser's interface

terminated by a flanged block valve143 □ Block valve.144 □ Each isolatable circuit to be provided with thermal relief valve.145 All Piping prefabricated. □ Material146 □ Self contained, forced circulation, closed circuit Cooling Water System (if reqd.)147 All Stage Cylinders □148 □ Packing□ Oil Coolers □ Gas Coolers149 □ Including drains, Vents, flow & temp. Indicators, Temp. Control Valve, Regulating &

Isolation valves, complete piping150 □ Main circulating pumps with drivers & suction strainers □ Single Coolers151 □ Reservoir (Make Up) □ Heater (if required)152 □ Pumps, Reservoirs, Coolers etc. to be mounted on a common skid as to make a

separate console.153 □ Material of piping:154 □ Type of coolant:155 □ Jacket cooling156 □ Gas Piping System

GAIL GAS LIMITED




Page 66 of 103

157 □ Vendor's Supply Includes:■ Separator

158 ■ Pulsation suppression equipment as per ‘next’ page159 ■ Suction Filter:160 ■ Temporary Strainer on Compressor Suction161 ■ Type of Strainer:162 ■ Relief Valves: on compressor ■ suction ■ Inter-stage □ on

compressor discharge163 ■ Check Valve on Discharge Line (compressor valve design,

and suction line)164 ■Process Gas Coolers Complete With Manual Drain Valve165 ■Separators Complete With Manual/ Automatic Drain

Values166 ■ Process Gas Piping167 ■Supply starts at inlet flange of CNG PACKAGE168 ■Terminates after priority panel with isolation valve169 □ Materials:170 □ By-Pass Line Piping171 □ Between172 □ Gas cooler173 □ Interconnecting Piping Between Packing Vents, PSV Relief terminating to

Vent Recovery System.174 □ Interconnecting piping between distance piece terminating to Vent

Recovery System upto package B/L175 □ Interconnecting piping between Drains terminating as a single point176 □ Interconnecting piping between Instrument Air terminating177 □ Pulsation Suppression Equipment178 Stage #: Stage#1 Stage#2 Stage#3179 Suction180 Puls.

EquipmentRequiredYes/No

YES yes

181 InletPressure

182 Residual Peak to Peak Pulsation % As per API 618 ( APPROACH –3 ),Cl 3.9.2.7

183 InletNozzleSize /Rating/Position

184 Discharge NozzleSize /Rating/Position

GAIL GAS LIMITED




Page 67 of 103

185 DesignPressureKg/cm²a

186 DesignTemperature P

0PC

187 Volume188 Material :

vesselsSA 516 Gr.60 SA 516

Gr.60189 Internals190 Corrosion

Allowance mm

33

191 Hydrostatic testPressurekg/cm²,g

1.3XMAWP

1.3XMAWP

192 Discharge193 Puls.

EquipmentSuppliedYes/No

YES YES

194 Inlet Pressure195 Residual Peak to Peak Pulsation

%As per API 618, Cl 3.9.2.7

196 InletNozzleSize /Rating/Position

197 Discharge NozzleSize /Rating/Position

198 DesignPressureKg/cm²a

199 DesignTemperature P

0PC

200 Volume201 Material :

vesselsSA 516 Gr.60 SA 516

Gr.60202 Internals203 Corrosion

Allowance mm

3 3

GAIL GAS LIMITED




Page 68 of 103

204 Hydrostatic testPressurekg/cm²,g

1.3XMAWP 1.3XMAWP

205 Design Code:. ASME SECT. VIII DIV. 1206 Analog Piping Study / Acoustic Simulation, As per Approach 3, Cl. 3.9.2.6 API618,

4P

thP edition

207 Upstream / downstream Inter-stage208 Performed By: □Vendor □ Any other agency having similar experience209 Piping Mechanical Analysis210 Performed By: □Vendor □ Any other agency having similar experience211 ■ Automatic Drain Valves For Each Stage suction KOD212 □ Capacity Control213 ■ Start / Stop, based on discharge receiver pressure: Fully Automatic214 Unloading for Start up/Shut down :Automatic Through □ Valve Unloader □ Recycle

Valve215 ■ Interlock against loaded start216 ■ Automatic Control based on217 □ Suction Pressure■ Discharge Pressure □ Flow Manual Signal218 □ Type of Actuator □ Actuation fluid to load □ Actuation fluid to unload219 ■On Power / Actuation fluid failure : Compressor to □ Load ■ Unload220 ■ Continuously □ Maximum Hrs.221 □ Continuously □ Maximum Hrs.222 ■ At All other capacity, Compressor should run continuously223 Vendor's scope Should Include :224 ■Pilot Devices (pressure / temperature / Flow devices ,Controllers & Switches)225 □ Intermediate Devices (Solenoid Valves | Pneumatic Relay / Valves)226 ■ Actuators227 □ Recycle valves228 □ Control Logic and System for Complete Capacity Control229 ■ Inter Connecting Tubing, Piping, Cabling & Wiring230 ■ Protection against extended unloaded operation (Trip)231 □ Valve unloaders are required as such Compressor should start / stop at specified

receiver pressures.232 □ Purchaser's Interface233 Type of Interface

(Single Point)Size Rating Face Position/Locatio

n234 Main Gas Piping

Inlet235 Main Gas Piping

Outlet236 Relief Valves

discharge237 Distance Piece Vent238 Packing Vent239 C.W. Inlet240 C.W. Outlet241 NB2B Inlet Supply242 NB2B Vent (Safe

GAIL GAS LIMITED




Page 69 of 103

location)243 Drains244 ■ MATERIALS245 Cylinder Materials246 Stage 1 Stage 2

Stage3Stage

247 Cylinder248 □ Liner249 □ Piston250 Piston Rings PTFE PTFE PTFE

.251 Rider Rings PTFE PTFE PTFE252 Piston Rod253 □ Packings Rings254 □ Valve Seats255 □ Valve Stops256 Valve Rings / Plates257 Valve Springs258 □ Cylinder Head259 Motion Work Materials :260 Material /

ASTM Grades261 Top Cover262 Crankcase263 Crankshaft264 Connecting Rods265 Cross heads266 Cross Head Shoes267 Cross Head Guide268 Main Bearings Type269 Cross Head Pin Bearings

Type270 Connecting Rod Bearings

Type271 Cross Head Pin Type272 Notes : Bidder to indicate the material273 Each package should be provided with two number drain lines, one from Suction

KOD and second drain as common drain line from intermediate and discharge KODrouted to drain vessels through gas recovery vessels

274 □ CONTROLS & INSTRUMENTATION275 ■ AC Power On/Off Switch With Indication Lamp276 ■ Control Power On/Off Switch With Indication Lamp YES277 ■ Selector Switch A/M Station For L/O Pump Motor278 ■ Selector Switch A/M Station For CW Pump Motor279 ■ Emergency Stop Push Button280 ■ Start Push Button For Air Compressor Motor281 ■ Emergency Stop Push Button for Gas Engine282 ■ Lamp Test Push Button

GAIL GAS LIMITED




Page 70 of 103

283 ■ Alarm / Trip Acknowledge / Reset Push Button284 ■ Frame Oil Heater ON (Indicating lamp)285 ■ Lubricator Oil Heater ON (Indicating lamp)286 ■ Interlock Against Loaded Start287 ■ Interlock Against Start Without Prelubrication288 Notes :289 Minimum required indications, alarms & trips are shown herewith. Bidder should

provide any additional instrumentation for safe operation.290 Compressor should start stop at pre determined receiver pressure as specified.

Bidder should include in his291 Scope includes the necessary hardware for the same.292 INSPECTION AND TESTS

293 Material Composition and Physical Properties Certificates Required For:294 ■ Cylinder and Liner ■ Piston295 ■ Crankshaft ■ Connecting Rod296 ■ Pressure Vessels ■ Heat Exchangers297 ■ X-Ray Examination for components: Pressure Vessels (certificates to be

furnished).298 By bidder Witnessed299 ■ Mech. Running Test with shop

Driver (4 Hours min.)■ ■

300 ■ Performance Test at site asperIS 5456/PTC9/BS 726 (*).

■ ■

301 ■ Partial Stripping and internalinspection

■ ■

302 ■ Functional/Continuity Tests -Control Panel.

■ □

303 ■ Field Trial Run ,underVendor's Supervision (Package)

■ ■

304 ■ Valve Leak Test ■ □305 ■ Lube Oil Console Run test ■ □306 ■ Closed Circuit C.W. System

test■ □

307 □ During package performance test308 □Test Certificates Required For:309 ■ Auxiliary Motor & Pumps ■ Safety Relief Valves310 ■ Safety Switches ■ Solenoid Valves311 □ WEIGHTS312 Overall supply (excluding driver and gear box, if any) Kg. approx.313 Maximum erection weight Kg. approx.314 Maximum maintenance weight Kg. approx.315 Gear Box Kg. approx.316 Driver Kg. approx.317 SCOPE OF SUPPLY318 ■ Compressor Assembly complete with frame, cylinders, cross head etc.319 ■ Motion work lubrication system320 ■ Cylinder and packing lubrication system

GAIL GAS LIMITED




Page 71 of 103

321 ■ Cooling system322 ■ Process Gas system323 ■ Local instrumentation323 ■ Local Gauge Board325 ■ Local Control Panel ■ PLC Panel ■ Human Machine Interface located

on skid326 ■ Main driver327 ■ Barring Device: ■ Manual ■ Electric.

Pneumatic328 ■ Flywheel329 ■ V-Belts with Pulley330 ■ Couplings331 ■ Driver Compressor332 ■ Guards for moving parts ■333 ■ Base plate Common for Compressor and Driver334 ■ Fabricated Steel skid Common for compressor, driver and accessories335 ■ Ladders and platforms336 ■ Special Tools - One Set for each package337 ■ Anchor Bolts for Complete Package338 ■ Piping supports and brackets : ■ prefabricated for piping in Vendor's Scope339 ■ Supports For Cylinders & Auxiliaries, Prefabricated & fitted in the Package340 ■ Commissioning Spares, erection and commissioning spares341 ■ Spares as specified in the Job Specification342 ■ Vendor Data as specified343 NOTE : Refer checklist for scope of supply

GAIL GAS LIMITED




Page 72 of 103

17.2 Data sheet- heat exchangers to be submitted for compressor.

1 GENERAL2 PROJECT:3 OWNER :M/S GAIL Gas Limited SITE : Kosi Kalan, Firozabad, Bharatpur, Ludhiana &

Jalandhar4 Service : Intercooler / After cooler for Compressor Package5 No. Reqd.:6 NOTE: ■ SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER □ INFORMATION REQUIRED FROM VENDOR.7 □ Manufacturer : Type : □ Forced Draft □Induced Draft8 □ Bundle Size : m x m x m Bundles/Section □ Number of Units :9 □ Bundles/Unit : In Parallel / Series □ Section Size :

10 □ Surface/Bundle : m² Bare Tube : m² □ Section/Unit :11 □ Surface/Unit : m² Bare Tube : m² □ Plot Area/Unit :12 PERFORMANCE (Of One Unit)13 □ Heat Exchanged : kcal/hr MTD (Corrected) : 0C14 □ Transfer Rate : kcal/hr m² 0C (Finned Surface) (Bare Surface)15 ■ TUBE SIDE16 ■ Fluid Circulated GAS Gravity : Liquid API SG @ 15.4EC17 ■ Total Entering Gas kg/hr Enthalpy / Latent Heat kcal/kg18 □ Operating Temperature In : Out : Fouling Resistance hr m² 0C/kcal19 □ Operating Pressure Passes / Bundle kg/cm²20 AIR SIDE21 ■ Temperature ■ In: Out : ■ Altitude m:115,168.3,172respecctively22 □ Total Flow/Unit kg/hr Static Pressure kg/cm²23 □ Quantity/Fan kg/hr Power/Fan kW24 □ Face Velocity m/sec Power/Unit kW25 CONSTRUCTION (Each Bundle)26 □ Design Pressure : kg/cm²g □ Test Pressure : kg/cm²g □ Design Temperature : 0C27 □ Code Requirements :28 ■ Type of Tubing : ■ Tube Material : ■ Fin Material : Al29 ■ Tube Bare Tubes (no's): □ No. of rows: O.D. □ BWG/Thk □ Length30 □ Fins: Spacing /inch. O.D. □ Root Dia □ Thickness :31 ■ Header Type: Plug / Cover □ No. of Splits: Material :32 □ Plugs/Gaskets ■ Side Frame : C.S. Inside Zinc Protected33 □ Nozzles In : Out :34 □ Couplings □ Vent: □ Drain :35 CONSTRUCTION (Each section)36 ■Structure CS □ Sec. /Gr. No. □ Design Wind Load : kgf/m37 ■ Plenum Chamber CS inside Zinc Protected Type :38 □ Fans No. Dia. RPM Mfr.39 □ Blades Material : No./Fan Pitch Angle(Design) :40 □ Hubs Material: Pitch: Auto variable / Adjustable (No.)41 □ Louvers Material : Type : Mfr.42 □ Weights kg Each Section(Dry) : Full of Water:43 □ Each Bundle (Dry) : Full of Water:44 ■ APPLICABLE SPECIFICATIONS API Standard 66145 ■ REMARKS 1. Air coolers should be designed for 10% excess capacity than required normally.46 ■ Exchanger should be designed with air side temperature of 44 0C.47 ■ Separate data sheet should be filled by the bidder for each service i.e. Inter cooler and After cooler

GAIL GAS LIMITED




Page 73 of 103

18.0 Data Sheet of Gas Engine: to be submitted for compressor.

1 GENERAL2 PROJECT: PROCUREMENT OF CNG COMPRESSORS3 OWNER: M/S GAIL Gas Limited4 SERVICE: DRIVER FOR CNG COMPRESSOR5 NO. REQD.: ONE FOR EACH UNIT.6 NOTE: ■ SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER □ INFORMATION REQUIRED

FROM VENDOR.7 SITE / INSTALLATION DATA8 SITE CONDITIONS:9 LOCATION: ■ OUTDOOR ■ CLOSED ROOM WITH FORCED AIR VENTILATION SYSTEM.10 SITE DATA: AMBIENT

TEMP. (0C):MAX : 45 MIN : 8

11RELATIVE HUMIDITY (%):

MAX : 85 %

12 ALTITUDE (M):13 EARTH QUAKE ZONE V WIND VELOCITY (KM/HR) 160 (MAX)13 ELECTRICAL AREA CLASSIFICATION14 CLASS 1 GROUP D DIVISION I OR 215 CLASS 1 GROUP IIA, IIB ZONE I16 □ UTILITY DATA17 COOLING WATER18 COOLING WATER TEMP. (0C) SUPPLY (DESIGN/MAX/NOR/MIN): RETURN

(MAX):19 COOLING WATER PR. (KG/CM²G) SUPPLY (DESIGN/MAX/NOR/MIN): RETURN

(MIN):20 COOLING WATER CHARACTERISTICS:21 □ INSTRUMENT AIR:22 SUPPLY PRESSURE (DESIGN/MAX/NOR/MIN)(KG/CM2 G):23 □ ELECTRIC POWER24 ELECTRIC SUPPLY: AC / DC VOLTS HZ25 □ APPLICABLE CODES & STANDARDS26 ■ NOISE SPECIFICATION: ■ APPLICABLE TO M/C MAX. 75 DBA @ 1.0 M OUTSIDE THE ACOUSTIC

ENCLOSURE27 ■ EXHAUST GAS EMISSION: - STATUTORY REQUIRMENTS AS PER Respective STATE POLLUTION

CONTROL BOARD28 ■LISTING/APPROVAL OF ENGINE REQUIRED FROM: ■ UL/FM □ TAC29 ■ AIR RECEIVER FOR STARTING AIR SYSTEM ASME SEC-VIII DIV 1 □ AIR COMPRESSOR FOR

STARTING AIR SYSTEM MANUFACTURER'S STD.AIR STARTER WITH SILENCER.30 □SHELL AND TUBE TYPE EXCHANGERS MANUFACTURER'S STD. □ AUXILIARY PUMPS

MANUFACTURER'S STD.31 □ AIR COOLED HEAT EXCHANGERS/RADIATOR MANUFACTURER'S STD. □ OTHER TANKS AND

VESSELS MANUFACTURER'S STD.32 DRIVEN EQUIPMENT33 ■ RECIPROCATING GAS COMPRESSOR34 ■ DUTY: INTERMITTENT35 PROBABLE PERIOD FOR CONTINUOUS RUNNING: 20 HOURS WITH FREQUENT STARTS AND STOPS36 ■DURATION OF MAX. LOAD: 20 HOURS37 □ MINIMUM BKW OF THE DRIVEN EQPT. KW: @ RPM:38 □ RATED BKW OF THE DRIVEN EQPT. KW: @ RPM:39 □ MAXIMUM BKW OF THE DRIVEN EQPT. KW: @ RPM: (@ R.V. SET PRESSURE)40 □ FOR MECH. DRIVE APPLICATIONS: MINIMUM SITE RATING OF THE ENGINE REQUIRED KW @ RPM4142 □ACCOUNTING FOR ENGINE DERATION FOR SITE CONDITIONS & ALTERNATOR EFFICIENCY WITH

ENGINE DRIVING ITS ALL AUXILIARIES.43 □ DIRECTION OF ROTATION OF DRIVEN EQUIPMENT VIEWED FROM COUPLING END :44 □ METHOD OF DRIVE: DIRECT THRU FLEXIBLE COUPLING OR V-BELTS45 CONSTRUCTION FEATURES

GAIL GAS LIMITED




Page 74 of 103

46 □ MANUFACTURER: □ ENGINE MODEL:47 ■TYPE OF ENGINE: FOUR-STROKE ENGINE COOLING : ■ WATER COOLED48 □TURBO-CHARGED WITH CHARGE AIR COOLER □ NORMALLY ASPIRATED49 □ NO. OF CYLINDERS: □ CYLINDER ARRANGEMENT:50 □ BORE/STROKE (MM/MM): □ COMPRESSION RATIO:51 □ SPEED (RPM): □ MEAN PISTON SPEED (M/SEC.):52 □ PERFORMANCE53 RATED ENGINE POWER AT STANDARD OPERATING CONDITIONS AS PER ISO 3046/ BS 5514 (ISO

STD. POWER):KW @ RPM

54 (USING ONLY THE ESSENTIAL DEPENDENT AUXILIARIES AND WITH 10 % OVERLOAD PROVISION55 RATED ENGINE POWER AT SITE CONDITIONS GUARANTEED, NO NEGATIVE TOLERANCE):

KW @ RPM56 (USING THE ESSENTIAL DEPENDENT AUXILIARIES AND WITH 10 % OVERLOAD PROVISION57 MIN. ENGINE SITE POWER AT, WHICH ENGINE CAN BE OPERATED CONTINUOUSLY.

KW @ RPM58 MIN. ENGINE SPEED & CORRESPONDING SITE POWER AT WHICH ENGINE CAN BE OPERATED

CONTINUOUSLY.RPM @ KW

59 STARTING TIME REQUIRED FOR FULL LOAD OPERATION (SECONDS):60 AIR FLOW REQUIRED FOR OPERATION OF THE ENGINE FOR: □ COMBUSTION & SCAVENGING

□ COOLING & VENTILATION OF ENCLOSURE □ AIR COOLERS61 ESSENTIAL DEPENDENT AUXILIARIES ARE:62 ENGINE SHAFT DRIVEN RADIATOR FAN: KW63 ENGINE SHAFT DRIVEN CW PUMP: KW64 ENGINE SHAFT MAIN LO PUM: KW65 □ SPECIFIC FUEL CONSUMPTION:66 DESCRIPTION FUEL CONSUMPTION, GM/KW-HR @ REFERENCE

CONDITIONS *67 ISO 3046* MANUFR'S. STD.* SITE * MANFR'S.

SHOP *68 (A) GUARANTEED

ENGINE RATED POWER(100 %

CONTINUOUS RATING)69 (B) 75 % OF (A)70 (C) 50 % OF (A)71 (D) 110 % OF (A)72 * STANDARD REFERENCE

CONDITIONS:73 TOTAL BAROMETRIC

PRESSURE, P, KG/CM2 A74 ATMOSPHERIC TEMP. 0C75 RELATIVE HUMIDITY %76 CHARGE AIR & COOLANT

TEMP 0C77 □ SPEED GOVERNING SYSTEM78 TYPE: □ SINGLE SPEED □ MULTIPLE SPEED □ ALL SPEED

(VARIABLE SPEED)79 GOVERNOR TYPE: □ ELECTRONIC □ ELECTRO HYDRAULIC □ MECHANICAL80 ■ MAKE: WOODWARD □MODEL:81 GOVERNOR CONTROL MECHANISM: □ MANUAL □ REMOTE82 □ STARTING SYSTEM83 ■ METHOD OF STARTING: AUTOMATIC84 ■ METHOD OF STOPPING: AUTOMATIC85 □ TYPE OF COLD STARTING: (CONSIDERING MIN. AMBIENT TEMP86 ■ TYPE OF STARTING SYSTEM: AIR STARTING THROUGH ENGINE MOUNTED

PNEUMATIC87 REMARKS:

GAIL GAS LIMITED




Page 75 of 103

88 1. BIDDER SHOULD ENGINEER AND SUPPLY THE COMPLETE AIR STARTING MECHANISMINCLUDING AIR COMPRESSOR, AIR RECEIVER.

89 THE PURCHASER SHALL PROVIDE ELECTRICITY FOR AIR COMPRESSOR MOTOR.90 ■STARTING AIR SYSTEM: (TO BE PLACED OUTSIDE THE ENCLOSURES)91 ■ AIR COMPRESSOR TYPE: RECIPROCATING92 □ RATED CAPACITY (AM3 /HR AT INLET CONDITIONS):93 □ DISCHARGE PRESSURE (KG/CM²G):94 □ BKW: □ RPM:95 ■ AIR COMPRESSOR DRIVEN BY: ELECTRIC MOTOR96 □ DRIVER RATING □ KW: □ RPM: ■□ VOLTS/N/HZ.: 230 /

SINGLE/ 5097 ■ AIR RECEIVER WITH PRESSURE GAUGE, RELIEF VALVE & MANUAL DRAIN VALVE:98 ■ START-STOP SWITCH FOR COMPRESSOR: AUTOMATIC99 □ NO. OF AIR RECEIVER: ONE /TWO CAPACITY OF EACH AIR RECEIVER (M3):100101 ■ COOLING SYSTEM102 TYPE: CLOSED CIRCUIT COOLING103 WATER PUMP DRIVEN BY: ENGINE104 COOLANT CIRCUIT PIPING WITH TEMP. CONTROL & MAKE-UP TANK.105 HEAT EXCHANGER WITH ANCHOR/FOUNDATION BOLTS: AIR COOLED EXCHANGER106 BY-PASS VALVE: CHECK VALVE:107 HEAT EXCHANGER TEMP (0C) INLET: OUTLET:108 ■FAN DRIVEN BY: DRIVER □ RATING/SPEED (KW/RPM):109 □ ENGINE WATER TEMP (0C): INLET: OUTLET:110 PACKAGER MAY CLUB THE ENGINE JACKET AND COMPRESSOR CYLINDER COOLING WATER

SYSTEM WITH ENGINE SHAFT OR COMPRESSOR SHAFT DRIVEN PUMP111 ■ FRAME LUBRICATION SYSTEM112 ■ TYPE: FORCE FEED LUBRICATION INCLUDING VALVES, OIL PUMP & PIPING113 □ OIL COOLER TYPE: □ □ AIR COOLED □ WATER

COOLED114 □ OIL FILTERS □ SELF CLEANING □ DUPLEX □ PAPER

CARTRIDGE115 □ PRELUBE OIL PUMP DRIVEN BY (IF REQUIRED):116 □ PRELUBRICATION □ MANUAL □ AUTOMATIC117 □ TYPE/GRADE OF LUB. OIL:118 □ OIL CONSUMPTION (LPH):119 □ OIL SUMP CAPACITY (LITRES):120 □ OIL COOLER TESTING PRESSURE (KG/CM²G):121 □ EXPLOSION RELIEF VALVE FOR CRANKCASE122 ■ AIR INLET SYSTEM123 ■SUCTION AIR FILTER ■AIR INLET DUCTING / PIPING / MANIFOLDS □□

INLET SILENCER124 EXPANSION BELLOWS (IF REQUUIRED) & ALL SUPPORTS / HANGERS125 ■ENGINE EXHAUST SYSTEM126 ■EXHAUST MANIFOLDS / DUCTING / PIPING TERMINATED AT SAFE HEIGHT OUTSIDE

ENGINE ENCLOSURE EXHAUST SILENCER (RESIDENTIAL TYPE)127 ■ EXPANSION BELLOWS ■ EXHAUST STACK / CHIMNEY ■ ALL SUPPORTS / HANGERS ■

PROTECTION INSULATION FOR COMPLETE EXHAUST PIPING128 □ PROVIDED AS ABOVE □YES □NO129 □ CONTROLS & INSTRUMENTATION130 ELECTRIC SUPPLY:131 LAMPS: ± V: AC/DC: N: ± HZ:132 ALARAM CIRCUIT: ± V: AC/DC: N: ± HZ:133 TRIP CIRCUIT: ± V: AC/DC: N: ± HZ:134 CONTROL CIRCUIT: ± V: AC/DC: N: ± HZ:135 SOLENOID VALVES: ± V: AC/DC: N: ± HZ:136 CONTROL SWITCHES:137 ■ AC POWER ON/OFF SWITCH WITH INDICATION LAMP

GAIL GAS LIMITED




Page 76 of 103

138 ■ CONTROL POWER ON/OFF SWITCH WITH INDICATION LAMP139 ■ START SWITCH WITH INDICATION YES140 ■ START/STOP PUSH BUTTON FOR AUX. DRIVE MOTOR141 ■ EMERGENCY STOP PUSH BUTTON142 ■ LAMP TEST PUSH BUTTON143 ■ ALARM/TRIP ACKNOWLEDGE /RESET PUSH BOTTON YES144 ■ LUBRICATING OIL HEATER `ON' INDICATING LAMP (IF PROVIDED)145 ■ INTERLOCK AGAINST START WITHOUT PRELUBRICATION146147 NOTE: VENDOR TO PROVIDE CONTACT/SIGNAL FOR EXECUTION IN DCS.148 □ MATERIAL149 CHARGE AIR COOLER SHELL: TUBES:150 WATER COOLER SHELL: TUBES:151 AIR COOLER SHELL: TUBES:152 AIR RECEIVER153154 INSPECTION AND TESTING155 WITNESS ■ OBSERVE BY SUPPLIER □156 □ STAGE INSPECTION DURING MANUFACTURE157 □ FULL LOAD TEST AT ENGINE MANUFACTURER'S SHOPAS PER ISO (PERFORMANCE

TEST)158 □ FUEL CONSUMPTION & GOVERNING TEST AT ENGINE MANUFACTURER'S SHOP AS PER

ISO159 □ FULL LOAD TEST FOR 4 HRS FOR GAS ENGINE WITH ALL AUXILIARIES & 1 HR @ 110 %

LOAD AT SITE.160 ■ NO LOAD MECHANICAL RUN TEST AT PACKAGER’S / DRIVEN EQUIPMENT MFR. SHOP161 ■ VENDOR'S STANDARD MECHANICAL RUN TEST (FOR ALL ENGINE)162 INSPECTION/TESTING WITNESSED BY: □ OTHERS ■ M/S GAIL Gas OR

THEIR REPRESENTATIVE163 □ WEIGHTS164 NET WEIGHT OF ENGINE WITH MOUNTED ANCILLARIES (KG):165 HEAVIEST PART TO BE HANDLED DURING ERECTION AND ITS WEIGHT (KG):166 HEAVIEST PART TO BE HANDLED DURING NORMAL MAINTENANCE AND ITS WEIGHT (KG):167 RECOMMENDED CRANE CAPACITY (TONS): CRANE HOOK HEIGHT

(M):168 □ MAINTENANCE DATA169 EXPECTED PERIOD OF RUNNING BETWEEN TOP OVERHAULS: HOURS170 EXPECTED PERIOD OF RUNNING BETWEEN MAIN OVERHAULS: HOURS171 THE TYPE AND GRADE OF LUBRICATING OIL RECOMMENDED:172 LUBE OIL CONSUMPTION

(KG/HR)/ (LITRES/HR)173 CHANGE OF LUBRICATING OIL AFTER: HOURS174 ■SCOPE OF SUPPLY / WORK175 ENGINE WITH LUBRICATION SYSTEM, GOVERNING SYSTEM, FUEL SYSTEM, COOLING

SYSTEM AND STARTING SYSTEM AS SPECIFIED176 SUCTION AIR FILTER WITH SUCTIONPIPING177 INSTRUMENTS AND CONTROLS AS SPECIFIED178 INLET AND EXHAUST MANIFOLDS, EXHAUST PIPING WITH FILLINGS, BENDS AND

INSULATION179 EXHAUST SILENCER (RESIDENTIAL, SPARK ARRESTING TYPE) WITH EXPANSION

BELLOWS AND COMPLETE WITH EXHAUST PIPING FROM180 MANIFOLD TO OUTSIDE SHED WITH FITTINGS AND INSULATION.181 FLYWHEEL WITH BARRING DEVICE182 GUARDS FOR MOVING PARTS

GAIL GAS LIMITED




Page 77 of 103

183 COUPLING FOR ENGINE - DRIVEN EQUIPMENT184 BASE PLATE FOR ENGINE & DRIVEN EQUIPMENT185 SPARES AS PER ORDER186 ERECTION AND COMMISSIONING SPARES187 TORTIONAL ANALYSIS REPORT ON ENGINE188 REFER TECHNICAL SPECIFICATION FOR COMPLETE SCOPE OF SUPPLY189 FOUNDATION/ ANCHOR BOLTS190 ANTI VIBRATION PADS191 FIRST FILL OF LUBRICATING OIL AND COOLANT.192 ACCOUSTIC ENCLOSURE WITH FORCED VENTILATION FAN193 REMARKS

GAIL GAS LIMITED




Page 78 of 103

18.1 DATA SHEET OF AIR COMPRESSOR MOTOR:

1 Project name: GAIL Gas Limited2 Driven equipment Air Compressor3 Tag No. / Equipment No.4 Duty5 Manufacturer6 Motor Duty & Type

7 Frame Size/Mounting8 Output _______________________ KW9 Voltage _____________________VOLT 415 V+/ - 10%

10 Full load current_______________AMP11 Starting current with star delta starting

AMP11 Full load speed _______________ RPM12 Enclosure TEFC/FLAMEPROOF/IP55 AS PER IS:4691-198513 Mounting14 Insulation Class F’ – Temp. rise limited to Class – ‘B’15 Ambient temperature ____________°C16 Temp. Rise by resistance __________ °C17 Applicable Code18 Full load torque ______________ Kg-m19 Starting torque ________________FLT20 Efficiency at _____________100% Load

________________________75% Load________________________50% Load

21 Rotation viewed from DE22 Bearing type No.23 Type of Lubrication24 Coupling / pulley DIRECT / FLEXIBLE25 Net weight (approximate) __________kg26 Cable size / type ______ mm sq.27 Phase / connection / No. of terminal28 Frequency _______________ Hz. 50 Hz + / - 5%29 No. of poles ______________30 Locked rotor current___________%FLC31 LR withstand time (HOT) _________Sec

(COLD) Sec32 Startor / rotor time constant _______Min33 Power factor at – 100% Load

- 75% Load- 50% Load

34 Break down or pull out torque ___ %FLTn35 Space heaters _________WATT / VOLT

36 Vibration Level / Noise Level As per IS12065 / IS12075

GAIL GAS LIMITED




Page 79 of 103

19.0 DATA SHEET OF DETECTORS:

19.1 Data Sheet IR-Gas Detection (LEL) System:

1 TECHNICAL GENERAL2 PROJECT:3 OWNER: M/S GAIL Gas Limited SITES: Kosi Kalan, Firozabad, Bharatpur,

Ludhiana & Jalandhar4 EQUIPMENT: GAS DETECTION FOR CNG STATIONS5 NO. GAS DETECTION TYPE:

6 NOTE: ■ SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER □ INFORMATIONREQUIRED FROM VENDOR.

7 □ MANUFACTURER: □ MODEL NO.:SIGNAL TRANSMISSION

8 □ ANALOG: TRANSMISSION BY 3CORE SHEILDED CABLE9 □ MEASUREMENT CONTROL: 4mA to 20Ma10 □ SENSOR DRIFTS BELOW ZERO:11 □ MEASURING RANGE EXCEEDED:12 □ TRANSMITTER FAULT:13 □ MAINTENACE SIGNAL:14 □ HART COMPATIBLE:

■ SITE / ENVIRONMENTAL DATA15 SITE DATA:16 AMBIENT TEMP.

(P

0PC):

MAX:

17RELATIVEHUMIDITY (%):

MIN:18

MAX:ALTITUDE (M):

19 INSTALLATION: ■INDOOR20 ■ ELECTRICAL AREA HAZARD:21 CLASS/ZONE: CLASS I ZONE I DIVISION: I GAS GROUP: D, GROUP IIA, IIB

■ APPLICABLE CODES AND STANDARDS22 ■ GAS DETECTION APPROVALS: CENELEC

:Exd IIC 6■ UL, CSA: Class 1, Div 1, Groups B,C,D

VOLTAGE OF SUPPLY23 □ OPERATING VOLTAGE: A.C/D.C V Ph

24 □ IN-RUSH CURRENT: A.C/D.C25 □ POWER INPUT A.C/D.C

■ PHYSICAL SPECIFICATIONS26 □ ENCLOSURE: Nema 4+7 (IP65)27 □ SIZE28 □ WEIGHT

■ INSPECTION AND TESTS29 □ Physical Tests on site:

REMARKS

GAIL GAS LIMITED




Page 80 of 103

19.2 Data Sheet- UV/IR Fire Detection System:

TECHNICAL GENERAL1 PROJECT:2 OWNER: M/S GAIL Gas Limited SITES: Kosi Kalan, Firozabad, Bharatpur,

Ludhiana & Jalandhar3 EQUIPMENT: UV FIRE DETECTION FOR CNG STATIONS4 NO. FIRE DETECTION TYPE:5 NOTE: ■ SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER □ INFORMATION

REQUIRED FROM VENDOR.6 □ MANUFACTURER: □ MODEL NO.:7 □ WAVE LENGTHS: ■ TYPICAL RESPONSE TIME: < 3 SEC @ 50FT8 □ FIELD OF VIEW: □ MINIMUM SENSOR RESPONSE TIME:9 □ SENSITIVITY □ MAINTENACE SIGNAL:10 ■ CLASSIFICATION: CLASS I, DIV 1,

GROUPS B, C & D: Eexd IIC, T5, IP66■ CLASS II, GROUP E,F & GCLASS III, TYPE 4X

11 ■ APPROVALS: CSA, FM, ATEX, CENELEC12 ■ ENVIRONMENTAL SPECIFICATIONS13 ■ OPERATING TEMPERATURE RANGE: -40 (0C) to 85 (0C)14 ■ STORAGE TEMPERATURE RANGE: -50 (0C) to 85 (0C)15 ■ OPERATING HUMIDITY RANGE: 0% TO 100% RH NON-CON-DENSING16 ■ ALTITUDE (M):17 ■ EARTH QUAKE ZONE V18 ■ INSTALLATION: ■ INDOOR■ ELECTRICAL SPECIFICATION:19 ■ INPUT POWER: 20 – 36 VDC, 24 VDC @

150Ma max.□ COPM FAULT

20 ■ANALOG SIGNAL: 4-20mA (600 Ohms Max.) □ READY SIGNAL21 □ FAULT SIGNAL: 0Ma □ UV SIGNAL:22 □ IR SIGNAL: □ WARN SIGNAL:23 □ ALARM SIGNAL: □ BAUD RATE:24 ■ RELAY CONTACT RATING: 8A, 250VAC, 8A @

24VDC□ RS-485 OUTPUT:

25 ■ RFI/EMI PROTECTION: COMPLIES WITH EN50081-2

□ STATUS INDICATOR:

26 □ FAULT MONITORING:■ MECHANICAL SPECIFICATION:28 ■ HOUSING: ■ LENGTH:29 ■ DIAMETER: ■ MOUNTING:30 ■ CABLE ENTRY: ■ WEIGHT:SCOPE OF SUPPLY31 ■ UV FIRE DETCTION SENSORS COMPLETE:32 ■ DATA SHEET COMPLETED33 REMARKS:

GAIL GAS LIMITED




Page 81 of 103

20.0 Operating Conditions & Experience Record Of Compressor (1200 SCMH)

20.1 Compressor Suction Pressure: 14 kg/cm2(g)

Slno

Units Stage 1 Stage 2 Stage 3

S1 ■ Gas Handled (See Analysis)2 □ Corrosion Due to NONE NONE NONE3 Suction Conditions4 ■ Pressure (@ Vendor's B/L) kg/cm² 145 ■Temp. (+@ Vendor's B/L) 0C 306 Discharge Conditions (Vendor's Battery Limit :7 ■ Pressure (@ Vendor's B/L kg/cm²8 Pressure @ Cylinder Flg. kg/cm²9 Temp., Adiabatic @Cyl. Flange 0C <150 < 150 <15010 Temp.,Actual @Cyl.Flange 0C11 Temp.,After After Cooler 0C12 Cp/Cv Ratio13 Compr. Factor (ZB2B ) or (Z avg )14 Operating Characteristics15 Capacity (wet) SM3 /Hr16 Mfr's Rated Cap. (Design) (No –ve tol.)17 Actual Inlet Flow (wet) SM3 /Hr18 Specific Gravity19 V Belt / Coupling Losses KW20 Volumetric Efficiency %21 Valve Lift Suction / mm / mm22 Valve Lift Area Suction/ Discharge mm2 / mm2

23 Valve Velocity m/sec24 Compressor Speed RPM25 Gas engine sped in RPM26 Compressor Shaft Power ( without

cooling fan )KW

27 Compressor Shaft Power KW @ RVSet Pr.

KW

28 Transmission efficiency %29 Gas engine heat rate Kcal/ Kwh30 Driver Power KW31 Kcal required by gas engine to drive

compressor per hour slno (26*29/28)

KW

32 Kcal required by gas engine perhour to drive fan and otherauxiliaries.

KW

33 Specific gravity of gas

GAIL GAS LIMITED




Page 82 of 103

20.2 Compressor Suction Pressure: 17.5 kg/cm2(g) (Guaranteed Clause)

Slno


1 ■ Gas Handled (See Analysis)2 □ Corrosion Due to NONE NONE NONE.3 Suction Conditions4 ■ Pressure (@ Vendor's B/L) kg/cm² 17.55 ■Temp. (+@ Vendor's B/L) 0C 306 Discharge Conditions (Vendor's Battery Limit :7 ■ Pressure (@ Vendor's B/L Kg/cm²(G)8 Pressure @ Cylinder Flg. Kg/cm²9 Temp., Adiabatic @Cyl. Flange 0C <150 < 150 <15010 Temp.,Actual @Cyl.Flange 0C11 Temp.,After After Cooler 0C12 Cp/Cv Ratio13 Compr. Factor (ZB2B ) or (Z avg )14 Operating Characteristics15 Capacity (wet) SM3 /Hr16 Mfr's Rated Cap. (Design) (No –ve tol.)17 Actual Inlet Flow (wet) SM3 /Hr18 Specific Gravity19 V Belt / Coupling Losses KW20 Volumetric Efficiency %21 Valve Lift Suction / Mm / mm22 Valve Lift Area Suction/ Discharge mm2 / mm2

23 Valve Velocity m/sec24 Compressor Speed RPM25 Gas engine sped in RPM26 Compressor Shaft Power ( without

cooling fan )KW

27 Compressor Shaft Power KW @RV Set Pr.

KW

28 Transmission efficiency %29 Gas engine heat rate Kcal/ Kwh30 Driver Power KW31 Kcal required by gas engine to

drive compressor per hour slno (26*29/28)

KW

32 Kcal required by gas engine perhour to drive fan and otherauxiliaries.

KW


GAIL GAS LIMITED




Page 83 of 103

20.3 Compressor Suction Pressure: 19kg/cm2(g) :

Slno


1 ■ Gas Handled (See Analysis)2 □ Corrosion Due to NONE NONE NONE3 Suction Conditions4 ■ Pressure (@ Vendor's B/L) kg/cm² 195 ■Temp. (+@ Vendor's B/L) 0C 306 Discharge Conditions (Vendor's Battery Limit :7 ■ Pressure (@ Vendor's B/L kg/cm²8 Pressure @ Cylinder Flg. kg/cm²9 Temp., Adiabatic @Cyl. Flange 0C <150 < 150 <15010 Temp.,Actual @Cyl.Flange 0C11 Temp.,After After Cooler 0C12 Cp/Cv Ratio13 Compr. Factor (ZB2B ) or (Z avg )14 Operating Characteristics15 Capacity (wet) SM3 /Hr16 Mfr's Rated Cap. (Design) (No –ve tol.)17 Actual Inlet Flow (wet) SM3/Hr18 Specific Gravity19 V Belt / Coupling Losses KW20 Volumetric Efficiency %21 Valve Lift Suction / mm / mm22 Valve Lift Area Suction/ Discharge mm2 / mm2

23 Valve Velocity m/sec24 Compressor Speed RPM25 Gas engine sped in RPM26 Compressor Shaft Power ( without cooling fan ) KW27 Compressor Shaft Power KW @ RV Set Pr. KW28 Transmission efficiency %29 Gas engine heat rate Kcal/ Kwh30 Driver Power KW31 Kcal required by gas engine to drive

compressor per hour slno ( 26*29/28)KW

32 Kcal required by gas engine per hourto drive fan and other auxiliaries.

KW


GAIL GAS LIMITED




Page 84 of 103

21.0 Experience Record Programme of Gas Engine Driven Compressor21.1 For 1200 SCMH

Sl.No. Description INFORMATION OFOFFERED COMPRESSOR

REQUIREMENT AS PER TENDER

1 a) Status of bidder (Indicate packager or agent of packager)

b) In case bidder is the agent submit the agreement of agentship/dealership with packager.

2 COMPRESSORName of compressor manufacturerPlace of compressor manufacturerCompressor modelAnticipated Life in running hoursCompressor maximum frame BKWCompressor operating RPMCompressor max design RPMComp Manufacturing code preferably API-618Lubricated or non lubricatedNos of stagesMax stage temperature deg cen ( 150)Compressor Operating RPM ( max RPM-1500 )Piston speed ( 4.5 m/s lub, 4m/s non lub)

Compressor maximum vibrations at cylinders and at frame shall notexceed 10 mm /sec. And 5 mm/s respectively unfiltered peak velocityMaterial for all stagesCylinderPiston RingsRider RingsPiston RodValve (Rings / Plates/ spring)

3 PERFORMANCE OF COMPRESSORCASE-L Performance of compressor at 14 kg/cm2(g) suction pr, 255 kg/cm2

(g)discharge pr and 30 deg c suction temperatureCASE-G Performance of compressor at 17.5 kg/cm2(g) suction pr, 255

kg/cm2 (g)discharge pr and 30 deg c suction tempCASE-H Performance of compressor at 19 kg/cm2(g) suction pr, 255

kg/cm2(g) discharge pr and 30 deg c suction temp

a) Capacity Sm3/hCASE-LCASE-GCASE-H

b) BKW required byCASE-L

GAIL GAS LIMITED




Page 85 of 103


compressor includingcompressor's lube oilpump BKW

CASE-G

CASE-H

c) BKW required bycompressor includingcompressor's lube oilpump BKW at RV set pr

CASE-L

CASE-G

CASE-Hd2 ) Power required forall heat exchanger fansincluding radiator fan ofengine in Kw

CASE-L

CASE-G

CASE-He) Ventilation fans for enclosureNo of fansType of fans (induced or forced draft) Power required for allventilation fans in KwCapacity of gas engine (max of b+ max of d2 +e above) *1.1Piston rod and cross head pin loading at any specified operatingcondition including the relief valve set condition shall not exceed80% 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

Gas EngineMake and modelAnticipated Life in running hoursCompression ratioPower ( ISO power) & corresponding Max RPM

Power ( ISO) and corresponding Operating RPM

Site power ( kW) at operating RPM after derationKW of engine with availability of 10 % overload for one hour withina period of 12 hrs operation with no negative tolerance.

5 PACKAGEName of packagerPlace of packagingName of enclosure manufacturer

Place of enclosure manufacturingSound level at 1 m distance from package in db(A) –75dBAMake & model LEL detectorMake & model fire detectorCo2 flooding system ( 2 cylinder each of 100% capacity required)

GAIL GAS LIMITED




Page 86 of 103


Quantity of CO2 in each cylinder in KgVolume of enclosure in m3Min 3 Nos of explosion proof tube lightCoupling Direct/V-beltSeparators between inter stage of compressor

6 Gas inlet trainWNRF, Flanged connection; outside canopyInlet relief valveInlet gas pressure gauge

Non return valveInlet filter of 5 micron sizeInlet twin filterTemporary suction filter after main filterInlet manual isolation valveInlet automatic isolation valve

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

8 Gas delivery systemHigh pr piping with SS 316 tubing, compression fittings , NRV.Coalescent final separatorCoalescent super fine filter for removal of liquid (e.g. water & oil)and solid particles down to 0.1 microns out of compressed naturalgas. Residual Oil Contents shall be less than 1 PPM.

Discharge isolation valve

PLC based Priority panel with SS 316 double ferrule compressionfillings, tubing and full bore valve ball. Indicate Nos of banksMass flow meter: Coriolis principle; interfaced with PLC; headmounted integral local display to indicate flow rate (Kg/hr),cumulative gas compressed (in Kgs) etc.; inbuilt totaliser non-volatile & non-resettable type ; suitable for hazardous areaclassification ;One at compressor dischargeOne at compressor inletOne for engine fuel gasFinal gas outlet connection from priority panel 3/4” ( 1” for bus )pipe OD SS double ferrule compression fittings.

9 ESD system10 Volume bottles/ dampers at each compressor stage of

compressor.11 Drainage system :Manual isolation valve and automatic valves12 Heat exchanger: Code of construction API 661, Coolers stamped

as per API-11P requirements.

GAIL GAS LIMITED




Page 87 of 103


13 Piping between stages shall be continuous with flange and weldedconnection or SS316 L tubing with ferrule fittings.

18 Instrument air tubing shall be SS 31620 Area classification; “Class 1, Group D, Division 1 as per NEC” OR

“Zone 1, Group IIA /IIB as per IS/ IEC”

Instruments.

Engine22 The size of the complete package23 Beam for chain pulley block with Chain pulley block ( indicate cap of

chain pulley block )24 Acoustic and pulsation study25 Separate Acoustic enclosure for engine and compressor or only one

.26 Instrumentation is as per tender.

27 The offered compressors and gas engine and auxiliaries are new.

28 Human-machine interfacing unit (MMI29 String test at shop30 Field trial run at site

31 Electric power requirement (purchaser will give electric power for aircompressor, ventilation fans and compressor controls)List out if any deviation w.r.t. tender.

Other information of existing compressor package :

a) Year of manufacturing / packaging the compressor package

b) Name and address of user with FAX no ,Phone no , E-mailaddress

c) Nos. of hours the compressor have clocked on bid due date. (Enclose certificate from user)d) Documentary evidence that the bidder/ manufacturer or packagerhaving the capability and facilities (i.e. shop, manpower, testingfacility etc.) for manufacturing / packaging compressor packages.e) Whether the bidder having office set up in India equipped withtrained and experienced technical manpower for the operation andmaintenance services. If not submit the agreement of O&Mcompany having experience of gas engine driven compressorpackage

GAIL GAS LIMITED




Page 88 of 103

22.0 LIST OF INSTRUMENTATION & CONTROLS

22.1 List of Instrumentation & Controls for Compressor:

INDICATION

ANNUNCIATION& PRE ALARM

TRIP & A/V ALARMANNUN.

Slno Description

GU

AGE

–LO

CA

L G

UAG

E BO

ARD

IND

ICAT

OR

LO

CA

L PA

NE

L (P

LC)

DIS

PLA

Y

LOW

LO

CAL

PAN

EL

DIS

PLA

Y

HIG

L LO

CAL

PAN

EL D

ISP

LAY

(PLC

)

LOW

–LO

CA

L P

ANEL

-PLC

-D

ISPL

AY

HIG

H L

OC

AL

PAN

EL P

LC-D

ISPL

AY

1 Frame Oil Sump/Reservoir Level ■yes

■ yes,switch

2 Main L/O Pump Disch. Pr (supplyheader).

■yes

■ yes ■ yes ■ yes

3 Oil Flow4 Oil Pressure at Main Bearing5 Supply Header Temp.6 Oil cooler Oil Inlet Temp.7 Stand by Pump Start8 Compressor Main bearing metal

Temp.9 Cylinder & Packing Oil10 Lubricator Oil Level ■

yeslocal

11 Lubricator Oil Flow12 Lubricator Failure ■ yes

13 Aux. Oil

14 Lub. Oil Supply Pr.15 Lub. Oil return

16 Elec. Motor bearing metal temp.17 Coolant System18 Each cylinder CW outlet temp.19 Inter/After/Oil Cooler CW outlet temp.

GAIL GAS LIMITED




Page 89 of 103

20 CW Supply header flow21 Sight Flow CW return each cylinder,

Cooler & Header22 For Closed Circuit Cooling

23 Coolant main pump disch. Pr. ■ yes ■ yes

24 Coolant standby pump disch. Pr.

25 Coolant stand by pump start26 Coolant supply header Pr.27 Coolant supply header temp28 Coolant cooler Outlet Temp. ■

yes29 Coolant reservoir Level ■

yes■ yes ■ yes

30 Cylinder Coolant Outlet temp.31 For Static/Thermo-siphon System32 Cylinder Coolant Outlet temp.33 Diff. Pr. Across packing coolant filter34 Process Gas System35 Temperature before twin filter at

suction■yes

36 Pressure before twin filter at suction * ■yes

■ yes ■ yes ■ yes ■ yes ■ yes

37 2nd stage Outlet Pressure ■yes

■ yes ■ yes

38 Each stage Outlet temp. ■yes


39 After Cooler Gas Outlet temp. ■yes


40 Ist stage dish pressure low / high ■yes


41 Cylinder Packing Vent Pressure42 Final Disch Pressure after coalescent

filter *■yes


43 Blow Down vessel level ■yes

44 Piston Rod Drop Indicator45 Distance piece diff. Purge pressure46 Common process parameters47 Common machine parameters48 Blow Down vessel Pressure ■

yes■ yes ■ yes

49 Vibration Measurement on comp ,heat exchanger fan

■ yesswitch

* Pressure transmitter shall be of smart type with LCD display

GAIL GAS LIMITED




Page 90 of 103

22.2 List of Instrumentation & Controls for Gas Engine:

INDICATION ANNUNCIATION &PRE ALARM

TRIP & A/VALARM ANNUN.

Slno Description

GU

AGE

–LO

CA

L G

UAG

EBO

ARD

IND

ICAT

OR

LO

CA

L PA

NE

L (P

LC)

DIS

PLA

Y

LOW

LO

CAL

PAN

EL

DIS

PLA

Y

HIG

L LO

CAL

PAN

EL D

ISP

LAY

(PLC

)

LOW

–LO

CA

L P

ANEL

-PLC

-D

ISPL

AY

HIG

H L

OC

AL

PAN

EL P

LC-

DIS

PLA

Y

1 RESERVOIR OIL LEVEL ■ yes ■ yes,switch

2 RESERVOIR TEMP. ■ yes ■ yes

3 MAIN L/O PUMP DISCH. PR. ■ yes

4 LUB OIL FILTER DIFF. PR.

5 L/O SUPPLY HEADER TEMP.

6 OIL COOLER OIL OUTLETTEMP.


7 STAND BY PUMP START

8 Differential pressure gauge forfuel and air mixture

■ yes

9 OIL COOLER CW OUTLETTEMP.

10 CW SUPPLY HEADER FLOW

11 SIGHT FLOW CW RETURNEACH COOLER & HEADER

12 Exhaust gas temperature fromengine

■ yes ■ yes

13 WATER LEVEL IN MAKE UPWATER TANK / RADIATOR

■ yes

14 ENGINE JACKET C.W SUPPLYTEMP.

■ yes ■ yes

15 ENGINE JACKET C.W RETURNTEMP. (INLET OF RADIATOR)

16 COOLANT MAIN PUMP DISCH.PR.

■ yes

17 COOLANT SUPPLY HEADER PR. ■ yes

18 COOLANT SUPPLY HEADERTEMP

19 COOLANT COOLER OUTLETTEMP.

■ yes

20 COOLANT RESERVOIR LEVEL ■ yes,

GAIL GAS LIMITED




Page 91 of 103

switch

21 STARTING SYSTEM

22 AIR RECIEVER PRESSURE ■ yes ■ yes

23 INLET AIR SYSTEM

24 INLET AIR FILTERDIFFERENTIAL PRESSURE

■ yes

25 BOOST AIR (TURBO CHARGER)DISCHARGE PRESSURE (IFREQUIRED

26 CHARGE AIR COOLER OUTLETAIR TEMP. (IF REQUIRED)

27 MISCELLANEOUS28 ENGIN E VIBRATIONS ■ yes

switch29 ENGINE/ MAIN motor speed ■ yes ■ yes

30 START STOP BUTTON ■ yes

31 ENGINE OVERSPEED ■ yes

32 ENGINE /MAIN FAILS TO START ■ yes

33 FEUL GAS / ELECTRIC POWERCONSUMPTION INDICATIONAND CUMMULATIVE

■ yes ■ yes

34 TACHO-HOUR METER ■ yes ■ yes

34 Fuel gas pressure after PRV ■ yes ■ yes

GAIL GAS LIMITED




Page 92 of 103

23.0 QUALITY ASSURANCE PLAN AND CONTROL:

The supplier shall perform all test and inspection as per tender and as per this quality assuranceplan.

CUSTOMER’S REF........................ :

REF..........................................….. :

COMPRESSOR MODEL...................:

Sl.No. Description D R TW W

CompressorMaterial TC for : crank shaft, connecting rods,cylinder, liner piston (compliance report/ certificate) Yes Yes - -

Hydro test of cylinder heads Yes Yes - -Hydro test of pressure vessels (at sub-vendorworks) Yes Yes Yes -

Ultrasonic test of – crank shaft, connecting rod,piston rod. (refer note: 1)- (MFR’s compliancereport/ certificate)

Yes Yes - -

End clearance of the cylinders, piston rod run out Yes Yes - -No load mechanical run test as per manufacturersstandard (4 hours test at packager’s end) Yes Yes Yes -

Strip check and internal inspection after "NLMRT"of all compressors –Refer note: 2 at packager’send

Yes Yes - -

EngineManufacturers’ compliance report Yes Yes - -Dimension and Visual Inspection Report as perdrawing Yes Yes - -

Material test certificates for RAW Material(Pressure Parts) Yes Yes - -

Radiography of pressure vessels at applicable Yes Yes - -Hydro test of pressure vessels Yes Yes - -Final painting and cleaning Yes Yes - -Heat Exchangers (at sub-vendor works)WPS / PQR – Welder Qualification Yes Yes - -Material test certificates for RAW material(pressure parts) Yes Yes - -

Dimension and visual inspection report as perdrawing / Data Sheet Yes Yes - -

Radiography of heat exchangers as applicable Yes Yes - -Hydro test of heat exchangers Yes Yes - -Final painting and cleaning Yes Yes - -Control Panel and Soft Starter Yes Yes Yes

GAIL GAS LIMITED




Page 93 of 103

Dimensions / visual as per drawing Yes Yes - YesFunctional test Yes Yes - YesInstrumentationManufacturers test certificates / calibrationcertificates of meas. Instruments for transmitters,gauges, switches & safety valve, filter, SS tubes,chain pulley block, acoustic material, pipe, fittings,flanges, fasteners, valves, etc.

Yes Yes - -

Manufacturers’ test certificates Yes Yes - -PLC/HMI Yes Yes - YesAcoustic EncloserSurface preparation after cleaning & prior to primerpainting, dimensions / visual as per drawing Yes Yes - -

Assembly check as per P&ID for each package Yes Yes - YesMechanical string test with Air/N2 Yes Yes - YesField trial runs at site for each package aftercommissioning. Yes Yes - Yes

Package performance test at site for eachpackage. Yes Yes - Yes

LEGENDS : D = Documents to be submitted by vendor / sub-vendor ; R = Review of documents byclient/consultant; TW = witness by third party; W = Witness by client or consultant.NOTES:1 Crank Shaft, Connecting Rod: UT / MPT shall be conducted either in forging or in finish condition.2 Strip test is limited to open Crank Case cover, X-Hd guide & Dist .pc. Cover and opening of bore &

other parts, Piston, one valve per cylinder.3 If bidder is only packager and not manufacturer of main CNG compressor the standard QAP of

compressor OEM with test report of compressor and motor from manufacturer or as witnessed byTPE appointed by manufacturer shall be accepted

GAIL GAS LIMITED




Page 94 of 103

24.0 MAKES OF BOUGHTOUT ITEMS:

Makes of equipments shall be as follows:

Sl.No.

Item description Makes

1. FLP motors ABB / Compton Greaves / Kirloskar / Siemens /Bharat Bijlee.

2 FLP Switchgear Baliga/ FCG/ FPE / Flexpro.

3 Switches/fuses/contactors L & T/ GEC/ Siemens

4 Push Button L & T/ Vaisno5 MCCB Siemens/ Legrand6 Vibration switch Robertshaw Control/ Murphy7 PLC Rockwell Automation/ GE Fanuc/ Siemens/ Allen

Bradley / L&T

8 IR Gas detectors General Monitors / Crowcon / Honeywell / Sieger /Detronics/ Khrome Schroder / Net safety.

9 UV Flame detectors General Monitors / Crowcon / Honeywell / Sieger/Detronics / Khrome Schroder/ Net safety.

10 Mass Flow meter Micro motion CNG 50

11 Pressure Transmitter Druck/ Wika/ Honeywell/ ABB/ Rosmount

12 Pressure Regulator M/s Pietro Fiorentini S.p.A. (Italy)/ M/s EmersonProcess Management/ M/s RMG-RegelMesstechnik (Germany) / M/s Mokveld Valves BV(Netherlands)/ Tartarini / Fisher / Nirmal (upto300#)

13 Pressure Safety Valve M/s BHEL, OFE & OE Group (New Delhi)/M/s Keystone Valves (India) Pvt. Ltd. Baroda/M/s Sebim Sarasin Valves India (P) Ltd. (NewDelhi/ Halol-Gujarat)/ M/s Tyco Sanmar Ltd. (NewDelhi/ M/s Parcol SPA, Italy/ M/s Nuopignone,Italy/ M/s Sarasin, France/ M/s Tai Milano SPA,Italy/ M/s Fisher Rosemount (Now M/s EmersonProcess) Singapore/ Mercer USA.

GAIL GAS LIMITED




Page 95 of 103

14 Pressure Gauges &Temperatures Gauges.

M/s AN Instruments Pvt. Ltd., New Delhi/ M/sGeneral Instruments Ltd., Mumbai/ M/s WIKA,

15 RTDs : M/s General Instruments Ltd. Mumbai/ M/sNagman Sensors (Pvt.) Ltd./ M/s Pyro Electric,Goa/ Altop

16 SS Tubes for CNGapplication

M/s Sandvik, Sweden/ M/s Tubasax

17 SS Fittings for CNGapplication

M/s Swagelok (USA)/ M/s Parker (USA)/ M/s Hoke(Circore Instruments)/ M/s Hamlet/ M/S SSP/M/SBMT Korea/ HYLOK.

18 Plug Valve for air water M/s Nordstrom Valves Inc. USA/ M/s Serck AudcoValves, UK/ M/s Breda Energia Sesto IndustriaSpa, Italy/ M/s Sumitomo Corporation, New Delhi/M/s Fisher Xomox Sanmar India Ltd., New Delhi/M/s Larsen & Toubro Ltd. (Audco India Limited),Chennai.

19 Solenoid Valve M/s ASCO / M/s Rotex / M/s parker Hanifen20 On off ball/ needle valve

for CNG application.M/s Parker / M/s Swageloc

21 Cables and wires INCAB/ Universal/ ASEAN/CCI/ FORT/ Closter/Finolex/ KEI

22 Barrier/ Isolators/Surgeprotector

MTL / Phoenix / P&F

23 LEL Detectors Detronics/Crowcon24 Master Control Valve for

CO2 CylinderCeodux, LPG

Notes:

1) Successful bidders shall request for prior approval of the make not covered for theabove items within one month from the date of FOI for which complete technicalcredentials of the proposed vendors shall be required to be submitted for evaluation byPurchaser/Consultant. The request will be considered only if no above vendors areresponding.

2) Some Items indicate only Indian Makes. Successful Foreign bidders may take priorapproval of any other make for those items also for which complete technical credentialsof the proposed vendors shall have to be submitted for evaluation byPurchaser/Consultant.

GAIL GAS LIMITED




Page 96 of 103

3) For any other item(s) for which the vendor list is not provided, bidders can supply thoseitem(s) from reputed vendors/ bidders who have earlier supplied same item(s) for theintended services in earlier projects and the item(s) offered is in their regularmanufacturing/ supply range. Further, the bidder shall have to certify that the item(s)has/have been regularly used by them in all the packages for the last two years and theyare working satisfactorily.

4) The bidder is not required to enclose documentary evidences (PO copies, InspectionCertificate etc.) along with their offer, however in case of successful bidder; thesedocuments shall be required to be submitted by them within 30 days from date ofPlacement of Order

GAIL GAS LIMITED




Page 97 of 103

25. CHECKLIST

Scope of Supply for Reciprocating Gas Compressor Package:

Notes :

(i) Bidder shall furnish all equipment, drivers, auxiliary systems, instruments andcontrols and safety devices as per the enquiry document. Anything required over andabove what is specified, for safe and satisfactory operation of the equipmentpackage shall be included by the Bidder in his scope.

(ii) Bidder to write YES/NO against each item. Bidder is required to include completescope, as such 'NO' is not warranted. However, in case for any of the items if ven-dor's reply is 'NO', vendor should give reasons for the same:

(iii) Bidders’ scope of supply shall include but not be limited to the following:

Sr.No.

Description Specifiedby

Purchaser(Yes/No)

Included byBidder

(Yes/No)

Remarks

1 Each Reciprocating Compressorpackage complete with :

1.11.2 Suction / discharge pulsation dampers Yes1.3 Process equipment such as separator

complete with supports, manual drainwith isolation valves, and automaticdrain system for separators

Yes

1.4 Air cooled, lube oil, cooling water,inter-stage and discharge gas coolerswith necessary air coolingarrangement

Yes

1.5 Combined or separate closed circuitcooling water system for compressor(As required)

Yes

1.6 Lubricating oil system for compressor.

Yes

1.7 Safety relief valves on each stage ofthe compressor

Yes

1.8 All interconnecting oil, gas, water, airpiping within the compressor package

Yes

1.9 All valves, tubing, fittings as specifiedand required within the compressorpackage

Yes

GAIL GAS LIMITED




Page 98 of 103

1.1O Fuel supply hardware complete withSS piping, control valves, Regulators,Flow-meter, filter, vent/drain within thepackage suitable for the specified fuelgas

Yes

1.13 Common skid for compressor andother auxiliary systems

Yes

1.14 Acoustic enclosures for compressorfor noise attenuation up to 70 dBA @1 m distance fitted with fire detectionand extinguishing system as specified

Yes

1.15 Instrumentation and control systemcomplete with PLC based controlpanel configured as RTU ofsupervisory computer and dataacquisition, instrumentation asspecified.

Yes

1.16 Cabling with cable trays for all theelectrical devices within the package.

Yes

1.17 Mass flow meter with integral display Yes

1.18 Inlet Pressure Regulators(Compressor Suction)

No

1.19 Priority Panel (as specified) atPackage Discharge

Yes

1.2O Compressor gas twin inlet Y-typetemporary strainer, permanent inletfilter.

Yes

1.21 Y-type strainers, valves, sight flowindicators, check valves, auto/manualdrain traps as required for variouscompressor auxiliary systems, i.e.frame lubrication system, cylinderlubrication, cooling water systems etc.

Yes

1.22 Manual package isolating valves andauto inlet isolation valve

Yes

1.23 All couplings and guards Yes1.24 Flywheels, barring device Yes

2 Spares and Tools / Tackles2.1 Mandatory Spares if specified in the

TS ” (Indicate separate price for eachitem)

No

2.2 Erection and commissioning sparesas recommended by Bidderincluding lube oil consumables etc. as

Yes

GAIL GAS LIMITED




Page 99 of 103

required for erection & commissioningof each compressor package.

2.3 Special tools and tackles required fornormal operation & maintenance ofeach equipment of compressorpackage as required andrecommended by the Bidder

Yes

3 Inspection and Testing3.1 As specified on the datasheets and

tech. Spec.Yes

4 Vendor data and drawings4.1 All data & drawings as required per

VDR formatYes

5 Erection, commissioning and trialruns at site of the completepackage

Yes

6 Miscellaneous6.1 Foundation and anchor bolts Yes6.3 Acoustical and mechanical analysis

report & pulsation study (apporoach-3)

Yes

6.4 Additional items not specified byPurchaser but recommended byBidder for safe smooth and normaloperation. (Bidder shall indicateseparate list of such items in hisproposal)

Yes

6.5 Optional price quoted for completecompressor package with Non-flameproof electric panel in lieu of flameproof electric panel.

Yes

6.6 Data sheet of compressor, gas enginemotor, LEL and UV Detection systemduly filled.

Yes

6.7 Combined Speed-TorqueCharacteristic curve of gas engineand Compressor at rated inletpressure.

Yes

6.8 Electrical Load summary Yes

6.9 Catalogues of electric motor, flameproof equipments and Instrumentation

Yes

6.10 Power required from UPS Supply (230V AC Single Phase

Yes

GAIL GAS LIMITED




Page 100 of 103

6.11 Power required from Non UPS Supply(415V TPN)

Yes

7 Operation maintenance contractincluding all operating spares,consumables, man power etc duringwarrantee period.

Yes

GAIL GAS LIMITED




Page 101 of 103

FORMAT OF DEVIATION TO THE TECHNICAL SPECIFICATION:

All deviations sought by the vendor shall be furnished in this format. If some deviations//observations/comments are furnished by the vendor at some other places of the offer, the sameshall not be considered as deviation. Purchaser may accept some deviation in the interest ofproject. However, 1.5 times the cost of deviation shall be loaded in the offered cost for evaluationpurpose.

SNo.

Clauseno.

TenderSpecification

Deviation taken Reasons for deviations / remarks

Certified that, only the above-mentioned deviations have been taken against this tender.

Name of the Bidder

Signature

Seal of the Company.

GAIL GAS LIMITED




Page 102 of 103

SECTION – IIIDRAWINGS

GAIL GAS LIMITED




Page 103 of 103

Date post:	10-Mar-2018
Category:	Documents
Upload:	lynguyet
View:	245 times
Download:	3 times