Technical Specifications - AWS

Technical

Specifications

Technical Specifications for PLC System

IOCL, Barauni Refinery, Instrumentation Department Page 2 of 59

TABLE OF CONTENTS

S. No. Description Page Number

1 Introduction 03

2 Ambient Conditions 04

3 Area Classification 05

4 Definitions 06

5 Codes & Standards 07

6 Bidder Scope of Work 08

7 Special Requirements for PLC System 12

8 Job Specifications for PLC System 16

9 Auxiliary Hardware 30

10 Power Supply 30

11 Distribution of Power Supply 32

12 Cabinets & Hardwired Console 33

13 Earthing System 36

14 Documentation Requirements 36

15 Factory Acceptance Test 38

16 Site Acceptance Test 40

17 Testing & Calibration Equipment 41

18 Logistic Support Services 41

19 Warranty & Post Warranty Maintenance 42

20 I/O Counts For PLC System 45

21 Special Instructions to Bidder 45

22 References 48



Indian Oil Corporation, Barauni Refinery invites bids from reputed Bidders of

Programmable Logic Controller (PLC) having latest model with state of the art technology

having proven track record of performance on LSTK basis.

Definitions

The following definition shall apply:

OWNER : Indian Oil Corporation Limited, Barauni Refinery

BIDDER : Bidder who is opting to quote for this tender document

SITE : Barauni Refinery, Barauni, Bihar, India

Name of the Project: Supply, Installation, Commissioning & Post warranty

Comprehensive Annual maintenance contract (CAMC) of new

Programmable Logic Controller (PLC)

1) Introduction



2.1 Atmospheric Temperature :-

Minimum Ambient Temperature : 10 deg C

Maximum Ambient Temperature : 50 deg C

Minimum Relative Humidity : 20%

Maximum Relative humidity : 98%

2.2 The PLC system hardware shall be installed inside the control room and normally the

system shall operate in a controlled atmosphere. However in the event of an HVAC

failure, environment inside the control room will be as specified above in clause no.

2.1 and the system shall be capable of operating continuously without any failures.

2.3 Control Room Environment

Bidder shall guarantee the system operation for the conditions listed below.

a. Temperature & Humidity Inside the control room relative humidity shall be maintained at approximately 50%

and typically temperature shall be regulated between 24 deg C to 28 deg C.

b. Control room ambience

The control room ambience shall be normally corrosive as it is nearby the main process

units. All electronic components / modules for controllers, data acquisition system,

operator interface, engineering interface sub system & gateway interface sub system

for PLC system shall be suitable & comply with ISA G3/GX level corrosive

environment as per ANSI/ISA-S71.04 or equivalent.

c. Electromagnetic Interference

The PLC system equipments and all electronic system shall be protected from any

electro-magnetic influence, particular care for software media such as diskettes,

magnetic tapes, distortion and abnormal color of monitors.

d. Vibration

Anti-vibration pads shall be provided in the system / marshalling cabinets to protect the

equipment.

e. RFI Immunity

Standard VHF radio equipment shall be operated within the control room building. The

supplied system shall be immune to interference from any such radio operation with

equipment cabinet doors closed and radios operated at approximately 3 meters from the

system equipment.

f. EMI generation

No equipment shall generate radiated electromagnetic emission in excess of the values

recommended by ANSI C63.12.

2) Ambient Conditions



g. Equipment Noise

The noise level of all the equipment including cooling fans shall be less than 55 dBA.

The noise level measurement shall be based on the type test carried out in accordance

with any of the methods detailed in international standards and expressed in terms of

dBA.

3.1 Plant Area classification is Zone-1, Gas Gr.IIA, IIB T3 as per IEC 60079. However

the control room where the system hardware is installed is a non-hazardous area. All

the barriers, isolators shall be suitable for instruments located for classified area EEx

(ia) Gr. IIA, IIB T3.

3.2 Following certificates shall be supplied by Bidder for final submission to End user:

a. Certificate from statutory authority like FM, CENELEC, ATEX etc. for Items of

foreign origin shall necessarily have approval certification from CCOE (Chief

Controller of Explosives) of Petroleum & explosive safety organization (PESO)

India for applicable items, irrespective of country of origin.

b. All the barriers, isolators shall be suitable for classified area and shall have

electrical classification EEx (ia) Gr. IIA, IIB T3.

3) Area Classification



4.1 Switch over Time: Time required for a back up instrument to come on-line automatically

in case of failure of the main instrument.

4.2 Loop Integrity: The system shall be said to have loop integrity if the failure of one

component in the system / subsystem does not affect more than one loop.

4.3 Interchangeability: Systems / sub-systems shall be said to have full interchangeability if

the functions and information available on one system / sub-system shall also be available

on the other in totality.

4.4 Redundancy: A system component shall be termed as redundant if it takes over the

operation automatically on failure of the main component in a bump-less manner without

causing any interruption in the system, upsetting the process and simultaneously making

the plant data continuously available for the operator for control and for historization. The

repaired or replaced device shall be brought inline only through operator action.

4.5 Scan Time: Scan time for different sub-systems shall be defined as follows:

a. Process Control System (Close-Loops): Scan time for a close-loop shall be defined

as the cycle time taken by controller to read and process input, perform control

calculations and update control output for all the loops configured within the

controller.

b. Process Control System (Open-Loops): Scan time for an open loop shall be defined as

the cycle time required by the data acquisition sub system to read input, processing and

computation of all the open loops configured within the data acquisition sub-system.

c. Programmable Logic Controller: The scan time for a Programmable logic controller

shall be defined as the cycle time taken by the system to read input, input processing

executing logic and Updating control output for all the logic configured within the

programmable logic controller.

4.6 Bus Degradation: Bus degradation shall be defined as a change in the system

performance from the specified one while loading the communication sub-system from 10

through 100 percent.

4.7 Real time trend: Real time trend shall be defined as a continuously progressing graphical

record showing continuously updated parameter with most recent value and a past record

of minimum 10 minutes without depressing any additional key for moving backward in

time.

4.8 Call-up time: Call-up time shall be defined as the time taken by the system to display a

particular display/data on the CRT after getting the corresponding command from the

operator.

4.9 Display Update Rate: Display update rate shall be defined as the rate at which the

information present in the system input terminal is getting updated on current display on

the LED screen.

4) Definitions



4.10 Mean time between failures (MTBF): MTBF is the mean (average) time between

failures of a system.

4.11 Mean Time To Repair (MTTR): MTTR is the average time to repair a system back to

acceptable operating conditions.

4.12 Engineering console: Engineering console shall be the engineer’s main interface device

via which engineer can view the plant gives instructions to peripherals to execute

commands and can configure and maintain the system.

The design, manufacture, inspection, testing and installation of all equipment and system

covered under this section shall conform to the latest editions of codes and standards at

the time of procurement.

IEC 801.4 - Electromagnetic compatibility for industrial

process measurement & control equipment.

IEC 529 - Classification of degree of protection provided by

enclosures.

NEC - National Electrical code.

NFPA-496 - Purged and pressurized enclosures for electrical

equipment.

ISA-S51.1 - Process Instrumentation Terminology

ISA-S5.2 - Binary Logic diagrams for process operations.

ISA-S5.3 - Graphic symbols for Distributed control/Shared

display instrumentation/Logic and computer system.

ISA-S5.4 - Instrument Loop Diagrams.

ISA-S18.1 - Annunciator Sequences and Specifications

ISA-RP55.1 - Recommended practice-Hardware testing of digital process

computers.

ISA-S71.01 - Environmental conditions for process measurement &

control systems-Temperature & Humidity.

ISA-S71.04 - Environmental conditions for process measurement &

control systems –Airborne Contaminants.

ICS-6 - Enclosures for Industrial control and systems

EN500014/IEC-79/API-500- Explosive Area Classification

IEC-61508 - Safety Integrity Level

IEC-61131/ISA S 5.2 - Logic

IEC-801.4 - Electromagnetic compatibility for industrial process

measurement & control equipment.

NFPA 70 - National Electrical code

IEC-61511 - Functional Safety-Safety Instrumented system for the

process industry sector.

5) Codes and Standards



6.1 This specification and it’s enclosed attachments covers the minimum requirements for

design, engineering, manufacture, selection & supply of all material & accessories,

assembly at manufacturer’s works, testing, Factory acceptance test, packing &

forwarding to IOCL site, dismantling of existing PLC systems, installation of new PLC

systems, testing, Site Acceptance Test, Pre-Commissioning, Commissioning and handing

over of complete PLC system to the IOCL on lump sum turnkey basis for TPS section of

Barauni Refinery.

6.2 The intent of this specification is to provide minimum requirements as required by the

Bidder and does not relieve the Bidder from his responsibility regarding design, reliable,

efficient and safe operation of the supplied system. Any omission in the specification

(hardware and or software) will not relieve the Bidder from his obligation to supply the

system compatible with the intent of this specification.

6.3 In case of any conflict between this specifications, enclosed data sheets, enclosed

attachments, related codes and standards etc, Bidder shall refer the matter in writing to

the IOCL and shall obtain clarification in writing before starting the manufacturing.

However, In general more stringent requirements will prevail & owner decision will be

final & binding to Bidder for execution without any implication to IOCL.

6.4 The intending tenderers are to meet the technical pre-qualification criteria and have to

enclose all necessary documents along with their bids. Technical evaluation of the

intending bidders/tenderers shall only be done if they are meeting the technical pre-

qualification criteria.

6.5 All system hardware and software shall be completely seamless integrated, factory tested

and ready to function as soon as assembled, powered and connected to field devices.

Bidder shall be responsible to comply with this specification & its attached enclosures,

codes, standards and statutory requirements (if any). Bidder shall be responsible for

selection of the hardware.

6.6 All software supply & generation is part of PLC system. Bidder’s scope shall essentially

consist of development of all the application software that is required to make the PLC

system fully functional to comply all requirements.

6.7 It is decided to replace the existing PLC systems of New DM Plant and BXP DM Plant

including I/O marshalling racks/ cabinets/Consoles/ Hardwired consoles/PDP etc by new

PLC system. To achieve this goal, all the existing I/Os are to be shifted to new PLC

system. The proposed PLC systems shall be installed in BXP DM Plant rack room.

Existing field cables shall be used for BXP DM Plant whereas new cables shall be used

for New DM Plant PLC. PLC systems shall be replaced as when clearance given by

IOCL.

6) Bidder’s Scope of Work



Details are as follows :-

Unit PLC

New DM Plant Rockwell PLC to be replaced

BXP DM Plant GE PLC to be replaced

6.8 The entire job of replacement of the above mentioned existing systems with proposed

new PLC system shall be carried out by the Bidder on LSTK basis. Bidders shall visit

site, prior to Pre-bid meeting for their own assessment of jobs involved & to survey the

control marshalling space available.

6.9 Any hardware or software not specifically mentioned in this tender document but

required to make the system complete for the safe operation shall be included in the

Bidder’s scope of supply.

6.10 Prior to submission of Techno-Commercial offer, a pre bid meeting shall be held, during

which Bidders shall be given opportunity to ask queries and get clarifications with

respect to the Tender. No extension of offer submission date shall be granted under any

circumstances thereafter.

6.11 Dismantling of existing PLC systems hardware, cabinets, hardwired consoles,

interconnecting cables & other associated hardware etc. as per the existing architecture

and to install the hardware based on new system architecture is in the scope of bidder.

Dismantled and unused component shall be handed over to the designated person from

IOCL side. Plan for shutdown activity shall be discussed and finalized during detailed

engineering.

6.12 Removal of termination of existing PLC system, all field cables from the existing

marshalling racks and dropping from the existing panels, proper fixing of identification

marks on these cables for re-use, dismantling of existing panel and shifting to outside

control room are in scope of Bidder.

6.13 Before dismantling of field cables from marshalling cabinets, it is responsibility of the

bidder to tag individual pair of cables with tag no. of the instruments, for ease of

reinstallation. A proper document of existing cables having information from field

instrument to marshalling cabinets shall be generated by the bidder & approved by

Engineer in In-charge. Ferruling in Multi-core side of the field Junction Box/ Panel etc in

the field, all of which will get changed because of reengineering in new PLC system, is

in the scope of vendor. The Job involves opening of field Junction Box/ panel, replace

existing ferrules with correct ferrules, dressing, termination, close and reseal the Junction

box cover properly with screws/ nuts/ gaskets etc.

6.14 Cutting, pulling back or re-routing of field cables inside control room and laying of new

cables inside control room wherever required, removal, refixing, modification of false

floor tiles etc. are in scope of Bidder.

6.15 Installation of all types of cabinets, consoles, monitors & all associated hardware of new

PLC system including cable glanding and termination of all types of existing cables is in

the scope of Bidder. The cabinets / consoles shall be installed on base frames. Supply &

installation of Base frames required for cabinets / consoles are in the scope of the Bidder.



6.16 Replacement of existing cable glands of field cables & replacement of existing ferrules

with new printed sleeves type ferrules for all type of existing cables is in scope of

Bidder. Ferruling machine shall be supplied by the bidder.

6.17 Bidder shall supply all interconnecting cables and cable glands for system cabinets,

marshalling cabinets, power distribution cabinets, auxiliary consoles, printers & operator

stations cabinets etc. Interconnecting cables between system cabinets and marshalling

cabinets shall also be supplied by the Bidder and shall consist of prefabricated cables

with plug-in connectors at both ends. All interconnecting cables which are not entirely

routed within the cabinets shall be preferably armored & run in minimum 2 mm thick GI

metallic trays with covers. All the cables shall be identified with heat shrink type ferrules

with proper cable dressing by providing permanent tags.

6.18 Bidder scope also includes supply of cable glands, glanding, and termination of

incoming cables from field in the marshalling cabinet wherever required.

6.19 Bidder’s scope shall include the supply of completely pre-wired panels, with all

necessary hardware duly mounted in cabinets and power distribution cabinets.

6.20 Transportation of new PLC systems and accessories from stores to site is in the scope of

Bidder. Approximate distance between stores and site is 1 KM.

6.21 The PLC shall be used for critical application of DM Plants in TPS unit. Shifting of the

control from the existing PLC to the new PLC shall be based on shutdown availability of

the individual units. Vendor’s job includes complete transfer of control from the existing

PLC to new PLC system.

6.22 Bidder shall be responsible for designing PLC systems to address cyber threat

vulnerabilities and provide system security updates during warranty and CAMC services

also. USB ports shall be disabled during SAT. In case any dongle is provided for license,

it shall be provided inside PC cabinet. Bidder is responsible to address weak network

design, inadequate firewall rules, privileges, permissions and access controls to protect

the system from cyber threats. Bidder is responsible to deliver systems that are able to

survive cyber attack without compromising critical functionality of the total control

system. Any additional hardware or software required to achieve the above objective

shall be in bidder’s scope of supply.

6.23 Supply of premium quality furniture required for installing engineering stations, printers

and peripherals is in the scope of Bidder. Make of furniture shall be of Godrej make only

6.24 Supply of Power distribution board (PDB) cabinet for control system, power supply

cables from PDB cabinet to individual cabinets of PLC system, PDB cabinet for Non-

control system consumers, isolation transformer for the control system power supply etc.

shall be under Bidder’s scope. Each Relay cabinet & marshalling cabinet shall have its

independent Regulated Power Supply (RPS) for control system components like barriers

etc. installed in it.



6.25 Bidder shall furnish colored System architecture diagrams and write-up of the proposed

system along with a bill of material (indicating redundancies) and make and model

number of all quoted hardware & software along with the offer.

6.26 Bidder to provide FAT and SAT procedure separately for the supplied system. FAT and

SAT procedure shall be finalized after incorporating comments from IOCL.

6.27 The minimum activities in terms of supply & execution for the replacement of existing

PLC by new PLC System has been described under Bidder scope of work. However, the

said job is not limited to above mentioned activities only, whatever else is required for

successful completion of the job shall be in Bidder scope of Supply / Execution.

6.28 Installed spares philosophy is as follows-

a. Loading of the controller of PLC system shall not be more than 60% i.e. each

Processor shall have 40% spare memory capacity for the future expansion. Loading

of communication bus shall not exceed 25%. However, controller, communication

bus & processor loading shall be verified during SAT considering with other I/O’s,

communications etc. specified elsewhere given vide technical specification.

Loading verified during FAT shall be taken as reference only.

b. All type of Input & output modules of PLC system shall have 25% spares channels

complete with all necessary hardware like barriers, relays fully wired up to field

terminals in the marshalling cabinets & shall be kept ready for field cables

termination.

c. Installed spare hardware items (i.e. barrier’s, signal isolators / multipliers, relays,

LED lamps, miniature push buttons etc.) shall be wired up to the marshalling /

relay cabinets terminals.

d. All the system power supplies shall be RPS type & shall not be loaded beyond 35%

in worst case. The loading of individual BPS should be such that the failure of

single BPS shall not result in loading of the other operating / redundant BPS

beyond 70% of their individual rated capacity.

e. Each I/O racks of PLC system shall have 20% additional usable spare slots for

installing I/O cards of each type for future requirement.

f. 20% spare terminals with sufficient space shall be provided in all the marshalling

cabinets of PLC system.

g. 25% spare MCBs to be provided.

h. Consumable Spare: All paper and ink cartridges required for printers, fuses,

potable solid state drives and all other consumable items, required for minimum of

six months duration after site acceptance test shall be supplied along with the

system.

6.29 All the Barriers (MTL or P&F make only) for inputs and outputs shall be of active type.

6.30 PLC Relays shall be plug-in type with LED indication. Make of the relay shall be

Omron/OEN only.

6.31 The process schemes and other inputs like analyzer readings are included in the total I/O

count specified in clause no. 20 of this document.



6.32 Bidder’s scope includes supply of network switches and firewall. Make of the switches

& firewall shall be Cisco / Netgear only. The switches and the firewall must be industrial

grade only with reliable 24 X 7 operation capability.

6.33 All changes / modifications as required during FAT / Pre-commissioning and

commissioning activities in PLC engineering at the Bidder works / site to meet the

functional requirements including manpower assistance shall be under Bidder scope

without any cost and time implication to IOCL.

6.34 Bidder’s shall be responsible for providing training to the IOCL’s personnel as specified

in tender document, both at manufacturer’s works and at site, in system software, system

operation, maintenance and engineering of the system.

6.35 All I/Os shall be duplicated as per DMR philosophy by duplicated signal conditioning

circuits per I/O point. The use of relays or signal multipliers shall not be implemented for

duplication of I/Os, same is to be implemented by use of duplicated signal conditioning

circuit boards.

6.36 Processor cards, I/O cards, FTA boards and other systems cards must be from same PLC

family offered by the vendor. The offered PLC processor system and associated I/O

cards/FTA boards must be latest and IOCL reserves the right to review the quoted

system.

6.37 IOCL shall provide following :-

110VAC UPS and 230VAC Non-UPS utility power supply

All control and signal cables upto PLC cabinets

All cable tray outside rack room/control room

FO cable from RO plant PLC to new PLC for third party communication

All armoured power cables upto the vendor Power distribution panels

Earthing cable shall not be provided by IOCL and Bidder shall arrange the same.

However, IOCL shall provide cable tray for the earthing cables.

7.1 Following system redundancy shall be available as a minimum

Controller - 1:1

All I/O cards - 1:1

Internal Communication - 1:1

Power Supply - 1:1

Communication Card - 1:1

7.2 The system shall be designed ‘fault avoidant’ as a minimum by selecting high grade

components of proven quality and proper design of system electronics. Redundancy shall

be provided as per these specifications to improve the system availability and reliability.

7) Special Requirement for PLC System



7.3 All sub-systems of the system shall be able to operate satisfactorily from 10 deg C to 50

deg C and 20 to 98 % non-condensing humidity. The system shall have high MTBF value.

7.4 The systems shall be modular in construction and expandable, in future by adding

additional modules. The type of modules shall be kept to the minimum possible in order to

have interchangeability and low inventory.

7.5 The system software shall be governed by the operating system running in a real time

mode and shall be able to meet all functional requirements specified in the specifications

as a minimum. Any other standard/special software package, if available shall also be

offered describing the full capabilities. All firmware & software offered for PLC hardware

shall be of latest version.

7.6 Bidder shall not quote any product/item which has become obsolete or which would

become obsolete within next 10 years time from the date of order placement of the system.

7.7 All updates/upgrades, hardware upgrades, software patches for system improvements shall

be provided free of cost to IOCL without any commercial implications from the date of

commissioning of the PLC system to next 10 years from the date of order placement of the

system.

7.8 Bidder shall confirm that service support of the supplied product/items shall be offered for

at least 10 years from the date of order placement of the system. Bidder shall guarantee the

availability of spares & services including all third party equipment supplied by Bidder

along with the system for next 10 years.

7.9 Bidder shall furnish services & spares support certificates from principals (parent

company) for the offered PLC along with the offer. Bidder to submit written

undertaking/guarantee certificates for the above to the IOCL.

7.10 Bidder shall confirm to supply the PLC system hardware like processor cards, I/O cards

Communication cards etc with necessary conformal coating suitable for G3/GX level

corrosive environment (as per standard ISA–71.04–1985 or equivalent) operating

condition, to avoid any hardware/software failure and to increase the system reliability &

availability of the system. The documentary evidence of compliance shall be furnished

along with the offer.

7.11 The system shall have an extensive set of self-diagnostic routines functions which shall

locate and identify the system failure at least up to I/O module level including redundant

modules through detailed LED displays and system log reports.

7.12 On-line replacement of any module shall be done without de-energizing/shutdown of the

system. Further there should not be any mal-functions in the PLC system while replacing a

faulty module.

7.13 The operator station, engineering station shall be designed in such a way that failure of one

operator/engineering station does not lead to the failure of the other operator/engineering

stations. Electronics of each operator station/engineering station shall be independent.



7.14 The system shall be suitable for power supply as specified in this tender specification.

Suitable battery backup shall be provided for volatile memory protection as required.

Battery drain indication & alarm shall be provided on operator stations.

7.15 One set of licensed system software for PLC system and any other system (which requires

licensed software) shall be supplied with the system and two sets of application software

shall be supplied with the system in a potable USB hard disk drive of 1TB.

7.16 The UPS power supply shall be provided by IOCL for PLC system up to PDB cabinet.

Redundant feeder shall be provided as per IOCL reliability schemes from UPS distribution

board up to PLC system PDB. Further distribution / conversion to different power levels

including isolation transformers if required, shall be in the scope of Bidder. Vendor shall

provide Molded Case Circuit Breaker of adequate capacity to connect all incoming

110VAC feeders from UPS. Normal MCBs shall be used for Non-UPS utility power

supply of 230VAC.

Unit UPS power supply Field SOV power

supply

Non-UPS utility

power supply

NDMP 110 VAC± 10%,

50±5% Hz

110 VAC± 10%,

50±5% Hz

230 VAC±10%,

50±5% Hz

BXP DMP 110 VAC± 10%,

50±5% Hz

230 VAC± 10%,

50±5% Hz

230 VAC±10%,

50±5% Hz

All HMI stations/ Engineering stations etc shall use 110VAC UPS power only.

7.17 110 VAC/230VAC power supply required for field solenoid valves shall be provided by

IOCL at PDB. All necessary cabling from PDB, glanding, termination and further

distribution to relay cabinets shall be in the scope of the Bidder. All necessary armoured

power cables shall be provided by IOCL.

7.18 The system load shall be calculated considering:

a. Expandability of I/Os including installed spares and installed future spare chassis slot.

b. In rush current for system/user load shall be considered.

c. Provision of proper switch ratings & fuse coordination in AC & DC power

distribution

Power load calculation shall be submitted to IOCL for approval.

7.19 All the terminals in PDB panel shall be provided independent accessibility in a segregated

way such that tripping of any single switch / MCB shall not affect other system / unit

operation.

7.20 Separate cable tray shall be used for system, power and signal cables with segregation

between different types of signals inside the rack room/control room. IS cables shall be

provided with blue color cable duct.



7.21 Bidder shall be responsible to carry out all the changes as required during FAT / Pre-

commissioning and commissioning activities in PLC system engineering at Bidder

works/site to meet the functional requirement without any cost implication to IOCL.

7.22 For all cabinets of PLC system, Graphic based monitoring, temperature indications, fan

failure alarm, individual Regulated power supply (RPS) supply failure alarms & individual

DC power supply unit loading indication, UPS trouble failure alarm, UPS power source

trending etc shall be provided.

7.23 PLC system engineering and execution shall be carried out by Original Equipment

Manufacturer (OEM) only.

7.24 All field instruments signal / Relay contact wiring shall terminate first at field terminal

blocks of marshalling cabinets of PLC system. Cross wirings cabinets shall not be

permitted. All powered outputs shall have fused terminals. All spare channels of the I/Os

shall be completely wired up to the field terminals along with barriers/relays etc.

7.25 Dynamic data display on a LED shall have an update time of one second or less.

7.26 Graphic call up time shall be a maximum of two seconds.

7.27 System basic software shall be held in non-volatile ROM.

7.28 The list of batteries and the identification of battery type shall be provided.

7.29 Time Synchronization :

The time synchronization with external clock i.e GPS shall be provided by vendor. The

frequency of time synchronization shall be configurable. Vendor scope shall include the

following as minimum

Development of time synchronization documents part of functional design specifications

(FDS)

Identification of the specific material required for time synchronizing between all the

control system and its sub-systems

Design, supply and installation of GPS antenna, receiver units, splitters, special cables

for interconnection time synchronization equipments, GPS antenna etc. including

glanding and termination at both ends

The GPS system with minimum 2 nos of additional (spare) NTP ports and 2 Nos of

IRIG-B ports for connection to external third party devices. These spare ports shall be

utilized by IOCL in future.

The supply, laying, and termination of cables for interface with vendor supplied PLC

systems shall be in the scope of vendor.



8.1 General

a) Programmable Logic Controller shall be microprocessor based system which shall be

used to execute all the process, and safety shutdown logic. Programmable logic

controller shall be of Dual Modular Redundant (DMR) type.

b) The PLC unit(s) shall be sized considering I/O’s and other sizing requirements like

scan time, CPU loading etc. The sizing calculations shall be reviewed during detail

engineering. Bidder shall be fully responsible to supply number of PLC’s as required

meeting above requirements and approved sizing calculations.

c) PLC shall be modular in concept, comprising of a Dual Modular Redundant (DMR)

configuration with redundant I/Os and multiple communication/network ports.

d) PLC shall utilize open system architecture with multiple communication/network

ports in order to maximize the number of telecommunication devices that they are

compatible with.

e) To compensate for possible hardware failure or testing, a software” override

function” shall be available to enable “forcing” of the measurement associated with

specific input point or to “force” changes to an output (analog, digital or software).

f) Even if the PLC main components (Engineering Work Stations, CPU/Electronics

Cabinets, I/O Modules Cabinets, Printers, Barriers Cabinets, etc.) will be installed in

air conditioned buildings, they shall be designed in accordance with the requirements

of ISA Standard S71.01: ”Environmental Conditions for Process Measurement and

Control Systems: Temperature and Humidity”.

g) In addition to the requirement of previous point, the PLC components must be

designed in order to match the recommendations of ISA Standard S71.04:

Environmental Conditions for Process Measurement and Control Systems: Airborne

Contaminants”.

h) The functionality of PLC shall be implemented in the standard open system

architecture utilizing standard operating system, standard network protocols, standard

user interface and standard software development tools.

i) Any element or system hardware such as processor, I/O modules, power supply etc.

shall be replaceable and upgraded by simple change out or “plug in” without

affecting the rest of the system and without requiring any software modification.

j) The design of PLC shall be carried out with the aim to achieve the following main

technical features:

User friendly operation of the Man Machine Interface

Easy future extensions for both Hardware and Software

8) Job Specification for PLC System

System Architecture



k) Bidder shall take into account the PLC sizing rules to define the hardware and

software requirements, especially the rules concerning: plant partition, PLC

functional splitting, redundancy requirements, estimate I/O count, system required

performances, data communication with other systems, etc.

l) A facility shall be provided for modification & online download of the PLC

application software from the engineering workstation without affecting the

operation of the plant. The access to the modification and download of the

application software shall be password protected. PLC shall have dedicated security

switch, which can be set to enable/disable any modification of program variable &

download of modified application software. The normal operation /run mode of the

key – switch will prevent inadvertent writing e.g. download, forcing, parameter

change etc. from the engineering workstation to PLC. Online modification shall be

possible in the offered PLC. The key switch can be set to enable the writing from the

engineering workstation.

m) Communication sub system shall be totally redundant such that failure of any

communication processor, cable or related hardware shall not result in interruption in

PLC and plant operation.

n) It shall be possible to modify the application program on-line and upload to PLC

without affecting plant operation. System shall have facility of logging the

engineering changes made along with detail of activities, user name and time stamp.

o) The rating for relays shall be as follows:

i) For feedback signals from MCC: Potential free MCC contacts shall be wired in

the 24 V DC coil circuit of interposing relays. Contact of the interposing relay shall

be wired to digital input of PLC (as required) in the 24 V DC interrogation circuit.

Each relay shall be with 2 change over contacts & contact rating shall be 3 Amps @

24 V DC. Fuse type terminals shall be used for outgoing 24 V DC positive line.

ii) For command signals to MCC: The coil rating of the interposing relay shall be

24 V DC. Each Relay shall be with 2 change over contacts & contact rating shall be

5 Amps @ 240 V AC for LT drives and 5 Amps @ 220 V DC for HT drives.

Terminals & wiring carrying 240 V AC /220 VDC shall be segregated from 24 VDC

wiring & terminals. No fuses / fused terminals shall be used.

iii) For Digital output signals for SOVs: The coil rating of the interposing relay

shall be 24 V DC. Each Relay shall be with 2 change over contacts & contact rating

shall be 5 Amps @ 240 V AC. Terminals & wiring carrying 240 V AC /110 VAC

etc shall be segregated from 24 VDC wiring & terminals. Fused terminals shall be

used for SOV operating supply.

p) PLC system engineering and execution shall be carried out by Original Equipment

Manufacturer (OEM) only.

q) All maintenance and operation related features to be demonstrated during factory

acceptance and site acceptance test.



r) The scan time of programmable controller shall be 100 milli second or better.

s) PLC shall have extensive self diagnostic capabilities & should able to identify faulty

channels in input/output cards, faulty system cards & power supplies. The outputs

shall be fail safe & shall have secondary means of de-energisation in case of CPU

failure. PLC shall have sequence of event (SOE) functionality. Time stamping of the

alarms shall be in HH:MM:SS:msec (e.g. 11:10:15:240) format.

t) The necessary software and hardware for Sequence of event recording shall be

provided. SOE shall be implemented in PLC with a resolution of 1 millisecond. SOE

shall be implemented in separate sequence of event retrieval station other than

engineering station. However engineering station shall have capability to process and

generate event logs and SOE as required. The SOE data shall also be stored in

engineering station of PLC for at least 10000 alarms. All I/Os points of PLC system

shall be considered in SOE. The system shall have facility of keeping 360 hours of

record at the time with last in and first out facility. It shall be possible to archive the

data from SOE on CD/DVD drive.

8.2 Functional requirements –

PLC shall have standard control algorithms required to achieve control of processes.

These shall include, but not limited to -

On/Off Control

Secure Digital outputs

Auto/manual control selection

PID Controls (P, P+I, P+I+D)

Standard logic gates

Mathematical functions

Totalizer function.

Timers, counter

Flip-flop functions.

Cause & effect matrix logic.

Ladder Logic

Boolean Operations

Discrepancy alarming,

Ratio Algorithms

Changing tuning constants.

Regulatory Control

Indication functions

Normal PID/Self Tuning PID

Cascaded Loops

Feed Forward Control

Set Point Tracking (Remote/Local)

Split range

Bumpless, Direct / Reverse action

Auto/manual processing,

Stand-by selection & change over

Change of controller mode

( Manual/ Auto/ cascade etc )

Increase/ Decrease of Set point

Changing Manipulated Variable.

Changing o/p to final control element.

In cascade loops, the primary controller output shall be able to track the set point

of the secondary controller when the secondary controller is not operating in the

cascade mode.

In case of UPS power failure, the set point should be latched to last value.

8.3 Controller Single Failure Mode

a) Controllers shall have 100 % availability and this will require a redundant controller

with the back up in hot standby. In the event of a single controller failure, the backup

shall take control with no loss or degradation of control.



b) Back-up controller shall be configured to track the primary controller and acquire all

information such as intermediate calculations and operator set points to ensure no

loss or degradation of control during switchover and ensure:

Automatic switchover to standby units

Bumpless switchovers. Transparent switchover (i.e. recognized by operator only

through a system alarm).

Initialization / Start-up Mode of Controllers

8.4 Hardware and Standard Software Design

a) Controller unit

PLC shall consist of dual processors configuration with redundant I/Os with automatic

changeover. PLC shall be supplied and engineered to achieve the required reliability

and integrity with the objective that spurious shutdown functions shall be avoided.

Central Processing Units (CPU) shall be microprocessor based multi-loop, devices

capable of receiving and transmitting different signals, performing control and/or

logic and sequence functions for plant safety condition. Design of PLC system shall

be such as to avoid any common mode failures. Failure of any card, Power supply,

Communication card etc. should not degrade the system performance/operation in any

way. The system should be engineered taking care of the same. All the maintenance

should be possible in the, on line, while the plant is running

CPU redundancy system (including power supply) shall ensure continuous automatic

control in the event of CPU failure. This means that the backup CPU shall

automatically take over all card functions and control strategies of primary controller

without loss of automatic control, process disturbance, or control upset (bump less

transfer).

Failure of any CPU shall cause an alarm to be displayed and logged on both PLC

Engineering stations & operator stations. Loss of both the active and redundant CPUs

shall cause system outputs to freeze at their last position, or to drive to pre-defined

fail-safe conditions.

Engineering stations & SOE stations shall be provided as indicated in the Ann-1 &

Ann-6.

The PLC operating system, PLC hardware and the engineering / programming

software version shall be of latest release. The system shall have a protection

mechanism against unrecoverable failure in case of PLC hardware malfunction and

power failure.

Microprocessors shall have non-volatile memory (24 hours battery backup for

memory is an acceptable alternate) and be able to perform their control functions

without access to the communication bus. Operator interfaces or communication bus

failure shall not destroy the process-to-CPU interface nor prevent blind operation of

the plant.



b) Functional requirements

It shall be responsibility of Bidder to fully develop the functionality of the PLC Logic

during the Detailed Design phase. The functional design shall be based upon the

following documents:

i. Trip Descriptions and process narratives.

ii. Cause and Effect Diagram

iii. Functional Logic Diagram

iv. Piping and Instrumentation Diagram

The PLC system shall be implemented using a failsafe design concept i.e. Energized

for Normal condition and De-energized for Abnormal conditions.

c) Digital Algorithms

i. The PLC must handle a large number of binary inputs and outputs to operate

valves and pumps. This requires the use of binary "blocks" allowing several

inputs and several outputs to be processed to implement: auto/manual processing,

on/off control, discrepancy alarming, interlocking, and duty/standby changeover.

ii. The PLC shall support logic functions such as AND, OR, NOR, NOT, as well as

timers, delays and counters.

d) Sequence Control

Possibility to have interactions between analogue algorithms and sequences is a

mandatory requirement.

The running of sequences in parallel in a controller is required. Bidder shall

ensure that the system is designed to avoid locking-up the processors on a

sequence.

e) Input/output requirements

All I/O modules provided with PLC shall have redundancy and shall be in hot stand-

by configuration with auto change over. All I/O modules shall be dual redundant. I/O

cards shall be designed such that a short circuit or a high-voltage on one I/O will not

induce a fault on any other I/O of the card. Redundancy shall be provided for all

systems and components as below -

Controller

I/O cards

Communication Bus

Communication port

Power Supply



f) Maintenance Override Switches for field input devices shall be implemented through

the PLC system engineering station. Process or Start-up Override Switches shall be

as specified in Cause & Effect Diagram or Functional Logic Diagram.

g) System I/O modules shall be selected so that the need for separate signal conversion

shall be avoided. The use of I/O with signal processing facilities built-in shall be

preferred.

h) System components shall be modular in design with rack mounting and plug-in type

assemblies. Each system module shall be equipped with light indicators for fault and

status display.

i) All I/O modules shall be redundant to provide hot swap capability of faulty I/O cards.

I/O cards shall be from same PLC controller version/family offered.

j) The system shall have self-diagnostic programs that run independently from the

application programs on a continuous basis with fault detection capability down to

the I/O module individual channel. It shall be possible to replace cards without

switching off the power. All modules shall be replaceable on-line without degrading

the system performance, affecting other components or causing a system failure. Re-

initialization of newly installed module shall be automatic.

k) The number of channels per I/O card shall be as follows-

For DI/DO/AI cards : 32 channels card

For AO cards : 16 or 32 channels card can be used

l) I/O requirements

i. Analogue Input

Analogue Input modules shall be designed to accept 0-22 mA current signals, being

the normal range of operation 4-20 mA. 0-22 mA input card shall also measure both

over range (> 20 mA) and under range (< 4mA) currents and shall provide a fault

alarm.

Linearization shall be provided for non-linear inputs.

Common and differential mode input surge protection shall be provided.

Accidental application of main supply voltage or test voltages shall not damage the

modules. Bidder shall state limits that his equipment can withstand.

ii. Digital Inputs

Input modules to be provided with LED indicators on the front, showing the status

of the field input circuits.

The system shall accommodate both normally open and normally closed contacts

(configurable).

Proximity Switches (NAMUR) shall also be used along with barriers

All DIs shall be isolated from field by interposing relays



Powering: “voltage free” input contacts, shall be powered by the system, using a

24 V DC.

iii. Digital Outputs

Digital outputs are relays, isolated per channel, free of voltage and ground.

The contact outputs shall be configurable

Fail-safe option is required

All DOs shall be isolated from field by interposing relays

Powering: the output channels will be powered by the PLC or by an external power

supply as required

m) Input and Output modules shall provide galvanic isolation between field & system.

8.5 Data communication System

a) Any PLC back up communication device (cable, interfaces) shall be automatically

and permanently self-tested and/or controlled by watchdog to ensure that it is not out

of service. A system alarm shall be generated in the case of failure. Transfer to a

back-up communication channel shall be automatic without disrupting the system

operation, but alarmed to the operator.

b) The communication cable shall be flexible for ease of installation and termination

within equipment cabinets. Cable and fittings shall be of premium quality and shall

be field proven. The system shall be designed for quick and easy connection and

disconnection of devices.

8.6 Software engineering tools

a) Bidder shall provide all the software and hardware engineering tools necessary to

build and to modify the configuration of Engineering workstation, PLC Logics as

well as network communication interfaces. The tools shall be clearly identified and

supplied in sufficient quantity.

b) The software engineering tools shall allow modifying the configuration. It shall

include as a minimum the facilities for:

I/Os assignment.

Point configuration.

Online control loop (analogue & digital).

Sequence and Logic diagrams.

Graphic builder.

Cross reference list between database and display.

c) All engineering tools must be self-documenting: all required reports, prints, drawings

etc. must be provided by the Bidder to allow engineering and maintenance staff to

understand the entire configuration and programming.

d) Bidder shall provide the programming language including software license and tools

necessary to implement sequential control



8.7 All stations like Operator, Engineering, SOE stations, OPC server should communicate

with the controllers directly and no communication/controller failure shall be initiated

in case of failure of the any station individually or simultaneously.

8.8 PLC Engineering Stations & SOE stations

PLC Engineering station shall also be capable of programming, program storing,

fault diagnostics, monitoring, SOE storage etc.

Manual forcing of any input or output connected to PLC shall be possible by

keyboard.

Engineering stations shall be loaded with Bidder license SCADA software and

graphical representation of system diagnostics shall be provided. Single line

graphical interlocks pages shall also be provided. Engineering station shall also have

SOE functionality.

It should be possible to connect and monitor both New DM Plant and BXP DM Plant

PLCs from all Engineering stations and SOE stations.

Engineering stations and SOE stations shall be a latest commercial grade type for use

in 24X7 hour continuous industrial application & shall have minimum specifications

as per Annexure-VI.

The printer connected with engineering station shall be able to print the ladder/logic

diagram, diagnostic messages as and when generated, and diagnostic reports when

called for, process alarms connected to PLC, I/O maps showing status of all inputs.

Configuration displays:

Configuration display shall provide a separate detailed display for each loop

indicating the configuration of that loop. When control requires more than one

loop, all inter related loops shall also be displayed. Following information is

required to be available for configuration display:

Loop configuration giving designation of each block.

Control blocks interconnection showing soft wiring or hard wiring.

Value of each block parameter like P,I,D, ratio bias, dead time, lead time

etc.

It shall be possible to configure & reconfigure the loops from this view using user-

friendly software.

Engineering station shall be capable of doing all the functions of operator station in

addition to all engineering functions.

It shall be possible to perform all system configuration functions from the

engineering station.



Tuning of a control loop shall be possible from engineering as well as from operator

station.

During the normal operation, the engineering station, in no case, shall interfere with

the process operation or system software. However any change in the configuration

shall be down loaded into the system with proper knowledge of the operator.

All detailed diagnostics of the system shall appear on the engineering station. Any

special diagnostic package if available with the system shall also be offered. Detailed

description and capability of this package shall be supplied.

It should be possible to search/ view all the related tags and Channel/slot/point

allocated to a particular tag. The Bidder shall supply any additional software required

for the same.

Engineering workstation software shall allow:

Cross-referencing and tag search function

Off-line simulation, Offline and online programming,

Test and debug program execution which allows software testing before actual

program downloading,

Download configuration software and application program,

Monitor the real time program execution with program variable updates on the

function block logic diagrams,

Automatic documentation and report generation for documenting programs, audit

trail of program changes and user actions,

Before any revised program download, a revision comparison shall be done

between the program running in the processor and the source program in the

engineering workstation to identify all the exceptions or modifications. The log

file of the revision comparator shall allow the engineer to view and verify that all

modifications have been correctly incorporated into the revised application

software.

8.9 Operator Stations

Four operator stations shall be installed in the Main DM Plant control room whereas

two operator stations shall be installed in BXP DM Plant rack room.

Four operator stations installed in the Main DM Plant control room shall be provided

with table top type control desk along with provision to install the annunciator. The

Consoles shall be designed properly to match the aesthetics of the Control Room.

Bidder shall provide console dimension drawings, layout drawings for approval to

IOCL before manufacturing.

Two operator stations shall be installed in BXP DM Plant rack room shall be normal

table top type without any annunciator provision.



The operator stations shall provide the centralized information to the plant Operators.

Operators will monitor the process and initiate all control functions from operator

interface stations. All operator stations should have the facility for data storage and

trend viewing.

Operator stations shall be a latest commercial grade type for use in 24X7 hour

continuous industrial application & shall have minimum specifications as per

Annexure-VI.

All operator stations shall have Dual Monitor Support (Provision of Connecting two

LED monitors)

Operator stations shall be loaded with antivirus software and other system related

software along with original CD/DVD of operating system, other software & all

licenses with lifetime validity.

Each HMI shall be capable of storing all particular graphics assigned to that console

and any other console graphics once transferred from the data storage medium,

without the need of disks, cartridges etc.

The visual Display shall be Anti glare type screen with high resolution graphics,

capable of displaying alpha-numeric & graphic displays and shall be flicker-free and

glare-free. Standard VDU controls such as brightness, etc., shall be accessible to the

operator. Multiple colors shall be used to distinguish parameters such as control,

information, process and alarms etc. The display screen shall be able to display the

full alpha numeric tag number of a process variable.

Bidder shall note that the PLC supply includes all software licences for the whole

system including operating stations (multiple Windows, Soft view), ES, SOE , OPC

Servers etc with lifetime validity.

Supply of PLC system shall also include the necessary design and maintenance

software (this shall include but not be limited to graphic display development tools,

testing tools in addition to configuration tools).

The controller and power supply cards shall have LED indications to indicate the

status of various cards and battery backup for memory protection. All I/O cards and

communication cards also shall have status indication.

All Process logics & PLC safe shutdown logics of all units, to be made in Graphics

for real time display on operator stations for monitoring by the operator.

The operator interface sub-system shall provide the plant personnel with following

information not limited to the following.

Indication of all analog and digital process variables of control loops, open loops

and all related parameters

Manipulation of closed loops for changing set points, output mode, configuration,

tuning and computational constants.

Display related to diagnostics of system



Graphic displays related to the plant with real time variables and status indication

in best colors.

Maintenance oriented displays for HW and SW maintenance of system.

Real time and historical trend and logging of parameters.

Displays related to emergencies, start up and shutdowns.

Alarm displays and annunciation.

Alarm summary for un-acknowledged and acknowledged alarms

Real time display of System Architecture of PLC system including all auxiliary

hardware.

Real time display of Process Interlocks & PLC logics

8.10 OPC Server

PLC system shall have OPC (Object Linking and Embedding for Process Control)

connectivity to MIS system. Bidder shall also provide necessary software &

hardware (OPC server and software) and manpower support & assistance for

establishing connectivity of the system with existing system. Bidder shall consider

license for minimum 2000 tags for OPC server connectivity to the OPC clients.

OPC Server station shall be a latest commercial grade type for use in 24X7 hour

continuous industrial application & shall have minimum specifications as per

Annexure-VI.

Supply of any additional hardware or software required for implementation of OPC

Servers connectivity through redundant firewalls with plant local network is in the

scope of the Bidder.

OPC server preloaded with Operating system, antivirus software and any other

OPC Server related software along with original CD/DVD & all licenses with

lifetime validity for the OPC servers. Operating System & the service packs should

be latest.

8.11 Operating system of all stations

Vendor is responsible to provide the latest operating system and service packs for

all the stations like operator/Engineering/OPC Server/SOE stations etc. Any up-

gradation of hardware or software due windows operating system obsolescence

upto completion of CAMC shall be in scope of vendor. For example, if the vendor

is providing Windows 7 operating platform, for which extended support shall end

on 14th January, 2020, vendor, shall be responsible to upgrade operator

/Engineering /Server/SOE/ stations etc to latest operating platform before 14th

January, 2020. Complete supply, installation and commissioning of such up-

gradation shall be done by vendor without any cost implication to IOCL.

8.12 Safety & Security

It is recommended to have different levels of access with each level having the

possibility for different passwords. The different levels could correlate to operator,

engineer access, as described below. Multilevel password protection is required.



Operator Access: Operators may operate the plant but are unable to modify

engineering data or system configuration. Rights of access are limited to control of

all process equipment and systems.

Engineer Access: Engineers may operate the plant and modify engineering data,

modify system configuration. Rights of access will include changing loop tuning

constants, calculations, report, trends and data related to application software

packages; modify engineering data and system configuration. Rights of access will

include, controller configuration, communications configuration and all other

parameters associated with system design.

A facility shall be provided for modification & download of the application

software from the Engineering Workstation. Access to the modification and

download of the application software shall be password protected.

All cabinets shall be provided with key locks. All cabinets shall be operable with

the same key.

The system shall have a protection mechanism against unrecoverable failure in

case of hardware malfunction and power failure.

The access criteria / parameter for each of access shall be detailed out during the

engineering stage of the project.

License dongle, if any, shall be installed inside the PC chassis.

8.13 Electrical Protection

Internal power supply wiring shall be clearly labeled. High voltage distribution and

modules above 48 V shall be clearly identified and all terminals protected by

transparent plastic covers.

Separate grounding systems are to be provided for equipment safety ground and

instrument ground. Dedicated copper instrument ground bars are to be provided for

each type of ground. Additionally the instruments ground bar shall be fully isolated

from all system cabinets. Field wiring from all field detectors and discrete device

inputs and outputs will consist of individual/overall shield wires. Terminals for all

shields are to be provided and linked together. These linked shield terminals are to

be connected to the instrument ground bar.

The safety ground bar shall be electrically connected to all system hardware and

cabinets. Cabinet doors shall be wired to the safety ground bar. Metallic structures,

enclosures, doors and equipment shall be bonded within each cabinet to a single

safety earth point. This single point shall be brass or copper bolted lug connection,

adequate to receive a minimum 16-mm2 copper earth cable terminated in a ring

lug.

Each cabinet shall contain an instrumentation earth bar, of minimum cross section

35 mm2, which shall be insulated from the cabinet.

8.14 Abnormal operation

a) Communication Failure:



In the case of communication failure the controllers will continue to operate using

the last valid values inputted from the operator and the current process variable

data.

The PLC will therefore perform no shutdown or other action in case of

communication failure other than to alarm. The plant will continue operating

without supervision (usually in automatic mode) until operators are mobilized to

the local control room.

PLC systems will continue operating during communications failure, therefore

maintaining plant safety.

b) Power Supply Failure

Power distribution system shall be redundant and supplied from the electrical

system by battery backed-up redundant UPS. Therefore, power failure is

considered a very remote possibility.

In the unlikely event of power failure the controllers shall be configurable to fail to

a safe/ pre-defined state.

c) Controller Single Failure Mode

Back-up controller shall be configured to track the primary controller and acquire

all information such as intermediate calculations and operator set points to ensure

no loss or degradation of control during switchover and shall ensure:

Automatic switchover to standby units.

Bump less switchover

Transparent switchover (i.e. recognised by operator only through a system alarm).

Initialisation / Start-up Mode of Controllers

Controllers shall start-up with all loops in manual mode.

8.15 Maintainability

The design shall incorporate a high degree of modularity and standardization for

the advantage of holding the minimum spare parts.

PLC shall be designed to allow “hot” replacement (online) of any failed component

without any damage to the module and without any loss of performance of the

system while maintaining the same level of safety protection. No plant, process

shutdown shall be initiated during the maintenance unless required by the process /

safety condition.

Fault repairs shall consist of replacing faulty modules only. All fault / diagnostics

messages shall be available at the engineering workstation.

System modules shall be provided with LEDs for normal and fault indication.

8.16 Trend displays

a) Both historical and real-time trend displays shall be available for any variable point.

In addition these shall be able to include set point. Trend displays shall be able to

accommodate at least three different points simultaneously in different colors.



b) The facility shall be included to allow the operator to create/save custom sets of trend

displays for repeated use as necessary.

c) The system shall be capable of displaying the following trends:

i. Real time trends.

ii. Historical trends.

d) Real time and historical trend shall be possible on any parameter or variable like

measured variable, set point, output etc.

e) It shall be possible to sample and store data of instantaneous and average value at the

intervals mentioned below.

At intervals 1 second and above for the real time trend.

At 5, 10, 30, 60 seconds, 1 minute and 10 minute interval for historical trend.

f) Selection of the tag number and sampling time for real time and historical trending

shall be possible.

g) History and Real time trend shall be considered for following

All analog Inputs

All set point variables

All analog output variables

All Setpoint changes by operator shall be historized

All control valve output changes by operator shall be historized

All control valve auto/manual selection alarm shall be historised

h) The system shall be sized to have real time trending for all the tags. The real time

trending sampling period shall be 1 sec. It should be possible to display all the real

time and historical trends in the Operator stations. Historical trending requirements

are mentioned below:

At 1 sec. sample rate for a period of 3 days for all tags.

At 1 min sample rate for a period of 30 days for all tags.

Hourly averages for all tags for 6 months.

It shall be possible to transfer the data to the removable media for the long term

historical data storage & archiving. The history storage shall be on redundant

stations.

i) The system shall be configured to provide shift wise and day wise reports for the

parameters provided by IOCL. The system shall allow parameter addition/deletion as

per requirement. The report shold be in printable format for daily shift wise printing

as required.



9.1 Alarm and Annunciator System

a) Alarm & Annunciator system shall be modular & split architecture type (Two

annunciators with 24 windows each). Annunciator system shall be mounted above

consoles. Design of each module shall be such that by simply jumpering suitable

point, it may be change from normally open mode of operation to a normally closed

mode of operation and vice versa. Alarm Annunciator window facia shall be

miniature type.

b) All the critical alarms shall be annunciated in the alarm annunciator. The list of all

such alarms shall be finalized during detail engineering.

c) Lamps shall be clustered LED type with long life and replaceable from the front.

d) Hooter in general, shall be solid state type with audibility of the order of 100 dB at a

distance of 3 meters.

e) An interruption of power supply for duration of 20 milli second or less shall not

affect the functioning of the annunciator.

9.2 Printers

Quantity, type and location of printers shall be as per Ann- 6 System components and

requirements. All printers supplied on hubs should be networked printers.

9.3 System Furniture:

All system furniture like table top equipments shall be of Godrej make.

10.1 AC Power

a) 110 VAC, 50 Hz, 1 phase, AC power supply shall be derived from Uninterruptible

Power Supply (UPS) provided by IOCL. The system shall be capable of operating

during voltage variations up to (+/-) 10% and frequency variation (+/-) 5%.

b) Redundant power supply shall be provided inside the control room up to the PDB,

the Bidder shall do further distribution. Each power supply shall have fuses /

isolators / MCBs etc. and shall be under Bidder’s scope of Supply. Power supply

shall be individual for each cabinet. All Power distribution cabinet shall be provided

by the Bidder.

c) Both PLCs shall have independent power distribution such that any problem in one

PLC PDB shall not affect other PLC.

9) Auxiliary Hardware

10) Power supply



d) IOCL shall provide redundant UPS supply upto the power distribution panel.

Glanding, termination and further power distribution shall be in the scope of bidder.

e) Bidder shall calculate and provide the source load for each system.

f) AC power supply throughout the system shall be divided, so as to obtain maximum

reliability on sub system basis. Power failure in one sub system shall not jeopardize

the functionality of the other sub system.

g) Power supply to 4-wire field transmitters shall be provided by the Bidder from the

AC PDB and individual MCB shall be provided for each 4-wire transmitter.

h) AC power for lighting and sockets shall be provided from non-UPS source. IOCL

shall provide non-UPS 230VAC power supply upto the power distribution panel.

Glanding, termination and further power distribution shall be in the scope of bidder.

i) Looping of power (110V AC, 110V DC, and 24V DC) is not acceptable and power to

each device (including barriers) shall be fed with two independent wires.

j) Each cabinet should have individual redundant RPS installed in the cabinets.

k) Power supply required for solenoid valves shall be provided through redundant UPS

feeders by IOCL to PLC system PDB. All necessary cabling from PDB, glanding,

termination and further distribution shall be in the scope of Bidder.

10.2 DC Power Supply

a) Bidder shall provide dedicated DC power supply to the controller sub system, I/Os,

etc.

b) 24VDC power supply for PLC system components like controller cards/IO Cards etc

shall be separate from the 24VDC power supply going to the field devices. Bidder

shall ensure complete 24VDC power segregation between field devices and PLC

system cards.

c) Analogue loop powered transmitters shall be powered by the system itself.

d) Each power supply unit shall have built in diagnostic circuitry to monitor out of

range voltage and over temperature conditions.

e) Each power supply unit shall have its own circuit breaker protection on the incoming

side.

f) Each power supply unit shall have status indication on its faceplate, provision to

provide load indication and power supply failure contact, which shall be hardwired to

PLC system for online monitoring & alarm status. Power supply failure contact

should actuate when power supply voltage drops below 20 VDC. Failure of power

supply shall be a system alarm.



g) Vendor to ensure that online replacement of faulty power supply, diode O ring unit

etc. should be possible. Such online replacement should not create any system

disturbance. MCBs for isolation to be provided at both ends.

11.1 The system shall normally operate on uninterrupted power supply unless otherwise

specified.

11.2 Isolation transformer shall be provided for AC power supply distribution from main

feeder to the subsystems, as applicable.

11.3 Supply of PDB along with MCBs, cables and other accessories required for further

distribution of power supply is in Bidder’s scope. All MCBs shall be DPDT type only.

11.4 In redundant configuration, individual RPS shall not be loaded more than 35% under full

load. Each RPS power shall be routed through individual diode ‘O’ ring for each RPS.

Each cabinet should have individual redundant RPS installed in the cabinets.

11.5 Each consumer shall be provided with a separate double pole MCB of suitable rating for

isolation and protection.

11.6 Transmitters in field are normally two wire type & shall be powered with individual

power supply through barrier, however in case of any transmitter / field instrument needs

separate 24V DC power supply, it shall be powered from common DC distribution using

individual power cable run, and double pole MCB for isolation.

11.7 The distribution network shall be designed in such a way that overload in any branch

shall not trip the main power supply.

11.8 Separate power supply is to be taken from PDB for each type of cabinet. Same MCB

should not be used for more than one cabinet of power supply

11.9 All Ethernet switches shall have redundant power supply taken from PDB panels, Power

of switches should not be sourced from adjacent available stations.

11.10 All type of stations, servers, printers supplied along with PLC system should accept

universal power i.e. 110 / 230V AC. Separate industrial grade continuous rating

electrical fittings and MCBs for power supply to be provided for each node/station of the

PLC system at both the end. Power distribution from ACDB to all workstations and

printers shall be through armored power cable only. The power cable for this shall be

provided by IOCL.

11) Distribution of Power supply



12.1 Following cabinets shall be required, in general:

a. Power distribution cabinets (for AC/DC Power distribution)

b. Barrier mounting cabinets

c. System cabinet.

d. Input / Output cabinets

e. Relay cabinets.

f. Other auxiliary card mounting cabinets.

12.2 All the cabinets and panels shall be completely wired.

12.3 All cabinets, panels, racks must be designed to avoid congestion for ease of maintenance.

Bidder shall be fully responsible for sizing of each cabinet / rack / panel to ensure

sufficient maintenance space. A cabinet found congested at any stage of job execution

shall be replaced by Bidder without any cost and time delay implication to IOCL.

12.4 All the cabinets shall be of free standing, enclosed type and shall be designed for bottom

entry for cable connection. Cabinet structure shall be sound and rigid and shall be

provided with removable lifting lugs to permit lifting of the cabinets.

12.5 Cabinets shall be fabricated from cold rolled steel sheet of minimum 1.6 mm thickness

suitably reinforced to prevent warping and buckling. Doors shall be fabricated from cold

rolled sheet of minimum 2 mm thick. Cabinets shall be thoroughly de-burred and all

sharp edges shall be grounded smooth after fabrication.

12.6 Each cabinet shall be of maximum of 2100 mm height and 800/1200 mm width.

Construction shall be modular preferably to accommodate 19” standard electrical racks.

All racks shall be of same height. Maximum swing out for pivoted card racks, doors and

drawers shall be limited to 600 mm.

12.7 Cabinet shall be equipped with front and rear access doors. Doors shall be equipped with

lockable handles and concealed hinges with pull pins for easy door removal. Cabinets

shall have double door facility except for system cabinet. All system cabinets shall have

glass door for ease of checking of status of modules.

12.8 In order to effectively remove dissipated heat from the cabinets, vent louvers backed by

filters shall be provided to cabinet doors.

12.9 Four no. fans are required on both front side & front top and rear side & rear top of

panel with Non UPS 230V AC and Fluorescent lamp with door operated (230V AC Non

UPS) shall be provided with each cabinets

12.10 Illumination shall be provided for all cabinets and door operated micro switch.

12.11 Equipment, within the cabinet, shall be laid out in an accessible and logically segregated

manner. Clamping rails shall be provided for incoming cables to prevent excessive stress

12) Cabinets & Consoles



on the individual terminal. All metal parts of the cabinet including doors shall be

electrically continuous and with a common grounding lug.

12.12 Bidder shall ensure that all the system and marshalling cabinets shall be of RITTAL

make only. Look, size and color of all the cabinets to be identical. Paint color and surface

coating shall be provided during detailed engineering

12.13 Cable color coding for power, signal, control etc., ferruling philosophy for heat shrink

ferrules, duct color inside the cabinets, tag numbering philosophy shall be provided

during detailed engineering. Bidder to comply for the same.

12.14 UPS incomer in PDB cabinet shall have bolted connection. Terminal blocks shall be

used only up to 6 mm2 cable. Above this size, bus bars with bolted connection shall be

provided.

12.15 Nameplates shall be provided for each Instrument / components mounted on Panel /

Console. Name plates shall be made of black laminated plastic with white engraved

letters. Nameplate shall be provided on the rear of the panel also for each instrument.

12.16 All cabinets shall have name plates of SS on both front & rear side. Exact philosophy of

nameplates shall be decided during detail engineering.

12.17 Panels / hard wired console should be fabricated preferably from 3 mm thick cold rolled

steel sheet. Angle iron frame shall use a minimum section of 50 x 50 x 3mm angle.

12.18 Provision shall also be kept for keeping plant communication console /handsets also on

hardwired console.

12.19 Notes on wiring

a. All wiring shall conform to API RP Part-1 sections 7 and 12. Different signal level

cables shall be routed under false flooring with separation distance as

recommended by API RP 550 section 7.

b. All wiring inside racks, cabinets and back of the panels shall be housed in

covered, non-flammable plastic raceways to permit easy accessibility to various

instruments for maintenance, adjustments, repair and removal.

c. All wiring in the raceways shall be properly clamped. All incoming cables shall be

terminated by Bidder at marshalling rack with cable glanding including supply of

cable glands. Total wiring cross sectional area shall not exceed 50% of the

raceway cross sectional area.

d. Separate wiring raceways shall be used for power supply wiring, DC and low level

signal wiring, and intrinsically safe wiring. Parallel runs of AC and DC wiring

closer than 300 mm shall be avoided. Bidder can alternately offer pre-fabricated

cables for interconnection between different cabinets/ panels.



e. Wire termination shall be done by using self insulating crimping lugs. More than

two wires shall not be terminated on one side of single terminal. The use of short

links for looping are not allowed.

f. Terminal housing shall be strictly sized with considerations for accessibility and

maintenance. Following points should be considered.

g. Distance between terminal strip and side of the cabinet parallel to the strip up to

50 terminals shall be minimum 50mm. Distance between terminal strip and top

and bottom of the cabinet shall be minimum 75mm. Distance between two

adjacent terminals strips shall be minimum 100mm. Distance between cable gland

plate and the bottom of the strip shall be minimum 300mm.

h. All terminal strips shall be mounted on suitable anodised metallic or plastic stand-

off. No splicing is allowed in between wire / cable straight run.

i. Terminal strips shall be arranged group wise for incoming and outgoing cables.

j. Cabinet and rack layout shall be made considering proper accessibility and

maintenance. Terminal blocks for intrinsically safe wiring shall be separate

k. All spare cores shall be terminated on the marshalling rack. No cable /core shall be

left un terminated in the rack/cabinet. No terminals or terminal strips shall be

located on the side panel of the rack/cabinet.

l. All digital output terminals except MCC shall be fused type provided with LED

indication. MCC related digital outputs terminals shall use non fuse TBs.

m. All power terminal blocks shall be provided with fused terminals and LED

indications. All live terminations at a voltage above 60 VAC or DC with respect to

earth shall be protected against accidental contact by covers requiring tools for

removal. Covers shall carry appropriate warning labels.

n. Sufficient space shall be provided between rows of terminal blocks for bending

the field cable and fanning out the leads for maintenance.

o. All unused channels shall be wired up to terminal board. This does not include

wired spares, which shall be wired up to terminal block.

p. Cross ferruling shall be used for all wiring/cabling

q. Instrument signal wiring (analog input/output, digital input) and low voltage alarm

wiring shall be 1.5 mm2, multi stranded, copper wire, shielded twisted pairs. 24

VDC control wiring shall be 2.5 mm2 (digital outputs).

r. All system wiring shall be flame retardant as described in references IEC 60331

and IEC 60332.

s. Interpanel wiring to be minimised. In case of unavoidable the same shall be

followed by use of armoured cable only.



13.1 Each panel, cabinet, console and other equipment in control room shall be provided with

an earthing lug. All these lugs shall be properly secured to the AC mains earthing bus.

13.2 All circuit grounds of electronic instruments, shields and drain wires of signal cables

shall be connected to instrument ground bus, which is electrically isolated from the AC

mains earthing bus. This bus shall be typically 25 mm wide and 6 mm thick copper

conductor.

13.3 The instrument ground bus is connected to independent instrument system ground buses

through insulated wires.

13.4 Bidder’s scope includes construction of redundant earth pits based on system

requirements for the complete system. Minimum four earth pits – 2 for frame earth and 2

for signal earth shall be constructed by vendor.

13.5 Bidder is responsible to meet all earthing requirements for the system provided by them.

13.6 The earth pit shall be made using 12”x12”x12mm size tinned annealed copper plate, with

dual 25mmx3mm copper strip of suitable connection along with GI pipe protection. The

earth pit shall have minimum resistance path for protection of system. Scope of supply of

redundant earthing copper cables (as per sizing) from pit to panel and distribution with

proper size tinned copper lugs for termination shall be under Bidder’s scope. Earth bus

bars inside rack room shall also be under Bidder’s scope. Bidder to submit earth pits

drawings, earthing system layout & resistance value of each earth pit before system

commissioning to IOCL for review & approval. The earth pit bus bar shall be covered

with metal-frame for maintenance activity.

13.7 Earth resistance of earth pits shall be meet system requirements and standards.

13.8 Earthing cable shall be minimum as follows –

- Frame Earth :- Separate 16AWG Earthing cables for frame earth

- Signal Earth – Separate 25AWG Earthing cables for signal earth

- Two cables from each earth pit are necessary

- Distance between earth pits and boiler panels is apprx. 200 meters.

- Existing earthing cable tray can be used

Documents that provide key information will be required for review/approval by IOCL.

System Specification Document: Following documents shall be submitted by Bidder

after award of contract.

13) Earthing System

14) Documentation Requirements



14.1 General Specifications and engineering documentation. Cabinets drawing (Layout &

wiring), individual controllers signal lists etc. shall be submitted by Bidder.

14.2 Bidder shall supply System architecture diagrams for complete PLC system showing all

processors, workstations, peripherals, consoles and external devices connected to the

system, including all interconnections between the components or modules.

14.3 Load calculation sheets of communications network and controller, power load

calculation of AC & DC power supply, Heat load calculation of total system offered

including the installed spares as well as components which would be installed in space

reserved for future expansion shall be submitted by bidder

14.4 Loop wiring diagrams, I/O assignment, General arrangements drawings (front, rear,

internal view, with racks and card location) of PDB, system, marshalling & relay

cabinets, Hardware design specification with system architecture diagram shall also be

submitted by bidder.

14.5 Project schedule: The schedule shall be kept updated at all times showing proposed,

revised and actual completions.

14.6 Commissioning Plan: IOCL shall review, comment and approve this plan and return it

to the Bidder for final preparation.

14.7 Periodic Progress Report: This shall be submitted by the Bidder on a regular basis.

Periodicity shall be agreed during kick off meeting (KOM) after placement of

FOA/Purchase order. The report shall indicate the progress made during the preceding

period. It shall show detailed progress of each item as well as cumulative progress

towards schedule completion, expressed as percentage of all items comprised in the

manufacturing schedule. It shall also include detail problem areas, potential future

problems and restraints caused by internal problems of Bidder’s or IOCL’s.

14.8 Hardware and software manuals: These documents shall contain all the necessary

information to install, operate and maintain the system at all levels. They have to be

comprehensive and of the highest professional quality. Examples contained shall be free

of errors.

14.9 Bidder shall be responsible for keeping documentation of supplied PLC system for a

minimum of five years from the date of placement of order. All such records shall be

made available to IOCL upon proper request.

14.10 As built documentation of PLC system shall be provided at final stage after completion

of the site work and commissioning. As built loop wiring diagram of PLC system should

also have details of Junction Boxes with terminal numbers, service of tag, type of relay

contact used etc. along with other system related data.

14.11 Soft copy of all type of documentations shall be provided by Bidder on CD/DVDs for

records.

14.12 Bidder to provide Two nos. portable Hard-Disc (external powered, USB supported) with

shock absorbing case of minimum 1 TB or higher capacity, separately for storage of soft



documentations, PLC system backup. Make of hard disks shall be

HP/Hitachi/Seagate/Transcend/WD.

15.1 Bidder shall test and demonstrate the functional integrity of the system hardware and

software. No material or equipment shall be transported until all required tests are

successfully completed and certified “Ready for Shipment” by the IOCL.

15.2 The purchaser reserves the right to be involved and satisfy himself at each and every

stage of inspection. The purchaser shall be free to request any specific test on any

equipment considered necessary by him although not listed in this specification, as a part

of approval of factory testing procedure.

15.3 Bidder to note that acceptance of any system or the exemption of inspection or testing

shall in no way absolve the Bidder of the responsibility for delivering the system meeting

all the requirements as specified in tender document.

15.4 It shall be Bidder’s responsibility to modify and/or replace any hardware and modify the

software if the specified functions are not completely achieved satisfactorily during FAT.

15.5 Factory acceptance test procedure shall be submitted for approval at least 4 weeks before

the FAT at Bidder works.

15.6 During FAT Bidder shall not replace any system component/module/sub-system unless it

is failed. A log of all failed components/modules in a system shall be maintained. If

malfunction of a component / module in a system repeat, the test shall terminate and

Bidder shall replace the faulty component / module. Thereafter the test shall commence

all over again. If a system fails during the test and is not repaired and made successfully

operational within four hours of active repair time after the failure, the test shall be

suspended and restarted all over again only after the Bidder has replaced the device for

the acceptable operation.

15.7 The inspection and FAT shall be carried out in two phases. The minimum requirements

for testing during these two phases shall be as follows:-

a) Under first phase Bidder shall perform tests at his works to ensure that all components

function in accordance with their respective specifications for each type of test. A

detailed test report shall be submitted to the IOCL for review within two weeks of

completion of each type of test.

b) The burn-in time shall start after the complete PLC system in fully assembled condition

is powered up. Systems shall undergo a minimum of 30 days burn-in period.

15.8 Following tests shall be performed by the Bidder and report shall be forwarded to the

IOCL.

15) Factory Acceptance Test (FAT)



a) Quality control tests shall be carried out to assure quality of all components and

modules in accordance with Bidder’s quality control and assurance procedures. Bidder

shall forward the details of these procedures for IOCL review.

b) System pre test which shall be physical check of all subsystem components, modules

and racks.

c) System Power-up test which shall functionally check the systems hardware and

software including diagnostic software at sub-system level by stimulating the inputs.

15.9 Second phase of test should systematically and functionally test all the hardware and

software in the presence of IOCL representative. All the systems shall be interconnected

to simulate, as close as possible, the total integrated system. Graphics and functionality

testing of interlock and closed loops shall be witnessed by IOCL representative. Bidder

purchased item shall also be connected to the system. Barrier cabinets shall be used as

the connecting points for test inputs and outputs.

The duration of the testing shall be mentioned by the Bidder with reasons. System shall

be shipped to site only after this testing and certified ready for shipment by IOCL.

Following steps will be carried out

Data review: IOCL shall perform a comparison of all current data. Any revision or

changes required shall be informed to the Bidder. The test reports forwarded by

Bidder after first phase testing shall be reviewed. IOCL has right to witness any test

performed in first phase, if deemed necessary.

Visual and mechanical testing : Visual and mechanical testing shall be carried out

in principle to assure correct, proper, good and neat workmanship by the Bidder.

Functional testing: This shall include the simulation of each input and output to

verify proper system response for both analog and discrete signals. The testing, as a

minimum, shall include the following:-

Complete system configuration loading

Demonstration of all Processor functions from local as well as from central level

e.g. changing of running constants, loop tuning, checking of algorithm functions

changing algorithms, changing Processor mode, changing Processor action etc.

Checking of scan time values of open loop & close loop in system & PLC scan

time. Bidder to make suitable arrangement for demonstration of scan time of PLC

system during FAT.

Checking of loop configuration for correctness with respect to ranges, limits,

alarm points, engineering units etc.

Checking of all types of displays including process and system displays on

operator, engineering stations.

System Redundancy checks including correct change-over of the back-up units in

case of main unit failure. This shall be carried out for processors, power supplies,

communication bus and any other redundancy as specified in tender document.

Checking of Processor loading & communication loading.



System diagnostics check for all sub-systems on local level as well as on operator

& engineering stations. These shall include failure of a sub-system, module,

power supply, interface unit, failure of transfer to redundant module on main

module failure etc. and other detailed diagnostic displays. Diagnostic alarms for

any ventilation fan failure shall also be checked.

Testing of proper functioning of all printers and others auxiliary hardware.

Checking of various log formats, shut down reports, I/O mapping and other MIS

formats printing.

Checking of process interlock, complex loops & PLC logics for safe shutdown

for all the units for their proper configuration and operation.

Checking of proper system operation at power supply specifications, interfacing,

communication etc. as specified in the tender document.

Checking of communication bus-degradation while loading the bus from 10% to

100%.

Simulation of power supply failure and restarts, changing the input voltage &

noting down the values at which power supply fail contact actuates.

Checking of all hardwired instrumentation including all alarm cards, alarm

annunciator system, switches and other indicating instruments.

15.10 Testing record

Each test carried out during second phase shall be recorded. Any deficiency or

problem shall be clearly brought-out and shall be corrected.

Any change in the data or configuration etc. informed to the Bidder shall be

recorded and carried out by the Bidder.

During FAT, on random selection basis few power supply, diode O ring etc. shall

be checked for 100% load testing and temperature rise will be observed & record

of the same shall be maintained / compare w.r.t. technical specification of the

same.

15.11 The Bidder shall notify the IOCL at least three weeks prior to final system testing. In the

event that representatives arrive and the system is not ready for testing, the Bidder will

be liable for back charges for any extra time and expenses incurred.

15.12 FAT shall not be commenced unless and until Bidder submits detailed QC test reports.

All engineering like configuration of process interlock, complex loops, and PLC logics

for safe shutdown for all the units shall be completed before starting of FAT. No

engineering shall be allowed to be carried out during FAT except for the punch list.

16.1 IOCL shall provisionally take over the system from Bidder after site acceptance test. Site

acceptance test shall be started only after the satisfactory performance of loop checking,

commissioning and verification of records by Engineer-in-charge.

16) Site Acceptance Test (SAT)



16.2 The site acceptance test shall be carried out in the presence of IOCL representative and

Engineer-in-charge or his authorized representative.

16.3 Bidder shall carry out the following functional tests, as a part of site acceptance test as a

minimum :-

Hardware verification

Visual and mechanical check-up for proper workmanship, identification, ferruling,

nameplates etc.

System configuration as per approved System architecture diagram.

Demonstration of all system diagnostics.

Checking of correct change-over of redundant devices

Checking of proper functioning of all disc drives, alarm summary, printers etc.

16.4 Performance Test (SAT) : IOCL shall take over the system after uninterrupted,

satisfactory, trouble free, fully functional performance test for a period of four weeks (to

check the system stability) after successful commissioning of PLC system in totality &

completion of all SAT punch points at the site. Minutes of meeting shall be made for

recording the date of handover of the PLC system. Warranty of the system shall start

from this date of handover.

16.5 During above Performance test period, any malfunctioning of the system components

shall be replaced / repaired as required free of cost by the Bidder. Once the system

failure is detected, the performance test shall start as a fresh from the beginning.

17.1 Bidder shall make available all consumable, instruments and equipments necessary for

testing, calibration, maintenance etc. as required during commissioning of the PLC

system. All instruments and equipments used for the above purpose shall be of standard

make with accuracy better than the accuracy expected from the calibrated/tested

instruments, and certified by National Physical Laboratory.

17.2 Bidder shall arrange for adequate number of test equipments like meggers, multimeters,

CROs, 2-wire transmitter simulators, thermocouple / RTD simulators etc as required for

testing & commissioning of the PLC system. Also test equipment of adequate

specifications to monitor main system power supply from UPS shall be arranged by

Bidder to establish power quality before system is powered on at site.

18.1 Training : The requirements of training for IOCL persons are given below.

Hardware & Software Maintenance training

- 10 * 5 = 50 Man days for PLC at Bidders works

17) Testing & Calibration Equipments

18) Logistic Support Service



Operation training

- 10 * 5 = 50 Man days for PLC at Bidder's works

18.2 Training shall be provided by the bidder free of cost at bidders works. Travelling and

lodging/boarding costs shall be borne by IOCL.

18.3 Bidder shall be responsible for furnishing details of course outlines, manuals of training,

equipment necessary to conduct the training, exercises to evaluate trainees’ progress.

Bidder shall also be responsible for any other requirements necessary to train the

engineers deputed by IOCL within a time limit so that they acquire the necessary

expertise to operate and maintain the supplied PLC system.

18.4 Training manuals

All training manuals shall be provided during training. After course completion, these

manuals shall become the property of the IOCL.

19.1 Warranty

a) Bidder shall be fully responsible for the system in respect of proper maintenance

& trouble free operation of PLC systems with quality workmanship of industrial

level and operation of all the equipment, accessories etc. supplied by the Bidder

during the warranty period. Warranty of the supplied system shall be as per GPC

of IOCL tender.

b) It shall be obligatory on the part of Bidder to modify and/or replace any

hardware/software and modify the operating software (application and

diagnostic) free of cost, in case any malfunctions is revealed even during online

operation of the PLC system during the warranty period.

c) Bidder shall also provide the total maintenance of the system during warranty

period. The scope of work during warranty period shall be identical / same as

Comprehensive Annual Maintenance Contract (CAMC) as specified in clause no.

19.2 to 19.9.

19.2 Comprehensive Annual Maintenance Contract (CAMC)

a) Bidder shall start the Post warranty CAMC for five years for complete PLC

system (This shall also cover all the bought out items like OPC servers, Printers

& any other hardware as supplied by the Bidder). The validity of CAMC should

be counted after completion of warranty period.

b) The CAMC shall cover supply of all necessary modules / all types of spares /

consumables of supplied PLC system including sub-vendors hardware &

19) Warranty & Post -Warranty Maintenance (CAMC)



software along with all services necessary in maintaining trouble free & reliable

operation of the PLC system.

c) No additional cost shall be payable towards renewal of all types of software

license fees, if any, for PLC system during the CAMC period.

d) The Bidder shall depute well experienced Service Engineer having sufficient

experience & expertise in maintaining the reliable & trouble free operation of

PLC system during the Warranty & CAMC period. It is an obligatory on the part

of Bidder to submit complete bio-data of the Service Engineer having details of

qualification & experience to IOCL for review / approval.

e) In the event of any malfunction of the PLC system hardware / software,

experienced expert service engineer shall be made available at IOCL site within

24 hours on the receipt of such information from the IOCL.

f) The Warranty service & CAMC charges shall include supply of all types of

spares, standard tools & tackles as required for trouble free operation of PLC

system and travel, boarding & lodging charges of service engineer.

19.3 The Post warranty CMAC shall cover following services

Preventive maintenance: Once in a year / planned shutdown, involving complete

overhaul of the system, cleaning of PLC system hardware, making the system dirt

& dust free, inspection of hardware and software, documentation node & Alarm

management system functionality check, fault prediction of the system, inspection

of power supply quality, environmental & operating condition, Earth-pits resistance

checks, calibration checks, major repairs / replacements, configuration of new

modules/chassis if required and submission of detailed structured report format

recording all relevant parameters/data of the PLC system in hardcopy & soft form

to IOCL.

Periodic maintenance: Quarterly, every three months in a year, involves

inspection of general healthiness of the system, study and advice on daily

maintenance including logic modifications, new documents additions in document

node, new configuration in alarm management system, inspection of hardware &

software, if any problem is reported and running of test programs on-line servicing

and solving reported problems. Checks shall be conducted on running system. Each

Quarterly visit shall be of two days each.

Software Maintenance: Maintaining existing system software including antivirus

software to improve and utilize existing application and improve performance of

the system. All modification in all types of software including addition of new

graphic building & graphics modifications as & when required shall be covered

under this scope. All types of software up gradation is also included in the scope of

the Bidder.

Emergency service: The service engineer must report at site within 24 hours of

report of failure, with necessary spares. The system must be brought back in

operation within 24 hours or earlier after reporting at site.



19.4 Bidder shall carry out engineering & configuration of new PLC tags, new graphics

building, communication of new tags with PLC, configuration & commissioning of new

tags as & when required during warranty & CAMC period without any additional cost

implication to IOCL.

19.5 Bidder to note that while carrying out the Post Warranty CAMC activities IOCL

engineers shall associate with system engineers. On-job training of these associated

engineers shall be covered under this scope. The details of modalities of CAMC shall be

finalized with Engineer-In-charge in a structured way.

19.6 Minimum Spares as per attached “List of Spares to be stocked at site at Bidder’s Risk &

cost for PLC” (Annexure-4) of this tender document should be stocked at site separately

to take care of the reliable operation of the PLC system & emergency situation during

Warranty & CAMC period. If the items are to be used from this stock, the same have to

be replaced within one month period from the date of consumption.

19.7 The spares stock as mentioned in Annexure-4 shall be maintained by the Bidder at IOCL

site without any commercial implication to IOCL. IOCL will provide used panel of

system to be made lockable cupboard to store all these items at site during warranty and

CAMC period. However, Bidder to take insurance of all the cards, items to be stored at

site. The faulty hardware shall be taken out from IOCL site by the Bidder as & when it is

replaced with new hardware. The unused spares shall be returned to the Bidder after

successful completion of CAMC.

19.8 If the Bidder fails to restore any system hardware, all types of stations/servers within 10

calender days of intimation including the day of intimation, during warranty & CMAC,

payment will be deducted on pro-rata basis of the quoted quarterly charges of CAMC

from the date of intimation.

19.9 Supply of printer cartridges subject to two nos. of each type per year is in the scope of

Bidder.



PLC I/Os Counts

Signal Type Barrier/

Relay

New DM Plant BXP DM Plant Total I/O

Count of

PLC I/O

Count

25%

Spare Total

I/O

Count

25%

Spare Total

ANALOG

INPUT

Redundant

AI 4 to

20mA

Barrier 120 30 150 100 25 125 275

ANALOG OUTPUT

Redundant

AI 4 to

20mA

Barrier 20 5 25 20 5 25 50

DIGITAL

INPUT

Redundant

DI Relay 400 100 500 400 100 500 1000

DIGITAL

OUTPUT

Redundant

DO Relay 280 70 350 230 58 288 638

1913

Note: Bidder to consider 25% installed spares as indicated.

21.1 The Bidder shall be responsible for the entire job of Programmable Logic Controller

(PLC) in TPS of Barauni Refinery. Bidder to execute the job on LSTK basis and as per

attached specifications and IOCL’s requirement. The offered PLC system shall be of

latest model / version of its range.

21.2 Prior to submission of Techno- Commercial offer, a pre bid meeting shall be held, during

which Bidders shall be given opportunity to ask queries and get clarifications with

respect to the Tender. Bidder is responsible to study the entire tender document &

understands the requirements prior to participating in Pre bid meeting.

21.3 Bidder shall confirm sub vendors service supports for all type of third party systems

supplied with the PLC system for reliable operation during warranty & CAMC period.

21.4 Technical discussions may be held with the Bidders on their un-priced bids/ offers to

address suitability, the functional requirements and specifications as stated in this tender

document.

20) I/O Counts for DCS & PLC System

21) Special instructions to Bidder



21.5 Details of barriers for different types of inputs like analog inputs & outputs etc. shall be

finalized during detail Engineering.

21.6 All barriers & relays should have tag number of the instrument for which it is being used

pasted on them. i.e. 07-FI-0909, 11-FV-565 etc. Spares barriers & relays should have tag

number as “Spare” written on them.

21.7 Online real time display of system architecture (including all PLC & auxiliary hardware)

to be made in graphics so as to monitor healthiness of all system.

21.8 Bidder to provide temperature indication, fan running status, Power feed module status,

Regulated power supply status on a separate graphic for all cabinets. Bidder to consider

these I/Os in addition to I/Os given in clause no. 20 of this tender document.

21.9 Voltage to current convertors with 4- 20mA output shall be provided in AC power

supply in PDB for online monitoring of supplied voltage with trending & alarm

configuration.

21.10 Bidder to provide separate Diode-O ring for each power supply installed to increase

reliability of the system.

21.11 All Process logics & PLC safe shutdown logics of all units, to be made in Graphics for

real time display operator stations for monitoring by the operator.

21.12 Bidder to ensure that 30% spare cable entries of each size shall be provided on the gland

plate with suitable plugs on the provided panels.

21.13 Open free space for office(s), go downs, assembly yard etc. shall be provided free of

charge to the Bidder as per IOCL’s convenience and availability of space. Water and

electricity shall be provided to the Bidder free of charge.

21.14 After placement of PO, Bidder shall submit certified drawings and spec sheet for each

item & its accessories which shall include the following as a minimum for IOCL

approval.

System Architecture diagram

Detailed dimensional drawings of internal component

Power consumption in volt amperes

GA drawings of system, marshalling, relay cabinets & PDBs cabinets

Rack layout including physical I/O modules locations

I/O assignments

Power supply distribution drawings

Load calculation sheets of communications network and controller

Power load calculation of AC & DC power supply

Total Heat load & Heat dissipation figures for each components

Functional design specification

FAT/SAT procedure

Wiring drawings for system cabinets & marshalling racks

I/O mapping with including MODBUS address



21.15 Bidder shall provide heat load calculations for the total system offered, considering the

installed spares as well as components which would be installed in space reserved for

future expansion. These calculations are required to be submitted within a week of

placement of FOA/Purchase order.

21.16 Bidder to indicate in their offer the source of all bought out item & it shall be premium

quality of reputed make. However IOCL’s concurrence regarding bought-out items is

must before finalizing the order.

21.17 Material brought in at site shall not be taken out and all items brought inside shall then

be the property of IOCL and shall be non-returnable. Excess material left out after

completion of the job shall be handed over to IOCL store by the Bidder.

21.18 The offer shall be in following format only. Each section shall be separately segregated

& highlighted with distinct Marker / Flags between the sections. Offer submitted in any

other format shall not be considered for evaluation & summarily rejected.

Section 1: Signed and stamped (on each page) copy of complete specifications shall be

submitted as a confirmation of acceptance of this tender specification without any

deviations. Bidder to fill values in Bidder response column wherever it is required to be

indicated, simply writing noted /confirmed in place of value is not acceptable. Bidder to

submit Bidder response sheet duly filled for every clause of tender document in the

following format, without which the offer of Bidder shall not be evaluated.

S. No. CLAUSE NO. DEVIATION TECHNICAL REASON FOR DEVIATION

Section 2: Deviations to specification if any shall be clearly listed under this section. If

there are no deviations, Bidder shall say “NO DEVIATIONS” under this section.

Deviations mentioned elsewhere in the offer shall be considered null and void and shall

not be considered for offer evaluation. In absence of any written deviation clearly

specified in the offer under this section, it will be assumed that all the specifications and

requirements of the subject tender are complied with and No deviations whatever will be

accepted after the placement of order.

Section 3: Complete technical catalogues of supplied PLC system & bought out item

shall be attached against this section. Wherever Bidder has been asked to furnish details

under the technical specifications, the same shall be included in this section.

Section 4: The offer shall be in the Price Schedule Format as given below. Offer in any

other format is not accepted & may be liable for rejection.



Annexure-1 – Proposed Architecture Diagram for PLC system

Annexure-2 – PLC Specification Table

Annexure-3 – Brief list of Sub-Supplier

Annexure-4 – List of Spares to be stocked at site at Bidder’s Risk & cost for PLC

Annexure-5 – Third Party Subsystem Serial Interfacing Requirements

Annexure-6 – System components and requirements

Annexure-7 – Specifications for PLC Workstations

22) References



Annexure-1 Proposed Architecture Diagram for PLC system



S. No Description Details Bidder’s

response

1.0 PLC model no. Bidder to indicate

2.0 Functional requirement Plant shutdown

Plant interlocks

3.0 System configuration Bidder to indicate

Redundant I/O

Redundant communication at all levels

Redundant power supply at all levels

4.0 Processor System

4.1 Functional capability Logic Functions

Timing functions

Least count for timing functions better than

0.1 secs

Registers

Counters

4.2 Interfacing capability bidirectional

4.3 Memory capacity Bidder to indicate

4.4 Memory used Bidder to indicate (shall include base

programs and applications)

4.5 Memory type Retentive

Erasive

Volatile

4.6 In case of volatile memory Confirm battery backup

Indicate battery type

Indicate battery life

4.7 Maximum scan time 100 milli second or better

4.8 Power supply redundancy To confirm

4.9 Processor failure Outputs shall be configurable for fail safe

4.10 Maintenance On line replacement of processor modules

required

4.11 Peak processor load in worst

case

Confirm not more than 60%

4.12 Switchover time Specify switcher over time in worst case

5.0 I/O SYSTEM

5.1 Type Discrete

5.2 Mounting Bidder to specify

5.3 Configuration Redundant I/O

5.4 Maintenance On line replacement of I/O modules

required

I/O status indication at local level and PLC

Annexure-2 PLC Specification Table



ES required.

5.5 Input isolation Optical isolation

5.6 Output isolation Optical isolation

5.7 I/O capability Digital input

Digital output

Analog output

Analog input

5.8 I/O capacity No. of channels in DI module

No. of channels in DO module

No. of channels in AO module

No. of channels in AI module

5.9 Model nos. Digital input module

Digital output module

Analog output module

Analog input module

5.10 Interrogation voltage Bidder to indicate/ 24V DC preferable

5.11 Power supply redundancy for

I/O

To confirm

5.12 I/O rack and processor link To confirm redundant.

5.13 Maintenance On line replacement of I/O modules

required

6.0 Communication system

6.1 Redundancy at all levels Processor – hot standby

Processor – I/O

Communication with third party PLC

6.2 Communication system load Bidder to indicate for worst case

7.0 Programming

7.1 PLC programming Confirm that any PLC can be programmed

from any PLC Engg Station

7.2 Logic forcing Confirm that logic elements can be forced

from any PLC Engg Station

7.3 On line program status Confirm that on line program status of any

PLC can be viewed from any PLC Engg

Station

8.0 Third Party PLC

Communication

8.1 Protocol Bidder to indicate

8.2 Mode Confirm bidirectional

8.3 Redundancy Confirm redundant

9.0 Operator/Engg sub system

9.1 No of Operator Stations Bidder to confirm as per Annexure-1

9.2 Complete Plant operation of

both DM Plants from any OS

Bidder to confirm

9.3 Engineering stations shall have Bidder to confirm



operator station facility along

with all Engineering

functionality

9.4 Tuning Confirm from OS & ES

9.5 All configurations i.e. loop,

logic, system, history, graphics,

alarms, tuning etc. as minimum

functions of Engg. Station.

Bidder to confirm availability

9.6 Engineering stations shall have

operator station facility along

with all Engineering

functionality

Bidder to confirm

9.7 System status For All hardware at ES & thru LEDs at

module level for all hardware

9.8 History Confirm history/ trend availability at all

Operating stations and Engg Stations

9.9 History Bidder to mention minimum period for

which historical trends shall be available



S. No Item Supplier

1.0 Push Buttons, lamps, electric

switches

Teknic

Idec-Izumi

2.0

Circuit Breakers and Fuses

L & T

Siemens

Schneider Electric

GE India

3.0 Barrier/ Back plane mount

barriers

MTL (5000 Series)

P+F (KFD Series)

4.0 Cabinets/Panel/Consoles Rittal

5.0 Relays Omron/OEN

6.0

Optical Fiber Cable

Birla Erriccon

RPG Cables

Sterlite Industries

Uniflex

7.0 Cables

Associated Flexi cables and Wires (P) Ltd.

Brooks Cable Works, Mumbai

Cords Cable Industries Ltd

Delton Cables Limited

Associated cables

KEI Industries Limited

Polycab Wires Pvt. Ltd

Thermopads Private Limited

Finolex Cables Ltd

Torrent Cables Ltd

Cable Corp. Of India Limited

Universal Cables Ltd

8.0 Terminal blocks Wago/Phoenix

9.0 Furniture Godrej

10.0 Cabinets Rittal

11.0 Junction Boxes & Cable Glands

Baliga Lighting Equipment (P) Ltd

FCG Flameproof Control Gears P Ltd

FCG Power Industries

Flameproof Equipments Pvt Ltd

Flexpro Electricals Pvt Ltd

ExProtecta

12.0 Alarm Annunciator

Idec-Izumi Corporation

IIC

ICA

MTL Instruments I Limited

13.0 Network Switches & Firewall Cisco / Netgear

14.0

Regulated Power Supply Cosel

Phoenix

Annexure-3 Brief list of Sub-Supplier



S. No PLC

1.0 Modules

A) Minimum one nos. modules of each type

(Processor module, I/O module,

communication module, power supply module,

etc.) being used inclusive of those used in

consoles. This shall include spares modules for

hardwired instrumentation also.

B) Minimum two nos. of each type of Safety

barriers, Signal converters, Signal multipliers,

relays etc.

C) Minimum two nos. of each type of fuses,

MCBs, Auxiliary relays etc.

D) Minimum one nos. of regulated power supply

unit of each rating.

E) Minimum one nos. of each type of

communication system components such as

hubs, network switches, routers, etc.

2.0 Stations/Servers

A) Minimum one nos. for Operator/Engineering

station

B) Minimum one no. Disks, DVD drive, LED,

switches, lamps, Push buttons, etc. whichever

is higher.

3.0 Printer Cartridges per year

Two nos. of each type

4.0

Annunciator

Power Supply Module, Flasher

Module, Tone Generator Card,

I/O Module, Lamps

A)

Minimum one no. of each type

Fuses B) 10 nos. of each type

Annexure-4 List of spares to be stocked at site at Bidder’s Risk & cost for PLC



Redundant serial communication shall be established between BXP DM Plant PLC and third

party Honeywell make ML200 PLC in RO plant. FO converters, media converters, special

cables, Interfacing cables etc for successful communication is under the Bidder’s scope. The

data received from RO plant PLC shall be further sent to outside network using new OPC server.

IOCL shall provide following to ensure the communication:-

Communication card at third party PLC end

Expert support from third party vendors for establishing communications

Fiber optic cable up to BXP DM Plant control room

Annexure-5 Third Party Subsystem Serial Interfacing Requirements



SN System Component Quantity Location Remark

1 PLC PLC for New DM Plant Dual Redundant

configuration

BXP DM plant rack

room

New DM Plant specific – PDB panel, system cabinet,

marshalling cabinets, relay

cabinets etc

2 PLC PLC for BXP DM Plant Dual Redundant

configuration

BXP DM plant rack

room

BXP DM Plant specific – PDB panel, system cabinet,

marshalling cabinets, relay

cabinets etc

3 PLC Operator stations 2 BXP DM plant rack

room

Common for both DM Plants, Table top installation

4 PLC Operator stations 4 Main DM

Plant Control room

Common for both DM Plants,

Control desk installation

5 PLC Operator stations A4

size color Laserjet

printer

1 BXP DM

plant rack

room

Network Printer connected to all

HMI

6 PLC Engineering station 2 BXP DM

plant rack

room

Common for both New DM and

BXP DM Plant,

Table top installation

7 PLC SOE station 2 BXP DM plant rack

room

Common for both New DM and BXP DM Plant,


8 PLC Engineering station A4 size color laserjet + scan

printer

2 Engineering room

Connected to individual engineering station, with both

print and scan facility, Table top

9 OPC OPC server for

RTDBMS connectivity with outside network

1 BXP DM

plant rack room


10 OPC Firewall 2 BXP DM

plant rack

room

11 Alarm

annunci

ator

24 window alarm

annunciator

2 Main DM

Plant Control

room

To be fixed above operator

station control desk

12 Communication

Communication with third party PLC

2 Bidirectional communication in redundant configuration to be

established between BXP DMP

PLC and existing Honeywell ML200 PLC

13 Commu

nication

Network switches in

redundant configuration

As required

14 Cyber security

Necessary hardware and software to be provided

As required As per Bidder standard

15 Furnitur

e

Computer tables As required

ANNEXURE-6 System components and requirements



A) Specifications for following OPC Server stations :

Feature Technical Specification

General Latest server grade 24 X 7 hour operation, server grade machines

Processor 6th generation Intel® Core™ i5 or i7 or better.

Operating System Preferred Operating System is Microsoft Windows Server 2016

or Microsoft Windows Server 2012 R2, x64 can be provided

Memory (RAM) 16GB DDR4 Memory or better

Slots 1x8 PCIe 3.0 (x16 connector), 1x4 PCIe 3.0 (x8 connector),

1x4 PCIe 3.0 (x8 connector), 1x1 PCIe 3.0 (x1 connector)

Graphics Graphics card suitable with bidder graphics resolution

Storage 3 X 500GB or better

Storage Controller RAID 5 or better

Communication Two 100/1000 Mbps PCIe Networking cards with two ports on each

network card or better

Audio Controller Integrated High Definition Audio (2 Channel)

Speakers Internal Speaker and External 2.0 stereo speaker systems

Add-in cards Optional Serial Port PCIe Card

Storage devices 1 optical drive: DVD-ROM; DVD+/-RW or better

Monitor 24inch Ultra HD 4K Monitor, Anti glare type screen

Power Supply Redundant power supply

Keybord Standard

ANNEXURE-7 Specifications for PLC Workstations



B) Specifications for PLC Operator, Engineering, SOE stations:

Feature Technical Specification

Processor 6th generation Intel® Core™ i7 or better.

Operating System Preferred Operating System is Windows® 10 Professional (64 bit).

Minimum Windows® 7 Professional (64 bit).

Memory (RAM) 16GB DDR4 Memory or better

Graphics One PCI Express® x16 Gen 3 Graphics card suitable with bidder

graphics resolution

Storage 1TB or better

Storage

Controller

RAID 1 or

Bidder system compatible best configuration

Communication Two 100/1000 Mbps PCIe Networking cards with two ports on each

network card or better

Audio Controller Integrated High Definition Audio (2 Channel)

Speakers Internal Speaker and External 2.0 stereo speaker systems

Add-in cards Optional Serial Port PCIe Card

Storage devices 1 optical drive: DVD-ROM; DVD+/-RW or better

Additional

Facility Dual monitor facility to be provided for operator stations only

Monitor 24inch Ultra HD 4K Monitor, Anti glare type screen

Keybord Standard

Common Requirements of all stations :-

1. Power supply shall be universal 110VAC to 230VAC UPS Supply with +/- 5% variation.

2. Stations shall be a latest commercial grade type for use in 24X7 hour continuous

industrial application.



3. Stations shall be Pre-loaded with Operating system, antivirus software and any other

DCS/PLC related system software along with original CD/DVD & all licenses with

lifetime validity.

4. Operating System & the service packs should be latest