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GAIL GAS LTD (A wholly owned subsidiary of GAIL (India) Limited)

CNG AND CITY GAS DISTRIBUTION PROJECT

BID DOCUMENT FOR

CNG COMPRESSOR PACKAGE VOLUME – II OF II (TECHNICAL)

(BID DOCUMENT NO: 110290/WGI/GAIL GAS/02-R0)

INTERNATIONAL COMPETITIVE BIDDING

ISSUED BY

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1

GAIL GAS LIMITED CITY GAS DISTRIBUTION

CLIENT JOB NO. - TECHANICAL SPECIFICATION FOR GAS ENGINE

DRIVEN CNG COMPRESSOR PACKAGES TOTAL SHEETS 58

DOCUMENT NO 11 0290 02 011 02 001

A 01.07.09 ISSUED FOR DRAFT TENDER MT PKS HM

REV DATE DESCRIPTION PREP CHKD APPD

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TECHANICAL SPECIFICATION

FOR GAS ENGINE DRIVEN CNG COMPRESSOR PACKAGES

SHEET 2 OF 58

CONTENTS

SR. NO

TOPIC

Page no

1 General

4

2 Utilities & Battery Limits 9

3 Basic Design 9

4 Control Philosophy

15

5 Instrumentation

16

6 Earthing / Cabling

19

7 Inspection & Testing

18

8 Performance Guarantees, Loading & Penalty

20

9 Painting & Protection

23

10 Erection, Testing & Commissioning

23

11 Field Trial Test

23

12 Spare Parts, Special Tools & Tackles

23

13 Maintenance Philosophy

24

14 Warranty Servicing and Spare Parts

24

15 Data & Drawing

25

16 ANNEXURES

26

Annexure-A (Normal Natural Gas Composition Range) 27

Annexure-B (Specified Natural Gas Composition for Performance Test) 28

Annexure-C (Delivery Location & Schedule for Packaged Compressor) 29

Annexure-D (Delivery Location & Schedule for Mandatory Spares) 30

1. . Annexure-I (Guaranteed Parameters)

33

2. Annexure-II (Approved Vendor List)

34 Annexure-III ( List of Third Party Inspection Agencies) 39

3. Annexure-IV(Bidder Data Requirement)

41

Annexure-V (M.R. Compliance Schedule)

47

4. Annexure-VI (Experience Record Performa for CNG

49

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SHEET 3 OF 58

Compressor Package)

5.

Annexure-VII ( Parameters Required for SCADA) 54

Annexure-VIII Catalytic converter technical specifications

57

Annexure-IX Technical Specification for UPS System 18

Annexure-X Technical Specification for Battery 05

DATA SHEETS

Data sheet- Compressor

16 pages

Data sheet- Gas Engine

10 pages

Data sheet – Heat Exchanger

3 pages

Data sheet – Data Sheet for UPS

7 pages

Data sheet – Data sheet for Battery Banks

4 pages

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1.0 GENERAL

GAIL Gas Limited (GGL), a subsidiary of GAIL India Limited is in the process of supplying Compressed

Natural Gas to cities like Sonipat, Meerut, Dewas & Kota. Several CNG stations are envisaged in these

cities. These CNG stations shall be equipped with CNG Compressors, Dispensers & few other facilities

for fuelling cars, autos, buses etc.

1.1 SCOPE

This specification along with applicable codes as referred, describe the minimum requirements for

Design, engineering, manufacturing, inspection, testing, packaging, delivery at site, erection &

commissioning including Field Performance Test at site along with two year operation & maintenance of

"GAS ENGINE DRIVEN RECIPROCATING CNG COMPRESSOR PACKAGES" as required for

dispensing CNG to vehicles at various locations in Cities like Dewas, Meerut, Kota & Sonepat. The

packages ordered on one packager shall be identical in all technical aspects. Various parts of this

specification shall be read in conjunction with each other and in case where the different parts of this

specification differ, the more stringent requirement shall govern.

Any additional work/equipment or technical requirement not mentioned in the specification but required

to make the offered system complete in accordance with the specification or required for safe operation,

shall be deemed to be included in the offer and provided by the bidder, without any additional payment.

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

S.NO. Description Quantity

01 Gas engine driven 1200 SCMH Packaged Reciprocating Compressor Unit.

8 nos.

02 Gas engine driven 1200 SCMH Packaged Reciprocating Compressor Unit along with LCV trailor panel complete with mass flow meter

8 nos.

1.1.3 Material Delivery Requirements

Packaged Compressor units alongwith mandatory spares shall be delivered by the Supplier at nominated delivery point, fixed by the Owner / Owner Representative as per Annexure “C” The Supplier shall be responsible for all handling and transportation between his production plant and the nominated delivery point in accordance with this specification

1.2 CODES & STANDARDS

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

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

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

API-11P (Second edition), API 618

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

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

IS: 5571, IS: 5572, IS: 5580

ANSI, ASTM, NEC, NEMA, ASN2

Indian Electricity Rules, Indian Explosives Act.

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

Any internationally recognised standard.

1.3 PRECEDENCE

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

1. Data sheets/drawings

2. Technical Specification

3. International standards/codes as applicable

4. Indian Standards / codes applicable

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

No deviations to the technical requirements and to the scope of supply specified in this enquiry document shall be accepted and offers not in compliance to the same shall be rejected. In case a deviation is required due to inherent design of the equipment offered, the bidder shall list all such deviations at one place giving reasons thereon.

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

(1) Checklist duly filled in with regards to scope of supply

(2) Completely filled in Data Sheets of compressor, Gas Engines, Heat Exchanger.

(3) Deviations if any to this Technical Specification

(4) Tentative Lay out/key plan/General Arrangement indicating size of skids, centre distance between skids and space required along with maintenance requirements

(5) (a) Utilities requirements (b) Electrical Load summary

(6) Catalogues of compressor, engine, instrumentation & controls

1.4 SCOPE OF SUPPLY FOR EACH COMPRESSOR PACKAGE

The scope of work/services to be provided by the bidder shall be inclusive of but not limited to:

Design, Engineering, Manufacture, assembly, testing at manufacturer’s works, erection, commissioning, and field trial runs along with Equipment performance test along with associated electrical, instrumentation etc. as per bid document.

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Each compressor Package shall be complete with:

- Lubricated or Non-Lubricated Reciprocating Compressors with suction / discharge volume bottles (dampers), mist separators at each stage and coalescent filters with timer based automatic drain system, lube oil system, closed circuit cooling water (console type) / air cooled system as required.

- Gas engine complete with lube oil, closed cooling system, fuel (Natural Gas) supply module, inlet air intake system, exhaust system with silencer, stack etc.

- Gas engine start up air compressor with receiver and necessary controls complete with air drier dry at (-23) degree centigrade dew point.

- UPS of required rating with 4 hours power back-up to run compressor package control panel.

- Mass flow meter to measure the Natural Gas consumption at packages inlet, package discharge and fuel consumption at Gas Engine inlet with online test arrangement.

- LCV trailer panel complete with mass flow meter (with integral local display) based on Coriolis principle of Micro motion, USA (Model CNG 50 with 2700 transmitter, cabling, suitable for hazardous area classification. Panel shall be weather proof. Sheet metal work shall be SS-304. LCV trailor panel shall be mounted near LCV stand. 316 tubing from compressor to trailer panel and from trailer panel to LCV filling point with hoses and fittings shall also be included in the scope.

LCV trailer panel shall have override facility in LCP to fill LCV in priority panel.

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

- Common structural steel skid for the compressor- engine combination and for all auxiliary systems with foundation bolts.

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

- Air-cooled heat exchanger for interstage and discharge gas as well as engine coolant.

- Priority Panel at Package Discharge.

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

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

- Separate junction boxes for different type of signals like intrinsically safe signals, alarm, shutdowns, thermocouples, RTDs etc. for interfacing to local panel.

- NRV at final discharge.

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

- One no. relief valve at each stage discharge and Blow Down Vessel (BDV) shall be provided.

- Y- type strainers, valves, sight flow indicators, check valves, auto & manual drain traps etc. as required for various auxiliary systems i.e. frame lube oil, cylinder lubrication system, cooling water systems etc.

- Coupling/V-belts/pulleys.

- Compressor and Gas engine shall be enclosed in an acoustic enclosure.

- Enclosure shall have two number L.E.L detectors and two UV detectors alongwith two numbers of Heat Detectors.

- Common CO2 extinguishing system consisting of two cylinders, piping, valves and control systems (details are given at Cl.No.1.6.9).

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

- Catalytic Converter for reduction of NOx, CO and THC from rich burn gas fired internal combustion engines as per Annexure-VIII.

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- Complete Erection, Testing & Commissioning of compressor packages.

- Supply of all Mandatory spares as specified, erection & commissioning spares as per Annexure-D.

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

- Training of six personnel in two batches at Packager’s works. The travelling, boarding and lodging of Gail Gas engineers shall be born by Gail Gas Limited. Each training module shall span for one week and shall cover the equipment constructional features, operational and maintenance procedures, practical hands on experience on assembling, dismantling etc.

- Bidder shall provide necessary provision in control panel (located in hazardous area) provision of availability of operating and fault condition data on PLC through SCADA system .The system shall be compatible with Gail Gas system.

- Maintenance and operation of compressor shall be for 365 days 24 hrs per day basis.

1.5 EXCLUSIONS

The following are excluded from the scope of the bidder:

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

- CNG storage cascade.

- All piping beyond battery limits except air piping from packaged compressor unit to air compressor for air starting and piping from CO2 cylinders up to the enclosure. The air and CO2 piping shall be of seamless CS pipe.

- Foundation structural drawing.

1.6 SAFETY

1.6.1 All controls shall operate in a fail-safe mode i.e. failure of any control shall not lead to running of equipment in unsafe mode.

1.6.2 The hazardous area classification Class-I, Division I, Group D as per NEC or Zone I, Group II A/ II B as per IS/ IEC for compressor and gas engine. Gas engine ignition system as per class 1, division 2 or zone II Group IIA/IIB as per IS/IEC is acceptable. Certificate from recognized agency to the effect that equipment supplied and/or installed conform to above area classification. All Devices shall meet the requirement for the specified area classification in which they are installed, including instrumentation leads.

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

1.6.4 Driver belt if used shall be of anti-static and fire resistant type.

1.6.5 Piping shall be arranged in a manner so as to provide clear headroom and accessibility within the package. Adequate clearances shall be provided for all the engineered components.

1.6.6 Package Enclosure shall have two L.E.L detectors (IR Type) and two Ultra Violet (UV) fire detectors alongwith two nos. of heat detectors to cover the enclosure effectively as already spelt in the scope of supply.

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

1.6.8 Relief Valves shall be provided at interstage/compressor discharge with setting as per Cl. 7.20.3 of API – 11P with R.V. venting as per Cl. 7.20.4 of API-11P. Suction separator at first stage inlet shall also be provided with Relief Valve.

1.6.9 CO2 Flooding System:

The package shall be protected by automatically operated CO2 flooding system designed as per NFPA-12 which should have minimum following features: -

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1. Gas Detection by installation of hydrocarbon gas detector (IR type) with self check function and transmitter with adjustable alarm levels (0-100%) with preset of 10%, 20% and 50%. Each enclosure should have at least 2 nos. gas detectors.

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

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

4. The System shall be designed to operate on 24 V DC supply. FRLS (Fire resistant low smoke) 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 automatic discharge of CO2 gas shall take place from the main cylinder simultaneously.

iii. Compressor shall not start if the CO2 Flooding System is faulty, not working, switched OFF etc. The compressor shall be able to start only when the CO2 Flooding System is in healthy working condition.

iv. Maintenance Override Switch shall be provided to keep the system off during maintenance. This feature shall be in compliance to the point no. 5 (iii) as above.

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

6. Alarm panel for CO2 Flooding System shall be integral with the main compressor panel. Necessary displays as system ON, OFF, FAULT, RESET, Gas/ Flame indication, Remote actuation of solenoid valve, distinguished hooter etc., shall be provided for CO2 flooding system.

7. CO2 Cylinders shall be provided outside the package at a safe place, minimum 4.5 meters away (aerial distance), where it is not exposed to fire in case of fire in the compressor. Facility shall be made to operate the system both manually from remote with the help of a switch/ call point and with help of pull down lever on cylinders.

8. Bidder shall provide suitable weighing arrangement to facilitate weighing of the cylinders without requiring the cylinders to be detached from the installation. For this, lever operated lifting arrangements shall be provided along with alarm system.

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

10. The system designed by the supplier shall be duly approved by Gail Gas Limited.

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

12. The supplier shall offer system for testing to GGL after commissioning at site by creating actual Gas leak and Gas fire situations and actual discharge of CO2 Gas from the Cylinders. This shall form a part of performance test and thereby acceptance of the package. The cylinders have to be refilled by the bidder at no extra cost to GGL after performance test. If the system fails during testing, subsequent testing and refilling would be at bidder’s cost.

13. Warning and operating instructions to be displayed at equipments as per the statutory/ safety regulations.

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1.7 AMBIENT CONDITIONS.

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

Wind velocity km/hr (max.) 160

Amb. Temperature (Min./Max.) 5oC / 48oC

Design Wet bulb Temp. 27oC

Design Relative Humidity 90%

Altitude, M above MSL 115 meters

Air Cooler design oC 48oC DBT, 27oC WBT & 90% RH.

2.0 UTILITIES & BATTERY LIMITS

2.1 Utilities

2.1.1 Bidder shall make his own provision for Instrument and starting air with an electric motor driven air compressor receiver system. Receiver to be sized for 6 consecutive starts of gas engine within one hour. Receiver to be sized to cater dispenser requirement also.

2.1.2 Cooling water is not available as utility and the package shall be provided with self sufficient cooling water system for Engine & Compressor, as required, with make up tank.

2.1.3 All electrical and instrumentation terminals shall be as specified.

2.1.4 Bidder to design compressor package to start and run without any external power, except for electric motor driven air compressor.

2.1.5 Bidder to design compressor package to start and run via 240V, 50 Hz single phase power supply. All equipment supplied in the package shall be powered via the control system, including any electrical motors, lighting and all emergency equipment.

2.1.6 240V, 50Hz single-phase supply shall be available at station distribution boards.

2.2 Battery limits

2.2.1 All customer interface connections (i.e. Gas Inlet & Gas Outlet) shall be brought out to the package edge. Gas inlet shall be terminated in nozzles with isolation valves having flange connections and Gas outlet (priority panel outlet connection) shall be terminated through high-pressure ¾” full flow ball valves for ¾” SS tube connections for supply item no.01.

All customer interface connections (i.e. Gas Inlet & Gas Outlet) shall be brought out to the package edge. Gas inlet shall be terminated in nozzles with isolation valves having flange connections and Gas outlet (mobile cascade filling panel with metering facility outlet connection) shall be terminated through high-pressure ¾” full flow ball valves for ¾” SS tube connections for supply item no.02.

2.2.2 As and where specified on the data sheets all vents (i.e. Relief valve, distance piece, packing and starting air) shall be manifolded and terminated at skid edge outside the enclosure and vented to safe height at package roof. Silencer has to be provided in the starting air vent line.

2.2.3 All drains from different process equipments, distance piece and packing shall be manifolded and terminated as single point for customer interface duly flanged with isolation valve. Drains should be through a common header and discharge to be allowed in a pit to avoid spillage around compressor package.

3.0 BASIC DESIGN

3. 1 General

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

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i. Data Sheets

ii. Technical Specification

iii. Code and specification API-11P, OISD 179, NFPA 37, NFPA 52, ANSI, ASTM, NEC, NEMA, Indian Electricity Rules and Indian Explosives Act are referenced to and made part of specification.

Compressor, engine and auxiliaries design shall be in conformity with API 11P, second edition

3.1.2 Compressor shall have minimum three stage with suction pressure range of 14 – 19 kg/cm2 (g). Compressor shall be of horizontal balanced opposed or trunk piston type configuration. Gas composition given in Annexure-A & B shall be used for Compressor sizing and performance guarantee estimates. However compressor shall be suitable for continuous operation with the indicated gas composition range and operating parameters given in the data sheet.

3.1.3 Suction line pressure may vary from 14-19 kg/cm2 g with discharge pressure remaining constant at 255 kg/cm2G.

A suction pressure regulator shall be installed to limit the suction pressure to19 kg/cm2 g .

The suction pressure of 16 kg/cm2 g shall be used for compressor sizing.

3.1.4 Bidder’s offer shall be based on firm and final compressor models on which basis the offer shall be evaluated. All bidders shall take full recognisance of this matter before submitting the bid.

3.1.5 Note that the pressures given on the data sheet are at the compressor package battery limits, bidder shall consider all pressure losses at suction, interstage and discharge at the specified capacity (with no -ve tolerance) for compressor/engine and indicate the same on the data sheets. No venting of the gas is allowed at any point during operation.

3.1.6 The compressor Driver shall be capable of running the compressor under loaded condition with each stage pressurised to its respective specified pressure and final pressure upto PSV set pressure.

3.2 Allowable speeds, temperature and vibration levels

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

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

3.2.3 The maximum discharge gas temperature for each stage shall be limited to 150ºC.

3.2.4 Compressor maximum vibrations of cylinders shall be as per manufacturer’s standard. However it should not exceed 7.5 mm/sec. unfiltered peak velocity. Maximum Vibration level of installed compressor frame shall not exceed an unfiltered peak velocity of 5 mm/sec. or 200 micron unfiltered peak to peak vibration whichever is less. The Bidder shall provide for all structural support within the package so that these levels can be achieved. The Compressor shall stop if the vibration limit crosses as specified above or manufacture’s specified limit.

3.3 Piston Rod, Bearings and Cross Heads

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

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

3.3.3 Piston rod and cross head pin loading at any specified operating condition including the relief valve set condition shall not exceed 80% of the maximum design rod load of the offered compressor. Rod loads shall have sufficient reversals in direction for all specified operating conditions including PSV Settings and part load operation.

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3.4 Packing Cases and Pressure Packing

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

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

3.4.3 Packing vent piping inside of the distance piece shall be designed for the maximum allowable working pressure of the cylinder.

3.5 Compressor Frame Lubrication

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

3.5.2 All lube oil piping after oil filter shall be 300 series stainless steel conforming to ASTM A 269.

3.5.3 Heating shall be provided for reservoir when the minimum ambient temperature is less than the Bidder's required minimum start up temperature.

3.6 Distance Pieces

3.6.1 Type–1 or Type-2 distance pieces as per API 11 P can be provided as per compressor design requirement.

3.7 Cylinder and Packing Lubrication

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

3.7.2 Lubricators shall be driven by crankshaft and bidder shall highlight any pre lubrication requirements of the cylinders and the method of achieving the same.

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

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

3.7.5 Lubricator reservoir capacity shall be adequate for 50 Hrs of normal operation, and shall be equipped with low-level alarm.

3.7.6 Bidder shall furnish along with their bids the details of the recommended Lubricating oil type, International Grades & Specifications along with their quantity and changing frequency/ schedule. The recommended oil shall be compatible with gaskets, ‘O’ rings, seals, packing, lubricating parts and other parts coming into contact.

3.8 Cooling System

3.8.1 Engine Jacket/Compressor Cylinder

3.8.2 Compressor cylinders may be air cooled, in case water-cooled cylinders are offered the bidder shall conceive and design the common or separate engine jacket / Compressor cylinder cooling water (CW) system. Bidder shall submit the authentication from respective equipment manufacturer for the same. The Cooling Water shall be cooled by an air-cooled heat exchanger.

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3.9 Inter/After Gas Coolers

Air-cooled Interstage and Final stage discharge coolers shall be provided which shall limit the gas temperature after the after cooler to 52 0C. For calculating the surface area of the air cooler, the ambient air temperature of 45.0 oC and 90% RH shall be considered. Cooler design shall be on the basis of 20% extra margin on the heat load at most severe condition corresponding to suction pressure. Gas sections of coolers shall be designed as per API-661 requirements and shall be inspected by any approved 3rd party inspection agency. Engine oil cooler and jacket water coolers shall be so designed that the bidder’s maximum permissible temperature is not exceeded at the maximum ambient temperature of 48.0 oC. The sizing shall be done in such a way so that at no point of time the discharge gas temperature exceeds 52 0C.

3.10 Separators & Oil Removal System

3.10.1 Carbon Steel separators at suction and inter-stage alongwith SS 300 series, mist extractors, auto drain system (time based) shall be provided for the capacity as required.

3.10.2 All pressure vessels shall be designed as per ASME VIII Div 1 practice.

3.10.3 The offered scrubber and mist removal shall restrict the oil level to < 5 ppm in the discharge gas of compressor and the equipment shall be designed accordingly.

All pressure vessels including pulsation dampers shall be fully (100 %) radiographed as per ASME VIII UW (a)

Minimum design temperature for separators shall be 100OC and minimum design pressure shall be maximum operating pressure plus 15% for interstages and plus 10% for final stage.

3.11 Gas Recovery System: Bidder shall provide gas recovery system with gas recovery vessel of sufficient capacity (however, operating BDV pressure should not exceed 35 Kg/cm2g) so as to limit the gas pressure inside vessel to 35 kg/cm2g after tripping of compressor at PSV trip set pressure of final stage discharge. The gas recovery vessel shall be provided with pressure relief valve and necessary arrangement to avoid cold flaring of gas. Gas recovery vessel shall be designed as per the ASME code and will be inspected by approved TPI.

3.12 All pressure vessels shall be provided with 3 mm corrosion allowance.

3.13 Pulsation, Vibration Control and Analog Study

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

3.13.2 The design of pulsation suppressing devices shall be based on the acoustic and mechanical evaluation carried out as per API 618-design approach 3.

3.13.3 These devices must reduce pressure pulsation in piping within 3%. These pulsation dampers shall be designed to limit pressure drop to 1%. The minimum acceptable volume of pulsation suppression device shall be 10 times the cylinder swept volume.

3.13.4 Bidder shall get the acoustic and mechanical evaluation study carried out for one compressor package (from inlet flange to discharge on skid edge) by an agency/bidder himself and should have conducted TEN such simulation studies. The compressor Bidder shall be totally responsible for all the coordination with the agency carrying out the study. Bidder shall submit acoustic and mechanical evaluation report to GGL for review.

3.14 Gas Engine

3.14.1 The offered gas engine shall be from one of the regular production range of approved make for mechanical drive applications. The gas engine shall be gas fired, 4-stroke, spark ignited type. The integral gas engine & compressor type design is not acceptable.

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3.14.2 The site rating of engine shall be 110% of greatest BkW required by compressor plus the auxiliary loads at any of the compressor operating conditions or 105% of BkW required at relief valve set pressure plus the auxiliary loads at any of the compressor operating conditions, whichever is higher. The normal operating speed of the engine shall be limited to 1500 rpm.

3.14.3 The site rating of engine shall be worked out considering the de-ration specified under the latest edition of British Standard 5514/ISO 3046 and deducting the power absorbed by all the engine driven auxiliaries, as conceived by the Packager. The site rating of engine shall be based on 48.0 oC ambient temperature, RH 90% and an altitude of 115 meter taking design case gas composition as specified, the site rating so arrived shall be suitable for the maximum Compressor BkW as arrived at and which can be applied 24 Hrs a day seven days a week. Bidder to furnish site-rating calculation including de-rating calculation along with bid. Note that the Design Gas specified for the compressor shall be used as engine fuel.

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

3.14.5 Engine shall be provided with Compressed air starting complete with air compressor & receiver of approved make. The air receiver vessel shall be suitable for 6 consecutive starts in one hour. Air compressor, drier, filter and air receiver for gas engine starting / instrument air, shall be kept off the package in safe area with rigid piping, electrical & instrumentation cabling in bidders scope. One air bottle of 300WL (or six starts per hour) whichever is of higher capacity must be installed outside the enclosure for engine starting. One more additional air-bottle of 500WL capacity shall be provided for dispenser feeding. Air compressor shall be complete with air drier at –40 deg centigrade dew point, complete with coalescent filter and particulate filter.

3.14.6 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 power cylinder. The spark plug shall be shielded and all low-tension wiring shall be enclosed in grounded steel conduits. But the spark plug connecting cables shall be enclosed in grounded, metal-shielded flexible conduits.

3.14.7 Constant speed hydraulic/electronic governor preferably of WOODWARD make adjustable for speed setting over the operating range.

3.14.8 The engine silencer shall be residential type mounted on the roof of the engine enclosure. Suitable enclosure to be provided above the silencer to avoid direct contact with the body of the silencer. Thermal insulation to be provided upto the Silencer.

3.14.9 Bidder shall provide the fuel gas supply line consisting of valves, pressure regulator, differential pressure regulator, shut off valve and necessary instrumentation etc as required for the engine to ensure continuous supply of conditioned gas to engine.

3.14.10 Bidder shall provide suitable provision in the exhaust so that the exhaust gas meets the emission norms of CPCB.

3.15 Coupling

The first preference is for directly coupled driver-compressor arrangement. However a V-Belt driven compressor is also acceptable. 3.16 Enclosure of CNG Compressor Package

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

The maximum temperature within the enclosure shall be limited to 53ºC based on the ambient temperature of 48ºC. Adequate ventilation fans shall be provided to meet the above and also to account for heat dissipation of the coolers as well as maintaining the positive pressure inside enclosure.

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

3.16.2 Enclosure shall provide a degree of protection equivalent to IP 55 as defined in AS 1939 and provided with adequate ventilation system.

3.16.3 The enclosure shall have doors for normal access and removable wall panels for ease of maintenance. The acoustic material should be fire resistant with fire retardant rating of 30 minutes. UL approval/IS certification shall be applicable for acoustic material.

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

3.16.5 Enclosure shall have internal flame proof lighting arrangement.

3.16.6 For handling of all heavy parts for maintenance purpose lifting arrangement i.e. beam fitted with spark proof chain hoist shall be provided in the enclosure. Certificate of chain hoist is to be provided.

3.16.7 All Coolers, Knock Out Drums, Separators, Cooling System, lubrication system alongwith interconnecting piping shall be inside the enclosure. Enough headroom shall be made available for easy access and maintenance of all equipment in the enclosure. The piping layout with respect to the compressor, intercoolers, KOD, separators and auxiliaries location shall be subject to Purchaser’s approval during detailed engineering stage.

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

3.16.9 Conduits and tubing shall be arranged in orderly and systematic manner and shall be routed neatly to enter the back of display or monitoring panels

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

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

3.16.12 Items, which must be operated & monitored during operation, shall be readily accessible without opening the door.

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

3.17 Piping

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

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

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

3.17.4 All rigid piping shall be continuous between their respective components & free of connections except welded joints. All high pressure joints shall be welded unless otherwise not feasible.

3.17.5 The instrument air tubing material shall be Stainless Steel series –316 conforming to ASTM-A269.

3.17.6 All high-pressure double ferrule fitting & 2/3 way valves shall be from SWAGELOK or PARKER makes & shall be SS 316 material only.

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

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

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

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

3.17.11 All gas piping after coalescent filter at compressor discharge shall be of SS 316 of Sandvik make and hardness less than Rb 80.

4.0 CONTROL PHILOSOPHY

4.1 The compressor package control system shall be designed for unattended operation in automatic mode and in case of any fault it will go in a safe mode.

Compressor Package shall be provided with a PLC based LCP of approved make which shall be weatherproof to IP55 and shall be certified suitable for specified hazardous area classification. PLC should be integral with the package with necessary Hazardous Area Certificate (HAC) compliance. All operational buttons shall be through explosion proof push buttons with numerical display of all parameters. All displays shall be made available in local explosion proof panel through numerical display.

PLC shall incorporate all process parameters (specified elsewhere) and status of compressor, engine & priority panels and shall be modular in construction with 100% redundancy with respect to CPU, Power supply, Interface. PLC components/system shall be tropicalised, MIL standard adopted with complete wiring and necessary terminals. Wiring to be colour coded with cross ferruling in position.

PLC shall be capable of carrying out on line routines for atleast ten separate loops without affecting the scan, cycle & up dating time etc.

PLC shall be capable for display of flow meter data (i.e. Gas Suction, Gas Discharge, Gas consumed by the engine, gas filling to mobile cascade), various trips/abnormal conditions, and compressor-running hour etc. in following manner:

a) Shift wise (for 3 shift operation i.e. 06:00-14:00, 14:00-22:00 & 22:00-06:00)- shall be available for atleast last 96 hours.

b) Daily basis- shall be available for atleast last 31 days

c) Fortnightly basis- shall be available for atleast last 3 fortnights

d) Monthly basis- shall be available for atleast last 2 months

PLC shall be configured as a remote terminal unit of supervisory computer and data acquisition system complete with dial up connectivity. One card for transferring and accessing data from minimum twenty devices with RS 485 port shall be provided. PLC SCADA connectivity is required as per the attached specification at Annexure-VII.

PLC would be provided with integral keyboard and display for configuring, programming and to view process and machine parameters. Suitable communication port for connectivity to PC with RS 485 card shall be provided to download programs etc from PLC through a Laptop. Laptop is also included in Bidder’s scope.

All source & object codes including logic flow chart, ladder diagram etc are to be furnished by the Packager and PLC shall be capable of incorporating function Block diagram, sequence function chart, ladder diagram and structural text as per IEC 61131. Bidder shall provide individual application software. Programming software one set usable for all machines is to be supplied.

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

4.3 In auto mode, compressor shall start automatically in case high bank storage pressure falls below 200 kg/cm2 and stop as soon as pressure of stationery cascade reaches 255 kg/cm2.

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4.4 The priority fill system (In bidder’s scope) shall ensure the filling of vehicle, storage cascade and mobile cascade in correct order. Priority fill system for 1200 SCMH capacity compressor package be designed with 5 bank package priority panel as given below:

With (5) bank priority panel:

Break up:

1st - Direct to dispenser unit

2nd – High Bank cascade

3rd - Medium bank cascade

4th - low bank cascade

5th - Mobile bank (LCV)

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

4.5 Control system shall be designed such that in case of any fault, discrepancy or abnormality, it will go in safe mode. All controls shall be made in fail-safe mode & failure of any control shall not lead to operation of equipment/ system in unsafe condition.

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

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

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

4.9 Bidder shall provide emergency shut down (ESD) system in the control room as well as locally mounted on the compressor panel.

4.10 Fail-safe system shall be designed and incorporated to isolate cascade storage from dispenser, stop compressor, isolate the compressor suction line and cut off fuel gas supply to engine on activation of ESD switch.

ESD switch shall have to be manually reset to restart the compressor package again.

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

5.0 INSTRUMENTATION

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

5.2 All package mounted transmitters/transducers & temperature element shall be intrinsically safe " ia" as per IEC 79-11 and solenoid valves, switches and related junction boxes shall be certified flame proof (Eexd) as per IEC 79-1 by a statutory body viz. FM, BASEEFA etc. for the specified hazardous area classification. Other special equipment’s/instruments, where intrinsic safety is not feasible or available the same shall be flame proof (Eexd) certified suitable for the specified hazardous area by a statutory body as per IEC 70-1. All analog as well as digital input to PLC shall be connected through barriers. All analog barriers shall be isolator type. Barrier shall be provided for all analog as well as digital inputs & outputs.

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5.3 The compressor package instrumentation & control is to be configured for manual as well fully automatic control system including starting, shutdown as applicable for unattended operation. Control system shall be PLC based with make and model no. duly approved by GGL. All inputs (analog and digital) will be connected through Barrier to PLC.

5.4 Instrumentation electronics shall be certified by a recognized authority such as BASEEFA, PTB, LCIE, CESI, INIEX, and SMRS.

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

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

5.7 All pressure gauges and pressure transducer shall be provided with isolation valves and have accuracy of + or - 1% of Full Scale Deflection (FSD).

5.8 The temperature gauge shall be generally mercury in steel filled type, weatherproof & with capillary extension. Capillary tubing shall be min Carbon Steel with CS flexible armouring. The gauge shall have accuracy of + or - 1% Full Scale Deflection (FSD). The range shall be 1.5 times of operating temperature.

5.9 All field instruments power shall be limited to 24 VDC. Power conversion unit if required shall be in the scope of the bidder. All instruments and enclosures shall be dust proof and weather proof to IP 65 as per IEC-529/ IS 2147.

5.10 Units of measurement shall be:

GAS FLOW - Kg/hr & SM3/hr

PRESSURE - Kg/cm2 g

TEMPERATURE - 0C

5.11 Following points to be noted regarding Mass Flowmeter – Coriolis type:

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

5.11.2 Allowable pressure drop for the flowmeter at the inlet of the engine is 0.2 kg/cm2 and allowable pressure drop for the flowmeter at the inlet and outlet of the compressor shall be 1.0 kg/ cm2. Offered mass flowmeter shall be necessary for Custody Transfer application but not exceeding 0.5% of span.

5.11.3 Calibration for the offered mass flowmeter shall be in Kg/hr and SM3/hr. Pressure, Temperature compensation shall be provided by the meter.

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

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

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

Meter Electronics shall include all the associated pre-amplifiers converters lineariser etc.

5.11.7 Installation details like straight run requirements, recommendation for horizontal /vertical installation, minimum distance between upstream and downstream pipe bends from Mass flowmeter to be provided.

5.11.8 Bidder shall calibrate each Mass Flowmeter at his shop or any recognised test house with the fluid (Use design process conditions) for which it is to be used as per Clause no.9 of MPMS (Draft standard Nov. 2000). In case it is not possible to calibrate the Mass Flowmeter with actual fluid, Bidder must indicate.

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a) Fluid used for calibration

b) Correction factor/Adjustment required for actual process fluid. In any case, inaccuracy when extended to actual process shall not exceed the specified limits (as per manufacturer’s standard).

5.11.9 Bidder shall submit the following test certificates and test reports for purchaser’s review: -

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

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

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

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

5.12 Screw Less Terminal strip should be used.

5.13 CERTIFICATION:

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

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

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

- Bidder shall provide certificates (from BASEEFA FM, UL, PTB, LCIE etc.) from country of origin for all intrinsically safe/flameproof protected by other methods equipment/instrument/systems, which are manufactured outside India. Bidder shall provide necessary certification/approvals/authentication, for all such intrinsically safe/flameproof equipment/instrument/systems, by the Indian authority–Chief Controller of Explosive (CCoE), Nagpur, India & BIS.

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

- For all intrinsically safe equipment manufactured within India the testing shall be carried out by any of the approved testing houses – Central Mining Research Institute (CMRI)/ERTL etc. The item shall in addition bear the valid certification from CCOE & BIS.

6.0 EARTHING / CABLING

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

6.1 Cabling

6.1.1 Cables for Power & Control inside as well as outside the enclosure shall be 2.5 Sqmm (Copper) and 1.0 Sqmm (Copper) respectively.

6.1.2 Cables shall be 1100-volt grade, stranded copper conductor, PVC insulated PVC sheathed, steel round wire armoured. FRLS cables.

6.1.3 Cables shall be terminated using double compression type metallic flameproof cable glands and copper lugs.

6.1.4 Spare cores to be kept in each control cable.

6.1.5 All Junction Boxes (JBs) shall have metallic enclosure

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6.1.6 Cables for control circuits shall be single phase (2 wire), 240 V, 50Hz A.C. supply from UPS.

7.0 INSPECTION AND TESTING

7.1 General

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

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

c) All tests which are required to be witnessed as per data sheet and this specification shall be witnessed by the Purchaser. The bidder shall notify the timing of such inspection and testing to GGL and GGL shall depute their representative for witnessing the test and/or a third party inspection agency shall be appointed by GGL for witnessing the test at GGL’s own cost.

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

7.2 Mechanical running test (MRT)

7.2.1 The MRT for the each compressors shall be carried out with job or shop driver including complete job driving system i.e., job driven V-belt, job pulleys etc., for 4 hours continuously at shop of compressor manufacturer. The compressor need not be pressure loaded for MRT test. During this test following shall be recorded at agreed intervals.

- Vibration levels measured on cylinders and frame. In case it cannot be measured on test bed the same shall be carried out during the field trial run at site.

- Oil cooler inlet and outlet temp

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

- Bore & other parts by opening a valve

- Piston & cylinder clearance

- Visual examination of position rod, controlled guide bore without dismantling

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

7.3 Gas Engine Performance

7.3.1 The performance testing of each engine shall be carried out by gas engine manufacturer in accordance with ISO 3046 or equivalent test procedure at his works. The routine load and fuel consumption test shall be for following minimum duration:

Part Load (50%, 75%) - 1/2 hour each

Full load (100%) - 4 hours

Bidder shall indicate the guaranteed fuel consumption for the Gas engine for the specified catalogue rating. The same shall be verified for each engine at engine manufacturer’s shop. In the event of the actual fuel consumption exceeding +5% of that guaranteed, the engine shall stand rejected and bidder shall offer other engine for testing after all efforts to reduce fuel consumption are exhausted.

7.4 Mechanical String Test

Mechanical String Test for 4 hrs is a mandatory requirement to be performed at packager’s shop before despatch in presence of GGL representatives (or a third party as arranged by GGL). This test can be clubbed up with the Mechanical Run Test of compressor as specified above, provided the job driver &

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lube Oil system is used for the test. At least 20% of the packages ordered shall be subjected to string test.

7.5 Package Performance Test

Bidder shall carry out performance test of the packages at packager works in fully assembled condition including auxiliary systems, instrumentation & safety devices within the enclosure. The performance test shall be done for 72 hours duration along with full load performance test for 4 hours. Natural gas Composition specified in Annexure B shall be used as baseline for Performance Test.

Performance test at site is optional & can be carried out in similar manner as described above.

Field trial run shall be carried out for 72 hours after full load performance test.

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

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

The test shall be the basis of assigning penalties on the bidder, acceptance / rejection of the package thereon. Bidder shall submit the detail test procedure for the same, which shall be approved by GGL. The test for the package shall be witnessed by GGL representatives.

8.0 PERFORMANCE GUARANTEES, LOADING AND PENALTIES

8.1 This section describes the guaranteed parameter, which the CNG compressor package must fulfil, the penalty for shortfall in guaranteed parameters and rejection of compressor package by the Purchaser.

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

ambient condition during testing.

8.3 Necessary calculations correction curves shall have to be furnished by Bidder along with bid, which shall be final & no deviation shall be permitted afterwards.

8.4 In case of any inconsistency in manufacture and/or operation of supplied compressor package, Bidder shall at his own risk and cost, eliminate the defects to the satisfaction of Owner. Bidder shall furnish guaranteed value as per Annexure –I enclosed with this specification

8.5 Compressor Capacity

8.5.1 Bidder shall guarantee 1200 SCM/hr capacity of compressor with design case gas composition as per Annexure- A & B, at suction pressure of 16 kg/cm2G, suction temperature of 350 C, discharge pressure of 255 kg/cm2G with the negative tolerance for errors in instruments and measurements.

Since the compressor suction pressure varies from 14 kg/cm2G to 19 kg/cm2G the compressor shall be sized / selected for specified capacity of 1200 SCM/Hr at 16 kg/cm2G (with no -ve tolerance) whereas the driver shall be selected on the basis of compressor BKW with either 14 kg/cm2G or 19 kg/cm2G whichever is higher.

The same shall be used to establish the capacity at test bed during package performance test.

8.6 Loading & Penalty Criteria

8.6.1 Loading

Bidder shall indicate the specific fuel consumption kg/hr / BHP and the total fuel consumption (above defined compressor capacity) in kg/hr as guaranteed value in the offer.

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

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The offers shall be loaded for the fuel consumption as given under

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

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

Where

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

B: Cost of Mandatory spares

C1: Differential operating cost for fuel consumption as defined hereunder

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

Differential operating cost (C1)

C1 (in Rs) = Nop x (Fe - Fr) x Cf X Df

Where

Nop: 8000 Hrs

Fe: Guaranteed fuel consumption in SCM/Hr by the bidder.

Fr: Lowest Guaranteed fuel consumption SCM/Hr (amongst technically accepted bidders)

Cf: Cost of fuel as Rs 12.00 / SCM

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

Differential operating cost (C2)

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

Where

Nop: 8000 Hrs

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

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

Cf: Cost of fuel as Rs 12.00 / SCM

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

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

8.6.2 Penalty

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

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

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

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

Where,

PY = Penalty Cost

FT = Fuel consumption as obtained from performance test in terms of SCM/hr

FG = Guaranteed fuel consumption in SCM/hr

CF = Rs. 12.00 /SCM

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

c) In shop performance test if the venting/ packing losses in percentage of throughput of 1200 SCMH or 2500 SCMH are found to be in excess of the guaranteed value the bidder shall be penalized for excess venting losses

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

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

Where,

PY = Penalty Cost

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

FG = Estimated venting/packing loss in percentage of throughput

CF = Rs. 12.00 /SCM

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

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

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

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

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

8.6.3.1 Details of Penalty for non performance of equipments

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

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

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

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

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

(b) On schedule maintenance day:

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

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

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

9.0 PAINTING AND PROTECTION

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

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

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

10.0 ERECTION, TESTING AND COMMISSIONING AT SITE

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

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

11.0 FIELD TRIAL RUN/ SITE PERFORMANCE TEST

Bidder shall conduct a field trial run of each compressor package for minimum 72 hours continuous duration at guaranteed points in which satisfactory operation of complete package together with all accessories/auxiliaries controls shall be established for specified operating conditions prior to the start of one year operation and maintenance period as defined in the contract. Full load performance test shall be carried out at site/work for 4 hours. Field trial run shall be carried out for 72 hours after full load performance test. During the field trial run the bidder will be allowed a maximum of THREE attempts to complete the above-specified test. The Equipment shall be considered commissioned after the successful completion of Field Trial Run.

The above conditions are also applicable in case the bidder carries out the performance test and trial run at their works.

12.0 SPARE PARTS, SPECIAL TOOLS AND TACKLES

12.1 Spare Philosophy

Two basic type of spare shall be required to support a maintainable system as under :

(a) Erection & Commissioning Spares : These are the spare which must supplied as a part of the package for assembly, erection & Commissioning of the package.

(b) Operational Spares : These spares shall be supplied along with the package to support on-going operation of the package unit.

The operation spares under the scope of supply of the bidder is further divided as under:

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i) Non comprehensive spares: Spares required to be supplied within the warranty period of the package unit.

ii) Comprehensive Spares: Spares required to be supplied for 12 months of trouble force operation after warranty period.

12.2 All spare parts, special tools & tackles for erection and commissioning and spare parts required for One Year Operation and maintenance of compressor package shall be arranged by the Packager and shall form his scope of supply. The bidder has to provide the list of spares, tools & tackles for erection and commissioning and spare parts required for operation & maintenance along with the bid. These tools and tackles and any spare parts left after work completion shall be the property of GGL.

Bidder shall maintain sufficient spares to fulfil the warranty period requirements. In case of additional requirement during the warranty period, if any spare part is taken from GGL, the same shall be replaced to GGL with new part supported by necessary document for its authenticity of being new & original spare part

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

12.4 As a minimum, all the spares as defined under Mandatory Spare Parts List (enclosed as Annexure-III) shall be supplied as part of the package.

No spare from the list of mandatory spare list shall be used during erection, commissioning and One Year Contractual Operation & Maintenance Period.

13.0 MAINTENANCE PHILOSPHY:

The maintenance philosophy shall be based on operational availability of the package. Operational availability is defined as the probability that at any arbitrary point in time, the system is operable and is expressed as:

Ao = UP time/ Total Time

Where,

Ao = Operational availability

UP time = It is function of the frequency of active maintenance item, waiting time, logistic time, ready time of the package.

Total Time = The combination of UP time & down time in which downtime is the time which a system spends in inoperable state.

The minimum value of Ao shall be 98%.

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

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

14.0 WARRANTY SERVICING AND SPARE PARTS

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

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15.0 DATA AND DRAWING

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

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

c) The data requirement after placement of Fax of Intent (FOI) is indicated in the Bidder Data Requirement Forms for the respective equipment, including the number of weeks within which this data is to be provided. Bidder shall confirm that all data as required shall be furnished by him and shall indicate the Bidder’s promised data in the columns provided.

d) After the placement of FOI, a conference (kick off meeting) will be held at such place, as may be mutually agreed upon between the Bidder and the purchaser within 15 days from the date of placement of FOI. The intent of this conference shall be to discuss / clarify various requirements and finalize the modus operandi for execution of the contract within the scheduled delivery period.

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

f) Along with the supply of compressor packages, the bidder shall provide application software for PLC & HMI, ladder logic. Licensed Programming software one set usable for all machines shall be supplied along with required nos. of development softwares.

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ANNEXURES

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ANNEXURE – A

Normal Natural Gas Composition Range

Name C1 C2 C3 C4 C5 C6+ N2 CO2

Gas Comp-osition (V/V%)

85-93 4-7 0.8-3.8 .04-1.4 0.2-0.3 0-0.2 0.05-0.15 3.0-4.0

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ANNEXURE – B

Specified Natural gas Composition for Performance Test

Name C1 C2 C3 C4 C5 C6+ N2 CO2

Gas Comp-osition (V/V%)

92.0012 4.1460 0.5487 .0405 0.0230 0.0000 0.1256 3.1357

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ANNEXURE – C

DELIVERY LOCATION & SCHEDULE FOR PACKAGED COMPRESSOR UNITS

a) The delivery location of 16 nos. compressor packages to be kept as follows:

1200 SCMH Compressor Packages Delivery Places

S.NO

Dewas Kota Sonipat Meerut CWC, Ghaziabad

Qnty. Of Delivery in each lot

Remarks

(i) 01 03 03

03

---- 10 08 nos.with LCV trailor panel

(ii) --- ---- ----- ----- 06 06

01 03 03 03 06 16

b) The delivery schedule of 16 nos. compressor packages to be kept as follows

LOT NO QTY

(NO)

Indian Bidder

(FOT site)

Foreign Bidder

(FOB port of Shipment) Remarks

LOT 1 2 6 Months 5 Months



8 Nos with LCV trailer Panel


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ANNEXURE – D

MANDATORY SPARES PARTS FOR PACKAGED COMPRESSOR UNIT ALONGWITH DELIVERY LOCATION:

NOTES:

1. Priced Bid Envelope which shall be considered for price comparison for set of 16 compressor packages.

2. Price of mandatory spares shall be loaded for evaluation purpose

3. Set means the quantity installed in one machine (BIDDERS TO SPECIFY ITEM WISE DETAILS IN THEIR OFFER)

S.NO.

PART DESCRIPTION

DELIVERY LOCATIONS

A Compressor Total (Sets) Dewas Meerut Sonipat Kota

CWC, Ghaziaba

d 1. All compressor

bearings / bushes (main, connecting rod big end. Connecting Rod small end, Cross Head etc.)

02 NIL NIL NIL NIL 02

2 Crosshead 02 NIL NIL NIL NIL 02 3 Crosshead shoes 02 NIL NIL NIL NIL 02 3 Piston rings/Rider

Ring (sealing wear rings) for all cylinders

03 01 NIL

01

01

NIL

4 Piston Rods 02 NIL NIL NIL NIL 02 5 Piston for all stages 03 NIL NIL NIL NIL 03 6 Piston Rings for all

cylinders. 03 NIL NIL NIL NIL 03

7 Complete valve assembly, suction, for all stages


8 Complete valve assembly, discharge, for all stages


9 Valve internals consisting of valve springs, valve plates etc.

04 01

01

01

01

NIL

10 Replaceable parts of main packing, partition packing, oil scraper ring, o-rings, gaskets etc.

04 01

01

01

01

NIL

11 Complete Lubricator assembly

02 NIL NIL 01

01

NIL

12 Digital No Flow Transmitter, if applicable

02 NIL NIL 01

01

NIL

13 Complete coupling / pulley

02 NIL NIL 01

01

NIL

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14 Idler pulley, if applicable

02 NIL NIL 01

01

NIL

15 Belt, if applicable / Bended Belt

08 01

01

01

01

04

16 Cooling fan bearing 04 01

01

01

01

NIL

17 Cooling fan shaft 03 NIL NIL NIL NIL 03 18 Cooling fan blades

with hub 03 NIL NIL NIL NIL 03

B GAS ENGINE

19 All engine bearings/ bushes (Main. Connecting rod big end, Connecting rod small end etc.)

04 01 01

01

01 NIL

20 Complete cylinder head assembly


21 Piston rings (all types) 04 01

01

01

01

NIL

22 Piston 03 NIL NIL NIL NIL 03 23 Liners 04 01

01

01

01

NIL

24 Connecting rod 03 NIL NIL NIL NIL 03

25 Ignition system (transformer / Contactor / Distributor etc.)

03 01 NIL 01 01

NIL

26 Spark plug 08 02

02

02

02

NIL

27 Carburettor assembly 03 NIL NIL NIL NIL 03

28 Fuel pressure regulator


29 Diaphragm kit for fuel pressure regulator

03 01

NIL 01

01

NIL

30 Starter motor 04 01

01

01

01 NIL

31 Starter motor repair kit

08 02

02

02

02

NIL

32 Complete coolant pump


33 Coolant pump repair kit

04 01

01

01

01

NIL

C INSTRUMENTATION

34 Display 03 NIL NIL NIL NIL 03

35 PLC (CPU/PS/interface Card/others)


36 Isolators 03 01

NIL 01

01 NIL

37 Pressure Transducer 03 01

NIL 01

01

NIL

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38 Temperature Element 03 01

NIL 01

01 NIL

39 Gas/Fire/Smoke Detectors


40 Pressure Gauge 03 01

NIL 01 01

NIL

41 Temperature Gauge 03 01 NIL 01 01

NIL

42 Solenoid Coils 04 01 01

01

01 NIL

D PACKAGE SPARES

43 NRV 03 01

NIL 01

01

NIL

44 Coalescing Filter Elements

36 09

09

09

09

NIL

45 Suction Gas Filters Elements

16 03

04

04

05 NIL

46 Lube Oil Filter Element

04 01

01

01

01

NIL

E AIR COMPRESSOR

47 Piston Rings 06 01

02

01 02

NIL

48 Air Filter 20 04

05

05

06

NIL

49 V-belts 20 04

05

05

06 NIL

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ANNEXURE – I

GUARANTEED PARAMETERS

Sr. No. Parameter Bidder’s Data

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

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

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

4 Net of all auxiliaries/package ventilation loads in KW

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

6 Fuel consumption of package in SM3/Hr (basis of loading & penalty)

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

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

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ANNEXURE-II

APPROVED VENDOR LIST

ITEM CODE / DESCRIPTION AIR FILTER REGULATORS

BIDDER NAME Remark ASEA BROWN BOVERI LTD.

BLUE STAR LTD

DIVYA CONTROL ELECMENTS PVT. LTD.

JANATICS INDIA PVT. LTD.

P.RAI AND COMPANY

PLACKA INSTRUMENTS & CONTROLS PVT. LTD

SHAH PNEUMATICS

SHAVO NORGREN (I) PVT. LTD

V AUTOMAT & INSTRUMENTS PVT. LTD.

VELJAN HYDRAIR PVT. LTD.

ITEM CODE / DESCRIPTION FIELD INSTRUMENTS (P, DP, F,L,T)

BIDDER NAME REMARKS ABB AUTOMATION LTD.

INVENSYS INDIA / EMERSON PROCESS

H.GURU

A.N INSTRUMENT

GENERAL INSTRUMENTS

BROWN BOVERT LTD.

ASCHROFT

MURPHY

CCS

WAREE

FISHER ROSEMOUNT INDIA LIMITED

FISHER ROSEMOUNT SINGAPORE PTE LTD.

FUJI ELECTRIC CO. LTD.

HONEYWELL INC.

TATA HONEYWELL

YOKOGAWA ELECTRIC CORPORATION

YOKOGAWA BLUE STAR LTD.

WIKA

DRUCK

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SHEET 35 OF 58

ITEM CODE / DESCRIPTION MASS FLOW METERS

BIDDER NAME REMARK

ENDRESS & HAUSER CMBH & COMPANY

CORIOLIS TYPE, MANUFACTUER, ENDRESS

+ HAUSER FLOWTEC AG, REINACE,

SWITZERLAND

EMERSON PROCESS MANAGEMENT

CORIOLIS TYPE

RHEONIK MESSGERATE GMBH CORIOLIS TYPE

ITEM CODE / DESCRIPTION PRESSURE GAUGES

BIDDER NAME REMARKS

AN INSTRUMENTS PVT. LTD.

BADOTHERM PROCESS INSTRUMENTS B. V.

BOURDON HAENNI S.A

BRITISH ROTOTHERM CO . LTD

BUDENBERG GUAGE CO. LTD.

DRESSER INC

GENERAL INSTRUMENTS CONSORTIUM

MANOMETER (INDIA) PVT. LTD.

NAGANO KEIKI SEISAKUSHO LTD.

WAAREE INSTRUMENTS LIMITED

WALCHANDNAGER INDUSTRIES LTD.

WIKA ALEXANDER WIEGAND & CO GMBH

WIKA INSTRUMENTS INDIA PVT. LTD.

DRUCK

ITEM DESCRIPTION PRESSURE RELIEF VALVE

BIDDER NAME REMARKS ALSTHOM FLUIDS SAPAG

PROTEGO EQUIPMENTS PVT. LTD.

FMC SANMAR LTD.

LARSEN & TUBRO

RMG REGAL + GmbH GERMANY

ANDERSON GREENWOOD CROSBY

BHEL (TRICHY )

DRESSER INC.

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SHEET 36 OF 58

FUKUI SEISAKUSHO CO. LTD.

MERCER (USA)

INSTRUMENTATION LTD. (PALGHAT)

NAKAKITA SEISAKUSHO CO LTD.

NUOVO PIGNONE SPA (ITALY)

PARCOL SPA

SAFETY SYSTEMS UR LTD.

SARASIN RSBD

SEBIN VALVES INDIA PVT. LTD.

TAI MILANO SPA

TYCO SANMAR LTD.

TYCO VALVES & CONTROLS INDIA PVT. LTD

ITEM DESCRIPTION SELF ACTUATED PR. CONTROL VALVE

BIDDER NAME REMARK DANIEL INDUSTRIES INC

DRESSER PRODUITS INDUSTRIES

ESME VALVES LTD.

FISHER ROSEMOUNT SINGAPORE PTE LTD.

FISHER EXMOX SANMAR LIMTED

GORTER CONTROLS B.V.

NIRMAL

INSTROMET INTERNATIONAL NV

KEYE & MACDONALD INC


PIETRO FIORENTINI SPA

RICHARDS INDUSTRIES (FORMERLY TRELOAR)

RMG REGEL + MESSTECHNIK GMBH

ITEM DESCRIPTION SOLENOID VALVES

BIDDER NAME REMARK ALCON ALEXANDER CONTROLS LIMITED

ASCO (INDIA) LIMITED

JEFFERSONS

ASCO JOUCOMATIC LTD.

ASCO JOUCOMATIC SA

AVCON CONTROLS PVT. LTD.

BARKSDALE INC.

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SHEET 37 OF 58

BLUE STAR LTD.

HERION WERKE

ROTEX

SCHRADER SCOVILL DUNCAN LIMITED

ITEM DESCRIPTION SPECIAL CONTROL VALVES

BIDDER NAME REMARK

FISHER ROSEMOUNT SIGAPORE PTE. LTD.

FLOWSERVE PTE. LTD. (FORMERLY DURIRON)

HOPKINSONS LIMITED

METSO AUTOMATION PTE LTD. (FORMERLY NELES)


SPX VALVES & CONTROLS (FORMERLY DEXURIK )

ITEM DESCRIPTION FLAME DETECTOR

MAKE REMARK DETECTION INSTRUMENT(I)PVT LTD

MEGGITT AVIONICS

SPECTREX

DETRONICS

HONEYWELL

ITEM DESCRIPTION GAS DETECTOR (IR TYPE)

MAKE REMARK DETECTION INSTRUMENT(I)PVT LTD

KROM SCHRODER

CROWCON

DETRONICS

ITEM CODE /DESCRIPTION PLC

MAKE REMARK ROCKWELL ANTOMATION

ALLAN BRADLEY

ABB

GE FANUC

TATA HONEYWELL

ITEM DESCRIPTION GAS ENGINE

MAKE REMARK CATERPILLAR

WAKESHA

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SHEET 38 OF 58

CUMMINUS

ITEM DESCRIPTION AIR COMPRESSOR

MAKE REMARK INGERSOL PAND

KIRLOSKER

CHICAGO PNEUMATIC

ELGI

ITEM DESCRIPTION MOTOR

MAKE REMARK KIRLOSKAR

BBL

ABB

NGEF

ITEM DESCRIPTION UPS

MAKE REMARK Hi-Rel ELECTRONICS

DB POWER

EMERSON NETWORK POWER ( INDIA) Pvt. Ltd.

KERALA STATE ELECT. DEV.CORP. LTD.

CHLORIDE IND. SYSTEM

GUTOR ELECTRONICS

FUJI ELECTRIC COMPANY LTD.

ITEM DESCRIPTION BATTERY

MAKE REMARK HBL NIFE POWER SYSTEM LTD.

AMCO POWER SYSTEM LTD.

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SHEET 39 OF 58

ANNEXURE-III

LIST OF RECOMMENDED THIRD PARTY INSPECTION AGENCY

S.NO

ITEM NAME OF VENDOR

ADDRESS

PHONE NO

FAX NO

1 TATA PROJECTS

LTD

22,SARVODAYA SOCIETY,

NIZAMPURA,BARODA-390002

0265-

2392863

0265-

2785952

2 Indian Register of

Shipping

52 AADI SHANKARACHARYA MARG

OPP. POWAI LAKE ,

POWAI,MUMBAI,400 072

91-22-

30519400

91-22-

25703611

3 BAX COUNSEL

INSEPECTION

BUREAU PVT.

LTD.

303, MADHAVA,BANDRA KURLA

COMPLEX BANDRA(E)-400051

022-

26591526,02

2-26590236

022-

26591526

4 BUREAU

VERITASQL

THE LEELA GALLERIA, 5TH FLOOR,

ANDHERI-KURLA

ROAD,ANDHERI(E),

MUMBAI-400059

022-

26956300

022-

26956309

5 GERMANISCHER

LLOYD

304-305, ANNA

SALAI,TEYANAMPET,CHENNAI-

600018

044-

24320335

044-

24328186

6 VELOSI

CERTIFICATION

SERRVICES,MU

MBAI

VELOSI CERTIFICATION

SERVICES(I)PVT.LTD,212,SHIVKRU

PA COMPLEX CENTRE,OFF

GHOKHALE ROAD,NAVPADA

THANE(W)400602

022-

25376770

022-

25426777

7

THIRD

PARTY

INSPEC

TION

AGENCY

ABS INDUSTRIAL

VERIFICATION

LTD., MUMBAI

404,MAYURESH

CHAMBERS,SECTOR-11,CBD

BELAPUR(E),NAVI MUMBAI-400614

022-

27578780 /1

/2

022-

27578784

/ 5

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8 CERTIFICATION

ENGINEERS

INTERNATIONAL

LTD.

EIL BHAVAN, 5TH FLOOR,1,BHIKAJI

CAMMA PLACE,NEW DELHI-110066

011-

26167539,26

102121

011-

26101419

9 DALAL MOTT

MACDONALD

501, SAKAR -II, ELLISBRIDGE,

AHMEDABAD-380006

079-

26575550

079-

6575558

10 INTERNATIONAL

CERTIFICATION

SYSTEMS

E-7,CHAND SOCIETY, JUHU ROAD,

JUHU, MUMBAI-4000049

022-

26245747

022-

22624816

7

11 SGS SGS INDIA PVT. LTD.,SGS

HOUSE,4B,A.S.MARG,VIKHROLI(W),

MUMBAI-400083

022-

25798421

TO 28

022-

25798431

TO 33

NOTE:

THE DETAILS OF VENDORS INDICATED IN THIS LIST ARE BASED ON THE INFORMATION AVAILABLE WITH WGEIL, BIDDER SHALL VERIFY THE CAPABILITIES OF EACH VENDOR FOR PRODUCING THE QUANTITY WITH PROPER QUALITY. PURCHASER OR PURCHASER REPRESENTATIVE DOES NOT TAKE ANY RESPONSIBILITY ON THE PERFORMANCE OF THE VENDOR.

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ANNEXURE-IV

BIDDER DATA REQUIRED

CERTIFIED INFORMATION REQUIRED

AFTER PURCHASE ORDER

S.

NO

DESCRIPTION PRINTS

WITH BID

FOR REVIEW FOR RECORDS

A GENERAL

1 PROJECT SCHEDULE YES

2 DULY FILLED-IN

“CHECKLIST FOR

COMPLETENESS OF BID”

YES

3 DULY FILLED-IN

“CHECKLIST FOR SCOPE

OF SUPPLY”

YES

4 DEVIATION LIST (IF ANY)

TO THE APPLICABLE

SPEC., DATASHEETS

YES

5 UTILITIES REQUIREMENT

SUMMARY

YES YES

6 FLANGE DETAILS OF

PIPING CONNECTION WITH

CONNECTION AT BATTERY

LIMIT

YES

7 DULY FILLED IN

EXPERIENCE RECORD

PROFORMA

YES

8 GUARANTEE

PARAMETERS AS

SPECIFIED

YES YES

9 TENTATIVE LOAD DATA

FOR FOUNDATION DESIGN

YES

10 LIST OF SUB-BIDDERS FOR

ALL BOUGHT OUT ITEMS

INCLUDING ELECTRICAL &

INSTRUMENTATION ITEMS

YES

11 LEAFLET, CATALOGUES

FOR ALL ITEMS

YES YES

12 O & M MANUAL YES

B COMPRESSOR

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1 DATASHEETS FOR THE

FOLLOWING

YES YES

A - COMPRESSOR YES YES

B - HEAT EXCHANGERS YES YES

C - PRESSURE VESSELS YES YES

D - GAS ENGINE YES YES

2 CATALOGUE FOR

COMPRESSOR

YES YES

3 TYPICAL CROSS

SECTIONAL DRAWING AND

LITERATURE TO FULLY

DESCRIBE THE DETAILS

OF OFFERING

YES

A - COMPRESSOR YES

B - SUCTION VALVE YES

C - DISCHARGE VALVE YES

D - PISTON ROD GLAND

PACKING & PISTON RINGS

YES

E - LUBE OIL PUMP YES

4 V-BELT & PULLEY WITH

SELECTION CHART &

CALCULATION

YES

5 COOLER DATA / DRG WITH

THERMAL & MECH DESIGN

CALCULATION

YES

6 DESIGN CALCULATION, GA

DRGS FOR PULSATION

DAMPNER

YES

7 PIPING &

INSTRUMENTATION

DIAGRAMS FOR THE

FOLLOWING

YES YES

A - PROCESS GAS YES YES

B - LUBE OIL YES YES

C - COOLING WATER YES YES

D - GAS ENGINE FUEL YES YES

E - AIR START UP / VENT YES YES

8 TORQUE ANGLE DIAGRAM, YES

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PISTON ROD LOAD VS

CRANK ANGLE

9 TORQUE SPEED

CHARACTERISTICS

YES

10 ACOUSTIC / MECHANICAL

EVALUATION REPORT

YES

11 ITEMIZED PRICE LIST OF

MANDATORY SPARES

YES YES

12 ITEM LIST OF SPARES

WITH PRICE FOR 5 YEARS

YES YES

13 DRG. FOR TESTING

ARRANGEMENT & TEST

PROCEDURE TO BE

ADOPTED

YES

14 CERTIFICATE FOR

FOLLOWING:

YES

A HYDRAULIC TESTING YES

B NON DESTRUCTIVE

TESTING

YES

C MATERIAL COMPOSITION

& PHYSICAL PROPERTIES

YES

D LEAK PROOFNESS TEST

OF FRAME

YES

E LUBE PUMP, FRAME OIL

PUMP, HYD OIL PUMP

YES

15 DESIGN / ACTUAL

ASSEMBLY CLEARANCE

CHART

YES

16 TEST RECORDS OF

FOLLOWING

A MECHANICAL RUNNING S YES

B PERFORMANCE TEST /

PACKAGE TEST

YES

C NOISE LEVEL TEST YES YES

17 LIST OF SPECIAL TOOLS &

TACKLES FOR

INSTALLATION &

MAINTENANCE

YES YES

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C GAS ENGINE

1 PERFORMANCE CURVES YES YES

2 TECHNICAL LITERATURE /

CATALOGUE, SELECTION

CHARTS, NOMOGRAPHS

ETC.

YES YES YES

3 CONTROL SCHEMATICS 3 YES YES

4 TYPICAL COMPONENT

CROSS SECTIONAL

DRAWING AND

LITERATURE TO FULLY

DESCRIBE THE DETAILS

OF OFFERING

YES

5 TEST PROCEDURE YES

6 FINAL ACCEPTANCE

TESTING AND

PERFORMANCE TESTED

RECORDS

YES

7 SCHEMATIC DIAGRAM

WITH START UP & SHUT

DOWN PROCEDURE &

LOGIC

YES

D INSTRUMENTATION

1 G.A. OF INSTRUMENT

PANEL WITH BILL OF

MATERIAL & WIRING DIG.

FOR LCP

YES

2 INSTRUMENT DATASHEET YES

3 LOGIC DIAGRAM / LADDER

DIAGRAM / FUNCTIONAL

DIAGRAM

YES

4 LOOP SCHEMATIC YES

5 INTER CONNECTING

DIAGRAM

YES

6 OPERATING / CONTROL

WRITE UP

YES

7 ALARM / SHUT DOWN

LIST7

YES

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8 WIRING DIAGRAM / INTER

CONNECTING PIPING

YES

9 START UP AND SHUT

DOWN WRITE UP

YES YES

10 START UP AND SHUT

DOWN INLET LOCK

DIAGRAM

YES YES

11 ALARM AND SHUTDOWN

LIST WITH SET POINT

YES YES

12 LOAD CONTROL PANEL

LAYOUT

YES

13 TERMINATION DIAGRAM,

PANEL WIRING DETAIL

YES

14 LOOP SCHEMATIC YES

15 INTER CONNECTING

DIAGRAM

YES

16 CABLE SCHEMATIC YES

17 BILL OF MATERIAL YES

18 TEST / INSPECTION

CERTIFICATE

YES

19 LIST OF RELIEF VALVES

WITH SETTINGS

YES

1.1.1 Document Distribution Schedule

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

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

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

1.1.5 Documents listed in Clause 1.2 below are to be submitted as hard bound indexed book containing the

following details in Twelve (12) copies & 2 AutoCAD software set and to be submitted within 4 weeks of

release note/dispatch of materials/ equipment from bidder's works.

1.2 Details to be included in Final Documents Books

1.2.1 Copy of P.O. and all amendments.

1.2.2 Copy of Purchase Requisition and all amendments.

1.2.3 Manufacturing Data Book containing all test certificates of components, raw materials, stage

manufacturing tests and inspections, final tests & inspection documents including welders' qualification

& welding procedure qualification, repairs & reworking carried out in shops. All raw material test

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certificates must be correlated to the P.O. Item No. & component to which they relate by clear notings

on the certificates.

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

1.2.5 All design calculations carried out by the bidder.

1.2.6 Final Drawing Index and all as-built drawings reduced to A3/ A4 size and wherever reduction is not

possible, full size copies duly folded and placed in plastic pockets.

1.2.7 Catalogues/leaflets of sub-bidders/suppliers of various bought out components highlighting the

components actually supplied correlated to P.O.Item Numbers.

1.2.8 Operating and maintenance instructions including lubrication schedules with details of suppliers for

procurement by OWNER for subsequent needs.

1.2.9 Release Note and Packing List.

1.2.10 Any other documents asked for in the Purchase Requisition.

1.2.11 All final drawings shall also be given to purchaser in digitized form on CD-ROM compatible to

AUTOCAD software (2 sets)

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ANNEXURE-V

M.R. COMPLIANCE SCHEDULE

ITEM: CNG COMPRESSOR

Bidder:

S. No. BIDDER REQUIREMENTS Compliance By Bidder (To Be Answered By Bidder)

1.0 Confirm compliance individually to following clauses of Job Specification.

SECTION: A

Clause no 1.0

Clause no 2.0

Clause no 3.0

Clause no 4.0

Clause no 5.0

Clause no 6.0

Clause no 7.0

Clause no 8.0

Clause no 9.0

Clause no 10.0

Clause no 12.0

Clause no 13.0

Clause no 14.0

Clause no 15.0

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

Guarantee Parameters (Annexure-I)

Mandatory Spares (Annexure-II)

Bidder Data Required (Annexure-V)

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

Material Requisition Compliance Schedule (Annexure-VI)

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

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Compressor Data Sheet

Engine Data Sheet

Inter cooler Data Sheet

Heat Exchanger Data sheet

Mass Flow Meter Data Sheet

Control Valves

Solenoid Valves

Self Actuated Pressure Control Valves

Pressure Relief Valve

Pressure Gauges

4.0 Confirm that following Documents have been enclosed with Bid.

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

Battery Limit (Interface) drawing/ information.

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

Utility requirement

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

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

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ANNEXURE – VI

EXPERIENCE RECORD PROFORMA

SR. NO DESCRIPTION INFORMATION OFFERED COMPRESSOR

INFORMATION OF EXISTING COMPRESSOR

REQUIREMENT AS PER TENDER Cap. 1200 sm3/h

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

Comp Manufacturing code API - 11P 2nd edition

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

Compressor operating RPM (max RPM - 1500)

Piston speed m/s

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

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

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

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3

PERFORMANCE OF COMPRESSOR

CASE - L

Performance of compressor at 14 kg/cm2 suction pr, 255 kg/cm2 discharge pr and 35 degree C suction temp

CASE - G GUARANTEED POINT:

Performance of compressor at 16 kg/cm2 suction, 255 kg/cm2 discharge pr and 35 ˚C suction temp

CASE -L

a) Capacity Sm3/h

CASE-G

CASE -L

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

CASE -L

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

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

CASE -L

d2) Power required for all fans including radiator fan of engine in Kw

CASE-G

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

Site Capacity of gas engine (max of bx1.1+d1+d2+e or Cx 1.05+d1 + d2 +e)

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

---- Piston rod : max design

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

--- Max cross head pin loading : Design '

--- Cross head pin loading :

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calculated at safety set pr condition

Guaranteed gas loss through rod deals ; sm3/h

Other information of compressor

a) Year of manufacturing of the compressor

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

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

4 Gas Engine Make and model Anticipated Life in running hours Compression ratio

Power (ISO power) & corresponding Max RPM

Power (ISO) and corresponding operating RPM

Site power (Kw) at operating RPM after deration

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

No sparking blower fan CSA approved Digital ignitions System Engine's protection system suitable for class 1, Group d, division 2

Governor make and type Operating air pressure for air starter

Free air consumption for per start of engine

Engine mounted Pressure switch, temperature switch , junction box, magnetic pick u p : Explosion proof type

Other information of gas engine

a) Year of manufacturing of the engine


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

5 PACKAGE Name of Packager Place of Packaging Name of Enclosure Manufacturer Palace of enclosure manufacturer

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

Make and model LEL detector - 2 nos each comp

Make and model fire detector - 2 nos each comp

2 no min 45 kg C02 cylinder with weighing arrangement

Volume of enclosure in m3

Nos of explosion proof tube light in each enclosure

Coupling Direct / V - belt

Mass flow meter to measure the Natural Gas consumption at packages inlet, package discharge and fuel consumption at Gas Engine inlet

Separators between inter stage of compressor

Other information of complete package

a) Year and place of manufacturing of the package


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

6 Gas inlet train Inlet relief valve Inlet-gas pressure gauge Non return valve Inlet duplex gas filter

Temporary suction filter after mail filter

Inlet manual isolation valve Inlet automatic isolation valve

Suction pr regulator : one PRV from 10/25 kg/cm2 compressor shall be designed for full range of pr from 14 to 19 kg/cm2

7 Gas recovery system

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

8 Gas Delivery system

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

KOD Coalescent filter PLC based Priority panel with full

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bore ball valve

Final gas outlet connection from priority panel 3/4" SS valves and 1" OD SS compression fittings

9 ESD system

10 Volume bottles / dampers at each compressor stage of compressor

Vessels Drainage system

11 Manual double isolation valve 12 Automatic valves 13 Heat exchanger 14 Code of construction API 11 P

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

16 Tube material SA-179

17 Piping between stages shall be continuous with flange connection

18 Gas recovery vessel provided

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

20 The size of the complete package

21 Chain pulley block and beam for chain pulley block

22 Acoustic and pulsation study 23 Acoustic enclosure for package 24 Instrumentation as indicated in TS

25 Human - machine interfacing unit (HMI)

26 String test as shop 27 Field trial run for 72 hours

28

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

29 Cabling - Double compression type cable glands and copper lugs

30 Junction box with metallic enclosure

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ANNEXURE-VII

Parameters required for SCADA

1. Hardware Details: Connector Type, Communication Standard, Communication port Pin details.

2. Communication Port Configuration: Baud Rate, data bits, stop bit, parity

3. Polling Constraints: Minimum time period between two consecutive poll cycles.

4. Protocol Details: Protocol name and message structure for different read / write

functions.

5. Function codes for reading digital and Analog inputs

6. Function code for writing analog values in the IED registers

7. List of parameters available in the IED which can be accessed from the IED through serial port.

8. Register address of each parameter in the IED.

A Sample of the details is given below for understanding:

PROTOCOL DETAILS:

Sr.No. DESCRIPTION Content/Details

1 Protocol MODBUS RTU 2 CONNECTION TYPE FCC -68 RJ45

3 Communication standard RS232D 4 Signals supplied Tx, Rx, GND 5 Baud Rate(Speed) 300, 600,1200,4800,9600,19200 6 Format Software configurable 7 Port Configuration Speed : 19,200 bps

Data Bits: 8 Bits Stop Bit : 1 Bit Parity : None

8 Min. Time period between consecutive Query

2 Sec.

• PORT PIN Details: • Example: RS232 Pin Details:

IED SCADA RJ45 1. GND 2. DTR 3. RTS 4. TX RX 5. RX TX 6. CTS

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7. DCR 8. DCD

• Function Code & Message Structure: Poll Format: Address 1 Byte Function 1 Byte Start Item 2 Byte 1.1 No. Item 2 Byte

Response Format: Address 1 Byte Function 1 Byte Length 1 Byte Date Item 1 4 Byte . . Date Item n 4 Byte � Function Code & Message Structure:

Function Code: 2 - Read Input Status Poll Format:

Address 1 Byte Function 1 Byte Start Item 2 Byte 1.2 No. Item 2 Byte

Response Format: Address 1 Byte Function 1 Byte Length 1 Byte Date Item 1 2 Byte . . Date Item n 2 Byte Memory Mapping, Data Type & Parameter Information: A) Digital Parameters :

Sr. No.

Description Address

1 Flow computer malfunction Alarm

8247

2 Mass Flow Low alarm 8245 3 Mass Flow High alarm 8246

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B) Analog Parameters:

Parameter Register details

Engineering Range and

Unit

GC Regis

ter Register Format

Density Kg/m3 (500-600)

8655-56

Float

Pressure 8657-58

Float

Temperature 8659-60

Float

Mass Flow Rate 8661-62

Float

Totalized mass flow

8663-64

Float

Yesterday’s Total Mass flow

8665-66

Float

Today's Total Mass Flow

8667-68

Float

Corrected volumetric Flow rate

8669-70

Float

Yesterday's Total corrected Volumetric Flow

8671-72

Float

Totalized Mass Flow at 6 AM (Snapshot of cumulative)

8673-74

Float

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ANNEXURE- VIII

CATALYTIC CONVERTER TECHNICAL SPECIFICATIONS

Type • Catalytic Converter for reduction of NOx, CO and THC from rich burn gas fired internal combustion engines.

Percentage Emissions Reduction Desired Nitrogen Oxides (NOx) 90% Carbon Monoxide (CO) 80% + Hydro Carbons (HC) 75% + Construction • A metal monolith supported catalyst.

• Corrosion resistant catalyst housing. Catalyst • Catalyst construction should be of stainless steel

foil honeycomb- like support for catalytic substance. Ceramic substrates will not be accepted.

• High cell density allowing min back pressure. Catalyst should be based on Platinum Group of Metals (PGM)

• MSDS of the offered catalyst should be provided. Catalyst Housing • Housing fabricated of mild steel

• Ports for installation of Sensors, Gauges and Thermo-couples (SS Bellows) to be provided on both ends to ease installation. Unused ports to be provided for emission sampling points.

• Sensors and back pressure monitoring to be provided.

• The housing should have open-able ports to remove the catalyst for cleaning.

• The hardware used should be of stainless steel. • The housing should also have an integral silencer

to offer Residential grade silencing. • The gasket material used in the housing should be

wire braided and suitable for over 500 degrees Celsius temperature.

Operating Guidelines (To be furnished by the supplier)

• Operating Temp range • Max sulphated ash allowed/type of lube oil

recommended • Max oxygen in the exhaust stream. • Life of the catalysts. • Maintenance program • Additional Backpressure on account of catalytic

converter. • Method of setting Air fuel ratio to achieve max

reduction. • Catalysts deactivators. • Washing procedure and percentage efficiency

reductions from washing. Engine Exhaust Monitoring • Onsite monitoring equipment must be available

with the supplier to set the Air fuel ratios and for monitoring of emissions.

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Other Requirements • The testing equipment should have facility to print report at site, for records.

• Bidder must provide details of the catalyst supplier and their details.

• Bidder should clearly indicate the operating life of the catalyst and its warranty coverage in case of drop in reduction efficiency.

• Bidder will be required to make periodic adjustments to air fuel ratio to get optimum reductions, and also provide efficiency report every 3 months during the warranty period.

Supplier Requirements • The supplier (or his principal) should be a basic manufacturer of Catalyst / Catalytic Converter and should not be just a trading house

• The supplier (or his principal) should have substantial experience in manufacturing of Catalytic Converters / Catalysts

• The supplier (or his principal) must have manufacturing base in India with capacity to manufacture the quoted catalysts.

• The supplier / manufacturer must have an in house test lab in India to measure the integrity / metal content of the catalyst

• The catalyst supplier should submit a copy of the test reports towards validation (testing) of the offered catalyst sample by Central Pollution Control Board approved lab (eg: ARAI) in India.

• The supplier must have installation references in India for stationary engine applications.

Make

• Air Shield • John Matthey

Page 59 of 129

1


CLIENT JOB NO. - DATASHEET- COMPRESSOR

TOTAL SHEETS 21

DOCUMENT NO 11 0290 02 09 03 002


REV. DATE DESCRIPTION PREP CHKD APPD

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DATASHEET-COMPRESSOR

SHEET 2 OF 21


1 GENERAL

2 PROJECT: PROCUREMENT OF CNG COMPRESSORS

3 OWNER: M/S GAIL GAS LIMITED SITE: MEERUT, DEWAS, KOTA & SONIPAT

4 SERVICE: COMPRESSOR FOR CNG MOTHER STATION

5 NO. REQD.: 16 DRIVER: GAS ENGINE

6 NOTE: ■ SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER □ INFORMATION

REQUIRED FROM VENDOR.

7 MANUFACTURER: MODEL NO.:

8 □ PLACE OF MANUFACTURE:

9 ■ NO. OF STAGES:

THREE. □ CYLINDER ARRANGEMENT:

10 CYLINDER LUBRICATION: □ LUBRICATED □ MINIMUM LUBRICATED □ NON

LUBRICATED

11 ■ DRIVER TYPE: GAS ENGINE

12 □ DRIVE: □V - BELTS (ANTI-STATIC TYPE) □DIRECT WITH

COUPLING

13 □ DIRECTION OF ROTATION (FACING DRIVEN END): □ CLOCKWISE □ COUNTER

CLOCKWISE

14 ■ SITE / INSTALLATION DATA

15 SITE DATA: AMBIENT TEMP. (0C): MAX: 48.0 MIN: 5

16 RELATIVE HUMIDITY (%): MAX: 90

17 ALTITUDE (M):115

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

19 INSTALLATION: ■OUTDOOR

20 ■ MOUNTED ON A COMMON SKID ALONGWITH DRIVER, ENCLOSED

INSIDE A ACOUSTIC ENCLOSURE

21 ■ ELECTRICAL AREA HAZARD:

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

23 APPLICABLE CODES AND STANDARDS

24 COMPRESSOR: API 11P, 2ND EDN./PISTON TRUNK

PIPING: ASME/ANSI B 31.3

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

GAS COOLER: API 11P /API 661

26 OIL COOLER: TEMA `C’. SOUND: 75 DBA @ 1M FROM ENCLOSURE

27 □AUX. ELECT. MOTORS:

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28 CONTROL PANEL & INSTRUMENTATION REFER:

29 UTILITIES DATA

30 □ Cooling Water (Not Available)

31 □ Type: □ Supply temperature (0C): □ Max return

temperature (0C):

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

(kg/cm²G):

33 □ Design pressure (kg/cm2A): □ Design temperature (0C):

34 □ Water Flow Rates (m3/hr)

35 □ Electricity

36 Auxiliary Motors: V Ph Hz

37 Oil Heaters: V Ph Hz

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

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

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

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

42 UPS: KVA, V Ph Hz

43 □ Total Utility Consumption

44 □ Cooling Water (Make UP) (m3 /hr)

45 □ Power (Auxiliaries) (kW)

46 □ Power (Heaters) (kW)

47 REMARKS:

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

49 □ CONSTRUCTION / DESIGN FEATURES

50 Nomenclature Unit Stage#1 Stage#2 Stage#3

51 Cylinders

52 No of Cylinders -

53 Single Acting (SA) / Double

Acting (DA)

54 Cylinder Bore / Stroke mm / mm

55 Rotational Speed RPM

56 Linear Average Piston

Speed

m/sec

57 Piston Displacement m3/ hr

58 Cylinder Liner (Yes / No)

59 Type of Cylinder Liner :

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Dry/Wet -

60 Clearance Pockets Yes / No

61 Max. Allow. Working

Pressure, Cylinder

kg/cm²a

62 Max./Min Allow. Working

Temp., Cylinder

0C

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

Temp.

kg/cm²a

64 Safety Valve Set Pressure,

Cylinder

kg/cm²a

65 Helium Test Pressure,

Cylinder

kg/cm²a

66 Hydrostatic Test Pressure,

Cylinder

kg/cm²a

67 Cylinder Jacket Cooling

Type As reqd.

68 Cooling Media, Cylinder

Jackets Water /AIR

69 Max. Allow. Working

Pressure, Cyl. Jacket

kg/cm²a

70 Hydrostatic Test Pressure,

Cyl. Jacket

kg/cm²a

71 Suction Nozzle

Size/Rating/Position

72 Discharge Nozzle

Size/Rating/Position

73 Suction Valve Number

74 Average gas Velocity m/sec

75 Discharge Valve Number

76 Average gas Velocity m/sec

77 Type of Suction valve -

78 Type of Discharge valve -

79 Suction Valve Unloaders

Yes / No

80 Clearance Pockets

Unloaders Type

81 Piston Rod Diameter mm

82 Rod Reversal at Crosshead Deg.

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Pin (min.)

83 Piston Rod Runout

Operating

84 Max. Allow. Rod Load

Comp.

kg

85 Tension kg

86 Rod Load Comp. kg

87 (Inertia Alone) Tension kg

88 Rod Load Rated Pr.

(Gas+Inertia) Comp.

kg

89 Tension kg

90 Rod Load at R.V Set Comp. kg

91 (Gas + inertia) Tension kg

92 Distance piece / Packing

93 Type of Packing

94 Packing Vent Connected to

##

95 Packing Cooling

96 Type of Distance Piece

97 Cyl. Side Compartment

Purged

98 Frame Side Compart.

Pressurised

99 Distance Piece purge gas

Pressure

mm H2O

100 Distance Piece purge gas

Flow

Nm3 /hr

101 Distance Piece Vent to Safe Height Safe Height Safe Height

102 Distance Piece Hydrostatic

Test Pressure

kg/cm²G

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

104 Frame

105 Frame Explosion proof Relief

device

106 Flame Arrestor Yes / No

107 Replaceable Crosshead

Shoes Yes / No

108 Crosshead Guide Integral /

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Separate

109 Maximum Frame Rating kW

110 Speed - Maximum/ Minimum rpm

111 □Lubrication Systems

112 Type of lube system Piping material

113 Carbon Steel

114 Main Oil Pump Driven By : Stainless Steel (all piping & valves Trims)

115 Standby Oil Pump, Driven By : Auxiliary oil tank

116 Hand Operated Prelube/Priming Pump:

Oil Grade :

117 Suction Strainer Lube Oil Consumption

118 Pressure Control Valve Main Pump Make : Model :

119 Level Sight Glass on the Crankcase Type : Material :

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

121 Size of Filter: Type : Material :

122 Oil Heater (if required).

123 Electric Heater with thermostat (Kw)

124 Thermostatic Valve

125 Type of Cylinder Lubrication Lubricator Equipped With :

126 Lubricator Type : Manzel or Equivalent . level sight glass

127 Single plunger per feed oil heater electric with thermostat

128 Divider blocks type. Electric Heater (Kw) (if required)

129 Lubricator Driven By : Auxiliary Oil Tank (if required)

130 Compressor Shaft Oil Grade :

131 Electric Motor KW Oil System Capacity: (min 150 Hrs.)

132 All tubing and valves in SS Oil Consumption rate

133 Double Ball Check valve on each

lubrication point

134 □Cooling System

135 □Static filled coolant system for

136 All Stage Cylinders □ 1 Stage Cylinder/s □ 2 Stage Cylinder/s □ 3 Stage Cylinder/s

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

138 All Piping prefabricated□ Material

139 □Atmospheric thermosyphon cooling system for


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

142 All Piping prefabricated. □ Material

143 □Forced Cooling Water System

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145 □Packings □ Oil Coolers □ Gas Coolers

146 □Including drains, Vents, flow & temp. Indicators, regulating & Isolation valves, complete piping

to provide one

147 □Common inlet and one common outlet connections for purchaser's interface terminated by a

flanged block valve

148 □Block valve.

149 □ Each isolatable circuit to be provided with thermal relief valve.

150 All Piping prefabricated. □ Material

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

152 All Stage Cylinders □ 1 Stage Cylinder/s □ 2 Stage Cylinder/s x 3 Stage Cylinder/s

153 □Packing□ Oil Coolers □ Gas Coolers

154 □Including drains, Vents, flow & temp. indicators, Temp. Control Valve, Regulating & Isolation

valves, complete piping

155 □Main circulating pumps with drivers & suction strainers □ Single Coolers

156 □Reservoir (Make Up) □ Heater (if required)

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

console.

158 □Material of piping:

159 □Type of coolant:

160 □Jacket cooling

161 □Gas Piping System

162 □Vendor's Supply Includes:□Suction Separator

163 □Pulsation suppression equipment as per ‘next’ page

164 □Suction Filter:

165 □Temporary Strainer on Compressor Suction

166 □Type of Strainer:

167 □ Relief Valves: on compressor □ suction □ Inter-stage □ on

compressor discharge

168 □Check Valve on Discharge Line (compressor valve design, and suction

line)

169 □Process Gas Coolers Complete With Manual Drain Valve

170 □Separators Complete With Manual/ Automatic Drain Values

171 □Process Gas Piping

172 □Supply starts at inlet flange of CNG PACKAGE

173 □Terminates after priority panel with isolation valve

174 □Materials:

175 □By-Pass Line Piping

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176 □Between 3rd stg. discharge and 1 st stg. suction

177 □Gas cooler

178 □Interconnecting Piping Between Packing Vents, PSV Relief terminating to Vent

Recovery System.

179 □Interconnecting piping between distance piece terminating to Vent Recovery

System upto package B/L

180 □Interconnecting piping between Drains terminating as a single point

181 □Interconnecting piping between Instrument Air terminating

182 □Pulsation Suppression Equipment

183 Stage #: Stage#1 Stage#2 Stage#3

184 Suction

185 Puls.

Equipment

Required

Yes/No

YES YES YES

186 Inlet Pressure

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

188 Inlet Nozzle

Size /

Rating/Position

189 Discharge

Nozzle Size /

Rating/Position

190 Design

Pressure

Kg/cm²a

191 Design

Temperature

0C

192 Volume

193 Material :

vessels

SA 516 Gr.60/70” SA 516 Gr.60/70” SA 516 Gr.60/70”

194 Internals

195 Corrosion

Allowance mm

3 3 3

196 Hydrostatic test

Pressure

kg/cm²g

1.3XMAWP 1.3XMAWP 1.3XMAWP

Page 67 of 129

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SHEET 9 OF 21

197 Discharge

198 Puls.

Equipment

Supplied

Yes/No

YES YES YES

199 Inlet Pressure

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

201 Inlet Nozzle

Size /

Rating/Position

202 Discharge

Nozzle Size /

Rating/Position

203 Design

Pressure

Kg/cm²a

204 Design

Temperature 0C

205 Volume

206 Material :

vessels

SA 516 Gr.60 SA 516 Gr.60 SA 516 Gr.60

207 Internals

208 Corrosion

Allowance mm

3 3 3

209 Hydrostatic test

Pressure

kg/cm²g

1.3XMAWP 1.3XMAWP 1.3XMAWP

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

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

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

213 Upstream / downstream Inter-stage

214 Performed By: □Vendor □ Any other agency having similar experience

215 Piping Mechanical Analysis

216 Performed By: □Vendor □ Any other agency having similar experience

217 □Automatic Drain Valves For Each Stage suction KOD

218 □Capacity Control

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

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

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SHEET 10 OF 21

221 □Interlock against loaded start

222 □ Automatic Control based on

223 □Suction Pressure□ Discharge Pressure □ Flow Manual Signal

224 □ Type of Actuator □ Actuation fluid to load □ Actuation fluid to unload

225 □ On Power / Actuation fluid failure : Compressor to □ Load □ Unload

226 □ At 0 % capacity through Valve Unloader, Compressor shall run

227 □ Continuously □ Maximum Hrs.

228 □ At 25 % capacity through Valve Unloader, Compressor shall run

229 □ Continuously □ Maximum Hrs.

230 □ At All other capacity, Compressor shall run continuosly

231 Vendor's scope Shall Include :

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

233 □ Intermediate Devices (Solenoid Valves | Pneumatic Relay / Valves)

234 □ Actuators

235 □ Recycle valves

236 □ Control Logic and System for Complete Capacity Control

237 □ Inter Connecting Tubing, Piping, Cabling & Wiring

238 □Protection against extended unloaded operation (Trip)

239 □valve unloaders are required as such Compressor shall start / stop at specified receiver

pressures.

240 □Purchaser's Interface

241 Type of

Interface

(Single

Point)

Size Rating Face Position/Location

242 Main Gas

Piping Inlet

243 Main Gas

Piping

Outlet

244 Relief

Valves

discharge

245 Distance

Piece Vent

246 Packing

Vent

247 C.W. Inlet

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SHEET 11 OF 21

248 C.W. Outlet

249 N2 Inlet

Supply

250 N2 Vent

(Safe

location)

251 Drains

252 MATERIALS

253 Cylinder Materials

254 Stage 1 Stage 2 Stage 3 Stage

255 Cylinder NODAL CAST

IRON / F.S

NODAL CAST

IRON / F.S

NODAL CAST IRON / F.S

256 Liner

257 Piston

258 Piston Rings PTFE/PEEK PTFE/PEEK PTFE/PEEK

259 Rider Rings PTFE/PEEK PTFE/PEEK PTFE/PEEK

260 Piston Rod Forged steel/ AISI

4142

Forged steel/ AISI

4142

Forged steel/ AISI 4142

261 Packings Rings

262 Valve Seats

263 Valve Stops

264 Valve Rings /

Plates

CS /plate should be

MT or PEEK.”

CS /plate should be

MT or PEEK.”

CS /plate should be MT or

PEEK.”

265 Valve Springs SS SS SS

266 Cylinder Head

267 Motion Work Materials :

268 Material /

ASTM Grades

269 Top Cover □ Cast □ Fabricated

270 Crankcase □ Cast □Fabricated

271 Crankshaft □ Die Forged □ Open Forged □

Cast

272 Connecting Rods □ Die Forged □Open Forged □

Cast

273 Cross heads □ Cast □ Fabricated □

274 Cross Head Shoes

275 Cross Head Guide □ Cast □ Fabricated □

276 Main Bearings Type □ Split Precision □ Bush

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SHEET 12 OF 21

277 Cross Head Pin Bearings

Type

□ Split Precision □ Bush

278 Connecting Rod Bearings

Type

□ Split Precision □ Bush

279 Cross Head Pin Type □ Split Precision □ Bush

280 Notes :

281 Each package shall be provided with two number drain lines, one from Suction KOD and second

drain as common drain line from intermediate and discharge KOD routed to drain vessels

through gas recovery vessels

282 □CONTROLS & INSTRUMENTATION

283 □ AC Power On/Off Switch With Indication Lamp

284 □ Control Power On/Off Switch With Indication Lamp YES

285 □ Selector Switch A/M Station For L/O Pump Motor

286 □ Selector Switch A/M Station For CW Pump Motor

287 □ Emergency Stop Push Button

288 □ Start Push Button For Air Compressor Motor

289 □ Emergency Stop Push Button for Main Motor

290 □ Lamp Test Push Button

291 □Alarm/Trip Acknowledge /Reset Push Botton

292 □ Frame Oil Heater ON (Indicating lamp)

293 □ Lubricator Oil Heater ON (Indicating lamp)

294 □ Engine Interlock Against Loaded Start

295 □ Engine Interlock Against Start Without Prelubrication

296 Notes :

297 Minimum required indications, alarms & trips are shown herewith. Bidder shall provide any

additional instrumentation for safe operation.

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

include in his

299 Scope includes the necessary hardware for the same.

300 All inter-stage / discharge and suction scrubber shall be provided with high / low level operated

auto drain solenoid valves.

301 INSPECTION AND TESTS

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

303 ■ Cylinder and Liner ■ Piston

304 ■ Crankshaft ■ Connecting Rod

305 ■ Pressure Vessels ■ Heat Exchangers

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

Page 71 of 129

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SHEET 13 OF 21

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

308 ■ Magnaflux Testing for components: Crankshaft, Piston Rod, Connecting Rod.

309 ■ Dye Penetration Testing for : Cylinder, Liner, Piston.

310 Required Observed Witnessed

311 ■ Shop inspection by Purchaser

during manufacture

□ □ □

312 ■ Cylinder Hydrostatic ■ □ ■

313 ■ Cylinder Pressure Test By Helium □ □ □

314 ■ Hydrostatic Test of Pressure

Vessels

■ □ ■

315 ■ Hydrostatic Test of Distance Piece. ■ ■ □

316 ■ Leak Proof Test of Crank case for

24 Hrs

■ □ ■

317 ■ Barring over to check clearance /

Rod run out

■ □ ■

318 ■ Mech. Running Test with shop

Driver ( 4 Hours min.)

■ □ ■

319 ■ Performance Test at Works as per

IS 5456/PTC9/BS 726 (*).

■ □ ■

320 ■ Partial Stripping and internal

inspection

□ □ □

321 ■ Functional/Continuity Tests - Control

Panel.

■ □ □

322 ■ Field Trial Run 72 Hrs. under

Vendor's Supervision (Package)

■ □ ■

323 ■ Valve Leak Test □ □ □

324 ■ Lube Oil Console Run test □ □ □

325 ■ Closed Circuit C.W. System test □ □ □

326 *: During package performance test

327 Test Certificates Required For:

328 ■ Auxiliary Motor & Pumps ■ Safety Relief Valves

329 ■ Safety Switches ■Solenoid Valves

330 □ WEIGHTS

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

332 Maximum erection weight Kg. approx.

333 Maximum maintenance weight Kg. approx.

334 Gear Box Kg. approx.

335 Driver Kg. approx.

Page 72 of 129

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SHEET 14 OF 21

336 SCOPE OF SUPPLY

337 ■ Compressor Assembly complete with frame, cylinders, cross head etc.

338 ■ Motion work lubrication system

339 ■ Cylinder and packing lubrication system

340 ■ Cooling system

341 ■ Process Gas system

342 ■ Local instrumentation

343 ■ Local Gauge Board

344 ■ Local Control Panel ■ PLC Panel ■ Man Machine Interface located in Control

Room

345 ■ Main driver (Gas Engine)

346 ■Barring Device : □ Manual □Electric . pneumatic

347 ■ Flywheel

348 □ V-Belts with Pulley

349 □Couplings

350 ■ Driver Compressor

351 ■ Guards for moving parts ■

352 ■ Base plate Common for Compressor and Driver

353 ■ Fabricated Steel skid Common for compressor, driver and accessories

354 ■Ladders and platforms

355 ■ Special Tools - One Set for each package

356 ■ Anchor Bolts for Complete Package

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

358 ■ Supports For Cylinders & Auxiliaries, Prefabricated & fitted in the Package

359 ■ Commissioning Spares, erection and commissioning spares

360 ■ Mandatory Spares as specified in the Job Specification

361 ■Train Torsion Analysis Study and Report

362 ■Acoustic Simulation Study & Report

363 ■ Vendor Data as specified

364 NOTE : Refer checklist for scope of supply

Page 73 of 129

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SHEET 15 OF 21

DATA SHEET- INSTRUMENTATION & CONTROLS FOR COMPRESSOR

INDICATION ANNUNCIATION & PRE ALARM

TRIP & A/V ALARM ANNUN.

S. NO DESCRIPTION

GU

AG

E –

LOC

AL

GU

AG

E

BO

AR

D

IND

ICA

TOR

LO

CA

L P

AN

EL

(PLC

) DIS

PLA

Y

LOW

LO

CAL

PA

NE

L D

ISP

LAY

HIG

H L

OC

AL P

AN

EL

DIS

PLA

Y (P

LC)

LOW

–LO

CAL

PA

NE

L -

PLC

-DIS

PLA

Y

HIG

H L

OC

AL P

AN

EL

PLC

- DIS

PLA

Y

1 Frame Oil Sump/Reservoir Level

■ yes

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

■ yes ■ yes ■ yes ■ yes

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

metal Temp.

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

13 Aux. Oil

14 Lub. Oil Supply Pr. to Electric Motor Driver

15 Lub. Oil return from Electric Motor Driver

16 Elec. Motor bearing metal temp.

17 Coolant System 18 Each cylinder CW outlet

temp.

19 Inter/After/Oil Cooler CW outlet temp.

20 CW Supply header flow 21 Sight Flow CW return each

cylinder, Cooler & Header ■ yes

22 For Closed Circuit Cooling

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

24 Coolant standby pump disch. Pr.

25 Coolant stand by pump start 26 Coolant supply header Pr. 27 Coolant supply header temp

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SHEET 16 OF 21



S. NO DESCRIPTION

GU

AG

E –

LOC

AL

GU

AG

E

BO

AR

D

IND

ICA

TOR

LO

CA

L P

AN

EL

(PLC

) DIS

PLA

Y

LOW

LO

CAL

PA

NE

L D

ISP

LAY

HIG

H L

OC

AL P

AN

EL

DIS

PLA

Y (P

LC)

LOW

–LO

CAL

PA

NE

L -

PLC

-DIS

PLA

Y

HIG

H L

OC

AL P

AN

EL

PLC

- DIS

PLA

Y

28 Coolant cooler Outlet Temp. ■ yes 29 Coolant reservoir Level ■ yes ■ yes 30 Cylinder Coolant Outlet temp. 31 For Static/Thermosyphon

System

32 Cylinder Coolant Outlet temp. 33 Diff. Pr. Across packing

coolant filter

34 Process Gas System 35 Each stage inlet Pressure 36 Each stage inlet temp. 37 Each stage Outlet Pressure ■ yes ■ yes ■ yes ■ yes 38 Each stage Outlet temp. ■ yes ■ yes ■ yes ■ yes 39 After Cooler Gas Outlet temp. ■ yes ■ yes ■ yes ■ yes 40 Ist stage pressure low / high ■ yes ■ yes ■ yes ■ yes ■ yes ■ yes 41 Cylinder Packing Vent

Pressure

42 Suction Pressure, low ■ yes ■ yes ■ yes 43 Blow Down vessel level ■ yes 44 Piston Rod Drop Indicator 45 Distance piece diff. Purge

pressure

46 Common process parameters 47 Common machine

parameters

48 Blow Down vessel Pressure ■ yes ■ yes ■ yes 49 Vibration Measurement ■ yes

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

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SHEET 17 OF 21

1 OPERATING CONDITIONS (EACH MACHINE) / PERFORMANCE

2 Operating Case: SUCTION PRESSURE: 14 kg/cm² g

3 Units Stage 1 Stage 2 Stage 3

4 ■ Gas Handled (See Analysis)

5 □ Corrosion Due to NONE NONE NONE

6 Suction Conditions

7 ■ Pressure (@ Vendor's

B/L)

Kg/cm² g 13

8 ■Temp. (+@ Vendor's

B/L)

0C 35

9 Discharge Conditions (Vendor's Battery Limit:

10 ■Pressure (@ Vendor's B/L Kg/cm² g 256

11 Pressure @ Cylinder Flg. Kg/cm² g

12 Temp.,Adiabatic @Cyl.

Flange

0C <150 < 150 < 150

13 Temp.,Actual @Cyl.Flange 0C

14 Temp.,After AfterCooler 0C < 52

15 Cp/Cv Ratio

16 Compr. Factor (Z2 ) or (Z

avg )

17 Operating Characteristics

18 Capacity (wet) SM3 /Hr

19 Mfr's Rated Cap. (Design) (No -ve tol.)

20 Actual Inlet Flow (wet) AM3 /Hr

21 Specific Gravity

22 V Belt / Coupling Losses kW

23 Volumetric Efficiency %

24 Valve Lift Suction / mm / mm

25 Valve Lift Area Suction/

Discharge

mm2 / mm2

26 Valve Velocity m/sec

27 Speed RPM

28 Compressor Shaft Power

KW

29 Power consumed @ RV Set Pr.

KW

30 Driver Power KW 31 Guaranteed Point 32 GAS ANALYSIS- Gas Composition attached in techanical specification.

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SHEET 18 OF 21







7 ■ Pressure (@ Vendor's

B/L)

Kg/cm² g 13


B/L)

0C 35





Flange

0C <150 < 150 < 150



15 Cp/Cv Ratio

16 Compr. Factor (Z2 ) or (Z

avg )





21 Specific Gravity





Discharge

mm2 / mm2


27 Speed RPM

28 Compressor Shaft Power

KW

29 Power consumed @ RV

Set Pr.

KW

30 Driver Power KW 31 Guaranteed Point 32 GAS ANALYSIS- Gas Composition attached in techanical specification.

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SHEET 19 OF 21







7 ■ Pressure (@ Vendor's B/L) Kg/cm² g 19


B/L)

0C 35





Flange

0C <150 < 150 < 150



15 Cp/Cv Ratio

16 Compr. Factor (Z2 ) or (Z avg

)





21 Specific Gravity





Discharge

mm2 / mm2


27 Speed RPM

28 Compressor Shaft Power KW

29 Power consumed @ RV Set

Pr.

KW

30 Driver Power KW

31 Guaranteed Point

32 GAS ANALYSIS - Gas Composition attached in Techanical specification.

Page 78 of 129

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SHEET 20 OF 21

DATA SHEET INTER COOLER

1 GENERAL


3 OWNER: GAIL GAS LIMITED SITE: MEERUT,DEWAS,KOTA

& SONIPAT

4 Item No. : Service : Intercooler / Aftercooler for Compressor Package

5 NOTE: ■ SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER □ INFORMATION

REQUIRED FROM VENDOR.

6 □ Manufacturer: Type: □ Forced Draft □Induced Draft

7 □Bundle Size: m x m x m Bundles/Section Number

of Units:

8 Bundles/Unit: In Parallel / Series Section Size:

9 Surface/Bundle: m² Bare Tube: m² Section/Unit:

10 Surface/Unit: m² Bare Tube: m² Plot Area/Unit:

11 PERFORMANCE (Of One Unit)

12 Heat Exchanged: kcal/hr MTD (Corrected): 0C

13 Transfer Rate: kcal/hr m² 0C (Finned Surface) (Bare

Surface)

14 TUBE SIDE

15 Fluid Circulated GAS Gravity: Liquid

API SG @ 15.4EC

16 Total Entering Gas kg/hr Enthalpy / Latent

Heat kcal/kg

17 Operating Temperature In: Out: Fouling Resistance hr m² 0C/kcal

18 Operating Pressure Passes / Bundle kg/cm²

19 AIR SIDE

20 Temperature In:47 Out: Altitude m

21 Total Flow/Unit kg/hr Static Pressure kg/cm²

22 Quantity/Fan kg/hr Power/Fan kW

23 Face Velocity m/sec Power/Unit kW

24 CONSTRUCTION (Each Bundle)

25 Design Pressure: kg/cm²g Test Pressure: kg/cm²g Design

Temperature: 0C

26 Code Requirements:

27 Type of Tubing: Tube Material: SA 179 Fin Material: Al

28 Tube Bare Tubes (no's) : No. of rows: O.D.

BWG/Thk Length

29 Fins : Spacing /inch. O.D. Root Dia

Page 79 of 129

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SHEET 21 OF 21

Thickness:

30 Header Type: Plug / Cover No. of Splits: Material :

31 Plugs/Gaskets Side Frame : C.S. Inside Zinc Protected

32 Nozzles In : Out :

33 Couplings Vent: Drain :

34 CONSTRUCTION (Each section)

35 Structure CS Sec./Gr. No. Design Wind

Load : kgf/m

36 Plenum Chamber CS inside Zinc Protected Type :

37 Fans No. Dia. RPM Mfr.

38 Blades Material : No./Fan Pitch Angle(Design) :

39 Hubs Material : Pitch : Autovariable / Adjustable (No. )

40 Louvers Material : Type : Mfr.

41 Weights kg Each Section(Dry) : Full of Water:

42 Each Bundle (Dry) : Full of Water:

43 APPLICABLE SPECIFICATIONS API Standard 661

44 REMARKS 1. Air coolers shall be designed for 20% excess capacity than required normally.

45 Exchanger shall be designed with air side temperature of 47.5 0C.

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

Page 80 of 129

1


CLIENT JOB NO. - DATASHEET GAS ENGINE

TOTAL SHEETS 12

DOCUMENT NO 11 0290 02 09 03 004



Page 81 of 129

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DATASHEET GAS ENGINE

SHEET 2 OF 12

DATASHEET-GAS ENGINE

1 GENERAL


3 OWNER: M/S GAIL GAS LIMITED SITE: MEERUT, DEWAS,KOTA & SONIPAT

4 SERVICE: DRIVER FOR CNG COMPRESSOR

5 NO. REQD. 16

6 NOTE: ■ SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER □

INFORMATION REQUIRED FROM VENDOR.

7 SITE / INSTALLATION DATA

8 SITE CONDITIONS:

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

SYSTEM.

10 SITE DATA: AMBIENT TEMP. (0C): MAX:48 MIN: 5

11 RELATIVE HUMIDITY (%): MAX: 90

12 ALTITUDE (M): 115

13 ELECTRICAL AREA CLASSIFICATION

14 CLASS 1, DIVISION I, GROUP D AS PER NEC

15 ZONE 1 GROUP IIA/IIB AS PER IS/IEC Engine Ignition system as per Class 1 Div 2 or Zone 2 Group 2D

16 □ UTILITY DATA

17 COOLING WATER

18 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 POWER

24 ELECTRIC SUPPLY: AC / DC VOLTS HZ

25 □ APPLICABLE CODES & STANDARDS

26 ■ NOISE SPECIFICATION: ■ APPLICABLE TO M/C MAX. 75 DBA @ 1.0 M OUTSIDE THE ACOUSTIC ENCLOSURE

27 ■ EXHAUST GAS EMISSION: - STATUTORY REQUIRMENTS AS PER CENTRAL POLLUTION CONTROL BOARD

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SHEET 3 OF 12

28 ■LISTING/APPROVAL OF ENGINE REQUIRED FROM: ■ UL/FM □ TAC

29 ■ AIR RECEIVER FOR STARTING AIR SYSTEM ASME SEC-VIII DIV 1 □ AIR

COMPRESSOR FOR STARTING AIR SYSTEM MANUFACTURER'S STD.

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 EQUIPMENT

33 ■RECIPROCATING GAS COMPRESSOR

34 ■ DUTY: INTERMITTENT

35 PROBABLE PERIOD FOR CONTINUOUS RUNNING: 20 HOURS WITH FREQUENT

STARTS AND STOPS

36 ■DURATION OF MAX. LOAD: 20 HOURS

37 □ 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 @ RPM

41 □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-BELTS

45 CONSTRUCTION FEATURES

46 □ MANUFACTURER: □ ENGINE MODEL:

47 ■TYPE OF ENGINE: FOUR-STROKE ENGINE COOLING: ■ WATER

COOLED

48 □TURBO-CHARGED WITH CHARGE AIR COOLER □ NORMALLY ASPIRATED

49 □NO. OF CYLINDERS: □ CYLINDER ARRANGEMENT:

50 □ BORE/STROKE (MM/MM): □COMPRESSION RATIO:

51 □ SPEED (RPM): □ MEAN PISTON SPEED

(M/SEC.):

52 □PERFORMANCE

53 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 PROVISION FOR ONE HOUR WITHIN A PERIOD OF 12 HOURS OF

Page 83 of 129

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SHEET 4 OF 12

OPERATION).

55 RATED ENGINE POWER AT SITE CONDITIONS GUARANTEED, NO NEGATIVE

TOLERANCE):

KW @ RPM

56 (USING THE ESSENTIAL DEPENDENT AUXILIARIES AND WITH 10 % OVERLOAD

PROVISION FOR ONE HOUR WITHIN A PERIOD OF 12 HOURS OF OPERATION).

57 MIN. ENGINE SITE POWER AT, WHICH ENGINE CAN BE OPERATED CONTINUOUSLY.

KW @ RPM

58 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 COOLERS

61 ESSENTIAL DEPENDENT AUXILIARIES ARE:

62 ENGINE SHAFT DRIVEN RADIATOR FAN: KW

63 ENGINE SHAFT DRIVEN CW PUMP: KW

64 ENGINE SHAFT MAIN LO PUM: KW

65 □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 A

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SHEET 5 OF 12

74 ATMOSPHERIC TEMP. 0C

75 RELATIVE HUMIDITY %

76 CHARGE AIR & COOLANT

TEMP 0C

77 □SPEED GOVERNING SYSTEM

78 TYPE: □SINGLE SPEED □MULTIPLE SPEED □ALL

SPEED (VARIABLE SPEED)

79 GOVERNOR TYPE: □ELECTRONIC □ELECTRO HYDRAULIC □

MECHANICAL

80 ■MAKE: WOODWARD □MODEL:

81 GOVERNOR CONTROL MECHANISM: □ MANUAL □

REMOTE

82 □STARTING SYSTEM

83 ■METHOD OF STARTING: AUTOMATIC

84 ■ METHOD OF STOPPING: AUTOMATIC

85 □TYPE OF COLD STARTING: (CONSIDERING MIN. AMBIENT TEMP. 1.70C)

86 ■TYPE OF STARTING SYSTEM: AIR STARTING THROUGH ENGINE

MOUNTED PNEUMATIC MOTOR

87 REMARKS:

88 1. BIDDER SHALL ENGINEER AND SUPPLY THE COMPLETE AIR STARTING MECHANISM INCLUDING 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: RECIPROCATING

92 □ RATED CAPACITY (AM3 /HR AT INLET CONDITIONS):

93 □DISCHARGE PRESSURE (KG/CM²G):

94 □BKW: □RPM:

95 ■ AIR COMPRESSOR DRIVEN BY: ELECTRIC MOTOR

96 □ DRIVER RATING □ KW: □RPM: ■□VOLTS/N/HZ.:

230 / SINGLE/ 50

97 ■ AIR RECEIVER WITH PRESSURE GAUGE, RELIEF VALVE & MANUAL DRAIN VALVE:

98 ■ START-STOP SWITCH FOR COMPRESSOR: AUTOMATIC

99 □ NO. OF AIR RECEIVER: ONE /TWO CAPACITY OF EACH AIR

RECEIVER (M3):

100 NOTE: TOTAL AIR RECEIVER CAPACITY SHALL BE SUITABLE FOR ATLEAST SIX (6) CONSECUTIVE STARTS.

101 ■COOLING SYSTEM

102 TYPE: CLOSED CIRCUIT COOLING

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SHEET 6 OF 12

103 WATER PUMP DRIVEN BY: ENGINE

104 COOLANT CIRCUIT PIPING WITH TEMP. CONTROL & MAKE-UP TANK.

105 HEAT EXCHANGER WITH ANCHOR/FOUNDATION BOLTS: AIR COOLED EXCHANGER

106 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

PUMP

111 ■FRAME LUBRICATION SYSTEM

112 ■TYPE: FORCE FEED LUBRICATION INCLUDING VALVES, OIL PUMP & PIPING

113 □OIL COOLER TYPE: □ □AIR COOLED □WATER

COOLED

114 □ OIL FILTERS □SELF CLEANING □DUPLEX □ PAPER

CARTRIDGE

115 □PRELUBE OIL PUMP DRIVEN BY (IF REQUIRED):

116 □ PRELUBRICATION □MANUAL □AUTOMATIC

117 □ 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 CRANKCASE

122 ■AIR INLET SYSTEM

123 ■SUCTION AIR FILTER ■AIR INLET DUCTING / PIPING / MANIFOLDS

□□ INLET SILENCER

124 EXPANSION BELLOWS (IF REQUUIRED) & ALL SUPPORTS / HANGERS

125 ■ENGINE EXHAUST SYSTEM

126 ■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 PIPING

128 □PROVIDED AS ABOVE □YES

□NO

129 CONTROLS & INSTRUMENTATION

130 ELECTRIC SUPPLY:

131 LAMPS: ± HZ: ± V: AC/DC: N:

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132 ALARAM CIRCUIT: ± HZ: ± V: AC/DC: N:

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

138 ■ CONTROL POWER ON/OFF SWITCH WITH INDICATION LAMP

139 ■ START SWITCH WITH INDICATION YES

140 ■ START/STOP PUSH BUTTON FOR AUX. DRIVE MOTOR

141 ■ EMERGENCY STOP PUSH BUTTON

142 ■ LAMP TEST PUSH BUTTON

143 ■ ALARM/TRIP ACKNOWLEDGE /RESET PUSH BOTTON YES

144 ■ LUBRICATING OIL HEATER `ON' INDICATING LAMP (IF PROVIDED)

145 ■ MOTOR INTERLOCK AGAINST START WITHOUT PRELUBRICATION

146

147 NOTE: VENDOR TO PROVIDE CONTACT/SIGNAL FOR EXECUTION IN DCS.

148 □MATERIAL

149 CHARGE AIR COOLER SHELL: TUBES:

150 WATER COOLER SHELL: TUBES:

151 AIR COOLER SHELL: TUBES:

152 AIR RECEIVER

153

154 INSPECTION AND TESTING

155 WITNESS

156 □ STAGE INSPECTION DURING MANUFACTURE

157 ■ FULL LOAD TEST AT ENGINE MANUFACTURER'S SHOPS PER ISO

(PERFORMANCE TEST)

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

AS PER ISO

159 ■ FULL LOAD TEST FOR 4 HOURS OF ENGINE-GENERATOR SET WITH ALL

AUXILIARIES & 1HR AT FULL LOAD AT SITE.

160 ■ NO LOAD MECHANICAL RUN TEST AT PACKAGER'S/DRIVEN EQPT. MFR. SHOP

161 ■ VENDOR'S STANDARD MECHANICAL RUN TEST (FOR ALL ENGINE)

162 INSPECTION/TESTING WITNESSED BY: □ OTHERS ■M/S GAIL GAS OR

THEIR REPRESENTATIVE

163 □WEIGHTS

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164 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 DATA

169 EXPECTED PERIOD OF RUNNING BETWEEN TOP OVERHAULS:

HOURS

170 EXPECTED PERIOD OF RUNNING BETWEEN MAIN OVERHAULS:

HOURS

171 THE TYPE AND GRADE OF LUBRICATING OIL RECOMMENDED:

172 LUBE OIL CONSUMPTION (KG/HR)/

(LITRES/HR)

173 CHANGE OF LUBRICATING OIL AFTER: HOURS

174 ■SCOPE OF SUPPLY / WORK

175 ENGINE WITH LUBRICATION SYSTEM, GOVERNING SYSTEM, FUEL SYSTEM,

COOLING SYSTEM AND STARTING SYSTEM AS SPECIFIED

176 SUCTION AIR FILTER WITH SUCTIONPIPING

177 INSTRUMENTS AND CONTROLS AS SPECIFIED

178 INLET AND EXHAUST MANIFOLDS, EXHAUST PIPING WITH FILLINGS, BENDS AND

INSULATION

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

BELLOWS AND COMPLETE WITH EXHAUST PIPING FROM

180 MANIFOLD TO OUTSIDE SHED WITH FITTINGS AND INSULATION.

181 FLYWHEEL WITH BARRING DEVICE

182 GUARDS FOR MOVING PARTS

183 COUPLING FOR ENGINE - DRIVEN EQUIPMENT

184 BASE PLATE FOR ENGINE & DRIVEN EQUIPMENT

185 MANDATORY SPARES AS PER ORDER

186 ERECTION AND COMMISSIONING SPARES

187 TORSIONAL ANALYSIS REPORT ON ENGINE

188 REFER TECHNICAL SPECIFICATION FOR COMPLETE SCOPE OF SUPPLY

189 FOUNDATION/ ANCHOR BOLTS

190 ANTI VIBRATION PADS

191 FIRST FILL OF LUBRICATING OIL AND COOLANT.

192 SEPERATE ACCOUSTIC ENCLOSURE WITH VENTILATION FAN

194 REMARKS

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SHEET 9 OF 12

DATA SHEET- INSTRUMENTATION & CONTROLS GAS ENGINE



S. NO DESCRIPTION

GU

AG

E –

LOC

AL

GU

AG

E B

OAR

D

IND

ICA

TOR

LO

CA

L P

AN

EL

(PLC

) D

ISP

LAY

LOW

LO

CAL

P

AN

EL

DIS

PLA

Y

HIG

H L

OC

AL

PA

NE

L D

ISP

LAY

(P

LC)

LOW

–LO

CAL

P

AN

EL

-PLC

-D

ISP

LAY

HIG

H L

OC

AL

PA

NE

L P

LC-

DIS

PLA

Y

1 RESERVOIR OIL LEVEL ■ yes ■ yes, switch

2 RESERVOIR TEMP. ■ yes ■ yes ■ yes 3 MAIN L/O PUMP DISCH.

PR. ■ yes ■ yes

■ yes

4 LUB OIL FILTER DIFF. PR. 5 L/O SUPPLY HEADER

TEMP.

6 OIL COOLER OIL OUTLET

TEMP.

7 STAND BY PUMP START 8 COOLING SYSTEM 9 OIL COOLER CW OUTLET

TEMP.

10 CW SUPPLY HEADER FLOW

11 SIGHT FLOW CW RETURN EACH COOLER & HEADER

12 LOCAL MOUNT TSV ON EACH ISOLATABLE CIRCUIT

13 WATER LEVEL IN MAKE UP WATER TANK / RADIATOR

■ yes ■ yes

14 ENGINE JACKET C.W SUPPLY TEMP.

■ yes ■ yes

15 ENGINE JACKET C.W RETURN TEMP. (INLET OF RADIATOR)

■ yes ■ yes ■ yes

16 COOLANT MAIN PUMP DISCH. PR.

■ yes

17 COOLANT SUPPLY HEADER PR.

■ yes

18 COOLANT SUPPLY HEADER TEMP

19 COOLANT COOLER OUTLET TEMP.

■ yes

20 COOLANT RESERVOIR LEVEL

■ yes ■ yes ■ yes, switch

21 STARTING SYSTEM 22 AIR RECIEVER

PRESSURE ■ yes ■ yes

23 INLET AIR SYSTEM

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SHEET 10 OF 12



S. NO DESCRIPTION

GU

AG

E –

LOC

AL

GU

AG

E B

OAR

D

IND

ICA

TOR

LO

CA

L P

AN

EL

(PLC

) D

ISP

LAY

LOW

LO

CAL

P

AN

EL

DIS

PLA

Y

HIG

H L

OC

AL

PA

NE

L D

ISP

LAY

(P

LC)

LOW

–LO

CAL

P

AN

EL

-PLC

-D

ISP

LAY

HIG

H L

OC

AL

PA

NE

L P

LC-

DIS

PLA

Y

24 INLET AIR FILTER DIFFERENTIAL PRESSURE

■ yes

25 BOOST AIR (TURBO CHARGER) DISCHARGE PRESSURE (IF REQUIRED

26 CHARGE AIR COOLER OUTLET AIR TEMP. (IF REQUIRED)

27 MISCELLANEOUS 28 ENGINE/MAIN ELECTRIC

MOTOR VIBRATIONS ■ yes

29 ENGINE/ MAIN MOTOR SPEED

■ yes ■ yes

30 START STOP BUTTON 31 ENGINE OVERSPEED ■ yes 32 ENGINE /MAIN MOTOR

FAILS TO START ■ yes

33 FEUL GAS / ELECTRIC POWER CONSUMPTION INDICATION AND CUMMULATIVE

■ yes

34 TACHO-HOUR METER ■ yes ■ yes

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SHEET 11 OF 12

DATASHEET-INTERCOOLERS

1 GENERAL 2 PROJECT: PROCUREMENT OF CNG COMPRESSORS 3 OWNER: M/S GAIL GAS LIMITED SITE:MEERUT,DEWAS,KOTA &

SONIPAT 4 Item No. : Service : Intercooler / Aftercooler for Compressor Package 5 NOTE: ■ SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER □ INFORMATION

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

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

10 Surface/Unit: m² Bare Tube: m² Plot Area/Unit: 11 PERFORMANCE (Of One Unit) 12 Heat Exchanged: kcal/hr MTD (Corrected):

0C 13 Transfer Rate: kcal/hr m² 0C (Finned Surface) (Bare

Surface) 14 TUBE SIDE 15 Fluid Circulated GAS Gravity: Liquid API SG @ 15.4EC

16 Total Entering Gas kg/hr Enthalpy / Latent Heat kcal/kg

17 Operating Temperature In: Out: Fouling Resistance hr m² 0C/kcal

18 Operating Pressure Passes / Bundle kg/cm² 19 AIR SIDE 20 Temperature In:47 Out: Altitude m 21 Total Flow/Unit kg/hr Static Pressure kg/cm² 22 Quantity/Fan kg/hr Power/Fan kW 23 Face Velocity m/sec Power/Unit kW 24 CONSTRUCTION (Each Bundle) 25 Design Pressure: kg/cm²g Test Pressure: kg/cm²g Design

Temperature: 0C 26 Code Requirements: 27 Type of Tubing: Tube Material: SA 179 Fin Material: Al 28 Tube Bare Tubes (no's) : No. of rows: O.D. BWG/Thk

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

30 Header Type: Plug / Cover No. of Splits: Material :

31 Plugs/Gaskets Side Frame : C.S. Inside Zinc Protected 32 Nozzles In : Out : 33 Couplings Vent: Drain : 34 CONSTRUCTION (Each section) 35 Structure CS Sec./Gr. No. Design Wind Load

: kgf/m 36 Plenum Chamber CS inside Zinc Protected Type : 37 Fans No. Dia. RPM Mfr. 38 Blades Material : No./Fan Pitch Angle(Design) :

39 Hubs Material : Pitch : Autovariable / Adjustable (No. )

40 Louvers Material : Type : Mfr.

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SHEET 12 OF 12

41 Weights kg Each Section(Dry) : Full of Water:

42 Each Bundle (Dry) : Full of Water:

43 APPLICABLE SPECIFICATIONS API Standard 661 44 REMARKS 1. Air coolers shall be designed for 20% excess capacity than required normally.

45 Exchanger shall be designed with air side temperature of 47.5 0C.

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

Page 92 of 129

1

GAL GAS LIMITED CITY GAS DISTRIBUTION

CLIENT JOB NO. - DATA SHEET - HEAT EXCHANGER

TOTAL SHEETS 03

DOCUMENT NO 11 0290 02 09 03 005

A 01.07.09 ISSUED FOR DARFT TENDER MT PKS HM


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Data Sheet - Heat Exchangers

SHEET 2 OF 3

28 Plug/Gas Side Frame: C.S.Inside Zinc

DATA SHEET - HEAT EXCHANGERS

1 Service: Intercooler / After cooler for Compressor Package

2 NOTE: Scope option / information specified by Purchaser * Information Required From Vendor

3 Manufacturer Type Forced

Draft Induced Draft

4 Bundle / Unit : m x m x m

Bundles / Section Number of Units

5 Bundles/Unit:

In Parallel / Series Section Size

6 Surface / Bundle: m2

Bare tube: m2

Section / Unit

7 Surface / Unit: m2 bare Tube: m2 Plot Area / Unit 8 Performance (of

one unit)

9 Heat Exchanged: kcal/hr

MTD (Corrected:0C

10 Transfer Rate: kcal/hr/m2°C

(Finned Surface) (Bare Surface)

11 Tube Side

12 Fluid Circulated: Gas Gravity: Liquid [email protected]

13 Total Entering Gas kg/hr

Enthalpy/Latent Heat kcal/kg

14 Operating /Temperature In: Out:

Fouling Resistance hrm2°C/kcal

15 Operating Pressure Passes/Bundle kg/cm2

16 Air Side 17 Temperat

ure In: 48 Out: Altitude (m): 155

18 Total Flow/Unit Kg/hr

Static Pressure kg/cm2

19 Quantity / Fan kg/hr Power / Fan kW 20 Face Velocity

m/sec Power / Unit kW

21 Construction (Each Bundle) 22 Design Pressure :

kg/cm2g Test Pressure :

kg/cm2g Design Temperature : 0°C

23 Code Requirements:

24 Type of Tubing: Tube material : CS (SA-179)

Fin material: AI

25 Bare Tubes (nos.) No. of rows: O.D BWG/Thk Length

36 Fins: Spacing/inch.OD

Root Dia Thickness

27 Header Type: Plug/Cover

No. of Splits:

Material:

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Data Sheet - Heat Exchangers

SHEET 3 OF 3

kets Protected 29 Nozzles In: Out: 30 Coupling

s Vent Drain

31 Construction (each Station) 32 Structure CS Sec/Gr.N

o. Design Wind Load: kgf/m

33 Plenum Chamber Cs inside Zinc Protected

Type

34 Fans No. Dia RPM Mfr. 35 Blades Materia

l No/Fan Pitch Angle

(Design) 36 Hubs Materia

l Pitch L Auto variable / Adjustable (No.)

37 Louvers Material

Type Mfr.

38 Weights kg Each Section (Dry):

Full of Water

39 Each Bundle (Dry) Full of Water

40 Applicable Specifications API Standard 11P

41 Remarks 1. Air coolers should be designed for 10% excess capacity than required normally.

42 Exchanger should be designed with air side temperature of 48°C

43 Separate data sheet should be filled by the bidder for each service i.e. Inter cooler and after cooler.

Page 95 of 129

GAIL GAS LIMITED CITY GAS DISTRIBUTION PROJECT

DEWAS

CLIENT JOB NO 0290 TECHNICAL SPECIFICATION FOR

UPS SYSTEM TOTAL SHEETS 18

DOCUMENT NO 11 0290 01 10 02 006

0 07/07/09 ISSUED FOR APPROVAL GK SB SB

A 29/06/09 ISSUED FOR IDC GK SB SB

REV DATE DESCRIPTION PREP CHK APPR

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Document No. Rev

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TECHNICAL SPECIFICATION FOR

UPS SYSTEM Page 2 of 18

TABLE OF CONTENTS

1.0 SCOPE 2.0 CODES AND STANDERDS 3.0 GENERAL REQUIREMENTS 4.0 SITE CONDITIONS 5.0 TECHINICAL REQUIREMENTS 6.0 INSPECTION, TESTING AND ACCEPTANCE 7.0 SITE ACCEPTANCE TESTS 8.0 PACKING AND DESPATCH

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1.0 SCOPE

The scope of this specification is to define the requirements of design, manufacture, testing. Packing and Despatch of static Uninterrupted Power Supply (UPS) system.

2.0 CODES AND STANDARDS

2.1 The equipment shall comply with the requirements of latest revision of following standards issued by BIS (Bureau of Indian standards) unless other wise specified:

IS: 5 Colours for ready mixed paints and enamels

IS: 1248 Direct acting indicating analogue electrical measuring instruments and (Part I. 2, 4 and 9) their accessories. IS:2147 Degree of protection provided by enclosures for low voltage switchgear

and control gear. IS: 3700 Essential ratings and characteristics of semi-conductor devices. (Part I to II ) IS: 3715 Letter symbols for semi-conducting devices (Part 1 to 4 ) IS: 4411 Code for designation of semi-conductor devices. IS: 5001 Guide for preparation of drawings of semiconductor devices and (Part 1 & 2 ) integrated Circuits. IS: 5469 Code of practice for the use of semi-conductor junction devices. (Part 1 & 3 ) IS: 7204 Stabilized power supplies D.C. output (Part 1 & 4 ) IS: 12021 Control transformers for switchgear and control gear for voltages not exceeding 1000V AC IS: 13314 Solid state inverters run from storage batteries IS: 13703 Low voltage fuses for voltage not exceeding (Part 1 & 4) 1000V AC or 1500V DC IS: 13947 Specification for low voltage switchgear and (Part4/Sec-I) control gear.

2.2 In case of imported equipments standards of the country of origin shall be applicable if these standards are equivalent or stringent than the applicable Indian standards.

2.3 The equipment shall also conform to the provisions of Indian Electricity rules and other statutory

regulations currently) in force in the country.

2.4 In case Indian standards are not available for any equipment, standards issued by IEC /BS /VDE /IEEE / NEMA or equivalent agency shall be applicable.

2.5 In case of any contradiction between various referred standards/specifications/data sheet and

statutory regulations, the following order of priority shall govern: - Statutory regulations - Data sheets - Job specification - This specification - Codes and standards

3.0 GENERAL REQUIREMENTS

3.1 The offered equipment shall be brand new with state of art technology and proven field track record. No. prototype shall be offered.

3.2 Vendor shall ensure availability of spare parts and maintenance support services for the offered

equipment at least for 15 years from the date of supply.

3.3 Vendor shall give a notice of at least one year to the end user of equipment and JPK before

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phasing out the product/spares to enable the end user for placement of order for spares and services.

3.4 The UPS system shall be an integrated system comprising static rectifiers, battery, static

inverters, static switches, manual by pass switch, AC distribution board, voltage stabilizer in bypass, isolating and protection devices and all other equipment/accessories required for completeness of the system whether specifically mentioned herein or not, but necessary for completeness and satisfactory performance of the system.

3.5 The UPS system shall be suitable to feed all loads connected to the output which are primarily

instruments, DIDS (DCS), computers, disc drives and other SMPS equipment leading to high crest factor of the load.

3.6 The inverter shall be transistorized (IGBT) type or with the latest proven technology. All

components shall be of a high quality and reliability that satisfy with the requirements of a secure AC power to vital equipment with respect to performance, controlling, monitoring and safeguarding function in continuously operating petrochemical process units, petroleum refineries, gas processing facilities, utility and other miscellaneous industrial plants. Components shall be capable of withstanding the thermal and dynamic stresses resulting from internal and external short circuits and switching surges etc.

3.7 The design of the UPS shall be such as to minimize the risk of short circuits and shall ensure

human and operational safety. 3.8 The vendor shall be responsible for design, engineering and manufacturing of the complete

system to fully meet the intent and requirements of this specification and enclosed data sheets. Selection, sizing and suitability of all equipment and components used for UPS system shall be vendor’s responsibility.

3.9 The UPS shall be single phase or three phase system as indicated in the data sheets. 3.10 The batteries shall meet the requirement of battery Data Sheet/ battery specifications attached

with the bid document. 4.0 SITE CONDITIONS

The UPS system shall be suitable for installation and satisfactory operation in a closed substation with restricted natural air ventilation in tropical. Humid and corrosive atmosphere. The UPS system shall be designed to operate under site conditions as specified in the data sheet. If not specifically mentioned therein, design ambient temperature of 40°C and altitude not exceeding 1000M above MSL shall be considered for the UPS.

5.0 TECHNICAL REQUIREMENTS 5.1 INPUT POWER SUPPLY 5.1.1 The UPS shall be suitable for input power supply as defined in the data sheet. If not specified

therein the UPS shall be suitable for the following input power supply. Voltage : 415 ± 10% Frequency : 50Hz ± 5%

In addition to above variations, the input voltage may be subject to transient variations comprising voltage dip to 20% of normal voltage motor start-up and voltage interruption during short circuit as well as frequency variations due to large motor start up. UPS system shall be designed to operate satisfactorily while deriving the input power from an emergency diesel generator set.

UPS system shall also operate satisfactorily on input power supply having:

- the ratio of negative to the positive sequence components not exceeding 5% and

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- total harmonic distortion of not more than 5%.

Total Harmonic Distortion is the ration in percentage of r.m.s. value of the harmonic content to the r.m.s. value of the fundamental component of alternating quantity.

5.1.2 The incoming power supply to UPS will be provided by 2 Nos. feeder. One feeder shall feed the

rectifier(s) while other shall supply power to stabilized bypass supply. 5.2 UPS CONFIGURATION AND OPERATIONAL REQUIREMENTS

The UPS system shall have the following basic configurations as specified in data sheet and drawings:

5.2.1 PARALLEL REDUNDANT UPS WITH BYPASS (REFER FIG. 1)

In UPS system having the configuration two sets of rectifiers and inverters shall be provided. Under normal conditions, when AC mains power is available, both the rectifiers shall operate in parallel and supply DC power for float/rapid charging the battery and simultaneously to inverters. In case of failure in one rectifier, the other rectifier shall feed the complete load and the battery without any interruption. In case of incoming supply failure of failure of both rectifiers the battery shall feed the inverters without any interruption. Each rectifier shall be designed for simultaneously feeding complete inverter load and float/rapid charging of the battery to its rated capacity. Each rectifier shall be equipped with ‘On Line’ automatic as well as manual charging facility.

5.2.2 SINGLE UPS WITH BYPASS (REFER FIG. 2)

In UPS system having this configuration a single rectifier and inverter shall be provided. Under normal conditions when AC mains power is available, the rectifier shall simultaneously feed DC power to inverter as well as for float/rapid charging of the battery. The AC supply to loads shall be fed from inverter output. In case of any fault of the inverter, the load shall be automatically transferred to stabilized bypass supply and retransfer of load from stabilized bypass supply [0 the inverter shall be possible in auto as well as in manual mode.

In case of AC input power failure or battery charger failure. the battery shall supply power to inverter without any interruption. The charger shall be designed for simultaneously feeding complete inverter load and for float/rapid charging the battery to its rated capacity. Charger shall he equipped with 'On Line' automatic as well as manual charging facility.

5.2.3 In all UPS configurations, the facility for uninterrupted manual transfer in either direction through static switches shall also be provided.

5.2.4 For ease of maintenance, it shall be possible to isolate inverters and static switches from load

through manually operated make before break switches. In case of large rating UPS, where it is not possible to provide one power switch with make before break feature, combination of breakers with the control scheme having make before break logic may be provided which ensures momentary paralleling before tripping of selected breaker.

5.3 UPS DESIGN AND PERFORMANCE REQUIREMENTS 5.3.1 Incoming AC supply shall be converted to DC through three phase full were controlled rectifiers.

The rectifiers shall operate according to the constant voltage current limiting principle and shall incorporate a” Soft Start” feature to gradually accept load on initial energizing.

5.3.2 The rectifier section of the UPS system shall be capable of precise regulation to prevent damage

to the battery. The output voltage of rectifier’s DC bus without the battery shall be stabilized to within ± 1 % of set value during load variation between 0 to 100% of the rectifiers and specified mains input supply voltage variation.

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5.3.3 Suitable protection shall be provided in the control circuits to guard against instability of phase

controlled rectifiers due to electrical oscillations which may be present in the input supply as caused by emergency DG set.

5.3.4 The UPS system including the stabilized by-pass shall be galvanically isolated from input power

supply system by providing double wound transformers. All transformers shall be natural air cooled, dry type suitable for location inside the panel. All rectifiers shall also have a double wound transformer at its input.

5.3.5 An RFI filter shall be provided. The performance of UPS system shall not get affected or in any

way e degraded by the use of portable radio transmitter receiver in the vicinity of the UPS system and or UPS room.

5.3.6 Transient/surge protection circuit shall be provided in the input circuit to rectifiers to protect the

UPS from surges & voltage spikes. 5.3.7 The UPS system shall be designed to draw power mains supply at a minimum power factor of

0.85 while working at rated load in normal operating UPS configuration. 5.3.8 The UPS shall be provided with automatic sequence and power walk in circuit(s) with time delay

of upto 15 sec. such that the rectifiers and inverters can start operating automatically when incoming AC power is restored allowing the UPS to be loaded automatically.

5.3.9 Facility for initial charging of batteries shall also be provided. The inverters may be disconnected

during initial charging of the battery. 5.3.10 For battery sizing, the following factors shall be considered unless specified otherwise in the data

sheet: a. Load Power Factor of 0.8 b. Minimum ambient temperature as specified in Data sheet. c. Inverter rated KVA x Rated load p. f. Battery Current = -------------------------------------------------------------- Inverter Efficiency* x End cell voltage x No. of cell * at 50% load on each inverter for parallel redundant UPS d. Aging factor of 0.8

e. Back up time of 60 minutes in case of mains power failure unless specified otherwise in data sheet.

f. Minimum end cell voltage for lead acid/VRLA battery 1.85 V per cell and 1.0 V per cell for Ni-Cd battery

g. Battery state of charge factor of 0.95

5.3.11 The rectifiers/chargers shall be designed to completely charge the Load acid and Nickel cadmium batteries in a maximum time of 10 hours after complete discharge. Facilities shall be provided to initiate battery rapid charge operation by manual & automatic means. An auto charging sequence should be provided for the rapid and float charging of the battery up to 90% of rated Ampere hours within duration of 24 hours and to 100% within 4 days. In addition to above, the charging shall be transferred from rapid to float mode after a preset time adjustable through 0-24 hours timer as back up protection against over charging.

5.3.12 The rectifiers shall be sized based on the maximum inverter input load when inverter is delivering

its rated output at 0.8 p.f. lagging and recharge the battery to nominal rated capacity of the battery. The DC load imposed by the inverters shall be considered under the most severe operating conditions where only one rectifier is operating but the UPS load is equally shared by all the inverters. The rating of each rectifier shall be not less than the value calculated as follows:

For Lead Acid Batteries = Inverter input current + 0.14 Ah (10 hr.Rating of the battery) For Nickel- Cadmium Batteries = Inverter input current +0.2Ah (5hr. Rating of the battery) For VRLA Batteries = Inverter input current +0.2Ah (10 hr. Rating of the battery)

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Rated KVA capacity of UPS X Load power factor Where Inverter input current = ------------------------------------------------------------ Battery charging voltage X Inverter efficiency 5.3.13 The DC rectifiers shall sense the battery charging current and adjust the DC bus voltage to

maintain the charging current to present level. A separate current limit circuit shall also be provided for adjustment of battery current. The rectifiers shall be protected against reverse battery connection at DC link voltage bus. Subsequent to a discharge cycle when battery is connected to rectifier, the battery current shall be monitored, controlled and limited to set value automatically irrespective of the inverter input current.

5.3.14 The battery may be taken out of service for maintenance, during which period is shall be possible

for the inverter to continue operation by drawing power from the rectifier. Ripple content at the DC link shall not exceed 2% even with battery disconnected.

5.3.15 Battery/ D.C. link shall be provided with a sensitive earth leakage protection. 5.3.16 The invertor shall be of the current limiting type ( short circuit proof ) and have nominal output

voltage and frequency as specified in the data sheet. The invertor output voltage and frequency shall not exceed the operational tolerances, as measured at the output terminals of the unit during the following conditions of UPS loading.

- Load variations between 0-100% of the rated output of UPS - Load power factor over the range of 0.7 lagging to unity. - Load current waveform having a relative harmonic content varying between. Zero and 50% the latter waveform having a crest factor not exceeding 2.5 and Individual harmonics not exceeding the following values: 3rd harmonic - 44% of fundamental 5th harmonic - 33% of fundamental 7th harmonic - 18% of fundamental 9th harmonic - 7% of fundamental 11th harmonic - 10% of fundamental

The Relative harmonic content is the ratio of the r.m.s. value of the harmonic content to the r.m.s. value of the total non-sinosoidal periodic waveform i.e. relative harmonic content =

rms value of the fundamental component of current or voltage √[1- (-----------------------------------------------------------------------------)²] rms value of total waveform of current or voltage DC input voltages over the range corresponding to battery rapid charge and battery discharge

operation during the specified discharge times.

The UPS output voltage waveform shall be sinusoidal with a relative harmonic content not exceeding 5% under linear load conditions, and not exceeding 15% under the non-linear load conditions specified above.

5.3.17 The inverter shall control the output voltage of the UPS such as to maintain synchronism with the

mains bypass voltage during variations in mains frequency up to the limits specified.

During variations in mains frequency exceeding these limits, the inverter shall revert to internal frequency control.

5.3.18 It shall be possible to vary the inverter output voltage steplessly within ± 5% of the specified

output voltage. This adjustment shall be possible to be made when the inverter is in operation. 5.3.19 The steady state output voltage and frequency ( free running) variation of inverters shall not

exceed ± 1 % from the set value for specified input power supply conditions from no load to full

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load condition and load power factor variation from 0.7 lag to 1.0. 5.3.20 The UPS system shall be able to operate satisfactorily on rated loads (in KVA) with power factors

in the range of 0.7 lag to 1.0. The overall efficiency of the UPS system shall not be less than 80% at rated load and 0.8 p.f.

5.3.21 The UPS shall have capacity to deliver a minimum overload of 125% for 10 minutes and 150%

for 10 sec. UPS shall be provided with current limit to avoid excessive loading beyond its permissible overload withstand capability.

5.3.22 The inverters shall be ‘phase locked’ to the stabilized bypass power supply as long as stabilized

bypass supply frequency remain within ± 4% of nominal. When bypass supply frequency variation exceeds the above limits, the inverters shall be delinked from mains. Free running frequency tolerance limit shall not exceed ± 1%. Facility shall also be provided for adjustment of range of synchronizing frequency.

5.3.23 Unless otherwise specified, the UPS system output voltage variation shall not exceed ± 10% and

complete recovery to normal steady state shall be within 0.1 Sec. The phase angle disturbance shall be less than 120 ± 3% in case of 3 phase inverter. The above requirement shall be complied for following transient disturbances.

a) 100% step load and unload (For single UPS and hot stand by UPS) b) 50% step load ( For parallel redundant UPS) c) Momentary interruption in power supply d) Load transfer to stabilized bypass supply

e) Complete load transfer to other healthy inverter when one of the two parallel inverters develop a fault.

5.3.24 For 3 phase UPS system, the maximum output voltage and angle variation between the phases

should not exceed 6% and 3 degrees respectively even under the condition of 100% unbalanced loading of the 3 phase output.

5.3.25 UPS system shall be suitable both for floating output or earthing of one leg/ star point in case of

single phase/ three phase system respectively. 5.3.26 The stabilized bypass supply shall be designed to regulate the output voltage within± 2% of the

rated voltage over complete range of load from no load to full load and for specified input supply voltage variation. The type of Voltage stabilizer in stabilized bypass supply shall be as indicated in data sheet.

5.3.27 The stabilized bypass supply shall have a continuous current rating equivalent to the rated output

of the UPS unit and be capable of conducting a current ten times the rated output for the duration more than the fault clearing time of the type of fuse provided. The load transfer devices shall comprise of continuously rated static elements in both inverter and stabilized bypass supply.

5.3.28 Adequately rated static switches in required number & configuration shall be provided in the

inverter(s) output and stabilized bypass supply to ensure positive isolation of faulty inverter section such that the other inverter and bypass circuits do not feed into the fault leading to under voltage trip. The short time rating of all the static switches shall be at least 10 times the rated output for the duration more than the fault clearing time of the type of fuse provided.

5.3.29 Facility shall be provided too manually and automatically initiate transfer of the load from

inverters to the stabilized bypass supply and from stabilized bypass supply to the inverters. Under voltage and over voltage sensing levels to initiate transfer shall be adjustable. The maximum transfer time between inverters and bypass supply shall not exceed 4 msec and 20 msec in synchronous and asynchronous mode respectively.

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5.3.30 The criteria for load transfer: A) Load transfer from inverter to the stabilized bypass supply shall be as follows: a) The load transfer shall only be possible when:

- the stabilized bypass output voltage is within ± 5% of rated UPS output voltage and - the mains bypass frequency is within ± 4 %. b) Auto-transfer of the load from inverter to stabilized bypass supply shall be initiated when:

- the inverter output voltage drops below 95% of nominal output voltage under steady

state condition and/or if the inverter output voltage falls below 90% of the nominal value under transient conditions.

OR - The inverter output voltage exceeds 105% of the nominal output voltage under steady

state condition and /or if the inverter output voltage reaches 110% of the nominal value under transient conditions.

OR - the inverter output current exceed it’s tolerable limits. B) Retransfer of load from stabilized bypass supply to the invertor shall be as follows:

a) The load transfer shall be possible when-

- The invertor output voltage is within ± 5% of nominal output voltage for more than 5 sec. and

- Inverter output and stabilized bypass supply are synchronized Retransfer of load from stabilized by pass to the inverter shall be done manually only unless otherwise specified in the data sheet. If automatic retransfer of load to the inverter is specified in the data sheet, then the retransfer of load to the invertor shall be inhibited following four automatic transfers of load to stabilized by pass within a period of 5 minutes.

5.3.31 All breakers shall be adequately rated for continuous rating as well as breaking capacity as

applicable. Paralleling of breaker/switch/contactor poles to achieve the required current rating is not acceptable. All output isolating device shall be double pole type.

5.3.32 All electronic power devices including thyristor, transistors (IGBTs), diodes etc. shall be rated

under operating conditions for approximately 200% of the maximum current carried by the device. All other electrical components such as transformers, reactors, breakers, contactors, switches, bus bars etc, shall be rated for at least 125% of the maximum required rating. No electronic device shall be subjected to PIV greater than 50% of its rated value.

5.3.33 All the thyristor, power transistors, diodes and other electronic devices of UPS shall be protected

with high speed semiconductor fuses. I²t co-ordination between fuse and semi-conducting power devices shall be ensured.

5.3.34 The outgoing circuits of ACDB shall be protected by semiconductor fuses. Each inverter shall be

designed to clear a fault in any of the branch circuits upto a maximum rating of 25 % of the system capacity without the assistance of the stabilized bypass supply. In case of any fault in branch circuits, the load connected to the healthy circuits shall not get affected. The fault clearing time shall be less than 4 m/sec.

5.3.35 All PCBs shall be provided with a transparent epoxy coating for environmental protection and

tropicalisation. They shall be suitably located away from heat sources.

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5.3.36 All electronic control and monitoring printed circuit cards shall be installed in standardized electronic equipment frames and shall be fitted with suitable means for easy removal. The frames shall incorporate guides for PCB's to facilitate correct insertion of PCB's and shall allow access to the wiring side of the connectors All PCBs shall be placed in a manner to avoid replacement of a PCB by a wrong spare PCB. Monitoring points shall be provided on each of the PCB's and the PCB shall be firmly clamped in position so that vibration or long usage do not result in loose contacts. Failure of each PCB shall be indicated by visual alarms. Visual fault diagnostics shall preferably identify faults upto various sections in the card.

5.3.37 Forced ventilation of pane!, if provided, shall be supplemented by 100% redundant fans. In

normal operation, normal & redundant fans shall run together. The power supply for the fans shall be tapped from the inverter output. However, the rating of the UPS as specified in the data sheet shall be the net output of UPS after deducting power consumption for fans etc. However in case of non-operation of 50 %. of running fans the UPS output shall not be affected. The fans shall be arranged to facilitate removal of faulty fan for maintenance without requiring system shutdown.

5.3.38 Maximum noise level from UPS system all meter distance. under rated load with all normal

cooling fans shall not exceed 60 dBA 5.4 CONSTRUCTION 5.4.1 Rectifier/charger and inverter. Stabilized bypass supply and static switch sections shall be

suitably housed in sheet steel panels complete with all interconnections. UPS panels, ACDB and cell booster enclosures shall be fabricated from structural/CRCA sheet

steel The frames shall be fabricated by using minimum 2mm thick CRCA sheet steel while the doors and covers shall be made from 1.6mm thick CRCA sheet steel Wherever required suitable stiffeners shal1 be provided.

The panels shall be free standing. fitted with suitable louvers for ventilation and cooling fans as

required. Hinged doors shall be provided at the front and back with dust tight gaskets. Interpanel sheet steel barriers shall be provided. The enclosure shall provide mll11mUm IP-31 degree of protection, if not specified otherwise in the data sheet. The maximum and minimum operating height of the switches shall be 1800 mm and 300 mm respectively.

5.4.2 Power cables shall be with aluminum / copper conductors and control cables shall be with

copper conductors. All the cable connections shall be from bottom and front of the panel, if not specified otherwise in the data sheet. A removable bolted gland plate shall be provided along with single compression type nickel plated brass cable glands for external cable connections. Clamp type terminals shall be used for Connection of all wires upto 10 mm2. Bolted type terminals suitable for cable lugs shall be provided for wire size above this. Tinned copper lugs for all external connections shall be provided with the panels.

5.4.3 Bus bars shall be used in all power circuits which are rated above 100 Amp. Copper conductor

PVC insulated cables or wires of 660V grade shall be used for power circuits rated less than 100 Amp. Bus bars shall be colour coded and live parts shall be shrouded to ensure complete safety to personnel intending routine inspection by opening the panel doors. All the equipment inside the panel and on the doors shall have suitable name plate and device tag numbers as per the schematic diagram. All wires shall be ferruled and terminals shall be numbered.

5.4.4 MCCBs and load break power switches shall be mounted inside the panel. The control switches

shall be rotary type, mounted all the door and shall be externally operable. An 11 W CFL lamp controlled through a door switch shall be provided for illumination in each panel. All instruments shall be analogue /digital switchboard type, back connected, 72 x 72 mm. square( Analogue type) of reputed make. Analogue instruments' scale shall have red mark indicating maximum permissible operating rating. Separate test terminals shall be provided for measuring and testing of the equipment to check the performance.

5.4.5 A suitably sized earth bus shall be provided at the bottom of the panels including ACDB running

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through the panels line up with provision for earth connection at both ends to purchaser's main earth grid. The minimum size of earth bus shall be 25 x 3 mm2 copper (or equivalent aluminum). All potential free metallic parts of various equipment shall be earthed suitably to ensure safety.

5.4.6 All panels shall be of same height so as to form a panel lineup which shall have good aesthetic

appearance. 5.4.7 Inside the panels, the controls connections shall be done with 660V grade PVC insulated wires

having stranded copper conductors. 1.5 mm2 size wire shall normally be used for circuits with control fuse rating of 10 Amp. or less. For control circuit having fuse of t6 Amps., 2.5 mm2 size wire shall be used, Control wiring for electronic circuits shall be through flat ribbon cable or through copper wire minimum of 0.5 mm dia.

5.4.8 All control wiring shall preferably be enclosed in plastic channels or otherwise neatly bunched

together. Each wire shall be identified at both ends by PVC ferrules. Ferruling of wires shall be as per relevant IS.

5.4.9 All metal surfaces shall be thoroughly cleaned and de-greased to remove mill scale, rust, grease

and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The under·-surface shall be made free from all imperfections before undertaking the finished coat.

5.4.10 After preparation of the under-surface, the panels shall be spray painted with two coats of epoxy-

based final paint or shall be powder-coated. Spray painted finished panels shall be dried in stoving ovens in a dust-free atmosphere. Panel finish shall be free from imperfections like pinholes, orange peels, runoff paint, etc. The vendor shall furnish the painting procedure along with the bids.

5.5 CELL BOOSTER 5.5.1 Cell booster shall be suitable for charging one to six cells within a time duration as specified at

C1.5.3.12. It shall be suitable for charging not only the new cells before being introduced to the battery hank but also any treatment to be given to the individual weak cells. Quantity of such boosters shall be as defined in the MR. Cell booster shall be suitable for 240 V ± 10%,50 Hz ± 3 % SPN input power supply" Cell booster output voltage shall be in the range of 0-18V and 0-12V for Lead Acid and Nickel Cadmium batteries respectively. Cell booster shall be sized as under:

For Lead Acid battery = 0.14 x Ah of cell ( 10 hr. Ratting of the cell) For VRLA battery = 0.2 x Ah of cell ( 10 hr. Ratting of the cell) For Ni-Cd battery = 0.2 x Ah of cell ( 5 hr. Ratting of the cell) Cell booster shall have heavy duty switch fuse or MCCB on AC incomer and DC output, AC

voltmeter, DC ammeter and voltmeter, indicating lamp for AC/ DC power ON. The output voltage and current of cell booster shall have manual control using a suitably rated variac or a full wave controlled rectifier bridge. Suitable interlock shall be provided so as to ensure that the variac controlled rectifier is at its minimum position while switching on the cell booster. Cell booster shall be portable type with wheels. Each cell booster shall be supplied with 5 m long flexible copper conductor. PVC insulated and braided cable for AC incomer power supply and DC output connection to the battery.

5.6 A.C. DISTRIBUTION BOARD

Sheet steel enclosed AC distribution board shall be provided as part of the complete package. It shall accommodate AC feeders as indicated in the data sheet. The distribution board shall be floor mounted, fixed type with compartmentalized construction unless otherwise indicated in the data sheet. It shall be possible to operate the switches without opening the doors. Switches shall be provided with door interlock. Vertical cable alley of minimum 200mm width with suitable supports shall be provided for the termination of outgoing cables. Suitable supports shall be

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provided for supporting incoming and outgoing cables. All outgoing switches shall be air insulated load break type Fuses on outgoing feeders shall be fast acting semiconductor type and cable entry shall be from bottom. The gland plate of the distribution board shall be non-magnetic type where single core cables are used as specified in the data sheet. Cable glands shall he of brass and single compression type and cable lugs shall be of tinned copper.

5.7 ALARM, CONTROL, INDICATION AND METERING REQUIREMENTS

If not specified otherwise in the data sheets, following schedule shall be followed for alarm, control, indication and annunciation. Any additional devices/features considered necessary for reliable operation and maintenance shall also be included in various panels and same shall be highlighted separately. An illuminated one line diagram indicating operational status shall be provided on the front of the panel. Metering, indications, audio-visual alarm shall be provided. Parameters/ information indicated shall be available in LCD panel or by other means directly or indirectly.

5.7.1 METERING 5.7.1.1 Rectifier a) Incoming line voltage ( For all the three phases) b) Input line currents (For all the three phases) c) D.C. voltage at each rectifier output. d) Battery current. 5.7.1.2 Inverters a) AC voltage at each inverter output (AC voltages for 3 phase inverter) b) AC current at each inverter output (AC currents for 3 phase inverter) c) Frequency meter at each inverter output 5.7.1.3 Stabilized bypass supply a) Frequency meter for incoming supply. b) Voltmeter with selector switch for incoming supply. c) Ammeter with selector switch for incoming supply. 5.7.1.4 ACDB Following shall be provided for each of the ACDB incomers: a) Voltmeter (voltmeter selector switch shall also be provided for 3 phase inverter). b) Ammeter (ammeter selector switch shall also be provided for 3 phase inverter). c) Power factor meter. 5.7.2 Indications

(All indication lamps shall be provided with series resistors. Clustered/Jumbo LED's of minimum l0mm dia. may be provided in place of lamps subject to their having at least equal illuminance.)

5.7.2.1a) AC mains ‘ON’ – Rectifier. b) AC mains ‘ON’ – By pass. 5.7.2.2 Rectifiers (for each rectifier) a) Rectifier output ‘ON’ b) Battery on float charge c) Battery on rapid charge 5.7.2.3 Inverters (for each inverter)

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a) DC input ‘ON’ b) Load on inverter. c) Inverter synchronized with mains. 5.7.2.4 Load on bypass. 5.7.3 AUDIO-VISUAL ALARM (separately for each circuit) 5.7.3.1a) Mains failure b) Battery charger failure c) Battery fault d) Inverter temperature high e) Low voltage from inverter f) Load on by pass g) Inverter overloaded h) All power fuse failures 5.7.3.2 2 Nos. changeover contacts shall be wired to the terminal strip. 1 no. for common remote alarm

of UPS fault’ in owner’s panel and 1 no. for ‘load on bypass supply’ annunciation. 5.7.4 CONTROLS a) All the switches for starting, shut down and testing sequence.

b) Primary input circuit breakers for feeding chargers, bypass line and de bus from battery including backup protection.

c) Inverter ON/OFF switch (to initiate inverter operation) d) Static switch transfer test Push Button.

5.8 RELIABILITY

All necessary care shall be taken in selection, design, manufacture, testing and commissioning of the equipment for ensuring high system reliability. Following design consideration shall be taken into account to ensure maximum availability of the system.

5.8.1 There shall be no common device. between main and redundant units (e ,g, master oscillators

etc,) in order to ensure that the failure of the same does not cause shutdown of more than one unit.

5.8.2 It shall be possible to take out any individual power circuit for maintenance without affecting the

total UPS supply 5.8.3 Series-parallel combination of smaller devices to achieve required rating shall not be acceptable, 5.8.4 Vendors shall offer their nearest higher standard size that will meet the requirement of the

specified UPS rating, 5.9 Fault Diagnostic Unit

If specified in the data sheet, each UPS set shall have provision for adding microprocessor based 'ON line' fault diagnostic unit. This shall supervise the UPS operation continuously. It shall identify and locate faults immediately so that corrective action can be taken. Fault Diagnostic unit shall be compatible to hook up with owner's PC through RS232/RS485 interface, the software shall be provided on a CD ROM,

The fault diagnostic unit shall have provision for automatic print out facilities for time. Input/output voltages, currents. Frequency as a minimum under the following conditions,

- UPS power source changeover from mains to battery.

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- UPS power source changeover from battery to mains.

- Changeover from inverter to stabilized bypass supply and vice versa.

- Changeover from one inverter to other inverter.

- Changeover time in case of inverter to stabilized bypass supply and from one inverter to

other inverter.

- UPS failure.

- Type of failure incident along with diagnostic report.

In addition to the above, any other feature which vendor feels may be useful shall be provided and highlighted separately.

If any additional equipment (eg. bin connector, adaptor cards etc,) are required for connecting this unit with UPS system as well as with owner's PC. the same are also to be included in the vendor's scope.

6.0 INSPECTION, TESTING AND ACCEPTANCE 6.1 During fabrication, the equipment shall be subjected to inspection by JPK / Owner or by an

agency authorized by the Owner. Manufacturer shall furnish all necessary information concerning the supply to JPK/ Owner's inspector. Tests shall be carried out at manufacturer's works under his care and expense

6.2 UPS system shall be tested in accordance with applicable standards. The following acceptance

tests shall be performed on each UPS system as a minimum. All tests shall be witnessed by owner or its authorized representative and 4 weeks prior notice shall be given before the date of commencement of tests. The tests certificates indicating test results shall be furnished.

Following system acceptance tests shall be conducted on each UPS system: 6.2.1 INSULATION TESTS Insulation tests shall be performed as per IEC 60146-1··1.

The insulation tests shall be carried out using an AC power frequency voltage or by using DC Voltage at the choice of the vendor. In the case of AC power frequency voltage test, the test voltage at the frequency available in the test facility or at the rated frequency, but not exceeding 100 Hz, of the full value starting at a maximum of 0.5 p.u. The unit on test shall withstand the specified voltage for I minute.

In case DC voltage is used for the test the value of DC voltage shall be equal to the crest value of the test voltage specified in the table.

Vp /√2 (Vp is the highest crest voltage to be

Expected between any pair of terminals) Test Voltage (AC rms value)

≤ 60 V 500 V ≤ 125 V 1000 V ≤ 250 V 1500 V ≤ 500 V 2000 V

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6.2.2 INTERCONNECTION CABLE CHECK

The interconnection cables are to be checked for correct wiring, insulation and quality of the terminations

6.2.3 A.C. INPUT FAILURE TEST

The test is performed with the test battery and carried out by tripping a.c. incoming circuit breakers or by switching off rectifiers and bypass supply at the same time. Output voltage and frequency variations are to be checked for specified limits.

6.2.4 A.C. INPUT RETURN TEST

The test is performed by closing a.c. incoming circuit breakers or is simulated by energizing rectifiers and bypass supply. Proper operation of rectifiers starting and voltage and frequency varations of output are to be checked.

6.2.5 SIMULATION OF PARALLEL REDUNDANT UPS FAULT

The test is applicable for UPS with parallel redundant configuration. Fault of rectifier or inverter are to be simulated and output transients are to be recorded.

6.2.6 TRANSFER TEST

Transients shall be measured during load transfer from inverter to bypass supply caused by simulated fault and load retransfer after clearing the fault.

6.2.7 REGULATION TEST

This test shall be carried out by measuring input voltage, input current, output voltage, output current, DC link voltage, output distortion, input active power, output active power and frequency at no load, 50% load and 100% load at 0.7 and 0.8 p.f.

Following parameters of rectifiers and inverters are to measured.

Measurement shall be carried out in the rectifier float charge mode and in rapid charge mode. Measurement shall be at nominal a.c. voltage and at no load, 50% load and 100% of rectifier full load. Rectifier measurement shall comprise of :-

- Input voltage, frequency, phase current and input power.

- D.C. output voltage and current.

- Ripple current at the DC link bus shall be recorded after isolating the test battery.

Inverter measurement shall also be al no load, 50% load and 100% load of inverter rated output current and shall be repealed for inverter D,C. input voltages corresponding to battery float charge operation as well as rated inverter maximum and minimum input D.C. voltage. Measurement shall comprise of :

- Input voltage, input current.

- Output voltage, frequency and waveform distortion, output power and current.

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6.2.8 UPS EFFICIENCY

This shall be determined by the measurement of the active power input and output at rated p. f for 50%,75% and 100% load

6.2.9 CURRENT DIVISION IN PARALLEL UPS

Load sharing between UPS units shall be measured with a dummy load under parallel redundant UPS configuration.

6.2.10 LIGHT LOAD LIST

The test is to verify that all functions of the UPS system operate properly. The load applied is limited to some percentage of rated load. The following points are to be checked.

a) Output voltage and frequency and correct operation of meters.

b) Operation of all control switches and other means to put UPS system into operation.

c) Functioning of protective and warning devices.

6.2.11 BURN-IN TEST FOR PRINTED CIRCUIT BOARDS

PCB's and other electronic components sub assemblies shall undergo a burn- in test for 96 hours at 50 C at a voltage varied between the maximum and minimum supply voltage. In case of failure of any component during testing, the tests shall be repeated after replacement of the faulty component.

6.2.12 CONTINUOUS FULL LOAD AT 0.8 POWER FACTOR WITH TEMPERATURE RISE

MEASUREMENT

The test is required to be performed by connecting resistive load or resistive and inductive load to the UPS system output. The load shall be placed outside the test room to avoid influences of its heat upon UPS ventilation.

UPS system in this test shall undergo a complete full load test for 32 hours at 0.8 power factor. Out of these 32 hours. each invertor section shall be subjected to full load test for 8 hours, both invertors sections operating in parallel shall be subjected to full load test for 8 hours and the for remaining 8 hours; the by pass section shall be subjected to full load test. Steady state temperature of rectifier transformer, rectifier set, D.C. choke, inverter set, static switch etc. shall be recorded during the test. The temperatures of all UPS panels are also to be recorded.

6.2.13 AUXILIARY EQUIPMENT AND CONTROL CIRCUIT TESTS

The correct functioning of all measuring instruments, alarms, indications, protection devices and controls are to be verified. The functioning of auxiliary devices such as lighting, cooling fans. annunciation etc. should he checked

6.2.14 SYNCHRONISATION TEST

Frequency variation limits of inverter is to be tested by feeding bypass supply incoming line by variable frequency generator and inverter synchronization limit is to be checked as specified.

6.2.15 UNBALANCED LOAD TEST (FOR 3 PHASE UPS ONLY)

Unbalance load at specified limits is applied to the UPS system. The specified voltage and phase angle variation may be checked for compliance with specified values.

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6.2.16 OUTPUT VOLTAGE UNBALANCE (FOR 3 PHASE UPS ONLY)

Output voltage unbalance shall be checked under symmetrical load conditions and unbalance load conditions. Phase to phase and phase to neutral output voltage are to he observed. The voltage unbalance is the ratio of highest phase voltage minus lowest phase voltage to the average value. Phase angle variation may be measured for phase to phase and phase to neutral voltages.

6.2.17 OVERLOAD CAPABILITY TEST

Specified values of short time overload arc to be applied for specified time interval. Values of output voltage and output current are to be recorded.

6.2.18 SHORT CIRCUIT CURRENT CAPABILITY TEST

Specified short circuit current capability is to be tested by application of a short circuit to UPS output if necessary via a suitable fuse. Short circuit current is to be recorded.

6.2.19 SHORT CIRCUIT FUSE TEST

Fuse tripping capability of the UPS system is to be tested by short circuiting the UPS system output via a specified rating of fuse. The test is carried out at an appropriate UPS load under normal operation.

6.2.20 RESTART

Manual restart to be tested after complete shut down of UPS system. 6.2.21 OUTPUT OVER VOLTAGE Operation of output over voltage protection is to be checked. 6.2.22 DYNAMIC RESPONSE TEST Output recording at different loads and operating condition to be done. 6.2.23 HARMONIC COMPONENTS

Harmonic components of output voltage are to be recorded at no load, 50% load and 100% load conditions. Harmonic voltages caused by UPS system components in the A.C. incomer side shall be recorded at site.

6.2.24 EARTH FAULT TEST

An earth fault is to be applied to the output terminal of UPS system. UPS output transients are to be measured. An earth fault is also to be applied to the battery terminal and UPS system output transient shall be measured.

6.2.25 AUDIBLE NOISE TEST

The audible noise is required to be measured at 1 meter distance from UPS system in at least 4 to 5 locations and its value shall be within permissible limit.

6.2.26 The detailed test schedule and test procedure shall be formulated in line with above. Before

giving call for the witness of the tests, vendor shall get JPK's approval on the test procedures. Vendor shall also indicate the max. allowable tolerance for each test result along with the test procedures.

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If tests show that certain requirements of the specifications are not met, 'vendor' shall make necessary corrections to the equipment so that it satisfies all the requirements before acceptance is made.

7.0 SITE ACCEPTANCE TESTS

Vendor shall furnish site Acceptance Tests procedure to be followed. Final acceptance testing along with the batteries shall be done at site. It shall be Vendor’s responsibility to arrange necessary instruments and tools as required by their commissioning engineer for these tests.

8.0 PACKING AND DESPATCH

All the equipment shall be divided in to several shipping sections for protection and ease to handling during transportation. The equipment shall be properly packed for transportation by ship/rail or trailer. The equipment shall be wrapped in polyethylene sheets before being placed in wooden crates leases to prevent damage to the finish. Crates leases shall have skid bottoms for handling. Special notations such as Fragile', 'This side up', ' center of gravity', 'weight', 'Owner's particulars', 'PO nos.' etc. shall be clearly marked on the package together with other details as per purchase order. The equipment may be stored outdoors for long periods before installation. The packing shall be suitable for outdoor storage in areas with heavy rains and high ambient temperature unless otherwise agreed.

* * * * *

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DEWAS

CLIENT JOB NO 0290 TECHNICAL SPECIFICATION FOR

NICKEL CADMIUM BATTERIES TOTAL SHEETS 05

DOCUMENT NO 11 0290 01 10 02 007




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NICKEL CADMIUM BATTERIES Page 2 of 5

TABLE OF CONTENTS

1.0 SCOPE 2.0 CODES AND STANDARDS 3.0 GENERAL REQUIREMENTS 4.0 SITE CONDITIONS 5.0 TECHNICAL REQUIREMENTS 6.0 PERFORMANCE 7.0 INSPECTION, TESTING AND ACCEPTANCE 8.0 PACKING AND DESPATCH

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1.0 SCOPE

The intent of this specification is to define the design, manufacture and testing requirements of Nickel cadmium batteries for AC UPS application

2.0 CODES AND STANDARDS 2.1 The equipment shall comply with the requirements of latest revision of following standards issued by BIS (Bureau of Indian standards) unless otherwise specified. IS-I0918 Specification for \Vented type\ Nickel Cadmium batteries. 2.2 In case of imported equipment, standard of the country of origin can be accepted if these standards are equivalent or stringent than the applicable Indian standards. 2.3 The equipment shall also conform to the provisions of Indian Electricity rules and other statutory Regulations currently in force in the country. 2.4 In case Indian standards are not available for any equipment, standards issued by IEC/ BS/ VDE/ IEEE/NEMA or equivalent agency shall be applicable. 2.5 In case of any contradiction between various referred standards/ specifications/ data sheet and

statutory regulations the following order of priority shall govern: a. Statutory regulations. b. Data sheets c. Job specifications. d. This specifications. e. Codes and standards. 3.0 GENERAL REQUIREMENTS

The offered equipment shall be brand new with state of art technology and proven field track record. No prototype equipment shall be offered.

4.0 SITE CONDITIONS

Stationary Nickel Cadmium battery shall be suitable for operating satisfactorily in humid and corrosive atmosphere found in refineries, petrochemical and gas processing plants, metallurgical plants and other industrial plants. Service conditions shall be as specified in project data sheets/job specification. If not specifically mentioned therein, design ambient temperature of 50°C and altitude not exceeding 1000m above MSL shall be considered.

5.0 TECHINICAL REQUIREMENTS 5.1 The Nickel Cadmium cell/battery shall be suitable for float duty operation at constant voltage

permanently applied to its terminals which is sufficient to maintain it in state close to full charge and shall be designed to supply load in the event of normal power supply failure. Type of plate construction for batteries shall he as per project data sheet.

5.2 The rated ampere hour capacity of the cell/ battery shall be at reference temperature of 27ºC,

constant current discharge at 5 hours rate (C5) and end cell voltage of 1.0 V/cell. 5.3 Ampere hour of the battery shall be selected based on following:

a. Minimum site ambient temperature of 10°C or as defined in data sheet b. Discharge duty cycle c. End cell voltage

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d. Ageing factor of 0.8 e. Design margin if defined in data sheet

5.4 Number of cells and end cell voltage shall be decided by the vendor on the basis of maximum permissible voltage to the load when batteries are float charged while feeding the load and minimum DC system voltage. However the number of cells and end cell voltage shall be as per project data sheet unless other wise specified.

5.5 The battery shall be suitable for being boost charged to fully charged condition from fully discharged

condition within 10 hours unless other wise specified.

5.6 Battery assembly shall be supplied in dry and uncharged. Dry electrolyte and required quantities of electrolyte liquid with 10% extra shall be delivered with the battery in suitable non returnable sealed containers unless otherwise specified.

5.7 Each cell shall have separate container. The cell container shall be of high strength alkali resistant translucent material and designed to withstand mechanical stresses, shocks and vibrations.

5.8 The components such as containers, lids/covers and seals used in manufacture shall meet the Fire, flame and smoke resistance rating as defined in ANSI/UL94 and have an oxygen Index of at least 28 in accordance with ASTM D-2863.

5.9 The terminal posts shall be of nickel plated steel. The terminals shall be suitable for short circuit current and specified discharge current without damage to cell as a result of terminal heating.

5.10 Stationary nickel cadmium cells shall be designed to withstand the mechanical stresses

encountered during normal transportation and handling. 5.11 Flame arrestor shall be mounted on the cell so that all the vented gasses diffuse through the

arrestor to the outside environment. The construction of the arrestor shall be such that hydrogen burning on the external surface of the arrestor shall not propagate back in to the cell to cause explosion.

5.12 The following information shall be permanently marked on the cell.

- Nominal voltage - Name of manufacturer/model reference - Rated capacity in ampere hours (Ah) with End Cell Voltage - Voltage for float operation of 27ºC with tolerance of ±1% - Month and year of manufacture

5.13 Each set of battery shall be supplied with all accessories including but not limited to the following:

a. Battery stand in formation as per enclosed data sheet. Mild steel stand pretreated and epoxy painted / PVC coated.

b. Inter cell, inter row and inter bank connector c. Cell insulator d. Stand insulator e. Cell number plates and fixing pins, Lugs for cable termination as required. f. Other accessories and their quantity as per data sheet. g. Voltmeter(D.C.) to measure individual cell voltage having centre zero with lead. h. Hydrometer, funnel, gloves, spare vent plug

6.0 PERFORMANCE

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Nickel Cadmium batteries shall have been type tested to meet the performance requirements for each design and AH rating of cells as per IS-10918.

7.0 INSPECTION AND TESTING

Batteries shall be subject to inspection by WGI/owner or by an agency authorized by the owner, to assess the progress of work. The manufacturer shall furnish all necessary information concerning the supply to WGI /owner's representative. WGI / owner's representative shall be given free access in the works from time to time for stage wise inspection and progress reporting. Four weeks advance notice shall be given to witness the final routine test and other test as agreed upon. Following routine tests shall be carried out as a minimum as part of acceptance tests for each AH rating of cells/battery. For long duration type tests, type test certificates of identical ampere hour rating shall be furnished. a. Physical examination b. Polarity and absence of short circuit c. Marking and packing d. Verification of dimensions e. Air pressure test f. Test for voltages during discharge g. Test for AH capacity h. Test for charge retention if specified in the data sheet. i. Insulation resistance j Test for impact in variation on ambient temperature Battery duty cycle test to meet the load cycle requirement shall also be performed at site after installation as part of commissioning unless otherwise defined in project data sheet.

8.0 PACKING AND DESPATCH

All the equipment shall be divided into several sections for protection and ease of handling during transportation. The equipment shall be properly packed for transportation by ship/rail or trailer. The equipment shall be wrapped in polythene sheets before being placed in crates/cases to prevent damage to finish. Crates/cases shall have skid bottom for handling. Special notations such as 'Fragile', 'This side up', 'Centre of gravity', 'Weight', 'Owner's particulars', 'PO nos.' etc., shall be clearly marked on the package together with other details as per purchase order. The equipment may be stored outdoors for long periods before installation. The packing shall be completely suitable for outdoor storage in areas with heavy rains/high ambient temperature.

* * * * *

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CLIENT JOB NO 0290 TECHNICAL DATA SHEET FOR

BATTERY BANKS TOTAL SHEETS 04

DOCUMENT NO 11 0290 01 10 03 008




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TECHNICAL DATA SHEET FOR

BATTERY BANKS Page 2 of 4

DATA SHEET BATTERY BANKS (BY VENDOR / CONTACTOR)

A. BATTERY 1. Item no. : 2. Tag no. : 3. Manufacture’s name : 4. Type and catalogue no. of cell : 5. Ampere hour capacity : 6. No. of cells : 7. Nominal cell voltage : 8. Cell voltage at the end of full discharge at : 10 hours/ 5 hours rate 9. Specific gravity of electrolyte at the end of : full charging at º C 10. Specific gravity of electrolyte at the end of : full discharge at 10 hours / 5 hours rate at º C 11. Quantity of electrolyte per cell (liters) : 12. Weight of each cell with electrolyte (kg) : 13. Quick charging current 13.1 Max. safe quick charging rate (amperes) : 13.2 Permissible ripple content : 14. Suggested quick charging rate (amperes) : 15. Quick charging voltage 15.1 Max. quick charging voltage per cell : 15.2 Quick charging voltage per cell for constant voltage finishing charging :

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16. Float charging voltage per cell : 17. Float charging current 17.1 Float charging current range (amperes) : 17.2 Permissible ripple content : 18. AH efficiency at 10 hours/ 5 hours rate : 19. Short circuit current of the battery bank : 20. Short circuit withstand time (sec.) : 21. Max. allowable temp. of electrolyte which the cells can withstand without injurious effects 21.1 Continuously : 21.2 For short periods : 22. Type of positive plate : 23. Type of negative plate : 24. No. of +ve plates per cell : 25. No. of –ve plates per cell : 26. Material and thickness of separators : 27. Ampere-hour capacity at min. ambient at º C 27.1 10 hour rate to end cell voltage specified at

S.no. 8 above : 27.2 5 hour rate to end cell voltage specified at S.no. 8 above : 27.3 2 hour rate to end cell voltage specified at S.no. 8 above : 27.4 1 hour rate to end cell voltage specified at S.no. 8 above : 27.5 30 minute rate to end cell voltage specified at S.no. 8 above :

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28. Dimensions of each battery rack : 28.1 Width (mm) : 28.2 Depth (mm) : 28.3 Height (mm) : 29. Number of battery racks :

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CLIENT JOB NO 0290 TECHNICAL DATA SHEET FOR UPS TOTAL SHEETS 07

DOCUMENT NO 11 0290 01 10 03 009




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TECHNICAL DATA SHEET FOR UPS

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DATA SHEET FOR UPS SYSTEM

PART-1 PURCHASER’S DATA

RATING AND JOB REQUIREMENTS

1.0 INPUT POWER SUPPLY 1.1 Voltage/freq./phases : 415 V± 10%, 50Hz ± 3%, 3Ph 1.2 System fault level : 25kA for 1 sec 2.0 SITE CONDITIONS 2.1 Design ambient temperature : 60° C Min. ambient for battery sizing : 10° C 2.2 Max. relative humidity : Highly Humid 2.3 Altitude above MSL : Less than 1000m 3.0 SYSTEM REQUIREMENTS 3.1 Type of inverter : Transistorized or Latest technology 3.2 Rating (KVA at 0.8 pf) : 5 KVA 3.3 No. of phases : 1 Phase (Ph-N) Output Voltage : 230 V± 1% (Ungrounded) Output frequency : 50Hz ± 1% 3.4 Mode of operation : Single UPS with bypass supply 3.5 Load p.f. (rated and variation) : 0.8, 0.6 to 1 (lag) 3.6 Type of battery : Nickel- Cadmium 3.7 Battery Backup Time : 4 hrs. 3.8 Battery rack formation : Double row double tier 3.9 Fault diagnostic unit : Not Required 3.10 Ingress protection of enclosure : IP-31 3.11 Cable entry : From bottom /top 3.12 Painting : Epoxy paint shade 631 as per IS:5 4.0 UPSDB

For incoming and outgoing feeder details of UPS DB, refer Single line diagram attached elsewhere with the tender document.

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ITEM NO. INCOMER RATING

NO. OF OUTGOING FEEDERS

KVA/KW RATING OF FEEDER

SWITCH RATING

FUSE RATING

5.0 SPECIFIC REQUIREMENTS 5.1 All interconnecting cables (including associated cable glands and lugs) between all panels of UPS

system are included in vendor’s scope. 5.2 LED shall be provided instead of conventional indicating lamps.

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PART-2

TECHNICAL DATA FROM MANUFACTURERS

1.0 UPS SYSTEM 1.1 Make : 1.2 Type designation : 1.3 Rating (KVA at 0.8 p.f.) : 1.4 Mode of operation : 1.5 Dynamic Response under following conditions : a) For 50% step load : b) For 100% step load and unload : c) Power supply interruption and restoration : d) Load Transferred to bypass line : e) When one inverter gets faulty and load : transferred to healthy inverter 1.6 Maximum recovery time to reach steady state : After above disturbance 1.7 Type of cooling/Redundancy in cooling system : 1.8 Degree of ingress protection of panels : 1.9 Noise level : 1.10 Colour shade : 1.11 Efficiency of each rectifier and inverter Module including input and output transformer

a) At 100% load : b) At 75% load : c) At 50% load : d) at no load :

1.12 Efficiency of bypass stabliser including input Transformer


1.13 Overall efficiency of UPS system (ration of output load to input power drawn from Mains when all charger and inverters are on and Synchronised with bypass operating at no load)

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1.14 Cable entry : 1.15 Guaranteed dimensions (LXDXH) of UPS : System except ACDB and Battery 1.16 Heat loss for the total system(KW) : 2.0 INVERTER 2.1 Rating (at specified ambient)/No. of phases : 2.2 Steady state output voltage (Nominal/Variation) : Steady state output frequency (Nominal/Variation) : 2.3 Output voltage adjustment range at rated load : 2.4 Input voltage DC (Nominal/Range) : 2.5 Frequency variation limit for inverter : Phase locked with mains

2.6 Allowable unbalance between phases (for 3 phase only) :

2.7 Harmonic distortion at inverter output at rated load a) For linear load : b) For nonlinear load : 2.8 Overloading capacity and duration : 2.9 Short circuit capacity and duration : 2.10 Output voltage and phase angles (for 3-Ph only) a) For 30% unbalance load : b) For 40% unbalance load : c) For 50% unbalance load : 2.11 Type of control circuit : 2.12 Load crest factor (for which UPS is designed) : 2.13 Max. allowed rating of outgoing feeders for fault

Clearance of feeder fault by UPS with and without Mains bypass supply back up (as percentage of UPS rating) a) With fast acting semi conducting fuses : b) With normal HRC fuses :

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3.0 STATIC SWITCHES 3.1 No. of static switches in each UPS system : 3.2 Current rating at specified ambient (continuous / short time) : 3.3 Type of static switch : 3.4 Transfer time a) Synchronized mode : b) Unsynchronized mode : 4.0 BATTERY CHARGER 4.1 Current Rating : 4.2 Type of Charger : 4.3 Output voltage under float/ rapid charging condition : 4.4 Output Voltage accuracy under specified input : 4.5 Maximum ripple content on DC side with battery : Connected / disconnected 4.6 Maximum harmonic content in input current : 4.7 Input transformer rating : 5.0 MANUAL TRANSFER DEVICES 5.1 Make / Type designation : 5.2 Rating (continuous/ short time) : 6.0 BATTERY 6.1 Make : 6.2 Type designation : 6.3 Type : 6.4 AH rating : 6.5 End cell voltage : 6.6 Nominal voltage : 6.7 No. of cells in each bank : 6.8 No. of battery banks : 6.9 Battery charging requirements a) Nominal Volts/cell :

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b) Float Volts/cell : c) Rapid charging Volts/cell : 6.10 Rapid charging time : 6.11 Overall rack dimensions, no. of Racks and tiers with clearances : 6.12 Container type : 6.13 No. of recommended air changes/ hour for : battery room 7.0 STEP DOWN BYPASS TRANSFORMER WITHOUT SOLID STATE VOLTAGE STABILIZER 7.1 Make / Type designation : 7.2 Rating and voltage ratio : 7.3 Accuracy of Stabilizer : 7.4 Type of Control : 7.5 Type of Cooling : 7.6 Type of Stabilizer : 8.0 AC DISTRIBUTION BOARD 8.1 Make / Type designation : 8.2 Rating of board : 8.3 No. of outgoing feeders/rating of each : 8.4 Overall dimensions (LXDXH) : 8.5 Maximum & minimum operating height : 9.0 CELL BOOSTER 9.1 Make / Type designation : 9.2 Voltage range : 9.3 Current range : 10.0 RELIABILITY 10.1 Safety factor used for selecting the components a) Electronic devices : b) Electrical devices : 10.2 MTBF/MTTR :

10.3 Availability factor * * *

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