Tender Document - Bharat Petroleum 13140.pdf · tender title : global 2- bid tender for design, supply, installation, testing & commissioning of 4 nos. automatic 24 station electronic

Domain : bpcleproc.in

Parent department: BPCL

Department : CPO (M) -ProcurementGroup 3

Department officer : D Manimaran

System ID : 13140 Tender Reference No. : CRFQ1000257169

Tender Title : GLOBAL 2- BIDTENDER FORDESIGN,SUPPLY,INSTALLATION,TESTING &COMMISSIONING OF 4 NOS.AUTOMATIC 24STATIONELECTRONICCAROUSELWITHINTEGRATEDELECTRONICDOWN STREAMFACILITIESINCLUDINGVISION UNITFORMANGALORE,BAITALPUR,RAIPUR & NRLLPG PLANTS.

Tender Date : 15/06/2016

Tender Description : 1. Global TENDER for Design, Supply, Installation, testing & commissioningof 4 nos. Automatic 24 station Electronic Carousel with Integrated ElectronicDown Stream facilities including vision unit & Annual Maintenance Contractfor 3 years at BPCL Mangalore, NRL, Baitalpur & Raipur LPG Bottling Plant,is floated in Two part bid through E-Tender system, consisting of BidQualification, Technical plus Commercial qualification & Price Bid floatedtogether.2. Evaluation of offers and award will be on location-wise lowest landed costbasis including AMC for 3 years. Bidders should qualify in BQC, Technical &Commercial bids , in order that their price bid is opened. First the BidQualification Criteria will be evaluated. Technical cum commercial bids of onlythose vendors who meet the BQC will be taken up further. Price bids of onlytechno-commercially qualified bidders will be opened.3. A Pre-bid meeting is scheduled for 24.06.16 at 11:00 hrs IST at the office ofBPCL. All prospective bidders can participate in the same. All queries to reachus before pre-bid meeting date. No queries will be entertained post pre-bidmeeting date.BPCL reserves the right to extend the Due Date of Tender.4. Forms/ Attachments to this tender may be noted while bidding.5.Please note that foreign bidders quotes should be either in USD or EUROonly. Please mention the currency in which you have quoted (USD/EURO).6.In price bid, wherever CST is applicable, vendor has to quote the CST (withform-c). Octroi/Entry tax shall be paid extra at actuals against documentaryevidence in original.

Tender Document

Tender reference No : CRFQ1000257169 System ID : 13140

Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY, INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24 STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR, RAIPUR & NRL LPG PLANTS.

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7. Contract will be placed by us. Actual Call-Off Shall be placed from MatsE&PNOIDA/LPG SBU/NRL. Payment shall be processed by the Originator ofCall-off/ BPEC & NRL for their requirement. For the NRL requirements , M/sNRL will be placing the contract/order & payments will also be made by them.8. Price will be firm till execution of order and no escalation will be entertainedon any ground. BPCL reserves the right to vary the quantities of the tender.9. Packing and Forwarding: The materials should be properly packed so as towith stand all transit hazards till our sites.10.OCTROI/Entry Tax : Octroi/Entry Tax, if, applicable will be reimbursed tovendor extra at actuals against documentary evidence.11. Unloading & stacking will be arranged by consignee. However, advanceinformation regarding expected date of delivery to Site In-charge must be givenwell in time for making unloading arrangements under advice to originator ofcall-off.12. IN CASE OF ANY CLARIFICATION PERTAINING TO E-PROCUREMENT PROCESS, THE TENDERER MAY CONTACT THEFOLLOWING PERSONNEL OF M/S BPCL.PROCUREMENT LEADER :MR.MANIMARAN DASARAJLANDLINE NO. : 022 24176408 / MOBILE NO. 8220002889 / E-MAIL :[email protected] MANAGER : MRS. SRINIVAS SONIALANDLINE NO. : 022 24176418 / MOBILE NO. 9820067543 / E-MAIL :[email protected]

Envelope Bidding Type : In 2 Part bidding Envelope Bidding Option : Document fees andEMD + Technicalbid + Price bid

Bid validity period (in days) : 180 Type of contract : Goods

Project duration / delivery orcompletion period (in days)

: 180 Form of Contract : Supply

Bid submission configuration

Bidding access : Open/Press

Base currency : INR Bidding type : Global

Bidding currencies : INR,EURO,USD

Key configuration

Bidding variant : Buy Mode of pre-bid meeting : Offline

Pre Bid Meeting Venue :

CENTRAL

PROCUREMENT

ORGANIZATION(MKTG),

BPCL, A INSTALLATION,

SEWREE FORT RD,

SEWREE(E), MUMBAI



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400 015, INDIA PHONE

022 24176408/24176418

Dates configuration

Document downloading startdate

: 17/06/201609:00:00

Document downloading enddate

: 14/07/201614:00:00

Bid submission start date : 25/06/201617:00:00

Bid submission end date : 14/07/201615:00:00

Pre-bid meeting start date : 24/06/201611:00:00

Pre-bid meeting end date : 24/06/201614:00:00

Bid opening date : 14/07/201615:01:00

Document / EMD / Security fee detail

Tender fees : Not Applicable EMD amount : INR :750000.00EURO :10021.00USD : 11138.00

EMD payable at : BHARATPETROLEUMCORPORATIONLIMITED,MUMBAI

Emd Clause :

Earnest Money Deposit

(EMD) ( also referred to as

Bid Security): You shall be

required to submit the

Earnest Money Deposit

(EMD) of Rs. 750000/-(

seven Lakhs,fifty thousand

only) for Indian bidders &

11138 USD or 10021 Euro

for foreign bidders , as

applicable in physical form

by the way of demand draft

drawn on any Nationalised

or scheduled bank in favour

of M/s Bharat Petroleum

Corporation Ltd. and

payable at Mumbai at our

office in a sealed cover

addressed to Procurement

Leader Gr 3, with following

boldly super-scribed on the



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outer cover CRFQ number,

Item, Closing date,Time,

Name of the tenderer. It

should be dropped in the

tender box or sent by

Registered Post/Courier to

the following address so as

to reach before the due date

& time of the tender.

Wire transfer shall be

allowed only for foreign

bidders.Exemption for

EMD would be in line with

govt. policy for MSE/NSIC

vendors.

EMD Payment Method : Demand Draft

Documents

Sr.No. File name File description

Filesize (in

MB)Date and time Status

1 DECLARATION13140.pdf

declaration 0.083 10/06/201623:14:52

Approved

2 GPC (with PMAArbitration clause &

Holiday Listing Link)on12.10.15.pdf

GPC 0.308 10/06/201623:14:52

Approved

3 SPC 13140.pdf spc 0.092 10/06/201623:14:52

Approved

4 Integrity pact 13140.pdf Ipact 0.325 10/06/201623:14:52

Approved

5 Instructionsto_the_vendors13140.pdf

ITB 0.388 10/06/201623:14:52

Approved

Bidding forms

Documentfees andEMD

EMD Form

EMD Form



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Details Bidder'sResponse

EMD Amount offering

Currency

EMD Payment Method

Instrument No.

Payment Date

In case of wire transfer by foreign vendor, pl submit details

In case of MSE vendor for the tendered item , submit EMII document & itshould mention the tendered item

Documentfees andEMD

EMD Form

Details Bidder's Response

EMD Amount offering

Currency

EMD Payment Method

Instrument No.

Payment Date

EMD Form

Technicalbid

BID-QUALIFICATION CRITERIA

BID-QUALIFICATION CRITERIA

S.No Bid-Qualification Requirement BiddersResponse

BID-QUALIFICATION CRITERIA (BQC)



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1 1.The Vendor should be a manufacturer of 24 station electronic carouselwith integrated electronic downstream facilities including vision unit. Thevendor should have supplied and successfully commissioned at least onenumber of 24 station electronic carousel with integrated electronic down-stream facilities including vision unit in the last seven years prior to duedate of tender.Documents required:Vendor should furnish copies of thepurchase order/s along with successful commissioning certificate from thebuyer in proof of above.Indian vendor to submit central excise registrationcertificate for manufacturer & foreign vendor to submit certificate from thecountry of origin’s chamber of commerce in support of them being amanufacturer of above mentioned equipment.

2 2.The vendor should have achieved a minimum average Annual financialturnover of Rs.5 Cr (For Indian vendors) / USD 0.74 Million or Euro 0.67Million (For Foreign vendors) as per Audited financial statements(including Balance Sheet and Profit & Loss account), during the last threeconsecutive accounting years prior to due date of tender The vendor’s networth should be positive as per last available Audited financial statements(including Balance Sheet and Profit & Loss account). The net worth isdefined as TOTAL ASSETS MINUS TOTAL LIABILITIES.Documentsrequired:Audited Balance Sheets & Profit & Loss account of the vendor forthe last three consecutive accounting years (English language only) prior todue date of tender.

Technicalbid

Acceptance Of ITB and GPC and SPC


SrNo

DocumentName

FileName

I / We have read, understood and accepted the followingAnnexure of the Tender Document. (To read theDocument please click the corresponding Download link)

1 GeneralPurchaseConditions

gpc.pdf

2 Instructions toBidders

ITB

3 specialconditions

SPC


Technicalbid

Annexures for acceptance and upload after duly filled, signed & Stamped.

Annexures for acceptance and upload after duly filled,

signed & Stamped.



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Annexures for acceptance

SrNo

DocumentName File Name

I / We have read, understood and accepted thefollowing Annexure of the Tender Document. (Toread the Document please click the correspondingDownload link)

1 Declaration Declaration.pdf

2 IntegrityPact (IP)

IP.pdf

Technicalbid

Particulars of Bidder for tender

Particulars of Bidder

. .

1. Name of the Tenderer

2.(a) Office Address/ PAN no.

2.(b) Factory Address

2.(c) Tel No - Office

2.(d) Tel No - Factory

2.(e) Fax No - Office

2.(f) Fax No - Factory

3. Email ID (The email ID should be valid for the full tender period and the informationshared/ advise issued/ other mails sent to this ID shall be treated as official communicationfrom either sides)

4.Name/ designation of personnel handling the email IDs

PL MENTION COUNTRY OF ORIGIN & LOAD PORT Please confirm the Item Number /Description and Part Number / BTN Classification / Custom Tariff Number (FOR FOREIGNBIDDERS)

Sales Tax Registration No

Particulars of Bidder for tender



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. .

a) State Sales Tax

b) Central Sales Tax

c) Service tax registration

Technicalbid

A.DETAILS OF RELATIONSHIP WITH BPC DIRECTORS

PART- A (Applicable where Manufacturer is Sole Proprietor)

Description Bidder response

1.Name of Tenderer

2.a.Office Address

2.b.Residence Address

3.Telephone

4. State whether manufacturer is related to any of the director(s) of BPC

5.If Yes to 4, state the name of the Director and manufacturer

Put NA whichever is not applicable

PART- B (Applicable where the manufacturer is a partnership firm)

Description BiddersResponse

1. Name of the Partnership firm

2.Address :

3.Name of Partners

4.State whether any of the partner is a Director to BPC

5. If Yes to 4 ,state the names(s) of Directors.

DETAILS OF RELATIONSHIP WITH BPC

DIRECTORS



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6.State whether any of the partner is related to any of the Director(s)of BPC

7.If Yes to 6 state the name(s) of Director(s) and the concerned Partnersrelationship with him/her.


PART - C (Applicable where the Manufacturer is a Public or Private Ltd. Co.)

Descrition BiddersResponse

1. Name of the Company

2.a.Address of Regd. Office

2.b.Address of Principal Office

3.State whether the company is a Pvt. Ltd. Co. or Public Ltd Co.

4. Names of Directors of the Company

5.State whether any of the Director of your Company is a Director of BPC .

6.If Yes to (5) state the name(s) name(s) of the Director

7.State whether any of the Director of your Company is related to any of theDirectors of BPC.

.If Yes to (7) state the name(s) of Director and the concerned Director's (of theVendor) relationship with him/her.


For the current list of BPC directors, please check on our website www.bharatpetroleum.in

Technicalbid

DEVIATION

Sr.No.

Tender clauseNo.

BPCL Requirements/specification

Deviations withJUstification

DEVIATION



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http://www.bharatpetroleum.in

Technicalbid

GENERAL DESCRIPTION OF DESIGN, SUPPLY, INSTALLATION, TESTING ANDCOMMISSIONING OF 24 STN ELECTRONIC CAROUSEL

DESCRIPTION Bidder'sConfirmation

1.1This Specifications mainly indicates the parameters, conditions andrequirements of BPCL as per which the manufacturer has to design, procure rawmaterials, manufacture, shop test/inspect and supply the equipment suitable forfilling, testing, conveying & transporting LPG cylinders. The specifications areintended to give the vendor the functions and the operating characteristics towhich the equipment shall be manufactured.

1.2The design capacity of 24 machine Electronic Type Carousel shall beguaranteed for minimum 1570 Cylinders per hour for filling of 14.2 Kgs capacityat a carousel speed of 55 seconds per revolution and 1000 Cylinders per hour forfilling of 19 Kgs capacity filling, with minimum 95% filled cylinders havingfilling accuracy of(-)50 to (+)50 gms range. The overfilled and under filledcylinders beyond +/- 50gms should not exceed 5% of the gross filling.

1.3 The quantity of LPG leakage during each detachment/cut off operation fromeach filling gun to be advised to BPCL.

1.4 The carousel type 24 machine Electronic Filling Machine is to be designedrequiring minimum manual intervention with production and monitoringfunctions carried out with the help of PLC, ensuring automatic and continuousfilling operation of the LPG cylinder.

1.5 Vendor must confirm the guaranteed system accuracy which will be proven atthe time of handing over the system and the same shall be guaranteed for Indianclimatic conditions (viz. temperature/ moisture/ dust/wind/ open sheds). Due tohandling conditions prevailing in Indian markets the cylinders may not hold thesame dimensional tolerances after repeated circulation. The carousel should beable to fill the cylinders as long as the cylinders are able to stand on the foot ring/ conveyor & the latching system of carousel should be designed to latch thecylinders on to the platforms. The guns should also be made with self aligningfacility to accommodate such cylinders. The system should perform satisfactorilyunder the ambient temp range of 5 Deg C to 50 Deg C.

1.6 The Scope of Supply & Works for the 24 station Electronic Carousel fillingsystem shall include design, procurement of raw materials, manufacturing, testingand delivering equipment and accessories and as follows:-

i. The ELECTRONIC Carousel Filling system shall consist of the following:-

a. 24 Electronic Filling Machines mounted on a steel frame with rails includingfoundation bolts & central column, swivel joints for instrument air, LPG, power .

b. Distribution piping network for each filling machine,

GENERAL DESCRIPTION OF DESIGN, SUPPLY,

INSTALLATION, TESTING AND COMMISSIONING

OF 24 STN ELECTRONIC CAROUSEL



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c. Suspension/supporting structure for SC type cylinders -24 nos.

d. Automatic centering and clamping device – 24 nos.

e. Automatic filling head for SC type of valve – 24 nos.

f. Electronic control system with data communication i.e. Power & data transferarrangement for complete carousel system, data storage, self diagnostic,electronic hardware & software etc complete PC ofHP/COMPAQ/IBM/HCL/WIPRO/DELL Brands , with minimum followingconfiguration

I7 or higher with latest CPU configuration 8 GB or higher RAM & 1 GB cache

2 TB hard disk

29" High resolution LCD flat screen monitor

Inbuilt DVD / Combo Drive Multimedia system

Keyboard and optical mouse (3 Button)

Licensed Windows OS latest

Including laser jet color printer min 22 Pages per minute(HP/CANON/WIPRO/EPSON/PANASONIC/TVS Network interface card10/100 base-T, minimum 3 extra USB 3.0 ports for future use, hot Standbymachine with KVM switch (sharing key board mouse & monitor) with pre-loadedoperating system along with workstation cabinet.

Hard disk device of 2 TB (or more) with Spin Speed of min 7200 rpm andsufficient for storing at least 60 Working days data (considering two shiftoperation of 8.5 Hours each, 1.5Hour Overlap, 6 Days per Week).

g. Tangential or Radial Type Automatic Ejection Unit – 01 no.

h. A Central Encoding station for tare weight input – 01 no.

i. Provision for Tare weight entry.

j. Filling guns & hoses for all filling machines 24 nos.

k. Carousal drive unit with FLP motor – 01 no.

l. Post filling Automatic Electronic Check Scale of 1600 cylinders per hourcapacity, to check weigh the filled cylinders with a provision of rejecting theunder& over filled cylinders –1 no.

m. Pneumatic/ Photo Sensors and internal wiring.

n. Uninterrupted power Supply Unit (UPS) for minimum 30 minutes. Minimum2000VA. Recommended Makes EPM, DB POWER, HIREL, APLAB, APC, GE,ABB.



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o. The necessary pipe manifold, valves including differential pressure valve,pressure gauge, safety valve, micro filter, earthing devices for the rotary carouselframe , machine and drive unit etc. including bolts & nuts complete.

p. Other accessories like photo sensor, diverters/pushers, complete.

q. Supply of all communication cables for equipments in the filling shed.

r. Equipments for SQC. Automatic SQC sequencing with least count of 10 gms tobe provided.SQC checking shall include checking of cylinder weight, valve leak,O-ring leak. MIS to be generated for cylinder weight, valve leak, O-ring leakalong with the time and date of checking of cylinder. Serial number of cylindershall also be part of MIS which shall be punched by the operator.

s. Spares for commissioning and trouble free operation of the entire systemsduring the warrantee period of two years.

ii. Each filling machine shall be provided with automatic filling guns for ‘SC’types of valves. ONE EXTRA GUN TO BE PROVIDED WITH EACHCAROUSEL TO FACILITATE SERVICING OF GUNS.

??? iii.??????? All the necessary air service units comprising of filter,regulator and lubricator units along with all the interconnection piping to all theequipment shall be under the scope of Vendor.

iv. Approval of Chief Controller of Explosives of Petroleum & Explosives SafetyOrganization (PESO) Nagpur, India for the Electronic carousel system to beobtained & submitted with the offer by the vendor or to be provided beforedispatch of equipment.

v. A detailed drawing showing complete arrangement of the system along withmeasurement should be enclosed.

vi. 6 sets of Erection, Operation & Maintenance Manuals in CD form and 3 setsof hard copies for each system.

vii. 6 sets of detailed drawing for civil foundation and general arrangementdrawing for each Carousel filling system.

viii. 6 sets of Electrical and pneumatic circuit diagram for the entire Carousalfilling system.

However, the Vendor shall be responsible to complete the work in all respectsand in doing so, provide/supply all facilities not covered below specifically, butnevertheless required for the satisfactory performance of complete system

ix. The following supply/works shall be carried out by BPCL.

a. All Civil Works. However, Vendor should furnish the details of foundationdrawings for all equipment within 2 months from the date of purchase order.

b. Erection/installation of all equipment supplied by the vendor shall be carriedout under the direct supervision of the vendor and BPCL will provide therequired semiskilled/unskilled manpower, power/ instrument air. The vendorshould specify the actual requirement of the same in advance.



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c. Vendor should specify the equipment-wise requirement of power/cables sizingetc.

Equipment : Power & Cable Size

Electronic Carousal Drive Unit

Other if any.(specify)

d. BPCL shall supply required Air connections for all pneumatics. Vendor shouldspecify the equipment – wise air consumption/requirement and pressure as givenbelow. However, vendor should supply internal connections within theirequipment for inter connection.

Equipment : Qty of Air & Pressure Required

Electronic Carousal Filling m/c.

Introduction/Ejection unit

Central Encoding station

Check Weighing Scale

Weight Correction unit

Valve Leak detector

O ring Leak detector

Others if any.(specify)

TOTAL AIR Requirement

e. Power cables from BPCL’s main power supply to carousel Drive unit and toUPS shall be arranged and laid by BPCL. All other cables including OFC/signalcables & connectors/ junction boxes shall be supplied by vendor and shall be laidby BPCL as per direction/ supervision of vendor’s engineer. G.I pipe forOFC/signal cable shall be provided and laid by BPCL as per direction ofvendor’s engineer.

f . Any other items not specified in the Purchase Order and essential for thesatisfactory commissioning of the total system shall be under the vendor’s scopeof supply.

1.7 An operator will enter the tare-weight of the cylinder by operating on thekeyboard of the Tare weight Central encoding station and thereafter filling shallbe fully automatic.

1.8 The encoded tare weight shall automatically be transferred to the cheekweighing system downstream of the carousals

1.9 The system is to be equipped with automatic electronic equipment for allfunctions with option for any future extension, modernization or any alteration



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which could be taken up with the incorporation of cylinder identification (byRFID ), palletisation etc.

1.10 All equipment should be suitable for filling 14.2Kg as well as 19.0Kgcylinders.

1.11 The measured static (electric) charge generated during filling of LPGcylinders to be advised to BPCL.

2. SCOPE OF SUPPLY BY VENDOR FOR ELECTRONIC CAROUSAL

Electronic carousal shall consist of but not limited to the detailed list indicated inclause no. 1.6 The entire electronic system shall be of FLP/Intrinsically Safeconstruction and fit for use in Hazardous Zone 1, for Gas group IIA and IIB withambient temperature rating of (–) 10 Deg C to (+)50 Deg C . All Electrical andElectronic components of equipments being supplied must have specific approvalconforming to the required parameters mentioned above.

3. CENTRAL ENCODING STATION

3.1 There shall be electronic key-board in the encoding station on which theoperator will punch the tare weight of the cylinder and this tare weight willautomatically be transferred to the filling machine as well as check weighingsystem without any error. The tare input shall be maximum of two digits.

3.2 The key-board shall be able to punch a tare weight range between 14.0 Kg to20.9 Kg tare weight cylinders. The key board should have required nos. of keyfor punching tare weight. The operator shall punch/encode only the last two digitson the key-board to transfer the tare weight to the electronic filling machine.

3.3 This equipment is mounted on a chain conveyor upstream of the LPG fillingcarousal. The operator will key in the tare weight of the cylinder. The display forthe check scales will be in two digits after the decimal (xx.yy) e.g. 17.95, 16.10,18.35 etc.

The OEM/ Supplier, type & certification of load cell is to be advised and theaverage life of the load cell used in check scales /filling machines is to beinformed.

4. CAROUSEL

4.1 The Carousel can be a steel platform supported by a number of runningwheels fixed underneath the frame and running on a steel rail fastened to thefloor. Alternatively, the wheels may be mounted on the ground and the platformmay rotate above. The carousal shall rotate around a central column, whichserves as the axis of rotation as well as a distributor of LPG, power/data/signalcables and compressed air to the individual filling machines.

4.2 The Carousel shall have a frame size for accommodating 24 filling machinesmounted on its rotating table. The minimum guaranteed filling capacity shall bemin 1570 LPG cylinders / hour with 14.2 Kg capacity at a carousel speed of 55seconds per revolution and 1000 cylinders/hour with 19 Kg net weight filling incylinders of 33.3 and 45.5 liters water capacity respectively. The SC Valve isprovided at the centre of the cylinder. Please see the attached drawings for detailsof cylinders.

4.3 Each filling machine with its filling head shall be of modular type and act asan independent unit along with its own controls and shall receive LPG, air and



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electricity feed from the central column.

I. The base frame shall be fitted with 24 electronic filling machines including aCentral column, LPG/Air/Power distributor rings, with individual LPG and Airisolating valves, & gas stop valves for individual filling machines.

ii. The power distribution in Central Column carrying power to all fillingmachines and communication signals among filling machines/Check Scale/PLCshould be of Flame Proof construction with guaranteed positive segregationbetween FLP and Intrinsically Safe, if separate channel for IS is provided.

iii. The carousal shall rotate around the central column, which will serve as anaxis of rotation and distributor of the LPG, electricity and compressed air to thefilling machine,

iv. In center column, there should be positive segregation between LPG and airportion. This can be obtained using proper leak proof seals, specifically coated &finished central pipe stems which should be rust resistant. Similarly, there shouldbe positive segregation between Power/communication channels and LPG/Air.

v. The control/isolation valves used for LPG isolation should be fire safe, anti-static types. Necessary certificate in support of Fire Safety shall be produced.LPG. Hoses and compressed air hoses should have anti-static properties.

vi The driving unit shall have speed regulation for controlling rotation speed ofthe carousal to match with the filling time of LPG cylinders. Carousel will beoperated at 55 seconds per revolution.

vii. The electronic filling machine shall be of modular construction and electronicweighing PLS type and shall be incorporable anywhere in the LPG filling system.

viii. The 24 Nos. electronic filling machine shall include:

a. Automatic lowering/raising of the LPG filling head. Automatic connection/disconnection clamping of filling head.

b. Automatic cylinder centering.

c. Clamping of cylinders covering the circumferential joint using arms/jawsoperated by pneumatic cylinders/valves.

d. Automatic filling operated by electronic weight controller.

e. No leakage from the filling gun if the cylinder valve is covered with safety capor gun is not latched on the cylinder valve.

f. The filling machine shall have a weight controller communicating with themain PLC which transfers the tare weight of cylinders entering through theCentral Encoding Station and controlling all pneumatic movements.

g. Auto calibration facility and auto tareing /zero setting to be provided. Themachine shall also have encoding via PLS/ RFID.

h. In case of malfunction or drift outside the set parameters, the system shall haveautomatic shut off facility.



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I. Each filling machine shall be provided with quick closing isolation valves toisolate both LPG & Air supplies to the scale. All air connections should be quickdisconnecting type push in connectors. Air tubing shall be flexible and anti staticconstruction of the scale should be such that maintenance can be carried outeasily without disturbing other scales.

j. The supply of LPG, electricity and compressed air shall be interrupted, ifrequired, for any individual filling machine(s) without stopping carousal, whichensures possibility for repair and maintenance during production.

k. The table of each filling unit shall be made of suitable material to ensure nospark generation during cylinder movements. All flexible copper jumpers forearthing shall be included in the scope of supply of vendor. Continuity fromfilling gun to the rail should be provided.

l. Each scale shall have individual FRL units to ensure lubricated air supply to thescale. Also non- lubricated air supply shall be available for use as pilot signal etc.

m. All filling machines shall have self-diagnostic facilities.

ix. CABLES: All cables including fiber- optic /communication cables andaccessories shall be supplied by the vendor. BPCL will supply power cable tocarousel drives. GI pipe for Fibre- optic /communication cables will be providedby BPCL and same will be laid under the supervision of the vendor’srepresentative.

x. The Hardware architecture of the system should be compatible with Windows7 or higher and able to exchange MS Excel/ txt file.

Interface -Compatibility with SAP R/3 System and plant automation system to beprovided and vendor to inform us the structure of their database, & in whichdatabase the files the filling data are stored, user id, password of the database sothat if required BPCL can develop its interface if required.

a. A back up disc of software of supervisory control and other spare cardsprogrammed with proven software to be provided at the time of handing over thesystem.

b. Provision for accommodating the automatic bar code reader/scanner/RFID fortare weight registering which may be installed in future.

c. Residual gas should be recorded. Print command should be optional.

d Machine wise accuracy data in form of +/- 0, +/- 50g, +/-100g, +/- 150g ,+/-200g, , +/-300g, >400 .

e. PLC Make – Allen Bradley (Rockwell)/ Siemens / Honeywell / GE Fanuc/Schneider Modicon / Yokagawa / Invensys / ABB / Emerson will be preferredand 20% spare capacity in PLC to be provided.

f. Format of the MIS reports to be provided with the bid and the same will berevetted again by BPCL after placing the order.

g. Complete filling operation will be automatic having centralized control panelwith CPU to facilitate data generation on all operations. Filling system should notget disrupted if communication between carousel & Central control room fails.



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4.4 In addition to the above, the following features should be incorporated in theCarousel.

I. Interlocking of Introduction/Ejection unit for :

a. Anti jamming output when exit conveyor is full of cylinders for Ejectiondevice, for Oring leak & Valve leak detectors.

b. Introduction only when platform empty.

c. Ejection only when cylinder is filled and gun is released.

ii. LPG Stop-Valve - Auto pneumatic.

iii. Emergency Stop - Easily accessible from front and distinctly visible forindividual machine.

iv. Cylinder centering - Auto clamp with Teflon/Non –sparking material/padsarms with jaws covering the circumferential parts of cylinder with pneumaticcylinder control.

v. Earthing connection :

a. Filling head – braided copper wire along with hose with insert.

b. Central column.

c. Guide rail.

d. Platforms of filling scales.

e. Frame.

vi. Security Guard - Mesh/steel plate on angle-iron frame all around upto 2 inchabove the platform height.

vii. LPG Entry - From top/ bottom and differential pressure bypass beforeCarousal entry. The details of bypass assembly is annexed in the document. Thebypass control valve will be pneumatic/micro- processor operated.

viii. Air Entry - from bottom/top

ix. Filter - 40 mesh SS strainers.

x. Pressure Gauge with needle valve & isolation valve - Before & after Filter.

xi. Guide Rail - 1-section .

xii. 5 micron Air filters where-ever required for each unit will be supplied by thevendor. The Filter/regulator/lubricator( Filtration 5? - Dimension ) forintroduction, ring , valve leak tester , Check scales to be provide with 25 NB sizeAir Filters units for entry /exit so as to ensure that is no drop in air pressure whenthe aforesaid equipments are in continuous operation.



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4.5 FILLING HEAD

I. The Filling head shall be suitable for filling SC type vales fitted at the center ofon top of LPG cylinders of 14.2 Kg(33.3L) and 19 Kg(45.5L) net weight.

ii. Filling head shall be pneumatically operated, assembled on a special supportthat allows a partial free horizontal and vertical movement to facilitate andguarantee leak proof connection of cylinders even if they slightly off-centered.The pin travel length of the filling head’s, valve pin shall be 2.8mm+/-0.2mm.

iii. If cylinders with cap on the SC valve get introduced on the filling machine theflow through the filling head should not start.

iv. Design of the gun should ensure no leak while filling /idling.

4.6 SYSTEM MAINTENANCE ASPECTS

I. ? The machine shall be designed in such a way that routine maintenance shallnot pose any operational problems and all parts requiring major maintenanceshall be easily accessible. Facility of lubrication of the central column is to beprovided.

ii. Central column & LPG distribution pipe & components in filling m/c shouldbe pressure tested to 30 bars and be suitable for working pressure of 20 bars.

iii. The table of each filling unit shall be made of suitable material to ensure nospark generation during cylinder movement. All flexible copper jumpers forearthing form filling head to the rail & earthing grid is in the scope of supply ofthe vendor.

iv. Location of Isolation valve /Gas stop valve on distribution pipe-ring should besuch that valves should not get hit by the filling machine frame, if the fillingmachine tilts by action due to impact of cylinder. Alternatively, either themachine should be fixed or suitable protection is to be provided to these valves asutmost safety measure.

5 AUTOMATIC INTRODUCTION SYSTEM

5.1 PNEUMATICALLY CONTROLLED Tangential or Radial type introductionunit for automatic introduction of LPG cylinders from the chain conveyor to thefilling carousal is to be provided.

5.2 Proper cylinder centering is to be ensured by means of proper clampingarrangement. The clamping arms should be robust and their guaranteed minimumexpected life is to be advised. Life time guarantee would be preferred.

5.3 The introduction of cylinders to be in synchronization with the speed ofrotation of the carousal. Also, the complete carousel system is to be synchronizedsuch that carousel should stop automatically in case introductions & ejections arenot synchronized with the speed of the carousel or any cylinder topples whileentering /ejecting from the filling platform to exit conveyor.

5.4 A safety device is to be provided which will prevent introduction of cylindersto the carousal, if a cylinder is already present in the filling machine.

5.5 The clamping arrangement shall have the property of anti-toppling and holdthe cylinders firmly along with filling heads.



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5.6 The complete introduction assembly should be robust, sturdy & stable.

6. AUTOMATIC EJECTION SYSTEM

6.1 A pneumatically controlled tangential or radial type automatic ejection unitfor ejection of filled LPG cylinders from the filling machines on the carousal tothe outlet of the chain conveyor is to be provided. No cylinder should topplewhile entering the ejection conveyor and cylinders should move away before thenext cylinder comes to the ejection conveyor.

6.2 A safety device is to be provided in such a way that if the filling head has notgot fully disengaged from the cylinder, the ejection process is automatically by-passed.

6.3 Ejection of cylinders should be individual with independent ejection pusher ineach filling unit to isolate the machine without stopping the carousal. In case ofcommon ejection unit, it should be sturdy & suitable for such continuousperformance & meet the system performance.

6.4 The complete Ejection assembly should be robust, sturdy & stable and anystructural failure will be rectified by replacement/modification in design withoutextra cost.

6.5 The speed of chain conveyor will be minimum 18 m/minute.

7. AUTOMATIC ELECTRONIC CHECK WEIGH SYSTEM:

7.1 This equipment is mounted on a chain conveyor downstream of LPG fillingcarousal. This check scale will have a capacity of 1600 cylinders per hour & willcontinuously check the weight of filled LPG cylinders to determine the overfilled / under filled cylinders.

The weighing platform shall be based on a load cell/strain gauge technology.

The tare weight input from Central Encoding Station to filling machines shallautomatically be transferred to the electronic weighing system and the scaleshould be able to recognize the same.

The scale should automatically work out the tare weight considering the grossweight and pre-set net weight.

The scale should automatically be able to detect under/over weight cylindersbased on the tare input and actual weight and accordingly reject such cylindersand push them off the main stream.

An explosion proof display to be provided near the scale. This device shalldisplay the weight of cylinder currently under weighment or the weight of theprevious cylinder that had just passed on the scale.

The electronic unit to have a micro-processing/PLC system which shall beprotected in an intrinsically safe enclosure suitable for hazardous area Zone I,Class IIA & IIB and weather proof IP 65 and hermetically sealed IP 67.

Load cell capacity of check scales & filling scales should be 200-300 kgs.



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7.2 General Description

The Electronic Check Weighing scale shall have a capacity of 1600 cylinders perhour of min 14.2 Kg cylinders & consist of:-

This device is to also adjust the actual capacity of the machine as well as controlsudden jamming.

The weighing platform to be suitability designed to give more stability to thecylinders.

A weight device with a digital display located on a control panel beside theplatform.

A sorting unit composed of one ejector for ejecting out, over/under weightcylinders.

Complete pneumatic and signal/communication circuits including earthingconnection etc

Accuracy should be +/- 50 gms but it should have provision to display inmultiples 10gm whenever required for checking.

Check scale should used as master incase of communication failure for datalogging.

The cylinder should come to the main conveyor on its own till the next cylindercomes for weighing and this cycle should continue automatically.

The maximum cycle time for checking should be less than 2.25 seconds percylinder & the capacity should be 1600 cylinders per hour min. for 14.2 Kgcylinders.

The net weight of LPG i.e 14.2 Kg or 19 Kg is set as default. The system shouldallow changes in these default setting as & when required.

Zero pre-setting when there is no cylinder on the platform.

The display unit should display the tare weight value after taking intoconsideration of actual gross weight and the pre-set net weight.

Based on tare weight input value from the Central Encoding Station/Fillingmachines, the scale should be able to decode the input and compare the tareweight value worked out by the system, considering gross weight and net weight.The system should be able to identify the over filled and under filled cylindersbeyond the specified tolerance limits and remove the same from the main line.

Under normal circumstances, the cylinder should automatically be passed on tothe weighing platform and check weighed. In case there is any problem in thesystem, there should be a manual override provision for manual sorting so thatthe operator can intervene and reject the over/under filled cylinders.

All check weighing process should be linked up with Central Control panel alongwith PLC and personal Computer with software for report generation.

7.3 Manual Sorting



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To enable manual sorting of cylinders in case of system failure, additionalprovisions are to be made. i.e. Provision is to be made for a rejection button, ifthe cylinder is not filled within permissible tolerances. An operator can press therejection button so that the rejected cylinder is removed from the main conveyorto a separate conveyor for rectification of under/over filled cylinders.

7.4 Check Weighing System Requirement

The check weighing system shall be fully automatic with a min capacity of 1600cylinders per hour of 14.2 Kg.

The system shall have automatic transfer of tare weight, automatic sorting outwithin preset parameters and statistical report function.

Cylinders that do not fall within the set tolerance shall be automatically sorted outvia the PLC and all relevant data from the check scale shall be transferred to thecentral computer system.

Further, the following facilities are to be incorporated:

Decode input including automatic sorting out of incorrectly filled cylinders to aseparate conveyor loop for correction.

Prepare a statistical report of correctly filled cylinders, overfilled cylinders andunder filled cylinders

8. FILLING MACHINE SHOULD HAVE FOLLOWING SPECIFICATIONS:

The filling machine shall have guaranteed output of 95% accurate cylinders withaccuracy of (-) 50 to (+) 50 gms

a. Level +550 mm from the floor level of filling shed.

b. Direction of rotation- Clockwise/Anti clockwise (to be confirmed after Awardof Job)

c. Accuracy shall be (-) 50gms to (+) 50 gms. or better.

d. Method of Filling – Gross weight

e. Gas stop valve to open after fixing of filling gun. NO GAS FLOW FROMTHE FILLING GUN UNLESS THE GUN IS LOCKED ON THE CYLINDERVALVE.

f. Pneumatic element shall be of standard makes of internationally reputedcompanies. Authorized stockiest to be available in India

g. Platform to have tubular guard.

h. Tandem pneumatic cylinder for flexibility to accommodate 14.2 and 19 Kgcylinders.

I Quick coupling with nylon or equivalent tubing with anti-static property forpneumatics.



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9 AUTOMATIC ELECTRONIC WEIGHT CORRECTION UNIT:

This machine will be similar to filling machine with filling scale of Least count/resolution of 10gms .The filling & evacuation provision of under/ over filledcylinders should happen automatically through 3 way valve or similar safetyinterlock arrangement and filling accuracy shall be +/-50g .

a. System should be able to detect over & under filled cylinder wrt to tare weightand fill the cylinder with correct weight. Manual punching of tare weight shouldnot be required for cylinder correction , data should automatically get transferredfrom Post Filling check scale to the cylinder correction unit. The system shouldhave provision of manually correcting the cylinders ( if required at any stage incase of system malfunction /overload of the system )

b. Also manual operation of three way valave or similar operation with multipleGas Stop valves should be eliminated and this operation of switch over fromfilling to evacuation and vice versa should be automatic with suitable safetyinterlocks to avoid simultaneous operation of filling and evacuation.

10. FILLING HEAD SHOULD HAVE THE FOLLOWING SPECIFICATION

Gun release: smooth release with hinged arrangement in jaws to facilitate littledownward movement of jaws at the time of release.

Pin travel: 2.8 mm +/- 0.2 mm

Material: Gun Metal (Copper alloy).

Head Cap: Gun metal (Copper alloy) threaded.

Pneumatic cut – off LPG inside the gun during gun release. No leak from the gunafter de-latching from the cylinder valve.

Hose attachment: side elbow.

Self centering horizontal alignment arrangement with cylinder valve.

11. VALVE/BUNG LEAK DETECTOR/TESTER:

11.1 Valve /Bung leak tester should have Sensitivity (0.5 grams/hour of LPG,equipment calibrated with commercial BUTANE# 0.5 gm/hr) and 100%repeatability to be established.

11.2 Minimum guaranteed capacity of valve/Bung tester should be 1600cylinders per hour which could be achieved through a single or double headerdevice. No extra payment for multi header device.

11.3 100% repeatability is to be proven in the field at the time of acceptance test.

11.4 Tolerance/sensitivity of valve leak tester should be such that “no cylinder isto get rejected below leakage level of 0.4 gm./Hr” and all cylinders with leak of0.5 gms/hr must get rejected.

11.5 Calibration, testing and inspection kit for each detection system shall be



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provided. For this the vendor should supply suitable test cylinder with fittings (orfittings which could be fitted on BPCL’s cylinders) which can be put onconveyor for checking on line accuracy /performance of the valve /bung leaktester.

11.6 Test cylinders for valve leak detector – To be supplied for different levels ofrange from 0. 6gm / hr to 0.3 gm/hr

11.7 Current leak detection system – Must not go out of range between breaks /starts and stops.

11.8 Separate cylinders/fittings for Valve & Bung testing should be provided.

11.9 Generation of 2% of valve leak cylinders shall not have any significantimpact on the capacity of the complete carousel system.

12. O-RING LEAK DETECTOR/TESTER

12.1 O-ring leak detector shall have a capacity of minimum 1600 cylinders perhour and Sensitivity (0.5 grams /hour of LPG).

12.2 Tolerance/sensitivity of O-ring leak tester should be such that “no cylinderis to get rejected below leakage level of 0.4 gm./Hr” and all cylinders with leakof 0.5 gms/hr & more must get rejected.

12.3 100% repeatability is to be proven in the field at the time of acceptance test.

12.4 Calibration, testing and inspection kit provided for the ‘ValveLeak.Detector/Tester’ should be suitable for O-ring Leak detection systemotherwise separate such calibration, testing kit shall be provided .

12.5 Test cylinders for valve leak detector should be suitable for on line O-ringleak testing otherwise separate cylinders are desirable.

12.6 Current leak detection system – Must not go out of range between breaks /starts and stops.

12.7 Generation of up to 10% of ‘O-ring leak cylinders shall not have anysignificant impact on the performance of the complete carousel system.

VENDOR TO provide the details of locations where their O-Ring & Valve Leakdetectors are in operation.

13. BPCL will provide differential pressure of 8 to 8.5 Kg./Cm2 at pumpdischarge and 7.0 to 7.5 Kg./Cm2 differential pressure at carousel.

The vendor will provide the necessary system required to keep the differentialpressure in line with requirement of your system by incorporating suitable device(flow control device/pressure control device). BPC will provide necessary pipingfrom pump to the carousel and from pressure control device to vessels. Theisolation valves required on either side of the pressure control device will also beprovided by BPCL. 40 mesh SS strainer will be provided by the vendor.

Details of Bypass assembly indicating the scope of valves /pipes /fittings isattached with document.



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Higher requirement of differential filling pressure for the performance of theoffered system is not desirable.

14. STATISTICAL QUALITY CONTROL (SQC) UNIT

Automatic SQC sequencing with least count of 10 gms to be provided.cylinderweight, valve leak, O-ring leak to be checked at SQC MIS to be generated forcylinder weight, valve leak, O-ring leak along with the time and date of checkingof cylinder. Serial number of cylinder shall also be part of MIS which shall bepunched by the operator.

15. UN-INTERRUPTED POWER SUPPLY (UPS)

Vendor to supply UPS of adequate rating as the part of the system.

The capacity of UPS shall be a minimum period of 30 minutes (2000VAminimum)

UPS shall be installed in a safe area in the Office/Control Room.

Power cable from UPS to the filling shed system shall be supplied by vendor andthe same will be laid by BPCL.

Independent Surge Protection for power supply to all electronic components anddata

/control communication system must be provided.

16. SAP INTEGRATION

The carousel data shall be integrated with the existing BPCL SAP system.Vendor to develop all necessary protocols and software drivers for integration ofcarousel data with SAP. All required hardware / software to be provided by thevendor. Interface -Compatibility with SAP R/3 System and plant automationsystem to be provided and vendor to inform us the structure of their database, &in which database the files the filling data are stored, user id, password of thedatabase so that if required BPCL can develop its interface if required.

17. GENERAL:

All solenoid valves and limit switches used in the system shall be intrinsicallysafe and approved by Chief Controller of Explosives of Petroleum & ExplosivesSafety Organization (PESO), Nagpur, India.

All control electronics including electronic weighing systems should be housed incertified intrinsically safe enclosures.

Load cells used shall be made intrinsically safe in conjunction with certifiedzenner barriers.

All cables used shall be of armoured and shielded type as per IS-1554 orequivalent international standard suitable for this application.

All control electronics shall operate at very low power requirements (Intrinsicallysafe) and shall be capable of working upto +55 degree Celcius ambienttemperature.



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Power supply will be have fluctuation of 220V +/-10% and frequency at 50Hz +/-6%.

All the cylinder movements to be controlled pneumatically. For operating thesepneumatic equipment. automatically, electro-pneumatic devices like FlameproofSolenoid Valves of required rating should be used.

Cylinder sensing and identification shall be done by using intrinsically safe limitswitches.

The limit switches and tare weight punching key board shall be intrinsically safe.

Vendor should give commitment to supply spares for ten years from the date ofcommissioning.

All pipes/fittings /valves for LPG shall be of minimum #300 psi and above as percode.

All butt welded joints should be 100% radiographed and shall be cleared by Thirdparty inspecting Agency.

Only Spiral wound stainless steel gaskets to be used in LPG pipeline joints.

All LPG Piping Central column and other components of filling machine shouldbe pressure tested to 30 bar.

LPG hoses - Anti-static wire braided reinforced. LPG hoses as per IS 9573/BS4089/EN 1762:1998. Earthing wire to be provided along with hose. ( workingpressure 25 bars)

Isolation Valves: SS Ball Valves of fire safe and anti-static type. (Necessarycertificate in support of "Fire Safe" to be provided.) Min PressureRating 300#

VENDOR is to advise in the technical bids the list of equipment & componentsout sourced for the system, their make & country of origin.

18. Excluded from vendor’s SCOPE

Power connection shall be made available near the encoding station and vendorto take connection to all other equipment from this station by providing suitableFLP Junction Box.

The cable for power connection for the terminals upto the carousel in the shedwill be provided by BPCL. Vendor to indicate the size and specifications of thecable However internal cable within the system in the filling shed shall beprovided by vendor

BPCL will be provide air line of required pressure near carousel, o-ring & valveleak detector . Vendor to supply & lay airline & air filter units to all requiredconsumption points.

The required LPG piping shall be provided by BPCL upto their equipment.Vendor to match their piping with BPCL piping. For this purpose, the vendorshall provide piping layout to BPCL.



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Earthing grid in the plant is provided by BPCL. However vendor to supplyearthing elements of equipment and conveyors, etc for connection to the plantearth grid.

19. SPARES

Vendor to dispatch the spares required during two years actual operation of theCarousal during warranty as per enclosed list to each plant. The spares requiredto be replaced frequently due to normal wear and tear are included in the abovelist and same is to be kept at the plant. Additionally, any spare or part which hasto be replaced during Warranty Period is also to be kept at a central location &made available at the earliest.

20. DRAWINGS AND DATA REQUIREMENTS TO BE SUBMITTED BYVENDOR FOR CAROUSEL, FILLING MACHINE, CHECK SCALE,ENCODER AND ACCESSORIES:-

These documents shall have to be submitted by vendor in two sets for bid and sixsets after placement of Order.

General arrangement drawings with outline dimensions including details forfoundation design.

Part list of all equipment.

Certified performance curves.

Certified test records of all equipment,

Diagram of wiring connections.

Piping and instrument diagrams for LPG, Air, water etc.

Test certificates for bought out items.

Assembly and Installation details.

Erection, operation and maintenance manuals.

Erection drawings and Completed Data sheets

Material specifications.

21. PERFORMANCE GUARANTEE

All equipment and component parts shall be guaranteed by Vendor againstdefective material, design and workmanship for a period of 24 months from thedate of commissioning or 30 months from the date of receipt at site, whichever isearlier. Date of Commissioning shall be considered as the date of proving thesystem by successfully conducting SAT.

The Vendor shall carry out the performance test run of the complete system atsite after satisfactory erection in line with the detail given in the Data Sheet.Training to BPCL personnel shall be given at site during erection/commissioning



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period without any extra cost to BPCL.

Vendor shall be solely responsible for smooth and trouble free performance ofthe plant as a whole during the guarantee period. In case of any problem arisingduring guarantee period even after taking over of the plant, Vendor shall have tocarry out any rectification/replacement at his own cost.

22. FACTORY ACCEPTANCE TEST

Factory Acceptance Test (Dry run under simulated conditions) may be witnessedby BPCL prior to dispatch of one system. For this purpose, a team of 04 (Four)officers might visit the vendor’s works to witness the tests as per scope ofinspection. However BPCL reserves the right to eliminate the FAT if required attime of award, ( pl note L1 price evaluation will be done including FAT ).Accommodation, local conveyance etc. to be arranged by the bidder at no extracost. Acceptance of this test will not absolve the vendor from the overallresponsibility of performance of the system at BPCL plants. NO EXTRA COSTWILL BE PAYABLE, if this option is exercised by BPCL. However, all systemswill be self tested at factory premises of the vendor by in-house competentofficial without extra charge and documents are to be sent along with invoice.This includes:-

I. Verification of Explosion proof /intrinsically safe component / sub system,checking of Vision unit , introduction /latching /filling/delatching /Ejection,operation of filling machine, safety interlocks as specified in datasheet/specification, assembling/manufacturing as per in house QAP.

ii. Checking of check scale accuracy and operation parameters

iii. Checking of Automatic weight correction operation.

iv. Checking of ‘O’ ring/vale/bung leak testing operation and ejection sortingsystem.

v. Checking Tare weight encoder and tare weight error rejection operations.

vi. Review of manufacture test certificates all bought out items viz., LPGPipelines, fittings, valves, flameproof motor, IS components, solenoid valves etc.

vii. All certificates to be provided in ENGLISH.

The entire system shall be inspected by a Third party inspection agency and thisshall be on Vendor's scope considering any one of the reputed third partyinspection agency approved by BPCL viz. LRIS / DNV/ IRS/ EIL/ BV/ ULINDIA PVT LTD .All equipment shall be dispatched only on certification andfinal clearance by third party inspection agency / BPCL.

23. SITE ACCEPTANCE TEST (SAT)

SAT shall be conducted by Vendor and Witnessed by BPCL at plant afterinstallation of complete system

Scope of inspection at site shall be:

1. Functional test under rotating conditions at site. All performance parameterssuch as rated production (cylinder per hour), filling accuracy (95% of cylinderswithin +/- 50 gms;), functioning of Tare Weight Entry Unit& Vision unit,



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functioning of Weight correction unit, detection of O-ring and Valve LeakCylinders (for leakage of 0.5 gm / hr), repeatability of detection of leakycylinders, recording of data in software etc.

2. Working of all safety interlocks.

3. Working of encoding station, transfer of data to fillings m/c check scale etc.

4. Hydraulic pressure testing of central column and complete assembled LPGpiping system including inlet manifold.

5. Functioning of electronic check scale.

6. Witnessing of running of complete conveyor system for its smooth operation.Jamming of cylinders to be avoided.

7. The inspection procedures mentioned in Special Terms and Conditions.

8. Verification of software data recorded in MIS for regular production as well asfor SQC.

9. Verification of CIMFR certificate for flameproof Enclosures.

10. Verification of PESO certificate and other statutory certificates as applicablefor complete system.

Inspection (FAT & SAT) will be regarded as a check-up and shall not relieve theVendor of any of the contractual obligations and performance guarantee. Thethird party inspection charges shall be as per the price bid format and tenderconditions.

24. APPROVAL OF DRAWINGS

Vendor will get all drawings approved from Corporation before supply and theapproval of drawing by Corporation does not absolve the vendor from hisresponsibility/ obligations towards the performance guarantee of the entire fillingsystem covered under this tender.

25. LOCAL STATUTORY APPROVALS:

a. Vendor will obtain statutory approval from Chief Controller of Explosives ofPetroleum & Explosives Safety Organization Nagpur India (PESO) within aperiod of six weeks from the date of LOI/FOI/e-mail message. Approval mustindicate the acceptability of the intrinsically safe equipment for AmbientTemperatures of (+)50 Deg C. Approval should be either general or specific forBPCL plant. Interim approval will not be accepted.

b. In case the above approval is not obtained on time, we may be constrained tocancel the order and claim damages.

c. Model approval from Legal Metrology department will also be required.

d. In principle approval from Weights and Measures (Legal Metrology)department and final approval/stamping on erection and commissioning of thesystem. All expenses to be borne by vendor. BPCL will reimburse/ bear onlystatutory stamping fee.



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e. Any other statutory requirement/approvals.

f. Approval for Intrinsic Safe equipment from statutory authority( likeBASEEFA/ CENELEC/ FM) of Country of Origin should certify suitability forthe ambient temperature of +50 degree Celsius.

26. DELIVERY

a. The delivery period shall be as 5 Months from the date of LOI.

b. Two sets of manuals for erection/maintenance/service should be provided/dispatched with the carousel and two such sets are be provided while handingover the system.

27. ERECTION

Erection of carousel will be done in the following sequence:

The first phase of erection of the carousel will include all mechanical, electrical,pneumatics, instrumentation & hardware jobs - to be done by VENDOR.

PESO / safety approvals by BPCL.

Charging of gas & filling on commissioning the plant will be done by vendor.Vendor will be given intimation in advance for this.

28. WARRANTY

The vendor should familiarize themselves with Indian operating condition likehumidity, dust, temperature, water sprinkler (fire fighting system@ 15 LPM) inthe filling shed and other factors so as to ensure that the system functions in linewith the specified performance parameter under these conditions.

WARRANTY PERIOD:

The system supplied/installed should have performance warranty for the periodof 24 months from the date of commissioning or 30 months from the date ofreceipt at site, whichever is earlier. Date of Commissioning shall be considered asthe date of proving the system by successfully conducting SAT. The system hasto perform consistently within the specified parameters while handing over thesystem after commissioning & stablising the operating parameters). All Sparesand consumables required during the performance warranty period will beprovided by the vendor free of cost. BPCL will provide consumable like water,lubricants, stationary & printer’s cartridge during warranty period.

Proving the system/site acceptance test will be done at plant after commissioningand stabilizing the operations. These will include verification of performanceparameters (Filling rate, Filling accuracy, rejection of cylinders of wrong tareweight, introduction & rejection operation, Check scale operation and accuracy,‘O’ ring , valve tester operation and rejection of leak cylinder and repeatability,verifying the cylinder filling production as specified, Cylinder filling datacollection system etc as per detailed parameters.

29. Vendor must dispatch the list of minimum spares that will be maintained ateach plant during the warranty period and will be hand over to plant in charge atend of the warranty period. Any intermittent consumption during the warranty



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period will be replenished within 15 days on consumption.

30. ANNUAL MAINTENANCE CONTRACT

a. We may enter into an Annual Maintenance Contract with the vendor for aperiod of three (03) years after the warranty period is over. Please indicate theannual cost of AMC separately in your quote. The Maintenance Contract shallcover all the equipment supplied by vendor

b. The AMC excluding & including the cost of spares and consumables may begiven separately. Quarterly visit of min 03 days may be considered and breakdown on per diem basis. The response time will be 24 hrs. and required spare willbe made available from the time of notification for both the warranty and AMCperiod within 48 hours. The scope of warranty and AMC both will cover thesupply of spares also by vendor and BPC will not purchase any spare formaintaining system supplied by vendor during the period of 2+3 = 5 (five) years.

c. Vendor to provide Comprehensive daily , weekly, monthly, quarterly, halfyearly , yearly , beyond checks/ routine preventive predictive and shut downmaintenance to be carried out for each equipment& component and list of criticalcomponents which are likely to get damaged/wear & tear/failure in a year foreach equipment. The spares during warranty period to be provided prior to eachpreventive maintenance / servicing activities. Maintenance schedules to bedeveloped and implemented without any production loss to BPCL

No extra payment shall be made to the vendor towards supply of any spare partsor replacement/ repair of equipments during defect liability period of two yearsfrom the date of successful commissioning. However, after the expiry of twoyears of Defect Liability Period , Vendor shall quote the Annual MaintenanceCharges for subsequent 03 years. These charges shall include the repair ofequipments, providing spares etc and shall be paid on quarterly basis in fourequal installments of quoted rates at the end of each quarter.

AMC shall be renewed by LPG SBU after end of every year subject to conditionsmentioned in this tender. However, renewal of AMC will be on the discretion ofBPCL.

The scope of work shall broadly consist of

I. INSPECTION

a) Adjustment of equipment

b) Optimization

c) Weighing-in

d) Lubrication of equipment e) Safety checks

f) Recommendations for optimization of equipment

g) Any other activity required for smooth operation of the system supplied by thevendor.

II. PREVENTIVE M AINTENANCE



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Preventative replacements of wearing parts according to pre-determined

preventive maintenance plan

III. CORRECTIVE M AINTENANCE

Carrying out of necessary repairs according to need identified by plant operatorsand maintenance staff

Plan & identify indent and maintain adequate spare parts inventory in co-ordination with BPCL.

Carry out necessary replacement of parts

IV. TRAINING AND OPERATIONAL SUPPORT

Monitor the filling operation to secure correct usage of equipment

Training and instructions to BPCL filling staff to secure correct usage of fillingequipment.

V. REPORTING AND PLANNING

Working out complete service report once per month

Conduct Monthly meetings with BPCL maintenance manager to report and planmaintenance and discuss the issues for optimizing the productivity.

VI. PERFORMANCE

Vendor shall prove the system for the rated productivity of minimum 1570Cylinders per hour for filling of 14.2 Kgs capacity at a carousel speed of 55seconds per revolution and 1000 Cylinders per hour for filling of 19 Kgs netweight filling, with minimum 95% filled cylinders during the maintenance periodalong with other parameters such as filling accuracy of (-)50 to (+)50 gms range,Valve Leak, O-Ring Leak Detection system with repeatability.

BPCL reserves the right to demand capacity performance tests periodically &shall terminate the contract in case the performance is not satisfactory.

Vendor shall take all necessary steps to prevent unscheduled stoppages andwould make all out efforts to re-commission the machine with least break downtime at no extra cost to BPCL. Necessary labour shall be provided by BPCL toattend to the same.

VII. SPARE PARTS

Spare parts during defect liability period of 2 years from the date of successfulcommissioning shall be supplied by the vendor at no extra cost. However, allspare parts inventory required for maintaining the highest productivity level shallplanned identified indented and maintained in co-ordination with BPCL.

VIII. GENERAL CONDITIONS



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The Service Agreement shall be periodically reviewed .

BPCL reserves the right to terminate the AMC by giving 3 months notice.

The Rates offered shall remain firm during the period of contract

The Vendor shall bring his own hand tools.

Vendor must adhere to applicable statutory laws issued by Govt of India andprovisions applicable must indemnify BPCL against any deviation or lapse on hispart

Vendor shall adhere to adhere all Safety Health Environment and securityGuidelines issued by BPCL time to time.

Vendor shall provide necessary uniform PPE like helmet and shoes at no extracost to BPCL.

Vendor shall indemnify BPCL against all claims and liabilities arising out ofperforming this contract.

Vendor shall indemnify BPCL against act of negligence by his personnel whileperforming this contract.

Free access to the equipment to the necessary extent will be granted by BPCL.

Office for the maintenance staff with common amenities shall be provided byBPCL

The work will be carried out in agreement with the BPCL service manager.

The work must as far as possible be carried out outside working hours to interfereas little as possible with the production.

The guarantee covers the work provided during the maintenance service only.

31. PAYMENT TERMS

The payment terms shall be as per Purchase Order & under:-

Supply Portion:

70% - payment against LC on despatch of the equipment.

30% - After erection & commissioning & within 3 weeks after handing over thefull system & on submission of performance bank guarantee for 10% value.

Erection & Commissioning Charges :

Supervision charges for erection of material, dry run & commissioning shall bereleased after the commissioning & handing over of the whole system

AMC Charges :



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The payment towards Annual Maintenance Contract (AMC) will be madeQuarterly after end of each quarter.

32. MANPOWER REQUIRED FOR ERECTION:

Vendor to advise us the details of skilled/ semiskilled/ unskilled man powerrequired for erection of the carousel system.

33. TRAINING OF OUR STAFF

Three tier training for our operating staff/maintenance and supervisory staff willbe carried out at our plant during erection, trial, proving & handing over period ofthe system.

Technicalbid

DATA SHEET- 24 STATION CAROUSAL & ASSOCIATED UPSTREAM & DOWNSTREAMEQUIPMENT

DATA SHEET- 24 STATION CAROUSAL & ASSOCIATED UPSTREAM & DOWNSTREAMEQUIPMENT

SrNo ITEM BPCL REQUIREMENT

Bidder'sConfirmation

. Operating Conditions :24 Station Electronicmachine carouselsuitable for filling14.2/19 KG SC TypeValve cylinderssimultaneously

.

1 System performanceparameters

.

. i) Production Capacity 1570 Cylinders per hour for filling of 14.2Kgs capacity at a carousel speed of 55seconds per revolution and 1000 Cylindersper hour for filling of 19 Kgs capacity filling

. ii) Filling Accuracy 95% of cylinders within +/- 50 gms or better

. iii) Valve LeakDetection

0.5 gm / hr

DATA SHEET- 24 STATION CAROUSAL &

ASSOCIATED UPSTREAM & DOWNSTREAM

EQUIPMENT



page 33 of 75

. iv) O-Ring LeakDetection

0.5 gm / hr

2 Cylinder As per Cylinder Data Sheet provided at theend of this data sheet

. Dimensions .

3 Installation Under covered roof all sides open

4 Duty Continuous

5 No. of hrs/day 16 hrs /day for 300 days in a year

II Carousel FillingMachines :

.

1 Type Electronic type with individual Gas stopsvalve and filling head.

2 Platform Level + 550 mm from floor level.

3. LPG Cylinder 14.2 Kg and 19 Kg

4 Working Pressure ofLPG

Max. 8.5 Kg/cm2 (Differential pressure)

5 Filling Time (Max.) atworking pressure of 16Kg/cm2

Vendor to Specify considering rotation time55 Seconds

6 Valve Details Refer to enclosed drawing

7 Type of Filling Gunrequired

Automatic lowering and centering type forSC Valve with pin travel of 2.8 +/-0.2mm.

8 Accuracy of filling(Min.)

+/- 50 gms. Or better

9 Filter 40 Mesh SS Strainer.

10 Bourden type 0-25 KgPressure Gauge

To be provided before & after the filter

11 Guide Rail I – Section/Square Section.

12 Carousel drive (AntiStatic)

Preferable – Tyre/Belt driven with hydraulicmotor or Gear type with electric motordriven. Vendor to specify.

13 Introduction unit Pneumatic / hydraulic operated or Gear typewith electric motor driven unit withautomatic introduction of cylinders



page 34 of 75

synchronous with the speed of the carousal.A safety device to be provided to preventintroduction of cylinders to the carousal ifthere is already a cylinder present on thefilling machines i.e. Introduction only whenmachines platform empty.

14 Ejection unit Pneumatic / hydraulic operated unit or Geartype with electric motor driven for automaticejection of cylinders from the carousal to thechain conveyor. A safety device to beprovided such that if the filling head has notdetached from the cylinder then carouselshould stop gradually . By this Anti jammingoutput is ensured i.e. Ejection only whencylinders are filled and gun released. Alsothe ejection has to operate only when theconveyor is free.

15 Emergency stop Easily accessible from front & distinctlyvisible .

16 Earthing connection a) Filling gun - braided copper wire alongwith hose with insert

. . b) Central column.

. . c) Guide Rail

. . d) Platform

. . e) Frame

17 Safety Guard Mesh or M.S. Flat on angle iron frames allaround 1" above the platform.

18 Table Speed (To be specified by Vendor)

19 Range of speedadjustment

(To be specified by Vendor)

20 Filling accuracy +/- 50 gm. Or better.

21 Utilities required &consumption per hourof operation.Compressed Airrequirement in LPM &Air pressure in Kg/cm2

(To be specified by vendor) Air pressuresupplied is 5-6 Kg/cm2

22 Overall size of machine (To be specified by vendor)

23 Paint High quality anti-corrosive

24 Working height Tare weight controls to be accessible fromfloor level.



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25 Pneumatic controlcircuit diagrams

(To be specified by vendor)

26 LPG Pressure dropacross filling machines.

(To be indicated by vendor in Kg/cm2including quantity)

27 Operating Temperature(-10? C to 50? C).


III Empty cylinder pushingarrangement.

.

1 Interlocking provision To be provided

2 Auto-ejection device To be provided

IV Details of CentralColumn & RotaryTable Design

.

1 Product feeddistribution & by-pass

LPG thru Top and air through bottom ofcolumn preferred

2 Sealing arrangementdetails

To be provided for positive segregation ofLPG and Air

3 Table supportingarrangement

Should be supported on rails

4 Table constructionarrangement.

Steel frame

5 Leveling arrangement Preferably by tripod

6 Material ofconstruction.

Steel

V Drive Arrangement : .

1 Drive motor type rating& characteristics

Hydraulic or electric with tyre/gear driveRating & characteristics to be specified byvendor

2 Speed reducinggearbox make type size& complete details.

Through Frequency control

3 Final anti-static drivearrangement details.

Arrangement to be indicated

VI Filling Head : .

1 Release Smooth release with hinged arrangement injaws to facilitate little downward movementof jaws at the time of release



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2 Liquid pressure 8.5 Kg/Cm2 (Differential)

3 Pin travel 2.8 + /- 0.2 mm

4 Flow rate 150 LPM

5 Material Gun metal

6 Head cap Gun metal threaded

7 Pneumatic cut off ofLPG inside the gunduring gun release.Hose attachment- Sideelbow.


8 Self-centeringhorizontal alignmentarrangement withcylinder valve.


VII General : .

1 Supporting rail size &fixing arrangement.


2 Wheel details Steel wheel with sealed bearings.

3 LPG and Air hoses Should be anti-static

4 Details of allinstrument & otherfittings indicating typemake & othercharacteristics.

To be specified by vendor in brief.

. Micro filter One unit of 5 micron filter with 1100-LPMcapacity at 17.5 Kg/cm2 working pressure.

. Safety relief valve To be provided by vendor

. Dif