Technical Specifications - Comp

TECHNICAL SPECIFICATION FOR ELECTRIC MOTOR DRIVEN RECIPROCATING COMPRESSORS FOR CNG MOTHER STATION (MEC/TS/05/62/S031)
CONSULTANT Limited
DELHI 110 092
1.0
GENERAL M/s Hindustan Petroleum Corporation Ltd. are installing CNG filling stations for vehicle in Bangladesh.
1.1
Scope of work This specification along with applicable codes as referred describe the minimum requirements for design, engineering, manufacturing, inspection, testing, supply including packaging, forwarding, insurance on C.I.F basis , package performance test at Bidder 's shop, supply, erection & commissioning at site of " ELECTRIC MOTOR DRIVEN RECIPROCATING GAS COMPRESSOR PACKAGE" as required for dispensing CNG to vehicles at various locations in Bangladesh. The Compressor Packages shall be identical in all technical respects. Various parts of this specification shall be read in conjunction with each other and in case where the different parts of this specification differs the more stringent requirement shall govern. Any additional work/equipment or technical requirement not mentioned in the specification but required to make the offered system complete in accordance with the specification and for safe and proper operation, shall be deemed to be included in the scope of work by the Bidder .
1.2
Codes & Standards The design, construction, manufacture, supply, testing and other general requirements of the compressor package equipment shall be strictly in accordance with the data sheets, applicable API codes, and shall comply fully with relevant National/ International standards, Bangladesh Electricity Act, Bangladesh Electricity Rules, regulations of Insurance Association of Bangladesh and Factories Act while carrying out work as per this specification. Any modification suggested by the statutory bodies either during drawing approval or during inspection, if any, shall be carried out by the Bidder without any additional cost and delivery implications. The following codes and standards (versions/ revisions valid on the date of order) are referenced to & made part of specification: CNG Compressor Code NZS 5425 CNG fuel System code NZS 5422 Natural Gas Vehicles NZS 5454 API-11P, Second edition NFPA-37, OISD 179, NFPA-52: 1992 ANSI, ASTM, NEC, NEMA Bangladesh Electricity Rules, Bangladesh Explosives Act.
1.3
Precedence In case of any conflict among the various documents of this requisition the following preferential order shall govern: 1. Data sheets/drawings 2. This Technical Specification 3. International standards/codes as applicable 4. Indian/ Bangladesh Standards / codes applicable
CONSULTANT MECON Limited
TS CNG COMPRESSOR FOR HPCL BANGLADESH
SPECIFICATION NO. MEC/TS/05/25/HPCL/S031
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Compliance with this specification shall not relieve the Bidder of the responsibility of furnishing equipment and accessories of proper design, material and workmanship to meet the specified operating conditions. No deviations to the technical requirements and to the scope of supply specified in this enquiry document shall normally be accepted and offers not in compliance to the same shall be rejected summarily. In case a deviation is required due to inherent design of the equipment offered, the Bidder shall list all such deviations at one place giving reasons thereon. 1.4 DOCUMENTS/DATA REQUIRED ALONG WITH BID Bidder shall necessarily furnish the following along with the bid without which the offer shall be considered incomplete: a. b. c. d. e. f. g. 1.5 Proven Track Record Formats duly filled in Checklist duly filled in with regards to scope of supply Completely filled in Data Sheets of compressor, Electric motors Deviations if any to this Technical Specification Tentative Lay out / key plan/ General Arrangement indicating size of skids, center distance between skids and space required along with maintenance requirements (a) Utilities requirements (b) Electrical Load summary Catalogues of compressor, electric motor, and instrumentation items.
SCOPE OF SERVICES Engineering, design and manufacturing. Procurement of raw materials etc. from sub-vendors. Preparation of documentation for design approval by Purchaser/consultant. Inspection and testing as per T.S. Surface preparation, protective coating and painting as per T.S. Packaging for transportation to site and supply. Erection testing & commissioning as per T.S. Field trial run and performance test at site. Post commissioning maintenance
1.6 -
SCOPE OF SUPPLY FOR EACH COMPRESSOR PACKAGE Each compressor Package shall be complete with: Lubricated or non-lubricated two throw balanced opposed reciprocating compressor with lube oil system and cooling system (console type) as required. Electric motor as compressor driver. Gas meter: Mass flow meter based on Coriolis principle of Micromotion, USA (Model CNG 50 or higher) or equivalent at compressor discharge. Instrumentation and control system as specified on data sheets, P&ID including Local panel, Console/Local gauge boards, PLC Common structural steel skid for the compressor- electric motor and for all auxiliary systems. Inlet twin suction gas filter with oil drain and temporary suction line strainer at 1st stage and at other stage if required, Inter-stage and discharge gas, air cooled heat exchangers Inter-stage and discharge gas, air cooled heat exchangers
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Separator/ Knockout drums with solenoid valve operated auto/ manual drains as required. Priority Panel at Package Discharge All interconnecting oil, gas, water, air piping within the compressor package. Impulse and pneumatic piping/Tubing for all valves, fittings as specified & required for mounting the instruments. Separate junction boxes for different type of signals like intrinsically safe signals, alarm, shutdowns, thermocouples, RTDs etc. for interfacing to local panel. NRV (compressor discharge valve type) at final discharge point. Structural supports within the compressor package for all piping, instruments etc. One no. relief valve at each stage discharge all vented to common relief valve header Y- type strainers, valves, sight flow indicators, check valves, auto/manual drain traps etc. as required for various auxiliary systems i.e. frame lube oil, cylinder lubrication system, cooling water systems, fuel supply/conditioning system etc. Coupling/V-belt/pulleys. Single Acoustic enclosure for both Compressor and electric motor as specified, with two number L.E.L detectors and two UV detectors in enclosure. CO2 extinguishing system consisting of two cylinders, piping and valves. Inlet and outlet manual / automatic isolating valves. All CNG gas tubing and valves between compressor, dispenser and cascade will supply and laid by bidder through GI tray. The distance from compressor to bus dispenser, car dispenser and cascades is about 20 m, 15m and 10 m respectively. Tube dia for bus dispenser shall be 1 OD. Complete Erection, Testing & Commissioning of compressor packages. All spares, consumables and lubricants for 1-year operating period (except electricity). Quote for second and third year repair and maintenance charges after warrantee period of one year Training of 4 persons (2 supervisors + 2 operators) at packagers workshop and at sub-vendors workshop. The traveling boarding and lodging of Purchasers engineers shall be borne by PURCHASER. Training module shall span for two week and shall cover the equipment constructional features, operational and maintenance procedures etc. (Bidder to indicate separate price, if any). Exclusions
The following are excluded from the scope of the Bidder : All civil works and foundation design. However the Bidder shall furnish all the relevant data for design of pedestal/ foundation. Grouting of equipment including supply of material is a part of erection. CNG storage cascade. Bidder to note piping from air compressor and CO2 cylinders up to enclosures in the scope of bidder.
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1.7 1.7.1 1.7.2
Safety All controls shall operate in a fail-safe mode i.e. failure of any control shall not lead to running of equipment in unsafe mode. The hazardous area classification Class-I, Division I, Group D as per NEC or Zone I, Group II A/ II B as per IS/ IEC. Certificate from recognized agency to the effect that equipment supplied and/or installed conform to above area classification. All Devices shall meet the requirement for the specified area classification in which they are installed, including instrumentation leads. All exposed rotating parts shall be provided with adequate guards of non-sparking type. Drive belt if used shall be of fire retardant and anti-static type. Piping shall be arranged in a manner so as to provide clear headroom and accessibility within the package. Adequate clearances shall be provided for all the engineered components. Package enclosures shall have two L.E.L detectors and two Ultra Violet (UV) fire detectors in each enclosure to cover the enclosures effectively. All material used in the package shall be flame retardant. The Compressor Package shall trip if any of the enclosure is opened while the machine is running. Relief Valves shall be provided at inter-stage / compressor discharge with setting as per cl. 7.20.3 of API 11P with R.V. venting as per cl. 7.20.4 of API-11P.
1.7.3 1.7.4 1.7.5
1.7.6 1.7.7 1.7.8 1.7.9
1.7.10 CO2 flooding system: - CO2 Cylinders shall be provided outside the package at a place where it is not exposed to fire in case of fire in the compressor. Facility shall be made to operate the system both manually from remote with the help of a switch/ call point and with help of pull down lever on cylinders. - CO2 flooding system will consist of 2 nos. of min 45 Kg. CO2 cylinders. However, preferred size of the cylinder & quantity of CO2 gas will be as per the size of enclosure. One cylinder will act as main cylinder & other as stand by, which shall have identical arrangement and connected to the system. The cylinders shall be placed in a shed to protect from weather and direct sunrays as per Gas Cylinder Rules, 1981. Cylinders shall be fitted with automatic actuated Valves, Solenoid valves etc. - Vendor shall provide suitable weighing arrangement to facilitate weighing of the cylinders without requiring the cylinders to be detached from the installation. For this lever operated lifting arrangements may be provided. - System shall be offered for testing to PURCHASER by the bidder after commissioning at site by creating actual Gas leak and Gas fire situations and actual discharge of CO2 Gas from the Cylinders. This shall form a part of performance test and thereby acceptance of the package.
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2.0 2.1 2.1.1 2.1.2
UTILITIES & BATTERY LIMITS Utilities Bidder shall make his own provision for Instrument air with an electric motor driven air compressor , receiver and air dryer system. Cooling water is not available as utility and the package shall be provided with self sufficient cooling water system for Compressor, as required, with make up tank. However cooling water for make up tank is available. All electrical and instrumentation terminals shall be as specified. Electric power shall be made available by Owner. For running the compressor and illumination 440 Volt (10 %) 3-phases 4 wire (TNS), 50 Hz ( 2 %) shall be provided by Owner at a single point outside the enclosure. Purchaser shall provide UPS (240 1 % V, 50 1 % Hz) for control supply requirements. Battery limits All customer interface connections (i.e. Gas Inlet & Gas Outlet) shall be brought out to the package edge and terminated in nozzles with isolation valves having flange connection for gas inlet and 3/4 SS tube union for gas outlet. As and where specified on the data sheets all vents (i.e. Relief valve, distance piece and packing) shall be manifolded and terminated at skid edge outside the enclosure and vented to safe height of 2.5 m at package roof. All drains from different process equipment, distance piece and packing shall be manifolded and terminated as single point for customer interface duly flanged with isolation valve. EQUIPMENT QUALIFICATION CRITERIA Gas Compressor The compressor model offered shall be from the existing regular manufacturing range of the compressor manufacturer and shall meet the following minimum service and manufacturing experience requirements. Compressors shall be identical or validly similar in mechanical design, frame rating, no. of throws, rotational and piston speeds, rod loading, cylinder sizes, pressure ratings, number of stages, process gas (i.e. natural gas) and materials as compared to at least five units manufactured, tested and supplied by the compressor manufacturer from the proposed manufacturing plant. At least two of the offered models must have been operating satisfactory in the field for a period of 8000 hours without any major overhaul as on the bid due date.
2.1.3 2.1.4 2.1.5
2.1.6 2.2 2.2.1
2.2.2
2.2.3
3.0 3.1
4.0
BASIC DESIGN
SPECIFICATION NO. MEC/TS/05/25/HPCL/S031 REV 0
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4.1 4.1.1 i. ii. iii. iv. 4.1.2
General The Compressor shall meet all the technical requirements as specified in: Data Sheets: As enclosed Technical Specification: Code and specification API-11P, API-618 ,OISD 179, NFPA, ANSI, ASTM, NEC, NEMA, Bangladesh Electricity Rules, and Bangladesh Explosives Act are referenced to & made part of specification. Compressor and its auxiliarys design shall be in conformity with API 11P, second edition. Gas composition given under Design Case shall be used for Compressor selection, sizing and performance guarantee estimates. However compressor shall be suitable for continuous operation with the indicated gas composition range and operating parameters given in this tender. Suction line pressure vary from 0.84 to 1.05 kg/cm2. Bidder to note suction pressure regulator shall not be allowed to reduce the pr below 1.05 kg/cm2. Bidder 's offer shall be based on firm and final compressor / electric motor models on which basis the offer shall be evaluated and no alternate compressor / electric motor models or change of models to lower frame shall be entertained. Note that the pressures given on the data sheet are at the compressor package battery limits, Bidder shall consider all pressure losses at suction, inter-stage and discharge at the specified capacity (with no -ve tolerance) for compressor and indicate the same on the data sheets. Allowable speeds, temperature and vibration levels The linear piston speed shall be limited to 4 m/sec for non-lubricated and 4.5 m/sec for lubricated compressors. The maximum discharge gas temperature for each stage shall be limited to 150oC. Compressor maximum vibrations of cylinders shall not exceed 10 mm /sec. unfiltered peak velocity. Maximum Vibration level of installed compressor frame shall not exceed an unfiltered peak velocity of 7.5 mm/s. The Bidder shall provide for all structural support within the package so that these levels can be achieved. Piston Rod, Bearings and Cross Heads The surface hardness of Rockwell C 50 minimum is required on piston rods in the areas that pass through the packing. Rolled threads shall be provided on the rods with thread relief area as polished. Crosshead shall be manufacturer standard material and designs. Adequate openings for removal of the crossheads shall be provided. Piston rod and cross head pin loading at any specified operating condition at the relief valve set pressure shall not exceed 80% of the maximum design rod load of the
4.1.3 4.1.4
4.1.5
4.2 4.2.1 4.2.2 4.2.3
4.3 4.3.1
4.3.2 4.3.3
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offered compressor. Rod loads shall have sufficient reversals in direction for all specified operating conditions including RV Settings and part load operation. 4.3.4 Frame rating of the offered compressor model at RV set pressure corresponding to max severe operating conditions shall not exceed 80% of the maximum design rating as published in catalogues. Packing Cases and Pressure Packing All oil wiper intermediate gas cylinder pressure packing shall be segmental rings with stainless steel garter springs. The pressure packing case shall be provided with a common vent and drain below the piston rod tube to the outside of the Package enclosure. ERW/ seamless steel tubing conforming to ASTM A-192 or series 300 SS tubing conforming to ASTM A-269 with minimum thickness as specified in Cl. 7.11 of API-11P shall be used for vent piping. Packing vent piping inside of the distance piece shall be designed for the maximum allowable working pressure of the cylinder. Compressor Frame Lubrication. Compressor frame lubrication shall be pressurized system, with a main oil pump driven directly by the compressor shaft. If required the Bidder shall provide an air driven pre-lubrication pump. Crankcase shall be fitted with lube oil temp & level indicator. All lube oil piping after oil filter shall be 300 series stainless steel conforming to ASTM A269. Heating shall be provided for reservoir when the minimum ambient temperature is less than the Bidder 's required minimum start up temperature. Heater besides meeting the area classification requirements specified in the Tender shall be star connected if designed for operation on 3-phase (4 wire), 415V, 50 Hz supply. Distance Pieces Distance piece as per API-11P with cylinder side compartment vented to safe location is specified. Distance pieces shall be provided with gasketted, solid covers and shall be suitable for a minimum differential compartment pressure of 1.75 kg/cmg. Cylinder and Packing Lubrication Single plunger per point force feed mechanical lubricator shall provide lubrication to compressor cylinders.
4.4 4.4.1
4.4.2
4.4.3 4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.5.5
4.6 4.6.1 4.6.2 4.7 4.7.1
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4.7.2 4.7.3 4.7.4 4.7.5 4.7.6
Lubricators shall be driven by crankshaft and bidder shall highlight any pre lubrication requirements of the cylinders and the method of achieving the same. Lubricators shall have a sight flow indicator for each lubricator point and a stainless steel double ball check valve shall be provided at each lubrication point. Digital no flow timer shall be provided to stop the compressor in case of loss of cylinder lubrication. Lubricator reservoir capacity shall be adequate for 100 Hrs of normal flow, and shall be equipped with low level alarm. Bidder along with the proposal shall furnish the recommended lubricating oil type, International Grades & Specification along with their quantity and frequency of change. The recommended oil shall be compatible with gaskets, O-rings, seals, packing, lubricator parts and other parts coming into contact. Cooling System Compressor Cylinder Compressor cylinders may be air cooled or water cooled. The CW shall be cooled by an air cooled heat exchanger.
4.8 4.8.1
4.8.2
Inter / After Gas Coolers Air-cooled inter-stage and final stage discharge coolers shall be provided which shall limit the gas temperature after the after cooler to 52 degree C. For calculating the surface area of the air cooler the ambient air temperature of 38 oC and 98% RH shall be considered. Cooler design shall be on the basis of 20% extra load corresponding to max severe operating conditions based on the thermal duty. Gas coolers shall be designed as per API-661 requirements. For cooling of the Heat Exchangers a cooling fan to be provided inside the enclosure(s). Cooling system to be preferably installed on same skid along with compressor due to space constraints. Bidder shall submit cooler sizing calculation for review.
4.9 4.9.1 4.9.2 4.9.3 -
Separators & Oil Removal System Carbon Steel separators / KOD at auto and manual drain system shall be provided for the capacity as required. All pressure vessels shall be designed as per ASME VIII Div 1 or equivalent. Scrubber service class - B shall be used for Inter-stage / discharge scrubbers. Service Class - C shall be used for suction scrubber. (Refer API -11P) The offered scrubber and mist removal shall restrict the oil level to < 5 ppm in the discharge gas of compressor. This shall be established during Performance Testing. All vessels including pulsation dampers shall be fully (100 %) radiographed as per ASME VIII UW (a) or equivalent.
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Minimum design temperature for separators shall be 71OC and minimum design pressure shall be maximum operating pressure plus 15% for inter-stages and plus 10% for final stage. Gas recovery system: Bidder shall provide blow-down tank to act as: A buffer tank during start-up Gas flow dampener during compressor operation Surge tank for depressurization of each of the compressor stage piston cylinders during shutdown. Blow-down tank size should be to manufacturers design standards. The gas recovery vessel shall be provided with pressure relief valve and necessary instrumentation to avoid cold flaring of gas. All separators / KOD's shall be provided with 3 mm corrosion allowance. Pulsation, Vibration Control and Analog Study
4.9.4 -
4.9.5 4.10
4.10.1 Suitable arrangement for interstage pulsation damping shall be provided in confirmation to API 618 and API 11P. 4.10.2 Bidder shall get the acoustic and mechanical evaluation study carried out for one compressor package (from inlet flange to discharge on skid edge as per API-618 approach-3 ) by an agency or in house experts. The compressor Bidder shall be totally responsible for all the coordination with the agency carrying out the study. Bidder shall submit acoustic and mechanical evaluation report to PURCHASER /CONSULTANT for review. Coupling
4.12
4.12.1 V-Belt drive upto 150 KW electric motor rating is acceptable. Direct drive shall be offered by the Bidder if electric motor rating is > 150 KW. Gear drive is not acceptable. 4.13 Enclosure of CNG Compressor Package
4.13.1 The maximum ambient temperature within the enclosure shall be limited to 43 C based on the ambient temperature of 38 C. Adequate ventilation fans shall be provided to meet the above and also to account for heat dissipation of the coolers. 4.13.2 The compressor package shall consist of single enclosure for Compressor and Electric Motor. The equipment shall be mounted on one common skid. The Enclosure to restrict maximum noise level to 65 dB(A) at 1 meter from the enclosure. 4.13.3 Enclosures shall be provide with a degree of protection equivalent to IP 54 as defined in AS 1939, shall be flame proof and provided with forced ventilation system. 4.13.4 The enclosures shall have doors for normal access and removable wall panels for ease of maintenance. 4.13.5 All the pressure, temperature, gas flow meter, oil level, lube oil pressure, coolant temperature, coolant level indicators shall be visible from outside of enclosures.
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4.13.6 Enclosures shall have internal flame proof lighting arrangement. 4.13.7 For handling of all heavy parts for maintenance purpose lifting arrangement i.e. beam fitted with chain hoist shall be provided in enclosure. 4.13.8 The Compressor shall be located inside an acoustic enclosure . All Coolers, Knock Out Drums, Scrubbers, Cooling System, lubrication system along with interconnecting piping shall be inside an enclosure. Enough headroom shall be made available for easy access and maintenance of all equipment. The piping layout with respect to the compressor, intercoolers, KOD and auxiliaries location shall be subject to Purchasers approval during detailed engineering stage. Components such as pressure gauges, temperature and pressure switches etc., which require in-situ adjustment and reading, shall be easily accessible. Conduits and tubing shall be arranged in orderly and systematic manner and shall be routed neatly to enter the back of display or monitoring panels Routine service item such as, but not limited to, crank case oil filters, inter stage gas filters, inlet and outlets gas filters and drive belt shall be located to facilitate easy oneman servicing. One person should be able to access crank case oil inlet and drains to allow addition or drainage of oil without removing panels or adjacent components and without the need of the pump. Items which must be operated & monitored during operation shall be readily accessible without opening the door. Suitable gradients shall be provided on the enclosure roof for rain drainage and to avoid water pockets. The sheet work used in the enclosure shall be SS 304 material due to corrosive environment. Bidder is requested to submit the details of enclosure indicting material proposed to used with bid. Piping
4.14
4.14.1 All gas piping shall be designed, fabricated & tested in accordance with ANSI B 31.3. 4.14.2 Gas piping shall be seamless carbon steel manufacturing in accordance with ASTM A- 53 Gr. B or ASTM A - 106 Grade B. All Gas piping shall be flanged connections. 4.14.3 All rigid piping, tubing & other components of compressor package shall be designed for full range of pressure & temp and loading to which they may be subjected with a factor of safety of at least 4 based on minimum specified tensile strength at specified ambient temperature. 4.14.4 All rigid piping shall be continuous between their respective components & free of connections except welded joints. All high pressure joints shall be welded unless otherwise not feasible. 4.14.5 The instrument air tubing material shall be SS316 as per ASTM A269. 4.14.6 All high-pressure double ferrule fitting and 2/3 way valves shall be from SWAGELOC/ PARKER/HOKE makes & shall be S.S. material only. Material of tube shall also be SS316 as per ASTM A269 Sandwich make..
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4.14.7 Bidder shall furnish a temporary start up conical strainer fitted with adequate size mesh. 4.14.8 All lube oil piping down stream of filter shall be series 300 Stainless Steel. 4.14.9 External drain & vent piping shall be Carbon Steel and not less than 1" nominal size. However, all the internal drains shall be SS 300 series material. 4.14.10 Mercapton/ THT dosing is envisaged hence all materials coming in contact with gas shall be compatible to such gas with Mercapton/ THT dosing and be of compressor manufacture's standard. The use of SA 515 material is prohibited. 4.14.11All piping after coalescent filter at compressor discharge shall be of SS 316. 5.0 5.1 5.1.1 ELECTRICS Starter/Control Panel/ Control philosophy Doors shall be interlocked isolator. Panel complete with start and stop push buttons, hours run meter, power on and fault indication lamps, fault reset button. All necessary timers and intrinsically safe relays to control the system on an automatic starting and stopping basis shall be provided. The compressor package control system shall be designed for unattended operation in automatic mode and in case of any fault it will go in a safe mode. The priority fill systems (in Bidder s scope) shall ensure the filing of vehicle, storage cascades & LCV in correct order. 7-bank priority panel shall be envisaged for compressor package. Compressor Package shall be provided with a PLC based LCP outside the package enclosure housed in weatherproof housing (min. IP55) suitable for hazardous area classification. All the interlock, monitoring and controlling of the CNG compressor package shall be done through PLC based control system which will be of proven type and make. PLC hardware shall be in accordance with IEC-61131-2 and PLC software shall be in accordance with IEC-61131-3. PLC shall be provided display & scrolling facilities to view process & machine parameters. All source & object codes including logic flow chart, ladder diagram etc are to be furnished by the Packager and PLC shall be capable of incorporating function Block diagram, sequence function chart, ladder diagram and structural text as per IEC 61131-3. Laptop shall not be in the Bidder s scope. PLC shall be suitable for recording of compressor parameters as indicated in instrumentation and all other parameters that are recommended by the compressor manufacturer for recording on hourly basis for the last 24 hours. Also PLC shall be able to record the last 10 Alarms of abnormal operations. PLC shall be suitable for interfacing with printer (HP Laser printer) for getting the printout of the parameters recorded (as mentioned above) for the last 24 hours. The units of measurement for flow shall be Kg/hr, for pressure shall be Kg/cm2(g) or and for temperature shall be degree C. PLC shall be of modular in construction with 100% mounted spares covering cards, isolators and zener barriers etc. PLC components / system shall be tropicalised, MIL standard adopted with complete wiring and necessary terminals. Wiring to be colour coded with cross ferruling in position. PLC shall be capable of carrying out on line routines calculations as per AGA (latest) mass to standard volume conversion as per requirement. PLC shall be configured as a
5.1.2
5.1.2
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remote terminal unit of supervisory computer and data acquisition system complete with dial up connectivity. One card for transferring and accessing data from minimum twenty devices with RS 485 port shall be provided. The PLC System offered shall be shall be capable of: a) Compressor Control & Emergency Shut down b) Fire and gas detection and monitoring c) Data acquisition, monitoring & logging d) Annunciation 5.1.4 The compressor package control system shall be so designed that the first item to go into alarm condition shall lock out to indicate the cause of the trip though the cause of the trip may have disappeared. The lock out condition shall be manually reset. A change over set of contacts shall be provided for Owners use to give a remote indication of alarm and trip. In auto mode, compressor shall start automatically in case high bank storage pressure falls below 220 kg/cm2 and stop as soon as pressure in all three banks of stationery cascade and mobile cascade reaches 255 kg/cm2. The priority fill system (In Bidder s scope) shall ensure the filling of vehicle, storage cascade and mobile cascade in correct order. Control system shall be designed such that in case of any fault, discrepancy or abnormality, it will go in safe mode. Pressure transmitter on priority panel shall be of smart type with LCD. All controls shall be made in fail-safe mode & failure of any control shall not lead to operation of equipment/ system in unsafe condition. In case of fault, a warning hooter shall operate, the sound of which should be audible at distance of at least 15 meter. Further the fault alarm and emergency stop PB shall be duplicated in the CNG station control room. Acknowledgement/resetting of fault shall be possible only from compressor panel. Emergency stop PBs shall be mushroom head turn lockable type. Once the fault is acknowledged or compressor is under normal maintenance, the valves of priority panel shall take the position so that gas available in the stationary CNG storage cascade can be dispensed. The points to be monitored for down stream of dispenser panel shall be
Pressures in each bank of stationary storage cascades. Pressure at outlet for dispenser. Pressure at outlet for mobile cascades. Control Air Pressure Indicators, Alarms and Trips as per Equipment Data Sheets. The Local Control Panel shall be provided with following display and control systems : e) f) g) h) i) j) 5.1.6 Display of all compressor parameters including temperature and pressure Display of all flow parameters. Display of all alarms and alerts. Compressor Control & Emergency Shut down Fire and gas detection and monitoring Annunciation
Emergency Shut Down Bidder shall provide emergency shut down (ESD) system in the control room as well as locally mounted near the Compressor. Fail safe system shall be designed and incorporated to isolate cascade storage from dispenser, stop compressor, isolate the
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compressor suction line . ESD switch shall have to be manually reset to restart the compressor package again. 5.3 5.3.1 Electric Motor And Drive Arrange Electric motors a) b) c) d) e) f) g) h) i) j) k) l) m) 5.3.2 Type of drive Protection Insulation Mounting Specification Standard Supply Voltage (assumed) Synchronous Speed Motor rating Motor efficiency Power factor Speed of motors Nos. of hot starts of motors Coupling type Totally enclosed fan ventilated (TEFV) high efficiency as per IEEMA standard-19-2000 Explosion proof IP.55 Class F with Class B temperature rise Horizontal foot mounting By Bidder 440 + 10% volt, 3 phase, 50 + 2%Hz By Bidder By Bidder % By Bidder By Bidder 4 per hours By Bidder
Motor accessories a) b) c) d) e) f) Compressor grooved flywheel Motor grooved drive pulley Drive vee belts Flexible coupling for direct drive Drive guard Adjustable motor slide rails for vee belt tensioning
5.4 5.4.1
Electrical supply parameters : All electrical shall be suitable for the following supply conditions. Electrical operating voltage Electrical control voltage Tolerance of voltage Tolerance of frequency : : : : AC, 3 phase, 415 V, 50 Hz 230 VAC, 50 Hz (under bidder s scope) + 10% + 2%
5.4.2
PURCHASER shall provide 415 V, 3 phase electrical connection at only one designated point for electric driven compressor package. Bidder shall distribute electric power to all equipment and control systems by providing a suitable switch gear distribution panel. Suitable flameproof double compression glands shall be provided for termination of main cable in main electrical panel. Exact size and specification of cable glands will be indicated to successful Bidder within 2 weeks of order placement and receipt of electrical single line diagram from Bidder . All solenoid coils, power contactors etc. shall have operating voltage of 240VAC, and 50 Hz.
5.4.3
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5.4.4
Motor shall be TEFV squirrel cage type in standard frame size as per IS/IEC rated for continuous duty with high efficiency as per ( EFF2) and designed for star/delta starting. Motors shall be suitable for starting under specified load conditions with 75% of rated voltage at the terminals. Motor torque shall be compatible with speed torque curve of compressor. Motor windings shall be class F insulated with temperature rise limited to class B. Minimum degree of protection of motor enclosure shall be IP55 as per IS. Motors for use in hazardous areas shall have protection Ex(d) as per area classification. The motor name plate rating (exclusive of service factor) shall be minimum 115% of the greatest HP required under any of the specification operating conditions. All motors shall be tested in accordance with IS/IEC. Each motor shall compulsorily be protected with thermal-magnetic over current relay. The electrical power supply distributions panels, switchgear panels and starter panels shall be skid mounted construction, weather and vermin proof suitable for installation in the compressor package. There shall be FLP push button panel available at the compressor skid. The switch gear shall have one incomer and adequate number of outgoing feeders. The incomers shall be provided with suitably rated switch fuse unit, ammeter, voltmeter with selector switch, energy meter, PF meter, etc. Motor feeders shall be provided with heavy duty switch. HRC link type fuses, contactors (AC-3 duty), bi-metal relay, single phase preventor, ammeter, push buttons, earth leakage relays, indication lamps for Start/Stop/Trip, etc. Adequate number of MCB feeders for control and lighting shall be provided. Bidder shall furnish single line diagram of the panel with the bid. There shall be separate panel for main incoming switch (MCCB) and the starter of main motor. There shall be a minimum clearance of 30 mm between the two power contractors. The compressor panel shall have phase reversal relay to detect the electrical supply phase sequence and trip the compressor on wrong phase sequence.
5.4.5
5.4.6 5.4.7
5.4.8
5.4.9
5.4.10 Bidder s shall make provisions for earthing of the complete package as required as per IS. All electrics shall comply with latest IS/IEC. Epoxy based paints shall be applied on all electrical equipments. Bidder s scope shall include obtaining statutory approvals for the complete package, wherever necessary.The present approving authority is Head CNG, Rupantarita Prakritik Gas Co. Ltd (RPGCL), Bangladesh. 5.4.11 Bidder to note that all control electronic / electrical / instrumentation, shall be capable of with standing voltage fluctuation within +/- 15 % of rated voltage (230 VAC). In case, the cards / components are not capable of withstanding above voltage fluctuation, the scope of supply of compressor package shall include an uninterrupted power supply (UPS) / voltage stabilizer (VS) / Voltage conditioner (VC), so as to take care of the voltage fluctuations. Each compressor packager shall provide individual UPS / VS /VC in such a condition. 5.4.12 Earthing: Metallic part of all equipment not intended to be alive shall be connected to earth as per provisions of IS: 3043/IEC recommendation. Grounding of all electronics shall be separately connected to earth using insulated copper wire. Grounding of electronic equipment shall not be connected to earthing for electrics or equi-potential bonding.
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5.4.13 Pre-lubricated sealed bearings for all motors may be considered provided a full guarantee is given for 4 to 5 years of trouble free service without necessity of relubrication. 5.4.14 Preferred makes of electrical equipments shall be as follows: a) b) c) d) e) f) 6.0 6.1 6.2 FLP motors FLP Switchgear Switches/fuses/contractors PLC IR Gas detectors UV Flame detectors ABB/Crompton Greaves / Kirloskar / Siemens / Bharat Bijlee. Baliga/FCG/FPE/Sterling / Flexpro L & T/GEC/Siemens Allen Bradley, GE Fanuc, Siemens Positronics General Monitors / Crowcon / Tata Honeywell / Sieger General Monitors / Crowcon / Tata
INSTRUMENTATION All Instruments shall be suitable for an area classification of Class 1, Group D, Division 1 as per NEC OR Zone 1, Group IIA /IIB as per IS/ IEC. All package mounted transmitters & temperature element shall be intrinsic safe "ib" as per IEC 79-11 and solenoid valves, switches and related junction boxes shall be flame proof D" as per IEC 79-1. Other special equipment's/instruments, where intrinsic safety is not feasible or available, shall be flame proof as per IEC 79-1. The compressor package instrumentation & control is to be configured for manual as well fully automatic control system including starting, shutdown as applicable for unattended operation. Control system shall be PLC based of a reputed make and proven type. Electrical instrumentation shall be certified by a recognized authority such as BASEEFA, PTB, LCIE, CESI, INIEX, CMRS or any agency approved by Bangladesh Government. All the instrumentation shall be capable of operating for full range of operation. Separate junction boxes shall be provided for each type of signal i.e., analog, digital, solenoids, RTD thermocouple and power supply. No cable shall share power & signal. All pressure gauges shall be provided with block & bleed valves and have accuracy of + or - 1% of FSD. The temperature gauge shall be generally mercury in steel filled type, weatherproof & with capillary extension. Capillary tubing shall be min Carbon Steel with CS flexible
6.3
6.4
6.5 6.6 6.7 6.8 6.9
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armoring. The gauge shall have accuracy of + or - 1% FSD. The range shall be 1.5 times of operating temperature. 6.10 Units of measurement shall be: GAS FLOW PRESSURE TEMPERATURE SM3/hr & kg/hr kg/cm2 g 0 C
6.11
Two nos. Of RS 485/RS232 Serial Communication Ports shall be provided for Hooking Up the PLC to SCADA & Laptop PC in Future. Also, Vendor shall include 2 sets of all relevant Software (Windows XP/Windows 2000 based) for accessing the PLC through Laptop PC and SCADA. CABLING Cabling inside the enclosure shall be of 1.5 Sq. mm core. Cabling outside enclosure shall be minimum 2.5 Sq. mm core. Cables shall be 1100-volt grade, stranded copper conductor, PVC insulated, PVC sheathed, round wire armoured, FRLS cables. Cables shall be terminated using double compression type metallic frame proof glands and copper lugs. Spare cores to be kept in each control cable. All JBs shall have flame proof metallic enclosure INSPECTION AND TESTING General a) b) c) Inspection and Test Requirements have been spelled out in respective Equipment Data Sheets and this Technical Specification. Bidder shall confirm compliance to all inspection and testing requirements stipulated therein and include the inspection charges in the lump sum cost. Owner/consultant shall witness tests as per data sheet and this specification. The Bidder shall notify the timing of such inspection and testing at least 15 days in advance to PURCHASER/CONSULTANT. PURCHASER/ CONSULTANT shall depute their representative for witnessing the tests. Bidder shall submit detailed Test Procedure for Approval of the Purchaser two months in advance of the actual date of conducting each test.
7.0 7.1 7.2 7.3 7.4 7.5 7.6 8.0 8.1
d) 8.2 8.2.1
Mechanical running test (MRT) The MRT for the each compressors shall be carried out in presence of PURCHASER/CONSULTANT with job or shop driver including complete job driving system i.e., job driven V-belt, job pulleys etc., for 4 hours continuously at shop of compressor manufacturer. The compressor need not be pressure loaded for MRT test. During this test following shall be recorded at agreed intervals. Vibration levels measured on cylinders and frame Bearing temperature
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Oil cooler inlet and outlet temp
Subsequent to satisfactory run the compressor shall be examined as per standard procedure & following shall be examined as minimum: Bore & other parts by opening a valve Piston & cylinder clearance Visual examination of position rod, controlled guide bore without dismantling Big end and small end bearing If any of part found damaged, all similar components shall be stripped for inspection. The MRT test shall be repeated after replacement of such parts. 8.3 Mechanical String Test Mechanical String Test for 4 hrs shall be performed at packagers shop before dispatch in presence of Purchaser/Consultant. This test can be clubbed up with the Mechanical Run Test of compressor as specified above, provided the job driver, lube Oil system is used for the test. Air/N2 can be used for string test purpose if natural gas is not available in the shop. All parameters including discharge pressure shall be demonstrated. One compressor shall be string tested. 8.4 Package Performance Test Bidder shall assemble the complete package including auxiliary systems, instrumentation, safety devices within the enclosure at his shop and dispatch, The machine shall be accepted after the performance test at site. Complete package shall be performance tested as a module whereby along with electric motor & compressor performance (PTC - 9) Bidder shall demonstrate all controls, shutdown, trips / alarms etc. The test shall be the basis of assigning penalties on the Bidder, acceptance / rejection of the package thereon. Bidder shall submit the detail test procedure for the same, which shall be approved by PURCHASER/CONSULTANT. The test for the package shall be witnessed by PURCHASERL/CONSULTANT 9.0 9.1 PERFORMANCE GUARANTEES, PRICE LOADING AND COMPENSATION FOR UNDER PERFORMANCE This section describes the guaranteed parameter, which the CNG compressor package must fulfill, the penalty for shortfall in guaranteed parameters and rejection of compressor package by the Purchaser. The guaranteed parameter shall be adjusted to account for variation in gas composition and prevailing ambient condition during testing. Necessary calculations correction curves shall have to be furnished by Bidder along with bid, which shall be final & no deviation shall be permitted afterwards.
9.2 9.3
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9.4
In case of any inconsistency in manufacture and/or operation of supplied compressor package, Bidder shall at his own risk and cost, eliminate the defects to the satisfaction of Owner. Bidder shall furnish guaranteed value as per Annexure I enclosed with this specification
9.5 9.5.1
Compressor Capacity Bidder shall guarantee 800 SCM/hr capacity for compressor with design case gas composition, suction pressure of 1.05 kg/cm2g, suction temperature of 300 C , discharge pressure of 255 kg/cm2g with the no negative tolerance for errors in instruments and measurements. Since the compressor suction pressure varies from 0.843 kg/cm2g to 1.05 kg/cm2g the compressor shall be sized / selected for specified capacity of 800 SCM/hr corresponding to 1.05 kg/cm2g (with no -ve tolerance) . The same shall be used to establish the capacity at test bed during package performance test.
9.6 9.6.1
Loading & Compensation Criteria Price Loading Criteria of compressor The guaranteed KW including all losses such as mechanical, transmission, power absorbed by compressor driven auxiliaries like cooler fans , auxiliary lube oil pump etc but excluding air compressor and ventilation fans at guaranteed flow with zero percent positive tolerance, of all the technically qualified Bidder s shall be compared. On the basis of the lowest KW quoted by the Bidder , other shall be loaded as follows; Total cost of the package for evaluation purpose (A+B+C+D+E); Where A: B: C: D: E: Capital cost of each package including cost of erection, commissioning, and special tools and commissioning spares. Cost of mandatory spares Differential operating cost as defined hereunder Cost of one year O&M during warrantee period and Annual Maintenance for 2 years post warranty from date of completion of one warrantee period Charges for training of 4 persons
Differential operating cost (Ex) Ex (in Rs) = (Eb-E0) X Re X 6570 X DF Where, Ex = Differential electric cost. Eb = Average total power quoted by the Bidder to be loaded for compressor package in KW E0 = Lowest average total power quoted by the any Bidder for compressor package in KW. Re -- Unit rate of electricity i.e. Rs 4.27 per KWH DF = 3.274 (Discounting factor based on 5 years of operating years)
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Maximum loading shall be limited to 5% of the total quoted cost i.e. A+B as defined above. For estimate purpose power consumption as indicated in the original bid shall be taken. 9.6.2 Compensation against performance of compressor During compressor package performance test, in case the absorbed electric power at guaranteed parameters for entire compressor package including auxiliaries but excluding air compressor and ventilation fans, is more than the guaranteed absorbed power mentioned at the time of bidding, compensation on the following basis shall be imposed on the Bidder : EY (in Rs) = 1.5 x (ET-EG) x Re x 6570 x DF Where, EY = Differential electric cost. ET = Average total power absorbed by the compressor package in KW, at the time of performance test the compressor package at site. EG = Total absorbed power guaranteed for the complete package at the time of bidding. Re -- Unit rate of electricity i.e. Rs 4.27 per KWH DF = 3.274 (Discounting factor based on 5 years of operating years) The total penalty to be charged for non-conformance of guaranteed parameter shall not exceed 10% of the ordered value i.e. A+B as defined above No advantage shall be given for higher performance than the guaranteed. Bidder shall indicate the Guarantee parameter in his offer as per AnnexureI of this specification. 9.6.3 Compensation against Gas leakage The bidder shall design the compressor package so that no venting and leakage of gas takes place. In case of loss of gas through venting or leakage, the purchaser shall be compensated @ Tk 15/Kg. The amount will be deducted from O&M monthly running bill in 1st year of warrantee period. However for 2nd and 3rd year the compensation shall be 4 times the compensation of last 6 months in warrantee period. 10.0 10.1 10.2 PAINTING AND PROTECTION Packing shall be sufficiently robust to withstand rough handling during ocean shipment & in-land journey. Sling points shall be clearly indicated on crates. The external steel surfaces of equipment & piping shall be painted. The paint shall be chosen, primed and applied as to have a service life of ten years. The exterior of equipment and container is required to be corrosion free for ten years and to have fade free life without oxidation of paint surface for five years in an environment of bright sunlight with an intense UV content. The Packager to specify the Grade of the paint intended to be used.
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10.3 11.0 11.1 11.2 12.0
The headers of air-cooled exchanger shall be galvanized. ERECTION, TESTING AND COMMISSIONING AT SITE Bidder shall be responsible for erection commissioning; performance test, field noise level test and field trial run of all compressor packages at site. Bidder shall be liable to pay all local taxes, levies applicable and comply with rules, laws prevailing in Bangladesh. FIELD TRIAL RUN Bidder shall conduct a field trial run of each compressor package for minimum 20 hours continuous duration near the guaranteed points in which satisfactory operation of complete package together with all accessories/auxiliaries controls shall be established for specified operating conditions prior to the start of one year operation and maintenance period as defined in the contract. During the field trial run the Bidder will be allowed a maximum of THREE attempts to complete the abovespecified test. The Equipment shall be considered commissioned after the successful completion of Field Trial Run.
13.0 13.1
SPARE PARTS, SPECIAL TOOLS AND TACKLES All spare parts, special tools & tackles for erection and commissioning and one year operation and maintenance of compressor package shall be supplied by the packager and shall form his scope of supply. A brand new separate set of min 10 nos special tools and tackles as required for Normal maintenance beyond the contractual one year operation period shall be supplied by the packager, which shall form the property of PURCHASER. Special st tools & tackles used by bidder in 1 year shall not be considered as old. DATA AND DRAWING a. b. c. Drawings and Data shall be furnished in conformity with the Bidder Data Requirements Forms attached with Enquiry Specifications. Bidder shall furnish all the information at the time of bidding as specified in the relevant Bidder Data Requirement (VDR) forms The data requirement after placement of Telex of intent is indicated in the Bidder Data requirement Forms for the respective equipment, including the number of weeks within which this data is to be provided. Bidder shall confirm that all data as required shall be furnished by him and shall indicate the Bidder s promised data in the columns provided. After the placement of TOI, a conference (kick off meeting) will be held at such date and at such place, as may be mutually agreed upon between the Bidder and the Purchaser. The intent of this conference shall be to discuss / clarify various requirements and finalize the modus operandi for execution of the contract within the scheduled delivery period. Bidder shall furnish the Drawings/Documents for Purchasers Review / approval as per the Bidder Data Requirement (as specified in the Specifications/ Bidder data requirement forms). The review comments for major and critical drawings (such as system P&IDs, General Arrangement
13.2
14.0
d.
e.
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Drawings, Foundation Drawings, Performance characteristics, Pulsation and Vibration Study Reports, Tensional Analyses etc.) shall be discussed across the table at such date and place as may be mutually agreed between the Purchaser and the Bidder. 15.0 OPERATION & MAINTENANCE OF COMPRESSOR UNDER ANNUAL MAINTENANCE CONTRACT The date of successful commissioning and performance test at site will considered date of start of the annual maintenance contract. However, bidder shall be paid 50% O&M charge for operating and maintenance the compressor. The bidder must follow the OPERATION & MAINTENANCE REQUIREMENT as stated below but not limited to and ensure to provide trouble free services to the satisfaction of the owner. 1.0 Accommodation/transportation/medical The bidder shall make his own arrangement for the accommodation of his personnel at respective locations and subsequent transportation arrangement for them from their place of residence to work place or any other place as required and company shall have no obligation in this respect. The company shall not be responsible for providing any medical assistance to the bidder personnel. 2.0 Discipline: The bidder shall be responsible for the discipline and good behaviour of all his personnel deployed in the services contracted out and should any complaint be received against any of his employee, he shall arrange to replace such persons within 24 hours of notice issued by the Engineer-in-Charge. The decision of the Engineer in-Charge in this matter shall be final and binding on the Bidder. 3.0 Gate pass/identity card The contract shall arrange to supply / renew identity card to his workforce at his own cost, if so required by the Purchaser for security or for any other reasons. Those Bidders personnel shall be required to carry their respective identity cards while on duty and produce on demand. 4.0 Right to get services carried out through other agencies. Nothing contained herein shall restrict Purchaser from accepting similar service from other agencies, at its discretion and at the risk and cost of the Bidder, if the bidder fails to provide the said services any time. 5.0 Sub-letting of contract No part of this contract nor any share or interest therein in any manner or extent, will be transferred or assigned or sub-let, directly or indirectly to any person/firm or organisation without prior permission of Purchaser. 6.0 Compliance of laws The bidder deploying 20(twenty) or more workmen as contract labour shall have to obtain license from appropriate licensing authority, if required. The bidder (which shall include the Contracting firm / company) shall be solely liable to obtain and to abide by all necessary licenses from the concerned authorities as provided under the various labour laws legislations including labour license from the competent
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authority under the Contract Labour (Regulation & Abolition) Act or similar act applicable to land of law. The Bidder shall be responsible for necessary contributions towards PF, Family Pension, ESIC or any other statutory payments to Government Agencies if applicable under the laws in respect of the contract and personnel deployed by the bidder for rendering services to PURCHASER and shall deposit the required amount with the concerned statutory authorities on or before due dates. The bidder shall not engage /deploy any person of less than 18 years under this contract and the persons to be deployed should be physically and mentally fit. The installations where job is to be carried out are live and have hydrocarbon environment. Bidder shall comply with all safety and security rules and regulations and other rules laid down by PURCHASER for its operation. It shall be the duty/responsibility of the bidder to ensure the compliance of fire, safety, security and other operational rules and regulations by his personnel. Disregard to these rules by the Bidders personnel will lead to the termination of the contract in all respects and shall face penal/legal consequences. The bidder shall arrange for insurance of all this workers engaged on the job as per the relevant Acts, rules and regulations, etc. In case by virtue of provisions of workers compensation Act, or any other law in force. PURCHASER has to pay compensation for a workman employed by the bidder due to any cause whatsoever the amount so paid shall be recovered from the dues payable to the bidder and /or security deposit. 7.0 The officer in charge shall have power to i) Issue the bidder from time to time during the running of the contract such further instructions as shall be necessary for the purpose of proper and adequate execution of the contract and the bidder shall carry out and bound by the same. During the currency of this contract, PURCHASER can increase and/or decrease the number of the services / technicians to meet contractual requirements. Order the bidder to remove or replace any workman whom the company considers incompetent or unsuitable and opinion of the company representative as to the competence of any workman engaged by the bidder shall be final and binding on the Bidder.
ii) iii)
8.0
Repatriation and termination PURCHASER shall reserves the right at any time during the currency of the contract, to terminate it by giving 30 days notice to Bidder, and upon expiry of such notice period the bidder shall vacate the site/office occupied by him immediately.
9.0
Indemnity agreement Bidder shall exclusively be liable for non-compliance of the provision of any act, laws, rules and regulations having bearing over engagement of workers directly or indirectly for execution of work and the bidder hereby undertake to indemnify the company against all actions, suits, proceedings, claims, damages demands, losses, etc. which may arise under minimum wages act, payment of wages act, workman compensation act, personnel injury (compensation insurance) act ESI Act, Fatal Accident Act, Industrial Dispute Act, Shops and Establishment Act,
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Employees Provident Fund Act, Family Pension and deposit Linked Insurance Scheme or any other act or statutes not herein specifically mentioned but having direct or indirect application for the persons engaged under this contract. (A certificate to this effect shall be submitted by the bidder immediately on receipt of LOA). 10.0 Compensation for non-fulfilment of obligation under Annual Maintenance Contract (AMC) During the AMC in warranty period of 1 year, the bidder must ensure that the compressor is available for a minimum of 18 continuous hours a day and 365 days a year for performing the required services as defined in the tender document. The timing of 18 hours will be decided by client. If the bidder fails to provide the required services for any day, The bidder shall compensate the owner @ Rs 2950/- per hr for compressor for the default period. For calculation of default period will be recorded jointly by the bidder and owner on daily basis. However, compensation will be on monthly cumulative basis rounded to nearest hour. During 6 hours bidder can carryout cleaning and preventive maintenance. Bidder in consultation with owner can club these 6 hours for two consecutive days for 2 times a month only without any penalty.In case bidder has utilized less down time of the compressor package than that allowed, the bidder can carry forward only max unutilized 9 hours downtime to immediate next month. 11.0 Bidders responsibility The bidder shall depute his Supervisor for supervision of the services to receive instructions from Engineer-in-Charge or his representative. 12.0 Employment liability of Bidder The bidder shall ensure and will be solely responsible for payment of wages and other dues latest by 7th of the following month to the personnel deployed by him in the presence of the Companys representative. The bidder shall be directly responsible and indemnify the company against all charges, claims, dues etc. arising out of disputes relating to the dues and employment of personnel deployed by him. The bidder shall indemnify the company against all losses or damages caused to it on account of acts of the personnel deployed by the Bidder. The bidder shall ensure regular and effective supervision of the personnel deployed by him. The bidder shall be liable for making good all damages/losses arising out of loss or theft of each handled, leakage, pilferage of any office, furniture equipment fitting and fixtures what-so-ever as may be caused directly or indirectly by the engaged persons through him/work carried out by them. 13.0 General The operation and maintenance services shall be provided in terms of shift pattern on the round the clock basis as mentioned in the tender document.
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i)
ii) iii)
iv)
v) vi) vii) viii) ix) x) xi) xii)
xiii) xiv)
xv)
The bidder shall deploy adequate number of technicians / supervisors / Engineers / helpers as well as tools & equipment for smooth and proper operation & maintenance of the compressors supplied in terms of the contract. In case required to meet operational requirements, the bidder shall augment the same as per direction of Engineer in-Charge. The bidder is required to carry out all services as mentioned in the Scope of Services and Schedule of Rates on all the 365 days including Sunday and all Holiday & around the clock. The bidder shall allow weekly rest and daily working hours to his workmen as per the relevant Act/Law/and Rule made thereunder. However, no work shall be left incomplete/unattended on any holiday/weekly rest. Technician/operators provided shall have minimum qualification of ITI. Contract in person or his authorised representative shall provide the services on daily basis to interact with Engineer-in-charge and deployed workman The work force deployed by the bidder for O&M services at CNG installation shall be of sound relevant technical professional expertise which is otherwise also essential from the safety point of view of the personnel of the bidder as well as for the installation. Bidder has to ensure the safety of man and machine all the times. Damages of equipment due to negligence will be recovered as per the decision of Engineer-in-Charge, which will be final. Regarding work completion, the decision of the Engineer-in-Charge will be final and binding. The bidder shall make his own arrangements to provide all facilities like boarding and transport etc. to his workmen. All personnel of the bidder entering on work premises shall be properly and neatly dressed and shall wear uniform, badges while working on premises of the company including work sites. Bidder shall maintain proper record of his working employees attendance and payment made to them. The Bidders representative/supervisor shall report daily to the Shift-inCharge for day to day working. All the safety rules and regulations prevailing and applicable from time to time at the installations as directed by PURCHASER will be strictly adhered to by the Bidder. The rates quoted by the Bidder must be inclusive of all the taxes, duties, services tax, work contract tax and any other levies, Bidders share of P.F. and insurance charges, Bidders profit and any other expenditure etc. It will be the responsibility of the bidder to pay as per the minimum wages of the appropriate government applicable under the Minimum Wage Act. The services shall be provided in terms of shift pattern on the round the clock basis. The bidder is responsible to provide effective and efficient services in all shifts and assure that there is no disruption in the services for want of any resources. The bidder shall establish a central control room to operate 24 hours, seven days a week where complaint regarding non-performance of the compressors in terms of the contract can be lodged. Further, the bidder shall deploy adequate number of technicians/ supervisors / engineers at various site offices in consultation with Engineer-in-Charge to provide trouble free operation & maintenance of the compressors.
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xvi) xvii)
All arrangements for communication from control room to the contract person working on job under the services shall be the responsibility of the Bidder, viz pagers / walky-talky. All the jobs mentioned under scope of services shall be carried out as per sound engineering practices, work procedure documentation, recommendation of the manufacturer and as per the guidelines/direction of engineer-in-charge of authorised representative.
14.0 14.1
Operation and Maintenance of compressor packages during one year warranty period Scope of supply during one year warranty period: All spares, consumables, lubricants, lubricating oil, coolant, sealant etc. required for carrying out the Operation and maintenance of the complete compressor package during the warranty period, including periodic, breakdown maintenance for continuous and uninterrupted operation of the compressor packages shall be in scope of the Bidder and shall be kept in stock. Electricity shall be supplied free of cost to the Bidder .
14.3
Scope of services: The Bidder shall have to keep all the spares, consumables, lubricants, coolant , etc required for carrying out periodic, breakdown, emergency maintenance etc of the package so as to minimise the down time of the compressor. Non-availability of compressor package for non-availability of spares shall be liable for compensation.
14.3.1
All tools, tackles and fixtures required for carrying out the above maintenance of the compressor shall be in scope of the Bidder . The scope will also include handling equipment like crane, forklift, chain pulley block, etc required during the any maintenance activity. Any expert services required from principal company or OEM shall be arranged by the bidder or his agent at his own cost. All arrangements like phone, fax, computer, Internet etc required for correspondences with above personnel shall be arranged by the Bidder . The periodic maintenance required to be done as per OEM recommendation shall be taken up promptly. The Bidder shall provide the detailed preventative maintenance schedule along with a) b) c) Estimated down time required for each type of maintenance schedule. List of spares and their quantities required for each type of maintenance schedule per compressor. Type and number of man days required for each type of maintenance schedule per compressor.
14.3.2
14.3.3
14.3.4
The bidder shall plan such maintenance during non-peak hours and in consultation with the Engineer In Charge (EIC) of PURCHASER. Any maintenance that needs to be taken up shall be well planned in advance with due approval of the EIC. The Bidder shall use only OEMs certified spares during maintenance. In case, the schedule maintenance of the OEM manual recommends to check and replace
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parts like valve spring, valve plates, piston rings etc. after certain time interval, same shall be replaced or used further only on approval from the PURCHASER representative. However any unto ward consequences for non-replacement of such parts shall be the responsibility of the Bidder . 14.3.5 All routine and periodic checks / inspections required to be done as per OEM recommendation shall be done by the Bidder . Instruments required for above inspection like vernier caliper, micrometer screw gauge, fill gauges, bore gauge etc shall be in scope of the Bidder and these instruments shall be calibrated every year. All parts replaced by the Bidder during the above contract period shall be properly packed and handed over to PURCHASER, on replacement. The bidder shall submit a copy of the daily / weekly / fortnightly / monthly / bimonthly / quarterly and yearly performance report to the EIC in both soft and hard form. All stationery including the printed material shall be in scope of the Bidder . All the maintenance / inspection job carried out by the Bidder shall be recorded and the report of the same shall be jointly signed by PURCHASER representative. The EIC will be final authority to take decision with regards to maintenance or replacement of parts or any disagreement between the Bidder and PURCHASER, during the execution of the contract. The Bidder shall carryout calibration of gas detectors and flame detectors every six months or earlier as per requirement or instruction of EIC of PURCHASER. Also yearly calibration of all instruments such as pressure gauges, transmitters, switches, mass flow meters etc shall be in the scope of the Bidder . In addition to the above all safety relief valves shall also be tested and calibrated every year. Calibration shall be done from government-approved laboratories and shall be carried out at least 15 days prior to the calibration due date. The Bidder shall keep 1 set of safety relief valves in spare for the purpose of calibration. The Bidder shall carry out retesting of pressure vessels periodically as per Gas Cylinder rules 1981 or Static & Mobile Pressure Vessels Rules. The periodic maintenance required to be done as per OEM recommendation shall be taken up promptly. The Bidder shall plan such maintenances during non peak hours and in consultancy with the Engineer In Charge (EIC) of PURCHASER. Any maintenance that needs to be taken up shall be well planned in advance with due approval of the EIC. The scope shall include preparation of maintenance schedule for carrying out the maintenance during the contract period. 14.3.11 In case, the schedule maintenance of the OEM manual recommends to check and replace parts like valve spring , valve plates , piston rings etc. after certain time interval, same shall replaced in the presence of PURCHASER representative.
14.3.6 14.3.7
14.3.8
14.3.9
14.3.10
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DESCRIPTION
(1) A A.1 A.2
DRAWINGS AND DATA REQUIRED FROM BIDDER (All drawings & Documents shall be in English Language only) PRINTS Certified Information Required after WITH Purchaserr order BID Prints For records Time from for & FOI in review Information weeks (To be indicated by vendor) (2) (4) (5) (6)
A.3
A.4 A.5 A.6 A.7 A.8
A.9 A.10 B B.1 B.2 B.3
B.4
GENERAL Schedule for furnishing the vendor data A specific statement that CNG compressor package is in strict accordance with data sheet , technical specification & applicable standards, In case of any deviation, specific list with details & reasons for each deviation. General arrangement (GA) indicating battery limit for electric and piping connection & schematic diagram. A statement on oil consumption and minimum allowable oil temp. Flange details of piping connection with connection at battery limit. Duly filled in experience record program Tentative load data for foundation design. List of sub-vendors with address / phone/ fax no. For all bought out items including electrical & instrumentation items. Leaflet, catalogues for all items. O & M manual Compressor Data Sheet duly filled in. Catalogue of compressor Typical cross sectional drg. and literature to fully describe the details of offering. Compressor Suction Discharge valve Piston rod gland packing & piston rings. Lube oil pump V-belt & pulley with selection chart & calculation
Yes
Yes
Yes
Yes
Yes
Yes Yes
Yes Yes Yes
Yes Yes
Yes
Yes Yes Yes Yes Yes
Yes Yes Yes
Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes Yes
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DESCRIPTION
PRINTS WITH BID
(1) B.5 B.6 B.7 B.8 B.9
B.10 B.11 B.11 B.12 B.13 B.14 B.15
B.16 B.17
B.18 B.19 C C.1
Cooler data / drg with thermal & mech. design calculation Design calculation, GA drgs for pulsation dampner. Gas hydraulic oil, lube oil piping & instrument diagram Torque angle diagram, piston rod load VS crank angle. Torque speed characteristic. Starting torque of motor and compressor to be superimposed over each other. Acoustic / mechanical evaluation report Itemized price list of spares Itemized list with price of spares for erection / commissioning. Item list of spares for one year warrantee period Drg. For testing arrangement & test procedure to be adopted. Quality Assurance Plan (QAP) and Quality Procedure Certificate for following a) Hydraulic testing b) Non destructive testing c) Material composition & physical properties. d) Leak proofness list of frame e) Lube pump, frame oil pump, hyd. Oil pump Design / Actual assembly clearance chart Test records of following a) Mechanical running b) Performance test c) Noise level test List of special tools & tackles for installation & maintenance Filled in air cooler data sheet Electric motor Performance curves
(2) Yes Yes Yes Yes Yes
Certified Information Required after Purchaserr order Prints For records Time from for & FOI in review Information weeks (To be indicated by vendor) (4) (5) (6) Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Yes Yes Yes Yes
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DESCRIPTION
PRINTS WITH BID
(1) C.2 C.3 C.4 C.5 C.6
(2) Technical literature / catalogue, Yes selection charts, nomographs etc. Filled in data sheet Yes Control schematics Yes Performance curves for auxiliaries like fan, pump Typical component cross sectional drawing and literature to fully describe the details of offering. Test procedure Mill test report Manufacturer's test report Stage inspection and test report Final acceptance testing and performance tested records. Schematic diagram with start up & shut down procedure & logic Inter connection & wiring diagram INSTRUMENTATION AND ELECTRICS Drawing & document index Instruments and electric motor data sheets Start up and shut down write up Start up & shut down inlet lock diagram Alarm & shut down list with set point Control panel layout Termination diagram, panel writing detail Loop schematic Inter connecting diagram Cable schematic Bill of material Inspection & test procedure Test / Inspection certificate List of relief valves with settings P & ID of priority panel. Yes Yes
Certified Information Required after Purchaserr order Prints For records Time from for & FOI in review Information weeks (To be indicated by vendor) (4) (5) (6) Yes Yes Yes Yes Yes
C.7 C.8 C.9 C.10 C.11 C.12 C.13 D D.1 D.2 D.3 D.4 D.5 D.6 D.7 D.8 D.9 D.10 D.11 D.12 D.13 D.14 D.15
Yes Yes Yes Yes Yes Yes Yes
Yes Yes Yes Yes
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Note: 1) The above documents shall be given by bidder after placement of order and approval of drawings/ document as explained above.
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a) 1 CD of all documents/drawing in editable form; transparency d) 2 nos CD of software for compressor PLC
b) 6 sets of prints; c) one set of
For consultant : 1 CD of all documents/drawing in editable form; b) 2 sets of prints The drawing submitted with bid will not be considered as final. Successful Bidder shall submit final drawing as per scope defined in tender for approval. GUARANTEED PARAMETERS ELECTRIC MOTOR DRIVEN COMPRESSOR Sr No 1 Description Compressor capacity in SM3/ Hr at suction pr 1.05 kg/cm2 discharge pr 255 kg/cm2 and gas inlet temp 30 C (required ii SM3/ hr) Electric power consumed by compressor package including 0.843498 power absorbed by following auxiliaries along with 1.054372 transmission losses and at guaranteed flow at specified conditions Lube oil pump motor, Inter cooler fan motors, Cooling water pump motors and Control panel
Electric power consumed by following auxiliaries shall not be included in the above electric power consumption figure. d) Air compressor motor e) Exhaust fan motor f) Enclosure lighting 3 Sound level of enclosure (required 65), dBA Note: Bidder shall indicate realistic power consumption. If power consumption indicated by Bidder is less than 3% of average power consumption (APC) of all technocommercially successful Bidder s, his power consumption may be increased to APC in case he fails to submit satisfactory power consumption calculation with supporting test results.
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Natural Gas Composition
Component
N2 CO2 Methane Ethane Propane I- Butane N- Butane I-Pantane N-Pantane Hexane Plus Water lb/mmscf
Titas
0.58 0.54 96.25 1.79 0.45 0.1 0.06 0.03 0.01 0.19 3.6
NOTE: 1.0 2.0 Specific gravity: Calorific value Net Kcal/SCM = = 0.59 to calculated by Bidder
CHECKLIST: SCOPE OF SUPPLY RECIPROCATING GAS COMPRESSOR (ELECTRIC MOTORDRIVEN) PACKAGE Notes : (i) Bidder shall furnish all equipment, drivers, auxiliary systems, instruments and controls and safety devices as per the enquiry document. Anything required over and above what is specified, for safe and satisfactory operation of the equipment package shall be included by the Bidder in his scope. (ii) Bidder to write YES/NO against each item. Bidder is required to include complete scope, as such 'NO' is not warranted. However, in case for any of the items if vendor's reply is 'NO', vendor should give reasons for the same: 's scope of supply shall include but not be limited to the following: Description Sr. No. 1 1.1 1.2 1.3 Each Reciprocating Compressor package complete with : Suction / discharge pulsation dampers Process equipment such as separator complete with supports, manual drain with double isolation valves, and automatic drain system for separators Air cooled, lube oil, cooling water, inter-stage and discharge gas coolers with necessary air cooling arrangement Yes Yes Specified by Purchaser (Yes/No) Included by Bidder (Yes/No) Remarks
(iii)
1.4
Yes
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1.5
Combined or separate closed circuit cooling water system for compressor (As required) Lubricating oil system for compressor . Safety relief valves on each stage of the compressor All interconnecting oil, gas, water, air piping within the compressor package All valves, tubing, fittings as specified and required within the compressor package Fuel supply hardware complete with SS piping, control valves, Regulators, Flow-meter, filter, vent/drain within the package suitable for the specified fuel gas
Yes
1.6 1.7 1.8 1.9 1.1O
Yes Yes Yes Yes Yes
Description Sr. No. 1.13 1.14 Common skid for compressor and other auxiliary systems Acoustic enclosures for compressor for noise attenuation up to 65 dBA @ 1 m distance fitted with fire detection and extinguishing system as specified Instrumentation and control system complete with PLC based control panel configured as RTU of supervisory computer and data acquisition, instrumentation as specified. Cabling with cable trays for all the electrical devices within the package. Compressor inlet gas flow meter with electronic volume correction and discharge mass flow meters with associated equipment Inlet Pressure Regulators (Compressor Suction) Priority Panel (as specified) at Package Discharge Compressor gas inlet Y-type temporary strainer, permanent inlet filter .
Specified by Purchaser (Yes/No) Yes Yes
Included by Bidder (Yes/No)
Remarks
1.15
Yes
1.16 1.17 1.18 1.19 1.2O
Yes Yes Yes Yes Yes
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1.21
Y-type strainers, valves, sight flow indicators, check valves, auto/manual drain traps as required for various compressor auxiliary systems, i.e. frame lubrication system, cylinder lubrication, cooling water systems etc. Manual package isolating valves and auto inlet isolation valve All couplings and guards Flywheels, barring device
Yes
1.22 1.23 1.24
Yes Yes Yes
Description Sr. No. 2 2.1 2.2 Spares and Tools / Tackles Mandatory Spares if specified in the TS (Indicate separate price for each item) Erection and commissioning spares as recommended by Bidder including lube oil consumables etc. as required for erection & commissioning of each compressor package. Two year normal operation and maintenance spares over and above the spares as required during one year warranty period normal operation and maintenance of each package by the Bidder Quote for five year Normal operation & maintenance spares (excluding lube oil etc.) Special tools and tackles required for normal operation & maintenance of each equipment of compressor package as required and recommended by the Bidder Inspection and Testing As specified on the datasheets and tech. Spec. Vendor data and drawings All data & drawings as required per VDR format Erection, commissioning and trial runs at site of the complete package Miscellaneous Foundation and anchor bolts
Specified by Purchaser (Yes/No) yes Yes
Included by Bidder (Yes/No)
Remarks
2.3
No
2.4
No
2.5
Yes
3 3.1 4 4.1 5 6 6.1
Yes Yes Yes Yes

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6.3 6.4
Acoustical and mechanical analysis report & pulsation study (apporoach-3) Additional items not specified by Purchaser but recommended by Bidder for safe smooth and normal operation. (Bidder shall indicate separate list of such items in his proposal) One year operation maintenance contract including all operating spares including consumables
Yes Yes
Yes
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DATA SHEET COMPRESSOR

1 2 3 4 GENERAL: Means required Means bidder shall indicate; if not indicated shall be in bidders scope PROJECT: : CNG & CITY GAS PIPELINE PROJECT FOR Bangladesh . OWNER: M/S HPCL SERVICE: PROCUREMENT OF CNG COMPRESSORS SITE: NO. REQD : 2 ELECTRIC MOTOR DRIVEN COMPRESSOR CAPACITY : 800 DRIVER: ONE ELECTRIC MOTOR SCMH NOTE: SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER INFORMATION REQUIRED FROM VENDOR. MANUFACTURER: MODEL NO.: PLACE OF MANUFACTURE: NO. OF STAGES: by Bidder CYLINDER ARRANGEMENT: CYLINDER LUBRICATION: LUBRICATED MINIMUM LUBRICATED NON LUBRICATED DRIVER TYPE: ELECTRIC MOTOR DRIVE: V BELTS (ANTI-STATIC TYPE) DIRECT WITH COUPLING DIRECTION OF ROTATION (FACING DRIVEN END): CLOCKWISE COUNTER CLOCKWISE SITE / INSTALLATION DATA SITE DATA: AMBIENT MAX: TEMP. MIN: 0 ( C): RELATIVE MAX: HUMIDITY (%): ALTITUDE (M): EARTH QUAKE ZONE V WIND VELOCITY (KM/HR) 160 (MAX) INSTALLATION: OUTDOOR MOUNTED ON A COMMON SKID ALONGWITH DRIVER, ENCLOSED INSIDE A ACOUSTIC ENCLOSURE ELECTRICAL AREA HAZARD: CLASS/ZONE: CLASS I ZONE I DIVISION: I GAS GROUP: D, GROUP IIA, IIB APPLICABLE CODES AND STANDARDS COMPRESSOR: Preferably API 618 PIPING: ASME/ANSI B 31.3 Latest Edition PRESSURE VESSELS: ASME SEC- GAS COOLER: Preferable API 661 VIII, DIV-1. OIL COOLER: TEMA `C. SOUND: 65 DBA @ 1M FROM ENCLOSURE AUX. ELECT. MOTORS: CONTROL PANEL & INSTRUMENTATION REFER: TECHNICAL SPECIFICATION UTILITIES DATA Cooling Water (Not Available) Type: Supply temperature (0C): Max return temperature (0C): Fouling Factor: Supply pressure (kg/cmG): Min. return pressure(kg/cmG): Design pressure (kg/cm A): Design temperature (0C): Water Flow Rates (m3/hr) Electricity Auxiliary Motors: V Ph Hz Oil Heaters: V Ph Hz Solenoid Valves: A.C/D.C V Ph Hz Instruments: A.C/D.C V Ph Hz Local Panel INDI./Alarm/Ann : A.C/D.C V Ph Hz Local Panel Trip Circuit: A.C/D.C V Ph Hz UPS: KVA, V Ph Hz Total Utility Consumption 3 Cooling Water (Make UP) (m /hr) Power (Auxiliaries) (kW) Power (Heaters) (kW) REMARKS: Vendor/ Bidder should estimate the requirement for all the Utilities and indicate the same in
5 6 7 8 9 10 11 12 13 14 15 16
17
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
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49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
tabular form. CONSTRUCTION / DESIGN FEATURES Nomenclature Unit Cylinders No of Cylinders Single Acting (SA) / Double Acting (DA) Cylinder Bore / Stroke Rotational Speed Linear Average Piston Speed Piston Displacement Cylinder Liner (Yes / No) Type of Cylinder Liner : Dry/Wet Clearance Pockets Yes / No Max. Allow. Working Pressure, Cylinder Max./Min Allow. Working Temp., Cylinder M.A.W.P, Cylinder @ Amb. Temp. Safety Valve Set Pressure, Cylinder G Helium Test Pressure, Cylinder Hydrostatic Test Pressure, Cylinder Cylinder Jacket Cooling Type As reqd. Cooling Media, Cylinder Jackets Water /AIR Max. Allow. Working Pressure, Cyl. Jacket Hydrostatic Test Pressure, Cyl. Jacket Suction Nozzle Size/Rating/Position Discharge Nozzle Size/Rating/Position Suction Valve Number Average gas Velocity Discharge Valve Number Average gas Velocity Type of Suction valve Type of Discharge valve Suction Valve Unloaders Yes / No Clearance Pockets Unloaders Type Piston Rod Diameter Rod Reversal at Crosshead Pin (min.) Piston Rod Run out Operating Max. Allow. Rod Load Comp. Tension Rod Load Comp. Tension Rod Load at R.V Set Comp. Distance piece / Packing Type of Packing Packing Vent Connected to ## Packing Cooling Type of Distance Piece Cyl. Side Compartment Purged
Stage#1
Stage #2
Stage #3
Stage #4
Stage# 5
mm / mm RPM M/sec M3/ hr
kg/cma
0
kg/cma kg/cma kg/cma kg/cma
kg/cma kg/cma
M/sec M/sec
Mm Deg.
Kg Kg Kg Kg Kg
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95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151
Frame Side Compartment Pressurized Distance Piece purge gas Pressure Distance Piece purge gas Flow Distance Piece Vent to
Mm H2O Nm3 /hr Safe Height Safe Height Safe Height Safe Height Safe Height
Distance Piece Hydrostatic kg/cmG Test Pressure ## Packaging should be connected to vent header Ref 7.19.4 of API-11 Frame Replaceable Crosshead Shoes Yes / No Crosshead Guide Integral / Separate Maximum Frame Rating KW Speed - Maximum/ Minimum Rpm Lubrication Systems Type of lube system Piping material Carbon Steel Main Oil Pump Driven By : Stainless Steel (all piping & valves Trims) Standby Oil Pump, Driven By : Auxiliary oil tank Hand Operated Prelube/Priming Pump: Oil Grade : Suction Strainer Lube Oil Consumption Pressure Control Valve Main Pump Make : Model : Level Sight Glass on the Crankcase Type : Material : Type of Oil Cooler : Standby Pump Make : Model : Size of Filter: Type : Material : Oil Heater (if required). Electric Heater with thermostat (Kw) Thermostatic Valve Type of Cylinder Lubrication Lubricator Equipped With : Lubricator Type: Manzel or Equivalent. Level sight glass Single plunger per feed Oil heater electric with thermostat Divider blocks type. Electric Heater (Kw) (if required) Lubricator Driven By : Auxiliary Oil Tank (if required) Compressor Shaft Oil Grade : Electric Motor KW Oil System Capacity: (min 30 Hrs.) All tubing and valves in SS Oil Consumption. Rate Double Ball Check valve on each lubrication point Cooling System Static filled coolant system for All Stage Cylinders Including expansion chamber, Vents, Drains, Level Gauge, Piping, etc. All Piping prefabricated Material Atmospheric thermosyphon cooling system for All Stage Cylinders Including expansion tank, Vents, Drains, Coolers, and Level & Temp. indicators, Piping, etc. All Piping prefabricated. Material Forced Cooling Water System All Stage Cylinders Packings Oil Coolers Gas Coolers Including drains, Vents, flow & temp. Indicators, regulating & Isolation valves, complete piping to provide one Common inlet and one common outlet connections for Purchaser's interface terminated by a flanged block valve Block valve. Each isolatable circuit to be provided with thermal relief valve. All Piping prefabricated. Material Self contained, forced circulation, closed circuit Cooling Water System (if reqd.) All Stage Cylinders Packing Oil Coolers Gas Coolers Including drains, Vents, flow & temp. Indicators, Temp. Control Valve, Regulating & Isolation valves, complete piping Main circulating pumps with drivers & suction strainers Single Coolers Reservoir (Make Up) Heater (if required)
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152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180
181 182 183
184
185
186
187 188 189 190
191
192
Pumps, Reservoirs, Coolers etc. to be mounted on a common skid as to make a separate console. Material of piping: Type of coolant: Jacket cooling Gas Piping System Vendor's Supply Includes: Separator Pulsation suppression equipment as per next page Suction Filter: Temporary Strainer on Compressor Suction Type of Strainer: Relief Valves: on compressor suction Inter-stage on compressor discharge Check Valve on Discharge Line (compressor valve design, and suction line) Process Gas Coolers Complete With Manual Drain Valve Separators Complete With Manual/ Automatic Drain Values Process Gas Piping Supply starts at inlet flange of CNG PACKAGE Terminates after priority panel with isolation valve Materials: By-Pass Line Piping Between Gas cooler Interconnecting Piping Between Packing Vents, PSV Relief terminating to Vent Recovery System. Interconnecting piping between distance piece terminating to Vent Recovery System upto package B/L Interconnecting piping between Drains terminating as a single point Interconnecting piping between Instrument Air terminating Pulsation Suppression Equipment Stage #: Stage#1 Stage#2 Stage#3 Stage#4 Stage#5 Suction Puls. YES Equipment Required Yes/No Inlet Pressure Residual Peak to Peak Pulsation % As per API 618 ( APPROACH 3 ), Cl 3.9.2.7 Inlet Nozzle 1.3XMAWP 1.3XMAWP Size / Rating/Posit ion Discharge Nozzle Size / Rating/Posit ion Design Pressure Kg/cma Design Temperatur e 0C Volume Material : SA 516 Gr.60 SA 516 SA 516 SA 516 SA 516 vessels Gr.60 Gr.60 Gr.60 Gr.60 Internals Corrosion 3 3 3 3 3 Allowance mm Hydrostatic 1.3XMAWP 1.3XMAWP 1.3XMAWP 1.3XMAWP test 1.3XMAWP Pressure kg/cm,g Discharge
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193
194 195 196
197
198
199
200 201 202 203
204
205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241
Puls. YES YES YES YES YES Equipment Supplied Yes/No Inlet Pressure Residual Peak to Peak Pulsation % As per API 618, Cl 3.9.2.7 Inlet Nozzle Size / Rating/Posit ion Discharge Nozzle Size / Rating/Posit ion Design Pressure Kg/cma Design Temperatur e 0C Volume Material : SA 516 Gr.60 SA 516 SA 516 SA 516 SA 516 vessels Gr.60 Gr.60 Gr.60 Gr.60 Internals Corrosion 3 3 3 3 3 Allowance mm Hydrostatic 1.3XMAWP 1.3XMAWP 1.3XMAWP 1.3XMAWP 1.3XMAWP test Pressure kg/cm,g Design Code:. ASME SECT. VIII DIV. 1 Analog Piping Study / Acoustic Simulation, As per Approach 3, Cl. 3.9.2.6 API618, 4th edition Upstream / downstream Inter-stage Performed By: Vendor Any other agency having similar experience Piping Mechanical Analysis Performed By: Vendor Any other agency having similar experience Automatic Drain Valves For Each Stage suction KOD Capacity Control Start / Stop, based on discharge receiver pressure: Fully Automatic Unloading for Start up/Shut down :Automatic Through Valve Unloader Recycle Valve Interlock against loaded start Automatic Control based on Suction Pressure Discharge Pressure Flow Manual Signal Type of Actuator Actuation fluid to load Actuation fluid to unload On Power / Actuation fluid failure : Compressor to Load Unload Continuously Maximum Hrs. Continuously Maximum Hrs. At All other capacity, Compressor should run continuously Vendor's scope Should Include : Pilot Devices (pressure / temperature / Flow devices ,Controllers & Switches) Intermediate Devices (Solenoid Valves | Pneumatic Relay / Valves) Actuators Recycle valves Control Logic and System for Complete Capacity Control Inter Connecting Tubing, Piping, Cabling & Wiring Protection against extended unloaded operation (Trip) Valve unloaders are required as such Compressor should start / stop at specified receiver pressures. Purchaser's Interface Type of Interface (Single Size Rating Face Position/Location Point) Main Gas Piping Inlet Main Gas Piping Outlet Relief Valves discharge Distance Piece Vent Packing Vent C.W. Inlet C.W. Outlet N2 Inlet Supply
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242 243 244 245 246
N2 Vent (Safe location) Drains MATERIALS Cylinder Materials Stage
1 Stage
2 Stage
3 Stage
4 Stage
5 Stage
247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273
Cylinder Liner Piston Piston Rings Rider Rings Piston Rod Packings Rings Valve Seats Valve Stops Valve Rings / Plates Valve Springs Cylinder Head Motion Work Materials :
PTFE PTFE
PTFE PTFE
PTFE PTFE
PTFE PTFE
PTFE PTFE
Material / ASTM Grades Top Cover Crankcase Crankshaft Connecting Rods Cross heads Cross Head Shoes Cross Head Guide Main Bearings Type Cross Head Pin Bearings Type Connecting Rod Bearings Type Cross Head Pin Type Notes : Bidder to indicate the material Each package should be provided with two number drain lines, one from Suction KOD and second drain as common drain line from intermediate and discharge KOD routed to drain vessels through gas recovery vessels CONTROLS & INSTRUMENTATION AC Power On/Off Switch With Indication Lamp Control Power On/Off Switch With Indication Lamp YES Selector Switch A/M Station For L/O Pump Motor Selector Switch A/M Station For CW Pump Motor Emergency Stop Push Button Start Push Button For Air Compressor Motor Emergency Stop Push Button for Main Motor Lamp Test Push Button Alarm / Trip Acknowledge / Reset Push Button Frame Oil Heater ON (Indicating lamp) Lubricator Oil Heater ON (Indicating lamp) Motor Interlock Against Loaded Start Motor Interlock Against Start Without Prelubrication Notes : Minimum required indications, alarms & trips are shown herewith. Bidder should provide any additional instrumentation for safe operation. Compressor should start stop at pre determined receiver pressure as specified. Bidder should include in his Scope includes the necessary hardware for the same.
INSPECTION AND TESTS
274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301
Material Composition and Physical Properties Certificates Required For: Cylinder and Liner Piston Crankshaft Connecting Rod Pressure Vessels Heat Exchangers X-Ray Examination for components: Pressure Vessels (certificates to be furnished). Required Observed Witnessed Mech. Running Test with shop Driver (4 Hours min.) Performance Test at site as per IS 5456/PTC9/BS 726 (*). Partial Stripping and internal
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302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 323 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343
inspection Functional/Continuity Tests - Control Panel. Field Trial Run 20 Hrs. under Vendor's Supervision (Package) Valve Leak Test Lube Oil Console Run test Closed Circuit C.W. System test During package performance test Test Certificates Required For: Auxiliary Motor & Pumps Safety Relief Valves Safety Switches Solenoid Valves WEIGHTS Overall supply (excluding driver and gear box, if any) Kg. approx. Maximum erection weight Kg. approx. Maximum maintenance weight Kg. approx. Gear Box Kg. approx. Driver Kg. approx. SCOPE OF SUPPLY Compressor Assembly complete with frame, cylinders, cross head etc. Motion work lubrication system Cylinder and packing lubrication system Cooling system Process Gas system Local instrumentation Local Gauge Board Local Control Panel PLC Panel Man Machine Interface located in Control Room Main driver electric Motor Barring Device: Manual Electric. Pneumatic Flywheel V-Belts with Pulley Couplings Driver Compressor Guards for moving parts Base plate Common for Compressor and Driver Fabricated Steel skid Common for compressor, driver and accessories Ladders and platforms Special Tools - One Set for each package Anchor Bolts for Complete Package Piping supports and brackets : prefabricated for piping in Vendor's Scope Supports For Cylinders & Auxiliaries, Prefabricated & fitted in the Package Commissioning Spares, erection and commissioning spares Spares as specified in the Job Specification Vendor Data as specified NOTE : Refer checklist for scope of supply
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ANNEXURE MS
MANDATORY SPARES PARTS FOR GAS COMPRESSOR PACKAGE 1 The quantity of spares as mentioned is the quantity required for a lot of 01 no compressor packages. If any set is not applicable for any compressor package , the same will be price loaded . The price of set will be taken as maximum from techno-commercially acceptable Bidder . Price of mandatory spares shall be loaded for evaluation purpose. 1 Set means the quantity installed in one compressor package. Details items in the set will as per OEMs spare parts & maintenance manual. Successful Bidder will furnish details of set with part nos.
2 3
S.No Part Description
Part No.
Qty. Reqd. by purchaser in set for each comp

2 1 1 4 4 2 2 2 2 4 2 2 2 1 2 2 2
Price Unit Total
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22
Set of piston rings & wearing ring for all cylinder Suction valve assembly for all cylinder Descharge valve assembly for all cylinder Suction valve internals (for all stages) Discharge valve internals (for all stages) Packing Ring for Cylinders Mechanical seal for lube oil pump and cooling water pump. O-Rings and Gaskets for Compressor Feed Assembly for Lubricator Filter Oil Cartridge for Suction Gas filter Cartridge for Discharge Gas filter Gasket & O-Ring for compressor package V-belts for motors Seal kit sets for Actuators Seal for Compressor Crankshaft Bearing Set for Air Cooler, Water Pump & Main Motor, AOP, AOP Motor Power Contctor for main motor starter Relay for main motor, cooler fan, water pump over load. 10% relay installed 10% Zener barrier installed Pressure transmitters ( 0 400 )
2 2 1 1 4
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23 24
Pressure transmitters ( 0 200 ) Temp element
2 2
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DATA SHEET OF COMPRESSOR MOTOR

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Project name: Driven equipment Tag No. / Equipment No. Duty Manufacturer Type Frame designation Output _______________________ KW Voltage _____________________VOLT Full load current_______________AMP Full load speed _______________ RPM Enclosure Mounting Insulation Class Ambient temperature ____________ C Temp. Rise by resistance __________ C Applicable Code Full load torque ______________ Kg-m Starting torque ________________FLT Efficiency at _____________100% Load ________________________75% Load ________________________50% Load Rotation viewed from DE Bearing type No. Type of Lubrication Coupling / pulley Net weight (approximate) __________kg Cable size / type ______ mm sq. Phase / connection / No. of terminal Frequency _______________ Hz. No. of poles ______________ Locked rotor current___________%FLC LR withstand time (HOT) _________Sec (COLD) Sec Startor / rotor time constant _______Min Power factor at 100% Load - 75% Load - 50% Load Break down or pull out torque ___ %FLT Space heaters _________WATT / VOLT GD Sq. of load __________Kg-m2 GD Sq. of motor __________Kg-m2 Starting time at 100% / 80% V-Sec No. of starts Hot / Cold Vibration Level / Noise Level Area classification PURCHASER Compressor
THREE PHASE, SQUIRREL INDUCTION MOTOR, EFF2 rated
CAGE
415 V+/ - 10%
TEFC/FLAMEPROOF/IP55 AS PER IS:4691-1985 F' - Temp. rise limited to Class - 'B'
21 22 23 24 25 26 27 28 29 30 31 32 33
DIRECT / FLEXIBLE
50 Hz + / - 5%
34 35 36 37 38 39 40 41
4 As per IS12065 / IS12075 CLASS - I, ZONE (DIV)-1, GAS GROUP IIA / II B
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DATA SHEET GAS DETECTION SYSTEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 TECHNICAL GENERAL PROJECT: OWNER: M/S PURCHASER SITE: Bangladesh EQUIPMENT: GAS DETECTION FOR CNG STATIONS NO. GAS DETECTION TYPE: NOTE: SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER INFORMATION REQUIRED FROM VENDOR. MANUFACTURER: MODEL NO.: SIGNAL TRANSMISSION ANALOG: TRANSMISSION BY 3CORE SHEILDED CABLE MEASUREMENT CONTROL: 4mA to 20Ma SENSOR DRIFTS BELOW ZERO: MEASURING RANGE EXCEEDED: TRANSMITTER FAULT: MAINTENACE SIGNAL: HART COMPATIBLE: SITE / ENVIRONMENTAL DATA SITE DATA: AMBIENT TEMP. (0C): MAX: MIN: RELATIVE HUMIDITY (%): MAX: ALTITUDE (M): INSTALLATION: INDOOR ELECTRICAL AREA HAZARD: CLASS/ZONE: CLASS I ZONE I DIVISION: I GAS GROUP: D, GROUP IIA, IIB
APPLICABLE CODES AND STANDARDS

GAS DETECTION APPROVALS: CENELEC :Exd IIC 6 VOLTAGE OF SUPPLY OPERATING VOLTAGE: A.C/D.C IN-RUSH CURRENT: A.C/D.C POWER INPUT A.C/D.C PHYSICAL SPECIFICATIONS ENCLOSURE: Nema 4+7 (IP65) SIZE WEIGHT UL, CSA: Class 1, Div 1, Groups B,C,D V Ph
INSPECTION AND TESTS

Physical Tests on site:
REMARKS
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DATA SHEET- UV FIRE DETECTION SYSTEM

TECHNICALGENERAL
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PROJECT: OWNER: M/S PURCHASER SITE: Bangladesh EQUIPMENT: UV FIRE DETECTION FOR CNG STATIONS NO. FIRE DETECTION TYPE: NOTE: SCOPE OPTION / INFORMATION SPECIFIED BY PURCHASER INFORMATION REQUIRED FROM VENDOR. MANUFACTURER: MODEL NO.: TYPICAL RESPONSE TIME: < 3 SEC @ 50FT WAVE LENGTHS: FIELD OF VIEW: MINIMUM SENSOR RESPONSE TIME: SENSITIVITY MAINTENACE SIGNAL:
CLASSIFICATION: CLASS I, DIV 1, GROUPS B, C & D: Eexd IIC, T5, IP66
CLASS II, GROUP E,F & GCLASS III, TYPE 4X
APPROVALS: CSA, FM, ATEX, CENELEC, CE MARKING ENVIRONMENTAL SPECIFICATIONS OPERATING TEMPERATURE RANGE: -40 (0C) to 85 (0C) 0 0 STORAGE TEMPERATURE RANGE: -50 ( C) to 85 ( C) OPERATING HUMIDITY RANGE: 0% TO 100% RH NON-CON-DENSING
ALTITUDE (M): 16 EARTH QUAKE ZONE V 17 INSTALLATION: INDOOR 18 ELECTRICAL SPECIFICATION: INPUT POWER: 20 36 VDC, 24 VDC @ 150Ma max. 19 ANALOG SIGNAL: 4-20mA (600 Ohms Max.) 20 21 FAULT SIGNAL: 0Ma 22 IR SIGNAL: 23 ALARM SIGNAL: RELAY CONTACT RATING: 8A, 250VAC, 8A @ 24VDC 24 RFI/EMI PROTECTION: COMPLIES WITH EN50081-2 25 26 FAULT MONITORING: MECHANICAL SPECIFICATION: HOUSING: 28 29 DIAMETER: 30 CABLE ENTRY: SCOPE OF SUPPLY 31 UV FIRE DETCTION SENSORS COMPLETE: 32 DATA SHEET COMPLETED REMARKS: 33
COPM FAULT READY SIGNAL UV SIGNAL: WARN SIGNAL: BAUD RATE: RS-485 OUTPUT: STATUS INDICATOR: LENGTH: MOUNTING: WEIGHT:
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OPERATING CONDITIONS: SUCTION PRESSURE: i kg/cm2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 OPERATING CONDITIONS (EACH MACHINE) / PERFORMANCE Operating Case: SUCTION PRESSURE: kg/cm Stage 1 Units Gas Handled (See Analysis) Corrosion Due to Suction Conditions Pressure (@ Vendor's B/L) kg/cm 0 Temp. (+@ Vendor's B/L) C Discharge Conditions (Vendor's Battery Limit : Pressure (@ Vendor's B/L Pressure @ Cylinder Flg. Temp., Adiabatic @Cyl. Flange < 52 Temp.,Actual @Cyl.Flange 0 Temp.,After After Cooler C Cp/Cv Ratio Compr. Factor (Z2 ) or (Z avg ) Operating Characteristics Capacity (wet) SM3 /Hr Mfr's Rated Cap. (Design) (No ve tol.) 3 Actual Inlet Flow (wet) AM /Hr Specific Gravity V Belt / Coupling Losses KW Volumetric Efficiency % Valve Lift Suction / mm / mm Valve Lift Area Suction/ Discharge mm2 / mm2 Valve Velocity m/sec Speed RPM Compressor Shaft Power KW Power consumed @ RV Set Pr. KW Driver Power KW Average Molecular Weight (wet/dry) Net Calorific Value
Stag e2
Stag e3
Stag e4
Stag e5
i
<150 < 52
<150 < 52
<150 < 52
<150 < 52
<150 < 52
KCal/SCM
REV 0
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OPERATING CONDITIONS: SUCTION PRESSURE: i kg/cm2 GUARANTEED CASE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 OPERATING CONDITIONS (EACH MACHINE) / PERFORMANCE Operating Case: SUCTION PRESSURE: kg/cm Stage 1 Units Gas Handled (See Analysis) Corrosion Due to Suction Conditions Pressure (@ Vendor's B/L) kg/cm 0 Temp. (+@ Vendor's B/L) C Discharge Conditions (Vendor's Battery Limit : Pressure (@ Vendor's B/L Pressure @ Cylinder Flg. Temp., Adiabatic @Cyl. Flange Temp.,Actual @Cyl.Flange < 52 Temp.,After After Cooler Cp/Cv Ratio Compr. Factor (Z2 ) or (Z avg ) Operating Characteristics Capacity (wet) SM3 /Hr Mfr's Rated Cap. (Design) (No ve tol.) Actual Inlet Flow (wet) AM3 /Hr Specific Gravity V Belt / Coupling Losses KW Volumetric Efficiency % Valve Lift Suction / mm / mm Valve Lift Area Suction/ Discharge mm2 / mm2 Valve Velocity m/sec Speed RPM Compressor Shaft Power KW Power consumed @ RV Set Pr. KW Driver Power KW Average Molecular Weight (wet/dry) Net Calorific Value
Stag e2
Stag e3
Stag e4
Stag e5
i
<150 < 52
<150 < 52
<150 < 52
<150 < 52
<150 < 52
KCal/SCM
REV 0
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B) Sl.No.
EXPERIENCE RECORD PROGRAMME OF ELECTRIC MOTOR DRIVEN COMPRESSOR Description INFORMATION OF OFFERED COMPRESSOR INFORMATION OF EXISTING COMPRESSOR
REQUIREMENT AS PER TENDER 1 a) Status of Bidder (Indicate packager or agent of packager) b) In case Bidder is the agent submit the agreement of agent ship/dealership with packager. COMPRESSOR Name of compressor manufacturer Place of compressor manufacturer Compressor model Anticipated Life in running hours Compressor maximum frame BKW Compressor operating RPM Compressor max design RPM Comp Manufacturing code preferably API 11P 2nd edition, API-618 Lubricated or non lubricated Nos of stages Max stage temperature deg cen ( 150 ded cen) Compressor Operating RPM ( max RPM-1500 ) Piston speed ( 4.5 m/s lub, 4m/s non lub) Vibrations at comp cylinders < 10 mm /sec. Unfiltered peak velocity. Vibration comp frame: Unfiltered peak velocity of 7.5 mm/s or 250 micron unfiltered peak to peak vibration whichever is less. Material for all stages Cylinder Piston Rings Rider Rings Piston Rod Valve (Rings / Plates/ spring) PERFORMANCE OF COMPRESSOR
CASE- Performance of compressor at 0.84 L kg/cm2 suction pr, 255 kg/cm2 discharge pr and 30 deg c suction temperature CASE- GUARANTEED POINT: G Performance of compressor at i kg/cm2 suction pr, 255 kg/cm2 discharge pr and 30 deg c suction temp a) Capacity Sm3/h CASE-L SPECIFICATION NO. MEC/TS/05/25/HPCL/S031 REV 0
Page 49
CASE-G b) BKW required by CASE-L compressor including compressor's lube oil pump CASE-G BKW c) BKW required by CASE-L compressor including compressor's lube oil pump CASE-G BKW at RV set pr d) KW rating of main compressor motor ,4 starts per hr , with 10% over rating w.r.t max of b+ transmission losses above.
e1) Gas cooler ( heat exchanger ) fans; nos required ( W+S) e2 )Power required for all fans in Kw
CASE-L CASE-G
II) Ventilation fans for enclosure No of fans Type of fans ( induced or forced draft ) Power required for all fans in Kw Piston rod and cross head pin loading at any specified operating condition including the relief valve set condition shall not exceed 80% of the maximum design rod load of the offered compressor. ----Piston rod : max Design ----Piston rod : calculated at safety set pr condition ----Max cross head pin loading: Design ----Cross head pin loading :calculated at safety set pr condition Electric motor Main compressor drive motor Make and model Name plate rating in Kw RPM of motor Site rating after deration kw Ventilation fan motor Make and model Nos provided ( W+s) Name plate rating in Kw RPM of motor Site rating after deration kw Cooler fan motors Make and model Nos provided ( W+s)
4 A
b)
c)
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d)
e)
Name plate rating in Kw RPM of motor Site rating after deration kw Coolant pump motor Make and model Nos provided ( W+s) Name plate rating in Kw RPM of motor Site rating after deration kw Any other motor Make and model Nos provided ( W+s) Name plate rating in Kw RPM of motor Site rating after deration kw PACKAGE Name and Address of packager Place of packaging (address) Name of enclosure manufacturer Place of enclosure manufacturing Sound level at 1 m distance from package in db(A) 65 Make & model LEL detector - 2nos Make & model fire detector -2nos Co2 flooding system ( 2 cylinder each of 100% capacity required) Quantity of CO2 in each cylinder in Kg Volume of enclosure in m3 Nos of explosion proof tube light in enclosure Coupling Direct/V-belt Separators between inter stage of compressor. Gas inlet train 6 WNRF, 150 # Flanged connection; outside canopy Inlet relief valve Inlet gas pressure gauge Non return valve Inlet filter of 5 micron size Temporary suction filter after main filter Inlet manual isolation valve Inlet automatic isolation valve Gas recovery system Gas recovery system with pr relief valve, pr regulator, pr gauge, manual & automatic drainage system Gas delivery system High pr piping with SS 316 tubing, compression fittings , NRV. Coalescent final separator Coalescent filter Discharge isolation valve
REV 0
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9 10
11
PLC based Priority panel with SS 316 compression fillings , tubings , full bore valve ball. Indicate nos of banks Mass flow meter: Coriolis principle; interfaced with PLC; head mounted display to indicate flow rate (Kg/hr) at compressor discharge, cumulative gas compressed (in Kgs) etc.; inbuilt totaliser non-volatile & non-resetable type ; suitable for hazardous area classification ; by pass arrangement Volume gas flow meter: with electronic volume correction ,interfaced with PLC; head mounted display to indicate flow rate ( Sm3/h and kg/h ) at compressor suction, cumulative gas compressed etc.; inbuilt totaliser non-volatile & nonresetable type ; suitable for hazardous area classification ; by pass arrangement Final gas outlet connection from priority panel 3/4 OD SS compression fittings. ESD system Volume bottles/ dampers at each compressor stage of compressor. Drainage system: Manual double isolation valve Automatic valves Heat exchanger Code of construction preferably API 661 Tube material
12
13 14 15
Piping between stages shall be continuos with flange and welded connection Other tubing shall be SS as defined in TS Gas recovery vessel provided Area classification ; Class 1, Group D, Division 1 as per NEC OR Zone 1, Group IIA /IIB as per IS/ IEC Instruments . Electric Motor The size of the complete package Chain pulley block and beam for chain pulley block Acoustic and pulsation study Acoustic enclosure for electric motor and compressor. Confirm that instrumentation will be supplied as per tender. Man-machine interfacing unit (MMI), PC color printer in control room
16 17 18 19 20 21
REV 0
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22 23 24
String test at shop Field trial run for 20 hours Electric power consumed by compressor package including power absorbed by lube oil pump motor , inter cooler fan motors , cooling water pump motors along with transmission losses but excluding power absorbed by air compressor motor, exhaust fan motor, control panel & enclosure lighting at guaranteed flow and at specified conditions Confirm no deviation w.r.t. tender. Max turn over of the Bidder / manufacturer or packager during any of the last three financial years. Other information of compressor package : a) Year and month of packaging the compressor package b) Name and address of user with FAX no ,Phone no , E-mail address c) Nos of hours the compressor have clocked on bid due date. ( Enclose certificate from user) d) Documentary evidence that the Bidder / manufacturer or packager having the capability and facilities (i.e. shop, manpower, testing facility etc.) for manufacturing / packaging five packages in a year. e) Whether the Bidder having office set up in Bangladesh equipped with trained and experienced technical manpower for the operation and maintenance services.
25 26
27
REV 0
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DATA SHEET- INSTRUMENTATION & CONTROLS FOR COMPRESSOR

ANNUNCIATION ALARM HIGL LOCAL PANEL DISPLAY (PLC) LOW LOCAL PANEL DISPLAY & PRE TRIP & ANNUN. LOW LOW LOCAL PANEL PLC-DISPLAY A/V HIGH HIGH LOCAL PANEL PLCDISPLAY ALARM FOR yes, wsitch yes yes REPEAT PLC/MMI CONTACT
INDICATION GUAGE PANEL INDICATOR LOCAL (PLC) DISPLAY
INDICATION AT MMI
DESCRIPTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Frame Oil Sump/Reservoir Level Main L/O Pump Disch. Pr (supply header). Oil Flow Oil Pressure at Main Bearing Supply Header Temp. Oil cooler Oil Inlet Temp. Stand by Pump Start Compressor Main bearing metal Temp. Cylinder & Packing Oil Lubricator Oil Level Lubricator Oil Flow Lubricator Failure Aux. Oil Lub. Oil Supply Pr. to Electric Motor Driver Lub. Oil return from Electric Motor Driver Elec. Motor bearing metal temp. Coolant System Each cylinder CW outlet temp. Inter/After/Oil Cooler CW outlet temp. CW Supply header flow Sight Flow CW return cylinder, Cooler & Header For Closed Circuit Cooling each
yes yes yes yes yes
GUAGE BOARD
LOCAL
S. NO
INDICATION AT/ MMI
yes, wsitch yes
yes yes
Coolant main pump disch. Pr. Coolant standby pump disch. Pr. Coolant stand by pump start Coolant supply header Pr. Coolant supply header temp Coolant cooler Outlet Temp. Coolant reservoir Level Cylinder Coolant Outlet temp. For Static/Thermo-siphon System yes yes
yes
yes
yes
yes yes
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INDICATION GUAGE PANEL
ANNUNCIATION ALARM HIGL LOCAL PANEL DISPLAY (PLC) LOW LOCAL PANEL DISPLAY
&
PRE
TRIP & ANNUN. LOW LOW LOCAL PANEL PLC-DISPLAY
A/V HIGH HIGH LOCAL PANEL PLCDISPLAY
ALARM FOR yes yes yes yes yes yes REPEAT PLC/MMI CONTACT
INDICATOR LOCAL (PLC) DISPLAY
INDICATION AT MMI
DESCRIPTION
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
Cylinder Coolant Outlet temp. Diff. Pr. Across packing coolant filter Process Gas System Each stage inlet Pressure Each stage inlet temp. Each stage Outlet Pressure Each stage Outlet temp. After Cooler Gas Outlet temp. Ist stage pressure low / high Cylinder Packing Vent Pressure Suction Pressure, low Blow Down vessel level Piston Rod Drop Indicator Distance piece diff. Purge pressure Common process parameters Common machine parameters Blow Down vessel Pressure Vibration Measurement yes yes yes yes yes switch yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes
such as Amperes, voltage, flow rate, total quantity of gas compressed, inlet outlet pressure, inlet outlet temperature, Kilo Watt Hour (KWH), electric power.
GUAGE BOARD
LOCAL
S. NO
INDICATION AT/ MMI
REV 0
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DEVIATIONS TO THE SPECIFICATION

S No. Clause no. Tender Deviation taken Specification Reasons for deviations / remarks
Certified that, only the above-mentioned deviations have been taken against this tender. Name of the Bidder
Signature
Seal of the Company.
REV 0
Page 56

Technical Specifications - Comp

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Technical Specifications - Comp

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TECHNICAL SPECIFICATION FOR ELECTRIC MOTOR DRIVEN RECIPROCATING COMPRESSORS FOR CNG MOTHER STATION (MEC/TS/05/62/S031)

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

SPECIFICATION NO. MEC/TS/05/25/HPCL/S031

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

SPECIFICATION NO. MEC/TS/05/25/HPCL/S031

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

SPECIFICATION NO. MEC/TS/05/25/HPCL/S031

1.7 1.7.1 1.7.2

1.7.3 1.7.4 1.7.5

1.7.6 1.7.7 1.7.8 1.7.9

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

SPECIFICATION NO. MEC/TS/05/25/HPCL/S031

2.0 2.1 2.1.1 2.1.2

2.1.3 2.1.4 2.1.5

2.1.6 2.2 2.2.1

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

4.1 4.1.1 i. ii. iii. iv. 4.1.2

4.2 4.2.1 4.2.2 4.2.3

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

SPECIFICATION NO. MEC/TS/05/25/HPCL/S031

4.4.3 4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.5.5

4.6 4.6.1 4.6.2 4.7 4.7.1

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

SPECIFICATION NO. MEC/TS/05/25/HPCL/S031

4.7.2 4.7.3 4.7.4 4.7.5 4.7.6

4.9 4.9.1 4.9.2 4.9.3 -

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

SPECIFICATION NO. MEC/TS/05/25/HPCL/S031

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

SPECIFICATION NO. MEC/TS/05/25/HPCL/S031

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

6.5 6.6 6.7 6.8 6.9

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

SPECIFICATION NO. MEC/TS/05/25/HPCL/S031

7.0 7.1 7.2 7.3 7.4 7.5 7.6 8.0 8.1

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

SPECIFICATION NO. MEC/TS/05/25/HPCL/S031

Oil cooler inlet and outlet temp

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

SPECIFICATION NO. MEC/TS/05/25/HPCL/S031

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

SPECIFICATION NO. MEC/TS/05/25/HPCL/S031

10.3 11.0 11.1 11.2 12.0

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

SPECIFICATION NO. MEC/TS/05/25/HPCL/S031

CONSULTANT MECON Limited

TS CNG COMPRESSOR FOR HPCL BANGLADESH

SPECIFICATION NO. MEC/TS/05/25/HPCL/S031

CONSULTANT MECON Limited