bharat petroleum corporation ltd. … petroleum corporation ltd. annexure- vi third party inspection...

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BHARAT PETROLEUM CORPORATION LTD. ANNEXURE- VI THIRD PARTY INSPECTION CHECKLIST SCOPE of THIRD PARTY INSPECTION AGENCY (TPIA) FOR MPDs

Random Sample size : a ) 5 % of each lot ready for dispatch covering all the types of MPDs in the lot, where it is mentioned

“ physically check for sample size” . b) Wherever “confirmation by TPIA” is sought, the random sample size can be decided by the TPIA to his satisfaction.

TECHNICAL SPECIFICATIONS OF MPDs

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OBSERVATION/ COMMENTS/

RESULTS of TPIA during Inspection

1 TYPE: High Hose Version Dispensers without pumping Unit suitable for Submersible Pumps. Submersible pumps are not in Vendor’s Scope

Physically check for sample size

1.a MODEL NAME : Model name to be as per following details.


Item: 2 PROD X 4H X 4 DISP (STD Duty ) MPD without printer, Minimum Width 1.2m



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and display on the edges.

Item: 2 PROD X 4H X 2 DISP (Std Duty), 3 PROD X 6H X 2 DISP (Std Duty), 4 PROD X 8H X 2 DISP DISP (Std Duty) and 1PROD X2HX2 DISP with Printer (Heavy Duty) On Either Sides i.e. total two printers per MPD.


1.b

Inlet Connection shall be 38 mm for all MPDs except Heavy Duty. For Heavy Duty Inlet connection would be between 38mm to 50mm However the delivery flow rates as referred in 2.a. should be achievable with FE PETRO / RED JACKET or equivalent make STPs of .75 HP.


2 DELIVERY RATE

2.a

Minimum 30 litres/minute per nozzle when one side and one product in operation. Minimum 60 litres/minute per nozzle when



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one side and one product in operation for Heavy Duty.

3 METERING UNIT 3.a Positive Displacement Type, with two or four

Piston with Integrated or Separate Pulse Generator. The shaft connecting pulser and metering unit should be in one piece without any transmission gears .

Confirmation by TPIA

3.b

Working Pressure – MAX 3.50 KG/SQ.CM for all MPDs


3.c ACCURACY +15 ml to 0 ml at delivery rate of 10 lpm to the maximum capacity of the pump for 5 litre measure .



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3.d Two consecutive readings out of three reading should be within accuracy limit.


3.e All measuring units should be electronically calibrated only. Metering unit accuracy shall be adjusted by electronic head in the range as per W&M laws. The electronic calibration must be possible only when W&M seal is broken.


3.f The range of calibration in ml in both plus as well as on minus side.


3.g Accuracy of the Meter shall be +/- 0.3% or better.


4 HOSE

4.a 4 M long – 19 MM FOR S.D And 25 MM for HD Nozzles.



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4.b To be of petrol resistant type of superior quality suitable for Petrol blended with Ethanol Of Max10%

Enclose test report from manufacturer


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4.c Hose shall be hard wall only confirming to BS EN 1360 Type III /UL 330 or Equivalent


4.d Hose hook (Material SS304 SGHC(JIS G 3302 / plastic material of adequate strength &longevity) to be provided to hold the hose in position so as to prevent it from rubbing against the ground.


4.e i. Colored Hoses for only 4x8x2 MPDs 1st Hose: Yellow for Speed 2nd Hose: Green for Petrol 3rd Hose: Black for Hi-Speed 4th Hose: Blue for HSD. ii. For all other MPDs, all Hoses would be Black in color.


5 NOZZLE

5a. Pressure sensitive auto cut-off Unleaded MS- 13/16” spout for STD Duty of ZVA/ OPW/ TATSUNO/CATLOW(USA) make with BPCL logo embedded on NOZZLE COVER . For Heavy Duty, Pressure sensitive Auto



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CutOff nozzle would be 15/16” or 1” size ZVA/OPW/TATSUNO/CATFLOW(USA) make with BPCL Logo embedded on Nozzle Cover. Nozzle Cover Color : 2X4X4 MPD : 1st Nozzle-Yellow 2nd Nozzle – Green 2x4x2 MPD: 1st Nozzle-Green 2nd Nozzle – Blue 3x6x2 MPD: 1st Nozzle- Yellow 2nd Nozzle – Green 3rd Nozzle- Blue 4x8x2 MPD: 1st Nozzle- Yellow 2nd Nozzle – Green 3rd Nozzle- Black 4th Nozzle-Blue


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1x2x2 MPD 1st Nozzle – Blue

6 REGISTER UNIT

6.a

MOTHERBOARD WITH MICROPROCESSOR/ MICROCONTROLLER

Electronic microprocessor control and display unit for 1 to 4 hydraulic modules with non volatile memory.


6.b

All power handling devices including transformer and power correction / protection will be on separate board ( Power/ SMPS card ) so as to enable replacement of only power/SMPS card in the event of any power related failures. BPC has installed high quality UPS at all their ROs, from which power is fed to electronics of MPDs. Hence warranty and post warranty AMC will cover all items including all electronics. In nut



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shell, all spares during warranty and post warranty AMC will be on vendor’s account, regardless of the reason for such spares failure. All exceptions to this rule is listed in Service Level Contract appended.

7

DISPLAY

7.a Liquid Crystal Display Capable of withstanding temperatures ranging from -20 Degree C to +80 Degree C .It must be visible during day and also at night with backlighting .

Enclose Test reports from Manufacturer


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7.b 1)LCD screens to be provided to display Volume, Amount, Unit Price and Density for all MPDs. The characters/digits shall be displayed in black and the background shall be white. Volume and amount will be displayed on a common bigger screen with character height of minimum 40 mm. 2)Density Display for the product of active Hose only. 3)Density input through keypad (security level L1) or POS.

4)“The Unit rate of each product available on MPD should be visible before commencement of dispensing fuel .However, during dispensing operation ,only Unit rate of product of active hose must be on display” 5) In case of power failure display

should remain at least for 30 seconds. No external battery should be used for back up.



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7.c 1)The size of the characters displayed product should be as follows: Amount: 40 mm Volume: 40 mm Unit Price: 25 mm Density: 25 mm Amount and volume will be on a common screen with character height of min 40 mm. 2) The configuration of the display shall be as under:

o Amount: 99999.99 Rs o Volume: 99999.99 lts o Unit Price: 999.99 Rs/lt o Density: 999.9 kg/m3



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7.d The Electronic Display should have masking of readings allowed up to 30 ml.


8 COMMUNICATION PORT

8.a The unit shall have an RS 485 port for communication with POS/OPT/any Automation system. For makes that support Current Loop as the default mode of communication, one RS 485 port shall also be provided with an option to switch to RS 485 output or back to Current Loop (using jumper settings). Vendor to ensure that communication port remains protected when connected to FCC of DOMS, POSTEC or any other make of repute for automation purposes.



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The communication to the local printers (when installed at a later date) shall be through RS 232. The printer shall work independent of the automation system. The receipt printing should be done by activating a button provided on the pump, the communication should be directly between the pump controller board and the local printer board, using RS232. This will ensure receipt printing whether there is automation or not


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8.b 1) The below requirement is applicable only for 2×4×2, 3x6x2, 4x8x2 and 1x2x2 MPDs :

i) A prompt should appear on the LCD screen or Key pad of the DU to enter the Vehicle Number (alphanumeric), before printing of the cash memo. Cash memo must depict Vehicle Number (alphanumeric). ii)If prompt is on LCD, all details of last transaction should reappear after Vehicle number is entered or skipped

2) The above are not applicable for 2×4×4

3) If Vehicle number is skipped, cash Memo must depict “ Not entered” against Vehicle number

Physically verify using POS terminal available with manufacturer for the sample size.


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9 COMMUNICATION PROTOCOL


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9.a For pumps working with POS or RO automation, following data must be available from dispenser on request from POS using an industry standard protocol or proprietary protocol:

o The delivery data, i.e., delivery amount and delivery volume message that provides updated information in real time as to the current delivery, amount marked upon the Microcontroller and volume delivered at Microcontroller respectively. If not possible, at least one of these data will be transferred on real time basis, while other data will be transferred at the end of each delivery. The data transmitted to the host are identical to those displayed on the Microcontroller.

o The overall total volume, i.e. the total number of liters delivered by each Microcontroller

o The overall total amount, i.e. the total number of monetary units counted Microcontroller.

o All density, price, calibration records. o Preset value entered on the key pad should

be transmitted to POS at the beginning of transaction.



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9.b o The communication protocol should

recognize the floating decimal.

o The protocol shall support remote

change of unit rates for all products in the MPD. This is in order to enable remote price change of products through Automation System.


9.c Pre-delivery status signals required are:

o Host generated block ( authorization from POS)

o Product identification o Nozzle out



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9.d Error status signals required:

o Display 1,2 connectivity error o Totaliser o Single sensor error o Twin sensor error

These error signals are illustrative only, and not exhaustive


9.e Under delivery status required for MPDs are: o Nozzle out



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9.f

POS commands to Microcontroller to work as under:

Command from POS: Action by Micro Controller

1)Recognize change in the nozzle position from IN to OUT: Activation of Delivery starts procedure. 2)Emergency Block delivery : Delivery fuel to be blocked at microcontroller 3)Preset amount to be delivered Memorization of “Preset by POS” function, 4)Preset volume to be delivered : Memorization of “Preset by POS” function,



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5)Unit price setting: Memorization of price received from POS visualization of new price received & activation of procedure of writing new price 6)Motor enable/disable : Suspends/ resumes delivery. 7) Density values entered in three digits + one decimal (in Kg/m 3) : The values entered from POS must be displayed on MPD on the LCD screen.

10 PRINTERS

10.a 1). 2x4x2,3x6x2,4x8x2 and 1X2X2 MPDs should be provided and supplied with Two inbuilt Thermal Printers i.e. one on either side. 2 ) Above is not applicable/ required for 2x4x4 MPDs



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10.b The RS 232/RS485 com port of the MPD shall enable communication with printers.


10.c The printers is to be provided 1.2m above Ground level.


10.d Printer specs and Cash Memo template would be as per purchase order specifications.


1 10.e The printer should allow one re-print of the ticket; the second copy shall be marked as “COPY/DUPLICATE”. The required format of the ticket/cash memo is enclosed with the printer specs.



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11 PULSE & SAFETY FEATURE

11.a

Pulser resolution of 10ml per pulse should consist of two/three pairs of photoelectric two sensors.


1 11.b

Pump to give error message and stop functioning if sensor (s) fail OR Alternate Technology – Any failure of sensor should give an error message, stopping sales


11.c They are to be flame proof/ explosion proof if they are placed with in the hazardous area.


11.d

If uni-directional pulsar is not used, and there is a situation of reverse movement in pulsar, the pump should display an error message and stop dispensing.


11.e There should be provision for sealing of the entire pulsar unit



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12 TOTALISER

12.a Electro-mechanical and Electronic Totaliser are both to be provided for each meter


12.b Electro-mechanical totalisers to have sealing arrangement. Integrity of Electro mechanical Totaliser shall be ensured through fool proof sealing system. Details as per vendor’s offer.


12.c Both Electro-mechanical and Electronic Totalisers should be irreversible type. The Electro-mechanical Totaliser including it’s gear train must be in tamper proof enclosure with sealing Arrangement.


12.d 7 DIGIT without decimal form Electromechanical Totaliser.



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12.e Electro mechanical totaliser should be readable from outside without removing the panel/doors


12.f Minimum 12 digits including two decimal digits Electronic Totaliser for all MPDs 2×4×2, 2X4X4 ,3x6x2 4x8x2 and 1x2x2 MPDs


12.g In case, Vendor has provided additional fail safe Electronic Totalizer in place of Electro Mechanical Totalizer, Fail safe Electronic Totaliser to be checked for Electronic Totalizer functionalties.


13 PRESET


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13.a Required as a standard feature for all the MPDs. Preset would be for Volume (ltrs) and Value (In Rs)


13.b

1.Preset shall have least count of 1 Litre by Volume and Rs 10/- by amount. 2. 3 pre-set keys in addition to all numeric keys in the key pad will be provided for fixed amount as well as volume configurable at site. This is required for three most frequent transactions.


13.c Solenoid Valve shall be of Two stages/ Proportional stages. Vendors to confirm the Cut-off level of the first stage.


14 OPERATING ENVIRONMENT


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14.a Pump shall be capable of operating in tropical conditions & in open atmosphere without over head canopy. Humidity of max. 95% and ambient temperature of -20 to +500c.


15 SECURITY AND CONTROLS

15.a History of last 10 electronic calibrations shall be stored in the CPU Memory of the ERA and shall be recalled on the pump display. There shall also be an option for printing the same using the local printer. The microcontroller must also be capable of communicating the details to a POS terminal/Automation System when the unit is automated.


15.b The microcontroller and ICs connected to Microcontroller shall be surface Mounted on to the PCBs. Other ICS and Circuits not directly effecting Microcontroller can be Non surface Mounted.



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15.c The manufacturer should have his mark on the mother board for identification. It shall be mounted on the structure through a screw/ bolt and the whole mounting will be a sealed wire system with manufacturer’s seal on it.


15.d Display of Software version: The pump software version should be readable on the LCD screen as and when required



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15.e Minimum 3 levels of security required for accessing various functions through the MPD keypad/Remote Control as below. 1. Level1 for density, Shift totalizer clearance

2.Level2 for Price, Auto to manual to Mode and for History of all price & Density changes with date and time for last 5 entries

3.Level3 for software changes etc. only with manufacturer 4.Level 3 can control all Levels below.


15.f The output going from Pulsar unit to Pump controller card should be secured so as to prevent manipulation of pulsar signals.

BPCL desires pulsar encrypted feature. Refer Vendor’s confirmation.

Enclose Test report from manufacturer.


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15.g Rate change through password Control- History of last 5 rate changes shall be stored in the CPU Memory of the ERA and shall be recalled on the pump display through keypad /Remote control. There shall also be an option for printing the same using the local printer (when installed at a later date). The microcontroller must also be capable of communicating the details to a POS terminal/ Automation System when the unit is automated.


15.h Tamper proof electronics to avoid unauthorized programming/ replacement of components. Details to be provided.


15.i Stand Alone and Auto mode: The MPD should be able to be taken to auto or stand alone mode through MPD’s keypad/ Remote Control and the access will be with higher level of security.


15.j Software programming should not be altered by any agency. However in case of updates, the same would be approved by BPCL Retail Eng (HQ) Dept.



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15.k BPCL expects the vendor to ensure that the pump software/microcontroller program and Level 3 or Highest level pass word remains strictly confidential. Vendor to ensure tight security with suitable internal processes to prevent the software from being disclosed to any outside party. BPCL reserves the right to debar the vendor for all future tenders in the event where BPCL has discovered that the same has come into the possession of any undesired person or agency. In such case, vendor shall load new software or replace the manipulated motherboard with new motherboard free of charge as per BPCL’s requirement without any cost to BPCL.



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15.l Each MPD should be provided with a Red color Mushroom type “STOP” button –one each on Front and Rear panel. All the power to the MPD including dispensing should stop , except display which should remain for minimum 30 seconds.


16 PAINTING SS surface will not be painted. Non SS

surfaces to be coated as under:

a) External surface of bottom panel (front and rear) and “MPD Top Fascia” to be finished for pasting of screen printed vinyl .

b) All external surface, other than (a) above, will be 50 micron pure polyester powder coated white.


17 STATUTARY LOCAL APPROVALS

17.a Valid Model Approvals from Weights & Measure Verify and


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and Certification / Approvals from Chief Controler Of Explosives, Govt Of India.(Vendor to enclose Model Approvals & CCOE approval copies for offered models)

enclose required approvals alongwith report

17.b Quality Assurance Plan by Vendor

Verify and enclose QAP

17. c Vendor to confirm that in all Models the position of

CARD READER IN DISPENSER (CRIND )will remain same. (Except 2x4x4 model)


18 OTHER REQUIREMENTS


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18.a Tray for keeping vehicle fuel tank cap of 75 mm diameter Stainless Steel/Nylon Glass Filled tray fixed on the front and rear bottom panel


18.b MPDs should be provided with reusable filters of 70 to 80 micron size. Lower micron is also acceptable provided flow rate is not compromised.


18.c i) The Dispensers should be provided with Swivels, Shear valves and single use safe breakaway couplings . ii) Breakaway couplings should be at top


18.d MPDs and its components should be suitable for fuel with 10% Mix Ethanol. Viton/ equivalent seals and not NBR seals to be used. All the rubber components coming in contact with the fuel will be of Viton/ equivalent Material.


18.e Please note that All Rubber Components Physically check


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which are in direct contact with the Product must be made of "Viton" (except hose)

for sample size

18.f MPD bottom panel and MPD Top Fascia

should be provided with 3M or Avery vinyl with screen printed graphics or silk screen directly printed on metal body . The graphic design will be provided by BPCL. Vendor to give five years warranty for loss of colour and gloss not below 80% level.


18.g The bottom door panels should be removable type and not to be hinged with main body. The nozzle support should be fixed on main body and not on the bottom door panels.


18.h Provision is to be made to retrofit ‘CRIND’ at a future date. Opening size should be of size 22 cm width , 20.5 cm height and 25 cm depth on either side of the MPD. Blanking plate on opening to be provided This CRIND could be even located in place of printer installed on MPD.



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18.i MPD Top should have a fascia. The shape of

the fascia should be wave type. (Drawing and photographic sample attached on page 42,43,44 of this Annexure).

Physically Check

19 PACKING/MARKING

19.a PACKING: Dispensers / Pumps to be covered with polythene covers and packed in a wooden box / crate to withstand multiple loading/ unloading and transportation from :- Overseas factory to Indian ports by ship Ports to storage locations by road Storage location to retail outlets by road NOTE : 1.Packing should capable to withstand rough



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sea weather for a minimum period of 4 to 6 months and should be commensurate with best commercial export practices. All packing shall be done in such a manner as to reduce the volume as much possible. Fragile articles should be adequately packed with special packing materials depending on type of materials. 2.All delicate surface and electrical equipment and other heavy article should be carefully protected and painted with protective paint/ compound and wrapped to prevent rusting and damage. 3.All mechanical and electrical equipment and other heavy articles should be securely fastened to the bottom of the case and shall be blocked and braced to prevent movement. 4.Attachments and spare parts of equipments and all small pieces shall be packed separately in wooden cases with adequate protection inside the case and wherever possible should be sent along with the main equipment. Each item shall be tagged so as to identify it with the main equipment and part


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number and reference number shall be indicated. 5. All protrusions shall be suitably protected and opening shall be blocked by wooden covers. 6. Wherever required equipment/materials shall be packed in polythene bags and silica gel or similar dehydrating compound shall be put inside the bags to protect them. 7. Pipes/tubes made of stainless steel, copper etc. Shall be packed in wooden cases irrespective of sizes. 8 The supplier shall be held liable for all damages or breakages to the goods due to the defective or insufficient packing as well as for corrosion due to insufficient packing. 9. Detailed packing list in waterproof envelope shall be inserted in each package together with equipment/materials. One c o p y of "detailed packing list", shall be fastened outside of the package in water proof envelop and covered by the metal cover. Marking: 1.each package shall be marked on four sides,


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with proper paint/indelible water proof inks as follows: Packing slip (with minimum following details ) To, M/S BHARAT PETROLEUM CORPORATION LTD. DESTINATION: MUMBAI/DELHI/CHENNAI/KOLKATA SHIPPING MARK: BPCL (M) MUMBAI PURCHASE ORDER NO ..............DATE ............. ITEM NO OF P.O………..MODEL NO……………... ITEM DESCRIPTION AS PER PO………………….. NETWEIGHT..........KGS.GR.WT.............. KGS COUNTRY OF ORIGIN .................................. SHIPPER’S NAME : …………………………….

2. Additional marking such as “ Handle with care” “This side up”, “Fragile” or any other additional indication for protection and safe handling shall be added depending on the type of material. All cases will have warning signs on the outside denoting ‘Center of gravity and sling mark’


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3.Name plate on each of the MPDs (02 nos. name plates on each MPDs- one on each side ) with minimum following details.

a. Purchase Order Number /date: b. Model No: c. Sr. No: d. Mfg. Date: e. Mfg. by M/s: f. Date verified and stamped by W&M legal

Metrology: g. CCOE certificate: h. Capacity: i. W&M no:

20 JUNCTION BOXES

20.a There will be two separate junction boxes inside MPDs; one for electrical input catering to MPD electronics, lights etc. and another to terminate the MPD communication cable. The location of the junction boxes shall be in the bottom enclosure of the MPD.


20.b Physically check


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The communication cable between the MPD controller card and the second Junction Box should be pre-wired, terminated with suitable FLP glands. A duly plugged opening to be provided on the JB to allow entry of communication cable from POS.

for sample size

21 REQUIRED STANDARDS AND CERTIFICATIONS

21.a The electronic and electric circuit of MPDs must conform to UL 87 or ATEX CE or equivalent standards. BPC would like these standards to be certified to this extent. Only exception to UL 87 would be motor trigger linked with nozzle instead of having a separate activation mechanism for motor.


21.b The power condition in India calls for a high degree of noise insulation for electronic and communication circuitry in the dispensing units. BPC would prefer to have CE standards followed in this regard. The equivalent US standards may also be



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acceptable. 21.c

All Measuring Units should be OIML certified or equivalent.


21.d The pulsar unit should adhere to CE standards. RS 485 should be Optically/Magnetically/ Capacitively isolated


NOTEs A. In addition to above, TPIA shall also verify the following for the specified sample size:

1. Segment check facility. 2. Automatic zeroing with respect to on/off operation. 3. Checking for internal component configuration, workmanship and finish. B. TPIA Report should also cover the following. 1. Witness Stuffing of cleared/inspected MPDs wooden Boxes/Crates in Containers. TPIA report should provide Container No details ,

No of MPDs, SR NO of MPDs in each container 2. Based on successful completion Sample check and Random check, full offered LOT can be cleared for Dispatch. Report should

provide all Sr Nos of MPDs in the LOT with Configuration and also list of SR Nos of MPDs selected for Sample and Random Check of MPDs. TPIA should Stamp all MPDs in the cleared LOT at an easily accessible but discreet place with an identification Mark. The location of Marking and identification Mark should be mentioned in the TPIA report.


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Photographic Sample of MPD Top Fascia.

TOP FASCIA


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Sample Drawing : The dimensions as mentioned in the drawings below can vary to some extent, but the overall profile (shape and size) of the Top Fascia should be maintained. The same will be approved by BPCL during FAT. The height of the fascia at the centre should be 220 mm. For 2X4X4, 3X6X2 and 4X8X2 (fig in mm)


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For 2x4x2 and 1x2x2 MPD (fig in mm)

bharat petroleum corporation ltd. … petroleum corporation ltd. annexure- vi third party inspection...

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