GAIL GAS LIMITED

CITY GAS DISTRIBUTION PROJECT,KOTA

CLIENT JOB NO. -

MECHANICAL DESIGN BASIS
TOTAL SHEETS 13
DOCUMENT NO 11 0290D 02 09 04 001

0 10/07/09 ISSUED FOR APPROVAL

A 06/07/09 ISSUED FOR IDC

REV DATE DESCRIPTION PREP CHK APPR

 TABLE OF CONTENT

1.0 PROJECT DESCRIPTION……………………………..................................................3

2.0 DEFINITIONS............................................................................................................. 3

3.0 WORK TENDERED....................................................................................................3

4.0 SCOPE OF WORK………………………………………………………………………….3

5.0 DESIGN CODES, STANDARDS AND SPECIFICATIONS …………………………... 4

6.0 BASIC DESIGN ……………………………………………………………………………..5

7.0 PRESSURE VESSEL…………………….....................................................................6

8.0 FILTER/COALESCER………………………………………………………………………7

9. 0 MECHANICAL DESIGN CRITERIA……………………………………………………….8

10.0 MATERIAL HANDLING FACILITIES……………………………………………………..9

11.0 INSPECTION, TESTING ANDCERTIFICATES……….…………………………………9

12.0 MATERIAL AND WELDING INSPECTION………………………………………………10

13.0 SPARE PARTS AND TOOLS……………………………………………………………...10

14.0 SPECIAL TOOLS……………………………………………………………………………10

15.0 BATTERY LIMITS…………………………………………………………………………..10

16.0 COLOUR CODING………………………………………………………………………….11

17.0 RESPONSIBILITIES OF THE CONTRACTOR………………………………...............11

18.0 GUARANTEE TEST……………………………………………………………………….. 13

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1.0 PROJECT DESCRIPTION

KOTA CITY GAS DISTRIBUTION

M/s Gail Gas Ltd intends to lay 10”/8” City Gas Distribution spurline (from Naya Nohra to Kota)by
taking Tap-off at Naya Nohra, from 16” Gadepan-Naya Nohra Pipeline network of Gail (India) Ltd
to supply the Natural Gas for Kota City Gas Project. The Proposed pipeline as envisaged is of
~40 km length.

City Gate Station and Steel Grid Pipe Line

The City Gate Station has been proposed near Samcor Glass Factory. Natural Gas from the CGS
is fed into single pipeline supplying gas to the city network. The pressure at the downstream of
CGS shall be 19 bar. A Primary network of steel pipeline shall connect the various CNG stations
and District Regulating Stations (DRS) for further gas supply distribution to automotive and and
PNG consumers. SV Stations are installed at approx every 2.5 km distance. As far as possible,
SV Stations are planned to be installed near CNG stations for prompt maintenance response.

2.0 DEFINITIONS

CLIENT / OWNER : GAIL Gas Ltd

CONSULTANT : Wood Group Engineering India Pvt. Ltd.

CONTRACTOR : The person, firm or company on the Purchase

Order and to whom the Purchase Order is
addressed.

VENDOR : “Vendor” means the person(s), firm, company,

organization from whom contractor procures
products/services.

3.0 WORK TENDERED

3.1 The work tendered in this bid package consists of fabrication, installation, testing and
commissioning of the City Gas Distribution Spurline inclusive of City Gate Station, CP works, SV
station, District Regulating Stations & above ground piping including all associated mechanical,
civil, structural, Telecommunication works.

3.2 Contractor will organize equipment and manpower accordingly to meet this requirement as per
instruction of Engineer-in-charge.

4.0 SCOPE OF WORK

4.1 The scope of work shall generally be, but not limited to the following:-

“The Contractor’s scope of work shall consist of preliminary activities like check survey, supply as
required, fabrication, installation, hook-up, testing and pre-commissioning of steel pipeline and
assistance during commissioning along with all associated mechanical, civil, structural, HDPE
conduit laying works and installation of OFC cable works. All such works, which are not indicated
here below but are otherwise required to complete the work in all respects shall form part of

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 Contractor’s scope of work. Further, the scope indicated below shall be read in conjunction with
the schedule of rates, drawings, standards, specifications, and other requirements forming part of
the contract document.”

5.0 DESIGN CODES, STANDARDS & SPECIFICATION

Design, engineering, fabrication, testing etc. shall be as per the list of codes and standards.

ASME Section - II, Div-1: Boilers and Pressure Vessel Code- Materials
ASME V : Boiler and Pressure Vessel Code - Non Destructive
Testing.
ASME VIII : Boiler and Pressure Vessel Code - Div 1- Pressure
Vessels.
ASME IX : Boiler and Pressure Vessel Code - Welding & Brazing
qualifications
ASME B 31.1 : Power Piping.
ASME B 31.3 : Process Piping.
ASME B 31.8 : Gas Transmission and Distribution Pipeline System.
ASME B 16.5 : Steel Pipe Flanges and Flanged Fittings.
ASME B 16.9 : Factory-made Wrought Steel Butt Welding Fittings.
ASME B 16.11 : Forges Steel Fittings, Socket Welding and Threaded.
ASME B 16.25 : Butt Welded Ends.
ASME B 16.47 : Large Diameter Steel Flanges: NPS 26 through NPS 60.
ASTM A 105 : Forging, Carbon Steel for Piping Components.
ASTM A 181 : Forging, Carbon Steel for General-Purpose Piping.
ASTM A 234 : Piping Fitting of Wrought Carbon Steel and Alloy Steel
for moderated and Elevated Temperatures.
ASTM A 370 : Mechanical Testing of Steel products .
ASTM A 216 : Carbon Steel Castings suitable for Fusion Welding for
High temperature Service.
ASTM A 20 : General requirements for steel plate for pressure
vessels.
ASTM A 516 : Carbon steel pressure vessel plates for moderate and
low temperature service.
ASTM A 106 : Carbon steel seamless pipe for high temperature
service.
ASTM A 193 : Alloy steel and stainless steel bolting materials for high

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 temperature.
ASTM A 194 : Carbon and alloy steel nuts for bolts for high pressure or
temperature.
MSS-SP-6 : Standard Finishes for Contact Faces of Pipe Flanges
and Connecting – End Flanges of Valves and Fittings.

MSS-SP-44 : Steel pipeline flanges.

MSS-SP-75 : High test wrought butt-welded fittings.
ISO 9712 : Non-destructive testing qualification and certification of
personnel.
ISO 10474 : Steel and Steel Structures Inspection documents.
ISO 9000 : Quality Management and Quality Assurance Standards.
ISO 9001 : Quality Systems – Model for quality assurance in design,
development, production, installation and servicing.
6.0 BASIC DESIGN
6.1 General Considerations
Various equipments, their capacity and quantity envisaged in the project are indicated in the
Scope of work (Basic Bid work). To minimize the interface responsibility, wherever practical,
Mechanical equipment shall be grouped together and specified in packages. Packages may be
procured in complete from a single point Contractor who would have sole responsibility for the
package performance. All packaged equipment shall be supplied as skid mounted, fully
assembled, piped, wired and tested as per specifications. Structural steel base frame of skid shall
be designed for single lift operation. Equipment shall be designed and selected for continuous
duty, unless specified otherwise.
Filled in Data-Sheets as stated in specifications for each item along with the drawings and
documents asked for in the specifications will be furnished for review and approval of the Owner.
During detailed engineering, the successful bidder shall furnish all the design details, calculations,
and drawings for approval by the Owner.
The equipment prone to leakage/spillage/moisture condensation shall be provided with drip pans
so as to avoid spillage of any liquid on the ground. Ease of accessibility to drain points and piping
connections shall be specified on all equipment that has an oil lubrication or heat transfer system.
In addition, following general considerations have to be kept in view for all Items while formulating
their specifications & also downstream procurement engineering activities.
6.1.1 Safety to personnel and equipment during both operation and maintenance
6.1.2 Reliability of service
6.1.3 Minimal fire risk

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6.1.4 Ease of maintenance and convenience of operation
6.1.5 Design for location in outdoor area
6.1.6 Packaged unit shall be furnished as skid mounted fully assembled equipment
6.1.7 Adequate provision for future extension and modification
6.1.8 Fail-safe feature
6.1.9 Suitability for applicable environment factors
6.1.10 Optimized spares inventory
The equipment in general, shall conform to requirements of data sheets, Functional specification
and the latest revision of relevant codes & Standards and shall be suitable for installation and
satisfactory operation in the applicable service conditions. Pressure piping within package shall
be designed and fabricated to ASME B 31.3.
Vendor shall be responsible for thermal and mechanical design and for Obtaining ASME code
stamping. Latest computer programs will be used.

7.0 PRESSURE VESSELS:

7.1 All vessels & columns shall be designed in accordance with equipment Specifications.
7.2 Calculations used to establish & check mechanical design of vessels shall be as per codes,
standards & code practices.
7.3  It shall be ensured that the equipment is free from overstressing for any loading within specified
maximum loading class.
7.4 Thinning allowance for dished ends should be 2 mm for cold pressing / 4 mm for hot pressing or
10% of nominal thickness whichever is lower.
7.5  The vessels sizing shall be on outside diameter for CS Alloy steel / SS and inside diameter for
clad steel vessels.
7.6 For cladded vessel, cladding thickness shall be minimum 3 mm
7.7 The preferred head cover shall be deep tori-spherical for medium pressure, hemispherical for
high
pressure. Flanged covers shall be provided for vessels up to 800 mm diameter. For other vessels
with Demisters, demisters shall be removable from bottom / manhole.
7.8 All vertical vessels are to be designed considering liquid hold up in addition to the design
pressure.
7.9 Minimum plate thickness for vessels shall be minimum 6 mm.
7.10 Skirt mounted vertical vessels & columns will include full diameter skirt.
7.11 Horizontal vessels shall include standard saddles.
7.12 All vessels shall be radio graphed as per code. However heads shall either be single piece
construction or shall be fully radio graphed.

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7.13 All nozzles shall be welded and flanged.
7.14 Minimum manholes size shall be DN 500 unless restricted by vessel Diameter. Covers shall be
equipped with swinging type davits. Davit Shall be provided for all pressure vessel man ways.
7.15 Vessel shall have 750 MM wide platform at all manholes and at any other identified maintenance
Location.
7.16 To ensure proper fit, level indication and instrumentation directly attached to the vessel shall be
included in the scope of vessel vendor.
7.17 Piping within equipment package should be as per given relevant specs.
7.18  All columns and vessels shall be fabricated at shop and shall be transported in single piece to
site.
7.19 For shop fabricated items, hydro-testing shall be carried out at shop also.
Scope in respect of PRESSURE VESSELS, includes but not limited to the following:
7.20 Design and detailed engineering of all pressure vessels based on data sheets provided as per
“ASME code section VIII, Division – I, Pressure Vessels” ( latest edition ), submission of design
calculations and detailed drawings including foundation drawings for approval by Owner, if any.
7.21 Fabrication of vessels at shop / site including all materials supply as per fabrication drawing duly
approved by Owner / consultant, if any.
7.22  NDT inspection by third party as per relevant standards mentioned in detailed scope
7.23 Transportation of vessels to site if fabricated at shop.
7.24 Construction of civil foundation as per approved drawings with all Materials supplied at site.
7.25  Erection of vessels in respective foundation and hydro-testing at the rated pressure as per
recommendation of relevant code and approved test procedure by owner.
7.26 Hooking-up of vessel to integrate with installation as per P&ID and Approved drawings.
7.27 Trial run and pre-commissioning test with water/ fluid.
7.28 Final commissioning of the system.
7.29 Insulation / Painting of Pressure Vessels
a) Cleaning and insulation / painting as per the requirement as per detail specification for insulation
/ painting.
b) Any other work which may necessary to complete the pressure vessels with respect to integrate
with the Gas GGS in all respects.
8.0 FILTER/COALESCER
Filters / Coalescer shall be complete and operable units comprising of supports, nozzles, flanged
inlet/outlet connections, drain connection, flange cover with pipe davit, filter element, relief valve,
differential pressure indicator and other accessories as required. The filter shall remove solid
particles / moisture content that may be present in the diesel system. Refer process design
criteria and P & ID for capacity and instrumentation requirements. The vessel shall be designed,

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 fabricated and tested in accordance with ASME Section VIII Div-1. As a minimum requirement,
the vessel shall be designed for spot radiography. Dish ends to shell circumferential joints shall,
as a minimum requirement, be fully radio graphed.
Filter shall be provided with Quick opening end end closure with davit assembly for easy
removal / Replacement of filter element. Filter shall be cartridge type. The selection criteria along
with the specifications and other details for the filter elements shall be fully described in the
Tender.
9.0 MECHANICAL DESIGN CRITERIA
9.1 The design criteria give the minimum requirements for mechanical design to be carried out. This
shall be read in conjunction with the specifications attached elsewhere in the bid.
9.2 The equipment proposed to meet the specification shall be designed and manufactured to
achieve the highest possible reliability for design life of 40 years.
9.3.1 All design calculations for pressure requirements, vibrations, considering seismic factors etc.
shall be made in accordance with code requirements and submitted to the OWNER for Approval.
9.4 In the event of conflict, the following order of priority shall govern:
9.4.1 Mechanical Design Basis
9.4.2 P&ID’s
9.4.3 Data Sheet
9.4.4 Drawings
9.4.5 Specifications
9.4.6 Codes and Standards
9.5 LAUNCHERS / RECEIVERS AND HINGED CLOSURE
9.5.1 The Launcher / Receivers shall be supplied along with hinged closure, pig detector and
accessories like trolley, jib crane and other pig handling devices. Launcher / Receiver shall be by
directional type.
9.5.2 The material specification shall be governed by the design conditions of
pressure, temperature, corrosion allowance and compatibility with contained media.
9.5.3 Contractor to calculate thickness / schedule against each size of piping class. Pipe internal
diameter from launcher / receivers shall be critically checked for the safe passage of pig. There
should not be any negative tolerance in internal diameter of Launcher/Receiver barrel.
9.5.4 Pig launchers and pig receivers are important for any pigging systems to ensure safe and efficient
working and handling of pigs. Both Launchers and receivers are required with suitable bandlock
type hinged closure and shall be provided for easy and safe access during pig loading and
unloading. Such closure shall be as per data sheets. Barrel shall be designed to suit the
intelligent pigging. The barrel and hinged closure shall be designed as per latest edition of ASME
Sec VIII Div 1. Launcher / Receiver dimensions shall be suitable for intelligent pigging.

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9.5.5 The design pressure and temperature for launching / receivers and hinged closure is 49 barg for
and 0 to 60 deg. C respectively.
9.5.6 Pipes, fittings, flanges of size 3/8”, 1 ¼”, 2 ½”, 3 ½”, 4 ½”, 5”, 7” and 9” shall not be used.
However, where equipment is regular supplied by the manufacturer with piping connections of the
above odd sizes, connection shall be made to approve nominal sizes using reducers.
9.5.6 Spectacle blind at the flanged end of Launcher / Receiver to be provided with other spectacle on
kicker line and by-pass line.
9.5.8 The venting arrangement in station should have ball and globe valve combination.

9.6 SCRAPPER TEES / BAR TEES

9.6.1 Scrapper tee is basically used for preventing the pig from entering into the branch line.
9.6.2 The design code followed shall be ASME B31.8 and ASME B16.9.
9.6.3 The design pressure and temperature for the scrapper tees shall be 49 barg and 0 to 60 deg. C.

10. 0 MATERIAL HANDLING FACILITIES

Material handling facilities study shall be carried out by contractor during
Detailed engineering stage based on the equipment sizes and weight. Actual requirement shall be
established based on this study and the facilities shall be provided accordingly. Necessary
hooks/Beam clamps shall be provided in the process areas and above all such maintenance
prone equipment where material Handling facilities are not permanently located or crane access
is not Available. All equipment supplied for mechanical handling including lifting points
And beams shall be identified with its applicable safe working load and shall be certified for that.
Material handling facilities to be provided in hazardous area shall be suitable for operation in
hazardous area application / requirements. Adequate facilities shall be provided on the site for the
following :
i) Handling and transfer of equipment assemblies / subassemblies during routine maintenance.
ii) Handling and transfer of materials, consumables from storage to respective consumption areas,
with most convenient manner requiring minimum time.

11.0 INSPECTION, TESTING AND CERTIFICATIONS

11.1 General
The responsibility for inspection and testing rests with the Contractor. The owner reserves the
right to witness any manufacturing operation, assembly or testing of the Equipment / Packages
within the Contractor’s or Manufacturer’s plant and review any audits and reports for the subject
works.
11.2 Inspection and Testing

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 All the systems/ equipment required to meet the design conditions as stated shall be
Performance and Function tested preferably at the manufacturer’s works in accordance with
respective codes and functional specifications.The Contractor shall submit for review and
approval by the Company a comprehensive Inspection and Test Plan (ITP) covering all relevant
components, completed equipment and systems. No work by the Contractor or its subcontractors
may commence without prior approval by the owner/consultant of the ITP’s. A detailed test
procedure of shop tests shall be submitted at least two (2) months in advance of any testing and
shall be approved by the Company. A dimensional check of the Package assembly and
components shall be performed for compliance with approved drawings. String tests and site
performance test shall also be carried out as per the requirement.

12.0 MATERIAL AND WELDING INSPECTION

Non-destructive material tests and pressure testing shall be in accordance with the ASME section
V and other Functional specifications enclosed in the bid. All non-destructive testing shall be
performed by an approved third party and accredited Non-Destructive Testing (NDT) inspection
organization.Full traceability of all material components (to material certificates) is require
13.0 SPARE PARTS & TOOLS
In view of above, the complete maintenance and spare parts requirements for the Equipment/
Package shall be furnished with the Tender. This shall include spares for start-up, commissioning
and one year’s operations.
Contractor shall supply spares for commissioning and start up. All spare parts furnished by the
Contractor shall be wrapped and packaged to preserve the parts as in original condition. The
same parts shall be appropriately tagged using stainless steel tags and coded so that later
identification as to their intended equipment usage will be facilitated. All items supplied shall be
packaged separately and clearly marked as “Spare Parts” and shipped with the equipment in
accordance with the instruction from the Company. Packing lists shall be furnished complete in
detail so that parts can be handled without uncrating,

14.0 SPECIAL TOOLS

With its Tender the Contractor shall provide a list of relevant special tools required for the
erection, maintenance for the all equipment. Included in the list of special tools shall be tools
required for access & removal operations such as mechanical handling and lifting aids, slings,
spreader bars, etc. Prior to shipment each special tool shall be packed in rugged tool box, tagged
with stainless steel tag detailing its description and where it is to be used.

15. 0 BATTERY LIMITS

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15.1 Battery limits for station shall be as per the drawings attached in the bid.

16.0 COLOUR CODING

16.1 Ball Valve (Above Ground) : Off White-- RAL 9010
16.2 Globe Valve (Above Ground) : Oxford Blue –RAL 5005,IS- 519941005
16.3 Check Valve (Above Ground) : Oxford Blue –RAL 5005,IS-519941005
16.4 ALL UNDER GROUND VALVES : Grey Epoxy
16.5 Pipelines (Above Ground) : Yellow Golden
16.6 Launcher/Receiver : Yellow Golden
16.7 Jib Crane/Trolley : Red & White Straps
16.8 All under ground valves shall have epoxy base coating after surface finish Of SA2.5
16.9 Valves and above ground pipes need to be properly blasted to achieve
surface Finish of SA 2:5 before the application of paints

17.0 RESPONSIBILITIES OF THE CONTRACTOR

17.1 All surveys such as pre-engineering, pre-construction, post construction etc shall be carried out as
required.
17.2.1 Design and detail engineering of all facilities in accordance with design parameters and
International codes and standards, but incorporating changes / revisions which are not
adequately covered and reflected, considering that the bid documents is solely based on
functional specifications.
17.2.2 Prepare all fabrication drawings, purchase specification for all equipment and specialty items,
specifications and procedure for fabrication, installation, coating of all items, painting, hook-up,
testing, pre-commissioning and commissioning and start-up as recommended for the items
supplied by him as per the specification attached in the bid.
17.3 Procurement including expediting and inspection of all materials and equipment for construction
and incorporation in the facilities. In addition to OWNER or OWNER appointed inspection agency,
the contractor has to carry out the inspection of material / equipment through third party
inspection agency duly approved by the OWNER.
17.4 Fabrication and assembly of all facilities included installation of equipment into the facilities in
accordance with the approved drawings and specifications.
17.5 Installation of all facilities, hook-up, testing and pre-commissioning all Such activities shall be
witnessed by the OWNER.
17.6 Any other works specified elsewhere in the bid document.
17.7 Contractor shall furnish all the information as sought by the OWNER in Formats for its data
storage and retrieval system at no cost to the OWNER.

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17.8 Procurement of all items shall be done from vendor list approved by OWNER. Necessary
documents such as purchase specifications, test certificates shall be furnished for review /
approval.
17.9 Contractor to plan and carry out suitable isolation, de-pressurization, purging, cleaning, Hydro
testing, Flushing, drying, painting and removal of temporary supports, scaffolding etc. Contractor
to execute the job safely without any operational hazard.
17.10 Any other work not specifically mentioned above but required for completeness of the work as per
specifications / drawings / codes and standards and instructions of engineer- in – charge at site.
17.11 It is the responsibility of the contractor to ascertain space and exact routing for meeting the
requirements of finally approved P&ID’s and design criteria.
17.12 The contractor shall conduct necessary site surveys, prepare additional drawings / data required
which are not parts of the enclosed bid package to ensure proper completion of work. The
contractor shall gather all information from existing facilities in case as-built drawings are not
available.
17.13 Contractor’s scope of work shall include modification / integration as per approved P&ID and other
requirements listed elsewhere in the bid package. For carrying out his scope of work, contractor
may be required to open / dismantle / realign / modify any facilities or instrument or piping or
equipment of the existing facilities and the cost of the same shall be included in the lump sum
price. IT will be contractor’s responsibility to make good, test and pre-commission all such facility
during and after completion of work with minimum period of shutdown. Details of total shutdown if
required for each modification / integration shall be indicated in the bid against each activity.
17.14 Contractor shall perform the necessary modification / integration work on the basis of actual
physical conditions / data / parameters foundduring the site survey during pre-engineering stage.
Contractor shall not be entitle to any cost and time compensation on this account.
17.15 Contractor shall ensure, before submission of his bid, that the space allocated for the various
facilities for the modification is adequate and satisfactory. In case any additional space / facility
such as provision of any walkway / operating platform for maintenance and operation of
equipment is required, the contractor shall indicated the same in his bid and the cost shall be
included in the lump sum price.
17.16 If the bid document / P&ID’s specifically required any existing facility to be altered or reused, the
same shall be done by the contractor after verifying / checking the condition of existing facility. IF
whole or any part of it is found to be defective, contractor, without any extra cost, shall replace
the same.
17.17 In accomplishing the above task the contractor shall take the total responsibility of executing the
project in accordance with this bid document including the supply of all materials and

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 consumables, construction equipment, labour etc. and will adhere to bid document instructions
and requirements in respect of all matter relating to the project.

18.0 GUARANTEE TEST

 In addition to the routine tests and guarantees by the manufacturers for the items being
procured and installed, the EPC contractor to demonstrate, as called for by the OWNER /
OWNER’s representative, by carrying out additional tests viz Hydro testing, NDT etc. at pressure
and temperatures as specified by the OWNER in order to ensure that the entire system is safe
and meeting the parameters specified in the bid documents.

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