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PURCHASE SPECIFICATIONS

FOR

PLC BASED DIGITAL POWER CONTROL ROOM (PCR)

FOR

OIL RIG APPLICATIONS

SPECIFICATION NO. : OR 12273 REVISION NO. : Rev 00 DATE : 23.07.2005 DISTRIBUTION : PI - 4 copies O/C - 1 copy

PREPARED BY CHECKED BY APPROVED BY Sanjay Ahirwar Rajesh Agrawal Dipak Sarma Sr Engr (D) Manager (D) Dy Gen Manager ISSUED BY

CONTROL EQUIPMENT ENGINEERING DIVISION BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

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INDEX

PART 1

COMMERCIAL and OTHER GENERAL TERMS and CONDITIONS

1. Supply of the Equipment

2. Delivery

3. Offer & Prices

4. Terms of Payment

5. Packing

6. Training

7. Manuals and As built Drawings

8. Progress Reports

9. Liquidated Damages

10. Arbitration

11. Jurisdiction

12. Indemnity / Liability

13. Secrecy and security

14. Taxes ,fees and other duties etc

15. Force Majeure

16. General Terms and condition

17. Drawings / document submissions & approvals

18. Acceptance Inspection

19. Correspondence to be addressed to

20. Deputation of experts & services

21. Warranty

22. Installation and commissioning

23. Insurance

24. Deficiencies and defective goods

25. Mode of dispatch

26. Performance bank guarantee

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PART -1

Part I covers the commercial and other various terms and conditions applicable for design, manufacture, supply ,installation and commissioning of PLC based digital PCR and associated equipments as detailed below :-

1. Supply of Equipment & Scope of work (for each set) :

(a) One set of PLC based PCR and associated equipments (Auto Driller (AD),

Mud pump synchronize (MPS), Soft Torque Rotary System (DSTRS)) alongwith commissioning spares, Tools & tackles , 2 years O&M spares, Installation and commissioning for successful execution on turnkey basis.

(b) The equipment should confirm to this BHEL specification and Pre Engineering

survey inputs to be conducted by supplier at ONGC site.

(c) Scope of work also includes commissioning of PCR, Supply of installation items (e.g. sensors ,cables etc) for Auto Driller, MPS & DSTRS & installation and commissioning of Auto Driller, Soft Torque Rotary system and Mud Pump synchronizer & Interfacing with AC Top Drive system.

(d) Details of all above (a), (b), (c) has been incorporated in “PART – II

TECHNICAL DETAILS & SPECIFICATION OF THE EQUIPMENT”

2. Delivery

The delivery, Ex-works factory, should not exceed 14 weeks incase LOI/PO is placed on the vendor. Supplier to indicate delivery in the offer.

3. Offer & Prices Offer should be given in two bid system :

1) Technical & Commercial offer 2) Price offer Part A – Technical & commercial Bid Shall contain all technical & commercial offer with respect to requirement of specification alongwith all the required documents to be submitted. Any deviation from the specification/commercial terms & condition shall be clearly mentioned in clause wise comments. Unfilled price formats should be submitted with the bid. Part B – Price Bid In price bid, supplier shall quote lump sum price for supply of each major equipment (PLC based PCR system, Auto Driller system, Mud Pump Sychroniser, Dynamic soft torque system for rotary) and lump sum erection & commissioning charges for each item separately. Price bid of only qualified vendor (after scrutiny of technical offer) shall be opened.

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BHEL standard purchase procedures shall be applicable for the tendering system. Prices should be quoted as below : (a) The price should be FOB supplier manufacturing place.

(b) Commercial packing for freighting is included in the prices.

(c) All prices should be fixed prices. No Price variation clause is acceptable. (d) Installation & commissioning charges should be separately given in the offer

(e) Prices for tools & tackles & PCR spare items prices to be covered in PCR

pricing and installation items & spares prices for items such as Auto Driller, MPS & DSTRS to be covered against pricing of respective items. However prices for each item given in the spares list is to be indicated separately also.

(f) Full breakup of the prices for each major equipment (PCR, Autodiller, MPS,

DSTRS) & corresponding installation and commissioning charges to be given by supplier.

(g) No separate charges for suppliers visit to ONGC sites for collecting any

information and pre-engineering surveys shall be applicable. 4) Terms of Payment

Supplier to furnish full details of payment terms & conditions. 10% of the payment for Supply of equipment against Item 1 shall be made after successful commissioning of the system. Installation and Commissioning Charges shall be payable after Successful commissioning of the complete system and certification by ONGC.

5) Packing Tropicalisation / Packing of assemblies

The equipment should be fully tropicalised inhibited and packed in sea worthy packing and should be capable of withstanding in sea freight conditions up to 550 C and 100% humidity. Packing shall be ready for export to INDIA and no entry charges for this is acceptable. Approximate overall packing sizes & weight to be informed to BHEL for all dispatch able items one month prior to dispatch by supplier.

Packing of spares / Loose items

Spare parts / loose items to be suitably packed for sea freight. BHEL/ONGC will be informed about preservation procedures to be forwarded by supplier in order to avoid damages during storage time.

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6) TRAINING

As the PLC based PCR is to be supplied along with new generation system/ equipments ie. Auto Driller with KEMS, Mud pump synchronizer and Soft torque system for rotary. Coordination of the above equipment with the PLC based ACSCR system is the fundamental requirement to keep the system operational for precise and safe drilling function. Training on above associated systems/equipments is required in the area of operation, maintenance & trouble shooting. Provision for training for six personnel of ONGC and BHEL at the supplier works is to be provided free of cost. The training shall consist of a week long training for each of the three systems which shall include class room lectures and training with simulators for above systems. If required, training of above six personnel can be split in to two batches. To and Fro travelling and stay charges shall be borne by BHEL/ONGC. The training course shall be conducted preferably prior to shipment of the system from supplier’s works or within one year from shipment date. Schedule of training is to be informed to BHEL suitably after placement of PO/LOI by BHEL. TRAINING AT SITE

After successful commissioning of the system at site, supplier shall demonstrate the working of the system to ONGC/BHEL representative and shall arrange an exclusive short on job training program for rig crew at site for a duration of one week by commissioning engineer. Schedule of training shall be mutually decided during commissioning of the system at site.

7) Manuals & As built Drawings Supplier shall supply drawing package containing following documents with the supply of equipment : 1) Equipment outline drawings 2) One line drawings 3) Detailed SCR, Generator & Field Control Schematics 4) Detailed PLC communication Schematics 5) MCC outline drawings 6) MCC one line drawings 7) MCC control schematics 8) Plug panel drawings 9) Driller Console & other loose supply items drgs 10) Bill of material of all the items & assemblies supplied. 11) Wiring list / drawings. Following to be provided for each system:

1) Supplier to provide seven (7) sets of “Operations and Maintenance” manuals and seven (7) sets of above as built Drawing Packages in hard print and on CD in PDF format.

2) The PLC operating software to be supplied in the two- (2) laptop computers with two (2) PLC software keys.

3) The system PLC program to be installed in the two- (2) laptop computers.

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4) The system PLC program to be supplied separately on a CD for reloading in case

there would be any corruption of the CPU installed PLC system program. 5) Layout and cable connection drawings to be provided. 6) Pre-commissioning and commissioning schedule. 7) Any Special Instructions

8) Progress Reports

Regular progress report on design, manufacture and supply shall be sent to BHEL by supplier on fortnightly basis in the form of PERT/bar chart.

9) Liquidated Damages

In all cases of delay in delivery caused by supplier, other than a delay prescribed as force majeure, BHEL shall be entitled to claim liquidated damages amounting to 0.5% of the contractual price of the delayed equipment for each additional week of delay. However, such damages shall not exceed 5% of the Contract price of the relevant equipment or part of the relevant equipment or part of it of which delivery has been delayed.

10) Arbitration Any disputes of differences arising in connection with the execution of this Purchase Order shall be taken to a court of Arbitration in terms of the Rules of the International Chamber of Commerce in UK. Ordinary legal proceedings shall be executed - whose award shall be final and binding. The venue for such arbitration proceedings shall be Bhopal, India. The language to be used in the arbitration proceedings shall be English. The arbitral award shall be substantiated in writing

11) Jurisdiction All suits or any matters arising out of this purchase order shall lie in Bhopal Courts only. Rules of the International Chamber of Commerce in UK shall be followed.

12) Indemnity / Liability Supplier would indemnify for its officials. BHEL and ONGC should indemnify for their respective officials. This is a standard international practice.

13) Secrecy and Security

1) Both parties (BHEL & Supplier) shall not disclose to third parties except as may be necessary for the execution of the agreement any confidential, private or proprietary information supplied under this Contract by them.

2) Any confidential or classified information, which has to be made available by

the receiving party to a third party for the execution of this Agreement shall be submitted to such third party with the same restrictions as included in this article.

3) The requirement of this article shall survive termination or completion of the

present agreement for a period of ten (10) years after the execution of the Contract.

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4) ONGC will be considered as a third party only.

14) Taxes, fees and other duties, etc.

All taxes, duties, charges and fees including personnel taxes which may be levied on this Contract in suppliers manufacturing facility country are to be borne by supplier. In case, any income tax is levied on supplier personnel for their services during erection and commissioning in India the same is to be borne by supplier. The Agreement between the Supplier’s manufacturing facility country and the Republic of India for the avoidance of Double Taxation with respect to taxes on Income and capital shall be considered, if applicable.

15) Force Majeure

The acts or omissions of Government in there sovereign capacity and causes beyond the reasonable control of supplier such as fires, floods, epidemics, acts of war, strikes, freight embargo, lockouts at the works of supplier or major sub contractors there is no other source, unforeseen delay in obtaining export license by supplier accidents to Contract items shall constitute force majeure provided :- (i) A notice shall be given to BHEL within fifteen working days of the occurrence

and cessation of such event in supplier works or at the works of there major sub contractors.

(ii) It can be established by supplier on its behalf through documentary proof by the local chamber of the commerce that the events.

1. Had delayed performance of works. 2. Were beyond reasonable control and not due to default or negligence

of supplier. The time for performance of the contractual obligations shall then be extended by

period not more than the duration of such events. If the delay caused by the event continues beyond a period of three months, the parties shall hold consultations to resolve the problem satisfactorily.

16) General Terms and Conditions

In case of common terms and condition laid down in this contract and the general terms and condition for overseas purchase vide enclosed Annexure , the former shall prevail.

17) Drawing / document submission & approval:

i) Prior to manufacturing, all system electrical & mechanical layout drgs are to be approved by BHEL.

ii) Manufacturing schedule shall be furnished by supplier so that BHEL/ONGC can optionally make any visit to the supplier manufacturing plant during engineering and manufacturing.

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18) ACCEPTANCE INSPECTION :

i) Acceptance Inspection & testing shall be carried out at supplier’s facility or any other

facility where supplier can conduct all the tests. Inspection and Testing is to be carried out by a reputed Third party Inspection (TPI) agency as per Test & Inspection procedures approved by BHEL. Supplier to arrange for Third Party Inspection agency. Supplier to furnish details of proposed Third part inspecting agencies in the offer. BHEL/ONGC may also depute their team of engineers to supplier premises to inspect the system in association with third party.

ii) Supplier shall furnish detailed standard specifications, details of tests to be

conducted, test procedure to be followed and test certificate format to BHEL. Test formats shall have minimum and maximum limits of all parameters as applicable to be recorded during testing. These documents to be made available to BHEL at least one month in advance before inspection call to BHEL/TPI. These documents shall be reviewed by BHEL . In case, there will be modifications desired by the BHEL in the documents supplier shall incorporate the same and the revised documents shall be submitted.

iii) Also, supplier shall notify BHEL at least 2 months in advance or 2 weeks after the

drawing approval, the readiness of system for testing & inspection. Schedule of tests along with duration shall be furnished by supplier after placement of PO alongwith test procedures.

iv) No charges for testing and inspection by Third Party inspection at supplier works

according to technical specifications & approved test procedures will be paid by BHEL. All necessary facilities for testing and inspections shall be arranged by supplier free of charge. All expenses for traveling, boarding and lodging for the ONGC inspection staff are to be borne by the ONGC and for BHEL’s inspection staff are to be borne by BHEL..

v) A detailed bounded test report shall be submitted by supplier duly signed by TPI

agency and supplier representative to BHEL without in any way absolving supplier of its contractual obligations.

19) All Correspondence to be addressed to

SR. DGM (MM) SCR BLOCK IV ANNEXE BHEL, BHOPAL – 462021 Tel. No.: 0091-755-201651 Fax no. :0091-755-5201429 dchatterjee@bhelpl.co.in

Contact Person : Mr D Chatterjee

20) Deputation of experts & Services

I) Supplier will depute expert qualified engineers for erection and commissioning & other various activities related to the PCR & associated equipment such as testing, installation, commissioning, trouble shooting.

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II) After installation and commissioning, if the system is not operating as per specifications during warranty period, the same shall be attended by Supplier free of charge.

III) SYSTEM SERVICES

If Supplier has a design situation that requires Supplier service representative to perform services, Supplier warranty services rendered are at no charge with all travel expenses related to warranty service calls at supplier’s account.

Supplier should have/appoint an Indian representative who shall assist supplier during rig-up, installation, commissioning & warranty services.

Supplier Indian representative shall associate with BHEL/ONGC for repair/replacement of warranty parts and shall arrange for shipment of warranty parts to & fro from supplier works and shall arrange the repaired parts/free replacement parts at ONGC site. All expenses towards shipment and custom duties are to be borne by supplier/supplier’s Indian representative.

21) WARRANTY

All and every item of supply will have supplier warranty. Supplier will warranty the products to be free from defects in materials and workmanship and to comply with specification. The warranty is to expire eighteen – (18) months after customer start up date (Provisional commissioning- at No load). In case of repeated/type failures of the components of the system warranty period shall be considered as extended for the time taken by the supplier to stabilize the system. The warranty applies to all supplier manufactured as well as items procured by the supplier from other agencies. Supplier will guarantee/warranty the equipments/components/system to be free from defects in the material and workmanship complying the specification requirement.

I) SERVICING:

Free servicing to the PCR system and associated equipments for 18 months after provisional commissioning shall be responsibility of supplier. After installation & commissioning, if the system is not operating as per specification requirement during warranty period, same shall be attended by the supplier free of cost. Service engineer of the supplier should reach the site in India within 3 days of sending the message.

II) PARTS/COMPONENT FAILURES

In case of parts/components failure during warranty period, BHEL will return the defective parts to supplier Indian representative for repair or replacement by supplier. Failure report received from ONGC site will be sent to supplier. Detailed failure analysis report is to be prepared by supplier after analysis of failed parts at supplier works.

Supplier will replace failed parts without waiting for receipt of defective parts as deemed by supplier and customer.

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Warranty parts/components repair or replacement would be to Supplier’s account and the turn around once received at supplier’s works should not be more than one week ex –works.

If required Supplier’s Indian representative, will be available for warranty calls at Supplier’s account. BHEL will provide help to supplier representative in releasing the defective component from ONGC, if required.

22) INSTALLATION & COMMISSIONING

All the equipment covered in the specification are to be installed and commissioned by supplier in two stages first Provisional commissioning then Final commissioning as explained below.

I) PROVISIONAL COMMISSIONING Provisional commissioning is to be taken up during Rig building period at actual rig site. Schedule of starting date will be communicated by BHEL 15 days in advance. During the provisional commissioning the supplier’s engineer will start up the system and do the preliminary checks and settings required as longer shutdown may not be available during final commissioning when the drilling is going on. Supplier is to furnish the datasheet of pre-commissioning checks 4 week after the placement of PO. Once the datasheet is filled and the tuning of the system is done the rig will be considered ready for start of drilling function. The day the system will be made functional duly meeting all the parameters of the datasheet will be considered the date of completion of pre commissioning and the system will be handed over to customer for start of drilling/spudding. Zero date of warranty will start from the date of submission of pre-commissioning datasheet. Supplier should not take more than 15 days for pre commissioning check.

II) FINAL COMMISIONING Final commissioning of the system is proposed to be done when the drilling is going on at about 1200 meter depth as this is the approximate right depth for checking operation of soft torque, auto-drill, Mud pump synchroniser. Supplier is to furnish data sheet for final commissioning checks within 4 weeks of placement of PO. Final commissioning and final tuning of the system is to be completed within one week.

EQUIPMENT SHALL SAID TO BE COMMISSIONED, IF ALL THE FOLLOWING ACTIVITIES ARE COMPLETED. a. Supplier will successfully ready (start-up) the equipments limited to the PCR,

Transformer Skid and the Mud Pump Synchronizer, Soft Torque Rotary System and Auto Driller and all other supplier supplied items.

b. Provisional commissioning (No load) by Supplier will be done at time of completion of supplier’s successfully ready (start-up) of the equipments limited to the PCR, Transformer Skid and the Mud Pump Synchronizer, Soft Torque Rotary System and Auto Driller and all other supplier supplied items.

c. The system will be accepted as finally commissioned after 1500 M trouble

free drilling or 3 months after provisional commissioning, whichever is

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earlier. Once the equipments limited to the PCR, Transformer Skid and the Mud Pump Synchronizer, Soft Torque Rotary System and Auto Driller are successfully commissioned and proved operational, BHEL will sign the commissioning documents supplied by supplier ,only after 1500 meters of drilling is over or 3 months from provisional commissioning which ever is earlier.

Supplier will stay additional ten (10) days to confirm commissioned equipments limited to the PCR, Transformer Skid and the Mud Pump Synchronizer, Soft Torque Rotary System and Auto Driller and all other supplier supplied items are operational to the individual equipments specified operational parameters and BHEL/ONGC satisfaction .In case there is any occurrence of system trouble during stay of additional 10 days ,the supplier representative is to extend stay till solution and further additional stay will be required to check the functionality.

NOTE: Supplier is required to stay up to the duration of the 1500 M drilling or 3 months after provisional commissioning which ever is earlier. Supplier to decide whether there is need for supplier engineer to stay. If any problem is faced by BHEL/ONGC on the supplier supplied equipments during 1500 m of drilling or 3 months from provisional commissioning, supplier is to provide assistance as per Cl no 20 above.

BHEL shall supply all external PCR cables, cable trays and connections of all external PCR cables, inclusive of labor and tools, except for the tools being supplied by Supplier as per clause 3.1 of part II, except for Transformer Skid - PCR interconnecting cables, Driller Console & MP Console communication cables, Auto Driller cables, MP Synchronizer cables & sensors, DSTRS cables. Installation of auto- driller, Mud Pump synchroniser, DSTRS along with connection of cables, sensors relevant for proper functionality of the system is to be carried out by supplier.

Due to any reason for successful commissioning as per the BHEL specification in the present scope of supply, if modification in the system is required, supplier to carry out such modifications free of cost.

The project is on turnkey basis and any additional special tools; material etc. not normally envisaged presently within the specification shall be in supplier scope for successful installation, commissioning and operation of the equipment limited to of the PCR, Transformer Skid and the Mud Pump Synchronizer, Dynamic Soft Torque Rotary System and Auto Driller and all other supplier supplied items against the PO.

Installation and commissioning charges should be firm irrespective of number of days required for commissioning. Supplier engineer(s) may be required to make multiple trip to ONGC site at supplier’s account for commissioning of the equipment. Supplier to plan the commissioning activities and to inform BHEL about required readiness for commissioning of systems at site.

23. INSURANCE:

Marine insurance will be arranged by BHEL at BHEL cost.

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24. DEFICIENCIES & DEFECTIVE GOODS

BHEL, ONGC and Supplier Indian representative shall jointly inspect the equipment after receipt of the same at ONGC site. Should any deficiency or defect due to design & packaging (other than good(s) is (are) damaged by accident, misuse, and environmental conditions such as lightning, floods, etc) be noticed in the goods during joint inspection same shall be replaced by the Supplier without any extra charge under no charge invoice. Any complaint in regard to the material will be notified to supplier who shall replace same promptly. The rejected material will have to be accepted back by the supplier who will bear its return freight also & the supplier will supply the items through supplier Indian representative customs duty paid.

25. MODE OF DESPATCH

By sea from suppliers manufacturing facility country if outside India.

26. PERFORMANCE BANK GUARANTEE

Supplier will be responsible for furnishing a Performance Bank Guarantee. The Performance Bank Guarantee will cover all the items in the P.O.

Bank Guarantee format will be provided by BHEL Bhopal.

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BHARAT HEAVY ELETRICALS LIMITRED BHOPAL (INDIA) – 462022

GENERAL TERMS & CONDITIONS FOR OVERSEAS PURCHASE ORDER 1. DOCUMENTATION

NON-NEGOTIABLE SET : Comprising of following :-

i. Copy of non negotiable bill of leading. ii. Two copies of signed commercial invoice. iii. Two copies or advice note / detailed packing list in English covering

each item and quantity. iv. Certificate of origin. v. Inspection/material certificate.

DOCUMENTATION CLAUSE :

Advance set of documents as listed in 1.1 above are to be forwarded to the following within 3 days of obtaining bill of leading through any international courier service so as to reach us within 10 days from the date of despatch material. Failure to do so will make the supplier responsible for making good any lose. Please note that the insurance by BHEL does not absolve the supplier from the responsibility of defective / bad packing, short/wrong supply. Details like BL with date, P.O.no. and value should be furnished by fax to the concerned Sr. Manager (mm). (i) Sr. manager (M.S.) ROD. (ii) Branch Manager, Bharat Heavy Electricals Ltd. United India Insurance Co.

World Trader Center, Center 1 9 – C, Indrapuri, BHEL 14th/15th FLOOR Cuffe Parade, COLABA BHOPAL (INDIA) PIN : 462022 MUMBAI 400005 Tel : 2180740 Phone 0755-2756806 / 2757819 FAX : 022-21877850. Fax : 0755-2555261 TLX : 022-82067 & 85390.

(iii) Sr. Manager (MM) FE, Administrative (iv) Manager (FIN) FP Building, BHEL, BHOPAL (INDIA) Administrative Bldg.BHEL, PIN: 462000. TELEX : 0705 265 Raisen Road, Piplani, 364, 365 CABLE BHOPAL: 462022 INDIA BHARATELEC, -BHOPAL (Two sets) Tlx: 0705/265/364 &365

Fax: 0755-540425 & 547591

Fax confirmation indicating full details of shipment i.e. P.O. No., Vessel Name, BL details, Material, Quantity and consignment value to be sent to other agencies as well at point 1.1.1. above, immediately after shipment/air freight.

NEGOTIABLE SET:

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Original documents will be given to the bank for payment against LC. Bank in turn will deliver these documents to BHEL Bhopal/Bombay and then BHEL would clear this consignment through customs. We would provide non- negotiable document to BHEL Bombay as soon as shipment is made so they can process requisite paper work for the custom clearance purpose. Original document would come from LC negotiating bank to BHEL Bhopal/Bombay in due course before shipment arrives at Indian Port.

INSTRUCTIONS FOR DOCUMENTS:

(i) Signed invoice should indicate quantity and value of all items supplied. If items is

supplied in sets, the quantity and value or pieces making each set should be indicated. For supply of spares (including spares supplied with main equipment) sale value break up should be indicated item wise. Split up value is a must together with consolidated value. Also items being supplied should be linked with purchase order, serial no. “Short shipments, if any, should be indicated clearly with quantity and value in the invoice. At the time of subsequent shipment of short shipped, items reference of original invoice should be indicated”.

(ii) In case of free supply: it should be indicated if supply is against short shipment or

replacement together with earlier shipment details and forward documents as per 1.1. and 1.2 above. Invoice should indicate value of material for customs purpose.

(iii) Packing list should include package wise details and each item clearly identified

with the respective packing list.

(iv) Any demurrage/wharfage paid at the ports because of delay/ discrepancy in the above documents will be to the account of supplier or their representative.

(v) For correspondence and documentation, language must be English.

2. CASE MARKING:

Following details should be clearly marked on each case: (i) Shipper: NOI (ii) Consignee : BHEL (BHOPAL) Via MUMBAI (INDIA) (iii) BHEL ORDER NO :________________________________________ (iv) Port of Entry : _____________________________________________ (v) Port of Destination : ________________________________________ (vi) Gross Weight : ____________________________________________ (vii) Net Weight : ______________________________________________ (viii) Brief Description : _________________________________________ (ix) Dimension in cm : _________________________________________ (x) Supplier : ________________________________________________

3. PACKING : Material should be packed suitably in all for normal transport by SEA to India and subsequently by Rail/Road to the destination point in India. It should be suitably

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protected against the effects of tropical salt laden climate. Timber in packing should be free from bark, insects and fungi. Special packing should be provided wherever required in addition to above. Damage to the consignment on account of poor/inferior packing shall be to the account of supplier of their representative. INSTRUCTION FOR PACKING :

(i) A broad red band about 100 mm (4”) vide all round and case just below top

for easy identification of BHEL package at the docks, should be painted. (ii) All marking for safety, handling, storage and protection etc. are to be clearly

marked on the cases as per international practice.

(iii) A special care should be taken in packing of hazardous material with all precautions for safety.

(iv) Proper care should be taken to ensure correct case marking and packing

should be in accordance with the details in Advice Note/Packing list. Any delay in clearance because of wrong case marking will be to the account of supplier or their representative. Similarly, if for any reason whatsoever discrepancies are noticed prejudicing our claim with underwriters/carriers with consequential loss will also be to the account of supplier or their representative.

4. INSTRUCTIONS FOR DISPATCH :

(i) Dispatch per post parcel is strictly prohibited. (ii) Four weeks notice to be given to shipping Agent about readiness of cargo for

finalizing the shipping arrangements. Bank not to be notified as Consignee or Joint Consignee.

(iii) Material to be shipped on board (FOB), port Inland freight, port packing

forwarding to port . to be borne by Supplier.

(iv) Material to be included in container full loads available for booking a container exclusively for BHEL. Otherwise this service is not to be used, without specific advice of purchaser.

Consignee for all item of PO shall be :- DGM (MS) ROD, BHEL World Trade Center (1) 14th/15th Floor, Cuff parade Mumbai – 400 005 Fax :- 0091-22-2187850 Tel :- 0091-22-2180742

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Annexure 01

Draft for Bank Guarantee format for warranty We understand from our customer, Messrs. ...….…..

– Hereinafter called “sellers” – That he has concluded with you the contract ….. for the supply of ….. in the total value of ….. According to the terms of contract, a guarantee for ….. for covering due fulfillment of the warranty obligations by the seller is required. On the instructions of the seller, we, ………………… in …………………., Hereby irrevocably undertake to pay to you an amount not exceeding ……..( say :…..) upon receipt of your first written demand in the original stating that and in which respect the seller has failed to comply with his warranty obligation purpose, please send us your written payment request containing the above declarations together with this document via your bankers requesting them to confirm to us the authenticity of signatures on your demand. Our guarantee expires is to be return of this document to us, latest however on ….. if and so far as we have not received a claim in the original hereunder at our counters in ……………. on or before the date. The document is to be returned to us when our guarantee is no longer required or its validity has expired. This guarantee shall be discharged unless a claim is made on us before 2 months after the validity of warranty period as stipulated in the agreement. We …….. undertake not to revoke this guarantee during its currency (name of bank) except with your previous consent in writing.

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Annexure - 02

Draft for Performance Bank Guarantee This deed of guarantee made this …….. Day of …………, 2003 by ……………………Bank,……………in favour of Bharat Heavy Electricals Ltd., Bhopal-462022 having its registered office at BHEL Bhavan, Siri Fort, New Delhi-110049 with its unit office at Bhopal (hereinafter called the ‘Company’) whereas NOI, ……………………………pin……………..(hereinafter called the ‘Contractor’) have entered in to a Contract with the first party for supply of One sets of PLC based PCR and associated equipments (Auto Driller, Mud pump synchronizer, Soft Torque Drive) alongwith commissioning spares, Tools and tackles and 2 years O&M spares and Erection and commissioning for successful execution on turnkey basis. And whereas the contractor NOI have approached ……….Bank for a guarantee and at their request and in consideration of the arrangement arrived at between the said Contractor and the BHEL, Bhopal the said Bank agreed to give such guarantee as herein after mentioned to aforesaid first party. Now, therefore, these present witness that …..Bank do hereby undertake to the first party a sum of US$ …………….(Dollar………………………………………only) without demur/on demand being made by the said first party and to keep the first party indemnified to the extent of US$…….. (Dollar………………………only) by virtue of this guarantee against any branch in execution of contract without giving prior information to the party of the same (The decision in this respect being solely the discretion of the first party). We further undertake to pay the aforesaid amount in a lumpsum on demand without demur or such part there of as the first party may demand from time to time, irrespective of the fact whether the said contractor admits or denies such claim or questions its correctness in any court tribunal or arbitration proceedings before any authority. The aforesaid guarantee will remain in force and we shall be liable under the same irrespective of any concession for time being granted by the first party to the contractor NOI in or for fulfilling the said agreement between the contractor NOI and the first party irrespective of any change of terms, conditions of stipulations or any variations in the terms of the agreement irrespective of whether notice of such change and or variation is given to us or not any claim to received such notice of any change and/or variation of terms and/or conditions of the said agreement is hereby specifically waived by us. Further we shall not be released from this guarantee by any forbearance of the exercise or non-exercise of any of the powers of rights under the said agreement by the said first party against the contractor irrespective of whether notice of such forbearance, enforcement or non enforcement of any power or rights modification or changes made in the said agreement or concessions shown to contractor NOI by the first party is given to us or not. The guarantee herein contained shall not be determined or affected by the liquidation or winding up or insolvency of or change in the constitution of the contractor NOI but shall in all respects and for all purpose binding and operative until payments of all moneys dues or that may here after becomes due to the said first party is paid in respect of any liability or

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obligation for the contractor under this guarantee subject to however that the first party shall have no right under this guarantee after expiry of six months from the date of completion of the contract unless this guarantee is extended by mutual agreement. Any lastly we, …..Bank undertake not to revoke this guarantee during its currency except with the previous consent of the first party in writing. The Bank hereby declares that it has power to issue this guarantee under the Bank’s memorandum and Article of Association and undersigned has full powers to do so on it’s behalf under the power of attorney dated……………. Granted to him by the proper authorities of the Bank. Notwithstanding anything contained herein :

a. Our liability under this guarantee shall not exceed US$…………(Dollar……);

b. This Bank Guarantee shall be valid up to …………………; and

c. We are liable to pay the guaranteed amount or any part thereof under this

Bank Guarantee only and only if you serve upon us a written claim or demand on or before ……………..

This guarantee must be returned to us for cancellation immediately on expiry. Dated……………the day of …………….., 2003 Bank by it’s constituted attorney.

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PART - 2

INDEX

TECHNICAL DETAILS & SPECIFICATION OF THE EQUIPMENT

1. Dimensional details & constructional features

2. Technical details & specifications

3. Spares, Tools & Tackles

4. General

5. Documents to be furnished by supplier

6. Pre-Engineering Survey

7. Technology Transfer

8. List of Annexure

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TECHNICAL SPECIFICATION FOR DIGITAL POWER CONTROL ROOM FOR OIL RIG APPLICATION

INTRODUCTION :

This specification covers the requirement for design, manufacturing, supply & commissioning of PLC based PCR with AC SCR system for drilling oil rig application along with associated equipments on turn key basis. The associated equipments shall consist of Built-in Auto Driller with KEMS, MP Synchronizer and Dynamic Soft Torque System for Rotary alongwith commissioning spares, tools, tackles and two years O & M spares. The PLC based PCR system should be capable of operating two draw works motors, three mud pumps(2 motors each) and one independent rotary table motor. The system shall also have provision for feeder circuit breaker to Top Drive.

The above requirement is for land rig No-E2000-3 presently operating in southern part of India. Presently, the rig is operational with DC-DC controls & drive systems and is to be upgraded to AC-SCR power drive system with digital AC & DC modules & PLC controls. The general requirements of the system shall be as per this specification however for any specific details, if required, supplier can conduct pre-engineering/tender survey of the rig.

1.0 DIMENSIONAL DETAILS & CONSTRUCTIONAL FEATURES :

PLC based digital power control room mainly consist of following shall have following limiting dimensions :

1. PCR control house : 11 Meter (L) x 3 Meter (W) x 3.25 Meter (H))

2. Transformer skid : 6M (L) x 3 Meter (W) x 3.25M (H)

3. Drillers Console : 0.95 M(L) x 0.375 M (W) x 0.85 M (H)

4. Mud Pump Console : 0.75 M(L) x 0.350 M(W) x 0.65 M(H)

Supplier to furnish dimensional drgs of each of above item along with dimension of other items such as AD, MPS & DSTRS consoles is to be furnished by supplier with offer.

General construction features of PCR :

The Digital power control room (Single PCR i.e. combined MCC & Gen/SCR) shall be an out door, weather proof, transportable steel housing with self-supporting skid suitable for oil field application . The total weight of the PCR house shall not be more than 30 Tons.

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PCR house columns and ceiling frame will be constructed from structural steel seam welded. The outside shall be fabricated from twelve-gauge sheet steel. All corners are to be formed by bending leaving no sheet edge exposed.

Three of the walls to be insulated with three-inch thick polystyrene block insulation. The floor and the wall with the receptacles and plugs is not required to be insulated. The inside surface of the walls to be finished with a sandwich style insulating board three eight’s of an inch thick with white pebble coating on the interior side and aluminum foil on the exterior side. A rubber neoprene mat should be over the full floor area of the house.

Fluorescent lighting fixtures (2-40WRS) will be supplied for house lighting. Two- (2) 230 volt duplex receptacles (suitable for Indian style 230V plugs) to be provided, one at each end of the house.

Paint should be Commercial Metal Blast Grade (SSPC-SP-6) 1.5 to 2.5 mils anchor profile or equivalent.

Primer Coat should be Sherwin Williams Tile Clad II Lt Gray at 4.0 to 6.0 Mils dry film thickness or equivalent.

Top Coat should be Sherwin Williams VOC. URETHANE Linear White at 2.0 to 3.0 Mils dry film thickness or equivalent.

(Supplier may offer their standard painting process however should be suitable for Oil rigs application for Outdoor duty)

The PCR can be designed for top lift or bottom lift. PCR shall be provided with four brackets to hold flood light poles of 60.5 mm Nominal bore dia. The details of brackets shall be provided by BHEL. Apart from suitable internal fluorescent lighting, two nos emergency lighting fixture with Nickel cadmium back-up batteries to be provided at both ends in the interior of PCR housing. The PCR shall have two doors one at each end and on opposite sides of the PCR designed to open outside with anti panic crash bar locks. The PCR shall have a recessed panel to feed electrical equipments mounted on the transformer skid such as the primary & secondary side of the transformers and other electrical equipments as required.

The lighting transformer will be provided with a primary of 415 VAC and should be fed from the individual feeders MCCBs from the PCR MCC.

A (2 x 44) lighting circuit panel with 44nos 2pole 20 Amp circuit breakers to be provided for 230V line to line lighting circuits of the PCR.

The power control room shall have suitable air conditioning system consisting of two nos forced cooled, split type air conditioner capable of maintaining 22+/- 2 degrees centigrade temperature with comfortable humidity level operating under ambient temperature of 50 deg centigrade with designed load operating conditions of the PCR. One of the two ACs should be sufficient to maintain requisite level of cooling ie 22+/- 2 deg centigrade in the corridor, so that the 2nd air conditioner shall be 100 % stand by. Cool air ducting of both the ACs can be connected to a common plenum and then can be routed in the PCR house. The vendor shall furnish the rating of air conditioners to be fitted in PCR alongwith required cooling calculation data for selection of air conditioners with respect to air conditioning requirement of PCR. The A/C cooling air & return air path shall be properly ducted with minimum four (4) cool air outlets in the PCR for uniform cooling inside the PCR , proper cooling of the hot pockets and the places where the PLC , Digital modules, electronic cards are

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located. Booster fans in the AC ducting can be provided, if required for proper air circulation. Roof mounted A/C units are not acceptable. General constructional features of Transformer skid :

Transformer skid shall be furnished with top lift or bottom lift transportable, steel structure with self-supporting skid suitable for oil field application, a complete covered roof and all components exposed to the weather to be weather proof for outdoor use.

The transformer skid house columns and ceiling frame to be constructed from structural steel seam welded. The outside shall be fabricated from twelve-gauge sheet steel. All corners are to be formed by bending leaving no sheet edge exposed.

Sides of the transformer skid to be provided with mesh / grid covers to allow sufficient cooling to the transformers & prevent any pilferages etc during rig transportation / rig building.

Paint should be Commercial Metal Blast Grade (SSPC-SP-6) 1.5 to 2.5 mils anchor profile or equivalent.

Primer Coat should be Sherwin Williams Tile Clad II Lt Gray at 4.0 to 6.0 Mils dry film thickness or equivalent.

Top Coat should be Sherwin Williams VOC. URETHANE Linear White at 2.0 to 3.0 Mils dry film thickness or equivalent.

(Supplier may offer their standard painting process however should be suitable for Oil rigs application for Outdoor duty)

Transformer skid to house all transformers (2 Nos 750 KVA & 2 Nos 45 KVA), air conditioner units (2 Nos) and a recessed panel with the transformers hardwired for the ease of connection in the field. The recessed panel will have 600 volt input hardwired to the primary side of the transformers. The secondary side of the transformer will be hardwired to the recessed panel to feed the 415 volts back to the PCR MCC bus.

Sufficient length of the each of interconnect cabling between transformer skid and PCR (1.5M gap between PCR & Transformer skid) to be provided by supplier for connection between the transformer skid equipment and PCR equipment. The cables should be removable from both ends through plug & receptacle arrangement. The cables should be supplied on removable type two tier cable tray arrangement which can be fitted during rig building at site and can be removed during transportation of the rig.

An additional sliding roof should be provided to cover the AC duct & socket board area on the transformer skid. During rig operation this sliding roof shall form a shed over the duct between PCR & Transformer skid.

The lighting transformer will be provided with a primary of 415 VAC and should be fed from the individual feeders MCCBs from the PCR MCC.

If required, the transformer skid to contain a fully enclosed and insulated room to contain the DSTRS, MPS, Auto Driller control units and other electrical components such as lights and power receptacle with associated receptacles and plugs for easy disconnect during rig move. The enclosed insulated room to be provided with air-conditioning from the main duct.

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General cubicle construction features :

Following method is suggested to be adopted for the internal cubicle construction, wiring, tagging etc, however supplier can propose their in-house equivalent or better procedures:

The enclosure sheet steel surface preparation shall include a three-step procedure. Step one is an acid washed using Oakite Cryscoat 747LTS at 120oF. Step two is a rinse using standard city tap water. Step three is a sealer rinse using Oakite Cryscoat Ultra Seal, 27-RL-40 at 110oF. The enclosure finish shall be ANSI 61 Light Gray polyester Ferro 5E-115 Series powder paint applied for a total dry film thickness of three mils / 80 microns. The power application uses an IPSI Power Coating Booth and Electrostatic “Nordson” Power Spray Guns. The paint shall be oven cured at 400oF for 20 minutes.

External equipment identification nameplates, control and instrument identification plates and operating and warning instruction plates are anodized aluminum with markings using a photographic etching process and to be attached with corrosion resistant self-tapping screws or rivets. Internal component identification tags to be laser printed thin plastic film designed to prevent removal. Component tag characters to be minimum 5mm high.

Wiring is to be done with ITT Surprenant Exane. The colour of insulation of all control wiring should be white or light grey. The Exane insulation is an irradiation cross-linked polyolefin compound, which is thermosetting in nature. Exane is rated for 120oC. Conductors are tinned copper, grouped in tied and secured bundles. Wire within the cubicle is 14 AWG minimums. Wire within guarded electronic enclosures may be sized to suit the lower current levels and higher wiring density often present in such devices. Wiring identification markers appear at each end of each wire which cannot be visually traced end to end. The wire numbers correspond to numbers appearing on schematic drawings. All wiring is routed to avoid sharp edges where possible and is protected by bushings and/or auxiliary wrapping where passing over sharp edges, through barriers and at service loops. All terminations are made to allow a minimum of one re-lugging operation.

Ring lugs are used at all critical connections such as CT connections and main bus taps. Components, including modules and printed wiring boards are connected using split lugs allowing removal of the device without removal of screws. No more than two wires or lugs may be attached under any one screw.

All terminal strips to have minimum 2 Nos spare terminals to accommodate any modification required during commissioning / operation.

Hardware for all bus connections shall be Stainless Steel bolts, aircraft locking nuts with nylon inserts suitable for bus bar operating temperature at full load or alternatively hardware with plain & spring washers to be used.

2.0 TECHNICAL DETAILS & SPECIFICATION :

The technical details & specifications covered under this part are broad technical details of the equipments to be supplied. As this project is to be executed by supplier on turnkey basis, if any other item required to achieve the desired performance is to be taken care by supplier during detailed technical offer/engineering of the system.

2.1 ENGINE / GENERATOR CONTROL PANEL (5 NOS).

2.1.1 Salient features of Engine / Generator controls :

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The engine & generator control system shall be suitable for 5 Nos. KATO/BHEL/AEG make 1215 /1430 KVA, 600V, 3-Phase, 50 Hz, 1000 /1500 RPM, 0.7 pf lag alternators driven by Caterpillar D399 engines/Cummins/equivalent diesel engines. Main bus bar to be designed for 75 kA Fault current. Supplier to furnish bus bracing calculations for suitability for 75kA and should perform Hi-Pot test during testing & acceptance inspection.

Control panel shall be suitable for Engine provided with electrical actuator with 40mA(max) at no-load and 160mA at full load extended up to 200mA and Alternator KATO/BHEL/AEG make with short circuit fault current of 75kA when 5 alternators are on line.

Control panel shall be suitable for generator provided with electrical exciter field with excitation requirement of 6 amps current @ 125 VDC or 12 amps current @ 63 VDC.

Control panel to have tinned plated bus bar of adequate design suitable for 600V AC application as per international standard. Connection leads from generator panel to the socket board should be of adequate size to carry 2000A continuous current .

2.1.2 Each engine generator control panel to include minimum following equipment:

Item Qty Description 1. 1 Air circuit breaker Siemens / Merlin Gerin / GE / ABB , 2000 A rated

600V AC, 3-pole, 50 Hz, Draw-out type with adjustable trip. Each breaker to be manually and electrically chargeable, electrically closed and electrically tripped and with auxiliary contacts. Electrical tripping through UV coil of 24 V solenoid. The Generator incomer circuit breaker should be directly interchangeable with the SCR Converter circuit breaker.

The interrupting rating of the breakers will minimally be 75 KA.

Breakers should have auxiliary contacts for control circuits, space heater for panel heater & alternator space heater.

2. 1 Voltmeter, 0-750 VAC; DB40 meter mounted on cubicle door

3. 1 Ammeter, 0-2000 AAC; DB40 meter mounted on cubicle door

4. 1 Kilowatt Meter, 0-2000 kW; DB40 meter mounted on cubicle door

5. 1 Kilovars Meter, 0-2000 KVAR; DB40 meter mounted on cubicle door

6. 1 Power Factor Meter; DB40 meter mounted on cubicle door

7. 1 Frequency Meter, 40-60 Hz; DB40 meter mounted on cubicle door

8. 1 Generator Exciter Amperage; DB40 meter mounted on cubicle door

9. 1 Actuator Amperage; DB40 meter mounted on cubicle door

10. 1 Energy-consumed meter in the form of Kilowatt Hours – displayed on Touch Screen

11. 1 Six- (6) channel Omega CN100 RTD or equivalent meter to indicate three- (3) of six- (6) Stator Winding(s) Temperature and two- (2) bearing temperatures with alarm output relay contact to trip circuit breaker upon high temperature reading.

All RTD’s shall be PT100 or CU 10 in alternators.

12. 1 Engine Control switch "OFF-IDLE-RUN-LOAD" The system is to be designed to allow opening and closing of the circuit breakers at no load.

13. 1 Generator "RUN" Indicating Lamp (White)

14. 1 Generator "ON LINE" Indicating Lamp (Red)

15. 1 Generator “PHASE ROTATION OK” indicating lamp (Green)

16. 1 Generator “SYNC ON” Synchronisation On lamp (Yellow)

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17. 1 Generator “HEATER ON” Space Heater Pilot Lamp. (Yellow)

18. 1 Generator “CB TRIP” Circuit Breaker trip lamp (Red)

19. 1 Manual Engine Speed Adjust Potentiometer

20. 1 Manual Voltage Adjust Potentiometer

21. 1 Phase rotation relay for Sync check

22. 1 The microprocessor based Digital Engine-Generator control module includes a four-line LCD display and a front panel keypad for easy operation and set-up. The fully digital module includes also the following:

• LED Display of status and alarms

• Front service port for programming and monitoring, RS-232, 19.2kbaud

• Rear service port for remote control and monitoring, RS-232, 19.2kbaud

• Working temperature range of -20oC to +50oC (-4oF to +122oF)

• Voltage Regulator: - No load to full load kW voltage regulation of +1% - Response time of one second typical - No load to full load kVAR voltage regulation of +3%

• KW sharing within +10% of its rated kilowatt load from no load to full load provided by a “Master-Slave” circuit

• Electronic Governor: - Speed regulation from no load to full load - Response time of 0.8 second typical

• Frequency / Voltage Scheduled for Engine Operation at Idle Speed

• Maximum load unbalance between engines (one hot, one cold) at all points, no load to full load, +10% of its rated load

• Ramped acceleration and deceleration between idle and run is furnished

• Electronic governor will have high system response, which minimizes actuator wear.

• Reactive power is shared between the generators by reactive power droop compensation – KVAR adjustment will not be required and only for fine tuning

• Automatic load sharing of KW and KVR with no need for initial load sharing.

• Pulse Width Modulation controlled load sharing for new engines

• Exciter power supply, 12 amp maximum current (the exciter current limit is set to suit the individual exciter)

• Exciter power supply maximum voltage is 240 volts (this is set by the choices of the exciter transformer and the generator self excitation requirements)

• Buffered Data Retrieval for viewing and diagnostics

• Real time power calculations

• Field setting of PID controls for speed and voltage regulation

• Alarm panel for easy system diagnostics

• Protective functions built into the module should be : - Reverse Power Trip @ 7%* - Over/Under Frequency Trip @ 10%* - Over/Under Voltage Trip @ 700/500 VAC*

- Over current*

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- Phase Loss - Pulse Pick-Up Failure - Over Excitation Protection - Loss of Excitation Protection Note: *To have visual and Audible alarm

23. 1 Engine protection circuit for following : Engine Overspeed with engine shutdown circuit Engine low lube oil pressure with breaker trip circuit Engine High water, Air, Oil temperature circuit with breaker trip A audible alarm in the PCR with visual indication “Engine Fault” to be provided on the cubicle door. A power supply of 24V DC 10 A is to be connected in parallel to the 24V DC engine alarm power supply for feeding trip solenoid in case of Cummins engines.

24. 1 Selective switching Off control circuit for the engines through a pull to off / twist & pull to off switch provided on the Driller Console

Digital AC control Modules should be suitable to work with all types of engines such as CAT D399, 3512 DITA & 3512B, Wartsilla, Cummins, and Detroit Diesel.

If engines were to change other than what the modules were set up during manufacturing; it should be possible for a field service engineer to recalibrate the AC Control Modules during initial location start up. This calibration process should not be chargeable if required within the commissioning period.

Circuit breakers to be directly interchangeable between the SCR feeders and Generator incomer with no modifications except the trip settings applicable to the place of installment such as an SCR feeder or a Generator incomer.

Circuit breakers to be wired the same in each cubicle and to be supplied with the same number of auxiliary contacts, electrical charging motor, electrical close coil, UV Trip and etc.

The system to be designed to allow the circuit breaker to open and close with no load applied to the circuit breaker unless there is an emergency tripping of the circuit breaker.

The placement of all power resistors in Generator control circuit should be such so that heat dissipation of the resistors should not affect the performance of the digital modules & other electronics in the panel.

2.1.3 SYNCHRONIZING SYSTEM :

The manual synchronizing system shall be designed to manually synchronize the selected generator. Breaker closing should be possible through electrical coil in the breaker with a push button on the individual generator cubicle.

Synchronizing system consisting of components and a sync section display panel which should be conveniently located to easily synchronize each Engine/Generator through high visibility sync lights and synchroscope. The sync section to have the following auxiliary controls and components:

i) Frequency meter

ii) Voltmeter

iii) Associated Generator Synchronization selector switch selectable to Main Bus and Generators 1/2/3/4/5

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iv) One- (1) Basler Veri-Sync Relay or equivalent.

v) Synchroscope.

vi) Lights for indicating synchronization.

As the normal sync check circuit detects the phase relationship of only one phase, a phase rotation relay is to be provided in each generator cubicle to verify that the phase rotation is correct for the generator before the main circuit breaker is allowed to close. An indication light on the Gen cubicle doors to indicate correct phase rotation be provided.

2.1.4 GROUND FAULT SENSING :

The system is to be provided with ground fault detection system with floating neutral and consists of the following items.

Three- (3) AC ground detection lights

One- (1) 600 VAC ground test button

One- (1) AC/DC ground fault relay

One- (1) Percent DC ground detection meter

One- (1) Percent AC ground detection meter

One- (1) set Associated PCB & other components of GF system.

One- (1) Test Push-button

The ground detection systems, such as AC Main bus, DC buses, MCC ground devices, will interface with PLC and activate the audible alarm.

2.1.5 POWER LIMIT CONTROLLER

The Power Limit Controller is to be provided to monitor the KW & “I” Total of each of the engine –generator sets. If either of these parameters reach its limits, the Power Limit Controller will reduce the power being delivered to the loads, so that the load on each generator is held at its limit until the loads on the SCR drives are reduced (by other action) to a level below the generator limit. The Controller to allow for adjustment of each parameter independent of the other. The range of adjustment to allow the Power Limit to be lowered to 80% or raised to 110%. The Controller to have built-in under frequency circuitry, which shall keep the engines operating when sudden engine problems, such as bad fuel, air choking may cause the engine to shutdown. A meter on the Drillers Console to be provided to indicate percent Power Limit. A warning lamp is illuminated on the Drillers Console at a load level just below the power limit. An additional lamp should be provided on one of Generator control panel to indicate Power Limit condition.

2.1.6 HANDS-OFF CIRCUIT (HOC)

The HOC to supply power for the engine actuator starting circuit suitable for supplying CAT D399 or equivalent engines actuator rated for 40-200 mA current and the pulse pick-up circuit in each of the AC generator control modules. The items to be included shall be as follows:

Item Qty Description 1 1 CPT fused on the primary and secondary.

2 1 Single-phase diode bridge.

3 1 Capacitive DC filter

4 1 Voltage clamping circuit.

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5 2 12V Batteries

6 2 Circuit breakers—DC feeders.

2.1.7 TRANSFORMER FEEDER PANEL (1 NO).

The transformer feeder panel to be consisting of the following main equipments:

Item Qty Description 1 1 1250 AF, 1250 Amps, 600 Volt, 3-Pole manually operated ACB, Draw-

Out Type circuit breaker, having breaking capacity of 75 KA at 600 VAC for feeding Top Drive. Make Siemens/Merlin Gerin/GE/ABB

2 2 1000 AF, 1000 Amps, 600 Volts, 3-Pole, manually operated ACB, Draw-Out Type feeder circuit breakers having breaking capacity of 75 KA each for 2 X 750 KVA 600/415V 50 Hz, Delta/Star Dry Type Power Transformer for powering auxiliary AC loads and rig lighting system. These circuit breakers to have a trip unit to trip the circuit breaker in the event of the secondary neutral restricted grounding limiting ground fault current reaches 750 mA. The trip circuit should have a delay timer for setting from 1msec – 10sec to achieve discrimination between tripping of individual MCC earth trip unit and 750KVA main feeder trip unit. Make Siemens/Merlin Gerin/GE/ABB

2.1.8 MAIN TRANSFORMERS :

Following main transformers to be provided :

Item Qty Description 1 2 Power transformers dry type, copper wound, natural cooled, 750 KVA

each, 600/415 volts 50 Hz, primary delta – secondary star with secondary neutral restricted grounding limiting ground fault current to 750 mA (upon reaching 750 milliamps, the system will be designed to trip the associated 750 KVA transformer feeder circuit breaker trip device). Transformers to be provided on transformer skid.

2 2 Lighting transformers dry type, copper wound, natural air cooled, 415-VAC Primary/Secondary 230 volts line to line, 45 KVA each with secondary neutral restricted grounding limiting ground fault current to 750 mA(upon reaching 750 mA, the system will be designed to trip the associated 45 KVA transformer feeder circuit breaker trip device). Transformers to be provided on transformer skid.

3 1 Earth fault indication with audio alarm to be provided for all power and lighting transformer outputs in the PCR.

All the transformers to be dry type, natural air cooled and copper wound. The class of insulation for the transformers should be selected on the basis of estimated temperature rise of the transformers and 50 deg ambient temperature and relative humidity of 95%. Adequate margins between estimated total temperature and

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insulation temperature index to be kept to take care of the hot spots and extreme operational conditions.

Note : Any breaker connected directly to the main 600 VAC bus should have breaking capacity of 75 KA.

2.2 SCR CONTROL PANEL (5 Nos).

2.2.1 Salient features of SCR panels :

Following should be the salient features of the SCR panels :

The SCR Control system and bus bar should be suitable for driving two DW motors, three Mud pumps (each mud pump driven by two DC motors) & one Independent rotary drive motor. All motors will be 1000HP, 750 V DC, separately excited shunt wound motors BHEL 4903CX / GE752R models (BHEL DC shunt motors 4903CX are equivalent to GE752R DC shunt motors). Design should have provision for assigning at least 2 drives from the each SCR panel.

The SCR control system should be an integrated control system for all 1000 HP drilling motor drives and are micro-processor controlled static power converters with digital regulation, drive protection, reference manipulation, sequencing, tune-up diagnostics and communication features.

SCR systems are to be equipped with provisions to interface and operate with Top Drive, KEMS, Soft Torque, Auto Drill, and Mud Pump Synchronizing systems.

Control panel to have tinned plated bus bar of adequate design suitable for 600V AC application as per international standard.

Hardware for all bus connections shall be of stainless steel bolts, aircraft locking nuts with nylon inserts suitable for bus bar operating temperature at full load or alternatively hardware with plain & spring washers to be used.

Each SCR panel to be consisting of the following main equipments:

Item Qty Description 1 1 2000 A rated 600V AC, 3-pole, 50 Hz, 75KA Siemens/ Merlin Gerin/ GE/

ABB make Air Circuit Breaker with adjustable trip, Draw-out type. Each breaker to be manually and electrically chargeable, electrically closed and electrically tripped and with auxiliary contacts. The SCR Converter circuit breaker will be furnished to be directly interchangeable with the Generator incomer circuit breaker. The SCR breakers will have the same auxiliaries as the generators and 24VDC UV coil trip. The Breakers should have under/over voltage & Thermal/Magnetic over current trip functions.

2 1 Voltmeter, 0-1000 V DC

3 1 Ammeter, 0-2000 A DC

4 1 SCR "ON" indicating lamp, (Green)

5 1 6-pulse, 2200 amp @ 750 V DC, vertical forced air cooled puck type SCR Bridge. The bridge shall be protected using semiconductor type fuses with form C contacts, which are activated when the fuse opens. (Bridge should be capable of 2400 amp intermittent duty for Draw works

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applications.) Thyristors in the bridge should have minimum V(rrm) of 2000V.

6 1 Surge Suppression "ON" Indicating Lamp (Green). Surge Suppression will be provided to clamp any transient voltages, which could be damaging to the SCR devices. The surge suppresser will consist of a fused set of metal oxide varistors (MOVs) in each SCR panel.

7 1 Set of DC assignment contactors.

8 1 Cubicle Space Heater. (To be “ON” when SCR is not in operation.)

9 1 The microprocessor based Digital SCR Control Module with LCD display with a front keypad for easy operation and set-up. The fully digital module to have following features:

• LED Display of status and alarms and diagnostics

• Self test feature

• Memory A-D and D-A

• Front Service Port for Programming & Monitoring, RS-232, 19.2kbaud

• Rear Rig Management Port for Remote Control & Monitoring, RS-232, 19.2kbaud

• Working temperature range of -20oC to +50oC (-4oF to +122oF)

• Thyristor firing circuits with "Hard Firing" outputs to insure positive SCR “turn on”. The synchronizing signal originates directly from the AC line.

• High-speed current regulator.

• Automatic current limit, load sharing for motors driving the same shaft and driven by separate armature supplies no setup or adjustment required.

• Individual control of current limit for all drilling functions. Over current gate suppression is software configurable and is set by the current limits. The rotary table torque limit pot will be mounted in the driller’s console.

• Ramp generator on the draw works current regulator to control the rate of rise of motor torque.

• All controls are designed to be "Foolproof"; no preset sequence of operation is required. The operator may push any button at any time and the system will either follow when it is safe or block the command, if it is not consistent with the operation.

• Manual voltage control for testing operation.

• Thyristor gate suppression at approximately 150% of the motor rating.

• "Zero Throttle Interlock", the hand throttle must be returned to zero after an assignment change before the motor can be powered.

• Buffered Data Retrieval for viewing and diagnostics

• Slip detection when driving two motors in parallel.

• Software tuning of controls

• Alarm functions built into the module are: - Phase Loss - Blown fuse - Blower off - Over-current - Power limit - Operational sequence fail - SCR over-temperature

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- Command mismatch

10 1 3 phase 600 V AC 2 HP blower for cooling of the SCR bridges. The motor to automatically start as soon as SCR circuit breaker is closed.

The digital module for the SCR control panels should have self test feature. The module to self check for its inputs and outputs.

Field interlocks such as field loss etc to be included in the system design.

Armature reversing / shunt motor field reversing feature should be available in the system for the DW & Rotary motors.

System to be designed so that in case SCR cooling blower is not working after closing of breaker, SCR panel can not be assigned for drilling function.

2.2.3 Draw works Regenerative Brake

The system to be designed to provide regenerative braking facility to slow the Draw works motors from full speed to a preset cathead speed within 10 to 15 seconds after the foot throttle is released. The power generated by the free wheeling DC motors is to be fed back into the 600 volt bus and absorbed by the engine-generator sets that are on line. During normal operation of the Draw works the regenerative brake should be non-operative. If, at any time of operation the hand throttle or foot throttle reference is reduced sharply and the motor speed is higher that the DW throttle reference from hand/foot throttle, the regenerative brake circuitry operates and reduces the speed sharply to the speed corresponding to reference speed setting of hand throttle. The slope of reduction of speed can also be controlled.

2.3 FIELD SUPPLY CUBICLE

All shunt motor field supplies to be current regulated and digital processor based to ensure same torque and current for Hot & Cold motors. Field supplies to have open/short circuit and motor over temperature protection through calculation of field resistance.

The field supply cubicle should include necessary Field Supply sections for the nine DC motors. The equipment to be consisting mainly of the following:

Item Qty Description 1 3 Field supply for DWA & DWB motor, and Rotary Table motor.

2 3 Dual motor field supplies for Mud Pumps MP1-3 (2 motors for each pump)

3 6 HOA switches for field supplies

4 6 Field current ammeters

5 6 Padlock Lock Out switches

6 3 MPA+B / MPA / MPB field supply selector Switches

7 3 Field imbalance illuminated reset push buttons for dual motor field supplies for MPs, if required for the system.

DC motor shunt Field supplies should be of adjustable design. It should be possible to operate the DC motors with field currents of 30, 40 or 57A at 100 VDC under normal arrangements. However the field currents & voltage should be adjustable to match with the DC motor requirements of BHEL 4903CX / GE752R models.

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DC motor Field supplies to have Hands-Off-Auto (HOA) switch to facilitate energizing of field supplies without drilling function is assigned.

Draw works DWA & DWB field supplies should both be reversing for drilling operations with left hand pipe.

Mud pump field supplies to be designed to facilitate operation of mud pump motors together or individually (A or A+B or B). Corresponding Current limits for mud pump operation with one motor or two motors will be automatic adjustable as per field supply assignment.

2.4 SCR Assignment :

Following is a sample assignment chart

Above assignment chart is an example only and final assignment chart to be furnished by supplier for approval of BHEL/ONGC.

Assignment function to be divided in two parts naming “Tripping Function” for switch positions (7-11) and “Drilling Function” for switch positions (1-5). Switch should have off position at 12’ O clock & 6’ O clock positions.

2.5 AC POWER CONTROL (MCC) PANELS

Following main features of the MCC sections to be provided for operation of AC motor auxiliary loads, Lighting loads and other loads for drill site requirement.

2.51 MCC main bus (415 volts) should be of 2 sections with each section powered by individual 750 KVA transformers through 1250 amps, 415 V, 50 KA incomer MCCBs with a bus coupler inter locked with incomer MCCBs. AC power and lighting loads will be equally distributed between the MCC Sections. MCC section I & II to be provided with Amp meter and voltmeter with voltmeter selector switch.

2.5.2 All the MCC starters should be draw out type. Each starter feeder contained in a

cubicle should have following facilities.

Switch position

SCR1 SCR2 SCR3 SCR4 SCR5

1 MP1 DWA IRT MP2 MP3

2 DWS MP1 IRT MP2 MP3

3 MP1 IRT MP2 MP3 DWA

4 DWS IRT MP2 MP3 ---

5 MP1 IRT DWS MP2 MP3

7 DWB IRT MP2 MP3 DWA

8 DWB MP1 IRT MP3 DWA

9 DWB DWA IRT MP2 MP3

10 MP1 IRT DWB MP2 MP3

11 MP1 IRT DWB MP2 DWA

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- Provision for Remote/Auto/Manual/Off selector by a rotating switch in the front door of cubicle (refer MCC load list for details of features on individual starters to be provided). This is applicable for starters only.

- Protection against Overload & earth fault. SPP(single phase protection) should be provided as additional feature for all 100HP starters (8 Nos)

- Earth leakage relays and ELCBs to have sensitivity of 100mA to 300 mA. - LED type Indications on the individual starter door for Run (red), Off (green),

Tripped (Yellow) - Individual ammeters on the door for each starter. - Resetting switch/pushbutton for O/L trip on the door. - Door interlocks disabling the closing of MCCB in door open condition. - Incoming MCCB of suitable rating. - 415V : 120 V AC Control supply Transformer. - MCB/fuses in the outlet of control supply transformer. - A single phase supply through MCB and relay for motor space heaters,

wherever applicable. Space heaters to be operational in case motor is not energized (except in Off position of the selector switch)

2.5.3 All motor starters should be of DOL type.

2.5.4 All the feeders shall have earth leakage protection of 300 mA sensitivity through ELR

actuated MCCBs with UV release. 2.5.5 Total no of starters & MCCB feeders along with respective rating to be as per the

Annexure 1 & 2. List of annexure is put at the end of the document.

2.5.6 The cabling from EC brake feeder (both power and control cable) should be brought up to the foundation of EC brake control box which should be located at any one corner of the panels inside PCR, a free floor space measuring 2.5 feet & 4 feet should be provided for installation of EC brake power supply module & transformer. Details of the items to be provided is given below.

Item Qty Description

1 1 Space for Baylor Brake Controller & transformer in the PCR.

2 1 Power cables from EC brake feeder in MCC up to the EC Brake transformer space for installation with some extra length for termination .

3 1 DC Output power cables of sufficient length of which one end will be terminated at socket board to a socket suitable for 4 x 16 sq mm power cable of OD 29 (+/- 1) mm and the other end will be left coiled near to the allotted space for installation of Baylor brake controller.

4 1 DC Output control cable ( for joystick) of sufficient length of which one end will be terminated at socket board to a socket suitable for 4 x 1.5 sq mm control cable of OD 14 (+/- 1) mm and the other end will be left coiled near to the allotted space for installation of Baylor brake controller.

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2.5.7 General points for MCC:

1. The Siemens or equivalent MCC to be US NEMA type or equivalent, 6 cans per

vertical section type for size 1 starters and 12 cans per vertical section for circuit breaker of 125 AF, 415-VAC, 50 Hz, with individual breakers. The horizontal bus to be of copper and rated for 1000 AAC. The vertical bus to be copper and rated for 300 AAC. A copper ground bus to run the full length of the MCC line-up.

2. Clear markings for cubicle in service, test & out should be provided. In test position the starter 3 phase power output should remain disconnected from the outgoing connections

3. When a cubicle is drawn out, no live parts should be approachable to prevent accident.

4. All control wiring should be terminated on a strip before being connected to contacts.

5. At least 10 % spares terminals should be provided on each terminal strip. 6. MCC should be painted, as per relevant international standard, suitable for

marine atmosphere. 7. Except MCCB, power contactor and O/L all other equipment should be DIN rail

mounted and all selector switch, ON/OFF switch, meters should be flush mounted on the door to the possible extent.

8. Each wire shall be identified at both ends by self sticking wire markers or PVC ferrules.

9. All bimetal relays should be separately mounted types with connecting links rated for the maximum rating of the respective contactor in the starter module. Each overload relay should have at least 1 NO + 1 NC auxiliary contacts.

10. The electrical components selected for different starter should provide class 10, type-II co-ordination with AC3 duty rated.

11. All contactors should have minimum: 2 No. + 2 NC auxiliary contacts and drop off voltage of the coil should be 75 % of rated voltage.

12. MCCB should be provided with tripping device with inverse time characteristic for overload protection, instantaneous characteristic for SC protection and under voltage protection.

13. All starter panel for auxiliary motors for draw works and mud pumps are to be hooked up with the assignment schemes along with necessary safety interlocks and interconnections inside the PCR & Driller’s Console. The interconnection cables between MCC & SCR to be routed through stud type terminal strips with indelible terminal marking in the socket board for easy identification and trouble shooting.

14. Details of name plate for starters and feeders will be as per the respective load list given in the Annexuresn I & II.

15. Each cubical to have a name plate bearing cubical number, rating of starter/feeder and name & number of the equipment for which it is made of.

2.5.8 Lighting / Space heater distribution panel :

44 nos 2 pole 240V AC feeder circuits to be provided in the lighting panels in the PCR for energisation of external/internal lighting circuits and space heater power supply. Supply to lighting panel (240V AC line to line) to be fed from the output of the 2 x 45 KVA lighting transformers located on the transformer skid.

Lighting Panel to have a change over switch to enable energisation of lighting transformer either through an external 415V AC (line to line) source or through internal MCC 415VAC bus-bar. Plug & socket of proper rating to carry current when both the 45KVA lighting transformers are on, to be provided for feeder

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for external power supply to lighting. Changeover switch functionality can also be achieved by using two circuit breakers, interlocked for normal or shore power, for each transformer (totaling 4 breakers).

Lighting distribution panel MCB feeders to be equipped with ELCB with 100 mA sensitivity as per MCC lighting panel feeder list.

List of lighting feeders is provided in annexure 3 of this document.

Space heaters

The space heater supplies to be suitable for 500 W, 230 VAC rating of the space heaters.

Space heater connections will be required for all the 100 HP AC motors to be provided thru MCC starter of the respective motor. The space heater supply should be cut as soon as the 3 phase supply to the motor is connected thru the main contactor of the respective starter. The space heater supply circuit to be protected thru a MCB of suitable rating.

Space heater connections for all nine DC motors & five alternators shall be provided thru the MCBs in the lighting distribution panel. DC motor space heaters to remain energized, if DC motor blower is not operational. Alternator space heaters to remain energized, if Alternator is not operational.

Any other method proposed by supplier for supply of Space heaters meets the functional requirement can be accepted, if full details are provided by supplier.

2.6 PLUG PANELS & EXTERNAL CONNECTIONS: 2.6.1 The rig external connections from the PCR to different loads and drives should be

through easy removable type plug & receptacles and following should be taken care in the design:

2.6.2 External power connections to Alternators, Top drive feeder and DC motor power connection to be done through single pole power plug & sockets of suitable rating. Plugs & sockets should be suitable to accommodate 300 sq mm flexible copper cable with OD of 35 mm (+/-1 mm). The alternator socket board should be provided with adequate nos. of plugs & sockets per phase to carry 2000A continuous current per phase .

2.6.3 Each of the actuator & MPU signals shall be through two separate 1.5 sq mm x 3 core cables. The exciter field supply, RTD and engine protection circuits shall be connected through a 2.5 sq mm x 20 core cable. Space heater connection for Alternators shall be through MCBs in the lighting distribution panel. The pin configuration for 20 core cable Alternator control connections is enclosed as Annexure-5. Pyle National make star line plugs & sockets should be used for Generator control connections for 3c & 20c cables.

2.6.4 Exclusive 20 Pin plugs & sockets to be provided for shunt fields of DC motors & control connections. The DC motor field supplies to run through 2x6 cores of 2.5 sq mm x 20 core cable. Space heater connections, air flow switch & lock out switch connections to the DC motors shall also be through this 20 core cable. The pin configuration for 20 core cable for DC motor control connections is enclosed as Annexure - 4. Space heater connection for DC motors shall be through MCBs in the lighting distribution panel. Pyle National make star line plugs & sockets should be used for Generator control connections for 20c cables.

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2.6.5 Motors such as AC blower motors for DC drilling motors, lube pumps, liner washers and chain oilers ,which are interlocked with different drives should be connected through separate 4 pin plugs & receptacles on PCR plug panel.

2.6.6 The external connections for AC motors should be through 4-pin industrial, weatherproof plug & sockets of suitable rating for both power and remote start. Plugs & sockets of M/s Appleton USA should be used on the plug panel board for 3 or 4 wire connections AC MCC loads & lighting circuits. Plugs & sockets also to be provided for space heaters for 100HP AC motors (Refer MCC load list). All MCC power plugs & sockets to have three phase and one neutral/ground pin. Earth pin (where ever applicable) and body of each socket & plug should have earthing with earthing bus bar. Wherever neutral is connected to the 4th pin of the socket, only body of the socket to be connected to the earthing bus bar.

2.6.7 Flap covers for rain protection to be provided for socket board including engine/ generator socket panels and to be flushed with the PCR wall.

2.6.8 To avoid damage due to sharp bend and injury to the cable due to its self weight ,sockets should be mounted on socket board of slant stair case design.

2.6.9 Earthing cable from earth bus bar should be brought out without any break before termination at the earth pit. A pass through connection gland to be provided for the user to tie the common ground bus to the earth ground during rig building. The neutral bus and the ground bus to be isolated.

2.6.10 Sufficient redundancy should be provided in sockets consisting of each ratings by quantity proportion and at least one for each rating. PCR socket board to have extra socket holes of each rating with blank covers for use to meet exigency.

2.6.11 Plug & socket of suitable rating to be provided for feeding power from external power supply for rig lighting through selector change over switch.

2.6.12 Plug & sockets to be provided for all motor starter & feeders as per MCC load list.

One no power plug & socket and one no control plug & socket for remote Push button station are required for each of the MCC starters as listed in the MCC section of this document.

2.6.13 10% extra plug and sockets of each type & rating shall be supplied as loose spare items by the supplier. Supplier to furnish list of plugs & sockets used and spare qty supplied. This should be included in the 2 years spares list by supplier.

2.6.14 BHEL shall supply all external cables except the cables for transformer skid & PCR interconnection, Driller Console & MP Console PLC communication cable, all Auto driller cables, all MP synchronizer and all DSTRS cables which are in scope of supply of supplier. The termination of all external cables to the loose plugs & sockets supplied by the supplier shall be the responsibility of BHEL. The outside diameters of cables for Plug grommet sizing is furnished by BHEL in Annexure.

2.7 PLC CONTROL PANEL:

2.7.1 The programmable logic control panel shall have following features for overall SCR

control, inter lock with accessories and monitoring. 2.7.2 The System Host PLC should be a high speed, versatile modular PLC.The PLC to be

used should be suitable for serial communication with remote consoles and other rig components and devices along with complete instruction set with “Built-in” functions.

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2.7.3 PLC should incorporate the SCR bridge assignment logic. 2.7.4 The PLC system shall have provision for 2 nos fiber optic or twisted pair cables. One

of the two cables should be sufficient for communication while both will be communicating at the same time .If one fails to communicate due to cut or damage , communication of data will be maintained through the other cable without any interruption of the system.

2.7.5 Interface with all SCR converter drives via the LAN network. 2.7.6 Interface with controls and indicators of the driller’s console via the field I/O units 2.7.7 Shall provide status, alarm and diagnostic tools via local annunciation functions 2.7.8 Automatic starting of mud pump auxiliaries, super charger pumps with indicating

lights on console 2.7.9 Manual backup for emergency drilling in case of PLC communication failure takes

place. The .bypass (manual back up mode) shall be through twenty (20) conductor cable (not in supplier scope) to be connected between the PCR and the Driller’s Console. the assignment in the bypass mode should allow atleast one drive per SCR. Since 5 SCR cubicles are available 5 drives can be assigned. We suggest five drives IRT,DW A,DW B,MP-1, MP-2 .

2.7.10 Fault storage facility should be available through the PLC in the system with built-in self diagnostic features.

2.7.11 PLC shall have touch screen for all miscellaneous indications for all generators & all SCR panels, indications for various drives, ground faults, power limits, Driller assignment, Hour meter, current & voltage metering, trending of historic data & faults etc.

2.7.12 The PLC of M/S SIEMENS may be offered. If Siemens make PLC is used the details of PLC system shall mainly consist of following:

Description 1 Siemens S7-300 Modular Mini-PLC

2 32 Bit, Fixed & Floating Point CPU

3 Up To 1024 Digital Inputs / 1024 Digital Outputs

4 Up To 256 Analog Inputs / 256 Analog Outputs

5 Complete Instruction Set With “Built-In” Functions

6 Built-In Self Diagnostics

7 System Status & Alarms When Used With Remote Display Screen

8 Fiber Optic / twisted pair wire Communication Capability

9 (1) Remote Graphic “Touch” Screen Display

Note : Above is for reference only. Supplier to furnish full details of PLC offered.

2.7.13 TOUCH SCREEN

The following represents data to be minimally displayed on multiple screens. Miscellaneous indicators

PLC System Communication OK Generator ON (For each Generator) Ground Fault Power Limit

SCR INDICATORS (To be repeated for each SCR panel) SCR ON Bridge Temp Switch B A Blown Fuse Bridge Current Gauge B Blown Fuse Bridge Volts Gauge

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C Blown Fuse Speed Reference Contactor Assignments % Power Limit MUD PUMP INDICATORS (To be repeated for each Pump) MP 1-3 Field ON MP 1-3 Gear Oilier ON MPB Blower ON MP 1-3 Liner Wash ON MPA Blower ON Charging Pump 1 ON Charging Pump 2 ON Charging Pump 3 ON

DRAWWORKS INDICATORS (Repeated for Each Motor)

DW Field ON DW Blower ON

ROTARY TABLE INDICATORS

RT Field On/ RT Blower ON RT Current Limit

GENERATOR CUBICLE INDICATORS (Repeated for Generator Cubicle)

Engine Load-% (Per EIP on Generator Skid) CT- Current Measurement Under/Over Voltage Load Sharing Under/Over Current Reverse Power Phase Loss-Trip Energy-consumed meter in the form of Kilowatt Hours

2.8 INTELLIGENT DRILLER CONSOLE :

2.8.1 DRILLER CONSOLE CONSTRUCTION :

The Driller’s Console to be a pressurized stainless steel enclosure, constructed suitably for installation in Class1, Division 2 locations as per standard NFPA 496 or equivalent standard.

The console should be constructed of 12 gauge No. 304 stainless steel and the hand throttle wheels of solid stainless steel. Each hand wheel will drive two (2) independent potentiometers to provide 100% backup of the throttle function. The console to be water tight and include a gasketed door. The console to be equipped with approved purging for application in a Class I Division 2, Group D Hazardous area. A rig air supply fitting (1/4" BSP male threads) to be provided for connection to an external 85 to 150 PSI air supply. A suitable air filtering & drying system should be supplied with the driller console. An internal pressure regulator is to be provided to

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maintain the internal pressure of the Console. The console should be capable of interfacing with KEMS systems.

The console to have the following standard equipment and features:

Item Qty Description 1 1 SCR Assignment Switch 12 position

2 1 Rotary Table Speed Control (Hand throttle)

3 1 Rotary Table Switch, "FWD-OFF-REV"

4 1 Rotary Table Torque Limit Switch

5 1 Draw works Speed Control (Hand throttle)

6 1 Draw works Switch "FWD-OFF-REV"

7 3 Mud Pump Speed Controls (Hand throttle)

8 3 MUD PUMP “On-Off” selector switch

9 1 Rotary Table Torque Meter Scaled for Amps

10 1 Power Limit Meter

11 5 Generator "ON" Lamps (Red)

12 5 SCR "ON" Lamps (Green)

13 2 Draw works DWA & DWB Blower "ON" Lamp (White) *

14 3 Mud Pump Auxiliaries "ON" Lamps (White) *

15 1 Rotary Table Auxiliaries “ON” Lamp (White)

16 3 Super Charger Auxiliaries “On” Lamp (White)

17 1 Power Limit Lamp (Amber)

18 1 Console Purge Loss Lamp (Amber) * 19 1 Audible alarm activated for items marked (*) 20 1ea. AC, DC Emergency Shutdown Button

21 1 PLC remote I/O

22 1 PLC “BYPASS” Switch One assignment provided in bypass mode

23 Lot Plugs & receptacles for console connection

24 3 Super charger on / off switches

25 5 Selective switching off of the engines (1-5)

26 5 Meters for amperage of Drilling motors (MP1, MP2, DWA, DWB & IRD)

Control circuit to be designed so that Super Chargers can be made operational without mud pumps are assigned.

The “E” STOP will trip all SCR breakers and will cut off the 120V power to the console.

When manual mode is selected one dedicated SCR for one DC motor shall be available. The assignment to be provided is one (1) motor per SCR bay. Since there will be 5 SCR cubicles there could be 5 drilling motors available for emergency operation in manual mode.

The Driller’s console Selective switching off of the engines (1-5) switches will allow the driller to shut off any engine selectively as desired.

Pressure switches for the DW are to be provided in the Driller’s Console. One for High and one for Low

2.8.2 DRILLER'S FOOT THROTTLE

The foot throttle to be manufactured of 12 gauge No.304 stainless steel throughout, built to withstand the environment normally encountered on the rig floor. It should contain dual stainless steel return springs to provide a fail-safe return to the off

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position in the event of the single spring failure. Provisions for a dry air connection to the electrical compartment are to be included. The foot throttle connects directly to the Driller’s console through a three-conductor cable. A spare plug to be provided with the foot throttle.

2.9 MUD PUMP CONSOLE:

The mud pump console should be manufactured of 12 / 14 gauge No.304 stainless steel and the hand throttle wheels of solid stainless steel. Each hand throttle will drive two (2) independent potentiometers to provide 100% backup of the throttle function. The console will be watertight and include a gasketed door. A rig air supply fitting (1/4" BSP male threads) to be provided for connection to an external 85 to 150 psi dry air supply.

The console shall include the following main controls and indicators:

Item Qty Description 1 3 Mud Pump Speed Controls

2 3 Mud Pump "ON-OFF" Switches

3 3 lot

Mud Pump "ON" Indicating Lamps (Green), current & voltage metering

4 - Mud Pump Console Purge loss light and console pressure switch required, as the console will be located in a classified area.

2.10 AUTO DRILLER, MUD PUMP SYNCHRONISER & SOFT TORQUE ROTARY SYSTEM

2.10.1 AUTO DRILL FEATURE

Built in auto drilling feature should be provided & interfaced with the system, which provides precise control of the Draw works brake in order to automatically drill

in two modes should be provided.

Firstly, when WOB (weight on bit) mode is selected the drill line is fed off to maintain

a preset hook load and in doing so maintains a constant weight on the drill bit.

Alternatively, when set to ROP (rate of penetration) mode the drill line is paid off at a

constant rate so that drilling proceeds at a steady, preset speed. This ROP

capability is particularly useful for "top-hole" section, casing runs and hole reaming

operations.

In WOB mode the system compares the actual bit weight to the desired bit weight

releasing the Draw works brakes to feed off drill line whenever needed. Thereafter,

any increase in bit weight is compared to the corresponding movement of the Draw

works drum allowing the relationship between rotation and weight transfer to be

determined. With this information the system alters the frequency and duration of the

brake release cycle in order to optimize ROP while maintaining a constant bit

weight. In ROP mode the system acts as a speed control device, lowering the blocks at a constant velocity as set by the operator. In order that the drill bit is not overloaded the system will automatically set and hold on the main brake should a preset WOB be reached.

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In addition to it's providing a dual Auto Drilling capability the Auto Driller should also

calculates and displays Ton-Mile usage of the drill line. To ensure reliability & service-ability the Auto Driller should employ a standard PLC

technology. Primarily the system comprises of two main equipment enclosures, a

number of field devices.

The Autodriller Control Unit should be suitable & certified for operation in a Class 1

Division 1 (Zone 1) hazardous area while the Signal Conditioning Unit should be

designed for use in a safe area.

Sensors for the Auto driller -1) Height and 2) Weight etc should be intrinsically safe

for Class 1 Division 1 (Zone 1) use.

All cables, sensors and hardware etc to be supplied by Supplier for complete erection & commissioning of AutoDriller.

Documentation -Seven- (7) data books to include the following documentation:

• System Layout Drawing • Electrical Interconnection Drawing • General Arrangement Drawing(s) • System Operating Manual • Ex Certification Data Book • Calibration and Factory Test Reports.

2.10.2 MUD PUMP SYNCHRONISATION SYSTEM :

Supplier to provide the following equipment & modifications manufactured to the latest IEEE, NEC and NEMA standards for mud pump synchronization.

Item Qty Description 1 1 Mud Pump Synchronizing System along with associated sensors,

cables & modification items for complete installation & commissioning of the mud pump synchronization.

Supplier to provide one Angle Controller for the purpose of synchronizing up to three (3) Mud Pumps. The Shaft angle Controller should utilizes inductive sensors installed on the Mud Pumps frames to detect and control the relative position of pump pistons. The purpose of the system is to reduce pump pressure pulsations by equally spacing the pressure peaks from each pump so that the peak to valley pressure difference is minimized. The system minimizes pressure ripple and eliminates pressure ripple beat frequencies caused by pressure ripples from two or more pumps operating at slightly different speeds. The system automatically accommodates any combination of pump on-line, requiring only that the operator select “Sync” for the pump required to synchronize and adjust the on-coming pump’s speed as the other pumps on-line. The system adjusts the on-coming pump’s speed to match the pump(s) already on-line until synchronization has been achieved. A lamp will indicate when synchronization has occurred. The synchronization controls shall consist of the following :

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Item Qty Description 1 3 Driller’s Console touch pad : “ON-OFF-SYNCH” 2 3 Driller’s Console Indicator : ‘SYNC. COMPLETE”

2.10.3 DYNAMIC SOFT TORQUE ROTARY SYSTEM

Self tuning Dynamic soft torque rotary system Mark-III along with associated sensors, cables & modification items for complete installation & commissioning confirming to NEC, IEEE-45, IEC, USCG and ABS standards or others as per ISO-9001 certificate to be provided. Supplier should ensure problem free interface of the DSTRS with the rig SCR systems or AC Top drive system. The system should work with all major SCR, DC-DC and AC drive system. The system should have suitable DSTRS Driller’s console for control, operating parameters & data entry. Supplier to indicate the approximate size of the console. The DSTRS process controller should be preferably mounted into the SCR Power Control Room (PCR) communicating with the Driller’s Console and interfacing with any SCR manufactured Drive or AC top drive. The DSTRS system should be suitable for interfacing with AC top drive or DC independent rotary drive. All enclosures used for DSTRS to be manufactured in stainless steel and

constructed to NEMA 4X (IP65) standards or equivalent.

Supplier shall submit the detailed features along with Brochures/Technical literature for above feature. All cables, sensors etc are in supplier scope and are to be installed and commissioned by supplier at site.

Supplier to provide interface engineering with supplier furnished SCR or the customer / rig’s SCR / Top Drive system. Seven – (7) sets of operation manuals are to be included with the system.

DSTRS INTERFACING WITH AC TOP DRIVE

The DSTRS system should be suitable for interfacing with top drive The interfacing to be done by supplier along with supply of any sensors and cables required for the interfacing.

3.0 SPARES, TOOLS & TACKLES:

Following tools, tackles & spares to be supplied by supplier along with each system other than specified against any specific clause earlier in this document. The list of spares furnished is for reference purpose & Supplier to furnish the list of spares, tools & tackle as per their system design for erection, commissioning & 2 years trouble free operation. 01 List of tools & tackles 02 Commissioning & 2 years operational spares 03 Spare plugs & sockets (10%) of each type & rating.

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Commissioning & operational spares to be clarified upon completion of system engineering by supplier. Supplier will inform BHEL of any parts or components being obsolete by any of sub-suppliers by a letter of notice

3.1 TOOLS & TACKLES :

Following minimum tools & tackles to be supplied by supplier with the system :

Item Qty Supplier Part No

Description

1. 3 TOOL-Crimping, F/Pins of 2.5 sqmm Control cables

2. 1 TOOL-Crimper, Manual Hydraulic for 300 sqmm cables

3. 1 TOOLS- Rig Tools (Consisting of the Following)

3a. 1 CONN-Tool, Expander, Size 8

3b. 1 CONN-Tool, Taper/Lead, Size 8

3c. 1 CONN-Tool, Insertion, Size 16

3d. 1 CONN-Tool, Insertion, Size 10

3e. 1 CONN-Tool, Removal, F, Size 16

3f. 1 TOOL-Removal Tool f/Amphenol

3g. 1 CONN-Tool, Removal, F, Size 10

3h. 1 CONN-Tool, Insertion, Size 12

3i. 1 CONN-Tool, Removal, Size 16, MOD2

3j. 1 CONN-Tool, Removal, Size 12, MOD3

3k. 2 0-1000ADC Clamp-On Ammeter (Extech P/N 380805)

3l. 1 1000V Crank Megger (AEMC P/N 1250)

3m. 1 Jigsaw (Porter Cable P/N 9543)

3n. 1 25 Piece Jigsaw Blade Kit

3o. 1 300sqmm Cable Cutter (Thomas & Bates P/N 366)

3p. 1 Set of Pyle-National Pin Extraction/Insertion Tool Kit

3q. 1 Vibrating Engraving Tool (Burgess P/N 7417070)

3r. 1 220VAC Drill Motor (Milwaukee P/N 0238-51)

3s. 10 Hard Hats

3t. 10 Safety Glasses

3u. 1 220VAC Soldering Iron (Weller P/N WTCPT-D)

3v. 1 Greenlee Punches ½” – 1-1/2” (Greenlee P/N 7238SB)

3w. 2 1-5/16” Combination Wrench

3x 2 1-1/2” Combination Wrench

3y. 1 T&B Hand Lug Crimper #8 AWG thru #2 AWG (Thomas & Bates P/N TBM-25S)

3z. 3 Tool Bags (Consisting of the Following)

3aa. 1 T&B Hand Lug Crimper #18 AWG thru #10 AWG (Thomas & Bates P/N WT2000)

3bb. 8 Standard Screwdrivers – Various Sizes

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3cc. 5 Phillips Screwdrivers – Various Sizes

3dd. 1 Klein Side Cutters (Klein Tools P/N D213-9NE)

3ee. 1 Klein Diagonal Wire Cutters (Klein Tools P/N D248-8)

3ff. 1 Klein Long-Nose Pliers (Klein Tools P/N D203-7)

3gg. 1 Hacksaw

3hh. 1 Pack Hacksaw Blades

3ii. 1 6” Adjustable Wrench

3jj. 1 ½” Adjustable Wrench

3kk. 1 1” Adjustable Wrench

3ll. 1 12” Slip-Joint Pliers

3mm. 1 Set Nut Drivers ¼” thru ½”

3nn. 1 Set Combination Wrenches

3oo. 1 Set Allen Wrenches thru 3/8”

3pp. 1 Socket Wrench Set (3/8” Drive w/Sockets ¼” to 7/8”)

3qq. 1 Utility Knife

3rr. 1 Set Drill Bits

3ss. 1 Set Taps & Dies

4 2 PLC-SIE, Software,

5. 2 PLC-SIE, Cable/Adptr, USB, PMB

6. 2 METER-Digital Multimeter Fluke 175

7. 1 SCOPE-20MHz, 2CH, Battery Operated

8. 2 HP Compaq Laptop; latest model supplier will consult with BHEL as to a model number repairable in India. Operating system should be Windows XP

9. 2 HP Compaq Desktop PC; latest model supplier will consult with BHEL as to a model number repairable in India. Operating system should be Windows XP

3.2 COMMISSIONING SPARES & 2 YEARS OPERATIONAL SPARES

3.2.1 COMMISSIONING SPARES FOR SCR SYSTEM IN PCR

Item Qty Supplier Part No

Description

1 12 600 A, Fuse, 700V C

2 6 SW-Micro, 250 V, 10A Rated, U/ W000

3 10 Fuse .6A, 500 V c, 10 KIC

4 10 Fuse 2A, 500 V c, 10 KIC

5 10 Fuse 3.5 A, 500 V c, 10 KIC

6 10 Fuse 6A, 500 V c, 10 KIC

7 10 Fuse 10A, 500 V c, 10 KIC

8 10 Fuse 15A, 600 V c, 200 KIC

9 6 Fuse 60A, 1000 V c, KIC

10 6 SCR-2000V, 2293A, 4” Pkg

11 2 RLY-24VDC, 2A2B0C, A, Fixed

12 2 RLY–120 V, 0A0B3C, 10A, BRKT

13 2 RLY-24 VDC, 0A0B3C, 10A, BRKT

14 4 SW-MICRO, DPDT, 15A, 125 VAC

15 5 LAMP-24VAC/DC, U/W GE C-2000

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16 5 BULB-6.3V, 0.15A, Miniature

17 5 LAMP BULB 18 V

18 2 LAMP-130VAC/DC, U/W GE C-2000

19 2 LAMP BULB 130 V, 10 W, Clear

20 3 MOV, 750 VRMS, 2600 J, 70 KA, 1880V

Note : Item 1 SCR fuses rating to be as per the system design

3.2.2 2 YEARS OPERATIONAL SPARES FOR SCR SYSTEM IN PCR

Item Qty Supplier Part No

Description

1 2 Module-AC, Digital For generator panel

2 2 Module-DC, Digital for SCR panel

3 1 Digital field supply unit (single reversing field)

4 1 Digital field supply unit (dual non-revering fields)

5 1 Exciter field supply transformer

6 1 set Control transformers (1 each) all type

7 2 DC Contactor for SCR

8 1 set Relays ( 1 each type)

9 1 Switch 4 position for Generator control

10 1 set Indicating meters DB40 (1 each type)

11 1 Phase rotation relay for generator panel

12 1 Syncronising Switch

13 12 600 A, Fuse, 700V C

14 6 SW-Micro, 250 V, 10A Rated, U/ W000

15 10 Fuse .6A, 500 V c, 10 KIC

16 10 Fuse 2A, 500 V c, 10 KIC

17 10 Fuse 3.5 A, 500 V c, 10 KIC

18 10 Fuse 6A, 500 V c, 10 KIC

19 10 Fuse 10A, 500 V c, 10 KIC

20 10 Fuse 15A, 600 V c, 200 KIC

21 6 Fuse 60A, 1000 V c, KIC

22 6 SCR-2000V, 2293A, 4” Pkg

23 2 Rheostat 1 KOHM, 25W

24 1 Rheostat 1 KOHM, Dual Assy F

25 2 Rheostat 200 OHM, W

26 2 RLY-120VAC, 4A0B0C, 10A, IEC D

27 2 RLY-120VAC, 0A0B4C, 1A, Bifur

28 2 RLY-24VDC, 2A2B0C, 10A, IEC

29 4 SW-MICRO, DPDT, 15A, 125 VAC

30 1 BLWR-G/3B, 600V, 3PH, 2. HP, 50 HZ

31 5 LAMP-24VAC/DC, U/W GE C-2000

32 5 BULB-6.3V, 0.15A, Miniature

33 10 LAMP BULB 18 V

34 2 LAMP-130VAC/DC, U/W GE C-2000

35 2 LAMP BULB 130 V, 10 W, Clear

36 3 MOV, 750 VRMS, 2600 J, 70 KA, 1880V

37 1 PCA PWR LIM CTRL

38 1 PC-DC SLIDE FOR MG CB

39 1 ASSY-GND Leakage Detector

40 1 PC Auctioneering CKT BD

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41 1 PC Voltage feedback

42 1 PC solid state relay ckt board

43 1 PC load monitor & slip detector for MP1-3

44 1 CABLE-ASSY, Profibus, 200 ft.

45 2 CB-2000AF/AT 690VAC, 75KIC, one for Gen & one for SCR panels.

46 1 CB-UVR (YU), 24VDC

47 1 CB-Shunt Closing Release

48 1 CB-Charging Motor, 120VDC

49 1 set PLC Power supply ( 1 each type)

50 1 PLC Processor card

51 1 PLC interface card

3.2.3 COMMISSIONING & 2YEARS SPARES FOR DRILLER CONSOLE

Item DESCRIPTION Supplier Pt No QTY. 1 Hand Throttle, Potentiometers, RTI limit Pot 1 set 2 SW- Assignment 12 position 1 3 SW – MP on/off 2 position with contact blocks 1 4 SW DW For/Rev 3 position with contact blocks 1 5 PCB – auctioneering circuit board 1 6 Relays (1 each type) 1 set

9. Pushbuttons 1 10. Indication lamps 1 set 11. Ammeters 1 12. PLC power supply 1

3.2.4 COMMISSIONING & 2 YEARS SPARES FOR MCC STARTERS & FEEDERS

Item DESCRIPTION Supplier Pt No QTY. 1. Contactors 1 each (All ratings) 1 set

2. Breakers 1 each (all ratings) 1 set 3. Indication lamps (Red, yellow, Green) 2 ea

4. MCC panel HOA & LOR switches 2 ea 5. MCC panel Ammeter (all rating) 1 ea 6. MCC panel ELR card 1 No

3.2.5 COMMISSIONING SPARES FOR AUTO DRILLER

Item No.

Description of Spare Parts Supplier Part No.

QTY

1 Rubber Gasket for Window 5FT

2. LENS-Lexan, KEMS 1 3 10K Potentiometer Contact Assy 1 4 Potentiometer Steel Knob Panel Mount 1 5 SW-3 POS, Maintained, Black 1 6 PB-Operator, Black 1

7 1 N.O. Contact Block for XB4 Switch Series 1 8 226 CPU AC/DC Relay, 16KB Version (24D1 &

16D0) – 2HSC 24VDC Powered 1

9 231 Analog Input Module 4PT 12 Bit 1

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10 232 Analog Output Module 2PT 11 Bit 1 11 Module, Barrier Power Rail 1 12 Driver, Current 4-20mA In/IS-Out 1 13 Barrier-IS Switch Isolator 1

14 Barrier-IS 4 Switch Inputs 1 15 Barrier-IS Pot Converter, 4-20 1 16 Power Supply 24VDC/4.2A 1 17 Circuit Breaker-4AT, 2P, 480VAC, 6KIC 1 18 Frequency to Current Converter 0-5KHz/09-20mA 1 19 TD200 2 x Row Alpha Numeric LCD 1

20 Encoder-Intrinsically Safe 250ppr 1” x 14TPIUNS 1 21. Transmitter-Pressure, 600-3kpsi 1

3.2.6 2 YEARS OPERATIONAL SPARES FOR AUTO DRILLER

Item Description of Spare Parts Supplier Part No.

QTY

1 Rubber Gasket for Window 5FT

2. LENS-Lexan, KEMS 1 3 10K Potentiometer Contact Assy 2

4 Potentiometer Steel Knob Panel Mount 1 5 SW-3 POS, Maintained, Black 4

6 PB-Operator, Black 4

7 1 N.O. Contact Block for XB4 Switch Series 2 8 226 CPU AC/DC Relay, 16KB Version (24D1 &

16D0) – 2HSC 24VDC Powered 1

9 231 Analog Input Module 4PT 12 Bit 1 10 232 Analog Output Module 2PT 11 Bit 1 11 Module, Barrier Power Rail 2

12 Driver, Current 4-20mA In/IS-Out 1 13 Barrier-IS Switch Isolator 1

14 Barrier-IS 4 Switch Inputs 1 15 Barrier-IS Pot Converter, 4-20 1 16 Power Supply 24VDC/4.2A 1

17 Circuit Breaker-4AT, 2P, 480VAC, 6KIC 3 18 Frequency to Current Converter 0-5KHz/09-20mA 1

19 TD200 2 x Row Alpha Numeric LCD 1 20 Encoder-Intrinsically Safe 250ppr 1” x 14TPIUNS 1

21. Transmitter-Pressure, 600-3kpsi 1

3.2.7 COMMISSIONING SPARES FOR MUD PUMP SYNCRONISER

Item DESCRIPTION Supplier Pt No QTY. 1. Lamp Bulb 120V 2 2. PL-LENS, Amber 1

3. FUSE-1.4A, 250V, 10KA, 20MM 10 4. Fuse 1 Amp 10 5. PL-120VAC, Green, NEMA 4X, Class 1 1 6. Diode 1000V 10 7. Lug Fork 18 awg 10

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8. PLC-AB, Rly Otpt, 8 Contacts 1

3.2.8 2 YEARS OPERATIONAL SPARES FOR MUD PUMP SYNCHRONISER

Item DESCRIPTION Supplier Pt No QTY. 1. PLC-AB, Processor Unit SLC5/03 1

2. EEPROM SLC 500 1 3. Filter EMI Filter Power line

PLC-AB, 16 bit analog 1

4. MDUL 1

5. PLC Cable Comm 1 6. Touch Screen 6” 1

7. SW-Proximity Sensor, 1030VDC 1 8. RLY-120VAC, 4PDT, 3A, 14 Blade 2 9. BOARD I/V Converter 1 10. Lamp Bulb 120V 5 11. PL Lens 1 12. FUSE-1.4A, 250V, 10KA, 20MM 10 13. Fuse 1 Amp 10

14. PL-SKT, Oil Tight, 11/16 Mtg. Hole 1 15. Diode 1000V 10

16. CONN-Plug, M, 10C, #16 1 17. PLC-AB, SLC500 Discrete 8-Input 1 18. CONN-Recp, 10F, 16AWG, 0 DGR, SZ12 1

3.2.9 COMMISSIONING SPARES FOR DSTRS

Item DESCRIPTION Supplier Pt No QTY. 1. Lug 750 MCM ½” bolt hole 1

2. Lug 720 MCM 5/8” bolt hole 1 3. Lamp Bulb 120V 2 4. PL Lens 1 5. FUSE-10A, 250V, KIC 10 6. FUSE-1A, 250V, KIC 10

7. KNOB-1-1/2 Dia, S/S, Knurled 1 8. Diode 1000V 10

9. RLY-Current Monitoring Relay 1 10. LUG-Fork, 18AWG, #4, Red 20 11. PCB voltage alternator board 1

12. PCB-Zero Throttle Relay Board 1 3.2.10 2 YEARS OPERATIONAL SPARES FOR DSTRS

Item DESCRIPTION Supplier Pt No QTY. 1. PLC-AB, SLC500, 5/04 Processor 1

2. EEPROM SLC 500 1 3. Filter EMI Filter Power line 1

4. PLC-AB, 16 bit analog MDUL 1

5. PLC-AB, Power Supply Module, 120VAC 1 6. Touch Screen 6” 1

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7. SW- Toggle 1 8. RLY-120VAC, SPDT, 6A TB Relay 2 9. XDCR-50MV=1000A 1 10. Lamp Bulb 120V 5

11. PL Lens 1 12. FUSE-1A, 500V, 10KIC 10 13. Fuse 1 Amp 10 14. PL-SKT, Oil Tight, 11/16” Mtg Hole 1 15. Diode 1000V 10 16. CONN-Plug, M, 4C, #16 1

17. Assy. Module tpp modif 1 18. CONN-Recp, F, 4C, #16-20, 4C 1 19. PCB-Soft Torque Interface Board 1

3.3 SPARE PLUGS & RECEPTACLES

10% plugs & sockets of each type are to be supplied loose as spares with minimum 1 No of each type of plug & receptacle used in the design. Supplier to furnish list of plugs & sockets used and spare qty. to be supplied after placement of PO.

4.0 GENERAL POINTS:

01 Though a broad outline on the requirement has been made, yet the scope should include anything not mentioned but required for completeness of the system to meet the requirement of oil well deep drilling rig (drilling capacity 6100 mtrs depth) and make the same suitable for dismantling, transportation and installation very often in rough and tough conditions .

02 The system offered should have proven performance record and suitable for military grade operation.

03 All relevant safety systems are to be incorporated and safety codes, relevant international codes to be strictly followed. Systems to be designed & manufactured to the latest IS, NEC, IEC, IEEE-45, API 500, and NEMA standards, & should meet all present accepted international standards for the product/application

04 Supplier shall use components/ sub-assemblies only of reputed and proven make.

05 All the equipments covered in the specification are to be installed and commissioned by the supplier at ONGC site. Supplier shall depute their experienced commissioning expert for E & C of the complete system.

5.0 DOCUMENTS TO BE FURNISHED BY THE SUPPLIER: 5.1 Documents to be submitted along with Offer:

01 Complete technical offer in line with requirements of specification. 02 Clause wise comments on all the clauses of the specification. 03 Drawings indicating general arrangement/dimensional outline, block diagram,

overall size, weight etc of the main & associated equipments. 04 Proposed electrical one line schemes. 05 List of recommended spares for the system.

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06 List of parameter/data required by the vendor for the system design. (Data to be collected by the vendor during pre engineering survey, if required).

07 Details of Indian representative authorized by the supplier. 08 Tonnage capacity of air conditioning system proposed by the supplier for the

system with heat loss calculations.

5.2 Documents to be submitted for approval of BHEL after placement of PO: Supplier to submit following documents for approval of BHEL within 3 weeks after receipt of LOI/PO. BHEL to approve or offer comments on the same within one week and send it back to supplier for further action. 01 Pre- engineering survey schedule, if required by the supplier. 02 Submission of outline & layout drawing of main equipment & associated items

with dimensional details. 03 Submission of schematic/logic drgs for the PLC based system including MCC

one line scheme details. 04 Interfacing details of associated equipments ie. AD, MPS, STRS. MPC,

D’Con with main equipment. 05 Plug panel layout & details. 06 Manufacturing Schedule for the system 07 Test & inspection procedure.

6.0 PRE ENGINEERING SURVEY:

After placement of order, supplier shall conduct a pre-engineering survey, if required, of the present rig installation to collect the rig data required to start the system engineering. The necessary interfacing details for associated equipments such as Built in Auto Driller, Mud Pump synchronizer & Dynamic Soft torque system for rotary can also be collected. BHEL/ONGC shall associate with the supplier in getting the required information from the present rig installation. After pre- engineering survey supplier shall confirm that complete information required for the system engineering, installation & commissioning of all the equipments is available.

No separate charges shall be applicable for any pre-engineering survey to be conducted by supplier.

7.0 TECHNOLOGY TRANSFER:

Supplier to spell out their terms and conditions for technology transfer to BHEL on the offered equipment such as line ups and associated engineering for co-production and business sharing for future requirement in India and out of India.

8.0 LIST OF ANNEXURES

vi) Annexure – 1 MCC starter Load list for E-2000-3 Rajamundry rig. vii) Annexure – 2 MCC Feeder load list for E-2000-3 Rajahmundry rig. viii) Annexure – 3 Lighting Distribution panel load E-2000-3 Rajamundry rig

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ix) Annexure – 4 20 pin receptacle pin connections for DC motors. x) Annexure – 5 20 pin receptacle pin connections for Alternators

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Annexure - 1

MCC STARTERS DATA FOR E-2000-3 RIG ONGC Rajahmundry (AP) India S.No Motor Load Application Full Load

Current HOA LOR External Cable Cable OD Remarks

001 100 HP Desander 131A YES 50 sq mmx3/4 c 39mm-45mm DOL Start

002 100 HP Desilter 131A YES 50 sq mmx3/4 c 39mm-45mm DOL Start

003 100 HP Mud Mix-1 131A YES 50 sq mmx3/4 c 39mm-45mm DOL Start

004 100 HP Mud Mix-2 131A YES 50 sq mmx3/4 c 39mm-45mm DOL Start

005 100 HP Super Charger-1 131A YES 50 sq mmx3/4 c 39mm-45mm DOL Start

006 100 HP Super Charger-2 131A YES 50 sq mmx3/4 c 39mm-45mm DOL Start

007 100 HP Super Charger-3 131A YES 50 sq mmx3/4 c 39mm-45mm DOL Start

008 100 HP Spare 131 A YES 50 sq mmx3/4c 39mm-45mm DOL Start

009 60 HP Drill Pipe Racker 78 A YES 35 sq mmx3/4c 30mm-37mm DOL Start

010 60 HP Hydraulic Drill pipe tong 78 A YES 35 sq mmx3/4c 30mm-37mm DOL Start

011 60 HP Hydraulic casing tong 78 A YES 35 sq mmx3/4c 30mm-37mm DOL Start

012 60 HP Hydraulic Tubing Tong 78 A YES 35 sq mmx3/4c 30mm-37mm DOL Start

013 40 HP Water Pump-1 52 A YES 16 sq mmx3/4c 26mm- 30mm DOL Start

014 40 HP Water Pump-2 52 A YES 16 sq mmx3/4c 26mm- 30mm DOL Start

015 30 HP Brake Water cooling-1 45 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

016 30 HP Brake Water Cooling-2 45 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

017 20 HP Trip Tank-1 28 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

018 20 HP Trip Tank-2 28 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

019 20 HP Mud Agitator -1 28 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

020 20 HP Mud Agitator -2 28 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

021 20 HP Mud Agitator -3 28 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

022 20 HP Mud Agitator -4 28 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

023 20 HP Mud Agitator -5 28 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

024 20 HP Mud Agitator -6 28 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

025 20 HP Mud Agitator -7 28 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

026 20 HP Mud Agitator -8 28 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

027 20 HP Mud Agitator -9 28 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

028 20 HP Mud Agitator -10 28 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

029 20 HP Mud Agitator -11 28 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

030 20 HP Mud Agitator -12 28 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

031 20 HP Ground Water Pump-1 28 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

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032 20 HP Ground Water Pump-2 28 A YES 6 sq mmx3/4c 18mm-22mm DOL Start

033 10 HP Recycling Motor 16 A YES 2.5 sq mmx3/4c 18mm-22mm DOL Start

034 10 HP Ezy- Torque 16 A YES 2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

035 7.5 HP Blower-DWA 11.2 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

036 7.5 HP Blower-DWB 11.2 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

037 7.5 HP Blower- MP1A 11.2 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

038 7.5 HP Blower- MP1B 11.2 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

039 7.5 HP Blower- MP2A 11.2 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

040 7.5 HP Blower- MP2B 11.2 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

041 7.5 HP Blower- MP3A 11.2 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

042 7.5 HP Blower- MP3B 11.2 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

043 7.5 HP Blower - IRD 11.2 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

044 5 HP Motorised casing spool 7.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

045 5 HP HP washing unit 7.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

046 5 HP MP1-Liner Flushing 7.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

047 5 HP MP2-Liner Flushing 7.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

048 5 HP MP3-Liner Flushing-MP3 7.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

049 5 HP MP1-Chain Oiler-1 7.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

050 5 HP MP1-Chain Oiler-2 7.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

051 5 HP MP2-Chain Oiler-1 7.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

052 5 HP MP2-Chain Oiler-2 7.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

053 5 HP MP3-Chain Oiler-1 7.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

054 5 HP MP3-Chain Oiler-2 7.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

055 3HP MP1-Mud Pump Lube 4.8A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

056 3HP MP2-Mud Pump Lube 4.8A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

057 3HP MP3-Mud Pump Lube 4.8A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

058 5 HP Fuel Transfer Pump-1 7.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

059 5 HP Fuel Transfer Pump-2 7.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

060 5 HP Chemical Mixing(Treatment tank)

7.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

061 3 HP DW Lube-1 4.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

062 3 HP DW Lube-2 4.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

063 3 HP IRD Lube 4.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

064 3 HP Degasser 4.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

065 3 HP Bug Blower 4.8 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

066 2.5 HP Shale Shaker-1A 4.3 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

067 2.5 HP Shale Shaker-1B 4.3 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

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068 2.5 HP Shale Shaker-2A 4.3 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

069 2.5 HP Shale Shaker-2B 4.3 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

070 2.5 HP Mud Cleaner-1 4.3 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

071 2.5 HP Mud Cleaner-2 4.3 A YES 1.5/2.5 sq mm x 3/4 c 12 mm- 14.5 mm DOL Start

Notes:

1. HOA- Hands Off Auto Switch. In auto mode the starter should pick up corresponding to the Assignment of the function for which MCC is feeding the auxillary. In Hands mode starter shall pick up through MCC.

2. LOR- Local Off Remote Switch. In local mode the starter shall pick up through MCC. In Remote mode the starter shall pickup through remote 3 wire connected Push Button station.

Receptacles to be provided on panel for connection of remote PBS. Cable size 1.5 sq mmx 3 C. Cable OD 12mm to 14.5mm. 3. All starter MCC panels and Receptacle should have identification tags as per the “Application” given in the table. 4. Other details of the MCC starters as given in the MCC section of the main document . 5. Minor changes in the load list, if any, shall be finalized in consultation with ONGC during pre-engineering discussions.

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ANNEXURE - 2

MCC- Feeder Circuit Breakers Data for E-2000-3 Rig ONGC Rajahmundry (AP) India

S No Rating Poles Application Connection

on Receptacle

Cable Size Cable OD Remarks

001 200AT/250AF 3 Compressor-1 R,Y,B,N 50sqmm x 4 core 39-45mm

002 200AT/250AF 3 Compressor-2 R,Y,B,N 50sqmm x 4 core 39-45mm

003 200AT/250AF 3 DSA feeder - 1 R,Y,B,N 50sqmm x 4 core 39-45mm

004 200AT/250AF 3 DSA feeder - 2 R,Y,B,N 50sqmm x 4 core 39-45mm

005 200AT/250AF 4 250 KVA DG set incoming

R,Y,B,N 50sqmm x 4 core 39-45mm

006 100AT/125AF 3 Welding set R,Y,B,G 35sqmm x 4 core 34-39mm

007 100AT/125AF 3 Site office & Canteen

R,Y,B,N 35sqmm x 4 core 34-39mm

008 100AT/125AF 3 Lighting Transformer -1

R,Y,B,G 35sqmm x 4 core 34-39mm

009 100AT/125AF 3 Lighting Transformer -2

R,Y,B,G 35sqmm x 4 core 34-39mm

010 100AT/125AF 3 Spare R,Y,B,G 35sqmm x 4 core 34-39mm

011 100AT/125AF 3 Spare R,Y,B,G 35sqmm x 4 core 34-39mm

012 70AT/125AF 3 BOP Feeder R,Y,B,G 16sqmm x 4 core 26-30mm

013 70AT/125AF 3 ECB Baylor brake unit feeder

1,2,3,4 16sqmm x 4core 26-30mm Cables from feeder to be left loose in the PCR at the place for Baylor brake unit & transformer. External cables from receptacle to Baylor brake unit to be left loose near unit location

014 70AT/125AF 3 Spare R,Y,B,G 16sqmm x 4 core 26-30mm

015 40AT/125AF 3 Spare R,Y,B,G 6sqmm x 4 core 18-22mm

016 20AT/125AF 3 Mud logging Unit R,Y,B,N 6sqmm x 4 core 26-30mm

017 ….AT/125AF 3 PCR A/C -1 - - - Ratings/connections/ cable sizes to be as per A/C requirement and to be decided by PCR

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manufacturer.

018 ….AT/125AF 3 PCR A/C -2 - - - ----do-----

019 20AT/125AF 3 Stabbing Board R,Y,B,G 1.5/2.5sqmm x 4core

12-14.5mm

020 20AT/125AF 3 Spare R,Y,B,N 1.5/2.5sqmm x 4core

12-14.5mm

Notes :

1. All feeder circuit breakers should be suitable for 415 V AC 50 Hz. 2. R to be connected on pin 1 of the receptacle, Y to be connected on pin 2 of the receptacle, B to be connected to pin 3 of he receptacle & N /

G(ground) to be connected on pin 4 of the receptacle. 3. Any other details for feeders shall be as per details given in the relevant MCC section of the main document. 4. Labels/ identifications tags to be put on Feeder and Receptacles along with Rating. 5. Minor changes in the load list, if any, shall be finalized in consultation with ONGC during pre-engineering discussions.

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Annexure – 3

MCC- Lighting Dist Panels Circuit Breakers Data for E-2000-3 Rig ONGC Rajahmundry (AP) India Panel - A S No Rating Poles Application Connection on

3P Receptacle Cable Size Cable OD ELCB 100mA

required Remarks

001 20AT/125AF 2 Mast Light – 1 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

002 20AT/125AF 2 Mast Light – 3 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

003 20AT/125AF 2 Below Substructure – 1 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

004 20AT/125AF 2 Rack Area Flood Light 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

005 20AT/125AF 2 Mud System lights-1 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

006 20AT/125AF 2 Mud System lights-3 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

007 20AT/125AF 2 Gen 1-5 lights - 1 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

008 20AT/125AF 2 Water Tank Area lights 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

009 20AT/125AF 2 Area Flood lights -1 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

010 20AT/125AF 2 Air Drier 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

011 20AT/125AF 2 Instrumentation feeder 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

012 20AT/125AF 2 MP1A space heater 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

013 20AT/125AF 2 MP1B space heater 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

014 20AT/125AF 2 MP3A space heater 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

015 20AT/125AF 2 MP3B space heater 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

016 20AT/125AF 2 IRT space heater 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

017 20AT/125AF 2 Gen-1 space heater 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

018 20AT/125AF 2 Gen-3 space heater 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

019 20AT/125AF 2 Gen-5 space heater 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

020 20AT/125AF 2 MCC-A Test Power 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

021 20AT/125AF 2 MCC-A motor space Heaters supply

1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

022 20AT/125AF 2 SCR House Lighting 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

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Panel – B

S No Rating Poles Application Connection on Receptacle

Cable Size Cable OD ELCB 100mA required

Remarks

001 20AT/125AF 2 Mast Light – 2 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

002 20AT/125AF 2 Mast Light – 4 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

003 20AT/125AF 2 Below Substructure – 2 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES 004 20AT/125AF 2 Derrik Area Flood light 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

005 20AT/125AF 2 Mud System lights-2 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

006 20AT/125AF 2 Mud Pump lights 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

007 20AT/125AF 2 Spare 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

008 20AT/125AF 2 Fuel Tank Area lights 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

009 20AT/125AF 2 Area Flood lights -2 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

010 20AT/125AF 2 ECB Alarm system 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

011 20AT/125AF 2 Dog House AC 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

012 20AT/125AF 2 MP2A space heater 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

013 20AT/125AF 2 MP3B space heater 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

014 20AT/125AF 2 DWA space heater 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

015 20AT/125AF 2 DWB space heater 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

016 20AT/125AF 2 Baylor Brake 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

017 20AT/125AF 2 Gen-2 space heater 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

018 20AT/125AF 2 Gen-4 space heater 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

019 20AT/125AF 2 PCR Cubicle space heater

1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

020 20AT/125AF 2 MCC-B Test Power 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

021 20AT/125AF 2 MCC-B motor space Heaters supply

1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

022 20AT/125AF 2 SCR House Receptacle 1,2,G 1.5/2.5sqmm x 4core 12-14.5mm YES

Notes :

1. All lighting distribution panel circuits are 220 V AC phase to phase 50 Hz. 2. The lighting circuit loads to be equally divided among three phases of the 2 x 45 KVA lighting transformers by supplier. 3. Any other requirements for are to be decided by supplier. 4. Any other details for the lighting circuits distribution feeder shall be as per the details given in the main document. 5. Labels/ identifications tags to be put on Dist. Panel & receptacles. 6. Minor changes in the load list, if any, shall be finalized in consultation with ONGC during pre-engineering discussions.

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ANNEXURE - 4 20 pin plug and socket connection details of DC motors.

Pin No Function Connectivity Remarks

1 + VE FIELD +VE FIELD OF DC MOTOR FOR + SIDE OF FIELD

2 + VE FIELD +VE FIELD OF DC MOTOR

3 + VE FIELD +VE FIELD OF DC MOTOR

4 + VE FIELD +VE FIELD OF DC MOTOR

5 + VE FIELD +VE FIELD OF DC MOTOR

6 + VE FIELD +VE FIELD OF DC MOTOR

7 - VE FIELD -VE FIELD OF DC MOTOR FOR -- SIDE OF FIELD

8 - VE FIELD -VE FIELD OF DC MOTOR

9 - VE FIELD -VE FIELD OF DC MOTOR

10 - VE FIELD -VE FIELD OF DC MOTOR

11 - VE FIELD -VE FIELD OF DC MOTOR

12 - VE FIELD -VE FIELD OF DC MOTOR

13

Spare KEEP CONNECTED BETWEEN FIELD TBs AND 20 PIN RECEPTACLE ON THE PLUG PANEL

BOARD. 14 Spare

15 AIR LOSS AIR LOSS SWITCH ON DC MOTOR AIR LOSS & LOCK OUT SWITCH CONNECTIONS FOR DC MOTORS 16 COMMON COMMON OF AIR LOSS SWITCH AND

LOCK OUT SWITCH

17 LOCK OUT SWITCH LOCKOUT SWITCH ON DC MOTOR

18 SPACE HEATER SPACE HEATER 230VAC 500W

SPACE HEATER ON DC MOTOR 19 SPACE HEATER

20 GROUND GROUND DC MOTOR GROUND CONNECTION

Note : 1.0 Presently following receptacles & plugs of Pyle National Star line (Amphenol) are being used in ONGC for 20 core control cables :

i) 20 pin plug with male inserts : Catalog No ZPEKLJ-2020-332PN ii) 20 pin receptacle with female inserts : Catalog No ZREP-20-332SN It is recommended that same type of the plugs & receptacles may be provided on the plug panel boards of the PCR.

2.0 Plug should be suitable for connection with 2.5sqmm x 20 core elastomeric screened cable for DC motor connection. 3.0 Plug gland to be suitable for cable outside diameter of 29 – 31 mm.

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ANNEXURE - 5

20 pin plug and socket connection details of Alternators.

Pin No Function Connectivity Remarks 1 RTD-1

2 RTD-2

3 RTD-3

4 RTD-4

5 EXCITER FIELD -VE EXCITER FIELD ON DG SET

6 EXCITER FIELD +VE --DO--

7 SPACE HEATER PHASE SPACE HEATER 230VAC 500W ON DG SET

8 SPACE HEATER NEUTRAL --DO-- 9 RTD-5

10 RTD-6 11 RTD-6 COM 12 RTD-5 COM 13

ENGINE SHUTDOWN ENGINE OVERSPEED (NO) SWITCH In case of engine overspeed switch activates the engine

should get shut down after CB trip. In case of LLOP or HAT or HWT or HOT Sensors activates the Gen panel CB should trip.

14 CIRCUIT BREAKER TRIP ENGINE LLOP (NC), HAT(NO), HWT(NO) & HOT(NO) SENSORS

15 COMMON COMMON SUPPLY FOR 13 & 14

16 RTD-4 COM

17 RTD-3 COM 18 RTD-2 COM 19 RTD-1 COM 20 RTD METER COM

Note : 1.0 Presently following receptacles & plugs of Pyle National Star line (Amphenol) are being used in ONGC for 20 core control cables :

iii) 20 pin plug with male inserts : Catalog No ZPEKLJ-2020-332PN iv) 20 pin receptacle with female inserts : Catalog No ZREP-20-332SN It is recommended that same type of the plugs & receptacles may be provided on the plug panel for Gen panels on PCR.

2.0 For RTD connections pin Nos are allotted as per our past experience. Supplier to decide the final pin configuration and inform BHEL. 3.0 Plug should be suitable for connection with 2.5sqmm x 20 core elastomeric screened cable for Alternator control connection. 4.0 Plug gland to be suitable for cable outside diameter of 29 – 31 mm.