HARIDWAR NATURAL GAS PVT. LTD.

A Joint Venture of Bharat Petroleum Corporation Limited

(BPCL) & GAIL GAS LIMITED

CITY GAS DISTRIBUTION PROJECT

BID DOCUMENT
FOR

CNG MOBILE CASCADES

DOMESTIC COMPETITIVE BIDDING

Bid Document No.: 05/51/Q7AU/HNGPL/034A

Visit: www.tenderwizard.com/MECON
(Tenderwizard helpdesk: 011-49424365)

VOLUME – II OF II

PREPARED AND ISSUED BY

MECON LIMITED
(A Govt. of India Undertaking)
Delhi, India

05/51/Q7AU/HNGPL/034A 1 of 28
 INDEX
OF
BID DOCUMENT

VOLUME – II OF II

Section-I : Material Requisition.

Section-II : Technical Specification.

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 Section-I

Material Requisition.

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 MATERIAL REQUISITION
(MR No. : MEC/Q7AU/05/25/M/002/S034)

Project : CNG and City Gas Distribution Project for Haridwar GA

Client : Haridwar Natural Gas Pvt. Ltd.
Items : CNG Mobile Cascades
MR No. : MEC/Q7AU/05/25/M/002/S034

Sl. Description Quantity

No. (Nos.)
1.0 CNG Mobile Cascades 3000 WL capacity
1.1 Design, Engineering, Manufacturing, Assembly, Supply, Inspection and Testing at 08
works and at site if required of CNG MOBILE STORAGE CASCADE OF
MINIMUM 3000 WL capacity at 15°C. for filling and storing of CNG at 250 bar (g)
at 20 to 48°C as specified in Technical Specification inclusive of services as
stipulated in the tender document. Mobile Cascade outlet connection to be provided
on the longest side of transporting vehicle.
1.2 Mandatory spares consisting of all the Quantities for total Quantity of the CNG
Cascades at Sr.No. 1.1 above
1.2.1 Pressure Gauge Range (0 – 400 kg/cm2(g) 08
1.2.2 Cylinder Valve with end tube fitting 08
1.2.3 Isolation Valve 08
1.2.4 Check Valve 08
1.2.5 Tube Pig Tail 08
1.2.6 Burst Disc with Washer 16
1.2.7 Spindle & Handles for cylinder valves 16
1.2.8 Safety Relief Device 08

Note :
1. The Vendor shall be completely responsible for the design, materials, manufacture & fabrication,
testing, inspection, preparation for shipment and transport of the above equipment strictly in
accordance with the MR and all attachment there to. All items shall be provided with test certificates.
2. Vendor has to appoint TPI Agency (Third Party Inspection Agency) for inspection at manufacturer’s
works as per approved QAP. No separate payment for the same shall be paid.
3. The mandatory spares shall be supplied along with the corresponding stationary / mobile cascade.

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 Section-II

TECHNICAL SPECIFICATION
FOR
MOBILE & STATIC STORAGE CASCADES

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 TECHNICAL SPECIFICATION
OF
MOBILE & STATIONARY STORAGE CASCADES

No. MEC/05/62/23N0/S034

(PROCESS & PIPING DESIGN SECTION)

MECON LIMITED
DELHI – 110 092

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 TABLE OF CONTENTS

1.0 CNG Mobile and Stationary Cascades Description

1.1 General

2.0 Feed gas composition

2.1 Gas composition

2.2 Gas storage pressure
2.3 CNG specification
2.4 Design philosophy
2.5 Design basis
2.6 Applicable standards and codes

3.0 Site STATIONARY Gas Storage and Mobile Storage cascades.

3.1 Cylinders
3.2 Pressure Relief Device
3.3 Safety Relief Devices for Cylinder Storage
3.4 Corrosion Protection
3.5 Valves
3.6 Rigid Piping
3.7 Pressure Gauges
3.8 Pipe work, Valves and Fittings
3.9 Cylinder Frame
3.10 Mobile storage cascades
3.11 Protection of Valves and Accessories
3.12 Equipment

4.0 Testing and Commissioning

5.0 Calibration, Test Certificates and Third Party Certification
6.0 Training requirements
7.0 Warranty servicing and spare parts
8.0 Services
9.0 Technical support
10.0 Data and Drawing Detail
11.0 Check list for Mandatory Spares of Storage Cascade System
12.0 Experience Record Proforma for Cascade
13.0 Check List for Scope of Supply

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 1.0 CNG MOBILE AND STATIONARY CASCADES DESCRIPTION

1.1 General

The intent of this tender is to outline minimum requirement for Design, Engineering,
Manufacturing, Assembly, Testing, Supply, Testing at site, Commissioning of CNG storage
in mobile storage systems as per Technical specification of tender.

This tender covers the supply of Mobile Storage Cascades for Haridwar GA.

Storage Sizing(WL)
Stationary / Mobile
Capacity Type Qty.
3000 WL Mobile 8

In the Mother Stations, the compressed natural gas would be directly filled into
stationary storage cascades and mobile storage cascades mounted on trailers. Once the
filling process into the storage trailer is completed, the filled storage trailer would be
transported to the respective daughter stations for off-loading. At the same time, an
empty storage trailer would be parked beside the compressor for filling.

At the daughter stations, the trailer storage modules will be connected to the trailer
decants panel located in the trailer bay. The decant panel will supply the inlet gas to
the dispenser for filling the gas to vehicles.

Upon depletion of the trailer storage, the CNG storage trailer would move off back to
the mother stations, for re-filling of the storage trailer.

2.0 FEED GAS SPECIFICATION

2.1 Gas Composition

The expected gas composition of the feed gas to the CNG Storage Cascade is given below.

Design Case Mole

Component Range mole %
%
Methane 90 92 94.00
Ethane 3.5 4.5 1.20
Propane 0.4 0.7 1.00
I Butane 0.02 0.03 0.40
N Butane 0.01 0.02 0.00
I Pentane 0.002 0.007 0.00
N Pentane 0.0001 0.0007 0.00
CO2 2.0 4.0 1.80
Nitrogen 0.1 0.2 1.60
Total 100 100 100

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 NOTES

· O2 not more than 0.5 % mole

· Total non hydrocarbon –Not more than 1.0 %
· Total S including H2S Not more than 10 PPM by weight
· H2S not more than 4 PPM by volume
· Moisture content in the range 112 to 144 Kg/ MMSCM
· Specific gravity to be calculated by Bidder
· Calorific value Net Kcal/SCM to be calculated by Bidder
· Temp of gas shall be max 50 °C

Climate

 Max. Height above Mean sea level: 314 meters (Approx.)

 Max. site temp.: 42 °C

 Minimum site temp.: 6 °C

 Maximum RH: 15% in the month of April.

 Minimum RH: 81% in the month of September

2.2 Gas Storage Pressure

Fill Pressure: - 250 Kg/cm2 (g)

Gas Delivery Temperature
Maximum 55 oC Dependant on ambient temperature

2.3 CNG Specification

The CNG specification shall meet the IS- 15403:2000 (E) natural gas quality designation for
use as a compressed fuel for vehicles.

The proposed specification of the CNG is as follows:

Gas Temperature 0 oC to +55 oC

Pressure dew-point - 25 oC
Particulate matter Less than 5 microns
Odorant - Mercaptane 2 to 7 mg/SCM

2.4 Design Philosophy

Storage fulfils four functions.

ONE - It allows more vehicles to fill than the compressor could fill directly one after
the other during peak times.

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 TWO - It allows the vehicle to fill at a faster rate than if directly from the compressor.

THREE - It prevents the compressor from stopping and starting too often.

FOUR- The combined storage capacity is compartmentalized in three banks. Each bank is
separated with check valve and direction of flow should be from high bank to low bank and
also provided with pressure relief valve.

It is anticipated that the natural gas feed composition, flow rate and pressure will be
fluctuating. Hence, Supplier should design the CNG storage facilities with optimum degree of
flexibility, reliability, operability to accommodate the varying composition of feed, other
unexpected contaminants, flow rate and pressure.

The CNG storage facilities should consist of standardised modules, which are assembled into
a complete system. Each system should be designed in standardized modular frames. The
modular approach allows the CNG Stationary storage and mobile storage facilities to be
easily installed there by reducing installation time.

The design life of the CNG storage facilities should be 20 years.

2.5 Design Basis

The Supplier should prepare the design basis required to meet the demands mentioned in
items 1.0 & 2.0 and liaise with HNGPL / MECON to obtain necessary confirmation and
approval.

2.6 Applicable Standards and Codes

The design, construction, manufacture, supply, testing and other general requirements of the
Storage Cascades should be strictly in accordance with the Applicable Standards and Codes
and should comply fully with relevant Indian / International standards, Gas Cylinder Rule
1981,Indian Explosives Act- 1884, Stationary and Mobile Pressure Vessels (Unfired) Rules
(SMPV) 1981, CNG Cylinder Design Code, IS:7285-2004 part-2 with amendment no. 4 &
including any other latest amendment, CNG Cylinder Valves, IS:3224-1979 (Amendments
1983,84,85,86,89,92,98), Hydrostatic Stretch Test, IS: 5844 – 1970, Safety Devices of Gas
Cylinders, IS : 5903 -1970, regulations of Insurance Association of India and Factories Act
while carrying out work as per this specification.

The bidder without any additional cost and delivery implications should carry out any
modification suggested by the statutory bodies either during drawing approval or during
inspection, if any.

The following codes and standards (versions/ revisions valid on the date of order) are
referenced to & made part of specification:

1. NFPA 52 Standards for CNG vehicular fuel systems & CNG Cylinder Codes IS:
7285-2004 part-2.

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 2. OISD 179 Safety requirements for compression, storage, handling and refueling of
CNG for use in automotive sector.

3. GAS CYLINDER RULE 2004 Standards for CNG Storage and Gas Cylinder Rules.

4. STATIC AND MOBILE PRESSURE VESSELS ( UNFIRED ) RULES, (SMPV)

1981

5. CNG CYLINDER DESIGN CODE, IS : 7285 – 2004 (part 2).

6. CNG CYLINDER VALVES, IS : 3224 – 1979 (Amendments

1983,84,85,86,89,92,98)

7. HYDROSTATIC STRETCH TEST, IS: 5844 – 1970,

8. SAFETY DEVICES OF GAS CYLINDERS, IS : 5903 -1970, regulations of

Insurance Association

9. INDIAN EXPLOSIVES ACT

10. ANSI, ASTM, NEC, NEMA, ASNZ, OISD 179

11. Latest PNGRB Guidelines

3.0 STATIONARY GAS STORAGE AND MOBILE STORAGE CASCADES

3.1 Cylinders

Supply of CNG storage cascades of water liter capacity as specified at clause no. 1.1.
Permissible tolerance -0 + 5% at 15°C with the following minimum details:

3.1.1 All cylinders should be designed, constructed and tested in accordance with the Indian
Standard 7285, as amended from time to time, IS : 7285 – 2004 or BS5045:Part1 or (US)
D.O.T 3AA or similar such other standard code approved by the Chief Controller of
Explosives.

3.1.2 Cylinder material shall be seamless alloy steel (Cr-Mo) or as per design approval by Chief
Controller of Explosives. The neck threading shall be as per IS: 3224 – 1979 or as per design
approval by Chief Controller of Explosives. The thread size of dia. 25.4 mm standards, type 4
threads with taper of 1 in 8 on diameter confirming to IS: 3224-1970 or equivalent is
recommended. The shut off valve shall be fusible burst disc confirming to requirements of IS:
3224 or as per design approval by Chief Controller of Explosives.

3.1.3 A Test and Inspection certificate issued by the manufacturer of the cylinder duly
countersigned by an Inspector that the Cylinder meets the requirements of the standard or
code referred above submitted to Chief Controller of Explosives shall be provided to the
Purchaser.

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 3.1.4 All cylinders should be new and unused. Re-certified cylinders are not acceptable. Before
using the Cylinder or before refilling the cylinder, which has to be made gas-free, air
contained therein shall be purged by an inert gas ( Nitrogen) or by the CNG gas. Cylinder of
75/125 lit water capacity at 15°C are only envisaged. All cylinders in a cascade shall be of
same capacity.

3.1.5 Total storage volume with no negative tolerance should be designed to meet storage patterns
sizes for storage:

Mobile Storage - 3000WL at 15 degree centigrade.

3.1.6. For ready access and to ensure that all cylinder fittings are easily accessible, multiple
cylinder units, which comprise a Stationary CNG storage facility and are stored in a
horizontal position should be limited to a width of 2m, a length of 5.5m and a height
of 1.6m above floor level. (L x W x H – 5500mm x 2000mm x 1600mm).

3.1.7 To ensure ready access, all cylinder fittings should be arranged to face one direction
in each unit. For easy access , operation and maintenance of the cascade system, 1.0
m clear space all around each of the cascades shall be provided. Each such storage
unit should be separated from other units by a distance of not less than 2m. Where
horizontal units are placed parallel to each other, cylinder fittings should be arranged
so that they do not face cylinder fittings of other units.

3.1.8 The cylinder shut-off valve shall be with fusible burst disc confirming to requirements
of IS:3224 or as per design approved by CCOE, Govt. of India.

3.1.9 The burst disc shall rupture on excess pressure as well as excess temperature either
individually or combined. The burst disc discharge shall be manifold to a common
header for safe venting. Vendor shall indicate burst pressure and temperature.

3.1.10 The cylinder shut-off valve orifice shall be designed for high flow to permit the
combined flow of 100 kg/min for each bank at a pressure of 250 bar(g). Vendor to
furnish necessary calculation indicating overall pressure drop of each bank,
coefficient of flow (Cv) values, valve orifice size etc.

3.1.11 Number of cylinders in the cascade shall be divided into three independent banks for
low, medium & high pressure of different storage pressure. Vendor shall optimise the
number of cylinder in each bank for maximizing the recovery from the storage
cascade and submit the calculations along with the bid. Generally cylinder ratio of
Low: Medium: High bank is kept as 5:3:2 by Volume. Single bank cascades will be
procured for Mobile cascades.

3.1.12 The interconnecting tube work of cylinder manifold in configuration suitable for
priority filling and sequential dispensing system by the electronic CNG dispensers.

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 3.1.13 Full bore ¾” ball valves for isolation shall be provided at inlet/ outlet of each line/
banks.

3.1.14 Interconnecting tube work shall be minimum of ¾” OD SS-316 tubing. The sizing of
connecting tubing between each outlet and its associated cylinder shall be such that
where they join the total incoming flow areas shall not be less than the total outgoing
area. The loops in the tube work shall be provided for absorbing contraction,
expansion and vibration. Piping/ tubing shall be suitably clamped to the frame
structure.

3.1.15 There shall not be any back flow between any two banks with all valves open for 3
bank cascades. However, for mobile cascades, single bank cascades will be procured.

3.1.16 Cylinders installed horizontally should be separated from one another in each storage
unit by a distance of not less than 30mm. The material used to separate the cylinders
should be sufficiently strong enough and should not absorb moisture. Special
precautions should be taken to avoid corrosion at the point of contact.

3.1.17 All cylinder valves and fittings must be rated for the full range of temperature and
pressures and the manufacturer should stamp or otherwise permanently mark the
valve body to indicate the service rating.

3.1.18. All cylinders to be hydrostatically tested and approved by third party certification
body. Test certificates shall be duly endorsed by approval body and issued before
delivery.

3.1.19 The location of inlet/ outlet tube manifold and pressure/temperature gauges shall be
towards the length side of cascade for stationary and width side of cascade for mobile

3.1.20 The cascade cylinder shall be purged & Blanketed with N2 at 1 bar(g) pressure
before dispatch.

3.1.21. Markings of Cylinders:-

a) Every Gas cylinder shall be clearly and permanently marked in accordance

with the following conditions by stamping, engraving or similar process;

i) on the shoulder of the cylinder which shall be enforced by forging or

other means, or
ii) on such a part which is inseparably bound with the cylinder and which
is not or only negligibly effected by the stresses due to the gas pressure
within it.

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 b) The name plate shall not be affixed to the cylinder by soldering, if there is risk
of corrosion or embrittlement.
c) In conjunction with the original marking, space shall be provided for stamping
the test date obtained at the periodic inspection.
d) Markings shall be as carried out and the letters and numerals used shall be of
such shape and size that the marking is clear and easily readable and does not
give place for misreading.
f) All cylinders must be permanently stamped with the word CNG together with
the following information:

1) manufacturer’s, owner’s and inspector’s marking and rotation number;

(These markings shall be registered with the Chief Controller of
Explosives);
2) specifying that the cylinder has been manufactured for “CNG only”
3) A symbol to indicate the nature of heat treatment (such as normalizing,
quenching, or tempering) given to the cylinder during manufacture.
4) The date of the last hydrostatic or hydrostatic stretch test, as the case
may be, with the code mark of recognized testing station where the test
was carried out. The code mark shall be registered with the Chief
Controller of Explosives.
5) Working pressure and test pressure;
6) Tare weight
7) Water capacity.

g) All the markings, except the manufacturer’s marking, which may be on the base, shall be
stamped on the neck end of the cylinder.

3.1.22 Marking on the Valves:-

Valves fitted to the cylinder shall be clearly and durably marked in accordance with the
following provisions by stamping, engraving or similar process:

1) the specification of the valves;

2) year and quarter of manufacture;
3) manufacturer’s symbol;
4) working pressure;
5) the name or chemical symbol of the gas for which the valve is to be used;
6) if possible the type of screw threads on the outlet namely left handed (L.H)
or right handed (R.H);
7) Inspector’s stamp if possible;

3.1.23 Identification colors:-

Every cylinder is painted with the appropriate identification colors specified in IS: 4379 for
Industrial cylinders.

Color of the Cylinder shell -------- White

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 Color of band at neck end of cylinder -------- Red (IS Standard Color No. 537)
Color of the Frame -------- Yellow

3.1.24 Labeling of cylinders

1) Every cylinder shall be labeled with the name “CNG ONLY” with letter of at least
25mm high in contrasting colour and the name and address of the Purchaser by
whom the cylinder was filled with gas.

2) A warning in the following terms shall be attached to every cylinder containing

Compressed Natural Gas namely:-

i) Do not change the color of the cylinder

ii) This cylinder should not be filled with any gas other than CNG.
iii) No flammable material should be stored in the immediate vicinity of this
cylinder or in the same place in which it is kept.

iv) No oil or similar lubricant should be used on the valves or other fittings of
this cylinder.

v) Please look for the next date of test, which is marked on a metal ring inserted
between the valve and the neck of the cylinder, and if this date is over, do not
accept the cylinder.

3.1.25 All storage system should be supplied in a three bank arrangement. Low bank 50%, Medium
bank 30% and High bank 20% of the total storage system.

3.2 Pressure Relief Devices

3.2.1. Each cylinder used for the storage of CNG should be equipped with a suitable pressure
relieving device and a suitable isolating valve which should be readily accessible when
installed in the storage bank. The isolating valve should not be capable of closing off the
pressure relieving device, or should be locked in the open position.

Relief devices should be positioned in such a way as to avoid discharge of high pressure gas
to the operator or persons in close vicinity.

3.3 Safety Relief Devices for Cylinder Storage

3.3.1 Cylinders manufactured in India, if fitted with safety relief devices in their bodies, shall have
such safety devices manufactured and maintained in accordance with IS: 5903.

3.3.2 Piping and gas storage systems should be protected against overpressure by safety relief
devices. Relief devices installed to protect the storage systems should have sufficient
capacity to vent the maximum flow produced by the compressor and should be set to open at
a pressure not exceeding 20% above the maximum allowable working pressure of the system

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 or the pressure which produces a hoop stress of 75% of the specified minimum yield strength,
whichever is lower.

3.3.3 A combination burst disc/fusible alloy assembly should be incorporated in the cylinder valve.
Burst disc should yield at a pressure not less than 1.5 times manufacturer’s recommended
operating pressure of the cylinder, and not more than test pressure. The disc should relieve
pressures in excess of 30Mpa

3.3.4 In addition to 3.3.2 a mechanical pressure relief valve which opens at a predetermined
pressure should be used, PRV set pressure 300 bar. This should not be part of the cylinder
valve.

3.3.5 Safety relief valves should be provided with means to seal to prevent tampering by
unauthorized persons.

3.3.6 Minimum required rate of discharge from the safety valve should be at least equal to any
input from the system whether stored or being compressed.

3.3.7 Each safety relief valve should be clearly marked by the manufacturer.

3.3.8 The maximum pressure in the storage system should not exceed 255 Kgf/cm2.

3.3.9 The cascade cylinders should be supplied with impact test certification.

3.3.10 Void

3.4 Corrosion Protection

3.4.1. Pressure vessels which are made of materials that are subject to corrosion by atmospheric
conditions should be protected by painting or other equivalent means necessary to prevent
corrosion.

3.4.2. Importance should be drawn to avoiding corrosion which can limit the working life of a
cylinder and affect the fatigue characteristics in serious cases. The implementation of good
periodic maintenance anti-corrosion procedures is strongly recommended.

3.5 Valves

3.5.1 All Valves fitted to gas cylinders shall comply in all respects with the following
Specifications namely:

a. In respect of Industrial Gas Cylinder, IS: 3224

b. Valves for cylinders shall have outlets provided with left hand screw threads for the
pipes or connections.
c. The valves shall be attached to the cylinder neck by screwing and not by making any
permanent attachment or inserting adapter in between.
d. The design of spindle operated valves shall be such that when fitted to the cylinders it
shall not be possible to withdraw the spindle under normal operating conditions.

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 3.5.2. Each gas storage unit should have a quick action gas storage isolation valve installed in the
steel supply pipe immediately adjacent to its gas storage unit to enable individual shut off and
isolation of each unit. These valves will be within fence enclosure.

3.5.3. Separate common valve system to be supplied for each storage bank complete with non-return
valve.

3.6 Rigid Piping

3.6.1. All rigid piping, tubing and other components on the storage system should be designed for
the full range of pressures, temperatures and loadings to which they may be subjected with the
factor of safety of at least 4 based on the tensile strength at 20°C. Any materials used
including gaskets and packing should be compatible with natural gas and its service
conditions.

3.6.2. All piping should be designed in accordance with engineering calculations based on the
requirements of ASME B31.3 in conjunction with EEMUA supplement to ASME B31.3 or
equivalent design standards. Standards used should be used in total.

3.6.3. All welding piping should be fabricated and tested in accordance with ANSI/ASME B31.3,
API 1104 or an equivalent standard. Whichever standard is chosen for use, it should be used
in total.

3.6.4 All piping to be tested after assembly to a pressure equal to that of the pressure relief device
setting and proved leak free.

3.6.5. Cylinders to be connected in stainless steel tubing 316 (Stainless Steel Tubing Specifications
ASTM A269, ultimate tensile 517 Mpa, or equivalent of Sandvik or Tubacax) incorporating
stress reducing hoops. Only approved manufacturers (e.g. Parker, Swagelok, SSP, BMT-
Superlok , Hylok and Hoke ) of high pressure fittings to be used.

3.7 Pressure Gauges

3.7.1. Every CNG storage unit including each manifold group or bulk storage tank should be
provided with a suitable pressure gauge for each bank. The pressure gauge should be directly
connected to the tank or storage system. The gauge should be dial graduated to read
approximately double the operating pressure. Pressure gauge should be equipped with 3-way
valve or 2-valve manifold block. Pressure gauges on mobile cascades shall have IP 55
protection.

3.7.2. A good quality industrial pressure gauge should be used with a dial face of at least 63mm or
larger. Gauges should be built to requirements of BS 1780 or ANSI/ASME B40.1 or OISD-
179 equivalent.

3.8 Pipe Work, Valves and Fittings

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 Pipe work should be designed, tested and installed to ensure its safe operation at the
worst conceivable conditions of flow, pressure and temperature.

All pipe work should be ASTM 316 stainless steel tube. Double compression ferrule Fittings
shall be used in tube connection tubes. And makes of these fittings shall be of SS 316L of
Swagelok , Parker ,SSP and Hylok and tubes shall be of SANVIK/ TUBACEX only. The
system should be “go-no-go” gaugable to demonstrate that fittings are properly tightened.
Wherever possible valves and control devices should incorporate the same end connector
system. The number of fittings used should be minimised. The Supplier should ensure that
personnel assembling the pipe work should be competent in the system employed.

The preferred valve types for isolation are ¼” turn ball valves. Such valves have similar
material to the tube they are attached to. Ball valves must be of good quality and be
appropriately selected frequency of use. Ball seats must be suitable for natural gas operation
of the gas composition indicated.
Valves and fittings subject to corrosion must be either inherently resistant, or be coated with a
corrosion inhibiting paint or surface treatment.

The gas inlet connection of each bank shall be terminated with ¾” union after the isolation
valve.

3.9 Cascade Frame

3.9.1 Cascade storage system to be skid mounted and complete with removable metal frames and
non-metal / non-sparking spacer material.

3.9.2 Cascade and spacer frame to be painted with anti-rust and etching primer under coat.
Importance should be drawn to avoiding corrosion which can limit the working life of a
cylinder and affect the fatigue characteristics in serious cases. The implementation of good
periodic maintenance anti-corrosion procedures is strongly recommended.

3.9.3 Each storage system should be supplied with suitable lifting lugs. Bottom and top of frame
shall be reinforced to prevent any twisting or strain to inter connections among cascade
cylinders during lifting by crane, forklift and during transport.

3.9.4 All cylinder tubing, manual isolation valves and pressure relief valves should be protected
from knocking by any moving object and should not protrude outside the metal frame or
brackets.

3.9.5 The frame shall not allow lateral and rotational movement of cylinders during regular road
transport under circumstances.

3.9.6 The frame structure of each cascade shall be capable of withstanding 4g (four times gravity)
impact from any direction without any distortion..

3.9.7 All structural items used in the frame shall be weather proof.

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 3.9.8 Supplier shall submit structural drawing of the frame giving details of the steel, welding
procedure, corrosion protection for approval before commencing fabrication work.

3.9.9 Frame shall be suitably covered with canopy from top to avoid the ingress of rain water.

3.9.10 Frame Painting

Surface preparation by Short Blasting as per grade SA 2 1/2,Swedish standard SIS-055909 or

Indian Standard IS 9954/International Standard ISO 8501-1. Three coats of paint shall be
applied with minimum thickness of 300 micron. (Permissible thickness in each coat shall be
within 80 to 120 micron.)

3.10 Mobile storage cascades

3.10.1 All the Cylinder Specifications, valves, safety relief devices, pressure gauges, pressure Relief
devices etc shall remain same as mentioned in the Stationary cascades but not limited so.

3.10.2 Every cylinders used in Mobile cascades used for transport of compressed gas shall be a type
approved, in writing, by the Chief Controller of Explosives.

3.10.3 Every Cylinder used for transportation for compressed gas shall be constructed and tested in
accordance with Indian Standard 2825, as amended from time to time, IS :7285 – 1988 or
BS5045:Part1 or (US) D.O.T 3AA or similar such other standard code approved by the
Chief Controller of Explosives.

3.10.4 The design stress shall include an allowance to include an allowance to enable the cylinder to
withstand shocks normally encountered by the movements on road, such as acceleration and
deceleration for a minimum of 4g (4 times gravity).

3.10.5 All the attachments to the cylinders shall be protected against accidental damage which may
result from collision, overturning or other operational cause.

3.10.6 All the cylinders shall be designed to withstand the most severe combined stresses to which
they may be subjected to by the pressure of the gas, the pumping pressures and shock loading
caused by transport conditions.

3.10.7 The isolation valves and the end connections shall be terminated at the left side of the storage
frame.

3.10.8 End connections shall be such that tube manifold accessible from side of the vehicle and can
be connected to station piping from any one side of the vehicle.

3.11 Protection of Valves and accessories

3.11.1 All valves and accessories shall be safeguarded against accidental damage or interference.

3.11.2 Valves and accessories shall be mounted and protected in such a way that risk of accidental
rupture of the branch to which the valve or accessory is connected is minimized.

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 3.11.3 Valves and accessories situated at the rear of a vehicle shall be protected by the rear cross
member of the frame of the vehicle against damage.

3.12 Equipment

3.12.1 Piping, Fittings and meters:

I) all piping, fittings and meters mounted on the vehicle shall be designed to with stand
the most severe combined stresses imposed by the following, namely:

a) the maximum designed pressure of the vessel.

b) the super imposed pumping pressure of the shock loading caused by road
movements;

II) the materials used for vessel equipment shall be sufficient ductile to withstand rough
usage and accidental damage. Brittle materials such as cast iron shall not be used.

3.12.2 Protection of piping and equipment;

I) all piping and equipment shall be adequately protected to minimize accidental

damage which may be caused by rough usage, collision or over-turning;

II) any equipment or section of piping in which liquid may be trapped shall be protected
against excessive pressure caused by thermal expansion of the contents.

3.12.3 Marking of connections- All connections on the vehicle which require manipulation by the
operator of the vehicle should be clearly marked to prevent incorrect operation. The form of
this marking should correspond with the operating procedure laid down for the vehicle.

4.0 TESTING AND COMMISSIONING

Before bringing any items of equipment to site, factory testing should be carried out to
demonstrate the function of all equipment within the system if so desired.

The Company should be given 2 weeks notice of the date and location of the tests so that the
equipment may be witnessed if desired.

Upon delivery to the site, all the equipment should be assembled in a complete system.
Thereafter, final site acceptance test would be carried out. Such tests should be witnessed and
signed off by the Company representative. The Supplier should rectify and replace all defects,
faults, failures, etc. and all costs should be borne by Supplier. The costs should include
accommodation, travelling, expenses, etc.

5.0 CALIBRATIONS, TEST CERTIFICATES AND THIRD PARTY CERTIFICATION

5.1. Every Cylinder should be carried with Hydrostatic or Hydrostatic stretch test and a certificate
should be provided.

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 5.2. Leak test should be carried for each cylinders or cascades with all tubing’s, valves and a
certificate should be furnished to the Owner.

5.3. All Instrument gauges, Valves, Pressure gauges, safety relief devices, shut off valves tubing’s
and piping etc should be Pressure tested, calibrated and such test , calibration certificates,
should be presented upon delivery to site. If any of the test certificates is not in order, the
Supplier’s should replace the affected equipment with valid certificate at Supplier cost.

5.4. Calculation shall be carried for 4g Stationary of one complete cascade with all cylinders
mounted and filled and the same should be submitted for review of the Owner.

5.5. Burst test of one cylinder from the entire supplies shall be produced and incase offered once
are new design the schedule for the test should be informed prior to enable the Owner or their
authorized representative to depute their personnel for witnessing the test.

5.6. All standards shop tests/ QA / QC as per the recommendation of the manufacturer / Chief
Controller of Explosives to be carried out and a copy of such certificates shall be furnished to
the Owner.

5.7. Record of storage capacity check of each cylinder in a cascade shall be furnished and same
shall be demonstrated to the Owner/ its representative.

5.8. Inspection: Vendor shall appoint the TPIA for inspection purpose in a manner described
hereunder-

5.9. “The Successful Vendor shall propose minimum four (4) nos. of TPIA’s from the below listed
TPIA’s within two (2) weeks from date of FOA. HNGPL / MECON shall approve any one
TPIA out of the four (4) nos. proposed TPIA’s. The Successful Vendor shall appoint the same
approved TPIA for inspection purpose."

a) Lloyd Register of Industrial Services

b) TechnischeUlierwachungsVerein(TUV)
c) Det Norske Veritas (DNV)
d) AB-Vincotte
e) Bureau Veritas
f) SGS
g) American Bureau Services
h) Velosi Certification Services
i) Certification Engineers International Limited(CEIL)
j) International Certification Services Limited
k) BVQI
l)Dr. Amin Controllers Pvt. Ltd.

6.0 TRAINING REQUIREMENTS

The Supplier should develop a training proposal and prepare a schedule for the Company’s
review, comment and approval.

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 The training programme should be phased to suit the construction program such that the
Company’s personnel are fully conversant with all aspects of the operations and maintenance
of the storage systems including all aspects of operations, including decanting CNG from
mobile gas storage trailers, pressure control and integration of the overall system.

Commissioning will not be deemed to have completed and formal acceptance will not be
granted until training has been completed to the satisfaction of the Company.

The training programme should cover but not limited to the following subject areas:

- The physical characteristics of the gas and the procedure and precautions to be
observed in handling and control.

- Start-up, operations and maintenance procedures for the CNG storage facilities.

7.0 WARRANTY SERVICING AND SPARE PARTS

7.1 All necessary spare parts to sustain the operations and maintenance of the CNG Stationary
and mobile storage facilities should be supplied and stock at the Supplier workshop /
warehouse located in India for immediate replacement of parts. The costs to stock these spare
parts should be at supplier cost. However, once the parts are replaced in the Stationary and
Mobile Cascades, the Company’s should compensate the Supplier’s accordingly provided that
the warranty period has expired.

7.2 Warranty shall be Governed by clause no 20 of GCC-Goods and 24 of SCC, Vol- I.

7.3 All the material and equipment to be free from defects in design, manufacture, material and
workmanship.

7.4 Replacement shall be made if any defective items found damaged or not performing to the
specified requirements of any part of cylinder for at least 24 months from the date of delivery
or 12 months from the date of successful commissioning whichever is later.

8.0 SERVICES

 Preparation of submission of document/ drawing.

 Obtaining approvals from statutory authorities.

 Bidder to submit foundation and other drawings indicating requirement of work to be

carried out by Owner within one month of placement of order.

 Supervision during trail run if required.

9.0 DATA AND DRAWING DETAIL

After the placement of FOI, a conference (kick off meeting) will be held at such date and at
such place, as may be mutually agreed upon between the Bidder and the purchaser. The intent

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 of this conference should be to discuss / clarify various requirements and finalize the modus
operandi for execution of the contract within the scheduled delivery period.

Along with the technical bid the following information is to be provided.

1. Process and instrument diagram along with Bill of Material. The Bill of Material should
indicate all items, quantity of all items installed per storage system, their part nos and make.

2. Process and instrument diagram along with Bill of Materials for all major components
within the tender.

3. General arrangement drawing of the storage system giving overall dimensions and
erection / shipping weight.

4. Technical data sheet of storage system.

5. Typical cross sectional drawing and literature to fully describe the details of all major
components such as Cylinders, valve, gauges piping etc. Data sheet indicating
material of tube, tube size etc, piping and instrument diagram.

6. List of mandatory spares, supplier to provide a comprehensive list of spares for all Major
components both within the storage system and all auxiliary equipment. (Itemized rate to be
given in price bid).

7. List of spares required in addition to those mentioned above for 2 years normal
operation & maintenance per storage system (itemized rate to be given in price bid)

8. List of commissioning spares per storage system.

9. List of special tools & Tackles required for installation & maintenance per storage
system.

10. Leaflets, catalogues for all major items.

11. Shop test procedure.

12. Maintenance schedule of the storage system along with list of Spares for O&M
during warranty period.

13. A complete zonal drawings of the Storage Cascade (complete package), all
certification for all components used within the hazardous areas should be provided

14. Reference list of similar / identical storage system supplied in last 7 years of CNG
application.

15. Deviation sheet (if any).

Within one month from date of P.O.

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 16. General arrangement drawing , schematic of cascade piping, drawing of
cascade frame the storage system giving overall dimension and erection /
shipping weight.

17. Detailed quality control procedure for manufacture of cascade, fabrication of frame
submitted to MECON /BPCL for approval.

18. Detailed foundation drawing of the storage system for casting foundation giving load
pattern etc.

19. Details of inlet gas termination to the storage system including X, Y, Z co-ordinates
with respect to center of storage system skid or any reference.

20. Detailed time schedule for supply indicating time periods required for cylinder
manufacturing, cascade frame fabrication, shop testing, despatch of material
from works and delivery at site.

Along with supply.

21. Operation and maintenance manuals – 3 sets all in original for each Storage
cascade. The instruction manual should describe in details the construction and
recommended procedure for maintaining, operating and trouble shooting of the
storage system should also include cross-sectional drawings, exploded views of all
spare parts along with part nos., quantity installed per storage unit. The manual
should provide detailed catalogues of all bought out items.

22. Test certificates of all major components like cylinders, shutoff valves, pressure relief
valves tubing / pipe work etc.

23. Calibration certificates for all measuring and protection devices.

24. In case of foreign supply, the bidder should get all certificates endorsed by office of
Chief Controller of Explosives (CCOE), Govt. of India within one month of delivery
of cascades at site.

10.0. Check List for Mandatory Spares of Storage Cascade System

Sl. No. Total in Numbers

Item
Item 1.0

1 Pressure Gauge Range (0 – 400 8

kg/cm2(g)
2. Cylinder Valve with end tube fitting 8

3. Isolation Valve 8
4. Check Valve 8

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 5. Tube Pig Tail 8
6. Burst Disc with Washer 16
7. Spindle & Handles for cylinder 16
valves for item no. 2
8. Safety Relief Device 8

10.1 All the mandatory spare parts shall be wrapped and packaged for prolonged life, so
that they will be preserved in original condition.

10.2 The spare parts shall be properly tagged and coded so as to facilitate easy identification.

10.3 Spares shall be packaged separately and clearly marked spares and shipped at same time as
the main equipment.

11.0 EXPERIENCE RECORD PROFORMA FOR CASCADE

Sl. PARAMETER Information Information on
No. on offered Existing Cascade
model
(Location)
1 2

1 No. of Units Supplied

2 Service CNG
3 Working Pressure of Cascade in bar (g)
4 Site min. /max. Temp.
5 Normal flow from each bank Kg/hr.
6 Cascades water capacity- Ltrs.
7 Water capacity of single cylinder used in cascade –
Ltrs.
8 Material of Cylinder
9 Thickness of cylinder wall and disc end in mm
10 Material of vent tubing
11 Piping material and make
12 Valve make
13 Valve type and Dia.
14 Nos. of banks in cascade
15 Nos. of cylinders in low bank
16 Nos. of cylinders in medium bank
17 Nos. of cylinders in high bank
18 Water capacity of cylinders individual banks – Ltrs.
19 4-G Stationary calculation for one complete
assembled package
20 Cylinder burst test for one cylinder
21 Design standard code used
22 Total weight of cascade in - Tonnes
23 Burst pressure and temperature for burst disc in bar
(g)
24 Hydrostatic or Hydrostatic Stretch test

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 Sl. PARAMETER Information Information on
No. on offered Existing Cascade
model
(Location)
1 2

25 Pressure test for Leakage

26 Design case gas composition
27 Approved Manufacturer License certificate from
CCOE Nagpur
28 Dimensions of the Total package
29 Warranty certificates
30 Dimension of package max.
31 Calibration certificates for all instrument gauges etc
of package

32 Test certificates of all instruments with cylinder,

tubing’s, fittings of total package
32 Date of commissioning of cascade
34 Where cascades are located :
Address and Fax/Telephone no. of Contact person
35 Major problems encountered if any

12. CHECK LIST FOR SCOPE OF SUPPLY

Notes:

1) Bidder shall furnish all the equipments of Storage Cascade System instruments and
gauges and safety devices as per the enquiry document. Anything required over and
above what is specified, for safe and satisfactory operation of the equipment package
shall be included by the bidder in his scope.
2) Bidder to write YES/NO against each item. Bidder is required to include complete
scope, as such ‘NO’ is not warranted. However, in case for any of the items if
vendor’s reply is ‘NO’, vendor should give reason for the same:
3) Bidder’s scope of supply shall include but not limited to the following:

S. Description Specified by Included Remarks

No Purchaser by
YES/NO Bidder
YES/NO
1.0 Each Storage cascade Package complete with:
1.1 Specification – Indian Standard 2825, as amended
from time to time, IS : 7285 – 1988 or BS5045:Part1 YES
or (US) D.O.T 3AA or similar such other standard
code approved by the Chief Controller of Explosives.
1.2 Cylinder material – Seamless alloy steel (Cr-Mo) or YES
standard code approved by the Chief Controller of
Explosives.
1.3 All the fittings, Valves, Safety devices, gauges are as
per IS 3224 or standard code approved by the Chief YES
Controller of Explosives.

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 S. Description Specified by Included Remarks
No Purchaser by
YES/NO Bidder
YES/NO
1.4 Tubing’s are of rigid type ASTM 316 stainless steel YES
tube.
1.5 All cylinders are Hydro static Tested
YES
1.6 Water capacity of single cylinder used in cascade not YES
less than 50 Ltrs.
1.7 Nos. of banks in cascade- three bank system
YES
1.8 One Cylinder should be burst test
YES
1.9 4-G Stationary calculation for one complete
assembled package is done YES
1.10 Working Pressure of Cascade min. 255 bar (g) YES
1.11 Pressure test for Leakage on cylinders with
assembled condition YES
1.12 Isolation Valve complete with venting line valve and
end plug installed on the inlet of the cylinder YES
1.13 Copy of Calibration certificates for all instrument
gauges etc of Cascade package, Test certificates of all YES
instruments with cylinder, tubing’s, fittings of total
package
1.14 BOQ with weight of each component YES
1.15 Drawing of cylinder of specified parameters and
proposed to be used in offered cascades approved by YES
CCOE
1.16 Drawing of cascade frame YES
1.17 Storage cascade with frame assembly is shipped in YES
fully and assembled condition only to be mounted on
anchored bolts laid at site.
1.18 GA drawing of the cascade
YES
1.19 Warranty for a period of 12 months is provided from
the date of final site acceptance of CNG facilities by YES
the Company’s.
1.20 Make of bought out items
1.21 Detailed time schedule for supply indicating time
periods required for cylinder manufacturing, cascade
frame fabrication, shop testing, dispatch of material
from works at delivery site
2.0 Spares and Tools /Tackles
2.1 All necessary spare parts to sustain the operations
and maintenance of the storage cascades facilities
within the warranty period are supplied and stock at YES
the supplier workshop/ warehouse located in India for
immediate replacement of parts
2.2 Mandatory spares as specified in the “Check List for
Mandatory Spares”(Indicate separate price for each
item)
3.0 Inspection and Testing

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 S. Description Specified by Included Remarks
No Purchaser by
YES/NO Bidder
YES/NO
3.1 As specified on the Inspection and testing clauses YES
4.0 Vendor Data and drawings
4.1 All data & drawings as required per VDR format as YES
per clause 11.
5.0 Supervision during the Trial Run if required
at site of the CNG storage cascade system
5.1 Additional Items not specified by purchaser but YES
recommended by bidder for safe smooth and normal
operation. (Bidder shall indicate separate list of such
items in his proposal)
6.0 Technical Parameters to be confirmed by
vendor
6.1 Pressure range from 19 bar (g) -250 bar at 15 °C YES
6.2 Fill Pressure Kg/cm2g or [bar(g)] -200 YES
6.3 Operating Temperature range –[ -55°C to 70°C] YES
6.4 Design Code :IS 2825, IS 7285, IS 3224 or as per YES
Applicable standard Codes or approved by CCOE
6.5 Calibration traceability - To NIST as per ISO 5168 YES
6.6 Enclosure weather proof to - IP65,NENA4x YES
6.7 Process Temperature effect - ± 0.01% of nominal YES
flow
rate/degree C on zero
offset
6.8 All valves as per IS 3224or as Applicable standard YES
code or approved by CCOE
6.9 Safety relief devices as per IS: 5903 or Applicable YES
standard code or approved by CCOE

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