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E-Tender no.

8000005410

TECHNICAL BID DOCUMENT


FOR

MRS & DRS

SCOPE of SUPPLY, WORK & TECHNICAL SPECIFICATION

for
Annual Rate Contract
for
Above-Ground Skid mounted (inside cabinet), Twin Stream District
Regulating Station (DRS) & Metering Station (MRS) with Filtration
and Pressure Regulation for Natural Gas Application


CONTENTS
1.0

GENERAL

2.0

SCOPE OF SUPPLY, WORK & BIDDERS RESPONSIBILITY


2.1
2.2
2.3

3.0

Scope of work
Scope of supply
Scope of Work & Supply

DESIGN PHILOSOPHY
3.1
3.2
3.3
3.4
3.5

General
Codes & Standards
Instrument Design Criteria
Junction Boxes & Cabling Philosophy
Instrument Painting Requirements

4.0

PROCESS DESCRIPTION

5.0

JOB SPECIFICATION

6.0

TESTING AND INSPECTION

7.0

DOCUMENTATION

8.0

MISCELLANEOUS

9.0

SHIPPING & PACKAGING

10.0

PERFORMANCE GAURANTEE

11.0

INSTALLATION & COMMISSIONING

12.0

BIDS

13.0

MANDATORY SPARES
ANNEXURES

Annexure -1
Annexure -2
Annexure -3
Annexure -4
Annexure -5
Annexure -6
Annexure -7
Annexure -8

Annexure -9
Annexure -10
Annexure -11
Annexure -12
Annexure -13
Annexure -14

Special Instruction to bidder


Bidder Scope of Supply & Installation
Schematic line diagram/ Typical P & ID
Approved Vendor List
Quality Assurance Plan
Data Sheet of Skid Components/ Equipment
Technical Questionnaire
Standard Specifications of Equipment & Technical
Requirements
FAT Procedure/ FAT Manual
PMS
CHECK LIST (TECHNICAL)
Checklist for evaluation of BEC-Technical
Standard Register List in Flow computers for SCADA
Bidders Data Requirement

JOB SPECIFICATION, SCOPE OF SUPPLY, WORK & TECHNICAL SPECIFICATION


1.0

GENERAL:
i)

This bid document is for Annual Rate contract for supply of DRS & MRS and covers requirement and
specification of Above ground Skid mounted, twin stream District Regulating Station (DRS) and Turbine
flow Meter / RPD flow Meter Based Metering Station (MRS), mounted inside Cabinet.

ii)

The specification provided in bid document, together with all Annexure enclosed covers the requirement for the
design, engineering, manufacturing, testing, inspection & supply of MRS/ DRS along with all accessories for
various site/ location as per the schematic line diagram/ typical P & ID, Technical specifications, datasheets
provided in the bid document.

iii)

This is a NO Deviation tender. Any deviation to tender condition/ job specification/ technical requirement of bid
document, shall lead to rejection of bidders offer/bid. Compliance with Technical Specification will be taken for
granted, if during bid submission, deviations are not specifically mentioned in format provided in tender.

iv)

For DRS (SOR Items- 1 & 2), the scope of work/ supply includes Design, Engineering, Manufacturing, Inspection,
Testing and Supervision for Installation & commissioning of DRS consisting of twin streams of Filtration and
Pressure Reduction system along with all the accessories and valves, piping, instruments & fittings as per
schematic line diagram and P & IDs.

v)

For MRS (SOR Items- 3 to 8), the scope of work/ supply includes Design, Engineering, Manufacturing, Inspection,
Testing and Supervision for Installation & commissioning of Metering Skid consisting of twin streams of
Filtration, Pressure Reduction system, flow measurement (through Turbine flow Meter / RPD Meter) including
Field mounted Flow Computer with Data Logger (for SOR Items- 4, 5, 7 and 8) / inbuilt field mounted EVC (for
SOR Items- 3 and 6), Solar panel, Battery along with all the accessories and valves, piping, instruments & fittings
as per P & IDs and schematic line diagram.

vi)

The Design, Required capacity, Pressure Rating of the Skids shall be as per schematic line diagram/ typical P &
IDs provided with this document.

1.1

Description and requirements contained in the tender specification are concise by necessity and cannot include all the details.
However, it is the responsibility of the bidder to execute the job on turnkey basis in accordance with the specifications and
internationally recognized good engineering practices.

1.2

Any activity which are not specifically listed/ mentioned in the bid document, does not absolve the bidder of their
responsibility to include such activities in their scope of work and supply, which otherwise is necessary, to meet technical
requirement of bid document and to complete instrumentation & mechanical work for the project.
All such activities which are not specifically in the tender document shall also be carried out by the bidder to meet the tender
requirement/ job requirement without any cost & time implication to GAIL.

1.3

In the event of any conflict between these specifications, related standards and codes, any other attachment to this package,
the bidder shall follow the following documents in the order of their priority:
a)
b)
c)
d)

Job Specifications for Gas metering package


Data Sheets and Typical P&ID
Technical Specification attached in the tender document.
Standard specifications

In case of any conflict in various documents, same shall be referred to GAIL for clarification. Bidder shall not proceed
without getting written approval in such a case.
2.0

SCOPE OF WORK & BIDDERS RESPONSIBILITY

2.1

Scope of Work
Salient features of DRS and MRS skids envisaged under rate contract are as under.
(a) SOR Items-1 & 2: District Regulating Station (DRS), 300# pressure class rating (entire skid inlet & outlet), which shall be
twin-stream skid mounted (inside cabinet).


(b) SOR Items-3 to 5: MRS will comprise of Metering, Filtration and Pressure reduction section. It shall be Skid mounted
(inside cabinet) having pressure class rating of 300# (skid inlet) / 150# (skid outlet). Flow meters for these SOR items shall
be as per P&ID/ schematic line diagram.
(c) SOR Items-6 to 8: MRS shall be designed for pressure class rating of 150# and shall comprise of Metering, Filtration and
Pressure reduction section, which shall be Skid mounted (inside cabinet). Flow meters for these SOR items shall be as per
P&ID/ schematic line diagram.
(d) Electronic Volume Corrector (EVC) installed on RPD Meter is acceptable for SOR Item-3 & 6 only. For rest of the MRS
skids, field mounted Flow computer is envisaged.
(e) Turbine flow meter is envisaged for SOR Items-5 & 8. For rest of MRS skids (SOR Items- 3, 4, 6 & 7), RPD flow meter is
envisaged.
2.1.1

The scope of supply and works shall include, all the activities of project management, design, engineering, training, factory
testing, supply, installation, commissioning, site testing, test run, quality assurance and quality control of the system, and
documentation with the turnkey responsibility and meet the requirements, its objectives, functional and specific requirements
described in the specifications and taking care of complete requirements.
Bidder shall be responsible for execution of the package on turnkey basis with scope of work, scope of supply, P&ID and job
Specifications attached in tender but not limited to the following:
i)
ii)
iii)
iv)

2.1.2

Design and Engineering


Procurement and Supply of bought out items,
Inspection, Factory testing and Acceptance
Supervision for Installation, field calibration, testing and commissioning

Performing all works required for designing, engineering, testing, supply, installation, interfacing with the communication
channels, commissioning (with supply of commissioning spares including consumables), site testing, test run and putting into
operation of the system complete in all respects.
Bidders Scope of supply & work includes design, engineering, technical requirement for design, engineering, procurement
of items/ skid components, manufacturing, construction features, assembly, testing & inspection, commissioning of skids
(DRS/ MRS) being procured under rate contract.

2.1.3

The scope of supply and works shall include all the activities required for design, engineering, procurement of bought out
items, manufacturing, assembly, factory testing, supply, installation, commissioning, site testing, test run, training, quality
assurance, quality control of the system and documentation with overall responsibility to meet the tender requirements, its
objectives, functional and specific requirements described in the tender specifications, technical requirements and
satisfactory performance.

2.1.4

Scope of supply and works also includes packing, forwarding (suitable for storage/ preservation at site), loading, unloading,
transportation and transit insurance for delivery of skids at GAILs site/stores. Storage and preservation of skids at site is in
the scope of GAIL. However Skids shall be supplied in such a way that the skids are suitable for outdoor installation, proper
storage & preservation.

2.1.5

The DRS and MRS shall be manufactured as per all the requirements of PNGRB Technical Standard T4SE, as per the
technical specification, other relevant standards and statutory requirements. All other relevant standards and requirements
shall also govern design and engineering of DRS and MRS. Bidder shall seek clarification (if any) in this regard before bid
submission. After submission of bid and post award, NO deviation to tender condition shall be entertained. Unless otherwise
specified, the latest edition of the standards mentioned herein this specification, including all addenda and revisions, shall
apply.

2.1.6

The design, manufacturing & fabrication of DRS & MRS skids shall be such that each of its equipment / component is easily
accessible, operable and maintainable and the same shall not obstruct the operation and maintenance of any other skid
component/ equipment or part thereof. Unless otherwise specified, the pressure indicated in this tender document is gauge
pressure.

2.1.7

Bidders scope of works includes supervision for installation and commissioning of entire skid package, as per the scope of
Supply and Works.

2.1.8

Bidder shall Furnish as built documentation, drawings, reports, certificates and other information required here-in including
operation and maintenance manuals of all the equipment/ skid components.

2.1.9

Type, Make and model number of all components of DRS / MRS shall be mentioned clearly in the bidders offer. Bidder
shall also submit sizing calculation, Cv/ Cg value of offered regulator & slam shut valve, pressure drop calculation across


filter, performance curve and specific technical catalogue (in English language only) of the models offered in their technical
bid.
2.1.10

DRS and MRS shall be designed for following design conditions and Process parameters:
Self-actuated Regulators (PCV) and SSV of DRS & MRS shall be pilot operated. Direct acting pressure regulators / SSV is
NOT Acceptable.

(a)

DRS (SOR- 1 & 2) Design Condition :


DRS shall be designed for pressure of 49 Kg/cm2g. Differential pressure (across DRS) shall be 3 Kg/cm2g or lower.
Monitor regulator with Integral Slam Shut valve is acceptable. However, bidder can also offer independent Regulator and
Slam Shut valve.
Inlet and outlet (delivery) pressure is being provided separately for each individual SOR items.

(b)

MRS envisaged for SOR- 3 to 5 shall be designed for:


Design pressure of Inlet of MRS (up to PRS): 49 Kg/cm2g
Design pressure of outlet of MRS (PRS downstream): 19 Kg/cm2g
Maximum differential Pressure across entire MRS skid shall be 2 Kg/cm2g
Regulators (PCV) and SSV shall be pilot operated.
Monitor regulator with Integral Slam Shut valve is also acceptable.
Spring range of offered PCV/ Regulator shall be : 1 to 5 Kg/cm2g (Spring range shall be used for selection / supply of Pilot
for PCV and shall be supplied with skid)
Spring range of SSV/ CRV shall be 1.5 to 6 Kg/cm2g.
Inlet and outlet (delivery) pressure provided elsewhere shall be used for sizing of piping of individual skid(s)/skid component
For sizing of Regulators and SSV, skid delivery pressure (provided elsewhere in tender) shall be used.

(c)

MRS envisaged for SOR-6 to 8 shall be designed for:


Design pressure of MRS (Inlet & Outlet): 19 Kg/cm2g
Maximum differential Pressure across entire MRS skid shall be 2 Kg/cm2g
Set point/spring range of offered PCV/ Regulator : 1 to 5 Kg/cm2g
SSV/ CRV shall be sized, designed, considering set point/ spring range of 2-6 Kg/cm2g.
Monitor regulator with Integral Slam Shut valve is also acceptable for SOR-6 to 8.
Inlet and outlet (delivery) pressure shall be used for sizing of skid/ its component and is provided separately for individual
SOR items (For sizing of Regulators and SSV, skid delivery pressure shall be used).

(d) DRS & MRS shall be designed considering following process parameters i.e. Flow rate, Inlet & outlet (delivery)
Pressure. Minimum size & rating of skid / components selected & offered shall be as indicated below. Offered size shall
be same or higher that the sizes indicated below.
For SOR Item-1 :

(i)

Flow Rate
: 200-2200 SCMH
Inlet Pressure (range)
: 16 - 49 Kg/cm2g
Outlet Pressure range
: 4 - 8 Kg/cm2g (shall be set at 5.5 Bar pressure)
Minimum size of main line inlet valves/ pipe (upto PRS inlet) : 2, 300#
Minimum size of main line valves/ pipe (downstream of PRS) : 4, 300#
Minimum size of SSV / Regulator : 1

(ii)

For SOR Item-2 :

Flow Rate
: 500-5000 SCMH
Inlet Pressure (range)
: 16 - 49 Kg/cm2g
Outlet Pressure range
: 4 - 8 Kg/cm2g (shall be set at 5.5 Bar pressure)
Minimum size of main line inlet valves/ pipe (upto PRS inlet) : 3 300#
Minimum size of main line valves/ pipe (downstream of PRS) : 6 300#
Minimum size of SSV/ Regulator : 2


For SOR Item-3 :

(iii)

Rated Flow Rate


: 500-5000 SCMD
Inlet Pressure (range)
: 5 - 45 Kg/cm2g
Outlet Pressure range
: 2 - 5 Kg/cm2g (shall be set at 3 Kg/cm2g pressure)
Minimum size of main line inlet valves/ pipe (PRS inlet)
: 1 300#
Minimum size of main line valves/ pipe (downstream of PRS) : 2 150#
Required G-Rating and size of RPD flow meter
: G 65, 2, 150#
For SOR Item-4 :

(iv)

Rated Flow Rate


: 1,500-12,000 SCMD
Inlet Pressure (range)
: 5-45 Kg/cm2g
Outlet Pressure range
: 2 - 5 Kg/cm2g (shall be set at 3 Kg/cm2g pressure)
Minimum size of main line inlet valves/ pipe (PRS inlet)
: 1.5 300#
Minimum size of main line valves/ pipe (downstream of PRS) : 3 150#
Required G-Rating and size of RPD flow meter
: G 160, 3150#
For SOR Item-5 :

(v)

Rated Flow Rate


: 2,500-22,000 SCMD
Inlet Pressure (range)
: 6 to 45 Kg/cm2g
Outlet Pressure range
: 2 to 5 Kg/cm2g (shall be set at 3 Kg/cm2g pressure)
Minimum size of main line inlet valves/ pipe (PRS inlet)
: 2 300#
Minimum size of main line valves/ pipe (downstream of PRS) : 4 150#
Required G-Rating and size of Turbine flow meter
: G 250/ 400, 4 150#
For SOR Item-6 :

(vi)

Rated Flow Rate


: 400-3600 SCMD
Inlet Pressure (range)
: 4 to 8 Kg/cm2g
Outlet Pressure (range)
: 1.5 to 4 Kg/cm2g (shall be set at 2.5 Kg/cm2g pressure)
Minimum size of main line inlet valves/ pipe (upto PRS inlet) : 1150#
Minimum size of main line valves/ pipe (downstream of PRS) : 2150#
Required G-Rating and size of RPD flow meter
: G 65, 2, 150#
(vii)

For SOR Item -7 :

Rated Flow Rate


: 1,600-16,000 SCMD
Inlet Pressure (range)
: 4 to 8 Kg/cm2g
Outlet Pressure (range)
: 2.5 to 4 Kg/cm2g (shall be set at 3 Kg/cm2g pressure)
Minimum size of main line inlet valves/pipe (upto PRS inlet) : 2150#
Minimum size of main line valves/ pipe (downstream of PRS) : 3150#
Required G-Rating and size of RPD flow meter
: G 160, 3 150#
(viii)

For SOR Item-8 :

Rated Flow Rate


: 2,000-19,000 SCMD
Inlet Pressure (range)
: 5 to 8 Kg/cm2g
Outlet Pressure (range)
: 2 to 4 Kg/cm2g (PCV shall be set at 3 Kg/cm2g pressure)
Minimum size of main line inlet valves/ pipe (upto PRS inlet) : 2150#
Minimum size of main line valves/ pipe (downstream of PRS) : 4150#
Required G-Rating and size of Turbine flow meter
: G 250/ 400, 4 150#
2.1.11

2.1.12

GAIL reserves the right to accept / reject the offer of bidder based on the past performance of their product(s) supplied in
GAIL, or elsewhere. Bidder to compulsorily submit report on satisfactory performance of completed/ executed orders by
bidder indicating satisfactory working for minimum 6 months period.
Design & Engineering :
The bid package consists of typical Piping & Instrumentation Diagrams, process data sheets and technical
specification of individual skid items/components. The bidder shall be responsible to carry out the design and
detailed engineering based on the data provided in the bid package and in line with other technical requirements
specified elsewhere in bid document. Scope shall also include sizing and verification for all items including where
data is dependent upon detailed engineering. Scope of supply/ work also includes detailing of basic engineering
designs, preparation of data sheets, drawings for instruments and system oriented items, engineering drawings etc.

(a)


Residual Engineering

(b)

The bidder shall also be responsible for carrying out any residual basic engineering necessary for detailed
engineering like equipment/ instrument sizing, utility consumption, specifying derived data in process data sheets,
type and material selection of instruments/ equipment wherever required.
Engineering Drawings & Documents

(c)

d)

i)

Vendor Data Requirements indicate the list of drawings and documents required to be supplied by the
bidder, as minimum. Bidder to note that the list specifies only the major deliverables. Documents and
drawings not listed but necessary for proper engineering, construction, operation and maintenance shall
also be prepared by the bidder.

ii)

Bidder shall be responsible for preparation of all engineering drawings and documents including those
necessary for construction like instrument index, tray layouts, location plans, cable schedules, installation
standards, bill of material etc.

iii)

Bidder shall also be responsible for providing all drawings and documents for package/ sub package
units.

iv)

It is expected that the bidder utilizes uniform data sheet formats enclosed along with this bid document,
for preparing specifications for various instruments, equipment and skid component including those,
which are being prepared by package/ sub package vendors. Items for which no format has been attached
with the document, bidder may use standard ISA formats. Use of manufacturer standard formats shall be
avoided.

v)

The bidder shall supply all the documents in both hard copy and soft copy. This includes all the
documentation including those for package units.

The scope for design and engineering shall also include review of post-order vendor drawings and documents for
all equipment/ instruments and system oriented items. Following methodology must be followed for drawings and
documents being forwarded to GAIL.

e)

i)

The Bidder shall thoroughly review and approve their vendor drawings for all equipment/instruments
including sub-package items, before forwarding to GAIL. Only approved drawings duly signed and
stamped by a competent and authorised representative/ engineer of Bidder shall be forwarded.

ii)

The Bidder shall be responsible for all System Engineering documents for the Gas metering systems.
This shall include all related documents such Functional design specifications, sizing calculations,
pressure drop calculation etc. and Engineering documents such as functional loop schematics,
instrument details and cable schedule, Power supply distribution schemes etc. These documents shall be
reviewed and approved by Bidder based on philosophy specified/ agreed for the engineering before
forwarding to GAIL.

iii)

All multidisciplinary fabrication and construction drawings shall be reviewed and signed by bidders
representatives before forwarding to GAIL for review/ approval/record.

Bidder shall be fully responsible for co-coordinating with all agencies concerned to ensure proper, uniform and
smooth engineering. This shall include coordination with:

f)

i)

All individual item suppliers for uniformity in engineering and documentation supplied by them
including P&IDs, instrument specifications, installation standards etc. and obtaining all requisite
drawing and documents for review, record and final documentation.

ii)

All instrument item suppliers including suppliers/ manufacturers of various system oriented items.

iii)

Bidders own inter-departmental coordination with departments like mechanical, piping, electrical, QC,
pressure vessel, heater group etc. This shall include furnishing all necessary engineering data in the form
of drawings & documents and review of drawings & data supplied by other departments.

Bidder shall be responsible for preparation of all As-Built drawing / documents including.
i)
ii)
iii)
iv)

All P&IDs, GADs, Foundation drawing


All Datasheets, sizing calculation, specifications of instruments
All Purchase documents.
All System documents including hardware and software documentation.


2.1.13

Procurement & Supply of bought out items, Factory testing and Acceptance
a)

2.1.14

Engineering for procurement & supply of bought out items, shall include preparation of various material
requisitions which shall include process data sheets, typical data sheets for equipment/ instruments, instrument
standard specifications, special requirements etc., evaluation of offers received from various manufacturers/ subvendors, preparation of Technical Bid Analysis, preparation of purchase requisition and review/ approval of subvendor drawings, incorporation of GAILs comments. Installation of all the loose supplied items, its
interconnection etc shall be in the scope of supplier. In case of any dispute / conflict arising due to difference in
opinion/ interpretation, the interpretation of GAIL shall be considered final.

b)

All Equipment/ Instrument items/ skid components shall be procured from vendor list attached elsewhere in this
package. Bidder must desist from procuring any items from vendor(s) not approved by GAIL. Along with the bid,
the bidder has to provide the list of items/ equipment with size, Make and Model Number selected only form the
approved vendor list provided in the bid document. Non-compliance to this may result into rejection of bid.

c)

Bidder shall prepare Bill of Material, purchase requisitions for all equipment/ instruments/ systems which shall
consist of a consolidated purchase document including all purchase specifications including data sheets, sizing
calculation, dimension details, special instructions/ requirements (if any), standard specifications/ purchase
specifications, testing requirements, quality requirements etc. All purchase requisitions shall be furnished to GAIL
for information/ review/ approval as applicable.

d)

Testing & calibration of all instruments, Factory Acceptance Test (FAT) and Site acceptance Test (SAT) shall be
carried out by the bidder. Range/ calibration span, set points, reports etc shall be modified as per GAIL requirement
by the bidder during FAT and SAT. GAIL shall witness testing of any or all items at various stages during
manufacture and/or at final stage before shipment at their discretion. Testing shall be carried out as per approved
procedures. No instrument shall leave manufacturers works without factory acceptance test. All necessary changes
shall be incorporated/ implemented as suggested by GAIL during FAT/ SAT etc. As build drawing, final technical
documentation shall be submitted by the bidder. It shall contain all such changes.

e)

The skid has to be transported to site in different modules. Individual modules shall be so designed that there are
no/ minimum cabling interconnections between various modules and such interconnections (if any) shall be in the
bidders scope.

f)

The quoted man-day rate for installation supervision and commissioning of skid (as per schedule of rate) shall be
valid for 24 months from date of issuance of FOI. Bidder shall depute qualified and competent person for
installation supervision / commissioning.

g)

Testing & Calibration:


Bidders scope of work includes testing of all supplied items and systems including impulse lines, pneumatic
signal tubes and instrument cables and special instruments/ items if any. Bidder shall also carryout testing and
calibration of all instruments as per the requirements specified elsewhere in tender document. Testing and
calibration of Gas metering system shall be as described elsewhere in the document.

h)

Commissioning:
It is the responsibility of Bidder to co-ordinate and make available the services of vendors/ sub-vendors for gas
metering system package, control system, etc. and other special instruments/ equipment like Gas flow meters, Flow
computers, Pressure regulators, testing, FAT, Site acceptance, start-up/ commissioning of the station. The bidder
shall provide assistance during commissioning without any condition/ pre-requisite. It is the responsibility of the
vendor to get the certification from site Engineer.

Installation, Field Calibration, Testing and Commissioning


a)

Bidder shall carryout installation of all instruments in the skid as described in this document. Installation shall
include but not limited to installation of all supplied items, installation skid assemblies explained in this package,
installation of junction boxes, interconnection between instruments and junction boxes, fabrication, laying and
painting of cable trays, laying of all single pair and multi pair cables in the skid, JB earthing/ grounding, Field
Instruments/ signal earthing/ Grounding, tagging, ferruling, cable glanding and pair/ core identification of all field
cables.

b)

Distribution of power to various instruments in the skid from single point in the skid. Separate JB is required for
different type of signals and also for power to field instruments (Power supply to Meter, transmitters and other
Field Instruments shall be provided through separate JBs).

c)

Installation shall be carried out as per GAIL standards or as recommended in the tender. For special instruments,
the installation may be carried out as per vendor/ manufacturers recommendations however all such installation
standards shall be subject to GAIL review.


d)

Bidders scope of supply/ work shall include earthing cable/ strips (as applicable) etc. (along with cable tray with
supports for installation) in the skid/ JB/ control room, as per the requirements of various instruments.

e)

Junction boxes and cable glands (as per the requirement of area classification) for different types of signals such as
intrinsically safe, alarm, power etc. should be supplied and mounted/ installed in skid. Preferably, all JBs shall be
mounted in skid at height of 1.3 meter from ground/ finished floor level/ skid base frame and accessible /
approachable from outside. JBs shall not to be installed inside Skid.

f)

Painting of pipes, equipment, instruments, enclosures, platforms, jump-overs/ crossovers, as required; in line with
the painting specifications attached elsewhere in this document.

g)

Suitable environmental enclosure for custody transfer field instruments for environmental effect protection with a
provision of locking. Any other erection material required for installation and commissioning of skid/ instruments.

h)

Any special tools/ tackles required shall be in scope of vendor.

i)

Galvanised iron/ copper earthing strip and earthing cables for earthing of all instrumentation items including
junction boxes etc. to instrument earthing system. Supply of earthing strip / cable is in bidders scope. Earthing pit
at a distance of 20 meters shall be considered for supply of cable/ other items.
Making of earth pit and laying of earthing cable/ strips is not in bidders scope.

j)

Platforms & cross-over(s) / Jump-over(s) shall be provided for the operation and maintenance of the equipment/
instruments/ JBs installed in the skid. Proper spacing shall be maintained between the equipment for operation &
maintenance. The vent & drains in skid shall be provided with proper support. All the vents shall be at a height of
minimum 3 meters above the working platforms. All flanges shall be connected through flexible jumpers of
Minimum 3 mm thickness and 20 mm wide copper strips.

k)

All the software used in the system and as specified elsewhere, shall be licensed in the name of GAIL.

l)

Compulsory spares and commissioning spares (for each skids separately) as listed elsewhere in this document.

m)

Drawings and documents as listed elsewhere in this document.

n)

All pipes, tubing, fittings, valves, gaskets, bolts, nuts, spades, etc., within the skid battery limit.

o)

A structural skid complete with necessary drip pan, walkways, staircase, platforms, gratings, handrails for access
for operation and maintenance.

p)

Earth bonding system and earthing boss.

q)

Lifting lugs and spreader beam / frame, foundation Anchor bolts for the skid.

r)

Stainless steel nameplate for each skid, each tagged equipment and component.

s)

All Tie-ins (flanged connections) with nuts and bolts.

t)

Inlet and Outlet matching flanges and Studs & nuts shall also be supplied along-with the skid.

u)

Sun/ rain protection shed for electronic instruments/ FC shall also be supplied by the bidder.

v)

Operation and maintenance manual for instruments/ equipment, as built drawing/ documentation.

2.2

SCOPE OF SUPPLY

2.2.1

Supply of all items as indicated in the typical Piping & Instrumentation diagrams (P&ID) / Schematic line diagram and other
technical documents & specifications attached along with the bid document.
The scope of supply shall be as per the typical P&ID attached and shall include but not limited to the following as a
minimum:
a)

Skid mounted Custody transfer Gas metering system package (MRS) inclusive of Filtration, Pressure let down skid
& Gas metering (through Turbine flow Meter / RPD flow Meter ) complete in all respect as per P & IDs, Process
data sheets & as described in Job specification for Gas metering system package for SOR Items 3 to 8. For SOR
Items 1 & 2, DRS (District regulating station) shall be skid mounted and shall include Filtration & Pressure let


down skid complete in all respect as per P & IDs, Process data sheets, Job specification, technical details and other
details described in bid document.
b)

Suitable Weather-proof cabinet for Skids with louvers for ventilation, doors, (with slanted top, checker plate
bottom) as specified in tender.

c)

All equipment/ field instruments such as Filters, valves, Pressure Transmitters, Pressure Gauges, Temperature
Gauge & RTDs, Pressure Control valves, Slam shut valves, Pressure relief valves, flow meters, FCV, on-line
Battery operated field mounted Flow Computer / EVC, JB, Solar power system, Battery etc. EVC is acceptable for
SOR Items- 3 and 6. For balance MRS, Field mounted flow computer is envisaged.

d)

GSM and GPRS Modem shall be provided with each Flow Computer for remote data configuration, remote data
uploading (previous 35 days data) and remote data monitoring.

e)

All installation and erection materials such as impulse tubing, piping, pipe fittings, valves, tube fittings, cable,
cable tray and supports, foundation bolts of the skid, gaskets, companion flanges for inlet and outlet of the skid, all
type of consumables and accessories for mounting of instruments, instrument supports, tray supports, canopies/
sunshields for all field mounted instruments.

f)

Supply of all types of interconnected cables (signal, control, power cables) between field instrument/ JBs & laying
of cables and cable trays in the skid including cable glands at both ends, angle tray, accessories required for cable
laying & JBs (as required) is in bidders scope.

g)

Installation arrangement as shown in the schematic drawing shall be used for guidance. Actual arrangement should
be proposed by vendor and shall be reviewed / approved by GAIL.

h)

Power source (for Flow computer and Modem):


Each flow computer shall be powered through two different power sources viz. primary re-chargeable battery and
backup lithium battery for un-interrupted operation of flow computer.
The 1st (primary) source of power shall be (user selectable) either 230 VAC to 12/14 VDC or solar power which
should be capable enough to charge the re-chargeable battery, whereas the 2nd (backup) source of power will be
Lithium battery.
Primary Power source:
A re-chargeable battery ( voltage rating :12V, of minimum 50AH rating Battery) shall be provide power to FC for at
least 720 Hours (30 days) of no sun day operation including data polling for a minimum of 5 times a day using GSM
and/or every 15 minutes using GPRS.
There shall be provision for charging the offered re-chargeable battery using appropriate charge regulator using :
a)
b)

an external 230 VAC to 12/14 VDC power convertor


Solar panel in such a manner that battery is charged through solar power when sunlight is available else it will
be charged using the external supply (230 VAC to 12/14 VDC converter). The 230 VAC to DC convertor is to
be mounted in a NEMA-4 enclosure in safe area where as the re-chargeable battery shall be mounted in an Exproof Junction box in hazardous area

Secondary Power source :


In addition, flow computer should also have in-built back up lithium battery which it to be used in case of nonavailability of primary power. The Lithium battery system should be designed to power on the flow computer for a
min. of 7 days. As soon as re-chargeable battery (primary source) is charged, flow computer will get power though
the same (primary source) and the Lithium power source shall be cutoff/ go to stand-by mode (Lithium Battery
required to power on, only in absence of power through external battery / when external battery gets discharged).
Re-chargeable Battery, SOLAR power charging system shall be designed for 30 NO sun day operation of Flow
Computer including data polling through Modem as mentioned elsewhere. Minimum capacity of re-chargeable
battery shall be 50 Amp-hour, 12 V.
External power source i.e. power convertor (230 VAC to 12/14 VDC) shall be installed in a NEMA-4
enclosure/box at distance of 20 meters from skid and same shall be suitable to charge re-chargeable battery
mentioned above. Charging cable of appropriate length shall also be supplied by the bidder.
SOLAR PANEL shall be of minimum 50W along with suitable rating rechargeable battery mentioned above.
Certification shall be provided for use of Solar panel in the Class-I, Div-II, Group C&D.


Charge Regulator should accept power to charge the re-chargeable battery from either through
a) 230 VAC to 12/14 VDC convertor or
b) Solar panel.
Input and Output required for Flow computers :
For SOR Item- 4 & 7 :
Minimum I/O required is mentioned below.
Pulse input for LF and HF
RTD Pt 100 (4 wire)
Integral pressure sensor or Analog input for metering PT

For SOR 5 & 8 :

Minimum required is as follows


Pulse input for LF and HF
RTD Pt 100 (4 wire)
Integral pressure sensor or Analog input for metering PT
4 Digital Inputs
2 Digital Outputs
2 Analog Inputs (skid inlet pressure and temperature)
1 PID/ Analog Output (for flow control valve)
In addition to above, provision must be there in the flow computers offered in all SOR items to increase the I/Os with
add on cards.

2.3

SCOPE OF WORK & SUPPLY:


a) Supply of complete skid package-DRS skids (comprising of filtration and pressure reduction with valves, pipe and
fittings) and MRS skids consisting of (Filtration, pressure reduction and Turbine Meter / RPD Meter along with Field
mounted Flow Computer / EVC) as per SOR, typical P&ID / Schematic line diagram and other technical specifications.
The schematic line diagram/ typical P&ID provided along with the bid document shall also be used to understand the
scope of supply/ work.
b) Vendor scope includes Design, Engineering, Manufacturing, Inspection, Testing, Transportation, Supervision for
Installation & commissioning of complete work of custody transfer skids consisting of two Independent streams of
Filtration, Pressure reduction, flow measurement, Stream Flow computers, safety valves, Pressure Instruments,
Temperature Instruments, complete integrated field instruments, piping, fittings and valves in a skid with the following
items described below as a minimum and as shown in the typical P&ID/ line diagram.
c) Metering Skid shall consist of complete metering package (consisting of Filtration, PRS and Turbine flow meter/ RPD
Meter for flow measurement) with two independent and redundant streams (1 operating + 1 stand by stream) should be
designed for 100% of maximum flow capacity indicated above (each PRS/ Metering stream should be designed for 100%
of design capacity of skid). Each of the Gas filtration, PRS and Metering Section shall be of required design flow
capacity meeting the specified operating design conditions as per process data of respective skids. The Vendors scope of
work shall include supply of the complete Gas Filtration, PRS & Metering System in accordance with this specification
and any other codes, standards and regulations stated herein. In each skid, one complete stream will be kept in hot
standby mode (including filtration, Pressure reduction, Metering etc).
DRS shall consist of complete package (consisting of Filtration and Pressure reduction) with two independent and
redundant streams (1 operating + 1 stand by stream) should be designed for 100% of maximum flow capacity indicated
above (each Pressure reduction stream should be designed for 100% of design capacity of skid). Each of the Gas
filtration, PRS section shall be of required as per design flow capacity meeting the specified operating design conditions
as per process data of respective skids. The Vendors scope of work shall include supply of the complete Gas Filtration,
PRS System in accordance with this specification and any other codes, standards and regulations stated herein. In each
skid, one complete stream will be kept in hot standby mode (including filtration, Pressure reduction etc). Maximum
permitted velocity through main header/ pipe / nozzle of filtration, pressure reduction, Metering shall be limited to 20
meter/sec.
d) The scope of supply for DRS (SOR Items- 1 & 2) as a minimum shall include, but not limited to the following.
i) One gas filtration system with two dry gas Horizontal/ Vertical type filters (1 operating + 1 standby stream), each
designed for 150 % of rated flow capacity of skid(s). The dry gas filtration system shall be used to remove dust particles
less than 3 micron with 99% efficiency and to remove condensate if any. Fire case Pressure safety Valves (PSV,


designed for fire case) shall also be provided on each filter. Filter cover shall have arrangement of Davit arm for ease of
maintenance.
ii) Pressure Reduction system with 2 streams of pilot operated Slam shut valve and Pressure Regulators (1 operating + 1
standby stream). Each stream shall contain two regulators (Active and monitor), it means, if active regulator fails then the
other one (monitor) will maintain desired output parameters. Under normal conditions, the downstream regulator is
considered as active regulator and upstream regulator performs the monitoring function. Active regulator shall be fail to
open and monitor regulator shall be fail to close type. Vendor shall confirm that the noise level for the PCV (Active &
Monitor) is within 85 dBA. In case, noise level through PCV is 85 dBA, Vendor shall provide noise treatment to limit
the noise level and include silencers or expanders as required in the scope of supply. Set Point of the PCV Pilots and
Slam Shut Valves shall be adjustable. Vendor shall furnish the adjustable range of the offered pilots and slam shut
valves. The construction of the Pressure Regulator shall be such that there will be no continuous gas bleeding.
e) The scope of supply for MRS ( SOR Items- 3 to 8) as a minimum shall include, but not limited to the following.
i) Gas filtration system consisting of two(2) stream of dry gas Vertical type filters (1 operating + 1 standby stream), each
designed for 150 % of rated flow capacity of skid(s). Dry gas filtration system shall be used to remove dust particles less
than 3 micron and to remove condensate if any. Fire case Pressure safety Valves (PSV) shall also be provided on each
filter. Filter cover shall have arrangement of Davit arm for ease of maintenance.
ii) Gas metering system consisting of two(2) streams of metering system (1 operating + 1 stand by stream) with Turbine
flow meters/ RPD flow Meter, flow conditioner, meter runs. Field mounted Flow Computer / EVC (as applicable) shall
be provided for each meter stream with all interface accessories. Each metering stream shall be designed for 100 % of
capacity. The maximum permitted velocity through flow meter shall be 20 meter per sec. The Gas Flow Meter shall be
certified for custody transfer application by a certifying agency equivalent to Nmi/ PTB/ NPL. For Turbine based skids
(SOR- 5 & 8), Meter run (10 D upstream and 5 D downstream) and Flow straightener is envisaged. The Flow meters
shall be air calibrated.
iii) Pressure Reduction system consisting of two(2) streams of pilot operated Slam shut valve and Pressure Regulators (1
operating + 1 standby stream) shall be designed. Each stream to contain two regulators (Active, monitor), it means, if one
regulator fails the other one will maintain desired output parameters. Under normal conditions, the downstream regulator
is considered as active regulator and upstream regulator performs the monitoring function. Active regulator shall be fail
to open and monitor regulator shall be fail to close type. Vendor shall confirm that the noise level for PCV / Regulator
(Active & Monitor) is within 85 dBA. In case, noise level is 85 dBA, Vendor shall provide noise treatment to limit the
noise level and include silencers or expanders as required in the scope of supply. Set Point of the PCV Pilots and Slam
Shut Valves shall be adjustable. Vendor shall furnish the adjustable range of the offered pilots and slam shut valves. The
design/construction of the Pressure Regulator shall be such that there will be no continuous gas bleeding.
f) Skid mounted field instruments like Pressure & Diff. Pressure gauges, Temperature gauges, Pressure Transmitters,
Temperature elements & Thermo wells, limit switches for slam shut valves shall be supplied along-with the skid.
g) The metering stream (flow meter, flow straightener impulse tubing of Pressure transmitter, thermo-well) shall be
completely insulated to ensure an even heat transfer throughout the meter run when subjected to ambient environment.

h)

The custody transfer equipment at field like transmitters (pressure & temperature) shall be installed in an environmental
enclosure to minimize the effects of ambient temperature variations and shall be lockable for prevention of unauthorized
data entry.

i)

On line Battery operated field mounted Flow Computer is required for all SOR Items 4, 5, 7 and 8. SOR Items 3 & 6,
shall be supplied with Electronic Volume corrector (EVC shall be inbuilt with RPD or field mounted EVC).
The system shall be designed in such a way that it should operate through battery. Bidder shall submit the Battery sizing
calculation, details of battery (make, model, rating), Product Technical Literature along with offer. The Rating, make and
other necessary details in support of selected model for Battery shall also be submitted along with offer. The power
consumption of Flow Computer, Modem, PT (low power consumption) and other associated utilities of online system
shall be considered for Backup calculation and finalisation of sizing of Battery.

j)

Internal / external USB converter shall also be provided with each Flow Computer and EVC for assessing/ connecting
for configuration through Laptop PC through the USB port of the respective FC/ EVC.

k)

Supply and installation of all tubing, instrument fittings, pipes, pipe fittings, other fittings, valves, gaskets, bolts, nuts,
spades, etc, within the skid and its battery limit are in bidders scope.

l)

Supply and installation of all required cables (including earthing cable), cable trays, earthing strips for grounding/
earthing of skid and wiring within the skid. All Interconnecting cables between Skid, Instrument / Junction boxes. Bidder
to supply required mounting accessories for Cabling, glanding, tray work etc.


m) Supply and installation of Junction boxes (as per the requirement of hazardous area classification) for power, signal,
alarm, instrument and control cables with suitable cable glands (if applicable) are in bidders scope.
n) Structural skid complete with necessary drip pan, walkways, staircase, platforms, crossover, gratings, handrails for access
for operation and maintenance are in bidders scope. Details of skid assembly, supporting positions, Anchor bolt layout
and equipment weights to be provided prior to equipment supply.
o) Lifting lugs and spreader beam / frame, foundation Anchor bolts, copper jumpers for flanges for the skid, Stainless steel
nameplate for each tagged equipment and component; All Tie-ins with flanged connections shall be in bidders scope.
Earth bonding system and earthing boss for skid are in bidders scope. Inlet and Outlet matching flanges and Studs &
nuts (for skid interconnection and Inlet & Outlet piping connection), suitable Gaskets shall also be supplied along-with
each skid.

p) Software :
i)

Vendor to provide licensed Software in the name of GAIL for authenticating the algorithm written in the Flow
Computer/ EVC as per AGA.

ii)

Vendor to provide the necessary hardware/ software (licensed in favour of GAIL) for configuration of Flow
Computer / EVC. Vendor shall provide all the details and required soft-ware for SCADA communication.

iii)

Vendor to supply all the hardware / software (licensed in name of GAIL) for accessing data of Flow meter/ flow
computer.

q) The Vendors scope of work shall also include:


i)

Inspection and testing of all components, sub-assemblies, and complete assemblies of items manufactured at
Vendors works, and other sub-vendors works in accordance with approved QA/QC procedure.
Shop assembly and hydro-test and Factory Acceptance Test (FAT) for the complete package at Vendors works
as per approved FAT procedure.
Supervision of Installation, start-up and commissioning of the complete package at site. Site acceptance test
(SAT) for the complete skid as per approved SAT procedure.
Preparation for shipment, packing and delivery of all packages, equipment and material to site.
Installation assistance, Start-up and commissioning assistance at site.
Preparation and submission of all documents including final as built drawings, technical documents as per
purchase requisition along with the bid and after award of contract. Preparation and submission of Final
technical Documentation, test / calibration reports, certificates, Completion files as per this specification. Two
copy (hard copy and soft copy) shall be submitted along with the complete system at stores / site for each skid.

ii)
iii)
iv)
v)
vi)

r) RPD flow meters shall have turn down ratio of 1:40 (minimum) and accuracy shall be within 1% of readings for flow
range from 20% to 100% of Qmax. 5 point Air calibration is required for RPD flow meters.
2.3.1

Any work not specifically mentioned but otherwise required, as per statutory rules/ codes and standards/ specifications and/
or for the completion and operation of equipment to the entire satisfaction of GAIL have to be done by the VENDOR
without any commercial implications.

2.3.2

The scope of work also includes the mechanical and structural detailed design of the skid, procurement of materials,
preparation of fabrication drawings, detailing of internals, fabrication, inspection and testing of the piping and structural
items at fabrication shop, painting, internal coating if any, preservation, transportation and undertaking Guarantee for the
equipment.

2.3.3

The scope of supply of skid also includes supply of mandatory spares as per list provided elsewhere.

2.3.4

The VENDOR shall assume single point responsibility for all aspects of job. This shall include timely completion, liaison
with CONTRACTOR, liaison with VENDOR of specified items, co-ordination of the work, quality and guarantee
for the equipment.

2.3.5

Where parts of the package are subcontracted and purchased by the VENDOR, these become part of the Vendors package
and it is the Vendors responsibility to ensure that the complete package complies with the specifications, codes and
standards and statutory regulations.

2.3.6

Scope of supply/ installation includes all instruments shown in the P&ID/ schematic, as within the Vendors scope.

2.3.7

The Vendor shall be responsible for obtaining necessary approvals, authorization and certification from local Government /


Local Statutory bodies, Authorized Inspector and Third Party Inspection Agency as applicable.
2.3.8

The equipment shall be suitable for the site conditions specified. All components/ consumables used shall be new and of
current manufacture.

2.3.9

In the event of any conflict between this specifications, data sheets, related standards codes etc., vendor shall refer the matter
to the PURCHASER for clarifications and only after obtaining the clarification shall proceed with the manufacture of the
items in question.

2.3.10

Vendor shall take single point responsibility for the engineering, design, certification, procurement, inspection, testing,
supply & performance of the Gas Pressure Reducing and custody transfer metering skids along with all instruments,
equipment and valves offered/ supplied in the skids based on the data sheets and the specifications furnished, taking into
consideration successful operation, safety and established International standards for the complete skids. As a part of skid
design & engineering, the following shall be undertaken/ decided/ furnished by bidder:
a)

Calibration of flow Meters (using air at/ near atmospheric pressure) considering the above mentioned overall
accuracy/uncertainty. RPD meter shall be air calibrated at 5 points. RPD Meter shall be calibrated at 0.05 Qmax,
0.2 Qmax, 0.4 Qmax, 0.7 Qmax, and Qmax. (i.e at flow rates of 5%, 20%, 40%, 70% and 100% of Qmax), subject
to minimum flow rate of 5 M3/Hr (or minimum flow rate as per calibration agency/ Laboratory).

b)

The calibration of Turbine meter shall be performed at 7 different flow points. Calibration of Turbine Flow Meters
shall be done at the following nominal flow rates: 0.025 Qmax, 0.05 Qmax, 0.1 Qmax, 0.25 Qmax, 0.5 Qmax, 0.75
Qmax, and Qmax. as per AGA- 7. (i.e at flow rates of 2.5%, 5%, 10%, 25%, 50%, 75% and 100% of Qmax),
subject to minimum flow rate of 5 M3/Hr (or minimum flow rate as per calibration agency/ Laboratory).

c)

Based on the approved design and tender requirement, Sizing of pipes, filtration, flow meters, self-actuated
Pressure control valves, Safety Shut Off (Slam Shut) valves, Pressure relief valves, Creep relief valve.

d)

Set points for Pressure Regulators (active, monitor) and slam shut valves.

e)

Instrument ranges to meet the Process operating and design conditions.

f)

Noise calculations for Regulators. Vendor to provide detailed Noise calculation and standard used and assumption
considered (if any).

g)

All the instruments/ equipment to be procured as per the approved vendor list provided in bid document.

2.3.11

Typical instrument data sheets for Pilot operated control valves (PCVs), Slam shut valves, pressure relief valves, field
transmitters, pressure gauges, and accessories indicate materials for body, internals etc. However, this does not absolve the
Vendor of the responsibility for proper selection with respect to the fluid and its operating and design conditions. Proper
sizing and selection of the pipe, isolation valves, self-actuated pressure control valves for monitor and active regulator, slam
shut valves, pressure relief valves and accessories are vendors responsibility.

2.3.12

All the major items like valves (Plug & Ball), Pressure control valves, Slam shut valves, Flow computers, Pressure relief
valves, Pressure & diff. Pressure transmitters, Temperature instruments etc. shall be supplied from the vendor list attached
elsewhere and the offered model of equipment shall have proven track record of successful operation for at least 6 months till
bid submission date (certificate, performance report to be provided as proof).

2.3.13

Vendor shall be fully responsible for proper integration of their supplied systems with GAILs SCADA (RTU) systems and
shall provide all the technical details to GAIL for configuration at SCADA/ RTU end. Configuration in the supplied Flow
Computer / EVC shall be bidders responsibility.

2.3.14

Apart from the above, Bidder shall follow the design and specification listed below.

a.

The size of line pipe, inlet/outlet valve size, mentioned in tender is the minimum size of line pipe / port/ nozzle size of each
component of Skid package. Components should be selected and designed for maximum designed gas flow rate at the
minimum pressure (inlet/ outlet as the case may be). All pressure parts shall be designed for design pressure and temperature
mentioned elsewhere. Unless specified & clarified by GAIL, sizes indicated in P&ID shall be followed for all pipe, mainline
valves and nozzle size. Materials, Equipment, items, components selected for skid should be suitable for natural gas application
and shall not erode during operation at worst process condition. All pipe work and equipment must be capable of withstanding
the maximum pressure resulting from a fault condition.

b.

Gas velocity in main line pipe, equipment, flow meter, main line valves, check valve etc must not exceed 20 meters/second,
(except SSV and PCV), when the maximum flow rate occurs at the lowest expected inlet pressure. Velocity limit for SSV shall
be 40 m/s.


c.

Regulators/ SSV of minimum 1 size is required in this project. Regulator and SSV of lower than 1 size shall not be accepted.
Noise through Regulator (Active/ monitor) shall be limited to 85 dB. The allowable pressure drop and noise values in regulator
should not exceed permissible limits.

d.

Complete DRS (SOR Items 1 and 2) shall be designed for 49 Kg/cm2g. Whereas MRS envisaged in SOR Items- 3 to 5, shall be
designed for 49 Kg/cm2g up to downstream header of Pressure Reduction (Inlet, Filtration and Pressure reduction system,
including downstream valves of pressure reduction system) and the downstream of pressure regulation (after downstream ball
valves) shall be designed for 19 Kg/cm2g. Safety Valve (provided on Filter of these MRS skids) shall be set at design pressure,
i.e. 49 Kg/cm2g.
For SOR Items- 6 to 8: Complete skid shall be designed for 19 Kg/cm2g pressure. All pipe, fitting and equipment (except
RPD Meter) must be capable of withstanding the maximum pressure resulting from a fault condition. RPD meter shall be
designed for 12 Kg/cm2g pressure. Safety Valve (provided on Filter) shall be set at design pressure, i.e. 19 Kg/cm2g. Design
Temperature for MRS and DRS shall be -29 deg. C to +65 Deg.C.
Charpy Test for all PRS downstream components (including Regulators, valves etc) shall be done at 0 (zero) degree C.

e.

In MRS, Metering shall be done though Turbine meter (for SOR- 5 & 8) / RPD Meter (for SOR- 3, 4, 6 & 7). For SOR Items4, 5, 7 and 8, Solar powered Flow computer with integral pressure sensor (for metering pressure sensing with pressure range of
gauge pressure sensor shall be 0-8 Kg/cm2g) is envisaged. However for SOR Items-3 & 6, Electronic volume corrector with
battery pack is acceptable.
Turbine flow meter and RPD flow meter shall be designed for 19 Kg/cm2g and 12 Kg/cm2g pressure respectively.

f.

Flow computer with In-built MVS sensor (for metering pressure) is acceptable. Alternately, separate/ independent metering
Pressure transmitter is also acceptable.

g.

The DRS and MRS should have provision for stream selection. Automatic switch over from active stream to hot stand-by
stream should take place in the event of shut down/ trip of the active stream for any abnormal reason.
In DRS, apart from skid inlet & outlet ball valves, there shall be one inlet and one outlet valve (of 300#) on every stream of
filtration with pressure reduction. PRS downstream header shall be designed for 150# and a flanged connection shall be
provided at PRS downstream header. Suitable transition piece (from vendor list) suitable for connecting to MDPE pipes,
PE100 shall be provided. Each of the valves shall be designed to seal on both upstream and downstream faces and the space
between the faces shall be fitted with vents.

h.

Pressure test points, pressure gauges, purge and vents shall be provided as specified in the schematic line diagram/ drawing/
typical line diagram/ schematic provided in tender. All the ends of drain shall be blinded/ plugged. The drain and purge valves
provided at the inlet and outlet ends shall be fitted at sufficient gap from the base level of the skid, so as to facilitate an easy
operation of the same. Vent valves shall be provided at sufficient height to facilitate venting (at 3 meters height from platform/
base).

i.

Schematic line diagram/ P&ID of DRS and MRS provided in tender shall be used for guidance purpose. Before fabrication,
actual arrangement (GAD) shall be proposed in soft & hard form by the vendor, for review and approval by GAIL. No
procurement/ fabrication job shall be undertaken/ started without written approval of GAIL.

j.

Vendor list provided in tender for bought out items, shall be followed for procurement for bought out items required in DRS/
MRS. The acceptance of make/ model of instrument, equipment, component offered by the bidder shall be at the sole discretion
of GAIL.

k.

The data sheet (provided with tender) should be filled up completely, signed, stamped and enclosed along with sizing
calculation, catalogue and drawings in the Technical Bid submitted by the bidder. Technical literature in English language,
along with dimensional details of the equipment and system hook up drawing shall be submitted by bidder along with the
technical bid.

l.

In general, all the connections in the DRS having design rating of 300# should be of welded or flanged type (threaded joints/
connections are not allowed) only. Only flanged and welded connection shall be used in DRS/ MRS. Unless clarified/ specified
by GAIL, no threaded connection shall be used in DRS/ MRS. Only blind plugs for drain connection can have threaded
connection in DRS and MRS.

m. Hole tight / leak tight shall not be used on threaded / flange joints. For all flange joints, Stud with nuts (hot dip galvanized)
shall be provided on flange joints. All Studs and nut used in this project shall be hot dip galvanized as per ASTM A 153 or
equivalent.
n.

No Flange made of cast iron, ductile iron or non-ferrous materials (brass or bronze) shall be used in skid. Flanged connections
(in mainline, inlet and outlet) of the DRS and MRS should be in sizes of 1, 1.5, 2, 3, 4 and 6 only (as defined in line


diagram). All instrument fitting/ tubing etc shall be of SS316 (minimum). No tube fitting/ tube of brass/ copper shall be used.
No valve Components like Valve body, bonnet, cover and / or end flanges made of cast iron or ductile iron shall be used.
o.

Suitable transition fittings (required for connecting to MDPE pipes) shall be provided at DRS outlet end. Suitable transition
fittings (required for connecting to MDPE pipes) shall be provided at inlet and outlet of MRS.

p.

The MRS shall have twin independent streams of Filtration, pressure regulation and Turbine meter/ RPD metering system
(along with solar powered flow computers). Solar panel, battery, flow computer etc shall be installed with required mounting
arrangement and accessories as per best engineering practices. GPRS enabled GSM Modem shall also be provided in Flow
computers. For metering temperature a RTD sensor shall be installed at Meter downstream and shall be connected for flow
computer.

q.

DRS and MRS shall be skid mounted on base frame of required size/ dimension. Suitable cabinet is required for DRS and MRS
(entire skid shall be provided in cabinet). Cabinet shall be made out of frame comprising of angle of minimum 75 mm width
and 5 mm thickness (minimum) and covered with MS sheet/ plate of 2.6 mm thickness from all sides and top. Suitable stiffener
shall be provided as per requirement. Checkered plate of appropriate strength shall be provided at bottom of skid cabinet.
Suitable mounting arrangement/ anchoring shall be provided in skid base frame. The cabinet shall be suitable for outdoor
installation. Top shall be slanted to avoid water inrush during rain. One side (front side) of cabinet shall be lockable from
outside, whereas the other sides (rear, top, side etc) of cabinet shall be lockable from inside the cabinet (GAD to be got
approved before proceeding for fabrication).

r.

DRS & MRS shall have pressure gauges provided at skid Inlet & skid outlet, mounted suitably in the cabinet of DRS / MRS, so
as to view it from outside of cabinet (without opening the cabinet). A cut out of suitable dimension shall be provided in cabinet
of DRS/ MRS for viewing reading of Pressure gauge and flow computers. Suitable glass cover (with locking arrangement) shall
be provided in cabinet to read/view the flow computer.

s.

Vendor shall supply the flow computer with IS Junction Box installed on the suitable Mounting frame/arrangement as per
GAIL site requirement. It shall have the stainless steel tubing connected to the pressure inputs using suitable SS tube fitting and
the other end of the tubing will be terminated in 2-Way Manifold Valve.

t.

The pressure gauges shall be aligned with reference to the regulator, such that it facilitates an easy viewing of the readings in
the pressure gauges. Arrangement for venting of pressure gauge and also pressure sensing lines shall be provided in skid. For
DRS/ MRS, the DP gauge shall be supplied along with 3-way, 5-valve manifold, whereas 2-way manifold is required for PGs.
DRS and MRS design shall meet various requirements of national/ international standards such as ANSI B-31.3/31.8; ASME
Sec. VIII, Div-I; EN-12279; EN-12186; IGE-TD-13; AGA-5, AGA-7 & AGA-8 and PED 97/23/EC Compliance.
Vendor shall design the DRS and MRS suitable for outdoor installation in tropical climate with the following conditions:
Ambient temperature: 0 to +60C.
Humidity: 100%.
Design Temperature shall be -29 to +65C.

u.

DRS shall have twin stream dry gas filters & Pressure reduction (with hot stand-by) in Active-Monitor configuration. No
metering is required in DRS. Whereas, MRS shall have twin stream of dry gas filters, twin-stream Pressure reduction (with
hot stand-by) in Active-Monitor configuration and twin-stream turbine flow metering/ RPD Metering system.
Skids shall have Lifting lugs/ Hooks of adequate strength provided to facilitate its lifting and convenience in handling.
v. Working platforms, if required should be provided in the skids at appropriate locations (and shown clearly in the drawing) to
facilitate easy access to all parts of the skid and to avoid any operational or maintenance problems.
w. Pressure test points, purge and vent points shall be fitted as indicated in the Installation Schematic drawing attached
herewith. When a test point is not provided on an item of equipment, a point shall be provided on the adjacent pipe work. All
the ends of drain and vent points shall be plugged. The vent purge valves provided at the inlet and outlet ends shall not be
fitted very close to the base level of the skid, which will be very difficult to be operated. A common vent header with flame
arrestor along with flapper shall be provided.
x. The bidder shall use only SS Pressure tubes OD (SS316) or 3/8 OD(SS316) (of make: - Sandvik), SS tube fittings (of
make: Parker/ Swage lock / HYLOK). No other make is acceptable.
y. Bidder shall take care of requirement of Pressure Tubing & its associated job for connection from the Inch tap off
provided from the Pipe to the 2-way valve manifold for Inlet Pressure connection (single stream) & outlet pressure
connection (twin stream).
Suitable provision shall be provided by bidder to avoid entrainment of liquids in the gas entering regulator assembly. If
required, means for removal should be provided by bidder. Sizing of components should be done considering avoidance of
unacceptably low temperatures, which may lead to requirement of preheating.


Skid should have a provision for stream selection wherever specified / mentioned in the specific requirements. Automatic
switch over from active stream to the hot standby stream should take place in the event of shut down of the active stream for
any abnormal reason.
In MRS, there shall be separate inlet and outlet valve in each stream of Metering section. Each valve shall be designed to seal
on both upstream and downstream faces and the space between the faces shall be fitted with vents.
Turbine/ RPD flow meter (of MRS) shall be positioned in such a way that the index can be read conveniently. Suitable
means to avoid condensation of water inside index head shall be provided by the bidder. When reading/ viewing the index
head, the gas flow direction through the meter shall be from the left to the right.
Technical literature (in English language only), dimensional details of the equipment and system hook up drawing shall be
submitted along with the technical bid. The data sheet should be filled up completely and should be enclosed along with the
Technical Bid.
Compliance with Technical Specification will be taken for granted by GAIL, if deviations are not specifically mentioned and
accepted by GAIL. Any deviation from the specified technical specification, vendor list, datasheet etc should be highlighted
by vendor. However, the acceptance of the same shall be at the sole discretion of GAIL.
As far as possible, all joints shall be Flanged joint only. No threaded joint shall be proposed / considered by the bidder. Stud
nuts are to be provided on flange joints. Hole tight / leak tight should not be used on threaded / flange joints in skid.
Flanges, fitting or any other skid component made of cast iron/ ductile iron/ non-ferrous materials (brass or bronze) is not
acceptable. Cast iron, ductile iron, non-ferrous materials (brass or bronze) shall not be used in skid/ skid components. All the
flanges used in skid shall be raised face. Flanged end connections for station piping (inlet and outlet) of the DRS/MRS
should be in sizes of 4 and 6 only. Bidder to provide suitable transition fittings on flanged ends and to ensure compatibility
with MDPE pipes. All stud bolts and nuts used in CGD networks shall be hot dipped galvanized as per ASTM A 153 or
equivalent.
Vendor shall confirm that the Skid is suitable for outdoor installation in tropical climate with the conditions specified in
tender. All required cable, conduit and suitable cable gland (ex-proof) required for power, signal, pulse input, RTD shall be
supplied / installed by bidder. The Supply & laying of perforated cable tray on supports and accessories required for cable
laying and routing lies in the scope of the bidder. All interconnecting signal, power, control cables used in the skid shall be
armoured. The signal/control cables shall be individual pair shielded and overall shielded. Vendor shall follow the cable
specifications as per control cable standard specifications. Battery shall be installed in ex-proof JB/ enclosure. Certificates
for JBs, enclosure shall be provided by bidder.
Bidder shall carry out installation of junction boxes on separate support, JB earthing / grounding, tagging, ferruling, cable
glanding & termination, pair/ core identification of all cables.
The Supply & laying of earthing strip and earthing cables (copper) for earthing of instruments, junction boxes etc. to
instrument earthing system lies in bidders scope. Bidder shall supply required earthing strip/ cable for earthing.
(Earth pit shall be provided by GAIL. However Hardware required for interconnection shall be provided by bidder).
Provision for anchoring skid (on foundation) shall be provided by bidder. Supply of suitable anchor bolts (preferably of 16
mm size) also lies in bidders scope.
Tapping with valve required for PG connection shall be of 3/4". PG shall have 1/2" NPT(M) as process connection.
Spring range of offered PCV/ Regulator in MRS (SOR-3 to 8) shall be 1 to 5 Kg/cm2g. SSV and CRV shall be designed
accordingly. For sizing of skid- PRS downstream components/ skid items/ equipment like Meter, Valves, Pipe etc, delivery
pressure (outlet pressure) shall be considered.
The following performance characteristic curves should be furnished:
a)
b)

Outlet pressure v/s flow (for various inlet pressures)


Inlet pressure v/s flow (for various outlet pressures)

3.0

DESIGN PHILOSOPHY

3.1

GENERAL

3.1.1

This Document together with the attachments covers the minimum requirements for the design and engineering of skid
complete with all accessories. Bidder shall be responsible for Design, engineering, sizing, selection, manufacture and/ or
procurement, of materials, components and equipment necessary for complete package.


3.1.2

This document provides in detail, the minimum qualitative requirements of most of the instruments. For instruments, where
no such requirements are indicated in this document, the bidder shall submit the same for GAIL,s approval. For metering
system, vendor shall submit the complete design and engineering of the skid including piping duly approved by NMI/ PTB/
NPL or Meter manufacturer for custody transfer application.

3.2

CODES AND STANDARDS

3.2.1

Design and terminology shall comply, as a minimum, with the latest edition prior to the date of bid enquiry of following
codes, standard practices and publications:

AGA
Report No.3
Report No.7 ANSI / ASME
B 1.20.1
B 16.47
B 16.20
ANSI/FCI
70.2
API
RP 520
Part-I Part-II RP 521
P 526
RP 527
MPMS
RP 551
Part 1 RP 552
S 1101
S 2000
S 2534
S 670
ASTM

American Gas Association, Gas Measurement Committee


Orifice Metering of Natural Gas.
Measurement of Gas by Turbine flow Meter / RPD Meters.
American National Standards Institute/ American Society of Mechanical Engineers.
Pipe Threads.
Steel Pipe Flanges and Flanged Fittings.
Ring Joint Gaskets and Grooves for Steel Pipe Flanges.
American National Standards Institute/Fluid Controls Institute
Control valve seat leakage classification.
American Petroleum Institute
Sizing, selection and installation of pressure relieving system in refineries.
Sizing and selection
Installation
Guide for pressure relieving and depressurizing systems
Flanged steel safety relief valves.
Seat tightness of pressure relief valves.
Manual of Petroleum Measurement Standards.
Process Measurement Instrumentation.
Process Control and Instrumentation
Transmission Systems
Measurement of Petroleum liquid hydrocarbon by Positive Displacement meter.
Venting Atmospheric and low pressure storage tank.
Measurement of liquid hydrocarbons by Turbine Meter / RPD Meter systems.
Vibration, Axial-Position and Bearing-Temperature Monitoring Systems.
American Society for Tests and Materials.

BS
BS-1042
BS-4368
BS-4800
BS-5308
BS-6364
BS-7244
DIN-43760
DIN-19234
IBR

British Standards
Measurement of fluid flow in closed conduits.
Compression coupling for tubes.
Colours for ready mixed paint.
Part-2 Specification for PVC insulated cables.
Specification for valves for cryogenic service.
Flame Arrestors for general use
Temperature v/s Resistance curves for RTDs.
Electrical Distance Sensors; DC interface for Distance Sensor and Signal Convertor.
Indian Boiler Regulations.

IEC
IEC 60079
IEC 60085
IEC 60332
IEC 60331
IEC 60529
IEC 60534-2
IEC 60584-2
IEC 60584-3
IEC 60751

International Electro-technical Commission.


Electrical Apparatus for Explosive Gas atmosphere
Thermal Evaluation and Classification of Electrical Insulation
Test on bunched wires or cables. Part 3 Cat 1
Fire resistance characteristics of electrical cables
Classification of degree of protection provided by enclosures.
Industrial Process Control Valves-Flow capacity
Thermocouples - Tolerances
Thermocouples extension and compensating cables, tolerances and Identification system.
Industrial platinum resistance thermometer sensors

IS
IS-5
IS-319
IS-1239
IS-1271
IS-1554-part I
IS-2074
IS-13947
IS-2148

Indian Standard
Colours for ready mixed paints.
Specification for free cutting Brass bars, rods and sections
Mild steel tubes, tubular and other wrought steel fittings.
Specification of Thermal Evaluation and Classification of Electrical Insulation.
PVC insulated (heavy duty) electric cables-working voltage up to and including 1100 V.
Ready mixed paints, air drying, red oxide- zinc chrome.
Degree of Protection provided by enclosures for low voltage switch gear and control gear.
Flame proof enclosures for electrical apparatus.


IS-3624
IS-5831
IS-7358
ISA
S-5.2
S-7.3
S-75.01
ISO 5167
NEC
NFPA
NFPA-496
EN
EN334
EN12186
EN14382

Specification for pressure and vacuum gauges


PVC insulation and sheath of electric cables.
Specifications for Thermocouples
Instrument Society of America.
Binary logic diagrams for process operations.
Quality standard for instrument air.
Flow equations for sizing control valves.
Measurement of fluid flow by means of orifice plates, nozzles and venturi tubes.
National Electric Code.
National Fire Protection Association.
Purged and pressurised enclosures for electrical equipment.
European Standard
European standard for pressure regulators upto 100 bar
Gas Pressure Regulating Stations for Transmission and distribution
Safety systems for Gas distribution

3.2.2

In general, Bidder shall carryout engineering as per IEC/ BIS standards.


Any other standard, if necessary, can also be referred by bidder during the execution of the job, without diluting the basic
requirements, however with prior information to Owner/ Owners Representative. In any case bidder must furnish a list of
codes and standards other than those specified in this document, which shall be followed by them during engineering.

3.3.

INSTRUMENT DESIGN CRITERIA

3.3.1

Instrument air shall not be provided by GAIL for FCV operation. Special care shall be paid for dealing the problem arising
from possible condensation due to pressure reduction. A well proven system shall be used for this application. Filter
regulators, Actuators, pneumatic positioner, I/P converter etc shall be suitable for Natural gas (sour) application.

3.3.2

The Equipment and instrumentation selected for the skids shall be rugged in design and must be well proven in the
hydrocarbon industry. Prototype design or equipment of experimental nature or design undergoing testing etc. shall not be
selected and supplied. Following criteria must be applied before selecting a particular instrument item: The instruments as
being offered/ supplied should have been operating satisfactorily in hydrocarbon industry like Refinery, Petrochemical and
Gas Processing Plant under similar process conditions for at least 4000 hrs. from the bid due date. Certificate of end user
shall be provided for the same.

3.3.3

All the mainline ball valves of complete skid package shall be full bore type only.

3.3.4

The complete station shall be designed in such a way that the mean gas velocity remains within 20 Meter per second except
in Pressure regulating valve / slam shut valve. Velocity in the piping upstream / downstream of Pressure reduction station
shall be within 20 Meter per second. Maximum seat velocity of Slam shut valves is limited to 40 meter / second. The
complete skid shall be designed for 100 % of the maximum flow capacity (except Filtration system, which shall be designed
for 150% of skid capacity).

3.3.5

Instrument Requirements for classified area:


a)

All electronic/electrical instruments and equipment shall be suitable for area classification as per IEC codes and shall be
tested by any recognized authority like BASEEFA, FM, PTB, CMRI etc. and shall be certified by CCOE. All the
configurators shall be certified by CCOE.

b)

Certified Intrinsically Safe (IS) equipment as per IEC-60079-11 shall be used, in general, in hazardous area. In case
intrinsically safe equipment is not available, flameproof enclosures as per IEC-60079.01 may be considered.

c)

Junction boxes and accessories required for flameproof instruments shall also be certified flameproof.

d)
e)
3.3.6

All non-flameproof panels and cabinets installed in classified area shall be purged as per requirements specified in
NFPA-496; as a minimum.
Other type of protection as specified in IEC-60079 shall not be used.

Statutory Approvals
a)

Bidder shall be responsible for obtaining all statutory approvals, as applicable for all instruments, equipment.

b)

In addition, equipment/instruments/systems located in the hazardous area shall be certified by the local statutory
authorities for their use in the area of their installation. In general following certification shall be given:
For all intrinsically safe/ explosion proof/ flameproof equipment/ instruments/ systems or equipment with any other
type of protection allowable as per this package which are manufactured abroad and certified by any statutory authority


like BASEEFA, FM, UL, PTB, LCIE etc. should also have the approval of Chief Controller of Explosives (CCOE),
Nagpur.
For all flame proof equipment manufactured locally (indigenously), the testing shall be carried out by any of the
approved test house like CMRI/ERTL etc. The equipment shall in addition bear the valid approval from Chief
Controller of Explosives, Nagpur and a valid BIS license.
For all intrinsically safe equipment manufactured locally (indigenously), the testing shall be carried out by any of the
approved test house like CMRI/ERTL etc. The equipment shall in addition bear the valid approval from Chief
Controller of Explosives, Nagpur.
Custody transfer approval from NMI/ PTB/ NPL or equivalent body from the country of origin.
CCOE certificate for the skid items / components shall be submitted during detailed engineering, however appropriate
approval certificates from the country of origin shall be provided with the bid.
3.3.7

All instruments in the skid shall be certified for IEC Zone 1 Gas Group IIA/IIB, T3.

3.3.8

Instruments, which are not available as per their standard design from any reputed manufacturer as intrinsic safe, can be
supplied in flameproof design. All such instruments shall be certified flameproof for the area classification and requirements
indicated in clause 3.3.6 above.

3.3.9 Flame-proof (explosion proof) junction boxes as applicable shall be certified for IEC-Zone-1, IIA/IIB for all the classified
areas for flame proof instruments.
3.3.10 The sizing for Pipe, Filters, Safety valves, Pilot operated self-actuating pressure control valve, Monitor valve, slam shut
valve, Turbine Meter / RPD Meter.
3.3.11 Any change in instrument size or revision in line sizes because of sizing shall be carried out by bidder without any financial
implications to GAIL.
3.3.12 All field instruments shall be provided with canopies of adequate size and strength to protect instruments from direct rain &
sunlight. All such canopies shall be prefabricated type of FRP material with sufficient strength.
3.3.13 Tube Fittings used for the installation of instruments shall be tested as per BS 4368 or equivalent standards.
3.4

JUNCTION BOXES AND CABLING PHILOSOPHY

3.4.1

Cable Routing

3.4.1.1 Single / multiple pair cables between instrument and junction box shall be through perforated trays. Cable glands shall be
provided at instrument end and junction box end. Supply of interconnected Cables is in bidders scope.
3.4.2

Junction Box

3.4.2.1 In general separate junction boxes shall be used for the following (if applicable):
a)
b)
c)
d)

4-20 mA DC signals (IS)


Metering Signal
Contact signals (Field switches, Limit switches, push buttons etc.)
Power supply to various instruments ( Flow Meters/ Flow computers/ Transmitters)

Separate JBs and cable are required for power supply to flow Meters and flow computers. The JBs shall have side entry for
Branch cable/ single pair cable and Bottom entry for multi-pair cable entry. No top entry shall be considered.
3.4.2.2

The multi-cable entry for 6-pair JB and 12 pair JB shall be 1" NPT (F) and 1.5 NPT (F) respectively. Each junction box
shall be provided with 2 multi-cable entries from the bottom of the junction box with one plugged with weather proof plugs.

3.4.2.3

Junction boxes, cable glands and accessories shall be weather proof in general. Slipper type PVC sleeves shall be used over
cable glands for all cable entries in junction boxes to avoid water entry in junction boxes. In case of explosion-proof
components used (only for packages), the respective junction boxes, cable glands and accessories shall be certified weatherproof and explosion proof.

3.4.2.4

Only one multi-cable entry shall be used in the junction box. The other cable entry shall be plugged.

3.4.2.5

The junction boxes in the field as well as in local panel shall be provided with sufficient number of terminals to terminate all
the pairs of multi-cable (including spare pairs) and shields of individual pairs as applicable.


3.5

INSTRUMENT PAINTING REQUIREMENTS

3.5.1

All instrument impulse lines (except SS 316 Tubing) and instrument structural items shall be painted by the bidder.

3.5.2

The painting/ coating shall be performed in totality for all instrument items such as:
a)
b)
c)

All line mounting and equipment mounted instruments.


All instrument impulse piping (except SS 316 Tubing)
All instrument structural items like M.S. cable trays, instrument supports and tray supports, instrument stanchion,
impulse line supports etc.
All surfaces of GI items wherever repair has been carried out shall also undergo painting.
All cabinets/panels, base frames which have undergone repair at site shall also be painted.
The final coating on external surfaces shall be applied just before handing over the plant or commissioning of the
plant. Name of the manufacturer, colour and quality of all types of primers and paints shall be subject to approval
of the owner/owners representative.

d)
e)
f)

3.5.3

Painting of other equipment shall be as per Painting specifications attached elsewhere.

4.0

PROCESS DESCRIPTION

4.1.

The bidders shall design the skid considering the worst case process condition scenario.
The set pressure of Pilots for PCV (Active & Monitor) & SDV shall cover the complete range of inlet & outlet condition. In
case of PCV / regulator (Active & Monitor) and Slam shut Valve, if one single pilot is not able to cater the complete set
pressure range, then additional suitable pilot / loose springs shall be supplied for each PCV / regulator (Active & Monitor)
and Slam shut Valve for each skid.
The Filter-PSV shall be set at maximum design pressure. However it shall be designed in such a way that the set pressure can
be adjusted within the operating pressure range/ set points. Separate spring(s) shall be provided, if one spring is not sufficient
to meet the requirement.
10 % of the maximum flow capacity shall be considered as the minimum flow.
Design Temperature: -29 to 65 deg C.
The maximum permissible pressure drop across the complete DRS skid and MRS skid is 3.0 kg/cm2g and 2.0 kg/cm2g
respectively.

4.2.

Detailed Process conditions:


Each stream of PRS / Metering in the quoted skid shall be designed for flow capacity of 100% of maximum flow mentioned
above.
The Heating value of Natural gas (GCV) shall be 9200 to 9880 Kcal/SCM. The Upstream of PRS of skid and its components
shall be designed for Pressure as specified in the P&IDs & Data Sheet.
The Slam shut valves and Pressure Regulators shall be selected such that these instruments can be set in the Pressure range
as specified in the data sheet. In case a single Pilot/ spring is not capable of meeting the above pressure set point requirement,
additional spring/ pilot shall be provided along with the Pressure Regulators. The PSVs for each Filter shall be designed for
fire case and shall have set point as specified in the data sheet.

4.3.

The bidder shall provide certification from Original Equipment manufacturer of gas flow meter/ calibrating agency that the
performance/ accuracy and repeatability of the Meters shall be within the prescribed limit as mentioned in tender during
operation with above mentioned Natural gas composition. The Material (and its composition) used in skids shall be suitable
for Natural gas of above mentioned composition. The bidders shall provide written confirmation from the Original Meter
Manufacturer that the meters offered by the bidder shall perform within the specified accuracy limit with the above
mentioned Gas composition.

4.4.

All the calculations for the sizing of the valves, meters etc shall be based on the design flow capacity with worst case Process
Temperature and Pressure, However for mechanical strength of the equipment, design temperature / pressure shall be
considered.

4.5.

All the Equipment shall be able to withstand maximum/ minimum design Pressure and temperature. Worst case process
pressure and temperature with design flow is to be considered for noise calculation of valves.

5.0

JOB SPECIFICATION

5.1

GENERAL
This document defines the instrument Job requirements over and above various Standards attached along with this bid
document.
The selection of type of instruments is Bidders responsibility. For the instruments where type is already identified in the


Typical P & IDs / data sheets, the Bidder shall follow the same. However during the engineering procurement stage if it is
found that a different type of instrument is most suited for a particular application then the same shall be referred to GAIL
for review, and if suitable, the changed instrument shall be supplied by the bidder. Bidder shall also be responsible for
selecting and reviewing the type of instrument where specifically indicated in typical P& ID.
Instrument selection and specifications shall be carried out as per specification, typical instrument data sheets and Standard
Specifications in general, as appended by special requirements specified here in. The referred Standard specification,
Technical Specification together with the P&IDs, Process data sheets, data sheets, standard specifications attached with the
Package, defines the requirement for the design, engineering, manufacture, fabrication & assembly, integration, calibration,
factory testing, supply, packaging, shipping and documentation including deliverables, statuary and other special approval,
inspection, testing overall skid performance guarantee of Gas custody transfer. If required, then installation supervision,
commissioning of the same at the same terms & condition of the contract/ tender.
6.0

TESTING & INSPECTION

6.1

GENERAL

6.1.1

All pressure boundary materials shall have certified material test reports (CMTRs) or certificate of compliance per the design
code. Certifications shall be to EN 10204 Type 3.1 for pressure parts and Type 2.2 for other parts. A system of positive
material identification (PMI) shall be implemented for the items mentioned in PMI specification attached elsewhere.

6.1.2

Vendor shall submit the QAP & FAT Manual / procedure for review and approval. A typical QAP and FAT Manual/
procedure is attached elsewhere.

6.1.3

Vendor shall carry out 3.1 certification for all the supplied pressure parts/ mechanical items (part of skid).

6.1.4

All materials and equipment shall be factory tested before shipment in the presence of Purchasers representative. No
material shall be transported to site until all required tests have been carried out and equipment is certified as ready for
shipment, issue of Inspection release note and delivery clearance/ advice. Acceptance of equipment or the exemption of
inspection or tests thereof, shall in no way absolve vendor of the responsibility for delivering equipment meeting the
requirements of the specifications.

6.1.5

Vendor shall furnish the following


Material test certificate, Hydrostatic test certificate, certificates of radiography for all line mounted items/ instruments on
the skid.
Certificates from statutory body for hazardous area approval for all electrical items mounted on the skid.
Calibration certificates, certificates for custody transfer, certificates for the conformity to the standards to be submitted.
All other certificates mentioned in individual general specification.

6.1.6

Supplier shall perform the usual standard tests to maintain quality control procedures. These test certificates shall be
submitted for review before starting inspection by Purchaser. Supplier shall be responsible for testing and complete
integration of the system. Detailed procedures of test and inspection shall be submitted by the supplier for review before
order and mutually agreed upon.

6.1.7

Vendor shall include inspection by GAIL/ their representative at vendors shop. For this inspection, labour, consumable,
equipment and utilities as required shall be in vendors scope. Third Party Inspectors shall be deployed by the bidder. Vendor
shall propose minimum 3 TPI agencies, from which one shall be selected/ approved by GAIL.

6.1.8

Other inspection and testing requirements shall be as per respective Standard specifications of various instrument items.

6.1.9

Qualification of the TPI appointed by the Vendor/ supplier and deputed for witnessing at various stages of Fabrication (like
Hydro-test, FAT etc) shall be provided by the supplier well in advance for our review and confirmation. The TPI involved to
witness shall have relevant experience. No TPI shall be deployed for our approval and FAT shall not commence without this.
PERFORMANCE & INSPECTION:
Adequate data on flow rate, Capacity, Range-ability, lock-up, minimum and maximum operating pressure differentials,
dynamic performance characteristics and predicted noise level emissions, set points of slam shut valve, relief valve, active
and monitor regulators etc., should be given by the manufacturer in order to determine the performance of the regulators
under various operating conditions. Results of such tests carried out by the manufacturer to determine operational
performance and thereby confirm these design data and Manufacturing Test Certificates (MTC) for all components / parts of
DRS, NDT results, Welding Procedure Specification (WPS), Welders Performance Qualification Record (WPQR), Welding
Procedure Qualification Record (PQR), etc., should be made available prior to offering the complete skid for witnessing the
performance testing by GAIL / Third party Inspection agency appointed by GAIL.
The final performance test of complete DRS / MRS skid shall be carried out in presence of third party inspecting agency /
GAIL representative before accepting the skid and giving clearance for dispatch. Bidder should quote separately towards


Third party inspection charges for the inspection to be carried out only by renowned agencies like Lloyds, Bax councel,
DNV, EIL, ABS, GLI, Velosi or any other agency only with prior approval of GAIL. Inspection is to be carried out as per
inspection plan stated below.
Inspection Plan:
a)

Visual inspection of DRS and MRS skid assembly.

b)

Witnessing of:
i) Hydrostatic & Pneumatic Testing of DRS and MRS Skid assembly, as per parameters given in tender.
ii) Performance testing of Regulator: Outlet pressure v/s flow (for various inlet pressures), inlet pressure v/s flow
for various outlet pressures (entire range of delivery pressure), checking lock up pressure within limits,
pressure setting & operation of Slam shut valve, Regulator and Relief valves.

c)

Stage-wise inspection to be carried out for inspection of workmanship quality and for inspection of surface preparation
and primer coat / intermediate coats to ensure proper adhesion / paint quality.

d)

Review of all Calibration certificates, reports, test certificates for all the Valves, relief device, regulation device,
filtration and measuring instruments at the time of inspection, i.e. used for checking and testing, along with the
calibration certificate of the master instruments from which the instruments is calibrated.

SKID TESTING:

6.2

The following tests shall be conducted for the skid.


Hydro Testing (for the integrated skid / individual pipe spools).
a)

Hydro testing of the integrated skid shall be carried out using water as the testing medium. The test pressure shall
be 1.5 times the design pressure and holding time for the test shall be 30 min. Wherever necessary, regulators,
relief valves and similar components that have been tested independently should be removed from the line. Blind
flanges or double flange pipes should be installed temporarily in their place. All small bore connections and
impulse lines should be disconnected and suitable plugs or blank flanges should be installed. A record of all
hydrostatic testing carried out shall be prepared for every skid and shall be provided during inspection.

b)

Pneumatic Leak Test of complete skid at 7 Bar(g).


i)
ii)
iii)
iv)
v)

Leak Tightness test of the skid shall be carried out at operating pressure, the test medium shall be Air/
Nitrogen at 7 Bar pressure (minimum) and the holding time for test shall be 30 minutes(minimum).
Pneumatic testing using air or an inert gas should be undertaken on all installations and should include
all equipment and associated small bore pipe work. Care must be taken to disconnect equipment, which
might get damaged at the testing pressure.
It should be confirmed that all main, by pass and impulse valves within the section under test are in the
open position. Any open ends should be blanked off. The installation should be pressurized slowly up to
the recommended test level as detailed in specific requirements column.
All joints, flanges and glands on valves and fittings should be tested for leakage with a suitable foaming
fluid.
Test Certificates: A record of pneumatic testing (of entire skid carried out by bidder) shall be prepared
for every skid and shall be provided to GAIL during inspection. Material test certificate for all
components of DRS, MRS should be furnished at the time of inspection by third party / GAIL
representative. GAIL reserves right to witness any/all the tests.

Test of Skid Equipment/ Instrument

6.3

The following tests shall be conducted:

a)

Requirements of non-destructive testing like radiography, magnetic particle test, hardness test, hydro-test, Charpy test
for pressure relief valves, slam shut valves, Straightener and meter runs shall be carried out strictly as per following
specification.

b)

100% radiography shall be carried out on all casting. Radiography procedure and area of casting to be radiographed
shall be as per ANSI B16.34 and acceptance criteria shall be as per ANSI B16.34 Annexure B. Two shots shall be
taken for each area to be radiographed, as a minimum.


c)

Radiography/ X-ray shall be carried out for all welded joints and vendor shall furnish test certificate for the same. Dyepenetration test certificate shall be provided for joints wherever radiography/ X-ray is not possible.

d)

Charpy impact test on each heat of base material shall be conducted as per A370 for all pressure containing parts such
as body, end flanges and welding ends as well as bolting material for pressure containing parts. Unless specified
otherwise, Charpy impact test shall be conducted at 0C. Charpy impact test specimen shall be taken in the direction of
principal grain flow and notched perpendicular to the original surface of plate or forging. The minimum average
absorbed energy per set of three specimens shall be 27J with an individual minimum per specimen of 22 J.

e)

Skid piping material testing and NDT of welds as per piping material specifications.

f)

Radiography/ X-ray, Charpy impact testing for line mounted instrument items such as pilot operated pressure control
valves in active monitoring configuration, pressure relief valves, slam shut valves, Turbine flow Meter / RPD Meter etc.

6.3.1

Flow Meter, Meter run, Flow Computer / EVC and accessories shall be offered for pre-dispatch inspection to GAIL/
it's representatives. Following tests, checks shall be conducted:
a) Functional and simulation tests including checking of hardware and software for Flow computers including turbine
flow meters with all its sub-systems in fully integrated configuration.
b) Review of all certificates and test reports.
c) In the event, the purchaser is unable to witness a test, the test shall anyway be completed by the vendor and
documents for the same shall be submitted for scrutiny before shipment.
d) All tests as per Standard specifications attached with this bid document.

6.3.2

Following tests shall be carried out by vendor at their works and test certificates shall be furnished:
Calibration/ test certificates for all instruments. Calibration test reports for flow meters duly signed and certified from
the recognized International laboratories / statutory weights and measures authority. Statutory body certificates for
instruments.
Type test report for JB and enclosure of all electronics/ electrical equipment. Radiographic / Charpy test certificates for
Turbine flow Meter / RPD Meters. Material test certificate for all line mounted instruments. Dimensional test report
Certificates for custody transfer application and other certificates mentioned elsewhere.

6.3.3

In addition vendor shall also refer the inspection & testing requirements of the standard specifications provided in tender
document and follow the same. Following test shall be performed and demonstrated during FAT.

6.3.4

Skid functional testing considering metering, pressure regulation, limiting and safety characteristics. (Functional testing
of Slam shut valves, PCs (active & monitor) shall be demonstrated by simulation in vendors shop).

6.3.5

Vendor shall include in his scope the shop inspection charges including factory acceptance test (FAT) inspection by
GAILs representative at vendors works.

6.3.6

Inspection of Slam Shut Valves, Pressure Regulators, and Pressure Relief Valves shall include the following:
a.
b.
c.

6.3.7

Test to demonstrate set point accuracy and actuation time for Slam shut valves
Calibration certificate for Pressure relief valve set pressure
Seat tightness test for PCVs (Active and Monitor), Slam shut valves and pressure relief valves. (Test
shall be conducted at manufacturers workshop and certificates shall be submitted).

The following certificates are required to be submitted during inspection for our review before dispatch of Materials:
Verification of certificates as applicable for the material certificates, NDT reports like radiography/ X-ray/ diepenetration/ MP, etc. Statutory certificates (from CCOE) for intrinsic safety and explosion proof, certificates of
conformity etc.
Visual verification for quantity, quality and workmanship.
Hydro testing and pneumatic testing as applicable.
Functional and performance testing including functional testing, calibration, accuracy, repeatability testing.
Seat leakage tests & hydraulic Pressure test, actuator cycling & fail condition tests for control valves
Set pressure, reseat pressure & seat leakage for pressure relief valves.


Calibration report of PT, TT, RPD flow Meter, Turbine Flow Meter with meter run and flow straightener.
Radiographic test for Thermo-wells etc.
Bidder must submit detailed performance specifications of each item which shall be verified by bidder or bidder
appointed agency/ GAIL/ GAILs representative during factory testing.
Inspection and testing requirements as per the respective standard specification shall be referred.
Bidder shall submit all test records / test results for records to purchaser as bound volume along with the test
procedure for each test carried out.
Custody transfer application certificate for flow meters and Flow computer.
Approval of MRS design as per AGA and any other agency (for Turbine Meter / RPD Meter based MRS skids)
from approving agencies mentioned elsewhere.
6.3.8

Wherever inspection at manufacturers shop is waived because of any reason, the bidder shall carry out the
inspection at vendor/ sub-vendors shop and Bidder shall forward these inspection reports for verification by GAIL
before dispatch. In no case, items shall be released without proper inspection/ verification.

6.3.9

The inspection and testing shall be carried out as per related specifications, international codes and practices/
standards, approved documents and/or any other document attached along-with specifically suggesting extent of
testing to be carried out at manufacturers works.

6.3.10

Items for which Witness Inspection is specifically exempted, manufacturer shall forward the test certificates as
desired for review.

6.3.11

Testing and inspection for all items shall be carried out as per approved factory testing procedures. The material
shall be dispatched only after obtaining written dispatch clearance. For items where no testing is witnessed by the
purchaser test certificate shall be forwarded for review before dispatch of such equipment

6.3.12

Contractor must detail out performance specifications of each item which shall be verified by contractor or
contractor appointed agency/ Owner/ PMC during factory testing.

6.3.13

Inspection and testing requirements as per the respective standard specification shall be referred.

6.3.14

Bidder shall submit all test records / test results for records to purchaser as bound volume along with the test
procedure for each test carried out.

6.3.15

Acceptable criteria for Radiography and other NDT requirements for all the instruments/ instrument castings shall
be inline with those specified in valve/ piping specifications for the similar service. Valve specifications/piping
specifications have been attached elsewhere in this package.

6.3.16

CCOE certificate shall be supplied by the bidder for all instruments, Flow computer, EVC, JB, enclosure for use/
installation in hazardous area.

7.0

DOCUMENTATION
7.1

All Detailed P&ID, GAD, Foundation drawings, Cabinet details, datasheet, sizing calculation, system architecture,
internal wiring diagram, cable schedule and catalogues is required from the bidder. The required number of
reproducible and prints should be dispatched to the address mentioned, adhering to the time limits indicated.

7.2

Final drawings from the Vendor shall include dimensional details, weight, mounting details and any other special
requirements etc for the skids. In general, all dimensions shall be in millimetres.

7.3

Vendor shall furnish all the required software, document, manuals necessary to test, operate and maintain the
system. All the certificates and licensed software shall be provided in name of M/s GAIL (India) Ltd.

8.0

MISCELLANEOUS

8.1

NAMEPLATE IDENTIFICATION
In addition to the instruments and equipment nameplate, the structural skid shall be supplied with a permanent,
weather resistant, stainless steel nameplate affixed to the skid, with the following details, as a minimum:
Project Title and number
Owner name


Equipment name and tag number
Manufacturers name and serial number
Skid overall process parameter, design pressure, temperature and dimension data.
Skid weight data.
Each skid and all the equipment/instruments in the skid shall have a S.S nameplate attached firmly to it at a visible
place (preferably at height of 1.2 meter from platform/ base level) furnishing the following information:
Manufacturer's name and Model number ------------------Tag number/ Serial No. of skid-----------------------.
Project Name with location: GAIL (I) Ltd, -------------------(name of site/ station)
Inlet size & Outlet Size (in inch) along with pressure class rating-------------------Min/ Normal/ Max. Flow capacity( in SM3/Hr)-----------------------------.
Min/ Normal/ Max. Pressure (range)-------------------------------------------Tag number of Instruments, JB as per purchaser's data sheets --------------Body sizes with class rating (in inches) and Cg value of Control Valve------------------------Set pressure range and flow capacity of pressure safety valves--------------------------Body sizes with class rating and G-Rating & Flow range in M3/hr for Flow meters------------------------Rating for all the individual instruments
Bidder to also note that all cable should have Tag no. at JB/ panel end and Instrument end. All wires terminated
inside skid should have identification mark, ferrules etc. (for the termination of supplied cables, Identification Tag
no, Ferrule etc. shall be provided by bidder).
9.0

SHIPPING & PACKAGING


Vendor shall indicate the shipping and packaging methodology for Metering system / each pieces of skid along with its size,
weight and no. of pieces.
Vendor shall try to fix as many types of equipment/ instruments as possible in skid before shipment.
If any of the items are shipped loose, then it shall be properly packed inside metallic or wooden cartoon with identification
tags painted on it. Loose materials, spares etc for any two skid shall not be mixed in one cartoon/ package. A System of
tagging, segregation to be followed for easy identification of parts and due care to be taken to avoid intermixing of some
parts of different skids.

10.0

PERFORMANCE GUARANTEE

10.1

The VENDOR shall guarantee that all work/ job will be performed in accordance with good and sound engineering and
construction practices and within the requirements of this specification. The equipment, accessories and all the materials
supplied by the VENDOR shall be free from defects, shall be suitable for the use for which they are intended and shall
perform in accordance with the requirements of this specification.
Vendor shall stand guarantee for a period of 24 months from the date of delivery or 12 months from the date of
commissioning, whichever is earlier.

10.2

The VENDOR shall furnish a guarantee for the entire skid package comprising of all of its component/ equipment including
instruments, piping, valves, fittings, internals, etc., for a period of 12 months from the date of commissioning or 24 months
from the date of receipt at GAIL store/ site, whichever is earlier.

10.3

The VENDOR shall take single point responsibility for the complete skid, including the sub-contractor supplied components,
the proprietary equipment and components included in skid package and supplied loose in accordance with this specification.

11.0

INSTALLATION & COMMISSIONING OF SKID

11.1

The VENDOR shall provide qualified and experienced personnel for assistance during installation, field-testing and
commissioning of Skid or part thereof.

11.2

INSTALLATION REQUIREMENTS:


All instruments shall be accessible from grade or a platform for operation and maintenance.
Bidder shall follow GAIL Installation standards attached with tender or equivalent for installation of each instrument. In
case, any instrument require a special installation or any instrument not provided with installation standard the bidder shall
prepare the standard and get it approved from GAIL along with other documents.
Impulse tube/ pipe of size shall be used as impulse lines. The Impulse pipe/ pipe fittings for instrument installation shall
be as per the piping material specifications of respective process lines. Tubing when used between manifold and the
instrument shall be, 12mm OD with SS316 material of construction as a minimum. The material selected shall be suitable for
the process fluid conditions.
Instrument in gas service are to be installed only above or at least parallel to the tapping with a slope in the impulse towards
the tapping to achieve self-draining condition.
Pressure Relief valves shall be installed in line only after proper flushing of the lines.
No unions shall be used in impulse lines/ pipes instead break flanges shall be used.
Plug valve/ Globe valve in combination with Ball valve shall be used for isolation, vent & drain valves and equalizing
service.
Minimum sized valves shall be used for Instrument isolation.
Impulse piping is to be suitably painted (except SS 316 tubing)
Schedule 80 seamless pipe with at least 3000 lb rating fittings should be used as a minimum for impulse piping.
Tube fittings shall be double ferrule type.
Based on the installation standards for each type of instrument, bidder shall prepare Bill of materials (BOM) which indicates
the requirements of different materials for installation of each instrument. However completeness of BOM is bidders
responsibility.
Mounting of field instruments (if remote mounted)/ JBs on the stanchion or instrument support shall be at the height of
1.3Meters from the grade level / finished floor level.
The installation and erection materials like, cables (signal, control, thermocouple extension and power), cable glands,
junction boxes, instrument valves and manifolds, impulse pipe and pipe fittings, pneumatic signal tubes, pneumatic fittings
and valves and cable trays required for installation of complete instrumentation shall be as per standard specifications
enclosed in this tender. Power supply for different instruments/ equipment having different power/ voltage rating shall be
installed in different JBs (if applicable).
11.3

LOOP CHECKING AND COMMISSIONING

11.3.1

Bidder is fully responsible for all work related to loop checking (inside the skid), including cable laying, tray work, dressing,
identification, ferruling, calibrations, loop testing.

11.3.2

Bidder shall be responsible for commissioning of each & every equipment installed in the skid and (Functionality, simulation
for these equipment shall be demonstrated during FAT).
The suppliers technical personnel shall supervise installation of skid and shall carry out commissioning of the DRS/ MRS at
GAIL site.

12.0

BIDS:Bidders Proposal shall include the following (as minimum):

12.1

Bidder's proposal shall include the detailed specifications for all items of filtration system, Gas pressure reducing packages
and Metering packages. The proposal shall include:

a)

Make, Model number and detailed specification along with technical details and catalogue for each applicable item of skid
like filter, Slam shut valve, pilot operated pressure control valve, pressure control valve with integral slam shut valve, flow
meter, meter tube details, flow computer, pressure relief valve, pressure transmitter, Temperature transmitters, pressure/
temperature gauges, limit switches, Ball valves, plug valves, Globe valves, Check valves etc.

b)

Slam shut valve, pilot operated pressure control valve details including type, construction material, CV data/ capacity curves,
regulation accuracy, set point spring ranges, details of the valve pilots etc.

c)

Sizing calculations and pressure drop calculations for inlet and outlet pipeline, filtration system, slam shut valves, pressure
control valve, Flow meters and Pressure relief valves. Calculation for Gas velocities and Pressure drop across slam shut
valves and meter runs at maximum flow and minimum pressure to be submitted. The entire system (including all the
components, equipment, Instruments) shall be selected and offered in such a way that the overall pressure drop across the


entire skid shall be minimum. Detailed sizing calculation for individual components and pressure drop for entire skid
(including diff. Pressure across individual components of skid to be provided.
d)

Vendor to provide Detailed Noise level calculations (and standards used and assumptions considered, if any) for self actuated
pressure control valves.

e)

All design and performance characteristics.

f)

P&ID for skid shall be as per Bid document attached.

g)

Completely filled Datasheet of all the supplied components/ items of skid with selected single and Model of equipment/
Instrument. (Multiple make/ model shall not be mentioned/ offered).

h)

Overall dimensions of each supplied items.

i)

Overall dimensions of each skid with proposed modules of each skid considered along with estimated dimensions.

j)

Weight of each skid.

k)

Base frame and Foundation details (suggestive) of skid.

12.2

All units of measurements in vendors specification sheets shall be same as those in purchasers data sheets.

12.3

All material specifications for the various parts in the vendors specification sheets shall be to the same standard as those in
purchasers data sheets

12.4

Vendor shall enclose catalogues giving detailed technical specifications, selection guide for decoding Model no. of offered
equipment/ instruments and other information for slam shut valve, piston operated pressure control valves, PCV with integral
SSV, flow computers, pressure relief valve, pressure transmitter, temperature transmitters, Ball valves, plug valves,
temperature gauges, pressure gauges, Modem etc. covered in the bid.

12.5

Vendors proposal including catalogues, drawings, operating and maintenance manuals etc. shall be in ENGLISH language
ONLY.

12.6

Vendor shall submit the sizing, calculation, pressure/ temperature rating details & specifications of all the instruments,
fittings and piping items, make & model, skid details etc., subsequent to award of contract. The relevant catalogue, technical
literature shall also be furnished. GAIL shall review the above and vendor to note that No post order deviation shall be
granted. Vendor shall change the make and/or models of items and specifications to meet the requirement of contract
without any price and delivery implications.

12.7

It is compulsory that bidder utilizes uniform data sheet formats enclosed along-with this document, for preparing
specifications for various instruments, including those, which are being prepared by package/ sub package vendors.
Additional information shall be provided in the given data sheets, if necessary. Items for which no format has been attached
with the document, bidder may use standard ISA formats. Use of manufacturer standard formats shall be avoided.

12.8

Vendors shall submit details of the only offered make and model of equipment/ instrument along-with the bid. Multiple
makes and / or equivalent for any item shall not be mentioned in the bid.

12.9

The Bidder shall submit all filled and signed formats including Data sheet, List of items etc

12.10

The Bidder shall provide Type approval for quoted make and model of Flow meter, Flow computer, Slam shut valve and
Regulator (PCV).

12.11

The Bidder shall furnish details provided in Technical questionnaire attached with tender doc.

12.12

VENDOR shall include in the bid, list of specific deviations, separately, if any, to this specification and all attachment
thereof, otherwise, the quotation will be deemed to be in compliance with the specification requirements and subsequent
claims for extra arising out of non-compliance with the specification will not be considered.

13.0

SPARES PHILOSOPHY:
The spare parts required during the warranty period (24 months from the date of delivery or 12 months from the date of
commissioning, whichever is earlier) should be supplied free of cost by the bidder.
Mandatory spares, commissioning spares and materials required for Erection and commissioning of skid shall be provided
along with skid. The skid consisting of Filtration and Pressure reduction/ let down, spares for Filtration and Pressure


reduction to be provided. Bidder shall provide all the relevant skid-wise spares for all the SOR items/ all the Skids. Also all
required spare parts during the warranty period (24 months from the date of delivery or 12 months from the date of
commissioning, whichever is earlier) should be supplied free of cost by the bidder.
13.1

List-Mandatory Spares: Shall be provided separately with each skid as per the following list.
i)

For Pressure reduction system (shall be supplied for each skid separately):
a) Repair kit for PCV (Diaphragm, O-rings, cone etc)
b) Repair kit for pilot (Diaphragm, O-rings etc)
c) Repair kit for SDV (Diaphragm, O-rings etc.)

02 sets. (1 set for Active and 1 set for Monitor PCV)


02 sets (1 set for Active and 1 set for Monitor PCV)
01 set.

Note to Bidder:
For Pressure regulators (PCV), Repair kit containing all consumables, components including Valve seat, pilot
filter, pilot regulator seat, diaphragms, springs, O Rings, Cone & gasket is required for all type of regulators
(active and Monitor).
For Slam shut valve, repair kit containing Valve seat, diaphragms, springs, O rings and gaskets, Slam Shut Valve
resetting handle is required.
For Relief valve, Standard spare kit containing diaphragms, valve seat springs, O rings and gaskets is required.
ii)

For filtration system (shall be supplied for each skid separately):


a)

Filter Element (installed in Filter) - 02 set per skid (one set shall consist of the No. of Filter elements installed in
complete filtration system i.e. both streams of Filtration skid.)
O-Ring for Filters (all type of O-Rings) 02 set (each set shall consist of all the O-Rings / gaskets installed in both
streams of Filters.

b)
iii)

Gasket & Studs for Skids (shall be supplied separately for each skid) :
All types of Gasket & Studs for complete skid system 01 Set.
(One set means all type of gasket/ studs. Bolts- to be supplied in quantity, at least 1 no. of each type and 20% of
installed items, gasket/ stud/ bolt of any size, which ever is higher).

iv)

For Flow Meters (shall be supplied separately for each skid):


a) Probe (all type installed in Flow meter)- 1 set
b) Lubrication Kit (Bottle/ other hardware)- I set

SPECIAL TOOLS AND EQUIPMENT:


Any special tools and equipment required for the installation or routine maintenance of DRS/ MRS shall be provided.
14.

DOCUMENTATION REQUIRED (MINIMUM 3 SETS) for each no. of DRS & MRS:
Bidder shall submit 2 sets of hard copies and one (1) digital copy on Compact Disc of following documents along with the
skid (in English language only):
a) Bill of Material and Packing List.
b) Approved P&ID (Process & Instrumentation Diagram), GAD (General arrangement drawing), Foundation drawing
and Base Frame details
c) Approved Quality Assurance Plan
d) Catalogs of each component of DRS/ MRS.
e) Construction drawings, dimensional drawing, sizing calculation, design calculations, material specifications and
technical data sheets of all components/ equipment/ instruments such as filters, valves, regulators, slam shut
Valves, Pressure Safety Valve, Creep Relief valve, Turbine meter, RPD flow Meter, Flow computer, EVC, Solar
panel, Battery, Charger, JB, Enclosure, etc.
f) Material test certificate for all the pipe and fittings material and traceability records.
g) Calibration report of Flow meters and Pressure gauge, Temperature gauge, Pressure Transmitter, Temperature
transmitter, RTD, FC, EVC etc.
h) Test Certificate (indicating Set point) of SSV, PCV, PSV and CRV.
i) Filter Construction drawing, flow calculation, cartridge details & specification;
j) Mechanical Gauge / Instrument Calibration Certificates
k) Performance Report/ Functional Test certificate.
l) Instructions and recommendations regarding installation, operation, and maintenance of all the components of the
unit.
m) FAT report, which shall include :


WPS, WPQR and PQR vetted by TPIA
Non Destructive Test reports vetted by TPIA
Dimensional check report
Painting Specification and report
Pressure Hydrostatic & pneumatic test certificates.
Warranty Certificate
TPI inspection report
n)

Instructions and recommendations regarding installation, operation, and maintenance of all the components of the
unit.
Operation and maintenance instruction manual.
Start up and commissioning procedure.
Weight of the skid.
Canopy, Foundation details and drawing.
As build drawing.
Configuration software of Flow computers.
Detailed Soft-Address in FC for SCADA/ RTU connectivity
Certificate from DVGW or equivalent.

o)
p)
q)
r)
s)
t)
u)
v)

ANNEXURES
Annexure -1
Annexure -2
Annexure -3
Annexure -4
Annexure -5
Annexure -6
Annexure -7
Annexure -8

Annexure -9
Annexure -10
Annexure -11
Annexure -12
Annexure -13
Annexure -14

Special Instruction to bidder


Bidder Scope of Supply & Installation
Schematic line diagram/ Typical P & ID
Approved Vendor List
Quality Assurance Plan
Data Sheet of Skid Components/ Equipment
Technical Questionnaire
Standard Specifications of Equipment & Technical
Requirements
FAT Procedure/ FAT Manual
PMS
CHECK LIST (TECHNICAL)
Checklist for evaluation of BEC-Technical
Standard Register List in Flow computers for SCADA
Bidders Data Requirement

BIDDING DOCUMENT No. 8000005410

ANNEXURE-1
SPECIAL INSTRUCTION TO BIDDERS
BIDDING INSTRUCTIONS:
A1.

A2

A3.

A4.

A5.
A6
A7

Bidders must follow the following guidelines while submitting their offer. Offers not
complying to these guidelines shall be rejected summarily without any intimation to
the Bidder.
a) Furnish quotations only for those items that bidder can supply strictly as per
Specifications including fulfillment of PTR (Proven Track Record) criteria as per BEC.
b) In case of any deviation in their offer, Bidder shall only furnish a technical deviation
list in format attached as Deviation form for the deviations (if any). Deviations shall
be highlighted clause wise. If discrepancy exists between the deviation list and any
other part of the offer, deviation list shall prevail. If deviation list is not furnished in the
offer, it shall be considered that no deviation exists. Generally, deviations are not
acceptable and owner reserves the right to reject the offer with out any further
clarifications. Evaluations shall be made based on deviation / compliance statement
only.
c) No correspondence whatsoever shall be entered into or entertained after the bid
submission.
d) The submission of prices by the vendor shall be construed to mean that they have
confirmed compliance with all technical specifications of the corresponding item(s).
e) Vendor to note that a pre-bid meeting shall be held in which, the vendor can seek
any clarification / confirmation if required. Vendor shall ensure that this conference is
attended by both the technical and commercial personnel of the vendor who should
have thoroughly scrutinized the tender beforehand so that all issues are finally
resolved in this meeting. Also the queries to be discussed during pre-bid meeting
shall be sent, at least 2 days in advance.
Vendor shall be responsible for selection of correct make and model of the
instruments/ equipments to meet the purchaser's specifications. In case the make/
model is required to be changed at a later stage, to meet the purchaser's
specifications as per the requisition, the same shall be done by the vendor without
any price and delivery implications.
Only the proposals which meet the Bid Evaluation Criteria (BEC) shall be technically
and commercially evaluated. In support of meeting the experience criteria as
indicated in BEC, bidders must fill in Annexure 10 A. Absence of any of the
information listed therein will be considered as not having the requisite experience
Various components of the gas metering skid (e.g. SSV, Pressure regulating valves,
Filtration system, Turbine / PD Gas flow meters, Flow computers, EVC, Flow control
Valves, DPT, Pressure & temperature transmitters, Valves) being offered shall be
from the reputed manufacturers and each component must have been in use for
similar application and worked satisfactorily for at least 4000 hrs as on bid due date.
Vendor to furnish Proven Track Record in the offer for offered model indicating model
number of the above items supplied, name of plant, name of client, type of
application, month and year of supply and commissioning of the plant, name &
address of the contact person. Items without field proven shall not be considered for
evaluation. PTR shall be furnished in the EQC forms attached along with the
supportive documentation in support of its proven performance.
Vendor shall furnish performance guarantee certificate in the formats attached
herewith. Also vendor shall be required to submit logistic support certificate from
OEM of the equipment in case of award.
VENDOR SHALL FILL AND FURNISH THE TECHNICAL DEVIATION LIST IF ANY
in the format enclosed.
Bidder to also necessarily submit the details (Make, Model, Ref Page of offered
documents No. etc. for EQC, Logistic support, Sizing calculation, Type certification/

approval, etc) of the major items offered for each SOR item separately in the
Checklist Format attached. Bidder to note that in case of unfilled, incomplete and
incorrect Checklist Format for all / any SOR item, bid is liable for rejection. Only
offered make/ Model for individual Skid component to be indicated in the checklist
format for each SOR item(s) separately.

CERTIFICATE OF LOGISTIC SUPPORT

1.

LOGISTIC SUPPORT CERTIFICATE:

1.1

Vendor must furnish Certificate for providing necessary support services in


favour of the Owner (M/s GAIL) for Gas Metering Skid committing
themselves to provide logistic to purchaser in the format furnished along
with.
For major bought-out items like Flow meter, flow computer, slam shut
valve, pressure regulator, FCV, Filtration, Transmitters etc, this certificate
must be furnished from each of the Sub vendors clearly indicating type,
model no. etc.
The Certificate must be signed with seal by the official signatory on the
companys letterhead.

1.2

1.3

CERTIFICATE FOR LOGISTICS SUPPORT


(To be signed by Manufacturer's corporate level signatory on company's
letterhead)
I, on behalf of M/s______________________________ confirm that the
Gas metering skid Items (Turbine / RPD flow meter / flow computer /
Filtration / Pressure Regulator (PCV) / FCV / SSV / EVC etc.) quoted by
M/s_______________________________ for M/s GAIL against Bid
document No.____________shall continue to be supported by us for a
period of minimum 10 years.
The quoted system shall not be withdrawn from Indian market as a matter
of our corporate policy. I further confirm that in case of placement of order
by GAIL on us, we shall continue to support GAIL in providing back-up
engineering, maintenance support and spare part support for a period of
10 years from the date of placement of order.

SIGNATURE WITH SEAL


AUTHOURIZED, SENIOR
MANAGEMENT LEVEL
SIGNATORY

DEVIATION FORM
ITEM: GAS METERING SKID
BID DOCUMENT No. ____________
Name of Vendor: Schedule of deviation: 1.
2.

3.
4.
5.

Sr. No.

Vendor shall furnish here a consolidated list of deviations taken in his


offer to the MR with necessary remarks for such deviations.
Deviations mentioned elsewhere in the offer but not listed in this form
shall not be binding on the owner. Any such deviations indicated
elsewhere (other than this form) shall render the offer non-responsive
and shall be liable to be rejected.
All the other clauses of the MR, not listed herein shall be deemed to be
fully complied by the vendor.
All other clauses of the MR shall be deemed to be fully complied by the
vendor.
Only the deviations listed herein, in conjunction with the MR shall
constitute the contract requirements for the award of job to the vendor.

Spec No

Clause No

Requirements as
per TENDER

Deviations
by Vendor

Clarifications

Remarks

Signature of authorized Signatory of vendor


Name of authorized signatory
Stamp & Date

Note : Additional sheets may be used as required.

EQUIPMENT QUALIFICATION CRITERION (EQC) FORM

Proven Track Record for the offered Filtration system, Slam shut valve, Pressure regulators, safety valves, Flow meters, flow computers,
FCV etc. shall be furnished by the bidder in the format given below.

Sr.
No

Make & Model


No. of offered
Instrument

Manufacturing
location

Manufacturing since
date/year

Name of the project


installation with PO
nos.

Type of Application

Working successfully
since Date / year

Details of major
breakdowns till
date (if any)

Users Name,
Address Tel /FAX
No. of Contact
person

Remarks

The PTR for each item shall be furnished in the above format separately. In addition for the flow meters and Flow computers bidder shall furnish the documentary
evidence in support of the proven performance like, Type Approval Certificate along with calibration certificates/ reports approved by MNI, PTB or equivalent Flow Labs
of repute.

BIDDING DOCUMENT NO. 8000005410

ANNEXURE-2
BIDDER SCOPE OF SUPPLY
&
INSTALLATION

BIDDERSS SCOPE OF SUPPLY AND INSTALLATION

DESCRIPTION
1.0

Supply

Installation

Instruments

1.1

All field mounted instruments & equipments.

By Bidder

By Bidder

1.2
a)

All instruments in
Gas metering skid consisting of Filtration,
Pressure Letdown & gas metering with/ without
flow control in skid
Filtration with pressure reduction skid
All instruments in Field mounted Solar panel for Gas
metering system package

By Bidder

By Bidder

By Bidder

By Bidder

--

BY GAIL

b)
1.3
1.4

Installation of skid package at GAIL Site.

2.0

Panels

2.1

Field mounted solar powered flow computers


along with Solar power system with charger,
battery etc.

3.0

Cabinet and Junction boxes

3.1

By Bidder

----

JB for interconnection of field signals and FC

By Bidder

By Bidder

3.2

JB/ enclosure for Battery, GSM, field Instruments

By Bidder

By Bidder

3.3

Separate junction box for:

a)

For 4-20 mA dc signals (intrinsic / non-intrinsic)

By Bidder

By Bidder

b)

For RTD signals

By Bidder

By Bidder

c)

Flow meter signals

By Bidder

By Bidder

d)

For contact signals

By Bidder

By Bidder

e)

For power supply to various instruments

By Bidder

By Bidder

f)

For any other signal not covered but required


for completion of job

By Bidder

By Bidder

3.4

Cabinet (covered from all sides and top) for


entire Skid package (DRS & MRS)

By Bidder

By Bidder

3.5

Bottom Checkered plate of adequate strength

By Bidder

By Bidder

4.0

Cables

4.1

Between field instruments and junction boxes


and local panels in the skid

By Bidder

By Bidder

4.2

Suitable Hardware, software & Communication


Cables for all field Instruments including Flow
Computer/ EVC

By Bidder

---

4.3

Any other cable / other Harware/ Software not


covered but required for completion of job.

5.0

Installation materials

5.1

By Bidder

By Bidder

Impulse tubing/ piping, tube/ pipe fittings, valves,


valve manifolds etc. as required.

By Bidder

By Bidder

5.2

Valves, pipes and fittings, Blind flanges, Matching


end flanges of skid,

By Bidder

By Bidder

5.3

Cable trays, cable glands and accessories

By Bidder

By Bidder

5.4

Instrument stanchions, supports, canopies/


sunshields, supports for cable tray all
consumables.

By Bidder

By Bidder

Cabinet for custody transfer instruments,


platform and cross over for operation &
maintenance of the equipment. Grouting
accessories nuts and bolts
6.0 Earthing

By Bidder

By Bidder

6.1

Earthing strips, earthing cable required for skid/ field


instrument
Earthing PIT & Interconnection between pit and
panel/ skid

By Bidder

By GAIL

By GAIL

By GAIL

7.0

Power Supply Distribution for Gas metering


system package

By Bidder

By Bidder

8.0

Civil works & Foundation for installation of skid

By GAIL

9.0

Special tools and tackles

By Bidder

10.0 Spares and spare parts

By Bidder

11.0 Documentation as per this package

By Bidder

5.5

6.2

By GAIL

NOTES:
1. Installation and Supervision & Commissioning of skid is in the Scope of Bidder.
Bidder shall quote Man-day Rate for Each Skid/ SOR items separately.
The Quoted rate shall be valid for 24 months from the date of issuance of FOI.
.
2. Items not mentioned in the above list, but mentioned elsewhere in tender document
Shall also be supplied and installed by the bidder.

BID DOCUMENT NO. 8000005410

ANNEXURE-3
General Line Diagram
&
Typical P&ID
for

Annual Rate Contract for


District Regulating Station (DRS) & Turbine/
RPD Meter based Metering Station (MRS)

GENERAL LINE DIAGRAM FOR DRS (SOR Item-1)


PRESSURE REDUCTION SYSTEM

DRY GAS FILTRATION


PSV

Vent

PG

PG

CRV
Vent

PG

Integral
SSV &
PCV(M)

4, 300#

3/4

NRV

BV 4, 300#

Vent

OUTLET
Integral
SSV &
PCV(M)

INTLET
1

BV,4

PCV(A)

DPG

NOTES:

2.
3.
4.
5.
6.
7.
8.
9.

CRV

PG

PG

1.

TG

3/4
PSV

Vent

PG

DPG

BV 2

BV,4

PCV(A)

Vents shall be located at a safe height (3 meters above the highest working platform)
with rain cap, flame arrester.
PSV of filter shall be sized for fire case.
Bidder to select Valve/ equipment sizes as per sizing calculation
All Ball Valves (BV) shall be full bore
DPG shall have tapping/ connection
Blind flange/ blind Plug shall be provided in each drain connection.
sensing line shall be provided for PCV & SSV.
Globe Valve of 1 required for Drain and size required for PG & Sensing lines for PCV/SSV
Suitable manifold is required for PG and DPG

1
3/4

LEGEND

Ball Valve
Globe Valve

GENERAL LINE DIAGRAM FOR DRS (SOR Item- 2)


DRY GAS FILTRATION
Vent

PRESSURE REDUCTION SYSTEM


PG

Integral
SSV &
PCV(M)

PG
1

4, 300#

CRV

PSV
PG

Vent

6 BV

PCV(A)

Vent

PSV

PG

NRV

CRV

PG

Vent

INTLET
1

Integral
SSV &
PCV(M)

6 BV

PCV(A)

DPG

NOTES:

2.
3.
4.
5.
6.
7.
8.
9.

BV 6, 300#

OUTLET

1.

TG

3/4

DPG

BV 3, 300#

PG

Vents shall be located at a safe height (3 meters above the highest working platform)
with rain cap, flame arrester.
PSV of filter shall be sized for fire case.
Bidder to select Valve/ equipment sizes as per sizing calculation
All Ball Valves (BV) shall be full bore
DPG shall have tapping/ connection
Blind flange/ blind Plug shall be provided in each drain connection.
sensing line shall be provided for PCV & SSV.
Suitable manifold is required for PG and DPG
Globe Valve of 1 required for Drain and size required for PG & Sensing lines for PCV/ SSV

1
3/4

LEGEND

Ball Valve
Globe Valve

GENERAL LINE DIAGRAM FOR MRS (SOR Item-3)


DRY GAS FILTRATION

PRESSURE REDUCTION SYSTEM

Vent

PSV

CRV
Integral
SSV &
PCV(M)

PG

PCV(A)

PG

4, 300#

Vent

PG

DPG

3/4

2 BV

EVC
P

TE

Vent
PG

1
NRV

BV 1, 300#

CRV
PSV

Vent

Integral
SSV &
PCV(M)

PG

PG

Vent

2 G65
RPD Meter

TE

Vent

2 BV

4 150#
2 BV

OUTLET

PCV(A)

1
INLET

3/4

EVC

DPG

3/4
NOTES:
1.
Vents shall be located at a safe height (3 mtrs. Above the highest working platform)
with rain cap and flame arrester.
2.
PSV shall be sized for fire case.
3.
Bidder to select Valve/ equipment sizes as per sizing calculation
4.
All Ball Valves (BV) shall be full bore
5.
DPG shall have tapping/ connection
6.
Blind flange/ Plug to be provided in each drain connection.
7.
Both RPD meters shall be connected to independent EVCs
8.
sensing line to be provided for PCV & SSV.
9.
Globe Valve of 1 required for Drain and size required for PG & Sensing lines for PCV/SSV
10.
Suitable manifold is required for PG and DPG
11.
Downstream valve of PRS, vent/ CRV of PRS shall also be of 300# pressure class rating.

LEGEND

Ball Valve
Globe Valve

GENERAL LINE DIAGRAM FOR MRS (SOR Item- 4)


PRESSURE REDUCTION SYSTEM

DRY GAS FILTRATION


Vent

CRV

PSV

PG

PG

Vent

COMMUNICATION
SCADA SYSTEM &
GSM Connectivity

FQY
3

Integral
SSV &
PCV

1.5
PG

ACTTIVE PCV

4, 300#

3/4

TE

Vent
PG

DPG

BV1.5
Vent

INLET

PSV

Integral
SSV &
PCV

3 G160
RPD meter

CRV
PG

PG

NRV

4150#

TE

Vent

OUTLET

3
ACTTIVE PCV

1.5

3/4

3 G160
RPD meter

DPG
GSM Connectivity

FQY

COMMUNICATION/
SCADA SYSTEM

NOTES:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Vents shall be located at a safe height (3 mtrs. Above the highest working platform)
with rain cap and flame arrester.
PSV shall be sized for fire case.
Bidder to select Valve/ equipment sizes as per sizing calculation
All Ball Valves (BV) shall be full bore
DPG shall have tapping/ connection
Blind flange/ Plug to be provided in each drain connection.
Both RPD meters shall be connected to independent flow computers
sensing line to be provided for PCV & SSV.
Globe Valve of 1 required for Drain and size required for PG & Sensing lines for PCV/SSV
Suitable manifold is required for PG and DPG
Downstream isolation valve of PRS, vent/ CRV of PRS shall also be of 300# pressure class rating.

3 BV

LEGEND

Ball Valve
Globe Valve

GENERAL LINE DIAGRAM FOR MRS (SOR Item- 5)


PRESSURE REDUCTION SYSTEM

DRY GAS FILTRATION


Vent

CRV

PSV

PG

PG

Vent

COMMUNICATION
SCADA SYSTEM &
GSM Connectivity

FQY

2
Integral
SSV &
PCV

PG

4, 300#

ACTTIVE PCV

3/4

4 BV

TE

Vent
PG

DPG

3/4

BV 2
PSV

Vent

INLET

Integral
SSV &
PCV

4 FCV

CRV
PG

PG

Vent

4, G250/ 400
Turbine Meter

NRV

TE

4 BV

OUTLET

4 BV

ACTTIVE PCV

3/4

DPG

NOTES:
1.
Vents shall be located at a safe height (3 mtrs. Above the highest working platform)
with rain cap and flame arrester.
2.
PSV shall be sized for fire case.
3.
Bidder to select Valve/ equipment sizes as per sizing calculation
4.
All Ball Valves (BV) shall be full bore
5.
DPG shall have tapping/ connection
6.
Blind flange/ Plug to be provided in each drain connection.
7.
Both Turbine meters shall be connected to independent flow computers
8.
sensing line to be provided for PCV & SSV.
9.
Turbine Meter with 10D + flow conditioner (at U/S) and 5D (at D/s) shall be provided as per AGA.
10.
Globe Valve of 1 required for Drain and size required for PG & Sensing lines for PCV/SSV
11.
Suitable manifold is required for PG and DPG
12.
FCV shall be controlled through PID signal from Flow computer
13.
Downstream isolation valve of PRS, vent/ CRV of PRS shall also be of 300# pressure class.

4 150#

FQY

COMMUNICATION/
SCADA SYSTEM &
GSM connectivity

LEGEND

Ball Valve
Globe Valve

GENERAL LINE DIAGRAM FOR MRS (SOR Item- 6)


PRESSURE REDUCTION SYSTEM

DRY GAS FILTRATION


Vent

CRV

PSV

PG

EVC

Vent

PG

PG

4,150#

PCV(A)

Integral
SSV &
PCV(M)

2 BV

3/4

TE

Vent
PG

DPG

4 150#

NRV

BV 1
PSV

Vent

INLET

Integral
SSV &
PCV

CRV
PG

PG

Vent

2, G65
Meter

RPD

TE
2 BV

OUTLET

2 BV
PCV(A)

3/4

2, G65
RPD Meter

DPG
GSM Connectivity

EVC

COMMUNICATION/
SCADA SYSTEM

NOTES:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Vents shall be located at a safe height (3 mtrs. Above the highest working platform)
with rain cap and flame arrester.
PSV shall be sized for fire case.
Bidder to select Valve/ equipment sizes as per sizing calculation
All Ball Valves (BV) shall be full bore
DPG shall have tapping/ connection
Blind flange/ Plug to be provided in each drain connection.
Both RPD meters shall be connected to independent EVCs
sensing line to be provided for PCV & SSV.
Globe Valve of 1 required for Drain and size required for PG & Sensing lines for PCV/SSV
Suitable manifold is required for PG and DPG

LEGEND

Ball Valve
Globe Valve

GENERAL LINE DIAGRAM FOR MRS (SOR Item- 7)


PRESSURE REDUCTION SYSTEM

DRY GAS FILTRATION


Vent

PG

Integral
SSV &
PCV

BV 2
PG

4,150#

CRV

PSV

Vent

PG

PCV(A)

FQY

3 BV

3/4

GSM Connectivity &


COM thru SCADA /
RTU SYSTEM

TE

Vent
PG

DPG
3 BV

BV 2
PSV

Vent

INLET

CRV

Integral
SSV &
PCV

PG

Vent

PG

3 G160
RPD Meter

TE

NRV

3 BV

BV 2
PCV(A)

DPG

3 BV
1

3/4

P
GSM Connectivity &
COM thru
SCADA/ RTU
SYSTEM

F
OUTLET

FQY

NOTES:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

4 150#

Vents shall be located at a safe height (3 mtrs. Above the highest working platform) with rain cap and flame
arrester.
PSV shall be sized for fire case.
Bidder to select Valve/ equipment sizes as per sizing calculation
All Ball Valves (BV) shall be full bore
DPG shall have tapping/ connection
Blind flange/ Plug to be provided in each drain connection.
Both RPD meters shall be connected to independent flow computers
sensing line to be provided for PCV & SSV.
Globe Valve of 1 required for Drain and size required for PG & Sensing lines for PCV/SSV
Suitable manifold is required for PG and DPG

LEGEND

Ball Valve
Globe Valve

GENERAL LINE DIAGRAM FOR MRS (SOR Item- 8)


PRESSURE REDUCTION SYSTEM

DRY GAS FILTRATION


Vent

CRV

PSV

PG

PG

Vent

FQY

BV 2

PG

Integral
SSV &
PCV(M)

4, 150#

PCV (A)

4 BV

3/4

GSM Connectivity &


COM thru SCADA /
RTU SYSTEM

TE

Vent
PG

DPG

4 150#

4 FCV

BV 2
Vent

PSV

INLET

Integral
SSV &
PCV(M)

4 G250/ 400
Turbine Meter

CRV
PG

PG

TE

NRV

Vent

OUTLET

4 BV

BV 2

4,150 BV

PCV(A)

1
1

3/4

DPG

NOTES:
1.
Vents shall be located at a safe height (3 mtrs. Above the highest working platform)
with rain cap and flame arrester.
2.
PSV shall be sized for fire case.
3.
Bidder to select Valve/ equipment sizes as per sizing calculation
4.
All Ball Valves (BV) shall be full bore
5.
DPG shall have tapping/ connection
6.
Blind flange/ Plug to be provided in each drain connection.
7.
Both Turbine meters shall be connected to independent flow computers
8.
sensing line to be provided for PCV & SSV.
9.
Globe Valve of 1 required for Drain and size required for PG & Sensing lines for PCV/SSV
10.
Turbine Meter with 10D + flow conditioner (at U/S) and 5D (at D/s) shall be provided as per AGA.
11.
Suitable manifold is required for PG and DPG
12.
FCV shall be controlled through PID signal from Flow computer

P
GSM
Connectivity

FQY

COMMUNICATION/
SCADA SYSTEM

LEGEND

Ball Valve
Globe Valve

BIDDING DOCUMENT No. 8000005410

ANNEXURE-4
VENDOR LIST
For
BOUGHT-OUT SKID ITEMS
For
DRS & MRS

LIST OF VENDORS FOR BOUGHT-OUT ITEMS


1. PCV (Pressure Regulators) & Slam shut valve:
1)
2)
3)
4)
5)
6)
7)
8)

M/s Emerson Process Management


M/s Gortor Controls BV
M/s Pietro Fiorentini S.p.a
M/s RMG, Germany
M/s Nirmal, Mumbai
M/s Dresser Inc, USA
M/s Tormene Gas Technology
M/s Samson AG Mess-und Regeltechnik

2. Dry gas Filter:


1) M/s Ultra filter
2) M/s Multitex
3) M/s Grand Prix Fab Pvt Ltd.
4) M/s PECO USA
5) M/s Forain, Italy
6) M/s Flashpoint Equipment Pvt Ltd
7) M/s Gujarat Otofilt
8) M/s Filtration Engineers India Pvt Ltd
9) M/s Perry Equipment (USA)
10) M/s Faudi Filter GmbH (Germany)
11) M/s Ravi Techno Systems (Mumbai)
12) M/s Siirtec NIGI SPA (Italy)
13) M/s Axsia Howmar Ltd. (UK)
14) M/s Filtan Filter Anlagenbau GmbH (Germany)
15) M/s Plenty Filters (UK)
16) M/s Burgess Manning, USA
3. Filter Elements
1)
2)
3)
4)

M/s PECO-FACET
M/s PALL-FILTERITE
M/s VELCON
M/s BURGESS MANNING

4. Turbine Flow Meter


1)
2)
3)
4)
5)
6)
7)

M/s Instromet (Belgium)


M/s RMG (Germany)
M/s Elster (Germany)
M/s Daniel Industries (USA)
M/s Rockwin Flowmeter
M/s ITRON
M/s VemmTec

5. Rotary Positive Displacement (RPD) Meter


1)
2)
3)
4)
5)
6)

M/s Romet, Canada


M/s Dresser(General Electric Co)
M/s ITRON
M/s RMG (Germany)
M/s Actaris (M/s Schlumberger)
M/s Instromet

6. Flow Computer
1)
2)
3)
4)
5)
6)
7)

M/s Daniel Measurement & control


M/s Instromet International, Belgium
M/s RMG, Germany
M/s Omni Flow computers
M/s Bristol Babcock
M/s Thermo Scientific
M/s Emerson Process management

7. Volume Corrector (EVC)


1)
2)
3)
4)
5)
6)
7)

M/s Schlumberger Gmbh, Germany (M/s Actaris)


M/s Barton Instruments, UK
M/s Romet, Canada.
M/s Daniel Flow Products inc.,USA
M/s Dresser
M/s Instromet-International, Belgium
M/s RMG Messtechnik Gmbh, Germany

8. Flow Control Valve (FCV)


1)
2)
3)
4)
5)
6)
7)
8)

M/s Fouress Engineering


M/s Fisher Xomox
M/s MIL Controls Ltd.
M/s Kent Introl (KOSO)
M/s Samson Control
M/s Dresser Industries
M/s Fisher Controls
M/s Valvitalia, Italy

9. Junction Box & Cable Gland


1)
2)
3)
4)
5)

M/s Ex-protecta
M/s Baliga
M/s Sudhir
M/s FLAMEPROOF CONTROL GEARS
M/s FLEXPRO ELECTRICAL

10. RTD (Resistance Temp. Detector)


1)
2)
3)
4)
5)

M/s General Instruments Ltd., Mumbai


M/s Nagman Sensors (Pvt) Ltd.
M/s Pyro Electric, Goa
M/s Altop Industries Ltd.
M/s ABB Automation Ltd.

11. Ball Valve


1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)

M/s Audco Valve


M/s Microfinish Valves
M/s Flowchem
M/s Virgo Engineers
M/s Larsen &Toubro
M/s Viza Valves, China
M/s Hopkinsons Limited (UK)
M/s O.M.S. Saleri (Italy)
M/s Fraz Schuck GMBH, Germany (Formerly Borsig)
M/s Petrol Valves SRL
M/s Nuovo Pignone (Italy)
M/s Perar SPA (Italy)

12. Pressure Gauge, Diff Pressure Gauge & Temperature Gauge


1)
2)
3)
4)
5)
6)
7)
8)

M/s Waree Instruments


M/s Wika Instruments
M/s Hirlekar
M/s FGB
M/s General Instruments
M/s H Guru
M/s A N Instruments Pvt. Ltd.
M/s Dresser Inc

13. Globe Valves and Check valves


1)
2)
3)
4)
5)
6)
7)
8)
9)
10)

M/s BDK Engineering India Ltd. Hubli, Karnataka


M/s Flowchem Valves
M/s Shayburg Valves Pvt. Limited, Navi Mumbai
M/s Ornate valves; Mumbai
M/s Panchvati valves; Mumbai
M/s AV Valves Ltd., Agra
M/s Shalimar Valves Pvt. Ltd.,Navi Mumbai
M/s Neco Schubert & Salzer Ltd. New Delhi
M/s Larsen & Toubro Ltd. (Audco India Limited, Chennai)
M/s KSB Pumps Ltd

14. Pressure safety valve


1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)

M/s SEBIM Valves (Mekaster)


M/s Bliss Anand
M/s BHEL
M/s Larson &Toubro Ltd
M/s Crosby/ Anderson Greenwood
M/s Keystone Valves
M/s Instrumentation Ltd.
M/s Tyco Sanmar Ltd.
M/s Nakakita Seisakusho Co Ltd
M/s Nuovo Pignone SPA (Italy) (GE Oil co)
M/s Parcol SPA
M/s Safety Systems UK Ltd
M/s Tai Milano SPA
M/s Weir Valves & Controls France

15. SS FITTINGS / TUBING (No other makes shall be acceptable)


1)
2)
3)
4)

M/s SWAGE LOCK (USA)


M/s PARKER (USA)
M/s HOKE (USA)
M/s Sandvik, Sweden (for Tubing)

16. Gaskets- Spiral Wound


1)
2)
3)

M/s IGP Engineers Pvt. Ltd., India


M/s Madras Industrial Products, India
M/s Starflex Sealing India Pvt Ltd, India

17. Control & Signal Cables


1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)

M/s Associated Cable


M/s Associated Flexibles
M/s Universal Cables Ltd, India
M/s Delton Cables Ltd, India
M/s Brook
M/s KEI Industries Ltd INDIA
M/s CMI Limited
M/s Cords Cable Industries Ltd, India
M/s Radiant Cables Pvt Ltd, India
M/s Reliance Engineers Ltd., India
M/s Suyog Electricals Ltd, India
M/s Thermo Cables Ltd
M/s Udey Pyrocables Pvt Ltd, India

18. Fasteners
1)
2)
3)
4)
5)
6)
7)
8)
9)

M/s AEP Company, India


M/s Boltmaster India Pvt. Ltd. India
M/s Deepak Fasteners Limited India
M/s Fasteners & Allied Products Pvt. Ltd.
M/s Hardwin Fasteners Pvt. Ltd. India
M/s J.J. Indistries India
M/s Multi fasteners Pvt. Ltd. India
M/s Nexo Indistries, India
M/s Pioneer Nuts and Bolts Pvt. Ltd.

19. Flanges & Fitting, Block Forged-Carbon Steel


1)
2)
3)
4)

M/s Eby Fasteners, India


M/s Leader valves Ltd. India
M/s M.S. Fitting Mfg. Co. Pvt. Ltd. India
M/s R. N. Gupta & Co. Ltd. India

20. Flanges & Fittings from Seamless Pipe-Carbon Steel


1)
2)
3)
4)
5)
6)
7)
8)
9)

M/s CD Engineering Co., India


M/s CD Industries (Ghaziabad), India
M/s Chaudhry Hammer Works Ltd, India
M/s Echjay Industries Pvt Ltd, (Rajkot), India
M/s Golden Iron & Steel Works, India
M/s J.K. Forgings, India
M/s JAV Forgings (P) Ltd, India
M/s Metal Forgings Pvt Ltd, India
M/s Pradeep Metal Limited, India

21. Pipe-Carbon Steel (Seamless) to ASTM Std.


1)
2)
3)
4)
5)
6)
7)
8)
9)

M/s BHEL (Trichy), India


M/s Heavy Metals & Tubes Ltd, Mehsana, India
M/s Indian Seamless Metal Tubes Ltd, Ahmednagar, India
M/s Indian Seamless Metal Tubes Ltd, Baramati, India
M/s Jindal Saw Ltd (Nashik Works), India
M/s Mahalaxmi Seamless Ltd, India
M/s Maharashtra Seamless Ltd, India
M/s Sainest Tubes Pvt Ltd, India
M/s Wuxi Erquan Special Steel Tube Co. Ltd.

22. Pressure/ Diff. Pressure & Temperature Transmitter


1)
2)
3)
4)

M/s Fisher Rosemount (Emerson)


M/s Yokogawa
M/s Fuji
M/s Honeywell

23. Barriers
1)
2)
3)

M/s MTL
M/s STHAL
M/s P&F

24. Instrument Valves & Manifolds


1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)

M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s
M/s

Anderson Greenwood Crosby


Astec Valves & Fittings Pvt Ltd, India
Aura Inc.
Autoclave Engineers Fluid Components
Chemtrols Engineering Ltd, India
Circor Instrumentation Ltd
Excel Hydro Pneumatics Pvt Ltd, India
Excelsior Engg Works, India
Ham-Let (Israel-Canada) Ltd
Hyd-Air Engg. Works Lonavala, India
Micro Precision Products Pvt Ltd, India
Parker Hannifin Corporation
Precision Engineering Industries, India
Prime Engineers
Swagelok Co.
Swastic Engineering Works, India
Technomatic (India) Pvt Ltd, India

Notes:
In general, the bought-out skid items/ components/ equipment/ instruments shall be offered from the
above vendor list.
For procuring bought-out items from vendors other than those listed above, Bidder shall take prior
approval for Make and Model No. of the offered skid item/ component. Only in exceptional case(s),
additional vendors shall be approved by GAIL based on past experience of offered item/ equipment,
provided it meets the following condition:
i)

The vendor/ supplier of bought out item(s) is a regular and reputed manufacturer/ supplier of
that item(s) for intended services and the sizes being offered is in their regular
manufacturing/ supply range.

ii)

The vendor/ supplier should have supplied these items for similar application to reputed
natural gas transmission / distribution companies, in quantities at least half the numbers (at
least 50% quantity being supplied) of required quantity in this tender of maximum size and
rating of item(s) as required for intended services in a single purchase order.

iii)

The supplied Item is working satisfactorily for a minimum 12 months period. Certification is
required from end user (authorised representative) on their letter head along with name,
designation, address phone number and e-mail id.

iv)

The vendor/ supplier should not be in the Holiday list of GAIL/ their consultant.

v)

For any other vendor (other than listed above), Documentary evidence i.e. PO copies,
Inspection release note, Certificate and performance report from end user substantiating the
above shall be submitted by bidder for approval of GAIL.
However, for any other item(s), for which the vendor list is not provided by GAIL, bidders
can supply those item(s) from reputed vendors/ suppliers who have earlier supplied same
item(s) for the intended services in earlier project(s) of GAIL and the item(s) offered is in
their regular manufacturing/ supply range.

BIDDING DOCUMENT No.


8000005410

1.1
2

2.1

Description

PROJECT : DRS/ MRS

DATE:

Job No. :

QUALITY ASSURANCE PLAN

CLIENT: M/s GAIL (India) Ltd.


P.O. NO. :
SR No

QAP No.:

MANUFACTURES NAME & ADDRESS:


Sheet No.
Characteristic

Class

Type of Check

Quantam of
Check

Reference
Documents

Inspection By

Acceptance Norms

Format of Records

CLIENT/TPI
M

vendor

Drawings & Calculations


P & ID, GAD, BOM, QAP for skid,
Mechanical Datasheet, Instrument
Datasheet, FAT

Complete Skid

Major

Submittals

100%

Technical Spec. and


Approved Datasheet
Datasheets

100%

Approved Datasheet Approved Datasheet

MFR'S. TC /
Compliance

100%

Approved Datasheet Approved Datasheet

MFR'S. TC /
Compliance

100%

Approved Datasheet Approved Datasheet /


/ Manufacturing STD Manufacturing STD

MFR'S. TC /
Compliance

Mfrs Format

Incoming Material Identification of Broughtout Items

Ball valves,Globe valves , Gate

Material TC for valves

Sr. No. verification ,


Major verification with
datasheet

Dimension- Size, Rating, End


connection

Major

Testing of valves (Body


hydro,hydro seat/backseat,air
seat)/applicable test

Major Leak Test

Visual,
Measurement

2.2

Pressure Gauges , Diff. Pressure Gauge

Calibration, Accuracy, Range,


Size, Dimension & End
connection

Major

Visual,
Measurement

100%

Approved Datasheet Approved Datasheet

MFR'S. TC /
Compliance

2.3

Turbine Meter / RPD meter, Flow


computer & EVC

Size, Range, Calibration,


Accuracy, configuration

Major

Visual,
Measurement

100%

Technical Spec. and


Approved Datasheet
Datasheets

MFR'S. TC /
Compliance

2.4

Pipe, Pipe Fitting, Flanges for


Interconnecting Piping

Material TC, Size &


Dimension

Chemical Analysis,
Major Physical Test, Size
& Rating

100%

Approved Piping
Material Spec

Approved Piping
Material Spec

MFR'S. TC /
Compliance

3.1

Raw Material -Material TC,


Size & Dimension

Chemical Analysis,
Major Physical Test, Size
& Rating

100%

Approved Piping
Material Spec

Approved Piping
Material Spec

MFR'S. TC /
Compliance

3.2

WPS & PQR

Major

100%

As per ASME SEC.


IX

As per ASME SEC. IX

WPS / PQR from


Record

--

--

--

--

Equipments

3.3

Welders
Qualification &

As per ASME SEC.


V
As per ASME SEC.
V

Approved Drawing &


Reports
Standards
As per ASME SEC. VIII
Reports
Div: 1
As per ASME SEC. VIII
Reports
Div: 1

100%

Approved Drawing

Approved Drawing

Reports

--

Major Strength

100%

Approved Drawing

1.3 times of Design


Pressure

Reports

--

Welders
Major Qualification &
Welding

100%

Approved WPS /
PQR

As per ASME SEC. IX

WPS / PQR

In Process Inspection

Major Fit Up

100%

DP test on Fillet Welds

Major Surface Defects

100%

Radiography after Final Weld

Major Internal Defects

Full

3.6

Visual & Dimensional Check

Surface Finish &


Major
Dimensions

3.7

Hydro Test

3.4

Cartridge Filter

3.5

4
4.1

Approved Drawing

Welding, NDT & Testing for Interconnecting Piping

WPS / PQR

WPS / PQR

BIDDING DOCUMENT No.


8000005410

Description

Characteristic

Class

Type of Check

Quantam of
Check

4.3

Radiography Test

To identify internal surface


defects on Buttweld joints

4.4

Hydro Testing of Interconnecting Piping

Hydro Testing 29 Barg for


150#, 73.5 Barg for 300# ,
Major Strength
155 Barg for 600 # for 30 Min

100%

4.5

Pneumatic Leak Test of Interconnecting


Piping

Pneumatic Leak Test at 7


Barg

Major Strength

100%

5.1

Material TC for Body & Trim

Major

Chemical Analysis &


Physical Test

100%

5.2

Dimension- Size, Rating, End


connection

Major

Visual,
Measurement

100%

Inspection By

Acceptance Norms

Format of Records

Internal Inspection
Report

CLIENT/TPI
M

vendor

100% of total
ASME Sec V
joints

ASME SEC.31.3

Major Radiographic test

100% all Butt


weld joints
ASME Sec V
(including
Vent &
Drain)

ASME SEC.31.3 ( table


341.3.2,Normal &
Interpretation Report
Category M fluid ) ,
ASME Sec V

Approved P&ID &


GAD

As per ASME SEC.31.8


Inspection Report
& IGE/TD/13

Approved P&ID &


GAD

As per ASME B.31.8 &


IGE/TD/13

Inspection Report

MFR'S. TC

MFR'S. TC & Reports

100%

Test Reports

100%

Test Reports

Mfg. of SSV, PCV, CRV, PSV

5.3

Body Hydro Test as per std.

Major Leak Test

5.4

Set Point

Major

Visual,
Measurement

Final Inspection of Skid Assembly

6.1

Final Dimensional/ Visual Inspection

Complete Skid

Major Visual Inspection

6.2

Painting of Skid

Painting

Major

6.3

Factory Acceptance Test

as per approved FAT


procedure

Major Performance Test

7.1

Reference
Documents

Major Dye Penetration test

Approved Data
Sheet

SSV, PCV, CRV, PSV

Job No. :

Sheet No.

To identify external surface


defects

DATE:
MANUFACTURES NAME & ADDRESS:

D P T of fillet weld joints

4.2

PROJECT : DRS/ MRS

QUALITY ASSURANCE PLAN

CLIENT: M/s GAIL (India) Ltd.


P.O. NO. :
SR No

QAP No.:

Visual & Final DFT


measurement

Approved Data Sheet

100%

Approved P&ID &


GAD

Approved Data Sheet

Reports

--

100%

Approved Painting
Spec.

Approved Painting
Spec.

Reports

--

100%

Approved Data
Sheet

Approved Data Sheet

FAT Report

--

100%

Approved
specification

As per approved
specification

History Docket

Final Documentation:
Design & Calculation, Material compliance
report as per EN 10204 3.1, Calibration
Certificates, GAD, P & ID, Final FAT
History docket
report, NDT reports, Hydro & Pneumatic
report,Test certificate of SSV, PCV, CRV,
FCV, PSV

Major

Verification of
records

BIDDING DOCUMENT No.


8000005410

Description

PROJECT : DRS/ MRS

DATE:

Job No. :

QUALITY ASSURANCE PLAN

CLIENT: M/s GAIL (India) Ltd.


P.O. NO. :
SR No

QAP No.:

MANUFACTURES NAME & ADDRESS:


Sheet No.
Characteristic

Class

Type of Check

Quantam of
Check

Reference
Documents

Inspection By

Acceptance Norms

Format of Records

3.1 certificate required


M : Manufacturer
Made By:

Chkd By:
Legend:

P : Performer
W : Witness ;

Approved By:
H : Hold

R : Review ; A: Approval; RW: Random


Witness
V : Verification

CLIENT/TPI
M

M/s

vendor

E-Tender no. 8000005410

ANNEXURE - 6

DATA SHEETS for SKIDS EQUIPMENTS

DATA SHEET INDEX

1. Ball Valve - NB - 2 and above


2. Ball Valve NB - below 2"
3. Check valve
4. Plug valve NB- 2 and above
5. Plug valve NB- below 2",
6. Globe valve below 2
7. Globe valve 2 and above
8. Pressure Safety Valves & CRV
9. Cartridge Filter
10. Pressure Gauges
11. Diff. Pressure Gauge
12. Temperature Gauges
13. Pressure Transmitter
14. Resistance Temperature Detector
15. Slam Shut Valve
16. Pressure Control Valve (self-actuated Regulator)
17. Turbine Flow Meter
18. Rotary Positive Displacement Meter
19. Flow Straightener (for Turbine flow Meter)
20. Field Mounted Flow Computer
21. Special Instruction to Vendor for FC
22. Electronic Volume Corrector
23. Differential Pressure Transmitter
24. Flow control valve
25. Pipework & Fittings

1.
UNITS : Gas Flow - SCMD,

Data Sheet- Ball Valves (2 & above)

Pressure - Kg/cm2g , Temperature Deg C

Valve Manufacturer

Size (NB)

Service

Natural Gas

Purchasers Specification

Full Bore Ball Valves

Design

Operating Pressure

Corrosion Allowance (mm)

Location

Valve Type (Floating or


Trunion / Pivot Mounted)

10

End Connections

Flanged (As per ASME B16.5)

11

Flanges

(a)

13

Locking arrangement

Lock Open

14

Stem Extension Required

NO

16

Gear Operator Required

YES

17

Gas Power Actuator Required

NO

18

Actuator Specification No.

19

Valve material Specification

20

As per approved vendor list *


Rating

Pressure

Standard

API 6D (latest) / BS : 5351

Design Temperature

**

(-)28 Deg C to +65 Deg C

Operating Temperature

**

-20 - 60

1.5 mm
Above Ground
Bore (Full/ Reduced)

Actuator Data Sheet No.

FLOATING BALL (for sizes 4 and below);


Trunion mounted for 6 and above

RF

FULL BORE

(a)

(for Sizes > 4" NB)

Serrated

For Size of 4 and below, Gear operator not


required

N.A.

N.A.

Part

Specified Material

Material Offered (Equivalent or Superior)

(a)

Body

ASTM A216 Gr. WCB/ A234 Gr. WPB/ A350


Gr. LF2/ A352 Gr. LCB

(b)

Ball

(ASTM A216 Gr. WCB/ A234 Gr. WPB/


A395) + 75 microns ENP / AISI 410

(c)

Body Seat Ring

PTFE / RPTFE / DERLIN

(d)

Seat Seal

N. A.

(e)

Stem (shall be anti-blow out type)

AISI 4140 + 75 microns ENP / AISI 410

(f)

Stem Seals

VITON / PTFE / Grafoil

(g)

Stud Bolts / Nuts

ASTM A193 Gr. B7 / A194 Gr. 2H

Fire Resistant Design Requirement

As per Standard API 607 / BS : 6755 (Part II )

SS 304/ ASTM A 182 Gr. F6 / F 304

SS304/ ASTM A 182 Gr. F6 / F 304

21

Valve Testing Requirement


Test Pressure (min) Kg/cm2 (g)
Hydrostatic Test

Body

**

Seat

**

15

Air Test
Anti-Static Testing and design
22

Min Duration , minutes

Required as per Standard API 6D (2002 Ed.) / BS : 5351

Valve Painting Specification


Suitable for Environment Type

Coastal Marine Environment

Manufacturers Paint Spec No.

Manufacturer to Furnish details

* By Vendor, ** From process data


Notes
1.

This Valve Data Sheet shall be read in conjunction with Purchasers Technical Specification

2.

Inspection and Testing shall be as per this Data Sheet, Purchasers T.S., API 6D and other relevant standards.

3.

Stops shall be provided for positive alignment of Ball with ports and ensure proper installation of handle.

4.

Short pattern Valves are not acceptable

5.

Valves shall have ball position indicator.

6.

Mechanical stops required for open and close position/ limits

7.

Sealant Injection Point and Body vent is required for Valve of Size 6 and above.

8.

For Valve of size 6 and above with pressure class rating 300#Trunnion mounted Valve and gear operator is required with round shaped wheel.
Rest of the valve (below 6) shall be Floating design and lever is required for valve operation
9.

For Valve, Fire safe design shall be as per : API 607 / API 6 FA (latest)

2. Data Sheet- Ball Valves (0.5 1.5)


UNITS : Gas Flow - SCMD,
1

Valve Manufacturer

Size (NB)

Pressure - Kg/cm2g , Temperature Deg C


As per approved vendor list *
BS 5351/
Rating

Standard

, , 1 & 1

ANSI

800#
BS EN ISO 17292: 2004

Service

Natural Gas

Purchasers Specification

-------

Design

Operating Pressure

Corrosion Allowance (mm)

1.5 mm

Location

Above Ground

Valve Type (Floating or


Trunion / Pivot Mounted)

10

Pressure

Design Temperature

**

-29 to +65 deg. C

Operating Temperature

**

-20 to 60 deg. C

Bore (Full/ Reduced)

Floating Ball

Full Bore

Flanged (As per ASME B16.5)

for main line Ball valves

Socket Weld Both Ends

100mm Extension Pups in ASTM


A106 Gr. B (Sch. 80) at both ends
for Vent. Drain valves

End Connections
(As per ASME B16.11)
Flanged One End Socket Weld Other End

Flanges (Wherever Applicable)

As applicable

(a)

RF

(a)

Serrated

(b)

FF

(b)

Smooth

(c)

RTJ

(d)

NA

11

12

(125 200 AARH)


(c)

NA

Connecting Pipe Specification


(a)

Material

API 5L Gr B / X-42 / ASTM A 106 Gr B

(b)

Diameter

**

(c)

Thickness

**

13

Locking arrangement

Lock Open

14

Stem Extension Required

NO

15

Gear Operator Required

NO

16

Gas Power Actuator Required

NO

17

Valve material Specification

Lever operated

Material Offered shall be Equivalent or


Superior

Part

Specified Material

(a)

Body

ASTM A105

(b)

Ball

13% Cr Steel/
SS304/ ASTM A 182 Gr. F6 / F 304

(c)

Body Seat

PTFE

(d)

Gland

13% Cr Steel

(e)

Stem

13% Cr Steel (No Casting)


SS304/ ASTM A 182 Gr. F6 / F 304

(f)

Body Seal

Grafoil

(g)

Stem Seal

Grafoil/ PTFE

(h)

Stud Bolts / Nuts

ASTM A193 Gr. B7 / A194 Gr. 2H

20

Fire Resistant Design Requirement

21

Valve Testing Requirement

Hydrostatic Test

Type - Test as per Standard API 607 / BS:6755 (Part-II) / API 6FA (latest)

Test Pressure (min) Kg/cm2 (g)

Min Duration (in minutes)

Body

210

Seat

155

7.0

15

Air Test
22

Anti-Static Testing Requirement

23

Valve Painting Specification

As per Standard BS : 5351

Suitable for Environment Type

Coastal Marine Environment

Manufacturers Paint Spec No.

Manufacturer to Furnish

* By Vendor
Notes :
i.

Painting of valves shall be as per Manufacturer's standard.

ii.

Material test certificates and hydrostatic test reports shall be furnished prior to dispatch.

iii.

Detailed dimensional drawings showing cross-section with part numbers and materials shall be submitted for Purchasers approval prior to manufacture of
the valves.

iv.

All tests shall be as per BS:6755 (Part-I).

v.

Valves shall have ball position (open/ close) indicator.

vi.

Mechanical stops required for open and close position/ limits

vii.

Stops shall be provided to ensure positive alignment of ball with ports and ensure proper installation of handle.

viii.

Each valve shall be provided with a wrench.

ix.

Valves shall be inspected and approved by Purchaser before dispatch.

x.

Inspection and Testing shall be as per this specification, BS:6755 (Part-I) and other relevant standards.

xi.

Gland packing assembly shall permit repair of gland packing under full pressure.

xii.

Stem design shall be Anti Blow out type

3. Data Sheet- Check Valve / NRV


UNITS : Gas Flow - SCMD,

Pressure - Kg/cm2g , Temperature Deg C

Valve Manufacturer

As per approved vendor list *

Size (NB)

Service

Natural Gas

Purchasers Specification

GAIL TS Check Valves

Design

Operating Pressure

Corrosion Allowance (mm)

1.5 mm

Location

Above Ground

Valve Port (Full / Regular)

REGULAR

10

End Connections

Flanged (As per ASME B16.5)

11

Flanges (Wherever Applicable)

(a)

12

Connecting Pipe Specification

Not Applicable

(a)

Material

-------

(b)

Diameter

-------

(c)

Thickness

-------

Rating

Standard

Pressure

**

API 6D / API 594 / BS:1868

Design Temperature

**

(-28) , +65

Operating Temperature

**

0 50 Deg. C

RF

Lock Open

(a)

Lock Close

Serrated

Not App.

13

Locking arrangement

14

Stem Extension Required

YES

15

Length of Stem Extension

NOT APPLICABLE

16

Gear Operator Required

YES

NO

17

Gas Power Actuator Required

YES

NO

18

Actuator Specification No.

N.A.

N.A.

19

Valve material Specification


Part

Specified Material

Material Offered (Equv or Superior)

(a)

Body

ASTM A 216 GR WCB

(b)

Cover

ASTM A 216 GR WCB

Disc / Plates

( ASTM A 216 GR WCB + 13% Cr. Steel


Facing ) / 13% Cr Steel

(c)

Actuator Data Sheet No.

NO

Body Seat Ring (See Note 3)

ASTM A 216 GR WCB + 13% Cr. Steel


Facing

(e)

Disc Hinge

ASTM A 216 GR WCB

(f)

Hinge Pin

13% Cr Steel ( No Casting)

(g)

Cover Stud Bolts

ASTM A 193 GR B7

(h)

Nuts

ASTM A 194 GR 2H

(i)

Cover Gaskets

SS 304 Spiral Wound with C.A. Filter

(j)

Spring

Inconel X-750

(d)

20

Fire Resistant Design Requirement

21

Valve Testing Requirement

Hydrostatic Test

22

Anti-Static Testing Requirement

23

Valve Painting Specification

N.A.

Test Pressure (min) Kg/cm2 (g)

Min Duration , minutes

Body

15 / As per API 6D : 2002 Ed

Seat

5 / As per API 6D : 2002 Ed

Not Applicable

Suitable for Environment Type

Coastal Marine Environment

Manufacturers Paint Spec No.

Manufacturer to Furnish

* By Vendor
** From process data.
Notes:
1.

This Valve Data Sheet shall be read in conjunction with Purchasers Technical Specification No. GAIL TS Check Valves

Inspection and Testing shall be as per this Data Sheet, Purchasers T.S., API 6D and other relevant standards.

3.
4.

Seats shall be non-renewable integral type.


Check valves shall be installed in each stream.

4. Data Sheet - Plug Valves (2 & above)


UNITS : Gas Flow - MMSCMD,

Pressure - Kg/cm2g , Temperature Deg C

Valve Manufacturer

Size (NB)

Service

Natural Gas

Purchasers Specification

GAIL TS Plug Valves

Design

Operating Pressure

Corrosion Allowance (mm)

1.5 mm

Location

Above Ground

Rating

Pressure

Standard

ANSI

**

API 6D

Design Temperature

**

65

Operating
Temperature

**

05 - 50

9
Flanged
10

11

12

End Connections

(a)

RF

(a)

Serrated

(b)

FF

(b)

Smooth

(c)

RTJ

(d)

NA

Flanges (Wherever Applicable)

Connecting Pipe Specification

Not Applicable

(a)

Material

-------

(b)

Diameter

-------

(c)

Thickness

-------

13

Locking arrangement

Not App.

14

Stem Extension Required

NO

15

Length of Stem Extension (in metres)

NOT APPLICABLE

16

Gear Operator Required

YES
dia)

(125 200 AARH)


(c)

( for sizes > 4

NA

Gear Operator is Not required for valve


of size 4 and below

17

Gas Power Actuator Required

NO

18

Actuator Specification
No.

N.A.

N.A.

19

Valve material Specification


Part

Specified Material

Material Offered (Equv or Superior)

(a)

Body

ASTM A216 Gr. WCB

(b)

Plug

ASTM A216 Gr. WCB + 75 microns


ENP

(c)

Cover

ASTM A216 Gr. WCB/ ASTM A516 Gr.


70

(d)

Stem

AISI 4140 + 75 microns ENP

(e)

Stud Bolts / Nuts

ASTM A193 Gr. B7 / A194 Gr. 2H

Actuator Data Sheet


No.

20

Fire Resistant Design Requirement

21

Valve Testing Requirement

Type - Test as per standard API 6FA / BS 6755 (Part - II)

Test Pressure (min) Kg/cm2 (g)


Hydrostatic Test

Body

**

Seat

**

15

Air Test
22

Min Duration , minutes

Valve Painting Specification


Suitable for Environment Type

Coastal Marine Environment

Manufacturers Paint Spec No.

Manufacturer to Furnish

* By Vendor , ** Refer Process data


Notes
1. Inspection and Testing shall be as per this Data Sheet, Purchasers T.S., API 6D and other relevant standards.
2. Stops shall be provided for positive alignment of plug with ports and ensure proper installation of handle.

5. Data Sheet- Plug Valves (0.5 1.5)


Pressure - Kg/cm2g , Temperature Deg C

UNITS : Gas Flow - SCMD,


1

Valve Manufacturer

As per approved vendor list *

Size (NB)

Service

Natural Gas

Purchasers Specification

-------

Design

Operating Pressure

Corrosion Allowance (mm)

1.5 mm

Location

Under Ground

Pattern (Short / Regular / Venturi)

REGULAR

Rating

Standard

Pressure

, , 1 , 1

ANSI 800#

BS 5353

Design Temperature

----

65

Operating
Temperature

6-8

05 - 50

Above Ground

Flanged
10

Socket Weld Both Ends (As per ASME


B 16.11)

End Connections

Socket Weld 3000#

1 End Flanged, Other End Socket Weld

11

(a)

RF

(a)

Serrated

(b)

FF

(b)

Smooth

(c)

RTJ

(d)

NA

Flanges (Wherever Applicable)


(125 200 AARH)
(c)

12

Connecting Pipe Material Specification

API 5L Gr B / X-42 / ASTM A 106 Gr B

13

Locking arrangement

Lock Open

14

Stem Extension Required

YES

15

Length of Stem Extension (in metres)

NOT APPLICABLE

16

Gear Operator Required

YES

NO

17

Gas Power Actuator Required

YES

NO

18

Actuator Specification
No.

N.A.

N.A.

19

Valve material Specification

Actuator Data Sheet


No.

Lock Close

NA

Not App.
NO

Part

Specified Material

(a)

Body

ASTM A 105

(b)

Plug (Lubricated)

ASTM A 105 + 75 micron ENP

(c)

Bung (Screwed)

ASTM A 105

(d)

Stem (No Casting)

AISI 410

(e)

Gland

ASTM A 105

(f)

Gland Packing

GRAPHITE / PTFE

(g)

Gasket, Body Stud Bolts / Nuts

N.A.

20

Fire Resistant Design Requirement

21

Valve Testing Requirement

Hydrostatic Test

Type - Test as per Standard BS 6755 (Part - II)

Test Pressure (min) Kg/cm2 (g)

Min Duration , minutes

Body

210

Seat

155

7.0

15.0

Air Test
22

Material Offered (Equv or Superior)

Valve Painting Specification


Suitable for Environment Type

Coastal Marine Environment

Manufacturers Paint Spec No.

Manufacturer to Furnish

* By Vendor
Notes to Plug Valve Datasheet of size below 2.
1.

Valves shall have an inherent feature using the line pressure to ensure that the line pressure cannot cause taper locking of the plug/ plug
movement into the taper, i.e., valves shall be of "pressure-balanced design".

2.

Painting of valves shall be as per Manufacturer's standard.

3.

Material test certificates and hydrostatic test reports shall be furnished prior to dispatch.

4.

Detailed dimensional drawings showing cross-section with part numbers and materials shall be submitted for Purchaser's approval prior to
manufacture of the valves.

5.

All tests shall be as per BS: 6755 (Part-I).

6.

Valves shall have valve position indicator.

7.

Stops shall be provided to ensure positive alignment of plug with ports and ensure proper installation of handle.

8.

Each valve shall be provided with a wrench.

9.

Valves shall be inspected and approved by Purchaser or his authorised representative before dispatch.

10.

Gland packing assembly shall permit repair of gland packing under full line pressure.

11.

Inspection and Testing shall be as per attached QAP, this specification, BS: 6755 (Part-I) and other relevant standards.

6. Globe Valve (below 2)


2

UNITS : Gas Flow -SCMD,

Pressure - Kg/cm g , Temperature Deg C

Valve Manufacturer

As per approved vendor list *

Size (NB)

Service

Natural Gas

Purchasers Specification

-----

Design

Operating Pressure

Corrosion Allowance (mm)

Rating

Pressure

Standard

15 ( ) to 40 (1)

ANSI 800#

BS : 5352

Design Temperature

- 29 to 65 C

Operating
Temperature

05 50 C
1.5 mm
Flanged (As per ASME B16.5)

End Connections

Socket Weld Both Ends, 3000# as per


ASME B 16.11
Flanged One End Socket Weld Other
End

Flanges (Wherever Applicable)

(a)

RF

(a)

Serrated

(b)

FF

(b)

Smooth

(c)

RTJ

(d)

NA

10

Connecting Pipe Specification

Not Applicable

(a)

Material

-------

(b)

Diameter

-------

(c)

Thickness

-------

11

Gear Operator Required

12

Valve material Specification

(125 200 AARH)


(c)

NA

YES

NO

Part

Specified Material

Material Offered (Equv or Superior)

(a)

Body

ASTM A105

(b)

Bonnet (Bolted)

ASTM A105

(c)

Stem (Rising)

13% Cr Steel (No Casting)

13

(d)

Disc (Loose Plug / Ball type)

13% Cr Steel/ Stellited

(e)

Body Seat ring

13% Cr Steel/ Stellited

(f)

Stem Packing (Renewable with valve open


on stream)

Graphite Braided Asbestos with


Sacrificial Corrosion Inhibitor & Inconel
wire reinforcement

(g)

Hand Wheel (Rising)

Malleable Iron / Cast Steel / Fab Steel

(h)

Bonnet Bolts

ASTM A 193 Gr B7

(i)

Bonnet Nuts

ASTM A 1943 Gr 2H

(j)

Bonnet Gasket

Spiral wound SS 304 +CA Filler

Valve Testing Requirement

Hydrostatic Test

Minimum Test Pressure in Kg/cm2 (g)

Duration (in Minutes)

Body

209

15

Seat

153

15

15

Air Test
14

Valve Painting Specification


Suitable for Environment Type

Coastal Marine Environment

Manufacturers Paint Spec No.

Manufacturer to Furnish

* By Vendor
Notes
1)

Stem Packing shall be renewable with valve open on steam.

2)

The data sheet shall be read in conjunction with technical notes for valves.

3)

Testing shall be as per BS : 6755 (Part I).

7. Data Sheet- Globe Valve (2 and above)


UNITS : Gas Flow -MSCMD, Liquid Flow - m3/hr , Steam Flow Kg/hr , Pressure - Kg/cm2g , Temperature Deg C , Level / Length mm
1

Valve Manufacturer

As per approved vendor list *

Size (NB)

Service

Natural Gas

Purchasers Specification

-----

Design

Operating Pressure

Corrosion Allowance (mm)

Rating

Pressure

Standard

All Sizes

ANSI 150#/ 300#/600#

Design Temperature

- 29 to 65 C

Operating
Temperature

05 - 50 C

BS : 1873 / API 6D**

1.5 mm
Flanged (As per ASME B16.5)

End Connections

Socket Weld Both Ends


Flanged One End Socket Weld Other
End

Flanges (Wherever Applicable)

(a)

RF

(a)

Serrated

(b)

FF

(b)

Smooth

(c)

RTJ

(d)

NA

10

Connecting Pipe Specification

Not Applicable

(a)

Material

-------

(b)

Diameter

-------

(c)

Thickness

-------

11

Gear Operator Required

12

Valve material Specification

(125 200 AARH)


(c)

NA

YES

NO

Part

Specified Material

Material Offered (Equv or Superior)

(a)

Body

ASTM A216 Gr. WCB

(b)

Bonnet (Bolted)

ASTM A216 Gr. WCB

(c)

Stem (Rising)

13% Cr Steel (No Casting)

13

(d)

Disc (Loose Plug / Ball type)

13% Cr Steel

(e)

Body Seat ring

13% Cr Steel

(f)

Stem Packing (Renewable with valve open


on stream)

Graphited Braided Asbestos with


Sacrificial inhibitor & inconel wire
reinforcement

(g)

Hand Wheel (Rising)

Malleable Iron / Cast Steel / Fab Steel

(h)

Bonnet Bolts

ASTM A 193 Gr B7

(i)

Bonnet Nuts

ASTM A 1943 Gr 2H

(j)

Bonnet Gasket

Spiral wound SS 304 +CA Filler

Valve Testing Requirement


Test Pressure (min) Kg/cm2 (g)

Duration (Minutes)

150#

300#

600#

Body

32

80

157

15

Seat

22

58

114

15

15

Hydrostatic Test

Air Test
14

Valve Painting Specification


Suitable for Environment Type

Coastal Marine Environment

Manufacturers Paint Spec No.

Manufacturer to Furnish

* By Vendor
** API 6D is applicable only for 300# and above.
Notes
1)

Testing shall be as per BS : 6755 (Part I)

2)

Stem Packing shall be renewable with valve open on steam

3)

The data sheet shall be read in conjunction with technical notes for valves.

8. Data Sheet-Pressure Safety Valves


UNITS : Gas Flow - SCMD,
General

Valve

Material

Pressure - Kg/cm2g , Temperature Deg C

Tag No.

Line No/ Size

Vessel Protected

Quantity

1 nos. at each Filter stream (for Fire case sizing) and 1 no. each at stream of
regulator outlet for creep relief designed for 1% of skid capacity

Safety / Relief

Safety valve / creep Relief valve

Make and Model No.

Type

Standard

Full Nozzle Full Lift Mod. Nozzle

Full Nozzle Full Lift

Bonnet Type

Closed

10

Conv./ Bellows/ Pilot Operated

Conventional

11

Inlet Conn. : Size & Rating

13

Outlet Conn. : Size & Rating

14

Inlet/ Outlet Conn. : Facing &


Finish

RF Serrated

125AARH

15

Cap Over Adj. Bolt :

Required

16

Screwed / Bolted

Bolted

17

Lifting Gear - Type

18

Test Gag

Required

19

Body and Bonnet

ASTM A216 Gr. WCB

20

Nozzle and Disc

SS 316 or better

21

Spring

Cadmium Plated CS

22

Bellows

23

Resilient Seat Seal

Options

24

Spring for diff. set point range

Required

Basis

25

Code

ASME Sec-VIII / API 520

26

Basis of Selection

Skid flow capacity

27

Fluid and State

Natural Gas

Gas

Service
Conditions

Orifice

28

Corrosive Constituent/ Corr.


Allow.

CO2 (4%) / 2.0 mm

29

Required Flow Capacity

30

Mol. Wt.

17.70 *

31

Operating Pressure, kg/cm2(g)

**

32

Operating Temperature (C ) Rel.


Temp.C

**

33

Valve Discharges to

Atmosphere

34

Back Pressure

Atmosphere

35

Set Pressure, kg/cm2(g) / Cold


Bench Test Pressure

36

% Over Pressure / % Blow Down

20

37

Cp / Cv

1.27 *

0.98 to 0.997 *

38

Viscosity at Rel. Temp. (cP)

39

Vess. : Wall
Temp.C

40

Calculated Area-inch2

41

Selected Area-inch2 Orifice


Design

42

No. of Valves Required for


capacity of each stream

1*

43

Total Area-inch2

44

Actual Flow Capacity Nm3/hr

45

Radiography

Required (100%)

Oper S.G.

Compressibility
Factor

Surface Aream2

0.619 *

Constant

*
*

*
*

* By Vendor
** Refer Process data mentioned elsewhere
Notes (*) Vendor to Furnish / Confirm
1.

Vendor shall furnish sizing calculations to support the valve selection.

2.

Valves shall be 100% radio-graphed

3.

Vendor to consider coefficient of discharge de-rated by a factor of 0.9 as per ASME VIII

4.

For safety valve sizing, furnish certified capacities as per API-520. It shall be designed as per PNGRB Regulation/ guidelines/
requirements.

5.

Pressure Safety Valve : 1 nos. at each Filter (for Fire case sizing)

6.

Creep Relief Valve : 1 no. each at regulator outlet for creep relief designed for 1% of skid capacity for Over Pressure
Protection at PCV Downstream.

9. Data Sheet- Dry Gas Cartridge Filter


UNITS : Gas Flow - SCMD , Pressure - Kg/cm2g Temperature Deg C,
General

Service Conditions

Design

Tag No.

Line Size & Schedule

Inlet Size / Out let size and pressure class rating

Service

Removal of Dust Particles

Quantity

02 nos. of dry gas filters per skid

Make & Model No. offered

Filter Separator Type

Horizontal / Vertical Cartridge filtration

Fluid / State

Natural Gas/ GAS

Operating S.G.

Mol. Wt.

**

**

10

Cp / Cv

Compress. Factor

**

11

Flash %

Viscosity c P (Op)

**

12

Flow Gas - Minimum /

13

Operating Pressure (
Minimum /
Normal /
Maximum)

14

Gas Composition (including Liquid Contaminant)

**

15

Dust Content

0 - 0.1 mg/dm3

17

Design Code

Design Class

As per ASME code


SEC.VIII Div-I (latest)

18

Design Pressure

Design Temperature

**

**

19

Corrosion Allowance (For CS


parts)

Corrosive/ Toxic
Component

2.0 mm

**

20

Particle/ Mesh Size (Micron)

Filtration Efficiency

3 Micron

99%

21

Pr. Drop Clean (Max)

Pr. Drop Dirty (Max)

0.10*

0.20*

22

Dust Content

23

Filter Element - MOC

Filter Element - Make

* Polyester to suit wet


gas

24

OD X Length

Nos of Cartridges

25

Element Bursting Pressure

Flow Direction

2.0

Outside to Inside

Normal /

Maximum

**

*
*

**

**

**

**
**

0.1 mg/dm3

Dimensions

Material of
Construction

Accessories to be
Provided

Inspection &
Testing

Others

26

Flange Type (end connection)

Flange Rating & Finish

WNRF

** , Smooth

27

Fixing Details

Nuts & Bolts / Studs

28

PSV Size

DPT Size

29

Vent Size

Drain Size

30

Utility Connection
requirement

UC Size

Required

31

Head Connection

Blind flange Davit arm required; Nuts & Studs /


Bolts required

32

Capacity

150% of rated/ design capacity of Skid.

33

Overall Length

34

Shell Diameter

35

Empty Weight (Kg)

36

DUST CONCENTRATION

UPTO 0.1 mg/SCM

37

DUST COLLECTION CAPACITY

15 Days at design flow rate (Filter shall have dust


collection capacity for 15 days of dust holding/
storage)

38

Shell

Shell Flange

SA515/ SA 516 Gr. 60/70 / SA106


Gr B

SA 105

39

Nozzle

Nozzle Flange

SA 106 Gr. B

SA 105

40

Head

Head Flange

SA 105

Bottom

Perforated Sheet

SA 515/ SA 516 Gr. 60/ 70 / SA


234 Gr WPB

41

Bolts / Studs

Nuts

SA 193 Gr. B7

SA 194 Gr. 2H

42

Gaskets

O Ring

CAF, IS: 2712 Gr. 0/1

BUNA `N'

43

Supports

SA 283 Gr. C/ IS:2062

44

Davit Details

45

Companion Flange, Blind, Flange, Gaskets, Bolts, Studs,


Nuts for All Nozzles

Required

46

Hydrostatic Test

Radiography

@ 150% Design
Pressure

Full (100%)

47

Dye Penetration Test

Post Weld Heat


Treatment

YES

YES

48

Painting

Overall Height

*
Operating Weight (Kg)

Suitable for Corrosives Marine Environment

* By Vendor,
**-From process data
Notes :
1.

All C S parts weld joints to be stress relieved. Hardness in welds not to exceed 200 BHN.

2.

Filtration area should be minimum 8 times of inlet nozzle area.

3.

Fire case PSV of suitable capacity shall be provided on each dry gas filter

4.

Proper support, crossover and platform required for Maintenance of Filter, PSV, DPT etc.

10. DATA SHEET- PRESSURE GAUGES (TYPICAL)

UNITS: Flow: Gas-Sm3/hr,


1.

Type

Pressure: Kg/Cmg

: Direct

2.

Mounting

: Local (Direct on pipe through manifold)

3.

Dial size

4.

Colour

: White with black numerals.

4.

Case Material

: Die-cast Aluminium

5.

Bezel ring

: Screwed

6.

Window material

7.

Enclosure

150 mm (Inlet, outlet)/ 100 mm for rest

: Shatter proof Glass

Temperature: Deg C

13.

Connection

NPT(M)

14.

Connection location :

BOTTOM ENTRY

15.
16.

Movement
Diaphragm seal

17.

Over range protection

18.

Blow out protection

19.

Options

a.

Gauge saver

b.

Liquid filled casing

SS 304

Not required

:
:

required
:

Required

: Weatherproof to IP-65
c. Solid front

8.

Pressure Element

: Bourdon

9.

Element material

: SS 316

10.

Socket material

: SS 316

11.

Accuracy

12.

Zero adjustment
Tag No

Range

d. 2 way, 3 valve manifold :


20. STANDARD

21. MAKE & MODEL No.

Required
BS EN 837
*

: 1% OF FSD
: Micrometer pointer required
Operating
pressure

Maximum
pressure

Maximum
Temp C

Fluid

Service

Options

* By Vendor
Notes
1.

Range shall be selected such a way that operating pressure shall be in middle one third of range. If maximum pressure is above than range,
gauge saver
shall be provided. However, if the range is specified in the process data sheets, same shall be followed.

2.

Solid front type shall be provided for the gauges above 60 kg/cmg operating pressure.

3.

Over range protection shall be suitable for maximum pressure or 130% of range, whichever is higher.

4.

Dial Size shall be 150 mm for Skid inlet and outlet. For PRS section, Dial size shall be 100/ 150 mm.

11. DATA SHEET- Diff. PRESSURE GAUGES (TYPICAL)

UNITS: Flow: Gas-Sm3/hr,


1.

Type

Pressure: Kg/Cmg

: Direct

2.

Mounting

: Local (Direct on pipe through manifold)

3.

Dial size

: 150 mm (Inlet/outlet)/ 100 mm for rest

4.

Colour

: White with black numerals.

4.

Case Material

: Die-cast Aluminium

5.

Bezel ring

: Screwed

6.

Window material

7.

Enclosure

: Shatter proof Glass

Temperature: Deg C

13.

Connection

NPT(M)

14.

Connection location :

BOTTOM / SIDE ENTRY

15.

Movement

16.

Diaphragm seal

9.

Element material

: SS 316

10.

Socket material

: SS 316

11.

Accuracy

12.

Zero adjustment

Not required

18.

Blow out protection

19.

Options

a.

Gauge saver

b.

Liquid filled casing

d. 3 way, 5 valve manifold :


: Bourdon

Over range protection

c. Solid front

Pressure Element

SS 304

17.

: Weatherproof to IP-65

8.

20. STANDARD

required

Required
Required
Required
BS EN 837

21. MAKE & MODEL No.

Tag No

: 2% OF FSD
: Micrometer pointer required

Range

Operating
pressure

Maximum
pressure

Maximum
Temp C

Fluid

Service

Options

* By Vendor
Notes
1.

Range shall 0 to 1.5 Kg/cm2(d).

2.

Solid front type shall be provided for the gauges.

3.

Over range protection shall be suitable for maximum pressure or 130% of range, whichever is higher.

4.

Dial Size shall be 150 mm.

5.
Over Pressure protection is required against full pressure (up to 50 Bar) on one side of DPG and no pressure on other side of DPG (when equalizing
valve of DPG is closed/ is in isolated condition).
6.

5-Valve Manifold of standard make (EIL approved) , suitable for required service is required for isolation, vent/ drain and process connection to DPG.

12. DATA SHEET- Temperature Gauges(Typical)


UNITS: Flow->Liquid-

Gas-

Steam-

1. Type :-

BI-METALLIC

2. Well :-

REQUIRED

Pressure->

Temperature->C

Level / Length-> mm

FILLED SYSTEM
15. SAMA Class :15.1. Compensation :-

3. Mounting :-

DIRECT

16. Bulb Type :-

4. Dial Size

150 mm (approx)

16.1. Bulb Material :-

5. Colour :-

WHITE WITH BLACK MARKING

16.2. Bulb Union Threaded to :-

6. Case Material :-

SS 316

16.3. Bulb Extension Type :-

7. Window Material :-

GLASS

16.4. Bulb Diameter :-

8. Connection Location :-

ALL ANGLE ROTATABLE

9. Accuracy :-

1% OF FSD

10. Enclosure :60529)

WEATHER PROOF ( IP65 as per IEC

11. Zero Adjustment Screw:-

EXTERNAL ZERO ADJUSTMENT

17. Capillary Material :18. Armour Flexible :19. Armour Material :20. Capillary Length :-

BIMETAL

21. Over Range Protection :-

12. Stem Type :-

THERMOWELL

ADJUSTABLE UNION Material :-

22. Material :-

SS 316

SS316

Size :-

1/2" NPT(M)

23. Construction :-

13. Stem Diameter :-

TO SUIT WELL

24. Process Connection :-

14. Zero Adjustment :-

130% OF RANGE

DRILLED BAR STOCK


1 1/2" FLANGED

25. Gauge Connection :-

Required

1/2" NPTF

26. Thermowell As Per Drawing :-

Tag Number

**

RANGE
*

TEMPERATURE

WELL DIM.

NOR.

MAX.

Material

**

**

7-52-035

Flange

Service

Rating, Facing, Finish


*

NOTES:-1. OPERATING TEMPERAURE SHALL BE WITH IN 40-60% RANGE. RANGE SHALL COVER INIMUM AND MAXIMUM TEMPERATURE.
*- BY VENDOR,
** - REFER PROCESS DATA MENTIONED ELSEWHERE.

Options

13. DATA SHEET- PRESSURE TRANSMITTER (Typical)


UNITS: Flow> SM3/hr
General

Pressure> Kg/cm2 G

Temperature > Deg C


Measuring Unit

Transmit and Indicate

24. Service

: Pressure measurement

Electronic, smart

25. Element

: Silicon Resonant / Capacitance

Manufacture standard

26. Body Material

: Carbon steel / Aluminium

Yoke (2 NB Pipe mounting)

27. Element Material

: SS 316

IEC Zone-1, GR IIA/ IIB, T3

28. Process Connection


Process connection location

: NPTF
: Bottom entry

29. Diaphragm Seal

: N/A

30. Static Pressure Rating

: 100 kg /cm2

1.

Function

2.

Type

3.

Case

4.

Mounting

5.

Electrical area classification

WP to IP-65

6.

Enclosure

Intrinsically safe

7.

Hazardous area protection

8.
10.

Power Supply
Cable Entry

11.

Accuracy (for Metering PTs) 0.04 % of span with


Turndown ratio of 1:5
(including linearity, hysteresis
& repeatability) for metering
PTs (used for Custody transfer
application),

12.

Accuracy (for other PTs)

12.

Operating
Tag No.
pressure
Make and Model
No.:

31. Options

24 vdc
NPTF ( two no)

a.

3-valve manifold

b.

Intrinsically safe O/P meter (LCD type) : Required

c.

: Required

Mounting Accessories for 2 pipe mounting :


(Bracket, U Bolts & Nuts suitable)

Required

0.075% of calibrated span


(including linearity, hysteresis
& repeatability) for other PT

Maximum
service
pressure

Maximum
service temp

Range
Span

Fluid

Service

Remarks

Calibrated

4-20 mA DC (Note-2 &


3) / low
Refer
Process data attached elsewhere
powered
24 V DC (Two Wire)/
12 V DC (low power)

Transmitter

* By Vendor
13.
Output
Notes
14.
Transmitter Power supply
1.

Set/ calibrated Range shall be selected in such a way that range shall cover operating pressure between 20-80 % of manufacturers span range

2.
Controller

Transmitter shall be suitable for external loop resistance of at least 600 ohms when powered with 24 V DC from control room.

3.
Output 4- 20 mA DC shall be super imposed on digital signal with HART Protocol (for control room mounted flow computer systems) .
15.
Output
4.
Digital
communication shall be possible with hand Held communicator.
16.
A/M
Switch
No of Positions
:
5.
Integral Intrinsic safe output meter (LCD type, integral with transmitter) shall be provided for all tags.
17.
6.
18.
19.
7.
20.
21.
22.
23.

Set point Adjustment


Over range protection shall be suitable for maximum pressure or 130% of range, whichever is higher.
Manual regulator
Mode
CCOE approval certificate shall be provided for transmitter
Chart
Chart Drive
Moving parts Material
Chart Speed

14. RTD (RESISTANCE TEMPERATURE DETECTOR -Typical)


UNITS: Flow: Gas-Sm3/hr,
1

Function

2
3
4
5

Type
Case
Mounting
Electrical area
Classification
Enclosure
Enclosure Class
Intrinsically safe
Power supply
Cable Entry

6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Service
Element
Assembly
Number of Elements
Calibration
Element Material
Tag No.

Element
Length
mm

Pressure: Kg/Cmg

Temperature: Deg C

Transmit

21

Manufacturer Standard
Transmitter Remote Mounted
IEC Zone-I, Group II A/II B, T3

22
23
24
25

Weatherproof
IP-65 As Per IS-13947
Yes Required
24 VDC / low powered
NPTF (2 nos)

Temperature Measurement
4 wire RTD Class A type
*
Single
As Per DIN 43760/IEC-60751-2
Platinum
Normal
Temp.

Max
Tem

Well
Dimension
U
T

26
27
28
29
30
31
32
33
34
35
36
37
38
39

Resistance at Zero
Degree Centigrade
Leads
Sheath O.D.
Sheath Material
Nipple & Union
Material

100 Ohms (PT-100)

Head Cover Type


Head Material
Cable entry
Number of Entries
Enclosure Type
Thermo-well
Material
Construction
Process Connection
Instrument Connection
Thermowell
Make
Model No.

Screwed Cap & SS Chain


Cast Aluminium
NPTF
*
Weatherproof to IP-65 As Per IS-13947
Required
SS 316
Drilled Barstock
1 Flanged
NPT
*

Flange
Material

Mineral Insulated
6.0 mm
SS 316
Cadmium Plated Carbon Steel

Service

Location Range set/


calibration of TT

Rating Facing Finish

Notes: * By vendor

Calibration Range for Temperature transmitters shall be 20 to 60 deg C for all line mounted temperature instrument.

-20 to 60 deg C

15. Slam Shut Valves(Typical)


UNITS: Flow> Gas- SM3/hr ; Pressure> Kg/cmg ; Temperature > Deg C
General

Body

Options

Service
Conditions

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Tag No.
Inlet Line No.
Outlet Line No.
Line size & Thickness
Service
Type of Valve
Body Size
& Port Size
End Connection: Flanged, Size & Rating
Facing / Finish
Body Material

**
**
**
**

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.

Trim Material
Other Wetted Parts
Leakage Class
Closing time
Set point Accuracy
Pilot operated
Manual Reset
Failure position
Limit Switch
Valve Position indicator (local)
Radiography
Charpy V-Notch Test
Impulse Tubing/ fittings
Pressure Indicator
Installation
Fluid
State

* / SS 316 or better (selected material to be mentioned)


* / SS 316 or better (selected material to be mentioned)
CLASS- VI as per ANSI/ FCI 70.2
Less than 2 Seconds
2.5% of set point, as per EN 14382: 2009
YES
REQUIRED
CLOSE
2 Nos. (Open/ Close)
REQUIRED
REQUIRED
REQUIRED
REQUIRED
not required
Horizontal body
Natural Gas
Gas

27.
28.
29.

Flow Gas- Min.


Nor. / Max.
Inlet Pressure range
Pressure Drop at Various Flow
rates. (Min, Normal, Max. Flow)
Shut Off Pressure
Temp. Operating
Max.
Operating S.G.
Mol. Wt.
Compress.
Cp / Cv
Factor
Kg or Cg Min.
Kg or Cg Max.
Kg or Cg
Selected
Predicted Sound Level (dBA)
Inlet Velocity (meters/second)
Adjustable
Valve set point
spring range
Valve
Pilot

30.
31.
32.
33.
Valve Data

34.
35.
36.
37.
38.

Make and
Model No. of

39.
40.

Down stream pressure protection


SLAM SHUT (pilot operated)
*
&
*
*
&
*
Flanged Serrated / 125 AARH

ASTM A216 WCB/ A234 WPB/ A350 Gr. LF2/ A352 Gr. LCB
or superior for withstanding the pressure requirements.

**
**
**
**
**
*

**

**

**

**
**
**
*
*

Less than 85 dBA *


*
*
*
*
*

Notes : * By Vendor
** As per Process data
1.

3.
4.

The Pilot shall be supplied suitable for the set point of complete output pressure range. Preferably one pilot shall cater the complete range,
however if it is not feasible then additional springs to be provided to cater the complete range.
Pressure drop across the Slam Shut Valve shall be decided on the basis of Total pressure drop permitted across the complete skid, flow rate
and the velocity limit.
Maximum permitted seat velocity is 40 meter / sec.
Connection : Flanged raised face

5.

Body : ASTM A216 WCB/ A234 WPB/ A350 Gr. LF2/ A352 Gr. LCB or superior for withstanding the pressure requirements.

2.

16. Pilot operated Self Actuated Pressure Control Valves


UNITS: Flow> Liquid m*3/hr Gas- Sm3/hr Steam - Kg/hr Pressure> Kg/cmg Temperature > Deg C Level/Length - MM
General
1. Tag No.
**
2. Inlet Line No.
**
3. Outlet Line No.
**
4. Line size & Thickness
**
Down Stream pressure
5. Service
Body

Options

Service
condition

6.
7.
8.
9.
10.
11.
12.
13.
14.

Type of regulator
Body Size
/
Port Size
End Connection( Flanged)
Size / Rating
Facing & Finish
Body Material
Diaphragm Material
Trim, plug Material
Other Wetted Parts
Leakage Class

15.
16.
17.
18.
19.
20.
21.

Impulse Connection
Valve Set Point
Regulation accuracy
Failure position
Radiography
Charpy V-Notch Test
Impulse tubing/ fittings

22. Installation
23. Fluid

State

24. Flow GasNor. /


Max.
25. Inlet
Min. Pressure: operating/ max

26. Max. Pressure Drop at Various


Flow rates.
27. Shut Off Pressure
28. Temp. Oper. Max. / Min.
29. Oper. S. G. Mol. Wt.
Compress.
30. Cp / Cv
Factor
Valve Data
31. Kg (Cg) Min. / Kg (Cg) Max.
32. Kg or Cg Normal / Selected Kg or Cg
33. Predicted Sound Level (dB)
34. Inlet Velocity m/s.
.
35. Make and Model No .Valve & Pilot
Notes:
* to be provided/ indicated by Bidder
** Refer Process data provided elsewhere.

Regulation
Self -actuated Pilot operated
*
/
*
*
/
*
RF serrated / 125 AARRH

ASTM A216 Gr WCB or better

*
* / SS316 or better
* / SS316 or better
CLASS- VI as per ANSI/ FCI 70.2
EXTERNAL

**

2.5% of the set point


Close/ open
100% Required
Required
Required
Horizontal
Natural gas

**
**

Gas

/ **
**

**

**
**
**
**

**
**
**

*
*
*
*
* (less than 85 dB)
Less than 20 meter/ second

/ **

Active and Monitor Regulator shall be designed as per following :


A.

Type : Pilot operated Self Actuated Pressure Control Valves for Downstream Pressure Regulation

1.

MATERIAL OF CONSTRUCTION :

a)

Body : ASTM A216 WCB/ A234 WPB/


REQUIREMENTS

b)

Internals : AISI 410 or SUPERIOR for WITHSTANDING PRESSURE REQUIREMENTS

c)

Diaphragm : SYNTHETIC RUBBER OR SUITABLE MATERIAL FOR WITHSTANDING THE PRESSURE REQUIREMENTS

2.

Standards and Regulation :

d)

Standards : REGULATOR SHALL BE DESIGNED AS PER EN 334: 2005 (+A1:2009) ; PNGRB REGULATION & OTHER APPLICABLE
STANDARDS

e)

COMPONENTS FOR GAS SUPPLY : DIN 30690-1: 2006 / DIN 30690-2: 1980 OR EQUIVALENT

f)

LOCK UP : +/- 5% of Set Pressure or better

A350 Gr. LF2/ A352 Gr. LCB OR SUPERIOR FOR

WITHSTANDING THE PRESSURE

3. Design criteria :
a) Set Point of the regulator shall be adjustable. Vendor shall furnish the adjustable range of the pilot.
b) Accuracy of the pressure regulation shall be better than or equal to 2.5 % of the set pressure for the entire pressure and flow range.
c) Active Pressure regulator valves shall be fail open type. Monitor regulator valves shall be fail close type.
d) Pressure drop across the valve shall be selected by the vendor considering the Maximum Pressure drop permitted across the skid,
given set points (staggered set point of the two regulators and the slam shut valves) and the given inlet / outlet pressure conditions.
e) Regulator shall be sized to deliver the maximum flow at minimum pressure condition and the minimum flow at the maximum
pressure condition.
f) The Inlet pressure variation is possible for all the flow rates and the PCV shall be sized accordingly to cater such variation in flow and
pressure.
g) In case valve noise level for the worst case of the given process conditions exceeds 85 d BA (flange to flange of the valve)
vendor shall provide and include the noise treatment with silencer/ expander.
h) The Pilot shall be supplied suitable for the set point of complete output pressure range. Preferably one pilot shall cater the
complete range, however if it is not feasible then additional springs/ pilot to be provided to cater the complete outlet pressure
range.

17. Data Sheet- Turbine Flow Meters (Typical)


UNITS :

Flow- Gas > Sm3/hr ; Pressure> Kg/Cm2g ; Temperature > Deg C

General
Meter

Options

Service
Conditions

Notes : * By Vendor

1.
2.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Tag No.
Line No., Size and Schedule
Service
End Connection: size & Rating
Facing & Finish
Pulses /m3
Flow Range
Enclosure
Cable Entry
Material Body
- End Connection
- Rotor
- Bearing & Other wetted parts

*
*
CUSTODY TRANSFER of Natural Gas
*/ *
RF serrated/ 125AARH
*
*
WEATHER PROOF
*
ASTM A216 GrWCB or better
FLANGED
Aluminium
STAINLESS STEEL

15.
16.
17
18.
19
20.
21
22
23
24
25
26
27

Linearity/ Repeatability
Output
Mechanical/Digital counter
Dowel Pin
Pressure tap from body
Straightening Vanes
Meter run(Up & down stream)
Local counter
Strainer - Mesh Size
Pressure Tap on Meter Body
Lubricator with Accessories
Roughness in side meter run
Cold Insulation on Meter, Meter
Tube(UP & Down stream), Thermowell & Impulse tubing

NOTE-1
HF PULSES (DUAL)
Required
Required
Required
REQUIRED
REQUIRED
REQUIRED 8 DIGIT NON
RESETTABLE
REQUIRED
REQUIRED
Not more than 300 micron
required

28
29
30
31.
32
33
34
35
36
37
38
39

Fluid & State


Flow Min/Normal/ Max.
Pressure Min/ Operating/ Max.
Temp Min/ Operating/ Max
Oper. Visc (cP)/Density (Kg/m3)
System Pressure Drop
Gas Mol Wt.
Compressibility Factor
Cp/CV
Area Classification
Make & Model No. - Turbine Meter
- Transmitter & Pre Amplifier

NATURAL GAS/ GAS


**
**
**
**
**
**
**
**
IEC ZONE 1 GR IIA, IIB T3
*
*

** As per Process data


1.

ACCURACY (INCLUDING LINEARITY AND HYTERESIS) SHALL BE WITHIN THE ENVELOPE OF +/-0.5% FOR FLOW RATES BETWEEN 20% TO
100% OF THE Q-MAX (Meter Max) & +/- 1% FOR FLOW RATES BETWEEN 5% TO 20% OF Q-MAX (METER MAXIMUM). AT NORMAL
OPERATING FLOW & PRESSURE, REPEATABILITY SHALL BE 0.1%.

2.

THE SYSTEM PRESSURE DROP INCLUDES PRESSURE DROP ACROSS STRAIGHTENER & TURBINE METER.

3.

TURBINE METERS SHALL BE RATED FOR THE MAXIMUM DESIGN PRESSURE AS INDICATED ABOVE.

4.
5.
6.
7.

THE OFFERED METER MUST BE DESIGNED AS PER AGA7 SPECIFICATIONS AND CALIBRATION CERTIFICATE FROM THE AGENCY
APPROVED FOR CUSTODY TRANSFER CERTIFICATION FROM THE COUNTRY OF ORIGIN SHALL BE SUPPLIED.
THE TURBINE METER SHALL BE HIGH FREQUENCY PULSAR TYPE..
VELOCITY THROUGH TURBINE METER SHALL NOT EXCEED 20 m/s. Meter shall be designed as per AGA-7(Latest).
Please refer Special Instruction to Vendor (for Turbine Flow meter) provided below

Special Instruction to Vendor (for Turbine Flow meter)


1) Vendor shall be responsible for selection of the correct model nos. of instruments to meet the purchasers
specifications. In case of model no. required to be changed at a later date to meet the Purchasers Specifications,
the same shall be done by the vendor without any price and delivery implications.
2) The Turbine Flow Meter shall be suitable for the area classification IEC Zone-I, Gr.IIA & IIB, T3. Certificates
from Statutory Bodies for Hazardous Area Classification shall be submitted along with the offer.
3) The meter tube shall be mounted at the upstream side of the Turbine meter. The material of construction and size
shall be as per attached data sheet. The meter tube shall be designed as per AGA-7(Latest) requirements.
4) Vendor shall include calibration of Turbine meters with Air and Natural gas in the scope of work and indicate
separate price for the same in the offer.
5) The upstream and downstream meter runs, flow straightener and Turbine Meter shall be cold insulated. The
thermo-well and Impulse tubing of Pressure Transmitter (for metering) shall also be cold insulated.
6) The design of the metering system shall be done by the manufacturer of the Primary metering device. The
manufacturer shall get the entire skid design approved from NMI/PTB / NPL or equivalent for Custody Transfer
application.
7) The Calibration of Turbine Flow meter shall be with the Flow Straightener / Meter Run.
8) Turbine meter shall be calibrated with Air.

18. Data Sheet- Rotary Positive Displacement Flow Meters (Typical)


UNITS: Flow> Gas Sm3/hr Pressure> Kg/cm*2 G Temperature > Deg C
1.
Line size & Sch
2.
Service (Fluid)
3.
Application Standard
4.
G Rating
5.
End Connection
6.
Max. / Normal/ Min. Flow Rate
7.
Accuracy ( including Linearity, hysteresis)

Meter

Service

Index

Notes

**

CUSTODY TRANSFER of NATURAL GAS

OIML/EEC/EN standard
G65/ G100/ G160 * (select any one)
2 / 3 Flanged, ANSI 125# *

/
* /
*
+/-1% for flow range 0.2 Qmax to Qmax

8.

Rangebility

20:1 in 1% Accuracy range


+/- 1% in the range 0.2 Qmax to Qmax
40:1 in 2% Accuracy range

9.

Intrinsic Safety

Required .

10.

Temperature Range

-20 Deg C to +50 Deg C

11.

Max. Working Pressure

12.0 Bar

12.
14.

Pressure Tapping and Thermo-well


Lubrication provision

Inbuilt; required
required while meter In service

15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
32.
51
33.
34.
35.
36.

Facing & Finish


Flow Direction
Pulse output
Pulses /m3
Enclosure protection- Meter head
Material Body
- Rotor
- Bearing
- Other Wetted Parts
Oper. Visc (cP)/Density (Kg/m3)
System Pressure Drop
Gas Mol Wt.
Compressibility Factor
Area Classification

RF serrated/ 125AARH
To be marked on body
2 Nos. ( 1no. each of HF and LF pulsar)
*
WEATHER PROOF, IP65
Corrosion resistant Aluminum/ Steel
Aluminum/ Steel
STAINLESS STEEL
STAINLESS STEEL/ suitable for NATURAL GAS

Volume Totalizer
Max Index head Reading
Transmitter
Manufacturer Calibration Certificate
Warranty Certificate
Operation And Maintenance Manual
Make and Model offered

Mechanical OR Digital Counter


8 digit index NON RESETABLE (999999.99)
1 LF and 1 HF Transmitter
To be Supplied along with each meter
To be Supplied along with each meter
To be Supplied along with each meter
*

+/-2% for flow range Qmin to 0.2 Qmax


REPEATABILITY- BETTER THAN +/- 0.2%

**
**
**
**

IEC ZONE 1 GR IIA, IIB T3

: * By Vendor

** As per Process data


1. METER SHALL BE RATED FOR THE MAXIMUM DESIGN PRESSURE AS INDICATED ABOVE. THE OFFERED METER MUST BE DESIGNED AS PER OIML SPECIFICATIONS (OIML R6/R32/
TC8/SC8) AND EN STANDARD EN-12480.
2.

THE RPD METER SHALL HAVE 2 NOS. OF PULSE/ FREQUENCY OUTPUT FOR FLOW COMPUTER INTERFACE (1LF and 1HF).

3.

VELOCITY THROUGH RPD METER SHALL NOT EXCEED 20 m/s.

4.

TYPE APPROVAL FOR CUSTODY TRANSFER APPLICATION FROM WEIGHTS AND MEASURES APPROVED LABORATORIES, SUCH AS NMI, PTB,MEASUREMENT CANADA, NIST OR OTHER
REPUTED NATIONAL STANDARD LABORATORY SUCH AS PIGSAR, TRANS CANADA CALIBRATIONS(TCC) CANADA, COLORADO ENGINEERING EXPERIMENT STATION INC.(CEESI) USA
SOUTH WEST RESEARCH INC. (SWRI) USA SHALL BE SUBMITTED.

5.

LUBRICATOR PUMP WITH LUBRICANT FOR FIRST FILL TO BE SUPPLIED BY BIDDER.

6.

BIDDER TO PROVIDE SUITABLE ADAPTER IF REQUIRED TO MEET THE ABOVE MENTIONED END CONNECTION REQUIREMENT.

7.

FOR EACH PD METER, BIDDER TO PROVIDE CALIBRATION CERTIFICATE PERFORMED WITH AIR AT ATMOSHPHERIC PRESSURE AND AMBIENT TEMPERATURE AT FOLLOWING FLOW
RATES : 0.025 Qmax, 0.05 Qmax, 0.10 Qmax, 0.25 Qmax, 0.50 Qmax, 0.75 Qmax, Qmax

8.

METER CASING SHALL BE TAMPER PROOF & CORROSION RESISTANT ALUMINIUM OR STEEL SUITABLE FOR OUTDOOR INSTALLATION

9. Please Refer, Special Instructions to bidders for RPD Meter provided below.

Special Instructions to bidders for RPD Flow Meter


Range-ability of RPD Meter : Shall be more than 20:1 (Higher Range-ability is referred).
Working Temperature Range : 0 C to 50 C (Ambient Temp.)
0

Max. Index Reading : 999999.99


Reverse flow Restriction : Essential (If not in-built non return valve to be Supplied)
Casing : Tamper proof & corrosion resistant Aluminum or Steel suitable for Indoor/outdoor Meter Internals
RPD Meter Internals : Metallic, tested low noise, frictionless, endurance for minimum 20 years life & external tamper proof.
Noise : Very low
End Connections : 2 / 3 Flanged Confirming to ANSI 125/ASME B16.5
Approved To : Measurement Canada, NMI, PTB as per OIML Specifications or equivalent
Bidder to also Note the following:
1.
2.
3.
4.

Flow capacity in SCMH is calculated considering Maximum Operating Pressure.


Bidder to provide suitable adapter if required to meet the above mentioned end connection requirement.
Bidder to provide Calibration Certificate using Air at atmospheric pressure.
Maximum error observed during calibration (as per calibration report of Meter) shall be within specified accuracy limit/
range
5. Necessary restricted orifice suitable for the respective RPD shall be provided by the bidder.
6. Bidder to include the supply of required length of spool piece, cable, connector etc. with the meters (as required). Lubricant
required for first fill shall be supplied by the bidder.
7. Make of the Meter shall be from Approved Vendor List provides in bid document.
8. The selected meter shall be suitable for Custody Transfer application.
9. RPD meter shall be calibrated by NABL approved Lab.
10. Preferred Installation of RPD Meter shall be Horizontal.
11. NO PLASTIC COMPONENTS Shall be used in RPD flow meter
12. Timing & Reduction Gears : Steel Alloy
13. PRESSURE BODY AND COVERS : Cast Aluminum Alloy
14. IMPELLERS : Extruded Aluminum Alloy
15. IMPELLER SHAFTS : High Grade Alloyed Steel
16. O RINGS/ GASKETS : Synthetic Elastomer
17. BEARINGS : High Carbon Steel
18. MAGNET COUPLING : Hard Ferrite Ceramic Magnet
19. PRESSURE CONNECTION : REQUIRED, 1/2" NPT

19. DATA SHEET FOR INLET FLOW STRAIGHTNER (TYPICAL)

1.

Flow straightener at the inlet of each Turbine meter shall be designed as per AGA Report
no.7 (Latest) and shall be supplied along with Turbine meter.

2.

Flow straightener shall be a bundle of Stainless steel tubes. The tube shall be fixed to the
main pipe rigidly. The profile and the length shall be as per AGA Report no. 7
recommendations.

3.

Pipe Material : API 5L Gr.B

4.

End Connection Inlet side/ Turbine meter side


Material : ASTM A 105

Size & Schedule : * (Size / rating shall be same as meter size/ rating)

Size : * (Size must be same as Turbine meter size)


Rating / Face : 300#/150# ; Raised Face

Finish : * (Must be same as Turbine meter) (As per ANSI B 16.5)


5.

Bolt Material : A 193 Gr. B7


Nut Material : A 194 Gr. 2H

Notes:

1.
2.
3.

* - By Vendor
Refer service conditions in the Turbine Flow Meter data sheets.
Pressure drop across the flow straightener shall be negligible.

20. DATA SHEET & TECHNICAL SPECIFICATION of FLOW COMPUTERS


Item
Type
Measurement Standards

Description
Microprocessor based, solar powered battery operated Flow Computer with integral/external
smart Pressure sensor along with GSM & GPRS Modem suitable for field mounting.
The Flow computer shall be used as custody transfer Application.
It Should meet or exceed :
1) AGA7 (of latest version)
2) AGA5 & AGA8 (Detail, Gross1, Gross2) of latest version
3) API chapter 21.1
In addition to above, the offered Flow computer shall be either Certified for custody transfer
applications by calibration agency/ laboratory / institutes authorized by weights and measures
authority of its country of origin such as NMI, PTB, Pigsar or the Flow computer shall be
Tested/ Calibrated for flow calculations from International Standard calibration agency/
Laboratories/ Institutes/ bodies/ authorized agency of Weights and measure department such
as Pigsar, Trans Canada Calibrations(TCC) Canada, Colorado Engineering Experiment
Station Inc.(CEESI), USA, GOST, South West Research Inc., FCRI, India.

Processor

Bidder to submit Certification for compliance to above.


32 bit Microprocessor or better

Enclosure

NEMA 4 (Copy of certification of the product to be provided by bidder).

RAM

Minimum 256K or better

Display capability

LCD, 2 lines x 15 characters or better. The display can be configured by the user or retain the
standard configuration as follows:
Refresh rate of Display data shall be min 5 sec

Accuracy
Static Pressure sensor (for
Metering)

Time & Date


Pulse rate/uncorrected flow meter cube per hour or day
Pressure
- Kg/cm2
Flowing Temperature
- Degree Celsius
Volumetric Flow Rate
- SCMH / SCMD
Volume as on Today
- SCM
Volume Yesterday
- SCM
Volume Totalized (Non Resettable) -SCM
Battery Voltage and Charging Voltage
Overall Flow measurement accuracy shall be 0.1 % or better
The flow computer module should consist of Inbuilt/external sensor for static metering
pressure with 3 way valve manifold.
Indicative pressure range shall be 0 to 8 Kg/cm2(g) (any other similar range is also
acceptable)
230VAC-12/14 VDC power convertor and Solar Panel along with chargeable SMF battery
with back up lithium battery.
Inbuilt modem GSM (retrofit type)

Minimum
required

Facilities

Type & service area

SCADA interface- Mod boss standard protocol,


Provision must be there to read and write, chromatographic parameters, default values and
alarm limits etc of various parameters by manually (Local interface by laptop/PC) or
through dial up network (through telephone land line or GSM).
Downloading / viewing of daily log, periodic log, audit trails and trend log.
Inbuilt PID loop to control Flow through flow control valve (Analog output-4 to 20 mA
to Control valve).
Non-incendive, Class-I, Division - 2, Group -C & D. (Copy of certification to be provided by
bidder).

Flow Meter type

Turbine / RPD flow Meter

Pulse input range

Flow computer to receive frequency or pulses from RPD Meter/ turbine meter. (Suitable pulse
converter/ barrier shall be supplied by bidder for taking HF pulse inputs)

Metering- Pressure Sensor

Integral, Smart type, with pressure range of 0 to 8 Kg/cm2(g).

Accuracy of
Pressure sensor

0.075% of calibrated span or better with Range ability: 1:10 (Minimum)

Process
temperature

Metering(operating)

0 to +50C

Temperature (RTD) Input

4 wire RTD PT100, Class-A

Long term stability

0.1% URL, over one year

No. of standard serial ports/


Ethernet
port
for
communication

Minimum Three ports required for the following functionality.


a)

1 No. of RS 232 Serial Port for PC/ LAPTOP connectivity

b) 1 No. of RS 232 Serial Port for GSM/GPRS modem connectivity


c) 1 No. RS 232/485 Serial Port OR Ethernet port for SCADA/ RTU
communication facility
Shall be suitable/ Designed to read/ write Data at least 5 times a day.
Operating Temperature

0 (zero) Deg.C to + 55 Deg.C

Operating humidity range

5 to 95% RH

POWER Source

Each flow computer shall be powered through two different power sources viz. primary rechargeable battery and backup lithium battery for un-interrupted operation of flow computer.
The 1st (primary) source of power shall be (user selectable) either 230 VAC to 12/14 VDC or
solar power which should be capable enough to charge the re-chargeable battery, whereas the
2nd (backup) source of power will be lithium battery.
Primary Power source:
A re-chargeable battery ( voltage rating :12V, of minimum 50AH rating Battery) shall be
provide power to FC for at least 720 Hours (30 days) of no sun day operation including data
polling for a minimum of 5 times a day using GSM and/or every 15 minutes using GPRS.
There will be provision for charging the re-chargeable battery using appropriate charge
regulator by a) an external 230 VAC to 12/14 VDC power convertor and b) solar panel in
such a manner that battery is charged through solar power when sunlight is available else it
will be charged using the external supply (230 VAC to 12/14 VDC converter). The 230 VAC

to DC convertor is to be mounted in a NEMA-4 enclosure in safe area where as the rechargeable battery shall be mounted in an Ex-proof Junction box in hazardous area
Secondary Power source :
In addition, flow computer should also have in-built back up lithium battery which it to be
used in case of non-availability of primary power. The Lithium battery system should be
designed to power on the flow computer for a min. of 7 days. As soon as re-chargeable battery
(primary source) is charged, flow computer will get power though the same (primary source)
and the Lithium power source shall be cutoff/ go to stand-by mode (Lithium Battery required
to power on, only in absence of power through external battery / when external battery gets
discharged).
8 to 16 VDC

Power input range:


Re-Chargeable
capacity

Battery

It shall be designed for 30 NO sun day operation of FC including data polling through
Modem as mentioned above. Minimum capacity shall be 50 Amp-hour, 12 V.

Power fail

Restart

Low Battery alarm for


power source

user-configurable low alarm limits to be made available on display and at remote/ host using
GSM/ GPRS Modem

External power source


Solar Panel

Charge Regulator
PROCESS INPUTS /
OUTPUTS

230 VAC to 12/14 VDC power convertor installed in a NEMA-4 enclosure/box and suitable
to charge re-chargeable battery as mentioned above.
50W or more along with suitable rating rechargeable battery mentioned above. Certification
shall be provided for use of Solar panel in the Class-I, Div-II, Group C&D.
Should accept input from either a) 230 VAC to 12/14 VDC convertor or b) Solar panel. It
shall charge the re-chargeable battery to optimum capacity.
For SOR 4 & 7
Minimum I/O required is mentioned below.
Pulse input for LF and HF
RTD Pt 100 (4 wire)
Integral pressure sensor or Analog input for metering PT
For SOR 5 & 8
Minimum required is as follows
Pulse input for LF and HF
RTD Pt 100 (4 wire)
Integral pressure sensor or Analog input for metering PT
4 Digital Inputs
2 Digital Outputs
2 Analog Inputs (skid inlet pressure and temperature)
1 Analog Output (flow control valve)

Transducers

In addition to above, provision must be there in the flow computers offered in all SOR items
to increase the I/Os with add on cards.
Gauge pressure transducers, external RTD,

Pulse Inputs

2 nos. of pulse inputs (HF or LF inputs shall be software selectable)


Note : Any isolator/.barrier as required for interfacing with high frequency output from RPD/

Turbine meter will be in scope of bidder.


Audit Trails

Storage of min. 250 nos. of audit trail alarms and events. All messages to be date and time
stamped.

Daily log

Minimum of 35 days of information, maintained on a daily basis, minimum 6 points user


configurable.

Periodic log
GSM Modem

Minimum of 35 days of information, maintained on an hourly basis.


Dual Band 900/1800 MHz (E 47)
Operating Temperature : -25 to 55 Deg C.
Input supply voltage : From Re-chargeable Battery pack provided along with Flow
Computer.
Serial RS232 serial communication cable.
Data Rates : min 2400 BPS
Data SIM Card : Mini SIM plug in/ removal
Cellular data Service : Radip Link Protocol/GPRS/Class BB (4+1)
Note :
1) GSM Modem shall be provided with flow computer (preferably installed inside
Flow Computer enclosure)
2) GSM modem must not affect the Flow Computer operation in any way (Modem
operation must be independent of with Flow Computer operation).
3) GSM power off smart Functionality: In order to safe guard the Flow Computer operation
on continuous basis GSM must get auto power off when Flow Computer battery backup
Voltage reaches Certain pre-defined LOW Value (say 11.2 V) and shall Power ON once
adequate power is available.
4) The offered Modem should be capable of being configured by user at site for GSM-data
and/or GPRS mode of communications

Calibration

Warranty
Indicative Register
configuration to be done in
serial manner for these
process parameters for data
retrieval in SCADA
(additional parameters,
inputs/ outputs and exact
configuration/ details will
be furnished during detail
engineering)

The flow computer shall be calibrated to the specified range. The calibration certificate to be
furnished by bidder.
Warranty period shall be in line with tender
Corrected Flow Rate
Today Total
Yesterday Total
Flow Cumulative
Pressure
Temperature
Uncorrected flow
Zf and Zb
Sp. Gravity
Calorific Value

N2 %
CO2 %
Methane %
Ethane %
Propane %
n-Butane %
i-Butane %
n-Pentane %
i-Pentane %
C6+
Energy Flow rate
Today Energy Total
Yesterday Energy Total
Re-chargeable Battery Voltage
(primary source)
Accessories required with
flow computer

1. 3-way Valve manifold - NPT( F) for process connection along with standard fittings.
The manifold shall have locking facility to prevent tampering after calibration.
2. Solar panel, SMF re-chargeable batteries along with connecting cable ((Distance
between re-chargeable battery and flow computer shall be minimum 20 meters
length)
3. 2 pipe mounting stand, brackets, necessary nuts and bolts and canopy for mounting of
Flow Computer and solar panel etc
4. Flow computer configuration Software and its license for retrieving the stored data,
(archives and audit), remote monitoring, remotely GC data updation, configuration
of process & metering parameters, programming the flow computer using portable
PC(Laptop), software based on Windows 2000/ XP shall be supplied in the form of CDs.
5. Inbuilt Modem shall be provided in the flow computer for interfacing and remote data
configuration, remote data uploading and remote data monitoring through GSM.
6. The communication speed for serial Communication port for flow computer shall be
configurable from 2400 to 19,200 bps.
7. The Modbus communication protocol and message structure details to be used on the RS
485 / 232 serial communication port (for GSM / SCADA) shall be supplied.
8. Sufficient double compression gland may be provided in Flow computer so that
connections are made for GSM, signal, power etc

9. Communication cable for communicating flow computer with lap top one no with each
flow computer.
10. Each flow computers should be tagged to particular location (location details shall be
provided later on)
2 sets of following drawings/documents shall be supplied with each Flow computer:
DOCUMENTATION -:

Catalog/product data sheet


Instruction, Operation & Maintenance manual in soft/hard copy.
Warranty certificate
Flow computer documentation including product literature, software/hardware manual,
operating manual, maintenance instructions, Certificates etc. shall be supplied one each
with all the Flow Computers.

Calibration Certificates to be submitted for all the Flow Computers separately.

Validation of Flow Computer (Flow Computation sheet comparing with standard


softwares like Kelton / Flow Cal etc.)

confirming to latest AGA-3 / AGA-8 to be submitted for all the flow Computers
separately
3-Way Valve Manifold (for metering pressure) shall have following specifications:

BODY MATERIAL: AISI 316 SS


RATING: 6000 PSI
HANDLE MATERIAL: AISI 304 SS
STEM TYPE: CONICAL METAL TIP
STEM PACKING: PTFE
(Inlet X Outlet) : NPT (F) x NPT (F). Further suitable SS tube fitting required
for connecting " SS TUBE for pressure tubing.
FEMALE TO BE PLUGGED

SPECIAL INSTRUCTIONS TO VENDOR (FOR FLOW COMPUTERS)


General:
1)

Vendor shall be responsible for selection of the correct model nos. of instruments to meet the purchasers
specifications. In case of Model no. required to change at a later date to meet the Purchasers Specifications, the same
shall be done by the vendor without any price and delivery implications. Each metering stream shall have separate
(independent) flow computer.

2)

Bidder shall submit Make, Model No. with decoding details, Technical Literature and Catalogue of Flow Computer

3)

DUAL Battery operated field mounted Flow Computer along with all the accessories shall be supplied. Flow computer
with integral data logger facility is also acceptable however there should be no compromise on functionality, I/Os,
power, communications etc.

4)

The flow computers shall be microprocessor based, with data entry keypad and alphanumeric display with AGA
firmware for natural gas flow measurement. Flow computer electronics shall be protected from industrial interferences
and shall be shock and vibration proof.

5)

Validation of Flow Computer (Flow Computation sheet comparing with standard software) confirming to latest AGA-7
(latest version) / AGA 5 / AGA-8 / GPA 2172 / GPA 2145 to be submitted for all the flow Computers separately.

6)

The flow computer shall have a facility for audit trail, web enabled and shall be compatible to calculate compressibility
factor as per AGA-8 detailed method, provision for digital communication and pulse / frequency both.

7)

The flow computer shall be certified for custody transfer applications by laboratory / institutes authorized by weights
and measures authority of its country of origin such as NMI, PTB, Pigsar or shall be tested/calibrated for flow
calculations from International Standard laboratories/ Institutes/ bodies such as Pigsar, Trans Canada Calibrations
(TCC) Canada, Colorado Engineering Experiment Station Inc.(CEESI) USA GOST, South West Research Inc., FCRI
Weights and Measure India. Certificate to be submitted by bidder.

8)

The flow computers shall compute and display the instantaneous and totalized flow rate for each stream corrected for
pressure and temperature variations.

9)

The Flow computers shall have serial ports for communication purpose with Data Logger/RTU/SCADA, USB port /
RS232 with adaptor for laptop connectivity.

10) The power consumption of Flow Computer and other associated utilities of online system shall be considered for
Backup calculation and finalization of Power requirement.
11) FC Vendor shall be provided all necessary assistance if required for Software Configuration, Flow Computation
Checking & Serial Communication checking with RTU/SCADA/ Data Logger etc. (RTU/SCADA are not in scope of
vendor)
12) Vendor/ Supplier shall provide all necessary hardware, software, serial communication cables with connectors etc. for
Flow Computer connectivity to RTU/ SCADA, USB port / RS232 with adaptor for Laptop. Other details required for
interfacing of their Flow Computers with Purchasers RTU/SCADA. In addition to this, the communication software
shall be supplied in CD / DVD for testing the communication link.
13) MODEM- GSM/GPRS (in-built) : Required GSM/GPRS MODEM would enable the Data to be sent to a HOST PC or
a Secure Web site using GSM and/or GPRS or equivalent technology.
14) Bidder shall follow Data sheet and Technical Specification of Flow computer provided in Tender.

22. ONLINE BATTERY OPERATED ELECTRONIC VOLUME CORRECTOR


1. Type : Microprocessor based internal Lithium battery operated Volume corrector with
integral Pressure transmitter and temperature sensor suitable for mounting in the field
location in Hazardous area. Offered EVC will be separate external unit to facilitate the
interchangeability of RPD Meter & EVC. In case of any malfunctioning of EVC,
same can be replaced without removing the RPD meter from line. Suitable mounting
bracket / arrangement for EVC would be provided by vendor.
2. Make

: * (By Vendor)

3. Model No. : * (By Vendor)


4. Quantity

: 1 No. for each RPD meter as per respective P&ID.

5. Function (measure and display):


To measure actual gas low (volume) based on pulse/ frequency input from flow meter,
metering pressure & metering temperature and calculate compressibility factors of the
gas (in flowing condition and standard/ base condition). Based on above parameters, it
shall calculate standard volumetric flow rate, totalized standard volume of gas (on
daily basis). It shall also be able to calculate energy flow rate & totalized energy (on
daily basis) based on gas composition/ GC Data entered in EVC.
Apart from this, it shall also display non-resettable totalizers for total corrected
volume, total uncorrected volume and total energy of gas. It should also have
capability of putting K-factor, meter factor (derived from flow meter calibration). The
unit shall be standalone unit and complete in all respect to achieve the above
mentioned functionality.
Minimum 2 lines of display is required to meet above display requirement.
6. Input capability:
a) HF and LF Pulse signal from RPD flow meter for flow (actual/ standard).
b) Temperature signal from 4-wire RTD temperature element (Pt-100) in the range of () 20 0C to 50 C; with an accuracy of +/- 0.2% of measured value (along with Thermowell). Thermo-well shall be provided with RTD element.
c) Pressure signal from built-in Pressure Sensor in the range of 0.9 to 10.0 Kg/cm2a
(absolute); with an accuracy of +/- 0.15% of measured value or better. Pressure sensors
shall be individually calibrated and characteristics stored within the volume corrector.
Required tubing and tube fitting accessories shall also be supplied by vendor.
Protection from over pressure upto 12 kg/cm2 g shall be provided.

Serial Output : RS 232 serial port for PC/ LAPTOP connectivity. (1 No. Port)
7.

Output / Measurement capability:


a)
b)
c)
d)
e)
f)
g)
h)
i)

Un-Corrected flow rate in actual cubic meter per hour (ACMH).


Corrected Flow rate (in SCMH)
Corrected Totalised volume : SCM
Temperature (in Deg. C)
Pressure (in Kg/cm2g)
Actual Volume (in ACM)
Correction Factor
Compressibility factor (Base/ Standard and Actual)
Alarm outputs for unit malfunctioning or Process parameter out of range/
limit

8.

Isolation : All inputs, outputs and power supply shall be individually isolated.

9.

Display capability:
Minimum 2 lines of large character Alphanumeric LCD display with selectable
decimal, Displaying all units of measurement, range of measurement, messages,
alarms (Battery Low, Pressure out of range, Temperature out of range, flow over
range, fault in measurement) etc, which shall be displayed in English language.

10.

Units of display :
a) Un-Corrected flow rate : ACM/Hr.
b) Corrected flow rate
: SCM/Hr
c) Corrected Totalised volume : SCM
d) Pressure
: Kg/cmg
e) Temperature
: 0C
f) Actual Total Volume : ACM
g) Correction Factor
h) Yesterdays Corrected Volume : SCM
i) Non resettable total : SCM
j) Days Total
: SCM
k) Energy Flow rate
: MMBTU/Hr (or MJ/Hr or MCal/Hr- user selectable)
l) Total Energy
: MMBTU (or MJ or MCal- user selectable)
m) % CO2, % N2, Sp.Gravity

11.

Power Supply : Lithium Battery (having minimum life of 5 years) Battery pack
should be intrinsically safe and replaceable in Field itself, without memory loss.
Battery along with mounting Hardware is required. Warranty for Battery required.

12.

Configuration Setup : Shall be done in factory for all volume corrector fully taking
into account the process conditions, sensor & flow meters characteristics and
calibration for direct on-site operations.

13.

14.

Calculation Standard :
Compressibility : AGA 8 (latest version)- gross 1 and gross 2, detailed (Latest)
Volumetric Flow calculations: AGA7 (Latest)
Features :
a) Built in diagnostics to detect proper functioning.
b) Data security through password, key-lock facility and volume conversion and
configuration to be sealed.

b) Parameters and programmed constants shall be stored in non-volatile memory, EEPROM /


flash memory.
d) Facility for entry and accessing live and stored data through Laptop.
e) Shall have facility to store at least 120 days of data (on hourly basis) of 4 parameters with
data and time stamping (such as flowing pressure, flowing temperature, corrected flow rate and
uncorrected flow.
f) Shall have facility to store at least last 35 days cumulative corrected flow on daily basis.
g) The stored data above shall be retrievable by using Laptops or GPRS/GSM Modem. Suitable
dedicated serial port shall be available on the volume corrector for portable PC / Modem
connection. Software required shall be supplied, which shall be compatible to use with
SCADA. Register address and protocol details shall be supplied by bidder.
15.

Hazardous area: EVC and related accessories shall be Certified intrinsically safe for hazardous
area as per IEC-79-Zone 1, Group IIA/IIB, T3/T4. Furnish copy of the certificate conforming
the suitability of the Meter for use in Hazardous Area as per IEC-79-Zone 1, Group IIA/IIB,
T3/T4.

16.

Site Condition : Temperature 0 to 50 C, Hot, humid, tropical, saline environment.


Vibration: Tested as per ISA s75-13-1989, Sec. 4.2 & 5.35, ECD susceptibility: Should meet
IEC- 801-2, Level 3.

17.

Enclosure : Weather proof to IP65/ IP66 and Compatible for mounting in Hazardous area,
mentioned above.

18.

Mounting : Outdoor open to atmosphere on pipe/ bracket as per skid arrangement.

20.

Overall Accuracy of EVC : +/- 0.5% (Bidder shall categorically indicate the system accuracy
i.e. overall accuracy considering RPD flow meter, PT, RTD etc.).

21.

Accessories required : (a) 2-Valve Manifold SS ( NPTF) for process


Connection. (b) Mounting brackets for 2 Pipe for installation of EVC at site.

Notes (to Bidder for EVC):


1. Two set of software for retrieving the stored data, programming the volume corrector using
portable PCs (Laptop), software based on Windows 2000/ XP shall be supplied with each
Skid.
2. 2 sets of Volume corrector documentation including product literature, software & hardware
manual, operating manual, maintenance instructions, Certificates etc. shall be supplied
along with each Skid.
3. The Volume corrector shall not be integral with RPD Flow Meter. There should a 2-Line
LCD Display in the Volume Corrector as per the specifications. The installation of EVC
shall be in safe area (approximately 15 feet) or in separate enclosure outside the main skid
canopy with the necessary cables and accessories shall be done. This should be as per the
IGE/TD/13 guidelines.
4. EVC shall be suitable for Custody Transfer of Natural Gas by NMI, PTB or Measurement
Canada or Directorate of Legal Metrology (India) under provision of OIML or related
guidelines.
5. Following features shall be available in volume corrector: Memory allocations shall be as given below: a) Flash memory with non-volatile copy of program code.
b) Programmable peripheral chip with EEPROM contains boot ladder code.
c) SRAM with copy of program code and data/exact logs.
d) Flash memory preservation to be achieved by 5-year data unpowered retention.
e) SRAM memory preservation to be backed by Lithium Cell / Super capacitors
6. Bidder/ Supplier shall configure and update records in Volume Corrector as per technical
requirement and data sheet before Final Inspection call. The process parameter and the
required measuring units are already specified in Data sheets/ tender documents and it shall
be made available in Volume Corrector. All the specified function and features shall be
demonstrated during the Final inspection.

23. Data Sheet- Differential Pressure Instruments (Typical)


Pressure> Kg/cm2 G

UNITS: Flow> Gas M3/hr


General

Temperature > Deg C


Controller

Transmit and Indicate

12. Output

2. Type

Electronic, smart .

3. Case

Manufacture standard

13. A/M Switch


No of Positions

:
:

4. Mounting

Yoke (2 NB Pipe mounting)

14. Set point Adjustment

15. Manual regulator

1. Function

5. Electrical area classification :

Zone-1, GR IIA/IIB, T3

6. Enclosure

WP to IP-65

7. Hazardous area protection


8. Air Supply

Intrinsically safe (Note 6)


N/A

9. Power Supply

10. Cable Entry

NPTF

11. Accuracy

0.04 % of span with


Turndown of 1:5 (including
linearity, hysteresis &
repeatability) for metering PTs
(used for Custody transfer
application),

16 Measuring Unit
17. Service
measurement

: Differential Pressure

18. Element:
Capacitance

: Silicon resonant /

19. Body Material

: Carbon steel / Aluminium

20. Element Material

: SS 316

21. Process Connection


Process connection location

: NPTF
: Bottom entry

22. Static Pressure Rating

: 100 Kg/cm2

0.075% of calibrated span (including 23. Options


linearity, hysteresis & repeatability)

a.

3/5 -valve manifold with equalizing valve : Required

b.

Intrinsically safe LCD Type O/P meter : Required

c.

Mounting Accessories for 2 pipe mounting : Required


(Along with suitable Bracket, U Bolts & Nuts)

Tag No

Range
Span

Calibration

Zero
Zero
Design
elevation Suppression Pressure
In H2O
In H2O
4-20 mA DC / Low power

Max
Temp
C

Fluid

Service

Remarks

24 V DC (Two Wire)
12.
Make, Model
:
Notes:
* - No.
By Vendor

12 VDC (low power)

1.

Transmitter shall be suitable for external loop resistance of at least 600 ohms when powered with 24 V DC .

2.

Output 4-20 mA shall be superimposed on digital signal with HART Protocol (flow computer systems).

For low power transmitters, output and power supply shall be different.
Transmitter
3.
Digital communication shall be possible with hand held communicator.
13. Output
:
4.
Integral intrinsic safe output meter (LCD type) shall be provided for all transmitters.
14. Transmitter Power supply :
5.
Over range protection shall be suitable for maximum pressure or 130% of range, whichever is higher.
6.
7.

CCOE approval certificate shall be provided for transmitter


Equipment shall be protected for full pressurization in one side and no pressure on other side with equalizing valve in closed condition.

24. Flow Control Valve (Typical)


3

UNITS : Gas Flow - MMSCMD, Liquid Flow - m /hr , Steam Flow Kg/hr , Pressure - Kg/cm2g , Temperature Deg C , Level / Length - mm
General

Tag No.

Inlet Line No.

Skid Mounted

Outlet Line No.

Skid Mounted

Service

Natural Gas

Line Size

Schedule

Inlet Line I.D.

Outlet Line I.D.

Type of Body
Body Size

Port Size

Same or higher than


the meter size

Full port

Guiding

No of Ports

10

End Connection: Flanged. Size & Rating

11

Facing & Finish

RF

125 AARRH

12

Body Material

ASTM A216 Gr WCB or better

13

Bonnet Type

Plain

14

Packing Material

Teflon

15

Lubricator

16

Trim Form

Equal Percentage

17

Trim Material Plug/Disc/Ball/Seat

SS 316 Stellited

18

Other Wetted Parts

SS 316

19

Soft Seating

20

ANSI Leakage Class

Class IV

21

Type

Spring & Diaphragm

22

Close At

23

Failure Position

FO

24

Hand wheel Position

Yes (Side Mounted)

25

NG Supply Pressure

26

Input

Output

0.2 - 1.0 Kg/cm2g

27

Bypass

Gauge

Note - 1

28

I/P Converter ( Suitable for NG)

Required

29

Filter With Gauge

Required , Two Sets

30

Limit Switch/ Proximity Switch

Body

Actuator

Positioner

Globe

Isolation Valve

Material

Open At

Three

Service
Conditions

31

Fluid

33

Flow Liquid- Min

Normal

Max

Flow Gas - Min

Normal

Max

35

Flow Water_Min

Normal

Max

36

Inlet Pr._Min

Normal

Max

37

MAX. D.P.
@Min Flow

38

Delta Pr. Shut Off

39

Temperature C operating

40

34

State

MAX. D.P@
normal Flow

Natural Gas

Gas

10% of
capacity

75% of
capacity

100% of
capacity

PDS

PDS

PDS

MAX. D.P@
max. Flow

*
Maximum

-20 to 50

-20 to +65

Operating S.G.

Mol Weight

CP/ CV

Compressibility
Factor

**

**

42

Flash %

Viscosity (CP)

---

**

43

Degree of Superheat % Solids

44

Vapour Pressure

45

% Opening Min./ Normal/ Max.

41

46

100% Radiography

Required

Cv. Min.

Cv. Max.

**

**

48

Cv. Nor.

Selected Cv

**

**

49

Predicted Sound Level DBA

50

Inlet Velocity (in m/sec)

Make and

51

Valve

Model Nos.

52

Positioner / I/P Converter (or Electro-Pneumatic

< 85 dBA
*
Actuator

Positioner
53

(As per process data )

Critical Pressure

47
Valve Data

(Refer Process data for the skid)

High Pressure gas supply trains

Notes :
1.

* -To Be Furnished By The Bidder

2.

**- To be derived from Process data sheet.

3.

By Pass is required if Input is equal to Output

4.

Valve size shall be same as Meter size and valve shall be of full port design.

25. MOC- PIPE WORK & FITTINGS


PIPE WORK & FITTINGS

MATERIAL

PIPE WORK

API 5L Gr B or ASTM A 106


Gr. B

FITTINGS

ASTM A 234 GR WPB, ASTM


A 105

Bid Document No. 8000005410


Annexure-7
TECHNICAL QUESTIONNAIRE
This questionnaire shall be duly filled in and submitted alongwith un-priced sets of offers to avoid further
queries and to ensure proper evaluation of your offer in time. If this is not complied with, your offer is liable
to be rejected.
ANSWER `YES, `NO OR `NOT APPLICABLE
Sl.
No.
1.

Description
Do you Have any deviation to the following :

i)

General specifications (Clause wise)

ii)

Special requirements (Clause wise)

iii)

Mechanical/ Instrument specifications indicated in the data


sheets, Technical specifications/ tender document.
The scope of supply as indicated in the Scope of work and
specifications.
If `Yes, have you included the list of deviations?
(If no deviations are furnished, It will be assumed that all the
specifications and requirements of the subject requisition are
complied with and no deviation whatever will be accepted
after the placement of order. Further, bidder shall give
undertaking that in case of any technical deviation observed in the
bid document, same shall be treated as null & void and tender
conditions shall govern).
Have you included in the quoted price for the mandatory
Spare parts, including consumables required during start-up
and normal operation & maintenance, mounting accessories,
cables, special calibration kits and equipment (complete with
technical details) required, if any, for the erection,
commissioning and maintenance of the Equipment/
Instruments?
Have you considered in your offer, the shop inspection
charges, if any, for inspection at your works by GAIL/ their
representative?
(The details of the tests to be carried out during shop
inspection are to be furnished by bidder).
Have you enclosed the relevant technical catalogue/ literature
in ENGLISH language including model decoding details,
drawings etc. necessary for the evaluation of your offer?

iv)

2.

2(a).

3.

Bidders Response
(YES / NO/ NOT APPLICABLE)

Have you confirmed that the documents required as per the


vendor data requirements will be supplied after placement of
order?

Have you furnished the certificates from statutory bodies viz.


BASEEFA, FM, CSA etc. for the explosion proof construction/
intrinsically safe design of the instruments wherever specified?

6.

Have you confirmed that certification from statutory bodies


viz. Lloyds, TUV, NMI, PTB etc. will be furnished wherever
specified?

GAIL (INDIA) LIMITED

TECHNICAL QUESTIONNAIRE
MRS/ DRS SKID BIDDING
DOCUMENT NO. 8000005410

GPRMS - TQ
Page 1 of 3

Sl.
No.
7.
8.

9
10
11.

12.

13.

Description
Have you indicated separately the Supervision charges for
installation, testing and commissioning? (Bidder to note that
same is included in bidders scope of work).
Have you furnished sizing calculation, certified capacity curve,
Noise calculations for all relevant instruments/ equipment (like
SSV, regulators, FCV, Flow meter, transmitters etc) with
complete details as per tender requirement?
Have you furnished the customer reference list in India/
Abroad?
Have you furnished the estimated power/ utility consumption
and special cable requirements, if any, for the instruments
quoted?
Have you submitted the pressure drop calculation across the
individual Metering skid / MRS/ DRS components and total
pressure drop across the complete skid?
Have you attached the completely filled data sheets and sizing
calculation for all the instruments, equipments and mechanical
items with all relevant details like make & model no., size etc.
Have you attached all the documents in English language?

14.

Have you enclosed detailed technical specifications and


Catalogue of each offered item?

15.

Do you Confirm that the all bought out items (like Filtration,
FCV, PCV, SSV, Flow meter, Ball Valves, Globe valves, Check
valves, Plug valves, PSV, CRV, Flow Computers, EVC etc.) has
been selected from the vendors list provided in tender
document (the bought out items shall be as per tender
requirement and make and model of items shall be subjected
to fulfilling tender requirement and approval by GAIL)?
Have you furnished CCOE certificate for field instrument?

16.
17.

18.
19.

20.

21.
22.

Bidders Response
(YES / NO/ NOT APPLICABLE)

For each SOR items, have you offered Flow computer, Turbine
meter/ RPD Flow meters from the vendor list and these
offered items have type approval for custody transfer
application?
Have you enclosed Type certification for the selected and
offered Make & Model of Flow computer, Flow meters?
(Any deviation shall be brought to notice of GAIL).
Have you enclosed Type approval for the selected and offered
Make, Model of Slam shut valves and PCV (Regulators).
Do you confirm to furnish (after award), the Logistic
support certificate for offered Make/ Model of all the major
items like Flow computer, Flow Meter, SSV, PCV
(Regulator), FCV, Filtration system, from the respective
Original Equipment Manufacturer (OEM)?
Have you furnished Equipment Qualification Form for
offered Make/ Model of all the major items like Flow
computer, Flow Meter, SSV, PCV (Regulator), FCV,
Filtration system, Electro Pneumatic Positioner/ I/P
converter from the manufacturer?
Have you furnished details for solar panel including system
architecture, make/ model of its components?
Have you furnished Performance Guarantee Certificate for
the metering skid?

GAIL (INDIA) LIMITED

TECHNICAL QUESTIONNAIRE
MRS/ DRS SKID BIDDING
DOCUMENT NO. 8000005410

GPRMS - TQ
Page 2 of 3

Sl.
No.
23.

24.

25.
26

Description

Bidders Response
(YES / NO/ NOT APPLICABLE)

Do you agree that after the award of contract, details shall be


provided by you for our review/ approval for qualification of
TPI and their representative appointed by you?
The TPI appointed by you shall be qualified enough for
inspection to be carried out at various stages of
manufacturing of Metering skid.
For each SOR items, Have you offered SSV and Regulator
(PCV) from the vendor list and these offered items have type
approval.
Have you enclosed Type certification for the selected and
offered Make & Model of SSV and Regulator (PCV)? (Any
deviation shall be brought to notice of GAIL)
Do you confirm compliance to the conditions mentioned in
Special conditions of Contract provided in tender?
Do you agree
a) that in case the above information is found to be
incorrect, the bid shall be rejected and no
explanation/ clarification shall be entertained/ sought
from the bidder?
b) In case there is ambiguity in respect to make, model
and size of any component/ item, the make/ model/
size most suitable for this application shall be
selected/ considered, without any financial implication
to GAIL?

Note:

Bidder to note that, if the answer provided by you for the questionnaire Sr. No. 2 to 25 is NO
(Negative), then Bidder shall furnish details thereof.

GAIL (INDIA) LIMITED

TECHNICAL QUESTIONNAIRE
MRS/ DRS SKID BIDDING
DOCUMENT NO. 8000005410

GPRMS - TQ
Page 3 of 3

ANNEXURE-8
TECHNICAL SPECIFICATION
FOR
INSTRUMENT & EQUIPMENT

GENERAL TECHNICAL SPECIFICATION


FOR
SELF ACTUATED PRESSURE CONTROL VALVES &
SLAM SHUT VALVES

TECHNICAL SPECIFICATION FOR


PRESSURE CONTROL VALVES & SLAM SHUT VALVES
1.

Set point of the Gas pressure regulators/ Monitor (PCVs) and Slam Shut Valves (SDVs) shall
be adjustable. Vendor shall furnish the adjustable range of the Gas pressure regulators and
slam shut valves.

2.

The Gas pressure regulator and slam shut valves shall be provided in redundant pressure
regulation stream as primary pressure regulating stream and secondary pressure regulating
stream as per P & IDs. It is intended to provide slam shut valves on upstream of self-actuated
pressure control valves at gas receiving points for tight shut off at increasing pressure beyond
a preset limit, to take care of self-actuated pressure control valves failure. The slam shut
valve of primary regulating stream shall close at its set pressure in case of failure of primary
operating regulator & monitor and the secondary regulating stream shall come in operation.
The automatic switchover shall be achieved with appropriate staggered setting of Pressure
regulator/monitor and slam shut valves. Vendor shall select the appropriate set points such
that the switch-over is smooth without affecting the safety of the system and gas supply to
consumers is also not interrupted.

3.

Each pressure regulator / monitor shall be designed for maximum gas flow rate at the
minimum inlet arrival pressure. Gas pressure regulators shall be with very high range-ability
since high fluctuations in flow demand are expected and also the inlet pressure may vary
considerably.

4.

Pressure regulators/ monitors shall be self-actuated pilot operated with regulation accuracy
of/ better than +/- 2.5% of set point. Slam shut valve shall have a set point accuracy of 2.5%
of set pressure over the whole operating pressure range.

5.

The construction of the pressure Regulators (active & monitors) shall be such that there will
be no continuous gas bleeding.

6.

Leakage class for pressure control valve & slum-shut valve shall be class-VI as per ANSI
B16.10

7.

Vendor to note that the noise level for each pressure regulator shall be less than 85 dBA at
one meter away from the valves. Vendor shall provide noise treatment to limit the noise level
and include silencers or expanders as required in their scope of supply. Vendor to provide
Noise calculation giving full details and standards used and any assumptions considered in
calculation (This calculation shall be submitted along with the bid).

8.

Slam shut valve shall be self-contained type requiring external control line such that the line
pressure acts directly on the diaphragm.

9.

Closing time of slam shut valve shall be less than 2 seconds for all sizes of the valves. Actual
closing time of the valve shall be furnished by vendor along with the bid. Resetting of slam
shut valves shall be manual only.

10.

Slam shut valves shall be provided with a mechanical indicator to indicate valve open or
close position. Slam shut valves shall be provided with position indicator and shall have
separate limit switches for open and close positions. Limit switches shall be with DPDT, snap
acting micro switch with contact rating 1 A @ 24 V DC. Limit switch enclosure shall be
weather proof to IP 55 and flame proof (Exd) suitable and certified for area classification
IEC Zone 1, Gr. IIA, IIB, T3. Cable entry shall be NPT without flying leads.

11.

Any By-pass valve provided for the slam shut valve shall be spring closing type.

12.

Velocity at pressure regulating valve may increase beyond 20 meter per second however in
the downstream pipe it shall be within 20 meter per second. Actual seat velocity shall be
indicated by vendor.

13.

Vendor shall furnish the flow rate versus trim lift curve to justify the pressure control valve
range-ability and valve regulation characteristics.

14.

The self actuating Pressure regulating valve shall be designed as per EN334 and Pressure
Equipment Directive PED 97/23/EC covering the production quality assurance. The Slam
shut valve shall be designed as per EN14382 and Pressure Equipment Directive PED
97/23/EC covering the production quality assurance.
GENERAL POINTS- SLAM SHUT VALVES & GAS PRESSURE REGULATORS (PCV):

1. Purpose:
It is required for supply of regulated natural gas to industrial, commercial & domestic customers
through pipeline distribution systems, distribution network and incorporating appropriate safety
devices to protect against excess and lack of downstream pressure. DRS shall cater requirement of
a cluster of customers, whereas MRS shall be installed for each customer separately.

Twin stream Pressure Regulating system is required for DRS and MRS. Each stream of
pressure Regulation shall have Monitor regulators (Fail Close type) and active regulators
(Fail Open type) along with Slam Shut Valves, so that if any one fails, then the other one
will come in line automatically and maintain required process in safe conditions. Under
normal conditions, the downstream regulator is considered as the active regulator and
upstream regulator performs the monitoring function. The installation of monitoring
regulator shall be such that it is the first acting device in the pressure safety system. Slam
shut valve is also required in each stream of Pressure regulation system. Each stream of
Pressure regulation shall be designed for full capacity. Monitor regulators with integral
Slam shut valve is also acceptable.
Stream discrimination is required in DRS & MRS skids. Each stream of PRS shall have the
capacity to supply 100% of design flow rate at the specified pressure. PCV (Regulator) and

SSV shall conform to the requirements of EN 334 and EN 14382 respectively. PSV shall
conform to the requirements of API 520/526.
2. Standard features of SSV and Regulators:
SSV and Regulator for DRS & MRS envisaged for SOR 1 to 8 shall be Pilot Operated (for
SOR- 1 to 8, Pilot operated Regulators and SSV is required).
Pressure shut-off device (SSV) should be provided to protect against excess and lack of
downstream pressure. SSV shall be provided before PRV, which shall be automatically activated,
in case of pressure at the downstream of PRV exceeds the set value. SSV shall protect the
downstream against over pressure. Preferably separate slam-shut valves should be provided at
upstream of regulators in each stream.
Accuracy and lock up class of pilot operated SSV & Regulator (for SOR- 1 to 8): Accuracy and
lock up class shall be 2.5% and 5% respectively (as per the requirements of EN 14382: 2009) or
better for pilot operated SSV & Regulator envisaged for SOR Items 1 to 8. Lock up: As the flow
through a governor is slowly reduced from 5% of maximum flow to zero, the governor must not
allow the outlet pressure to rise by more than 10 mbar or 5% of the set pressure (g), whichever is
greater, above the value at 5% of the maximum flow.
The selection of SSV and PRV shall be based on maximum flow at minimum inlet pressure. The
active regulator will be of Fail-to-open design. Monitor regulator and SSV shall be of Fail-toclose design. Separate slam-shut valves should be provided upstream of the regulators in each
stream. However integral slam shut valve with Monitor regulator is also acceptable.

Pressures Regulators/ SSV shall be pilot operated for DRS and MRS Skids. Same shall be
designed in such a way that inlet pressure does not come in direct contact with the main
valve diaphragm (i.e. only loading type of regulator shall be accepted).
Creep Relief Valve is required to prevent over pressurization of the downstream system, as the
result of the active failing to lock-up during period of low flow demand. The capacity of the
relief valve (CRV) shall be 1% of the stream design capacity. Vent at downstream of regulator shall
be provided for depressurizing the PRS stream and also to discharge gas from relief valve to a safe
place at least 3 meters away from the working platform in DRS/ MRS vicinity and it should be
provided with suitable flame arrestors and rain protection. Open end of vent pipe shall be provided
with weather hood (with cover, which automatically opens in case of venting and closes during
normal condition, to avoid water/ rain drops to enter the skid). Care shall be taken, so as not to
allow generation of spark during valve operation. Isolation valve (with lock-open) shall be
provided at the inlet of creep relief valves.
In general, burst pressure of a diaphragm should be at least three times the maximum working
differential pressure.
Adequate clearance should be provided between the top of the regulator, SSV, skid etc and roof of
skid-cabinet in order to carry out the adjustment and maintenance of PRS without any
inconvenience.

3. Marking
The Regulator, SSV and CRV shall be marked with the details like Sr. No., Make, Model, Type,
pressure rating, year of manufacture, flow range & flow at set outlet pressure, inlet pressure range,
outlet pressure range and set point, over pressure shut off range and set point, under pressure shut
off range and set point, relief pressure range and set point and orifice size; and identification marks
shall be provided on pilots of active and monitor regulator.

TECHNICAL SPECIFICATION
FOR
FILTRATION

SPECIFICATION OF GAS FILTERS


Bidder shall read the Specification of filters in combination with Data Sheet and tender specification.
Twin Dry gas Filtration system (each filter stream designed for 150% of design skid capacity) shall
be provided at skid inlet, to remove the dust, debris & impurities damaging the Regulating &
Metering blocks, as per IGE/TD/13, Sub-section 7.3 (Latest).

Design and construction shall meet the requirements as per ASME Boiler & Pressure Vessel
(BPV) Code, ASME Section VIII: Div-1 latest. The flow of gas shall be of out-to-in type,
i.e. the design of the filters shall be such that (unfiltered) gas from the inlet piping shall
enter in the annular space (i.e. the space between the filtering element(s) and the wall of the
filter) and then the filtered gas should flow in the skid. The design flow rate of each stream
of filter shall be 150% of rated skid capacity.
For MRS (SOR Items-3 to 8), dry gas filters shall have Vertical Configuration. For DRS
(SOR Item-1 & 2), the filters & strainers shall be of vertical / horizontal design (as
applicable and with prior approval of GAIL). GAD of skid and filtration shall be submitted
by bidder for our approval before fabrication of filters. There should be enough clearance
provision between the top end of the filter and the roof of the skid for removing the vertical
filter element from the top end.
The impurities that are likely to be present in gas and may be carried over with the gas shall
be filtered in this block. Normally, the Degree of filtration shall be better than/ equal to 3
m @ 99% efficiency.
Each stream of Filtration shall have the capacity to cater 150% of the flow at the minimum
inlet pressure.
DP across filters at worst condition shall not exceed 0.1 Kg/cm2g in clean condition.
Burst pressure of filter element shall be 1.5 Kg/cm2g or higher.
Each stream of filter of DRS/ MRS shall be fitted with a Differential Pressure Gauge (DPG),
designed for design condition and with DP range of 1.5 Kg/cm2g, which is required to
monitor the choking of filter element. Isolation valves and manifold for DPGs shall also be
provided.
Manual drain valve (Globe type) with backbone ball valve in series shall be provided for
handling of condensate/ drain.
All the filters shall have purge, vent & drain connections with valves (with positive blind
arrangement). These should be suitably located and sized to ensure a reasonably short blow
down time. The filter drain (of minimum 1 size) shall be vertical and in downward
direction. L-shaped vent/ drain shall not be provided. The straight vent shall be provided so
that it facilitates easy flushing of the dust particles from the filter. Also there shall be
provision for providing a hand hole at the filter vessel for removing the dust particles. All
welded joints should be radio graphically examined and acceptance criteria should comply
with ASME BPV Codes.

Safety valves of filters shall be designed for fire case and shall be set at maximum design
pressure (as per pressure class rating).
Marking on Filtration
The Filtration system shall be marked with the details like Sr. No., Make, Model, pressure rating,
year of manufacture, flow range, operating pressure range, design pressure, relief pressure range
and set point and identification marks shall be provided on it.

INSTRUMENTATION SECTION

TECHNICAL SPECIFICATION
FOR
MRS

Specification of Metering System (for MRS):


1. Purpose:
For flow measurement through MRS, twin-stream Turbine/ RPD flow Meter based Metering
system is required. MRS shall consist of 2 streams of Turbine/ RPD meter along with
independent Solar powered flow computer with solar panel, battery, charger & accessories,
which shall be installed at downstream of Pressure Regulation. One Ball valve at skid outlet
shall be provided. Pressure tap shall be provided with Isolation valve. For SOR 3 and 6,
threaded thermo-well shall be provided at downstream of Flow meters for measurement of
metering temperature. For other Metering skids, flanged thermo-well shall be provided for
metering temperature.
Metering System is not required for DRS. Ball Valve at skid outlet shall be provided.
Flow Meter & Flow Computers shall be installed in cabinet. Bidder shall confirm that the
flow meter and flow computer is suitable for installation in tropical climate with the
following conditions:
Ambient temperature range : 0 60 0C
Design Temperature

: -20 to 60 0C

Humidity

: 100 %

Turbine meter shall be air calibrated at 7 points (namely 2.5%, 5%, 10%, 25%, 50%, 75%
and 100% of Qmax). RPD Meter shall be air calibrated at 5 points (namely 5%, 20%, 40%,
70% and 100% of Qmax).
Turbine meter shall have HF probe as per datasheet. RPD meters shall have at least one HF
probe and will be calibrated with air at 7 points.
Each Metering stream shall have independent and separate flow computer with Battery,
Solar panel and charger unit.
2 sets of field mounted Flow computer (powered through solar panel) shall be supplied for
Flow measurement through Turbine flow meter. GPRS enabled GSM Modem is required for
Flow computers. Indication of metering signals (Pressure and Temperature), shall be
provided in flow computers. Apart from solar power, one lithium battery pack (each of 25
Ah, 12 VDC) shall also be provided in Flow computers to power when battery voltage falls
below threshold limit. Lithium Battery will support only Metering functions. Each Solar
panel (minimum of 50 watt) and external battery (minimum of 50 AH, 12 V) shall be
designed to cater requirement of entire skid including GPRS Modem (designed for 10 no
sunny days). During no sun, Modem functionality may be discontinued on temporary basis.
For natural gas flow measurement, supplied Turbine flow meter/ RPD Meter should have
calibration certificates duly signed by Weights and Measures Authority. In house calibration
certificate of original manufacturer (OEM) is also acceptable for Turbine meter/ RPD flow
Meters, provided the uncertainty of their meter proving system is traceable to National /

International mass standards. In that case, the certificate indicating the uncertainty of meter
proving system of OEM used for calibration shall be provided by the bidder.
Turbine flow meters shall have turn down ratio of 1:20 (minimum) and accuracy shall be
within 0.5% of readings for flow range- 20% to 100% of Qmax.. RPD flow meters shall
have turn down ratio of 1:40 (minimum) and accuracy shall be within 1% of readings for
flow range- 20% to 100% of Qmax..
Flow meter should in addition be fitted with an open ended top hat type or conical/ Y type
strainer inserted in horizontal pipe work before flow meter and it should be located upstream
of straight pipe. The strainer mesh size shall not be finer than the mesh size of the main
filter, nor should it be coarser than 250 microns. Provision should be made in the design of
pipe work to enable removal of strainer for cleaning and inspection. HF probes (provided on
Turbine meter body) with safety barriers / suitable converter shall be used for flow
computation (using HF signals from flow meter to flow computers). The Pulse/ frequency
converter shall be of specified make only (refer vendor list).
The offered Flow Computer should have adaptability to offered/supplied Turbine / RPD
flow Meters.
Turbine Metering system shall be provided with inlet and outlet straight piping requirement
and flow straightening device as per PTB/ EC/ TRG13 or equivalent. Proper lubrication
arrangement should be provided in flow meters. Bidders in their bid shall include
accessories such as intrinsic safety barrier for pulse output, lubrication pumps, lubrication oil
etc, for Turbine Flow meter etc.
2. Nameplate (on Flow Meter) fixed on flow meter shall include following
Name of the manufacturer

Type and G-Rating of flow meter :


Serial number

Maximum flow

Minimum flow

Maximum working pressure

Pressure Class rating

Direction of the gas flow

TECHNICAL SPECIFICATION
FOR
TURBINE METER

TECHNICAL SPECIFICATION FOR TURBINE METER


1.

The Turbine meter shall be axial flow type gas turbine meter in which the entire gas
stream passes through the turbine meter rotor. The turbine metering of natural gas
shall be designed, manufactured and tested, as per AGA report no. 7.

2.

Transmitter and other electrical accessories of Turbine meter shall be suitable for
area classification. Enclosure of intrinsically safe system shall be weather proof as
per NEMA 4.Explosion proof enclosure shall also be made weather proof as per
NEMA 4.

3.

Vendor shall furnish the sizing calculations to justify the selection of turbine meters
considering the density/compressibility of the given composition of the gas. The
sizing shall be done at the minimum operating pressure.

4.

The maximum velocity through the Turbine meter shall be less than 20 m/sec.

5.

Vendor shall select the proper type and material of bearing for the service conditions
indicated.

6.

The pulse generator shall be non-contact proximity switches mounted near turbine
wheel and reference wheel or non-contact type pulse pick up unit. The unit shall be
tropicalized hermetically sealed and shall be either intrinsically safe or explosion
proof as per data sheet. Further it shall be weatherproof to NEMA 4.

7.

Turbine meter shall have LOCAL INDEX HEAD WITH mechanical/ electronic 8-digit
totaliser. Electronic totaliser (when supplied in the data sheets) shall have LCD
indication and shall be complete with dry cell batteries for power lasting for one year.

8.

The system shall be immune to RF/FM interferences in that area.

9.

Straightening vanes shall be provided to eliminate swirls and cross current setup by
the pipe-fittings, valves or regulators preceding the meter inlet piping. Straightening
vanes shall be designed according to latest revision of AGA Report No-3.
Straightening vanes shall be tube bundle of 316 SS tubes and shall be designed and
approved by the meter manufacturer.

10.

Vendor shall furnish pressure drop figures for each turbine meter, flow straightener
at normal operating conditions and at maximum flow condition.

11.

While selecting the meter, vendor to ensure that the fluid velocity in the turbine meter
shall not exceed 20 m/s.

12.

Turbine meter/ flow computer shall have a continuous monitoring feature for
detecting missing blades or bearing problems and to give alarm in such situation.

13.

The meters shall be certified by weights and measures, and shall be calibrated to an
accuracy of +/-0.5% band. Vendor shall furnish the documentary proof in support of
the above along with certified calibration curve.

14.

All turbine flow meters selected/ offered shall be of field proven quality with respect
to design, material and application. Field mounted instruments shall be capable of
working under high ambient Temperature and environmental condition without any
degradation in accuracy and repeatability.

15.

The pulse pick-up and transmitters shall comply with the principles of ISO 6551
'Cabled transmission of electric and/or electronic pulse data'. At least security level B
and the checking facility of type P as defined by ISO 6551 shall be provided.

16.

The turbine meter shall be calibrated with air at/ near atmospheric pressure and shall
have following performance:
Range-ability: Range-ability of Turbine Meters of sizes above G-100 shall be 20 : 1.
Accuracy: For flow rates between 20 % to 100% (of meter max.) at operating
pressure, calibration curve (min. 7 points) shall be within an envelope of +/- 0.5%.
For flow rates between 5% and 20% (of Meter max.) at operating pressure the
calibration curve shall be within an envelope of +/- 1%.
Repeatability: The repeatability of meter shall be +/- 0.1 % from Qmin to Qmax.

17.

The turbine flow meters shall have HF pulses on the meter body and shall be
connected to the flow computer. For Turbine meter of size 4" and above, two(2) nos.
of HF pulse is required. For Turbine meter of size up to 3", one(1) HF pulse and
one(1) LF pulse is also acceptable.

18

CERTIFICATION FOR CUSTODY TRANSFER AND CALIBRATION

18.1

Turbine meter shall have type approval certificates from weights and measures
approved laboratories, such as NMI, PTB or other reputed National Standard
laboratory such as Pigsar, Trans Canada Calibrations (TCC) Canada, Colorado
Engineering Experiment Station Inc.(CEESI) USA, South West Research Inc.
(SWRI) USA., FCRI.

18.2

The Vendor shall furnish the regulations of the certifying authority considered by
them for custody transfer applications. If other instruments are also needed to be
certified as per the regulations the same shall be complied.

18.3

Flow calibration shall be performed for at least seven points and error curve shall be
obtained. Test medium shall be Air.

18.4

Vendor shall carryout performance test and certify the meter in combination with its
companion electronics. A recognized test facility with traceable reference
measurements shall be used. Flow test data at 7 points covering the minimum to the
maximum flow rate shall be obtained for ascertaining the meter linearity and
repeatability with in the specified limits. Calibration of Flow Meters shall be done at
average metering pressure at the following nominal flow rates: 0.025 qmax, 0.05
qmax, 0.1 qmax, 0.25 qmax, 0.5 qmax, 0.75 qmax, and qmax.

TECHNICAL SPECIFICATION
FOR
FLOW COMPUTERS

TECHNICAL SPECIFICATION FOR FLOW COMPUTERS


Specifications of Field Mounted (and Solar panel powered) Flow Computer:
1.1

The flow computers shall be Microprocessor based, with digital display, data entry keyboard.
Flow computer electronics shall be protected from industrial interferences; shock and vibration
proof and have low power supply consumption.

1.2

For Field mounted flow computers approval for custody transfer applications by reputed
calibration agency/ laboratory/ institutes authorized by weights and measures authorities such as
NMI, PTB, NIST, Measurement Canada, Weights and Measure India or tested/calibrated for flow
calculations from International Standard flow calibration laboratories/ Institutes/ bodies such as
Pigsar, Trans Canada Calibrations(TCC) Canada, Colorado Engineering Experiment Station
Inc.(CEESI) USA, GOST, South West Research Inc., FCRI, Weights and Measure India to be
submitted along with bid.

1.3

The flow computers shall compute and display the instantaneous and totalised flow rate for each
stream corrected for pressure and temperature variations. The flow computers receive data
through GSM modem from Gas chromatograph/SCADA for calculation of compressibility factor
as per AGA-8 detail method. The flow computers shall be microprocessor based, with keypad and
alphanumeric display with AGA firmware for natural gas flow measurement. The flow computers
shall be linked to the GAILs RTU through GSM for providing the flow measurements of the
individual stream runs and related process variables.

1.4

For field mounted Flow computers, the port for Laptop connectivity shall be extended to access
flow computer without need of opening JB (housing of Flow computer). Mounting shall be field
mounted suitable for IEC Zone 2, Gr. IIA, IIB, temp. class T3 with NEMA 4 type enclosure.

1.5

POWER SUPPLY: Solar powered with battery back-up suitable for 30 no-sunny days along with
back up lithium battery for 7 working days. Flow computer should also have built in back up
lithium battery which it to be used in case of non-availability of solar based system. The lithium
based system should be good enough to power on the flow computer for a min. of 7 days
including HF isolator/ barrier(if required) . As soon as re-chargeable battery is charged, flow
computer needs to source power from solar based system and not the lithium power source.

1.6

INPUT/ OUTPUT SIGNAL CAPABILITY : The supplied flow computers shall have capability
to accept following input/output signals :
a) High (HF) and low (LF) pulse input signals from RPD meter/ Turbine meter (through isolator/
barrier as required) for interfacing with flow computers
b) Metering Pressure through Integral gauge pressure sensor
c) Metering Temperature (RTD) input

d) Serial Inputs through SCADA and GSM Modem (read/ write)


e) Key pad entry (for key pad values, configuration, GC data entry etc)
f) Lap-top connectivity and Other standard inputs.
1.7. INTERFACE CAPABILITY WITH OTHER FOREIGN DEVICES:
Vendor shall provide serial links along with cables and connectors at both ends for all the signals
with MODBUS protocol to communicate with SCADA. Flow computers shall be interfaced with
GAILs RTU through GPRS enabled GSM modem to get gas temperature and pressure, energy
flow rate and total energy, corrected & uncorrected volumetric flow rate and total flow, last days
cumulative energy and volume, current days running volumetric total and energy total, volume
and energy integrated at 6 a.m., gas composition (mole% of C1, C2, C3, iC4, nC4, iC5, nC5,
C6+, N2, CO2), Specific gravity, Calorific value (GCV/ NCV) etc. The digital and analog data
shall be made available to SCADA and it shall be mapped in the contiguous registers so that data
can be fetched/ written in minimum transactions. Provision shall also be kept at flow computer
for writing data like gas compositions, calorific value etc. from SCADA. Vendor shall furnish all
details like pin configuration and signal wise MODBUS address mapping list etc. for smooth
interfacing of this communication link with SCADA. Vendor shall also furnish the details of
implemented MODBUS protocol like function codes for read and write, CRC implementation,
BCC implementation, register addressing methods/mapping etc. during detail engineering for
serial interfaces to SCADA. Vendor shall supply connectors and cable for interfacing with laptop.
1.8. KEYBOARD CAPABILITY:
The data entry keyboard shall have the provision to enter the following:
a) Pressure and temperature base factor
b) Specific gravity and scaling factor
c) Atmospheric Pressure (absolute)
d) Mol % or composition of the gas to be metered
e) Linearization of error curve & change of K-factor
The flow computer shall have provision to enter default values of all inputs (inclusive of gas
chromatograph) low/high alarms for all inputs (inclusive of gas chromatograph) and shall be user
configurable. The flow computer shall use the default values in case any input goes beyond
low/high limit.
1.9

OUTPUT CAPABILITY:

a)

USB output link for laptop / configurator. (Necessary converter for USB to be provided)

b)

1 no. of Serial port for GSM communication.

c)

1.10.

Additional Spare port shall be provided in Flow computer for SCADA communication via
Ethernet and RS 422/ RS 485/ RS 232 (user selectable). Default shall be 1 no. each of Ethernet
and RS485.
COMPUTATIONAL CAPABILITY :

(a) Volume flow rate at standard, normal or operator specified base conditions (Sm3/hr)
(b) Integrated corrected volume in SCM.
(c) Energy flow rate and integrated energy (user configurable in kcal, MJ & MMBTU).
(d) Linearization of error flow curve and meter factor.
(e) Calculation of compressibility factor as per AGA-8 detail method.
(f) Previous days flow / energy (i.e. yesterdays 6.00 A.M total volume / energy to todays 6.00 A.M
total volume / energy) & current running total for the day (i.e. volume totalizer/ integrator value at
6.00 A.M from first day) to be stored in a separate location (register) and these shall be user
configurable.
(g) Todays accumulated flow /energy (running total since morning 6.00 A.M to current time) and
shall be user configurable.
(h) Generation of reports for totalised volume & energy at daily (6 a.m.), weekly, fortnightly &
monthly intervals, flow rate, pressure, temperature, compressibility factor, alarms etc. shall be
user configurable. All the above data shall also be made available through GPRS enabled GSM
modem to SCADA.
1.11.

STANDARDS USED:
For the above, applicable standards are:
(a) AGA report 7 for Turbine meter/ RPD Meter
(b) AGA-8 characterization method to determine density, compressibility, super compressibility
factor etc. for flow computers
(c) AGA Report 5 / GPA 2145 & GPA 2172 / ISO6976 (user configurable) for energy rate and
integrated energy.

1.12.

ENGINEERING UNITS (User Configurable) :


Volume flow rate -Sm3/hr, Mass - kg/hr, Pressure - kg/cm2g,
Energy MMBTU / MCal / MJ/ (user selectable), Temperature - C,
Primarily the unit of measurement for Pressure, Temperature, total energy and Energy flow rate
shall be Kg/Cm2g, Deg. C, MMBTU and MMBTU/hr respectively.

1.13

MEMORY TYPE: Non volatile

1.14.

ACCURACY

1.15.

Gauge pressure accuracy

: 0.075% of full scale or better

Flow computation Accuracy

: 0.1% of full scale or better

SCAN PROCESSING TIME:


a) The interval between computer readings of Process variables shall not exceed 1 sec.
b) The interval between each cycle for computation of instantaneous flow rate and totalized flow
shall be less than 1 sec.
c) Algorithm and rounding off error for computation shall be with in 0.001% of Computed value
SECURITY: 3-Level password protection should be standard feature in Flow computer.

1.16. DISPLAY CAPABILITY:


The flow computer shall have the capability to display the following parameters: Uncompensated
volume flow rate, Compensated volume flow rate, Integrated volume (corrected and not corrected),
Density/Specific gravity, Pressure, Temperature, Energy rate & total energy, Complete gas
composition, Calculated parameters (compressibility factor etc.), Current accumulation, previous
day accumulation, Data entry, Error codes, Selected parameter codes, Alarms (process and systems)
including diagnostic message, Engineering units as per selected parameter, Other standard displays
available. Custody transfer flow computers shall have audit trail, all the above data shall also be
made available by vendor in the serial links to RTU.
Display Type: Alphanumeric LCD display (multiple line display with touch screen)
1.17

Enclosure : NEMA-4 Enclosure

1.18.

DIAGNOSTICS:
Flow computers shall have elaborate and sufficient on-line diagnostics to ascertain accurate and
proper functioning of the flow computer. Results of diagnostics/checking shall be displayed.
Facility for easy testing of the accuracy shall be provided. Provision for high and low limit check
for each input, sensor break, saturation and alarms shall be provided.

1.19

Any Hardware/ software required for configuration of flow computer, integral Pressure sensor/
transmitters, RTD etc shall be supplied by the bidder.

SPECIFICATIONS- PIPE WORK, FITTINGS & GENERAL


CONSTRUCTION

PIPE WORK, FITTINGS & GENERAL CONSTRUCTION


For DRS & MRS skids, construction, fabrication, reinforcement pads, etc. shall meet the
requirements of codes ASME B31.8: 2007 and ASME BPV Code, Section VIII: 2007. The design
and assembly of all the equipment shall be such that there is no difficulty in the operation and
maintenance of the same. The material used for manufacturing of the pipes and fittings shall be fully
killed. Components made of cast iron shall not be used in manufacturing.
Pipe work and fittings shall be of seamless type and as per ASTM A 106 Gr. B / API 5L Gr. B and
ASTM A 234 Gr. WPB & ASTM A 105 respectively. All branch connections should be of weldolet
type up to d/D ratio less than 0.3 and Sweepolet type up to d/D ratio less than 0.6. All valves for
pressure / vent, pressure gauge and bleed should have positive blind arrangement.
Size of sensing line and pressure test points shall be minimum size. Tapping for sensing lines,
Pressure tapping of shall be provided.
The DRS and MRS should be vertical skids mounted inside cabinet arrangement.
Welders and welding procedures have to be qualified in accordance with ASME BPV Code Section
IX / API 1104. All the welded joints should be radio-graphically examined and acceptance criteria
should comply with ASME BPV Code, Section VIII / API 1104.

The Regulator and shut off valve of the DRS/ MRS shall be easily accessible. SSV should
indicate the position/ directions of opening as well as closing. The direction of flow of gas in
the piping system of the skid shall be indicated on the pipes on both the streams. SSV with
integral Monitor is also acceptable.
Painting of pipes, valves, skid components, JB, enclosure, cabinet, support and other metal
components (as applicable) shall be carried out by application of one coat (DFT 45-50
microns) of zinc phosphate primer followed by two coats (DFT 100 microns each) of
chlororubber high build paint of colour canary yellow.
Piping spools shall be painted with CANARY YELLOW paint shade. Other metal
components shall be painted as per manufacturer's painting standard. Base frame and pipe
support shall be painted in smoke grey shade. Before painting, surfaces shall be thoroughly
cleaned by applying mechanical methods.
The minimum 100 mm distance has to be maintained between the canopy and the component
of DRS/ MRS (i.e. vent point of filters, pilot of regulator and CRV) and also maintain the
sufficient distance between the canopy and skid component, in order to ensure easy operation
and maintenance of the system.
The copper jumper (flat of 3 to 4 mm thickness and appropriate width) shall be provided at
each flange connections. Ends of copper jumper shall be such that it will be removed only
after opening the studs provided. The inlet and outlet matching flanges/ companion flange/
transition fitting (as the case may be) with blind, stud, nut and gaskets shall be provided.

SPECIFICATION- CABINET

SPECIFICATION-CABINET
Suitable Protecting cabinet should be provided to cover the DRS and MRS skids from all sides and
slanted top to avert the ingress of water. It should be constructed with durable, corrosion resistant
and non-inflammable materials and should be mounted on frame and shall have adequate strength so
that it should not get damaged / deformed during handling, transportation, unloading and installation.
The material of cabinet/ canopy shall be MS sheet with minimum 2 mm thickness. MS Checker plate
of appropriate strength (as per load calculation) shall be provided at base of cabinet (inside cabinetbottom).
The cabinet shall be made on frame of angle of 50 mm (minimum) and MS plate shall be attached to
frame. Paint DFT of Cabinet shall be minimum 150 microns. Louvers shall be provided for
ventilation inside cabinet. Cabinet colour shall be cement grey or any other suitable colour (to be
decided during detail engineering).
The cabinet should have free ventilation of at least 10% of the surface area. The doors of cabinet
shall be foldable type with Aldrop locking system. It should have front doors that open fully on
either sides, and also be lockable from the outside by padlocks, and rear doors (at all the three sides)
that are lockable from the inside, which are to be supplied by the vendor. The slope type of sheet
shall be provided on the both side of the roof in order to avoid the water accumulation on it.
Adequate cut-out should be provided at appropriate location on the cabinet such that the readings of
the counter of the Meter, flow computer-reading as well as the reading of the Pressure Gauge are
easily visible from outside. Suitable cut-out shall also be provided for vent and drain connection.
Regulator vents should protrude through the cabinet wall and terminate with flame arrestors. The
constructional details of the flame arrestor are also to be provided. Lever handle of outlet valves
should protrude through the cabinet wall.
Adequate ventilation shall be provided in cabinet to avoid excessive heating, accumulation of gas
inside cabinet etc. For this purpose louvers shall be provided as required.
The name plate should be fixed on the front door of the cabinet in the mid position and the font size
should be of minimum 1.5 cm in height so that it facilitates easily reading of the details of DRS
provided on the cabinet.

A nameplate should be fixed on the Cabinet, which will give the following information:

Name of the Manufacturer


Description of DRS/ MRS Skids
Skid Flow Capacity
Inlet Pressure
Outlet Pressure
Set points of Regulators, SSV and CRV of both stream
Filter (design condition, Micron rating, No. of cartridges and size)
Flow meter (make, Model no, G-rating)
Month and year of Skid Manufacturing

Serial Number

On the DRS/ MRS cabinet, the following instructions shall be inscribed in English and Local
language (to be provided by GAIL during detail engineering) :

Danger Inflammable Gas.


GAIL Toll Free No.:
No Smoking or spark flame or naked flame within a radius of 1.5 meters.

in order to facilitate lifting and convenient handling of the skids, Hooks/ lifting arrangement
of adequate strength at the base frame of the skid should be provided by bidder. Working
platforms, if required should be provided in the skids at appropriate locations (and shown
clearly in the drawing) to facilitate easy access to all parts of the skid(s) and to avoid any
operational or maintenance problems. Also provide the identification tag for individual
streams (working and standby), so that the same can be interchange during the maintenance
activity.
Lifting rods (of adequate strength) as required, should be provided along with the skid to facilitate
easy handling of the skid, and lugs should be placed at locations such that it should not damage the
cabinet during the loading and unloading of the skid.
In case screws are used to fix nameplates etc., on the cabinet, all the sharp points should be
adequately filed and smoothened.

Specification- Junction Box

Specification- Junction Box


The bidder shall supply junction box for of digital inputs, analogue inputs and outputs.
Bidder shall supply junction boxes of die cast aluminum alloy (LM-6) body and shall be weather
proof to IP 65, as minimum & and flameproof certified ( with Ex-d Certification) suitable to install
in area classification.
Flame-proof (explosion proof) junction boxes as applicable shall be certified for IEC-Zone-1,
IIA/IIB for all the classified areas for flame proof instruments.
The enclosure/junction box shall meet requirements of IEC60079. Ingress protection for the
enclosures/junction boxes & cable glands etc. shall be IP-55/NEMA 4 as minimum Weather proof
housing shall be IP55 and flameproof housing shall be EX (d).
The junction box shall have a minimum of 2 Nos. of spare entry. All spare entries shall be provided
with plugs certified Exd for flameproof junction boxes.
The JBs shall have side entry for control cable/ single pair cable and Bottom entry for multi-pair
cable entry. No top entry shall be considered
Each junction box shall be provided with 2 multi-cable entries from the bottom of the junction box
with one plugged with weather proof plugs.
The junction boxes in the MRS skid shall be provided with sufficient number of terminal blocks for
termination of control cable. In the Junction Boxes, at least 20 % additional installed spare terminal
blocks shall be provided for future use.

SPECIFICATIONFOUNDATION/ BASE FRAME

FOUNDATION/ BASE FRAME DETAILS


DRS and MRS Skids should be mounted on a base frame inside a cabinet. Skid shall be
mounted on base frame/ foundation (channel of adequate strength) and bottom of inside
cabinet shall be covered and M S Checker plate of appropriate strength shall be provided
inside cabinet. Base frame of skid shall have lifting arrangement. In case where the piping
assembly is at a height of more than 1.6 meters from the ground level, a ladder/ working
platform has to be provided in the DRS/MRS to facilitate proper accessibility of the
components for the purpose of operation and maintenance.
Vendor shall furnish skid layout, General arrangement drawings, details of foundation, base frame
details during bidding stage. Anchor bolts of 16 mm shall be supplied with skid. Supply of
foundation bolts of adequate quantity (number) and strength is in the scope of the vendor. The
position of the foundation bolts in the drawing (to be submitted for approval) should be clearly
indicated in all the views of the MRS/DRS. Centre point of skid inlet and outlet flanged connections
should be clearly marked / visible in all the views in the drawing submitted for GAIL approval.
Manufacturer shall furnish the details of foundation and anchoring requirement. Suitable hole shall
be provided for anchoring on base frame, outside the cabinet. Anchor fasteners of adequate strength
shall be supplied by the bidder. Bidder shall supply additional anchor fasteners bolts-nuts set (20%
extra) along with shipment.
The position of the foundation bolts in the drawing (to be submitted for approval) should be clearly
indicated in all the views of the DRS/ MRS skid. The center point of the inlet and outlet flanged
connections should be clearly marked/ visible in all the views in the drawing submitted for GAIL
approval.

General Specification &


Technical Requirement
of
MRS & DRS

General Specification and Technical Requirement of MRS & DRS:

1. The size of line pipe, inlet/outlet valve size mentioned in tender is minimum size of line pipe / port/
nozzle size of each component of DRS and MRS package. Components should be selected and
designed for maximum designed gas flow rate at the minimum pressure (inlet/ outlet as the case
may be). All pressure parts shall be designed for design pressure and temperature. Unless specified
& clarified by GAIL, above sizes to be followed for all mainline valves and nozzle size.
2. Gas velocity in main line pipe, equipment, flow meter, main line valves, check valve etc must not
exceed 20 meters/second, (except SSV and PCV), when the maximum flow rate occurs at the
lowest expected inlet pressure. Velocity limit for SSV-Seat shall be 40 m/s.
3. Regulators/ SSV of minimum 1 size is required in this project. Regulator and SSV of lower than
1 size shall not be accepted. Noise through Regulator (Active/ monitor) shall be limited to 85 dB.
The allowable pressure drop and noise values in regulator should not exceed permissible limits.
4. Materials, Equipment, items, components selected for skid should be suitable for natural gas
application and shall not erode during operation at worst process condition.
5. Complete DRS shall be designed for 49 Kg/cm2g. Whereas MRS envisaged in SOR- 3 to 5, shall
be designed for 49 Kg/cm2g up to downstream header of Pressure Reduction (Inlet, Filtration and
Pressure reduction system, including downstream valves of pressure reduction system) and the
downstream of pressure regulation (after downstream ball valves) shall be designed for 19
Kg/cm2g. Safety Valve (provided on Filter of DRS & MRS) shall be set at max. design pressure,
i.e. 49 Kg/cm2g.
6. For SOR- 6 to 8, Complete MRS shall be designed for 19 Kg/cm2g pressure. All pipe, fitting and
equipment must be capable of withstanding the maximum pressure resulting from a fault condition.
Safety Valve (provided on MRS-Filter) shall be set at design pressure, i.e. 19 Kg/cm2g.
7. In MRS, Metering shall be done though Turbine meter (for SOR- 5 & 8) / RPD Meter (for SOR- 3,
4, 6 & 7) with Solar powered Flow computer with integral pressure sensor (for metering pressure
sensing with pressure range of gauge pressure sensor shall be 0-8 Kg/cm2g).
8. Flow computer with In-built MVS sensor (for metering pressure) is acceptable. Alternately,
separate/ independent metering Pressure transmitter is also acceptable.
9. Turbine flow meter and RPD flow meter shall be designed for 19 Kg/cm2g and 12 Kg/cm2g
respectively.

10. The DRS and MRS should have provision for stream selection. Automatic switch over from active
stream to hot stand-by stream should take place in the event of shut down/ trip of the active stream
for any abnormal reason.
11. Design Temperature for MRS and DRS shall be -29 deg. C to +65 Deg.C.
Charpy test for all PRS downstream components (including regulators, valves etc) shall be done at
0 (zero) degree C.

In DRS, apart from skid inlet & outlet ball valves, there shall be one inlet and one outlet
valve (of 300#) on every stream of filtration with pressure reduction. PRS downstream
header shall be designed for 150# and a flanged connection shall be provided at PRS
downstream header. Suitable transition piece (from vendor list) suitable for connecting to
MDPE pipes, PE100 shall be provided. Each of the valves shall be designed to seal on both
upstream and downstream faces and the space between the faces shall be fitted with vents.
12. Pressure test points, pressure gauges, purge and vents shall be provided as specified in the
schematic line diagram/ drawing/ typical line diagram/ schematic provided in tender. All the ends
of drain shall be blinded/ plugged. The drain and purge valves provided at the inlet and outlet ends
shall be fitted at sufficient gap from the base level of the skid, so as to facilitate an easy operation of
the same. Vent valves shall be provided at sufficient height to facilitate venting (at 3 meters height
from platform/ base).
13. Technical literature in English language, along with dimensional details of the equipment and
system hook up drawing shall be submitted by bidder along with the technical bid.
14. Schematic line diagram/ P&ID of DRS and MRS provided in tender shall be used for guidance
purpose. Before fabrication, actual arrangement (GAD) shall be proposed in soft & hard form by
the vendor, for review and approval by GAIL. No procurement/ fabrication job shall be undertaken/
started without written approval of GAIL.

15. Vendor list provided in tender for bought out items, shall be followed for procurement for
bought out items required in DRS/ MRS. The acceptance of make/ model of instrument,
equipment, component offered by the bidder shall be at the sole discretion of GAIL.
16. The data sheet (provided with tender) should be filled up completely, signed, stamped and enclosed
along with sizing calculation, catalogue and drawings in the Technical Bid submitted by the bidder.
17. Compliance with Technical Specification will be taken for granted, if deviations are not specifically
mentioned during bid submission.

18. This is a no deviation tender. Any deviation to tender condition/ specification shall lead to
rejection of bid.
19. In general, all the connections in the DRS having design rating of 300# should be of welded or
flanged type (threaded joints/ connections are not allowed) only. Only flanged and welded
connection shall be used in DRS/ MRS. Unless clarified/ specified by GAIL, no threaded
connection shall be used. Only blind plugs for drain connection can have threaded connection.
20. Hole tight / leak tight shall not be used on threaded / flange joints. For all flange joints, Stud with
nuts (hot dip galvanized) shall be provided on flange joints. All Studs and nut used in this project
shall be hot dip galvanized as per ASTM A 153 or equivalent.
21. No valve Components like Valve body, bonnet, cover and / or end flanges made of cast iron or
ductile iron shall be used.
22. No Flange made of cast iron, ductile iron or non-ferrous materials (brass or bronze) shall be used in
skid. Flanged connections (in mainline, inlet and outlet) of the DRS and MRS should be in sizes of
1, 1.5, 2, 3, 4 and 6 only (as defined in line diagram). All instrument fitting/ tubing etc shall
be of SS316 (minimum). No tube fitting/ tube of brass/ copper shall be used.
23. Suitable transition fittings (required for connecting to MDPE pipes) shall be provided at DRS outlet
end. Suitable transition fittings (required for connecting to MDPE pipes) shall be provided at inlet
and outlet of MRS.
24. The MRS shall have twin independent streams of Filtration, pressure regulation and Turbine meter/
RPD metering system (along with solar powered flow computers). Solar panel, battery, flow
computer etc shall be installed with required mounting arrangement and accessories as per best
engineering practices. GPRS enabled GSM Modem shall also be provided in Flow computers. For
metering temperature a RTD sensor shall be installed at Meter downstream and shall be connected
for flow computer.
25. DRS and MRS shall be skid mounted on base frame of required size/ dimension. Suitable cabinet is
required for DRS and MRS (entire skid shall be provided in cabinet). Cabinet shall be made out of
frame comprising of angle of minimum 75 mm width and 5 mm thickness (minimum) and covered
with MS sheet/ plate of 2.6 mm thickness from all sides and top. Suitable stiffener shall be provided
as per requirement. Checkered plate of appropriate strength shall be provided at bottom of skid
cabinet. Suitable mounting arrangement/ anchoring shall be provided in skid base frame. The
cabinet shall be suitable for outdoor installation. Top shall be slanted to avoid water inrush during
rain. One side (front side) of cabinet shall be lockable from outside, whereas the other sides (rear,
top, side etc) of cabinet shall be lockable from inside the cabinet (GAD to be got approved before
proceeding for fabrication).

26. DRS & MRS shall have pressure gauges provided at skid Inlet & skid outlet, mounted suitably in
the cabinet of DRS / MRS, so as to view it from outside of cabinet (without opening the cabinet). A
cut out of suitable dimension shall be provided in cabinet of DRS/ MRS for viewing reading of
Pressure gauge and flow computers. Suitable glass cover (with locking arrangement) shall be
provided in cabinet to read/view the flow computer.
27. Vendor shall supply the flow computer with IS Junction Box installed on the suitable Mounting
frame/arrangement as per GAIL site requirement. It shall have the stainless steel tubing connected
to the pressure inputs using suitable SS tube fitting and the other end of the tubing will be
terminated in 2-Way Manifold Valve.
28. The pressure gauges shall be aligned with reference to the regulator, such that it facilitates an easy
viewing of the readings in the pressure gauges. Arrangement for venting of pressure gauge and also
pressure sensing lines shall be provided in skid.
29. Vendor shall design the DRS and MRS suitable for outdoor installation in tropical climate with the
following conditions:

Ambient temperature: 0 to +60C.


Humidity: 100%.
Design Temperature shall be -29 to +65C.

DRS and MRS design shall meet various requirements of national/ international standards such as
ANSI B-31.3/31.8; ASME Sec. VIII, Div-I; EN-12279; EN-12186; IGE-TD-13; AGA-5, AGA-7 &
AGA-8 and PED 97/23/EC Compliance.
30. DRS shall have twin stream dry gas filters & Pressure reduction (with hot stand-by) in ActiveMonitor configuration. No metering is required in DRS.
31. MRS shall have twin stream of dry gas filters, twin-stream Pressure reduction (with hot stand-by) in
Active-Monitor configuration and twin-stream turbine metering/ RPD Metering system.
32. Skids shall have Lifting lugs/ Hooks of adequate strength provided to facilitate its lifting and
convenience in handling.
33. Working platforms, if required should be provided in the skids at appropriate locations (and shown
clearly in the drawing) to facilitate easy access to all parts of the skid and to avoid any operational or
maintenance problems.
34. Pressure test points, purge and vent points shall be fitted as indicated in the Installation Schematic
drawing attached herewith. When a test point is not provided on an item of equipment, a point shall
be provided on the adjacent pipe work. All the ends of drain and vent points shall be plugged. The
vent purge valves provided at the inlet and outlet ends shall not be fitted very close to the base level
of the skid, which will be very difficult to be operated. A common vent header with flame arrestor
along with flapper shall be provided.

35. The bidder shall use only SS Pressure tubes OD (SS316) or 3/8 OD(SS316) (of make: - Sandvik),
SS tube fittings (of make: - Parker/ Swage lock / HYLOK). No other make is acceptable.
36. Bidder shall take care of requirement of Pressure Tubing & its associated job for connection from the
Inch tap off provided from the Pipe to the 2-way valve manifold for Inlet Pressure connection
(single stream) & outlet pressure connection (twin stream).
37. For DRS/ MRS, the DP gauge shall be supplied along with 3-way valve manifold.
38. Means to avoid entrainment of liquids in the gas entering regulator assembly & if necessary, suitable
provision for their removal should be provided. Sizing of components should be done considering
avoidance of unacceptably low temperatures, which may lead to requirement of preheating.
39. All pipe work and equipment must be capable of withstanding the maximum pressure resulting from a
fault condition.
40. Skid should have a provision for stream selection wherever specified / mentioned in the specific
requirements. Automatic switch over from active stream to the hot standby stream should take place
in the event of shut down of the active stream for any abnormal reason.
41. In MRS, there shall be an inlet and an outlet valve on each stream of Regulation and Metering. Each
valve shall be designed to seal on both upstream and downstream faces and the space between the
faces shall be fitted with vents.
42. Turbine/ RPD flow meter (in MRS) shall be positioned in such a way that the index can be read
conveniently. When viewing the index, the gas flow direction through the meter is from the left to
the right. General piping arrangement shall be made in such a way that meter with Flow computer
can be installed on upstream as well as on downstream of regulator.
43. Technical literature (in English language only), dimensional details of the equipment and system hook
up drawing shall be submitted along with the technical bid. The data sheet should be filled up
completely and should be enclosed along with the Technical Bid.
44. Installation arrangement for guidance is as shown in the schematic drawing enclosed. Actual
arrangement should be proposed by vendor and shall be reviewed / approved by GAIL.
45. Compliance with Technical Specification will be taken for granted by GAIL, if deviations are not
specifically mentioned and accepted by GAIL. Any deviation from the specified technical
specification, vendor list, datasheet etc should be highlighted by vendor. However, the acceptance of
the same shall be at the sole discretion of GAIL.
46. As far as possible, all joints shall be Flanged joint only. Any threaded joint proposed by bidder should
have prior approval of GAIL, without which same shall be rejected. Stud nuts are to be provided on
flange joints. Hole tight / leak tight should not be used on threaded / flange joints in skid.
47. Flanges, fitting or any other skid component made of cast iron/ ductile iron/ non-ferrous materials
(brass or bronze) is not acceptable. Cast iron, ductile iron, non-ferrous materials (brass or bronze)
shall not be used in skid/ skid components. All the flanges used in skid shall be raised face. Flanged

end connections (inlet and outlet) of the DRS/MRS should be in sizes of 4 and 6 only. Bidder to
provide suitable transition fittings on flanged ends and to ensure compatibility with MDPE pipes. All
stud bolts and nuts used in CGD networks shall be hot dipped galvanized as per ASTM A 153 or
equivalent.
48. Vendor shall confirm that the Skid is suitable for outdoor installation in tropical climate with the
conditions specified in tender.
49. All required cable, conduit and suitable cable gland (ex-proof) required for power, signal, pulse input,
RTD shall be supplied / installed by bidder. The Supply & laying of perforated cable tray on supports
and accessories required for cable laying and routing lies in the scope of the bidder. All
interconnecting signal, power, control cables used in the skid shall be armoured. The signal/control
cables shall be individual pair shielded and overall shielded. Vendor shall follow the cable
specifications as per control cable standard specifications.
50. Battery shall be installed in ex-proof JB/ enclosure. Certificates for JBs, enclosure shall be provided
by bidder.
51. Bidder shall carry out installation of junction boxes on separate support, JB earthing / grounding,
tagging, ferruling, cable glanding & termination, pair/ core identification of all cables.

52. The Supply & laying Copper earthing strip and earthing cables for earthing of instruments,
junction boxes etc. to instrument earthing system lies in bidders scope. Bidder shall supply
required earthing strip/ cable for earthing.
(Earth pit/ earthing system shall be provided by GAIL), however Hardware required for
interconnection shall be provided by bidder).
53. Provision for anchoring skid (on foundation) shall be provided by bidder. Supply of suitable
anchor bolts (preferably of 16 mm size) also lies in bidders scope.
54. Tapping with valve required for PG connection shall be of 3/4". PG shall have 1/2" NPT(M) as
process connection.
55. Spring range of offered PCV/ Regulator in MRS (SOR-3 to 8) shall be 1 to 5 Kg/cm2g. SSV and
CRV shall be designed accordingly. For sizing of components like Meter, Valves, Pipe etc, delivery
pressure (outlet pressure) shall be considered.
56. Meter run (10 D upstream and 5 D downstream) and Flow straightener is envisaged for Turbine
based skids (SOR- 5 & 8) only.
57. Performance characteristic curves:
The following performance characteristic curves should be furnished:
a) Outlet pressure v/s flow (for various inlet pressures)
b) Inlet pressure v/s flow (for various outlet pressures)

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BIDDING DOCUMENT NO. 8000005410

ANNEXURE-9

FAT PROCEDURE / FAT MANUAL


For
MRS & DRS SKIDS
(To be filled by the Bidder for Factory Acceptance Test to be
conducted at the Bidders works)

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FACTORY ACCEPTANCE TEST

Doc. No.: _______________, Rev: 0


Date ____________

FACTORY ACCEPTANCE TEST


PROCEDURE

Project Description:
Supply of MRS SKIDs/ DRS SKIDs
P.O./ FOI Ref : ------------------------------------ Dated------------

Prepared by: Company Name

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TABLE OF CONTENTS
1. PREFACE
1.1
1.2
1.3
1.4
1.5
1.6

Introduction
Scope
Reference Documents
Orientation of Witnesses
Test Certificates
Action List

2. VISUAL INSPECTION
2.1 Skid Review
2.2 Test Certificates
3. FACTORY ACCEPTANCE TEST
3.1 Hydrostatic Test
3.2 Pneumatic Leak Test
3.3 Functional test of SSV, PCV, PSV, CRV and FCV
3.4 Functional Test of flow computer
3.5 Transmitter Test Procedure
3.6 Turbine Flow Meter/ PD Meter
3.7 SOLAR Panel
4.

SPARES

5.

PAINTING

6.

DOCUMENTS REVIEW

7.

ANNEXURES

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1. PREFACE
1.1 Introduction:
This document defines procedure for Factory acceptance Test (FAT) to be carried out for
Turbine / RPD Flow meter based Metering Skid(s). The purpose of carrying out FAT is to check
functionality of the entire natural Gas skid (Filtration, Pressure regulation, Metering system) with
respect to agreed technical documents.
General:
All the tests, inspection, checking, data-configuration etc shall be conducted by the vendor as
per FAT procedure and the same shall be got verified by TPI appointed by them. After
verification / witness by their TPI, the vendor shall submit duly signed/ stamped verified report to
GAIL for review before calling for witnessing FAT by GAIL representative. The verified FAT
report shall contain all the Records/ Test Reports/ calibration reports/ certificates, configuration
sheet (for flow computers, EVC) and other relevant documents. These documents shall be
prepared by the vendor or obtained from their sub-vendor and sent to GAIL for review before
calling for FAT.
Bidder shall give advance intimation of minimum 7 days for FAT. Following documents as a
minimum shall be furnished along with the intimation for FAT for MRS. For DRS only the
relevant documents shall be submitted.
1. Configuration report (for FC, EVC) duly filled and signed by TPI and QC department of
Bidder.
2. Functional design specifications for Metering system.
3. Duly filled and signed FAT procedure document after conducting internal FAT
4. Calibration Report of Flow meter.
5. Confirmation that Bidders TPI shall be present for witness during FAT.
6. List of Software, mandatory spares, commissioning items (including cable with type and
length, canopy, calibration equipments, loose supplied items, Laptop etc) as per tender
requirement.
Bidder to note that the FAT procedure/ report is generic in nature. Same shall be modified/
edited to suit the tender/ project requirement.
1.2 Scope:
The FAT will confirm to the compliance of DRS/ MRS/ Metering Skid with the tender
specifications. The purpose of FAT is to check the performance of each component as well as
entire skid. Upon completion of the test described in the following procedures and acceptance of
the same, the system will be considered to be ready to be dispatched to the site. All the physical
& functional tests are described in the remaining sections. When each functional test has been
completed, the TPIA (appointed by GAIL) & Customer representative will indicate acceptance of
the tests by signing the test certificates.

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All the equipments / instruments/ items shall be installed (as far as possible) for functionality
demonstration during FAT. In case some of the items can not be erected/ installed during FAT,
list of such item along with the reason for not installing the same shall be provided before start
of FAT. FAT shall not be conducted before approval of such list by Client. In case difference is
observed in calculation of process parameter i.e the calculated values (calculated by different
Instruments for any parameter), the list of such parameters along with values and suitable
reason for such deviation shall be submitted to GAIL in advance for review by GAIL/ GAILs
representative. In case deviation is observed in the parameter-values displayed by various
components, the same shall be recorded, which may also result in to rejection of FAT.
All connectivity/ its simulation mentioned elsewhere in tender (like Laptop, Flow meter, SCADA,
FC etc) shall be established and demonstrated during FAT. Non-compliance to any of these
shall result in rejection of Metering skid
1.3 Reference Documents:
Design Documents of Skid (Document No.)
1
2
3
4
5
6
7

P & ID for Skid Drawing No. -----------------------GA Drawing for Skid Drawing No. -----------------------------------Base frame and Foundation Drawing No. -------------------------Base frame Calculation Doc. No. ----------------------------------------------Quality assurance plan - Mechanical Items Doc. No. ---------------------------------Quality assurance plan Instrumentation Equipment Doc. No. --------------------Material Test certificate, Radiography test report, Hydro-test certificate ___________

Datasheet / Drawing of Equipment:


1
2
3
5
6
7
8
9
10
11
12
13
14
15
16
18
19
20
21

Turbine / PD Flow meter Data sheet No._____________________


Upstream/ Downstream Flow straighteners Drawing No.______________________
Pressure Transmitter Data Sheet No.___________________________
Differential Pressure Transmitter- Data Sheet No.___________________________
RTD with Temperature Transmitter Data Sheet No.__________________________
Pressure Gauge Data sheet No.___________________________
Temperature Gauge Date sheet No.___________________________
Flow Computer Data Sheet No.___________________________
Flow Control Valves Data sheet No.___________________________
Pressure Control Valve (Regulator) Data Sheet No.___________________
Slam Shut of Valve Calculation, GA Drawing No.______________________
Pressure safety Valve Data Sheet No.___________________________
Creep relive Valves Data Sheet No.___________________________
SOLAR PANEL, BATTERY (POWER SOURCE) __________________________
Ball Valves ---------- make - Drawing No.___________________________
Plug / Globe Valves - Drawing No.___________________________
Check Valves- Drawing No.___________________________
Cartridge Filter Design data Doc. No.___________________________
EVC Data Sheet No.______________________________________________

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1.4 Orientation of Witnesses:


All representatives shall be briefed on details/ description/ operating principles of the Metering
Skid for this project before commencing the FAT.
1.5 Test Certificates:
Upon completion of the tests mentioned in this document, Test Certificates should be filled with
the results and signed / stamped by all the parties.
1.6 Check list: Complete job is summarized in the Checklist as per attachment.
1.7 Action List:
Any discrepancies noted during the functional tests shall be defined, recorded and summarized
in the Action List Form. Once proper action has been taken on those points, this Action List shall
be signed / stamped by Customer/ TPIA duly filled with the results.
2. VISUAL INSPECTION OF SKID.
2.1 Skid Review:
The Skid will be inspected for installation of all the components as per approved P & ID and
approved G.A. Drawing. Dimensional Checking shall be done as per approved G.A. Drawing.
Skid will also be inspected for correctness of installed Equipments/ instruments (including
make/Model of instruments) and approachability for maintenance. The Skid will be inspected for

proper support with rubber pads / clamps for the major equipments/ Instruments, pipes
and impulse lines.
2.2 Test Certificate for Visual Inspection:
Upon completion of the visual inspection described in this section, the test certificate for Visual
Inspection of skid should be dully filled and signed by both parties.
3. FACTORY ACCEPTANCE TEST:
3.1
3.1.1
3.1.2
3.1.3

Hydrostatic Test.
Complete skid shall be offered for hydrostatic test.
Non Corrosive water shall be used for hydro testing at ambient temperature.
During the hydro test Flow meter, SSV, PCV and FCV and filter cartridges / elements
shall not be installed with pipeline as internals will get damaged in contact with water.
3.1.4 All valves shall be kept at open position.
3.1.5 Either inlet or outlet pipe shall be closed with blind flange and the other side will be
connected with water line (hose pipe) to fill up water in side the skid.
3.1.6 After filling water, the skid shall be pressurized to _______ kg/cm from outlet of skid to
PCV outlet and then pressurized to -------------- kg/cm from inlet of skid to inlet of PCV.
3.1.7 Maintain this pressure for four to six hours.
3.1.8 Pressure should not exceed hoop stress of the line pipe at any given moment of time.
3.1.9 No leakage is allowed through any joints and shell.
3.1.10 Record pressure and temperature reading at 30 minutes interval.

Page 6 of 21

Company
symbol(insert)

FACTORY ACCEPTANCE
TEST

Doc. No.:_____________
Rev. : 0
Date _________________

3.2 Pneumatic Test


3.2.1 After completion of hydro-test, drain out water from the skids.
3.2.2 Pass the air through the entire skid for some time to dry out the pipeline.
3.2.3 Assemble the Flow meter, SSV, PCV and impulse tubes in pipe line.
3.2.4. Keep all valves open and close either inlet or outlet side pipe with blind flange.
3.2.5 Pressurize the entire skid by air/ nitrogen up to 7 kg/cm and hold for one hour.
3.2.6 No leakage/ drop in pressure is allowed.
3.2.7 Check the leakage using soap water.
3.3 Functional test of SSV, PCV and FCV
3.3.1 Set point of PCV set the required pressure of PCV as per approved data sheet/
approved P&ID by Pilot adjusting screw.
3.3.2 Set point of SSV - Increase the PCV pressure to cross the set point of SSV. The SSV
should trip at set pressure value as per approved data sheet/ approved P&ID. Record
the Over Pressure Shut off value during test.
3.3.3 SSVs Limit switch feed back (contact) signal to be checked with Multimeter.
3.3.4 Flow control valves position (0-100%) shall be checked by simulation of analogue signal
(4-20 mA signal).
3.3.5 Test report/ record for Set pressure of PCV/ SSV shall be reviewed during FAT.
3.4 Functionality Test of Flow Computer
3.4.1
3.4.2
3.4.3
3.4.5
3.4.6
3.4.7
3.4.8
3.4.9
3.4.10
3.4.11
3.4.12
3.4.12
3.4.13
3.4.13

Configuration check, parameter settings/ checking etc shall be carried out as per
approved Data Sheet/ Tender specifications.
Volumetric flow rate, Energy flow rate, Total Flow and Energy Totalizers by simulation
of Flow meter signal using Function Generator shall be checked.
SCADA/ RTU Simulation for data to/from flow computer / EVC using laptop.
Visual checking of cable connection including cable gland, cable tag No., Installation of
JB, cable dressing etc. as per approved drawing/ wiring diagram.
Facility of entry of Atmospheric pressure, base pressure and temperature by user.
Various Units of measurement (Pressure, Temperature, flow rate, total flow, heating
value, energy etc.) shall be verified as per approved documents.
Functioning of PID loop (AO) for FCV shall be done by simulation. Provision to accept
FCV set-point through Remote (SCADA/ GSM Modem) and local (FC Keypad) shall be
demonstrated.
Simulation of Flow Computer / EVC output to SCADA by GSM Modem.
GC data input to Flow computer/ EVC from SCADA via GSM modem.
Proper entry of the Turbine/ PD meter error curve, K factors, Meter factors etc.
Checking of Audit Trail facility in the flow computer and its printing.
Availability and functioning of USB ports with connecting cables for communication of
various devices/ Instruments/ Equipment (like GSM, RTU/ SCADA, Laptop etc) with flow
computers/ EVC.
Functioning of standalone Software for flow calculation verification shall be checked.
Check functioning of Power source including Solar Panel, battery charger, Batteries
with enclosure.

Page 7 of 21

Company
symbol(insert)

FACTORY ACCEPTANCE
TEST

Doc. No.:_____________
Rev. : 0
Date _________________

3.4.15 Provision to calculate Energy Flow rate and totalized Energy through both GCV and NCV
shall be demonstrated. For easy switchover selection of NCV and GCV for Energy flow
rate calculation shall be provided in Flow computer
3.5 Transmitter / Gauge Test Procedure (Pressure, Differential Pressure, Temperature):
Provide power supply to the transmitter and check the local indication & output during the
pneumatic test. Calibration report (from approved Lab) to be checked. (Accuracy, range-ability,
calibration range, provision for calibration, changing range etc shall also be checked). For
Gauge, process parameters shall be simulated by feeding the required parameters.
3.6 Turbine Flow Meter / RPD Flow Meter:
The Turbine / RPD Flow Meter has been manufactured by ----------------- and is calibrated at ----------------------------------- using Natural Gas as per approved data sheet. The calibration
Certificates shall be submitted for review during FAT. Insulation of metering system and
Environmental enclosure for custody metering equipments shall be checked visually during
FAT.
3.7 Solar Panel :
1. Check the functional test of each/ both stream as per approved Document.
2. No. of Batteries with model, current/ power rating, Amp-hour rating as per approved Battery
sizing Calculation shall be checked
3. Output Voltage of each stream shall be recorded.
4. Visual Check: Support for Solar Panel, Battery enclosure, their mounting arrangement,
Cabling, identification marking
5. Test certificate for Battery Enclosure shall be checked.

4.0 Spares:
List of Spares, mandatory spares shall be prepared and submitted in advance for approval by
GAIL for all the skids separately (list shall include mandatory spares, commissioning spares,
cables etc.) materials required for erection, installation, testing, commissioning etc as per P.O.
terms/ tender documents. During FAT test, all these items as per list shall be verified by TPIA
and GAIL representative. All these items shall be clearly identified with proper tags/
identification no. Foundation bolts, stud and bolts for interconnection etc, mating flanges, Blind
flanges, blind plugs etc. shall also be checked during FAT. List of applicable software licensed
in name of GAIL shall also be prepared in advance and the same shall be reviewed during FAT.

5.0 Painting:
The painting shall be carried after cleaning the surface by sand blasting to remove all mill scale,
rust, rust scale, paint, oil or foreign particles etc. and maintain the surface finishing as Sa 2 .
Primer Coat Zinc rich epoxy primer - thickness of 75 Micron (DFT).
Interim coat polyamide epoxy - thickness 125 Micron (DFT)
Finished Coat polyurethane - thickness 75 Micron (DFT).
Total Thickness- 275 Micron (DFT)

Page 8 of 21

Company
symbol(insert)

FACTORY ACCEPTANCE
TEST

Doc. No.:_____________
Rev. : 0
Date _________________

Colour code of pipelines Golden Yellow


Other colours as per approved colour scheme.

6.0 Documents Review:

After completion of all tests, Documents like material test certificates, Radiography test,
Hydro-test, calibration/ test reports etc. for Ball valves/ Globe valve/ Plug valves/ CRV/
NRV/ PSV/ FCV/ Filters, pipes, fittings, Tee/ elbow/ weld joints, shall be reviewed to check
the compliance with the tender specifications and approved QAP for the equipments /
instruments.

7.0 Annexure to FAT Manual:


Apart from the FAT procedure, FAT Manual shall have Annexure which shall include the
following:
a. List of all the loose items with details to be provided by vendor (like Mandatory Spares,
commissioning spares, Consumables, Parts of metering skids, Parts of Solar panel,
mating flanges, Gaskets, materials required for installation of skid, Communication cable
(FC- laptop) for laptop, Earthing strips, Cable Trays, cable glands, plugs, blind flanges,
lugs, ferrules, earthing Cables, Mounting Accessories, any other hardware required for
establishing various connectivity mentioned elsewhere, Software etc.) to be enclosed as
Annexure in the FAT Manual for our review/ approval. The items mentioned in the list
(Annexure) shall be demonstrated during FAT.
b. List of all the reports (like calibration reports for various Instruments, test reports for all
the equipments, CCOE certificates etc.), with details like Report no., date, description
etc shall also be prepared as Annexure of FAT manual. The same shall also be
reviewed during FAT
The FAT Procedure/ FAT Manual indicate only some of the required items to be
performed/ demonstrated by the bidder during FAT. In case some more test(s) are
required to be performed, same shall be shown/ demonstrated by the bidder during
FAT. Bidder shall strike-off the tests which are not relevant / applicable to any
particular Skid.
Any discrepancy / deviation observed during FAT Inspection shall be recorded/ noted
in the Action list. Issue of Inspection Release note and Dispatch clearance shall be
subject to compliance of all the FAT Check-list points and Action list with full
satisfaction to GAIL.

Page 9 of 21

Company
symbol(insert)

FACTORY ACCEPTANCE
TEST

Doc. No.:_____________
Rev. : 0
Date _________________

VISUAL INSEPCTION of DRS/ MRS SKID


Customer: M/s GAIL INDIA LTD, New Delhi
P.O. No.: ------------------ Dtd. ----------------------Sr. No
1
2
3
4
5
6
7
8
9
10
11
12.
13.

POINT INSPECTED

RESULTS FOUND OK

Physical verification of Skid as per P & ID and GA Drawing


Process parameters in Name Plate (adequacy)
Lifting hook
Copper jumper for all flanges
Earthing Connection at base frame, Filter, JBs
Insulation for Metering system (meter run, flow meter,
Thermo-well etc)
Instrumentation cable connection, cable dressing,
JB mounting installation etc. as per wiring diagram.
Identification Tags for cable and all Instruments
Painting colour of pipe line (golden Yellow)
Spares as per P.O. requirement
Foundation bolt and Matting flanges
Support for all the equipments/ Instruments, Pipe, Trays
Adequacy of Platform and Cross-over, jump-over, for
Access, approach for operation and maintenance

_____________________
Company Representative

_____________________
TPIA

YES / NO
YES / NO
YES / NO
YES / NO
YES / NO
YES / NO
YES / NO
YES / NO
YES / NO
YES / NO
YES / NO
YES / NO
YES / NO

_____________________
GAILs representative

Date:
Note : Strike off, whichever is not applicable.

Page 10 of 21

FACTORY ACCEPTANCE
TEST

Company
symbol(insert)

Doc. No.:_____________
Rev. : 0
Date _________________

TEST CERTIFICATE
HYDROTEST OF SKID/ SPOOLS
Project: DRS/ MRS / METERING SKID
Customer: M/s GAIL INDIA LTD, New Delhi
P.O. No.: ----------------------------------dated-------------------------Test Pressure:

1) ________Kg/cm2 (g) up to PCV,


2) ________ Kg/cm2 (g) after PCV

Test Media:
Duration:
TIME
1
2
3
4
5
6
7
8

Water
minimum 240 minutes
Pressure before PCV

Pressure after PCV

POINT INSPECTED

RESULT FOUND OK

a) Leak test at flange joints and other connections


up to PCV
b) Leak test at flange joints and other connections
after PCV

YES / NO

___________________
Company Representative

_____________________
GAILs representative

_____________________
TPIA

YES / NO

Date:

Page 11 of 21

FACTORY ACCEPTANCE
TEST

Company
symbol(insert)

Doc. No.:_____________
Rev. : 0
Date _________________

TEST CERTIFICATE
PNEUMATIC TEST OF DRS/ MRS/ METERING SKID
Project: : DRS/ MRS/ METERING SKID
Customer: M/s GAIL INDIA LTD, New Delhi
P.O. No.: ------------------ Dtd. -----------------------

Test Pressure:
Test Media:
Duration:

7.0 Kg/cm2(g)
Air / Nitrogen Gas
60 minutes

POINT INSPECTED

RESULT FOUND OK

Leak test at flange joints and other connections

YES / NO

_____________________
Company Representative

_____________________
GAILs representative

_____________________
TPIA

Date:

Page 12 of 21

Company
symbol(insert)

FACTORY ACCEPTANCE
TEST

Doc. No.:_____________
Rev. : 0
Date _________________

DIMENSIONAL INSPECTION
Project: DRS/ MRS/ METERING SKID
Customer: M/s GAIL INDIA LTD, New Delhi
P.O. No.: ------------------ Dtd. ----------------------Sr. No
1.
2.
3.
4.
5.
6.
7.

Parameters Requirement

Result Found

Base Frame, Canopy Dimension As per approved


Foundation drawing
Height of inlet pipe from base in mm ___________
Height of Outlet pipe from base in mm ___________
Upstream flow straightener Length in mm ___________
Down stream flow straightener Length in mm ___________
Location of Thermo-well as per AGA 7
Painting thickness of pipe line as per approved
Specifications: 275 microns (DFT)

_____________________
Company Representative

_____________________
TPIA

YES / NO
YES / NO
YES / NO
YES / NO
YES / NO
YES / NO
YES / NO

_____________________
GAILs representative

Date:
Note : Strike off, whichever is not applicable.

Page 13 of 21

Company
symbol(insert)

FACTORY ACCEPTANCE
TEST

Doc. No.:_____________
Rev. : 0
Date _________________

PRESSURE REGULATION SYSTEM


Project: DRS/ MRS/ METERING SKID
Customer: M/s GAIL INDIA LTD, New Delhi
P.O. No.: ------------------ Dtd. -----------------------

SR. No.

1.
2.
3.
4.
5.
6.

ITEM

CHECKED

Set Point of PCV(A)-1 ----------Set Point of PCV(A)-2 ----------Set Point of PCV(M)-1 ----------Set Point of PCV(M)-2 ----------Set Point of SSV-1 -------------Set Point of SSV-2 --------------

Accepted
Accepted
Accepted
Accepted
Accepted
Accepted

REMARKS

Rejected
Rejected
Rejected
Rejected
Rejected
Rejected

Remarks :

_____________________
Company Representative

_____________________
TPIA

_____________________
GAILs representative

Date :

Page 14 of 21

Company
symbol(insert)

FACTORY ACCEPTANCE
TEST

Doc. No.:_____________
Rev. : 0
Date _________________

FIELD TRANSMITTERS
Project: DRS/ MRS/ METERING SKID
Customer: M/s GAIL INDIA LTD, New Delhi
P.O. No.: ------------------ Dtd. -----------------------

SR. No.

ITEM DESCRIPTION

LOCAL INDICATION CHECKED

1.

Inlet & Outlet Pressure Gauge/


Transmitter
Inlet Temperature Gauge/ Transmitter
Diff Press. Gauge / Transmitter- Filter 1
Diff Press. Gauge / Transmitter- Filter 2
Metering Pressure Transmitter Stream-1
Metering Pressure Transmitter Stream-2
Metering Temp. Transmitter Stream-1
Metering Temp. Transmitter Stream-2

Accepted

Rejected

Accepted
Accepted
Accepted
Accepted
Accepted
Accepted
Accepted

Rejected
Rejected
Rejected
Rejected
Rejected
Rejected
Rejected

2.
3.
3.
4.
5.
6.
7.

_____________________
Company Representative

_____________________
TPIA

REMARKS

_____________________
GAILs representative

Date :

Page 15 of 21

Company
symbol(insert)

FACTORY ACCEPTANCE
TEST

Doc. No.:_____________
Rev. : 0
Date _________________

FLOW COMPUTER/ EVC


Project: TURBINE / RPD FLOW METER BASED METERING SKID
Customer: M/s GAIL INDIA LTD, New Delhi
P.O. No.: ------------------ Dtd. ----------------------Tag No.: Stream-1 and 2
Inspection / Simulation done for

CHECKED/ OBSERVED

Volumetric Flow rate (SCMH)


Flow Total / Volume Totaliser (SCM)
Mass Flow rate (kg/ hr)
Energy Flow rate (Kcal/ hr)
Atmospheric pressure entry at site condition
Base Pressure/ Base Temperature entry
Configuration check, parameter settings
PID controller Analog O/P check
Functioning of PID loop for FCV (though PID
O/P Signal)
Interface data of flow computer with
RTU Measurement by Laptop
Various Units of measurement
( Flow rate in MMSCMD or SCM/Hr, heating
value in Kcal/SCM, energy in MMBTU)
Flow computer o/p to SCADA by GSM modem
GC data input to Flow computer via GSM
modem
K factors for meter error curves
Audit trail printout (to be attached)
Software for flow calculation verification
Flow set point and Gas composition through
GSM Modem

Accepted
Accepted
Accepted
Accepted
Accepted
Accepted
Accepted
Accepted
Accepted

Rejected
Rejected
Rejected
Rejected
Rejected
Rejected
Rejected
Rejected
Rejected

Accepted

Rejected

Accepted

Rejected

Accepted
Accepted

Rejected
Rejected

Accepted
Accepted
Accepted
Accepted

Rejected
Rejected
Rejected
Rejected

_____________________
Company Representative

_____________________
TPIA

REMARKS

_____________________
GAILs representative

Date :
Note : Strike off whichever is not applicable.
Page 16 of 21

Company
symbol(insert)

FACTORY ACCEPTANCE
TEST

Doc. No.:_____________
Rev. : 0
Date _________________

FLOW CONTROL VALVES


Project: TURBINE FLOW METER BASED METERING (MRS) SKID
Customer: M/s GAIL INDIA LTD, New Delhi
P.O. No.: ------------------ Dtd. ----------------------Tag No.: Stream-1
Current

4 mA
8 mA
12 mA
16 mA
20 mA

INSPECTION
Open Position

100 %
75 %
50 %
25 %
0%

CHECKED/ OBSERVED

Accepted
Accepted
Accepted
Accepted
Accepted

REMARKS

Rejected
Rejected
Rejected
Rejected
Rejected

Tag No.: Stream-2


Current

4 mA
8 mA
12 mA
16 mA
20 mA

INSPECTION
Open Position

100 %
75 %
50 %
25 %
0%

_____________________
Company Representative

CHECKED/ OBSERVED

Accepted
Accepted
Accepted
Accepted
Accepted

REMARKS

Rejected
Rejected
Rejected
Rejected
Rejected

_____________________
TPIA

_____________________
GAILs representative

Date :

Page 17 of 21

Company
symbol(insert)

FACTORY ACCEPTANCE
TEST

Doc. No.:_____________
Rev. : 0
Date _________________

TEST CERTIFICATE
SOLAR PANEL
Project: METERING / MRS SKID
Customer: M/s GAIL INDIA LTD, New Delhi
P.O. No.: ------------------ Dtd. ----------------------Type of Skid :
POINT INSPECTED

OBSERVATION/ RESULT FOUND

1) Functional check of Solar panel in stream-1

Yes/ NO

2) Output Voltage ____________ VDC in stream-1

Yes/ NO

3) No. of ________(Ah) Batteries per stream_________

Yes/ NO

4) Functional check of Solar panel in stream-2

Yes/ NO

5) Output Voltage ____________ VDC in stream-2

Yes/ NO

6) Identification mark/ tagging

Yes/ NO

7) Adequacy of the Solar panel system and mounting


arrangement, fittings, requires cable and other hardware

Yes/ NO

8) Provision for Charging through 230 Vac supply

Yes/ NO

Remarks (if any):


_____________________
Company Representative

_____________________
TPIA

_____________________
GAILs representative

Date :
Page 18 of 21

Company
symbol(insert)

FACTORY ACCEPTANCE
TEST

Doc. No.:_____________
Rev. : 0
Date _________________

CHECK LIST
Project:: METERING SKID/ DRS SKID
Customer: M/s GAIL INDIA LTD, New Delhi
P.O. No.: ------------------ Dtd. ----------------------Sr.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.

Description

Accepted
(Yes/ No)

Installation of all the equipments in Skid as per approved make, model


and size/ rating
Installation of all the equipment/ components (including FC, EVC,
converter, Modem etc.) in control panel as per approved make, model
and size/ rating
Dimensional inspection, Size/ dimension of skid, straight length of meter
tube, location of thermo-well, height etc.
Painting quality, Size/ dimension of control panel
Functionality of PT, TT, DPT, PG, DPG, FCV etc,
Functionality with set-point of PCV, SSV, PSV, CRV etc.
Pneumatic leak check of entire skid
Functionality of Flow meter after flowing air/ nitrogen
Configuration of flow computers & EVC
Review of installation of JB & Enclosure, Cable tags, Cable dressing etc.
Review of adequacy of Support with pads, clamps provided for valves,
Pipe, PSV outlet, Skid vents, impulse tubing etc
Laptop connectivity
Functionality test / simulation of SCADA and GSM / GPRS Modem
Availability of adequate Platforms, approach, Cross over and Jump over
Review of Calibration reports for Instrumentation items, CCOE approval
of field equipments
Review of i) TC/ report, documents for all mechanical items, valves,
meter, JB, pipes and fittings. ii) Radiography, welder qualification
Availability of Copper jumpers for all flanges.
Availability of adequate no. of Handle for Valves, Blind flanges, Matting
flange, expander, tool and tackles.
Review of Software, mandatory spares, commissioning spares, cable,
canopy, loose items as per list attached with FAT

____________________
Company Representative

_____________________
TPIA

_____________________
GAILs representative

Date :
Page 19 of 21

Company
symbol(insert)

FACTORY ACCEPTANCE
TEST

Doc. No.:_____________
Rev. : 0
Date _________________

REVIEW OF DOCUMENTS
Project: METERING SKID / DRS SKID
Customer: M/s GAIL INDIA LTD, New Delhi
P.O. No.: ------------------ Dtd. ----------------------Sr. No.

1.
2.
3.

4.

DOCUMENTS REVIEWED
Checked
Radiography Test for all items of skid (as per List Accepted Rejected
prepared by vendor and attached as Annexure)
Dye Penetration Test for all items of skid (as per Accepted Rejected
List prepared by vendor and attached as
Annexure)
Test Certificate (for Filtration system, Slam Accepted Rejected

Shut valves, Pressure Regulator (PCV), PSV,


CRV, FCV, NRV, Flow profiler, Flow meter,
Ball Valves, Plug valves, Flow computer, PT,
DPT, PG, DPG, Thermo-well, RTD, Solar
panel, JBs, Pipe spools etc.)
Hydro test for all items of skid (as per List Accepted Rejected

7.

prepared by vendor and attached as Annexure)


Material test Report for all items of skid (as per Accepted Rejected
List prepared by vendor and attached as
Annexure)
Certification as per 3.1 for all Pressure Accepted Rejected
Equipments (as per approved List prepared by
vendor and attached as Annexure)
Calibration Report for PT, DPT, TT, PSV, Accepted Rejected

8.

Accepted Rejected

5.
6.

9.
10.
11.

Remarks

CRV, Flow Computer, EVC, Flow Meter and


Test report for SSV, PCV.
Welding Procedure Specification, Welder
qualification.
Configuration Sheet for Flow computers, EVC
Compliance Certification for Painting of skid
including all items (Filtration system, PRS,
Valves, PSVs, CRVs etc) and Solar panel
Material Correlation Chart & Welding Joints
Correlation Chart

_____________________
Company Representative

Accepted Rejected
Accepted Rejected
Accepted Rejected

_____________________
TPIA

_____________________
Customer representative
Page 20 of 21

Company
symbol(insert)

FACTORY ACCEPTANCE
TEST

Doc. No.:_____________
Rev. : 0
Date _________________

Date :

ACTION LIST (FORMAT)


Project:: MRS/ METERING SKID / DRS SKID
Customer: M/s GAIL INDIA LTD, New Delhi
P.O. No.: ------------------ Dtd. ----------------------Sr. No.

Description

Action By

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

_____________________
Company Representative

_____________________
TPIA

_____________________
GAILs representative

Date :

Page 21 of 21

PIPING MATERIAL SPECIFICATION (PMS)

GAIL (INDIA) LTD


NEW DELHI

PIPING MATERIAL SPECIFICATION

SPECIFICATION

REV-0

GAIL/PMS/SP-01

Page 1 of 20

TABLE OF CONTENTS

1.0

SCOPE

2.0

CODES AND STANDARDS

3.0

MATERIAL SPECIFICATIONS

4.0

PIPELINE

5.0

PIPES

6.0

FITTINGS

7.0

BENDS

8.0

FLANGES

9.0

GASKETS

10.0

BOLTING AND THREADS

11.0

THREAD SEALANT

12.0

VALVES

13.0

QUICK OPENING END CLOSURE

14.0

HYDROTESTING VENTS AND DRAINS

15.0

PIPELINE SPECIALITY ITEMS

ATTACHMENTS
ANNEXURE A- PMS 150# CLASS
ANNEXURE B- PMS 300# CLASS
ANNEXURE C- PMS 600# CLASS

GAIL (INDIA) LTD


NEW DELHI

PIPING MATERIAL SPECIFICATION

SPECIFICATION

REV-0

GAIL/PMS/SP-01

Page 2 of 20

1.0

SCOPE

1.1

M/s GAIL (India) Ltd., Delhi proposes to procure Metering Skids of different capacities for
installations at various locations (customers ends) to measure the quantity of Natural Gas supplied
to the individual consumer installations. The metering skid and its associated pipeline shall be
designed to handle regasified LNG/ Natural Gas at specified operating parameters.
This document covers minimum requirements for various piping materials necessary for the design
of the piping/ pipeline and metering skid facilities coming under the project. This specification shall
be read in conjunction with various Codes and Standards of latest edition, as applicable.

2.0

CODES AND STANDARDS

2.1

Pipeline and pipeline terminal facilities envisaged as part of this project shall be designed and
engineered primarily in accordance with the provisions of the latest edition of the following codes:
(i)

ASME B31.8

Gas transmissions and Distribution Piping System

(ii)

ASME B31.3

Chemical Plant and Petroleum Refinery Piping

(iii)

OISD Standard 141

Design and Construction Requirements for Cross Country


Hydrocarbon Pipelines.

2.2

All codes, standards and specifications referred herein shall be the latest edition of such documents.

2.3

For sake of brevity the initials of the society to which the codes are referred may be omitted in the
specifications, for example, B16.5 is a code referring to ASME; A106 is a code referring to ASTM.

2.4

In addition, GAIL specifications and standards for various piping and pipeline materials shall also
be applicable.

3.0

MATERIAL SPECIFICATIONS
Individual piping class has been generally designed to cover a set of service operating within
pressure-temperature consideration as per ASME B16.5/ B16.34 or part of it. Deviations of material
from class specifications may occur due to specific design conditions and/ or availability. These
deviations are permissible if they equal or better the individual class requirements and shall be
subjected to approval on case-to-case basis. All materials shall conform to detailed specifications /
data sheets for items as applicable.

4.0

PIPELINE

4.1

Line pipe material grade and wall thickness details are indicated in Annexure-I.

5.0

PIPES

5.1

Carbon steel pipe shall be made by open hearth, electric furnace or basic oxygen process only. The
steel used shall be fully killed and made with fine grain structure. The grade and wall thickness of
various sizes of pipes shall be as per piping material specification for the applicable class.

5.2

Pipe dimensions shall be in accordance with ASME B 36.10 for carbon steel ASTM standard pipes;
& API 5L for carbon steel API 5L grade pipes.

5.3

All pipe threads shall conform to American Standard taper as per ASME B1.20.1 NPT, unless
otherwise specified.

GAIL (INDIA) LTD


NEW DELHI

PIPING MATERIAL SPECIFICATION

SPECIFICATION

REV-0

GAIL/PMS/SP-01

Page 3 of 20

5.4

For butt weld end, bevel shall be in accordance with API specification 5L or ASME B 16.25 as
applicable.

6.0

FITTINGS

6.1

Fully killed carbon steel shall be used in the manufacture of fittings. The fitting shall have carbon
equivalent not exceeding 0.45, based on check analysis.

6.2

Threaded joints, if used, shall conform to American Standard taper as per ASME B1.20.1 NPT.

6.3

Dimensions of socket welded/ screwed fittings shall conform to ASME B 16.11. Swage shall be as
per BS 3799.

6.4

Dimensions of steel butt welded fittings shall be as per ASME B 16.9.

6.5

Bore of socket welded fittings shall suit outside diameter (OD) of pipe and its thickness.

6.6

Butt welding ends shall conform to API specification 5L or ASME B 16.25 as applicable. In case of
difference in thickness of matching ends, requirements of ASME B 31.8 shall apply.

6.7

Integrally reinforced forged branch fittings such as Sockolet, Weldolet etc. shall be as per MSS-SP97. Fittings not covered in ASME B16.9 and MSS-SP-97 shall conform to manufacturers standard.

6.8

Fittings thickness tolerances shall match pipe thickness tolerance.

7.0

BENDS

7.1

Unless otherwise specified for process piping, elbow of radius R = 1.5 D shall only be used.
Minimum Bend Radius D = Specified Outside Diameter

7.2

In order to accommodate changes in vertical and horizontal alignment in piggable section of


pipeline, Elastic bends/ Cold field bends/ Hot formed long radius bends shall be used. Long Radius
Bend shall be used only when indicated in the drawing.

7.3

Miters shall not be used.

8.0

FLANGES

8.1

Pressure Temperature rating of flanges shall conform to B16.5/ MSS-SP44/ B16.47 Series A, as
applicable.

8.2

Dimensions of flanges shall be in accordance with B16.5/ MSS-5P44/ B16.47 Series A, as


applicable.

8.3

Neck of weld neck (WN) flanges shall suit pipe bore and thickness.

8.4

Bore of socket welded (SW) flanges shall suit pipe O.D. and its thickness.

8.5

Threads for screwed flanges, if used, shall conform to American Standard taper as per ASME B
1.20.1 NPT.

8.6

Sizes for blind flanges shall be indicated by nominal pipe size.

8.7

Unless specified otherwise in Piping Material Specification the flange face finish shall be as per
ASME B16.5.

GAIL (INDIA) LTD


NEW DELHI

PIPING MATERIAL SPECIFICATION

SPECIFICATION

REV-0

GAIL/PMS/SP-01

Page 4 of 20

8.8

Butt welding ends of WN flanges shall conform to ASME B 16.25.

8.9

Spectacle blind/ spacer & blinds shall be in accordance with ASME B16.48/ manufacturers
standard.

8.10

Two jack screws, 1800 apart shall be provided in spectacle blind or spacer & blind assemblies as per
GAIL standards.

9.0

GASKETS

9.1

Spiral wound metallic gasket with compressed asbestos filler shall conform to ASME B16.20/ API
601. All spiral wound gaskets shall be provided with stainless steel centering ring.

9.2

Spiral wound gasket shall be self-aligning type.

10.0

BOLTING & THREADS

10.1

Nuts for stud bolts shall be American Standard Hexagon Heavy Series and double chamfered.

10.2

Dimension and tolerances for stud bolts and nuts shall be as per ASME B18.2.1 and 18.2.2 with full
threading to ASME B 1.1 Class 2A thread for bolts and Class 2B for nuts. Diameter and length of
stud bolts shall be as per ASME B 16.5/ ASME B16.47 with full threading.

10.3

Threads for nuts shall be as per ASME B 1.1

10.4

Nuts for stud bolts dia to 1

UNC-2B

Nuts for stud bolts dia 1 to 3

8UN-2B

Threads for stud bolts shall be as per ASME B 1.1, as follows:


Stud bolts dia to 1

UNC-2A

Stud bolts dia 1 to 3

8UN-2A

10.5

Threads for threaded pipe, fitting, flanges and valve shall be in accordance with B1.20.1 taper
threads, unless specified otherwise.

10.6

Heads of jack screws shall be heavy hexagonal type. Jack screw end shall be rounded. Stud bolts
shall be fully threaded with two hexagonal nuts.

11.0

THREAD SEALANT

11.1

Threaded joints shall be made with 1 wide PTFE jointing tape.

12.0

VALVES

12.1

Valve ends shall be as per valve data sheets (enclosed in Annexure-II) for various piping class.

12.2

Sectionalizing valves, Block valves and other isolation valves installed on the main pipeline shall
be ball valves with butt welding ends. All inline isolation valves on the mainline (pipeline) shall be
full bore valves to allow smooth passage of cleaning as well as intelligent pigs.

12.3

All buried valves shall be provided with stem extension, sealant, vent/drain and shall have butt
welded ends as per relevant specification/ data sheet.

GAIL (INDIA) LTD


NEW DELHI

PIPING MATERIAL SPECIFICATION

SPECIFICATION

REV-0

GAIL/PMS/SP-01

Page 5 of 20

12.4

Flange dimensions and face finish of flanged end valves shall conform to clause 9.0 of this
specification.

12.5

Butt welding ends of Butt Welded valves shall conform to ASME B 16.25.

12.6

Face to face and end to end dimensions shall conform to applicable standards.

12.7

Valves shall conform to following standards unless specified otherwise in piping material
specification for various piping class.
Flanged/ Socket Welded end valves (1 and below)
Design STD. for Process lines
Gate Valves
Globe Valves
Ball Valves
Plug Valves

:
:
:
:

API 602
BS 5352
BS 5351
BS 5353

Flanged/ Butt Welded end valves (2 and above)


Design STD. for Process Lines
Gate Valves
Globe Valves
Check Valves
Ball Valves
Plug Valves
12.8

:
:
:
:
:

API 6D
BS 1873
API 6D
API 6D
API 6D

All manual operated valves shall be provided with wrench I hand wheel or gear operator as
specified here in below.

12.8.1 Gate Valves


For ANSI class 150 and 300

Hand wheel operated for size 12 NB.


Gear operated for size 14 NB.

For ANSI class 600

Hand wheel operated for size 10 NB.


Gear operated for size 12 NB

12.8.2 Globe Valves


For ANSI class 150, 300, 600 and 900 - Hand Wheel operated for all size
12.8.3 Ball valves & Plug Valves
For all ANSI class

Wrench operated for size 4 NB.


Gear operated for size 6 NB.

12.8.4 Gas Actuated Valves


Gas actuated valves shall be as per P & IDs. The actuator shall have provision for remote operation
as per P & IDs. All gas actuated valves shall have additional provision of hand wheel operation.
13.0

QUICK OPENING END CLOSURE


GAIL (INDIA) LTD
NEW DELHI

PIPING MATERIAL SPECIFICATION

SPECIFICATION

REV-0

GAIL/PMS/SP-01

Page 6 of 20

Quick opening end closure to be installed on scraper traps shall be designed in accordance with
Section VIII of ASME Boiler and Pressure Vessel Code and equipped with safety locking devices
in compliance with Section VIII, division 1. UG-35.2 of ASME Boiler and Pressure Vessel Code.
14.0

HYDROTESTING VENTS AND DRAINS


In terminal piping, high point vents and low point drains required for the purpose of hydrotesting
shall be of size 0.75. These vents & drains shall consist of gate valves with blind flange assembly.

15.0

PIPELINE SPECIATLITY ITEMS


Pipeline specialty items viz, scraper traps, flow tees, insulating joints, LR bends etc. shall be as per
specifications attached elsewhere.

GAIL (INDIA) LTD


NEW DELHI

PIPING MATERIAL SPECIFICATION

SPECIFICATION

REV-0

GAIL/PMS/SP-01

Page 7 of 20

ANNEXURE A
PIPING MATERIAL SPECIFICATION
(CLASS 150#)

GAIL (INDIA) LTD


NEW DELHI

PIPING MATERIAL SPECIFICATION

SPECIFICATION

REV-0

GAIL/PMS/SP-01

Page 8 of 20

PIPING CLASS

150 #

BASE MATERIAL

CARBON STEEL

CORROSION ALLOWANCE

1.5 MM

SPECIAL REQUIREMENT

NON IBR

TEMP. (0C)

- 29 TO 65

PRESS. (kg/cm2)

--------

SERVICE
NON CORROSIVE PROCESS - FLAMMABLE / NON FLAMMABLE, NON LETHALHYDROCARBONS, AMMONIA, STEAM & GAS CONDENSATE (NON- IBR), UTILITIES (WATER,
INST, AIR, NITROGEN, CARBON DIOXIDE) AND LUBE OIL BEFORE THE FILTER.
NOTES
1.

ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.

2.

NDT OF WELDS SHALL BE AS FOLLOWS:


RADIOGRAPHY

ALL BUTT WELDS

100%

MPI

SOCKET WELDS

100%

3.

PIPING DESIGN AS PER ASME B 31.8 & OISD 141.

4.

FLANGES OF SIZE 22 SHALL BE AS PER MSS-SP-44.

5.

CHARPY V-NOTCH TEST & HARDNESS TEST SHALL BE CONDUCTED FOR PIPE, FITTINGS AND
FLANGES.

6.

ALL BRANCH CONNECTIONS INCLUDING VENT, DRAIN, PRESSURE AND TEMPERATURE


CONNECTION SHALL BE AS PER BRANCH CONNECTION TABLE GIVEN ON NEXT PAGE. THE
BRANCH DETAILS INDICATED IN APPLICABLE STANDARD SHALL BE IGNORED.

SPECIAL NOTES
ITEM
MAINTENANCE
JOINTS
PIPE JOINTS

DRAINS

VENTS

TEMP. CONN

GAIL (INDIA) LTD


NEW DELHI

SIZE
ALL

DESCRIPTION
FLANGED TO BE KEPT MINIMUM

1.5 & BELOW

SW COUPLING

2.0 & ABOVE

BUTT WELDED

ON LINES 1.5

REFER GAIL STD.

ON LINES 2.0

AS PER P&ID OR 0.75

ON LINES 1.5

REFER GAIL STD

ON LINES 2.0

AS PER P&ID OR 0.75

1.5

FLANGED, INSTALLATION AS PER GAIL STD.

PIPING MATERIAL SPECIFICATION

SPECIFICATION

REV-0

GAIL/PMS/SP-01

Page 9 of 20

S
S
S

S
S
S

S
S
S

T
T

T
T
T

T
T
S

T
S
S

S
S
S

5.000

S
S
S

4.000

W
W
W
S

3.500

W
W
W
S

3.000

T
T
W
S

2.500

T
T
T
T

72
70
68
66
64
62
60
58
56
54
52
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8.0
6.0
5.0
4.0
3.5
3.0
2.5
2.0
1.5
1.25
1.0
0.75
0.5

BRANCH PIPE (SIZE IN INCHES)

10.00

8.000

T
T
T

6.000

T
T

T
T
T
T

T
T
T

2.000

1.000

SW NIPPLE WITH GATE VALVE TO SPEC AS PER


STD.

1.500

T
T
T
1.250

T
T
0.750

72
70
68
66
64
62
60
58
56
54
52
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8.0
6.0
5.0
4.0
3.5
3.0
2.5
2.0
1.5
1.25
1.0
0.75
0.5

0.75

0.500

BRANCH PIPE (SIZE IN INCHES)

PRESS. CONN

RUN PIPE (SIZES IN INCH)

SPECIFICATION
GAIL (INDIA) LTD
NEW DELHI

PIPING MATERIAL SPECIFICATION

GAIL/PMS/SP-01

REV-0
Page 10 of
20

CODE

DESCRIPTION

F
H
P
R
S

SADDLE FUSED JT
H.COUPLING
PIPE TO PIPE
REINFORCED
SOCKOLETS

T
W
I
X
L

TEES
WELDOLETS
INSTRUMENT TEE
REFER NOTES
SWEEPOLET

Lower
Size
(Inch)

Upper
Size
(Inch)

Sch./
Thk

Dim.
STD

Material

Description

PIPE

00.500

00.750

S160

B 36.10

ASTMA 106 GR.B

PE, SEAMLESS

PIPE

01.000

01.500

XS

B 36.10

ASTMA 106 GR.B

PE, SEAMLESS

PIPE

02.000

02.000

XS

B 36.10

ASTMA106 GR.B
(CHARPY)

BE, SEAMLESS

PIPE

02.500

02.500

XS

B 36.10

ASTMA106 GR.B
(CHARPY)

BE, SEAMLESS

PIPE

03.000

06.000

STD

B 36.10

ASTMA106 GR.B
(CHARPY)

BE, SEAMLESS

PIPE

08.000

08.000

8.2

API 5L

API 5L GR.B PSL2

BE, SEAMLESS

PIPE

10.000

10.000

9.3

API 5L

API 5L GR.B PSL2

BE, SEAMLESS

NIPPLE

00.500

00.750

B 36.10

ASTMA 106 GR.B

PBE, SEAMLESS

NIPPLE

01.000

01.500

B 36.10

ASTMA 106 GR.B

PBE, SEAMLESS

FLNG.WN

00.500

01.500

B-16.5

ASTM A 105

150, RF/125AARH

FLNG.WN

02.000

10.000

B-16.5

ASTM A 105 (CHARPY)

150, RF/125AARH

FLNG.BLIND

00.500

01.500

B-16.5

ASTM A 105

150, RF/125AARH

PLNG.BLIND

02.000

10.000

B-16.5

ASTM A105 (CHARPY}

150, RF/125AARH

FLNG.FIG8

00.500

01.500

B-16.48

ASTM A 105

150, RF/125AARH

FLNG.FIG8

02.000

08.000

B-16.48

ASTM A105 (CHARPY)

150, RF/125AARH

SPCR &BLIND

10.000

10.000

B-16.48

ASTM A105 (CHARPY)

150, RF/125AARH

Item Type

Pipe Group

Flange Group

Fitting Group

SPECIFICATION
GAIL (INDIA) LTD
NEW DELHI

PIPING MATERIAL SPECIFICATION

GAIL/PMS/SP-01

REV-0
Page 11 of
20

ELBOW.90

00.500

0..750

B-16.11

ASTM A 105

SW, 6000

ELBOW.90

01.000

1.500

B-16.11

ASTM A 105

SW, 3000

ELBOW.90

02.000

10.000

B-16.9

ASTM A 234,GR. WPB


(CHARPY)

BW, 1.5D

ELBOW.45

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

ELBOW.45

01.000

01.500

B-16.11

ASTMA 105

SW, 3000

ELBOW.45

02.000

10.000

B-16.9

ASTM A234,GR. WPB


(CHARPY)

BW, 1.5D

T.EQUAL

00.500

00.750

B 16.11

ASTM A 105

SW, 6000

T.EQUAL

01.000

01.500

B 16.11

ASTM A 105

SW, 3000

T.EQUAL

02.000

10.000

B-16.9

ASTM A234,GR.WPB
(CHARPY)

BW

T.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

T.RED

01.000

01.500

B-16.11

ASTMA 105

SW, 3000

T.RED

02.000

10.000

M, M

B-16.9

ASTM A234,GR. WPB


(CHARPY)

BW

REDUC.CONC

02.000

16.000

M,M

B-16.9

ASTM A234,GR. WPB


(CHARPY)

BW

REDUC.ECC

02.000

10.000

M,M

B-16.9

ASTM A234,GR. WPB


(CHARPY)

BW

SWAGE.CONC

00.500

03.000

M,M

BS-3799

ASTM A 105 (CHARPY)

PBE

SWAGE.ECC

00.500

03.000

M,M

BS-3799

ASTM A 105 (CHARPY)

PBE

CAP

00.500

00.750

B-16.11

ASTMA 105

SCRF, 6000

CAP

01.000

01.500

B-16.11

ASTMA 105

SCRF, 3000

CAP

02.000

10.000

B-16.9

ASTM A234,GR. WPB


(CHARPY)

BW

CPLNG.FULL

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.FULL

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG-HALF

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.HALF

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG.LH

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.LH

01.000

01.500

B-16.11

ASTM A 105

SW,3000

SPECIFICATION
GAIL (INDIA) LTD
NEW DELHI

PIPING MATERIAL SPECIFICATION

GAIL/PMS/SP-01

REV-0
Page 12 of
20

CPLNG.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.RED

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

SOCKOLET

00.500

0.750

MSSSP97

ASTM A 105

SW, 6000

SOCKOLET

01.000

01.500

MSSSP97

ASTM A 105

SW, 3000

WELDOLET

02.000

03.000

MSSSP97

ASTMA 105 (CHARPY)

BW

VLV.GATE

00.500

01.500

API-602

BODY-ASTM A
105, TRIM-STELLITED,
STEM13%CR. STEEL

SW,800, 3000,B16.11

VLV.GLOBE

00.500

01.500

BS-5352

BODY-ASTM A
105,TRIM-STELLITED,
STEM13%CR STEEL

SW,800, 3000,B16.11

VLV.CHECK

00.500

01.500

BS-5352

BODY-ASTMA
105,TRIM-STELLITED

SW,800, 3000, B16.11

00.500

10.000

B18.2

BOLT: 193 GR.B7,NUT:


A194 GR. 2H

00.500

10.000

B16.20ANSI B
16.5

SP,WND, SS316+CAF

Olet Group

M,
XXS

Valves Group

Bolt Group
BOLT.STUD

Gasket Group
GASKET

SPIRAL, 150

SPECIFICATION
GAIL (INDIA) LTD
NEW DELHI

PIPING MATERIAL SPECIFICATION

GAIL/PMS/SP-01

REV-0
Page 13 of
20

ANNEXURE B
PIPING MATERIAL SPECIFICATION
(CLASS 300#)

SPECIFICATION
GAIL (INDIA) LTD
NEW DELHI

PIPING MATERIAL SPECIFICATION

GAIL/PMS/SP-01

REV-0
Page 14 of
20

PIPING CLASS

300 #

BASE MATERIAL

CARBON STEEL

CORROSION ALLOWANCE

1.5 MM

SPECIAL REQUIREMENT

NON IBR

TEMP. (0C)- Design

-29 TO 65

PRESS.-Min/ Max

SERVICE
NON CORROSIVE PROCESS- FLAMMABLE / NON FLAMMABLE, NON LETHALHYDROCARBONS, AROMATICS, AMMONIA, SWEET GAS, FLUSHING OIL AND OTHER
UTILITIES -MP CONDENSATE, INSTRUMENT AIR, PLANT AIR, NITROGEN, AMMONIA GAS ETC.
NOTES
1.

ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.

2.

NDT OF WELDS SHALL BE AS FOLLOWS:


RADIOGRAPHY

ALL BUTT WELDS

100%

MPI

SOCKET WELDS

100%

3.

PIPING DESIGN AS PER ASME B 31.8 & OISD 141

4.

FLANGES OF SIZE 22 SHALL BE AS PER MSS-SP-44.

5.

CHARPY V-NOTCH TEST & HARDNESS TEST SHALL BE CONDUCTED FOR PIPE, FITTINGS AND
FLANGES.

6.

ALL BRANCH CONNECTIONS INCLUDING VENT, DRAIN, PRESSURE AND TEMPERATURE


CONNECTION SHALL BE AS PER BRANCH CONNECTION TABLE GIVEN ON NEXT PAGE. THE
BRANCH DETAILS INDICATED IN APPLICABLE STANDARD SHALL BE IGNORED.

ITEM

SIZE

DESCRIPTION

MAINTENANCE JOINTS
PIPE JOINTS

ALL
1.5 & BELOW

FLANGED, TO BE KEPT MINIMUM


SW COUPLING

2.0 & ABOVE

BUTT WELDED

ON LINES 1.5

REFER GAIL STD.

ON LINES 2.0

AS PER P&ID OR 0.75

ON LINES 1.5

REFER GAIL STD.

ON LINES 2.0

AS PER P&ID OR 0.75.

TEMP. CONN

1.5

FLANGED, INSTALLATION AS PER GAIL STD.

PRESS. CONN

0.75

SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD.

DRAINS

VENTS

SPECIFICATION
GAIL (INDIA) LTD
NEW DELHI

PIPING MATERIAL SPECIFICATION

GAIL/PMS/SP-01

REV-0
Page 15 of
20

T
T
T
T
T
T
W

T
T
T
T
T
T
T
W
W

T
T
T
T
T
T
T
T
W
W
W

T
T

T
T
T

T
T
T
T

W
S

W
S

S
S

S
S

S
S

S
S

S
S

S
S

S
S

S
S

S
S

S
S

6.000

S
S

5.000

S
S

4.000

S
S

3.500

S
S

3.000

T
T

2.500

T
T

1.250

26.000

W
S

24.000

W
S

22.000

W
S

20.000

W
S

18.000

W
S

16.000

W
S

14.000

W
S

12.000

W
S

10.000

W
S

8.000

T
S

2.000

T
S

1.500

T
T

1.000

72
70
68
66
64
62
60
58
56
54
52
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8.0
6.0
5.0
4.0
3.5
3.0
2.5
2.0
1.5
1.2
5
1.0
0.7
5
0.5

BRANCH PIPE (SIZE IN INCHES)

T
T
T
T
T

T
T
T
T
T
T

T
T
T
T
T
T
T
W

T
T
T
T
T
T
T
T
W
W

0.750

72
70
68
66
64
62
60
58
56
54
52
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8.0
6.0
5.0
4.0
3.5
3.0
2.5
2.0
1.5
1.2
5
1.0
0.7
5
0.5

0.500

BRANCH PIPE (SIZE IN INCHES)

SPECIAL NOTES

RUN PIPE (SIZES IN INCH)

CODE

DESCRIPTION

F
H
P
R
S

SADDLE FUSED JT
H.COUPLING
PIPE TO PIPE
REINFORCED
SOCKOLETS

T
W
I
X
L

TEES
WELDOLETS
INSTRUMENT TEE
REFER NOTES
SWEEPOLET

SPECIFICATION
GAIL (INDIA) LTD
NEW DELHI

PIPING MATERIAL SPECIFICATION

GAIL/PMS/SP-01

REV-0
Page 16 of
20

Lower
Size
(Inch)

Upper
Size
(Inch)

Sch./
Thk

Dim.
STD

Material

Description

PIPE

00.500

00.750

S160

B 36.10

ASTM A106 GR.B

PE, SEAMLESS

PIPE

01.000

01.500

XS

B 36.10

ASTM A106 GR.B

PE, SEAMLESS

PIPE

02.000

02.000

XS

B 36.10

ASTM A106 GR.B (CHARPY)

BE, SEAMLESS

PIPE

02.500

02.500

XS

B 36.10

ASTM A106 GR.B (CHARPY)

BE, SEAMLESS

PIPE

03.000

03.000

STD

B 36.10

ASTM A106 GR.B (CHARPY)

BE, SEAMLESS

PIPE

04.000

06.000

STD

B 36.10

ASTM A106 GR.B (CHARPY)

BE, SEAMLESS

PIPE

08.000

08.000

8.2

API 5L

API 5L GR.B PSL2

BE, SEAMLESS

PIPE

10.000

10.000

9.3

API 5L

API 5L GR.B PSL2

BE, SEAMLESS

PIPE

12.000

14.000

9.5

API 5L

API 5L GR.B PSL2

BE, SEAMLESS

PIPE

16.000

18.000

10.3

API 5L

API 5L GR.B PSL2

BE, SAW

PIPE

18.000

18.000

8.7

API 5L

API 5L GR.X-52 PSL2

BE, SAW

PIPE

20.000

20.000

9.5

API 5L

API 5L GR.X-52 PSL2

BE, SAW

PIPE

22.000

22.000

10.3

API 5L

API 5L GR.X-52 PSL2

BE, SAW

PIPE

24.000

24.000

11.1

API 5L

API 5L GR.X-52 PSL2

BE, SAW

PIPE

26.000

26.000

11.1

API 5L

API 5L GR.X-52 PSL2

BE, SAW

NIPPLE

00.500

00.750

B 36.10

ASTM A 106 GR.B

PBE, SEAMLESS

NIPPLE

01.000

01.500

B 36.10

ASTM A 106 GR.B

PBE, SEAMLESS

FLNG.SW

00.500

01.500

B-16.5

ASTM A 105

300,
RF/125AARH

FLNG.WN

02.000

16.000

B-16.5

ASTM A 105 (CHARPY)

300,
RF/125AARH

FLNG.WN

18.000

24.000

B-16.5

ASTM A 694 GR. F-52


(CHARPY)

300,
RF/125AARH

FLNG.WN

26.000

26.000

B-16.5

ASTM A 694 GR. F-52


(CHARPY)

300,
RF/125AARH

FLNG.BLIND

00.500

01.500

B-16.5

ASTM A 105

300,
RF/125AARH

PLNG.BLIND

02.000

24.000

B-16.5

ASTM A105 (CHARPY}

300,
RF/125AARH

Item Type

Pipe Group

Flange Group

SPECIFICATION
GAIL (INDIA) LTD
NEW DELHI

PIPING MATERIAL SPECIFICATION

GAIL/PMS/SP-01

REV-0
Page 17 of
20

PLNG.BLIND

26.000

26.000

B-16.47
A

ASTM A105 (CHARPY}

300,
RF/125AARH

FLNG.FIG8

00.500

01.500

B-16.48

ASTM A 105

300,
RF/125AARH

FLNG.FIG8

02.000

08.000

B-16.48

ASTM A105 (CHARPY)

SPCR &BLIND

10.000

24.000

B-16.48

ASTM A105 (CHARPY)

SPCR &BLIND

26.000

26.000

B-16.48/
GAIL
STD

ASTM A105 (CHARPY)

300,
RF/125AARH
300,
RF/125AARH
300,
RF/125AARH

ELBOW.90

00.500

0..750

B-16.11

ASTM A 105

SW, 6000

ELBOW.90

01.000

1.500

B-16.11

ASTM A 105

SW, 3000

ELBOW.90

02.000

16.000

B-16.9

ASTM A 234,GR. WPB CHARPY)

BW, 1.5D

ELBOW.90

18.000

26.000

MSSSP75

MSS-SP75 GR.WPHY-52

BW, 1.5D

ELBOW.45

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

ELBOW.45

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

ELBOW.45

02.000

16.000

B-16.9

ASTM A234, GR. WPB CHARPY)

BW, 1.5D

ELBOW.45

18.000

26.000

MSSSP75

MSS-SP75 GR.WPHY-52

BW, 1.5D

T.EQUAL

00.500

00.750

B 16.11

ASTM A 105

SW, 6000

T.EQUAL

01.000

01.500

B 16.11

ASTM A 105

SW, 3000

T.EQUAL

02.000

16.000

B-16.9

ASTM A234,GR.WPB (CHARPY)

BW

T.EQUAL

18.000

26.000

MSSSP75

MSS-SP75 GR.WPHY-52

BW

T.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

T.RED

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

T.RED

02.000

16.000

M, M

B-16.9

ASTM A234,GR. WPB(CHARPY)

BW

T.RED

18.000

26.000

M, M

MSSSP75

MSS-SP75 GR.WPHY-52

BW

REDUC.CONC

02.000

16.000

M,M

B-16.9

ASTM A234,GR. WPB(CHARPY)

BW

REDUC.CONC

18.000

26.000

M,M

MSSSP75

MSS-SP75 GR.WPHY-52

BW

REDUC.ECC

02.000

16.000

M,M

B-16.9

ASTM A234,GR. WPB(CHARPY)

BW

REDUC.ECC

18.000

26.000

M,M

MSS-

MSS-SP75 GR.WPHY-52

BW

Fitting Group

SPECIFICATION
GAIL (INDIA) LTD
NEW DELHI

PIPING MATERIAL SPECIFICATION

GAIL/PMS/SP-01

REV-0
Page 18 of
20

SP75
SWAGE.CONC

00.500

03.000

M,M

BS-3799

ASTM A 105 (CHARPY)

PBE

SWAGE.ECC

00.500

03.000

M,M

BS-3799

ASTM A 105 (CHARPY)

PBE

CAP

00.500

00.750

B-16.11

ASTM A 105

SCRF, 6000

CAP

01.000

01.500

B-16.11

ASTM A 105

SCRF, 3000

CAP

02.000

16.000

B-16.9

ASTM A234,GR. WPB (CHARPY)

BW

CAP

18.000

26.000

MSSSP75

MSS-SP75 GR.WPHY-52

BW

PLUG

00.500

00.750

B 16.11

ASTM A 105

SCRM, 6000

PLUG

01.000

01.500

B 16.11

ASTM A 105

SCRM, 3000

CPLNG.FULL

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.FULL

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG-HALF

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.HALF

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG.LH

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.LH

01.000

01.500

B-16.11

ASTM A 105

SW,3000

CPLNG.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.RED

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

SOCKOLET

00.500

0.750

MSSSP97

ASTM A 105

SW, 6000

SOCKOLET

01.000

01.500

MSSSP97

ASTM A 105

SW, 3000

WELDOLET

02.000

10.000

MSSSP97

ASTM A 105 (CHARPY)

BW

VLV.GATE

00.500

01.500

API-602

BODY-ASTM A 105, TRIMSTELLITED, STEM13%CR.


STEEL

SW,800, 3000,B16.11

VLV.GATE

02.000

12.000

API-6D

BODY-ASTM A 216 GR. WCB


TRIM-STELLITED, STEM 13%
CR. STEEL

FLGD, 300, B16.5, RF/ 125


AARH

VLV.GLOBE

00.500

01.500

BS-5352

BODY-ASTM A 105,TRIMSTELLITED, STEM13%CR


STEEL

SW,800, 3000,B16.11

O let Group

M,
XXS

Valves Group

SPECIFICATION
GAIL (INDIA) LTD
NEW DELHI

PIPING MATERIAL SPECIFICATION

GAIL/PMS/SP-01

REV-0
Page 19 of
20

VLV.GLOBE

02.000

12.000

BS-1873

BODY-ASTM A 216 GR. WCB


TRIM-STELLITED, STEM 13%
CR. STEEL

FLGD, 300, B16.5, RF/ 125


AARH

VLV.CHECK

00.500

01.500

BS-5352

BODY-ASTMA
105,TRIM-STELLITED

SW,800, 3000, B16.11

VLV.CHECK

2.000

12.000

API -6D

BODY-ASTM A 216 GR. WCB


TRIM-STELLITED, STEM 13%
CR. STEEL

FLGD, 300, B16.5, RF/ 125


AARH

VLV.BALL

00.500

01.500

BS-5351

BODY-ASTM A 105,TRIM-SEAT
RPTFE

FLGD, 300, B16.5, RF/ 125


AARH

VLV.BALL

02.000

12.000

API-6D

BODY-ASTM A 216 GR. WCC/


A234 GR WPC, TRIM-SEAT AISI
4140+0.003 ENP/ AISI 410

FLGD, 300, B16.5, RF/ 125


AARH

VLV.BALL

02.000

02.000

API-6D

BODY-ASTM A 216 GR. WCC/


A234 GR WPC, TRIM-SEAT AISI
4140+0.003 ENP/ AISI 410

BW, 300, B-16.25,


RF/ 125 AARH

VLV.PLUG

00.500

01.500

BS-5353

BODY-ASTM A 105, PLUG-A 105


+0.003 ENP

SW,800 3000, B16.11

VLV.PLUG

02.000

12.000

API-6D

BODY-ASTM A 216 GR. WCB


PLUG-A 216 GR. WCB+0.003
ENP

FLGD, 300, B16.5, RF/ 125


AARH

00.500

26.000

B18.2

BOLT: 193 GR.B7,NUT: A194 GR.


2H

GASKET

00.500

24.000

B16.20ANSI B
16.5

SP,WND, SS316+CAF

SPIRAL, 300

GASKET

26.000

26.000

B16.20ANSI B
16.47A

SP,WND, SS316+CAF

SPIRAL, 300

Bolt Group
BOLT.STUD

Gasket Group

SPECIFICATION
GAIL (INDIA) LTD
NEW DELHI

PIPING MATERIAL SPECIFICATION

GAIL/PMS/SP-01

REV-0
Page 20 of
20

E-Tender no. 8000005410


CHECK LIST (Technical)

Bidder shall positively include all the information/ documents asked in this check list for proper evaluation.
Sr. No.
Description
Bidder's response

1
3

P&ID of each Quoted Skid enclosed


Tentative Bill of Material for each Quoted items (Skid) as per the MR.
Make, Model No. and decoding details of each quoted items.

Yes / No
Yes / No
Yes / No

Letter of confirmation for "No Deviation" enclosed separately for each skid

Yes / No

Filled in data sheets of each offered item submitted.


Letter of confirmation that offered materials are as per data sheets enclosed
separately

Yes / No

7
8
9
10
11
12
13
14
15
16

GA drawing (with dimensional details)/ Catalogue of each quoted item like


Cartridge Filter, PCVs, SDVs, Valves, PSV, Meters etc. submitted separately.
Signed & Stamped copy of Tender Document with all Annexures
Contents / Index sheets with page numbering details for attached documents /
drawings / certificate enclosed
Sizing/ Design calculation for each offered item like Cartridge Filter, PCV & SDV,
PSV, Flow Meters etc., submitted
Flow computer sizing details submitted.
Documents submitted as per "Vendor Data requirement" sheets
Filled-in Technical Questionnaire submitted
Letter of confirmation that make of the various items shall be as per "Approved
Vendor List" enclosed with this tender document.
Items and vendor list for approval of GAIL or the items and vendors not covered
in "Approved Vendor List" of this tender document.
Estimated shipping weight & volume of each item furnished with the offer.

Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No

Check List for SOR ITEM No. 3 to 8 (MRS / METERING SKIDS)


NAME OF BIDDER:
OFFER NO & DATE :
QUOTED FOR SOR ITEM NO. :
Sl. No.

BEC CLAUSE NO.

CLAUSE NO. - 3.1.1

CLAUSE NO. - 3.1.1.1

CLAUSE NO. - 3.1.1.2

CLAUSE NO. - 3.1.1.3

CLAUSE NO. - 3.1.2

DOCUMENT REFERENCE
AGAINST THE CLAUSE

P.O REF. NO. & DATE

INLET / OULET SIZE


& RATING
OF SUPPLIED SKID

NOTE : BIDDER SHALL SUBMIT THE SEPARATE CHECK LIST (BEC) FOR EACH QUOTED SKID.

SUPPLIED TO
(NAME OF
CUSTOMER)

Page No. Ref


(Attached with Bid
Document)

Remarks

Standard Register List in Flow computers for SCADA communication


S.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43

Point Description
Inlet Pressure
Inlet Temperature
Meter Pressure
Meter Temperature
Differential Pressure 1
Differential Pressure 2
Corrected Volume Flow Rate
Corrected Todays Running Total Volume
Yesterday's Volume Total
Corrected Energy Flow Rate
Corrected Todays Running Total Energy
Yesterday's Energy Total
Corrected Mass Flow Rate
Corrected Todays Running Total Mass
Yesterday's Mass Total
Specific Gravity
Gross Calorific Value (GCV)
Net Calorific Value (NCV)
Average Days GCV
Average Days NCV
Meter Density
Relative Density
Compressibility Factor (Zf)
Carbon Dioxide Content
Nitrogen Content N2
Methane Content C1
Ethane Content C2
Propane Content C3
iButane Content iC4
nButane Content nC4
iPentane Content iC5
nPentane Content nC5
Hexane+ Content( C6+)
FCV Setpoint (Auto)
FCV % Opening Manual Setpoint
FCV % Opening Feedback
Battery Voltage
Meter Inlet Valve Open
Meter Inlet Valve Close
Slam Shut Valve 1 Open
Shut Down Valve 1 Close
Shut Down Valve 2 Open
Shut Down Valve 2 Close

Data Type
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Float
Boolean
Boolean
Boolean
Boolean
Boolean
Boolean

Paramater Proposed Registers to


Remarks
Type
Be configured
Read
To be configured if the paramater is coming in
40001
Read
the Flowcomputer
40003
Read
40005
Read
40007
Read
40009
Read
40011
Read
40013
Read
40015
Read
40017
Read
40019
Read
40021
Read
40023
Read
40025
Read
40027
Read
40029
Read Write
40031
Read Write
40033
Read Write
40035
Read
40037
If it is availaible in Flow computer
Read
40039
Read
40041
Read
40043
Read
40045
Read Write
40047
Read Write
40049
Read Write
40051
Read Write
40053
Read Write
40055
Read Write
40057
Read Write
40059
Read Write
40061
Read Write
40063
Read Write
40065
Read Write
40067
If FCV is installed and connected with Flow
Read Write
40069
Computer
Read
40071
Read
40073
Read
10001
Read
10002
In case Valve Status is availaible in Flow
Read
10003
Computer
Read
10004
Read
10005
Read
10006

Protocol - Modbus RTU, Baud Rate - 9600, Parity- None, Databits - 8 and Stopbits -1,
Modbus Register size is 16 bit and paramater will be IEEE 32bit Float
Refrence address will be start from 40001 (Actual Start Address is 1)
The parameters for SCADA to be configured in continuous registers as per the register number mentioned above and register details along with
Serial port shall be provided by Bidder/Flowcomputer vendor during detail engineering. Vendor shall configure Analog parameter in IEEE 32 point
floating point registers and option shall be made available by the bidder/ Flowcomputer vendor for configuring the parameters in two 16 bit
register or one 32 bit register based on the requirement of the RTU. RS-485 port may be provided by bidder for SCADA and a single RS485
interface for SCADA shall be provided through mutidropping for multiple flowcomputers.

ANNEXURE - 14

BIDDER DATA REQUIREMENT

BIDDER DATA REQUIREMENT


1.0

BIDDER DRAWING/ DOCUMENT REQUIREMENT


1.1 This section defines the requirement for Drawing / Document / Data for Gas
metering / MRS/ DRS package to be furnished by Bidder, during and after
award of job. This shall include the following:
(i)
ii)
III)
IV)
v)
vi)
vii)

All Basic Engineering Documents


Detailed Engineering Documents.
Documents for Procurement
Study, Schematic and Construction drawings.
All Manufacturer/ Supplier/ Sub-Vendor related Drawings, Manuals and
other Technical Literature.
All As Built Drawing/ Documents
Any other Drawing/Document/Deliverable not specifically covered but
generated by Bidder as part of project execution.

1.2 Bidder shall Submit all Drawings/ Documents generated by them to GAIL for
Approval/Review/ Records. These categories are as defined below:
Approval Category : Critical Drawing/ Documents for which GAIL approval is
essential.
Review Category ; Drawing /Documents which GAIL shall review and
comment.
Records
: Drawing /Documents essentially retained by GAIL/PMC
for Information/Records.
However Bidder shall note that approval/Review of any drawing by GAIL does
not absolve the Bidder from the responsibility of ensuring complete compliance
to the requirements. Noncompliance to the requirement observed at any stage
of Project execution shall be rectified by Bidder without any FINANCIAL
implication.
1.3

Bidder shall follow following philosophy with respect to number of copies to be


submitted at different stages of Project execution.
Initial submission: 2 sets of Hard Copy + 2 sets on Portable Media. (for each
skid/ SOR item)
Final / after approval/ For Construction: 2 sets of Hard Copy + 2 sets on
Portable Media.
Final as Built: 2 sets of Hard Copy + 2 sets on Portable Media. (FOR each skid/
SOR Item)

1.4

Bidder shall note that Language of all documents during Engineering, execution
stage, all final documents and as-built documents shall be English.

1.5

Bidder shall on award of Contract prepare and submit for GAIL approval a
detailed drawing document schedule as mentioned in Annexure in XII. The
schedule shall ensure sequential and logical sequence of document
submission. Bidder shall ensure that subsequent documents are submitted only
after the basic documents have been reviewed/ approved. Haphazard and
en-Bulk submission of documents shall not be entertained by client.

BIDDER DATA REQUIREMENT


S.
No.
1

Drawing and Document Schedule

Instrument Index

3
4

Vendor List for Instruments and


accessories
Instrument Sizing calculations

Power consumption list Skid wise

Material Requisition

Purchase Requisition

Functional Schematic

Instrument Loop Drawings

10

Detailed P&ID for Gas metering system


package
Control Panel layout

13

Control panel / metering supervisory


system front arrangement
Power Supply Distribution

14

Cabinet / Rack GADs

15

overall dimensional drawings (including


foundation details and weights)

16

Wiring diagram for Metering system/


FC/EVC
Instrument Cable Schedule

11
12

17
18
19
20
21

Description

Approval

Review

Records

for
critical
items only

for
critical
items only

for
critical
items only

complex &
critical
loops only

Metering skid and control


panel interconnection details
Instrument location, JB location
drawings
Gas metering system drawing with
foundation details
Instrument Termination details

Remarks

22

Instrument installation drawings

23

Instrument grounding details

24

Bill of material for installation


items
Special test equipment / tool
requirement for maintenance
Spare part list for:
a)
Mandatory spares
b)
Start up and commissioning

25
26

27
28
29

30
31
32
33

Statutory body certificates for


hazardous area
Test / calibration / inspection
certificates for all instruments
Inspection and test (FAT) procedures
for Gas metering system package

for
critical
items only

Complete catalogues with part list


for all Bidder supplied instruments,
control etc.
Installation, operation and
maintenance manuals
Closing time calculation for slam
shut valves
Custody transfer approval
certificates

Note :
1. As built drawings / documents shall be provided for all items for each skid.
2. Critical items include items like Gas Metering system, Slam shut valve,
Pressure regulator, Flow Control Valves, turbine meter, PD Meter, Pressure
relief valve, Transmitters, etc.
3. Any other documents not listed under critical item but necessary for quality
control shall be decided with Bidder after placement of the order.

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