TENDER FOR SUPPLY OF CNG STORAGE STATIONARY & MOBILE CASCADES FOR CGD PROJECT AT ROHTAK IN THE STATE OF HARYANA Project No. P.013460 Document No. P.013460 D11031 030 E - Tender No. 1000328759 Bharat Petroleum Corporation Limited New Delhi | INDIA PUBLIC 10 April 2019 TECHNICAL DOCUMENTATION Technical, Vol II of II, Rev. 0
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TENDER FOR SUPPLY OF CNGSTORAGE STATIONARY & MOBILECASCADES FOR CGD PROJECT ATROHTAK IN THE STATE OF HARYANA Project No. P.013460Document No. P.013460 D11031 030E - Tender No. 1000328759
Bharat Petroleum Corporation LimitedNew Delhi | INDIA
PUBLIC
10 April 2019
TECHNICAL DOCUMENTATIONTechnical, Vol II of II, Rev. 0
Sr. No. Rev. Pages Page No.
I.
1
2
3
4
5
6
II.
1 0 3 1
2 MR 0 11 4
3 PTS 0 17 15
4 DATA SHEET 0 2 32
5 DATA SHEET 0 1 34
6 DATA SHEET 0 1 35
7 DATA SHEET 0 1 36
8 QAP 0 4 37
Temperature Gauge P.013460 D 11087 002
Pressure Safety Valve P.013460 D 11087 003
High Pressure Gas Cylinder, Cascade Frames &
FitttingsP.013460 D11013 001
CNG Storage Cascade P.013460 D11077 001
CNG Storage Cascade P.013460 D 11088 001
Pressure Gauge P.013460 D 11087 001
TECHNICAL VOLUME II OF II
Introduction P.013460 D11031 030
Material Requisition P.013460 D11071 001
Section - I Invitation of Bids (IFB)
P.013460 D11031
0300 110
Section - II Instructions to Bidders ( ITB)
Section - III General Conditions of Contract (GCC)
Section - IV Special Conditions of Contract (SCC)
Section - VI Price Schedule / Schedule of Rates (SOR)
Rev. Date Description Prepared by Checked by Approved by
Page 4 of 40
MATERIAL REQUISITIONP.013460D11071
001
Rev.0 Supply of Cascade for City Gas Distribution Project Page 2 of 11
Project : City Gas Distribution Project
Subject : CNG STORAGE CASCADE
A. DESCRIPTION OF GOODS AND/OR SERVICES
Item Quantity Unit Description IdentificationNumber
1.0STATIONARY CNG CASCADE (3000 WL)
1.1 01 No.Design, Engineering, Manufacturing, Assembly, Supply, Inspectionand Testing at works and at site if required, transportation andunloading at site of CNG Stationary Storage Cascade of minimum3000 WL capacity of sum total of cylinders proposed at fillingtemperature of 15°C, for filling and storing of CNG at 250 bar (g)and suitable for 20 to 48°C with 3 bank as specified in TechnicalSpecification inclusive of services as stipulated in the tenderdocument.
Scope also includes Supply of required nos. of 20 dia. J typefoundation bolts with nuts, 200 mm long with threaded length 50mm& Supply of required nos. of 20 dia. Anchor bolts with nuts, 100 mmlong with threaded length 50mm as applicable will be in the scope ofvendor for suitable fixing of stationery storage cascades.
1.2Mandatory Spares suitable for 3000 WL Capacity Cascades.
1.2.1 1 Pressure Gauge range (0-400 kg/cm2)
1.2.2 1Cylinder Valve with end tube fitting
1.2.3 1Isolation Valve
1.2.4 1Check Valve
1.2.5 1Tube Pig Tail
1.2.6 2Burst Disc with washer
1.2.7 2Spindle & handles for cylinder valves
1.2.8 1Safety Relief device
Page 5 of 40
MATERIAL REQUISITIONP.013460D11071
001
Rev.0 Supply of Cascade for City Gas Distribution Project Page 3 of 11
Item Quantity Unit Description IdentificationNumber
2.0 STATIONARY CNG CASCADE (4500 WL)
2.1 5 Design, Engineering, Manufacturing, Assembly, Supply, Inspectionand Testing at works and at site if required, transportation andunloading at site of CNG Stationary Storage Cascade of minimum4500 WL capacity of sum total of cylinders proposed at fillingtemperature of 15°C, for filling and storing of CNG at 250 bar (g)and suitable for 20 to 48°C with 3 bank as specified in TechnicalSpecification inclusive of services as stipulated in the tenderdocument.
Scope also includes Supply of required nos. of 20 dia. J typefoundation bolts with nuts, 200 mm long with threaded length 50mm& Supply of required nos. of 20 dia. Anchor bolts with nuts, 100 mmlong with threaded length 50mm as applicable will be in the scope ofvendor for suitable fixing of stationary storage cascades.
2.2 - Mandatory Spares suitable for 4500 WL Capacity Cascades.
2.2.1 5Pressure Gauge range (0-400 kg/cm2)
2.2.2 5Cylinder Valve with end tube fitting
2.2.3 5Isolation Valve
2.2.4 5Check Valve
2.2.5 5Tube Pig Tail
2.2.6 10Burst Disc with washer
2.2.7 10Spindle & handles for Cylinder valves
2.2.8 5Safety Relief device
3.0 MOBILE CNG CASCADE (3000 WL)
3.1 2 Design, Engineering, Manufacturing, Assembly, Supply, Inspectionand Testing at works and at site if required, transportation andunloading at site of CNG Mobile Storage Cascade of minimum 3000WL capacity of sum total of cylinders proposed at fillingtemperature of 15°C, for filling and storing of CNG at 250 bar (g)and suitable for 20 to 48°C with single bank as specified inTechnical Specification inclusive of services as stipulated in thetender document.
Scope also includes Supply of required nos. of 20 dia. J typefoundation bolts with nuts, suitable for mounting on LCV/ HCV willbe in the scope of vendor for suitable fixing of Mobile storagecascades.
Page 6 of 40
MATERIAL REQUISITIONP.013460D11071
001
Rev.0 Supply of Cascade for City Gas Distribution Project Page 4 of 11
3.2 - Mandatory Spares suitable for 3000 WL Capacity Mobile Cascades.
3.2.1 2Pressure Gauge range (0-400 kg/cm2)
3.2.2 2Cylinder Valve with end tube fitting
3.2.3 2Isolation Valve
3.2.4 2Check Valve
3.2.5 2Tube Pig Tail
3.2.6 4Burst Disc with washer
3.2.7 4Spindle & handles for Cylinder valves
3.2.8 2Safety Relief device
4.0 MOBILE CNG CASCADE (4500 WL)
4.1 8 Design, Engineering, Manufacturing, Assembly, Supply, Inspectionand Testing at works and at site if required, transportation andunloading at site of CNG Mobile Storage Cascade of minimum 4500WL capacity of sum total of cylinders proposed at fillingtemperature of 15°C, for filling and storing of CNG at 250 bar (g)and suitable for 20 to 48°C with single bank as specified inTechnical Specification inclusive of services as stipulated in thetender document.
Scope also includes Supply of required nos. of 20 dia. J typefoundation bolts with nuts, suitable for mounting on LCV/ HCV willbe in the scope of vendor for suitable fixing of Mobile storagecascades.
4.2 - Mandatory Spares suitable for 4500 WL Capacity Mobile Cascades.
4.2.1 8Pressure Gauge range (0-400 kg/cm2)
4.2.2 8Cylinder Valve with end tube fitting
4.2.3 8Isolation Valve
4.2.4 8Check Valve
4.2.5 8Tube Pig Tail
4.2.6 16Burst Disc with washer
4.2.7 16Spindle & handles for Cylinder valves
4.2.8 8Safety Relief device
Page 7 of 40
MATERIAL REQUISITIONP.013460D11071
001
Rev.0 Supply of Cascade for City Gas Distribution Project Page 5 of 11
Note:
All the mandatory spare parts shall be wrapped and packaged for prolonged so that they will be preserved inoriginal as new condition:
The spare parts shall be properly tagged and coded so as to facilitate easy identification.
Spares shall be packaged separately and clearly marked spares and shipped at same time as the mainequipment.
Page 8 of 40
MATERIAL REQUISITIONP.013460D11071
001
Rev.0 Supply of Cascade for City Gas Distribution Project Page 6 of 11
B. REMARKS / COMMENTS
1. GENERAL NOTES
VENDOR's compliance
Vendor shall submit his bid in full compliance with the requirements of this MR and attachments.
Vendor must include the following statement in his bid:
We certify that our bid is fully complying with your enquiry dated……………,and referenced………………….
Compliance with this material requisition in any instance shall not relieve the Vendor of his responsibility tomeet the specified performance.
2. COMPLIANCE WITH SPECIFICATION
The vendor shall be completely responsible for the design, materials, fabrication, testing, inspection,preparation for shipment and transport of above equipment strictly in accordance with the MaterialRequisition and all attachments thereto.
All items shall be provided with EN 10204 -3.2 certifications.
3. VENDOR'S SCOPE
Vendor scope of work includes the equipment with all internals and accessories shown on the data sheets,specifications and all unmentioned parts necessary for a satisfactory operation and testing except thosewhich are indicated to be out of the Vendor's supply.
4. INSPECTION
Vendor shall appoint a TPIA for inspection purpose and issuance of 3.2 certificates in a manner describedbelow:
The successful vendor shall purpose minimum two (02) Nos. of TPIA‘s from the below list within (02)weeks from the date of FOA for Purchaser / Purchaser’s consultant approval. Vendor shall appoint approvedTPIA for inspection purpose.”
a) Lloyd Register of Industrial Services
b) TUV – NORD
c) DNV GL
d) Bureau Veritas
e) SGS
f) American Bureau Services
g) APPLUS VELOSI
h) Certification Engineers international Limited (CEIL)
i) AIB-Vincotte
Apart from inspection by TPIA, inspection shall also be performed by Purchaser / Purchaser’s consultantRepresentative, as set out and specified in the codes and particular documents forming this MR.
Page 9 of 40
MATERIAL REQUISITIONP.013460D11071
001
Rev.0 Supply of Cascade for City Gas Distribution Project Page 7 of 11
5. APPLICABLE DOCUMENTS
General prescriptions, requirements and information are listed in annex C of this Material Requisition.
6. VENDOR'S DOCUMENTS
Vendor shall supply the documentation as listed under point D of this Material Requisition.
All documents shall be supplied in English language.
Vendor shall strictly follow the document numbering procedure in their document as illustrated below:
Document numbering shall consist of Maximum 20 Characters.
Document No.
Project No. Item Document Index No. Serial No. Revision No.
Where,Project No. is P.013460; Item is CNG CASCADES;
Document Index No. will be of three characters as indicated under point D of this MR; Serial No. shall be 4digit no. ranging from 0001 to 9999
Revision No. is Revision of the document starting with R0, Rl ;
Example: For QA/QC program, the document no. will be
P.013460 CSCD QAP/QCT/ITP 001 R0
Page 10 of 40
MATERIAL REQUISITIONP.013460D11071
001
Rev.0 Supply of Cascade for City Gas Distribution Project Page 8 of 11
C. LIST OF ATTACHMENTS
The table here below lists the documents which are integral part ofthis Material Requisition. The applicable revision index of eachdocument is mentioned in the column below the current MaterialRequisition revision index.
Material Requisition revision
When the Material Requisition revision index is "A" or "1", alllisted documents are attached. For other Material Requisitionrevision index, only modified or new documents are attached.
QAP - HIGH PRESSURE GAS CYLINDER, CASCADE FRAME& FITTINGS
P.013460 D 11013 001
0
Page 11 of 40
MATERIAL REQUISITIONP.013460D11071
001
Rev.0 Supply of Cascade for City Gas Distribution Project Page 9 of 11
D. DOCUMENTS & DATA REQUIREMENTS
The table hereunder specifies the quantities and the nature of the documents to be submitted by the VENDOR to theENGINEER.The documents required at the inquiry stage and to be included in the bid are listed under column A.The documents required after award of the AGREEMENT and subject to the written approval of the ENGINEER arelisted under column B.The final and certified documents are listed under column C are to be produced along with the dispatched of the mainconsignment.Any document, even when preliminary, shall be binding and therefore duly identified and signed by the VENDOR. Itshall bear the ENGINEER's Project reference, the Material Requisition number and the identification number.THE DOCUMENTS ARE FULLY PART OF THE SUPPLY WHICH SHALL BE COMPLETE ONLY IF AND WHENTHE DOCUMENTS COMPLYING FULLY WITH THE MATERIAL REQUISITION REQUIREMENTS ARERECEIVED BY THE ENGINEER.
SI.No.
Documents and Data Doc.
Index
No.
A B C
Numberof copies
Numberof copies
Requireddate
Number ofcopies
Requireddate
1. Copy of valid ISO Certificate dulyissued by BIS or any other accreditedagency.
ISO 2 2 2
weeks
2 With FinalTech File
2 Drawing of cylinder of specifiedparameters proposed to be used inoffered cascade approved from ChiefController of explosives,Government of India
DWC 2 2 2
weeks
2 With FinalTech File
3 Copies of Chief Controller ofExplosives approval.
CCOE 2 2 2
weeks
2 With FinalTech File
4 Compliance to Technicalspecification for CNG StorageCASCADE with Accessories ofvarious components
TSC 2 2 2
weeks
2 With FinalTech File
5. Process and instrument diagram. PID - 2 2
weeks
2 With FinalTech File
6. Installation requirements for allequipment included in the supply
INS - 2 2
weeks
2 With FinalTech File
7. Typical cross sectional drawing andliterature to fully describe the detailsof all major components such asCylinders, valve, gauges piping etc.Data sheet indicating material oftube, tube size etc, piping andinstrument diagram.
PPG - 2 2
weeks
2 With FinalTech File
Page 12 of 40
MATERIAL REQUISITIONP.013460D11071
001
Rev.0 Supply of Cascade for City Gas Distribution Project Page 10 of 11
SI.No.
Documents and Data Doc.
Index
No.
A B C
Numberof copies
Numberof copies
Requireddate
Number ofcopies
Requireddate
8. Leaflets, catalogues for all majoritems.
CT - 2 2
weeks
2 With FinalTech File
9. Factory acceptance test procedure FAT - 2 2
weeks
2 With FinalTech File
10 Engineering manuals includingO&M manual.
OMM - 2 2
weeks
2 With FinalTech File
11
Maintenance schedule of the storagesystem along with list of Spares forO&M during warranty period.
MS - 2 2
weeks
2 With FinalTech File
12 A complete drawings of the StorageCascade (complete package), allcertification for all components usedwithin the hazardous areas should beprovided.
ZDWG
- 2 2
weeks
2 With FinalTech File
13 Quality Assurance Plan (QCT) ofCascade Frame and Cylinders alongwith GAD, dimensional drawings,load data.
QAP,GAD,DMD,LDS
- 2 2
weeks
-- --
14 Cascade Data Sheet, GA drawings CDS - 2 2
weeks
2 With FinalTech File
15 Schematic of cascade piping PPG - 2 2
weeks
2 With FinalTech File
16 Drawing of cascade frame along with4 G static calculations for onecomplete assemble cascade with allthe cylinders mounted & filled
DWF - 2 2
weeks
2 With FinalTech File
17 Make of bought out items BGT - 2 2
weeks
2 With FinalTech File
18 Bill of quantities with weight of eachcomponent
BOM - 2 2
weeks
2 With FinalTech File
19 Detailed time schedule for supplyindicating time periods required forcylinder manufacturing, cascadeframe fabrication, shop testing,despatch of material from works anddelivery at site
SCH - 2 2
weeks
2 With FinalTech File
Page 13 of 40
MATERIAL REQUISITIONP.013460D11071
001
Rev.0 Supply of Cascade for City Gas Distribution Project Page 11 of 11
SI.No.
Documents and Data Doc.
Index
No.
A B C
Numberof copies
Numberof copies
Requireddate
Number ofcopies
Requireddate
20 Test certificates TCS - - - 2 With FinalTech File
NOTES
1) Documents listed in column A is required to be submitted during bid time (1 original+ 1 copies).
Durations in column B (Required date) two weeks after FOI date or as indicated in Table.
Durations in column C (Required date) are weeks after document approval during final dispatch of consignment..
Due date of each document may be proposed.
2) Final technical file shall be supplied in hard copy as indicated, and in electronic format(PDF Acrobat files) on 3 (Three) CD-ROMs.
� All rigid piping, tubing and other components on the storage system should be designed for the full
range of pressures, temperatures and loadings to which they may be subjected with the factor of safety
of at least 4 based on the tensile strength at 20°C. Any materials used including gaskets and packing
should be compatible with natural gas and its service conditions.
� All piping should be designed in accordance with engineering calculations based on the requirements of
ASME B31.3 in conjunction with EEMUA supplement to ASME B31.3 or equivalent design standards.
Standards used should be used in total.
� All welding piping should be fabricated and tested in accordance with ANSI/ASME B31.3, API 1104
or an equivalent standard. Whichever standard is chosen for use, it should be used in total.
� All piping to be tested after assembly to a pressure equal to that of the pressure relief device setting and
proved leak free.
Page 25 of 40
PTS – CNG STORAGE CASCADES P.013460
D11077
001
Rev. 0 Supply of Cascade for City Gas Distribution Project Page 10 of 15
� Materials used for the piping shall be stainless steel 316 fully annealed seamless confirming to ASTM
A269 with maximum hardness of Rb80 or less and suitable for bending and flaring. OD tolerance shall
not exceed +0.005%. The piping/ tubing material shall be of Swagelok/ Parker make.
� All fittings including valves shall be of Swagelok, Parker make. Material shall be SS 316 conforming to
ASTM A269. Open ends on fittings and vents shall be provided with caps.
� Double compression ferrule Fittings shall be used in tube connection tubes.
� Liquid filled pressure gauge of diameter 4", (0-400 kg/cm2) with a 3- way isolating valve or 2 – valve
manifold block on each bank shall be used. Thus each cascade shall have three pressure gauges.
Pressure gauges shall be securely mounted.
� Every CNG storage unit including each manifold group or bulk storage tank should be provided with a
suitable pressure gauge for each bank. The pressure gauge should be directly connected to the tank or
storage system. The gauge should be dial graduated to read approximately double the operating
pressure.
� A good quality industrial pressure gauge should be used with a dial face of at least 63mm or larger.
Gauges should be built to requirements of BS 1780 or ANSI/ASME B40.1 or OISD-179 equivalent.
� Temperature gauge of diameter 4" with necessary arrangement on high bank only shall be used. Thus
each cascade shall have only one Temperature gauge on high bank.
� All end connections, pressure & Temperature gauges, valves and fittings of cascade shall be within
tamper proof, wire cage enclosure. These shall be on one side of cascade for ease of operation.
� Material of vent tubing shall be SS 316 and make shall be of Swagelok /Parker make.
7.12 Painting
Every cylinder is painted with the appropriate identification colors specified in IS: 4379 for industrial
cylinder
Color of the Cylinder shell --- White
Color of band at neck and of cylinder ---- Red (IS standard color No. 537)
Color of the Frame ---- Yellow
� The paint shall be chosen, primed and applied as to have a service life of five (5) years. The exterior
surface is required to be corrosion free for five (5) years and to have faded free life without oxidation of
paint surface for five years in an environment of bright sun light with an intense UV content.
� Surface preparation by Shot Blasting as per grade SA 2 1/2, IS 9954 / ISO 8501. Three coats of paint
shall be applied with minimum thickness of 300 micron. The recommended painting system should be
of Category C5–I Very high (Industrial) as specified in the Standard ISO 12944 Part 1 to 8. The
proposed Painting system shall conform to Table A 5 of ISO 12944 – 5 Standard.
8.0 MOBILE STORAGE CASCADES
� All Mobile storage system should be supplied in a single bank arrangement.
� All the Cylinder Specifications, valves, safety relief devices, pressure gauges, pressure Relief devices
etc shall remain same as mentioned in the Stationary cascades but not limited so.
� Each cylinder of mobile cascades used for the transport of compressed natural gas shall be a type
approved by the PESO/ CCOE.
� Every cylinder used for transportation of compressed gas shall be constructed and tested in accordance
with IS: 2825, as amended from time to time, or BS5045:Part1 or (US) D.O.T 3AA or similar such
other standard code approved by the Chief Controller of Explosives.
� The design stress shall include an allowance to include an allowance to enable the cylinder to withstand
shocks normally encountered by the movements on road, such as acceleration and deceleration for a
minimum of 4g (4 times gravity).
Page 26 of 40
PTS – CNG STORAGE CASCADES P.013460
D11077
001
Rev. 0 Supply of Cascade for City Gas Distribution Project Page 11 of 15
� All the attachments to the cylinders shall be protected against accidental damage which may result from
collision, overturning or other operational cause.
� All the cylinders shall be designed to withstand the most severe combined stresses to which they may
be subjected to by the pressure of the gas, the pumping pressures and shock loading caused by transport
conditions.
� The isolation valves and the end connections shall be terminated at the left side of the storage frame.
� End connections shall be such that tube manifold accessible from side of the vehicle and can be
connected to station piping from any one side of the vehicle.
9.0 PROTECTION OF VALVES & ACCESSORIES
� All valves and accessories shall be safeguarded against accidental damage or interference.
� Valves and accessories shall be mounted and protected in such a way that risk of accidental rupture of
the branch to which the valve or accessory is connected is minimized.
� Valves and accessories situated at the rear of a vehicle shall be protected by the rear cross member of
the frame of the vehicle against damage.
10.0 EQUIPMENT
� Piping, Fittings and meters:
a. All piping, fittings and meters mounted on the cascade shall be designed to with stand the most
severe combined stresses imposed by the following, namely.
a.1 The maximum designed pressure of the vessel.
a.2 The super imposed pumping pressure of the shock loading.
b. The materials used for vessel equipment shall be sufficient ductile to withstand rough usage and
accidental damage. Brittle materials such as cast iron shall not be used.
� Protection of piping and equipment;
a. All piping and equipment shall be adequately protected to minimize accidental damage which
may be caused by rough usage, collision or overturning;
b. Any equipment or section of piping in which liquid may be trapped shall be protected against
excessive pressure caused by thermal expansion of the contents.
� Marking of connections-
All connections on the vehicle which require manipulation by the operator of the vehicle should be
clearly marked to prevent incorrect operation. The form of this marking should correspond with the
operating procedure laid down for the vehicle.
11.0 INSPECTION AND TESTING
� Before bringing any items of equipment to site, factory testing should be carried out to demonstrate the
function of all equipment within the system if so desired.
� supplier shall be given 2 weeks notice of the date and location of the tests so that the equipment may be
witnessed if desired.
� Upon delivery to the site, all the equipment should be assembled in a complete system. Thereafter, final
site acceptance test would be carried out. Such tests should be witnessed and signed off by the
Company representative. The Supplier should rectify and replace all defects, faults, failures, etc. and all
costs should be borne by Supplier. The costs should include accommodation, travelling, expenses, etc.
� Supplier shall carryout 4G static calculation of one complete assembled cascade with all the cylinders
mounted and filled and submit the same for Owner review.
� Supplier shall carryout cylinder bursting test of one cylinder from the entire batch produced for supply
to OWNER in case offered cylinders are of new design (conforming to the requirement of IS
Page 27 of 40
PTS – CNG STORAGE CASCADES P.013460
D11077
001
Rev. 0 Supply of Cascade for City Gas Distribution Project Page 12 of 15
7285:2004). Supplier shall inform the schedule of the test well in advance to enable Owner or their
authorized representative to depute technical personnel for witnessing the test.
� Supplier shall carry out all standards shop tests/QA/QC as per recommendation of manufacturer/Chief
Controller of Explosives. Copies of the testing/inspection carried shall be furnished to OWNER.
� Supplier shall furnish record of storage capacity check of each cylinder in a cascade and the same need
to be demonstrated to Owner or their authorized representative.
� Each assembled storage cascade with all tubing, valves shall be pressures tested to ensure existence of
no leakage prior to dispatch.
� Manifold of the cascade shall be tested to 250-bar g. The manifold shall be checked for sequencing and
no back flow between any two banks with all valves open.
� Dispatch Clearance to be given by OWNER after final Inspection to be witnessed by OWNER/Third
Party Inspection agency appointed by OWNER.
12.0 CALIBRATIONS, TEST CERTIFICATES AND THIRD PARTY CERTIFICATION
� Every Cylinder should be carried with Hydrostatic or Hydrostatic stretch test and a certificate should be
provided.
� Leak test should be carried for each cylinders or cascades with all tubing’s, valves and a certificate
should be furnished to the Owner.
� All Instrument gauges, Valves, Pressure gauges, safety relief devices, shut off valves tubing’s and
piping etc should be Pressure tested, calibrated and such test , calibration certificates, should be
presented upon delivery to site. If any of the test certificates is not in order, the Supplier’s should
replace the affected equipment with valid certificate at Supplier cost.
� Calculation shall be carried for 4g Stationary of one complete cascade with all cylinders mounted and
filled and the same should be submitted for review of the Owner.
� Burst test of one cylinder from the entire supplies shall be produced and incase offered once are new
design the schedule for the test should be informed prior to enable the Owner or their authorized
representative to depute their personnel for witnessing the test.
� All standards shop tests/ QA / QC as per the recommendation of the manufacturer / Chief Controller of
Explosives to be carried out and a copy of such certificates shall be furnished to the Owner.
� Record of storage capacity check of each cylinder in a cascade shall be furnished and same shall be
demonstrated to the Owner/ its representative.
13.0 TRAINING REQUIREMENTS
� The Supplier should develop a training proposal and prepare a schedule for the Company’s review,
comment and approval.
� The training programme should be phased to suit the construction program such that the Company’s
personnel are fully conversant with all aspects of the operations and maintenance of the storage systems
including all aspects of operations, including decanting CNG from mobile gas storage trailers, pressure
control and integration of the overall system.
� The training programme should cover but not limited to the following subject areas:
� The physical characteristics of the gas and the procedure and precautions to be observed in
handling and control.
� Start-up, operations and maintenance procedures for the CNG storage facilities.
14.0 PROTECTION DURING SHIPPING
The cascade shall be packaged to withstand rough handling during ocean shipment and inland journey. It
shall be supplier's responsibility to make good any deterioration and that occurs during shipment. Sling
points shall be clearly indicated on crates.
Page 28 of 40
PTS – CNG STORAGE CASCADES P.013460
D11077
001
Rev. 0 Supply of Cascade for City Gas Distribution Project Page 13 of 15
15.0 EXPERIENCE RECORD PROFORMA FOR CASCADE
Supplier must fill the following format, which is essential to access the bidder’s capability.
S. No. Parameter Information on
offered model
Information on
existing cascade
(Location)
1. No. of units 1 2 3
2. Service
3. Working pressure of cascade in bar g
4. Site min/ max temp.
5. Normal flow from each bank kg/hr
6. Cascade water capacity-liters
7. Water capacity of single cylinder used in
cascade-liter
8. Material of cylinder
9. Thickness of cylinder wall and disc end in
mm
10. Material of vent tubing
11. Piping material and make
12. Valve make
13. Valve type and dia.
14. Nos. of banks in cascade
15. Nos. of cylinder in low bank
16. Nos. of cylinder in medium bank
17. Nos. of cylinder in high bank
18. Water capacity of cylinders in individual
banks
19. Contact person
20. 4 G static calculation for one complete
assembled package
21. Cylinder burst test for one cylinder
22. Design standard (Code) used
23. Total weight of cascades in tones
24. Burst pressure and temperature for burst disc
in bar g and deg C.
25. Hydrostatic or Hydrostatic Stretch Test
26. Pressure test for leakage
27. Design case gas composition
28. Approved Manufacturer License certificate
from PESO
29. Dimensions of the Total package
30. Warranty certificates
31. Dimension of package max.
32. Calibration certificates for all instrument
gauges etc of package
33. Test certificates of all instruments with
cylinder, tubing's, fittings of total package
34. Date of commissioning of cascade
35. Approval from PESO Nagpur
36. Dimensions of package Max.
37. Date of commissioning of cascade
38. Where cascades are located: Address and
fax/ telephone no. of
39. Major problems encountered, if any
Page 29 of 40
PTS – CNG STORAGE CASCADES P.013460
D11077
001
Rev. 0 Supply of Cascade for City Gas Distribution Project Page 14 of 15
16.0 CHECK LIST FOR SCOPE OF SUPPLY
� Vendor shall furnish all the equipments of Storage Cascade System instruments and gauges and safety
devices as per the enquiry document. Anything required over and above what is specified, for safe and
satisfactory operation of the equipment package shall be included by the Vendor in his scope.
� Vendor to write YES/NO against each item. Vendor is required to include complete scope, as such 'NO'
is not warranted. However, in case for any of the items if supplier's reply is 'NO', supplier should give
reason for the same:
� Vendor's scope of supply shall include but not limited to the following :
Sr. No Description Specified
by
Purchaser
YES / NO
Included
by Vendor
YES / NO
Remarks
1.0 Each Storage cascade Package complete with:
1.1 Specification - Indian Standard 2825, as amended
time to time, IS : 7285 – 2004 similar such other
standard code approved by PESO
YES
1.2 Cylinder material - Seamless alloy steel (Cr-Mo) or standard code approved by the Chief Controller of Explosives.
YES
1.3 All the fittings, Valves, Safety devices, gauges are as per IS 3224 or standard code approved by the Chief Controller of Explosives.
YES
1.4 Tubing's are of rigid type ASTM 316 stainless steel tube.
YES
1.5 All cylinders are Hydro static Tested YES
1.6 Water capacity of single cylinder used in cascade not less than 75 Ltrs.
YES
1.7 Nos. of banks in cascade- three bank system for
Stationary Cascade YES
1.8 One Cylinder should be burst test YES
1.9 4-G Stationary calculation for one complete assembled package is done
YES
1.10 Working Pressure of Cascade min. 250-255 bar (g) YES
1.11 Pressure test for Leakage on cylinders with assembled condition
YES
1.12 Isolation Valve complete with venting line valve and end plug installed on the inlet of the cylinder
YES
1.13 Copy of Calibration certificates for all instrument gauges etc of Cascade package, Test certificates of all instruments with cylinder, tubing's, fittings of total package
YES
1.14 BOQ with weight of each component YES
1.15 Drawing of cylinder of specified parameters approved by CCOE
YES
1.16 Drawing of cascade frame YES
1.17 Storage cascade with frame assembly is shipped in fully and assembled condition only to be mounted on anchored bolts laid at site.
YES
1.18 GA drawing of the cascade YES
1.19 Warranty for a period of 12 months is provided from the date of final site acceptance of CNG facilities by the Company's.
YES
1.20 Make of bought out items YES
1.21 Detailed time schedule for supply indicating time YES
Page 30 of 40
PTS – CNG STORAGE CASCADES P.013460
D11077
001
Rev. 0 Supply of Cascade for City Gas Distribution Project Page 15 of 15
Sr. No Description Specified
by
Purchaser
YES / NO
Included
by Vendor
YES / NO
Remarks
periods required for cylinder manufacturing, cascade frame fabrication, shop testing, dispatch of material from works at delivery site
2.0 Spares
2.1 Mandatory spares as specified in the "Check List for Mandatory Spares"(Indicate separate price for each item)
YES
3.0 Inspection and Testing
3.1 As specified on the Inspection and testing clauses YES
4.0 Supplier Data and drawings
4.1 All data & drawings as required per VDR format as per Material Requisition.
YES
5.0 Supervision during the Trial Run if required at site of the CNG storage cascade system
5.1 Additional Items not specified by purchaser but recommended by bidder for safe smooth and normal operation. (Bidder shall indicate separate list of such items in his proposal)
YES
6.0 Technical Parameters to be confirmed by supplier
6.1 Pressure range from 19 bar (g) -250 bar at 15 °C YES
6.2 Fill Pressure Kg/cm2g or [bar(g)] -200 YES
6.3 Operating Temperature range -[ -55°C to 70°C] YES
6.4 Design Code :IS 2825, IS 7285-2004, IS 3224 or as per Applicable standard Codes or approved by CCOE
YES
6.5 Calibration traceability - To NIST as per ISO 5168 YES
6.6 Enclosure weather proof to - IP65,NENA4x YES
6.7 Process Temperature effect - ± 0.01% of nominal flow rate/degree C on zero offset
YES
6.8 All valves as per IS 3224 or as Applicable standard code or approved by CCOE
YES
6.9 Safety relief devices as per IS: 5903 or Applicable standard code or approved by PESO
2 At the time of approval of DS, Supplier shall furnish DS with Catalogues.
DEVIATION NO DEVIATION VENDOR'S SIGNATURE WITH SEAL
0-400
Pressure Element:-
Element Material:-
PRESSURE GAUGE
UNITS: Flow<-> Liquid- m*3/hr Gas- Sm*3/hr Steam- kg/hr Pressure-> kg/cm*2 G Temperature<-> oC Level/Length<-> mm
Type:-
Mounting:-
Dial Size:-
Colour:-
Case Material:-
Bezel Ring:-
Window Material:-
Enclosure:-
Movement:-
SL.
NO.TAG NO.
RANGE
kg/cm2g
Socket Material
Accuracy:-
Zero adjustment:-
Connection:-
OPTIONSOP. MAX. DES. MIN MAX. DES.
PRESSURE kg/cm2g TEMPERATURE ºc
SERVICE
Sheet No. 1 of 1 CLIENT: Owner's Name
400
Datasheet No: P.013460 D 11087 001
250 400
PROJECT: City Gas Distribution Project
CKS
VENDOR: REV. DATE PREP CHKD APPD
0 10.04.2019 GGMA
Page 34 of 40
1 Mercury Filled 17 Rigid
2 Required 18 To suit thermowell
3 Local 19
4 100mm
5 White with black inscription
6 SS316
7 Shatterproof glass 20 Over Range Protection:-
8 Bottom
9 +/-1% of FSD 21 Material:- SS316
10 WP to IP 65 as per IEC 60529/IS 13947
11 Required 22
23 *
12
24 ½' BSP(F)
25 *
13 Stem Dia:-
26
14 SAMA Class:- V
Case
15 Bulb Type:- Adjustable union 27SS316
16 1/2” BSP(M) a) Liquid Filled:- Yes
b)
c)
* * * * * * a
NOTES:
*: Vendor to furnish
U: Immersion Length
T: Lagging Extension
1 Element length shall,be suitable for thermowell.
2 U-length shall be selected in such a way that the thermowell tip shall be preferably at the centre of pipe to sense the temperature accurately.
3 Process Data shall be as per tender document
4 At the time of approval of DS, Supplier shall furnish DS with Catalogues.
DEVIATION NO DEVIATION VENDOR'S SIGNATURES WITH SEAL
130%
TEMPERATURE GAUGE
UNITS: Flow<-> Liquid- m*3/hr Gas- Nm*3/hr Steam- kg/hr Pressure-> kg/cm*2 G Temperature<-> oC Level/Length<-> mm
Type:- Extension Type:-
Well:- Bulb Dia.:-
Mounting:- Cappillary Material:-
Dial Size:-
Window Material:-
Conn. Location:- THERMOWELL:-
Accuracy:-
Armour Flexible:-
Colour:- Armour Material:-
Case Material:- Capillary Length:-
Enclosure:-
Size:- Thermowell Dwg.:-
Drilled bar stock upto immersion length 500 mm,
otherwise fabricated
BIMETAL:- Process Conn.:-
Stem:
Zero Adj. Screw:-
Type:- Gauge Conn.:-
Material:-
Constn.:-
Compensation:-
Bulb Material:-
Options:
Filled System:- Over range protection
SL.
NO.TAG NO. RANGE
TEMP.
MIN NOR MAX
WELL DIM. FLANGE
Bulb Union Threaded To:-
LINE NO. / VESSEL
NO. / PIPING CLASSOPTIONS
U T MATERIALRATING, FACING,
FINISH
Sheet No.1 of 1 CLIENT: Owner's Name
PROJECT: City Gas Distribution Project
Datasheet No: P.013460 D 11087 002
PREP CHKD
0 10.04.2019 MA GG
APPDVENDOR: REV. DATE
CKS
Page 35 of 40
1 Tag No. Quantity * *
2 Line No. Schedule * *
3 Vessel No. *
4 Safety / Relief Safety relief
5 Full Nozzle Full Lift/Mod. Nozzle Full nozzle full lift
6 Bonnet type Closed
7 Conv./Bellows/Pilot Operated *
8 Inlet Conn. Size & Rating *
9 Facing & Finish *
10 Outlet Conn. Size & Rating *
11 Facing & Finish *
12 Cap Over Adj. Bolt Yes
13 Screwed / Bolted Bolted
14 Lifting Gear - Type
15 Test Gag Yes
16
17
18 Body and Bonnet A351 CF8M
19 Nozzle and Disc SS316
20 Spring SS304
21 Bellows --
22
23
24 Resilient Seat Seal --
25
26
27 Code API 520
28
29
30 Fluid State Natural Gas Gas
31 Corrosive Constituent
32 Required Flow Capacity
33 Mol.Wt. S.G. at Rel. Temp
34 Oper. Pressure Normal Note 1
35 Oper. Temp. Rel. Temp. Note 1
36 Valve Discharges to Atmosphere
37 Back Press. Const. Or Variable Constant
38 Set Pressure
39 Cold Bend Test Pressure
40 % Over Pressure % Blow Down
41 Cp/Cv Compressibility Factor
42 Viscosity @ Rel. Temp. mPas(cP)
43 Vess. Wall Temp. Surf.Area-m2
44 Max & Min Pressure *
45 Calculated Area cm2 *
46 Sel. Area cm2 Orifice Design * *
47 No. of Valves Reqd. for capacity *
48 Total Area - cm2 *
49 Actual Flow Capacity *
50
51 Model No. *
52 IBR Certification No
53
54
NOTES:
'*' : Contractor to furnish
1 Process data shall be as per tender specification mentioned elsewhere.
2 At the time of approval, vendor shall furnish sizing calculation and catalogues of PSV
3 Test GAG Required for safety valve & Pressure Safety valve shall be fire case type
DEVIATION NO DEVIATION CONTRACTOR'S SIGNATURE WITH SEAL
*
Options
Basis
Service
conditions
Orifice
Data Sheet No P.013460 D 11087 003
Sheet No. 1 of 1
PRESSURE SAFETY VALVES
UNITS: Flow<-> Liquid- m*3/hr Gas- Sm*3/hr Steam- kg/hr Pressure-> kg/cm*2 G Temperature<-> oC Level/Length<-> mm
General
Valve
Material
CLIENT: Owner's Name
PROJECT: City Gas Distribution Project
CKS
PREP CHKD APPD
CONTRACTOR:
REV. DATE
0 10.04.2019 MA GG
Page 36 of 40
QAP No. : P.013460 D11013 001 Rev 0
Date : 10.04.2019
Prepared by : GG
Checked by : RP
Approved by : CKS
S.NO. OPEARTION / PARAMETERCHARATERISTICS/
PARAMETERSACCEPTANCE CRITERIA & CERTIFICATION INSPECTION FREQUENCY VENDOR TPIA CA REMARKS
1 Raw Material Chemical CompositionChrome Moly Steel,Grade-DS-202/IS:7285-2004
Cl. 5.2 Table-1One sample per heat No. P R R
Verification of RMT Certicate Received
from RM supplier.
Length As per process heat 4-5 jobs during setting approval & every two
hour.
Thickness Minimum as per approved drawing Tolerance + 30%3-4 jobs during setting approval & every four
hour.
Outside Diameter As per Approved drawing (Tolerance + 1 %)
IS-7285 : 2004
3-4 jobs during setting approval & every four
hour.
Surface FlawsFree from Lamination, crack,Dent, corrosion , silvers
etc.
3-4 jobs during setting approval & every four
hour.
Ultrasonic Examination IS-7285 : 2004 Each Cylinder
3 Bottom Forming
Bottom Thickness
Centre of Bottom
Side of Bottom
Footring
Visual Inspection
Ultrasonic Examimation
1.5 T min (where T is wall thickness)
IS: 7285 : 2004
Free from crack,excess metal, pin hole, ball
formation,roller mark and other surface defects.
IS: 7285 : 2004
4-5 jobs during setting approval & every four
hour.
4-5 jobs during setting approval & every four
hour.
Each Cylinder
P W/R R
4 Neck Forming
Solid Neck Length
Neck Diameter
Surface finish, defects
Ultra sonic Examination
As per Approved Drawing
As per Approved Drawing
Free from roller mark, Pit mark, excess metal at neck,
crak and other surface defects
IS: 7285 : 2004
4-5 jobs during setting approval & every two
hour.
4-5 jobs during setting approval & every two
hour.
4-5 jobs during setting approval & every two
hour.
Each Cylinder
P W/R R
2
QUALITY CONTROL TABLE
HIGH PRESSURE GAS CYLINDER , CASCADE FRAME & FITTINGS
W/RRaw Materiasl Cutting
( seamless Tube)P R
IN PROCESS
Supply of Cascade for City Gas Distribution Project Page 1 of 4
Page 37 of 40
QAP No. : P.013460 D11013 001 Rev 0
Date : 10.04.2019
Prepared by : GG
Checked by : RP
Approved by : CKS
S.NO. OPEARTION / PARAMETERCHARATERISTICS/
PARAMETERSACCEPTANCE CRITERIA & CERTIFICATION INSPECTION FREQUENCY VENDOR TPIA CA REMARKS
QUALITY CONTROL TABLE
HIGH PRESSURE GAS CYLINDER , CASCADE FRAME & FITTINGS
5 Heat Treatment
Hardness
(As Tempered)
Mechanical Properties
Tensile Strength
Yield Strength
% Elongation
Impact test (at -20 0C)
Bend Test
Burst Test
As per approved drawing
IS:7285 : 2004
As per IS;7285 : 2004
IS: 7285 : 2004
IS: 7285 : 2004
IS: 7285 : 2004
IS: 7285 : 2004
Every Cylinder
One random cylinder will be selected from
Heat treament Batch comformimg the
mechanical properties like tensile test,
impact test, bend test etc, in presence of
inspecting officer.
One Cylinder from prototype batch.
P W R
6 Ultrasonic testing
Crack dtection
Wall Thickness measurement
As per IS:7285 -2004
As per approved drg.
IS:7285-2004
Every Cylinder P W R
7 Neck cutting & Threading
Neck Length
Machined neck step diameter
Neck thread configuration.
Visual inspection thread finish.
As per approved drawing.
As per approved drawing.
As per approved drawing.
Free from crack blow hole excess metal at inside
neck, thread damage, flat threads etc.
Audit Check by Q.A staff.
Audit Check by Q.A staff
Every Cylinder.
Every Cylinder.
P W R
8Water Capacity checking &
Hydrostatic Strength testing.
Measurement of water capacity.
Total expansion and permanent
expansion at test pressure.
Holding Time = 30 Sec min.
Tolerance on water capacity
+ 5 % IS-7285 : 2004
Permanent expansion shall not exceed 10% of total
expansion. IS: 7285 : 2004
Every Cylinder.
Audit Check by Q.A staff
P W R
9 Air Leakage Test
Access leakage from cylinder
body, neck and bottom side at
working pressure.
Holding Time= 60 Sec.
Free from Leakage.
IS: 7285 : 2004
Every Cylinder.
Audit Check by Q.A staff
P W R
Supply of Cascade for City Gas Distribution Project Page 2 of 4
Page 38 of 40
QAP No. : P.013460 D11013 001 Rev 0
Date : 10.04.2019
Prepared by : GG
Checked by : RP
Approved by : CKS
S.NO. OPEARTION / PARAMETERCHARATERISTICS/
PARAMETERSACCEPTANCE CRITERIA & CERTIFICATION INSPECTION FREQUENCY VENDOR TPIA CA REMARKS
QUALITY CONTROL TABLE
HIGH PRESSURE GAS CYLINDER , CASCADE FRAME & FITTINGS
10 Bursting Test
The value of hoop stress shall be
not less than 0.95 of the
minimum specified tensile
strenght of the cylinder material.
IS-7285- 2004 One Cylinder of the first batch . P W R
11 Steam Cleaning & Air DryingExamination of Oil residue,
Moisture Etc.
Free from Oil residue, Moisture etc when Cylinder is
exposed to steam jet at steam temp.
160-180 0 C for period minimum 5-6 minutes.
Audit Check by Q.A staff P R R
12 Internal shot blasting Scale free surfaceInner surface should be free from sclaes, metallic
particles etcAudit Check by Q.A staff P R R
13 External shot blasting Scale free surfaceCylinder should be free from scales & Other surface
imperfectionAudit Check by Q.A staff P R R
14 Fixed data Stamping Stamp Data As per IS:7285 : 2004 Audit Check by Q.A staff P R R
15 Variable Data stamping Stamp DataVerification of data
As per Drawing & Test ResultEvery Cylinder check by Q.A staff P R R
16 Vacuum cleaningAny scales, dustetc inside
cylinderFree from scales, dust etc from inside cylinder. Every Cylinder check by Q.A staff P R R
17 Weighing Tare weight/ Calibration As per approved Drawing Every Cylinder check by Q.A staff P W R
18Painting (Primer & Finish
painting)Paint coating thickness As per process sheet Audit Check by Q.A staff P W R
19 IS: 7285 : 2004 Each Cylinder P R R
20 IS: 7285 : 2004 Each Cylinder P R R
21
Cascade Frame
Fabrication
Painting
Cascade Frame Complete
Visual (Welding etc)
Dimensional
Physical Test
Chemical Test
Approved Drwaing/ Manufactures Standard.
Owner's Specification
Approved Drawing
100% P R R
22 Polyuretherane/ Epoxy paint Chemical Properties Approved Make / Owner's Specification P W R
23 SS Tubes
Physical test
Chemical Test
Visual (Welding etc)
Dimensional
Fitment & Alingment
Approved Drawing, Manufacture Test Certificate for
bought out items.As per tender / Owner's Instruction P R R
Marking
Color Identification
Supply of Cascade for City Gas Distribution Project Page 3 of 4
Page 39 of 40
QAP No. : P.013460 D11013 001 Rev 0
Date : 10.04.2019
Prepared by : GG
Checked by : RP
Approved by : CKS
S.NO. OPEARTION / PARAMETERCHARATERISTICS/
PARAMETERSACCEPTANCE CRITERIA & CERTIFICATION INSPECTION FREQUENCY VENDOR TPIA CA REMARKS
QUALITY CONTROL TABLE
HIGH PRESSURE GAS CYLINDER , CASCADE FRAME & FITTINGS
24 Fittings
Visual
Dimensional
Pressure Test
Fitment & Alingment
Approved Drwaing/ Manufactures Standard. As per tender / Owner's Instruction P R R
25 Valves 2 Way
Visual
Dimensional
Fitment & Alingment
Approved Drawing, Manufacture Test Certificate for
bought out items.As per tender / Owner's Instruction P R R
26 CNG Cascade Assembly
Visual (Welding etc)
Dimensional
Fitment & Alingment
Approved Drwaing/ Manufacture Std. Owner's specification/ Instruction P W R
27SS Tubes for venting of Burst
Disc seperator
Visual (Welding etc)
Dimensional
Pressure Test
Leakage Test
Fitment & Alingment
Approved Drwaing/ Manufacture Std. Owner's specification/ Instruction P W R
28 Cylinder Valves
Visual
Dimensional
Fitment & Alingment
As per Approved CCOE Drawing, Bill of Material. Owner's specification/ Instruction P 100% W R
29 Gauge
Visual
Dimensional
Fitment & Alingment
Approved Drawing, Bill of Material. Owner's specification/ Instruction P 100 % W R
30 IS:7285-2004 Each Cylinder P 100 % W R
Notes1
2
3
4
5
6
7
8
9
All reference Codes/ Standards, Documents, P.O. Copies shall be arranged by vendor / supplier for reference of TPIA/Owner at the time of Inspection
Supplier shall submit Calibration certificates of all Instruments/Equipment to be used for Inspection and Testing to TPIA with relavant procedures and updated standards for TPIA reveiew/Approval.All reference codes / documents shall be arranged by Vendor for reference of TPIA
at the time of inspection.
Owner / Owner's representative including TPIA will have the right to inspect any activity of manufacturing at any time.
TPIA along with Owner/Owner representative shall review/approve all the documents related to QAP/Quality manuals/Drawings etc.submitted by supplier.
Contractor shall in coordination with Supplier/Sub vendor shall issue detailed Production and Inspection schedule indicating the dates and the locations to facilitate Owner/Owner's representative and TPIA to organise Inspection.
Special manufacturing procedures have to be specially approved or only previously approved procedures have to be used, in case of conflict between specifications more stringent condition shall be applicable.
Certification requirement shall comply with European standard EN 10204 - 3.2 (latest edition).
The Above Testing and acceptance critera are minimum requirements, however, manufacturer shall ensure that the product shall also comply to the additional requirements as per Particular Technical specifications(PTS) and Data Sheet.
The supplier shall submit their own detailed QAP prepared on the basis of above / Technical specification for approval of Owner/Owner's representative.
LEGEND : W= WITNESS; H= HOLD; M= MONITORING; P= PERFORM; R= REVIEWS OF DOCUMENTS; R/M= RANDOM CHECH; A= APPROVED; TPIA= THIRD PARTY INSPECTION AGENCY
Final Inspection of Finished Cylinders:
Visual inspection for internal cleaning and painting of Cylinder
and Cascade frame.
Final dimensional checking of cylinders & cascade frame.
Check every cylinder for neck threads & cleaning from inside/
outside surface.
Verification of stamped data like Cylinder Serial No., Tare Weight,
Water Capacity etc.
Supply of Cascade for City Gas Distribution Project Page 4 of 4
Page 40 of 40
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