SUPPLY & INSTALLATION OF GAS DISTRIBUTION SYSTEM AT BPCL LUBE DEPOT-ADBLUE PLANT

TECHNICAL SPECIFICATION FOR

LABORATORY GAS DISTRIBUTION

SL. CHAPTER NAME DESCRIPTION

1 CHAPTER-03 LABORATORY GAS DISTRIBUTION SYSTEM

1 SCOPE OF SUPPLY /WORK

1.1 General Requirements:

The gas distribution system has two independent types of systems namely Bottled

gas system and Compressed air system. The bottled gas system feeds the process

fluids from the gas banks to the laboratory utility points whereas the compressed

air is fed from the compressor room.

The gas system consists of the following from the gas yard; main isolation valve,

floor isolation valves, branch isolation valves, pressure gauges, tubes & tube

fittings, point of use regulators, gas purifiers, supports, clamps etc.

2 TECHNICAL REQUIREMENTS

It is the intent of this specification to provide a high quality gas distribution

System for the laboratory usage.

2.2. Gas Tubing:

2.2.1. Tubing sizes 1/4” up to 1” OD should be made of SS 316 seamless tube.

2.2.2. Tubing should have a minimum of 8% Nickel

2.2.3. Tubing should have carbon content < 0.040%.

2.2.4. The tubing should be supplied with plugged ends.

2.2.5. Tubing hardness should have a max HRB

2.2.6. Tubing supplied has MOC of SS

2.3. Tube Fittings:

2.3.1. The fittings shall be of “Flareless” design and consist of primarily four

components, i.e. body, front ferrule, rear ferrule and nut.

2.3.2. Tube to tube joints and braches are joined by the way of compression.

2.3.3. The fittings shall be capable of holding the maximum working pressure of

the tubing without any leak after only one and a quarter turn pull up of the

2.3.4. The rear / back ferrule on Stainless Steel Tube Fittings shall have a

machined recess on the inside diameter and shall have complete surface

hardening to substantially reduce the required pull up torque. Both the

requirements i.e., complete surface hardness and machined recess shall be

met for all rear ferrules of sizes ranging from 1/4” to 1” OD

2.3.5. Nuts for SS fittings shall have silver plated threads to act as a lubricating

agent to avoid galling and to reduce tightening torque.

2.3.6. All the fittings end connections shall be compatible to tube of hardness

less than or equal to RB

2.3.7. Stainless Steel Tube Fittings made from bar stock (straight configurations)

should meet ASTM A269 / ASTM A269M standards and those made from

forgings (including elbows, crosses and tees) should meet ASTM A182 /

ASME SA182 standards. For Brass fittings the standards are respectively

ASTM B16 / ASTM B453 & ASTM B283.

2.3.8. HDPE Drainage: HDPE pipes and fittings thermal weld type, 4mm thick.

2.3.9. Moisture trap: Inline type, Clear acrylic / glass tube, regenerable, with

1/4" ferrule fittings at both ends with all SS 316/316 fittings inside. Make:

Reputed Valves manufacturer (Panel mounted).

2.4. PRIMARY CONTROL MODULES

2.4.1. Supply of Gas Primary control modules along with pig tails, bull noses,

cylinder brackets, restraining chains, support brackets and necessary fittings

for connecting cylinders in the gas banks.

2.4.2. Performance testing of the manifolds with respect to the purity, flow rate

and leakage of gases.

2.4.3. Material of construction for the manifold will be SS 316L and working

pressure rating shall be 250 bar. The manifold should have been tested for

2.4.4. The gases used for this application shall be high purity analytical grade so

it is intended to have the complete primary control module pre-cleaned and

certified for 5.0 purity gas application.

2.4.5. Only SS 316 double braided bellow hoses, heavy wall construction.

2.4.6. The braided hoses shall be tested for 300 bar and certificate produced.

2.4.7. The primary control module shall be supplied with the following

specifications.

(a) The Body of the primary control module is Brass

(b) The regulator shall be provided with an inlet (0-300 bar)and an outlet

gauge (0-10 bar)

(c) The regulators shall be provided a back mounting support which shall

be mounted on a Powder coated MS profile.

(d) Inlet and outlet port size is 1/4” Female NPT connections.

(e) The regulator shall be provided with an integrated relief vent to blow

at 1.5 times the outlet pressure.

(f) Helium leak tests shall be performed on all the regulators and

certification used by the manufacturer.

2.4.8. Mild steel cylinder holding brackets to hold both 9” dia and 15” dia

cylinders, powder coated with restraining chains with locking arrangements.

2.5. ISOLATION VALVES

2.5.1. Stainless Steel 316 SS, ¼”, ½”. 1” ferrule type

2.5.2. Teflon gland packing with Silicone base lubricant

2.5.3. The valves shall be factory tested at 1000 PSIG and certification shall be

2.5.4. The factory leak test shall be performed to a maximum allowable leak rate

of 1 X 10-3 cc / sec He

2.5.5. Operating pressure 0-150 Bar.

2.6. PRESSURE GAUGES

2.6.1. Bourdon type, centre back connection for dropper gauge and bottom

connection for Regulator gauge.

2.6.2. Inlet size ¼” MNPT with dial size of 60 mm

2.6.3. Bourdon and socket material SS

2.6.4. Casing is SS

2.6.5. Accuracy shall be +/- 1% of FSD.

2.6.6. Factory Calibration Certificate required along with supply.

Flanges will be as per ANSI B 16.5 class

Flanges will be socket weld type.

3. SUMMARY OF MATERIAL OF CONSTRUCTION

Tube fittings : SS

Primary Control Modules : SS

Tubing Supports : Mild Steel

Piping Supports : GI

Tube support clamps : Polypropylene

Cylinder Bracket : Mild steel

Pressure Gauge : SS Bourdon and BLACK Zinc body

Gas fixtures : Brass Powder Coated

4.0 INSPECTION AND TESTING

4.1 Performance Test for Gas System:

4.1.1 Installation Purging Procedures:

4.1.1.1 The sealed tubes after starting the process of cutting and deburring has to

be purged with general purity nitrogen.

4.1.1.2 Connect the tubes to the flexible hose of the regulated supply (at 2 bars)

and blow the debris for 5 min.

4.1.1.3 To ensure the purging is totally complete, blow the tubes intermittently

holding the pressure for few seconds at the end of the tube.

4.1.1.4 Now use the tube to swage the fitting. And install the tube with the fitting

at the required place.

4.1.2 Pre Testing Purging Procedure

4.1.2.1 Once the main header and the sub header installation is complete, check

for the misalignment or improper fitting connections

4.1.2.2 Connect the regulated pressure from the Nitrogen cylinder and

blow the system for 15 mins non stop.

4.1.2.3 Start the process again after a 15 mins duration and blow the system for

another 10 mins.

4.1.2.4 Reconnect the needle valves and open the port fully.

4.1.2.5 Start the purging process one more time with the valve open blow the

whole system for 30 mins.

4.1.2.6 Now the system is completely purged and now ready for handing over

after the pressure test.

4.1.2.7 Please note purged air must be directed to outside of Lab.

4.1.3 Pressure Testing Procedure

4.1.3.1 Ensure complete piping is purged with prior to pressure test. Use Nitrogen

for leak check. Please note purged air must be directed to outside of Lab.

4.1.3.2 Ensure the system point is not hooked up to the lab equipment.

4.1.3.3 Shut-off point of use valve and pressurize system through the cylinder

4.1.3.4 Increase pressure slowly to maintain 30 psi and shut-off the cylinder

valve. Observe the pressure gauge for evidence of pressure drop.

4.1.3.5 If the pressure drops, trouble-shoot leaking joints by using “Snoop” liquid

leak detector rectify as necessary.

4.1.3.6 Proceed to increase pressure to 100 psi if no leak is detected after 15 mins.

of pressurization at 30 psi.

4.1.3.7 Repeat item (a) if leak is detected.

4.1.3.8 Proceed to increase pressure to 1.5 times the working pressure of the

system. (Normally system with same procedure as above.

4.1.3.9 Maintain pressure for 12 hours and check for evidence of pressure drop.

4.1.4 Preliminary Testing

4.1.4.1. Preliminary Leak testing will be carried out in two phases:

- Pressure decrease method (Pressure testing: 1.5 times the maximum working

Necessary formats will be used and all relevant data will be recorded during the

test. GDS vendor and Management staff of Watson Pharma will jointly witness

the test and certify the same.

- TIFF leak detection.

Necessary formats will be used and all relevant data will be recorded during the

test. GDS vendor and Management staff of Watson Pharma will jointly witness

the test and certify the same.