corrigendum annexure i tender no. crfq no ......2003/02/28 · 3. the level transmitter shall also...

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CORRIGENDUM ANNEXURE – I

TENDER NO. CRFQ NO. : 1000179338 E – TENDER NO. : 10736 Based on queries raised at Pre- Bid meeting held on 19.02.2013 at

Kolkata , Bid Qualification Criteria of the job is amended as follows : A. BID QUALIFICATION CRITERIA (BQC) :

Sub Clause No. 1.6 under Technical Criteria

AMENDED CLAUSE (Relevant Portion)

Experience of having successfully completed similar works during last 10 years ending at the time of bid due date should be either of the following: Three similar completed works each costing not less than INR 3.7 Crores (USD 0.67

Million) OR Two similar completed works each costing not less than INR 4.6 Crores (USD 0..84

Million) OR

One similar completed work costing not less than INR 7.4 Crores (USD 1.35 Million)

Sub Clause No. 2.2 under Financial Criteria

AMENDED CLAUSE

Bidder shall have following minimum average annual turnover as per audited financial results in the preceding three financial / calendar years ending before the bid due date as under: Indian Bidder : INR 9.28 Crores Foreign Bidder : USD 1.69 Million . “Turnover shall mean Consolidated Turnover in case of a Bidder having wholly owned subsidiaries”.

Sub Clause : 1.1(i) under Technical Criteria

AMENDED CLAUSE

Past Experience: Vendor should have executed successfully at-least 1 project of “Terminal automation system using their own Terminal Automation Software Package”, at Petroleum oil terminals / depots handling Petroleum products viz. MS, HSD & SKO in the preceding past 10 years reckoned from date of this notice in India or abroad. Such systems should be operating successfully for at least one year at the time of bid due date. i) The past experience shall be of handling turnkey responsibilities including Project Management, Design, Engineering, Integration, Testing, Supply, Installation and Commissioning

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of complete automation system consisting of: a. Tank Lorry filling (TLF) automation system comprising of Load Rack Computers (LRCs), Flow Meters, batch controllers etc. for at-least 12 loading points for TLF Gantry, employing programmable logic controllers (PLC) or DCS systems.

WITH OR WITHOUT * Experience in supply, erection & successful commissioning of Safety PLC (SIL2 or SIL3) systems. Such safety PLC systems must have been provided for Safety / Emergency Shutdown Operations (monitoring & control) with or without Fire & Gas (Monitoring & Control) at Liquid Hydrocarbon Industries [e.g. Oil Installations handling receipt, storage & dispatch of liquid hydrocarbons (MS/ HSD/ SKO/ LPG etc.)/ Refineries/ Petrochemical plants] in India or abroad

* “ WITH OR WITHOUT ” replaces the earlier “AND” specified in original PQ Note. All other Text remains same.

Sub Clause No. 1.6 under Technical Criteria

AMENDED CLAUSE (Relevant Portion)

Bidder shall submit the following documents (as a minimum) in support of full filling the above criteria:- - PO copy for the similar works done in the past, indicating value of work.

- Completion Certificate indicating P.O No & Date from User.

- User’s Feedback about successful operation of the Terminal Automation System/s with or without # Safety PLC System for at least one year at the time of bid due date. # “ WITH OR WITHOUT ” replaces the earlier “WITH ” specified in original PQ Note. All other Text remains same.

All Bidders are required to submit the Corrigendum Annexure – I in Bid

Qualification Criteria section in Part 1 of the tender duly signed and stamped as token of acceptance without any deviation . Note : All other conditions of Bid Qualification Criteria of the tender will remain unchanged and to be accepted without any deviation.

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CORRIGENDUM ANNEXURE - II TENDER NO. CRFQ NO. : 1000179338 E – TENDER NO. : 10736

Following Points were discussed and clarified during Pre- Bid Meeting on 19.02.2013 and now clarified by BPCL: 1.Detail scope of job as per Bid qualification Criteria

2. Detail discussion on Technical Bid of Tender

3. Detail discussion on Special Condition of Tender

4. Detail discussion on Performance criteria of the job and CAMC

5. Drawings uploaded along with tender documents consisting of Loop wiring diagrams, tender purpose general arrangement drawings based on loop wiring diagram , Single line diagram of MCC Panel, equipment layout drawings to be followed by the Bidders . Bidders are also requested to visit site in order to access the local condition and to carryout site survey ..

6. PLC IO count details are uploaded with the tender documents.

7. System architecture drawings of Safety Automation system and Tank Farm management system with Terminal automation system are uploaded by BPCL along with the tender documents in stages .

8. Schedule of quantities of tender is uploaded in Price Bid of the tender document

9. BPCL NIT document and Integrity Pact with no deviation to be signed and uploaded in e tender response by the Bidders.

10. BPCL has confirmed all the Bidders that No deviation in special condition of tender, Payment Terms , CAMC clause , Performance criteria and completion period as specified in the tender will be accepted .Bidders to quote according .

11. BPCL has confirmed the Bill of quantity document will supercede the technical specification document in case of any discripency ,

12. BPCL has also confirmed that the acceptance criteria for other bought out item shall be against TPIA approved documents .

13. In case of instruments , items manufactured outside India , the scope of Third party Inspection will be limited to review of Test Certificates with serial Number and Country of Origin by the Indian Third Party Agency as per the approved list of TPIA ( ref : BQC Document ).However , the acceptable manufacturing unit outside India shall be of vendors appearing in our list only and no deviation of the same shall be accepted .

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14. Bidders have been advised /instructed / informed to correlate the System Architecture drawing for Conventional + Safety automation system, Detailed scope of work as per BQC ( Bid Qualification Document ) and Technical Bid document , System Architecture Drawing uploaded in First Corrigendum for Tank farm management system , PLC I/O counts , Tender purpose general arrangement drawings , equipment layout drawings and detailed Priced Schedule of Quantities during submission of Three Part Bid tender.

15. All the Bidders are requested to Fill up Source of Supply Forms as provided in Page No.160,161,162,163 & 164 of Technical Document No. I with Option I & II including Country of origin during submission of the tender document based on approved vendor list .This is a mandatory requirement from BPCL side . Deviation in the enclosed Format in not acceptable to BPCL.

16. Bidders to refer Technical document No. I clause 16 pages 168,169 & 170 on the scope of job of resident engineer during warranty period and accordingly load the same in the Bid . BPCL have been confirmed by BPCL that no separate payment will be disbursed for the same . However , during CAMC period the scope and extent of maintenance will be based on the special condition of tender clause no. 4 . The scope also covers any soft ware modification due to addition of new product ( max 2 nos ) , pumps ( max 2 nos ) , Bay (max 2 nos ), valves ( max 6 nos ) , instruments ( 6 nos), pipeline and tanks ( 2 nos max ) , any batch controllers ( 4 nos ) as per approved makes etc, making new graphics / modifying existing graphics including installation of any hardware module in Vendor`s SIL PLC based automation system for new BPCL requirement any time is in vendor`s scope of work.

17. Radar level transmitter ( SIL2 certified relay output) and Hi level switch ( SIl2 certified relay output ) are to be connected with two DI Modules of safety PLC( i.e. logic solver). Logic solver( DO Module) will be hardwired with ROSOV(SIL 2 certified ) . This entire loop is to be treated as safety instrumented loop per tank .Design , engineering of these loops are to be done by vendor in order to ensure SIL2 levels of such Loops as per IEC 61511. Bidder is also required to carry out „SIL verification study‟ of such Safety instrumented Loops by the Global agencies authorized for conducting such SIL verification studies( eg .TUV, EXIDA , HIMA ) prior to commissioning . .For ROSOV SIL certification reports with SFF values and other relevant values will be provided by BPCL . Also note that Safety PLC shall be provided with SIL 2 certified floating power supplies (18-32 Volt DC range ) to provide power to HC detectors.

18.BPCL clarified that CAMC scope is not for free issue items . Balance scope of work will be as per BQC, Technical specification and special condition of job .However BPCL expects that the Bidder to be the nodal point for coordination for CAMC for the free issue items of BPCL for over all satisfactory performance of the system supplied by Bidder through Resident Engineer during warranty Period .

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19.BPCL confirmed and clarified that MOVs are of M/s Limitorque make with ESD port . Model No. L120 - 10 + UEC 3 + DDC 100 & l120 - 10 + TB + UEC 3 + DDC 100 . MOV are to be serially interfaced at conventional PLC and ESD ports of MOVs are to be hardwired to safety PLC.

20. Bidders to visit site and refer tender purpose general arrangement drawings based on loop wiring diagram and schedule of quantities . Final quantity of cables and cable sizes will be based on detailed engineering drawing by successful bidder .

21. BPCL has confirmed that the power, signal & Communication cables shall be laid separately. However, as regards to spacing between the cables- detail engineering to be done based on route survey, availability of space and quantity of cable tray with sizing available in SOQ as well as Underground cables laying quantities on a totality.

22. A SIL Requirement for RADAR type Level Transmitter :

1. SIL 2 Certificate by TUV/ EXida as per IEC 61508/ 61511 along with Test

Reports specified in the certificate.

2. The functionality of overfill protection (i.e. Relay Output ) of Level

Transmitter has to be certified minimum SIL 2 (as per IEC 61508/61511) in

mono mode.

3. The Level Transmitter shall also satisfy the criteria for SIL 2 certification

according to IEC 61508 Part 2, Table 3 (i.e. Hardware Safety Integrity:

Architectural constraints on type B safety related sub-systems).

22. B SIL Requirement for Vibrating Fork type High Level Switch :

1. SIL 2 Certificate by TUV/ EXida as per IEC 61508/ 61511 along with Test

Reports specified in the certificate.

2. The functionality of overfill protection (i.e. Relay Output ) of Level Switch

has to be certified minimum SIL 2 (as per IEC 61508/61511) in mono

mode.

3. The Level Switch shall also satisfy the criteria for SIL 2 certification

according to IEC 61508 Part 2, Table 3 (i.e. Hardware Safety Integrity:

Architectural constraints on type B safety related sub-systems).

23. Servo gauges of ENRAF make and Model no. 854 ATG are already installed on AG Tanks . Ref general arrangement tender purpose drawings for details. These gauges are to be integrated with TAS and safety PLC system through hardwire cables , including supply and laying of cable .Bidders are request to visit site .

24. CIU of servo gauge to be supplied by Bidder as per the Schedule of Quantities in the tender .

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25. Free issue items for TAS : Flowmeters and TFMS : Servo level gauges are in working condition. Other all safety items related to MBLal recommendation report are being procured by BPCL which will be provided as free issue items.

26. Flowmeters are of Liquid Control Make .Digital control valves , earthing relay and RIT and batch controllers are to be supplied and integrated with the existing flowmeters .Bidders are requested to visit site for further detailing .

27. Bidder to coordinate with OEM for spares on behalf of BPCL for existing instruments already installed .

28. Successful Bidder to provide detail engineering drawing as per scope of work to complete the job in totality following technical specification and special condition of tender and scope of work and Schedule of quantities.

29. Apart from SOQ , the successful Bidders are required to carry out detail engineering based on cable route survey and finalize the quantities of cable.

30.Bidder to refer loop wiring diagram of ROSOV and tender purpose GA drawing . All Free issue items are to be hardwire including cable laying through by the bidders for instrument , control and power as applicable .

31. Bidder to refer loop wiring diagram of HC Detector and tender purpose GA drawing . All Free issue items are to be hardwire including cable laying through by the bidders for instrument , control and power as applicable .

32.Bidders to refer to System Architecture drawing provided by BPCL. All Free issue and Bidders supplied instruments are to be serially / hardwired with safety and conventional PLC based on system architecture drawing and scope .

33. 230 Volt AC for MCC of all pumps and necessary modification at MCC panel to be carried out by the bidders based on SOQ.

34. Requirement of SIL Verification Study of Safety Instrumented Loops SIL verification to be done by Bidder through TUV/ EXIDA/HIMA or alternate equivalent competent agencies approved by BPCL. Bidder shall arrange certification of all SIL loops by TPIA . All the safety relevant data for each components of SIF ,eg PFD , failure rate ( safe and dangerous failure ) DC (% Safe and dangerous detected ) needs to be provided by vendor for their supplied SIL 2 certified instruments ( eg . Safety PLC , Hi Level switch , radar Type level transmitters ). In this regard BPCL will provide such data for ROSOV ,Hydrocarbon Detectors . The main safety instrumented loop for which SIL verification study upto SIL level 2 is to be conducted consisting of radar Type level transmitter and Hi Level switch ( Primary sensors) , safety PLC ( Logic solver) and ROSOV ( Final Control element ). Proof Test interval certified by TUV is to be submitted by vendor . In case if , Proof testing is to be done during warranty , same is to be carried out by the vendor through TUV/EXIDA/HIMA or alternative equivalent agencies as approved by BPCL. Note : The design engineering of all SIF loops with an objective to ensure SIL2 level for the entire safety instrumented loop as per IEC 61511 is in vendor`s scope .This detail engineering will be part of FDS documentation and the performance of the SIL verification study at site to comply IEC 61511 for the SIF loop compliance as per IEC 61511.

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35. In order to ensure requirement of IEC 61508 / IEC 61511whatever is required for SIL2 compliance for safety instrumented loops to ensure SIL2 level are to be provided .This is to be noted that all components of SIF loops required to be SIL compliant . Note: ROSOV Open / Close Status Indication will be provided thru P+F make SIL Certified Proximity type limit switches. In order to hardwire / interface these limit switches corresponding Zener safety barriers of P+F make (SIL certified) are to be provided at Safety PLC cabinet by the bidder. The bidders are required to supply Switch Amplifier ( Model No. KFA6 – SR2- Ex1 .w.LB of P+F make which requires 230V AC power supply . Please note that the Output voltage of the switch amplifier is 8V DC over which ROSOV limit switches will be hardwired with these switch amplifiers ) . Such loops will require 8 VDC as Interrogation Voltage which is to be provided by bidder thru their Safety PLC System.

36. TAS vendor is responsible for the total performance of the system supplied by them and to adhere at performance criteria strictly .It is the sole responsibility of the Bidder to comply with the CAMC and warranty clause .As BPCL will enter into agreement with the Bidder , therefore the sole responsibility for fulfilling performance criteria of the job through OEM`s shall be on Bidder`s scope .

37. BPCL requires minimum Window 7 for all operating systems..

38. For batch Controllers, OIML approval, approval from Legal metrology (W&M Dept. India) apart from CCOE approval are required to be submitted by the bidder along with technical bid of the tender .

39. Clause of Limitation of Liability as per clause no 31 of NIT document to be accepted by Bidders .The final payment by the OWNER in pursuance of the CONTRACT terms shall not mean release of the CONTRACTOR from all his liabilities under the CONTRACT. The CONTRACTOR will be liable and committed under this CONTRACT to fulfill all his liabilities and responsibilities, till such time Contract cum- Equipment Performance Bank Guarantee is released by the OWNER. The total liability of the contractor shall be limited to the contract value and the contractor shall not be held liable for consequential damages. 40. All the bidders are advised to ensure that the entire SIL 2 certified PLC cabinet/ system including Input/ output modules, interposing relays, zener safety barriers, signal isolators, Power supplies & any other active component shall have proper SIL2 certification to meet the requirement of IEC 61508 / IEC 61511 / SIL2 compliance for all the field instrumentation (analog & digital loops) to be interfaced with the Safety PLC system as per I/O details / system architecture drawing provided for the purpose.

All Bidders are required to submit the Corrigendum Annexure – II in Technical Bid Section of the tender duly signed and stamped as token of acceptance without any deviation .

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CORRIGENDUM ANNEXURE –III TENDER NO. CRFQ NO. : 1000179338 E – TENDER NO. : 10736

Bidders have raised queries based on the discussion held during Pre- Bid meeting on 19.02.2013 and the point wise clarification provided by BPCL are stated below :

SL

Document Details

BPCL requirement

Query raised by Bidders

Clarification by BPCL

1.

Document-1-Scope of work-Page 2-clause-1.1.7

Installation, cabling (supply/laying) ,field testing, commissioning, Integration(hardwiring/ digital interface with PLC ), site acceptance test of following instrumentation/ sub-systems to be provided by BPCL as Free issue items

M/s Honeywell have requested M/s BPCL to exclude the Installation, field testing and commissioning of free issue items from their scope. Bidders understand that Warranty and CAMC of free issued items/ BPCL supplied item will not be part of our scope. .As bidders do not have expertise for ROSOV /MOV for erection as this is a mechanical items and having the piping modification and hydrotest type of activity .

BPCL clarified that CAMC scope is not for free issue items . Balance scope of work will be as per BQC, Technical specification and special condition of job .However BPCL expects that the Bidder to be the nodal point for coordination for CAMC for the free issue items of BPCL for over all satisfactory performance of the system supplied by Bidder through Resident Engineer during warranty Period .

2.

Document-1-Scope of work-Page 2-clause-1.1.7.5

MOV-to be hardwired / Serially interfaced (2-wire control System) with PLC as applicable`

M/s Honeywell requested M/s BPCL to clarify whether the MOV shall be hardwired or serially interfaced with

MOVs are Limitorque make with ESD port . Model No. L120 - 10 + UEC 3 + DDC 100 & l120 - 10 + TB + UEC 3 + DDC 100 . MOV are to be serially interface at

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PLC. Bidders further requested M/s BPCL to confirm the make and model of MOV to be interfaced alongwith the quantity and location of MOV's in the terminals.

conventional PLC and ESD ports of MOVs are to be hardwired to safety PLC.

3.

Document-1 Scope of work-Page-3-Clause-1.1.12

Any other instrument/ equipment/ service which are not explicitly mentioned in the tender but deemed necessary for the successful operation of the system complete in all respects, shall be in bidder‟s scope

M/s Honeywell understand that we have to supply items as per the SOQ

Items rates to be quoted by bidders are as per Schedule of Quantities in Price Bid and scope of job .

4.

Document-1-Scope of work-Page-5-clause-1.2.12

Two PD Meters,Two Air Eliminators,Two Stariners for each bay

M/s Honeywell understand from the BOQ that the PD Meters,Air Eliminator and Strainer will be existing and will be handed over to us in working condition and also the warranty and AMC of these items shall be in BPCL scope .Request M/s BPCL to confirm our understanding.

Not applicable in the scope of tender .However the Bidders / RE will coordinate the activities with OEM of the PD meters for the execution / performance of equipment awarded by BPCL. .

5.

Document-1-Scope of work-Page-5-clause-1.2.12

Pneumatically powered type(along with air compressor, refrigerated air drier and GI Piping/copper tubing required for pneumatic/air supply at individual loading points.

M/s Honeywell request Ms/ BPCL to provide clarity on the scope of tubing, supply of air compressor, Size of compressor etc. Kindly provide the details specification sheet

Not applicable in the scope of tender.

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for compressor.

6.

Document-1,Scope of work-Page-6,clause-1.2.13

Each product header running between TLF pump house & TLF Gantry will be provided with pressure gauges, pressure safety valve, Meter proving system, Pressure transmitter & Bulk Air Eliminator (Dead volume capacity -10% volume of the product accumulated in 1 minute at combined max. rated flow rate of all the TLF pumps of the specified product).

M/s Honeywell understand that Bulk air eliminator is not part of our scope. Kindly confirm.


7

Document-1,Scope of work-Page-7

Dedicated power distribution cabinets with individual MCBs is to be provided for powering of field MOVs

M/s Honeywell understand that Power distribution cabinets required for powering Field MOV's is not in our scope. Request M/s BPCL to confirm our understanding.


8

Document-1,Scope of work-Page-7-Clause-1.2.17

For each bay, 36C X 1.5 sq mm copper conductor, armoured, FRLS PVC cable is to be laid from control Room (Power distribution cabinet) up to bay specific FLP Junction box

M/s Honeywell understand that the cable type and length has to be provided as per the SOQ .Request M/s BPCL to confirm our understanding.

Bidders to visit site and refer tender purpose general arrangement drawings based on loop wiring diagram and schedule of quantities . Final quantity of cables and cable sizes will be based on detailed engineering drawing by successful bidder .

9

Document-1,Scope of work-Page-7-Clause-1.2.17

From the above FLP Junction box, 3C X 1.5 sq mm copper conductor, armoured, FRLS PVC cables, are to be provided / laid to

M/s Honeywell informed that solenoid valves are powered through batch controllers. Request M/s

Accepted by BPCL.

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the following instruments of a bay - Four Solenoid Valves of the two Set stop valves

BPCL to accept the same.

10

Document-1,Scope of work-Page-13-Clause-1.3

Details of Existing Installation to be provided by regional E&P on the basis of which the work will be quantified

M/s Honeywell request M/s BPCL to provide Operating Pressure/flow (min/max) at each loading point. Request M/s BPCL to provide Details of MCCs to be interfaced with TAS

Details already provided in the tender document. Bidders are also requested to visit site for obtaining confirmation in this regard .

11 Document-1,Functional design specification-Page-17-Clause-2.13

2.13 Site License for Operating System for each of the LRC & client stations and shall be equivalent to Full pack of Windows 2008 Server.

M/s Honeywell will provide the Windows 7 pre loaded .

windows 7 Pre- loaded is accepted if the same is the latest used by them .

12

Document-1,Page-48, Licenses

2-Name / Version of RDBMS offered.

M/s Honeywell informed that the RDBMS License is inbuilt in certain software. Request M/s BPCL to accept the same.

Accepted by BPCL.

13

Document-1,Page-50, Diagonistic Display

The I/O status display shall provide detailed information of each I/O Channel of the associated device.

M/s Honeywell have offered PLC system with diagnostics on module level as per OEM standard.

BPCL agreed for fuse Channel Indiaction .

14

Document-1,Page-54, Programmable Logic Controller Conventional

Programmable logic controller (PLC) system shall be programmable, modular microprocessor based safety system, which shall be used for implementation of safety

M/s Honeywell understand that the specification calls for general purpose PLC system as per the mentioned tender clause. Request M/s BPCL to confirm the same.

BPCL confirmed that this pertains to conventional PLC

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shutdown/interlocks and terminal operation monitoring.

15

Document-1,Page-58, Programmable Logic Controller Conventional-Clause-7.19.3.1.12

The digital output module offered should have this functionality; separate terminal block with fuse blow indication in conjunction with a general-purpose digital output module shall not be acceptable.

M/s Honeywell informed that this functionality shall be provided using RTP board as per OEM standard. Request M/s BPCL to accept the same.

Accepted by BPCL as OEM standard .

16

Document-1,Page-64, SAFETY PROGRAMMABLE LOGIC CONTROLLER-SIL 2-Clause-7.20.1.7

The PLC System (Processor & I/O) shall also comply to UL 508 & CSA C22.2 No 142 Standards for Industrial Control Equipments / Process control equipments

M/s Honeywell have confirmed that the system is compliant to IEC 61508/IEC61511 and is certified by TUV for the same.

The clarification given by BPCL is for Sil requirement .

17


TUV Certified SIL PLC and in order to maintain the Integrity of SIL Certification V

M/s Honeywell opined that for TUV Certified SIL PLC and in order to maintain the Integrity of SIL Certification Value Chain even up to site, it is recommended that Design & Engg (incl making of Cause & Effect drg) as well as the commissioning is done by TUV Certified Engrs and the Manufacturing premises should also be TUV certified. :

Radar level transmitter ( SIL2 certified relay output) and Hi level switch ( SIl2 certified relay output ) are to be connected with two DI Modules of safety PLC( i.e. logic solver). Logic solver( DO Module) will be hardwired with ROSOV(SIL 2 certified ) . This entire loop is to be treated as safety instrumented loop per tank .Design , engineering of these loops are to be done

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by vendor in order to ensure SIL2 levels of such Loops as per IEC 61511. Bidder is also required to carry out „SIL verification study‟ of such Safety instrumented Loops by the Global agencies authorized for conducting such SIL verification studies( eg .TUV, EXIDA , HIMA ) prior to commissioning . .For ROSOV SIL certification reports with SFF values and other relevant values will be provided by BPCL . The above requirement is also valid for SIL2 certified HC Detectors which will be free issue items by BPCL. Also note that Safety PLC shall be provided with SIL 2 certified floating power supplies (18-32 Volt DC range ) to provide power to HC detectors.

18 Document-1,Page-64, SAFETY PROGRAMMABLE LOGIC CONTROLLER-SIL 2-Clause-7.20.1.11

The scan time of programmable controller shall be of the order of 100 milliseconds for logic & 300 milliseconds for closed loops.

M/s Honeywell informed that there is no separate scan time for Loops.

Bidder to follow technical specification of safety PLC.

19 Document-1,Page-67, SAFETY PROGRAMMABLE LOGIC CONTROLLER-SIL 2-Clause-

Each module shall have LED for each I/O channel to indicate the status of each input/output.

M/s Honeywell informed that clause is not applicable for analog modules.

Accepted by BPCL.

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7.20.3.1.5

20


Communication Interface between each I/O rack & the dual processor system shall be via separate dedicated dual redundant communication link in multi-drop mode; daisy chained redundant communication bus to establish interface between I/O racks & processor system shall not be acceptable.

M/s Honeywell informed that communication bus is integrated at the CPU chassis & is controlled by both the CPU.In case of failure of one CPU there is no loss of protection and there is no bump in the system. This meets the functional requirement of SIL-3, confirming to IEC61508

Accepted by BPCL

21 Document-1,Page-69, SAFETY PROGRAMMABLE LOGIC CONTROLLER-SIL 2-Note

These Technical specifications & I/O count will be frozen during Technical evaluation.

M/s Honeywell understand that we have to consider I/O Count as per the SOQ. Request M/s BPCL to confirm the same.

BPCL has provided IO count list and the same are mentioned in schedule of quantities also.

22

Document 1,Page-78 cable laying

The cables shall be laid with min. spacing of “D” (D being the diameter of the thicker cable) * 15mm from edge of the cable tray. Power Cable shall be laid in separate trench and Signal & Communication Cabling shall be laid different trench

M/s Honeywell request M/s BPCL to remove this clause as this will increase the tray sizing drastically. Kindly confirm. Or please segregate the Main cables and Branch cables

BPCL has confirmed that the power, signal & Communication cables shall be laid separately. However, as regards to spacing between the cables- detail engineering to be done based on route survey, availability of space and quantity of cable tray with sizing available in SOQ as well as Underground cables laying quantities on a totality.

23 Document-1,Page-92-Technical specification for Equipment and its data sheet

Needle valve - SS 316 high pressure rated ,built in block

As understood by M/s Honeywell that this is not part of supply and same shall be handed over to us

Not applicable for this job.

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in working condition. Also we understand that warranty and AMC of all free issue items shall not be in our scope.Request M/s BPCL to confirm the understanding.

24

Document 1,Page-93-Technical specification for PD Meter with pulse Transmitter

PD Meter with pulse transmitter

As understood by M/s Honeywell that PD Meter is not part of supply as per the SOQ. Request M/s BPCL to confirm the same.

BPCL confirmed bidder to follow the schedule of quantities of the tender.

25

Document 1Page-97-Technical specification for Strainer

Strainer

As understood by M/s Honeywell that same is not part of supply as per the SOQ. Request M/s BPCL to confirm the same.


26

Document 1,Page-99-Technical specification for Air Eliminator

Air Eliminator

As understood by M/s Honeywell that same is not part of supply as per the SOQ. Request M/s BPCL to confirm the same.


27

Document 1,Page-102-Technical specification for Pressure Gauge

Pressure Gauge

As understood by M/s Honeywell that same is not part of supply as per the SOQ.Request M/s BPCL to confirm the same.


28

Document -1,Page-109-Technical specification for Digital Control Valve

Air compressor with refrigerated air drier along with heavy duty GI Piping and copper tubing is to be supplied, installed & Commissioned by vendor for proving

M/s Honeywell understand that this requirement is not applicable for this enquiry

Not applicable

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air supply to pneumatic actuators

29

Document 1,Page-113-Technical specification for Batch Controller Unit

Diagnostic Alarm-BC front panel shall have status LED's for indicating alarms, Operation mode and permissive status etc.

Status messages, alarms faults & errors will appear on display. M/s Honeywell request M/s BPCL to accept the same.

BPCL agreed as OEM standard.

30


Hardware Performance & Parameters-EPROM-128K,RAM-128KB,NVRAM-0.5MB

M/s Honeywell have offered Batch controller will have Flash memory-768KB,RAM-24KB,NVRAM-0.5MB as per OEM Standard. Kindly accept..


31


Alpha numeric key pad (each alpha numeric shall be followed by a number) Back lighted LCD

M/s Honeywell have offered Batch controller that will have Graphic dot matrix LCD display as per OEM standard. Request M/s BPCL to accept the same.


32


Protocol Requirement – Modbus RTU / TCP-IP/ Fieldbus / profibus /any other open Protocol [ Protocol details are required along with Technical bid]

The protocol shall be as per Honeywell`s own BCU standard. Their Batch Controller has been successfully integrated with other competitors apart from their own installations.


33

Document 1,Page-115-Technical specification for Earthing Relay Unit

Cable /Connector - Flexible cable with Ball & socket type clip.

M/s Honeywell requested M/s BPCL to accept the crocodile type clamp in place of Ball & Socket Type. Kindly accept.

BPCL requested vendors to adhere to the specification of the tender.

34 Document 1,Page-133-Technical specification for

Point-8-All cable glands and plugs shall be nickel plated

M/s Honeywell asked BPCL to clarify the

BPCL confirmed that SS type cable glands are to be supplied by the

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Junction Box brass material. mismatch w.r.t the SOQ and technical specification.

bidder as per that SOQ .

35

Document 1,Page-134-Technical specification for Electro Magnetic Display Board

Type of Display Board

M/s Honeywell informed that one of the approved OEM has offered Weather Proof IP-55 Electro Magnetic Display without embedded LCD. We request M/s. BPCL to accept the same. As they are only sound supplier of display board.

Can be accepted if it is an OEM Deviation .

36


Size of Mosaic

M/s Honeywell informed that One of the approved OEM has offered 12mm Round Pixel at 16 mm pitch. We request M/s. BPCL to accept the same.


37


LEDS - Centre of each mosaic shall have an yellow-green LCD/ equivalent

M/s Honeywell informed that One of the approved OEM does not require LCD. The display will be visible without LED/LCD during day time. For night time visibility focusing a 75 watts white halogen is sufficient. We request M/s. BPCL to accept the same.



Visibility M/s Honeywell informed that One of the approved


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Electro Magnetic Display Board

OEM has offered Visibility Up to 50 Meters. We request M/s. BPCL to accept the same.

39


Display mode - Out of the 5 lines displayed, 4 lines should display the Truck Registration Number allocated to 4 loading bays. The 5th line should flash the Truck Registration Number with the words "WL" against it to advice that the truck is "Wait Listed

M/s Honeywell informed that One of the approved OEM has offered with Time out written between 4th and 5th Line. We request M/s BPCL to accept the same.


40


Integrated Voice Announcement system

M/s Honeywell informed that One of the approved OEM offers Integrated Voice Announcement system via RS485 interface from Display board to an external announcement processor. We request M/s. BPCL to accept the same.


41

Document 1,Page-138-Technical specification for Additive Injection Block - Additive Flow Meter

Flow range - 0.3 GPM to 2 GPM

M/s Honeywell informed that one of the approved OEM has offered Flow Range of 0.3 - 3.0 GPM instead of 0.3 GPM to 2 GPM. We request M/s. BPCL to accept the same..

Not applicable as per scope of job .


All wetted parts - SS 316

M/s Honeywell informed that one of the bidders


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Additive Injection Block - Additive Flow Meter

injection Block is standard wetted parts of SS 303 & 304. The same is being used at HPCL / IOCL at several installations.

43


Check Valve - SS 316, built-in block

M/s Honeywell informed that one of the bidders provides SS 304 MON for Check Valve. We request M/s. BPCL to accept the same.


44


Strainer Size - 15/12 mm

M/s Honeywell informed that one of the bidders Strainer of Size as 17mm instead of 15/12mm. We request M/s. BPCL to accept the same.


45


Needle valve - SS 316 high pressure rated ,built in block

M/s Honeywell informed that one of the bidders additive block has standard needle valve of SS304. We request M/s. BPCL to accept the same.


46 Document 1,Page-156-Approved vendor List

Orifice Plate - Star-Mech, Micro-precision ;Switzer

M/s Honeywell request M/s BPCL to accept Baliga make Orifice Plate as part of approved vendor list. Kindly confirm.

Not applicable


Access Control System - WSE, Balogh, Daniel – For loading rack ; HID – Control Room

M/s Honeywell requested to accept Honeywell make Access Control System as part of approved vendor list. Kindly confirm.

Acceptable as this product is manufacturer of the bidder who is the manufacturer of terminal automation automation vendor .


Strainer & Air Eliminator - Liquid controls/ Brooks

M/s Honeywell request M/s BPCL to accept

Not applicable for this job.

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/Bopp & Reuther/Flash point/FMC/Flash Point

Cryogenic make Strainer & Air Eliminator as part of approved vendor list


Level Switch (Vibrating Fork type)-SIL2 certified - E&H , SAAB, Magnetrol

M/s Honeywell request M/s BPCL to accept Krohne & Vega make Level Switch as part of approved vendor list. Kindly confirm. Also the magnetrol make , level switch will have assembly which works on ultrasonic pulse frequency ., Looking to the delivery we request to incorporate the additional vendor

Bidders to follow Technical specification / makes as per Tender document .


C.S.Ball/ Gate Valve - Audco, Fisher – Xomox, Virgo Engineers.

M/s Honeywell requested M/s BPCL to accept Flowchem make Ball Valve as part of approved vendor list. Kindly confirm.



Tube & Tube Fittings - Swagelock, Parkar,

M/s Honeywell requested M/s BPCL to accept EXCEL HYDRO PNEUMATICS , WINTECH ENGINEERS, ARYA CRAFT make Tube & Tube Fittings as part of approved vendor list. Kindly confirm.



Electro Magnetic displays - Bharat Electronic Limited,

M/s Honeywell requested M/s BPCL to accept

Not acceptable

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IRA, Magneto Dynamic.

Team Power make LED Type Display Board as part of approved vendor list. Kindly confirm


Print servers HP, INTEL, IBM

M/s Honeywell requested M/s BPCL to accept D Link make print server as part of approved vendor list. Kindly confirm. Looking to the delivery we request to incorporate the additional vendor

Not acceptable .Bidders to follow Technical specification / makes as per Tender document .


Barrier gate - Heidz India, Autodoor, Technica.

M/s Honeywell request M/s BPCL to accept Metachem make barrier gates as part of approved vendor list. Kindly confirm.

Metachem make barrier is acceptable to BPCL meeting the technical specification .

55 Page 159-Note-4

Party shall offer various components of flow meter assembly i.e. PD meter, strainer cum air eliminator and pulse transmitter, proving vessel etc. of one family only

M/s Honeywell request M/s BPCL to restrict this requirement to PD Meter and Pulser only. Kindly Confirm. As Meter is a active device and proving is Passive device

Not applicable . Please refer SOQ .

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56 Page 1 of 38-1 Objective

TFMS system shall be SIL 2 Certified

M/s Honeywell have requested to clarify this point. As safety function of Radar gauge ( Relay out put) will only be used for safety loops , And TFMS system cannot be SIL 2 certified. The safety loop comprising of Radar safety function (relay output) , Logic Solver (PLC) and control element ( Tank Body Valve) would need a safety verfication for SIL2 compliance by competent body.

A) SIL Requirement for RADAR type Level Transmitter :

1. SIL 2 Certificate by

TUV/ EXida as

per IEC 61508/

61511 along with

Test Reports

specified in the

certificate.

2. The functionality of

overfill protection

(i.e. Relay Output )

of Level

Transmitter has to

be certified

minimum SIL 2 (as

per IEC

61508/61511) in

mono mode.

3. The Level

Transmitter shall

also satisfy the

criteria for SIL 2

certification

according to IEC

61508 Part 2,

Table 3 (i.e.

Hardware Safety

Integrity:

Architectural

constraints on type

B safety related

sub-systems).

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57 Page 1 of 38 -2 Scope of Work: 2.1.1.1

SIL-2 certified Radar gauges

M/s Honeywell supplied radar gauges ( Honeywell Enraf Flexline Radar gauges ) have a separate safety function (1 - Relay function) suitable for use in safety instrumented system (SIS) and this function meets the minimum Safety Integrity Level 2 (SIL 2) requirements as per IEC 61508. TÜV Rheinland in Koln , Germany, has provided them with the approval report for the FlexLine Radar , which certifies that the product meets the SIL-2 level as per IEC 61508 Part 1 -7: year 2010. TUV document attached. Honeywell further would like to explain that other vendor of radar has a certificate from EXIDA , however meets only the obsolete standard of IEC61508 . Another approved vendor has a proven in use Certificate , and have a SFF of 77% ( much less than the 90% requirements of



TUV/ EXida as

per IEC 61508/

61511 along with

Test Reports

specified in the

certificate.


overfill protection


of Level

Transmitter has to

be certified

minimum SIL 2 (as

per IEC

61508/61511) in

mono mode.

3. The Level

Transmitter shall

also satisfy the

criteria for SIL 2

certification

according to IEC

61508 Part 2,

Table 3 (i.e.

Hardware Safety

Integrity:

Architectural

constraints on type

B safety related

sub-systems).

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IEC 61508 ) .Also while Honeywell Enraf provides safety function output (relays) directly from Radar ( Primary sensor ), other approved vendors offers this from Tank Side indicators ( which is NOT a primary sensor ) . Additionally for one vendor , the safety function (relay out put from the tank side indicator ) are not been certified for safety loops , and no data on reliability /safety parameters for these safety function is available , in public domain. Looking at these facts and to the M B Lal recommendations , where clear and unambiguous recommendation is to enhance the SIL level of entire safety loop , it is only just that any report / approval/ certificate from a independent and accredited Third party Safety assessor is accepted for choosing the instrumentation to design a safety loop. Also bidder would like to clarify on record that

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Honeywell will be able to bid for this valuable tender only with Honeywell make tank gauging system , which meets the latest standards of safety which is year 2010 release of IEC 61508 .

58 Page 1 of 38-2 Scope of Work: 2.1.3

All process parameters like gross level, water lever, temp & density shall be available in locally in the TSI for each tank. These process parameters as well as inventory calculations shall be available in the TFMS computer & all the client machines at control room, Installation manager room & planning room.

M/s Honeywell informed that Client machine will be receiving the data from TAS server.

This not relevant to this clause .

59 Page 2 of 38-2 Scope of Work: 2.2.3.3 / 2.2.3.4 and 7.5 & 10.1.8

Relay output shall be hardwired to safety PLC / Conventional PLC

M/s Honeywell noted that Radar Gauge has 2 relay output , however for safety function (SIL2) , these relays would be operating in series and only one relay output would be available if used for safety function .We would like to add here that Honeywell and EMERSON Radar

Noted as per clarification made earliest on radar level gauges .

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gauges have only relay output ( single relay output) as safety function . Any additional relay output OR Analog output ( 4-20 MA ) is NON -SIL.

60 Page 4 of 38-2 Scope of Work: 2.10

Level Transmitters ( Radar Type): Four level transmitters are to be multi dropped up to redundant CIU.

M/s Honeywell informed that the clause # 11.7.1.5 of the tender document contradicts this requirement. Also the TENDER purpose diagram given (Radar level C/30061 / 1 / 1 ) shows 2 loops of 3 and 4 tanks each . Please confirm what needs to be followed.

BPCL informed to follow the Tender purpose GA Drawing sent with tenders .

61 Page 14 of 38-10.1 Radar Level Gauge : 10.1.9.1

Both inclination & orientation of the antenna shall be adjustable

M/s Honeywell informed that this is not applicable for Honeywell Enraf Radar antenna design.

Noted .

62 Page 15 of 38-10.1 Radar Level Gauge :10.1.10.4

Radar gauge antenna shall be factory desinged to be easily removable from still pipe to allow access for manual gauging, temp dipping & sampling.

M/s Honeywell informed that the still pipe ( in case of combined gauge well ) can be accessed through spool pieces . It is not recommended to move the antenna/radar /wave guide as operator needs to realign the radar/antenna/waveguide for accurate measurments and this situation leads to unsafe handling of instrument.

Noted

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63 Page 16 of 38-11 Technical specifications : 11.1 Radar Transmitter

Radar input capabilities-4- 20 mA HART input from Pressure TX

M/s Honeywell informed that as density measurement is being given from Servo Gauge , and hence Radar gauge will not be measuring density.

Pressure transmitters connectivity is required in the level transmitter .


Radar Output capabilities: TSI, Serial out put for CIU & Relay output

1 one SIL relay output possible. 1 additional relay (NON -SIL) possible. Analog output from Radar gauges are NON-SIL. This clarification applicable to Honeywell Enraf and other vendors.

Noted and refer clarification above for radar level gauges .


Sealing / O Ring : Teflon/ Viton or Flurosilicon

M/s Honeywell being OEM standard proposed radar would be having NBR 70 material O Rings. We request M/s BPCL to accept the same.

Noted and accepted as OEM standard .

66

Page 16 of 38-11 Technical specifications : 11.1 Radar Transmitter

Hazardous area classification: T3

M/s Honeywell informed that being OEM standard proposed radar would be having temperature class T6. We request M/s BPCL to accept the same.

Accepted .

67

Page 16 of 38-11 Technical specifications : 11.1 Radar Transmitter

Approvals & certifications: SIL 2 certification

Kindly refer M/s Honeywell clarification for the clause Page 1 of 38 -2 Scope of Work: 2.1.1.1 .

Noted. as per clarification made earlier on radar level gauges .

68 Page 21 of 38-11.4: Avg.Temp Sensor

Type: RTD pt 100 Multi point

Honeywell Enraf offers VITO technology which uses combination

Accepted as OEM standard

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of PT100 and Thermocouple. These are in use with IOCL/BPCL/HPCL india and other international customers . Accuracy of this sensor is +/- 0.1 deg C .


RTD spacing

Honeywell Enraf has designed the temperature sensors as per the API and ISO guidelines for the averaging temperature measurement which is to position the 1st element at 1 mtr from bottom to avoid tank bottom temperature effect on temperature measurement. As a special the First element can be given at 65mm from bottom of probe . Also Honeywell Probe gives flexibility retain the last valid temperature measurement through software.



Measuring Range : -10 to 100 Deg C

Honeywell`s Average temperature sensor have temperature measurement range of -55 to +135 Deg C, however being water sensor would be integral part of it, It shall be


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having temperature range of 0 to 100 Deg C.

71 Page 22 of 38-11.6 High High level switch

Primary Sensor: vibrating tuning fork

We Honeywell Enraf have pulsed type level switch, which is SIL 2 compliant .These switches are manufactured by Magnetrol and Magnetrol is already in approved vendor list.Also we would like to clarify that Other vendors too have only a FMEDA report , which in any case meets the requirement.

Not acceptable .Bidders to follow Technical specification / makes as per Tender document .

72 Page 24 of 38-11.7: HMI : 11.7.2.1.1

All standard windows shall have ability to be customized on demand

Honeywell`s TFMS software screens can be customised for tank names/ tank groups/ product wise .

Noted

73 Page 27 of 38-11.8: TFMS Software : 11.8.25

The system shall provide importing & exporting flow indications based on volume movements in the tank. Indications of estimated end time of batch shall be provided based on user set points.The batch handling shall be able to handle multiple destinations & sources. The batch function shall generate printable batch report.

M/s Honeywell informed that detailed Batch handling function is part of TAS system.

BPCL requires this functionality in the through dedicated TFMS software residing in in the dedicated TFMS computer . Bidders to follow Technical specification as per Tender document .

74 Corrigendum Annexure-2: 2 c & d

Low Low Level (LL) Trip setting - Floating roof tanks &

Please refer M/s Honeywell`s comments above


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Fixed Roof Tanks SN # 2 & 4.Radar safety function if being used for SIL , only one realy output would be available.

75

Corrigendum Annexure-2: A: Description of new TFMS requirement:Primary TFMS Measurement system 2:d (page 5 of 8)

The hardwired outputs i.e. 4-20 mA signal (level), Hi-Hi Level trip Alarm and Lo-Lo Level Trip Alarm of level tx. will be interfaced with Safety PLC

Please refer M/s Honeywell`s comments above for the clause on Page 2 of 38-2 Scope of Work: 2.2.3.3 / 2.2.3.4 and 7.5 & 10.1.8.


76 Special Conditions of the tender-Page 1-Clause-General

Following Instrumentation is to be covered for the Inspection & Testing: a. Programmable Logic Controllers – Manufacturer`s premises b. UPS systems- Manufacturer`s premises c. Integrated Safety PLC Automation System- Manufacturer`s premises d. Hi-Hi Level Switch- Manufacturer`s premises

M/s Honeywell have understood that this clause is applicable for local items and for all bought out items inspection shall be conducted at site against test certificates .Request M/s BPCL to confirm the same.

BPCL has also confirmed that the acceptance criteria for other bought out item shall be against TPIA approved documents .

77

Special Conditions of the tender-Page 1-Clause-Factory Acceptance test & Acceptance-Clause-1.1.1

Vendor shall demonstrate functional integrity of the system hardware and software at their factory/ premises. System is defined as „Entire centralized instrumentation connected with field instrumentation (as per System Arch. Drawing)‟. As a minimum, various

M/s Honeywell have asked that dose this mean that items like cables, PD Meters DCVs etc also cant be dispatched till FAT is complete.

BPCL clarified that only Control room instruments are required for conducting FAT, including Batch controllers, data entry terminal, display board , pulse transmitter etc.

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type of field instruments (one each) which are to be serially interfaced with centralized instrumentation are to be made available by vendor during FAT.

78

Special Conditions of the tender-Page 2-Clause-Testing and FAT shall be carried out in two phases -Clause-1.1.8

30 Days burn in test

M/s Honeywell have requested to reduce the time period of the burn out test .

Not acceptable.

79

Special Conditions of the tender-Page 4-Clause-Installation,Testing and precommisioning checks-Point .

Ensuring proper installation & hydro testing of Process instrumentation subsequent to their installation in field.

M/s Honeywell request M/s BPCL to list the equipments for which hydro testing is required.

Not in scope of job .

80

Special Conditions of the tender-Page 4-Clause-Trial Run-Point 3 and Point 4

3. Trial Run will be conducted by Vendor for a continuous period of 60(Sixty) days to verify the satisfactory performance of the system. 4. In case of major failure in the system, the trial run shall be repeated for a period of another 60 days

Please note that the trial run period is too long, also request M/s BPCL to define the term "major failure" and relook the trail run period.

60 days of trail run is to be conducted as performance criteria .

81

Special Conditions of the tender-Page 4-Clause-SAT-Point 3

3. In case of failure of SAT , same shall be repeated for another 15 days.

Request M/s BPCL to define what will constitute the failure of SAT.

BPCL asked the bidders to refer performance criteria as acceptance criterai for SAT. Concurrence from HQ is required.

82

Special Conditions of the tender-Page 7-Clause-Post warranty period

Software/ hardware modifications required as per revised requirement of Installation during

Request M/s BPCL to specify the exact requirement .Please note that

The scope covering any soft ware modification due to addition of new product ( max 2 nos ) , pumps (

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CAMC period are to be carried out by automation vendor as part of CAMC.

any upgradation of the system shall be on per Man day basis or on mutually agreed terms and conditions.

max 2 nos ) , Bay (max 2 nos ), valves ( max 6 nos ) , instruments ( 6 nos), pipeline and tanks ( 2 nos max ) , any batch controllers ( 4 nos ) as per approved makes etc, making new graphics / modifying existing graphics including installation of any hardware module in Vendor`s SIL PLC based automation system for new BPCL requirement any time is in vendor`s scope of work.

83

Special Conditions of the tender-Page 9-Completion period

7 1/2 months

Please note that looking at the quantum of job the completion period is small .Request M/s BPCL to increase the completion period to 12 months.

BPCL confirmed that completion time will remain unchanged .

84 General Due date extension

M/s Honeywell requested M/s BPCL to extend the bid submission due date by 21 Working days from the date of prebid replies for internal approvals

Extension date for submission of tender is mentioned in enclosed annexure.

85 General List of Spares to be kept during Warranty & CAMC

M/s GE request M/s BPCL to provide list of Spares which are to be maintain as minimum during Warranty & AMC.

BPCL clarified that the list of spares will be based on the requirement by OEM of individual equipment in order to fulfill the system performance requirement as per tender document ..

86 General Gantry Equipment

M/s GE have understood that protocol details of all free Issue components to

BPCL Confirmed the same.

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interface the same with TAS shall be provided by customer to us at free of cost.

87 Approved Vendor List

Access Control System - Daniel - For Loading Rack

M/s GE have informed that subsequent to name change from M/s. Daniel Measurement and Control (India) Pvt. Ltd., the company is now known as M/s. Advanced Sys-tek Pvt. Ltd., also note that all statutory certificates of M/s. Daniel were transfer in the name of M/s. Advanced Sys-tek.

BPCL noted and confirmed the same

88 General Any addition or deletion

M/s GE understand that necessary order amendment shall be issued for additional work prior to execution of the same, also proper Time Extension shall be provided. Request M/s BPCL to kindly confirm.

Bidder to refer NIT document .

89 General Any addition or deletion

M/s GE informed that In case of deletion of quantities, the revised quantity shall be finalized before issuance of Detailed PO / WO. Kindly confirm.

Bidder to refer NIT document .

90 EMD EMD

M/s GE understood that parties registered under NSIC and or registered with

ASTL has been taken over by GE . Needs clarification on the status of ASTL as NSIC.

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BPCL are exempted from payment of EMD.

91 BOQ flow meter

M/s GE informed that as per price bid we understand flow meter is not in our scope of supply, pls confirm the same.

BPCL re-confirmed the same.

92 BOQ strainer

M/s GE informed that as per price bid we understand strainer & Air Eliminator is not in our scope of supply, pls confirm the same.


93 BOQ Master meter & prover tank (2KL & 5KL)

M/s GE request M/s. BPCL to clarify the need of both master meter & prover tank of 2KL & 5 KL

2KL Prover is for online calibration and 5L prover is for master meter calibration.

94 BOQ Servo Level gauge

M/s GE understood only integration of servo gauge is in scope of work, request you to clarify our understanding is correct.

Servo gauges of ENRAF make are already installed on AG Tanks . Ref general arrangement tender purpose drawings for details. These gauges are to be integrated with TAS and safety PLC system through hardwire cables , including supply and laying of cable .Bidders are request to visit site .

95 BOQ Servo Level gauge -CIU

M/s GE understand that CIU of servo gauge shall be provided in Satisfactorily working condition. Also necessary protocol shall be provided by Customer at free of cost to us.

CIU of servo gauge to be supplied by Bidder as per the Schedule of Quantities in the tender ..

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96 BOQ Servo Level gauge

M/s GE request M/s. BPCL to provide make & model of existing servo gauge.

ENRAF servo level gauges, Model no. 854 ATG . Bidders are requested to visit site to check for further details.

97 BOQ MOV actuator & master control station

M/s GE understood that only intregration of MOV actuator & master control station is in scope of work, request you to clarify our understanding is correct.

MOVs are Limitorque make with ESD port . Model No. L120 - 10 + UEC 3 + DDC 100 & l120 - 10 + TB + UEC 3 + DDC 100 . MOV are to be serially interfaced at conventional PLC and ESD ports of MOVs are to be hardwired to safety PLC. Except for power cabling sreial interfacing with conventional PLC and hardwire cabling with safety PLC to be done by the Bidder.


M/s GE understood that all MOV Actuators are already connected to Control Room mounted Master Control Station. Cabling for these MOVs shall not be in TAS Vendor's scope.

MOVs are Limitorque make with ESD port . Model No. L120 - 10 + UEC 3 + DDC 100 & l120 - 10 + TB + UEC 3 + DDC 100 . MOV are to be serially interface at conventional PLC and ESD ports of MOVs are to be hardwired to safety PLC. Cabling need to be done by the bidder.


M/s GE requested M/s. BPCL to provide make & model of existing MOV actuator & Master control station.

MOVs are Limitorque make with ESD port . Model No. L120 - 10 + UEC 3 + DDC 100 & l120 - 10 + TB + UEC 3 + DDC 100 . No Master Control station required for interfacing with Limitorque make and model actuators . MODBUS registers will be shared to the vendors .

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100 BOQ ROSOV

M/s GE understood that supply & Installation of ROSOV is not in our scope of work, pls confirm the same.


101 BOQ ROSOV

M/s GE understood that Cabling for these ROSOVs shall not be in TAS Vendor's scope.

Hardwire cabling including supply and laying for safety PLC is in the scope of the Bidder. Please refer Loop wiring diagram for ROSOV and general arrangement tender purpose drawing .

102 BOQ Hydrocarbon Detector

M/s GE understood that supply & Installation of hydrocarbon detector is not in their scope of work,their scope will be limited to interfacing of same and for which required protocol details / communication details shall be provided by Customer at free of cost.

Hardwire cabling including supply and laying for safety PLC is in the scope of the Bidder. Please refer Loop wiring diagram for HC Detectors .

103 BOQ Fire fighting system

M/s GE understood that supply & Installation of fire fighting system is not in our scope of work, pls confirm the same.

Hardwire cabling for safety PLC including supply and laying is in the scope of the Bidder.

104 General

M/s GE understood all free issue item given by M/s. BPCL to us shall be in satisfactory working condition.

Free issue items for TAS : Flowmeters and TFMS : Servo level gauges are in working condition. Other all safety items related to MBLal recommendation

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report are being procured by BPCL which will be provided as free issue items.

105 General Flow meter system

M/s GE request M/s. BPCL to kindly provide the Make & Model of PD Meter. Also they understand that PD Meter will provide required pulse input to Batch Controller.

Flowmeters are of Liquid Control Make .Digital control valves , earthing relay and RIT and batch controllers are to be supplied and integrated with the existing flowmeters .Bidders are requested to visit site for further detailing .

106 General Spare for existing system

M/s GE request M/s. BPCL to remove spare for existing system from our scope of work.

Bidder to coordinate with OEM for spares on behalf of BPCL for existing instruments already installed .

107 General Tank Details for Radar Gauge

M/s GE request M/s. BPCL to kindly provide the Complete tank Details including Tank Dia, Height and Number of Manhole with Diameter.

Already provided in the tender purpose drawings and location detail. Bidders are requested to visit site to cross check the data .


M/s GE understood that All tanks will have necessary manhole to install Radar Gauges, Multi Spot Temperature Element kindly confirm.

Separate drawing for installation of gauges will be submitted to successful bidders .


M/s GE request M/s. BPCL to confirm whether Pressure Transmitter at Tank Bottom to calculate Density is required?

Pressure transmitters not required.

110

TFMS requirement & Implementation methodology

The hardwired outputs i.e. 4-20 mA signal (level), Hi-Hi

M/s GE request M/s. BPCL to kindly note that 4 -

Noted and accepted as OEM standard

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Level trip Alarm and Lo-Lo Level Trip Alarm of level tx. will be interfaced with Safety PLC

20 mA with SIL output is not possible in Radar Gauge.

111 TFM System SIL Output

M/s GE request M/s. BPCL to note that none of BPCL Approved OEM can provide 2 nos. SIL Relay output for Alarm. There can be only one SIL output Relay, kindly accept the same.

Noted and accepted as OEM standard

112 BOQ DBB Valve

M/s GE understood that supply of DBB Valve with MOV Actuator and Cables for the same shall not be in our scope. Kindly confirm.

BPCL confirmed the same.

113 BOQ Powering ON Various items / systems

M/s GE understood that Powering ON means develop interfacing with Safety PLC and Run the system via PLC logic. Supply, Installation & Erection of mentioned components / system shall not be TAS Vendor's scope. Kindly confirm.

BPCL confirmed the same. Bidders to ensure powering On of entire system and refer Schedule of Quantiteis .

114 BOQ Powering ON HVLR system

M/s GE request M/s. BPCL to kindly clarify the HVLR System.

Bidders are requested to refer tender purpose drawings .

115 BOQ Hi - Hi Level Switch

M/s GE request M/s. BPCL to kindly confirm that whether they

Yes .

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required separate Level Switch other than Radar Gauge & Servo Gauge for Hi Hi Alarm.

116 BOQ Hi - Hi Level Switch

M/s GE informed In case there is separate Level Switch other than Radar & Servo Gauge. Kindly confirm that required Manhole will be made available at All tanks by Customer.

Separate drawing for installation of gauges will be submitted to successful bidders .

117 BOQ

Engineering Hardware like Cables, JBs, Cable trays.

M/s GE informed that in case of requirement of any other type of Cables, JBs or Cable Trays than mentioned in SOQ, M/s. BPCL will approve the same and issue Order Amendment before commencement of work at mutually agreed rates. Kindly confirm.

Successful Bidder to provide detail engineering drawing as per scope of work to complete the job in totality following technical specification and special condition of tender and scope of work and Schedule of quantities.

118 BOQ

Modification at MCC Panels including Supply of relays / contactors, PVC wires, lugs, ferrules, erection hardware (as required) to provide potential free contacts to be connected to the PLCs (Safety) for status (Motor Running / Trip) & command (Start / Stop / ESD command) from PLCs. Note : applicable for

M/s GE request M/s. BPCL to kindly confirm the requirement of TWF / TWD pumps.

No TWD / TWF pumps available at Barauni and the same is mentioned in IO counts of PLC. Bidders requested to visit site for obtaining further details.

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existing MCCs of TLF/ TWF/ TWD / FW Pumps

119 PLC PLC IO with Spare

M/s GE request M/s. BPCL to kindly confirm that we have to quote as per PLC IO list given in tender. Additional Spare Module as mentioned in specs. Will not be applicable.

PLC IO counts list are provided separately in the tender document considering 20% spares and 20% space in the rack . Bidders requested to go through the documents in totality .

120 Trial Run After SAT

60 Days Trial Run after SAT

M/s GE request M/s. BPCL to note that Trial Run for 60 Days is quite high period. Maximum this will be 15 Days time. Kindly confirm.

60 Days Trial Run after SAT to be conducted .

121 BQC

BQC Documents are to be stamped / verified from TPI as per Given list in Tender.

M/s GE request M/s. BPCL to also accept BVIS as approved TPI Agency.

BPCL requested Bidders to obtain verification of TPIA as per the list provided in BQC.

122 Delivery Period

M/s GE request M/s. BPCL to kindly note that looking in to scope of work, mentioned delivery period is very low. Request M/s. BPCL to keep it 10 Month.

No further change is possible.

123 Site Details

M/s GE request M/s. BPCL to kindly provide the complete details including Address, Contact details & TIN Number for BPCL Barauni Site. Kindly note that these information is required us to fill up our GE internal Work flow while

Details already provided in the tender document. Bidders are also requested to visit site for obtaining confirmation in this regard .

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bidding.

124

Field Instrumentation/scope of work clause # 1.2.20

All instrument installation materials as well as cable laying material such as instrument supports (2” pipe yokes), MS angles/flats, Field Junction boxes, trays, ducts, compression fittings, cable glands, aluminium saddles, lead markers , sand, bricks, cement, etc. as required for the system.

M/s Chemtrols understand that supply of field junction boxes, trays, ducts etc is to be considered as per SOR,no separate supply of JB's,trays & ducts wiil be in our scope of supply.Pl confirm

Please refer to LS items in SOQ also wherein scope of supply is made explicit .

125


Supply and laying of all cables including ferruling, dressing, glanding and termination etc. as per Plant lay out & finalized cable routes.

M/s Chemtrols understand that supply and laying of all cables including ferruling, dressing, glanding and termination etc is to be considered as per SOR only.Pl confirm

Apart from SOQ , the successful Bidders are required to carry out detail engineering based on cable route survey and finalize the quantities of cable.

126


Pipes, Bends, Isolation Valves & Flanges only below 80 mm size required in this regard will be supplied/ by the vendor.

M/s Chemtrols understand that all scope related to piping is in the scope of BPCL, as it is not mentioned in SOR . Pl confirm


127


All the structural & other materials are to be supplied by the vendor.

M/s Chemtrols understand that all structural & other materials required for installation shall be as per the SOR.

BPCL confirmed the same. However all consumable and hardware required for installation to be supplied by bidder .

128


All the instruments/ equipments/ subsystem supplied shall be from original

M/s Chemtrol will submit this meeting tender requirement during

Bidders to provide this during their bid submission stage in Source of supply form.

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manufacturers and make/model offered shall have sufficient successful proven operational track record at the time of the bid.

detail engineering as we have to work out based on the vendor selected from approved vendor list once order is awarded to us.

This is essential requirement .

129


Tank farm overview with MOV open/close status and Pump house overview with MOV open/close status to be given based on P & IDs provided by BPCL.

M/s Chemtrols request BPCL to provide P & Ids for our undestanding.

BPCL requested vendors to visit site . P&ID will be provided to successful bidder .

130

Detailed scope of work will be include following clause no - 1.2.16 BPCL will provide in its MCC control room following power tap-off points.

Any further power distribution including supply & laying of proper size power cable /signal cable from MCC room to Automation control room alongwith provision of Power distribution cabinets (UPS & Non UPS Power supply) required for Power supply requirement of control room instrumentation & Field Instrumentation is in vendor‟s scope of work.

M/s Chemtrols understand that power/control & signal cable for MOVs & other instruments is considered in SOR,no separate cable in in our scope of supply.

Bidder to carry out detail engineering based on cable quantities provided in SOQ .

131


Vendor should also consider a power distribution panel with one incoming feeder and minimum four out going feeder with proper size of Switch fuse unit/MCCBs.

M/s Chemtrols requested to confirm the requirement with scope.

Bidders to provide this requirement for the input power supply to control room and UPS.

132

Detailed scope of work will be include following clause no - 1.2.16

The Power distribution cabinet referred above shall have individual

M/s Chemtrols requested to confirm the requirement with

Bidders to provide this requirement for the input power supply to control room and UPS.

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BPCL will providein its MCC control room following power tap-off points.

MCBs for all discrete instruments/ equipments pertaining to control room & field instrumentation( either supplied by vendor or the free issue instrumentation supplied by BPCL & integrated by TAS vendor).

scope.

133


Dedicated power distribution cabinets with individual MCBs is to be provided for powering of field MOVs.

M/s Chemtrols requested to confirm the requirement with scope.

Not in the scope of job for Barauni .

134

Detailed scope of work will be include following clause no - 1.2.13 Flow Measurement & Control sub-system for each bay

Each product header running between TLF pump house & TLF Gantry will be provided with pressure gauges, , pressure safety valve , Meter proving system, Pressure transmitter & Bulk Air Eliminator(Dead volume capacity -10% volume of the product accumulated in 1 minute at combined max. rated flow rate of all the TLF pumps of the specified product) as indicated in P&ID.

M/s Chemtrols understand that Pressure gauges, densitometer, pressure safety valves, Bulk Air Eliminator & Meter Proving System is not in our scope of supply. Please confirm the same.


135

Detailed scope of work will be include following clause no - 1.2.14 Flow Measurement & Control sub-system for each

Pressure/Temp. Gauges, Pressure safety valves , Pressure/Temp/Flow Transmitters along with isolation valves , fittings , impulse piping(SS 304)

M/s Chemtrols understand that supply of PD & Mass flow meters is not in our scope. Please confirm the same


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bay wherever indicated in the P&IDs are to be provided & integrated with TAS .

136


Hardwired Level Alarm contacts (to be provided by TFMS vendor in control room ) are to be interfaced with PLC by TAS vendor.

M/s Chemtrols understand that our scope is limited to provide only I/Os in ESD PLC not in normal PLC & digital outputs in normal PLC for alarm annunciator Panel (if both PLCs are communicating with each other). Please confirm the same.

Refer system architecture drawing provided .

137


Two Positive Displacement type flow meters with pulse transmitters OR Two Mass Flow Meters (as applicable at TLF gantry)

M/s Chemtrols confirm the requirement.


138


Mass Flow Meters (as applicable at TLF gantry)

M/s Chemtrols spicify the line pressure with products.


139

Document-I, Scope of work, 1.1.4

Calculations for PLC, LRC and Network loading

M/s Chemtrols can submit this meeting tender requirement during detail engineering as we have to work out based on the vendor selected from approved vendor list once order is awarded to us.

Noted and confirmed by BPCL

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140

Document-I, Scope of work, 1.1.7

BPCL free issue items

M/s Chemtrols understand that our scope is limited to integration at control room level and all cabling shall be supplied & laid will be in package vendor scope who is supplying these devices.

Bidder to refer loop wiring diagram and tender purpose GA drawing . All Free issue items are to be hardwire including cable laying through by the bidders for instrument , control and power as applicable .

141

Document-I, Scope of work, 1.1.7.1

ROSOVs

M/s Chemtrols understand that supply & installation of ROSOVs are in the M/S BPCL scope. Our scope is limited for termination of power/signal & control cable. Any hardware software required during the installation & commissioning will be any M/s BPCL scope. Please confirm the same.

Bidder to refer loop wiring diagram of ROSOV and tender purpose GA drawing . All Free issue items are to be hardwire including cable laying through by the bidders for instrument , control and power as applicable .

142


HC DETECTORS

M/s Chemtrols understand that supply of HC detectors are not in vendor's scope of work. Please confirm the same

Bidder to refer loop wiring diagram of HC Detector and tender purpose GA drawing . All Free issue items are to be hardwire including cable laying through by the bidders for instrument , control and power as applicable .

143


Fire Fighting System

M/s Chemtrols understand that all required Panel & instrument is in M/S BPCL scope, vendor scope is limited for termination of cable at both ends, any modification in

Bidders to integrate Fire fighting system of BPCL including cable supply and laying and providing ESD port for safety PLC system.

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panel required during commission will be M/S BPCL or its vendor scope.

144


MOV system

M/s Chemtrol understand that supply & installation of MOVs are in the M/S BPCL scope. Our scope is limited for termination of power/signal & control cable. Any hardware or software required during the installation & commissioning will be in M/s BPCL scope. Please confirm the same.

MOVs are Limitorque make with ESD port . Model No. L120 - 10 + UEC 3 + DDC 100 & l120 - 10 + TB + UEC 3 + DDC 100 . MOV are to be serially interface at conventional PLC and ESD ports of MOVs are to be hardwired to safety PLC. Except for power cabling sreial interfacing with conventional PLC and hardwire cabling with safety PLC to be done by the Bidder including cable laying

145


MCC modification

M/s Chemtrol request the M/S BPCL to provide the existing MCC SLD drwgs.

SLD of existing MCC panel already provided with the tender document.

146


1.1.1 SIL2 certified Programmable Logic Controller (PLC) [for Emergency shutdown operations /safety Interlocks ] as per actual I/Os quantity including spares based on functional requirements of all MOVs , HC detectors, ROSOVs

M/s Chemtrols understand that MOVs, Batch controllers ,Barrier Gates, Pumps & field instruments are part of Normal PLC not with ESD PLC. The ROSOVs , Fire fighting system & HC detectors are free issued by the M/S BPCL. Our

Please refer to System Architecture drawing provided by BPCL. All Free issue and Bidders supplied instruments are to be serially / hardwired with safety and conventional PLC based on system architecture drawing and scope .

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, HI HI Level switches, Batch controllers Barrier Gates, Pumps, Fire fighting equipments, Field instruments etc. complete,.. This

will include simulation of all the interlocks .

scope is to integrate this system with our supplied ESD system. Please confirm the same with quantities.

147


PLC for normal plant operations/controls)-as per actual I/Os quantity including spares based on functional requirements of all MOVs , Batch controllers , Barrier Gates, Pumps, Field instruments etc. Complete, Tank farm instrumentation. This will include simulation of all the interlocks .

M/s Chemtrols understand that MOVs are not hardwired to the normal PLC. We have to provide only communication modules in normal PLC.M/S BPCL will provide us the master station & MOV as a free issue. Tank form instrument is directly communicating with CIU/FCU system not with PLC system. Please confirm the same with quantities.

MOVs are Limitorque make with ESD port . Model No. L120 - 10 + UEC 3 + DDC 100 & l120 - 10 + TB + UEC 3 + DDC 100 . MOV are to be serially interface at conventional PLC and ESD ports of MOVs are to be hardwired to safety PLC. Except for power cabling serial interfacing with conventional PLC and hardwire cabling with safety PLC to be done by the Bidder including cable laying .

148

Programmable Logic controller, General, Clause # 7.1.19.1.2

Programmable logic controller (PLC) system shall be programmable, modular microprocessor based safety system, which shall be used for implementation of safety shutdown/interlocks and terminal operation monitoring.

M/s Chemtrols understand that this specification is for Process PLC & not of Safety PLC.Pl confirm

This for safety PLC .

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149

Programmable Logic controller, General, Clause # 7.19.2 Spare Philosophy.

Installed engineering spare modules upto 20% shall be provided in input/output, subsystem on module basis and/or with a minimum of one module of each type to enhance the system functional requirements for future.

M/s Chemtrols understand that I/Os quantities provided in the SOR is inclusive of all spares.

BPCL confirmed the same , however, bidders to provide space for further 20% expansion of modules .

150

Programmable Logic controller, General, Clause # 7.19.2 Spare Philosophy.

In addition the system shall have the following minimum spare capability.(a) I/O racks of PLC shall have 20% useable spare slots for installing I/O modules of each type in future. These racks shall be part of the offer.(b) The processor system shall have the capability to execute logic for I O's including 20 % installed spares.(c) Whenever relays are used to interface process input/outputs with PLC 20% additional relays shall be provided. In addition, 20% spare space shall be provided in cabinets to install 20% additional relays in future.


BPCL confirmed the same , however, bidders to provide space for further 20% expansion of modules .

151


The output contact ratings.- All output cards for driving LT motors/pumps/solenoids is 230V AC & current rating of 5.0A

M/s Chemtrols understand that Potential free contacts are available in MCC for all pumps, so we can provide

230 V AC for MCC of all pump and necessary modification at MCC panel to be carried out by the bidders based on SOQ.

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the 24Volts VDC card instead of 230VAC.Pl confirm

152


For all analog inputs & outputs related to Auto Re-circulation Valve for pumps; I/O redundancy is to be offered for closed loop control (if applicable

M/s Chemtrols understand that the mentioned clause is not in TA vendor scope.Pl confirm

Not applicable at Barauni for any product pump..

153 Specifications of SIL-2 PLC system,

System design and testing

M/s Chemtrols understand that loop verification is not applicable for SIL-2 system by third party like TUV / equivalent certified agency. Pl confirm

SIL verification to be done by Bidder through TUV/ EXIDA/HIMA or alternate equivalent competent agencies approved by BPCL. Bidder shall arrange certification of all SIL loops by TPIA . All the safety relevant data for each components of SIF ,eg PFD , falirue rate ( safe and dangerous failure ) DC (% Safe and dangerous detected ) needs to be provided by vendor for their supplied SIL 2 certified instruments ( eg . Safety PLC , Hi Level switch , radar Type level transmitters ). In this regard BPCL will provide such data for ROSOV & Hydro carbon Detectors . The main safety instrumented loop for which SIL verification study upto SIL level 2 is to be conducted consist of radar Type level transmitter and Hi Level switch ( Primary sensors , safety PLC ( Logic solver) and ROSOV ( Final Control element ). Proof Test interval certified by TUV is to be submitted by vendor . In

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case if , Proof testing is to be done during warranty , same is to be carried out by the vendor through TUV/EXIDA/HIMA or alternative equivalent agencies as approved by BPCL. Note : The design engineering of all SIF loops with an objective to ensure SIL2 level for the entire safety instrumented loop as per IEC 61511 is in vendor`s scope. This detail engineering will be part of FDS documentation and the performance of the SIL verification study at site to comply IEC 61511 for the SIF loop loop compliance as per IEC 61511.

154 Specifications of SIL-2 PLC system,

System design and testing

M/s Chemtrol understand that panel accessories not required SIL-2 certification like SMPS, Relays, terminals & Barrier for analog input of SIL-2 PLC. Please confirm the same

In order to ensure requirement of IEC 61508 / IEC 61511whatever is required for SIL2 compliance for safety instrumented loops to ensure SIL2 level are to be provided. This is to be noted that all components of SIF loops required to be SIL compliant .

155

SIL-2 Programmable Logic controller, General, Clause # 7.20.2 Spare Philosophy.

Installed engineering spare modules upto 20% shall be provided in input/output, subsystem on module basis and/or with a minimum of one module of each



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type to enhance the system functional requirements for future.

156

SIL-2 Programmable Logic controller, General, Clause # 7.20.2 Spare Philosophy.

In addition the system shall have the following minimum spare capability.(a) I/O racks of PLC shall have 20% useable spare slots for installing I/O modules of each type in future. These racks shall be part of the offer.(b) The processor system shall have the capability to execute logic for I O's including 20 % installed spares.(c) Whenever relays are used to interface process input/outputs with PLC 20% additional relays shall be provided. In addition, 20% spare space shall be provided in cabinets to install 20% additional relays in future.



157 General DET

M/s Chemtrols request BPCL to provide datasheet/specification of DET

Data entry terminal should be of approved make of vendors : MTL ( EXTEC) , P&F , STAHL, DANIEL, B&R , CONTRECT make. Vendor to provide technical specifications for the offered data entry terminal in their technical bid for their purpose of evaluation.

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158 Approved vendor list, 13,

Access control system

M/s Chemtrols request to approve Chemtrols (FMC) for access control at various place using card reader.

Accepted.


Cables

M/s Chemtrols request to approve EIL approved and other public sector company approved KEI industries for all type of cables.

Cables approved vendor list will be as per BPCL approved list .


RTD with thermowell

M/s Chemtrol request to approve Chemtrols make RTD with thermowell in approved vendor list.

Not is tender scope.

161 General Extension

M/s Chemtrols request BPCL to extend tender for further 15 working days from the date of queries replies.

Noted.

162 General TPI for approval & inspection

M/s Chemtrols understand that TPI of instruments/equipments/systems will be in scope of BPCL.CHEMTROL'S will access it's factory for system inspection.Pl confirm

TPIA will be in the Bidder`s scope of job. Bidders to kindly quote accordingly.

163 Spares Spare list applicable under warranty & CAMC

M/s Chemtrol request BPCL to provide detail spares list as required to be maintained on terminal during warranty and AMC period for estimation purpose as well as it will keep all vendors

BPCL clarified that the list of spares will be based on the requirement by OEM of individual equipment .During CAMC bidder`s representative should be the nodal point to follow up with AMC contract entered by BPCL for free issue items. Refer similar reply /

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understanding at the same level.

clarification made earlier.

164

Comprehensive maintenance contract

CAMC for 5 years

M/s Chemtrols understand that CAMC is applicable for items supplied by them applicable under this contract. Any free issue items AMC will be in BPCL scope. Pl confirm

BPCL confirmed the same .

165 Warranty period Specified under payment terms clause

M/s Chemtrols understand that Warranty is applicable for items supplied by them applicable under this contract. Any free issue items warranty will be in BPCL scope. Pl confirm

BPCL confirmed the same .

166 Comprehensive Warranty

During warranty, all repairs/ comprehensive maintenance (including supply of spares & consumables quarterly preventive maintenance visits, breakdown visits by various OEMs) will be ensured by the Automation vendor.

M/s Chemtrols understand that OEM/OEM authorized representative visit is necessary in case fault / rectification is not possible to resolved by TAS vendor and shall indicated by TAS vendor for OEM visit. Kindly confirm

TAS vendor is responsible for the total performance of the system supplied by them and to adhere at performance criteria strictly .It is the sole responsibility of the Bidder to comply with the CAMC and warranty clause .As BPCL will enter into agreement with the Bidder , therefore the sole responsibility for fulfilling performance criteria of the job through OEM`s shall be on Bidder`s scope .

167

POST WARRANTY PERIOD - COMPREHENSIVE AMC

Quarterly preventive maintenance visits by respective OEMs in addition to breakdown visits,

M/s Chemtrols request M/S BPCL to accept the OEM authorized representative

Not accepted by BPCL.

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during warranty & post warranty period

instead of OEM for all items.

168 COMPLETION PERIOD:

i. 3½ Months – Delivery of Material at site

M/s Chemtrols request BPCL to accept 5 months for delivery period of material instead of 3 1/2 months period by looking towards Scope of the project.

The dates as confirmed by BPCL cannot be changed .

169

ERECTION & COMMISSIONING SERVICES:

90% of order value (erection & commissioning services) on compl. of erection after submission of PBG equivalent to 10 % of order value towards erection & commissioning services, valid for 2 yrs

M/s Chemtrols understand that 90% payment of erection & commissioning services shall be paid on pro-rata basis under running bill. Pl confirm

Bidders are requested to follow payment terms as per Special Condition of Tender which shall prevail for the tender .

170 General conditions of tender

BPCL may issue form "C"

M/s Chemtrols request to confirm whether BPCL will issue form "C" for this project.

C Form will not be issued. Also BPCL will not get any CENVAT benefit from the project .

171

POST WARRANTY PERIOD - COMPREHENSIVE AMC

Vendor is required to furnish a Performance Bank Guarantee of 10% of supply order value inclusive of all taxes with a validity of 2 years. The performance bank guarantee shall be required to be extended suitably so as to provide guarantee for system performance till end of the comprehensive maintenance contract (CMC) period of 5 years. The last Bank

M/s Chemtrols clarified that The PBG will be valid till warranty period of the system and new BG will be submitted for 10% of CAMC value at the start of AMC instead of 10% value of contract. The CAMC BG will be renewed every year with reducing value year on year basis. Pl confirm

Bidders are requested to follow payment terms and CAMC clause as per Special Condition of Tender which shall prevail for the tender .

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guarantee shall be valid for 6 months after completion of CMC period.

172 Page no. 3 of 251 -Clause # point B

TANKAGE DETAILS

M/s Chemtrols requested to kindly confirm the make and model no. of existing servo gauges. Whether the existing gauge has SIL 2 approved relay contact outputs. If no confirm whether the same needs to be replaced .For u/g tanks - whether still pipes are provided for installation of Radar Gauges. This will be required as the nozzle neck height will be longer.

ENRAF servo level gauges, Model no. 854 ATG . Bidders are requested to visit site to check for further details. Bidders to refer tender purpose GA drawings and visit site for confirmation of the same .

173 Page no. 30 of 251, Clause # c) ii.

The analog outputs of the level transmitters (4-20 mA) shall be interfaced through AI modules of conventional PLC.

M/s Chemtrols informed that From radar gauges we offer SIL2 4-20 mA and from tank side monitor we offer DIBt approved relay contact outputs. Hence, we suggest to interface Servo Gauges SIL 2 relay contact output to safety PLC.



TUV/ EXida as

per IEC 61508/

61511 along with

Test Reports

specified in the

certificate.


overfill protection


of Level

Transmitter has to

be certified

minimum SIL 2 (as

per IEC

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61508/61511) in

mono mode.

3. The Level

Transmitter shall

also satisfy the

criteria for SIL 2

certification

according to IEC

61508 Part 2,

Table 3 (i.e.

Hardware Safety

Integrity:

Architectural

constraints on type

B safety related

sub-systems).

174 Page no. 35 of 251

M/s Chemtrols requested to kindly confirm if the interface is from TFMS or TAS

Bidders to follow System architecture drawing provided with tender document and system architecture drawing submitted along with 1 st Corrigendum of the tender for tank farm management system .

175

Page no. 173 of 251, Clause # 2.2.2

TFMS computer along with TFMS software( Windows 7)] . The TFMS computer shall communicate with main Terminal automation system through Ethernet (over TCP/IP protocol). TFMS software shall have Custody Transfer Approvals (as per OIML R 85 ) from country of origin & „ Dept. of Weights & Measures, India‟. The TFMS software shall also be

M/s Chemtrols informed that TankVision software is OPC compliant, however, for OPC connectivity we need Windows XP Professional OS for TFMS.

BPCL requires OS to be minimum Window 7 .

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OPC Compliant.

176 General TPI

M/s Chemtrols informed that TPI shall be for verification of offered instruments as per the BPCL approved QAP

QAP to be provided by the Bidders to BPCL through it`s OEM of the instruments for approval and TPIA inspection .

177 General Site Visit

M/s Chemtrols requetsed to c onfirm the site contact person and contact number, for site survey

Already provided in the tender .

178 General OIML Certification for Batch Controller

M/s Chemtrols request BPCL to kindly clarify whether OIML certification is required for Batch Controller

OIML , approval from Legal metrology apart from CCOE approval are required ..

179 General Batch Controller

M/s Chemtrols understand that additive & blending is not required for SKO system.

Bidders to following technical specification of batch Controllers.

180 General / Additional Point

Limitation of Liability

M/s Honeywell request M/s BPCL to accept : “The total liability of Supplier, on all claims of any kind, whether in contract, warranty, indemnity, tort (including negligence), strict liability, or otherwise, arising out of or related to the Contract, or its performance or breach, shall not exceed the Contract price. All liability of Supplier

Clause of Limitation of Liability as per clause no 31 of NIT document to be accepted by Bidders .The final payment by the OWNER in pursuance of the CONTRACT terms shall not mean release of the CONTRACTOR from all his liabilities under the CONTRACT. The CONTRACTOR will be liable and committed under this CONTRACT to fulfill all his liabilities and responsibilities, till such time Contract cum- Equipment Performance

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on all claims of any kind shall terminate upon expiration of the relevant warranty period. In no event, whether as a result of breach of contract, warranty, indemnity, tort (including negligence), strict liability, or otherwise, shall Supplier or its subcontractors or suppliers be liable for loss of profit or revenues, cost of capital, cost of substitute components or any associated equipment, or any special, consequential, indirect, punitive or exemplary damages, or claims of Buyer's customers for any of the foregoing damages. The provisions of this article shall prevail over any provisions contained in any of the documents comprising the Contract.”

Bank Guarantee is released by the OWNER. The total liability of the contractor shall be limited to the contract value and the contractor shall not be held liable for consequential damages.

All Bidders are required to submit the Corrigendum Annexure – III in Technical Bid Section of the tender duly signed .

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CORRIGENDUM ANNEXURE – IV TENDER NO. CRFQ NO. : 1000179338 E – TENDER NO. : 10736 TECHNICAL SPECIFICATION OF SAFETY PLC AS ENCLOSED WILL

SUPERCEEDE THE TECHNICAL SPECIFICATION OF AS PROVIDED IN DOCUMENT I

GENERAL NOTE : THE ‘SCOPE OF WORK’ & ‘TECHNICAL SPECIFICATIONS’

ARE TO BE READ IN CONJUNCTION WITH SYSTEM ARCHITECTURE DRAWING

SPECIFIED BELOW.

A. System Architecture Drawing [E&P:INST/SIL-PLC/SA/1]

1. INTRODUCTION

BPCL intends to provide for it various POL Installations / Depots all across India an Safety PLC based Emergency Shutdown System (ESD). This ESD system is provided so as to enhance the operational safety at these locations and to have centralized monitoring and control of various critical activities and hazardous areas within its facility. The Safety PLC based ESD system would primarily consist of integration (with the Safety PLC) of various field instruments as per the MB Lal Recommendation.

2. SCOPE OF WORK

1.1 BIDDER’S SCOPE OF WORK FOR THE JOB SHALL BROADLY COMPRISE OF THE

FOLLOWING :

1.1.1 Design and system engineering of complete Safety PLC based Automation

System as per given System Architecture.

1.1.2 Dynamic & static graphic representation of the all the operating facilities in

installation on the basis of system architecture as well as site survey/study by

vendor is required at Operator Interface Consoles.

1.1.3 Manufacture, Supply, Installation, Cable laying, Field Testing, Commissioning,

Trial Run, Site Acceptance and Stabilization of the complete system of

complete Safety PLC System (hardware and software) consisting of sub –

systems as per enclosed System Architecture Dwg :

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1.1.3.1 Emergency shutdown sub-system [based on SIL2 (or better) certified

Programmable Logic controller] as per system architecture enclosed.

1.1.3.2 Hi-Hi Level Switch on Product Tanks

1.1.3.3 ESD PB Station

1.1.3.4 FLP /WP Hooter

1.1.3.5 FLP Junction Boxes (Power / Control Signal)

1.1.3.6 Uninterrupted Power supply system

1.1.3.7 Laying / Glanding / Termination / Loop Checking of signal / power / control

cables

1.1.4 Cabling (laying), Field Testing, Commissioning, Integration (hardwiring/ digital

interface with PLC), Site Acceptance Test of following instrumentation/ sub-

systems [to be provided by BPCL as Free issue items; protocol details (open/

proprietary) wherever applicable, will be provided by BPCL], with the

proposed Automation System including development & successful

implementation of serial interface as well as supply/ laying/ termination of

signal/ communication cables .

1.1.4.1 ROSOVs (Remote Operated Shut-Off Valves to be installed by BPCL) – to be

hardwired with safety PLC

1.1.4.2 Hydrocarbon Detectors / Transmitters( to be installed by vendor) - to be

hardwired with safety PLC

1.1.4.3 Existing Tank Farm Management system (Analog Level measurement O/P

and Hi Level Contact O/P) - to be hardwired with safety PLC

1.1.4.4 Rim Seal Protection system ( for Classs A product tanks – to be installed by

BPCL) - to be serial interfaced(MODBUS RTU) with safety PLC

1.1.4.5 Existing Fire Fighting system (Pr .switches/ MCPs/ FW pumps / MCC starter

panels)- to be hardwired/serially interfaced ( MODBUS RTU) with safety PLC

1.1.4.6 Existing MOVs (ESD ports ) – to be hardwired with safety PLC as

applicable.

1.1.4.7 HVLR System( to be provided by BPCL) - to be hardwired / serial

interfaced(MODBUS RTU) with safety PLC

1.1.4.8 Existing On-line Blending systems -serial interfaced (MODBUS RTU)

through its PLC/ VFD/ ]

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1.1.4.9 Existing MCC panels / VFD control panels ( of Product Pumps ) are to be

modified for provision of ESD ports . Such ESD ports are to be hardwired

with safety PLC to stop these pumps on actuation of ESD Push Button.

NOTE: Protocol details for proprietary/open protocols will be arranged by BPCL.

However software drivers are to be developed by automation Vendor

1.1.5 Vendor to submit the following calculation along with technical bid.

Processor loading for PLCs

Processor loading for LRCs.

Network loading.

I/O requirement vis-à-vis provision in the selected PLC

Heat load calculation.

Actual UPS Capacity based on full load condition.

1.1.6 Vendors are required to furnish complete model listing for offered

devices/equipments backed up by model selection guide as part of technical

offer.

1.1.7 Subsequent to award of job vendor is required to visit Installations/ locations

for the following engineering activities-

1.1.7.1 Ascertaining the type and quantity cable (power / control / signal) required

based on the cable routes as provided by respective Regional E&Ps.

1.1.7.2 Ascertaining the size and quantities of cable trays (for power / control /

signal) required based on the cable routes as provided by respective

Regional E&Ps.

1.1.7.3 The finalized cable route drawings , cable schedules & estimated

quantities for cable trays and cables are to be prepared by vendor & same

are to be given to BPCL for procurement of cables & cable trays by BPCL.

Subsequent to procurement of cables & cable trays same will be given to

vendor as free issue item for execution of job at site.

1.1.8 Packing, forwarding, transportation, custom clearance, insurance, octroi,

storage etc. complete of the system.

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1.1.9 Laying (overhead/underground) & termination of power / control / signal cables

for all Instruments / equipment along with erection hardware required for the

complete job.

1.1.10 System Documentation, Training, AMC & Warranty etc.

1.1.11 Supply of special tools, test equipments and spares required for testing,

calibration, commissioning and maintenance of the system.

1.1.12 Any other instrument/ equipment/ service which are not explicitly mentioned in

the tender but deemed necessary for the successful operation of the system

complete in all respects, shall be in bidder‟s scope.

1.2 DETAILED SCOPE OF WORK WILL INCLUDE FOLLOWING:

1.2.1 Radio Frequency interface (RFI) & Electro Magnetic Interference (EMI)

requirements in line with IEC 61000-4 to be strictly followed.

1.2.2 Transient & Surge Protection – The entire automation system needs to be

protected against system errors & hardware damage caused by -

1.2.2.1 Electrical Transients on power wiring.

1.2.2.2 Electrical Transients on signal wiring

1.2.3 All the Networking devices (Control Room) connected with field

instrumentation are to be provided with surge protection devices for protection

against electric transients.

1.2.4 Transient Voltage Surge Suppressors (TVSS) are to be provided at the UPS

(power supply inlet ports) to protect control room & field instrumentation from

Electric transients.

1.2.5 Supply of SIL2 (or better) certified Programmable Logic Controller (PLC) [for

Emergency shutdown operations /safety Interlocks] as per actual I/Os quantity

including spares based on functional requirements of all MOVs , HC

detectors, ROSOVs , Hi-Hi Level switches, Batch controllers Barrier Gates,

Pumps, Fire fighting equipments, Field instruments etc. complete. This will

include simulation of all the interlocks.

1.2.6 The PLC systems shall have surge withstanding capability for their

input/output modules as per IEEE 472 standard. The PLC system shall be

capable of preventing noise arising caused by solenoids, relays & contactors

carrying heavy currents.

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1.2.7 Earthing - Each cabinet shall have segregated earthing system as detailed

below-

1.2.7.1 Instrument Earth (NIS Earth) – Non IS signal cable shields are to be

connected to the „Instrument signal ground earth bar‟

1.2.7.2 Intrinsic safe grounding (IS earth) - The IS instrument signal cable shields are

to be connected to „intrinsic safe earth bar‟.

1.2.7.3 Electrical safety & cabinet steel earth (Dirty earth) - The grounding from all

racks, doors, gland plates & other metallic objects are to be connected to

„safety earth bar‟.

All the above specified earth systems in cabinets shall have isolated copper bar (25

mm X 25mm or more) properly drilled & tapped for connecting earthing lugs.

1.2.8 Hardwired Level Alarm contacts (to be provided by TFMS vendor in control

room) are to be interfaced with PLC by the Automation vendor.

1.2.9 BPCL will provide in its MCC control room following power tap-off

points-

One no. 230 VAC (+/- 10%), 50Hz (+/- 1%), Single phase, power supply point for

non-UPS loads.

One no. 440 VAC (+/- 10%), 50Hz (+/- 1%), Three phase, power supply point for

UPS system.

One no. 440 VAC (+/- 10%), 50Hz (+/- 1%), Three phase, power supply point for

Power Distribution cabinet of MOVs.

Any further power distribution including supply & laying of proper size power cable

/signal cable from MCC room to Automation control room alongwith provision of

Power distribution cabinets (UPS & Non UPS Power supply) required for Power

supply requirement of control room instrumentation & Field Instrumentation is in

vendor‟s scope of work. Vendor should also consider a power distribution panel with

one incoming feeder and minimum four outgoing feeder with proper size of Switch

fuse unit/MCCBs.

The Power distribution cabinet referred above shall have individual MCBs for all

discrete instruments/ equipments pertaining to control room & field instrumentation.

Dedicated power distribution cabinets with individual MCBs is to be provided for

powering of field and control room equipments as applicable.

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1.2.10 The following philosophy will be applicable for power cabling for the

field instrumentation:

In general, 20% spare cores in cables & 20% spare terminals in JBs &

Marshalling cabinets / system cabinets are to be provided.

Note: During design stage, in case of long distances, if voltage drop between Power

supply source & receiving instrument exceeds more than 5%, then 2.5 sq mm copper

conductors are to be considered instead of 1.5 sq mm as specified above.

1.2.11 The following philosophy will be applicable for signal cabling for the

field instrumentation.


Marshalling cabinets/system cabinets are to be provided

1.2.12 The following philosophy will be applicable for control cabling for the

field instrumentation.


Marshalling cabinets/system cabinets are to be provided

Open/ Close status-Limit switches (ROSOVs/ MOVs/ Barrier Gates/ Dyke Drain

valve)

o Control cable [2 core, 1.5 sq mm copper conductor, PVC, armoured,

FRLS PVC] between a Switch & field JB.

o One no. multi core control cable [24 core, 1.5 sq mm copper

conductor, PVC, overall shielded, armoured, FRLS PVC] between

field JB & Marshalling/PLC cabinet (control room).

1.2.13 Field instrumentation /scope of work will include following

All instrument installation materials as well as cable laying material such as

instrument supports (2” pipe yokes), MS angles/flats, Field Junction boxes,

trays, ducts, compression fittings, cable glands, aluminium saddles, lead

markers, sand, bricks, cement, etc. as required for the system.

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Supply and laying of all cables including ferruling, dressing, glanding and

termination etc. as per Plant layout & finalized cable routes.

Civil/ Mechanical/ Electrical works including the casting of foundation as per

requirements for instruments support where paved surfaces do not exist.

Minor civil works like chipping of pavement and grouting on the pavements for

the instruments panels/supports stand, and chipping and refilling of the pavement

for conduits.

Sealing of cables/tube/pipe entries into the control room after laying and testing

of all boxes, cables etc. by installing Multi cable transit (MCT) blocks. All works

relating to the sizing, designing and installation of MCT blocks is within the scope

of the vendor.

Installation of main control panels, marshalling cabinets and system cabinets in

control room.

Supplying & providing supports for installation of equipments are included in the

scope of the vendor.

All the structural & other materials are to be supplied by the vendor.

Laying and termination at both ends of instruments earth buses provided in

control panels to instrument earth pit.

Complete earthing of control room equipment, & FLP equipment in the field.

Painting of all structural supports for trays, panels, junction boxes, instruments,

ducts etc.

Drilling holes on all panels, shut down cabinets, power supply cabinets, control

panels, etc. for cables/ glands/ grommets.

No hot work in the Hazardous area, only fabricated clamps are to be used for

installing cable trays, equipment erection etc.

Grounding of shielded cables to respective instrument earth bus.

Supply of all types of consumables required for erection of the job.

Completion of drawings/documents as per the execution of work at site and

submission to BPCL.

Preparation and submission of as built drawings as required and submission to

BPCL.

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The bought out items shall be supplied from BPCL approved vendors/SOS Form

as per vendor list enclosed.

All the instruments/ equipments/ subsystem supplied shall be from original

manufacturers and make/model offered shall have sufficient successful proven

operational track record at the time of the bid.

1.2.14 Control room instrumentation will be as per System Architecture drawing &

will include following -

Open table top type control desk for workstations.

Marshalling racks, power supply distribution cabinets/ boxes, power pack units,

intrinsic safe barriers/ isolators, other auxiliary cabinets etc. as per specifications.

Inter tank transfer screens to be provided.

Tank farm overview with MOV open/close status and Pump house overview with

MOV open/close status to be given based on P & IDs provided by BPCL.

Adequate help screens to be provided.

Dedicated network printers with print servers as shown in system architecture

diagram enclosed.

1.2.15 Emergency Shutdown System Field cabling Philosophy – Field

instrumentation specified for integration with ESD –PLC system shall be

provided with dedicated FRLS cabling ( signal/ power/ control ) & FLP

Junction Boxes ( signal/ power/ control) .

1.3 SPECIAL CONDITIONS :

i. Vendor shall indicate the load requirement for all types of power supplies.

Break-up for power requirement of each equipment is to be furnished along with

the offer at bid stage.

ii. Vendor shall be required to furnish ventilation and air-conditioning requirement

in the control room during detail engineering.

iii. Vendor to ensure that the equipment shall not be damaged due to black-outs /

brown-outs and indicate following :

Steps to be taken for fail safe operation of the system under following conditions:

a. Power failure.

b. Voltage variation upto +/- 10 %

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c. Frequency variation +/- 3%

d. Air conditioning failure.

e. Start – up procedure of the system.

1.4 APPLICABLE CODES & STANDARDS

The components of instrumentation and control system shall be designed, manufactured, assembled and tested in accordance with the latest standards of the Standards Institution, Instrument Society of America, Institute of Electrical Engineers and Manufacturer's association of the country where they are manufactured / country of principals. They shall also confirm to the relevant latest standards of the Bureau of Indian Standards (BIS) wherever available, so that specific aspects under Indian conditions are taken care of.

The equipment shall also conform to the latest Indian Electricity Rules, OISD, PESO & petroleum rules as regards safety, earthing and other essential provisions specified there in for the installation and operation of electrical plants.

The equipment in the hazardous area shall have CMRI, CCOE approvals. OEM shall have BIS approval.

All painting shall be done in accordance with the General Specification for Painting.

All equipment shall comply with the statutory requirements of the Government of India and the State Government of respective states.

The Vendor shall execute the job to comply with the requirements of the relevant regulations or acts in force in the area together with design specifications with respect to:

Indian Electricity rule

Indian Factories act

Regulations laid down by chief electrical inspector

Regulations laid down by Factory Inspector of state Indian Standard Specifications

Oil Industries safety directorate norms.

International Organization of Legal Metrology.

Regulations relevant to explosion hazardous areas

Petroleum & Explosive Safety Organisation norms & regulations

The equipment supplied shall be designed in accordance with the requirement of all internationally &locally applicable standards/specifications listed below.

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American National Standards Institute (ANSI)

American Society for Testing and Materials (ASTM)

National Electrical Manufacturers Association (NEMA)

American Society of Mechanical Engineers (ASME)

American Petroleum Institute (API)

Institute of Electrical electronic Engineers (IEEE)

National Fire Protection Agency (NFPA)

International Electro-technical Commission (IEC)

International Standard Organisation (ISO)

Open Software Foundation (OSF)

Bureau of Indian Standards (BIS) The following codes as a minimum shall be applicable in designing the system. These codes (Latest edition) shall be produced as & when required by BPCL for checking the system

Code / Standard Description

AMSE B1.20.1 AMSE B16.5 AMSE B16.20 ASME SEC VIII

Pipe thread Steel Pipe flanges and flanged fittings Ring-Joint gaskets and grooves for steel flanges Boiler & pressure vessel code rules.

ANSI/ISA 575-01 Control valve sizing , capacity test procedures, face to face dimensions, leakage

RP 520 Fire sizing of safety and control valve

RP 598 Control valve leakage

OIML standard R 117 (Measuring systems for liquids other than water)

ISA RP SS-1 S 62-01, S82-02 S8-03, S18.1

Instrument Society of America standard and codes

IEC 801/EN 50081/82 Electromagnetic compatibility

IEC 79.10/BS 4683/ IS 2148

Hazardous area classification

IEC-529/IS 2147/ NEMA For execution of Inst. Enclosures

OISD recommendations For storage, handling and safety systems and transportation

API MP MS Ch 21 Flow measurement using Electronic Metering System

ISO/TC28/Section 3 Terms relating to calculation of oil quantity

ISO 4266 Petroleum and liquid petroleum products – Measurement of level and temperature in storage tanks by automatic methods.

OIML R85 Automatic level gauges for measuring the level of liquid in fixed storage tanks.

IS 2801 PD meter Accuracy

BASEEFA/PTB/KEM A/FM/ATEX/ TUV/ PESO/CMRS/ IBR/ RDSO/W&M

Statutory standards

BS 5308 Part-I Instrumentation Cable

ISA –S5.1 Instrument Symbol & Identification

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ISA- S 5.2 Graphical symbol for Process Operators

IS 2148 Flame proof , enclosure for electrical apparatus

IS 3043 Cod of Practice for Earthing

2 FUNCTIONAL DESIGN SPECIFICATION (FDS) :

2.1 The objective of FDS is to present all aspects of Safety PLC system with various

subsystem such Field Automation subsystem, Flow Metering subsystem, Tank Farm

Management system, ESD System, etc. It is expected that FDS shall be used by all

levels of operating personnel i.e. system engineers, maintenance engineers, operators,

supervisors etc. who should get complete insight and understanding of the following

aspects about Terminal Automation system.

System design aspects.

Operational & Functional requirements.

Complete details of systems configuration, all hardware, software & equipments

offered for this project to fulfill the obligation of the contract document.

Redundancy and backup aspects (system fail over)

Configuration and engineering aspects. (Database preparation, Alarm/Event

presentation, System maintenance and engg. Function).

System diagnostics.

System expansion capacity and up gradation methodologies.

Operator‟s MMI.

Interfacing integration and communication aspects between various subsystems.

System performance parameters covering CPU, Disk and main memory utilization,

memory mapping, system time outs, computers switch over timings, Display updates,

Display call ups etc.

System testing and evaluation criteria.

2.2 The operational requirements as specified in this tender might undergo revisions during

detail design and engineering. Vendor must ensure that the offered system software

packages have the capacity and flexibility to take care of these revisions

2.3 The capacity of offered software should be with 20 % spares with respect to nos. of data

base points/ tags after calculating requirements of the total system. The offered software

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should have in-built capability/provision to take care for future System should be flexible

from the point of view of up-gradation. These shall be verified during FAT.

2.4 Vendor is required to submit/ offer system network configuration as per details provided

in “Functional Specifications”.

2.5 The offered software should be of proven technology & latest version; with copyright or

trademark registration. The offered software has to be from principal manufacturer/ as

per norms of vendor registration/ acceptance for BPCL empanelment for terminal

projects as specified in the tender.

2.6 The original copy of the license certificate for the operating system, RDBMS & OS (10

user license – 2 Nos for redundant SCADA/PLC software) needs to be provided to

BPCL from the principal collaborator from the country of origin clearly mentioning the

details like project name, end user name, name & version of the offered software for

each of above, data base sizing as a minimum. The original copy of the license

certificate in name of BPCL supported with unpriced shipping import documents shall be

provided to BPCL for effecting payment to the vendor. In the absence of the above

documents payment shall be held back by BPCL.

2.7 In case the prime bidder has an MOU / Joint venture with the principal who is the

technology supplier or the vendor is a 100% subsidiary of the principal a letter shall be

submitted by the prime bidder on the principals letter head from the country of origin

declaring qualified technical support for the offered application software for the next 10

years as a minimum.

2.8 All software licenses shall be from the principal software manufacturer and not from the

resellers.

2.9 Vendors are required to produce following documentary evidence to BPCL before

integrated FAT for offered system :-

i) Site License for Operating System for each of the Server & client stations and shall be equivalent to Full pack of Windows 2008 Server.

ii) Site License for SCADA / MMI iii) Site License for RDBMS. iv) Site License of PLC loader software

2.10 Configuration of Software loaded on various terminals shall be as per

below

* Operating System shall be Windows 2008 Server for Engg cum Operator Station and Windows 7 for the Operator Stations. ** HMI / SCADA shall be either of the following only, as per the tender:

CS3000

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ADVANT / T-MAC

EXPERION PKS R400 – HONEYWELL

SMART TERMINAL MANAGER (Latest Version)

SIMATIC Win CC

WONDERWARE

INTELLUTIONS The offered software should be of the latest version

The 2 sets of original copy of the license certificate of the operating system, RDBMS ( min. 5 user license) and HMI / SCADA application software for Safety PLC System needs to be provided clearly mentioning the details like project name, end user name, name & version of the offered software for each of above, data base sizing as a minimum. Each operator / client station shall be provided with Runtime + Network license with no. of licenses being equal to the no. of client / operator stations.

2.10.1 Following SCADA / DCS LRC software are acceptable

a) Experion PKS SCADA R 400 - Honeywell

b) INDUSTRIAL IT (T-MAC) – ABB Germany or latest version.

c) Advant – ABB Norway or latest version.

d) Invensys FOX I/A Invensys USA or latest version.

e) Yokogawa EXATAS + Centum CS 3000 – Yokogawa Japan

f) LNTAS with iFIX latest version.

g) Freelance 2000 – ABB Germany

2.10.2 Following are the approved Operating Systems and RDBMS.

Operating Systems ( 10 CAL license)

a) Microsoft Windows 2008 Server Standard Edition – SERVER

b) Microsoft Windows 7 Professional - CLIENT

RDBMS (10 user license)

a) Microsoft SQL Server 2010

b) Oracle 11 g or latest

2.11 Vendor should also submit operation flow chart & functional specifications for

the system offered during detail engineering.

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2.12 Customization of software will have to be carried out by the vendor to suit the

system requirement.

2.13 Vendor shall have to give a guarantee on a non-judicial stamp paper /

company‟s letter head for availability of spares and back-up engineering for

maintenance of this system for a post warranty period of 10 years.

2.14 The site should be free from all scrap and other material/ equipment after

completion of job.

2.15 Bidders shall quote strictly as per the approved vendor list of BPCL as attached

with the tender. No deviations to the same shall be acceptable and the offer may be

liable for rejection. Bidders shall in their offer fill up the enclosed SOS format clearly

indicating the make, model and country of origin for both 1st and 2nd choice. Technical

literature for all the items needs to be submitted with the bid offer.

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3 DRAWINGS TO BE SUBMITTED DURING DETAILED ENGG:

3.1 Dimensional plan and layout drawing showing equipment layout inside control room

3.2 Routing and details of entire cable installation complete with JUNCTION BOX details

and cable trays.

3.3 General arrangement drawing and installation drawing of all the equipment viz. Control

room mounted and field mounted.

3.4 Power supply distribution panels / Power cable/control cable/ signal cable drawing inside

control room and in the field.

3.5 Detailed proposed system architecture diagram showing all interconnection complying to

the functional specifications.

3.6 Detailed software block diagram showing various functional modules & tasks for the

offered software & their interconnection.

3.7 Detailed PLC system architecture & sub system.

On completion of work, the vendor shall supply one set of as built drawings in CDROM and two

sets of prints of all as-built drawings incorporating all changes that might have been affected

during execution of contract. Vendor shall also submit minimum two sets of equipment

Operation and Maintenance manuals.

Vendor shall also arrange & submit softcopy of as built drawings & Operation & Maintenance

manuals

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4 FUNCTIONAL SPECIFICATIONS.

This specification defines the minimum requirements of safety PLC Automation System

designed for reliable, effective and optimum control & monitoring of a Marketing terminal

Operations.

4.1 NETWORK REQUIREMENTS:

- The automation system communication shall be on the high-speed modern local

area network (LAN) confirming to IEEE 802.3 standards and utilize industry

standard protocols with minimum 100 Mbps bandwidth.

- To ensure maximum reliability, communications shall be dual redundant. The

communications system shall be capable of sustaining loss of one media channel

without loss of data or performance degradation.

- Ethernet Switches with auto sensing for 10/100 MBPS port selection &

Simple Network Management Protocol support are to be used for establishing

LAN inter-connectivity in dual redundant configuration. All the STP/ UTP/Co-

axial cabling within Ethernet network should have 100% redundancy or better.

- 20 % spare ports are to be provided on each of the Ethernet Switches.

- Loss of communications shall not cause loss of control at the local subsystem.

- The communication software should employ a peer to peer communications

(master less) protocol between all sub-systems where-ever applicable.

- Loss of a subsystem or module shall not disrupt communications to other

subsystems or result in performance de-gradation. Loss of a subsystem or

module shall cause automatic isolation by pass of the failed subsystem without

disrupting communications & without performance degradation; loss of a

subsystem or module or module channel shall generate a diagnostic

message to be displayed at the operator stations and logged; identifying

location /type of fault.

- Dedicated Front End Communication Processors /LAN Server are to be

offered with 100 % redundancy in hardware with 20 % spare ports capacity.

PLC shall be connected in dual redundant configuration to Ethernet ports

of the primary & secondary (redundant) Ethernet switch / Communication

Processor. Maximum 16 port Ethernet Switch are acceptable.

- Interfacing of field serial communication links directly to adapters / interface cards

residing within the EISA/ISA/PCI slots & using LRC CPU clock cycles shall not

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be acceptable. Interfacing of redundant serial links from field equipment to a

single front-end terminal or communication server shall not be acceptable.

4.2 ENGINEER cum OPERATOR INTERFACE: -

- Access to Operator/Engineering Station functions shall be provided by a multi-

level password system.

4.3 ENGINEERING FEATURES: -

- The software shall provide extensive user-friendly tools for creation of dynamic

displays and total system configuration. All the Engineering tools shall be initiated

within the system.

4.4 SYSTEM ACCESS SECURITY:

– All operator commands shall be automatically checked for validity of

authorization by the system.

– Validity checks shall be automatically performed by the system to ensure that

control parameters entered by the operator are within the defined limits.

– Access to all system functions shall be protected by a multi-level password

system.

4.5 SYSTEM DIAGNOSTICS :

– The system diagnostics shall support fault isolation to a specific module or

channel or subsystem device, which can be subsequently removed and replaced.

– The system diagnostics shall include both hardware and software diagnostics

routines which upon detecting an abnormal conditions, reports this information on

standard diagnostics displays on the OIC and printers.

– Once a diagnostic test has detected a failure, a descriptive alarm shall be

generated and bumpless transfer to control to a redundant component shall be

triggered wherever specified.

4.6 DIAGNOSTIC DISPLAY

– The system status level shall be accessible by a single dedicated key.

– A flashing diagnostic message prompt shall be displayed and allow the user to

immediately view the specific error message in a single key stroke without going

through a diagnostic display hierarchy.

– A system status display shall provide the current status of every subsystem.

Subsystems with a diagnostic alarm shall be identified by flashing indicator. The

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system status display shall include information on the communications system

including status of each of the communication modules for every subsystem.

– The subsystem level status display should provide detail information on the

subsystem itself and the status of the individual modules contained therein.

– The I/O status display shall provide detailed information of each I/O Channel of

the associated device.

– The message level diagnostic display shall provide English text message

explaining the exact nature of the diagnostic error and the time and frequency of

occurrence. The users shall be able to go to an archive file to obtain a history of

diagnostic messages for the entire system and additionally shall be able to make

a backup copy to a removable media.

4.7 SYSTEM SOFTWARE (LATEST VERSION) & APPLICATION SOFTWARE

(LATEST VERSION):

– O.S. environment may be Windows 2008 SERVER STD EDN (for Sever) &

Windows 7 PROF (for Client) & Application software may have RDBMS like SQL

Server ; ORACLE. The operating system software should be modular in design &

shall provide effective utilization of all system resources and facilitate future

expansion.

– The application software should be GUI (i.e. Graphic User Interface) based &

should have excellent features in regard to real time data acquisition, data &

alarm processing, database downloading, Terminal security, access etc. The

software should also meet our desired operational criterion in regard to TLF

loading, scheduling, stock recording, monitoring & control of product movement,

the GUI shall be standard programming tools as part of D+R+N package.

4.8 The operator interface module shall provide centralized information to terminal operator

to monitor and control the complete automated terminal operation at various locations

of terminal in the fields like menu driven data entry screen through structured pull up &

pull down menus, manipulation of control loops, alarm displays & annunciation, bar

graphic displays & status indications, logging & trending including historical trend

recording, self diagnostic messages etc. As far as operational displays are concerned,

displays viz. Overview display, Group display, Loop/Point display, Graphic display,

Alarm monitoring & display, Database Management system display, Trend display shall

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be possible at the minimum. The offered base software shall have a copyright or

registered trademark.

4.9 The report generation module shall be capable of generating various reports and logs

for all measured and computed parameters as per requirement. The system should

provide scope for database generation & configuration with multilevel security access

into the system. All the communication between PLC and peripheral units shall be

established through secured data transfers. The networking communication shall be

selected keeping in view of number of peripherals & instrument connected on the

network and with higher throughput.

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4.10 SAFETY PROGRAMMABLE LOGIC CONTROLLER-SIL 2 (or better)

CERTIFIED

4.10.1 GENERAL

4.10.1.1 This safety PLC is required for Emergency Shut down operations.

The PLC shall have SIL2 (or better) certification along with TUV approvals.

4.10.1.1.1 Programmable logic controller (PLC) shall be dual redundant hot

standby PLC with dual processors and single I/O.

4.10.1.1.2 Programmable logic controller (PLC) system shall be

programmable, modular microprocessor based safety system,

which shall be used for implementation of safety

shutdown/interlocks and terminal operation monitoring.

4.10.1.1.3 The system shall be designed "fault avoidant", as a minimum by

selecting high grade components of proven quality and proper

design of system electronics. The system shall be highly reliable,

high-integrity safety system on both qualitative and quantitative

technologies. Redundancy shall be provided as a minimum, as

per this specification to improve system availability, reliability and

safety. Due consideration shall be given to the environmental

conditions particularly for field mounted subsystems.

4.10.1.2 The system shall be modular in construction and expandable in future by

adding additional modules which shall be easily accessible for maintenance

and repair. The modules shall be suitable for inserting in rack mount. The

types of modules shall be kept to minimum possible in order to have

interchangeability and low spares inventory.

4.10.1.3 The PLC (Processor & I/O SYSTEM) shall have very high noise immunity

in order to ensure safe and reliable operation when subjected to electrical

radio frequency interference and electromagnetic disturbances expected in a

plant. The design of system electronics shall be in compliance with the

electromagnetic compatibility requirements as per 'IEC-801-2, IEC – 801 – 3,

IEC–801-5: Electromagnetic compatibility for Industrial Process Measurement

and Control Equipment'.

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4.10.1.4 The safety PLC should be SIL2 (or better) in accordance with IEC 61508 /

IEC 61511.

4.10.1.5 Designed SIL 2 (or better) type of safety PLC is required. Pl. Note

that SIL2 approval of the PLC shall remain valid in case of failure of any

one of redundant module (i.e. CPU / power supply/ communication

module). Documentary proof from SIL2 approving agency (TUV/

equivalent) is required for above.

4.10.1.6 PLC system should meet the following :

Industrial Noise Test : NEMA1- 109 Showering Arc test. Surge withstand capability test: IEEE 472/ANSI C37.90A 2KV/5KV Isolation test: IEC 255-4

4.10.1.7 The PLC System (Processor & I/O) shall also comply to UL 508 & CSA

C22.2 No 142 Standards for Industrial Control Equipments / Process control

equipments.

4.10.1.8 The system shall have extensive set of self diagnostics hardware and

software for easy and fast maintenance of PLC. Routine checks should run

automatically at frequent intervals for identifying any fault in software or

hardware. Diagnostics shall be required at local module as well as operator

interface console level.

4.10.1.9 Operation of the PLC shall be completely unaffected by a momentary

power loss of the order of 20 milli –seconds.

4.10.1.10 The total load on any communication bus at any point of time shall not

exceed 60% of total capacity.

4.10.1.11 The scan time of programmable controller shall be of the order of 100

milliseconds for logic & 300 milliseconds for closed loops. Scan time of PLC

is defined as the cycle time taken by the system to read input, process input

executing logic, and update control output for all the logic configured within

the system. Other activities like diagnostic routines, output/dump of data to

peripherals, or any other activity which consume processor time shall also be

accounted while computing scan time.

4.10.1.12 On-line replacement of any module shall be possible in such a way that

the removal and addition of the module shall be possible without de-

energizing the system. Further, there shall not be any interruption in the

system while replacing a faulty module except for the inputs/outputs, which

are being handled, by that module.

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4.10.1.13 Auto I/O Testing of all the Input and Output Modules is required.

4.10.2 SPARES PHILOSOPHY

Installed engineering spare modules up to 20% shall be provided in input/output subsystem on module basis and/or with a minimum of one module of each type to enhance the system functional requirements for future. In addition the system shall have the following minimum spare capability

(a) I/O racks of PLC shall have 20% useable spare slots for installing I/O modules of each type in future. These racks shall be part of the offer.

(b) The processor system shall have the capability to execute logic for I O's including 20 % installed spares.

(c) Whenever relays are used to interface process input/outputs with PLC 20% additional relays shall be provided. In addition, 20% spare space shall be provided in cabinets to install 20% additional relays in future.

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4.10.3 SYSTEM CONFIGURATION

The system shall consist of following major subsystems:-

4.10.3.1 INPUT /OUTPUT SUBSYSTEM

4.10.3.1.1 The I/O modules shall be mounted in the I/O racks located in

control room i.e. I/O modules shall be general purpose unless

otherwise specified. I/O devices interface with PLC shall be at I/O

racks only.

4.10.3.1.2 The maximum number of input/outputs per module shall be limited

as follows :

__________________________________________________________ Sr.No. Type of Configuration No. of I/Os __________________________________________________________ 1. I/O Sub-system 16 for Digital inputs

08 for Analog inputs (3wire Tx. HART)

08 for Analog inputs (2wire Tx. HART)

16 for Digital outputs 8 for pulse Input

8 for Analog output 2 ports for Serial Interface -------------------------------------------------------------------------------------------------

4.10.3.1.3 Each I/O shall be electrically isolated from external control circuit

by suitable means. The minimum isolation level between I/O and

logic circuit shall be 1000 VDC. I/O status indication shall be

provided for each I/O module.

4.10.3.1.4 Each I/O shall be protected against reversal of polarity of the

power supply voltage to I/O.

4.10.3.1.5 Each module shall have LED for each I/O channel to indicate the

status of each input/output.

4.10.3.1.6 Each input shall be provided with filters to filter out any noise in

the input line or noise because of input contact bouncing.

4.10.3.1.7 PLC inputs shall be provided with potential free/dry contacts

unless otherwise specified.

4.10.3.1.8 All the inputs shall preferably be double ended i.e. two wires per

input and not common return for all inputs.

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4.10.3.1.9 The interrogation voltage (24 V DC / 110 V AC) to the input/output

contact shall be powered from separate redundant power supply

units and shall not be a part of PLC.

4.10.3.1.10 Output contacts from the PLC shall be potential free/dry

contacts with contact ratings as below. Wet contracts/ powered

contacts/TTL outputs etc., shall not be acceptable. Suppression

device for each output contact is to be provided.

4.10.3.1.11 The output contact rating shall be as follows

---------------------------------------------------------------------------------------- Sr.No. Applicable For VOLT Current Rating ------------------------------------------------------------------------------------- 1. All output cards for driving} 230V AC 0.5 A

solenoid valves and alarm} annunciator. } 24 V DC 2.0 A 2. All output cards for driving

LT motors/pumps/solenoids 230V AC 5.0 A

4.10.3.1.12 Input type shall be intrinsically safe with barriers for analog

input modules and explosion proof type for digital input

modules. Only Active Barriers shall be employed for

achieving galvanic isolation.

All analog input channels shall be provided with barriers.

4.10.3.1.13 Each output shall be short-circuit proof and protected by

fuse. Visual indication of fuse down/blown must be

provided for each output. The digital output module

offered should have this functionality; separate

terminal block with fuse blow indication in conjunction

with a general-purpose digital output module shall not

be acceptable.

4.10.3.1.14 Failure in the ESD system will de-energise the relevant

system components causing them to move to tripped

(safe) position. All relays are normally energized and all

contact normally closed (normally here means process

normal condition and not “no power condition”). Where

ever normally open field contacts are used, the ESD PLC

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I/O cards shall have line monitoring to detect wire open

condition.

4.10.4 PROCESSOR SYSTEM ( 32 BIT)

4.10.4.1 The offered processor type shall have a minimum reference capacity to

handle 2000 real time I/O. Redundancy shall be provided such that in case of

failure of the primary processor, the secondary processor shall take over

automatically without any time lag. Both processors shall access the inputs

simultaneously. If not possible, changeover time shall be maximum 100

millisecond. The changeover shall be bumpless and the system shall be safe.

Redundancy shall be provided for complete processor subsystem including

CPU, memory, power supply & host system communication interface i.e.

rack to rack redundancy.

4.10.4.2 Memory shall be non-volatile. However, incase volatile memory is

provided, rechargeable battery backup shall be provided for a minimum of

one year to keep the stored program intact. A battery drain /pass indication

shall be provided .The size of the memory shall be sufficient for storage of the

program instructions required by the logic schemes. 20 % spare capacity

shall be available.

4.10.4.3 In case of failure of complete processor system i.e. both processors

system outputs shall take fail safe automatically.

4.10.4.4 The processor shall have capability to implement all the control functions

required to implement the logic scheme, as logic/ladder diagram.

4.10.4.5 Time stamping for all alarms / event shall be done at the PLC processor

level.

4.10.4.6 It shall be possible to generate the first out alarm output by the PLC in

case where a group of parameters are likely to trip the system.

VENDOR TO FURNISH DETAILS OF THE PROCESSOR LOADING

ALONGWITH THE TECHNICAL OFFER.

4.10.5 VENDOR TO FURNISH DETAILED CONTROLLER SCHEMATIC SHOWING

MODULE WISE INTER CONNECTIVITY, WITH THE PROCESSOR, I/O

MODULE, COMMUNICATION MODULE ETC. ALSO CONNECTIVITY OF

VARIOUS FIELD DEVICES / INTERFACING DEVICES TO THE

CONTROLLER SHALL BE SHOWN. THE SAME SHALL BE ENCLOSED

ALONGWITH THE TECHNICAL OFFER.

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4.10.6 COMMUNICATION SUB SYSTEM

4.10.6.1 The communication subsystem shall be a digital communication bus that

provides reliable and high speed data transfer between the processor

subsystem & I/O subsystem.

4.10.6.2 The PLC shall have open protocol and share data with read only

permission through Ethernet. PLC shall be configured in fail safe manner

considering processor I/O module / power supply failure.

4.10.6.3 Redundancy in communication subsystem shall be as follows unless

otherwise specified.

(a) Communication Interface between each I/O rack & the dual processor system shall be via separate dedicated dual redundant communication link in multi-drop mode; daisy chained redundant communication bus to establish interface between I/O racks & processor system shall not be acceptable.

(b) The communication interface between each processor subsystem and host LRC system shall be dual redundant consisting of two separate communication interface modules located in / from each individual processor rack and two individual communication links, with each one configured in redundant mode. Use of PLC processor CPU port for establishing host interface connectivity shall not be acceptable.

4.10.6.4 In case of redundant communication subsystem on the failure of

the active device the redundant device shall take-over automatically

without interrupting the system operation.

Information about the failed device shall be displayed locally as on well as

the console. It shall be possible to manually switch-over the

communication from main bus/device to redundant bus/device without

interrupting the PLC functions.

The mechanism used by the system for error checks and control shall be

transparent to the application information/program. Error checking shall

be done on all data transfers by suitable codes. All communication

interfaces shall be galvanically or optically isolated.

4.10.7 SELF DIAGNOSTICS

4.10.7.1 The system shall have an extensive set of self-diagnostic routines which

shall be able to identify the system failures at least upto module level

including redundant components and power supplies through detailed CRT

displays report print outs and logic programming.

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4.10.7.2 At the local level, failure of a module in any subsystem shall be identified

by an individual LED.

4.10.7.3 Self-diagnostics shall be provided to detect faults (which make the

contacts in fail safe mode) in the input and output modules. Each module

shall have separate arrangement for self-diagnostic facility. This may be

achieved by automatically running the testing software at cyclic intervals.

Testing software shall be capable of detecting faults in case of normally

closed system as well as in normally open system.

4.10.7.4 Feedback shall be provided internally from the output voting logic system

to detect any latent faults of the system.

4.10.8 POWER SUPPLY DISTRIBUTION

4.10.8.1 PLC system shall be powered with 230 VAC +/- 3%, UPS Supply. Power

pack shall be 100% redundant with safety factor of 1.5. The distribution

network for AC power supply shall be designed such that a single power fault

in any branch system shall not cause a trip of the entire system. The

distribution network for interrogation voltage shall be designed such that a

single fault in any branch shall not cause trip of the logic other than where the

fault has occurred. Sequential starting of various load centers shall be

provided whenever specified.

4.10.9 PLC SYSTEM CABINETS

All PLC system cabinets shall be completely wired with all modules in

place. Inside cabinet wiring shall be done using ribbon type pre-

fabricated cables. All the cabinets shall be free standing, enclosed type

and shall be designed for bottom entry of cables. Cabinet structure shall

be sound and rigid and shall be provided with removable lifting lugs to

permit lifting of the cabinets.

Cabinet shall be fabricated from cold rolled steel sheets of minimum 2

mm thickness suitably reinforced to prevent warping and buckling. Doors

& side panels shall be fabricated from cold rolled steel sheet of minimum

1.5mm thickness. Cabinets shall be thoroughly debarred and all sharp

edges shall be grounded smooth after fabrication.

Cabinet finish shall include sand blasting, grinding, chemical cleaning, surface finishing by suitable filter and two coats of high grade lacquer with wet sanding between two coats. Three coats of paint in the cabinet colour shall be given for non-glossy high satin finish.

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Each cabinet shall be maximum 2100 mm high (excluding 100-mm channel base), 1000 mm wide and 800 mm deep, in general. Construction shall be modular preferably to accommodate 19" standard electrical racks. All cabinets shall be of same height. Maximum swing out for pivoted card racks, doors and drawers shall be limited to 600 mm.

Cabinets shall be equipped with the front and rear access doors. Doors shall be equipped with lockable handles and concealed hinges with pull pins for easy door removal.

In order to remove dissipated heat effectively from cabinets, vent louvers backed by wire fly screen shall be provided in cabinet doors. Further two ventilation fans shall be provided.

Illumination shall be provided for all cabinets by incandescent lamps, which shall be operated by door switch.

Equipment within the cabinet shall be laid out in an accessible and logically segregated manner. Cable glands shall be provided for incoming and outgoing cables to prevent excessive stress on the individual terminals. All metal parts of the cabinet shall be electrically continuous and shall be provided with a common grounding lug.

The front doors for the PLC cabinet shall have toughened glass / acrylic window for visual ergonomics.

4.10.10 EARTHING

Each cabinet, console and other equipment supplied as a part of PLC

system shall be provide with an earthing lug. All these lugs shall be

properly secured to the AC mains earthing bus.

All circuit grounds, shields and drain wires of control cables shall be connected to the system ground bus which shall be electrically isolated from AC mains earthing bus. This bus shall be typically of 25 mm wide and 6 mm thick of copper.

All barriers, if used, shall be securely grounded. Safety barrier ground wire shall be capable of carrying a maximum fault level current of 0.5 A at 250 V r.m.s per barrier.

NOTE : Analog Input modules for 3-wire Transmitters (HC Detectors/Tx.) are also required for this PLC. Detailed Technical specifications of the PLC system are to be furnished by vendor as part of Technical bid. These Technical specifications & I/O count will be frozen during Technical evaluation.

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5 SYSTEM SOFTWARE SPECIFICATIONS

5.1 System Software

The operating system must be having real time capabilities. The operating system shall be modular in design and shall provide effective utilization of resources and facilitate future expansion. It shall have the following features:

• Real time capabilities. • Multiprogramming and Multitasking facilities including background and foreground operations in real time mode. • Virtual Memory System. • Event based priority scheduling/ priority driven preemptive kernel • Dynamic memory allocation • Memory lock/unlock feature • Hardware based control interrupt handling • System Security Features • RDBMS/SQL database management system • Dual LAN support • Bulk Storage Management • OSI/TCP/IP network connectivity support • Input/output drivers for all peripherals • Graphic support package • Online and detailed offline diagnostic package to troubleshoot CPU, memory and various system and peripheral cards

6 CABLE LAYING

Cables shall be laid above ground or in some road cuttings etc if required the same shall be laid underground. All above ground cables shall be laid on the cable tray with cover as per specification. When the cable is laid above ground, it shall be laid on the perforated cable tray with cover. The cable shall be tied on the GI or Aluminium Cable tray (as per site conditions) with GI Clamps. No PVC ties or MS wire shall be used for tying the cable on the GI cable tray. The cable shall be laid on the tray with min. D spacing (D being the diameter of the thicker cable). Bunching of cables or laying cable on top of each other is not permitted. Separate cable tray shall be used for laying Power & Signal / Communication / Control Cables. The perforated GI or Al Cable Tray shall be supported at regular interval. The existing structural support at Gantry, Tanks may be used for supporting the cable tray. In case additional supports are required the same shall be supplied & erected by the vendor & shall be include in the cost of cable laying. Laying of the cables underground shall be in trenches of min. 1mt depth in all types of soil both hard and soft soil including dewatering, if required. Big boulders, sharp edges of the steel sections, vegetation, growth roots etc. if encountered shall be removed completely. Only soft earth excavated shall be kept for refilling. Such earth shall be approved by the BPCL Engg-In-Charge (EIC). Excavated trench shall be in true straight line as far as possible and bends if necessary shall be provided. Such bends shall be gradual and not sharp in nature, the excavated trench shall be approved by BPCL EIC before cables. In

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case, during excavation hard rock is encountered which in opinion of BPCL EIC / cannot be excavated further, then additional sand bedding of 150mm shall be provided over & above the 150mm specified for the bedding. The decision of BPCL / is final & binding in this regard. Rate of cable laying shall include excavation, supply and laying of two layers (150mm thick each, below and above) of river sand conforming to IS 383 and a layer of good quality bricks of compressive strength min. 35kg/sqcm on top of the second layer of sand & backfilling with good quality excavated earth. Job shall also include cutting / excavation of RCC wherever encountered & construction of RCC Culvert / cable alley in RCC 1:1.5:3 with reinforcement as per design requirement. All care shall be taken to ensure that no underground utilities like cables, pipelines etc. gets damaged. However, in case any underground utility like cables / pipes are damaged, the same shall be repaired / replaced by the vendor immediately at no extra cost. Rate to include backfilling of the excavated earth & carting away surplus earth within the depot premise as directed by BPCL EIC / Installation Manager. Before cutting the cables exact length as per the site conditions shall be measured and recorded. Cut ends of the cable shall be wound by insulating tape to protect them from rain water etc. Cable ends shall not be kept open for long. The cables shall be laid with min. spacing of “D” (D being the diameter of the thicker cable) * 15mm from edge of the cable tray. Power Cable shall be laid in separate trench and Signal & Communication Cabling shall be laid different trench. The same may be laid in common trench provided physical barrier in the form of bricks are provided in such a way that both are laid min 300mm apart. Power & Signal / Communication / Control Cables shall be laid separately. Wherever the cables have to cross the asphalt roads, the job shall include cutting of the asphalt and WBM roads including soiling and necessary excavation to the required depth and back filling the trench with river sand and restoring the asphalt / WBM roads to its original condition including compacting and rolling the surface. Road crossing shall be done through the Hume pipe. The existing Hume pipes may be used in case sufficient space is available for laying the cables. Supply & laying of the NP2 Hume pipes, if required, shall be in the scope of the vendor. Wherever the cable comes aboveground, a suitable size GI sleeve with bend shall be used. Such pipe shall be laid 150mm below ground level and the projecting bend shall raise to 500mm above ground level along the steel / concrete / brick columns. The sleeve shall be neatly clamped by MS clamps of adequate size and wooden bushes. Necessary precautions shall be taken to make the opening water tight by wooden bushes. All the cables be neatly clamped on the cable tray and loose hanging cables shall not be allowed. Required loops shall be provided at both ends of the main cables. Cable shall be laid without any joints. Cable route markers at 20m/c and at all the bends/turnings shall be provided. Bending radius of cables shall not be less than 12times O.D. of cable. All cores of cable shall be identified at both ends by means of PVC ferrule. Line drivers & all other accessories required in this regard are included in the scope of work of the vendor. Cable laying shall also include termination of cables at both the ends. Cable leads shall be terminated at both ends by crimped type soldering. Rate shall also include megger test by 1000V megger for establishing the healthiness of cable in the drum before removing the same, unwinding and straightening the cable & after laying of cables.

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7 Earthing

All junction boxes, local cabinets, field mounted instruments shall be connected to the nearby earth bus bar/earth pit through minimum 1.5 mm2 copper conductor Earthing network shall be realized with earth electrodes and/or buried bare conductors. Two types of earthing system shall be envisaged – Main earthing system ( ME)

Electronic earthing system ( EE)

The electronic earth system shall be separate from main earthing system. Main earthing system (ME) shall be installed by BPCL. However, Electronic-earthing system (EE) is included in the tenderer scope. The earth electrode(s) for EE shall be of the same type as those for the ME, but in addition shall be placed in a galvanized steel pipe line for a depth of 4m to shield the electrode from surface earth stray currents which may cause unwanted interference. In general, the earth conductor between cabinets/instruments/junction box upto the local earth bus shall be 1.5 mm 2 insulated copper conductor. From local earth bus to the earth pit 2.5 mm2 insulated copper conductor shall be used. In general the following rules shall be apply for earthing : The metallic housing of electronic equipment/junction box/panel shall be

connected to the main earthing system ( ME). The active electronic parts of a electronic equipment/computer system shall be

connected to the electronic earth (EE). All armors of armored cables shall be connected to the earth (ME) at both ends. The shield of the shielded cable shall be earthed with electronic earth at one end

only i.e. at control room end.

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8 Painting

This part of the specification is applicable to cable ducts, cable trays, CS impulse pipes, instrument supports and all other structural supports for cable trays, ducts, impulse tubes, air lines etc. The surface to be painted shall be thoroughly cleaned with wire brush, sandpaper to remove all scales. After cleaning, the surface is painted with one coat of red oxide zinc chromate primer conforming to IS 1074 and allowed to dry completely. Primer coated surface is painted with one coat of synthetic enamel paint to the colour nearest to the final paint and allowed to dry. The colour number shall be from IS 5. Final second coating shall be with the paint of desired colors and shall be elected from IS 5. The name of manufacturer, colour and quality of all types of primer paint shall be subject to approval of purchaser.

9 TECHNICAL SPECIFICATIONS FOR EQUIPMENTS & ITS DATA SHEETS.

9.1 HIGH HIGH LEVEL SWITCH

Objective Tank overfill protection

Service ESD- Tank overfill protection

Primary Sensor Vibrating tuning fork (intrinsically safe)

Mounting/ process connection On tank top / 2” ANSI 150 class , RF Regional E&P to confirm

Safety Requirement/Approvals 1. SIL 2 Certificate by TUV/ EXida as per

IEC 61508/ 61511 along with Test Reports

specified in the certificate.

2. The functionality of overfill protection (i.e.

Relay Output) of Level Switch has to be

certified minimum SIL 2 (as per IEC

61508/61511) in mono mode.

3. The Level Switch shall also satisfy the

criteria for SIL 2 certification according to

IEC 61508 Part 2, Table 3 (i.e. Hardware

Safety Integrity: Architectural constraints

on type B safety related sub-systems).

Sensor Material/ other wetted parts SS316

Enclosure Housing Die cast aluminium / SS316

Insertion Length Elevation difference between Process nozzle (Top) & 90% of safe filling height of tank. Regional E&P to Provide

Area Classification Zone1, Gas Group IIA, IIB

Enclosure Approvals Flameproof / intrinsically safe as per IS 2148 ; Weatherproof as per IP 65 ; CCOE/ PESO/ATEX approvals

Power supply 230 V AC , 50HZ

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Contact output SPDT switch (1 NO + 1 NC) ; Potential free contact(Relay ); Switch Rating-230 V AC, 5 Amp.

Fail safe Requirement Relay shall be in De-energized state

Cable Entry ½ “ NPT , 2 Nos.

Inputs required for overall SIL calculations SFF, HFT, PFD

WHG overfill protection Vendor to specify

Revalidation Requirement Testing of Level switch shall be possible without raising the Level or removing the switch

9.2 Technical Specifications of Flameproof / Weatherproof Electronic Hooters

Flameproof Zone – 1 & , Gas groups – I, IIA & IIB as per IS:2148/1981, Temp. Class – T6

Weatherproof IP 65 Degree of protection as per IS:13947 (Part-1) 1993. IP certificate for the same to be submitted.

Material Cast Aluminium Alloy LM6 / SS

Finish Inside & Outside light grey epoxy powder coated to shade 631 as per IS:5

Earthing Required

Terminals 8 Nos. for 1.5/2.5 sqmm clip-on Terminals

Cable Entries 2 Nos 1/2” NPT cable entries from bottom side. FLP / Weatherproof double compression cable glands are to be provided on cable entries.

Sound Level Shall be audible atleast upto 1 km coverage( Vendor to specify dB)

Mounting Surface Mounting Type (Mounting Accessories / Canopy to be provided)

Certified temperature

–20°C to +55°C.

Power Supply 230 VAC

Approvals PESO, CMRI. Certificate for the same to be submitted for approval before procurement of the same.

Makes Baliga / FCG/ Flexpro/ Ex-protecta/ CEAG/ Sudhir Switchgears / Equivalent

9.3 Technical Specifications of ESD PB Station SIL 2 certified

Product Flameproof – Weatherproof Enclosure of Indicating lamp with Stop push button station with separate cable terminal box wired upto the terminal.

Flameproof Zone – 1 & , Gas groups – IIA & IIB as per IS:2148/1981, Temp. Class – T6

Weatherproof IP 65 Degree of protection as per IS:13947 (Part-1) 1993. IP certificate for the same to be submitted.

Material Cast Aluminium Alloy LM6

Finish Inside & Outside light grey epoxy powder coated to shade 631 as per IS:5

Earthing 1 No. inside & 2 No

Hardware Stainless Steel

Gasket „O‟ Ring endless Neoprene rubber gasket.

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Terminals 8 Nos. for 1.5/2.5 sqmm clip-on Terminals

Cable Entries 2 Nos ¾” ET cable entries from bottom side. SS plugs to be provided on cable entries.

Indicating Lamp. 1 No. 24V DC . 5 Watt LED type Indication Lamp (RED COLOUR)

Element 2 Nos. 5A, 230 VAC (1NO + 1NC Contact elements)

Actuator „Stop‟ push button of red mushroom head press to Stop & Reverse turn to release with pad locking arrangement in stop position.

Mounting Surface Mounting Type (Mounting Accessories / Canopy to be provided)

Approvals PESO, CMRI. Certificate for the same to be submitted for approval before procurement of the same. SIL 2 certification by TUV

Makes Baliga / FCG/ Flexpro/ Ex-protecta/ CEAG/ Sudhir Switchgears or equivalent

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9.4 DATA SHEET FOR EXPLOSION PROOF / WEATHER PROOF JUNCTION

BOX

S.No. Item Description Requirement

1 Body & Cover Cast Al. Alloy (LM6); Minimum 5mm thick

2 Gasket Neoprene rubber

3 Terminals Clip on type, block locked at both ends suitable for up to 2.5 sqmm conductor. Make - Elmex, Phoenix

4 Tag Nameplate To be provided

5 Paint Anti Corrosive epoxy paint, shade light gray

6 JB Type Suitable for area classified as IEC Zone 1&2, Gr. IIA & IIB T6; as per IS:2148

7 Protection Class IP-65 as per IS:2147

8 Other Explosion proof junction boxes shall have detachable cover, which is fixed, to the box by means of cadmium plated hexagonal head screws. Terminal shall be spring loaded, vibration proof, clip on type, mounted on nickel plated steel rails completed with end cover and clamps for each row.

Sizing shall be done with due consideration for accessibility and maintenance in accordance with the following guidelines:

o 50 to 60 mm between terminals and sides of box parallel to terminals strip for up to 50 terminals and additional 25 mm for each additional 25 terminals. o 100 to 120 mm between terminals for up to 50 terminals and additional 25 mm for each additional 25 terminals.

o All junction boxes shall be provided with 20% spare cable entries and terminals.

o All cable glands and plugs shall be nickel plated brass material. o Double compression type cable glands shall be used for armoured cable.

9 Approvals CMRI & CCOE/PESO approval is required for Flameproof and Weather proof enclosures.

10 Accessories required a) Flame Proof Double compression Aluminium Cable Glands / Plugs for all the cable entries are in Vendor‟s scope. b) Mounting Accessories for JB‟s are in vendor‟s scope.

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9.5 DATA SHEET FOR ENGINEERING CUM OPERATOR STATION

SR.NO PARTICULARS REQUIREMENTS

1. PC Type Server

2. Form Factor Tower

3. Make / Model Vendor to specify

4. Processor Quad core Intel Xeon or better

5. Processor Chip Set Intel Latest

6. Display Colour, 21” LCD Monitor (Resolution 1920x1080)

7. Display arrangement Single tier

8. HDD 180 GB minimum (SCSI) Hot swappable with RAID5 configured

9. Hard Disk Controller SMART ARRAY CONTROLLER WITH RAID 5 SUPPORT

10. RAM Minimum 4 GB ECC, DDR3 low power

11. I/O Expansion Slots SIX; with 3 PCI EXPRESS.

12. CD – R/ W Drive DVD-RW Drive

13. Graphics Suitable graphics adapter with 16MB of Video RAM

14. Keyboard USB Minimum 101 keys, Membrane type / dust proof

15. Mouse USB Optical

16. NIC support Dual Integrated 10/100/1000 Mbps Ethernet (standard) + 2 Additional 10/100/1000 Mbps NIC card with RJ45 / UTP interface with wake on LAN enabled

17. Built In IO 1 serial; 1 parallel; keyboard, mouse, 4 USB required

18. Power Supply Redundant

19. Operating System Windows Server 2008 Stnd Edition, preloaded and on media (DVD) with paper license and recovery media

20. RAID Storage box RAID level 5 to be offered using internal storage box with redundant power supply & cooling fans connected to each server in RAID 5 configuration is to be offered.

Note :

USB / Parallel port converters shall be provided in absence of parallel ports.

RAID Diagnostics: The System shall have software for checking RAID diagnostics. The level of RAID 5 shall be clearly demonstrated by the system. In case of defective hard disk, it shall be possible to replace the same online without shutting down the system. Hot spare or clod spare drive shall not be acceptable. The system shall show auto build of date on the new drive.

USB ports to be disabled

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DATA SHEET FOR OPERATOR STATION

SR.NO PARTICULARS REQUIREMENTS

1. PC Type Workstation

2. Form Factor Tower

3. Make / Model Vendor to specify

4. Processor Intel Core 2 Duo or better

5. Processor Chip Set Intel Latest

6. Display Colour, 21” LCD Monitor (Resolution 1920x1080)

7. Display arrangement Single tier

8. HDD 160 GB minimum (SCSI) (Redundant)

9. Hard Disk Controller Integrated Controller

10. RAM Minimum 2 GB DDR-2 SDRAM

11. I/O Expansion Slots Min Four (2PCI/ 2PCI Xi) full height

12. CD – R/ W Drive DVD-RW Drive

13. Graphics Suitable graphics adapter with 16MB of Video RAM

14. Keyboard USB Minimum 101 keys, Membrane type / dust proof

15. Mouse USB Optical

16. NIC support Dual Integrated 10/100/1000 Mbps Ethernet (standard) + 2 Additional 10/100/1000 Mbps NIC card with RJ45 / UTP interface with wake on LAN enabled

17. Power Supply Redundant

18. Operating System Windows 7 Professional, preloaded and on media (DVD) with paper license and recovery media

Note :

USB / Parallel port converters shall be provided in absence of parallel ports.

USB ports to be disabled

9.6 DATA SHEET FOR LASER PRINTER

1. Make As per approved list.

2. Type Laser

Printer Specs

3. Print Speed (black, A4) 20 PPM

4. Print Speed (Color) 15 PPM

5. Printing Resolution (Color)

600 x 600 dpi

6. Duplex Printing Option Automatic (Standard)

7. Processor speed Minimum 540 MHz

8. Pages per month Up to 35000

9. Standard memory 128 MB

10. Memory slots One 100-pin DIMM slot

11. Standard connectivity 1 Hi-Speed USB (compatible with USB 2.0 specifications) port, 1 built-in Fast Ethernet Print Server (10/100Base-TX, RJ45)

12. Compatible Operating Windows 9X, 2000, 2003, XP, Windows 7 Prof

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13. Supply Voltage 230 V ac, +/- 10%, 50 Hz +/-2Hz

14. Note: The DOT Matrix printers are required for text and Laser printer for graphics / text printout. The printers shall be Network printer put on the LAN and shall be accessed over the LAN.

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9.7 DATA SHEETS FOR CABLES

9.7.1 SIGNAL & COMMUNICATION CABLE

1 Type of cable PVC Insulated (Fire Redundant Low Smoke) copper

cable, Single Pair/ Multipair shielded copper cable

2 Construction 1.5 sq. mm multi strand/ solid annealed electrolytic copper

3 Primary insulation Extrude PVC as per IS 5831 type A. Min thickness 0.6mm

4 Pair twist Two cores of the pair shall be twisted. Ten number of twist

per meter shall be minimum

5 Shield (Individual Pair) Each pair shall be shielded with aluminum backed myler,

tape with 100 % coverage and minimum 25 % overlap.

6 Shield (Multipair) Same as above for individual pair shielding. Also the

overall shield shall be of aluminum backed myler tape with 100 % coverage and minimum 25 % overlap

7 Shield thickness Min. 0.05 mm for individual and overall shielding

8 Inner Jacket Extruded PVC, type STI, Min. thickness 0.7 mm

9 Outer Jacket Extruded PVC, type STI, Min. thickness 1.4 mm

10 Pair identification Pair identification number shall be provided at distance of

not more than 1 meter

11 Rip cord Shall be provided

12 Drain wire 0.5 sq.mm multistrand bare tinned copper conductor in a

continuous contact with aluminum side of the shield shall be provided

13 Armour Armour over inner jacket shall be of Galvanised steel wire

as per IS 1554 Part – I. (1.4 mm. Wire for 2-pairs and 4x0.8mm strip for multipair)

14 Electrical characteristics

Maximum resistance of the conductor of the complete cable shall not exceed 26.6 ohm /Km at 20-deg. c. Mutual capacitance of the adj. cores or pair shall not exceed a Max. Of 250 pF/mtrs at a frequency of I kHz. Capacitance between any core and screen shall not exceed 400 pF/mtr at a frequency of 1 kHz. The drain wire resistance including shield shall not exceed 30 ohms/km. Electrostatic noise rejection ratio shall be over 76 dB. L/R ratio shall not exceed 25 microhenries per ohm.

9.7.2 CONTROL CABLE

1 Type of cable PVC (FRLS) insulated armoured Cable

2 Construction 1.5 sq. mm solid bright annealed electrolytic copper

conductor, insulated and sheathed.

3 Voltage Rating Up to and including 1100 volts

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4 Primary insulation Extruded PVC compound as per IS 5381 type A. Min

thickness 0.7 mm

5 Inner Sheath Extruded PVC compound, type STI, min thickness 0.7mm

as per IS 5831.

6 Outer Sheath Extruded PVC compound, type STI, min thickness 1.4mm

7 Electrical characteristics Max. resistance of the conductor of the complete cable

shall not exceed 12.3 ohm/km at 20 deg. C

8 Armour over inner sheath

Armour over inner sheath shall be provided of galvanised steel wire/flat strip (1.4 mm. wire for 2-pairs and 4x0.8mm strip for multipair)

9 Core identification Core identification number shall be provided at a distance

of not more than 1 meter

10 Rip cord Shall be provided

9.7.3 POWER CABLE

1 Type of cable PVC (FRLS) insulated armoured Cable

2 Construction Size as per actual design, multi stranded annealed bare

electrolytic grade copper conductor.

3 Voltage Rating Up to and including 1100 volts

4 Primary insulation Extruded PVC compound as per IS 5831 type A

5 Inner Sheath Extruded PVC compound type STI, min thickness as per

table 4 of IS 1554 Part (I)

6 Outer Sheath Extruded PVC compound, type STI, Min thickness as per

table 7 of IS 1554 part (I), Colour black, Oxygen index of 29 at 27 (+/- 2) deg C.

7 Armour over inner sheath Galvanized steel wire for UAD less than 13 mm,

Galvanised steel strip for UAD greater than 13 mm Dimensions as per table 5 of IS 1554 Part I

8 Core identification 2 Core : Red & Black

3 Core : Red, Yellow & Blue

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10 APPROVED VENDOR LIST FOR BOUGHT OUT ITEMS.

Server & Work Stations with Monitor HP, IBM, DELL

Printers (Dot Matrix/ Laserjet ) WIPRO, EPSON, PANASONIC, HP, PANASONIC, CANON.

PLC –SIL2 (OR Better) certified Allen Bradley, GE, HIMA, YIL, Invensys (Triconix), Emerson, Siemens, Honeywell, ABB, Schnieder,

UPS EPM, DB Power, Hirel, Aplab, APC.

Control Panels Pyrotech, Rittal, Hoffmann

Signal Cables, Control Cables, Power Cables

Associated Cables, Associated Flexible & wires, Brooks cable works, Thermopads, Finolex, Fort gloster, CCI, Cords Cables, Universal Cables,

Cable trays GRAM ENGG, HOPES MANFG, INDIANA, GLOBE ELECT. ; INDMARK ASSOCIATES

Alarm Annunciator IIC, Procon, Aplab.

Zener Barriers/Surge Arrestors MTL, Pepperl & Fuchs, STAHL.

Level Switch (Vibrating Fork type)-SIL2 certified

E&H , SAAB (Rosemount),

FLP/WP Junction Box & Cable Gland, ESD PB Station

Baliga, FCG, Flexpro,Ex-Protecta,CEAG, STAHL,

Ethernet switches IBM, DELL,CISCO ,EMULEX, STALLION, SYSTECH, NORTEL NET WORKS, D-LINK, ,MOXA

Relays OMRON, TELE MECHANIQUE, HONEYWELL,

Push Buttons Teknic, Siemens, L&T, Merlin Gerin/ Telemechanique

Terminal Blocks Phoenix, WAGO,

MCBs/ Contactors MDS, Siemens, L&T, Merlin Gerin

Ni-Cd Battery

AMCO Batteries Limited ( Bangalore ) / HBL – Nife Batteries Ltd ( Hyderabad ) - ( Formerly called SABNIFE), Exide

MMI Software As listed in General Specification.

LRC Application Software As listed in General Specification

Operating Software As listed in General Specification

RDBMS As listed in General Specification

Maintenance Manager Software As listed in General Specification

Downtime Analysis system Software As listed in General Specification

Note:

1) Approved vendor list is for the manufacturers only. The list is not for any specific model. For

any instrumentation, offered model for the same must meet the Technical specifications

given in tender document.

2) For any other items not listed above, purchaser‟s approval shall be taken before ordering.

3) Party should indicate the vendors name on which they have based their offer as first choice

and indicate another vendors name as second choice positively for all the components

indicated in the above list in the SOS format as well as not indicated in the list.

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4) Party shall offer various components of flow meter assembly i.e. PD meter, strainer cum air

eliminator and pulse transmitter, proving vessel etc. of one family only.

5) Party shall submit technical literature of make & model offered. CCOE approval for all FLP

(IS/Ex) materials shall be furnished along with the supply of material, else payment for the

materials will be affected.

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11 SOURCE OF SUPPLY (SOS) FORM TO BE FILLED AND SUBMITTED ALONG WITH

TECHNICAL DATA/ LITRATURE BY VENDOR ALONG WITH TECHNICAL BID.

S. No.

Description Qty Make- Option - 1

Model No.

Country of Origin

Make- Option - 2

Model No Country of Origin

1. Engg cum Operator Station

Operator Station

2 Printers

Laser printer

3 Hot Standby Programmable Logic Controller (SIL 2 or Better) complete.

4 Safety PLC Processor [SIL2 or better]

5 Relays.

6 Electrical Contactor

7 Flameproof / Weatherproof Hooter

8 Weatherproof Hooter

9 ESD Push Button Station (SIL 2 certified)

10 Control panels and consoles.

11 Managed Ethernet switches

12 System Software and Application Software packages to meet the all requirements.

13 Operating software system

14. RDBMS

15. HMI

16 24 volt Power supply at PLC cabinets

17 Cable Trays

18 FLP/WP Junction box & associated accessories

19 UPS system

20 Level Switch (SIL2 certified)

21 Signal barriers/ surge arrestors/ signal multiplier

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NOTE:

1. Vendor to note that make and Model no. offered against Option –1 shall only be supplied. Option – 2 shall be considered only after prior approval from BPCL.

2. Any other item not mentioned but required for safe and efficient operation of system shall be indicated and included by the vendor in their offer. Any item not included by vendor but later found necessary for implementation of the system shall be vendor‟s responsibility to supply without any extra charge to the client.

3. Make and Model number shall be clearly indicated in the SOS form complete along with the necessary supporting catalogue, model de-codification details.

4. Shipping documents shall be provided for all imported equipment.

Any other item not mentioned but required for safe and efficient operation of system shall be indicated and included by the vendor in their offer. Any item not included by vendor but later found necessary for implementation of the system shall be vendor‟s responsibility to supply without any extra charge to the client. Shipping documents shall be provided for all imported equipment.

All Bidders are required to submit the Corrigendum Annexure – IV in

Document I : Technical Bid Section of the tender duly signed .

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CORRIGENDUM ANNEXURE - V TENDER NO. CRFQ NO. : 1000179338

E – TENDER NO. : 10736 TANK FARM MANAGEMENT SYSTEM : PRODUCT LEVEL PHILOSOPHY & METHODOLOGY Please find below the methodology on the basis of which various Product Levels in product storage tanks are to be determined to fix the Level set Points meant for various alarms & Trips . 1. Product High High Level(HH) [at which High High Level switch is to be actuated for closure

of ROSOV] is to be decided on the basis of following factors:

a. Safe Filling Volumetric Capacity of individual product tanks (as specified during tank designing on the basis of which CCOE/PESO licenses are obtained) and the „Safe Filling Level corresponding to safe volumetric capacity as certified in Tank Calibration chart‟ is the maximum allowable product level. „Safe Filling Height‟ of Fixed roof Tanks & Floating Roof Tanks is defined as below:

SFH ( Fixed roof tanks): o “95 % of tank height upto kerb angle for fixed roof tanks as per std. Engg.

Convention” OR “Safe Filling Level corresponding to safe volumetric capacity as certified in Tank Calibration chart” whichever is lower, shall be considered as „Safe Filling height‟ .

SFH ( Floating roof tanks) : o “Safe Filling Level corresponding to safe volumetric capacity as certified in

Tank Calibration chart” shall be considered as „Safe Filling height‟.

b. HH Level switch to be set below SFH ,considering following factors:

Maximum pumping capacities at which product receipt operation in tanks take place at the following type of locations:

Tanker/Ship Unloading locations ( 2500 kl/hr)

Rail Wagon Unloading locations (1000 kl/hr.)

Pipeline Transfer locations ( depends from location to location)

Closure time of tank inlet ROSOV to be derived considering closure time as 2 secs per inch valve dia of tank inlet ROSOV for which Industry Tender is floated by HPCL.

Any other location specific operational requirement due to which safe filling operating levels gets further decreased.

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2. Level Transmitters ( Radar & Servo type as applicable ) to be provided on Product storage Tanks , shall have following Level Set points :

a. High High Level (HH) Trip setting : It shall be at the same level at which High High

Level Switch will get actuated (refer point 1 above) Note : Level Transmitter ( in-built Potential Free Relay contact ) is to be used for the purpose.

b. High Level (H) Alarm setting : It is to be set at 95% of HH Level.

Note : This is software configured / generated Alarm setting at Control Room (through PLC / TFMS software as applicable)

c. Low Low Level (LL) Trip setting [Floating roof tanks]: It is to be set at 105 % of the level

at which the roof starts de-floating. (Fine tuning to be done tank specific calibration chart) Note : Level Transmitter ( in –built Potential Free Relay contact ) is to be used for the purpose.

d. Low Low Level (LL) Trip setting [ Fixed roof tanks] : It is to be set at 105 % of the outlet

nozzle top level. (Fine tuning to be done tank specific calibration chart) Note : Level Transmitter ( in –built Potential Free Relay contact ) is to be used for the purpose.

e. Low Level (L) Alarm setting [ Floating roof tanks] : It is to be set at 105 % of LL Level


f. Low Level (L) Alarm setting [ Fixed roof tanks]: It is to be set at 105 % of LL Level


TFMS requirement & Implementation methodology is as below :

A. DESCRIPTION ABOUT NEW TFMS REQUIREMENT:

1. New TFMS requirement is described in the attached System Architecture Dwg.

(E&P/INST/SA/TFMS-MBLR/0113) for the two types of TFMS measurement

system enumerated below.

2. Primary TFMS Measurement system-

a. Primary TFMS Measurement system will consist of Radar Type Level Tx.

(SIL2) along with Multi-Spot Temperature cum Water Bottom Sensor as

field instrumentation for individual product storage tanks.

b. The product level, temperature, water level (as measured by field

instrumentation referred vide Pt.2a above), will be interfaced primarily with

control Room located Redundant Communication Interface Unit (CIU) which

in turn will be interfaced with TFMS computer (hardware + software).

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c. The Communication Interface Units will be interfaced with Conventional

PLC over Serial Communication i.e. MODBUS RTU.

d. The hardwired outputs i.e. 4-20 mA signal (level), Hi-Hi Level trip Alarm and

Lo-Lo Level Trip Alarm of level tx. will be interfaced with Safety PLC.

e. Please refer attached System Architecture Dwg. (E&P/INST/SA/TFMS-

MBLR/0113) specific for the detailed Instrumentation requirement and

interconnections.

f. Control Room Instrumentation (i.e. CIU and TFMS software / computer)

shall be capable of interfacing min. 50 level tx. to take care of future TFMS

requirement.

g. In order to have open connectivity, the TFMS computer (Hardware +

Software) is required to communicate with other makes of CIUs (to be

supplied by other OEMs along with their level tx. in future) over MODBUS

RTU Serial Communication specified.

h. Tender includes the requirements of Primary TFMS measurement system

referred above.

3. Secondary TFMS Measurement will be done by Servo Type Level Tx.

a. Secondary TFMS Measurement system consist of Servo Type Level Tx.

as field instrumentation for individual product storage tanks.

b. The product level and Average density measured by field instrumentation

(i.e. Servo Type Level Tx.), will be interfaced primarily with control room

located Non-Redundant Communication Interface Unit (CIU)

c. The Communication Interface Unit will be interfaced with Safety PLC over

Serial Communication i.e. MODBUS RTU.

d. The hardwired outputs i.e. 4-20 mA signal (level), Hi-Hi Level trip Alarm and

Lo-Lo Level Trip Alarm of level tx. will be interfaced with Safety PLC.

e. The OEM of Servo Level Tx. will provide its „Software-serial interface

driver‟ in Engineering station in included in the tender package which will

ensure following at Operator station/ Engg. Station computers:

Viewing of Product Level

Execution of Density measurement command which will provide

viewing of Product Spot Density as well as Product Density

Profile.

The above job will be considered as part of commissioning activity for Servo type TFMS system.

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f. Please refer attached System Architecture Dwg. (E&P/INST/SA/TFMS-

MBLR/0113) specific to the detailed Instrumentation requirement and

interconnections.

g. Control Room Instrumentation (i.e. CIU and Software-serial interface driver

in the Safety PLC Engg. Station) shall be capable of interfacing min. 50

level tx. to take care of future TFMS requirement.

h. In order to have open connectivity, the Safety PLC Engg. Station is required

to communicate with other makes of CIUs (to be supplied by other OEMs

along with their level tx. in future) over MODBUS RTU Serial

Communication specified.

i. This includes the requirements of Secondary TFMS measurement system

referred above.

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All Bidders are required to submit the Corrigendum Annexure – V in

Document II : Technical Bid Section of Tank Farm Management System the tender duly signed .

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CORRIGENDUM ANNEXURE – VI TENDER NO. CRFQ NO. : 1000179338 E – TENDER NO. : 10736

1. Bidders to follow / adhere to NIT consisting of 80 pages sent as corrigendum

2. All Item Rates to be quoted inclusive of all taxes, duties.

3. No “C” Form will be issued by BPCL

4. Octroi & Entry Tax will be reimbursed on actual basis.

5. Bidders are requested to submit TAX BREAK UP details for each individual item

as per the above attached Excel File in NIT Bid.

6. All item rates are to be quoted in price bid will be inclusive of all type of

taxes duties in PRICE BID envelop and break up of Tax & Duties for the

same line item to be duly filled and attached in NIT bid document.

7. Single PO will be issued for entire job per location, based on the evaluation of

Lowest Quote.

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DETAILS ,BREAKUP OF ITEMWISE TAXES CONSIDERED IN FILLING PRICE BID

A CONVENTIONAL PLC EXCISE DUTY

CUSTOM DULY/CVD

Sales Tax(VAT/CST)

SERVICE TAX

Any other Tax/Duties/Levies and Cess Etc

REMARKS

1

Supply of -Digital Control Valve (Hydraulically powered ,3 " size , 150# pressure class, Max Flow rate 1200 LPM)

2 Supply of -Explosion Proof Earthing Relay & accessories

3

Supply of -Field Mounted Single Channel Batch Controller with Additive Blending / Injection.

4

Supply of -IS / Explosion Proof Proximity Type Card Reader (for TLF Gantry - Loading Bays)

5 Supply of -Proximity Cards

6

Supply of -Explosion Proof Remote Interacting Terminal (RIT) (for TLF Gantry - Loading Bays)

7

Supply of -IS/Flameproof Data Entry Terminal cum Card Reader (for Sealing Bay)

8

Supply of -Weatherproof Data Entry Terminal cum Card Reader (for Overnight Registration of Tank Lorries at Main Gate)

9

Supply of -Explosion Proof / Weather proof ESD Push Button Station

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10

Supply of -Electrically Operated Auto Barrier Gate with 6 - 8 mt Boom [at entry and exit points of Licensed Area and at Main entry and exit points of Installation / Depot] with ESD port and PLC connectivity

11

Supply of -Weather Proof Proximity Type Card Reader - at Main Entry / Exit points, - at Licensed Area Entry / Exit Points - at Planning Room

12

Supply of -Temperature Transmitter [at TLF Header (entry point of TLF Gantry)]

13

Supply of -Pressure Transmitter [at TLF Header (entry point of TLF Gantry)& Pump Discharge]

14

Supply of -Trolley Mounted Master Meter System [for MS]

15

Supply of -Trolley Mounted Master Meter System [for HSD/SKO]

16

Supply of -Proving Tank System [Fixed type Prover Tank Capacity 5KL with pump and associated accessories, for MS / HSD / SKO]

17

Supply of -Mobile Proving Tank System [Prover Tank Capacity 2KL with pump, FLP Switch/Socket and associated skid mounted

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accessories for MS / HSD / SKO]

18

Supply of -Pressure Switch [for low suction pressure measurement of each TLF Pump]

19

Supply of -Electromagnetic Display Unit [at Tank Lorry parking area]

20

Supply of -Turnstiles [at entry and exit points of Licensed Area and at Main entry and exit points of Installation / Depot with ESD port and PLC connectivity)

21

Supply of -FLP/WP Power Junction Box, FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification. No. of Cable Entries - for Multi Core : 2 Nos (bottom entry) - for Branch Cables : 12 Nos (side entry) Cable Size for Power JB - Multi Core : 36C x 1.5 mm2 - Branch Cable : 3C x 1.5 mm2

22

Supply of -FLP/WP Power Junction Box, FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification. - Branch Cables : 6 Nos (side entry)

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- Multi Core : 24C x 1.5 mm2 - Branch Cable : 3C x 1.5 mm2

23

Supply of -NFLP- Control Junction Box, NFLP cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification.(For pump automation MCC room ) No. of Cable Entries - for Multi Core : 4 Nos (bottom entry) - for Branch Cables : 18 Nos (side entry) Cable Size for Control JB - Multi Core : 36C x 1.5 mm2 - Branch Cable : 10 C x 1.5 mm2

24

Supply of -FLP/WP Control Junction Box, FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification.(Tank farm) No. of Cable Entries - for Multi Core : 2 Nos (from bottom only) - for Branch Cables : 12 Nos (from sides) Cable Size for control JB - Multi Core : 24C x 1.5 mm2 - Branch Cable: 2Cx1.5mm2

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25

Supply of -FLP/WP Control Junction Box, FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification.(fOR EXISTING MOV'S) No. of Cable Entries - for Multi Core : 2 Nos (from bottom only) - for Branch Cables : 12 Nos (from sides) Cable Size for Signal JB - Multi Core : 64C x 1.5 mm2 - Branch Cable:8Cx1.5mm2

26

Supply of -FLP/WP Control Junction Box, FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification.(For TLFG ) No. of Cable Entries - for Multi Core : 2 Nos (from bottom only) - for Branch Cables : 12 Nos (from sides) For 02 nos of SABC in one bay MC : 24Cx 1.5 sqmm:2 nos Bottom Entries BCab : 2C x 1.5 sqmm: 8 no side entries BCab: 8C x 1.5 sqmm : 2 nos side entries BCab: 3Cx 1.5 sqmm:2 nos side entries

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27

Supply of -FLP/WP Signal Junction Box, FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification. No. of Cable Entries - for Multi Core : 2 Nos (from bottom only) - for Branch Cables : 12 Nos (from sides) Cable Size for Signal JB - Multi Core : 12P x 1.5 mm2 - Branch Cable: 1Px1.5mm2

28

Supply of -FLP/WP Signal Junction Box, FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification. From BC to Multi drop box For 02 nos of SABC in one bay: MC: 12Px 1.5 mm2 :2 Bottom entries:320M BCab : 2P x 1.5 sqmm: 4 nos Side entries BCab:1P X 1.5 sqmm: 2 nos Side entries BCab:4Px 1.5 sqmm:2 nos Side entries

29

Supply of -FLP/WP Signal Junction Box, FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification. TLFG 2 WO & 1 BO(From multidrop box to control room) For 02 nos of SABC in one bay:

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MC : 12Px 1 mm2:2 nos Bottom entries BC : 4P x 1 mm2: 4 no.

30

Supply of -Set of FLP / WP Junction Boxes (includig FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material) of smaller sizes (other than specified above) required for any specific requirement.

31

Supply of -GI Cable Trays (Perforated) having width 300mm and Thickness 3mm alongwith necessary erection material like coupler plate, aluminium saddles, screws, nuts, washers etc;

32

Supply of -GI Cable Trays (perforated) having width 450mm and Thickness 3mm alongwith necessary erection material like coupler plate, aluminium saddles, screws, nuts, washers etc;

33

Supply of -GI Cable Trays (Perforated) having width 50mm and Thickness 2mm alongwith necessary erection material like coupler plate, aluminium saddles, screws, nuts, washers etc; cable trays shall be with tray covers.

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34


35


36

Supply of -GI Cable Trays (Perforated ) having width 200mm and Thickness 2mm alongwith necessary erection material like coupler plate, aluminium saddles, screws, nuts, washers etc;

37

Supply of cable-Signal Cable - 1pair x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

38

Supply of cable-Signal Cable - 12pair x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

39

Supply of cable-Signal Cable - 2P x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

40

Supply of cable-Signal Cable - 4Px 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

41

Supply of cable-Power Cable - 3C x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

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42


43


44

Supply of cable- Control Cable - 2C x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

45

Supply of cable-Control Cable - 24C x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

46

Supply of cable-Control Cable - 10C x 1.5 mm2(Copper Conductor, FRLS PVC Armoured) (For pump automation: Branch cable for each pump)

47


48


49

Supply of power Cable - 4 C x 4 mm2 (Copper Conductor, FRLS PVC Armoured)

50

Supply of Control cable 6 C x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

51

Supply of Control cable 4C x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

52

Supply of Control cable 12C x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

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53

Supply of Control Cable 16C x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

54

Supply of -Dual Redundant Programmable Logic Controller(conventional) with Licensed Software (Engg./ Loader software) including marshalling cabinet/s .IO COUNT :: DI- 331,DO-179,AI 2WIRE - 8,AO-0,PULSE INPUT - 0, SERIAL PORT RS485 - 42

55

Supply of -Operating system - 5 CAL User License for each server & client stations License for each work stations .

56

Supply of -SCADA / HMI / GUI Software (OPC compliant) - D + R + N for each LRC & R + N for each client work station .

57 Supply of -RDBMS for Transactionl DATA Base - 5 CAL User License.

58

Supply of -LRC Application software (OPC compliant) with backup software

59

Supply of -Redundant LRC Server(1+1) with 21" LCD Monitor. Operating System Windows 2008 Server

60

Supply of -Workstation (OIC) with 21" LCD Monitor. Operating System Windows 7

61

Supply of -Workstation (TTES) with 21" LCD Monitor. Operating System Windows 7

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62

Supply of -SAP-TAS Workstation with 21" LCD Monitor. Operating System Windows 2008 Server

63

Supply of -540 CPS BOL Dot Matrix Printer (including paper stand with mounting rack)

64

Supply of -440 CPS Alarm, Event, Report Dot Matrix Printer (including Paper stand & mounting Rack)

65 Supply of -Laser Jet Printer A4 size color

66 Supply of -Laser Jet Printer A3 size B/W

67

Supply of -Networking Hardware comprising of : Redundant Terminal Servers (including surge arrestors at all field ports), Redundant Manageable Fast Ethernet Switches, Fibre Optic / UTP Transceivers, etc. and Miscellaneous hardware

68

Supply of -LAN Networking with CAT 6 structured cabling and fiber optics cables.

69

Supply of -Open Table type console centers for mounting the servers / workstations in control room (i.e. LRC-1, LRC-2, OIC-1, OIC-2, OIC-3,TFMS-PC.)

70

Supply of -Open Table type console centres for mounting the servers / workstations in Planning Room. (i.e. TTES-1, TTES-2 and SAP-TAS PC.)

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71

Supply of -System cabinets to house Terminal Servers, Ethernet Switch, CIU, Alarm Annunciator cum push button panel as per tender specification.

72

Installation Testing & Commissioning of existing Flow Metering System (for White Oils ,3 " size , 150# pressure class, Max Flow rate 1200 LPM for Tank Lorry Filling operations) consisting of: - Positive Displacement Meter with Dual Pulse Transmitter (as one composite unit) - Strainer with DPG - Pressure Gauge - Air Eliminator - Resistance Temp. Detector (RTD)

73

Installation Testing & Commissioning of above-Digital Control Valve (Hydraulically powered ,3 " size , 150# pressure class, Max Flow rate 1200 LPM)

74

Installation Testing & Commissioning of above-Explosion Proof Earthing Relay & accessories

75

Installation Testing & Commissioning of above-Field Mounted Single Channel Batch Controller with Additive Blending / Injection.

76

Installation Testing & Commissioning of above-IS / Explosion Proof Proximity Type Card Reader (for TLF Gantry - Loading Bays)

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77

Installation Testing & Commissioning of above-Explosion Proof Remote Interacting Terminal (RIT) (for TLF Gantry - Loading Bays)

78

Installation Testing & Commissioning of above-IS/Flameproof Data Entry Terminal cum Card Reader (for Sealing Bay)

79

Installation Testing & Commissioning of above-Weatherproof Data Entry Terminal cum Card Reader (for Overnight Registration of Tank Lorries at Main Gate)

80

Installation Testing & Commissioning of above-Explosion Proof / Weather proof ESD Push Button Station

81

Installation Testing & Commissioning of above-Electrically Operated Auto Barrier Gate with 6 - 8 mt Boom [at entry and exit points of Licensed Area and at Main entry and exit points of Installation / Depot]

82

Installation Testing & Commissioning of above-Weather Proof Proximity Type Card Reader - at Main Entry / Exit points, - at Licensed Area Entry / Exit Points - at Planning Room

83

Installation Testing & Commissioning of above-Temperature Transmitter

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[at TLF Header (entry point of TLF Gantry)]

84

Installation Testing & Commissioning of above-Pressure Transmitter [at TLF Header (entry point of TLF Gantry)& Pump Discharge]

85

Installation Testing & Commissioning of above-Trolley Mounted Master Meter System [for MS]

86

Installation Testing & Commissioning of above-Trolley Mounted Master Meter System [for HSD/SKO]

87

Installation Testing & Commissioning of above-Proving Tank System [Fixed type Prover Tank Capacity 5KL with pump and associated accessories, for MS / HSD / SKO]

88

Installation Testing & Commissioning of above-Mobile Proving Tank System [Prover Tank Capacity 2KL with pump, FLP Switch/Socket and associated skid mounted accessories for MS / HSD / SKO]

89

Installation Testing & Commissioning of above-Pressure Switch [for low suction pressure measurement of each TLF Pump]

90

Installation Testing & Commissioning of above-Electromagnetic Display Unit

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[at Tank Lorry parking area]

91

Installation Testing & Commissioning of above-Turnstiles [at entry and exit points of Licensed Area and at Main entry and exit points of Installation / Depot with ESD port and PLC connectivity .

92

Installation& Commissioning of above-FLP/WP Power Junction Box, FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification. No. of Cable Entries - for Multi Core : 2 Nos (bottom entry) - for Branch Cables : 12 Nos (side entry) Cable Size for Power JB - Multi Core : 36C x 1.5 mm2 - Branch Cable : 3C x 1.5 mm2

93

Installation& Commissioning of above-FLP/WP Power Junction Box, FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification. - Branch Cables : 6 Nos (side entry) - Multi Core : 24C x 1.5 mm2 - Branch Cable : 3C x 1.5 mm2

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94

Installation& Commissioning of above-NFLP- Control Junction Box, NFLP cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification.(For pump automation MCC room ) No. of Cable Entries - for Multi Core : 4 Nos (bottom entry) - for Branch Cables : 12 Nos (side entry) Cable Size for Control JB - Multi Core : 36C x 1.5 mm2 - Branch Cable : 10C x 1.5 mm2

95

Installation& Commissioning of above-FLP/WP Control Junction Box, FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification.(Tank farm) No. of Cable Entries - for Multi Core : 2 Nos (from bottom only) - for Branch Cables : 12 Nos (from sides) Cable Size for Signal JB - Multi Core : 24C x 1.5 mm2 - Branch Cable: 2Cx1.5mm2

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96

Installation& Commissioning of above-FLP/WP Control Junction Box, FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification.(fOR EXISTING MOV'S) No. of Cable Entries - for Multi Core : 2 Nos (from bottom only) - for Branch Cables : 12 Nos (from sides) Cable Size for Signal JB - Multi Core : 64C x 1.5 mm2 - Branch Cable: 8Cx1.5mm2

97

Installation& Commissioning of above-FLP/WP Control Junction Box, FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification.(For TLFG ) No. of Cable Entries - for Multi Core : 2 Nos (from bottom only) - for Branch Cables : 12 Nos (from sides) For 02 nos of SABC in one bay MC : 24Cx 1.5 sqmm:2 nos Bottom Entries BCab : 2C x 1.5 sqmm: 8 no side entries BCab: 8C x 1.5 sqmm : 2 nos side entries BCab: 3Cx 1.5 sqmm:2 nos side entries

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98

Installation& Commissioning of above-FLP/WP Signal Junction Box, FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification. No. of Cable Entries - for Multi Core : 2 Nos (from bottom only) - for Branch Cables : 12 Nos (from sides) Cable Size for Signal JB - Multi Core : 12P x 1.5 mm2 - Branch Cable: 1Px1.5mm2

99

Installation& Commissioning of above-FLP/WP Signal Junction Box, FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification. From BC to Multi drop box For 02 nos of SABC in one bay: MC: 12Px 1.5 mm2 :2 Bottom entries:320M BCab : 2P x 1.5 sqmm: 4 nos Side entries BCab:1P X 1.5 sqmm: 2 nos Side entries BCab:4Px 1.5 sqmm:2 nos Side entries

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100

Installation& Commissioning of above-FLP/WP Signal Junction Box, FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material as per tender specification. TLFG 2 WO & 1 BO(From multidrop box to control room) For 02 nos of SABC in one bay: MC : 12Px 1 mm2:2 nos Bottom entries BC : 4P x 1 mm2: 4 no

101

Installation& Commissioning of above-Set of FLP / WP Junction Boxes (includig FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete and other installation material) of smaller sizes (other than specified above) required for any specific requirement.

102

Erection of above-GI Cable Trays (Perforated) having width 300mm and Thickness 3mm alongwith necessary erection material like coupler plate, aluminium saddles, screws, nuts, washers etc;

103

Erection of above-GI Cable Trays (perforated) having width 450mm and Thickness 3mm alongwith necessary erection material like coupler plate, aluminium saddles, screws, nuts, washers etc;

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104

Erection of above-GI Cable Trays (Perforated) having width 50mm and Thickness 2mm alongwith necessary erection material like coupler plate, aluminium saddles, screws, nuts, washers etc; cable trays shall be with tray covers.

105


106


107

Erection of above-GI Cable Trays (Perforated ) having width 200mm and Thickness 2mm alongwith necessary erection material like coupler plate, aluminium saddles, screws, nuts, washers etc;

108

Laying / Glanding / Termination / Loop checking at both ends of cable-Signal Cable - 1pair x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

109

Laying / Glanding / Termination / Loop checking at both ends of cable-Signal Cable -

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12pair x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

110

Laying / Glanding / Termination / Loop checking at both ends of cable-Signal Cable - 2P x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

111

Laying / Glanding / Termination / Loop checking at both ends of cable-Signal Cable - 4Px 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

112

Laying / Glanding / Termination / Loop checking at both ends of cable-Power Cable - 3C x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

113


114


115

Laying / Glanding / Termination / Loop checking at both ends of cable- Control Cable - 2C x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

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116

Laying / Glanding / Termination / Loop checking at both ends of cable-Control Cable - 24C x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

117

Laying / Glanding / Termination / Loop checking at both ends of cable-Control Cable - 10C x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured) (For pump automation: Branch cable for each pump)

118


119


120

Laying / Glanding / Termination / Loop checking at both ends of cable-power Cable - 4 C x 4 mm2 (Copper Conductor, FRLS PVC Armoured)

121

Laying / Glanding / Termination / Loop checking at both ends of cable- Control Cable - 6C x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

122

Laying / Glanding / Termination / Loop checking at both ends of

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cable-Control Cable - 4C x 1.5 mm2 (Copper Conductor, FRLS PVC Armoured)

123

Laying / Glanding / Termination / Loop checking at both ends of cable- Control Cable - 12C x 1.5mm2 (Copper Conductor, FRLS PVC Armoured)

124


125

Erection, Testing & Commissioning of above-Dual Redundant Programmable Logic Controller(conventional) IO COUNT :: DI- 331,DO-179,AI 2WIRE - 8,AO-0,PULSE INPUT - 0, SERIAL PORT RS485

- 42 with Licensed Software (Engg./ Loader software) including marshalling cabinet/s

126

Erection, Testing & Commissioning of above-Operating system - 5 CAL User License for each server & client stations License for each work stations .

127

Erection, Testing & Commissioning of above-SCADA / HMI / GUI Software (OPC compliant) - D + R + N for each LRC & R + N for each client work station .

128 Erection, Testing & Commissioning of above-RDBMS for Transactionl

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DATA Base - 5 CAL User License.

129

Erection, Testing & Commissioning of above-LRC Application software (OPC compliant) with backup software

130

Erection, Testing & Commissioning of above-Redundant LRC Server(1+1) with 21" LCD Monitor. Operating System Windows 2008 Server

131

Erection, Testing & Commissioning of above-Workstation (OIC) with 21" LCD Monitor. Operating System Windows 7

132

Erection, Testing & Commissioning of above-Workstation (TTES) with 21" LCD Monitor. Operating System Windows 7

133

Erection, Testing & Commissioning of above-SAP-TAS Workstation with 21" LCD Monitor. Operating System Windows 2008 Server

134

Erection, Testing & Commissioning of above-540 CPS BOL Dot Matrix Printer (including paper stand with mounting rack)

135

Erection, Testing & Commissioning of above-440 CPS Alarm, Event, Report Dot Matrix Printer (including Paper stand & mounting Rack)

136 Erection, Testing & Commissioning of above-Laser Jet Printer A4 size

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color

137

Erection, Testing & Commissioning of above-Laser Jet Printer A3 size B/W

138

Erection, Testing & Commissioning of above-Networking Hardware comprising of : Redundant Terminal Servers (including surge arrestors at all field ports), Redundant Manageable Fast Ethernet Switches, Fibre Optic / UTP Transceivers, etc. and Miscellaneous hardware

139

Erection, Testing & Commissioning of above-LAN Networking with CAT 6 structured cabling and fiber optics cables.

140

Erection of above-Open Table type console centers for mounting the servers / workstations in control room (i.e. LRC-1, LRC-2, OIC-1, OIC-2, OIC-3,TFMS-PC.)

141

Erection of above-Open Table type console centres for mounting the servers / workstations in Planning Room. (i.e. TTES-1, TTES-2 and SAP-TAS PC.)

142

Erection of above-System cabinets to house Terminal Servers, Ethernet Switch, CIU, Alarm Annunciator cum push button panel as per tender specification.

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143

Development of software Driver(LRC Resident) for an an existing / new automated facility (provided /being provided by BPCL separately ) to be serially interfaced with PLC/ TAS. Following facilities may be considered for the purpose as a minimum: - HART Protocol based Field Pr/Temp/ Flow Tx/Mass FLow Meters/Hydrocarbon Detectors - MODBUS RTU Protocol based PLCs pertaining to (a) Rim Seal Protection system; (b) Fire Fighting Control system ; (c) Master control station of MOVs; (d) Instrument Air compressors;(e) Eletric Fail safe Remote operated shut-off valves. NOTE : (1) The scope of work under this item include Data base generation, Graphic configuration, PLC loader software modification & any other requirement at LRC/ OIC. (2) Development of software drivers for all the instruments / systems to be supplied by vendor will not be considered under this item.;

144

Excavation & backfilling of Cable Trenches - Staking out, marking the outline for excavation, excavation in any type of soil, PCC or hard rock for general site grading by machinery or manually

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up to 750 mm below NGL for all depths, 400 mm width including supply of sand, brick , cement etc..

145

SUPPLY/FAB OF Structural Steel for fabrication of supports required forerection of field instrumenation ( Measuring instruments , control instruments, Junction Boxes , cable trays & other vendor supplied instruments)

146

Making of Electrical Earthing Pits - Complete electrical earthing for control room equipments & field equipments. Designing, providing & constructing plate electrode type earthing pits etc; as per tender specifications.

147

Making of Instrument Earthing Pits -Complete instrument earthing for control room equipments & field equipments. Designing, providing & constructing plate electrode type earthing pits etc; as per tender specifications.

B SAFETY PLC

1 Supply of -Dual Redundant Safety Programmable Logic Controller (SIL2 Certified) with Licensed Software (Engg./ Loader software) including marshalling cabinet/s [for ESD System] IO

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COUNTS : DI- 164, DO- 132 , AI 2 WIRE - 55, AI 3 WIRE - 4 & RS485 SERIAL- 18

2 Supply of -Power Distribution cabinet with MCBs for individual isolation for distribution of 230VAC, Single Phase UPS/Non-UPS Supply to field and control room instrumentation.

3 Supply of Engg Cum Operator Station with 21" LCD Monitor. Operating System Windows 2008 Server

4 Supply of - Operator Station with 21" LCD Monitor. Operating System Windows 7

5 Supply of -Laser Jet Printer A4 size color

6 Supply of -Networking Hardware comprising of : Redundant Manageable Fast Ethernet Switches, including LAN Networking CAT 6 structured cables, associated hardware and cables (power / signal / control) required for interpanel connectivity of centralized instrumentation.

7 Supply of -System cabinets to house Ethernet Switch, Networking Hardware as per tender specification. TFMS System centralized hardware ( e.g CIUs , surge arrestors etc. ) to be provided by BPCL shall

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also be housed in the System Cabinet.

8 Supply of -Open Table type console centers for mounting the servers / workstations in control room (i.e. Engg Cum Operator Station, Operator Station)

9 Supply of -Un-Interrupted Power Supply of Parallel Redundant UPS System of a min 15KVA with 30 mins backup using Ni-Cd batteries. Note: Incase if actual calculated system load exceeds 15KVA then UPS rating shall be 120% of the actual calculated load.

10 Supply of -Explosion Proof / Weather proof ESD Push Button Station as per tender specification

11 Supply of -Flameproof / Weatherproof Hooter

12 Supply of -Weatherproof Hooter

13 Supply of -Level Switch SIL 2 Certified ( AG + UG TANK )

14 Supplying of Signal Cables (Copper Conductor, FRLS PVC Armoured) Cable size - 1 pair x 1.5 mm2

15 Supplying of Signal Cables (Copper Conductor, FRLS PVC Armoured)

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Cable Size - 1Triad x 1.5 mm2

16 Supplying of Multicore Signal Cables (Copper Conductor, FRLS PVC Armoured) Cable Size - 12pair x 1.5 mm2

17 Supplying of Multicore Signal Cables (Copper Conductor, FRLS PVC Armoured) Cable Size - 8Triad x 1.5 mm2

18 Supplying of Signal Cables (Copper Conductor, FRLS PVC Armoured) Cable Size - 6pair x 1.5 mm2

19 Supplying of Power Cables (Copper Conductor, FRLS PVC Armoured) Cable Size - 3C x 1.5 mm2

20 Supplying of Multicore Power Cables (Copper Conductor, FRLS PVC Armoured) Cable Size - 24C x 1.5 mm2

21 Supplying of Multicore Power Cables (Copper Conductor, FRLS PVC Armoured) Cable Size - 36C x 1.5 mm2

22 Supplying of Control Cables (Copper Conductor, FRLS PVC Armoured) Cable Size - 2C x 1.5 mm2

23 Supplying of Multicore Control Cables (Copper Conductor, FRLS PVC Armoured)

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Cable Size - 24C x 1.5 mm2

24 Supplying of Multicore Control Cables (Copper Conductor, FRLS PVC Armoured) Cable Size - 12C x 1.5 mm2

25 Supply of -FLP/WP Power Junction Box (including FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete) and other installation material as per tender specification. No. of Cable Entries - Multi Core : 2 Nos (bottom entry) - Branch Cables : 12 Nos (side entry) Cable Size for Power JB - Multi Core : 36C x 1.5 mm2 - Branch Cable : 3C x 1.5 mm2 Note: These are copper cables.

26 Supply of -FLP/WP Power Junction Box (including FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete) and other installation material as per tender specification. No. of Cable Entries - Multi Core : 2 Nos (bottom entry) - Branch Cables : 6 Nos (side entry) Cable Size for Power JB - Multi Core : 24C x 1.5 mm2 - Branch Cable : 3C x 1.5 mm2

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Note: These are copper cables.

27 Supply of -FLP/WP Control Junction Box (including FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete) and other installation material as per tender specification. No. of Cable Entries - Multi Core : 2 Nos (bottom entry) - Branch Cables : 12 Nos (side entry) Cable Size for Power JB - Multi Core : 24C x 1.5 mm2 - Branch Cable : 2C x 1.5 mm2 Note: These are copper cables.

28 Supply of -FLP/WP Control Junction Box (including FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete) and other installation material as per tender specification. No. of Cable Entries - Multi Core : 2 Nos (bottom entry) - Branch Cables : 6 Nos (side entry) Cable Size for Power JB - Multi Core : 12C x 1.5

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mm2 - Branch Cable : 2C x 1.5 mm2 Note: These are copper cables.

29 Supply of -FLP/WP Signal Junction Box-Triad, (including FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete) and other installation material as per tender specification. No. of Cable Entries - Multi Core : 2 Nos (from bottom only) - Branch Cables : 8 Nos (from sides) Cable Size for Signal JB - Multi Core : 8 Triad x 1.5 mm2 - Branch Cable: 1 Triad x1.5 mm2 (for HC Detectors / Transmitters) Note: These are copper cables.

30 Supply of -FLP/WP Signal Junction Box, (including FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete) and other installation material as per tender specification. No. of Cable Entries - Multi core : 2 Nos (from bottom only) - Branch Cables : 4 Nos (from sides)

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Cable Size for Power JB - Multi Core : 12C x 1.5 mm2 - Branch Cable: 3 C x1.5 mm2 ( For Hi level switch) Note: These are copper cables.

31 Supply of -FLP/WP Signal Junction Box, (including FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete) and other installation material as per tender specification. No. of Cable Entries - Multi core : 2 Nos (from bottom only) - Branch Cables : 12 Nos (from sides) Cable Size for Signal JB - Multi Core : 12 P x 1.5 mm2 - Branch Cable: 1 P x1.5 mm2 Note: These are copper cables.

32 Supply of -FLP/WP Signal Junction Box, (including FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete) and other installation material as per tender specification. No. of Cable Entries - Multi core : 2 Nos (from bottom only) - Branch Cables : 6 Nos (from sides) Cable Size for Signal JB - Multi Core : 6 P x 1.5

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mm2 - Branch Cable: 1 P x1.5 mm2 Note: These are copper cables.

33 Supply of perforated GI cable trays along with accessories (e.g coupler plate , aluminium saddles, screws, nuts, washers ) of following sizes:a) 50 mm

34 Supply of perforated GI cable trays along with accessories (e.g coupler plate , aluminium saddles, screws, nuts, washers ) of following sizes:b) 100 mm

35 Supply of perforated GI cable trays along with accessories (e.g coupler plate , aluminium saddles, screws, nuts, washers ) of following sizes:c) 150 mm

36 Supply of perforated GI cable trays along with accessories (e.g coupler plate , aluminium saddles, screws, nuts, washers ) of following sizes:d) 200 mm

37 Supply of perforated GI cable trays along with accessories (e.g coupler plate , aluminium saddles, screws, nuts, washers ) of following sizes:e) 300 mm

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38 Erection of perforated GI cable trays along with accessories (e.g coupler plate , aluminium saddles, screws, nuts, washers ) of following sizes:

39 Erection of perforated GI cable trays along with accessories (e.g coupler plate , aluminium saddles, screws, nuts, washers ) of following sizes:a) 50 mm

40 Erection of perforated GI cable trays along with accessories (e.g coupler plate , aluminium saddles, screws, nuts, washers ) of following sizes:b) 100 mm

41 Erection of perforated GI cable trays along with accessories (e.g coupler plate , aluminium saddles, screws, nuts, washers ) of following sizes:c) 150 mm

42 Erection of perforated GI cable trays along with accessories (e.g coupler plate , aluminium saddles, screws, nuts, washers ) of following sizes:d) 200 mm

43 Erection of perforated GI cable trays along with accessories (e.g coupler plate , aluminium saddles, screws, nuts, washers ) of following sizes:e) 300 mm

44 Supply & laying of Hume pipes (NP2) across Road crossing including road cutting & remaking of WBM roads of following

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sizes ( if required as per site condition)

45 Supply & laying of Hume pipes (NP2) across Road crossing including road cutting & remaking of WBM roads of following sizes ( if required as per site condition)a) 6 inch dia Hume pipe

46 Supply & laying of Hume pipes (NP2) across Road crossing including road cutting & remaking of WBM roads of following sizes ( if required as per site condition)b) 8 inch dia Hume pipe

47 Supply & laying of Hume pipes (NP2) across Road crossing including road cutting & remaking of WBM roads of following sizes ( if required as per site condition)c) 10 inch dia Hume pipe

48 Modification at MCC Panels including Supply of relays / contactors, PVC wires, lugs, ferrules, erection hardware (as required) to provide potential free contacts to be connected to the PLCs (Safety) for status (Motor Running / Trip) & command (Start / Stop / ESD command) from PLCs. Note : applicable for existing MCCs of TLF/ TWF/ TWD / FW Pumps

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(as applicable)

49 Laying of Signal Cables (Copper Conductor, FRLS PVC Armoured) in above ground cable trays including Glanding / Termination / Loop checking at both ends Cable size - 1 pair x 1.5 mm2

50 Laying of Signal Cables (Copper Conductor, FRLS PVC Armoured) in above ground cable trays including Glanding / Termination / Loop checking at both ends Laying / Glanding / Termination / Loop checking at both ends. Cable Size - 1Triad x 1.5 mm2

51 Laying of Multicore Signal Cables (Copper Conductor, FRLS PVC Armoured) in under ground cable trenches or in above ground cable trays including Glanding / Termination / Loop checking at both ends Cable Size - 12pair x 1.5 mm2

52 Laying of Multicore Signal Cables (Copper Conductor, FRLS PVC Armoured) in under ground cable trenches or in above ground cable trays including Glanding /

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Termination / Loop checking at both ends Cable Size - 8Triad x 1.5 mm2

53 Laying of Signal Cables (Copper Conductor, FRLS PVC Armoured) in above ground cable trays including Glanding / Termination / Loop checking at both ends Laying / Glanding / Termination / Loop checking at both ends. Cable Size - 6pair x 1.5 mm2

54 Laying of Power Cables (Copper Conductor, FRLS PVC Armoured) in above ground cable trays including Glanding / Termination / Loop checking at both ends Laying / Glanding / Termination / Loop checking at both ends. Cable Size - 3C x 1.5 mm2

55 Laying of Multicore Power Cables (Copper Conductor, FRLS PVC Armoured) in under ground cable trenches or in above ground cable trays including Glanding / Termination / Loop checking at both ends Cable Size - 24C x 1.5 mm2

56 Laying of Multicore Power Cables (Copper Conductor, FRLS PVC Armoured) in under ground cable trenches or in above ground cable trays including Glanding / Termination / Loop

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checking at both ends Cable Size - 36C x 1.5 mm2

57 Laying of Control Cables (Copper Conductor, FRLS PVC Armoured) in above ground cable trays including Glanding / Termination / Loop checking at both ends Laying / Glanding / Termination / Loop checking at both ends. Cable Size - 2C x 1.5 mm2

58 Laying of Multicore Control Cables (Copper Conductor, FRLS PVC Armoured) in under ground cable trenches or in above ground cable trays including Glanding / Termination / Loop checking at both ends Cable Size - 24C x 1.5 mm2

59 Laying of Multicore Control Cables (Copper Conductor, FRLS PVC Armoured) in under ground cable trenches or in above ground cable trays including Glanding / Termination / Loop checking at both ends Cable Size - 12C x 1.5 mm2

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60 Excavation & backfilling of cable trenches Staking out, marking the outline for excavation, excavation in any type of soil, PCC or hard rock for general site grading by machinery or manually up to 750 mm below NGL for all depths as given below of width 400mm including removal of stumps and roots to full extent removal of all vegetation including bushes and grass, dewatering & leveling., dressing and backfilling after cable is laid etc; complete as per specifications and instructions of Engineer In-Charge (EIC). Scope of work shall also include Supply/filling of sand & supply /placing of Class B bricks in for excavated trenches subsequent to laying of cables.

61 Erection, Testing & Commissioning of -Dual Redundant Safety Programmable Logic Controller (SIL2 Certified) with Licensed Software (Engg./ Loader software) including marshalling cabinet/s [for ESD System] :IO

COUNTS : DI- 164, DO- 132 , AI 2 WIRE - 55, AI 3 WIRE - 4 & RS485 SERIAL- 18

62 Erection, Testing & Commissioning of -Power Distribution cabinet for distribution of 230 VAC

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Single Phase UPS/Non-UPS supply to equipments / instruments in control Room & field.

63 Erection, Testing & Commissioning of -Un-Interrupted Power Supply of Parallel Redundant UPS System of a min 15KVA with 30 mins backup using Ni-Cd batteries. Note: Incase if actual calculated system load exceeds 15KVA then UPS rating shall be 120% of the actual calculated load.

64 Erection, Testing & Commissioning of -Engg cum Operator Station with 21" LCD Monitor. Operating System Windows 2008 Server

65 Erection, Testing & Commissioning of -Workstation (OIC) with 21" LCD Monitor. Operating System Windows 7

66 Erection, Testing & Commissioning of -Laser Jet Printer A4 size color

67 Erection, Testing & Commissioning of - Networking Hardware comprising of : Redundant Manageable Fast Ethernet Switches, including LAN Networking CAT 6 structured cables, associated hardware and cables (power / signal / control) required for interpanel connectivity of centralised

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instrumentation.

68 Erection of -Open Table type console centers for mounting the servers / workstations in control room (i.e. Engg. Cum Operator Station, Operator Station)

69 Erection of -System cabinets to house Ethernet Switch, Networking Hardware as per tender specification. TFMS System centralized hardware ( e.g CIUs , surge arrestors etc. ) shall also be housed in the System Cabinet.

70 Installation Testing & Commissioning of -Explosion Proof / Weather proof ESD Push Button Station

71 Installation Testing & Commissioning of -Flameproof / Weatherproof Hooter

72 Installation Testing & Commissioning of -Weatherproof Hooter

73 Installation Testing & Commissioning of -Level Switch SIL 2 Certified ( AG+ UG Tank)

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74 Installation Testing & Commissioning of FLP/WP Power Junction Box (including FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete) and other installation material as per tender specification. No. of Cable Entries - Multi Core : 2 Nos (bottom entry) - Branch Cables : 12 Nos (side entry) Cable Size for Power JB - Multi Core : 36C x 1.5 mm2 - Branch Cable : 3C x 1.5 mm2 Note: These are copper cables.

75 Installation Testing & Commissioning of -FLP/WP Power Junction Box (including FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete) and other installation material as per tender specification. No. of Cable Entries - Multi Core : 2 Nos (bottom entry) - Branch Cables : 6 Nos (side entry) Cable Size for Power JB - Multi Core : 24C x 1.5 mm2 - Branch Cable : 3C x 1.5 mm2 Note: These are copper cables.

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76 Installation Testing & Commissioning of -FLP/WP Control Junction Box (including FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete) and other installation material as per tender specification. No. of Cable Entries - Multi Core : 2 Nos (bottom entry) - Branch Cables : 12 Nos (side entry) Cable Size for Power JB - Multi Core : 24C x 1.5 mm2 - Branch Cable : 2C x 1.5 mm2 Note: These are copper cables.

77 Installation Testing & Commissioning of -FLP/WP Control Junction Box (including FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete) and other installation material as per tender specification. No. of Cable Entries - Multi Core : 2 Nos (bottom entry) - Branch Cables : 6 Nos (side entry) Cable Size for Power JB - Multi Core : 12C x 1.5 mm2 - Branch Cable : 2C x 1.5 mm2 Note: These are copper cables.

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78 Installation Testing & Commissioning of - FLP/WP Signal Junction Box-Triad, (including FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete) and other installation material as per tender specification. No. of Cable Entries - Multi Core : 2 Nos (from bottom only) - Branch Cables : 8 Nos (from sides) Cable Size for Signal JB - Multi Core : 8 Triad x 1.5 mm2 - Branch Cable: 1 Triad x1.5 mm2 (for HC Detectors / Transmitters)

79 Installation Testing & Commissioning of - FLP/WP Signal Junction Box, (including FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete) and other installation material as per tender specification. No. of Cable Entries - Multi core : 2 Nos (from bottom only) - Branch Cables : 4 Nos (from sides) Cable Size for Power JB - Multi Core : 12 C x 1.5 mm2 - Branch Cable: 3 C x1.5 mm2 (required for Hi Level switch )

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80 Installation Testing & Commissioning of - FLP/WP Signal Junction Box, (including FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete) and other installation material as per tender specification. No. of Cable Entries - Multi core : 2 Nos (from bottom only) - Branch Cables : 12 Nos (from sides) Cable Size for Signal JB - Multi Core : 12 P x 1.5 mm2 - Branch Cable: 1 P x1.5 mm2 Note: These are copper cables.

81 Installation Testing & Commissioning of - FLP/WP Signal Junction Box, (including FLP/WP SS cable glands, thimbles, ferrules, connectors etc. complete) and other installation material as per tender specification. No. of Cable Entries - Multi core : 2 Nos (from bottom only) - Branch Cables : 12 Nos (from sides) Cable Size for Signal JB - Multi Core : 6 P x 1.5 mm2 - Branch Cable: 1 P x1.5 mm2 Note: These are copper cables.

82 Testing & Commissioning of MCC Panels (subsequent to modifications carried out by vendor)

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83 Powering ON and functional checking of following field instrumentation at Safety PLC and Engg cum Operator Station as per Functional Design Specification.

84 Powering ON and functional checking of following field instrumentation at Safety PLC and Engg cum Operator Station as per Functional Design Specification. a) Hi-Hi Level Switch

85 Powering ON and functional checking of following field instrumentation at Safety PLC and Engg cum Operator Station as per Functional Design Specification. b) Level Tx. - Radar Type

86 Powering ON and functional checking of following field instrumentation at Safety PLC and Engg cum Operator Station as per Functional Design Specification. c) Level Tx. - Servo Type

87 Powering ON and functional checking of following field instrumentation at Safety PLC and Engg cum Operator Station as per Functional Design Specification. d) Electric Fail Safe ROSOV (Electric Actuator)

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88 Powering ON and functional checking of following field instrumentation at Safety PLC and Engg cum Operator Station as per Functional Design Specification. e) DBB Valve (Electric Actuator)

89 Powering ON and functional checking of following field instrumentation at Safety PLC and Engg cum Operator Station as per Functional Design Specification. f) HC Detector - Point Type

90 Powering ON and functional checking of following field instrumentation at Safety PLC and Engg cum Operator Station as per Functional Design Specification. g) HC Detector - Open Path Type

91 Powering ON and functional checking of following field instrumentation at Safety PLC and Engg cum Operator Station as per Functional Design Specification. h) ESD Push Button Station

92 Powering ON and functional checking of following field instrumentation at Safety PLC and Engg cum Operator Station as per Functional Design Specification. i) FLP / WP Hooter

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93 Powering ON and functional checking of following field instrumentation at Safety PLC and Engg cum Operator Station as per Functional Design Specification. j) WP Hooter

94 Powering ON and functional checking of following field instrumentation at Safety PLC and Engg cum Operator Station as per Functional Design Specification. k) Modified MCC Panel

95 Powering ON and functional checking of following field instrumentation at Safety PLC and Engg cum Operator Station as per Functional Design Specification. l) Existing MOVs (ESD Ports)

96 Powering ON and functional checking of following field instrumentation at Safety PLC and Engg cum Operator Station as per Functional Design Specification. m) Existing Batch Controller (ESD Ports)

97 Powering ON and functional checking of following field instrumentation at Safety PLC and Engg cum Operator Station as per Functional Design Specification. n) Existing Main Power Distribution system (Non-Critical Loads) ESD Port

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98 Powering ON and functional checking of following field instrumentation at Safety PLC and Engg cum Operator Station as per Functional Design Specification. o) HVLR System (PLC)

99 Development of software Drivers (Engg cum Operator Station Resident) to serially interface follwoing field instrumentation / sub-systems with safety PLC. 1) HART Protocol based Field Instrumentation [eg. (Pr / Temp / Flow) Tx. / Mass FLow Meters / Hydrocarbon Detectors 2) MODBUS RTU Protocol based PLCs pertaining to (a) Rim Seal Protection system; (b) Fire Fighting Control system ; (c) Master control station of MOVs; (d) Electric Fail safe Remote operated shut-off valves (e) Communication Interface Unit of TFMS System (f) HVLR system (g) VFDs 3) TCP/IP Protocol between TAS and TFMS system NOTE : (1) The scope of work under this item include Data base generation, Graphic configuration, PLC loader software modification & any other requirement at Engg / Operator Station. (2) Development of software drivers for all

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the instruments / systems to be supplied by vendor will not be considered under this item.; (3) Vendors have to develop dynamic graphics of all the facilities at an Installation.

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100 Supply, fabrication, welding, erection and painting of structural steel confirming to IS 2062 latest edition, consisting of channels, beams, angles, flats, tubular sections, etc; fabrication of steel structures, structural frame for Junction Boxes, cable trays, field instruments [ under vendor' scope of supply & only HC Detectors free issue item from BPCL). This includes supply of bolts, nuts washers, shims, packs, putty, gas, welding electrodes, and all other consumables as required, cleaning and surface preparation of all steel surfaces with emry paper/wire brush, supply and application of 2 coats of red oxide zinc phosphate primer of 30 to 35 microns dft each, supply and application of 2 coats of synthetic enamel paint of 30 to 35 microns dft of approved shade. Rate to include excavating pit for grouting the member, grouting the structural steel member in PCC M15, shuttering, ramming, finishing the same with cement slurry etc; complete at all depths and as per approved drawing or instruction of EIC. The height of frame shall be 1.3m from the FGL and 0.45m inside earth for

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grouting purpose. The buried portion shall be coated with bitumen on all sides before grouting the same in PCC. PCC shall be minimum 350mm x 350mm x 450mm for each leg of the frame / member. The exposed portion of the PCC surface shall be whitewashed.

101 Making of Electrical Earthing Pits - Complete electrical earthing for control room equipments & field equipments. Designing, providing & constructing earthing pits etc; as per tender specifications.

102 Making of Instrument Earthing Pits -Complete instrument earthing for control room equipments & field equipments. Designing, providing & constructing earthing pits etc; as per tender specifications.

103 Supply of -Radar Gauge (SIL 2 Certified) of +/- 1mm accuracy

104 Supply of -Tank Side Indicator [for Radar Gauges

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mentioned above]

105 Supply of -Multi-Spot Average Temp Sensor with Water Bottom Sensor [1 each on all above ground vertical product tanks (i.e. fixed roof and floating roof). This is to be hardwired/ interfaced with one of the RADAR type Level TX mentioned above ]

106 Supply of -Computer Interface Unit (CIU) - Redundant for Radar Level Gauge and Servo Level Gauge

107 Supply of -TFMS Workstation with 21" LCD Monitor

108 Supply of -TFMS Software, OPC Compliant

109 Installation Testing & Commissioning of above-Radar Gauge (SIL 2 Certified) of +/- 1mm accuracy

110 Installation Testing & Commissioning of above-Tank Side Indicator [for Radar Gauges mentioned above]

111 Supply of -Guided Wave Radar Gauge of +/- 3mm accuracy [1 each on horizontal tanks]

112 Installation Testing & Commissioning of above-Multi-Spot Average Temp Sensor with Water Bottom Sensor [1 each on all above ground vertical product tanks (i.e. fixed roof and

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floating roof). This is to be hardwired/ interfaced with one of the RADAR type Level TX mentioned above ]

113 Installation Testing & Commissioning of above-Guided Wave Radar Gauge of +/- 3mm accuracy [1 each on horizontal tanks]

114 Erection, Testing & Commissioning of above-Computer Interface Unit (CIU) - Redundant

115 Erection, Testing & Commissioning of above-TFMS Workstation with 21" LCD Monitor

116 Erection, Testing & Commissioning of above-TFMS Software, OPC Compliant

117 System Design & Engineering

118 Factory Acceptance Test

119 Training (at Factory)

120 Training (at Site)

121 Site Acceptance Test

122 Documentations including as built drawings (6 Sets).

123 CMC (Comprehensive Maintenance Charges) for 5 years (Post Warranty Period)

BIDDERS TO UPLOAD THE DETAILS OF TAX BREAK UP AS CONSIDERED IN PRICE BID OF EACH AND EVERY LINE ITEMS AS PER THE ABOVE DETAILS . THESE BREAK UP DETAILS DULY SIGNED TO BE UPLOADED IN NIT ( TECHNICAL BID DUOCUMENT ) .