DESIGN, SUPPLY, INSTALLATION AND COMMISSIONING OF LNG STORAGE & REGASIFICATION SYSTEM IN THE STATE OF MAHARASHTRA, INDIA Project No. P.013752 Document No. P. 013752 D11031 003 BGRL Tender No. BGRL/CGD/LCNG/AA/2 Bharat Gas Resources Ltd, New Delhi | INDIA PUBLIC 1 July 2019 TECHNICAL DOCUMENTATION Technical, Vol II of II, Rev. 0 MAIN TABLE OF CONTENTS P.013751 DESIGN, SUPPLY, INSTALLATION AND COMMISSIONING OF LNG STORAGE & D 11031 REGASIFICATION SYSTEM IN THE STATE OF MAHARASHTRA, INDIA 003 S.No. Description Document / Drawing No. Rev. No. Pages Page No. I VOLUME IA OF II COMMERCIAL 1 SECTION - I INVITATION FOR BID (IFB) 2 SECTION - II INSTRUCTION TO BIDDERS (ITB) 3 SECTION - III GENERAL CONDITIONS OF CONTRACT (GCC) P.013751 D11031 002 1 145 Page No. 01 to 148 4 SECTION - IV SPECIAL CONDITIONS OF CONTRACT (SCC) 5 SECTION - V FORMS AND FORMATS 6 SECTION - VI SCHEDULE OF RATES (SOR) II VOLUME II OF II TECHNICAL 1 PTS - MECHANICAL P.013751 D11077 019 0 2 PTS - CIVIL CONSTRUCTION P.013751 D11077 020 0 3 PTS - GRAVEL FILLING P.013751 D11077 021 0 4 STRUCTURAL CONCRETE Z/02/0004 0 5 SITE PREPARATION FOR EXCAVATION WORKS & BACK FILLING Z/02/0005 0 6 EXCAVATION, BACKFILLING, COMPACTION Z/02/0006 0 7 SEWER AND DRAINAGE SYSTEM Z/02/0008 0 MISC. CIVIL AND STRUCTRUAL WORKS FOR UNDERGROUND PIPING AND OTHER 8 Z/02/0015 0 CIVIL WORKS 191 9 MISCELLANEOUS ITEMS Z/02/0016 0 Page No 01 to 191 10 SOIL INVESTIGATION Z/02/0022 0 11 STRUCTURAL STEEL WORKS Z/02/0023 0 12 PLASTERING AND POINTING Z/02/0025 0 13 BRICK MASONRY Z/02/0026 0 14 DEMOLITION AND DISMANTLING Z/02/0027 0 15 BARICADES Z/02/0062 0 SCHEMATICS FOR TYPICAL LNG STORAGE AND 16 REGAS+LCNG/LNG DISP SYSTEM 17 PTS-HEALTH, SAFETY & ENVIRONMENT P.013751 D11077 025 0 Construction of LNG Satellite with LNG LCNG Dispensing Facility Page 1 of 1 P.013751 PTS - MECHANICAL D11077 019 BHARAT GAS RESOURCES LTD. (BGRL) DESIGN, SUPPLY, INSTALLATION AND COMMISSIONING OF LNG STORAGE & REGASIFICATION SYSTEM IN THE STATE OF MAHARASHTRA, INDIA PTS - MECHANICAL 0 29.06.2019 Issued for Construction Vishal Agarwal Amitabh Ranjan Brajesh Kumar Rev Date Subject of Revision Prepared By Checked By Approved By Page 1 of 191 P.013751 PTS - MECHANICAL D11077 019 TABLE OF CONTENTS 1.0 GENERAL : ....................................................................................................................... 1 2.0 MAJOR APPLICABLE CODES ............................................................................................ 1 3.0 SCOPE .............................................................................................................................. 1 4.0 MAJOR EQUIPMENT ........................................................................................................ 1 ANNEXURE # 1 DETAILED SCOPE OF WORK ............................................................................. 5 ANNEXURE # 2 DATA SHEETS ................................................................................................. 10 ANNEXURE # 3 LIST OF SUPPLIERS OF MAJOR BOUGHT-OUT ITEMS .................................... 16 Rev. 0 Construction of LNG Satellite With LNG & LCNG Dispensing Facility Page 1 of 1 Page 2 of 191 P.013751 PTS - MECHANICAL D11077 019 1.0 GENERAL : LNG SATELLITE STATION WITH LNG & LCNG DISPENSING FACILITY Contractor shall be required to do system design, develop P&ID and detailed layout as per PESO guidelines. The complete system shall be designed for automatic operation with minimal human interference. However, there shall be human interface available in the PLC based control panel. The system shall be designed for most economic and reliable operations with minimal LNG boil-off even under no consumption condition. The system shall be designed in accordance with latest PESO guidelines and other relevant codes/regulations/ laws applicable in India. 2.0 MAJOR APPLICABLE CODES Static and Mobile Pressure Vessel (SMPV) Rules (Unfired) Gas Cylinder Rules NFPA 59A PNGRB regulations OISD codes ASME BPV Code Sec VIII EN 13458-2 In case of any discrepancies in the requirements of above codes, the most stringent requirement shall govern. Only latest edition of above mentioned codes shall be followed. 3.0 SCOPE For Detailed Scope Refer Annexure # 1 of this document. 4.0 MAJOR EQUIPMENT 4.1.1 LNG Unloading Pump Storage facility shall have 1 tanker unloading skid which will unload LNG from road tanker to storage tank with minimum 350 LPM flow and approx. 12 bar (g) differential pressure of LNG. The unloading skid shall have centrifugal pump suitable for LNG service and shall have a return line for tanker. The unloading skid shall have automatic PLC based control system. The LNG unloading skid shall be provided with SS-braided LNG transfer hoses. The skid shall have required number of isolation valves, non-return valve, relief valve designed as per applicable codes and standards as required for safe and reliable operation. Instrumentation such as pressure & temperature gauges, transmitters etc. shall be provided as required. 4.1.2 LNG Storage Tank(S) The LNG satellite station shall have 2 Nos. of 56 KL gross capacity vertical LNG storage tanks. The maximum allowable working pressure of inner storage tank shall be approx. 17Bar(g). The gross capacity of LNG storage tanks shall have a negative tolerance of 5%. However, the contractor can supply LNG tank of any higher capacity. The LNG storage tank shall be designed for a design temperature of -196°C to +40 °C. LNG storage tank shall be designed and manufactured in accordance with latest version of ASME BPV Code Sec VIII/ EN 13458-2. It shall be fit for LNG service and shall be designed to minimize LNG boil-off even during low/ no consumption. The LNG storage tank shall be double-walled and insulated with suitable insulation such as perlite insulation under vacuum etc. The inner tank shall be made from X5CrNi1810/ SA 240 TYPE 304 or equivalent/ superior material and shall be 100% radiographed. All internal piping/ fittings shall be seamless type and made from ANSI 304L (or equivalent). The piping shall be 100% radiographed and pressure tested. The outer tank shall be made from carbon steel or equivalent/ superior material. The outer surface of the tank shall be coated with polyurethane based paint of minimum 240µm DFT to avoid rusting/ corrosion. Rev. 0 Construction of LNG Satellite With LNG & LCNG Dispensing Facility Page 1 of 18 Page 3 of 191 P.013751 PTS - MECHANICAL D11077 019 4.1.3 Low Pressure Re‐Gasification System Odorization LNG Storage Ambient Air PRESSURE Gas at 4 Bar (g) Tank Vaporizer REGULATING SKID Schematic for Low Pressure Re‐gasification system The above figure shows schematic for low pressure re-gasification system wherein LNG from storage tank is directly regasified using a low pressure ambient air vaporizer. The gas pressure is then regulated using pressure regulating skid with dual stream. 4.1.3.1 Low Pressure Vaporizer Low Pressure ambient air Vaporizer shall be provided with a 100 % standby for continuous duty operations. Each ambient air vaporizer shall be designed to work for 8 hours duty cycle and after that automatic change over to idle vaporizer to run re‐gas plant on continuous duty operations. The change-over shall be automated with the help of PLC based control system and shall require no human intervention. Each low pressure ambient air vaporizer shall have a capacity of 2000 Sm3/hr (each) at 10 bar (g). The maximum allowable working pressure of vaporizer shall be approx. 24 Kg/cm2. The desired delivery pressure shall be 4 bar (g) after pressure control regulator. The inlet design temp for the vaporizer shall be from - 196°C to +65 °C. The low pressure atmospheric vaporizer shall be ambient air heated and shall be designed in accordance with latest version of ASME SEC VIII, DIV I and shall be fit for LNG service. The low pressure atmospheric vaporizer shall be made from Aluminium A 6061-T6/ A 6063-T5/T6 or equivalent/ superior material. 4.1.3.2 Pressure Regulating Skid Re‐gasified natural gas shall be passed through pressure regulator skid which is equipped with twin stream pressure regulators to get natural gas at 4 Bar (g) pressure without any interruption. 4.1.3.3 High Pressure LCNG System Odorization LNG HIGH PRESSURE HIGH CNG STORAGE PRESSURE VAPORIZER PANEL DISPENSING PUMP & CASCADE FILLING Schematic for High pressure LCNG system The above figure shows schematic for high pressure LCNG system wherein a LNG tank is connected with high pressure reciprocating pump which can pump LNG liquid to high pressure ambient air vaporizer for high pressure re‐gasification LCNG application. The system shall be designed for CNG cylinder cascade filling at minimum 250 Bar (g). The CNG shall be odorized with an odorant consisting of 70-80% TBM + 20-30% MES as per requirements of PNGRB codes. Rev. 0 Construction of LNG Satellite With LNG & LCNG Dispensing Facility Page 2 of 18 Page 4 of 191 P.013751 PTS - MECHANICAL D11077 019 i. High Pressure Reciprocating Pump LNG tank is connected with high pressure reciprocating pump which can pump LNG liquid at 650 SCMH at min. 250 bar(g). The pump shall have a normal suction pressure of 2 bar and a max of approx. 17 bar. The delivery pressure of LCNG pump shall be minimum 250 bar. ii. High Pressure Vaporizer Pressurized LNG is converted to high pressure CNG after passing through high pressure ambient air vaporizer and stored into the cylinder cascade of 3000/ 4500 WL after odorization process. CNG cascade is further connected to 2 No of CNG dispenser through priority panel which will decide sequence of operation. Fixed CNG cascade has additional taping to fill other mobile CNG cascades. The high pressure vaporizer shall max a maximum operating pressure of approx. 318-325 Kg/cm2 (g) and shall be suitable for CNG cylinder filling at 250 Bar. The high pressure vaporizer shall be ambient air heated and shall be designed in accordance with latest version of ASME SEC VIII, DIV I and shall be fit for service of LNG.