Bom

SABARMATI GAS LIMITED
(A Joint venture with GSPCL & BPCL)
CITY GAS DISTRIBUTION PROJECT BID DOCUMENT FOR PROCUREMENT OF COMPRESSOR PACKAGE VOL II OF II TECHNICAL
(BID DOCUMENT NO 11/0353/WGI/SGL/01-R0) LIMITED INTERNATIONAL BIDDING
ISSUED BY
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SABARMATI GAS LIMITED CITY GAS DISTRIBUTION PROJECT
CLIENT JOB NO. SPECIFICATIONS FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGES TOTAL SHEETS
64
DOCUMENT NO
11
0353
02
09
02
007
0 C B A REV.
02.05.11 26.04.11 11.04.11 07.04.11 DATE
ISSUED FOR TENDER RE-ISSUED FOR CLIENT APPROVAL ISSUED FOR CLIENT APPROVAL ISSUED FOR IDC DESCRIPTION
MH MH SS SS PREP
RM RM RM RM CHKD
RC RC RC RC APPD
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CONTENTS 1.0 GENERAL ...................................................................................................................................................3 2.0 UTILITIES & BATTERY LIMITS ..................................................................................................................9 2.1 UTILITIES ...................................................................................................................................................9 2.2 BATTERY LIMITS ......................................................................................................................................10 3.0 BASIC DESIGN..........................................................................................................................................10 4.0 CONTROL PHILOSOPHY..........................................................................................................................20 5.0 INSTRUMENTATION .................................................................................................................................23 6.0 EARTHING / CABLING ..............................................................................................................................25 7.0 INSPECTION AND TESTING ....................................................................................................................25 8.0 PERFORMANCE GUARANTEES, LOADING AND PENALTIES ...............................................................27 9.0 PAINTING AND PROTECTION.................................................................................................................29 10.0ERECTION, TESTING AND COMMISSIONING AT SITE ..........................................................................30 11.0FIELD TRIAL RUN/ SITE PERFORMANCE TEST....................................................................................30 12.0SPARE PARTS, SPECIAL TOOLS AND TACKLES..................................................................................30 13.0MAINTENANCE PHILOSPHY: ..................................................................................................................30 14.0WARRANTY SERVICING AND SPARE PARTS .......................................................................................30 15.0DATA AND DRAWING ..............................................................................................................................31 ANNEXURE I: GAS COMPOSITION.............................................................................................................33 ANNEXURE-II : GUARANTEED PARAMETERS ..............................................................................................34 ANNEXURE III: LIST OF RECOMMENDED THIRD PARTY INSPECTION AGENCY ...................................35 ANNEXURE IV: APPROVED BIDDER LIST..................................................................................................36 ANNEXURE-V: BIDDER DATA REQUIRED ....................................................................................................39 ANNEXURE-VI: M.R. COMPLIANCE SCHEDULE...........................................................................................49 ANNEXURE VII : EXPERIENCE RECORD PROFORMA .............................................................................53 ANNEXURE- VIII : PARAMETERS REQUIRED FOR SCADA .........................................................................64
DATA SHEETS FOR COMPRESSOR (1200 SCMH) DATA SHEETS FOR COMPRESSOR (650 SCMH) DATA SHEET FOR LT MOTOR DATA SHEETS FOR HEAT EXCHANGER
SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE
DOCUMENT NO. 11-0353-02-09-02-007 SHEET 2 OF 64

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1.0
GENERAL Sabarmati Gas Limited (SGL) is a joint venture of GSPCL & BPCL & it proposes to install refuelling outlets in Gandhinagar,Mehsana & Sabarkanta district of Gujarat. SGL is inviting tenders on Competitive Bidding basis for procurement of CNG COMPRESSORS for CNG Stations.
1.1
SCOPE This specification along with applicable codes as referred describe the minimum requirements for Design, engineering, manufacturing, inspection, testing, packaging, supply & delivery at site , erection & commissioning including Field Performance Test at site along with 1st year operation and maintenance during warranty period & next 3 Years operation & comprehensive maintenance of "ELECTRIC MOTOR DRIVEN RECIPROCATING CNG COMPRESSOR PACKAGES as required for dispensing CNG to vehicles in Gandhinagar, Mehsana & Sabarkanta district of Gujarat. The CLIENT/CONSULTANT at his sole discretion may order all the packages on one bidder or split the order among two or more bidders. The packages ordered on one packager shall be identical in all technical aspects. Various parts of this specification shall be read in conjunction with each other and in case where the different parts of this specification differ the more stringent requirement shall govern. Any additional work/equipment or technical requirement not mentioned in the specification but required to make the offered system complete in accordance with the specification or required for safe operation, shall be deemed to be included in the offer and provided by the bidder, without any additional payment.
1.1.2
THE DESCRIPTION OF TOTAL SUPPLY OF PACKAGED COMPRESSOR IS AS UNDER: Sl. No. 1. 2. Description Electric Motor driven 1200 SCMH Packaged Reciprocating Compressor Unit Electric Motor driven 650 SCMH Packaged Reciprocating Unit Quantity 03 Nos.+ 2 Nos Optional 01 Nos.+ 1 Nos Optional
1.2
CODES & STANDARDS The design, construction, manufacture, supply, testing and other general requirements of the compressor package equipment shall be strictly in accordance with the data sheets, applicable API Codes, and shall comply fully with relevant National/ International standards. Any modification suggested by the statutory bodies either during drawing approval or during inspection, if any shall be carried out by the bidder without any additional cost and delivery implications. The following codes and standards (versions/revisions valid on the date of order) are referenced to & made part of specification: API-11P (Second edition), API 618 NFPA-37, OISD 179, NFPA-52: 1992 NFPA-12, IS: 6382, Gas Cylinder Rule-2004 IS: 5571, IS: 5572, IS: 5580 ANSI, ASTM, NEC, NEMA Indian Electricity Rules 1956 and updates thereafter, Indian Explosives Act, Factory Rules, 1950 Australian and New Zealand Refuelling Standards (AG 901/NZS 5425) Any internationally recognised standard. OISD rules should be followed be complied as this falls under hazardous Gas Area classifications.
1.3
PRECEDENCE In case of any conflict among the various documents of this requisition the following preferential order shall govern: DOCUMENT NO. 11-0353-02-09-02-007 SHEET 3 OF 64
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1. 2. 3. 4.
Data sheets/drawings Technical Specification Indian Standards / codes applicable International standards/codes as applicable
Compliance with these specifications shall not relieve the bidder of the responsibility of furnishing equipment and accessories of proper design, material and workmanship to meet the specified operating conditions. No deviations to the technical requirements and to the scope of supply specified in this enquiry document shall be accepted and offers not in compliance to the same shall be rejected. 1.3.1 Bidder shall necessarily furnish the following along with the bid without which the offer shall be considered incomplete: (1) Proven Track Record Formats duly filled in along with general reference list shall be submitted for the earlier supplied CNG packages as per BEC requirement. One similar package, which is in operation and number of hours of operation as on due date, shall be clearly indicated in the format by the Bidder. Checklist duly filled in with regards to scope of supply. Completely filled in Data Sheets of compressor, electric Motor & Heat exchanger. Tentative Lay out/key plan/General Arrangement indicating size of skids, centre distance between skids and space required along with maintenance requirements. (a) Utilities requirements (b) Electrical Load summary (6) 1.4 Catalogues of compressor, Electric Motor, Instrumentation and controls.
(2) (3) (4)
(5)
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 manufacturers works erection, commissioning, and field trial runs along with Equipment performance test along with associated electricals, instrumentation etc. as per bid document. Each compressor Package shall be complete with: Lubricated Compressor (Lubrication includes: Cylinder Lubrication, Frame Lubrication, Piston & Piston-Rings Lubrication, Packings Lubrication) with suction/discharge volume bottles for each stage (separators) with manual & automatic drain system, lube oil system, and lubricated connecti-ng rod. SGL will provide 3 KVA UPS for power back up. Air Compressor with receiver & drier of suitable capacity to cater compressor and 4 nos. dispenser (For 1200SCMH Compressor) & 3 Nos. Dispenser for 650 SCMH Compressors). Provision for overhead mounting of 3000 WL capacity stationary cascade to be included in bidders scope. The overhead structure required for putting Cascade (3000WL capacity of 75 cylinders which have approximate weight 5.5 Tonne) should be of enough strength having

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working space & along with ladder arrangement.Design of such structure shall be approved by SGL. Mounting of Cascade on the structure shall be in the scope of bidder however cascade shall be provided by owner. Mass flow meter to measure the Natural Gas consumption at packages inlet, package discharge. Instrumentation and control system as specified on data sheets, P&ID including Local panel, Console/Local gauge boards, PLC. Common structural steel skid for the compressor Electric Motor combination and for all auxiliary systems with foundation bolt. Duplex Suction gas filters with oil drain and temporary suction inline strainer at the compressor package inlet. Air-cooled heat exchanger for inter-stage and discharge gas. Suction, interstage and discharge Knockout Drums (KOD) with solenoid valve operated auto & manual drains. Demisters to be provided for each KOD. Bidder to ensure that KOD & coalescent filter shall be provided after the final discharge and before the mass flow meter. All drain lines shall be provided with level operated / time based auto drain valves and NRVs. Priority Panel at Package Discharge. Priority panel shall be kept outside in a separate enclosure preferably mounted on compressor side walls. All interconnecting oil, gas, water, air piping within the compressor package. Impulse and pneumatic piping/Tubing for all valves, fittings as specified & required for mounting the instruments. Block & bleed valves to be provided for Pressure gauges and pressure Transmitters. Separate junction boxes for different type of signals like intrinsically safe signals, alarm, shutdowns, thermocouples, RTDs etc. for interfacing to local panel. NRV at final discharge. Structural supports within the compressor package for all piping, instruments etc. One no. safety relief valve at suction, discharge, Blow down Vessel (BDV) and in priority panel banks shall be provided. Y- type strainers, valves, sight flow indicators, check valves, auto & manual drain traps etc. as required for various auxiliary systems i.e. frame lube oil, cylinder lubrication system, air cooled systems etc. Coupling/Pulleys Acoustic enclosure for both Compressor and Electric Motor assembly with two number L.E.L detectors and two UV detectors in the enclosure. Common CO2 extinguishing system consisting of two cylinders for Motor driven, piping, valves and control systems (details are given at s.no.1.5.8). Flame proof (FLP) electrical motors and Flame Proof control panel and other panels. The soft starter to be placed in the electrical panel room. Cable from starter to electric motor is in compressor bidders scope.

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Inlet and outlet automatic and manual isolating valves for maintenance & emergency. Package should be so designed that there should be sufficient space for operation and maintenance. Complete Erection, Testing & Commissioning of compressor packages. Supply of all spares as required for erection & commissioning. As built drawings and Operation & Maintenance catalogue with each compressor package. Training of six personnel in two batches at Packagers works. The travelling, boarding and lodging of SGLs engineers shall be borne by SGL. Each training module shall span for one week and shall cover the equipment constructional features, operational and maintenance procedures, practical hands on experience on assembling, dismantling etc. Bidder shall provide necessary provision in control panel (located in hazardous area) provision of availability of operating and fault condition data on PLC through SCADA system .The system shall be compatible with SGLs system. Maintenance and operation of compressor shall be for 365 days 24 hrs per day basis. Any item which is not included in the BOM/ Scope but required for commissioning/operation of the system shall be made available by the bidder without any extra cost & time implication. Temperature element shall be of INSERTION TYPE NOT SKIN TYPE. Foundation Drawings/ Equipment drawings of SYSTEM offered shall be submitted along with Technical bid. Load Torque Graph and the speed torque graph should be provided for electrical motor. Power consumption Vs. Suction Pressure Graph to be submitted by bidder along with Technical Bid.
Exclusions The following are excluded from the scope of the bidder: 1.5 1.5.1 All civil works and foundation design, however the bidder shall furnish all the relevant data for design of any pedestal if required. All piping beyond battery limits except piping from CO2 cylinders up to the enclosure. The CO2 piping shall be of seamless CS pipe. Foundation structural work.
SAFETY 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. The hazardous area classification Class-I, Division 2, Group D as per NEC or Zone II, Group II A/ II B as per IS/ IEC for compressor and Electric Motor. Certificate from recognized agency to the effect that equipment supplied and/or installed conform to above area classification. All Devices shall meet the requirement for the specified area classification in which they are installed, including instrumentation leads. All exposed rotating parts shall be provided with adequate guards of non-sparking type. Necessary hazard identification signs to be displayed on each equipment inside the package.
1.5.2
1.5.3 1.5.4

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1.5.5
Piping shall be arranged in a manner so as to provide clear headroom and accessibility within the package. Adequate clearances shall be provided for all the engineered components so as to have sufficient space for carrying out maintenance. Each package ENCLOSURE shall have two L.E.L detectors (IR Type) and two Ultra Violet (UV) fire detectors to cover the enclosure effectively as already spelt in the scope of supply. All material used in the package shall be flame retardant. 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. CO2 Flooding System: The package shall be protected by automatically operated CO2 flooding system designed as per NFPA12 which should have minimum following features: 1. Gas Detection by installation of hydrocarbon gas detector (IR type) with self check function and transmitter with adjustable alarm levels (0-100%) with preset of 10%, 20% and 50%. Each enclosure should have at least 2 nos. gas detectors. -The local panel of CO2 flooding system shall be flame proof type. 2 Installation of flame detector (UV-IR type) with self check function and transmitter, alarm on detection of flame. Each enclosure should have at least 2 nos. flame detectors.
1.5.6
1.5.7 1.5.8
1.5.9
3. CO2 flooding system will consist of 2 nos. of adequately sized CO2 cylinders. One cylinder will act as main cylinder & other as stand by, which shall have identical arrangement and connected to the system. The cylinders shall be placed in a shed to protect from weather and direct sunrays as per Gas Cylinder Rules, 2004. Cylinders shall be fitted with automatic actuated Valves, Solenoid valves etc. No extra utility as air, inert Gas shall be made available by SGL/used by the supplier to operate the system other than the UPS. 4. The System shall be designed to operate on 24 V DC supply. FRLS (Fire resistant low smoke) Copper cables with glanding on both the ends shall be used for the wiring of the system. All the wires /cables used/installed inside the compressor should be tagged on both sides. 5. Interlock of CO2 Flooding system with compressor as per following sequence: i. ii. Compressor shall trip on detection of gas at preset level. Compressor shall trip on detection of flame at preset level and automatic discharge of CO2 gas shall take place from the main cylinder simultaneously.
iii. Compressor shall not start if the CO2 Flooding System is faulty, not working, Switched OFF etc. The compressor shall be able to start only when the CO2 Flooding System is in healthy working condition. iv. Maintenance Override Switch shall be provided to keep the system off during maintenance. This feature shall be in compliance to the point no. 5 (iii) as above. v. Selector switch shall be provided to put Main/Stand by Cylinder in line at the turn of a switch as per requirement.
6. Alarm panel for CO2 Flooding System shall be integral with the main compressor panel. Necessary displays as system ON, OFF, FAULT, RESET, Gas/ Flame indication, Remote actuation of solenoid valve, distinguished hooter etc., shall be provided for CO2 flooding system. The remote push button shall be installed in the control room at site. Bidder to include all cabling etc. up to remote actuator DOCUMENT NO. 11-0353-02-09-02-007 SHEET 7 OF 64
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7. CO2 Cylinders shall be provided outside the package at a safe place, minimum 4.5 meters away (aerial distance), where it is not exposed to fire in case of fire in the compressor. Facility shall be made to operate the system both manually from remote with the help of a switch/ call point and with help of pull down lever on cylinders. 8. Bidder shall provide suitable weighing arrangement to facilitate weighing of the cylinders without requiring the cylinders to be detached from the installation. For this, lever operated lifting arrangements shall be provided along with alarm system. 9. All installation shall be compatible for hazardous area Class 1, Division 1, Group-D for Methane Gas as per NACE. 10. The system designed by the supplier shall be duly approved by SGL. 11. Technical specifications, Operation and Maintenance Manual, CCOE Certificate, Approval/ Manufacturing certificates for cylinders and cylinder valves, gas detectors, flame detectors, solenoid valves etc. shall be furnished by the supplier along with system. Necessary tools (1 set per package) shall be provided with the system. 12. Warning and Operating instructions to be displayed at equipments as per the statutory/ safety regulations. 1.6 AMBIENT CONDITIONS. Complete compressor package shall be suitable to work under the following climatic conditions: Wind velocity km/hr (max.) Amb. Temperature (Min./Max.) Design Wet bulb Temp. Design Relative Humidity Altitude, M above MSL Air Cooler design C 2.0 2.1 2.1.1 UTILITIES & BATTERY LIMITS UTILITIES Bidder shall make his own provision for Instrument and starting air with an electric motor driven air compressor receiver system. Air Compressor with receiver & drier of suitable capacity to cater compressor and 4 nos. dispenser (For 1200SCMH Compressor) & 3 Nos. Dispenser for 650 SCMH Compressor) instrument air requirements shall be provided by the Bidder. - The connectivity for instrument air for dispensers from the air compressor shall be in bidders scope. 2.1.2 2.1.3 2.1.4 Cooling water is not available as utility and the package shall be provided with air cooled heat exchanger. All electrical and instrumentation terminals shall be as specified. For motor driven compressor package, SGL shall provide the required control supply for LCP (230 V, 1 phase (2 wire), 50 Hz A.C.) through UPS and supply of (230 V, 1 phase (2 wire), 50 Hz A.C.) for lighting at single point in the Local Control Panel mounted on the package. Electric Power (a) SGL shall supply 415 V 3 phase, N, AC 50 Hz electrical power at the incomer of the Soft Starter panel supplied by the contractor. All further distribution of electric power shall be carried out by the contractor.
o
13 4 C / 47 C 27oC 95% 110 meters 47 C DBT, 27 C WBT & 94% RH

o o o o

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(b) SGL shall supply 230 V AC, 50 Hz electrical power for instrumentation through UPS at the inlet of the Soft Starter panel supplied by the contractor. All further distribution of electric power shall be carried out by the contractor. 2.1.5 ELECTRICAL SUPPLY PARAMETERS (For Electric Motor Driven Compressor Package) All electrical shall be suitable for the following supply conditions Electrical operating voltage: AC, 3 phase, Neutral 415 V, 50 Hz Electrical control voltage: 240V AC, 50 Hz (under suppliers scope) Tolerance of voltage: + 10% Tolerance of frequency: + 3% 1) CLIENT shall provide 415V, 3 phase, Neutral electrical connection at only 1 designated point for electric driven compressor package. Bidder shall distribute electric power to all equipments and control systems, by providing a suitable switch gear distribution panel. Suitable flameproof double compression gland shall be provided for termination of main cable in main electrical panel. Exact size and specification of the cable gland will be indicated to successful bidder within 2 weeks of order placement and receipt of electric signal line diagram from bidder. 2) All solenoid coils power contactor etc. shall have operating voltage of 240V AC and 50 Hz. The control supply of power contractor and PLC unit should be different. 2.2 2.2.1 BATTERY LIMITS 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 full flow ball valves with Tube OD End Connections. As and where specified on the data sheets all vents (i.e. Relief valve, distance piece, packing and starting air) shall be manifolded and terminated at skid edge outside the enclosure and vented to safe height of 3m from working platform of cascade. All drains from different process equipments, distance piece and packing shall be manifolded and terminated as single point for customer interface duly flanged with isolation valve. Drains should be through a common header and discharge to be allowed in a pit to avoid spillage around compressor package. Metallic collecting pot to be provided by the bidder suitable for collecting and disposal of drained oil.
2.2.2
2.2.3
3.0 3.1 3.1.1
BASIC DESIGN General The Compressor shall meet all the technical requirements as specified in: i. ii. iii. Data Sheets Technical Specification Code and specification API-11P, OISD 179, NFPA 37, NFPA 52, ANSI, ASTM, NEC, NEMA, Indian Electricity Rules and Indian Explosives Act are referenced to & made part of specification. Compressor, motor and auxiliaries design shall be in conformity with API 11P, second edition
3.1.2
Minimum Three stage Compressor configuration is envisaged. Gas composition given under design Case shall be used for Compressor selection, sizing and performance guarantee estimates. However

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compressor shall be suitable for continuous operation with the indicated gas composition range and operating parameters given in the data sheet. 3.1.3 Suction line pressure may vary from 14 kg/cm2G to 19 kg/cm2G with discharge pressure remaining constant at 250 kg/cm2G. A suction pressure regulator shall be installed to limit the suction pressure to 19 kg/cm2G. The suction pressure of 16 kg/cm2G shall be used for compressor sizing/selection. However, compressor shall operate at maximum available pressure at any time. Bidder to provide filter cum regulating skid with PCV at inlet. The pressure regulator at inlet should be of approved make with slam shut off valve of 300# rating. The inlet pressure range of the regulator shall vary between 20 to 35 bar pressures. Outlet pressure should be in the range of 14 to 19 bars. However, sizing of the compressor shall be carried out at 16 kg/cm2. 3.1.4 Bidders offer shall be based on firm and final compressor models on which basis the offer shall be evaluated. All bidders shall take full cognizance of this matter before submitting the bid. Note that the pressures given on the data sheet are at the compressor package battery limits, bidder shall consider all pressure losses at suction, interstage and discharge at the specified capacity (with no ve tolerance) for compressor/motor and indicate the same on the data sheets. No venting of the gas is allowed at any point during operation. 3.1.6 The compressor Driver shall be suitable to start the compressor against the stabilized pressure (35 Kg/cmg) of the system. A gas recovery vessel of suitable capacity shall be provided to collect the gas of 1st, 2nd & 3rd stage of compression. The operating pressure of gas recovery vessel shall be 35 kg/cmg maximum. No venting of gas is allowed. The compressor driver shall be capable of running the compressor under loaded condition with each stage pressurized to its respective specified pressure and final pressure upto PRV set pressure.
3.1.5
3.1.7
3.2 Allowable speeds, temperature and vibration levels 3.2.1 The rotational speed of both compressor & Electric motor (driver) shall be limited to maximum of 1500 rpm. The linear piston speed shall be limited to 4 m/sec for non-lubricated compressors and 4.5 m/sec for lubricated compressor. The maximum discharge gas temperature for each stage shall be limited to 150C before cooler. Compressor maximum vibrations of cylinders shall not exceed 7.5 mm/sec. of unfiltered peak velocity. Maximum Vibration level of installed compressor frame shall not exceed an unfiltered peak velocity of 5 mm/sec. or 200 micron unfiltered peak to peak vibration whichever is less. The Bidder shall provide for all structural support within the package so that these levels can be achieved. Piston Rod, Bearings and Cross Heads The surface hardness of Rockwell C 50 minimum is required on piston rods in the areas that pass through the packing. Crosshead shall be as per manufacturers standard material and designs. Adequate openings for removal of the crossheads shall be provided. Piston rod and cross head pin loading at any specified operating condition including the relief valve set condition shall not exceed 80% of the maximum design rod load of the offered compressor. Rod loads shall have sufficient reversals in direction for all specified operating conditions including PSV Settings and part load operation. The calculation for rod loading at various conditions needs to be submitted. Packing Cases and Pressure Packing
3.2.2
3.2.3 3.2.4
3.3 3.3.1 3.3.2
3.3.3
3.4

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3.4.1
All oil wiper intermediate gas cylinder pressure packing shall be segmental rings with stainless Steel garter springs. The pressure packing case shall be provided with a common vent and drain routed outside the package enclosure. ERW steel, seamless steel tubing conforming to ASTM A-192 or series 300 SS tubing conforming to ASTM A-269 with minimum thickness as specified in Cl. 7.11 of API-11P shall be used for vent piping.
3.4.2
Packing vent piping inside of the distance piece shall be designed for the maximum allowable working pressure of the cylinder. Gas flow direction to be marked on all internal pipes carrying Natural Gas. Bidder to indicate the allowable packing vent in their designs in SCMH along with the bid. Methodology of demonstration of packing losses shall also be submitted & should be demonstrated at the time of performance test. Compressor Frame Lubrication Compressor frame lubrication shall be pressurized system, with main oil pump driven directly by the compressor shaft. All lube oil piping after oil filter shall be 300 series stainless steel conforming to ASTM A 269. Heating shall be provided for reservoir when the minimum ambient temperature is less than the Bidder's required minimum start up temperature. Distance Pieces Compressor manufacturers standard Type1 or Type-2 of API 11 P shall be provided as a minimum. Cylinder and Packing Lubrication Single plunger per point force feed mechanical lubricator or divider block system shall provide lubrication to compressor cylinders. Lubricators shall be driven by crankshaft and bidder shall highlight any pre lubrication requirements of the cylinders and the method of achieving the same. 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. Digital no flow switch shall be provided to stop the compressor in case of loss of cylinder lubrication in any stage/ packing. Lubricator reservoir capacity shall be adequate capacity & to be topped up 7 days of normal operation, and shall be equipped with low-level alarm. 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. Cooling System Compressor Cylinder Compressor cylinders shall be air cooled,
3.4.3
3.5 3.5.1
3.5.2 3.5.3
3.6 3.6.1 3.7 3.7.1
3.7.2
3.7.3
3.7.4
3.7.5
3.7.6
3.8 3.8.1

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3.8.2
Inter/After Gas Coolers Air-cooled Interstage and Final stage discharge coolers shall be provided which shall limit the gas temperature after the cooler to 52oC. For calculating the surface area of the air cooler, the ambient air temperature of 47OC and 95% RH shall be considered. Bidder to indicate the motor ratings with the bid. Cooler design shall be on the basis of 20% extra margin on the heat load at most severe condition corresponding to suction pressure. Gas sections of coolers shall be designed as per API-11P requirements and shall be inspected by any approved 3rd party inspection agency.
3.9 3.9.1
Separators & Oil Removal System Carbon Steel separators / KOD at suction and interstage and with SS 300 series, mist extractors, auto and manual drain system (level/time based) shall be provided for the capacity as required. All pressure vessels shall be designed as per ASME VIII Div 1 practice. The offered scrubber and mist removal shall restrict the oil level to < 5 ppm in the discharge gas of compressor and the equipment shall be designed accordingly. All vessels including pulsation dampers shall be fully (100 %) radiographed as per ASME VIII UW (a). Minimum design temperature for separators shall be 100OC and minimum design pressure shall be maximum operating pressure plus 15% for interstages and plus 10% for final stage.
3.9.2 3.9.3
3.9.4
Gas Recovery System: Bidder shall provide gas recovery system with gas recovery vessel of sufficient capacity (however, operating BDV pressure should not exceed 35 Kg/cm2g) so as to limit the gas pressure inside vessel to 35 kg/cm2g after tripping of compressor at PSV trip set pressure of final stage discharge. The gas recovery vessel shall be provided with pressure relief valve and necessary instrumentation to avoid cold flaring of gas. Gas recovery vessel shall be designed as per the ASME code and will be inspected by Third Party Inspection Agency approved by WGI. All pressure vessels shall be provided with 3 mm corrosion allowance. Pulsation, Vibration Control and Analog Study
3.9.5 3.10
3.10.1 Bidder shall provide pulsation, suppression devices at each suction and discharge of compressor cylinders. 3.10.2 The design of pulsation suppressing devices shall be based on the acoustic and mechanical evaluation carried out as per API 618-design approach 3. 3.10.3 These devices must reduce pressure pulsation in piping within 3%. These pulsation dampers shall be designed to limit pressure drop to 1%. %. The minimum acceptable volume of pulsation suppression device shall be 10 times the cylinder swept volume 3.10.4 Bidder shall get the acoustic and mechanical evaluation study carried out for one compressor package (from inlet flange to discharge on skid edge) by an agency who should have conducted TEN such simulation studies. The compressor Bidder shall be totally responsible for all the coordination with the agency carrying out the study. Bidder shall submit acoustic and mechanical evaluation report to WGI for review. 3.11 Electric Motor
3.11.1 Motors shall be capable of starting and accelerating the load with the applicable method of starting without exceeding permissible winding temperature, when the supply voltage is 75% of the rated motor voltage.

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3.11.2 The motor design shall normally allow at least 3 starts in quick succession from cold against full load torque (motor coasting to rest in between starts) without injurious heating of the insulated windings. (Two consecutive starts shall be possible within 6 minutes after final steady working temperature. Further one additional (hot) start shall be possible after an interval of 30 minutes form the previous hot start.) 3.11.3 Motors shall be designed for restart under full load, after momentary loss of voltage and with possibility of restoration in few cycles. Supply voltage being 100% out of phase with motor residual voltage, motors shall be capable of withstanding transient torques associated under such reaccelerating conditions. Constructional details 1. The rotor shall be of squirrel cage type, dynamically balanced to provide a low vibration level and a long service life for the bearings. The accepted values of peak to peak vibration amplitudes for a motor at rated voltage and speed on a machined surface bedplate with the motor levelled and with a half-key or coupling fitted shall not exceed those given in IS:12075. Windings -insulation and bracing. Motors shall be provided with Class F insulation with temperature rise limited to Class B.The permissible temperature rise above the specified ambient temperature by thermometer method shall be limited to these specified in the applicable Indian standards for class B insulation. The windings shall be treated so as to resist the action of corrosive agents or substances(solids, liquids or gases) as may be present in the atmosphere of chemical, petrochemical and natural gas plants which may tend to adversely affect the insulation. Sulphur vapour may be present in the atmosphere. The windings shall be tropicalised. The windings shall be suitably varnished, baked and treated with epoxy gel for operating satisfactory in humid and corrosive atmosphere. The windings shall be adequately braced to prevent any relative movement during operation and, in this respect, particular attention is drawn to the stator windings of full voltage started squirrel cage motors insulation shall be provided between coils of different phases which lie together. In case of motors driving equipment with pulsating loads, special attention shall be paid to the joints of rotor bars and end rings to avoid failure due to induced fatigue stress. Phase connections. (a) The windings shall preferably be connected in delta. However, for motors rated 1.5KW and below, star connection may be accepted. If star-delta starting is required, this will be specified in the data sheet and the motor windings shall be fully insulated for delta connection.
2. 3.
4.
5.
6.
7.
b)
8.
Winding terminations (a) The ends of the windings shall be brought out into a terminal box. They shall be terminated by means of terminals mounted on an insulating base made of nonhygroscopic and non-flammable material. Preferably, all motors shall be with six terminals and suitable links to connect them in star or in delta. However, motors rated up to and including 2.2KW may be accepted with three terminals. The terminals shall be adequately designed and thoroughly insulated from the frame using material resistant to tracking.
(b)
(c)
9.
Terminal box and cable entries

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(a)
The terminal box shall be located on the right hand side viewed from the driving (coupling) end. It shall be routable in steps of 900 to allow cable entry from any direction. The terminal box shall be of sturdy construction and large enough to facilitate easy connection of the cables. An adequately sized earth terminal shall be provided in the motor terminal box for termination of the fourth core of cables. The terminal box shall be provided with bolted terminals, Cu cable lugs and entries for suitable cable glands corresponding to the number and size of specified cables. If specified in the requisition, nickel-plated brass (or aluminium if specifically required) double compression type cable glands and pin type lugs shall be supplied along with the motor for the mentioned cable sizes. Equipment and accessories provided should conform to the area classification and the environmental conditions specified in the motor data sheet. The terminal box shall be capable of withstanding the full internal short-circuit conditions without danger to personnel or plant from the emission of hot gases or flame or due to excessive distortion or damage to the terminal enclosure. Unless otherwise specified, the fault level to be considered shall be 31 MVA for 415V System, (For motors rated below 55KW, the fault energy to be considered shall depend upon the back-up fuse rating). A separate terminal box shall be supplied for space heater as specified.
(b)
(c)
(d)
(e)
(f)
(g) 10.
Phase marking (a) Appropriate phase markings as per IS: 4728 shall be provided inside the terminal box. The Markings Shall be non-removable and indelible.
Other Details : Motor shall be TEFC squirrel cage type in standard frame size as per IS/IEC rated for continuous duty with high efficiency and designed for soft starting. Motor shall be suitable for starting under specified load conditions with 75% of rated voltage at the terminals. Motor torque shall be compatible with the speed torque curve of the compressor. Motor winding shall be Class F insulated with temperature rise limited to Class B. Minimum degree of protection of enclosure shall be IP55 as per IS. Motor for use of hazardous shall have flameproof protection ex (d) as per area classification. The main motor starter should be soft starter and all accessories motor above 5.5kW should have start-delta except main compressor motor. Adequate space shall be provided along/ around the motor for maintenance purpose. The motor name-plate rating (exclusive of service factor) shall be minimum 110% of the greatest kW/ HP required under any of the specification operating conditions. All motor shall be tested in accordance with IS/IEC. Each motor shall be compulsorily be protected with thermal magnetic over-current relay. Electric power supply distribution panel switchgear panel and starter panels shall be skid mounted construction, weather and vermin proof suitable for installation in the compressor package. There shall be FLP push button panel available at the compressor skid. The switchgear shall have 1 incomer and adequate no. of outgoing feeders. The incomer shall be provided with suitable rated switch fuse unit, ammeter, voltmeter with selector switch, energy meter, pf meter, etc. Motor feeder shall be provided with heavy duty dwitch. HRC link type fuses, contractors (Ac 3 duty) bimetallic relays, single phase prevented, ammeter, pushbutton, earth leakage relay and indication lamp for start/stop/trip etc. Adequate nos. of MCB feeders for control and lighting shall be provided. Supplier shall furnish single line diagram of panel with the bid. The switch for change over of phase shall be provided inside the panel.

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Multi functional digital energy meter preferably HPL socomac CT2emfA1- basic version with maximum demand in kVA and kW with suitable fuse protection required within the panel. There shall be separate panel for main incoming switch (MCCB) and starter for main motor. There shall be minimum clearance of 30mm between the 2 power contactor. The compressor panel shall have phase reversal relay to detect electric supply phase sequence and trip the compressor on wrong phase sequence. Supplier shall make provision for earthing of the complete package as required as per IS All electrical shall comply with latest IS/ IEC. Epoxy base paint shall be applied on all electrical equipments. Suppliers scope shall include obtaining statutory approvals for all complete package, wherever necessary. Bidder to note that all control electronics/ electrical, instrumentation shall be capable of withstanding voltage fluctuation within+ 15% of rated voltage (240 VAC). In case the card/components are not capable of withstanding above voltage fluctuation, the scope of supply of compressor package shall include an UPS/ voltage stabilizer (VS) / voltage conditioner(VC) so as to take care of voltage fluctuation. In such condition each compressor packager shall be provided with individual UPS / VC / VS. along with necessary interconnecting cable. Bidder shall also be responsible for lying of such cable, installation and commissioning of UPS. Pre-lubricated sealed bearing for all motors may be considered provided a full guarantee is given for 4- 5 years of trouble, free service without necessity of lubrication. Various Datas Curves & Design calculation for selection of Driver i.e. Electrical Motor to be submitted by bidder. Superimposed Torque-Speed characteristics of motor & compressor. Starting time calculation at 100%, 80% & 58% of rated voltage.
Motor casing and type of enclosure 1. Motors for use in safe areas shall be normal industrial types meeting the specified ambient conditions and operating requirements. The minimum degree of motor enclosures, including terminal boxes and bearing housing, shall be IP-44 as per IS: 4691 for motors meant for indoor use and IP-55 for outdoor duty motors. Motors for use in hazardous area (Zone 1 or Zone 2) shall have type of protection Ex (d) or ex (p) or Ex (e) or ex (n) as specified in the data sheet and shall meet the requirements of applicable Indian standards. The minimum degree of motor enclosure, including terminal boxes and bearing housings, shall be IP-55 as per IS: 4691 for all motors, used in hazardous areas. Motors for outdoor use shall be suitable for installation and satisfactory operation without any protective shelter or canopy. In case of manufacturers view that the motors for outdoor duty should have a canopy at any particular site, the same shall be deemed to be included in manufacturers scope of supply. Motor casing shall be provided with a suitable drain for removal any of condensed moisture. Vertical motors with downward shaft shall be provided with fully covering rain canopies. Vertical motors with upward shaft, e.g. on fin-fan coolers, shall be adequately protected, (such as with cowls/canopies) against ingress of water into the enclosure or the bearing housing, even when standing still for long periods of time. DOCUMENT NO. 11-0353-02-09-02-007 SHEET 15 OF 64
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2.
3.
4.
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5.
All internal and external metallic parts which can come into contact with cooling air, (piping, air supply and discharge conduit, protective grills, air deflectors, filters and supports) shall be of corrosion-resistant material or appropriately treated to resist the corrosive agents which may be present in the atmosphere. Screws and bolts shall be hot- dip galvanised or zinc passivated to protect against corrosion. Unless otherwise agreed, industrial and non-sparking type Ex (n) motors shall have standard frame sizes for various output ratings as stipulated in IS:1231. Acoustic enclosure should be fabricated in such that it is completely sealed so that gas or fire should not travel from one enclosure to another. Two number L.E.L detectors and two UV detectors in each enclosure shall be provided.
6.
7.
Bearings and lubrication 1. Motors shall have grease-lubricated ball or roller bearings. In all cases, the bearings shall be chosen to provide a minimum operating life of 40,000 hours. Unless otherwise specified the bearing shall be adequate to absorb axial thrust in either direction produced by the motor itself or due to shaft expansion. Vertical motors shall be provided with thrust bearings suitable for the load imposed by the driven equipment. In cases such as pumps for hot liquids, the driven machine operates at high temperatures and the bearings, particularly of vertical motors, which are exposed to high temperature, shall be cooled by an impeller fan mounted on the shaft. This shall ensure efficient ventilation of the bearing and disperse the heat transmitted from the driven object by conduction or convection. Bearings shall be capable of grease injection from outside without removal of covers with motors in the running condition. The bearing boxes shall be provided with required seals, to prevent loss of grease or entry of dust or moisture, where grease nipples are provided, these shall be associated, where necessary, with appropriately located relief devices which ensure passage of grease through the bearing. Pre-lubricated sealed bearings will be considered provided a full guarantee can be given for 4 to 5 years trouble-free service without the necessity of relubrication.
2.
COOLING SYSTEM 1. All motors shall be self ventilated, fan cooled. The fans shall be of bronze, brass, aluminium, mild steel, stainless steel or of plastic. Plastic fans shall be antistatic type. i.e. they shall not permit the accumulation of electric charge on the fan surface. Brass or bronze fans shall not be used for motors installed in fertiliser plants. In all cases fans shall be corrosion-resistant or appropriately protected against corrosion. They shall be suitable for rotation in either direction without affecting the performance of the motor. If this is not possible for large outputs, it shall be possible to reverse the fan without affecting the balancing of the motor. Motors for installation in dusty atmospheres or in the presence of sand, fuel or other solid particles in suspension in the air, shall be fitted with filters for the cooling air. The filters shall be easily accessible for inspection and removable for cleaning and re-use. The material of the filter and support trays shall be rustproof or protected against oxidation or corrosion.
2.
3.
Other requirements 1. Anti-condensation heaters (a) All motors rated above 75KW shall be provided with 240V anti-condensation heaters, sized and located so as to prevent condensation of moisture during shutdown periods. Motors meant for humid locations such as cooling tower fans, sump pump, etc. shall be provided with space heaters irrespective of the motor rating. The heaters shall

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permanently remain ON when the motor is not in service and as such shall not cause damage to the windings. (b) For motors installed in hazardous atmospheres (Zone 1 or Zone 2) such heaters shall conform to the provision of applicable Indian standards and temp. Classification specified in the data sheet. The heater leads shall be brought out to a separate terminal box of the same specification and grade of protection as the main power terminal box excepting that the cable glands provided shall be suitable for three core 2.5 Sq.mm. copper conductor, armoured cable.
(c)
2. 3.
Motors shall be provided with a single shaft extension with keyway and full key. All motors above 25Kg of weight shall be provided with lifting hooks of adequate capacity to facilitate safe lifting. Two earth terminals located preferably on diametrically opposite points shall be providing for each motor. Necessary nuts and spring washers shall be provided for earth connection. A warning with indelible red inscription shall be provided on the motor to indicate that isolation of the power line alone is not sufficient and that the heater supply should also be isolated before carrying out any work on the motor. Fixing bolts: All motors shall be supplied with fixing bolts. Special tools and spanners (a) Each motor shall be provided with a set of spanners and special tools, required for dismantling and maintenance of the motor. Triangular spanners required for explosion-proof or increased safety motors are considered as special tools.
4.
5.
6. 7.
(b)
8.
A name plate as required under specification IS: 325 shall be provided on each motor in addition to the motor rating plate. A separate motor plant equipment number plate shall be fixed in readily visible position. This number is indicated on the attached data sheets. Additional information as stipulated in applicable Indian standards shall be included in the nameplate for motors meant for use in hazardous atmospheres. The permissible noise level shall not exceed the stipulations laid down in IS: 12065. Motor vibrations shall be within the limits of IS: 12075 unless otherwise specified for the driven equipment. Internal and external parts of the casing and all metal parts likely to come in contact with the surrounding air shall be protected with anti-acid paint that will resist the particular ambient condition. All external surfaces shall be given a coat of epoxy based paint.
9. 10.
11.
Performance 1. The pull out torque at the rated voltage shall be not less than 175% of the rated load torque with no negative tolerance. In the case of motors driving equipment with pulsating loads (e.g. reciprocating compressors) the minimum value of pull out torque at 80% of the rated voltage shall be more than the peak value of the pulsating torque. Unless otherwise agreed, the pull out torque shall not exceed 300 % of the rated load torque. The minimum value for product of efficiency and power factor for motors rated up to and including 37KW shall be as per IS: 8789
2.

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3.13
Coupling The first preference is for directly coupled driver-compressor arrangement.
3.14
Enclosure of CNG Compressor Package
3.14.1 The Compressor package shall be housed in an acoustic leak proof enclosure. The equipment shall be mounted on one common skid. Enclosure shall restrict maximum noise level to 75 dBA at 1 meter from the enclosure. The maximum temperature within the enclosure shall be limited to 52C based on the ambient temperature of 47C. Adequate ventilation fans shall be provided to meet the above and also to account for heat dissipation of the coolers as well as maintaining the positive pressure inside enclosure. Suitable interlocks shall be built in for clearing the entrapped gases (if any) within the enclosure before the start up of the compressor package. The CLIENT/CONSULTANT shall review the vent requirements to meet the above & interlocks during detailed engineering. 3.14.2 Enclosures shall provide a degree of protection equivalent to IP 54 as defined in AS 1939 and provided with adequate ventilation system. 3.14.3 The enclosures shall have doors for normal access and removable wall panels for ease of maintenance. The acoustic material should be fire resistant with fire retardant rating of 30 min. UL approval/IS certification shall be applicable for acoustic material.. 3.14.4 All the pressure, temperature, gas flow meter, oil level, lube oil pressure, coolant temperature, coolant level indicators shall be visible from outside of enclosures. 3.14.5 Enclosure shall have internal flame proof lighting arrangement. 3.14.6 For handling of all heavy parts for maintenance purpose lifting arrangement i.e. beam fitted with chain hoist shall be provided in the enclosure. The beams should be properly centered over the heavy equipments. Certificate of chain hoist is to be provided. 3.14.7 All Coolers, Cooling System, lubrication system along with interconnecting piping shall be inside the enclosure. Enough headroom shall be made available for easy access and maintenance of all equipment in the enclosure. Components such as pressure gauges, temperature and pressure switches etc., which require in-site adjustment and reading, shall be easily accessible. Conduits and tubing shall be arranged in orderly and systematic manner and shall be routed neatly to enter the back of display or monitoring panels. Routine service item such as, but not limited to, crank case oil filters, inter stage gas filters, inlet and outlets gas filters shall be located to facilitate easy one-man servicing. One person should be able to access crank case oil inlet and drains to allow addition or drainage of oil without removing panels or adjacent components and without the need of the pump. Items which must be operated & monitored during operation shall be readily accessible without opening the door. Suitable gradients shall be provided on the enclosure roof for rain drainage and to avoid water pockets.
3.15
Piping
3.15.1 All gas piping shall be designed, fabricated & tested in accordance with ANSI B 31.3.

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3.15.2 Gas piping shall be seamless carbon steel manufactured in accordance with ASTM A- 53 Gr. B or ASTM A - 106 Grade B. All Gas piping shall be flanged connections. 3.15.3 All rigid piping, tubing & other components of compressor package shall be designed for full range of pressure & temp and loading to which they may be subjected with a factor of safety of at least 4 based on minimum specified tensile strength at specified ambient temperature. 3.15.4 All rigid piping shall be continuous between their respective components & free of connections except welded joints. All high pressure joints shall be welded unless otherwise not feasible. 3.15.5 The instrument air tubing material shall be Stainless Steel series 316 conforming to ASTMA269. 3.15.6 All high-pressure double ferrule fitting & 2/3 way valves shall be from SWAGELOK or PARKER makes & shall be SS 316L material only. 3.15.7 Bidder shall furnish a temporary start up conical strainer fitted with adequate size mesh at the gas inlet before the filter. 3.15.8 All lube oil piping down stream of filter shall be series 300 Stainless Steel. 3.15.9 External drain & vent piping shall be Carbon Steel and not less than 1" nominal size. 3.15.10 Mercaptan/THT dosing is envisaged hence all materials coming in contact with gas shall be compatible to such gas with Mercaptan/THT dosing and be of compressor manufacturer's standard. The use of SA 515 material is prohibited. 3.15.11 All gas piping after coalescent filter at compressor discharge shall be of SS 316 of Sandvik/Tubacex make and hardness less than Rb 80. 4.0 4.1 CONTROL PHILOSOPHY The compressor package control system shall be designed for unattended operation in automatic mode and in case of any fault it will go in a safe mode. Compressor Package shall be provided with a PLC based LCP of approved make (i.e. Siemens/ABB/GE Fanuc/Tata Honeywell/Allen Bradley), which shall be weatherproof to IP55 and shall be certified suitable for specified hazardous area classification. PLC should be integral with the package with necessary Hazardous Area Certificate (HAC) compliance. HMI shall be of text display type. PLC shall incorporate all process parameters (specified elsewhere) and status of compressor, engine & priority panels and shall be modular in construction with 100% redundancy with respect to CPU, Power supply, Interface. PLC components/system shall be tropicalised, MIL standard adopted with complete wiring and necessary terminals. Wiring to be colour coded with cross ferruling in position. PLC shall be capable of carrying out on line routines for at least ten separate loops without affecting the scan, cycle & up dating time etc. PLC shall be capable for display of flow meter data (i.e. Gas suction, Gas Discharge), various trips/abnormal conditions, compressor running hour etc. in following manner: a) Shift wise (for 3 shift operation i.e. 06:00-14:00, 14:00-22:00 & 22:00-06:00)- shall be available for at least last 96 hours. b) Daily basis- shall be available for at least last 31 days. c) Fortnightly basis- shall be available for at least last 3 fortnights. d) Monthly basis- shall be available for at least last 2 months. SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE DOCUMENT NO. 11-0353-02-09-02-007 SHEET 19 OF 64
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PLC shall be configured as a remote terminal unit of supervisory computer and data acquisition system complete with dial up connectivity. One card for transferring and accessing data from minimum twenty devices with RS 485 port shall be provided. PLC SCADA connectivity is required as per the attached specification at Annexure-IX. PLC would be provided with integral keyboard and display for configuring, programming and to view process & machine parameters. Suitable communication port for connectivity to PC with RS 485 card shall be provided to download programs etc from PLC through a Laptop. Laptop not included in Bidders 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 SGLs use to give a remote indication of alarm and trip. In auto mode, compressor shall start automatically in case high bank storage pressure falls below 200 kg/cm2 and stop as soon as pressure of stationery cascade reaches 250 kg/cm2. The priority fill system (In bidders scope) shall ensure the filling of vehicle, storage cascade and mobile cascade in correct order. Priority fill system shall be necessarily of actuator type. Following Priorities are envisaged for supply of compressor packages: With (5) bank priority panel: Break up: 1st - Direct to dispenser unit 2nd High Bank cascade 3rd - Medium bank cascade 4th - low bank cascade 5th - Mobile bank (LCV) Priority panel shall of high bank and pneumatic actuated type consisting of inlet and outlet valves and NRV, safety valves, pressure transmitter in each bank and should be controlled through PLC. Each line must be complete with necessary NRV and Full flow control trunion mounted ball valve, inter connected NRV and ball valves required for smooth operation and shall have 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. 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. 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. The pressure in each bank shall be monitored from down stream of priority panel.
4.3
4.4
4.6
4.7
4.8

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4.9
Bidder shall provide emergency shut down (ESD) system in the control room as well as locally mounted on the compressor panel and one no. on the enclosure. Total 3 nos. of ESD switches to be provided as a minimum. Fail-safe system shall be designed and incorporated to isolate cascade storage from dispenser, stop compressor, isolate the compressor suction line on activation of ESD switch. ESD switch shall have to be manually reset to restart the compressor package again.
4.10
4.11
Bidder shall provide individual Application program for PLC, HMI (Human Machine Interface) on LCP (one set) along with all interfacing adaptors and cables. Bidder shall also provide one set of source & object codes for PLC, HMI on LCP (in both forms, hard & soft). Programming software one set usable for all machines is to be supplied. All pressure and temperature at compressor inlet, outlet, at each stage before and after cooling, to be available on the PLC. Suction gas filter with oil drain, differential pressure gauge and temporary suction inline strainer at the compressor package inlet before PRV and Slam Shut off valve. All material use in the package should be flame retardant. The maximum discharge temperature for each stage shall be limited to 150 degree centigrade before cooler and 52 degree centigrade after cooler. The motor selected should be for continuous duty operation. The motor bearing should guarantee for minimum of 40000 hours of trouble free operations. Winding temperature sensor of the motor to be interlocked with emergency shutdown system for tripping in case of winding temperature increases above the limit. Enclosure shall be flameproof and provided with forced ventilation system. All the pressure, temperature, gas flow meter, oil level, lube oil pressure shall be visible from outside of enclosures. Enclosure shall have flame proof (internal/external) lighting arrangements. Bidder shall furnish a temporary start up conical strainer fitted with adequate size mesh at the gas inlet before filter. Priority panel should be at package discharge, however priority panel should be kept outside the package preferable mounted on the walls of the compressor enclose covered with additional doors. The compressor package should trip if any of the doors is kept open. The enclosure shall have doors for normal access and removable wall panels for east of maintenance. The acoustic materials should be fire resistant with fire retardant rating of 30 min. the materials used should be UL approved. Necessary documents to be submitted for the material selected. Priority panel shall be by PLC based. The pressure in each bank should be monitored downstream of priority panel. PLC shall incorporate all process parameter (specified elsewhere) and status of compressor, priority panels and shall be modular in construction with 100% redundancy. PLC components/ system shall be tropicalised, MIL standard adopted with compete wiring and necessary terminals. Wiring to be colour coded with cross ferruling in position. Type approval for compressor package including all instrument items from PESO is needed. The bidder shall have servicing facility in India existing since, last six months. Proof of the same has to be submitted. Compressor foundation size with all projected portion should not exceed 6.0mm in length and 3.5m in width in all direction. Basis for calculation of venting loss/ KWH (Loading factor) to be demonstrated. Quoted valve shall be demonstrated at site by successful bidder. DOCUMENT NO. 11-0353-02-09-02-007 SHEET 21 OF 64
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4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 4.23 4.24 4.25
4.26 4.27 4.28
4.29 4.30 4.31 4.32
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4.33
RPM meter shall be in package
5.0 5.1
INSTRUMENTATION All Instruments shall be suitable for an area classification of Class 1, Division 2, Group D as per NEC OR Zone II, Group IIA/IIB as per IS/IEC. All package mounted transmitters/transducers & temperature element shall be intrinsically safe" i.e." as per IEC 79-11 and solenoid valves, switches and related junction boxes shall be certified flame proof (Eexd) as per IEC 79-1 by a statutory body viz. FM, BASEEFA etc. for the specified hazardous area classification. Other special equipments/instruments, where intrinsic safety is not feasible or available the same shall be flame proof (Eexd) certified suitable for the specified hazardous area by a statutory body as per IEC 70-1. All analog as well as digital input to PLC shall be connected through barriers. All analog barrier shall be isolator type. The compressor package instrumentation & control is to be configured for manual as well fully automatic control system including starting, shutdown as applicable for unattended operation. Control system shall be PLC based with make & model no. duly approved by CLIENT/CONSULTANT. Instrumentation electronics shall be certified by a recognized authority such as BASEEFA, PTB, LCIE, CESI, INIEX, and CMRS. All the instrumentation shall be capable of operating for full range of operation. 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. All pressure gauges and pressure transmitters shall be provided with common isolation valve and have accuracy of + or 1 % of Full Scale Deflection (FSD). The temperature gauge shall be generally mercury in steel filled type, weatherproof & with capillary extension. Capillary tubing shall be min CS with CS flexible armouring. The gauge shall have accuracy of + or - 1% Full Scale Deflection (FSD). The range shall be 1.5 times of operating temperature. 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. Units of measurement shall be: GAS FLOW PRESSURE TEMPERATURE Kg/hr & SM3/hr Kg/cm2 g 0C
5.2
5.3
5.4
5.5 5.6
5.7
5.7.1
5.8
5.9
5.10
Following points to be noted regarding Mass Flow meter Coriolis type:
5.10.1 Each Mass Flow meter shall include a sensor with integral transmitter i.e. meter electronics certified intrinsically safe/explosion proof by statutory authority suitable for the required hazardous area as per IS2148 /IEC-79. Also the offered sensor and the transmitter shall be weather proof to IP 65 as per IS2147/IEC-529. Statutory authority for local installation is CCOE. 5.10.2 Allowable pressure drop for the flow meter at the inlet and outlet of the compressor shall be 1.0 kg/ cm2. Offered mass flow meter shall be necessary for Custody Transfer application but not exceeding 0.5% of span. 5.10.3 Calibration for the offered mass flow meter shall be in Kg/hr and SM3/hr. Pressure, Temperature compensation shall be provided by the meter.

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5.10.4 Flying lead type electrical termination is not acceptable. All electrical connections shall be NPTF. Cable glands shall be provided for electrical power, signal and control connections. Cable glands shall be double compression type and certified weatherproof and explosion proof for the required area classification as per IS-2147 and IS-2148. 5.10.5 Offered Mass flow meter shall be completely free from corrosion of measuring tube due to alternating stresses continuously occurring in the tube. Also measuring tube shall be completely free from erosion, which may result due to fluid velocity. 5.10.6 The design of meter electronics shall be in compliance with the electromagnetic compatibility requirements as per IEC-801. Meter Electronics shall include all the associated pre-amplifiers converters lineariser etc. 5.10.7 Installation details like straight run requirements, recommendation for horizontal /vertical installation, minimum distance between upstream and downstream pipe bends from Mass flow meter to be provided. 5.10.8 Bidder shall calibrate each Mass Flow meter at his shop or any recognized test house with the fluid (Use design process conditions) for which it is to be used as per Clause no.9 of MPMS (Draft standard Nov. 2000). In case it is not possible to calibrate the Mass Flow meter with actual fluid, Bidder must indicate:a) Fluid used for calibration b) Correction factor/Adjustment required for actual process fluid. In any case, inaccuracy when extended to actual process shall not exceed the specified limits (as per manufacturers standard). 5.10.9 Bidder shall submit the following test certificates and test reports for purchasers review: a) Material test certificate with detailed chemical analysis from foundry (MIL Certificate). b) Certificate of radiography / x-ray for any welded joint. c) Hydrostatic test report with pressure of 1.5 times the design pressure. d) Calibration report including calibration factors for each Mass flow meter certificate from statutory body for offered sensor and transmitter for required area classification. 5.11 CERTIFICATION: The requirement of statutory approvals for usage of equipment/instruments/system in electrically hazardous areas shall be as follows: a) The bidder shall be responsible for obtaining all statutory approvals, as applicable for all instruments and control systems.
b) Equipments/instruments/systems located in electrically hazardous areas shall be certified for use by statutory authorities for their use in the area of their installation. In general, the following verification shall be provided by the bidder. Bidder shall provide certificates (from BASEEFA, FM, UL, PTB, LCIE etc.) from country of origin for all intrinsically safe/flameproof protected by other methods equipment/instrument/systems, which are manufactured outside India. Bidder shall provide necessary certification/approvals/authentication, for all such intrinsically safe/flameproof equipment/instrument/systems, by the Indian authorityChief 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. SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE DOCUMENT NO. 11-0353-02-09-02-007 SHEET 23 OF 64
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6.0
EARTHING / CABLING Metallic part of all equipment not intended to be live shall be connected to earth as per provisions of IS: 3043/IEC recommendation. Grounding of all electronics shall be separately connected to earth using insulated copper wire. Grounding of electronic equipment shall not be connected to earthing for electrics or equi-potential bonding.
6.1 6.1.1
Cabling Cables for Power & Control inside as well as outside the enclosure shall be minimum 2.5 Sqmm (copper) and 1.5 Sqmm (copper) respectively. Cables shall be 1100-volt grade, stranded copper conductor, PVC insulated PVC sheathed, steel round wire armoured. FRLS cables. Cables shall be terminated using double compression type metallic flameproof cable glands and copper lugs. Spare cores to be kept in each control cable. All Junction Boxes (JBs) shall have metallic enclosure Cables for control circuits shall be single phase (2 wire), 240 V, 50Hz A.C. supply from UPS. All cables shall be of armoured type. INSPECTION AND TESTING General a) Inspection and Test Requirements have been spelled out in respective Equipment Data Sheets & Technical Specification. b) Bidder shall confirm compliance to all inspection and testing requirements stipulated therein and include the inspection charges in the lump sum cost. c) All tests which are required to be witnessed stagewise as per data sheet and this specification shall be witnessed by a TPI duly appointed by the bidder. For major tests and inspection points as per data sheet and specification shall be witnessed by CLIENT/CONSULTANT. The bidder shall notify the timing of such inspection and testing to CLIENT/CONSULTANT one week before the schedule Inspection date. d) Bidder shall submit detailed Test Procedure for Approval of the CLIENT/CONSULTANT one week in advance of the actual date of conducting each test.
6.1.2
6.1.3
6.1.4 6.1.5 6.1.6 6.1.7 7.0 7.1
7.2 7.2.1
Mechanical running test (MRT) The MRT for the each compressors shall be carried out with job or shop driver including complete job driving system i.e., job pulleys etc., for 4 hours continuously at shop of compressor manufacturer. During this test following shall be recorded at agreed intervals. - Vibration levels measured on cylinders and frame - Bearing temperature - Oil cooler inlet and outlet temp Subsequent to satisfactory run the compressor shall be examined as per standard procedure & following shall be examined as minimum: - Bore & other parts by opening a valve DOCUMENT NO. 11-0353-02-09-02-007 SHEET 24 OF 64
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- Piston & cylinder clearance - Visual examination of piston rod, cylinder guide bore without dismantling If any of part found damaged, all similar components shall be stripped for inspection. The MRT test shall be repeated after replacement of such parts. 7.3 Motor Performance 1. Tests on the completely assembled motor shall be carried out in the presence of CLIENT/CONSULTANT or his representative. The results shall be tabulated and signed by both contractor and owner or their representatives. Though the motors shall be accepted on the basis of the satisfactory results of the tests at the works, it shall not absolve the contractor from liability regarding the proper functioning of motor coupled to the driven equipment at site. 2. General Inspection (a) Check for installation according to drawings. (b) Check equipment for clean and dry conditions, proper lubrication of bearings, earthing and terminations. 3. The motors shall be tested in accordance with IS:325 and IS:4029. Type tests including any specific test to ascertain compliance with these specifications shall be carried out if necessary, on one sample from each kW rating and frame size. Routine tests shall be carried out on all motors which are as follows: (a) Insulation resistance test. (b) High voltage test. (c) No load running of motor and reading of current in three phases and voltage. (d) Locked rotor test at a suitable voltage. (e) Reduced voltage running up test. (f) Temperature rises test. 1. Before connecting power cables to motor, the insulation resistance of all motor windings shall be measured with 500 Volts megger for 415 Volts systems and with 5 KV megger for H.V system. Minimum megger reading shall be 10 Mega ohms. Measurements shall be repeated after power cable terminations are completed. 2. After checking the direction of rotation, all motors shall be run uncoupled for a minimum period of 4 hours before the driven equipment is placed in regular service. 7.4 Mechanical String Test Mechanical String Test for 4 hrs is a mandatory requirement to be performed at packagers shop before despatch in presence of CLIENT/CONSULTANT representatives (or a third party as arranged by SGL). This test can be clubbed up with the Mechanical Run Test of compressor as specified above, provided the job driver & lube Oil system is used for the test. At least 25% of the packages ordered shall be string tested.Mechanical run test however is a mandatory requirement. 7.5 Package Performance Test Bidder shall send fully assembled package including auxiliary systems, instrumentation, safety devices within the enclosure to the site and carry out the performance test for 72 hours duration at site or works. Full load performance test shall be carried out at site/work for 4 hours. Field trial run shall be carried out for 72 hours duration added with interval after full load performance test. In case the bidder has the facility to carry out the complete field performance test satisfactorily at their works then the bidder need not repeat the field performance test. This shall be in addition to tests carried out as per clause nos. 8.2, 8.3 & 8.4. Complete package shall be performance tested as a module whereby along with motor & compressor performance bidder shall demonstrate all controls, shutdown, trips/alarms etc. DOCUMENT NO. 11-0353-02-09-02-007 SHEET 25 OF 64
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The test shall be the basis of assigning penalties on the bidder, acceptance/rejection of the package thereon. Bidder shall submit the detail test procedure for the same including methodology of demonstration of venting losses, which shall be approved by SGL. The test for the package shall be witnessed by SGLs representative.
8.0 8.1
PERFORMANCE GUARANTEES, LOADING AND PENALTIES This section describes the guaranteed parameter, which the CNG compressor package must fulfill, the penalty for shortfall in guaranteed parameters and rejection of compressor package by the CLIENT/CONSULTANT. The guaranteed parameter shall be adjusted to account for variation in gas composition and prevailing ambient condition during testing. Necessary calculations correction curves shall have to be furnished by Bidder along with bid, which shall be final & no deviation shall be permitted afterwards. In case of any inconsistency in manufacture and/or operation of supplied compressor package, Bidder shall at his own risk and cost, eliminate the defects to the satisfaction of CLIENT/CONSULTANT. Bidder shall furnish guaranteed value as per Annexure II enclosed with this specification. Compressor Capacity Bidder shall guarantee 1200 SCM/hr capacity of compressor with design case gas composition, at suction pressure of 16 kg/cm2g, suction temperature of 19oC, discharge pressure of 250 kg/cm2g. Since the compressor suction pressure varies from 14 kg/cm2g to 19 kg/cm2g the compressor shall be sized / selected for specified capacity of 1200 SCM/Hr at 16 kg/cm2g (with no ve tolerance) whereas the driver shall be selected on the basis of compressor BkW with either 14 kg/cm2g or 19 kg/cm2g whichever is higher.
8.2
8.3
8.4
8.5 8.5.1
8.5.2
Bidder shall guarantee 650 SCM/hr capacity of compressor with design case gas composition, at suction pressure of 16 kg/cm2g, suction temperature of 190 C, discharge pressure of 250 kg/cm2g with the negative tolerance for errors in instruments and measurements. Since the compressor suction pressure varies from 14 kg/cm2g to 19 kg/cm2g the compressor shall be sized / selected for specified capacity of 650 SCM/Hr at 16 kg/cm2g (with no -ve tolerance) whereas the driver shall be selected on the basis of compressor BkW with either 14 kg/cm2g or 19 kg/cm2g whichever is higher. The Total connected load of 650 SCMH compressors should not exceed 98 KW.The same shall be used to establish the capacity at test bed during package performance test. Bidder to note that a separate filtering cum regulating skid to be provided at the inlet with pressure range of 20-35 bar to feed the compressor at 14-19 bar.
8.6 8.6.1
Loading & Penalty Criteria Loading Bidder shall indicate the Power Consumption and/or BHP as guaranteed value in the offer. Bidder shall also indicate the venting losses due to leakages from packings in percentage of total throughput of the package. The offers shall be loaded for the fuel/electricity consumption as given under:The loading per package shall be the differential cost evaluated as follows; Total cost of the package for evaluation purpose (A+C1+C2) Where A: Capital cost of each package including cost of erection, commissioning, special tools and commissioning spares

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C1: Differential operating cost for power consumption as defined hereunder C2: Differential operating cost for vent/packing losses as defined hereunder Differential operating cost (C1) C1 (in Rs) = Nop x (Fe - Fr) x Cp X Dp Where Nop: Fe: Fr: Cp: Dp: 8000 Hrs Guaranteed power consumption in KW by the bidder. Lowest Guaranteed power consumption KW (amongst technically accepted bidders) Cost of power as Rs 3.85 / KWH 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: Fv: Fr: Cf: Df: 8000 Hrs Estimated venting/packing losses in percentage of throughput of package by the bidder. Lowest venting/packing losses in percentage of throughput (amongst technically accepted bidders) Cost of fuel as Rs 14 / SCM discounting factor to arrive at Net Present Value (NPV) based on 5 years i.e. 3.274
Maximum loading shall be limited to 10% of the total quoted Cost i.e. A as defined above. 8.6.2 Penalty During compressor package performance test, in case the compressor package fails to meet the guaranteed values, the following penalties shall be imposed. A. In case during shop performance test of compressor package the power consumed in terms of KW, to achieve the guaranteed compressor capacity of 1200 SCM/Hr or 650 SCM/Hr as the case may be is found more than 10% the entire package shall stand rejected. However, for every extra KW consumed over and above the guaranteed value upto a maximum of ten percent the Bidder shall be penalized for extra power consumption. The penalty per package shall be the differential cost calculated as follows: PY (in Rs) = (FT-FG) X CP X 8000 X DP Where, PY = Penalty Cost FT = Power consumption as obtained from performance test in terms of KW FG = Guaranteed power consumption in KW CP = Rs. 3.85 / KWH DP = 3.274 (Discounting factor based on 5 years of operating years) B. In shop performance test if the venting/ packing losses in percentage of throughput of 1200 SCM/Hr or 650 SCM/Hr are found to be in excess of the guaranteed value the bidder shall be penalized for excess venting losses.

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The penalty per package shall be the differential cost calculated as follows: PY (in Rs) = (FT-FG) X CF X 8000 X DF Where, PY = Penalty Cost FT = Venting/packing loss as obtained from performance test in terms percentage of throughput FG = Estimated venting/packing loss in percentage of throughput CF = Rs. 14 /SCM DF = 3.274 (Discounting factor based on 5 years of operating years) The total penalty to be charged for non-conformance of guaranteed parameter shall not exceed 10% of the ordered value i.e. A+B as defined above. No advantage shall be given for higher performance than the guaranteed. Bidder shall indicate the Guaranteed parameter in his offer as per AnnexureI of this specification.
8.6.3
Penalty for Non-Performance during Period of Operation & Maintenance
8.6.3.1 Details of Penalty for non performance of equipments (a) On normal day (i.e. the day other than the schedule maintenance day): (i) (ii) 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. If the equipment is down for more than 4 hours on any day or availability is less than 98% in a month. Penalty would be applicable as follows: Upto 12 hours: Rs. 10,000/- per day. Beyond 12 hours: Rs. 25,000/- per day. (b) On schedule maintenance day: (i) The party would be required to carry out the recommended schedule/preventive maintenance of the equipments for which the party has to indicate the time required for each type of schedule maintenance. 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.
(ii)
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 9.1 PAINTING AND PROTECTION Packing shall be sufficiently robust to withstand rough handling during ocean shipment & inland journey. Sling points shall be clearly indicated on crates. 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.
9.2

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9.3 10.0 10.1
The headers of air-cooled exchanger shall be zinc sprayed. ERECTION, TESTING AND COMMISSIONING AT SITE Bidder shall be responsible for erection commissioning; performance test, field noise level test and field trial run of all compressor packages at site. Bidder shall be liable to pay all local taxes, levies applicable and comply with rules, laws prevailing in India. FIELD TRIAL RUN/ SITE PERFORMANCE TEST Bidder shall conduct a field trial run of each compressor package for minimum 72 hours continuous duration at guaranteed points in which satisfactory operation of complete package together with all accessories/auxiliaries controls shall be established for specified operating conditions prior to the start of 1st year operation and maintenance during warranty period & next 3 Years operation & comprehensive maintenance period as defined in the contract. Full load performance test shall be carried out at site/work for 4 hours. Field trial run shall be carried out for 72 hours after full load performance test. During the field trial run the bidder will be allowed a maximum of THREE attempts to complete the above-specified test. The Equipment shall be considered commissioned after the successful completion of Field Trial Run. All punch points raised by CLIENT/CONSULTANT should be completed before performing the FTR/ Site PT. The above conditions are also applicable in case the bidder carries out the performance test and trial run at their works.
10.2
11.0
12.0 12.1
SPARE PARTS, SPECIAL TOOLS AND TACKLES All spare parts, special tools & tackles for erection and commissioning and spare parts required for 1(One)+ Three (03) Year Operation and maintenance of compressor package shall be arranged by the Packager and shall form his scope of supply. The bidder has to provide the list of spares, tools & tackles for erection and commissioning and spare parts required for operation & maintenance along with the bid. These tools and tackles and any spare parts left after work completion shall be the property of Client. Bidder shall maintain sufficient spares to fulfill the warranty period requirements. A brand new separate set of Special Tools & Tackles per compressor as required for preventive maintenance as well as breakdown maintenance beyond the contractual One Year Operation Period shall be supplied by the Packager, which shall form the property of CLIENT/CONSULTANT.
12.2
13.0
MAINTENANCE PHILOSPHY: Bidder shall provide maintenance philosophy and schedule of maintenance along with offer. First year of operation, when equipment is in warranty period, bidder shall arrange and store all necessary spares to avoid any loss in operating times. Bidder also intimate the list of recommended spares envisaged for maintenance and shall store in the custody.
14.0
WARRANTY SERVICING AND SPARE PARTS The supplier should provide a warranty for a period of 12 months after commissioning or 24 months from the date of shipment, whichever expires first inline with GCC. All necessary spare parts during warranty period shall be provided by bidder free of cost for which bidder shall provide sufficient stock of spares at CT of installation.

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15.0
DATA AND DRAWING a) Drawings and Data shall be furnished in conformity with the Bidder Data Requirements Forms attached with Enquiry Specifications. Bidder shall furnish all the information at the time of bidding as specified in the relevant Bidder Data Requirement (BDR) forms. 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 Bidders promised data in the columns provided. After the placement of FOI, a conference (kick off meeting) will be held at such place, as may be mutually agreed upon between the Bidder and the CLIENT/CONSULTANT within 15 days from the date of placement of FOI. The intent of this conference shall be to discuss / clarify various requirements and finalize the modus operandi for execution of the contract within the scheduled delivery period. Bidder shall furnish the Drawings/Documents for CLIENT/CONSULTANTs 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&IDs, General Arrangement Drawings, Foundation Drawings, Performance characteristics, Pulsation and Vibration Study Reports, Torsional Analysis etc.) shall be discussed across the table at such date and place as may be mutually agreed between the CLIENT/CONSULTANT and the Bidder. Along with the supply of compressor packages, the supplier shall provide application software for PLC & HMI, ladder logic. Programming software one set usable for all machines is to be supplied.
b)
c)
d)
e)
f)

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ANNEXURES

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ANNEXURE I: GAS COMPOSITION Component Methane Ethane Propane i-Butane n-Butane i-Pentane n-Pentane Nitrogen Carbon dioxide C6+ Total % mole 94.5189 4.3663 0.5405 0.0877 0.1227 0.0057 0.0020 0.2863 0.0663 0.0037 100
Oxygen Total Non Hydrocarbon Total Sulphur including H2S Water Content Specific Gravity (SG) Net Calorific Value
: Not more than 0.5 mole% : Not more than 2.0 mole% : Not more than 10 ppm by weight expected H2S content not more than 4 ppm by volume : <112 Kg per MMSCM : 0.55 - 0.63 : 8485.096 Kcal/SCM

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ANNEXURE-II: GUARANTEED PARAMETERS GUARANTEED PARAMETERS II (A) 1200 SCMH (Electric Motor Driven with suction pressure 14 - 19 kg/cm2G)
Sr. No. 1 2 3 4 5 6 7
Parameter Compressor Capacity in SM3/Hr (required 1200 SM3/Hr) Compressor BKW in KW @ Rated Conditions (No +ve tolerance) Compressor BKW in KW @ RV Set Conditions (No +ve tolerance) Net of all auxiliaries/package ventilation loads in KW Site rated BKW of Motor (No ve tolerance) Vent/packing losses in package in percentage of throughput(Basis of loading and penalty) Noise level 75 dBA @ 1 meter from enclosure (required 75 dBA max)
Bidders Data
GUARANTEED PARAMETERS II (B) 650 SCMH (Electric Motor Driven with suction pressure 14 - 19 kg/cm2G)
Sr. No. 1 2 3 4 5 6 7
Parameter Compressor Capacity in SM3/Hr (required 650 SM3/Hr) Compressor BKW in KW @ Rated Conditions (No +ve tolerance) Compressor BKW in KW @ RV Set Conditions (No +ve tolerance) Net of all auxiliaries/package ventilation loads in KW Site rated BKW of Motor (No ve tolerance) Vent/packing losses in package in percentage of throughput(Basis of loading and penalty) Noise level 75 dBA @ 1 meter from enclosure (required 75 dBA max)
Bidders Data

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ANNEXURE III: LIST OF RECOMMENDED THIRD PARTY INSPECTION AGENCY
LIST OF RECOMMENDED THIRD PARTY INSPECTION AGENCY S.NO ITEM NAME OF VENDOR Tata Projects Ltd. ADDRESS 22,Sarvodaya Society,Nizampura,Baroda-390002 52 AAdi Shankaracharya Marg Opp. Powai Lake , Powai,MUMBAI,400 072 303, Madhava,Bandra Kurla Complex, Bandra(E),Mumbai-400051 The Leela Galleria,5th floor,AndheriKurla Road,Andheri(E),Mumbai400059 304-305, Anna Salai,Teyanampet,Chennai-600018 Velosi Certification Services(I)Pvt.Ltd.,212,Shivkrupa Complex Centre,Off Ghokhale Road,Navpada Thane(W)-400602 404,Mayuresh Chambers,Sector11,CBD Belapur(E),Navi Mumbai400614 EIL Bhavan,5th floor,1,Bhikaji Camma Place,New Delhi-110066 501, Sakar -II, Ellisbridge,Ahemedabad-380006 E-7,Chand Society, Juhu Road, Juhu, Mumbai-4000049 SGS India Pvt. Ltd.,SGS House,4B,A.S.Marg,Vikhroli(W),Mum bai-400083 PHONE NO 02652392863 02230519400 02226591526, 02226590236 02226956300 04424320335 02225376770 02227578780 /1 /2 01126167539,26 102121 07926575550 02226245747 02225798421 to 28 FAX NO 02652785952 02225703611 02226591526 02226956309 04424328186 02225426777 02227578784 / 5 01126101419 0796575558 022226248167 02225798431 to 33
Indian Register of Shipping Bax counsel Insepection Bureau Pvt. Ltd. Bureau Veritas Ql Germanischer Lloyd Third Party Inspection Agency Velosi Certification Serrvices,Mumbai ABS Industrial Verification Ltd., Mumbai Certification Engineers International Ltd. Dalal Mott MacDonald International Certification Systems SGS
10
11 Note:
The details of Vendors indicated in this list are based on the information available with WGEIL, BIDDER shall verify the capabilities of each vendor for producing the quantity with proper quality. Purchaser or purchaser representative does not take any responsibility on the performance of the vendor.

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ANNEXURE IV: APPROVED BIDDER LIST

ITEM CODE / DESCRIPTION BIDDER NAME 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 BIDDER NAME ABB AUTOMATION LTD. BROWN BOVERT LTD. ASCHROFT MURPHY CCS WAREE FISHER ROSEMOUNT INDIA LIMITED FISHER ROSEMOUNT SINGAPORE PTE LTD. FUJI ELECTRIC CO. LTD. HONEYWELL INC. TATA HONEYWELL YOKOGAWA ELECTRIC CORPORATION YOKOGAWA BLUE STAR LTD. WIKA DRUCK ITEM CODE / DESCRIPTION BIDDER NAME ENDRESS & HAUSER CMBH & COMPANY AIR FILTER REGULATORS REMARK
FIELD INSTRUMENTS (P, DP, F,L,T) REMARKS
EMERSON PROCESS MANAGEMENT RHEONIK MESSGERATE GMBH ITEM CODE / DESCRIPTION BIDDER NAME 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 CODE / DESCRIPTION BIDDER NAME
MASS FLOW METERS REMARK CORIOLIS TYPE, MANUFACTUER, ENDRESS + HAUSER FLOWTEC AG, REINACE, SWITZERLAND CORIOLIS TYPE CORIOLIS TYPE PRESSURE GAUGES REMARKS
PRESSURE RELIEF VALVE REMARKS

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

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

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ANNEXURE-V: BIDDER DATA REQUIRED (A) BIDDER DATA REQUIRED (For 1200 SCMH (Electric Motor Driven) with suction pressure 14 19 kg/cm2) S. NO A 1 2 DESCRIPTION PRINTS WITH BID CERTIFIED INFORMATION REQUIRED AFTER PURCHASE ORDER FOR REVIEW FOR RECORDS
5 6
9 10
11 12 B 1 A B C D 2 3
A B C
GENERAL PROJECT SCHEDULE DULY FILLED-IN CHECKLIST FOR COMPLETENESS OF BID DULY FILLED-IN CHECKLIST FOR SCOPE OF SUPPLY DEVIATION LIST (IF ANY) TO THE APPLICABLE SPEC., DATASHEETS UTILITIES REQUIREMENT SUMMARY FLANGE DETAILS OF PIPING CONNECTION WITH CONNECTION AT BATTERY LIMIT DULY FILLED IN EXPERIENCE RECORD PROFORMA GUARANTEE PARAMETERS AS SPECIFIED TENTATIVE LOAD DATA FOR FOUNDATION DESIGN LIST OF SUB-BIDDERS FOR ALL BOUGHT OUT ITEMS INCLUDING ELECTRICAL & INSTRUMENTATION ITEMS LEAFLET, CATALOGUES FOR ALL ITEMS O & M MANUAL COMPRESSOR DATASHEETS FOR THE FOLLOWING - COMPRESSOR - HEAT EXCHANGERS - PRESSURE VESSELS - MOTOR CATALOGUE FOR COMPRESSOR TYPICAL CROSS SECTIONAL DRAWING AND LITERATURE TO FULLY DESCRIBE THE DETAILS OF OFFERING - COMPRESSOR - SUCTION VALVE - DISCHARGE VALVE
YES YES
YES
YES
YES YES
YES
YES
YES
YES
YES YES
YES
YES YES
YES YES YES YES YES YES
YES YES YES YES YES YES YES
YES YES YES DOCUMENT NO. 11-0353-02-09-02-007 SHEET 38 OF 64 REV B
SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGES
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D E 4 5
A B C 8
9 10 11
12 A B C D E 13
14 A B C 15
C 1 2
- PISTON ROD GLAND PACKING & PISTON RINGS - LUBE OIL PUMP PULLEY WITH SELECTION CHART & CALCULATION COOLER DATA / DRG WITH THERMAL & MECH DESIGN CALCULATION DESIGN CALCULATION, GA DRGS FOR PULSATION DAMPNER PIPING & INSTRUMENTATION DIAGRAMS FOR THE FOLLOWING - PROCESS GAS - LUBE OIL - AIR START UP / VENT TORQUE ANGLE DIAGRAM, PISTON ROD LOAD VS CRANK ANGLE TORQUE SPEED CHARACTERISTICS ACOUSTIC / MECHANICAL EVALUATION REPORT DRG. FOR TESTING ARRANGEMENT & TEST PROCEDURE TO BE ADOPTED CERTIFICATE FOR FOLLOWING: HYDRAULIC TESTING NON DESTRUCTIVE TESTING MATERIAL COMPOSITION & PHYSICAL PROPERTIES LEAK PROOFNESS TEST OF FRAME LUBE PUMP, FRAME OIL PUMP, HYD OIL PUMP DESIGN / ACTUAL ASSEMBLY CLEARANCE CHART TEST RECORDS OF FOLLOWING MECHANICAL RUNNING S PERFORMANCE TEST / PACKAGE TEST NOISE LEVEL TEST YES LIST OF SPECIAL TOOLS & TACKLES FOR INSTALLATION & MAINTENANCE ELECTRIC MOTOR PERFORMANCE CURVES TECHNICAL LITERATURE /
YES YES YES YES
YES
YES
YES
YES YES YES
YES YES YES YES
YES YES YES
YES YES YES YES YES
YES YES
YES YES
YES
REV B
Page 40 of 129
3 4
5 6
D 1
2 3
4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19
CATALOGUE, SELECTION CHARTS, NOMOGRAPHS ETC. CONTROL SCHEMATICS 3 TYPICAL COMPONENT CROSS SECTIONAL DRAWING AND LITERATURE TO FULLY DESCRIBE THE DETAILS OF OFFERING TEST PROCEDURE FINAL ACCEPTANCE TESTING AND PERFORMANCE TESTED RECORDS SCHEMATIC DIAGRAM WITH START UP & SHUT DOWN PROCEDURE & LOGIC INSTRUMENTATION G.A. OF INSTRUMENT PANEL WITH BILL OF MATERIAL & WIRING DIG. FOR LCP INSTRUMENT DATASHEET LOGIC DIAGRAM / LADDER DIAGRAM / FUNCTIONAL DIAGRAM LOOP SCHEMATIC INTER CONNECTING DIAGRAM OPERATING / CONTROL WRITE UP ALARM / SHUT DOWN LIST7 WIRING DIAGRAM / INTER CONNECTING PIPING START UP AND SHUT DOWN WRITE UP START UP AND SHUT DOWN INLET LOCK DIAGRAM ALARM AND SHUTDOWN LIST WITH SET POINT LOAD CONTROL PANEL LAYOUT TERMINATION DIAGRAM, PANEL WIRING DETAIL LOOP SCHEMATIC INTER CONNECTING DIAGRAM CABLE SCHEMATIC BILL OF MATERIAL TEST / INSPECTION CERTIFICATE LIST OF RELIEF VALVES WITH SETTINGS
YES
YES YES
YES YES
YES
YES
YES YES
YES YES YES YES YES YES YES YES YES
YES
REV B
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1.1.1 Document Distribution Schedule 1.1.2 Documents and drawings under column no. 3 shall be submitted with each copy of the bid. 1.1.3 Documents listed under column 4 are to be submitted in 4 copies 1.1.4 Documents listed under column 5 are to be submitted in 4 copies. 1.1.5 Documents listed in Clause 1.2 below are to be submitted as hard bound indexed book containing the following details in Twelve (12) copies & 2 AutoCAD software set and to be submitted within 4 weeks of release note/dispatch of materials/ equipment from bidder's works. 1.2 Details to be included in Final Documents Books
1.2.1 Copy of P.O. and all amendments. 1.2.2 Copy of Purchase Requisition and all amendments. 1.2.3 Manufacturing Data Book containing all test certificates of components, raw materials, stage manufacturing tests and inspections, final tests & inspection documents including welders' qualification & welding procedure qualification, repairs & reworking carried out in shops. All raw material test certificates must be correlated to the P.O. Item No. & component to which they relate by clear notings on the certificates. 1.2.4 Spares details including assembly drawings, part numbers, delivery, prices and ordering information. 1.2.5 All design calculations carried out by the bidder. 1.2.6 Final Drawing Index and all as-built drawings reduced to A3/ A4 size and wherever reduction is not possible, full size copies duly folded and placed in plastic pockets. 1.2.7 Catalogues/leaflets of sub-bidders/suppliers of various bought out components highlighting the components actually supplied correlated to P.O.Item Numbers. 1.2.8 Operating and maintenance instructions including lubrication schedules with details of suppliers for procurement by OWNER for subsequent needs. 1.2.9 Release Note and Packing List. 1.2.10 Any other documents asked for in the Purchase Requisition. 1.2.11 All final drawings shall also be given to purchaser in digitized form on CD-ROM compatible AUTOCAD software (2 sets). 1.3 Special instructions for submission of Dwgs./Documents: to
1.3.1 Fold all prints to 216 MM x 279 MM size & roll transparencies. 1.3.2 Contractor to forward the drawings and documentation to SGL (Attention bidder prints control department) clearly specifying purchasers Job no. & Req. No. 1.3.3 The drawing/Document no. with Rev. No. is essential. The number may be up to a maximum of 28 characters in length. 1.3.4 Each Drawing/Document submitted to SGL must be checked and signed/stamped by contractor before it is submitted to SGL. 1.3.5 Revision number must change during subsequent submission of bidder document. 1.3.6 Multi-sheet documents other than drawings must be submitted in their entirety in the event of a resubmission even if only a few sheets are revised. 1.3.7 Final submission in bound volumes shall necessarily have a cover page giving project title, Item name, P.O.No. particulars of owner & bidder and an index giving list of drawings & documents included (with revision no. 1.3.8 All bidder drawings to be provided with a blank space measuring 75 mm W x 38 mm H for marking of review codes etc. by SGL. 1.3.9 The review of the bidder drawings shall be done by SGL, as applicable, under the following review codes: DOCUMENT NO. 11-0353-02-09-02-007 SHEET 41 OF 64 REV B
Page 42 of 129
Review Code A Review Code B Review Code C Review code D
No comments. P Proceed with manufacture/fabrication as per commented drawings. Revise drawings required Document does not conform to basic requirements. For information
1.3.10 Review of bidder drawings by SGL would be only to check compatibility with basic designs & concepts & would in no way absolve the contractor/bidder of his responsibility to meet applicable codes, specifications & statutory rules/regulations. Bidder shall submit within 10 days after placement of FOI, the complete list of drawings/ documents with submission dates against each. Critical drawings, only, the list of which will be agreed during kickoff meeting shall be reviewed jointly at SGL's office.
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(B) BIDDER DATA REQUIRED (For 650 SCMH (Electric Motor Driven) with suction pressure 14 19 kg/cm2) S. NO A 1 2 DESCRIPTION PRINTS WITH BID CERTIFIED INFORMATION REQUIRED AFTER PURCHASE ORDER FOR REVIEW FOR RECORDS
5 6
9 10
11 12 B 1 A B C D 2 3
A B C D
GENERAL PROJECT SCHEDULE DULY FILLED-IN CHECKLIST FOR COMPLETENESS OF BID DULY FILLED-IN CHECKLIST FOR SCOPE OF SUPPLY DEVIATION LIST (IF ANY) TO THE APPLICABLE SPEC., DATASHEETS UTILITIES REQUIREMENT SUMMARY FLANGE DETAILS OF PIPING CONNECTION WITH CONNECTION AT BATTERY LIMIT DULY FILLED IN EXPERIENCE RECORD PROFORMA GUARANTEE PARAMETERS AS SPECIFIED TENTATIVE LOAD DATA FOR FOUNDATION DESIGN LIST OF SUB-BIDDERS FOR ALL BOUGHT OUT ITEMS INCLUDING ELECTRICAL & INSTRUMENTATION ITEMS LEAFLET, CATALOGUES FOR ALL ITEMS O & M MANUAL COMPRESSOR DATASHEETS FOR THE FOLLOWING - COMPRESSOR - HEAT EXCHANGERS - PRESSURE VESSELS - MOTOR CATALOGUE FOR COMPRESSOR TYPICAL CROSS SECTIONAL DRAWING AND LITERATURE TO FULLY DESCRIBE THE DETAILS OF OFFERING - COMPRESSOR - SUCTION VALVE - DISCHARGE VALVE - PISTON ROD GLAND
YES YES
YES
YES
YES YES
YES
YES
YES
YES
YES YES
YES
YES YES
YES YES YES YES YES YES
YES YES YES YES DOCUMENT NO. 11-0353-02-09-02-007 SHEET 43 OF 64 REV B
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E 4 5
A B C 8
9 10 11
12 A B C D E 13
14 A B C 15
C 1 2
PACKING & PISTON RINGS - LUBE OIL PUMP PULLEY WITH SELECTION CHART & CALCULATION COOLER DATA / DRG WITH THERMAL & MECH DESIGN CALCULATION DESIGN CALCULATION, GA DRGS FOR PULSATION DAMPNER PIPING & INSTRUMENTATION DIAGRAMS FOR THE FOLLOWING - PROCESS GAS - LUBE OIL - AIR START UP / VENT TORQUE ANGLE DIAGRAM, PISTON ROD LOAD VS CRANK ANGLE TORQUE SPEED CHARACTERISTICS ACOUSTIC / MECHANICAL EVALUATION REPORT DRG. FOR TESTING ARRANGEMENT & TEST PROCEDURE TO BE ADOPTED CERTIFICATE FOR FOLLOWING: HYDRAULIC TESTING NON DESTRUCTIVE TESTING MATERIAL COMPOSITION & PHYSICAL PROPERTIES LEAK PROOFNESS TEST OF FRAME LUBE PUMP, FRAME OIL PUMP, HYD OIL PUMP DESIGN / ACTUAL ASSEMBLY CLEARANCE CHART TEST RECORDS OF FOLLOWING MECHANICAL RUNNING S PERFORMANCE TEST / PACKAGE TEST NOISE LEVEL TEST YES LIST OF SPECIAL TOOLS & TACKLES FOR INSTALLATION & MAINTENANCE MOTOR PERFORMANCE CURVES TECHNICAL LITERATURE / CATALOGUE, SELECTION
YES YES YES
YES
YES
YES
YES YES YES
YES YES YES YES
YES YES YES
YES YES YES YES YES
YES YES
YES YES
YES
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3 4
5 6
D 1
2 3
4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19
CHARTS, NOMOGRAPHS ETC. CONTROL SCHEMATICS 3 TYPICAL COMPONENT CROSS SECTIONAL DRAWING AND LITERATURE TO FULLY DESCRIBE THE DETAILS OF OFFERING TEST PROCEDURE FINAL ACCEPTANCE TESTING AND PERFORMANCE TESTED RECORDS SCHEMATIC DIAGRAM WITH START UP & SHUT DOWN PROCEDURE & LOGIC INSTRUMENTATION G.A. OF INSTRUMENT PANEL WITH BILL OF MATERIAL & WIRING DIG. FOR LCP INSTRUMENT DATASHEET LOGIC DIAGRAM / LADDER DIAGRAM / FUNCTIONAL DIAGRAM LOOP SCHEMATIC INTER CONNECTING DIAGRAM OPERATING / CONTROL WRITE UP ALARM / SHUT DOWN LIST7 WIRING DIAGRAM / INTER CONNECTING PIPING START UP AND SHUT DOWN WRITE UP START UP AND SHUT DOWN INLET LOCK DIAGRAM ALARM AND SHUTDOWN LIST WITH SET POINT LOAD CONTROL PANEL LAYOUT TERMINATION DIAGRAM, PANEL WIRING DETAIL LOOP SCHEMATIC INTER CONNECTING DIAGRAM CABLE SCHEMATIC BILL OF MATERIAL TEST / INSPECTION CERTIFICATE LIST OF RELIEF VALVES WITH SETTINGS
YES
YES YES
YES YES
YES
YES
YES YES
YES
1.1.1 Document Distribution Schedule SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGES DOCUMENT NO. 11-0353-02-09-02-007 SHEET 45 OF 64 REV B
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1.1.2 Documents and drawings under column no. 3 shall be submitted with each copy of the bid. 1.1.3 Documents listed under column 4 are to be submitted in 4 copies 1.1.4 Documents listed under column 5 are to be submitted in 4 copies. 1.1.5 Documents listed in Clause 1.2 below are to be submitted as hard bound indexed book containing the following details in Twelve (12) copies & 2 AutoCAD software set and to be submitted within 4 weeks of release note/dispatch of materials/ equipment from bidder's works. 1.2 Details to be included in Final Documents Books
1.2.1 Copy of P.O. and all amendments. 1.2.2 Copy of Purchase Requisition and all amendments. 1.2.3 Manufacturing Data Book containing all test certificates of components, raw materials, stage manufacturing tests and inspections, final tests & inspection documents including welders' qualification & welding procedure qualification, repairs & reworking carried out in shops. All raw material test certificates must be correlated to the P.O. Item No. & component to which they relate by clear notings on the certificates. 1.2.4 Spares details including assembly drawings, part numbers, delivery, prices and ordering information. 1.2.5 All design calculations carried out by the bidder. 1.2.6 Final Drawing Index and all as-built drawings reduced to A3/ A4 size and wherever reduction is not possible, full size copies duly folded and placed in plastic pockets. 1.2.7 Catalogues/leaflets of sub-bidders/suppliers of various bought out components highlighting the components actually supplied correlated to P.O.Item Numbers. 1.2.8 Operating and maintenance instructions including lubrication schedules with details of suppliers for procurement by OWNER for subsequent needs. 1.2.9 Release Note and Packing List. 1.2.10 Any other documents asked for in the Purchase Requisition. 1.2.11 All final drawings shall also be given to purchaser in digitized form on CD-ROM AUTOCAD software (2 sets). 1.3 Special instructions for submission of Dwgs./Documents: compatible to
1.3.1 Fold all prints to 216 MM x 279 MM size & roll transparencies. 1.3.2 Contractor to forward the drawings and documentation to SGL (Attention bidder prints control department) clearly specifying purchasers Job no. & Req. No. 1.3.3 The drawing/Document no. with Rev. No. is essential. The number may be up to a maximum of 28 characters in length. 1.3.4 Each Drawing/Document submitted to SGL must be checked and signed/stamped by contractor before it is submitted to SGL. 1.3.5 Revision number must change during subsequent submission of bidder document. 1.3.6 Multi-sheet documents other than drawings must be submitted in their entirety in the event of a resubmission even if only a few sheets are revised. 1.3.7 Final submission in bound volumes shall necessarily have a cover page giving project title, Item name, P.O.No. particulars of owner & bidder and an index giving list of drawings & documents included (with revision no. 1.3.8 All bidder drawings to be provided with a blank space measuring 75 mm W x 38 mm H for marking of review codes etc. by SGL. 1.3.9 The review of the bidder drawings shall be done by SGL, as applicable, under the following review codes: Review Code A No comments.
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Review Code B Review Code C Review code D
Proceed with manufacture/fabrication as per commented drawings. Revise drawings required Document does not conform to basic requirements. For information
1.3.10 Review of bidder drawings by SGL would be only to check compatibility with basic designs & concepts & would in no way absolve the contractor/bidder of his responsibility to meet applicable codes, specifications & statutory rules/regulations. Bidder shall submit within 10 days after placement of FOI, the complete list of drawings/ documents with submission dates against each. Critical drawings, only, the list of which will be agreed during kick-off meeting shall be reviewed jointly at SGL's office.
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ANNEXURE-VI: M.R. COMPLIANCE SCHEDULE ANNEXURE VI (A): 1200 SCMH ELECTRIC MOTOR DRIVEN CNG COMPRESSOR
ITEM: CNG COMPRESSOR Bidder: S. No. 1.0 Requirements Confirm compliance individually to following clauses of Job Specification. SECTION: A Clause no 1.0 Clause no 2.0 Clause no 3.0 Clause no 4.0 Clause no 5.0 Clause no 6.0 Clause no 7.0 Clause no 8.0 Clause no 9.0 Clause no 10.0 Clause no 12.0 Clause no 13.0 Clause no 14.0 Clause no 15.0 Clause no 16.0 2.0 Confirm that you have filled-up the following Schedules/ Annexure and enclosed these with the Bid Gas Composition (Annexure-I) Guarantee Parameters (Annexure-IIA) List of Recommended Third Party Inspection Agency (Annexure-III) Approved Vendor List (Annexure-IV) Bidder Data Required (Annexure-VA) Compliance By Bidder (To Be Answered By Bidder)
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3.0
Experience Record Schedule for CNG Compressors Package (Annexure-VIA) Material Requisition Compliance Schedule (Annexure-VIIA) Confirm that you have filled-up the Data Sheet and enclosed with the Bid. Compressor Data Sheet Electric Motor Data Sheet Inter cooler Data Sheet Heat Exchanger Data sheet Mass Flow Meter Data Sheet Control Valves Solenoid Valves Self Actuated Pressure Control Valves Pressure Relief Valve Pressure Instruments Pressure Gauges
4.0
Confirm that following Documents have been enclosed with Bid. List of components of CNG Compressor with Make & Specification of components alongwith Technical Catalogues of components. Battery Limit (Interface) drawing/ information. Process flow diagrams (PFDs) and Piping & Instrumentation diagrams (P & IDs) of sub systems and complete system with write-up on operation Utility requirement Detail of control wiring diagram, interlock/shutdown/ control scheme with write up on operation. Sizing calculation for instrument items. G.A. drawing of Compressor showing maintenance clearances required.
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ANNEXURE VI (B): 650 SCMH ELECTRIC MOTOR DRIVEN CNG COMPRESSOR

ITEM: CNG COMPRESSOR Bidder: S. No. 1.0 Requirements Confirm compliance individually to following clauses of Job Specification. SECTION: A Clause no 1.0 Clause no 2.0 Clause no 3.0 Clause no 4.0 Clause no 5.0 Clause no 6.0 Clause no 7.0 Clause no 8.0 Clause no 9.0 Clause no 10.0 Clause no 12.0 Clause no 13.0 Clause no 14.0 Clause no 15.0 Clause no 16.0 2.0 Confirm that you have filled-up the following Schedules/ Annexure and enclosed these with the Bid Gas Composition (Annexure-I) Guarantee Parameters (Annexure-IIB) List of Recommended Third Party Inspection Agency (Annexure-III) Approved Vendor List (Annexure-IV) Bidder Data Required (Annexure-VB) Experience Record Schedule for CNG Compressors Package (Annexure-VIB) Compliance By Bidder (To Be Answered By Bidder)
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3.0
Material Requisition Compliance Schedule (Annexure-VIIB) Confirm that you have filled-up the Data Sheet and enclosed with the Bid. Compressor Data Sheet Motor Data Sheet Inter cooler Data Sheet Heat Exchanger Data sheet Mass Flow Meter Data Sheet Control Valves Solenoid Valves Self Actuated Pressure Control Valves Pressure Relief Valve Pressure Instruments Pressure Gauges
4.0
Confirm that following Documents have been enclosed with Bid. List of components of CNG Compressor with Make & Specification of components along with Technical Catalogues of components. Battery Limit (Interface) drawing/ information. Process flow diagrams (PFDs) and Piping & Instrumentation diagrams (P & IDs) of sub systems and complete system with write-up on operation Utility requirement Detail of control wiring diagram, interlock/shutdown/ control scheme with write up on operation. Sizing calculation for instrument items. G.A. drawing of Compressor showing maintenance clearances required.
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ANNEXURE VII : EXPERIENCE RECORD PROFORMA ANNEXURE VII (A): EXPERIENCE RECORD PROFORMA OF ELECTRIC MOTOR DRIVEN COMPRESSOR PACKAGE FOR GAS KCAL / SCM = 8485.096 COMPRESSOR CAPACITY 1200 SM3/H (SUCTION PRESSURE 14 - 19 kg/cm2G) SR. NO DESCRIPTION INFORMATION OFFERED COMPRESSOR Cap 1200 sm3/h INFORMATION OF EXISTING COMPRESSOR
REQUIREMENT AS PER TENDER 1 Status of bidder a) Compressor manufacturer b) Motor manufacturer c) Packager 2 COMPRESSOR Name of compressor manufacturer Place of compressor manufacturer Compressor model Anticipated Life in running hours Compressor max frame BKW Comp Manufacturing code API - 11P 2nd edition Lubricated or non lubricated Nos of stages "3" Max stage temperature oC (150oC ) Compressor max RPM Compressor operating RPM (max RPM - 1500) Piston speed m/s Vibrations at comp cylinders <10 mm / sec. Unfiltered peak velocity Vibration comp frame : Unfiltered peak velocity of 7.5 mm/sec or 250 micron unfiltered peak to peak vibration whichever is less Material for all stages Cylinder as per datasheet Piston Rings (PTFE/PEEK) Rider Rings (PTFE/PEEK) Piston Rod (Forged steel) Valve (Rings / plates / spring) : (SS/PEEK) 3 PERFORMANCE OF COMPRESSOR
Performance of compressor at 19 CASE kg/cm2 suction pr, 250 kg/cm2 L discharge pr and 35oC suction temp
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CASE GUARANTEED POINT: G Performance of compressor at 16 kg/cm2 suction, 250 kg/cm2 discharge pr and 35 o C suction temp a) Capacity Sm3/h CASE L CASE-G b) BKW required by compressor including compressor's lube oil pump BKW c) BKW required by compressor including compressor's lube oil pump BKW at RV set pr d1) Gas cooler (heat exchanger ) fans; nos required (W+S) CASE L CASE-G e) Ventilation fans for enclosure No of fans Type of fans (included or forced draft) Power required for all fans in KW Site Capacity of Motor Piston rod and cross head pin loading at any specified operating condition including the relief valve set condition shall not exceed 80% of the maximum design rod load of the offered compressor ---- Piston rod : max design --- Piston rod: calculated at safety set pr condition --- Max cross head pin loading : Design --- Cross head pin loading : calculated at safety set pr condition Guaranteed gas loss through rod deals ; sm3/h Other information of compressor a) Year of manufacturing of the compressor CASE L CASE-G CASE L CASE-G
d2) Power required for all fans in KW
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b) Name and address of user with FAX no, phone no, E-mail address c) Nos of hours the compressor have clocked on bid due date (Enclose certificate from user) 4 Motor Make and model Anticipated Life in running hours Power (ISO power) & corresponding Max RPM Site power (KW) at operating RPM after deration KW of motor with availability of 10% overload for one hour within a period of 12 hrs operation with no negative tolerance 240V anti-condensation heaters, sized and located so as to prevent condensation of moisture during shutdown periods Lifting hooks of adequate capacity to facilitate safe lifting. Other information of electric motor a) Year of manufacturing of the motor b) Name and address of user with FAX no, phone no, E-mail address c) Nos of hours the motor has run as on bid due date (Enclose certificate from user) 5 PACKAGE Name of Packager Place of Packaging Name of Enclosure Manufacturer Palace of enclosure manufacturer Sound level at 1 m distance from package in db (A) 75 Make and model LEL detector - 2 nos each comp Make and model fire detector - 2 nos each comp 2 no min 45 kg C02 cylinder with weighing arrangement Volume of enclosure in m3 Nos of explosion proof tube light in each enclosure
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Coupling Direct Mass flow meter to measure the Natural Gas consumption at packages inlet, package discharge. Separators between inter stage of compressor Other information of complete package a) Year and place of manufacturing of the package b) Name and address of user with FAX no, phone no, E-mail address c) Nos of hours the complete package (including engine and compressor) have clocked on bid date (enclose certificate from user) 6 Gas inlet train Inlet relief valve Inlet-gas pressure gauge Non return valve Inlet duplex gas filter Temporary suction filter after mail filter Inlet manual isolation valve Inlet automatic isolation valve Suction Skid: PRV shall be designed for pressure range from 20-35 bar to 14-19 bar 7 Gas recovery system Gas recovery system with pr relief valve, pr regulator, pr gauge, manual & automatic drainage system 8 Gas Delivery system High pr piping with SS 316, tubing, compression fittings, NRV KOD Coalescent filter PLC based Priority panel with full bore ball valve. Priority panel shall be kept
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outside in a separate enclosure preferably mounted on compressor side walls. Final gas outlet connection from priority panel 3/4" SS valves WITH 3/4" Tube OD end connections. 9 10 ESD system Volume bottles / dampers at each compressor stage of compressor Vessels Drainage system 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Manual double isolation valve Automatic valves Heat exchanger Code of construction API 11 P Gas sections of coolers shall be as per API - 11P requirements Tube material SA-179 Piping between stages shall be continuous with flange connection Gas recovery vessel provided Area classification; " class 1, group D, division 1 as per NEC " OR " Zone 1, group IIA / IIB as per IS/IEC" The size of the complete package Chain pulley block and beam for chain pulley block Acoustic and pulsation study Acoustic enclosure for package Instrumentation as indicated in TS Human - machine interfacing unit (HMI) String test as shop Field trial run for 72 hours Electric power requirement (purchaser will give electric power for air compressor and compressor controls) Cabling - Double compression type cable glands and copper lugs
29
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30
Junction box with metallic enclosure
ANNEXURE VII (B): EXPERIENCE RECORD PROFORMA OF ELECTRIC MOTOR DRIVEN COMPRESSOR PACKAGE FOR GAS KCAL / SCM = 8485.096 COMPRESSOR CAPACITY 650 SM3/H (SUCTION PRESSURE 14 19 kg/cm2) SR. NO DESCRIPTION REQUIREMENT AS PER TENDER 1 Status of bidder a) Compressor manufacturer b) Motor manufacturer c) Packager 2 COMPRESSOR Name of compressor manufacturer Place of compressor manufacturer Compressor model Anticipated Life in running hours Compressor max frame BKW Comp Manufacturing code API - 11P 2nd edition Lubricated or non lubricated Nos of stages "3" Max stage temperature oC (150oC ) Compressor max RPM Compressor operating RPM (max RPM - 1500) Piston speed m/s Vibrations at comp cylinders <10 mm / sec. Unfiltered peak velocity Vibration comp frame : Unfiltered peak velocity of 7.5 mm/sec or 250 micron unfiltered peak to peak vibration whichever is less Material for all stages Cylinder as per datasheet Piston Rings (PTFE/PEEK) Rider Rings (PTFE/PEEK) Piston Rod (Forged steel) Valve (Rings / plates / spring) : (SS/PEEK) 3 PERFORMANCE OF COMPRESSOR INFORMATION OFFERED INFORMATION OF COMPRESSOR EXISTING COMPRESSOR Cap 650 sm3/h
Performance of compressor at 19 CASE - kg/cm2 suction pr, 250 kg/cm2 L discharge pressure and 35oC suction temp SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGES DOCUMENT NO. 11-0353-02-09-02-007 SHEET 57 OF 64 REV B
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CASE GUARANTEED POINT: G Performance of compressor at 16 kg/cm2 suction, 250 kg/cm2 discharge pressure and 35 o C suction temp a) Capacity Sm3/h CASE L CASEG CASE L CASEG CASE L CASEG
b) BKW required by compressor including compressor's lube oil pump BKW c) BKW required by compressor including compressor's lube oil pump BKW at RV set pr d1) Gas cooler (heat exchanger ) fans; nos required (W+S)
d2) Power required for all fans in KW
CASE L CASEG
e) Ventilation fans for enclosure No of fans Type of fans (included or forced draft) Power required for all fans in KW Site Capacity of Motor Piston rod and cross head pin loading at any specified operating condition including the relief valve set condition shall not exceed 80% of the maximum design rod load of the offered compressor ---- Piston rod : max design --- Piston rod: calculated at safety set pr condition --- Max cross head pin loading : Design --- Cross head pin loading : calculated at safety set pr condition Guaranteed gas loss through rod deals ; sm3/h Other information of compressor a) Year of manufacturing of the compressor
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b) Name and address of user with FAX no, phone no, E-mail address c) Nos of hours the compressor have clocked on bid due date (Enclose certificate from user) 4 Motor Make and model Anticipated Life in running hours Power (ISO power) & corresponding Max RPM Site power (KW) at operating RPM after deration KW of motor with availability of 10% overload for one hour within a period of 12 hrs operation with no negative tolerance 240V anti-condensation heaters, sized and located so as to prevent condensation of moisture during shutdown periods Lifting hooks of adequate capacity to facilitate safe lifting. Other information of electric motor a) Year of manufacturing of the motor b) Name and address of user with FAX no, phone no, E-mail address c) Nos of hours the motor has run as on bid due date (Enclose certificate from user) 5 PACKAGE Name of Packager Place of Packaging Name of Enclosure Manufacturer Place of enclosure manufacturer Sound level at 1 m distance from package in db (A) 75 Make and model LEL detector - 2 nos each comp Make and model fire detector - 2 nos each comp 2 no min 45 kg C02 cylinder with weighing arrangement Volume of enclosure in m3 Nos of explosion proof tube light in each enclosure
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Coupling Direct Mass flow meter to measure the Natural Gas consumption at packages inlet, package discharge. Separators between inter stage of compressor Other information of complete package a) Year and place of manufacturing of the package b) Name and address of user with FAX no, phone no, E-mail address c) Nos of hours the complete package (including engine and compressor) have clocked on bid date (enclose certificate from user) 6 Gas inlet train Inlet relief valve Inlet-gas pressure gauge Non return valve Inlet duplex gas filter Temporary suction filter after mail filter Inlet manual isolation valve Inlet automatic isolation valve Suction Skid: PRV shall be designed for pressure range from 20-35 bar to 14-19 bar 7 Gas recovery system Gas recovery system with pr relief valve, pr regulator, pr gauge, manual & automatic drainage system 8 Gas Delivery system High pr piping with SS 316, tubing, compression fittings, NRV KOD Coalescent filter PLC based Priority panel with full bore ball valve. Priority panel shall be kept
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outside in a separate enclosure preferably mounted on compressor side walls. Final gas outlet connection from priority panel 3/4" SS valves WITH 3/4" Tube OD end connections. 9 10 ESD system Volume bottles / dampers at each stage of compressor Vessels Drainage system 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Manual double isolation valve Automatic valves Heat exchanger Code of construction API 11 P Gas sections of coolers shall be as per API - 11P requirements Tube material SA-179 Piping between stages shall be continuous with flange connection Gas recovery vessel provided Area classification; " class 1, group D, division 1 as per NEC " OR " Zone 1, group IIA / IIB as per IS/IEC" The size of the complete package Chain pulley block and beam for chain pulley block Acoustic and pulsation study Acoustic enclosure for package Instrumentation as indicated in TS Human - machine interfacing unit (HMI) String test at shop Field trial run for 72 hours Electric power requirement (purchaser will give electric power for air compressor and compressor controls) Cabling - Double compression type cable glands and copper lugs
29
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30
Junction box with metallic enclosure
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ANNEXURE- VIII : Parameters Required for SCADA
Hardware Details: Connector Type, Communication Standard, Communication port Pin details, Communication Port Configuration: Baud Rate, data bits, stop bit, parity Polling Constraints: Minimum time period between two consecutive poll cycles. Protocol Details: Protocol name and message structure for different read / write functions. Function codes for reading digital and Analog inputs Function code for writing analog values in the IED registers List of parameters available in the IED which can be accessed from the IED through serial port. Register address of each parameter in the IED. A Sample of the details is given below for understanding: PROTOCOL DETAILS: Sr.No. 1 2 3 4 5 6 7 Description Protocol Connection Type Communication standard Signals supplied Baud Rate(Speed) Format Port Configuration Min. Time period between consecutive Query PORT PIN Details: Example: RS232 Pin Details: IED RJ45 GND DTR RTS TX RX CTS DCR DCD SCADA Content/Details MODBUS RTU FCC -68 RJ45 RS232D Tx, Rx, GND 300, 600,1200,4800,9600,19200 Software configurable Speed : 19,200, 9,600 & 115,200 bps Data Bits: 8 Bits Stop Bit : 1 Bit Parity : None 2 Sec.
RX TX
Function Code & Message Structure: Function Code: 3 - Read Output Register Poll Format: Address 1 Byte Function 1 Byte Start Item 2 Byte No. Item Response Format: Address Function Length Date Item 1 2 Byte 1 Byte 1 Byte 1 Byte 4 Byte SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGES DOCUMENT NO. 11-0353-02-09-02-007 SHEET 63 OF 64 REV B
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Date Item n
4 Byte
Function Code & Message Structure: Function Code: Poll Format: Address Function Start Item No. Item Response Format: Address Function Length Date Item 1 . . Date Item n 2 - Read Input Status 1 Byte 1 Byte 2 Byte 2 Byte 1 Byte 1 Byte 1 Byte 2 Byte
2 Byte
Memory Mapping, Data Type & Parameter Information: A) Digital Parameters: Sr. No. 1 2 3 B) Analog Parameters: Parameter Engineering Range and Unit Kg/m3 (500-600) GC Register 8655-56 8657-58 8659-60 8661-62 8663-64 8665-66 8667-68 8669-70 8671-72 8673-74 Register details Register Format Float Float Float Float Float Float Float Float Float Float Remarks Description Flow computer malfunction Alarm Mass Flow Low alarm Mass Flow High alarm Address 8247 8245 8246
Density Pressure Temperature Mass Flow Rate Totalized mass flow Yesterdays Total Mass flow Today's Total Mass Flow Corrected volumetric Flow rate Yesterday's Total corrected Volumetric Flow Totalized Mass Flow at 6 AM (Snapshot of cumulative)
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CLIENT JOB NO.
DATASHEET- COMPRESSOR (1200 SCMH)

TOTAL SHEETS
28 101
DOCUMENT NO
11
0353
02
09
03
0 C B A REV.
02.05.11 26.04.11 11.04.11 07.04.11 DATE
MH MH SS SS PREP
RC RM RM RM CHKD
RC RC SB SB APPD
1
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Datasheet-Compressor
GENERAL
PROJECT:
PROCUREMENT OF CNG COMPRESSORS
OWNER: M/S SABARMATI GAS LIMITED
SITE: GANDHINAGAR
SERVICE: COMPRESSOR FOR CNG MOTHER STATION
NO. REQD.: 3no.+2no. optional (1200 SCMH)
DRIVER: ELECTRIC MOTOR
NOTE: SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER REQUIRED FROM VENDOR
INFORMATION
MANUFACTURER:
MODEL NO.:
PLACE OF MANUFACTURE:
NO. OF STAGES:
THREE.
CYLINDER ARRANGEMENT:
10
CYLINDER LUBRICATION:
LUBRICATED
MINIMUM LUBRICATED
NON LUBRICATED
11
DRIVER TYPE: ELECTRIC MOTOR
12
DRIVE:
DIRECT WITH COUPLING
13
DIRECTION OF ROTATION(FACING DRIVEN END): CLOCKWISE
CLOCKWISE
COUNTER
14
SITE / INSTALLATION DATA AMBIENT TEMP. (0C): MAX: 47.0
15
SITE DATA:
MIN: 4.0
16
RELATIVE HUMIDITY (%):
MAX: 95
17
ALTITUDE (M): 110
DATASHEET-COMPRESSOR
REV B
Page 67 of 129
18 19
EARTH QUAKE ZONE III INSTALLATION:
BASIC WIND SPEED(m/sec) 47 OUTDOOR
20
MOUNTED ON A COMMON SKID ALONGWITH DRIVER, ENCLOSED IN AN ACOUSTIC ENCLOSURE
21
ELECTRICAL AREA HAZARD:
22
CLASS I, DIVISION I, GROUP D AS PER NEC OR ZONE I, GROUP II A/ II B AS PER IS/ IEC
23
APPLICABLE CODES AND STANDARDS
24
COMPRESSOR : API 11P, 2ND EDN./PISTON TRUNK
PIPING: ASME/ANSI B 31.3
25
PRESSURE VESSELS: ASME SECVIII, DIV-1.
GAS COOLER: API 11P /API 661
26
OIL COOLER: TEMA `C.
SOUND: 75 DBA @ 1M FROM ENCLOSURE
27
AUX. ELECT. MOTORS:
28
CONTROL PANEL & INSTRUMENTATION REFER:
29
UTILITIES DATA
30
Cooling Water (Not Available) Supply temperature (0C): Max return temperature (0C):
31
Type:
32
Fouling Factor: Design pressure (kg/cm2A):
Supply pressure (kg/cmG):
Min. return pressure (kg/cmG): Design temperature (0C):
33
34
Water Flow Rates (m3/hr)
35
Electricity
36
Auxiliary Motors:
Ph DOCUMENT NO. 11-0353-02-09-03-101 SHEET 3 OF 29
Hz REV B
Page 68 of 129
37
Oil Heaters:
Ph
Hz
38
Solenoid Valves:
A.C/D.C
Ph
Hz
39
Instruments:
A.C/D.C
Ph
Hz
40
Local Panel INDI./Alarm/Ann : A.C/D.C
Ph
Hz
41
Local Panel Trip Circuit: A.C/D.C
Ph
Hz
42
UPS: KVA,
Ph
Hz
43
Total Utility Consumption Cooling Water (Make UP) (m3 /hr)
44
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 51
Nomenclature Cylinders
Unit
Stage#1
Stage#2
Stage#3
52
No of Cylinders
53
Single Acting (SA) / Double Acting (DA)
54
Cylinder Bore / Stroke
mm / mm
55
Rotational Speed
RPM DOCUMENT NO. 11-0353-02-09-03-101 SHEET 4 OF 29 REV B
Page 69 of 129
56
Linear Average Piston Speed
m/sec m3/ hr
57
Piston Displacement
58
Cylinder Liner (Yes / No)
59
Type of Cylinder Liner : Dry/Wet
60
Clearance Pockets Yes / No
61
Max. Allow. Working Pressure, Cylinder
kg/cma
62
Max./Min Allow. Working Temp., Cylinder
0C
63
M.A.W.P, Cylinder @ Amb. Temp.
kg/cma
64
Safety Valve Set Pressure, Cylinder
kg/cma
65
Helium Test Pressure, Cylinder
kg/cma
66
Hydrostatic Test Pressure, Cylinder
kg/cma
67
Cylinder Jacket Cooling Type As reqd.
68
Cooling Media, Cylinder Jackets Water /AIR
69
Max. Allow. Working Pressure, Cyl. Jacket
kg/cma
70
Hydrostatic Test Pressure, Cyl. Jacket
kg/cma
REV B
Page 70 of 129
71
Suction Nozzle Size/Rating/Position
72
Discharge Nozzle Size/Rating/Position
73
Suction Valve Number
74
Average gas Velocity
m/sec
75
Discharge Valve Number
76
m/sec
77
Type of Suction valve
78
Type of Discharge valve
79
Suction Valve Unloaders Yes / No
80
Clearance Pockets Unloaders Type
81
Piston Rod Diameter
mm
82
Rod Reversal at Crosshead Pin (min.)
Deg.
83
Piston Rod Runout Operating kg
84
Max. Allow. Rod Load Comp. kg
85
Tension
86
Rod Load Comp.
Kg kg
87
(Inertia Alone) Tension
88
Rod Load Rated Pr. (Gas+Inertia) Comp.
kg
REV B
Page 71 of 129
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/cmG
103
## Packaging shall be connected to vent header Ref 7.19.4 of API-11 P
104
Frame
105
Frame Explosion proof Relief device DOCUMENT NO. 11-0353-02-09-03-101 SHEET 7 OF 29 REV B
Page 72 of 129
106
Flame Arrestor Yes / No
107
Replaceable Crosshead Shoes Yes / No
108
Crosshead Guide Integral / Separate
109
Maximum Frame Rating
kW
110
Speed - Maximum/ Minimum
Rpm
111
Lubrication Systems
112
Type of lube system
Piping material
113
Carbon Steel
114
Main Oil Pump Driven By :
Stainless Steel (all piping & valves Trims)
115
Standby Oil Pump, Driven By :
Auxiliary oil tank
116
Hand Operated Prelube/Priming Pump:
Oil Grade :
117
Suction Strainer
Lube Oil Consumption
118
Pressure Control Valve
Main Pump
Make : Type :
Model : Material :
119
Level Sight Glass on the Crankcase
Standby Pump Make : Type :
Model : Material :
120
Type of Oil Cooler :
121
Size of Filter:
122
Oil Heater (if required).
123
Electric Heater with thermostat (Kw) DOCUMENT NO. 11-0353-02-09-03-101 SHEET 8 OF 29 REV B
Page 73 of 129
124
Thermostatic Valve
125
Type of Cylinder Lubrication
Lubricator Equipped With : level sight glass
126 127
Lubricator Type : Manzel or Equivalent . Single plunger per feed oil heater electric with thermostat
128
Divider blocks type.
Electric Heater (Kw) (if required)
129
Lubricator Driven By :
Auxiliary Oil Tank (if required)
130
Compressor Shaft
Oil Grade :
131
Electric Motor KW
Oil System Capacity: (min 150 Hrs.)
132
All tubing and valves in SS
Oil Consumption rate
133
Double Ball Check valve on each lubrication point
134
Cooling System
135
Static filled coolant system for
136
All Stage Cylinders
1 Stage Cylinder/s
2 Stage Cylinder/s
3 Stage Cylinder/s
137
Including expansion chamber, Vents, Drains, Level Gauge, Pipings, etc.
138
All Piping prefabricated Material
139
Atmospheric thermosyphon cooling system for
140
All Stage Cylinders
1 Stage Cylinder/s
2 Stage Cylinder/s
3 Stage Cylinder/s
141
Including expansion tank, Vents, Drains, Coolers, Level & Temp. indicators, Pipings, etc.
REV B
Page 74 of 129
142
All Piping prefabricated.
Material
143
Forced Cooling Water System
144
All Stage Cylinders
1 Stage Cylinder/s
2 Stage Cylinder/s
3 Stage Cylinder/s
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
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:
REV B
Page 75 of 129
160
Jacket cooling
161
Gas Piping System
162
Vendor's Supply Includes: Suction Separator
163
Pulsation suppression equipment as per next page
164
Suction Filter:
165
Temporary Strainer on Compressor Suction
166
Type of Strainer:
167
Relief Valves: on compressor
suction
Inter-stage
on compressor discharge
168
Check Valve on Discharge Line (compressor valve design, and suction line)
169
Process Gas Coolers Complete With Manual Drain Valve
170
Separators Complete With Manual/ Automatic Drain Values
171
Process Gas Piping
172
Supply starts at inlet flange of CNG PACKAGE
173
Terminates after priority panel with isolation valve
174
Materials:
175
By-Pass Line Piping
176
Between 3rd stg. discharge and 1 st stg. Suction
177
Gas cooler
178
Interconnecting Piping Between Packing Vents, PSV Relief terminating to Vent Recovery System.
REV B
Page 76 of 129
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/cma
191
Design Temperature 0C
192
Volume
193
Material : vessels
SA 516 Gr.60/70
SA 516 Gr.60/70
SA 516 Gr.60/70
194
Internals
195
Corrosion
3 DOCUMENT NO. 11-0353-02-09-03-101 SHEET 12 OF 29 REV B
Page 77 of 129
Allowance mm
196
Hydrostatic test Pressure kg/cmg
1.3XMAWP
1.3XMAWP
1.3XMAWP
197
Discharge
198
Puls. Equipment Supplied Yes/No
YES
YES
YES
199
Inlet Pressure
200
As per API 618, Cl 3.9.2.7
201
202
203
204
205
Volume
206
Material : vessels
SA 516 Gr.60
SA 516 Gr.60
SA 516 Gr.60
207
Internals
208
Corrosion Allowance mm
209
1.3XMAWP
1.3XMAWP
1.3XMAWP
210
Pulsation Suppressors are complete and installed on the Skid with supports & anchor bolts DOCUMENT NO. 11-0353-02-09-03-101 SHEET 13 OF 29 REV B
Page 78 of 129
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
221
Interlock against loaded start
222
Automatic Control based on
223
Suction Pressure Discharge Pressure
Flow Manual Signal
224
Type of Actuator
Actuation fluid to load
Actuation fluid to unload
225
On Power / Actuation fluid failure : Compressor to
Load
Unload
226
At 0 % capacity through Valve Unloader, Compressor shall run
227
Continuously
Maximum Hrs.
228
229
Continuously
Maximum Hrs.
REV B
Page 79 of 129
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
REV B
Page 80 of 129
246
Packing Vent
247
C.W. Inlet
248
C.W. Outlet
249
N2 Inlet Supply
250
N2 Vent (Safe location)
251
Drains
252
MATERIALS
253
Cylinder Materials
254
Stage
1 Stage
2 Stage
3 Stage
255
Cylinder
NODAL CAST IRON / F.S
256
Liner
257
Piston
258
Piston Rings
PTFE/PEEK
PTFE/PEEK
PTFE/PEEK
259
Rider Rings
PTFE/PEEK
PTFE/PEEK
PTFE/PEEK
260
Piston Rod
Forged steel/ AISI 4142
261
Packings Rings
262
Valve Seats
REV B
Page 81 of 129
263
Valve Stops
264
Valve Rings / Plates
CS /plate should be MT or PEEK.
265
Valve Springs
SS
SS
SS
266
Cylinder Head
267
Motion Work Materials :
268
Material / ASTM Grades
269
Top Cover
Cast
Fabricated
270
Crankcase
Cast Fabricated
271
Crankshaft
Die Forged Cast
Open Forged
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
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 : DOCUMENT NO. 11-0353-02-09-03-101 SHEET 17 OF 29 REV B
Page 82 of 129
281
Each package shall be provided with two number drain lines, one from Suction KOD and second drain as common drain line from intermediate and discharge KOD routed to drain vessels through gas recovery vessels
282
CONTROLS & INSTRUMENTATION
283
AC Power On/Off Switch With Indication Lamp
284
Control Power On/Off Switch With Indication Lamp YES
285
Selector Switch A/M Station For L/O Pump Motor
286
Selector Switch A/M Station For CW Pump Motor
287
Emergency Stop Push Button
288
Start Push Button For Air Compressor Motor
289
Emergency Stop Push Button for Main Motor
290
Lamp Test Push Button
291
Alarm/Trip Acknowledge /Reset Push Button
292
Frame Oil Heater ON (Indicating lamp)
293
Lubricator Oil Heater ON (Indicating lamp)
294
Driver Interlocked against loaded start
295
Driver Interlock against start without pre-lubrication
296
Notes :
297
Minimum required indications, alarms & trips are shown herewith. Bidder shall provide any additional instrumentation for safe operation.
298
Compressor shall start stop at pre determined receiver pressure as specified. Bidder shall include DOCUMENT NO. 11-0353-02-09-03-101 SHEET 18 OF 29 REV B
Page 83 of 129
in his
299
Scope includes the necessary hardware for the same.
300
All inter-stage / discharge and suction scrubber shall be provided with high / low level operated auto drain solenoid valves.
301
INSPECTION AND TESTS
302
Material Composition and Physical Properties Certificates Required For/Compliance certificate:
303
Cylinder and Liner
Piston
304
Crankshaft
Connecting Rod
305
Pressure Vessels
Heat Exchangers
306
X-Ray Examination for components: Pressure Vessels (certificates to be furnished).
307
Ultrasonic Testing for components: Piston Rod, Crankshaft, Big End Bolts, Main Bearing Studs.
308
Magnaflux Testing for components: Crankshaft, Piston Rod, Connecting Rod.
309
Dye Penetration Testing for : Cylinder, Liner, Piston.
310
Required
Observed
Witnessed
311
Shop inspection by Purchaser during manufacture
312
Cylinder Hydrostatic
313
Cylinder Pressure Test By Helium
314
Hydrostatic Test of Pressure Vessels
315
Hydrostatic Test of Distance Piece.
316
Leak Proof Test of Crank case for 24 Hrs DOCUMENT NO. 11-0353-02-09-03-101 SHEET 19 OF 29 REV B
Page 84 of 129
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.
REV B
Page 85 of 129
334 335
Gear Box Kg. approx. Driver Kg. approx.
336
SCOPE OF SUPPLY
337
Compressor Assembly complete with frame, cylinders, cross head etc.
338
Motion work lubrication system
339
Cylinder and packing lubrication system
340
Cooling system
341
Process Gas system
342
Local instrumentation
343
Local Gauge Board
344
Local Control Panel
PLC Panel
Man Machine Interface located in Control Room
345
Main driver (Electric motor)
346
Barring Device :
Manual
Electric . pneumatic
347
Flywheel
348
349
Couplings
350
Driver Compressor
Guards for moving parts 351 352 Base plate Common for Compressor and Driver
353
Fabricated Steel skid Common for compressor, driver and accessories DOCUMENT NO. 11-0353-02-09-03-101 SHEET 21 OF 29 REV B
Page 86 of 129
354
Ladders and platforms
355
Special Tools - One Set for each package
356
Anchor Bolts for Complete Package
357
Piping supports and brackets :
prefabricated for piping in Vendor's Scope
358
Supports For Cylinders & Auxiliaries, Prefabricated & fitted in the Package
359
Commissioning Spares, erection and commissioning spares
360
Train Torsion Analysis Study and Report
361
Acoustic Simulation Study & Report
362
Vendor Data as specified
363
NOTE : Refer checklist for scope of supply
REV B
Page 87 of 129
DATA SHEET- INSTRUMENTATION & CONTROLS FOR COMPRESSOR
INDICATION GUAGE LOCAL GUAGE BOARD INDICATOR LOCAL PANEL (PLC) DISPLAY
ANNUNCIATION & PRE ALARM HIGH LOCAL PANEL DISPLAY (PLC) LOW LOCAL PANEL DISPLAY
TRIP & A/V ALARM ANNUN. LOW LOCAL PANEL PLC-DISPLAY HIGH LOCAL PANEL PLC- DISPLAY REV B
Page 88 of 129
S. NO
DESCRIPTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Frame Oil Sump/Reservoir Level Main L/O Pump Disch. Pr (supply header). Oil Flow Oil Pressure at Main Bearing Supply Header Temp. Oil cooler Oil Inlet Temp. Stand by Pump Start Compressor Main bearing metal Temp. Cylinder & Packing Oil Lubricator Oil Level Lubricator Oil Flow Lubricator Failure Aux. Oil Lub. Oil Supply Pr. to Electric Motor Driver Lub. Oil return from Electric Motor Driver Elec. Motor bearing metal temp. Coolant System Each cylinder CW outlet temp. Inter/After/Oil Cooler CW outlet temp. CW Supply header flow For Closed Circuit Cooling Coolant standby pump disch. Pr. Coolant stand by pump start Coolant supply header Pr. Coolant supply header temp Coolant reservoir Level Cylinder Coolant Outlet temp. Cylinder Coolant Outlet temp.
yes yes yes yes yes
yes yes
yes
yes
TRIP & A/V ALARM ANNUN. LOW LOCAL PANEL PLC-DISPLAY HIGH LOCAL PANEL PLC- DISPLAY yes yes yes yes yes yes yes REV B
Page 89 of 129
S. NO
DESCRIPTION
29 30 31 32 33 34
35 36 37 38 39 40 41 42 43 44 45 46
47 48
Diff. Pr. Across packing coolant filter Process Gas System Each stage inlet Pressure Each stage inlet temp. Each stage Outlet Pressure Each stage Outlet temp. (before air cooler and after cooler) After Cooler Gas Outlet temp. Ist stage pressure low / high Cylinder Packing Vent Pressure Suction Pressure, low Blow Down vessel level Piston Rod Drop Indicator Distance piece diff. Purge pressure Common process parameters Common machine parameters Blow Down vessel Pressure Vibration Measurement Temperature Instrument (shall be Insertion type but Not skin type) Winding Temperature RPM meter
yes yes
yes yes
yes yes
yes yes
yes yes
yes
yes yes
yes
yes yes
yes
yes
yes
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).
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
OPERATING CONDITIONS (EACH MACHINE) / PERFORMANCE Operating Case: SUCTION PRESSURE: 14 kg/cm g Stage 1 Stage 2 Stage 3 Units Gas Handled (See Analysis) NONE NONE NONE Corrosion Due to Suction Conditions 14 Pressure (@ Vendor's Kg/cm g B/L) 0 35 Temp. (+@ Vendor's C B/L) Discharge Conditions (Vendor's Battery Limit: 250 Pressure (@ Vendor's B/L Kg/cm g Pressure @ Cylinder Flg. Kg/cm g 0 <150 < 150 < 150 Temp.,Adiabatic @Cyl. C Flange 0 Temp.,Actual @Cyl.Flange C 0 < 52 Temp.,After AfterCooler C Cp/Cv Ratio Compr. Factor (Z2 ) or (Z avg ) Operating Characteristics Capacity (wet) SM3 /Hr Mfr's Rated Cap. (Design) (No -ve tol.) Actual Inlet Flow (wet) AM3 /Hr Specific Gravity Coupling Losses kW Volumetric Efficiency % Valve Lift Suction / mm / mm Valve Lift Area Suction/ mm2 / mm2 Discharge Valve Velocity m/sec Speed RPM Compressor Shaft Power KW Power consumed @ RV KW Set Pr. Driver Power KW Guaranteed Point GAS ANALYSIS- Gas Composition attached as Annexure-I.
REV B
Page 90 of 129
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
OPERATING CONDITIONS (EACH MACHINE) / PERFORMANCE Operating Case: SUCTION PRESSURE: 16 kg/cm g Stage 1 Stage 2 Stage 3 Units Gas Handled (See Analysis) NONE NONE NONE Corrosion Due to Suction Conditions 16 Pressure (@ Vendor's B/L) Kg/cm g 0 35 Temp. (+@ Vendor's C B/L) Discharge Conditions (Vendor's Battery Limit: 250 Pressure (@ Vendor's B/L Kg/cm g Pressure @ Cylinder Flg. Kg/cm g 0 <150 < 150 < 150 Temp.,Adiabatic @Cyl. C Flange 0 Temp.,Actual @Cyl.Flange C 0 < 52 Temp.,After AfterCooler C Cp/Cv Ratio Compr. Factor (Z2 ) or (Z avg ) Operating Characteristics Capacity (wet) SM3 /Hr Mfr's Rated Cap. (Design) (No -ve tol.) Actual Inlet Flow (wet) AM3 /Hr Specific Gravity Coupling Losses kW Volumetric Efficiency % Valve Lift Suction / mm / mm Valve Lift Area Suction/ mm2 / mm2 Discharge Valve Velocity m/sec Speed RPM Compressor Shaft Power KW Power consumed @ RV Set KW Pr. Driver Power KW Guaranteed Point GAS ANALYSIS Gas Composition attached as Annexure-I.
REV B
Page 91 of 129
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
OPERATING CONDITIONS (EACH MACHINE) / PERFORMANCE Operating Case: SUCTION PRESSURE: 19 kg/cm g Stage 1 Stage 2 Stage 3 Units Gas Handled (See Analysis) NONE NONE NONE Corrosion Due to Suction Conditions 19 Pressure (@ Vendor's B/L) Kg/cm g 0 35 Temp. (+@ Vendor's C B/L) Discharge Conditions (Vendor's Battery Limit: 250 Pressure (@ Vendor's B/L Kg/cm g Pressure @ Cylinder Flg. Kg/cm g 0 <150 < 150 < 150 Temp.,Adiabatic @Cyl. C Flange 0 Temp.,Actual @Cyl.Flange C 0 < 52 Temp.,After AfterCooler C Cp/Cv Ratio Compr. Factor (Z2 ) or (Z avg ) Operating Characteristics Capacity (wet) SM3 /Hr Mfr's Rated Cap. (Design) (No -ve tol.) Actual Inlet Flow (wet) AM3 /Hr Specific Gravity Coupling Losses kW Volumetric Efficiency % Valve Lift Suction / mm / mm Valve Lift Area Suction/ mm2 / mm2 Discharge Valve Velocity m/sec Speed RPM Compressor Shaft Power KW Power consumed @ RV Set KW Pr. Driver Power KW Guaranteed Point GAS ANALYSIS Gas Composition attached as Annexure-I.
REV B
Page 92 of 129
DATA SHEET INTER COOLER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 GENERAL PROJECT: PROCUREMENT OF CNG COMPRESSORS OWNER: SABARMATI GAS LIMITED SITE: GANDHINAGAR Item No. : Service : Intercooler / Aftercooler for Compressor Package NOTE: SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER INFORMATION REQUIRED FROM VENDOR. Manufacturer: Type: Forced Draft Induced Draft Bundle Size: m x m x m Bundles/Section Number of Units: Bundles/Unit: In Parallel / Series Section Size: Surface/Bundle: m Bare Tube: m Section/Unit: Surface/Unit: m Bare Tube: m Plot Area/Unit: PERFORMANCE (Of One Unit) Heat Exchanged: kcal/hr MTD (Corrected): 0C 0 Transfer Rate: kcal/hr m C (Finned Surface) (Bare Surface) TUBE SIDE Fluid Circulated GAS Gravity: Liquid API SG @ 15.4EC Total Entering Gas kg/hr Enthalpy / Latent Heat kcal/kg Operating Temperature In: Out: Fouling Resistance hr m 0C/kcal Operating Pressure Passes / Bundle kg/cm AIR SIDE Temperature In:47 Out: Altitude m Total Flow/Unit kg/hr Static Pressure kg/cm Quantity/Fan kg/hr Power/Fan kW Face Velocity m/sec Power/Unit kW CONSTRUCTION (Each Bundle) Design Pressure: kg/cmg Test Pressure: kg/cmg Design Temperature: 0C Code Requirements: Type of Tubing: Tube Material: SA 179 Fin Material: Al Tube Bare Tubes (no's) : No. of rows: O.D. BWG/Thk Length Fins : Spacing /inch. O.D. Root Dia Thickness: Header Type: Plug / Cover No. of Splits: Material : Plugs/Gaskets Side Frame : C.S. Inside Zinc Protected Nozzles In : Out : Couplings Vent: Drain : CONSTRUCTION (Each section) Structure CS Sec./Gr. No. Design Wind Load : kgf/m Plenum Chamber CS inside Zinc Protected Type : Fans No. Dia. RPM Mfr. Blades Material : No./Fan Pitch Angle(Design) : Hubs Material : Pitch : Autovariable / Adjustable (No. ) Louvers Material : Type : Mfr. Weights kg Each Section(Dry) : Full of Water: Each Bundle (Dry) : Full of Water: APPLICABLE SPECIFICATIONS API Standard 661 REMARKS 1. Air coolers shall be designed for 20% excess capacity than required normally. Exchanger shall be designed with air side temperature of 47.5 0C. DOCUMENT NO. 11-0353-02-09-03-101 SHEET 28 OF 29 REV B
Page 93 of 129
46
Separate data sheet shall be filled by the bidder for each service i.e. Inter cooler and After cooler
REV B
Page 94 of 129
SABARMATI GAS LIMITED CITY GAS DISTRIBUTION
CLIENT JOB NO.
4 004
DATA SHEET FOR LT MOTOR

TOTAL SHEETS
DOCUMENT NO
11
0353
02
10
03
0 C B A REV.
02.05.11 26.04.11 11.04.11 07.04.11 DATE
MH MH SS SS PREP
RC RM RM RM CHKD
RC RC SB SB APPD
1
Page 95 of 129
DATASHEET-LT MOTOR
1 2 3 PROJECT: OWNER: GENERAL PROCUREMENT OF MOTOR DRIVEN COMPRESSORS M/S SABARMATI GAS LIMITED SITE: Mehsana &
Sabarkanta Dist of Gujarat 4 5 6 SERVICE: NO. REQD. NOTE: DRIVER FOR CNG COMPRESSOR 3+ 2 Optional for 1200SCMH & 1 + 1 Optional for 650 SCMH
SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER
INFORMATION REQUIRED FROM VENDOR. 7 8 9 SITE / INSTALLATION DATA SITE CONDITIONS: LOCATION: SYSTEM. 10 SITE DATA: AMBIENT TEMP. (0C): MAX:40 RELATIVE HUMIDITY (%): 11 ELECTRICAL AREA CLASSIFICATION CLASS 1, DIVISION II, GROUP D AS PER NEC ZONE II GROUP IIA/IIB AS PER IS/IEC MIN: 5 MAX: 95 OUTDOOR CLOSED ROOM WITH FORCED AIR VENTILATION
12 13 14 15 16 17 18 19 20 21 22 23 24
DUTY MANUFACTURER TYPE FRAME DESIGNATION OUTPUT (KW) VOLTAGE (VOLT) FULL LOAD CURRENT (AMP) FULL LOAD SPEED (RPM) ENCLOSURE TYPE OF PROTECTION GAS GROUP MOUNTING AMB. TEMP/TEMP RISE ( C) CLASS 1, DIVISION II, GROUP D AS PER NEC ZONE II GROUP IIA/IIB AS PER IS/IEC 415 10% V
REV B
Page 96 of 129
25 26 27 28
FULL LOAD TORQUE (KGM) APPLICABLE CODE STARTING TORQUE AS (%FLT) EFFICIENCY AT : %EFF @100% LOAD
29 30 31 32 33 34 35 36
%EFF @75% LOAD %EFF @50% LOAD BEARING TYPE TYPE OF LUBRICATION NET WEIGHT (APPR.) (KG) TYPE OF COUPLING CABLE SIZE TYPE (Sq. mm) PHASE CONN. NO OF TERMINAL FREQUENCY (Hz) INSULATION No. OF POLES LOCKED ROTOR CURRENT %FLC LR WITHSTD TIME HOT/COLD STATOR THERMAL TIME CONST MIN POWER FACTOR : PF @-100% LOAD PF @ 75% LOAD PF @- 50% LOAD 3 Phase
37 38 39 40 41 42
50 5% Hz CLASS F (Temp. rise limited to class B) as standard
43
44 45 46 47
PULL OUT TORQUE - %FLT SPACE HEATERS - WATTS/VOLTS ACCESSORIES PAINT SHADE DOCUMENT NO. 11-0353-02-10-03-004 SHEET 3 OF 4 REV B
Page 97 of 129
48 49 50 51 52 53 54 55
TERMINAL BOX POSITION LOAD GD SQ. (KG-M) MOTOR GD SQ. (KG-M) STARTING TIME @100% V SEC TYPE OF STARTING NOISE LEVEL VIBRATION SEPERATE ACCOUSTIC ENCLOSURE WITH VENTILATION FAN
56
REMARKS
NOTE: 1) ALL PERFORMANCE FIGURES ARE SUBJECT TO IS 325 - 1996 TOLERANCES. .
REV B
Page 98 of 129
CLIENT JOB NO.
DATASHEET- COMPRESSOR (650 SCMH)

TOTAL SHEETS
28 102
DOCUMENT NO
11
0353
02
09
03
0 C B A REV.
02.05.11 26.04.11 11.04.11 07.04.11 DATE
MH MH SS SS PREP
RC RM RM RM CHKD
RC RC SB SB APPD
1
Page 99 of 129
Datasheet-Compressor
GENERAL
PROJECT:
PROCUREMENT OF CNG COMPRESSORS
OWNER: M/S SABARMATI GAS LIMITED
SITE: GANDHINAGAR
SERVICE: COMPRESSOR FOR CNG MOTHER STATION
NO. REQD.: 1+1 optional (650 SCMH)
DRIVER: ELECTRIC MOTOR
NOTE: SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER REQUIRED FROM VENDOR.
INFORMATION
MANUFACTURER:
MODEL NO.:
PLACE OF MANUFACTURE:
NO. OF STAGES:
THREE.
CYLINDER ARRANGEMENT:
10
CYLINDER LUBRICATION:
LUBRICATED
MINIMUM LUBRICATED
NON LUBRICATED
11
DRIVER TYPE: ELECTRIC MOTOR
12
DRIVE:
DIRECT WITH COUPLING
13
DIRECTION OF ROTATION(FACING DRIVEN END): CLOCKWISE
CLOCKWISE
COUNTER
14
SITE / INSTALLATION DATA AMBIENT TEMP. (0C): MAX: 47.0
15
SITE DATA:
MIN: 4.0
16
RELATIVE HUMIDITY (%):
MAX: 95
17
ALTITUDE (M): 110
18
EARTH QUAKE ZONE III
BASIC WIND SPEED(m/sec) 47 DOCUMENT NO. 11-0353-02-09-03-102 SHEET 2 OF 28 REV B
Page 100 of 129
19
INSTALLATION:
OUTDOOR
20
MOUNTED ON A COMMON SKID ALONGWITH DRIVER, ENCLOSED IN AN ACOUSTIC ENCLOSURE
21
ELECTRICAL AREA HAZARD:
22
CLASS I, DIVISION I, GROUP D AS PER NEC OR ZONE I, GROUP II A/ II B AS PER IS/ IEC
23
APPLICABLE CODES AND STANDARDS
24
COMPRESSOR : API 11P, 2ND EDN./PISTON TRUNK
PIPING: ASME/ANSI B 31.3
25
PRESSURE VESSELS: ASME SECVIII, DIV-1.
GAS COOLER: API 11P /API 661
26
OIL COOLER: TEMA `C.
SOUND: 75 DBA @ 1M FROM ENCLOSURE
27
AUX. ELECT. MOTORS:
28
CONTROL PANEL & INSTRUMENTATION REFER:
29
UTILITIES DATA
30
Cooling Water (Not Available) Supply temperature (0C): Max return temperature (0C):
31
Type:
32
Fouling Factor: Design pressure (kg/cm2A):
Supply pressure (kg/cmG):
Min. return pressure (kg/cmG): Design temperature (0C):
33
34
Water Flow Rates (m3/hr)
35
Electricity
36
Auxiliary Motors:
Ph
Hz
REV B
Page 101 of 129
37
Oil Heaters:
Ph
Hz
38
Solenoid Valves:
A.C/D.C
Ph
Hz
39
Instruments:
A.C/D.C
Ph
Hz
40
Local Panel INDI./Alarm/Ann : A.C/D.C
Ph
Hz
41
Local Panel Trip Circuit: A.C/D.C
Ph
Hz
42
UPS: KVA,
Ph
Hz
43
Total Utility Consumption Cooling Water (Make UP) (m3 /hr)
44
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 DOCUMENT NO. 11-0353-02-09-03-102 SHEET 4 OF 28 REV B
Page 102 of 129
56
Linear Average Piston Speed
m/sec m3/ hr
57
Piston Displacement
58
Cylinder Liner (Yes / No)
59
Type of Cylinder Liner : Dry/Wet
60
Clearance Pockets Yes / No
61
Max. Allow. Working Pressure, Cylinder
kg/cma
62
Max./Min Allow. Working Temp., Cylinder
0C
63
M.A.W.P, Cylinder @ Amb. Temp.
kg/cma
64
Safety Valve Set Pressure, Cylinder
kg/cma
65
Helium Test Pressure, Cylinder
kg/cma
66
Hydrostatic Test Pressure, Cylinder
kg/cma
67
Cylinder Jacket Cooling Type As reqd.
68
Cooling Media, Cylinder Jackets Water /AIR
69
Max. Allow. Working Pressure, Cyl. Jacket
kg/cma
70
Hydrostatic Test Pressure, Cyl. Jacket
kg/cma
REV B
Page 103 of 129
71
Suction Nozzle Size/Rating/Position
72
Discharge Nozzle Size/Rating/Position
73
Suction Valve Number
74
m/sec
75
Discharge Valve Number
76
m/sec
77
Type of Suction valve
78
Type of Discharge valve
79
Suction Valve Unloaders Yes / No
80
Clearance Pockets Unloaders Type
81
Piston Rod Diameter
mm
82
Rod Reversal at Crosshead Pin (min.)
Deg.
83
Piston Rod Runout Operating kg
84
Max. Allow. Rod Load Comp. kg
85
Tension
86
Rod Load Comp.
Kg kg
87
(Inertia Alone) Tension
88
Rod Load Rated Pr. (Gas+Inertia) Comp.
kg
REV B
Page 104 of 129
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/cmG
103
## Packaging shall be connected to vent header Ref 7.19.4 of API-11 P
104
Frame
105
Frame Explosion proof Relief device
REV B
Page 105 of 129
106
Flame Arrestor Yes / No
107
Replaceable Crosshead Shoes Yes / No
108
Crosshead Guide Integral / Separate
109
Maximum Frame Rating
kW
110
Speed - Maximum/ Minimum
Rpm
111
Lubrication Systems
112
Type of lube system
Piping material
113
Carbon Steel
114
Main Oil Pump Driven By :
Stainless Steel (all piping & valves Trims)
115
Standby Oil Pump, Driven By :
Auxiliary oil tank
116
Hand Operated Prelube/Priming Pump:
Oil Grade :
117
Suction Strainer
Lube Oil Consumption
118
Pressure Control Valve
Main Pump
Make : Type :
Model : Material :
119
Level Sight Glass on the Crankcase
Standby Pump Make : Type :
Model : Material :
120
Type of Oil Cooler :
121
Size of Filter:
122
Oil Heater (if required).
123
Electric Heater with thermostat (Kw)
REV B
Page 106 of 129
124
Thermostatic Valve
125
Type of Cylinder Lubrication
Lubricator Equipped With : level sight glass
126 127
Lubricator Type: Manzel or Equivalent Single plunger per feed oil heater electric with thermostat
128
Divider blocks type.
Electric Heater (Kw) (if required)
129
Lubricator Driven By :
Auxiliary Oil Tank (if required)
130
Compressor Shaft
Oil Grade :
131
Electric Motor KW
Oil System Capacity: (min 150 Hrs.)
132
All tubing and valves in SS
Oil Consumption rate
133
Double Ball Check valve on each lubrication point
134
Cooling System
135
Static filled coolant system for
136
All Stage Cylinders
1 Stage Cylinder/s
2 Stage Cylinder/s
3 Stage Cylinder/s
137
Including expansion chamber, Vents, Drains, Level Gauge, Pipings, etc.
138
All Piping prefabricated Material
139
Atmospheric thermosyphon cooling system for
140
All Stage Cylinders
1 Stage Cylinder/s
2 Stage Cylinder/s
3 Stage Cylinder/s
141
Including expansion tank, Vents, Drains, Coolers, Level & Temp. indicators, Pipings, etc.
REV B
Page 107 of 129
142
Material
143
Forced Cooling Water System
144
All Stage Cylinders
1 Stage Cylinder/s
2 Stage Cylinder/s
3 Stage Cylinder/s
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
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:
REV B
Page 108 of 129
160
Jacket cooling
161
Gas Piping System
162
Vendor's Supply Includes: Suction Separator
163
Pulsation suppression equipment as per next page
164
Suction Filter:
165
Temporary Strainer on Compressor Suction
166
Type of Strainer:
167
Relief Valves: on compressor
suction
Inter-stage
on compressor discharge
168
Check Valve on Discharge Line (compressor valve design, and suction line)
169
Process Gas Coolers Complete With Manual Drain Valve
170
Separators Complete With Manual/ Automatic Drain Values
171
Process Gas Piping
172
Supply starts at inlet flange of CNG PACKAGE
173
Terminates after priority panel with isolation valve
174
Materials:
175
By-Pass Line Piping
176
Between 3rd stg. discharge and 1 st stg. Suction
177
Gas cooler
178
Interconnecting Piping Between Packing Vents, PSV Relief terminating to Vent Recovery System.
REV B
Page 109 of 129
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
As per API 618, Cl 3.9.2.7
188
189
190
191
192
Volume
193
Material : vessels
SA 516 Gr.60/70
SA 516 Gr.60/70
SA 516 Gr.60/70
194
Internals
195
Corrosion
3 DOCUMENT NO. 11-0353-02-09-03-102 SHEET 12 OF 28 REV B
Page 110 of 129
Allowance mm
196
1.3XMAWP
1.3XMAWP
1.3XMAWP
197
Discharge
198
Puls. Equipment Supplied Yes/No
YES
YES
YES
199
Inlet Pressure
200
As per API 618, Cl 3.9.2.7
201
202
203
204
205
Volume
206
Material : vessels
SA 516 Gr.60
SA 516 Gr.60
SA 516 Gr.60
207
Internals
208
Corrosion Allowance mm
209
1.3XMAWP
1.3XMAWP
1.3XMAWP
210
Pulsation Suppressors are complete and installed on the Skid with supports & anchor bolts
REV B
Page 111 of 129
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
221
Interlock against loaded start
222
Automatic Control based on
223
Suction Pressure Discharge Pressure
Flow Manual Signal
224
Type of Actuator
Actuation fluid to load
Actuation fluid to unload
225
On Power / Actuation fluid failure : Compressor to
Load
Unload
226
227
Continuously
Maximum Hrs.
228
229
Continuously
Maximum Hrs.
REV B
Page 112 of 129
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
REV B
Page 113 of 129
246
Packing Vent
247
C.W. Inlet
248
C.W. Outlet
249
N2 Inlet Supply
250
N2 Vent (Safe location)
251
Drains
252
MATERIALS
253
Cylinder Materials
254
Stage
1 Stage
2 Stage
3 Stage
255
Cylinder
256
Liner
257
Piston
258
Piston Rings
PTFE/PEEK
PTFE/PEEK
PTFE/PEEK
259
Rider Rings
PTFE/PEEK
PTFE/PEEK
PTFE/PEEK
260
Piston Rod
261
Packing Rings
262
Valve Seats
REV B
Page 114 of 129
263
Valve Stops
264
Valve Rings / Plates
265
Valve Springs
SS
SS
SS
266
Cylinder Head
267
Motion Work Materials :
268
Material / ASTM Grades
269
Top Cover
Cast
Fabricated
270
Crankcase
Cast Fabricated
271
Crankshaft
Die Forged Cast
Open Forged
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
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 :
REV B
Page 115 of 129
281
Each package shall be provided with two number drain lines, one from Suction KOD and second drain as common drain line from intermediate and discharge KOD routed to drain vessels through gas recovery vessels
282
CONTROLS & INSTRUMENTATION
283
AC Power On/Off Switch With Indication Lamp
284
Control Power On/Off Switch With Indication Lamp YES
285
Selector Switch A/M Station For L/O Pump Motor
286
Selector Switch A/M Station For CW Pump Motor
287
Emergency Stop Push Button
288
Start Push Button For Air Compressor Motor
289
Emergency Stop Push Button for Main Motor
290
Lamp Test Push Button
291
Alarm/Trip Acknowledge /Reset Push Button
292
Frame Oil Heater ON (Indicating lamp)
293
Lubricator Oil Heater ON (Indicating lamp)
294
Driver Interlocked against loaded start
295
Driver Interlock against start without pre-lubrication
296
Notes :
297
Minimum required indications, alarms & trips are shown herewith. Bidder shall provide any additional instrumentation for safe operation.
298
Compressor shall start stop at pre determined receiver pressure as specified. Bidder shall include in his
REV B
Page 116 of 129
299
Scope includes the necessary hardware for the same.
300
All inter-stage / discharge and suction scrubber shall be provided with high / low level operated auto drain solenoid valves.
301
INSPECTION AND TESTS
302
Material Composition and Physical Properties Certificates Required For/Compliance certificate:
303
Cylinder and Liner
Piston
304
Crankshaft
Connecting Rod
305
Pressure Vessels
Heat Exchangers
306
X-Ray Examination for components: Pressure Vessels (certificates to be furnished).
307
Ultrasonic Testing for components: Piston Rod, Crankshaft, Big End Bolts, Main Bearing Studs.
308
Magnaflux Testing for components: Crankshaft, Piston Rod, Connecting Rod.
309
Dye Penetration Testing for: Cylinder, Liner, Piston.
310
Required
Observed
Witnessed
311
Shop inspection by Purchaser during manufacture
312
Cylinder Hydrostatic
313
Cylinder Pressure Test By Helium
314
Hydrostatic Test of Pressure Vessels
315
Hydrostatic Test of Distance Piece.
316
Leak Proof Test of Crank case for 24 Hrs
REV B
Page 117 of 129
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.
REV B
Page 118 of 129
334 Gear Box Kg. approx.
335
Driver Kg. approx.
336
SCOPE OF SUPPLY
337
Compressor Assembly complete with frame, cylinders, cross head etc.
338
Motion work lubrication system
339
Cylinder and packing lubrication system
340
Cooling system
341
Process Gas system
342
Local instrumentation
343
Local Gauge Board
344
Local Control Panel
PLC Panel
Man Machine Interface located in Control Room
345
Main driver (Electric Motor)
346
Barring Device :
Manual
Electric . pneumatic
347
Flywheel
348
349
Couplings
350
Driver Compressor
Guards for moving parts 351 352 Base plate Common for Compressor and Driver
REV B
Page 119 of 129
353 Fabricated Steel skid Common for compressor, driver and accessories
354
Ladders and platforms
355
Special Tools - One Set for each package
356
Anchor Bolts for Complete Package
357
Piping supports and brackets :
prefabricated for piping in Vendor's Scope
358
Supports For Cylinders & Auxiliaries, Prefabricated & fitted in the Package
359
Commissioning Spares, erection and commissioning spares
360
Train Torsion Analysis Study and Report
361
Acoustic Simulation Study & Report
362
Vendor Data as specified
363
NOTE : Refer checklist for scope of supply
REV B
Page 120 of 129
DATA SHEET- INSTRUMENTATION & CONTROLS FOR COMPRESSOR
TRIP & A/V ALARM ANNUN. LOW LOCAL PANEL PLC-DISPLAY HIGH LOCAL PANEL PLC- DISPLAY REV B
Page 121 of 129
S. NO
DESCRIPTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Frame Oil Sump/Reservoir Level Main L/O Pump Disch. Pr (supply header). Oil Flow Oil Pressure at Main Bearing Supply Header Temp. Oil cooler Oil Inlet Temp. Stand by Pump Start Compressor Main bearing metal Temp. Cylinder & Packing Oil Lubricator Oil Level Lubricator Oil Flow Lubricator Failure Aux. Oil Lub. Oil Supply Pr. to Electric Motor Driver Lub. Oil return from Electric Motor Driver Elec. Motor bearing metal temp. Coolant System Each cylinder CW outlet temp. Inter/After/Oil Cooler CW outlet temp. CW Supply header flow Sight Flow CW return each cylinder, Cooler & Header For Closed Circuit Cooling Coolant main pump disch. Pr. Coolant standby pump disch. Pr. Coolant stand by pump start Coolant supply header Pr. Coolant supply header temp
yes yes yes yes yes
yes yes
yes
yes
yes
TRIP & A/V ALARM ANNUN. LOW LOCAL PANEL PLC-DISPLAY HIGH LOCAL PANEL PLC- DISPLAY yes yes yes yes yes yes yes REV B
Page 122 of 129
S. NO
DESCRIPTION
28 29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48 49 50
Coolant cooler Outlet Temp. Coolant reservoir Level Cylinder Coolant Outlet temp. For Static/Thermosyphon System Cylinder Coolant Outlet temp. Diff. Pr. Across packing coolant filter Process Gas System Each stage inlet Pressure Each stage inlet temp. Each stage Outlet Pressure Each stage Outlet temp. (before air cooler and after cooler) After Cooler Gas Outlet temp. Ist stage pressure low / high Cylinder Packing Vent Pressure Suction Pressure, low Blow Down vessel level Piston Rod Drop Indicator Distance piece diff. Purge pressure Common process parameters Common machine parameters Blow Down vessel Pressure Vibration Measurement RPM meter
yes yes
yes
yes yes
yes yes
yes yes
yes yes
yes yes
yes
yes yes
yes
yes yes
yes
yes yes
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).
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
OPERATING CONDITIONS (EACH MACHINE) / PERFORMANCE Operating Case: SUCTION PRESSURE: 14 kg/cm g Stage 1 Stage 2 Stage 3 Units Gas Handled (See Analysis) NONE NONE NONE Corrosion Due to Suction Conditions 14 Pressure (@ Vendor's Kg/cm g B/L) 0 Temp. (+@ Vendor's C 35 B/L) Discharge Conditions (Vendor's Battery Limit: 250 Pressure (@ Vendor's B/L Kg/cm g Pressure @ Cylinder Flg. Kg/cm g 0 <150 < 150 < 150 Temp.,Adiabatic @Cyl. C Flange 0 Temp.,Actual @Cyl.Flange C 0 < 52 Temp.,After AfterCooler C Cp/Cv Ratio Compr. Factor (Z2 ) or (Z avg ) Operating Characteristics Capacity (wet) SM3 /Hr Mfr's Rated Cap. (Design) (No -ve tol.) 3 Actual Inlet Flow (wet) AM /Hr Specific Gravity Coupling Losses kW Volumetric Efficiency % Valve Lift Suction / mm / mm Valve Lift Area Suction/ mm2 / mm2 Discharge Valve Velocity m/sec Speed RPM Compressor Shaft Power KW Power consumed @ RV KW Set Pr. Driver Power KW Guaranteed Point GAS ANALYSIS- Gas Composition attached as Annexure-I.
REV B
Page 123 of 129
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
OPERATING CONDITIONS (EACH MACHINE) / PERFORMANCE Operating Case: SUCTION PRESSURE: 16 kg/cm g Stage 1 Stage 2 Stage 3 Units Gas Handled (See Analysis) NONE NONE NONE Corrosion Due to Suction Conditions 16 Pressure (@ Vendor's B/L) Kg/cm g 0 35 Temp. (+@ Vendor's C B/L) Discharge Conditions (Vendor's Battery Limit: 250 Pressure (@ Vendor's B/L Kg/cm g Pressure @ Cylinder Flg. Kg/cm g 0 <150 < 150 < 150 Temp.,Adiabatic @Cyl. C Flange 0 Temp.,Actual @Cyl.Flange C 0 < 52 Temp.,After AfterCooler C Cp/Cv Ratio Compr. Factor (Z2 ) or (Z avg ) Operating Characteristics Capacity (wet) SM3 /Hr Mfr's Rated Cap. (Design) (No -ve tol.) Actual Inlet Flow (wet) AM3 /Hr Specific Gravity Coupling Losses kW Volumetric Efficiency % Valve Lift Suction / mm / mm 2 2 Valve Lift Area Suction/ mm / mm Discharge Valve Velocity m/sec Speed RPM Compressor Shaft Power KW Power consumed @ RV Set KW Pr. Driver Power KW Guaranteed Point GAS ANALYSIS Gas Composition attached as Annexure-I.
REV B
Page 124 of 129
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
OPERATING CONDITIONS (EACH MACHINE) / PERFORMANCE Operating Case: SUCTION PRESSURE: 19 kg/cm g Stage 1 Stage 2 Stage 3 Units Gas Handled (See Analysis) NONE NONE NONE Corrosion Due to Suction Conditions 19 Pressure (@ Vendor's B/L) Kg/cm g 0 35 Temp. (+@ Vendor's C B/L) Discharge Conditions (Vendor's Battery Limit: 250 Pressure (@ Vendor's B/L Kg/cm g Pressure @ Cylinder Flg. Kg/cm g 0 <150 < 150 < 150 Temp.,Adiabatic @Cyl. C Flange 0 Temp.,Actual @Cyl.Flange C 0 < 52 Temp.,After AfterCooler C Cp/Cv Ratio Compr. Factor (Z2 ) or (Z avg ) Operating Characteristics Capacity (wet) SM3 /Hr Mfr's Rated Cap. (Design) (No -ve tol.) Actual Inlet Flow (wet) AM3 /Hr Specific Gravity Coupling Losses kW Volumetric Efficiency % Valve Lift Suction / mm / mm 2 2 Valve Lift Area Suction/ mm / mm Discharge Valve Velocity m/sec Speed RPM Compressor Shaft Power KW Power consumed @ RV Set KW Pr. Driver Power KW Guaranteed Point GAS ANALYSIS Gas Composition attached as Annexure-I.
REV B
Page 125 of 129
DATA SHEET INTER COOLER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 GENERAL PROJECT: PROCUREMENT OF CNG COMPRESSORS OWNER: SABARMATI GAS LIMITED SITE: GANDHINAGAR Item No. : Service : Intercooler / After cooler for Compressor Package NOTE: SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER INFORMATION REQUIRED FROM VENDOR. Manufacturer: Type: Forced Draft Induced Draft Bundle Size: m x m x m Bundles/Section Number of Units: Bundles/Unit: In Parallel / Series Section Size: Surface/Bundle: m Bare Tube: m Section/Unit: Surface/Unit: m Bare Tube: m Plot Area/Unit: PERFORMANCE (Of One Unit) Heat Exchanged: kcal/hr MTD (Corrected): 0C 0 Transfer Rate: kcal/hr m C (Finned Surface) (Bare Surface) TUBE SIDE Fluid Circulated GAS Gravity: Liquid API SG @ 15.4EC Total Entering Gas kg/hr Enthalpy / Latent Heat kcal/kg Operating Temperature In: Out: Fouling Resistance hr m 0C/kcal Operating Pressure Passes / Bundle kg/cm AIR SIDE Temperature In:47 Out: Altitude m Total Flow/Unit kg/hr Static Pressure kg/cm Quantity/Fan kg/hr Power/Fan kW Face Velocity m/sec Power/Unit kW CONSTRUCTION (Each Bundle) Design Pressure: kg/cmg Test Pressure: kg/cmg Design Temperature: 0C Code Requirements: Type of Tubing: Tube Material: SA 179 Fin Material: Al Tube Bare Tubes (no's) : No. of rows: O.D. BWG/Thk Length Fins : Spacing /inch. O.D. Root Dia Thickness: Header Type: Plug / Cover No. of Splits: Material : Plugs/Gaskets Side Frame : C.S. Inside Zinc Protected Nozzles In : Out : Couplings Vent: Drain : CONSTRUCTION (Each section) Structure CS Sec./Gr. No. Design Wind Load : kgf/m Plenum Chamber CS inside Zinc Protected Type : Fans No. Dia. RPM Mfr. Blades Material : No./Fan Pitch Angle(Design) : Hubs Material : Pitch : Autovariable / Adjustable (No. ) Louvers Material : Type : Mfr. Weights kg Each Section(Dry) : Full of Water: Each Bundle (Dry) : Full of Water: APPLICABLE SPECIFICATIONS API Standard 661 REMARKS 1. Air coolers shall be designed for 20% excess capacity than required normally. Exchanger shall be designed with air side temperature of 47.5 0C. Separate data sheet shall be filled by the bidder for each service i.e. Inter cooler and After cooler
REV B
Page 126 of 129
CLIENT JOB NO.
03 301
DATA SHEET AIR COOLED HEAT EXCHANGER

TOTAL SHEETS
DOCUMENT NO
11
0317
02
09
03
0 C B A REV.
02.05.11 26.04.11 11.04.11 07.04.11 DATE
MH MH SS SS PREP
RC RM RM RM CHKD
RC RC SB SB APPD
1
Page 127 of 129
DATA SHEET AIR COOLED HEAT EXCHANGERS Service: Intercooler / After cooler for Compressor Package 2 NOTE: Scope option / information specified by Purchaser Information Required From Vendor 3 Manufacturer Type Forced Draft 4 Bundle / Unit : m x Bundles / Section mxm 5 Bundles/ In Parallel / Series Unit: 6 Surface / Bundle: Bare tube: m2 m2 7 Surface / Unit: m2 bare Tube: m2 8 Performance (of one unit) 9 Heat Exchanged: kcal/hr 10 Transfer Rate: (Finned Surface) kcal/hr/m2C 11 Tube Side 12 Fluid Circulated: Gas 13 Total Entering Gas kg/hr 14 Operating /Temperature In: Out: 15 Operating Pressure Passes/Bundle kg/cm2 16 Air Side 17 Temperat In: 47 ure 18 Total Flow/Unit Kg/hr 19 Quantity / Fan kg/hr 20 Face Velocity m/sec 21 Construction (Each Bundle) 22 Design Pressure : kg/cm2g 23 Code Requirements: 24 Type of Tubing: 25 Bare Tubes (nos.) 36 Fins: Spacing/inch.OD 27 Header Type: Plug/Cover 28 Plug/Gas kets 1
Induced Draft Number of Units Section Size Section / Unit Plot Area / Unit
MTD (Corrected:0C (Bare Surface)
Gravity: Liquid APISG@15.4EC Enthalpy/Latent Heat kcal/kg Fouling Resistance hrm2C/kcal
Out:
Altitude (m): 110 Static Pressure kg/cm2 Power / Fan kW Power / Unit kW
Test Pressure : kg/cm2g
Design Temperature : 0C
Tube material : CS (SA-179) No. of rows: O.D Root Dia No. of Splits: Side Frame: C.S.Inside Zinc Protected
Fin material: AI BWG/Thk Thickness Material: Leng th
DATA SHEET - HEAT EXCHANGER
REV B
Page 128 of 129
29 30 31 32
Nozzles Couplings Construction (each Station) Structure
In: Vent CS
Out: Drain
33 Plenum Chamber 34 Fans 35 Blades 36 Hubs 37 Louvers
Sec/Gr.N Design Wind o. Load: kgf/m Cs inside Zinc Type Protected No. Dia RPM Mfr. Materia No/Fan Pitch Angle l (Design) Materia Pitch L Auto variable / l Adjustable (No.) Materia Type Mfr. l
38 Weights kg Each Section (Dry): 39 Each Bundle (Dry) 40 Applicable Specifications API Standard 11P 41 Remarks 1. Air coolers should be designed for 10% excess capacity than required normally. 42 Exchanger should be designed with air side temperature of 48C 43 Separate data sheet should be filled by the bidder for each service i.e. Inter cooler and after cooler.
DATA SHEET - HEAT EXCHANGER
REV B
Page 129 of 129

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SABARMATI GAS LIMITED

(A Joint venture with GSPCL & BPCL)

SABARMATI GAS LIMITED CITY GAS DISTRIBUTION PROJECT

02.05.11 26.04.11 11.04.11 07.04.11 DATE

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 2 OF 64

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

(2) (3) (4)

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 4 OF 64

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 5 OF 64

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 6 OF 64

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

13 4 C / 47 C 27oC 95% 110 meters 47 C DBT, 27 C WBT & 94% RH

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 8 OF 64

3.0 3.1 3.1.1

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 9 OF 64

3.3 3.3.1 3.3.2

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 10 OF 64

3.6 3.6.1 3.7 3.7.1

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 11 OF 64

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 12 OF 64

Terminal box and cable entries

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 13 OF 64

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 14 OF 64

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 16 OF 64

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 17 OF 64

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

Enclosure of CNG Compressor Package

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 18 OF 64

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 20 OF 64

4.26 4.27 4.28

4.29 4.30 4.31 4.32

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

RPM meter shall be in package

Following points to be noted regarding Mass Flow meter Coriolis type:

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 22 OF 64

6.1.4 6.1.5 6.1.6 6.1.7 7.0 7.1

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 26 OF 64

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 27 OF 64

Penalty for Non-Performance during Period of Operation & Maintenance

SPECIFICATION FOR ELECTRIC MOTOR DRIVEN CNG COMPRESSOR PACKAGE

DOCUMENT NO. 11-0353-02-09-02-007 SHEET 28 OF 64

9.3 10.0 10.1