BHARAT GAS RESOURCES LIMITED (BGRL)

CITY GAS DISTRIBUTION PROJECT

TECHNICAL SPECIFICATION FOR

SUPPLY OF 450 SCMH ELECTRIC MOTOR DRIVEN CNG BOOSTER (HYDRAULIC)

COMPRESSOR PACKAGE
 TABLE OF CONTENTS

1.0 GENERAL .......................................................................................................................... 2

2.0 SCOPE ............................................................................................................................... 2

3.0 CODES AND STANDARDS: ................................................................................................ 6

4.0 SCOPE OF SUPPLY FOR EACH COMPRESSOR PACKAGE ................................................... 8

5.0 BATTERY LIMITS ............................................................................................................ 10

6.0 UTILITIES ....................................................................................................................... 10

7.0 GENERAL DESCRIPTION ................................................................................................ 11

8.0 SAFETY ........................................................................................................................... 12

9.0 BASIC DESIGN CRITERIA OF COMPRESSOR .................................................................. 15

10.0 INSTRUMENTATION & CONTROLS ................................................................................. 20

11.0 SKID AND ENCLOSURE ................................................................................................... 24

12.0 INSPECTION & TESTING ................................................................................................ 25

13.0 GUARANTEE, LOADING AND PENALTY CRITERIA .......................................................... 27

14.0 SPECIAL TOOLS AND TACKLES ....................................................................................... 29

15.0 DOCUMENTATION .......................................................................................................... 29

ANNEXURE – I : GUARANTEED PARAMETERS......................................................................... 32

ANNEXURE – II : COMPRESSOR DATA SHEET FOR 450 SM3/HR ........................................... 33
ANNEXURE - III - DATA SHEET FOR ELECTRIC MOTOR ............................................................ 40
ANNEXURE – IV: LIST OF MOTORS............................................................................................ 42
ANNEXURE – V: SPECIFICATIONS OF INSTRUMENTS ............................................................... 43
ANNEXURE – VI: VENDOR LIST ................................................................................................. 51
ANNEXURE – VII: VENDOR DATA REQUIRED ............................................................................ 59
ANNEXURE – VIII: DEVIATION SCHEDULE FOR CNG ON-LINE COMPRESSOR PACKAGE ......... 63
ANNEXURE – IX DELETED : ........................................................................................................ 64
ANNEXURE –X: EXPERIENCE PROFORMA RECORD ................................................................... 65
ANNEXURE – XI : PARAMETERS FOR SCADA ............................................................................ 69
ANNEXURE – XII : QUALITY ASSURANCE PLAN ........................................................................ 71
DATA SHEET: MEDIUM VOLTAGE SQUIRREL CAGE INDUCTION MOTOR ELECTRICAL DESIGN
DATA .......................................................................................................................................... 75
DATA SHEET: PRESSURE, VESSEL ............................................................................................. 78

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1.0 GENERAL

OWNER is responsible for distribution of Natural Gas for household/commercial sectors including setting up
CNG refuelling stations for vehicles etc.
2.0 SCOPE

2.1 The intent of this tender is to outline minimum requirement for Design, Engineering, Manufacturing,
Assembly, Inspection, Testing, FAT, painting, Packaging and forwarding, Insurance, customer clearances,
Supply, handling and unloading, Erection & Commissioning including Performance Acceptance Test at site
along with operation and comprehensive AMC during One year warranty period and subsequent nine (9)
year period including supply of all spares and consumable items for “ ELECTRIC MOTOR DRIVEN
BOOSTER COMPRESSORS PACKAGES ” as required for dispensing CNG to vehicles at various locations
in allotted GA as per this technical specification and applicable codes as referred.

2.2 The compressor packages shall be identical in all technical respects. Various parts of these specifications shall
be read in conjunction with each other and in case where the different parts of this specification differs the
more stringent requirement shall govern.

2.3 Any additional work / equipment or technical requirement not mentioned in the specification but required to
make the offered system complete in accordance with the specification and for safe and proper operation ,
shall be deemed to be included in the scope of work by the Bidder.

2.4 Booster Compressors have to be installed at the CNG outlets of OWNER and other Oil and Marketing
Company (OMC) retail Outlets located in allotted GA as per the instructions of Engineer in charge to increase
the pressure of natural gas for dispensing in vehicles.

2.5 Bidder shall also be responsible for supply, erection, commissioning and field trial run. Noise level test and
performance test of all packages at sites. The field trial run of the compressor will be for minimum of 4 hours
(can be in multiple runs) and the package should be kept under observation for 72 hours for stable operation
and no major breakdown in which satisfactory performance of the package together with all accessories
auxiliaries and controls shall be established for satisfactory performance for specified operating conditions. In
case of any detect, discrepancies under specified site conditions. Supplier shall first rectify the same and
repeat the field trial run.

2.6 It will be the endeavor of all the parties to get the performance acceptance test (PAT) at site conducted within
a period of 20 days from the start of commercial operation of a particular package. The bidder has to keep the
compressors operational round the clock in three shifts or as defined by EIC and all the expenditures including
spares and consumables, oil etc. to make the compressors operational shall have to be borne by the bidder.
The power required to run the compressors will be provided by OWNER/ OMC. The contractor shall maintain
the compressors in sound mechanical condition at all times. The contractor shall rectify the defects notified by
OWNER immediately and should submit all the history log sheets and spares availability status along with the
report in the format mutually agreed between OWNER and the bidder.

2.7 The bidder shall depute adequate numbers of qualified, experienced and competent persons and supervisors
for smooth maintenance of the compressors. The maintenance staffs have to be available round the clock daily
throughout the year.

2.8 Periodic inspections of Safety Valves, Transmitters, Pressure vessel gauge and any other equipment as per
statutory norms of State Factory rules. SMPV and Gas Cylinder Rules shall have to be carried out by the
bidder at his own cost during the period of maintenance by the bidder. The inspections have to be carried out
by competent persons as per advice of Engineer-in-Charge and certificates have to be submitted to OWNER.

2.9 The bidder has to maintain an office at site with telephone and fax facility and keep his services personnel
ready to attend problems any time of the day. Name and mobile phone number of in-charge of the services
team has to be provided to Engineer-in-Charge / his representatives.

2.10 The bidder shall allow weekly rest and restrict daily working hours of his workmen as per relevant Act/Law
and Rule made there under. However no work shall be left incomplete/ in dismantled condition on any
holiday/weekly rest. Technician provided shall have minimum qualification of ITI. The bidder in person or his
authorized representative shall be available on regular basis to interact with Engineer –in-charge.

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2.11 The work force deployed by the bidder for the maintenance services at the CNG installation in at site shall be
of sound relevant technical professional expertise which is otherwise also essential from the safety point of
view of the personnel of the contractor as well as for the installation.

2.12 All personnel of the bidder entering on work premises shall be properly and neatly dressed while working on
premises of the company including work sites.

2.13 Bidder shall maintain proper record of his working employee’s attendance and payment made to them.

2.14 The bidder’s representative/supervisor shall report on regular basis to the Shift-in-charge at OWNER control
rooms for day to day working.

2.15 All the safety rules and regulations prevailing and applicable from time to time at the installations as directed
by OWNER will be strictly adhered to by the Contractor and his workforce.

2.16 The bidder shall plan schedule maintenance in consultation and prior permission of Engineer in-charge or his
representatives.

2.17 The bidder shall be responsible for the discipline and good behaviour of all his personnel deployed to carry
out the services. In case of any complaint received against any of his employee, he shall arrange to replace
such persons within 24 hrs of notice issued by the Engineer-in-charge. The decision of the Engineer-in-charge
in this matter shall be final and binding on the Contractor.

2.18 The bidder shall arrange to provide identity cards to his workforce at his own cost. The contractor’s personnel
shall be required to carry their respective identity cards while on duty and produce on demand. Without valid
identity cards, they will not be allowed to enter into the CNG station.

2.19 Engineer-in-charge shall have authority to issue instructions to the Contractor from time to time during the
contract period necessary for the purpose of proper and safe execution of the contract and the Contractor shall
carry out and bound by the same. In case of non-fulfilment of any obligations under the contract and /or non-
execution of any instruction issued by Engineer-in-charge as per terms and conditions of the contract,
Engineer-in-charge shall have power to withhold payment for an amount equivalent to the amount to be spent
for execution the obligations/instructions issued by him. The decision of engineer-in-charge in this regard will
be final and binding to the Contractor.

2.20 Receipt at site, storage in warehouse as per manufacturer’s recommendation and safety and security from theft
and breakage/damage during transportation, handling including security guard at site.

2.21 Submission of drawings & documents.

2.22 Erection, O&M and all others relevant manuals for compressor & its accessories, priority panel, electrical
motor & all instrumentation.

2.23 GENERAL

2.23.1 The contractor must follow the OPERATION & MAINTENANCE REQUIREMENT as stated below but not
limited to and ensure to provide trouble free services as defined in the bid documents.

A. ACCOMMODATION/ TRANSPORTATION/ MEDICAL

The contractor shall make his own arrangement for the accommodation of his personnel at respective
locations and subsequent transportation arrangement for them from their place of residence to work
place or any other place as required and owner shall have no obligation in this respect.
B. DISCIPLINE
The contractor shall be responsible for the discipline and good behaviour of all his personnel deployed
in the services contracted out and should any complaint be received against any of his employee, he
shall arrange to replace such persons within 24 hours of notice issued by the Engineer-in-Charge. The
decision of the Engineer –in-Charge in this matter shall be final and binding on the contractor.
C. GATEPASS / IDENTITY CARD
The contract shall arrange to supply / renew identity card to his workforce at his own cost, if so
required by OWNER for security or for any other reasons. Those contractor’s personnel shall be
required to carry their respective identity cards while on duty and produce on demand.
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 D. RIGHT TO GET SERVICES CARRIED OUT THROUGH OTHER AGENCIES
Nothing contained herein shall restrict OWNER from accepting similar service from other agencies, at
its discretion and at the risk and cost of the contractor, if the contractor fails to provide the said services
any time.
The maintenance services shall be provided in terms of shift pattern or the round the clock basis as
mentioned in the bid document.
E. OWNER will notify the start date for operation and Comprehensive Maintenance services
- After the successful completion of test run & commissioning, system taking over certificate shall be
issued by the owner.
2.24 Operation and Maintenance of Compressor Packages
i. The contractor shall deploy adequate number of technicians / supervisors / Engineers / helpers as well as
tools, spares, consumables and equipment for smooth and proper maintenance of the Compressor
supplied in terms of the contract. In case required to meet operational requirements, the contractor shall
augment the same as per direction of Engineer–in-Charge. Contractor to submit a detailed organogram
with key person details before starting maintenance of the compressor package.
ii. The contractor is required to carry out all services as mentioned in the Scope of Services and Schedule of
Rates on all the 365 days including Sunday and all Holiday & around the clock.
iii. The contractor shall allow weekly rest and daily working hours to his workmen as per the relevant
Act/Law and Rule made there under. However, no work shall be left incomplete/unattended on any
holiday/weekly rest. Technician/operators provided shall have minimum qualification of ITI. Contract
in person or his authorized representative shall provide the services on daily basis to interact with
Engineer-in-charge and deployed workman.
iv. The work force deployed by the contractor for maintenance service of Compressors, shall be of sound
relevant technical professional expertise which is otherwise also essential from the safety point of view of
the personnel of the contractor as well as for the installation.
v. Contractor has to ensure the safety of man and machine all the times. Damages of equipment due to
negligence will be recovered as per the decision of Engineer-in-Charge, which will be final.
vi. Regarding work completion, the decision of the Engineer-in-Charge will be final and binding.
vii. The contractor shall make his own arrangements to provide all facilities like boarding and transport etc.
to his workmen.
viii. All personnel of the contractor entering on work premises shall be properly and neatly dressed and shall
wear uniform, badges while working on premises of the Owner including work sites.
ix. Contractor shall maintain proper record of his working employee’s attendance and payment made to
them.
x. The contractor’s representative/supervisor shall report daily to the Shift-in-Charge for day to day
working.
xi. All the safety rules and regulations prevailing and applicable from time to time at the installations as
directed by OWNER will be strictly adhered to by the contractor.
xii. It will be the responsibility of the contractor to pay as per the minimum wages of the appropriate
government applicable under the Minimum Wage Act 1948.
xiii. The services shall be provided in terms of shift pattern on the round the clock basis. The contractor is
responsible to provide effective and efficient services in all shifts and assure that there is no disruption in
the services for want of any resources.
xiv. The contractor shall establish a central control room to operate 24 hours, seven days a week where
complaint regarding non-performance of the Compressors in terms of the contract can be lodged. Further,
the contractor shall deploy adequate number of technicians/ supervisors / engineers at various site offices
in consultation with Engineer-in-Charge to provide trouble free maintenance of the Compressors.
xv. All arrangements for communication from control room to the contract person working on job under the
services shall be the responsibility of the contractor, viz. cell phone / walky-talky.
xvi. The successful bidder shall indemnify the Owner from any claim of the contract labour.

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xvii. The successful bidder shall comply to all the rules regarding PF,ESI etc. as stated in the tender
document.
xviii. All the jobs mentioned under scope of services shall be carried out as per sound engineering practices,
work procedure documentation, recommendation of the manufacturer and as per the guidelines/direction
of engineer-in-charge of authorized representative.
xix. Summary of breakdown hour’s station wise with analysis shall be submitted to CNG control room on a
fortnightly basis both in hard and soft form as per OWNER format.
xx. The contractor has to submit the following documents on monthly basis along with the bill:
o Preventative maintenance compliance report for that month along with the detailed service report.
o Details of the compressor breakdown, summary of break down hours for that month and the
cumulative break down hours along with breakdown response time.
o Compressor parameter log book for the month.
o Certificate to be given by the bidder stating that they have complied with all the labour regulations
and are following the minimum wages act.
o All consumables, lubricating oil, coolant required for carrying out preventive / any type of
maintenance shall be in the scope of supplier during the warranty period. The warranty spares shall
be supplied by the vendor during the warranty period as per warranty clause.
o All tools, tackles and fixtures required for carrying out the above maintenance of the compressor
shall be in scope of the bidder. The scope will also include handling equipments like crane,
forklift, chain pulley block, etc required during the any maintenances activity.
o Any correspondence required to be made with the principal company or OEM or various offices
shall be made by the bidder or bidder’s agent. All arrangements like phone, fax, computer, Internet
etc required for above correspondences shall be arranged by the bidder at his own cost.
o The periodic maintenance required to be done as per OEM recommendation shall be taken up
promptly. The bidder shall provide the detailed preventative maintenance schedule along with
a) Estimated down time required for each type of maintenance schedule.
b) List of spares and their quantities required for each type of maintenance schedule per
compressor.
c) Type and number of man days required for each type of maintenance schedule per compressor.
xxi. The bidder shall plan such maintenances during non-peak hours and in consultancy with the Engineer In
Charge (EIC) of OWNER. Any maintenance that needs to be taken up shall be well planned in advance
with due approval of the EIC.
xxii. The bidder shall use only OEM’s certified spares during maintenances. All spares shall be kept in
sealed OEM stamped packages. The packages shall be opened in front of OWNER representative during
maintenance. In case, the schedule maintenance of the OEM manual recommends to check and replace
parts like valve spring, valve plates, piston rings etc. after certain time interval, same shall replaced or
used further only on approval from the OWNER’s representative. However any untoward consequences
for non-replacement of such parts shall be the responsibility of the bidder and spares, repair required to
put back the unit into operation will be to bidders account.
xxiii. All routine and periodic checks / inspections required to be done as per OEM recommendation shall be
done by the bidder. Instruments required for above inspection like Vernier calliper, micrometre screw
gauge, fill gauges, bore gauge etc shall be in scope of the bidder and these instruments shall be calibrated
every year.
xxiv. All parts replaced by the bidder during the above contract period shall be properly packed and handed
over to OWNER, on replacement.
xxv. The contractor shall submit a copy of the daily / weekly / fortnightly / monthly / bimonthly / quarterly
and yearly performance report to the EIC in both soft and hard form. All stationery including the printed
material such as compressor parameter log book, complaint log book, service report, break down
summary report etc. shall be in scope of the bidder.

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 xxvi. All the maintenance / inspection job carried out by the bidder shall be recorded in a service report and
the report of the same shall be jointly signed by OWNER representative and submitted immediately after
carrying out the maintenance. Service report format shall be approved by OWNER.
xxvii. The EIC will be final authority to take decision with regards to maintenance or replacement of parts or
any disagreement between the bidder and OWNER, during the execution of the contract.
xxviii. The bidder shall carryout calibration of gas detectors and flame detectors every six months or earlier as
per requirement or instruction of EIC of OWNER. Also yearly calibration of all instruments such as
pressure gauges, transmitters, switches, mass flow meters etc shall be in the scope of the bidder. In
addition to the above all safety relief valves shall also be tested and calibrated every year.
xxix. Calibration shall be done from government-approved laboratories and shall be carried out at least 15
days prior to the calibration due date.
xxx. The bidder shall keep 1 set of safety relief valves in spare for the purpose of calibration.
xxxi. The bidder shall carry out retesting of pressure vessels periodically i.e. every year or earlier as per Gas
Cylinder rules 2016 / Static & Mobile Pressure Vessels Rules.
3.0 CODES AND STANDARDS:

3.1 The design, construction, manufacture, supply, testing & other general requirements of the compressor
package equipment shall be strictly in accordance with the data sheets, applicable API codes, and shall
comply fully with relevant National / International standards, Indian Electricity Act, Indian Electricity rules,
regulations of Insurance Association of India and Factories Act while carrying out work as per this
specification.

3.2 Any modification suggested by statutory bodies either during drawing approval or during inspection, if any,
shall be carried out by the bidder without any additional cost and delivery implications.

i. The following National & International Codes & Standards of Latest editions shall be applicable.
 OISD 142:
 IS 5572
 OISD 179, NFPA-52: 2006, NFP-496, NFPA-68, NFPA-70 or equivalent
 NFPA – 37
 NFPA – 12- CO2 Flooding system
 IS: 325/ IEC or International standards. – Standards for electric Motor
 IS: 6382
 Applicable ANSI, ASTM, NEC, NEMA code
 API – 618/API 11 P
 EURO EAN NORM P.E.D., Italian NOR M D.P.R. 47/55
 EURO EAN NORM P.E.D , D.M. 24.5.02 - D.M. 2 8 .6.02
 D.M 2 4.11.84 parte prima - sez. II° , D.M . 24.5.02 - D.M. 28.6.02, DIN 2413, S AE J 514
 EURO EAN NOR MS, CEI N 60079- 0/CEI EN 60079-14/ CEI, EN 60204-1/ CEI EN 60439-1, ATEX
STAN DARD
 API – 661 : Specifications for Air cooled exchangers
 ASME Section – VIII Div. – 1/2 Design codes for pressure vessels.
 Gas Cylinder Rules 2016.
 Standard Specifications of Bureau of Indian Standards (BIS).
 Specifications/Recommendations of IEC.
 Indian Electricity Rules.
 Indian Explosives Act.
 Delhi Factory Rules, 1950
 TEMA – C - Water cooled heat exchangers
 ASME / ANSI – B-31.3 Code for Process Piping
 DIN 2413-This standard covers the design of steel bends and bent pipes of circular cross section used in
pressure pipelines.
 SAE J 514-Standard for CNG hydraulic tube fittings and O-ring
 CEI EN 60079-10-Classification of area for explosive gas atmosphere
 CEI EN 60079-14-Design, selection and installation of electrical systems for areas with potentially
explosive atmosphere.

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  CEI, EN 60204-1-Standard for safety of machinery — Electrical equipment of machine
 CEI EN 60439-1-Standard for safety of electrical equipment
 ATEX-Standard for describing electrical equipment and work space is allowed in an explosive
atmosphere.

3.3 Precedence

In case of any conflict among the various documents the following preferential order shall govern:
1. Data sheets/drawings
2. Technical Specification
3. International standards/codes as applicable
4. Indian Standards / codes as applicable
In case of any conflict among the various documents of this requisition the more stringent requirement shall
govern.
Compliance with these specifications shall not relieve the bidder of the responsibility of furnishing equipment and
accessories of proper design, material and workmanship to meet the specified operating conditions.
No deviations to the technical requirements and to the scope of supply specified in this enquiry document shall be
accepted and offers not in compliance to the same shall be rejected. In case a deviation is required due to inherent
design of the equipment offered, the bidder shall list all such deviations at one place giving reasons thereon.
3.4 Document /Data Required along with Bid

Bidder shall necessarily furnish the following along with the bid, without which the offer shall be considered
incomplete:

(1) Proven Track Record Formats, duly filled in along with general reference list shall be submitted for the
earlier supplied CNG compressor packages as per the BEC requirements.
(2) Checklist duly filled in with regards to scope of supply
(3) Completely filled in Data Sheets of compressor, motor
(4) Deviations if any to this Technical Specification

 Tentative Lay out/key plan/General Arrangement Drawing indicating size of skids, center distance
between skids and space required along with maintenance requirements,
 The Design of trenches for installation of interconnecting pipeline if any
(5) (a) Utilities requirements (b) Electrical Load summary
(6) Datasheets of compressor, motor, instrumentation & controls

3.5 Gas Composition

Typical Gas Composition Range

Normal Gas Composition Design Gas Composition
C1 82.43- 99.10 91.01
C2 7.27- 0.90 5.23
C3 3.47- 0.00 0.88
i-C4 0.65-0.00 0.08

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 n-C4 0.78-0.00 0.09
i-C5 0.17-0.00 0.03
n-C5 0.13-0.00 0.01
C6 0.10-0.00 0.05
C7 0.00-0.00 0.00
N2 0.06-0.00 0.22
CO2 4.93-0.00 2.4
H2O 0.01-0.00 0.00
TOTAL 100.00 100
Average Calorific Value
8950- 8150 8302.3
(Kcal/SCM)

NOTE: Compressor guaranteed performance shall be estimated for the design gas composition and
performance shall be reported for the two extreme gas compositions above.
Both average over life cycle shaft power consumption & gas loss certificate from compressor block
manufacturer to be provided.
3.6 Climate

 Ambient temperature min/max0C : 2 0C / 47.5 0C

 Design wet bulb temp (WBT), 0C : 27 0C
 Design relative humidity % : 90
 Altitude above MSL, M : 650
 Wind velocities km/hr (max) : 160
 Air Cooler Design 0C : 52°C DBT, 27°C WBT & 90% RH

4.0 SCOPE OF SUPPLY FOR EACH COMPRESSOR PACKAGE

The scope of Supply to be provided by the bidder shall be inclusive of but not limited to:
4.1 Design, Engineering, Manufacturing, Assembly, Inspection, Testing, FAT, surface preparation and Painting,
Packaging and forwarding, Insurance, customer clearances, Supply, handling and unloading, Erection &
Commissioning including Performance Acceptance Test at site along with operation and comprehensive AMC
including supply of all spares and consumable items along with associated electrical, instrumentation etc. as
per bid document.
4.2 Hydraulic booster with lube oil system and cooling system as required.
4.3 Flame proof Electrical Electric motor as compressor driver.
4.4 2 nos. mass flow meters to measure the Natural Gas consumption at packages inlet and package discharge
(both Coriolis type) with online test arrangement. Both mass flow meters should be of same make and should
have local display and should be weather proof. The flowmeters should be enabled with MODBUS/RS 485
communications.
4.5 PLC based control panel with HMI.
4.6 Instrumentation and control system as specified as per tender documents.
4.7 Electric equipment / Instruments being required in the Compressor package.
4.8 Common structural steel skid for the compressor- Motor combination and for all auxiliary systems
4.9 Air-cooled heat exchanger for inter stage and discharge gas.
4.10 Priority Panel (3 bank) at Package Discharge as per priority fill system.

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4.11 All interconnecting oil, gas, water, air piping within the compressor package.
4.12 Impulse and pneumatic piping/Tubing for all valves, fittings as specified & required for mounting the
instruments.
4.13 Block and bleed valves to be provided for Pressure gauges and pressure Transmitters.
4.14 Separate junction boxes for different type of signals like intrinsically safe signals, alarm, shutdowns,
thermocouples, RTDs etc. for interfacing to local panel as per requirement.
4.15 Main incoming cable from owners Power Distribution Board (PDB) to main control panel of the compressor
through heavy duty GI conduit or trenches, Earthing Cable from owner’s electronic earth pit (EE) for
electronic circuit in control panel, cable from owner’s main earthing grid to control panel for body earth and
all inter connecting cables including complete erection accessories like double compression cable gland, cable
tags, lugs etc. as required.
4.16 NRV as required for smooth operation.
4.17 Structural supports within the compressor package for all piping, electrical, instruments etc.
4.18 One no. relief valve at each stage discharge, first (1st) stage suction.
4.19 Y- type strainers, valves, sight flow indicators, check valves, auto & manual drain traps etc. as required for
various auxiliary systems i.e. frame lube oil, cylinder lubrication system, cooling water systems etc.
4.20 Coupling/V-belts/pulleys.
4.21 Single acoustic enclosure for Compressor package, with one number L.E.L detectors and one UV detectors in
the enclosure.
4.22 Common automatic CO2 extinguishing system consisting of two cylinders, piping, valves and control systems
as per details given in this specification.
4.23 Inlet and outlet manual and automatic isolating valves for maintenance & emergency.
4.24 The provision for overhead mounting of cascade 3000 Water Liter capacity with approximate weight of 7
tons) should be there & same should be of enough strength having working space and with ladder
arrangement. However, cascade supply and its mounting on the structure shall be in scope of purchaser.
Structure Stability compliance Certificate of the unit where cascade will be mounted to be submitted during
detail engineering.
4.25 LCV filling hose with Breakaway & Quick Release Coupling (QRC) (01 set per compressor package) shall be
in bidder’s scope of supply. LCV filling Hose shall be of minimum 4.5 mtrs. Long and shall have ½ “Parker
make Quick Release Coupling (QRC) connected to it to be provided by the bidder. Long refilling Hose (3.5
Mtr. before Break Away + 1 Mtr. after Break Away) should be provided with protective guard. Hose crimp to
be provided with protective sleeve. Hose crimp should be of SS and have protection Sleeve. Filling post to be
supplied with 4” Pressure Gauge for pressure monitoring of CNG. Supply & Installation of Filling Post (150
MM wide & 3mtr in height) and Hose Assembly with Breakaway / QRC shall be in bidder’s scope. Cost of
these items shall be included in supply cost of the booster compressor and no separate payment shall be given
for these items. Hose will be installed with ¾” OD Three Way Ball Valve. Bidder to select end connection of
Hose accordingly.
4.26 Complete Erection, Testing & Commissioning of compressor packages.
4.27 Field Performance test at site
4.28 Supply of all essential spares as specified, erection & commissioning spares.
4.29 One set of spare parts catalogue along with the priced bid (Part-II), as built drawings and Operation &
Maintenance catalogue with each compressor package.
4.30 An oil drain pot outside of the package shall be provided to collect all drains from packing, distance pieces,
processes etc.
4.31 Closed circuit cooling water system (console type)/Air cooled as required including heat exchangers, coolant
circulation system, fan operated radiator, etc. for inter stage and final cooling of compressed gas, lubrication
oil and hydraulic oil.
4.32 Priority refueling system outside of the package or as per vendors design.
4.33 Drive belt, if used shall be anti-static fire retardant type.
4.34 Two stage filtration at discharge so as to limit oil carryover is to be provided.
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4.35 Three no. Emergency stop button (push type) along with one hooter in office/customer interface room.
4.36 Wires mesh type guard for heat exchanger fan.
4.37 Erection, O&M and all others relevant manuals for compressor & its accessories, priority panel, electrical
motor & all field instruments.
4.38 Annual Operation and comprehensive maintenance services for a period of 1 year during the warranty period,
including supply of all spares and consumable items.
4.39 Annual Operation and comprehensive Maintenance services for a period of 9 (nine) years after the warranty
period including supply of all spares and consumable items.
4.40 Exclusions

The following are excluded from the scope of the bidder:

 All civil works and foundation design, however the bidder shall furnish all the relevant data for design
of any pedestal/foundation. Grouting of equipment including supply of material is a part of erection
and is in scope of Supplier.
 CNG Storage cascade.
 All piping beyond battery limits except from air compressor & air piping for air and piping from CO2
cylinders up to the enclosure.
 Three banks Cascades.
 CNG Dispensers and Interconnected SS tubes & fittings.
5.0 BATTERY LIMITS

5.1 All customer interface connections (i.e. Gas inlet & gas outlet) shall be brought out to the package edge. Gas
inlet shall be terminated in nozzles with isolation valves having flange connections and gas outlet (priority
panel outlet connection) shall be terminated through high pressure ¾” full flow ball valves with 3/4” end
connectors.
5.2 As and where specified on the data sheets all vents (i.e. Relief valve, distance piece, packing and starting air)
shall be manifolded and terminated at skid edge outside the enclosure and vented to safe height 3Mtrs at
package roof. Silencer has to be provided in the starting air vent line.
5.3 All drains from different process equipment’s, distance piece and packing shall be manifolded and terminated
as single point for customer interface duly flanged with isolation valve. Drains should be through a common
header and discharge to be allowed in a pit to avoid spillage around compressor package.
5.4 Electronics/Instrument earth pit shall be constructed by Owner. Owner shall give instrument earth in UPS DB
in separate core of cable. Where ever the UPS supply is given, instrument earthing shall be given by third
core. For body earthing of compressor and its equipment’s; Earthing shall be given from earth grid. Earth gird
shall be in scope of owner. Owner’s earthing main ring shall be made available at compressor foundation for
equipment earthing. Electrical earthing for motor shall be done through Cable and the body earthing to be
done through GI strip of 25 x 3 inside the compressor package shall be in the bidder’s scope.

6.0 UTILITIES

6.1 Bidder to provide Instrument air with an electric motor driven air compressor with a suitably sized receiver &
Refrigerant type air drier system. The instrumentation air shall also be used for CNG Dispensers. Hence the
system to be designed considering the same.
6.2 Air Compressor with discharge pressure of 7 kg/cm2 suitable for 1.5 KW electric motor rating with dryer
shall be supplied by the bidder.
6.3 Compressor to be supplied should be preferably of Emtex/IR/KPCL/Elgi/CP make; air receiver of min. 100
water litre capacities shall be provided.
6.4 Air dryer suitable for automatic operation shall also be supplied along with all accessories.
6.5 Air compressor, drier and air receiver for instrument air, shall be kept off the package in safe area or owner’s
building.
6.6 Piping, electrical & instrumentations cabling shall be in bidder’s scope. Drain should be through a common
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 header and discharge to be allowed in pot outside the package (capacity not more than 2.5 litres) to avoid
spillage around the compressor package.
6.7 Manual drains and automatic moisture trap shall be provided in the system.
6.8 Air receiver shall be provided as provided with SRV, Pressure switch and pressure gauge shall have isolation
valve. Air dryer shall be with bypass pass arrangement.
6.9 Tapping from air receiver and dryer shall be provided as follows;
For dispenser: one½ “tapping with isolation valve from air receiver
For booster compressor: one ½ “tapping with isolation valve from air receivers.
6.10 Cooling water is not available as utility and the package shall be provided with self-sufficient cooling water
system for compressor as required, with makeup tank. However cooling water for makeup tank is available.
6.11 All electrical and instrumentation terminals shall be as specified.
6.12 Electric Power shall be made by Purchaser.
6.13 Purchaser shall provide 415 V, 3Ph, 50Hz, 4 wire electric power for running the compressor and illumination
in the electrical room. Supplier shall indicate power/ Feeder (KW/Amp) requirement in the offer, if different.
All cabling (supply & laying) from electrical room to booster compressor shall be in bidder’s scope. Bidder
shall indicate power /Feeder (KW/Amp) requirement in the offer and shall supply power KWH meter for
power consumption of the complete package including all accessories to be installed in the control panel.
KWH reading shall be available at HMI.
6.14 Purchaser shall provide UPS (230+1%V, 50+1%Hz) for control supply requirement at single point (feeder in
UPS ACDB) in the electrical room.
6.15 All cabling (supply & laying) from electrical room to booster compressor shall be in bidder’s scope. Bidder
shall indicate power Feeder (KW/Amp) requirement in the offer. Surge protection devices of
Schneider/MTL/Phoenix make shall be provided in the control panel.

7.0 GENERAL DESCRIPTION

A. GENERAL DATA

1.1 Compressor type

1.1.1 Oil lubricated
1.2 Type of cooling Gas cooling and cylinder cooling should be by air.
1.3 No of compression stages 02
Cylinders Opposed design with lined cylinder/ trunk piston
1.4
Design.
1.5 Maximum intake temperature 350C
1.6 Compressor package BKW at To be indicated in KW Detailed break up to be given as
Specified flow including all losses per Annexure –I
such as mechanical, leakage,
transmission & power absorbed by
compressor driven and other electric
driven auxiliaries.
Maximum motor power To be indicated with 10 % margin over BKW as per
1.7
Annexure –I
V- belts (antistatic type) / Direct coupled. If Belt Driven,
idler pulley for tensioning of Belts is required. Direct
1.8 Drive mode
drive (from prime mover to compressor) is preferred over
belt driven. Power Transmission should be thro’ flexible
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 coupling.

B. COMPRESSOR PERFORMANCE DATA

2.1 Gas pressure at compressor inlet Refer below Section 2.5

2.2 Compressor Discharge Pressure 250 Kg/Cm2 g at 52 deg. C (Max)

Compressor Discharge temperature 52 ºC (After
cooler) with ambient air temperature of 47.5ºC
and gas inlet temperature of 35ºC (max.).
2.3 Compressor speed To be indicated by bidder.
2.4 Ambient Conditions
2.4.1 Ambient temperature 2 0C to 47 ºC.
2.4.2 Maximum relative humidity 90 %
2.5 Required guaranteed capacities of electric motor driven compressor packages at rated suction
pressure and discharge pressure as mentioned below:

Rated Suction pressure at Rated Discharge pressure in Guaranteed capacity at rated

which guaranteed flow is Kg/Cm2 g and at 52 deg C suction and discharge
required, and at 35 deg. C (MAX.) pressure in Sm3/hr (SCMH)
(MAX), in Kg/Cm2 g.
30 to 200 250 450

Hereinafter the rated suction pressure, where guaranteed flow is required, will be referred as Rated Suction
Pressure range from 30 to 200 Kg/Cm2g at varying on continuous compressors. Suction pressures will be
measured at inlet flange of the compressor package. Bidder has to ensure that compressors are designed such
that the desired flow is achieved (without any negative tolerance) at Rated Suction Pressure.
Note:
a) No advantage shall be given in case bidder offers compressor with flows higher than as detailed above for
various types.
b) Bidders offer shall be based on firm and final compressor model on which basis the offer shall be
evaluated and no alternate compressor model or change of model, after submission of bid shall be
entertained / considered. This is very important and all bidders shall take full cognizance of this matter
before submitting the bid.
c) Bidder to indicate the capacity and absorbed power of the offered compressors at various suction
conditions starting from 30 to 200 Kg/Cm2g (Temperature 40 deg C max.) and 255 Kg/Cm2g and 52 deg.
C (max) discharge condition.
Performance curves and tables i.e. Flow versus suction pressure and temperature and power curves i.e.
absorbed power versus suction pressure and temperature at specified discharge conditions shall be
furnished. In addition to above, flow capacity and absorbed power values for suction conditions from 30
to 200 Kg/Cm2g in steps of 0.5 Kg/Cm2 shall also be given in tabular form. The graph shall be plotted at
various suction pressures ranging from 30 to 200 Kg/Cm2g and at various suction temperatures ranging
from 20o to 40o C. Similarly the graphs shall be plotted at various discharge pressures ranging from 220
Kg/Cm2g to 250 Kg/Cm2g, however at 520 C (max) discharge conditions.
d) Bidder to note that the compressor package required shall be suitable for operating at a suction pressure
from 30 Kg/Cm2g to 200 Kg/Cm2g at 40 deg. C.
Bidder to note that negative tolerance on the guaranteed capacity will not be acceptable. Also no
advantage shall be given for positive tolerance of the capacity.
8.0 SAFETY

a) All controls shall operate in a fail-safe mode i.e. failure of any control shall not lead to running of
equipment in unsafe mode. Fail safe control shall be available through hardware for all trips & also in
software. The Compressor Package shall trip if any of the enclosure is opened while the machine is
running.
b) The hazardous area classification Class-I, Division I, Group D as per NEC or Zone I, Group II A/ II B as
per IS/ IEC. Certificate from recognized agency to the effect that equipment supplied and/or installed

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 conform to above area classification. All Devices shall meet the requirement for the specified area
classification in which they are installed, including instrumentation leads.
c) Bidder needs to submit either the copy of valid type approval for compressor packages from PESO before
completion of techno-commercial evaluation.
d) All exposed rotating parts shall be provided with adequate guards of non-sparking type.
e) Driver belt if used shall be of anti-static and fire resistant type.
f) Piping shall be arranged in a manner so as to provide clear headroom and accessibility within the
package. Adequate clearances shall be provided for all the engineered components
g) Each package ENCLOSURE shall have one no. (1) LEL detectors (IR Type) and one no. (1) Ultra Violet
(UV) fire detectors to cover the enclosure effectively as already spelt in the scope of supply.
h) All material used in the package shall be flame retardant.
i) Relief valves shall be provided at suction and discharge and each inter stages of compressor with setting
as per cl.7.20.4 of API-618 with R.V. venting as per cl. 7.20.4 of API-618. All vented to common relief
valve header.
j) Provide all the required warning notices, barriers, safety boards, padlocks etc, for safe commissioning of
the equipment’s.
8.1 Carbon Dioxide (CO2) Flooding System

a) CO2 flooding system should be installed for the protection of CNG compressor by automatic actuation
system. The package should be protected by automatic operated CO2 flooding system designed as per
NFPA-12.
 Gas Detection by installation of hydrocarbon gas detector (IR type) with self-check function and
transmitter with adjustable alarm levels (0-100% of flammability range) with preset of 10%, 20% and
50%. Package should have at least one no gas detector.
 Installation of flame detector (UV-IR type) with self-check function and transmitter, alarm &
shutdown on detection of flame shall be provided. Package should have at least one no flame detector.
Self-check function to generate fault alarm and trip alarm in case of flame detection Indication lamp
shall be provided for fault and trip signal in LCP.
 CO2 flooding system will consist of Min 2 nos. brand new CO2 cylinders of 45 Kg capacity. However
actual size of the cylinder shall be as per compressor enclosure size and necessary calculation shall be
submitted and approval shall be taken before finalization / supply. One cylinder will act as main &
other as stand by, which shall have identical arrangement and connected to the system.
 The cylinders should be placed in a shed raised above ground level to protect from weather and direct
sunrays as per Gas Cylinder Rules, 2016.
 Cylinders shall be fitted with automatic actuated Valves, Solenoid valves for automatic actuation No
extra utility as air, and inert Gas shall be made available by OWNER /used by the supplier to operate
the system other than the UPS.
Cylinder should be ISI marked as per IS: 7285 and CCOE approved.
 Control philosophy shall be such that in case detection of fire by fire detector cylinder shall discharge
CO2 automatically.
 One pressure gauge to be located at gauge panel to detect the pressure in Cylinder shall be provided.
b) The System shall be designed to operate on 24 V DC supply.
c) FRLS (Fire resistant low smoke) cables shall be used for the wiring of the system.
d) Interlock of CO2 Flooding system with compressor as per following sequence:
 Compressor shall trip on detection of gas at preset level and close the inlet & Outlet valve.
 Compressor shall trip on detection of flame at preset level and automatic discharge of CO2 gas shall
take place from the main cylinder simultaneously. Compressor shall not start if the CO2 Flooding
System is faulty, not working, SWITCHED OFF etc.

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  Compressor shall not start if the CO2 flooding system is faulty or (Pressure is low), not working,
SWITCHED OFF etc. The compressor shall be able to start only when the CO2 Flooding System is in
healthy working condition.
 Maintenance Override Switch shall be provided to keep the system off during maintenance.
 Selector switch shall be provided to put Main/Stand by Cylinder in line at the turn of a switch as per
requirement.
e) Alarm panel for CO2 Flooding System shall be integral with the main compressor panel. Necessary
displays as system ON, OFF, FAULT, RESET, Gas/ Flame indication, Remote actuation of solenoid
valve, distinguished hooter etc., shall be provided for CO2 flooding system.
f) CO2 Cylinders shall be provided outside the package at a safe place, minimum 4.5 meters away (aerial
distance), where it is not exposed to fire in case of fire in the compressor. Facility shall be made to operate
the system both manually and also from remote with the help of a switch/ call point and with help of pull
down lever on cylinders.
g) Suitable online weight (CO2) loss monitoring/ indication device to be provided to ascertain the health of
the CO2 flooding system.
h) All installation shall be compatible for hazardous area Class 1, Division 1, Group-D for Methane Gas.
i) One Blinking aviation lamp shall be provided at the top of compressor canopy suitable for hazardous area
for fire indication.
j) The system designed by the supplier shall be duly approved by Owner/ Owner’s representative.
k) Technical specifications, Operation and Maintenance Manual, CCOE Certificate, Approval/
Manufacturing certificates for cylinders and cylinder valves, gas detectors, flame detectors, solenoid
valves etc. shall be furnished by the supplier along with system.
l) Software and hardware, calibration procedure shall be provided by the supplier along with the supply
sufficient enough to handle the system independently.
m) Necessary tools (1 set) shall be provided with the system.
n) System shall be offered for testing to OWNER by the supplier after commissioning at site by creating
actual Gas leak and Gas fire situations and actual discharge of CO2 Gas from the Cylinders. This shall
form a part of performance test and thereby acceptance of the package. The cylinders have to be refilled
by the vendor at no extra cost to OWNER after performance test. If the system fails during testing,
subsequent testing and refilling would be at vendor’s cost.
o) Warning and Operating instructions to be displayed at equipment as per the statutory/ safety regulations.
p) Piping of CO2 flooding system shall be seamless high pressure pipe of Schedule 40 of 50 mm dia of
appropriate length with a minimum safe distance of 4 Meter from CNG Compressor, The fittings like
elbows, Tees, Union, sockets should be of same schedule and capacity for installation in a high pressure
system as per NFPA-12.
q) Flameproof online weighing system, complete frame with shed and all accessories should be of good
quality, weighing scale should be of reputed make.
r) Specifications:
Non Return Valve for CO2 High Pressure Hose:
As per BIS specifications
Operating Media: CO2
Body Material: Brass, BIS: 319
Ball: SS 316
Pin: SS 316
Seal: Teflon (PTFE- Polytetrafluoroethylene)
Working Pr.: 60Bars
Test Pressure: 90 Bars for 1 min
Weight: 70gm
Outlet Size: ¾ BSP (British Standard Pipe Parallel) at manifold end
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 Inlet Size: ½” BSP (British Standard Pipe Parallel) at CO2 Discharge Hose end
Temp. Range: -29° C to 66° C
Hose Adopter:
As per BIS specifications
Operating Media: CO2
Body Material: Mainly Brass
Test Pressure: 250 Bar
Max. Working Load: 150 Bar
Temp. Range: -29° C to 66° C
Discharge Nozzle:
As per BIS specifications
Operating Media: CO2
Body Material: Leaded Tin Bronze as per BIS: 318:1981
Design Nozzle Pr.: Not less than 20.6 kgf/cm2 at 27° C
Test Pressure: 140 kgf/cm2
Marking for Code No. (on the basis of equivalent single orifice dia.): As per BIS: 6382:1982
Temp. Range: -29° C to 66° C
High Pressure Hoses:
As per BIS 7285:1974
Operating Media: CO2
Hose Type: Double wire breaded (perforated) rubber covered
Min. Bursting Pr.: 420 kgf/ cm2 at 54° C
Length: 40 cm
Cross-section: ½”
End Connection: ½” BSP (F) xW21.614 TPI
End Fittings: Brass
Temp. Range: -29° C to 66° C
8.2 Following warning and caution signage shall be marked on the housing/package:

“No Smoking”
Caution notice “This Machine may automatically start at any time”.
“Flammable Gas”
9.0 BASIC DESIGN CRITERIA OF COMPRESSOR

9.1 Following specification is intended to give the bidder the technical and operating conditions the compressor
must fulfil. Compressor shall be hydraulic booster type suitable for variable suction pressure.

9.2 The bidder shall meet all applicable statutory codes, national law and local regulation for safety and
environment protection.

9.3 The design shall conform to API 618 or other relevant reputed international standards but approved by CCOE
(bidders to indicate).

9.4 Offered package shall be complete with compressor, electric motor, hydraulic pump and piping, cooling
system, suction and discharge filters, controls panel safety and control devices and other accessories required
for automatic and safe operation the system.

9.5 The supply shall include all interconnecting piping/tubing/cables.

9.6 Cooling system shall be of closed circuit type. Ultimate cooling shall be by air.

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9.7 The compressor package control system shall be designed for unattended safe operation in automatic mode and
shall unload, start, load, stop safely.

9.8 The compressor shall start in auto in case high bank pressure in dispenser falls below 200 kg/cm2 and stop
once the pressure in all three banks reaches to 250 kg/cm2.

9.9 Compressor shall be suitable for continuously variable suction pressure from 200 kg/cm2g to 30 kg/cm2g,
supplied through LCV mounted CNG storage cascade.

9.10 Compressor should also stops when suction pressure falls below 30kg/cm2g.

9.11 Compressor shall be suitable for discharge pressure from 250 kg/cm2 to 220 kg/cm2, corresponding to suction
of 200 kg/cm2g to 30 kg/cm2g.

9.12 Compressor shall be designed to ensure flow capacity as indicated in data sheet

9.13 Due to space constraint, we will be installing the stationary cascade of 7.0 tons (7000 kgs) on the top of the
canopy of compressor. the bidder will therefore design the canopy to take the load of a stationary cascade of
7.0 tons. The bidder shall also provide 2 nos. monkey ladders for safe climbing on the top of the canopy along
with hand railing on the top for ease maintenance and operation. Provision should be made such that, the
cascade can be placed anywhere above the canopy. the bidder shall ensure that adequate space ( minimum 2
feet width) walk way in front side of cascades(i.e valve mounting side) is available for carrying out routine
checking / maintenance.

9.14 Priority Fill System:

9.15 Vendor shall provide PLC Controlled Priority fill system with compressor top-up facility inclusive of
regulating valves by pass valve & liquid filled pressure gauges all mounted in a stainless steel structural.

The priority fill system is to be installed to ensure that vehicle filling takes priority over cascade filling and
direct CNG TO THREE STORAGE BANKS IN CORRECT SEQUENCE.

The compressor shall shut down once all three-cascade storage banks are filled to 250 bar g.

Compressor shall start on pressing of manual start push button & automatically when the cascade storage high
bank pressure of compressor falls to 200 barg and shutdown automatically when all 3 stages of stationery
cascade are filled to a pressure of 250barg

Full bore ball valves shall be provided so that compressor can take suction either from LCV cascade or
stationary cascade.

All fittings and tubes used in priority system shall be of stainless steel of suitable pressure rating.

Tubing and valves from LCV cascade and stationary cascade to compressor shall be ¾” SS 316 L OD and
other tubing and valves shall be 1\2” size.

End connection s shall be 3\4” size pipe OD.

Priority panel shall be of 3 Bank priority panel along with emergency actuators.

9.16 CASE – I : Valves positioned to take suction from LCV cascade.

a) If the LCV cascade pressure is more than 200 kg/cm2, the gas dispensing should take place
directly from LCV to dispenser bypassing booster compressor.

b) Compressor shall start on pressing of manual push button or auto start when the LCV Cascade
and Stationary cascade at all banks pressure falls below 200 kg/cm2. The priority of filling s hall
be as follows;

- First priority: Priority panel shall first fill the vehicle through dispenser

- Second priority: If no vehicle is to be fuelled, priority panel shall fill the stationary cascade.
The compressor shall shutdown automatically when either all stages of stationary cascade
are filled to a pressure of 250 kg/cm2 or pressure in mobile cascade is less than 30 kg/cm 2.
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9.17 CASE – II : Valves positioned to take suction from Stationary cascade.

a. Dispensing shall be done through stationary cascade without compressor running, if stationary
cascade pressure is more than 200 kg/cm2.

b. Compressor shall start on pressing of manual/auto start push button if stationary cascade
pressure is less than 200 kg/c m2. Dispensing into the vehicle should take place as usual.
Compressor shall trip if either there is no vehicle for fuelling or pressure in stationary cascade is
less than 30 kg/cm2.

9.18 The compressor package control system shall be designed for unattended safe operation in automatic mode and
shall unload, start, load, stop safely. The compressor shall start in auto in case high bank storage pressure falls
below 200 barg and stop once the pressure in all three banks of storage cascade reaches 250 barg.

9.19 Noise level shall not exceed 75 dBA at 1m from the compressor package enclosure.

9.20 The compressor package control system shall be so designed that the first item to go into alarm condition shall
”Lock out” to indicate the cause of the trip though the cause of the trip may have disappeared. The lock out
condition shall be manually reset.

9.21 An automatic restart shall be provided on restoration of power with a 10-second delay after temporary
interruption. Existing alarm condition shall remain indicated.

9.22 Prime mover (Electric Motor)

The motor shall be flame proof/ explosion proof and confirm to IS: 2148 & IEC 60079-1 suitable for zone 1
group II area as per IS/IEC. The Motor shall be of standard frame size as per IS/IEC and rated for continuous
duty with high efficiency and shall be designed for star-delta starting. The Motor shall be provided with class
‘F’ insulation, however, temperature rise shall be limited to the temperature specified for class ’B’ insulation
as per IS and shall be suitable for voltage variation of 415V+ 10%. The bidder shall indicate the guaranteed
total power requirement in KW. The motor rating shall be 110% of the greatest BKW required by the
compressor.
9.23 Motor Specification

Electric Motor
a) Type of drive Totally Enclose Fan Cooled (TEFC) high efficiency as per IEEMA standard-19-2000
b) Protection Flame proof & weather proof enclosure
c) Insulation Class F with class B temperature rise
d) Mounting Horizontal Foot Mounting
e) Specification standard By Bidder
f) Supply Voltage(assumed) 415+ 10% volt, 3 phases,50+ 5%Hz
g) Synchronous speed By bidder
h) Motor rating By Bidder
i) Motor Efficiency By Bidder
j) Power factor By Bidder
k) Speed of motor By Bidder
l) Nos. of hot starts of motor 4 per hours
m) Coupling Type By Bidder
n) Torque speed cure By Bidder
o) starting torque, speed, thermal withstand curve load, current speed curve, Efficiency power factor vs load
curve by Bidder
Motor Accessories

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 a) Compressor grooved flywheel (if any)
b) Motor grooved drive pulley (if any)
c) Drive VEE belts (if any)
d) Flexible coupling for direct drive
e) Drive guard
f) Adjustable motor slide rails for belts tensioning to be used (if any)
9.24 Cooling system

Each compressor package shall be complete with its own cooling system. The cooler shall be air-cooled heat
exchanger. The gas temperature after after-cooler shall not exceed 52 degree C.
Special attention to be given while designing the gas cooler considering the local conditions. Bidders shall
ensure that final delivered gas temperature is less than 520C. Cooler design shall be on the basis of 10% extra
load corresponding to maximum severe operating conditions based on thermal duty. Gas cooler shall be design
as per manufacturer standard.
For cooling of the heat exchanger a cooling fan to be provided.
Cooling system to be in a single enclosure. Bidder to submit cooling sizing calculation for review.
Direction of flow should be marked on the pipe line and nomenclature of all vessels (e.g. 1st stage discharge
dampener etc.) should be written on them. Cross head inspection windows if applicable should be transparent
for ease of inspection during running. Set values should be prominently marked on the gauges.
Packages design should be such that its vent should not go upward (package vent in vertical direction not
required) i.e opening of package vent should be in horizontal directional with duct arrangement.
9.25 Oil Filter

The ingress of oil into CNG adversely effects vehicle emission and storage system. Only lubricated cylinder
compressors are allowed and vendor shall supply oil separators after cooler at each stage with automatic and
manual drain. The maximum permissible oil content in CNG is 5 PPM.
Contractor to supply a proven, maintenance free oil removal system after after–cooler to remove oil from
compressed gas. The offered oil mist removal system shall restrict the oil to less than 5PPM in discharge of
compressor.
9.26 Gas recovery system

If required, the Contractor shall provide gas recovery system with gas recovery vessel. The gas recovery
vessel shall be provided with pressure relief valve and necessary instrumentation to avoid cold flaring of gas.
Gas recovery vessel shall be ASME/IBR code designed.
9.27 Piping & Appurtenances

The materials for gas piping shall be seamless carbon steel of ASTM A-106 Grade B. The piping / tubing at
the outlet of the compressor and of priority fill system shall be of seamless stainless steel of proper pressure
rating and specifications as under:
SS TUBING SPECIFICATIONS:
 Seamless SS Tubing
 Material of construction Stainless Steel 316L
 Tube hardness shall be less than 80 RB
 Sizes : Metric system (inch)
 Max Working Pressure : 350 barg
SS FITTINGS & VALVES SPECIFICATIONS:
 Material of construction Stainless Steel 316
 Sizes : Metric/SI

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  Standard : ASTM/ ASME/ DIM
 End connections : Single or Double ferrule Compression type / NPT
 Max Working Pressure : 350 barg
 PSV Vent Line to be extended above the package to safe height.
 Priority system should be designed so that the gas flow from mobile cascade to dispenser is possible even
with the Compressor shutdown & de-energized
 Dedicated Air compressor of adequate capacity
9.28 Electrical System

 All electrical equipment of compressor package shall be installed in accordance with NFPA 70, NEC for
Class 1, Division 1, Group D, and IS 5571 and shall have approval of a recognized certifying authority.
 OWNER shall provide 415+/- 10% volts, 3 phase and 50+/- 3% Hz electrical connection at CNG station
electrical panel only. Vendor shall distribute electrical power to all equipment and control system by
providing cables and suitable switch-gear distribution panel.
 The electrical power supply distribution panel, switch gear panel and starter shall be in flame proof
construction. Certificate from recognized agency to the effect that equipment supplied and or installed
conform to above area classification. All devices shall meet the requirement for the specified area
classification in which they are installed, including instrumentation leads.
 Heavy duty on-load phase changeover should be provided for H.T motor.
 Semiconductor fuses to be provided, where applicable.
 All illumination fittings should be single phase AC supply based and LED type only.
 All wire/ cable to be used in compressor and panel shall be of copper conductor and FRLS type through
proper cable tray conduit etc.
 Sufficient space to be provided for Motor JB for cable glanding work.
 Chain pulley to be provided in package for easy extraction of motor from package
 Multifunction meter to be provided for metering of package total energy and other parameters (viz; KVAH,
KWH, Voltage, current, PF, Frequency, MDI (KVA), MD (KWH).
 Multifunction meter also required for fan motor electrical parameters monitoring.
 Bidder to ensure that spares and service support of all switchgears, instruments, or meter etc. used in
package/ panel, shall be available in Indian market.
 The power factor (PF) of the whole electrical system should not be below 0.95. Motor feeder shall be
provided with energy meter, heavy duty switch, HRC link type with single phase presenter fuses,
contractors (AC-3 Duty), bi-metal relay switch fuse unit, voltmeter, push buttons, earth leakage relays,
indication lamps for start/stop/trip/ etc. Ammeters shall be provided for all motors above 3.7. KW rating.
Stop push buttons shall be lockable and have stay put except in case of critical devices such as lube oil
pumps etc.
9.29 Earthing System

The design & installation of earthing system shall be as per IS 3043 or equivalent international specification.
One or more no of earth plates with provision of inter connection to main earth grid shall be provided. All
hardware used for earthing system shall be hot dip galvanized or zinc passivated.
All cables shall be terminated at equipment by means of double compression type compression glands and
shall be flame proof cable glands if located in hazardous area
9.30 Phase sequence preventer (current based) shall be provided.

9.31 Vibration

Compressor maximum vibration of cylinders shall not exceed 10 mm/sec unfiltered peak velocity. Maximum
vibration level of installed compressor frame shall not exceed an unfiltered peak velocity of 5mm/sec or as per

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 IEC Code unfiltered peak-to-peak vibration whichever is less. The bidder shall provide for all structural
support within the package so that these levels can be achieved.
10.0 INSTRUMENTATION & CONTROLS

10.1 All the Instruments and Control Shall Be Suitable For Area Class I, Group D, Division1

10.2 All package mounted transmitters & temperature elements shall be intrinsic safe as per IEC 79-11 and solenoid
valves, switches and related junction boxes shall be flame proof ‘d’ as per IEC 79-1. Other special equipment /
instrument, where intrinsic safety is not feasible or available, shall be flame proof/ explosion proof as per IEC
79-1.

10.3 All pressure gauges shall have an accuracy of + 1/-% of FSD (full scale division) and 100mm dial size.
Pressure sensing elements shall be minimum of SS316 and movement of SS304. All pressure gauges on
process lines having range more than 40kg / cm2g shall be with two isolation valves.

10.4 Panel shall be complete with start and stop push buttons, hours run meter, power on and fault indication lamps,
fault reset button. All necessary timers and intrinsically safe relays to control the system on an automatic
staring and stopping basis shall be provided. The compressor package control system shall be designed for
unattended operation in automatic mode and in case of any fault it will go in a safe mode.

10.5 Compressor package shall be provided with a PLC based local control cum operator panel (LCP), which shall
be mounted on the package enclosure. PLC shall be housed inside flameproof iiA/iiB(Ex’d’) enclosure. All the
equipments/ sub panel of LCP shall also be provided on the flameproof enclosure. All the interlock,
monitoring and controlling of the CNG compressor package shall be done through PLC based control system.
PLC hardware shall be in accordance with IEC-61131-2 and however PLC shall be capable to convert
programmed in flowchart, functional block diagram, structural text etc. In accordance with IEC-61131-3. PLC
shall be provided graphics /text display & scrolling facilities to view process & machine parameters. All
source & object codes including logic flowchart, ladder diagram etc is to be furnished by the packager during
detailed engineering. The same can be view on client’s laptop.

10.6 PLC shall be of modular in construction with EEPROM, redundant power supply for CPU and HMI, redundant
power supply for load, non-redundant I/Os, communication cards for connecting mass flow meter,
communication card card /port for future scada connectivity

10.7 PLC shall be suitable for recording of compressor parameters as indicated in instrumentation and all other
parameters that are recommended by the compressor manufacturer for recording on hourly basis for the last 24
hours. PLC shall be suitable for interfacing with printer (HP Laser printer) for getting the printout of the param
eters recorded (as mentioned above) for the last 24 hours through remote HMI PC (if provided)/ external
Laptop in same format as programmed in PLC

10.8 Pressure Transmitter and Temperature Transmitters shall be used for CNG Gas application and not pressure
and temperature switches. The units of measurement for flow shall be Kg/hr, for pressure shall be Kg/cm2 (g)
or and for temperature shall be degree C

10.9 The selected I/O shall have 40 % s are of used capacity (40% in each used card) for future use. 10% of used IO
or Minimum two of each card out of 40% shall be extended upto terminal block with necessary isolator/
barriers.

10.10 Diagnosis feature shall be available in CPU and I /O used in PLC.

10.11 Mounting of PLC components such as CPU, HMI, I/Os in one JB and power supply relay barriers/isolators,
fuses, MCB, electrical earthling bus bar in other JB. PLC components / system shall be tropicalised, adopted
with complete wiring and necessary terminals. Wiring to be color-coded with cross printed ferruling in
position

10.12 PLC shall be configured as a remote terminal unit of supervisory computer and data acquisition system
complete with Ethernet Port RS 485 (MODBUS TCP/IP) shall be readily configurable for communication over
MODBUS TCP protocol through Leased Line/MPLS/VSAT/RF. PLC shall be capable of carrying out on line
routines for at least ten separate loops without affecting the scan, cycle & up dating time etc.

10.13 Human Machine Interface

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10.14 HMI shall be provided with text/graphic display and operating system software for interlocking, monitoring
and control. All operational buttons shall be on display except the Emergency stop button. Display system
shall be weather proof to IP65. This should be provided in the flame proof panel with HMI mounted on the
door of the panel. The HMI screen shall be back side of the toughened glass. During running of the compressor
the HMI should be assessable through the external push button provided on the panel. The PLC shall be
interfaced with SCADA in future. All the parameters on the PLC shall be available on the HMI. Bidder shall
provide application program for PLC, HMI on LCP (licensed one set) along with all interfacing adaptors and
cables. Bid der shall also provide one set of source &object code s for PLC, HMI on LCP (in both forms, hard
& soft).

10.15 The temperature gauge shall be generally mercury in steel field type. Capillary tubing shall be min. SS304
with SS flexible armouring. The gauge shall have an accuracy of +1/-% FSD (full scale division) and 100mm
dial size. The range shall be 1.5 times of operating temperature. Skin type temperature gauges shall not be
used. In PLC pressure process values should be taken from pressure transmitters and should be independent
from pressure gauges installed on local gauge panel. Temperature process values should be taken from
temperature transmitters and should be independent from temperature gauges installed on local gauge panel.
The compressor package instrumentation & control is to be configured for manual as well fully automatic
control system including starting, shutdown as applicable for unattended operation.

10.16 Individual (2/3 core) cabling is required for each field instrument from field JB to avoid multiple JB’s and
multicore cables in field for easy trouble shooting & replacement.

10.17 Each cable shall be neatly tagged & dressed for each instrument with ferrule.

10.18 The PLC System offered shall be supplied with monitor and memory card for Processing of live data and
stored data. PLC shall be capable of

a) Compressor Control & Emergency Shut down

b) Fire and gas detection and monitoring

c) Graphics, Data acquisition, monitoring & logging, viewing, modifying set point and range of all
process parameters for which transmitters are provided.

d) Record the last 20 Alarms of abnormal operations on separate page.

e) PLC shall be capable for display of flow meter data for flow rate and flow totalizer (i.e. Gas Suction,
Gas Discharge) and power consumed by the motors, compressor running hour :

f) The above data will be viewed / analyze offline (during shutdown of com pressor) or online through
dedicated SCADA port (Ethernet / RS 485) on client laptop and local PC

The compress or package control system shall be so designed that the first item to go into alarm condition shall
lock out to indicate the cause of the trip though the cause of the trip may have disappeared. The lock out
condition shall be manually reset. A change over set of contacts shall be provided for Owner’s use to give a
remote indication of alarm and trip.
Where three bank cascade has been envisaged; in auto mode, compressor shall start automatically/manual in
case high bank storage pressure falls below 200kg/cm2 and stop as soon as pressure in all three banks of
stationery cascade reaches 255 kg/cm2. The priority fill system (In Bidder’s scope) shall ensure the fill ng of
vehicle, storage cascade in correct sequence. Control system shall be designed such that in case of any fault,
discrepancy or abnormality, it will go in safe mode. All controls shall be made in fail-safe mode failure of any
control shall not lead to operation of equipment in unsafe condition.
In case of fault, a warning hooter shall operate, the sound of which should be audible at distance of at least 15
meter. Further the fault alarm and emergency stop PB shall be duplicated in the CNG station control room.
Acknowledgement/resetting of fault shall be possible only from compressor panel. Emergency stop PBs shall
be mushroom head turn lockable type. Once the fault is acknowledge or compressor is under normal
maintenance, the valves of priority panel shall take the position so that gas available in the stationary CNG
storage cascade can be dispensed.
Calibration certificates required for all instruments such as Mass Flow Meter, Pressure transmitters, Pressure
gauges, Temperature gauges, Temperature transmitters, Gas detectors, Flame detectors etc.

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10.19 PLC make should be as per suggested vendor list.

10.20 All the instrumentation shall be capable or operating for full range of operation.

10.21 Separate junction boxes shall be provided for each type of signal i.e. analog, digital, solenoids RTD,
thermocouple, intrinsic safe and for power supply. No cable shall share power & signal. This is not applicable
for direct run cable.

10.22 Suitable bypass for interlocks shall be provided for start-up.

10.23 Compressor package shall be provided with the following indicators:

 Pressure indicator each stage suction and discharge.

 Oil pressure indicator on each pressure lubrication system
 Oil levels indicator, field mounted
 Hour meter
 Non- resettable electromechanical hour meter on local control panel.
 Compressor jacket water coolant temperature indicator on local gauge panel
 Hydraulic oil cooler inlet & outlet temperature on local gauge panel (if required)
 Hydraulic oil pressures each stage on local gauge panel (if required) The Compressor package shall be
provided with the following trip devices:
a. Low oil level protection devices
b. High oil temperature devices
c. Low suction pressure protection devices
d. High discharge temperature protection device
e. Coolant flow low devices
 Flame detection
 Gas detection
 Emergency stop devices
 Fail safe/ wire break alarm for safe operation
 Interlocking provision in PLC program for tripping of machine
10.24 Compressor package shall be furnished with the following trip logic that shall stop the compressor and suction
of compressor shall be isolated:

 On high oil temperature

 On low suction gas pressure
 On high discharge pressure
 On high discharge gas temperature
 On coolant flow low
 On fire detection
 On gas detection
 On pressing manual sop button at local control panel
 On pressing emergency stop devices button
10.25 Compressor package shall be furnished with following tripping circuit (the motor shall stop and suction of
compressor shall be isolated)

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  On actuation of gas detector alarm.
 On actuation of flame detection alarm.
 On pressing of manual stop button at compressor package
 On pushing of emergency stop device
10.26 Each compressor package shall be provided with an audible and visual alarm system for annunciation on
compressor abnormalities.

10.27 Junction box shall be of explosion proof type with 10-20% extra terminal strip & cable gland shall be of
double compression type.

10.28 Gas detectors and flame detectors should be mounted within the canopy.

10.29 ESD button (3 Nos.) shall be provided (Customer Interface room, locally mounted on package and Panel
room). A separate hooter for customer interface room shall be provided with annunciation window alarm of
individual protection device.

10.30 All instrument shall be of internationally reputed manufacturer

10.31 Emergency shut down devices

The emergency shut down (ESD) system is also in scope of vendor. This shall be in accordance with NZS
5425. A fail safe system shall be designed and incorporated to isolate cascades storage from dispensers, stop
compressor isolate the compressor suction storage line and cut off power supply on activation of ESD switch.
This ESD switch shall have to be manually reset to restart the compressor package again. Red ESD button ( 5
nos. ) shall be located in Control Room, Process Area fencing, one side of compressor, one control panel and
one to be kept in electrical room.
10.32 Local Control Panel

 There shall be three independent ports available in the PLC with all the parameters available on each
individual port.
 Redundancy in PLC is required. PLC shall incorporate all process parameters (specified elsewhere) and
status of compressor, engine & priority panels and shall be modular in construction with 100% redundancy
with respect to CPU, Power supply, Interface. PLC components/ system shall be tropicalized, MIL standard
adopted with complete wiring and necessary terminals. Wiring to be color coded with cross ferruling in
position. PLC shall be capable of carrying out on line routines for at least ten separate loops without
affecting the scan, cycle & updating time etc. PLC shall be configured as a remote terminal unit of
supervisory computer and data acquisition system complete with GPRS and Ethernet connectivity. One
card for transferring and accessing data from minimum twenty devices with RS485 port shall be provided.
In case of failure of master/ active controller/ CPU, standby controller/ CPU should take over the control in
seamless and bump less manner. All values & data should be available through both the controllers
immediately, i.e. there should be no data loss.
 Successful bidder to include in scope live demonstration of remote monitoring of all PLC logged
parameters in one machine at his works. OWNER may ask for the same. However, this may be required to
be demonstrated at site.
 PLC based logic circuits shall be used for control & interlock of the compressor package with RS485
SCADA Connectivity as per details in Annexure-IX.
 Local control panel shall be furnished with annunciation window alarm of individual protection device and
a common hooter for audible alarm.
 Local panel should have separate push button for start, stop, emergency stop, alarm acknowledge, alarm
rest & test button for checking healthiness of annunciation system.
 PLC shall be housed inside flameproof IIA/ IIB (Ex’d’). Local operator panel shall also be provided on the
flameproof enclosure. The operator panel is provided for parameterization, indication, monitoring, and
alarms and first out sequence of the system. PLC system shall have memory modules for storing user
programs, symbol lists, program comments and should facilitate debugging/ trouble shooting without the
application program. Program shall be ladder logic and communication shall be in English for each run.
Program should have signal/ parameter tags as labels for easy identification/ troubleshooting. Each section
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 of the program whether it is in the form of rung or page or network should have comment to classify the
interlock being executed. A soft copy of the program should be sent by email/ CD.
 PLC & electronic shall be housed in flameproof control panel & shall be mounted on compressor skid
itself. Main cable entry shall be bottom to up. Also control panel shall have 2 nos. spare 2.5 sq mm slots
with copper gland arrangement.
 Bidder to quote for complete package with all relevant panels required for the compressor to perform as
desired. The electric panel shall consist of electric MCC, switchgear, contractors, power supply distribution
panel etc. and shall be located in hazardous area. The compressor package with control panel (including
PLC and other controls) and other electric/ electronic instruments etc. shall meet hazardous area
classification of Class I, Division I, Group D as per NEC or Zone I, Group IIA/ IIB as per IS/ IEC.
10.33 Priority fill system

Contractor shall supply 3-bank of cascade priority fill system with compressor top-up facility inclusive of
regulating valves, check, by pass valves & liquid filled pressure gauges all mounted in a stainless steel panel.
All fittings and tubes used in priority system shall be of stainless steel of suitable pressure rating. The priority
fill system is to be installed to ensure that vehicle filling takes priority over cascade filling and direct CNG to
three storage banks in correct sequence. The compressor shall shut down once all three-cascade storage banks
are filled to 250 barg g. Compressor shall start on pressing of manual start push button & automatically when
the cascade storage high bank pressure of compressor falls to 200 barg and shutdown automatically when all 3
stages of stationery cascade are filled to a pressure of 250barg.
10.34 Documents to be provided with package

10.34.1 Operation and Maintenance Manual (In English) – 02 Copies

10.34.2 Calibration certificates of all instruments & devices

10.34.3 P&ID Diagrams

10.34.4 Interlock Block Diagrams

10.34.5 Bill of Material with Tag No & Technical Specifications

10.34.6 Wiring Diagram of Electrical & Instrument Panel

10.34.7 Electrical Power & Control Diagram

10.34.8 Specifications of Electric Motor & Characteristic Curves

10.34.9 Foundation Drawings

10.34.10 Capacity vs. Suction Pressure curve

10.34.11 Capacity vs. Energy Consumption curve

10.34.12 List of spares for nine years of operation and maintenance. The list of spares should include ordering
specification and manufacturer’s catalogues.

10.34.13 List of special tools & tackles to be provided along with the bid.

11.0 SKID AND ENCLOSURE

The maximum allowed temperature within the enclosure shall be 5° C above ambient temperature. Adequate
ventilation fans shall be provided to meet the above and also to account for heat dissipation of the coolers.
Interlock shall be provided to start the exhaust fan to vent out any entrapped gases in the enclosure before
starting the main compressor. In case heat exchanger fan is compressor shaft driven, the same can’t be utilized
as ventilation fan.
The compressor package shall consist of single enclosure for Compressor and Electric Motor. The equipment
shall be mounted on one common skid. The Enclosure to restrict maximum noise level to 75 dB(A) at 1 meter
from the enclosure.

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 Material used in the enclosures shall be fire retardant. Rain water should not enter into the enclosure and
forced ventilation system shall be provided.
The enclosure s shall have doors for normal access and removable wall panels for ease of maintenance.
All he pressure, temperature, oil level, lube oil pressure, coolant temperature, coolant level indicators shall be
visible from outside of enclosures and shall be mounted on gauge panel visible from outside.
Enclosures shall have internal flame roof lighting arrangement.
For handling all heavy arts for maintenance purpose lifting arrangement i.e. beam fitted with chain hoist shall
be provided in enclosure
The Compressor shall be located inside an acoustic enclosure. All Coolers, Knock Out Drums, Scrubbers,
Cooling System, lubrication system along with interconnecting piping shall be inside an enclosure. Enough
headroom shall be made available for easy access and maintenance of all equipment. The piping layout with
respect to the compressor, intercoolers, KOD and auxiliaries location shall be subject to Purchaser’s approval
during detailed engineering Stage.
Components such as pressure gauges, temperature , pressure switches, filter automatic ball valves, safety
valves etc., which require in-situ adjustment, maintenance and reading, shall be easily accessible.
Conduits and tubing shall be arranged in orderly and systematic manner and shall be routed neatly to enter the
back of display or monitoring panels
Routing service item such as, but not limited to, crank case oil filters, inter stage gas filters, inlet and outlets
gas filters and drive belt shall be located to facilitate easy one-man servicing.
One person should be able to access crank case oil inlet and drains to allow addition or drainage of oil without
removing panels or adjacent components and without the need of the pump.
Items which must be operated & monitored during operation shall be readily accessible without opening the
door
Suitable gradients shall be provided on the enclosure roof for rain drainage and to avoid water pockets.
11.1 Painting and protection:
Packing shall be sufficiently robust to withstand rough handling during ocean shipment & inland journey.
Sling points shall be clearly indicated on crates.
Painting of Internal process piping should be as per international colour coding standard, e.g- Gas line-Yellow,
Water line- green, Airline-Blue, Fire suppressing system – Red etc. The paint shall be chosen, primed and
applied to have a service life of ten years the exterior of equipment and enclosure is required to be corrosion
free for ten years.
12.0 INSPECTION & TESTING

a) Inspection shall be carried out as per Quality control table approved by Owner or its representative.
Supplier will submit the Quality control table (complying to tender QCT) for approval.
b) The bidder has to provide 15 days advance notice prior to said inspection & test.
c) The bidder shall be responsible for specified inspection & testing requirements including at all sub
bidders.
d) Bidder shall keep following data available for at least 5 years for examination by purchaser.
e) All necessary certification of materials, such as mill test reports.
f) Purchaser specification for all items on bills of materials.
g) Test data to verify that requirement of the specification have been met
h) Result of quality control test.
i) Pressure retaining parts including auxiliaries shall be hydrostatically tested with water at following
minimum test pressure for a minimum period of 1 hour :
 Cylinder: 1-1/2 times maximum allowable working pressure.
 Cylinder cooling jacket & packing case 1-1/2 times coolant pressure but not less than 8 barg effective.
Mechanical Running Test (MRT)
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 a) These tests shall have mechanical operation of compressor, driver and accessories, Instruments, control
system and the coolers.
b) The MRT for the 25% compressors block of the lot shall be carried out with job or shop driver including
complete job driving system i.e., job driven V-belt, job pulleys etc., for 4 hours continuously at the
premises of compressor block OEM. The compressor need not be pressure loaded for MRT test. During
this test following shall be recorded at agreed intervals (as applicable).
- Operational Parameter
- Vibration levels measured on cylinders and frame
- Bearing temperature
- Oil cooler inlet and outlet temp
Subsequent to satisfactory run the compressor shall be examined as per standard procedure & following
shall be examined as minimum:
- Bore & other parts by opening a valve
- Piston & cylinder clearance
- Visual examination of position rod, cylinder guide bore without dismantling
If any of part found damaged, all similar components shall be stripped for inspection. The MRT test shall be
repeated after replacement of such parts.

12.1 Mechanical String Test

Mechanical String Test for 4 hrs. is a mandatory requirement to be performed at packager’s shop before
dispatch in presence of Owner’s representatives (or a third party as arranged by OWNER). This test can be
clubbed up with the Mechanical Run Test of compressor as specified above, provided the job driver & lube
Oil system is used for the test. At least 25% of the package lot ordered shall be string tested. String test on air
is not acceptable. It shall be on natural gas or N2.

12.2 Erection, Testing & commissioning at Site

The bidder shall be responsible for erection, testing, commissioning & performance test and noise level test of
all packages at site. Commissioning of various equipment and systems shall be carried out by the bidder as per
the accepted procedures and as per the instruction of the manufactures of the equipment. The units will be
considered commissioned only after the successful performance tests are carried out by the bidder.

The bidder shall ensure integrity of compressor package and safety of electrical supply system available at
back end while testing package, at site. Also, bidder shall arrange its own control/ single phase (UPS supply)
for testing and commissioning of package.

12.3 Field Trial Run

Bidder shall conduct a field trial run of each compressor package for minimum 4 (four) hrs. (can be in
multiple runs) in which satisfactory operation of complete package together with all accessories controls shall
be established for specified operation conditions. In case of any defect, discrepancies under specified site
conditions, bidder shall first rectify the same and repeat the field trial run. The bidder shall record data of
field trial run.

12.4 Noise Level Test

During the field trial run, noise level test shall be carried out and bidder shall demonstrate /achieve the granted
noise level. All necessary instruments /accessories required for fields trial run and noise level test shall be
arranged by the bidder.

12.5 Performance Acceptance Test (PAT)

Before conducting performance acceptance test at site, Bidder is required to clear all punch points (if any)
raised by OWNER / OWNER’s authorized representative.

Compressor Package Performance test at sites shall be carried out as per ASME PTC9. All necessary
instruments/accessories required for this test at site shall be arranged by the bidder and repatriated after
successful performance test by the bidder.

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 All such instrument shall be pre-calibrated. In case any defect/deficiency is noticed under the specified site
conditions bidder shall first rectify the same and repeat the performance test. Bidder to quote for performance
test per compressor package separately at site inclusive of boarding, lodging office space, local transport for
bidder personnel and hiring ;of local contractor, crane etc. bidder shall be liable to pay all local taxes, levies
applicable and strictly comply with rules, laws prevailing in India.

13.0 GUARANTEE, LOADING AND PENALTY CRITERIA

This section describes the guarantee parameters, which the booster compressor package must fulfil, the penalty
for shortfall in guaranteed parameters and rejection of compressor package by the purchaser.

The guaranteed parameter shall be adjusted to account for variation in gas composition and prevailing ambient
condition during testing.

Necessary calculations correction curves shall have to be furnished by bidder along with bid, which shall be
final & no deviation shall be permitted afterwards.

In case of any inconsistency in manufacture and / or operation of supplied compressor package, Bidder shall at
his own risk and cost, eliminate the defects to the satisfaction of owner.

For loading and compensation purpose, power consumption with suction pressure of 30 to 200 kg/cm2 and
discharge pressure equal to dispensing pressure may be considered. Dispensing pressure will depend on empty
vehicle pressure to be fuelled and compressor discharge pressure may not be 250 kg/cm2 continuously. For
power consumption purpose discharge pressure may be taken 230 kg/cm2.

The bidder shall furnish the guaranteed value for the following:
Compressor Capacity: Compressor shall guarantee the capacity as mentioned in Guaranteed Parameters.
Compressor BKW: Bidder shall indicate guaranteed BKW including all losses such as mechanical,
transmission etc.
Motor Power Output of the prime mover (KW)
Total power required for the package including power consumed by accessories.
13.1 Compressor Capacity
Bidder shall guarantee average capacity of 450 SCMH from suction pressure 30 to 200 kg/cm2 at suction
temperature of 52 degree centigrade , discharge pressure of 255 Kg/cm2 with the negative tolerance for errors
in instruments and measurements.
For calculation purpose 1kg of CNG =1.33 SCMH
If bidder quotes less than 22.5 KWH. No advantage will be given for quoting less than 22.5 KWH
The same shall be used to establish the capacity at test bed during package performance test.
13.2 Loading against Energy Consumption:
The compressor package shall be designed in such a way that Energy Consumption of package (KWH/Kg)
should be minimum for production of CNG.
Bidder shall indicate actual energy consumption for their compressor package. This quoted figure will be used
for evaluation and total quoted price for all compressors towards supply, special tools & tackles, erection and
commissioning will be loaded as per following formulas:
F = (G-22.5) x H x I x N Where,
F = Loading amount in Rs.
G = Bidder’s Energy consumption rate quoted in KWH
(G-22.5) = Bidder’s Energy consumption rate over and above 22.5 KWH
H = Cost of Energy INR 8.0 /KWH
I = Factor towards lifecycle in hours @ 36,500 hours
N = No. of Booster Compressor

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 Penalty towards Excess Energy Consumption:
At the start of O&M period or even at any point of time during the O&M period, cost towards excess power
consumption beyond quoted figure shall be deducted from O&M bills.
Following calculations shall be used for deduction towards excess power consumption.
F = (G-Q) x H
Where,
F = Monthly Penalty in Rs.
G = Monthly Actual power consumption

Q = Guaranteed consumption rate quoted by supplier for every 338 Kg of CNG x CNG produced during the month
338
H = Cost of power Rs 8.0/kwh
 Penalty towards Package Efficiency Loss
This penalty shall be imposed on compressor blocks not capable of delivering rated capacity of 450 SCMH
Following calculations shall be used for penalty towards package efficiency loss:
F = 2 x {(450 x H x RD x AD) – M}
Where,
F = Penalty Amount in Rupees
H = Hours clocked in a month
RD = Average RD for the month using GC Data
AD = Air Density = 1.22541
M = Discharge mass flow during the month in Kgs
Note:
 Gauge Pressure at Station Inlet shall be used as benchmark for imposition of penalties and not suction
pressure being displayed at the PLC.
 Penalty for Non-Performance during One Year Period of Operation & Maintenance
Details of Penalty for non performance of equipments
a. On normal day (i.e. the day other than the schedule maintenance day):
i. The party has to ensure that the equipments are available for operation for minimum 20 hours per day
and on an average the equipment availability has to be 98% in a month.
ii. If the equipment is down for more than 4 hours on any day or availability is less than 98% in a month.
Penalty would be applicable as follows:
upto 12 hours : Rs. 20,000/-
Beyond 12 hours: Rs. 40,000/- per day.
In case of daily availability is 20 hrs. but monthly average availability is below 98%. Then penalty @ of
10,000 per % or part thereof shall be applicable.
b. On schedule maintenance day:
i. The party would be required to carry out the recommended schedule/preventive maintenance of the
equipments for which the party has to indicate the time required for each type of schedule
maintenance.
ii. If the equipment is down for more than 4 hours & upto 12 hours beyond the time indicated for the
agreed schedule maintenance, the party would be penalized Rs. 20,000/- and for more than 12 hours
Rs. 40,000/- per day.
iii. In any case, the maximum penalty imposed in a month for non-performance of the equipment turns
out be 50% or more of the amount of O&M charges to be paid to the party per month per compressor
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Booster Compressors for CGD Project
 (a complete cost break up of O&M charges need to be furnished by the bidder during bid), OWNER
will take necessary actions as per terms and conditions of the contract for such non-performance).
14.0 SPECIAL TOOLS AND TACKLES

Special tools & tackles for erection and commissioning and for operation & maintenance are required to be
arranged by successful bidder.
Vendor shall maintain sufficient spares to fulfill the warranty & subsequent nine years period requirements. In
case of additional requirement during the warranty period, if any spare part is taken from OWNER, the same
shall be replaced to OWNER with new part supported by necessary document for its authenticity of being new
& original spare part
15.0 DOCUMENTATION

 The drawings/documents to be submitted by the bidder shall be divided in three categories:

a. Drawing documents to be supplied with the bid
b. Drawing /document to be submitted for approval (After award of work)
c. Drawing/document to be submitted for information (After award of work )
 The bidder shall submit list of drawings, which shall be submitted by them in above three categories. All
drawing /document shall be submitted in 6 sets of soft copy in pen drive/hard drive.
 Title block of each drawing shall contain at least following information:
Name of the Owner :
Name of the Consultant : TRACTEBEL ENGINEERING PVT. LTD.
Name of the Project :
Name of Bidder :
Descriptive title :
Drg. No :
Revision No :
Sheet No./ Total No. of sheet in the drawing :
 Bidder shall furnish relevant calculation and protection relay setting table for the equipment /system being
supplied by them, It shall also contain the manufacture’s catalogue, operation and maintenance manuals for
all types of relays/components used,
 The bidder shall submit all drawing within specified time, in requisite number, for each equipment/item for
approval.
 Approval of drawings by Owner.
 The bidder shall submit furnish drawings as indicated/agreed for each item for approval of the
Owner/Consultant.
 Owner/Consultant will scrutinize drawing/data furnished by Bidder and comments, if any, will be
communicated to the Bidder within 2 weeks from the date of receipt.
 The Bidder shall submit all the drawings/documents in two (2) sets. All the drawing of sub-bidder/bidders
etc. shall be checked by Bidder for correctness and compliance with requirement of order/contract and
signed before submission to Owner.
 The drawings shall be stamped in either of following category and one print shall be returned to the Bidder.
“APPROVED”
“APPROVED SUBJECT TO INCORPORATION OF COMMENTS”
“NOT APPOVED”
“FOR INFORMATION ONLY”

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 Wherever drawings are returned to the Bidder with the marking “Approved subject to incorporation of
comments” the bidder shall make the necessary modifications/corrections and resubmit the revised
drawings and data for final approval.
 Bidder shall be responsible for correctly incorporating all the points conveyed to him and resubmit the
drawings to the Owner for final approval. Specified number of copies of approval drawing and
reproducible of specified quality shall be submitted after the final approval of drawings.
 Approval of drawing by owner shall not relieve the suppliers of his contractual obligations and
responsibility for engineering design, workmanship, materials and performance of equipment, Work shall
be carried out exactly as indicated on the approved drawings and data and no alterations shall be made
without the written approval of the Owner,
 If any subsequent alterations are found necessary and approved by the Owner, all drawings and data
affected by such alterations shall be duly revised and re-submitted for the approval.
 Bidder shall incorporate/cause to incorporate all change made in the drawings from approval stage to the
handing over of equipment and submit as built drawings in the requisite sets (these will be in addition to
the sets submitted at the time of approval/for information and up to commissioning). The drawing to be
submitted shall include all the drawings submitted for approval, information as also the drawings required
for normal operations, troubleshooting repair, and maintenance and testing of equipment etc.
 Bidder shall submit the following drawings/data/document in bound volume prior to submission of final
bill to the Owner in soft and hard copies (2 Sets).
 All drawings submitted to Owner for approval information
 Equipment manufacturing drawings submitted for information of Owner.
 Equipment drawings required for operation and maintenance.
 Fault calculations, protection relay setting calculations and recommended settings.
 Inspection reports, factory and site test certificates in bounded volume.
 As built drawings incorporating all site modifications.
 Instruction manuals
 List of spares for nine years operation and maintenance. The list of spares should include ordering
specification and manufacture’s catalogues.
 Operation and maintenance procedures for individual equipment and total system.

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 ANNEXURES
(BIDDER TO SUBMIT FILLED UP ANNEXURES FOR 450 SCMH)

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 ANNEXURE – I : GUARANTEED PARAMETERS

(ELECTRIC MOTOR DRIVEN 450 SCMH HYDRAULIC BOOSTER COMPRESSOR)

Guaranteed General Package Data

Bidder’s
Sr. No. Parameter Unit
Data
Compressor BKW in KW @ Rated Conditions (No + ve
1 KW
tolerance)
Compressor BKW in KW @ RV Set Conditions (No + ve
2 KW
tolerance)
3 Net of all auxiliaries/package ventilation loads in KW KW
4 Site rated BKW of Electric Motor (No – ve tolerance) KW
5 Noise level 75 DBA @ 1 meter from enclosure db
Footprint area of compressor package quoted as mentioned in
6. mtxmt
SOR

NOTE:
1. Parameters under Sl. No. 3 4and 5 are for reference only.
2. SI.No.2 Bidder must indicate the guaranteed KW including all losses such as mechanical transmission
power absorbed by compressor auxiliary like cooler fan etc. but excluding air compressor.
3. Power consumption and capacity should be indicated corresponding average discharge pressure 250
Kg/cm2
4. The above parameters shall be quoted gas against suction temperature of 40 to45 de centigrade at
mobile cascade
5. Bidder has to fill all rows in above table. If any row is not filled by bidder or above tables are modified
in any manner, bid will be rejected summarily

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 ANNEXURE – II : COMPRESSOR DATA SHEET FOR 450 SM3/HR

1.0 PROJECT: CNG Expansion Project DATA SHEET NO:

:
1.1 NO. OF UNITS As per SOR DRIVE: Electrical Motor

1.2 DUTY : Continuous LOCATION: As per SOR

2.0 OPERATING CONDITIONS
2.1 Service/Stage : Compressor for CNG Stations/ Two
2.2 Gas Handled : Natural Gas
2.3 Composition (%) : Natural Gas
2.4 Corrosive due to:
2.5 Molecular Weight at Intake (Avg.)
2.6 Cp/Cv at intake/compressibility Factor
2.7 Relative Humidity
2.8 Suction Temperature (°C) : 35°C max
2.9 Suction Pressure (Kg/cm², Gauge) : 200 to 30 varying
2.10 Discharge Temperature (°C) : Maximum 52°C After Cooler
2.11 Discharge Pressure (Kg/cm², G) : 250Kg/cm² (Gauge)
2.12 Required Capacity (SM³/hr.) : 450 Driver Motor Rating: KW
Drive arrangement
2.13
Direct Coupling/V-belt
Standard Atmospheric pressure (1.033 Kg/cm² abs)
2.14 Standard Conditions referred to :
and Temperature of 15.6°C
3.0 SITE CONDITIONS
3.1 Place : Installation: Outdoor
Min : 2 °C
: Max. Relative Humidity
3.2 Site Ambient Temp. (°C)
(%) : 90%
Max : 47 °C
3.3 MSL – 205 m
Class1 Div1 Group D or Zone 1 Div1 Group IIA
3.4 Area Classification :
Group IIB
4.0 APPLICABLE CODES & SPECIFICATIONS
Piping: ASME/ANSI B
4.1 Compressor : As per tender
31.3
Electrical Motor Data
4.2 Driver :
Sheet
Water cooled exchangers :
4.3 Air Cooled Exchangers : API 661
TEMA ‘C’
ASME Sec. VIII Control Panel : Refer
4.4 Pressure Vessel :
Div.1/2 Tech Specs

5.0 MANUFACTURER’S SPECIFICATION

5.1 Name : Model:
Compressor RPM/Stroke
5.2 No. Off :
(mm):
5.3 Type : Drive Arrangement:
5.4 Service/Stage
Cp/Cv Value/
Mol. Wt. At Intake (Avg.) Compressibility Factor at
5.5
(Gas Composition) : Intake

Shaft Power @ RV set

5.6 Adiabatic Power (KW) :
pressure (KW)
5.7 Driver Rating & Speed (KW/RPM) : Noise level:
Discharge Nozzle
5.8 Suction Line (Size/ Rating) :
(Size/Rating)
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 5.9 Direction of Rotation from Driving End:
5.10 Compressor Weight : Max. Erection Weight: Max. Maintenance Weight::
5.11 Diff. Pr. In Suc. Strainer, Piping, puls Dampener: Diff. Pr. In after Cooler
5.12 PERFORMANCE DATA OF PACKAGE

Gas Suction Pr ( 200 to 30 kg/cm2 )

Ist Stage IInd Stage IIIrd
Stage
Mol. Wt at intake
Specific Gravity
Cp/Cv Value / compressibility Factor at intake
Cp/Cv Value / compressibility Factor at discharge
Suction Pressure, kg/cm2 g
Suction Temp. °C 40
Suction capacity, SM3 / Hr
Discharge pressure, kg/cm2 g
Discharge Temp. Adiabatic °C
Discharge Temp. Actual, °C
shaft power, Kw
V-belt / coupling losses, kW
Shaft power at RV set pressure including
V-belt / coupling losses, kW
Volumetric Efficiency, %
Valve lift
Valve lift area
Valve velocity (Average) M/sec

5.13 DESIGN DATA

Suction Pressure ( 200 to 30 kg/cm2 )
Ist Stage IInd Stage IIIrd
Stage
Mol. Wt at intake
Specific Gravity
Cp/Cv Value / compressibility Factor at intake
Cp/Cv Value / compressibility Factor at discharge
Suction Pressure, kg/cm2 g
Suction Temp. °C 40
Suction capacity, SM3 / Hr
Discharge pressure, kg/cm2 g
Discharge Temp. Adiabatic °C
Discharge Temp. Actual, °C
Shaft power, kW
V-belt / coupling losses, kW
Shaft power at RV set pressure including

V-belt / coupling losses, kW

Volumetric Efficiency, %
Valve lift
Valve lift area

Valve velocity (Average) M/sec

6.0 CYLINDER & PACKAGING DATA
6.1 Service / stage Ist Stage IInd Stage IIIrd
Stage
6.2 Cylinder bore (mm/No. off)
6.3 Single / Double Acting
6.4 Liner (yes/ No.)
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6.5 Type of Valves
6.6 Piston Displacement (M3/Hr)
6.7 Volumetric Efficiency (%) Min/ Nor/max
6.8 Mean Piston Speed(m/sec) [<3.5 m/sec]
6.9 Suction / discharge valve gas velocity (m/sec)
6.10 Relief valve setting (kg/cm2 g)
6.11 Max. allowable cylinder pressure (kg/cm2 g)
6.12 Max. allowable cylinder temperature (°C)
6.13 Pneumatic Test By (kg/cm2 g)
6.14 Hydrostatic test (kg/cm2 g)
6.15 Hydrostatic test water jacket (kg/cm2 g)
6.16 Suction / discharge nozzle orientation
6.17 No.of suction / discharge valves
6.18 Piston Rod Dia (mm)
6.19 Piston Load
-Max. Rod load gas compression, Kg
-Max. Rod load gas tension, Kg
- Rod load (Inertia alone) compression, Kg
- Rod load (Inertia alone) tension, Kg
-Rod load rated Pr. (gas + inertia) compression, Kg
-Rod load rated Pr. (gas + inertia) tension, Kg
-Rod load at R.V set Pr. (gas + inertia) compression, Kg
-Rod load at R.V. set Pr. (gas + inertia) tension, Kg
6.20 Max. Permissible Piston Rod loads (kg)
6.21 Rod packing cooling by liquid (yes/No.)
6.22 Rod packing lubrication (Yes/No)
6.23 Rod packing vent to
6.24 distance piece type
6.25 Cylinder jacket cooling by

7.0 LUBRICATION SYSTEM

7.1
 Splash  Force feed Lubricated
 Pressure lubrication including piping, valves and  Mini Lubricated
 Oil filter : single  Non Lubricated
Degree of filtration  Lubricator Driven by
 Oil cooler  Compressor shaft
 Oil pump driven by compressor shaft  Electric Motor (kW)
 Auxiliary oil pumps, if reqd,  Lubricator equipped with sight flow
indicator for each point storage tank with
level gauge
 Pre-lube Motor driven pump, in case of splash system
Grade / viscosity of lube oil Grade / viscosity of lube oil
Oil sump capacity Oil sump capacity (For 500 hrs)
Lube oil consumption (Lt/100 Hr.) Lube oil Consumption(Lt./100 hr)
Change lube oil after Hours
Type of bearing : Main Big End: Small End:
8.0 COMPRESSOR CONTROLS
8.1 Automatic start / stop on storage pressure level and manual  Actuators (To be included in supply)
start stop
8.2 Automatic drain of separators  Manual on machine
8.3  Compressor to start automatically after power  Intermediate devices (to be included in
interruption with 10 seconds delay. supply)
8.4 Automatic recovery of gas form gas recovery vessel  Solenoid valves
8.5 Automatic closing of suction isolating valve on  Manual -mounted in a local panel.
compressor trip
 Controller(For auto control)
 Pressure switches (For auto control)

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8.6 Compressor shall unload on Power failure/ stoppage  Any other instrument required.
through (Vendor to indicate) Automatically 
Manually
8.7 Compressor shall load on start through (Vendor to  Automatically
indicate)  Manually
8.8 Recommended time duration for compressor operation @ 0% capacity (minutes)
8.9 Recommended number of starts/ stops for the Motor : Per Hours
AUXILIARIES
9.0 COOLERS
9.1.1 Oil Cooler After cooler Inter coolers
(Required)
9.1.2 Cooler Type
9.1.3 Tube Material
9.1.4 Tube sheet material
shell Material
9.1.5 Shell Material
9.1.6 ASME / IBR CODE Yes Yes Yes
STAMP/TPIA
9.2 Suction Strainer Temporary Mesh Size
9.3 Volume Bottles / Pulsation Dampers 1st Stage 2nd Stage 3rd Stage

9.3.1 Type at Suction /Discharge

9.3.2 Residual Pulse Amplitude ( peak to peak ) 3% / 3%
9.3.3 Maximum Allowable Working Pressure (kg/cm2g)

9.3.4 Capacity (M3)

9.3.5 ASME / IBR CODE STAMP/TPIA Yes Yes Yes
9.4 Separator 1st 1st Discharge 2nd Final
Suction Discharge Discharge
9.4.1 Type
9.4.2 Max allowable Pr (kg/ cm2g)
9.4.3 Capacity (M3)
9.4.4 ASME / IBR CODE STAMP/TPIA Yes Yes Yes Yes
9.5 Oil Mist separator at final discharge to limit oil carry over to 5 PPM
9.5.1 Type Capacity:
9.5.2 Max allowable Pr (kg/ cm2g) ASME / IBR CODE
STAMP/TPIA: Yes
9.6 Gas Recovery vessel Capacity:
9.6.1 Max allowable Pr (kg/cm2g)
9.6.2 ASME / IBR CODE STAMP/TPIA Yes

10.0 INSTRUMENTATION
10.1 PRESSURE INDICATION
Gas At inlet
Gas at discharge (each stage)
Frame oil Header
Frame oil filter (Differential local)
Gas at after cooler exit (local)
Hydraulic Oil Pr. (each stage)
10.2 PRESSURE SWITCHES
Frame oil header (1 no. For trip on low pressure.)
Jacket water system failure
Compressor discharge Pr high (Each stage)
Compressor discharge Pr Low (Final stage)
Compressor suction pressure low
Compressor suction pressure high
10.3 TEMPERATURE INDICATION
Gas at suction to compressor
Gas at Discharge of Comp (Each stage before cooler)

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 Gas at after cooler
Oil cooler oil outlet
10.4 Temperature Switch
Temperature after compressor discharge before cool (each stage)
10.5 Level Switch
Oil tank level low
10.6 OTHER INSTRUMENTS

Junction Box with interconnecting wiring

Pressure Relief Valve at discharge each stage
Pressure Relief Valve at suction to compressor
Instruments for closed circuit cooling water system
Hour meter
Gas detection system
Flame detection system
Forced feed lubrication failure to stop comp.
Priority fill panel
Emergency shut down system
10.7 LEVEL GAUGE AND INDICATORS
Frame oil (Bull's eye type)
Packing / cylinder lubrication oil
Make up water tank
10.8 SIGHT FLOW INDICATORS
As reqd. in close ckt. cooling system
Sight flow indicators, cylinder and packing lubrication oil lines
10.9 Other instrument for safe running of compressor
Note : 1. Each pressure gauges and pressure switch with an isolating valve and a drain valve.
Switch contacts to open under fault conditions
Switch / junction box enclosure ( As per the electrical area classification)
11.0 INSTRUMENT PANEL
11.1 PNEUMATIC CONTROLS FOR TRIP CIRCUIT TO BE CONNECTED TO MAIN
DRIVER CONTROL SWITCH
11.2 Capacity Indication Cause of shut down
11.3 Pressure Regulator Frame Oil Pressure-Low
11.4 Low Cooling Water Flow
11.5 PUSH BUTTONS AND SIGNAL LIGHTS FOR
11.6 Main Motor & Aux.Motors Compressor discharge PR.(Each stage)
11.7 Ammeters for main and Aux. Motors Compressor suction Pr. Low
11.8 ESD Compressor suction Pr.
11.9 Common machine trip-alarm
11.10 Following to be included in vendor's scope of supply :
11.11 All interconnecting oil gas water piping & tubing as per schematic attached.
11.12 All electrical power distribution and interconnection as specified.
11.13 Intrinsically safe system for trips ( Ref. Inst. specs)
11.14 Electrical circuits to be housed in Explosion Proof Cabinet (Refer Elect. & inst. Specs)
11.15 Electrical circuits to be provided for repeating pre alarm and trip alarm on the local panel.
11.16 Annunciation system with test / acknowledgement push buttons & sole first off sequences
11.17 Motor Interlock against loaded start
11.18 Motor Interlock against start without air cooler fan running
11.19 Motor interlock against start without pre-lubrication
11.20 Provision shall be made for common alarm and trip alarm
11.21 Any additional instruments & controls required for safe operation of compressor ( as recommended by
compressor vendor)
12.0 MATERIAL OF CONSTRUCTION & GRADES
12.1 Stage 1st 2nd 3rd Remar
ks
12.2 Cylinder & Head
12.3 Liner
12.4 Piston

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12.5 Piston Ring
12.6 Piston Shoe ( Wear Band)
12.7 Valve seat
12.8 Valve stop
12.9 Valve / plate / Ring
12.10 Valve spring
12.11 Cylinder Packing Ring
12.12 Crank Shaft F.S ( Forged Connecting Road (CR) F.S CR cap. Bolts FS
steel)
12.13 Main bearing: Big End Beating: Small end bush:
12.14 Piston Rod Yield strength Hardness(RC) Surface Finish
12.15 Pulsation Dampers / Volume Bottles Suction/Discharge KOD
12.16 Non Return Valve- Shall be compressor Discharge valve type

13.0 INSPECTION AND TESTING

13.1 X-ray examination for welded joints for heat exch./ NO only TC
Press. Vessel / gas Piping ( Certificate to be
furnished)
13.2 Ultrasonic testing for piston rod, connecting rod, YES
crank shaft, big end bolts, main brg. studs.
13.3 Magnaflux testing for crankshaft, piston rod, YES
connecting rod
13.4 Dye penetrant testing for cylinder liners , piston YES
13.5 Shop inspection by purchaser during construction YES
13.6 Barring over to check clearance YES
13.7 Mechanical running test with shop job driver at YES
compressor vendor's works
13.8 Stripping check and internal inspection for one comp
13.9 Hydrostatic test of Cylinders, Pressure Yes
Vessels
13.10 Leak proof test of crank case ( min 24 hrs with Yes
With kerosene)
13.11 Fit up test at compressor packager’s Yes
13.12 Performance Acceptance Test YES
13.13 Field noise level test YES
13.14 Field trial run at site for 12 hours YES
13.15 Functional / continuity tests - control panel ( At sub YES
vendor's works)
13.16 Inspection and tests of compressor vessels
Piston Piston Rod
Cylinder and liner Connecting Rod Crank case
Crank shaft Heat Exchangers Valve components
Pressure vessels
Test Certificate required for
Auxiliary Motor & Pumps Safety Relief Valves Capacity control devices
(Temp / F
Safety switches Solenoid valves All instruments
Note : 1. For electrical / instrument items, vendor shall provide certificates issued by statutory inspection
authority confirming suitability of design / construction for specified Hazardous area classification.
Service

Size Type (Induced Force) Craft/No. of Bays

Surface per Unit-Finned Tube (m2) Bare Tube (m2)

Heat Exchanged (KW) MTD. Eff °C

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 Transfer Rate * Finned Tube : Bare Tube, Service Clean W/m2 °C

PERFORMANCE DATA-TUBE SIDE

Min. Suc. Pr. Normal. Suc. Pr. Max. Suc. Pr

In Out In Out In Out

Inter Flow Kg/s
Cooler Temp °C
1st Stage Pr. Kg/cm2
Total Heat KJ/Kg
Inter Flow Kg/s
Gas Cooler Temp °C
Composition 2nd Stage Pr. Kg/cm2
Total Heat KJ/Kg
After Flow Kg/s
Cooler Temp °C
Stage Pr. Kg/cm2
Total Heat KJ/Kg

Oil Cooler Stage Flow Kg/s

Temp °C
Pr. Kg/cm2
Total Heat KJ/Kg
Water/Air Cooler Flow Kg/s
Stage Temp °C
Pr. Kg/cm2
Total Heat KJ/Kg
Total Heat all streams KJ

Pressure Drop Allow/Calc. Kg/cm2 g

Soft Starter Data Sheet to be provided by the Compressor.

Performance –Data –Air Side

Air Quantity (Total Kgs.)

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 ANNEXURE - III - DATA SHEET FOR ELECTRIC MOTOR

ITEM NO.:
QUANTITY: As per requirement
DESCRIPTION:
IS:325 / IEC / EQUIVALENT INTERNATIONAL
A. APPLICABLE SPECIFICATION AND STANDARDS
STANDARDS
B. SERVICE CONDITIONS:
Max. Ambient Temp. (Deg. C)
Min. Ambient Temp. (Deg. C)
Design Ambient Temp. (Deg. C)
Altitude Above MSL (MTS)
Relative Humidity (Max.) (%)
Environment
Location ( Indoor / Outdoor )
Area ( Safe / Hazardous )
C. SYSTEM CHARACTERISTICS:
Systems Voltage with ± % 415 V ±10%
Number of Phases 3
Rated Frequency with ± % 50 Hz ±5%
Combined Variation ±10%
Fault Level 25 KA
Space Heater Supply Space heater for 30KW & above rating motor
Low Voltage Stator Winding Heating Supply NA
D. Motor Rating / Details:
Rated Output As per Vendor
Rotor Type Squirrel Cage
Syn. Speed (RPM) As per pump and fan vendor
Direction of Rotation Bi-Directional
Insulation Class ‘F’, Temperature Rise Limited to ‘B’
Duty S1, Continuous
Winding Treatment Moisture Protection Varnish
Insulation Process Anti-Corrosive Treatment
Starting Method Star / delta
Starting Current Vendor to Furnish
Minimum Voltage Start at Terminal 80% of 415V
Starting Torque Min. 200% of FLT
Pull Out Torque
No. of Hot Starts 2 Nos.
No. of Cold Starts 3 Nos.
Shaft Extension Required
Type of Coupling
Earth Terminals 2 Nos. on Body & 2 Nos. on T. Box
Greasing Arrangement Yes
Name Plate Yes, as per IS:325
Starter Connection Vendor to Furnish
Efficiency at
100% load
75% load
50% load
E. ENCLOSURE:
Degree of Protection EExd IP55
Mounting Arrangement As per requirement.
Type of Cooling TEFC
F. TERMINAL BOX
i) Terminal Box (Main) 1 No.
Type
Fault Withstand
No. of Terminals 6 Nos.

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 Side of Terminal Box seen from the Driven End RHS
ii) Auxiliary Terminal Box --
1. Separate Terminal Box for
Space Heaters YES
Thermistors --
G. TESTS TO BE WITNESSED
Type Tests CMRS test certificate to be furnished
Routine Tests As per IS:325
H. ACCESSORIES
Anti-condensation Heaters Yes
PTC Thermistors NA
Voltage Rating of Space Heaters 230V
Foundation Bolt Yes
Cable Glands Required
Earthing Terminals Body & T. Box
Motor peak Amplitude Vibration at no Load at 40 Microns for 1500 RPM
Bearing should not exceed 15 Microns for 3000 RPM
Max. Motor Noise Level Measured at a Distance of
75 dB
1. Mts. from Motor
I. CABLES
1. Type & Size
- Motor Vender to furnish
- Space Heater Vender to furnish
- Thermister NA
2. Cable Lugs
- For Motor Copper
- Space Heater Copper
- Control Cables NA
3. Cable Glands – Type Material
- Motor FLS-Double Compression, Ni-Cd Plated
- Space Heater FLS-Double Compression, Ni-Cd Plated
- Control Cables FLS – Double Compression Ni-Cd Plated
J. PAINTING
TYPE Epoxy
SHADE (AS PER IS:5) 692 (Smoke Grey)

Note: Certificate from Compressor block manufacturer towards guaranteed shaft power calculation at 450 SCMH per hour
compression (on given parameter) and from Motor manufacturer towards their KWh consumption (KWh on guaranteed
parameters) on above guaranteed shaft power to be submitted by bidders along with bid. A confirmation is required from
bidders prior to bid opening.

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 ANNEXURE – IV: LIST OF MOTORS

S.No. DESCRIPTION KW DUTY QTY.

NOTE:- Motors are in hazardous area classification Zone 1 and Zone 2. Therefore, the Motors shall be flame proof.
Vendor shall furnish the list of motor(s).

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 ANNEXURE – V: SPECIFICATIONS OF INSTRUMENTS

SPECIFICATION OF CORIOLIS MASS FLOW METER ( SUCTION )

Sl. No. PARAMETER REQUIREMENT

1. Fluid Compressed Natural Gas
2. Measuring Principle Coriolis Principle
3. Operating Pressure 250 (max.) bars and 8 (min.) bars
4. Molecular Weight 17 – 22
5. Ambient Temperature 0 – 6 OC
6. Hazardous area classification Class I, Div I, Gas Group D as per NEC or Zone1,Group IIA/ IIB as per
IS/IEC specifications
7. Range of operation

8. Accuracy ± 0.5% of indicated flow accepted (over the whole operating range on
gas)
9. Rangeabiliy for specified 50:1
accuracy (Min.)
10. Line Size 2.0 "( Flange type),300# WNRF ( Material: 316 L)

11. Pressure drop at max. flow < 0.2 Kg/cm2g

12 Repeatability ± 0.25% or better
13. Material - Tube SS 316 or Better
14. End Connection To suit the line size(2.0") , Flange connections

15 Power supply (nominal) 230±10% V, 50±2 Hz, 1 

16 Outputs (Active)
16.1. 4 – 20 mA dc Reqd.
16.2. Frequency Reqd.
16.3. RS 485 Reqd.
17 Outputs Informations 
17.1 Mass Flow rate Reqd.
17.2 Mass totalizer, non-resettable Reqd.
17.3 Temperature Reqd.
17.4 Integral Display Display all outputs with specified accuracy, programmable and
sequential with password protection, Touch screen or touch keypad
type
18 Communication MODBUS with RS485
19 Mounting Field mounting
20 Certification Hazardous area compatibility, Weather proof certification i.e. IP 67
,Material Test, Manufacturer’s certification, Custody Transfer approval,
AGA 11 Conformance certification and Calibration Certificate on water
and Natural Gas from accredited test labs with traceability acceptable
internationally

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 SPECIFICATION OF CORIOLIS MASS FLOW METER (DISCHARGE)

Sl. No. PARAMETER REQUIREMENT

1. Fluid Compressed Natural Gas
2. Measuring Principle Coriolis Principle
3. Operating Pressure 300 (max.) bars ,250 (Normal) bars, 100 (min.) bars
4. Molecular Weight 17 – 22
5. Ambient Temperature 0 – 60 OC
6. Hazardous area classification Class I, Div I, Gas Group D as per NEC or Zone1,Group IIA/ IIB as
per IS/IEC specifications
7. Range of operation

8. Accuracy ± 0.5% of indicated flow accepted (over the whole operating range on
gas)
9. Rangeabiliy for specified 50:1
accuracy (Min.)
10. Line Size 0.5 "( TUBE END)
11. Pressure drop at max. flow < 0.2 Kg/cm2g
12 Repeatability ± 0.25% or better
13. Material – Tube SS 316 or Better
14. End Connection To suit the line size(0.5")

15 Power supply (nominal) 230±10% V, 50±2 Hz, 1 

16 Outputs (Active)
16.1. 4 – 20 mA dc Reqd.
16.2. Frequency Reqd.
16.3. RS 485 Reqd.
17 Outputs Information 
17.1 Mass Flow rate Reqd.
17.2 Mass totalizer, non-resettable Reqd.
17.3 Temperature Reqd.
17.4 Integral Display Display all outputs with specified accuracy, programmable and
sequential with password protection, Touch screen or touch keypad
type
18 Communication MODBUS with RS485
19 Mounting Field mounting
20 Certification Hazardous area compatibility, Weather proof certification i.e. IP 67
,Material Test, Manufacturer’s certification, Custody Transfer
approval, AGA 11 Conformance certification and Calibration
Certificate on water and Natural Gas from accredited test labs with
traceability acceptable internationally

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Booster Compressors for CGD Project
 SPECIFICATION SHEET FOR FLAME DETECTORS

Flame detector Type: UV and IR Detector

Wave Length UV radiation over the range of 185 to 260 nanometers (1850 to 2600 angstroms)
IR radiation in the 4.35 micron range
Field of View 120° cone of vision (or) Better.
Approved Performance Specification-50 feet (15.2m) distance for a 1 sq. ft (0.092m2)
Sensitivity
heptane fire.
Response Time: Less than 5 seconds
Status Indicator: LEDs indicate status of Healthy, fault, and alarm conditions
Operating Medium Natural Gas.
Nominal supply voltage: 24 VDC
Supply voltage range: 20 to 36 VDC
Maximum supply current: 400 mA during COPM only
Typical current: 80 to 150 mA Depend on relays ETC
Maximum output signal load: 600 Ohms
Electrical Specifications [OUTPUT: mA, Relay, Hart ]
(all 3 below mentioned outputs must be available in separate connectors/ ports)
1. Analog (mA):
Output signal range: 0 to 20 mA *
FAULT signal: 0 to 0.2 mA *
COPM fault signal: 2.0 ± 0.2 mA *
Ready signal: 4.0± 0.2 Ma
IR only signal: 8.0 ± 0.2 Ma
UV only signal : 12.0 ±0.2 mA
WARN signal: 16.0 ±0.2 Ma
ALARM signal: 20.0 ± 0.2 mA
Fire relay (alarm)- Both Contact output NO and NC required.
2.Relay Contacts: (Alarm, Fault and
Fault relay - Contact output NO and NC required.
Auxiliary)
Contact rating 30 VDC, 2 A or 125 VAC, 1 A
3. HART
Protocol HART protocol
External HART Port connector (without opening of Housing cover of Flame Detector)
is required in transmitter for calibration and parameter accessing.
As the detector shall be vibrations arising mounted inside CNG compressor canopy,
Vibration
the same shall be capable of withstanding from compressor.
Approvals ( sensor, Transmitter and
CCOE,CSA, FM, ATEX, HART Registered, and AMS Aware
Terminal box / Junction Box)
Class 1, Div 1, groups B, C, and D (-40°C to +65°C),Type 4X, Exd iic,T5
CCOE CCOE approval Must
IP54
Reliability IEC 61508
AMS Aware: Certified by AMS
RFI/EMI Protection: Complies with EN 50130-4, EN 61000-6-4
four year warranty against sensor and electronics for the supplied product.
WARRANTY
ONSITE SERVICE TO BE PROVIDED DURING WARRANTY PERIOD
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Booster Compressors for CGD Project
 Housing: Anodized aluminum with powder coated finish or equivalent (Explosion
proof enclosure)
Mounting: Roof mounted or wall mounted. For threaded type detectors suitable
termination box (approved for use inside hazardous area) shall be provided.
ACCESSORIES The detector shall be supplied with suitable Sunshade/ Deluge protection, Strombaffle,
Weather protection, Dust barrier, Gassing Cap, etc as applicable protection against
dust particles.
.
2 No's Cable Glands(3/4" Double compression)
FLAME DETECTOR BUILT-IN
AUTOMATIC AND MANUAL TEST
TEST
False alarm sources like Arc
FLAME DETECTOR IMMUNITY
welding, X-Ray’s or hot vibrating object, lightening.
Manuals (soft and Hard Form) Operation, Maintenance, Calibration and Troubleshooting
Software or additional device, cables required for calibration or troubleshooting of
Software (soft and Hard Form)
instrument shall be supplied free of cost with instrument.
FLAME DETECTOR must be inbuilt or else calibration device must be supplied along with FD at free of
CALIBRATION cost.
(BOTH ZERO AND SPAN) FOR THE MODEL QUOTED TO BE PROVIDED IN
CALIBRATION PROCEDURE
DETAIL

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Booster Compressors for CGD Project
 SPECIFICATION SHEET FOR GAS DETECTORS

Type Infrared sensor with Transmitter, with Local Display or Indicator

Measurement
0-100% LEL
Range
Operating Medium Natural Gas.
Operational and
Certified 65 °C Maximum
Temperature Range
Power Supply 18 to 32Vdc(24Vdc nominal)
Power
< 4.5W max
Consumption
Current Demand < 235 mA at 18V
< 190 mA at 24V
< 155 mA at 32V
Output Signals :- mA, Relay, Hart
(all 3 below mentioned outputs must be available in separate connectors/ ports)

1.Analog (mA): 4-20mA,Non-Isolated,Current Source or Sink.(Default Configuration is Current Source).

Maximum 4-20mA
600 Ohms
Loop Resistance
Measuring Range (0-
4-20 mA
100% FSD)
Inhibit 1 to 3mA(Default 2mA)
Warning 0 to 6mA(Default 3mA)
Fault 0mA
Over-Range 20 to 21.5mA(Default 21 mA)
Relay output: (High alarm, Low alarm,Trip, Fault)
2.Contact output:
Contact rating: 2 A, 230 VAC/24 VDC
3. HART
protocol HART protocol
External HART Port connector (without opening of Housing cover of Gas Detector) is required in
transmitter for calibration and parameter accessing.
Status indication: LED indication OR Local Display. Separate indication for No gas leak, Low alarm,
Status Indicator:
High alarm, optics failure and calibration in progress shall be available
As the detector shall be vibrations arising mounted inside CNG compressor canopy, the same shall be
Vibration
capable of withstanding from compressor.
Accuracy ± 5 % LEL through-out the range
Response Time Less than 5 seconds

Housing: Anodized aluminum with powder coated finish or equivalent (Explosion proof enclosure)
Mounting: Roof mounted or wall mounted. For threaded type detectors suitable termination box
(approved for use inside hazardous area) shall be provided.
ACCESSORIES The detector shall be supplied with suitable Sunshade/ Deluge protection, Strombaffle, Weather
protection, Dust barrier, Gassing Cap, etc. as applicable protection against dust particles.

2 No's Cable Glands(3/4" Double compression)

4 year warranty against sensor and electronics for the supplied product.
WARRANTY
Onsite Service To Be Provided During Warranty Period
Safety Approval /
For both sensor, Transmitter and Terminal box / Junction Box
Certificate

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Booster Compressors for CGD Project
ATEX/UT/UT/CSA/F ATEX: BAS992259X II 2GD EEx d IIC T100°C (Tamb -40°C to +55°C) T135°C (Tamb -40°C to
M/CCOE +65°C)
UL / CSA Class 1, Div 1, groups B, C, and D (-40°C to +65°C) GOST and SAA
CE,IEC,EEC,EMC, CENELEC AND Eexd.
IP66/67, NEMA 4
CCOE CCOE approval Must
Performance
EN61779 EXAM, BVS 03 ATEX G 016 X, CSA,FM C22.2 152
Approval
EMC COMPLIANCE
EN 50270 ; EN 50271
SOFTWARE
Manuals (soft and
Operation, Maintenance, Calibration and Troubleshooting
Hard Form)
Software (soft and Software or additional device, cables required for calibration or troubleshooting of instrument shall be
Hard Form) supplied free of cost with instrument.
GAS DETECTOR
must be inbuilt or else calibration device must be supplied along with GD at free of cost.
CALIBRATION
CALIBRATION
(BOTH ZERO AND SPAN) FOR THE MODEL QUOTED TO BE PROVIDED IN DETAIL
PROCEDURE

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 48 of 81

Booster Compressors for CGD Project
 SPECIFICATION FOR KWH METER

1 Meter type 3Phase 4 wire Static Energy meter

2 Accuracy class 0.5 S as per IS14697
3 Connection Transformer Operated
4 Rated Voltage 240V(P-N), 415V(P-P) ± 10%
5 Rated Basic current 5A
6 Rated maximum current 10A
7 Rated Frequency 50 HZ
8 Power Factor range Zero lag- Unity- Zero lead
9 Standards compliance IS 14697, IEC 62052-11, IEC 62053-21, IS 15959

10 Calibration Meter shall be calibrated at factory and no modifications should be

permissible
a. Meter serial number
b. Date and time
c. Cumulative forwarded active energy
11 Energy Audit Data d. Cumulative reactive energy - Lag
e. Cumulative reactive energy - Lead
f. Cumulative forwarded apparent energy
g. Cumulative Maximum Demand in kW and kVA with date and time
Metering should be 2 quardrant lag only and programmed
12 Metering philosophy
accordingly
a. LCD test
b. Date
c. Time
d. Cumulative Active Energy
e. Cumulative Apparent Energy
f. Cumulative Reactive Energy – Lag
g. Cumulative Reactive Energy – Lead
h. Active Maximum demand with date and time
i. Apparent Maximum demand with date and time
j. Active load
k. Reactive load
13 Auto/Manual Scroll mode
l. Apparent load
m. Phase wise power factor
n. Average power factor
o. R phase voltage
p. Y phase voltage
q. B phase voltage
r. R phase current (line)
s. Y phase current (line)
t. B phase current (line)
u. Instantaneous average power factor with sign for lag/lead
v. Frequency reading
Meter should store and display maximum demand in kW/kVA with date
14 Maximum demand Registration and time. Demand integration period should be 30 minutes. It is
preferred that MD is computed using separate counter rather than by
difference of initial and final energy counter.
Auto Reset of Maximum
15 Meter should reset to zero and date should be customisable date
Demand

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Booster Compressors for CGD Project
 SPECIFICATIONS FOR DISCHARGE FILTER

SUPER FINE FILTER (Coalescing

Filter)

Super fine filter for removal of liquid (e.g. water & oil )and solid particles down to 0.01 microns out of compressed
natural gas

Residual Oil Contents less than 0.01 mg/m3.

Filter Designed :
Paint Compatible
CE mark in accordance with European Directive for Pressure
Equipment, PED ( 97 / 23 / EC )
Are Designed to meet the ATEX European Directive for Explosion
Protection , ( 94 / 9 / EC)
All natural gas filters in accordance to CE Eex 2GD IIB T6.

Standard equipment:
Complete filter including manual drain.

Specification Filter Elements.

Filter Fabric : Borosilicate Microfibre Fabric coated with polypropylene homopolymer support - fabric.

Drainage Layer: Parafil - Fibre fabric incorporated in the filter fabric.( Without Foam Sock)

Rib Mesh : Stainless Steel VA 1.4306

Temperature : + 1 ° C to + 80 ° C
Direction Of Flow : From Inside to Outside.

NOTE : Bidder to get the inspection done by TPIA accordance with European Directive for Pressure
Equipment, PED (97 / 23 / EC ) if CE marks are not available.

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 50 of 81

Booster Compressors for CGD Project
 ANNEXURE – VI: VENDOR LIST

Item code / Description AIR FILTER REGULATORS

VENDOR NAME Remark
ASEA BROWN BOVERI LTD.
BLUE STAR LTD
DIVYA CONTROL ELEMENTS PVT. LTD.
PLACKA INSTRUMENTS & CONTROLS PVT. LTD
SHAH PNEUMATICS
SHAVO NORGREN (I) PVT. LTD
VELJAN HYDRAIR PVT. LTD.
PARKER
SWAGELOK
VANAZ ENGINEERS LIMITED
ITEM CODE / DESCRIPTION FIELD INSTRUMENTS (P, DP, F,L,T)
VENDOR NAME REMARKS
ABB AUTOMATION LTD.
ASHCROFT
MURPHY
CCS
WAREE
FISHER ROSEMOUNT INDIA LIMITED
FUJI ELECTRIC CO. LTD.
HONEYWELL INC.
TATA HONEYWELL
YOKOGAWA ELECTRIC CORPORATION
YOKOGAWA BLUE STAR LTD.
WIKA
DRUCK
BEKO
ITEM CODE / DESCRIPTION PRESSUREGAUGES
VENDOR NAME REMARKS
AN INSTRUMENTS PVT. LTD.
BADOTHERM PROCESS INSTRUMENTS B. V.
BOURDON HAENNI S.A
BRITISH ROTOTHERM CO. LTD
BUDENBERG GUAGE CO. LTD.
DRESSER INC.
GENERAL INSTRUMENTS CONSORTIUM
MANOMETER (INDIA) PVT. LTD.
NAGANO KEIKI SEISAKUSHO LTD.
WAAREE INSTRUMENTS LIMITED

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 51 of 81

Booster Compressors for CGD Project
BAUMER
WALCHANDNAGER INDUSTRIES LTD.
WIKA ALEXANDER WIEGAND & CO GMBH
WIKA INSTRUMENTS INDIA PVT. LTD.
DRUCK
ASHCROFT
ITEM CODE / DESCRIPTION TEMPERATURE GAUGES
VENDOR NAME REMARKS
AN INSTRUMENTS PVT. LTD.
GENERAL INSTRUMENTS LTD
WIKA
ASCHCROFT
BAUMER
ITEM CODE / DESCRIPTION PRESSURE RELIEF/SAFETY VALVE
VENDOR NAME REMARKS
ALSTHOM FLUIDS SAPAG
ANDERSON GREENWOOD CROSBY
BHEL (TRICHY )
ASPRO
DRESSER INC.
FUKUI SEISAKUSHO CO. LTD.
INSTRUMENTATION LTD. (PALGHAT)
NAKAKITA SEISAKUSHO CO LTD.
NUOVO PIGNONE SPA (ITALY)
PARCOL SPA
SAFETY SYSTEMS UR LTD.
SARASIN RSBD
SEBIN VALVES INDIA PVT. LTD.
TAI MILANO SPA
TYCO SANMAR LTD.
TYCO VALVES & CONTROLS INDIA PVT. LTD
FARINOSLA
FAINGER LASER
MERCER
FISHER ROSEMOUNT (EMERSON)
OFE & OE GROUP KEYSTONE VALVES PVT. LTD
BARODA SEBIM VALVES PVT. LTD. HALOL

ITEM CODE / DESCRIPTION SUCTION & DISCHARGE FILTER

VENDOR NAME REMARKS
BEKO FILTER
ULTRA FILTER

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Booster Compressors for CGD Project
 ITEM CODE / DESCRIPTION VIBRATION SWITCH
VENDOR NAME REMARKS
MURPHY
METRIX
ROBERTSHAW CONTROL
ITEM CODE / DESCRIPTION CARTRIDGE FILTERS
VENDOR NAME REMARKS
BEKO FILTER
ULTRA FILTER
FILTRATION TECHNIQUES
ZANDER GMBH (GERMANY)
GRAND PRIX FAB (PVT.) LTD., NEW DELHI
MULTITEX FILTRATION ENERGY PVT. LTD.,
ITEM CODE / DESCRIPTION AIR COMPRESSOR
VENDOR NAME REMARKS
INGERSOL RAND (IR)
ELGI
ANESTA IWATA MOTHERSON
ITEM CODE / DESCRIPTION SELF ACTUATED PR. CONTROL VALVE
VENDOR NAME REMARK
DANIEL INDUSTRIES INC
DRESSER PRODUITS INDUSTRIES
ASPRO
ESME VALVES LTD.
FISHER ROSEMOUNT SINGAPORE PTE LTD.
FISHER EXMOX SANMAR LIMTED
GORTER CONTROLS B.V.
INSTROMET INTERNATIONAL NV
KEYE & MACDONALD INC
NUOVO PIGNONE SPA (ITALY)
PIETRO FIORENTINI SPA
RICHARDS INDUSTRIES (FORMERLY TRELOAR)
RMG REGEL + MESSTECHNIK GMBH
VANAZ
NIRMAL INDUSTRIES LIMITED
ITEM CODE / DESCRIPTION SOLENOID VALVES/ACTUATOR
VENDOR NAME REMARK
ALCON ALEXANDER CONTROLS LIMITED
ASCO (INDIA) LIMITED
JEFFERSONS
ASCO JOUCOMATIC LTD.

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 53 of 81

Booster Compressors for CGD Project
ASCO JOUCOMATIC SA
AVCON CONTROLS PVT. LTD.
BARKSDALE INC.
BLUE STAR LTD.
HERION WERKE
SCHRADER SCOVILL DUNCAN LIMITED
ROTEX AUTOMATION LIMITED
OPERATED VALVES ASCO
PARKER HANIFEN
HABONIM VASS
FESTO
ITEM CODE /DESCRIPTION SPECIAL CONTROL VALVES
VENDOR NAME REMARK
FISHER ROSEMOUNT SIGAPORE PTE. LTD.
FLOWSERVE PTE. LTD. (FORMERLY DURIRON)
HOPKINSONS LIMITED
METSO AUTOMATION PTE LTD. (FORMERLY NELES)
NUOVO PIGNONE SPA (ITALY)
SPX VALVES & CONTROLS (FORMERLY DEXURIK)
ITEM CODE /DESCRIPTION FLAME DETECTOR/SURGE PROTECTORS
MAKE REMARK
MEGGITT AVIONICS
GENERAL MONITORS/ MSA
SPECTREX
DETRONICS
HONEYWELL
NET SAFETY
CROW ON
SIEGER
ISOLATORS
BARRIERS
ITEM CODE /DESCRIPTION GAS DETECTOR (IR TYPE)
MAKE REMARK
DETRONICS
SENSITRON
HONEYWELL
NET SAFETY
GENERAL MONITORS/ MSA
CROW ON
SIEGER
ITEM CODE /DESCRIPTION PLC
MAKE REMARK
Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 54 of 81
Booster Compressors for CGD Project
SIEMENS
SCHNEIDER
ALLAN BRADLEY, ROCKWELL
ROCKWELL AUTOMATION
LHP
ABB
ITEM CODE /DESCRIPTION COMPRESSOR MAIN MOTOR
MAKE REMARK
CROMPTON GREAVES
SIEMENS
WEG
ABB
LHP
KIRLOSKAR
BHARAT BIJLEE
ITEM CODE /DESCRIPTION MAIN MOTOR VFD STARTER
MAKE REMARK
SIEMENS
SCHNIEIDER
FUJI
ABB
ITEM CODE /DESCRIPTION SOFT STARTER
MAKE REMARK
SIEMENS
SCHNEIDER
ABB
FUJI
ITEM CODE /DESCRIPTION CO2 CYLINDER VALVE WITH ACTUATOR
FOR CO2 FLODDING SYSTEM
MAKE REMARK
GINGEKERR
CEODUEX (ROTAREX)
KIDDE
FIKE
ANSUL
LPG
VTI
ITEM CODE / DESCRIPTION SS TUBING
VENDOR NAME REMARK
SANDVIK
FAE

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Booster Compressors for CGD Project
TUBACEX (SCHOELLER-BLECKMNN)
PARKER
RATNAMANI
ITEM CODE / DESCRIPTION SS FITTINGS & VALVES
VENDOR NAME REMARK
SWAGELOK
PARKER
ABAC
VOSS
SSP
ITEM CODE / DESCRIPTION HOSES
VENDOR NAME REMARK
SWAGELOK
PARKER
PARKER
SYNFLEX
ITEM CODE / DESCRIPTION BREAKAWAY COUPLING
VENDOR NAME REMARK
OPW
STAUBLI
OASIS
OASIS
ITEM CODE / DESCRIPTION MASS FLOW METERS
VENDOR NAME REMARK
EMERSON PROCESS MANAGEMENT CORIOLIS TYPE
ENDRESS & HAUSER CMBH & COMPANY
ITEM CODE / DESCRIPTION FLP SWITCH
VENDOR NAME VENDOR NAME
BALIGA
FCG
FPE
FLEXPRO
ITEM CODE / DESCRIPTION SWITCHES/FUSES/CONTRACTORS
VENDOR NAME REMARK
L&T
GEC
SIEMENS
ITEM CODE / DESCRIPTION CABLES & WIRES
VENDOR NAME REMARK
INCAB
UNIVERSAL

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 56 of 81

Booster Compressors for CGD Project
ASEAN
CCI
FORT GLOSTER
FINOLEX
KEI
POLYCAB
HAVELLS
ITEM CODE / DESCRIPTION PRESSURE TRANSMITTERS
VENDOR NAME REMARK
DRUCK
WIKA
HONEY WELL
ABB
ROSMOUNT
WAREE
ITEM CODE / DESCRIPTION RTDs
VENDOR NAME REMARK
GENERAL INSTRUMENTS PVT LTD
NAGMAN SENSORS PVT LTD
PYRO ELECTRIC
WIKA
SIEMENS
BAUMER
ITEM CODE / DESCRIPTION PLUG VALVE
VENDOR NAME REMARK
AIR & NORDSTROM VALVES INC
SERCK AUDCO VALVES
SUMITOMO CORPORATION
FISHER XOMOX SANMAR
L&T (AUDCO INDIA LTD, CHENNAI)
ITEM CODE / DESCRIPTION ON OFF BALL/NEEDLE VALVE
VENDOR NAME REMARK
PARKER
SWAGELOK
ABAC
SPIRAX SARCO
WORCESTER
ITEM CODE / DESCRIPTION PRESSURE & TEMPERATURE SWITCH
VENDOR NAME REMARK
INFOS
SWITZER
CCS
Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 57 of 81
Booster Compressors for CGD Project
 Notes:

1. Above vendor list is indicative only and any other vendor(s) apart from as mentioned above may be accepted subject to
approval by Owner/Owners representative based on past track record. / credentials. However no relaxation or advantage in
delivery period will be given to the successful bidder on account of this approval.

2. For the vendors of items not covered in above vendor list, but required for completion of project successfully, supplier shall
take approval form Owner/Owners representative for the same during project execution. Bidder shall submit the required
certifications, documents, PTR and Performance letters from clients for the same.

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 58 of 81

Booster Compressors for CGD Project
 ANNEXURE – VII : VENDOR DATA REQUIRED

CERTIFIED INFORMATION REQUIRED

S. PRINTS AFTER PURCHASE ORDER
DESCRIPTION
NO WITH BID
FOR REVIEW FOR RECORDS
A GENERAL
1 PROJECT SCHEDULE YES
2 DULY FILLED-IN “CHECKLIST FOR YES
COMPLETENESS OF BID”
3 DULY FILLED-IN “CHECKLIST FOR YES
SCOPE OF SUPPLY”
4 DEVIATION LIST (IF ANY) TO THE YES
APPLICABLE SPEC., DATASHEETS
5 UTILITIES REQUIREMENT SUMMARY YES YES
6 FLANGE DETAILS OF PIPING YES
CONNECTION WITH CONNECTION AT
BATTERY LIMIT
7 DULY FILLED IN EXPERIENCE YES
RECORD PROFORMA
8 GUARANTEE PARAMETERS AS YES YES
SPECIFIED
9 TENTATIVE LOAD DATA FOR YES
FOUNDATION DESIGN
10 LIST OF SUB-VENDORS FOR ALL YES
BOUGHT OUT ITEMS INCLUDING
ELECTRICAL & INSTRUMENTATION
ITEMS
11 LEAFLET, CATALOGUES FOR ALL YES YES
ITEMS
12 O & M MANUAL YES
B COMPRESSOR
1 DATASHEETS FOR THE FOLLOWING YES YES
A - COMPRESSOR YES YES
B - HEAT EXCHANGERS YES YES
C - PRESSURE VESSELS YES YES
D - ELECTRIC MOTOR YES YES
2 CATALOGUE FOR COMPRESSOR YES YES
3 TYPICAL CROSS SECTIONAL YES
DRAWING AND LITERATURE TO
FULLY DESCRIBE THE DETAILS OF
OFFERING
A - COMPRESSOR YES
B - SUCTION VALVE YES
C - DISCHARGE VALVE YES
D - PISTON ROD GLAND PACKING & YES
PISTON RINGS

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Booster Compressors for CGD Project
 CERTIFIED INFORMATION REQUIRED
S. PRINTS AFTER PURCHASE ORDER
DESCRIPTION
NO WITH BID
FOR REVIEW FOR RECORDS
E - LUBE OIL PUMP YES
4 V-BELT & PULLEY WITH SELECTION YES
CHART & CALCULATION
5 COOLER DATA / DRG WITH YES
THERMAL & MECH DESIGN
CALCULATION
6 DESIGN CALCULATION, GA DRGS YES
FOR PULSATION DAMPNER
7 PIPING & INSTRUMENTATION YES YES
DIAGRAMS FOR THE FOLLOWING
A - PROCESS GAS YES YES
B - LUBE OIL YES YES
C - COOLING WATER YES YES
8 TORQUE ANGLE DIAGRAM, PISTON YES
ROD LOAD VS CRANK ANGLE
9 TORQUE SPEED CHARACTERISTICS YES
10 ACOUSTIC / MECHANICAL YES
EVALUATION REPORT
11 ITEMIZED PRICE LIST OF ESSENTIAL YES YES
SPARES
12 ITEM LIST OF SPARES WITH PRICE YES YES
FOR 5 YEARS
13 DRG. FOR TESTING ARRANGEMENT YES
& TEST PROCEDURE TO BE ADOPTED
14 CERTIFICATE FOR FOLLOWING: YES
A HYDRAULIC TESTING YES
B NON DESTRUCTIVE TESTING YES
C MATERIAL COMPOSITION & YES
PHYSICAL PROPERTIES
D LEAK PROOFNESS TEST OF FRAME YES
E LUBE PUMP, FRAME OIL PUMP, HYD YES
OIL PUMP
15 DESIGN / ACTUAL ASSEMBLY YES
CLEARANCE CHART
16 TEST RECORDS OF FOLLOWING
A MECHANICAL RUNNING S YES
B PERFORMANCE TEST / PACKAGE YES
TEST
C NOISE LEVEL TEST YES YES
17 LIST OF SPECIAL TOOLS & TACKLES YES YES
FOR INSTALLATION &
MAINTENANCE

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 60 of 81

Booster Compressors for CGD Project
 CERTIFIED INFORMATION REQUIRED
S. PRINTS AFTER PURCHASE ORDER
DESCRIPTION
NO WITH BID
FOR REVIEW FOR RECORDS
C ELECTRIC MOTOR
1 MOTOR DATA SHEET YES YES
2 TECHNICAL LITERATURE / YES YES YES
CATALOGUE, SELECTION CHARTS,
NOMOGRAPHS ETC.
3 GA DRAWING YES YES
4 TERMINAL BOX ARRANGEMENT YES
DRAWING
5 MOTOR CHARACTERISTIC CURVES YES
6 TORQUE SPEED CURVES YES
7 CURRENT TIME CURVES YES
8 P.F AND EFFICIENCY YES
9 TYPE TEST CERTIFICATES YES
10 CERTIFICATE FROM THE RELEVANT YES
STATUTORY AUTHORITY (BASED ON
THE COUNTRY OF MANUFACTURE)
FOR SUITABILITY OF THE OFFERED
MOTOR FOR INSTALLATION IN THE
SPECIFIED AREA CLASSIFICATION
11 PRE-COMMISSIONING AND YES
COMMISSIONING PROCEDURE
D INSTRUMENTATION
1 G.A. OF INSTRUMENT PANEL WITH YES
BILL OF MATERIAL & WIRING DIG.
FOR LCP
2 INSTRUMENT DATASHEET YES
3 LOGIC DIAGRAM / LADDER YES
DIAGRAM / FUNCTIONAL DIAGRAM
4 LOOP SCHEMATIC YES
5 INTER CONNECTING DIAGRAM YES
6 OPERATING / CONTROL WRITE UP YES
7 ALARM / SHUT DOWN LIST7 YES
8 WIRING DIAGRAM / INTER YES
CONNECTING PIPING
9 START UP AND SHUT DOWN WRITE YES YES
UP
10 START UP AND SHUT DOWN INLET YES YES
LOCK DIAGRAM
11 ALARM AND SHUTDOWN LIST WITH YES YES
SET POINT
12 LOAD CONTROL PANEL LAYOUT YES
13 TERMINATION DIAGRAM, PANEL YES

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 61 of 81

Booster Compressors for CGD Project
 CERTIFIED INFORMATION REQUIRED
S. PRINTS AFTER PURCHASE ORDER
DESCRIPTION
NO WITH BID
FOR REVIEW FOR RECORDS
WIRING DETAIL
14 LOOP SCHEMATIC YES
15 INTER CONNECTING DIAGRAM YES
16 CABLE SCHEMATIC YES
17 BILL OF MATERIAL YES
18 TEST / INSPECTION CERTIFICATE YES
19 LIST OF RELIEF VALVES WITH YES
SETTINGS
20 CERTIFICATE FROM THE RELEVANT YES
STATUTORY AUTHORITY (BASED ON
THE COUNTRY OF MANUFACTURE)
FOR SUITABILITY OF THE OFFERED
INSTRUMENTS FOR INSTALLATION
IN THE SPECIFIED AREA
CLASSIFICATION

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 62 of 81

Booster Compressors for CGD Project
 ANNEXURE – VIII: DEVIATION SCHEDULE FOR ELECTRIC MOTOR DRIVEN 450 SCMH
HYDRAULIC BOOSTER COMPRESSOR

Vendor:
Vendor to specify Specification number and clause Description of Deviation and give reasons in
S.No.
number against which Deviation is sought support of Deviation

-------------NO DEVIATION --------------------------- -------------NO DEVIATION ------------------

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 63 of 81

Booster Compressors for CGD Project
 ANNEXURE – IX
DELETED

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 64 of 81

Booster Compressors for CGD Project
 ANNEXURE –X: EXPERIENCE PROFORMA RECORD

A) EXPERIENCE RECORD PROFORMA FOR ELECTRIC MOTOR DRIVEN 450 SCMH HYDRAULIC
BOOSTER COMPRESSOR PACKAGE
INFORMATION OFFERED INFORMATION OF
SR. NO DESCRIPTION
COMPRESSOR EXISTING COMPRESSOR

Min.: 450SCMH
REQUIREMENT AS PER TENDER

1 Status of bidder
a) Compressor manufacturer
b) Electric Motor manufacturer
c) Packager
2 COMPRESSOR
Name of compressor manufacturer
Place of compressor manufacturer
Compressor model
Anticipated Life in running hours
Compressor max frame BKW
Comp Manufacturing code
Lubricated or non lubricated
Nos of stages
Max stage temperature oC (150oC )
Compressor max RPM
Compressor operating RPM
Piston speed m/s
Vibrations at comp cylinders <10 mm /
sec. Unfiltered peak velocity Vibration
comp frame : Unfiltered peak velocity of
5 mm/sec or 200 micron unfiltered peak
to peak vibration whichever is less
Material for all stages
Cylinder (C.S)
Piston Rings (PTFE)
Rider Rings (PTFE)
Piston Rod (Forged steel)
Valve (Rings / plates / spring) :
(SS/SS/SS)

3 PERFORMANCE OF COMPRESSOR

GUARANTEED POINT:
Average Flow capacity (overfull range of
A suction pressure from 30 barg to 200 barg
varying on continuous basis)

Minimum Flow capacity corresponding to

B
suction pressure of 200 to 30 kg/cm2

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 65 of 81

Booster Compressors for CGD Project
 A) EXPERIENCE RECORD PROFORMA FOR ELECTRIC MOTOR DRIVEN 450 SCMH HYDRAULIC
BOOSTER COMPRESSOR PACKAGE
INFORMATION OFFERED INFORMATION OF
SR. NO DESCRIPTION
COMPRESSOR EXISTING COMPRESSOR

Min.: 450SCMH
REQUIREMENT AS PER TENDER

BKW required by compressor including

C
compressor’s lube oil pump BKW
Power required for all fans including
D
radiator fan in Kw

Ventilation fans for enclosure

E No of fans
Type of fans (included or forced draft)

Site Capacity of Motor (max of “B+D”

F
above) * 1.1

Piston rod and cross head pin loading at

any specified operating condition
including the relief valve set condition
shall not exceed 80% of the maximum
design rod load of the offered compressor
---- Piston rod : max design
--- Piston rod: calculated at safety set pr
condition
--- Max cross head pin loading: Design ‘
--- Cross head pin loading: calculated at
safety set pr condition

Guaranteed gas loss through rod deals;

sm3/h

Other information of compressor

a) Year of manufacturing of the
compressor
b) Name and address of user with FAX
no, phone no, E-mail address
c) Nos of hours the compressor have
clocked on bid due date (Enclose
certificate from user)
4 ELECTRIC MOTOR
Make
Model
Rating
Speed

5 PACKAGE

Name of Packager

Place of Packaging

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 66 of 81

Booster Compressors for CGD Project
 A) EXPERIENCE RECORD PROFORMA FOR ELECTRIC MOTOR DRIVEN 450 SCMH HYDRAULIC
BOOSTER COMPRESSOR PACKAGE
INFORMATION OFFERED INFORMATION OF
SR. NO DESCRIPTION
COMPRESSOR EXISTING COMPRESSOR

Min.: 450SCMH
REQUIREMENT AS PER TENDER

Name of Enclosure Manufacturer

Palace of enclosure manufacturer

Sound level at 1 m distance from package

in db (A) 75
Skid size (LxBxH)
Skid Gross Weight (Comp. + Motor +
Aux.) Kg
Make and model LEL detector – 1 no.
each comp
Make and model fire detector – 1 no. each
comp
2 nos. min CO2 cylinder with online
weight monitoring.
Volume of enclosure in m3
Nos. of explosion proof tube light in each
enclosure
Coupling Direct / V – belt

Other information of complete package

a) Year and place of manufacturing of the
package

b) Name and address of user with FAX

no, phone no, E-mail address

c) Nos of hours the complete package

have clocked on bid date (enclose
certificate from user)
7 Gas recovery system
Gas recovery system with pr relief valve,
pr regulator, pr gauge, manual &
automatic drainage system

8 Gas Delivery system

High pr piping with SS 316, tubing,
compression fittings, NRV
KOD

Coalescent filter
PLC based Priority panel with full bore
ball valve

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 67 of 81

Booster Compressors for CGD Project
 A) EXPERIENCE RECORD PROFORMA FOR ELECTRIC MOTOR DRIVEN 450 SCMH HYDRAULIC
BOOSTER COMPRESSOR PACKAGE
INFORMATION OFFERED INFORMATION OF
SR. NO DESCRIPTION
COMPRESSOR EXISTING COMPRESSOR

Min.: 450SCMH
REQUIREMENT AS PER TENDER

Final gas outlet connection from priority

panel 3/4” SS valves and 1” OD SS
compression fittings
9 ESD system
Volume bottles / dampers at each
10
compressor stage of compressor
Vessels

Drainage system

11 Manual double isolation valve

12 Automatic valves

13 Heat exchanger

14 Code of construction API 661

Gas sections of coolers shall be as per
15
API – 618
16 Tube material
Piping between stages shall be continuous
17
with flange connection
Other tubing shall be SS 304/ 316 as per
18
TS.
19 Gas recovery vessel provided
Area classification; “ class 1, group D,
20 division 1 as per NEC “ OR “ Zone 1,
group IIA / IIB as per IS/IEC”
21 The size of the complete package

25 Instrumentation as indicated in TS

Cabling – Double compression type cable

30
glands and copper lugs

31 Junction box with metallic enclosure

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 68 of 81

Booster Compressors for CGD Project
 ANNEXURE – XI: PARAMETERS FOR SCADA

Parameters required for SCADA

We want to monitor / control all parameters available on the PLC through SCADA system.
Hardware Details: Connector Type, Communication Standard, Communication port Pin details,
Communication Port Configuration: Baud Rate, data bits, stop bit, parity
Polling Constraints: Minimum time period between two consecutive poll cycles.
Protocol Details: Protocol name and message structure for different read / write functions.
Function codes for reading digital and Analog inputs
Function code for writing analog values in the IED registers
List of parameters available in the IED which can be accessed from the IED through serial port.
Register address of each parameter in the IED.
A Sample of the details is given below for understanding:

PROTOCOL DETAILS:

Sr.No. Description Content/Details

1 Protocol MODBUS RTU
2 Connection Type FCC –68 RJ45
3 Communication standard RS485
4 Signals supplied Tx, Rx, GND
5 Baud Rate(Speed) 300, 600,1200,4800,9600,19200
6 Format Software configurable
7 Port Configuration Speed : 19,200 bps
Data Bits : 8 Bits
Stop Bit : 1 Bit
Parity : None
8 Min. Time period between 2 Sec.
consecutive Query

 Function Code & Message Structure:

Function Code: 3 – Read Output Register
Poll Format:
Address 1 Byte
Function 1 Byte
Start Item 2 Byte

No. Item 2 Byte

Response Format:
Address 1 Byte
Function 1 Byte
Length 1 Byte
Date Item 1 4 Byte
Date Item n 4 Byte

 Function Code & Message Structure:

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 69 of 81

Booster Compressors for CGD Project
 Function Code: 2 – Read Input Status
Poll Format:
Address 1 Byte
Function 1 Byte
Start Item 2 Byte

No. Item 2 Byte

Response Format:
Address 1 Byte
Function 1 Byte
Length 1 Byte
Date Item 1 2 Byte
Date Item n 2 Byte

Memory Mapping, Data Type & Parameter Information:

A. Digital Parameters :

Sr. No. Description Address

1 Flow computer malfunction Alarm 8247
2 Mass Flow Low alarm 8245
3 Mass Flow High alarm 8246

B) Analog Parameters:

Parameter Register details

Engineering Register
GC Register
Range and Unit Format
Density Kg/m3 8655-56 Float
(500-600)
Pressure 8657-58 Float
Temperature 8659-60 Float
Mass Flow Rate 8661-62 Float
Totalized mass flow 8663-64 Float
Yesterday’s Total Mass flow 8665-66 Float
Today’s Total Mass Flow 8667-68 Float
Corrected volumetric Flow rate 8669-70 Float
Yesterday’s Total corrected Volumetric 8671-72 Float
Flow
Totalized Mass Flow at 6 AM (Snapshot of 8673-74 Float
cumulative)

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 70 of 81

Booster Compressors for CGD Project
 TECHNICAL SPECIFICATION - 450 SCMH
ELECTRIC MOTOR DRIVEN HYDRAULIC CNG
BOOSTER COMPRESSORS

ANNEXURE – XII

QUALITY ASSURANCE PLAN

Inspection By
Quantum of Reference Acceptance Format Of Vendor TPIA Owner/ Owner's
Sr.No Description Remarks
Check Document Norms Records Representative

Hydrotest of Cylinder, Press. Vessels, Heat Technical Technical

1.1 Test Report W W W
Exchangers Specification Specification
Technical Technical
1.2 Hydrotest of Cylinder Heads Test Report W R R
Specification Specification
Leak Proof Test of Crank Case (4 Hours . with Technical Technical
1.3 Test Report W W W
Kerosene ) Refer Note :4 Specification Specification
Ultrasonic Test of - Crank Shaft, Connecting Technical Technical
1.4 Test Report R R R
Rod, Piston Rod Etc. Refer Note: 1 Specification Specification
Magnetic Particle Test of - Crank Shaft, Technical Technical
1.5 Test Report R R R
connecting Rod., Piston Rod Refer Note: 1 Specification Specification
Radiography as Applicable - Pressure Vessels,
Technical Technical
1.6 Heat Exchanger. Gas Piping (Only 10% Joints 10% Witness Test Report R W W
Specification Specification
To Be Witnessed)
Barring Over to check Cylinder End Clearance Technical Technical
1.7 Test Report W W W
And Piston Rod Runout Specification Specification
No Load Mechanical Run Test Of the Compr.
Technical Technical
1.8 with Rated (Or More) Speed And Shop Driver. Test Report W W W
Specification Specification
(4 Hrs. Min.)
Strip Check And Internal Inspection After
Technical Technical
1.9 "NLMRT" Of All Compressors Refer Note: Test Report W W W
Specification Specification
2

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 71 of 81

Booster Compressors for CGD Project
 TECHNICAL SPECIFICATION - 450 SCMH
ELECTRIC MOTOR DRIVEN HYDRAULIC CNG
BOOSTER COMPRESSORS

Electric Motor Performance Test- at Sub-

Technical Technical Performance
1.10 Vendor's Works as per ISO Std. Refer Note: R R R
Specification Specification Test Report
3
Material Test Certificates for: Crank Shaft,
Connecting Rods, Cylinder Liner, Piston Technical Technical
1.11 MTC R R R
(Compliance Cert.), Pressure Vessels, Heat Specification Specification
Exchanger
Canopy Structure Painting Inspection
At Works. Surface Preparation to be Technical Technical Inspection
1.12 W W W
Inspected after cleaning and before Specification Specification Report
application of First Coat of Primer.
Functional / HV / Continuty Test for Control Technical Technical
1.13 Test Report W W W
Panel (at Sub Vendor's Works) Specification Specification
Mechanical String Test for 4 Hours, 10% of 10% of Each Technical Technical
1.14 Test Report W W W
Package Lot for CNG Compressor Package Lot Specification Specification
Test Certificates For - Safety Switches, Safety Technical Technical
1.15 Test Certificate R R R
Relief Valves, Solenoid Valves Specification Specification
Final Mock-Up Assembly of the Package - As Technical Technical P&ID, Wiring
1.16 W R R
Per GAFD, P& I Drawings. Wiring Diagram Specification Specification Diagram
Performance Test at site at Guaranteed Technical Technical Performance
1.17 W W W
Parameters. Specification Specification Test Report
Technical Technical Field Trial run
1.18 Field Trial Run for 72 Hrs. W W W
Specification Specification report

LEGENDS : W = WITNESS, R = REVIEW OF DOCUMENTS, Y = DOC. SUBMISSION BY VENDOR / SUB-VENDOR

NOTES:
1 Crank Shaft, Connecting Rod: UT / MPT shall be conducted in either in forging-OR-in finish condition
2 Strip test is limited to open Crank Case cover, Crosshead guide & Distance piece. Cover and opening of bore & other (sails. Piston one valve per cylinder).
3 Review of manufacturer's test reports/certificates of all compressor package.
4 Witness of tests by TPIA or owner/owner’s representative.
5 Inspection of the components / assembly, shall be conducted as per standard Test Procedures.

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Booster Compressors for CGD Project
 TECHNICAL SPECIFICATION - 450 SCMH
ELECTRIC MOTOR DRIVEN HYDRAULIC CNG
BOOSTER COMPRESSORS

6 All reference codes/ Standards, documents, P.O. copes shall be arranged by vendor/ supplier for reference of Owner / Owner’s representative / TPIA at the time of inspection.
7 The owner shall submit their own detailed QAP prepared on the basis of above technical specification for approval of Owner/ Owner’s representative.

NOTE: TPIA (THIRD PARTY INSPECTION AGENCY WILL BE APPOINTED BY SUPPLIER AFTER DUE APPROVAL FROM OWNER.

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 73 of 81

Booster Compressors for CGD Project
 TECHNICAL SPECIFICATION - 450 SCMH
ELECTRIC MOTOR DRIVEN HYDRAULIC CNG
BOOSTER COMPRESSORS

ANNEXURE - XIII

DATA SHEET

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 74 of 81

Booster Compressors for CGD Project
 TECHNICAL SPECIFICATION - 450 SCMH
ELECTRIC MOTOR DRIVEN HYDRAULIC CNG
BOOSTER COMPRESSORS

DATA SHEET: MEDIUM VOLTAGE SQUIRREL CAGE INDUCTION MOTOR ELECTRICAL DESIGN
DATA

1. Motor tag no.

2. Voltage (V) 415V + 10% Phase 3 Frequency (Hz.) 50
Hz+3%
3. Fault level (KA) NOT APPLICABLE
4. Method of starting Star-Delta
5. Phase THREE Connection – No. of terminal – 6
STAR-DELTA
6. Design Ambient temp (0c) 50 0C (IN ACCOUSTIC ENCLOSURE) Temp. rise (0c) 70 0C
(Maximum)
7. Cable size (mm2) AS PER SPEC ATTACHED Type CU. COND. PVC
INS.
8. Enclosure type IP 55, Ex-d, IIA, Cooling TEFC
IIB,T3
9. Insulation class CLASS-F with temperature rise of CLASS B
10. Haz. Area classification/ Gas ZONE-1, GROUP-IIA, IIB, Temp Class T3 as per IS/IEC
Group
11. Type of explosion protection: Ex (d) Applicable standards: IS/IEC
Technical particulars from Driven equipment manufacturer
12. Suggested Motor Rating in KW/ Manufacturer #/#
13. Shaft kw/kw at end of curve #/#
14. Speed/ rotation of equipment from Coupling End #/#
15. Starting/ max. Torque required (mkg) #/#
16. WK2 of equipment including/ excluding   lywheel #/#
(kgm2)
17. Thrust up/ down (kg) #/#
18. Equipment/ coupling type #/#
19. Starting Condition-On no load/ Under loaded condition #
Technical particulars from motor manufacturer
20. Manufacturer *
21. KW Rating * No. of poles *
22. Frame designation * Mounting (Horizontal) *
23. Full load speed (Max. 1500 rpm) * Full load Torque (mkg) *
24. Starting torque as % of full load torque *
25. Full load current (A) *
26. Starting current at 100% Voltage (A) *
27. Breakdown or pull out torque % *
28. Rotation viewed from coupling end *
29. Starting time at 75%V * (sec.) Starting time at 100%V * (sec)
30. Time (Te) for increased safety motors at 100% Voltage NOT APPLICABLE
(secs.)
31. Locked rotor with stand time cold/ hot * At 100% V(sec) *
at 75% V(sec)
32. WK2 of motor (kg m2) *
33. Power factor at 100% load * Power Factor at 75% load *
34. Efficiency at 100% load * Efficiency at 75% load *
35. Space heater watts/ volts */ 240V AC
36. Bearing type/ no. DE */* Bearing type/ no. NDE */*
37. Type of Lubrication *
38. Weight of motor (kg) *
39. Canopy required/ Not required NOT REQUIRED

# TO BE FILLED BY BIDDER BASED ON THE PACKAGE DESIGN

* TO BE FILLED BY MOTOR MANUFACTURER
Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 75 of 81
Booster Compressors for CGD Project
 TECHNICAL SPECIFICATION - 450 SCMH
ELECTRIC MOTOR DRIVEN HYDRAULIC CNG
BOOSTER COMPRESSORS

Bidder must quote for only one make of motor. Bidder shall submit filled up data sheet for the selected make of motor
only.
Motor Terminal Box must be suitable for the cable size indicated on data sheet.

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 76 of 81

Booster Compressors for CGD Project
 TECHNICAL SPECIFICATION - 450 SCMH
ELECTRIC MOTOR DRIVEN HYDRAULIC CNG
BOOSTER COMPRESSORS

POWER CABLE SIZES FOR 415V MOTORS

S.No. Motor CABLE SIZE mm2 No. of CABLE DIAMETER - mm

Rating Cores (APPROX)
KW
CU AL Overall Under Over
Armour Armous
Below 3.7 4 3
KW
3.7 6 3

5.5 10 3

7.5 10 3

11.0 16 3

15.0 16 3

18.5 16 3

22.0 16 3

30.0 25 3

37.0 25 3

45.0 35 3

55.0 50 3

75.0 95 3

90.0 120 3

110.0 2x95 3

125.0 2x120 3

132.0 2x120 3

NOTES: 1. Above table is valid for 2/4/6 pole motors. For low speed motors cable sizes shall be defined at the
time of detail engineering.
2. Cable size for motor space heater shall be 3x2.5 mm2 with Cu Conductor.
3. Cables will be 650/1100V, copper conductor, FRLS-PVC insulated, FRLS-PVC extruded inner
sheath armoured with overall FRLS-PVC sheath.

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 77 of 81

Booster Compressors for CGD Project
 TECHNICAL SPECIFICATION - 450 SCMH
ELECTRIC MOTOR DRIVEN HYDRAULIC CNG
BOOSTER COMPRESSORS

DATA SHEET: PRESSURE, VESSEL

(To be filled in by the Vendor)

PROJECT

UNIT

ITEM NO.

EQUIPMENT

CLIENT

JOB NO.

PACKAGE

MR. NO.

CODE FOR DESIGN AND CONSTRUCTION ASME SEC-VIII DIV1

DESIGN CONDITION

PRESSURE (kg./ cm2g)

TEMPERATURE (0C)

OPERATING CONDITIONS

PRESSURE (kg./ cm2g)

TEMPERATURE (0C)

CORROSION ALLOWANCE 3 MM

SERVICE CNG LETHAL [X] OTHERS CO2

LIQUID LEVEL (mm)

SPECIAL SURFACE FINISH INSIDE VESSEL REQD. [ ] NOT REQD. [ ]

TYPE OF VESSEL HORIZONTAL [ ] VERTICAL [ ]

DIAMETER (mm)

HEIGHT TL TL (mm)

SKIRT/ LEG HEIGHT

JOINT EFFICIENCY SHELL 1.0 HEAD 1.0

RADIOGRAPHY SHELL100% HEAD 100%

POST WELD HEAT TREATMENT

MATERIALS OF CONSTRUCTION SA 516 GR 60/70

SHELL, REINFORCEMENT PADS

Supply of 450 SCMH Electric Motor Driven Hydraulic CNG Page 78 of 81

Booster Compressors for CGD Project
 TECHNICAL SPECIFICATION - 450 SCMH
ELECTRIC MOTOR DRIVEN HYDRAULIC CNG
BOOSTER COMPRESSORS

HEADS/ CONES

SHELL FLANGES

NOZZLE FLANGES

NOZZLE NECK

MAN-WAY NECK

PIPE FITTINGS

GASKETS (EXTERNAL)

GASKET (INTERNAL)

SKIRT/ LEG SUPPORT

INTERNAL PARTS

EXTERNAL PARTS

INTERNAL BOLTS/ NUTS

CLIP ATTACHMENTS (EXTERNAL)

ANY OTHER GENERAL REQUIREMENT

NOTE: VENDOR SHALL SUBMIT COMPLETED DATA SHEET ALONG WITH OFFER WHEREVER
ENGG. DRAWING IS NOT ATTACHED FOR THE VESSEL.

------

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Booster Compressors for CGD Project
 TECHNICAL SPECIFICATION - 450 SCMH
ELECTRIC MOTOR DRIVEN HYDRAULIC CNG
BOOSTER COMPRESSORS

1. DOCUMENT DISTRIBUTION SCHEDULE

1.1. Documents and drawings under column no. 3 shall be submitted with each copy of the bid.
1.2. Documents listed under column 4 are to be submitted in 4 copies
1.3. Documents listed in column 5 are to be submitted as hard bound indexed book containing the following details
in Two (2) copies and to be submitted within 4 weeks of release note/dispatch of materials/ equipment from
vendor's works.
2. DETAILS TO BE INCLUDED IN FINAL DOCUMENTS BOOKS

2.1. Copy of P.O. and all amendments.

2.2. Copy of Purchase Requisition and all amendments.
2.3. Manufacturing Data Book containing all test certificates of components, raw materials, stage manufacturing
tests and inspections, final tests & inspection documents including welders' qualification & welding procedure
qualification, repairs & reworking carried out in shops. All raw material test certificates must be correlated to
the P.O. Item No. & component to which they relate by clear noting on the certificates.
2.4. Spares details including assembly drawings, part numbers, delivery, prices and ordering information.
2.5. All design calculations carried out by the vendor.
2.6. Final Drawing Index and all as-built drawings reduced to A3/ A4 size and wherever reduction is not possible,
full size copies duly folded and placed in plastic pockets.
2.7. Catalogues/leaflets of sub-vendors/suppliers of various bought out components highlighting the components
actually supplied correlated to P.O. Item Numbers.
2.8. Operating and maintenance instructions including lubrication schedules with details of suppliers for
procurement by OWNER for subsequent needs.
2.9. Release Note and Packing List.
2.10. Any other documents asked for in the Purchase Requisition.
2.11. All final drawings shall also be given to purchaser in digitized form on CD-ROM compatible to AUTOCAD
software.
2.12. Final documents including operation and maintenance manual should be submitted, one copy per package plus
one original.
2.13. Operation and maintenance manual shall include assembly and disassembly, specification (torque chart), parts
manual, complete list of bill of material, bought out spares and accessories. One original plus individual
copies for the no. of compressor packages supplied.
3. SPECIAL INSTRUCTIONS FOR SUBMISSION OF DWGS./DOCUMENTS:

3.1. Fold all prints to 216 MM x 279 MM size.

3.2. Contractor to forward the drawings and documentation to OWNER (Attention vendor prints control
department) clearly specifying purchasers Job no. & Req. No.
3.3. The drawing/Document no. with Rev. No. is essential. The number may be upto a maximum of 28 characters
in length.
3.4. Each Drawing/Document submitted to OWNER must be checked and signed/stamped by contractor before it is
submitted to OWNER.
3.5. Revision number must change during subsequent submission of vendor document.
3.6. Multi-sheet documents other than drawings must be submitted in their entirety in the event of a re-submission
even if only a few sheets are revised.
3.7. Final submission in bound volumes shall necessarily have a cover page giving project title, Item name, P.O.
No. particulars of owner, consultant & vendor and an index giving list of drawings & documents included
(with revision no.).

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Booster Compressors for CGD Project
 TECHNICAL SPECIFICATION - 450 SCMH
ELECTRIC MOTOR DRIVEN HYDRAULIC CNG
BOOSTER COMPRESSORS

3.8. All vendor drawings to be provided with a blank space measuring 75 mm W x 38 mm H for marking of review
codes etc. by OWNER.
3.9. The review of the vendor drawings shall be done by OWNER, as applicable, under the following review
codes:
R Review Code 1 N No comments.
P Proceed with manufacture/fabrication as per commented drawings.
R Review Code 2
Revise drawings required
R Review Code 3 D Document does not conform to basic requirements.

3.10. Review of vendor drawings by OWNER would be only to check compatibility with basic designs & concepts
& would in no way absolve the contractor/vendor of his responsibility to meet applicable codes, specifications
& statutory rules/regulations.
Vendor shall submit within 10 days after placement of FOI, the complete list of drawings/ documents with
submission dates against each. Critical drawings, only, the list of which will be agreed during kick-off meeting
shall be reviewed jointly at OWNER's office.

∑ ∑ ∑

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