tender.tractebelindia.comtender.tractebelindia.com/IGL/EC15857/Technical Vol II of II.pdfS.No. Document / Drawing No. Rev. No. Pages Page No. I COMMERCIAL 1 2 3 4 5 6 II TECHNICAL

DEVELOPMENT OF LNG SECONDARYSTATIONS INCLUDING TRANSPORTATION OFLNG FROM PRIMARY STATIONS TOSECONDARY STATIONS ON WETLEASE BASISIN THE STATE OF RAJASTHAN

Project No. P.013429Document No. P.013429 D 11031 005Tender No. IGL/ET2/CP/EC15857

INDRAPRASTHA GAS LIMITED (IGL), NEW DELHINew Delhi | INDIA

PUBLIC

14 February 2020

TECHNICAL DOCUMENTATIONTechnical, Vol II of II, Rev. 0

S.No. Document / Drawing No. Rev. No. Pages Page No.

I COMMERCIAL

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II TECHNICAL

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SECTION - V FORMS AND FORMATS

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SECTION - VI

SECONDARY STATION (RAJASTHAN) SCHEMATIC DIAGRAM LNG STORAGE &

REGASSIFICATION WITH LCNG + LPNG DISPENSING FACILITIES

MAIN TABLE OF CONTENTS

DEVELOPMENT OF LNG SECONDARY STATIONS INCLUDING TRANSPORTATION OF

LNG FROM PRIMARY STATIONS TO SECONDARY STATIONS IN AJMER, PALI &

RAJSAMAND DISTRICTS IN THE STATE OF RAJASTHAN ON WETLEASE BASIS

P.013429

D 11031

005

Description

VOLUME IA OF II

SECTION - I INVITATION FOR BID (IFB)

SECTION - II INSTRUCTION TO BIDDERS (ITB)

Page 1 to 97

SCHEDULE OF RATES (SOR)

SECTION - III GENERAL CONDITIONS OF CONTRACT (GCC)

SECTION - IV SPECIAL CONDITIONS OF CONTRACT (SCC)

DATA SHEET - PRESSURE GAUGE

PTS - CNG STORAGE CASCADES

DATA SHEET - TEMPERATURE GAUGE

DATA SHEET - PRESSURE RELIEF VALVES

OVERALL SCHEMATIC DIAGRAM FOR LNG TRANSPORTATION, STORAGE &

REGASSIFICATION WITH LCNG + LNG + LPNG DISPENSING FACILITIES

VOLUME II OF II

PTS - MECHANICAL

PTS - CAR DISPENSERS

PTS - CAR CUM BUS DISPENSERS

DATA SHEET - CNG STORAGE CASCADES

LNG Transportation Devlopment of LNG Storage Regasification Stations Page 1 of 1

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INDRAPRASTHA GAS LIMITED. (IGL)

TRANSPORTATION OF LNG FROM PRIMARY

STATION TO SECONDARY STATION & DEVLOPMENT OF

LNG STORAGE & REGASIFICATION STATIONS

(SECONDARY STATION) IN THE STATE OF RAJASTHAN

(AJMER-PALI-RAJSAMAND GA)

PTS - MECHANICAL

2 10.02.2020 Revised as per client comments VA AR MS

1 29.01.2020 Revised as per client comments VA AR MS

0 15.04.2019 Issued for Construction VA AR MS

Rev Date Subject of Revision Prepared By Checked By Approved By

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Rev. 2 Development of Secondary Stations including transportation of LNG in Ajmer, Pali &

Rajsamand Districts in the State of Rajasthan Page 1 of 1

TABLE OF CONTENTS

1.0 GENERAL : ....................................................................................................................... 1

2.0 MAJOR APPLICABLE CODES ............................................................................................ 1

3.0 SCOPE .............................................................................................................................. 2

4.0 EXCLUSIONS ................................................................................................................... 8

5.0 MAJOR EQUIPMENT ........................................................................................................ 8

ANNEXURE # 1 ........................................................................................................................ 15

DATA SHEETS

ANNEXURE # 2 ........................................................................................................................ 21

LIST OF SUPPLIERS OF MAJOR BOUGHT-OUT ITEMS

ANNEXURE # 3 ........................................................................................................................ 24

LIGHTING

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1.0 GENERAL :

M/s IGL has awarded Project management consultancy services to TRACTEBEL ENGINEERING Pvt. Ltd.

for setting up LNG Transportation, storage & regasification station with LNG, LCNG & LPNG dispensing

facilities located in the State of Rajasthan (Ajmer-Pali-Rajsmand GA).

This project shall make LNG (Liquefied Natural Gas) / R-LNG (Re-gasified Liquefied Natural Gas) available

in the State of Rajasthan (Ajmer-Pali-Rajsmand GA) and pave the path for clean energy in the form of L-PNG/

L-CNG/ LNG to various domestic as well as commercial consumers in the area.

Brief scope of work of this project is divided into three parts as below:

• Part A- Transportation of LNG through trucks (LNG cryogenic tankers, Capacity – Minimum 16

Ton) from Dahej terminal to IGL Primary Stations located in Rajasthan (Ajmer-Pali-Rajsmand GA).

• Part-B – Development of 03 Nos. Primary Station including design, engineering, supply of

equipment, fabrication, erection, transportation, loading, unloading, handling, installation, testing,

assistance in statutory approval, documentation, pre-commissioning and commissioning, Operation

and Comprehensive Maintenance for dispensing of LNG, L-PNG & L-CNG in the state Rajasthan

(Ajmer-Pali-Rajsmand GA).

Consumption/Demand for Primary Station is as follows:

i) Ajmer - 1,00,000 SCMD

ii) Pali - 55,000 SCMD

iii) Rajsamand - 28,000 SCMD

This demand shall gradually increase over the period of time.

• Part C – Transportation of LNG from Primary station to 20 Nos. secondary station and Development

of 20 nos. Secondary Station design, engineering, supply of equipment, fabrication, erection,

transportation, loading, unloading, handling, installation, testing, assistance in statutory approval,

documentation, pre-commissioning and commissioning, Operation and Comprehensive Maintenance

for dispensing of L-PNG & L-CNG at Ajmer-Pali-Rajsmand GA in the State of Rajasthan only.

Consumption/Demand for Secondary Station is approximate 4000 Kg per day. This demand shall

gradually increase over the period of time.

L-CNG & L-PNG shall be supplied from all 20 Nos. secondary stations.

Transportation of LNG from Primary Station to Secondary Stations within 50 kms, 60 Kms & 40 Kms

from the Primary Stations Located in the District of Ajmer, Pali and Rajsmand respectively.

Contractor shall also be required to carry out system design, Engineering, to develop P&ID and detailed layout

as per PESO / Other Statutory guidelines. The work also includes associated mechanical, piping,

instrumentation and automation works etc. providing technical assistance to Owner in obtaining PESO

approvals. The complete system shall be designed for automatic operation with minimal human interference.

However, there shall be human interface available in the PLC based control panel. The system shall be

designed for most economic and reliable operations with minimal LNG boil-off even under no consumption

condition. The system shall be designed in accordance with latest PESO guidelines and other relevant

codes/regulations/ laws applicable in India.

2.0 MAJOR APPLICABLE CODES

Static and Mobile Pressure Vessel (SMPV) Rules (Unfired) Gas Cylinder Rules

NFPA 59A

PNGRB regulations

OISD Standards

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ASME BPV Code Sec VIII EN 13458-2

Any Other Applicable codes

In case of any conflict in the requirements of above codes, the most stringent requirement shall govern. Only

latest edition of above mentioned codes shall be followed.

3.0 SCOPE

This Specification covers only Part C (Development of 20 Nos. Secondary Stations in the state of Rajasthan

including Transportation of LNG from Primary Stations to Secondary Stations within 50 kms, 60 Kms & 40

Kms from the Primary Stations Located in the District of Ajmer, Pali and Rajsmand respectively).

The Scope of work (Transportation, supply, installation, Commissioning, Operation & Maintenance etc.)

consists of but not limited to the following services:

3.1 The Secondary Stations will be located in respective districts within a radius of KM as mention below,

• Ajmer District – 10 Nos. Stations. Secondary Stations will be located within radius of 50 KM from

IGL’s Primary Station.

• Pali District – 06 Nos. Stations. Secondary Stations will be located within radius of 60 KM from IGL’s

Primary Station.

• Rajsamand District – 04 Nos. Stations. Secondary Stations will be located within radius of 40 KM from

IGL’s Primary Station.

3.2 To own/lease and operate LNG tankers, be it combination of prime movers and tank trailers or LNG tanks

mounted on rigid truck chassis, for transporting and unloading of LNG at secondary LNG stations in the state

of Rajasthan (Ajmer-Pali-Rajsmand GA) from Primary LNG Stations.

3.3 Coordination with Personnel at Primary Station (Ajmer-Pali-Rajsmand GA) for loading the LNG in Cryogenic

Tank mounted on vehicle.

3.4 Certifying the LNG which is loaded in LNG Cryogenic Tank mounted on Vehicle with Owner/ Owner’s

authorized personnel at Primary LNG Station.

3.5 Transportation of LNG from Primary Station to Secondary Stations Located in the District of Ajmer, Pali and

Rajsmand within 50 kms, 60 Kms & 40 Kms respectively from the Primary Stations.

3.6 Unloading of LNG from Cryogenic tank mounted on vehicle to LNG Tank (Installed at secondary LNG

station)

3.7 The CONTRACTOR shall be required to measure the LNG transported by way of weighbridge measurement

before & after loading at primary LNG stations (Located in the state of Rajasthan)

3.8 The Contractor shall be required to measure the LNG transported by way of weighbridge measurement after

decanting/ unloading at owner’s Secondary station.

3.9 The contractor shall be required to submit the receipts of weighbridges for reconciliation purposes. Charges (if

any) for weighbridge measurement shall be deemed to be included in the quoted rates.

3.10 The Contractor shall be required to submit reconciliation of LNG along with Weighbridge measurement

receipts per trip.

3.11 Only LNG tanks mounted on suitable chassis or trailers meeting the required parameters shall be allowed to be

engaged and the contractor should take clearance of the mounting drawing from Owner and other statutory

bodies before the mounting. Tanks mounted in deviation to above stipulations shall not be engaged.

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3.12 Tracking LNG tankers movement and ensuring safety during transportation.

3.13 LNG tankers must possess certificate of inspection, approval by independent third-party agency, statutory

approvals from PESO, RTO, etc for carrying out the work of taking LNG from Dahej LNG Terminal,

transporting and delivering LNG to LNG storage facility at Secondary stations (Ajmer, Pali, Rajsamand). The

Contractor shall have to arrange all state /intra-state permits and must comply with all the statutory

requirements necessary for transportation/handling of LNG, at its own cost.

3.14 In case the LNG tanks are mounted on trailers, the Contractor shall register Prime Movers and keep the LNG

Tankers endorsed in the Registration Certificate of the Prime Movers. All expenses pertaining to such

endorsement shall be borne by the Contractor.

3.15 The Contractor shall submit copy of all statutory approvals, certificates, permits, insurance certificates,

renewals, etc for LNG carriage vehicle and any other documents as may be required by Owner for its records

prior to commencement of the services under this Contract. All expenses associated with referred permits,

approvals, renewals, etc shall be in the scope of Contractor.

3.16 In case of an accident, or any other damage caused to the LNG tankers, it shall be the responsibility of the

Contractor to report immediately to police, fire department, owner and any other body as per the prevalent and

applicable norms.

3.17 The Contractor shall maintain the LNG tankers in good condition at all times during the term of the Contract

without any service failure. Owner shall have the right to inspect and reject any LNG tanker if not found in

safe and satisfactory condition.

3.18 The selection of type(s)/model of trucks/prime movers and trailers and their number(s) to be engaged shall be

decided by the Contractor based on various factors including storage tank capacity at the Buyer’s location, road

condition, requirements of meeting the scope of work, etc.

3.19 All Documentation works shall be in bidder’s scope as defined in tender for Loading, Transportation &

Unloading etc.

3.20 Any third party loss of life or property resulted due to negligence of driver or fault of the vehicle shall be

responsibility of the bidder.

3.21 Bidder has to ensure safety of man and machine all the time. The bidder shall remain at all times liable to IGL

for any loss or damage caused to any building, plant, machinery, employee/agents/customers of IGL due to

careless, negligent, inexperienced act or default of the bidder, his/their agents, representative or employees.

IGL shall be the sole judge as regards the quantum of loss or damage and it shall be entitled to deduct from the

amounts payable hereunder to the bidder, the cost of repairs or the amount of loss or damages.

3.22 The bidder agrees to indemnify IGL to directly or indirectly any loss or injury caused to IGL

employees/agents/customers/third party due to careless, negligent, inexperienced act or default of the bidder,

his/her agents, representatives or employees.

3.23 Bidder shall ensure completion of the work in time bound manner failing which IGL shall have full Liberty to

impose penalty & terminate the contract. The Bidder or his authorized representative shall interact with

Engineer-in-charge for smooth movement of the transport services.

3.24 The bidder shall be required to take Comprehensive Insurance Policy including third party insurance coverage

for each vehicle taken from a reputed Insurance Company and shall keep in force during the tenure of the

contract. The bidder shall also take necessary insurance coverage for drivers and supervisors engaged in the

work and shall provide relevant documents on demand.

3.25 The bidder shall ensure that no person smokes in vehicle. And should not permit any fire or other Ingredients

of ignition near vehicle, LNG station. The vehicle engaged for transportation of LNG should not carry any

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persons or goods other than the crew of the vehicle.

3.26 All arrangements for communication from LNG stations (Loading & Unloading) to the drivers working on jobs

under the contract shall be the responsibility of the bidder. The bidder has to provide mobile phones or radio

handsets to his supervisors.

3.27 All personnel of the bidder entering on work premises shall remain properly and neatly dressed up and shall

wear cotton uniform, safety shoes, badges, (identity card) while working on premises of the company including

work sites. In case the bidder does not provide uniform, shoes, engineer-in-charge has the right to withhold

payment in full or part. Decision of engineer-in-charge regarding amount to be retained is binding on the

bidder. The Transport Emergency (TREM) Card shall always be available with the vehicle.

3.28 The bidder shall provide GPS automatic Vehicle Locating & tracking system for all the vehicles:

a) GPS Automatic Vehicle Locating & Tracking system is required for monitoring the vehicles at real time

round the clock. For this purpose, the bidder shall install vehicle tracking system in all deployed LNG

Mounted vehicle. The vehicle tracking system shall have

latest features such as Realtime / Live Location on map, Speed Monitoring, Distance covered in

Km, Route or path taken by vehicle, Stoppage Report,history detail of 30 days, Ignition on/off, inbuilt

battery, inbuilt memory, stop your vehicle by SMS, SOS Button, SMS alerts,

fleet management reports, graphical reports for better and quicker understanding. The safety and security

of Vehicle Tracking System will be the responsibility of the bidder.

The CONTRACTOR shall also install necessary software on Owner’s PC for day to day monitoring.

Owner is not intended to Purchase software but use only during contract period including extended perio

d if any. One time licence fees if any shall be included in the vehicle tracking system. Operation and main

tenance of the GPS Automatic Vehicle Locating & Tracking system throughout contract period including

extended period if any shall be done by CONTRACTOR free of cost.

b) The GPS system shall have a display provision for a monthly MIS sheet consisting of following

information of individual Vehicle- Nos. of over speed incidents, max speed, no data period (total period

for which GPS was not Available, start location, end location etc. The monthly GPS MIS sheet shall be

submitted along with monthly invoices. In addition, bidder shall provide the API / URL link of GPS to

IGL to connect with MGV live movement tracking mobile app by IGL.

3.29 The bidder shall obtain the Traffic Police clearance for plying LNG vehicles on road. The bidder would be

responsible for obtaining the permission from Traffic Dept (Central / State) and compliance of all statutory

requirements. Any assistance/document required in this regard shall be provided by IGL. However, in case of

non-availability of permit, additional cost of running of vehicles because of penalty by traffic authority shall be

borne by bidder.

3.30 The bidder shall ensure safe & correct delivery of LNG at nominated destinations in same Condition in terms

of quality and quantity. Any infringement will be deemed as unlawful and IGL will hold the bidder legally

responsible for the same. Additionally, IGL also reserves the right in such an event, to forthwith terminate the

contract and/or to impose penalties on the bidder as it deems fit.

3.31 The mobilized fleet shall be fitted with spark/flame arrestor and other safety equipment’s prescribed by

statutory requirements of a design approved by Chief Controller of Explosives and provided with wheel jack,

tool kit, 2 traffic cones, reverse gear buzzer and spare wheel in good condition. IGL may depute their

representative for inspection of condition of MGV and bidder has to maintain vehicles to the satisfaction of

IGL.

3.32 All the vehicles for MGV shall be in good and safe working conditions. Fitness certificate required from RTO /

OEM of vehicle. Fitness certificate may need to produce at the time of deployment.

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3.33 Design and supply of LNG vacuum insulated storage tank/s along with

• MAWP – 12 barg.

• Minimum size & quantity of LNG Tank shall be decided by bidder for catering for catering the 4000 kg

per day demand. Since, bidder will transport the LNG from primary station to secondary station.

However, Minimum storage capacity shall be 10 KL.

• Isolation valves, instruments and interconnected piping.

• Level and Pressure transmitter.

• Emergency shut down Fire safe valves on Filling and delivery/pump lines.

• Junction box for connecting the instruments and valves on tank.

• 4 x 100% Safety valves.

• Common vent stack.

• PESO approval for the Design and TPI approval.

3.34 LNG Unloading Pump along with :

• Qty & Capacity per station as defined below in the specification.

• Skid mounted With Vacuum jacketed sump.

• Related valves and instruments including pressure and temperature sensors.

• Electrical panel located in the control room.

• Emergency shut down PB.

• Local vent stack.

3.35 Unloading Hose Trolley with Hoses – 1 sets for each working pump for easy and safe hose handling along with

Earthing reel for ensuring effective earthing.

3.36 Design and supply of 02 Nos. Atmospheric vaporisers (divided in 2 banks) at every Secondary LNG station to

meet required duty cycle to supply Natural gas with valves at inlet. The Flow of each vaporizer shall be 2000

SCMH. The change-over shall be automated with the help of PLC based control system and shall require no

human intervention.

3.37 Inlet / outlet valve skids for the Low Pressure vaporisers at every Secondary LNG station including:

• Automatic switchover based on time and outlet temperature.

• Temperature transmitters at outlet of each vaporizer.

• Interconnecting piping and supports.

• valves and instruments all mounted on skid complete with cabling , pneumatic tubing and junction boxes.

3.38 1 No. of Pressure reduction skid complying to PNGRB guidelines at every Secondary LNG station for delivery

of PNG upto 2000 SCMH flow and delivery pressure at 4 barg along with:

• 2 x 100% regulation stream with Active monitor combination with isolation valves and pressure gauges.

• slam shut off valve with isolation valve & pressure gauge.

• Creep relief valve.

• All mounted on skid with cabling and junction box.

3.39 Flow metering skid at every Secondary LNG station along with :

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• RPD type Flow Meter.

• Pressure and temperature compensation.

• Flow totalizer and indicator.

• Bypass valve and interconnecting piping duly mounted on skid with required valves and instruments.

3.40 PLC controlled Odoriser (For PNG stream without Odorant charge) at every Secondary LNG station along

with:

• Controlling valves.

• Odorant storage tank with level indicator.

• Air operated dosing pump.

• Flow sensor.

• Interconnecting piping duly mounted on skid.

• Each Odoriser system shall have redundancy of odorant pump ( 1 Working + 1 Stand by).

3.41 All Interconnecting piping between skids and Equipment till PRS skid outlet within dyke wall including piping

supports for PNG supply stream at every secondary LNG station.

3.42 02 Nos. (1 Working + 1 Standby) LNG High pressure pump/s at every secondary LNG station along with :

• 650 SCMH Flow rate of each pump @ 250 bar.

• Electrical control panel in control room

• Temperature sensors for pre cooling and dry run protection.

• LP and HP side safety valves.

• High pressure gauge and switch.

• Other instruments and interconnecting piping.

• Mounted on skid.

3.43 Design and supply of 02 Nos of atmospheric High pressure vaporizers per station to meet required duty cycle

to supply CNG at every secondary LNG station with instruments and isolation valves for manual switchover

after 8 hrs for continuous operation if required. The Flow of each Vaporizer shall be 650 SCMH.

3.44 PLC controlled Odoriser ( for CNG stream without Odorant charge) at every Secondary LNG station along

with:

• Controlling valves.

• Odorant storage tank with level indicator.

• Air operated dosing pump.

• Flow sensor.

• Interconnecting piping duly mounted on skid.

• May be a common system with PNG based on design.

• Each Odoriser system shall have redundancy of odorant pump ( 1 Working + 1 Stand by).

3.45 Sequencing/Priority Panel for sequencing of CNG flow (Quantity – 1 Nos, 10 Lines) at every secondary LNG

station.

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3.46 All Interconnecting piping for development of every secondary LNG station in totality i.e.

• In between Tank to HP Pump, Pump to HP vaporizer and HP vaporizer to PESO safe area boundary

including piping supports. Interconnecting piping from PESO area limit to Dispensers, priority panel,

CNG cascade fill point.

• In between Tank to LP Vaporiser, LP vaporizer to PESO safe area boundary including piping supports.

Interconnecting piping from PESO area limit to inlet of LPNG connection.

• In between Tank to Pump (Unloading LNG from LNG Tanker), Pump to PESO Safe area boundary

including piping supports.

3.47 At every Secondary LNG station, Total safety system inclusive of Special gas detection devices, low and high

temperature sensors, ESS etc. as per PESO guidelines in PESO storage area.

3.48 Programmable logic controller (PLC) including SCADA at every secondary LNG station along with:

• Control panel

• Including software initial programming.

• UPS for PLC power backup of 30 minutes.

• Licensed Personal computer for SCADA system.

3.49 Supply of all Electrical Cables from PLC to field instruments/Valves at every secondary LNG station.

3.50 Supply of cable trays, Electrical hardware , supports etc. at every secondary LNG station.

3.51 Supply of cable glands and other Electrical hardware at every secondary LNG station.

3.52 Supply of Air compressor (1 No) with Built in reservoir; Air distribution piping to all required components in

PESO area and dispenser area at every Secondary LNG station.

3.53 Pump for removal of water from dyke with control mechanism at every secondary LNG station.

3.54 As required by PESO norms, Supply of Fire extinguishers, sand buckets, warning signs etc. at every secondary

LNG station.

3.55 Supply of Earthing lugs on each equipment, Spring loaded earthing reel 10mtr wire ( 1 No per unloading

pump) at every secondary LNG Station.

3.56 Supply of Supporting systems such as Fire water system consisting of 1 set of water tank/pump/hose as per

PESO guidelines at every secondary LNG Station.

3.57 All Supplied Equipment shall be approved by PESO.

3.58 Supply of all required Foundation bolts for tanks and vaporizers; Supply of expansion bolts for skid and

supports.

3.59 Hazop Study, Emergency plan and safety report per MSIHC (Manufacture, Storage and import of Hazardous

chemical rules) if required.

3.60 Installation of cables and cable trays between PLC panel and station components inside PESO storage area

including all instrumentation at every secondary LNG Station.

3.61 At every secondary LNG Station, installation and commissioning of system including piping, welding, cabling

and pressure testing at site upto our Battery limit.

3.62 Supply of Liquid Nitrogen for tank cooling during commissioning at every secondary LNG Station..

3.63 Spares for commissioning for all Secondary LNG stations.

3.64 Supervision for unloading of tanks and Supervision of erection and commissioning of entire LNG Secondary

stations.

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3.65 Transport of Equipments to site and transit Insurance, Unloading and Erection, Provision for cranes for

unloading, erection and installation for all LNG Station Equipment.

3.66 Supply of Utilities such as Electrical power, water, Air etc. and N2 gas for testing during commissioning at

every secondary LNG Station.

3.67 Spare parts for normal operation.

3.68 Civil, Structural & Architectural Design & Drawings including Layout, P&ID etc. shall be submitted for

approval for all secondary LNG stations. However, Execution of Civil related works shall not be bidder scope.

3.69 Unloading of LNG from LNG Tanker mounted on vehicle to LNG storage tank (Secondary Station).

3.70 Supply of Stationary Cascade as per specification at every secondary LNG station.

3.71 Supply of 2 Nos. Dispenser as per specification at every secondary LNG Station.

3.72 Five Year Operation & Maintenance of all equipments shall be in the bidder scope.

3.73 Any other items not mentioned above (Except Exclusions as per Clause no. 4.0) shall be required for

development of Secondary LNG stations and transportation of LNG from Primary station to secondary station

in totality as per PESO or compliance of statuary requirements, that work shall also be in bidder scope.

4.0 EXCLUSIONS

The following work shall only be excluded from the bidders scope :

4.1 Execution of Civil related works shall be carried by owner based on the drawings issued by bidder.

4.2 Yard Lighting (including Light poles located just outside the SMPV area); its cabling and control panel at

every primary LNG Station.

4.3 Land for secondary LNG stations will be provided by IGL.

5.0 MAJOR EQUIPMENT

5.1.1 LNG Unloading Pump

Storage facility shall have tanker unloading skid which will unload LNG from road tanker to storage tank with

minimum flow as specified below and approx. 8 bar (g) differential pressure of LNG. The unloading skid shall

have centrifugal pump suitable for LNG service and shall have a return line for tanker. The Unloading Skid

shall have following minimum configuration at following locations i.e.

Part C (Secondary Station)

Sl. No. Location No of Pumps (Configuration) Capacity

1 Ajmer 2 No. ( 1 Working + 1 Standby) 350 -380 LPM

2 Pali 2 No. ( 1 Working + 1 Standby) 350 -380 LPM

3 Rajsamand 2 No. ( 1 Working + 1 Standby) 350 -380 LPM

The unloading skid shall have automatic PLC based control system. The LNG unloading skid shall be provided

with SS-braided LNG transfer hoses. The skid shall have required number of isolation valves, non-return

valve, relief valve designed as per applicable codes and standards as required for safe and reliable operation.

Instrumentation such as pressure & temperature gauges, transmitters etc. shall be provided as required.

5.1.2 LNG Storage Tank(S)

The LNG station shall have minimum gross capacity of vertical LNG storage tanks as per following

configuration i.e.

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Part C (Secondary Station)

Sl. No. Location Configuration of LNG storage tanks

1 Ajmer Note 1

2 Pali Note 1

3 Rajsamand Note 1

Note :-

1. In Part C (Secondary station), Vendor to decide the Total gross storage capacity of LNG for

catering the 4000 kg per day demand. Since, bidder will transport the LNG from Primary station

to secondary station within 50 kms, 60 Kms & 40 Kms from the Primary Stations Located in the

District of Ajmer, Pali and Rajsmand respectively. However, Minimum Storage capacity shall

be 10 KL.

The Minimum gross capacity of vertical storage tank is as per above table. The maximum allowable working

pressure of inner storage tank shall be approx. 12 Bar (g). The gross capacity of LNG storage tanks shall have

a negative tolerance of 5%. However, the contractor can supply LNG tank of any higher capacity. The LNG

storage tank shall be designed for a design temperature of -196°C to +65 °C.

LNG storage tank shall be designed and manufactured in accordance with latest version of ASME BPV Code

Sec VIII/ EN 13458-2. It shall be fit for LNG service and shall be designed to minimize LNG boil-off even

during low/ no consumption.

The LNG storage tank shall be double-walled and insulated with suitable insulation such as perlite insulation

under vacuum etc. The inner tank shall be made from X5CrNi1810/ SA 240 TYPE 304 or equivalent/ superior

material and shall be 100% radiographed. All internal piping/ fittings shall be seamless type and made from

ANSI 304L (or equivalent). The piping shall be 100% radiographed and pressure tested. The outer tank shall

be made from carbon steel or equivalent/ superior material. The outer surface of the tank shall be coated with

polyurethane based paint of minimum 240µm DFT to avoid rusting/ corrosion.

5.1.3

Schematic for Low Pressure Re-gasification system

The above figure shows schematic for low pressure re-gasification system wherein LNG from storage tank is

directly regasified using a low pressure ambient air vaporizer. The gas pressure is then regulated using pressure

regulating skid with dual stream. The PNG shall be odorized with an odorant consisting of 70-80% TBM + 20-

30% MES as per requirements of PNGRB codes.

L-PNG system shall be designed for 2000 SCMH at secondary stations (Ajmer, Pali & Rajsamad).

i. Low Pressure Vaporizer

Low Pressure ambient air Vaporizer shall be provided with a 100 % standby for continuous duty operations.

Each ambient air vaporizer shall be designed to work for 8 hours duty cycle and after that automatic change

over to idle vaporizer to run re‐gas plant on continuous duty operations. The change-over shall be automated

with the help of PLC based control system and shall require no human intervention.

Low Pressure Re‐Gasification System (L-PNG)

LNG Storage

Tank

Ambient Air

Vaporizer

PRESSURE

REGULATING SKID

Natural Gas at 4 Bar (g)

Odorization

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LNG

STORAGE

HIGH PRESSURE

PUMP

HIGH PRESSURE VAPORIZER

PANEL

CNG

DISPENSING

& CASCADE

FILLING

Each low pressure ambient air vaporizer shall have a following capacity at 10 bar (g) i.e.

Sl. No. Stations Capacity Total Station (Nos.)

1 Secondary LNG Station 2000 SCMH 20

The maximum allowable working pressure of vaporizer shall be approx. 24 Kg/cm2. The desired delivery

pressure shall be 4 bar (g) after pressure control regulator. The inlet design temp for the vaporizer shall be from

-196°C to +65 °C.

The low pressure atmospheric vaporizer shall be ambient air heated and shall be designed in accordance with

latest version of ASME SEC VIII, DIV I and shall be fit for LNG service. The low pressure atmospheric

vaporizer shall be made from Aluminium A 6061-T6/ A 6063-T5/T6 or equivalent/ superior material.

ii. Pressure Regulating Skid

Re‐gasified natural gas shall be passed through pressure regulator skid which is equipped with twin stream

pressure regulators to get natural gas at 4 Bar (g) pressure without any interruption.

5.1.4 High Pressure Re-Gasification System (L-CNG)

Odorization

Schematic for High pressure LCNG system

The above figure shows schematic for high pressure LCNG system wherein a LNG tank is connected with high

pressure reciprocating pump which can pump LNG liquid to high pressure ambient air vaporizer for high

pressure re‐gasification LCNG application. The system shall be designed for CNG cylinder cascade filling at

minimum 250 Bar (g). The CNG shall be odorized with an odorant consisting of 70-80% TBM + 20-30% MES

as per requirements of PNGRB codes.

i. High Pressure Reciprocating Pump

LNG tank is connected with high pressure reciprocating pump which can pump LNG liquid at min. 250 bar (g)

at following capacity i.e.



The pump shall have a normal suction pressure of 2 bar and a max of approx. 12 bar. The delivery pressure of

LCNG pump shall be minimum 250 bar (g)

ii. High Pressure Vaporizer

Pressurized LNG is converted to high pressure CNG after passing through high pressure ambient air vaporizer

and stored into the cylinder cascade of 3000/ 4500 WL after odorization process. CNG cascade is further

connected to 2 No of CNG dispenser & Stationary Cascades through priority panel which will decide sequence

of operation. The high pressure vaporizer shall max a maximum operating pressure of approx. 318-325

Kg/cm2 (g) and shall be suitable for CNG cylinder filling at 250 Bar. Each high pressure vaporizer shall have a

capacity i.e.

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The high pressure vaporizer shall be ambient air heated and shall be designed in accordance with latest version

of ASME SEC VIII, DIV I and shall be fit for service of LNG. The high pressure atmospheric vaporizer shall

be made from aluminum A 6061-T6/ A 6063-T5/T6 or equivalent/ superior material. Each ambient air

vaporizer shall be designed to work for 8 hours duty cycle and after that Instruments and isolation valves for

manual switchover after 8 hrs for continuous operation if required.

5.1.5 Centralized Control & Monitoring System

LNG storage and distribution plant operations should be controlled by centralized SCADA based PLC system

for better and safe operations with manual interventions where ever applicable. The offered control system

(PLC & SCADA) should have provision to accommodate data and control for 1 no. future LNG storage tank.

All solenoid valves should have provision for manual override. The control system should be user friendly and

menu driven.

SCADA system shall have open protocol to have compatibility with owner SCADA system.

PLC System shall be supplied with licensed software required for accommodation of signals from field

instruments / panels. PLC System shall comprise of fully wired free standing panels which include processors,

power supply units, I/O cards, relay modules, communication modules, interfacing modules, I/O racks,

Ethernet switches (manageable & stackable), serial modules, any kind of signal converters , Terminal Server /

Data Concentrator, media converters, MCBs, TBs, fuses, surge protection devices, signal distribution cards,

annunciators, lamps, hooter cum strobe, etc. ; HMIs (Engineering Workstation/ Operator Workstation) and

licensed software for developing / modification of logics ; consoles for HMI installation ; A3 color laser printer

; necessary LAN network & accessories ; chairs, etc.

In hazardous area applications, electronic/electrical instrumentation equipment shall be suitable for hazardous

area classification as per IEC. These equipment shall be intrinsically safe conforming to CENELEC standard

and certified by appropriate statutory bodies (ATEX,FM, BASEFA or equivalent). Intrinsically safe systems

shall be designed using zener/ IS barriers. Where intrinsically safe design is not feasible, ex-proof

equipment/enclosure, certified by statutory bodies like CMRI Dhanbad/ CCOE Nagpur shall be supplied. Other

acceptable safety procedures (e.g. increased safety procedure, pressurization etc.) shall be used, wherever

applicable.

5.1.6 Safety Systems

LNG satellite station shall be equipped with state of the art safety systems and interlocks for safe and reliable

operations. LNG satellite station shall be equipped with gas detection and fire/temperature detection sensors

with emergency shutdown buttons at strategic locations as a proactive safety measures which is continuously

monitored by centralized control system. Interlocks shall be designed for operation of the plant in most safe

and reliable manner with minimal human intervention.

The LEL gas detectors shall be provided as required for detection of gas leakages if any. Further the station

shall be provided with fire water network, sufficient number of fire extinguishers and sand buckets.

LNG storage and distribution plant operations should be controlled by centralized SCADA based PLC system

for better and safe operations with manual interventions where ever applicable.

5.1.7 Fire Protection Facilities:

• Each LNG storage facility shall be provided with continuously monitored low - temperature sensors or

flammable gas detectors, which shall activate visual and audible alarms at the plant site.

• Flammable gas detection system shall activate an audible and a visual alarm at level not higher than 20% of

the LEL of the gas being monitored.

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• Fire detectors shall activate an alarm at the plant site and at a constantly attended location if the plant site is

not attended continuously. If determined by an evaluation that it is necessary, then fire detectors shall be

permitted to activate the ESD system

5.1.8 Fire Hydrant System: A fire water supply and delivery system shall be provided based on the risk analysis. However, as a

minimum a fire water storage tank of 10 % of LNG storage tank capacity or 5000 liter whichever is higher

with pumping facilities and hose reel system away from the LNG storage facility shall be provided for

dispersion of LNG vapor cloud in case of leakage or spillage

5.1.9 Interconnecting Piping, Fittings, Valves The interconnecting pipes shall be double-walled vacuum jacketed. Piping, fittings, valves used shall be fit for

LNG service.

5.1.10 LNG Transportation

Transportation of LNG from Primary Station to Secondary Stations within 50 kms, 60 Kms & 40 Kms from the

Primary Stations Located in the District of Ajmer, Pali and Rajsmand respectively.

Schematic for LNG Transportation

i. LNG Tanker

There are the following minimum specification for the LNG Tanker mounted on vehicles:-

• Global Positioning System (GPS) enabled to track the position of the LNG tanker while transporting

LNG by road.

• GPS nodal connectivity shall be enabled at LNG Station and at such other locations as may be advised by

Owner.

• LNG tankers shall only follow predefined and Owner’s approved route.

• Required Gross Cumulative Weight (GCW) & Horse Power (HP).

• Power steering.

• Anti-lock braking system (ABS).

• BS-IV compliant or above.

• Suitable type and brand/make axle of reputed and experienced manufacturer.

• 2016 or “later make”.

• PBU (Pressure build-up coil) of suitable make and capacity with sufficient protection.

• Vehicle shall be fitted with rear view mirrors (one on each side) /wipers / Signal/ Lights / Breaks / Hand

breaks.

• LNG Tanker must have requisite end connections.

• Reputed branded tyres. For safe operations all tyres shall be replaced with new tyres as per requirement

or maximum after every 50000 kms. Re-treaded tyres shall not be used.

Primary Station at Ajmer- Pali - Rajsamand GA

Secondary Station at Ajmer - Pali - Rajsamand GA

LNG Transportation

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• Emergency information panel / Hazchem panel of LNG and all required signs displayed on sides of

the tanker in visible manner as per requirement of latest SMPV rules /central motor vehicle rules.

• All other transportation requirements as per latest SMPV rules, latest Central motor Vehicle Rules and

carriage by latest road act shall be followed and complied.

• Equipped with requisite minimum Personnel Protection Equipments, First aid medical boxes, special

non- sparking tools, fire extinguishers, etc.

• The mobilized fleet shall be painted as per colour code and description provided by Owner in addition to

the statutory display requirements (such as NFPA ratings, MSDS no., emergency contact numbers etc.)

carry LNG. Further owner’s Logo and any promotional branding material as desired by owner shall be

painted on the LNG tanker. Painting of the colour codes and all other statutory displays has to be done by

CONTRACTOR at his own cost before deploying the vehicles for carrying LNG. Also, necessary logo,

marking, painting, coding for transportation of flammable substance to be marked as per the norms. Each

vehicle to be painted on rear and side panels for display of company name and logo in combination to

fulfill the requirements of display under the provisions of the latest motor vehicle Act and Rule 129 to

137 (both inclusive) of latest central motor vehicle rules.

The LNG tanker shall be repainted at least annually or as required whichever is earlier.

• Periodic Maintenance is based on the manufacturer’s recommendations and has to be carried out by the

authorized service representative of the vehicle manufacturer. The vehicles need to be tracked for the no.

of kms that they have plied and the service planned well in advance.

• Age of Prime-Mover should not exceed 8 years during the continuation of contract.

ii. Requirements of Trained/Skilled manpower

• Manpower shall be trained/skilled for necessary safety checks, ”heel check”, pressure check, log entries,

connecting loading arms to the road tanker; following unloading procedures, starting of pump (if

required),filling/unloading process, disconnecting the filling/unloading system ,etc.

• Sufficient Trained drivers are to be provided when the tankers are in operation and such trained drivers

should not be withdrawn without consent of Owner.

• For this purpose, drivers and other employees shall be extensively trained in all aspects including safety.

• The Contractor shall maintain adequate and requisite skilled manpower for transport and handling of

hazardous goods as per requirements of latest Central Motor Vehicles Rules.

• Minimum educational qualification shall be 8th class pass for driver and helper of LNG tanker. Driver

and helper of LNG tanker shall be trained by Contractor as per requirement of Rule 9 of Central motor

vehicle rules 1989.

• Endorsement on driving license shall be required from licensing authority that the driver is authorized to

drive a goods carriage carrying goods of dangerous or hazardous nature.

• The Drivers must be medically fit and shall have a certificate issued form registered doctor. The

certificate shall be revalidated at least on annual basis or as per doctor’s advice.

• The Drivers / attendants shall wear cotton uniform, safety shoes, badges, identity card at the time of duty.

Drivers have to maintain the discipline & decorum in the LNG stations. Drivers without proper uniform

& shoes will not be allowed to carry on duties.

• Bidder shall provide communication handsets to the supervisors & drivers for communicating &

movement control. The safety and security of the handsets will be the responsibility of the bidder. In case

of loss and damage, the bidder shall be liable for replacing the sets immediately at his own cost.

• The CONTRACTOR shall conduct periodic training programme to get the drivers fully acquainted with

LNG Safety requirements. New drivers prior to commencing their duties shall undergo an induction

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program carried out by contractor. In case of complaint against driver for rash driving / drunken driving,

the driver should be replaced.

iii. Driver’s discipline

o Follow the posted speed limits not cross 50 KM/ Hr.

o Don’t operate / attend mobile phone call while driving.

o Don’t drive if feels unwell or tired due to fatigued condition.

o Don’t drive under medication (consult doctor if so)

o Don’t drive under intoxicated state (alcohol/ drug consumption)

o While re‐fuelling, switch off engine, cell phone and do not smoke.

o Don’t drive in abnormal weather condition.

o Get full knowledgeable of roads & areas of travelling route.

o Follow only the approved route.

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ANNEXURE # 1

DATA SHEETS

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DATA SHEET FOR CRYOGENIC LIQUID STORAGE TANK

Equipment Manufacturer

Equipment Inner Vessel Outer Vessel

Storage Fluid LNG Vacuum

Installation Vertical

Approx. Capacity (Gross) **

Approx. Capacity (Net) **

Empty Weight *

Diameter * *

Total Height * *

Material of Construction AISI 304 SA 516 Gr. 70

Piping Material SA 312 TP 304

Valve Material AISI 304 body and trim

Design temp in deg C (-) 196 to 37 deg C (-) 20 deg C to 65 deg C

Design, Fabrication, Inspection and

Testing EN13458-2 (+) ANNEX-C EN13458-2

MAWP 12 bar Approx Vacuum

Insulation (Interspaced) Perlite under Vacuum

Surface Treatment

• Shot Blast – SA 21/2

• Precoat – Inorganic Zinc Silicate – DFT 70-90 µm

• Intermediate Cost – Epoxy – DFT 70-90 µm

• Finish Coat – Polyurethane – DFT 50-60 µm

• Total Thickness of Paint – 240 µm

* Vendor to indicate

** In Part C (Secondary station), Vendor to decide the Net & Gross storage capacity of LNG for catering the 4000 kg

per day demand. Since, bidder will transport the LNG from Primary station to secondary station in the state of

Rajasthan. However, Minimum Storage capacity shall be 10 KL.

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DATA SHEET FOR HIGH PRESSURE ATMOSPHERIC VAPORIZER FOR LNG

1) GENERAL:

Manufacturer Name

Type Ambient Air Heated

Configuration Service Vertical

Product Vaporizer

Fluid LNG

Design Temperature (-) 196 C to 65 C

Outlet Temperature

2) DATA:

Capacity of each vaporizer 650 SCMH

Qty per Station 2 No

Manufacturing Code ASME Sec VIII Div I

Duty Cycle 16 Hours (Continuous)

Maximum Operating Pressure *

Design Pressure *

Hydraulic Test Pressure *

Inlet 0.5" SS NPT Female Socket

Outlet 0.5" SS NPT Female Socket

3) DESIGN:

Fin Cross Section *

Area Required (Calculation to be provided) *

Area Provided *

4) MATERIAL OF CONSTRUCTION:

Fins Aluminium A 6063 T5

Pipe, Bends and Headers ASTM A 312 TP 304 Expanded Type

Flangers Aluminium A 6063 T6

Structural and Frame SS 304

Bolts/Natural SS 304

Nuts SS 304 Nyloc Anti Vibration Nuts


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DATA SHEET FOR LOW PRESSURE ATMOSPHERIC VAPORIZER FOR LNG

1) GENERAL:

Manufacturer Name

Type Ambient Air Heated

Configuration Vertical

Service Product Vaporizer

Fluid LNG

Design Temperature (-) 196 C to 65 C

Outlet Temperature *

2) DATA:

Capacity of each vaporizer 2000 SCMH

Qty per station 2 No

Manufacturing Code ASME Sec VIII Div I

Duty Cycle Continuous

Maximum Operating Pressure 24 kg/cm2

Design Pressure 40 kg/cm2

Hydraulic Test Pressure 40 kg/cm2

Inlet ½” SS NPT Female Socket

Outlet ½” SS NPT Female Socket

3) DESIGN:

Fin Cross Section *

Area Required (Calculation to be provided) *

Area Provided *

4) MATERIAL OF CONSTRUCTION:

Fins Aluminium A 6063 T5

Pipe, Bends and Headers ASTM A 312 TP 304 Expanded Type

Flangers Aluminium A 6063 T6

Structural and Frame SS 304

Bolts/Natural SS 304

Nuts SS 304 Nyloc Anti Vibration Nuts


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DATA SHEET FOR LNG HIGH PRESSURE PUMP

Manufacturer Name

Medium LNG

Installation The pump must be suitable for installation on a

Thermosiphon Tank

Capacity of each pump 650 SCMH

Suction pressure ( Normal/Max) 2/12 Bar

Delivery Pressure 250 Bar Minimum

Suction Nozzle Size *

Discharge Nozzle Size *

Design Temperature *

Pump Material of Construction AISI 304/ Equivalent Casting Grade

Pump Type Positive Displacement

Design Code API 674

Motor RPM 1500

Voltage 415V 50Hz 3 Phase

Scope of supply

The pump shall be supplied complete with skid,

motor slide rails, control panel, Pulley for Pump and

motor, Vee belts with guard, interlocks for

precooling and dry run, safety /vent valves , strainer ,

HP gauge etc


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DATA SHEET FOR LNG UNLOADING PUMP

Manufacturer Name

Medium LNG

Installation Submerged in a vacuum insulated sump

Capacity of each pump 350 - 380 LPM

Suction pressure ( Normal/Max) Static head of LNG tanker

Delivery Pressure 8 bar (g)

Suction Nozzle Size *

Discharge Nozzle Size *

Design Temperature *

Pump Material of Construction AISI 304/ Equivalent Casting Grade

Pump Type Vertical submersible

Design Code API 610

Motor RPM *

Voltage 415V 50Hz 3 Phase

Scope of supply

The pump shall be supplied complete with skid,

interlocks for precooling and dry run, safety /vent

valves , strainer , Pressure gauge, VFD etc

CONTROL PANEL

1. All safeties, trips , overloads and control

required for safe operation

2. NEMA 4 enclosure

3. Stop and start buttons

4. Protection against single phase

5. Gauges/Instruments for Volt Meter with

Selector Switch, Amp. Meter with Selector Switch,

Hr. run meter


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ANNEXURE # 2

LIST OF SUPPLIERS OF MAJOR BOUGHT-OUT ITEMS

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Annexure # 2 - LIST OF SUPPLIERS OF MAJOR BOUGHT-OUT ITEMS

ITEM DESCRIPTION MAKE

STORAGE TANK INOX / VRV / CHART / CRYOGAS / Taylor

Wharton

VAPORIZER INOX / CRYOQUIP / THERMAX / CRYOGAS

MANUAL CRYOGENICC

GLOBE /CHECK VALVE

BESTOBELL/HEROSE

EP OPERATED CRYOGENIC VALVES HEROSE / HABONIM/ BESTOBELL

ESD VALVES BESTOBELL/HEROSE

3-WAY MANIFOLD VALVE BALDOTA

PRESSURE SAFETY VALVE BESTOBELL/HEROSE

LEVEL GAUGE, PR. GAUGE WIKA

BALL VALVES AUDCO/MICROFINISH/ROTEX

CRYO REGULATOR &

PRESSURE REGULATOR

SAMSON/ CASH

PRESSURE CONTROL

REGULATOR

NIRMAL INDIA/ CHEMTROL/ PIETRO

FIORENTINI

SAFETY VALVE HEROSE /LESSER/ ROCKWOOD

THERMAL RELIEF VALVE HEROSE/ REGO

PRESSURE GAUGE WIKA

TEMPERATURE ELEMENTT GENERAL INSTRUMENT

PRESSURE/TEMPERATURE

TRANSMITTER

EMERSON/ SIEMENS

JUNCTION BOX BALIGA OR EQUIVALENT PESO

APPROVED

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PLC SYSTEM HARDWARE

WITH COMPLETE CONTROL

PANEL

ALLEN BRADLEY / SIEMENS

LEL NG GAS DETECTOR PENTEX / HNL

EMERGENCY STOP PUSH

BUTTON STATION NEAR

TANK

BALIGA

ELECTRICAL CABLES RR CABLES/THERMO CABLES LTD.

CRYOGENIC PUMP

CENTRIFUGAL / SUBMERGED

CRYOSTAR / ACD /VANZETTI /CRYOMECH

CRYOGENIC PUMP

HP PISTON PUMP

CRYOSTAR / ACD /VANZETTI /INDIAN

COMPRESSORS

HIGH PRESSURE VALVES MASCOT/TUBEFIT

CNG HIGH PR HOSE AND

FITTINGS PARKER /SWAGELOK

ODORIZER VARICON/ CPL/ INIMO

PRIORITY PANEL PARKER /TULSA

NEEDLE VALVES BALDOTA

STATIONARY CASCADE RAMA CYLINDERS / EKC (EVEREST KANTO

CYLINDERS) / JIOLAT

DISPENSER COMPAC / PARKER / TULSA / SHUBH EXIM

Note :

1. Any other vendor(s) apart from as mentioned above may be accepted subject to approval by Owner/Owners

representative based on past track record.

2. For the vendors of items not covered in above vendor list, but required for completion of project

successfully, supplier shall take approval form Owner/Owners representative for the same during project

execution. Bidder shall submit the required certifications, documents, PTR and Performance letters from

clients for the same.

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ANNEXURE # 3

LIGHTING

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Annexure # 3 (Lighting)

Sl.

No. Item Description

1

Luminaire Details & Lux Level :

• For Street lighting - integral flame proof well glass fixture (CMIFR approved for Zone-1/2 gas

group IIA & IIB) with 72 W LED luminaire with flame proof control gear.

• For area lighting - Integral flame proof Flood Light fixture (CMIFR approved for Zone-1/2 gas

group IIA & IIB) with 160 W LED luminaire.

• Street lighting pole 6mtr high GI octagonal pole (Type BOP-6030 of Bajaj make or equivalent)

complete with bracket, GI clamps for fixing flame proof control gear box.

• For indoor lighting - Surface/ recess mounted LED light fixture with LED lamp (type LCTL-18 -

CDL of CG make or equivalent). Industrial Flame proof fluorescent lamp fitting with lamp (type

EXTL 240 of CG make or equivalent).

• Lux level-

a. Control Room - 300 lux

b. Office Room - 300 lux

c. Electrical Room - 150 lux

d. DG Room - 150 lux

e. Process Area - 50 lux

f. Road Area - 20 lux

g. Open Area - 10 lux

2

Hazardous Area Lighting :

• The construction of lighting fixtures shall be such that replacement of lamp or any normal

Maintenance of fixture shall not affect their suitability for use in classified area.

• Glass used for lighting fixture shall be clear suitable for use under conditions involving

Exceptional risk of mechanical damage.

• Well glass lighting fixture for Zone 2 classified area shall meet requirement IS 6381.

• Mechanical strength of well glass shall satisfy requirement of IS 2206 (for type A glass) for

Flameproof lighting fixtures and IS 6381 for Div. 2 lighting fixtures. All well glass fixtures shall

be provided with a galvanized steel wire protective cage having mesh dimensions not exceeding 50

mm.

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INDRAPRASTHA GAS LTD.SUPPLY, INSTALLATION, COMMISSIONING &

COMPREHENSIVE MAINTENANCE OF CNGDISPENSERS

PTS - CNG CAR DISPENSERS

A 29.01.2020 Issued for Approval GG SHD BK

Rev. Date Description Prepared By Checked By Approved By

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SECTION – A GENERAL SPECIFICATION ......................................................................................... 1

SECTION – B INSTRUMENTATION & CONTROL SPECIFICATION .................................................. 14

SECTION – C ELECTRICAL SPECIFICATION .................................................................................. 23

SECTION - D MECHANICAL SPECIFICATION ................................................................................. 26

DATA SHEET - CNG DISPENSER FOR CAR ..................................................................................... 30

DATA SHEET - MASS FLOW METERS (CORIOLIS TYPE) FOR CAR DISPENSER ............................. 31

DATA SHEET - CONTROL VALVES .................................................................................................. 32

DATA SHEET - SOLENOID VALVES ................................................................................................ 33

DATA SHEET - SELF ACTUATED PRESSURE CONTROL VALVES ..................................................... 34

DATA SHEET - PRESSURE RELIEF VALVES .................................................................................... 35

DATA SHEET - PRESSURE INSTRUMENTS..................................................................................... 36

DATA SHEET - PRESSURE GAUGES ............................................................................................... 37

ANNEXURE-1: RECOMMENDED VENDOR LIST…….……….….……………………..………………………41

ANNEXURE-2: VENDOR DATA REQUIREMENT ............................................................................... 42

ANNEXURE-3: DEVIATION SCHEDULE FOR CNG DISPENSER ....................................................... 46

ANNEXURE- 4: M.R. COMPLIANCE SCHEDULE............................................................................... 47

ANNEXURE-5: VENDOR DATA REQUIREMENT (INSTRUMENTATION) .......................................... 50

ANNEXURE -6: QUALITY ASSURANCE PLAN .................................................................................. 52

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TABLE OF CONTENTS

SECTION - A

1.0 SCOPE ................................................................................................................................... 2

2.0 INSTRUCTIONS TO VENDOR ................................................................................................ 2

3.0 SCOPE OF SUPPLY & SERVICES FOR 105 NUMBERS CAR DISPENSERS ............................. 3

4.0 DESIGN & ENGINEERING. .................................................................................................... 5

5.0 EXCLUSION .......................................................................................................................... 5

6.0 EXPERIENCE RECORD SCHEDULE FOR DISPENSERS........................................................... 6

7.0 DESIGN BASIS ...................................................................................................................... 6

8.0 TECHNICAL SPECIFICATIONS FOR CAR DISPENSER ........................................................... 8

9.0 DATA SHEETS ..................................................................................................................... 10

10.0 CLIMATIC CONDITIONS ..................................................................................................... 10

11.0 UTILITY SPECIFICATION ................................................................................................... 10

12.0 INSPECTION AND TESTING ............................................................................................... 10

13.0 VENDOR DATA REQUIREMENT ........................................................................................... 11

14.0 DEVIATION SCHEDULE....................................................................................................... 11

15.0 MATERIAL REQUISITION COMPLIANCE SCHEDULE .......................................................... 12

16.0 PACKAGING ........................................................................................................................ 12

17.0 ON SITE TRAINING ............................................................................................................ 12

18.0 TRAINING TO IGL PERSONNEL AT VENDOR'S SHOP ......................................................... 12

19.0 COMMISSIONING OF DISPENSERS ................................................................................... 12

20.0 COMPREHENSIVE MAINTENANCE ...................................................................................... 12

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SECTION: A

GENERAL SPECIFICATION

1.0 SCOPE

1.1. The intent of this technical specification is to outline the Purchaser's requirement under which the vendorshall Design, Engineer, Manufacture, Inspection & Testing at Works, Painting, Packaging & forwarding,Supply to Sites/Stores, Installation & Commission and Performance Testing at Vendor’s works and Sites ofCNG Car Dispensers complete with all auxiliaries & Compatibility/capable for communicating with any thirdparty devices, required for efficient & safe operation, in accordance with this specification, data sheets &other enclosures of this Material Requisition.

1.2. The Car Dispensers shall be complete including any/ all required auxiliary equipment/ systems for efficient& safe operation as a whole. Vendor shall be responsible for furnishing all electrical/ electronics,instrumentation, inter connecting piping & safety Items as required to make the Dispensers complete.

1.3. It is not the intent of Purchaser to specify every piece of equipment/item but nevertheless any item notspecifically mentioned but required as per Good Engineering Practice and for the safe & trouble free operationof the dispensers deemed to have been specified & shall be in the scope of Vendor without any implicationin the price or schedule.

2.0 INSTRUCTIONS TO VENDOR

2.1. M/s IGL is expanding its CNG refilling outlets in the National Capital Region (NCR) and National Capitalof Territory (NCT) of Delhi (India). The dispensers shall be installed at various refuelling outlets throughoutNCT as well as in the NCR for dispensing CNG to all types of smaller Natural Gas Vehicles.

2.2. The dispensing stations shall be spread throughout NCT of Delhi & NCR.

2.3. The specification states the scope of supply and services as completely and clearly as possible. Any additionalwork/equipment or technical requirement not mentioned in the specification but required to make the offeredsystem complete in accordance with the specification or required for safe operation shall be deemed to beincluded in the scope of vendor.

2.4. Vendor may contact and obtain from IGL clarifications, if required, at any stage, before submission of offer.

2.5. The offered dispenser units' model shall have certification for specified flow and accuracy from the Weights& Measurement Department of the country of origin. In case it is not available for dispenser unit then offeredmass flow meter model shall have certification for specified flow and accuracy from the Weights &Measurement Department of the country of origin. The certificate(s) shall be in English language or in thelanguage of originating country along with English translation. Bids received without copy of suchcertificate(s) shall be liable to be rejected. Vendor to arrange for Weights and Measures approval from IndianAuthorities. The dispenser model has to be type approved by the Indian Weights & Measurement Department.Further manufacturing license, dealer of weights & measures, importer (where ever applicable) and licenseto repair by the bidder is mandatory at the time of bid due date.

2.6. The offered dispensers for dispensing CNG shall be type approved by the Petroleum & Explosive safetyorganisation, Govt. of India as per latest Gas Cylinder Rules. If the vendor is yet to get the dispenser modeltype approved, the vendor shall have to give the model type approved as on bid due date.

2.7. The Vendor shall carry out modification required by the statutory bodies either during the approval or duringinspection of the installation. All expenses shall be done and borne by the vendor. Unless the above formalitiesare cleared, supply part would be deemed incomplete.

2.8. The Vendor shall provide civil foundation/ dispenser frame drawings within two weeks of placement of order.

2.9. Any work, which is considered to be unsatisfactory and of poor workmanship shall be rectified by the vendorwithout any extra cost and time implications.

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2.10. The approval from concerned Govt. Bodies in respect of complete installation of a CNG Dispensing Stationshall be obtained by the IGL. Necessary Information/Data as may be required by Govt. Bodies shall befurnished by vendor to facilitate IGL in obtaining approval.

3.0 SCOPE OF SUPPLY & SERVICES FOR CAR DISPENSER

3.1. Supply of double arm type having flow capacity of ≥ 15 kg/min for a single arm under discharge toatmospheric condition. Each Car Dispenser shall have following as a minimum:-

3.1.1. Two CNG flexible electrically conductive twin (fill & vent) hose, with both hoses fitted with NGV-I forfilling of vehicles. However, both the hoses shall be suitable to be attached with NZS-5425 nozzles. Vendorshall include the supply of 3-way valve with each hose for filling & venting of gas. Vendor shall also includesupply of Breakaway Coupling, suitable for NGV Industry, in the hose. Hose shall be 3/8” ID 5000 psig, atleast 3m long. Vendor shall demonstrate the function of breakaway coupling during performance test. Thedispensers shall be designed in such a way that free movement of hoses is possible, by spring loaded highmast. Supply of NZS 5425 nozzles is excluded from bidders’ scope.

3.1.2. Two numbers of Coriolis true mass flow metering system.

3.1.3. Three rows of liquid crystal backlit display for night viewing showing total sale in Rupees (00000.00),quantity of gas sold in kg (00000.00), unit price of CNG in Rs./kg (000.00) for each hose on either side of thedispenser (total two sets of three rows for each Dispenser, one display for each side). The whole dispenserelectronic unit shall have IP - 65 protection and display cabinet shall have IP 54 protection.

3.1.4. Non-resettable and non-volatile totalizer up to 999999.99 for total CNG sold in Kg with an independentbattery backup. For further details refer Section B: Instrumentation & Control specification.

3.1.5. One number of three banks electronic software and controller including hardware.

3.1.6. Two numbers of holster/ cradle for fill nozzles along with weather caps for the protection of nozzles. Holster/cradle shall be suitable for both NZS and NGV nozzles. Holster/cradle shall be provided for NGV nozzle andshall be compatible to be attached with NZS-5425 nozzles. Supply of NZS 5425 is excluded from bidder’sscope.

3.1.7. Two number of Hi-mast with flexible hose arrangement so that the hose doesn’t touch the ground

3.1.8. Emergency stop switch is required on both side of the dispenser. However, the filling on both sides shouldstop in emergency condition, when any one of the emergency switch is pressed. During activation ofemergency switch, the power supply to the dispenser should be available.

3.1.9. Two nos. of liquid filled 4” dia. (0-400 Kg/cm2g) pressure gauges showing the vehicle filling pressure foreach filling arm.

3.1.10. Two Nos. bubble tight manual shut-off valve for fill hose.

3.1.11. One Stainless Steel body of cabinet thickness 1.6 mm with door/panel, along with powder coating as per IGLcolour scheme.

3.1.12. Vendor has to supply the dispensers with solenoid operated valve made of ANSI 316 SS, for ON-OFF controlof flow, on the gas inlet with 1/2” tube OD end connection. Valves shall be provided for each bank per hoseseparately. Vendor to ensure the system design in such a way that any gas if passes, should be recorded bydispenser and there should not be any possibility of unmetered gas supply through dispenser in case ofmalfunctioning of solenoid valves. Air actuated valves are not acceptable.

3.1.13. The gas tubing inside the dispensers shall be seamless SS 316 fully annealed (Bright Annealed) conformingto ASTM A 269 with maximum hardness of RB 80 or less and suitable for bending and flaring. The tubesshall be fully annealed (bright annealed), 1/2” OD with a 1/2” SS 2-way Ball valve at inlet and 1/2” OD endconnection suitable for connecting with 1/2” OD SS Tube. Any open ends on fittings and vents shall beprovided with caps/ dust plugs.

3.1.14. Coalescent and particulate filter of Grade 6 or better to be provided at inlet of each bank supply line withmanual drain valve to ensure that the oil carryover in the CNG being filled to vehicle is < 1 ppm and particulatesize is < 0.5 Micron. Filter housing for said filter must be capable for collection of oil for a drain interval of24 hrs. with oil carryover < 1 ppm. Filter elements made of paper shall not be accepted. Vendor to provide

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appropriately plugged drain valve outside the dispenser housing with suitable arrangement to collect thedrained oil. Filter size shall be in accordance with max flow through the dispenser. Filtration efficiency shallnot be less than 95%.

The CNG specification should meet the ISO 15403:2000 (E) or IS: 15958 natural gas quality designation foruse as a compressed fuel for vehicles.

3.1.15. Vendor shall ensure that the system design in such a way that any gas if passes, should be recorded by massflow meter and there should not be any possibility of unmetered gas supply through dispenser in case ofmalfunctioning of solenoid valves. Any unmetered gas passing shall be recorded in the dispenser isretrievable as and when required. Vendor shall also provide surge protection device of approved make at 230V AC power inlet to protect the dispenser from any electrical surge/spike.

3.1.16. Any other item required for safe and accurate operation of Dispenser.

3.1.17. Any spare(s) required during commissioning shall be in the scope of vendor.

3.1.18. Supply of complete O&M manual (along with instruments datasheet & schedule, bill of materials, instrumenthook-up diagram, electrical wiring diagram, control logic algorithm & flowchart and certificates & user guideof bought out items) for each dispenser for easy operation & trouble shooting.

3.1.19. Supply of manual for list of error codes with description for programming the dispenser parameter.

3.1.20. If dedicated programming unit is required for programming/ parameter change. The same shall be submittedin “CD” along with supply of dispenser also hard copy of the same also be submitted.

3.1.21. Supply of GA drawings & documents along with bid.

3.1.22. Instrumentation & Electrical items specified in section B & C of the Job Specification. All electricalequipment shall be supplied with approved cable glands tested & certified to be used in hazardous areaclassified as Zone-I.

3.1.23. On-Site Training to IGL personnel (Three days each for three separate groups).

3.1.24. Training to IGL personnel at vendor's shop (10 personnel for three working days). The travelling, boarding& lodging of IGL’s Engineers shall be borne by IGL. The training module shall cover the equipmentconstruction features, operational & maintenance procedures, practical hands on experience on assembling,dismantling etc.

3.1.25. Vendor shall make a provision to change the price of CNG through the keypad inside the dispenser unit thatshall be covered with security lock. It shall also be possible to change the price from remote station (fromSCADA/ from any part of the city). RS 485 port shall also be provided for price change. In case standardRS485 port is not available in the dispenser, then RS232C to RS485 convertor with all relevant hardware andsoftware to be provided by vendor.

3.1.26. RS 485 serial port shall be provided for down loading the CNG sale data with the help of Purchaser's PersonalComputer for each shift (8 hours interval). In case standard RS485 port is not available in the dispenser, thenRS232C to RS485 converter with all relevant hardware and software to be provided by vendor. Suitablesoftware shall be provided to obtain the same for each shift (8 hours interval).

3.1.27. Vendor shall provide a common processor and open communication protocol/ RS 485 port for RTU to transferall the dispenser data to central SCADA system. In case standard RS485 port is not available in the dispenser,then RS232C to RS485 converter with all relevant hardware and software to be provided by vendor.

3.1.28. Vendor must note that non-standard/ propriety type communication protocol in dispenser for communicationwith RTU is not acceptable. Protocol must be standard as specified above or any standard protocol withcompatible convertor shall be made available and must be compatible to any make of RTU. RTU will haveSerial communication port RS 485 protocol to interface with dispenser. Vendor is responsible to provide thecommunication port compatibility with RTU. Vendor is required to carry the communication port functionaltest and display all the values in Lap top or in applicable device during dispenser inspection (FAT) at vendorpremises. Also functional test shall be carried out by vendor after installation and looping is junction box atsite. Vendor shall also share the dispenser protocol/RS485 details with IGL during FAT at vendors works andsubmit relevant documents in desired format (both hardware/ software)

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3.1.29. Contractor must furnish/ share the details of implemented MODBUS/RS485 protocol like function codes forread and write, slave ID, list of signals to be transferred, CRC implementation, register addressing methods /mapping etc. with M/s IGL and provide their assistance during interfacing with RTU to automation vendor.Vendor must provide looping details and number of dispensers connected in one loop.

3.1.30. Dispenser vendor shall loop (multidrop) all the dispensers in common junction box per station in the safearea. Supply of Communication Cables, cable glands, termination of cable and cable laying from dispenserto junction box is in dispenser Vendor’s scope. Supply of standard make, WP IP 42 junction boxes, terminalblocks and installation of junction box shall be is in dispenser Vendor’s scope. Junction box shall have 8inputs cables entry points (side) and two outgoing entry points including spare (bottom), cable entry from topis not accepted, size of junction box to be decided by vendor. All the spare entry shall be plugged properly.Vendor shall be responsible to provide all the signals at the junction box which will be connected to RTU.During installation & commissioning of dispenser same will be checked by IGL’s Engineer.

3.1.31. Communication cable is single pair (1Px 1.5mm2), multi strand, armoured cable with HR PVC insulation andPVC st2 inner and outer sheath. Tentative cable length form each dispenser to junction box is approx. 50meters, however vendor shall provide cable length as per requirement.

3.1.32. Vendor must share junction box termination details with IGL. Vendor shall Loop all the dispensers in junctionbox and looping shall be ring type or re-loop so that is case of communication break or physical loop breakthen only faulty dispenser should isolate, all others dispensers remain connected and continue to report.

3.2. Vendor must submit the following documents within 2 weeks of placement of LOI/ PO for review andapproval of IGL:a) Detailed project schedule giving all activities such as Design and review, Major bought out items (such

as Mass flow meter, electronics, Valves, Hoses etc.), Sub-assemblies, Stage inspection, Final Assembly,Final factory testing of dispensers, Final inspection, dispatch etc.

b) Process and instruments diagram (P&ID) of gas flow giving Bill of Material. The Bill of Material shallclearly indicate all items, quantity of all items installed per dispenser, make and part number etc.

c) Certification from Weights and Measures department, PESO Department or other statutory authorities ofthe country of origin for offered model dispenser for specified flow and accuracy.

4.0 DESIGN & ENGINEERING FOR DISPENSER

4.1. Design & engineering4.2. Manufacturing & Assembling4.3. Procurement from Sub-vendors.4.4. Inspection & Testing at Works.4.5. Documentation and obtaining statutory approvals from the country of origin.4.6. Packing, Forwarding and Transportation up to Job Sites/IGL's stores.4.7. Testing and commissioning, after site installation, of each Dispenser, individually.4.8. Submit/ apply for obtaining type approval for the offered dispensers from Petroleum & Explosive Safety

Organisation, Govt. of India as per the provisions of Gas Cylinder Rules, 2016.

5.0 EXCLUSION

5.1. Civil Foundation/ Mounting Frame

5.2. Trenches for pipes

5.3. Erection of Dispensers

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6.0 EXPERIENCE RECORD SCHEDULE FOR DISPENSERS

Sr. No. Parameter Information onoffered Model

Information on existing dispenser

1 2 3 4 5 6 7 8 9 10

1. Number of Units

2. Fluid handled CNG

3. Gas molecular weight range

4. Site min/max temp.

5. Dispenser rated flow

6. Dispenser overall Cv

7. Dispenser batch accuracy %

8. Dispenser with temperatureCompensation Yes

9. Number of Hoses Twin

10. Mass flow meter make/model.

11.Where dispenser is located:Address and fax/telephonenumber of contact person.

12. Any other information onInstallation

13. Date of commissioning ofDispenser

14. Number of hours completed as onbid due date.

15. Major problems encountered, ifany

7.0 DESIGN BASIS FOR DISPENSER

7.1 Area Classification

For details refer Electrical Specification at section-C attached with this Specification.

7.2 Codes and Standards

Following Codes and Standards are referenced to and made part of this Material Requisition.

NFPA52 Standards for CNG Vehicular Fuel Systems

NGV 4.1/AG.A 2-92 Requirements for CNG Dispensing Equipment for Vehicles

NGV 4.2/AG.A 1-93 Requirements for Hoses for NGVs and Fuel Dispensers.

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ANSI/NGV1 Compressed Natural Gas Fueling Connection Devices Standard for fuelingnozzles and receptacles.

NGV 4/AG.A Requirements for Breakaway Devices for CNG Vehicle Fuel Dispensers andFueling Hoses

AG.A 2-90 Compressed Natural Gas Fueling Appliances.

AG 901 Code of practice for NGV refueling stations.

IS 5572 Classification of hazardous areas (other than mines) for electrical installations.

IS 5571 Guide for selection of electrical equipment for hazardous area.

OISD 113 Classification of areas for electrical installations at hydrocarbon processing andhandling facilities.

OISD 179 Safety requirements of compression, storage, handling and refueling of CNGfor use in Automotive sector.

OIML TC8/SC7 Recommendation with regards to CNG dispensers, December 2000.

The Standards of Weights and Measures Act 1976.

The Standards of Weights and Measures (Enforcement) Act, 1985.

The Consumer Protection Act, 1986.

The Standards of Weights and Measures (General), Amendment Rules, 2005 –Part X (Compressed Gaseous Fuel (CNG) Measuring Systems for Vehicles

Any other Codes & Standards mentioned elsewhere in this Specification/MR. or which are required to becomplied with as per the prevailing Government of India regulations shall also be followed.

7.3 Precedence

In case of any conflict between Job Specification & other documents, the following order of precedence shallapply:

· Data sheets.

· Particular technical Specifications (PTS)

· Indian Standards/Codes as applicable, International Standards/Codes as applicable.

7.4 Gas Compositions to Be Handled by Dispensers:

GAS COMPOSITION

Normal Gas Composition Design Gas Composition

C1 82.43 – 99.10 89.45

C2 7.27 – 0.90 4.58

C3 3.47 – 0.00 0.83

I C4 0.65 – 0.00 0.07

N C4 0.78 – 0.00 0.06

I C5 0.17 – 0.00 0.09

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N C5 0.13 – 0.00 0.28

C6 0.10 – 0.00 0.17

C7 0.00 – 0.00 0.00

CO2 4.93 – 0.00 4.38

N2 0.06 – 0.00 0.10

H2O 0.01 – 0.00 0.00

Total 100 100

Average C.V.(kcal/SCM)

8950 – 8150 8302.3

Apart from Gas composition, the proposed specification of the CNG is as follows:

Gas Temperature : -10ºC to +70ºC

Oil Content : 10 PPM

Particulate matter : Less than 5 microns

Odorant : ≤10 mg/sm3 (Ethyl Mercaptane).

The CNG specification should meet the ISO 15403:2000 (E)/ IS: 15958 natural gas quality designation foruse as a compressed fuel for vehicles.

7.5 Safety

7.5.1 All Electrical devices shall meet the requirement for the area classification specified elsewhere in tenderdocument.

7.5.2 Tubing & other devices shall be so arranged that there is proper access for operation & maintenance.

7.6 Location

All the Dispensers shall be suitable for Outdoor installation without roof/shed.

8.0 TECHNICAL SPECIFICATIONS FOR CAR DISPENSERS

8.1. The specifications described herewith are intended to give vendor the technical & operating conditions theDispenser must fulfil. These are to be referred along with relevant description including in earlier sections.Vendor may indicate in his bid, the additional features, which his dispenser has in terms of better design,enhance reliability etc., however such feature may be accepted subject to IGL's review and approval.

8.2. The specifications of FLOW METER are described under Instrumentation & Control Specification Section-B attached with this Specification.

8.3. The Car dispensers shall be designed to handle flow rate of ≥ 15 kg/min, under discharge to atmosphericcondition. The dispensers shall be suitable for a turn down of not less than 50:1 on flow.

8.4. Dispensers shall be based on three banks sequential filling. The sequential panel shall be within the cabinetof the dispenser itself and not as a separate unit. Sequencing should be on flow rate and pressure.

8.5. The normal operating pressure of CNG at dispenser inlet shall be 250Kg/cm²(g). However, supply fromdispenser to the Car shall get positively cut off at outlet pressure of 200 Kg/ cm² (g) to ensure the safety ofthe vehicle.

8.6. Once the particular-cycle of filling has been completely stopped (on achieving the maximum fill pressureand/or minimum flow rate) then next filling can be started only after initialization.

8.7. The normal operating temperature of wetted parts of dispenser shall be (-) 10 °C to 55°C.

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8.8. The Dispenser shall automatically and immediately shut-off CNG supply to fill hose individually (with errorcodes for diagnose) in case of:

· Power failure or excursion beyond permissible limit.

· Loss of display

· Power failure of mass meter (Provided with Single Error code for Power failure in Mass meter).

· Failure for metering

· Flow beyond high and low limits

· Failure of totalizer

· Overfill by quantity and/or pressure

· Failure of pressure sensing transmitter

· Malfunctioning / Passing of electro valve

· Repeated operation of reset or start/ stop switch as per IGL customization.

· Removal of any electrical wire connected to controller.

· Program step is in hold due to any error.

8.9. Cabinet

8.9.1. Complete cabinet shall be of Stainless Steel (SS-304) with appropriate powder coating as per IGL schemeand shall have tamper proof locking arrangement. Cabinet wall thickness shall not be less than 1.6 mm.Cabinet shall be sized to accommodate all electrical, electronic and mechanical components for metering anddisplay within the cabinet. Cabinet shall be designed to protect all tubing, pressure gauges, valves, fittings,electrical & electronics item from tampering, rain, dust, vermin etc. Dispenser cabinet shall be provided withadequate size bottom opening for the entry of gas supply line/lines and power supply connections. Adequateventilation shall be provided so that there is natural convection current and cooling takes place inside. Cabinetshall be structurally robust and should not resonate at the frequencies emanated during normal flow or duringchoked flow through the nozzles, breakaway coupling or valves etc.

8.9.2. Appropriately plugged drain valves of the filter outside the dispenser housing with suitable arrangement tocollect the drained oil to facilitate the operator to drain the oil on regular basis without requiring to open thelock of the dispenser cabinet. The layout of tubing and other component should be such that it givesunhindered access to all parts and maintenance becomes easy.

8.9.3. IGL's Logo and name to be displayed on both sides of dispensers, in IGL approved colour scheme. IGL'sLogo and name shall be painted on stainless steel panel with an appropriate coloured background oralternatively, vendor shall provide self-adhesive PE film sheet with IGL's Logo and name. The artwork shallbe of three colours. The colours, Logo size and name size shall be informed to successful bidder duringdetailed engineering.

8.9.4. The dispensers shall be shipped in fully wired and assembled condition. Only gas and power supplyconnection shall be made at Site.

8.10. Spring Type Hi-Mast shall be of appropriate height and shall allow free movement of flexible hose, preventstrain on the fill hose connection and avoid touching of ground.

8.11. Fill Hose & Fill Nozzle

8.12. Two CNG flexible electrically conductive twin (fill & vent) hose shall be included for supply of Dispensersmeeting the requirement of NFPA-52 and NGV 4.2. (As per specification & make provided in point no.3.1.1)

8.12.1. Both fill hose shall be fitted with NGV-I for filling of vehicles. The nozzle shall meet the requirements ofNGV-1 Type-2, Class B nozzle (As per specification & make provided in tender doc). Vendor shall includethe supply of 3-way valve with each hose for Filling & venting of gas. Vendor shall also include supply ofBreakaway Coupling, suitable for NGV Industry, in the hose (As per specification & make provided in tender

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doc). Hose shall be 3/8” ID 5000 psig, at least 3 m long. Vendor shall demonstrate the function of breakawaycoupling during performance test.

8.12.2. Designing of the dispensers would take into account severity of service. The dispensers shall be designed insuch a way as to operate in cyclic (start, fill, stop, start.) round the clock basis with about 1 minute (typical)interval between stop and start modes. The dispenser also to work satisfactorily when the time between stopand start is indefinitely high, e.g. during lull time or when the dispenser is commissioned after it wasdecommissioned for prolonged period or in storage after initial commissioning. For this purpose if anyspecific storage facility is required, the same to be indicated by the bidder.

8.13. Dispensers should be ergonomically designed.

9.0 DATA SHEETS

Vendor shall fill up data the as per enclosed Data Sheet, attached with this job specification and submit alongwith bid.

10.0 CLIMATIC CONDITIONS

10.1. Wind Velocity : 160.0 Km/Hr

10.2. Minimum ambient temperature : 1.0 ºC

10.3. Maximum ambient temperature : 49 ºC

10.4. Maximum relative humidity : 98% non-condensing

10.5. Maximum shed temperature : 47.5 ºC

All the Dispensers shall be suitable for outdoor installation without roof / shed.

11.0 UTILITY SPECIFICATION

11.1. Electric Power Supply

Single phase, AC, 230 Volts ± 10%, 50Hz ± 3% will be provided by IGL. Surge protector is to be providedby the vendor at the 230 VAC inlet. All instrument (such as mass meter, solenoid, pressure transmitter/ switchetc.) power supply shall be as per approved OEM design. Suitable voltage conditioning unit shall be in thescope of vendor wherever required.

Note: Vendor to confirm that supplied dispensers are suitable with the above power supply. Vendor toinclude suitable voltage conditioning unit in their scope, if required.

For further details refer Electrical Specification, Section-C, attached with this job specification.

12.0 INSPECTION AND TESTING

12.1 At Vendor's Works

All the dispensers shall be subjected to Inspection (“Stage wise” if required by IGL) by IGL's or theirAuthorised Representative

12.1.1. The following activities shall be covered under inspection:

· Review of Q.A. documents.

· Review of calibration certificates for flow meter, dispenser, pressure transmitters, pressure gauges andall instruments.

· Review of all statutory certificates including W &M, type approval from PESO, Govt. of India.

· Review of area classification compatibility of all items including bought out items.

· Review of Mill Test reports.

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· Review of NDT reports.

· Review of bought out sub-assemblies/major components, test/inspection certificates.

· Dimensional checks as per approved drawings and data sheets.

· Safety shutdown of dispensers.

· Immediate cut off of dispensers due to abnormalities.

12.1.2. Functional Test

All the dispensers shall be tested to demonstrate the functioning of all the components and controls.

12.1.3. Performance Acceptance

All the dispensers shall be performance tested for flow capacity, measuring accuracy and dispenserfunctioning with CNG/Nitrogen. CNG/Nitrogen shall be arranged by vendor.

12.1.3.1. During the shop test of dispenser, in case the dispenser flow capacity from inlet of dispenser to the outlet offilling nozzle is found below the specified capacity the dispenser shall stand rejected.

12.1.3.2. During the shop testing if the dispenser batch accuracy is found beyond ± 1.5% dispenser shall stand rejected.

12.2 At IGL Sites

All the dispensers shall be tested by vendor for their function & performance in presence of IGL authorisedrepresentative. Any part or components, which are not functioning to the satisfaction of IGL, shall be repairedor replaced by the vendor without cost & time implication to purchaser and performance test again carriedout.

12.3 Performance Guarantee

12.3.1 The vendor shall guarantee the satisfactory performance of each dispenser as per the operating parametersindicated in data sheets. The dispensers shall be performance tested after installation at site by vendor. Vendorshall carry out tests as required by Govt. Statutory Agencies.

12.3.2 Guaranteed Performance for the Dispensers shall be as follows:

· Flow Rate (≥ 15 kg/min for Car Dispenser)

· Batch Accuracy of + 1.5%.

Note:

1 All the dispensers shall be tested by Vendor for their function & performance in presence of IGLauthorised representative.

2 Any part or component, which is not functioning to the satisfaction of IGL, shall be repaired or replacedby the vendor without cost & time implication to purchaser and performance test shall be carried out allover again.

3 Vendor to execute performance test of all the dispensers after commissioning for accuracy andrepeatability and safety parameters.

4 Vendor to make all arrangements for carrying out performance test viz. Std. Mass Flow Meter, Laptopetc. Vendor shall also carry out tests as required by Govt. statutory agencies.

13.0 VENDOR DATA REQUIREMENT

Vendor data requirement shall be as per attached specification Annexure-2.

14.0 DEVIATION SCHEDULE

A typical format of Deviation Schedule is attached at Annexure-3. Vendor shall categorically specify thedeviation they have on entire material requisition in above format and sign & stamp each sheet and submit italong with bid. In case vendor has no deviation, even then they should write "No Deviation" on this deviation

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schedule and submit it along with bid. This is an essential requirement, the bid should accompany DeviationSchedule.

15.0 MATERIAL REQUISITION COMPLIANCE SCHEDULE

A typical format of Material Requisition Compliance Schedule is attached at Annexure-4. Vendor shallcategorically confirm the requirements in above format and sign & stamp each sheet and submit it along withbid. This is essential requirement; the bid should accompany Material Requisition Deviation Schedule.

16.0 PACKAGING

The dispensers shall be packaged to withstand rough handling during ocean shipment and in-land journey. Itshall be vendor's responsibility to make good any deterioration that occurs during shipment. Sling points shallbe clearly indicated on crates.

17.0 ON SITE TRAINING

Vendor shall provide 3 days of training to 3 separate groups of IGL personnel.

The details of Training Program shall be finalized with purchaser after award of order.

18.0 TRAINING TO IGL PERSONNEL AT VENDOR'S SHOP

Vendor shall provide adequate training to IGL personnel (10 personnel for three working days). Thetravelling, boarding & lodging of IGL’s Engineers shall be borne by IGL. The training module shall coverthe equipment construction features, operational & maintenance procedures, practical hands on experienceon assembling, dismantling etc. The details of Training Program shall be finalized with purchaser after awardof order.

19.0 COMMISSIONING OF DISPENSERS

Vendor shall carry out commissioning of Dispensers within 3 days of receipt of intimation from IGL.

20.0 COMPREHENSIVE MAINTENANCE

Vendor to include five years comprehensive maintenance of all the Dispensers. The start/ commencement ofthe one plus four years comprehensive maintenance shall be after successful testing, commissioning andcommencement of commercial operation of the dispenser. Contractor to submit the organogram of themaintenance team on receipt of the order. This maintenance shall include all spares (flow meter, electroniccards etc.), manpower & consumables (except electric power).

· Contractor to furnish the list of consumables required for normal operation of the dispensers and the timeinterval between change of the consumables like filters, valve repair kit for both solenoid valve, 2 way& 3 way valves, breakaway coupling, display, reset switches etc.

· The Contractor has to provide scheduled maintenance details and list of normal operation spares requiredfor operation & maintenance along with bid. The bidder should also maintain sufficient spares forbreakdown & scheduled maintenance. However, IGL can check/ audit spare stock and vendor has toensure availability of required spares for next 6 months operation.

· The contractor has to replace coalescent filter at least once every year during comprehensive maintenanceperiod.

· If any damage is caused to the dispenser by third party, required spare will be provided by IGL aftermutual agreement.

For comprehensive maintenance, the penalty per dispenser per instance in case of breakdown beyondstipulated time frame reckoned from time of complaint lodged would be as mentioned in volume I of II.

A Log Book for time records shall be maintained in the central Control Room (Vendors) wherein the recordsshall be made for the time dispensers develops trouble and the time at which the trouble is rectified bycontractor’s maintenance staff and dispenser put back to service.

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Statutory compliances like calibration of safety relief valve, PT, PG etc. will be in vendor’s scope forcomprehensive maintenance duration and shall be done minimum once in a year.

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Rev. 0 Supply of CNG Dispensers for CGD Project Page 14 of 53

TABLE OF CONTENTS

SECTION – B

1.0 SCOPE ................................................................................................................................. 15

2.0 BID PROPOSAL ................................................................................................................... 15

3.0 DESIGN PHILOSOPHY ........................................................................................................ 16

4.0 SPECIAL INSTRUCTION TO VENDOR ................................................................................. 16

5.0 REQUIREMENT FOR AUTOMATION SYSTEM IN DISPENSER…………………………………….18

6.0 MAINTENANCE………………………………………………………………………………………………19

7.0 REJECTION CRITERIA………………………………………………….…………………………………..19

8.0 EXCLUSION ........................................................................................................................ 21

9.0 SPARES ............................................................................................................................... 21

10.0 VENDOR DATA REQUIREMENTS ......................................................................................... 21


12.0 ENVIRONMENTAL AND SITE CONDITIONS ARE AS FOLLOWS .......................................... 21

13.0 LIST OF ATTACHMENTS ...................................................................................................... 21

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SECTION: B:

INSTRUMENTATION & CONTROL SPECIFICATION

1.0 SCOPE

1.1. The purpose of this specification is to define the minimum general requirements and philosophy ofinstrumentation & control for the dispenser package of IGL.

1.2. This specification cover the design, engineering, procurement, supply and testing, calibration &commissioning of instrumentation and control system with all accessories and materials and any special testrequirements required for completing the job in all respects.

1.3. Coriolis mass flow meter, electronics and other accessories shall be provided as required for the Dispenserarms.

1.4. Vendor's scope of instrumentation and control for the dispenser package shall include the following as:

a) Basic instrumentation and control indicated in this document.

b) All local and field-mounted instruments in dispenser panel.

c) All additional instruments and control system necessary for safe and efficient operation of the dispenserswhich are not listed specifically in this document but which are required as per vendor'sexperience/recommendations.

d) Impulse piping/tubing including all miniature valves, fittings and mounting to install all sub vendorsupplied instruments.

e) All other erection material necessary for mounting of instruments in vendor's scope as per IGLinstallation standard.

f) Shop testing of all instruments and control system under vendor supply.

g) Calibration, loop checking, pre commissioning and commissioning of the complete system.

h) All weather proof and explosion proof double compression type cable glands for all instruments, junctionboxes, dispenser panel etc.

i) All pressure relief valves.

1.5. In case of further clarifications, bidder shall obtain clarification/confirmation from IGL before proceeding.

1.6. All instruments must be procured from IGL recommend vendor list. However for those instrument/equipment,which are not covered in the list, the sub vendors shall be approved by IGL.

2.0 BID PROPOSAL

The bid proposal shall be accompanied by the following as minimum for technical evaluation of offer.

a) Filled in data sheet of all instrument.

b) Deviation list.

c) Write up on control philosophy.

d) Power supply consumption for each item & type of power supply whether earthed/ floating.

e) Utility requirement & consumption.

f) Complete dispenser along with mass flow meter shall be approved by Weights & Measures Departmentof India and NMI or PTB as per latest standards. In case dispenser has not been approved by Weights &Measures Department of India, the mass flow meter shall have Weights & Measures Department of Indiaapproval.

g) PESO approval for explosion proof enclosure for all electrical & electronic instruments. Bidder to ensurecompliance to all statutory requirements such as PESO, weight & measurement department etc. In caseany penalty is imposed by authorities, same shall be borne by the supplier

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h) Type approval certificate from Petroleum & Explosive Safety Organization (PESO), Nagpur, Govt. ofIndia.

3.0 DESIGN PHILOSOPHY

3.1 All Electrical and electronic instruments shall be installed in accordance with NFPA 70, IEC for Gas GroupIIA, IIB & Temperature Class T3 and shall have approval of a recognized certifying authority.

3.2 Mass flow meter shall be coriolis type and shall conform to AGA 11 standard.

3.3 Each and every mass flow meter 'zeroing' shall be done before delivery from vendor's works.

3.4 Mass flow meter design considerations, piping, meter, zero verification and proving facility shall be as perAGA 11 standard.

3.5 Control valve and solenoid valves shall be of conventional type design, no integral design is acceptable.

3.6 Control valve body and trim materials selection shall be done by the bidder to ensure that there is no erosion,cavitation and flashing. Trim & seat shall be fully stellited.

4.0 SPECIAL INSTRUCTION TO VENDOR

4.1 Supply of Car dispenser with two arm of flow rate ≥ 15 kg/min under differential pressure of 200 kg/cm2 g.

4.2 Each dispenser arm shall have Coriolis type mass flow meter with necessary sensor, electronic and specialcable recommended by vendor. Performance record and Weight and Measure (W&M) certification of themeter to be submitted for acceptance.

4.3 Three rows liquid crystal backlit displays for night viewing showing total sale in Rupees of (00000.00),quantity of gas sold in Kg.(00000.00), unit price of CNG in Rs/Kg (000.00) for each hose of the dispenser(total two sets and three rows for each dispenser).

4.4 Vendor shall make a provision to change the price of CNG through the keypad inside the dispenser unit thatshall be covered with security lock. RS 485 port shall also be provided for price change. In case standardRS485 port is not available in the dispenser, then RS232C to RS485 convertor with all relevant hardware andsoftware to be provided by vendor.

4.5 Non-resettable and non-volatile totalizer upto 999999.99 (8 digits and a decimal) for total CNG sold in Kgs.Since the dispensers are used for custody transfer purpose, the totalizer must not reset/change/jump in anyeventuality not even in the case of electronic failure/power supply failure or excursion beyond permissiblelimit. If there is any abnormality in power circuit during filling, the running batch value should be added intotalizer. Dispenser electronics shall be common for both totalizers.

4.6 Totalizer figure would be displayed only when it is recalled through a remote keypad or some device integralto dispenser. The totalizer value would cover up to the last transaction details at the time of recall. Theseremote key pad device should not be used for any programming of the dispenser and are distinct from those,if used for programming the dispenser while operating these keys in no way shall hinder the operations,functioning, veracity of display, storage of parameters and values. These remote keys can be used even whenthe filling is on without affecting up-counting/real time data.

4.7 Dispenser shall be capable of communicating with outside system using the open system architecture/protocol(OPC)/RS 485. Bidder must handover the details of communication port of dispenser and signals to betransferred to IGL. It should be possible to transfer the data through twisted pair wires, transaction data asalso flow meter data (both process and diagnostic) RTU.

4.8 One number of three bank electronic software and controller including hardware. Vendor shall includesolenoid operated valve made of ANSI 316 SS for dispensing of gas. Vendor to ensure the system design insuch a way that in both options any gas if passes, should be recorded by dispenser and there should not beany possibility of unmetered gas supply through dispenser in case of malfunctioning of valves. The valveassembly shall be fatigue free and tight shut off characteristics at least for 8000 operation hours.

4.9 Two number of liquid filled 4" dia. (0-400 kg/cm2g) pressure gauge showing the vehicle filling pressure.Pressure gauge shall be provided with shatterproof glass. Vendor to provide a bypass isolation valve withassociated tubing to facilitate routine servicing/calibration of Pressure gauge without shut down of thedispenser.

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4.10 Temperature compensator to limit fill pressure to an adjustable value (with normal value 200 Kg/cm2g)equivalent at 15 degree C. A temperature compensation facility button shall be provided to enable or disablethe temperature compensator.

4.11 To limit fill pressure to 200 Kg/ cm2 g, Vendor to provide the following options per hose / arm of thedispenser:

a) One number of pressure limiter ( electronics transducer) (with adjustable value up to 250 Kg/cm 2 g) andone number of mechanical pressure regulator and one number pressure relief valve as final safety toavoid overfilling. Pressure regulator shall be designed such that there shall not be any flow restriction tothe maximum flow of dispenser. Otherwise, minimum flow through the regulator shall be 15 Kg/min at5 kg/cm2g differential pressure.

4.12 Back-up Power supply for displays so that display remains at least for 5 minutes after power failure. Vendorshall provide battery backup of 72 hours to the RAM of dispenser controller.

4.13 Hardware required with the dispenser for Weights and Measures (W&M) certification.

4.14 All parameter setting shall be password protected. Facility of change of password also to be provided toenhance the security of password.

4.15 Car Dispensers shall be designed for handling flow rate of more than or equal to 15 kg/min. flow capacitywith turn down of not less than 50:1.

4.16 The batch accuracy of dispensed gas shall be within ± 1.5% or better.

4.17 Bidder shall indicate overall flow coefficient Cv of dispenser from inlet to the dispenser upto outlet of nozzleincluding mass flow sensor, interconnecting tubing, valves, hose, fill valve etc.

4.18 Normal operating inlet pressure of dispenser shall be 220-250 Kg/cm²g. The dispenser supply to the vehicleshall be positively cut off at outlet pressure of 200 Kg/cm²g.

4.19 Normal operating temperature of wetted parts of dispenser shall be –10 to 55 deg C.

4.20 Vendor shall confirm that any momentarily flow of gas shall be registered in dispenser totalizer. Vendor shallenvisage a temper proof design. Dispenser shall generate error signal in case of passing valve with date andtime and display on the dispenser LCD.

4.21 After power on, the controller delay time to start filling be such that the mass meter and pressure transmitterare initialized properly to avoid any un-metered gas.

4.22 Complete control loop would be so fast that if the filling is terminated at any point of filling, the flow wouldstop immediately.

4.23 Reset switch assembly should be suitable for failure free operation and the same shall be supported withproper PTR for CNG duty.

4.24 Controller shall be in reset state for the SOV open signal to be generated. Any departure to this shall stop thedispenser. Dispenser controller shall monitor the status of flow, monitor the status of flow meter / transmitterand in case of any abnormality from set condition the dispenser shall shut down.

4.25 In case the power supply is beyond acceptable limit the dispenser shall not start at all. The controller shallprovide an operational alarm with pre-stated error code and it shall be displayed on LCD display.

4.26 Flow meter signal shall be considered as the highest level of interrupt. It shall not be possible to fill anyvehicle cylinders by repeated operations of reset switches. Reset time delay is required with adjustable time.

4.27 A Provision shall be available in dispenser unit, which shall be suitable for programmable/changeable fillingpressure from 180kg/cm²g to 220kg/cm²g in vehicle. Original filling shall be same as defined elsewhere indata sheet.

4.28 Emergency stop switch is required on both side of the dispenser. However, the filling on both sides shouldstop in emergency condition, when any one of the emergency switch is pressed. However during activationof emergency switch, the power supply to the dispenser should be available.

4.29 Overfill Protection

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Overfill protection shall be through electronically programmed hose to terminate the fill after 200 Kg/cm²g.Vendor shall include one number pressure transducer and one number pressure regulator per hose. Pressurerelief valve shall be provided to avoid overfilling. Relief valve set pressure shall be at 250kg/cm²g withresetting at 245kg/cm²g. Relief valve setting to be adjustable from 225kg/cm²g to 260kg/cm²g with resettingat 220 to 255 kg/cm²g respectively. Calibration certificate shall be provided.

4.30 Electronics

4.30.1 Electronics shall be microprocessor based. The processor shall be the latest available in the field and shall becapable of processing the data faster. All the electronic cards shall be located in flameproof boxes inside thedispenser cabinet. No parts of electronics shall be filled with epoxy resin etc. The controller electronics shouldhave immune to EMI interference and vendor to provide relevant certification in this regard.

4.30.2 The dispenser electronics should have self-diagnostic features and should generate error code accordingly.Vendor should define such error codes in trouble shooting guide and procedure of their rectification. Errorcode related to operational parameters should also be displayed and defined in trouble shooting guide.Password protection should be provided for entry of critical data through key pad.

4.30.3 The change in setting shall be done either through lap top computer or through hand held configurator throughthe port provided for this purpose with security lock.

4.30.4 Vendor shall provide suitable electronics for processing both arms dispenser data. Totalizer display anddisplay for both arms in the dispenser shall be shown separately

4.31 Tubing & Fittings

Materials used for the tubing shall be SS 316 fully annealed (Bright annealed) seamless conforming to ASTMA269 with maximum hardness of RB80 or less and suitable for bending and flaring. Open ends on fittingsand vents shall be provided with caps/dust plugs.

4.32 Certification:

· Equipment/instrument/systems shall be certified for use by statutory authorities for their use in area oftheir application.

· For all intrinsically safe/flame proof equipment/instruments/systems, certification by any approvingauthority like BASEEFA, FM, UL, PTB, LCIE, Petroleum & Explosive safety organization (PESO),India is mandatory.

· The supplier should specify the hazardous area in accordance with the IS 5572 / Australian Re-fuellingStandard AG901 / NZS5425. All electrical equipment cabling and earthing should be appropriate for thezone in which it is fitted, and all cables passing from the hazardous to safe area should be equipped withappropriate barriers where necessary.

· All Instruments should be suitable for an area classification of “Class 1, Division 1, Group D as per NEC”OR “Zone 1, Group IIA / IIB as per IS 5780 / IEC 6007”. All dispensers mounted transmitters &temperature element should be intrinsic safe “Exia” as per IEC 79-11. Solenoid Valves, Switches andrelated junction boxes should be flame proof “Exd” as per IEC 79-1.

· Other special equipment / instruments, where intrinsic safety is not feasible or available, should be flameproof as per IEC 79-1. Flying leads from any of the instrumentation items are not acceptable. TheElectronics of the dispenser shall not be open and shall be provided within a suitable enclosure. Acomplete dossier of all electrical equipment will be provided, showing area classification and certificationof equipment.

4.33 In case the mass flow meter design is having transmitter with local integral display, the mass flow metersignal through the transmitter shall be wired to the mother board used in the dispenser and there shall not beany difference in reading between this integral display unit and non-resettable display in the electronic controlunit or,

If the mass flow meter design does not have provision for transmitter with local integral display, then themass flow meter signal shall be directly wired to the mother board of the dispenser.

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4.34 Dispenser manufacturer is required to submit approval of weight & measure department, Gov of India. Forthe dispenser unit or for the mass flow meter installed in the dispenser unit. In future, if any non-conformityor objection is raised by W&M department or if any penalty action is taken against IGL, vendor shall be fullyliable, indemnify IGL against any liquidity and shall bear all the cost implication, if any.

4.35 One no. of non-resettable and non-volatile totalizers per hose of the dispenser i.e. one integral local digitaltotalizer with display along with mass flow meter transmitter and the second totalizer of liquid crystal backlitdisplay in kg. (999999.99) on the front panel of the dispenser shall be provided. Besides this, an electro-mechanical type totalizer shall also be provided with 7 digits and reading of both the totalizer shall be thesame.

There shall be a non-resettable & non-volatile totalizer per hose of the dispenser with liquid crystal backlitdisplay in kg. (999999.99) on the front panel of dispenser. Besides this, a 7 digit electro-mechanical totalizershall also be provided.

4.36 All equipment should be communicated with the common communication protocol.(MODBUS/PROFIBUS/HART)

4.37 All the safety norms to be followed by vendor as per IGL guidelines.

4.38 All the approvals and certification to be provided by vendor for the hardware, software supply as per IGLrequirements.

4.39 During installation & commissioning vendor will ensure that routine operation of the equipment will notsuffer or vendor will install the equipment as per IGL guidelines.

4.40 RFID Systems

The dispenser must be compatible with future RFID system suitable for monitoring and control of vehicle/vehicle on-board cylinder authentication mechanism. (TBD)

5.0 REQUIREMENT FOR AUTOMATION SYSTEM IN DISPENSER

5.1 It is intended to monitor / control following parameters through automation system:

Vendor shall ensure availability of following parameters at communication port of dispenser to connect withautomation system for monitoring & control purpose.

These parameters shall also be checked during inspection at vendor’s works.

a. Mass Totalizer from Dispenser Motherboard.

b. Mass Flow per Filling.( note that Gas sale data- the reading which is visible to customer and used forbilling purpose is mandatory to be transmitted to server whether it is from flow meter or motherboard orfrom both)

c. To Read Gas Selling Price from Dispenser.

d. To download the gas selling price into the dispenser from Server system.

e. Mass Flow Meter Status.

f. Tripping Status Dispenser.

g. Reset Switch Operation Status.

h. Dispenser Power Supply Status.

i. Identity of vehicle using RFID (In-built option to be provided).

5.2 In addition to above bidder shall make provision for monitoring and control of following parameters as well

A. Shift Reports

(Shift – A: 6:00 to 14:00)

(Shift – B: 14:00 to 22:00)

(Shift – C: 22:00 to 06:00)

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a) Showing Date /Start time/ Finish time of every shift

b) Individual Arm-wise and Dispenser-wise totals.

c) Total sale for each shift in Kgs and Rs.

d) Total sale with variable pricing.

e) Full day report with total Sale for the 24 Hr. period.

B. Remote Price Change facility to facilitate

· Station-wise sortable and selectable

· Time-wise selectable

· Area-wise selectable

· Variable price change in a day

C. Transaction reports

Remotely the following parameters can be viewed in transaction reports

· Station Name and Dispenser serial number.

· Showing Date /Start time/ End time of every filling.

· Individual Arm-wise and Dispenser-wise totalizer at start of filling and end of filling.

· Transaction number totals for individual Arm-wise, Dispenser-wise and Station-wise to count number offills in selectable particular duration. (Monthly and daily basis)

· Batch reading of fill.

· Sale for each batch in Kgs and Rs.

· Unit price Data.

· Dispenser power ON/OFF count.

· Pressure during last fill

· Vehicle pressure at start of filling

· Vehicle pressure at end of filling

· Temperature during the last fill

· End of sale indicator (Code number showing the reason that the last sale stopped. This is useful if adispenser stops during a fill for no apparent reason).

5.3 The remote monitoring and automation will consist of reading, transferring and controlling all thedata/parameter from the dispensers to RTU and then to any centralized remote server in India as per IGLrequirement.

5.4 The above list is tentative and final list shall be decided during execution phase.

6.0 MAINTENANCE

6.1 The two-year comprehensive maintenance of all the dispensers is in vendor’s scope.

6.2 The start/commencement of the two years comprehensive maintenance shall be after successful testing,commissioning and commencement of commercial operation of the dispenser. As warranty is for a maximumof 18 months, the end date of AMC period would be 42 months (18+12+12 month) from date of dispatch ofa lot.

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7.0 REJECTION CRITERIA.

7.1 During the shop test of dispenser, in case the dispenser flow capacity from inlet to dispenser to the outlet offilling nozzle is found below the specified capacity the dispenser shall stand rejected.

7.2 During the shop testing if the dispenser batch accuracy is found beyond ± 1.5% dispenser shall stand rejected.

7.3 The bids received without the certification from the Weights and Measurement department of the Country oforigin for offered mass flow meter (Coriolis type) as per specifications may be liable for rejection. In casecountry of origin of mass flow meter does not issue weights and measure certificate then the same shall beprovided from approved agency for weights and measure from other country.

7.4 Bid received without technical documentation including GA drawing shall be liable for rejection.

8.0 EXCLUSION

Vendor’s offer shall exclude following:a) UPS for instrumentation & control.UPS shall be made available to bidder/contractor at battery limit.

9.0 SPARES

Commissioning and warranty spares to be provided and included in the base offer.

10.0 VENDOR DATA REQUIREMENTS

Vendor data requirement shall be strictly as per Annexure-5 this job specification.


11.1 Functional and simulation test for the following shall be carried out at vendor’s works and shall be witnessedby IGL/Third party.

11.2 Control panels along with all instruments mounted in it.11.3 Following tests shall be carried out by bidder at his works or his sub-vendor’s works and test certificates shall

be furnished :a) Calibration/test certificates for all instruments, control valves & safety valves.b) Seat leakage test for control valve and safety valve.c) Test certificates for safety valve set pressure and reset pressure.d) Material test certificates for all line mounted instruments.e) Sub-vendors conformity certificates.

12.0 ENVIRONMENTAL AND SITE CONDITIONS ARE AS FOLLOWS

: Minimum Temperature: 1°C

: Maximum Temperature: 49°C: Maximum Shed Temperature: 47.5°C: Relative humidity 98% Non-condensing: Wind Velocity 160.0 Km/Hr

13.0 LIST OF ATTACHMENTS

Data sheet for CNG Dispenser for CAR.Data sheets formats (along with calibration certificate wherever applicable) for

· Mass flow meter

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· Control valve

· Solenoid valve

· Self-actuated control valve

· Pressure relief valve & Pressure Gauge and transmitter

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TABLE OF CONTENTS

SECTION – C

1.0 GENERAL ............................................................................................................................ 24

2.0 CODES AND STANDARDS ................................................................................................... 24

3.0 AREA CLASSIFICATION AND EQUIPMENT SELECTION ...................................................... 24

4.0 EQUIPMENT SPECIFICATIONS ........................................................................................... 25

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SECTION: C: ELECTRICAL SPECIFICATION

1.0 GENERAL

1.1 This specification defines the requirements of design, engineering, supply and installation, testing andcommissioning of electrical facilities for CNG Dispenser Package.

1.2 It is not intended to cover all aspects of design but to indicate the basic requirements only. Vendor shall ensurethat the design and installation on the skid is carried out as per good engineering practice to meet therequirements of safety, reliability, ease of maintenance and operation, aesthetics and interchange ability ofequipment.

2.0 CODES AND STANDARDS

2.1 All electrical equipment and complete package shall meet the requirement of relevant Publications and Codesof Practice of Bureau of Indian Standards, statutory regulations and good engineering practices. Completesystem must conform to the latest revisions of the following:

a. Indian Electricity Act and Rules framed there under.

b. Fire Insurance Regulations.

c. Petroleum Rules and any other regulations laid down by Petroleum & Explosive safety organization.

d. Regulations laid down by local statutory authorities and Electrical Inspectorate.

2.2 Vendor shall provide all assistance required for obtaining approvals from statutory authorities for materials,plant design/drawings and complete installation.

2.3 Where Indian Standards do not exist, the relevant IEC/British/ German (VDE) standards shall apply. AnyOther international standard may also be followed provided it is equivalent to or more stringent than thestandards specified above.

2.4 In case of any discrepancy/conflict between the specified codes and standards, the following order ofdecreasing precedence shall govern:

i) Statutory Regulations.

ii) Codes and Standards.

Owner’s concurrence shall, however, be sought before taking a decision in the matter.

3.0 AREA CLASSIFICATION AND EQUIPMENT SELECTION

3.1 In case of storage, handling or processing of flammable materials within the battery limits of the package,area classification shall be carried out in line with IS: 5572 & Petroleum Rules and OISD-179 guidelineswhere applicable.

3.2 Selection of the type of equipment for use in hazardous areas shall be done in accordance with IS: 5571 andother safety regulations as applicable. The electrical equipment shall meet the requirements of relevant IS,IEC or NEC standards. Increased safety type Ex (e) equipment shall not be permitted for use in Zone-1 areas.For Zone-2 areas, increased safety type Ex (e) or Non-Sparking Type Ex (n) equipment shall be provided asa minimum, subject to the same being acceptable to statutory authorities. Ordinary safe area type electricalequipment shall not be used in Zone-2 areas (even though this may be permitted by NEC for Div.2 areas).

3.3 Electrical equipment for hazardous areas shall be certified by CMRI and approved by PESO (or equivalentstatutory authority of the country of origin) for installation and use in the specified hazardous area. Flameproofequipment of indigenous origin shall be BIS marked. Vendor shall furnish the necessary certificates indicatingsuch approvals.

3.4 All the electrical and electronic component shall be in flame/explosion proof housing suitable for areaclassification: Hazardous area, Class 1, Division 1, Group D as per NEC or Class 1, Zone 1, Group IIA/IIBas per IS/IEC, Temperature Class T3, and completely enclosed in a securely lockable dispenser cabinet. Nocomponent of the dispenser shall be installed outside the cabinet.

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Certificate from recognized agency to the effect is required to be produced that equipment supplied and/orinstalled conforms to above area classification.”

4.0 EQUIPMENT SPECIFICATIONS

4.1 Specifications of equipment shall be furnished for review by the owner. All equipment and components shallbe new and supplied by approved reputed manufacturers. Equipment requiring specialized maintenance oroperation shall be avoided as far as possible and prototype equipment shall not be accepted. All equipmentshall be complete with all necessary weather protection including tropicalization to prevent damage due toclimate, dust and corrosive vapours.

4.2 Vendor shall be responsible for any damage to the equipment during transit. All packages shall be clearly,legibly and durably marked with uniform block letters giving the relevant equipment material details. Eachpackage shall contain a packing list in a waterproof envelope.

4.3 All electrical components and equipment shall be sized to suit the maximum load under the most severeoperating conditions.

4.4 All electrical equipment shall be supplied with approved cable glands, made of nickel-plated brass, tested andcertified to be used in zone-1, hazardous area.

4.5 All electrical components should be suitably weather proof to prevent short circuits, corrosion and should besuitable for installation in Hazardous classification as class I, Division 1, Group D

4.6 Although the supply is being arranged through UPS System, but in some remote occasions, the power supplymay be from DG sets with poor regulations and thus power supply available from IGL may contain harmonics,transients and surges etc. The Electronics shall be compatible to the supply system as no transient, surge orharmonics protection is provided by IGL. Bidder to include suitable surge protection device/ voltageconditioning unit, as required, in their scope for accurate and safe operation of dispenser.

4.7 Rated voltage and frequency for the equipment shall be indicated below:

Ambient Temp: Max. 49 ºC & Min. 1 ºCSystem Voltage: 230V + 10% Single Phase ACSystem Frequency: 50 Hz + 3%System Earthing: Solidly Earthed

We have envisaged solid earthing for the system. However, if specific earthing is required for the system –electronics, the same to be highlighted by bidder; otherwise system earthing including making of earth-pitsetc. shall be provided by the successful bidder.

4.8 Name of the manufacturer, type of enclosure protection and certificate no. with name of testing/Certifyingagency shall be furnished with bids / for approval.

4.9 General Requirement

· All power supply J.B.’s shall be flame-proof type as per area classification.

· Fill hoses should be conductive type to mitigate the static charges.

· Provision for connecting earth strip at two points inside the dispenser.

· Supply cable entry to dispenser shall be suitable for armoured 2.5sq.mm. 4 core.

There should be effective static charges (as generated in hoses) mitigation design. All hoses shall beconductive so that auto earthing of static charges (as generated in system) could be ensured. Vendor shallsubmit the requisite documents/demonstration against the same at vendors shop.

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SECTION D: MECHANICAL SPECIFICATION

Hoses:

Two CNG flexible electrically conductive (fill & vent both should be separate) hose, having followingspecification:

1. Car long hose breakaway to nozzle:

a. Car Dispenser Fill hose (Long)

b. Hose ID- 3/8",

c. OD- 0.77",

d. Length- 3000 mm,

e. Minimum Bend Radius-4",

f. End SIZE 1:- 9/16"-18 UNF SAE6(M)

g. End SIZE 2:- 1/4 NPTM , in SS 316

h. Nominal Size-3/8",

i. Working Pressure: 5000 PSI (345 Bar),

j. Minimum Burst Pressure: 20000 PSI (1379 Bar),

k. Temperature Range: -40° C to 65° C),

l. Electrically conductive polymer core tube, two or more layers of fiber reinforcement, and abrasion-resistant urethane cover. Cover must be pinpricked for use with CNG. High-strength conductivepolymer core tube is required to dissipate static electrical build-up. Thick urethane cover for abrasionand wear resistance.

m. Spring guards must be provided at both ends for the assembly.

n. Hose should conform to NFPA 52 & ANSI / CSA NGV 4.2-2014 / CSA12.52-2014

2. Car short hose dispenser to break away:

a. Car Dispenser Fill hose- 1800 mm (Short),

b. Hose ID- 3/8",

c. OD- 0.77",

d. Length- 1800 mm,


f. End Size 1- 9/16"-18 UNF SAE 37* JIC (F) Swivel

g. End size 2- 9/16"-18 UNF SAE6(M) (Both Ends),in SS 316


i. Working Pressure :5000 PSI (345 Bar )

j. Minimum Burst Pressure : 20000 PSI (1379 Bar ),

k. Temperature Range : -40° C to 65° C ),

l. Electrically conductive polymer core tube, two or more layers of fiber reinforcement, and abrasion-resistant urethane cover. Cover must be pinpricked for use with CNG. High-strength conductivepolymer core tube is required to dissipate static electrical buildup. Thick urethane cover for abrasionand wear resistance.


n. Hose should conform to NFPA 52 & ANSI / CSA NGV 4.2-2014 /CSA .52-2014

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3. Vent hose:

a. Vent hose- 3000mm ,

b. Hose ID- 1/4",

c. OD- 0.63",

d. Length- 3000 mm




h. Nominal size - 1/4"

i. Working Pressure : 5000 PSI ( 345 Bar ),

j. Minimum Burst Pressure : 20000 PSI ( 1379 Bar ),

k. Temperature Range : -40 C to 65 C ),

l. Electrically conductive polymer core tube, two or more layers of fiber reinforcement and abrasion-resistant urethane cover. Cover must be pinpricked for use with CNG. High-strength conductivepolymer core tube is required to dissipate static electrical buildup. Thick urethane cover for abrasionand wear resistance.


n. Hose should conform to NFPA 52 & ANSI / CSA NGV 4.2-2014 / CSA52-2014

Nozzles:

Both hose shall be fitted with NGV-I nozzle for filling of vehicles. Specification for NGV 1 nozzle is asfollows:

Nozzle Type NGV-1 TYPE 2, CLASS B

Normal working Pressure PN200 bar

Temperature Range 0°C to +65°C

Max. Length Max. 115 mm

Cv minimum 1.05

Max. Weight 0.65 kg

Min. Flow Rate: 1500 SCFM @ 3000 psig

Max nozzle body diameter 2 inches

Filling Line Male Thread UNF 9/16”-18 Female or

1/4” Male NPT

3 way valve:

Vendor shall include the supply of 3-way valve with each hose for filling & venting of gas. Specifications areas follows:

Connection Size : ¼ “NPT Female

Pressure Rating : 5000 PSI (minimum)

Temperature Rating : 0 to 65 deg. C

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Minimum Life : 40000 cycles at site conditions (one on & off is considered asone cycle)

Material of construction

Body : SS 316 as per ASTM A276 or as per ASTM A479 or ASTM A 182

Ball : SS 316 ASTM A479 or Alloy S21800 as per ASTM A276

Stem : SS 316 ASTM A479 or as per ASTM A276

End connection : SS 316 ASTM A479 or ASTM A 276

Seat carrier : SS 316 as per ASTM A276

Seat springs : Alloy X-750 / AMS 5542 / 17-7 PH

Seat : PEEK

O-rings : BUNA-N or BUNA-C or Fluorocarbon FKM

Backup rings/bearings : PEEK / PTFE

Orifice Size / Cv : min 4.75 mm / min 0.62

Weight : Max. 350 grams.

Design Features

1. The valve should be of trunnion ball design.

2. Blow out resistant two piece ball/stem.

3. Should have positive handle stoppers.

4. Flow direction indication must be there on handle.

5. Directional indication must be provided for panel mounting.

6. Complete repair kit must be available and comprises of (all internals installed in valve body) followingitems :

a. Stem

b. Stem washer

c. All sealing rings for stem i.e. stem o-rings, primary backup rings, secondary backup rings etc.

d. All Seat with carrier

e. All Seat retainer o-rings, backup rings, guide, springs etc.

f. Connector end seals

g. Ball trunnion

h. Trunnion bearing

Break away:-

Vendor shall also include supply of Breakaway Coupling, suitable for NGV Industry. Vendor shalldemonstrate the function of breakaway coupling during performance test.

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DATA SHEETS

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CNG DISPENSER FOR CAR

SR. NO.

PARAMETER SPECIFICATION OFFERED

1.0 Dispenser Car1.1 Make1.2 Model1.3 Normal Inlet Pressure Kg/cm2 g 2501.4 Maximum Fill Pressure Kg/cm2g 2001.5 Operating Temperature range of wetted parts (-) 10 °C to 60°C1.6 Flow Rate (kg/min) > 151.7 Nominal flow (kg/min)1.8 Minimum flow (kg/min)

1.9 Overall Cv of dispenser from inlet of dispenserto outlet of fill nozzle

1.10 Batch accuracy ± 1.5%

1.11 Electrical Supply AC 230 Volts ± 10%50Hz ± 3%

1.11.1 Tolerable value of voltage range for accurateoperation

1.12 Fill Nozzle1.12.1 Type NGV1 & NZS 54251.12.2 Make OPW1.12.3 Pressure Rating Kg/cm2 g 250 Kg/cm2 g1.13 Flexible fill & vent hose Both should separate1.13.1 Type1.13.2 Make1.13.3 Pressure Rating Kg/cm2 g1.14 Sequential filling Three bank1.15 Mass Flow Meter1.15.1 No. of metering lines Two independent1.15.2 Metering principle Coriolis1.15.3 Make1.15.4 Model

1.15.5 Mass Flow accuracy for gas meter (inclusive oflinearity, hysteresis, repeatability errors) ± 0.5%

1.15.6 Repeatability ±.0.25%1.16 Temperature compensation Yes1.17 Breakaway coupling YesNOTE: For all Electrical/Instrumentation items vendor shall provide certificates issued by statutory InspectionAuthority confirming suitability of Design/Construction for specified Hazardous Area Classification.

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MASS FLOW METERS (CORIOLIS TYPE) FOR CAR DISPENSER

Units: Flow -> CNG CNG-Kg/HrPressure->

Temperature->oC

Level /Length->mm

General 1. Tag No.2. Line No.3. Service4.

Meter 5 Type6 Function7 Conn. Size: Size &Rating,

Facing & Finish8 Body Material9 Wetted Parts Material10 Enclosure11 Conduit connection12 Range13 Accuracy1415

Convertor 16 Load Resistance – ohms.17 Output18 Power Supply19 Area Classification20 Intrinsically safe /Expl. Proof21 Enclosure22 Conduit connection23 Mounting24 Distance from control room2526

Options 27 Filter/Mesh Wire28 Mounting Brackets29 Interconnecting30 Special cabling31 Cable glands32 Accessories for hot tap333435

ServiceConditions

36 Fluid & state37 Maximum Flow38 Minimum Flow39 Normal Flow40 Pressure – Open. Max.41 Temp. C – Open. Max.42 Oper. S.G. Mol. Wt43 Max. order Viscosity mpa . s(cp)44 Max. Allowable Pr. Drop45 Model No. Meter convertor46 Specification Remarks47 Specification Remarks

Notes: DEVIATION NO DEVIATION

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CONTROL VALVES


Temperature-> oC Level /Length->mm

General 1 Tag No.2 Inlet Line No.3 Outlet Line No.4 Service5 Line Size Schedule6 Inlet Line I.D. Outlet line ID

Body 7 Type of Body8 Body Size Port Size9 Guiding No. of Ports10 End Conn: Flgd. Size & Rating11 Facing & Finish12 Body Material13 Bonnet Type14 Packing Material15 Lubricator Isol. Valve16 Trim form17 Trim Mat. Plug. /Disc/Ball & Seat18 Other wetted parts19 Soft seating Materials20 ANSI Leakage Class

Act. 21 TypeUat or. 22 Close at Open at

23 Failure Position24 Handwheel & Location

Position 25 Air Supply Pressure26 Input Output27 Bypass Gauges

Options 28 Solenoid Valve29 I/P convertor30 Filter with Gauge31 Limit Switch3233

ServiceConditions

34 Fluid State35 Flow Liquid Min: Normal: Max36 Flow vapour Min : Normal : Max37 Flow Water Min Normal Max38 Inlet Pr. Nor. Min.39 P @Flow rat Min :Normal : Max40 Pressure Shut Off41 Temp. Open. Max.42 Open S.G. Mol. Wt.43 Cp/Cv Compress Factor44 Flash% visc.mPas (open)45 Deg. Of Superheat % Solids46 Vapour Pr. Critical Pr.47

Valve Data 48 CV Min. Cv Max.49 CV Nor. Selected CV50 Predicted Sound Level Dba51 Inlet Velocity m/s

Model Nos. 52 Valve Actuator53 Positioner Solenoid Valve54 IBR Certification

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SOLENOID VALVES

Units:Flow -> CNG CNG-Kg/Hr

Pressure->Temperature->oC

Level /Length->mm

General 1 Tag No.2 Line No.3 Line Size & Sch.4 Service

Valve 5 No. of ways6 Size – Body Port7 End Connection8 Material Body9 Material Trim10 Body Rating11 Operating mode NC/NO/Univ.12 Packing131415 Enclosure

Electrical 16 Area Classification17 Cable Entry18 Ty. Of Energisation Dropout19 Power Supply20 Power Consumption VA/W21 Inrush Current22 Insulation Class23 Voltage – Energising –

Dropout24

Options 25 Manual reset26 Latching on Energ./De-Energ.27 Bug screen for vent port28 Intrinsically safe2930

ServiceConditions

31 Fluid32 Press. Open / Max.33 Temperature C-Open/ Max34 Maximum Flow35 S.G. at open Temp. Mol. Wt.36 Viscosity mPa.s (cp)37 Allowable Press Frop38 Del. P Shut Off39 Valve CV404142 Model No.43 Specification Remarks

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SELF ACTUATED PRESSURE CONTROL VALVES



General 1 Tag. No2 Line No.3 Line Size & Sch.4 Service5

Valve 6 Ty. Of Regulator: Std/pilot op7 Size: Body Port8 End Conn.:- Size & Rating9 - Facing & Finish10 Body Material11 Trim Material12 Set Point13 Impulse Conn.: Int. / Ext.14 Conn. Size & Type if external15 Material of Diaphragm16 Bonnet Type17 Cv: Min. Max.18 Cv: Normal19 Selected Valve CV.20 Predicted Sound Level (dBA)21 Inlet Velocity22 Packing of Seals23 Lubricator ISO – Valve24 Guiding No. of Ports25

Accessories 26 Pressure Indicator27 Relief Valve28 Line Stainer

Serviceconditions

29 Fluid & State30 Flow - Min. / Max.31 Flow - Normal32 Inlet Pr. - Max. / Min33 Inlet Pr. - Normal34 Del. Pr. – Max. Min35 Del. Pr. - Shut Off36 Temperature ºC - Oper. Max.37 Oper. S.G. Mol Wt.38 Cp/ Cv compress factor39 Flash% open visc. Mpa. S (cp)40 Deg. Of Superheat % solids41 Vapour Pr. / Critical Pr.42 Model No. Valve / Actuator4344 IBR certificate45 Specification Remarks

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PRESSURE RELIEF VALVESUnits: Flow -> CNG CNG-Kg/Hr

Pressure->Temperature-> oC Level /Length-

>mmGeneral 1 Tag No.

2 Line No.3 Vessel Protected4 Safety / Relief

Valve 5 Type:6 Full Nozzle Full Lift/ Mod Nozzle7 Bonnet Type8 Conv. / Bellows / Pilot Operated9 Inlet Conn.: Size & Rating10 Facing & Finish11 Outlet Conn.: Size & Rating12 Facing & Finish13 Cap Over Adj. Bolt14 Screwed/Bolted15 Lifting Gear – Type16 Test Gag17

Material 18 Body and bonnet19 Nozzle and Disc20 Spring21 Bellows22 Resilient Seat seal

Options 2324

Basis 25 Code26 Basis of selection27

Serviceconditions

28 Fluid and state29 Corrosive constituent30 Required flow capacity31 Mol. Wt./ S.G. at Ref Temp.32 Open Pressure33 Open temp C / Ref Temp C34 Valve discharge to35 Back Press. / Const or variable36 Set Pressure37 Cold Bench Test pressure38 % Over pressure/ % blow down39 Cp/cv [ compressibility Factor]40 Viscosity At Ref. Temp. mPa s(cp)41 Vess.: Walltemp.C/ Surf Area-m2

42Orifice 43 Calculated Area cm2

44 Sel. Area cm2 / Orifice Design45 No. of valves Reqd. for capacity46 Total Area - cm2

47 Actual Flow Capacity4849 Model No.5051 IBR Certification

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PRESSURE TRANSMITTER

Units: Flow -> CNG CNG-Kg/Hr Pressure-> Temperature-> oC Level /Length->mmGeneral

1. Function2. Type: -3. Case: -4. Mounting: -5. Electrical Area Classification6. Enclosure :

Enclosure Class7. Intrinsically safe: -8. Air Supply9. Power Supply10. Cable Entry:11. Accuracy: -12. Repeability: - TRNSMITTER13. Output14. Trans. Power Supply Controller15. Output:-16. A/M switch:-

No. of positions:-17. Set point adjustment18. Manual Regulator19. Mode20. Chart21. Chart Driver22. Moving parts matl.; -23. Chart Speed: -

Measuring Unit24. Service: -25. Element : -26. Body Material: -27. Element Material28. Process conn.: -

process conn. Location29. Diaphragm seal

wetted parts materials: -other MaterialProcess Conn.: Size & Rating Facing & Finish: -Capability Material:-Armour Flexible: -Armour Flexible Matl.: -Capillary length:- mmFlushing/filling conn. With Miscellaneous

30. Over range protection31. Options: -

(a) Intrinsically Safe Output meter(b) Air Filter Regulator(c) Mounting Accessories(d) 3-way manifold(e) --------------------------

32. Load Capability:-TAGNO.

OPERATINGPRESSURE

MAXIMUMPRESSURE

MAXIMUMTEMPERATURE

RANGE CONTROL

SERVICE

OPTIONS

Span Set

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PRESSURE GAUGES

Units: Flow -> CNG CNG-Kg/Hr Pressure-> Temperature-> oC Level /Length->mm1. Type: -2. Mounting: -3. Dial Size: -

Colour: -4. Case Matl. :-5. Bezel Ring :-6. Window Matl.:-7. Enclosure : -8. Pressure Element :-9. Element Matl.:-10. Socket Material11. Accuracy12. Zero adjustment

13 Connection connection location: -

14 Movement: -15 Diaphragm Seal:-

Typewetted parts material – Element Matl. Lower Boy Matl.Non-wetted parts materials :Process connection: size & RatingFacing & FinishCapability MaterialArmour – Flexible – Matl.capability LengthFlushing / filling connection

16 Over Range Protection:-17 Blow out Protection:-18 Options: (a) Snubber

(b) Syphon (c) Gauge Saver (d) Liquid filled casing (e)-------------------------

TAGNo.

Range OperatingPressure

MaximumServicePressure

MaximumServiceTempe.

Fluid Service Options

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ANNEXURES

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ANNEXURE-1: RECOMMENDED VENDOR LIST

ITEM CODE / DESCRIPTION COALESCENT FILTER / REGULATORSVENDOR NAME REMARKASEA BROWN BOVERI LTD.BLUE STAR LTDPLACKA INSTRUMENTS & CONTROLS PVT.LTDSHAH PNEUMATICSSHAVO NORGREN (I) PVT. LTDV AUTOMAT & INSTRUMENTS PVT. LTD.VELJAN HYDRAIR PVT. LTD.COMPAC NEWZEALANDITEM CODE / DESCRIPTION FIELD INSTRUMENTS (P, DP, F,L,T)VENDOR NAME REMARKSABB AUTOMATION LTD.BROWN BOVERT LTD.FISHER ROSEMOUNT INDIA LIMITEDFISHER ROSEMOUNT SINGAPORE PTE LTD.FUJI ELECTRIC CO. LTD.HONEYWELL INC.ASHCROFTMURPHYCCSTATA HONEYWELLYOKOGAWA ELECTRIC CORPORATIONYOKOGAWA BLUE STAR LTD.WIKADRUCKITEM CODE / DESCRIPTION MASS FLOW METERSVENDOR NAME REMARK

CORIOLIS TYPE,EMERSON PROCESS MANAGEMENT Model CNG 50-2700COMPAC , NEW ZEALAND Model KG 80ITEM CODE / DESCRIPTION PRESSURE GAUGESVENDOR NAME REMARKSAN INSTRUMENTS PVT. LTD.GENERAL INSTRUMENTS CONSORTIUMWAAREE INSTRUMNETS CONSORTIUMGENERAL INSTRUMENTS CONSORTIUMMANOMETER (INDIA) PVT. LTD.WIKA INSTRUMENTS INDIA PVT. LTD.DRUCKITEM CODE / DESCRIPTION PRESSURE RELIEF VALVEVENDOR NAME REMARKSALSTHOM FLUIDS SAPAGANDERSON GREENWOOD CROSBYBHEL (TRICHY )DRESSER INC.FUKUI SEISAKUSHO CO. LTD.INSTRUMENTATION LTD. (PALGHAT)NAKAKITA SEISAKUSHO CO LTD.PARCOL SPASAFETY SYSTEMS UR LTD.SARASIN RSBD

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SEBIN VALVES INDIA PVT. LTD.TAI MILANO SPATYCO SANMAR LTD.TYCO VALVES & CONTROLS INDIA PVT. LTDSWAGELOKPARKERCOMPAC NEWZEALANDITEM CODE / DESCRIPTION SELF ACTUATED PR. CONTROL VALVEVENDOR NAME REMARKDANIEL INDUSTRIES INCDRESSER PRODUITS INDUSTRIESESME VALVES LTD.FISHER ROSEMOUNT SINGAPORE PTE LTD.FISHER EXMOX SANMAR LIMTEDGORTER CONTROLS B.V.INSTROMET INTERNATIONAL NVKEYE & MACDONALD INCNUOVO PIGNONE SPA (ITALY)PIETRO FIORENTINI SPARICHARDS INDUSTRIES (FORMERLYTRELOAR)RMG REGEL + MESSTECHNIK GMBHCOMPAC INDUSTRIES LTD., NZL.ITEM CODE / DESCRIPTION SOLENOID VALVESVENDOR NAME REMARKALCON ALEXANDER CONTROLS LIMITEDJEFFERSONSASCO (INDIA) LIMITEDASCO JOUCOMATIC LTD.ASCO JOUCOMATIC SAPARKER HANNIFIN, USAAVCON CONTROLS PVT. LTD.BARKSDALE INC.BLUE STAR LTD.HERION WERKESCHRADER SCOVILL DUNCAN LIMITEDSEITZ AGCOMPAC NEW ZEALANDITEM CODE /DESCRIPTION SPECIAL CONTROL VALVESVENDOR NAME REMARKFISHER ROSEMOUNT SIGAPORE PTE. LTD.FLOWSERVE PTE. LTD. (FORMERLYDURIRON)HOPKINSONS LIMITEDMETSO AUTOMATION PTE LTD. (FORMERLYNELES)NUOVO PIGNONE SPA (ITALY)SPX VALVES & CONTROLS (FORMERLYDEXURIK )COMPAC IND. LTD. NZLITEM CODE /DESCRIPTION REGULATORSVENDOR NAME REMARKCOMPAC IND. LTD.FISHER ROSEMOUNT SIGAPORE PTE. LTD.

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FLOWSERVE PTE. LTD. (FORMERLYDURIRON)ITEM CODE /DESCRIPTION TWO WAY / THREE WAY VALVESVENDOR NAME REMARKSWAGELOKPARKERCOMPACHAMLETHYLOCKITEM CODE /DESCRIPTION SS FITTINGSVENDOR NAME REMARKSWAGELOKPARKERHAMLETHYLOKITEM CODE /DESCRIPTION SS TUBINGVENDOR NAME REMARKSANDVIKFAEITEM CODE /DESCRIPTION HOSESVENDOR NAME REMARKPARKEREATONITEM CODE /DESCRIPTION BREAKAWAY COUPLINGVENDOR NAME REMARKOPWSTAUBLIWEHITEM CODE /DESCRIPTION FLAMEPROOF GLANDSVENDOR NAME REMARKCOMET/OEM MakeITEM CODE /DESCRIPTION SURGE PROTECTORVENDOR NAME REMARKPHONEXITEM CODE /DESCRIPTION NGV NOZZLESVENDOR NAME REMARKOPWWEHSTAUBLIITEM CODE /DESCRIPTION CABLESVENDOR NAME REMARKCORDS CABLES INDUSTRIESASSOCIATED CABLESKEI INDUSTRIESUNIVERSAL CABLES LTS/OEM Cables

Note:

Above is only recommended vendor list for guidance to bidders. Bidder will be solely responsible for any materialfor quality and compliance to tender specification. Any vendor can be approved at latter stage also based on theirPTR at the sole discretion of IGL. In case of imported kits, foreign cables are acceptable.

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ANNEXURE-2: VENDOR DATA REQUIREMENT

1.0 DRAWING AND DATA REQUIREMENT

1.1 The following data and information marked “X” shall be furnished by the vendor for Car Dispenser:

S. No. Description WithBid

After Job Award

ForReview For Information Final in Book

Form

1 2 3 4 5 6

1.0 GENERAL

1.1 Filled in Material Requisition ComplianceSchedule. X

1.2 Filled in Deviation Schedule. X

1.3

Duly filled up “Experience Record Schedule”.Vendor to note that information furnished by them shallbe used to assess the provenances of offered Dispensersand Qualification of vendor, Accordingly vendor tofurnish references of those cases which are matchingwith offered Dispensers.

X

1.4 Installation manual X X

1.5List of components of Dispenser with Make &Specification of components. Vendor shall also submit“Technical Catalogues” of components

X

1.6Start-up, operation & maintenance manual showingassembly details and critical tolerances. A copy of allcertified drawings & documents to be enclosed.

X X

1.7 Lubricant list with specification X X

1.8 Battery limit (interface) drawing/ information X X

1.9 Drawing list and submission schedule X

1.10 Project implementation schedule, ordering andinspection schedule for long lead and major items X

1.11 Pre-commissioning & commissioning procedure X

1.12 Performance guarantee test procedure X

1.13

Weights & Measures Certificates from the country oforigin for offered models of Car Dispensers unitmodel/mass flow meter model for dispensing specifiedmass flow rate at specified overall batch accuracy.

X X X

1.14 The “Test Certificate” for mass flow meter. X

1.15 Weights & Measures approval from Indian Authorities. X

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1.16 Type approval for the offered dispenser from Petroleum& Explosive safety organization, Govt. of India X X X

2.0 DESIGN

2.1Process flow diagrams (PFDs) and Piping &Instrumentation diagrams (P&IDs) of sub systems andcomplete system with write-up on operation

X X

2.2 Data sheets of Car Dispensers duly filled up. X X X

2.3 Basic design calculations for system design, equipmentselection X X

2.4Performance data, vendor literature for equipmentselection, performance curves with duty point markedfor individual equipment

X X

2.5 Specification for piping material & valves. X X

2.6 Utility requirement X X

2.7Detail of control wiring diagram, interlock/ shutdown/control scheme with write up on operation. Sizingcalculation for instrument items.

X X

2.8 Dispenser communication port details and requirementinformation as per specification and list of signals X X

3.0 CONSTRUCTIONAL FEATURES

3.1 G.A. drawing of Dispensers showing maintenanceclearances required. X X X

3.2 Cross section drawings of individual equipment/ skid,material & parts list. X X

3.3 Termination & Wiring Diagrams X X

4.0 SPARES

4.1 List of spares for two years normal operation per CarDispenser. X

5.0Drawings, documents, data as asked under Electrical &Instrumentation specifications of this MaterialRequisition.

X

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1.2 DOCUMENT DISTRIBUTION SCHEDULE

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

1.2.2 Documents listed under column 4 are to be submitted in 2 copies

1.2.3 Documents listed under column 5 are to be submitted in 2 copies.

1.2.4 Documents listed in column 6 are to be submitted as hard bound indexed book containing the following detailsin Two (2) copies to be submitted within 4 weeks of release note/dispatch of materials/ equipment fromvendor's works.

1.3 DETAILS TO BE INCLUDED IN FINAL DOCUMENTS BOOKS

1.3.1 Copy of P.O. and all amendments.

1.3.2 Copy of Purchase Requisition and all amendments.

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

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

1.3.5 All design calculations carried out by the vendor.

1.3.6 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.

1.3.7 Catalogues/leaflets of sub-vendors/suppliers of various bought out components highlighting the componentsactually supplied correlated to P.O.Item Numbers.

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

1.3.9 Release Note and Packing List.

1.3.10 Any other documents asked for in the Purchase Requisition.

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

1.4 SPECIAL INSTRUCTIONS FOR SUBMISSION OF DWGS./DOCUMENTS:

1.4.1 Contractor to forward the drawings and documentation to IGL (Attention vendor prints control department)clearly specifying purchasers Job no. & Req. No.

1.4.2 The drawing/Document no. with Rev. No. is essential. The number may be upto a maximum of 28 charactersin length.

1.4.3 Each Drawing/Document submitted to IGL must be checked and signed/stamped by contractor before it issubmitted to IGL.

1.4.4 Revision number must change during subsequent submission of vendor document.

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

1.4.6 Final submission in bound volumes shall necessarily have a cover page giving project title, Item name, P.O.No. Particulars of owner & vendor and an index giving list of drawings & documents included (with revisionno.).

1.4.7 All vendor drawings to be provided with a blank space measuring 75 mm W x 38 mm H for marking of reviewcodes etc. by IGL.

1.4.8 The review of the vendor drawings shall be done by IGL, as applicable, under the following review codes:

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Review Code 1/A No comments.

Review Code 2/B Proceed with manufacture/fabrication as per commented drawings.Revise drawings required

Review Code 3/C Document does not conform to basic requirements.

1.4.9 Review of vendor drawings by IGL would be only to check compatibility with basic designs & concepts & wouldin no way absolve the contractor/vendor of his responsibility to meet applicable codes, specifications & statutoryrules/regulations.

1.4.10 Vendor shall submit within 10 days after placement of FOI, the complete list of drawings/ documents withsubmission dates against each. Critical drawings, only, the list of which will be agreed during kick-off meetingshall be reviewed jointly at IGL's office.

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ANNEXURE-3: DEVIATION SCHEDULE FOR CNG DISPENSER

Vendor:

S.No. Vendor to specify Specification number and clausenumber against which Deviation is sought

Description of Deviation and give reasons insupport of Deviation

----------------NO DEVIATION-----------------------------

----------------NO DEVIATION-----------

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ANNEXURE- 4: M.R. COMPLIANCE SCHEDULE

Item: CNG DISPENSERS

Vendor:

S. No. Requirements Compliance By Vendor (To Be AnsweredBy Vendor)

1.0 Confirm compliance individually to following clausesof SpecificationSECTION: 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

Clause no 17.0

Clause no 18.0

Clause no 19.0

Clause no 20.0


SECTION B: Instrumentation & Control Specification

Clause no 1.0

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Vendor:


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 11.0

Clause no 12.0

SECTION C: Electrical Specification

Clause no 1.0

Clause no 2.0

Clause no 3.0

Clause no 4.0

2.0 Confirm that you have filled-up the followingSchedules and enclosed these with the Bid

Experience Record Schedule for Car Dispensers.

Deviation Schedule

Material Requisition Compliance Schedule

3.0 Confirm that you have filled-up the Dispenser DataSheet and enclosed with the Bid.

Dispenser Data Sheet

Mass Flow Meter Data Sheet

Control Valves

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Vendor:


Solenoid Valves

Self Actuated Pressure Control Valves

Pressure Relief Valve

Pressure Instruments

Pressure Gauges

4.0 Confirm that following Documents have been enclosedwith Bid.

Battery Limit (Interface) drawing/ information.

Weights & Measures Certificates from the country oforigin for offered models of Car Dispenser unitmodel/mass flow meter model for dispensing specifiedmass flow rate at specified overall batch accuracy.Type approval for the offered dispenser from Petroleum& Explosive safety organization, Govt. of IndiaG.A. drawing of Dispensers showing maintenanceclearances required.

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ANNEXURE-4: VENDOR DATA REQUIREMENT (INSTRUMENTATION)

S.No. DescriptionDocument Category

Inf. Review As built

1. Drag and Document Schedule * *

2. Piping and Instrument Diagram * *

3. Instrument Index * *

4. Sub- Vendor List for Instruments and Accessories *

5. Instrument Sizing calculations * *

6. Utility requirements *

7. Level Sketches *

8. Material requisition *

9. Purchase Requisition * *

10. Functional schematic * *

11. Logic diagrams * *

12. Instrument loop drawings * *

13. Control room layout * *

14. Panel front arrangement * *

15. Power Supply Distribution * *

16. Wiring diagram for panels * *

17. Configuration diagram * *

18. I/O assignment * *19 Details of OPC, configuration port, signals details etc * *

20. Instrument Duct/Tray layout * *

21 Instrument Cable schedule * *

22 Instrument location plans * *

23 Instrument installation drawings * *

24 Bill of material for installation items * *

25 Spare part list for

(a) 2 years operation *

(b) Start up and commissioning *

(C) Spare instruments (10%) * *

26 Inspection and test procedures * *

27 Complete catalogues with part list for all vendor suppliedinstruments, controls etc * *

28 Installation, operation and maintenance manuals *

Note: This list indicates the minimum drawings and document requirements. However vendor shall submit acomplete list of document and drawing schedule listing all drawings and documents to be submitted by them

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during the course of execution of the job. The schedule shall list all drawings and documents along with theirnumber and expected date of submission.

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PTS - CNG CAR DISPENSERSP.013429D 11077

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ANNEXURE - 6 QUALITY ASSURANCE PLAN

CODING STRUCTURE ManufacturerCodes for Extent of Inspection, Tests & Test Certificates Codes for DocumentsCode Description Code Description Code Description1 Visual 12 Power failure D1 Approved GA Drawing2 Dimensional 13 Failure of metering D2 Approved P&ID3 Fitment & Alignment 14 Failure of totalizer D3 Approved data sheet4 Physical Test 15 Calibration D4 Approved Bill of material5 Chemical Test 16 Pressure test D5 Purchase requisition Customer’s Information6 Running Test 17 Noise & vibration D6 W&M Certificate from country of origin Customer: M/s Indraprastha

Gas Limited, New Delhi(INDIA)Consultant : NoneLOA No.: IGL/ND/datedItem : CNG Car Dispensers

7 Leak Test 18 Enclosure protectiontest

D7 Calibration certificate of all measuring test /instruments and gauges

8 Dispenser shouldautomatically stop incase of failure oftotalizer

19 Paint shadeverification

9 Check for single banksystem

20 Test certificate forbought outcomponents

10 Check for manual shutoff

21 Flow capacity test

11 Batch accuracy test

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DETAILED INSPECTION AND TEST PLAN

EQUIPMENT DETAILS INSPECTION AND TESTS SCOPE OF INSPECTION AND TESTSSr.No

Description Qty. RAW MATERIAL ANDStage Inspection

FINAL INSPECTION Documents forsubmission toIGL/PMC/TPI

Acceptance Criteria Activity byIGL/PMC/TPI

MFR IGL/PMC/TPI

MFR IGL/PMC/TPI

1 DispenserFrame

360 1.2.3.4.5 1.2.3. 1.2.3 D1,D2,D3,D4 Tech. Specs in POReview of documents

2 Mass FlowMeter

720 1.2.3.4.5.15 1.2.3.15 1.2.3.15 D1,D2,D3,D4,D7 D7 & Tech Specs in PO Review of documents

3 Filling hose 720 1.2.3.4.5.16 1.2.3.16 1.2.3.16 D1,D2,D3,D4 Tech. Specs in PO Review of documents4 Totalizer 720 1.2.3.8 1.2.3.8 1.2.3.8 D1,D2,D3,D4,D7 D7 & Tech Specs in PO Review of documents5 Software 1 9 9 9 D3 Tech. Specs in PO Witness6 Pressure

Gauge720 1.2.3.4.5.15 1.2.3.15 1.2.3.15 D1,D2,D3,D4,D7 D7 & Tech Specs in PO Review of documents

7 PressureTransducer


8 Shut off valves 720 1.2.3.4.5.10 1.2.3.10 1.2.3.10 D1,D2,D3,D4,D7 D7 & Tech Specs in PO Review of documents9 Performance

Test (usingCNG)

360 11.21 11.21 11.21 D3,D7 D6, D7 & Tech Specs in PO Witness

10 Dispenserresponse

360 12.13.14.17.19.20

12.13.14.17.19.20

12.13.14.17.19.20 D3,D7 D7 & Tech Specs in PO Witness

Note:1. The Above Testing and acceptance criteria are minimum requirements, however, manufacturer shall ensure that the product shall also comply to the

additional requirements as per Particular Technical specifications(PTS)2. Owner/Owner representative shall review/approve all the documents related to QAP/Quality manuals/Drawings etc. submitted by supplier.3. All reference Codes/ Standards, Documents, P.O. Copies shall be arranged by vendor / supplier for reference of TPIA/IGL at the time of Inspection4. At the time of delivery of material in stores, vendor will submit copy of all related document of inspection along with release note & MTC.5. TPI/PMC/IGL have right to inspect minimum 10% of all manufacturing activities as specified above

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PTS – CAR CUM BUS DISPENSERSP.013429D 11077

010

INDRAPRASTHA GAS LTD.SUPPLY, INSTALLATION, COMMISSIONING &

COMPREHENSIVE MAINTENANCE OF CNGDISPENSERS

PTS – CAR CUM BUS DISPENSERS

A 29.01.2020 Issued for Approval GG SHD AR

Rev. Date Description Prepared By Checked By Approved By

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SECTION – A GENERAL SPECIFICATION ......................................................................................... 1

SECTION – B INSTRUMENTATION & CONTROL SPECIFICATION .................................................. 14

SECTION – C ELECTRICAL SPECIFICATION .................................................................................. 23

SECTION - D MECHANICAL SPECIFICATION ................................................................................. 26

DATA SHEET - CNG DISPENSER FOR CAR ..................................................................................... 30

DATA SHEET - MASS FLOW METERS (CORIOLIS TYPE) FOR CAR DISPENSER ............................. 31

DATA SHEET - CONTROL VALVES .................................................................................................. 32

DATA SHEET - SOLENOID VALVES ................................................................................................ 33

DATA SHEET - SELF ACTUATED PRESSURE CONTROL VALVES ..................................................... 34

DATA SHEET - PRESSURE RELIEF VALVES .................................................................................... 35

DATA SHEET - PRESSURE INSTRUMENTS..................................................................................... 36

DATA SHEET - PRESSURE GAUGES ............................................................................................... 37

ANNEXURE-1: RECOMMENDED VENDOR LIST…….……….….……………………..………………………41

ANNEXURE-2: VENDOR DATA REQUIREMENT ............................................................................... 42

ANNEXURE-3: DEVIATION SCHEDULE FOR CNG DISPENSER ....................................................... 46

ANNEXURE- 4: M.R. COMPLIANCE SCHEDULE............................................................................... 47

ANNEXURE-5: VENDOR DATA REQUIREMENT (INSTRUMENTATION) .......................................... 50

ANNEXURE -6: QUALITY ASSURANCE PLAN .................................................................................. 52

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TABLE OF CONTENTS

SECTION - A

1.0 SCOPE ................................................................................................................................... 2

2.0 INSTRUCTIONS TO VENDOR ................................................................................................ 2

3.0 SCOPE OF SUPPLY & SERVICES FOR NUMBERS CAR CUM BUS DISPENSERS ........... ERROR!BOOKMARK NOT DEFINED.

4.0 DESIGN & ENGINEERING. .................................................................................................... 5

5.0 EXCLUSION .......................................................................................................................... 6

6.0 EXPERIENCE RECORD SCHEDULE FOR DISPENSERS........................................................... 6

7.0 DESIGN BASIS ...................................................................................................................... 7

8.0 TECHNICAL SPECIFICATIONS FOR CAR CUM BUS DISPENSER ........................................... 8

9.0 DATA SHEETS ..................................................................................................................... 10

10.0 CLIMATIC CONDITIONS ..................................................................................................... 10

11.0 UTILITY SPECIFICATION ................................................................................................... 10


13.0 VENDOR DATA REQUIREMENT ........................................................................................... 12

14.0 DEVIATION SCHEDULE....................................................................................................... 12

15.0 MATERIAL REQUISITION COMPLIANCE SCHEDULE .......................................................... 12

16.0 PACKAGING ........................................................................................................................ 12

17.0 ON SITE TRAINING ............................................................................................................ 12

18.0 TRAINING TO IGL PERSONNEL AT VENDOR'S SHOP ......................................................... 12

19.0 COMMISSIONING OF DISPENSERS ................................................................................... 12

20.0 COMPREHENSIVE MAINTENANCE ...................................................................................... 12

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SECTION: A

GENERAL SPECIFICATION

1.0 SCOPE

1.1. The intent of this technical specification is to outline the Purchaser's requirement under which the vendorshall Design, Engineer, Manufacture, Inspection & Testing at Works, Painting, Packaging & forwarding,Supply to Sites/Stores, Installation & Commission and Performance Testing at Vendor’s works and Sites ofCNG Car Cum Bus Dispensers complete with all auxiliaries & Compatibility/capable for communicating withany third party devices, required for efficient & safe operation, in accordance with this specification, datasheets & other enclosures of this Material Requisition.

1.2. The Car Cum Bus Dispensers shall be complete including any/ all required auxiliary equipment/ systems forefficient & safe operation as a whole. Vendor shall be responsible for furnishing all electrical/ electronics,instrumentation, inter connecting piping & safety Items as required to make the Dispensers complete.

1.3. It is not the intent of Purchaser to specify every piece of equipment/item but nevertheless any item notspecifically mentioned but required as per Good Engineering Practice and for the safe & trouble free operationof the dispensers deemed to have been specified & shall be in the scope of Vendor without any implicationin the price or schedule.

2.0 INSTRUCTIONS TO VENDOR

2.1. M/s IGL is expanding its CNG refilling outlets in the National Capital Region (NCR) and National Capitalof Territory (NCT) of Delhi (India). The dispensers shall be installed at various refuelling outlets throughoutNCT as well as in the NCR for dispensing CNG to all types of smaller Natural Gas Vehicles.

2.2. The dispensing stations shall be spread throughout NCT of Delhi & NCR.

2.3. The specification states the scope of supply and services as completely and clearly as possible. Any additionalwork/equipment or technical requirement not mentioned in the specification but required to make the offeredsystem complete in accordance with the specification or required for safe operation shall be deemed to beincluded in the scope of vendor.

2.4. Vendor may contact and obtain from IGL clarifications, if required, at any stage, before submission of offer.

2.5. The offered dispenser units' model shall have certification for specified flow and accuracy from the Weights& Measurement Department of the country of origin. In case it is not available for dispenser unit then offeredmass flow meter model shall have certification for specified flow and accuracy from the Weights &Measurement Department of the country of origin. The certificate(s) shall be in English language or in thelanguage of originating country along with English translation. Bids received without copy of suchcertificate(s) shall be liable to be rejected. Vendor to arrange for Weights and Measures approval from IndianAuthorities. The dispenser model has to be type approved by the Indian Weights & Measurement Department.Further manufacturing license, dealer of weights & measures, importer (where ever applicable) and licenseto repair by the bidder is mandatory at the time of bid due date.

2.6. The offered dispensers for dispensing CNG shall be type approved by the Petroleum & Explosive safetyorganisation, Govt. of India as per latest Gas Cylinder Rules. If the vendor is yet to get the dispenser modeltype approved, the vendor shall have to give the model type approved as on bid due date.

2.7. The Vendor shall carry out modification required by the statutory bodies either during the approval or duringinspection of the installation. All expenses shall be done and borne by the vendor. Unless the above formalitiesare cleared, supply part would be deemed incomplete.

2.8. The Vendor shall provide civil foundation/ dispenser frame drawings within two weeks of placement of order.

2.9. Any work, which is considered to be unsatisfactory and of poor workmanship shall be rectified by the vendorwithout any extra cost and time implications.

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2.10. The approval from concerned Govt. Bodies in respect of complete installation of a CNG Dispensing Stationshall be obtained by the IGL. Necessary Information/Data as may be required by Govt. Bodies shall befurnished by vendor to facilitate IGL in obtaining approval.

3.0 SCOPE OF SUPPLY & SERVICES FOR CAR CUM BUS DISPENSER

3.1. Supply of Car Cum Bus Dispenser of double arm type having flow capacity of ≥ 15 kg/min and ≥ 75 kg/minrespectively, under discharge to atmospheric condition. Each Car Cum Bus Dispenser shall have followingas a minimum:-

3.1.1. For Car End -

One CNG flexible electrically conductive twin (fill & vent) hose, with both hoses fitted with NGV-I forfilling of vehicles. However, both the hoses shall be suitable to be attached with NZS-5425 nozzles. Vendorshall include the supply of 3-way valve with each hose for filling & venting of gas. Vendor shall also includesupply of Breakaway Coupling, suitable for NGV Industry, in the hose. Hose shall be 3/8” ID 5000 psig, atleast 3m long. Vendor shall demonstrate the function of breakaway coupling during performance test. Thedispensers shall be designed in such a way that free movement of hoses is possible, by spring loaded highmast. Supply of NZS 5425 nozzles is excluded from bidders’ scope.

For Bus End -

One CNG flexible electrically conductive twin (fill & vent) hose, with both hoses fitted with One Sherex CT-5000 (with captive vent) transit fill nozzle include the supply of 3-way valve for filling & venting of gas.Vendor shall also include supply of Breakaway Coupling, suitable for NGV Industry, in the hose. Hose shallbe 1/2” ID 5000 psig, at least 3m long. The end connection of main and vent hose shall be SAC (JIC) 37 deg.female swivel 1 1/16”-12 UNF. Vendor shall demonstrate the function of breakaway coupling duringperformance test.

3.1.2. Two numbers of Coriolis true mass flow metering system.

3.1.3. Three rows of liquid crystal backlit display for night viewing showing total sale in Rupees (00000.00),quantity of gas sold in kg (00000.00), unit price of CNG in Rs/kg (000.00) for each hose on either side of thedispenser (total two sets of three rows for each Dispenser, one display for each side). The whole dispenserelectronic unit shall have IP - 65 protection and display cabinet shall have IP 54 protection.

3.1.4. Non-resettable and non-volatile totalizer up to 999999.99 for total CNG sold in Kg with an independentbattery backup. For further details refer Section B: Instrumentation & Control specification.

3.1.5. One number of three banks electronic software and controller including hardware for car dispensing and onenumber of single bank electronic software and controller including hardware for Bus Dispensing

3.1.6. Two numbers of holster/ cradle for fill nozzles along with weather caps for the protection of nozzles. Holster/cradle shall be suitable for both NZS and NGV nozzles. Holster/cradle shall be provided for NGV nozzle andshall be compatible to be attached with NZS-5425 nozzles. Supply of NZS 5425 is excluded from bidder’sscope.

3.1.7. Two number of Hi-mast with flexible hose arrangement so that the hose doesn’t touch the ground

3.1.8. Emergency stop switch is required on both side of the dispenser. However, the filling on both sides shouldstop in emergency condition, when any one of the emergency switch is pressed. During activation ofemergency switch, the power supply to the dispenser should be available.

3.1.9. Two nos. of liquid filled 4” dia. (0-400 Kg/cm2g) pressure gauges showing the vehicle filling pressure foreach filling arm.

3.1.10. Two Nos. bubble tight manual shut-off valve for fill hose.

3.1.11. One Stainless Steel body of cabinet thickness 1.6 mm with door/panel, along with powder coating as per IGLcolour scheme.

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3.1.12. Vendor has to supply the dispensers with solenoid operated valve made of ANSI 316 SS, for ON-OFF controlof flow, on the gas inlet with 3/4” tube OD end connection. Valves shall be provided for each bank per hoseseparately. Vendor to ensure the system design in such a way that any gas if passes, should be recorded bydispenser and there should not be any possibility of unmetered gas supply through dispenser in case ofmalfunctioning of solenoid valves. Air actuated valves are not acceptable.

3.1.13. The gas tubing inside the dispensers shall be seamless SS 316 fully annealed (Bright Annealed) conformingto ASTM A 269 with maximum hardness of RB 80 or less and suitable for bending and flaring. The tubesshall be fully annealed (bright annealed), ½” & 3/4” OD with a ½” & 3/4” SS 2-way Ball valve at inlet and½” & 3/4” OD end connection suitable for connecting with ½”& 3/4” OD SS Tube respectively to Car side& Bus Side. Any open ends on fittings and vents shall be provided with caps/ dust plugs.

3.1.14. Coalescent and particulate filter of Grade 6 or better to be provided at inlet of each bank supply line withmanual drain valve to ensure that the oil carryover in the CNG being filled to vehicle is < 5 ppm and particulatesize is < 2 Micron. Filter housing for said filter must be capable for collection of oil for a drain interval of 24hrs with oil carryover < 5 ppm. Filter elements made of paper shall not be accepted. Vendor to provideappropriately plugged drain valve outside the dispenser housing with suitable arrangement to collect thedrained oil. Filter size shall be in accordance with max flow through the dispenser. Filtration efficiency shallnot be less than 95%.

The CNG specification should meet the ISO 15403:2000 (E) or IS: 15958 natural gas quality designation foruse as a compressed fuel for vehicles.

3.1.15. Vendor shall ensure that the system design in such a way that any gas if passes, should be recorded by massflow meter and there should not be any possibility of unmetered gas supply through dispenser in case ofmalfunctioning of solenoid valves. Any unmetered gas passing shall be recorded in the dispenser is retrievableas and when required. Vendor shall also provide surge protection device of approved make at 230 V AC inpanel room to protect the dispenser from any electrical surge/spike.

3.1.16. Any other item required for safe and accurate operation of Dispenser.

3.1.17. Any spare(s) required during commissioning shall be in the scope of vendor.

3.1.18. Supply of complete O&M manual (along with instruments datasheet & schedule, bill of materials, instrumenthook-up diagram, electrical wiring diagram, control logic algorithm & flowchart and certificates & user guideof bought out items) for each dispenser for easy operation & trouble shooting.

3.1.19. Supply of manual for list of error codes with description for programming the dispenser parameter.

3.1.20. If dedicated programming unit is required for programming/ parameter change. The same shall be submittedin “CD” along with supply of dispenser also hard copy of the same also be submitted.

3.1.21. Supply of GA drawings & documents along with bid.

3.1.22. Instrumentation & Electrical items specified in section B & C of the Job Specification. All electricalequipment shall be supplied with Approved type of cable glands tested & certified to be used in hazardousarea classified as Zone-I.

3.1.23. On-Site Training to IGL personnel (Three days each for three separate groups).

3.1.24. Training to IGL personnel at vendor's shop (10 personnel for three working days). The travelling, boarding& lodging of IGL’s Engineers shall be borne by IGL. The training module shall cover the equipmentconstruction features, operational & maintenance procedures, practical hands on experience on assembling,dismantling. etc.

3.1.25. Vendor shall make a provision to change the price of CNG through the keypad inside the dispenser unit thatshall be covered with security lock. It shall also be possible to change the price from remote station (fromSCADA/ from any part of the city). RS 485 port shall also be provided for price change. In case standardRS485 port is not available in the dispenser, then RS232C to RS485 convertor with all relevant hardware andsoftware to be provided by vendor.

3.1.26. RS 485 serial port shall be provided for downloading the CNG sale data with the help of Purchaser's PersonalComputer for each shift (8 hours interval). In case standard RS485 port is not available in the dispenser, then

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RS232C to RS485 converter with all relevant hardware and software to be provided by vendor. Suitablesoftware shall be provided to obtain the same for each shift (8 hours interval).

3.1.27. Vendor shall provide a common processor and open communication protocol/ RS 485 port for RTU to transferall the dispenser data to central SCADA system. In case standard RS485 port is not available in the dispenser,then RS232C to RS485 converter with all relevant hardware and software to be provided by vendor.

3.1.28. Vendor must note that non-standard/ propriety type communication protocol in dispenser for communicationwith RTU is not acceptable. Protocol must be standard as specified above or any standard protocol withcompatible convertor shall be made available and must be compatible to any make of RTU. RTU will haveSerial communication port RS 485 protocol to interface with dispenser. Vendor is responsible to provide thecommunication port compatibility with RTU. Vendor is required to carry the communication port functionaltest and display all the values in Lap top or in applicable device during dispenser inspection (FAT) at vendorpremises. Also functional test shall be carried out by vendor after installation and looping is junction box atsite. Vendor shall also share the dispenser protocol/RS485 details with IGL during FAT at vendors works andsubmit relevant documents in desired format (both hardware/ software)

3.1.29. Contractor must furnish/ share the details of implemented MODBUS/RS485 protocol like function codes forread and write, slave ID, list of signals to be transferred, CRC implementation, register addressing methods /mapping etc with M/s IGL and provide their assistance during interfacing with RTU to automation vendor.Vendor must provide looping details and number of dispensers connected in one loop.

3.1.30. Dispenser vendor shall loop (multidrop) all the dispensers in common junction box per station in the safearea. Supply of Communication Cables, cable glands, termination of cable and cable laying from dispenserto junction box is in dispenser Vendor’s scope. Supply of standard make, WP IP 42 junction boxes, terminalblocks and installation of junction box shall be is in dispenser Vendor’s scope. Junction box shall have 8inputs cables entry points (side) and two outgoing entry points including spare (bottom), cable entry from topis not accepted, size of junction box to be decided by vendor. All the spare entry shall be plugged properly.Vendor shall be responsible to provide all the signals at the junction box which will be connected to RTU.During installation & commissioning of dispenser same will be checked by IGL’s Engineer.

3.1.31. Communication cable is single pair (1Px 1.5mm2), multi strand, armoured cable with HR PVC insulation andPVC st2 inner and outer sheath. Tentative cable length form each dispenser to junction box is approx. 50meters, however vendor shall provide cable length as per requirement.

3.1.32. Vendor must share junction box termination details with IGL. Vendor shall Loop all the dispensers in junctionbox and looping shall be ring type or re-loop so that is case of communication break or physical loop breakthen only faulty dispenser should isolate, all others dispensers remain connected and continue to report.

3.2. Vendor must submit the following documents within 2 weeks of placement of LOI/ PO for review andapproval of IGL:a) Detailed project schedule giving all activities such as Design and review, Major bought out items (such

as Mass flow meter, electronics, Valves, Hoses etc.), Sub-assemblies, Stage inspection, Final Assembly,Final factory testing of dispensers, Final inspection, dispatch etc.

b) Process and instruments diagram (P&ID) of gas flow giving Bill of Material. The Bill of Material shallclearly indicate all items, quantity of all items installed per dispenser, make and part number etc.

c) Certification from Weights and Measures department, PESO Department or other statutory authorities ofthe country of origin for offered model dispenser for specified flow and accuracy.

4.0 DESIGN & ENGINEERING FOR DISPENSER

4.1. Design & engineering4.2. Manufacturing & Assembling4.3. Procurement from Sub-vendors.

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4.4. Inspection & Testing at Works.4.5. Documentation and obtaining statutory approvals from the country of origin.4.6. Packing, Forwarding and Transportation up to Job Sites/IGL's stores.4.7. Testing and commissioning, after site installation, of each Dispenser, individually.4.8. Submit/ apply for obtaining type approval for the offered dispensers from Petroleum & Explosive Safety

Organisation, Govt. of India as per the provisions of Gas Cylinder Rules, 2016.

5.0 EXCLUSION

5.1. Civil Foundation/ Mounting Frame

5.2. Trenches for pipes

5.3. Erection of Dispensers

6.0 EXPERIENCE RECORD SCHEDULE FOR DISPENSERS

Sr. No. Parameter Information onoffered Model

Information on existing dispenser

1 2 3 4 5 6 7 8 9 10

1. Number of Units

2. Fluid handled CNG

3. Gas molecular weight range

4. Site min/max temp.

5. Dispenser rated flow

6. Dispenser overall Cv

7. Dispenser batch accuracy %

8. Dispenser with temperatureCompensation Yes

9. Number of Hoses Twin

10. Mass flow meter make/model.

11.Where dispenser is located:Address and fax/telephonenumber of contact person.

12. Any other information onInstallation

13. Date of commissioning ofDispenser

14. Number of hours completed as onbid due date.

15. Major problems encountered, ifany

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7.0 DESIGN BASIS FOR DISPENSER

7.1 Area Classification

For details refer Electrical Specification at section-C attached with this Specification.

7.2 Codes and Standards

Following Codes and Standards are referenced to and made part of this Material Requisition.

NFPA52 Standards for CNG Vehicular Fuel Systems

NGV 4.1/AG.A 2-92 Requirements for CNG Dispensing Equipment for Vehicles

NGV 4.2/AG.A 1-93 Requirements for Hoses for NGVs and Fuel Dispensers.

ANSI/NGV1 Compressed Natural Gas Fueling Connection Devices Standard for fuelingnozzles and receptacles.

NGV 4/AG.A Requirements for Breakaway Devices for CNG Vehicle Fuel Dispensers andFueling Hoses

AG.A 2-90 Compressed Natural Gas Fueling Appliances.

AG 901 Code of practice for NGV refueling stations.

IS 5572 Classification of hazardous areas (other than mines) for electrical installations.

IS 5571 Guide for selection of electrical equipment for hazardous area.

OISD 113 Classification of areas for electrical installations at hydrocarbon processing andhandling facilities.

OISD 179 Safety requirements of compression, storage, handling and refueling of CNGfor use in Automotive sector.

OIML TC8/SC7 Recommendation with regards to CNG dispensers, December 2000.

The Standards of Weights and Measures Act 1976.

The Standards of Weights and Measures (Enforcement) Act, 1985.

The Consumer Protection Act, 1986.

The Standards of Weights and Measures (General), Amendment Rules, 2005 –Part X (Compressed Gaseous Fuel (CNG) Measuring Systems for Vehicles

Any other Codes & Standards mentioned elsewhere in this Specification/MR. or which are required to becomplied with as per the prevailing Government of India regulations shall also be followed.

7.3 Precedence

In case of any conflict between Job Specification & other documents, the following order of precedence shallapply:

· Data sheets.

· Particular technical Specifications (PTS)

· Indian Standards/Codes as applicable, International Standards/Codes as applicable.

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7.4 Gas Compositions to Be Handled by Dispensers:

GAS COMPOSITION

Normal Gas Composition Design Gas Composition

C1 82.43 – 99.10 89.45

C2 7.27 – 0.90 4.58

C3 3.47 – 0.00 0.83

I C4 0.65 – 0.00 0.07

N C4 0.78 – 0.00 0.06

I C5 0.17 – 0.00 0.09

N C5 0.13 – 0.00 0.28

C6 0.10 – 0.00 0.17

C7 0.00 – 0.00 0.00

CO2 4.93 – 0.00 4.38

N2 0.06 – 0.00 0.10

H2O 0.01 – 0.00 0.00

Total 100 100

Average C.V.(kcal/SCM)

8950 – 8150 8302.3

Apart from Gas composition, the proposed specification of the CNG is as follows:

Gas Temperature : -10ºC to +70ºC

Oil Content : 10 PPM

Particulate matter : Less than 5 microns

Odorant : ≤10 mg/sm3 (Ethyl Mercaptane).

The CNG specification should meet the ISO 15403:2000 (E)/ IS: 15958 natural gas quality designation foruse as a compressed fuel for vehicles.

7.5 Safety

7.5.1 All Electrical devices shall meet the requirement for the area classification specified elsewhere in tenderdocument.

7.5.2 Tubing & other devices shall be so arranged that there is proper access for operation & maintenance.

7.6 Location

All the Dispensers shall be suitable for Outdoor installation without roof/shed.

8.0 TECHNICAL SPECIFICATIONS FOR CAR CUM BUS DISPENSERS

8.1. The specifications described herewith are intended to give vendor the technical & operating conditions theDispenser must fulfil. These are to be referred along with relevant description including in earlier sections.Vendor may indicate in his bid, the additional features, which his dispenser has in terms of better design,enhance reliability etc., however such feature may be accepted subject to IGL's review and approval.

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8.2. The specifications of FLOW METER are described under Instrumentation & Control Specification Section-B attached with this Specification.

8.3. The Car & Bus dispensers shall be designed to handle flow rate of ≥ 15 kg/min and ≥ 75 kg/min respectively,under discharge to atmospheric condition. The dispensers shall be suitable for a turn down of not less than50:1 on flow.

8.4. Dispensers shall be based on three banks sequential filling. The sequential panel shall be within the cabinetof the dispenser itself and not as a separate unit. Sequencing should be on flow rate and pressure.

8.5. The normal operating pressure of CNG at dispenser inlet shall be 250Kg/cm²(g). However, supply fromdispenser to the Car & Bus shall get positively cut off at outlet pressure of 200 Kg/ cm² (g) to ensure thesafety of the vehicle.

8.6. Once the particular-cycle of filling has been completely stopped (on achieving the maximum fill pressureand/or minimum flow rate) then next filling can be started only after initialization.

8.7. The normal operating temperature of wetted parts of dispenser shall be (-) 10 °C to 55°C.

8.8. The Dispenser shall automatically and immediately shut-off CNG supply to fill hose individually (with errorcodes for diagnose) in case of:

· Power failure or excursion beyond permissible limit.

· Loss of display

· Power failure of mass meter (Provided with Single Error code for Power failure in Mass meter).

· Failure for metering

· Flow beyond high and low limits

· Failure of totalizer

· Overfill by quantity and/or pressure

· Failure of pressure sensing transmitter

· Malfunctioning / Passing of electro valve

· Repeated operation of reset or start/ stop switch as per IGL customization.

· Removal of any electrical wire connected to controller.

· Program step is in hold due to any error.

8.9. Cabinet

8.9.1. Complete cabinet shall be of Stainless Steel (SS-304) with appropriate powder coating as per IGL schemeand shall have tamper proof locking arrangement. Cabinet wall thickness shall not be less than 1.6 mm.Cabinet shall be sized to accommodate all electrical, electronic and mechanical components for metering anddisplay within the cabinet. Cabinet shall be designed to protect all tubing, pressure gauges, valves, fittings,electrical & electronics item from tampering, rain, dust, vermin etc. Dispenser cabinet shall be provided withadequate size bottom opening for the entry of gas supply line/lines and power supply connections. Adequateventilation shall be provided so that there is natural convection current and cooling takes place inside. Cabinetshall be structurally robust and should not resonate at the frequencies emanated during normal flow or duringchoked flow through the nozzles, breakaway coupling or valves etc.

8.9.2. Appropriately plugged drain valves of the filter outside the dispenser housing with suitable arrangement tocollect the drained oil to facilitate the operator to drain the oil on regular basis without requiring to open thelock of the dispenser cabinet. The layout of tubing and other component should be such that it givesunhindered access to all parts and maintenance becomes easy.

8.9.3. IGL's Logo and name to be displayed on both sides of dispensers, in IGL approved colour scheme. IGL'sLogo and name shall be painted on stainless steel panel with an appropriate coloured background oralternatively, vendor shall provide self-adhesive PE film sheet with IGL's Logo and name. The artwork shall

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be of three colours. The colours, Logo size and name size shall be informed to successful bidder duringdetailed engineering.

8.9.4. The dispensers shall be shipped in fully wired and assembled condition. Only gas and power supplyconnection shall be made at Site.

8.10. Spring Type Hi-Mast shall be of appropriate height and shall allow free movement of flexible hose, preventstrain on the fill hose connection and avoid touching of ground.

8.11. Fill Hose & Fill Nozzle

8.12. Two CNG flexible electrically conductive twin (fill & vent) hose shall be included for supply of Dispensersmeeting the requirement of NFPA-52 and NGV 4.2. (As per specification & make provided in point no.3.1.1)

8.13. One fill hose shall be fitted with NGV-I for filling of vehicles. The nozzle shall meet the requirements ofNGV-1 Type-2, Class B nozzle (As per specification & make provided in tender doc). Vendor shall includethe supply of 3-way valve with each hose for Filling & venting of gas. Vendor shall also include supply ofBreakaway Coupling, suitable for NGV Industry, in the hose (As per specification & make provided in tenderdoc). Hose shall be 3/8” ID 5000 psig, at least 3 m long. Vendor shall demonstrate the function of breakawaycoupling during performance test.

8.14. One CNG flexible electrically conductive twin (fill & vent) hose, with both hoses fitted with One Sherex CT-5000 (with captive vent) transit fill nozzle include the supply of 3-way valve for filling & venting of gas.Vendor shall also include supply of Breakaway Coupling, suitable for NGV Industry, in the hose. Hose shallbe 1/2” ID 5000 psig, at least 3m long. The end connection of main and vent hose shall be SAC (JIC) 37 deg.female swivel 1 1/16”-12 UNF. Vendor shall demonstrate the function of breakaway coupling duringperformance test

8.15. Designing of the dispensers would take into account severity of service. The dispensers shall be designed insuch a way as to operate in cyclic (start, fill, stop, start.) round the clock basis with about 1 minute (typical)interval between stop and start modes. The dispenser also to work satisfactorily when the time between stopand start is indefinitely high, e.g. during lull time or when the dispenser is commissioned after it wasdecommissioned for prolonged period or in storage after initial commissioning. For this purpose if anyspecific storage facility is required, the same to be indicated by the bidder.

8.16. Dispensers should be ergonomically designed.

9.0 DATA SHEETS

Vendor shall fill up data the as per enclosed Data Sheet, attached with this job specification and submit alongwith bid.

10.0 CLIMATIC CONDITIONS

10.1. Wind Velocity : 160.0 Km/Hr

10.2. Minimum ambient temperature : 1.0 ºC

10.3. Maximum ambient temperature : 49 ºC

10.4. Maximum relative humidity : 98% non-condensing

10.5. Maximum shed temperature : 47.5 ºC

All the Dispensers shall be suitable for outdoor installation without roof / shed.

11.0 UTILITY SPECIFICATION

11.1. Electric Power Supply

Single phase, AC, 230 Volts ± 10%, 50Hz ± 3% will be provided by IGL. Surge protector is to be providedby the vendor at the 230 VAC inlet. All instrument (such as mass meter, solenoid, pressure transmitter/ switch

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etc.) power supply shall be as per approved OEM design. Suitable voltage conditioning unit shall be in thescope of vendor wherever required.

Note: Vendor to confirm that supplied dispensers are suitable with the above power supply. Vendor toinclude suitable voltage conditioning unit in their scope, if required.

For further details refer Electrical Specification, Section-C, attached with this job specification.


12.1 At Vendor's Works

All the dispensers shall be subjected to Inspection (“Stage wise” if required by IGL) by IGL's or theirAuthorised Representative

12.1.1. The following activities shall be covered under inspection:

· Review of Q.A. documents.

· Review of calibration certificates for flow meter, dispenser, pressure transmitters, pressure gauges andall instruments.

· Review of all statutory certificates including W &M, type approval from PESO, Govt. of India.

· Review of area classification compatibility of all items including bought out items.

· Review of Mill Test reports.

· Review of NDT reports.

· Review of bought out sub-assemblies/major components, test/inspection certificates.

· Dimensional checks as per approved drawings and data sheets.

· Safety shutdown of dispensers.

· Immediate cut off of dispensers due to abnormalities.

12.1.2. Functional Test

All the dispensers shall be tested to demonstrate the functioning of all the components and controls.

12.1.3. Performance Acceptance

All the dispensers shall be performance tested for flow capacity, measuring accuracy and dispenserfunctioning with CNG/Nitrogen. CNG/Nitrogen shall be arranged by vendor.

12.1.3.1. During the shop test of dispenser, in case the dispenser flow capacity from inlet of dispenser to the outlet offilling nozzle is found below the specified capacity the dispenser shall stand rejected.

12.1.3.2. During the shop testing if the dispenser batch accuracy is found beyond ± 1.5% dispenser shall stand rejected.

12.2 At IGL Sites

All the dispensers shall be tested by vendor for their function & performance in presence of IGL authorisedrepresentative. Any part or components, which are not functioning to the satisfaction of IGL, shall be repairedor replaced by the vendor without cost & time implication to purchaser and performance test again carriedout.

12.3 Performance Guarantee

12.3.1 The vendor shall guarantee the satisfactory performance of each dispenser as per the operating parametersindicated in data sheets. The dispensers shall be performance tested after installation at site by vendor. Vendorshall carry out tests as required by Govt. Statutory Agencies.

12.3.2 Guaranteed Performance for the Dispensers shall be as follows:

· Flow Rate (≥ 15 kg/min for Car end and ≥ 75 kg/min for Bus end)

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· Batch Accuracy of + 1.5%.

Note:

1 All the dispensers shall be tested by Vendor for their fuction & performance in presence of IGL authorisedrepresentative.

2 Any part or component, which is not functioning to the satisfaction of IGL, shall be repaired or replacedby the vendor without cost & time implication to purchaser and performance test shall be carried out allover again.

3 Vendor to execute performance test of all the dispensers after commissioning for accuracy andrepeatability and safety parameters.

4 Vendor to make all arrangements for carrying out performance test viz. Std. Mass Flow Meter, Laptopetc. Vendor shall also carry out tests as required by Govt. statutory agencies.

13.0 VENDOR DATA REQUIREMENT

Vendor data requirement shall be as per attached specification Annexure-2.

14.0 DEVIATION SCHEDULE

A typical format of Deviation Schedule is attached at Annexure-3. Vendor shall categorically specify thedeviation they have on entire material requisition in above format and sign & stamp each sheet and submit italong with bid. In case vendor has no deviation, even then they should write "No Deviation" on this deviationschedule and submit it along with bid. This is an essential requirement, the bid should accompany DeviationSchedule.

15.0 MATERIAL REQUISITION COMPLIANCE SCHEDULE

A typical format of Material Requisition Compliance Schedule is attached at Annexure-4. Vendor shallcategorically confirm the requirements in above format and sign & stamp each sheet and submit it along withbid. This is essential requirement; the bid should accompany Material Requisition Deviation Schedule.

16.0 PACKAGING

The dispensers shall be packaged to withstand rough handling during ocean shipment and in-land journey. Itshall be vendor's responsibility to make good any deterioration that occurs during shipment. Sling points shallbe clearly indicated on crates.

17.0 ON SITE TRAINING

Vendor shall provide 3 days of training to 3 separate groups of IGL personnel.

The details of Training Program shall be finalized with purchaser after award of order.

18.0 TRAINING TO IGL PERSONNEL AT VENDOR'S SHOP

Vendor shall provide adequate training to IGL personnel (10 personnel for three working days). Thetravelling, boarding & lodging of IGL’s Engineers shall be borne by IGL. The training module shall coverthe equipment construction features, operational & maintenance procedures, practical hands on experienceon assembling, dismantling etc. The details of Training Program shall be finalized with purchaser after awardof order.

19.0 COMMISSIONING OF DISPENSERS

Vendor shall carry out commissioning of Dispensers within 3 days of receipt of intimation from IGL.

20.0 COMPREHENSIVE MAINTENANCE

Vendor to include five years comprehensive maintenance of all the Dispensers. The start/ commencement ofthe one plus four years comprehensive maintenance shall be after successful testing, commissioning andcommencement of commercial operation of the dispenser. Contractor to submit the organogram of the

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maintenance team on receipt of the order. This maintenance shall include all spares (flow meter, electroniccards etc.), manpower & consumables (except electric power).

· Contractor to furnish the list of consumables required for normal operation of the dispensers and the timeinterval between change of the consumables like filters, valve repair kit for both solenoid valve, 2 way& 3 way valves, breakaway coupling, display, reset switches etc.

· The Contractor has to provide scheduled maintenance details and list of normal operation spares requiredfor operation & maintenance along with bid. The bidder should also maintain sufficient spares forbreakdown & scheduled maintenance. However, IGL can check/ audit spare stock and vendor has toensure availability of required spares for next 6 months operation.

· The contractor has to replace coalescent filter at least once every year during comprehensive maintenanceperiod.

· If any damage is caused to the dispenser by third party, required spare will be provided by IGL aftermutual agreement.

For comprehensive maintenance, the penalty per dispenser per instance in case of breakdown beyondstipulated time frame reckoned from time of complaint lodged would be as mentioned in volume I of II.

A Log Book for time records shall be maintained in the central Control Room (Vendors) wherein the recordsshall be made for the time dispensers develops trouble and the time at which the trouble is rectified bycontractor’s maintenance staff and dispenser put back to service.

Statutory compliances like calibration of safety relief valve, PT, PG etc. will be in vendor’s scope forcomprehensive maintenance duration and shall be done minimum once in a year.

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Rev.A Supply of CNG Dispensers for CGD Project Page 14 of 53

TABLE OF CONTENTS

SECTION – B

1.0 SCOPE ................................................................................................................................. 15

2.0 BID PROPOSAL ................................................................................................................... 15

3.0 DESIGN PHILOSOPHY ........................................................................................................ 16

4.0 SPECIAL INSTRUCTION TO VENDOR ................................................................................. 16

5.0 REQUIREMENT FOR AUTOMATION SYSTEM IN DISPENSER…………………………………….18

6.0 MAINTENANCE………………………………………………………………………………………………19

7.0 REJECTION CRITERIA………………………………………………….…………………………………..19

8.0 EXCLUSION ........................................................................................................................ 21

9.0 SPARES ............................................................................................................................... 21

10.0 VENDOR DATA REQUIREMENTS ......................................................................................... 21


12.0 ENVIRONMENTAL AND SITE CONDITIONS ARE AS FOLLOWS .......................................... 21

13.0 LIST OF ATTACHMENTS ...................................................................................................... 21

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SECTION: B:

INSTRUMENTATION & CONTROL SPECIFICATION

1.0 SCOPE

1.1. The purpose of this specification is to define the minimum general requirements and philosophy ofinstrumentation & control for the dispenser package of IGL.

1.2. This specification cover the design, engineering, procurement, supply and testing, calibration &commissioning of instrumentation and control system with all accessories and materials and any special testrequirements required for completing the job in all respects.

1.3. Coriolis mass flow meter, electronics and other accessories shall be provided as required for the Dispenserarms.

1.4. Vendor's scope of instrumentation and control for the dispenser package shall include the following as:

a) Basic instrumentation and control indicated in this document.

b) All local and field-mounted instruments in dispenser panel.

c) All additional instruments and control system necessary for safe and efficient operation of the dispenserswhich are not listed specifically in this document but which are required as per vendor'sexperience/recommendations.

d) Impulse piping/tubing including all miniature valves, fittings and mounting to install all sub vendorsupplied instruments.

e) All other erection material necessary for mounting of instruments in vendor's scope as per IGLinstallation standard.

f) Shop testing of all instruments and control system under vendor supply.

g) Calibration, loop checking, pre commissioning and commissioning of the complete system.

h) All weather proof and explosion proof double compression type cable glands for all instruments, junctionboxes, dispenser panel etc.

i) All pressure relief valves.

1.5. In case of further clarifications, bidder shall obtain clarification/confirmation from IGL before proceeding.

1.6. All instruments must be procured from IGL recommend vendor list. However for those instrument/equipment,which are not covered in the list, the sub vendors shall be approved by IGL.

2.0 BID PROPOSAL

The bid proposal shall be accompanied by the following as minimum for technical evaluation of offer.

a) Filled in data sheet of all instrument.

b) Deviation list.

c) Write up on control philosophy.

d) Power supply consumption for each item & type of power supply whether earthed/ floating.

e) Utility requirement & consumption.

f) Complete dispenser along with mass flow meter shall be approved by Weights & Measures Departmentof India and NMI or PTB as per latest standards. In case dispenser has not been approved by Weights &Measures Department of India, the mass flow meter shall have Weights & Measures Department of Indiaapproval.

g) PESO approval for explosion proof enclosure for all electrical & electronic instruments. Bidder to ensurecompliance to all statutory requirements such as PESO, weight & measurement department etc. In caseany penalty is imposed by authorities, same shall be borne by the supplier

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h) Type approval certificate from Petroleum & Explosive Safety Organization (PESO), Nagpur, Govt. ofIndia.

3.0 DESIGN PHILOSOPHY

3.1 All Electrical and electronic instruments shall be installed in accordance with NFPA 70, IEC for Gas GroupIIA, IIB & Temperature Class T3 and shall have approval of a recognized certifying authority.

3.2 Mass flow meter shall be coriolis type and shall conform to AGA 11 standard.

3.3 Each and every mass flow meter 'zeroing' shall be done before delivery from vendor's works.

3.4 Mass flow meter design considerations, piping, meter, zero verification and proving facility shall be as perAGA 11 standard.

3.5 Control valve and solenoid valves shall be of conventional type design, no integral design is acceptable.

3.6 Control valve body and trim materials selection shall be done by the bidder to ensure that there is no erosion,cavitation and flashing. Trim & seat shall be fully stellited.

4.0 SPECIAL INSTRUCTION TO VENDOR

4.1 Supply of Car Cum Bus dispenser with two arm of flow rate ≥ 15 kg/min & ≥ 75 kg/min under differentialpressure of 200 kg/cm2 g.

4.2 Each dispenser arm shall have Coriolis type mass flow meter with necessary sensor, electronic and specialcable recommended by vendor. Performance record and Weight and Measure (W&M) certification of themeter to be submitted for acceptance.

4.3 Three rows liquid crystal backlit displays for night viewing showing total sale in Rupees of (00000.00),quantity of gas sold in Kg.(00000.00), unit price of CNG in Rs/Kg (000.00) for each hose of the dispenser(total two sets and three rows for each dispenser).

4.4 Vendor shall make a provision to change the price of CNG through the keypad inside the dispenser unit thatshall be covered with security lock. RS 485 port shall also be provided for price change. In case standardRS485 port is not available in the dispenser, then RS232C to RS485 convertor with all relevant hardware andsoftware to be provided by vendor.

4.5 Non-resettable and non-volatile totalizer upto 999999.99 (8 digits and a decimal) for total CNG sold in Kgs.Since the dispensers are used for custody transfer purpose, the totalizer must not reset/change/jump in anyeventuality not even in the case of electronic failure/power supply failure or excursion beyond permissiblelimit. If there is any abnormality in power circuit during filling, the running batch value should be added intotalizer. Dispenser electronics shall be common for both totalizers.

4.6 Totalizer figure would be displayed only when it is recalled through a remote keypad or some device integralto dispenser. The totalizer value would cover up to the last transaction details at the time of recall. Theseremote key pad device should not be used for any programming of the dispenser and are distinct from those,if used for programming the dispenser while operating these keys in no way shall hinder the operations,functioning, veracity of display, storage of parameters and values. These remote keys can be used even whenthe filling is on without affecting up-counting/real time data.

4.7 Dispenser shall be capable of communicating with outside system using the open system architecture/protocol(OPC)/RS 485. Bidder must handover the details of communication port of dispenser and signals to betransferred to IGL. It should be possible to transfer the data through twisted pair wires, transaction data asalso flow meter data (both process and diagnostic) RTU.

4.8 One number of three bank electronic software and controller including hardware. Vendor shall includesolenoid operated valve made of ANSI 316 SS for dispensing of gas. Vendor to ensure the system design insuch a way that in both options any gas if passes, should be recorded by dispenser and there should not beany possibility of unmetered gas supply through dispenser in case of malfunctioning of valves. The valveassembly shall be fatigue free and tight shut off characteristics at least for 8000 operation hours.

4.9 Two number of liquid filled 4" dia. (0-400 kg/cm2g) pressure gauge showing the vehicle filling pressure.Pressure gauge shall be provided with shatterproof glass. Vendor to provide a bypass isolation valve with

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associated tubing to facilitate routine servicing/calibration of Pressure gauge without shut down of thedispenser.

4.10 Temperature compensator to limit fill pressure to an adjustable value (with normal value 200 Kg/cm2g)equivalent at 15 degree C. A temperature compensation facility button shall be provided to enable or disablethe temperature compensator.

4.11 To limit fill pressure to 200 Kg/ cm2 g, Vendor to provide the following options per hose / arm of thedispenser:

a) One number of pressure limiter ( electronics transducer) (with adjustable value up to 250 Kg/cm 2 g) andone number of mechanical pressure regulator and one number pressure relief valve as final safety toavoid overfilling. Pressure regulator shall be designed such that there shall not be any flow restriction tothe maximum flow of dispenser. Otherwise, minimum flow through the regulator shall be 15 Kg/min at5 kg/cm2g differential pressure.

4.12 Back-up Power supply for displays so that display remains at least for 5 minutes after power failure. Vendorshall provide battery backup of 72 hours to the RAM of dispenser controller.

4.13 Hardware required with the dispenser for Weights and Measures (W&M) certification.

4.14 All parameter setting shall be password protected. Facility of change of password also to be provided toenhance the security of password.

4.15 Car Cum Bus Dispensers shall be designed for handling flow rate of more than or equal to 15 kg/min & 75kg/min at Car and Bus end respectively. Flow capacity with turn down of not less than 50:1.

4.16 The batch accuracy of dispensed gas shall be within ± 1.5% or better.

4.17 Bidder shall indicate overall flow coefficient Cv of dispenser from inlet to the dispenser upto outlet of nozzleincluding mass flow sensor, interconnecting tubing, valves, hose, fill valve etc.

4.18 Normal operating inlet pressure of dispenser shall be 220-250 Kg/cm²g. The dispenser supply to the vehicleshall be positively cut off at outlet pressure of 200 Kg/cm²g.

4.19 Normal operating temperature of wetted parts of dispenser shall be –10 to 55 deg C.

4.20 Vendor shall confirm that any momentarily flow of gas shall be registered in dispenser totalizer. Vendor shallenvisage a temper proof design. Dispenser shall generate error signal in case of passing valve with date andtime and display on the dispenser LCD.

4.21 After power on, the controller delay time to start filling be such that the mass meter and pressure transmitterare initialized properly to avoid any un-metered gas.

4.22 Complete control loop would be so fast that if the filling is terminated at any point of filling, the flow wouldstop immediately.

4.23 Reset switch assembly should be suitable for failure free operation and the same shall be supported withproper PTR for CNG duty.

4.24 Controller shall be in reset state for the SOV open signal to be generated. Any departure to this shall stop thedispenser. Dispenser controller shall monitor the status of flow, monitor the status of flow meter / transmitterand in case of any abnormality from set condition the dispenser shall shut down.

4.25 In case the power supply is beyond acceptable limit the dispenser shall not start at all. The controller shallprovide an operational alarm with pre-stated error code and it shall be displayed on LCD display.

4.26 Flow meter signal shall be considered as the highest level of interrupt. It shall not be possible to fill anyvehicle cylinders by repeated operations of reset switches. Reset time delay is required with adjustable time.

4.27 A Provision shall be available in dispenser unit, which shall be suitable for programmable/changeable fillingpressure from 180kg/cm²g to 220kg/cm²g in vehicle. Original filling shall be same as defined elsewhere indata sheet.

4.28 Emergency stop switch is required on both side of the dispenser. However, the filling on both sides shouldstop in emergency condition, when any one of the emergency switch is pressed. However during activationof emergency switch, the power supply to the dispenser should be available.

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4.29 Overfill Protection

Overfill protection shall be through electronically programmed hose to terminate the fill after 200 Kg/cm²g.Vendor shall include one number pressure transducer and one number pressure regulator per hose. Pressurerelief valve shall be provided to avoid overfilling. Relief valve set pressure shall be at 250kg/cm²g withresetting at 245kg/cm²g. Relief valve setting to be adjustable from 225kg/cm²g to 260kg/cm²g with resettingat 220 to 255 kg/cm²g respectively. Calibration certificate shall be provided.

4.30 Electronics

4.30.1 Electronics shall be microprocessor based. The processor shall be the latest available in the field and shall becapable of processing the data faster. All the electronic cards shall be located in flameproof boxes inside thedispenser cabinet. No parts of electronics shall be filled with epoxy resin etc. The controller electronics shouldhave immune to EMI interference and vendor to provide relevant certification in this regard.

4.30.2 The dispenser electronics should have self-diagnostic features and should generate error code accordingly.Vendor should define such error codes in trouble shooting guide and procedure of their rectification. Errorcode related to operational parameters should also be displayed and defined in trouble shooting guide.Password protection should be provided for entry of critical data through key pad.

4.30.3 The change in setting shall be done either through lap top computer or through hand held configurator throughthe port provided for this purpose with security lock.

4.30.4 Vendor shall provide suitable electronics for processing both arms dispenser data. Totalizer display anddisplay for both arms in the dispenser shall be shown separately

4.31 Tubing & Fittings

Materials used for the tubing shall be SS 316 fully annealed (Bright annealed) seamless conforming to ASTMA269 with maximum hardness of RB80 or less and suitable for bending and flaring. Open ends on fittingsand vents shall be provided with caps/dust plugs.

4.32 Certification:

· Equipment/instrument/systems shall be certified for use by statutory authorities for their use in area oftheir application.

· For all intrinsically safe/flame proof equipment/instruments/systems, certification by any approvingauthority like BASEEFA, FM, UL, PTB, LCIE, Petroleum & Explosive safety organization (PESO),India is mandatory.

· The supplier should specify the hazardous area in accordance with the IS 5572 / Australian Re-fuellingStandard AG901 / NZS5425. All electrical equipment cabling and earthing should be appropriate for thezone in which it is fitted, and all cables passing from the hazardous to safe area should be equipped withappropriate barriers where necessary.

· All Instruments should be suitable for an area classification of “Class 1, Division 1, Group D as per NEC”OR “Zone 1, Group IIA / IIB as per IS 5780 / IEC 6007”. All dispensers mounted transmitters &temperature element should be intrinsic safe “Exia” as per IEC 79-11. Solenoid Valves, Switches andrelated junction boxes should be flame proof “Exd” as per IEC 79-1.

· Other special equipment / instruments, where intrinsic safety is not feasible or available, should be flameproof as per IEC 79-1. Flying leads from any of the instrumentation items are not acceptable. TheElectronics of the dispenser shall not be open and shall be provided within a suitable enclosure. Acomplete dossier of all electrical equipment will be provided, showing area classification and certificationof equipment.

4.33 In case the mass flow meter design is having transmitter with local integral display, the mass flow metersignal through the transmitter shall be wired to the mother board used in the dispenser and there shall not beany difference in reading between this integral display unit and non-resettable display in the electronic controlunit or,

If the mass flow meter design does not have provision for transmitter with local integral display, then themass flow meter signal shall be directly wired to the mother board of the dispenser.

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4.34 Dispenser manufacturer is required to submit approval of weight & measure department, Gov of India. Forthe dispenser unit or for the mass flow meter installed in the dispenser unit. In future, if any non-conformityor objection is raised by W&M department or if any penalty action is taken against IGL, vendor shall be fullyliable, indemnify IGL against any liquidity and shall bear all the cost implication, if any.

4.35 One no. of non-resettable and non-volatile totalizers per hose of the dispenser i.e. one integral local digitaltotalizer with display along with mass flow meter transmitter and the second totalizer of liquid crystal backlitdisplay in kg. (999999.99) on the front panel of the dispenser shall be provided. Besides this, an electro-mechanical type totalizer shall also be provided with 7 digits and reading of both the totalizer shall be thesame.

There shall be a non-resettable & non-volatile totalizer per hose of the dispenser with liquid crystal backlitdisplay in kg. (999999.99) on the front panel of dispenser. Besides this, a 7 digit electro-mechanical totalizershall also be provided.

4.36 All equipment should be communicated with the common communication protocol.(MODBUS/PROFIBUS/HART)

4.37 All the safety norms to be followed by vendor as per IGL guidelines.

4.38 All the approvals and certification to be provided by vendor for the hardware, software supply as per IGLrequirements.

4.39 During installation & commissioning vendor will ensure that routine operation of the equipment will notsuffer or vendor will install the equipment as per IGL guidelines.

4.40 RFID Systems

The dispenser must be compatible with future RFID system suitable for monitoring and control of vehicle/vehicle on-board cylinder authentication mechanism. (TBD)

5.0 REQUIREMENT FOR AUTOMATION SYSTEM IN DISPENSER

5.1 It is intended to monitor / control following parameters through automation system:

Vendor shall ensure availability of following parameters at communication port of dispenser to connect withautomation system for monitoring & control purpose.

These parameters shall also be checked during inspection at vendor’s works.

a. Mass Totalizer from Dispenser Motherboard.

b. Mass Flow per Filling.( note that Gas sale data- the reading which is visible to customer and used forbilling purpose is mandatory to be transmitted to server whether it is from flow meter or motherboard orfrom both)

c. To Read Gas Selling Price from Dispenser.

d. To download the gas selling price into the dispenser from Server system.

e. Mass Flow Meter Status.

f. Tripping Status Dispenser.

g. Reset Switch Operation Status.

h. Dispenser Power Supply Status.

i. Identity of vehicle using RFID (In-built option to be provided).

5.2 In addition to above bidder shall make provision for monitoring and control of following parameters as well

A. Shift Reports

(Shift – A: 6:00 to 14:00)

(Shift – B: 14:00 to 22:00)

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(Shift – C: 22:00 to 06:00)

a) Showing Date /Start time/ Finish time of every shift

b) Individual Arm-wise and Dispenser-wise totals.

c) Total sale for each shift in Kgs and Rs.

d) Total sale with variable pricing.

e) Full day report with total Sale for the 24 Hr. period.

B. Remote Price Change facility to facilitate

· Station-wise sortable and selectable

· Time-wise selectable

· Area-wise selectable

· Variable price change in a day

C. Transaction reports

Remotely the following parameters can be viewed in transaction reports

· Station Name and Dispenser serial number.

· Showing Date /Start time/ End time of every filling.

· Individual Arm-wise and Dispenser-wise totalizer at start of filling and end of filling.

· Transaction number totals for individual Arm-wise, Dispenser-wise and Station-wise to count number offills in selectable particular duration. (Monthly and daily basis)

· Batch reading of fill.

· Sale for each batch in Kgs and Rs.

· Unit price Data.

· Dispenser power ON/OFF count.

· Pressure during last fill

· Vehicle pressure at start of filling

· Vehicle pressure at end of filling

· Temperature during the last fill

· End of sale indicator (Code number showing the reason that the last sale stopped. This is useful if adispenser stops during a fill for no apparent reason).

5.3 The remote monitoring and automation will consist of reading, transferring and controlling all thedata/parameter from the dispensers to RTU and then to any centralized remote server in India as per IGLrequirement.

5.4 The above list is tentative and final list shall be decided during execution phase.

6.0 MAINTENANCE

6.1 The two-year comprehensive maintenance of all the dispensers is in vendor’s scope.

6.2 The start/commencement of the two years comprehensive maintenance shall be after successful testing,commissioning and commencement of commercial operation of the dispenser. As warranty is for a maximumof 18 months, the end date of AMC period would be 42 months (18+12+12 month) from date of dispatch ofa lot.

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7.0 REJECTION CRITERIA.

7.1 During the shop test of dispenser, in case the dispenser flow capacity from inlet to dispenser to the outlet offilling nozzle is found below the specified capacity the dispenser shall stand rejected.

7.2 During the shop testing if the dispenser batch accuracy is found beyond ± 1.5% dispenser shall stand rejected.

7.3 The bids received without the certification from the Weights and Measurement department of the Country oforigin for offered mass flow meter (Coriolis type) as per specifications may be liable for rejection. In casecountry of origin of mass flow meter does not issue weights and measure certificate then the same shall beprovided from approved agency for weights and measure from other country.

7.4 Bid received without technical documentation including GA drawing shall be liable for rejection.

8.0 EXCLUSION

Vendor’s offer shall exclude following:a) UPS for instrumentation & control.UPS shall be made available to bidder/contractor at battery limit.

9.0 SPARES

Commissioning and warranty spares to be provided and included in the base offer.

10.0 VENDOR DATA REQUIREMENTS

Vendor data requirement shall be strictly as per Annexure-5 this job specification.


11.1 Functional and simulation test for the following shall be carried out at vendor’s works and shall be witnessedby IGL/Third party.

11.2 Control panels along with all instruments mounted in it.11.3 Following tests shall be carried out by bidder at his works or his sub-vendor’s works and test certificates shall

be furnished :a) Calibration/test certificates for all instruments, control valves & safety valves.b) Seat leakage test for control valve and safety valve.c) Test certificates for safety valve set pressure and reset pressure.d) Material test certificates for all line mounted instruments.e) Sub-vendors conformity certificates.

12.0 ENVIRONMENTAL AND SITE CONDITIONS ARE AS FOLLOWS

: Minimum Temperature: 1°C

: Maximum Temperature: 49°C: Maximum Shed Temperature: 47.5°C: Relative humidity 98% Non-condensing: Wind Velocity 160.0 Km/Hr

13.0 LIST OF ATTACHMENTS

Data sheet for CNG Dispenser for CAR.Data sheets formats (along with calibration certificate wherever applicable) for

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· Mass flow meter

· Control valve

· Solenoid valve

· Self-actuated control valve

· Pressure relief valve & Pressure Gauge and transmitter

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TABLE OF CONTENTS

SECTION – C

1.0 GENERAL ............................................................................................................................ 24

2.0 CODES AND STANDARDS ................................................................................................... 24

3.0 AREA CLASSIFICATION AND EQUIPMENT SELECTION ...................................................... 24

4.0 EQUIPMENT SPECIFICATIONS ........................................................................................... 25

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SECTION: C: ELECTRICAL SPECIFICATION

1.0 GENERAL

1.1 This specification defines the requirements of design, engineering, supply and installation, testing andcommissioning of electrical facilities for CNG Dispenser Package.

1.2 It is not intended to cover all aspects of design but to indicate the basic requirements only. Vendor shall ensurethat the design and installation on the skid is carried out as per good engineering practice to meet therequirements of safety, reliability, ease of maintenance and operation, aesthetics and interchange ability ofequipment.


2.1 All electrical equipment and complete package shall meet the requirement of relevant Publications and Codesof Practice of Bureau of Indian Standards, statutory regulations and good engineering practices. Completesystem must conform to the latest revisions of the following:

a. Indian Electricity Act and Rules framed there under.

b. Fire Insurance Regulations.

c. Petroleum Rules and any other regulations laid down by Petroleum & Explosive safety organization.

d. Regulations laid down by local statutory authorities and Electrical Inspectorate.

2.2 Vendor shall provide all assistance required for obtaining approvals from statutory authorities for materials,plant design/drawings and complete installation.

2.3 Where Indian Standards do not exist, the relevant IEC/British/ German (VDE) standards shall apply. AnyOther international standard may also be followed provided it is equivalent to or more stringent than thestandards specified above.

2.4 In case of any discrepancy/conflict between the specified codes and standards, the following order ofdecreasing precedence shall govern:

i) Statutory Regulations.

ii) Codes and Standards.

Owner’s concurrence shall, however, be sought before taking a decision in the matter.

3.0 AREA CLASSIFICATION AND EQUIPMENT SELECTION

3.1 In case of storage, handling or processing of flammable materials within the battery limits of the package,area classification shall be carried out in line with IS: 5572 & Petroleum Rules and OISD-179 guidelineswhere applicable.

3.2 Selection of the type of equipment for use in hazardous areas shall be done in accordance with IS: 5571 andother safety regulations as applicable. The electrical equipment shall meet the requirements of relevant IS,IEC or NEC standards. Increased safety type Ex (e) equipment shall not be permitted for use in Zone-1 areas.For Zone-2 areas, increased safety type Ex (e) or Non-Sparking Type Ex (n) equipment shall be provided asa minimum, subject to the same being acceptable to statutory authorities. Ordinary safe area type electricalequipment shall not be used in Zone-2 areas (even though this may be permitted by NEC for Div.2 areas).

3.3 Electrical equipment for hazardous areas shall be certified by CMRI and approved by PESO (or equivalentstatutory authority of the country of origin) for installation and use in the specified hazardous area. Flameproofequipment of indigenous origin shall be BIS marked. Vendor shall furnish the necessary certificates indicatingsuch approvals.

3.4 All the electrical and electronic component shall be in flame/explosion proof housing suitable for areaclassification: Hazardous area, Class 1, Division 1, Group D as per NEC or Class 1, Zone 1, Group IIA/IIBas per IS/IEC, Temperature Class T3, and completely enclosed in a securely lockable dispenser cabinet. Nocomponent of the dispenser shall be installed outside the cabinet.

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Certificate from recognized agency to the effect is required to be produced that equipment supplied and/orinstalled conforms to above area classification.”

4.0 EQUIPMENT SPECIFICATIONS

4.1 Specifications of equipment shall be furnished for review by the owner. All equipment and components shallbe new and supplied by approved reputed manufacturers. Equipment requiring specialized maintenance oroperation shall be avoided as far as possible and prototype equipment shall not be accepted. All equipmentshall be complete with all necessary weather protection including tropicalization to prevent damage due toclimate, dust and corrosive vapours.

4.2 Vendor shall be responsible for any damage to the equipment during transit. All packages shall be clearly,legibly and durably marked with uniform block letters giving the relevant equipment material details. Eachpackage shall contain a packing list in a waterproof envelope.

4.3 All electrical components and equipment shall be sized to suit the maximum load under the most severeoperating conditions.

4.4 All electrical equipment shall be supplied with approved cable glands, made of nickel-plated brass, tested andcertified to be used in zone-1, hazardous area.

4.5 All electrical components should be suitably weather proof to prevent short circuits, corrosion and should besuitable for installation in Hazardous classification as class I, Division 1, Group D

4.6 Although the supply is being arranged through UPS System, but in some remote occasions, the power supplymay be from DG sets with poor regulations and thus power supply available from IGL may contain harmonics,transients and surges etc. The Electronics shall be compatible to the supply system as no transient, surge orharmonics protection is provided by IGL. Bidder to include suitable surge protection device/ voltageconditioning unit, as required, in their scope for accurate and safe operation of dispenser.

4.7 Rated voltage and frequency for the equipment shall be indicated below:

Ambient Temp: Max. 49 ºC & Min. 1 ºCSystem Voltage: 230V + 10% Single Phase ACSystem Frequency: 50 Hz + 3%System Earthing: Solidly Earthed

We have envisaged solid earthing for the system. However, if specific earthing is required for the system –electronics, the same to be highlighted by bidder; otherwise system earthing including making of earth-pitsetc. shall be provided by the successful bidder.

4.8 Name of the manufacturer, type of enclosure protection and certificate no. with name of testing/Certifyingagency shall be furnished with bids / for approval.

4.9 General Requirement

· All power supply J.B.’s shall be flame-proof type as per area classification.

· Fill hoses should be conductive type to mitigate the static charges.

· Provision for connecting earth strip at two points inside the dispenser.

· Supply cable entry to dispenser shall be suitable for armoured 2.5sq.mm. 4 core.

There should be effective static charges (as generated in hoses) mitigation design. All hoses shall beconductive so that auto earthing of static charges (as generated in system) could be ensured. Vendor shallsubmit the requisite documents/demonstration against the same at vendors shop.

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SECTION D: MECHANICAL SPECIFICATION

Hoses:

Two CNG flexible electrically conductive (fill & vent both should be separate) hose, having followingspecification:

1. Car & Bus long hose breakaway to nozzle:

a. Car side & Bus side Dispenser Fill hose (Long)

b. Hose ID- 3/8" & ½”

c. OD- 0.77" & 0.90” approx.

d. Length- 3000 mm,





i. Working Pressure: 5000 PSI (345 Bar),

j. Minimum Burst Pressure: 20000 PSI (1379 Bar),

k. Temperature Range: -40 C to 65 C),

l. Electrically conductive polymer core tube, two or more layers of fiber reinforcement, and abrasion-resistant urethane cover. Cover must be pinpricked for use with CNG. High-strength conductivepolymer core tube is required to dissipate static electrical build-up. Thick urethane cover for abrasionand wear resistance.


n. Hose should conform to NFPA 52 & ANSI / CSA NGV 4.2-2014 / CSA12.52-2014

2. Car &Bus short hose dispenser to break away:

a. Car Dispenser Fill hose- 1800 mm (Short),

b. Hose ID- 3/8" & ½”

c. OD- 0.77"& 0.90” approx.

d. Length- 1800 mm,


f. End Size 1- 9/16"-18 UNF SAE 37* JIC (F) Swivel

g. End size 2- 9/16"-18 UNF SAE6(M) (Both Ends),in SS 316


i. Working Pressure :5000 PSI ( 345 Bar )


k. Temperature Range : -4°0 C to 65° C ),

l. Electrically conductive polymer core tube, two or more layers of fiber reinforcement, and abrasion-resistant urethane cover. Cover must be pinpricked for use with CNG. High-strength conductivepolymer core tube is required to dissipate static electrical buildup. Thick urethane cover for abrasionand wear resistance.


n. Hose should conform to NFPA 52 & ANSI / CSA NGV 4.2-2014 /CSA .52-2014

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3. Vent hose:

a. Vent hose- 3000mm ,

b. Hose ID- 1/4",

c. OD- 0.63",

d. Length- 3000 mm




h. Nominal size - 1/4"

i. Working Pressure : 5000 PSI ( 345 Bar ),


k. Temperature Range : -40 C to 65 C ),

l. Electrically conductive polymer core tube, two or more layers of fiber reinforcement and abrasion-resistant urethane cover. Cover must be pinpricked for use with CNG. High-strength conductivepolymer core tube is required to dissipate static electrical buildup. Thick urethane cover for abrasionand wear resistance.


n. Hose should conform to NFPA 52 & ANSI / CSA NGV 4.2-2014 / CSA52-2014

Nozzles:

Both hose shall be fitted with NGV-I nozzle for filling of vehicles. Specification for NGV 1 nozzle is asfollows:

Nozzle Type NGV-1 TYPE 2, CLASS B

Normal working Pressure PN200 bar

Temperature Range 0°C to +65°C

Max. Length Max. 115 mm

Cv minimum 1.05

Max. Weight 0.65 kg

Min. Flow Rate: 1500 SCFM @ 3000 psig

Max nozzle body diameter 2 inches

Filling Line Male Thread UNF 9/16”-18 Female or

1/4” Male NPT

3 way valve:

Vendor shall include the supply of 3-way valve with each hose for filling & venting of gas. Specifications areas follows:

Connection Size : ¼ “NPT Female (All three end)

Pressure Rating : 5000 PSI (minimum)

Temperature Rating : 0 to 65 deg. C

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Minimum Life : 40000 cycles at site conditions (one on & off is considered asone cycle)

Material of construction

Body : SS 316 as per ASTM A276 or as per ASTM A479 or ASTM A 182

Ball : SS 316 ASTM A479 or Alloy S21800 as per ASTM A276

Stem : SS 316 ASTM A479 or as per ASTM A276

End connection : SS 316 ASTM A479 or ASTM A 276

Seat carrier : SS 316 as per ASTM A276

Seat springs : Alloy X-750 / AMS 5542 / 17-7 PH

Seat : PEEK

O-rings : BUNA-N or BUNA-C or Fluorocarbon FKM

Backup rings/bearings : PEEK / PTFE

Orifice Size / Cv : min 4.75 mm / min 0.62

Weight : Max. 350 grams.

Design Features

1. The valve should be of trunnion ball design.

2. Blow out resistant two piece ball/stem.

3. Should have positive handle stoppers.

4. Flow direction indication must be there on handle.

5. Directional indication must be provided for panel mounting.

6. Complete repair kit must be available and comprises of (all internals installed in valve body) followingitems :

a. Stem

b. Stem washer

c. All sealing rings for stem i.e. stem o-rings, primary backup rings, secondary backup rings etc.

d. All Seat with carrier

e. All Seat retainer o-rings, backup rings, guide, springs etc.

f. Connector end seals

g. Ball trunnion

h. Trunnion bearing

Break away:-

Vendor shall also include supply of Breakaway Coupling, suitable for NGV Industry. Vendor shalldemonstrate the function of breakaway coupling during performance test.

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DATA SHEETS

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CNG DISPENSER FOR CAR CUM BUS

SR. NO.

PARAMETER SPECIFICATION OFFERED

1.0 Dispenser Car Cum Bus1.1 Make1.2 Model1.3 Normal Inlet Pressure Kg/cm2 g 2501.4 Maximum Fill Pressure Kg/cm2g 2001.5 Operating Temperature range of wetted parts (-) 10 °C to 60°C1.6 Flow Rate (kg/min) > 15 & > 751.7 Nominal flow (kg/min)1.8 Minimum flow (kg/min)

1.9 Overall Cv of dispenser from inlet of dispenserto outlet of fill nozzle

1.10 Batch accuracy ± 1.5%

1.11 Electrical Supply AC 230 Volts ± 10%50Hz ± 3%

1.11.1 Tolerable value of voltage range for accurateoperation

1.12 Fill Nozzle1.12.1 Type NGV1 & Sherex CT1.12.2 Make -1.12.3 Pressure Rating Kg/cm2 g 250 Kg/cm2 g1.13 Flexible fill & vent hose Both should separate1.13.1 Type1.13.2 Make1.13.3 Pressure Rating Kg/cm2 g

1.14 Sequential filling Three bank for car end andSingle bank for Bus end

1.15 Mass Flow Meter1.15.1 No. of metering lines Two independent1.15.2 Metering principle Coriolis1.15.3 Make1.15.4 Model

1.15.5 Mass Flow accuracy for gas meter (inclusive oflinearity, hysteresis, repeatability errors) ± 0.5%

1.15.6 Repeatability ±.0.25%1.16 Temperature compensation Yes1.17 Breakaway coupling YesNOTE: For all Electrical/Instrumentation items vendor shall provide certificates issued by statutory InspectionAuthority confirming suitability of Design/Construction for specified Hazardous Area Classification.

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MASS FLOW METERS (CORIOLIS TYPE) FOR CAR CUM BUS DISPENSER


Temperature->oC

Level /Length->mm

General 1. Tag No.2. Line No.3. Service4.

Meter 5 Type6 Function7 Conn. Size: Size &Rating,

Facing & Finish8 Body Material9 Wetted Parts Material10 Enclosure11 Conduit connection12 Range13 Accuracy1415

Convertor 16 Load Resistance – ohms.17 Output18 Power Supply19 Area Classification20 Intrinsically safe /Expl. Proof21 Enclosure22 Conduit connection23 Mounting24 Distance from control room2526

Options 27 Filter/Mesh Wire28 Mounting Brackets29 Interconnecting30 Special cabling31 Cable glands32 Accessories for hot tap333435

ServiceConditions

36 Fluid & state37 Maximum Flow38 Minimum Flow39 Normal Flow40 Pressure – Open. Max.41 Temp. C – Open. Max.42 Oper. S.G. Mol. Wt43 Max. order Viscosity mpa . s(cp)44 Max. Allowable Pr. Drop45 Model No. Meter convertor46 Specification Remarks47 Specification Remarks

Notes:

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DEVIATION NO DEVIATION

CONTROL VALVES



General 1 Tag No.2 Inlet Line No.3 Outlet Line No.4 Service5 Line Size Schedule6 Inlet Line I.D. Outlet line ID

Body 7 Type of Body8 Body Size Port Size9 Guiding No. of Ports10 End Conn: Flgd. Size & Rating11 Facing & Finish12 Body Material13 Bonnet Type14 Packing Material15 Lubricator Isol. Valve16 Trim form17 Trim Mat. Plug. /Disc/Ball & Seat18 Other wetted parts19 Soft seating Materials20 ANSI Leakage Class

Act. 21 TypeUat or. 22 Close at Open at

23 Failure Position24 Handwheel & Location

Position 25 Air Supply Pressure26 Input Output27 Bypass Gauges

Options 28 Solenoid Valve29 I/P convertor30 Filter with Gauge31 Limit Switch3233

ServiceConditions

34 Fluid State35 Flow Liquid Min: Normal: Max36 Flow vapour Min : Normal : Max37 Flow Water Min Normal Max38 Inlet Pr. Nor. Min.39 P @Flow rat Min :Normal : Max40 Pressure Shut Off41 Temp. Open. Max.42 Open S.G. Mol. Wt.43 Cp/Cv Compress Factor44 Flash% visc.mPas (open)45 Deg. Of Superheat % Solids46 Vapour Pr. Critical Pr.47

Valve Data 48 CV Min. Cv Max.49 CV Nor. Selected CV50 Predicted Sound Level Dba51 Inlet Velocity m/s

Model Nos. 52 Valve Actuator53 Positioner Solenoid Valve54 IBR Certification

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SOLENOID VALVES

Units:Flow -> CNG CNG-Kg/Hr

Pressure->Temperature->oC

Level /Length->mm

General 1 Tag No.2 Line No.3 Line Size & Sch.4 Service

Valve 5 No. of ways6 Size – Body Port7 End Connection8 Material Body9 Material Trim10 Body Rating11 Operating mode NC/NO/Univ.12 Packing131415 Enclosure

Electrical 16 Area Classification17 Cable Entry18 Ty. Of Energisation Dropout19 Power Supply20 Power Consumption VA/W21 Inrush Current22 Insulation Class23 Voltage – Energising –

Dropout24

Options 25 Manual reset26 Latching on Energ./De-Energ.27 Bug screen for vent port28 Intrinsically safe2930

ServiceConditions

31 Fluid32 Press. Open / Max.33 Temperature C-Open/ Max34 Maximum Flow35 S.G. at open Temp. Mol. Wt.36 Viscosity mPa.s (cp)37 Allowable Press Frop38 Del. P Shut Off39 Valve CV404142 Model No.43 Specification Remarks

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SELF ACTUATED PRESSURE CONTROL VALVES



General 1 Tag. No2 Line No.3 Line Size & Sch.4 Service5

Valve 6 Ty. Of Regulator: Std/pilot op7 Size: Body Port8 End Conn.:- Size & Rating9 - Facing & Finish10 Body Material11 Trim Material12 Set Point13 Impulse Conn.: Int. / Ext.14 Conn. Size & Type if external15 Material of Diaphragm16 Bonnet Type17 Cv: Min. Max.18 Cv: Normal19 Selected Valve CV.20 Predicted Sound Level (dBA)21 Inlet Velocity22 Packing of Seals23 Lubricator ISO – Valve24 Guiding No. of Ports25

Accessories 26 Pressure Indicator27 Relief Valve28 Line Stainer

Serviceconditions

29 Fluid & State30 Flow - Min. / Max.31 Flow - Normal32 Inlet Pr. - Max. / Min33 Inlet Pr. - Normal34 Del. Pr. – Max. Min35 Del. Pr. - Shut Off36 Temperature ºC - Oper. Max.37 Oper. S.G. Mol Wt.38 Cp/ Cv compress factor39 Flash% open visc. Mpa. S (cp)40 Deg. Of Superheat % solids41 Vapour Pr. / Critical Pr.42 Model No. Valve / Actuator4344 IBR certificate45 Specification Remarks

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PRESSURE RELIEF VALVESUnits: Flow -> CNG CNG-Kg/Hr

Pressure->Temperature-> oC Level /Length-

>mmGeneral 1 Tag No.

2 Line No.3 Vessel Protected4 Safety / Relief

Valve 5 Type:6 Full Nozzle Full Lift/ Mod Nozzle7 Bonnet Type8 Conv. / Bellows / Pilot Operated9 Inlet Conn.: Size & Rating10 Facing & Finish11 Outlet Conn.: Size & Rating12 Facing & Finish13 Cap Over Adj. Bolt14 Screwed/Bolted15 Lifting Gear – Type16 Test Gag17

Material 18 Body and bonnet19 Nozzle and Disc20 Spring21 Bellows22 Resilient Seat seal

Options 2324

Basis 25 Code26 Basis of selection27

Serviceconditions

28 Fluid and state29 Corrosive constituent30 Required flow capacity31 Mol. Wt./ S.G. at Ref Temp.32 Open Pressure33 Open temp C / Ref Temp C34 Valve discharge to35 Back Press. / Const or variable36 Set Pressure37 Cold Bench Test pressure38 % Over pressure/ % blow down39 Cp/cv [ compressibility Factor]40 Viscosity At Ref. Temp. mPa s(cp)41 Vess.: Walltemp.C/ Surf Area-m2

42Orifice 43 Calculated Area cm2

44 Sel. Area cm2 / Orifice Design45 No. of valves Reqd. for capacity46 Total Area - cm2

47 Actual Flow Capacity4849 Model No.5051 IBR Certification

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PRESSURE TRANSMITTER

Units: Flow -> CNG CNG-Kg/Hr Pressure-> Temperature-> oC Level /Length->mmGeneral

1. Function2. Type: -3. Case: -4. Mounting: -5. Electrical Area Classification6. Enclosure :

Enclosure Class7. Intrinsically safe: -8. Air Supply9. Power Supply10. Cable Entry:11. Accuracy: -12. Repeability: - TRNSMITTER13. Output14. Trans. Power Supply Controller15. Output:-16. A/M switch:-

No. of positions:-17. Set point adjustment18. Manual Regulator19. Mode20. Chart21. Chart Driver22. Moving parts matl.; -23. Chart Speed: -

Measuring Unit24. Service: -25. Element : -26. Body Material: -27. Element Material28. Process conn.: -

process conn. Location29. Diaphragm seal

wetted parts materials: -other MaterialProcess Conn.: Size & Rating Facing & Finish: -Capability Material:-Armour Flexible: -Armour Flexible Matl.: -Capillary length:- mmFlushing/filling conn. With Miscellaneous

30. Over range protection31. Options: -

(a) Intrinsically Safe Output meter(b) Air Filter Regulator(c) Mounting Accessories(d) 3-way manifold(e) --------------------------

32. Load Capability:-TAGNO.

OPERATINGPRESSURE

MAXIMUMPRESSURE

MAXIMUMTEMPERATURE

RANGE CONTROL

SERVICE

OPTIONS

Span Set

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PRESSURE GAUGES

Units: Flow -> CNG CNG-Kg/Hr Pressure-> Temperature-> oC Level /Length->mm1. Type: -2. Mounting: -3. Dial Size: -

Colour: -4. Case Matl. :-5. Bezel Ring :-6. Window Matl.:-7. Enclosure : -8. Pressure Element :-9. Element Matl.:-10. Socket Material11. Accuracy12. Zero adjustment

13 Connection connection location: -

14 Movement: -15 Diaphragm Seal:-

Typewetted parts material – Element Matl. Lower Boy Matl.Non-wetted parts materials :Process connection: size & RatingFacing & FinishCapability MaterialArmour – Flexible – Matl.capability LengthFlushing / filling connection

16 Over Range Protection:-17 Blow out Protection:-18 Options: (a) Snubber

(b) Syphon (c) Gauge Saver (d) Liquid filled casing (e)-------------------------

TAGNo.

Range OperatingPressure

MaximumServicePressure

MaximumServiceTempe.

Fluid Service Options

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ANNEXURES

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ANNEXURE-1: RECOMMENDED VENDOR LIST

ITEM CODE / DESCRIPTION COALESCENT FILTER / REGULATORSVENDOR NAME REMARKASEA BROWN BOVERI LTD.BLUE STAR LTDPLACKA INSTRUMENTS & CONTROLS PVT.LTDSHAH PNEUMATICSSHAVO NORGREN (I) PVT. LTDV AUTOMAT & INSTRUMENTS PVT. LTD.VELJAN HYDRAIR PVT. LTD.COMPAC NEWZEALANDITEM CODE / DESCRIPTION FIELD INSTRUMENTS (P, DP, F,L,T)VENDOR NAME REMARKSABB AUTOMATION LTD.BROWN BOVERT LTD.FISHER ROSEMOUNT INDIA LIMITEDFISHER ROSEMOUNT SINGAPORE PTE LTD.FUJI ELECTRIC CO. LTD.HONEYWELL INC.ASHCROFTMURPHYCCSTATA HONEYWELLYOKOGAWA ELECTRIC CORPORATIONYOKOGAWA BLUE STAR LTD.WIKADRUCKITEM CODE / DESCRIPTION MASS FLOW METERSVENDOR NAME REMARK

CORIOLIS TYPE,EMERSON PROCESS MANAGEMENT Model CNG 50-2700COMPAC , NEW ZEALAND Model KG 80ITEM CODE / DESCRIPTION PRESSURE GAUGESVENDOR NAME REMARKSAN INSTRUMENTS PVT. LTD.GENERAL INSTRUMENTS CONSORTIUMWAAREE INSTRUMNETS CONSORTIUMGENERAL INSTRUMENTS CONSORTIUMMANOMETER (INDIA) PVT. LTD.WIKA INSTRUMENTS INDIA PVT. LTD.DRUCKITEM CODE / DESCRIPTION PRESSURE RELIEF VALVEVENDOR NAME REMARKSALSTHOM FLUIDS SAPAGANDERSON GREENWOOD CROSBYBHEL (TRICHY )DRESSER INC.FUKUI SEISAKUSHO CO. LTD.INSTRUMENTATION LTD. (PALGHAT)NAKAKITA SEISAKUSHO CO LTD.PARCOL SPASAFETY SYSTEMS UR LTD.SARASIN RSBD

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SEBIN VALVES INDIA PVT. LTD.TAI MILANO SPATYCO SANMAR LTD.TYCO VALVES & CONTROLS INDIA PVT. LTDSWAGELOKPARKERCOMPAC NEWZEALANDITEM CODE / DESCRIPTION SELF ACTUATED PR. CONTROL VALVEVENDOR NAME REMARKDANIEL INDUSTRIES INCDRESSER PRODUITS INDUSTRIESESME VALVES LTD.FISHER ROSEMOUNT SINGAPORE PTE LTD.FISHER EXMOX SANMAR LIMTEDGORTER CONTROLS B.V.INSTROMET INTERNATIONAL NVKEYE & MACDONALD INCNUOVO PIGNONE SPA (ITALY)PIETRO FIORENTINI SPARICHARDS INDUSTRIES (FORMERLYTRELOAR)RMG REGEL + MESSTECHNIK GMBHCOMPAC INDUSTRIES LTD., NZL.ITEM CODE / DESCRIPTION SOLENOID VALVESVENDOR NAME REMARKALCON ALEXANDER CONTROLS LIMITEDJEFFERSONSASCO (INDIA) LIMITEDASCO JOUCOMATIC LTD.ASCO JOUCOMATIC SAPARKER HANNIFIN, USAAVCON CONTROLS PVT. LTD.BARKSDALE INC.BLUE STAR LTD.HERION WERKESCHRADER SCOVILL DUNCAN LIMITEDSEITZ AGCOMPAC NEW ZEALANDITEM CODE /DESCRIPTION SPECIAL CONTROL VALVESVENDOR NAME REMARKFISHER ROSEMOUNT SIGAPORE PTE. LTD.FLOWSERVE PTE. LTD. (FORMERLYDURIRON)HOPKINSONS LIMITEDMETSO AUTOMATION PTE LTD. (FORMERLYNELES)NUOVO PIGNONE SPA (ITALY)SPX VALVES & CONTROLS (FORMERLYDEXURIK )COMPAC IND. LTD. NZLITEM CODE /DESCRIPTION REGULATORSVENDOR NAME REMARKCOMPAC IND. LTD.FISHER ROSEMOUNT SIGAPORE PTE. LTD.

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FLOWSERVE PTE. LTD. (FORMERLYDURIRON)ITEM CODE /DESCRIPTION TWO WAY / THREE WAY VALVESVENDOR NAME REMARKSWAGELOKPARKERCOMPACHAMLETHYLOCKITEM CODE /DESCRIPTION SS FITTINGSVENDOR NAME REMARKSWAGELOKPARKERHAMLETHYLOKITEM CODE /DESCRIPTION SS TUBINGVENDOR NAME REMARKSANDVIKFAEITEM CODE /DESCRIPTION HOSESVENDOR NAME REMARKPARKEREATONITEM CODE /DESCRIPTION BREAKAWAY COUPLINGVENDOR NAME REMARKOPWSTAUBLIWEHITEM CODE /DESCRIPTION FLAMEPROOF GLANDSVENDOR NAME REMARKCOMET/OEM MAKEITEM CODE /DESCRIPTION SURGE PROTECTORVENDOR NAME REMARKPHONEXITEM CODE /DESCRIPTION NGV NOZZLESVENDOR NAME REMARKOPWWEHSTAUBLIITEM CODE /DESCRIPTION CABLESVENDOR NAME REMARKCORDS CABLES INDUSTRIESASSOCIATED CABLESKEI INDUSTRIESUNIVERSAL CABLES LTS/OEM MAKE

Note:

Above is only recommended vendor list for guidance to bidders. Bidder will be solely responsible for any materialfor quality and compliance to tender specification. Any vendor can be approved at latter stage also based on theirPTR at the sole discretion of IGL. In case of imported kits, foreign cables are acceptable.

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ANNEXURE-2: VENDOR DATA REQUIREMENT

1.0 DRAWING AND DATA REQUIREMENT

1.1 The following data and information marked “X” shall be furnished by the vendor for Car Cum BusDispenser:

S. No. Description WithBid

After Job Award

ForReview For Information Final in Book

Form

1 2 3 4 5 6

1.0 GENERAL

1.1 Filled in Material Requisition ComplianceSchedule. X

1.2 Filled in Deviation Schedule. X

1.3

Duly filled up “Experience Record Schedule”.Vendor to note that information furnished by them shallbe used to assess the provenances of offered Dispensersand Qualification of vendor, Accordingly vendor tofurnish references of those cases which are matchingwith offered Dispensers.

X

1.4 Installation manual X X

1.5List of components of Dispenser with Make &Specification of components. Vendor shall also submit“Technical Catalogues” of components

X

1.6Start-up, operation & maintenance manual showingassembly details and critical tolerances. A copy of allcertified drawings & documents to be enclosed.

X X

1.7 Lubricant list with specification X X

1.8 Battery limit (interface) drawing/ information X X

1.9 Drawing list and submission schedule X

1.10 Project implementation schedule, ordering andinspection schedule for long lead and major items X

1.11 Pre-commissioning & commissioning procedure X

1.12 Performance guarantee test procedure X

1.13

Weights & Measures Certificates from the country oforigin for offered models of Car Cum Bus Dispensersunit model/mass flow meter model for dispensingspecified mass flow rate at specified overall batchaccuracy.

X X X

1.14 The “Test Certificate” for mass flow meter. X

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1.15 Weights & Measures approval from Indian Authorities. X

1.16 Type approval for the offered dispenser from Petroleum& Explosive safety organization, Govt. of India X X X

2.0 DESIGN

2.1Process flow diagrams (PFDs) and Piping &Instrumentation diagrams (P&IDs) of sub systems andcomplete system with write-up on operation

X X

2.2 Data sheets of Car Cum Bus Dispensers duly filled up. X X X

2.3 Basic design calculations for system design, equipmentselection X X

2.4Performance data, vendor literature for equipmentselection, performance curves with duty point markedfor individual equipment

X X

2.5 Specification for piping material & valves. X X

2.6 Utility requirement X X

2.7Detail of control wiring diagram, interlock/ shutdown/control scheme with write up on operation. Sizingcalculation for instrument items.

X X

2.8 Dispenser communication port details and requirementinformation as per specification and list of signals X X

3.0 CONSTRUCTIONAL FEATURES

3.1 G.A. drawing of Dispensers showing maintenanceclearances required. X X X

3.2 Cross section drawings of individual equipment/ skid,material & parts list. X X

3.3 Termination & Wiring Diagrams X X

4.0 SPARES

4.1 List of spares for two years normal operation per CarCum Bus Dispenser. X

5.0Drawings, documents, data as asked under Electrical &Instrumentation specifications of this MaterialRequisition.

X

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1.2 DOCUMENT DISTRIBUTION SCHEDULE

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

1.2.2 Documents listed under column 4 are to be submitted in 2 copies

1.2.3 Documents listed under column 5 are to be submitted in 2 copies.

1.2.4 Documents listed in column 6 are to be submitted as hard bound indexed book containing the following detailsin Two (2) copies to be submitted within 4 weeks of release note/dispatch of materials/ equipment fromvendor's works.

1.3 DETAILS TO BE INCLUDED IN FINAL DOCUMENTS BOOKS

1.3.1 Copy of P.O. and all amendments.

1.3.2 Copy of Purchase Requisition and all amendments.

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

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

1.3.5 All design calculations carried out by the vendor.

1.3.6 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.

1.3.7 Catalogues/leaflets of sub-vendors/suppliers of various bought out components highlighting the componentsactually supplied correlated to P.O.Item Numbers.

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

1.3.9 Release Note and Packing List.

1.3.10 Any other documents asked for in the Purchase Requisition.

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

1.4 SPECIAL INSTRUCTIONS FOR SUBMISSION OF DWGS./DOCUMENTS:

1.4.1 Contractor to forward the drawings and documentation to IGL (Attention vendor prints control department)clearly specifying purchasers Job no. & Req. No.

1.4.2 The drawing/Document no. with Rev. No. is essential. The number may be upto a maximum of 28 charactersin length.

1.4.3 Each Drawing/Document submitted to IGL must be checked and signed/stamped by contractor before it issubmitted to IGL.

1.4.4 Revision number must change during subsequent submission of vendor document.

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

1.4.6 Final submission in bound volumes shall necessarily have a cover page giving project title, Item name,P.O.No. Particulars of owner & vendor and an index giving list of drawings & documents included (withrevision no.).

1.4.7 All vendor drawings to be provided with a blank space measuring 75 mm W x 38 mm H for marking of reviewcodes etc. by IGL.

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1.4.8 The review of the vendor drawings shall be done by IGL, as applicable, under the following review codes:

Review Code 1/A No comments.

Review Code 2/B Proceed with manufacture/fabrication as per commented drawings.Revise drawings required

Review Code 3/C Document does not conform to basic requirements.

1.4.9 Review of vendor drawings by IGL would be only to check compatibility with basic designs & concepts & wouldin no way absolve the contractor/vendor of his responsibility to meet applicable codes, specifications & statutoryrules/regulations.

1.4.10 Vendor shall submit within 10 days after placement of FOI, the complete list of drawings/ documents withsubmission dates against each. Critical drawings, only, the list of which will be agreed during kick-off meetingshall be reviewed jointly at IGL's office.

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ANNEXURE-3: DEVIATION SCHEDULE FOR CNG DISPENSER

Vendor:

S.No. Vendor to specify Specification number and clausenumber against which Deviation is sought

Description of Deviation and give reasons insupport of Deviation

-------------------NO DEVIATION-------------------------

-------------------NO DEVIATION--------

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ANNEXURE- 4: M.R. COMPLIANCE SCHEDULE


Vendor:


1.0 Confirm compliance individually to following clausesof SpecificationSECTION: 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

Clause no 17.0

Clause no 18.0

Clause no 19.0

Clause no 20.0


SECTION B: Instrumentation & Control Specification

Clause no 1.0

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Vendor:


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 11.0

Clause no 12.0

SECTION C: Electrical Specification

Clause no 1.0

Clause no 2.0

Clause no 3.0

Clause no 4.0

2.0 Confirm that you have filled-up the followingSchedules and enclosed these with the BidExperience Record Schedule for Car Cum BusDispensers.

Deviation Schedule

Material Requisition Compliance Schedule

3.0 Confirm that you have filled-up the Dispenser DataSheet and enclosed with the Bid.

Dispenser Data Sheet

Mass Flow Meter Data Sheet

Control Valves

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Vendor:


Solenoid Valves

Self Actuated Pressure Control Valves

Pressure Relief Valve

Pressure Instruments

Pressure Gauges

4.0 Confirm that following Documents have been enclosedwith Bid.

Battery Limit (Interface) drawing/ information.

Weights & Measures Certificates from the country oforigin for offered models of Car Cum Bus Dispenserunit model/mass flow meter model for dispensingspecified mass flow rate at specified overall batchaccuracy.Type approval for the offered dispenser from Petroleum& Explosive safety organization, Govt. of IndiaG.A. drawing of Dispensers showing maintenanceclearances required.

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ANNEXURE-4: VENDOR DATA REQUIREMENT (INSTRUMENTATION)

S.No. DescriptionDocument Category

Inf. Review As built

1. Drag and Document Schedule * *

2. Piping and Instrument Diagram * *

3. Instrument Index * *

4. Sub- Vendor List for Instruments and Accessories *

5. Instrument Sizing calculations * *

6. Utility requirements *

7. Level Sketches *

8. Material requisition *

9. Purchase Requisition * *

10. Functional schematic * *

11. Logic diagrams * *

12. Instrument loop drawings * *

13. Control room layout * *

14. Panel front arrangement * *

15. Power Supply Distribution * *

16. Wiring diagram for panels * *

17. Configuration diagram * *

18. I/O assignment * *19 Details of OPC, configuration port, signals details etc * *

20. Instrument Duct/Tray layout * *

21 Instrument Cable schedule * *

22 Instrument location plans * *

23 Instrument installation drawings * *

24 Bill of material for installation items * *

25 Spare part list for

(a) 2 years operation *

(b) Start up and commissioning *

(C) Spare instruments (10%) * *

26 Inspection and test procedures * *

27 Complete catalogues with part list for all vendor suppliedinstruments, controls etc * *

28 Installation, operation and maintenance manuals *

Note: This list indicates the minimum drawings and document requirements. However vendor shall submit acomplete list of document and drawing schedule listing all drawings and documents to be submitted by them

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during the course of execution of the job. The schedule shall list all drawings and documents along with theirnumber and expected date of submission.

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PTS - CNG CAR CUM BUS DISPENSERSP.013429D 11077

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ANNEXURE - 6 QUALITY ASSURANCE PLAN

CODING STRUCTURE ManufacturerCodes for Extent of Inspection, Tests & Test Certificates Codes for DocumentsCode Description Code Description Code Description1 Visual 12 Power failure D1 Approved GA Drawing2 Dimensional 13 Failure of metering D2 Approved P&ID3 Fitment & Alignment 14 Failure of totalizer D3 Approved data sheet4 Physical Test 15 Calibration D4 Approved Bill of material5 Chemical Test 16 Pressure test D5 Purchase requisition Customer’s Information6 Running Test 17 Noise & vibration D6 W&M Certificate from country of origin Customer: M/s Indraprastha

Gas Limited, New Delhi(INDIA)Consultant : NoneLOA No.: IGL/ND/datedItem : CNG Car Cum BusDispensers

7 Leak Test 18 Enclosure protectiontest

D7 Calibration certificate of all measuring test /instruments and gauges

8 Dispenser shouldautomatically stop incase of failure oftotalizer

19 Paint shadeverification

9 Check for single banksystem

20 Test certificate forbought outcomponents

10 Check for manual shutoff

21 Flow capacity test

11 Batch accuracy test

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DETAILED INSPECTION AND TEST PLAN

EQUIPMENT DETAILS INSPECTION AND TESTS SCOPE OF INSPECTION AND TESTSSr.No

Description Qty. RAW MATERIAL ANDStage Inspection

FINAL INSPECTION Documents forsubmission toIGL/PMC/TPI

Acceptance Criteria Activity byIGL/PMC/TPI

MFR IGL/PMC/TPI

MFR IGL/PMC/TPI

1 DispenserFrame

360 1.2.3.4.5 1.2.3. 1.2.3 D1,D2,D3,D4 Tech. Specs in POReview of documents

2 Mass FlowMeter


3 Filling hose 720 1.2.3.4.5.16 1.2.3.16 1.2.3.16 D1,D2,D3,D4 Tech. Specs in PO Review of documents4 Totalizer 720 1.2.3.8 1.2.3.8 1.2.3.8 D1,D2,D3,D4,D7 D7 & Tech Specs in PO Review of documents5 Software 1 9 9 9 D3 Tech. Specs in PO Witness6 Pressure

Gauge720 1.2.3.4.5.15 1.2.3.15 1.2.3.15 D1,D2,D3,D4,D7 D7 & Tech Specs in PO Review of documents

7 PressureTransducer


8 Shut off valves 720 1.2.3.4.5.10 1.2.3.10 1.2.3.10 D1,D2,D3,D4,D7 D7 & Tech Specs in PO Review of documents9 Performance

Test (usingCNG)

360 11.21 11.21 11.21 D3,D7 D6, D7 & Tech Specs in PO Witness

10 Dispenserresponse

360 12.13.14.17.19.20

12.13.14.17.19.20

12.13.14.17.19.20 D3,D7 D7 & Tech Specs in PO Witness

Note:1. The Above Testing and acceptance criteria are minimum requirements, however, manufacturer shall ensure that the product shall also comply to the

additional requirements as per Particular Technical specifications(PTS)2. Owner/Owner representative shall review/approve all the documents related to QAP/Quality manuals/Drawings etc. submitted by supplier.3. All reference Codes/ Standards, Documents, P.O. Copies shall be arranged by vendor / supplier for reference of TPIA/IGL at the time of Inspection4. At the time of delivery of material in stores, vendor will submit copy of all related document of inspection along with release note & MTC.5. TPI/PMC/IGL have right to inspect minimum 10% of all manufacturing activities as specified above

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PTS – CNG STORAGE CASCADESP.013429D11077

008

INDRAPRASTHA GAS LTD.

CITY GAS DISTRIBUTION PROJECT

PTS – CNG STORAGE CASCADES

A 29.01.2020 Issued for Approval Gunja Gupta Rajveer Panwar ManishChandra

Rev. Date Description Prepared by Checked by Approved by

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Rev. A Supply of Cascade for City Gas Distribution Project Page I of I

TABLE OF CONTENTS

1.0 SCOPE ................................................................................................................................... 12.0 SITE ENVIRONMENT ............................................................................................................ 13.0 DESIGN BASIS & PHILOSOPHY ............................................................................................ 14.0 GAS COMPOSITION .............................................................................................................. 15.0 CODES AND STANDARDS ..................................................................................................... 2

6.0 SUPPLY AND SERVICES ........................................................................................................ 37.0 TECHNICAL SPECIFICATIONS .............................................................................................. 48.0 STORAGE CASCADES .......................................................................................................... 109.0 PROTECTION OF VALVES & ACCESSORIES ........................................................................ 11

10.0 EQUIPMENT ........................................................................................................................ 1111.0 INSPECTION AND TESTING ............................................................................................... 1112.0 CALIBRATIONS, TEST CERTIFICATES AND THIRD PARTY CERTIFICATION ...................... 1213.0 TRAINING REQUIREMENTS ............................................................................................... 1214.0 PROTECTION DURING SHIPPING ...................................................................................... 1215.0 EXPERIENCE RECORD PROFORMA FOR CASCADE ............................................................. 1316.0 CHECK LIST FOR SCOPE OF SUPPLY .................................................................................. 14

S S S

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Rev. A Supply of Cascade for City Gas Distribution Project Page 1 of 15

1.0 SCOPE

This document covers minimum requirement for design, engineering, procurement, fabrication /manufacture, assembly, inspection, testing at works and supply at site / OWNER’s stores CNG storagecascades.

2.0 SITE ENVIRONMENT

The climatic conditions to be considered for selection, design and derating of equipment shall be asindicated below:

· Maximum Wind Velocity : 160 Km/hr

· Maximum Ambient Temperature : 40 0C

· Minimum Ambient Temperature : 3 0C

· Design wet bulb Temperature (WBT) : 27 0C

· Relative Humidity : 90 %

· Altitude, M above MSL : 12.48 meters

The equipment offered shall be suitable for smooth, efficient and trouble free service in the tropical climateprevailing at site as indicated above.

The equipment shall be designed to give efficient and reliable performance under outdoor industrial conditionsand shall be rendered proof against rats, lizards and other vermin.

3.0 DESIGN BASIS & PHILOSOPHY

3.1 Design Basis

The Supplier should prepare the design basis required to meet the requirement with respect to technicalspecification and liaise with PMC/ Owner to obtain necessary confirmation and approval.

3.2 Design Philosophy

Storage fulfils three functions.

1. It allows more vehicles to fill than the compressor could fill directly one after the other during peak times.

2. It allows the vehicle to fill at a faster rate than if directly from the compressor.

3. It prevents the compressor from stopping and starting too often.

It is anticipated that the natural gas feed composition, flow rate and pressure will be fluctuating. Hence, Suppliershould design the CNG storage facilities with optimum degree of flexibility, reliability, operability toaccommodate the varying composition of feed, other unexpected contaminants, flow rate and pressure.

The CNG storage facilities should consist of standardised modules, which are assembled into a completesystem. Each system should be designed in standardized modular frames. The modular approach allows theCNG Stationary facilities to be easily installed there by reducing installation time.

The design life of the CNG storage facilities should be 20 years.

4.0 GAS COMPOSITION

Component Design case mole. %

Methane 94

Ethane 1.2

Propane 1

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i-Butane 0.4

n- Butane 0.00

i- Pentane 0.00

n- Pentane 0.00

Carbon Dioxide 1.8

Carbon Monoxide 00

Nitrogen 1.6

SUM 100

NOTE:

· Oxygen: Not more than 0.5% mole.

· Total non-hydrocarbon: Not more than 2.0 mole%

· Total Sulphur including H2S: Not more than 100 ppm by weight.

· Expected H2S content not more than 4 ppm by volume

· Water content: Less than 112 kg/MMSCM specific gravity

· Mass density (kg/Sm3) : 0.736

· Molar mass (kg/Kmol) : 17.3551


The design, construction, manufacture, supply, testing and other general requirements of the StorageCascades should be strictly in accordance with the Applicable Standards and Codes and should comply fullywith relevant Indian / International standards, Gas Cylinder Rule1981, Indian Explosives Act- 1884,Stationary and Mobile Pressure Vessels (Unfired) Rules (SMPV) 1981, CNG Cylinder.

Design Code, IS:7285, CNG Cylinder Valves, IS:3224-1979 (Amendments 1983,84,85,86,89,92,98),Hydrostatic Stretch Test, IS: 5844 – 1970, Safety Devices of Gas Cylinders, IS : 5903 -1970, regulations ofInsurance Association of India and Factories Act while carrying out work as per this specification.

The bidder without any additional cost and delivery implications should carry out any modificationsuggested by the statutory bodies either during drawing approval or during inspection, if any.

CODES AND STANDARDS TO BE FOLLOWED

Latest edition shall be followed

IS 7285 Specification for seamless steel cylinders for permanent and high pressureliquefiable gases.

IS 3224:2002 Valve fittings for compressed gas cylinders excluding liquefied petroleum gas(LPG) cylinders.

IS 5844 – 1970 Hydrostatic Stretch Test

IS 5903 – 1970 Safety Devices of Gas Cylinders

OISD - 179 Safety requirements on compressors, storages, handling and refueling of naturalgas for use in automotive sector.

GAS CYLINDER RULES - 2016

INDIAN EXPLOSIVES ACT -1884

STATIONARY AND MOBILE PRESSURE VESSELS (UNFIRED) RULES (SMPV) 1981

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ANSI, ASTM, NEC, NEMA, ASNZ, NFPA

NFPA 52 Standards for CNG vehicular fuel systems

SAFETY DEVICES OF GAS CYLINDERS IS: 5903 -1970, regulations of Insurance Association

PNGRB Regulation: Notification on 9th March, 2016 (with Principal regulation notification no. G.S.R612(E), dated 27th August, 2008, amended vide G.S.R 750 (E) dated 14.10.2009, F. No. M(I)/T4S/CGD/1/2010 dated 16.12.2014.

GAS CYLINDER CASCADE: A battery of cylinders connected with each other, a tube trailer, multipleelement gas containers and bundle of cylinders, confirming to the specification: BS EN -13769, BS EN -13807, ISO-10961 or any other specification accepted by the Cheif Controller.

All the applicable statutory codes, national laws and local regulations for safety and environment protectionshall be followed by the supplier for design, engineering, fabrication etc. The supplier shall obtain fromconcerned authorities all necessary approvals.

6.0 SUPPLY AND SERVICES

6.1 Supply

Supply of CNG storage cascades of capacity 3000 water liter (- 0%, + 5%) at 15°C with followingminimum details:

Cylinders & Others

· All cylinders should be designed, constructed and tested in accordance with the Indian Standard 2825,as amended from time to time, IS : 7285 Part II or similar such other standard code approved by theChief Controller of Explosives

· Robust painted Iron cascade frame. The iron surface shall be properly cleaned, primer and paintselected and applied to have a service life of at least five years. The exterior of the equipment isrequired to be corrosion free for at least five years and to have a fade free life without oxidation of paintsurface for at least five years in an environment of bright sunlight with an intense UV content. Thebidder to specify the grade of paint intended to be used.

· Material of Flange, Header pipe, female nipple for vent manifold should be of Carbon Steel (CS).

· Interconnecting tubing/piping, fitting, valves.

· Non return valves (NRVs) as required for three bank operation.

· Pressure on each bank (Low, Medium & high Bank).

· Temperature gauge on high Bank.

6.2 Services

The services to be rendered by supplier shall include but not limited to the following:

· Preparation and submission of documents/ drawings as per schedule under point “D” of MR and Gasflow calculations, 4-G static test Calculation of one complete assembled cascade with all the cylindersmounted & filled and sequencing calculations for cascade for maximizing the recovery from thecascade storage for residual cylinder pressure of incoming vehicle for refill pressure 35 bar g

· Obtaining approvals from concerned departments/ agencies/ statutory authorities such as BISCertificate, PESO etc.

· Procurement of raw materials, bought out components, fabrication, shop assembly.

§ Pipe work should be designed, tested and installed to ensure its safe operation at the worst conceivableconditions of flow, pressure and temperature.

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· Shop inspection and testing including third party inspection (TPIA) or inspections by OWNER’sdelegate and statutory approvals.

· Testing at site, if required.

· Packaging, crating, dispatch of cascades.

· Cascade commissioning assistance.

· Paintings as per the present document.

· Preparation and submission of documents / drawings as per schedule.

· Bidder to submit foundation and other drawings indicating requirement of work to be carried out byOwner within one month of placement of order.

· Supervision during trail run, if required.

7.0 TECHNICAL SPECIFICATIONS

The following specification is to give the supplier the technical and operating conditions the cascades mustfulfil. Features other than those indicated herein but which call for a better design, increase in efficiency,enhance reliability, optimization may be accepted subjected to OWNER’s approval. The Supplier maysubmit their bid for any alternative design as optional item which may be indicated separately describing alladvantages. The cascade shall be shipped in completely assembled condition. Gas supply line and deliveryconnection shall be made at site.

The supplier shall bid in their main offer, items according to the technical specifications outlined below.

7.1 Cascade

§ Cascade shall be a group of identical cylinders of capacity required to meet the specified total watercapacity, dimensional and weight limitations. The cascades shall also be provided with structural framehaving facility of lifting and placement.

§ Cascade Storage Capacity

The water storage capacity of cascade shall be 3000 and 4500 (-0%, +5%) water litres at 15 degree C(Cylinders conforming to IS: 7285).

§ Cascade storage dimension :

For ready access and to ensure that all cylinder fittings are easily accessible, multiple cylinder units,which comprise a CNG storage facility and are stored in a vertical position should be limited to a widthof 1.2m, a length of 5.5m and a height of 1.6m above floor level.

For 3000 WL : L x W x H – 3600mm x 2000mm x 1600mm.

In the case of storage facilities in which cylinders are in a horizontal position, each storage unit shouldbe limited to a height of 1.6m, a length 5.5m and a width equal to the length of one cylinder up to 2m.To ensure ready access all cylinder fittings should be arranged to face one direction in each unit. Eachsuch storage unit should be separated from other units by a distance of not less than 2m. Wherehorizontal units are placed parallel to each other, cylinder fittings should be arranged so that they do notface cylinder fittings of other units.

§ The water liter capacity of any individual cylinder in-group of cylinders forming cascades shall notexceed 75 liters at 15o C for 3000 water liter capacity cascades.

§ The design, construction & testing of cylinder shall be as per IS 7285 and approved by Petroleum andExplosive Safety Organization (PESO), Government of India for use in India for specified conditions.-

§ Storage cylinder manufactured older than 2016 shall not be accepted.

§ Working Pressure of cascade cylinder shall be minimum 250 bar g at 15 0C.

§ Cylinder material shall be seamless alloy steel (Cr-Mo) as per design / drawings approval by approvedby Petroleum and Explosive Safety Organization (PESO), Government of India.

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§ Cylinder neck threading shall be as per IS 3224- 2002 or as per design approved by PESO, Governmentof India.

§ Offered Cascades shall be of 75 liters Water Capacity cylinders and supplier shall observe minimumneck threads size of dia 25.4 mm standard. Type 4 threads with a taper of 1 in 8 on diameter confirmingto IS-3224: 2002 or equivalent.

§ The cylinder shut-off valve shall be with combination Fusible Bursting Disc conforming torequirements of IS 3224: 2002 or as per design approved by PESO, Government of India

§ The burst disc shall rupture on excess pressure as well as excess temperature either individually orcombined. The burst disc discharge shall be manifold to a common header for safe venting. Suppliershall indicate burst pressure and temperature.

§ The cylinder shut-off valve orifice shall be designed for high flow to permit the combined flow of 100kg/min from each bank at pressure of 250 bar g. Supplier to furnish necessary calculations indicatingoverall pressure drop for each bank, Coefficient of flow (Cv) values, valve orifice size etc.

§ Number of cylinders in the Stationary cascade shall be divided into three independent banks of low,medium and high pressure of different storage pressures. Supplier shall optimize the number ofcylinders in each bank for maximizing the recovery from the cascade storage and submit thecalculations along with the bid. Supplier may assume the residual cylinder pressure of the vehiclecoming for refill at 35 bar g

§ The interconnecting tube work of cylinders manifold in configuration suitable for priority filling andsequential dispensing system by the electronic CNG dispensers at the Retail Outlets.

§ Full bore ball valves for isolation shall be provided at inlet of each fill line and at each bank outlet line.The final end connection at battery limit shall be ¾” OD with union and double ferrules for directlyconnecting a ¾” OD tube.

§ Ball Valve must be of good quality and be appropriately selected frequency of use.

§ Ball valve seats must be suitable for natural gas operation of the gas composition indicated.

§ Valves and fittings subject to corrosion must be either inherently resistant, or be coated with acorrosion inhibiting paint or surface treatment.

§ The interconnecting tube work shall be minimum of ¾”OD tubing. The sizing of connecting tubingbetween each outlet and its associated cylinders shall be such that where they join the total incomingflow areas shall not be less than outgoing area. The loops in tube work shall be provided for absorbingcontraction, expansion and vibration piping / tubing shall be suitably clamped to the frame structure.

§ Pipe work should be designed, tested and installed to ensure its safe operation at the worst conceivableconditions of flow, pressure and temperature

§ The system should be “go-no-go” gaugable to demonstrate that fittings are properly tightened.Wherever possible valves and control devices should incorporate the same end connector system. Thenumber of fittings used should be minimized.

§ A Test and Inspection certificate issued by the manufacturer of the cylinder duly countersigned by anInspector that the Cylinder meets the requirements of the standard or code referred above submitted toPESO shall be provided.

§ All cylinders should be new and unused. Re-certified cylinders are not acceptable. Before using theCylinder or before refilling the cylinder, which has to be made gas free, air contained therein shall bepurged by an inert gas or by the CNG gas. Cylinders of 75 liter water capacity at 15°C are onlyenvisaged. All cylinders in a cascade shall be of same capacity.

§ The Supplier should ensure that Personnel assembling the piping work should be competent in thesystem employed.

§ The preferred valve types for isolation are ¼” turn ball valves. Such valves have similar material to theattached tube / Fittings.

§ Cylinders in the cascade may be vertically or horizontally placed. In case of horizontal configuration,minimum 30mm cylinder to cylinder gap shall be provided (Conforming to requirements of OISD-

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179). The material used to separate the cylinders should be sufficiently strong enough and should notabsorb moisture. Special precautions should be taken to avoid corrosion at the point of contact.

§ All cylinder valves and fittings must be rated for the full range of temperature and pressures and themanufacturer should stamp or otherwise permanently mark the valve body to indicate the servicerating.

§ Double compression ferrule Fittings shall be used in tube connection tubes.

§ Each cylinder shall be hydrostatically tested by the cylinder manufacturer. Third Party Inspectionagency shall review the test certificate of the manufacturers.

§ The location of inlet/ outlet tube and pressure gauges shall be as per approved drawing.

§ Cascade to be purged with N2 after testing and shipped with a positive pressure of N2 in the cascade .Suitable arrangement for venting natural gas shall be provided at a level above the cascade shed (orroof) in case of a leakage.

§ Suitable vent to be provided for stationary cascade. The height of the vent should be 3m from the baseof the cascade.

7.2 Marking of cylinders

a) Every Gas cylinder shall be clearly and permanently marked in accordance with the followingconditions by stamping, engraving or similar process;

a.1 on the shoulder of the cylinder which shall be enforced by forging or other means, or

a.2 on such a part which is inseparably bound with the cylinder and which is not or only negligiblyeffected by the stresses due to the gas pressure within it.

b) The name plate shall not be affixed to the cylinder by soldering, if there is risk of corrosion orembrittlement.

c) In conjunction with the original marking, space shall be provided for stamping the test dateobtained at the periodic inspection.

d) Markings shall be as carried out and the letters and numerals used shall be such shape and size that themarking is clear and easily readable and does not give place for misreading.

e) All cylinders must be permanently stamped with the word CNG together with the followinginformation:

e.1 Manufacturer’s, owner’s and inspector’s marking and rotation number; (These markings shall beregistered with the PESO;

e.2 Specifying that the cylinder has been manufactured for “CNG only”

e.3 A symbol to indicate the nature of heat treatment (such as normalizing, quenching, or tempering)given to the cylinder during manufacture.

e.4 The date of the last hydrostatic or hydrostatic stretch test, as the case may be, with the code markof recognized testing station where the test was carried out. The code mark shall be registered withthe PESO.

e.5 Working pressure and test pressure;

e.6 Tare weight

e.7 Water capacity.

f) All the markings, except the manufacturer’s marking, which may be on the base, shall be stamped onthe neck end of the cylinder.

7.3 Marking on valves

Valves fitted to the cylinder shall be clearly and durably marked in accordance with the followingprovisions by stamping, engraving or similar process:

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i) Specification of the valves.

ii) Year and quarter of manufacture.

iii) Manufacturer’s symbol.

iv) Working pressure.

v) The name or chemical symbol of the gas for which the valve is to be used.

vi) The type of screw threads on the outlet namely left handed (L.H) or Right handed (R.H).

vii) Inspector’s stamp.

7.4 Labeling of cylinders

§ Every cylinder shall be labeled with the name “CNG ONLY” with letter of at least 25mm high incontrasting colour and the name and address of the Purchaser by whom the cylinder was filled with gas.

§ A warning in the following terms shall be attached to every cylinder containing Compressed NaturalGas namely:-

i) Do not change the color of the cylinder

ii) This cylinder should not be filled with any gas other than CNG.

iii) No flammable material should be stored in the immediate vicinity of this cylinder or in the sameplace in which it is kept.

iv) No oil or similar lubricant should be used on the valves or other fittings of this cylinder.

v) Please look for the next date of test, which is marked on a metal ring inserted between the valveand the neck of the cylinder, and if this date is over, do not accept the cylinder.

§ All Stationary storage system should be supplied in a three bank arrangement. Low bank 50%, Mediumbank 30% and High bank 20% of the total storage system.

§ Supply of required nos. of 20 dia. J type foundation bolts with nuts, 200 mm long with threaded length50mm & Supply of required nos. of 20 dia. Anchor bolts with nuts, 100 mm long with threaded length50mm as applicable will be in the scope of supplier for suitable fixing of stationary storage cascades atsite.

7.5 Pipe Work, Valves and Fittings

Pipe work should be designed, tested and installed to ensure its safe operation at the worst conceivableconditions of flow, pressure and temperature.

All pipe work should be ASTM 316 stainless steel tube. Double compression ferrule Fittings shall be usedin tube connection tubes. And makes of these fittings shall be of SS 316 of Swagelok, Parker only. Thesystem should be “go-no-go” gaugable to demonstrate that fittings are properly tightened. Whereverpossible valves and control devices should incorporate the same end connector system. The number offittings used should be minimised. The Supplier should ensure that personnel assembling the pipeworkshould be competent in the system employed. The preferred valve types for isolation are ¼” turn ballvalves. Such valves have similar material to the tube they are attached to. Ball valves must be of goodquality and be appropriately selected frequency of use. Ball seats must be suitable for natural gas operationof the gas composition indicated. Valves and fittings subject to corrosion must be either inherently resistant,or be coated with a corrosion inhibiting paint or surface treatment.

The gas inlet connection of each bank shall be terminated with ¾” union after the isolation valve.

Supply of required nos. of 20 dia. J type foundation bolts with nuts, 200 mm long with threaded length50mm & Supply required nos. of 20 dia. Anchor bolts with nuts, 100 mm long with threaded length 50mmas applicable will be in the scope of supplier for suitable fixing of stationary storage cascades.

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7.6 Pressure Relief Devices

§ Each cylinder used for the storage of CNG should be equipped with a suitable pressure relieving deviceand a suitable isolating valve which should be readily accessible when installed in the storage bank.The isolating valve should not be capable of closing off the pressure relieving device, or should belocked in the open position.

§ Relief devices should be positioned in such a way as to avoid discharge of high pressure gas to theoperator or persons in close vicinity.

7.7 Safety Relief Devices for cylinder storage

§ Cylinders manufactured in India, if fitted with safety relief devices in their bodies, shall have suchsafety devices manufactured and maintained in accordance with IS: 5903.

§ Piping and gas storage systems should be protected against overpressure by safety relief devices. Reliefdevices installed to protect the storage systems should have sufficient capacity to vent the maximumflow produced by the compressor and should be set to open at a pressure not exceeding 20% above themaximum allowable working pressure of the system or the pressure which produces a hoop stress of75% of the specified minimum yield strength, whichever is lower.

§ A combination burst disc/fusible alloy assembly should be incorporated in the cylinder valve. Burstdisc should yield at a pressure not less than 1.5 times manufacturer’s recommended operating pressureof the cylinder, and not more than test pressure. The disc should relieve pressures in excess of 30Mpa.

§ In addition to above a mechanical pressure relief valve which opens at a predetermined pressure shouldbe used. This should not be part of the cylinder valve.

§ Safety relief valves should be provided with means to seal to prevent tampering by unauthorizedpersons.

§ Minimum required rate of discharge from the safety valve should be at least equal to any input from thesystem whether stored or being compressed.

§ Each safety relief valve should be clearly marked by the manufacturer.

§ The maximum pressure in the storage system should not exceed 275 bar (g).

§ The cascade cylinders should be supplied with impact test certification.

7.8 Corrosion Protection

§ Pressure vessels which are made of materials that are subject to corrosion by atmospheric conditionsshould be protected by painting or other equivalent means necessary to prevent corrosion.

§ Importance should be drawn to avoiding corrosion which can limit the working life of a cylinder andaffect the fatigue characteristics in serious cases. The implementation of good periodic maintenanceanti-corrosion procedures is strongly recommended.

7.9 Valves

§ All Valves fitted to gas cylinders shall comply in all respects with the following Specifications namely:

a. In respect of Industrial Gas Cylinder, IS: 3224

b. Valves for cylinders shall have outlets provided with left hand screw threads for the pipes orconnections.

c. The valves shall be attached to the cylinder neck by screwing and not by making any permanentattachment or inserting adapter in between.

d. The design of spindle operated valves shall be such that when fitted to the cylinders it shall not bepossible to withdraw the spindle under normal operating conditions.

§ Each gas storage unit should have a quick action gas storage isolation valve installed in the steel supplypipe immediately adjacent to its gas storage unit to enable individual shut off and isolation of each unit.These valves will be within fence enclosure.

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§ Separate common valve system to be supplied for each storage bank complete with non-return valve.

7.10 Cascade Frame

§ The frame shall not allow lateral and rotational movement of cylinders during regular road transportunder any circumstances. Suppliers shall take into account the rough patches / bumps on roads.

§ Frame shall be free standing and have facility for lifting by crane and forklift the complete assembledcascade. Bottom and top of frame shall be reinforced to prevent any twisting or strain to inter-connections among cascade cylinders during lifting by crane, forklift and during the transport.

§ Frame structure of each cascade shall be capable of withstanding 4G impact (four times gravity) fromany direction without any distortion. Supplier to submit 4-G static test Calculation of one completeassembled cascade with all the cylinders mounted.

§ Each storage system should be supplied with suitable lifting lugs. Bottom and top of frame shall bereinforced to prevent any twisting or strain to inter connections among cascade cylinders during liftingby crane, forklift and during transport.

§ Cascade storage system to be skid mounted and complete with removable metal frames and non-metal /non-sparking spacer material.

§ Cascade and spacer frame to be painted with anti-rust and etching primer under coat. Importanceshould be drawn to avoiding corrosion which can limit the working life of a cylinder and affect thefatigue characteristics in serious cases. The implementation of good periodic maintenance anti-corrosion procedures is strongly recommended.

§ All cylinder tubing, manual isolation valves and pressure relief valves should be protected fromknocking by any moving object and should not protrude outside the metal frame or brackets.

§ Frame shall be suitably covered with canopy from top to avoid the ingress of Sunlight & rain water.The storage of the cascade of cylinders should be made in a well – ventilated shed having a light roof orcanopy with at least one side open. An area of least 1 meter around the cascade shall be provided withinshed, Conforming to Gas Cylinder Rule: 2016. Height for vent pipe of the Stationary cascade shall be1m above canopy All items used in the frame shall be weatherproof.

§ Supplier shall submit structural drawing of the frame giving details of the steel, welding procedure,corrosion protection for approval of Owner / Owner’s representative before commencing fabricationwork.

§ Frame shall support the cylinder adequately and allow the cleaning of cylinder.

7.11 Piping / Tubing / Fitting/ Pressure gauges / Temperature gauges

§ All rigid piping, tubing and other components on the storage system should be designed for the fullrange of pressures, temperatures and loadings to which they may be subjected with the factor of safetyof at least 4 based on the tensile strength at 20°C. Any materials used including gaskets and packingshould be compatible with natural gas and its service conditions.

§ All piping should be designed in accordance with engineering calculations based on the requirements ofASME B31.3 in conjunction with EEMUA supplement to ASME B31.3 or equivalent design standards.Standards used should be used in total.

§ All welding piping should be fabricated and tested in accordance with ANSI/ASME B31.3, API 1104or an equivalent standard. Whichever standard is chosen for use, it should be used in total.

§ All piping to be tested after assembly to a pressure equal to that of the pressure relief device setting andproved leak free.

§ Materials used for the piping shall be stainless steel 316 fully annealed seamless confirming to ASTMA269 with maximum hardness of Rb80 or less and suitable for bending and flaring. OD tolerance shallnot exceed +0.005%. The piping/ tubing material shall be of Sandvik / tubacex make.

§ All fittings including valves shall be of Swagelok/ Parker make. Material shall be SS 316 conformingto ASTM A269. Open ends on fittings and vents shall be provided with caps.

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§ Double compression ferrule Fittings shall be used in tube connection tubes.

§ Liquid filled pressure gauge of diameter 4", (0-400 kg/cm2) with a 3- way isolating valve or 2 – valvemanifold block on each bank shall be used. Thus each cascade shall have three pressure gauges.Pressure gauges shall be securely mounted.

§ Every CNG storage unit including each manifold group or bulk storage tank should be provided with asuitable pressure gauge for each bank. The pressure gauge should be directly connected to the tank orstorage system. The gauge should be dial graduated to read approximately double the operatingpressure.

§ A good quality industrial pressure gauge should be used with a dial face of at least 63mm or larger.Gauges should be built to requirements of BS 1780 or ANSI/ASME B40.1 or OISD-179 equivalent.

§ Temperature gauge of diameter 4" with necessary arrangement on high bank only shall be used. Thuseach cascade shall have only one Temperature gauge on high bank.

§ All end connections, pressure & Temperature gauges, valves and fittings of cascade shall be withintamper proof, wire cage enclosure. These shall be on one side of cascade for ease of operation.

§ Material of vent tubing shall be SS 316 and make shall be of Sandvik / tubacex.

7.12 Painting

Every cylinder is painted with the appropriate identification colors specified in IS: 4379 for industrialcylinder

Color of the Cylinder shell --- White

Color of band at neck and of cylinder ---- Red (IS standard color No. 537)

Color of the Frame ---- Yellow

§ The paint shall be chosen, primed and applied as to have a service life of five (5) years. The exteriorsurface is required to be corrosion free for five (5) years and to have faded free life without oxidation ofpaint surface for five years in an environment of bright sun light with an intense UV content.

§ Surface preparation by Shot Blasting as per grade SA 2 1/2, IS 9954 / ISO 8501. Three coats of paintshall be applied with minimum thickness of 300 micron. The recommended painting system should beof Category C5–I Very high (Industrial) as specified in the Standard ISO 12944 Part 1 to 8. Theproposed Painting system shall conform to Table A 5 of ISO 12944 – 5 Standard.

8.0 STORAGE CASCADES

§ All storage system should be supplied in a threebank arrangement.

§ All the Cylinder Specifications, valves, safety relief devices, pressure gauges, pressure Relief devicesetc shall remain same as mentioned in the Stationary cascades but not limited so.

§ Each cylinder of storage cascades used for the transport of compressed natural gas shall be a typeapproved by the PESO/ CCOE.

§ Every cylinder used for transportation of compressed gas shall be constructed and tested in accordancewith IS: 2825, as amended from time to time, or BS5045:Part1 or (US) D.O.T 3AA or similar suchother standard code approved by the Chief Controller of Explosives.

§ The design stress shall include an allowance to include an allowance to enable the cylinder to withstandshocks normally encountered by the movements on road, such as acceleration and deceleration for aminimum of 4g (4 times gravity).

§ All the attachments to the cylinders shall be protected against accidental damage which may result fromcollision, overturning or other operational cause.

§ All the cylinders shall be designed to withstand the most severe combined stresses to which they maybe subjected to by the pressure of the gas, the pumping pressures and shock loading caused by transportconditions.

§ The isolation valves and the end connections shall be terminated at the left side of the storage frame.

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§ End connections shall be such that tube manifold accessible from side of the vehicle and can beconnected to station piping from any one side of the vehicle.

9.0 PROTECTION OF VALVES & ACCESSORIES

§ All valves and accessories shall be safeguarded against accidental damage or interference.

§ Valves and accessories shall be mounted and protected in such a way that risk of accidental rupture ofthe branch to which the valve or accessory is connected is minimized.

§ Valves and accessories situated at the rear of a vehicle shall be protected by the rear cross member ofthe frame of the vehicle against damage.

10.0 EQUIPMENT

§ Piping, Fittings and meters:

a. All piping, fittings and meters mounted on the cascade shall be designed to with stand the mostsevere combined stresses imposed by the following, namely.

a.1 The maximum designed pressure of the vessel.

a.2 The super imposed pumping pressure of the shock loading.

b. The materials used for vessel equipment shall be sufficient ductile to withstand rough usage andaccidental damage. Brittle materials such as cast iron shall not be used.

§ Protection of piping and equipment;

a. All piping and equipment shall be adequately protected to minimize accidental damage whichmay be caused by rough usage, collision or overturning;

b. Any equipment or section of piping in which liquid may be trapped shall be protected againstexcessive pressure caused by thermal expansion of the contents.


§ Before bringing any items of equipment to site, factory testing should be carried out to demonstrate thefunction of all equipment within the system if so desired.

§ supplier shall be given 2 weeks notice of the date and location of the tests so that the equipment may bewitnessed if desired.

§ Upon delivery to the site, all the equipment should be assembled in a complete system. Thereafter, finalsite acceptance test would be carried out. Such tests should be witnessed and signed off by theCompany representative. The Supplier should rectify and replace all defects, faults, failures, etc. and allcosts should be borne by Supplier. The costs should include accommodation, travelling, expenses, etc.

§ Supplier shall carryout 4G static calculation of one complete assembled cascade with all the cylindersmounted and filled and submit the same for Owner review.

§ Supplier shall carryout cylinder bursting test of one cylinder from the entire batch produced for supplyto OWNER in case offered cylinders are of new design (conforming to the requirement of IS 7285.Supplier shall inform the schedule of the test well in advance to enable Owner or their authorizedrepresentative to depute technical personnel for witnessing the test.

§ Supplier shall carry out all standards shop tests/QA/QC as per recommendation of manufacturer/ChiefController of Explosives. Copies of the testing/inspection carried shall be furnished to OWNER.

§ Supplier shall furnish record of storage capacity check of each cylinder in a cascade and the same needto be demonstrated to Owner or their authorized representative.

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§ Each assembled storage cascade with all tubing, valves shall be pressures tested to ensure existence ofno leakage prior to dispatch.

§ Manifold of the cascade shall be tested to 250-bar g. The manifold shall be checked for sequencing andno back flow between any two banks with all valves open.

§ Dispatch Clearance to be given by OWNER after final Inspection to be witnessed by OWNER/ThirdParty Inspection agency appointed by OWNER.

12.0 CALIBRATIONS, TEST CERTIFICATES AND THIRDPARTY CERTIFICATION

§ Every Cylinder should be carried with Hydrostatic or Hydrostatic stretch test and a certificate should beprovided.

§ Leak test should be carried for each cylinders or cascades with all tubing’s, valves and a certificateshould be furnished to the Owner.

§ All Instrument gauges, Valves, Pressure gauges, safety relief devices, shut off valves tubing’s andpiping etc should be Pressure tested, calibrated and such test, calibration certificates, should bepresented upon delivery to site. If any of the test certificates is not in order, the Supplier’s shouldreplace the affected equipment with valid certificate at Supplier cost.

§ Calculation shall be carried for 4g Stationary of one complete cascade with all cylinders mounted andfilled and the same should be submitted for review of the Owner.

§ Burst test of one cylinder from the entire supplies shall be produced and incase offered once are newdesign the schedule for the test should be informed prior to enable the Owner or their authorizedrepresentative to depute their personnel for witnessing the test.

§ All standards shop tests/ QA / QC as per the recommendation of the manufacturer / Chief Controller ofExplosives to be carried out and a copy of such certificates shall be furnished to the Owner.

§ Record of storage capacity check of each cylinder in a cascade shall be furnished and same shall bedemonstrated to the Owner/ its representative.

13.0 TRAINING REQUIREMENTS

§ The Supplier should develop a training proposal and prepare a schedule for the Company’s review,comment and approval.

§ The training programme should be phased to suit the construction program such that the Company’spersonnel are fully conversant with all aspects of the operations and maintenance of the storage systemsincluding all aspects of operations, pressure control and integration of the overall system.

§ The training programme should cover but not limited to the following subject areas:

Ø The physical characteristics of the gas and the procedure and precautions to be observed inhandling and control.

Ø Start-up, operations and maintenance procedures for the CNG storage facilities.

14.0 PROTECTION DURING SHIPPING

The cascade shall be packaged to withstand rough handling during ocean shipment and inland journey. Itshall be supplier's responsibility to make good any deterioration and that occurs during shipment. Slingpoints shall be clearly indicated on crates.

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15.0 EXPERIENCE RECORD PROFORMA FOR CASCADE – NOT APPLICABLE FOR THISTENDER

Supplier must fill the following format

S. No. Parameter Information onoffered model

Information onexisting cascade

(Location)1. No. of units 1 2 32. Service3. Working pressure of cascade in bar g4. Site min/ max temp.5. Normal flow from each bank kg/hr6. Cascade water capacity-liters7. Water capacity of single cylinder used in

cascade-liter8. Material of cylinder9. Thickness of cylinder wall and disc end in

mm

10. Material of vent tubing11. Piping material and make12. Valve make13. Valve type and dia.14. Nos. of banks in cascade15. Nos. of cylinder in low bank16. Nos. of cylinder in medium bank17. Nos. of cylinder in high bank18. Water capacity of cylinders in individual

banks19. Contact person20. 4 G static calculation for one complete

assembled package21. Cylinder burst test for one cylinder22. Design standard (Code) used23. Total weight of cascades in tones24. Burst pressure and temperature for burst disc

in bar g and deg C.25. Hydrostatic or Hydrostatic Stretch Test26. Pressure test for leakage27. Design case gas composition28. Approved Manufacturer License certificate

from PESO29. Dimensions of the Total package30. Warranty certificates31. Dimension of package max.32. Calibration certificates for all instrument

gauges etc of package33. Test certificates of all instruments with

cylinder, tubing's, fittings of total package34. Date of commissioning of cascade35. Approval from PESO Nagpur36. Dimensions of package Max.37. Date of commissioning of cascade38. Where cascades are located: Address and

fax/ telephone no. of39. Major problems encountered, if any

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16.0 CHECK LIST FOR SCOPE OF SUPPLY

§ Vendor shall furnish all the equipments of Storage Cascade System instruments and gauges and safetydevices as per the enquiry document. Anything required over and above what is specified, for safe andsatisfactory operation of the equipment package shall be included by the Vendor in his scope.

§ Vendor to write YES/NO against each item. Vendor is required to include complete scope, as such 'NO'is not warranted. However, in case for any of the items if supplier's reply is 'NO', supplier should givereason for the same:

§ Vendor's scope of supply shall include but not limited to the following :

Sr. No Description Specifiedby

PurchaserYES / NO

Includedby VendorYES / NO

Remarks

1.0 Each Storage cascade Packagecomplete with:

1.1 Specification - Indian Standard 2825, as amendedtime to time, IS : 7285 similar such other standardcode approved by PESO

YES

1.2 Cylinder material - Seamless alloy steel (Cr-Mo)or standard code approved by the Chief Controllerof Explosives.

YES

1.3 All the fittings, Valves, Safety devices, gaugesare as per IS 3224 or standard code approved bythe Chief Controller of Explosives.

YES

1.4 Tubing's are of rigid type ASTM 316 stainlesssteel tube. YES

1.5 All cylinders are Hydro static Tested YES1.6 Water capacity of single cylinder used in

cascade not less than 75 Ltrs. YES

1.7 Nos. of banks in cascade- three bank system forStationary Cascade YES

1.8 One Cylinder should be burst test YES1.9 4-G Stationary calculation for one complete

assembled package is done YES

1.10 Working Pressure of Cascade min. 250-255 bar (g) YES1.11 Pressure test for Leakage on cylinders with

assembled condition YES

1.12 Isolation Valve complete with venting line valveand end plug installed on the inlet of the cylinder YES

1.13 Copy of Calibration certificates for all instrumentgauges etc of Cascade package, Test certificates ofall instruments with cylinder, tubing's, fittings oftotal package

YES

1.14 BOQ with weight of each component YES1.15 Drawing of cylinder of specified parameters

approved by CCOE YES

1.16 Drawing of cascade frame YES1.17 Storage cascade with frame assembly is shipped in

fully and assembled condition only to be mountedon anchored bolts laid at site.

YES

1.18 GA drawing of the cascade YES1.19 Warranty for a period of 12 months is provided

from the date of final site acceptance of CNGfacilities by the Company's. YES

1.20 Make of bought out items YES

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Sr. No Description Specifiedby

PurchaserYES / NO

Includedby VendorYES / NO

Remarks

1.21 Detailed time schedule for supply indicating timeperiods required for cylinder manufacturing,cascade frame fabrication, shop testing, dispatch ofmaterial from works at delivery site

YES

2.0 Spares2.1 Mandatory spares as specified in the "Check List

for Mandatory Spares"(Indicate separate price foreach item)

YES

3.0 Inspection and Testing3.1 As specified on the Inspection and testing clauses YES4.0 Supplier Data and drawings4.1 All data & drawings as required per VDR format

as per Material Requisition. YES

5.0 Supervision during the Trial Run if required atsite of the CNG storage cascade system

5.1 Additional Items not specified by purchaser butrecommended by bidder for safe smooth andnormal operation. (Bidder shall indicate separatelist of such items in his proposal)

YES

6.0 Technical Parameters to be confirmed bysupplier

6.1 Pressure range from 19 bar (g) -250 bar at 15 °C YES6.2 Fill Pressure Kg/cm2g or [bar(g)] -200 YES6.3 Operating Temperature range -[ -20°C to 65°C] YES6.4 Design Code :IS 2825, IS 7285, IS 3224 or as per

Applicable standard Codes or approved by CCOE YES

6.5 Calibration traceability - To NIST as per ISO 5168 YES6.6 Enclosure weather proof to - IP65,NENA4x YES6.7 Process Temperature effect - ± 0.01% of nominal

flowrate/degree C on zero offset

YES

6.8 All valves as per IS 3224 or as Applicablestandard code or approved by CCOE YES

6.9 Safety relief devices as per IS: 5903 orApplicable standard code or approved by PESO YES

S S S

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DATA SHEETCNG STORAGE CASCADE

P.013429D11088

001

INDRAPRASTHA GAS LTD.

CITY GAS DISTRIBUTION PROJECT

DATA SHEET

A 29.01.2020 Issued for Approval Gunja Gupta Rajveer Panwar Chandan KrSingh

Rev. Date Description Prepared by Checked by Approved by

155 of 165

DATA SHEETCNG STORAGE CASCADE

P.013429D11088

001


CASCADE DATA SHEET

S.No. Parameter Specification Offered1 Type of service CNG

2 Capacity (in water liter) 3000 & 4500(-0%, +5%)

3 No. of Banks Stationary : 3

4 Cascade Dimensions OISD-179

5 Cascade frame structure is be able to withstand 4G (four time ofgravity) test from any direction without any distortion Yes

6 No. of Cylinders in each banka. Low Bank *b. Medium Bank *c. High Bank *

7 Cylindera. Cylinder Make *b. Compliance Code IS 7285c. Cylinder Size at 15 ºC (in water liter) 75 litresd. Cylinder Operating Condition 250 bar g at 15 ºCe. Cylinder Testing parameters As per IS: 7285

f. Cylinder Material Seamless alloy steel(Cr-Mo)

g. PESO Approval Yesh. Gas quantity stored in the cylinder at 15 ºC *

8 Cylinder Shut-off Valvea. Make Vanaz/ Tekno

b. Compliance Code (Valves Fittings for Compressed Gas Cylinder) IS 3224

9 Combination Bursting Disc and Fusible Plug To be provideda. Burst Pressure (in bar g) *b. Fuse Melting Temperature (in ºC) *

10 Interconnecting Tube Size Minimum ¾” OD11 Pressure Drop for each bank

a. Low Bank *b. Medium Bank *c. High Bank *

12 Coefficient of Flow (Cv) *

Note:1. All tubing fittings & other piping components shall conform to recommendations of ANSI B

31.3”Process piping”.2. (*) To be furnished by supplier.

156 of 165

1 Direct 15 Diaphargm Seal:- --

2 Local Type:- --

3 100 mm Wetted Parts Material:- --

White with black inscriptions Others Material:- --

4 SS316 Process Connection: Size & Rating --

5 Beyonet type SS316 Facing & Finish:- --

6 Shatterproof glass Capillary Material:- --

7 WP to IP 65 as per IEC 60529 / IS 2147 Armour - Flexible Material:- --

8 Bourdon Capillary Length:- --

9 SS316 Flushing/Filling connection with:- --

10 SS316 16 Over Range Protection:- 130% of FSD

11 +/-1% of FSD 17 Blow Out Protection:- Yes

12 Micropointer 18 Options :- a) Snubber

13 1/2"NPT(M) b) Syphon c) Gauge Saver

Connection Location:- Bottom d) Liquid Filled casing e) Vaccum Protection

14 SS316 f) Solid front

g) Two valve manifold

19 Make, Model & Quantity :- *

* Natural Gas d,e,f,g

NOTES: '*' : Supplier to furnish

1 Process Data shall be as per Tender document2 At the time of approval of DS, Supplier shall furnish DS with Catalogues.

DEVIATION NO DEVIATION VENDOR'S SIGNATURE WITH SEAL

0-400

Pressure Element:-

Element Material:-

PRESSURE GAUGE

UNITS: Flow<-> Liquid- m*3/hr Gas- Sm*3/hr Steam- kg/hr Pressure-> kg/cm*2 G Temperature<-> oC Level/Length<-> mm

Type:-

Mounting:-

Dial Size:-

Colour:-

Case Material:-

Bezel Ring:-

Window Material:-

Enclosure:-

Movement:-

SL.NO. TAG NO. RANGE

kg/cm2g

Socket Material

Accuracy:-

Zero adjustment:-

Connection:-

OPTIONSOP. MAX. DES. MIN MAX. DES.

PRESSURE kg/cm2g TEMPERATURE ºcSERVICE

Sheet No. 1 of 1 CLIENT: Owner's Name

400

Datasheet No: P.013429 D 11087 001

250 400

PROJECT: City Gas Distribution Project

CKS

VENDOR: REV. DATE PREP CHKD APPD

0 29.01.2020 GGMA

157 of 165

1 Gas actuated 17 Rigid2 Required 18 To suit thermowell3 Local 194 100mm5 White with black inscription6 SS3167 Shatterproof glass 20 Over Range Protection:-8 Bottom9 +/-1% of FSD 21 Material:- SS316

10 WP to IP 65 as per IEC 60529/IS 13947

11 Required 22

23 *12

24 ½' NPT(M)

25 *13 Stem Dia:-

2614 SAMA Class:- V

Case15 Bulb Type:- Adjustable union 27

SS31616 1/2” BSP(M) a) Liquid Filled:- Yes

b)c)

* * * * * * a

NOTES:*: Vendor to furnishU: Immersion LengthT: Lagging Extension

1 Element length shall,be suitable for thermowell.

2 U-length shall be selected in such a way that the thermowell tip shall be preferably at the centre of pipe to sense the temperature accurately.3 Process Data shall be as per tender document4 At the time of approval of DS, Supplier shall furnish DS with Catalogues.

DEVIATION NO DEVIATION VENDOR'S SIGNATURES WITH SEAL

130%

TEMPERATURE GAUGE

UNITS: Flow<-> Liquid- m*3/hr Gas- Nm*3/hr Steam- kg/hr Pressure-> kg/cm*2 G Temperature<-> oC Level/Length<-> mm

Type:- Extension Type:-Well:- Bulb Dia.:-Mounting:- Cappillary Material:-Dial Size:-

Window Material:-Conn. Location:- THERMOWELL:-Accuracy:-

Armour Flexible:-Colour:- Armour Material:-Case Material:- Capillary Length:-

Enclosure:-

Size:- Thermowell Dwg.:-

Drilled bar stock upto immersion length 500mm, otherwise fabricated

BIMETAL:- Process Conn.:-Stem:

Zero Adj. Screw:-

Type:- Gauge Conn.:-Material:-

Constn.:-

Compensation:-

Bulb Material:-Options:

Filled System:- Over range protection

SL.NO. TAG NO. RANGE

TEMP.

MIN NOR MAX

WELL DIM. FLANGE

Bulb Union Threaded To:-

LINE NO. / VESSELNO. / PIPING CLASS OPTIONS

U T MATERIAL RATING, FACING,FINISH

Sheet No.1 of 1 CLIENT: Owner's Name


Datasheet No: P.013429 11087 002

PREP CHKD

0 29.01.2020 MA GG

APPDVENDOR: REV. DATE

CKS

158 of 165

1 Tag No. Quantity * *2 Line No. Schedule * *3 Vessel No. *4 Safety / Relief Safety relief5 Full Nozzle Full Lift/Mod. Nozzle Full nozzle full lift6 Bonnet type Closed7 Conv./Bellows/Pilot Operated *8 Inlet Conn. Size & Rating *9 Facing & Finish *10 Outlet Conn. Size & Rating *11 Facing & Finish *12 Cap Over Adj. Bolt Yes13 Screwed / Bolted Bolted14 Lifting Gear - Type15 Test Gag Yes161718 Body and Bonnet A351 CF8M19 Nozzle and Disc SS31620 Spring SS30421 Bellows --222324 Resilient Seat Seal --252627 Code API 520282930 Fluid State Natural Gas Gas31 Corrosive Constituent32 Required Flow Capacity33 Mol.Wt. S.G. at Rel. Temp34 Oper. Pressure Normal Note 135 Oper. Temp. Rel. Temp. Note 136 Valve Discharges to Atmosphere37 Back Press. Const. Or Variable Constant38 Set Pressure39 Cold Bend Test Pressure40 % Over Pressure % Blow Down41 Cp/Cv Compressibility Factor42 Viscosity @ Rel. Temp. mPas(cP)43 Vess. Wall Temp. Surf.Area-m244 Max & Min Pressure *45 Calculated Area cm2 *46 Sel. Area cm2 Orifice Design * *47 No. of Valves Reqd. for capacity *48 Total Area - cm2 *49 Actual Flow Capacity *5051 Model No. *52 IBR Certification No5354

NOTES: '*' : Contractor to furnish

1 Process data shall be as per tender specification mentioned elsewhere.2 At the time of approval, vendor shall furnish sizing calculation and catalogues of PSV3 Test GAG Required for safety valve & Pressure Safety valve shall be fire case type

DEVIATION NO DEVIATION CONTRACTOR'S SIGNATURE WITH SEAL

*

Options

Basis

Serviceconditions

Orifice

Data Sheet No P.013429 D 11087 003

Sheet No. 1 of 1

PRESSURE SAFETY VALVES

UNITS: Flow<-> Liquid- m*3/hr Gas- Sm*3/hr Steam- kg/hr Pressure-> kg/cm*2 G Temperature<-> oC Level/Length<-> mm

General

Valve

Material

CLIENT: Owner's Name


CKS

PREP CHKD APPD

CONTRACTOR:

REV. DATE

0 29.01.2020 MA GG

159 of 165

QAP No. : P.013429 D11013 001 Rev ADate : 29.01.2020

Prepared by : GGChecked by : RPApproved by : MC

S.NO. OPEARTION / PARAMETER CHARATERISTICS/PARAMETERS ACCEPTANCE CRITERIA & CERTIFICATION INSPECTION FREQUENCY VENDOR TPIA CA REMARKS

1 Raw Material Chemical Composition Chrome Moly Steel,Grade-DS-202/IS:7285Cl. 5.2 Table-1 One sample per heat No. P R R Verification of RMT Certicate Received

from RM supplier.

Length As per process heat 4-5 jobs during setting approval & every twohour.

Thickness Minimum as per approved drawing Tolerance + 30% 3-4 jobs during setting approval & every fourhour.

Outside Diameter As per Approved drawing (Tolerance + 1 %)IS-7285 : 2004

3-4 jobs during setting approval & every fourhour.

Surface Flaws Free from Lamination, crack,Dent, corrosion , silversetc.


Ultrasonic Examination IS-7285 Each Cylinder

3 Bottom Forming

Bottom ThicknessCentre of BottomSide of BottomFootringVisual Inspection

Ultrasonic Examimation

1.5 T min (where T is wall thickness)IS: 7285

Free from crack,excess metal, pin hole, ballformation,roller mark and other surface defects.

IS: 7285



Each Cylinder

P W/R R

4 Neck Forming

Solid Neck Length

Neck Diameter

Surface finish, defects

Ultra sonic Examination

As per Approved Drawing

As per Approved Drawing

Free from roller mark, Pit mark, excess metal at neck,crak and other surface defects

IS: 7285

4-5 jobs during setting approval & every twohour.



Each Cylinder

P W/R R

2

QUALITY CONTROL TABLEHIGH PRESSURE GAS CYLINDER , CASCADE FRAME & FITTINGS

W/RRaw Materiasl Cutting( seamless Tube) P R

IN PROCESS

Supply of Cascade for City Gas Distribution Project Page 1 of 4160 of 165





5 Heat Treatment

Hardness(As Tempered)

Mechanical PropertiesTensile Strength

Yield Strength

% Elongation

Impact test (at -20 0C)

Bend Test

Burst Test

As per approved drawingIS:7285 : 2004

As per IS;7285 : 2004IS: 7285 : 2004

IS: 7285 : 2004

IS: 7285 : 2004

IS: 7285 : 2004

Every Cylinder

One random cylinder will be selected fromHeat treament Batch comformimg themechanical properties like tensile test, impacttest, bend test etc, in presence of inspectingofficer.

One Cylinder from prototype batch.

P W R

6 Ultrasonic testing

Crack dtection

Wall Thickness measurement

As per IS:7285 -2004

As per approved drg.IS:7285-2004

Every Cylinder P W R

7 Neck cutting & Threading

Neck Length

Machined neck step diameter

Neck thread configuration.

Visual inspection thread finish.

As per approved drawing.



Free from crack blow hole excess metal at insideneck, thread damage, flat threads etc.

Audit Check by Q.A staff.

Audit Check by Q.A staff

Every Cylinder.

Every Cylinder.

P W R

8 Water Capacity checking &Hydrostatic Strength testing.

Measurement of water capacity.Total expansion and permanentexpansion at test pressure.Holding Time = 30 Sec min.

Tolerance on water capacity+ 5 % IS-7285 : 2004

Permanent expansion shall not exceed 10% of totalexpansion. IS: 7285

Every Cylinder.


P W R

9 Air Leakage Test

Access leakage from cylinderbody, neck and bottom side atworking pressure.Holding Time= 60 Sec.

Free from Leakage.IS: 7285

Every Cylinder.


P W R






10 Bursting Test

The value of hoop stress shall benot less than 0.95 of theminimum specified tensilestrenght of the cylinder material.

IS-7285 One Cylinder of the first batch . P W R

11 Steam Cleaning & Air Drying Examination of Oil residue,Moisture Etc.

Free from Oil residue, Moisture etc when Cylinder isexposed to steam jet at steam temp.160-180 0 C for period minimum 5-6 minutes.

Audit Check by Q.A staff P R R

12 Internal shot blasting Scale free surface Inner surface should be free from sclaes, metallicparticles etc Audit Check by Q.A staff P R R

13 External shot blasting Scale free surface Cylinder should be free from scales & Other surfaceimperfection Audit Check by Q.A staff P R R

14 Fixed data Stamping Stamp Data As per IS:7285 Audit Check by Q.A staff P R R

15 Variable Data stamping Stamp Data Verification of dataAs per Drawing & Test Result Every Cylinder check by Q.A staff P R R

16 Vacuum cleaning Any scales, dustetc insidecylinder Free from scales, dust etc from inside cylinder. Every Cylinder check by Q.A staff P R R

17 Weighing Tare weight/ Calibration As per approved Drawing Every Cylinder check by Q.A staff P W R

18 Painting (Primer & Finishpainting) Paint coating thickness As per process sheet Audit Check by Q.A staff P W R

19 IS: 7285 Each Cylinder P R R

20 IS: 7285 Each Cylinder P R R

21

Cascade FrameFabricationPaintingCascade Frame Complete

Visual (Welding etc)DimensionalPhysical TestChemical Test

Approved Drwaing/ Manufactures Standard.Owner's SpecificationApproved Drawing

100% P R R

22 Polyuretherane/ Epoxy paint Chemical Properties Approved Make / Owner's Specification P W R

23 SS Tubes

Physical testChemical TestVisual (Welding etc)DimensionalFitment & Alingment

Approved Drawing, Manufacture Test Certificate forbought out items. As per tender / Owner's Instruction P R R

Marking

Color Identification






24 Fittings

VisualDimensionalPressure TestFitment & Alingment

Approved Drwaing/ Manufactures Standard. As per tender / Owner's Instruction P R R

25 Valves 2 WayVisualDimensionalFitment & Alingment

Approved Drawing, Manufacture Test Certificate forbought out items. As per tender / Owner's Instruction P R R

26 CNG Cascade AssemblyVisual (Welding etc)DimensionalFitment & Alingment

Approved Drwaing/ Manufacture Std. Owner's specification/ Instruction P W R

27 SS Tubes for venting of BurstDisc seperator

Visual (Welding etc)DimensionalPressure TestLeakage TestFitment & Alingment

Approved Drwaing/ Manufacture Std. Owner's specification/ Instruction P W R

28 Cylinder ValvesVisualDimensionalFitment & Alingment

As per Approved CCOE Drawing, Bill of Material. Owner's specification/ Instruction P 100% W R

29 GaugeVisualDimensionalFitment & Alingment

Approved Drawing, Bill of Material. Owner's specification/ Instruction P 100 % W R

30 IS:7285 Each Cylinder P 100 % W R

Notes123

456

789

All reference Codes/ Standards, Documents, P.O. Copies shall be arranged by vendor / supplier for reference of TPIA/Owner at the time of Inspection

Supplier shall submit Calibration certificates of all Instruments/Equipment to be used for Inspection and Testing to TPIA with relavant procedures and updated standards for TPIA reveiew/Approval.All reference codes / documents shall be arranged by Vendor for reference ofTPIA at the time of inspection.Owner / Owner's representative including TPIA will have the right to inspect any activity of manufacturing at any time.TPIA along with Owner/Owner representative shall review/approve all the documents related to QAP/Quality manuals/Drawings etc.submitted by supplier.Contractor shall in coordination with Supplier/Sub vendor shall issue detailed Production and Inspection schedule indicating the dates and the locations to facilitate Owner/Owner's representative and TPIA to organise Inspection.

Special manufacturing procedures have to be specially approved or only previously approved procedures have to be used, in case of conflict between specifications more stringent condition shall be applicable.

Certification requirement shall comply with European standard EN 10204 - 3.2 (latest edition).

The Above Testing and acceptance critera are minimum requirements, however, manufacturer shall ensure that the product shall also comply to the additional requirements as per Particular Technical specifications(PTS) and Data Sheet.The supplier shall submit their own detailed QAP prepared on the basis of above / Technical specification for approval of Owner/Owner's representative.

LEGEND : W= WITNESS; H= HOLD; M= MONITORING; P= PERFORM; R= REVIEWS OF DOCUMENTS; R/M= RANDOM CHECH; A= APPROVED; TPIA= THIRD PARTY INSPECTION AGENCY

Final Inspection of Finished Cylinders:Visual inspection for internal cleaning and painting of Cylinder andCascade frame.

Final dimensional checking of cylinders & cascade frame.

Check every cylinder for neck threads & cleaning from inside/outside surface.

Verification of stamped data like Cylinder Serial No., Tare Weight,Water Capacity etc.


164 of 165

Checked

SUBJECT

Discipline Code

ModificationsD M Y Drawn

Approved

Validated

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Scale

PROJECT

CUSTOMER

REV

TRACTEBEL Engineering pvt. ltd.

Rev.

Project No.

Sheet

System Code Serial No.

Size

A3 of 011

P.013429 D 20995 005

ENGINEERING CONSULTANCY SERVICESFOR CGD PROJECT

INDRAPRASTHA GAS LIMITEDigl

SECONDARY STATION (20 Nos.)

DYKE SCOPE

PESO SAFETY AREA

Odorizer

Panel

Odorizer

Sump

Priority

MDPENetwork

PUMP

LNG TANK MIN. CAPACITY(TO BE DECIDED BY BIDDER)

LP Vaporizer2000 SCMH

(Standby / Defrosting)

@4 Barg

NATURAL GAS2000 SCMH

LCNG

LPNG

HPPump

HPPump

LP Vaporizer2000 SCMH

HP Vaporizer650 SCMH

(Standby / Defrosting)

HP Vaporizer650 SCMH

PUMP

LNG VEHICLE

(1 working + 1 standby)

Valve Skid & PRS / DRS

650 SCMH @ 250Bar

650 SCMH @ 250Bar

LNG UnloadingPump Capacity :

350-380 LPM (Typ)

NOTE

1. THIS IS INDICATIVE SCHEMATIC ARRANGEMENT. BIDDER SHALL

DEVELOP THE PRIMARY LNG STATION IN LINE WITH STATUTORY i.e.

PESO etc. REQUIREMENTS.

2. ALL EQUIPMENT SHALL BE SUPPLIED BY BIDDER.

3. ALL CIVIL WORKS IS EXCLUDED FROM BIDDER SCOPE. OWNER WILL

EXECUTE THE CIVIL WORKS BASED ON THE (ISSUED FOR

CONSTRUCTION) DRAWINGS SUBMITTED BY BIDDER.

4. IN PART C (SECONDARY STATION), VENDOR TO DECIDE THE TOTAL

GROSS STORAGE CAPACITY OF LNG FOR CATERING THE 4000 kg PER

DAY DEMAND. SINCE, BIDDER WILL TRANSPORT THE LNG FROM

PRIMARY STATION TO SECONDARY STATION.

5. CONSUMPTION/DEMAND FOR SECONDARY STATION IS 4000 KG PER

DAY. THIS DEMAND SHALL BE GRADUALLY INCREASE OVER THE

PERIOD OF TIME.

6. L-CNG & L-PNG SHALL BE SUPPLIED FROM ALL 20 Nos, SECONDARY

STATIONS IN THE STATE OF RAJASTHAN.

SECONDARY STATION (RAJASTHAN)

SCHEMATIC DIAGRAM FOR LNG STORAGE & REGASIFICATION

WITH LCNG+LPNG DISPENSING FACILITIES

CNG250Bar

LCNG Dispensers

(1 working + 1 standby)

Stationary Cascades

165 of 165

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14.11.19

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At the helm of the Energy Transition, Tractebel provides a full range of engineering and advisory servicesthroughout the life cycle of its clients’ projects, including design and project management. As one of the world’sleading engineering and advisory companies and with more than 150 years of experience, it's our mission toactively shape the world of tomorrow. With about 5,000 experts and presence in more than 70 countries, we areable to offer our customers multidisciplinary solutions in energy, water and urban.

TRACTEBEL ENGINEERING PVT. LTD.

GURGAON OFFICEIntec House, 37Institutional Area, Sector 44122002 - Gurgaon - INDIAtractebel-engie.com

Manish CHANDRAtel. +91 124 469 8500fax +91 124 469 [email protected]