JOB SPECIFICATION FOR ULTRASONIC METER BASED GAS METERING SKIDS PACKAGE OF GAIL

CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 Introduction Codes and Standards Area Classification Environment Protection Scope of Work and supply Bids Design Consideration Specification for Instruments

JOB SPECIFICATION FOR GAS METERING SYSTEM PACKAGE 1.0 1.1 1.2 Introduction General Scope

This specification together with the P&IDs, Process data sheets, data sheets, standard specifications attached with the Package, defines the requirement for the design, engineering, manufacture, fabrication & assembly, integration, calibration, factory testing, supply, packaging, shipping and documentation including deliverables, installation supervision, commissioning and overall skid performance guarantee of Gas custody transfer Pressure Regulating & Metering Systems packages for inventory creation (to be installed at gas consumer terminals to be installed at different locations in the Pipeline network.) The environmental conditions and the contractual obligations of the COMPANY shall also be considered for the design. The VENDOR 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 2.1 CODES AND STANDARDS The related standards referred to herein and mentioned below shall be of the latest editions prior to the date of the bid:

AGA - American gas association, Gas measurement committee -AGA Report No. 7 Measurement of gas by Turbine meters -

AGA Report No. 9

Measurement of gas by Multipath Ultrasonic meters

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

AGA Report No. 8 Compressibility and Super-compressibility for Natural Gas and other Hydrocarbon Gases. Transmission Measurement AGA Report No. 5 Energy Calculations in Natural gas AGA Report No. 3 Orifice Metering of Natural gas and Other hydrocarbon related fluids

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 Manufacturers 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 Natural gas Performance evaluation for On-line Analytical

ISO 10723 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/GPA2145-GPA2172 Natural gas - Calculation of Calorific Value, Density and

Relative Density ISO 6974/6975 Natural gas-determination of composition with defined uncertainty by gas chromatography & Natural gas extended analysys-gas chromatographic method. ISO 170125: Calibration of all primary and secondary instruments ISO 6142/6143- Traceablity of calibration gas for gas chromatograph. EN 334 European Standard for Gas pressure regulators up to Inlet of 100 bar 3.0 AREA CLASSIFICATION The Custody transfer metering skid shall be installed outdoors and shall be suitable for installation in Zone 1 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 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 IEC60529 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. Ambient air temperature range : 0-55 oC Relative humidity range : 95% However, in case of failure of air-conditioning system the equipment shall be capable of operating for a minimum period of 48 hours continuously in 30 days at the ambient conditions without any damage or degradation in the performance.

5.0

Scope of Work and supply Vendors scope shall include the Gas custody transfer Pressure Regulating & Metering Systems for various gas consumers to be installed at respective consumer terminals. The gas custody transfer metering system shall consist of the complete works required for metering including filtration system, Pressure reduction system, the ultrasonic meters, GC, Stream Flow Computer, Pressure Instruments, Temperature Instruments, Control Panel, metering supervisory system, complete integrated field instruments, piping and valves in a skid and a control room equipment with the following items described below, as a minimum and as shown on the P& I D. Gas Pressure Regulating & Ultrasonic Metering Skid package (refer P&ID) is required to be supplied for custody transfer application of gas to each of gas consumer for the following flow requirements: ITEM NO. 1. 2. CAPACITY 1.0 MMSCMD for Inventory 2.0 MMSCMD for Inventory QUANTITY 1 No 1 No.

Note : 1) Provision for heater connection shall be kept just before Pressure reduction system for Inventory skids i.e for 1 and 2 MMSCMD skids Each of the Gas Pressure Regulating & Metering Skid at the above locations shall be of required capacity meeting the specified operating design conditions as per process data of respective skids. The VENDORs scope of work shall include supply of the complete Gas Pressure Regulating & Metering Skid 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 P& I D shall include, but not limited to the following: One dry gas filtration system with two dry gas filters (vertical type with one operating and with one standby), each of 125% of maximum capacity. The dry gas filtration system shall be used to remove dust particles up to 3 micron and to remove condensate if any. Fire case PSV shall also be provided on each filter. Filter cover shall have arrangement of Davit arm for ease of maintenance. One Gas pressure let down regulating system with two redundant stream (1operating + 1stand by stream) each stream of 125% of maximum capacity using Self actuated pilot operated pressure control valves as Regulator Valve / monitor valve (wide open regulator) and Slam shut valve. The complete system will be kept on a hot stand-by mode. The creep relief valve shall be designed for 1 % of the maximum flow. The pressure reduction system shall be designed to minimize the generation of ultrasonic noise in the frequency range of Ultrasonic meter.

Also, the pressure reduction system and metering system should be separated with blocking tees / other piping lay outs, so that the Ultrasonic noise does not affect Ultra Sonic Meter performance. One Gas metering system with two metering stream of multi-path ultrasonic flow meters (1operating + 1stand by stream) with meter runs & flow control valve. Flow computer shall be provided for each meter stream with all interface accessories. Each metering stream shall be designed for 100 % of capacity. The up-stream & down stream valves of the meter shall be full-bore ball valve. The ultra sonic flow meters shall have sizes between 3 to 16. If the design flow rate is such that a 16 USM is not capable to handle, then 2+1 working philosophy is to be adopted. All the ultra sonic meters shall be #600 only. The meters shall be configured with check & pay i.e at a time both the meters can be run in series (if required). The Ultrasonic Meter shall be certified for custody transfer application by a certifying agency equivalent to Nmi/PTB/NPL. The maximum permitted velocity through US meter shall be 25 meter per sec. The meter shall be wet calibrated as per operating conditions along with its upstream and down stream meter runs and profiler. The upstream & down stream meter run shall be honed and the maximum meter tube roughness should not exceed 300 micro-inch. The upstream/down stream meter run and profiler shall be supplied by meter manufacturer. Flow control valve to be installed with positioner & I/P converter for limiting flow to consumer (Since Instrument air is not available at site, line gas is to be taken from pipe line of metering system. Necessary filtration and regulator arrangement shall be considered to provide the gas supply to I/P converter& valve positioner / actuator). The I/ P converter shall be designed & certified for natural gas application (instead of air). The GC probe shall be installed at least 20D downstream from any flow disturbing elements such as elbows, valves, headers, tees as per ISO 10715. Separate Flanged Outlet pipe with provision for GC probe installation shall be provided for the same. Gas Chromatograph system with complete field mounted GC analyser cabinet and cylinder assembled on a skid, retractable sample probe, sample tubing, sample conditioning system, remote GC programming controller (control panel mounted) shall be supplied. The calibration gas shall have 3 years stability with complete traceability. The on line GC shall be certified for custody transfer application by a certifying agency equivalent to Nmi/PTB/NPL. The gas cylinder shall be approved by CCOE or equivalent body. Pressure relief Valves of suitable size shall be installed after the pressure reduction and shall be sized for full capacity of the skid. Skid field instruments like pressure gauges, Temperature gauges, pressure & diff. Pressure transmitters, temperature transmitters, temperature elements & thermo wells, limit switches for slam shut valves
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shall be supplied along-with the skid. The metering stream (meter, up-stream & down stream meter tube, impulse tubing of Pressure transmitter, thermo- well, impulse tubing of on line GC) shall be completely insulated to ensure an even heat transfer throughout the meter run when subjected to ambient environment. For all the ball valve in the main lines , the equalizing line with double block and bleed valves (of 2 size)to be provided. Equalizing valves are not required for ball valves up to 2 sizes. For all the ball valves (except vent and drain lines) of sizes between 3 and 4 , the equalizing and vent valves shall be of 1 size as per Typical P&ID and For all the ball valves (except vent and drain lines) of higher sizes the equalizing and vent valves shall be of 2 size as per typical P&ID. All the drain valves shall be of size. All the vent valves shall be of two sizes lower than the main line size subjected to minimum of size and maximum of 4 size The complete station shall be designed in such a way that the mean gas velocity remains within 20 Meter per second except at the Pressure regulating valve and ultrasonic meter. Velocity in the piping downstream of Pressure reduction station shall also be within 20 Meter per second Velocity in the Ultrasonic meter shall be limited to 25 meter second. The custody transfer equipments at field like transmitters (pressure & temperature) shall be installed in a environmental enclosure to minimize the effects of ambient temperature variations and shall be lockable for prevention of unauthorized data entry. The size of the cabinet shall be suitable for removing and fixing of transmitters for ease of maintenance. The transmitters shall be fixed in mounting brackets inside the cabinet. The cabinet shall be mounted and fixed in the skid. LEL HC gas detectors (IR Type point detectors) on the skid and LEL Gas monitor in the control panel shall be provided. No of detectors shall be decided on the basis of size of skid and applicable standard. Flow computer & its accessories for metering skid The flow computers shall be control room mounted with GSM modem. The system shall be designed in such a way that it should operate at 230VAC-50 Hz as well as 24 VDC with metering supervisory system. Signal selector, Single loop microprocessor based controller for flow control, Isolating IS barriers & accessories, a separate terminal strip for all SCADA signals to/from GAILs RTU duly mounted completely wired also to be provided. The entire system shall be mounted on control panels. GSM Modem shall be used for Communication with remote station in case of non-availability of GAIL RTU. Supply of complete Metering supervisory system along with Laser jet Printer is in scope of bidder Internal or external USB converter shall also be provided with each flow computer for connecting it to USB port of Laptop for configuration).

Connecting cable from Flow computer to USB Port of laptop shall also be supplied for each skid. All pipes, fittings, valves, gaskets, bolts, nuts, spades, etc., within the skid battery limit. All tubing, and fittings within the skid All cables, cable trays and wiring within the skid;and from skid to metering control panel Junction boxes (as per the requirement of area classification) for power, instrument and control cables with glands; A structural skid complete with necessary drip pan, walkways, staircase, platforms, gratings, handrails for access for operation and maintenance; Earth bonding system and earthing boss; Lifting lugs and spreader beam / frame, foundation Anchor bolts for the skid, Stainless steel nameplate for each tagged equipment and component; All Tie-ins shall be provided with flanged connections. Details of skid assembly, supporting positions, Anchor bolt layout and equipment weights to be provided prior to equipment supply; All Interconnecting cables between skid Instrument/ Juncton boxes to metering panel.(to be located in Local equipment room in safe area) Distance between Skid and control room shall be considered as 150 meter. Inlet and Outlet matching flanges and Studs & nuts shall also be supplied along-with the skid. The sun / rain protection shed for Gas chromatograph field unit and for electronic instruments shall also be supplied by the bidder. 5.1 i) The VENDORs scope of work shall also include: For metering system, vendor shall submit the complete design and engineering of the metering skid including piping duly approved by Nmi/PTB/NPL or Ultrasonic meter manufaturer for custody transfer application. The total uncertainty calculation of the metering system to be submitted as per the design data prior to the fabrication of skid. Design, engineering, sizing, selection, manufacture and/or procurement of materials, components and equipment necessary for complete package;

ii)

iii)

iv) v) vi) viii) ix) x) xi)

Inspection and testing of all components, sub-assemblies, and complete assemblies of items manufactured at VENDORs works, and other subvendors works in accordance with approved QA/QC procedure; Shop assembly and hydro-test; Factory Acceptance Test (FAT) for the complete package at VENDORs works. supervision of Installation and commissioning of the complete package at site. Preparation for shipment, packing and delivery of all packages, equipment and material to site. Start-up and commissioning assistance at site. Preparation and submission of all documents as per requisition with the bid and after award of contract. Preparation and submission Final Documentation / Completion files as per this specification. One copy shall be submitted along with the complete system at stores / site for each skid. Flow Computer Validation Software :Vendor to provide licensed Software in the name of Client for authenticating the algorithm written in the Flow Computer as per AGA-9. Vendor to provide the necessary hardware / software (licensed in favor of GAIL) for configuration of Flow computer and Gas chromatograph. Vendor to provide the necessary software (licensed in favor of GAIL) for accessing data of Flow computer and Gas chromatograph from Remote via GSM Modem. Vendor to supply all the hardware / software ( licensed in name of GAIL) of metering supervisory system. 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 CONTRACTOR have to be done by the VENDOR without any commercial implications. VENDOR shall include in the bid, list of specific deviations, separately, if any, to this specification and all attachment thereof, otherwise, the quotation will be deemed to be in compliance with the specification requirements and subsequent claims for extra arising out of noncompliance with the specification will not be considered. The scope of work also includes the mechanical and structural detailed design of the skid, procurement of materials, preparation of fabrication drawings, detailing of internals, fabrication, inspection and testing of the piping and structural items at fabrication shop, painting, internal coating if any, preservation, transportation and undertaking Guarantee for the equipment. The scope of supply per metering skid also includes : Mandatory Spares: a) Repair kit for PCV (diaphragm, O-rings, cone etc)- 02 nos.

xii) xiii) xiv) xv) 5.2

5.2.1

5.2.2

5.2.3

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b) Repair kit for pilot ( Diaphragm, O-rings etc) -02 nos. c) Repair kit for SDV (Diaphragm, O-rings etc.)- 01 nos. d) Filter cartridges: 02 sets for each type of filter. e) Metallic Gasket : 04 sets for each size & schedule. f) All the IO cards/ barriers/relays/terminals shall be installed 20% in excess than the required for future expansion. Optional Spares: a) Recommendations for 2 years operational spare parts, special tools and documentation. 5.2.4 The VENDOR shall assume single point responsibility for all aspects of the work. This shall include timely completion, liaison with CONTRACTOR, liaison with VENDOR of specified items, co-ordination of the work, quality and guarantee for the equipment. Where parts of the package are subcontracted and purchased by the VENDOR, these become part of the VENDORs package and it is the VENDORs responsibility to ensure that the complete package complies with the specifications, codes and standards and statutory regulations. Scope to include all instruments shown in the P&ID/schematic, as within the VENDORs scope. The VENDOR shall be responsible for obtaining necessary approvals, authorization and certification from local Government / Local Statutory bodies, Authorized Inspector and Third Party Inspection Agency as applicable. The equipment shall be suitable for the site conditions specified. All components/ consumables used shall be new and of current manufacture. In the event of any conflict between this specifications, data sheets, related standards codes etc., vendor shall refer the matter to the PURCHASER for clarifications and only after obtaining the clarification shall proceed with the manufacture of the items in question.

5.2.5

5.2.6 5.2.7

5.2.8 5.2.9

5.2.10 Vendor shall take single point responsibility for the engineering, design, certification, procurement, inspection, testing, supply & performance of the Gas Pressure Reducing and custody Metering System skids along with all instruments, equipment and valves of the skids, Gas chromatographs 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 undertaken / decided /furnished by vendor: Approval from Nmi/PTB/NPL or meter manufacturer for the complete skid (including up-stream/down stream piping) design including GAD & P&ID for custody transfer application.

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Calculation of metering system uncertainty based on the approved design and it shall be within 0.3 %. (Vendor shall submit the Calculation for overall system uncertainty including all components of the metering system). Based on the approved design Sizing of flow meters, Self actuated Pressure control valves (monitor & Regulator), Safety Shut Off (Slam Shut) valves, Pressure relief valves and Flow control valve. Set points for Pressure regulators, Monitor and slam shut valves. Instrument ranges to meet the Process operating and design conditions Noise calculations for Regulator / monitor valves. Vendor to Provide detailed Noise calculation Methodology and formulae and standard used and any assumption considered. (This calculation is to be provided for Each PCV along-with the bid)

Response and transportation time calculation for Gas chromatograph Blocking Tee/ Double Tee/ other Noise attenuation devices downstream of Pressure reduction skid for proper protection / functioning of Ultrasonic meters as required. Check & pay facility for USM meter run to be provided. All the instruments/equipments to be procured as per the approved vendor list of GAIL/consultant.

5.2.11 Typical instrument data sheets for Self actuated pressure control valves (PCVs), Slam shut valves, Ultrasonic flow meters, Gas chromatograph, pressure relief valves, Flow control valve, field transmitters, pressure gauges, and accessories indicate materials for body, internals etc. However, this does not absolve the Vendor of the responsibility for proper selection with respect to the fluid and its operating and design conditions. Proper sizing and selection of the 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 vendors responsibility.
5.11.1 If any of the major items which is not included in the vendor list like Self

actuated valves (plug & Ball), pressure control valves , Slam shut valves, Ultrasonic flow meters, Flow computers, Gas chromatograph, pressure relief valves, flow Control valve, Pressure & diff. Pressure transmitters, Temperature instruments, LEL detection system then the bidder has to supply the above mentioned equipments having proven track record of successful operation for at least 6 months till bid submission date. Documentary evidences shall be furnished for approval of any vendor other than those mentioned in the list of vendors for bought-out items.

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5.2.12 Vendor shall be fully responsible for proper integration of their supplied systems with GAILs SCADA (RTU) systems and shall provide all the technical details to GAIL for configuration at SCADA end. Configuration in the supplied control panel shall be bidders responsibility. 6.0 6.1 BIDS Vendor's proposal shall include the detailed specifications for all items of Gas pressure reducing and metering skids packages and Metering packages. The proposal shall include: Make, Model no, detailed specification for each Slam shut valve, self actuated pressure control valve, flow meter, meter tube detail, flow computer, pressure relief valve, gas chromatograph, pressure/differential pressure transmitter, Temperature transmitters, hydrocarbon (LEL) detector and monitors, pressure / temperature gauges, limit switches, metering supervisory system, 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 Noise level calculations for self actuated pressure control valves / monitor valves. Vendor to Provide detailed Noise calculation Methodology and formulae and standards used and assumptions considered, if any.. All design and performance characteristics. Overall dimensions of each item. Overall dimensions of each skid with proposed modules of each skid considered along with estimated dimensions: Weight of each skid Foundation details (suggestive) of each skid
6.2 6.3

All units of measurements in vendors specification sheets shall be same as those in purchasers data sheets. All material specifications for the various parts in the vendors specification sheets shall be to the same standard as those in purchasers data sheets. Vendor shall enclose catalogues giving detailed technical specifications and other information for slam shut valve, self actuated pressure control

6.4

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valve for monitor and Regulator, control valve, multi-path ultrasonic flow meter, Turbine flow meters, flow computers, pressure relief valve, gas chromatograph, LEL gas detection system, pressure/differential pressure transmitter, temperature transmitters. temperature gauges, pressure gauge, digital indicators, PLC, HMI/Monitor, receiver switches, barriers and isolators, etc. covered in the bid.
6.5 6.6

Vendors proposal including catalogues, drawings, operating and maintenance manuals etc. shall be only in ENGLISH language. Vendor 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 shall review the above and vendor to note that No post order deviation shall be granted. Vendor shall change the make and/or models of items and specifications to meet the requirement of contract without any price and delivery implications. The Ultra Sonic Meter (multi path-Minimum 04 path), flow computers and on line Gas chromatograph shall be approved for custody transfer application. The Type approval certificate for Flow computer , GC and the quoted size of USM to be submitted along with the bid. It is compulsory that bidder utilises uniform data sheet formats enclosed along-with this document, for preparing specifications for various instruments, including those, which are being prepared by package/ sub package vendors. Additional information shall be provided in the given data sheets, if necessary. Items for which no format has been attached with the document, bidder may use standard ISA formats. Use of manufacturer standard formats shall be avoided. DESIGN CONSIDERATIONS Vendor shall submit the complete design and engineering of the metering skid including piping duly approved by Nmi/PTB/NPL or equivalent for custody transfer application and shall be strictly as per the guidelines of AGA. The total uncertainty calculation of the metering system to be submitted as per the design data prior to the fabrication of skid. Critical components within the custody transfer metering system should be compatible to ensure Overall System Uncertainty for this critical fiscal transaction purpose with all components within the metering system must be well proven and compatible in the similar application. The meter tube shall be shim less and honed for a maximum internal roughness exceeding 300 micro-inches. The design of the flow straightner (for turbine meter) & Profiler (for USM) shall be as per AGA. The wet calibration/proving of the meter shall be as per situ condition. For USM, the wet calibration shall be done along with up-stream, down stream meter run and flow profiler. The up-stream & down stream meter run including meter shall be cold insulated. The thermo-wells & impulse tubing for the custody transfer

6.6.1

6.7

7.0 7.1

7.2

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transmitters and GC probe/ tubings to be cold insulated. The custody transfer field instruments to be kept under controlled atmosphere. 7.3 The skid shall be complete in all respect, ready for quick installation and commissioning of equipment with minimum work at site. All fieldmounted instruments shall be mounted on the skid. Ease of transportation shall be one of the considerations in deciding the size of skid. The skid shall be complete with piping, flanges, and fittings for pressure reduction and metering as required. All the valves at the up-stream & down stream of meter run shall be full bore ball valves. All ball valves shall have equalization line with block and bleed arrangement. The design, installation and selection of equipments and piping shall be strictly as per AGA for custody transfer applications. The Ultra Sonic Meter (multi path-Minimum 04 path), flow computers and on line Gas chromatograph shall be approved for custody transfer application. The approval certificate for the quoted size of USM to be submitted along with the bid. 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. 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. As a minimum, flow conditioners shall be 316 stainless steel of a between-flanges. These shall comply with the requirements of AGA 9 for ultrasonic meters and AGA7 for turbine meters. Where 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.

7.4

7.5

7.6

7.8

7.9

7.10.1 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. 7.10.2 Each skid shall be complete in all respect ready for alignment & grouting at site. 7.11 7.12 The items shall be properly supported to avoid vibration. Special support as required shall be provided by vendor. Optimize access to instruments and fittings. All equipment shall be orientated to permit servicing without undue dismantling and to have good access and maximum safety. Pressure let down skid shall be with redundant identical let down streams ( 1 working and 1 standby)with automatic switchover from failed

7.13

15

regulator stream to standby stream. In case of failure of pressure regulation with the working stream the slam shut valve of this stream shall close and the standby stream shall start regulation. Monitor valve of particular stream shall regulate pressure when active regulator mails and stream switchover to take place when the monitor fails. Appropriate set points of regulator, monitor, and slam shut valve of each stream shall be decided by the vendor and regulate the downstream pressure so that gas to consumer is always ensured at the contracted pressure. 7.14 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. Lifting lugs and their supporting structure shall be designed for a load equal to two times the weight to be lifted (shipping weight). The detailed stress analysis of the skid structure and frames shall be submitted by the vendor. The 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. The fittings shall be swage-lock type/ design. The specifications of all the instruments shall be as per the attached typical Instrument Data Sheets, Job Specifications and Standard Specifications. The piping materials including valves & flanges shall be supplied as per specifications attached elsewhere in the package. Skid piping design shall comply to Piping specifications including Inspection and testing requirements attached elsewhere in the bid package. Gas filters specifications and design requirements including Inspection and testing requirements shall be as per the specifications for Gas filters attached elsewhere in the bid package. The drain pipes shall be installed at the bottom of the inlet chamber (un-filtered gas) with block & bleed arrangements. All interconnecting instrument cables in skid and cables to control room shall be armored. All signal and alarm cables shall be individual pair shielded and overall shielded. Vendor shall follow the cable specifications as per signal cable standard specifications. All field transmitters 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. All limit switches, 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.

7.15

7.16

7.17

7.18

7.19

7.20

7.21

7.22

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7.23

The certification for use of all instrumentation items including junction boxes/cable glands etc. in hazardous areas shall be as follows. o Certificates from statutory authorities like BASEEFA, FM, CENELEC etc. for items of foreign origin and from CMRI etc. for items of Indian origin. Approval certificate from CCOE (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.

o 7.24

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 shall be suitable for installation in tropical hot and humid climate considering: Temperature: 0 to 55 deg C ; Rel.Humidity : 95% The flange rating & materials of all instrument items shall be as per the Specifications attached elsewhere. The vendor 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. Transmitters shall be microprocessor based SMART type with HART Protocol. Accuracy of transmitters shall be + 0.075% of FSD or better for PT/DPT and 0.1% FSD or better for Temperature Transmitters. All transmitter shall be provided with integral output meter with digital display. 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.

7.25 7.26

7.27

7.28

7.29 Hand held configurator shall be provided for remote calibration, remote configuration and remote diagnostics of the transmitters. 7.30 Vendor shall furnish details of foundation required for the gas pressure reducing & metering skid and the gas chromatograph skid. 7.31 In view of the total weight and overall dimensions of the skids, vendor may decide to fabricate and transport the skid in more than one part. In that case, vendor 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 vendor. 7.32 The gas chromatograph field analyser cabinet alongwith sample
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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 Pressure reduction & metering skid. 7.33 The PT & TT shall be connected to the flow computer through HART communication. 7.34 The signal from equipments to the GAIL SCADA system will be through analog as well as serial communication (Modbus). 7.35 The equipments and piping installed at the up-stream of USM shall be designed in such a way that noise produced should not interfere with USM performance. 7.36 All the field switches shall be suitable for Flameproof and weather proof enclosure contacts. The process switch shall be silver plated with contacts rated for rating of 30 V DC, 1 Amp. This requirement shall also be applicable for any other switch contact like push button, selector switches in the intrinsically safe service. The field switches shall be normally closed type and open to alarm. Switch contacts shall be SPDT. For all field switches (except Limit Switches), differential of switch shall be less than 60% of difference between set value & operating value. 7.37 Equalizing valves are not required for ball valves up to 2 sizes. For all the ball valves (except vent and drain lines) of sizes between 3 and 4 , the equalizing and vent valves shall be of 1 size as per Typical P&ID and For all the ball valves (except vent and drain lines) of higher sizes the equalizing and vent valves shall be of 2 size as per typical P&ID. All the drain valves shall be of size. All the vent valves shall be of two sizes lower than the main line size subjected to minimum of size and maximum of 6 size. 7.38 Floating ball valves are acceptable up-to 4 size in class 300# and Trunion mounted Ball valves (TMBV) shall be provided for ball valves above 4. For 600# class Trunion mounted Ball valves (TMBV) are required for sizes 2 and above. 7.39 7.40 Platforms, ladders, and vessel supports shall be designed in accordance with the AISC Steel Construction Manual The following minimum stress analyses shall be conducted as applicable (in addition to basic code calculation requirements): a.Complete detailed calculations shall be provided for lug, leg, or ring type vessel supports, when used. These shall include the effects on the vessel shell local to the attachment. b. Complete design calculations shall be provided for special, large-diameter closures when used. c. Stresses at saddle supports. d. External loading on vessel nozzles and structural attachments. e. Analysis of lifting and tailing lugs and analysis of vessel stress during lifting. f. Vertical vessels shall be designed and checked for dynamic wind loading when
18

all of the following conditions occur: L is greater than 50 L/D is greater than 15 W/ (LxD2 )is less than 25 where L=Vessel Total Height in ft. D=Average inside diameter of the top third of the vessel in ft. W=Vessel empty weight in lbs

8.0 8.1

SPECIFICATIONS FOR INSTRUMENTS SELF ACTUATED PRESSURE SLAM SHUT VALVES CONTROL VALVES AND

8.1.1

Set point of the Gas pressure regulators/Monitor (PCVs) and Slam Shut Valves (SDVs)shall be adjustable. Vendor shall furnish the adjustable range of the Gas pressure regulators/monitors and slam shut valves. The Gas pressure regulat and slam shut valves shall be provided in redundant pressure regulation stream as primary pressure regulating stream and secondary pressure regulating stream as per P&IDs. It is intended to provide slam shut valves on upstream of self actuated pressure control valves at gas receiving points for tight shut off at increasing pressure beyond a preset limit, to take care of self actuated pressure control valves failure. The slam shut valve of primary regulating stream shall close at its set pressure in case of failure of primary operating regulator & monitor and the secondary regulating stream shall come in operation. The automatic switchover shall be achieved with appropriate staggered setting of Pressure regulator/monitor and slam shut valves. Vendor shall select the appropriate set points such that the switch-over is smooth without affecting the safety of the system and gas supply to consumers is also not interrupted. Each pressure regulator / monitor shall be designed for maximum gas flow rate at the minimum inlet arrival pressure. Gas pressure regulators shall be with very high rangeability since high fluctuations in flow demand are expected and also the inlet pressure may vary considerably. Pressure regulators / monitors shall be self actuated pilot operated with regulation accuracy of better than +/- 1% of set point. The construction of the Regulators / monitors shall be such that there will be no continuous gas bleeding. Leakage class for pressure control valve & slum-shut valve shall be class-VI as per ANSI B16.104 Vendor to note that the noise level for each Regulator / monitor valve shall be less than 85dBA at one meter away from the valves. Vendor shall provide noise treatment to limit the noise level and include silencers or expanders as required in their scope of supply. Vendor to

8.1.2

8.1.3

8.1.4 8.1.5 8.1.6 8.1.7

19

provide Noise calculation giving full details of formulae / standards used and any assumptions considered in calculation. (This calculation shall be submitted alongwith the bid) 8.1.8 8.1.9 Slam shut valve shall be self-contained type requiring external control line such that the line pressure acts directly on the diaphragm. Closing time of slam shut valve shall be less than 2 seconds for all sizes of the valves. Actual closing time of the valve shall be furnished by vendor with the quotation.

8.1.10 Slam shut valves shall be provided with position indicator and shall have separate limit switches for open and close positions. Limit switches shall be with DPDT, snap acting micro switch with contact rating 1 A @ 24 V DC. Limit switch enclosure shall be weather proof to IP 55 and flame proof (Exd) suitable and certified for area classification IEC Zone 1, Gr. IIA, IIB, T3. Cable entry shall be NPT with out flying leads. 5.2.11 Resetting of slam shut valves shall be only manual. 8.1.12 Slam shut valves shall be provided with a mechanical indicator to indicate valve open or close position. 8.1.13 Slam shut valve shall have a set point accuracy of 1% over the whole operating range. 8.1.14 Any by-pass valve provided for the slam shut valve shall be spring closing type. 8.1.15 Velocity at pressure regulating valve may increase beyond 20 meter per second however in the downstream pipe it shall be within 20 meter per second. Actual velocity shall be indicated by vendor. 8.1.16 Vendor shall furnish the flow rate versus trim lift curve to justify the valve rangeability and valve regulation characteristics. 8.1.17 The PCV & SDV shall be designed in such a way the noise generated by these equipments shall not interfere with the performance of the meter. 8.1.18 The self actuating Pressure regulating valve shall be designed as per EN334 / Pressure Equipment Directive PED 97/23/EC covering the production quality assurance. 8.2. 8.2.1 TECHNICAL SPECIFICATION FOR ULTRASONIC FLOWMETER Ultrasonic flow meter shall be multi path type of minimum 4 path & above for natural gas custody transfer flow metering application and the design, construction and operation shall conform to AGA Report 9 (latest version) for multi-path. The meter shall be approved by Nmi/PTB/NPL or equivalent body for custody transfer application. 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. The over-all uncertainty (including lab

8.2.2

20

uncertainities) of the supplied system shall be better than 0.3%.

8.2.3

The design used shall provide maximum reliability, maximum on-line performance and minimum maintenance having on-line diagnostic features. 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. The upstream & down stream meter tube shall be honed for a maximum internal roughness exceeding 300 micro-inches Wet calibration of Ultrasonic meters at operating pressure with natural gas shall be conducted with Upstream & down stream meter runs along with profiler. The Accuracy specified in the tender documents for USM shall be Overall accuracy (inclusive of all lab uncertainty) and it is in percentage of reading. The meter manufacture shall certify that the overall accuracy will be met with the proposed installation-piping configuration of the complete skid.

8.2.4

8.2.5

8.2.6

8.2.4 FLOW METER: 8.2.4.1 The flow meter shall be direct path type with minimum 4 path ultrasonic transducers. The transducers shall be energized by the integral electronics to transmit and receive ultrasonic waves. Vendor 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. 8.2.4.2 The turndown ratio of each flow meter shall be minimum 1:40. Repeatability shall be better than 0.1% for qt<qi<qmax & 0.2% for qmin<qi<qmax and resolution better than 0.001 m/s . Accordingly vendor shall select the no. of paths (minimum 4 paths or more than 4 path) 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 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. 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-

21

peak error as detailed in AGA-9 shall not be exceeded.

22

8.2.4.7 The vendor shall comprehensively advise the impact of transducer failure on the performance and accuracy of the USM. Vendor shall confirm that the measurement will not degrade by more than 0.05% 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. Area classification shall be IEC Zone-1, Gas Gr. II A & IIB, and Temperature Class T4. All electrical instruments in the field shall be suitable for the specified area classification and certified by a statutory body such as FM, UL, CENELEC, BASEEFA, and PTB etc. The transducers shall be intrinsically safe certified suitable for the specified area classification and weather proof to IP65/NEMA-4 and vendor 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.

8.2.4.9

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. Ultrasonic meters shall be rated for the maximum design pressure as indicated in the data sheets. 8.2.4.11 Ultrasonic flow meter spool inside diameter to meet the specified I.D as per AGA. Internal surface roughness shall be as specified elsewhere. 8.2.4.12 All ultrasonic flow meters shall be supplied with upstream meter run with flow conditioner/ profiler (min.10D before flow profiler, 10 D between flow profiler and US meter) and downstream meter runs (min.5D). 8.2.4.13
8.2.4.14

Ultrasonic meters and the meter runs/flow conditioners shall be rated for 600#.

The Meter body length and bore has to be specified by the US Meter Manufacturer. The USM bore and the adjacent upstream pipe along with flanges should have the same inside diameter to within 1% of each other. Vendor has to provide document to justify the same duly certified by third party internationally recognized certifying agencies

8.2.4.15 Fixed Dowel pin to be provided in the USM body for proper alignment with the connecting flanges. 8.8.4.15 External meter body shall be blast cleaned to near white metal as per international standard and primed with inorganic zinc primer (two coats each of 40 micron minimum dry film thickness) and the final coat of epoxy paint of 40-micron dry film thickness.

8.2.5 ELECTRONICS: 8.2.5.1 Meter electronics shall include all associated transmitters, pre-amplifiers etc. 8.2.5.2 The transmitter 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, CENELEC, BASEEFA, PTB etc. 8.2.5.3 The electronics unit shall preferably be mounted integral on the meter. 8.2.5.4 The 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 nonvolatile memory and shall be secured with password such that un-authorised changes
23

are prohibited. 8.2.5.6 Configuration software and firmware shall be provided for each skid. The license shall be in the name of GAIL India Limited. 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 vendor 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 vendor and the WP & flameproof cable glands to be supplied accordingly. Cable entry sizes shall be as per NPT standards. 8.2.5.9 The ultrasonic meters shall be #600 (sizes ranges between 2 to 16 dia) irrespective of operating condition. The maximum velocity shall be less than 25 m/see through the ultrasonic meter. 8.2.5.10 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. Digital discrete outputs for direction of flow, trouble alarm and output data validation. 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. Vendor 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. d) The USM shall be connected to the flow computer serially for digital communication and also for frequency pulse signal shall be connected to flow computer for custody transfer flow indication. Facility of any error correction in USM as permitted for custody transfer application shall be provided . On Line Field Verification : 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 as per AGA 10. If the difference between the SOS between the actual and the calculated one is more than the permissible limit then the flow computer shall generate a alarm. Separetely, Licensed software shall be provided in name of GAIL for Speed of Sound calculation (as per AGA 10) as mentioned in Clause No 8 of AGA9.

b) c)

e) 8.2.5.11

8.2.6

CERTIFICATION FOR CUSTODY TRANSFER AND CALIBRATION

8.2.6.1 Each USM meter shall have calibration certificate, duly signed by approved laboratories of weights and measures authority of country of origin. The Vendor 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. 8.2.6.2 The flow computer shall be certified for custody transfer applications by laboratory / institutes authorized by weights and measures authority of its country of origin or reputed International Standard laboratories / Institutes like NMI, PTB, Pigsar Trans Canada Calibrations(TCC) Canada ,Measurement Canada, Colorado Engineering Experiment Station Inc.(CEESI) USA ,South West Research Inc. (SWRI) USA.
24

8.2.6.3 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 8.2.6.4 Flow calibration shall be performed for at least six points and error curve shall be obtained. Test medium shall be Natural Gas. 8.2.6.5 Vendor shall carryout performance test and certify the meter in combination with its companion electronics. A recognized test facility with traceable reference measurements shall be used. Flow test data at 6 points covering the minimum to the maximum flow rate shall be obtained for ascertaining the meter linearity and repeatability with in the specified limits. The average of minimum and maximum Outlet Pressure of the skid shall be considered as operating pressure for wet calibration. 8.2.6.6 The Ultrasonic meters shall be flow calibrated with natural gas and shall have calibration certificate duly signed by laboratories approved by weights and measures authority of its country of origin or recognized international Institutes like NMI, PTB, Pigsar, Trans Canada Calibrations(TCC) Canada, Measurement Canada, Colorado Engineering Experiment Station Inc.(CEESI) USA etc. 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 vendor 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 ( for the ultrasonic meters with its associated upstream / downstream meter runs & flow profiler) should be done in flow labs as detailed above. 8.3 TECHNICAL SPECIFICATION FOR FLOW COMPUTER and Metering Supervisory System The flow computer shall be certified for custody transfer applications by laboratory / institutes authorized by weights and measures authority of its country of origin such as NMI, PTB, Pigsar or other reputed International Standard laboratories such as Trans Canada Calibrations,(TCC) Canada ,Measurement Canada, Colorado Engineering Experiment Station Inc.(CEESI) USA , The flow computers shall have an audit trail facility. It should be able to store data for 30 days. The bidder has to submit the flow chart for Functional Design Specification of the flow computer. All the configuration software shall be supplied with each skid . The license shall be in the name of GAIL (India) Limited. 8.4.1 Control Room Mounted Flow computer The flow computers shall be Microprocessor based, with digital display, data entry keyboard. Flow computer electronics shall protected from industrial interferences; shock and vibration proof and have low power supply consumption. The flow computers shall compute and display the instantaneous and totalised flow rate for each stream corrected for pressure and temperature variations. The flow computers receive data from the Gas chromatograph for calculation of compressibility factor as per AGA-8 detail method. The flow computers shall be microprocessor based, with keypad and alphanumeric display with AGA firmware for natural gas flow measurement. The flow computers shall be linked to the GAILs RTU for providing the flow measurements of the individual stream runs and related process variables. All diagnostics available in Ultra Sonic Meter shall be replicated in Flow Computer also. For evaluation of measurement performance of Ultra Sonic Meter as per Appendix- C clause no 4 of AGA- 9, the Vendor has to select & quote suitable Flow Computer meeting the AGA recommendations. Mounting shall be Flush panel type. General purpose enclosure.
25

POWER SUPPLY: 230 V AC 10%, 50 Hz 3% (UPS) or 24 VDC. The same shall be compatible of available power at control panel mentioned elsewhere. For KRIBHCO Hazira, 230 Volts ac, 50 HZ shall be provided at single point in the control panel INPUT SIGNAL CAPABILITY: a) Frequency & pulse signals from ultrasonic flow transmitter (meter mounted electronics) and dual HF for turbine meter (panel mounted) b) c) d) e) f) 4-20 mA D.C. (2 wire) superimposed with digital signal (HART protocol) from SMART pressure transmitter representing line pressure. 4-20 mA D.C. (2 wire) superimposed with digital signal (HART protocol) from SMART temperature transmitter representing line temperature. RS 485/422 MODBUS from ultrasonic flow meter electronics for meter diagnostics and healthiness parameter. Other standard inputs available. Discrete inputs from ultrasonic meter electronics

8.4.1.1 INTERFACE CAPABILITY WITH OTHER FOREIGN DEVICES: Vendor shall provide serial links along with cables and connectors at both ends for all the signals with MODBUS protocol. The communication between flow computers and on line GC & SCADA, shall be through serial communication and also through GSM modem in-build or separately installed with the flow computers. 8.4.1.1.1 WITH GAS CHROMATOGRAPH Flow computer shall be interfaced with Gas chromatograph for feeding online gas composition to flow computer through a modbus serial link. Vendor shall be responsible for proper integration of their flow computer with gas chromatograph. Vendor shall provide all necessary hardware, software etc. in vendors supplied systems and other details required for interfacing of their Flow computers. 8.4.1.1.2 WITH RTU (For all flow computers): Flow computers shall be interfaced with GAILs RTU to get gas temperature and pressure, energy flow rate and total energy, corrected & un-corrected volumetric flow rate and total flow, last days cumulative energy and volume, current days running volumetric total and energy total, volume and energy integrated at 6 a.m., gas composition ( mole%C1, C2, C3, iC4, nC4, iC5, nC5, C6+, N2, CO2,Specific gravity, Calorific value) etc. Contractor to note that SCADA vendors shall provide RS 232 serial link at the RTUs for interfacing of intelligent electronic devises like flow computers. For flow computer interface to RTU, vendor shall accordingly provide RS 232 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. Provision shall also be kept at flow computer for writing data from RTU like gas compositions, calorific value etc. from RTU. Vendor 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). Vendor shall also furnish the details of implemented MODBUS protocol like function codes for read and write, CRC implementation, BCC implementation, register addressing methods/mapping etc. during detail engineering for serial interfaces to SCADA (RTU). Vendor shall supply 15 meter of interface cable (RS232) between the Flow computers and RTU along with connectors at both ends & necessary converters and other cables accordingly for each flow computer. 8.4.1.1.3 WITH Metering Supervisory system metering system:
26

All the process parameters of the skid including flow computer & GC data shall be provided in the metering supervisory system.. The supervisory system shall be capable to provide read only data to consumer through serial communication and shall be web enabled. 8.4.1.2 KEYBOARD CAPABILITY: The data entry keyboard shall have the provision to enter the following: (a) Pressure and temperature base factor (b) Specific gravity and scaling factor (c) 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) Linearization of error curve & change of K-factor (i) Other standard features available 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. 8.4.1.3 OUTPUT CAPABILITY: (a) 4-20 mA compensated volume flow rate, line pressure, line temperature and energy rate (or mass flow rate) (4 Nos.) (b) Contact alarms output for unit malfunction, process alarm like low pressure etc. (3 nos.). (c) RS 232 serial output link for telemetry link for all signals as specified elsewhere. (d) RS232C serial link for owners PC for reports (e) Serial port for printers (f) Ethernet port for interface with LAN connection of GAIL for getting web enabled data of the flow computer. (g) Other standard outputs available. (Galvanic / Opto- isolation is required for all inputs and outputs) (h) Additional USB port for connecting laptop (internal or external shall be provided with each flow computer for connecting it to USB port of Laptop for configuration). Connecting cable from Flow computer to USB Port of laptop shall also be supplied for each skid. (i) Output (4 to 20 mA) for flow control valve. 8.4.1.4 COMPUTATIONAL CAPABILITY : (a) (b) (c) (d) (e) (f) (g) (h) Volume flow rate at standard, normal or operator specified base conditions (Sm3/hr) PID algorithm for Flow control. Integrated corrected volume in SCM Energy flow rate and integrated energy (user configurable in kcal, MJ & BTU). Linearization of error flow curve. Generation of standard and user defined reports at printer. All reports shall be user configurable. Calculation of compressibility factor as per AGA-8 detail method. Previous days flow / energy (i.e. yesterdays 6.00 A.M total volume / energy to todays 6.00 A.M total volume / energy) & current running total for the day (i.e. volume 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. Todays accumulated flow /energy (running total since morning 6.00 A.M to current time) and shall be user configurable. Generation of reports for totalised volume & energy at daily (6 a.m), weekly, fortnightly & monthly intervals, flow rate, pressure, temperature, compressibility factor, alarms etc.shall be user configurable. All the above data shall also be made available by vendor in the serial links to RTU.
27

(i) (j)

8.4.1.5

STANDATRDS USED : For the above, applicable standards are: (a) AGA report 7 and 9 for flow rate and total flow for all tags for Turbine meter and Ultrasonic meter (as applicable) (b) AGA-8 characterisation method to determine density, compressibility, super compressibility factor etc. for flow computers (c ) AGA Report 5/GPA 2145/ISO6976 for energy rate and integrated energy.

8.4.1.6 ENGINEERING UNITS (User Configurable) : Volume flow rate -Sm3/hr, Mass - kg/hr, Pressure - kg/cm2g, Energy Kcal / GJ (selectable) ,Temperature - C, 8.4.1.7 MEMORY TYPE: : Non volatile 8.4.1.8 A/D AND D/A CONVERTORS: Calculation accuracy shall be better than 0.05% of full scale including linearity, hysterisis, repeatability and resolution. Accuracy for analogue inputs to be minimum 0.075% and for analogue outputs accuracy shall be minimum 0.1%. 8.4.1.9 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 8.4.1.10 SECURITY: The custody transfer equipments at field like PT & TT shall be installed in a environmental enclosure duly locked for prevention of unauthorised data entry and to minimize the effects of ambient temperature variations. The size of the cabinet shall be suitable for removing and fixing of transmitters, ease of maintenance. The transmitters shall be fixed in mounting brackets inside the cabinet. The cabinet shall be mounted and fixed in the skid. 8.4.1.11 DISPLAY CAPABILITY: The flow computer shall have the capability to display the following parameters: Uncompensated volume flow rate, Compensated volume flow rate, Integrated volume (corrected and not corrected), 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 vendor in the serial links to RTU. 8.4.1.12 DISPLAY TYPE: Alphanumeric LCD display

8.4.1.13 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. 8.4.1.14 Flow Computer Validation Software : Supplier to provide licensed Software in the name of Client for authenticating the algorithm written in the Flow Computer as per AGA-9.
28

8.4.2

METERING SUPERVISORY SYSTEM All the process parameters of the skid including flow computer & GC data shall be provided in the metering supervisory system. 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. The system shall be supplied complete with keyboard, monitor, pointing device and a HP laser Printer with1000 A4 size plain white paper. 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 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. Metering supervisory system shall be designed to work in non air conditioned environment. It shall be suitable for environmental condtions mentioned elsewhere. The computer of metering supervisory system shall have minimum specification of 1GHZ Pentium IV Processor with high resolution SVGA Monitor. The HMI software shall be a standard Software like wonderware, IFIX, Intellution etc. licensed in the name of GAIL INDIA Ltd. The supplied software shall be Full version (not the run time version) so that future changes can be made, if required.

8.5

TECHNICAL SPECIFICATION FOR ON LINE GAS CHROMATOGRAPH (with each skid)

These Online gas chromatograph systems shall mainly comprise of following components: 1. 2. 3. 4. Sample conditioning system Field Analyzer unit Remote display and control unit Portable configurator

Sample Conditioning System: It shall be provided to avoid all undesirable gas contamination including liquid, oil mist etc and to ensure that the gas sample is supplied at suitable pressure and temperature . It should have a regulator with isolation valves and PSV for regulating the sample pressure & flow. The sample flow should be controlled by a needle valve and flow should be indicated through Rota meter. The enclosure for this unit should have heating system so as to maintain minimum temperature of 30 deg C. The sample conditioning system should be field mounted & adjacent to the sampling point of the pipeline. Field analyzer Unit: The function of this unit will be to analyze the gas sample, do the calculation of Heating Value, Relative Density (specific gravity), Compressibility Factor etc. and send the information to remote control/display unit. The technical details of this unit are given as under: i. ii. iii Type: No.of streams: a) Column: Continuous On-line Gas Chromatograph Single stream Micro pack column with high resolution and low carrier gas consumption. b) Column size (length / diameter) : By vendor c) Backflush technique should be used for separation of C6+ components. Detector: Thermal conductivity
29

iv.

v.

vi vii.

viii.

xi.

x. xi.

xii. xiii. xiv. xv.

Carrier gas: a) Helium gas along with pressure regulators and Rota Meter flow-indication. The consumption of carrier gas should be as low as possible. b) Flow rate: 10-30ml/min Cycle time: Operator assignable (10 minutes max). GC shall have provision for automatic calibration every 24 hrs or manually on demand as & when required. Ananlyser: a) The design of Analyser should be based on solid-state electronics with protection from industrial EMI /RFI Interference. b) Inputs / Outputs: It should communicate digitally to remote control / display unit to send the analysis related information. c). Analyzer & analyzer electronics should be supplied with prefabricated / installed tube connection etc., so that field tubing etc. to be done as minimum as possible at site for connection of sample line & carrier gas and calibration gas cylinders d) Functions: Control of all analysis functions in a cycle from operation of sampling valves to detection of peaks and precise calculations for peak measurements, area integration and internal normalization. Average values of analysis and computed results for 8, 24 hours shall be available automatically or on-demand. Also generation of gas analysis report (scheduled or on-demand) and average report (8, 24 hr. averages) for calorific value and specific gravity which will be printed by self contained printer (installed with the remote control display unit). Calibration: Automatic calibration with user selectable time intervals. To accurately determine the relative response factors with/without single component calibrations such as high purity methane. Vendor shall indicate the accuracy and repeatability of the measurement achieved by the calibration method adopted. Calculations : The Analyzer should have the facility of calculating Real Net dry Heating Value, Real gross heating value, Real relative density, base compressibility factor at base pressure = 1.01325 bar, base temperature=15 deg C and at 15.56 deg.C as per latest standard of ISO-6976/ASTM D-3588/GPA2145-GPA2172. The tables used for these calculations should be user configurable. Initially the method table shall be configured with base pressure 1.01325 bar and base temperature 15.56 Deg.C and the heating value shall be in Kcal/scm. Provision to change it to any other configuration as per site requirement to be kept without any further financial implication to GAIL. The analyzer should have the facility for remote communication through GSM modem. The analyzer should be supplied with a calibration gas stand equipped with a heating plate so as to ensure that calibration gas cylinder is maintained at minimum required temperature of 30 deg C. Please note that GC system shall be installed in the Hazardous area. Bidder should ensure that the heating system comply the relevant standard requirement. The analyzer should have the facility for storing at least last 524 analysis-reports and should have the facility for giving the average report for last 24 hours. Diagnostics: Online automatic diagnostics for self checking of system integrity periodically for giving alarms. Area classification: NEC Class I, Div II, Group C & D, temp. Class T3 Type of enclosure / protection: Sample conditioning unit, analyzer, analyzer electronics sha11 be mounted in an enclosure certified as weather proof (NEMA-12) and explosion proof from statutory body. The field mounted equipments shall be suitable for ambient temperature 0-60 degree Celsius and under a shed of suitable size and design, so that there should not be any direct environmental effect.

Remote control/Display unit: The main function of this shall be to access all the gas analysis related parameters from field analyzer unit, send the required O/P in Analog/Digital form to Flow Computers and provide the local display for the composition of all the components. It should also provide the facility for calibration of analog outputs, printing of reports and configuration of user assignable options. It should have separate processor and memory boards, which should operate independent of analyzer. It can be configured to support various options selected by the user via
30

keypad or configurator. i. Type: A Microprocessor based unit with alphanumeric I CRT display for input, output signals. Diagnostics, results and other parameters with integral alphanumeric keyboard for Data entry and other manual commands. Calibration: This should have the calibration facility for calibrating the analogue outputs . Diagnostics: Online automatic diagnostics for self checking of system integrity periodically for giving alarms. Inputs / Outputs: a) Operator inputs via keyboard and configerator/laptop through serial port.. b) Potential free contact output for malfunction. c) Four nos. 4 - 20 mA (isolated) output signals for driving 600 Ohms load resistance four outputs out of six will be used for mostly (and shall be user configurable): I Gross calorific value II. Relative density (specific gravity) III. Mole % CO2 IV. Mole % N2 Each output should be user assignable. d) RS 232c (Modbus) serial link for transmission of the following signals: - Complete gas composition - Calorific value - Relative density (specific gravity) - Compressibility factor RS485/Rs-232C communication port with modbus protocols to connect various make flow computers like Instromet, RMG, Daniel, Bristol Babcock, FMC, OMNI, PIETRO etc. installed in the same control room. It should communicate through GSM modem to other remotely installed number of flow computers having GSM modem for gas compositions. It should communicate to GAIL SCADA through serial communication as well as through GSM modem. Complete details and documentation with respect to protocol details with message structures, frame structures, synchronizing / timing signals, memory locations for data addressability and interface software driver details shall be furnished in order to successfully implement a serial & GSM link with the RTU (by owner). Terminal block suitable for wire size of 1.5 mm2 at the back of chromatograph for connecting to flow computers, etc.

ii. iii. iv.

f)

g.) i) j)

h)

v.

Interface: a) Digital link with analyzer electronics in the field. b) Also the communication between analyzer & programmable control unit shall be either through OFC or copper cable. Printing : It should have the facility for printing the analysis reports on user defined intervals or on demand and should provide a serial communication port(RS-232 C) for the purpose of connecting an external serial dot matrix printer . Mounting: All mounting accessories to be supplied by vendor. All the analysis results shall be stored in the Analyser and it should be retrieved through programmable control unit to portable configurator. The configurator should have provision to take print out of chromatograms, results etc. PORTABLE CONFIGURATOR:

vi.

vii. viii.

i.

The configurator should have at least Pentium-4 processor, 10 GB hard disk, 128 MB
31

ii.

internal RAM, serial port, CD Combo Drive, 15 LCD display. Other details are as under: a) The portable configurator should provide the facility to store all the analysis results made in the past. They can be retrieved and printed out at any time. This PC will be used for following functions: I.) Any modification in the programs, which will be used by the analyzer. II) To Retrieve all data from the analyzer including the chromatogram and should have the facility to configure/ change user related data and should have diagnostic features to face any trouble shootings. b) Power Supply : 230 V AC , 50 Hz with allowable voltage variation of +/- 10%. c) All the software and operating system (Minimum Windows Vista/XP) shall be lisensed in the name of GAIL (India) Limited. Cabling: Vendor to provide required interconnecting cables.

The typical composition of Standard calibration gas to be supplied in two different cylinder of 2.13 m3 capacity:

Name of component C6 N2 CO2 C2 C3 IC4 NC4 IC5 NC5 C1

8.5.1 a) b) c) d) e) f) 8.5.2 8.5.3

Semi rich 0.15 0.08 4.80 7.50 2.80 0.50 0.50 0.20 0.20 Balance

Rich 0.2 0.09 4.50 7.00 3.75 0.70 0.80 0.20 0.20 Balance

The on line Gas Chromatograph shall be consisting of the following subsystems, as a minimum. Probe and sample conditioning system along with fast loop, wherever required as per data sheet. Analyser with electronics Control room mounted programming Control unit Cables, cable glands, junction box, tubing, fitting etc. Calibration gas (with 03 years stability and traceability to NPL) cylinder and carrier gas cylinders. The on line gas chromatograph shall be certified for custody transfer application from Nmi/PTB/NPL. Any additional item required to meet the performance requirement shall be indicated and supplied. The enclosure for sampling system, analyser & electronics shall be complete in all respects, ready for quick installation at site. Each gas chromatograph shall complete the analysis of sample in a maximum time of 10 minutes to a repeatability 0.1% (10 Kcal at 10,000 Kcal/SCM), based on ambient temperature at site between 0C to 50C. The computed GHV shall not exceed an uncertainty of 0.5%. The performance and repeatability of each analyser 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
32

8.5.4

8.5.5 8.5.6 8.5.7 8.5.8

the inspection. Manufacturer shall provide a test certificate showing, 24-hour test data with calibration gas analysed live under flowing conditions for few GC as a sample along with the bid. Ambient temperatures will be included along with repeatability data Vendor to note that the GC skid in field consisting of analyser field cabinet, sample conditioning system, calibration (3 years stability with traceability to NPL or equivalent) & carrier gas cylinder racks etc. shall be assembled together and mounted on a single steel structure by vendor. This skid shall be suitable for floor mounting in a rain/sun shed provided by the Vendor. Gas chromatograph shall be compact, rugged and of proven design to meet the specified needs of energy measurement for natural gas. Vendor to indicate the distance limitation, if any, for this communication cable. Cable shall be armoured. Vendor shall furnish complete specification of these cables. All sample tubing and the tubing between the calibration & carrier gas cylinders and analyser shall be included in the scope of supply. The tubing shall be SS316. Vendor to indicate that the distance limitation, if any, for the sample tubing. Vendor to include minimum two numbers of carrier gas(with 99.99% purity) 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. Gas volume per cylinder is 7m3. The certificate for purity to be submitted from a reputed third party. The vendor shall supply two each pre-filled calibration gas cylinders (one for rich and other for semi rich gas) 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 certification accuracy of 0.2% for components (mole%) greater than 10 % and 0.5 % for components(mole%) between 1 % to 10% and 1.0% for components (mole%) below 1%. The calibration shall be traceable to NPL or equivalent (the traceability certificate to be submitted) with 03 years stability. Mixer category shall be PRIMARY. Gas volume per cylinder is approx. 2.13 m3. Vendor to include 1" 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 vendor. Vendor 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. Vendor 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 vendor to the common atmosphere vent header to be supplied by vendor. Gas chromatograph shall be serially interfaced to all the Flow computers simultaneously for transfer of gas compositions etc. Vendor shall be totally responsible for this interface and the same shall be demonstrated by vendor during FAT. Vendor 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. Vendor shall furnish the certificate at the time of inspection. Vendor shall provide an interconnection diagram for all components from sample take off up to the analyser and also showing interconnection of analyser with programmer in control room. 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 vendor. All fittings shall be double compression type swagelock or equivalent. Sample shall be returned to sample return header located in the analyser cabinet in the field. From sample header, sample shall be vented to atmosphere at a safe height. All interconnection, tubing/fittings/piping/valves between analyser and return header shall be in vendors scope of supply. Vendor 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. Vendor shall provide cable entry sizes and cable gland sizes as specified in the respective data sheet. All the electrical items of the gas chromatograph system in the field (sampling system, analyser, electronics, isolation transformer, power switches, flame proof Lighting, junction box, glands etc) shall be certified flame proof suitable for the specified
33

8.5.9

8.5.10 8.5.11

8.5.12 8.5.13 8.5.14 8.5.15 8.5.16 8.5.17

8.5.18

8.5.19

8.5.20 8.5.21 8.5.22 8.5.23 8.5.24

8.5.25 8.5.26

hazardous area (IEC Zone-1, Gas Gr. IIA & IIB, Temperature T3) from statutory body such as Nmi, FM, CENELEC, UL, BASEEFA, PTB etc. and shall be suitable for ambient conditions as given else where. Vendor to mount the analyser, 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. Vendor to note that analyser, programmer and accessories shall be suitable for power supply of 230 V AC 10%, 50 Hz 3 % or 24 VDC available in control panel mentioned elsewhere. Vendor to ensure that Gas Chromatograph system shall not be damaged because of black outs / brown outs. Vendor to indicate steps to be taken for fail safe operation under power failure. The application programs to be stored in RAM for 6 months battery backup and also for reloading without any external storage device. All controller software and firmware with licenses shall be in Customer's name. The system shall be supplied with an undertaking from the vendor to upgrade all software and firmware to the latest version and to incorporate all algorithm corrections and changes in line with latest industry standards. Such upgrade shall be supplied and executed free of charge by the vendor for ten years from the date of supply of the system Vendor to indicate time period between successive calibrations of analyser and time period for routine preventive maintenance. Vendor shall submit the certificate confirming that the natural gas analysys done by the on line GC confirms to ISO 6974-4 /IS 15130-4.

8.6 8.6.1 8.6.2

HYDROCARBON (LEL) DETECTORS Hydrocarbon detectors shall be used to monitor hydrocarbon gas leakages from the equipments (like metering system, filters), valves, piping etc. LEL detectors shall be provided for each skid. The isolated 4-20mA analog output from each detector shall be taken to LEL Monitors (to be mounted on Metering Control Panel. Construction and performance of hydrocarbon gas detection system shall be as per BS EN-50054 and 50057. Basic criteria for deciding location shall be prevailing wind direction and gas densities. The infra-red type LEL detectors shall be used and shall be dual beam, dual wavelength type. LEL detectors/transmitters shall be microprocessor based and shall be immune to RF and EM interference. LEL detectors shall be immune to catalytic poisons and sunlight Heated optics shall be provided in the LEL detectors to avoid condensation on the window/mirror in the detectors. Vendor to indicate drift in the calibration of the LEL detectors.

8.6.3 8.6.4 8.6.5 8.6.6 8.6.7 8.6.8 8.6.9

8.6.10 All LEL detectors/transmitters shall be supplied pre-calibrated by the vendor either with the gas to be sensed or by applying cross sensitivity factors to achieve an installed accuracy of 2% LEL at site. 8.6.11 All calibration equipment required for site calibration of the detectors including calibration kit with S/W and special connector, calibration gases (for 6 months use), gas cylinders, self regulating valves, pressure gauges, hose, interconnection tubing, fitting etc., shall be supplied by the vendor. 8.6.12 Any special tool required for the maintenance of the system /detector head shall be supplied by the vendor. The maintenance of any detector head/module should not necessitate shutdown of total/partial detection system except those that are being maintained.
34

8.6.13 Lamps in the infra-red detectors shall be replaceable type. Lamp life shall be minimum 5 years or better. 8.6.14 Infra-red detectors shall be compensated for lamp intensity variation due to dust, variation in humidity etc.All the supplied LEL dectectors/transmitters shall be weather proof to NEMA 4 or IP 55. 8.6.15 Vendor to furnish calibration procedure for the LEL detectors/transmitters. 8.6.16 Response time of LEL detectors shall be indicated. Time lag caused by splash deflectors/guards and dust filters shall be taken into consideration. 8.6.17 All mounting accessories/plates for mounting the LEL detectors/transmitters shall be supplied by vendor. 8.6.18 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. 8.6.19 One set of portable gas detector shall be provided complete with its controller, audiovisual alarm and shall be suitable for use in hazardous area. 8.6.20 Battery charger shall be provided for portable calibrator and which shall be chargeable with 230 V AC. 8.7. 8.7.1 Metering Panels 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 shall be free-standing type. Vendor 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. Power supply of 230 V AC 10%, 50 Hz 3% UPS or 24 VDC or both (as per the availability of power at site) shall be made available by GAIL to vendor at a single point in the Metering control panel being supplied by vendor. Further distribution to all the instruments, accessories in panel and field instruments like GC and Meters at Gas metering skid with all items like MCBs, Bus Bars etc. shall be in vendors scope. All the equipments by vendor shall be suitable for the specified voltage variation. Vendor has to made provision in the panel for accepting both the 230 VAC as well as 24 VDC by installing rectifier for DC supply and inverter for AC based on suitable load calculation of the entire supplied system. Vendor shall furnish power consumption details for each type of power supply mentioned above. Vendor 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 vendor for the Metering Control panel. It shall be obligatory on the part of vendor 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. Factory Acceptance Test and Calibration of all items shall be carried out by the vendor and fully compliant reports shall be furnished to Owner meeting the complete requirements. Owner can witness any or all items testing in stages during manufacture and/or at final stage before shipment at the discretion of Owner. Vendor 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.
35

8.7.2

8.7.3

8.7.4 8.7.5

8.7.6

8.7.7

8.7.8

8.7.9

Vendor shall provide hot redundant Power supply in control panel. All the hubs / routers/ switches shall also be redundant. FILTRATION SYSTEM

8.8

8.8.1 8.8.2 8.8.3 8.8.4 8.8.5 8.8.6 8.8.7 8.8.8 8.8.9

The filter cover shall be provided with Davit arm for ease of maintenance. The design of the filter shall be such that , the liquid/condensate can be drained in pressurized condition. All drains and vents shall have one ball valve & one plug valve. Fire case PSV of suitable capacity shall be installed in each filter . The filtration capacity shall be 3 micron for dry gas filter. Ball valves across the filter shall be provided with equalizing (Block and bleed ) arrangements. The withstanding capacity of the filter cartridge shall be more than 1 kg/cm2. However the DP across the filter in operating condition shall not exceed mare than 0.1 kg/cm2. The filration capacity shall be suitable for 125% of rated capacity. PWHT (Post weld Heat Treatment) shall be as per ASME code requirement.

8.9 8.9.1 8.9.2

FIELD TRANSMITTERS (Custody & non-custody type) Bidder shall supply all transmitter of SMART type transmitters as per vendor list. Accuracy of the pressure and differential type of transmitters shall be 0.075% of span or better within the rangeability of 1:10. This accuracy includes the combined effect of linearity, hysteresis and repeatability. Transmitter element material shall be minimum AISI SS 316. All smart transmitters shall have rangeability of 1:100 having local display. Transmitter with lower rangeability shall not be supplied. Static pressure rating for all the transmitters should be of the order of 100 Kg/cmg for all applications in general. However bidder must ensure that static pressure shall not be less than 1.3 times of maximum operating pressure for ranges above than 1 kg/cm g. The transmitters shall be enabled to HART protocol. TEMPERATURE TRANSMITTERS with CLASSA 4-wire RTD (PT-100).

8.9.3 8.9.4

8.9.5 8.10

8.10.1 RTD sheath material shall normally be SS 316 as a minimum and RTD shall be Class A type with 4 wire system. 8.10.2 The gauge head of the Temperature elements (RTD's ) shall be 80 mm, as a minimum to ensure maintenance ease. 8.10.3 All field mounted temperature transmitters shall be remote mounted and shall meet the requirements specified in package. The temperature transmitters shall be smart type and shall provide HART output. 8.10.4 Bidder to note that all thermowells except surface temperature instruments shall be of flanged type only.

8.10.5 The RTD shall be ClassA type-4 wire PT-100. The RTD & thermowell shall be designed in such a way that the insertion length in side the pipe shall be more than 60%.
36

8.11

PRESSURE RELIEF VALVE

8.11.1 All pressure relief valves in hydrocarbon service shall be flanged only. Threaded relief valves shall not be acceptable. 8.11.2 Pressure relief valves shall be full nozzle full lift type except for thermal relief valves. 8.11.3 Conventional valves shall be specified for constant back pressure while bellows seal type valves shall be specified for variable back pressure more than 10% of set pressure. 8.11.4 The body material shall, as a minimum, be as per piping specifications. Nozzle and disc material shall be SS316 as a minimum with machined stainless steel guide and spindle. Whenever semi nozzle designs are unavoidable, body material shall be at least same as nozzle material. 8.11.5 Flanged connection shall be for standard sizes 1" or larger. Minimum flange rating shall be 150 # ANSI. 8.11.6 The pressure relief valves shall be type tested for capacity with 5% blow-down as per ASME sec VIII UG-131 and the actual blow-down of individual valves shall meet the process requirement. Bidder shall furnish the type test certificate for the same. 8.11.7 Test gag shall be provided for all pressure relief valves. 8.12 RECEIVER INSTRUMENTS

8.12.1 Specification for receiver instruments such as Single loop Controllers and Indicator shall be as per typical data sheet and Standard specification. 8.12.2 8.12.3 8.13 Other than custody transfer transmitters, the indication/ display like Filter DP, pressure & Temperature at Inlet & outlet etc. shall be provided in the control panel. Indication for slam-shut valve s shall also be provided. ISOLATING BARRIERS In general, intrinsically safe philosophy shall be followed for all transmitters. Bidder to note that external barriers shall be selected based on entity concept. Typically barrier selection must be made based on the following: i) ii) iii) 8.14 8.14.1 CABLES All cables shall have PVC insulated primary insulation of 85DC PVC as per IS-5831 Type C/ IEC 502. Inner and outer jacket shall be made of extruded flame retardant 90 deg C PVC to IS-5831 Type ST-2 / IEC 502. Oxygen index of PVC shall be over 30% and temperature index shall be over 250 degC. 8.14.2 8.14.3 8.14.4 8.14.5 8.14.6 All cables shall be fire retardant as per standard IEC 332-3 Part 3 Cat.A. Fire resistance cables whenever specified shall be as per IEC 331 Cat. A. Signals cables shall be Type I for single pair and Type IV for multi-pair cables. For cable specification, refer enclosed standard specification elsewhere. All cables glands shall be of nickel-plated brass and they shall be double compression type suitable for armoured cables. Flame proof glands wherever required shall be supplied with Exd certification.
37

Analog Inputs (4-20 mA): Series 5000 of MTL/ P&F KFD series/Eqv. Analog Outputs (4-20 mA): Series 5000 of MTL/P&F KFD series/Eqv. Proximity Inputs: Series 5000 of MTL/ P&F KFD series/Eqv.

8.15

JUNCTION BOXES

8.15.1 Bidder shall supply junction boxes as per the cables selected, wherever required. These shall be of die cast aluminium alloy (LM-6) body and shall be weather proof to IP 55, as a minimum. 8.15.2 8.15.3 8.15.4 Flame proof junction boxes wherever required shall be supplied with Exd certification. All such boxes shall be weatherproof to IP 55 also. Each junction box shall have a minimum of 2 Nos. All spare entries shall be provided with plugs certified Exd for flameproof junction boxes. For junction box and cable glands specification, refer enclosed standard specification elsewhere. 8.16 8.116.1 8.116.2 8.116.3 INSTRUMENTATION VALVES AND MANIFOLDS Bidder shall supply instrument valves (miniature type) and valve manifolds wherever required. Body rating shall be as per piping class or better. All valves and manifolds shall be forged type only. Valve body and trim material shall be SS 316 unless otherwise specified. Superior trim material shall be selected as required by process conditions. Packing material in general shall be of PTFE. 8.116.4 8.116.5 For instrument air isolation valves, body material shall be Nickel or cadmium plated corbon steel. For instrument valves and manifolds specification, refer enclosed standard specification elsewhere. 8.17 IMPULSE TUBING annealed, cold drawn and seamless tubes as a minimum for impulse lines upto 600 # class. Higher thickness according to pressure rating shall be considered for higher pipe classes. 8.17.2 The hardness of SS tubes shall be Rockwell RB 70-79. 8.17.3 Instrument air distribution shall be with 6 mm soft annealed copper, 1 mm thick PVC coated as per ASTM B 68M copper no. C 12200 8.17.4 For tubing and tube fittings specification, refer enclosed standard specification elsewhere.

8.17.1 Impulse tubing shall be 1/2" OD x 0.049" thick ASTM A 269 TP 316 stainless steel fully

38