JOB SPECIFICATIONS FOR GAS METERING SKIDSgailtenders.in/writereaddata/Tender/6921-000-jobspec gas metering... · AGA Report No. 8 Compressibility and Super-compressibility for Natural

JOB SPECIFICATIONS FOR

GAS METERING SKIDS

DOCUMENT No. 6921-001-16-51-SP-01

Rev. A Page 1 of 38

A 05.07.2010 ISSUED FOR BIDS AM DKY SR

Rev. No Date Purpose Prepared

by Checked

by Approved

by Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved


GAS METERING SKIDS


GAS METERING SKIDS

DOCUMENT No. 6921-001-16-51-SP-01

Rev.A Page 2 of 38

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

1.0 Introduction

This specification together with the Sketches/ P&IDs, Process data sheets, Instrument data sheets, standard specifications attached with the Package, defines the requirement for the design, engineering, manufacture, fabrication & assembly, integration, calibration, factory testing, wet flow calibration, supply, packaging, shipping and documentation including deliverables, custody transfer approvals/certifications, installation supervision, commissioning assistance and overall performance guarantee of Gas Metering System Skids along with associated equipments/instruments/panels & accessories as applicable to be installed at Bhilwara RT , Chittorgarh RT. The Gas Metering skids as defined in these specifications are required to be supplied by bidder.

The environmental conditions and the contractual obligations of the COMPANY shall also be considered for the design.

The BIDDER of the metering system shall provide detailed specifications of all the equipment that form part of the system.

This specification also lists the relevant international industry standards and practices, Local and Company Codes & standards, etc. to whose recommendations and guidelines the design of the Metering system shall be strictly adhered and stringently followed.

The objective of the specification is to provide a system that is: a) Reliable and Accurate b) Consistent and Compliant c) Cost effective d) Simple to maintain e) Simple to operate f) Flexible to accommodate changes in technology, operating requirements and

future expansions / upgrades, as required. 2.0 CODES AND STANDARDS 2.1 The related standards referred to herein and mentioned below shall be of the latest

editions prior to the date of the purchaser's enquiry:

AGA - American gas association, Gas measurement committee

I. AGA Report No. 9 Measurement of gas by Multipath Ultrasonic meters

II. AGA Report No. 10 Speed of sound in Natural Gas & other Related Hydrocarbon Gases

III. AGA Report No. 8 Compressibility and Super-compressibility for Natural Gas and other Hydrocarbon Gases. Transmission Measurement

IV. AGA Report No. 5 Energy Calculations in Natural gas

V. AGA Report No. 7 Measurement of Gas by Turbine Meters.


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ANSI/ASME- / American Society of Mechanical Engineers

B 1.20.1- Pipe Threads

B 16.5 - Steel pipe flanges and flanged fittings

B 31.8 -Gas transmission and distribution piping systems

ANSI/FCI - American National Standards Institute/ Fluid controls Institute

70.2 Control valve seat leakage classification

DIN- 43760 Temperature Vs Resistance curves for RTDs

IEC 801- Electromagnetic compatibility for industrial process measurement and control equipment

IGE/TD/13- Recommendation on transmission and distribution practice for pressure regulating installations for transmission and distribution systems

BS EN-50054-Electrical apparatus for the detection and measurement of combustible gases-General requirements and test methods

BS EN-50057-Performance requirements for Group-II apparatus indicating upto 100% LEL

NEMA 4 & 7-National Electrical Manufacturer’s association

International Organisation for Standardisation (ISO) Process Measurements Control Functions Instrumentation Representations Natural Gas - Calculation of Calorific Value, Density and Relative Density. ISO 12765 Measurement of Fluid Flow in Closed Conduits – Methods using Transit

Time Ultrasonic Flow meters ISO 10723 Natural gas – Performance evaluation for On-line Analytical Systems ISO 5168 Measurement of Fluid Flow: Estimation of Uncertainty of Ultrasonic

Flow meters ISO 2186 Fluid Flow In Closed Conduits - Connections for Pressure Signal

Transmissions Between Primary and Secondary Elements ISO 6569 Natural Gas - Rapid Analysis by Gas Chromatography ISO 6976 Natural gas - Calculation of Calorific Value, Density and Relative

Density

ISO 9951 Measurement of gas flow in closed conduits- Turbine meters

ISO 12213-2 Natural gas. Calculation of compression factor-

Part 2: Calculation using molar-composition analysis,

ISO 12213-3 Natural gas . Calculation of compression factor- Part 3: Calculation using physical properties.

OIML R137-1 Gas meters-Part 1 Requirements. OIML R32 Rotary Piston gas meters and turbine gas meters.

OIML R6 General Provisions for gas volume meters


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3.0 AREA CLASSIFICATION

The gas metering skid/ system shall be installed outdoors and shall be suitable for installation in Zone 1/ Zone 2 Gas Group IIA / II B Temp Class T3 hazardous area. The electronic equipment installed shall be certified by a recognised certifying authority in the country of origin or by an internationally recognised certifying authority and approved by the local authorities. The electronic equipment shall be suitable for continuous operation in the designated hazardous area. Intrinsically Safe (IS) shall be the preferred mode of protection for all instruments. Only where IS certified instruments are not available flameproof EEx ‘d’ certified instruments shall be considered. The junction boxes shall be certified as increased safety (EExe). Conduit connection shall not be used. Intrinsic Safety (IS) protection shall be achieved by providing Fused Galvanic Isolators with status indicating LEDs, located in the respective Metering Panels/ cabinets in the control room/ local equipment room in a safe area. The flow computers, gas chromatograph controller, LEL monitor, Supervisory System and electronic receiver instruments shall be installed in air-conditioned control room/ local equipment room which is a non-hazardous area.

4.0 Environment Protection

All field instruments shall be suitable for reliable and continuous operation under the project environmental conditions specified. The field electronic instruments and junction boxes shall be certified weatherproof to IEC-60529 classification IP 65 as minimum for protection against moisture or dust ingress. The instruments and panels located indoor shall be certified weatherproof to IEC-60529 classification IP 42, minimum. The indoor equipment located in air-conditioned environment shall be designed to operate continuously in the following conditions.

a) Ambient air temperature range : 12 to 48oC b) Relative humidity range : 35% to 65%

However, in case of failure of air-conditioning system the equipment shall be capable of operating for a minimum period of 48 hours in 30 days (Continuous) at the ambient conditions without any damage or degradation in the performance.

5.0 Scope of Work

5.1 Bidder’s scope shall include the skid mounted Gas metering system consisting of Filtration, Pressure Regulating , Metering & associated items for various gas consumers to be installed at respective consumer terminals(Bhilwara & Chittorgarh RT), with the following items described below as a minimum and as shown on the P&IDs.

5.1.1 Gas Metering System Skid 087-M-1201 at Bhilwara RT (Refer enclosed P&ID 6921-02-41-087-1112) is required to be provided as below:

Skid Filtration section, Pressure Reduction section shall be of 600# (piping spec. D1A) & Metering section shall be of 300# (piping spec. B1A).

The skid mounted Gas Metering System as above shall be of required capacity meeting the specified operating design conditions as per process data attached in MR. Bidder’s scope of work shall include supply of the complete skid mounted gas metering System in accordance with this specification and any other codes, standards and regulations stated herein. The scope of supply as a minimum and as shown on the above referred P&ID shall include, but not limited to the following:


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I. Gas Filtration system with two streams (1 operating + 1 stand by stream) each stream of 100% capacity.

II. Gas pressure let down regulating system with two redundant stream (1operating + 1stand by stream) each stream of 100% capacity using Self actuated pilot operated pressure control valves as Regulator Valve and Monitor Valve, Slam shut valve.

III. Additional Gas pressure let down regulating system with two stream (1operating + 1stand by stream) each stream of 10% capacity using Self actuated pilot operated pressure control valves as Regulator Valve and Monitor Valve, Slam shut valve. In full operation condition this unit will be stand-by.

IV. Gas metering system with Ultrasonic multi-path gas flow meters (1-operating + 1stand by stream) with upstream and down stream meter runs and flow profiler. Also Blocking Tee/ Double Tee/ other noise attenuation and piping arrangement as per original meter manufacturer recommendations shall be provided by bidder.

V. Additional gas metering system with turbine gas flow meters (1 operating + 1 stand by stream) with upstream and down stream meter runs and flow profiler. Also Blocking Tee/ Double Tee/ other noise attenuation and piping arrangement as per original meter manufacturer recommendations shall be provided by bidder. This system is only for 5% consumers demand ,during full operation condition this unit will be stand-by.

VI. Four nos. of gas Flow Computer i.e. one for each of the above Ultrasonic Gas Flow meter and Turbine Gas Flow meter .

VII. 1 no. Gas Chromatograph system complete with the following accessories as a minimum:

a) Sample probe with sample transport line & return line including fast loop and pressure reduction station along with all necessary components inclusive of tube fittings, tube connectors etc.

b) Sample conditioning system. c) Skid mounted Field GC, GC enclosure/cabinet fully assembled complete

with all the interconnection tubing, fittings, interconnection cables, junction boxes, glands and other installation accessories.

d) Field calibration equipment e) Carrier gas, Calibration gas cylinders with regulators & fittings. f) Gas chromatograph programming control unit (to be mounted on

metering control panel at control room) and Deskjet colour A4 size printer. g) All the Interconnecting special signal cables (armoured) between field GC

analyzer and control room mounted GC programmer. Power cable from control room to GC analyzer.


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h) Serial interface cables along with all necessary connectors at both ends for communication to the flow computers.

VIII. Metering Supervisory system (as per details specified in this job

specification)

IX. 2 Nos. flow control valve (one with USM metering section & one with Turbine metering section) with E/P Positioner for limiting flow to consumer. Complete Instrument line gas supply system with gas pressure regulator, filter & integral safety valve shall also be provided by bidder for instrument line gas supply to the control valve, as shown in the P&ID.

X. Pressure relief Valves on each filter sized for external fire case.

XI. Skid field instruments like pressure gauges, Temperature gauges, pressure & diff. Pressure transmitters, temperature transmitters, temperature elements & thermo wells, limit switches for slam shut valves.

XII. Metering control panel (to be remote mounted in Local Equipment/ Control room) complete with all Flow computer, GC Control Unit, Metering Supervisory System HMI, Digital indicators, Alarm Annunciator, Single Loop Controller for flow control valve, LEL monitor, Isolating IS barriers, signal selectors, signal distributors, relays, power supplies & accessories, duly mounted and completely wired.

XIII. One no. of laptop with licensed software for GC, FC Configuration, Flow check and SOS calculations.

XIV. LEL detection system with 5-nos. of detectors duly mounted on the skid and one number detector to be supplied loose.All installation accessories shall also be supplied. For skid mounted detectors, cable tray within the skid shall also be supplied & installed by the bidder.

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

XVI. All tubing, and fittings within the skid.

XVII. All cables, cable trays and wiring within the skid.

XVIII. Junction boxes for power, instrument and control cables.

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

XX. Earth bonding system and earthing boss.

XXI. Lifting lugs and spreader beam / frame.

XXII. Stainless steel nameplate for each tagged equipment and component;

XXIII. All Tie-ins shall be provided with flanged connections.

XXIV. Details of skid assembly, supporting positions, Anchor bolt layout and equipment weights to be provided prior to equipment supply.


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XXV. All Interconnecting cables between skid Instrument/Junction boxes to metering panel (to be located in Local equipment/ control room in safe area). Consider cable routing distance of 200 meters from skid to control panel.

5.1.2 Gas Metering System Skid 089-M-1201 at Chittorgarh RT (Refer enclosed P&ID 6921-02-41-089-1112) is required to be provided as below:

Skid Filtration section, Pressure Reduction section shall be of 600# (piping

spec. D1A) & Metering section shall be of 300# (piping spec. B1A).

The skid mounted Gas Metering System as above shall be of required capacity meeting the specified operating design conditions as per process data attached in MR. Bidder’s scope of work shall include supply of the complete skid mounted gas metering System in accordance with this specification and any other codes, standards and regulations stated herein. The scope of supply as a minimum and as shown on the above referred P&ID shall include, but not limited to the following:

I. Gas Filtration system with two streams (1 operating + 1 stand by stream) each stream of 100% capacity.

II. Gas pressure let down regulating system with two redundant stream (1operating + 1stand by stream) each stream of 100% capacity using Self actuated pilot operated pressure control valves as Regulator Valve and Monitor Valve, Slam shut valve.

III. Additional Gas pressure let down regulating system with two stream (1 operating + 1 stand by stream) each stream of 35% capacity using Self actuated pilot operated pressure control valves as Regulator Valve and Monitor Valve, Slam shut valve. In full operation condition this unit will be stand-by.

IV. Gas metering system with turbine gas flow meters (1 operating + 1 stand by stream) with upstream and down stream meter runs and flow profiler. Also Blocking Tee/ Double Tee/ other noise attenuation and piping arrangement as per original meter manufacturer recommendations shall be provided by bidder

V. Additional gas metering system with turbine gas flow meters (1 operating + 1 stand by stream) with upstream and down stream meter runs and flow profiler. Also Blocking Tee/ Double Tee/ other noise attenuation and piping arrangement as per original meter manufacturer recommendations shall be provided by bidder. This system is only for 15% consumers demand ,in full operation condition this will be stand-by.

VI. Four nos. of gas Flow Computer i.e. one for each of the above Turbine Gas Flow meter.

VII. 1 no. Gas Chromatograph system complete with the following accessories as a minimum:

a) Sample probe with sample transport line & return line including fast loop and pressure reduction station along with all necessary components inclusive of tube fittings, tube connectors etc.

b) Sample conditioning system.


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c) Skid mounted Field GC, GC enclosure/cabinet fully assembled complete

with all the interconnection tubing, fittings, interconnection cables, junction boxes, glands and other installation accessories.

d) Field calibration equipment e) Carrier gas, Calibration gas cylinders with regulators & fittings. f) Gas chromatograph programming control unit (to be mounted on

metering control panel at control room) and Deskjet colour A4 size printer. g) All the Interconnecting special signal cables (armoured) between field GC

analyzer and control room mounted GC programmer. Power cable from control room to GC analyzer.

h) Serial interface cables along with all necessary connectors at both ends

for communication to the flow computers.

VIII. Metering Supervisory system (as per details specified in this job specification)

IX. 2 Nos. flow control valve (one with 100% metering section & one with 15% metering section) with E/P Positioner for limiting flow to consumer. Complete Instrument line gas supply system with gas pressure regulator, filter & integral safety valve shall also be provided by bidder for instrument line gas supply to the control valve, as shown in the P&ID.

X. Pressure relief Valves on each filter sized for external fire case.

XI. Skid field instruments like pressure gauges, Temperature gauges, pressure & diff. Pressure transmitters, temperature transmitters, temperature elements & thermo wells, limit switches for slam shut valves.

XII. Metering control panel (to be remote mounted in Local Equipment/ Control room) complete with all Flow computer, GC Control Unit, Metering Supervisory System HMI, Digital indicators, Alarm Annunciator, Single Loop Controller for flow control valve, LEL monitor, Isolating IS barriers, signal selectors, signal distributors, relays, power supplies & accessories, duly mounted and completely wired.

XIII. One no. of laptop with licensed software for GC, FC Configuration, Flow check and SOS calculations.

XIV. LEL detection system with 5-nos. of detectors duly mounted on the skid and one number detector to be supplied loose. All installation accessories shall also be supplied. For skid mounted detectors, cable tray within the skid shall also be supplied & installed by the bidder.

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

XVI. All tubing, and fittings within the skid.

XVII. All cables, cable trays and wiring within the skid.


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XVIII. Junction boxes for power, instrument and control cables.

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

XX. Earth bonding system and earthing boss.

XXI. Lifting lugs and spreader beam / frame.

XXII. Stainless steel nameplate for each tagged equipment and component;

XXIII. All Tie-ins shall be provided with flanged connections.

XXIV. Details of skid assembly, supporting positions, Anchor bolt layout and equipment weights to be provided prior to equipment supply.

XXV. All Interconnecting cables between skid Instrument/Junction boxes to metering panel (to be located in Local equipment/ control room in safe area). Consider cable routing distance of 200 meters from skid to control panel.

5.2 The BIDDER’s scope of work shall also include: i) Design, engineering, sizing, selection, manufacture and/or procurement of materials, components and equipment necessary for complete package. ii) Inspection and testing of all components, sub-assemblies, and complete assemblies of items manufactured at bidder’s works, and other sub- bidder’s works in accordance with approved QA/QC procedure. iii) Shop assembly and hydro tests iv) Factory Acceptance Test (FAT) for the complete package at bidders works. v) Installation supervision for the complete package at site. vi) Site Acceptance Test (SAT) for the complete package at site. vii) Preparation for shipment, packing and delivery of all packages, equipment and material to site. viii) Start-up and commissioning assistance at site. ix) Training of COMPANY’s operating and maintenance personnel x) Preparation and submission of all documents as per requisition with the bid and after award of contract. xi) Preparation and submission Final Documentation / Completion files as per this specification.

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

5.4 Bidder shall include in the bid, list of specific deviations, separately, if any, to this

specification and all attachment thereof, otherwise, the quotation will be deemed to be in compliance with the specification requirements and subsequent claims for extra arising out of non-compliance with the specification will not be considered.

5.5 The scope of work also includes the mechanical and structural detailed design of the

skid, procurement of materials, preparation of fabrication drawings, detailing of internals, fabrication, inspection and testing of the piping and structural items at


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fabrication shop, painting, internal coating if any, preservation, transportation and undertaking guarantee for the equipment.

5.6 The scopes of supply also include the commissioning and start up spares, special

tools & tackles and documentation, bidder to also furnish recommended list of 2 years operational spare parts.

5.7 The bidder shall assume single point responsibility for all aspects of the work. This

shall include timely completion, liaison with purchaser, liaison with his sub vendor of specified items, co-ordination of the work, quality and guarantee for the equipment.

5.8 Where parts of the package are subcontracted and purchased by the bidder, these

become part of the bidder’s package and it is the bidder’s responsibility to ensure that the complete package complies with the specifications, codes and standards and statutory regulations.

5.9 Scope to include all instruments shown in the sketches/ P&ID/schematic, as within

the bidder’s scope.

5.10 The bidder shall be responsible for obtaining necessary approvals, authorization and certification from local Government / Local Statutory bodies, Authorized Inspector and Third Party Inspection Agency as applicable.

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

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

5.13 Bidder shall take single point responsibility for the engineering, design, certification, procurement, inspection, testing, supply & performance of the Gas Filtration, Pressure Reduction and Metering System skids along with all instruments, equipment and valves of the skids, Gas chromatographs, LEL Gas Detection System, and Metering control panels based on the data sheets and the specifications furnished and taking into consideration successful operation, safety and the established International standards for the complete skids. As a part of skid design & engineering, the following shall be decided by bidder:

Sizing of flow meters, Self actuated Pressure control valves (monitor &

Regulator), Safety Shut Off (Slam Shut) valves, Pressure relief valves/ Creep relief valves and Flow control valves.

Set points for Pressure regulators Monitor and slam shut valves. Instrument ranges to meet the Process operating and design conditions Noise calculations for PCVs, Slam Shut valves Noise attenuation devices for Ultrasonic meters, provision of appropriate

protection as required. Meter Run design Skid Piping sizing and design

Bidder to note that skid main piping size (from skid inlet upto PCV (active) & from PCV (active) outlet upto skid (outlet) shall be as shown in the relevant sketch are to be followed by bidder. Similarly the meter size has also been decided as per respective datasheets to be followed.


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5.14 Typical instrument data sheets for Self actuated pressure control valves (PCVs), Slam shut valves, Ultrasonic flow meters, Turbine flow metes ,Gas chromatograph, LEL Gas Detection System, Pressure relief valves, Flow control valve, field transmitters, pressure gauges, Diff. pressure gauges, temperature gauges and accessories indicate materials for body, internals etc. However, this does not absolve the Bidder of the responsibility for proper selection with respect to the fluid and its operating and design conditions. Proper sizing and selection of the ultrasonic flow meters, Turbine flow meters, self actuated pressure control valves for monitor and regulator, slam shut valves, flow control valve and Pressure relief valves and accessories are bidder’s responsibility.

5.15 Bidder to note that all the items including Self actuated pressure control valves (Regulator and monitor Valves), Slam shut valves, flow meters, Flow computers, Gas chromatograph, Pressure relief valves, Control valve, Pressure & diff. Pressure transmitters, Temperature instruments, LEL Detection System, etc. shall be supplied from bidders having proven track record of successful operation for at least 4000 hours till bid due date. Details of earlier supplied references shall be furnished as part of the bid.

5.16 Bidder shall be fully responsible for proper integration of their supplied systems and

Flow Computers and also integration with GAIL’s SCADA (RTU) systems. Bidder shall provide all necessary assistance to purchaser for establishing communication between Flow Computers/ GC and SCADA RTU through serial link.

6.0 BIDS

6.1 Bidder's proposal shall include the detailed specifications for all items of Gas Filtration, pressure reduction and metering, and gas chromatograph packages. The offer shall include: Make, Model no, detailed specification for each flow meter, flow computer,

pressure relief valve, gas chromatograph, LEL Gas Detection System, pressure/ differential pressure transmitter, Temperature Elements, Temperature transmitters and monitors, pressure/ temperature/ Differential Pressure gauges, proximity limit switches, Alarm annunciators, Single loop Controllers, indicators, etc.

Slam shut valve, self actuated pressure control valve (monitor and Regulator Valves) details including type, construction material, CV data/ capacity curves, regulation accuracy, set point spring ranges, details of the valve pilots etc.

Sizing calculations for slam shut valves, self actuated pressure control valves (monitor and Regulator Valves), Flow control valve, flow meters and pressure relief valves. Gas velocities and Pressure drop across slam shut valves and meter runs at maximum flow and minimum pressure

All design & performance characteristics.

Noise level calculations for self actuated pressure control valves.

Overall dimensions of each item

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


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Weight of each metering skid, gas meter run, GC skid

Foundation details (suggestive) of each metering skid, GC skid

Bidder shall submit certification of complete design and engineering of the metering skid including piping GAD and P&ID duly approved by NMI Netherlands/ PTB Germany/ LNE France or the original equipment manufacturer of Ultrasonic meter for custody transfer application and certificate shall state that the ‘Overall System Uncertainty’ and repeatability of flow measurement shall be within the specification limits of the MR.

6.2 All units of measurements in bidder’s specification sheets shall be same as those in

purchaser’s data sheets.

6.3 All material specifications for the various parts in the bidder’s specification sheets shall be to the same standard as those in purchaser’s data sheets.

6.4 Bidder shall enclose catalogues giving detailed technical specifications and other information for slam shut valve, self actuated pressure control valve for monitor and Regulator, control valve, multi-path ultrasonic flow mete ,turbine flow meter, flow computers, pressure relief valve, gas chromatograph, LEL Gas Detection System, Metering Supervisory System, pressure/ differential pressure transmitter, temperature transmitters, temperature elements, temperature gauges, pressure gauges, digital indicators, alarm annunciator, barriers and isolators, etc. covered in the bid.

6.5 Bidder’s quotation including catalogues, drawings, operating and maintenance manuals etc. shall be only in ENGLISH language.

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

7.0 DESIGN CONSIDERATIONS

7.1 The skids shall be complete in all respect, ready for quick installation and commissioning of equipment with minimum work at site. All field-mounted instruments shall be mounted on the skid. Ease of transportation shall be one of the considerations in deciding the size of skid.

7.2 The skid shall be complete with piping, flanges, and fittings for Filtration, pressure reduction and metering as required.

7.3 Ultrasonic/Turbine Gas Metering System (both for skids) i.e. meter, meter run, flow

profiler and flow computer shall be built and integrated by the original equipment manufacturer of the Ultrasonic/Turbine Flow Meter, since critical components within the custody transfer metering system should be compatible to ensure “Overall System Uncertainty” with all components within the metering system must be well proven and compatible in the similar application. Bidder shall take full responsibility for the performance of gas meters, flow computers and its integration with the gas chromatograph, Metering Supervisory System and to be involved in meter run design, configuration, testing & calibration of meter. The straight length of calibrated


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pipe forming the upstream and downstream parts of the meter tubes shall be cut from one piece of pipe without any intermediate girth weld.

7.4 All meter run pipes shall be specially selected for dimensional accuracy and shall be free from all imperfections and corrosion on internal surfaces. Meter runs shall be chosen according to applicable geometric requirements of AGA 9. For Turbine meter these shall be as per AGA7.

7.5 The calibrated meter runs shall be easily removable and shall be connected to a adjacent piping by means of flanges.

7.6 All piping shall be rigidly supported. Adequate pipe supports shall be provided for the complete meter tube assembly. These shall be bolted to the skid structure and shall be designed and located with due regards to weight distribution and operational pipe stress.

7.7 The gas flow meter and meter tube piping shall be installed in a region of zero stress

in the pipeline to minimize strain on the meter. The upstream pipe work shall be carefully aligned to minimize flow disturbances, especially at the upstream flange of the meter.

7.8 As a minimum, flow conditioners shall be 316 stainless steel between-flanges. These shall comply with the requirements of AGA 9 for ultrasonic meters and AGA7 for turbine meters.here flow conditioners are recommended, care must be taken to select flow conditioners that do not generate acoustic noise with harmonic frequencies that may interfere with the USM performance.

7.9 The skid shall be prefabricated and mounted on a steel frame. It shall have inlet flange for inlet side and outlet flange suitable for outlet side. It shall have separate vent connections.

7.10 Each skid shall be complete in all respect ready for alignment & grouting at site.

7.11 All items shall be properly supported to avoid vibration. Special support as required

shall be provided by bidder.

7.12 Optimise access to instruments and fittings. All equipment shall be oriented to permit servicing without undue dismantling and to have good access and maximum safety.

7.13 The equipment shall be bonded for earth continuity and two external earthing bosses shall be provided, on each skid at diagonally opposite ends, for connection to the plant earth grid.

7.14 Lifting lugs and their supporting structure shall be designed for a load equal to two times the weight to be lifted (shipping weight).

7.15 All tubing and fittings used for impulse piping shall be of SS 316. Tube fittings shall

be flare less compression type of three-piece construction consisting of ferrule, nut and body suitable for use on SS tubes. Instrument valves and manifolds shall be of SS316 construction of forged type.

7.16 The specifications of all the instruments shall be as per the attached Instrument Data Sheets, Job Specifications and Standard Specifications. All piping materials including valves & flanges shall be supplied as per the piping material specification (PMS) attached elsewhere in the package.


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7.17 All interconnecting instrument cables in skid, for meter transducers and cables to

control room shall be armoured. All signal and alarm cables shall be individual pair shielded and overall shielded. Bidder shall follow the cable specifications as per signal cable standard specifications.

7.18 All field transmitters, proximity type limit switches and I/P converters shall be certified weather proof to minimum IP65 and intrinsically safe suitable for hazardous area classification IEC Zone 1, Gr. IIA, IIB, T3.

7.19 All Junction boxes, cable glands & accessories shall be certified weather proof to

minimum IP55 and Flame proof suitable for hazardous area classification IEC Zone 1, Gr. IIA, IIB, T3.

7.20 The certification for use of all instrumentation items including junction boxes/cable glands etc. in hazardous areas shall be as follows: • Certificates from statutory authorities like BASEEFA, FM, PTB, UL, and

CENELEC etc. for items of foreign origin and from CMRI etc. for items of Indian origin.

• Approval certificate from PESO/ CCE (Chief Controller of Explosives) for items to be installed in India, irrespective of country of origin and the same is mandatory.

• Approval certificate from BIS (Bureau of Indian Standards) for all flameproof instruments manufactured in India.

7.21 All field mounted instrumentation items shall be suitable for continuous working in outdoor installations, considering temperature, humidity etc. as per data given elsewhere in this bid. Ingress protection for all field instruments and enclosures/ junction boxes/ cable glands etc. shall be IP-55/ NEMA 4 as minimum. Instruments mounted on the skid, gas metering systems shall be suitable for installation in tropical hot and humid climate considering:

Temperature 0-48 deg. C

Rel. Humidity 90%

7.22 The flange rating & materials of all instrument items shall be as per the PMS.

7.23 The bidder shall include isolation valves in Impulse Lines for the pressure regulators and monitors, slam shut valves etc. The pressure instruments shall be provided with individual process isolation valves and block and bleed manifolds.

7.24 Transmitters shall be microprocessor based “SMART” type with HART Protocol. Accuracy of transmitters shall be + 0.04% of FSD or better for PT, + 0.075% of FSD or better for DPT and ±0.2% FSD or better for Temperature Transmitters. All transmitter shall be provided with integral output meter with digital display.

7.25 The temperature transmitters shall be PT 100 RTD sensor type with integral head mounted SMART transmitter with two wire 4-20 mA DC output, 24 VDC loop powered complete with local output meter (LCD type). The temperature transmitter shall be provided with flanged thermowell of 316SS material fabricated from drilled bar stock.


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7.26 Any pipe line size less than 4" nominal bore shall be blown to 4" size to install thermowell. However thermowell in meter run shall be screwed type and of suitable length, where meter size is less than 4”.

7.27 Bidder shall furnish details of foundation required for the gas Filtration, pressure reducing & metering skids, GC skids.

7.28 For ease of transportation of the skids, bidder may decide to fabricate and transport

the skid in more than one section (Filtration section, Pressure reduction section, Metering section), especially for skids having 6” & higher inlet/ outlet sizes. In that case, bidder shall ensure that the site job shall only be limited to bolting together these parts at site and no further welding or joining of components together etc. are required. The responsibility of such jointing together and its proper functioning would rest on the bidder.

7.29 The gas chromatograph field analyser cabinet along with sample conditioning system

and carrier & calibration gas cylinder racks shall be mounted on a standalone steel frame structure with its independent mounting arrangement along side the main Filtration, Pressure reduction & metering skid (as applicable).

8.0 SPECIFICATIONS FOR INSTRUMENTS

8.1 SELF ACTUATED PRESSURE CONTROL VALVES (MONITOR AND REGULATOR VALVE) AND SLAM SHUT VALVES

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

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

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

8.1.4 The construction of the Regulators shall be such that there will be no continuous gas bleeding.

8.1.5 Bidder to note that the noise level for each Regulator/ monitor and Slam Shut valve shall be less than 85dBA at one meter away from the valves. Bidder shall provide noise treatment to limit the noise level and include silencers or expanders as required in their scope of supply.


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

8.1.7 Closing time of slam shut valve shall be less than 2 seconds or better for all sizes of the valves. Actual closing time of the valve shall be furnished by bidder with the quotation.

8.1.8 Slam shut valves shall be provided with position indicator and shall have separate limit switches for open and close positions. Limit switches shall be proximity type with DPDT contact rating 1 A @ 24 V DC. Limit switch enclosure shall be weather proof to IP 55 suitable and certified for area classification IEC Zone 1, Gr. IIA, IIB, T3. Cable entry shall be ½” NPT with out flying leads.

8.1.9 Resetting of slam shut valves shall be only manual.

8.1.10 Slam shut valves shall be provided with a mechanical indicator to indicate valve open or close position.

8.1.11 Slam shut valve shall have a set point accuracy of ±1% over the whole operating range.

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

8.1.13 For slam shut valve sizing a maximum velocity of 40 meter per second shall be considered. Actual velocity shall be indicated by bidder in the offer.

8.1.14 Bidder shall furnish the flow rate versus trim lift curve to justify the valve rangeability and valve regulation characteristics.

8.2 TECHNICAL SPECIFICATION FOR ULTRASONIC FLOWMETER

8.2.1 Ultrasonic flow meter shall be multi path (minimum four path) type gas flow metering application and the design, construction and operation shall confirm to AGA report9 (latest version) for multi path.

8.2.2 The principle of operation used shall be simple in design and shall avoid analytical complexity associated with development of information, which is extraneous to the application.

8.2.3 The design used shall provide maximum reliability, maximum on-line performance and minimum maintenance. Instrument shall be field proven. No prototype instrument shall be supplied. Technique of measurement used shall be interference free. It shall be immune to other impurities in the fluid stream.

8.2.4 FLOWMETER

8.2.4.1 The flow meter shall comprise of multipath (minimum four path) ultrasonic transducers. The transducers shall be energized by the integral electronics to transmit and receive ultrasonic waves. Bidder shall size all the ultrasonic flow meters for the given process conditions as per AGA 9. Sizing shall be done considering maximum flow capacity at minimum inlet operating pressure & gas composition and other process conditions. Meter size shall not be smaller than the size as indicated in flow meter datasheets . Bidder may offer higher size meter in case manufacturer`s meter have lower velocity limitations.


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8.2.4.2 The turndown ratio of each flow meter shall be minimum 1:50. The accuracy of the Ultrasonic flow meter shall be ±0.3% or better (accuracy shall include the uncertainties of all the skid components) and repeatability shall be better than ±0.1 % of reading with flow calibration and accordingly bidder shall select the no. of paths (four path or higher) to meet accuracy requirement and indicate the same in calculations/back-up literature.

8.2.4.3 The meter shall be provided with pressure tap of ½” NPT (F) size to measure the

static pressure in the meter.

8.2.4.4 The meter body shall be made of carbon steel as per data sheets (ASTM A 216 GR. WCB or equivalent). All flanges shall be weld neck, raised face and shall meet ANSI B 16.5.

8.2.4.5 The ultrasonic metering system shall be provided with full diagnostics and customer user interface for the gas meter.

8.2.4.6 It shall be possible to replace or relocate transducers without a change in meter

performance. After an exchange of transducers and a possible change of the associated software constants, the resulting shift in the meter's performance should not be more than the allowable repeatability of the meter. In addition, the maximum error and the maximum peak-to-peak error as detained in figure 5.2 of AGA-9 shall not be exceeded.

8.2.4.7 The bidder shall comprehensively advise the impact of transducer failure on the performance and accuracy of the USM. Bidder shall confirm that the measurement will not degrade by more than ± 0.1% in case of loss of one path.

8.2.4.8 The meter design shall have the facility to remove /replace the transducers in situ under line operating condition. Failure or removal of one pair of transducers shall not cause the meter to lose all measurement function. Failure of any path shall generate an alarm identifying the affected path. Also transducers ports shall be designed in a way to reduce the possibility of liquid or solid accumulation.

8.2.4.9 Area classification shall be IEC Zone-1, Gas Gr. II A & IIB, and Temperature Class

T3. All electrical instruments in the field shall be suitable for the specified area classification and certified by a statutory body such as FM, UL, ATEX etc. The transducers shall be intrinsically safe certified suitable for the specified area classification and weather proof to IP65/NEMA-4 and bidder shall supply necessary isolating barriers between the transducers and preamplifier/transmitter. However the transducer/sensor housing can be flameproof (EEx d) certified suitable for the specified area classification instead of intrinsically safe.

8.2.4.10 Overall pressure drops across the meter assembly including meter runs shall be less than 0.1 Kg/cm2g. Pressure drop calculation across the meter shall be furnished.

8.2.4.11 Ultrasonic meters shall be rated for the maximum design pressure as indicated in the datasheet.

8.2.4.12 Ultrasonic flow meter spool inside diameter to meet the specified I.D and internal surface roughness shall be as per standard AGA Report no. 9.

8.2.4.13 All ultrasonic flow meters shall be supplied with upstream meter run with flow conditioners (min.10D+10D) and downstream (min.5D) meter runs as per AGA 9.


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8.2.4.14 Ultrasonic meters and the meter runs/flow conditioners shall be rated for the maximum design pressure.

8.2.5 ELECTRONICS:

8.2.5.1 Meter electronics (Signal Processing Unit) shall include all associated transmitters, pre-amplifiers etc.

8.2.5.2 The meter signal processing unit shall be microprocessor-based electronics suitable for installation in the field under the ambient condition specified. Meter electronics shall be Weather proof to IP 65/ NEMA 4 and flameproof certified suitable to install in area classification IEC Zone-1, Gas Gr. IIA & IIB, Temp. Class T3 by a statutory body such as FM, UL, ATEX etc.

8.2.5.3 The electronics unit shall preferably be mounted integral on the meter.

8.2.5.4 The signal processing unit /transmitter shall have extensive diagnostic capability. Self-diagnostic feature should include monitoring the health of the transducers and signal quality.

8.2.5.5 Meter parameters and factors set into the meter electronics shall be retained in non-volatile memory and shall be secured with password such that un-authorised changes are prohibited.

8.2.5.6 Configuration software, diagnostic software and firmware shall be provided.

8.2.5.7 Meter output signals from the meter electronics shall be without flying leads. All the signals from the meter electronics shall be terminated in a junction box (JB) supplied by the meter bidder and shall be mounted on skid. JB shall be weather proof (WP) to IP 65/NEMA 4 and flameproof certified suitable for the specified area classification.

8.2.5.8 The cable entry sizes between meter electronics and transducers shall be decided by bidder and the WP & flameproof cable glands to be supplied accordingly. Cable entry sizes shall be as per NPT standards.

8.2.5.9 Meter electronics shall be capable of multiple output signals as follows:

a) Dual frequency pulse outputs to flow computers configurable for flow rate signals and shall be user selectable to be either same outputs or one signal dedicated to each direction of flow.

b) Digital discrete outputs for direction of flow, trouble alarm and output data validation.

c) RS-485/422 communication port with MODBUS protocol for communicating with the other control system i.e. control room mounted flow computer for meter diagnostics, test and health data.

Bidder shall supply the RS 485/422 cables interconnecting serial link cables which shall be armoured including & connectors against each tag for communication between flow meter in field and flow computers mounted on metering control panel located at respective control room as per the station wise distances between field & control room.

8.2.5.10 Meter electronics shall operate on 230 V AC ± 10%, 50 Hz ± 3% UPS or 24 VDC and shall be protected from overload and from transients. Low power consumption is desired.


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8.2.5.11 Speed of Sound comparison should be done in the stream flow computer for the

speed of sound measured value from the USM and the speed of sound calculation based on the GC component data.

8.2.6 CALIBRATION AND CERTIFICATION:

8.2.6.1 Each meter shall be “zero calibrated” (“dry calibrated”) with nitrogen. Test results shall be furnished. In the dry calibration set up, the gas velocity observed on all the acoustic paths shall be zero. The speed of sound of the individual acoustic path in the dry calibration set up shall not exceed ±0.2% of the mean velocity of all the paths.

8.2.6.2 Flow calibration shall be performed for at least seven points with two point verification and error curve shall be obtained. Calibration of meter shall be done near Operating Pressure(average of minimum & maximum metering/outlet pressure) Test medium shall be Natural Gas. Flow calibration of each ultrasonic meter shall include the associated U/S meter run with flow conditioner and D/S meter run being supplied with the meter.

8.2.6.3 Bidder shall carryout performance test and certify the meter in combination with its

companion electronics. A recognized test facility with traceable reference measurements shall be used. Flow test data at 7 points covering the minimum to the maximum flow rate shall be obtained for ascertaining the meter linearity and repeatability with in the specified limits.

8.2.6.4 The Ultrasonic meters shall be ‘wet flow calibrated’ with natural gas and shall have calibration certificate duly signed by weights and measures authority such as NMI, PTB or other reputed National Standard laboratory such as Trans Canada Calibrations, (TCC) Canada ,Colorado Engineering Experiment Station Inc.(CEESI) USA ,South West Research Inc. (SWRI) USA. Accuracy with wet flow calibration shall be demonstrated within ±0.3% for multi path type under flow conditions in the turndown ratio of 1:10. The meter proving system to be used by bidder shall be traceable to international standards and uncertainty of meter proving system shall be furnished. Gas metering system integration, testing, validation and including third party "wet' calibrations (only for the ultrasonic meters with its associated upstream / downstream meter runs) should be done in flow labs as detailed above. Wet flow calibration shall be performed at pressure and flow rate close to the operating pressure and flow rate, depending upon the highest pressure and flow rate available with the calibration facility.

8.2.6.5 The gas flow computer for use in custody transfer applications shall be certified by laboratory / institutes authorized by weights and measures authorities such as NMI, PTB, NIST, Measurement Canada or certification for custody transfer from International Standard laboratories/ Institutes /bodies such as Pigsar, Trans Canada Calibrations(TCC) Canada, Colorado Engineering Experiment Station Inc.(CEESI) USA GOST, South West Research Inc. (SWRI) USA.

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


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8.2.7 CHECK & PAY CONFIGURATION AND APPLICABLE FOR ULTRASONIC METER (USM) BASED METERING SKIDS

The following Procedure is applicable for USM based Metering skids having Z-Configuration (for Meter Verification through PAY-CHECK configuration). This scheme/ configuration shall be implemented in the Supervisory system (refer details provided in this job specification) being provided by the Bidder:

Stream-1 shall be selected in “PAY” mode and Stream-2 can be selected in “CHECK” mode. Both “PAY” and “CHECK” Flow computers (Stream-1 and 2) shall do fiscal metering separately/ independently and update data in the supervisory computer. In “PAY” Flow computer all fiscal totals get incremented. In “CHECK” Flow computer only maintenance totals get incremented. When the User decides to do meter verification and selects the “PAY” and “CHECK” streams at the meter verification window. The stream selected as “CHECK” shall put its Flow computer in “Maintenance mode” automatically by the HMI system and thereby its maintenance mode totals in the Flow computer shall increment, keeping the fiscal totals at the last reading. Once the streams-1 and 2 are selected in “PAY” and “CHECK” mode respectively and the User clicks on the begin button, a confirmation is required from the user to proceed ahead. Once the user confirms, system prompts to align the Valves according to PAY-CHECK streams configuration. The Valve alignment procedure during meter verification is mentioned below. Once User manually aligns the Valves according to PAY-CHECK streams, reconfirmation is requested from the User that the Valve alignment has been completed. HMI system also verifies the correct valve alignment by checking valve open / close feedbacks. After User confirmation by clicking Start button, the system captures cumulative UVOL, CVOL, Mass and Energy Totals of “PAY” Flow computers and are stored as Start status. For “CHECK” Flow computer, Maintenance UVOL, CVOL, Mass and Energy Totals are recorded as Start status of “CHECK” Flow computer. Cumulative Totalisers of “PAY” Flow computer and “CHECK” Flow computer increment till User Clicks on Stop Button. When verification is stopped, the system displays respective Totalisers for the Flow computers as Stop status and also calculates the difference between Stop status and Start Status. Percentage difference between “PAY” Flow computer Totalisers and “CHECK” Flow computer Maintenance Totalisers are calculated and displayed as accuracy indication of Meter under Test. After Meter verification has been stopped, User can either press Yes Button to continue with the meter verification or else press NO Button to move ahead in the sequence and then align the valves as per the procedure mentioned below. After User clicks “RESET” Button, and confirms the “Reset” then the Flow computer status of “CHECK” stream is changed from Check to Offline, resets all other parameters like difference and accuracy readings.

This completes the Meter Verification.

a. Valve Alignment procedure during meter verification:

Correct sequence of Valve operation is as follows when “PAY” stream is to be verified using “CHECK” Stream.

1. Open “PAY” stream Inlet Valve 2. Open Crossover Valve(s) and rotate spectacle blind to open position. 3. Ensure closure of “CHECK” Stream Inlet valve


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4. Open Outlet valve of “CHECK” Stream 5. Close “PAY” stream Outlet Valve.

b. Valve Re-alignment procedure after completion of meter verification:

1. Close Cross over Valve(s) and put spectacle blind in close position. 2. Open “PAY” stream Outlet Valve 3. Close Outlet valve of “CHECK” Stream

8.3 TECHNICAL SPECIFICATION FOR TURBINE METER

8.3.1 The turbine meter shall be axial flow type gas turbine meter in which the entire gas stream passes through the turbine meter rotor.

8.3.2 The turbine metering of natural gas shall be designed manufactured and tested, as per AGA report no. 7.

8.3.3 Transmitter and other electrical accessories of Turbine meter shall be suitable for area classification. Enclosure of intrinsically safe system shall be weather proof as per NEMA 4. Explosion proof enclosure shall also be made weather proof as per NEMA 4 + 7.

8.3.4 Bidder shall furnish the sizing calculations to justify the selection of turbine meters considering the density/compressibility of the given composition of the gas. The sizing shall be done at the minimum operating pressure, maximum flow and max operating temperature for determining the meter max. flow. Meter size shall not be smaller than the size indicated in Annexure I.

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

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

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

8.3.8 The transmitter shall provide two separate output pulse. Transmitter shall be mounted separate from the Turbine Meter or Bidder to bring pulse output to flow computer.

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

8.3.10 Straightening vanes shall be provided to eliminate swirls and cross current setup by the pipe fittings, valves or regulators preceding the meter inlet piping. Straightening vanes shall be according to AGA Report No-7. Straightening vanes shall be bundle of 316 SS tubes.

8.3.11 Bidder shall furnish pressure drop figures for each turbine meter, flow straightner at normal operating conditions and at max case.


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8.3.12 While selecting the meter, bidder to ensure that the fluid velocity in the turbine meter shall not exceed 15 m/s.

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

8.3.14 The meters shall be certified by weights and measures, and shall be calibrated to an accuracy of 0.5% band (with gear adjustment of ± 0.1%). Bidder shall furnish the documentary proof in support of the above along with certified calibration curve. All meters selected shall be of field proven quality with respect to design, material and application. Field mounted instruments shall be capable of working under high ambient Temperature and environmental condition without any degradation in accuracy and repeatability.

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

8.3.16 The turbine meter shall be calibrated with natural gas near operating pressure and shall have following performance:

Range ability: 20: 1

Repeatability: ±0.1%

Linearity: For flow rates between 10% and 100% (of meter max.) at normal pressure the calibration curve (min.7 points) shall be within an envelope of 0.5%.

8.3.17 Certification and calibration

8.3.17.1 The gas flow computer for use in custody transfer applications shall be certified by laboratory / institutes authorized by weights and measures authorities such as NMI, PTB, NIST, Measurement Canada or certification for custody transfer from International Standard laboratories/ Institutes /bodies such as Pigsar, Trans Canada Calibrations(TCC) Canada, Colorado Engineering Experiment Station Inc.(CEESI) USA GOST, South West Research Inc. (SWRI) USA.

8.3.17.2 The Bidder shall furnish the regulations of the certifying authority considered by him

for custody transfer applications. If other instruments are also needed to be certified as per the regulations the same shall be complied.

8.3.17.3 Flow calibration shall be performed for at least seven points. Test medium shall be

Natural Gas.

8.3.17.4 Bidder shall carryout performance test and certify the meter in combination with its companion electronics. A recognized test facility with traceable reference measurements shall be used. Flow test data at 7 points covering the minimum to the maximum flow rate shall be obtained for ascertaining the meter linearity and repeatability with in the specified limits. Each meter calibration shall be done for at least two pressure settings covering the minimum & max. pressure range of the turbine meter.

The Turbine flow meters shall be ‘flow calibrated’ with natural gas and shall have calibration certificate duly signed by weights and measures authority such as NMI,


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PTB or other reputed National Standard laboratory such as Trans Canada Calibrations, (TCC) Canada ,Colorado Engineering Experiment Station Inc.(CEESI) USA ,South West Research Inc. (SWRI) USA. Accuracy with wet flow calibration shall be demonstrated under flow conditions in the turndown ratio of 1:10. The meter proving system to be used by bidder shall be traceable to international standards and uncertainty of meter proving system shall be furnished. Gas metering system integration, testing, validation and including third party "wet' calibrations (only for the Turbine meters with its associated upstream / downstream meter runs) should be done in flow labs as detailed above Wet flow calibration shall be performed at pressure and flow rate close to the operating pressure and flow rate, depending upon the highest pressure and flow rate available with the calibration facility

8.4 TECHNICAL SPECIFICATIONS FOR CONTROL ROOM MOUNTED FLOW COMPUTER

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

8.4.2 For Control Room mounted flow computers approval for custody transfer applications by laboratory / institutes authorized by weights and measures authorities such as NMI, PTB, NIST, Measurement Canada or certification for custody transfer from International Standard laboratories/ Institutes /bodies such as Pigsar, Trans Canada Calibrations(TCC) Canada, Colorado Engineering Experiment Station Inc.(CEESI) USA GOST, South West Research Inc. (SWRI) USA shall be submitted.

8.4.3 The flow computers shall compute and display the instantaneous and totalized flow rate for each stream corrected for pressure and temperature variations. The flow computers receive data from the Gas Chromatograph for calculation of the Gross Heating Value (GHV) and Net Heating Value (NHV) of the gas. The flow computers shall be microprocessor based, with keypad and alphanumeric display with AGA firmware for natural gas flow measurement. The flow computers shall be linked to the GAIL’s RTU for providing the flow measurements of the individual stream runs and related process variables.

8.4.4 Mounting shall be Flush panel type. General purpose enclosure.

8.4.5 POWER SUPPLY: Power supply of 230 V AC ± 10%, 50 Hz ± 3% UPS .

8.4.6 INPUT SIGNAL CAPABILITY:

a) Dual frequency/pulse signals from ultrasonic flow transmitter (meter mounted electronics)

b) 4-20 mA D.C. (2 wire) superimposed with digital signal (HART protocol) from ‘SMART’ pressure transmitter representing line pressure.

c) For line temperature bidder shall take 4-wire RTD signal input directly to Flow Computer (without using TT) using Quad cable (by bidder).

(b) & (c) shall be a part of intrinsically safe circuits. Transmitters shall have a load driving capability of 600 ohm at 24 V D.C. Bidder to note this while choosing the precision resistor inside the flow computer for converting 4-20 mA signal to voltage signal. Maximum value of this resistor shall not exceed 250 ohm.


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d) RS 485/422 MODBUS from ultrasonic flow meter electronics for meter

diagnostics and healthiness parameter.

e) Other standard inputs available.

f) Discrete inputs from ultrasonic meter electronics

8.4.7 INTERFACE CAPABILITY WITH OTHER FOREIGN DEVICES:

Bidder shall provide serial links along with cables and connectors at both ends for all the signals with MODBUS protocol.

8.3.6.1 WITH GAS CHROMATOGRAPH (as applicable) Flow computer shall be interfaced with Gas chromatograph for feeding online gas composition to flow computer through a modbus serial link. Bidder shall be responsible for proper integration of their flow computer with gas chromatograph. Bidder shall provide all necessary hardware, software etc. in bidder’s supplied .

8.3.6.2 WITH RTU :

Flow computers shall be interfaced with GAIL’s RTU for flow metering and gas composition data such as gas temperature and pressure, energy flow rate and total energy, corrected volumetric flow rate and total flow, last day’s cumulative energy and volume, current day’s running volumetric total and energy total, volume and energy integrated at 6 a.m., gas composition (C1, C2, C3, iC4, nC4, iC5, nC5, C6+, Specific gravity, Calorific value, mol% of N2, CO2) etc. Bidder to note that SCADA vendor shall provide RS 485 serial link at the RTUs for interfacing of intelligent electronic devices like flow computers. For flow computer interface to RTU, bidder shall accordingly provide RS 485 link (Modicon Modbus ASCII & RTU protocol supporting IEEE single precision floating point no. with user configurable register). The digital and analog data shall be made available to RTU (SCADA) and it shall be mapped in the contiguous registers so that data can be fetched / written in minimum transactions. Flow computer shall have provision to configure a IEEE floating point in two 16 bit modbus register. Provision shall also be kept at flow computer for writing data from RTU e.g. in some Flow computer there will be requirement of downloading gas compositions, calorific value and flow set point etc. from RTU.

Bidder shall furnish all details like pin configuration and signal wise MODBUS address mapping list etc. for smooth interfacing of this communication link with RTU (SCADA). Bidder shall also furnish the details of implemented MODBUS protocol like function codes for read and write, CRC implementation, BCC implementation, register addressing methods/mapping etc. during detail engineering for serial interfaces to SCADA (RTU).

8.3.6.3 With metering Supervisory System (refer details specified in this job specification)

8.4.8 KEYPAD CAPABILITY:

The data entry keypad shall have the provision to enter the following: (a) Pressure and temperature base factor

(b) Specific gravity and scaling factor


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(c) Mol % or composition of the gas to be metered

(d) Report headings, frequency and timing of reports

(e) Selection of parameter to be displayed and on-demand printing of reports

(f) Calorific value

(g) Flow, pressure, temperature and density values and give compensated flow for any external conditions

(h) Gas Compressibility

(i) Other standard features available

(j) Atmospheric pressure, K-factor, Meter factor, Linearization curve, Flow set point, selection of local/remote FCV set point, Selection of GCV/NCV for Energy calculations.

The flow computer shall have provision to enter default values of all inputs (inclusive of gas chromatograph) low/high alarms for all inputs (inclusive of gas chromatograph) and shall be user configurable. The flow computer shall use the default values in case any input goes beyond low/high limit.

8.4.9 OUTPUT CAPABILITY:

(a) 4-20 mA compensated volume flow rate output & Flow set point ( as external remote set point )for flow controller, energy rate (or mass flow rate),

(b) Contact alarms output for unit malfunction, process alarm etc. (3 nos.).

(c) RS 485 serial output link for telemetry link for all signals as specified (refer clause No. 8.4.6.2 of this specification).

(d) RS232C serial link for owner’s PC for reports

(e) Other standard outputs available (Minimum 2 nos. 4-20mA analog output for pressure & temperature)

(Galvanic isolation is required for all inputs and outputs. Active isolators, as required, shall be included by the bidder suitable for DIN rail mounting inside bidder supplied control panel. 24 V DC for powering the isolators shall be distributed by bidder inside their cabinet. Isolating relays shall be provided for potential free contact generation from switched inputs)

8.4.10 COMPUTATIONAL CAPABILITY:

(a) Volume flow rate at standard, normal or operator specified base conditions (Sm3/hr)

(b) Integrated corrected volume.

(c) Mass flow rate and integrated mass.

(d) Energy flow rate and integrated energy.


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(e) Linearization of temperature input.

(f) Generation of standard and user defined reports at ticket printer. All reports shall be user configurable.

(g) Co-efficient of deviation from ideal gas law as per AGA 8 on the basis of specific gravity, temperature, pressure and mol % of N2 and CO2 and other compositions for all flow computers

(h) Previous day’s flow / energy (i.e. yesterday’s 6.00 A.M total volume / energy to today’s 6.00 A.M total volume / energy) & current running total for the day (i.e. volume tantalizer/ integrator value at 6.00 A.M from first day) to be stored in a separate location (register) and these shall be user configurable.

(i) Today’s accumulated flow /energy (running total since morning 6.00 A.M to current time) and shall be user configurable.

(j) Generation of reports for totalized volume & energy at daily (6 a.m), weekly, fortnightly & monthly intervals etc. shall be user configurable.

(k) All the above data shall also be made available by bidder in the serial links to RTU.

8.4.11 STANDARDS USED:

For the above, applicable standards are: (a) AGA report 9 for flow rate and total flow for all tags for Ultrasonic meter (b) AGA-8 characterization method to determine density, compressibility, super

compressibility factor etc. for flow computers (c) AGA Report 5 / GPA 2145 & GPA 2172 (2009 version) / ISO6976 (user

configurable) for energy rate and integrated energy.

8.4.12 ENGINEERING UNITS:

Volume flow rate - Sm3/hr, Mass - kg/hr, Pressure - kg/cm2g, Temperature - °C, Energy – Kcal /MMBTU / MCal / MJ (user User configurable or configurable during FAT)

8.4.13 MEMORY TYPE: Non-Volatile

8.4.14 A/D AND D/A CONVERTORS:

Calculation accuracy shall be better than ± 0.05% of full scale including linearity, hysteresis, repeatability and resolution. Accuracy for analogue inputs to be minimum 0.05% and for analogue outputs accuracy shall be minimum 0.1%.

8.4.15 SCAN PROCESSING TIME:

a) The interval between computer readings of Process variables shall not exceed 1 sec.

b) The interval between each cycle for computation of instantaneous flow rate and totalized flow shall be less than 1 sec.

c) Algorithm and rounding off error for computation shall be with in ± 0.001% of computed value.


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8.4.16 SECURITY:

One hardware and two software security levels shall be provided.

8.4.17 DISPLAY CAPABILITY:

The flow computer shall have the capability to display any two of the following parameters at a time:

Uncompensated volume flow rate, Compensated volume flow rate, Integrated volume (corrected and not corrected), Mass flow rate, Integrated mass, Density/Specific gravity, Pressure, Temperature, Energy rate & total energy, Complete gas composition, Calculated parameters (compressibility factor etc.), Current accumulation, previous day accumulation, Data entry, Error codes, Selected parameter codes, Alarms (process and systems) including diagnostic message, Engg. units as per selected parameter, Other standard displays available, Custody transfer flow computers shall have audit trail, All the above data shall also be made available by bidder in the serial links to RTU.

8.4.18 DISPLAY TYPE: Alphanumeric LCD display

8.4.19 DIAGNOSTICS:

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

8.5 TECHNICAL SPECIFICATION FOR GAS CHROMATOGRAPH

8.5.1 Bidder shall supply one no. Gas chromatograph for each of the gas metering skid at Bhilwara RT, Chittorgarh RT.

8.5.2 The Gas Chromatograph shall be consisting of the following subsystems, as a minimum.

a) Probe and sample conditioning system along with fast loop, wherever required as per data sheet.

b) Analyzer with electronics c) Control room mounted programming Control unit d) Cables, cable glands, junction box, tubing, fitting etc. e) Calibration gas cylinder and carrier gas cylinders.

8.5.3 Any additional item required to meet the performance requirement shall be indicated

and supplied. The enclosure for sampling system, analyzer & electronics shall be complete in all respects, ready for quick installation at site.

8.5.4 Each gas chromatograph shall complete the analysis of sample in a maximum time of 4 minutes to repeatability ±0.05% (±5 Kcal at 10,000 Kcal/SCM), based on ambient temperature at site between 0°C to 50°C. The computed GHV shall not


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exceed an uncertainty of ± 0.5%. The performance and repeatability of each analyzer employed in the metering system must be third party/factory tested in an Environmental Test Chamber, from 0-50 deg. C for at least 24 hours to verify repeatability data as a part of the inspection. Manufacturer shall provide a test certificate showing, 24-hour test data with calibration gas analyzed live under flowing conditions for few GC as a sample along with the bid. Ambient temperatures will be included along with repeatability data. Type approval of GC for custody transfer is required.

8.5.5 Bidder to note that the GC skid in field consisting of analyzer field cabinet, sample conditioning system, calibration & carrier gas cylinder racks etc. shall be assembled together and mounted on a single steel structure by bidder. This skid shall be suitable for floor mounting in a 3 side & top protection metallic canopy covered with rain/sun shed provided by Bidder.

8.5.6 Gas chromatograph shall be compact, rugged and of proven design to meet the specified needs of energy measurement for natural gas/ RLNG.

8.5.7 Special cable for communication between analyser unit in field & programmer unit located in control room metering control panel shall be supplied by the bidder for gas chromatograph. Bidder to indicate the distance limitation, if any, for this communication cable. Cable shall be armoured. Bidder shall furnish complete specification of these cables.

8.5.8 All sample tubing and the tubing between the calibration & carrier gas cylinders and analyzer shall be included in the scope of supply. The tubing shall be SS316. Bidder to indicate that the distance limitation, if any, for the sample tubing.

8.5.9 Bidder to include minimum two numbers of carrier gas cylinders for Gas Chromatograph with regulator mechanism and automatic switch over including pressure gauges on cylinder with 3 way valve for auto switching over of standby cylinder.

8.5.10 The bidder shall supply two each pre-filled calibration gas cylinders with regulator mechanism. A recognized laboratory must certify the calibration gas. The calibration gas specification must be approved by the purchaser prior to purchase. The calibration gas shall have a minimum specification of ±0.4% on components greater than 1 % and ±1 % on components less than 1 % and ±0.2% on methane.

8.5.11 Bidder to include 1½" full bore ball valve with flanged ends for probe connections at the tapping point. Probe retractor for removing the probe at the line-pressurized condition shall be included in scope of supply by bidder.

8.5.12 Bidder to include for electrical tracing of the sample tubing, in case required for the optimal performance of the system for the given operating conditions. Electrical tracing, if required, shall be certified from statutory body for the given area classification and shall be included.

8.5.13 Bidder shall note that there is no low-pressure process line to which the bypass loop can be connected and hence the same shall also be connected by bidder to the common atmosphere vent header to be supplied by bidder.

8.5.14 Gas chromatograph system shall be serially interfaced to Flow computers (for transfer of gas composition, Z-factor etc.), RTU/ SCADA system. Also GC system should have suitable ports for connecting Printers, Laptop (for configuration etc.). All


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these ports (for serial & other interfaces) should preferably be in-built in the GC system, however if not then bidder can also use external Hub/ Switches for the same. Bidder shall be totally responsible for this interface and the same shall be demonstrated by bidder during FAT.

8.5.15 Bidder shall note that the test samples to be used during inspection for testing and calibration shall be certified for the concentration of the gas components and shall have tractability. Bidder shall furnish the certificate at the time of inspection.

8.5.16 Bidder shall provide an interconnection diagram for all components from sample take off up to the analyzer and also showing interconnection of analyzer with programmer in control room.

8.5.17 Material of construction shall be SS316 as a minimum for sampling system, isolation valves, instrument fittings, vent lines etc. and shall be included in scope of supply by bidder. All fittings shall be double compression type swage lock or equivalent.

8.5.18 Sample shall be returned to sample return header located in the analyzer cabinet in the field. From sample header, sample shall be vented to atmosphere at a safe height. All interconnection, tubing/fittings/piping/valves between analyzer and return header shall be in bidder’s scope of supply.

8.5.19 Bidder to note that separate cable entries shall be provided for power supply and signal cables in Gas Chromatograph system. All cable glands shall be weather proof and explosion proof to NEMA 4 and NEMA 7. Cable entries and cable gland sizes shall be in NPT standards. Bidder shall provide cable entry sizes and cable gland sizes as specified in the respective data sheet.

8.5.20 All the electrical items of the gas chromatograph system in the field (sampling system, analyzer, electronics, isolation transformer, power switches, junction box, glands etc) shall be certified flame proof suitable for the specified hazardous area (IEC Zone-1, Gas Gr. IIA & IIB, Temperature T3) from statutory body such as FM, CENELEC, UL, BASEEFA, PTB etc. and shall be suitable for ambient conditions as given else where.

8.5.21 Bidder to mount the analyzer, sampling system with explosion proof NEMA 7 enclosure which shall be weather proof to NEMA 4/IP 55 with suitable mounting arrangement for gas cylinders.

8.5.22 Bidder to note that analyser, programmer and accessories shall be suitable for power supply of 230 V AC ± 10%, 50 Hz ± 3 %. Power supply shall be made available by bidder from the feeder to be provided by bidder in their metering control panel. Also suitable distribution / conversion if required in the field shall be provided by the bidder. Bidder to indicate the power consumption for the Gas Chromatograph unit in the field.

8.5.23 Bidder to ensure that Gas Chromatograph system shall not be damaged because of black outs / brown outs. Bidder to indicate steps to be taken for fail safe operation under power failure.

8.5.24 The application programs to be stored in RAM for 6 months battery backup and also for reloading without any external storage device.

8.5.25 All controller software and firmware with licenses shall be in Customer's name. The system shall be supplied with an undertaking from the bidder to upgrade all software and firmware to the latest version and to incorporate all algorithm corrections and


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changes in line with latest industry standards. Such upgrade shall be supplied and executed free of charge by the bidder for ten years from the date of supply of the system.

8.5.26 Bidder to indicate time period between successive calibrations of analyzer and time period for routine preventive maintenance.

8.6 PRESSURE SAFETY VALVES 8.6.1 All pressure relief valves shall be designed as per API 526 (Latest edition). 8.6.2 The pressure relief valve shall meet the seat tightness requirement as per the API

527.

8.7 METERING CONTROL PANELS 8.7.1 The prefabricated metering control panels shall be supplied and tested with all

items/instruments mounted and all wiring installed requiring only connection of field wiring to terminal blocks provided for this purpose and inter-panel wiring in order to commission the panels. Metering control panel free-standing type shall be supplied for each gas metering skid.

8.7.2 Bidder shall be responsible for manufacture/ supply of all hardware and software necessary to meet the functional requirements including Factory Testing and Acceptance of the system, warranty, documentation, packing, forwarding, transportation, custom clearance (as applicable), insurance, storage etc. of the system.

8.7.3 Bidder shall supply free-standing type metering control panel (to be mounted at the respective control room) along with all accessories for mounting the flow computers, GC programming control unit, LEL Monitor, Metering Supervisory System, PID Controller indicators, barriers, isolators, relays, termination blocks, 24 V DC power packs, power supply distribution etc. for flow metering and other analogue/ digital signals of the skid & also other non-skid signals as per data sheet for control panels, standard specification and following drawings attached in this requisition:

i) (Panel front layout): 6921-087-16-51-SK-001, 6921-089-16-51-SK-001 ii) (Power supply distribution): 6921-087-16-51-SK-004, 6921-089-16-51-SK-

004. iii) (Schematic diagram of scope division): 6921-087-16-51-SK-003, 6921-089-

16-51-SK-003. iv) Gas Chromatograph System (Indicative Sketch): 6921-087-16-51-SK-002,

6921-089-16-51-SK-002. v) P&IDs as per P&ID index. SCADA (RTU) instrument signal indicated in the P&IDs, are required to be terminated in Metering Control Panel for marshalling purpose. Necessary adequate number of terminal block on a dedicated terminal strip in the Metering Control Panel shall be provided by vendor.

8.7.4 Power Supply Distribution for Metering Control Panels: Power supply of 230 V AC ± 10%, 50 Hz ± 3% UPS and 24V DC shall be made available by purchaser to bidder at a single point in the Metering control panel being supplied by bidder to be installed in respective control room. Further distribution to all the equipments with all items like MCBs, Bus Bars etc. shall be in bidder’s scope. All the equipments offered by bidder shall be suitable for the specified voltage variation. Power supply for lighting the control room panels shall be 230 V AC, 50 Hz, non-UPS and purchaser shall provide single feeder for the same.

8.7.5 Bidder shall also refer power supply distribution drawings attached along with this requisition.


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8.7.6 Bidder shall furnish power consumption details for each type of power supply mentioned above.

8.7.7 Bidder shall supply two sets of soft copies of all as built drawings / documents/ programs, manuals etc. required as per Bidder Data Requirement in the form of CD.

8.7.8 Bidder shall be fully responsible for the manufacture in respect of proper design, quality workmanship and operation of all the equipment, accessories, etc. supplied by the bidder for the Metering Control panel.

8.7.9 It shall be obligatory on the part of bidder to modify and / or replace any hardware and modify the operating, application and diagnostic software free of cost, in case any malfunction is revealed even during on line operation after taking over by the owner within the warranty period.

8.7.10 Factory Acceptance Test and Calibration of all items shall be carried out by the bidder and fully compliant reports shall be furnished to Purchaser/EIL meeting the complete requirements. Purchaser/EIL shall witness any or all items testing in stages during manufacture and/or at final stage before shipment at the discretion of Purchaser/EIL. No such items shall leave manufacturer’s works without Factory Acceptance Testing.

8.7.11 Bidder shall provide Commissioning Spares for the package and shall provide a list of these spares. If however any additional spare is consumed during erection and commissioning the same shall be provided free of cost by the bidder.

8.7.12 Bidder shall supply Consumable for duration of one year operation after acceptance of the system. The price for the same shall be included in base offer.

8.8 HYDROCARBON (LEL) DETECTORS 8.8.1 Hydrocarbon detectors shall be used to monitor hydrocarbon gas leakages from the

equipments (like metering system, filters), valves, piping etc. 8.8.2 LEL detectors shall be provided for each Gas Metering Skid. The 4-20mA analog

output from each detector shall be taken to LEL Monitors to be provided by bidder. LEL monitors are to be mounted on Metering Control Panel being supplied by bidder. Common LEL alarm high and high-high of each station is to be wired to the alarm annunciator (as applicable) on the metering control panel.

8.8.3 Construction and performance of hydrocarbon gas detection system shall be as per BS EN-50054 and 50057.

8.8.4 The infra-red type LEL detectors shall be dual beam, dual wavelength type.

8.8.5 LEL detectors/transmitters shall be microprocessor based and shall be immune to RF and EM interference.

8.8.6 LEL detectors shall be immune to catalytic poisons and sunlight

8.8.7 Heated optics shall be provided in the LEL detectors to avoid condensation on the window/mirror in the detectors.

8.8.8 Bidder to indicate drift in the calibration of the LEL detectors.

8.8.9 All LEL detectors/transmitters shall be supplied pre-calibrated by the bidder either with the gas to be sensed or by applying cross sensitivity factors to achieve an installed accuracy of ± 2% LEL at site.

8.8.10 All calibration equipment required for site calibration of the detectors including calibration gases (for 6 months use), gas cylinders, self regulating valves, pressure gauges, hose, interconnection tubing, fitting etc., shall be supplied by the bidder.


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8.8.11 Any special tool required for the maintenance of the system /detector head shall be supplied by the bidder. The maintenance of any detector head/module should not necessitate shutdown of total/partial detection system except those that are being maintained.

8.8.12 Lamps in the infra-red detectors shall be replaceable type. Lamp life shall be minimum 5 years or better.

8.8.13 Infra-red detectors shall be compensated for lamp intensity variation due to dust, variation in humidity etc.

8.8.14 All the supplied LEL detectors/transmitters shall be weather proof to NEMA 4 or IP 55.

8.8.15 Bidder to furnish calibration procedure for the LEL detectors/transmitters.

8.8.16 Response time of LEL detectors shall be indicated. Time lag caused by splash deflectors/guards and dust filters shall be taken into consideration.

8.8.17 All mounting accessories/plates for mounting the LEL detectors/transmitters shall be supplied by bidder.

8.8.18 One no. Portable purge Hydrocarbon calibrator complete with 20 liter volume bottle of calibration gas of known gas/ air mixture, pressure regulator, adapter cap, flow meter shall be provided for each skid.

8.8.19 One set of portable gas detector shall be provided complete with its controller, audio-visual alarm and shall be suitable for use in hazardous area for each skid.

8.8.20 Battery charger shall be provided for portable detector and which shall be chargeable with 230 V AC.

8.9 METERING SUPERVISORY SYSTEM

All the process parameters of the skid including flow computer & GC data shall be provided in the metering supervisory system, which shall be the Human Machine Interface Station Computer. The operating system of HMI of the Metering Supervisory System shall be window based. The computer system for the supervisory control system shall be industrial type IBM compatible, suitable for continuous operation in the non-air-condition environment. It will be mounted in the control panel.

The system shall be supplied complete with keyboard, 17” LCD Monitor, pointing device, hub, signal converter (RS 485-232 or vice-versa), all accessories, cables, Connectors and HP laser Printer with 1000 A4 size plain white paper (shall be used for printing reports, trends etc.). Licensed version (in name of “GAIL”) of all the required software to be installed and supplied with the supervisory system.

The supervisory system shall be capable to provide read only data to consumer through serial communication and shall be web enabled. The computer shall be capable for generating Reports, Audit trail, current and historical trend for the process variables. It should have facility of Process data, Alarm manager, Diagnostic Manager (Automatic Verification), Configuration log, Audit trail etc.

Online validation software with license shall be supplied and shall be installed in HMI. Validation software shall be compatible with supplied front end software of HMI and shall be suitable for the application.


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Metering supervisory system shall be designed to work in non air conditioned environment and shall be panel mounted (supplied by bidder). It shall be suitable for environmental conditions mentioned elsewhere.

The computer of metering supervisory system shall have hardware with latest configuration and shall have minimum specification of 1GHZ Pentium IV Processor with high resolution SVGA Monitor with 17” LCD screen, 512 MB RAM, R/W CD ROM Drive. The monitor shall have high speed refresh rates, 1280 X 1024 pixels and 256 basic distinct colors. The monitor shall be anti-glare, anti-reflective and anti-static. No obsolete hardware shall be supplied.

The HMI software shall be a internationally renowned standard Software’s like wonderware, IFIX, Intellution, cimplicity, licensed in the name of GAIL (INDIA) Ltd. The supplied software shall be Full version (not the run time version) so that it can be upgraded and future changes can be made, if required. All the hardware required to meet the functionality shall be installed in a Control panel.

Metering supervisory system as a minimum shall contain the following:

Display of all the major equipments (indicated in P&ID) along with its Status (BV open/close indication, SSV open/ close status indication etc.) indication in dynamic body colour (depending on change in the status, body colour of equipments shall change).

Display of all analog parameter-values (like Inlet PT, Inlet TT, Metering PTs, Meter TTs, DPTs, Corrected Volumetric Flow rates, Uncorrected Volumetric Flow rates, GC–DATA (composition), Specific Gravity, SOS-USM-Paths(path-1, Path-2.---, Path-x), SOS-FCs, GCV-FC, GCV, NCV, Compressibility factors, Energy flow rate, mass flow rate, Total energy flow, total Mass flow, Total Volumetric Flow etc. Display of GC parameters (GC-DATA), FC-DATA(FC-configuration Parameters, base conditions, Keypad values, Alarm values, Atmospheric pressure, Error curve, Meter factor, K-factor etc.) shall also be provided.

The screenshots shall also have feature of display of current/ historical trends, History, Audit trail, Reports etc.

LOG Reports (Shift/ Daily/ weekly/ Monthly/ fortnightly Reports) of Metering Supervisory system shall include the following (as a minimum):

Shift-wise Log Report (for Morning (A) shift, Evening (B) shift and Night (C) shift) shall be generated at pre-defined 8-hour time interval (say at 06:00 hrs, 14:00 hrs and 22:00 hrs). The report header shall display:

Report type: Shift-wise;

Name of shift: Morning (A)/ Evening (B)/ Night shift (C) (which ever applicable)

Date and Time of Report;

Report from (---:00 hr.) to (---:00 hr)

The parameters (Hourly Average value of parameters) to be displayed shall be for the following parameters:

Inlet PT, Inlet TT, DPTs, Metering PTs, Metering TTs, Uncorrected volumetric flow rates, Corrected Volumetric Flow Rates, Mass flow rates, Energy Flow rates, NCV,GCV, Specific Gravity, Compressibility factors(base/ line), GC-Data (Gas


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Composition in %), SOS readings from USM, SOS calculated by FC, Heating values calculated by Flow Computers etc.

Parameter name, Parameter description, Unit of Measurement of various parameters should be provided in the Shift Log report.

Daily Log Report shall be generated at pre-defined 24-hour time interval (say at 06:00 hrs). The report header shall display :

Report type: Daily Log; (which ever applicable)

Date and Time of taking Report;

Report from (---:00 hr. on --/--/--) to (---:00 hr on --/--/--).

In the static Fields of Daily Log report, column-wise display of Parameter name, Parameter description and Unit of Measurement of various parameters should be provided (Column-A shall display parameter-name, Column–B shall display parameter Description and Column–C shall display Unit of measurement).

The Daily (24 hourly) Log Report shall contain at least 4 columns for display of Parameter-values. The contents of the first 3 columns shall be 8-hourly values (taken at the end of each shift mentioned above) for each Parameters/ Totalized values. For example, 1st column shall display 8-hourly average reading for each parameter from 06:00 hrs. to 14:00 hrs of previous day. The 2nd column shall display 8-hourly average reading of parameter from 14:00 hrs. to 22:00 hrs of previous day. 3rd column shall display 8-hourly average of parameter from 22:00 hrs. of previous day to 06:00 hrs of current day. The 4th Column shall display Daily average value (average of the last 24 hrs reading, reckoned from 06:00 hrs of previous date to 06:00 hrs. of current date)/ Accumulated value during last 24 hrs. The parameters to be displayed shall be for Inlet PT, Inlet TT, DPTs, Metering PTs, Metering TTs, Uncorrected vol. flow rates, Corrected Volumetric Flow Rates, Mass flow rates, Energy Flow rates, NCV, GCV, Specific Gravity, Total Uncorrected Volumetric Flow (during last 24 hrs), Total Corrected Volumetric Flow (during last 24 hrs), Total Mass Flow (during last 24 hrs), Total Energy Flow (during last 24 hrs), etc.

Fortnightly/ Monthly report shall display daily average figures (24-hourly average values) of various parameters mentioned above for the last 15 days/ last month. These reports shall be automatically generated at pre-defined 15/ monthly interval (say on 01.04.2009, 16.04.2009 ------ at 06:05 hrs). The Header of Fortnightly/ Monthly Reports shall be: Fortnightly Report/ Monthly Report (as applicable) with date and time of report and date and time of values displayed (from 06:00 hrs of --/--/-- to 06:00 hrs of --/--/--).

9.0 TESTING AND INSPECTION

9.1 GENERAL

9.1.1 All materials and equipment shall be factory tested before shipment in the presence of Purchaser’s representative. No material shall be transported to site until all required tests have been carried out and equipment is certified as ready for shipment. Acceptance of equipment or the exemption of inspection or tests thereof, shall in no way absolve bidder of the responsibility for delivering equipments meeting the requirements of the specifications.


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9.1.2 Bidder shall furnish

• Material test certificate, Hydrostatic test certificate for all line mounted instruments on the skid.

• Certificates from statutory body for hazardous area approval for all electrical items mounted on the skid.

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

9.1.4 Bidder shall include inspection by EIL/ third party personnel at bidder’s shop. For this inspection, labour, consumable, equipment and utilities as required shall be in bidder’s scope.

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

9.2 SKID: The following tests shall be conducted for the skid

a. Hydro testing

b. Leak test of complete skid with Nitrogen.

c. Skid functional testing considering filtering, metering, pressure regulation, limiting and safety characteristics.

d. Skid piping material testing and NDT of welds as per Piping material specifications. Radiography/X-ray shall be carried out for all welded joints and bidder shall furnish test certificate for the same. Dye-penetration test certificate shall be provided for joints wherever radiography/x-ray is not possible.

e. Radiography/X-ray , Charpy impact testing for line mounted instrument items such as Self actuated control valves , pressure relief valves, slam shut valves, Ultrasonic meters and meter runs etc.

f. Testing and inspection requirements as specified in Static Equipment Inputs for Gas filter equipment and Pipeline Engineering Inputs for skid piping materials, attached elsewhere in the MR.

9.3 Instruments

The following tests shall be conducted for instruments:

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


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a) 100% radiography shall be carried out on all casting. Radiography procedure and area of casting to be radiographed shall be as per ANSI B16.34 and acceptance criteria shall be as per ANSI B16.34 Annexure B. Two shots shall be taken for each area to be radiographed, as a minimum. b) Radiography/X-ray shall be carried out for all welded joints and bidder shall furnish test certificate for the same. Dye-penetration test certificate shall be provided for joints wherever radiography/x-ray is not possible. c) Each ultrasonic meter along with meter runs shall be subjected to hydrostatic test with a pressure of 1.5 times the design pressure. d) Charpy impact test on each heat of base material shall be conducted as per A370 for all pressure containing parts such as body, end flanges and welding ends as well as bolting material for pressure containing parts. Unless specified otherwise, the Charpy impact test shall be conducted at 0°C. The Charpy impact test specimen shall be taken in the direction of principal grain flow and

notched perpendicular to the original surface of plate or forging. The minimum average absorbed energy per set of three specimens shall be 27J with an individual minimum per specimen of 22 J.

9.3.2 Ultrasonic flow meter, meter run, flow computer and accessories shall be offered

for pre-dispatch inspection to EIL and / or purchaser's representatives.

a) Physical/ dimensional checks and workmanship.

b) Calibration including establishing linearity and repeatability over the entire range.

c) Functional and simulation tests including checking of hardware and software for Flow computers including ultrasonic flow meters and gas chromatographs with all its sub-systems in fully integrated configuration.

d) All the panels along with all instruments mounted on it including flow computers, indicators, alarm annunciators, receiver switches, barriers, isolators and accessories etc.

e) Review of all certificates and test reports.

In the event the purchaser is unable to witness a test, the test shall anyway be completed by the bidder and documents for the same shall be submitted for scrutiny before shipment.

9.3.3 Following tests shall be carried out by bidder at his works and test certificates shall

be furnished:

a) Calibration / test certificates for all instruments. Calibration test reports for ultrasonic meters duly signed and certified from the recognised National laboratory / statutory weights and measures authority. b) Statutory body certificates for instruments. Type test report for enclosure of all electronics/electrical equipments. c) Radiographic / Charpy test certificates for Ultrasonic meters and meter runs. d) Material test certificate for all line mounted instruments. e) Dimensional test report

9.3.4 In addition bidder shall also refer the inspection & testing requirements of the

standard specifications attached to this requisition and follow the same.


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9.3.5 Bidder shall include in his scope the shop inspection charges including factory acceptance test for inspection by EIL and/or purchaser’s representative at bidder’s works.

9.3.6 SLAM SHUT VALVES, PCVs, PRESSURE RELIEF VALVES

a. Testing to demonstrate set point accuracy and actuation time for Slam shut valves

b. Testing to demonstrate set point accuracy for PCVs for the complete range of pressure and flow conditions.

c. Calibration certificate for Pressure relief valve set pressure

d. Seat tightness test for PCVs, Slam shut valve and pressure relief valves.

9.3.7 FAT formats for Ultrasonic & Turbine as given in this MR (Refer Appendix A & B) need to be followed as a minimum by the bidder for FAT testing.

10.0 DOCUMENTATION

10.1 Detailed drawings, data and catalogues required from the Bidder are indicated by the PURCHASER in bidder data requirement sheet. The required number of reproducible and prints should be dispatched to the address mentioned, adhering to the time limits indicated.

10.2 Final drawings from the Bidder shall include dimensional details, weight, mounting details and any other special requirements etc for the skids. All dimensions in general shall be in millimeters.

10.3 Bidder shall furnish all manuals necessary to test, operate and maintain the system.

11.0 MISCELLANEOUS

11.1 NAMEPLATE IDENTIFICATION In addition to the instruments and equipment nameplate, the structural skid shall be supplied with a permanent, weather resistant, stainless steel nameplate affixed to the skid, with the following details, as a minimum: • Project title and number • Owner and Owner name • Equipment name and tag number • Manufacturer’s name and serial number • Skid overall dimension data. • Skid weight data. Each skid including all the instruments in the skid and also all other non-skid instruments shall have a S.S nameplate attached firmly to it at a visible place furnishing the following information:

Tag number of the skid.


GAS METERING SKIDS

DOCUMENT No. 6921-001-16-51-SP-01

Rev.A Page 38 of 38


Tag number of Instruments and filters as per purchaser's data sheets

Body sizes in inches and the Valve Cg value or meter G rating

Set pressure range and flow capacity of pressure safety valves

Flow range

Rating for all the individual instruments

Manufacturer's name and model number

11.2 SHIPPING Bidder shall indicate the shipping methodology for each, its size, weight and no. of pieces.

11.3 REJECTION

Bidder shall make his offer in detail, with respect to every item of the

PURCHASER'S specification. Any offer not conforming to this shall be summarily rejected.

11.4 PERFORMANCE GUARANTEE a) The bidder shall guarantee that all work will be performed in accordance with

good and sound engineering and construction practices and within the requirements of this specification. The equipment, accessories and all materials supplied by the bidder shall be free from defects, shall be suitable for the use for which they are intended and shall perform in accordance with the requirements of this specification.

b) The bidder shall furnish a guarantee for the entire skid & gas metering system package comprising of its entire component including instruments, piping, valves, fittings, internals, etc., for a period of 12 months from the date of commissioning or 24 months from the date of last shipment/despatch, whichever is earlier.

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

11.5 Supervision of Installation and Commissioning assistance The BIDDER shall provide qualified and experienced personnel for supervision of installation, field-testing and commissioning of the equipment (if required). BIDDER shall quote separate lump sum price for installation supervision and commissioning assistance.

Documents

JOB SPECIFICATIONS FOR GAS METERING SKIDSgailtenders.in/writereaddata/Tender/6921-000-jobspec gas metering... · AGA Report No. 8 Compressibility and Super-compressibility for Natural