Tender Document 1lng 7d765d

TENDER FOR ENGINEERING, PROCUREMENT
AND CONSTRUCTION OF LNG STATIONS AT

AVINASHI, TIRUPPUR (TAMIL NADU) &
PANANCHERY, THRISSUR (KERALA) ON
TURNKEY BASIS
Project No.P.017398/P.017399
Document No. P.017398/P.017399-G-11031-R001
Bharat Petroleum Corporation Ltd,

Mumbai | INDIA
RESTRICTED
24 May, 2021
TECHNICAL DOCUMENTATION
Technical, Volume
Page 1 of 921
TABLE OF CONTENTS
PROJECT - ENGINEERING, PROCUREMENT AND CONSTRUCTION OF LNG STATIONS AT AVINASHI, TIRUPPUR (TAMIL
NADU) & PANANCHERY, THRISSUR (KERALA) ON TURNKEY BASIS
S.NO. DESCRIPTION DOCUMENT / DRAWING NO. REV. NO PAGES PAGE NO.
COMMERCIAL VOLUME (VOLUME-I OF II)
SECTION-I INVITATION FOR BID (IFB)
SECTION-II INSTRUCTION TO BIDDERS (ITB)

P.017398/P.017399-G-11031-R001
SECTION-III GENERAL CONDITIONS OF CONTRACT (GCC)
SECTION-IV SPECIAL CONDITIONS OF CONTRACT (SCC)
SECTION-V FORMS AND FORMATS
TECHNICAL VOLUME (VOLUME-II OF II) #REF!
A GENERAL
1 OVERALL SCOPE OF WORK P.017398/P.017399-G-11039-M001 0 6 3
B TECHNICAL VOLUME - MECHANICAL 3
1 GENERAL TECHNICAL SPECIFICATION FOR LNG UNLOADING, STORAGE & DISPENSING PACKAGE P.017398/P.017399-G-11077-M001 0 17 9
2 PROCESS DESIGN BASIS P.017398/P.017399-G-11061-M001 0 13 26
3 SPECIFICATION FOR LNG UNLOADING & DISPENSING PUMP P.017398/P.017399-G-11077-M002 0 18 39
4 SPECIFICATION FOR LNG STORAGE TANK P.017398/P.017399-G-11077-M003 0 15 57
5 SPECIFICATION FOR LNG DISPENSER P.017398/P.017399-G-11077-M004 0 17 72
6 SPECIFICATION FOR SATURATION ON THE FLY VAPORIZER PACKAGE P.017398/P.017399-G-11077-M005 0 16 89
7 SPECIFICATION FOR STATION PIPING P.017398/P.017399-G-11077-M006 0 14 105
8 SPECIFICATION FOR FLANGE & FITTINGS P.017398/P.017399-G-11077-M007 0 21 119
9 SPECIFICATION FOR SUPPORTS P.017398/P.017399-G-11077-M008 0 8 140
10 PIPING MATERIAL SPECIFICATION P.017398/P.017399-G-11077-M009 0 24 148
11 SPECIFICATION FOR QUALITY ASSURANCE/QUALITY CONTROL P.017398/P.017399-G-11077-M010 0 12 172
12 SPECIFICATION FOR HEALTH SAFETY AND ENVIRONMENT P.017398/P.017399-G-11077-M011 0 21 184
13 SPECIFICATION FOR PAINTING SYSTEM & COLOR CODING P.017398/P.017399-G-11077-M012 0 3 205
14 SPECIFICATION FOR VACUUM JACKETED PIPING P.017398/P.017399-G-11077-M013 0 6 208
15 SPECIFICATION FOR COLD INSULATION P.017398/P.017399-G-11077-M014 0 16 214
16 DATA SHEET FOR LNG UNLOADING PUMP P.017398/P.017399-G-11087-M001 0 2 230
17 DATA SHEET FOR LNG DISPENSING PUMP P.017398/P.017399-G-11087-M002 0 2 232
18 DATA SHEET FOR LNG STORAGE BULLET/TANK P.017398/P.017399-G-11087-M003 0 2 234
19 DATA SHEET FOR LNG DISPENSER P.017398/P.017399-G-11087-M004 0 3 236
20 DATASHEET OF BOG VAPORIZER & SATURATION-ON-THE FLY VAPORIZER PACKAGE P.017398/P.017399-G-11087-M005 0 3 239
21 DATASHEET OF DRAIN PUMP P.017398/P.017399-G-11087-M006 0 2 242
22 DATASHEET OF ELECTRIC HEATER P.017398/P.017399-G-11087-M007 0 2 244
23 TECHNICAL DATASHEET OF INSTRUMENT AIR COMPRESSOR PACKAGE P.017398/P.017399-G-11087-M008 0 3 246
C TECHNICAL VOLUME - FIRE DETECTION, ALARM AND PROTECTION SYSTEM
GENERAL TECHNICAL SPECIFICATION & SCOPE OF WORK FOR

1 P.017398/P.017399-G-11077-M013 0 11 249
FIRE FIGHTING SYSTEM
2 SPECIFICATION FOR FIRE WATER PUMPS P.017398/P.017399-G-11077-M014 0 20 260
3 SPECIFICATION FOR FIRE FIGHTING EQUIPMENT P.017398/P.017399-G-11077-M015 0 20 280
4 SPECIFICATION FOR FIRE DETECTION SYSTEM P.017398/P.017399-G-11077-M016 0 20 300
5 DATA SHEET FOR FIRE WATER PUMP & JOCKEY PUMP P.017398/P.017399-G-11087-M006 0 5 320
D TECHNICAL VOLUME - ELECTRICAL
1 ELECTRICAL DESIGN BASIS P.017398/P.017399-G-11061-E001 0 15 325
2 SPECIFICATION FOR LV INDUCTION MOTOR P.017398/P.017399-G-11077-E001 0 13 340
3 SPECIFICATION FOR VARIABLE FREQUENCY DRIVE (VFD) P.017398/P.017399-G-11077-E002 0 9 353
4 SPECIFICATION FOR GAS ENGINE GENERATOR (GEG) P.017398/P.017399-G-11077-E003 0 21 362
E TECHNICAL VOLUME - CIVIL
1 ARCHITECTURAL, CIVIL & STRUCTURAL DESIGN BASIS P.017398/P.017399-G-11061-C001 0 20 383
TECHNICAL SPECIFICATION WITH STANDARD GTS AND SOR FOR ARCHITECTURAL, CIVIL AND
2 P.017398/P.017399-G-11077-C001 0 446 403
STRUCTURAL WORKS
F TECHNICAL VOLUME - INSTRUMENTATION 0
1 TECHNICAL SPECIFICATION & DATA SHEET FOR INSTRUMENTATION SYSTEM P.017398/P.017399-G-11077-I001 0 43 849
G ANNEXURES
1 PLOT PLAN LAYOUT OF LNG STATION AT M/S. BP-AVINASHI (TAMIL NADU) P.017398-G-21095-P001 A 2 892
2 PLOT PLAN LAYOUT OF LNG STATION AT PANANCHERY (KERALA) P.017399-G-21095-P001 A 2 894
3 FIRE WATER PIPING LAYOUT OF LNG STATION AT M/S. BP-AVINASHI (TAMIL NADU) P.017398-G-21095-P002 A 1 896
4 FIRE WATER PIPING LAYOUT OF LNG STATION AT PANANCHERY (KERALA) P.017399-G-21095-P002 B 1 897
SCHEMATIC DIAGRAM OF FIRE WATER SYSTEM LNG STATION AT M/S. BP-AVINASHI (TAMIL
5 P.017398-G-21095-P003 A 1 898
NADU)
6 SCHEMATIC DIAGRAM OF FIRE WATER SYSTEM LNG STATION AT PANANCHERY (KERALA) P.017399-G-21095-P003 A 1 899
PIPING AND INSTRUMENTATION DIAGRAM (P&ID ) OF LNG STATION AT AVINASHI (TAMIL

7 P.017398-G-20968-M001 TO M005 A 5 900
NADU)-OPTION 1
PIPING AND INSTRUMENTATION DIAGRAM (P&ID ) OF LNG STATION AT AVINASHI (TAMIL
8 P.017398-G-20968-M001 TO M005 A 5 905
NADU)-OPTION 2
PIPING AND INSTRUMENTATION DIAGRAM (P&ID ) OF LNG STATION AT PANANCHERY (KERALA)-
9 P.017399-G-20968-M001 TO M005 A 5 910
OPTION 1
PIPING AND INSTRUMENTATION DIAGRAM (P&ID ) OF LNG STATION AT PANANCHERY (KERALA)-
10 P.017399-G-20968-M001 TO M005 A 5 915
OPTION 2
11 OVERALL SINGLE LINE DIAGRAM P.017398/99-G-21098-E001 A 1 920
Page 2 of 921
LNG Unloading, Storage Dispensing Stations in the State of Tamil Nadu and Kerala Page 1 of 1
P.017398/ P.017399
OVERALL SCOPE OF WORK G11039
M001
BHARAT PETROLEUM CORPORATION LIMITED

(BPCL)
CONSTRUCTION OF LNG STATIONS IN THE

STATE OF TAMIL NADU & KERALA
ENGINEERING, PROCUREMENT AND CONSTRUCTION OF LNG STATIONS AT

AVINASHI, TIRUPPUR (TAMIL NADU) & PANANCHERY, THRISSUR (KERALA)
ON TURNKEY BASIS
OVERALL SCOPE OF WORK
P.017398/P.017399-G-11039-M001
0 24.05.2021 Issued for Tender KKR MKR KNS

REV DATE DESCRIPTION PREPARED CHECKED APPROVED
Page 3 of 921
P.017398/ P.017399
M001
TABLE OF CONTENTS
1.0 INTRODUCTION .................................................................................................................. 1
2.0 SCOPE OF WORK ................................................................................................................. 1
2.1 SCOPE OF SUPPLY ............................................................................................................... 1
2.2 SCOPE OF SERVICES ........................................................................................................... 3
3.0 TERMINAL POINTS & BATTERY LIMITS ................................................................................ 3
3.1 MECHANICAL & PIPING ....................................................................................................... 3
3.2 ELECTRICAL ........................................................................................................................ 4
3.3 ARCHITECTURAL, CIVIL & STRUCTURAL WORKS .................................................................. 4
3.4 CONTROL & INSTRUMENTATION ......................................................................................... 4
4.0 EXCLUSIONS ....................................................................................................................... 4
Rev. 0 LNG Unloading, Storage & Dispensing Stations in the State of Tamil Nadu & Kerala
Page 4 of 921
P.017398/ P.017399
M001
1.0 INTRODUCTION
Bharat Petroleum Corporation Limited (BPCL) intends to set up LNG unloading, storage & dispensing
stations at Avinashi (Tamil Nadu) and Pananchery (Kerala).
Tractebel Engineering Pvt. Ltd. (TEPL) has been appointed as Project Management Consultant
(hereinafter referred as PMC), by BPCL for providing Engineering, Procurement and Construction
(EPC) services for a mentioned project.
The purpose of this document is to describe the scope of work for the EPC contractor of the aforesaid
LNG unloading, storage and dispensing package.
2.0 SCOPE OF WORK
2.1 Scope of Supply
Scope of supply for each station shall include but not limited to the design, engineering, manufacturing,
purchase of all bought out items, testing at manufacturer works, properly packed, FOR delivery at site
including transportation & insurance of the followings:
1. 1 no. 56.8 KL vacuum insulated double walled Steel LNG Tank with the following accessories:
a. Isolation valves, Non return valves, Globe valve, instruments and interconnected piping
b. Level, pressure transmitter & gauges as per P&ID
c. Emergency shut down Fire safe valves on Filling and delivery/pump lines
d. Safety relief valves & thermal relief valves
e. Vent stack with all support structure
f. Pressure builtup coil & economizer with back pressure controller
2. 1 no. 350 LPM LNG unloading pump with the following accessories:
a. Related valves and instruments including pressure and temperature sensors
b. Variable frequency drive (VFD)
c. Ex proof push button station for local operation
d. Interlocks for precooling and dry run, safety / vent valves, strainer, Pressure gauge, Soft
Starter, Control panel, Gas Detector, Low and High Temperature Sensor, Ex Proof
Emergency Push Button etc.
e. All associated piping & fittings
3. 1 no. 150 LPM LNG dispensing pump with the following accessories:
a. Related valves and instruments including pressure and temperature sensors
b. Variable frequency drive (VFD)
c. Ex proof push button station for local operation
d. Interlocks for precooling and dry run, safety / vent valves, strainer, Pressure gauge, Soft
Starter, Control panel, Gas Detector, Low and High Temperature Sensor, Ex Proof
Emergency Push Button etc.
Rev. 0 LNG Unloading, Storage & Dispensing Stations in the State of Tamil Nadu & Kerala Page 1 of 4
Page 5 of 921
P.017398/ P.017399
M001
e. All associated piping & fittings

4. 1 no. LNG dispenser with the following accessories:
a. Related valves and instruments
b. Mass flow meter
c. Fill & gas return hoses
d. All associated piping & fittings and safety interlocks
e. LNG Dispenser shall have one cool down line, Screen with driver instruction, Dead-man
pushbutton with a programmable interval, ESD pushbutton, Driver choice of cold or
saturated LNG, Earthing connection, Compatible with all truck brand.
5. 1 no. Saturation on the fly Vaporizer
6. 2 set of unloading hose trolley/stand with LNG fill & return hoses alongwith break away
coupling of length suitable as per the approved layout.
7. Nitrogen purging system
8. Instrument air system which includes suitable capacity instrument air compressors, air dryer,
wet & dry air receivers with all air piping and tubing.
9. Submersible Pump for removal of rain water from dyke with control mechanism.
10. Complete Boil off gas management system
11. Entire interconnecting piping/tubing for the normal and cryogenic use along with valves,
supports , fittings and flanges & its accessories for the LNG unloading, storage, dispensing
system as well as for firefighting, instrument air, nitrogen purging, service water, potable water
etc. for the safe, trouble free & efficient operation of the plant.
12. Supply of complete electrical system which includes but not limited to incoming cable,
transformer, distribution boards, emergency diesel generator sets, complete cabling, earthing,
lighting and lightning protection, all electrical safety equipment like danger board, shock chart,
first aid box etc. for the safe, trouble free & efficient operation of the plant.
13. Complete plant control, instrumentation system which include the PLC based SCADA system,
all the field Instruments PG, PT, DPT, TT, LT, Mass Flow meter etc. as per P&ID including
mandatory spares, Instrument Hookup material including branch cable tray, all the
instrumentation & control cable & cabling system, total safety system inclusive of Special gas
detection devices, low and high temperature sensors, ESS etc. as per PESO guidelines, plant
access control etc. for the safe, trouble free & efficient operation of the plant.
14. Entire civil, structural and architectural work except the area grading, fencing at boundary wall
and dispenser canopy.
15. Spare parts for installation, testing and commissioning.
16. Spare parts for 2 years of satisfactory operation. Bidder will include the list of spare parts along
with the bid.
17. Supply of all consumables and hardwires required for erection, testing and commissioning.
Page 6 of 921
P.017398/ P.017399
M001
18. Any other items and material which are necessary to complete the system but not included in
the above description within the scope battery limit of EPC Contractor.
2.2 Scope of Services
Scope of service shall include but not limited to the followings:

1. Design, detail engineering of the entire plant which include preparation of detail P&IDs, layouts,
general arrangement drawings, data sheets, specifications, all engineering calculations for
mechanical, piping, electrical, architectural, civil & structural, control and instrumentation
system of the entire plant.
2. Conductance of safety study like HAZOP, HAZID, QRA, SIL study etc. and safety study
closeout reports.
3. Receipt of material at site, unloading, unpacking and storage of the material at the designated
place at site including supply of all manpower, tools, tackles etc.
4. Shifting of the material from the storage location to the actual equipment foundation location.
5. Technical supports and submission of all documents required for statutory approval from
various authorities like PESO, CFO, Electricity board and all other local bodies.
6. Installation, field testing, commissioning and putting into successful commercial operation of
the entire system includes complete civil, structural and architectural work.
7. Cleaning of site, attending all the punch points, handling over the complete plant.
8. Daily liaison with Employer/Employer’s representatives regarding access to work areas and safe
working arrangements / work permit system
9. Project management, preparation of detailed project schedule and follow the same throughout
the entire duration of the project.
10. Preparation of all QA/QC documents and follow those approved QA/QC procedures strictly.
11. Contractor should establish health, safety and environment policy at the workplace as per
Employer HSE guidelines.
12. Preparation and submission of all “AS BUILT” drawings.
13. Preparation and submission of operation and maintenance manual.
14. Training of Owner’s personnel.
15. Insurance during construction till handing over of the plant as per Special Condition of Contract
(SCC).
16. Any other requirement which is not specially mentioned above but required for satisfactory
completion of the project within the scope battery limit of EPC Contractor.
3.0 TERMINAL POINTS & BATTERY LIMITS
3.1 Mechanical & Piping
1. At Road tanker hoses for inlet/return of LNG
Page 7 of 921
P.017398/ P.017399
M001
2. At vehicle fuel tank for LNG dispensing to vehicles

3. Potable and service water at one point near plant boundary further distribution by EPC contractor.
4. At inlet of fire water filling connection at plant fencing
3.2 Electrical
1. 11 kV or 0.415 kV, 3 phase, 50 Hz power supply terminal at the 4 pole/2 pole structure
inside/outside the plant premises.
3.3 Architectural, Civil & Structural works
1. Preparation of Detail Design Engineering (Drawing / Design documents) of the complete Civil
Architectural & Structural work of Fire water Storage Tank, Shed (If required), Control Cum
Electrical Room Building, Soak pit, & Septic tank along with the all Plumbing Facilities &
fixtures. All Architectural drawing shall be reviewed and approved by BPCL before
construction.
2. Preparation of Detail Design Engineering ( Drawing / Design documents) of the of dyke wall,
Paving under Dyke area, LNG Storage tank foundation, Vaporizer foundation, LNG Unloading
Pump, Hard Stand Details, LNG Dispenser foundation, Cable & Tubing trench with Heavy &
Medium Duty Precast Cover and Air Compressor & receiver foundation along with Anchor Bolt
Base plate etc.
3. Site Grading & Filling with proper Compaction, Boundary wall Cum Retaining wall with Slope
Protection (if required) and chain link fencing shall be provided to the EPC contractor by BPCL.
Further all Sub structures, super structures and architectural work as mentioned above shall be
in EPC contractor’s scope.
3.4 Control & Instrumentation
Entire work is in bidder’s scope.
4.0 EXCLUSIONS
1. Area grading, compaction, levelling, landscaping work of the site area.

2. Edge Protection of the area to be filled.
3. Boundary wall/ fencing
4. Dispenser canopy structure
5. Soil testing and all geotechnical survey
6. Soil Resistivity Survey
7. All other works beyond this package.
Page 8 of 921
GENERAL TECHNICAL P.017398/ P.017399
SPECIFICATION FOR LNG
G11077
UNLOADING, STORAGE &
DISPENSING PACKAGE M001

(BPCL)

ENGINEERING, PROCUREMENT AND CONSTRUCTION OF LNG

STATIONS AT AVINASHI, TIRUPPUR (TAMIL NADU) & PANANCHERY,
THRISSUR (KERALA) ON TURNKEY BASIS
GENERAL TECHNICAL SPECIFICATION FOR LNG UNLOADING,

STORAGE & DISPENSING PACKAGE
P.017398/P.017399-G-11077-M001
0 24.05.2021 Issued for Tender ASA MKR KNS

Page 9 of 921
G11077
UNLOADING, STORAGE &
TABLE OF CONTENTS
1.0 INTRODUCTION ........................................................................................................... 1

2.0 DEFINITIONS ............................................................................................................... 1
3.0 BRIEF SCOPE OF WORK ................................................................................................ 1
4.0 CODES & STANDARDS .................................................................................................. 2
5.0 DRAWINGS & ANNEXURES ............................................................................................ 2
6.0 COMPLETENESS OF SUPPLY .......................................................................................... 3
7.0 GAURANTEED PERFORMANCE ....................................................................................... 3
8.0 DEVIATION .................................................................................................................. 3
9.0 DRAWING APPROVAL ................................................................................................... 3
10.0 SUPPLY & ERECTION SCHEDULE ................................................................................... 3
11.0 QUALITY ASSURANCE ................................................................................................... 4
12.0 PACKING OF SHIPMENT................................................................................................ 4
13.0 SITE CONDITION ......................................................................................................... 5
14.0 SYSTEM DESCRIPTION AND MAJOR EQUIPMENT ........................................................... 5
15.0 PAINTING AND COLOUR CODING ................................................................................. 8
16.0 QUALITY CONTROL & QUALITY ASSURANCE ................................................................. 8
17.0 HEALTH SAFETY & ENVIRONMENT COMPLIANCE ........................................................... 8
18.0 RECOMMENDED VENDOR LIST...................................................................................... 8
Page 10 of 921
UNLOADING, STORAGE & G11077
1.0 INTRODUCTION
Bharat Petroleum Corporation Limited (BPCL) intends to set up LNG unloading, storage & dispensing
stations at Avinashi (Tamil Nadu) and Pananchery (Kerala).
The purpose of this document is to describe the minimum technical requirement for the design, detail
engineering, purchase of all bought out items, manufacturing, testing at manufacturer works, supply,
delivery at site, erection, field testing and commissioning of the aforesaid LNG unloading, storage and
dispensing station.
2.0 DEFINITIONS
Owner/ Client / Purchaser Bharat Petroleum Corporation Limited (BPCL)
Consultant / Client’s Tractebel Engineering Private Limited (TEPL)

Representative
Bidder / Supplier / vendor The firm or company whose bid has been accepted by the
purchaser and includes the Supplier’s legal representatives,
successors and permitted assigns
Third Party Inspection Agency The inspection agency to be appointed by Client / Client
(TPIA) Approved TPIA
Control Authority Client / Client’s Representative or Client’s Approved TPIA
3.0 BRIEF SCOPE OF WORK
The scope of work shall include but not limited to design, detail engineering, purchase of all bought out
items, manufacturing, testing at manufacturer works, supply, delivery at site, erection, field testing,
commissioning and handing over to client of the LNG unloading and storage and dispensing package
which briefly includes the following:
1. 1 no. 350 LPM LNG unloading pump
2. 1 no. 56.8 KL LNG storage tank
3. 1 no. 150 LPM LNG dispensing pump
4. 1 no. 150 LPM Saturation on the fly vaporizer
5. 1 no. 150 LPM LNG dispenser
6. Nitrogen purging system
7. Instrument air system which includes suitable capacity instrument air compressors, air dryer, wet
& dry air receivers with all air piping and tubing LNG unloading flexible hoses with trolley
8. Submersible Pump for removal of rain water from dyke with control mechanism.
Page 11 of 921
9. Complete Boil off gas management system

10. All associated cryogenic piping, valves, fittings, field instruments, JBs, LCS etc.
11. Complete electrical and instrumentation system
12. Complete fire alarm, detection and protection system
13. All architectural, civil and structural works for the entire plant
14. Service Water supply, Potable water supply, storm water system, sewerage system etc.
The detailed scope of work is included in a separate scope of work (Doc. No. P.017398-G-11039-M001)
document. The same shall be referred for further detailing.
.
4.0 CODES & STANDARDS
1. All equipment and materials shall be designed, manufactured and tested in accordance with the
latest applicable Indian Standards except where modified and/or supplemented by this
specification.
2. Equipment and materials conforming to any other standard that ensures equal or better quality
may be accepted. In such case, copies of the English version of the standard adopted shall be
submitted along with the bid.
3. The electrical installation shall meet the requirements of Indian Electricity Rules as amended up
to date, relevant IS Codes of Practice, applicable PESO regulations and all applicable OISD. In
addition, other rules or regulations applicable to the work shall be followed. In case of any
discrepancy, the more restrictive rule shall be binding.
4. Applicable codes for each equipment and systems are detailed in the individual specification.
5. Unless modified, the latest editions of the standards, codes mentioned herein, including all
addenda and revisions, shall apply.
5.0 DRAWINGS & ANNEXURES
1. All drawings and annexure appended to this specification shall form part of this specification
and supplement the requirements specified herein.
2. This specification shall be read and construed in conjunction with the drawings and annexure to
determine the scope of work and terminal points.
3. The quantities shown on drawings and annexure are tentative for bidding purpose only. Any
variation arising during detailed engineering stage will be taken into account for adjustment of
contract price based on unit rates quoted in the bid.
Page 12 of 921
6.0 COMPLETENESS OF SUPPLY
1. It is not the intent to specify completely herein all details of the equipment. Nevertheless, the
equipment shall be complete and operative in all aspects and shall conform to highest standard
of engineering, design and workmanship.
2. Any material or accessory which may not have been specifically mentioned but which is
necessary or usual for satisfactory and trouble-free operation and maintenance of the equipment
shall be furnished without any extra charge.
3. The Contractor shall supply all brand-new equipment and accessories as specified herein with
such modification and alteration as agreed upon in writing after mutual discussion.
7.0 GAURANTEED PERFORMANCE
The performance figures quoted in Technical Particular sheets shall be guaranteed within the tolerance
permitted by relevant standards. In case of failure of the equipment to meet the guarantee, the
equipment may be liable for rejection
8.0 DEVIATION
Should the Bidder wish to deviate from this specification in any way, he shall draw specific attention
to such deviation.
9.0 DRAWING APPROVAL
1. Before starting manufacture of any equipment, the bidder shall have to take approval of relevant
drawings and data from Engineer in writing.
2. Any manufacture done prior to the approval of drawings/data shall be rectified in accordance
with the approved drawings/data by the Bidder at his own cost and the equipment shall be
supplied within the stipulated period.
10.0 SUPPLY & ERECTION SCHEDULE
1. Commissioning date of LNG dispensing is six months from date of issue of LOI. Hence, supply
and erection schedule are to be planned accordingly.
2. The erection schedule, as approved by the Owner’s Engineer, shall be strictly followed by the
erection contractor. If, for any reason beyond the control of the Contractor, the work is held-up
then the contractor shall bring it to the notice of the Owner’s Engineer without any delay.
Page 13 of 921
11.0 QUALITY ASSURANCE
1. Contractor shall follow his standard procedures for quality assurance and control. However,
said standard procedures shall be submitted to the Owner/ Owner’s representative.
2. The procedure shall be in such a form as to clearly delineate the manufacturing sequence and
major inspection points and to reference Bidder's test and inspection procedures.
3. The Owner/ Owner’s representative will inform the Contractor as to which of the inspection
points and tests will be witnessed. As a minimum, a final inspection of the equipment will be
made prior to shipment.
4. Manufacturing and quality control procedures shall be available for audit to the Owner and/or
its representative at the place of manufacture.
5. The Owner and/or its representative reserves the right to inspect the equipment at the point of
manufacture and witness factory and other such tests as may be necessary to ensure conformance
to the specifications.
6. The Owner and/or its representative may inspect the Contractor's facilities prior to award of
contract.
7. The Owner and/or its representative may witness any or all of the tests described.
8. The Owner and/or its representative may conduct surveillance of the Contractor's facilities for
compliance to his standard procedures of quality assurance and quality control while work on
the specified equipment is in progress.
12.0 PACKING OF SHIPMENT
1. The equipment complete with its accessories, spares, special tools and tackles shall be suitably
protected by respective packing for shipment considering handling during transit, distance and
weather conditions involved. The Contractor shall submit the packaging method for shipment
to be adopted by him, if so desired by the Owner/Purchaser.
2. Each consignment shall be marked with Equipment name, Owner/Purchaser’s name & address,
Project details, handling instruction etc. It shall be completed with part list and identification
details. The copies of the part list of each consignment shall also be furnished to the
Owner/Purchaser after dispatch.
3. Equipment shall be packaged for transportation so as to meet the space and weight limitation of
transport facilities. The contractor shall obtain approval from concerned authorities for
transportation of over dimensioned consignment/package, if any, before starting manufacture of
such equipment
Page 14 of 921
13.0 SITE CONDITION
Site is located at Avinashi, Tiruppur (Tamil Nadu) and Pananchery, Thrissur (Kerala)
Major site Climatic data of Avinashi (Tamil Nadu) & Pananchery (Kerala) are given below:
Parameters Avinashi (Tamil Nadu) Pananchery (Kerela)
Altitude above MSL 329 m 18 m
Ambient Temperature 18-40 deg C 21-36 deg C
Relative Humidity 50% 89%
Annual Average Rainfall 450 mm 650 mm
Annual Avg. Wind Speed 47 m/s 39 m/s
Seismic zone III III
14.0 SYSTEM DESCRIPTION AND MAJOR EQUIPMENT
14.1 Brief System Description
LNG shall be brought by vacuum insulated transport tankers of suitable size at the LNG station. The
tanker shall be parked at a designed place on Hardstand. One Liquid Hose and one gas hose shall be
connected from tanker to LNG unloading pump skid. LNG tanker shall be unloaded by one (1) X 100%
unloading pump of 350 LPM capacity at 12 bar max. differential pressure to LNG storage tank.
LNG unloading pump shall be submerged type configured inside a vacuum insulated sump driven by
VFD. Non-submersible type pump is also acceptable.
LNG is stored in one (1) no. vacuum insulated cryogenic storage tank of gross volume 56.8 KL and
MAWP of 12 barg. The normal operating pressure of tank is approx. 8 barg. LNG storage tank has
provision for both top and bottom filling.
LNG storage tank consists of an inner vessel of stainless steel and outer jacket of carbon steel. The
annular space shall filled with perlite and vacuumed to a high degree.
One (1) x 100% LNG dispenser pump are provided to supply LNG from LNG storage tank for filling
of high capacity LNG fueled vehicles through one no. LNG Dispenser of 150 LPM capacity.
Page 15 of 921
14.2 LNG Unloading Pump
LNG Facility shall have 1 no. LNG unloading pump skid which will unload LNG from road tanker to
storage tank with minimum 350 LPM flow and approx. 9 bar (g) differential pressure at normal
operating point. The unloading skid shall have cryogenic centrifugal pump suitable for LNG service
and shall have a return line for road tanker. LNG unloading pump shall be submerged type configured
inside a vacuum insulated sump driven by VFD.
The LNG unloading skid shall be provided with SS-braided LNG transfer hoses and all associated
fittings, flow meter and safety interlocks. The skid shall also 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 also
be provided as required.
14.3 LNG Storage Tank
The LNG station at present shall have 1 No. of 56.8 KL gross capacity vertical LNG storage tank. The
maximum allowable working pressure of inner storage tank shall be approx. 12 Bar(g). The gross
capacity of LNG storage tanks may have a maximum tolerance of ± 5%. The LNG storage tank inner
shell shall be designed for a design temperature of -196°C to +50 °C.
LNG storage tank shall be designed and manufactured in accordance with latest version of EN 13458-
2 & SMPV rules. 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 240 µm DFT to
avoid rusting/ corrosion.
14.4 LNG Dispensing Pump
Facility shall also have 1 no. LNG dispensing pump skid which will pump the LNG to the dispenser
with minimum 150 LPM flow. The dispensing pump skid shall have cryogenic centrifugal pump
suitable for LNG service and shall have a vapor return line for LNG storage tank. LNG dispensing
pump shall be submerged type configured inside a vacuum insulated sump driven by VFD.
Page 16 of 921
One (1) 150 LPM capacity saturation on the fly vaporizer at the discharge of LNG dispensing pump
shall be installed. This shall ensure supply of LNG at saturation temperature around (-) 125 deg C to
the vehicle. There shall also be a bypass line provided for the saturation vaporizer for supplying cold
LNG to the vehicle, if required. LNG shall be filled in the vehicles through one no. LNG Dispenser of
150 LPM capacity.
14.5 Nitrogen Purging System
Nitrogen purging system will be required for the LNG unloading pump, dispensing pump and for the
complete LNG network at various condition for the safe operation of the system. Required numbers of
nitrogen cylinder with necessary piping/tubing connections at the various points as per P&ID shall be
provided. Necessary measuring instruments, valves, fittings shall be provided for the complete nitrogen
purging system.
Nitrogen requirement for LNG storage tank pre-cooling during commissioning (one time requirement)
shall be met by hiring a portable Nitrogen supply system as the quantity requirement will be more and
cannot be met by cylinders.
14.6 Safety Systems
LNG station shall be equipped with state of the art safety systems and interlocks for safe and reliable
operations. LNG station shall be equipped with gas detection and fire/temperature detection sensors
with emergency shutdown buttons at strategic locations as a proactive safety measures which is
continuously monitored by centralized control system. Interlocks shall be designed for operation of the
plant in most safe and reliable manner with minimal human intervention.
The LEL gas detectors shall be provided as required for detection of gas leakages if any. Further the
plant shall be provided with fire water network (extension of existing network, if available), sufficient
number of fire extinguishers and sand buckets.
LNG storage and distribution plant operations should be controlled by centralized SCADA based PLC
system for better and safe operations with manual interventions wherever applicable.
14.7 Interconnecting Piping, Fittings, Valves
The interconnecting cryogenic pipes shall be double-walled vacuum jacketed. Piping, fittings, valves
used shall be fit for LNG service. For further details, piping specification (Doc. No. P.017398-G-11077-
M010) shall be referred.
Page 17 of 921
15.0 PAINTING AND COLOUR CODING
Please refer Specification for Painting and Colour coding (Doc. No. P.017398-G-11077-M012) as
attached with this tender document.
16.0 QUALITY CONTROL & QUALITY ASSURANCE
Please refer Quality Control and Quality Assurance Specification (Doc. No. P.017398-G-11077-M010)
as attached with this tender document.
17.0 HEALTH SAFETY & ENVIRONMENT COMPLIANCE
Please refer Health Safety & Environment Specification (Doc. No. P.017398-G-11077-M011) as
attached with this tender document.
18.0 RECOMMENDED VENDOR LIST
Recommended vendor list is given below:
LIST OF RECOMMENDED SUPPLIERS OF MAJOR BOUGHT-OUT ITEMS
ITEM DESCRIPTION MAKE
INOX / VRV / CHART / TAYLOR

LNG STORAGE TANK
WHARTON/CRYOGAS
MANUAL CRYOGENICC
BESTOBELL / HEROSE OR EQUIVALENT
GLOBE /CHECK VALVE
HEROSE / HABONIM /
EP OPERATED CRYOGENIC
BESTOBELL/MECAINOX OR
VALVES
EQUIVALENT
ESD VALVES BESTOBELL / HEROSE OR EQUIVALENT
3-WAY MANIFOLD VALVE BALDOTA OR EQUIVALENT
PRESSURE SAFETY VALVE BESTOBELL / HEROSE OR EQUIVALENT
LEVEL GAUGE, PR. GAUGE WIKA OR EQUIVALENT
AUDCO / MICROFINISH / ROTEX OR

BALL VALVES
EQUIVALENT
Page 18 of 921
CRYO REGULATOR & SAMSON / CASH/BESTOBELL OR

PRESSURE REGULATOR EQUIVALENT
PRESSURE CONTROL NIRMAL INDIA/ CHEMTROL/ PIETRO

REGULATOR FIORENTINI OR EQUIVALENT
HEROSE /LESSER/ ROCKWOOD OR

SAFETY VALVE
EQUIVALENT
THERMAL RELIEF VALVE HEROSE/ REGO OR EQUIVALENT
PRESSURE GAUGE WIKA OR EQUIVALENT
GENERAL INSTRUMENT/NASHA OR
TEMPERATURE ELEMENT
EQUIVALENT
PRESSURE/TEMPERATURE EMERSON/ SIEMENS/HONEYWELL OR

TRANSMITTER EQUIVALENT
BALIGA/KAYSON OR EQUIVALENT
JUNCTION BOX PESO
APPROVED
PLC SYSTEM HARDWARE
ALLEN BRADLEY / SIEMENS OR
WITH COMPLETE CONTROL
EQUIVALENT
PANEL
PENTEX / HNL/HONEYWELL OR
LEL NG GAS DETECTOR
EQUIVALENT
EMERGENCY STOP PUSH
BUTTON STATION NEAR BALIGA/KAYSON OR EQUIVALENT
TANK
POLYCAB/KEI/PRIMECAB/CCI/KEC/CMI
ELECTRICAL CABLES
OR EQUIVALENT.
CRYOGENIC PUMP CRYOSTAR / ACD NIKISSO /VANZETTI

CENTRIFUGAL / SUBMERGED /CRYOMECH OR EQUIVALENT
CRYOSTAR/ACD NIKISSO/CRYOGAS OR
LNG DISPENSER
EQUIVALENT
ABB/SIEMENS/CGL/BBL/MARATHON OR
MOTOR
EQUIVALENT
ABB/SIEMENS/HITACHI OR
VFD
EQUIVALENT
C0NTROL & INSTRUMENTATION
PRESSURE GAUGES &

WIKA, GENERAL INSTRUMENTS, PYRO
DIFFERENTIAL PRESSURE
ELECTRIC
GAUGES
Page 19 of 921
LEVEL GAUGES CHEMTROL, KROHNE, WIKA
LEVEL TRANSMITTER VEGA, MAGNETROL, EMERSON
GENERAL INSTRUMENTS,
TEMP. GAUGES
PYROELECTRIC, ASHCROFT
ODORIZER VARICON/ CPL/ INIMO/ SV GAS
GENERAL INSTRUMENT, TEMPSENS,

TEMPERATURE ELEMENT
PYROELECTRIC
PRESSURE/ DIFFERENTIAL
PRESSURE /TEMPERATURE EMERSON/ SIEMENS/ YOKOGAWA
TRANSMITTER
PRESSURE SWITCHES INDFOS, SWITZER, ASCHCROFT
INSTRUMENT VALVES FITTING,

SWAGELOK / PARKER
TUBE FITTINGS & AIR MANIFOLD
BALIGA /FLEXPRO ELECTRICALS PVT.
JUNCTION BOX LTD./ EXPROTECTA ELECTRICALS OR
EQUIVALENT PESO APPROVED
PLC SYSTEM HARDWARE WITH ALLEN BRADLEY / SIEMENS/
COMPLETE CONTROL PANEL YOKOGAWA
SCADA ABB, HONEYWELL, YOKOGAWA
PENTEX / HNL/ DRAGER(I)/ DETRONICS/

LEL NG GAS DETECTOR
HONEYWELL
EMERGENCY STOP PUSH
BUTTON STATION NEAR BALIGA/ SIEMENS INDIA/ L&T
TANK
RPD METER ROMET/ITRON/ CAMERON
MASS FOW METER EMEROSN / E&H
LVS (LARGE VIDEO SCREEN) BARCO/ PYROTECH/DELTA
CONTROL CONSOLE EVAN/ PYROTECH
SURGE PROTECTOR MTL/ P&F
Page 20 of 921
INSTRUMENTATION CABLES POLYCAB WIRES PVT. LTD. /THERMO

(SIGNAL/CONTROL/POWER) CABLES LTD./ LAPP/ KEI/ CORDS CABLE
LAN SWITCH/ROUTERS/FIRE
CISCO/3COM/ NORTEL/ HIRSCHMANN
WALL
LASER JET COLOUR PRINTER HP/ CANON/ EPSON
SCADA SERVER/ /ACHIEVE

DELL/HP
SERVER/HMI
DETECTOR ELECTRONICS PVT.LTD./
FIRE AND GAS DETECTION
DETECTION INSTRUMENTS INDIA PVT.
SYSTEM
LTD./HONEYWELL/
PRIORITY PANEL PARKER /TULSA
M/S ASSOCIATED CABLES/

M/S DELTON CABLES LTD, INDIA /
M/S KEI INDUSTRIES LTD INDIA /
M/S - CORDS CABLE INDUSTRIES LTD,
INDIA /
CONTROL AND SIGNAL CABLES
M/S POLYCAB WIRES PVT LTD, INDIA /
T. C. COMMUNICATION PVT. LTD.,
DELHI
M/S SUYOG /
M/S THERMO CABLES
ZENER BARRIERS/ISOLATORS MTL/ P & F
MCB’S HAVELL’S/ INDO ASIAN/MDS
RELAYS OEN/JYOTI/OMRON
POWER SUPPLY UNIT ELNOVA /APLAB
M/S ABB/M/S EUROTHERN/M/S TATA

INDICATORS
HONEYWELL/ M/S MASIBUS
M/S KELTRON CONTROLS LTD/M/S
CONTROL ROOM EQUIPMENT ITTAL M/S PYROTECH/M/S POSITRONICS
CONTROL PANEL & ACCESSORIES PVT. LTD./ RITTAL/ PYROTECH
CONTROLS
FLOW DIVERTER BESTOBELL / REGO
CROWCON DETECTION INSTRUMENTS

LTD / DETECTION INSTRUMENTS (I) PVT
L.E. L DETECTION SYSTEM LTD/DETECTOR ELECTRONICS
CORPORATION /DRAGER SAFETY AG &
CO. KGAA MSA MINESSAFETY
Page 21 of 921
APPLIANCES/OLDHAM FRANCE S.A.

HO/HONEYWELL
FIRE FIGHTING SYSTEM
LUBI / KIRLOSKAR / FLOWMORE / WILO

FIRE WATER PUMPS
M&P / PENTAIR
DIESEL ENGINE KOEL / CLARKE / CUMMINS
PIPES (MS / GI) TATA / JINDAL
HEAVY METALS / RATNAMANI / SURAJ /

PIPES (SS)
REMI
KIRLOSKAR / KARTAR / HD FIRE / L&T /

OS & Y TYPE GATE VALVES
OSWAL
SINGLE HEADED HYDRANT

NEWAGE / SBJ / WINCO
VALVES & HOSE BOX
FOUR WAY FIRE BRIGADE INLET NEWAGE / SBJ / WINCO
SHUT OFF NOZZLE NEWAGE / SBJ / WINCO
RUBBER PIPE FOR HOSE REEL NEWAGE / SBJ / WINCO
NON-RETURN VALVES TYCO / L&T / WEIR BDK / OSWAL
PRESSURE SWITCH /
SWITZER / HONEYWELL
TRANSMITTER
PRESSURE GAUGES WAREE / WIKA / FORBES
FIRE PUMP MONITORING PANEL ARMSTRONG / FIRE TROL / KIRLOSKAR
TYCO / INTERVALVE / L&T / FOURESS /

BUTTERFLY VALVE AV VALVES / ADVANCE/ DELVAL /
LEADER
ENAMEL PAINT ASIAN / BERGER
PAINT PRIMER ASIAN / BERGER
FASTENERS HILTI / FISCHER
Page 22 of 921
WELDING RODS ADVANI / ESAB
TYCO / DELVAL / INTERVALVE / OSWAL

BALL VALVES
/ MICROFINISH / LEADER
MINIMAX / CEASE FIRE / KANEX /

FIRE EXTINGUISHERS
SUPERMAX
RRL HOSE NEWAGE / SBJ / WINCO
SPRAY NOZZLE, QB DETECTORS HD FIRE / FIRETECH
DELUGE VALVE HD FIRE / FIRETECH / DOROT
CLEAN AGENT FIRE SUPPRESSION

TYCO / SEVO SYSTEM / UTC
SYSTEM
RUBBER GASKETS VARUNA / UNIT KLINGER
HOSE DRUM NEWAGE / SBJ / WINCO
MECHANICAL SEAL BURGMANN / DURA / SEALOL
SANT / TELEFLOW / FLAIR / VENUS /

STRAINER
LEADER
AIR RELEASE VALVE GIACOMINI / RAPIDROP / CLA-VAL
FIRE PUMP RELIEF VALVE CLA-VAL / TYCO / RAPIDROP
FIRE PUMP TEST METER TYCO / RAPIDROP
STRUCTURAL STEEL SAIL / VIZAK
TRACTEL TIRFOR / BRADYS & MORRIS /

CHAIN PULLEY BLOCK
INDEF
PRESSURE REDUCING VALVE CLA-VAL / SAMSON
PRESSURE SAFETY VALVE CLA-VAL / SAMSON
BRANCH PIPES NEWAGE / SBJ / WINCO
Page 23 of 921
WRAPPING & COATING IWL / RUSTECH / AR LAMINATOR
UNIK /ZOLOTO/VENUS/FITWELL/
WELDFIT/JK FORGE /R BRAND /OMEGA
PIPE FITTINGS
/HB /DRP-M/GREENLINE/HARDIK
FORGING / METRO METAL
NUTS & BOLTS LAKSHMI/UNBRAKO/GKW/TVS
GROOVED FITTINGS VICTAULIC / TYCO / JAINSONS
ELECTRICAL ITEMS
CCI / RPG /
POWER & CONTROL CABLES UNIVERSAL/POLYCAB/KEI/CMIL/KEC/PR
IMECAB
CONDUIT IS APPROVED
ABB/GE/C&S/
CONTACTOR & OVERLOAD
TELEMECHANIQUE/SIEMENS/L&T/SCHN
RELAY
EIDER
AE/ IMP/ MECO/ RISHAB/
ELECTRIC METER
L&T/CONSERVE
AE/ KAPPA/ JYOTI/ L&T/ PRAGATI/ C&S/

CT/PT
G&M/ PRECISE/ RECO/ SIEMENS
L&T/GE POWER CONTROL/SCHNEIDER

MCCB
ELECTRIC/SIEMENS/C&S
HAVELLS/STANDARD/ MDS
SWITCHGEAR/ INDOASIAN/ SIEMENS/
MCB/RCCB/ELCB
L&T/ABB/INDO ASIAN / GE POWER/
SCHNEIDER/C&S
SIEMENS/L&T/GE POWER/ TEKNIC/
PUSH BUTTONS
VAISHNO /RASS/BCH/CONCORD/C&S
SIEMENS/L&T/JYOTI/WILSON/HAVELLS/
SWITCHES
SWITORN DEVICES/ SIEMENS/ KAYCEE
SIEMENS/L&T/GE POWER/ TEKNIC/
LED TYPE INDICATION LAMP
VAISHNO /RASS/BCH/CONCORD/C&S/
(CLUSTER LEDS)
ESSEN
GRAM ENGG., HOPES METAL, INDIANA,
GLOBE ELECTRICALS, MM ENGG.,
CALCUTTA MANUFACTURERS, ELCON
CABLE TRAY
CABLE TRAY’S PVT. LTD.,PREMIER
POWER PRODUCTS, ADVANCE POWER
PRODUCTS
Page 24 of 921
BHARAT BIJLEE/CROMPTON
ELECTRIC MOTOR GREAVES/KIRLOSKAR
ELECTRIC/ABB/SIEMENS
ABB/SIEMENS/L&T/SCHNEIDER/HITACH
SOFT STARTER/VFD
I
TRICOLITE/ MILESTONE/VENUS OR
PUMP LOCAL CONTROL PANEL
EQUIVALENT
FIRE ALARM & DETECTION SYSTEM
EDWARD/SIEMENS FIRE FINDER /

FIRE ALARM PANEL NOTIFIER / TYCO

FIRE ALARM REPEATER PANEL NOTIFIER / TYCO

MONITOR MODULES & CONTROL
NOTIFIER / TYCO
MODULES

SMOKE, HEAT & MULTI
NOTIFIER / TYCO
DETECTORS
PVC INSULATED COPPER FRLS

POLYCAB/ FINOLEX / GEMSCAB / LAPP
CABLES (ARMOURED OR
OTHERWISE)
DISPLAY UNIT NOTIFIER / TYCO

MANUAL CALL BOX NOTIFIER / TYCO

RESPONSE INDICATOR WITH
NOTIFIER / TYCO
PIEZO
Note:
1. Any other vendor(s) apart from as mentioned above (item where less than three vendor is indicated) may
be accepted subject to approval by Owner/Owner’s representative based on past track record.
2. For the vendors of items not covered in above vendor list, but required for completion of project
successfully, supplier shall take approval form Owner/Owner’s representative for the same during project
execution. Bidder shall submit the required certifications, documents, PTR and Performance letters from
clients for the same.
3. Refer clause 5.0 of TECHNICAL SPECIFICATION FOR ARCHITECTURAL, CIVIL AND
STRUCTURAL WORKS for List of approved manufacturers for Architectural, Civil and Structural works.
Page 25 of 921
P.017398/ P.017399
PROCESS DESIGN BASIS G11061
M001

(BPCL)


STATIONS AT AVINASHI, TIRUPPUR (TAMIL NADU) & PANANCHERY,
THRISSUR (KERALA) ON TURNKEY BASIS
PROCESS DESIGN BASIS
P.017398/P.017399-G-11061-M001
Page 26 of 921
P.017398/ P.017399
M001
TABLE OF CONTENTS
1.0 INTRODUCTION ........................................................................................................................1
2.0 OBJECTIVE ................................................................................................................................1
3.0 ABBREVATIONS .........................................................................................................................1
4.0 CODES AND STANDARDS ...........................................................................................................3
5.0 SITE CONDITIONS .....................................................................................................................4
6.0 OVERALL FACILITY DESCRIPTION ..............................................................................................5
7.0 PROCESS DESIGN PARAMETERS .................................................................................................7
8.0 BOIL OF GAS MANAGEMENT ......................................................................................................8
9.0 PIPE SIZING CRITERIA ..............................................................................................................8
10.0 PLANT LIFE ...............................................................................................................................8
11.0 SPARING PHILOSOPHY ..............................................................................................................9
12.0 SAFETY AND RISK CONSIDERATION FOR MECHANICAL SYSTEM AND EQUIPMENTS .....................9
13.0 FIREFIGHTING SYSTEM .............................................................................................................9
14.0 FREEZE PROTECTION SYSTEM ................................................................................................. 10
15.0 CLEANING AND PAINTING ....................................................................................................... 10
Page 27 of 921
P.017398/ P.017399
M001
1.0 INTRODUCTION
1.1 Project Description
Bharat Petroleum Corporation Limited (BPCL) intends to set up LNG unloading, storage &
dispensing stations at Avinashi (Tamil Nadu) and Pananchery (Kerala).
This station is also equipped with LNG unloading, storage and dispensing facility for the high power
LNG fueled vehicles.
1.2 LOCATION
Site is located at Avinashi, Tiruppur (Tamil Nadu) and Pananchery, Thrissur (Kerala).
2.0 OBJECTIVE
Objective of this document is to provide basic process design guidelines of LNG unloading, storage
and dispensing facility at the aforesaid LNG stations.
3.0 ABBREVATIONS
LNG Liquefied Natural Gas
CNG Compressed Natural Gas
BOG Boil off Gas
PNG Pipe Natural Gas
P&ID Piping and Instrumentation Diagram
MFM Mass Flow Meter
PI Pressure Indicator
PT Pressure Transmitter
LT Level Transmitter
Page 28 of 921
P.017398/ P.017399
M001
TRV Temperature Relief Valve
PRV Pressure Relief Valve
TI Temperature Indicator
PLC Programmable logic controller
GD Gas detector
FD Flame detector
ODR Odorizer
MAWP Maximum Allowable Working Pressure
M3/h Cubic meter per Hour
NM3/h Normal cubic meter per Hour
LPM Liter per minute
SCMH Standard Cubic meter per Hour
SCMD Standard Cubic meter per Day
ESD Emergency Shut Down
PRE Pressure Control Regulator valve
Ex proof Explosion proof
NPSH Net Positive Suction Head
SOP Standard Operating Procedure
OISD Oil Industry Safety Directorate
PESO Petroleum and Explosives Safety Organization
Page 29 of 921
P.017398/ P.017399
M001
4.0 CODES AND STANDARDS
Natural gas fueling stations — LNG stations for fueling

ISO 16924 :
vehicles
GSR 388(E)_ New

Schedule 4: “Storage, Handling and Dispensing at
SMPV Rule for LCNG- :
LNG/LCNG Dispensing Stations”
2018
ASME B 31.3 : Process Piping Code
API 521 : Pressure Relieving and Depressurizing System
ASME Sec V : Boiler and Pressure Vessel Code- Non-Destructive Testing
ASME Sec VIII : Boiler and Pressure Vessel Code Div. I- Pressure Vessels
Boiler and Pressure Vessel Code- Code Welding and Brazing

ASME Sec IX :
Qualifications
ASME B 16.5 : Steel Pipe Flanges and Flanged Fittings
SME B16.9 : Factory made Wrought Steel Butt Welding Fittings.
ASME B.16.11 : Forges Steel Fittings, Socket Welding and Threaded
ASTM A20 : General Requirements for steel plate for pressure vessels
MSS-SP-44 : Steel pipeline flanges
SSPC VIS-1 : Steel Structure Painting Council
Codes of practice for design loads (other than earthquake) for

IS 875 Part 3 :
buildings and structures
PESO Guideline : Petroleum and Explosives Safety Organization
OISD : The Oil Industry Safety Directorate
OSHA : Occupational Safety & Health Administration
IEEE 383/1974 : Flammability test
IEC 754-1 : Acid gas generation test
Page 30 of 921
P.017398/ P.017399
M001
ASTM–D – 2843 : Smoke generation test
Guide for Instrumentation and Control Equipment Grounding

IEEE-1050 :
in Generating Station.
IEEE 472 (1974) : IEEE Guide for surge withstand capability (SWC) Tests
MC 12.1-1975 : Electronic Industrial Process Instruments
IEC 326 C : Printed Circuit Boards
NEMA ICS
: Contact Rating for AC services
Part-2-125,A600
NEMA ICS
: Contact Rating for DC services
Part-2-125,N600
ISO 1745 : Control procedures for Data Communication System
NEMA Std.
: Types of enclosures through 110.22 (Type 4 to 13)
ICS-6-110-15
Protection Class for Enclosure, Cabinets, Control Panels and

IS-13947 :
Desks
Specifications and guides for the use of general-purpose

ISA RP 19.1-1979 :
annunciators
Relays and relay system associated with electric power

IEEE std.3.13 :
apparatus
BS 5887 : Code of Practice for Testing of Computer-based Systems
Electromagnetic Compatibility for Industrial Process

BS EN 60801 :
Measurement and Control
5.0 SITE CONDITIONS
Parameters Avinashi (Tamil Nadu) Pananchery (Kerela)
Altitude above MSL 329 m 18 m
Ambient Temperature 18-40 deg C 21-36 deg C
Page 31 of 921
P.017398/ P.017399
M001
Relative Humidity 50% 89%
Annual Average Rainfall 450 mm 650 mm
Annual Avg. Wind Speed 47 m/s 39 m/s
Seismic zone III III
6.0 OVERALL FACILITY DESCRIPTION
LNG shall be brought by vacuum insulated transport tankers of suitable size at the LNG station. The
tanker shall be parked at a designed place on Hardstand. One Liquid Hose and one gas hose shall be
connected from tanker to LNG unloading pump skid.
Each LNG station facility shall have one LNG unloading pump skid with one (1) no. of unloading
pump which will unload LNG from road tanker to LNG storage tank with minimum 350 LPM flow
and approx. 9-12 bar (g) differential pressure of LNG (or as per the requirement). The unloading skid
shall have submersible type pump with vacuum insulated sump suitable for LNG service and shall
have a return line required for precooling of unloading pump upto road tanker. Suitable type strainer
shall be provided at suction of the pump.
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, pressure relief valve designed as per applicable
codes and standards as required for safe and reliable operation. Instrumentation such as pressure
transmitters, differential pressure transmitters, pressure gauges & temperature transmitters etc. shall be
provided as required for safe operational. LNG unloading pump shall be submerged type configured
inside a vacuum insulated sump driven by VFD.
Each LNG station shall have one (1) No. 56.8 KL gross capacity vertical LNG storage tank. The
maximum allowable working pressure of inner storage tank shall be approx.12 bar (g). The normal
operating pressure of tank shall be approx. 8 barg. LNG storage tank shall have provision for both top
and bottom filling.
The gross capacity of LNG storage tanks can have a negative tolerance of 5%. The LNG storage tank
shall be designed for a design temperature of (-)196°C to (+) 50°C.
Two no. of Level transmitters, pressure transmitter, safety relief valves shall be provided on LNG
storage bullet. Additionally, Thermal relief valves shall be provided on isolatable pipe sections to
protect pipes from high pressure generated due to thermal expansion of trapped LNG or BOG in
piping.
LNG storage tank pressure shall be maintained by the pressure building coil PBU provided below the
tank with pressure control regulator valve.
The LNG storage tank shall be designed to have minimum boil-off even during no consumption
Page 32 of 921
P.017398/ P.017399
M001
conditions.
LNG storage tank shall be designed, manufactured and designed 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 240 µm DFT to
avoid rusting/ corrosion.
LNG from LNG storage tank shall be transferred to LNG Dispenser for filling in LNG fuelled
vehicles at 8~10 barg pressure & saturation temperature through one (1) X 100% LNG Dispensing
Pump.
One (1) 150 LPM capacity saturation on the fly vaporizer at the discharge of LNG dispensing pump
shall be installed. This shall ensure supply of LNG at saturation temperature around (-) 125 deg C to
the vehicle. There shall also be a bypass line provided for the saturation vaporizer for supplying cold
LNG to the vehicle, if required. LNG shall be filled in the vehicles through one no. LNG Dispenser of
150 LPM capacity.
LNG dispensing pump shall be submersible type pump with vacuum insulated sump suitable for LNG
service.
One (1) x 100% LNG dispenser pump of 150 LPM capacity are provided to supply LNG from LNG
storage tank for loading/filling LNG run vehicles through one (1) no. LNG Dispenser of 150 LPM
capacity.
Presently, One (1) no. LNG dispenser of 150 LPM shall be provided with complete arrangement as
required to refuel a truck. Based on LNG demand, if required one additional LNG dispenser of 150
LPM capacity shall be installed in future.
6.1 Utility System
The following utilities are envisaged for the facility:

1. Instrument Air
Instrument air shall be required for all the pneumatically operated valves in the facility. This
instrument air shall be generated at site by a suitable rated air compressor which will cater the
instrument air for the LNG facilities.
2. Nitrogen
Nitrogen shall be required to meet purging requirements for pumps during
pre-commissioning/commissioning, maintenance etc. Nitrogen system shall consist of required
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P.017398/ P.017399
M001
nos. of nitrogen cylinders along with necessary tubing with field instruments.
Nitrogen requirement for LNG storage tank pre-cooling during commissioning (one time
requirement) shall be met by hiring a portable Nitrogen supply system as the quantity
requirement will be more and cannot be met by cylinders.
3. Fire Water
Water for firefighting system will be provided by local municipal authority which will come
through water tanker and the reservoir will be filled.
4. Service Water
Plant service water will be provided by local municipal authority which will come through
water tanker and the service water tank will be filled.
5. Potable Water
Potable water also will be provided by local municipal authority or shall be purchased
separately by BPCL.
6. Dewatering Sump & Pump
Dewatering sump shall be provided to collect contaminated rainwater & any leakage/spillage
in the dyke area. An electric driven small sump pump shall be provided at this sump for
draining of the wastewater.
7.0 PROCESS DESIGN PARAMETERS
7.1 LNG Composition
LNG COMPOSITION LEAN CASE (mol %) RICH CASE (mol %)
C1 97.7 81.6
C2 1.8 13.4
C3 0.2 3.7
C4+ 0.2 0.7
N2 0.1 0.7
Molecular Weight 16.4 19.3
Liquid Density (kg/m3) 427 485
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P.017398/ P.017399
M001
7.2 LNG Pressure and Temperature
LNG shall be brought by vacuum insulated transport tankers of suitable size at the LNG station.
Minimum temperature of LNG shall be (-) 162°C.
7.3 Design Capacity
The design capacity of major equipments is as follows:

1. LNG Unloading Pump: 350 LPM
2. LNG Storage Tank: 56.8 KL (Gross)
3. LNG Dispenser Pump: 150 LPM
4. Saturation On the Fly Vaporizer: 150 LPM
5. LNG Dispenser: 150 LPM
8.0 BOIL OF GAS MANAGEMENT
BOG shall primarily be generated due to heat leakages into the tank and piping through insulation and
BOG return from vehicle fuel tank during LNG dispensing.
For each of the station, utilization of BOG shall be evaluated on case to case basis. As a first option,
the feasibility of installing a Gas Engine Generator by using the BOG as a source of power supply to
the station shall be evaluated. However, in the station where first option is not suitable, BOG shall be
vented off through vent stacks at safe location.
LNG Storage tank insulation shall be so designed as to limit the average NER to 0.1% of maximum
liquid volume in the tank at 15 deg C.
9.0 PIPE SIZING CRITERIA
Pipe sizing shall be carried out based on velocity and pressure drop. LNG service lines velocity shall
not be more than 5 m/s.
For Vapor / Air Service:
For vapor and air service, the fluid velocity shall be limited to 20 m/s. Higher velocity can be consider
after due consideration of noise, if required.
10.0 PLANT LIFE
Design life of the station shall be 30 years.
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P.017398/ P.017399
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11.0 SPARING PHILOSOPHY
In general, those equipments, which are in continuous service and are critical for operation, shall be
provided with installed spare/stand-by.
For intermittent service, installed spare/stand-by equipment shall not be provided.
12.0 SAFETY AND RISK CONSIDERATION FOR MECHANICAL SYSTEM AND EQUIPMENTS
Piping system in LNG service that can be isolated shall be provided with thermal relief valve. This
shall be shown in P&ID. Thermal relief valve/safety relief valve discharge shall be routed to safe
location as per code requirement or back to the system, as feasible.
13.0 FIREFIGHTING SYSTEM
Fire and gas detection system shall be composed of spill, gas and fire detectors located on the station.
The spill detectors shall be installed below the storage tank and pumps, at offloading point and at the
LNG dispenser.
The flame detectors shall be installed in offloading area and in fuelling area. The gas detectors shall be
installed in the complete LNG station. Smoke detectors and ESD push button will be installed in the
technical room.
Water based fire protection system has been envisaged for the plant consisting of underground fire
water reservoir, diesel engine driven main fire water pumps, electric motor driven standby fire water
pump, motor driven jockey pump, hydrants, water monitors, distribution piping network etc.
Fire water pumps, and jockey pumps shall be designed in accordance with NFPA-20.
A fire water ring main shall be provided all around the perimeter of the LNG plant facilities with
hydrants / monitors spaced at intervals not exceeding 30 M while measured aerially.
The hydrant network shall be in closed loop to ensure multi-directional flow in the system.
The hydrant network shall be laid mostly aboveground except in areas of road crossings and areas
where vehicular movement is expected.
Requisite nos. of water monitors are envisaged around LNG Storage Bullet dyke area for dispersion of
LNG vapor cloud.
The entire fire water system shall be designed for a minimum residual pressure of 7.0 kg/cm2 g at the
remotest place of application of the plant.
In addition to water based firefighting system, suitable nos. of portable and mobile fire extinguishers
are envisaged at strategic locations of the plant in accordance with SMPV rules.
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P.017398/ P.017399
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14.0 FREEZE PROTECTION SYSTEM
Suitable insulation shall be provided on equipment and piping to avoid fluid from evaporating and for
personal protection.
Line Operative
Line Designation Insulation Purpose
Suffix Temperature range
Insulation for Cold Service (reduction of 20°C down
Cold Conservation C
heat gain) to -196°C
Personnel -10°C down
P Personnel Protection in cold service
Protection to -196°C
Cold insulation (C) shall be applied to equipment and piping, where reduction of heat gain and
prevention of surface condensation is desired.
Vacuum Jacketed piping shall be used from 'Saturation-Fly-On-Vaporizer' to 'LNG Dispenser'.
Balance LNG process piping shall be cold insulated.
Material for cold insulation shall be as per below table:
Applications in the range from

Polyurethane Foam -
-120 deg C to +110 deg C
PIR PN EN 14308/
Applications in the range from
Cold Insulation (Poly-Isocyanurate ASTM C591
+120°C to -200°C.
Rigid Foam) Grade-2 Type-V
PN EN 14305/ Applications in the range from
Cellular Glass
ASTM C552 (-) 200°C to 420°C
*The insulation material shall meet the requirements of ASTM C795, when applied on austenitic
stainless-steel surfaces.
Pipe after on the fly saturation vaporizer to LNG dispenser shall be vacuum jacketed. The design and
manufacturing of the vacuum insulated pipe shall be in accordance with ASME B31.3. Material of the
outer pipe shall be Stainless steel.
Vacuum Jacket shall be designed in accordance with ASME Code for Unfired Pressure Vessel, Section
VIII for an internal vacuum and external atmospheric pressure with the assembly at ambient
temperature. Vapor stops shall be utilized for all piping and equipment insulation.
Vapor stops shall be utilized for all piping and equipment insulation. Vapor stops shall be located at
pipe supports, pipe fittings, flanges, valves, nozzles, insulation terminations, branch connections and
other protrusions through the insulation system.
CLEANING AND PAINTING

The surface preparation shall be in accordance with American standard SSPC or Swedish standard SIS
05 59 00. Preliminary surface cleaning shall be in accordance to SSPC-SP 1. Stainless steel requiring
painting shall be abrasive blast cleaned as per SSPC-SP7 with aluminum oxide or garnet.
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P.017398/ P.017399
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Carbon steel surface preparation by grit as per SSPC -SP 10 or SA 21/2 SIS 05 5900.The minimum
thickness of each dried painted coat shall not be less then as specified in the table below.
Total
Intermediate Finish Final
Item Cleaning Pre-Coat Dry Film
Coat Coat Color
Thickness
Tank (CS SIS 05 Epoxy
Epoxy Polyurethane RAL
outer 5900 Zinc Rich 240 µm
90 µm 60 µm 9010
Vessel) SA 2 1/2 90 µm
Tank (SS SIS 05 Epoxy
Epoxy Polyurethane RAL
Outer 5900 Zinc Rich 225 µm
125 µm 60 µm 9010
Vessel) SA 2 1/2 40 µm
SS Pipe
and SS Un-Painted
plate
All Underground carbon steel pipe shall be buried, after wrapping and coating to avoid corrosion.
Page 38 of 921
SPECIFICATION FOR LNG- P.017398/ P.017399
UNLOADING AND DISPENSING G11077
PUMP M002

(BPCL)
CONSTRUCTION OF LNG STATIONS IN THE STATE

OF TAMIL NADU & KERALA

AVINASHI, TIRUPPUR (TAMIL NADU) & PANANCHERY, THRISSUR (KERALA) ON
TURNKEY BASIS
TECHNICAL SPECFICATION FOR LNG UNLOADING

AND DISPENSING PUMP
P.017398/P.017399-G-11077-M002

Page 39 of 921
SPECIFICATION FOR LNG - P.017398/ P.017399
PUMP M002
TABLE OF CONTENTS
1.0 SCOPE ...................................................................................................................................... 1
2.0 CODES, STANDARDS AND REFERENCE DOCUMENTS ................................................................... 1
3.0 GENERAL .................................................................................................................................. 2
3.1 DEFINITIONS ............................................................................................................................ 2
3.2 CONFLICT REQUIREMENTS, EXCEPTIONS .................................................................................. 3
3.3 MANUFACTURER’S EXPERIENCE QUALIFICATIONS ...................................................................... 3
3.4 UNITS ...................................................................................................................................... 3
3.5 ABBREVIATIONS ....................................................................................................................... 4
4.0 TECHNICAL REQUIREMENTS ..................................................................................................... 4
4.1 General .................................................................................................................................... 4
4.2 Pump Type ............................................................................................................................... 6
4.3 Scope ...................................................................................................................................... 6
4.4 Horizontal Centrifugal pump (if offered by supplier) .................................................................... 6
4.5 Can Mounted Pumps ................................................................................................................. 6
4.6 Suction Can.............................................................................................................................. 6
4.7 Impeller ................................................................................................................................... 7
4.8 Shaft ....................................................................................................................................... 7
4.9 Bearing & Bearing Housing ....................................................................................................... 7
4.10 Sealing .................................................................................................................................... 7
4.11 Casing ..................................................................................................................................... 8
4.12 Coupling .................................................................................................................................. 8
4.13 Auxiliary Process Piping ............................................................................................................. 8
4.14 Electrical .................................................................................................................................. 8
4.15 Power and Instrumentation cables ............................................................................................. 9
4.16 Controls and Instrumentation .................................................................................................. 10
5.0 MATERIALS ............................................................................................................................. 10
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PUMP M002
5.1 Material of Construction .......................................................................................................... 10
6.0 INSPECTION, TESTING AND CERTIFICATION ........................................................................... 10
6.1 General .................................................................................................................................. 10
6.2 Material Inspection ................................................................................................................. 11
6.3 Testing ................................................................................................................................... 11
6.4 Certification............................................................................................................................ 12
7.0 SPARE PARTS .......................................................................................................................... 13
8.0 IDENTIFICATION AND MARKING.............................................................................................. 13
9.0 PAINTING AND COATING......................................................................................................... 13
10.0 PRESERVING AND SHIPPING ................................................................................................... 14
11.0 DOCUMENTATION ................................................................................................................... 14
Page 41 of 921
PUMP M002
1.0 SCOPE
This specification covers the minimum technical requirements for the design, materials,
manufacturing, inspection, testing and supply of LNG Unloading and Dispensing Pump along with all
required accessories.
2.0 CODES, STANDARDS AND REFERENCE DOCUMENTS
It is Supplier’s responsibility to fully comply with the local regulations.

In case of discrepancies the Supplier shall apply the most stringent requirement but will maintain
consistency and homogeneity in its supply.
In case of doubt the Supplier shall refer to the Owner/ Owner’s representative.
Current editions of the codes and standards, including all mandatory addenda in effect at the time of
the contract award, shall apply unless otherwise indicated
The design, engineering, manufacture, supply and testing and other general requirements of the
equipment shall be strictly in accordance with the data sheets, this job specification, P&IDs, standard
specifications etc.
Supplier shall make all possible efforts to comply strictly with the requirements. However, if any
requirement is not possible to comply due to inherent design of Supplier (and not due to cost or time
considerations), then such deviations as required by Supplier shall be separately consolidated and
furnished under “List of Deviations” with specific references to Document no., Page no., Clause
no./Para no., Line no. etc. of the applicable document to which deviation applies, along with adequate
reasons for each deviation. Further, Supplier shall furnish a statement, that except for the deviations
furnished by him, his offer is in total conformity with all the data sheets and document and the
referenced codes, standards and recommended practices. No deviation shall be considered after award
of order. Any comment, deletion, correction on the body of the data sheets/specifications/VDR etc.
will not be taken cognisance of and all such deviations shall be deemed to have been withdrawn by the
supplier.
Essential applicable codes, directives and standards are:
Centrifugal Pumps for Petroleum, Petrochemical and
API 610/ ISO 13709
Natural Gas Industries
Standard Specification for Alloy-Steel and Stainless-Steel
ASME A320 / A320M – 10
Bolting for Low-Temperature Service
ASME B31.3 Process Piping
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PUMP M002
ASME V Non-destructive Testing
ASME VIII - Div.1 Rules for Construction of Pressure Vessels
ASME B16.5 Pipe Flanges and Flanged Fittings
Installations and equipment for liquefied natural gas -General

EN 1160
characteristics of liquefied natural gas
Installation and equipment for liquefied natural gas - Design
EN 1473
of onshore installations
Liquid pumps. Safety requirements. Procedure for hydrostatic
EN 12162
testing
GSR 388(E)_ New SMPV Schedule 4: “Storage, Handling and Dispensing at
Rule for LCNG- 2018 LNG/LCNG Dispensing Stations”
Mechanical Vibration – Balance Quality Requirements for
ISO 1940-1 Rotors in a Constant (Rigid) State – Part 1: Specification
and Verification of Balance Tolerances
ISO 10474 Steel and steel products -- Inspection documents
Natural gas fuelling stations — LNG stations for fuelling ve

ISO 16924
hicles
EN 10204 Metallic materials. Types of Inspection documents
Petroleum and Natural Gas Industries - Materials for Use in

NACE MR0175 / ISO 15156
H2S Containing Environments in Oil and Gas Production
IS 325 Three Phase Induction Motors - Specification
Standard for the Production, Storage, and Handling of Liquef

NFPA 59A (2009)
ied Natural Gas (LNG)
3.0 GENERAL
3.1 Definitions
Owner/Client/ Company/Purchaser Bharat Petroleum Corporation Limited (BPCL)
Consultant Tractebel Engineering Private Limited (TEPL)
LNG Unloading, Storage & Dispensing Stations at Avinashi

Project Title
(Tamil Nadu) & Pananchery (Kerala)
The firm or company whose bid has been accepted by the
Supplier/ Vendor
purchaser and includes the Supplier’s legal representatives,
successors and permitted assigns
The inspection agency to be appointed by Client / Client
Third Party
Approved TPIA
Page 43 of 921
PUMP M002
3.2 Conflict Requirements, Exceptions
In case of conflicts between requirements of the documents referenced in this Specification, the
following order of precedence shall govern:
1. Data Sheet
2. This Specification
3. Codes and standards
Should any doubt arise regarding the precedence, the Supplier shall raise the question to the
Company and obtain written approval if deviations /clarifications are necessary.
3.3 Manufacturer’s Experience Qualifications
LNG Pumps shall be selected from the established product range.

The Supplier shall be an established centrifugal pump manufacturer for cryogenic application having
adequate engineering, manufacturing and testing facilities for pumps conforming to API Standard
and shall be the manufacturer of the offered pumps.
Pump models which are successfully operational in at least two similar operations, for a minimum of
three years, in comparable service and climatic region, shall only be offered. Prototypes models are
not accepted under any circumstances.
The pump model offered shall be from the existing regular manufacturing range of the Supplier. The
mechanical as well as the hydraulic performance (including NPSHR) for the complete range of
operation of the offered model shall have been established in the shop test. The offered pump model
shall meet the following minimum service and manufacturing experience requirements.
Pumps shall be identical or validly similar in terms of Power rating, Hydraulic Performance
(including NPSHR), Inlet flow, Differential Head, Operating Pressure & Temperature, Pumping
Liquid, Speed, Number & Type of Impellers, Mechanical Design, Materials, Bearing span
(applicable for between bearing pumps), Column Length (applicable for vertically suspended
pumps) etc. as compared to at least TWO UNITS of the proposed model designed, manufactured,
tested and supplied from the proposed manufacturing plant in the last fifteen years and at least ONE
of these units shall have successfully operated in the field for at least 8000 hours individually
without any major problem as on the date of issue of bid package.
3.4 Units
All dimensions and rating shall be metric to SI, except:

1. For the temperatures, which shall be in degrees Celsius instead of Kelvin;
2. For the piping connections which shall be per ANSI standards with British imperial
units (or US customary units);
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PUMP M002
3. For the pipe and fittings threads which shall be in inches to NPT.
3.5 Abbreviations
ANSI American National Standards Institute

API American Petroleum Institute
ASME American Society of Mechanical Engineers
BPVC Boiler and Pressure Vessel Code
EN European Standard
HMI Human Machine Interface
ISO International Organization for Standardization
LCS Local Control Station
MAWP Maximum Allowable Working Pressure
NACE National Association of Corrosion Engineers
NDE Non-Destructive Examination
NPSH Net Positive Suction Head
NPT National Pipe Thread
OISD Oil Industry Safety Directorate
PLC Programmable Logic Controller
Ra Arithmetic Average Roughness
SI International System of Units
4.0 TECHNICAL REQUIREMENTS
4.1 General
Vertical can type multistage pumps/ Horizontal centrifugal pumps with motors and all auxiliaries.
Pumps, all accessories and materials, which are in contact with transported medium, shall be suitable
for handling of products stated in relevant data sheet.
Any and all lessons learned of the CRYOGENIC PUMPS of same type shall be incorporated and
included.
Supplier shall deliver each pump together with coupling, motor, VFD and other auxiliary piping
elements mounted on the same baseplate/ mounting frame, forming the complete pump unit.
Unless otherwise specified, all equipment and auxiliaries shall be suitable for outdoor operation
unprotected from the environment.
Pumps shall be installed in positions convenient for operating and servicing.
Pump design shall be appropriate to give minimum of 40 years of continuous service. The pump shall
be designed to facilitate ease of maintenance, inspection and repairs.
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PUMP M002
The pumps shall be designed for reliable and continuous operation without any major overhaul for
three years duration under specified service and ambient conditions.
Supplier shall modify if necessary the construction details as appropriate to their design.
Pumps shall be suitable to operate at its corresponding minimum continuous flow for prolonged
duration. Unless otherwise specified, pump minimum continuous flow shall be less than process rated
and normal flow.
No cast iron pressure containing parts shall be used.
Use of asbestos, mercury or any other harmful chemical is strictly prohibited.
All piping connection shall be weld-neck flanged connections in compliance with project
specification.
Slip-on flanges included within the package shall be SS flanges to match the piping material.
Supplier to indicate the clearance provided between impeller and casing and ensure that in all
operating condition the clearance is adequate for safe operation of the pump. The clearance should not
be so high – that impact the pump performance.
The standard performance envelope curves covering the maximum and minimum impeller sizes, for
the offered model, NPSH Curve, Power Curve and efficiency curve at the offered speed of pump shall
be furnished along with other data, drawings and documents as per specified VDR with the offer.
Preferred Operating Region and Allowable Operating Region to be marked on the characteristic curve
for each pump item. The rated and the normal operating points shall be marked on the characteristic
curve. The rated flow shall not exceed 110% of pump capacity at best efficiency point.
The bearings shall be of ceramic material and be suitable for product lubrication under all operating
conditions.
Supplier shall perform a pump analysis / calculation as indicated on individual data sheet.
Supplier shall determine and indicate on the data sheet the minimum continuous stable flow required
for the pump for the intended service to prevent loss of suction, overheating, excessive vibration or
damage to the pump.
Supplier shall confirm that the pump is suitable for continuous operation at all specified operating
conditions including operation at any point on the curve between minimum continuous flow and the
end of curve.
Supplier shall determine and indicate on the data sheet the predicted axial thrust developed over the
entire operating range from minimum flow to end of curve.
Supplier shall fill Utility Data sheet forming part of the Enquiry Document and submit his
recommendation along with his proposal.
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PUMP M002
4.2 Pump Type
The pumps for LNG Unloading Line shall be vertical can, submerged motor multistage, centrifugal
type or Horizontal centrifugal type and the pumps for LNG Dispensing shall be vertical can,
submerged motor multistage, centrifugal type.
4.3 Scope
Supplier shall deliver complete set of pumps with its motor driver, VFD and LCS with option of
remote start and stop and relevant auxiliary system.
Supplier shall provide design deliverables and other documents for Owner/ Owner’s representative
approval prior to the manufacturing of the pump and motors. Refer Section 11 for details of
documentation required.
4.4 Horizontal Centrifugal pump (if offered by supplier)
The pump shall have electric motor with VFD, Gearbox or direct coupling with pump. Pump casing
shall be suitably designed for MAWP. The MAWP is pump shut off head considering maximum
impeller diameter + maximum suction pressure with 5% margin. Sealing shall be in accordance with
section 4.10 of this specification.
4.5 Can Mounted Pumps
The pressure casings for pot mounted pumps are subjected to discharge pressure internally and suction
regions shall be designed for the same MAWP as the discharge section. The pressure casings for pot
mounted pumps shall be designed for the maximum discharge pressure plus 5% increase in
differential head or maximum surge pressure, whichever is greater.
The discharge nozzle for pot mounted pumps is subjected to full discharge pressure.
The discharge nozzle shall be designed for the maximum discharge pressure plus 5% increase in
differential head or maximum surge pressure, whichever is greater.
4.6 Suction Can
Suction Cans shall be designed, manufactured, and tested in accordance with ASME VIII - Div.1 /EN
13445 requirements. Design pressure shall be stated on pump data sheet.
Pressure containing components of the pots shall be fabricated, not cast.
The head plate shall be manufactured to allow tightening with hydraulic tensioning equipment for ease
of maintenance.
Bolt centres of flanges shall evenly straddle vertical axis.
All flanges and flange fittings shall comply with the applicable ASME Standards.
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PUMP M002
Materials of construction shall be per ASME standards. All parts welded to shell shall be the same
material as shell.
4.7 Impeller
The impeller shall be closed type, single-piece construction and shall be properly keyed to the shaft
and secured against axial movement.
The impeller shall be designed to withstand the maximum rotational speed of the motor.
Impeller shall be dynamically balanced to a quality grade of 2.5 according to ISO 1940-1. Impeller
balancing shall be performed by metal removal. Adding material is not acceptable.
The rotor of the pump (assembly of all rotating parts of the centrifugal pump) shall be designed in
such way, that the first dry-bending critical speed is at least 20% above the pump's maximum
continuous operating speed, according to API 610 / ISO 13709.
4.8 Shaft
Pump shaft shall be designed to transmit the maximum possible output from the electric motor. The
maximum allowable torque of the shaft shall be higher than transmissible torque of the coupling.
Shaft sleeves shall be locked or keyed made of corrosion-erosion resistant material and shall be
replaceable. Sleeves shall be sealed at the inner end, machined and assembled for concentric rotation.
4.9 Bearing & Bearing Housing
The pumps shall be fitted with rolling element radial and thrust bearings.
Bearing system life shall be equivalent to at least 25000 hours with continuous operation at rated
conditions, and at least 16 000 hours at maximum radial and axial loads at rated speed.
Bearing housing for rolling-element bearing shall be designed to prevent contamination by moisture,
dust and other foreign matter.
Bearing housing shall be designed to enable replaced bearings without removing the pump from its
baseplate.
4.10 Sealing
Mechanical shaft seal not applicable based on vertical can submerged motor type pump.
Sealing for horizontal centrifugal pump shaft sealing shall be provided by mechanical seal and shall
be selected in accordance with service conditions and seal manufacturer’s recommendations, in
accordance with API 682 / ISO 21049.
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PUMP M002
4.11 Casing
Casing of centrifugal pumps shall be cast of material as required by the application.

The pumps shall be designed to withstand at least a maximum allowable working pressure equivalent
to the shut-off pressure developed at maximum suction pressure and with maximum impeller
diameter.
Maximum discharge pressure shall be increased to incorporate worst operating scenario including max
density of liquid.
Suction region of the pump shall be designed for same rating as the discharge region.
The suction and discharge nozzles shall be flanged in accordance with ASME B16.5 and shall be
provided with equal rating.
Supplier shall ensure that baseplates are also suitable for withstanding above loads.
Pumps shall be provided with vent and drain connections, except that vent connections may be
omitted if the pump is made self-venting by the arrangement of the nozzles.
Drain and vent manifold shall be provided to a single inlet or outlet flanged end connection near the
edge and within the confines of the baseplate.
Casing shall be designed to permit disassembly from the rear to remove pump internals without
disturbing the system.
Lifting lugs and eyes shall be provided to allow for easy handling of the pump.
4.12 Coupling
The couplings between motor and pump shall be as per manufacture’s standard.
4.13 Auxiliary Process Piping
Auxiliary process liquid piping includes vent and drain lines, product flushing lines and lines for
injection of external fluid shall be in the scope of supply of the Supplier.
Pressure-temperature rating of piping components shall be at least equal to MAWP of the pump
casing.
Piping and components shall be made of corrosion-erosion resistant materials.
4.14 Electrical
Motor shall be supplied in line with Technical Specification of LV Induction Motor as attached
elsewhere with this package.
However, submersible electric motors shall be supplied in accordance with the Manufacturer
Standards. Minimum requirements for such type of submersible motor are detailed below:
The motor has to be sized with an oversize factor of 10%.
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PUMP M002
The motor driver shall be designed for starting voltages between 80 and 100%. The motor torque at
80% voltage and at or below rated pumping temperature shall be capable of accelerating the pump to
full speed with the discharge valve open.
Hazardous area certificates are not applicable to cryogenic submersible motors as the pump / motor
operate in an oxygen free environment where there is no possibility for explosion to occur. However,
in case of non-submersible pump, motor shall be suitable for Zone-1, Gas Group IIA/IIB,
Temperature class – T3 operation.
Electrical and instrument system shall be designed and shall be suitable to be installed in the
“Hazardous Area Classification”
All equipment of supply must be in accordance with Indian Local Laws. All such electrical equipment
shall be PESO certified for hazardous area.
4.15 Power and Instrumentation cables
All cables (electrical and instrumentation) shall be suitable for the specified voltage level and at the
cryogenic conditions. The cable and its support system shall have sufficient mechanical strength to
withstand vibration and bending resulting from operation and retraction from the storage tank. The
cable shall be protected with a woven stainless-steel braid or equivalent metallic armour.
Power and instrument cables shall be terminated at separate junction boxes. Each junction box shall be
provided with connections for purging, insulated studs, heavy duty earthing terminal, drain / breather
valves.
The pump suspension cable shall provide the motor cable with adequate support protection from
damage due to abrasion or vibration.
The interconnecting piping/conduit between the junction box and the pump head plate shall be
provided with a double electrical conductor seal. Each seal shall be capable of withstanding the design
pressure and temperature imposed on the primary seal.
Flanged nitrogen purge connections shall be provided for a static nitrogen purge in the space between
the seals. Pressure regulation for the nitrogen supply will be provided by Purchaser.
There shall be a flanged pressure tap between the seals for pressure monitoring complete with a
pressure transmitter. The transmitter (by others) will be used for both high- and low-pressure alarms to
detect leaks and / or failures on the primary seal.
If the pressure differential between the sealing pressure and the nitrogen purge pressure is not
sufficient to detect leaks, the Supplier may propose alternate purge methods.
The Supplier shall be responsible for the following:
1. Power plans and details required for electrical equipment mounted on equipment skids.
2. Cable tray plans and details required for the equipment skids.
3. Grounding plans and details required for the equipment skids.
4. Schematic and wiring diagrams for process controls, equipment control systems, control panels
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and junction/terminal boxes.

Supplier shall supply and install as minimum two earthing bosses on diagonally opposite corners of all
equipment skids. Purchaser will connect the bosses to the plant earth loop.
4.16 Controls and Instrumentation
All Pumps must drive by the frequency drives - VFD to ensure controlled capacity for each pump, and
they must be equipped with instrumentation for automatic activation (in sequence) without the need to
perform the manual operation in the facility. Layout of loads for each pump must be generated
automatically, with priority given to the units that will be started next.
Control sequence (start-up of unit, stop, change of capacity, emergency stop, etc) will be initiated by
PLC. Supplier to submit signal exchange list and confirm VFD communication to PLC on Ethernet
(TCP/IP) or RS 485 (Modbus).
5.0 MATERIALS
5.1 Material of Construction
Material of construction shall be compatible with the pumped fluid and shall be selected with respect
to service and site conditions.
For all pressure containing parts and major components, shafts, impellers, inducers, Can, head plate,
valves, Supplier shall furnish material certification with chemical and mechanical data for the heat
from which the material is supplied.
All repairs shall be submitted to Purchaser/ its representatives for review and written approval prior to
proceeding with repair.
6.0 INSPECTION, TESTING AND CERTIFICATION
6.1 General
The Supplier shall submit the quality control plan and inspection and test plan to the Company for
approval.
The Supplier shall give at least 30 days’ notice to the Company when the fabrication will start.
The Supplier shall give at least five (5) working days in advance notification of the witnessed or
observed inspection or test.
All test procedures shall be submitted to Company for approval prior to test.
All quality control operations carried out by the Supplier during manufacturing shall be recorded in
the form the reports, which shall be made available to Company and/or its representatives at any time
and shall be submitted as a part of documentation.
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Unless otherwise agreed, the inspection and testing requirements shall comply with API 610 / ISO
13709.
This document shall read in conjunction with client approved QAP’s /Approved technical
specifications and data sheets.
6.2 Material Inspection
The materials and casting inspection shall be done to ensure the safety and integrity. Pressure-casing
materials shall be inspected in accordance with requirements stated in API 610 / ISO 13709, Table 14.
6.3 Testing
The centrifugal pumps shall be tested in accordance with the requirements of API 610/ ISO13709.
Impact tests at -196°C in accordance with ASME VIII div1 section UG-84 whenever applicable.
1. Hydrostatic Test
All pressure-casing components shall be hydrostatically tested as assemblies.
The test shall be performed with liquid of 1.5 times the maximum allowable working pressure
of the pump.
The test shall be considered satisfactory when no leakage through the pressure containing parts
and joints or drop of testing pressure is observed within 30 minutes.
The testing fluid shall not have more than 50 ppm chloride content. After testing, all residual
liquid shall be removed from tested components.
Mechanical seals (where applicable) shall not be used during hydrostatic test but shall be used
during all running or performance tests.
2. Performance Test
Supplier shall check parameters including head, flow rate, power, efficiency and vibration at a
minimum following point during pump performance test:
a. shut-off head
b. minimum continuous stable flow (beginning of allowable operating region),
c. between 95 % and 99 % of rated flow,
d. between rated flow and 105 % of rated flow,
e. approximately the best efficiency flow,
f. End of allowable operating region.
These values shall be corrected for speed, viscosity and density and shall comply with API 610
/ ISO 13709, Table 16.
Pump performance curve shall be produced from the results of performance test for each
individual pump and submitted to Company.
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During performance test, vibration and seal leakage shall be measured according to API 610 /
ISO 13709.
The combined maximum noise level for the pump unit, include driver and coupling assembly
shall not exceed the value in datasheet.
3. NPSH Tests
NPSH test shall be performed on all horizontal pumps, in accordance with API 610 / ISO
13709. The NPSH shall be taken at each test point except shut-off.
4. Complete Unit Tests

The pump and driver with all auxiliaries as a complete unit shall be tested, in accordance with
API 610 / ISO 13709.
5. Sound level test

Sound level test shall be carried out during performance test and shall meet the limitations as
specified on the data sheets.
6.4 Certification
Material certification shall be provided in accordance with EN 10204.

Inspection certificates type 3.2 are required for shaft, impeller and all pressure retaining
components and as a minimum shall include following:
1. Chemical analysis by heat
2. Mechanical properties
3. Heat treatment statement and number
4. Non-destructive test results
5. Hydrostatic test results
6. Heat or melt number
All other components which are not covered by certificate type 3.2 shall be provided in
accordance with type 2.2 of EN 10204 standards.
Supplier shall also provide following certification (as a minimum):
1. Visual inspection for steel casting
2. Welding procedure records for repair
3. Welder’s qualification records for repair
4. Radiographic tests on repair
5. Hydrostatic tests
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6. Check calibration and gauging of necessary instrumentation for testing

7. Compliance with specification and purchase order check
8. Marking check
9. Painting check
10. Materials check
7.0 SPARE PARTS
Procurement and supply of mandatory spares as specified attachment-6 in this Material Requisition
shall be part of Supplier’s scope.
The recommended spare parts shall be supplied with the package in two parts:
1. Commissioning and startup Spares
2. Two years’ operational Spares
Any special tools for adjusting, assembling and disassembling the pump and its accessories shall be
supplied by Supplier as a part of each pump unit.
8.0 IDENTIFICATION AND MARKING
A stainless-steel nameplate shall be securely attached with non-corrosive fixings at a readily and
visible location on the equipment and on any other major peace of auxiliary equipment. The
nameplate shall contain all important data according to API 610 / ISO 13709, in units consistent with
the datasheet.
The nameplates, operation, maintenance and warning plates shall be in English and Hindi languages.
9.0 PAINTING AND COATING
Supplier shall quote own procedure for coating and painting of pumps to which coating systems shall
be applied according to Project colour scheme and in full conformity to ISO 12944 Class C5M unless
otherwise specified. Company reserves the right to request copies of and review procedures during the
life of the order. Use of any paint system is subject to the prior approval of the Company.
After installation, equipment shall be touched up and if required finish coated to match the colour
scheme of the Project.
The supplier shall include cans of adequate paints in the shipment, for on site touch up and upgrade
purposes.
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10.0 PRESERVING AND SHIPPING
Preservation and shipping shall be provided in accordance to API 610 / ISO 13709 standards.
All pump parts made of material which are not corrosive resistant shall be treated with rust inhibitor to
prevent corrosion during shipment, storage, handling or hydrostatic testing.
Rotating parts shall be secured as required to avoid damage caused by vibration during transport.
Flanges shall be covered with heavy duty flange protectors. Threaded openings shall be provided with
steel caps or round-head steel plugs.
All rotating equipment shall be packed for an outside storage period of twelve (12) months. Supplier’s
recommended extended storage and preservation procedure shall be furnished to Purchaser/Owner/
Owner’s representative before dispatch.
Equipment Supplier to ensure the following before dispatch:
1. All the openings shall be plugged & sealed condition during dispatch .
2. Instruments like gauges, speed indicators, probes, oiler etc shall be removed from the
main equipment and dispatched separately to avoid the damage of these components
during transportation handling and erection.
3. In addition to normal packing the pump and motor skids.
11.0 DOCUMENTATION
The Supplier shall provide following documents for Company’s approval:

1. Data sheets for pump, motor and auxiliary equipment
2. Mechanical Seal Plan and GA Drawings
3. P&ID for process side, lube oil system (as applicable), sealing system, cooling system
(as applicable), machine monitoring system (as applicable) for the comp lete equipment
package
4. Pump curves for differential head, efficiency and shaft power against flow capacity, in
the case of variable speed motors also the curves for 90%, 70% and 50% of rated rpm.
Curves shall include allowable and preferred operating region.
5. Curve recommended / required NPSH versus capacity - Speed-torque curve
6. Allowable forces and moments
7. General arrangement of the complete pump unit
8. Complete description of all parts of the pump unit
9. Foundation drawings for complete unit
10. Material specifications, certificates and chemical analysis
11. Heat treatment certifications
12. NDE testing and inspection procedure
13. Inspection and test certificates including NDE
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14. Quality control Procedure and Plan

15. Inspection and test plan
16. Lubrication schedule
17. Painting and coating procedures
18. List of special tools
19. Installation, operating and maintenance manuals
20. List of spare parts for commissioning and start-up
21. List of spare parts for two-years operation
22. Analysis reports (as applicable) (Lateral analysis, Torsional analysis, t rain Torsional
analysis)
23. Instrument List and data sheet
24. Instrument Installation / location drawings
25. Cable Schedule and cable termination details
26. Control & Instrumentation system BOQ
27. Manufacturer’s Catalogue for all main & sub-items of an equipment package
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(BPCL)


STATIONS AT AVINASHI, TIRUPPUR (TAMIL NADU) & PANANCHERY, THRISSUR
(KERALA) ON TURNKEY BASIS
SPECFICATION FOR LNG STORAGE TANK
P.017398/P.017399-G-11077-M003

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TABLE OF CONTENTS
1.0 SCOPE ...................................................................................................................................... 1
2.0 DEFINITIONS ............................................................................................................................ 1
3.0 GENERAL NOTES ....................................................................................................................... 1
4.0 SCOPE OF SUPPLY ..................................................................................................................... 2
5.0 REFERENCE DOCUMENTS .......................................................................................................... 4
6.0 DESIGN AND CONSTRUCTIONAL REQUIREMENTS ...................................................................... 6
7.0 SPARE PARTS, SPECIAL TOOLS AND CONSUMABLES ................................................................... 7
8.0 SURFACE PREPARATION AND PAINTING ..................................................................................... 8
9.0 TEST AND INSPECTION ............................................................................................................. 8
10.0 PERFORMANCE AND GUARANTEE .............................................................................................. 9
11.0 PACKING AND SHIPMENT ........................................................................................................ 10
12.0 MARKING................................................................................................................................ 11
13.0 DOCUMENTATION ................................................................................................................... 11
14.0 DELIVERY ............................................................................................................................... 13
15.0 WORKING SCHEDULE .............................................................................................................. 13
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1.0 SCOPE
This specification covers the minimum technical requirements for the design, materials, manufacturing,
inspection, testing and supply of LNG tank along with all required accessories.
(hereinafter referred as PMC), by BPCL for providing Engineering, Procurement and Construction (EPC)
services for a mentioned project.
2.0 DEFINITIONS
Owner/ Client / Purchaser Bharat Petroleum Corporation Limited (BPCL)
Consultant / Client’s Representative Tractebel Engineering Private Limited (TEPL)

The firm or company whose bid has been
accepted by the purchaser and includes the
Bidder / Supplier / vendor
Supplier’s legal representatives, successors and
permitted assigns
Third Party Inspection Agency The inspection agency to be appointed by Client /
(TPIA) Client Approved TPIA
Client / Client’s Representative or Client’s
Control Authority
Approved TPIA
3.0 GENERAL NOTES
1. This specification is issued for obtaining supplier’s quotation for the following the 56.8 KL
cryogenic LNG tank.
2. Work tendered as part of this bid document consists of design, supply of equipment, fabrication,
supervision of erection, testing, loading & unloading, handling, assistance in statutory approval,
documentation, installation, testing, pre-commissioning and commissioning of LNG Storage Tank
as specified hereinafter. The work also includes associated mechanical, piping, instrumentation and
automation works etc. Scope also includes getting approval from statutory authority for equipment
supplied, providing technical assistance to purchaser in obtaining PESO approvals & local
authority approval etc.
3. Where no code or standard is specified in the project specifications and other reference documents,
the supplier shall propose applicable codes and / or standards on which the supplier’s design and
manufacturing is based, for review and approval by the purchaser/ its representatives.
4. In case of any conflict between these documents, the supplier shall notify the purchaser and obtain
a written clarification of the points in question. The decision of the purchaser shall be final.
5. Supplier shall provide separate price list for any special tools and tackles, which are recommended
for regular operation and maintenance.
6. Supplier shall provide separate price list for the start-up & commissioning spares, which are
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recommended for the purpose of commissioning.

7. The scope of supply should be in full compliance with all the requirements stated in this
requisition. No deviation from and / or alternative to this requisition shall be permitted, except for
those deviations and / or alternatives listed in the supplier’s quotation and accepted in writing by
the purchaser.
8. If the Supplier intends any deviation from and / or alternative to this specification, the Supplier
shall submit a deviation and / or alternative list by giving detailed comparison between the project
requirements and the supplier’s recommendations.
9. Supplier shall be responsible for any discrepancies, errors or omissions in the drawings /
documents prepared by supplier, even if these have been approved / reviewed by the purchaser.
Review of supplier’s documents by Purchaser does not relieve the supplier of his responsibility for
correctness of design and supply. If any such errors or omissions are discovered later, the same
shall be made good, by Supplier, at his sole expense.
10. All documents, drawings, manuals, reports and written instructions shall be in the English
language. Metric System units shall be used, unless otherwise specified.
11. The Supplier shall carry out pre-shipment protection and preservation of equipment and materials
as per supplier’s standard, unless otherwise specified.
12. Supplier shall clearly describe how the equipment and materials are to be transported and shall
submit a preliminary shipping / packing list indicating number and estimated size of package.
13. Inspection Test Plan (ITP) shall be approved by the Purchaser / Purchaser’s Engineer In Charge.
Purchaser / Purchaser’s appointed TPIA will witness key stages, events and tests and the same will
be included in the approved ITP.
14. Documents to be submitted along with offer
a. Equipment and devices breakdown and summary price schedule.
b. Delivery schedule for design, procurement, supply, fabrication and erection time
schedule.
c. Data Sheet of LNG Storage Tank.
d. Equipment GA along with weight and dimension
e. Compliance to specification and in case of any deviation, it shall be listed clearly
f. Inspection and Test Plan (ITP)
g. Design calculation and foundation load data
h. Boil Off Gas data with calculation
4.0 SCOPE OF SUPPLY
1. The Scope shall include design, engineering, manufacture, fabrication, assembly, testing at
manufacturer’s works, seaworthy packing, transportation, handling, erection, testing,
commissioning, and Conductance of Performance and Acceptance Tests.
The scope of work shall consist of following major components but not limited to the following:
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a. One no (1) Vacuum + perlite insulated double walled vertical LNG Storage Tank along
with all necessary accessories including vessel, support, connected piping with
accessories, vent stack, manual isolation valves on all connections, non-return valves,
globe valves, ESD valve on tank filling & delivery lines, safety relief valves, thermal
relief valves, level indicator & transmitter, pressure indicator & transmitter and other
required accessories etc.
b. Pressure building coil suitable to maintain 5 to 6 bar(g) internal pressure, considering
150 lpm for LNG dispensing and to generate BOG for GEG operation
c. Economizer with back pressure controller
d. Thermal and personnel protection insulation and lagging design, as required
e. Foundation templates and foundation bolts
f. Shop primer and finish painting for all items
g. Touch up painting at site
h. One set (for the facility) of all special tools or special lifting beams and lugs for erection
as required.
i. All consumables required for erection
j. Shop testing including functional testing of equipment specified.
k. Spares
i. Start-up and Commissioning Spares
ii. Optional Operational Spare Parts- Bidder shall provide an optional quotation for two
(2) years with unit price.
l. Interface Review and Resolution
m. Equipment labelling
n. Safety Tags
o. Lifting Lugs and tailing lug
p. Earthing boss
q. Foundation design information including loading data and arrangement and assembly
drawings (plan and section)
r. All data, information, drawings and documents including instruction manuals for
installation, site test/commissioning, operation and maintenance and other information
and works necessary for Bidder’s whole system design.
s. Seaworthy packing and marking for shipment
t. Technical direction and Supervision service for erection & installation, commissioning
and performance test as an option.
u. O&M manuals
v. As-built drawings and documents
w. Obtaining any statutory permission or approval
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5.0 REFERENCE DOCUMENTS
1. It is Supplier’s responsibility to fully comply with the local regulations.

2. In case of discrepancies the Supplier shall apply the most stringent requirement but will maintain
consistency and homogeneity in its supply. In case of doubt the Supplier shall refer to the
Purchaser.
3. Current editions of the codes and standards, including all mandatory addenda in effect at the time
of the contract award, shall apply unless otherwise indicated
4. The design, engineering, manufacture, supply and testing and other general requirements of the
equipment shall be strictly in accordance with the data sheets, this job specification, P&IDs,
standard specifications etc. as attached elsewhere with this tender volume.
5. Supplier shall make all possible efforts to comply strictly with the requirements. However, if any
requirement is not possible to comply due to inherent design of Supplier (and not due to cost or
time considerations), then such deviations as required by Supplier shall be separately consolidated
and furnished under “List of Deviations” with specific references to Document no., Page no.,
Clause no./Para no., Line no. etc. of the applicable document to which deviation applies, along
with adequate reasons for each deviation. Further, Supplier shall furnish a statement, that except
for the deviations furnished by him, his offer is in total conformity with all the data sheets and
document Listed under “List of Attachments” and the referenced codes, standards and
recommended practices. No deviation shall be considered after award of order. Any comment,
deletion, correction on the body of the data sheets/specifications/VDR etc. will not be taken
cognisance of and all such deviations shall be deemed to have been withdrawn by the bidder.
6. Essential applicable codes, directives and standards are:
Cryogenic Vessels – Static Vacuum Insulated Vessels: Design,

EN 13458
Fabrication, Inspection & Testing
GSR 388(E)_ New SMPV Schedule 4: “Storage, Handling and Dispensing at LNG/LCNG
Rules for LCNG 2018 Dispensing Stations”
ASME B 31.3 Process Piping Code
API 521 Pressure Relieving and Depressurizing System
ASME Sec V Boiler and Pressure Vessel Code- Non Destructive Testing
ASME Sec VIII Boiler and Pressure Vessel Code Div. I- Pressure Vessels

ASME Sec IX
Qualifications
ASME B 16.5 Steel Pipe Flanges and Flanged Fittings
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SME B16.9 Factory made Wrought Steel Butt Welding Fittings.
ASME B.16.11 Forges Steel Fittings, Socket Welding and Threaded
ASTM A20 General Requirements for steel plate for pressure vessels
Carbon steel pressure vessel plates for moderate and low Temperature
ASTM A516
service.
MSS-SP-44 Steel pipeline flanges
SSPC VIS-1 Steel Structure Painting Council
Codes of practice for design loads ( other than earthquake ) for buildings
IS 875 Part 3
and structures
IS 2062 Hot rolled medium and high tensile structural steel — specification
OSHA Occupational Safety & Health Administration
IEEE 383/1974 Flammability test
IEC 754-1 Acid gas generation test
ASTM – D – 2843 Smoke generation test
Guide for Instrumentation and Control Equipment Grounding in

IEEE-1050
Generating Station.
IEEE 472 (1974) IEEE Guide for surge withstand capability (SWC) Tests
MC 12.1-1975 Electronic Industrial Process Instruments
IEC 326 C Printed Circuit Boards
NEMA ICS Part-2-125,

Contact Rating for AC services
A600
NEMA ICS Part-2-125,
Contact Rating for DC services
N600
ISO 1745 Control procedures for Data Communication System
ISO 16924 Natural gas fuelling stations — LNG stations for fuelling vehicles
NEMA Std. ICS-6-110-15 Types of enclosures through 110.22 (Type 4 to 13)
IS-13947 Protection Class for Enclosure, Cabinets, Control Panels and Desks
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ISA RP 19.1-1979 Specifications and guides for the use of general purpose annunciators
IEEE std.3.13 Relays and relay system associated with electric power apparatus
BS 5887 Code of Practice for Testing of Computer-based Systems
Electromagnetic Compatibility for Industrial Process Measurement and

BS EN 60801
Control
Oil Industry Safety Directorate
OISD
6.0 DESIGN AND CONSTRUCTIONAL REQUIREMENTS
1. Environmental Conditions
The Climatic and Environmental Conditions prevailing at the location of facility shall be as per
Site data as provided in the general technical specification.
2. The design life is the assumed period for which a structure is to be used for its intended purpose
with anticipated maintenance but without major repair being necessary. Planned design life: 40
years.
3. The vessel meant for storage of LNG including piping between inner and outer vessel shall be
designed in accordance with EN 13458 or equivalent code & SMPV rules.
4. The inner vessel shall be designed for the most critical combination of loading as specified in EN
13458 part-2. The Inner vessel supports system shall be designed for shipping, seismic, and
operating loads.
5. The outer vessel shall be equipped with a relief or other device to release internal pressure and
shall have discharge area of at least 0.34 mm2/litre of the water capacity of the inner vessel but not
exceeding 2000 cm2 and have pressure setting not exceeding 25 psi (1.72 Kg/cm2).
6. The design of saddles and legs for the LNG vessel shall include erection load, wind loads, seismic
loads, and thermal loads. Foundation and support shall have a fire resistance rating of not less than
two hrs. Support up to 0.4 meter may not need fire proofing
7. Thermal barriers shall be provided to prevent outer tank from falling below its design temperature.
8. Those parts of LNG vessels which come in contact with LNG and all materials used in contact
with LNG or cold LNG vapor shall be physically and chemically compatible with LNG and
intended for service at (–)196°C to +50°C.
9. All piping that is a part of LNG vessel including all piping internal to the vessel, within void space,
and external piping connected to the vessel up to the first circumferential external joint of the
piping shall be in accordance with ASME Boiler and Pressure Vessel Code, Section VIII or ASME
B 31.3 or equivalent.
10. LNG vessels shall be designed to accommodate both top and bottom filling unless other positive
means are provided to prevent stratification.
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11. Any portion of the outer surface area of an LNG vessel that could accidentally be exposed to low
temperatures resulting from the leakage of LNG or cold vapor from flanges, valves etc. shall be
intended for such temperatures or protected from the effects of such exposure.
12. An overview of the inlet and discharge line with nozzle connection are shown in P & ID.
Orientation of the nozzle shall be decided later. All interface points will have butt-welded
connection for both vacuum isolated lines and normal insulated line and will be connected on site
to the piping by welding.
13. The tank shall be designed in such a way that boil off gas generation shall be limited to average
NER to 0.1% of maximum liquid volume in the tank at 15 deg C.
14. Venting of BOG if required shall be done at a safe distance as per dispersion study which shall
done by the contractor. Necessary pipe, fitting and support structure for the vent shall be supplied
by the contractor.
7.0 SPARE PARTS, SPECIAL TOOLS AND CONSUMABLES
1. All spare parts shall be interchangeable with the corresponding original parts. The material should
be same and shall present the same properties as the corresponding parts of the main equipment.
2. Spare parts shall be system-tested spares to the maximum practical extent such that spares can be
installed without the need for additional adjustment or calibration.
3. The conditions concerning the tests and treatment of surfaces and painting etc. of the main
equipment according to the scope documents shall also be valid for spare parts.
4. Spare parts, special tools and consumables must be properly marked and numbered for ease of
identification. The spare parts ordered shall be delivered with the main equipment but in separate
boxes clearly marked "SPARE PART".
5. The list of special tools shall be accompanied by descriptions sufficiently detailed to identify the
function of the tool and the specific item or items for which it applies. The Supplier shall indicate
whether the tool is required for installation, adjustment or routine maintenance.
6. The list of recommended spare parts and consumables shall be accompanied by the Supplier’s
expected lifetime of wearing parts and descriptions sufficiently detailed to identify the spare parts
and the specific item or items for which it applies. The Supplier shall indicate the minimum
recommended inventory for routine maintenance during start-up, commissioning, start-up and
continuous operation.
7. The Supplier shall provide in the manner and within the time limits as set forth in the Contract, its
list of mandatory and recommended spare parts, special tools and consumables necessary for
installation, commissioning, start-up, operation and maintenance for each specified years operation
of equipment and accessories furnished by the Supplier.
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8.0 SURFACE PREPARATION AND PAINTING
1. Surface preparation, cleaning and painting shall be in accordance with the applicable codes and
standards.
2. The cleaning and painting for all the equipment shall be made suitably for use under the
Mediterranean saline environment close to the sea at the site.
3. The relative humidity of 95% shall be applied for protection of equipment for mechanical and
electrical equipment such as material selection, painting and electrical clearance.
4. The painting specification with final colors and identification system for the equipment shall be
approved by the Client.
5. Areas within 100 mm of field welds shall not be primer coated.
6. Weld ends shall be coated with a product such as de-ox-aluminates paint or an alternate acceptable
to the Client, unless otherwise specified.
7. All machined surfaces, except weld ends, shall be coated with suitable protective material to
prevent corrosion. The use of greases or oil, other than light grade mineral oil, for corrosion
protection shall be prohibited.
8. The inside and outside of the tank shall first be thoroughly cleaned and be free of weld splatter,
weld slag, flux deposits, burrs and splinters, loose mill scale, oil grease, moisture and all other
foreign materials.
9. Nameplates shall be suitably masked during tank cleaning and surface preparation.
10. Tank shall be completely drained and thoroughly dried within 48 hours of completing hydro test.
Acceptable method of drying includes mopping, wiping or blow drying with cool air to be adopted
by Supplier after getting approval from Purchaser/ its representative.
9.0 TEST AND INSPECTION
1. Inspection and testing shall conform to EN 13458 part-2 and all the local safety codes and
regulations.
2. The Purchaser reserves the right to have access to the Supplier’s facility at any time during the
fabrication and testing. The Purchaser shall have the right to witness any manufacturing or testing
procedures upon request. When requested, the Supplier shall provide a minimum two (2) weeks’
notice in advance of any test date to allow for the Purchaser to make necessary travel
arrangements.
3. The Purchaser reserves the right to require additional or more extensive tests to be conducted in
the event of marginal design or performance
4. All items purchased or manufactured by a sub-supplier used in the work shall be clearly identified
to the Purchaser
5. Bidder shall submit Inspection and Test Plant for Purchaser / Consultant approval.
6. Acceptance Tests
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a. Tests Off Site

The system shall undergo initial component testing at the Supplier’s facility prior to
shipment. The testing shall include but not limited to the following:
i. Pressure, vacuum and leak testing shall be performed on the distribution piping. All
components that function in vacuum shall be certified as being leak tight at the
factory except for the field connection.
ii. Leak testing shall be performed on the LNG storage tank. The Purchaser may
require separate test to be performed or accept factory acceptance test depending
upon the system proposed.
iii. The Purchaser may require factory acceptance tests on all major components
including spares.
b. Final Acceptance Test at Site:

Final acceptance of the cryogenic system shall require a successful test to be performed at
site.
Leak Tests
i. All equipment shall be cleaned and demonstrated leak tight. All field connections
shall be demonstrated as Helium Leak tight.
ii. All piping and components shall be leak tight to the insulating vacuum at room
temperature and at the mean average working temperature.
All mechanical system shall be checked for proper operation. All valves and actuators shall be
stroked and verified to operate normally.
All sensors shall be checked for normal operation.
All interlock functions shall be checked for proper operation and indications. All fault status
indicators shall latch until reset.
Control functions shall be exercised through all states.
The Supplier shall develop test procedures to verify all the major performance criteria of the LNG
system.
7. Test Reports
The certified reports for shop test and inspection, and site acceptance tests shall be prepared by the
Supplier and submitted to the Client as soon as possible after completing each test. The report shall
include executive summary, test procedure, test arrangement, instrumentation and calibration data,
test measurement data, test results, evaluation of test results, etc. as well as the recommendations
in the applicable Code.
10.0 PERFORMANCE AND GUARANTEE
1. The Supplier shall guarantee that all equipment and materials comply with all applicable codes and
as follows:
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2. The Supplier shall guarantee that the proposed system and its components shall be entirely suitable
for the conditions of service described herein and shall safely and satisfactorily meet the design
conditions.
3. The Supplier shall guarantee that the system furnished, and its components are free from fault in
design, workmanship and material, and of sufficient size, capacity and of proper materials to fulfill
satisfactorily the operating conditions specified.
4. The Supplier shall state and guarantee performance of the equipment or system in accordance with
submitted Forms of Proposal for “Guarantee Data Sheet”.
5. The whole system or equipment shall be accepted after the final functional and operational test
conducted by Purchaser /Supplier. The Supplier's personnel shall witness these tests. The test
procedures shall be as mutually agreed to before performance tests are conducted.
11.0 PACKING AND SHIPMENT
1. The Supplier shall clean all components and preserve and protect them on the basis that equipment
and all accessories will be stored unprotected in the field for a minimum period of twelve (12)
months
2. Prior to shipment, the equipment shall be completely drained and thoroughly dry. When such
draining requires removal of plugs, drain valves, etc., the Supplier shall make sure that these parts
are reinserted or reassembled prior to shipment.
3. All openings, nozzles, flanged, threaded and weld-end connections shall be provided with
protection to prevent damage, corrosion, and entrance of foreign matter during shipment and
storage.
4. Each plate and structural member shall be clearly marked with the specification number, drawing
number and assembly number.
5. All necessary test instrumentations for performance test shall be supplied by the supplier.
6. All openings shall be provided with substantial wooden or metal closure.
7. Flanged connections shall be protected by a 7 mm or thicker plywood disc bolted to the face of the
flange.
8. Threaded connections shall be protected with screwed or snap-in (snap-on) type plastic protectors.
9. Metal straps, fasteners or covers shall not be tag-welded to any manufactured part.
10. All electric and electronic equipment shall be packed to ensure against physical damage during
shipment and storage and shall be wrapped to protest against humidity and contact with water.
11. All exterior parts of the unit except for machined surfaces shall be painted in accordance with the
specification.
12. Equipment shall be adequately supported for shipment. All loose parts shall be crated or boxed for
shipment. Each box shall be approximately marked for identification purposes. Where shipment is
braced internally, it shall be marked conspicuously, “Remove internal braces before testing and
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operating”.
13. Spare parts shall be packed for long term storage.
12.0 MARKING
All major components shall carry a manufacturer’s name plate containing the data required by the
applicable code, and have a clearly marked by the minimum following details:
1. Manufacturer name
2. Equipment type and serial number
3. Capacity
4. Gross Weight of the unit
5. Date of Manufacture
6. Project Name
7. CLIENT’s Name
The name plate shall be firmly fixed to a part of the equipment or to independent supports such that it is
easily visible. It should be constructed of durable materials and maintained in good condition.
Supplier to furnish name plate/ bracket Drawing for Purchaser / Consultant approval
Transportation marking shall be painted with synthetic resin paint
13.0 DOCUMENTATION
Supplier shall provide complete documentation of all components and subsystems contained in the system.
The documentation shall include but not limited to the following:
1. List of Applicable Codes & Standards
2. Equipment and devices breakdown and summary price schedule
3. Technical Specifications
4. Boil Off Gas data with back up calculation
5. Utility List
6. P&ID
7. Equipment Data Sheets - with at least containing following information:
a. Maximum and minimum operating temperature and maximum pressure
b. Mechanical design temperature and pressure
c. Diameter and height or length
d. Construction materials and corrosion resistance / allowance
e. Head type
f. Number, size, duty and position of nozzles
g. High and low liquid levels
h. Insulation requirements
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i. Details of special internals, e.g. supports, distributors, mist eliminators pans etc.
j. Specific design details and fabrication requirements
k. Platforms, ladders, lifting lugs
l. Machinery handling, transportation and lifting manual.
8. The minimum requirements for the delivery of relief valves shall be, Specification sheets with
identification of all design data required. A summary shall be provided of the loads from each
relief valve for each emergency condition under which relief valves opens, e.g. power failure,
blocked conditions etc.
9. General Arrangement Drawings
10. Foundation outline drawing showing plan dimensions, elevations and load distributions
11. Base Plate details and foundation cut-outs
12. Vessel fabrication drawings
13. Name Plate Drawing
14. Surface Protection and Painting Procedure
15. Shipping and Transportation drawings
16. Storage and preservation requirements
17. Welding plan, welding procedures and welder’s prequalification (in accordance with the applicable
ASME –or equivalent- code)
18. Complete material specification, including certificates of mechanical and chemical test.
19. Quality Assurance Plan
20. Inspection & Test Plan (in accordance with the applicable ASME –or equivalent- code)
21. Complete details regarding materials, welding, filler material, welding process, heat treatment,
non-destructive examination (NDE) method related to welds, leak test, pressure test, etc. Reference
to applicable WPS / WPQR, welding books, material traceability, etc. shall be made.
22. Manufacturer’s data report for piping covering the followings:
a. Cover sheet shall identify as a minimum, project identification, project code and equipment
number, manufacturers serial number, name and address of Supplier
b. Numbered list of contents
c. Certificate of inspection and pressure test issued “Third Party Inspection” according to
Codes, Standards and Regulations.
d. As built drawing with parts list
e. Strength calculation
f. List of materials
g. Material certificates (3.1)
h. NDE reports
23. As-built drawings in AutoCAD version
24. Instruction manuals, operation and maintenance manuals, spare parts lists and any other
documents pertaining to the supplied devices required for construction, operation, maintenance
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and repair
25. Sub vendor list
26. Instrument List
27. Control System & Instrument data-sheet & catalogues
29. Operation and control philosophy
30. I/O list
31. Alarm Trip set point list
32. PESO approval letter for design and fabrication of LNG storage bullets.
14.0 DELIVERY
At the place indicated in the Purchaser / Consultant’s Purchase Order.
15.0 WORKING SCHEDULE
Contractor shall submit to the Purchaser / Consultant, a detailed “working schedule” that will include the
engineering fabrication, purchasing, testing and delivery.
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SPECIFICATION FOR LNG P.017398/ P.017399
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(BPCL)

SPECFICATION FOR LNG DISPENSER
P.017398/P.017399-G-11077-M004

REV DATE DESCRIPTION PREPARED u
CHECKED APPROVED
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TABLE OF CONTENTS
1.0 PURPOSE .................................................................................................................................. 1
2.0 DEFINITIONS ............................................................................................................................ 1
3.0 GENERAL NOTES ....................................................................................................................... 1
4.0 SCOPE OF SUPPLY ..................................................................................................................... 2
7.0 SPARE PARTS, SPECIAL TOOLS AND CONSUMABLES ................................................................. 10
8.0 SURFACE PREPARATION AND PAINTING ................................................................................... 10
9.0 TEST AND INSPECTION ........................................................................................................... 11
9.1 Shop Test ............................................................................................................................... 11
9.2 Functional Test ....................................................................................................................... 12
9.3 Performance Acceptance ......................................................................................................... 12
9.4 Site Acceptance Test ............................................................................................................... 12
9.5 Test Reports ........................................................................................................................... 12
10.0 PERFORMANCE AND GUARANTEE ............................................................................................ 12
12.0 MARKING................................................................................................................................ 13
13.0 DOCUMENTATION ................................................................................................................... 14
14.0 DELIVERY ............................................................................................................................... 15
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1.0 PURPOSE
This specification covers the minimum technical requirements for the design, materials, manufacturing,
inspection, testing and supply of LNG Dispenser along with all required accessories.
2.0 DEFINITIONS
Client / Purchaser Bharat Petroleum Corporation Limited (BPCL)
Consultant / Client’s Representative Tractebel Engineering Private Limited (TEPL)
The firm or company whose bid has been

accepted by the purchaser and includes the
Bidder / Supplier / vendor
vendor’s legal representatives, successors and
permitted assigns
The inspection agency to be appointed by Client /
Third Party Inspection Agency (TPIA)
Client Approved TPIA
Client / Client’s Representative or Client’s
Control Authority
Approved TPIA
3.0 GENERAL NOTES
1. Work tendered as part of the bid document consists of design, supply of equipment, fabrication,
documentation, pre-commissioning and commissioning of LNG Dispenser as specified hereinafter.
The work also includes associated mechanical, piping, instrumentation and automation works etc.
Scope also includes getting approval from statutory authority for equipment supplied, providing
technical assistance to purchaser in obtaining PESO approvals & local authority approval etc.
manufacturing is based, for review and approval by the purchaser/ its representative.
the purchaser.
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6. If the Supplier intends any deviation from and / or alternative to this requisition, the Supplier shall
submit a deviation and / or alternative list giving detailed comparison between the project
11. Inspection Test Plan (ITP) shall be approved by the Owner / Owner’s Engineer In Charge. Owner/
Owner’s appointed TPIA will witness key stages, events and tests and the same will be included in
the approved ITP.
b. Delivery schedule for design, procurement, supply, fabrication and erection time schedule.
c. Data Sheet of LNG Dispenser and its accessories.
e. Compliance to specification and in case of any deviation, it shall be clearly
f. Inspection and Test Plan (ITP) listed
g. Design calculation(If Any) and foundation load data
h. Boil Off Gas data with calculation
4.0 SCOPE OF SUPPLY
1. The Scope shall include design, engineering, manufacture, fabrication, assembly, testing at
manufacturer’s works, seaworthy packing, transportation, handling, advisory service for erection,
commissioning, and Conductance of Performance and Acceptance Tests.
The scope of work shall consist of following major components but not limited to the following:
a. One no. (1) LNG dispenser along with all necessary accessories including:
i. Coriolis flow meter
ii. Inlet and return control valves
iii. Emergency stop button on the front of the dispenser with plastic cover protection
iv. LNG dispensing nozzle: Size 1”, Type By Vendor
v. Vapour outlet nozzle : Size = By vendor, Type: By Vendor
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vi. LNG Hose length (with armor guard at ends) = 15 ft

vii. Vapour Hose Length = 15 ft.
viii. Measurement to include both the option of Kg and Rupees
ix. Digital electronic display for weight, price/kg, and total price
x. Break-away system for highest safety on fuelling and vent line
xi. Integrated air purge gun to clean the nozzle
xii. Thermal relief valves connected to a vent collection line
xiii. A dead-man button for starting and ending manually the fuelling operation (the
system will automatically stop the filling when the tank will be full)
xiv. Integration to card payment and printing facility
xv. LNG inlet connection through the bottom of the dispenser
xvi. Earthing cable and shop air hose to dry frost from nozzles prior to connecting to fuel
tank.
xvii. Connected piping with accessories,
xviii. Manual isolation valves on all connections, instrumentations and other required
accessories etc.
b. Foundation templates and foundation bolts
c. Shop primer and finish painting for all items
d. All consumables required for erection
e. Shop testing including functional testing of equipment specified.
f. Spares
i. Start-up and Commissioning Spares
ii. Optional Operational Spare Parts- Bidder shall provide an optional quotation for two
(2) years with unit price
g. Interface Review and Resolution
h. Equipment labelling
i. Safety Tags
j. Foundation design information including loading data and arrangement and assembly
drawings (plan and section)
k. All data, information, drawings and documents including instruction manuals for
installation, site test/commissioning, operation and maintenance and other information and
works necessary for Bidder’s whole system design.
l. Seaworthy packing and marking for shipment
m. Technical direction and Supervision service for erection & installation, commissioning, and
performance test as an option.
n. O&M manuals
o. As-built drawings and documents
p. Obtaining any statutory permission or approval
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Reference has also been made in this specification to the latest edition of the following codes, standards,
and specifications:
ISO 16924 Natural gas fuelling stations — LNG stations for fuelling vehicles
ISO 12617(en) Road vehicles — Liquefied natural gas (LNG) refuelling connector
ISO 21012 (en) Cryogenic vessels - Hoses
GSR 388(E)_
New SMPV Schedule 4: “Storage, Handling and Dispensing at LNG/LCNG
:
Rule for LCNG- Dispensing Stations”
2018

ASME Sec IX :
Qualifications
Carbon steel pressure vessel plates for moderate and low Temperature
ASTM A516 :
service.
Codes of practice for design loads ( other than earthquake ) for buildings
IS 875 Part 3 :
and structures
OISD The Oil Industry Safety Directorate
PESO
Petroleum And Explosives Safety Organisation
Guidelines
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ASTM – D –
: Smoke generation test
2843
IEEE-1050 :
Generating Station.
NEMA ICS
Part-2-125,A600
NEMA ICS
Part-2-125,N600
NEMA Std.
ICS-6-110-15
IS-13947 : Protection Class for Enclosure, Cabinets, Control Panels and Desks
ISA RP
: Specifications and guides for the use of general-purpose annunciators
19.1-1979
ISO 16924:2016
Natural gas fuelling stations — LNG stations for fuelling vehicles
(en)
IEEE std.3.13 : Relays and relay system associated with electric power apparatus
Electromagnetic Compatibility for Industrial Process Measurement and

BS EN 60801 :
Control
Client approved Drawings / TDS / Working Procedures / ITP / QAP / Codes & Standards / NDT
procedure.
In case of conflict between the requirement of this specification and the codes, standards and
specifications referred above, most stringent requirement shall apply.
1. An LNG dispenser that meet the requirement of project as specified in dispenser datasheet and provided
reliable LNG dispensing at the lowest installed cost with minimum maintenance requirements.
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2. The LNG Dispenser is to be suitable to dispense / fill LNG in Vehicles at saturated condition, i.e. 8-10
barg & (-) 125 Deg C and at cold condition i.e. (-) 162 Deg C, depending upon the type of fuelling in
vehicles.
3. The control panel of the Dispenser is to include push button (for switch over from saturation filling to
cold filling and vice versa) and light indication for saturation and cold filling.
4. The Control panel and LCD display are to be explosion proof and intrinsically safe, suitable for methane
service hazardous area.
5. The LNG Dispenser package, along with Coriolis flow meter are to be PESO approved and any other
approval required for safe usage of the facility.
6. The LNG dispenser may be operated in several modes, which include the following:
a. Manually or automatic.
b. Metered or un-metered.
c. Assisted or self-service.
7. LNG dispenser components
The dispenser shall be equipped with the following components:
a. nozzle(s) for fuelling LNG with vapour return/recovery.
b. hose(s) for fuelling LNG with vapour return/recovery.
c. hose(s) for vapour recovery when not integrated with the fuelling hose.
d. dummy receptacle or parking dock for the nozzle when the fueling hose is not in use.
e. breakaway device, which may be an integral part of the hose assembly.
f. system for safe stowage of the hose(s) when not in use.
g. flow meter
h. optional LNG vessel to contain the flow meter.
i. temperature and pressure sensors and transmitters.
j. electronic evaluation unit, which may communicate with a payment terminal.
k. monitor displaying quantity, price, etc.
l. pipe work and control valves, including thermal and pressure relief valves.
m. electrical and pneumatic power supply.
n. Housing/cabinet.
o. start and stop buttons.
p. emergency stop button, which can also be used as start-stop button.
q. dead man’s button or handle.
8. Breakaway system
The breakaway system shall break the connection of the hose to the dispenser at a defined place in
case of excessive force. It shall seal each of the separated parts so that spillage of LNG from any of
both the sides is prevented. For this purpose, check valves shall be installed at each of the
separated parts. Where required by local regulations, two check valves in series shall be used.
The disconnection force (the axial force in the fueling hose) of the breakaway device shall, in any
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direction, be according to ISO 12617.

9. Fuelling Hose
The fueling hose shall comply with ISO 21012. The fueling hose shall be
a. suitable for LNG and designed to reduce and/or avoid the risk of cryogenic frostbite,
b. suitable for the pressure duty,
c. resistant to corrosion and mechanical damage, protected by stainless steel wire-braiding or
an equivalent design, and adequately supported or coated to prevent kinking and abrasion,
if thermoplastic/composite hoses are used.
d. The hose connections shall withstand the hose’s burst pressure.
e. The hose design and installation shall include provisions for returning of the liquid
remaining in the fueling hose after fueling and the associated vapor back to the LNG
storage. Heat leak rate, pressurization and hydrostatic head aspects of such a system shall
be taken into account.
f. The fueling nozzle shall be designed such that LNG can only be transferred when the
nozzle is correctly connected to the receptacle of the vehicle tank.
g. Where a hose or arm of nominal 76 mm diameter or larger is used for liquid transfer or
where one of nominal 100 mm diameter or larger is used for vapor transfer, an emergency
shutoff valve shall be installed in the piping of the transfer system within 3.1 m from the
nearest end of the hose or arm.
h. Where the flow is away from the hose, a check valve shall be permitted to be used as the
shutoff valve.
i. Where either a liquid or vapor line has two or more legs, an emergency shutoff valve shall
be installed either in each leg or in the feed line before the legs.
j. The operating instructions for dispenser shall be posted near or on the dispenser.
10. The dispenser shall be equipped with a hose and a nozzle to recover the overpressure gas in the vehicle
tank. For the single-hose fuelling, the hose shall be used before vehicle fuelling commences when in
situations where the vehicle presents for refuelling with a pressure in the vehicle tank that is too high to
permit effective fuelling.
11. The holes in doors for installing wire seals should be provided. The location of the holes will be finalized
during the inspection of the first lot of the dispensers at vendor’s works
12. The Dispenser shall automatically and immediately shut-off LNG supply to fill hose individually (with
error codes for diagnose) in case of:
a. Power failure or excursion beyond permissible limit.
b. Loss of display
c. Power failure of mass meter (Provided with Single Error code for Power failure in Mass
meter).
d. Failure for metering
e. Reading creeping problem
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f. Flow beyond high and low limits

g. Failure of totalizer
h. Overfill by quantity and/or pressure
i. Failure of pressure sensing transmitter
j. Malfunctioning / Passing of electro valve
k. Repeated operation of reset or start/ stop switch as per Purchaser customization.
l. Removal or break of any electrical wire, communication wire connected to controller and
other electronics cards.
m. Removal of any electrical wire connected to controller.
n. Program step is in hold due to any error
13. Cabinet
Complete cabinet (except base frame) shall be of Stainless Steel (SS-304) Cabinet wall thickness shall
not be less than 1.6 mm. Cabinet shall be sized to accommodate all electrical, electronic, and mechanical
components for metering and display within the cabinet. Cabinet shall be designed to protect all tubing,
pressure gauges, valves, fittings, electrical & electronics item from tampering, rain, dust, vermin etc.
Dispenser cabinet shall be provided with adequate size bottom opening for the entry of gas supply
line/lines and power supply connections. Adequate ventilation shall be provided so that there is natural
convection current and cooling takes place inside. Cabinet shall be structurally robust and should not
resonate at the frequencies emanated during normal flow or during choked flow through the nozzles,
breakaway coupling, or valves etc.
Appropriate drain valves of the filter outside the dispenser housing with suitable arrangement to collect
the drained oil to facilitate the operator to drain the oil on regular basis without requiring to open the lock
of the dispenser cabinet. The layout of tubing and other component should be such that it gives
unhindered access to all parts and maintenance becomes easy.
Purchaser's Logo and name to be displayed on both sides of dispensers, in Purchaser approved colour
scheme. Purchaser's Logo and name shall be painted on stainless steel panel with an appropriate coloured
background or alternatively, Supplier shall provide self-adhesive PE film sheet with Purchaser's Logo and
name. The artwork shall be of three colours. The colours, Logo size and name size shall be informed to
successful bidder during detailed engineering.
The dispensers shall be shipped in fully wired and assembled condition. Only LNG and power supply
connection shall be made at Site.
14. Spring Type Hi-Mast shall be of appropriate height and shall allow free movement of flexible hose,
prevent strain on the fill hose connection and avoid touching of ground.
15. Designing of the dispensers would take into account severity of service. The dispensers shall be designed
in such a way as to operate in cyclic (start, fill, stop, start.) round the clock basis with about 1-minute
(typical) interval between stop and start modes. The dispenser also to work satisfactorily when the time
between stop and start is indefinitely high, e.g. during lull time or when the dispenser is commissioned
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after it was decommissioned for prolonged period or in storage after initial commissioning. For this
purpose, if any specific storage facility is required, the same to be indicated by the supplier
16. Dispensers should be ergonomically designed.
17. All LNG flow from dispenser, flow meter under normal filling conditions must be recorded in electronic
totalizer and mechanical (user non-resettable) totalizer
18. Dispenser shall be capable of communicating with outside system using Modbus protocol over RS 485
port. Supplier must handover the details of communication port of dispenser and signals to be transferred
to Purchaser. It should be possible to transfer the data through twisted pair wires, transaction data as also
flow meter data (both process and diagnostic) RTU. All totalizer readings, batch filled reading,
transaction details, which are accessible in motherboard should also be accessible in RS 485 for remote
monitoring and data acquisition
19. Any un-intentional flow of LNF from dispenser, flow meter (without filling initialisation by user) must
be recorded in electronic totalizer and mechanical (user non-resettable) totalizer
20. The communicating port/switch for adjusting flow meter mass/meter factor should not have any other
functionalities and parameter controls.
21. Dispenser manufacturer is required to submit approval of weight & measure department, Govt. of India.
Forth dispenser unit or for the mass flow meter installed in the dispenser unit. In future, if any
non-conformity or objection is raised by W&M department or if any penalty action is taken against
OWNER, vendor shall be fully liable, indemnify OWNER against any liquidity and shall bear all the cost
implication, if any
22. W&M co-ordination before commercial sales. Annual stamping and If any other incident/problem
occurs during the warranty period which needs breaking of W&M seal and coordinate with W&M
department for stamping.
23. All totalizer readings, batch filled reading, transaction details, which are accessible in motherboard
should also be accessible in open system architecture/protocol (OPC)/RS 485 for remote monitoring and
data acquisition
24. All Electrical and electronic instruments shall be installed in accordance with NFPA 70, IEC for Gas
Group IIA, IIB & Temperature Class T3 and shall have approval of a recognized certifying authority.
25. Mass flow Meter shall be W & M /MID/ OIML 117 approved for custody Transfer Metering.
26. Control valve and solenoid valves shall be of conventional type design, no integral design is acceptable.
27. Control valve body and trim materials selection shall be done by the bidder to ensure that there is no
erosion, cavitation and flashing. Trim & seat shall be fully stellited.
28. Electric Power Supply
Single phase, AC, 230 Volts ± 10%, 50Hz ± 3% will be provided by Purchaser. Surge protector is to be
provided by the vendor at the 230 V AC inlet. All instrument (such as mass meter, solenoid, pressure
transmitter/ switch etc.) power supply shall be as per approved OEM design. Suitable voltage
conditioning unit shall be in the scope of vendor wherever required.
Note: Supplier to confirm that supplied dispensers are suitable with the above power supply. Supplier to
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include suitable voltage conditioning unit in their scope, if required.

29. MOC of all components is to be Stainless Steel. LNG supply pipe/ tube & isolation valve MOC is to be
SS-304/equivalent.
1. All spare parts shall be interchangeable with the corresponding original parts. The material should be
same and shall present the same properties as the corresponding parts of the main equipment.
3. The conditions concerning the tests and treatment of surfaces and painting etc. of the main equipment
according to the scope documents shall also be valid for spare parts.
identification. The spare parts ordered shall be delivered with the main equipment but in separate boxes
clearly marked "SPARE PART".
5. The list of special tools shall be accompanied by descriptions sufficiently detailed to identify the function
of the tool and the specific item or items for which it applies. The Supplier shall indicate whether the tool
is required for installation, adjustment, or routine maintenance.
6. The list of recommended spare parts and consumables shall be accompanied by the Supplier’s expected
lifetime of wearing parts and descriptions sufficiently detailed to identify the spare parts and the specific
item or items for which it applies. The Supplier shall indicate the minimum recommended inventory for
routine maintenance during start-up, commissioning, start-up, and continuous operation.
7. The Supplier shall provide in the manner and within the time limits as set forth in the Contract, its list of
mandatory and recommended spare parts, special tools and consumables necessary for installation,
commissioning, start-up, operation and maintenance for each specified years operation of equipment and
accessories furnished by the Supplier
standards.
2. The cleaning and painting for all the equipment shall be made suitably for use under the Mediterranean
saline environment close to the sea at the site.
3. The relative humidity of 95% shall be applied for protection of equipment for mechanical and electrical
equipment such as material selection, painting and electrical clearance.
4. The painting specification with final colors and identification system for the equipment shall be approved
by the Client.
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6. Weld ends shall be coated with a product such as de-ox-aluminates paint or an alternate acceptable to the
Client, unless otherwise specified.
7. All machined surfaces, except weld ends, shall be coated with suitable protective material to prevent
corrosion. The use of greases or oil, other than light grade mineral oil, for corrosion protection shall be
prohibited.
8. The inside and outside of the tank shall first be thoroughly cleaned and be free of weld splatter, weld slag,
flux deposits, burrs and splinters, loose mill scale, oil grease, moisture and all other foreign materials.
10. Equipment shall be completely drained and thoroughly dried within 48 hrs. of completing hydro test.
Acceptable method of drying includes mopping, wiping or blow drying with cool air to be adopted by
Supplier after getting approval from Purchaser/ its representative.
1. All the test and inspection for the Supplier’s equipment shall be conducted in accordance with the
applicable codes and standards, including prudent practices in the hydrocarbon industries, unless
otherwise specified in this Specification.
2. Any inspection by the Client will not relieve the Supplier of any responsibility for conformance with
stated conditions and shall not be considered as a waiver of warranty or other rights.
3. NDE personnel shall be qualified in accordance with the requirements of SNT-TC-1A or equivalent.
4. In case Client and /or Client will indicate its intention to attend on the inspection & test plan (ITP), the
Supplier shall give the relevant information to the Client at least before 4 weeks for the expected
inspection/test date.
10.0 SHOP TEST
All the dispensers shall be subjected to Inspection (“Stage wise” if required by Purchaser) by Purchaser's
or their Authorised Representative
The following activities shall be covered under inspection:
1. Review of Q.A. documents.
2. Review of calibration certificates for flow meter, dispenser, pressure transmitters, pressure gauges
and all instruments.
3. Review of all statutory certificates including W &M, type approval from PESO, Govt. of India.
4. Review of area classification compatibility of all items including bought out items.
5. Review of Mill Test reports.
6. Review of NDT reports.
7. Review of bought out sub-assemblies/major components, test/inspection certificates.
8. Dimensional checks as per approved drawings and data sheets.
9. Safety shutdown of dispensers.
10. Immediate cut off of dispensers due to abnormalities.
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9.1 Functional Test
All the dispensers shall be tested to demonstrate the functioning of all the components and controls.
9.2 Performance Acceptance
1. All the dispensers shall be performance tested for flow capacity, measuring accuracy and dispenser
functioning with LNG/Nitrogen. LNG/Nitrogen shall be arranged by vendor.
2. During the shop test of dispenser, in case the dispenser flow capacity from inlet of dispenser to the
outlet of filling nozzle is found below the specified capacity the dispenser shall stand rejected.
3. During the shop testing if the dispenser batch accuracy is found beyond ± 0.5% dispenser shall stand
rejected.
9.3 Site Acceptance Test
Site Acceptance Test shall be performed at Purchaser discretion to ensure as far as this can be made
possible, that the Machinery has not been adversely affected in transit. A Site Acceptance Test will be
performed during the pre-commissioning, commissioning and start-up phase of the project. Any part or
components, which are not functioning to the satisfaction of Purchaser, shall be repaired or replaced by the
supplier without cost & time implication to purchaser and performance test again carried out
9.4 Test Reports
The certified reports for shop test and inspection, and site acceptance tests shall be prepared by the Supplier
and submitted to the Client as soon as possible after completing each test. The report shall include
executive summary, test procedure, test arrangement, instrumentation and calibration data, test
measurement data, test results, evaluation of test results, etc. as well as the recommendations in the
applicable Code.
as follows:
conditions.
conducted by Owner/Supplier. The Supplier's personnel shall witness these tests. The test procedures
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shall be as mutually agreed to before performance tests are conducted.

6. The Supplier shall guarantee the satisfactory performance of the dispenser as per the operating
parameters indicated in data sheets. The dispensers shall be performance tested after installation at
site by Supplier. Supplier shall carry out tests as required by Govt. Statutory Agencies.
months
3. All openings, nozzles, flanged, threaded and weld-end connections shall be provided with protection
to prevent damage, corrosion, and entrance of foreign matter during shipment and storage.
flange.
specification.
operating”.
13.0 MARKING
a. Manufacturer name
b. Equipment type and serial number
c. Capacity
d. Gross Weight of the unit
e. Date of Manufacture
f. Project Name
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g. CLIENT’s Name
Transportation marking shall be painted with synthetic resin paint.
14.0 DOCUMENTATION
Supplier shall provide complete documentation of all components and subsystems contained in the system.
The documentation shall include but not limited to the following:
4. Utility List
5. P&ID
6. Equipment Data Sheets - with at least containing following information:
c. Width and height or length
d. Construction materials and corrosion resistance / allowance
e. Number, size, duty and position of nozzles
f. Details of special internals, e.g. supports, distributors, mist eliminators pans etc.
g. Specific design details and fabrication requirements
h. Machinery handling, transportation and lifting manual.
7. The minimum requirements for the delivery of relief valves shall be, Specification sheets with
identification of all design data required. A summary shall be provided of the loads from each relief
valve for each emergency condition under which relief valves opens, e.g. power failure, blocked
conditions etc.
15. Welding plan, welding procedures and welder’s prequalification (in accordance with the
applicable ASME –or equivalent- code)
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18. Inspection & Test Plan (in accordance with the applicable ASME –or equivalent- code)
non-destructive examination (NDE) method related to welds, leak test, pressure test, etc.
Reference to applicable WPS / WPQR, welding books, material traceability, etc. shall be made.
20. Manufacturer’s data report for piping
number, manufacturers serial number, name and address of vendor
h. NDE reports
and repair
23. Sub vendor list
24. Instrument List
25. PID
26. Control System & Instrument datasheet & catalogues
27. Serial interface list
29. I/O list
15.0 DELIVERY
At the place indicated in the Owner/ Consultant’s Purchase Order.
Contractor shall submit to the Owner / Consultant, a detailed “working schedule” that will include the
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SPECIFICATION FOR SATURATION
G11077
ON THE FLY VAPORIZER PACKAGE
M005

(BPCL)

TECHNICAL SPECFICATION
FOR
SATURATION ON THE FLY VAPORIZER PACKAGE
P.017398/P.017399-G-11077-M005

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TABLE OF CONTENTS
1.0 INTRODUCTION ........................................................................................................................ 1
1.1. Project Description ................................................................................................................... 1
2.0 DEFINITIONS ............................................................................................................................ 1
3.0 GENERAL NOTES ....................................................................................................................... 1
4.0 SCOPE OF SUPPLY ..................................................................................................................... 3
6.1. General .................................................................................................................................... 6
6.2. Saturation-on-the-Fly Vaporizer ................................................................................................. 7
6.3. Material ................................................................................................................................... 7
7.0 SPARE PARTS, SPECIAL TOOLS AND CONSUMABLES ................................................................... 8
8.0 SURFACE PREPARATION AND PAINTING ..................................................................................... 8
9.0 TEST AND INSPECTION ............................................................................................................. 9
9.1. Shop Test ................................................................................................................................. 9
9.2. Site Acceptance Test ............................................................................................................... 10
9.3. Test Reports ........................................................................................................................... 10
10.0 PERFORMANCE AND GUARANTEE ............................................................................................ 10
12.0 MARKING................................................................................................................................ 12
13.0 DOCUMENTATION ................................................................................................................... 12
14.0 DELIVERY ............................................................................................................................... 14
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1.0 INTRODUCTION
1.1. Project Description
Bharat Petroleum Corporation Limited (BPCL) is setting up a LNG stations at Avinashi (Tamil Nadu) and
Pananchery (Kerala) to transfer of LNG from LNG Storage Bullets to adjacent Retail outlet by LNG
Dispenser Pumps. At Retail outlet, LNG shall be filled in LNG Cylinders of LNG fueled Vehicles
(specifically, Trucks, Dumpers, Tankers and Horses etc.) through LNG Dispensers.
2.0 DEFINITIONS
Client / Purchaser Bharat Petroleum Corporation Limited (BPCL)
Consultant / Client’s
Tractebel Engineering Private Limited (TEPL)
Representative
The firm or company whose bid has been accepted by
Bidder / Supplier / vendor the purchaser and includes the vendor’s legal
representatives, successors and permitted assigns
Third Party Inspection Agency The inspection agency to be appointed by Client /
(TPIA) Client Approved TPIA
Client / Client’s Representative or Client’s Approved
Control Authority
TPIA
3.0 GENERAL NOTES
1. This technical specification is issued for obtaining supplier’s quotation for LNG Saturation on the
Fly Vaporizer Package.
2. Work tendered as part of this bid document consists of design, supply of equipment, fabrication,
documentation, pre-commissioning, and commissioning of Vaporizer Packages as specified
hereinafter. The work also includes associated mechanical, piping, instrumentation and automation
works etc. Scope also includes getting approval from statutory authority for equipment supplied,
providing technical assistance to purchaser in obtaining PESO approvals & local authority
approval etc.
manufacturing is based, for review and approval by the purchaser/ its representative.
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6. Supplier shall provide separate price list for the start-up & commissioning spares, which are
recommended for the purpose of commissioning.
the purchaser.
8. If the Supplier intends any deviation from and / or alternative to this requisition, the Supplier shall
submit a deviation and / or alternative list) giving detailed comparison between the project
13. Inspection Test Plan (ITP) shall be approved by the Owner / Owner’s Engineer In Charge. Owner/
Owner’s appointed TPIA will witness key stages, events and tests and the same will be included in
the approved ITP.
b. Delivery schedule for design, procurement, supply, fabrication, and erection time schedule.
c. Data Sheet of Saturation on the fly Vaporizer Package
e. Compliance to specification and in case of any deviation, it shall be listed clearly
f. Inspection and Test Plan (ITP)
g. Design calculation and foundation load data
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4.0 SCOPE OF SUPPLY
1. The scope of this package shall include but not limited to Design, Engineering, Manufacturing,
Procurement of materials and bought out components including sub-vendor management,
Fabrication, Assembly at shop, Inspection and Testing, FAT, packing, shipping to site; specialist
assistance in Supervision of erection and installation, SAT, Site Testing, Pre-commissioning;
Commissioning, RFSU, and Performance Guarantee Test Run including associated QHSE
management for Vaporizer Packages in accordance with approved pressure vessel codes.
2. Supplier’s scope of supply is described in data sheets and as described below, forming part of the
inquiry document. However, it shall be the responsibility of the Supplier to ensure safe and
satisfactory operation and maintenance of the offered equipment. For this purpose, in case Supplier
envisages additional equipment / instruments / control and safety devices, the same shall be
offered by the Supplier and included in his scope of supply. Such additional items shall be
separately listed with reasons for their inclusion.
3. Saturation On-The-Fly Vaporizer Package:
Sl.
Quantity Tag no. Description Price
No.
One (1) no. Saturation On the Fly Vertical
forced draft Type, Vaporizer in order to
increase the temperature of the cold LNG to
saturated temperature before LNG dispenser,
along with VFD motor driven FD Fan and all
necessary accessories.
a) Finned tube bundles, inlet & outlet
headers, internal U-bends, Tube
supporting arrangement etc.
b) All flanges, gaskets, bolts, nuts and
washer including counter flanges for
flanged connections.
c) Foundation bolts
d) Suitable number of Earthing lugs for
3a. 1 No VAP-0401 connection with Purchaser’s main
earthing grid.
e) Equipment Supporting & lifting
arrangement
f) Nameplates with labelling
g) Cleaning and painting. Final painting at
shop and supply of touch up paints (min 5
%).
h) All necessary instrumentation for operation
and performance and acceptance testing of
the furnished equipment mounted within
the Supplier’s scope of supply.
i) All Piping with insulation inside the skid,
with suitable hardware for instrument
j) Installation.
3b. 1 LOT - Documentation
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3c. 1 LOT - Preservation, Packing and transportation
Special tools and tackles for installation and

3d. 1 LOT - commissioning (provide the separate itemized
price list), if any
Day rate for supervision during installation,
commissioning, testing, etc. (please also
3e. 1 LOT - indicate no of days required and the facility
such as equipment and manpower to be
provided by Purchaser)
Spares f or startup and Commissioning with
3f. 1 LOT -
separate itemized price list
Spare for 2 year of operation with separate
3g. 1 LOT
itemized price list
Consumable / lubricants to be required
3h. 1 LOT during installation and commissioning with
itemized price list
Consumable / lubricants to be required for
3i. 1 LOT -
first fill. (if required)
Supplier to provide the mandatory spare parts for
2 years as per the Attachment – 6. Supplier to
provide breakdown cost of mandatory spare parts
with the offer and deviation shall be provided, if
3j 1 LOT any item is not applicable. The cost of the
mandatory spare parts shall be provided as an
option in the offer.
Note: Please ensure that the commercial price shall be submitted as per break up provided above, in case
of any item not applicable shall be clearly marked as NA.
Reference has also been made in this specification to the latest edition of the following codes, standards,
and specifications:
ISO 16924 : Natural gas fuelling stations — LNG stations for fuelling vehicles
GSR 388(E)_ New

Schedule 4: “Storage, Handling and Dispensing at LNG/LCNG
SMPV Rule for :
Dispensing Stations”
LCNG- 2018
API 661, 6th Edition /

: Air-Cooled Heat Exchangers for General Refinery Service
ISO 13706-1:2005
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ASME Sec IX :
Qualifications
Carbon steel pressure vessel plates for moderate and low

ASTM A516 :
Temperature service.
Codes of practice for design loads (Other than earthquake) for

IS 875 Part 3 :
buildings and structures
OISD The Oil Industry Safety Directorate
PESO Guidelines Petroleum and Explosives Safety Organization
ASTM – D – 2843 : Smoke generation test

IEEE-1050 :
Generating Station.
NEMA ICS
Part-2-125, A600
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NEMA ICS
Part-2-125, N600
NEMA Std.
ICS-6-110-15
IS-13947 : Protection Class for Enclosure, Cabinets, Control Panels and Desks
Specifications and guides for the use of general purpose

ISA RP 19.1-1979 :
annunciators
IEEE std.3.13 : Relays and relay system associated with electric power apparatus
Electromagnetic Compatibility for Industrial Process Measurement

BS EN 60801 :
and Control
E.E.M.U.A.
PUBLICATION 143 Recommendations for Tube End Welding
Publications
Precision Equations and Enhanced Diagrams for Local

WRC Bulletin 537 Stresses in Spherical and Cylindrical Shells due to External
Loadings for implementation of WRC Bulletin 107.
Local Stresses in Cylindrical Shells due to External Loadings

WRC Bulletin 297
on Nozzles.
Client approved Drawings / TDS / Working Procedures / ITP / QAP / Codes & Standards / NDT
procedure.
specifications referred above, most stringent requirement shall apply.
6.1. General
1. Vaporizers shall be designed, fabricated, and inspected as per the requirements of ASME Boiler
and Pressure Vessel Code, Section VIII Div. 1 or any other equivalent code.
2. The vaporizer shall be anchored and connecting piping shall be sufficiently flexible to provide for
expansion and contraction due to temperature change.
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3. The vaporizer shall be designed to withstand the loads created by wind, earthquake and frost and
snow accumulation.
4. The vaporizers shall be equipped with attachments (e.g.: lifting lug etc.) to facilitate lifting.
6.2. Saturation-on-the-Fly Vaporizer
1. The Saturation-on-the-Fly-LNG Vaporizer Package shall be installed in the LNG Station to heat
cold LNG from LNG Storage Bullet from (-) 162 Deg C to the saturation temperature at
dispensing pressure i.e. fuel tank pressure of the vehicle, for example for fuel tank pressure of 8
bar g, LNG saturation temperature shall be (-) 125 Deg C. (Vendor is to confirm the operating
pressure of LNG in fuel tank of the Vehicle and corresponding saturation temperature).
2. The Saturation-on-the-Fly-LNG Vaporizer Package is to be designed to feed saturated LNG to one
no. of LNG Dispenser at a time, the capacity of LNG Dispenser is 150 LPM. Therefore, the
Saturation-on-the-Fly-LNG Vaporizer package is to be designed to heat 4000 kg/hr of LNG from
(-) 162 Deg C to saturation temperature (Vendor to confirm the capacity, based on their past
experience).
3. LNG, in Saturation-On-the-Fly Vaporizer, shall be heated by ambient air. The Saturation vaporizer
is to be designed to heat design flow rate of LNG to saturation temperature, based on minimum
ambient air temperature. However, air flow is to be controlled to maintain the heat duty during
higher ambient air temperature. Maximum temperature of the ambient air can be as high as 40 Deg
C for Avinsahi site & 36 Deg C for Pananchery site.
4. The Saturation-on-the-Fly- LNG Vaporizer Package is preferably to be “Forced Draft” type and to
be provided with FD fan driven by variable speed motor. The VFD driven motor is to be explosion
proof and shall be suitable for LNG operation.
5. Vendor to ensure to avoid ice / frost formation on heat transfer surfaces i.e. tubes / fins for
satisfactory and trouble-free operation of the Vaporizer, specifically for operation during low
ambient air temperature. The FD fan should vent out Fog to atmosphere during humid condition.
6. The Saturation-on-the-Fly-LNG Vaporizer Package, along with its VFD driven FD Fan, shall be
suitable for satisfactory operation for following extreme cases:-
a. Case 1: Flow rate of 4000 kg/hr (1 no. of Dispenser in operation) and at minimum ambient
air temperature.
6.3. Material
1. The material must be suitable for LNG service and shall be new and defect free.
2. The material of construction of LNG vaporizer is recommended as Stainless-Steel piping with
outer Aluminum fins.
3. Material procured and used for fabrication of equipment shall be new of first quality, supported
with test certificates and shall meet the ASME Boiler and Pressure Vessel Code Section-II.
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1. All spare parts shall be interchangeable with the corresponding original parts. The material should
be same and shall present the same properties as the corresponding parts of the main equipment.
3. The conditions concerning the tests and treatment of surfaces and painting etc. of the main
equipment according to the scope documents shall also be valid for spare parts.
identification. The spare parts ordered shall be delivered with the main equipment but in separate
boxes clearly marked "SPARE PART".
5. The list of special tools shall be accompanied by descriptions sufficiently detailed to identify the
function of the tool and the specific item or items for which it applies. The Supplier shall indicate
whether the tool is required for installation, adjustment or routine maintenance.
6. The list of recommended spare parts and consumables shall be accompanied by the Supplier’s
expected lifetime of wearing parts and descriptions sufficiently detailed to identify the spare parts
and the specific item or items for which it applies. The Supplier shall indicate the minimum
recommended inventory for routine maintenance during start-up, commissioning, start-up and
continuous operation.
7. The Supplier shall provide in the manner and within the time limits as set forth in the Contract, its
list of mandatory and recommended spare parts, special tools and consumables necessary for
installation, commissioning, start-up, operation and maintenance for each specified years operation
of equipment and accessories furnished by the Supplier
standards.
2. The cleaning and painting for all the equipment shall be made suitably for use under the
Mediterranean saline environment close to the sea at the site.
3. The relative humidity of 95% shall be applied for protection of equipment for mechanical and
electrical equipment such as material selection, painting and electrical clearance.
4. The painting specification with final colors and identification system for the equipment shall be
approved by the Client.
6. Weld ends shall be coated with a product such as de-ox-aluminates paint or an alternate acceptable
to the Client, unless otherwise specified.
7. All machined surfaces, except weld ends, shall be coated with suitable protective material to
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prevent corrosion. The use of greases or oil, other than light grade mineral oil, for corrosion
protection shall be prohibited.
8. The inside and outside of the tank shall first be thoroughly cleaned and be free of weld splatter,
weld slag, flux deposits, burrs and splinters, loose mill scale, oil grease, moisture and all other
foreign materials.
10. Equipment shall be completely drained and thoroughly dried within 48 hrs. of completing hydro
test. Acceptable method of drying includes mopping, wiping or blow drying with cool air to be
adopted by Supplier after getting approval from Purchaser/ its representative.
1. All the test and inspection for the Supplier’s equipment shall be conducted in accordance with the
applicable codes and standards, including prudent practices in the hydrocarbon industries, unless
otherwise specified in this Specification.
2. Any inspection by the Client will not relieve the Supplier of any responsibility for conformance
with stated conditions and shall not be considered as a waiver of warranty or other rights.
3. NDE personnel shall be qualified in accordance with the requirements of SNT-TC-1A or
equivalent.
4. In case Client and /or Client will indicate its intention to attend on the inspection & test plan (ITP),
the Supplier shall give the relevant information to the Client at least before 4 weeks for the
expected inspection/test date.
5. For the equipment stage-wise & final inspection shall be by a reputed third party inspection agency.
Inspection shall be carried out only after drawings are approved by Owner/Owner’s representative.
6. Ensure that all alloy steel and stainless steel materials are properly identified and finally check
tested by a PMI analyzer.
7. Inspection test plan shall comply with all requirements specified or enclosed herein. It must
specify various stages of inspection. Any comments by Owner/Owner’s representative shall be
complied with without time & cost implication.
8. Packaging inspection for imported extruded finned tubes shall be carried out by the Vendor and the
same shall be witnessed by the Contractor.
9.1. Shop Test
1. The Supplier shall prepare and submit the shop test and inspection procedures/plan for approval.
2. When witness testing is required, the test required shall be witnessed by the client or its authorized
representative unless waived in writing, and the equipment shall not be shipped until it has been
approved for shipment by the Client.
3. Requisite factory tests shall be given to each component as necessary to determine that works and
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materials are free from defects and to establish that the design and construction meet the
requirements of this Specification.
4. The Client shall have free access to the Supplier’s shop for the purpose of inspecting the work and
witnessing tests on equipment to be furnished by the Supplier.
5. If the results of shop tests indicate that the equipment fail to comply with the performance
guarantees, the Supplier shall immediately proceed with developing proposed equipment
modifications to obtain the guaranteed performance. Proposed modifications shall be subject to the
Client’s review and acceptance prior to implementation. Modifications which do not comply with
this Specification, or in the opinion of the Client could result in a decrease in equipment generator
reliability, will not be acceptable.
6. If the Supplier’s proposed modifications are acceptable, the Supplier shall immediately proceed
with such modifications and retesting. However, acceptance does not relieve the Supplier of the
responsibility for meeting guarantees.
7. Hydrostatic test of the equipment/ system shall be performed as per test & inspection plan or
wherever specified in this specification.
8. Weld repair procedures are subject to approval of the Client/ its representative.
9.2. Site Acceptance Test
Site Acceptance Test shall be performed at Owner discretion to ensure as far as this can be made possible,
that the Machinery has not been adversely affected in transit. A Site Acceptance Test will be performed
during the pre-commissioning, commissioning and start-up phase of the project. Any part or components,
which are not functioning to the satisfaction of Purchaser, shall be repaired or replaced by the supplier
without cost & time implication to purchaser and performance test again carried out.
9.3. Test Reports
The certified reports for shop test and inspection, and site acceptance tests shall be prepared by the
Supplier and submitted to the Client as soon as possible after completing each test. The report shall
include executive summary, test procedure, test arrangement, instrumentation and calibration data, test
measurement data, test results, evaluation of test results, etc. as well as the recommendations in the
applicable Code.”.
as follows:
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conditions.
conducted by Owner/Supplier. The Supplier's personnel shall witness these tests. The test
procedures shall be as mutually agreed to before performance tests are conducted.
months
3. All openings, nozzles, flanged, threaded and weld-end connections shall be provided with
protection to prevent damage, corrosion, and entrance of foreign matter during shipment and
storage.
flange.
specification.
operating”.
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12.0 MARKING
1. Manufacturer name
2. Equipment type and serial number
3. Capacity
4. Gross Weight of the unit
5. Date of Manufacture
6. Project Name
7. CLIENT’s Name
Transportation marking shall be painted with synthetic resin paint.
13.0 DOCUMENTATION
Supplier shall provide complete documentation of all components and subsystems contained in the
package. The documentation shall include but not limited to the following:
4. Utility List
5. Equipment Data Sheets - which at least containing following information:
c. Width and height or length
d. Construction materials and corrosion allowance
e. Number, size, duty and position of nozzles
f. Details of special internals, e.g. supports, distributors, mist eliminators, pans etc.
g. Specific design details and fabrication requirements
h. Platforms, ladders, lifting lugs
i. Machinery handling, transportation and lifting manual.
9. Equipment fabrication drawings
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14. Welding plan, welding procedures and welder’s prequalification (in accordance with the applicable
ASME or equivalent code)
17. Inspection & Test Plan (in accordance with the applicable ASME or equivalent code)
non-destructive examination (NDE) method related to welds, leak test, pressure test, etc. Reference
to applicable WPS / WPQR, welding books, material traceability, etc. shall be made.
19. Manufacturer’s data report for piping
number, manufacturers serial number, name and address of vendor
h. NDE reports
and repair
22. Sub vendor list
23. Instrument List
24. PLC Configuration Diagram
25. Control System & Instrument datasheet & catalogues
26. Loop diagrams
28. Serial interface list
29. Logics and Write-up
31. I/O list
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33. Civil concrete & structure design information pertaining to vendor print, anchor bolts, embedment
& interference drawings, foundation loading data etc.
14.0 DELIVERY
At the place indicated in the Owner/ Consultant’s Purchase Order.
Contractor shall submit to the Owner / Consultant, a detailed “working schedule” that will include the
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SPECIFICATION FOR
G11077
STATION PIPING
M006

(BPCL)
CONSTRUCTION OF LNG STATIONS IN THE STATE OF

TAMIL NADU & KERALA

TURNKEY BASIS
SPECFICATION FOR STATION PIPING

P.017398/P.017399-G-11077-M006
0 24.05.2021 Issued for Tender AMA MKR KNS

Page 105 of 921

P.017398/ P.017399
SPECIFICATION FOR
G11077
STATION PIPING
M006
TABLE OF CONTENTS
1.0 INTRODUCTION...................................................................................................................... 1
2.0 CODES & STANDARDS ............................................................................................................ 1
3.0 DESIGN AND CONSTRUCTION ................................................................................................. 3
4.0 MATERIAL .............................................................................................................................. 3
5.0 INSPECTION TEST .................................................................................................................. 4
5.1 Visual and Dimensional Examination ......................................................................................... 5
5.2 Mechanical Testing .................................................................................................................. 5
5.3 Chemical Analysis.................................................................................................................... 7
5.4 Non-destructive Testing ........................................................................................................... 7
6.0 INSPECTION BY CONTROL OPERATIONS: L.O.F.C .................................................................... 7
7.0 PAINTING, MARKING & PROTECTION ...................................................................................... 7
8.0 CORROSION PROTECTION ...................................................................................................... 8
9.0 DOCUMENTATION AND CERTIFICATION .................................................................................. 8
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SPECIFICATION FOR
G11077
STATION PIPING
M006
1.0 INTRODUCTION
This specification (Technical Specification) describes the requirement of seamless & welded piping
carbon steel and stainless steel to be installed for LNG Unloading, Storage & Dispensing Stations at
Avinashi (Tamil Nadu) & Pananchery (Kerala).
2.0 CODES & STANDARDS
Codes, Norms and standards (latest revision); but not limited to:
ASME B31.3 Gas transmission and distribution piping systems
ASME B31.3 Butt welding ends
ASME B31.3 Welded and seamless wrought steel pipe
ASME B31.3 Welded and seamless wrought stainless-steel pipe
ASTM A 106 Seamless Carbon steel pipe for High temperature service
ASTM A 312 GR.304 Seamless Stainless-steel pipe
ASTM A 370 Mechanical testing of steel products
ASTM E 112 Standard test methods for determining the average grain size
ASME Boiler and Pressure Vessel code
EN 10204 Metallic Products : Type of Inspection Documents
ISO 9001 Quality management standard
Determine the impact strength of steel and energy absorbed by Charpy

ISO 148
V-notch.
Steel Pipes For Water And Sewage Specification ( 168.3 To 2540 Mm
IS 3589
Outside Diameter)
IS 1239 Steel Tubes & Other Wrought Steel Fittings Specification
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The present specification can confirm, complete or alter certain characteristics or tolerances of existing
laws or specifications.
In his offer, the bidder shall specify all proposed modifications or alternatives to the present specification.
In all cases, each modification has to be submitted to the Control Authority and the owner. The complete
upgrading cycle shall be supervised by the Control Authority. All consequences after eventual order for
non-respect of this obligation are at the manufacturer's charge and responsibility.
Before the order is placed, a technical audit could take place by the client.
The manufacturer's specification of the steel, the manufacturing procedure itself and the laboratories in
which testing takes place, shall be approved and registered by the Control Authority. Valid approval
certificates must be available.
The Control Authority shall verify the control equipment of the vendor, its calibration and the points at
which it is located. If during the control of the pipes certain problems arise the Control Authority may
demand supplementary tests.
At all times while work on the contract of the owner is being performed, the Control authority shall have
free entry to all parts of the manufacturer's facilities and those of all subcontractors, who are involved in
the manufacturing and testing of the pipes. All reasonable facilities shall be afforded to the Control
authority to satisfy him that the product is being furnished in accordance with these specifications. All
tests and inspections called for by these specifications will be made in the manufacturer's plant prior to
shipment and at the manufacturer's expense, unless otherwise, and shall be conducted as not to interfere
unnecessarily with the operations of the manufacturer's plant. The manufacturer shall notify the owner/
its representative prior to completion or shipment of all requiring such inspection.
Eventual interpretations and deviations to this specification by the Manufacturer shall be requested by
writing in his offer with detailed justification and approved by the Owner/Consultant and the Control
Authority before eventual order to the Manufacturer. The latter is responsible and shall indemnify the
Owner/Consultant for any damage resulting from the non-respect of this obligation.
An approval of documents can never be considered as an acceptance of deviations or relaxations to
requirements. A deviation is only possible after specific request to the owner.
A valid copy of the ISO-9001 certificate shall be included in the offer.
The manufacturer shall inform the Control Authority MIN. 5 working days in advance of any control test
or examination under the supervision of the control Authority required by this specification and shall send
a copy (fax/E-mail) of it to the owner/consultant).
The Manufacturer shall send for approval a List of Operation in Manufacturing and Control to the Control
Authority and Owner/consultant, TEN (10) working days before manufacturing. This list shall be in
conformity with the Annexure 1 to this document. Before starting any manufacturing, the Manufacturer
shall be in possession of this approved document, filled in with all intervention points. Reference has also
been made in this specification to the latest edition of the following codes, standards and specifications:
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P.017398/ P.017399
SPECIFICATION FOR
G11077
STATION PIPING
M006
specifications referred above, the requirements of this specification shall govern.
3.0 DESIGN AND CONSTRUCTION
1. The pressure temperature ratings of the pipes are in accordance with ASME B31.3; the dimension
standard shall be in conformance to ANSI /ASME B 36.10/ASME B 36.19.
2. Wall thickness shall meet the following requirements:
The maximum allowable stress in the base material shall be equal to fifty per cent (50%) of the
minimum yield strength guaranteed by the specification of the steel used.
3. The specified pipe wall thickness/schedule and grade (with reference to the equivalent grade in ASTM
spec.) with which the pipe is intended to be used is specified in the data sheet/piping class.
4. The design shall take into consideration performance requirements prescribed in paragraph 3.1.
5. All pipe under this specification shall be designed to withstand a field hydrostatic test pressure with
non-corrosive water, after installation, during 24 hours at a following pressure level:
Hydrostatic test pressure shall not be less than
P = 1.5 * Design pressure
Where:
P = hydrostatic test pressure, bar
6. Properties of the Pipes
The Properties of Pipe manufactured as per this PTS, shall be as listed below:
Length of the Pipes : Single Random Length
4.0 MATERIAL
1. The steel used in the manufacture of pipe shall be in conformance to the ASTM standard.
2. The chemical composition of the steel shall meet the requirements of material specification.
3. The steel used has tensile properties conforming to the requirements prescribed in the ASTM standard.
4. The steel shall be fully killed, fine grain practice.
5. The steel used shall be suitable for field welding to other fittings, pipes, flanges, or valves
manufactured under ASTM specifications or API standards specifications or MSS standards in line
with the Piping Specification attached with the tender document.
6. If preheating of the material is required to ensure proper weldability under normal field conditions, the
manufacturer shall state so in the offer, specifying preheat requirements and if accepted by the
purchaser, this shall be permanently indicated on the pipe.
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P.017398/ P.017399
SPECIFICATION FOR
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STATION PIPING
M006
7. The manufacturer of pipe must deliver a certificate EN 10204 type 3.2 stating the quality, the
mechanical properties (yield strength, tensile strength, percent elongation, impact test as per below
table, the chemical analysis, the process of manufacture and the marking (for example the heat number
of material) of the steel.
8. A new chemical analysis (upgrading) shall be done on a specimen of pipe in presence of the Control
Authority; one per heat number, see par. 5.3.
9. Chemical composition:
a. For each heat the manufacturer shall check a chemical analysis of the steel.
b. Check analysis: carbon equivalent shall be computed by the following equation :
Mn Cr + Mo + V Ni + Cu
C. E .= C+ + +
6 5 15
And shall not exceed 0.43
5.0 INSPECTION TEST
Before NDT and Destructive tests, all pipes shall be Hydrostatically tested as per applicable code /
standards as under 100% witness of TPIA / Control Authority. All Destructive & Non-Destructive Test
shall be carried out as per approved QAP by Owner / Consultant.
Following tests shall be conducted on the pipes as per applicable ASTM specification:
REFERENCE
TEST OF EXAMINATION NUMBER OF TESTS
A 312/A 312M
Heat analysis Cl. no. 6, Table 2 Each heat of steel
Tensile test Cl. no. 10, Table 4 5 % from each lot
Bend Test Cl. no. 11 5 % from each lot
Flattening test Cl. no. 11 5 % from each lot
One set of 3 specimens of each

Impact test ASME Section VIII Division 1
lot
Hydrostatic test Cl. no. 12 Each length
Nondestructive Test Cl. no. 12 Each length
Dimensional examination Cl. no. 13 Each length
Each length – Single Random

Length Cl. no. 13
Length
Page 110 of 921

P.017398/ P.017399
SPECIFICATION FOR
G11077
STATION PIPING
M006
REFERENCE
TEST OF EXAMINATION NUMBER OF TESTS
A 312/A 312M
Workmanship, Finish and
Cl. no. 14 Each length
appearance
Each length Traceability to be
Marking Cl. no. 17
guaranteed on test report
5.1 Visual and Dimensional Examination
Before any other testing, each pipe length shall successfully undergo a visual and dimensional
examination.
The condition of the pipe shall be checked; particularly the external and internal surface aspects
(cleanliness).
The dimensions shall be verified (thickness, diameters, out of roundness, straightness) and shall be within
the tolerance of the specification.
5.2 Mechanical Testing
The mechanical properties shall be verified after acceptance of the pipes as pertaining from one same lot.
The procedure for mechanical testing needs to provide with the required quantities of pipes, as per
material data sheets and as per prepared lot, the necessary over lengths for removal of testing specimens.
These over lengths are in no way included in the material data sheets.
The nature of mechanical tests to be performed is specified in the applicable ASTM specification. Number
of tests shall be as per ASTM A106 specification.
Location and removal of specimens from pipe to be carried-out according to ASTM specification.
Test specimens may only be cut after a marking transfer by the Authorised Control Authority / TPIA.
The following mechanical tests shall be performed on material; the supervision of the Control Authority
delegate and the certificates shall be added to the CMTR.
1. Tension Test
a. Test specimen
The test specimen shall represent all pipes from the same lot.
b. Test locations and orientations
For base material, test specimens shall be orientated transversally and if this orientation is not
feasible, it shall be orientated longitudinally.
c. Test method
Testing shall be performed in accordance with ASTM A370 standard rectangular plate type 1-
1/2" wide (Fig. 4-A370) or standard round (Fig. 5 or Fig. 6-A370). Yield strength shall be
determined either by the 0.2 % offset or the 0.5 % extension under load (EUL) method.
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P.017398/ P.017399
SPECIFICATION FOR
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STATION PIPING
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d. Retest
If the tension test specimen from any lot fails to conform to the requirements of the particular
grade ordered, the manufacturer may elect to conduct retests on two additional pieces from the
same lot, each of which shall conform to the requirements specified in the ASTM standard. If
one or both of the retests fail to conform to the requirements, the whole lot of that specimen
will be rejected.
2. Impact Test
a. Requirements
CVN Impact test shall be carried out at 0ºC. For base material, one set of three specimens for
each lot, shall be taken from coupon.
b. Acceptance Criteria (At 0°C):
The average value of a set of 3 specimens from a pipe length shall be an absolute value not less
than 27J/cm2. In addition, the lowest individual value of any one of the three specimens shall
not be less than 80% of the specified average value (i.e. 22 J/cm2).
c. Test specimen
The test specimen shall be machined from material obtained as in paragraph Test specimen for
Tension test (par. 1.).
Flattening of test specimens are not allowed.
d. Number of tests and orientation
Three test specimens shall constitute one test set.
For pipes NPS 2 and greater, the following number of tests shall be performed:
Base material: 2 test sets, one set shall be orientated longitudinally and another one
transversally.
e. Test method
The notched bar impact test shall be made in accordance with ISO 148 - Charpy V - Notch.
If the wall thickness of the pipe or the coupon does not enable machining of full size specimens,
the largest possible size must be used but not less than (10 x 5 mm). The axis of the notch shall
be orientated through the wall thickness of the pipe.
3. Retreatment
If the result of the mechanical tests does not conform to the requirements specified in par. 5.2, the
manufacturer, with the acceptance of the purchaser and the Control Authority, may retreat the
pipes as applicable and repeat all the tests specified.
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P.017398/ P.017399
SPECIFICATION FOR
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STATION PIPING
M006
5.3 Chemical Analysis
For each lot/item a new chemical analysis of the steel shall be done.
The chemical analysis shall conform to the requirements material specification.
The carbon equivalent shall be computed by "check analysis": see par. 3.i.
C.E.  0.43.
5.4 Non-destructive Testing
After the Hydro testing, all pipes must be checked with NDT over all the surface and bevels. Eddy current
must be performed as per ASTM A106.
6.0 INSPECTION BY CONTROL OPERATIONS: L.O.F.C
Control and tests are carried out by the Piping Supplier under his responsibility and at his cost.
In order to ensure that material is in accordance with the applicable standard specification and with this
specification, Supplier shall follow a program of inspection as set in the L.O.F.C. (List of Operations for
Control).
The intended intervention points of the Control Authority and of Engineer's inspection are indicated in the
L.O.F.C. form attached.
It is the responsibility of the Quality Control department to fill in the L.O.F.C. sheet with their intervention
points.
Each operation step, after checking of execution, shall be signed by the responsible Q.C. Inspector.
Notification to the Control Authority for witnessing of testing operations, shall be done atleast five (5)
working days, by E-mail, prior to the date scheduled to perform the test.
Each pipe in which injurious defects are found after delivery shall be rejected. The vendor shall be notified.
In this case, the pipe shall be replaced immediately by the vendor. All costs involved, including wages and
travel expenses of the Control Authority / Consultant shall be borne by the manufacturer/ supplier.
7.0 Painting, MARKING & PROTECTION
1. All pipes furnished under this specification shall be clearly identified on the O.D. with the following
information marked with low stress die stamps or interrupted dot stamps as noted :
a. Manufacturer's name or trademark.
b. Heat code identity.
c. Pipe number: the pipe number shall be as per PMS.
d. The monogram of the Control Authority / TPIA. This marking shall only be applied after
complete approval of the Certified Material Test Report.
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P.017398/ P.017399
SPECIFICATION FOR
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STATION PIPING
M006
2. In addition to the above, for NPS 2" and larger, it shall also include the following information :
3. Grade symbol: the grade symbol must designate the material of the pipe conforming to ASTM code.
4. Marking must be done prior to final inspection.
5. All material will be painted. Surface edge preparation & paint as per Particular technical specification
for painting
6. All surfaces must be free of particles such as scale, steel chips, weld spatter, dirt, rust or greases and
oils.
7. The components shall be prepared for shipment in such a manner so as to avoid damage or atmospheric
corrosion to the inside or outside surfaces and other parts during storage or while in transit.
8. They must also be dry before sealing off of all openings.
8.0 CORROSION PROTECTION
1. The corrosion protection will be applied by the vendor after final inspection by the Control Authority.
2. The corrosion protection shall be line sealed oil at the outside of the pipe.
3. This product shall meet the following criteria:
a. Guarantee a corrosion protection for a storage period in open air for at least 6 months.
b. Shall be easily removable by wire brushing or by grinding.
c. Shall not produce toxic vapour or smoke when heated by blow troches or during welding.
4. The vendor shall deliver the necessary quantity of product (tri - chlore - ethylene) to remove this oil.
9.0 DOCUMENTATION AND CERTIFICATION
Inspection and certification shall be done by the Quality Control department of the pipe supplier and in
presence of the Control Authority representative / TPIA and apply to:
1. Identification of pipes with respect to mill certificates.
2. Visual and dimensional inspection.
3. Sampling preparation for testing: stamping of specimens.
4. Testing (destructive and non-destructive).
5. Hydrostatic test.
6. Marking: all accepted pipe lengths shall be identified by Control Authority's representative / TPIA.
Final certification shall be as per EN 10204:3.2 and shall include the results of all performed destructive,
chemical check, hydrostatic test values and heat treatment data. This certificate shall be signed by the Control
Authority.
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P.017398/ P.017399
SPECIFICATION FOR
G11077
STATION PIPING
M006
FIG. 1
m
m
L
2
0
≤
Fitting size 24" and smaller may be furnished with 37° ½ bevel at manufacturer's option.
Recommended bevel for wall thickness (t) at end of fitting: 20 mm or less.
FIG. 2
Recommended bevel for wall thickness (t) at end of fitting, greater than 20 mm
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P.017398/ P.017399
SPECIFICATION FOR
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STATION PIPING
M006
FIG. 3
Note
1. No min.
when materials joined
have equal yield
strength.
2. t2 must be limited to the
minimum
P F
I I
P T
E T
I
N
ACCEPTABLE DESIGN FOR UNEQUAL WALL THICKNESS G
FIG. 4
TRANSVERSE FACE AND ROOT BEND TEST SPECIMENS
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P.017398/ P.017399
SPECIFICATION FOR
G11077
STATION PIPING
M006
FIG 5
GUIDED-BEND TEST JIG DIMENSIONS
CLASS OF STEEL
Y52 and low- Y56 Y60 Y70
grade
Radius of male member R A ½A ½A ½A ½A
Radius of female member R B ½B ½B ½B ½B
Width of male member, A 4t 5t 6t 8t

Width of groove in female A + 2t + 3.2 mm A + 2t + 3.2 A + 2t + 3.2 A + 2t + 3.2
member, B mm mm mm
t = specimen thickness
The manufacturer shall use a jig based on this dimension, or a smaller dimension at his option
Page 117 of 921

P.017398/ P.017399
SPECIFICATION FOR
G11077
STATION PIPING
M006
FIG. 6
SPECTACLE FLANGE
Note: Bore of the Spectacle Blind (d) which is to be installed on Mainline shall match with inside diameter
of Connecting Pipeline.
Page 118 of 921

P.017398/P.017399
SPECFICATION FOR
FLANGES AND FITTINGS
G11077
M007

(BPCL)

SPECFICATION FOR FLANGES AND FITTINGS
P.017398/P.017399-G-11077-M007

Page 119 of 921

P.017398/P.017399
SPECFICATION FOR
G11077
M007
TABLE OF CONTENTS
1 GENERAL .................................................................................................................................. 1
2 DESIGN AND CONSTRUCTION ................................................................................................... 2
3 MATERIALS ............................................................................................................................... 6
4 FABRICATION AND TEST ........................................................................................................... 6
5 UPGRADING FROM 3.1 TO 3.2 CERTIFICATE .............................................................................. 9
6 INSPECTION ........................................................................................................................... 13
7 CORROSION PROTECTION ...................................................................................................... 14
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P.017398/P.017399
SPECFICATION FOR
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M007
1.0 GENERAL
This specification describes the requirements of fittings and flanges to be installed on pipeline systems for LNG
Unloading, Storage & Dispensing Stations at Avinashi (Tamil Nadu) & Pananchery (Kerala).
TRACTEBEL has been appointed as Project Management Consultant (hereinafter referred as PMC), by BPCL for
providing Engineering, Procurement and Construction (EPC) services for a mentioned project.
This specification also describes the examinations and upgrading tests to be performed for obtaining A3.2 certificate
on the standard new fittings and flanges or taken out of stock with A3.1 certificate.
The fittings have to be delivered in accordance to the following particular specification, Codes, Norms and
standards (latest revision); but not limited to:
ASME B16.5 Pipe flanges and flanged fittings
ASME B16.9 Factory - made wrought steel butt welding fittings.
ASME B 16.11 Forged steel fittings
ASME B16.28 Wrought steel butt welding short radius elbows and returns
ASME B 31.3 ASME code for process piping.
ASME B 31.4 Pipeline transportation system for Liquid hydrocarbons
ASME B 31.8 Gas transmission and distribution piping systems.
ANSI B36.10 Welded and seamless wrought steel pipe
ASTM A 105/ Forging, carbon steel, for piping components.
A 105 M
ASTM A 203 Pressure vessel plates, alloy steel, nickels
ASTM A 234/ Piping, fittings of wrought carbon steel and alloy steel for
moderate and elevated temperatures
A 234 M
ASTM A 333 Seamless and welded steel pipe for low temperature
ASTM A 350/ Forging, carbon and low alloy steel, requiring notch toughness
testing for piping components.
A 350 M
ASTM A 370 Mechanical testing of steel products.
ASTM A 420/ Piping fittings of wrought carbon steel and alloy steel for low
temperature service.
A 420 M
ASTM E 112 Standard methods for determining the average grain size.
MSS SP 25 Standard marking system for valves, fittings, flanges and unions.
MSS SP 55 Quality standard for steel castings for valves, flanges and fittings
and other piping components (visual method).
MSS SP 75 Specification for high test wrought butt welding fittings.
ASME Boiler and Pressure Vessel code.
DIN 2413 Design of Steel Pressure Pipes
EN 10204 Type of Inspection documents
ISO 148 Metallic Material - Charpy Pendulum impact test
ISO 9001 Quality management standard
Page 121 of 921
P.017398/P.017399
SPECFICATION FOR
G11077
M007
The present specification can confirm, complete, or alter certain characteristics or tolerances of existing laws or
specifications.
In his offer, the manufacturer or vendor shall specify all proposed modifications or alternatives to the present
specification. In all cases, each modification has to be submitted to the pipe laying contractor and the
Client/Consultant. The complete upgrading cycle shall be supervised by a pipe laying contractor. All
consequences after eventual order for non-respect of this obligation are at the manufacturer's charge and
responsibility.
A valid copy of the ISO 9001 certificate shall be included in the offer.
Before the order is placed, a technical audit will take place with pipe laying contractor/ Client.
The manufacturer's specification of the steel, the manufacturing procedure itself and the laboratories in which
testing takes place, shall be approved and registered by the pipe laying contractor. Valid approval certificates must
be available.
The pipe laying contractor shall verify the control equipment of the manufacturer, its calibration and the points at
which it is located. If during the control of the fittings certain problems arise the pipe laying contractor agent may
demand supplementary tests at the cost of the manufacturer.
At all times while work on the contract of the Client is being performed, the inspector representing the Client shall
have free entry to all parts of the manufacturer's facilities and those of all subcontractors, who are involved in the
manufacturing of the fittings. All reasonable facilities shall be afforded to the inspector to satisfy him that the
product is being furnished in accordance with these specifications. All tests and inspections called for by these
specifications will be made in the manufacturer's plant prior to shipment and at the manufacturer's expense, unless
otherwise, and shall be conducted as not to interfere unnecessarily with the operations of the manufacturer's plant.
The manufacturer shall notify the Client prior to completion or shipment of all fittings requiring such inspection.
Eventual interpretations and deviations to this specification by the Manufacturer shall be requested by writing in his
offer with detailed justification and approved by the Client/Consultant and the Authorised pipe laying contractor
before eventual order to the Manufacturer. The latter is responsible and shall indemnify the Client/Consultant for
any damage resulting from the non-respect of this obligation.
An approval of documents can never be considered as an acceptance of deviations or relaxations to requirements. A
deviation is only possible after specific request to the Client.
2.0 DESIGN AND CONSTRUCTION
2.1 The pressure temperature ratings for tee, weldolets, elbows and flanges shall be calculated respectively in
accordance with ANSI B31.3 and ANSI B16.5. For all other types of fittings (caps, reducers, nipple) ASME
section VIII shall apply.
2.2 The standard dimension shall be in accordance
• Flanges such as weld neck flanges and blind flanges shall conform to the requirements as
follows:
- ASME B16.5 upto sizes DN 200 mm (8")
• With ANSI B16.9 for the tees, reducers and elbows (except for short radius elbows which
should be in accordance with ANSI B16.28)
• With ANSI B 16.9 for the caps,
• With ANSI B 36.10 for the nipples,
• And with ANSI B16.5 / MSS SP 44 for the flanges.
2.3 The wall thickness shall meet the following requirements:
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SPECFICATION FOR
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M007
2.3.1 The maximum allowable stress in the base material and in the weld shall be equal to fifty per cent (50%) of
the minimum yield strength guaranteed by the specification of the steel used.
2.3.2 The minimum wall thickness must be greater than the following:
a) Thickness calculated in line with requirements given in ASME B 16.9 Para 2.2
b) Nominal Thickness of pipe
Thickness calculation is to be submitted to Owner/Owner’s Representative for prior approval before
manufacturing.
2.3.3 If the fitting has yield strength lower than the yield strength of the pipe to which it is intended to be welded,
the wall thickness in each zone of the fitting is at least equal to the largest value "tr" of either.
a) The specified pipe wall thickness times the ratio of the minimum yield strength guaranteed by the
standard of the steel of the pipe and the minimum yield strength guaranteed by the standard of the steel
of the fitting;
b) The absolute minimum thickness required by the applicable code(s).
2.3.4 The specified pipe wall thickness and grade (with reference to the equivalent grade in ASTM spec. or API
5L spec.) with which the fitting and flange is intended to be used is specified in the piping material
specification.
Fittings such as tees, elbows, reducers, etc. shall be either welded or seamless type. All welded fittings shall
be subjected to heat treatment. All fittings (except weldolets) shall comply with the requirements of
MSS-SP-75. Fittings such as weldolets etc. shall be manufactured in accordance with MSS-SP-97.
Welded pipes used for fittings shall be LSAW type only.
2.3.5 The thickness at the welding end shall not exceed 1.5 times the nominal wall thickness of the pipe to be
matched.
2.3.6 All the above requirements also apply to the welding ends of the flanges.
2.4 The manufacturer shall submit for approval to the Pipe Laying contractor and to the Client the dimensional
drawings, calculations, and the material part lists for all the types of fittings and flanges. All the documents
must be identified with the Client's order number.
2.5 The design shall take into consideration performance requirements prescribed in paragraph 2.6.
The design of tees, reducers or elbows must be established, by proof testing, in accordance with par. 2.7.
The design of the other fittings must be established by mathematical analysis according to ASME code.
2.6 All fittings under this specification shall be designed to withstand a field hydrostatic test pressure with
non-corrosive water, after installation, during 24 hours at a following pressure level:
Minimum: P = 1.5 MOP
Where:
P = hydrostatic test pressure, bar
The pressure level will however not exceed 1.9 MOP for the fittings and 1.5 times the 38°C pressure rating
for the flanges.
2.7 Design proof test
This applies to fitting only and not to flanges.
2.7.1 In addition to the requirements of par. 2.3.1 to 2.3.4 proof tests shall be made as evidence of the adequacy to
the design references. Records of design or successful proof tests shall be available at the facility for
inspection by the Client and copy shall be added to the Certified Material Test Report (CMTR, par. 6.3.).
2.7.2 Unless otherwise agreed upon between manufacturer and Client, the only required proof test is a bursting
strength test.
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SPECFICATION FOR
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M007
2.7.2.1 Prototype fittings, representatives of production, selected for test shall be identified as to material, grade,
and lot, including heat treatment. They shall be inspected for dimensional compliance to this standard.
2.7.2.2 Straight seamless or welded pipe sections, whose calculated bursting strength is at least as great as that
calculated for the fittings, shall be welded to each end of the fitting to be tested. Any internal
misalignment greater than 0.06 inch (1.6 mm) shall be reduced by taper boring at a slope not over 1:3.
Length of pipe sections for closures shall be at least twice the pipe O.D. Shorter lengths may be used as
follows:
• The assembly must withstand at least 110 % of the pressure computed in 2.7.2.3.
• Minimum length of pipe shall be one pipe O.D. for sizes NPS 8" and smaller.
Test fluid shall be water or other liquid used for hydrostatic testing.
2.7.2.3 Hydrostatic pressure shall be applied until the fitting ruptures. The actual test pressure prior to rupture
must at least be equal to the adjusted proof test pressure defined as follows:
S ( act .)
P (adj.) = P x
s
where
P (adj.) = the adjusted proof test pressure, bar
P= the computed proof test pressure at burst of any part of the assembly, bar
S= minimum specified tensile strength of the pipe for which the fitting is intended to be
used, N/mm2
S (act.) = the actual tensile strength of the material of the test fitting (determined on specimen
representative of the test fitting), N/mm2
The computed proof test pressure shall be determined as follows:
which refers to the pipe which the fitting's marking identifies and, where
20S . t
P=
D
where,
P= Computed bursting pressure of the pipe, bar
S= Minimum specified tensile strength of the pipe, N/mm 2
t= Nominal pipe wall thickness, mm
D= Specified outside diameter of pipe, mm

2.7.2.4 As an alternate, if the pipe ruptures, or if sufficient pressure to rupture any part of the assembly cannot be
attained, the test pressure is acceptable if a final test pressure is at least 105 % of the adjusted proof test
pressure.
2.7.3 A successful proof test on a prototype fitting, selected as required in subsection 2.7.2.1., may be used to
qualify other fittings to the extent described herein.
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SPECFICATION FOR
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2.7.3.1 One test fitting may be used to qualify similar designs which shall not be smaller than one-half nor larger
than two times the size of the test fitting.
2.7.3.2 The test on a non-reducing fitting qualifies reducing fittings of the same pattern.
2.7.3.3 The untested fitting must have a t/D ratio neither less than one-half nor more than three times the t/D of the
test fitting.
2.7.3.4 The pressure retaining capacity of a fitting, made of various grades of steel, will be essentially directly
proportional to the tensile properties of the various grades. Hence, it is necessary to test a prototype in
only a single grade to prove the geometric design of the fitting.
2.7.3.5 A test on a prototype elbow qualifies elbows having longer radii than the test fitting providing they qualify
under 2.7.3.1 and 2.7.3.3.
2.7.3.6 A change in design from seamless fitting to fitting containing (a) seam weld(s) require(s) an appropriate
prototype test. A change of location of the seam weld requires a separate prototype test. Any deviation
must be submitted for approval to the pipe laying contractor.
2.7.4 If the manufacturer cannot give the certificate of prototype bursting test, the design of fittings shall be
verified as follows.
• A prototype must withstand during 24 hours 1.4 times the maximum operating pressure (M.O.P).
• The prototype is considered to be agreed upon if the deformations measured during the test at 1.4 X
M.O.P. shows that the stress does not exceed 70 % of the minimum guaranteed yield strength of the
fitting.
The certificate of this prototype qualifies in the same limits than par. 2.7.3.
2.8 Fitting dimensions
2.8.1 One of the principles of this standard is the maintenance of a fixed position for the welding ends with
reference to the centre line of the fittings or the overall dimensions.
2.8.2 Dimensional standards will be in accordance with §2.1.
2.9 Fitting and flanges tolerances
2.9.1 Tolerances for welding ends, out-of-roundness at the welding ends and inside diameter at the bevel are
shown hereafter. Other tolerances wall thickness are as per corresponding codes: ANSI B16.9 standard and
for short radius elbows ANSI B16.28 standard.
2.9.2 Welding ends
The welding end and bevel shall be in accordance with Figure 1 for wall thickness up to 20.0 mm; for
thicker walls, refer to Figure 2. The welding end land of the fitting & flanges shall be machined flat and
shall not vary from the plane by more than 0.03 in (0.8 mm) at any point. If a fitting & flange has a
thickness unequal to the pipe with which it is intended to be used, the welding end preparation at the joint
has to conform with Figure 3.
2.9.3 Out-of-roundness at the welding ends
The out-of-roundness, defined as the difference between the maximum and the minimum inside diameter at
the welding ends shall not exceed 1 % of the specified inside diameter for sizes NPS 4 and smaller.
Fittings & flanges NPS 4 and larger shall be machined true round.
2.10 Inside diameter
The inside diameter at any place at end (bevel) shall be the following:
NPS Tolerance of inside Ø at end (mm)
1/2" – 12” + 1.6 - 0.4
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SPECFICATION FOR
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M007
(1) The tolerance refers to variation from nominal I.D. calculating by (O.D. nom. - 2 t nom.).
(2) Flange Bore to match with I.D. of the pipe.
3.0 MATERIALS
3.1 The steel used in the manufacture of fittings & flanges shall be selected by the manufacturer and submitted
for approval to the Client and the pipe laying contractor at the time of the offer. The manufacturer shall fill
in the data sheet.
3.2 The chemical composition of the steel meets the requirements of Table 1.
3.3 The steel used has tensile properties conforming to the requirements prescribed in the ASTM standards.
3.4 The ratio of yield strength to tensile strength shall not exceed 0.90.
3.5 The material for fittings shall consist of blooms, billets, slabs, forging quality bar, plate, seamless or fusion
welded tubular products with filler metal added.
3.6 The steel shall be fully killed, fine grain practice.
3.7 The steel used shall be suitable for field welding to other fittings, pipes, flanges, or valves manufactured
under ASTM specifications or API standards or MSS standards in line with Piping Specification attached
with the tender document.
3.8 If preheating of the material is required to ensure proper weldability under normal field conditions, the
manufacturer shall state so in the offer, specifying preheat requirements and if accepted by the Client this
shall be permanently indicated on the fitting & flanges.
3.9 The Manufacturer must deliver a certificate EN 10204 (3.1 for upgrade fitting & flange; 3.2 if new), stating
the quality, the mechanical properties (yield strength, tensile strength, percent elongation, impact test,
chemical analysis, the process of manufacture and the marking (for example the heat number of material) of
the steel.
3.10 Chemical Composition
3.10.1 For each heat the manufacturer shall check a chemical analysis of the steel (see Table 1).
3.10.2 Check analysis
Carbon equivalent shall be computed by the following equation:
Mn Cr + Mo + V Ni + Cu
C.E. = C + + +
6 5 15
And shall not exceed 0.43
4.0 FABRICATION AND TEST
For all forging materials, the specimen shall be taken from the integral part of the forging.
The par.4.1 to 4.2 are only applicable on welded fittings.
4.1 Welding Fabrication
4.1.1 All welds and repair welds shall be performed according to written procedures. The welding procedure
must be submitted for approval to the pipe laying contractor before any fabrication.
4.1.2 Only qualified & approved welders and welding operators shall be used in production.
4.1.3 The joints shall be furnished in accordance with the requirements of Section VIII of ASME Boiler and
Pressure Vessel Code.
4.1.4 Machine welding shall be done by an electric process, preferably by submerged arc.
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4.1.5 All butt welds shall have full penetration. Submerged arc machine welding shall be done with at least one
pass from the inside, except when accessibility makes this impossible, then a manual or machine root bead
may be employed provided that a visual inspection of the root bead is possible. Backing rings shall be not
used.
4.1.6 Repair, chipping or grinding of welds shall be done in such a manner as not to gouge, groove, or reduce the
original metal thickness by more than 6 1/2 % of nominal specified wall.
4.1.7 Except for bar in the tees, fillet welds shall not be permitted.
4.1.8 Welded-on braces, if used, should be removed before heat treatment and the weld spot shall be repaired and
ground flush and smooth. However, when braces are required for heat treatment, they shall be cut out and
the surface shall be ground flush and smooth after heat treatment. Except for bar in the tees, welding shall
not be permitted after heat treatment. The ground areas shall be inspected by magnetic particle or liquid
penetrant testing.
4.2 Welding Procedure
4.2.1 All welds, repair welds and repair by welding shall be performed according to written procedures. These
welding procedures shall be qualified according to the requirements of the ASME Boiler and Pressure
Vessel Code, Section IX.
The welding procedure tests are required on material which is on the high side of the chemistry
specification.
The manufacturer shall maintain a weld record of the procedure and performance test results. The test
coupons shall be submitted to the same fabrication and heat treatment as the actual fittings.
The welding procedure qualification must include an impact test set in the weld and in the HAZ with
requirements of paragraph 5.1.2 and a macrographic examination described in paragraph 4.2.2. These tests
shall be performed after eventual final heat treatment.
4.2.2 Macrographic examination: the etched surface of the macro test specimen viewed macroscopically must
display the image of a well performed welded joint with sufficient penetration, free from linear defects and
important inclusions. In case of doubt, the etched surface must be examined microscopically and additional
macroscopical examinations of other areas may be required.
The macrographic examination will include hardness measurements in the weld and the HAZ. The hardness
will not exceed the values measured on the parent metal by more than 80 points for the welds and 100 point
for HAZ, with an absolute maximum of 350HV10.
The acceptance of inclusions can be decided upon with the NDE of the welded plates (see paragraph 5.3).
4.3 Transverse Guided Bend Test
4.3.1 TEST METHOD
Transverse weld test specimens shall be subjected to face and root guided bend tests. The specimens shall
be approximately 1.5 in (38 mm) wide, at least 6 in (152 mm) long with the weld at the centre and shall be
machined in accordance with Figure 4. The face bend specimen shall be bent with the inside surface of the
pipe against the plunger, and the root bend specimen with the outside surface against the plunger. The
dimensions of the plunger for the bending jig shall be in accordance with Figure 5 and the other dimensions
shall be substantially as shown in Figure 5.
The manufacturer shall use a "jig" based on this dimension or a smaller dimension at this option.
4.3.1.1 TEST SPECIMEN
The weld bend test specimens, as described hereabove shall be cut from the coupon. The specimens may
be taken from a fitting or from sample plates as described in par. 4.2.3.1.
4.3.1.2 ACCEPTANCE CRITERIA
The bend test shall be acceptable if no cracks or other defects exceeding 0.12 in (3.2 mm) in any direction
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are present in the weld metal or between the weld metal and the fitting metal after the bending. Cracks
which originate along the edges of the specimen during testing and which are less than 0.25 in (6.4 mm)
measured in any direction, shall not be considered unless obvious defects are observed.
4.3.1.3 RETEST
If either test fails to conform to specified requirements, the manufacturer may elect to make retests on two
additional specimens from the same lot, each of which shall conform to the requirements specified
hereabove. If any of these specimens fail to conform to the requirements, the welding procedure
qualification test is not accepted.
(*) A lot consists of all fittings/flanges from one heat of steel with same initial wall thickness, from the same
furnace charge for final normalizing heat treatment, from the same shape and the same main pipe dimension.
4.3.2 Number of tests
The nature and number of tests are specified in the Table below and only one retest is allowed.
Test Test Spec. Number of test
Non destructive test par. 5.3. -
X-ray and U.S. testing par. 5.3 -
Destructive test All specimens shall be taken transverse to the weld
Tensile par. 5.1.1.2 2
Bend test par. 4.3.1.2 2
par. 5.2 (1 set of 3
Impact 1 set of 3 specimens
specimens)
Macrographic
par. 4.2.2 1
examination
4.4 Normalising Heat Treatment
Start & stop temperature chart shall be signed by TPIA, also power failure log shall be maintained.
4.4.1 After forming and welding, all fittings & flanges shall be heat treated by normalising. Normalising shall
be carried out in such a way that the base material acquires a fine grained perlitic structure. If the
manufacturer can give proof by qualified manufacturing procedure that after forming, the steel of the fitting
& flanges has a homogeneous fine grained perlitic structure, he can ask for a derogation supported by
technical file to the Client and to the pipe laying contractor.
The normalizing procedure requires the approval of the pipe laying contractor. Good care shall be taken to
avoid direct contact of the flames with the material to be heated.
During the normalizing period, the temperature of the heat treatment lot shall be automatically recorded by a
sufficient number of thermocouples attached to the material surface. The thermocouples shall be
adequately protected against the influence of heat radiation. Temperature variations shall be within ±
20°C. The manufacturer shall furnish time temperature charts of each heat treatment lot. The fittings &
flanges belonging to each treatment lot shall be specified on the charts. Temperature measurements by
other means are permitted only if approved by the pipe laying contractor.
4.4.2 The fine grained perlitic structure of the steel shall be verified by at least one micrographic examination per
lot (definition in §4.2.4), according to ASTM E 112. The grain size shall be in the range of 8 to 12.
4.4.3 The manufacturer shall include in the CMTR data of this treatment.
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5.0 UPGRADING FROM 3.1 TO 3.2 CERTIFICATE
5.1 Mechanical Tests

The following mechanical tests shall be performed by the vendor under the supervision of the PIPE
LAYING contractor and the certificates shall be added to the CMTR.
Test specimens may only be cut after a marking transfer by the Authorised PIPE LAYING contractor. All the
tests shall be performed after final heat treatment.
Certification requirements to comply with EN 10204 – 3.2 certificates shall issued by TPIA
5.1.1 Tension test
5.1.1.1 Requirements
The material shall be in conformance with the ASTM standards and the ratio of yield stress to tensile stress
shall not exceed 0.90.
For fittings containing welds, the fracture must be outside of the weld. If there is a fracture in weld or
HAZ, the tensile strength shall at least meet the requirements for tensile properties as per ASTM standards.
5.1.1.2 Test specimen
The test specimen shall represent all forgings from the same lot. Test specimens shall be taken from the
fitting after final heat treatment or from a piece of pipe or plate of the same nominal thickness, same heat of
steel from which the fitting is made and which has been heat treated in a lot with any of the fitting(s) it
represents. For welded fittings, this coupon (piece of pipe or plate) shall contain a weld in prolongation of
the weld of the fitting.
5.1.1.3 Number of tests
For fittings NPS 2 and greater the following number of test shall be performed:
• Base material : one tension test
• Weld : one tension test
5.1.1.4 Test locations and orientations
For welds, the test specimen shall be orientated transversally to the weld. For base material, test specimens
shall be orientated transversally and if this orientation is not feasible, it shall be orientated longitudinally.
For flanges, the test location shall be in accordance with ASTM A350.
5.1.1.5 Test method
Testing shall be performed in accordance with ASTM A 370 standard rectangular plate type 1-1/2" wide (Fig.
4-A370) or standard round (Fig. 5 or Fig. 6-A370). Yield strength shall be determined either by the 0.2 %
offset or the 0.5 % extension under load (EUL) method.
5.1.1.6 Retest
If the tension test specimen from any lot fails to conform to the requirements of the particular grade ordered,
the manufacturer may elect to make retests on two additional pieces from the same lot. If one or both of
the retests fail to conform to the requirements, the whole lot of that specimen will be rejected.
5.2 Impact test
5.2.1 Requirements
For product, the Charpy V- Notch test shall be conducted as per following requirements:
Material Impact Test Temperature Energy Absorption Value
(Minimum)
Carbon Steel -20 Deg. C Individual 28J
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Material Average 35J

-20 Deg. C Individual 28J
Stainless Steel Average 35J
Material Standard’ impact test Material Standard’s impact test
requirements temperature or requirement
- 45 Deg. C whichever is lower
5.2.2 Test specimen

The test specimen shall be machined from material obtained as in paragraph Test specimen for Tension test
(par. 5.1.1.2.).
Flattening of test specimens are not allowed.
5.2.3 Number of tests and orientation
Three test specimens shall constitute one test set.
For fittings NPS 2 and greater, the following number of tests shall be performed:
a. Base material: 2 test sets, one set shall be orientated longitudinally and another one transversally.
b. Weld: 1 test shall be orientated transversally.
c. HAZ: 1 test shall be orientated transversally.
5.2.4 Test method
The notched bar impact test shall be made in accordance with ISO 148 - Charpy V - Notch.
If the wall thickness of the fitting or the coupon does not enable machining of full-size specimens, the
largest possible size must be used but not less than (10 x 5 mm). The axis of the notch shall be orientated
through the wall thickness of the fitting.
5.3 Flattening test
This is not applicable to the flanges.
5.3.1 Requirements
Flatten to 1/3 original O.D. without cracks or breaks in the fitting, continue flattening until meeting opposite
walls of the fitting.
No evidence of lamination of burnt metal may develop during entire test.
5.3.2 Test specimen
The test specimen represents all the fittings from the same heat of steel of the same shape and of the same
main pipe dimension of the fittings.
5.3.3 Number of tests
For fittings size lower than 2” one flattening test shall be made per test specimen.
5.3.4 Retreatment
If the result of the mechanical tests does not conform to the requirements specified in par. 5.1.3.1., the
manufacturer, with the acceptance of the Client and the pipe laying contractor, may reheat treat the fittings
as applicable and repeat all the tests specified.
5.4 Chemical Analysis
For each lot/item a new chemical analysis of the steel shall be done.
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The chemical analysis shall conform to the ASTM requirements specified in the specification.
The carbon equivalent shall be computed by "check analysis": see par. 3.10.2 with C.E.  0.43.
The reports shall be added to the CMTR reports and approved by the pipe laying contractor.
5.5 Non-Destructive Examinations (NDE)
The following mechanical tests shall be performed by the vendor under the supervision of the pipe laying
contractor and the certificates shall be added to the CMTR.
5.5.1 Radiography
All butt and repair welds shall be 100% radiographed in accordance with ASME section V - non destructive
examination - article 2 - using fine grain film and lead screens. Acceptance criteria shall be as be ASME B
31.4 or ASME B 31.8 as applicable and API 1104. Radiography shall be performed after the final heat
treatment.
5.5.2 U.S., Magnetic, Visual and Dimensional examination
5.5.2.1 NON-DESTRUCTIVE examinations
In the presence of the TPIA, the manufacturer shall perform the following non-destructive examinations on
the fittings after the mechanical tests and according to an inspection procedure to be submitted for approval.
• For fitting with wall thickness larger than or equal to 6 mm, ultrasonic inspection on the whole surface
(with angle probe and straight probe) to the maximum extent possible.
• All finished wrought weld ends shall be 100% tested for lamination type defects by ultrasonic test. Any
lamination larger than 6.35 mm shall not be acceptable.
• When elbows of size > DN 300 mm (12") are manufactured, the first elbow of each radius, diameter
and wall thickness shall be ultrasonically checked for sufficient wall thickness in areas where a
minimum wall thickness is to be expected. This shall be followed by random inspection of one out of
every three elbows of the same radius, diameter and wall thickness.
• Magnetic Particle or Liquid Penetrant Examination shall be performed on cold formed.
• Butt welding tees with extruded outlets as per applicable material standard.
• Welds, which cannot be inspected by radiographic methods, shall be checked by Ultrasonic or
Magnetic particle methods. Acceptance criteria shall be as per ASME section VIII Appendix U and
Appendix VI respectively.
• Magnetic particle inspection on the whole external surface and the accessible internal surface.
5.5.2.2 Ultrasonic inspection
Ultrasonic inspection of all welds and 25 mm of base material at each side of the weld shall be done.
5.5.2.3 Visual examination
All fitting & flanges shall be visually examined.
5.5.2.4 Test after machining
After machining, all the finished bevels shall be submitted to the following tests:
• Magnetic particle or liquid penetrant
• For fitting and flanges with wall thickness larger than or equal to 6 mm, ultrasonic inspection on 25
mm of base material.
5.5.2.5 Dimensional examination
• For fittings up to NPS 6, the TPIA shall choose 10 % with a minimum of one piece per item of the
order and these pieces shall be submitted to a dimensional examination.
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• For fittings larger than NPS 6, all pieces shall be submitted to a dimensional examination
• All flanges shall be submitted to a dimensional examination.
5.5.3 Acceptance criteria of the different NDE
5.5.3.1 Visual examination
The following defects are unacceptable:
• Undercuts exceeding 1 mm in depth and 25 mm in length.
• Undercuts of the outside weld which overlap undercuts of the inside weld.
• Lack of penetration.
• Continuous occurrence of under-cutting.
5.5.3.2 Magnetic particle inspection
Magnetic particle inspection on the external surface. ASME code, section VIII, division 1, appendix VI.
5.5.3.3 Ultrasonic inspection
• For the longitudinal welds: ASME code, section VIII, division 1, appendix 12.
• For welding ends,
• For base material :
Procedure: ASME code, section V, art. 23, SA-388.
Criteria: ASME code, section VIII, division 1, UF-55 (angle probe will be used).
5.5.3.4 Radiographic examination
• For longitudinal seam welds :
Criteria : ASME code, section VIII, division 1, UW 51
• For girth welds :
Criteria: API standards 1104, section 6.0.
5.5.3.5 Magnetic particle or liquid penetrant on the finished bevel
The following defects are unacceptable:
• Defects extending into the bevel provided the lamination is parallel to the surface and has a
transverse dimension exceeding 6.35 mm.
• All defects not parallel to the surface extending into the bevel.
5.6 Fitting & Flange Testing
Hydrostatic testing by the manufacturer is not required, but welding fittings shall be capable to withstand a
field hydrostatic testing in accordance with par. 2.6.
5.7 Workmanship and Finish
5.7.1 Fittings & Flanges shall be free of injurious defects and shall have workmanlike finish.
5.7.2 Injurious defects are defined as those having a depth in excess of 6-1/2 % of specified nominal wall.
5.7.3 Machining and grinding of surface defects shall be treated as follows: sharp defects such as notches,
scratches, scraps, seams, laps, tears, or slivers not deeper than 6-1/2 % of nominal wall thickness shall be
removed by grinding. Repair of injurious defects by welding shall be permitted only after agreement by
the Client and the pipe laying contractor, except that welding of injurious defects shall not be permitted
when the depth of defects exceeds 33-1/3 % of the nominal wall thickness, or the length of repair exceeds
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25 % of the specified diameter. Defects must be completely removed, and welding performed by a welder
qualified specifically for repair welding, as per par. 4.2.1. Such repair welding shall be ground flush with the
surface and all welding shall be done before final heat treatment. Repair welding shall be done with low
hydrogen electrodes in shielded metal arc welding, gas metal arc process or submerged arc process. In no
case, repair welding or cracks nor repair or repairs is allowed. Repair welding will not be permitted for
flanges.
5.7.4 Repair welding shall be done before the last heat treatment. Adjusting weld preparations, intended for field
welding, by means of welding is not allowed. For "standard fitting" repair by welding is not permitted.
5.7.5 Repair welding on the welds & in the body shall be 100 % radiographed and U.S tested.
5.7.6 At the discretion of the TPIA, finished fittings & flanges shall be subject to rejection if surface
imperfections acceptable under par. 5.5.2 are not scattered but appear over an area in excess of what is
considered as a workmanlike finish.
5.8 Marking
5.8.1 All fittings and flanges furnished under this specification shall be clearly identified on the O.D. with the
following information marked with low stress die stamps or interrupted dot stamps as noted (refer to MS
SP25):
• Manufacturer's name or trademark.
• Heat code identity.
• Fitting or flange number: the fitting or flange number shall be made up of six figures specified as
follows: the item and his number specified in the purchase order.
• The monogram of the pipe laying contractor. This marking shall only be applied after complete
approval of the Certified Material Test Report (see par. 6.4.).
5.8.2 In addition to the above, for NPS 2" and larger, it shall also include the following information:
• Grade symbol: the grade symbol must designate the material of the fitting or flange.
5.8.3 Marking must be done prior to final inspection.
6.0 INSPECTION
6.1 Information
The manufacturer shall inform the Pipe Laying contractor MIN. 5 working days (15 in case of foreign
supplier) in advance of any intervention required by this specification and shall send a copy (fax) of it to the
Client/Consultant.
6.2 Documentation
Before starting any control, the manufacturer shall submit for approval to the pipe laying contractor and the
Client/Consultant the following documents:
• Detailed fabrication drawing and calculations.
• Fabrication and control procedure (if new -not if upgraded).
• List of Operations of Control (LOC) in accordance with annex 1(if new -not if upgraded).
• Material list.
• Qualified welding procedures (if new -not if upgraded).
• Welder’s performances qualifications (if new -not if upgraded).
• Heat treatment procedure-(if new -not if upgraded).
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• Non destructive testing procedures.

Each company dealing in the order by fabrication and/or control shall implement a LOC for all operations
and interventions performed in its organization. They shall also be responsible for the implementation of
the same by their subcontractors.
6.3 Certified Material Test Report
A Certified Material Test Report (CMTR) shall be furnished listing as built drawing and calculations, the
LOC (see paragraph 6.2.), the proof test certificate, the base material certificate, the chemical check
analysis. The certificate of the heat treatment, the mechanical tests, the non-destructive examination, the
mechanical properties, the quality release note (see paragraph 6.4.) and any special test required by the
purchase order the fitting or flange individual number (see paragraph 5.6.1.) must be indicated in the CMTR
to permit the correct traceability of each piece. The manufacturer shall furnish one copy of the CMTR to
the pipe laying contractor and one original and one copy to the Client/Engineer.
6.4 Inspection Release Note- IRN
After final approval of fittings/flanges and the acceptance of the CMTR, the PIPE LAYING contractor shall
furnish to the Client/Consultant and to the manufacturer an Inspection Release Note (IRN). The
manufacturer shall deliver one copy of the IRN with the fittings/flanges and one copy shall be included in
the CMTR (see paragraph 6.3.).
6.5 Rejection
Each fitting or flange in which injurious defects are found during inspection and after delivery shall be
rejected. The manufacturer shall be notified. In this case, the fitting shall be replaced immediately. All
the costs involved, including wages and travel expenses of the pipe laying contractor/Client/ Consultant
shall be borne by the manufacturer.
7.0 CORROSION PROTECTION
The corrosion protection will be applied by the manufacturer after final inspection by the pipe laying
contractor.
The product shall meet the following criteria:
• Guarantee a corrosion protection for a storage period in open air for at least 6 months.
• Shall be easily removable by wire brushing or by grinding.
• It shall not produce toxic vapour or smoke when heated by blow torches or during welding.
TABLE 1
CHEMICAL COMPOSITION FOR FITTINGS
Maximum limit of chemical elements which may be used in material under this standard.
COMPONENT % MAXIMUM
C 0.230
Mn 1.60
Si 0.50
P 0.030
S 0.025
Nb 0.080
V 0.120
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Mo 0.250
Nt 0.0150
Alternate alloy elements may be used but they shall be discussed with the user prior to delivery of the
material. This table is not intended to represent the composition of any heat of steel, but merely to record
the maximum permissible amounts of one element. The combination of elements of any heat must
conform to the carbon equivalent, subsection 3.10.2.
For each heat the manufacturer shall analyse the following elements:
C, Mn, Si, P, S, Nb, V, Cr, Mo, Ni and Cu.
The intentional addition of elements other than those specified is not permitted unless agreed upon by the
Client.
In any case, for unintentional additions, the following limitations shall be respected:
Cr  0.15 % Mo  0.05 % Cu  0.20 %
Ni  0.30 % Co  0.01 % Al  0.07 %
The content of N total (Nt) may be up to 0.0150 % and must be guaranteed by the manufacturer. If the
manufacturer cannot give any guaranty of N content, he shall analyse this element.
The total content for Nb + V will be limited to 0.150 %.
For each reduction of 0.01 % below the maximum carbon content, an increase of 0.05 % manganese above
the specified maximum is permissible, up to maximum of 1.70%
FIG. 1
L ≤ 20mm
Fitting size 24" and smaller may be furnished with 37° ½ bevel at manufacturer's option.
Recommended bevel for wall thickness (t) at end of fitting: 20 mm or less.
FIG. 2
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Recommended bevel for wall thickness (t) at end of fitting, greater than 20 mm
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FIG. 3
Note
1. No min.
when materials joined
have equal yield
strength.
2. t2 must be limited to the
minimum
PIPE FITTING
ACCEPTABLE DESIGN FOR UNEQUAL WALL THICKNESS
FIG. 4
TRANSVERSE FACE AND ROOT BEND TEST SPECIMENS
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FIG 5
GUIDED-BEND TEST JIG DIMENSIONS
CLASS OF STEEL
Y52 and Y56 Y60 Y70
low-grade
Radius of male member R A ½A ½A ½A ½A
Radius of female member R B ½B ½B ½B ½B
Width of male member, A 4t 5t 6t 8t

Width of groove in female A + 2t + 3.2 mm A + 2t + 3.2 A + 2t + 3.2 A + 2t + 3.2
member, B mm mm mm
t = specimen thickness
The manufacturer shall use a jig based on this dimension, or a smaller dimension at his option
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FIG. 6
SPECTACLE FLANGE
Note: Bore of the Spectacle Blind (d) which is to be installed on Mainline shall match with inside diameter of
Connecting Pipeline.
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SPECIFICATION FOR SUPPORTS G11039
M001

(BPCL)


SPECIFICATION FOR SUPPORTS
P.017398/P.017399-G-11077-M008

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TABLE OF CONTENTS
1.0 SCOPE .................................................................................................................................... 1
1.1 UNITS OF MEASUREMENT ...................................................................................................... 1
1.2 DEFINITIONS AND ABBREVIATIONS........................................................................................ 1
2.0 REFERENCES .......................................................................................................................... 1
3.0 SUPPORTS MATERIAL.............................................................................................................. 2
4.0 DESIGN REQUIREMENT ........................................................................................................... 3
5.0 MATERIAL CERTIFICATION ...................................................................................................... 5
6.0 SUPPORT WELDING - NON DESTRUCTIVE EXAMINATION (NDE) ............................................... 5
7.0 PACKAGING ............................................................................................................................ 5
8.0 MANUFACTURER DOCUMENTATION ......................................................................................... 5
9.0 RESPONSIBILITY .................................................................................................................... 6
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1.0 SCOPE
The scope of this specification is to outline the minimum requirements for the design and supply of
supports for cold insulated or uninsulated piping lines in cryogenic service and utility services,
Manufacturer shall supply each support completely assembled, even if made of several.
1.1 Units of Measurement
If not otherwise indicated in this document, the unit of measurement will be in compliance with the
international standardisation (SI).
1.2 Definitions and abbreviations
The following definitions and abbreviations are used in this specification:
The Manufacturer charged with the performance of the activities

Manufacturer
required for design and execution of cryogenic pipe supports
NPS Nominal Pipe Size
HD PUF High Density Polyurethane Foam
2.0 References
This specification makes reference to the following standards and codes:

Flexible cellular polymeric materials - laboratory assessment of
BS EN ISO 3582 horizontal burning characteristics of small specimens subjected to a
small flame
UNI EN ISO 7089 Plan washer – normal series – product grade A
Thermal Performance of building materials and Product.

BS EN 14308:2009
Thermal insulation product for building equipment and industrial
installations.
Factory made rigid polyurethane foam (PUR) and polyisocyanurate
foam (PIR) products.
Thermal insulating products for building equipment and industrial
EN 13467:2001 installations. Determination of dimensions, squareness and linearity
of preformed pipe insulation
Thermal insulating product for Buiding equipment and industrial
EN 826:1996
installations. Determination of compression behaviour.
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M001
Rigid cellular plastic.

BS EN ISO 4590:1196 Determination of the volume percentage of open cells and of closed
cells.
EN ISO 1461:2009 Hot dip galvanized coatings on fabricated iron and steel articles -
Specification and test methods
Test method for compressive properties of rigid cellular plastics.
ASTM D 1621
3.0 SUPPORTS MATERIAL
1. Cryogenic supports consists of the following layers, starting from the pipe (see Pic 1):
a. HD PUF (Density from 160 to 320 kg/m3)
b. Vapour barrier
c. Cladding
d. Insulating rubber sheet
e. External hot dip galvanized carbon steel full encircled clamp and Painting where
indicated.
f. Hot dip galvanized carbon steel shoe with or without guide shoes
g. Miscellaneous: stainless steel sliding plate (if any), hot dip galvanized bolting and carbon
steel spring washers (dracomet coated)
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2. Following are some commonly used materials for support components. However except
auxiliary steel, most of the support components are procured as bought-out items which the
suppliers provide based on their standard catalogues.
a. Plates
i. Carbon Steel: ASTM A283, ASTM A515, ASTM A36
ii. Stainless Steel: ASTM A240
b. Bars, rods
i. Carbon Steel: ASTM A36
ii. Stainless Steel: ASTM A479
c. Auxiliary Steel
i. ASTM A36.
4.0 DESIGN REQUIREMENT
1. The shoe cradle shall either be moulded seamless sections or cut from bun stock may be single
or multi-layer. Each layer shall consist of two seamless half-pipe sections.
2. Circumferential joints are not permitted.
3. The high density polyurethane shall be supplied with the same thickness in a one, two or three
layer system as the adjacent line insulation (Refer to project specification for cold insulation).
4. Manufacturer shall verify that designed gaps between longitudinal joints are sufficient to
accommodate pipe tolerance and clamping forces of bearing plates.
5. The longitudinal joints of all layers shall be furnished with a clearance (gap) to accommodate
the clamping to the top HD PUF cradle to the bottom HD PUF cradle
6. Curvature of high density polyurethane segments shall conform to curvature of pipe and
external clamp with a gap smaller than 1% of the pipe NPS or 10 mm.
7. Cryogenic pipe supports are required to perform three distinct functions -
a. To support the pipe by restraining it against static and thermally generated forces.
b. To isolate the pipe from the supporting structure.
c. To maintain the thermal conditions within the pipe.
To carry out these functions effectively the support must combine strength with good thermal
properties; high density polyurethane foam offers a good combination of both allowing for
reasonably compact designs to be achieved.
8. Primary importance is protection against the ingress of moisture, which if allowed to occur will
cause a build-up of ice around the pipe and a consequent break-down of the thermal insulation.
Ultimately icing will lead to failure of the support. Therefore consideration for providing a
vapour seal, for layering of the insulation and for fit-up to line insulation must be given to
ensure the thermal integrity of the support.
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9. Where multi-layering is necessary, radial joints are staggered to avoid potential break-down of
the vapour seal.
10. Cryogenic Adhesive selected for the range of operating temperatures
11. Sealant Mastic used to prevent ingress of moisture at joints and edges.
12. Foil vapour barrier, applied to the external surface of the insulation to provide primary
resistance to moisture ingress.
13. All exposed surfaces of HD PUF where the high density skin has been removed are coated with
sealant mastic to prevent damage by moisture ingress during the installation phase.
14. Protection of the vapour barrier is provided by the use of a suitable thin gauge steel or
aluminium wrap.
15. A rubber membrane shall be provided between galvanized carbon steel cradle and protection
shield in order to avoid corrosion.
16. The Vapour Barrier to be adhesive bonded on the surface of High Density Polyurethane
Cradles shall have a water vapour permeance of maximum 0.02 Perms.
17. Vendor shall supply adhesive tape vapour barrier to seal the overlap during installation.
18. Resilient Glass Fibre Blanket to be filled for gap, max. 10 mm after clamping between upper
and lower cradles in each layer.
19. U-bolt shall be used for non- insulated carbon steel and stainless steel pipe. U-bolt dimension
and detail has been shown below. For stainless steel pipe U-PVC coated U-bolt shall be used.
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M001
5.0 MATERIAL CERTIFICATION
The support manufacturer shall issue the documentation necessary to confirm that the supports conform to
the requirements of applicable codes & standards.
Certification shall be based on tests carried out on product material or on of the material test samples, in
accordance with the material specification and the purchase order requirement. Tests shall be carried out
by a testing centre independent from the Manufacturer production department.
6.0 SUPPORT WELDING - Non Destructive Examination (NDE)
For the support welding examination, see table below:

Controls on the
Extending Acceptance
Method joints after Standards method
Control criterion
repair
VT
100% PN EN ISO 5817
(Visual 100% PN-EN ISO17637
Level C
Test)
MT
PN-EN ISO 23278
(Magnetic 10% 100% PN-EN ISO 17638
Level 2
Test)
7.0 PACKAGING
The packaging type and material shall be adequate to maintain all supports dry, clean and free from
moisture, dirt and loose foreign materials.
During packaging, the Manufacturer shall take all possible measures to ensure that the assembled supports
arrive at destination in good conditions and shall enclose all the instructions for a correct installation.
The packaging material shall show the following information: manufacture, material, type, production
date, Batch number and quantity.
All items shall be handled and stored in such a manner that they are always protected against damages and
ingress of moisture.
8.0 MANUFACTURER DOCUMENTATION
Together with his quotation Manufacturer will supply the following information:
1. Cross sectional drawing of cryogenic supports showing all essential details and major
dimensions, including the indication of components materials.
2. Procedures for manufacturing, tests, inspections and welding.
3. Colour coding
4. Field installation procedure with the torque requirements of the clamping force for each pipe
size.
5. Package procedure.
Any exception to the requirements of this specification shall be listed and described.
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9.0 RESPONSIBILITY
The Manufacturer shall assume full responsibility for the content of drawings and documentation
supplied.
The responsibility for examination and testing rests with the Manufacturer. However, Purchaser reserves
the right to inspect the cryogenic supports at any time during fabrication to assure that materials and
workmanship are in accordance with this specification.
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P.017398/ P.017399
PIPING MATERIAL
G11077
SPECIFICATION
M009

(BPCL)


PIPING MATERIAL SPECIFICATION
P.017398/P.017399-G-11077-M009

Rev. A LNG Unloading, Storage & Dispensing Stations in the State of Tamil Nadu & Kerala
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P.017398/ P.017399
PIPING MATERIAL
G11077
SPECIFICATION
M009
TABLE OF CONTENTS
1.0 GENERAL .................................................................................................................................. 1
2.0 ABBREVIATIONS / ACRONYMS ................................................................................................... 1
3.0 PIPING MATERIAL CLASS DESIGNATION .................................................................................... 4
3.1 Class/ Rating Table-2 ................................................................................................................ 4
3.2 MATERIAL TABLE - 3 ................................................................................................................. 5
3.3 EXAMPLE PMS DESIGNATION .................................................................................................... 6
4.0 PIPING & VALVE MATERIAL SPECIFICATION ............................................................................... 7
1. PMC: 1C1 (PIPING) ................................................................................................................... 7
2. PMC: 1C8 (PIPING) ................................................................................................................. 10
3. PMC: 1S1 (PIPING) ................................................................................................................. 13
4. PMC: 1S5 (PIPING) ................................................................................................................. 16
5. PMC: 3S1 (PIPING) ................................................................................................................. 19
4.0 GENERAL NOTES ..................................................................................................................... 22
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P.017398/ P.017399
PIPING MATERIAL
G11077
SPECIFICATION
M009
1.0 GENERAL
When the piping is connected to equipment, this specification shall be applied to the extent indicated
below;
Companion flanges, gaskets, bolts and nuts at the equipment nozzle.
First block valve with companion flanges, gaskets, bolts and nuts in the instrument connection line.
Companion flanges, gaskets, bolts and nuts for relief valves.
Companion flanges, gaskets, bolts and nuts at the matching point between the piping furnished as part of
equipment by supplier and that provided by purchaser.
Welded connections at matching point between the piping furnished as part of equipment by supplier and
that provided by purchaser.
Note: “First block valve” in instrument connecting line as used herein shall mean the nearest valve to a
line to which the instrument is connected.
2.0 ABBREVIATIONS / ACRONYMS
Abbreviation/ Acronyms Expanded Form
AG Above Ground
AB Adhesive Bonded
BB Bolted Bonnet
BC Bolted Cover
BE Bevel End
BF Butt Fusion Joint
BW Butt Welded
BS Bell and Spigot Joint
CAFF Compressed Asbestos Free Fiber
CJ Compression Joint
CP Coupler Joint
CS Carbon Steel
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PIPING MATERIAL
G11077
SPECIFICATION
M009
EFW Electric Fusion Welded
ERW Electric Resistance Welded
FB Full Bore
FF Flat Face
FL Flanged Joint
FT Flanged Tee
FTE Female Threaded End
FLGD Flanged
GALV Galvanized
GRP Glass- Reinforced Plastic
DN Nominal diameter in mm
LNG Liquefied Natural Gas
MI Malleable Iron
MJ Mechanical Joint
MTE Male Threaded End
NB Nominal Bore
NPT National Pipe Threads
NPS Nominal pipe size in inches
N/A Not Applicable
OS&Y Outside Screw and Yoke
PE Plain End
PN Nominal Pressure
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PIPING MATERIAL
G11077
SPECIFICATION
M009
RF Raised Face
RFT Reducing Tee Flanged
RJ Ring Joint
RT Reducing Tee (BE)
RTJ Ring Type Joint
SCH Schedule
SCRD Screwed
SMLS Seamless
SO Slip On
S-OL Sockolet
SWRT Socket Welded Reducing Tee
SS Stainless Steel
STD Standard
S-IN Stub In
S-ON Stub On
SWT Socket Welded Equal Tee
SW Socket Weld
SWE Socket Weld End
SWING Swing Type
SWG Spiral Wound Gasket
T Equal Tee (BE)
THRD Threaded Joint
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PIPING MATERIAL
G11077
SPECIFICATION
M009
THRD-RT Threaded Reducing Tee
THRDT Threaded Equal Tee
T-OL Threadolet
UG Under Ground
W-OL Weldolet
WB Welded Bonnet
WC Welded Cover
WJ Butt and Wrap joints
WN Weld Neck
CS-GALV Carbon Steel with Hot Dip Galvanized
XS Extra Strong
XXS Double Extra Strong
3.0 PIPING MATERIAL CLASS DESIGNATION
The Piping Material Class (PMC) will be indicated by a three (3) alpha-numeric code as indicated below.
1 2
1
Class/ Rating code from Table 2.
2
Material Code from Table 3
3.1 Class/ Rating Table-2
CODE RATING
1 150 # (ASME B16.5)
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PIPING MATERIAL
G11077
SPECIFICATION
M009
CODE RATING
3 300 # (ASME B16.5)
6 600 # (ASME B16.5)
9 900 # (ASME B16.5)
25 2500 # (ASME B16.5)
3.2 Material Table - 3
CODE MATERIAL TYPE
C1 Carbon Steel A 106 Gr. B
C2 Carbon Steel A 106 Gr. C
C3 Carbon Steel A 106 Gr. B Galvanized
C4 Low Temperature Carbon Steel A333 Gr.6
C5 Carbon Steel A 53 Gr. B Galvanized
C6 Carbon Steel A 106 Gr. B (Killed)
C7 Carbon Steel A 53 Gr. B Rubber Lined
C8 Carbon Steel IS 1239 / IS 3589
C9 Carbon Steel IS 1239 / IS 3589 Galv.
S1 Dual Certified -Stainless Steel 304/304L
S2 Stainless Steel 304L
S3 Stainless Steel 316
S4 Stainless Steel 316L
S5 Stainless Steel 304
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PIPING MATERIAL
G11077
SPECIFICATION
M009
3.3 Example PMS Designation
Class 300
Material Carbon Steel - ASTM A 106, Gr. B
PMC 3C1
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PIPING MATERIAL SPECIFICATION G11077
M009
4.0 PIPING & VALVE MATERIAL SPECIFICATION
1. PMC: 1C1 (Piping)
ASME CLASS– Class 150 Fluid: Low Pressure Natural Gas/ Nitrogen Gas
50
Corrosion Allowance – 1.6 mm Temperature (0C) -29 to 38 100
Design Limits
150
Principal Piping Material: Carbon steel, A 106- B Pressure (barg) 19.6 19.2 17.7
200
Min. Size Max. Size Rating, Schedule, 250
Item Dimensional Standard Material Specification General Description300 Remarks
NB(NPS) NB(NPS) or Gauge
325
15 (1/2) 40 (1.5) SCH 80 Carbon Steel; Pipe; Seamless; PE 350
PIPE 50 (2) 50 (2) SCH 80 ASME B 36.10M ASTM A 106 Gr. B Carbon Steel; Pipe; Seamless; BE 375
65 (2.5) 100(4) SCH 40 Carbon Steel; Pipe; Seamless; BE 400
15 (1/2) 40 (1.5) Class 3000 ASME B 16.11 ASTM A 105 Carbon Steel; Fittings; Forged; SW
FITTING 50 (2) 50 (2) SCH 80 ASME B 16.9 ASTM A 234 Gr. WPB Carbon Steel; Fittings; Wrought; BW
65 (2.5) 100(4) SCH 40 ASME B 16.9 ASTM A 234 Gr. WPB Carbon Steel; Fittings; Wrought; BW
SOCKOLET 15 (1/2) 40 (1.5) Class 3000 ASTM A 105 Carbon Steel; Sockolet; Forged; SW
MSS SP-97
Threadolet shall only be

THREADOLET 15 (1/2) 40 (1.5) Class 3000 ASTM A 105 Carbon Steel; Threadolet; Forged; THRD
MSS SP-97 used for Thermowell
50 (2) 50 (2) SCH 80

WELDOLET MSS SP-97 ASTM A 105 Carbon Steel; Weldolet; Forged; BW
65 (2.5) 100(4) SCH 40
15 (1/2) 40 (1.5) Carbon Steel; Flange; Forged; SW-RF

FLANGE Class 150 ASME B16.5 ASTM A 105
50 (2) 100(4) Carbon Steel; Flange; Forged; WN-RF
25 (1) 40 (1.5) Carbon Steel; Orifice Flange; Forged; WN-RF

ORIFICE FLANGE Class 300 ASME B 16.36 ASTM A 105
50 (2) 100(4) Carbon Steel; Orifice Flange; Forged; WN-RF
15 (1/2) 40 (1.5) Carbon Steel; Fig.8 Flange; Forged; FLGD

SPECTACLE & BLIND Class 150 ASME B16.48 ASTM A 105
50 (2) 100(4) Carbon Steel; Spacer & Blind; Forged; FLGD
4.5 mm Thick Spiral Wound 316 with C.S. outer centering ring and
GASKET 15 (1/2) 100(4) Class 150 ASME B16.20 -
316 S.S. inner ring and graphite filler
4.5 mm Thick Spiral Wound 316 with C.S. outer centering ring and
GASKET (ORIFICE) 25 (1) 100(4) Class 300 ASME B16.20 -
316 S.S. inner ring and graphite filler
STUD BOLT All - ASME B16.5 /ASME B 18.2.1 ASTM A 193 Gr B7 (Galv.) Threads as per ASME B 1.1
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M009
NUT All - ASME B 18.2.2 ASTM A 194 Gr 2H (Galv.) Threads as per ASME B 1.1
PMC: 1C1 (Valves)
Pressure Class Standard: ASME B16.34
Dimensional Standard: ASME B16.10
Min. Size Max. Size Body / Bonnet

Item End Type Rating Design Standard Trim material
NB (NPS) NB (NPS) Material Remarks
Stem Disk/Plug/Ball Seat
Stem Type Seat / Back- Seat
Material Material Material
BS EN ISO 15761/ Integral/ Replaceable

15 (1/2) 40 (1.5) SW Class 800 ASTM A 105
BS 5352
GLOBE 13 % Cr /
OS & Y 13% Cr Welded / Integral/ Stellite/ PTFE
50 (2) 100(4) FLGD Class 150 ASTM A 216 Gr WCB SS304L
BS 1873 Replaceable
BS EN ISO 15761/BS Lift Check Integral/ Replaceable

15 (1/2) 40 (1.5) SW Class 800 ASTM A 105
5352
CHECK 13 % Cr /
Swing Check / 13% Cr Welded / Integral/ Stellite/ PTFE
50 (2) 100(4) FLGD Class 150 ASTM A 216 Gr WCB SS304L
BS 1868 Dual plate Replaceable
BS EN ISO 17292/
15 (1/2) 40 (1.5) SW Class 800 ASTM A 105 -
BS 5351 13 % Cr /
BALL 13% Cr Replaceable
SS304L Stellite
50 (2) 100(4) FLGD Class 150 ASTM A 216 Gr WCB -
BS 5351
15 (1/2) 40 (1.5) SW Class 800 ASTM A 105 -

PLUG 13 % Cr /
BS 5353 13% Cr Replaceable PTFE
SS304L
50 (2) 100(4) FLGD Class 150 ASTM A 216 Gr WCB -
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P.017398/ P.017399
M009
BRANCH TABLE -1C1
15 SWT
20 SWRT SWT
25 SWRT SWRT SWT
40 SWRT SWRT SWRT SWT

HEADER
50 S-OL SWRT SWRT SWRT T
65 S-OL S-OL SWRT SWRT RT T
80 S-OL S-OL S-OL SWRT RT RT T
100 S-OL S-OL S-OL SWRT RT RT RT T
15 20 25 40 50 65 80 100
BRANCH
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M009
2. PMC: 1C8 (Piping)
ASME CLASS– Class 150 Fluid: Fire Fighting

50
Corrosion Allowance – 1.6 mm Temperature (0C) -29 to 38 100
Design Limits
150
Principal Piping Material: Mild Steel, IS 1239 / IS 3589 Pressure (bar) 19.6 19.2 17.7
200
Min. Size Max. Size Rating, Sch. 250
Item Dimensional Standard Material Specification General
300 Description Remarks
325
350
15 (1/2) 40 (1.5) Heavy IS 1239 IS 1239 Part-1 Mild Steel; Pipe; ERW;375
PE Thickness and OD of
PIPE 50 (2) 150 (6) Heavy IS 1239 IS 1239 Part-1 Mild Steel; Pipe; ERW;400
BE 200NB Pipe shall be as per
200 (8) 200 (8) Thk. 6.35 ASME 36.10 IS 3589, Gr. 410 Mild Steel; Pipe; ERW/EFW; BE ASME 36.10.
15 (1/2) 40 (1.5) Class 3000 ASME B 16.11 ASTM A 105 Carbon Steel; Fittings; Forged; SWE
** Same as pipe
FITTING 50 (2) 150 (6) ** ASME B 16.9 ASTM A 234 Gr. WPB-W Carbon Steel; Fittings; Wrought; BE
schedule/rating
200 (8) 200 (8) SCH 20 ASME B 16.9 ASTM A 234 Gr. WPB-W Carbon Steel; Fittings; Wrought; BE
SOCKOLET 15 (1/2) 40 (1.5) Class 3000 MSS SP-97 ASTM A 105 Carbon Steel; Sockolet; Forged; SW
Threadolet shall only be

THREADOLET 15 (1/2) 40 (1.5) Class 3000 MSS SP-97 ASTM A 105 Carbon Steel; Threadolet; Forged; THRD
used for Thermowell
WELDOLET 50 (2) 200 (8) SCH STD MSS SP-97 ASTM A 105 Carbon Steel; Weldolet; Forged; BW
15 (1/2) 50 (2) Class 150 Carbon Steel; Flange; Forged; SW-RF

FLANGE ASME B16.5 ASTM A 105
65 (2.5) 200 (8) Class 150 Carbon Steel; Flange; Forged; SO-RF
25 (1) 50 (2) Class 300 Carbon Steel; Orifice Flange; Forged; SW-RF
ORIFICE FLANGE ASME B 16.36 ASTM A 105
65 (2.5) 200 (8) Class 300 Carbon Steel; Orifice Flange; Forged; WN-RF
GASKET 15 (1/2) 200 (8) Class 150 ASME B 16.20 - 1.5 mm Thick graphite reinforced with Tang stainless steel
GASKET (ORIFICE) 25 (1) 200 (8) Class 300 ASME B 16.20 - 1.5 mm Thick graphite reinforced with Tang stainless steel
BOLT All - ASME B16.5 /ASME B 18.2.1 ASTM A 193 Gr B7 (Galv.) Threads as per ASME B 1.1
NUT All - ASME B 18.2.2 ASTM A 194 Gr 2H (Galv.) Threads as per ASME B 1.1
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P.017398/ P.017399
M009
PMC: 1C8 (Valves)
Trim Material
Item End Type Rating Design Standard
NB (NPS) NB (NPS) Material Stem Disk/Plug Seat Remarks
15 (1/2) 40 (1.5) SW Class 800 BS 5352 ASTM A 105 Replaceable

GLOBE OS & Y 13% Cr 13 % Cr / SS304L PTFE
50 (2) 200 (8) FLGD Class 150 BS 1873 ASTM A 216 Gr WCB Replaceable
15 (1/2) 40 (1.5) SW Class 800 API 602 ASTM A 105 Replaceable

GATE OS & Y 13% Cr 13 % Cr / SS304L PTFE
50 (2) 200 (8) FLGD Class 150 API 600 ASTM A 216 Gr WCB Replaceable
15 (1/2) 40 (1.5) SW Class 800 BS 5352 ASTM A 105 Lift Check Replaceable
CHECK 13% Cr 13 % Cr / SS304L PTFE
50 (2) 200 (8) FLGD Class 150 BS 1868 ASTM A 216 Gr WCB Swing Check Replaceable
BS 5351
15 (1/2) 40 (1.5) SW Class 800 ASTM A 105 - Replaceable
BALL 13% Cr 13 % Cr / SS304L PTFE
50 (2) 200 (8) FLGD Class 150 ASTM A 216 Gr WCB - Replaceable
BS 5351
Wafer
BUTTERFLY 65 (2.5) 200 (8) Class 150 API 609/BS5155 ASTM A 216 Gr WCB - 13% Cr 13 % Cr / SS304L Replaceable TEFLON
Type
Page 160 of 921
P.017398/ P.017399
M009
BRANCH TABLE -1C8
15 SWT
20 SWRT SWT
25 SWRT SWRT SWT
50 S-OL SWRT SWRT SWRT SWT

HEADER
80 S-OL S-OL S-OL SWRT RT RT T
100 S-OL S-OL S-OL SWRT RT RT RT T
150 S-OL S-OL S-OL S-OL W-OL RT RT RT T
200 S-OL S-OL S-OL S-OL W-OL W-OL W-OL RT RT T
15 20 25 40 50 65 80 100 150 200
BRANCH
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M009
3. PMC: 1S1 (Piping)
ASME CLASS– Class 150 Fluid: LNG/LNG Vapor Return
Corrosion Allowance – 0.00 mm Temperature (0C) (-)26 to 38 50 100

Design Limits
Principal Piping Material: Dual Certified -Stainless Steel,
Pressure (bar) 15.9 15.3 13.3
A312 GR. TP304/304L
Min. Size Max. Size Rating, Schedule,
Item Dimensional Standard Material Specification General Description Remarks
15 (1/2) 20 (3/4) SCH 80S Stainless Steel; Pipe; Seamless; BE

PIPE 25 (1) 50 (2) SCH 40S ASME B 36.19 ASTM A312 GR.TP304/304L Stainless Steel; Pipe; Seamless; BE
65 (2.5) 100 (4) SCH 10S Stainless Steel; Pipe; Seamless; BE
15 (1/2) 20 (3/4) SCH 80S ASME B 16.9 ASTM A182 GR. F304/304L Stainless Steel; Fittings; Forged; BW
FITTING 25 (1) 50 (2) SCH 40S ASME B 16.9 ASTM A403 GR. P304/304L Stainless Steel; Fittings; Wrought; BW
65 (2.5) 100 (4) SCH 10S ASME B 16.9 ASTM A403 GR. P304/304L Stainless Steel; Fittings; Wrought; BW
15 (1/2) 40 (1.5) SCH 80S

WELDOLET 50 (2) 50 (2) SCH 40S MSS SP-97 ASTM A182 GR. F304/304L Stainless Steel; Weldolet; Forged; BW Refer Branch Table
65 (2.5) 100 (4) SCH 10S
15 (1/2) 40 (1.5) Stainless Steel; Flange; Forged; WN-RF

FLANGE Class 150 ASME B16.5 ASTM A182 GR. F304/304L
50 (2) 100 (4) Stainless Steel; Flange; Forged; WN-RF
25 (1) 40 (1.5) Stainless Steel; Orifice Flange; Forged; WN-RF

ORIFICE FLANGE Class 300 ASME B 16.36 ASTM A182 GR. F304/304L
50 (2) 100 (4) Stainless Steel; Orifice Flange; Forged; WN-RF
SPECTACLE & 15 (1/2) 40 (1.5) Stainless Steel; Fig.8 Flange; Forged; FLGD
Class 150 ASME B16.48 ASTM A182 GR. F304/304L
BLIND 50 (2) 100 (4) Stainless Steel; Spacer & Blind; Forged; FLGD
4.5 mm Thick Spiral Wound 316 with S.S. outer centering ring and 316
S.S. inner ring and graphite filler
GASKET 4.5 mm Thick Spiral Wound 316 with S.S. outer centering ring and 316
25 (1) 100(4) Class 300 ASME B16.20 -
(ORIFICE) S.S. inner ring and graphite filler
STUD BOLT All - ASME B16.5 /ASME B 18.2.1 ASTM A320 B8M CL.2 Threads as per ASME B1.1
NUT -
All ASME B 18.2.2 ASTM A194 Gr. 8M Threads as per ASME B1.1
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M009
PMC: 1S1 (Valves)
Trim material
Item End Type Rating Design Standard
NB (NPS) NB (NPS) Material Stem Disk/Plug/Ball Seat Remarks

15 (1/2) 40 (1.5) Class 800 ASTM A182 GR. F304
BS 5352 13% Cr
GLOBE BW 13 % Cr /
OS & Y NO Welded / Integral/ Stellite/ PTFE
50 (2) 100 (4) Class 150 ASTM A351 GR CF3 SS304
BS 1873/API 623 CASTING Replaceable
BS EN ISO 15761
Lift Check Integral/ Replaceable
15 (1/2) 40 (1.5) Class 800 BS 5352 ASTM A182 GR. F304
CHECK BW
Swing Check / 13% Cr 13 % Cr / SS304 Welded / Integral/ Stellite/ PTFE
50 (2) 100 (4) Class 150 BS 1868/ ASTM A351 GR CF3
Dual plate Replaceable
API 594
BS EN ISO 17292/
15 (1/2) 40 (1.5) Class 800 ASTM A182 GR. F304 -
BS 5351
BALL BW 13% Cr 13 % Cr / SS304 RPTFE -Replaceable
Stellite
50 (2) 100 (4) Class 150 ASTM A351 GR CF3 -
API 608
15 (1/2) 40 (1.5) Class 800 BS 5352 ASTM A182 GR. F304 - 13% Cr
GATE BW NO 13 % Cr / SS304 Replaceable PTFE
50 (2) 100 (4) Class 150 API 600 ASTM A351 GR CF3 - CASTING
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M009
BRANCH TABLE-1S1
15 T
20 RT T
25 RT RT T
40 RT RT RT T
HEADER
50 W-OL W-OL RT RT T
65 W-OL W-OL RT RT RT T
80 W-OL W-OL W-OL RT RT RT T
100 W-OL W-OL W-OL RT RT RT RT T
15 20 25 40 50 65 80 100
BRANCH
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M009
ASME CLASS– Class 150 Fluid: Instrument Air
Corrosion Allowance – 0.00 mm Temperature (0C) (-)29 to 38 50 100

Design Limits
Principal Piping Material: Stainless Steel, A312 GR. TP304 Pressure (bar) 15.9 15.3 13.3

15 (1/2) 20 (3/4) SCH 40S Stainless Steel; Pipe; Seamless; PE

PIPE 25 (1) 40 (1.5) SCH 40S ASME B 36.19 ASTM A312 GR.TP304 Stainless Steel; Pipe; Seamless; PE
50 (2) 100 (4) SCH 10S Stainless Steel; Pipe; Seamless; BE
15 (1/2) 20 (3/4) Class 3000 ASME B 16.11 ASTM A182 GR. F304 Stainless Steel; Fittings; Forged; SW
FITTING 25 (1) 40 (1.5) Class 3000 ASME B 16.11 ASTM A403 GR. P304 Stainless Steel; Fittings; Wrought; SW
50 (2) 100 (4) SCH 10S ASME B 16.9 ASTM A403 GR. P304 Stainless Steel; Fittings; Wrought; BW
SOCKOLET 15 (1/2) 40 (1.5) Class 3000 MSS SP-97 ASTM A182 GR. F304 Stainless Steel; Sockolet; Forged; SW
WELDOLET 50 (2) 100 (4) SCH 10S MSS SP-97 ASTM A182 GR. F304 Stainless Steel; Weldolet; Forged; BW Refer Branch Table
15 (1/2) 40 (1.5) Stainless Steel; Flange; Forged; SW-RF

FLANGE Class 150 ASME B16.5 ASTM A182 GR. F304
25 (1) 40 (1.5) Stainless Steel; Orifice Flange; Forged; SW-RF

ORIFICE FLANGE Class 300 ASME B 16.36 ASTM A182 GR. F304
Class 150 ASME B16.48 ASTM A182 GR. F304
25 (1) 100(4) Class 300 ASME B16.20 -
-
NUT All ASME B 18.2.2 ASTM A194 Gr. 8M Threads as per ASME B1.1
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PMC: 1S5 (Valves)
Trim material
Min. Size Max. Size Rating Body / Bonnet
Item End Type Design Standard
SW BS EN ISO 15761/ Integral/ Replaceable

15 (1/2) 40 (1.5) Class 800 ASTM A182 GR. F304
BS 5352 13% Cr
GLOBE 13 % Cr /
BW OS & Y NO Welded / Integral/ Stellite/ PTFE
BS EN ISO 15761
15 (1/2) 40 (1.5) SW Class 800 BS 5352 ASTM A182 GR. F304
CHECK
50 (2) 100 (4) BW Class 150 BS 1868/ ASTM A351 GR CF3
API 594
BS EN ISO 17292/
15 (1/2) 40 (1.5) SW Class 800 ASTM A182 GR. F304 -
BS 5351
BALL 13% Cr 13 % Cr / SS304 RPTFE -Replaceable
Stellite
50 (2) 100 (4) BW Class 150 ASTM A351 GR CF3 -
API 608
15 (1/2) 40 (1.5) SW Class 800 BS 5352 ASTM A182 GR. F304 - 13% Cr
GATE NO 13 % Cr / SS304 Replaceable PTFE
50 (2) 100 (4) BW Class 150 API 600 ASTM A351 GR CF3 - CASTING
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M009
BRANCH TABLE-1S5
15 SWT
20 SWRT SWT
25 SWRT SWRT SWST

HEADER
50 S-OL S-OL SWRT SWRT T
80 S-OL S-OL W-OL SWRT RT RT T
100 S-OL S-OL W-OL SWRT RT RT RT T
15 20 25 40 50 65 80 100
BRANCH
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ASME CLASS– Class 300 Fluid: LNG
Corrosion Allowance – 0.00 mm Temperature (0C) (-) 29 to 38 50 100

Design Limits
Principal Piping Material: Dual Certified -Stainless Steel,
Pressure (bar) 41.4 40.0 34.8
A312 GR. TP304/304L

15 (1/2) 20 (3/4) SCH 80S Stainless Steel; Pipe; Seamless; BE

PIPE 25 (1) 50 (2) SCH 40S ASME B 36.19 ASTM A312 GR.TP304/304L Stainless Steel; Pipe; Seamless; BE
65 (2.5) 100 (4) SCH 10S Stainless Steel; Pipe; Seamless; BE
15 (1/2) 20 (3/4) SCH 80S ASME B 16.9 ASTM A182 GR. F304/304L Stainless Steel; Fittings; Forged; BW
FITTING 25 (1) 50 (2) SCH 40S ASME B 16.9 ASTM A403 GR. P304/304L Stainless Steel; Fittings; Wrought; BW
65 (2.5) 100 (4) SCH 10S ASME B 16.9 ASTM A403 GR. P304/304L Stainless Steel; Fittings; Wrought; BW
15 (1/2) 40 (1.5) SCH 80S
WELDOLET 50 (2) 50 (2) SCH 40S MSS SP-97 ASTM A182 GR. F304 Stainless Steel; Weldolet; Forged; BW Refer Branch Table
65 (2.5) 100 (4) SCH 10S
15 (1/2) 40 (1.5) Stainless Steel; Flange; Forged; WN-RF

FLANGE Class 300 ASME B16.5 ASTM A182 GR. F304
25 (1) 40 (1.5) Stainless Steel; Orifice Flange; Forged; WN-RF

ORIFICE FLANGE Class 300 ASME B 16.36 ASTM A182 GR. F304
Class 300 ASME B16.48 ASTM A182 GR. F304
25 (1) 100(4) Class 300 ASME B16.20 -
NUT
All - ASME B 18.2.2 ASTM A194 Gr. 8M Threads as per ASME B1.1
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PMC: 3S1 (Valves)
Trim material
Min. Size Max. Size Rating Body / Bonnet
Item End Type Design Standard

15 (1/2) 40 (1.5) Class 800 ASTM A182 GR. F304
BS 5352 13% Cr
GLOBE BW 13 % Cr /
OS & Y NO Welded / Integral/ Stellite/ PTFE
BS EN ISO 15761
15 (1/2) 40 (1.5) Class 800 BS 5352 ASTM A182 GR. F304
CHECK BW
50 (2) 100 (4) Class 300 BS 1868/ ASTM A351 GR CF3
API 594
BS EN ISO 17292/
15 (1/2) 40 (1.5) Class 800 ASTM A182 GR. F304 -
BS 5351
BALL BW 13% Cr 13 % Cr / SS304 RPTFE -Replaceable
Stellite
50 (2) 100 (4) Class 300 ASTM A351 GR CF3 -
API 608
15 (1/2) 40 (1.5) Class 800 BS 5352 ASTM A182 GR. F304 - 13% Cr
GATE BW NO 13 % Cr / SS304 Replaceable PTFE
50 (2) 100 (4) Class 300 API 600 ASTM A351 GR CF3 - CASTING
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BRANCH TABLE-3S1
15 T
20 RT T
25 RT RT T
40 RT RT RT T
HEADER
50 W-OL W-OL RT RT T
65 W-OL W-OL RT RT RT T
80 W-OL W-OL W-OL RT RT RT T
100 W-OL W-OL W-OL RT RT RT RT T
15 20 25 40 50 65 80 100
BRANCH
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P.017398/
P.017399
PIPING MATERIAL SPECIFICATION
G11077
M009
4.0 GENERAL NOTES
1. The size of all pipes is identified by the nominal pipe size (NPS) as indicated in ASME B36.10M or
ASME B 36.19M.
2. All butt joints shall be complete penetration welds.
3. Flanged joints shall only be used if specifically designated on the Design Drawings.
4. Pipe flanges mating with flanged components such as fittings, piping specialties, valves, and
equipment shall be matched in outside diameter and drilling.
5. Only asbestos free materials suitable for the operating conditions shall be utilized for pipe flange
gaskets.
6. Short radius elbow and return fittings shall not be used unless specifically indicated on the Design
Drawings.
7. The size range indicated is for the outlet size of the branch outlet fitting. Refer to the
manufacturer's catalog for the range of run sizes that correspond with a given outlet size.
8. Stud bolt dimensions for flange classes and flanged fittings shall be in accordance with ASME
B16.5
9. As required by ASME B16.5, purchaser shall specify the flange bore. The flange bore shall match
the bore of the adjoining pipe.
10. As required by ASME B16.36, purchaser shall specify the orifice flange bore. The orifice flange
bore shall match the bore of the adjoining pipe.
11. Orifice flange pressure sensing pipe connections shall be NPS 1/2 - socket welding type per ASME
B16.11 unless otherwise indicated in the Project Specification.
12. Stud bolt dimensions for all orifice flange classes shall be in accordance with ASME 16.36
13. Spiral-wound metallic gasket with centering ring; dimensions per ASME B16.20, Gasket materials
of construction (metal strip, asbestos-free filler, and metal ring) shall be suitable for the service
conditions or as indicated in the Project Specification.
14. Branch outlet fittings for outlet sizes NPS 2 and larger shall be Bonney Forge Weldolet or
approved equal.
15. Face finish for the flanges shall be between 125 - 250 AARH
16. Pipe threads shall as per ASME B 1.20.1
17. Nominal outside diameter of tubing shall be their equivalent sizes is in inches.
18. For buried piping (U/G) suitable polyethylene coating & wrapping shall be done on pipe and
fittings.
19. All quality related points are covered in respective QAP.
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SPECIFICATION FOR QUALITY
G11077
ASSURANCE/QUALITY CONTROL
M010

(BPCL)


TURNKEY BASIS
SPECFICATION
FOR
QUALITY ASSURANCE/QUALITY CONTROL
P.017398/P.017399-G-11077-M010
0 24.05.2021 Issued for Tender PSH MKR KNS
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G11077
M010
TABLE OF CONTENTS
1.0 INTRODUCTION .............................................................................................................................. 1
2.0 SCOPE ............................................................................................................................................. 1
3.0 DEFINITIONS .................................................................................................................................. 1
4.0 CERTIFICATION - QUALITY ASSURANCE & QUALITY CONTROL .......................................................... 2
4.1 BASIC PRINCIPLES ........................................................................................................................... 2
4.2 QUALITY PLAN ................................................................................................................................ 2
4.3 CERTIFICATION SPECIFIC TO GAS RELATED FACILITIES ................................................................... 2
4.4 TESTING ......................................................................................................................................... 4
4.5 NON TESTED TIE-INS WELDS ........................................................................................................... 4
5.0 INSTRUCTIONS ............................................................................................................................... 5
5.1 THIRD PARTY INSPECTION AGENCY (TPIA) APPOINTED BY CONTRACTOR. ........................................ 5
5.2 QUALITY ASSURANCE PLAN ............................................................................................................. 5
5.3 INSPECTION & TEST PLAN ............................................................................................................... 5
5.4 DRAWING SCHEDULE....................................................................................................................... 5
5.5 PROGRESS REPORT AND SCHEDULE ................................................................................................. 5
5.6 WAIVER & DEVIATION ..................................................................................................................... 5
5.7 PROCUREMENT OF BOUGHT OUT MATERIALS ................................................................................... 6
5.8 CALIBRATION RECORDS .................................................................................................................. 6
5.9 INSPECTION TEST STATUS .............................................................................................................. 6
5.10 QUALITY RECORDS .......................................................................................................................... 6
5.11 NON-CONFORMITY REPORTS (NCR) ................................................................................................. 6
5.12 IDENTIFICATION AND TRACEABILITY ............................................................................................... 6
5.13 CONTRACTOR DOCUMENTS FOR OWNER/OWNER'S REPRESENTATIVE’S REVIEW/ RECORDS .............. 7
6.0 ATTACHMENT (WAIVER / DEVIATION PERMIT) ................................................................................. 8
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1.0 INTRODUCTION
This document covers and describes the Project Quality Data Requirements and Contractor’s other
obligations towards Quality Assurance which shall form a part of every Material Requisition (MR)/
Technical Specifications released by Contractor or documents submitted for approval, so as to ensure that all
purchased products/ services consistently conform to planned Quality and project’s stated and implied needs
are met to Owner / Owner’s Representative total satisfaction.
Tractebel Engineering Pvt. Ltd. (TEPL) has been appointed as Project Management Consultant (hereinafter
referred as PMC), by BPCL for providing Engineering, Procurement and Construction (EPC) services for a
mentioned project.
The TPIA is engaged for a defined motive to ensure that all quality related requirements during
manufacturing are followed as per Owner/Owner’s representative specifications and other approved
documents. The extent of TPIA involvement as indicated in this document shall be binding on the contractor
and no activity shall be accepted if not approved/certified by TPIA.
2.0 SCOPE
The requirements of this document are applicable to all Vendors/Contractors for supply of Packages,
Equipments and Materials, which are purchased on behalf or directly by Contractor.
This document also indicates general quality control requirements for various activities pertaining to Gas
Pipeline Projects.
3.0 DEFINITIONS
1. “Contractor” shall mean EPC Contractor appointed by Owner for execution of the project.
2. “Vendor” shall mean the person(s), firm, and company, organisation from which Contractor procures
products/ services.
3. “Sub-Contractor”, “Sub-Vendor”, “Supplier”, “Seller”, “Agents” are considered synonymous to
“Vendor”.
4. ‘’Third Party Inspection Agency (TPIA)” means the agency other than the in-house quality control
department appointed by the Vendor from the list of such approved agencies as indicated in the tender
document.
5. Certification shall have the meaning as provided by EN 10204 Code and summarised as follow. “The
manufacturer’s authorised inspection representative independent of the manufacturing department.”
6. Certification shall have the meaning as provided by EN 10204 Code and summarised as follow. “The
manufacturer’s authorized inspection representative independent of the manufacturing department and
either the purchaser’s authorised inspection representative or the inspector designated by the official
regulations.”
7. MR means Material Requisition.
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4.0 CERTIFICATION - QUALITY ASSURANCE & QUALITY CONTROL
All material and equipment to be permanently incorporated in the project shall be duly Quality Controlled -
Inspected and certified for full compliance with the "Laws - Rules - Codes & Standards" prevailing for the
project and as per approved quality assurance plan.
Quality Control, Inspection and Certification shall be as follow:
4.1 Basic Principles
Equipment Vendors must be duly approved, qualified, and certified for their ability to supply basic materials
and to fabricate the equipment according to the Codes and Specifications.
Sub-Contractors must be duly qualified and certified for their ability to assemble, erect, install, test
commission, proceed to Civil Works, etc. as necessary to implement the project
All basic materials and equipment shall be the subject of 3.1. Certification before leaving the mills. The same
applies to shop prefabrication or field construction/erection.
In addition, some activities may, as mandatory by Law or at the discretion of Owner/Owner’s representative,
be audited and/or subjected to 3.2 Certification.
4.2 Quality Plan
Vendor/Contractor shall, on due time, establish and submit to approval of Owner/Owner’s representative a
comprehensive Quality Assurance Program and Quality Plan clearly stating the organisation it proposes to set-
up and the ways it intends to organise the Certifications.
It is responsibility of Vendor/Contractor to set-up any such organisation that is necessary to supervise and
control the good execution of the agreed Quality Plan and to procure sub-contractors to achieve the necessary
goals.
4.3 Certification Specific to Gas Related Facilities
Not withstanding any other control-aimed necessary by Vendor/Contractor, Vendor/Contractor shall assure the
Certification of its activities or works as well as of any Sub-contractors as follow:
1. General
Document issued by the manufacturer in which he declares that the products supplied are in compliance
with the requirements of the order and in which he supplies test results.
The test unit and the tests to be carried out are defined by the product specification, the official
regulation and corresponding rules and/or the order.
The document is validated by the manufacturer’s authorised inspection representative, independent of
the manufacturing department.
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It shall be permissible for the manufacturer to transfer on to the inspection certificate 3.1 relevant test
results obtained by the specific inspection or primary or incoming products he uses, provided that the
manufacturer operates traceability procedure and can provide the corresponding inspection documents
required.
2. Certification
Document prepared by both manufacturers authorized inspection representatives, independent of the
manufacturing departments and either the purchaser’s authorized inspection representatives or the
inspector designated by the official regulations and in which it is declare that the products supplied are
in compliance with the requirements of the order and in which test results are supplied.
It shall be permissible for the manufacturer to transfer on to the inspection certificate 3.2 relevant test
results obtained by the specific inspection or primary or incoming products he uses, provided that the
manufacturer operates traceability procedure and can provide the corresponding inspection documents
required.
Owner reserves the right to nominate one or more Third Party Inspection Agency (TPIA) to execute in
its name all inspection and Certification it aims necessary or is mandatory by Law.
Owner/Owner’s representative may also be nominated to act in name of Owner for the purpose and
present for specific items or activities; in that case, "Owner” shall also mean" Owner’s representative"
in the frame of its "Commitment".
Owner/Owner’s representative presence to Certification events and/or final issue of Certificates shall, in
no way, reduce the obligation of Vendor/Contractor to proceed to its own 3.1. Certification or release
Vendor/Contractor from its duties, obligations, and liabilities.
Vendor/Contractor shall, in its Quality Assurance Plans (QAP), propose procedures to inform
Owner/Owner’s representative, on due time, to allow for 3.2 Certification. Events subjected to 3.2
Certification shall be confirmed to Owner/Owner’s representative, in advance, according to the Plan
and to actual time-schedule.
Too late notification to Owner/Owner’s representative and resulting absence of its staff to Certification
event shall lead to rejection of the event up to when Owner/Owner’s representative will reasonably be
able to be present.
For what relates to line pipes, valves, fittings, hot factory made bends and in general piping works, such
3.2 Certification shall at least cover the following:
a. Audits of the overall Certification of the Vendors/Contractors and their sub-contractors.
b. Audits of the 3.1. Certification Procedures and Organisation of the Vendor/Contractor, its sub-
contractors and Vendors and sub-contractors/Vendors thereof;
c. Audits of the 3.1. Certification process, from time to time at Owner/Owner’s representative
discretion;
d. Assistance to main acceptance tests for line pipes, valves and main fittings.
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As a general rule, 100% of all pipe welds shall be radio graphed with some specific weld to be
submitted to ultrasonic testing also as per procedure and requirement of Owner’s Representative.
Prior to shop prefabrication and field welding, the welding procedures shall be submitted to
Owner/Owner’s representative for comments. Vendor/Contractor shall proceed to all necessary
Destructive and Non Destructive testing as provided by the codes and/or specifications for all
Qualification Welds or Joints. The results thereof shall be submitted to Owner/Owner’s representative
for final approval. In case of rejection by Owner/Owner’s representative, Vendor/Contractor shall
modify or adapt the proposed procedures and start again the entire process of approval by
Owner/Owner’s representative.
Each individual welder shall pass welding qualification in presence of Owner/Owner’s representative,
which may reject the qualification in case of non-conformity.
For shop prefabrication and field welding, Vendor/Contractor shall proceed to all necessary Non
Destructive Testing and shall submit their results for Owner/Owner’s representative 3.2 Certification.
Field Welds to be Non Destructively Tested in presence of Owner/Owner’s representative shall be
designated by Owner/Owner’s representative; interpretation by Owner/Owner’s representative shall be
done as soon as reasonably possible; "non rejection" notification of the Weld shall be issued by
Owner/Owner’s representative as soon as reasonably possible. Such Welds shall not be coated nor
back-filled before the issue of this "non rejection" notification.
Direct costs and relating travel expenses of Owner/Owner’s representative's staff and/or compensation
of the Third Party Inspection Agency appointed by Owner for 3.2 Certification shall be born by Owner
for so far the relevant Certification is granted. Should the audited item be found faulty or not conform,
Vendor/Contractor shall remedy with no delay to the default at no cost for Owner/Owner’s
representative and ask for a new audit. All cost incurred by Owner/Owner’s representative for such
new audit shall be borne by Vendor/Contractor.
All other costs incurred by Vendor/Contractor or its sub-Vendors or sub-Contractors for the audits or
giving the auditor due evidence of conformity shall be borne by Vendor/Contractor.
4.4 Testing
Final acceptance tests (pressure and tightness) of the completed installation shall be performed in presence of
Owner/Owner’s representative or Third-Party Inspection Agency and subjected to 3.2 Certification.
Pipelines shall be divided into sub-sections, as necessary.
4.5 Non tested Tie-ins Welds
All tie-ins Welds (called "Golden Welds") which have not been the subject to Pressure Final Testing shall be
100% Radiographic and ultra-sonic controlled (steel Welds) and tightness tested under gas pressure (all
Welds/joints) in presence of Owner/Owner’s representative or Third Party Inspection Agency and duly 3.2
Certified.
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5.0 INSTRUCTIONS
5.1 Third Party Inspection Agency (TPIA) appointed by Contractor.
Vendor shall appoint an independent Third-Party Inspection Agency, which shall maintain/review/monitor all
Quality of the equipment as per the QAP approved by Owner/Owner's representative.
The Inspection Agency shall be appointed from the approved list of Third-Party Inspection agency as indicated
in tender documents.
5.2 Quality Assurance Plan
Vendor during bidding stage shall confirm to the compliance to the Quality Assurance Plans (QAP) attached
with this document. However, in post order stage they shall submit the detail QAP complying with all the
requirements already confirmed by them in pre order stage duly reviewed by the Owner / Owner’s
Representative.
Other documents such as procedures covering various activities like design and engineering, material
procurement, manufacture, inspection and testing, documentation, despatch to site, erection and
commissioning where applicable and maintenance of Quality records shall be submitted for the review of
Owner/Owner’s representative.
Vendor shall submit the above documents duly reviewed within week time from the date of receipt of purchase
order indicating the deviations/exceptions if any for approval.
5.3 Inspection & Test Plan
Vendor shall submit Inspection and Test plan for approval within 2 weeks or before to Owner/Owner’s
representative and obtain their approval before commencement of manufacture duly reviewed by the Owner /
Owner’s Representative.
5.4 Drawing Schedule
Vendor shall submit a total index of drawings and documents required for review / records based on the
Vendor data requirement given in the MR along with the scheduled data of submission of each
drawing/document within a week by Telefax/ Letter of Intent duly reviewed by the Owner / Owner’s
Representative. The drawing schedule shall be specific with regard to drawing/ document number.
5.5 Progress Report and Schedule
Vendor shall submit Fortnightly / Monthly Report and updated procurement, engineering and Manufacturing
Schedule every month, beginning within 2 weeks and Telefax/ Letter of intent.
5.6 Waiver & Deviation
Vendor shall strictly comply with Purchase Order stipulations and no deviation shall be permitted. However, if
the need for deviation arises under exceptional circumstances, on the post order stage, such deviation shall be
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subject to the approval of Owner/Owner's representative and shall be submitted through Owner / Owner's
representative in the prescribed “WAIVER /DEVIATION /EXCEPTION REQUEST” format. The WAIVER
/DEVIATION / EXCEPTION REQUEST shall also indicate the cost benefit to the Owner.
5.7 Procurement of Bought out Materials
All critical materials such as casting, forging, fittings, pressure holding parts, electrical and instrument
accessories, etc. shall be purchased by the Vendors from approved Vendors meeting Qualification Criteria
stipulated, if any. Vendor shall submit a list of bought out materials and sub-Vendors for these bought out
materials for Owner/Owner's representative approval within 2 weeks by Telefax/ Letter of Intent.
5.8 Calibration Records
Vendor shall use only calibrated measuring and test instruments and maintain calibration records. Vendor shall
furnish records of calibration of measuring and Test instruments including recalibration records to Third Party
Inspection Agency.
5.9 Inspection Test Status
Inspection test status of products shall be identified by using markings, authorised stamps, tags, route cards,
inspection records etc. during the course of manufacture to clearly indicate acceptance/rejection of tests/stages
of inspection performed during its manufacturing cycle. The identification of inspection and test status shall be
maintained, and records thereof shall be submitted as and when demanded by Owner/Owner's representative or
Third-Party Inspection Agency.
5.10 Quality Records
Vendor shall maintain quality records as per his procedures. Inspection Reports & Test Record copies shall be
furnished to Owner/Owner's representative duly accepted by the Third-Party Inspection Agency.
5.11 Non-Conformity Reports (NCR)
TPIA will issue a NCR on observing any deviation to Owner/Owner’s representative technical specifications
or approved documents for Owner/Owner’s representative approval. On Receipt of NCR, the
Vendor/Contractor shall submit a detailed corrective action procedure for Owner/Owner’s representative
approval, and shall carryout all necessary corrective action so required to the satisfaction of Owner/Owner’s
representative/TPIA.
5.12 Identification and Traceability
1. Vendor shall establish and maintain a standard written procedure for identifying the products from
applicable drawings, specification, or other documents during all stages of production, delivery and
installation. A copy of this standard procedure shall be made available to Owner/Owner's
representative.
2. Besides other usual requirements for other equipment, Vendor shall pay due attention towards detailed
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traceability of all equipments which are subjected to pressurised gas under normal operation. For such
equipment, the following shall apply:
a. All items of line pipes, pipefitting, valves, and equipment to be permanently integrated in the
project shall be duly identified such that its origin and history can be traced during the whole life
of the project.
b. When pipes are cut in piece, each piece shall be duly marked and identified.
c. No piece shall be integrated in the project if not duly identified.
d. All Welds shall be identified (up-stream and down stream line pipe identification and length)
and date and circumstances of execution (including welder identification-results of “Quality
Control”-etc.) recorded in adequate log book; identification code shall be indicated on the Weld
itself by suitable marking system (stamping is strictly forbidden) before coating; after coating,
the same code shall be indicated on the top of the Weld by suitable marking system.
e. When line pipes are bend on site, the characteristics of the bend (original line pipe identification
number-degree of bending-length of remaining straight sections) shall be duly recorded in the
above logbook.
f. Logbooks shall be setup under the form of a comprehensive computer Database using Microsoft
Access software or similar system.
As Built Survey:
All Welds, bends and fittings/equipment shall be duly topographically surveyed when in final place but
before back filling and exact co-ordination added to the Weld logbook as well as on the “As built”
drawings.
3. On job-to-job basis, Vendor shall confirm its validity and only revisions/deviations, if any, shall be
submitted for approval. The Vendor shall ensure that each product, which is going in the process of
fabrication/manufacture/construction/erection, has proper identification throughout the process
including the final output.
4. The extent of TPIA involvement is indicated in the various quality control sheets attached with this
document and also shall be as per final approved QA/QC procedures or as per codes and standards,
wherever applicable. For items/construction activities for which, Assurance Plan are not attached,
Vendor shall require to submit the Quality Control Sheets and Quality manual and shall obtain
Approval of Owners/Owner’s representative prior to start of any activity pertaining to supply of
material or carrying out construction at site. Owner/Owner’s representative shall get the above
documents reviewed by the TPIA.
5.13 Contractor Documents for Owner/Owner's Representative’s Review/ Records
1. General
a. All Documents shall be in ENGLISH language and unit of working shall be SI system.
b. Review of the Contractor drawings by Owner/Owner's representative would be only to review
the compatibility with basic design and concepts and in no way absolve the Contractor of his
responsibility to comply with Purchase Order requirements, applicable codes, specifications and
statutory rules/regulations.
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c. Unless otherwise agreed, submission of documents for Review/Records shall commence within
4 weeks from the date of Telefax/ Letter of Intent or as per the mutually agreed duration as per
the duration of project.
d. Unless otherwise agreed, Contractor shall submit all Drawings and Documents in number of
copies as stipulated in the Contractor Data Requirement. The Documents shall be supplied in
soft copies where specified.
e. The Drawing/ Documents shall be checked, approved and duly signed / stamped by Contractor
before submission. Revision Number shall be changed during submission of the revised
Contractor Documents and all revisions shall be highlighted by clouds. Before submitting any
sub-contractor drawings for review by Owner/Owner's representative, the Contractor shall
ensure that these sub-Contractor drawings have been reviewed shall not be entertained.
f. While resubmitting the Drawings/ Documents, the Contractor shall send in a covering letter,
specifically confirm whether all the comments have been incorporated if not, shall furnish
reasons with justification.
g. Multi-sheet Document other than Drawings shall be submitted in their entirety in the event of a
resubmission even if only few sheets are revised.
2. Documents under Records Category
Documents under this category are meant for Owner/Owner's representative Records. These documents
would not be returned to Contractor. However, comments, if any, will be communicated to Contractor.
3. Final Documentation
Final Drawings/ documents consisting of Technical Data Manual/ Mechanical Catalogue are a
compilation of “as built” certified, drawings and data, manufacturing and test records, installation and
operating and maintenance instructions shall be submitted to Owner and Owner’s representative in
multiple sets.
6.0 ATTACHMENT (WAIVER / DEVIATION PERMIT)
Waiver / Deviation Permit.
Report No.:
Date:
Page 181 of 921

P.017398/ P.017399
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M010
WAIVER / DEVIATION FORMAT
(TO BE RAISED BY CONTRACTOR / VENDOR)
Project :
Client :
Consultant :
Third Party Insp. Agency :
Order/Contract No :
Contractor :
Originator :
Requirement as per Specification / Drawing Description of Waiver/Deviation sought
Why the Waiver / deviation is required?
Contractual implications if Waiver / Deviation is granted

• Time taken shall be More / No change
• Cost of item shall be Note :- Detailed break up of cost benefit to be attached
• Performance requirement shall be
Under present constraints requested waiver / deviation is most optimum for the Project and does not involve
any security and safety hazard.
Date: Signature of Originator:
Name & seal:
Recommended by TEPL (Site):
Date Signature of Originator:
Name & Seal:
Justification by TEPL (H.O) when required:
Report No.:
Date:
Date: Signature:
Name & Seal:
Page 182 of 921

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M010
Recommended by Owner (Site):
Date: Signature:
Name & Seal:
Recommended by TPIA (When required):
Date: Signature:
Name & Seal:
Final Approval by PM Owner:
Date: Signature:
Name & Seal:
Acceptance by Contractor/ Vendor:
Signature:
Date: Name & Seal:
Page 183 of 921

P.017398/ P.017399
SPECIFICATION FOR HEALTH,
G11077
SAFETY AND ENVIRONMENT
M011

(BPCL)


TURNKEY BASIS
SPECIFICATION
FOR
HEALTH, SAFETY AND ENVIRONMENT
P.017398/P.017399-G-11077-M011
0 24.05.2021 Issued for Tender KKR MKR KNS

Page 184 of 921

P.017398/ P.017399
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M011
TABLE OF CONTENT
1.0 SCOPE ...................................................................................................................................... 1
2.0 REFERENCES ............................................................................................................................ 1
3.0 RESPONSIBILITY & ORGANISATION .......................................................................................... 1
4.0 GENERAL REQUIREMENT .......................................................................................................... 1
5.0 ACCIDENT, INCIDENT AND NEAR-MISS REPORTING................................................................... 2
5.1 ACCIDENT ................................................................................................................................ 2
5.2 INCIDENT................................................................................................................................. 2
5.3 NEAR-MISS ............................................................................................................................... 2
6.0 HSE REQUIREMENTS AT SITE ................................................................................................... 2
6.1 PERSONNEL PROTECTIVE EQUIPMENTS .................................................................................. 2
6.2 WELDING ................................................................................................................................. 3
6.3 GAS CUTTING ........................................................................................................................... 3
6.4 GRINDING OPERATION ............................................................................................................. 3
6.5 USE OF POWER TOOLS AND CABLES ......................................................................................... 4
6.6 MATERIAL HANDLING AND STORAGE ........................................................................................ 4
6.7 TRENCHES AND EXCAVATION ................................................................................................... 5
6.8 PIPE TRANSPORTATION AND LOWERING .................................................................................. 5
6.9 PRESSURE / LEAK TESTING ....................................................................................................... 5
6.10 SCAFFOLDING AND LADDER...................................................................................................... 6
6.11 WORK PERMIT PROCEDURE ...................................................................................................... 7
6.12 BARRICADES AND WARNING SIGNS .......................................................................................... 7
6.13 EMERGENCY PLAN AND PROCEDURES ....................................................................................... 7
6.14 6.14 ROAD SAFETY NORMS ....................................................................................................... 7
6.15 LABOUR WELFARE & LEGAL REQUIREMENT ............................................................................... 8
ANNEXURE – A ................................................................................................................................... 1
ANNEXURE – B ................................................................................................................................... 1
Page 185 of 921
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1.0 SCOPE
This specification establishes the Health, safety, and Environment (HSE) aspects to be complied with by
the contractor during construction at site.
2.0 References
This document should be read in conjunction with following:

1. Job Specifications
2. Relevant IS codes
3. Reporting Formats
3.0 Responsibility & Organisation
Safety activities at site shall be under control of contractor’s RCM. He shall be responsible for
implementation of HSE provisions. The nominated or designated safety engineer/ officer shall assist and
perform day to day HSE work as per his advise.
4.0 General Requirement
1. The contractor should follow HSE policy of owner as applicable to construction site.
2. The contractor shall deploy a full time HSE engineer / officer to coordinate the site.
The HSE officer shall be duly qualified in Industrial Health & Safety management with an
experience of 4 -5 years.
3. The contractor shall ensure that HSE requirements are clearly understood & faithfully
implemented at all level, at each site.
4. The contractor shall organize safety awareness programs regularly.
5. The contractor shall ensure his participation in the every HSE meeting called by owner/owner’s
representative.
6. The contractor shall conduct daily tool box talk.
7. The contractor shall submit Monthly HSE reports (Form attached in ANNEXURES).
8. The contractor shall provide all help and support to the injured person got injury at site during
construction work and arrange compensation as per insurance policy / Act.
9. The contractor shall adhere consistently to all provisions of HSE.In case of non- compliance or
continuous failure the owner/ owner’s representative may impose stoppage of work without any
cost time implication to owner. A penalty amount of Rs 1000/-shall be imposed on the contractor
for the serious HSE violation.
Page 186 of 921

P.017398/ P.017399
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10. Three times of this penalty may count as a serious violation of contractor in line with HSE. This
may affect to new work assignment/award of contractor.
5.0 Accident, Incident and near-miss Reporting
5.1 Accident
Unintended occurrence arising out of and in the course of employment of a person, which results into
injury with or without damage to plant/equipment/materials.
5.2 Incident
It means an unplanned and uncontrolled event which results in damage to plant or equipment or loss of
material without causing any injury to persons, like fire, spill, leak, property damage etc.
5.3 Near-miss
An unexpected, unwanted event not causing loss, injury or illness but which under slightly altered
conditions can lead to an accident.
It can be defined as “Any event which under slightly unfavorable circumstances, may have resulted in any
of the following:
1. Injury, fatal or otherwise or ill health to people
2. Loss of property, damage to plant or materials
3. Damage to the environment
4. A business interruption”
Accident, Incident and Near miss reporting form listed in ANNEXURES
6.0 HSE Requirements at site
6.1 Personnel Protective Equipments
The contractors shall provide sufficient numbers of following personal protective equipment’s (PPEs) to
workmen and supervisors/engineers to use them properly at work site.
Following five numbers of Personnel protective equipments are identified as MANDATORY for all.
1. Safety Helmet
2. Coverall
3. Safety shoes/footwear
4. Safety Glasses
5. Hand Gloves (as per job requirement)
6. Other PPEs depend upon nature of job like
a. Arc Welding – Welding face shield
b. Grinding – Grinding face shield
Page 187 of 921
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c. Height work – Full Body harness (above 2 meters)

Ask site supervisor for proper use and selection of protective clothing / equipment for specialised jobs
6.2 Welding
1. Ensure that welding machine is in order and approved by site engineer.

2. Ensure that welding cables are in order.
3. Ensure that welding machine is properly earthed.
4. Remove all combustible material from welding area to avoid fire
5. Place a fire extinguisher near by welding premises.
6. Ensure welding holder, cable and its lugs in good condition and use only industrial power socket
and plugs (3 Pin) to avoid electricity risk.
7. Make sure that welding machine is provided with ON/OFF switch and is earthed/grounding.
8. Do not overload electrical appliances and cable, Shocked pin etc,
9. Ground the work piece separately from the welding return connection only.
6.3 Gas Cutting
1. Check the cylinder and its valve or leakage and move out any leaking cylinder immediately.
2. Ensure that flash back arresters are installed with torch and NRV (Non return valve) on the gas
cylinders side.
3. Ensure cylinders in vertical position (Cylinder trolley) and far away from fall of sparks and hot
metal.
4. Check the regulator and torches that they are inspected prior to every use.
5. Check for leaks around regulators, hoses/fittings & nozzle with soap solution.
6. Check the entire hose length if it is cracked or worn out cut that length of hose or replace the hose.
7. Check that flash back arrester used for the purpose is of approved make/specification only.
8. Place a fire extinguisher nearby welding premises.
6.4 Grinding Operation
1. Grinding wheels should be stored in dry place.

2. After expiry date, grinding wheel must be condemned, broken into pieces.
3. Power supply cable of adequate current carrying capacity shall be used and it should be in good
workable condition without abrasions, cuts or puncture in outer insulation.
4. Socket pin provided at supply end and on/off switch in working condition.
5. Proper earthing of the body in case of metallic body.
6. Wheel guard properly fitted in position.
7. Machine body without any damage like crack etc.
Page 188 of 921
P.017398/ P.017399
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M011
8. Moving part (wheel) must be properly fixed to the machine with the help of spanner.
9. Grinding wheel must be of suitable size as per the speed of grinding machine.
10. Grinding wheel without manufacturer’s sticker showing size, speed and expiry date must be
condemned.
11. Don’t use portable grinding machine as bench grinder.
12. Don’t fit over size wheel than recommended size by machine/wheel manufacturer.
13. Don’t grind small, unstable object without fixing it in the vice.
14. Don’t over press the grinding wheel against the job for fast removal of metal.
15. Put OFF the main switch, while machine is not in use (tea break etc.)
16. Don’t chip off grinding/cutting wheel for achieving fast cutting rate.
PPEs:
17. Use of helmet, face shield or safety goggles (where face shield is not possible.) and hand gloves.
6.5 Use of Power Tools and Cables
1. All electrical equipment and tools used by the contractors and their employees shall be properly
checked by contractor’s supervisor before use.
2. All power tools must have proper guard at all time.
3. Leads /cables must be placed so that they do not create a tripping hazard.
6.6 Material Handling and Storage
The Contractor will only use crane/Hydra and lifting equipment that has been tested and certified as fit for
purpose by 3rd Party. All crane operators and riggers will be adequately trained and certified. The
Contractor will keep records of tests and certification of all lifting equipment crane employed on the
Works.
Maintenance records shall be routinely inspected by the Contractor and made available for Safety audits.
LIFTING GEAR: Lifting machine, chains, ropes and lifting tackles used at site shall conform to the
following:
1. All parts shall be good construction, sound material and adequate strength and free from defects.
2. Shall be properly maintained, thoroughly examined, load tested by competent person.
3. No lifting machine and no chain, rope or lifting tackle shall except for purpose of test be loaded
beyond safe working load and this safe working load must be plainly marked on the gear
concerned.
4. All material must be properly stacked and secured to prevent sliding, falling or collapse.
5. Stairs and passageways must be kept clear at all time.
Page 189 of 921
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6.7 Trenches and Excavation
Before commencing any excavation work the Site in charge will ensure that the proposed works have
been adequately assessed and planned to ensure that they are executed safely and without risks to Health
and safety. The factors to be assessed and planned will include:
1. The nature and stability of the material being excavated and the need for any support of walls.
2. The effect of excavation on nearby area.
3. The foreseeable presence of hazardous contaminants.
4. The proximity of mobile plant.
5. The provision of edge protection (fall prevention of people and materials)
6. Access and egress
6.8 Pipe Transportation and lowering
1. All drivers shall hold a valid driving license for the class of vehicle.
2. Securing of the load shall be according to established and approved methods.
3. All overhangs shall be made clearly visible and restricted to acceptable limits.
4. Load shall be checked before moving off and after traveling a suitable distance.
5. All vehicles used by Contractors shall be in worthy condition and in conformance to the Land
Transport requirement.
6. Use of certified side booms after 3rd Party inspection.
7. Effective communication should be done among all involved personals.
8. Signaling shall be done by authorized foreman only.
9. Ensure appropriate measures are taken for overhead hazards.
10. Persons are not allowed towards trench side / under the boom at the time of lowering.
11. Co-ordination of lowering in by a single man only.
12. Inspection of equipment before use.
13. All personnel should stay clear of moving equipment.
14. Use of certified lifting tools and tackles.
6.9 Pressure / Leak Testing
Hydraulic and Pneumatic Test

Access to the test area shall be limited to essential personnel only before the test commences compliance
is required with the following points:
1. Persons supervising pressure or leak tests must have sufficient knowledge and experience of
testing to fully understand the hazards of the activity and the precaution, which must be taken.
2. Effective communication, including formal procedures, must be established between sites
whenever the test envelope extends beyond one site, for example, pipelines.
Page 190 of 921
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3. The area shall be cordoned off (using tape, shields or barriers, etc) at an adequate distance from the
equipment to be tested, as specified on the Permit to Work
4. Warning signs shall be posted at access ways, at other strategic positions, and on the equipment to
be tested (including the doors of test workshops or other designated areas
5. Pressuring equipment shall be provided with suitably calibrated pressure control / regulator
devices.
6. Pressuring equipment shall not be left unattended at any time during the test.
7. Pressuring equipment shall be isolated from the equipment under test and where practicable
disconnected when the test pressure has been reached.
8. Care must be taken to ensure that materials of construction have the required ductility at the test
temperature to prevent brittle fracture.
9. A safety valve should be fitted to the equipment/system being tested, set to relieve at a pressure
that will prevent over pressurization
10. Sufficient venting / draining points shall be provided in order to prevent trapping of pressurizing
medium behind non-return valves, check valves, between isolation valves, or within dead legs of
the pressure envelope
11. The equipment/plant to be pressure tested must be subjected to thorough examination prior to
testing. It may be necessary to 100% inspect all welds using visual, radiographic or other NDT
techniques
12. The gas supply must be isolated when test pressure has been achieved
13. The pressure envelope must contain sufficient vents, to a safe location.
14. De-pressurization after pneumatic testing must be gradual.
6.10 Scaffolding and Ladder
1. All working platform must be constructed with the specific requirement of job.
2. All portable ladders must be in good condition as per the site norms.
3. If the working platform is not permanent, then safety belt must be used.
4. There shall be firm foundation for all scaffoldings. All scaffolding shall be made of sound
material.
5. Scaffolding material shall be inspected and used, only if found in good condition.
6. Provide metal base plate is used under all upright or standard scaffoldings. Correct type of
couplers shall be used for all connections.
7. Plumb and level scaffoldings as erection proceeds, so that braces will fit without forcing. Fasten all
braces securely.
8. Working platforms shall be provided with guards. This should consist of top rail, mid rail, and toe
board. The toe board shall be of minimum height 100 mm, while the mid rail and top rail shall be
at heights of 600 mm and 1200 mm respectively.
Page 191 of 921
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M011
9. Do not use ladders or makeshift devices on top of scaffoldings to increase the height.
10. Shall be placed at least 75 deg. to the floor.
11. Ladder shall extend 3' to 4' above the point of Landing and topmost 3 rungs shall not be used.
12. Ladder is checked visually for defects before every use.
13. Ladders shall not be used in a horizontal position as runways or scaffoldings.
14. Ladders shall not be placed in front of a door that opens toward the ladder unless the door is
locked, blocked or guarded.
15. Fall arrestor to be used wherever applicable.
6.11 Work Permit Procedure
1. For working at more than 10’ height the permission must be obtained from site in-charge.
2. For doing any hot work in the fire risk areas the permission must be obtained from site in charge or
safety officer.
3. For any Excavation work it must be ensured that there are no underground utilities like cables,
Water pipeline etc.
4. For any work inside confined space, entry permit must be obtained from site engineer.
6.12 Barricades and Warning Signs
1. Area where work is being carried out above man height or below 1’ ground depth must be
barricaded.
2. Follow the instruction of all types of warning signs like “NO SMOKING” “NO ENTRY”
“DANGER”, “Work at height”
6.13 Emergency Plan and Procedures
1. All Contractor’s employees should be aware of site Emergency control plan

2. Periodic drill to train employees for their awareness & information should be followed.
6.14 6.14 Road Safety Norms
1. For roadside working site to be barricaded as per approved barricading norms given in drg. No.
7452-L-15-0107. Penalty clause for road safety & barricading shall be applicable as per relevant
clause of commercial part of tender.
2. Only eligible driver can drive required vehicle inside site
3. Speed limit norms of site must be followed
4. No riding or travelling on the back of open-end vehicle, fork lift or trailers should be done.
Page 192 of 921
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6.15 Labour Welfare & Legal Requirement
1. All mandatory provisions with regard to safety as prescribed under contract Labour (Abolition &
Regulation) Act 1970 and Rules made there under are applicable.
2. Workmen compensation insurance and registration under ESI should be maintained.
3. Time to time, all rules and regulations suggested by safety committee of site must be followed and
implemented.

Page 193 of 921
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ANNEXURE – A
RELEVANT IS-CODES FOR PERSONNEL PROTECTION
IS : 2925 – 1984 : Industrial Safety Helmets.
IS : 4770 – 1968 : Rubber gloves for electrical purposes
IS : 6994 – 1973 (Part – I) : Industrial Safety Gloves (Leather & Cotton)
IS : 1989 – 1986 (Part – I & III) : Leather safety boots and shoes
IS : 3738 – 1975 : Rubber knee boots
IS : 5557 – 1969 : Industrial and Safety rubber knee boots
Code of practice for selection, care and repair

IS : 6519 – 1971 :
of Safety footwear
Leather Safety footwear having direct moulding
IS : 11226 – 1985 :
sole
IS : 5983 – 1978 : Eye protectors
IS : 9167 – 1979 : Ear protectors.
IS : 3521 – 1983 : Industrial Safety belts and harness

Rev.0 LNG Unloading, Storage & Dispensing Stations in the State of Tamil Nadu & Kerala Annex A -Page 1 of 1
Page 194 of 921
P.017398/ P.017399
SPECIFICATION FOR HEALTH, SAFETY AND
G11077
ENVIRONMENT
M011
ANNEXURE – B
FORMAT - 1.0
1.0: HEALTHY, SAFETY & ENVIRONMENT (HSE) PLAN
Project : ------------------------------------------------------ Contractor:----------------------------------------------------------------------
Date : ---------------------------------------------------------- Owner: ………………………………………………………………….

(To be prepared & submitted by each Construction Agency)
Performing Function Audit Function

Procedure/ W.I./
Activity Description Code of Conformance Customer Review/ Audit
Guidelines Performance Checker Approver
Requirements
PREPARED BY REVIEWED APPROVED BY
Rev. 0 LNG Unloading, Storage & Dispensing Stations in the State of Tamil Nadu & Kerala Annex B - Page 1 of 10
Page 195 of 921

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2.0: MONTHLY CHECKLIST CUM COMPLIANCE REPORT REGARDING HSE (1/6)
Project: ______________________ Contractor :________________________

Date: ______________________ Owner :________________________
Inspection By : ______________________
Note: write ‘NC’ (Not Concern) wherever any of the items are not applicable
Item Yes No Remarks Action

HOUSEKEEPING
Waste containers provided and used
Sanitary facilities adequate and Clean
Passageways and Walkways Clear
General neatness of working areas
Proper Material Storage
Wooden Boards properly stacked and
nails removed
Cords, leads out of walk and traffic ways
Scraps removed from the work site
Other
PERSONNEL PROTECTIVE
EQUIPMENT
Goggles : Shields
Face protection
Hearing protection
Safety Shoes provided
Hand protection
Respiratory Masks etc.
Safety Belts
Safety Helmets
Other
EXCAVATIONS / OPENINGS
Excavation permit
Excavated earth kept away from edge
Dewatering pump kept away from edge
Safe access into excavated area
Opening properly covered or barricaded
Excavations shored
Excavations barricaded
Overnight lighting provided
Other
Page 196 of 921
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MONTHLY CHECKLIST CUM COMPLIANCE REPORT REGARDING HSE (2/6)

Item Yes No Remark Action
Welding Cutting
Valid not work permit
Flashback arrester provided for cylinders
Power cable not crossing the welding

cable
Adequate earthing provided

No combustible materials kept near
welding & cutting works
Gas cylinder chained upright & kept in
trolleys
Cables and hoses not obstructing
Screens or shields used
Flammable materials protected
Fire extinguisher (s) accessible
Other
SCAFFOLDING
Fully decked platform
Guard and intermediate rails in place
Toe boards in place & tied properly
Adequate shoring
Adequate access
Other
LADDERS
Extension side rails I m above
Top of landing
Properly secured at top & bottom
Angle + 70° from horizontal
Other
Page 197 of 921
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M011

HOISTS, CRANES AND DERRICKS
Condition of cables and sheaves OK
Condition of slings, chains, hooks and
eyes OK
Inspection and maintenance logs
maintained
Outriggers used
Singh/ barricades provided
Signals observed and understood
Qualified operators
Other
MACHINERY, TOOLS AND
EQUIPMENT
Proper instruction
Safety devices
Proper cords
Inspections and maintenance
Other
VEHICLE AND TRAFFIC
Rules and regulations observed
Inspection and maintenance
Licensed drivers
Others
Page 198 of 921
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M011

TEMPORARY FACILITIES
Emergency instruction posted
Fire extinguishers provided
Fire-aid equipment
Secured against storm damage
General nemeses
In accordance with electrical
requirements
Other
Fire Prevention
Personnel instructed
Fire extinguishers checked
No smoking in prohibited areas
Hydrants clear
Other
ELECTRICAL
Proper wiring & earthing
ELCB’s provided
Ground fault circuit interruptors
Protection against damage
Prevention of tripping hazards
Proper electrical cable joints
Light poles secured
Clear way to power distribution board
Proper rating of fuses
Page 199 of 921
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M011

HANDLING AND STORAGE OF
MATERIALS
Properly stored or stacked
Passageways clear
Other
FLAMMABLE GASES AND LIQUIDS
Containers clearly identified
Proper storage
Fire extinguishers nearby
Other
WORKING AT HEIGHT
Erection plan
Safety nets
Safety belts tied properly
Illumination
No loose material at height
No body under working area
All openings covered
Other
ENVIRONMENT
Chemical and other Effluents properly
disposed
Cleaning liquid of pipes disposed off
properly
Seawater used for hydrotesting disposed
off as per agreed proceeding
Lubricant Waste/ Engine oils properly
disposed
Waster from Canteen office, sanitation
etc. disposed properly
Disposal of surplus earth stripping
materials, Oily rags and combustible
materials done properly
Green belt protection.
Page 200 of 921

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TENDER FOR ENGINEERING, PROCUREMENT

AND CONSTRUCTION OF LNG STATIONS AT

Bharat Petroleum Corporation Ltd,

S.NO. DESCRIPTION DOCUMENT / DRAWING NO. REV. NO PAGES PAGE NO.

COMMERCIAL VOLUME (VOLUME-I OF II)

SECTION-I INVITATION FOR BID (IFB)

SECTION-II INSTRUCTION TO BIDDERS (ITB)

SECTION-IV SPECIAL CONDITIONS OF CONTRACT (SCC)

SECTION-V FORMS AND FORMATS

TECHNICAL VOLUME (VOLUME-II OF II) #REF!

1 OVERALL SCOPE OF WORK P.017398/P.017399-G-11039-M001 0 6 3

B TECHNICAL VOLUME - MECHANICAL 3

2 PROCESS DESIGN BASIS P.017398/P.017399-G-11061-M001 0 13 26

3 SPECIFICATION FOR LNG UNLOADING & DISPENSING PUMP P.017398/P.017399-G-11077-M002 0 18 39

4 SPECIFICATION FOR LNG STORAGE TANK P.017398/P.017399-G-11077-M003 0 15 57

5 SPECIFICATION FOR LNG DISPENSER P.017398/P.017399-G-11077-M004 0 17 72

6 SPECIFICATION FOR SATURATION ON THE FLY VAPORIZER PACKAGE P.017398/P.017399-G-11077-M005 0 16 89

7 SPECIFICATION FOR STATION PIPING P.017398/P.017399-G-11077-M006 0 14 105

8 SPECIFICATION FOR FLANGE & FITTINGS P.017398/P.017399-G-11077-M007 0 21 119

9 SPECIFICATION FOR SUPPORTS P.017398/P.017399-G-11077-M008 0 8 140

10 PIPING MATERIAL SPECIFICATION P.017398/P.017399-G-11077-M009 0 24 148

11 SPECIFICATION FOR QUALITY ASSURANCE/QUALITY CONTROL P.017398/P.017399-G-11077-M010 0 12 172

12 SPECIFICATION FOR HEALTH SAFETY AND ENVIRONMENT P.017398/P.017399-G-11077-M011 0 21 184

13 SPECIFICATION FOR PAINTING SYSTEM & COLOR CODING P.017398/P.017399-G-11077-M012 0 3 205

14 SPECIFICATION FOR VACUUM JACKETED PIPING P.017398/P.017399-G-11077-M013 0 6 208

15 SPECIFICATION FOR COLD INSULATION P.017398/P.017399-G-11077-M014 0 16 214

16 DATA SHEET FOR LNG UNLOADING PUMP P.017398/P.017399-G-11087-M001 0 2 230

17 DATA SHEET FOR LNG DISPENSING PUMP P.017398/P.017399-G-11087-M002 0 2 232

18 DATA SHEET FOR LNG STORAGE BULLET/TANK P.017398/P.017399-G-11087-M003 0 2 234

19 DATA SHEET FOR LNG DISPENSER P.017398/P.017399-G-11087-M004 0 3 236

21 DATASHEET OF DRAIN PUMP P.017398/P.017399-G-11087-M006 0 2 242

22 DATASHEET OF ELECTRIC HEATER P.017398/P.017399-G-11087-M007 0 2 244

23 TECHNICAL DATASHEET OF INSTRUMENT AIR COMPRESSOR PACKAGE P.017398/P.017399-G-11087-M008 0 3 246

C TECHNICAL VOLUME - FIRE DETECTION, ALARM AND PROTECTION SYSTEM

GENERAL TECHNICAL SPECIFICATION & SCOPE OF WORK FOR

2 SPECIFICATION FOR FIRE WATER PUMPS P.017398/P.017399-G-11077-M014 0 20 260

3 SPECIFICATION FOR FIRE FIGHTING EQUIPMENT P.017398/P.017399-G-11077-M015 0 20 280

4 SPECIFICATION FOR FIRE DETECTION SYSTEM P.017398/P.017399-G-11077-M016 0 20 300

D TECHNICAL VOLUME - ELECTRICAL

1 ELECTRICAL DESIGN BASIS P.017398/P.017399-G-11061-E001 0 15 325

2 SPECIFICATION FOR LV INDUCTION MOTOR P.017398/P.017399-G-11077-E001 0 13 340

3 SPECIFICATION FOR VARIABLE FREQUENCY DRIVE (VFD) P.017398/P.017399-G-11077-E002 0 9 353

4 SPECIFICATION FOR GAS ENGINE GENERATOR (GEG) P.017398/P.017399-G-11077-E003 0 21 362

E TECHNICAL VOLUME - CIVIL

1 ARCHITECTURAL, CIVIL & STRUCTURAL DESIGN BASIS P.017398/P.017399-G-11061-C001 0 20 383

F TECHNICAL VOLUME - INSTRUMENTATION 0

2 PLOT PLAN LAYOUT OF LNG STATION AT PANANCHERY (KERALA) P.017399-G-21095-P001 A 2 894

PIPING AND INSTRUMENTATION DIAGRAM (P&ID ) OF LNG STATION AT AVINASHI (TAMIL

11 OVERALL SINGLE LINE DIAGRAM P.017398/99-G-21098-E001 A 1 920

BHARAT PETROLEUM CORPORATION LIMITED

CONSTRUCTION OF LNG STATIONS IN THE

ENGINEERING, PROCUREMENT AND CONSTRUCTION OF LNG STATIONS AT

OVERALL SCOPE OF WORK

0 24.05.2021 Issued for Tender KKR MKR KNS

2.0 SCOPE OF WORK

2.1 Scope of Supply

e. All associated piping & fittings

Scope of service shall include but not limited to the followings:

3.0 TERMINAL POINTS & BATTERY LIMITS

3.1 Mechanical & Piping

1. At Road tanker hoses for inlet/return of LNG

2. At vehicle fuel tank for LNG dispensing to vehicles